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  • 3-Part Master Specification: Macrosynthetic-Fiber Reinforced Concrete

    July 20, 2014

    This specification is specific to the use of Macrosynthetic-Fiber Reinforced Concrete as secondary/temperature-shrinkage reinforcement and post-first crack reinforcement. The purpose of this document is to assist design professionals in the preparation of project or office master specifications. It follows guidelines established by the Construction Specifications Institute and, therefore, may be used with minor editing in most master specification systems.

    This specification assumes that standard section numbers are used in the project or master specifications, and it should be placed in Section 3240 – Fibrous Reinforcement.

    NOTES:

    • Edit carefully to suit project requirements.
    • Modify as necessary and delete requirements regarding the fibers that are not applicable to the specific project.
    • Verify that reference section numbers and titles are correct.
    • Ensure all references to ACI and ASTM specifications, test procedures and state-of-the-art reports are current.

    The design professional can find a number of references to synthetic-fiber reinforcement and to synthetic fiber-reinforced concrete in ACI and ASTM documents. Some of these documents are listed in Sections 1.02, 6.a and b.

    ASTM AND ACI CONSENSUS SPECIFICATIONS AND TEST METHODS, AND STATE-OF-THE-ART DOCUMENTS RELATING TO FIBER REINFORCED CONCRETE.

    The following is an example of a detailed macrosynthetic fiber specification.

    ABC POLYMER’s Macrosynthetic Fiber Three-Part Master Specification

    03240: CONCRETE REINFORCEMENT/FIBROUS REINFORCEMENT

    Source
    ABC Polymer Industries, LLC
    545 Elm St.
    Helena, AL 35080
    Phone: 205.620.9889
    Fax: 205.620.9888
    Website: www.abcpolymerindustries.com
    E-mail: Denzil Schmitz, SVP of Sales & Marketing, Concrete Fibers at Denzil@ABCFibers.com.

    Product Names: FiberForce 650™ (Tuf-Max DOT™)
    Performance Plus DOT™
    Macro-Pro™

    03241: FIBROUS CONCRETE REINFORCEMENT

    ABC Polymer’s Macrosynthetic Fibers compose a group of next-generation synthetic fibers that provide post-first crack reinforcement combined with the fundamental benefits of plastic shrinkage reinforcement and secondary/temperature-shrinkage reinforcement.

    The general use range for macrosynthetic fibers is 3.0 to 8.0 pcy. The engineer shall use the application parameters and the designation of specific minimum results from ASTM Test Method C1609 to determine the exact dosage of macrosynthetic fibers required.

    ABC Polymer’s Macrosynthetic Fibers are typically specified within a dosage range of 3.0 to 8.0 pounds per cubic yard (1.8 to 4.8 kg per cubic meter). ABC Polymer’s Macrosynthetic Fibers are specifically designed to be used at the higher dosage levels in post-first crack applications.

    At these higher dosage levels, ABC Polymer’s Macrosynthetic Fibers are appropriate for use in industrial and warehouse floor slabs and shotcrete tunnel liners as well as other applications where post-first crack performance is a consideration.

    PART 1: GENERAL

    1.01 SUMMARY
    This section includes Macrosynthetic Fibers or Synthetic Fibers as post-first crack and secondary reinforcement for concrete.
    Related Sections:

    1. Section 03210 – Reinforcing Steel
    2. Section 03300 – Cast-in-Place Concrete
    3. Section 03370 – Specially Placed Concrete (shotcrete)
    4. Section 03400 – Precast Concrete
    5. Section 03500 – Cementitious Decks and Underlayment

    All materials furnished per this section shall conform to applicable codes and/or standards.

