Mechanical Properties

S1-3-5APPLICATION OF HIGH STRENGTH FIBER REINFORCED MORTARTO PRESTRESSED CONCRETE STRUCTURES
Michihiro SAKURADA
Senior Research Engineer, Technical Research Institute, P.S. Mitsubishi Construction Co., Ltd., Japan.
Hiroaki OHYAMA
Section Manager, Design Proposal Dept., Branch Office of East Japan, P.S. Mitsubishi Construction Co., Ltd.,
Japan.
Takuya MORI
General manager of Nagoya Branch, P.S. Mitsubishi Construction Co., Ltd., Japan.

ABSTRACT:High strength fiber reinforced mortar was developed and its applicability for towers and low height girder bridges
were studied. Various material experiments and the loading experiments of tower and girder specimens wereconducted. As a result, it showed that it is possible to construct towers and low height girder bridges by applicationof high strength fiber reinforced mortar. High strength fiber reinforced mortar was already applied to actual lowheight girder bridges and towers. In addition, it can be economically applied to the prestressed concrete structures
whereas ordinary concrete cannot be adopted.䎃
Keywords: high strength fiber reinforced mortar, creep, drying shrinkage, diffusion coefficient of chloride ions

1. INTRODUCTION
Recently in Japan, high strength concrete whosestrength is over 150N/mm2 has developed and beenused for various structures such as buildings andbridges [1]. But, as for high strength concrete, coarse
aggregates sometimes reduce fluidity of fresh concrete,increase fluctuation of strength and limit compressive
strength. Therefore, coarse aggregate used for highstrength concrete should be selected carefully.
Consequently, the authors developed a high strengthmortar hereinafter called high strength fiber reinforced
mortar that was reinforced steel fibers and had nocoarse aggregate [2]. Photo 1 and Photo 2 show thehigh strength fiber reinforced mortar and the steel fiber
respectively. Since coarse aggregate is not mixed, thehigh strength fiber reinforced mortar has high fluidity
and high design strength of 120N/mm2. And because ofsteel fibers, it is possible to prevent cracks caused by
autogenous shrinkage and prevent brittle failure causedby high strength [2], [3].
When the high strength fiber reinforced mortar wasdeveloped, various material tests were conducted andcompressive strength, Young’s modulus, creep
coefficient, drying shrinkage, diffusion coefficient ofchloride ions were confirmed. The authors invented
applications of the mortar to prestressed concrete
bridges with low height girders and prestressed
concrete towers. And also, loading experiments ofgirder and tower specimens were conducted. By
application of the mortar, prestressed concrete bridges
with low height girders and a prestressed concrete
tower were actually realized and it was verified that
there were many advantages such as reduction of thegirder height, increment of the durability and cost
reduction by using the mortar. In addition, it was also
shown that these advantages can not be obtained byusing ordinary strength concrete.
In this report, it is introduced that material propertiesof the high strength fiber reinforced mortar andapplications of the mortar to actual prestressed concrete
structures.

Photo 1 High strength fiber reinforced mortar

Photo 2 Steel fiber

8th International Symposium on
Utilization of High-Strength and High-Performance Concrete451

Mechanical Properties

2.1 Materials and Specified MixTable 1 and Table 2 show the materials and thespecified mix of high strength fiber reinforced mortar
respectively. High strength fiber reinforced mortar is
consist of silica fume premixed cement, crushed sand,steel fiber and water with super plasticizer. Thesematerials are weighted and mixed by actual equipments
such as batching units and forced action mixers forordinary strength concrete. As for high strength fiber
reinforced mortar, special materials and equipments are
not used in consideration of the economy.
Steel fiber is mixed in order to prevent cracks causedby autogeneous shrinkage and prevent brittle failure
which is characteristic of high strength concrete. Inhigh strength fiber reinforced mortar, steel fiber
If mix rate of steel fiber is 0.5 vol.%, it is confirmedthat no shrinkage cracks and no brittle failure occur by
results of various experiments and construction of
actual structures [3], [4].
Curing method of high strength fiber reinforced
mortar is steam curing as shown in Figure 1 in order togain high strength early and prevent cracks caused by
autogenous shrinkage.

