Steel Fiber Concrete Flooring Uses and Benefits

Steel fiber concrete flooring can provide superior resistance to minimize cracks in hardened concrete, as well as maximum resistance to withstand heavy loads, either dynamic or static. If you decide to use steel fiber concrete flooring, you can select to use a &#;joint-less floor&#;. Joint-less floors are floors that have minimal joints, providing spaces without joints as large as 40 or 50-meter span wide.

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Steel fiber dosage will vary greatly upon the project intended use, and the types of mesh being replaced. Common dosages are in the range between 20-30kg/m3 to 40-50kg/m3 for joint-less floors. Trowelling concrete will help to embed steel fibers into the concrete surface producing a better-finished product. Steel fibers will enhance the crack resistance of the concrete, and they can also be used to replace or supplement structural reinforcement. It only can be done through a structural engineer and with proper guidance.

How and When the Fiber is Added

Typically the fibers are added at the batch plant, just after all concrete aggregates are being mixed. Some people would request to have the fiber added at the job site, but then the QA/QC should have more control on how much fiber is added. The steel fiber manufacturer can provide guidance on how to mix and the amount needed to obtain the desired results. Be aware that if you add too much fiber, it might show up at the surface when finishing the concrete so be cautious about the amounts being mixed.

Costs of Steel Fiber Concrete Flooring

In general, and depending on the type of steel fiber used, it can add between $6 to $10 per cubic yard on top of the ready-mix concrete cost. This cost is based on the assumption that you are using 1.5 pounds per cubic yard of concrete.

How Workability is Affected

If you opt-in to add fiber to your concrete mix, be aware that there will be some changes in the way you manage this concrete. First of all, the slump will be affected, and it is recommended to add a superplasticizer to enhance the slump and make the concrete a little more fluid. Not all steel fiber can be used as a substitute for steel reinforcement, so make sure that your structural engineer has reviewed and analyzed the loads before proceeding. 

Where to Use Steel Fiber Concrete Floors

Typical applications for steel fiber concrete flooring can be found on parking lots, playgrounds, airport runways, taxiways, maintenance hangars, access roads, and workshops. This method is also widely used for port pavements, container storage and handling areas, bulk storage warehouses, and military warehouses. Steel fiber reinforced concrete is commonly used in tunnel construction, as it provides additional flexural strength, reduces shrinkage cracking and reduces permeability.

Advantages of Steel Fibers in Concrete

Several advantages can be obtained from this product, for example:

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• The increased load-bearing capacity of concrete
• Reduction of concrete slab thickness
• Load capacity is not diminished by concrete cracks
• Increased durability
• Low maintenance costs
• Improved flexural properties
• Reduced absorption of water, chemicals, etc.
• Can be used on fast track schedule
• Easier positioning of joints
• Reduced site labor for managing steel reinforcement
• Reduced project costs
• Increased impact and abrasion resistance
• Even distribution of fibers throughout the concrete
• Tougher surface with fewer bleed holes
• Savings will be greater for heavier crack control systems

INTRODUCTION

Industrial floors are exposed to various loading conditions, such as heavy rack posts, stacked loads, material handling equipment like forklifts, heavy tanks, and other processing machines.
Enterprises typically install a concrete-grade slab with reinforcement in the upper one-third layer to accommodate these loads, control shrinkage, and prevent cracks. Although support is generally placed in a specific region, it may not effectively manage cracks throughout the slab

Therefore, reinforcement should be provided at the bottom of the slab in the form of steel fibers mixed with concrete to ensure effective crack control throughout the slab.

This reinforcement method will ensure that the slab remains durable and can withstand the demands of a busy industrial environment.

How Steel-Fiber Reinforced Concrete Works

Steel fiber-reinforced concrete is a composite material consisting of hydraulic cement, fine or coarse aggregates, and steel fibers of rectangular cross-sections randomly dispersed throughout the matrix.

Unlike conventional reinforcement, which strengthens in one or two directions, TOCO stel fibers reinforce the concrete isotropically, improving its resistance to cracking, fragmentation, spalling, and fatigue.

Advantages of Steel Fiber Reinforced Concrete in Industrial Floors

• Improved Crack Resistance

One of the critical advantages of SFRC on industrial floors is its superior crack resistance. The random distribution of steel fibers throughout the concrete intercepts micro-cracks before they develop and impair the performance of the structure. This significantly reduces the risk of cracking, ensuring the long-term integrity and durability of the floor.
 

