100% Recycled Fibres for Concrete

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Global production of new tyre cord manufactured from the highest quality steel is approximately 4.25 million tonnes per annum. The manufacturing process generates about 2% (85,000 tonnes) of waste most of it in the form of high quality steel cord but in short lengths which have no economic value as tyre reinforcement. In concrete construction the addition of small steel fibres in to fresh concrete is a well established way of enhancing the concrete's tensile strength and toughness. Over 1,000,000 tonnes of fibre is manufactured from cold drawn steel wire for this purpose every year. This project focuses on removing the barriers to market and turning these significant volumes of tyre cord waste into a new steel fibre product for high value applications in heavily loaded concrete structures such as suspended slabs, walls and tunnel linings.To achieve this, research and technological development will be performed to improve the Quality Assessment of the recycled cord production, a detailed Life Cycle Assessment will be undertaken to prove the high environmental credentials, as well as structural testing to confirm the performance of this new fibre and lead to certification. This will remove current barriers to market and guarantee a wide and speedy market acceptance of this innovative fibre.This project will give the waste steel cord a second life as reinforcement for concrete construction, only requiring about 1% of the energy needed to manufacture new steel fibre thereby contributing to the circular economy and significantly improving the sustainability of the construction industry.