Gayake and Desai  Smart Construction and

Smart Construction and Sustainable Cities (2024) 2:7

https://doi.org/10.1007/s44268-024-00031-9 Sustainable Cities

RESEARCH Open Access

Multi‑criteria decision making tool

for sustainable concrete production using
waste polyethylene terephthalate bottle cap
aggregates
Sudhir Bhaskarrao Gayake1,2*   and Atul K. Desai1

Abstract
The widespread use of concrete has raised concerns about the consumption of its raw materials. To address this issue,
researchers are actively exploring alternative waste materials to reduce the environmental impact of the construc-
tion industry. With this objective current study aims to investigate potential use of waste polyethylene terephthalate
(PET) bottle cap aggregates on the characteristics of concrete, both in its fresh and hardened states. Three variations
of modified waste PET aggregates (PETA): full (F), half (H), and quarter (Q), with the aim of evaluating their suitability
as replacements for conventional coarse aggregates (CCA) was examined. The research assesses the effects of dif-
ferent PETA proportions (3%, 5%, and 8%) on concrete workability, compressive strength, splitting tensile strength,
and flexural strength. The findings reveal that PETA-F and PETA-H adversely affect workability, primarily due to their
larger surface area and difficulty in achieving homogeneous blending with other ingredients. In contrast, PETA-
Q exhibits superior workability. The use of PETA-Q results in reduced compressive strength due to its smaller size
and limited load-bearing capacity. Notably, PETA-H demonstrates improved compressive strength after 28 days. Inter-
estingly, PETA-Q shows enhancements in splitting tensile and flexural strength, making it the top-performing alterna-
tive for fresh and hardened concrete properties. Overall, this research indicates that PETA-Q is most suitable for sus-
tainable concrete production. Furthermore, the application of a multi-criteria decision-making tool validates our
findings and determines that a 5% replacement of CCA with PETA is optimal, as higher replacements result in strength
reduction. The utilization of PETA not only minimizes CCA consumption but also contributes to the development
of eco-friendly, sustainable concrete. This study underscores the potential of environmentally conscious concrete
and encourages the adoption of sustainable solutions for plastic waste management.
Keywords Polyethylene terephthalate, Concrete properties, Waste utilization, Analytical hierarchy process, Decision
making

1 Introduction
Concrete, as a fundamental construction material for
infrastructure development, wields substantial poten-
*Correspondence: tial for environmental impact. It ranks among the most
Sudhir Bhaskarrao Gayake extensively employed man-made substances on a global
gayakesudhirst@sanjivani.org.in
1
Department of Civil Engineering, Sardar Vallabhbhai National Institute scale, prompting growing concerns about the over con-
of Technology, Surat 395007, India sumption of raw materials in concrete manufacturing.
2
Department of Structural Engineering, Sanjivani College of Engineering, Comprising two pivotal constituents - an inert filler and
Savitribai Phule Pune University, Kopargaon 423603, India
a binding agent - concrete forms a chemically interlinked,

