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physical and mechanical properties of recycled concrete
physical and mechanical properties of recycled concrete
TOPICAL REVIEW
Keywords: durability, hybrid concrete, mechanical properties, optimization, physical properties, RAC, RCA
Abstract
The current state-of-the-art review indicates the need for future research to develop recycled concrete
aggregate (RCA) properties like natural aggregate (NA) as specified by Indian or international codes.
By improving the physical and mechanical properties of RCA, recycled aggregate concrete (RAC) may
achieve more similar performance to natural aggregate concrete (NAC). RCA’s physical and
mechanical properties are enhanced by mechanical treatments, chemical treatments, chemical-
mechanical treatments, thermal treatments, and thermomechanical treatments. Additionally, RCA is
coated with supplementary cementitious material (SCM) and nanomaterials to increase its properties.
RCA can be thermally treated to improve its properties while lowering its energy consumption by
adjusting the treatment duration. RCA properties are altered by mechanical treatment when charges
and revolutions are changed. It is possible to determine the set of charges and drum revolutions that
may produce the RCA with optimal physical and mechanical properties using decision-making
statistical techniques. A specific weight can be given to each physical or mechanical property of a
treated RCA when evaluating its performance. The same procedure can be used for chemical-
mechanical and thermomechanical treatments. It is possible to manufacture industrial RAC from the
RCA produced by this procedure. It may be anticipated that RAC composed of RCA with optimized
physical and mechanical properties will be more similar to NAC in terms of its physical, mechanical,
and durability properties. It is also possible to improve the material properties of the treated RCA by
coating them with SCMs or nanomaterials even more. The effect of SCM, nanomaterial, and fiber on
the physical, mechanical, and durability properties of RAC composed of treated RCA could be studied
in the future.
1. Introduction
Increasing construction aggregate demand and demolition waste have led researchers to recycle concrete waste
and produce recycled concrete aggregates (RCA), which can replace natural aggregates (NA) partially or fully
(Xiao et al 2012, Arezoumandi et al 2015, Bhasya and Bharatkumar 2018, Hu and Kundu 2020, Dos Reis et al
2021). Over 50 billion metric tons (BMT) of construction aggregate were expected to be consumed worldwide in
2017 (Hu and Kundu 2020). Construction and demolition waste (CDW) generation, and its recovery rate
worldwide are shown in figure 1 (Meyer 2009, Rao et al 2011, Yuan et al 2011, Yu et al 2013). Figure 2
demonstrates the country-wise awareness of recycling construction and demolition waste regarding the number
of recycling plants set up according to BMTPC (2018). Note that natural aggregate concrete (NAC) containing
some fraction of RCA refers to hybrid concrete (HBC) in the subsequent paragraphs or sections. Additionally,
the replacement of NA with RCA in the concrete is expressed as a percentage of hybridization or hybridization
ratio. RAC refers to concrete that contains one hundred percent RCA (hybridization ratio equal to one).
RCAs differ from NAs because their peripheral surfaces contain residue mortar (Martín-Morales et al 2011).
RCA’s mechanical and physical properties are affected by the mortar attached to the surface (Amer et al 2016)
(a) (b)
Figure 1. (a) Worldwide CDW generation and (b) recovery rate in 2017 (Dos Reis et al (2021)).
Figure 2. Worldwide recycling plants for CDW in year 2017 (BMTPC 2018).
and the processing method (Pedro et al 2014, Lavado et al 2020). RCA properties are also influenced by the
source concrete and its constituent aggregates (parent aggregate) (Padmini et al 2009, Adams et al 2016, Verian
et al 2018). The removal of attached mortar from RCA, the use of different mixing processes, and the addition of
mineral admixtures have been suggested as methods of improving the mechanical and durability properties of
HBC/RAC (Duan and Poon 2014, Pan et al 2017). Nanomaterials are also capable of modifying the mechanical
and durability properties of HBC/RAC (Zhang et al 2016). Adding mineral admixtures is an expensive and time-
consuming process, and engineers avoid using complicated, uneconomic, and time-consuming methods (Mi
et al 2020). A lack of technical guidelines, standard test methods, mixed proportioning methods, and standard
code specifications hinders the use of RCA in the construction industry (Adams and Ideker 2020, Mi et al 2020).
It is possible to eliminate costly modifications to HBC by using a predictive design relationship based on
statistical analysis. According to Knaack and Kurama (2015), some specific acceptance criteria may be employed
to achieve and satisfy the target mix-proportion performance in the case of HBC or RAC.
The factors that affect the mechanical and durability properties of RAC/HBC are strength and water
absorption in the source concrete (Tavakoli and Soroushian 1996, Ferreira et al 2011). According to Kou et al
(2011b), if the source concrete has high strength and the same water-cement ratio, the target strength of RAC is
easily achieved. It is possible to increase RAC’s compressive strength and reduce porosity using proper mixing
methods, surface pre-treatment, and the water-cement ratio (Liang et al 2015). Workability and mechanical
properties of RAC are greatly influenced by the water absorption of RCA (Ajdukiewicz and Kliszczewicz 2002,
Tam et al 2008, Princigallo 2018). Thus, by using a water compensation method (WCM), HBC has equivalent
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workability to the control mix with minimal strength loss (Poon et al 2004a, Fonseca et al 2011, De Brito and
Barra Bizinotto 2011, Amorim et al 2012). According to De Brito and Barra Bizinotto (2011), WCM can produce
a stronger RAC than pre-saturated RCA. Pre-saturated RCA pores are water-filled, preventing cement paste
from penetrating them, resulting in weaker formation of interfacial transition zones (ITZ). Surface saturated dry
(SSD) RCA in an HBC mix may release water during vibration, increasing the water-cement ratio, weakening the
aggregate-cement bond, and lowering concrete strength (Poon et al 2004a).
