A DETAILED OVERVIEW OF

STEEL FIBER REINFORCED CONCRETE

Heri Siswanto | July 2021
Heri Siswanto
 Alumni Fakultas Teknik Universitas Sebelas Maret (UNS), Surakarta
 Anggota aktif American Concrete Institute (ACI)
 Certified Commercial / Industrial Flooring Technician – ACI
 Certified Concrete Flatwork Associate – ACI
 15 tahun di bidang teknologi bahan bangunan dan konstruksi
 11 tahun di bidang fiber concrete technology
 7 tahun menekuni bidang steel fiber untuk perkuatan beton
 Aktif mengajar Teknologi Bahan Bangunan di beberapa universitas

E heri.siswanto@bekaert.com
M +62 811 330 7800
AGENDA
1. Fiber Reinforced Concrete History
2. What is Steel Fiber Reinforced Concrete (SFRC)
3. Steel Fibers and Basic Material Properties of SFRC
4. How Current Codes and Standards Deal With SFRC
5. SFRC Analysis and Design Software
6. Study Case
7. Steel fibers and synthetic fibers
1.Fiber Reinforced Concrete History
 CONCRETE!

BC

? ?
 History of
fibers concrete

Thousands of years ago, the Romans used fibers reinforcement in their concrete – in the
form of horse hair
History of
fibers concrete
Ancient times
History of
fibers concrete
1900s
History of
fibers concrete
1960s

Steel, Glass (GFRC), and synthetics such

as polypropylene
History of Steel Fiber
Today

James Romualdi 1963

Ann Lambrecht 2011

NOW

2000 - Now
2. What is Steel Fiber Reinforced Concrete (SFRC)
How it works?
Beam Test EN 14651
Material Characterization (EN 14651)

Bending stresses

Constitutive law (Model Code 2010)

Tension stresses
compression
zone

tension zone
(steel fibers)

Section moment capacity

Internal moment
capacity Mrd
3. Steel Fibers and Basic Material Properties of SFRC
Steel Fibers
Performance
Tensile Strength Wire Elongation

Length/Diameter Anchorage
(L/D) Ratio
 Anchorage

300N 500N 1200N

+67% +140%

+300%
Length/Diameter
Long fibre
(L/D) Ratio
The longer the length of the fibre the
better the anchorage.

The higher the L/D ratio, the better the performance of steel
fibre reinforced concrete.

Length

Short fibre

Diameter

The longer fibre = the better the anchorage

Smaller diameter = dense network / overlap
.
SFRC Performance
The higher dosage the better performance
SFRC Performance
The better concrete quality the better performance
SFRC Performance
The higher L/D ratio the better performance
SFRC Performance
The longer fibers the better performance
SFRC Performance
The better anchorage system the better performance
SFRC Performance
The stronger wire the better performance
4. How Current Codes and Standards Deal With SFRC
International
product standards
for steel fibres
• ISO 13270
• EN 14889-1
• ASTM A 820

ISO 13270

EN 14889 ASTM A 820

Important note
about product standards

• a product standard defines the properties of a product and the related

quality control procedures
• it doesn’t certify the product for a specific application

Example from EN14889:

• product certification for “structural uses” does not mean the product is
suitable for any structural use as such
• the term “structural uses” confirms that the production quality control and
the attestation of conformity satisfy the requirements for products that shall
be used in a structural application
Important (structural) application standards for SFRC
Important (structural) application standards for SFRC
2003: RILEM TDF
• origin of all modern SFRC standards

2010: DAfStb ‘Steel Fiber Concrete’

• first fully integrated and approved national design code for SFRC structural applications

2012: fib Model Code 2010

• state of science as blueprint for international codification
• pre-normative

2019: IAPMO UES ER-465

• Bekaert’s US approval for SFRC structural and non-structural applications
• in accordance with IRC and IBC
• fully integrated with ACI 318 and 360 and ASTM A820 and C1609

202?: Eurocode 2, Annex L (draft)

• future European standard for SFRC structural applications
• currently at committee draft level
 SFRC in ACI 318 and 360 vs. IAPMO UES
IAPMO UES ER-465

Bekaert launched IAPMO UES ER-465

• comprehensive design approach for SFRC
• structural applications
• non-structural applications
• covering ACI 318 and ACI 360 and linking into it
• referenced by US codes (e.g. IBC and IRC)
5. SFRC Analysis and Design Software
Software available in the market

