™
the ultimate reinforcement for concrete in challenging applications
Pultron Composites would like to thank the following experts, companies and research institutions for their help in testing and developing mateenbarTM:
01
™
mateenbar™
™
™
research & testing
Professor Mohammad Harajli Department of Civil & Environmental Engineering American University of Beirut Lebanon Professor Mesfer M. Al-Zahrani Department of Civil Engineering King Fahad University of Petroleum & Minerals Saudi Arabia Kevin Spoo Tanya Redfern Owens Corning
Standards Measurements Laboratory Industrial Research Ltd New Zealand Professor Ayman Mosallam Civil & Environmental Engineering University of California USA Frank Alderton FIQ New Zealand
material property
value
imperial
standard
tensile strength
minimum *
>1000 MPa **
145 ksi
ASTM D3916-84
modulus (tensile)
typical *
54.5 GPa
7904 ksi
ASTM D3916-84
minimum *
>50 GPa
7250 ksi
typical
260 MPa
37.7 ksi
minimum
230 MPa
33.4 ksi
typical
520 MPa
75.4 ksi
minimim
460 MPa
66.7 ksi
typical
690 MPa
100 ksi
minimim
500 MPa
72.5 ksi
moisture absorption
typical
0.024%
BS2782 pt 4, method 430/ ISO 62-1980
thermal conductivity
typical
0.25 W/mK-1
ASTM C117
electrical strength
typical
5 - 40 kV/mm
DIN 53 481
volume resistivity
typical
10 â„Ś.m
DIN 53 482
dielectric constant
typical
<5
DIN 53 483
shear strength (single sided)
shear strength (double sided)
compressive strength (longitudinal)
magnetic properties density
10
non-magnetic typical
1.9 - 2.1 g/cm3
* tensile strength and modulus are typically higher for smaller diameter bars ** based on 20mm diameter
ASTM B769-94
ASTM B769-94
ASTM D695
03
mateenbarâ&#x201E;˘
02
mateenbarâ&#x201E;˘
technical characteristics
sizes & shapes metric (mm) 8 10 12 16 20 25 32 38
imperial #3 #4 #5 #6 #8
diameter range: other sizes available on request lengths: made to order, to minimise on-site installation time and material wastage. shapes available: right angles angles stirrups links specialist shapes made to order
mateenbar™ is the ideal product, developed specifically for engineers who are working in environments with demands beyond the abilities of (traditional) steel reinforcement.
04
mateenbar™
™
™
designed for performance
Traditionally, the preferred reinforcement system for concrete structures has been steel. However, steel has its limitations, making it unsuitable for certain environments and applications. In such conditions, design engineers have struggled to find a satisfactory material and often had to accept inadequate solutions. For 25 years, Pultron Composites has been working closely with engineers to develop FRP reinforcement with high performance engineering properties, to solve problems beyond the abilities of steel. In 1985, Pultron worked in conjunction with DuPont to develop a reinforcement system that addressed the shortfalls of steel. These were introduced to the coal mining industry to help improve mine safety in difficult geotechnical situations and also to increase productivity by eliminating the down-time previously caused by the use of steel reinforcements. Since then, Pultron has worked with key market players, developing FRP reinforcement specific to their requirements. Ongoing R&D projects ensure that Pultron is at the leading edge of technology.
• Perfect for highly corrosive environments • Non-conductive • Non-magnetic • Cutable • Low carbon imprint • Culmination of 20 years FRP reinforcement development • Cost effective alternative to stainless steel
™
™
05
mateenbar™
™
™
advantages
resistance to corrosion & chemicals mateenbar™ is highly resistant to chemical attack, so it does not rust. This makes it ideal for marine applications, chemical plants and other environments where steel is unsuitable. Design engineers working in such conditions select mateenbar™ to achieve acceptable life-spans. mateenbar™ is also the ideal material for applications where minimal concrete coverage may be required – since its corrosion resistance eliminates leaching of rust stains which otherwise ruin the surface aesthetics.
