Helix Steel is proud to announce that three of its team members — Luke Pinkerton, Justin Idalaski, and TJ Lambert — were featured in the January 2026 issue of Concrete Engineering International.
Their article, titled “Advancements in concrete reinforcement: moving beyond hook-end fibers to twisted steel fiber,” highlights the continued evolution of fiber-reinforced concrete and introduces the performance advantages of 0.8 x 52mm twisted steel fiber (TSF) technology.
The publication outlines how twisted steel fiber reinforcement improves both pre-crack and post-crack concrete performance, including increased modulus of rupture (MOR), enhanced long-term tensile strength, and stable residual load capacity. The article also explores how TSF can contribute to more efficient concrete designs by enabling thinner slabs and reducing overall embodied carbon.
This feature reinforces Helix Steel’s ongoing commitment to innovation, performance-driven reinforcement solutions, and sustainable construction practices worldwide.
The full article appears in Concrete Engineering International, January 2026 edition.
Working with traditional reinforced concrete with rebar or wire mesh can be time-consuming. Although the up-front cost of using Helix® Micro Rebar® is similar to mesh or standard rebar, this alternative saves time and labor. Learn how much money contractors actually save using micro rebar with case studies and examples below.
The Indirect Costs of Traditional Rebar
When making concrete reinforcement cost comparisons, you may overlook some of the hidden expenses of traditional rebar.
Tying and placing the rebar is often the biggest bottleneck in your concrete project timeline. It can take days or even weeks before you can pour the concrete. This labor-intensive process also risks injuries, such as back strain from handling the materials. Safety and insurance costs can impact your bottom line.
You also have to factor in the price of cranes and transport for rebar. Additionally, rebar can take up a great deal of storage space until it’s ready for placement.
There are other inefficiencies, such as the scrap generated when cutting and bending rebar. You may think that because you’ve always used traditional rebar, it’s best for the job. Being open to alternatives like Helix Micro Rebar can improve productivity and reduce many of these extra expenses associated with traditional rebar.
How Helix Micro Rebar Saves Time
The key areas where Helix Micro Rebar saves money are time and labor. For every 10,000 square feet of rebar you replace with Helix Micro Rebar, you can save a full day of construction.
Consider the impact of the time saved alone. If you finish a project two weeks early, you open another two weeks for your crew to work more jobs. Micro Rebar labor savings maximize your profits in the busy season by increasing your capacity to take on more work.
When you use Helix Micro Rebar, you don’t need a massive rodbuster crew. Instead of having your team spend hours tying and placing rebar, they can focus on finishing the concrete. With a ready-mix truck driver and a smaller finishing crew, you may need fewer workers overall, reducing construction labor costs.
The current construction worker shortage is projected to reach nearly 350,000 in 2026. Labor savings from using Helix Micro Rebar go beyond cost reduction — you can overcome much of the challenge of finding reliable workers to finish your job on time.
Material and Installation Savings
In tilt-up wall applications, Helix Micro Rebar can eliminate 70% or more of traditional rebar cages. This capability removes the congestion of double-mat rebar, allowing for faster pours and better consolidation. Not only do you use less steel tonnage for your project, but you also gain the benefits of a more efficient and effective process.
As Helix Micro Rebar is pumped or poured directly where needed, you don’t have to rent cranes to lift heavy rebar cages. You’ll save on rental costs and logistics.
In some engineered designs, Helix Micro Rebar allows for thinner slabs. These slabs offer the same strength and performance as traditional rebar-reinforced slabs. The advantage here is reducing your concrete volume costs.
Why In-Place Cost Matters
Per pound, Helix Micro Rebar may look comparable to the price of traditional rebar, but you need to consider the in-place cost. The cost of steel rebar, plus the cost of tying, time, labor, and crane rentals, is higher than the installed cost of Helix Micro Rebar. The time and labor savings compound across large-scale projects.
The other consideration is the engineering cost of rebar versus Helix Micro Rebar. Traditional rebar requires expensive detailing. Helix Steel provides the engineering expertise and exact amount needed to complete a project. You don’t have to work with multiple parties for stamped drawings.
