Startseite Production of novel reinforcing rods of waste polyester, polypropylene, and cotton as alternatives to reinforcement steel rods
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Production of novel reinforcing rods of waste polyester, polypropylene, and cotton as alternatives to reinforcement steel rods

  • Abdeliazim Mustafa Mohamed EMAIL logo , Bassam A. Tayeh , Yazan Issa Abu Aisheh und F. Alqurashi
Veröffentlicht/Copyright: 12. November 2025
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Abstract

This study investigates the development of novel reinforcing rods produced from waste polyester, polypropylene, and cotton ropes treated with epoxy resin, as a sustainable alternative to conventional steel reinforcement. Compared with steel bars, the treated ropes (TR) provide several advantages, including light weight, low cost, corrosion resistance, ease of application, and alignment with sustainable development goals. Experimental testing was carried out to evaluate their physical, mechanical, and durability properties. The results showed that the bond strengths of polyester, polypropylene, and cotton ropes were lower than those of steel rods by 63.3, 69.0, and 76.1%, respectively; however, the ropes exhibited comparable elongation capacity, zero water absorption after epoxy treatment (except cotton), and superior resistance to corrosion and alkali attack. The performance mechanisms were analyzed, revealing that rope failure was governed primarily by tensile rupture rather than debonding, indicating higher rope strength relative to bond capacity with concrete. Furthermore, empirical models were proposed to predict the stress–strain and bond behavior of the TR. These findings confirm that although the tensile and bonding capacities of the ropes remain lower than steel, their environmental benefits, corrosion resistance, and cost-effectiveness make them promising candidates for eco-friendly reinforcement solutions in certain structural applications.

1 Introduction

Changes in usage and load requirements necessitate reinforcing existing concrete structures [1,2]. Various strategies for strengthening a specific structure or a portion of it have been successfully developed to date, depending on the type of construction and the situation [3,4]. In recent years, the employment of cement mortar, concrete, and steel confinement has received much attention [5,6]. Synthetic fiber-reinforced polymer (FRP) composites have emerged as a viable alternative to steel bars, plagued by issues such as the cumbersome handling of heavy steel bars, welding challenges, and corrosion. Over the past few decades, an alternative to steel has gained popularity as it offers improved strength, flexibility, and durability to reinforced concrete structures [7,8]. Polyester is very strong and has excellent abrasion resistance. It stretches much less than nylon but does not absorb shock like nylon; this makes polyester very popular for marine or industrial applications, where stretch is not desired. It is resistant to ultraviolet (UV) rays, rot, petroleum products, and most chemicals [9,10]. Ropes are distinguished by high axial strength and stiffness in proportion to their weight and low flexural stiffness [11,12,13]. A rope can be a critical load-carrying member in many engineering applications, including cranes, lifts, mine hoisting, bridges, cableways, electrical conductors, offshore mooring systems, and so on [14,15]. Synthetic fiber ropes have been proven to be the most acceptable substitute for steel wire ropes or chains in deep-water mooring applications over the past two decades due to their perceived cost, ease of handling, and ability to lower peak loadings compared to steel wire ropes or chains [16,17]. Polypropylene ropes have properties such as cohesiveness, freeze–thaw resistance, fire resistance, impact resistance, abrasion resistance, structural strength, and ductility. However, the effectiveness of polypropylene ropes is dependent on several factors, including fiber length, diameter, and the number of fibers [18,19]. Polypropylene ropes, textile fibers, marine ropes, and battery separators are used for molded items and films and have properties such as lightweight, hydrophobicity, and chemical resistance [20,21]. Cotton rope is a naturally occurring fiber that is usually white. Cotton cordage is soft and enjoyable to work with. It also knots well. A lightweight, cotton 3-strand rope is frequently used as a decorative item. It may be cultured and flame-proofed with ease. Cotton rope is slightly elastic due to its soft weave and is not usually used for lifting. It is, nevertheless, extremely easy to handle, making it a favorite among aerialists. Cotton ropes are still used on traditional small boats [22]. Cotton rope has a soft feel and was one of the first fibers used in horse rope goods despite its lower strength than other fibers [23,24]. Previous studies have explored the potential of using sprayed FRP to rehabilitate and strengthen concrete structures. The results indicated that the use of sprayed FRP composites is highly effective in enhancing the load capacity of members. Moreover, the use of the sprayed FRP method could serve as a promising alternative to conventional FRP strengthening methods [25,26,27]. Ropes possess several key characteristics, such as their easy availability, simple application, low cost, and environmentally friendly nature. It has been previously observed that dry vinylon and polypropylene fiber ropes are highly efficient for modifying the ultimate stress and strain of concrete [28,29]. Both studies [30,31] demonstrated that carbon fiber reinforced polymer (CFRP) ropes can effectively alter the load-carrying capacity and ultimate failure of strengthened concrete beams. This led to significant improvements in beam flexural and shear capacities, leading to enhanced structural performance and durability of reinforced concrete elements. Using epoxy-bonded synthetic CFRP ropes offers a simple and cost-effective way of strengthening the existing concrete structures, which can be used instead of traditional strengthening methods [32,33,34].

