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Pre-packed aggregate fibre-reinforced concrete (PAFRC) is an innovative type of concrete composite using a mixture of coarse aggregates and fibres which are pre-mixed and pre-placed in the formwork. A flowable grout is then injected into the cavities between the aggregate mass. This study develops the concept of a new PAFRC, which is reinforced with polypropylene (PP) waste carpet fibres, investigating its mechanical properties and impact resistance under drop weight impact load. Palm oil fuel ash (POFA) is used as a partial cement replacement, with a replacement level of 20%. The compressive strength, impact resistance, energy absorption, long-term drying shrinkage, and microstructural analysis of PAFRC are explored. Two methods of grout injection are used—namely, gravity and pumping methods. For each method, six PAFRC batches containing 0–1.25% fibres (with a length of 30 mm) were cast. The findings of the study reveal that, by adding waste PP fibre, the compressive strength of PAFRC specimens decreased. However, with longer curing periods, the compressive strength enhanced due to the pozzolanic activity of POFA. The combination of fibres and POFA in PAFRC mixtures leads to the higher impact strength energy absorption and improved ductility of the concrete. Furthermore, drying shrinkage was reduced by about 28.6% for the pumping method PAFRC mix containing 0.75% fibres. Due to the unique production method of PAFRC and high impact resistance and energy absorption, it can be used in many pioneering applications.

The Impact Resistance and Deformation Performance of Novel Pre-Packed Aggregate Concrete Reinforced with Waste Polypropylene Fibres