Morningstar Storage Facility | Fiber Reinforced Concrete Flooring Project
BarChip reduced the carbon footprint of reinforcement by 75% and eliminated 2 days of steel installation.
Located in Huntersville, North Carolina, the new Morningstar Storage Facility utilised BarChip MQ58 macro synthetic fiber reinforcement in a 10-inch monolithic concrete slab. By replacing a traditional #5 rebar mat, the project reduced the reinforcement carbon footprint by approximately 75% and eliminated two days of steel installation while maintaining the performance requirements of the slab. Morningstar Storage demonstrates how macro synthetic fiber reinforcement can be successfully used in large scale industrial flooring applications.
Project Facts
Location: Huntersville, North Carolina, USA
Application: Industrial Flooring
Concrete Volume: 1,470 yd³
Mix Design: 4000 psi normal weight non air
Slab Thickness: 10 inches
Original Reinforcement: #5 rebar at 12 inches on center
Fiber Reinforcement: BarChip MQ58 @ 7 lbs/yd³
Steel Replaced: 37,000 lbs
Carbon Reduction: Approximately 75%
Placement Method: Telebelt Truck
Contractor: Concrete Supply Co.
Replacing Traditional Steel Reinforcement
The original design specified a #5 rebar mat at 12 inches on center. This was changed to a BarChip reinforced design using MQ58 at a dosage rate of 7 lbs/yd³. In total, approximately 10,000 lbs of BarChip MQ58 replaced 37,000 lbs of steel reinforcement while maintaining the structural performance requirements of the slab.
To support the large concrete placement, two ready-mix plants supplied the project. Quality control managers from each plant, together with two BarChip technical representatives, oversaw batching and fiber mixing procedures to ensure consistency throughout the pour. Fibers were added at the wash rack after each truck was fully loaded and mixed on high speed to ensure complete dispersion.
Before dispatch, slump was confirmed at 6-inches and air content remained consistent with the non air-entrained target of approximately 1.5%.
Faster Construction and Reduced Labor
One of the key advantages delivered by BarChip MQ58 was the elimination of steel placement activities prior to the concrete pour.
By removing the specified rebar mat, the project eliminated two full days of steel placement by two eight-man crews, reducing labor and accelerating the construction schedule.
At the site, concrete was discharged onto two telebelt trucks to distribute material efficiently across the slab area. This setup supported continuous placement, reduced pour time and helped prevent cold joints or delays in finishing operations.
The simplified reinforcement system reduced site congestion and allowed crews to focus on efficient concrete placement and finishing.
Lower Carbon Footprint
Replacing 37,000 lbs of steel reinforcement with 10,000 lbs of BarChip MQ58 reduced the embodied carbon of the reinforcement by approximately 75%. Learn more about the role of macro synthetic fiber in low carbon concrete reinforcement.
In addition to reducing steel consumption, the project benefited from lower transportation requirements and reduced material handling activities associated with traditional reinforcement systems. The result was a more efficient and sustainable construction process without compromising performance.
The Morningstar Storage Facility demonstrates how macro synthetic fiber reinforcement can help project teams reduce both carbon emissions and construction complexity while maintaining the structural requirements of industrial flooring applications.
Durable Industrial Flooring Performance
Once placed, the finishing crew began screeding and power troweling operations. The MQ58 fibers behaved as expected, working smoothly into the surface paste to produce a clean, fiber free finish.
The completed floor delivered the durability required for a modern storage facility while eliminating the challenges associated with traditional steel reinforcement. With proper batching controls and quality oversight, the project demonstrated that macro synthetic fiber reinforced concrete can provide performance and finish quality equal to, or better than, conventional steel reinforced construction.
Morningstar Storage remains a strong example of how BarChip MQ58 can combine structural performance, construction efficiency, labor savings and sustainability benefits in a large-scale industrial flooring project.