To better understand the role of FRP composites in structural strengthening, it is important to summarize their performance based on the type of fiber and resin system [35]. Different fibers, such as carbon, glass, aramid, and basalt, provide distinct balances of strength, stiffness, fatigue resistance, durability, and cost [36]. Likewise, the selection of resin (epoxy, polyester, or vinyl ester) influences the bonding efficiency, environmental resistance, and overall performance of the composite. A concise overview of their comparative characteristics is presented in Tables 1 and 2, which highlight the advantages and limitations of each combination in relation to structural applications.

Table 1

Summary of fiber- and resin-based FRP composite properties and advantages

FRP type Mechanical properties Fatigue and durability Key advantages Ref.
CFRP (carbon fiber) Very high tensile strength and stiffness; excellent strength-to-weight ratio Excellent fatigue resistance; durable in aggressive environments Superior structural performance; ideal for flexural and shear strengthening [37]
GFRP (glass fiber) Moderate tensile strength and stiffness; lightweight Good corrosion resistance, but moderate fatigue performance Cost-effective; easy handling; non-magnetic; widely used in infrastructure [38]
AFRP (Aramid fiber) High tensile strength; good impact resistance Excellent fatigue durability but sensitive to UV/moisture Good toughness; suitable for dynamic/impact-prone structures [39]
BFRP (Basalt fiber) Strength higher than GFRP but lower than CFRP; good stiffness Excellent chemical resistance; stable at high temperatures Eco-friendly, cost-efficient, and sustainable alternative [40]
Table 2

Common resin systems in FRP composites

Resin type Properties Cost Advantages Ref.
Epoxy Excellent adhesion, mechanical strength, and moisture resistance High Best performance for structural strengthening [41]
Polyester Adequate strength; lower chemical resistance Low Economical and widely available [42]
Vinyl ester Good chemical resistance; balance of strength and cost Moderate Resistant to alkaline and acidic environments; good compromise option [43]

In addition to conventional FRP composites, waste-derived fiber ropes such as polyester, polypropylene, and cotton have attracted attention for their potential in sustainable reinforcement applications. Their effectiveness depends largely on their mechanical, physical, and durability properties. Polyester ropes exhibit high tensile strength, chemical resistance, and long-term durability under marine or industrial environments [44]. Polypropylene ropes, while lightweight and hydrophobic with good freeze–thaw resistance, are more sensitive to UV exposure and elevated temperatures [45]. Cotton ropes, though weaker and less durable than synthetic alternatives, offer good bonding behavior with cementitious matrices due to their hydrophilic and rough surface texture [46,47]. These findings from existing studies provide an important reference for assessing the feasibility of using these ropes, treated with epoxy resin, as novel reinforcing rods in concrete.

The current study evaluated whether polyester, polypropylene, or cotton ropes would replace steel bars since they possess high tensile strength but low weight, are easy to establish, do not rust or erode, and provide full reinforcement. This study mainly examines how polyester, polypropylene, and cotton ropes behave when cured with epoxy materials compared to steel bars.