non-conductive & non-electro magnetic Due to the non-electromagnetic and non-conductive properties, stray electrical currents do not cause induction in mateenbar™. Often, in areas of high electrical fields significant power is lost due to induction in the surrounding steel reinforcement. This creates a number of problems including: extensive earthing systems required for electrical safety; greater concrete coverage requirements for electrical insulation; accelerated corrosion of rebars due to high levels of electrolysis; as well as increased installation costs and time welding every joint. In addition, a two-fold energy wastage problem is created by the presence of steel: induction losses create eddy currents which heat the reinforcement - so increased cooling is required to remove this unwanted heat.
™ ™
™ ™
low thermal conductivity The excellent insulation properties of mateenbar™ help ensure that the concrete maintains a good thermal insulation value.
cutable In tunnelling projects, Pultron mateenbar™ is specified for soft-eyes. The Tunnel Boring Machine (TBM) can cut through the soft eyes easily without risk of damage to expensive cutting equipment. The saving in down-time is also critical in helping engineers keep projects running on schedule.
non-magnetic Close to magnetic apparatus - such as hospital MRI rooms, compass calibration areas and certain high-voltage applications - steel reinforcement is unsuitable because the magnetic properties interfere with sensitive equipment. These problems are avoidable by specifying mateenbar™ as the reinforcement for these applications.
minimum moisture absorption Moisture absorption must be minimised to ensure longevity of composites. Our moisture absorption rates are extremely low, ensuring mechanical properties are maintained for as long as possible.
06
mateenbar™
™
™
price/performance advantage
tensile strength Glass content, fibre straightness, and the bond between fibres and matrix are well controlled to ensure maximum tensile strength. The high tensile strength of mateenbar™ offers designers comparatively higher factors of safety.
modulus The modulus of mateenbar™ is almost at the theoretical limit for the material - meaning maximum benefit is achieved from the raw materials, ultimately offering designers a price/ performance advantage
bond strength microscopic view of mateenbar™
bond strength testing of mateenbar™
The bond strength of mateenbar™ has been optimised to offer reinforcement suitable for most commercial strengths of concrete.
destructive tensile testing of mateenbar™
™
™
cost advantage In any application where corrosion resistance is paramount, mild steel is unsuitable. High-grade stainless steel or mateenbar™ may be considered suitable reinforcements. In such cases, a cost saving of 40% on reinforcement would be expected by specifying mateenbar™. Where coverage can be reduced by use of mateenbar™, the saving on concrete will also be considered favourable in a total system cost analysis.
life-span mateenbar™ is formulated from some of the most highly corrosion resistant materials available. Precise process control ensures optimum performance is achieved from these materials for maximum durability. This is most critical in harsh environments where performance of other materials may prove inadequate.
materials mateenbar™ is manufactured from a proven epoxy backboned resin system for maximised corrosion resistance and increased interlaminar shear strength. Carefully selected glass types are used to ensure immunity to alkaline attack.
™
™
Rita Elementary School
Rita Elementary School
Laura School
College of Marshall Islands
07
mateenbar™
Pultron’s mateenbar™ was specified for a series of new school and college buildings built throughout the low-lying island chain of the Republic of the Marshall Islands. This eliminated steel corrosion problems, considerably extended the expected life-span, and gave reassurance to design and construction engineers as well as the owners of the new buildings. It also gave the children much needed improvements to their learning environment.
Marshall Islands
period 2004 - 2007 designer Beca Carter Hollings & Ferner construction Pacific International Anil Developments projects Laura School Jaluit School Rita Elementary School Marshall Islands High School – Phase I College of Marshall Islands Dormitory College of Marshall Islands - Phase I Namdrik Elementary School - Phase I College of Marshall Islands - Phase II Namdrik Elementary School – Phase II Northern Islands High School – Phase I & II
™
™
The mateenbar™ was used to create isolation breaks within the Springvale Road tunnel, on the new USD 2.0 billion “Eastlink M3” toll road in Melbourne, Australia. If steel reinforcement is continuous throughout the length of a tunnel, eddy currents created by induction are sufficient to accelerate the rate of corrosion within the steel reinforcement. Solving this was traditionally costly: extra reinforcement was allowed for within the design to compensate for the accelerated corrosion; joints were welded to ensure electrical contact; and earthing systems were linked to sacrificial cathodic blocks. This was both time consuming and expensive.