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Gayake and Desai Smart Construction and Sustainable Cities
rigid structure. Cement serves as the critical binding
component, while coarse and fine aggregates provide
the load-bearing strength. The worldwide construction
industry is actively investigating alternative materials for
concrete to mitigate reliance on conventional raw materi-
als, given concrete’s diverse applications and adaptability.
Recent research has demonstrated promising outcomes
in employing polyethylene plastic waste as a feasible sub-
stitute for traditional aggregates in concrete [1, 2].
Annually, the global production of non-recyclable plas-
tic waste amounts to millions of tons, with the major-
ity ending up in landfills or contaminating the world’s
oceans. In the context of India, plastic consumption has
experienced a substantial upswing, rising from 6,800
kilo tonnes in 2010 to approximately 20,898 kilo tonnes
in 2021. This signifies a remarkable 2.28-fold increase in
consumption between 2010 and 2016, as illustrated in
Fig. 1 [3].
The adoption of plastic recycling entails energy con-
sumption, thereby contributing to heightened envi-
ronmental pollution on land, in the oceans, and in the
atmosphere. The increased production of single-use
plastic items and the management of waste disposal have
emerged as significant global environmental challenges.
Plastics are classified into two primary categories based
on polymer properties: thermosetting plastics and ther-
moplastics [4]. Among them, PET (polyethylene tereph-
thalate) polymer stands out for its extensive application
in packaging, including bottled drinking water, and vari-
ous products due to its durable semi-crystalline nature,
exceptional mechanical strength, and robust resistance
to hydrolysis, chemicals, and solvents, along with com-
mendable tensile strength [5]. The ease of utilizing PET
Fig. 1 Plastic consumption annually from year 1990 to 2021 [3]
(2024) 2:7 Page 2 of 17
bottles has led to a surge in demand, consequently mak-
ing their waste management a pressing concern [6].
In recent years, several experiments have explored
the replacement of natural aggregates in cementitious
composites with waste plastic aggregates. These experi-
ments encompass various approaches, such as shredding
and altering the geometric characteristics of heated and
melted PET plastic. Incorporating these waste plastics
in construction projects significantly reduces the density
and overall weight of the resultant concrete structures
[7]. Reusing waste plastics in construction is regarded
as one of the most efficient disposal methods among the
multitude of recycling management strategies. The inte-
gration of used PET bottles as filler materials in concrete
offers opportunities for recycling these waste materials.
Many studies have explored the application of PET bottle
fibers as structural concrete reinforcements, albeit at the
cost of a reduction in primary strength and a concurrent
improvement in flexibility [8].
Numerous experimental investigations, employing
life cycle assessment techniques [9, 10], have evaluated
concrete incorporating varying proportions of pow-
dered PET, indicating that a 5% substitution yielded the
most improved strength [11, 12]. These investigations
have also addressed performance, optimization [13], and
chemical surface treatment of PET fibers, revealing their
role in enhancing concrete properties [14]. Notably, the
alteration of PET waste shape allows precise size match-
ing with natural sand, with an increase in PET aggregate
content leading to a decrease in mortar consistency [15].
The use of PET waste and recycled materials has become
increasingly prevalent in lightweight mortars and light-
weight concrete [16, 17]. The geometric attributes of PET
Gayake and Desai Smart Construction and Sustainable Cities
fibers have a negligible impact on concrete workability,
while the use of thinner-diameter fibers enhances work-
ability [18]. Furthermore, studies incorporating 10% recy-
cled PET granules as a replacement for fine aggregate
have demonstrated improvements in concrete properties,
especially up to approximately 10% volumetric replace-
ment [19–22].
The incorporation of PET-aggregates in concrete, in
any form, invariably leads to a reduction in compressive
strength. However, the compressive strength develop-
ment of concrete containing various PET-aggregates
exhibits behavior akin to that of conventional concrete.
No discernible differences in the mechanism of flex-
ural failure were observed when PET waste concrete
was used for monolithic and hybrid beams [23, 24]. The
utilization of PET bottle shredding material as a substi-
tute for fine aggregate yielded improved workability and
strength at lower replacement percentages. Neverthe-
less, an increase in the percentage of replacement corre-
lated with a decrease in strength [25–27]. The inclusion
of Bakelite waste in concrete represents a sustainable
approach to waste management and promotes the use
of environmentally friendly construction materials.
However, as the replacement ratio for coarse aggregate
increases, the mechanical properties of the concrete
deteriorate [28, 29].
In the contemporary world, decision-making is of
paramount importance for achieving optimal outcomes
while balancing conflicting criteria to attain specific
objectives. To tackle this challenge, advanced techniques
such as Multi-Criteria Decision Making (MCDM) tools
have been developed, leading to a paradigm shift in civil
engineering applications [30]. These tools facilitate the
evaluation of performance by considering technologi-
cal, economic, and environmental factors. The objective
of incorporating MCDM tools in civil engineering is to
advocate for a sustainable approach to material design in
the construction sector. These tools play a pivotal role in
determining concrete mixtures by considering various
inputs and selecting the most suitable alternative through
different MCDM methods. The final decision-making
process hinges on the alternatives presented [31]. Some
studies introduce an intelligent multi-criteria decision-
making model to handle complex construction scenarios,
incorporating expert judgments. It proposes a decision
hierarchy for method selection and demonstrates the
models feasibility, providing a valuable tool for decision-
making in underground construction [32]. Also a deci-
sion-making method for identifying optimal risk-control
schemes for excavation engineering projects utilizing
the fuzzy VIKOR method and triangular fuzzy sets was
implemented based on engineering experience and envi-
ronmental factors [33].
(2024) 2:7 Page 3 of 17
Numerous studies have assessed the properties of
concrete incorporating PET-aggregates through experi-
mentation. Typically, raw PET obtained from recycling
programs has been manipulated or heated, and then
shaped artificially using a specific mechanism or post-
processing method. This, in turn, consumes energy and
utilizes a minor amount of natural resources, contribut-
ing to pollution. The fundamental purpose and innova-
tion of this study are to evaluate the benefits of using
raw PET waste as a coarse aggregate in concrete, facili-
tating a sustainable construction process in the context
of modern infrastructure development and smart cit-
ies. Replacement percentages of conventional coarse
aggregates (CCA) with PET aggregates were set at 3%,
5%, and 8% without any preheat treatment or shredding.
PET waste in the form of full bottle caps was adopted
as a replacement for CCA, capitalizing on the natural
shape of the bottle cap body and configuring it into half
and quarter shapes. Additionally, the Analytical Hierar-
chy Process (AHP), a Multi-Criteria Decision Making
(MCDM) tool, is employed to recommend the most suit-
able concrete mix based on strength properties. Analytic
Hierarchy Process (AHP) is often favored over other
Multi-Criteria Decision-Making (MCDM) tools due to
its flexibility in structuring decision problems hierarchi-
cally, ease of use through pairwise comparisons ability to
handle both quantitative and qualitative criteria, trans-
parency in decision-making, and widespread acceptance
and application across various applications. The find-
ings aim to provide a more sustainable material for the
production of environmentally friendly concrete with
minimal alteration of waste and a reduction in post-pro-
cessing treatment, thereby mitigating land and water pol-
lution. The management of these substantial quantities
of plastic waste, however, presents a significant environ-
mental challenge.
2 Experimental program
2.1 Mixture materials
Portland pozolana cement (PPC) of 43 grade, the most
common cementitious component for concrete, has been
employed in the design. For concrete making, 20mm-
sized quarry stones are employed as conventional coarse
aggregates (CCA) together with natural river sand as fine
aggregate (FA). Before being used in the concrete mix,
the material was first cleaned to eliminate presence of
any dirt. Prior test such as specific gravity, water absorp-
tion capacity was measured using Indian standard tech-
niques using IS 2386 (Part IV) – 1963 and IS 1489 (Part
I)-1991 [34, 35].
Table 1 represents physical properties of raw materials
used for mix design of concrete.
Gayake and Desai Smart Construction and Sustainable Cities (2024) 2:7 Page 4 of 17