It is well documented that ITZs are weak links between aggregate and cement mortar matrix (Otsuki et al
2003, 2011a, Poon Chisun and Kou Shicong 2010, Kou et al 2007, Silva et al 2015a, Makul 2020). The mechanical
and durability properties of HBC are significantly affected by ITZ width, porosity, hardness, strength, and
calcium hydroxide (CH) content (Hu and Stroeven 2004, Scrivener et al 2004). In HBC, two types of ITZ
surround the RCA. First type ITZ occurs between mortar and aggregate (OITZ), and the second type occurs
between RCA and freshly mixed cement mortar matrix (NITZ) (Otsuki et al 2003, Zhang et al 2016, Mi et al
2021). It has been reported by Otsuki et al (2003) that mortar quality has a significant impact on ITZ. When the
water-binder ratio is high, the NITZ is weaker and the OITZ is stronger. According to Ryu (2002), RACs with a
low water-cement ratio tend to have strong NITZ. This is a case where OITZ determines the strength of RAC. By
lowering the water-binder ratio, the compressive strength of RAC is increased by increasing the strength of
NITZ up to the strength of OITZ.
Pores and cracks within the OITZ may provide the higher water content in NITZ and, thus, result in CH
crystals accumulating at the surface of the OITZ, reducing the mechanical and durability properties of concrete
(Kong et al 2010). According to Zhang et al (2019), adding pozzolanic material before mixing cement into RCA
and fine aggregate strengthens the porous structure of ITZ by filling cracks and pores. The addition of a
superplasticizer and supplementary cementitious material (SCM) provides a thin layer of cementitious materials
throughout the RCA. Additionally, the nano-fillers migrated towards the ITZ due to their particle size being
smaller than the binder particles (Wang et al 2020b). In this way, nano-fillers coated the surface of RCA and
hydration products, thereby inhibiting CH crystal growth and enhancing ITZ microstructure. Coating the RCA
with pozzolanic materials such as fly ash (FA), silica fume (SF) and ground granulated blast slag (GGBS) as a
stone-enveloping technique densifies the ITZ around it (Li et al 2009). RCA surface coating with nano-slurries
reduces crack width and increases elastic modulus for NITZ, but is ineffective for OITZ due to inadequate un-
hydrated cement particles (Zhang et al 2016). Mi et al (2021) discovered that the two-stage mixing method and
cement paste encapsulating the aggregate technique improved NITZ by filling the voids and cracks with cement
paste at the residual mortar surface.
Thus, RCA quality is a major factor that determines the physical, mechanical, and durability properties of
RAC/HBC. The following sections provide a comprehensive overview of the quality improvement techniques
for RCA reported in the literature. These methods are evaluated based on their performance. According to the
critical evaluation, the benefits and shortfalls of the methods are discussed by drawing on the literature. Based on
the improved properties of RCA, the structural performance of RAC/HBCs is also discussed.
The RCA is processed by crushing the parent concrete, reducing landfill waste, and providing construction
aggregate, as shown in figure 3 according to BMTPC (2018). Several studies have been published to improve the
material properties of RCA while also examining the mechanical properties, durability properties, and structural
performance of RAC/HBC. As shown in figure 4, a flow chart illustrates the methodology for reviewing the
literature. There have been many treatments used to improve the physical properties, and mechanical properties
of RCA to achieve the optimum strength of RAC/HBC. The improved physical and mechanical properties
obtained by several scholars using mechanical treatment, thermal treatment, acid treatment, thermo-
mechanical treatment, acid treatment followed by mechanical treatment, and pozzolanic treatment are
summarised in table 1 (Prince and Singh 2014, Butler et al 2014, Purushothaman et al (2014), Pandurangan et al
2016, Bhasya and Bharatkumar 2018, Surya et al 2019, Dilbas et al 2019, Shaban et al 2021, Verma et al 2021).
The following sections discuss the process of improving RCA’s physical and mechanical properties and its
impact on the mechanical properties, durability properties, and structural performance of RAC/HBC.
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Figure 3. Processing methodology of recycling the concrete from CWD (BMTPC 2018).
without affecting its compressive strength or split tensile strength is reported in this study. Despite this, the
authors have not studied the physical and mechanical properties of treated RCA when the drum revolutions and
charges are altered during the Los Angeles treatment. Additionally, the authors suggest that removing the mortar
may damage the RCA because of the higher revolutions of the drum. However, another study conducted by
Purushothaman et al (2014), considers the abrasion value of RCA as a quality parameter. Researchers have tried
to reduce the abrasion values of RCA by mechanically treating it with 12 charges and 150 revolutions of the
drum. According to their study, only the abrasion and crushing values of processed RCA are closer to NA. The
compressive strength and modulus of elasticity (MOE) of RAC consisting of processed RCA are therefore lower
than those of NAC. Additionally, the water absorption of RAC is 1.46 times higher than NAC.
Additionally, the drum revolutions and charges are changed to 300 and 12 to treat the RCA mechanically by
Pandurangan et al (2016). Although the RAC has a compressive strength like NAC, its bond strength is
significantly lower as reported in this research. In another study, 150, 300, and 450 drum revolutions for eight
charges (60 mm dia.) are used in the mechanical treatment of RCA by Alqarni et al (2021). As a quality
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Table 1. Physical and mechanical properties of NA, untreated RCA and treated RCA.
