APPLICATION OF POLYPROPYLENE NONWOVEN FABRICS FOR CEMENT COMPOSITES REINFORCEMENT

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1 ASIAN JOURNAL OF CIVIL ENGINEERING (BUILDING AND HOUSING) VOL. 12, NO. 5 (2011) PAGES APPLICATION OF POLYPROPYLENE NONWOVEN FABRICS FOR CEMENT COMPOSITES REINFORCEMENT H. Pakravan a, M. Jamshidi b,c*, M. Latifi a and M. Neshastehriz a a Department of Textile Engineering, Textile Research & Excellence Centers, Amirkabir University of Technology, Tehran, Iran b Department of Chemical Engineering, Polymer Group, Iran University of Science and Technology c Building and Housing Research Center (BHRC), Tehran, Iran Received: 10 July 2010 Accepted: 25 February 2011 ABSTRACT This study addresses the application of polypropylene (PP) nonwoven layers for strengthening cement composite by investigating its flexural performance. Nonwoven layers produced by two different bonding techniques (needle-punching and calendaring) were used to reinforce cement sheets. The effect of some parameters related to layers on cement reinforcement was considered in this study. In addition, the application of short fibers (PP and acrylic) on cement/nonwoven composites was experienced. It was found that the cement composite made of thinner layers exhibits greater load-bearing capacity, because of the better penetration of the cement paste to nonwoven layers. The cement matrixes reinforced by nonwoven layers showed better flexural performance and strain-hardening behaviour compared to short fibers reinforced cement composites. Keywords: Nonwoven; textile fabric; cementitious composite; flexural strength 1. INTRODUCTION Cement matrixes were brittle in nature. For these reason, asbestos fibers were applied for cement reinforcement during the last century. At first, asbestos fibers were used in industrial process to produce flat and corrugated fiber reinforced cement sheets. Despite of all proper properties gained by this reinforcement, it can also constitute a major health hazard to human's safety. Thereafter, various types of synthetic fibers were produced and used as asbestos substitute [1]. Polypropylene fibers were used as a direct substitute for asbestos fibers in cement reinforced composites but this has not been fully explored, partly because of very significant * address of the corresponding author: masoud52@yahoo.com (M. Jamshidi)

2 552 H. Pakravan, M. Jamshidi, M. Latifi and M. Neshastehriz differences in material characteristics. For instance, asbestos fibers have greater fiber strength and durability, high physical and chemical resistance, and a significant affinity to cement particles which makes possible their inclusion to cement matrix up to 10% volume fraction in a continuous production process [2]. While, polypropylene fibers have a low modulus of elasticity and do not have chemical bonding to cement paste [3], and it was difficult to have high fiber content in cement paste because of their hydrophobic property and specific weigh which was lower than water. In cement composite containing low-modulus fiber, such as PP, the reinforcement enhances mainly its ductility, but does not reinforce the brittle cement matrix at its postcrack zone. This brings the strain-softening behaviour of the cement composite [3-4]. The bonding improvement of low-modulus fibers to the cement matrix can be led to a strain-hardening behaviour of reinforced composites. Several researchers have been worked on the increase of bonding between fibers and cement matrix by employing various chemical and mechanical treatments [5-8]. Although, they showed the improvement of fiber performance in cement composites due to chemical/mechanical treatment, but these improvements have limitations because of difficulty in the application of higher amount of fiber content in the cement matrix. For this reason, a new class of cement composite materials have been introduced which were called textile reinforced cement based composites (TRCC) [9-10]. Textile reinforcement provides higher amount of fibers contained in cementitious materials compared to ordinary FRCCs and shows better bonding to cement based materials because of the interlocking of textiles net and hydrated cement matrix. Textile reinforced concrete (TRC) was a sophisticated composite material with enhanced tensile strength and ductility. There is a growing interest in the use of fabrics as the main reinforcement in cement based composites. Many researchers have studied on different type of fabrics for strengthening cement materials [11-13]. These materials exhibit superior tensile strength and ductility in comparison to other discrete FRCCs such as glass fiber reinforced concrete (GFRC) and engineering cementitious composite (ECC) [14]. In every case of textile reinforcement, the following criteria were noticeable: load bearing capacity, minimum reinforcement, The necessary anchorage of the textile reinforced cementitious layer [9]. Textiles can improve the strain capacity or ductility of the inherently brittle cementitious matrix and its energy absorption capability or toughness which was generally characterized by the area under a stress-strain or load-deformation curve. The degree of improvement depends on the type of textiles and their structural characteristics. There were many structures for fabrics which depend on its method of weaving. Different types of fabrics were investigated for cement based materials reinforcement, including woven fabrics [15-16], weft knitted fabric and warp knitted fabrics [17-18]. Another type of textiles were Nonwoven fabrics that made by arrangement of short fibres in random directions. Many definition exist for Nonwoven Fabrics, INDA (North America s Association of the Nonwoven Fabrics Industry), defines a nonwoven fabric as a manufactured sheet or web structures bonded together by entangling fibers or filaments, by

