CRYPSYSTEMS PROCESS: ENHANCED CRYPLON BASED

OXYFIBRE REINFORCEMENT PERFORMANCE IN

SHOTCRETE AND CONCRETE

A. Lubbe
Oxyfibre (Pty) Ltd, PO Box 1168, Hartbeespoort, 0216.
E-mail: annette@oxyfibre.com

ABSTRACT

Reinforcement in concrete and shotcrete can be provided using various materials such
as conventional reinforcing bars, prestressed wires and cables, steel mesh and different
types of fibres. Various types of fibres, man-made or natural have been used in
construction materials since ancient times. The choice depends mainly on the
reinforcement qualities, cost effectiveness, durability, etc. Over the years vast amounts
of research has been done on the use of fibres in concrete matrixes.

The patented Crypsystems process leads to the enhanced performance of Cryplon based
Oxyfibre reinforcement in shotcrete and concrete applications. The Crypsystems
process results in the synthesis of a modified fluoropolymer on the Oxyfibre surface
named Cryplon. Cryplon is a wettable, polarized surface with enhance adhesion
capabilities. This enhanced adhesion characteristics of Cryplon make it susceptible to
printing, painting, glueing and bonding with other substrates.

1. FIBRE REINFORCEMENT

Generally fibres can be classified into two categories, i.e.:

1. High strength, high modulus fibres such as glass, asbestos, steel and carbon;
2. Low modulus, high elongation fibres such as nylon, polypropylene and polyethylene.

However, the distinction has become blurred with the development and improvement of fibre
technology. In energy absorption testing, some low modulus fibres, exhibit qualities similar to
those achieved by high modulus fibres.

Fibres are added to the matrix in order to overcome the brittleness that is evident when
shotcrete and concrete are subjected to flexural or tensile forces. Fibres, and other forms of
reinforcement play an important role in improving the performance of the cementitious
composites. The design or properties of the concrete or shotcrete matrix, plays an important
role in the performance of the composite material.

Paper presented at the Conference: Developing Concrete to Serve Practical Needs Hosted by:
ISBN Number: 1-920-01717-8 The Industrial Development Engineers Association (IDEA)
13 – 14th October 2004, Midrand, South Africa. The Cement and Concrete Institute (C&CI)
CD produced by: Document Transformation Technologies 253 The Concrete Society of Southern Africa (CSSA)
Fibre characteristics influence the effectiveness of fibre reinforcement. Some of these are:
1. Aspect ratio;
2. Ductility;
3. Dosages;
4. Fibre Count;
5. Shape;
6. Rebound and
7. Resistance to balling.

Fibre surfaces can be modified or altered to improve their characteristics, i.e. the addition of
admixtures or wetting agents.

This presentation will concentrate on the characteristics of two types of fibre surfaces created by
permanent chemical modification, namely:
• Oxyfluorinated surfaces and
• Cryplon surfaces.

2. OXYFLUORINATED SURFACES

In 1998 joint research by the Rand Afrikaanse University and the Atomic Energy Corporation of
South Africa Limited investigated the effect of the chemical modification by oxyfluorination of
polypropylene surfaces.

A summary of their findings were as follows:

1. The interfacial bond between the oxyfluorinated polypropylene fibre and the cementitious
matrix was improved by increasing the surface free energy of the fibre surface bond;
2. Contact angles of water on the polypropylene fibre surfaces were decreased, increased
wettability;
3. Increased acid-based components of the surface energy;
4. Mechanical properties such as impact resistance, flexural load and compressive strength
were determined and significant improvements were observed;
5. Dramatically improved shrinkage cracking resistance;
6. Increased fibre/concrete matrix interfacial bonding

Oxyfluorination as a chemical method of modifying fibre polymer surfaces, overcome some of

polypropylene inherent characteristics such as poor wettability and weak interfacial bonding.
This technology resulted in the patenting of the first generation of Oxyfibre with its unique
characteristics. These results were presented in 2002 at the Concrete of the 21st Century
Symposium.

Oxyfluorination was done in a static batch process. Although results were promising the nature
of the static process presented certain restrictions, such as:
1. Handling – cutting, packing of stillages, oxyfluorination, packing of fibres;
2. Low production trough put – 40kg per 4 hour cycle;
3. Poor activation distribution through the bed thickness – resulting in reworks;
4. Results with high dosages were border line on minimum specifications, therefore unable to
penetrate structural markets such as shotcrete.

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3. CROSS ROADS…

Facing the consequences of these limitations and various other challenges relating to the
production facility, such as:
1. The commercial availability of specific gas mixtures;
2. The cost and practicality of using near absolute vacuum,

Oxyfibre increased its effort’s to improve the process of oxyfluorination even further.

