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Laboratory Analysis of Barchip Fiber-Reinforced Cocrete Durability Inside the

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 International Conference on Contemporary Iran on Civil Engineering
Architecture and Urban Development
Iran Tehran - August 16, 2017

Laboratory Analysis of Barchip Fiber-Reinforced

Cocrete Durability Inside the lining of Water Supply
Tunnels

Amir Behravan1*, Zahra Ahmadi 2

1- Ph.D Student, Oklahoma State University, Civil Engineering Department, USA

2- Graduate Student, Islamic Azad University- Najafabad branch, Iran
* Corresponding author contact: amir.behravan@okstate.edu

Abstract
In this study, an experimental study of new types of polypropylene fibers entitled Barchip
(HPP fiber) has been conducted to investigate the usage of this fiber in water tunnel
lining. In this study, concrete mixtures with 0.4,0.6 and 0.8 volume percent of HPP fiber
and steel fibers were provided. Changes in water absorption, permeability of concrete and
chloride penetration depth and abrasion strength were measured relative to the control
sample. All tests were undertaken according to ASTM and BS requirements. The results
showed that with application of HPP fibers, durability and serviceability of the concrete
linings could be remarkably extended.

Keywords: Fiber Reinforced Concrete, Barchip, Steel Fiber, Lining, Durability

1. Introduction
Water supply tunnels may be constructed for various purposes, including drinking water
supply, water supply, water supply from the basin openings to water power plants, controlling
flood water, diversion, or other hydraulic aims [1]. For the primary maintenance after drilling
the main tunnel, it is covered by lining to make a smooth surface for walls, ceiling and the
floor of the main tunnel, in order to meet requirements, ensure stability in long-term, prevent
entrance of ground waters or control them into the tunnel [2]. These tunnels may be
constructed on the soil or rock, and they may pass in their routes from different regions with
different geological properties [3]. It may be possible that different types of internal coatings
to be used along the rout of a tunnel. For instance, for passing through a permeable slots or a
region with gypsum, a non-permeable cover may be required, while other systems may be use
for the rest of the tunnel [4]. Regarding the types of materials, the internal cover is composed
of concrete and steel.
Advantages of concrete, such as easy ductility and formability in fresh state, fire-proof
properties compared to wood and steel, better stability against destructive weather effects,
easy production, and finally cheaper price, have caused proper welcome from this substance.
Along with the advantages, concrete has disadvantages including high weight of built
components with concrete, low tensile strength, and easy breaking due to frangibility. Tensile
forces are created either due to application of load, deformations, or even due to independent
load effects, such as temperature changes [5]. Shortage of tensile strength can be compensated

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by placing steel reinforcements for tolerating tensile forces. Moreover, using fiber is another
approach for overcoming this deficiency. Fibers are narrow strips with rather short lengths
and with different materials and shapes, distributed in the concrete randomly [6].
Fiber usage for promoting behavioral properties is an old idea, and according to “New
Fibers” written by Tungo and Philips, humans used fibers as reinforcing elements in clay,
about 4000 years ago [7]. Using built adobes (bricks) with straw for constructing Aqar Guf
Hill is one of the applications of fibers in old ages [8]. Furthermore, applying fibers in China
Wall about 2000 years ago indicates the matters that the knowledge in textile engineering
beside civil engineers was effective in promoting the useful life of various structures [7]. In
fact, fiber-reinforced concrete is the advanced type of this technology in a way that new
natural and artificial fibers have replaced straw, and cement has replaced the used mud in the
thatch composition.
Adding fibers to concrete increases tensile, shear, and bending strengths, increases
cracking strength, controls cracking and in some cases, it increases compressive strength [9].
Moreover, adding fibers can result in high strength against cavitation, high ductility, better
tolerability and resistance to erosion, and alluvial erosion and creeping properties [9, 10].
Various studies have been done so far on application of fiber-reinforced concrete as the
lining of tunnels. The results of Nordstrom[12] studies indicated that increasing steel fibers
reduces the depth of permeation of chlorine ions in the concrete. Results of Leung et al.
research[13] showed that fiber-reinforced concrete increases compressive strength and
absorbs higher energy, and found out that its permeability was almost lower that fiber-
reinforced shotcrete.
Results by Mashio et al. studies about empirical design for analyzing the cracking
mechanism of fiber-reinforced concrete indicated that fiber-reinforced concrete has cracks
with narrow width [14]. Moreover, the results of the analysis by Chiaia et al. [15] indicated
that the rate of consuming reinforced steel bars can be reduced by using steel fibers along the
reinforced steel bars. Fuente et al. [16] expressed the results of using steel fibers in three
actual and executed projects in tunnel linings, such that the consumed steel reinforcing bars
reduced by 70% in one tunnel.
Considering the above points, it can be expected that using fibers in water tunnel linings
can be effective in designing to reduce executing and maintenance costs.