3 APPLICATION OF POLYPROPYLENE NONWOVEN FABRICS FOR various mechanical, thermal and/or chemical processes [19]. These types of textiles were made directly from separate fibres. There were some researches on application of nonwoven fabric in concrete [20-21]. In this study nonwoven fabrics were suggested for cementitious composites reinforcement. It was expected to nonwoven fabrics provide some benefits such as excellent anchorage and bond development in cement reinforcement because of their opening structures and non uniformity. The aim of this work was to evaluate the effect of PP nonwoven fabrics on the ductility of reinforced composites. The PP nonwoven fabrics with different weights at different textile layers were used in cement composites and flexural properties were investigated. The effects of re-punching of needles on nonwoven fabrics performance in cementitious matrix was studied, too. 2. MATERIALS AND METHODS 2.1 Materials Nonwoven fabrics were layers made of filament fibers which were bonded together in order to have a desired strength for different application. Different PP nonwoven fabrics were used in this study including nonwoven fabrics bonded by needle-punching and calendaring methods (Figure 1). The basis weight of the calendared nonwoven was 97gr/m 2 and for the needlepunched layers was 200 and 262 gr/m 2. The variable parameters were the number of fabric layers, the number of needle-punching process, and the production system of nonwovens. (a) Action of a barbed needle through the batt of fibres [19]

4 554 H. Pakravan, M. Jamshidi, M. Latifi and M. Neshastehriz (b) Schematic description of calendaring process Figure 1. Nonwoven fabric production methods Images of both types of used Nonwoven fabrics were shown in Figure 2. In these pictures, position of needles and bonded points were shown clearly. (b) (a) Bonded points Trace of needle Figure 2. PP nonwoven fabrics; (a) needle-punched type and (b) calendared type Short polypropylene fibre was used to comparing with performance of nonwoven fabric in cementitious composites. The physical and mechanical properties of fibre were given in Table 1. Table 1: Properties of PP fibers Fiber type Diameter (µm) Density (gram/cm 3 ) Tensile strength (MPa) Elongation (%) Polypropylene

5 APPLICATION OF POLYPROPYLENE NONWOVEN FABRICS FOR Preparation of specimens All specimens were prepared by the moulding equipments and the special mould which were used for cement/fibre sheets production, as shown in Figures 3 & 4. Individual nonwoven fabrics were laid in the centre or designed level of the cement pastes by hand. The dimension of the nonwoven fabrics in the composite was equal to the area of used mould. The dimension of the specimens was 6-8 mm thick, 80 mm wide and 200 mm long. During the preparation of the specimens, a 100N sinker was applied over the composite to remove pores from the composite matrix. The specimens were reinforced by two and five layers of Nonwovens and were left in the conditioning room for 28 days. Thereafter, they were tested by the three point bending method. In the same way, cement/nonwoven/fibre composite specimens were prepared with loose short fibres (PP and acrylic). Figure 3. Sample preparation system Figure 4. Parts of the sample preparation mould 2.3. Test methods Flexural test The flexural strength of the composite was determined by the three points bearing test in accordance with EN12467 standard [22]. The Clear span was 160 mm. The test was carried out in Tinius Olsen testing machine at the crosshead rate of 0.02 mm/min. The loaddeflection curves were recorded. The flexural strength of the composite was calculated. The average of at least three specimen's results was finally reported. Alkali resistance test In the next step, the long term durability and performance of nonwovens in an alkaline environment similar to the cement paste was assessed. The aim was to evaluate the effect of alkaline environment on the mechanical property of nonwovens. For this purpose, the layers were soaked to alkali solution with ph of 12. After 28 days, nonwovens were studied for mechanical and physical performances by Instron tensile testing machine. The results show that the tensile property of nonwovens was not changed. Thus, it can be concluded that PP layers were durable in the alkaline environment of cement hydrates. Microstructures analysis The microstructure of samples was characterized using scanning electron microscopy (SEM) and optical microscopy (OM). The goal was to correlate the penetration of the cement paste in nonwoven pores with the fibre bonding to matrix. The fragments of specimens after

