CurvedNFR

Development of Curved Non-Ferrous Reinforcement for Concrete Applications

This project aimed to develop a novel process route to fabricate curved non-ferrous rebars for reinforcing concrete. These materials are highly durable and enable the structural engineer to optimise concrete units without suffering the weight penalties associated with protecting reinforcing steel from corrosion. Their application can typically reduce the weight of precast components by 25% and make handling and installation significantly easier and safer.

Non-ferrous reinforcement has been specifically developed for use in concrete to overcome the problems associated with steel rebar corrosion. Many steel reinforced structures are rust stained and excessively heavy through the requirement to provide protection for the steel within.

A number of design approaches and preferred solutions have been adopted throughout Europe for providing durable reinforced concrete structures and non-ferrous reinforcement fits into the market as an exciting new product. Curved non-ferrous rebar presents an opportunity to provide low cost durable alternatives to the existing methods, particularly for concrete components where lightweight and low cover are seen as desirable features.

Research was required into both the manufacturing process for producing curved non-ferrous rebar and the performance testing of the resulting materials to ensure that the durability performance was maintained and cost effectiveness was optimised.

The project designed, manufactured and tested curved non-ferrous rebar. Research was undertaken to produce complex shapes and reinforcement arrangements that are more cost effective than existing steel solutions. A range of pre-cast concrete components using the new reinforcement were designed, manufactured and tested for structural and environmental performance.

The research focused on pre-forming and vacuum injection moulding as the main new method of producing curved non-ferrous rebar, although the use of formable thermoplastic resins will also be included. Appropriate materials were selected and curved non-ferrous bars produced from the two processes. The resulting rebar was tested for mechanical and durability performance in concrete. In parallel three precast components were redesigned specifically for reinforcing with non-ferrous rebars. The best rebars were cast into the new components and subjected to mechanical property testing and environmental durability assessment.

WWW Link: http://www.curvednfr.com