Application Examples of Composite Rebars and Mesh

Self-serviced car wash network near Entertainment and Shopping Center “Koltso”, Chelyabinsk, 18 Darvina str.

50% budget saving at foundation reinforcement

Fiberglass composite material manufactured by COMPOSITE GROUP CHELYABINSK company, with diameter of 10 mm was for reinforcing the foundation. The main selection criteria for composite rebars for foundation reinforcing at this facility was: convenience of transportation. Steel rebars are delivered in rods of 6 or 11.7 meters. Composite rebars are delivered in coils of any construction length. For delivery of rebars to the facility an ordinary vehicle like "Gazelle" was used. At delivery of steel rebars, the customer should have employed a 12-meter vehicle. And this means expenses of a higher level. Since the dimensions of the future car wash are 7*30 meters, usage of steel rebars would entail a large amount of steel scraps. Composite rebars are delivered in coils of 50 and 100 meters. And the construction workers performing the works in situ cut the rebars for the required pieces. The price in comparison with steel reinforcement. The total amount saved by the customer made about 1950 USD. It was achieved by virtue of equal-strength replacement by a smaller diameter, from 14 mm of steel reinforcement to 10 mm of composite rebars. When calculating the costs the price of rebars was taken as of September 2016. In total, arrangement of one square meter of the reinforcing structure with steel rebars would cost 17,86 USD, and fiberglass made 8,5 USD, which means more than 50% budget saving. In addition to saved funds, the customer receives more reliable and durable design vs. steel reinforcement as fiberglass rebars won't react to chemical detergents and rust.

Entertainment and Shopping Center “Pobeda” with Magnit grocery store inside it, Chelyabinsk, 282 Pobedy avenue

Floor reinforcing cost saving is 7 600 USD, transportation costs down by 590 USD

For reinforcing the floors in the Entertainment and Shopping Center “Pobeda” on the crossing of Tchaikovskogo Street and Pobedy Avenue, with Magnit grocery store located inside it, composite material manufactured by COMPOSITE GROUP CHELYABINSK company with diameter of 8 and 10 mm was applied. The Magnit company has been being a market leader in Russia for several years considering such indicators as the number of stores and the volume of shopping capacities. The management of Magnit has not been looking for innovative technologies in the sphere of sales and development of retail network only, but also in the construction segment. Therefore, for several years the Magnit company has been using composite rebars at arranging the foundations and reinforcing the floors. Replacement of steel rebars by composite ones is caused by the price and convenience of transportation. Reinforcing of one sq.m with use of composite rebars of 8 and 10 mm diameter cost the customer 6,9 USD. When using steel reinforcing of 12 and 14 mm diameter the total amount for arrangement of a square meter would make 15,4 USD. Thus, budget saving at reinforcing the foundation with composite material made over 7 600 USD. When calculating the costs, the price of rebars was taken as of September 2016. Budget-saving through transportation of composite rebars in coils made over 590 USD

Warehouse complex “Krasnopolskaya Site”, Chelyabinsk, Krasnoye Pole settlement, Severny Highway, 9/2

budget saving by 2 times at foundation reinforcing

Composite rebars manufactured by COMPOSITE GROUP CHELYABINSK, LLC, with diameter of 6 and 10 mm were used. Use of steel reinforcing at this facility wasn't considered at all, for one simple reason. The owners of this warehouse complex had already dealt with composite material at construction of other facilities and knew firsthand about the chance to save with foundation reinforcing. Total budget saving when using composite rebars of 10 and 6 mm diameter instead of steel reinforcing of 14 and 10 mm diameter exceeded 8500 USD, that made more than 2-fold economy. The total cost of installation of one square meter of the reinforcing structure would cost 13,4 USD, and with use of composite rebars 6,1 USD.

Finished product warehouse of Chelyabinsk Compressor Plant, Chelyabinsk, Brodokolmaksky Highway

Chelyabinsk Compressor Plant. Finished product warehouse. City of Chelyabinsk, Brodokolmaksky highway, city exit. Composite rebars manufactured by COMPOSITE GROUP CHELYABINSK, LLC, with diameter of 8 mm were used. The main motive of selecting the composite rebars of 8 mm diameter instead of steel reinforcing of 12 mm was purely economic benefit. At equal-strength replacement of steel reinforcing with composite material the budget saving related to foundation reinforcing made over 6 800 USD. Since the installation of one m ² of reinforcing structure with use of steel would require about 13 USD, and with use of composite rebars this indicator made 5,8 USD. When calculating the costs, the price of rebars was taken as of September 2016.

Storage boxes of transportation terminal of “Zheldorexpeditsiya”, Yekaterinburg, 19 Zavokzalnaya str.

Budget-saving at foundation reinforcing 6 780 USD

Composite material of COMPOSITE GROUP CHELYABINSK company of 8 mm diameter was used for floor reinforcing in storage boxes. Main benefit of the selection of composite materials at this facility was the price and lack of scraps. Steel rebars have a standard length of delivery — rods of 6 and 11.7 meters, so there would inevitably be the remains (scraps) of rebars at the facility, which should have been paid too. Total budget-saving on foundation reinforcing at this facility exceeded 6 780 USD. It occurred through equal-strength replacement of steel rebars of 12 mm diameter with composite rebars of 8 mm diameter. When calculating the costs, the price of rebars was taken as of September 2016. The total cost of installation of 1 m ² of reinforcing structure with use of composite material cost the customer 5,8 USD. If steel reinforcing of 12 mm diameter were used, then the cost of installation of 1 m ² or structures would make 13,5 USD. Respectively, the use of composite rebars brought more than 2-fold economy.

