Optimal design of a low-cost high-performance hybrid fiber engineered cementitious composites

Engineered cementitious composites (ECC) is a fiber reinforced high-performance cementitious material with an ultra-high tensile strain capacity (above 3%) and excellent durability. However, such excellent strain capacity far exceeds some engineering requirements and is usually not fully utilized. Meanwhile, its high cost limits it application only in local engineering. In this study, a low-cost high-performance hybrid fiber ECC (HF-ECC) with both polypropylene (PP) fiber and polyethylene (PE) fiber was manufactured. Both macroscopic and microscopic mechanism analyses were conducted to investigate the effect of fiber characteristics and proportions on the performance of HF-ECC. The results show that the ultimate tensile strain of HF-ECC can reach 5% even the volume fraction of PP and PE fibers account for 1%, respectively. Its fiber cost is 43.8% lower than that of pure PE-ECC, which reduces the corresponding total cost by 27.5%. This paper presents an in-depth investigation of the characteristics of HF-ECC, direct tension, compression, fiber-bridging, pore structure, fiber distribution, and fiber dispersion. Finally, the optimal design of the HF-ECC is conducted through pseudo-strain-hardening indices and multi-criteria evaluation.