For specific applications (slab on For more complex structural applications, SCIA software (Europe based
grade, slab on piles, …) or section company) or ADAPT software (North-American based company)
calculations (moment capacity,
shear, …).
• SCIA Engineer: 3D software offering SFRC design
• Design and optimize the required Kgs of fibres
based on capacity
• Design of concrete floors with and without traditional
reinforcement
• Possibility to do ULS and SLS checks
• Linear and non-linear calculation with real material
behavior simulation to predict the cracking stages
• Two different stress-strain diagrams for material
behavior
ADAPT developed a structural analysis software to
design and calculate steel fibre reinforced concrete
for structural and non-structural applications.
6. Study Case
PROJECT STUDY CASE

1. SAW CUT JOINT FLOOR – Instant Coffee Production Facility, Semarang, Indonesia

2. JOINTLESS FLOOR – FMCG Warehouse, Tarlac, Philippine

3. SEAMLESS FLOOR – Modern Building Material Outlet, Surabaya, Indonesia

Comparison of different floor concepts

Sawcuts Joint Floor Jointless Floor Seamless Floor

30x60m 30x60m 30x60m
SAW CUT JOINT FLOOR
INSTANT COFFEE PRODUCTION FACILITY, INDONESIA
Why/why not Saw Cut Joint Floor

High maintenance cost

Joints filler replacement Economical Solution
Joints repair Low initial investment
Forklift operation

Joints problem
Damaged
Easy to construct
To achieve flatness/levelness
Delamination
No special equipment required
Unlevel
No special joint

Operation problem
Forklift movement not smooth
Less construction risks
Concrete supply problem
Slower movement
Workmanship
Extra operation cost
Project Background
Instant Coffee Production Facility, Indonesia
Year of construction 2019 – 2021

Type of application Slab On Ground (indoor & outdoor)

Floor area 77,000m2 (indoor) and 60,000m2 (outdoor)

Product / brand Dramix 3D 80/60 BG

User PT Teamworx Indonesia (Consultant)

PT Tata Mulia Nusantara Indah
Project description The client is the biggest instant coffee manufacturer in
Indonesia. Apart of quality, they need fast construction method
due to high demand of their products.

PROJECT REQUIREMENTS CHALLENGES

LOADS DESIGN STAGE

1. Live Load UDL 4 ton/m2 Need to collaborate information and requirements from 3 different
2. Axle loads = 14ton/axle (truck), 6 ton/axle (forklift) parties; owner, consultant, contractor during the final design stage
3. Point load = 10 ton/point

CONSTRUCTION
A fast track project :
SOIL SUPPORT - Casting outdoor before upper structure installed
K value = 0.039 N/mm3 - Heavy equipment movement on the floor
(CBR 5%) - Trucks load on the floor before 28 days
Dramix Design

Uniformly Distributed Loads

SFRC Design

Axle Loads
SFRC Design

Point Loads
SFRC Design

SOIL SUPPORT
SFRC Design
CONSTRUCTION PROCESS

Mixing Steel Fibers

Screeding process Slab casting

CONSTRUCTION PROCESS

Concrete curing

Finishing Saw cut

RESULT
RESULT
LESSON AND LEARN FROM JOBSITE
LESSON AND LEARN FROM JOBSITE

PROBLEM SOLVING
- Consultant and Bekaert did another calculation by including
jacking loads
- Contractor could continue jacking but need to make 50x50cm base
plate for each leg
- No change required on the floor design

LEARNING
- More detail information we have, the more accurate design we can Execution control is very important!
provide
- Good communication of all project parties is essential
JOINTLESS FLOOR
FMCG WAREHOUSE, TARLAC, PHILIPPINE
Why/why not Jointless Floor

Need specialist applicator

Faster construction and equipment
400m2 to 2,500m2 per day Experienced worker and finisher
Laser screeder

Low maintenance cost

Protected by armor joints Need special joints
No Sawcuts Armor joints
Longer lifetime

Smooth operation Higher initial investment

Less joints Special joints
Faster forklift movement Specialist applicator and equipment
Why/why not Jointless Floor

SAWCUT JOINT FLOOR JOINTLESS FLOOR

Project Background

FMCG Warehouse, Tarlac, Philippine

Year of construction 2019

Type of application Slab On Ground

Floor area 33,000 m2

Product / brand Dramix 3D 80/60 BG – 105 MT

User Infratex Environmental Services, Inc

ILO Construction (Main Contractor)

Project description A warehouse project for Dramix international customer, Nestle.

