materials

Article
Mixture Proportion Design Method of Steel Fiber
Reinforced Recycled Coarse Aggregate Concrete
Danying Gao 1 , Lijuan Zhang 1, * , Michelle Nokken 2 and Jun Zhao 1
1 School of Mechanics and Engineering Science, Zhengzhou University, No.100 Science Avenue,
Zhengzhou 450001, China; gdy@zzu.edu.cn (D.G.); zhaoj@zzu.edu.cn (J.Z.)
2 Faculty of Engineering and Computer Science, Concordia University, 1455 de Maisonneuve, West,
Ontreal H3G1M8, QC, Canada; m.nokken@concordia.ca
* Correspondence: zhanglj0526@zzu.edu.cn; Tel.: +86-136-5381-8353




Received: 23 December 2018; Accepted: 22 January 2019; Published: 25 January 2019


Abstract: Steel fiber reinforced recycled coarse aggregate concrete (SFRCAC) is an impact
minimisation building material. Mixture proportion design method of SFRCAC is developed in
this paper to obtain concrete with target strength and workability, which can be used in structural
members. Four key parameters of mixture proportioning, steel fiber content, water-cement ratio,
water content and sand ratio are discussed through the mixture design tests. The formula for
calculating the four key parameters of mixture proportions for SFRCAC are established through the
statistical analysis of test results, which mainly consider the influences of recycled coarse aggregate
(RCA) replacement ratio and steel fiber characteristic coefficient. The detailed procedure by using
the new mixture proportion design method is illustrated with examples. The formulas established
have the simple form, reflect the properties of RCA and steel fibers, enhance the mixture proportion
design accuracy, and provide the reference for the mix proportion design of SFRCAC.

Keywords: recycled aggregate concrete; steel fiber; mixture proportion design; water-cement ratio;
water content; sand ratio

1. Introduction
Recycled coarse aggregate (RCA) presents a sustainable solution to the depletion of natural
coarse aggregate (NCA) resources, and plays a key role in reducing the need for landfilling the waste
disposal [1–4]. Because RCA is mainly composed of two different materials, NCA and the attached
cement mortar [5,6], it has much higher water absorption and lower apparent density [7,8]. As well,
a large number of micro cracks are produced in the crushing process of waste concrete, which causes
the higher crushing index and reduces the soundness of RCA.
Due to the poor properties, the application of RCA has been limited. Adding steel fibers to
recycled coarse aggregate concrete (RCAC) can provide the bridging effect to prevent and reduce
the development of inherent micro-defects in RCAC [9], improve the mechanical properties of the
RCAC and especially better control its fracture process [10–12]. It has been well established that the
incorporation of steel fibers improves the engineering performance of RCAC, including better crack
resistance, increasing ductility and toughness as well as the enhancement in resistance to fatigue and
impact [13]. Also, steel fiber reinforced recycled aggregate concrete has better strength and durability
than recycled aggregate concrete, it can extend the service life of construction, the combination of
steel fibers and RCA has great environmental and economic benefits [14]. Hence, steel fiber reinforced
recycled coarse aggregate concrete (SFRCAC) has great potential for use in structural member.
The methods for the mixture design of SFRCAC is the basis of material research as well as
engineering application. The mixture proportions, such as varying coarse aggregate and steel fiber

Materials 2019, 12, 375; doi:10.3390/ma12030375 www.mdpi.com/journal/materials

Materials 2019, 12, 375 2 of 16

contents, will lead to the different properties of cement-based materials. Previous studies about the
mixture proportion of RCAC mostly focus on the following aspects:

