Concrete is one of the most widely used construction materials in the world due to its durability and compressive strength. However, conventional concrete suffers from low tensile strength and cracking. Adding short discrete fibers helps control cracking by bridging the cracks.

Types of Fibers Used
There are different types of fibers that can be used for reinforcing concrete based on their material properties:

Steel Fibers
Steel fibers are most commonly used reinforcement material due to their high strength and aspect ratio. They are made of cold-drawn, low carbon steel wire and are available in hooked, crimped and smooth shapes. Straight steel fibers improve toughness while hooked ends improve aggregate interlock and tensile strength. Due to corrosion resistance issues, steel fibers are usually coated with zinc, plastic or concrete.

Synthetic Fibers
Synthetic fibers such as polypropylene, polyvinyl alcohol, nylon and polyester are also used for reinforcing concrete. They have high tensile strength, are lighter weight, and are less prone to corrosion compared to steel. Polypropylene fibers have excellent alkali resistance and are most commonly used. Nylon fibers improve toughness and impact resistance.

Glass Fibers
Glass fibers have high tensile strength and modulus similar to steel but are non-corrosive. Alkali-resistant or coated glass fiber reinforced concrete as well as reduce shrinkage cracking in concrete.

Other Natural Fibers
Other natural fibers gaining attention are coconut fibers, bamboo fibers, sisal fibers etc. They are low cost, sustainable and biodegradable but have lower strength compared to synthetics.

Properties and Benefits of Fiber Reinforced Concrete
The incorporation of random discrete fibers into concrete leads to several improvements in its properties compared to plain concrete:

Tensile Strength - Addition of just 0.5-2% fibers by volume can increase the post cracking residual tensile strength of concrete by 1.5-5 times. This improves ductility and prevents explosive spalling failure.

Flexural/Bending Strength - Both direct tensile and flexural/bending strengths of concrete increase significantly with the inclusion of fibers. This improves structural performance under dynamic and impact loading.

Fatigue Resistance - FRC exhibits higher resistance to fatigue loading cycles and shows lesser deterioration of properties due to fatigue.

Impact/Shock Resistance - Fibers improve concrete's toughness and resistance to impact, shocks and vibrations. This minimizes cracking from impact.

Abrasion Resistance - Wear and abrasion resistance of concrete surfaces like bridge decks, pavements, etc. improve with fiber reinforcement.

Shrinkage Cracking - Some fibers like glass, steel and PP fibers have shown to reduce early age plastic shrinkage as well as hardened shrinkage cracking in concrete by restraining cracks.

Durability - The presence of tightly spaced micro-cracks throughout the mix increases concrete’s diffusion path length and improves its durability in harsh environments like marine, chlorides etc.

Applications of Fiber Reinforced Concrete
Based on the enhanced properties, fiber reinforced concrete has applications in diverse fields:

- Industrial floors - For improved abrasion and impact resistance in heavy duty usage areas like manufacturing plants.

- Bridge decks - Replacing steel bars to reduce corrosion induced cracking and increase fatigue life.

- Parking decks - Provides durability against environment and reduces maintenance costs.

- Shotcrete - Used as a sprayed concrete for rock stabilization, slope stabilization, tunnel linings etc. due to improved cohesion and build properties.

- Overlays - FRC polymer overlays on existing concrete pavements increase surface life by preventing cracks.

- Precast concrete - FRC allows casting of thin, pre-cracked structural elements like hollow core slabs with structural integrity.

- Concrete masonry units - Bricks and blocks with fibers have improved flexural strength and resistance to impact, cracking.

- 3D Printed concrete - Recent applications in contour crafting and 3D concrete printing for durable construction.

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