4. CRYPLON SURFACES

This led to the development of Crypsystems Technology, a dynamic process to utilize alternative
fluorine gas mixtures and address the limitations of the production process. The Crypsystems
process can be applied on a wide variety of surfaces, such as metal, glass, carbon fibre, etc.
This technology was patented in December 2003.

In polymers, activation of surfaces resulted in the synthesis of a modified fluoropolymer named

Cryplon. Cryplon is a wettable, polarized surface with enhance adhesion capabilities. This
enhanced adhesion characteristics of Cryplon make it susceptible to printing, painting, glueing
and bonding with other substrates.

Cryplon based Oxyfibre has enhanced adhesion characteristics and increased mechanical
property results were achieved. Increased interfacial shear bond strength were obtained.
Performance enhancement of fibre reinforcement has been confirmed in panels subjected to the
Efnarc energy absorption panel test.

The improvements made to oxyfluorination resulted in the development of the Crypsystems

process with the following advantages:
1. Enhanced adhesion characteristics that could overcome the limitations of the static batch
process;
2. Continuous dynamic process;
3. Increased production capabilities;
4. Improved efficiencies and lowered the environmental impact of the process.

Mechanical and structural test results confirmed the improved characteristics of Cryplon based
Oxyfibre.

The most significant of these were:

1. Improvement of more than 50% in the interfacial shear bond strength;
2. Improvement of more than 40% in the Efnarc panel test results.

Based on the above results a decision was taken to enter the structural shotcrete market.
Selected data resulting from an extensive research and development program is reflected in the
following test results.

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5. TEST RESULTS

5.1 Compression Test

Mix design
Cement Sand Stone Water
1.0 2.15 2.82 0.62

Oxyfibre Dosage: 0.6% by volume (6 kg/m3)

Three-day compressive strengths:

Plain concrete Oxyfibre Reinforced concrete

Load (N) 118 102 119 132 116 120
Compressive strength 11.3 12.3
(MPa)

Although Oxyfibre does not significantly influence compressive strength, slight increases occur

5.2 Early Compressive Strength Development

Curing time Compressive strength (MPa)

(hrs) Plain concrete PP fibrillated Oxyfibre
fibre
8 1.0 ± 0.2 0.9 ± 0.2 1.6 ± 0.03
16 6.5 ± 0.3 5.1 ± 0.1 6.6 ± 0.2
24 6.5 ± 0.1 6.2 ± 0.3 7.8 ± 0.3
72 14.3 ± 0.5 14.8 ± 0.4 17.5 ± 0.3

Oxyfibre improved early curing

5.3 Impact Resistance Test

Mix design
Cement Sand Stone Water
1.0 2.15 2.82 0.62

Oxyfibre Dosage: 0.6% by volume (6 kg / m3)

Number of blows to cause initial cracking and final failure of the concrete:

Plain concrete ORC

Initial cracking 8 12
Final failure 13 68

Impact strength of the fibre reinforced concrete increases greatly with increased dosages of
Oxyfibre.

5.4 Flexural Test

Commercially available, pre-bagged shotcrete material was used with a water/cement ratio of
0.38.
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Oxyfibre Dosage was 6.07 kg / m3

Plain concrete ORC

Flexural strength (MPa) 4.6 4.7 4.7 4.9 4.9 4.8
Average flexural strength 4.7 4.9
(MPa)

Regardless of cracking, the Oxyfibre reinforced beam stayed intact.

5.5 Restrained Plastic Shrinkage Test

The cracking control capacity of the Oxyfibre in concrete is calculated using the following
formula:

[1 - (cracking area of a fibrous concrete) / (cracking area of plain concrete)] x 100

Plain concrete ORC

Average crack width 0.37 mm 0.15 mm
Total crack length 870 mm 120 mm
Cracking Area 321.9 mm2 18.0 mm2
Cracking control capacity 0 94.4%

Oxyfibre effectively control plastic shrinkage cracking

5.6 Concrete Bleeding Test

The effect of fibre addition on the rate of bleeding was measured. Bleed water was withdrawn
from a specific surface area of concrete during a specific interval and collected. The bleeding
percentage was calculated from the volume bleed water and the volume of mixing water in the
test sample:

Plain concrete ORC

Bleeding percentage 9.43 % 3.18 %

Most of the moisture is retained throughout the profile of the matrix

5.7 Interfacial Shear Bond Strength

Type of fibre Interfacial Shear Bond Strength (MPa)

PP fibrillated fibre < 0.10
Cryplon based Oxyfibre (0.42 – 0.54)

Significant improvement in interfacial shear bond strength

5.8 Wettability

With Crypsystem adhesion technology, the Cryplon surface becomes wettable and polarized

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5.9 Efnarc Test Results

Fibre type Energy Joule Absorption (J)

PP fibrillated fibre 627
Oxyfibre 1024

Significant improvement occurs in both the energy absorption and the residual energy.