1. The effect of RCA on concrete strength. RCA may lead to 20–25% decrease in compressive strength
compared to NCA with the same mixture proportion [15–18]. The compressive strength of RCAC
depends on the RCA properties and RCA replacement ratio [19,20]. All strength grades of RCA
are suitable to produce low strength concrete (20 MPa), but, the production of medium (40 MPa)
and high strength (60 MPa) concrete requires the RCA to have a source strength matching or
exceeding the strength of the new concrete [3].
2. The method to adjust the water content of RCAC. The water absorption and cement mortar of RCA
can be reduced by surface modification or pre-soaking methods [7,21], both the pre-saturation
method and the mixing water compensation method can be adopted to mix RCAC [22]. For the
latter, a two-stage mixing approach divides the mixing process into two parts and proportionally
splits the required water into two, this method has been found to improve the strength of
RCAC [23,24]. However, the methods mentioned above only make some adjustments of water
content in the batching process and do not provide the suitable calculation method for water
content of RCAC.
3. The equivalent mortar volume method [25]. This method considers RCA as a two-phase material
including mortar and NCA. The mixture design principle is the quantity and quality of each
phase of RCAC should achieve the same total mortar volume with NCAC, but the calculation
process of the method is too complicated to be easily used by engineers. A new mixture design
method was put forward by taking into account the higher porosity of RCAs, but now it’s only in
conceptual and the RCA replacement ratio can’t reach 100% [26].

Although ACI-555R [27] provides the guidelines for proportioning of concrete mixtures made
with RCA, neither it nor any other source gives a specific mixture design method for achieving target
fresh and hardened properties for SFRCAC. Therefore, to obtain a specific and effective mixture design
method for SFRCAC to ensure it has the similar fresh and hardened properties as conventional NCAC
even if using the different RAC replacement ratios is the main aim of this study. The calculating
formulas of steel fiber content, water-cement ratio, water content and sand ratio are proposed by
extensive experiments and analysis.

2. Materials and Methods

2.1. Materials
Portland cement (P.O 42.5) conforming to the stipulation in GB 175 [28] was used in all mixtures.
The coarse aggregate included NCA and RCA. NCA was crushed limestone with continuous grading
of particle sizes from 4.75 mm to 20 mm. RCA was obtained from the waste commercial ready-mixed
concrete in a concrete testing station with the compressive strength ranging from 30 MPa to 50 MPa,
and unknown age. The waste concrete was collected and crushed through a jaw crusher, then screened
through sieves with a maximum size of 20 mm and a minimum size of 4.75 mm. The grading of the
NCA and RCA was within the upper and lower limit bounds of ASTM C33 [29] except that the particle
size distribution was in the percentage passing the 9.5 mm sieve, and 24% for NCA, 35% for RCA.
The fine aggregate was river sand with a fineness modulus of 2.67. The properties of all aggregates
used in the test are shown in Table 1. The test was carried out according to Chinese standard GB/T
25177 [30] and GB/T 14685 [31]. The test method of crush index is pressuring the coarse aggregate with
the size from 9.5 mm to 19 mm which is put into the specified modulus to 200 kN with the speed of
1 kN/s, and then the mass of these coarse aggregate which size is below 2.36 mm is measured and the
crush index was calculated. Crush index mainly reflects the soundness of coarse aggregate. It can be
seen from Table 1 that the crush index of RCA is much higher than NCA, it means that the soundness
of RCA is poorer than NCA. The void ratio of coarse aggregate is calculated by the difference between
 Materials
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2019, 12 12 FOR
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FOR PEER
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Materials 2019, 12, 375 3 of 16

