Recycled Polypropylene Fibers as an Addition to Concrete Fabrication Based on Portland

Cement

HISTORY
Polypropylene fibers were first suggested as an admixture to concrete in 1965 for
the construction of blast resistant buildings for the US Corps of Engineers. The
fiber has subsequently been improved further and at present it is used either as
short discontinuous fibrillated material for production of fiber reinforced concrete
or a continuous mat for production of thin sheet components. Since then the use
of these fibers has increased tremendously in construction of structures because
addition of fibers in concrete improves the toughness, flexural strength, tensile
strength and impact strength as well as failure mode of concrete. Polypropylene
twine is cheap, abundantly available, and like all manmade fibers of a consistent
quality.

The use of fibers to reinforce concrete materials is a well-known concept. It has been practiced since
ancient times, with straw mixed into mud bricks and horsehair in mortars. Straw was used to reinforce
sun-baked bricks and horsehair was used to reinforce masonry mortar and plaster (ACI 544). The
concept of fiber reinforcement of cement based materials using asbestos started with the invention of
the Hatschek process in 1898. Later, glass fibers were proposed as reinforcement of cement paste and
mortar (Biryukovich et al., 1965). In modern times, the choice of fibers can vary from synthetic organic
materials such as polypropylene or carbon, synthetic inorganic such as steel or glass, natural organic
such as cellulose or sisal to natural inorganic asbestos. Using fibers in concrete matrices addresses the
issue of cracking in cement based materials. Concrete is considered to be a relatively brittle material
with a low tensile strength compared to its compressive strength. When subjected to tensile stresses,
unreinforced concrete will crack and fail. The use of fibers modifies properties of concrete both in plastic
and hardened stages and results in a more durable concrete

Polypropylene is a synthetic hydrocarbon polymer material, first introduced in 1957. It is one of a group
of synthetic, polymeric fibers (including but not limited to nylon, polyester, and polyethylene) adapted
from the textile industry which have been added to PCC in an attempt to improve performance.
Currently polypropylene is the most widely used of the synthetic fibers for paving applications2 2 .

MATERIAL
Properties of Polypropylene Fibers

The raw material of polypropylene is derived from monomeric C3H6 which is

purely hydrocarbon. Its mode of polymerization, its high molecular weight and the
way it is processed into fibers combine to give polypropylene fibers very useful
properties as explained below [9]:

 There is a sterically regular atomic arrangement in the polymer molecule

and high crystallinity. Due to regular structure, it is known as isotactic
polypropylene.
 Chemical inertness makes the fibers resistant to most chemicals. Any
chemical that will not attack the concrete constituents will have no effect on
the fiber either. On contact with more aggressive chemicals, the concrete
will always deteriorate first.
 The hydrophobic surface not being wet by cement paste helps to prevent
chopped fibers from balling effect during mixing like other fibers.
 The water demand is nil for polypropylene fibers.
 The orientation leaves the film weak in the lateral direction which facilitates
fibrillations. The cement matrix can therefore penetrate in the mesh
structure between the individual fibrils and create a mechanical bond
between matrix and fiber.

Figure 1: monofilament fiber Figure 2: Fibrillated fiber

The fibers are manufactured either by the pulling wire procedure with circular
cross section or by extruding the plastic film with rectangular cross-section. They
appear either as fibrillated bundles, mono filament or microfilaments as shown in
Fig. 1 & 2. The properties of these three types of PP fibers are given in Table 1
[10]. The fibrillated polypropylene fibers are formed by expansion of a plastic film,
which is separated into strips and then slit. The fiber bundles are cut into
specified lengths and fibrillated. In monofilament fibers, the addition of buttons at
the ends of the fiber increases the pull out load. Further, the maximum load and
stress transfer could also be achieved by twisting fibers [11].
Role of Fibers

Cracks play an important role as they change concrete structures into permeable
elements and consequently with a high risk of corrosion. Cracks not only reduce
the quality of concrete and make it aesthetically unacceptable but also make
structures out of service. If these cracks do not exceed a certain width, they are
neither harmful to a structure nor to its serviceability. Therefore, it is important to
reduce the crack width and this can be achieved by adding polypropylene fibers
to concrete [13]. The bridging of cracks by the addition of PP fibers has been
shown in Fig 3.