Water absorption (%) Specific gravity Bulk density (Kg m−3) Impact value (%) Crushing value (%) Abrasion value (%)
Publications TR
i ii iii i ii iii i ii iii i ii iii i ii iii i ii iii
Dilbas et al 2019 M 0.67 8.95 0.84 2.67 2 2.47 1350 1150 1270 — — 21 55 28
Verma et al (2021) CM 0.5 4.35 1.52 2.65 2.57 2.63 1620 1545 1588 15.48 29.68 16.1 27.62 38.4 27.4 16.97 34.92 16.92
Bhasya and Bharatkumar (2018) TM 0.69 4.67 1.59 2.77 2.41 2.52 1572 1430 1550 — 26.56 29.49 27.44 —
Purushothaman et al (2014) AC 0.3 1.56 0.92 2.79 2.38 2.44 1508 1239 1438 23 31 29 27 36 33 29 45 30
5
Note: - i: NA, ii: Untreated RCA, iii: Treated RCA, TR: Treatment, A: Acid, M: Mechanical treatment, T: Thermal treatment, AC: Acid Treatment with HCL, AS: Acid treatment with H2SO4, CM: Chemical and mechanical treatment, NT:
No treatment, PT: Pozzolanic treatment, TM: Thermal and mechanical treatment, R1, R2, R3: RCA from different sources.
parameter, the treated RCA gradation is considered in this study in a different way. Grading of aggregate is
commonly used to improve concrete matrix packing. As a result, the authors are unable to achieve the target
strength of the concrete mixtures at a replacement level of over 33%. A quality improvement process has been
demonstrated by Dilbas et al (2019), Dilbas and Cakir (2021), and Cakir and Dilbas (2021) by fixing RCA’s water
absorption below 1%. Only 60% of the NA is replaced with treated RCA without degrading the properties
of HBC.
It is essential that the physical and mechanical properties of NA meet specific criteria set by national and
international standards to achieve the desired physical, mechanical, and durability properties of NAC
(ACI 2007, IS 2016). Water absorption by NA ranges from 0.5 to 4% according to the international standard
(ACI 2007). As a result, the arbitrary selection of some of the RCA’s physical or mechanical properties as a quality
parameter in the mechanical treatment leads to fewer properties falling under the prescribed limits set for NA.
Due to the inferior quality of RCA, RAC has mechanical and durability properties that are lower than those of
NAC. Nevertheless, several standards and guidelines specify water absorption as the most fundamental
parameter for RCA quality (Martin-Morales et al 2013). The workability, mechanical properties, and water-
cement ratio of RAC are highly dependent on the controlled water absorption of RCA (Princigallo 2018).
If RCA is mechanically treated to reduce its water absorption to 1% or less, its other properties, such as
crushing value and impact value, may be severely affected. Therefore, this criterion cannot be applied to all types
of RCA, especially those containing parent aggregates that are relatively weak in impact and crushing. By
lowering the mortar content in RCA, it is possible to bring water absorption below 1%. There is no doubt that
the process will reduce RCA’s productivity, which will increase production costs. However, it is not necessary to
reduce only the water absorption of RCA to much lower levels to improve the strength and durability properties
of RCA. In addition to water absorption, specific gravity, crushing values, impact values, abrasion values,
flakiness, and elongation must also be included in a quality improvement process (Kim 2022).
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M25 grade. According to Pandurangan et al (2016), the compressive strength of concrete is 95% that of NAC for
M35 grade RAC. In terms of bond strength, this RAC falls short of NAC and is about 21% weaker.
According to Sui and Muller (2012), hardened cement paste can be removed at 250 °C–300 °C if mechanical
treatment is intensive enough. It is possible to produce coarse aggregates with apparent densities close to those of
virgin aggregates using this method. In addition, a thermal treatment at 500 °C can be followed by a short
mechanical treatment. Purushothaman et al (2014) treated concrete rubble thermally for 24 h by using a hot air
oven at a temperature of around 300 °C. Then, it was cooled and scrubbed for five minutes in the Los Angeles
abrasion machine. The researchers were able to increase RCA strength up to 96% of NAC strength through this
process. According to Pawluczuk et al (2019), the degree of aggregate cleaning is determined by the temperature
at which the concrete rubble is roasted. It is measured by the amount of cement mortar removed from the grain
surface. Granite grains are damaged by excessive temperatures (900 °C), resulting in significant deterioration of
aggregate properties, concrete mix consistency, and hardened concrete properties. With the fines being reused,
it is observed in this study that treatment temperatures at 600 °C are most effective.
Literature published on thermal treatment or thermal mechanical treatment produces RCA that have a
much lower specific gravity and a much higher water absorption than the parent aggregates. These studies have
been focused on removing mortar from the aggregate surface. However, there are some aggregates in RCA that
are only made of mortar. Hence, removing mortar content to a very low extent is not cost-effective. Even though
these studies can produce RAC up to M35 grade, only a few physical and mechanical properties are considered
when comparing it with NAC composed of parent aggregate. In order to eliminate the mortar content from RCA
to an optimum extent, it is necessary to use a method that involves the optimal temperature for heating and the
use of Los Angeles with charges. It is pertinent to consider the aggregate’s physical and mechanical properties
when determining treatment criteria. It may result in RAC having similar physical, mechanical, and durability
properties to concrete containing parent aggregate.
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treated RCA closer to the parent aggregate by applying suitable mechanical treatment. As a result, RAC may have
properties closer to those of concrete made from parent aggregate.
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different packing densities. However, a low strength source is usually used to obtain light weight RCA. RCA
obtained from high strength sources, however, may not be lightweight. It is reasonable to consider geopolymer
concrete separately since the present review focuses on cement concrete.
