MPI - ACI BIGE-FPP FRC Slab-On-ground Technical Report Rev-0

ABOITIZ CONSTRUCTION, INC.
PRELIMINARY DESIGN REPORT

SLAB-ON-GROUND
FIBER-REINFORCED CONCRETE (FRC)

(Revision-0)
BIG E FOOD PROCESSING PLANT

Aboitiz Construction, Inc.
Fiber-Reinforced Concrete (FRC)
TABLE OF CONTENTS
1. Introduction……………………………………………………………….3
2. Design of Conventional Reinforcement……………………….…….4
3. Design of Fiber-Reinforced Concrete………………………….…….6
3.1 Using linear model for Ultimate Limit State (ULS)…………….6
4. Recommendation…………………..……………………………………8
5. References……………………………………...………………………...8
6. Notice……………………………………......………………………….....8
Appendix A – Technical Data Sheet of Dramix 4D 65/60 BG

Appendix B – Technical Data Sheet of Dramix 4D 80/60 BGE
Appendix C – Method Statement Fiber-Reinforced Concrete (FRC) Slab-on-Grade
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Disclaimer
The attached design proposal has been made using the methodology detailed in technical design manuals and detailed specifications of Maccaferri. These manuals and
specifications are available for inspection on request. However, it should be noted that the design proposal has been computer generated from information provided to
Maccaferri which has not been independently verified, and may contain assumptions and inaccuracies regarding geotechnical, hydraulic, or other parameters. Maccaferri,
accordingly, does not accept responsibility for the accuracy or completeness of information or assumptions from which the design proposal has been produced, or for the
interpretation of the design proposal. Maccaferri and its suppliers shall not be liable to any person or property for loss, damage, or injury (whether direct, special,
consequential, or indirect) arising out of the use or interpretation of the attached design proposal. The design proposal remains the copyright and property of Maccaferri
and is not to be copied or disclosed to any person other than the person to whom it is originally intended.
1. INTRODUCTION
The purpose of this document is to present the preliminary design of Fiber-Reinforced Concrete
(FRC) for the slab-on-ground within the scope of the BIG E Food Processing Plant. Aboitiz
Construction, Inc., the contractor for the proposed building, intends to use fiber reinforcement to
efficiently facilitate the construction of the slab and achieve their carbon footprint savings targets.
The proposed FRC design is based on the equivalent capacity of a conventional reinforcement.
This analysis has led to the exploration of two distinct reinforcement configuration solutions as
follows:
Case 1: 200mm THK – Dramix 4D 65/60 BG at 30kg/m3
Case 2: 150mm THK – Dramix 4D 80/60 BGE at 30kg/m3
Figure 1-1. Proposed BIG E Food Processing Plant General Site Plan (taken from
12595611-GHD-00-00-DRG-CI-00012)
This technical proposal summarizes the design analysis of the reinforcement option, this
document aims to provide an informed foundation for the design and selection of an alternative
fiber reinforcement.
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Disclaimer
2. DESIGN OF CONVENTIONAL REINFORCEMENT

To ensure the successful implementation of the fiber reinforced concrete solution, it is crucial to
thoroughly analyze the existing conventional reinforcement solution. The given data serves as
the initial foundation for this analysis and includes the following:
Table 2-1. Slab-on-ground design parameters

DESIGN PARAMETER VALUE1
Thickness 200/150 mm
Slab section unit width 1000 mm
Depth of Reinforcing Mesh 100/75 mm
Reinforcing Area per unit width– As 1005.0 mm2
Concrete Strength - f’c 4000 psi / 28 MPa
Reinforcement diameter 16 mm
Spacing 200 mm
Yield Strength - Fy Grade 60 - 415 MPa

1 Values based on the Engineering Design given by the client.
Figure 2-1. Case 1 - Typical slab-on-ground reinforcement configuration

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Figure 2-2. Case 2 - Typical slab-on-ground reinforcement configuration