2 Research novelty and significance

The novelty of this research lies in the development of epoxy-treated reinforcing rods produced from waste polyester, polypropylene, and cotton ropes as an innovative alternative to conventional steel reinforcement. Unlike previous studies that mainly focused on FRP composites or synthetic fibers, this work introduces recycled textile and polymer ropes into structural applications, directly addressing sustainability and circular economy principles. The study provides a comprehensive evaluation of the physical, mechanical, and durability properties of the treated ropes compared with steel rods, while also proposing new empirical models to predict their stress–strain behavior and bond performance. By combining experimental validation with the use of recycled materials, this research contributes to advancing eco-friendly construction solutions that align with the sustainable development goals of the United Nations, offering both engineering feasibility and significant environmental benefits.

This study presents experimental findings on the use of ropes as a potential alternative to conventional construction steel bars. The study examines the ropes’ physical, mechanical, and durability properties; see Figure 1. It aims to produce novel bars that match the strength and other properties of traditional steel bars while also being cost-effective. Additionally, in this study, the results are compared with those of previous research conducted by different researchers.

Figure 1 
               (a) Mix preparation, (b) processing, and (c) ropes after processing (layer of protection and strength).
Figure 1

(a) Mix preparation, (b) processing, and (c) ropes after processing (layer of protection and strength).

3 Experimental work

A group of destructive tests was carried out on ropes to show the performance of these novel bars, and the tests were compared with control bars (Steel Bars).

3.1 Polyester, polypropylene, and cotton fiber

Polyester, polypropylene, and cotton ropes are lightweight and have high tensile bearing capacity, in addition to their low cost compared to other substitutes. This experimental study demonstrates the properties of ropes; see Figure 2. Polyester, polypropylene, and cotton ropes brought locally were used. In the textile consolidation fund (Alexandria), they had these necessary tests: First, the humidity content of the instrument is illustrated in Figure 3 and Table 3. Second, the Pressley tester measures fiber tensile strength, as shown in Figure 4.

Figure 2 
                  Polyester, polypropylene, and cotton ropes.
Figure 2

Polyester, polypropylene, and cotton ropes.

Figure 3
                
                  (Libeccio) semiautomatic regains cabinet code 245B.
Figure 3

(Libeccio) semiautomatic regains cabinet code 245B.

Table 3

Humidity content, breaking strength, elongation, and structures of polyester, polypropylene, and cotton fibers

No. Test Standard specifications Sample Note
Polyester Polypropylene Cotton
1 Humidity content% ASTM-D 2495 0 0 7.8 Temperature, 20°C; relative humidity, 65%
2 Elongation% (Pressley Tester) ASTM-D 1445 12:18% 13–17% 10% Temperature. 20°C; relative humidity, 65%
3 Rope structure BS EN ISO 1181:2004 3 strand laid (twisted)
4 Number of ends/strand 18
5 Level of twist 50 turns/m
Figure 4 
                  Pressley tester – code 231 A.
Figure 4

Pressley tester – code 231 A.

3.2 Characterization of bars after processing

Ropes of polyester, polypropylene, and cotton, with a diameter of 16 mm, are the most available in the market; fibers in the form of ropes were processed by good tightness and then rubbed with kemapoxy 150 to ensure the bar’s intransigence. It is easy to handle fibers such as steel bars. This type of rope was compared with indented steel (highly resistant), as there is the indentation on the ropes. It is normally used in reinforcing elements of concrete. The structures of polyester, polypropylene, and cotton ropes are shown in Table 4.

