What is fiber concrete: pros and cons, where it is used

Modern construction materials like fiber concrete are becoming more and more popular because of their increased durability and strength. Fiber concrete contains different kinds of fibers into the mixture, in contrast to traditional concrete, which can be prone to cracking and other problems. These fibers, which are used to reinforce concrete and increase its resilience, can be created from glass, steel, synthetic materials, or natural elements.

The resistance of fiber concrete to shrinkage and cracking is one of its key advantages. Because of this, it is especially helpful in situations where structural integrity is essential. Fiber concrete provides a dependable and long-lasting solution for a variety of applications, including sidewalks and driveways, as well as larger construction projects like highways and bridges.

Fiber concrete has certain disadvantages in spite of all of its benefits. The performance of the finished product may be impacted by the irregular distribution that occasionally results from the addition of fibers to the mixture. Furthermore, fiber-reinforced concrete may be more expensive than regular concrete, which is something to think about for projects with tight budgets.

All things considered, fiber concrete is a strong, adaptable material that can be used in a variety of construction projects. Builders and homeowners can use this innovative material to achieve the best results by knowing its advantages and disadvantages and making informed decisions about when and where to use it.

Fiber: types of materials and their classification

It is worthwhile to take a brief look at history in order to comprehend what fiber concrete is. The material was initially introduced in 1907 when Russian scientist V.P. Nekrasov described his research into creating a composite material reinforced with tiny wire segments in his publications.

In the past, builders evenly distributed different types of scattered fibers in the mass by adding them to the solution. As a result, concrete’s qualities were enhanced, including its ability to withstand physical stress and environmental variables, decrease the amount of cracks, and increase its strength index by an average of 30%.

Artificial fibers from various non-metallized and metallized threads of mineral or organic origin are used to reinforce concrete mixtures. The characteristics of the concrete preparation and the kind and quantity of fiber added to the mixture directly affect the material’s technical and physical qualities, such as thermal conductivity, strength, density, and chemical resistance.

These days, fiber concrete is produced industrially, all technologies are tried and tested, and the properties of the material can be predicted in advance based on its specifications. Production uses two types of fibers: metal (steel fibers of various sizes and shapes) and non-metallic (acrylic, glass, polyethylene, basalt, carbohydrate, and carbon D).

The most common types of fibers are glass and metal, though polypropylene fiber is steadily gaining favor. Due to their high cost, carbon and basalt are rarely used. The unique qualities of concrete that viscose, cotton, and nylon offer aren’t always necessary in contemporary building.

Main types of fiber

GOST 14613-83 "Fiber. Technical conditions" divides fiber into six major categories based on origin and production methods. The standards outlined in GOST determine the composition of fiber concrete, and the technology is followed during production. As a result, the established qualities and characteristics of fiber concrete products directly depend on the type of fiber.

Fiber kinds that are added to the composition:

1) Steel fiber: Made by molding a melt or using a mechanical or electrical process, the fibers are straight or wave-shaped pieces of wire that are 10 to 50 millimeters long and have bent ends. The fiber diameter determines which technology is used.

Steel fiber is used to strengthen the structure and exhibits superior resistance to wear. The low degree of corrosion resistance, the heavy final product, and the poor adhesion to the concrete base are among the drawbacks that should be noted.

2) Glass fiber: Melted glass mass is drawn on special installations to create inorganic glass threads, which are used as filler. The chemical makeup of the glass and the process used to extract the material have a direct impact on the threads’ characteristics.

The length, strength, and thickness of the fibers determine the structural and mechanical characteristics of fiber concrete reinforced with glass fiber, which can vary greatly. Despite being plastic, the material is sensitive to alkaline environments.

3) Melted volcanic minerals in furnaces provide the raw material for basalt fiber, an artificial inorganic mineral fiber. The threads exhibit the following characteristics: resistance to burning, resistance to acids and alkalis, and resistance to mechanical stress.