Disclaimer
Ultimate Moment Capacity of Reinforced Section referenced from ACI – 318
Figure 2-2. Schematics of stress block for a cracked reinforced concrete member: (a)
reinforced concrete beam section; (b) actual distribution of normal stresses; (c) simplified
distribution of normal stresses.
Calculate for the depth of compressive zone:
𝑨𝑺 ∙ 𝒇𝒚
𝒂 =
𝟎. 𝟖𝟓 𝒇 𝒄 ∙ 𝒃
Case 1: 200mm THK
SYMBOL DESCRIPTION VALUES UNITS
a Depth of compressive zone 14.02 mm
𝒂
𝑴𝒏𝒖 𝑹𝑪 = 𝑨𝑺 ∙ 𝒇𝒚 ∙ (𝒅 − )
𝟐

Ø Reduction Factor 0.90 -
Mnu-FRC Nominal moment capacity of RC under ULS 27.90 kN-m/m
Case 1: 150mm THK

a Depth of compressive zone 14.02 mm
𝒂
𝑴𝒏𝒖 𝑹𝑪 = 𝑨𝑺 ∙ 𝒇𝒚 ∙ (𝒅 − )
𝟐

Ø Reduction Factor 0.90 -
Mnu-FRC Nominal moment capacity of RC under ULS 20.40 kN-m/m
*For applications where FRC replaces steel mesh reinforcement, designed solely for serviceability limit
state (SLS) conditions like slab-on-ground, a working stress of 80% of the yield strength is assumed for
the steel reinforcement.
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Disclaimer
3. DESIGN OF FIBER REINFORCED CONCRETE

ACI 544.4R-18 “Guide to Design with Fiber-Reinforced Concrete reported by ACI
Committee 544" Section 4.6 - Design of FRC for flexure (Model Code 2010 [fib 2013])
Figure 3-1. Schematics of stress block for a cracked FRC flexural member: (a) FRC beam
section b) distribution of flexural stresses; and c) simplified distribution of normal stresses.
The FRC design may be performed using the moment-crack width relationship obtained from BS
EN 14651-2005 test on notched beams using Model Code 2010 (fib 2013) design guideline
summarized herein. The nominal moment for an FRC section, Mn-FRC is calculated according
to Equation 2 and Equation 3 from the force equilibrium in the cross-section as shown in Figure
3.4. As presented schematically, Fig. 3.4a is an FRC beam reinforced with fibers, Fig. 3.4b shows
the distribution of flexural stresses, whereas Fig 3.4c shows the simplified distribution of normal
stresses in the cracked section. A constant value of tensile residual strength fFtu is used for
ultimate state design.
For the rigid plastic model, the ultimate strength of FRC, fFtu-FRC is taken as a constant value of
one-third times the flexural residual strength of FRC, fR3 that is measured from BS EN 14651:2005
beam test. The formulas for calculating the tensile strength and nominal bending moment are
shown in Equation 2 and Equation 3, respectively.[1]
3.1 Using linear model for Ultimate Limit State (ULS):
𝒘𝒖
𝒇𝑭𝒕𝒖 𝑭𝑹𝑪 = (𝟎. 𝟒𝟓𝒇𝒓𝟏 ) − (𝟎. 𝟒𝟓𝒇𝒓𝟏 − 𝟎. 𝟓𝒇𝒓𝟑 + 𝟎. 𝟐𝒇𝒓𝟏 ) ≥ 𝟎 Equation 2
𝑪𝑴𝑶𝑫𝟑
𝒃𝒉𝟐
𝑴𝒏𝒖 𝑭𝑹𝑪 = 𝒇𝑹,𝟑 × Equation 3
𝟔
Case 1. Geometry of slab-on-ground

B Width of the section considered 1,000.00 mm
H Thickness of slab 200.00 mm
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Disclaimer
Steel Fibers Properties:

fR,3 As measured from beam test, EN 14651:2005 4.67 N/mm2
Fiber Type and Recommended Dosage:
Concrete 4000 PSI/C28
DRAMIX 4D 65/60 BG at 30kg/m3*
*Recommended dosage for testing according to EN 14561
Nominal moment capacity of FRC under ULS:

