Startseite Effect of polypropylene fiber and nano-silica on the compressive strength and frost resistance of recycled brick aggregate concrete
Artikel Open Access

Effect of polypropylene fiber and nano-silica on the compressive strength and frost resistance of recycled brick aggregate concrete

  • Shangwei Gong , Ting Wang , Md Mahmudul Hasan , Xuefeng Mei , Zhenyu Tan , Tian Su EMAIL logo und Fubo Cao EMAIL logo
Veröffentlicht/Copyright: 25. Dezember 2023
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Abstracts

Wasted clay bricks as coarse aggregate of recycled concrete is an effective solution to save energy and reduce CO2 emissions in the construction industry. However, the mechanical properties and frost resistance of recycled brick aggregate (RBA) concrete are inferior to those of ordinary concrete, which limits its widespread application. In this research, the effects of RBA, polypropylene fiber (PPF) and nano-silica (NS) on the mechanical properties and frost resistance of concrete were investigated. The effect of RBA, PPF, and NS on the compressive strength was quantitatively analyzed, and microstructural analysis and fractal dimension calculation of the concrete were performed. The results show that the concrete compressive strength decreased with the increase in RBA replacement rate, and it was effectively improved by adding PPF and NS (PPF-NS). The compressive strength first increased and then decreased with the increase in PPF and NS. The improvement effect of 0.12% PPF and 2% NS on the compressive strength of 50% replacement rate of RBA concrete was most effective. The gray relational degrees between the compressive strength and RBA, PPF, and NS were 0.6578, 0.8297, and 0.5941, respectively. The frost resistance of PPF-NS modified concrete was better than that of ordinary concrete, mainly manifested in its superior apparent phenomena, mass loss, and strength loss. Compared with normal concrete, the microstructure was denser and the fractal dimension of the cross-section was higher for RBA concrete modified with PPF-NS before and after freeze–thaw cycles.

1 Introduction

The rapid development of the construction industry driven by global economic growth has led to the consumption of a large amount of energy and the emission of a large amount of CO2. The CO2 emissions of the construction industry have reached 10 billion tons, ranking second in global CO2 emissions [1]. According to a report by the United Nations Environment Program, the construction industry accounted for more than 34% of global energy demand and contributed approximately 37% of CO2 emissions in 2021 [2]. CO2 is the most important greenhouse gas, accounting for 76% of all greenhouse gas emissions [3]. The emission of a large number of greenhouse gases has led to global warming, frequent natural disasters, and increased extreme weather events.

Facing the increasingly serious global ecological environment and the shortage of natural resources, the construction industry must open up a road of sustainable development. Concrete and brick waste are the main components of construction waste, each accounting for approximately 40% of construction waste [4]. Using construction waste to make recycled aggregate can reduce the consumption of natural resources, the accumulation of construction waste, and the occupation of land resources [5]. Moreover, the use of recycled aggregate avoids the mining aspect of the traditional concrete production process, which greatly reduces energy consumption and CO2 emissions. However, recycled aggregate greatly affects the compressive strength and frost resistance of concrete due to its drawbacks such as low strength and high water absorption and porosity [6], which limits the production and application of recycled aggregate concrete.

Many scholars have studied the mechanical properties and durability of recycled coarse aggregate concrete. Zhang and Zheng [7] used orthogonal experiments and revealed that the most influential factor on the compressive strength of recycled concrete was the recycled coarse aggregate replacement rate, followed by the water-cement ratio and finally the fine aggregate replacement rate. Xiao et al. [8] investigated recycled concrete coarse aggregates with different replacement rates and showed that the concrete axial compressive strength and cubic compressive strength decreased with the increase in recycled concrete coarse aggregate. Zong et al. [9] found that there was a good linear relationship between the cube compressive strength and flexural strength of recycled brick coarse aggregate concrete by regression analysis. Recycled coarse aggregate had a large deteriorating effect not only on the mechanics of concrete but also on the durability of concrete. Zhu and Li [10] found that the higher water absorption of recycled aggregate seriously affected the frost durability of recycled concrete, which made the compressive strength, mass loss, and relative dynamic elastic modulus of recycled concrete decrease more than that of ordinary concrete after freeze–thaw cycles. Cheng et al. [11] performed a study on the frost resistance of recycled concrete by a rapid freeze–thaw cycle test and showed that the frost resistance of recycled aggregate concrete gradually decreased with the increase in the recycled aggregate admixture. Peng [12] showed that the reason for the large difference in mechanical properties and durability between recycled concrete and ordinary concrete was that the recycled aggregate itself had more initial microcracks, which were analyzed by microscopic tests. It is now generally recognized that recycled coarse aggregates have a detrimental effect on the mechanical properties and durability of concrete.

To improve the compressive strength and frost resistance of recycled aggregate concrete, many scholars have conducted many studies. There are two simple and common methods to modify recycled concrete. The first method is to incorporate fibers, which can effectively inhibit the generation and development of cracks, blunt the stress concentration in the crack tip region, and enhance the bond between aggregate and mortar, thereby improving the mechanical properties and durability of recycled concrete [13]. The commonly used fibers are mainly steel fibers, glass fibers, carbon fibers, and polypropylene fibers (PPFs). Different types of fibers have different modification effects on concrete. However, the binding force between steel fibers and mortar is poor, glass fibers are brittle, and carbon fibers are more expensive [14]. In contrast, PPF has a lighter weight, higher tensile strength, higher acid and alkali resistance, and cheaper price [15], and is a cost-effective choice for modified recycled concrete. Das et al. [16] found that the compressive (flexural and split tensile) strength of recycled concrete was increased by 25% (9 and 12%) when PPF was admixed at 0.6%. Yang et al. [17] found that the addition of fiber to concrete can effectively improve the flexural strength and compressive strength. Chen et al. [18] found that fiber can reduce the interfacial transition zone (ITZ) of concrete through SEM image analysis, thus effectively improving the mechanical properties and durability of concrete. Akid et al. [19] showed through SEM image investigation that longitudinal and transverse PPFs formed a 3D mesh structure in recycled aggregate concrete, which effectively inhibited the formation and development of cracks and thereby effectively improved the compressive strength and frost resistance of concrete. PPF improves not only the mechanical properties of recycled aggregate concrete but also frost resistance of recycled aggregate concrete. Wang et al. [20] found that PPF concrete greatly increased the bond between the aggregate and paste when PPF was added to a 0.9 kg/m3 admixture. Teng et al. [21] found that PPF can prevent water infiltration inside the matrix, reducing the osmotic pressure which enhances the frost resistance of concrete through internal changes in the material. Wang and Niu [22] performed microscopic observation of PPF concrete after freeze–thaw cycle and revealed that the internal pores of the concrete increased with the increase in the PPF admixture, which could retard the crack development during the freeze–thaw process.