Concrete is reinforced three times on average. Basalt fiber is used in many different applications, such as road slabs, permanent formwork for pile foundations, interior partitions, sculptures, fountains, basement panels of multi-story buildings, walls and monoliths, and reconstruction details.

4) Carbon fiber: finely chopped threads made of carbon that have been heated to their highest possible temperatures. ensures that building structures will withstand mechanical stress and chemical reactions with exceptional quality.

The main benefits of fiber are its high adhesion, resistance to acids and alkalis, high temperature tolerance, and lack of fear of corrosion. Strength and elasticity are the same as those of glass fiber and steel fiber, respectively. The expensive price is the only drawback.

5) Cellulose fiber is a polymer hydrocarbon material that is resistant to fire, acids, and dissolution in water. It improves the polymer coating’s vapor permeability, reduces shrinkage, and aids in removing moisture from the screed’s lower layers and onto the surface of the fiber concrete.

6) Polypropylene fiber: propylene film is cut and twisted to create synthetic fibers with a cross-section of 0.02-0.038 millimeters. The fiber expands and forms a mesh structure in concrete, ensuring a notable enhancement in the technical properties of fiber concrete. demonstrates strong resistance to chemical and impact influences. Among the drawbacks, the following should be noted: Not very strong against high temperatures, spread in raw material quality, and compression and tension.

Less frequently, nylon is used to give concrete specific properties; instead, viscose and other fibers are occasionally used. Prior to selecting fiber concrete blocks, it is important to choose the appropriate fiber for construction and repair work, taking into account the loads, costs, operating conditions, and functions.

Fibre concrete is a strong, adaptable building material that uses fibers to improve its performance and structural integrity. This kind of concrete is perfect for a variety of applications, including pavements, bridges, and residential construction. It has many advantages, including increased strength, improved crack resistance, and enhanced durability. It does, however, have certain disadvantages, including increased expense and the requirement for specific handling and mixing methods. Comprehending the advantages and disadvantages of fiber concrete enables engineers and builders to make well-informed choices regarding its application in diverse construction endeavors.

Pros and cons

When attempting to comprehend fiber concrete, it is important to realize that all of its primary attributes are contingent upon the materials utilized in its manufacturing and adherence to technological advancements. However, when planning work, there are some characteristics common to all types of fiber concrete that need to be considered.

Principal benefits of fiber-based concrete:

• Reduced construction costs – due to the increased strength of the slabs, it is possible to refuse reinforcement, reducing the duration of the work, the cost of additional materials, their transportation, installation
• Increasing the strength of finished structures – the technology for producing fiber concrete of any type suggests that such material is not afraid of shrinkage, does not crack, chip, guaranteeing even higher strength than in structures with reinforcement
• Excellent adhesive properties
• Resistance to sudden temperature changes, moisture, cooling/thawing
• Non-flammability – a concrete structure reinforced with a composite eliminates the disruption of the monolith structure and the appearance of cracks under the influence of high temperatures
• Lightness of fiber concrete blocks, which reduces transportation and installation costs
• Savings on building materials – due to a significant increase in strength, the foundation or walls can be made with a smaller monolith thickness, without sacrificing stability and reliability
• Extension of the operating life – the introduction of fiber fibers allows you to achieve a greater life of concrete while maintaining all important operational characteristics
• Reducing concrete consumption

The comparatively high cost of fiber concrete is the only drawback. Costly supplies must be purchased in order to prepare the solution, and prefabricated fiber concrete blocks cost more than regular concrete. However, this drawback was entirely offset by the savings at later phases of the building’s construction and operation.

Manufacture of reinforced fiber concrete

When considering fiber concrete and its application in construction, it is important to remember that proper production is the most critical component of good material characteristics. When creating a solution with fiber, whether it is manufactured in a factory or by hand, it is crucial to accurately calculate the composition and proportions while adhering to the technology of creation and application.

Industrial production

The kind of fiber and the ratios of the concrete’s constituent parts determine the technology. The most even distribution of fibers in the solution and their proper orientation in the mixture guarantee the density of fiber concrete. The consistency of the fibers within the monolith directly affects the concrete structure’s resistance to external mechanical loads and chemical environments.

