Concrete Cloth
Concrete Cloth
Concrete Cloth
INTRODUCTION
Concrete cloth is an upcoming revolution in civil world, which in turn have a wide
range of application in rapid construction, in state of emergency etc. due to its own physical
property, mainly, flexibility and easy to use. Among various engineering applications of
3D spacer fabric reinforced cementitious composites; concrete canvas (CC, the concept
was first proposed by Brewin and Crawford in 2005) is one of the most promising products.
Prior to hydration, Concrete cloth layers can be cut to length using basic hand tools
eliminating the hazards associated with using power tools in high risk environments. The
concrete is pre-mixed so there is no need for mixing, measuring or compacting but just add
water. It greatly reduces transportation cost and on site storage. It is a low mass, low carbon
technology.
The British Engineering Company had found the revolutionary material, concrete cloth. It’s a recent
innovation in the concrete sector. The technology was first found for emergency shelters, application to
military world and later on applied to commercial construction work.
The key was the use of inflation to create a surface that was optimized for compressive loading. This allowed
thin-walled concrete structures to be formed that are both robust and lightweight.
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.
2.2.1 PACKAGING
Concrete Canvas Shelters (CCS) are supplied in polyethylene, airtight, water proof, rot proof sacks within
ISPM15 heat treated timber/ply panel crates.
CCS are rapidly deployable structures that can be deployed by two people in less than 24 hours. There are
two shelter sizes available, the CCS25 and the CCS50 with respective deployed areas of 25 and 50sqm.A
CCS50 will require a vehicle or winch to aid with the unfolding of the shelter prior to inflation. Each shelter
is provided with the ground pegs required for inflation. CCS are prefabricated structures consisting of
Concrete Canvas fixed to an inflatable inner with integral steel door sets at each end. The shelter is deployed
in the following four stages:
2.2.1 a. Delivery
The shelter is supplied folded and sealed in a sack. The 16 m2 variant is light enough to transport in a pickup
truck or light aircraft.
2.2.1 b. Inflation
Once delivered, an electric fan is activated to inflate the inner PVC liner and lift the structure until it is self-
supporting.
2.2.1 c. Hydration
The shelter is sprayed with water. Hydration is aided by the fiber matrix, which wicks water into the mixture
CHAPTER-3
MATERIAL PROPERTY
3.1 STRENGTH
Very high early strength is a fundamental characteristic of concrete cloth. The first crack strength of CC is
attributed to two aspects: matrix strength and fiber bridging effect. The first crack strength σfc is defined as
the applied tensile stress at which a matrix crack spreads throughout the cross section of the sample under
tension. The maximum bridging stress σB is defined as the maximum stress that bridging fibers can transfer
across the crack of specimen.
Typical strengths and physical characteristics are as follows:
Compressive testing
The test is based on ASTM C473-07. By the test the 7-day minimum compressive strength is equal to 38 MPa
Bending test:
This test based on ASTM C-1185. The test is used to determine the ability of material to resist the bending.
The 7-day minimum bending stress is equal to 3.3 MPa and 7-day modulus minimum is equal to 180 MPa.
Abrasion Resistance:
ASTM C1353-8 is the standard test method to determine abrasion resistance of the material. CC lost 60%
less weight than marble over 1000 cycles.
Resistance to imposed loads on vehicle traffic areas:
CHAPTER-4
METHOD OF HYDRATION& WORKING
Concrete cloth can be hydrated using saline or non-saline water. The minimum ratio of water to Concrete
Cloth is 1:2 by weight. It 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.
Immersion:
Immerse Concrete cloth in water for a minimum of 90 seconds.
Spraying:
Spray the dry Concrete cloth 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.
WORKING
It is bifurcated into four steps
4.4. Hydrating
After fastening of CC to desired place, it only needs to be hydrated for its final hardening. It is designed in
such a way that, it cannot be over hydrated. Only in 24 hours Concrete cloth is ready to serve its purpose.