• Enhanced Flexural Strength

The addition of steel fibers improves the post-crack flexural strength of the concrete, providing excellent structural stability and load-bearing capacity. This is particularly important on industrial floors that experience heavy loads and high traffic.
 

• Increased Impact Resistance

Industrial floors are subjected to frequent impacts from heavy machinery, forklifts, and other equipment. SFRC provides excellent impact resistance, reducing the risk of surface damage, cracking, and spalling. The steel fibers absorb and distribute the impact load.
 

• Greater Durability

The steel fibers reinforce the concrete, making it more resistant to wear, abrasion, and fatigue. This results in a longer service life and reduced maintenance costs, making SFRC an economically viable choice for industrial flooring applications.
 

• Thinner Slab Designs

The use of steel fiber reinforcement allows for the design of thinner floor slabs without compromising structural integrity. Thinner slabs reduce the amount of concrete required, resulting in cost savings and faster construction times.
 

• Improved Joint Performance

The random distribution of steel fibers throughout the concrete ensures there is no weak plane for cracks to follow, reducing the risk of joint failure. This results in a more robust and durable floor capable of withstanding heavy loads and frequent traffic.
 

• Resistance to Spalling

Spalling, or the breaking off of concrete surface layers, is a common issue on industrial floors. SFRC significantly reduces the risk of spalling by enhancing the overall durability and crack resistance of the concrete.
 

• Simplified Construction Process

The elimination of conventional reinforcement, such as welded wire fabric, reduces the complexity of joint formation and maintenance. Additionally, the random distribution of steel fibers throughout the concrete eliminates the need for precise placement of reinforcement, saving time and effort during construction.

Case Study of a Warehouse: Application Of Steel Fiber Reinforced Slab

With the rapid advancements in technology, warehouse facilities are now able to make full use of automated systems and radio shuttles to optimize their operations.

One of the warehouses installed storage tanks and heavy racks. To make sure their design was conventional, a thorough check was done for the grade slab using elastic analysis. They added reinforcement to control cracks and shrinkage, resulting in a thickness of 300 mm in most areas.

Next, they examined the design for steel fiber-reinforced concrete using plastic analysis. As a result, they reduced the thickness to 200 mm in most sections and 220 mm in a strip in the process area, which had ample storage tanks.

Steel fiber has a unique aspect ratio, which is the ratio of its length to its diameter. Fibers with a higher aspect ratio provide better pull-out resistance, but an excessively high aspect ratio can cause balling. To avoid this, they chose fibers with hooked ends. They used threads with a thickness of 0.75 mm and a length of 60 mm, resulting in an aspect ratio of 80.

To determine the slab thickness, the point loads were the critical loads in all areas. They used variable dosages and grades of concrete to achieve an economical solution. Designing a uniform slab for the entire room would have resulted in a conservative design in most areas, so they opted for this approach instead.

Steel fibers are commonly used as an effective means to prevent cracking in concrete slabs. The fibers are evenly distributed throughout the thickness of the slab, which allows them to stop cracks from spreading from the location they originate.

In addition, steel fibers provide excellent resistance to moments, energy absorption, and impact. The effectiveness of the steel fibers depends on the fiber type, the fiber content, and the length-to-diameter ratio, as this affects the interfacial surface area and the fiber efficiency. It's important to note that while excellent aspect ratios lead to higher efficiency, excessively high ratios can reduce the workability of the concrete mix. In practical applications, it's common to use an aspect ratio of less than 100.

Conclusion

Embracing the Benefits of Steel Fiber Reinforced Concrete for Durable and Resilient Industrial Flooring Solutions. At TOCO Steels Pvt. Ltd., we manufacture hook-end steel fibers, which are mainly used for concrete reinforcement of industrial floors. From improved crack resistance and enhanced flexural strength to increased impact resistance and excellent durability, SFRC provides a reliable and cost-effective solution for demanding industrial environments.

The use of SFRC allows for thinner slab designs, simplifies the construction process, and results in long-term cost savings. With its superior performance characteristics, SFRC is revolutionizing the construction industry and setting new standards for industrial flooring.

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