Table 1 Materials
Material

Spec
Silica fume premixed cement,
CementC
Density: 3.08g/cm3
Tensile strength: 2340N/mm2, Density:
Steel fiberSF
7.85g/cm3, Length:13mm, Diameter: 0.16mm
Crushed sand, Density: 2.57g/cm3, Absorption:
Sand
S
1.03%, Maximum diameter: 5mm
Super-plasticizer SP Polycarboxylic acid family

Mark

Table 2 Specified mix
Unit weight(kg/m3)
W
C
S
SF*
120
17
2.0 210 1235
948
40
*Mix rate of steel fiber: 0.5vol.%f’ck(N/mm2)

W/C
(%)

Air
(%)

SP/C
(%)
3.0

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㪫㪼㫄㫇㫉㪸㫋㫌㫉㪼㩷㩿㪻㪼㪾㪅㪚㪅㪀

2. PROPERTIES OF HIGH STRENGTH FIBER
REINFORCED MORTAR

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2.2 Strength㪊㪍㪋㪏㪫㫀㫄㪼㩷㩿㪿㪀

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Figure 1 Method of curing

2.3 Durability
Results of accelerating carbonation tests, freeze-thaw
tests and diffusion coefficient tests of chloride ions areshown in Figure 2, Figure 3 and Table 4 respectively.
These durability tests were conducted under thecondition of without steel fiber, the rest was mix
proportion shown in Table 2.
High strength fiber reinforced mortar has highdurability in terms of carbonation, freeze-thaw andchloride attack because of low water cement ratio of
17%. Especially, diffusion coefficient of chloride ionsis 0.0217cm2/year which is approximately 1/20 times as
small as ordinary strength concrete whose water cement
ratio is 36% for general prestressed concrete structures[5].
Figure 4 shows the concentration of chloride ion at
surface of the reinforcement. The concentration was
calculated according to standard specifications for
452

Table 3 Strength properties
Unit
Design strength
N/mm2
Tensile strength
N/mm2
Flexural strength N/mm2
Young’s Modulus kN/mm2

High strength
fiber reinforced
mortar
120
8.0
15.0
40

Ordinary
strengthconcrete
40
2.7
5.3
33

ratio
3.0
3.0
2.8
1.2

Table 4 Diffusion coefficient of chloride ions (cm2/y)High strength fiber reinforced mortar Ordinary strength concrete*
0.0217**0.463**** Water cement ratio is 36%** Result of test according to JSCE-G572-2003*** Calculated by “log Dp㧩-3.9(W/C)2㧗7.2(W/C)㧙2.5” [6]䎃㪋㪇㪛㪼㫇㫋㪿㩷㫆㪽㩷㪺㪸㫉㪹㫆㫅㪸㫋㫀㫆㫅㩷㩿㫄㫄㪀

Table 3 shows the strength properties of highstrength fiber reinforced mortar after steam curing.
Design strength, tensile strength, flexural strength andYoung’s modulus are 120N/mm2, 8.0N/mm2,
15.0N/mm2 and 40kN/mm2 respectively. These strength
are 3 times as high as ordinary strength concrete usedprestressed concrete structures but Young’s modulus is
not so high compared with ordinary concrete. It is
confirmed that only flexural strength increases alongwith mix rate of steel fiber but compressive strength,
tensile strength and Young’s modulus are notinfluenced.