How Helix Micro Rebar Saves Money: Case Studies
Let’s explore a few examples of how Helix Micro Rebar has saved money for various concrete construction projects.
Zekelman Industries
Independent steel and tube manufacturer Zekelman Industries needed to renovate two buildings. The contractor chose Helix Micro Rebar. They saved 15% on construction time and replaced 120,000 pounds of steel rebar. Large-scale industrial projects like these see even more savings when using Helix Micro Rebar.
Whether it’s faster rebar installation or reduced material usage, replacing traditional rebar with Helix Micro Rebar significantly reduces the total project cost.
Hilton Garden Inn
When your client wants to minimize downtime, the efficiency of your work becomes even more important. The contractors working on the Hilton Garden Inn in Uniontown, Pennsylvania, saved hundreds of thousands of dollars by using Helix Micro Rebar. These savings were partly due to the construction speed — they saved 10 days of labor compared to the original design.
In this project, Helix Micro Rebar replaced all horizontal rebar reinforcement, reducing the time required for wall paneling. There was 66% less rebar used overall, too, which drove down material and labor costs.
Allied Properties
Helix Micro Rebar can deliver exceptional performance while saving costs. Allied Properties in Laredo, Texas, needed pavement covering more than 600,000 square feet. This pavement needs to withstand the daily traffic of 700 units a day, with cargo loads averaging 40,000-50,000 pounds each.
The contractor completed the project two months early using Helix Micro Rebar. The scale of the project would have made placing and tying rebar a significant constraint. Improving the concrete project timeline in this way drastically reduced labor costs.
The Ridge at Kettle Creek
A homebuilding project by Liberty Ridge Homes used Helix Micro Rebar in the wall footings, ICF walls, and slabs. The project’s priority was to build higher-quality, energy-efficient homes at a more affordable price.
With Helix Micro Rebar, the contractor accelerated the entire construction timeline and reduced costs. They were able to lock up a three-story, six-plex building in a month and a half, reducing construction time by 20%. The contractor also eliminated 330,000 pounds of rebar using Helix Micro Rebar.
How to Calculate Your Own Savings
Find out how much you can save by switching to Helix Micro Rebar. Some factors to consider in your calculation are:
- Crew hourly rate
- Daily overheads
- Crane rental cost
- Penalty clauses for delays
- Material costs
Use Helix’s dosage calculator to make sure your comparisons are accurate.
Partner With Helix Steel for Your Next Project
You can experience savings in three main areas by replacing traditional rebar with Helix Micro Rebar: time and labor, safety, and materials. In a tight labor market, finding more efficient processes not only reduces costs but also ensures you have the force to keep up with demand and complete projects.
More than 40,000 projects worldwide have used Helix Micro Rebar. To experience faster, stronger concrete in your next project, contact us today.
Helix Steel is proud to announce that Dan Lucas has been promoted to Sales Manager. Lucas has long been a key sales representative at the concrete reinforcement innovator, working from the company’s early years of growth to the unprecedented global COVID-19 pandemic and now through these exciting years of construction growth.
In his position as Sales Manager, Lucas will work closely with management and the sales team to launch new sales strategies and focus on converging the team’s ideas, insights and creativity to foster a teamwork-focused environment that improves communication with customers like never before.
“I’m thrilled to take on this new role at Helix Steel,” says Lucas. “We believe not only in selling products, like traditional salespeople, but we strive to make projects better by finding out what’s best for the projects themselves. It’s not only that we can replace rebar, but it’s also that we can do everything from enhancing corrosion resistance to making concrete more durable while improving the constructability across the entire project including the architectural and electrical phases.”
Helix Steel’s employees take pride in doing good work for its customers, and in improving so many projects. Lucas and his team look forward to forging new relationships across North America.
“The future at Helix Steel is exciting,” adds Lucas. “We’re working on some of the largest projects in North America, like electric car plants and solar farms. And we’re seeing our customers grow from ordering a few boxes for a driveway and now we’re selling truckloads of product.”
“Dan has always been a major contributor to our sales team,” says Luke Pinkerton, Helix Steel’s CTO and President. “Everyone here congratulates him on his promotion and wishes him the best of luck as he continues to grow with Helix Steel.”