In the second method, nanomaterials with ultrafine particle sizes are used to improve the performance of recycled concrete by exerting their pozzolanic properties and pore-filling effects [23]. Among them, nano-silica (NS) has a high surface area and high pozzolanic properties. It can not only react with Ca(OH)2 to generate more C–S–H gels to fill the cracks and pores within the concrete but also inhibit the growth of CH crystals to make the microstructure of concrete denser [24]. Zhang et al. [25] reported that the compressive (flexural and split tensile) strength of concrete modified by NS increased by a maximum of 15.5% (27.3 and 19%). Esteves [26] found that NS can enter the ITZ and react with Ca(OH)2 to generate more C–S–H gels, effectively improving the compactness of concrete. Zhang and Wu [27] investigated that the compressive strength of NS concrete with different water-cement ratios was improved compared with the baseline group, in which the compressive strength enhancement was most obvious when the water-cement ratio was 0.3 and the NS admixture was 3%. Similarly, NS not only has a good effect on enhancing the mechanical properties of recycled concrete but also on improving the frost resistance of recycled concrete. Liu et al. [28] found that after 150 freeze–thaw cycles, the compressive strength of ordinary concrete decreased by 68%, the compressive strength of 0.2% PPF concrete decreased by 42%, and the compressive strength of 5% NS concrete decreased by 10%. Liu [29] found that the compressive strength of unmodified recycled concrete decreased by 49.3% after freeze–thaw cycles, and the compressive strength of 4% NS modified recycled concrete decreased by 25.26% after freeze–thaw cycles. Ding et al. [30] found that NS can improve the frost resistance of concrete by the filling effect, nucleation effect, and volcanic ash effect.

Fibers and nanomaterials have a good synergistic effect in concrete. The modification of concrete is more effective through the enhancement of macroscopic fiber materials and optimization of microscopic nanomaterials. Guo [31] and Wei [32] showed that the NS reacted with Ca(OH)2 to generate more C–S–H gel, which could effectively improve the binding force between the fiber and matrix, making the fiber play a better role of bridging cracks and blunting stress concentration within the concrete. PPF and NS (PPF-NS) modification can achieve complementary advantages [33]. Therefore, the addition of PPF and NS can effectively improve recycled concrete performance, extend the service life of concrete, and reduce the dependence on natural aggregates (NCAs), thus realizing the purpose of saving energy and reducing CO2 emissions in the construction industry.

The existing research mainly focuses on the modification of recycled concrete aggregate, and few studies have focused on the modification of recycled brick aggregate (RBA). Therefore, this research investigated the effect of RBA (0, 50, and 100%), PPF (0, 0.08, 0.12, and 0.16%), and NS (0, 1, 2, and 3%) on the compressive strength of concrete, and the degree of their influence on the compressive strength was quantified by gray relation analysis. The frost resistance of PPF-NS-modified 50% RBA replacement ratio concrete and ordinary concrete was compared by the rapid freeze–thaw test. The microstructure and fractal dimension of concrete SEM images before and after freeze–thaw cycles were analyzed, and the modification mechanism of PPF-NS was explored from a microscopic perspective.

2 Experimental program

2.1 Materials

The cement used in this test was conch brand P•O 42.5 ordinary Portland cement, and the performance indicators conformed to the requirements of GB/T 39698-2020 [34]. The physical performance and chemical composition of the cement are shown in Tables 1 and 2, respectively. The fine aggregate used in this test was natural river sand with a particle size of 0–5 mm and a fineness modulus of 3.48. The grading curve of natural river sand is shown in Figure 1. The NCA used in this test was made from crushed stone. There is great randomness and variability in the RBA from different sources. To ensure the single source of RBA, the RBA in this test was crushed from red bricks in the laboratory. The performance of NCA and RBA is shown in Table 3. The performance of NCA and RBA used in this test conformed to the requirements of GB/T 14685-2022 [35] and GB/T 25177-2010 [36], respectively. The grading curves of NCA and RBA are shown in Figure 2. The performance of PPF and NS are shown in Tables 4 and 5, respectively. The appearance of the material is shown in Figure 3.

Table 1

Physical and mechanical performance of cement

Physical and mechanical performance P•O 42.5
Specific surface area (m2/kg) 325
Setting time (min) Initial 187
Final 253
Soundness Qualified
Compressive strength (MPa) 3 days 6.3
28 days 8.2
Flexural strength (MPa) 3 days 22.3
28 days 48.1
Table 2

Chemical composition of cement

Chemical compositions P•O 42.5
CaO 60.14
SiO2 22.21
Al2O3 6.41
Fe2O3 3.04
SO3 2.95
MgO 1.43
Others 3.82
Loss on ignition 1.70
Figure 1 
                  The grading curve of sand.
Figure 1

The grading curve of sand.

Table 3

Physical performance of coarse aggregate

Type of coarse aggregate NCA RBA
Water absorption (%) 1.3 13.9
Apparent density (kg/m3) 2,635 1,811
Crush index (%) 7.5 29.5
Flat elongated particles content (%) 7.7 9.1
Mud content (%) 0.5 13.1
Maximum particle size (mm) 26.5 26.5
Figure 2 
                  The grading curve of coarse aggregate.
Figure 2

The grading curve of coarse aggregate.

Table 4

Performance of PPF

Fiber PPF
Length (mm) 19
Equivalent diameter (μm) 40
Density (g/cm3) 0.91
Melting point (℃) 165
Breaking elongation (%) 20
Tensile strength (MPa) 400
Elastic modulus (GPa) 5
Table 5

Performance of NS

Property NS
Density (g/cm3) 2.3
Melting point (°C) 1,750
Average particle size (nm) 20
Specific gravity (g/cm3) 1.4
Figure 3 
                  Appearance: (a) NCA; (b) RBA; (c) PPF; and (d) NS.
Figure 3

Appearance: (a) NCA; (b) RBA; (c) PPF; and (d) NS.