㪟㫀㪾㪿㩷㫊㫋㫉㪼㫅㪾㫋㪿㩷㪽㫀㪹㪼㫉㩷㫉㪼㫀㫅㪽㫆㫉㪺㪼㪻㩷㫄㫆㫉㫋㪸㫉㪊㪌㪦㫉㪻㫀㫅㪸㫉㫐㩷㫊㫋㫉㪼㫅㪾㫋㪿㩷㪺㫆㫅㪺㫉㪼㫋㪼㩿㪮㪆㪚㪌㪌㩼㪀㪊㪇㪫㪼㫊㫋㩷㪺㫆㫅㪻㫀㫋㫀㫆㫅㫊䊶㪚㪦㪉 㩷㪚㫆㫅㪺㪼㫅㫋㫉㪸㫋㫀㫆㫅㪑㩷㪌㩼䊶㪩㪼㫃㪸㫋㫀㫍㪼㩷㪿㫌㫄㫀㪻㫀㫋㫐㪑㩷㪍㪇㩼

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Figure 2 Result of accelerating carbonation tests

8th International Symposium on
Utilization of High-Strength and High-Performance Concrete

㪈㪈㪇

㪈㪉

㪈㪇㪇
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Mechanical Properties䍃㪧㫆㫊㫀㫋㫀㫆㫅㪑㩷㪪㫌㫉㪽㪸㪺㪼㩷㫆㪽㩷㫋㪿㪼㩷㫉㪼㫀㫅㪽㫆㫉㪺㪼㫄㪼㫅㫋䍃㪜㫄㫍㫀㫉㫆㫅㫄㪼㫅㫋㪑㩷㪪㫇㫃㪸㫊㪿㩷㫑㫆㫅㪼䍃㪚㫆㫍㪼㫉㪑㩷㪊㪎㫄㫄㪈㪇㪏㪍㪟㫀㪾㪿㩷㫊㫋㫉㪼㫅㪾㫋㪿㩷㪽㫀㪹㪼㫉㩷㫉㪼㫀㫅㪽㫆㫉㪺㪼㪻㩷㫄㫆㫉㫋㪸㫉㪋㪦㫉㪻㫀㫅㪸㫉㫐㩷㫊㫋㫉㪼㫅㪾㫋㪿㩷㪺㫆㫅㪺㫉㪼㫋㪼㩿㪮㪆㪚㪊㪍㩼㪀㪉㪣㫀㫄㫀㫋㩷㪺㫆㫅㪺㪼㫅㫋㫉㪸㫋㫀㫆㫅㪑㩷㪈㪅㪉㫂㪾㪆㫄㪊

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Figure 3 Result of freeze-thaw tests

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3.1 Low Height Girder Bridges

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㪈㪇㪇 㪈㪌㪇 㪉㪇㪇 㪉㪌㪇 㪊㪇㪇 㪊㪌㪇 㪋㪇㪇㪣㫆㪸㪻㫀㫅㪾㩷㫇㪼㫉㫀㫆㪻㩷㩿㪻㪸㫐㪀

Figure 5 Result of creep tests㪍㪇㪇㪣㪼㫅㪾㫋㪿㩷㪺㪿㪸㪾㪼㩷㫎㫀㫋㪿㩷㪻㫉㫐㩷㫊㪿㫉㫀㫅㫂㪸㪾㪼㩷㩿㱘

3. APPLICATIONS

㪎㪌

㪈㪅㪋

2.4 Creep And Drying Shrinkage
Figure 5 and Figure 6 show the result of creep tests
and result of dry shrinkage tests respectively. For
comparison, results of the ordinary strength concretethat of unit quantity of water is 150kg/m3 and that ofwater cement ratio is 35% are also shown. In addition,
results of high strength fiber reinforced mortar were
measured after steam curing of 3 days and those ofordinary strength concrete were measured after
underwater curing of 28 day.
From these results, it is confirmed that creep
coefficient of the high strength fiber reinforced mortar
is 0.75 which is 75% of the ordinary strength concrete.
Meanwhile, it is also confirmed that dry shrinkage ofthe mortar is from 300Ǵ to 400Ǵ which is the samelevel of the ordinary strength concrete.䎃㪌㪇㪫㫀㫄㪼㩷㩿㫐㪼㪸㫉㫊㪀

Figure 4 Concentration of chloride ions㪚㫉㪼㪼㫇㩷㪺㫆㪼㪽㪽㫀㪺㫀㪼㫅㫋

concrete under the environmental conditions whichwere splash zone, cover of 37mm and elapsed time of
100 years [6].
The concentration of the chloride ions is less than
1.2kg/m3 which is limit of rust development at thesurface of the reinforcement after 100 years. Therefore,
it is verified that high strength fiber reinforced mortar
has durable period of 100 years under the splash zone if
its cover is over 37mm.

