Post-Consumer Carpet Fibers in Concrete: Fiber Behavior in Alkaline Environments and Concrete Durability

The widespread use of carpets in residential and commercial buildings and their relatively short life span result in large volumes of carpet being landfilled. A potential solution to this problem is the use of post-consumer carpet fibers in concrete. To this end, this paper systematically identifies the common fiber types in a typical post-consumer carpet fiber bale and evaluates their durability under exposure to varying levels of alkalinity. The tensile strengths and toughness of the fibers belonging to the nylon and polyethylene terephthalate (PET) families (the dominant fibers in most post-consumer carpets) are reduced by up to 50% following exposure to extreme alkalinity, the reasons for which are determined using spectroscopic and microscopic evaluations. The chloride ion transport resistance of concretes (~40 MPa strength) containing 2.5% carpet fibers by volume (~25 kg of fibers per cubic meter of concrete) is comparable to that of the control mixture, while mortar mixtures containing the same volume fraction of carpet fibers demonstrate negligible enhancement in expansion and loss of strength when exposed to 1 N NaOH. This study shows that moderate-strength concretes (~40 MPa) for conventional building and infrastructure applications can be proportioned using the chosen volume of carpet fibers without an appreciable loss of performance. Consideration of low volume fractions of carpet fibers in low-to-moderate-strength concretes thus provides a sustainable avenue for the use of these otherwise landfilled materials in construction applications.