2.2 Mix proportion

According to JGJ55-2019 [37], the details of the mixing proportions are shown in Table 6. The design strength of the control concrete is 30 MPa, and the water-cement ratio is 0.5. In the number of specimens, N represents ordinary concrete; R represents RBA concrete; 0, 0.08, 0.12, and 0.16 represent PPF incorporation rate; and 0, 1, 2, and 3 represent NS incorporation rate. For example, R50-0.12-1 indicates that the RBA volume replacement rate is 50%, the PPF volume replacement rate is 0.12%, and the NS volume replacement rate is 1%.

Table 6

Concrete mix proportion design

Specimen RBA NCA Cement Water Sand NS PPF
(kg/m3) (kg/m3) (kg/m3) (kg/m3) (kg/m3) (%) (%)
N-0-0 0 1,043 400 200 657 0 0
N-0.08-0 0 1,043 400 200 657 0 0.08
N-0.12-0 0 1,043 400 200 657 0 0.12
N-0.12-1 0 1,043 400 200 657 1 0.12
N-0.12-2 0 1,043 400 200 657 2 0.12
N-0.12-3 0 1,043 400 200 657 3 0.12
N-0.16-0 0 1,043 400 200 657 0 0.16
R50-0-0 458.5 521.5 400 200 657 0 0
R50-0.08-0 458.5 521.5 400 200 657 0 0.08
R50-0.12-0 458.5 521.5 400 200 657 0 0.12
R50-0.12-1 458.5 521.5 400 200 657 1 0.12
R50-0.12-2 458.5 521.5 400 200 657 2 0.12
R50-0.12-3 458.5 521.5 400 200 657 3 0.12
R50-0.16-0 458.5 521.5 400 200 657 0 0.16
R100-0-0 917 0 400 200 657 0 0
R100-0.08-0 917 0 400 200 657 0 0.08
R100-0.12-0 917 0 400 200 657 0 0.12
R100-0.12-1 917 0 400 200 657 1 0.12
R100-0.12-2 917 0 400 200 657 2 0.12
R100-0.12-3 917 0 400 200 657 3 0.12
R100-0.16-0 917 0 400 200 657 0 0.16

PPF and NS are easily agglomerated, thus they need to be treated to make them dispersible. NS was placed in the water solution and manually stirred for 5 min, then an F-S600N ultrasonic processor was used to disperse the NS solution. In addition, the treated NS solution should not be left for too long, otherwise NS will agglomerate again. During the concrete mixing process, while adding water, PPF was added in batches and mixed separately for 1 min to achieve the purpose of dispersing PPF. PPF and NS provided an improved effect on the compressive strength and frost resistance of concrete. However, excessive amounts of PPF and NS were easily agglomerated, which reduced the compressive strength and frost resistance of the concrete [19,26]. Therefore, the maximum admixture of PPF and NS was designed as 0.16 and 3%, respectively.

2.3 Specimen production process

Due to the high water absorption of RBA, the direct use of RBA not only reduced the fluidity of fresh concrete but also caused a large number of shrinkage cracks in the specimens during the curing period [38]. Therefore, the RBA was pre-absorbed to achieve a saturated surface dry state in this test. The RBA was soaked for 24 h and then removed to dry in the shade for approximately 2 h allowing the RBA to reach a saturated surface dry state [39]. The steps for specimen production were as follows:

1) Waste bricks were crushed by a jaw crusher;

2) The crushed aggregate was screened for different particle sizes and bagged;

3) The NCA was washed and dried;

4) The RBA was treated with pre-absorption;

5) Sand, cement, PPF, NCA, and RBA were placed in the mixer and stirred for 3 min;

6) NS was mixed with the water used in the concrete;

7) The mixed solution of NS and water was put into the mixer and stirred for 2 min;

8) The specimens were poured and then vibrated;

9) Demolding was done after 24 h;

10) The specimens were put into the standard curing room for 28 days.

2.4 Test process

According to GB/T 50081-2019 [40], the compressive strength of concrete was tested by an electrohydraulic servo universal testing machine with a loading rate of 0.5 MPa/s. According to GB/T 50082-2009 [41], the specimens were placed in water for 4 days to saturate the water absorption, and then the rapid freeze–thaw test was carried out. Cube specimens of 100 mm × 100 mm × 100 mm were tested for compressive strength, while prismatic specimens of 100 mm × 100 mm × 400 mm were tested for apparent phenomena and the rate of mass loss before and after freeze–thaw cycles. Three specimens were tested in each group, and the average value was taken as the test result to reduce the test error.

3 Compressive performance analysis

3.1 Compressive strength

The average, standard deviation, and variation coefficient of the compressive strength are shown in Table 7. The test data of each group were less discrete and had high reliability.

Table 7

Statistical analysis of compressive strength

Specimen Compressive strength (MPa)
Average Standard deviation Variation coefficient
N-0-0 34.3900 1.4991 0.0436
N-0.08-0 35.4100 1.8243 0.0515
N-0.12-0 37.9500 2.4324 0.0641
N-0.12-1 38.4600 0.4950 0.0129
N-0.12-2 41.8800 1.5698 0.0375
N-0.12-3 39.2400 0.3536 0.0090
N-0.16-0 35.6500 0.3536 0.0099
R50-0-0 28.4200 1.3011 0.0458
R50-0.08-0 29.4500 1.8526 0.0629
R50-0.12-0 31.5400 2.8751 0.0912
R50-0.12-1 37.7910 2.8751 0.0761
R50-0.12-2 39.0973 0.8934 0.0229
R50-0.12-3 35.8293 0.3695 0.0103
R50-0.16-0 27.5000 1.9799 0.0720
R100-0-0 25.2700 2.1355 0.0845
R100-0.08-0 25.6300 0.2121 0.0083
R100-0.12-0 26.3900 0.5798 0.0220
R100-0.12-1 28.1390 1.8943 0.0673
R100-0.12-2 30.4143 3.8357 0.1261
R100-0.12-3 28.7043 2.3578 0.0821
R100-0.16-0 23.4000 0.7495 0.0320

3.1.1 Compressive strength of PPF-modified RBA concrete

The compressive strength of RBA concrete with different PPF admixtures is shown in Figure 4. The compressive strength decreased with the increase in the RBA replacement rate. The compressive strength was reduced by 17.35 and 26.52% when the RBA replacement rate was 50 and 100%, respectively. The reason is that the porosity, crushing index, and water absorption of recycled aggregate are much higher than those of NCA, resulting in the strength of recycled concrete being lower than that of ordinary concrete [42,43].

