Mechanical and Durability Characterization of Hybrid Recycled Aggregate Concrete.

The recycling of construction and demolition waste (CDW) for the extraction of recycled concrete aggregates (RCAs) to be used to produce recycled aggregate concrete (RAC) is widely acknowledged internationally. However, CDW not only contains concrete debris but may also contain burnt clay bricks. The recycling of such CDW without the segregation of different components would result in recycled aggregates having different proportions of concrete and brick aggregates. The utilization of these aggregates in concrete requires a detailed investigation of their mechanical and durability properties. In this regard, the present study focused on investigating the mechanical and durability properties of hybrid recycled aggregate concrete (HRAC) made by the 100% replacing of natural aggregates with recycled brick (RBAs) and RCA in hybrid form. The partial replacement of cement with fly ash was also considered to reduce the corban footprint of concrete. An extensive experimental program was designed and carried out in two phases. In the first phase, a total of 48 concrete mixes containing coarse RBA and RCA in mono and hybrid forms were prepared and tested for their compressive strength. The test results indicated that the compressive strength of HRAC is greatly affected by the proportion of coarse RBA and RCA. In the second phase, based on the results of the first phase, eight concrete mixes with the most critical proportions of RBA and RCA in hybrid form were selected to evaluate their mechanical and durability performance. In addition, four mixes with natural aggregates were also prepared for comparison purposes. To evaluate the mechanical properties of the concrete mixes, compressive strength and modulus of rupture (MOR) tests were performed, while for the evaluation of durability properties, water absorption and behavior after exposure to aggressive conditions of acidic and brine solutions were studied. The results revealed that a 20% replacement of cement with fly ash resulted in acceptable mechanical and durability properties of HRAC intended to be used for making concrete bricks or pavers.

Development of Concrete Mixture for Spun-Cast Full-Scale Precast Concrete Pipes Incorporating Bundled Steel and Polypropylene Fibers.

Spin casting is the oldest method of manufacturing precast concrete pipes among all existing methods. While improved concrete mixtures incorporating fibers for other methods of concrete pipe manufacturing, such as the vibration method and roller compaction method, have been developed, no such concrete mixture has yet been developed for spun-cast concrete pipes. This study was designed to explore the possibility of incorporating locally manufactured steel fibers and commercially available polypropylene fibers to develop an improved concrete mixture for use in the manufacturing of full-scale spun-cast concrete pipes. The used steel fibers were of two types, i.e., straight and bundled steel fibers, manufactured by cutting locally available long straight and bundled steel wires, respectively. Various dosages of steel fibers (i.e., 20, 30, 40, and 50 kg/m3) and polypropylene fibers (i.e., 5, 10, 15, and 20 kg/m3) were used in mono and hybrid (steel and polypropylene) forms. The properties in the fresh state and mechanical properties of the test mixtures were investigated. Full-scale spun-cast concrete pipes having a 450 mm internal diameter were manufactured and tested using the three-edge bearing test. The compressive strength of the mixtures was largely insensitive to the dosage of the fibers. The splitting tensile strength of all fiber-reinforced concrete mixtures was higher than that of the reference mixture without fibers, with a 24% increase recorded for the concrete mixture incorporating 50 kg/m3 of bundled steel fibers relative to the reference mixture with no fibers. The flexural performance of the fiber-reinforced concrete mixtures was superior to that of the reference mixture without fibers in terms of flexural strength, toughness, residual strength, and crack control, with up to 28% higher flexural strength relative to the reference mixture without fibers. The three-edge bearing tests on full-scale spun-cast pipes incorporating steel fibers showed that the use of fibers is a promising alternative to the traditional steel cage in spun-cast concrete pipes.

Investigating the Behavior of Waste Alumina Powder and Nylon Fibers for Eco-Friendly Production of Self-Compacting Concrete.