Table 1 Physical Properties of raw materials Figure 2 shows the geometry of modified PETA used in
Test Description Type of Material
the experimentation according to shape alterations. Here
the post processing, per-heating or shredding of waste
Cement Sand Coarse PET Aggregates plastic is completely eliminated and the collected PET
Aggregate
bottle cap are directly used by making variation in the
Specific Gravity 3.15 2.62 2.74 1.23 surface configuration of PETA. The detailed work chart
Water absorption - 6.50 2.20 0.35 illustrating the experimental flow is represented in Fig. 3.
Capacity %
2.3 Design mix
Four mixture types with the natural CCA substituted
with PETA by 3%, 5% and 8% were chosen in order to
2.2 Modified PETA evaluate the performance of PET aggregate on the fresh
In this experimentation waste packaged drinking water and harden characteristics of concrete. Due to the differ-
bottle were collected from local restaurants and hotels ence in specific gravity between natural CCA and PETA,
and the bottle caps was segregated from collected waste. the volumetric design technique was adopted. Here, full
The segregated caps were then cleaned and open dried in cap PETA, half cap PETA, and quarter cap PETA con-
an enamel try for 24 h. The full (F) caps were then cut into crete was compared to Normal M25 concrete, which
half (H) and quarter (Q) shape approximately 28mm in served as the controls specimen.
diameter and adopted for experimentation by a replace- In the concrete mix design, each combination had
ment of 3%, 5% and 8% with CCA with varying shapes. the same kind of Portland pozolana cement (PPC) of

Fig. 2 PETA normal and cut shaped configurations a Full, b Half, and c Quarter

Fig. 3 Flow chart of the experimentation work

Gayake and Desai Smart Construction and Sustainable Cities (2024) 2:7 Page 5 of 17

43 grade and river sand as fine aggregate. Based on the
findings of earlier tests on the core raw materials, an
experimentation mix design for M25 concrete adopting
IS10262:2009 [36] was designed and implemented. In
Table 2, the weighted average mix proportions for each
mix for a concrete volume of one cubic meter are listed.
The concrete mix was created with a water cement ratio
of 0.50 and a target strength of 25 MPa at 28 days. The
proportions of cement, fine aggregate, coarse aggregate,
and water/cement followed the formula 1:2.09:2.83:0.5
for the concrete mix design.
2.4 Test performed
splitting tensile strength was then calculated for
each mix blend adopted for experimentation.
iii. Flexural strength (FS)-A total of 24 beam speci-
mens (100mm × 100mm × 500mm) were cast,
cured for 28 days and tested for two-point load and
simply supported condition. The necessary fail-
ure load was then progressively and consistently
applied at a standard rate. During testing, fracture
patterns were noted and crack initiation and prop-
agation were observed visually. The experimental
summarized test findings are presented in Table 3
and its significance is explained in the discussion.

i. Workability- Utilizing the slump cone test method

[37], flow ability of each freshly mixed mixture
was assessed. Concrete was poured into a surface-
leveled slump cone during the mixing of various
concrete blends, and it was then tamped for every
interval of concrete filling. The slump value was
then calculated as the height difference between
the cone and sample after the cone had been lifted.
ii. Compressive (CS) and Splitting tensile strength
(STS) - After 28 days of fully immersed water-cur-
ing, tests for concrete compressive strength and
splitting tensile strength were conducted. Typical
size molds were used for the experiments as per
[38]. Loading was then induced gradually and con-
stantly at a standard rate until the corresponding
failure load occurs. The compressive strength and
3 Results and discussions
3.1 Workability
Figure 4 illustrates the results of the slump test con-
ducted on the investigated concrete mixtures. Notably,
an increase in the percentage of PETA (Polyethylene
Terephthalate Aggregates) replacement in the mix cor-
relates with a reduction in the slump value. This obser-
vation aligns with prior research findings reported by
Edmund et al. [7], Lee et al. [14], and Islam et al. [5]. The
diminished slump is attributed to the sub optimal bond-
ing between PETA and the concrete matrix, primarily
caused by the smooth surface texture of PETA. Initially,
a controlled mixture was meticulously formulated to
achieve a 100 mm slump. However, as the PETA replace-
ment percentage rises, both PEAT-F and PETA-H exhibit