Figure 4 
                     Compressive strength of RBA concrete with different PPF admixtures.
Figure 4

Compressive strength of RBA concrete with different PPF admixtures.

Moreover, the compressive strength of concrete first increased and then decreased with the increase in the PPF admixture. The compressive strength was increased by 2.97, 10.35, and 3.67% (3.62, 10.98, and −3.24%; 1.42, 4.43, and −7.4%) when the PPF admixture was 0.08, 0.12, and 0.16% with an RBA replacement rate of 0 (50 and 100%). The improvement in concrete compressive strength was most effective when the PPF admixture was 0.12%. The reasons are as follows: a 3D mesh structure is formed by the PPF inside the specimen, which improves the bonding between the matrix and the aggregate and effectively reduces the generation and development of cracks [44]. The tensile strength of the PPF is high, which can effectively improve the toughness of the specimen [45]. However, excessive PPF reduces the fluidity of the specimen, which affects the density of the specimen during pouring [46]. An excessive amount of PPF is more easily agglomerated, resulting in an increased ITZ between the PPF and matrix [47]. In addition, the improvement effect of PPF on the compressive strength of recycled concrete was better than that of ordinary concrete. After adding PPF, the compressive strength of recycled concrete increased by a maximum of 10.98%, while the compressive strength of ordinary concrete increased by a maximum of 10.35%. This is consistent with the results of Ahmed et al. [45] and Hesami et al. [47], indicating that using PPF to improve the mechanical properties of recycled concrete has advantages.

The fitting surface of compressive strength with RBA and PPF is shown in Figure 5, and the fitting equation is as follows:

(1) Z = 18.76821 + 17.08179 e x 101.93217 y 3.17997 × 10 108 R 2 = 0.91839 ,

where x represents the RBA, y represents the PPF, and Z represents the compressive strength, e represents euler number. The restriction conditions are: {x, y| 0 ≤ x ≤ 100, 0 ≤ y ≤ 0.16}. Among them, R 2 > 0.91, and the fitting model has high accuracy. From the model of formula (1), it can be seen that the larger the independent variable x and the smaller the y, the smaller the dependent variable Z. The model better reflects the deterioration effect of RBA on recycled concrete and the positive effect of PPF on recycled concrete.

Figure 5 
                     Fitting surface of compressive strength with RBA and PPF.
Figure 5

Fitting surface of compressive strength with RBA and PPF.

The experimental data of Liu [48] were used to verify the applicability of the compressive strength with RBA and PPF fitting functions. The fitting surface is shown in Figure 6, and the fitting equation is as follows:

(2) Z = 70.22553 22.42846 e x 126.71013 y 16.37875 R 2 = 0.99755 , ,

where R 2 > 0.997, and the fitting accuracy was high, indicating that the fitting function of this test had high applicability.

Figure 6 
                     Fitting surfaces of test data from Liu [48].
Figure 6

Fitting surfaces of test data from Liu [48].

3.1.2 Compressive strength of PPF and NS modified RBA concrete

The compressive strength of RBA concrete with different NS admixtures is shown in Figure 7 (with 0.12% PPF admixture). The compressive strength first increased and then decreased with the increase in NS admixture when the fixed admixture of PPF was 0.12%. The compressive strength was increased by 1.34, 10.36, and 3.4% (19.82, 23.96, and 13.6%; 6.62, 15.24, and 8.77%) when the NS admixture was 1, 2, and 3% with RBA replacement rates of 0% (50 and 100%). The reasons are as follows: NS has higher pozzolanic properties than silica fume and fly ash [49], which reacts with Ca(OH)2 in cement to produce more C–S–H gel in the presence of water. C–S–H gel can fill the cracks and contribute to the improvement of the ITZ of concrete [50]. Moreover, the reduction of Ca(OH)2 is beneficial to the strength [51,52]. Due to the high surface area and pozzolanic properties that compete with cement for water, excessive NS reduces the fluidity of the specimen, which affects the density of concrete [53,54]. Moreover, excessive NS is prone to agglomeration reactions, and aggregated NS is also difficult to react with the hydration product Ca(OH)2 of cement. When concrete specimens are subjected to external loads, the low strength agglomerated NS zone is easily destroyed, leading to easier stress concentration in the specimens [55]. In addition, the improvement effect of NS on the compressive strength of recycled concrete was better than that of ordinary concrete. After adding NS, the compressive strength of recycled concrete increased by a maximum of 23.96%, while the compressive strength of ordinary concrete increased by a maximum of 10.35%. This is consistent with the results of Guo [31] and Cheng [53].

Figure 7 
                     Compressive strength of RBA concrete with different NS admixtures at 0.12% PPF admixture.
Figure 7

Compressive strength of RBA concrete with different NS admixtures at 0.12% PPF admixture.

The compressive strength of concrete with 0.12% PPF admixture was further increased when NS was added, which showed that PPF-NS had a good synergistic effect in the concrete. The reason is that NS with small particles can enter the ITZ between the PPF and matrix and exert a nucleation effect, where more C–S–H gels are generated, thus improving the adhesion between the PPF and matrix [23]. After PPF-NS modification, the compressive strength of concrete with a 50% RBA replacement rate was higher than that of ordinary concrete indicating that the addition of PPF-NS could compensate for the negative impact of RBA on concrete strength.

The fitting surface of compressive strength with RBA and NS is shown in Figure 8, and the fitting equation is as follows:

(3) Z = 38.5475 + 5.05475 y 1.344 y 2 30.10432 e 1 e x 181.52534 49.53516 181.52534 x 49.53516 R 2 = 0.95795 , ,

where x represents the RBA, y represents the NS, and Z represents the compressive strength, e represents euler number. The restriction conditions are: {x, y| 0 ≤ x ≤ 100, 0 ≤ y ≤ 3}. Among them, R 2 > 0.95, and the fitting model has high accuracy. From the model of formula (3), it can be seen that the smaller the independent variable x and the larger the y, the larger the dependent variable Z. The model better reflects the deterioration effect of RBA on recycled concrete and the positive effect of NS on recycled concrete.

