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In the present article, the authors have conducted a review on some of the recent developments given in the literature pertaining to the passive protection of concrete structures using intumescent coatings. Here, the main thrust is placed on the spalling phenomenon of concrete elements when exposed to elevated temperatures and fires.

In this context, it has been long established that prolonged thermal insult on concrete members will lead to egress of water, both physically bound as well as those present as water of hydration within the concrete matrix, in the form of steam through microchannels and associated pathways of least resistance, often resulting in the flaking of the surface of the structure. The latter process can ultimately lead to the exposure of the ferrous-based reenforcement elements, for instance, to higher temperatures, thus inducing melting. This, in turn, can result in substantial loss of strength and load-bearing capacity of the structural element that is already undergoing disintegration of its base matrix owing to heat/fire. Even though spalling of concrete structures has long been recognized as a serious problem that can often lead to catastrophic failure of infrastructures, such as buildings, bridges and tunnels, the utility of intumescent coating as a mitigation strategy is relatively new and has not been explored to its fullest possible extent. Therefore, in the latter parts of the review, the authors have endeavored to discuss the different types of intumescent coatings, their modes of actions and, in particular, their wider applicability in terms of protecting concrete elements from detrimental effects of severe or explosive spalling.

Given that spalling of concrete components is still a very serious issue that can result in loss of lives and destruction of critical infrastructures, there is an urgent need to formulate better mitigating strategies, through novel means and methods. The use of the intumescent coating in this context appears to be a promising way forward but is one that seems to be little explored so far. Therefore, a more systematic investigation is highly warranted in this area, especially, as the authors envisage a greater activity in the building and commissioning of more infrastructures worldwide incommensurate with augmented economic activities during the post-COVID recovery period.

The authors have conducted a review on some of the recent developments given in the literature pertaining to the passive protection of concrete structures using intumescent coatings. The authors have also included the results from some recent tests carried out at the facilities using a newly commissioned state-of-the-art furnace.

This paper presents the physical, mathematical and numerical models forming the main structure of the numerical analysis of the thermal, hydral and mechanical behaviour of normal, high‐performance concrete (HPC) and ultra‐high performance concrete (UHPC) structures subjected to heating. A fully coupled non‐linear formulation is designed to predict the behaviour, and potential for spalling, of heated concrete structures for fire and nuclear reactor applications. The physical model is described in more detail, with emphasis being placed upon the real processes occurring in concrete during heating based on tests carried out in several major laboratories around Europe as part of the wider high temperature concrete (HITECO) research programme. A number of experimental and modelling advances are presented in this paper. The stress‐strain behaviour of concrete in direct tension, determined experimentally, is input into the model. The hitherto unknown micro‐structural, hydral and mechanical behaviour of HPC/UHPC were determined experimentally and the information is also built into the model. Two examples of computer simulations concerning experimental validation of the model, i.e. temperature and gas pressure development in a radiatively heated HPC wall and hydro‐thermal and mechanical (damage) performance of a square HPC column during fire, are presented and discussed in the context of full scale fire tests done within the HITECO research programme.

The purpose of this paper is to evaluate high strength concrete (HSC) containing polypropylene fibers (PP-fibers) at high temperature under a compressive load.

The use of PP fibers in HSC is known to reduce and at times eliminate the risk of spalling. HSC containing 0, 1 and 2 kg/m³ of PP-fibers were subjected to various temperatures from 20°C to 150°C, 300°C and 450°C and evaluated in a “hot condition”. One group of specimens was in a non-stressed condition during heating (unstressed hot), while a second group was subjected to an initial preload of 40 per cent of the room temperature compressive strength during the heating (stressed hot).

Results showed that stressed concrete containing PP-fibers had lower thermal gradients (the temperature difference between the surface and center temperatures as a function of radial distance) and a decrease in relative porosity. However, the compressive strength of stressed specimens was improved with or without fibers as compared to that of the unstressed HSC. The increased stress levels due to concrete expansion at elevated temperature were also reported. The PP-fibers did not have a significant effect on the compressive strength of stressed concrete as compared to the unstressed state.

This paper reports the compressive strength of PP-fibers in HSC at elevated temperature with and without a pre-load.

The present work focuses on evaluating the physical and mechanical characteristics of geopolymer concrete (GPC) by replacing the sodium silicate waste (SSW) in place of traditional river sand. The aim is to create eco-friendly concrete that mitigates the depletion of conventional river sand and conserves natural resources. Additionally, the study seeks to explore how the moisture content of filler materials affects the performance of GPC.

