Carbon Fibre Laminate / Plate

dura.®fibre CFP is a ready-to-use epoxy pre-impregnated, extruded laminated carbon fibre plate. The carbon fibre laminate system offers outstanding tensile strength for bending loads,deformation, or increased stress and E-modulus for the structural strengthening of reinforced concrete elements.

Uses
    • Increase load requirements:

Increased live loads
Increased traffic
Heavy machinery installed in buildings
External reinforcing flat structures like slabs and beams
Building/structure use change

    • Damage to structures through:

Aging
Corrosion of steel
Seismic activity
Durability reduction by fire

    • Durability:

Reduced stress in rebar
Prevention of further cracking
Suppression of crack width due to expansion
Reduce deformation
Satisfy design change requirements

    • Design or construction defects/changes:

Structures having insufficient reinforcing
Structures with insufficient element dimensions
New openings in structure to accommodate changes

Advantages
  • Easy-to-apply
  • Carbon fibre offers exceptional tensile strengths and E-Modulus
  • Light weight, hardly no additional weight to the structure
  • Increase in bending moment
  • Composite system offer outstanding fatigue properties
  • Quick turn-around time for repair work
  • Corrosion resistant
  • Reliable structure repair system
  • Long lengths reduce additional joint work
  • Quality and performance is uniform due to pre-lamination of the carbon fibre with epoxy resin
  • No multiple layers need to be applied
  • Can be coated
Surface Preparation

See dura.®fibre CFP adhesive data sheet
Spalling repairs required:
Request the relevant spalling methodology.

dura.®fibre CFP carbon fibre plates:

Precaution:

When opening the 100 metre roll, take care when loosening the ties all at once, this may cause a hazard due to rapid unwinding. Carefully cut the length of dura.®fibre CFP plate to the required length using a diamond cutter or file saw. Wear goggles, dust mask, gloves and other appropriate PPE.

Cleaning the dura.®fibre CFP carbon plates:

Clean the rough side of the carbon plate that will be in contact with the dura.®fibre CFP adhesive and concrete by thoroughly wiping using abe® thinners No. 3 and allow it to dry, cleanliness must be maintained prior to bonding the dura.®fibre CFP plates.

Typical Physical Properties

Colour 

Black

Fibre type 

High strength carbon 

Dimensions

Width (mm)
50 and 100
50 and 100
Thickness (mm)
1.2
1.4

Tensile strength (ASTM D 3039) 

> 3 000 MPa

Elongation at break 

> 1.8% 

E-Modulus (ASTM D 3039) 

> 165 GPa 

Mean tensile strength at break 

3 050 MPa 

Elongation at break 

> 1.7% 

Density 

1.5 g/cm3 

Mass/100 m (W = width and T = thickness)
50 mm (W) x 1.2 mm (T)
100 mm (W) x 1.2 mm (T)
50 mm (W) x 1.4 mm (T)
100 mm (W) x 1.4 mm (T)

50 mm (W) x 1.2 mm (T)
100 mm (W) x 1.2 mm (T)
50 mm (W) x 1.4 mm (T)
100 mm (W) x 1.4 mm (T) 

Mass
9 kg
12 kg
10.5 kg
21 kg
Cross sectional area
60 mm2
120 mm2
70 mm2
140 mm2 

Shelf life 

Unlimited (store clean and dry)

Application

Precaution:

Prevailing weather conditions must be taken into account. Thoroughly mix the dura.®fibre CFP adhesive and apply the adhesive on the concrete surface using a rubber spatula 1 mm thick to enhance the adhesion properties. Also apply the mixed adhesive to the ground side of the carbon plate. The adhesive coat shall be 4 mm thick in total.

Attach the adhesive-coated carbon plate to the concrete surface by pressing. Using a rubber roller apply enough pressure to allow the excess adhesive to exude between the carbon plate panels.

 

Remove the excess adhesive with a rubber spatula or dry cloth.

Carbon plate attached to the concrete surface should be left alone for at least three to four hours for sufficient curing to take place.