㪉㪌

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㪋㪇㪇
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Generally, the ratio between the girder height and thespan length, hereinafter called height span ratio, isapproximately 1/20 in terms of the ordinary prestressed
concrete girder bridges. However, as for prestressed
concrete girder bridges, the lower girder height causes
the larger flexural stress in the girder as shown in
Figure 7. If the height of the girder is extremely low(the height span ratio is under 1/30), it is necessary to
introduce the large prestress to the girder in order toincrease the compressive strength of the girder in order
to introduce the large prestress to the girder. Therefore,
the low height girder bridges whose height span ratio is㪇㪌㪇㪈㪇㪇 㪈㪌㪇 㪉㪇㪇 㪉㪌㪇 㪊㪇㪇 㪊㪌㪇 㪋㪇㪇㪛㫉㫐㫀㫅㪾㩷㫇㪼㫉㫀㫆㪻㩷㩿㪻㪸㫐㪀

Figure 6 Result of dry shrinkage tests
up to approximately 1/50 can become possible byapplication of the high strength fiber reinforced mortar
to the girders. In addition, it is also possible to reducethe cost of the low height girder bridge because thehigh strength fiber reinforced mortar can reduce thenumber of girders.
When the low girder bridge with the high strength
fiber reinforced mortar, flexural load experiments, shear

8th International Symposium on
Utilization of High-Strength and High-Performance Concrete453

Mechanical Properties

Table 5 Actual application results of the prestressed concrete bridges with low height girders
MAMEKAI Bridge
Kind of bridge
Road bridge
Structural system
Simple girder bridge (post-tensioned)
Design strength
120N/mm2
Mix rate of steel fiber
0.5vol.%Bridge length
26.0m
Span length
25.2m
Girder height
1.05m (Center), 0.85m (End)Height span ratio
1/24㨪1/30
Owner
Hitachi-Ohta city
Construction Period
2005.12.7㨪2006.3.30

KAIKI Bridge
Road bridge
Simple girder bridge (pre-tensioned)
120N/mm2
1.0vol.%
17.7m
8.3m
0.3m
1/28
Bizen city
2006.2.15㨪2006.5.31

load experiments and fatigue experiments wereconducted and it was verified that the prestressed
concrete beams with the mortar had enough strengthand high durability against fatigue [3], [7].
After these experiments, the low height girder
bridges with the high strength fiber reinforced mortar
were applied to three actual prestressed concrete
bridges. The actual application results of the low height
girder bridges are shown in Table 5.
(1) MAMEKAI Bridge [8]MAMEKAI Bridge is the first low height girder
bridge with the high strength fiber reinforced mortar.
This bridge is a simple supported girder bridge with
one span, 26.0m long, 6.0m wide and its span length is
25.2m. The section of this bridge is T-shaped. The
completed MAMEKAI Bridge is shown in photo 3.
Though the original plan was a usual prestressed
concrete bridge whose design strength was 40N/mm2
with T-section, it became possible to make the height of
the girder end to be low by using the high strength fiber
reinforced mortar. As a result, the earthwork volume of
the approach part was reduced.
Photo 4 and Photo 5 show the situation of the placingof the mortar and the situation of the erection of girders
respectively. This bridge was constructed with the
pre-cast segment method. The precast segments were
manufactured in a factory and carried to the site. Thesesegments were combined by prestressing on theerection girders and erected by the truck crane.
Photo 6 shows the aspect of MAMEKAI bridge after
one year from the completion. Problems such as cracks
and the rust by corrosion of the steel fiber were notobserved at MAMEKAI Bridge where one year passed
from the completion.
(2) KAIKI bridge[9]The completed KAIKI bridge is shown in Photo 7.
KAIKI Bridge is a simple supported girder bridge with
2 spans, 17.7m long, 5.8m wide and its span length is
8.3m. The section of this bridge is hollow-shaped. Thisbridge is located on the sea that is severe environment
against the salt damage.
The construction of this bridge was conducted inorder to replace old bridge that was the reinforced
concrete damaged by salt. In the plan of this bridge, theeffective width was going to be spread from 4.3m to
5.0m and the substructure was going to be used
continuously without replacing. Therefore, it wasnecessary to make the superstructure as light as

