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What Is Fiber-Reinforced Concrete?

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Concrete is the most commonly used building material in the world and is used in almost every type of construction. Concrete is an essential construction material due to its durability, strength, and extreme longevity. It can withstand compressive and tensile stress and harsh weather conditions without compromising its architectural stability.

Concrete is used to make an immense variety of structures like highways, bridges, parking structures, buildings, foundational surfaces, and much more. Many concrete structures are built with steel rebar reinforcement, to increase their tensile strength and ability to carry heavy loads. The compressive strength of concrete paired with the tensile strength of the reinforcement material improves the concrete&#;s overall durability. Fiber-reinforced concrete is one type of reinforced concrete. 

What is fiber-reinforced concrete?

Fiber-reinforced concrete is a type of concrete mix containing fibrous materials either synthetic or natural fibers, or glass fibers. It is made up of cement, mortar, and discrete, short fibers distributed in a uniform manner throughout the composite material.

Adding fibers to concrete helps reduce cracking in the concrete, and increases its overall energy absorption and structural integrity. The fibers are no replacement for stainless steel-reinforced concrete, however, as they do not aid in flexural strength, or the ability for concrete to bend without breaking.

Types of fiber-reinforced concrete and how they&#;re used

Fiber reinforcement is used in both regular concrete and shotcrete (which is a type of concrete that can be sprayed). Round-shaped steel fibers are the most common type used in fiber-reinforced concrete. 

• Steel fiber in concrete is often used for road pavement overlays, bridge decks, and airfield pavement. 
• Glass fibers in concrete can be used for more modern and aesthetically pleasing, lower-weight structures, like furniture or architectural claddings on buildings. 
• Synthetic fiber in concrete is made up of one of two types of fibers: microfibers or macrofibers. The use of microfibers in concrete reduces shrinkage cracks and are commonly made of acrylic, polyester, nylon or polypropylene, amongst others. Macrofiber, on the other hand, is a more cost-effective reinforcement replacement for welded wire in concrete structures where high tensile strength is a necessity. Sidewalks, curbs, and driveways are all common structures that are built with microfibers added to the mix, while septic tanks and manholes are common structures built using macrofibers. 

How is fiber-reinforced concrete made?

Fiber-reinforced concrete can be made using regular mixed concrete or in mortar, as long as the fibers mix in evenly throughout. Things to consider when mixing fiber-reinforced concrete are the water to cement ratio, and the size of the fiber (referred to as the aspect ratio, which is the length of the fiber divided by the diameter). 

The percentage of fiber used in the concrete is also important to consider, since the volume of fibers used can impact the strength and sturdiness of the structure. When mixing together fiber-reinforced concrete, it should be done in a uniform way without segregation. Fibers must be added before mixing in the water so that they are dispersed in a way where they won&#;t get balled together, preferably using a laboratory mixer and filtered through a wire mesh basket.

Concrete is the most commonly used building material in the world and is used in almost every type of construction. Concrete is an essential construction material due to its durability, strength, and extreme longevity. It can withstand compressive and tensile stress and harsh weather conditions without compromising its architectural stability.

Concrete is used to make an immense variety of structures like highways, bridges, parking structures, buildings, foundational surfaces, and much more. Many concrete structures are built with steel rebar reinforcement, to increase their tensile strength and ability to carry heavy loads. The compressive strength of concrete paired with the tensile strength of the reinforcement material improves the concrete&#;s overall durability. Fiber-reinforced concrete is one type of reinforced concrete. 

What is fiber-reinforced concrete?

Fiber-reinforced concrete is a type of concrete mix containing fibrous materials either synthetic or natural fibers, or glass fibers. It is made up of cement, mortar, and discrete, short fibers distributed in a uniform manner throughout the composite material.

Adding fibers to concrete helps reduce cracking in the concrete, and increases its overall energy absorption and structural integrity. The fibers are no replacement for stainless steel-reinforced concrete, however, as they do not aid in flexural strength, or the ability for concrete to bend without breaking.

Types of fiber-reinforced concrete and how they&#;re used

Fiber reinforcement is used in both regular concrete and shotcrete (which is a type of concrete that can be sprayed). Round-shaped steel fibers are the most common type used in fiber-reinforced concrete. 