Residential complex “West Ray”, Chelyabinsk, 154 Truda str.

Budget-saving at floor reinforcing in technical premises made 17-20%

For reinforcing of floors in technical premises the composite mesh manufactured by COMPOSITE GROUP CHELYABINSK company in sheets of 2000*1000 mm, cell size of 100*100 mm, bar diameter of 2,5 mm was applied. Customer’s selection for application of composite mesh for floor reinforcing of floors in process premises of RC "Western Ray" was proved by three main criteria. The first and the main one was the price. The price of 1 sq.m of composite mesh is 17-20% lower than the price of mesh made of steel. At that, the mash made of composite polymeric rebars with diameter of a bar of 2,5 mm, can sustain greater loads, than the "obsolete" metal mesh with diameter of a bar of 4 mm. The second criterion is the resilience to corrosion. Since in technical premises and basements there is often excessive moisture, the composite mesh won't rust and lose its initial properties. And the third criterion. Weight of composite polymeric mesh and convenience of its transportation. To bring the composite mesh to the facility a Gazelle vehicle was used. Delivery of the same number of metal mesh by volume would require a transport of a higher loading capacity.

Experimental reinforcing of road paving with composite meshes, Chelyabinsk, Tankistov str.

Reinforcing of road paving with composite mesh at the leveling layer after asphalt concrete milling. The experimental section of the city road down the Tankistov street, city of Chelyabinsk (from Bazhova street to 2nd Shcherbakovskaya street) 300 meters long. Road paving reinforcing with composite meshes was made according to the following scheme: — area of 100-meter distance without reinforcing; — area 100-meter distance was reinforced with composite mesh on the leveling layer after asphalt concrete milling. Reinforcing with use of composite mesh, diameter of reinforcing rod is 2,5 mm, cell size is 100*100 mm, sheet size is 1000*6000 mm. Installation of composite mesh was made by laying the finished product on the road surface. — area of 100-meter distance without reinforcing; Activities on experimental application of reinforcing composite mesh manufactured by COMPOSITE GROUP CHELYABINSK, LLC, in road construction, were carried out jointly with municipal budgetary institution "Directorate of Road Maintenance of the City of Chelyabinsk". CJSC Yuzhuralmost acted as the general contractor for these activities.

Composite mesh wall reinforcement, Chelyabinsk, Settlement named after Uritsky, 18 Svyazi str.

For reinforcing and bonding of the main wall block material and the facing brick the composite mesh manufactured by COMPOSITE GROUP CHELYABINSK company was used. The selection of composite polymeric reinforcing mesh for bonding of slag blocks with the facing brick was caused by many indicators. The main criterion was the lack of "thermal bypasses", which reduce the general level of thermal capacity of the building. And it is the most rational approach. Why invest money in purchase of modern and energy efficient materials to later “install thermal bypasses” with your own hands? Composite mesh isn't subject to corrosion and rust. It will help both keep appearance of the building (avoid rusty smudges on the facade), and prevent further collapse of the mesh inside the laying. Small weight of the mesh makes the general structure of walls of the building lighter, and they in turn make less impact on the foundation. The composite sheet of 1500*500 mm in size with a cell of 50*50 mm and diameter of a bar weighs 292 grams only. The steel mesh with diameter of a bar of 4 mm and the similar sizes weighs 2,1 kg. The important criterion is, of course, the price of the composite mesh vs. steel. The price of 1 m ² of composite mesh is 17-20% lower than the price of steel mesh.

Transportation and Logistics Complex Yuzhnouralsky, Chelyabinsk region, Uvelsky district

TLC Yuzhnouralsky is the largest investment project of Chelyabinsk region in 2015. TLC Yuzhnouralsky is a full-fledged multimodal transportation and logistic complex including all facilities required for effective functioning of the logistic system: a railway container terminal, modern warehouse complexes of A class, a customs post, a developed transport infrastructure. It occupies the territory of 60 hectares. The engineering institution at designing the warehouse complexes was solving the main task — removal of electrostatic field as operation of electric loaders was provided in these warehouse complexes. The combined framework was applied for installation of reinforcing structure. The first reinforcing layer was steel rebars with diameter of 16 mm, the second one was composite material with diameter of 16 mm. By virtue of using this material manufactured by COMPOSITE GROUP CHELYABINSK,LLC, all tasks were solved. Over 10 companies manufacturing composite materials from Yekaterinburg, Chelyabinsk and Perm were considered to be suppliers of composite rebars for this facility. And only due to price-quality ratio of its products COMPOSITE GROUP CHELYABINSK company became the exclusive supplier of composite material for this iconic project. Within 9 months over 400 km of composite rebars with diameter of 16 mm were delivered to the facility.