CHAPTER-5
MARKET AVAILABILITY
Concrete cloth is available in two standard roll sizes; bulk rolls or smaller batched rolls. Bulk rolls provide
the fastest method of laying Concrete cloth and have the additional advantage of reducing the number of
joints required.
The shelter is supplied folded and sealed in a sack. The 16 m2 variant is light enough to transport in a pickup
truck or light aircraft.
There are 3 Concrete cloth types available with the following indicative specifications
5.2. RAIL
Concrete Canvas (CC) has been used in the rail sector since 2009 and is rapidly establishing itself as the
construction material of choice with network providers around the world. Some specific examples of
applications are:
Ditch Lining
Slope Protection
The speed and ease of installation means that CC is well suited to time-critical track-side work, vastly
reducing line possessions and overall project costs. Eliminating issues associated with rebound from shotcrete
means slope protection work can continue without line closures.
The resulting reduction in staffing levels and plant requirement has obvious safety benefits for contractors.
Existing users of CC in the Rail sector include:
UK Network Rail
Canada National Rail
ADIF, Spain
5.3. UTILITIES
Concrete Canvas (CC) is increasingly being used by utilities such as power, waterworks, landfill and hydro-
electric companies. Some specific examples of applications are:
Ditch Lining
Slope Protection
5.4. MUNICIPAL
Concrete Canvas (CC) has been used on a large range of projects for national governments, public works,
councils and local authorities. Some specific examples of applications are:
Gabion Reinforcement
Ditch Lining
Slope Protection
CC has an expected design life of over 50 years and has more than 200 cycles of freeze-thaw testing.
The concrete used within CC is extremely hard wearing and has twice the wear resistance of OPC; as well
as excellent resistance to chemical attack and UV degradation.
Existing users of CC in the Municipal sector include:
Caerphilly Council, UK
Ras Al Kamiah, UAE
Far North Council, New Zealand
Rother Council, UK
5.5. MINING
Concrete Canvas (CC) is being used extensively on large-scale mining projects around the world with
customers in South Africa, Canada, Chile, Australia and the UK. Some specific examples of applications are:
Ditch Lining
Vent Walls
Slope Protection
CC cannot be over-hydrated and there is no need for mixing, measuring or compacting on site.CC is well
suited to use in extreme environments and has been used installed in environments with sub-zero temperatures
such as Northern BC in Canada and at 4000m altitude in the Chilean Andes.
Existing users of CC in the Mining sector include:
Vale, Canada
5.6. AGRO
Concrete Canvas (CC) is well suited to agricultural applications where water management and erosion control
are key. Some specific examples of applications are:
Remediation
Ditch Lining
Slope Protection
CC also has a low alkaline reserve, a low washout rate and a low carbon footprint, ensuring minimal impact
on the environment.
CC can be used to reline existing concrete infrastructure in fisheries, canals or irrigation ditches, allowing
time-critical remediation work to be completed quickly and easily.
Mendez Soluciones, Chile
Concesión Sabana De Occidente, Colombia
Oranje Riet Water Users Association, South Africa
OSEPA Confed. Hidrografica del Ebro, Spain
5.7. PETROCHEMICAL
Concrete Canvas (CC) is increasingly being used by oil and gas companies around the world for a wide range
of containment, erosion control and water management applications. Some specific examples of applications
are:
Bund Lining
Pipe Protection
Ditch Lining
CC is typically 10 times faster to install than conventional concrete solutions, reducing plant and personnel
on site and consequently improving site safety.
CC can also be supplied in batched rolls allowing work to be done in areas with limited access.
Existing users of CC in the Petrochem sector include:
Phillips 66, UK
Petrobras, Brazil
Pacific Rubiales, Colombia
Shell, UK
CHAPTER-6
APPLICATIONS OF CONCRETE CLOTH
Concrete cloth 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.
Traditionally, the most common renovations were to replace smaller canals with pipelines and line larger
canals with concrete. But lining canals with concrete is expensive and requires significant upkeep.
Improved Impermeability: CC joints can be thermally welded or sealed with mortar to effectively reduce
water loss.