𝒃𝒉𝟐
𝟔

φ Reduction Factor 0.90 -
Mnu-FRC Nominal moment capacity of FRC under ULS 28.02 kN-m/m
Case 2. Geometry of slab-on-ground

B Width of the section considered 1,000.00 mm
H Thickness of slab 150.00 mm
Steel Fibers Properties:

fR,3 As measured from beam test, EN 14651:2005 6.20 N/mm2
Fiber Type and Recommended Dosage:
Concrete 4000 PSI/C28
DRAMIX 4D 80/60 BGE at 30kg/m3*
*Recommended dosage for testing according to EN 14561
Nominal moment capacity of FRC under ULS:

𝒃𝒉𝟐
𝟔

φ Reduction Factor 0.90 -
Mnu-FRC Nominal moment capacity of FRC under ULS 20.93 kN-m/m
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Disclaimer
Table 3-1. Summary of slab-on-ground reinforcement capacity

Type of reinforcement Moment capacity (kN-m/m)
200mm THK – Ø16 @ 200mm B.W. 27.90
150mm THK – Ø16 @ 200mm B.W. 20.40
200mm THK – 4D 65/60 BG 30kg/m3 28.02
150mm THK – 4D 65/60 BG 30kg/m3 20.93
4. RECOMMENDATION
Fiber-reinforced concrete (FRC) offers significant advantages for enhancing the handling and
placement of concrete structures while also reducing job-site labor requirements. Additionally,
FRC significantly enhances post-cracking behavior, which is defined as toughness (di Prisco et
al., 2009), and exhibits superior crack control characteristics compared to conventional steel-bar
reinforced concrete (Minelli et al., 2011; Tiberti et al., 2014). For achieving the required loading
capacity in the proposed fiber-reinforced slab-on-ground, it is recommended to perform
calculations using Dramix 4D 65/60 BG at 30kg/m3 and Dramix 4D 80/60 BGE at 30kg/m3.
5. REFERENCE
[1] ACI Committee 544, Guide to Design with Fiber-Reinforced Concrete (ACI 544.4R-
18), American Concrete Institute, Farmington Hills, MI, 2018.
6. NOTICE
This document contains an Application Suggestion, which has been prepared by Maccaferri
(Philippines), Inc. (MPI) on a confidential basis to enable the application of Fiber Reinforced
Concrete. The Application Suggestion is illustrative and is not a detailed design. Copyright of this
Application Suggestion belongs to MPI. It may not be reproduced in whole or in part without the
prior written permission of MPI. It must not be disclosed to any third party other than for the
purpose of evaluating its commercial application for the use of Maccaferri materials.
The information provided in this document is supplied without charge. It does not form part of any
contract or intended contract with the recipient. No liability in negligence will arise from the
construction of any project based on such information or material. Final determination of the
suitability of any information or material for the use contemplated and the manner of use is the
sole responsibility of the user and its professional advisors, who must assume all risk and liability
in connection therewith. MPI assumes no responsibility to the recipient or any third party for the
whole or any part of the content of this document.
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Disclaimer
APPENDIX A – Technical Data Sheet

DRAMIX 4D 65/60 BG
9
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Disclaimer
®
Dramix
Data Sheet Aspect ratio Length Bright Glued
65/60 G
Dramix ®
Conforms to
0749-CPD
ASTM A820
EN 14889-1
DRAMIX® 4D PERFORMANCE PRODUCT CERTIFICATES

Material properties Conforms to
0749-CPD
ASTM A820
Tensile strength: Rm,nom: 1.500 N/mm 2
EN 14889-1
Tolerances: ± 7,5% Avg
Young’s Modulus: ± 210.000 N/mm2 Dramix® is certified for structural use
according to EN 14889-1 (system ‘1’).
Detailed information is available on request.
Geometry
The Dramix® 4D series is designed with
Fibre family 4D
optimal serviceability in mind. Tensile strength
SYSTEM CERTIFICATES
Dramix ®
®
Dramix
and anchorage are engineered specifically

to affect cracks between 0,1 and 0,3 mm,
enabling you to create durable and liquid-tigth Length (l) 60 mm
structures. The 4D series is also a perfect
solution for combined reinforcement.
All Dramix® plants are ISO 9001 and
Diameter (d) 0,90 mm
ISO 14001 certified.
> optimised anchorage, glued fibre 80
65
> high tensile strength 55
Aspect ratio (l/d) 65
45
PACKAGING
Dramix 4D is a cost efficient solution
®
for SLS applications