08
mateenbar™
™
™
Eastlink tunnel
year 2007 project cost USD 2.0 Billion owner ConnectEast Pty Ltd designer CW-DC Pty Ltd construction Thiess John Holland JV
CW-DC is a wholly owned subsidiary of Connell Wagner
Isolation Joint 200mm clear spacing required between longitudinal steel reinforcement
The electrical insulation properties of mateenbar™ allowed the designers to isolate short sections of reinforcement - thereby reducing eddy currents and reducing the affects of accelerated corrosion, as well as saving both time and money on the project. mateenbar™ Lap Joints at isolation breaks.
09
mateenbar™
™
™
Singapore MRT
year 2002 owner SMRT Trains Ltd size 109km of lines stations 64 currently operating (expansion in progress) daily usage 1.654 million passengers During the construction of the Singapore MRT underground stations, various concrete walls and columns had to be built in the path of the Tunnel Boring Machine (TBM) prior to tunnelling. mateenbar™ was used for ‘soft-eyes’ within walls and ‘soft-column’ sections in positions where the TBM would be required to cut through during later stages of construction.
Singapore MRT Station
™
™
Muscat Expressway
Dubai Marina
Central Corridor
Muscat Airport
In soil walls and highway barriers, high strength reinforcement is required - but steel is subject to accelerated corrosion due to the high salt levels within the soil. The high corrosion resistance of Pultron’s reinforcement has made it the ideal material for these applications. Basements are often below the level of the water table. The harshest of artesian water in the region is termed sabkha and is very highly corrosive. Sabkha presents particular difficulties for engineers – with corrosion of steel reinforcement being a major problem. The excellent durability of mateenbar™ has made it the preferred choice of engineers in such applications. mateenbar™ is also a superior and costeffective alternative to stainless steel for the reinforcement of submerged sections of bridge footings in tidal zones and other structures subject to the salt-laden waters of the Gulf.
10
mateenbar™
Pultron has worked closely with major industry leaders within the region to gain a full understanding of the requirements and develop the perfect reinforcement for the harsh conditions.
™
™
Middle East
project
year
owner
Main Contractor
Consultant
Muscat Expressway
under const.
Muscat Municipality - Oman
Galfar Engineering & Contracting
Parsons
Shahama Saadiyat Freeway Package 1
under const.
Aldar
Six Construct Co. Ltd
Halcrow
Central Corridor
under const.
Muscat Municipality - Oman
Galfar Engineering & Contracting
Parsons
Seeb International Airport
2007
Muscat Municipality - Oman
Carillion Alawi LLC
Parsons
Shahama Saadiyat Freeway Package 2A
under const.
Aldar
Taisei Corporation
Halcrow
Qatar Primary Rout North Road C2 & C3
under const.
Qatar Petroleum
Tekfen Construction & Installation INC
Dar al-handasah
Mesaieed Bridges
2005
Qatar Petroleum
ASKA
Qatar Petroleum
EMAAR West side Marina Infrastructure Package 3D
2004
EMAAR
Al Futtaim Carillion
Hyder Consulting
3rd Bridge Crossing Abu Dhabi
2005
Abu Dhabi Public Works Dept
Archirodon/Bin Hafeez Est.
High-Point Rendel
King Abdul Aziz Interchanges Jn. 65A to Jn.14G
2006
Government of Sharjah
Sharjah General Contracting
Halcrow Int.
R659-2 Jumeirah Lake Interchanges
2007
RTA
Dutco Balfour Beatty
Parsons International Ltd.
Baharain Map I/C
under const.
