Kevlar concrete is a novel material that combines the remarkable strength of Kevlar fibers with the long-lasting properties of conventional concrete. This cutting-edge concrete is a desirable alternative for contemporary building projects because it is made to provide improved performance in a range of structural applications.
Kevlar concrete is distinct due to its special mixture of ingredients. The concrete gains increased flexibility and toughness by incorporating Kevlar fibers, which are well-known for their high tensile strength and resistance to impact. Because of this, it is especially appropriate for high-stress situations where traditional concrete might not be adequate.
Kevlar fibers are mixed with regular concrete ingredients to create Kevlar concrete. As a result, a composite material is created that is stronger than ordinary concrete and can withstand higher loads without cracking or deforming. Kevlar concrete constructions can therefore benefit from a longer lifespan and less maintenance requirements.
When one examines the properties and manufacturing process of Kevlar concrete, one can see how advantageous it is for a range of construction projects, from industrial buildings to infrastructure. This material promises improved durability and performance in the future, marking a major breakthrough in concrete technology.
- General information
- Schematic diagram
- Materials
- Equipment
- Video on the topic
- Kevlar concrete technology
- Kevlar concrete
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General information
The material’s strength properties were similar to those of the well-known Kevlar fabric, which is where the analogy ended, giving rise to its sonorous name. For this reason, please do not mistake this review for DIY Kevlar body armor publications. These are entirely distinct entities.
We will go into great detail in this publication about what makes ultra-concrete, what materials are used in its production, and how to make Kevlar concrete by hand. We suggest watching the video in this article if you still have questions after reading the material that has been presented.
Schematic diagram
The primary distinction between conventional and ultra-concrete brands is that at the intermediate stage of production, the product is made up of pellets, or balls, with a diameter ranging from 2 to 5 cm. The pellet is a lump of mortar with an oval shape.
A sphere of compacted cement-sand mixture is formed around a core made up of one or two coarse aggregate grains in the center of such a composite.
The final pellets are arranged on a vibrating table in unique shapes. The balls compact and spread inside the forms as a result of vibration, creating a dense product devoid of air inclusions.
There are multiple stages that make up the entire production process, and they are as follows:
- preparation of a dry mixture;
- production of pellets;
- placing pellets in forms;
- vibration;
- stripping and drying of products.
The proper combination selection, the order in which materials are added, and the concrete mixer drum’s rotational speed are the primary requirements for production. Granite-based products and natural stone-based building materials are identical in appearance.
Using pellet concrete:
- creation of small architectural forms;
- production of paving slabs;
- production of decorative slabs for precast reinforced concrete fences;
- arrangement of stairway structures (see. photo);
- production of facing tiles, etc.
Materials
The primary benefit of Kevlar concrete is that it uses a standard set of ingredients, which are also used to prepare heavy and decorative concrete, as the raw material for product production. These ingredients are as follows:
- binder – Portland cement PC 500 D0;
- water;
- granite crushed stone;
- sand;
- modifiers;
- coloring pigments.
Cement clinker, gypsum, and, depending on the type and brand, plasticizers and mineral additives are used to make Portland cement.
Clinker: what is it? This material is made by sintering and firing a dry blend of organic clays. The material is crushed, gypsum is added, and any required modifiers are added after heat treatment. We consequently get premium Portland cement (GOST 31108-2003).
Natural enriched quartz sand with a 1.5–2.5 mm fraction is used to create high-quality products with a smooth surface. This is a granular material that was left over after rocks containing quartz were destroyed.
Apart from the primary ingredient, the sand could also include iron oxides, clay carbonates, etc. Clay component content shouldn’t be more than 2.5–3.0%.
The color of the material can vary from yellow to brown depending on the region, which also has an impact on the final color of the manufactured goods.
Crushed granite is a material made from crushed igneous rocks. Gravel or crushed stone with a 2.5–5 mm grain size is used in the technology used to prepare granite.
The material’s high density (beginning at 1000 kg/cm3) gives concrete containing granite chips exceptional performance qualities.
- increased frost resistance;
- low abrasion 0.2 g/cm2;
- high hardness;
- tensile and compressive resistance;
- water resistance;
- durability.