Although cracking occurred no catastrophic failures were observed.

Visual observation:

Normally a typical four-way crack is observed on an Efnarc panel. Cryplon based Oxyfibre
exhibits a spider web type fracture panel. It is apparent that the cracking stresses are more
widely distributed.

Photograph 1. PP fibrillated fibre panel. Photograph 2. Cryplon based Oxyfibre panel.

In addition Oxyfibre exhibits high residual values at the end of the 25mm deflection loading
cycle. This indicates that the panel can still provide further energy absorption beyond the
loading cycle specified in the Efnarc test.

Figure 1. Efnarc test result – Cast panel – 36 mm fibre – Dosage 8.6 kg/m3
1222 joules.

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 Figure 2. Efnarc test result – Sprayed panel– 36 mm fibre – Dosage 7.8 kg/m3.
853 joules.

Mechanical property tests were conducted by Dr Lin Tu at the Rand Afrikaanse University.

Shotcrete panel tests were conducted by RG Forester of Omega Consulting Services and
tested at Geopractica.

6. CONCLUSION

Crypsystems synthesized Cryplon surfaces have unique characteristics:

1. Increases of up to 30% were observed in the Efnarc energy absorption panel tests;
2. The high performance of Cryplon based Oxyfibre allows lower dosage rates to be used;
3. In the mechanical properties tests, significant improvements were observed.

The Crypsystems process has been proven to be an effective method of improving the
performance of fibrillated polypropylene tape type fibres for shotcrete and civil concrete
markets.

7. DISTRIBUTORS

Oxyfibre specializes in Crypsystems activation of surfaces. In fibres these surfaces are mainly
polypropylene. However in other applications we are activating polyethylene, ultra high density
polyethylene, steel and glass to mention some.

Therefore we forged relationships in the relevant markets that have the expertise in that specific
market. One such a relationship was the appointment of Chryso Mining Division as a distributor
in the mining sector.

We also have Roadmat in the Western Cape that distribute Oxyfibre in that region.

8. APPLICATIONS

1. Wetcrete
2. Drycrete
3. Housing

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9. FUTURE DEVELOPMENTS

The improvements observed on the fibrillated tape type fibre in structural applications led to
reductions in dosages in that specific application. Research and development are currently
taking place to activate different types of fibres and testing reduced dosages in non structural
applications, i.e. plastic and drying shrinkage crack control.

Oxyfibre is committed in developing the Crypsystems Technology for application in

concrete matrixes to serve practical needs

10. REFERENCES

[1] Fibre reinforced concrete, Cement and Concrete Institute, Midrand.

[2] Forester, RG, Crypsystem treatment process enhances Polypropylene fibre reinforcement
performance in shotcrete and Concrete, 2004.
[3] Tu, L and Kruger, D and Wagener, JB and Carstens, PAB. Surface modified polypropylene
fibres for use in concrete. Magazine of concrete research, 1998, 50, No. 3, Sept. 209-217.
[4] Lubbe, A., and Tu, Dr. L, Oxyfibre: A Surface Wettable Fibre. Proceedings: Concrete for
the 21st Century, Midrand, Gauteng, South Africa. 2002. p 2.

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CRYPSYSTEMS PROCESS: ENHANCED CRYPLON BASED
OXYFIBRE REINFORCEMENT PERFORMANCE IN
SHOTCRETE AND CONCRETE

A. Lubbe
Oxyfibre (Pty) Ltd, PO Box 1168, Hartbeespoort, 0216.
E-mail: annette@oxyfibre.com

Biography

Annette Lubbe (Mrs)

Annette Lubbe matriculated in 1978 from the Koster High School. She graduated with a BSc
degree with majors in chemistry, microbiology and plant physiology from Potchefstroom
Universiteit vir CHO in 1983.

After graduation she worked at the CSIR as a researcher for two years. For the next four years
she worked in the private sector. In 1991 she joined the Atomic Energy Corporation of SA and
worked on various projects.

In 1996 she joined Fluoro Pack (Pty) Ltd as Marketing Manager and was involved in market and
product development of the surface fluorination business in South Africa. In 2002 she was
promoted to General Manager of Fluoro Pack (Pty) Ltd.

During the restructuring of the surface fluorination businesses, she also became the General
Manager of Oxyfibre (Pty) Ltd in 1999. In Oxyfibre (Pty) Ltd she focuses on the product and
market development of oxyfluorinated fibres into the civil and mining industries as well as
product and market development of oxyfluorinated polymer adhesive surfaces.

In December 2003 Oxyfibre patented the new Crypsystem technology which enhanced
adhesion capabilities of Cryplon surfaces

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