• Steel fiber in concrete is often used for road pavement overlays, bridge decks, and airfield pavement. 
• Glass fibers in concrete can be used for more modern and aesthetically pleasing, lower-weight structures, like furniture or architectural claddings on buildings. 
• Synthetic fiber in concrete is made up of one of two types of fibers: microfibers or macrofibers. The use of microfibers in concrete reduces shrinkage cracks and are commonly made of acrylic, polyester, nylon or polypropylene, amongst others. Macrofiber, on the other hand, is a more cost-effective reinforcement replacement for welded wire in concrete structures where high tensile strength is a necessity. Sidewalks, curbs, and driveways are all common structures that are built with microfibers added to the mix, while septic tanks and manholes are common structures built using macrofibers. 

How is fiber-reinforced concrete made?

Fiber-reinforced concrete can be made using regular mixed concrete or in mortar, as long as the fibers mix in evenly throughout. Things to consider when mixing fiber-reinforced concrete are the water to cement ratio, and the size of the fiber (referred to as the aspect ratio, which is the length of the fiber divided by the diameter). 

The percentage of fiber used in the concrete is also important to consider, since the volume of fibers used can impact the strength and sturdiness of the structure. When mixing together fiber-reinforced concrete, it should be done in a uniform way without segregation. Fibers must be added before mixing in the water so that they are dispersed in a way where they won&#;t get balled together, preferably using a laboratory mixer and filtered through a wire mesh basket.

What are the advantages of using fiber-reinforced concrete?

Using fiber-reinforced concrete on a construction project has a few unique advantages as compared to using regular concrete or reinforcing the concrete with steel rebar.

• Early crack prevention. Fibers aid in controlling shrinkage cracking as the moisture level changes when the water evaporates from the concrete mix. Fiber-reinforced concrete prevents, or at least heavily reduces, early cracking right from start. 
• Durability and strength. The addition of fiber increases the overall durability of the concrete, can help lower corrosion levels, cavitation damage, and has a higher level of tensile strength when compared to concrete that is not reinforced. 
• Improved ductility. Fiber-reinforced concrete is less likely to become damaged by high tensile stress and can increase the amount of weight the structure is able to carry, especially when microfibers are used. 
• An alternative to rebar. Depending on the structure, fibers can be an alternative reinforcement material to steel rebar or can be added to steel-reinforced concrete, lowering the amount of steel necessary. This could also be beneficial in lowering the overall cost of the project. 

What are the disadvantages of using fiber-reinforced concrete?

While there are many advantages to using fiber-reinforced concrete, the material has some downsides as well. 

• Must be mixed carefully. The fibers used in fiber-reinforced concrete must be dispersed meticulously and uniform throughout the concrete mix. The margin of error for mixing fiber reinforced concrete can be high if done improperly. It is important that the fibers don&#;t bunch up, which can be monitored, but there is always the possibility of fibers orienting in a way that causes the dispersion to be inconsistent. 
• Cost. Compared to non-reinforced concrete, fiber-reinforced concrete is more expensive. However, it should be noted that most concrete is reinforced in some way, and many projects require it.
• Weight. Adding fibers to concrete will make it heavier than plain concrete, generally. This adds weight to the overall structure, meaning an engineer needs to plan for this weight to maintain structural integrity. 

MT Copeland offers video-based online classes that give you a foundation in construction fundamentals with real-world applications, like how the commercial construction industry works today. Classes include professionally produced videos taught by practicing craftspeople, and supplementary downloads like quizzes, blueprints, and other materials to help you master the skills.

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Wire ropes are complex mechanical devices with many moving parts working harmoniously to provide adequate support for heavy loads and objects. Wire ropes are used in many different industries, from construction to marine and other various applications. Their function is supported with swivels, shackles, or hooks to allow for controlled movement. There are two different types of core materials that make up these industrial wire ropes: fibre or steel.

Today, we&#;ll look at the components of wire ropes, their core materials, and the difference between fibre and steel wire rope cores.

components of a wire rope

The strength of wire rope makes it an incredible and often essential asset for any industry where lifting and rigging are a part of daily operation. Its design consists of multiple wires made from stainless steel or galvanised steel arranged in a spiral shape, wrapped around an independent steel or fibre core. This wire strand core promotes high strength and flexibility and can handle extreme bending stresses.