454

TSUNEISHI Landing Bridge
Landing bridge
Simple girder bridge (Post-tensioned)
120N/mm2
0.5vol.%
26.4m
25.6m
0.55m
1/47
KAMTECS Co., Ltd.
2006.7.10㨪2006.12.20(NGZWTCNUVTGUU1TFKPCT[JGKIJVIKTFGT%QODKPGF
UVTGUU

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Figure 7 Stresses in prestressed concrete girders

Photo 3 MAMEKAI Bridge

Photo 4 Situation of placing of the mortar

Photo 5 Situation of erection of the girder

8th International Symposium on
Utilization of High-Strength and High-Performance ConcreteMechanical Properties

possible. However, if the ordinary strength concrete
was used for this bridge, the cover should be 70mm
according to specification for highway bridges in Japanbecause this bridge was located on the splash zone.
Therefore, it was difficult to make the superstructure ofthis bridge light. Consequently, the low height girder
bridge with high strength fiber reinforced mortar wasapplied to this bridge since the mortar made it possible
to lighten the superstructure due to decrease the girderheight and the durable period against the salt damage
could be 100 years if the cover was approximately
40mm.
The girders of this bridge were manufactured in afactory. Prestressing of the girders was introduced by
pre-tension method. The girders were carried to the siteby trucks and erected by the truck crane.

Photo 6 MAMEKAI Bridge after one year(3) TSUNEISHI Landing Bridge[10]Completed TSUNEISHI Landing Bridge is shown in
Photo 8. This landing bridge is a simple supported
girder bridge with one span, 26.4m long, 2.0m wide
and its span length is 25.6m. The section of this bridge
is hollow-shaped. The location of this landing bridge ison the sea and the environment is classified into thesplash zone. The old bridge made of steel was decided
to be replaced because of the severe corrosion by thesalt. The low girder bridge with high strength fiber
reinforced mortar was applied because the mortar had
durable period of 100 years against the salt damage
without maintenance and made it possible to decrease
the height of the girders as low as the old bridge.
The girder height of this bridge is 0.55m against the
span length of 25.6m and the height span ratio of 1/47
is achieved though it is not the road bridge. In order toachieve the low height girders, 4 prestressing strands of
19S15.2 were arranged to the girder. The designed
compressive stress of the girders in the prestressing was
35N/mm2, therefore it was impossible to realize such
low height by the ordinary strength concrete.

Photo 7 KAIKI Bridge


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The high strength fiber reinforced mortar was applied
not only to the bridges but also to a prestressed concrete
tower. Figure 8 and Photo 9 show the profile and thecompleted tower respectively. The height of this tower
is 40m and the purpose of this tower is to install theequipments for mobile phones.
Though the towers for the mobile phones are
generally made of steel, the tower made from the highstrength fiber reinforced mortar was used because themortar made it possible to improve the durability of thetower.
Photo 10, Photo 11 and Photo 12 show the situationsof the construction. This tower was constructed with the
pre-cast segmental method. The pre-cast segments
which were 5.0m long and octagon shaped were
manufactured in a factory and carried to the site. In thesite, the pre-cast segments were combined byprestressing which were introduced by the verticalprestressing steel bars anchored in the footing.
The diameter of this tower is 1167mm at the base and㧡㧜 㧜 㧜

4.2 Prestressed Concrete Tower

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㧡 㧜㧜 㧜Ǿ㧡 㧜 㧜㧜

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Photo 8 TSUNEISHI Landing bridgeFigure 8 Profile
Photo 9 Tower