Carbonation treatment is another method to improve the quality of RCA. In this treatment, the reaction
between CH and C-S-H available in the adhered mortar and CO2 forms solid calcium carbonate (Shi et al 2012,
Morandeau et al 2014). Calcium carbonate as a reaction product precipitates in the pore space and thus densify
the microstructure of RCA (Xuan et al 2016). According to Shi et al (2018), the water absorption of the RCA is
reduced by 26.41% and the apparent specific gravity is increased from 2.49 to 2.56 after the carbonation
treatment. In comparison to untreated RCA, 24 h CO2 treatment decreases water absorption by 19%-25% and
porosity by 18%-21% in the treated RCA (Zhan et al 2014). The mixture made with CO2 cured aggregate has
approximately 10%–15% lower drying shrinkage and 41%–46% higher resistance to chloride ion penetration
than the control sample (Kou et al 2014). According to Li et al (2017b), CO2 curing reduces the water absorption
and crushing value by 22.29% and 21.22% and increases the apparent specific gravity from 2.58 to 2.60. Thus,
the compressive strength of carbonated RAC is improved by 8.18%, 17.49% and 12.18% at 7, 28 and 91 days
respectively. MOE of carbonated RAC is increased by 12.19% at a strain rate of 0.0001/s.
According to Qidong et al (2022), graphene oxide enhances RAC strength and ITZ. The 28-day compressive
strength of RAC is improved from 7.8% to 20.6%, and the porosity of RAC samples decreases by 8.1% to 35.7%
when graphene oxide is added from 0.01 to 0.05 % by weight of cement. The addition of graphene oxide reduces
pore phase and unhydrated phase content in the matrix and increases the volume fraction of C–S–H phase,
especially high-density C–S–H phase. The width of the NITZ is reduced by 25%, but the OITZ remains
unchanged. As a result of the nucleation of graphene oxide and the filling effect of micro-aggregates, it
strengthens RAC strength and improves its pore structure and ITZ.
The performance of carbonation is highly dependent on the quality of the adhered mortar in terms of the
amount of available CH and C-S-H (Xuan et al 2016). A majority of RCA comes from CDW. The carbonation
treatment of RCA is not effective in improving its quality if it is obtained from an aged source. According to
Xuan et al (2016), the carbonation treatment increases the compressive strength of RAC made up of old RCA
(CDW) by 6.6%, while the compressive strength of the new RCA (batching plant) is 22.6%. In addition, MOE is
improved by 8.3% and 13.2%, and flexural strength by 0.9% and 28.7%, depending on the old RCA or the
new RCA.
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pozzolanic powder (SEPP) improves the compressive strength of RAC by 45.39%, 33.94% and 30.14% for SF
(20%), FA (20%) and GGBS (20%) compared to stone enveloped with Portland cement (SEPC). Additionally,
SEPP improves flexural strength by 1.92%, 22.69%, and 27% for SF (20%), FA (20%) and GGBS (20%) and
increases slump. Li et al (2017a) have experimented with other mixing approaches using NS and nano lime.
Despite this, no significant differences are observed in the compressive strength of HBC at 7 and 28 days
regardless of the exact dosage of NS.
Furthermore, other mixing approaches are also available in the literature, such as encapsulating the RCA
with cement paste during mixing (Liu et al 2016). By using this method, the residual mortar and the
microstructure between old and freshly applied mortar are strengthened. The cement paste encapsulating
aggregate approach (CPEAA) and using a TSMA decrease the carbonation zone width and corrosion zone width
in RAC (Mi et al 2021). Compared to NMA, TSMA and CPEAA decrease the carbonation zone width in RAC by
19% and 28.6% at the existing and added mortar interfaces, according to Mi et al (2021). At the residual and
added mortar interfaces, the steel corrosion zone width is also reduced by 3% and 5.43%, respectively. However,
the compressive strength of RAC produced by TSMA and CPEAA is almost the same and is around 7.55% higher
than NMA. In optimized triple mixing approach (OTMA) which is induced by Zhang et al (2019), SCM is added
after mixing RCA and water (60%–80%) with a superplasticizer. The addition of SCM just after water (60%–
80%) is beneficial for its dispersion and the formation of thin layers around RCA. OTMA produces RAC
compressive strength that is 19% and 10.6% higher than DMA and TMA, respectively.
According to Kong et al (2010), finer admixtures produce a denser microstructure due to their ability to
produce more hydration products in ITZ. The GGBS is finer than FA and produces denser ITZ when mixed in
the RAC and produces compressive strength comparable to NAC. RCA and FA together achieve a RAC strength
of 96% of NAC. The impact of the mixing approach with or without mineral additives (FA, GGBS and SF) on the
mechanical and durability properties of RAC is reported by Faysal et al (2020). Compared to NMA, TSMA
produces 20.70% and 23.73% higher compressive strength, and 16.67% and 29.16% higher split tensile strength
with GGBS (20%) and SF (7%), respectively. Meanwhile, TSMA produces 12.5% higher split tensile strength of
RAC in comparison to NMA without mineral admixture. Compared to NMA, TSMA reduces water absorption
of RAC by 1.96%, 13.72%, and 7.84%, and RCPT by 8.75%, 18.88% and 59.08%, without mineral admixture,
with GGBS, and SF respectively.
The mechanical properties of RAC are significantly correlated with the order of RCA placement during
mixing. The order in which RCA is added to the mix is critical to achieving hydration and maintaining slump
retention. Additionally, it is critical to order the correct SCM application when coating RCA, since this will
strengthen the OITZ by sealing microcracks. The mechanical and durability performance of RAC is enhanced
when blended with SCM than when mixed without SCM.
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Eng. Res. Express 5 (2023) 012007 A Kumar and G J Singh
Figure 7. Comparison of compressive strength of NAC, untreated and treated RAC (Note: - C: Chemical treatment, M: Mechanical
treatment, T: Thermal treatment, AC: Acid Treatment with HCL, AS: Acid treatment with H2SO4, CM: Chemical and mechanical
treatment, NT: No treatment, TM: Thermal and mechanical treatment).