Self-compacting concrete (SCC) incorporating secondary raw materials has been extensively used around the globe due to its improved fresh, mechanical and durability properties. This study was planned to evaluate the suitability of locally available waste alumina powder (AP) and nylon textile fibers (NF) as a partial replacement for fine and coarse aggregates with the ultimate goal to locally produce SCC with desired properties. The used AP was acquired from a local market and NF was collected from a local textile factory. Various dosages of AP (10%, 20%, 30%, 40% and 50% by volume of fine aggregates) and NF (1% and 2% by volume of coarse aggregates) were studied. Tests including slump flow, V-funnel and J-ring tests were performed for examining the fresh properties of developed SCC. Results showed that the addition of AP has an insignificant effect on the superplasticizer dosage for maintaining a constant flow of 70 cm. However, a higher dosage of superplasticizer was required for a mixture with increasing dosages of NF to sustain a constant flow. Similarly, slump flow time (for a spread of 50 cm) and V-funnel time increased for mixtures with higher dosages of AP and NF. Tested SCC mixtures incorporating 40% and 50% of AP with 1% and 2% of NF showed an extreme blocking assessment due to their increased interparticle friction, the higher water absorption capacity of used AP and NF leading to increased flow resistance and hence, showed lower passing ability. The compressive strength was 16% higher for specimens incorporating 40% of AP due to the filling effect of AP which fills the micro-pores, leading to a more dense and compact internal micro-structure, confirmed through scanning electron microscopy analysis. An ultrasonic pulse velocity test conducted on hardened specimens verified the findings of the compressive strength results. Moreover, it was observed that NF has an insignificant effect on the compressive strength; however, flexural strength was increased due to the incorporation of NF, especially at higher dosages of AP.

Potential of Waste Marble Sludge for Repressing Alkali-Silica Reaction in Concrete with Reactive Aggregates.

The continuous development of the marble industry has led to an increase in the accumulation of waste marble sludge causing landfilling and health-associated issues. The intention of the current study is to explore the potential of waste marble sludge powder (MS) utilization as a means of controlling alkali-silica reaction (ASR) in concrete. Specimen (cubes, prisms, and mortar bars) were prepared to incorporate reactive aggregates and various proportions of MS ranging from 5% to 40% as a replacement for aggregates. Expansion and mechanical strength characteristics were determined to investigate the effectiveness of MS to control ASRfor up to 150 days. Results revealed that on replacing aggregates in the control specimen with 25% MS, the ASR expansion at 14 days reduced from 0.23% to 0.17%, and the expansion at 28 days reduced from 0.28% to 0.17% which is within limits as per American Standard for Testing of Materials (ASTM) C1260. Furthermore, specimens incorporating MS exhibited improved compressive and flexural strength as compared to the identical specimen without MS. Microstructural analysis using Scanning electron microscopy (SEM) revealed micro-cracks in the control specimen while the specimen incorporating MS was found intact. Thus, it can be foreseen that the use of MS as a partial replacement of aggregates can control ASR in concrete as well as reduce the dumping and harmful emissions issue.

Manufacturing of Sustainable Untreated Coal Ash Masonry Units for Structural Applications.

Burnt clay bricks are one of the most important building units worldwide, are easy and cheap to make, and are readily available. However, the utilization of fertile clay in the production of burnt clay bricks is also one of the causes of environmental pollution because of the emission of greenhouse gases from industrial kilns during the large-scale burning process. Therefore, there is a need to develop a new class of building units (bricks) incorporating recycled industrial waste, leading toward sustainable construction by a reduction in the environmental overburden. This research aimed to explore the potential of untreated coal ash for the manufacturing of building units (coal ash unburnt bricks). Coal ash unburnt bricks were manufactured at an industrial brick plant by applying a pre-form pressure of 3 MPa and later curing them via water sprinkling in a control shed. Various proportions of coal ash (i.e., 30, 35, 40, 45, 50, and 55%) were employed to investigate the mechanical and durability-related properties of the resulting bricks, then they were compared with conventional burnt clay bricks. Compressive strength, flexural strength, an initial rate of water absorption, efflorescence, microstructural analysis via scanning electron microscopy, and cost analysis were conducted. The results of the compressive strength tests revealed that the compressive strength of coal ash unburnt brick decreased with an increase in the content of coal ash; however, up to a 45% proportion of coal ash, the minimum required compressive strength specified by ASTM C62 and local building codes was satisfied. Furthermore, bricks incorporating up to 45% of coal ash also satisfied the ASTM C62 requirements for water absorption. Coal ash unburnt bricks are lighter in weight owing to their porous developed microstructure. The cost analysis showed that the utilization of untreated, locally available coal ash in brick production leads us on the path toward more economical and sustainable building units.

