Fiber for concrete: advantages, types of fiber, scope of application and consumption rates

Fiber is a contemporary remedy that improves concrete’s performance. Fibers can be added to concrete to increase its strength, toughness, and resistance to cracking. Because of this, fiber-reinforced concrete is becoming a popular option for a variety of construction projects, ranging from large-scale infrastructure projects to residential buildings.

There are numerous kinds of fibers available, and each has unique advantages. There is a fiber type that works well if you want it to be tougher, more impact-resistant, or easier to work with. The durability and quality of the concrete can differ significantly depending on which fiber you choose for your project.

Getting the best results requires knowing the extent of the application and how much fiber to use. Various projects call for varying quantities of fiber, so striking the correct balance is crucial. You can be confident that your structure will last for a long time by using fiber properly to ensure that your concrete performs well in a variety of situations.

What is fiber -fiber

Concrete is classified as a fragile material with a heterogeneous structure based on certain features. The ultimate deformation value is significantly less than that of, say, composites made of polymers, steel, or glass.

For concrete structures, the use of fibrous additives, or fibers, as microarmators was required to raise the elasticity indicators. This feature has been widely used in construction process technology, including the creation of high-strength materials and the preparation of cement mixtures.

Fiber is a material that can be either inorganic or organic, appearing as thin strips or fragments of thread. The quantity and configuration of fibers in the mixture determine the mechanical properties of fiber concrete.

The concrete dispersed reinforcement method allows fibers to be oriented in both arbitrary and directed directions.

Utilizing thin, continuous threads, bundles, woven and non-woven meshes, and other materials of a similar nature are examples of directional materials. When roll materials such as mats, canvases, and veils are used, the result is arbitrary, or free.

Fiber for concrete improves the strength, resilience, and durability of the material, making it a useful addition in a variety of construction projects. Steel, polypropylene, and glass are a few examples of the various fiber types. Each has its own advantages and is best suited for particular uses, such as flooring, pavements, and precast components. It is possible to guarantee best performance and cost-effectiveness in concrete structures by being aware of the benefits, appropriate applications, and rates of consumption of these fibers.

Main components of the additive

The type of reinforcing component used determines the technology used to produce the additives. Not every fiber satisfies the specifications needed for reinforcement cages.

Fibers can be both metallic and non-metallic, with varying cross-sectional sizes and lengths:

1. In terms of design, the greatest effect is obtained from the use of steel fibers, the modulus of deformation of which is 6 times higher than that of concrete.
2. The use of polypropylene allows you to reduce the risk of cracking during plastic shrinkage of mixtures by 60-90%.
3. Fiberglass has low alkali resistance and is used only for preliminary reinforcement in the manufacture of gypsum products or wall blocks from cellular concrete.
4. Basalt fiber is resistant to alkaline processes. The modulus of elasticity is 15-20% higher than that of glass fibers.
5. Asbestos fibers are neutral to the aggressive effects of cements, they are characterized by high strength and fire resistance.

By choosing additives for concrete reinforcement logically, you can produce goods that can withstand mechanical loads.

Advantages

Because fiber concrete’s mechanical and physical qualities are many times better than those of comparable traditional materials, it is used widely. The products’ performance attributes also meet the standards at the same time.

Strengthening the screed

Steel fibers with a diameter of 0.3 to 1.0 mm and a length of 35 to 75 mm are advised to make the coatings stronger. Heavy concrete of classes B25–B35 with large aggregate sizes of no more than 20 mm is selected as the cement matrix.

Utilizing steel fibers for dispersed reinforcement will improve performance, fortify the base’s upper layer, and increase the structure’s durability, wear resistance, bending strength, and crack resistance.

Prevention of defects

A breach of the technological process is linked to the occurrence of flaws in concrete coatings. This can be attributed to careless cost-cutting and a disregard for the standards and guidelines established for these kinds of establishments. Such carelessness causes surface cracks, chips, and potholes to appear.