Table 2 Mix proportion details ingredients

Mix Type Quantity of Ingredient PETA Shape Water/
3 3
Cement
Cement (kg/m ) Fine Coarse Aggregate (kg/m ) PET Aggregate (Approximately Nos.) ratio
Aggregate
(kg/m3) 3% 5% 8% 3% 5% 8%

CCA​ 383.2 800.94 1087.7 1087.7 1087.7 -- -- -- -- 0.50

PEAT-F 383.2 800.94 1055.0 1033.3 1000.6 2331 3886 6217 Full 0.50
PETA-H 383.2 800.94 1055.0 1033.3 1000.6 4662 7772 12,434 Half 0.50
PETA-Q 383.2 800.94 1055.0 1033.3 1000.6 9324 15,544 24,468 Quarter 0.50

Table 3 Summarized test results at 28-day strength

Test Results for % Compressive Strength (MPa) Split Tensile Strength (MPa) Flexural Strength (MPa)
PETA/ Shapes
3% 5% 8% 3% 5% 8% 3% 5% 8%

CCA​ 23.420 23.420 23.420 2.724 2.720 2.720 2.250 2.250 2.250
PETA-F 24.550 26.074 24.160 2.632 2.795 2.590 2.020 2.120 1.960
PETA-H 30.203 33.190 28.270 2.789 3.065 2.611 3.335 3.665 3.130
PETA-Q 28.527 31.348 26.780 3.059 3.325 2.840 4.096 4.452 3.803
Gayake and Desai Smart Construction and Sustainable Cities
Fig. 4 Observed slump variation for PETA concrete
a declining slump. This decrease in workability can be
ascribed to the larger diameter of PEAT-F and PETA-H
aggregates and their inability to blend effectively with
the other concrete matrix constituents. It becomes evi-
dent that an escalation in the surface area of PETA leads
to a commensurate decrease in workability. Interestingly,
the slump value for PETA-Q remains nearly identical to
that of the controlled concrete, signifying excellent work-
ability. This congruence with results obtained by Bamig-
boye et al. [4] suggests that the shape of PETA-Q closely
matches that of the natural aggregate, thereby contribut-
ing to its favorable workability. Consequently, a smaller
PETA surface area is associated with improved concrete
flow, as evidenced in this study.
3.2 Compressive and splitting tensile strengths
The evaluation of concrete quality places significant
emphasis on its compressive strength, a pivotal and
fundamental parameter. The results of the tests, as
summarized in Table 3, indicate that the replacement
of Conventional Coarse Aggregates (CCA) with Poly-
ethylene Terephthalate Aggregates (PETA) leads to an
enhancement in both compressive strength and splitting
tensile strength, but only up to a 5% substitution level.
This observation concurs with the findings of Umasabor
and Daniel. After a curing period of 28 days, it is note-
worthy that H-PA (Hybrid PETA Aggregates) exhibited
the highest compressive strength, reaching 31.348 MPa.
This superior performance is attributed to the efficient
packing of PEAT-F (Full PETA) and PETA-H (Half PETA)
in conjunction with CCA within the concrete matrix. In
contrast, PETA-Q (Quarter PETA) displayed a decrease
(2024) 2:7 Page 6 of 17
in compressive strength when compared to the control
specimens and other combinations. These outcomes
align with the experimental results reported by Bamig-
boye et al. [4], Islam et al. [5], and Edmund et al. [7]. The
decrease in strength can be ascribed to the relatively
smaller size of PETA particles within the concrete, which
fails to effectively contribute to load shearing, conse-
quently leading to early concrete crushing. The variation
in compressive strength of the designed PETA-modified
concrete mixes is graphically illustrated in Fig. 5. Regard-
ing splitting tensile strength, a negative correlation with
the surface area of PETA is observed, coupled with a
marginal increase in response to changes in the shape of
PETA. This relationship is depicted in Fig. 6. The finer
surface texture and expanded surface area of PETA,
which result in sub optimal bonding at the interface and
the accumulation of free water, have also been identified
as factors contributing to the decline in tensile strength.
These observations align with the findings of Bamigboye
et al. [4] and Islam et al. [16].
In comparison to the controlled mixture, PETA-Q
(Quarter PETA) exhibited a remarkable improvement in
strength, ranging from 16 to 22%. After 28 days of cur-
ing, PETA-Q achieved a peak strength of 3.325 MPa.
In this context, the smaller size and shape of PETA-Q
particles serve as fibrous materials within the concrete
mixture, augmenting its splitting behavior. A visual rep-
resentation of the cylindrical specimen following the test
is presented in Fig. 7. Unlike PETA-Q and PETA-H (Half
PETA), no indications of sudden, brittle concrete failure
were observed, suggesting an enhancement in the dura-
bility of the fractured concrete. These observations align
Gayake and Desai Smart Construction and Sustainable Cities
Fig. 5 Compressive strength variation for PETA modified concrete
Fig. 6 Splitting tensile strength variation for PETA modified concrete
with the findings of Fakhruddin et al. [24] and Aocharoen
et al. [27].
3.3 Flexural strength
Figure 8 illustrates the flexural behavior of beams sub-
jected to a two-point load system using a Universal Test-
ing Machine, following 28 days of curing. The experiment
involved untreated plain M25 grade concrete beam spec-
imens, measuring 100 mm × 100 mm × 500 mm, without
reinforcement. These beams were treated with PETA to
evaluate the bending strength of the concrete. The results
presented in Fig. 8 reveal that, after 28 days, PETA-Q
(2024) 2:7 Page 7 of 17
(Quarter PETA) exhibited an impressive maximum
strength of 4.452 MPa, nearly double the strength of the
controlled beam. This enhancement can be attributed to
the smaller size and shape of PETA-Q particles, which
function as fibrous materials within the mixture, reduc-
ing the propagation of fractures and leading to improved
bending strength. These findings contradict the results
reported by Umasabor and Daniel [11], Islam et al. [16],
and Fakhruddin et al. [24].
When comparing PETA-Q to PETA-H (Half PETA) and
PEAT-F (Full PETA), PETA-Q demonstrated a 26% and
90% increase in flexural strength, respectively. Notably,
Gayake and Desai Smart Construction and Sustainable Cities (2024) 2:7 Page 8 of 17