Figure 8 
                     Fitting surface of compressive strength with RBA and NS at 0.12% PPF admixture.
Figure 8

Fitting surface of compressive strength with RBA and NS at 0.12% PPF admixture.

The experimental data of Chen [56] were used to verify the applicability of the compressive strength with RBA and NS fitting functions. The fitting surface is shown in Figure 9, and the fitting equation is as follows:

(4) Z = 115.51626 + 4.46333 y 0.99 y 2 91.99275 e 1 e x 137.22757 204.61594 137.22757 x 49.53516 R 2 = 0.98053 , ,

where R 2 > 0.981 and the fitting accuracy was high, indicating that the fitting function of this test had high applicability.

Figure 9 
                     Fitting surfaces of test data from Chen [56].
Figure 9

Fitting surfaces of test data from Chen [56].

3.2 Gray relational analysis

Gray relational analysis is a multifactor analysis method based on mathematical statistics to determine the relative relationship of each sequence. The gray relational degree is used to represent the closeness of the two sequences. The greater the gray relational degree is, the closer the relationship between the two sequences [57]. Moreover, the gray correlation model does not require the data to have a typical distribution, which can effectively reduce the influence of subjective factors.

3.2.1 Model analysis

Suppose a set of data is divided into several sequences. X i (k) = {X i (1), X i (2), X i (3), … X i (n)}, X represents the reference sequence, Y j (k) = {Y j (1), Y j (2), Y j (3), … Y j (n)}, Y represents the main sequence.

The mean value method is used to perform dimensionless processing on the original matrix D, and the processed matrix is D'.

(5) D i ( k ) = D i ( k ) 1 n k = 1 n D i ( k ) .

The difference between the reference sequence and the main sequence was calculated to form the difference matrix Δ as follows:

(6) Δ = Y j ( k ) X i ( k ) .

The two-level maximum value M and the two-level minimum value m of the difference matrix Δ were calculated as follows:

(7) M = max i max k Δ i ( k ) m = min i min k Δ i ( k ) .

The correlation coefficient was calculate, and where ρ is 0.5.

(8) ε ( k ) = m + ρ M Δ i ( k ) + ρ M .

The gray relational degree was calculated.

(9) γ i = 1 n k = 1 n ε ( k ) .

3.2.2 Test results analysis

Suppose D is the original matrix, RBA, PPF, and NS are the reference sequences, and compressive strength is the main sequence:

(10) D i ( k ) = 0 0 0 34.39 0 0.08 0 35.41 0 0.12 0 37.95 0 0.12 1 38.46 0 0.12 2 41.88 0 0.12 3 39.24 0 0.16 0 35.65 50 0 0 28.42 50 0.08 0 29.45 50 0.12 0 31.54 50 0.12 1 37.79 50 0.12 2 39.1 50 0.12 3 35.83 50 0.16 0 27.5 100 0 0 25.27 100 0.08 0 25.63 100 0.12 0 26.39 100 0.12 1 28.14 100 0.12 2 30.41 100 0.12 3 28.7 100 0.16 0 23.4 .

The original D matrix is made dimensionless, and D' is the processed matrix:

(11) D i ( k ) = 0 0 0 1.0612 0 0.7778 0 1.0927 0 1.1667 0 1.171 0 1.1667 1.1667 1.1868 0 1.1667 2.3333 1.2923 0 1.1667 3.5 1.2108 0 1.5556 0 1.1001 1 0 0 0.877 1 0.7778 0 0.9088 1 1.1667 0 0.9732 1 1.1667 1.1667 1.1661 1 1.1667 2.3333 1.2065 1 1.1667 3.5 1.1056 1 1.5556 0 0.8486 2 0 0 0.7798 2 0.7778 0 0.7909 2 1.1667 0 0.8143 2 1.1667 1.1667 0.8683 2 1.1667 2.3333 0.9384 2 1.1667 3.5 0.8856 2 1.5556 0 0.7221 .

The difference sequence matrix of D' is calculated as follows:

(12) Δ = 1.0612 1.0612 1.0612 1.0927 0.3149 1.0927 1.171 0.0044 1.171 1.1868 0.0201 0.0201 1.2923 0.1256 1.041 1.2108 0.0442 2.2892 1.1001 0.4555 1.1001 0.123 0.877 0.877 0.0912 0.131 0.9088 0.0268 0.1934 0.9732 0.1661 0.0006 0.0006 0.2065 0.0399 1.1268 0.1056 0.061 2.3944 0.1514 0.0707 0.8486 1.2202 0.7798 0.7798 1.2091 0.0131 0.7909 1.1857 0.3523 0.8143 1.1317 0.2983 0.2983 1.0616 0.2283 1.395 1.1144 0.2811 2.6144 1.2779 0.8335 0.7221 .

The two-level maximum value M is 2.6144, and the two-level minimum value m is 0.0006 for the difference matrix Δ. Furthermore, the correlation coefficient is calculated as follows:

(13) ε ( k ) = 0.5522 0.5522 0.5522 0.5449 0.8062 0.5449 0.5277 0.9971 0.5277 0.5244 0.9853 0.9853 0.5031 0.9127 0.5569 0.5194 0.9677 0.3636 0.5433 0.7419 0.5433 0.9144 0.5987 0.5987 0.9352 0.9093 0.5902 0.9804 0.8715 0.5735 0.8876 1 1 0.8639 0.9708 0.5373 0.9256 0.9558 0.3533 0.8966 0.6493 0.6066 0.5174 0.6266 0.6266 0.5197 0.9905 0.6233 0.5246 0.788 0.6164 0.5362 0.8145 0.8145 0.5521 0.8517 0.484 0.54 0.8234 0.3335 0.5059 0.6109 0.6445 .

The gray relational degrees between RBA, PPF, NS, and compressive strength were 0.6578, 0.8297, and 0.5941, respectively. PPF had the greatest effect on compressive strength, followed by RBA, and NS had the least effect. However, Gong et al. [58] found that the gray relational degree between PPF and compressive strength was lower than that of RBA. The gray relational degree between the PPF and compressive strength was increased by the admixture of NS. The good synergistic effect of NS and PPF improved the influence of PPF on compressive strength.