To learn more about Dan Lucas’s new role, his commitment to improving lives throughout the construction industry and how Helix Steel is changing the entire construction industry, reach out to Lucas directly at dan.lucas@helixsteel.com.
Helix Steel’s concrete reinforcement succeeds as a leading concrete repair product in a three-year test on the Minnesota highway system.
September 15, 2021 (Ann Arbor, Michigan) – Helix Steel is proud to announce that its innovative reinforcement Helix® Micro Rebar® is one of the few concrete patch products to withstand heavy traffic, freeze-thaw and de-icing agents of Minnesota’s highway system.
The multi-year project was undertaken by the National Road Research Alliance’s (NRRA) Preventive Maintenance Team and sought to determine the most effective joint repair programs. By selecting longer-lasting patches for Minnesota’s roadways, the results will be: reduced need for lane closures, lower maintenance costs and the increased availability of staff to perform other duties.
Helix Steel performed two tests involving Helix Micro Rebar (also known as Helix 5-25) in conjunction with CTS Rapid Set DOT Repair Mix. The one-inch twisted steel reinforcement was mixed in a revolving drum mixer with the concrete mix, placed on the patch area, then finished using traditional materials. Within one hour, the road for each test was reopened to traffic. Results after one, two and three years proved that the patches would last greater than five years.
“We are thrilled with the results of the independent real-world testing of our product,” says Luke Pinkerton, President and Chief Technology Officer of Helix Steel. “Helix Micro Rebar has been tested in labs and has been used in more than 50,000 applications across North America. This project proves yet again that our American-made reinforcement works to strengthen concrete, save money and reduce maintenance.”
The project’s final report describes the methodology of the tests, summarizes each of the products used in the research project and explains details pertaining to the estimated service life, installation and curing, shelf life and packaging.
Making the Most of Infrastructure Spending
By using proven techniques to extend the lifespan of its roads, Minnesota hopes to make better use of the funds available. This is especially important since early in August 2021 the Senate passed a package that includes $110 billion for roads, bridges and other large infrastructure projects. If the bill is passed by the House in October, then this could be one of the largest infrastructure funding injections in America’s history.
Contractors will be under intense pressure to provide American taxpayers with the biggest return on their investment. They will need to use highly efficient materials that focus on long-term resilience and safety.
If you are a contractor, government representative, maintenance manager, road engineer, architect or anyone else who is interested in learning more about using Helix Micro Rebar to repair highways or any other concrete application, please contact Helix Steel for a project specification review and preliminary concrete design: sales@helixsteel.com.
For more information on the study administered by the Minnesota Department of Transportation, please visit: Effective Long Lasting PCC Partial Depth Joint Repairs for Challenging Conditions
About Helix Steel
Helix Steel the innovative manufacturer of Helix® Micro Rebar® reinforcement, used in more than 50,000 concrete applications across America to provide structures with quantifiably better resiliency, ductility and elasticity to concrete structures. Since 2003, Helix® Micro Rebar® has been used in structures around the world and continues to support America by manufacturing its products in Grand Rapids, Michigan. To learn more, visit www.helixsteel.com.
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For more information on Helix Steel:
Luke Pinkerton, President and Chief Technology Officer
Helix Steel
2300 Washtenaw Avenue, Suite 201
Ann Arbor, MI 48104
Email: luke.pinkerton@helixsteel.com
Website: www.helixsteel.com
Office: 734-322-2114 ext. 60
Mobile: 734-649-5663
An American concrete reinforcement manufacturer is eliminating cracks in concrete slabs on grade with Infinity Slab™.
July 28, 2021 (Ann Arbor, Michigan) – Helix Steel is announcing the launch of its Infinity Slab™ concrete solution that can extend concrete joints to over 100 feet.
The Michigan-based concrete reinforcement innovator created this approach for commercial developers who seek to have fewer concrete joints in their slabs on grade. Control joints require costly and time-consuming cutting and sealing, and leaves long-term maintenance issues, which Helix Steel has now made a thing of the past.
