Sustainable Use of Waste Polypropylene Fibres to Enhance the Abrasion and Skid Resistance of Two-Stage Concrete

Two-stage concrete (TSC), also known as prepacked aggregate concrete (PAC), differs from traditional concrete in terms of site application and manufacturing process. Although this type of concrete is not a replacement for conventional concrete applications, it is an ideal option for unusual and difficult placing conditions, especially for repairing existing concrete structures. In other words, this type of concrete is a newly developed concrete and made by placing and packing coarse aggregates and fibres in a designed formwork, then injecting a cement grout mixture into the free spaces between the aggregate particles using gravity or a pump device. For the mentioned system and others, concrete components used as floors or pavements must have an adequate degree of roughness during service life when exposed to skid and abrasion. Thus, this research work introduced a new concrete method (prepacked aggregates fibre-reinforced concrete—PAFRC) with high abrasion and skid resistance reinforced with waste polypropylene (PP) fibres from the carpet industry. The effects of PP fibres at 0–1% dosages on the mechanical properties, abrasion resistance, and skid resistance of PAFRC mixes were studied. The results revealed that the addition of PP fibres reduces the compressive strength of concrete mixtures. Nonetheless, the presence of PP fibres results in PAFRC mixes having higher tensile strength, abrasion resistance, and skid resistance than plain concrete. It was detected that in both grouting methods (gravity and pump), with the addition of PP fibre up to a specific dosage, the resistance against abrasion and skid was increased by about 26% compared to plain PAC mix. Additionally, the outcomes indicated that PAFRC is a promising material for applications such as pavements with high abrasion and skid resistance.