6 556 H. Pakravan, M. Jamshidi, M. Latifi and M. Neshastehriz bending tests were used for SEM imaging. 3. RESULTS AND DISCUSSIONS The performance of the composites was evaluated by bending tests. The cement matrix load carrying capacity was 44 N. Figure 5. Flexural behaviour of plain and fibre reinforced matrix According to Figure 5, randomly distributed fibres (polypropylene) improve the flexural strength of the cement matrix, but do not change their ductility. The yield lines were very similar to that of none reinforced cement matrix. At the higher fibre content, strainhardening behaviour of composite can be achieved, but incorporation of higher percent of polypropylene fibres to cement matrix because of its chemical characterization was very difficult. In the higher fibre content, fibres bundling and clamping occurs during the composite production. Literature reviews showed that the application of nonwoven fabrics allows the incorporation of higher percent of fibres to cement composites. The fiber volume content in the case of using one layer of 97, 200 and 262 gram/m 2 of the PP nonwoven fabrics in cement matrix was 1.384%, 2.58% and 3.25%, respectively. It was evident that the volume percentages of fiber can be increased considerably by increase in fabric layer. Figure 6 represent the application of three layers of 97 and one layer of 200 gram/m 2 of the PP nonwoven fabrics (calendared and needle-punched, respectively) in comparison to the short polypropylene fibres in cement reinforcement. It was evident that both types of the nonwoven fabrics show better performance in toughness and load-bearing capacity (the area under stress-strain curve) in comparison to the short fiber. Also needle-punched specimens displayed better performance in comparison to calendared specimen. The needle-punched nonwovens have inherently greater open structures with respect to thermo-bonded layers.

7 APPLICATION OF POLYPROPYLENE NONWOVEN FABRICS FOR Figure 6. Effect of nonwoven types on flexural behaviour of composite 4.1 Effect of re-punching Figure 7 shows the effect of punching of 97gr/m 2 nonwovens on the flexural performance of nonwoven/cement specimens. Regarding the load-deflection curve, punching usage increases the load bearing capacity of composites. The area under the load-deflection curve was increased comparing to basic nonwoven. Thus, the toughness of reinforced composites was improved by punching of thermo-bonded nonwovens. Figure 7. Effect of re-punching on flexural behaviour

8 558 H. Pakravan, M. Jamshidi, M. Latifi and M. Neshastehriz It was attributed to this fact that re-punching causes more opened structure and generation of some free fibre ends. The more opened structure allows cement paste to diffuse in better in the nonwoven layer and the free fibre ends can adhere to cement paste interlock the nonvowen layer to cement paste. The load carrying capacity of composites depends on cement penetrability to nonwoven layers. The results showed no significant difference between flexural behaviour of normal 97gr/m 2 and re-punched layer reinforced composites. It was attributed to degradation of fabrics during re-punching and decrease in strength because of fineness of the 97 gr/m 2 fabrics. The effect of re-punching on 200 gr/m 2 nonwovens was illustrated in Figure 8. It was evident that repeated punching has considerable effect on improving the composite performance. In other words, repeated punching open the structure of these needle-punched nonwoven fabrics. Figure 8. Effect of re-punching on flexural behaviour 4.2. Effect of basis weight The effect of the needle-punched nonwoven fabrics weight on the flexural strength of composites containing 200 and 260 gr/m 2 layers was evaluated. Results were shown in Figure 9. Based on the obtained results, increasing in fabrics weight has no effect on the improvement of flexural strength and toughness. It illustrate that the increase in nonwoven fabrics weight to achieve improved performance have optimum point that after that the flexural behaviour decreases.

9 APPLICATION OF POLYPROPYLENE NONWOVEN FABRICS FOR Figure 9. Effect of basis weight on flexural performance 4.3. Effect of number of the fabric layers The load-deflection curves, as shown in Figures 10 and 11, demonstrate the effect number of the nonwoven layers on the flexural performance. Figure 10 and 11 show that by increase in the number of 97 gr/m 2 fabric layers from 3 to 5 and 200 gr/m 2 layers from 1 to 2 layers, load-bearing capacity decreases. This was attributed to the fact that increase in number of layers, decreases the cementitious binder content between layers. Therefore, it leads to weakening bonding between nonwoven layers and the cement paste. Figure 10. Effect of layer numbers on flexural performance

10 560 H. Pakravan, M. Jamshidi, M. Latifi and M. Neshastehriz Figure 11. Effect of layer numbers on flexural performance 4.5. Microscopic analysis The microstructure of reinforced composites was studied using optical microscopy and SEM images. Figure 12 shows the image of a punched nonwoven in the cement matrix. The entanglement of fibers in nonwoven layer can be seen in the image. The empty spaces between fibers in the nonwoven layer were filled by cement hydrates. This interaction and interlocking result in a better adhesion between fibers and the cement matrix and improve the ductility and energy absorption capacity of composites. Figure 12. Entanglements of nonwovens fibres in cement matrix, a) optical microscopy, b) SEM micrograph 5. CONCLUSIONS Regarding the obtained test results, the following issues can be concluded: The utilization of PP nonwoven fabrics (both calendared and needle punched types) as