4 Frost resistance

4.1 Apparent phenomenon

After different freeze–thaw cycles, the apparent phenomena of the N-0-0 and R50-0.12-2 specimens are shown in Figure 10. After 30 freeze–thaw cycles, small pores appeared on the surface of the specimens. After 60 freeze–thaw cycles, the aggregate of the specimens was exposed, and large holes appeared. Under the same number of freeze–thaw cycles, the R50-0.12-2 specimen had fewer surface holes than the N-0-0 specimen, and the falling concrete debris was connected to the matrix through the PPF. After 75 freeze–thaw cycles, the N-0-0 specimen was destroyed, while the R50-0.12-2 specimen was still able to withstand some freeze–thaw cycles. It can be observed from the apparent phenomenon that the R50-0.12-2 specimen had better frost resistance than the N-0-0 specimen [31,32].

Figure 10 
                  Appearance of specimens after freezing and thawing: (a) N-0-0 and (b) R50-0.12-2.
Figure 10

Appearance of specimens after freezing and thawing: (a) N-0-0 and (b) R50-0.12-2.

4.2 Mass loss

The mass loss formula of specimens after freeze–thaw cycles is as follows:

(14) Δ W n i = W 0 i W n i W 0 i × 100 % ,

where ΔW ni is the mass loss of specimen i after N freeze–thaw cycles (%), W 0i is the mass of specimen i before the freeze–thaw cycle experiment (g), and W ni is the mass of specimen i after N freeze–thaw cycles (g).

Figure 11 shows the mass loss of the specimens after freeze–thaw cycles. The mass loss of the specimens first decreased and then increased with the increase in the number of freeze–thaw cycles. The reasons are as follows: on the one hand, the closed holes of the specimen gradually became connected holes during the freeze–thaw cycle, and the specimen gradually absorbed water, resulting in an increase in mass [59]. On the other hand, during the freeze–thaw process, the mortar of the specimen gradually loosens, and under the pressure of water freezing, cracks continue to form and develop, causing the mortar to peel off, leading to a decrease in mass [60]. When the water absorption exceeds the peeling loss of the specimen, the mass of the specimen increases, and vice versa.

Figure 11 
                  Mass loss.
Figure 11

Mass loss.

In addition, the descending segment slope of the mass loss of the R50-0.12-2 specimen was 3.76 times that of the N-0-0 specimen, which indicated that the mass of water absorbed by the R50-0.12-2 specimen was higher than that absorbed by the N-0-0 specimen. The reason is that the lower strength RBA concrete was more easily cracked with the increase in freeze–thaw cycles, leading to the gradual transformation of the more closed pores of the R50-0.12-2 specimen into connected pores [61]. The increasing segment slope of the mass loss of the R50-0.12-2 specimen was 0.384 times higher than that of the N-0-0 specimen, which indicated that the freeze–thaw spalling mass of the R50-0.12-2 specimen was lower than that of the N-0-0 specimen. The reason is that the synergistic effect of PPF and NS effectively enhances the bonding of fiber, aggregate, and mortar [62], which reduces the mass loss of the R50-0.12-2 specimen.

4.3 Compressive strength

The compressive strength loss is as follows:

(15) Δ f n i = f 0 i f n i f 0 i × 100 % ,

where Δf is the strength loss of specimen i after N freeze–thaw cycles (%), f 0 is the strength of specimen i before the freeze–thaw cycle experiment (MPa), and f n is the strength of specimen i after N freeze–thaw cycles (MPa).

Figure 12 shows the relationship between the compressive strength and different numbers of freeze–thaw cycles. The compressive strength of the specimens decreased with the increase in the number of freeze–thaw cycles. Moreover, the compressive strength of the R50-0.12-2 specimen was higher than that of the N-0-0 specimen after the same number of freeze–thaw cycles. When the number of freeze–thaw cycles was 0 (15, 30, 45, 60, and 75), the compressive strength of the R50-0.12-2 specimen was 1.137 (1.448, 1.284 1.617, 1.911, and 3.852) times that of the N-0-0 specimen. Figure 13 shows the relationship between the compressive strength loss of the specimens and different numbers of freeze–thaw cycles. The compressive strength loss of the specimens increased with the increase in the number of freeze–thaw cycles. The compressive strength loss of the R50-0.12-2 specimen was lower than that of the N-0-0 specimen. The reason is that a part of the large pores in the RBA is filled by mortar and PPF, and a part of the smaller capillary pores is filled by NS, which results in a better densification of specimens and a significant reduction in water infiltration into the interior [63,64]. Moreover, RBA also had a large number of closed pores as harmless pores, which could buffer the expansion stress of specimens during freezing [65]. Therefore, the frost resistance of the R50-0.12-2 specimen was greatly improved after PPF-NS modification.

Figure 12 
                  Compressive strength of specimens after freeze–thaw cycles.
Figure 12

Compressive strength of specimens after freeze–thaw cycles.

Figure 13 
                  Compressive strength loss.
Figure 13

Compressive strength loss.

The fitting equations of compressive strength with different numbers of freeze–thaw cycles are as follows:

(16) N - 0 - 0 y = 0.37802 x + 35.65905 , R 2 = 0.98262 ,

(17) R 50 - 0.12 - 2 y = 0.24819 x + 41.63381 , R 2 = 0.91498 .

5 Microscopic analysis of SEM images

5.1 SEM image analysis of mechanical performance

The microstructure of the specimens before freeze–thaw cycling is shown in Figure 14. Comparing Figure 14a and b, it can be seen that the ITZ of the PPF-NS-modified specimens was filled with more C–S–H gel. Moreover, the fibers in the PPF-NS modified specimens were covered by a layer of C–S–H gel. Therefore, NS had high pozzolanic properties and could react with Ca(OH)2 in cement to produce more C–S–H gels [23]. Similarly, after being filled with more C–S–H gel produced by NS, the ITZ of the R50-0.12-2 specimen was less than that of the N-0-0 sample before freeze–thaw cycles (Figure 14c and d). The crisscrossed PPF (Figure 14e) eventually formed a 3D network structure within the specimen, which filled the internal pores of the specimen and effectively improved the bond between the aggregate and the mortar, thus increasing the compressive strength of the specimen [15]. However, the excessive PPF was easily mixed unevenly and formed agglomerates (Figure 14f). The agglomeration phenomenon made the ITZ between the PPF and the matrix larger [15], which led to a poor bond between the PPF and the matrix. The excessive PPF increased the defective areas of stress concentration within the specimen, which decreased the compressive strength and frost resistance

Figure 14 
                  SEM images of modified specimens: (a) N-0.08-0, (b) N-0.12-2, (c) N-0-0, (d) R50-0.12-2, (e) N-0.12-0, and (f) N-0.16-0.
Figure 14

SEM images of modified specimens: (a) N-0.08-0, (b) N-0.12-2, (c) N-0-0, (d) R50-0.12-2, (e) N-0.12-0, and (f) N-0.16-0.