the flexural strength of PEAT-F was found to be compa-
rable to that of the controlled beam, implying a higher
likelihood of voids in the concrete, which compromise
the cohesion of the matrix. Figure 9 provides a visual
representation of the tested beam specimens, along with
the fracture dispersion pattern induced during testing. It
is evident that in the controlled beam, the fracture initi-
ates at the center and follows a vertical bending crack,
while in the PETA-modified concrete beam specimen,
the crack moves toward the support as inclined crack.

Fig. 7 Tested specimens for splitting tensile strength a M25 Controlled concrete b Full cap PETA concrete c Half cap PETA concrete and d Quarter
cap PETA concrete

Fig. 8 Flexural strength variation for PETA modified concrete

Fig. 9 Crack initiation and pattern of failure a M25 Controlled concrete b Full cap PETA concrete c Half cap PETA concrete and d Quarter cap PETA
concrete
Gayake and Desai Smart Construction and Sustainable Cities
Furthermore, it can be observed that the crack initially
displays a semi-vertical orientation up to one-third of the
beam’s depth on the tension side before transitioning into
a shear fracture-like behavior below the point load.
4 Application of analytical hierarchy process
for selecting best concrete mix design
The Analytical Hierarchy Process (AHP) is a critical
tool in the selection of the most suitable concrete mix
parameter from a range of available options. Figure 10
illustrates the hierarchical structure of the AHP analysis
used to identify the best mix parameter for PETA con-
crete, considering various criteria and alternatives. These
tools are instrumental in prioritizing available options
and facilitating the selection of the optimal decision from
among the accessible alternatives. The AHP approach
adheres to a hierarchical structure, with the ultimate goal
positioned at the top, criteria at the second level, and
alternatives at the lowest level. AHP stands out as the
most widely employed mathematical model for resolv-
ing intricate and challenging decision-making problems.
These tools excel in determining the highest priority
among the offered alternatives. Notably, when conflicts
arise in decision-making, one of the significant advan-
tages of AHP is its ability to rank options while adhering
to the defined objectives.
The following steps were implemented to determine
the weight of the mix for all the combinations tested in
the experimentation:
i. In the initial AHP step, a pairwise comparison of
the experimental observations for attributes ‘i’ and
‘j’ as detailed in Table 3 is conducted, employing
the normalization technique. When an attribute
is compared to itself, it is invariably assigned the
value 1, resulting in the main diagonal elements of
Fig. 10 Schematic diagram showing hierarchy of AHP
(2024) 2:7 Page 9 of 17
the pairwise comparison matrix being equal to 1.
An excerpt of the pairwise matrix for the compres-
sive strength parameter is provided in Table 4 with
matrix size M = 12.
ii. The geometric mean of each row in the compari-
son matrix is computed, and the geometric means
of the rows are normalized to ascertain the rela-
tive normalized weight of each attribute as given in
Eqs. 1 and 2.
M 1/M
Geometric mean (GMj ) = [ bij] (1)
j=1
Weight of each attribute = Wj = GMj /
M
GMj (2)
j=1
iii. Three PETA aggregate shapes were tested for com-
pressive, splitting tensile, and flexural strength
of concrete, with comparisons made to conven-
tional concrete strength. By examining the weight
obtained for the compressive strength of concrete,
it becomes evident that PETA-H holds the highest
weight (0.10) for the mix, positioning it as the top-
ranking choice for compressive strength.
iv. Analogous steps from i to iii were executed for
splitting tensile and flexural strength evaluations of
PETA concrete in comparison to conventional con-
crete. The most suitable alternatives for each test
are highlighted in Tables 4, 5 and 6, and they are
visually presented in Figs. 11 and 12.
v. Figure 13 displays the maximum weights of alter-
natives for all tested mix combinations. The most
appropriate mix parameter among the various
combinations experimented with is ranked, and
PETA-Q emerges as the top choice in the list.
vi. As depicted in Fig. 13, it is notably evident that
the highest weight is attributed to the 5% replace-
Table 4 Pair-wise matrix for compressive strength property for all mix types
% PETA Compressive 3% 5% 8% Product of Weight
Strength (MPa) the row of the
CCA​ PEAT-F PETA-H PETA-Q CCA​ PEAT-F PETA-H PETA-Q CCA​ PEAT-F PETA-H PETA-Q mix
Gayake and Desai Smart Construction and Sustainable Cities

