Concrete Canvas
Concrete Canvas
Engineering
Prof. K.Srinivas and Prof. Ravinder, Asst. Professors, National Institute of
Construction Management and Research, Hyderabad.
Introduction
Worldwide there is increasing demand for construction and construction materials,
for that concrete is the most extensively used material in construction. These days
concrete is being used for so many purposes in many different adverse conditions.
1. Cement
2. Fine aggregate
3. Coarse aggregate &
4. Water
Concrete is a freshly mixed material, which can be moulded into required shape.
There are many advantages of concrete, but there is one drawback is that, it is not
flexible, when it is hardened. To overcome through this drawback of concrete. a
new construction material was developed by British Engineering Company called
Concrete Canvas.
Concrete cloth (CC) is a unique proprietary material. It has a very wide range of
applications throughout the building & civil engineering industry. Concrete cloth is
a flexible; cement impregnated fabric that hardens when hydrated to form a thin,
durable, water & fire proof concrete layer. CC allows concrete construction without
the need for plant or mixing equipment. Simply position the canvas & just add
water. CC has a design life of above 10 years and is significantly quicker and less
expensive to install compared to conventional concrete.
Figure 1: Concrete Cloth Section
Literature Review
General
Concrete Cloth is a flexible, cement impregnated fabric that hardens on hydration
to form a thin, durable, waterproof and fire resistant layer.
The story behind its inception is somewhat unusual. Four years ago, we entered a
competition run by the British Cement Association. At the time, we had no idea that
our entry for a rapidly deployable emergency shelter would result in the launch of
our own technology development company. Our research has now included trips
to disaster zones around the world, including Uganda and New Orleans.
Four years later, the concept has matured into a technology that has applications
far beyond emergency shelter. Following development funded through a
combination of private equity investment and grants, the company relocated to a
dedicated production site in South Wales, UK, where we have begun volume
production of Concrete Cloth and Concrete Canvas Shelters.
The British Army quickly saw potential uses for this new material and started trials
using Concrete Cloth as a method of reinforcing sandbag defence. This solution,
shown in Fig 2, reduces degradation of sandbag walls in harsh environments such
as Afghanistan, where the combination of wind, sand, and extreme temperatures
mean frequent repairs to frontline defence. In addition, damage is caused by
incoming fire and outgoing muzzle flash. Concrete Cloth is completely fireproof
and has performed very well during range trials where it was tested with small-and
transported medium-calibre weapons. The material comes in 10 m (33 ft) rolls to
eliminate the need for heavy lifting equipment and plant machinery. This is a big
advantage when operating in remote areas where most supplies have to be by
helicopter. The material is then simply unrolled over the sandbag wall, secured
using battens, and sprayed with water. A durable and hard wearing surface is
produced within 24 hours. Key to the success of the material is the fibre that form a
reinforcing matrix within the Concrete Cloth. These provide a stable failure mode,
absorb energy, and help maintain the structural integrity of the concrete when
impacted. A ballistic projectile will pass through the cloth, but crack propagation is
limited. The sand in the sandbag is therefore retained within the concrete shell. In
contrast, standard sandbag cloth will typically tear, and the fill is lost very quickly.
In January 2008, a small quantity was used on the frontline in Afghanistan to
validate its performance in the field. As a result of these trials, the UK Ministry of
Defence has just awarded Concrete Canvas a contract to supply 5500 m2 (6600 yd2)
to the frontline.
Deployable Shelters
The original concept for Concrete Canvas was to create rapidly deployable
hardened shelters that required only water and air for construction. The key was
the use of inflation to create a surface that was optimized for compressive loading.
This allowed thin-walled concrete structures that are both robust and lightweight.
The shelter, such as the one shown in Fig 3, is deployed in the following four
stages:
Figure 3: CC Shelter
Delivery-the shelter is supplied folded and sealed in a sack. The 16 m2 (19 yd2)
variant is light enough to transport in a pickup truck or light aircraft;
Inflation-once delivered, an electric fan is activated to inflate the inner PVC liner
and lift the structure until it is self-supporting. The shelter is then pegged down
with ground anchors around the base;
Hydration-the shelter is sprayed with water. Hydration is aided by the fibre matrix,
which wicks water into the mixture; and
Setting-the Concrete Cloth cures in the shape of the inflated inner PVC liner. The
structure is ready to use 24 hours later. Access holes allow the installation of
services such as water, power, air conditioning, and heating units. The structures
are designed as part of a modular system. Units can be easily linked together,
allowing the space to be tailored to the application. If required, they can be
demolished using basic tools. The thin-walled structure has a very low mass,
leaving little material for disposal.
