FP McCann awarded Department for Energy Security and Net Zero (ESNZ) funding as part of the Industrial Energy Efficiency Accelerator, IEEA Phase 4

FP McCann aims to validate the use of non-corrosive basalt fibre reinforced polymer macro fibres (BFRPmf) for use in precast concrete.

BFRP is an emerging construction material, made of continuous basalt fibre bound together in a resin matrix.  Corrosion susceptible carbon steel reinforcement is primarily used in concrete to counter tensile stresses expected during the service life of a structure.  Reinforcement, in the form of bars, meshes, or cages, is meticulously positioned in the formwork before concrete placement.  Fabrication, transport, and placement of reinforcement cages in moulds are energy, time, and labour-intensive processes.  BFRPmf can be used to replace or to reduce the need for the traditional steel reinforcement by uniformly dispersing the fibres in the concrete mix during the batching process, saving on energy and carbon emissions as well as improving productivity.

This project will involve laboratory mix optimisation and testing, industrial upscaling at modified production line, full-scale structural and surface quality testing, and establishing design protocols.  The environmental impacts will be quantified through energy monitoring, environmental product declarations and life cycle assessment.  This will contribute to the industries broader understanding of the technology and may influence the development of international specifications and standards.  It is expected that the project will demonstrate steel reinforcement replacement of at least 25%, leading to 20% reduced energy consumption and lower carbon footprint.