Floor reconstruction at industrial plant, Zlatoust, 1 Parkovy passage

    

For floor reinforcing at reconstruction of industrial workshops composite rebars manufactured by COMPOSITE GROUP CHELYABINSK with diameter of 8 mm were used. Replacement of metal rebars by composite was caused by several factors. The main and the basic one was the price. In the project of floor reconstruction steel rebars with diameter of 12 mm were provided. When obtaining the final estimate on purchase of steel reinforcing the project investors started looking for an expense reduction and referred for consultancy to COMPOSITE GROUP CHELYABINSK, LLC. Technical experts of the company suggested replacing the steel reinforcement with diameter of 12 mm with composite fiberglass rebars with diameter of 8 mm. By virtue of such concept as equal-strength replacement when reinforcing made of steel is replaced with composite rebars and at the same time it has the same tensile strength and similar physical and mechanical values, which entailed cutting expenses on purchase of reinforcing materials by more than 2 times. The second important factor is the cost of delivery. All volume of composite rebars intended for floor reinforcing was delivered to the facility by one vehicle. When using steel rebars 7 vehicles for this purpose would be required. Thus, when using composite material it was managed to satisfy the main condition of the investors - to lower the budget on installation of one meter of reinforcing structure for more than twice.

Grocery store “Monetka”, Chelyabinsk region, Argayash dictrict, Argayash settlement, 2b Chelyabinskaya str.

The facility designed was the Monetka grocery store located at the address: Chelyabinsk region, Argayash district, Argayash settlement, 2b Chelyabinskaya str. At designing of Monetka grocery store the designers considered fact that the building of the future store with a drugstore Klassika attached to would be erected in a marshland. As per design, two layers of steel rebars of 12 and 14 mm diameter were required for foundation reinforcing. In order to save funds for purchase of reinforcing materials the investors made a decision on use of composite rebars taking into account equal-strength replacement. The designers calculated the loads affecting the foundation slab and allowed replacement of steel reinforcing with diameter of 14 and 12 mm with composite rebars of 10 and 8 of mm, respectively. In addition, 2 significant factors showed the benefit of applying composite materials for reinforcing of the foundation slab: lack of corrosion at fiberglass rebars, which would occur if using steel and the cost of delivery of all volume of rebars to the facility. Since composite rebars with diameter of 8 and 10 mm are delivered in coils, for its delivery to the facility taking into account all delivered volume they spent 4 times less money in comparison with steel that would be used. By virtue of using composite rebars expenses on purchase and delivery of the material were lowered for more than twice.

Yard for heavy equipment parking, South-Ural State University, Chelyabinsk, 8 Marata str.

30% budget saving for purchase of reinforcing materials

Project facility is the open area for parking of tanks and heavy equipment of Military Training Department of the South-Ural State University. Cooperation of COMPOSITE GROUP CHELYABINSK, LLC, and the South-Ural State University began in the beginning of 2015. At that time, technical experts of COMPOSITE GROUP CHELYABINSK, LLC, were looking for a laboratory capable to carry out tests of their products. So they referred for assistance to the Department of Architecture and Construction of the SUSU. Tests for determination of tensile strength according to requirements of GOST 12004-81 "Steel Reinforcing. Tension Testing Methods" and amendments provided by GOST 31938-2015 "Fiberglass Reinforced Polymer for Reinforcing Concrete Structures" were conducted. By results of the research test reports on compliance of the manufactured products with GOST 31938-2015 were received. For installation of the reinforcing structure according to the design, metal rebars with diameter of 18 mm should be used for the first reinforcing layer and 10 mm for the second reinforcing layer. For budget-saving purpose the customer made a decision to apply the combined frame, so steel reinforcement with diameter of 18 mm was replaced with composite rebars of 14 mm diameter. Delivery of composite material to the facility was made in rods of 12 meters in length. As a result the customer saved more than 30% of the budget allocated for purchase of reinforcing materials and applied the material, which tests had been carried out on the basis of its laboratory capacities.

Medical Center “Sakura”, Chelyabinsk, 16 Zakharenko str.

According to the Customer’s calculations the total economy rate will make over 15 254 USD

Project facility is two-floor medical center Sakura located in Chelyabinsk. Composite basalt mesh with diameter of a bar of 2,5 mm, cell of 50*50 mm in size and sizes of sheets 2000*1000 and 1500*500 mm was delivered. Also,composite fiberglass rebars are used at this facility for a three-layer bonding (facing brick, mineral wool and a large-format stone with tongue-and-groove joint). Application of composite mesh and composite fiberglass rebars at construction of the medical center was caused by two factors. The main one is that the medical center will have a high-precision expensive medical equipment for carrying out medical research. By having removed steel from the walls the customer minimized the electric field influencing the accuracy of indicators of this equipment. Similar innovative approaches to construction of medical entities are widespread in countries of Western Europe, America and Canada. Also an important factor of use of composite materials at construction of this facility is the price. According to the estimates of the customer, the total budget saving for purchase of reinforcing materials will make more than 15 250 USD.

Town-House Complex, Chelyabinsk, 5 Polyanka str.

