No abstract

Spin casting is the oldest method of manufacturing precast concrete pipes among all existing methods. While improved concrete mixtures incorporating fibers for other methods of concrete pipe manufacturing, such as the vibration method and roller compaction method, have been developed, no such concrete mixture has yet been developed for spun-cast concrete pipes. This study was designed to explore the possibility of incorporating locally manufactured steel fibers and commercially available polypropylene fibers to develop an improved concrete mixture for use in the manufacturing of full-scale spun-cast concrete pipes. The used steel fibers were of two types, i.e., straight and bundled steel fibers, manufactured by cutting locally available long straight and bundled steel wires, respectively. Various dosages of steel fibers (i.e., 20, 30, 40, and 50 kg/m3) and polypropylene fibers (i.e., 5, 10, 15, and 20 kg/m3) were used in mono and hybrid (steel and polypropylene) forms. The properties in the fresh state and mechanical properties of the test mixtures were investigated. Full-scale spun-cast concrete pipes having a 450 mm internal diameter were manufactured and tested using the three-edge bearing test. The compressive strength of the mixtures was largely insensitive to the dosage of the fibers. The splitting tensile strength of all fiber-reinforced concrete mixtures was higher than that of the reference mixture without fibers, with a 24% increase recorded for the concrete mixture incorporating 50 kg/m3 of bundled steel fibers relative to the reference mixture with no fibers. The flexural performance of the fiber-reinforced concrete mixtures was superior to that of the reference mixture without fibers in terms of flexural strength, toughness, residual strength, and crack control, with up to 28% higher flexural strength relative to the reference mixture without fibers. The three-edge bearing tests on full-scale spun-cast pipes incorporating steel fibers showed that the use of fibers is a promising alternative to the traditional steel cage in spun-cast concrete pipes.

The alkali–silica reaction (ASR) is a primary cause for premature concrete degradation. An accelerated mortar bar test is often used to access the detrimental phenomena in concrete caused by the ASR of aggregates. However, this test requires a certain environmental conditioning as per ASTM C1260. The objective of this study is to explore the effects of the cement alkali content, exposure solution concentration, temperature, and test duration on mortar bar expansion. Factorial experimental design and analysis was conducted to delineate the effects of the individual factors as well as their interaction. Five different aggregates with various mineralogical properties were used, representing reactive and non-reactive aggregates. Various dosages of cement alkalis (0.40, 0.80, and 1.20 Na2Oe), sodium hydroxide (NaOH) solution concentrations (0.5, 1.0, and 1.5 N), and temperature (40 °C, 80 °C, and 100 °C) were the studied variables. Mortar bar expansion was measured at 3, 7, 14, 21, 28, 56, and 90 days. Mortar bars incorporating Jhelum aggregates incurred expansion of 0.32% at 28 days, proving to be reactive aggregates as per ASTM C1260. Similarly, specimens incorporating Taxila aggregates showed expansion of 0.10% at 28 days, indicating non-reactive nature. It was observed that specimens with Sargodha aggregates showed expansion of 0.27% at 28 days for 0.50 N NaOH solution concentration compared to 0.31% expansion for identical specimens exposed to 1.5 N solution. Moreover, expansion increased with exposure duration for all the tested specimens. Experimental results showed that the cement alkali contents had relatively lesser effect on expansion for 1.0 N NaOH; while, in the case of 0.5 N and 1.5 N NaOH, the cement alkali had a significant effect. It was noted that expansion increased with an increase in the temperature. Jhelum aggregates showed 28-day expansion of 0.290% when exposed to 40 °C, but at a temperature of 100 °C, expansion increased to 0.339%. Factorial analysis revealed that the exposure solution had a major contribution towards the expansion of mortar bar specimens. This study highlights the contribution of various exposure conditions on the ASR expansion, which leads to a decisive role in selecting the aggregate sources for various applications and exposure conditions leading to sustainable construction.