Effectiveness of Ternary Blend Incorporating Rice Husk Ash, Silica Fume, and Cement in Preparing ASR Resilient Concrete.

Although the disposal of waste ashes causes environmental hazards, recycling them helps in reducing their harmful impacts and improves the characteristics of building materials. The present study explores the possible use of locally available waste ashes including Rice husk ash (RHA)and Silica Fumes (SF) as a partial replacement for cement in concrete to counter the negative impact of alkali-silica reactions (ASRs). In the present study, ternary blends including RHA (0-30%), SF (5% and 10%) and Portland cement were investigated. The amorphous behavior of RHA and SF was confirmed by conducting an X-ray diffraction analysis. A petrography analysis was carried out to ensure the reactive nature of aggregates used to prepare the concrete specimen. Accelerated mortar bar tests were performed in accordance with ASTM C 1260 for up to 90 days. It was revealed that specimens incorporating a ternary blend of SF, RHA, and Portland cement exhibited less expansion compared to the control specimens without SF and RHA. The incorporation of 5% SF along with 20% RHA exhibited a 0.13% expansion at 28 days and 10% SF, along with 5% RHA which exhibited 0.18% expansion at 28 days which is within the range specified by ASTM C 1260, with the lowest compromise of the mechanical properties of concrete. Thus, the utilization of SF and RHA in the partial replacement of cement in concrete may be considered a practical approach to mitigate ASR effects as well as to reduce the environmental burden.

Recycled Untreated Rubber Waste for Controlling the Alkali-Silica Reaction in Concrete.

Recycled rubber waste (RW) is produced at an alarming rate due to the deposition of 1.5 billion scrap tires annually around the globe, which causes serious threats to the environment due to its open land filling issues. This study investigates the potential application of RW in concrete structures for mitigating the alkali-silica reaction (ASR). Various proportions of RW (5%, 10%, 15%, 20%, and 25%) partially replaced the used aggregates. RW was procured from a local rubber recycling unit. Cubes, prisms, and mortar bar specimens were prepared using a mixture design recommended by ASTM C1260 and tested for evaluating the compressive and flexural strengths and expansion in an ASR conducive environment for specimens incorporating RW. It was observed that the compressive and flexural strength decreased for specimens incorporating RW compared to that of the control specimens without RW. For example, an 18% and an 8% decrease in compressive and flexural strengths, respectively, were observed for specimens with 5% of RW by aggregates volume at 28 days. Mortar bar specimens without RW showed an expansion of 0.23% and 0.28% at 14 and 28 days, respectively, indicating the potential ASR reactivity in accordance with ASTM C1260. A decrease in expansion was observed for mixtures incorporating RW. Specimens incorporating 20% of RW by aggregate volume showed expansions of 0.17% at 28 days, within the limit specified by ASTM C1260. Moreover, specimens incorporating RW showed a lower reduction in compressive and flexural strengths under an ASR conducive environment compared to that of the control specimen without RW. Micro-structural analysis also showed significant micro-cracking for specimens without RW due to ASR. However, no surface cracks were observed for specimens incorporating RW. It can be argued that the use of RW in the construction industry assists in reducing the landfill depositing issues with the additional benefit of limiting the ASR expansion.

Potential of Alkali-Silica Reactivity of Unexplored Local Aggregates as per ASTM C1260.