3% CCA​ 1 0.95 0.78 0.82 1.00 0.90 0.71 0.75 1.00 0.97 0.83 0.87 0.88 0.07
PEAT-F 1.05 1 0.81 0.86 1.05 0.94 0.74 0.78 1.05 1.02 0.87 0.92 0.92 0.08
PETA-H 1.29 1.23 1 1.06 1.29 1.16 0.91 0.96 1.29 1.25 1.07 1.13 1.13 0.09
PETA-Q 1.22 1.16 0.94 1 1.22 1.09 0.86 0.91 1.22 1.18 1.01 1.07 1.07 0.09
(2024) 2:7

5% CCA​ 1.00 0.95 0.78 0.82 1 0.90 0.71 0.75 1.00 0.97 0.83 0.87 0.88 0.07
PEAT-F 1.11 1.06 0.86 0.91 1.11 1 0.79 0.83 1.11 1.08 0.92 0.97 0.97 0.08
PETA-H 1.42 1.35 1.10 1.16 1.42 1.27 1 1.06 1.42 1.37 1.17 1.24 1.24 0.10
PETA-Q 1.34 1.28 1.04 1.10 1.34 1.20 0.94 1 1.34 1.30 1.11 1.17 1.17 0.09
8% CCA​ 1.00 0.95 0.78 0.82 1.00 0.90 0.71 0.75 1 0.97 0.83 0.87 0.88 0.07
PEAT-F 1.03 0.98 0.80 0.85 1.03 0.93 0.73 0.77 1.03 1 0.85 0.90 0.90 0.07
PETA-H 1.21 1.15 0.94 0.99 1.21 1.08 0.85 0.90 1.21 1.17 1 1.06 1.06 0.09
PETA-Q 1.14 1.09 0.89 0.94 1.14 1.03 0.81 0.85 1.14 1.11 0.95 1 1.00 0.08
Sum 13.81 13.17 10.71 11.34 13.81 12.40 9.74 10.32 13.81 13.38 11.44 12.07 12.08
Page 10 of 17
Table 5 Pair-wise matrix for split tensile strength property for all mix types
% PETA Split Tensile 3% 5% 8% Product of Weight
Strength (MPa) the row of the
CCA​ PEAT-F PETA-H PETA-Q CCA​ PEAT-F PETA-H PETA-Q CCA​ PEAT-F PETA-H PETA-Q mix
Gayake and Desai Smart Construction and Sustainable Cities

3% CCA​ 1 1.03 0.98 0.89 1.00 0.97 0.89 0.82 1.00 1.05 1.04 0.96 0.97 0.08
PEAT-F 0.97 1 0.94 0.86 0.97 0.94 0.86 0.79 0.97 1.02 1.01 0.93 0.93 0.08
PETA-H 1.02 1.06 1 0.91 1.03 1.00 0.91 0.84 1.03 1.08 1.07 0.98 0.99 0.08
PETA-Q 1.12 1.16 1.10 1 1.12 1.09 1.00 0.92 1.12 1.18 1.17 1.08 1.09 0.09
(2024) 2:7

5% CCA​ 1.00 1.03 0.98 0.89 1 0.97 0.89 0.82 1.00 1.05 1.04 0.96 0.97 0.08
PEAT-F 1.03 1.06 1.00 0.91 1.03 1 0.91 0.84 1.03 1.08 1.07 0.98 0.99 0.08
PETA-H 1.13 1.16 1.10 1.00 1.13 1.10 1 0.92 1.13 1.18 1.17 1.08 1.09 0.09
PETA-Q 1.22 1.26 1.19 1.09 1.22 1.19 1.08 1 1.22 1.28 1.27 1.17 1.18 0.10
8% CCA​ 1.00 1.03 0.98 0.89 1.00 0.97 0.89 0.82 1 1.05 1.04 0.96 0.97 0.08
PEAT-F 0.95 0.98 0.93 0.85 0.95 0.93 0.84 0.78 0.95 1 0.99 0.91 0.92 0.08
PETA-H 0.96 0.99 0.94 0.85 0.96 0.93 0.85 0.79 0.96 1.01 1 0.92 0.93 0.08
PETA-Q 1.04 1.08 1.02 0.93 1.04 1.02 0.93 0.85 1.04 1.10 1.09 1 1.01 0.08
Sum 12.4 12.8 12.1 11.07 12.4 12.1 11.0 10.19 1245 13.0 12.9 11.92 12.03
Page 11 of 17
Table 6 Pair-wise matrix for flexural strength property for all mix types
% PETA Flexural 3% 5% 8% Product of Weight
Strength the row of the
(MPa) CCA​ PEAT-F PETA-H PETA-Q CCA​ PEAT-F PETA-H PETA-Q CCA​ PEAT-F PETA-H PETA-Q mix
Gayake and Desai Smart Construction and Sustainable Cities