Repair mortars reinforced with different types of fibers are the most effective way to prevent and eliminate defects that have arisen, as practice has demonstrated. By using steel or polypropylene fibers, you can prevent mixture stratification during application, which leads to premature coating wear and destruction.

Improving adhesion and water resistance

Reinforcement that is scattered throughout the concrete can increase its water resistance. Since the characteristics of the fibers used determine the properties of fiber concrete, you can effectively solve the problem by selecting a material with the desired characteristics.

For instance, products’ water resistance will increase multiple times when steel and basalt fibers are used. It is essential to accurately choose the ideal length and diameter of the sections used in order to achieve improved fiber adhesion to the cement matrix and uniform distribution of fibers.

Economy and anti-corrosion properties

When a portion of the frame is replaced with scattered fibers in reinforced concrete structures, you can use fiber to achieve a real benefit because modifiers are significantly less expensive than rod reinforcement.

The fact that steel fiber is coated heavily in cement to prevent corrosion is yet another significant benefit of using it.

You can create a product that is both economically viable and has improved performance properties by using additives correctly.

Types of fiber for concrete and its properties

Concrete’s operational and performance qualities can be enhanced by adding modifiers in the form of fibers. Fiber-reinforced composite materials’ mechanical qualities are determined by the kind of additive, element size, and volume.

Steel fiber

There are several ways to create the metal fibers that serve as a cage for reinforcement:

• electromechanical;
• mechanical;
• from molten metal, molding.

The most popular are mechanical techniques, which yield the following kinds of materials:

1. Wire fibers, which are pieces of thin wire 10-50 mm long.
2. Sheet fibers are obtained by milling a thin sheet of metal.
3. Ultra-thin fibers are made by extruding the melt and then drawing through diamond filters.

Advantages of using metal fibers for dispersed reinforcement:

• increases resistance to dynamic and static loads;
• crack resistance;
• wear resistance;
• seismic resistance;
• frost resistance.

Mixtures become more workable when they contain 0.5% or more fiber. An enhancement in the tensile-compressive strength is noted with an increase in the additive volume within the range of 0.2-0.8%.

Glass fiber

This class of additives is made from rock melts and silicate materials. Glass fiber measures 10 μm in diameter and 20–40 mm in length. High tensile-compressive strength (1500-3000 MPa) is its primary characteristic. These modifiers have elasticity moduli that are several times higher than concrete’s.

Cement matrices are made of bundles of glass threads woven together. The process chart specifies the precise dimensions of each segment that makes up the bundle, and it is divided into equal length segments.

Asbestos fiber

Concrete is reinforced with fiber slices, veils, canvases, and materials in the form of non-woven meshes.

The characteristics of asbestos fibers are as follows:

• high strength (300 kgf/mm²);
• fire resistance (up to 1500 °C);
• resistance to alkaline environments (9.0-10.1 pH);
• low electrical and thermal conductivity (0.045-0.065 W / m∙K);
• durability.

The comparable properties of steel are surpassed by the tensile strength of asbestos fiber.

Basalt fiber

Basalt fiber is composed of uniformly sized segments that are extracted from molten volcanic rock.

The following metrics are improved by the addition of additives:

• crack resistance – 2 times;
• frost resistance – up to 500 cycles;
• impact resistance – 5 times;
• modulus of elasticity – by 30-40%;
• compressive strength by 20-50%;
• water resistance – 50%.

Basalt fibers have a strong bond with the cement matrix, are resistant to corrosion, and do not catch fire when exposed to open flames.

Polypropylene fiber

Alkali-resistant polypropylene fiber works well with gypsum and cement binders.

The fiber is synthetic and measures 0.02-0.038 mm in diameter. Polypropylene film is cut and twisted into bundles to create fiber. There are 0.3–0.5 mm long segments that separate the bundle. The weave opens up and forms a mesh structure in concrete mortar.

When you use polypropylene fiber, you can:

• increase water resistance;
• frost resistance;
• tensile strength in bending;
• increase fatigue and impact strength;
• heat resistance;
• wear resistance;
• improve the quality of the base of concrete products;
• increase the ability to withstand alternating loads;
• eliminate delamination of mixtures.