The compressive strength of HBC mainly depends on the hybridization percentage, RCA’s type, size, and
origin (Silva et al 2015a). Hybridization that exceeds 30% gradually reduces the compressive strength of HBC
(Dhir and Paine 2004, Etxeberria et al 2007b, Yang et al 2008, Akbarnezhad et al 2011). With increasing RCA
fraction in HBC, more internal defects occur as a result of the increased amount of old mortar attached (Wang
et al 2020a). Additionally, the various treatments described in the literature, such as mechanical treatment,
chemical treatment, chemical-mechanical treatment, thermal treatment, and thermal-mechanical treatment,
improve RCA’s quality. As a result, the mechanical properties of RAC/HBC are also improved. For example,
TRCA, TRCA with FA and TRCA with SF are higher in compressive strength than URAC by 12.06 %, 43.38%,
and 40.98%, according to Bhasya and Bharatkumar (2018). Furthermore, figure 7 summarises a comparative
study of the compressive strength of URAC, TRAC, and NAC reported by various scholars (Purushothaman et al
2014, Pandurangan et al 2016, Bhasya and Bharatkumar 2018, Dilbas et al 2019, Ahmed et al 2020, Dilbas and
Çakır 2021).
Increasing RCA replacement fraction increases HBC peak strain due to its lowered MOE (figure 8) (Xiao et al
2005). It has been determined by Xiao et al (2005) that HBC/RAC has a 20% higher peak strain than NAC.
Although RAC shows less plastic deformation than NAC, according to Xiao et al 2005, the theory of plasticity can
be applied to RAC for structural design. As per Xiao et al (2018), RAC has a lower MOE than NAC by 9.4%. Peak
strain for RAC varies between 0.0018 to 0.0023 and ultimate strains varied between 0.0028 to 0.0033. For NAC
the peak and ultimate strains are 0.0018 and 0.0030. Thus, an improved RCA elastic modulus is necessary to
control the peak stress, peak strain, MOE and brittleness of RAC. The stress-strain curve is depicted in figure 9
(Xiao et al 2005, Xiao et al 2018, Bhasya and Bharatkumar 2018). RCA replacement increases the interfaces
between aggregates and mortar, leading to the progressive development of microcracks. The strains increase
faster, and the stress-strain curvature of RAC is steeper than NAC which shows the reduced ductility of RAC in
comparison to NAC (figure 9). In a study conducted by Bhasya and Bharatkumar (2018), MOE of RAC is
reported 19% lower and peak strain is enhanced by 8% as compared to NAC. MOE becomes only 12.40% lower
and peak strain becomes comparable to NAC when RCA is thermomechanically treated. Additionally, the
synergistic application of treatments and SCM may improve the peak stress, peak strain, and MOE of RAC
(Bhasya and Bharatkumar 2018). RCA density is a determinant of MOE of RAC. Thus, a specific treatment is
necessary to improve the RCA specific gravity.
Nano slurry strengthens the mortar over RCA and reduces its crushing value by 9.61%, and water absorption
by 43.75% as reported by Zhang et al (2016). By improving the quality of the RCA, the compressive strength is
increased by 14.26 %, and the chloride ion penetration is lowered by 14.75 %. Compared with the untreated
RAC, the treated RAC has significantly improved workability and compressive strength, and has reduced NITZ
width (Li et al 2017). NS increases the formation of C-S-H gel by reacting with CH and NS. Figure 10 compares
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Figure 8. Comparison of modulus of elasticity of NAC, untreated and treated RAC (Note: - C: Chemical treatment, M: Mechanical
treatment, T: Thermal treatment, AC: Acid Treatment with HCL, AS: Acid treatment with H2SO4, CM: Chemical and mechanical
treatment, NT: No treatment, TM: Thermal and mechanical treatment).
water absorption by NAC and treated and untreated RAC/HBC reported by Purushothaman et al (2014),
Bhasya and Bharatkumar (2018), Dilbas et al (2019), Ahmad et al (2020); and Dilbas and Çakır 2021. Based on
SEM analysis, HBC with NS has a denser microstructure with fewer micro cracks (Mukharjee and Barai 2014).
Additionally, NS treatment reduces the water absorption of HBC by 4.52% and 3.62%, respectively. According
to Mukharjee and Barai (2014), NS also reduces voids in aggregates and cement mortars.
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Figure 10. Comparison of water absorption of NAC, untreated and treated RAC (Note: - M: Mechanical treatment, AC: Acid
Treatment with HCL, AS: Acid treatment with H2SO4, CM: Chemical and mechanical treatment, TM: Thermal and mechanical
treatment).
31.62%, and 33.99% higher than URAC. The improvements in the tensile strength of HBC/RAC as reported in
the literature considering the various treatment methods are summarized in table 2.
Tensile strength is a measure of the fracture toughness of concrete. The split tensile strength or fracture
toughness is significantly affected by the surface characteristics (mainly texture) and abrasion values (hardness)
of the coarse aggregate (Özturan and Çeçen 1997, Siregar et al 2019). Additionally, for high-strength concrete, an
aggregate’s crushing value (crushing strength) also becomes the determining parameter of tensile strength
(Butler et al 2011). Flexure and split (indirect tension) are also determined by OITZ strength (Kumar and
Dhinakaran 2012). The shape (angularity number) and texture of the aggregate influence both the flexural
strength and split strength of concrete (Kim 2022). Improving the elastic properties and rough surface textures
of the RCA results strengthen NITZ, and improves the flexural strength of HBC/RAC.