SSW obtained from the sodium silicate industry was used as filler material in the production of GPC, which was cured at ambient temperature. Instead of the typical conventional river sand, SSW was substituted at 25 and 50% of its weight. Three distinct moisture conditions were applied to both river sand and SSW. These conditions were classified as oven dry (OD), air dry (AD) and saturated surface dry (SSD).

As the proportion of SSW increased, there was a decrease in the slump of the GPC. The setting time was significantly affected by the higher percentage of SSW. The presence of angular-shaped SSW particles notably improved the compressive strength of GPC when replacing a portion of the river sand with SSW. When exposed to elevated temperatures, the performance of the GPC with SSW exhibited similar behavior to that of the mix containing conventional river sand, but it demonstrated a lower residual strength following exposure to elevated temperatures.

Exploring the possible utilization of SSW as a substitute for river sand in GPC, and its effects on the performance of the proposed mix. Analyzing, how varying moisture conditions affect the performance of GPC containing SSW. Evaluating the response of the GPC with SSW exposed to elevated temperatures in contrast to conventional river sand.

The exposure of concrete elements to high temperatures during fire can cause major risk to life safety and to the serviceability of a building. One of the main reasons for this is due to concrete spalling which caused by pore pressure and thermal stresses. Previous research has indicated that the inclusion of polypropylene fibres to concrete reduces explosive spalling. However, concrete containing polypropylene fibre can still be vulnerable to explosive spalling during fire. This paper presents the outcomes of a research investigating the effect of using steel fibres in addition to polypropylene fibres to reduce explosive spalling of concrete. The experimental part of this study evaluates the performance of six normal strength columns under a loading ratio = 60% of the design capacity and subjected to severe heating rate higher than ISO 834. The columns were cast using various dosages of steel and polypropylene fibres. Analyses of the main findings included evaluation of the measured concrete temperatures along with axial displacement recordings. The analysis demonstrates a clear assessment of the spalling levels of the various representative specimens. The study also compares the experimental axial displacement with theoretical predictions using DIANA. Conclusions drawn from the study indicate that adding steel fibresalong with polypropylene fibres can reduce the degree and severity of spalling if compared with concrete containing polypropylene fibres only. The spalling degree was reduced from 22.03% to 12.41% in best case and from 14.95% to 10.49% in average when steel fibres were used with polypropylene fibres.

The purpose of the study was to investigate the spalling phenomenon in ultra-high performance fibre reinforced concrete (UHPFRC) beams on exposure to a standard fire curve (ISO 834) under a sustained load.

The variables in this study were steel fibre dosage, polypropylene (PP) fibres and loading levels. The research investigated seven beams – three of which contained steel fibres with 2 vol.%, another three had steel fibres with 4 vol.% dosage and the seventh beam had a combination of steel fibres (2 vol.%) and PP fibres (4 kg/m³). The beams were tested for 1 h under three loading levels (20, 40 and 60 per cent) based on the ambient temperature ultimate flexural strength of the beam.

Spalling was affected by the loading levels; it exacerbated under the load level of 40 per cent, whereas under the 60 per cent load level, significantly less spalling was recorded. Under similar loading conditions, the beams containing steel fibres with a dosage of 4 vol.% spalled less than the beams with fibre contents of 2 vol.%. This was attributed to the additional tensile strength provided by the excess steel fibres. The presence of PP fibres eliminated spalling completely.

There is insufficient research into the performance of UHPFRC beams at elevated temperature, as most studies have largely focussed on columns, slabs and smaller elements such as cubes and cylinders. This study provides invaluable information and insights of the influence of parameters such as steel fibre dosage, PP fibres, loading levels on the spalling behaviour and fire endurance of UHPFRC beams.

The purpose of this paper is to examine the effect of various polypropylene fibre additions (types and volume) to concrete with regard to explosive spalling when subject to high temperatures similar to those experienced in building or tunnel fires.

Medium strength concrete was manufactured with varying proportions of polypropylene fibres. Plain control samples were used to determine the original concrete strength and this was used as a benchmark following high temperature heat tests to evaluate the surface condition and final compressive strength. A pilot study was used to determine an appropriate heat source for the test. This was three Bunsen burners, however sufficient heat could not be generated within 150 mm concrete cubes and the concrete was shown to be a significant insulator and fire protection for structural members. The concrete test cubes were tested in a saturated condition which may reflect conditions where concrete is used in an external environment and thus is subject to soaking.