Table 4

Technical data for kemapoxy 150f

No. Characteristics Value
1 Density (at 25°C) 1.32 ± 0.02 kg/1
2 Mixing ratio (a:b) by weight 2:1
3 Pot life (at 25°C) 2 h
4 Initial setting time (at 25°C) 3–4 h
5 Final setting time (at 25°C) 24 h
6 Full hardness (at 25°C) 7 days
7 Min application temperature 15°C
8 Compressive strength ≥400 kg·cm−2
9 Heat resistance Up to 250°C

3.3 Processing of ropes

A substance that makes fiber ropes strong and intransigent was used in processing fibers. The ropes were first cleaned and dried to remove any surface impurities. The epoxy resin was then applied using a controlled brushing and impregnation method, ensuring that the resin penetrated uniformly into the interstices of the rope strands. To enhance uniformity, the impregnated ropes were gently rotated and passed through rollers to remove excess resin and achieve even distribution along the fibers. Finally, the ropes were cured under controlled temperature and humidity conditions to facilitate complete resin polymerization and strong bonding with the fibers. This stepwise process ensures that the epoxy resin is evenly processed across the rope fibers, improving mechanical performance and durability. The ropes were rubbed with kimapoxy 150f. After rubbing, fibers were tied from both sides to dry and to avoid bending or deflection. Then, the ropes became stubborn, hard, and strong. Table 4 shows the features of the rubbing substance, the processing stage, and the epoxy resin matrix (kemapoxy 150). Ropes were dried and primarily intransigent after 24 h, but final intransigence occurred after 7 days, when ropes were extremely strong and stubborn.

3.4 Experimental tests

The testing procedures for the novel reinforcing rods are discussed in the following sections.

3.4.1 Physical tests

Standard ASTM-D 1445 was used to perform the physical tests on the reinforcing rods. This would test properties like high temperature, working limit, electrical conductivity, etc.

3.4.2 Mechanical tests

Bond and tensile strengths were tested according to standard ESS 4756-1/2007. This measures how well the rebar bonds to the concrete and determines the maximum stress the rebar can withstand before failure. Water absorption testing was performed to determine the amount of water the rebar can absorb, which can impact corrosion resistance. Elongation percentage was measured to evaluate ductility according to the standard ASTM-D 1445.

3.4.3 Durability tests

Durability properties, including absorption of shock loads, acid exposure, alkali exposure, abrasion resistance, and aging resistance, were evaluated. Specifically, for acid and alkali resistance tests, the rope specimens were immersed in 5% H2SO4 and 5% NaOH solutions, respectively, for a period of 30 days at room temperature (25 ± 2°C). For abrasion resistance, a standard abrasion wheel method was adopted, and the test was conducted under ambient laboratory conditions. For aging resistance, the specimens were exposed to continuous UV radiation and elevated temperature (60 ± 2°C) for 15 days in an accelerated weathering chamber. Shock load absorption tests were performed under repeated impact loading using a drop-weight setup, and the response was recorded until failure.

In summary, comprehensive testing was performed using relevant standards to evaluate the novel reinforcing rods’ physical, mechanical, and durability properties. This is essential to determine their suitability and performance for structural use; see Eq. (1) and Figures 5 and 6:

(1) T b = F / π d L ,

where Ƭ b is the bond stress (MPa), F is the pullout force (N), L is the embedded length (mm), and d is the bar diameter (mm).

Figure 5 
                     Machine bending on the cold.
Figure 5

Machine bending on the cold.

Figure 6 
                     Tensile strength machine.
Figure 6

Tensile strength machine.

4 Results and discussion

The results of the polyester, polypropylene, and cotton ropes in terms of physical, mechanical, and durability properties were studied. The high- and low-temperature working limits of the polyester, polypropylene, and cotton ropes were determined based on data provided in Material Property Handbooks and relevant manufacturer’s specifications, which define the safe service temperature range where the ropes retain their mechanical integrity without significant loss of strength or brittleness. Tables 57 present the results obtained from the experiments.

