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About this event

Traditional rebar-based reinforcement is labor-intensive, time-consuming, and often over-designed, especially under today's pressure for sustainable, cost-efficient construction. In this comprehensive session, Dylan Field (Sales Engineer, Helix Steel) and Paige Beichner (Sales Engineer, Forta) revealed how advanced fiber-reinforced concrete (FRC) systems are replacing or reducing steel across slabs, footings, precast, and more.

You’ll get immediate value if you're a structural engineer or designer who:

• Spends too much time detailing rebar in slabs or foundations
• Struggles with cracking in early-age concrete or durability concerns
• Wants to simplify designs without sacrificing performance
• Needs to comply with ACI 318 using performance-based design provisions
• Is exploring sustainable materials to reduce embodied carbon in concrete structures

In this webinar, we covered:

• How to design smarter with FRC: Performance-based building codes enable innovative construction methods, and Forta’s fiber-reinforced concrete (FRC) solutions demonstrate how alternative materials and methods can enhance modern concrete infrastructure.
• Why engineers are switching from steel to fibers: Advanced fiber technologies – like Forta-Ferro and Helix Micro Rebar – are examples of macrosynthetic and steel fibers that reduce cracking, enhance durability, and replace or reduce traditional steel reinforcements.
• Variety of structural applications: Forta’s fiber systems extend beyond typical pavement use to applications such as slabs, walls, precast, foundations and more – delivering sustainability, cost-efficiency, and long-term resilience.

You’ll walk away with the knowledge to design more efficiently, reduce cracking, meet code requirements, and streamline your workflow, without compromising safety or durability.

Key insights

Dylan and Paige explained why fiber geometry matters - both synthetic and steel fibers are twisted (synthetic also crimped), with steel featuring rectangular cross-sections. These deformations work like screws versus nails, creating superior anchoring in concrete.

Three categories of fiber solutions

Micro Fibers: Residential applications, 1 lb dosage for plastic shrinkage control

‍Fibrillated Network Fibers: Commercial projects, 1.5 lb dosage to replace light-duty mesh

‍Macro Synthetic Fibers: Structural applications, 3-7.5 lb dosage replacing mesh and lighter rebar

Steel fiber advantages

Helix Steel's micro rebar delivers 246 ksi strength, zinc-coated corrosion resistance, made in Michigan. The twisted geometry requires significantly more force to pull out compared to hooked or straight fibers.

Real cost savings

While material costs may be comparable, the real savings come from eliminated labor - no more laying mesh, tying rebar, or installing chairs. Projects save approximately one day per 10,000 square feet of slab.

Both Forta and Helix Steel products comply with ACI 318 Section 110 through performance-based evaluation reports:

• ICC Report: Based on increased modulus of rupture (up to 12x√f'c vs traditional 5x√f'c)
• IAPMO Report: Direct tension methodology allowing replacement of structural and shear reinforcement

Real project examples

Commercial success stories

• Detroit Skyscraper: First since 1979, replaced wire mesh in all elevator decks
• Seattle Monorail Pile: Replaced 8 #6 bars and #3 hoops with fiber plus single #6 center bar
• North Carolina Warehouse: Eliminated two layers of #5 rebar (12" o.c. each way) entirely
• Ohio Distribution Center: 3 million sq ft with three different fiber dosages

Versatile applications

• Healthcare Facility: 3-4 lb dosages for slab-on-metal-deck applications
• Art Museum: Deep ground polish at 7.5 lb dosage with clean visual results
• Agricultural Projects: Irrigation channels with enhanced durability
• Single Family Homes: ICF walls, foundations, driveways (not CMU)

Questions and answers

‍1. Can fibers be pumped like regular concrete?

‍Answer: Yes - fibers are no bigger than largest aggregate, so if you can pump the aggregate, you can pump the fiber.

2. Where should fibers be added - on-site or at the plant?

Answer: Preferably at the batch plant for even distribution, though on-site addition is possible with proper procedures.

3. Do you still need rebar at cold joints and corners?

Answer: Yes - arrangement bars, dowels, and cold joint reinforcement remain as originally designed. Fibers replace field reinforcement only.

4. How do fibers improve durability?

Answer: By creating smaller, tighter cracks that transfer loads more efficiently, reducing permeability and better protecting any remaining reinforcement.

5. Can this work for residential projects?

Answer: Absolutely - fibers scale from single-family homes up to millions of square feet of industrial applications.

6. Any issues with finishing or polishing?

‍A: Proper timing is critical - let paste layer develop on top, then final float will smooth down any protruding fibers.

Complete engineering support

Forta and Helix Steel provide full engineering services including:

• Calculations and submittals stamped in all 50 states
• 2-3 day turnaround on project conversions
• On-site support during concrete placement
• Delegated design services when needed
• Building official coordination and support

Watch the complete session to see detailed technical data, test results, and project case studies that demonstrate how fiber-reinforced concrete can streamline your designs while maintaining safety and durability.

Contact the Experts:

• Dylan Field, Helix Steel
• Paige Beichner, Forta

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