From high-performing tires to sustainable concrete reinforcement

Every year, over a billion tires reach the end of their useful life. Traditionally, these tires face limited options: landfilling, incineration for energy generation, or downcycling into low-grade products. This represents a missed opportunity, especially for the valuable high-tensile steel reinforcement embedded within them.

The circular economy principle of keeping materials in use at their highest value is perfectly demonstrated when tire cords are transformed into second-life steel fibers. What was once considered end-of-life becomes a valuable construction material with a new life and purpose. This closed-loop approach ensures that the valuable properties of high-tensile steel—originally manufactured for tire performance—continue to provide strength and durability in another product and for a different industry. Of course, to be fully circular, the other tire components should also be recycled. Shredded, the rubber can for example be reused in the production process of asphalt for roads and pavements, for playground surfaces, sports fields or rubber mats and flooring.

As steel has a higher tensile strength than concrete, it can better withstand harsh conditions before it gets deformed or, in the case of concrete, presents cracks. This is the reason why concrete structures are generally reinforced with steel. Mesh and rebar are the more traditional way to do so. But steel fibers present many advantages compared to these two options, as it allows to reduce the amount of material used – steel, water and concrete altogether¹ – and is much easier to transport, store and install. These steel fibers, that have demonstrated their efficiency over the past decades, can also be mixed with steel fibers made of recycled steel cord from tires.

Steel fiber reinforced concrete offers a simpler and more efficient way to build. Instead of placing and tying traditional steel mesh or bars — which can be time-consuming and labour-intensive — small steel fibers are mixed directly into the concrete. This makes construction faster and easier, while often using less material overall. In applications like industrial floors or tunnel segments, this approach can even outperform traditional methods, helping to lower costs and reduce environmental impact.

These fibers also help concrete last longer. Because they are spread evenly throughout the mix, they help prevent cracks from forming and growing. This makes the structure more resistant to impact and everyday wear and tear. In more demanding situations, steel fibers can be combined with traditional reinforcement to further limit cracking and improve performance — for example in large infrastructure or underground structures exposed to water pressure.

Better crack control means structures stay stronger for longer. By choosing the right mix of fibers and traditional reinforcement, designers can either focus on improving quality and durability or on reducing the amount of material needed. In both cases, steel fibers help create more robust, cost-effective and sustainable concrete structures.

All the above benefits remain valid when a percentage of second-life steel fibers is added to the mix, while giving an extra sustainability boost. Up to 80% CO2 reduction can be achieved compared to rebar solutions². In less demanding applications, they can also be used as a stand-alone solution. They are therefore a great opportunity for projects with ESG-driven requirements.

Second-life steel fibers prove that environmental responsibility doesn’t have to come at a premium. These fibers offer comparable performance to traditionally manufactured alternatives, while maintaining cost neutrality. This means projects can embrace high-performance concrete and circular solutions without increasing budget pressure.

Steel fiber reinforcement is a cost-effective solution as such. Compared to traditional reinforcement methods, they reduce overall cost by requiring less labor and less material.

By unlocking the embedded value of materials that would otherwise go to waste, the use of second-life fibers creates economic opportunities while conserving resources. This is a true win-win for business and the environment.

The environmental benefits of second-life steel fibers exemplify the power of circular thinking. Their production requires only a fraction of the energy needed for manufacturing conventional steel fibers, resulting in a dramatically smaller carbon footprint compared to traditional alternatives.

By repurposing steel tire reinforcement, valuable materials are diverted from landfills or lower-value applications, addressing two environmental challenges simultaneously. This circular flow of materials prevents the extraction of virgin resources and eliminates the energy-intensive processes associated with new steel production. Additionally, fiber reinforcement often allows for reduced concrete volume in projects, further decreasing the environmental impact of construction.

This closed-loop approach represents a fundamental shift from the traditional linear "take-make-dispose" model to a regenerative system where materials maintain their value and utility across multiple lifecycles.

While second-life steel fibers offer tremendous potential for creating circular material flows, their implementation raises a number of questions. Ensuring consistent quality and cleanliness of recovered steel is essential, as is the use of specialized dispensing systems to achieve optimal fiber dispersion within concrete mixes. Bekaert has successfully addressed these challenges through dedicated processes and technologies.

The objective is not to eliminate virgin materials entirely, but to strategically reduce their use where feasible and leverage second-life alternatives in sectors where they meet performance criteria. Second-life fibers should be prioritized for less demanding applications, while virgin materials remain reserved for critical, high-performance needs.

Through extensive testing and application experience, Bekaert has established suitable fiber dosages for a wide range of uses and continues to expand this knowledge base. At the same time, the company actively contributes to the development of industry standards and specifications that support broader adoption. As a result, the circular use of steel fibers is no longer a future concept, but a practical and proven solution available today.

As construction and tire industries continue to pursue sustainability goals, second-life steel fibers represent an exciting intersection of their interests. By creating high-value applications for what was once considered waste, we're demonstrating how circular economy principles can deliver practical, economical solutions across industry boundaries.

The ongoing innovation in processing, quality control, and application techniques continues to expand the potential of these fibers. As stakeholders throughout the value chain—from tire manufacturers to recyclers to construction companies—collaborate more closely, the circular flow of materials becomes smoother and more efficient.

As a worldwide expert for both steel tire reinforcement and steel fibers for the construction industry with a sustainability focus across end markets, Bekaert has launched its own second-life steel fibers: Dramix® Loop, expanding the Dramix® product family with a solution designed to support lower-carbon construction. With its validated Life Cycle Assessment and third-party verified Environmental Product Declaration (EPD), they offer the construction players the highest sustainable standards.

As the construction industry seeks greener building solutions without compromising performance, steel fibers and second-life steel fibers offer a compelling answer,proving that sustainability and structural excellence can go hand in hand.

By building structures with second-life steel fibers, construction professionals are also building a more sustainable future based on regenerative, circular principles that preserve value and protect our planet.