    1.02 SUBMITTALS
    Submit the following information/data for macrosynthetic fibers:

    1. Product Data: Required physical property data for the product specified per ASTM C1116, Section 4.1.3 and Note 2 and where applicable ICC ES Acceptance Criteria 32, Sections 3.1.1 and 3.1.2. Additionally, vendor or manufacturer must furnish an Engineering Report that provides ASTM C1399 and/or C1609 test data encompassing the proposed dosage rate required for the subject project from an ICC-qualified commercial laboratory.
    2. Letter of Certification stating compliance with applicable specifications and/or codes from the manufacturer.
    3. Samples: Samples of the specific products recommended for use shall be submitted. Samples must be of the length and configuration specified.
    4. Quality Assurance/Control Submittals furnished by the manufacturer:
      * Related concrete test reports from commercial and/or university laboratories.
      * Installation instructions (mixing, placing, finishing)
      * MSDS for products proposed for use.
    5. Technical Support:
      In the use of macrosynthetic fibers, the dosage level is a major component of success. The structural/project engineer may require technical assistance in developing the design of the specific concrete element utilizing the macrosynthetic fiber; the structural/project engineer is directed to contact the engineering group of the source (see item 2.01 A).
    6. References
    7. American Concrete Institute (ACI)
      1. ACI 211.1 – Standard Practice for Selecting Proportions for Normal, Heavyweight and Mass Concrete
      2. ACI 302 – Guide for Concrete Floor and Slab Construction
      3. ACI 318 – Building Code Requirements for Reinforced Concrete
      4. ACI 330 – Guide for Design and Construction of Parking Lots
      5. ACI 345 – Guide for Concrete Highway Bridge Deck
      6. ACI 360 – Design of Slabs on Grade
      7. ACI 362 – Guide for Design of Durable Parking Structure
      8. ACI 506.1R – State-of-the-Art Report on Fiber Reinforced Shotcrete
      9. ACI 544.1R – State-of-the-Art Report on Fiber Reinforced Concrete
      10. ACI 544.3R – Proportioning, Mixing, Placing, and Finishing Steel Fiber Reinforced Concrete
      11. ASTM International
      12. C1116 – Specification for Fiber-Reinforced Concrete and Shotcrete
      13. C1399 – Test Method for Obtaining Average Residual-Strength of Fiber-Reinforced Concrete
      14. C1550 – Test Method for Flexural Toughness of Fiber-Reinforced Concrete (using Centrally Loaded Round Panel)
      15. C1609 – Flexural Performance of Fiber Reinforced Concrete (Using Beam with Third-Point Loading)
      16. C1579 – Evaluating Plastic Shrinkage Cracking of Restrained Fiber Reinforced Concrete (using a Steel Form Insert)
      17. C78 – Test Method for Flexural Strength of Concrete
      18. C143 – Test Method for Slump of Hydraulic Cement Concrete
      19. C94 – Specification for Ready-Mixed Concrete
      20. C173 – Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method
      21. C231 – Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

    1.03 QUALITY CONTROL

    1. Qualifications:
      1. The engineer can require that a pre-construction trial mix or mixes, using proposed ingredients, be fabricated to ensure targeted-engineering properties are met and the mix workability is within standard parameters. This requirement is especially important when three pounds or more of the macrosynthetic fibers are added per cubic yard.
      2. In order to accommodate the macrosynthetic fibers at or above 3.0 pcy, the coarse aggregate volume may need to be reduced and the mortar volume increased. Contact the manufacturer to retain the assistance of the engineers.

    1.04 DELIVERY, STORAGE AND HANDLING

    1. Delivery: Standard methods of transportation. The product is to be packaged in pre-weighed bags, boxed, palletized and identified for traceability per an ICC AC10-approved quality control program for the manufacturing plant processing the macrosynthetic fibers.
    2. Special Instructions: Please read the macrosynthetic fibers’ MSDS for handling instructions.
    3. Storage: Polypropylene and polypropylene/polyethylene fibers are hydrophobic. To ensure the integrity of the mixer-ready bags, keep packaging dry prior to use.
    4. Introducing Fibers to Mix: Count out and add the proper number of pre-weighed bags of product to the mixing system based on the dosage in pounds per cubic yard or kilograms per cubic meter. There is no correct time to introduce the bags to the concrete. There is a single warning: Do not add the bags containing the fibers at the same time the cement is being introduced to the mixing system. When added after all of the standard ingredients have been added and mixed, allow for an extra 3-4 minutes at mixing speed or approximately 70 revolutions of the drum to thoroughly distribute the macrosynthetic fibers.

    1.05 PROJECT/SITE CONDITIONS

    1. Environmental Requirements: No unique/special requirements
    2. Sampling/Testing:
      • Externally vibrate all specimens for use in strength tests; internal rodding is precluded from use.
      • Preferred air content test method is ASTM C173.