5.2 SEM image analysis of frost resistance

The microstructure of the specimens after freeze–thaw cycling is shown in Figure 15. Figure 15a shows that the mortar around the NCA of the N-0-0 specimen became looser after 75 freeze–thaw cycles. Figure 15b shows that the bond between the NCA and the mortar of the R50-0.12-2 specimen remained tight after 75 freeze–thaw cycles, which could be seen that the R50-0.12-2 specimen had better frost resistance. The surface of RBA was rougher than that of NCA [66], and the elasticity modulus of RBA and mortar were closer [6], which led to a smaller ITZ in RBA concrete (Figure 15c). The ITZ of the R50-0.12-2 specimen modified by PPF-NS after freeze–thaw cycle was better than that of the N-0-0 specimen. It was verified from the microstructure that PPF-NS could effectively improve the ITZ of the specimen.

Figure 15 
                  SEM images of specimen ITZ: (a) N-0-0 of 75 freeze–thaw cycles (NCA), (b) R50-0.12-2 of 75 freeze–thaw cycles (NCA), and (c) R50-0.12-2 of 75 freeze–thaw cycles (RBA).
Figure 15

SEM images of specimen ITZ: (a) N-0-0 of 75 freeze–thaw cycles (NCA), (b) R50-0.12-2 of 75 freeze–thaw cycles (NCA), and (c) R50-0.12-2 of 75 freeze–thaw cycles (RBA).

5.3 Fractal dimension analysis based on SEM image

The surface of the concrete microstructure sample was uneven, porous, and cracked, and it was difficult to quantitatively characterize the fracture surfaces by directly observing the SEM images. The fractal dimension is an index to measure the roughness of the surface texture of the SEM images, which can quantitatively describe the difference in human visual perception of images [67,68]. The commonly used methods for calculating fractal dimension include gray interpolation, the carpet covering method, and the differential box dimension method. The box dimension method easily calculates the fractal dimension and is convenient to program [69]. Therefore, the box dimension method was used to quantitatively analyze the SEM images. The formula for calculating the fractal dimension by the box dimension method is as follows:

(18) D = lim k 0 lg ( N k ) lg 1 k ,

where D b is the fractal dimension, k is the length of the sides of the square grid, and N k is the minimum assembly number covering a square grid of size k. The fractal dimension measures the pattern in which the number of square boxes N k grows as the length k of the sides of the square decreases.

SEM images are usually grayscale, and the key step before the calculation of the box dimension method is the binarization of the grayscale images. Threshold selection is a very important parameter in the binarization process of grayscale images. When the difference between the target area and the background area is not much different, the Otsu algorithm can effectively segment the threshold, and the Otsu method can divide SEM images into two parts based on grayscale levels. This experiment uses the Otsu method to determine binarization threshold calculations. Due to the large difference in surface characteristics between NCA and RBA, only NCA cement stones from specimens before and after freeze–thaw cycles were extracted for fractal dimension analysis. The SEM images in the specimens before and after freeze–thaw cycles (both SEM images magnified by 1,000 times) and their SEM images after binarization are shown in Figures 16 and 17, respectively. The fractal dimension of the SEM images was calculated by the box dimension method, as shown in Figure 18.

Figure 16 
                  SEM images before and after freeze–thaw cycle: (a) N-0-0 after 0 freeze–thaw cycle; (b) R50-0.12-2 after 0 freeze–thaw cycle; (c) N-0-0 after 75 freeze–thaw cycles; and (d) R50-0.12-2 after 75 freeze–thaw cycles.
Figure 16

SEM images before and after freeze–thaw cycle: (a) N-0-0 after 0 freeze–thaw cycle; (b) R50-0.12-2 after 0 freeze–thaw cycle; (c) N-0-0 after 75 freeze–thaw cycles; and (d) R50-0.12-2 after 75 freeze–thaw cycles.

Figure 17 
                  SEM images after binarization treatment: (a) N-0-0 after 0 freeze–thaw cycle; (b) R50-0.12-2 after 0 freeze–thaw cycle; (c) N-0-0 after 75 freeze–thaw cycles; and (d) R50-0.12-2 after 75 freeze–thaw cycles.
Figure 17

SEM images after binarization treatment: (a) N-0-0 after 0 freeze–thaw cycle; (b) R50-0.12-2 after 0 freeze–thaw cycle; (c) N-0-0 after 75 freeze–thaw cycles; and (d) R50-0.12-2 after 75 freeze–thaw cycles.

Figure 18 
                  Fractal dimension: (a) N-0-0 after 0 freeze–thaw cycle; (b) R50-0.12-2 after 0 freeze–thaw cycle; (c) N-0-0 after 75 freeze–thaw cycles; and (d) R50-0.12-2 after 75 freeze–thaw cycles.
Figure 18

Fractal dimension: (a) N-0-0 after 0 freeze–thaw cycle; (b) R50-0.12-2 after 0 freeze–thaw cycle; (c) N-0-0 after 75 freeze–thaw cycles; and (d) R50-0.12-2 after 75 freeze–thaw cycles.

The fractal dimension can be used to characterize the roughness of the specimen cross-section [70], and the relevant results are shown in Table 8. The goodness of fits of the functions were above 0.99, indicating that the cross-sections of the concrete SEM images had fractal characteristics. These results are nearly identical to the findings of Lv et al. [67] and Zhang et al. [68]. The fractal dimension calculation shows that the roughness increased with the increase in the fractal dimension at the same magnification [71]. The fractal dimension of the cross-section of the R50-0.12-2 specimen before and after freeze–thaw cycles was greater than that of the N-0-0 specimen, indicating that the R50-0.12-2 specimen could withstand larger loads. This shows that PPF-NS can effectively improve the microstructure of RBA concrete specimens, resulting in the improvement of compressive strength and frost resistance.