Together with our Distributor, the contractor manage to convince
the owner and consultant to use SFRC.

PROJECT REQUIREMENTS
CHALLENGES
LOADS DESIGN STAGE
1. Double racking = 8 ton/point Design with various load case including earthquake consideration
2. Forklift = 3 ton/wheel (downward force)

CONSTRUCTION
Concrete supply continuity
SOIL SUPPORT
K value = 0.041 N/mm3
DRAMIX DESIGN
EXECUTION PROCESS

Corner reinforcement + PE sheet

Subbase preparation Steel Fiber Mixing

EXECUTION PROCESS

Steel Fiber Wash Out Test Procedure : BS EN 14721:2005 +A1:2007

EXECUTION PROCESS

Trowelling

Finishing process Flatness/levelness measurement

RESULT
SEAMLESS FLOOR
MODERN BUILDING MATERIAL OUTLET, SURABAYA, INDONESIA
Why/why not Seamless Floor

High serviceability
Very small cracks
Water tight

Higher initial investment

No maintenance cost Compared to SCJ and Jointless Floor
Monolithic floor Double reinforcement (wiremesh + steel fibers)
No joints repair/maintenance
Most durable floor

Seamless operation
Smooth forklift movements
Less forklift maintenance
Why/why not Seamless Floor

Traditional reinforcement:

Combined (steel mesh/rebar) + Dramix) reinforcement:

Project Background

Modern building material outlet, Surabaya, Indonesia

Year of construction 2019
Type of application Slab On Piles – Combi
Floor area 8,000 m2
Product / brand 4D 65/60BG
User PT Citra Graha Selaras (General Contractor/Floor applicator)
Project description As one of the largest building material outlet in Indonesia, customers
need to have high quality floor, both for the durability and serviceability.

PROJECT REQUIREMENTS CHALLENGES

DESIGN STAGE
LOADS
CRACK WIDTH - Initial design was beam slab, large pile spacing and thin slab
1. UDL 4 ton/m2
0.2MM - Loads information was very limited, only UDL

CONSTRUCTION
PILES SUPPORT - Have to pump SFRC with 30kg/m3 of 4D 65/60BG
Pile grid 4000x4000mm - Contractor use big laser screed on the top of wiremesh
Pilecap size 800x800mm - Contractor require very low W/C ratio – a lot of chemical used
Dramix Design
Dramix Design
EXECUTION PROCESS

Top mesh and Corner reinforcement Concrete Pump

• 69m Horizontal pump
• One 90degree angle
EXECUTION PROCESS

Bridge for big laser screeder

EXECUTION PROCESS

• Continuous top mesh and tie bars to conform with project requirement (Monolitch)
RESULT
LESSON AND LEARN

• Use small laser screed as need to walk on mesh

LESSON AND LEARN

Which one do you prefer?

7. Steel fibers and synthetic fibers
These days we particularly use steel and synthetic fibres

Steel fibres Macro synthetic fibres Micro synthetic fibres

• Typically 30–70 mm long
and 0.5–1 mm in diameter.
• They can have straight,
wavy, hooked ends
• Typically 30–70 mm long and • Typically 5–20 mm long and
0.5–1 mm diameter 0.03 mm or less in diameter
• Embossed or wavy • Monofilament or fibrillated
fibres
• Polypropylene is typically the
most used material for macro
synthetic fibre
Material properties of steel and synthetic fibres

Concrete Steel fibres Synthetic fibres

Young’s modulus 30,000 MPa 210,000 MPa 3,000–10,000 Mpa
Tensile strength 1–2.5 MPa 1,100 – 2,300 MPa 200–600 MPa
Loss of mechanical
> 370°C > 50°C
performance
Melting point 1500°C 165°C
Creep > 370°C At all temperatures
Young’s modulus
The young’s modulus is essentially a measurement of the stiffness of a material. The young’s modulus of concrete is a
key factor in estimating the deformation of buildings and members.