Infinity Slab™ is a Better Way to Build with Concrete
Using a combination of Helix Steel’s proprietary Helix® Micro Rebar™ concrete reinforcement, professional engineering and local ready-mix techniques, Infinity Slab™ increases concrete’s strength, lowers maintenance costs and minimizes a building’s ownership costs.
The customized design increases the long-term reliability of the concrete slab, rather than designing using ultimate load after cracks already form. Helix Steel also recommends methods to eliminate the need for wet curing, which saves developers even more time and money in the construction process.
“Many concrete slab applications would benefit from fewer joints, which is why we developed Infinity Slab™ to address this important need,” says Luke Pinkerton, Helix Steel’s President and Chief Technology Officer. “Simply doubling the joint spacing reduces the number of joints by a factor of four. There’s a significant long-term savings, and the upfront cost is minimal.”
A key aspect of Infinity Slab™ is Helix Steel’s one-inch twisted steel concrete reinforcement called Helix® Micro Rebar® reinforcement. The product increases concrete’s resiliency, ductility, and strength, and eliminates or reduces the traditional reinforcement (rebar and mesh) required by building codes. Concrete slabs built with Helix® Micro Rebar® reinforcement are ACI 318 building code compliant to carry structural loads.
How Does Extending Control Joints Work?
Infinity Slab™ incorporates the benefits of Helix® Micro Rebar™, and combines them with Helix Steel’s decades of expertise. The engineering team starts by performing a custom structural concrete analysis and works alongside developers, contractors and local ready-mix producers to devise a low-shrinkage mix to better manage water, aggregate and reinforcement. Helix Steel has access to a team of engineers who are some of the county’s leading professionals in flatwork and mix design.
A highly detailed custom design is then produced, customized to the precise application, using one of four Infinity Slab™ options (depending on the joint distances), and followed by field support.
Limitless Slab-on-Grade Concrete Applications With Infinity Slab™
For commercial developers who have large, open spaces, Infinity Slab™ is the optimal solution, from warehouses and fulfillment centers to cold storage and manufacturing facilities. It provides value with tenants in mind, but also takes into account other applications which the slab may be used for in the future.
“It’s designed to work on any slab-on-grade application, but it is most widely used in concrete that will have high traffic from forklifts, loaders or other heavy vehicles,” says Pinkerton. “Our philosophy here at Helix Steel is that concrete slabs should remain uncracked under service loads, no matter the application.”
Moving Forward with Fewer Slab-on-Grade Joints
Infinity Slab™ is already being used by leading developers who seek to eliminate cracks in concrete slabs, with no additional engineering or site support fees. Those interested in learning more about the engineering approach are asked to contact Helix Steel for a project specification review and preliminary concrete design at sales@helixsteel.com.
About Helix Steel
Helix Steel the innovative manufacturer of Helix® Micro Rebar™ reinforcement, used in more than 20,000 concrete applications across America to provide structures with quantifiably better resiliency, ductility and elasticity to concrete structures. Since 2003, Helix® Micro Rebar™ has been used in structures around the world and continues to support American by manufacturing its products in Grand Rapids, Michigan. To learn more, visit www.helixsteel.com.
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For more information on Helix Steel:
Luke Pinkerton, President and Chief Technology Officer
Helix Steel
2300 Washtenaw Avenue, Suite 201
Ann Arbor, MI 48104
Email: luke.pinkerton@helixsteel.com
Website: www.helixsteel.com
Office: 734-322-2114 ext. 60
Mobile: 734-649-5663
Helix Steel is proud to once again sponsor the National Ready Mixed Concrete Association’s Global Concrete Summit. As a business built on concrete innovation for almost 20 years, Helix Steel plays a lead role in helping ready-mix producers through leadership, innovation and education, and looks forward to furthering sustainable development in the concrete industry through the Summit.
As a five-month online event, there has never been a better opportunity for industry professionals to access highly valuable information on a wide variety of topics from the comfort of your office. Register by visiting the Global Concrete Summit website.
The Michigan-based concrete reinforcement manufacturer is making a significant contribution to help build durable new homes for families in need.
Helix Steel is coordinating delivery of its Helix® Micro Rebar™ concrete reinforcement to help build durable homes for families in high-need communities across America. The move is being done in partnership with Habitat for Humanity and Build with Strength, a coalition of the National Ready Mixed Concrete Association.