Thus addition of fibers in cement concrete matrix bridges these cracks and
restrains them from further opening. In order to achieve more deflection in the
beam, additional forces and energies are required to pull out or fracture the
fibres. This process, apart from preserving the integrity of concrete, improves the
load-carrying capacity of structural member beyond cracking. This improvement
creates a long post-peak descending portion in the load deflection curve as
shown in Fig 4 [12]. Reinforcing steel bars in concrete have the same beneficial
effect because they act as long continuous fibres. Short discontinuous fibres
have the advantage, however, of being uniformly mixed and dispersed
throughout the concrete.

The major reasons for crack formation are Plastic shrinkage, Plastic settlement,
Freeze thaw damage, Fire damage etc.

Plastic shrinkage: It occurs when surface water evaporates before the bleed
water reaches the surface. Polypropylene fibers reduce the plastic shrinkage
crack area due to their flexibility and ability to conform to form. The addition of
0.1% by volume of fibers is found effective in reducing the extent of cracking by a
factor of 5-10. The extent of crack reduction is proportional to the fiber content in
the concrete.

Polypropylene is occasionally recycled. PP is strong and can usually withstand higher temperatures. It is
used to make lunch boxes, margarine containers, yogurt pots, syrup bottles, prescription bottles. Plastic
bottle caps are often made from PP.
APPLICATION OF Polypropylene Fiber Reinforced Concrete

To improve the adhesion of polypropylene to cement matrix, geometrically deformed or

modified fibres are commonly used. Good results are obtained by application of fibrillated fibres
with the net-like structure obtained from the polypropylene types. The fibrillated polypropylene
fibres were produced. The fibres were chopped to specified lengths and used for the
reinforcement of concrete and cement mortars. From the group of synthetic fibres the
polypropylene fibres are the most frequently applied. The great interest in polypropylene fibres
results from their relatively low price, abundant availability and several valuable properties.
Thanks to high resistance the fibres are rust free and do not corrode during the utilisation of
concrete. The polypropylene fibres are hydrophobic, show practically no wet absorption and do
not absorb water during the mixing of cement paste. Polypropylene Fibres effectively restrict the
propagation of contraction cracks through dispersing the internal stresses. In the moment when
the crack is formed some fibres break, some, after the breaking of bonds connecting them with
the concrete, are partially pulled out and some bridge the widening cracking

Polypropylene Fibres added to the concrete improve the parameters of a fresh concrete. Fibres
have a relatively little effect on the compressive strength of concrete before freezing. The
beneficial effect of fibres is revealed after freezing and thawing cycles. After multiple
freeze/thaw cycles the compressive strength of reinforced concrete exceeds the strength of plain
concrete. Simultaneously, the reinforced concrete exhibits lower water absorbability. The
fibrillated fibres do not affect the compressive strength of the reinforced cement mortars.
Independently on the fibres’ length and their dosage the compressive strength of the reinforced
mortar does not change and is equal to the strength of the plain mortar. The fibres cause the
change of the mortar bending strength. The increase in the bending strength results from
enhanced interfacial adhesion and mechanical anchoring, which results from opening of the
network structure and splitting of fibrillated fibres.

At optimum percentage, fiber concrete can be used over normal concrete. The fibers can be used as a
replacement for steel reinforcement and have various advantages such aslight weight, tight cracks, ease of
use, safe handling, rapid dispersion and no corrosion. However specific design considerations and
construction procedures should be adopted in order to obtain optimum performance. In earthquake prone
areas, the use of fiber reinforced concrete would certainly minimize the human casualties. The PPFRC
can extensively be used in slabs, beams, balconies, overhangs, driveways, sidewalks, water storage tanks
(both overhead and underground), basements, foundations, drainage etc. As these are synthetic fibres so
there is no risk of corrosion to occur

Polypropylene Fiber Reinforced Concrete

Although concrete offers many advantages when it comes to mechanical characteristics and economic
aspects of the construction, the brittle behavior of the material remains a large handicap for the seismic
and other applications where flexible behavior is essentially required. However, the development of
polypropylene fiber-reinforced concrete (PFRC) has provided a technical basis for improving these
deficiencies.