Additionally, the mixing approach combined with SCM improves the surface properties of RCA. As a result
of coating the RCA with SCM, microcracks are reduced and pores are filled, thus strengthening the NITZ (Tam
et al 2005, 2006). SCM also strengthens OITZ by facilitating hydration in it. In ITZ, finer admixtures produce
more hydration products, resulting in a denser microstructure (Kong et al 2010). In the NMA, there are more
voids and cracks between RCA and mortar than in the TSMA due to the lack of water in the mortar at ITZ (Tam
et al 2005, 2006). The coating of RCA with SF (TSMA) increases the flexural strength and split tensile strength of
HBC by 8.38% and 12.84%, respectively (Tam and Tam 2008). SEPP improves flexural strength by 1.92%,
22.69%, and 27%, respectively, for SF (20%), FA (20%) and GGBS (20%) (Li et al 2009). Compared to NMA,
TSMA produces 16.67% and 29.16% higher split tensile strength with GGBS (20%) and SF (7%), respectively
(Faysal et al 2020). Meanwhile, TSMA produces 12.5% higher split tensile strength of RAC in comparison to
NMA without mineral admixture.
The synergistic effect of fibers and SF also increases the tensile capacity of RAC (Xie et al 2018, Ali et al 2020).
The flexural strength of RAC with SF and fibers is 28.18% higher compared to NAC without fibers and SF.
Compared with NAC, the fracture toughness of RAC with steel-fibre and SF (10%) is increased by 60.3%. The
flexural and split tensile strength of RAC are also reported to be 0.96 and 0.90 fraction of NAC by Ahmed et al
(2020). In some studies, the tensile strength of RAC is 29% higher than that of NAC due to an increase in bond
strength between the fibers and the concrete matrix (Ali et al 2020). The coupling of fibers with SF enhances the
flexural strength of RAC by 46% compared with plain RAC. Added steel fiber to HBC increases the flexural
capacity and ductility (Reza et al 2018).
To increase the tensile strength of HBC/RCA, it is crucial to improve the quality of the RCA to avoid the
complicated production process for industrial concrete. The material properties such as surface characteristics,
abrasion values, and crushing values of RCA that determine the tensile strength of HBC/RAC. Flexure strength
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Eng. Res. Express 5 (2023) 012007
Table 2. Variations in tensile strength of HBC/RAC as reported in the literature.
Literature HBC/RAC SCM/Fibers Split tensile strength (MPa) Flexural strength (MPa) Treatments/mixing methods
2.7 TSMA
20% FA 2.4 NMA
2.6 TSMA
20% GGBS 2.6 NMA
2.8 TSMA
7% SF 2.7 NMA
3.1 TSMA
Li et al (2009) 100 % URCA 20% SF 5.84 SEPP
20% FA 5.73
20% GGBS 7.23
20% SF 5.73 SEPC
20% FA 4.67
20% GGBS 5.69
16
Younis and Mustafa (2018) 100 % URCA 3.31 Coating with nano silica
0.4% NS 3.37
0.8% NS 3.46
1.2% NS 3.58
Yonggui et al (2020) 100% URCA 1.69 Synergistic effect of fiber
BF (3 kg m−3) 1.72
and nano silica
6% NS 1.76
6% NS + BF(3 kg m−3) 1.82
Wang et al (2019b) 100% URCA 1.69 1.83 Synergistic effect of fiber
and split tensile strength are also determined by OITZ strength. The shape and texture of the aggregate influence
both the flexural strength and split strength of the concrete (Kim 2022). Improved elastic properties and rough
surface textures of the RCA result in a higher strength NITZ that increases the flexural strength of HBC/RAC. A
process that may improve RCA’s physical properties, mechanical properties, and surface texture to resemble
with NA is therefore necessary.
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Eng. Res. Express 5 (2023) 012007 A Kumar and G J Singh
et al (2019). The split tensile strength of RAC is also reduced by 10.85% and 8.33% for hybridization ratios of 0.5
and 0.75 compared to NAC. Thus, the bond strength of RAC is reduced compared to NAC because of its higher
brittleness index and lower split tensile strength.
In contrast to the standard concrete beam, HBC beams with a hybridization ratio of 0.5 show irregular crack
patterns and split before yielding the reinforcement during full-scale bending tests (Sadati et al 2017). The
treatment of RCA significantly influences the bond strength in RAC compared to untreated RCA as shown in
figure 11 (Pandurangan et al 2016, Alhawat and Ashour 2020). According to Pandurangan et al (2016), the bond
strength of RAC is reduced by 40.47%, 24.23%, 13.33% and 7.27% compared to NAC when untreated,
thermally treated, mechanically treated, and acid-treated RCA are utilized.
Stiffness of HBC beam decreases with increasing hybridisation ratio (Knaack and Kurama 2015). Moreover,
the quality of reinforcing bars, aggregate, concrete cover, and bonding length affects the bond strength of HBC
like NAC (Alonso et al 1996, Mangat and Elgarf 1999, Vidal et al 2004, Knaack and Kurama 2020). HBC has
similar crack patterns and failure modes to NAC according to Maruyama et al (2004). The shear strength and
flexural strength also decrease with the hybridisation ratio in HBC beams (Choi et al 2010). The increasing
hybridisation ratio results in extensive concrete crushing in the compression zone and flexural cracks in the
tension zone of the HBC. According to Choi et al (2010), the span-to-depth ratio (a/d) significantly affects the
ultimate shear strength of beams. Compared to HBC beam of a/d ratio of 3.5, the ultimate shear strength of
HBC beam is observed to be 200% higher for HBC beam of a/d equals to 1.5 for same longitudinal
reinforcement ratio and RCA replacement ratio. Additionally, the cracking strength (first crack) of HBC is
lowered by 20% compared to NAC, because of the small tensile strength of RAC. The shear strength of RAC
decreases by 27% and 34% for longitudinal reinforcement ratios of 1.61% and 0.53%.
