One Project, Three Optimised Fibre Reinforced Concrete Designs. 

The project required the construction of three concrete slabs with distinct operational demands. These included an internal slab, an external slab and a small carpark, each designed to support a 10 ton rolling load while reducing installation complexity and incorporating Armourforce construction joints for long term durability. The original internal slab design called for a 220 mm thick conventionally reinforced concrete floor, but achieving the required bar chair heights proved impractical, creating installation challenges and significant time pressures. 

To resolve these issues, the design approach was restructured around a single project with three optimised fibre reinforced solutions. Each slab received a tailored reinforcement strategy designed to match its specific performance requirements. 

For the 1,000 m² internal slab, the selected fibre was Dynaforce, chosen to deliver high reinforcement efficiency with reduced material demand. Its 80/60 aspect ratio and high tensile strength provide substantially higher performance compared to traditional hookend fibres. This allowed the dose rate to be reduced to approximately 20 kg per cubic metre, which is about 33 percent lower than the conventional 30 kg per cubic metre 65/60 approach, while achieving an equivalent fibre count per kilogram. The outcome was a cost effective, high strength reinforcement system without compromising fibre density. 

The 2,500 m² external slab retained the original 200 mm thickness but replaced steel mesh with Proforce 80. This change accelerated installation, eliminated the logistical burden of mesh handling and reduced carbon emissions associated with transporting steel. Proforce 80 increased loadbearing capacity, improved shrinkage crack control and enhanced multidirectional durability. Its ability to transfer stresses uniformly through the post crack zone provided improved fracture energy absorption and consistent long term performance. This design also ensured full depth reinforcement for a stronger slab.  

For the 200 m² carpark slab, Radforce was selected for its ability to improve impact resistance and early crack behaviour. Supplied in lightweight water dissolvable 5 kg boxes, Radforce simplified on site handling and removed the need for cutting, transporting and chairing steel, reducing labour requirements and further speeding up construction. 

Together, these three optimised designs delivered a unified project solution that streamlined construction, reduced environmental impact and produced high performance slabs engineered for their individual operational conditions.