How-to Micro-Rebar - Precast Concrete Manufacturers’ Guide to Proactive Concrete Reinforcement - Helix Steel Article - Banner Image

How-to Micro-Rebar: Precast Concrete Manufacturers’ Guide to Proactive Concrete Reinforcement

Saving one to two days of production time may not seem like a lot, but when you consider that precasters can save up to two days every week, it’s a game changer. Helix® Micro Rebar has been able to deliver that and much more for the world’s precast operations.

Delivering a superior concrete product on time and on budget is crucial for the success of your precast business. Being able to deliver an excellent product while also reducing your time and overhead costs is practically unheard of – except for those who use Helix® Micro Rebar.

It’s not a cheap plastic fiber.

Helix® Micro Rebar is a patented one-inch twisted piece of steel that is incredibly strong, and can replace up to 100% of rebar in precast forms.

Mixed in your concrete prior to pouring, Helix® Micro Rebar forms with the concrete, proactively resisting cracks from forming in concrete, whether you are producing precast fences, septic tanks, suspended panels, pipes, concrete arches, storm shelters, wall panels, floor panels, burial vaults or even bank vaults.

Imagine reducing the time and energy required to assemble rebar cages. Now is the time to cut the rebar and mesh; it’s time for Helix® Micro Rebar

Why Helix® Micro Rebar Concrete Reinforcement Instead of Mesh & Rebar in Precast Production?

Labor and Space Savings

You need a large workshop to manufacture jigs and forms, install the rebar and maintain the rebar cages. Think of the space and materials this requires. Consider also the satisfaction of your crew, reducing manual labor and harm. 

For Helix Steel’s present precast customers, they have seen labor costs reduced by over 70%. For example, a precast vault that originally took 90 hours to produce can be done with Helix® Micro Rebar in only 25 hours – no backbreaking labor required. 

Engineering Support

Some of the most-asked questions regarding the use of Helix® Micro Rebar involves how to properly determine exact dosages. Fortunately, we do all of that hard work for you. Helix Steel’s in-house engineers have the engineering ready for precast applications across America and beyond. It is all done for you – and any new applications can be determined at no charge, all part of our commitment to you.

Concrete Performance Improvements

Precast concrete elements are known for their fast production speed, and with Helix® Micro Rebar precast is also given unparalleled strength and durability, setting your business apart from your precast competitors. Imagine a shear strength increase of over 450%; a modulus of rupture increase of over 25% and a durability increase of more than 60% increase. These are not just numbers; these are actual results experienced by precasters

Post-Construction Risk

With Helix® Micro Rebar’s higher strength and durability ratings, it can withstand more from external forces. From damaging water penetration to crack-inducing earthquakes to explosive blasts, concrete with proactive reinforcement can take a beating.

Helix® Micro RebarConcrete Reinforcement Mixing & Pouring for Precasters

1. Helix Mix Design and Slump Recommendations 

  • Refer to the Alternative Design solution for each precast element to confirm the MPa and the engineers’ notes for the slump requirements for each element. 
  • Water reducing admixture is to be used to achieve the specified slump levels (no additional water to be added).

2. Loading and Mixing Instructions 

This outline is applicable for a pan mixer or drum mixer.

  1. Set the mixer to the proper speed.
  2. Add Helix® Micro Rebar at a rate of 45–60 seconds per 45 lbs (20 kgs).
  3. Helix® Micro Rebar should be added with the aggregates.
  4. Mix at maximum speed for five minutes after Helix® Micro Rebar is added.

For all other loading and mixing scenarios, please visit our Dosing and Mixing page

3. Pouring Instructions 

Step 1. Assemble your moulds as you normally would.

Step 2. You may need to still install some rebar in vessel lids, but much of the remaining reinforcement can be accomplished by Helix® Micro Rebar. Be sure to contact Helix Steel to discuss your dosage requirements.

Step 3. Pump and finish as you normally would.

Make Your Precast Business Better with Proactive Concrete Reinforcement

This article is to just give you a taste of what your precast business can be transformed into. Take the next step and learn more. Reach out to the professional engineers here at Helix Steel to speak about your unique precast requirements