Fund saving at usage of composite mesh made over 30%

Designed facility is a complex of townhouses located at the address: Chelyabinsk, 5 Polyanka str. The Developer elaborated a project especially for construction of the whole complex of townhouses, where composite rebars with diameter of 6 mm were used as "flexible connections" for bonding of facing bricks, heat insulation and large format stone with tongue-and-groove joint manufactured by the Chelyabinsk plant of construction industry "KEMMA". Also the project initially stipulated application of composite mesh for reduction of influence of stretching loads in the structure of the building. The selection for use of composite materials to replace the steel was caused by several reasons: The first and the most important reason is the price. The composite mesh, due to price fluctuations related to steel mesh, became even more attractive for construction of houses and facilities. Fund economy if using composite mesh at these facilities made over 30%. If converted in the monetary equivalent, then the saved amount will have 5 zeros. The second reason is the resistance of composite mesh and composite rebars to corrosion. Since they use the brick of ivory color for facing of the townhouse complex, the developer, let’s say, kills two birds with one stone, as he uses modern, beautiful materials and avoid further problems. Because if the composite mesh and composite flexible connections are applied the building facade will never have rust spots caused by rusting in the laying steel mesh. The third reason is low heat conductivity. At use of composite materials due to their physical properties the problem of occurrence of so-called "thermal bypasses" is completely solved. They may entail a large amount of condensate on the internal wall surface, which slowly but surely will destroy the building from inside. Besides, through “bypasses” a third of thermal energy of the house is lost, what can respectively cause additional expenses borne by the future owners. Considerable economy of funds was also reached in the delivery of materials for construction — all volume of composite rebars and composite mesh was brought to the construction site by several Gazelle vehicles. Delivery of the same volume of steel rebars and mesh would require a transport with a higher loading capacity.

Private house, strip foundation reinforcing, suburbs of Chebarkul

Budget saving for purchase and delivery of reinforcing materials to the facility, house with area of 250m2 made ~ 760 USD

Designed facility — a private house (strip foundation reinforcing) in the suburbs of Chebarkul, Chelyabinsk region. Th constructors applied composite frames of "START SYSTEM" to reinforce the strip foundation. Diameter of a rod of composite rebars was 10 mm, cell 200*200 mm, sheet dimensions — length 5950 mm and width 2350 mm. At preparation for foundation installation the developer representatives bought 7 composite frames and the required quantity of composite mesh with diameter of a bar of 4 mm, and cell size of 100*100 mm. Preparatory process on sawing up the composite frames by sizes, required for the design took 4 working hours. Sawing up by an angle grinder was performed by one person. Further the composite frames were "connected" among themselves by means of the composite mesh. At the same time, the operations on "tying" the spatial composite frames took one working day only. Delivery to the facility of spatial composite frames, ready for installation, was conducted by a Gazelle vehicle. Further, construction of monolithic concrete walls by means of polystyrene foam timbering of the Amvic Building System is planned on the base of "START SYSTEM" reinforced by means of composite frames. They also used composite rebars with diameter of 10 mm for the timbering to create a monolithic wall. One of the main reasons for using composite materials at this facility is, of course, a lower price vs. steel reinforcing. In addition, composite materials have similar coefficients of expansion with concrete. And in the future, at positive temperatures the foundation is guaranteed to avoid micro cracks. This property of composite rebars is especially important at operating in winter time. Use of composite materials is caused by lack of change of its properties at low temperatures in winter season (down to -60 degrees). As a result: saving of time for foundation preparation (fittings tying in situ) for concrete pouting made over 50 manhours. Economy of funds for purchase and delivery to the site of the composite reinforcing materials replacing the steel, for pouring of the strip foundation under the house with a total area of 250 sq.m made about 760 USD.

Pool basin reinforcing

Residential complex in Tumen city

Since 2017 Composite group has started supply of flexible ties to the construction site of one of the ambitious project in Tumen. According to design-project Residential complex in Tumen city will consist of 10 multi-sections houses with 13 and 18 stores. Apartment blocks are build on monolithic-frame technology, outer brick walls have three layers of bricks and warm-preserving coating, internal walls have one layer. Flexible ties used to connect internal wall with outer wall and coating. Low temperature conductivity of ties allow to avoid warmth lost and in the end to achieve savings when heating building. Moreover high resistance to corrosion of flexible ties will allow to avoid expensive repair of the façade in the future. Lifetime of flexible ties exceeds 80 years. According to design, flexible ties with length of 350 mm are used in this project. Moreover, metal flexible tie is 1,2 ruble more expensive than composite one. Even this small difference will bring millions of saving when building major projects with usage of a few millions flexible ties.

Medical center “Sakura”

Two-story medical center “Sakura” located in Chelyabinsk. For this object the contractor used basalt composite mesh with diameter of rod 2,5 mm and with grid dimensions 50*50 mm. The dimensions of mesh is 2000*1000 and 1500*500 mm. Also, Glass fiber reinforced polymer bar was used on this object to reinforce the three-layer –wall (wall consisted of façade bricks, mineral wool coating, and big-sized stones with cam connection). Two factors were reasons to use composite mesh and GFRP bar on this project. The main factor was expensive high tech medical equipment that would be in the center. Having removed the metal from walls the contractor removed possibility that electric field may influence on medical equipment data. Such innovative approach well known in Western Europe, US and Canada. The other important factor is price. According to contractor’s estimation savings on composite materials will be about 13 000 USD.

