Does Polypropylene Fiber Replace Welded Wire Mesh?

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Why Wire Mesh Is Commonly Used

Welded wire mesh (WWM) has long been used as a secondary reinforcement material in concrete slabs and pavements. Its primary function is to hold cracks together once they occur (post-crack crack-width control), and to help maintain slab integrity during loading, curling, and temperature movement.

Mesh provides a predictable level of residual strength—but only when it is correctly positioned at the mid-depth of the slab. In practice, however, mesh is often misplaced or left on the ground due to construction constraints, reducing its intended structural effectiveness.

Microfibers vs Mesh: What Each Controls

Monofilament polypropylene microfibers, such as HPM® PP, work very differently from welded wire mesh.

Microfibers primarily control:

• Plastic shrinkage cracking (first 24 hours)

• Plastic settlement cracking

• Early-age surface defects

• Bleeding and segregation

• Durability of the slab surface

They create a 3D micro-reinforcement network that bridges microcracks before they grow, reducing early-age cracking by 60–90% depending on dosage.

Wire mesh controls:

• Crack-width control after cracks form

• Temperature and drying shrinkage (long-term)

• Structural integrity under load

• Slab restraint and fatigue performance

Conclusion: Microfibers prevent cracks.Mesh controls cracks after they exist.

When Polypropylene Fiber Replaces Welded Wire Mesh

Polypropylene microfibers can replace wire mesh when the reinforcement requirement is non-structural, primarily targeting plastic shrinkage and surface durability.

PP fibers replace mesh in:

• Residential slabs-on-ground

• Sidewalks, driveways, patios

• Light commercial slabs

• Toppings & overlays

• Thin pavement sections

• Mortar, plaster & rendering

• Fiber-reinforced screeds

• Precast elements where mesh is only for early crack control

Reasons PP fiber can replace mesh in these cases:

• Fibers do not require precise placement

• Fibers disperse uniformly throughout the slab

• They reduce labor, time, and safety risks

• The required function is early-age crack control—not structural load transfer

For these applications, HPM® PP at 0.6–1.2 kg/m³ provides better crack control than wire mesh, at significantly lower installed cost.

When Mesh Is Still Required

Welded wire mesh is still needed when structural reinforcement is required and crack control is not the only consideration.

Mesh remains necessary in:

• Heavy-duty industrial floors

• High load-transfer sections

• Structural slabs with bending requirements

• Elevated slabs

• Pavements with heavy traffic or axle loads

• Projects referencing mesh within design codes

• Designs needing specific post-crack residual strength

PP microfibers cannot replace mesh for:

• Flexural capacity

• Moment resistance

• Load redistribution

• Structural crack-width control

In these cases, PP fibers serve as an addition to mesh—not a substitute.

Combined Use in Industrial Floors

In medium- and heavy-duty industrial floors, the best strategy is often to use both PP microfibers and wire mesh:

✔ Microfibers prevent early-age cracks

✔ Mesh maintains post-crack capacity

This combined system improves slab durability, reduces curling-related issues, and enhances long-term performance under forklift or warehouse loading.

For large logistic centers and industrial platforms, some engineers now replace mesh entirely with macro synthetic fibers, depending on load class and design. However, micro PP fibers alone are not a structural substitute.

Learn more about HPM® PP polypropylene microfiber 

See all micro synthetic fiber types

Compare with macro synthetic fibers

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