Table 5

Physical properties of reinforcement steel rods (RSR), polyester rope, polypropylene rope, and cotton rope

No. Properties RSR Polyester Polypropylene Cotton
1 High-temperature working limit 1,500°C 150°C 65°C 150°C
2 Low-temperature working limit 250°C −22°C −71°C −38.8°C
3 Melting point 1,538°C 262°C 172°C NA
4 Electrical conductivity resistance Good Good Good Poor
5 Storage requirements Dry only Wet or dry Wet or dry Dry only
Table 6

Mechanical properties of RSR, polyester rope, polypropylene rope, and cotton rope

No. Properties RSR Polyester Polypro-pylene Cotton
1 Bond strength Stresses (MPa) 7.1 2.6 2.2 1.7
2 Mode of failure Splitting Cut Cut Cut
3 Cold bending Excellent Very good Very good Good
4 Tensile strength Yield stresses (MPa) 43.7
5 Maximum stresses 59.0 15.03 13.23 12.74
6
7 Water absorption Zero Zero Zero Zero
8 Elongation (%) 20 (high tensile steel) 18 16 11
Table 7

Durability properties for RSR, polyester rope, polypropylene rope, and cotton rope

No. Properties RSR Polyester Polypropylene Cotton
1 Absorption of shock loads Excellent Good Very good Very poor
2 Acid exposure Affected Most mineral acids resist it, but it is decomposed by 95% percent sulfuric acid. Very resistant In hot dilute and cold concentrates, it disintegrates
3 Alkali exposure Affected Cold has little impact; powerful alkalis slowly destroy it at boiling point Very resistant When exposed, it weakens
4 Abrasion resistance Good Very good Good Good
5 Aging resistance Excellent Excellent Moderate Good

4.1 Physical properties

The physical properties of RSR, polyester ropes, polypropylene rope, and cotton rope are shown in Table 7. First, the high-temperature working limit of the RSR and ropes was studied, which were 200, 150, 65, and 150°C for RSR, polyester ropes, polypropylene rope, and cotton, respectively. It is shown that polyester and cotton had the same results, and RSR recorded the highest temperature, while polypropylene recorded the lowest temperature. This indicates that the properties of cotton and polyester are as close as possible to those of RSR. Second, the study of the low-temperature working limit were 45, −22, −71, and −38.8°C for RSR, polyester ropes, polypropylene rope, and cotton, respectively. From this, it was clear that the RSR were the highest, while the ropes were below zero. On the other hand, RSR recorded the highest melting point because it is a metal, followed by polyester and polypropylene. As cotton is a fiber, they have no melting point [9,22,48].

Electrical conductivity resistance was good for all rods and ropes, but cotton recorded poor resistance. Finally, storage requirements were wet or dry for polyester and polypropylene; in contrast, RSR and cotton were dry only. This is because polyester and polypropylene can withstand drought and moisture, which are good properties. As for the reinforcement steel, it must be dried to prevent rust, and the cotton must be dried to avoid rotting [49,50,51,52].

4.2 Mechanical properties

A bond strength test was conducted on cylinder samples (15 × 30 cm) after 28 days to ensure cohesiveness and bond strength between ropes and concrete; see Figure 7. When the tests were conducted, the ropes (polyester, polypropylene, and cotton) did not split during the test; however, they were cut, which displays these samples loaded on the machine after 28 days.

Figure 7 
                  Bond strength test.
Figure 7

Bond strength test.

Table 8 shows the bond strength of RSR, which is higher than that of polyester, polypropylene, and cotton ropes. The bond strengths for RSR, polyester, polypropylene, and cotton were 7.1, 2.6, 2.2, and 1.7 MPa, respectively. The bond strengths of polyester, polypropylene, and cotton ropes were lower than those of RSR by 63.3, 69.0, and 76.1%, respectively; this behavior is consistent with that observed in the literature [53,54,55,56].