One hundred and fifty millimetre concrete cubes with and without fibres were placed into a furnace at 1,000°C. Explosive spalling was shown to be reduced with the use of polypropylene fibres but the final compressive strength of concrete was significantly reduced and had little residual structural value after a two hour period of heating.

As the concrete tested was saturated, this condition provided a worst case scenario with regards to the build up of hydrostatic and vapour pressure within the cube. A range of percentage moisture contents would produce a more evenly balanced view of the effects of fibres in concrete. A single grade of concrete was used for the test. As the permeability of concrete influences the rate at which steam can escape from the interior of a saturated concrete cube, testing a range of concrete strengths would show this aspect of material performance with regard to spalling and final residual strength. Further research is recommended with regard to moisture contents, strengths of concrete and a range of temperatures.

This research has significance for the designer, in that buildings subject to terrorist activity may suffer from impact damage and an outbreak of fire following the initial attack.

The use of polypropylene fibres in concrete to provide anti spalling qualities is relatively new and this research adds to the knowledge regarding fibre type and volume with regard to first spall time, total area and number of areas subject to spalling and the final compressive strength of concrete following two hours of raised temperatures.

This paper reports on an experimental study regarding the behavior of restrained high-strength concrete in response to the type of extreme heating associated with fire. The study was intended to support estimation of thermal stress from the strain in a restraining steel ring and vapor pressure in restrained concrete under the conditions of a RABT 30 rapid heating curve. The size of the specimens was φ300 X 100 mm, and the results showed that explosive spalling occurred between 4 and 10 minutes in terms of heating time. It was also observed that the thermal stress was greater than the vapor pressure value of 0.1 MPa at a point 10 mm from the heated surface at 5 minutes. The maximum spalling depth was about 61 mm. It was inferred that spalling behavior caused by thermal stress may become predominant under restrained conditions.

The purpose of this study is to investigate the effect of standard fire on the strength and microstructure properties of concrete with different strength grades.

Different strength grades of concrete used for the investigation are M20, M30, M40 and M50. An electrical bogie hearth furnace was developed to simulate the International Standards Organization 834 standard fire curve.Concrete samples were subjected to high temperatures of 925, 1,029, 1,090 and 1,133°C for the duration of 1, 2, 3 and 4 h, respectively, as per standard fire curve. Compressive strength, tensile strength, thermal crack pattern and spalling of heated concrete specimens were evaluated by experimental investigation. Scanning electron microscopy and thermo-gravimetric analysis were performed to investigate the microstructure properties of heated concrete specimens.

Test results indicated reduction in the strength and changes in the microstructure properties of concrete exposed to elevated temperature. The degree of weight and the strength loss were found to be higher for concrete with higher grades. An empirical relation is proposed to determine the residual strength of concrete with different strength grade using regression analysis.

Results of this research will be useful for the design engineers to understand the behavior of concrete exposed to elevated temperature as per standard fire.

When concrete is exposed to elevated temperature, its internal microstructure changes, thereby strength and durability of concrete deteriorates. The performance of concrete with different strength grade exposed to standard fire is well understood. This research’s findings will be useful for the designers to understand more about fire resistance of concrete. A simple relationship is proposed to determine the residual strength of concrete exposed to various durations of heating.

The paper aims to present an advanced 2 D transient heat transfer analysis capable of accounting for the effect of spalling in terms of amount, location and time. The model accounts for moving thermal boundary conditions to comply with the changing member cross section. The discussed numerical model provides a tool to quantify the effect of spalling on the flexural capacity of reinforced concrete beams.

The implementation of the presented numerical model in an in-house code and its validation has been discussed. The thermal subroutine has been sequentially coupled with the mechanical subroutine (sectional-analysis) to compute the variation of sectional moment carrying capacity with exposure time.

The temperatures predicted while considering spalling were in good agreement with experiments available in literature. The presented results also emphasise the importance of considering the time of spalling. The results also show that the fire rating of simply supported beams is also affected by spalling in the compression zone.

It should be acknowledged that the model does not predict spalling, rather is developed as a tool to study the effect of spalling. The model takes the information related to spalling in terms of the location, amount and time, as user input.

The paper quantitatively presents the effect of spalling on the predicted temperature variation across the beam cross section and the moment carrying capacity.