The University of Bath in Bath, UK, has conducted finite element analysis of the
shelters, showing that the structures can withstand a high distributed compressive
load. This allows sandbags, earth, or snow to be piled on top-giving the shelters
excellent thermal properties and protection against shrapnel, blasts, and small
arms fire.
Concrete Canvas Shelters are specified to withstand 0.75 m (2.5 ft) of wet sand on
the sides (sufficient to stop 7.62 mm [.30 calibres] rounds) and 0.5 m on the roof (to
protect against shell fragments).
Methodology
General
Concrete Canvas (CC) is a flexible; cement impregnated fabric that hardens when
hydrated to form a thin, durable, water and fire proof concrete layer. The following
data provides useful information for installers, customers and specifies of CC. It
provides an overview of useful data and techniques that can be used across a wide
range of applications.
CC Specification
CC Types
There are 3 CC types available with the following indicative specifications:
Examples of CC Applications
Some examples of applications for the different CC types are given in Table 2.
CC Material Properties
Strength
Tensile Test
Abrasion Resistance (DIN 52108)
- Similar to twice that of OPC Max 0.10 gm/cm2
CBR Puncture Resistance EN ISO 12236: 2007 (CC8 & CC13 only)
- Min. Push-through force 2.69kN
- Max. Deflection at Peak 38mm
Physical Properties
Initial Set≥ 120 min
Final Set.≤ 240 min.
Method of Hydration
CC can be hydrated using saline or non saline water. The minimum ratio of water to
CC is 1:2 by weight. CC cannot be over hydrated so an excess is recommended. The
recommended methods are: In a hot/arid environment, re-wet the material 2 - 4
hours after the initial hydration.
Figure 6: Spray The Fiber Surface With Water Until It Feels Wet To Touch For Several Minutes After Spraying.
Spraying: Spray the dry CC with water until it is saturated. Do not use a direct jet of
pressurized water as this may wash a channel in the material and create a
weakened area
Cutting of CC
A ‘snap off’ type disposable blade is the most suitable tool for cutting CC before it is
hydrated or set. When cutting dry CC, a 20mm allowance should be left from the
cut edge due to lost fill. This can be avoided by wetting the CC prior to cutting.CC
can also be cut using handheld self sharpening powered disc cutters.
Cutting Set CC
Set CC can be cut as with conventional concrete, with angle grinders, construction
disc cutters or good quality tile cutters.
CC Mechanical Fixing
There are a large number of mechanical fixings that are suitable for use with
Concrete Canvas. Some of these fixings can be used in conjunction with the non-
mechanical joining methods described later in this to improve the mechanical
strength or water proofing properties of joints.
Staples
The versatility of CC means that a wide range of manual, electric or gas powered
staplers are suitable for attaching CC to soft substrates such as wooden boarding
for building cladding. Commercially available hand staplers are suitable for fixing 2
layers of CC together where a small amount of compression force is required.
Figure 11: Standard Nail Attached to CC Figure 12: Self Tapping Screw
Nails
Standard nails can be used to attach CC. Alternatively, a power tool such as the
Hilti nail gun, provides a quick and effective method of securing CC to hard surfaces
such as concrete or rock. This may be appropriate where CC is being used to
recondition an existing concrete surface or for spall lining in mining applications. It
is important to ensure that the nail is used with at least a 15mm washer to ensure
the head does not penetrate through the surface of the Canvas.
Screws
Self tapping screws provide a quick and readily available means of attaching CC to
a substrate or to itself. Typical applications include sandbag reinforcement or
covering existing wooden or steel structures.
If a more water proof seal is required, a Bitumen tape can be applied over the hog-
rings, onto the PVC backing, using a blow-torch. Using this method, large panels of
Concrete Canvas can be prefabricated with relative ease.
Medium gauge wire can be used as a simple alternative to hog-rings where plant
equipment is not available. The end of the wire should be cut to a sharp point to
aid penetration through the CC layers.
Pegging
Pegging is recommended for ground surfacing applications such as ditch lining,
slope stabilization or erosion control. Typically pegs are specified every 2m for
most applications, but this will vary depending on the ground conditions and
application. Pegs should be used at joints where possible to secure adjacent layers
together. Pegs are available directly from Concrete Canvas Ltd. in a range of sizes
which are suitable for use with CC. The peg must have a sufficiently sharp point to
penetrate the surface of the Canvas.
Figure 15: Peg Used to Join CC Figure 16: Recommended Minimum Coverage
CC Bonding Sealant
Concrete Canvas can be joined and sealed by applying a bonding sealant between
overlapping layers. Concrete Canvas Ltd. can provide a recommended sealant
which bonds to both the PVC backing and fiber surface of Concrete Canvas. A
minimum bead size of 6mm should be applied along the length of the joint and the
two layers firmly pushed together. The sealant works in both wet and dry
conditions so can be applied before hydration or immediately after. The bonding
sealant will fully cure in 24 hours.