Minimum Volume Loss: CC typically replaces 100-150mm of poured or sprayed concrete. Therefore, re-
lining a channel or reservoir with just 5, 8 or 13mm of CC minimizes capacity losses associated with
conventional solutions.
Landslides may occur due to shallow erosion or reduction of shear strength caused by seasonal rainfall and
may be triggered by anthropic activities such as adding excessive weight above the slope, digging at mid-
slope or at the foot of the slope.
Concrete cloth can be used for 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.
Fig.6.6 Mining
Fig.6.7 Capping
Gabion is a cage, cylinder, or box filled with rocks, concrete, or sometimes sand and soil for use in civil
engineering, road building, and military applications. In a military context, earth- or sand-filled gabions are
used to protect artillery crews from enemy fire.
Concrete cloth can be used to cap or repair gabion walls to provide long-term protection and prevent
FOD (Foreign Object Damage). CC helps prevent loss of fill if the geo-textile has degraded from UV exposure
or weathering and securely ties together multi-level gabion walls preventing movement and extending their
life by decades.
CC provides a gabion covering solution which is fast, easy and cost effective to install. Capping: CC prevents
water ingress which can cause slump due to water saturation and the migration of fines.
Fig.6.8 Helipad
The turbulent air currents created by the helicopter rotor wash drives loose soil particles into the air.
The airborne dust particles negatively impact humans and wildlife, including aquatic life and vegetation. The
dust also increases vehicle, helicopter, and equipment wear and damage due to mechanical abrasion.
So the concrete cloth was used as a dust suppression surface around Helicopter Landing Sites.
CHAPTER-8
ADVANTAGES OF CONCRETE CLOTH
RAPID CONSTRUCTION
A 25sqm CCS can be deployed by 2 people in less than 1 hour and is ready to use in only 24 hours. The
material can be hydrated by either spraying it or fully immersing it in water. Once hydrated, it remains
workable for 2 hours and hardens to 80% of its final strength within 24 hours.
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.
FLEXIBLE
Concrete cloth can be easily nailed through before setting. It has good drape characteristics, allowing it to
take the shape of complex surfaces including those with double curvature.
STRONG
The fiber reinforcement acts to prevent cracking, absorbs energy from impacts, and provides a stable failure
mode.
FIREPROOF
Concrete cloth is a ceramic-based material and will not burn.
ADAPTABLE
Concrete cloth is currently supplied on 1.2 m wide rolls but can be manufactured with a roll width of up to 5
m. The cloth can be produced in a range of thicknesses from 5 to 20 mm.
DURABLE
Concrete cloth is chemically resistant and will not degrade in ultraviolet light. They are far more durable than
conventional soft skinned tents with a design life of over 10 years.
ENVIRONMENT FRIENDLY
The material can be reused and recycled.
EARTH BERMING
The compressive structure of CCS has been modeled to be covered with sand or earth fill, to provide
additional thermal mass and insulation providing excellent level of thermal performance.
CHAPTER-9
LIMITATIONS OF CONCRETE CLOTH
Concrete cloth cannot be over hydrated and an excess of water is always recommended.
Jets of high pressure water should not be impacted directly onto the concrete cloth as this may wash a channel
in the material.
Concrete cloth has a working time of 1-2 hours after hydration. So CC cannot be moved once it has
begun to set.
Working time will be reduced in hot climates.
If concrete cloth is not fully saturated, the set may be delayed and strength may get reduced.
REFERENCES
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Volume 1: Issue 3: March 2015, pp 6-12. www.aetsjournal.com
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Engineering Applications and Technology Volume 1, pp 2-7.
http://www.ijfeat.org/
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Volume 3: Issue 01: 2015, pp 314-315.
www.ijsrd.com
4. F. Han et al. 3D spacer fabrics. Construction and Building Materials 65 (2014) 620–629
5. http://www.concretecanvas.com/
6. http://www.concreteinternational.com/
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applications. Fiber Polym 2009; 10(1):116–23.