Lately, the use of PP fibers has increased greatly in construction of structures, because the addition of
fibers in concrete improves the toughness, flexural strength, tensile strength and impact strength, as well
as failure mode of concrete. Polypropylene twine is cheap, abundantly available, and like all manmade
fibers of a consistent quality.

Pavements and guard rails of highways and expressways

•Airport runway and parking apron

•Sprayed concrete at the wall surface and top of tunnel and mine revetment

•Major structure of bridge and deck

•Composite floor in building constructions

•Waterproof layer, floor, inner & outer wall of industrial and civil constructions 
Properties of Polypropylene Fiber
Fiber Structure and Characteristics
PP fibers are composed of crystalline and non-crystalline regions.
Each crystal is surrounded by non-crystalline material. Fiber spinning
and drawing may influence the orientation of both crystalline and
amorphous regions.
The degree of crystallinity of polypropylene fiber is between 50-65%
in general, depending on the processing conditions. Crystallization
occurs between glass transition temperature and the equilibrium
melting point of PP. The crystallization rate is faster at low
temperatures.
In general, polypropylene fiber has excellent chemical resistance to
acids and alkalis, high abrasion resistance and resistance to insects
and pests. PP fiber is also easy to process and inexpensive compared
to other synthetic fibers. It also has low moisture absorption.
Some of the main PP fiber characteristics:
 gives good bulk and cover
 resistant to abrasion, deterioriation from chemicals, mildew,
perspiration, rot, stain, soil and weather conditions
 resistant to bacteria and micro-organisms
 colorfast
 quick drying
 anti-static behavior
 thermally bondable
 strong
 dry hand
 comfortable and lightweight
Because of its low specific gravity, polypropylene yields the greatest
volume of fibre for a given weight. This high yield means that
polypropylene fibre provides good bulk and cover, while being lighter
in weight. Polypropylene is the lightest of all fibers (for example, it is
34% lighter than polyester and 20% lighter than nylon), even lighter
than water.
Mechanical Properties
Polypropylene fibers are produced in a variety of types with different
tenacities in order to suit varying market requirements. Fibers for
general textile uses have tenacities in the range of 4.5-6.0 g/den. High
tenacity yarns up to 9.0 g/den are produced for the use in ropes, nets
and other similar products. High performance PP fibers have been
made with high strength and high modulus.
The techniques include ultra-drawing, solid state extrusion and crystal
surface growth. It is possible to make the filaments with tenacities over
13.0 g/den.
Table of Mechanical Properties of PP Fibres
Tensile strength (gf/den) 3.5 to 5.5

Elongation (%) 40 to 100

Abrasion resistance good

Moisture absorption (%) 0 to 0.05

Softening point (ºC) 140

Melting point (ºC) 165

Chemical resistance generally excellent

Relative density 0.91

Thermal conductivity 6.0 (with air as 1.0)

Electric insulation excellent

Resistance to mildew and moth excellent

The degree of orientation achieved by drawing has influence on the
mechanical properties of polypropylene filaments. The higher the
degree of stretch, the higher the tensile strength and the lower the
elongation. Commercial monofilaments have an elongation at break in
the region of 12-25%. Multifilaments and staple fibers are in the range
of 20-30% and 20-35%.
Thermal Properties
Polypropylene fibers have the lowest thermal conductivity of any
natural or synthetic fibre (6.0 compared to 7.3 for wool, 11.2 for
viscose and 17.5 for cotton). PP fibres retain more heat for a longer
period of time, have excellent insulative properties in apparel, and,
combined with its hydrophobic nature, keep wearer dry and warm.
Polypropylene fibers have a softening point around 150°C and a
melting point at 160-170°C. At low temperatures of -70°C or lower, PP
fibers keep their excellent flexibility. At high temperature (but below
120°C), PP fibers nearly keep all of their normal mechanical
properties. PP fibers have the lowest thermal conductivity of all
commercial fibers, and in this respect they are the warmest fibers of
all, even warmer than wool.
When it comes to the effect of extreme cold, they remain flexible at
temperatures in the region of -55°C.