2. Laboratory Program
2-1. Consumed Materials
About three fourth of concrete is formed by aggregates. Thus, aggregates can affect the
strength and properties for concrete durability. The used sand was prepared from Esfahan
desert, with 1.46% of humidity before modifications. Sand was completely dried before the
gradation test, and then, the gradation test was done by using standard sieves, and after
coinciding the gradation curve on the requirements of ASTM C33 regulations, the required
modifications were applied on the sand. Hence, Fig. 1 was extracted in that respect.

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Figure 1: Granulation curve for the modified sand

Large aggregates are considered as one of the important elements of concrete. Such that
the size of the largest consumed aggregate in the mixing plan is quite an effective element.
Moreover, when the concrete paste has not weak zones during failure of the concrete, cracks
extends from the aggregates. The used large aggregates in this study was prepared from
Harapay mine in Zarrinshahr, Esfahan, and the largest aggregate in this stockpile was 12.5mm
diameter. The prepared gravel was of crushed type, having appropriate conformity with the
requirements of the geometric shape of suitable aggregate for using in concrete. Also, the
gradation test was done on this type of material, the results of which are shown in Figure. 2.
Percentage of passing

Figure 2: Granulation curve for the used large aggregates

The used cement in the study was type II Ardestan cement with the chemical composition
as in Table 1. This cement has softness (3000 + 50 kg/m3), primary cement setting time (95 +
5 min), and final cement setting time (150 + 10 min).
Consumed water for concrete preparation should have no contamination and harmful
materials, or it should be within the permissible range by standard specifications. The best
type of water for concrete preparation is drinking water. Drinking water was used in all stages
of this study for preparing the concrete samples.
The superplasticizer used in the study was Fluimax 2HA produced by Kimia tech.
Moreover, this substance is in the form of white powder, soluble in water and properly
without chloride materials. The used artificial fibers in this research were Barchip type with
the length of 48 mm, being available under the trade name of “Shogun”. The apparent form
and microscopic image of this type of fiber shown in Figure. 3, and its specifications are
indicated in Table 2

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Close image of the lateral

surface of filament

Figure 3: Apparent form of Barchip filament (HPP) [17]

According to measurements by digital caliper, the cross section of this type of fiber was
obtained equal to 0.66 mm2, with a diameter of 0.917 mm and apparent relation of 52.34.
Steel fibers used in this study were of ST 37 steel type with the nominal length of 32 mm and
copper coating and the apparent relation of 53.33. Specifications of the used steel fibers in the
study are provided in Table 3, and the comparisons of the apparent forms of steel and Barchip
fibers are illustrated in Figure. 4.

Table 1: Chemical combinations of consumable cement

Chemical
L.O.I Na2O K2O SO3 MgO CaO Fe2O3 Al2O3 SiO2
elements
percentage
0.0 ± 1.2 0.0 ± 25.15 0.0 ± 49.2 1.0 ± 5.2 1.0 ± 9.2 0.0 ± 64.5 3.0 ± 82.2 0.0 ± 5.3 0.0 ± 22.4
of cement

Table 2: features of barchip fibers of the Shoogan (Barchip kind)

the base resin Poly Alyfyn
Length 48 mm
tensile strength 550 Mpa
surface texture prominent
The number of fibers in a kg >35000
specific gravity 0.90 – 0.92
young’s modulus 10 Gpa
Melting point 150 -160 ˚C
flash point Higher than 45 ˚C

Table3: profile steel fibers

Fiber shape Hooked ending
original length (mm) 32
Area (mm2 ) 0.2827
Fy (MPa) 240
Fu (MPa) 520

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(a) (b)
Figure 4: (a) HHP fibers of Barchip kind
(b) Comparison of the size of steel fibers and utilized HHP in the research

2-2. Concrete mix design

The preliminary mixture design was analyzed by the use of ACI 211.1 regulations and
after making the first samples, the necessary water/cement ratio for the purpose of good
efficiency was corrected. The final commixture has been written in Table.4, which all the
features have been unchanged within the whole period of the research. The only change was
the utilized fibers and their proportions.

