Mineral-impregnated carbon fibers reinforcement for concrete elements manufactured by extrusion

Mineral-impregnated carbon fibers (MCF) introduce an innovative reinforcement approach for creating material-efficient structures. Once cured, MCF display a substantially improved bond with the concrete matrix compared to similar polymer-impregnated textiles. Consequently, these novel composites exhibit increased crack density and more uniform crack distribution under uniaxial tensile load. This article explores the integration of both freshly impregnated and cured MCF into an extrusion process suited for stiff concrete mixtures. It provides insights into the impregnation process of carbon rovings with a mineral suspension and the incorporation of the MCF into the extrusion process. Mechanical characterization of the MCF and the extruded lightweight elements is also detailed, bolstered by visual examinations using computed tomography. Finally, the paper proposes a vision for material-efficient structures composed of extruded and subsequently freely formed MCF-reinforced concrete.