Ministry of Works & Housing
NASS Construction Co. W.L.L
Parsons
EMAAR West side Marina Infrastructure Package 3B
2003
EMAAR
Al Futtaim Tarmac
Parsons International Ltd.
Mina Al Arab Phase I
under const.
RAKPROPERTIES
Darwish Engineering
Halcrow
Halul Island
2003
OXY Occidental Petroleum
CBI/Archirodon
Mott Macdonald Ltd
Al Hamra Village Development, RAK
2005
Private
Stratcon
Maunsell
™
™
Northside storage tunnel construction
The tunnel was commissioned to collect storm overflows from the sewerage system to reduce contamination from raw sewage entering Sydney’s iconic harbour.
11
mateenbar™
The Northside Storage Tunnel was built in Sydney, Australia (1998 – 2000) from the suburb of Lane Cove (Western Sydney) to North Head. The total tunnel length was in excess of 20km, with diameters from 3.8 metres to 6.6 metres, a total excavation of 750,000m3 of ground and a project cost of USD 400 million.
™
™
Northside storage tunnel
year 1998 – 2000 project value USD 400 million designer Connell Wagner construction MWH, Transfield owner Sydney Water
Due to the potentially corrosive nature of the chemicals present in the storm-water and sewage overflow, it was determined that stainless steel reinforcement could not offer the required life-span and that a more corrosion resistant material would be required. Pultron worked in conjunction with the tunnel design engineers to develop specialised tunnel reinforcement rockbolts based on mateenbar™ which fulfilled the required mechanical properties and offered the extreme corrosion resistance requirements for this difficult application. Tunnel Network
12
mateenbar™
™
™
underwater applications
year 1999 onwards projects & applications Various cable stabilisation projects design & installation Ocean Technix Ocean Technix specialises in difficult undersea engineering projects. In the shallow reef waters of the Indian Ocean off the coast of Western Australia, divers had the task of stabilising sub-sea cables by drilling holes into hard rock areas of the sea bed and gluing rockbolts based on mateenbar™ in place with an epoxy resin system designed to cure under water. Neoprene straps were then used to secure the cable in place.
Stabilisation of sub-sea cables
Research Publications & Reference Material “Analysis of Aged Vinylester & Polyester Pultruded Composites”, Dr Salwan Al-Assafi, Composite Materials Research (* see note). Journal of Advanced Materials, approved for publication, December 2003 “Performance of Composites with Various Resin Systems in Aqueous Environment”, Dr Salwan Al-Assafi, Composite Materials Research. Proceedings of first International Conference on Applications of Traditional and High Performance Materials in Harsh Environments, American University of Sharjah, UAE, 2004 “Impact of Aqueous Environments on Performance of Pultruded Composites”, Dr Salwan Al-Assafi, Composite Materials Research, A.Mosallam. Proceedings of the International Conference on Future Vision and Challenges for Urban Development, 2004 “Thermomechanical Analysis of Water Aged Pultruded Composites”, Dr Salwan Al-Assafi, Composite Materials Research. Proceedings of the fourth Asian-Australian Conference on Composite Materials, 2004 “ACI 440R-07 Report on Fiber-Reinforced Polymer (FRP) Reinforcement for Concrete Structures” – American Concrete Institute. “ACI 440.3R-04 Guide Test Methods for Fibre Reinforced Polymers (FRP’s) for Reinforcing or Strengthening Concrete Structures” – American Concrete Institute. * Composite Materials Research is a subsidiary of Pultron Composites Ltd.
â&#x201E;˘
Manufactured by: Pultron Composites Ltd PO Box 323, 342 Lytton Road Gisborne, New Zealand Tel: +64 6 867 8582 Fax: +64 6 867 8542 Email: sales@pultron.com Pultron Composites Middle East PO Box 17522 Jebel Ali Free Zone, Dubai United Arab Emirates Tel: +971 50 640 4345 Fax: + 971 4 361 9675 Email: pultronME@pultron.com
www.mateenbar.com www.pultron.com