500mm at the top. The high strength fiber reinforced
mortar could make the shape slender as well as the steel
towers. And, though the mean thickness of the member

8th International Symposium on
Utilization of High-Strength and High-Performance Concrete455

Mechanical Properties

was more than 250mm if the ordinary strength concrete
was used, the mean thickness could become 150mm by
the utilization of the high strength fiber reinforced
mortar. The reduction of the member thickness could
realize the reduction of the inertia force by earthquake
and the simplification of the erection.
It is thought that such prestressed concrete towers
without bolted connections are effective to make theaspect of the tower improve since the scenery is often
demanded in the city area.
Photo 10 Completed pre-cast segments

5. CONCLUSIONIn this paper, the properties of high strength fiber
reinforced mortar and its application results to theprestressed concrete structures were introduced. From
the results of the material tests, loading experiments
and actual executions, the following were verified.
(1) High strength fiber reinforced mortar has highfluidity and high design strength of 120N/mm2.
(2) Owing to steel fibers, it is possible to prevent cracks
caused by autogenous shrinkage and prevent brittle
failure.
(3) High strength fiber reinforced mortar make itpossible to realize prestressed concrete structures suchas low height girder bridges whose height span ratio is
1/47, high durable bridges, slender towers and so on.
And it was difficult for the ordinary strength concrete torealize these prestressed concrete structures that hadhigh added value in terms of structural performance,
durability and cost.
(4) For the reasons stated above, it is thought that the
number of the adoptions of the high strength fiber
reinforced mortar increases from now on.

Photo 11 Situation of the erection

REFERNCES
1. JCI, “Report of The Study Committee for Structural
Performance of High Strength concrete,” Jul., 2006.
2. Sakurada, M., Amemiya, Y., Ohyama, H., Mori, T.,“Material Properties of High Strength Fiber
Reinforced Mortar,” Proceedings of the JCI, Vol.29,
June, 2007, pp.133-138.
3. Amemiya, Y., Sakurada, M., Mori, T., Niwa, J.,“Characteristics of PC Beams Used Ultra HighStrength Fiber Rainforced Mortar,” Proceedings of
the JCI, Vol.25, July, 2005, pp.1657-1662.
4. Sakurada, M., Ohyama, H., Mori, T., Niwa, J.,“Experimental Study on Prestressed Concrete Pole
made with Ultra High Strength Fiber Reinforced
Mortar,” Proceedings of the 15th symposium on
developments in prestressed concrete, JPCEA, Oct.,2006, pp.449-454.
5. Japan Road Association, “Specifications for
Highway Bridges, Part III, Concrete Bridges.” Mar.,
2002, pp.171-175.
6. JSCE, “Standard Specifications for Concrete
Structures -2002, Materials and Construction,” Mar.,2002.
7. Sakurada, M., Ohyama, H., Ishida, K., Hamada, S.,“Fatigue Experiments of Prestressed Concrete Beammade from High Strength Fiber Reinforced Mortar,”
456

Photo 12 Situation of prestressingProceedings of the 16th symposium on developments
in prestressed concrete, JPCEA, Oct., 2007,
pp.363-366.
8. Miyamae, T., Kikuchi, T., Kimura, K., Konishi, T.,“Design of MAMEKAI Bridge,” Proceedings of the
15th symposium on developments in prestressed
concrete, JPCEA, Oct., 2006, pp.29-32.
9. Iwai, T., Kamezawa, N., Fujioka, Y., Ishida, K.,“Construction of Pre-tensioning Girder made from
Ultra High Strength Fiber Reinforced Mortar -KAIKI
Bridge-,” Proceedings of the 15th symposium on
developments in prestressed concrete, JPCEA, Oct.,2006, pp.33-36.
10. Tanaka, H., Uchida, K., Ishida, K., “Construction of
Post-tensioning Girder made from Ultra HighStrength Fiber Reinforced Mortar,” Proceedings ofthe 16th symposium on developments in prestressed
concrete, JPCEA, Oct., 2007, pp.367-370.

8th International Symposium on
Utilization of High-Strength and High-Performance Concrete