    PART 2: PRODUCTS

    2.01 FIBROUS CONCRETE REINFORCEMENT

    Fiber reinforced concrete, or more specifically macrosynthetic fiber reinforced concrete, utilizes discrete macrosynthetic fibers typically a minimum of 1.5 inches in length to provide defined enhancements to quantifiable concrete properties. These enhancements include modifications to the macro/micro cracking mechanism, impact resistance, and fatigue strength in addition to reducing permeability. Most importantly, the macrosynthetic fibers contribute to the properties measured by ASTM Test Methods C1399, C1550, and C1609. The degree of enhancement is dependent on the dosage level in addition to the properties of the concrete matrix. Optimizing the mortar fraction to provide an adequate mechanical bond with the macrosynthetic fibers is important.

    1. Acceptable Source: ABC Polymer Industries, LLC, 545 Elm St., Helena, AL 35080, Phone: 205.620.9889, Fax: 205.620.9888, Website: abcpolymerindustries.com; Email: Denzil Schmitz, SVP of Sales & Marketing, Concrete Fibers at Denzil@ABCFibers.com.
    2. Alternate Sources::

    2.02 MATERIALS

    1. Description of Products:
      ABC Polymer’s FiberForce 650 is a macrosynthetic fiber that is a blend of polypropylene and polyethylene resins. The product is an embossed tape fiber meeting the requirements of ASTM C1116 Section 4.1.3 and Note 2 in addition to those requirements established by the structural engineer (based on ASTM C1399 or C1609).

    ABC Polymer’s Performance Plus DOT™ is a macrosynthetic fiber that is a blend of polypropylene and polyethylene resins. The product is a blend of embossed tape fiber (FiberForce 650) and a highly modified fibrillated tape fiber (Macro-Pro™) meeting the requirements of ASTM C1116 Section 4.1.3 and Note 2 in addition to those requirements established by the structural engineer (based on ASTM C1399 or C1609).

    ABC Polymer’s Macro-Pro is a macrosynthetic fiber that is a blend of polypropylene and polyethylene resins. The product is a highly modified fibrillated tape fiber meeting the requirements of ASTM C1116 Section 4.1.3 and Note 2 in addition to those requirements established by the structural engineer (based on ASTM C1399 or C1609).

    2.03 PHYSICAL CHARACTERISTICS

    1. Configuration: See above product configuration descriptions in 2.02 A.
    2. Length:
      Primary: 1.5″
      Alternate: 2.0″
    3. Typical Dosage Range: 3.0-8.0 pcy
      Extended Dosage Range: 3.0-15.0 pcy
      Specific dosage to be determined based on project specifications
    4. Macrosynthetic Fiber Reinforced Concrete Mix Design:
      Standard mix design as modified to accommodate the macro fibers when dosage level is 3.0 or more pounds per cubic yard.
      Compressive Strength: Per project specifications.
      Flexural Strength: Per project specifications.
      Slump: Per project specifications. Note: please identify if there is a difference for plain concrete versus FRC.

    PART 3: EXECUTION

    3.01 EXAMINATION

    1. Verify by comparing packing slip and box or bag label to ensure that the packaged product is the correct product specified for the project per the engineer.
    2. Verify that the bag weight of the product imprinted on the bags is the same as on packing slip and per the project specifications.
    3. Verify that the combination of bagged product to be added per cubic yard and per truckload of concrete meet the project dosing requirements.
    4. Verify that the concrete producer has allotted sufficient mixing time to ensure proper distribution of the macrosynthetic fibers.

    3.02 INTRODUCING, MIXING, PLACING, FINISHING

    1. Follow procedures outlined in source’s printed instructions (see Section 1.02 6.a)
    2. Comply with standard procedures found in ACI 302 and other related consensus documents.
    3. Vibrating screed or laser screed are the preferred methods of consolidating concrete in large-square-footage industrial and commercial interior slabs-on-grade.

    3.03 SOURCE’S FIELD SUPPORT

    1. Macrosynthetic fiber source will provide field support at pre-construction laboratory mix design trials and project start-up when requested.
    2. Macrosynthetic fiber source will provide phone access to technical support to ready mixer and project personnel.

    Prepared by:
    Bobby Zellers, PE, Director of Engineering Services, (RZellers@ABCFibers.com)