Scope

The kind of fibrous material being used determines which technical solutions are best for dispersed reinforcement.

Is suitable for reinforcing structures used in locations with higher requirements for mechanical impacts because it is wear-resistant:

• production sites;
• industrial floors;
• pedestrian paths with heavy traffic, etc.d.

Because basalt fiber is resistant to chemicals and earthquakes, it can be used in the following residential and commercial construction applications:

• in the construction of hydraulic structures;
• in coastal protection works;
• in the construction of seismic-resistant structures;
• explosive objects;
• in the production of chemically resistant reinforced concrete pipes for transporting aggressive liquids.

In addition to being a necessary ingredient in the creation of aerated concrete, foam concrete, and other cellular concrete products, basalt fiber is also used in the structure-forming process to create shaped products for small architectural forms.

1. Monolithic structures: highways, industrial floors, screeds, etc.d.
2. Water-deflecting dams, breakwaters, irrigation canals, liquid tanks, tunnels.
3. Defensive structures.
4. Reinforced concrete structures: production of precast foundations, piles, wall panels, beams, columns, pipelines.
5. Construction of road, airfield and sidewalk surfaces.

• installation of industrial floors and screeds;
• installation of external walls, insulation based on cellular concrete blocks;
• production of individual decorative products (paving slabs, curbs);
• preparation of solutions, shotcrete mixtures, plasters.

• corrugated and flat roofing coverings;
• pressure and gravity pipes;
• strengthening modifying additives for the upper layer of concrete;
• decorative facade slabs;
• repair compounds, asphalt mixtures.

Is employed in the building of homes, sewer manholes, etc. Its application is, however, restricted by the fibers’ inadequate resistance to the hydrating cement environment.

Consumption rates

One m3 of fiber concrete products requires the following quantity of modifier:

• paving stones for pedestrian paths — 0.6-1.5 kg/m³;
• industrial floors — from 1.0 kg/m³;
• concrete screeds — 0.9-1.5 kg/m³;
• molded gypsum products — 0.4-0.8 kg/m³;
• decorative solutions — 0.6-0.9 kg/m³.

The kind of structures, operational needs, and production technology all affect how much additive is added.

Fiber Type	Advantages, Application & Consumption Rates
Steel Fiber	Increases tensile strength, reduces cracks. Ideal for industrial floors, tunnels, and pavements. Typical consumption: 20-40 kg/m³.
Polypropylene Fiber	Prevents shrinkage cracks, improves impact resistance. Used in lightweight structures and residential slabs. Consumption: 0.9-1.8 kg/m³.
Glass Fiber	Enhances durability, reduces permeability. Suitable for facade panels and decorative concrete. Consumption: 1-2 kg/m³.
Nylon Fiber	Improves surface finish, reduces micro-cracks. Common in precast elements and thin-walled structures. Consumption: 0.6-1 kg/m³.
Basalt Fiber	Increases fire resistance, improves thermal stability. Applied in refractory structures and fire-resistant panels. Consumption: 2-5 kg/m³.

Fiber reinforcement is now a necessary part of concrete construction in the modern world. Fiber integration gives concrete improved strength, resilience, and crack resistance—all essential for long-lasting constructions.

Numerous fiber kinds, including steel, synthetic, glass, and natural fibers, each have special advantages that make them appropriate for a range of uses. Selecting the appropriate fiber type can greatly enhance the performance of concrete, whether it is being used for residential projects, commercial floors, or pavements.

It is essential to comprehend the proper application techniques and consumption rates in order to attain the intended outcomes. Fiber reinforcement that has been dosed correctly not only extends the life of concrete but also guarantees that it functions at its best under difficult circumstances.

Fiber-reinforced concrete is expected to become more significant in the industry as building codes continue to change. Adopting this technology can result in building solutions that are more resilient, long-lasting, and economical.

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