According to Ignjatovic et al (2013), the ultimate load, yield load and cracking load of RAC are decreased by
5.46%, 4.10% and 20% respectively compared to NAC for a tensile reinforcement ratio of 0.28%. The deflection
of a beam at ultimate load is also increased by 22.81% for RAC compared to NAC because of the MOE of RAC.
According to Arezoumandi et al (2015), the HBC beam retains its linear elastic behaviour only up to the first
flexural crack due to its low MOE. When the tensile reinforcement ratio is increased from 0.28% to 1.46%, the
ultimate load, yield load and cracking load of RAC become 3.93-, 4.32- and 2-times of the RAC with tensile
reinforcement ratio of 0.28%. The deflection at ultimate load also decreases around 58% (92.6 mm to 38.9 mm).
According to Seara-Paz et al (2018), because of the lowered splitting tensile strength of HBC the cracking
moment of HBC beams reduces by 10.88%, 45.55% and 46.31% for hybridization ratios of 0.2, 0.5 and 1,
respectively. The yield moment and ultimate moment are reduced by 3.43% and 5% for hybridization ratio 1.
The crack width of HBC with hybridization ratios 0.2, 0.5 and 1 is reported as 0.25 mm, 0.25 mm, and 0.27 mm,
and for NAC it is 0.22 mm. Thus, a higher hybridisation ratio decreases the split-tensile strength of HBC and
thus the cracking moment (Seara-Paz et al 2018). According to Choi and Yun (2013), maximum deflection in the
HBC beam satisfies the ACI (2011) code provision for maximum permissible deflection of NAC. However, the
HBC beam shows more cracks and longer cracks at failure than the NAC beam. The HBC beam fails abruptly
after reinforcement yields because of its high brittleness. Figure 8 shows the comparative analysis of the MOE of
NAC and treated and untreated RAC/HBC.
The high reinforcement ratio increases the shear capacity of an HBC beam (Arezoumandi et al 2014, 2015,
Ignjatović et al 2017). The shear strength of RAC beam is increased by 29% and 56% when the shear
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Eng. Res. Express 5 (2023) 012007 A Kumar and G J Singh
reinforcement is increased from 0.14% to 0.19% (Ignjatović et al 2017). According to Trindade et al (2020), the
shear strength of HBC (50%) composed of RCA obtained from 35–40 MPa source concrete is augmented by
46.15% compared to HBC composed of RCA obtained from 15–20 MPa. Similarly for RAC composed of RCA
obtained from 35–40 MPa the shear strength is increased by 47.35% compared to RAC composed of RCA
obtained from 15–20 MPa. Thus, the shear strength of HBC increases closer to NAC as the strength ratio is
increased. The shear resistance capacity for HBC beams constructed with high strength RCA is similar to that of
NAC. RCA with a high strength produces a better aggregate interlocking mechanism and more shear resistance.
Even 50% hybridization affects the aggregate behaviour and shear resistance capacity of HBC beams (Zhang
et al 2020). In Zhang et al (2020), the first crack shear stress is observed to be 1.71 MPa, 1.90 MPa, and 2.37 MPa,
correspondingly, for RAC, HBC (50%), and NAC, because of split tensile strength of RAC, HBC, and NAC is as
2.9, 3, and 3.2 MPa respectively. Additionally, the peak strains of RAC and HBC (50%) are reported to be 1.96
and 1.88 respectively, which are also higher than NAC (1.55). The MOE of RAC is 27.1 MPa where NAC has
31.2 MPa. The shear carrying capacity of HBC (50%) for 0 %, 0.46% and 0.81% transverse reinforcement ratio is
observed as 2.01, 5.31 and 7.14 MPa. Thus, after increasing the transverse reinforcement ratio by 76% the shear
stress of HBC is increased by 34.46%.
According to Kim et al (2020), the compressive strength rather than the level of hybridization plays a
significant role in determining the shear strength of HBC. Although crack propagation in RAC and NAC
without shear reinforcement is the same, crack spacing is observed to be closer in RAC by Pradhan et al (2018).
Comparing RAC with a NAC beam without shear reinforcement, 17%–22% less cracking load and
approximately 14% less ultimate load are observed in the studies conducted by Choi et al (2010), Etxeberria et al
(2007a), and Kim et al 2013. According to Butler et al (2014) and Kang et al (2014), RAC with higher tensile and
compressive strains, and lower bond strength, develops cracks faster. Additionally, in direct compression, the
ultimate axial load carrying capacity of HBC columns is inferior to that of NAC columns (Choi and Yun 2012),
and this is predicted conservatively by ACI 2008. According to Xu et al (2018), HBC columns with a high
hybridization ratio and a high strength ratio have a lower load-carrying capacity. The volumetric ratio of the
transverse reinforcement increases the load-carrying capacity and ductility of HBC columns significantly rather
than concrete grade.
The cracking moment of RCC beams mostly depends upon the tensile strength of concrete. As a result, RAC
has a lower cracking moment than NAC due to its lower tensile strength. Poor ITZ and available microcracks on
the RCA surface reduce the tensile strength of RAC (Ignjatovic et al 2013). In addition, various studies have also
shown that microcracks on the RCA surface increase RAC brittleness and reduce its energy consumption during
failure (Shi et al 2016, Seara-Paz et al 2018). The bond strength decreases as the brittleness index of RAC/HBC
increases. Additionally, it is suggested by Reza et al (2018) that adding steel fiber to HBC increases flexural
capacity and ductility, aligns crack distribution, and reduces crack width. Confinement in RAC beams with
stirrups are more effective than NAC beams (Sunayana and Barai 2020). In addition, confinement with stirrups
also changes the failure mode to ductile, resulting in flexural cracks and some flexure-shear cracks. However,
these studies do not discuss the effect of crushing strength on RCA on the structural performance of RAC. The
mechanical properties of aggregate are pertinent to discuss when discussing these types of mechanical properties
of concrete. It is possible that these effects are caused by the conglomeration of the two types of concrete used in
HBCs. Furthermore, the low crushing value of RCA compared to NA may also contribute to the crushing of
concrete in compression zones (Neville 1995).