Alkali-silica reaction (ASR) is one of the major durability issues that affect the material degradation and structural performance, compromising the service life of concrete structures. Therefore, this study was planned to investigate the potential of ASR for locally available unexplored and vastly used aggregates, as per ASTM C1260. Aggregates from five different sources (Shalozan, Abbotabad, Orakzai, Swabi and Sada) were procured from their respective crusher sites. Mineralogical components of these aggregates were studied using the petrographic analysis. Cube, prism and mortar bar specimens were cast using mixture design in accordance with ASTM C1260 and placed in sodium hydroxide solution at 80 °C for 90 days. Identical specimens were also cured in water for the purpose of comparison. It was observed that mortar bar expansion of Orakzai aggregate was higher among the other tested aggregates and greater than 0.20% at 28 days, indicating the reactive nature according to ASTM C1260. Petrographic analysis also revealed the presence of reactive silica (quartzite) in the tested Orakzai source. It was observed that the compressive and flexural strengths of specimens exposed to ASR conducive environment was lower than the identical specimens placed in water. For instance, an approximately 9% decrease in compressive strength was observed for Orakzai aggregates exposed to ASR environment at 90 days compared to similar specimens placed in water curing. Moreover, microstructural analysis showed the development of micro-cracks for specimens incorporating Orakzai source aggregates. This study assists the construction stakeholders for the potential of unexplored local aggregates with regard to ASR before its utilization in mega construction projects.

Debonding of Thin Bonded Rubberised Fibre-Reinforced Cement-Based Repairs under Monotonic Loading: Experimental and Numerical Investigation.

In this study, the durability of cement-based repairs was observed, especially at the interface of debonding initiation and propagation between the substrate-overlay of thin-bonded cement-based material, using monotonic tests experimentally and numerically. Overlay or repair material (OM) is a cement-based mortar with the addition of metallic fibres (30 kg/m3) and rubber particles (30% as a replacement for sand), while the substrate is a plain mortar without any addition, known as control. Direct tension tests were conducted on OM in order to obtain the relationship between residual stress-crack openings (σ-w law). Similarly, tensile tests were conducted on the substrate-overlay interface to draw the relationship between residual stress and opening of the substrate-overlay interface. Three-point monotonic bending tests were performed on the composite beam of the substrate-overlay in order to observe the structural response of the repaired beam. The digital image correlation (DIC) method was utilized to examine the debonding propagation along the interface. Based on the different parameters obtained through the above-mentioned experiments, a three-point bending monotonic test was modelled through finite elements using a software package developed in France called CAST3M. Structural behaviour of repaired beams observed by experimental results and that analysed by numerical simulation are in coherence. It is concluded from the results that the hybrid use of fibres and rubber particles in repaired material provides a synergetic effect by improving its strain capacity, restricting crack openings by the transfer of stress from the crack. This enhances the durability of repair by controlling propagation of the interface debonding.

Mechanical Behavior of Ultrahigh-Performance Concrete Tunnel Lining Segments.

Ultrahigh-performance concrete (UHPC) is a novel material demonstrating superior mechanical, durability and sustainability performance. However, its implementation in massive structures is hampered by its high initial cost and the lack of stakeholders' confidence, especially in developing countries. Therefore, the present study explores, for the first time, a novel application of UHPC, incorporating hybrid steel fibers in precast tunnel lining segments. Reduced scale curved tunnel lining segments were cast using UHPC incorporating hybrid 8 mm and 16 mm steel fibers at dosages of 1%, 2% and 3% by mixture volume. Flexural and thrust load tests were conducted to investigate the mechanical behavior of UHPC tunnel lining segments thus produced. It was observed that the flow of UHPC mixtures decreased due to steel fibers addition, yet steel fibers increased the mechanical and durability properties. Flexural tests on lining segments showed that both the strain hardening (multiple cracking) and strain softening (post-peak behavior) phases were enhanced due to hybrid addition of steel fibers in comparison with the control segments without fibers. Specimens incorporating 3% of hybrid steel fibers achieved 57% increase in ultimate load carrying capacity and exhibited multiple cracking patterns compared to that of identical UHPC segments with 1% fibers. Moreover, segments without fibers incurred excessive cracking and spalling of concrete at the base under the thrust load test. However, more stable behavior was observed for segments incorporating steel fibers under the thrust load, indicating its capability to resist typical thrust loads during tunnel lining field installation. This study highlights the potential use of UHPC with hybrid steel fibers for improved structural behavior. Moreover, the use of UHPC allows producing structural members with reduced cross-sectional dimensions, leading to reduced overall structural weight and increased clear space.