Concrete Steel fibres Synthetic fibres

Young’s modulus 30,000 MPa 210,000 MPa 3,000–10,000 MPa

Steel has a very high Polypropylene has a low

young’s modulus.
young’s modulus.
The young’s modulus of
synthetic fibres is 3,000–
10,000 MPa, which is
largely insufficient to
reinforce concrete material
with a modulus of 30,000
MPa.
Young’s modulus

If we look at the Young's modulus of different

types of fibre, we gain a very important insight –
Steel Fibres are significantly stiffer than concrete
(higher Young's modulus), whereas Synthetic
Fibres are less stiff than concrete (lower Young's
modulus).
 Tensile strength
Concrete Steel fibres Synthetic fibres
Tensile strength 1–2.5 MPa 1,000–2,300 MPa 200–600 MPa

Tensile curves different wire qualities

2500

 Steel is up to 5 times
2000
stronger than PP
Tensile strength steel
Stress (MPa)

1500

1000

500
Tensile strength PP PP Yarn

0
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00

Strain (%)

3D 65/60BG 4D 65/60BG 5D 65/60BG PP yarn

Melting point
Concrete Steel fibres Synthetic fibres
Loss of mechanical
370°C 50°C
performance
Melting point 1500°C 165°C

Steel fibres only lose Synthetic fibres lose their

their mechanical mechanical properties at 50°C
properties at 370°C and and they melt at 165°C.
they melt at 1500°.
In a fire, the mechanical
properties of synthetic fibres
will decrease very fast.
 900°C Creep
Creep is the tendency of a solid material to move slowly or
deform permanently under the influence of permanent
mechanical stresses. It can occur as a result of long-term
exposure to high levels of stress that are still below the yield
strength of the material.

370°C Creep is more severe in materials that are subjected to heat

for long periods, and generally increases as they near their

NO CREEP
melting point.
CREEP

Liquid 165°C (Tm)

Visco-
elastic
Elastic -20°C (Tg)

Synthetic fibres Steel fibres

Creep
Concrete Steel fibres Synthetic fibres
Creep >370 °C At all temperatures

Creep (1/100 mm)

1200

Stop test: max. strain of gauge

1000
Beam fell down
800
Beam fell down

600

400

200

0
0 200 400 600 800 1000 1200
Time (days)
Macro synth 1 4.55 kg/m³ Macro synth 2 4.55 kg/m³ 3D65/35BG 20 kg/m³
Macro synth 1 4.55 kg/m³ Macro synth 2 4.55 kg/m³ 3D65/35BG 20 kg/m³
Macro synth 1 4.55 kg/m³ Macro synth 2 4.55 kg/m³
 The differences between steel fibre and synthetic fibres in a nutshell

Macro synthetic Micro synthetic

Steel fibres
fibres fibres

Young’s modulus 210,000 MPa

3,000–10,000 MPa
Tensile strength 1,100–2,300 MPa 200–600 MPa
165°C
(does not reinforce)
Melting point 1500°C

Plastic shrinkage reinforcement X X V

Drying shrinkage reinforcement V V X
Load bearing reinforcement SLS V X X
Load bearing reinforcement ULS V V X
 Steel Synthetic
fibres fibres

Jointless Floor X
Saw cut Floor X
Floor Seamless Floor X
Floor on piles X
Screed/compression layer X
Piers and piles X
Raft/Mat foundation X
Advised fibre use for different applications
Foundation
Shallow foundations X
Underwater concrete X Steel fibres:
Asphalt pavement X Structural Applications for
Pavement
Concrete pavement X
moment capacity
Pipes X
Sewerage enhancement and controlling
Water tanks/collectors X
drying shrinkage
Walls X
Beams X
Macro synthetic fibres:
Structural Cable stay X
(excl foundation) Decks X Non structural applications:
Pre/post tensioned When SLS is not important
structures X
Other structural X
When fire resistance is not important
Coupling beams X x
For temporary structures
Seismic Diaphragm X X
Shear walls X X
Final lining X
Secondary lining X
Underground
structures Segmental lining X
Single shotcrete lining X
Temporary shotcrete lining X X
TERIMA KASIH
HERI SISWANTO
E heri.siswanto@bekaert.com
M +62 811 330 7800