Note: Ensure adequate ventilation is available and prohibit open flames at the site. Protect from any wind pressure in tunnels or underground rail tracks that may cause the carbon plate panels to detach from the concrete surface before curing. Keep the panels physically supported until fully cured. Grind the first surface layer of carbon plates applied to reinforce slabs in a cross before applying the second layer.

Design Work

Consultation with a structural engineer is imperative when the design criteria and application configurations are required subject to load calculations of the various elements that are under consideration.

Curing

Protect outdoor applications from rain, dust and debris using a suitable plastic covering.

Allow the carbon plate adhesive to cure for 24 hours or more (increase the curing time when low ambient temperature is experienced).

Note: Discard mixed adhesive when its useful life is over. No solvent of whatever type should be mixed in with the adhesive. The use of any thinning solvent, coating roller or brush is strictly prohibited.

The longer the adhesive is mixed at a higher temperature, the shorter will be its useful life. The useful life varies depending on the site conditions. Discard a mixed batch of adhesive when its rising temperature or viscosity has made it difficult to apply, as this means its useful life is over.

Coverage – Approximate Adhesive Consumption

100 m length x 50 mm wide = 20 L

100 m length x 100 mm wide = 40 L

 

These calculations are theoretical and exclude waste or surface profile irregularities.

Cleaning

Cleaning of tools and equipment use abe® super brush cleaner before the epoxy has cured. Cured material will have to be removed mechanically.

Protection on Completion

All applied product needs to be protected for at least 24 hours against the weather and high winds.

Finishing

 

It is desirable to apply a polyurethane paint to the carbon fibre plate system for protection against ultra-violet rays and or subsequent environmental conditions. See “coating types”.

Painting should be performed in not less than 24 hours after the application of the carbon plate lay-up process.

Coating types

 

UV protection – abe.®cote tough PU paint

 

Damp/wet conditions – dura.®flex, abe® silocoat

 

Submerged conditions – dura.®flex

 

Chemical spill environments – abe.®cote SF 356 or SF 217

Temperature and Relative Humidity

dura.®fibre CFP system should be applied at material temperatures between 12 °C and 18 °C and ambient temperatures of 5 °C to 30 °C. Temperatures should not fall below 5 °C in the 24 hours after application. Do not apply coating if the substrate temperature is at least 3 ºC (5 ºC is better) above dew point or highly humid conditions to cause condensation.

Model Specification

High strength epoxy extruded carbon fibre plates incorporating an epoxy adhesive system to be used for structural strengthening.

The system shall be dura.®fibre CFP high strength carbon fibre plates including the dura.®fibre CFP adhesive applied in accordance with the structural engineers detail and the recommendations of a.b.e.® Construction Chemicals.

Packaging

dura.®fibre CFP is supplied in 100 m rolls.

50 mm wide x 1.2 mm thick (code: 12601169)

50 mm wide x 1.4 mm thick (code: 12602177)

100 mm wide x 1.2 mm thick (code: 12603173)

100 mm wide x 1.4 mm thick (code: 12604178)

Handling & Storage

dura.®fibre CFP has an unlimited shelf-life if kept in a dry store in its sealed package.

Health & Safety

dura.®fibre CFP is a carbon fibre product therefore when cutting/handling suitable protection must be employed to avoid contact with skin and eyes, avoid inhalation of particles during processing by wearing dust masks. The use of gloves, eye protection and dust masks is advised. Immediately wash with water in the event of contact with skin. Splashes into eyes should also be washed immediately with plenty of clean water and medical advice sought.

Important Notice

This data sheet is issued as a guide to the use of the product(s) concerned. Whilst a.b.e.® Construction Chemicals endeavours to ensure that any advice, recommendation, specification or information is accurate and correct, the company cannot – because a.b.e.® has no direct or continuous control over where and how a.b.e.® products are applied – accept any liability either directly or indirectly arising from the use of a.b.e.® products, whether or not in accordance with any advice, specification, recommendation, or information given by the company.

Further Information

Where other products are to be used in conjunction with this material, the relevant technical data sheets should be consulted to determine total requirements. a.b.e.® Construction Chemicals has a wealth of technical and practical experience built up over years in the company’s pursuit of excellence in building and construction technology.