Table 4: The applied commixture design for 1 m3 of concrete

project component Amount (kg)
Water 208.25
Cement 350
coarse-grained 848
fine-grained 1066
super-lubricants 4

For the purpose of having a brief introduction for the samples, each design has been given
a specific code and these codes have been generally introduced in Table5.

Table 5: Naming designs of experiments

Fiber percent Fiber type sample name Fiber percent Fiber type Sample name
0.8 Steel SFRC - 8 0.8 HPP HFRC - 8
0.6 Steel SFRC - 6 0.6 HPP HFRC - 6

0.4 Steel SFRC - 4 0.4 HPP HFRC - 4

Witness OC

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2-3. Preparation of samples

To test water absorption and chloride ion penetration depth and for testing permeability,
cube samples with dimensions 150 × 150 × 1 50 mm were prepared. Then, cores of 50 mm in
diameter were taken to conduct permeability test. In order to test abrasion, cube samples were
cut, to eliminate the effect of bleeding on surface and to effect of fibers in abrasion resistance
be judged better. All samples were demolded after 24 hours and were immersed into water to
be cured for 28 days in the ponds at a controlled temperature of 20 ± 2 ° C.

3. Results
3-1. Percent of water absorption
In order to assess effect of fiber on water absorption rate and also effect of chloride ion on
water absorption percentage, this experiment was conducted in two stages. The first phase is
related before immersing the samples to solution containing chlorine. In the second phase, the
samples were submerged for 5 months in chlorinated solution. After this time the samples
were taken out of solution and the water absorption percentage of samples was measured;
Results of water absorption percentage is shown in Tables 6 and 7.
.
Table 6: Results of water absorption percent of samples before exposure to chlorinated
solution
Sample Average Ratio to Sample Name Average Ratio to
Name (Percent) control (Percent) control
OC 2.481 1 1 0.451
HFRC-4 1.366 0.55 SFRC-4 1.12 0.463
HFRC-6 0.749 0.705 SFRC-6 1.15 0.48
HFRC-8 1.419 0.572 SFRC-8 1.19

Table 6 shows that the addition of fibers reduces water absorption, but the effect of steel
fibers is slightly more than HPP fibers. A mechanism can be considered for reduction of water
absorption by the fiber, which is fibers disconnect internal holes and pores. If in the ordinary
concrete without fibers all of these pores are saturated with water, in the presence of fibers,
only some of these pores are filled with water.
Table 7 shows the results of water absorption of concrete samples with fiber and without
fibers (control) after 5 months of exposure to chloride solution.

Table 7: Results of absorption of prepared samples after exposure to solutions

containing chlorine
Sample Name Average Ratio to control Sample Name Average Ratio to control
sample sample
OC 0.558 1
HFRC-4 0.381 0.683 SFRC-4 0.242 0.433
HFRC-6 0.443 0.794 SFRC-6 0.281 0.504
HFRC-8 0.36 0.645 SFRC-8 0.318 0.57

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Comparing the results in Table 6 and 7 show that absorption rate of all samples after
exposure to chlorine solutions has reduced significantly in comparison to the results of before
exposure. The reason of this observation is the influence of chloride ions and blocking pores
of concrete due to Friedel's salt production. At this stage of the experiment by increasing fiber
in the samples prepared with steel fibers, effect in reducing water absorption weakened. In the
stage before exposure to chloride solution, difference of the recorded value in the column
"ratio to control sample" for the sample containing 0.4 % volume of steel fibers with the
recorded value in the same column for the sample containing 0.8% of steel fibers has
difference about 0.03; while in stage after exposure to chloride solution, the performance
difference compared the two recent samples is equal to 0.137. Regarding the short time of
experiment (5 months), and unexpected potential impacts of chlorine ions on steel fibers
corrosion, this event can be due to rust produced from steel fibers. Since rust has greater
volume than the metal itself, in samples containing steel fibers also rust causes a space
surrounding the fiber and that increases the amount of water absorption and the more amount
of fiber used, the greater the number of these open spaces between fibers and the concrete.

3-2. Permeability of concrete

Recognized and valid standards, do not offer a method to do this experiment. This
experiment was conducted according to the report CRD C 163-92 [18]. In this experiment, the
cylindrical samples with a diameter of 50 mm were placed inside an equipment and lateral
pressure is imposed on the sample. By applying water head on the sample, the volume of
water leaked within a specified time after the steady flow is measured. Because of the large
fiber length and small diameter required for performing experiment of permeability,
placement of fibers in the mold could be affected. To solve this problem, the sample were
prepared with larger size (150 × 150 × 150 mm) and then cores with diameter 50 mm were
taken, so that dimension of mold has no effect on orientation of fibers and test results. Table 8
represents the results of this test. In this test, the lateral pressure was adjusted on 2 MPa and
water head for all samples was kept unchanged as 101.9 meter equal to 1 MPa.