> seamless floors Fibre network
> combislab (Dramix® 4D + mesh)
> underwater concrete 2,9 km per m3 (for 15 kg/m3)
> motorways 3.200 fibres/kg
Minimum dosage:
Bekaert supplies all of the support you need 15 kg per m3 (according to CE)
for your project. We help you determine the
most suitable fibre types, calculate optimal BAGS 20kg BIG BAG 1100 kg
dosages, select the right concrete quality. Dramix® range
STORAGE
5D 4D 3D
Dramix®®
Dramix ®
Dramix ®
Dramix
Tensile strength KEEP DRY

71.62.05 - 02/2013
NO STACKING
Contact your local support.
Wire ductility
Go to www.bekaert.com/dosingdramix Modifications reserved.
for our recommendations on handling, All details describe our products in general form only.
dosing and mixing. Anchorage strength For detailed information, product specifications
available on request.
APPENDIX B – Technical Data Sheet

DRAMIX 4D 80/60 BGE
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Disclaimer
Dramix®
80 / 60 GE
Aspect ratio Length Bright Glued Extra anchorage
DATASHEET
Characteristics Product certificates* DRAMIX® 4D 80/60BGE

Material properties
Optimized anchorage
Nom. tensile strength:
1.800 (N/mm²) Dramix® 4D provides optimal crack control
for standard statically indeterminate
Young’s modulus: 200.000 (N/mm²)
concrete structures that are submitted to
Strain at ultimate strength: 0,8 % regular static, fatigue and dynamic loadings
with high serviceability requirements.
Geometry Glue technology for three-dimensional

reinforcement
fibre family Dramix® steel fibres are bundled with
* Product certificates are plant specific. water-soluble glue. The glue helps avoiding
fibre balling during mixing and ensures
Length (l) 60 mm a homogeneous distribution of fibres
ll
Product conformity throughout the concrete mix.
Dramix® conforms to ASTM A820, EN 14889-1

Diameter (d) 0,75 mm d The high performant anchorage
d and ISO 13270 Class A.
Dramix® 4D Extra is a high performant fibre
100 with an optimized 4D hook to create optimal
80 anchorage in normal strength concrete.
Aspect ratio (l/d) 80 65 55 45
System certificates
l/d
Bekaert construction support
All Dramix® plants You can count on our support for each
are ISO 9001 and step of your project, from concept design
Minimum EN 14889-1 dosage ISO 14001 certified. to on-site quality support. Our services
10 kg/m³ include recommendations on slab
design, construction detailing, concrete
optimization and automatic total quality
Fibre network
Packaging control procedures. We are also happy to
2.879 m/m³ at 10 kg/m³ share our knowledge with you and your
4.644 fibres/kg team.
Feel free to ask us for a workshop
or training on the topic of steel fibre
Dramix® family reinforcement in your offices.
3D Typical SFRC applications

4D Supreme serviceability control
5D Advanced structural applications
Datasheet_Dramix 4D 8060BGE_EN-UK_20230210
BAGS BIG BAG

20 kg 1.100 kg
®
Dramix
Tensile strength
Handling
Wire ductility
For recommendations on handling, dosing and mixing
Anchorage strength KEEP DRY visit www.bekaert.com/dosingdramix.
Any other specific document or certificate can be
found on www.bekaert.com/dramix/downloads.
Bekaert reserves the right to modify, discontinue or rebrand this product at any time with or without notice. All information contained herein is general and may not be complete. For further details, please contact the
local Bekaert office.
APPENDIX C – Methodology
Fiber-Reinforced Concrete (FRC) Slab-on-Grade Method Statement
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Disclaimer
Method Statement for Dramix® Steel Fiber Reinforce Concrete
A. GROUND PREPARATION
1. For slab on grade, the sub-grade shall be 8. Additional reinforcement should be