The preparation instructions suggest using plasticizing additives based on sodium polymethylene naphthalene sulfonate as modifying additives for Kevlar concrete production, and organic monomer compounds as additives speeding up the setting process.
The two that are currently on the market are superplasticizer C-3 and "Relamix N" (Polyplast).
By adding these additives to the mixture, you can benefit from the following advantages:
- increase the mobility of the solution by 6-7 times;
- increase the rate of strength gain by 30% (in the first day);
- reduce the volume of mixing water to the required 17-20%;
- reduce cement consumption by 10-15%;
- reduce the time, and therefore energy costs, for vibrating products;
- obtain frost resistance F300 and higher;
- water resistance W6 and higher.
Colored powders, either natural or synthetic, derived from minerals or organic materials, are known as pigments for ultra-concrete. Mineral dyes have an advantage because they are essentially oxides or salts of different metals.
Several color compositions can be used thanks to Kevlar concrete production technology. This method allows for the creation of products with an extensive color spectrum as well as the ability to mimic the structure of natural stone (granite, marble, malachite, etc.) through the use of specialized techniques.
Take note! Ultraconcrete dyes need to be highly resistant to light, moisture, and alkali, and they can’t include heavy metal salts like lead or zinc, which can negatively impact the concrete’s setting time.
Equipment
Using gravity-type concrete mixers is a prerequisite for making pelletized concrete. These are devices that have a rotating bulb-shaped container with a tilter-style unloading mechanism.
Fixed blades are affixed to the inside of the pear’s body. As the pear rotates, these blades catch and raise portions of the solution.
The solution, with its own weight, slides off the blades and falls at the top of the pear. The mixture gradually forms pellets because of the carefully chosen composition and the suggested pear rotation speed.
The following factors have a big impact on the finished product’s quality:
- the shape of the installed blades;
- the rotation speed;
- the angle of the drum.
Benefits of using a gravity-type concrete mixer:
- reliability and simplicity of design;
- affordable price;
- relatively low weight of the unit;
- low energy consumption.
Apart from a concrete mixer, other tools required for product production are a vibrating table and plastic molds that replicate the material’s structure as specified by the project.
In order to increase its strength and durability, conventional concrete is mixed with Kevlar fibers to create innovative construction materials like Kevlar concrete. This novel mixture increases the concrete’s resilience to impact and cracking, which makes it perfect for demanding applications. Kevlar, which has a high tensile strength, is added to this concrete to make it more resilient and long-lasting than other options. Gaining an understanding of Kevlar concrete’s properties, constituent materials, and manufacturing procedure is essential to realizing the revolutionary potential of this material in contemporary building.
| Characteristic | Description |
| Definition | Kevlar concrete is a type of concrete reinforced with Kevlar fibers, known for its enhanced strength and durability. |
| Main Material | Kevlar fibers, which are synthetic and known for their high tensile strength. |
| Properties | Increased tensile strength, improved impact resistance, and enhanced crack resistance compared to regular concrete. |
| Production Process | Kevlar fibers are mixed into the concrete mix before casting. The fibers are uniformly distributed to strengthen the concrete matrix. |
| Applications | Used in high-stress environments like bridges, buildings, and military structures where durability is crucial. |
| Advantages | Improved resistance to cracking and impact, longer lifespan, and reduced maintenance costs. |
| Disadvantages | Higher cost due to the expense of Kevlar fibers and potentially more complex production process. |
A notable development in building materials is Kevlar concrete, which combines the strength of Kevlar fibers with the durability of concrete. When compared to conventional concrete, this mixture produces a material that is not only stronger but also more resilient to stress and impact. Kevlar is used, which increases the structure’s overall longevity and helps to prevent cracking.
Kevlar fibers are mixed into the concrete mixture to create Kevlar concrete. By increasing the concrete’s tensile strength and flexibility, these fibers increase its resistance to different kinds of damage. Careful application and mixing are required during this process to guarantee that the fibers are dispersed equally throughout the concrete.
Kevlar concrete is therefore especially helpful in situations where increased resistance and durability are essential. Kevlar concrete is a durable material that can endure harsh environments and increase the lifespan of constructions, making it ideal for use in high-traffic areas and harshly conditioned structures.