Table 8: Results of permeability tests

Sample Name Permeability (m2) Ratio to control
OC 5.785*10-11 1
HFRC-8 ≈0 0
-12
HFRC-6 9.375*10 0.16
HFRC-4 9.91*10-12 0.171
HFRC-8 8.97*10-12 0.155
-11
HFRC-6 1.995*10 0.345
-11
HFRC-4 4.415*10 0.78

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The results in Table 8 show that addition of fibers reduces the permeability of concrete. As
fiber volume ratio in concrete increased, the permeability is reduced more. By comparing the
results obtained in similar percentages for steel fibers and Barchip HPP fibers , it is observed
that effect of BarChip fibers on permeability is more significant than steel fibers, so that in
volume percentage of 0.4, the difference of obtained result for these two patterns is
significantly high ( ratio of permeability of the samples prepared with BarChip to the control
sample is equal to 0.171, compared with the ratio of permeability of the samples prepared
with steel fibers to control sample is 0.78); By increasing the fiber volume ratio the difference
decreases. HPP fibers in volume percent 0.4 have significantly positive impact, while this
impact is not that much for steel fibers. In both types of fibers, increasing the volume of fibers
used in concrete resulted in further reduction of permeability. Reduced permeability in the
presence of fibers can be justified by three reasons. The first reason considered is that
penetration of water into the concrete, apart from the effect of capillary cracks and pores in
concrete that have a greater share in the permeability of concrete, is through cement paste.
Presence of fibers in concrete in a constant volume, reduces the amount of cement paste and
subsequently permeability is reduced. The second reason which is more important as shown
in Figure 5, is that fibers block path of water permeability by making bridge connection
among capillary cracks or pores of concrete, and reduces permeability of concrete. Third
reason is the reduction of concrete bleeding in the presence of fibers and thus decrease of the
internal pores in the concrete matrix.
Barchip fibers with larger length, block more number of pores. Another reason for better
performance of HPP fibers compared to steel fibers is that this is because of the physical
properties of fibers and compliance of HPP fiber or non-compliance of steel fibers among
aggregates. Non-compliance of fibers among aggregates creates a series of tiny pores in
concrete that increases permeability.

Capillary holes

Fibers

C.S.H net

Figure 5: Performance of fibers in reduction of concrete permeability

3-3. Penetration depth of chloride ion

Generally, factors contributing to the destruction of concrete are divided into two
categories of external factors and internal factors. External factors include three types of
chemical, physical and mechanical factors. One of the chemical factors of concrete
degradation is attack of chloride on the body of concrete. Reinforcement corrosion due to
penetration of chloride ions from surrounding to the concrete is the most important factor in
reduction of the useful service life of concrete structures. One of the discussions related to
inner lining of the tunnel is durability and service life. Chloride ions can enter the lining of

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tunnel through surrounding stones and water passing through tunnel. The method chosen for
this experiment is the easiest possible way to assess the depth of penetration of chloride ion;
this technique is called colorimetric in the scientific literature [19]. In this experiment, the
samples that have been exposed to chloride ions are cut and the section is exposed to silver
nitrate solution spray. After a while, the site containing chloride ion gets milky white and
with the passage of time gets black and the depth of penetration of chloride ion can be
accurately measured with less than 0.2 mm. Figure 6 shows the results expressed in the form
of graphical representation. In figure 6, it is found that in similar percentages for two types of
fibers used, the effect of HPP fibers in reducing penetration of chloride ion in concrete was
better than steel fibers. The reason for this can be in produced rust and creation of new routes
for penetration of chloride ions by rust.
Penetration depth of Cl )mm

Fibers percent

Figure 6: Penetration depth of chloride ion in concrete samples

3-4. Abrasion Resistance

In water transfer tunnels, one of the most important features of durability is
erosion resistance. If abrasion resistance can be increased by a technique, erosion resistance is
also expected to increase. As stated in the articles, adding fibers cause increase in abrasion
resistance [20]. This is due to prevention of concrete bleeding in presence of fibers and lack
of a weak layer against abrasion. The samples tested in this study are cut to obtain a surface
without being affected by bleeding because in this review, the aim was investigating the role
of fibers material in abrasion resistance. In order to evaluate the abrasion resistance, concretes
containing Barchip HPP fibers were measured in accordance with the standard 755 of Iran
related to mechanical abrasion. It should be noted that due to the sensitivity of the abrasion
test device, this experiment was not performed on samples containing steel fibers. Table 9
shows the results.