mechanically compacted until th required installed at critical location such as edge,
bearing capacity (k-value or CBR) and a floor drop, openings, column (Fig.2) and
layer of fine crushed rock or similar to be should be placed at about 30mm below
placed in order to provide a satisfactory the top of the slab and 50mm from the
leveling course. edges of critical location (Fig.3)
2. Ground compaction shall be in accordance
with the general codes of practice. The
tolerance of the sub-grade level should be
±10mm.
3. For pile supported slab, cement stabilized
or lean concrete can be used to improve
the sub-grade. If the SFRC is to be placed
directly on the excavated ground, the base
surface should be evenly dampened to
avoid any differential drying of the wet Fig. 2: Isolation of Columns
concrete.
4. Polythene (PE) sheeting shall be placed
between subgrade and concrete slab
(Fig.1) in order to decrease friction and to
reduce drying out of the wet concrete.
Fig. 3: Typical slab joint details
9. Allocate a convenient area to dose steel

fiber behind the mixing truck for onsite
mixing.
10. Make sure all the access way, concreting
Fig. 1: Placing of PE Sheets
machinery and materials are ready before
concreting.
5. The slab area for placing concrete should 11. Prepare sufficient tools, flooring machinery
be avoided from all weather influences and others concreting machinery. All
(strong air flows, raining, exposed to sun- machineries shall be tested before
light etc.) casting.
6. Make sure the formwork for the
construction joint has been properly Note
installed. 1. Finalize all slab joint details, location and
7. Ensure the slab finishing level control within others slab detailing before the casting.
the specified tolerance slab thickness. 2. Experienced and fully equipped flooring
specialist shall be considered.
Maccaferri (Philippines), Inc. 11Floor, Asian Star Building, 2404 ASEAN Drive, Filinvest Corporate City
Alabang, 1781 Muntinlupa City, Philippines
www.maccaferri.com/ph Tel: +63-2 8889-0623
3. Discussion regarding casting sequence, flooring contractor before the actual
capacity and methodology shall be concreting works, to finalize the concrete
determined by flooring contractor before design mix and to observe quality of floor
actual casting. being executed.
4. Perform trial mix and sample slab casting
(if required) with the concrete supplier and
B. BATCHING OF STEEL FIBRES
1. Ensure the concrete grade and slump

(Fig.5) delivered to site is according to
specification.
Fig. 6: Dosing of fibres manually
7. Keep mixer drum running at highest speed

when adding steel fiber (min. drum speed :
Fig. 5: Concrete slump test
12 rpm).
2. The concrete slump requirements before 8. Full speed rotation of mixer drum after
batching SF depends on the method of mixing (1 minute/m3).
placement and design dosage.
3. Recommended concrete slump without SF
Placing method Direct discharge Concrete pump

Fibre dosage (kg/m )3
Slump (mm) Slump (mm)
15 -253) 150 170 9. If necessary proceed concrete slump test
(kg/m
30 -35 150 – 170 170 – 200 after mixing SF. Reject concrete if it fails
40 -45 170 – 200 170 -200 below 80mm slump.
10. Discharge the concrete at designated
4. For slump lesser than 130mm, it is location.
suggested that super- plasticizers (SP) to
be used as a water reducing admixture. Note
5. Additional water at site to increase concrete 1. Plan the volume of concrete delivered in
slump or workability is strictly prohibited. order to reach total steel fibre weight per
6. Position the concrete truck and dose the truck in round figure (80kg, 100kg etc).
steel fibers according to design dosage 2. In order to reduce the batching time, avoid
(kg/m3). Add Dramix® Steel fiber at the high capacity concrete truck mixer.
rate of 30 seconds per bag (Fig.6).
3. To ensure the SF volume for every batch, 4. Erect a scaffolding (x2 stack high) platform
prepare the total weight of steel fibre for adding steel fibres manually incase the
needed per batch and placed it near to dosing system unfunctional.
dosing machine or platform before the truck
mixer ready.
C. CONCRETING
1. Discharge concrete directly or by using