Application of composite reinforcement grid START SYSTEM for floor arrangement in warehouse

In the beginning there was 14 mm metal rebar in amount of 11 000 meters meant to be used in the project of 700 m2 warehouse construction. The design demanded arrangement of two reinforcing structures (upper and lower structure) with grid dimensions 250*250 mm. One of the condition was that reinforcing works had to be performed within very short terms without losing technology and quality. Due to this demand the contractor chose composite reinforcing grids START SYSTEM manufactured by Composite group. The decision to replace metal reinforcement by composite grid was not easy. Grid START SYSTEM is ready-to-use product which is more expensive than coiled GFRP. To estimate economic proprieties of grids following decision was made – to arrange lower structure of reinforcement using standard composite rebar (coiled rebar was cut and bounded on site), to arrange the upper structure using grid START SYSTEM. It took 4 working days for team of 15 workers to prepare and bind rebar for the lower reinforcing structure. And only 2 ancillary workers and 2 reinforcing workers did the job connecting START SYSTEM grids according to Composite Group technology. As the result it took 8 hours of work for team of 4 workers to arrange the upper structure of reinforcement on territory of 700 m2. After estimation of expense for upper and lower reinforcement structure arrangement (estimation included work and price for product) it was found out that saving was about 1000 USD. More saving was achieved by transportation technology because GFRP transported in coils 50 or 100 meters long, but metal rebar transported in rods 12 meters long. When binding rods, overlap of rebar must be not less than 30 diameters of used rebar. Thus using GFRP the material consumption diminished on 1000 meters. More saving was achieved by replacing 14 mm of metal rebar on 10 mm GFRP bar without losing quality and strength characteristics. Finally, due to replacement of metal rebar by GFRP and START SYSTEM grid total saving reached approx. 4000 USD.

Capital garage for trucks. Usage of composite mesh when building garage for trucks.

Any construction company is commercial organization that has one main purpose – getting profit. For this reason any contractor pays attention not only on technical characteristics of material but also on price. Considering the fact that composite mesh exceeds metal one on all parameters the choice of contract for this project was obvious. For the reinforcement of brick walls we supplied following quantity of composite mesh for this object: 2000 pieces with dimensions 1500*380 mm, grid 50*50 mm and rod diameter 2,5 mm. For reinforcement of internal walls we supplied 675 pieces of composite mesh with dimensions 1500*240 mm, grid 50*50 mm and rod diameter 2,5 mm. As composite mesh 9 times lighter than metal one to transport mesh on site contractor used less expensive truck with less load capacity. Moreover, due to lighter weight it was not necessary to use lifting devices for transportation and unloading. All this gave an opportunity to achieve savings. According to estimation, replacement of metal mesh with rod diameter of 4 mm, by composite mesh with rod diameter of 2,5 mm gave savings in mount 1 300 USD.

Modern Residential Complex of comfort-class, Republic Kazakhstan.

Saving on reinforcing materials is approx. 25 000 USD

To reinforce floors in living space and technical rooms the contractor used composite mesh with grid dimensions 100*100 and with diameter of rod 2,5 mm. Dimension of pieces were 2000*1000 and 3000*1000 mm. The choice of contractor to use the basalt fiber composite mesh was based on better physical and mathematical proprieties of basalt mesh in comparison with metal reinforcement mesh. One piece of composite mesh with following dimensions: diameter of rod 2,5 mm, size 2000*1000 mm weights 0,3 kg, at the same time, one piece of metal mesh with dimensions 4 mm diameter of rod, and size 2000*1000 mm, weights 3,74 kg which is 12 times heavier than composite mesh. Thus, having replaced metal by composite mesh, which is lighter it become possible to diminish load on house basement. Approximate estimation gave saving in 25 000 USD for whole project.

Reinforcement of underground parking lot with FRP bar in one of the most modern residential complexes in Tumen city

If earlier, the main difficulty of FRP bar usage in major construction projects was absence of normative base for such material on stage of design-project and all negotiations ended up by phrase “We would like to use FRP but we can’t due to absence of regulation”, now everything has changed. As Ministry of Construction of Russia confirmed Regulations № 295 “Usage of FRP bar in concrete objects. Rules for designers”, more contractors started to consider FRP bar as replacement for metal rebar. Because of this document Composite group started supply of FRP to one of the major construction companies in Russia for its project of underground parking lot. According to initial design the power plate of parking lot had to be reinforced with upper and lower layers of metal rebar with diameter of 12 mm, and grid dimensions 200 *200 mm. After designing engineers recalculated the load on basement plate using new regulations it was decided to use Fiber Reinforced Polymer bar with 8 mm diameter instead of 12 mm metal rebar. Dimensions of grid remained the same. As initially, it was designed to use 70 000 meters of 12 mm metal rebar, the savings of use FRP instead of metal rebar was more than 10 000 USD.

Residential complex

Usage of FRP bar for “floating floor” reinforcement. Saving exceed 3 500 USD for each building

As ground floor in residential buildings widely used for shops, offices and administration objects the contractor must solve the problem of noise cutting from residents of the building. Today one of the most efficient, ecological and convenient way to cut off the noise is method of “floating floor” construction. His method means that sound absorbing material must be laid between constructive elements of the house and the floor. In earlier days contractors laid on sound absorbing material reinforcing structures made of 10 mm rebar of metal mesh 5 ВР. But such structure increased load on slabs and on basement itself. That’s why such method was not used often. But contractors found solution - Fiber Reinforced Polymer bar. Cons of FRP bar usage even exceeded expectations. Apart from less load on slab, prices for reinforcement were smaller than price for metal rebar. FRP bar also diminish vibration which lead to more comfortable conditions for residents. Total amount of savings exceeded 3 500 USD per one residential house. It is also worth to note that cost of unloading and transportation was not considered in mentioned savings.