Table 8

Costs of RSR, polyester rope, polypropylene rope, and cotton rope

e Shape Diameterᴓ (mm) Length of bars (m) Number of bars for 1 ton Weight of bars (kg) Weight of bar of 12 m (kg) Cost of tone (USD)
RSR (Control)
16 12 53 1.579 18.95 806
Polyester Before processing
16 12 14,286 0.070 8.4 59
After processing
16 12 8,334 0.120 14.40 84
Polypropylene Before processing
16 12 15,385 0.065 7.80 55
After processing
16 12 7,143 0.140 16.80 80
Cotton Before processing
16 12 13,334 0.075 9.0 63
After processing
16 12 6,452 0.155 18.6 88

The fact that the ropes were cut rather than rebounded from the concrete indicates that the ropes’ strength is greater than the bond strength between the ropes and the concrete. Therefore, this test method was unsuitable for determining the actual bond strength. To effectively improve the rope–concrete bonding performance in future applications, several approaches can be considered: (i) applying surface treatments such as epoxy impregnation, resin coating, or roughening to increase adhesion; (ii) chemical modification of rope fibers to improve compatibility with cementitious matrices; and (iii) using alternative test methods (e.g., pull-out tests with end anchorage or embedded length adjustment) that prevent premature rope failure and allow for a more reliable assessment of interfacial bonding.

  1. The following key factors have to be considered:

  • The ropes (polyester, polypropylene, and cotton) are likely considerably stronger than the bond between the ropes and concrete. These ropes can withstand high tensile loads before failure.

  • Cutting the ropes in the test never exceeded the actual bond strength between the ropes and concrete. The ropes failed in tension before any debonding could occur.

  • Other test methods are needed to determine the bond strength.

The test of bending in cold was conducted on RSR, polyester rope, polypropylene rope, and cotton rope, as shown in Figure 8. The results of this test do not yield a value but provide in terms of the bending shapes of the samples. After the test, it was noted that the cohesive samples were together and not unassembled in the test area after exposure to bending in cold, as shown in Figure 8. This test was conducted on the three samples of the bars, and the length of the sample was 1,000 mm; the bending on the cold test was carried out according to the American Code ACI 318M-2019 [57,58].

Figure 8 
                  (a) Before and (b) after bending.
Figure 8

(a) Before and (b) after bending.

Samples were tightened on the steel tension machine, as shown in Figure 8, and the results are shown in Table 8. A problem encountered was that the samples were not stable or held firmly on the machine. The ropes can be used at a higher tension capacity, but the machine test could not show this force. Because of the ductility of ropes and the large elongation during the test process, rope breaking load can be calculated from the following equation:

(2) σ t = ρ l × T f × η ,

where σ t is the tensile strength of the ropes (MPa), ρ l is the linear density of the rope (kg·m−1), T f is the fiber tenacity (N/tex), and η is the strength conversion efficiency (dimensionless fraction).

Table 8 shows the results for RSR, polyester rope, polypropylene rope, and cotton rope, which were 43.7, 15.03, 13.23, and 12.74, respectively. From the results, the RSR sample had a higher value, followed by the polyester sample, and the polypropylene and cotton samples converged. The tensile strength was measured according to American Code ACI 318M-2019 [58,59].

Water absorption was zero for all samples because the processing material protects against water for liquids [60,61]. The elongation values were convergent to all samples; the RSR sample exhibited the highest value by 20% and the cotton sample the lowest value by 11% [16,62].

4.3 Durability properties

4.3.1 Absorption of shock loads

Table 7 suggests that the mechanical energy absorption capacity of reinforcement materials is closely related to their fiber morphology, tensile strength, and deformation behavior under impact or shock loading. In our study, the observed ranking for shock load absorption was steel rods > polypropylene ropes > cotton ropes > polyester ropes, which aligns with expectations based on their intrinsic material properties. Steel reinforcement is specifically designed for concrete reinforcement, offering high tensile strength and durability. It is an excellent choice for resisting shock loads in concrete [63,64].

Steel reinforcement rods exhibit the highest energy absorption due to their high tensile strength, ductility, and ability to undergo plastic deformation before failure. This enables them to dissipate large amounts of energy under sudden loads, making them highly suitable for structural reinforcement in concrete. Polypropylene is a tough, durable plastic that can withstand some impact and shock loading, though not at the same level as steel. A “good” rating seems appropriate.

Cotton ropes, being natural fibers, demonstrate moderate energy absorption. Although cotton fibers have relatively lower tensile strength than synthetic fibers, their hierarchical fiber structure provides some capacity to deform and dissipate energy under shock loading [65]. A “very good” rating indicates they provide decent durability while still being lower than steel or polypropylene.