Wire rope structure

• Wires are created with strands of metal to form one singular rope
• Wire strands are laid in a spiral pattern
• The wire rope contains a steel or fibre core

While keeping the basic components of wire rope construction intact, manufacturers will edit the strand pattern type, wire or core material for different applications and benefits. Some industries require greater crushing resistance, bending fatigue resistance or corrosion protection, which is where selecting the correct wire rope becomes paramount.

A wire rope is a machine with many moving parts, but ultimately, the rope&#;s abilities come down to its core. The core is the foundation of the rope. The core runs through the centre of the rope to support the strands and keep the wires in position under intensive stress.

Wire Rope Cores

When looking for the correct rope core for your application, consider the following two types&#;

IWRC &#; Independent wire rope core

This refers to an independent wire rope core made from steel or fibre.

WSC &#; Wire Strand Core

A wire strand core is a steel wire rope with a core from the same material and construction of the rope.

For example, 6×19 FC refers to a six-strand lay with 19 wires per strand wrapped around a fibre core.

Wire rope Core materials

Two different types of material make up wire rope cores: Fibre and Steel.

• Fibre cores are made from natural vegetable material, such as sisal, or man-made material, such as polypropylene. Theses are an independent wire rope core (IWRC).

• Steel cores have either an IWRC or a WSC. Generally, a steel core is slightly more diverse in its application than a fibre core, with higher resistance to heat, resistance to crushing, and increased strength.

Fibre Core Wire Ropes

A fibre core wire rope is formed with either natural or synthetic fibres. This creates a more flexible wire rope than a wire rope with a steel core.

Fibre core wire ropes are manufactured for their flexibility and resistance to fatigue over time; however, their susceptibility to crushing is unsuitable for environments with high heat or open flame.

Fibre core wire rope applications

• Cranes, winches, and hoists
• Engineering applications
• Holding and closing grab crane ropes
• Rigging applications
• Lifeboat falls
• Mooring wire rope
• Towing and luffing ropes

The advantages of fibre wire rope cores

• High flexibility
• High strength to weight ratio
• Superior breaking load
• Good fatigue life

The disadvantages of fibre wire rope cores

• Lower crush resistance
• Lower strength than steel in some applications
• Cannot be used in high-heat environments

Steel Core Wire Ropes

Wire ropes with steel cores are created with either stainless steel or galvanised steel. They are best suited to applications where a fibre core will not provide enough support or where the temperature may exceed 180° F.

Steel Core Wire Rope Applications

• Construction
• Mining 
• Cranes 
• The marine industry 
• Manufacturing 
• Mooring 
• Mining 
• Transportation 

The advantages of steel core wire rope

• High strength
• High crush resistance
• Suitable for most applications
• Highly durable
• Longer lasting rope diameter
• High strength
• High crush resistance
• Suitable for most applications
• Highly durable
• Longer lasting rope diameter

The disadvantages of steel core wire rope

• Lower flexibility
• Poor resistance to bending deformation
• Lower flexibility
• Poor resistance to bending deformation

Choose the Right Wire Rope core for your application

Selecting the correct wire rope and type of wire rope lubrication for your application, environment, and industry is of the utmost importance. Incorrect selection can result in poor stress resistance, premature breakage, or unsafe and inefficient function. The load-bearing abilities of your wire rope will be highly regulated based on their application. Its core type determines its strength and flexibility.

Safety is compromised whenever the wire rope is used out of accordance with its intended purpose. Understanding the construction and material used in the wire rope core is a great first step to correct wire rope selection.

Strong wire rope material is essential for the safety of your workers and worksite. It also affects how you maintain and care for your ropes over time.

Extend the lifespan of your wire rope core with proper lubrication

All wire ropes are lubricated during the manufacturing process to add flexibility, corrosion resistance and strength; however, this lubrication will wear off over time. A poorly lubricated wire rope with a dried-out core will be susceptible to snapping, premature fatigue, poor performance and a lack of flexibility. Lubrication without a wire rope lubricator that penetrates to the core can be ineffective and messy

Viper&#;s vast range of wire rope lubrication systems apply lubrication evenly and properly to increase the lifespan of your rope up to 300% longer. The strength and flexibility of your wire rope begins at its fibre or steel core.

Browse our range today, or contact our crew if you have any further questions about wire rope lubrication or the maintenance needs of your specific wire rope and its core.

The company is the world’s best Crimped Steel Fibers supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.