South – Ural Logistic center, Chelyabinsk region, Uvelka district.

South – Ural Logistic center is the biggest investment project in Chelyabinsk region in 2015. The center is full-scope multi-module transport & logistic center that includes following objects necessary for efficient functioning of logistic system: railroad container terminal, modern warehouses of “A” class, Customs post, developed transport infrastructure. The center occupies 60 hectares of territory. One of the main task for designers was removal of electrostatic field because of electric forklifts usage in the center. Combined reinforcement structure was designed for the project. First layer was made of 16 mm metal rebar, the second layer was made of 16 mm fiber reinforced polymer bar. Because the GFRP bar by Composite Group was used, all tasks were solved. Choosing the supplier of GFRP, contractor researched offers from more than 10 suppliers, but only Composite group was able to provide best offer as for price as for quality.

The use of a composite masonry mesh for reinforcing brickwork, during the construction of a residential complex, erected using monolithic frame technology

The savings on the purchase of reinforcing materials will be 35%, compared to the original budget.

After the adoption by the Ministry of Construction of Russia Amendment No. 2 to SP 15.13330.2012 "Stone and reinforced masonry structures", which stipulates that reinforcing meshes should be designed, including from composite materials (based on glass, basalt, carbon and other fibers), to large construction companies finally, they "untied" their hands. The legitimate use of modern materials - composite masonry nets, instead of metal ones, can significantly reduce the cost of purchasing reinforcing materials.

The start of deliveries of the composite mesh was preceded by a complex and painstaking work. Tests have been carried out:
- strength of masonry reinforced with composite meshes;
- to determine the maximum operating temperature;
- to determine the change in the strength of composite materials at a temperature of minus 50 ⁰С, etc.

Despite our own production of welded metal masonry mesh, it is economically profitable to use a composite mesh manufactured by "COMPOSITE GROUP CHELYABINSK" - this is the conclusion made by the financial service of the developer. According to economists' calculations, due to the use of composite masonry meshes, savings on the purchase of reinforcing materials will be 35%, compared to the original budget.

Savings do not include indirect costs such as on-site delivery, material handling, use of tower cranes to deliver the net to the upper floors, and rust damage to the net from outdoor storage.

The use of composite masonry mesh in the construction of a comfort-class club village.

Reducing the cost of purchasing reinforcing mesh by 25%

The area of residential development, one of the largest cottage villages located in the Chelyabinsk region, exceeds 100,000 square meters. The entire building area will be divided into several blocks, and each block will have its own architecture. The maximum number of storeys of houses in the club village is 3 floors. The composite masonry mesh began to be "introduced" into projects after the adoption by the Ministry of Construction of Russia of Amendment No. 2 to SP 15.13330.2012 "Stone and reinforced stone structures." Composite masonry mesh with a bar diameter of 2.5 mm is used to reinforce both bearing and facing masonry, which, in turn, are interconnected by means of flexible composite ties with thickening. Mineral wool insulation is laid between the bearing and facing wall. In order to prove to the developer that the composite mesh in its physical characteristics is not only inferior, but superior to the metal mesh with a bar diameter of 4 mm, the Composite Group Chelyabinsk company conducted a series of tests of its products in accordance with GOST 32047 - 2012 “Stone masonry. Compression test method ". The tests were carried out on the basis of the Faculty of Architecture and Civil Engineering of the South Ural State University. For testing, a large-format ceramic stone with a tongue-and-groove joint was selected, which is produced by one of the largest brick factories in the Chelyabinsk region. The tests carried out have proved that brickwork reinforced with a composite mesh with a bar diameter of 2.5 mm is not inferior in its strength characteristics to brickwork reinforced with metal meshes with a bar diameter of 4 mm. The use of a composite masonry mesh, in addition to reducing the "direct" costs - for the purchase of reinforcing materials, will further save on cosmetic repairs - removing rust stains from the facades of buildings from a metal mesh rusting in the masonry. In addition, composite materials do not conduct heat at all, as a result of which much less heating costs for these houses in winter will be required.

The use of composite masonry mesh in the construction of a residential 5-storey building

Composite mesh made of composite polymer reinforcement was used to reinforce the masonry walls during the construction of a residential two driveway 5-storey building. Especially for the use of composite mesh, the developer company made changes to replace the metal masonry mesh with composite mesh - in the project. The costs of changing the project will pay off in the future, since according to this, which has already become a "standard" project, it is planned to build more than 25 similar houses.

Application of fiberglass reinforcement for filling underground parking

For the reinforcement of the slab of the underground parking, composite reinforcement with a diameter of 8 mm produced in accordance with GOST 31938 was used. The total amount of reinforcement used in this project exceeded 100,000 meters. The reinforcement was supplied in coils of 50 meters and whips of 6 meters in a 50/50 ratio. The beginning of concrete work related to the filling of underground parking, as a rule, begins with the onset of cold weather. Since the work is carried out under the residential complex, the air temperature, even in winter, does not drop below + 5⁰C, therefore, there is no need to use expensive antifreeze additives for concrete. Approximate savings (excluding transportation and handling costs amounted to) more than 70% of the original budget for the purchase of valves.