11 APPLICATION OF POLYPROPYLENE NONWOVEN FABRICS FOR the replacement of short fibers can be proposed for reinforcement of cementitious composites especially in prefabricated concrete elements. Since the volume fraction of fibers was a sensitive and important parameter that affects composites performance, using nonwoven fabrics can increase fibers' volume content in composites without side effects. Employing nonwoven layers increases flexural performance and especially the ductility of cementitious composites. Nonwoven layers improve the composites strainhardening behaviour. 200 gr/cm 2 extra-punched PP nonwoven layers perform very well in cementitious sheets. Re-punching process prepare opened structure nonwoven layer which perform better in cementitious composites. The PP nonwoven fabrics can be considered as well as woven fabrics for cement based composite reinforcement. It was anticipated that they have better bonding to cement matrix due to better wetting by cement paste. Besides, in concrete reinforcement, sands can permeate to nonwoven structure along with cement paste while this cannot occur in woven fabric reinforced concretes. REFERENCES 1. Bentur A, Mindess S. Fiber Reinforced Cementitious Composites, Elsevier Science Publishing Ltd., NY, USA, Daude G, Lasnier JM, Guillabert B, Filliatre C, Sabouraud A, Guilhemat R. Extraction and identification of organic fibres from fibre-reinforced cement composites without asbestos, Cement and Concrete Research, No. 5, 26(1996) Bentur A, Mindess S. Fiber Reinforced Cementitious Composites, Elsevier Applied Science, UK, Hannant DJ, Zonsveld JJ. Polyolefin Fibrous Networks in Cement Matrices for Low Cost Sheeting, Philosophical Transactions of the Royal Society of London. Series A, Mathematical and Physical Sciences, No. 1411, 294 (1980) Pakravan HR, Jamshidi M, Latifi M. Flexural Behavior of Cementitious Composites Reinforced by Synthetic Fibers, submited to Journal of Amirkabir, Bentur A, Peled A, Yankelevsky D. Enhanced Bonding of Low Modulus Polymer Fibers-Cement Matrix by means of Crimped Geometry, Cement and Concrete Research, No. 7, 27(1997) Singh S, Shukla A, Brown R. Pull-out Behavior of Polypropylene Fibers from Cementitious Matrix, Cement and Concrete Research, 34(2004) Peled A, Guttman H, Bentur A. Treatment of Polypropylene fibers to Optimize their reinforcing Efficiency in Cement Composites, Cement and Concrete Composites, No. 4, 14(1992) Peled A, Mobasher B. Pultruded fabric-cement composites, ACI Material Journal, No. 1, 102(2005) Bruckner A, Ortlepp R, Curbach M. Textile reinforced concrete for strengthening in

12 562 H. Pakravan, M. Jamshidi, M. Latifi and M. Neshastehriz bending and shear, Materials and Structures, 39(2006) Häußler-Combe U, Hartig J. Bond and failure mechanisms of textile reinforced concrete (TRC) under uniaxial tensile loading, Cement and Concrete Composites, No. 4, 29(2007) Soranakom C, Mobasher B. Geometrical and mechanical aspects of fabric bonding and pullout in cement composites, Materials and Structures, No. 6, 42(2009) Gencoglu M. Effect of fabric types on the impact behavior of cement based composites in flexure, Materials and Structures, 42(2009) Peled A, Cohen Z, Pasder Y, Roye A, Gries T. Influences of textile characteristics on the tensile properties of warp knitted cement based composites, Cement & Concrete Composites, 30(2008) Peld A, Sueki S, Mobasher B. Bonding in fabric cement systems: effects of fabrication methods. Cement Concrete Research, 36(2006) Peled A, Bentur A, Yankelevsky D. Flexural performance of cementitious composites reinforced by woven fabrics. Advance Material Civil Engineering (ASCE), No. 4, 11(1999) Peled A, Bentur A. Reinforcement of cementitious matrices by warp knitted fabrics. Material and Structures (RILEM), 31(1998) Peled A, Bentur A. Fabric structure and its reinforcing efficiency in textile reinforced cement composites. Composites: Part A, 34(2003) Albrecht W, Fuchs H, Kittelmann W. Nonwoven Fabrics, WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim, Robert LL, Use of Geotextiles for Reinforcement and Strain Relief in Asphalt Concrete, Geotextiles and Geomembranes, 8(1989) Long JH, Paul SL. Bond Strength between Geotextiles and Concrete, Geotextiles and Geomembranes, 8(1989) BS EN Fiber-cement flat sheets- product specification and test methods. British Standards / European Norm, 12467:2004.

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