This inspiring community-focused initiative will involve constructing highly durable, affordable and sustainable homes at 16 locations across the U.S.A.
Helix Steel’s concrete reinforcement will help to make the homes the best that they can be. The science behind the product is in its proprietary design: a one-inch piece of twisted steel that’s combined with thousands of others, mixed with concrete and poured in place. From slabs, walls and footings to foundations and infrastructure projects, Helix® Micro Rebar™ has been used in thousands of projects and applications, and is proven to improve concrete resiliency, ductility, and strength.
“We’re proud to support Habitat in furthering its mission to build homes, communities and hope,” Luke Pinkerton, Helix Steel’s President and Chief Technology Officer. “Our contribution of materials and expertise will help to ensure faster construction and lower costs for 16 communities across America. Our support will help to create homes that are built to last many lifetimes.”
The first project in the partnership will break ground in April with the construction of three homes in Paradise, California. This town was devastated by wildfires in recent years. Building the homes of concrete will provide families with a durable home that resists fire.
“Residents have had their lives turned upside down,” said Nicole Bateman, executive director of Habitat for Humanity of Butte County. “We are grateful for our partners in the concrete industry for stepping in to help with the rebuilding process. Their generous donations will not only provide affordable housing but also resilient homes that will resist destruction from future wildfires.”
Other industry groups involved in the collaboration and contributing to the projects include the Insulating Concrete Forms Manufacturing Association (ICFMA) and the American Concrete Pumpers Association (ACPA).
“We are extremely proud to be a part of the partnership with Habitat for Humanity. It gives us a great opportunity to set an example for how we should be building resilient communities across the country,” said Mike Kennaw, Board Chairman, ICFMA. “ICF construction can help hard-working families by providing safe and strong homes, and we are really grateful to be a part of that.”
“Habitat for Humanity is an incredible partner for these projects. It’s an amazing feeling to know that the industry will help to provide affordable homes that are comfortable and safe for those living in them,” said Christi Collins, Executive Director of ACPA. “Concrete can provide great peace of mind for homeowners.”
For more information on Habitat for Humanity International, please visit www.habitat.org.
To learn more about Helix Steel and its concrete reinforcement products, please visit www.helixsteel.com.
About Helix Steel
Helix Steel the innovative manufacturer of Helix® Micro Rebar™ reinforcement, used in more than 20,000 concrete applications across America to provide structures with quantifiably better resiliency, ductility and elasticity to concrete structures. Since 2003, Helix® Micro Rebar™ has been used in more than 20,000 structures around the world and continues to support American by manufacturing its products in Grand Rapids, Michigan. To learn more, visit www.helixsteel.com.
About National Ready Mixed Concrete Association
NRMCA is celebrating 90 years of representing the producers of ready mixed concrete and the companies that provide materials, equipment, and support to the industry. It conducts education, training, promotion, research, engineering, safety, environmental, technological, lobbying and regulatory programs. To learn more, visit www.nrmca.org.
About Build with Strength
Build with Strength is a coalition of the National Ready Mixed Concrete Association and works with communities, lawmakers, and industry employees to advocate for safer, sustainable building materials. To learn more, visit www.buildwithstrength.com.
About Habitat for Humanity
Driven by the vision that everyone needs a decent place to live, Habitat for Humanity began in 1976 as a grassroots effort on a community farm in southern Georgia. The Christian housing organization has since grown to become a leading global nonprofit working in local communities across all 50 states in the U.S. and in more than 70 countries. Families and individuals in need of a hand up partner with Habitat for Humanity to build or improve a place they can call home. Habitat homeowners help build their own homes alongside volunteers and pay an affordable mortgage. Through financial support, volunteering or adding a voice to support affordable housing, everyone can help families achieve the strength, stability and self-reliance they need to build better lives for themselves. Through shelter, we empower. To learn more, visit www.habitat.org.