The use of composite mesh in construction

Since the developer company is already cooperating with COMPOSIT GROUP CHELYABINSK on other projects, it was no longer necessary to prove the feasibility of replacing metal reinforcement with a diameter of 12 mm with fiberglass reinforcement with a diameter of 8 mm. The fiberglass reinforcement for reinforcing the floors of the underground parking was originally “incorporated” into the project. More than 1.5 years passed from the project to the first delivery of valves. But even in this short period, the economic effect of replacing metal fittings with composite ones increased by 5%. This was due to the increase in metal prices in 2018. Fiberglass reinforcement with a diameter of 8 mm, in the amount of 20,000 meters, was delivered to the site by two GAZelle vehicles. The loading and unloading of the fittings was carried out manually, without the use of any lifting mechanism. The time for unloading the entire volume at the facility was 1 hour, taking into account the fact that only one person was involved in unloading. When using standard metal reinforcement with a diameter of 12 mm, measuring whips of 11.7 meters, delivery would require a car with a carrying capacity of 20 tons, the involvement of a crane and a team of slingers. But even without taking into account the indirect costs (delivery and unloading of reinforcement at the site), the savings due to the use of composite materials would exceed 60% of the original budget if metal reinforcement were used at the site.

Application of composite reinforcement for the reinforcement of underground parking

Composite rebar saved 60% of original budget

Since the developer company is already cooperating with COMPOSIT GROUP CHELYABINSK on other projects, it was no longer necessary to prove the feasibility of replacing metal reinforcement with a diameter of 12 mm with fiberglass reinforcement with a diameter of 8 mm. The fiberglass reinforcement for reinforcing the floors of the underground parking was originally “incorporated” into the project. More than 1.5 years passed from the project to the first delivery of valves. But even in this short period, the economic effect of replacing metal fittings with composite ones increased by 5%. This was due to the increase in metal prices in 2018. Fiberglass reinforcement with a diameter of 8 mm, in the amount of 20,000 meters, was delivered to the site by two GAZelle vehicles. The loading and unloading of the fittings was carried out manually, without the use of any lifting mechanism. The time for unloading the entire volume at the facility was 1 hour, taking into account the fact that only one person was involved in unloading. When using standard metal reinforcement with a diameter of 12 mm, measuring whips of 11.7 meters, delivery would require a car with a carrying capacity of 20 tons, the involvement of a crane and a team of slingers. But even without taking into account the indirect costs (delivery and unloading of reinforcement at the site), the savings due to the use of composite materials would exceed 60% of the original budget if metal reinforcement were used at the site.

The use of fiberglass reinforcement with a diameter of 8 mm in the construction of a building materials store

Reinforcement costs have been reduced by more than 2.1 times.

The object is a building materials store with an area of more than 14,000 m² in the Orenburg region, made with the use of composite reinforcement manufactured by LLC COMPOSIT GROUP CHELYABINSK. The total volume of the supplied reinforcement with a diameter of 8 mm is more than 145,000 running meters. We have been cooperating with the company - the general contractor for the construction of this facility for more than 5 years and are the general supplier of fiberglass reinforcement for facilities under construction throughout the country - from the Krasnoyarsk Territory to the Arkhangelsk Region. But, despite this, the company "COMPOSITE GROUP CHELYABINSK" from year to year, from object to object, has to go through a rigorous selection and prove its worth as one of the leaders in the production of composite building materials in Russia. So it was this time. More than 10 companies from all over Russia applied for the role of a supplier of fiberglass reinforcement. Commercial offers, documentation confirming the quality and product samples were sent from Yekaterinburg, Orenburg, Perm, Kazan, Volzhsky, Nizhny Novgorod and Taganrog. 100% of applicants for the supply of fiberglass reinforcement were eliminated for one single reason - the absence of real test protocols for manufactured products. Of all the documentation that can confirm the quality of products - a certificate of conformity, that is, not a single manufacturer could. The cost of purchasing composite reinforcement with a diameter of 8 mm produced in accordance with GOST 31938 - 2012 bastard amounted to a little more than 2,000,000 rubles. When using metal reinforcement with a diameter of 12 mm to reinforce floors on an area of 14,000 m2, the cost of reinforcement would exceed 4,300,000. That is, the cost of purchasing reinforcement was reduced by more than 2.1 times (excluding the costs of unloading and moving reinforcement by object).

The use of composite reinforcing mesh in the renovation of floors.

Reduction of costs for the purchase of reinforcing mesh by 26%

The total area of reconstruction of floors in a 2-storey building of a former sewing factory is 2000 m². Composite reinforcing mesh with a cell of 50 * 50 mm was supplied in rolls 1 meter wide and 25 meters long. When choosing a material for reinforcing a building screed, one main task was solved - to reduce the cost of reinforcing materials. Earlier, for this kind of work, a metal reinforcing mesh was used, standard in cards 1000 * 2000 mm. But the metal mesh has a number of disadvantages - a significant weight, a higher price compared to composite reinforcing meshes and thermal conductivity, due to which the metal wire forms cold bridges inside the screed - and, as a consequence, the need to insulate such a structure, and this is an additional cash cost. Composite reinforcing mesh is devoid of these disadvantages, and plus has a number of additional advantages - tensile strength, significantly higher than the tensile strength of the wire of the metal mesh, corrosion resistance, minimal weight and ease of transportation. And most importantly, the composite reinforcing mesh has a lower price. The use of composite mesh, instead of metal mesh, has reduced the cost of purchasing reinforcing materials by 26%.