Table 9: Results of concrete abrasion test (mm)

Sample Name The average groove width Ratio of control
OC 44.66 1
HFRC-8 14.33 0.977
HFRC-6 14.33 0.977

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The results in this table imply that fibers have very little role in improving abrasion
resistance. Perhaps two main reasons can be cited for this. The first reason is that concrete
matrix has primary role in abrasion resistance and fibers may be affected by abrasion later and
by abrasion of matrix surrounding the fiber, the fiber itself remains alone that has no role in
the abrasion resistance and this can be generalized to other types of fiber as well. This is
shown in Figure 7.

Fibers Concrete sample

Figure 7: Early abrasion of the concrete matrix around fibers and fibers remaining

In the first mentioned reason, fibers role is considered ineffective or low. In the mosaic
abrasion test, abrasion wheel gets involved with a small part of sample and for this reason,
concentration or dispersion of the fibers in this area can affect the results. The recent case is
one of the disadvantages of mosaic abrasion test method. For fiber concrete that has randomly
distributed fibers, a test is suitable in which abrasion wheel is connected with entire surface of
laboratory sample, so that effect of fiber dispersion and aggregation is minimized. It is
expected that the test presented by ASTM C 1138 or even ASTM C 944 and ASTM C 779
provides more accurate and reliable results and impact of fiber in concrete is seen better.

4. Conclusion
1- Adding fiber reduces water absorption of concrete samples. In reducing water
absorption percent, steel fibers act more effective than HPP fiber.
2- Adding fiber reduces concrete permeability. This is due to blockage of connection ways
of internal pores in concrete. In this experiment, Barchip fibers have more impact than steel
fibers.
3- Due to the lower permeability of fiber reinforced concrete, life of tunnel lining
construction increases because of less risk of reinforcement corrosion, as well as increased
resistance to freeze-thaw cycles increases.
4- According to reduced permeability of concrete fibers, leakage potential is decreased
and stability of the lining structure is increased because 59.25 percent for failures occurred for
internal lining age of tunnel are caused by the water leakage.
5- Adding fibers reduces chloride penetration into concrete. The effect of steel fibers in
the similar percentages due to rust and increase of penetration into the concrete is less than the
impact of HPP fibers.
6- Reduction of penetration depth of chloride, due to the use of fibers, increases the life of
exploitation of tunnel and lining structures.
7- According to the kind of abrasion tests carried out, increase in abrasion resistance in the
presence of fiber is only 2.3 percent.
8- As a general conclusion, it can be said that Barchip fibers in durability characteristics
act better than steel fibers.

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5. Acknowledgments
The authors would also like to express their thanks to Mr. Shahrokh Soltaninia for his
valuable advice and assistance.

References
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buried tunnels, 5th national congress on civil engineering, Mashahd, 2010.
[3] EM 1110-2-2901, ''Design of Permanent, Final Linings'', chapter9, May 1997.
[4] Benson.R.P," Design of unlined and lined pressure tunnels", Tunneling and underground
space technology, Vol.4.Vol.2, PP.155-170, 1989.
[5] Gilbert, R.I. and Mickleborough, N.C., Design of prestressed concrete, SponPress, London
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[9] ACI Committee 544, "State-of-the-Art Report on Fiber Reinforced Concrete", ACI 544.1-
96, American Concrete Institute, Farmington Hills, MI, 1997.
[10] Shah, S.P., Rangan, B.V., "Fiber reinforced concrete properties", ACI journal, Vol.68,
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[14] Mashimo, H., Isago, N., Kitani, T., Endou, T., “Effect of Fiber Reinforced Concrete on
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ITA Assembly, Seoul, Korea, 22–27 April 2006.
[15] Chiaia .B., Fantilli.A.P., Vallini.P." Combining fiber-reinforced concrete with traditional
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60-71, 2012.
[17] Barchip Catalog, "Product data sheet (Barchip 48)", Elasto plastic concrete, see the web
site http://www.elastoplastic.com, 2009.

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[18] Corps of Engineers Standards, Test method for water permeability of concrete using
triaxial cell CRD-C 163-92, Handbook for Concrete and Cement, See the web site
http://www.wes.army.mil/SL/MTC/handbook/handbook.htm, 1992.
[19] Meck, E., Sirivivatnanon, V., "Field indicator of chloride penetration depth ", Cement
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[20] National Ready Mixed Concrete Association, "Synthetic Fibers for Concrete", National
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