For more information on Helix Steel:
Luke Pinkerton, President and Chief Technology Officer
Helix Steel
2300 Washtenaw Avenue, Suite 201
Ann Arbor, MI 48104
Email: luke.pinkerton@helixsteel.com
Website: www.helixsteel.com
Office: 734-322-2114 ext. 60
Mobile: 734-649-5663
This latest report ensures that architects, ICF/residential contractors and ready mixers are able to reduce costs, work faster and create a better concrete product.
The International Code Council Evaluation Service (ICC-ES) has published a report that allows engineers, architects and builders to easily implement Helix Steel’s concrete reinforcement in residential slabs, foundations, footings, walls and pavements. The report was originally published in September 2020 and was updated in February 2021.
Helix® Micro Rebar™ is Helix Steel’s one-inch twisted steel concrete reinforcement that increases concrete’s strength and resilience, and eliminates or reduces the traditional reinforcement (rebar and mesh) required by building codes. Thousands of the reinforcement pieces are added at a ready-mix plant or onsite directly to the concrete mix, reducing costs and increasing time. Since 2003, Helix® Micro Rebar™ has been used in more than 12,000 homes and thousands of businesses in applications ranging from concrete slabs and foundations to tunnels and bridges.
There are a number of important highlights in ESR-3949:
- The prescriptive design tables eliminate the need for engineered designs for footings and foundation walls. Builders, engineers and architects can now simply refer to the design tables to determine the required Helix® Micro Rebar™ reinforcement dosage to replace traditional rebar.
- This revised report includes pavement in addition to slabs, foundations, footings and walls. The pavement design approach is in accordance with ACI 330-08 Guide for the Design and Construction of Parking Lots.
- The report demonstrates compliance under the 2018 IBC and IRC.
- Helix® Micro Rebar™ reinforcement is now fully code approved in Abu Dhabi through the 2013 Abu Dhabi Building Code.
The technical report would not be possible without all of the proven field experience Helix Steel has demonstrated over 18 years, in addition to laboratory testing. The ICC-ES requires public information, peer review, independent data and multiple factory audits to develop and maintain its reports.
The complete report can be downloaded from Helix Steel’s website here: https://www.helixsteel.com/pdfs/Helix-Steel-ICC-ES-Evaluation-Report-ESR-3949.pdf
“We are really excited to have worked with ICC-ES to make Helix® Micro Rebar™ reinforcement even more accessible to the residential construction community,” says Luke Pinkerton, president of Helix Steel. “This report truly solidifies Helix Steel as an American manufacturing company that is committed to innovation and leadership in providing safe, more efficient and sustainable options to the concrete industry.”
Learn more about Helix Steel, Helix® Micro Rebar™ reinforcement and Helix Steel’s commitment to quality by continuing to explore our website. To find out if your project is best suited with Helix® Micro Rebar™ reinforcement submit your confidential project details online.
Helix Steel is pleased to announce a new course, Alternative Concrete Reinforcement Materials, that is registered with AIA and RCEP for continuing education/professional development credit for civil and structural engineers and architects. The course is hosted by Ron Blank & Associates and can be accessed through this link.
- Course title: Alternative Concrete Reinforcement Materials
- Course Number: HEL03A (AIA); 164029 (RCEP)
- Course Credit: 1 AIA LU/HSW CE Hour. 1 RCEP PDH
Course Description:
Navigating through building codes can sometimes be a challenge for even the seasoned professional at times. Join us in this hour course as we focus on how performance-based building codes are developed. Design professionals will learn how alternative allowances are there to help keep the door open for innovation in the marketplace. Innovation in terms of structural and another area, such as fire, where performance-based design and alternative methods are routinely used. We will also examine how that alternative process of code allowance is incorporated, while focusing on the subject of concrete reinforcement; and lastly, it is our hope that you will grasp a better understanding of the process for your next project.
Learning Objectives:
- Identify how building codes effect innovation in the space of concrete construction.
- Define and implement the code process in order to meet performance standards and show how these codes provide ways to meet the performance standards through innovation and technology. This will also include alternative allowances that are in the codes.
- Explain the purpose of ISO evaluation reports, such as ICC and IAPMO which are used to demonstrate compliance for these bodies in certifying products, processes that are not necessarily spelled out in the building codes.
- Examine applications through examples of how this process is implemented to provide value by analyzing at several different projects.