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 (Taichung City, Taiwan) unveils ExCfiber, a modified recycled carbon fiber (rCF) designed specifically to reinforce cement and concrete. This material enhances structural durability, carbon reduction and life cycle efficiency for modern infrastructure and green construction.

ExCfiber is produced through Thermolysis’ patented microwave-assisted pyrolysis (MAP) process, which converts carbon fiber-reinforced polymer (CFRP) waste into high-purity carbon fiber with virgin-like mechanical properties. Unlike conventional recycled fibers that suffer from poor dispersion or residual resin, ExCfiber is reported to achieve clean surfaces (99.9% carbon by EDS) and optimal bonding with cement matrices after proprietary surface modification. The result is an easily dispersible reinforcement fiber that uniformly distributes throughout the cement, enhancing mechanical and structural performance.

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When added at only 1-2 wt% of cement weight, ExCfiber dramatically improves the performance of cementitious composites, Thermolysis cites, with +125% flexural strength, +60% compressive strength and +45.7% split tensile strength. It offers 30 times greater impact resistance at 50 J and 12 times greater improvement at 75 J (based on Thermolysis internal testing under ASTM C39, C393, C469 and ACI 544.2R-89). ExCfiber has also proven its blast resistance — concrete slabs with ExCfiber (12 mm/24 mm lengths) maintained integrity after exposure to 150G C4 explosive simulation.

Compared to traditional steel fibers, ExCfiber also delivers improved dispersion, no corrosion risk, 0.7% lower density impact and 40% longer service life, while reducing fiber cost per cubic meter by nearly 20%.

Beyond immediate performance gains, ExCfiber reinforces the microstructure of concrete, preventing water infiltration and corrosion initiation. Buildings and infrastructure using ExCfiber have shown fewer surface cracks, lower permeability and slower structural degradation, effectively doubling service life from 20 to 40 years (based on life cycle assessments/LCAs). This means less maintenance, fewer repair cycles and reduced total cost of ownership for both public and private projects.

ExCfiber has been successfully applied in multiple civil engineering and infrastructure projects, including:

• Tunnel and bridge deck reinforcement for the Highway Bureau (Fuhe Bridge project in Taiwan, Taipei)
• Seismic retrofitting and waterproofing of historic buildings and temple structures (Taiwan, Taipei)
• Blast-resistant concrete for military bunkers, chemical plants and government facilities (Taiwan)
• 3D printed concrete and precast elements for global cement manufacturers (Canada and Isarel).

Its excellent dispersion and easy mixing are ideal for both ready-mix and on-site construction.

As a 100% recycled fiber, ExCfiber also complies with UL 2809 and ISO 14067 standards for low-carbon materials. LCAs have shown ExCfiber-reinforced mortar emits only 0.98 kg CO_â‚‚/kg, roughly 40% less than steel-fiber mortar, while extending service life to 40 years.