Table 8

Results of fractal dimensions

Species Binarization threshold (%) Fractal dimension Fitting formula
Formula R 2
N-0-0 (0) 13.66 1.5583 y = 1.55826 x + 12.80459 0.999
R50-0.12-2 (0) 24.97 1.7328 y = 1.73283 x + 13.4437 0.999
N-0-0 (75) 31.98 1.7723 y = 1.77229 x + 13.5472 0.999
R50-0.12-2 (75) 33.81 1.806 y = 1.80604 x + 13.68894 0.999

6 Strengthening mechanism of PPF and NS on RBA concrete

6.1 Mechanical performance

The ITZ of RBA and mortar in RBA concrete is relatively loose and porous. After adding NS, NS can enter into the pores and microcracks of RBA surface due to its small particle size, and react with Ca(OH)2 of cement hydration products to generate C–S–H gel making the ITZ area more compact. In addition, concrete is not a uniform structure and is prone to stress concentration during the loading process. The addition of PPF can be mixed in mortar, effectively improving the overall connectivity of the mortar. When stress concentration occurs in the specimen, some of the stress can be transferred to other areas through PPF, thereby achieving the purpose of relieving stress concentration. Therefore, the addition of NS and PPF can effectively improve the mechanical properties of RBA concrete.

6.2 Frost resistance

RBA concrete is a heterogeneous material with uneven distribution of pore structure, and the pores have a significant impact on the freeze-thaw damage of concrete. On the one hand, the water solution in the pores has about 9% volume expansion when water freezes to ice [72]. As the temperature decreases, the concrete gradually freezes from the outside to the inside, and there is a coexistence of ice and water in the pores. As the volume of ice continues to increase, the unfrozen water is gradually pressed toward the interior of the concrete. When all of the surrounding pores are frozen, unfrozen water accumulates in an area and continues to freeze, causing damage to the pores in that area due to the greater expansion pressure of ice (Figure 19). After adding PPF, when the pores in the concrete are subjected to a certain degree of expansion pressure, the expansion pressure can be transferred to other areas through PPF, thus relieving the stress concentration in the concrete. After adding NS, the C–S–H gel generated by NS can improve the pore structure of concrete, reduce the porosity, and increase the average spacing between the pores, which improves the ability of concrete pores to withstand the ice expansion pressure.

Figure 19 
                  Damage modeling of pores subjected to expansion pressure of ice.
Figure 19

Damage modeling of pores subjected to expansion pressure of ice.

On the other hand, the water in the pores of the concrete is not pure water, but a water solution dissolved with potassium, sodium, and calcium ions. The pure water in the pores gradually freezes into ice as the temperature decreases, causing the concentration of remaining water solution ions to continuously increase. The unfrozen water of the pores produces a pressure difference due to different concentrations, resulting in the migration of unfrozen water toward the pore of frozen water. The water solution absorbed in the pores of the frozen water continues to increase, which increases the water pressure on the pore walls and causes damage (Figure 20). Moreover, according to the size of the pores, the pores in concrete interior can be divided into macropores (50–104 nm), capillary pores (10–50 nm), and gel pores (0.5–10 nm) [73]. The temperature of the water solution starting to freeze in the macropores is higher than that of the capillary pores and gel pores [72], which causes the macropore to freeze first, resulting in a large amount of water solution being absorbed by the macropores, and the pore walls to suffer greater water pressure and damage. After adding NS, the C–S–H gel generated by NS can improve the pore structure of concrete, especially reduce the number of macropore in concrete, thus effectively reducing the damage of concrete. After adding PPF, the water pressure can be transferred to other areas through PPF, thus alleviating the stress concentration inside the concrete.

Figure 20 
                  Damage modeling of pore subjected to water pressure.
Figure 20

Damage modeling of pore subjected to water pressure.

7 Conclusions

  1. The compressive strength of concrete decreased with the increase in the RBA, while addition of PPF and NS could effectively improve the compressive strength of concrete.

  2. The compressive strength of concrete showed a trend of first increasing and then decreasing with the increase in the PPF and NS content.

  3. The gray relational degrees between the RBA, PPF, NS, and compressive strength were 0.6578, 0.8297, and 0.5941, respectively, indicating that PPF had the greatest effect on compressive strength, followed by RBA, and NS had the least effect.

  4. The addition of PPF and NS could improve the frost resistance of recycled concrete, and its frost resistance was even better than ordinary concrete, mainly manifested in less change in apparent phenomena, lower mass loss, and lower compressive strength loss after same freeze–thaw cycles.

  5. The strengthening mechanism of PPF-NS on concrete performance was revealed through SEM image analysis and fractal dimension calculation.

Consequently, the effect of PPF-NS on the compressive strength, frost resistance, and microscopic mechanism of RBA concrete was investigated in this experiment. However, the higher price of NS results in higher costs for PPF-NS modified recycled concrete in engineering applications. In addition, there is no effective control method for PPF and NS agglomeration reactions in engineering applications. These issues need to be further investigated in subsequent explorations.

  1. Funding information: This work was supported by the China Postdoctoral Science Foundation under Grant 2022M723687; Shandong Province Natural Science Foundation under Grant ZR2021QE209; Doctoral Science and Technology Startup Foundation of Shandong University of Technology under Grant 420048; and Shandong University of Technology Student Innovation and Entrepreneurship Training Program.

  2. Author contributions: Shangwei Gong: investigation, experimental program, funding acquisition, and writing – original draft preparation; Ting Wang: writing – original draft preparation, data analysis, writing – review and editing, and checking the original draft; Md Mahmudul Hasan and Zhenyu Tan: experimental program; Xuefeng Mei: writing – review and editing and checking the original draft; Tian Su: investigation, funding acquisition, writing – original draft preparation, checking the original draft, and writing – review and editing; Fubo Cao: checking the original draft and data analysis. All authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  3. Conflict of interest: The authors state no conflict of interest.

  4. Data availability statement: All data generated or analyzed during this study are included in this published article (and its supplementary information files).

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Received: 2023-09-25
Revised: 2023-11-27
Accepted: 2023-11-29
Published Online: 2023-12-25

© 2023 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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