3% CCA​ 1 1.11 0.67 0.55 1.00 1.06 0.61 0.51 1.00 1.15 0.72 0.59 0.80 0.06
PEAT-F 0.90 1 0.61 0.49 0.90 0.95 0.55 0.45 0.90 1.03 0.65 0.53 0.72 0.06
PETA-H 1.48 1.65 1 0.81 1.48 1.57 0.91 0.75 1.48 1.70 1.07 0.88 1.18 0.09
PETA-Q 1.82 2.03 1.23 1 1.82 1.93 1.12 0.92 1.82 2.09 1.31 1.08 1.45 0.12
(2024) 2:7

5% CCA​ 1.00 1.11 0.67 0.55 1 1.06 0.61 0.51 1.00 1.15 0.72 0.59 0.80 0.06
PEAT-F 0.94 1.05 0.64 0.52 0.94 1 0.58 0.48 0.94 1.08 0.68 0.56 0.75 0.06
PETA-H 1.63 1.81 1.10 0.89 1.63 1.73 1 0.82 1.63 1.87 1.17 0.96 1.30 0.10
PETA-Q 1.98 2.20 1.33 1.09 1.98 2.10 1.21 1 1.98 2.27 1.42 1.17 1.58 0.13
8% CCA​ 1.00 1.11 0.67 0.55 1.00 1.06 0.61 0.51 1 1.15 0.72 0.59 0.80 0.06
PEAT-F 0.87 0.97 0.59 0.48 0.87 0.92 0.53 0.44 0.87 1 0.63 0.52 0.69 0.06
PETA-H 1.39 1.55 0.94 0.76 1.39 1.48 0.85 0.70 1.39 1.60 1 0.82 1.11 0.09
PETA-Q 1.69 1.88 1.14 0.93 1.69 1.79 1.04 0.85 1.69 1.94 1.22 1 1.35 0.11
Sum 15.70 17.49 10.59 8.63 15.70 16.67 9.64 7.94 15.70 18.03 11.29 9.29 12.53
Page 12 of 17
Gayake and Desai Smart Construction and Sustainable Cities
Fig. 11 Maximum weight of alternatives for a compressive strength and b split tensile strength
ment of Conventional Coarse Aggregates (CCA)
with PETA. Furthermore, out of the three tests
conducted, the maximum weight is observed for
PETA-Q and PETA-H types of aggregates. The
triangular shape of PETA contributes to effective
particle packing, rendering the concrete denser and
subsequently enhancing its strength.
vii. Here it is evident that, though the compressive
strength of PETA concrete is improved by adding
PETA-H the remaining two strengths have shown
improvement using PETA-Q. Here the PETA of
smaller shape acts like and fiber in the matrix
resisting the crack initiation and thus improve-
ment in the strength. If the weight for compressive
(2024) 2:7 Page 13 of 17
strength of PETA-Q is observed from Table 4 and
Fig. 11a the weight is equal to 0.096 which is almost
equals with 0.10 and therefore concluded as the
best suitable shape of PETA.
4.1 Field applications of AHP
The application of Multi-Criteria Decision-Making
(MCDM) tools can provide significant advantages in the
process of material selection for concrete production.
These tools enable the consideration of a multitude of
factors, encompassing aspects such as strength, sustain-
ability, physical properties, shape and size, and feasibil-
ity, when making informed decisions. In particular, the
Gayake and Desai Smart Construction and Sustainable Cities
Fig. 12 Maximum weight of alternatives for flexural strength
Fig. 13 Ranking of most suitable concrete mix
Analytic Hierarchy Process (AHP) offers a systematic
and structured approach to the comparative assessment
and prioritization of different formulations of PET-
based concrete, with a specific focus on its mechanical
strength. This comprehensive evaluation involves the
examination of various variables, including the shape of
(2024) 2:7 Page 14 of 17
PET aggregates, the extent of substitution, and diverse
mechanical strength properties. By harnessing the capa-
bilities of AHP, the primary objective is to discern the
most suitable concrete mixture from the available alter-
natives, taking into account a range of critical factors.
Furthermore, the AHP methodology can be effectively
Gayake and Desai Smart Construction and Sustainable Cities
deployed in practical field applications, facilitating the
simplification of material selection processes and the
refinement of material choices for concrete production.
5 Conclusions
This experimental study aimed to enhance the perfor-
mance of materials and structures while retaining the
use of conventional coarse aggregates by integrating
discarded PET bottle caps into structural concrete. A
significant impetus behind this investigation was the
promotion of sustainable concrete production and the
realization of environmental benefits through the effec-
tive utilization of this waste material. Furthermore, the
study sought to validate the experimental findings by
employing a multi-criteria decision-making optimiza-
tion tool to address conflicting alternatives. The follow-
ing conclusions are drawn from this research:
1. PETA (Polyethylene Terephthalate Aggregates) with
a smaller surface area exhibits workability compara-
ble to that of the controlled mix. This enables optimal
flow and improved compaction, resulting in denser
concrete with enhanced strength properties. PETA-
Q, in particular, maintains a similar slump as the con-
trolled mix, signifying that a larger surface area and a
higher percentage of PETA have a detrimental effect
on concrete workability, leading to harsher mixes and
reduced strength in the final product.
2. Compressive strength (CS) improves up to a 5%