The current state-of-the-art review suggests future research on improving RCA’s physical properties and
mechanical properties to increase RAC’s performance similar to that of NAC. It is possible to produce RCA by
improving its physical and mechanical properties in accordance with the requirements specified by the code for
NA. Specific gravity, water absorption, crushing and impact values, abrasion values, flakiness, and elongation are
some of the physical and mechanical properties that may be considered for the treatment criteria. Following are
the summary of the present study along with the scope for future research.
• The mortar attached to RCA determines critical physical and mechanical properties such as water absorption,
specific gravity, crushing and impact values, and characteristics of ITZ. Mineral admixtures slurry and
nanomaterials are sprayed with or without cement to enhance RCA quality. These treatments only improve
the physical properties of RCA through pozzolanic reactivity and filler effect. Researchers have also used
mineral admixtures and mixing approaches to enhance the strength, durability, and structural performance
of HBC. However, to improve the structural performance of RAC/HBC, the mechanical properties of RCA
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Eng. Res. Express 5 (2023) 012007 A Kumar and G J Singh
need to be improved. Additionally, these treatments make the concrete production process tedious and
expensive and is demoralizing the construction industry.
• Pre-treatment can improve the characteristics of RCA. By using SCM, the cement matrix (new and old) is
strengthened. Fiber generally increases the tensile strength of concrete. Using a mixing approach, the effective
water-cement ratio can be controlled. There are relatively few discussions of improving RCA’s physical and
mechanical properties in the literature. If the physical and mechanical properties of RCA are improved by any
process closer to NA, it may not be required additional treatment to improve its material properties even
more. The process may also be a direct way of producing RCA for industrial use.
• Researchers have attempted to remove mortar by machine grinding (Los Angeles) using some random charges
and drum rotations. If the number of charges and drum revolutions is reduced, RCA may not meet an
expected quality parameter like NA. Moreover, the high rotation (number of rotations) of the drum can cause
damage to the RCA after the mortar is removed. For some drum revolutions, the literature does not consider
the impact of charges on the physical and mechanical properties of RCA when treating with Los Angeles
abrasion. Different charges may affect the physical and mechanical properties of RCA differently.
• Mechanical treatment can be used to obtain the physical and mechanical properties of RCA for certain charges
and drum revolutions. It is possible to compare the physical and mechanical properties of treated RCA based
on varying charges and drum revolutions. The selection of RCAs with superior physical and mechanical
properties among the RCAs treated at different combinations of charge and drum revolutions is not
straightforward. Meanwhile, the performance of treated RCA can be evaluated by assigning a particular weight
to any physical or mechanical property. Through statistical techniques, the optimal set of charges and drum
revolutions can be determined, resulting in the most optimal physical and mechanical properties for the
treated RCA. For the preparation of concrete mixes, treated RCA with the most suitable material properties
can be used.
• Pre-soaking the RCA in an acid solution (strong or mild) removes the hydration product present in the
mortar. Strong acids negatively impact the physical, mechanical, and durability properties of RAC and
severely impact the environment. A weak acid is preferred for acid treatment of RCA to improve its physical
properties. To enhance RCA’s physical and mechanical properties even more, weak acids and mechanical
grinding are used. As a result, weak acid treatment accompanied by mechanical treatment with different
charges and drum revolutions may also result in RCA with different physical and mechanical properties. In
accordance with the process proposed for mechanical treatment, acid-mechanical treatment can also produce
RCA with optimal physical and mechanical properties. Acid treatment followed by mechanical treatment may
be expected to produce better results. An acid treatment reduces CH content, microcracks, and pores in
adhered mortar, while a mechanical treatment removes mortar adhered to the surface, thereby reducing the
amount of said microcracks and pores.
• Due to the difference in thermal expansion coefficients between NA and cement mortar, thermal treatment
also removes mortar from RCA. Thermal treatment at high temperatures, however, degrades the physical and
mechanical properties of the parent aggregate in RCA. There is no literature on optimizing thermal treatment
duration. In order to achieve optimal material properties of RCA, the duration of the thermal treatment can
be adjusted. A thermal treatment can be applied following the mechanical treatment as proposed in this study
to produce RCA with optimal material properties. At a minimum temperature, mechanical treatment can
produce RCA with superior properties. To manufacture RCA, heating (up to 350 °C) following mechanical
grinding may be energy efficient. It is possible to evaluate the mechanical properties, durability properties, and
structural performance of RAC using these RCA compared to NAC.
• Mineral admixture mixed with a mixing procedure improves RAC/HBC performance. The synergistic effects
of fibers and SCM densify the mortar matrix, increase the bond strength between the fibers and the mortar
matrix in RAC like NAC, and produce an additional gain in strength and tensile strength. As a result, RAC or
HBC is not widely accepted due to implicit predictions of strength and durability. Using statistical analysis to
predict design relationships can also eliminate costly modifications to HBC. After reviewing previous studies,
it is concluded that if RCA’s physical and mechanical properties can be improved to meet the code
requirements for NA, then RAC’s mechanical and durability properties and structural performance similar to
NAC’s can be achieved.
20
Eng. Res. Express 5 (2023) 012007 A Kumar and G J Singh
Funding
The authors declare that no funds, grants, or other support were received during the preparation of this
manuscript.
Competing interests
Appendix A
Nomenclatures
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Eng. Res. Express 5 (2023) 012007 A Kumar and G J Singh
ORCID iDs
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