Polyester ropes showed the lowest shock absorption in our tests. Despite having high tensile strength, polyester fibers are relatively stiff and exhibit lower elongation at break than polypropylene, which limits their ability to absorb mechanical energy during impact. The compact, less deformable fiber morphology reduces inter-fiber load redistribution, resulting in early localized damage under repeated shock loads.

In summary, the relative ratings in Table 7 match expectations for the durability and resistance to shock loads of these common reinforcement materials, with steel reinforcement providing the highest durability, followed by polypropylene, cotton, and polyester ropes. The test results confirm steel reinforcement is the best choice when high durability and resistance to impact loads are required in concrete reinforcement applications.

4.3.2 Alkali exposure

Steel reinforcement is likely more susceptible to corrosion from acids and alkalis than rope samples. Steel does not have inherent chemical resistance and relies on concrete to provide a protective environment. However, acids and alkalis can permeate the concrete and corrode the steel over time [60,66]. Polypropylene and polyester ropes, being synthetic polymers, possess excellent inherent chemical resistance to alkaline environments [67]. Their molecular chains are stable under high-pH conditions and they do not react chemically with hydroxide ions present in concrete. As a result, these ropes maintain their structural integrity, tensile strength, and flexibility over extended periods, making them suitable for use in alkaline concrete matrices.

Cotton ropes, as natural cellulose-based fibers, are significantly more vulnerable to alkaline attack. The hydroxide ions in the concrete can hydrolyze the glycosidic bonds in cellulose, leading to fiber swelling, weakening, and gradual loss of tensile capacity [68]. Prolonged exposure to high-pH environments accelerates this degradation, which can compromise the mechanical performance of cotton ropes in concrete reinforcement applications.

In summary, the differences in alkali resistance among steel, synthetic, and natural fiber ropes highlight the critical role of chemical stability in durability. While steel requires sufficient concrete cover for protection, cotton is prone to degradation. In contrast, synthetic ropes such as polypropylene and polyester provide superior performance in alkaline environments, combining chemical resistance with mechanical durability.

4.3.3 Abrasion resistance

All the reinforcement materials appear to provide acceptable abrasion resistance for use in concrete, although this may vary to some degree. The properties of the individual materials will influence their abrasion resistance [69,70,71]. The abrasion resistance of reinforcement materials is strongly influenced by fiber composition, surface roughness, and inter-fiber bonding within the rope structure. Steel reinforcement rods exhibit excellent abrasion resistance due to their high hardness, continuous metallic surface, and resistance to wear under frictional contact with concrete aggregates. They maintain structural integrity even under repeated mechanical action.

Polypropylene ropes demonstrate moderate abrasion resistance. Their synthetic polymer filaments are relatively tough and flexible, allowing them to withstand surface wear without immediate failure. The braided structure of the rope helps distribute localized frictional forces among multiple filaments, reducing the rate of fiber degradation. However, prolonged exposure to rough concrete surfaces may lead to surface fibrillation or fiber fraying over time.

Cotton ropes, composed of natural cellulose fibers, show intermediate abrasion resistance. While cotton fibers can absorb energy and deform under friction, their softer surface and weaker inter-fiber bonding make them more prone to wear and gradual thinning of individual strands under repeated contact with rough surfaces. On the other hand, polyester ropes exhibit higher initial tensile strength but relatively lower abrasion resistance compared to polypropylene. The stiffer, less deformable fiber structure of polyester limits its ability to redistribute frictional stress among filaments, which can lead to localized fiber wear. Surface roughness and compact fiber packing in polyester ropes can accelerate micro-abrasion under repeated mechanical loading.

4.3.4 Aging resistance

Steel reinforcement generally provides the longest service life and best-aging resistance due to its high strength and durability. However, adequate concrete cover is required to protect it from corrosion. Polyester ropes may offer aging resistance comparable to that of steel reinforcement, due to the high strength and durability of modern polyester fibers. However, polyester will still degrade faster over time in a concrete environment.

