Advancing Hybrid Fiber-Reinforced Concrete: Performance, Crack Resistance Mechanism, and Future Innovations

Abstract

This research investigates the effects of steel (ST) and synthetic (SYN) fibers on the workability and mechanical properties of HPFRC. It also analyzes their influence on the material’s microstructural characteristics. ST fibers improve tensile strength, fracture toughness, and post-cracking performance owing to their rigidity, mechanical interlocking, and robust adhesion with the matrix. SYN fibers, conversely, mitigate shrinkage-induced micro-cracking, augment ductility, and enhance concrete performance under dynamic stress while exerting negative effects on workability. Hybrid fiber systems, which include ST and SYN fibers, offer synergistic advantages by enhancing fracture management at various scales and augmenting ductility and energy absorption capability. Scanning electron microscopy (SEM) has been crucial in investigating fiber–matrix interactions, elucidating the effects of ST and SYN fibers on hydration, crack-bridging mechanisms, and interfacial bonding. ST fibers establish thick interfacial zones that facilitate effective stress transfer, whereas SYN fibers reduce micro-crack formation and enhance long-term durability. Nonetheless, research deficiencies persist, encompassing optimal hybrid fiber configurations, the enduring performance of fiber-reinforced concrete (FRC), and sustainable fiber substitutes. Future investigations should examine multi-scale reinforcing techniques, intelligent fibers for structural health assessment, and sustainable fiber alternatives. The standardization of testing methodologies and cost–benefit analyses is essential to promote industrial deployment. This review offers a thorough synthesis of the existing knowledge, emphasizing advancements and potential to enhance HPFRC for high-performance and sustainable construction applications. The findings facilitate the development of new, durable, and resilient fiber-reinforced concrete systems by solving current difficulties. © 2025 by the authors.