concrete pump (Fig. 8).
Fig. 10: Vibrating truss screeding

7. Curing compound or others curing method
Fig. 8: Direct discharge concrete should be apply accordingly, immediately
2. Compacting, screeding and leveling the after all the required finishing step
concrete slab with proper or other completed.
conventional method. 8. Protect the fresh casting area from weather
3. Finishing should commence when there is and loading before the curing process
no free bleed water on the surface and accomplished.
should be done by using a steel hard trowel,
bull float or power rotary trowelling machine Note:
(power float).
4. Power trowelling can only start 3-4 hrs. after 1. The SFRC should be fresh and no longer
concreting (no water bleeding on the slab than 60min after batch time from concrete
surface). plant.
5. Introduced contraction joint (Saw cut joint) 2. The concrete delivery should be constant
within 8--12 hrs after concreting. and consistent rate throughout the pour.
6. Saw cut joint width to be within 3-5mm; 3. In order to avoid appearance SF on slab
depth to be 1/3 of slab thickness (Fig. 9). surface, vibrating screeding method
(Vibrating Truss-Fig.10, Magic Screed,
Laser Screed, etc) and Ride On Trowelling
method shall be considered)
Fig. 9: Saw cutting

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ABOITIZ CONSTRUCTION, INC.

PRELIMINARY DESIGN REPORT

FIBER-REINFORCED CONCRETE (FRC)

BIG E FOOD PROCESSING PLANT

Appendix A – Technical Data Sheet of Dramix 4D 65/60 BG

2. DESIGN OF CONVENTIONAL REINFORCEMENT

Table 2-1. Slab-on-ground design parameters

Slab section unit width 1000 mm

Depth of Reinforcing Mesh 100/75 mm

Reinforcing Area per unit width– As 1005.0 mm2

Concrete Strength - f’c 4000 psi / 28 MPa

Yield Strength - Fy Grade 60 - 415 MPa

Figure 2-1. Case 1 - Typical slab-on-ground reinforcement configuration

Figure 2-2. Case 2 - Typical slab-on-ground reinforcement configuration

Ultimate Moment Capacity of Reinforced Section referenced from ACI – 318

Calculate for the depth of compressive zone:

SYMBOL DESCRIPTION VALUES UNITS

Case 1: 150mm THK

SYMBOL DESCRIPTION VALUES UNITS

3. DESIGN OF FIBER REINFORCED CONCRETE

Case 1. Geometry of slab-on-ground

Steel Fibers Properties:

Nominal moment capacity of FRC under ULS:

SYMBOL DESCRIPTION VALUES UNITS

Case 2. Geometry of slab-on-ground

Steel Fibers Properties:

Nominal moment capacity of FRC under ULS:

SYMBOL DESCRIPTION VALUES UNITS

Table 3-1. Summary of slab-on-ground reinforcement capacity

200mm THK – Ø16 @ 200mm B.W. 27.90

150mm THK – Ø16 @ 200mm B.W. 20.40

200mm THK – 4D 65/60 BG 30kg/m3 28.02

150mm THK – 4D 65/60 BG 30kg/m3 20.93

APPENDIX A – Technical Data Sheet

Data Sheet Aspect ratio Length Bright Glued

DRAMIX® 4D PERFORMANCE PRODUCT CERTIFICATES

and anchorage are engineered specifically

for SLS applications

Tensile strength KEEP DRY

APPENDIX B – Technical Data Sheet

Characteristics Product certificates* DRAMIX® 4D 80/60BGE

Geometry Glue technology for three-dimensional

Dramix® conforms to ASTM A820, EN 14889-1

3D Typical SFRC applications

BAGS BIG BAG

1. For slab on grade, the sub-grade shall be 8. Additional reinforcement should be

Fig. 3: Typical slab joint details

9. Allocate a convenient area to dose steel

B. BATCHING OF STEEL FIBRES

1. Ensure the concrete grade and slump

Fig. 6: Dosing of fibres manually

7. Keep mixer drum running at highest speed

Placing method Direct discharge Concrete pump

1. Discharge concrete directly or by using

Fig. 10: Vibrating truss screeding

Fig. 9: Saw cutting

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