replacement of conventional coarse aggregate (CCA).
In this context, PETA-H demonstrates the highest
CS value of 33.190 MPa. When combined with CCA,
PETA-H offers a mix with improved workability,
reduced PETA surface area, and enhanced CS. Since
the CS values for PETA-H and PETA-Q are nearly
identical, it can be inferred that PETA-F decreases
concrete strength by reducing density, aggregate con-
tent, and ultimately resulting in lighter concrete.
3. The addition of PETA has a marginal impact on split-
ting tensile strength (STS) and flexural strength (FS).
In this scenario, PETA-Q outperforms PETA-F and
PETA-H. A maximum STS of 3.325 MPa, which is
22.24% higher than the standard concrete cylinder
after 28 days, was observed. Additionally, the maxi-
mum FS is approximately double that of CCA con-
crete, measuring 4.45 MPa. This increase in strength
is attributed to the fact that smaller PETA shapes
function as fibrous materials, enhancing particle
packing and overall strength.
4. The application of a Multi-Criteria Decision-Making
(MCDM) tool facilitated the ranking of the most
suitable mix type among the tested trial mixes, taking
into consideration various test parameters. It is con-
(2024) 2:7 Page 15 of 17
cluded that PETA-Q, with an optimal 5% replacement
of CCA, significantly enhances concrete strength and
is ranked as the most suitable mix.
This study underscores the positive impacts of
incorporating PETA in concrete, leading to improved
structural properties, addressing CCA scarcity, and
mitigating pollution stemming from discarded plastic
bottles through sound waste management practices.
6 Limitations and scope for future work
The integration of PET waste in concrete production
may not be universally suitable for all types of cement.
The results of the experimental investigation empha-
size that the replacement of conventional coarse aggre-
gate with PET aggregates is most effective up to a 5%
replacement ratio. Beyond this threshold, a noticeable
decline in the mechanical properties of the concrete is
observed. It’s worth noting that the tested concrete in
this study was plain cement concrete, and variations
may arise when dealing with reinforced cement con-
crete (RCC). In light of the limitations identified in this
research, the following areas merit consideration for
future studies.
1. Further experiments are recommended to explore the
generalization of these findings to reinforced cement
concrete (RCC). This extension of the research can
provide insights into the behavior of PET aggregates
in a more complex and structurally demanding envi-
ronment.
2. The influence of different shapes of PET aggregates
on the mechanical properties of concrete can be sys-
tematically investigated by varying the shapes and
conducting comprehensive tests. This approach can
yield a deeper understanding of how the geometry of
PET aggregates impacts concrete performance.
3. Exploring the long-term durability of concrete
incorporating PET aggregates and evaluating the
economic feasibility of this approach for large-scale
applications are excellent avenues for further inves-
tigation. This area of study can delve into the long-
term performance, resilience, and resistance of
PET-modified concrete in various environmental
conditions, providing valuable insights into its poten-
tial for sustainable construction.
Abbreviations
PET Polyethylene terephthalate
PETA Polyethylene terephthalate aggregates
CCA​ Conventional coarse aggregates
PETA-F Polyethylene terephthalate aggregates-full shaped
PETA-H Polyethylene terephthalate aggregates-half shaped
PETA-Q Polyethylene terephthalate aggregates-quarter shaped
Gayake and Desai Smart Construction and Sustainable Cities (2024) 2:7
MCDM Multi criteria decision making
AHP Analytical hierarchy process
PPC Portland pozolana cement
FA Fine aggregates
CS Compressive strength
STS Splitting tensile strength
FS Flexural strength
Authors’ contributions
*
Sudhir Bahaskarrao Gayake- Conceptualization, Methodology, Formal analysis,
Validation, Investigation, Writing - Original Draft. Dr. Atul K. Desai- Writing -
Review & Editing, Supervision, Project administration.
Funding
The authors did not receive any financial support from any organization for
the submitted work.
Availability of data and materials
The authors declare that the data supporting the findings of this study are
available within the paper.
Declarations
Competing interests
The authors declare that they have no known competing financial interests
or personal relationships that could have appeared to influence the work
reported in this paper.
Received: 10 April 2023 Revised: 27 February 2024 Accepted: 28 March
2024
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