The aging resistance of reinforcement materials is influenced by their chemical composition, environmental exposure, and fiber morphology. Steel reinforcement rods generally provide the longest service life due to their high strength and toughness; however, they rely on adequate concrete cover to prevent corrosion. Exposure to moisture, chlorides, or carbonation can gradually compromise steel, leading to a reduction in mechanical performance over time.

Polyester ropes demonstrate relatively superior aging resistance among the rope materials tested. This is due to the high chemical stability of polyester polymers, which exhibit strong resistance to hydrolytic degradation, thermal stress, and UV radiation. The tightly packed filament structure and inherent hydrophobicity of polyester fibers reduce moisture uptake and prevent significant loss of tensile strength over prolonged exposure to environmental stressors.

Polypropylene ropes show moderate aging resistance. Although polypropylene is chemically stable and hydrophobic, it is more sensitive to UV radiation and high temperatures compared to polyester. Prolonged exposure can lead to surface embrittlement, micro-cracking, or a gradual reduction in tensile performance, limiting its long-term durability in outdoor or exposed concrete applications.

Cotton ropes, being natural cellulose fibers, are most vulnerable to aging. They are susceptible to hydrolysis, thermal degradation, and microbial attack, especially under conditions of high moisture and temperature. UV exposure accelerates cellulose breakdown, resulting in decreased fiber strength and flexibility over time.

In summary, RSR has some disadvantages related to chemical resistance but provides the best overall durability and aging resistance due to its high strength and toughness. Polyester ropes offer better-aging resistance than the cotton and polypropylene samples, though still not at the level of steel reinforcement [9,72,73].

5 Comparison of the cost between RSR, polyester rope, polypropylene rope, and cotton rope

As shown in Table 8, before processing, the polyester ropes were reduced in cost by 99.93%, the polypropylene rope by 99.92%, and the cotton rope by 92.7% of the control (RSR). On the other hand, after processing, the cost of the cotton ropes was reduced by 99.9%, the polyester rope by 99.01%, and finally, the polypropylene rope by 90.06% of the control (RSR).

When comparing the cost with other characteristics, it was found that polyester ropes are the best type, followed by polypropylene ropes and cotton ropes [56,74,75].

6 Conclusion

  1. Polyester ropes exhibited physical properties comparable to steel reinforcement, with the exception of electrical conductivity. However, the bond strengths of polyester, polypropylene, and cotton ropes were lower than those of steel reinforcement rods by 63.3, 69.0, and 76.1%, respectively.

  2. Samples remained cohesive and intact during cold bending tests. Steel reinforcement rods (RSR) demonstrated the highest tensile strength, followed by polyester ropes, with polypropylene and cotton ropes showing similar but lower performance.

  3. All treated samples displayed zero water absorption, except for cotton ropes, which exhibited 100% liquid absorbency due to their inherent material characteristics.

  4. The elongation values across all samples were comparable, with steel reinforcement rods showing the highest elongation at 20%, while cotton ropes had the lowest at 11%. Polyester and polypropylene ropes exhibited intermediate elongation values.

  5. Steel reinforcement rods showed greater susceptibility to acids and alkalis compared to the ropes. However, all tested materials exhibited acceptable abrasion resistance.

  6. Steel reinforcement rods demonstrated the longest service life and superior aging resistance compared to the alternative materials, while polyester ropes showed moderate durability over time.

Acknowledgments

The authors extend their appreciation to Prince Sattam bin Abdulaziz University for funding this research ( project number PSAU/2025/01/33470).

  1. Funding information: This study was supported by a research fund from Prince Sattam bin Abdulaziz University, 2025.

  2. Author contributions: All authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  3. Conflict of interest: The authors state no conflict of interest.

  4. Data availability statement: The datasets generated and/or analyzed during the current study are available from the corresponding author on reasonable request.

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Received: 2025-05-15
Revised: 2025-09-03
Accepted: 2025-09-27
Published Online: 2025-11-12

© 2025 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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