The use of fiberglass reinforcement in the reconstruction of floors in a chemical warehouse.

Reinforcement costs have been reduced by more than 50%. The interval for floor reconstruction has been extended by 20 years.

Object - reconstruction of a warehouse of raw materials for chemical products (alkali and acid) used in production at one of the industrial enterprises of the Sverdlovsk region. Composite reinforcement in the project for the reconstruction of floors was laid as a replacement for metal reinforcement grade A III with a diameter of 16 and 20 mm. The design solution for the use of fiberglass reinforcement with a diameter of 12 and 16 mm was developed based on the customer's requirements. This room is used as a warehouse where aggressive substances are stored. During storage, transshipment and packaging of alkalis and acids, aggressive substances often fall on the floors, then seep into the concrete and destroy the metal reinforcement inside the concrete. As a result, the floors had to be completely renovated every 5 years. After the use of fiberglass reinforcement - the time interval, possibly, the reconstruction will be more than 25 years. Since the composite reinforcement belongs to the materials of the 1st group of chemical resistance, it is not destroyed by the action of acids and alkalis. Thus, the customer managed to save more than 160,000 rubles through the purchase of fittings, but also to increase the time interval for the complete reconstruction of floors by 5 times.

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Reinforcement of floors with composite reinforcement, during the reconstruction of the warehouse complex.

Saving more than 750,000 rubles

In the project for the reconstruction of the floors of the industrial complex built in the 70s of the last century, the design organization designed metal fittings with a diameter of 12 mm. When signing the contract for the required amount of work, the contractor company, at the very first meeting with the customer, "came out" with the initiative to replace the metal with fiberglass reinforcement with a diameter of 8 mm produced by KOMPOSIT GROUP CHELYABINSK. This is not the first, not the second or even the 10th facility where our partners - builders use this type of reinforcement. The total volume of the supplied fittings was 38,000 meters. Moreover, taking into account the complex configuration of the premises (on one half of the warehouse complex there was a rack storage system, which the new owner did not want to dismantle), the supply of reinforcement was made both in bays of 50 meters, and in whips of 6 meters. Rebar rods of 6 meters were used to reinforce the floors just under the racking system. The total costs for the purchase of fittings amounted to 570,000 rubles, delivery of fittings to the site did not exceed 1% of the cost of the fittings themselves. The time for loading and unloading the reinforcement by a team of 3 people was 1 hour 40 minutes. Thus, the approximate savings on the purchase of reinforcing materials, delivery, loading and unloading amounted to more than 750,000 rubles.

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The use of composite reinforcement when pouring the foundation slab and basement walls

Savings, taking into account the use of fiberglass reinforcement, amounted to 159,000 rubles, excluding delivery and loading - unloading.

The use of composite reinforcement when pouring the foundation slab and the walls of the basement floor. Savings, taking into account the use of fiberglass reinforcement, amounted to 159,000 rubles, excluding delivery and loading - unloading. With the advent of a more modern and durable material (in comparison with metal) - composite reinforcement, more and more builders begin to use it not only for the construction of warehouses, hangars and other industrial facilities. Fiberglass is gradually penetrating into the sphere of private construction. The private developer is the pickiest client you can imagine. If he decided to build a house, then this house should be built with the best materials that are currently on the "market". During the construction of a 2-storey private residential building with a full basement floor, composite fiberglass reinforcement with a diameter of 8 mm was used. The total volume is 8 350 running meters. More than 5000 meters were used to reinforce the foundation slab, cell 150 * 150 with two reinforcing meshes - upper and lower. The remaining 3350 meters were used to reinforce the plinth. To form the frame of the basement walls, a combined reinforcement method was applied (metal reinforcement with a diameter of 12 mm was used in the vertical axes, composite reinforcement in the vertical axes). To connect the reinforcement, metal embedded elements were used. The time for "knitting" the frame for the basement floor was 4 working days, but even during this short time, due to the abundance of precipitation, steel reinforcement with a diameter of 12 mm was covered with rust. Therefore, immediately before pouring, it was treated with an acid-free rust converter, which was applied by spraying. Savings due to the use of composite reinforcement 8 mm instead of steel reinforcement with a diameter of 12 mm amounted to about 140,000 rubles (the calculation of prices for metal and fiberglass reinforcement produced in accordance with GOST 31938 - 2012 was carried out in 2018 prices).

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Self-service car wash for 6 posts, located between the shopping center "KS" hypermarket "Lenta", Chelyabinsk, st. Cherkasskaya 15.

Savings on the purchase of reinforcing materials - more than 140,000 rubles.

During the construction of another car wash, a developer company from St. Petersburg, as expected, turned to its long-standing partners - suppliers, Composite Group Chelyabinsk LLC, for composite reinforcement. But at the time of the work, the cost of metal fittings of 14 diameters was 50 rubles per meter. The cost of composite fiberglass reinforcement of 10 diameters, used at the facility, instead of metal, was 21 rubles per meter.

Thus, by replacing the metal fittings with fiberglass, the developer saved about 140,000 rubles, only on the purchase of reinforcing material.

The total amount of reinforcement used in the reinforcement of the car wash foundation is 4 800 meters.