To study the hybrid effects of polypropylene fiber and basalt fiber on the fracture toughness of concrete, 13 groups of notched concrete beam specimens with different fiber contents and mass ratios were prepared for the three-point bending test. Based on acoustic emission monitoring data, the initiation cracking load and instability load of each group of specimens were obtained, and the fracture toughness parameters were calculated according to the double-K fracture criterion. The test results show that the basalt fiber-reinforced concrete has a greater increase in initial fracture toughness, and the toughness of coarse polypropylene fiber-reinforced concrete is more unstable. Moreover, after the coarse polypropylene fiber content reaches 6 kg/m³ and the basalt fiber content reaches 3 kg/m³, increasing the content will not significantly improve the fracture toughness of the concrete. The polypropylene–basalt fiber will produce positive and negative effects when mixed, and the mass ratio of 2:1 was optimal. Finally, the fitting analysis revealed that the fracture process of polypropylene–basalt fiber-reinforced concrete (PBFRC) can be objectively described by the bilinear softening constitutive curve improved by Xu and Reinhardt.

To explore the effect of multi-scale polypropylene fiber (PPF) hybridization on the mechanical properties of roller-compacted concrete (RCC), the early-age (3, 7, 14, 28 days) compressive strength, splitting tensile strength and uniaxial tensile test of RCC reinforced with micro-, macro- and hybrid polypropylene fibers were investigated. Then, the tensile stress–strain curve of polypropylene fiber-reinforced roller-compacted concrete (PFRCC) and the corresponding tensile parameters were obtained. The uniaxial tensile constitutive equation of PFRCC and fiber hybrid effect function was also proposed. Finally, the enhancement mechanism of fiber hybridization on mechanical properties of RCC was analyzed. The results indicated that the strength and toughness of PFRCC improved with the incorporation of PPF, showing obvious plastic failure characteristics of PFRCC. Before curing the concrete for 7 days, micro-PPF played a major role in strengthening RCC, while macro-PPF played a major role in reinforcing concrete after that. Moreover, the tensile strength and toughness indexes of multi-scale PFRCC performed the best, indicating the positive hybridization of three types of PPF. The proposed PFRCC uniaxial tensile constitutive equation and fiber hybrid effect function based on existing researches were also well matched with the experimental results.

The bending performance of a basalt-polypropylene fiber-reinforced concrete (HBPFRC) was characterized by testing 24,400 × 100 × 100 mm³ prismatic specimens in a four-point bending test JSCE-SF4 configuration. The type and content of both fibers were varied in order to guarantee different target levels of post-cracking flexural performance. The results evidenced that mono-micro basalt fiber reinforced concrete (BFRC) allows the increase of the flexural strength (pre-cracking stage), while macro polypropylene fiber reinforced concrete (PPFRC) can effectively improve both bearing capacity and ductility of the composite for a wide crack width range. Compared with the plain concrete specimens, flexural toughness and equivalent flexural strength of macro PPFRC and the hybrid fiber-reinforced concrete (HFRC) increased by 3.7–7.1 times and 10–42.5%, respectively. From both technical and economic points of view, the optimal mass ratio of basalt fiber (BF) to polypropylene fiber (PPF) resulted in being 1:2, with a total content of 6 kg/m³. This HFRC is seen as a suitable material to be used in sewerage pipes where cracking control (crack formation and crack width control) is of paramount importance to guarantee the durability and functionality of the pipeline as well as the ductility of the system in case of local failures.

In order to explore the frost-resistance mechanism of multi-scale polypropylene-fibre-reinforced concrete (PFRC), the mass loss rate and relative dynamic elastic modulus variation curves of concretes made with different sizes of polypropylene (PP) fibre were analysed based on the fast freeze–thaw cycle test. Nuclear magnetic resonance testing and scanning electron microscopy were carried out to study the micropore structure of the PFRCs. The results showed that the multi-scale PFRC had excellent frost resistance. Compared with plain concrete, the concretes mixed with coarse and fine PP fibres showed a 0·242–0·427% improvement in porosity, with 75·68–84·00% of pores of radius less than 100 nm. When the total PP fibre content was held constant, but the amount of fine fibre was larger and the fibre diameter was smaller, the improvements in concrete micropore structure and spalling resistance were more obvious. For the multi-scale PFRCs studied, it was found that three sizes of fibres formed a better holistic network system as the fibres supported and complemented each other. The micropore structure and frost resistance of the concrete were improved significantly, while the cracking resistance and toughness of the specimens were adequate.