The following are the primary steps involved in producing any type of fiber concrete: solution preparation, fiber formation, cutting of the fibers in accordance with specifications, addition to the mixture, superior mixing, compaction, pouring into the mold, and monolith solidification.

The process of making fiber and adding it to the solution can vary depending on the kind of fibers used, which can be metallic or non-metallic. Glass is formed from a molten mass, steel fiber is cut from a metal strip, and cellulose is cut and rolled into tubes that are straightened and form a mesh in the solution. There are various ways to distribute the fiber within the solution, but the main goal is to guarantee maximum homogeneity.

Plasticizers are frequently added to the mixture to increase the concrete’s level of plasticity, which improves the material’s quality. Plasticizers give you the ability to manage shrinkage and the rate at which concrete sets.

Preparation at the construction site

Before the solution is used at the site, reinforcing filler can be added right away. The following technological processes are seen here: sand and filler mixture, sieve-filtered fiber introduction, cement mixture, water with plasticizer. excellent mixing up until the final mass is uniform.

After pouring the completed mixture into molds, it is allowed to set for three days. Then, outside drying is preferable.

Use of composite fiber concrete

The material can be used in both residential and commercial construction when better concrete properties are required. Bridge coverings, floors, tunnels, coastal protection strips, foundations, sleepers, roadways, runways, sidewalks, structural frames, curbs, drainage channels, dams, well shafts for sewageage, water treatment systems, and fiber concrete floors are among the applications for steel fiber concrete.

Glass fiber concretes are useful for a variety of applications, including: finishing residential building facades with fiber concrete; waterproofing treatment structures; noise abatement panels; lightweight decorative products for coatings; industrial spaces with often contaminated coatings; benches; fences; and flower beds.

Concrete with basalt fibers is used to build roads, floors, dams, reservoirs, and railroad structures. Fibers made of polypropylene are used to make foam block structures, cellular concrete, and lightweight items. Cotton and viscose fibers are required for the mixing of textile concrete, which is becoming more and more common in contemporary building.

Aspect	Details
Pros	High strength, crack resistance, improved durability, reduced shrinkage, enhanced impact resistance.
Cons	Higher cost, more complex mixing process, potential for uneven fiber distribution.
Uses	Construction of buildings, pavements, bridges, industrial floors, precast concrete elements.

Fiber concrete is a creative and adaptable material that strengthens and lasts longer by mixing traditional concrete with fibrous materials. This combination produces a product that can withstand a great deal of stress, is less likely to crack, and is more resilient to wear and tear. It is a desirable option for many different types of construction projects because of its distinctive qualities.

The increased structural integrity of fiber concrete is one of its key advantages. Fibers like steel, glass, or synthetic materials are added to the concrete to distribute the load more evenly, lowering the chance of fractures and increasing the concrete’s lifespan. Because of this, it is perfect for high-stress areas where conventional concrete might fail, such as industrial floors, bridges, and pavements.

Fiber concrete does, however, have certain disadvantages. Fiber addition may be more expensive than using regular concrete, so this is something to keep in mind for projects with tight budgets. Furthermore, handling and mixing fiber concrete differently is necessary to guarantee that the fibers are dispersed uniformly, which may necessitate hiring more specialized workers and purchasing specialized tools.

Notwithstanding these difficulties, fiber concrete frequently has more benefits than drawbacks, especially for applications requiring high performance and durability. It can be used for anything from commercial and residential building foundations to infrastructure projects like airport runways and highways. The use of fiber concrete is anticipated to increase as technology develops, opening up new opportunities for resilient and sustainable building.

In summary, fiber concrete, which offers improved strength and durability, is a major advancement in building materials. Despite some extra expenses and technical requirements, its advantages make it a worthwhile option for a variety of building projects. Fiber concrete offers a dependable and durable solution, whether you’re building a new house or strengthening a bridge.

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