Figure 17: CC8 over lapped joint with CC Grout Figure 18: Ditch lining
CC Jointing Grout
Concrete Canvas can be joined and sealed by overlapping layers and applying a
grouting compound along the joint. Concrete Canvas Ltd. can provide a bespoke
cementious grout called CC Jointing Grout for use in drainage and ditch lining
applications. CC Jointing Grout is based on the same cementitious mix as Concrete
Canvas to create a homogenous joint. The use of other grouting compounds may
retard setting time and reduce set strength. Grout should be applied after
hydrating the two overlapped layers. Ensure that the bottom layer, including the
overlapped area is properly hydrated. CC Jointing Grout has similar setting
characteristics to CC and initial set takes place after two hours. After applying the
grout, continue to hydrate as per CC hydration instructions, ensuring not to apply
jets of water directly onto the joint to avoid washout of the grout.
Finishing
The fiber surface of CC can be easily painted once set using standard exterior
masonry paint. This provides a quick and simple method of improving the aesthetic
appearance of CC. Alternatively, Concrete Canvas Ltd. can recommend a range of
copolymer concrete surface treatments which can provide a coloured uniform
finish as well as hydrophobic protection against staining and organic growth. Fire
retardant paints have also been shown to be effective where thermal performance
is critical.
Findings
Applications of CC
Ditch lining
CC can be rapidly unrolled to form ditch or tank lining. It is significantly quicker and
less expensive to install than conventional concrete ditch lining and requires no
specialist plant equipment. The 30m ditch shown below was lined in 45min.
Slope Protection
CC can be used as slope stabilization and other erosion control applications such
as temporary and permanent slope protection, retaining walls, boulder fences, low
level bunds and river bank and dam revetments.
Pipeline Protection
CC can be used as a coating for overland or underwater pipeline protection,
providing a superior tough rock shield. In remote areas it can be used to coat steel
pipe on site without expensive wet concrete application plants. CC will set
underwater and provide negative buoyancy.
Ground Resurfacing
CC can be secured with ground anchors to rapidly create a concrete surface for
flooring, pedestrian walk-ways or dust suppression. CC8 and CC13 have been
tested to EN 1991-1-1:2002 (Resistance to Imposed Loads on Vehicle Traffic Areas)
Mining Applications
CC can be used as an alternative to poured or sprayed concrete or as a quick way of
erecting strong permanent or temporary blast and vent structures and spall lining.
CC has been successfully tried in Mpumalanga, South Africa.
Sandbag Reinforcement
CC has been proven to prevent the degradation of sandbags from sustained
incoming fire, outgoing muzzle fly ash and environmental exposure. A sandbag wall
protected by CC withstood 900 rounds of 7.62 NATO, fired by a GPMG LR at a range
of 100m. There is currently over 5500sqm of CC being used by the British Army in
Afghanistan.
Advantages of CC
Easy to use-dry Concrete Cloth can be cut or tailored using simple hand
tools such as utility knives. The PVC side can be supplied with an adhesive
backing and the fibrous side bonds well to concrete or brick surfaces when
set. It can be easily repaired or upgraded using existing cement products;
Environmentally Friendly
CC is a low mass, low carbon technology which uses up to 95% less material than
conventional concrete for many applications. It has minimal impact on the local
ecology due to its limited alkaline reserve and very low wash rate.
Limitations of CC
Do not jet high pressure water directly onto the CC as this may wash a
channel in the material..
CC has a working time of 1-2 hours after hydration. So do not move CC once
it has begun to set.
If CC is not fully saturated, the set may be delayed and strength reduced.
Cost comparison of CC
Engineers Incorporated Ltd (EIL) was commissioned by Concrete Canvas Ltd (CCL)
to prepare a comparison of costs for lining an open, trapezoidal ditch 900 x 900 x
900mm, 500m in length.
The comparison for construction costs requested, were:-
The above rates assume that the initial ditch excavation to form the trapezoidal
shape is complete prior to commencement of lining and therefore has been
excluded in the costs.
The above rates assume that the site has tarmac access for pouring in-situ
concrete, delivery of sprayed concrete and paving slabs.
Analysis of Rates
Conclusion
Concrete cloth (CC) is a unique proprietary material. It is a time & material saving
technique. It is very easy to place & handle. Concrete cloth is a flexible; cement
impregnated fabric that hardens when hydrated to form a thin, durable, water &
fire proof concrete layer. CC allows concrete construction without the need for
plant or mixing equipment. Simply position the canvas & just add water. CC has a
design life of 10 years and is significantly quicker and less expensive to install
compared to conventional concrete. It is specially used, where the workmanship is
very difficult. It is specially used in emergency works such as in military.