compactness
compactness
compactness of of coarse
of
coarse aggregate,
coarse
aggregate, thethe
aggregate, higher
the
higher of of
higher the
theof void
the
void ratio,
void
ratio, thethe
ratio, poorer
the of of
poorer
poorer compactness
of of of
compactness
compactness coarse
of
coarsecoarse
aggregate.
aggregate.
aggregate. It can
Itbe
theirItapparent
can be
can seen
be
seen from
seen
from
density Table
from
Table
and 1density.
Table that
1 that
bulk 1 thethe
that void
the
void
The ratio
void
ratio
void of of
ratio
RCA
ratioRCA
of RCAis higher
is
is higher
mainly higherthan
than
reflecting NCA.
than
NCA.
the NCA.
compactness of coarse
aggregate, the higher of the void ratio, the poorer of compactness of coarse aggregate. It can be seen
Table
Table Table1. Physical
1. Physical properties
1. Physical
properties of the
properties
of theof coarse
the
coarse andand
coarse fine
and
fine aggregate.
fine aggregate.
aggregate.
from Table 1 that the void ratio of RCA is higher than NCA.
Loose
Loose Loose
Apparent
Apparent
Apparent Table 1. Physical Dry-Rodded
Dry-Rodded
Dry-Rodded
properties of the coarse and Water
Water Water
fine Crush
Crush
aggregate. CrushVoidVoid
Void
Aggregate
Aggregate
Aggregate Packing
PackingPacking
Density
DensityDensity Density Absorption
Density Absorption
Density AbsorptionIndex Index Ratio
IndexRatio Ratio
Type
Type Type Apparent Density
DensityDensity
Loose Packing Dry-Rodded Water
(kg/m
(kg/m
Aggregate
3) 3) 3)
(kg/m (kg/m
(kg/m 3) 3) 3)
(kg/m (wt.(wt. %)%)Crush(%)
(wt.
%) (%)(%) Void
Index (%)(%) (%)
Ratio
Density (kg/m (kg/m3) 3) 3)
(kg/m
Density Density Absorption
Type 3
(kg/m ) 3 3 (wt. %) (%) (%)
(kg/m ) (kg/m )
RCARCA
RCA 2640
2640 2640 1302
1302 1302 1412
1412 1412 4.85
4.85 4.85 17.7
17.7 17.7 50.350.350.3
NCA
NCA NCA RCA 2814
2814 2640
2814 1568
1568 1302
1568 1630 1412
16301630 4.85
1.40
1.40 1.40 17.7
8.88.88.8 44.350.3
44.344.3
NCA 2814 1568 1630 1.40 8.8 44.3
Sand
Sand SandSand 2556 2556
2556
2556 1611
1611 1611
1611 1486
1486 1486
1486 0.56
0.56
0.56 0.56 –– – – – –– –

Compared
Compared
Compared with
with thethe
with NCA,
the
NCA, thethe
NCA, RCARCA
the RCA
hadhad higher
had water
higher
higher water waterabsorption,
absorption,
absorption, void
void ratio
void
ratio and
ratio
and crushing
and crushing
crushing index,
index,index,
Compared with the NCA, the RCA had higher water absorption, void ratio and crushing index,
butbut lower
but
lower apparent
lower apparent
apparent density.
density. AllAll
density. aggregates
All used
aggregates
aggregates used were
used
were in in
werethethe oven-dry
inoven-dry
the oven-dry condition.
condition.
condition. Three
Three Threetypes
types of of
types steel
of
steel steel
but lower apparent density. All aggregates used were in the oven-dry condition. Three types of steel
fiber
fiber were
fiber
were used
were
used in in
used this
in
this study,
this
study, thethe
study, photos
the
photos and
photos
and characteristics
and of of
characteristics
characteristics steel
of
steel fibers
steel
fibers areare
fibers shown
are
shown in in
shown Table
in
Table 2. 2. 2.
Table
fiber were used in this study, the photos and characteristics of steel fibers are shown in Table 2.
Table
Table 2. Photos
Table
2. Photos andand
2. Photos characteristics
and of steel
characteristics
characteristics fibers.
of fibers.
of steel steel fibers.
Table 2. Photos and characteristics of steel fibers.
Steel
Steel Fiber
Steel
Fiber Type
Fiber
Type Type MFMFMF WFWFWF HFHFHF
Steel Fiber Type MF WF HF

Fiber
Fiber photo
Fiber
photo
Fiber photo
photo

Mean length (lf )/mm 32.3 30 62

Mean
Mean
Mean Mean length
length
diameter
length (l(df)/mm
(lf)/mm f(l f)/mm
)/mm 32.3
0.94
32.3 32.3 30 30
300.76 62 620.7562
MeanMean Aspect
Mean
diameter ratio
diameter
diameter (l
(df(d /d
)/mm
f f(d
f )
)/mm f)/mm
34.2
0.940.940.94 0.7639.7
0.76
0.76 0.750.75 82.3
0.75
Aspect
Aspect Aspect ratio
ratio ratio
(lf/d(lf/d)(lf/d) f) 34.234.234.2 39.739.7
39.7 82.382.382.3
2.2. Mixture Proportion Method
2.2.2.2. Mixture
2.2.
MixtureMixture Proportion
Proportion
Proportion
The research
Method
Method Method
objective of this paper is to precisely determine the mixture design parameters of
SFRCAC
The TheThe
research to achieve
research
research objective
objective the
objective oftarget
of this
of
this strength
paper
this
paper paperisand
is to to workability.
precisely
is to precisely
precisely Generally,
determine thethe
determine
determine the
the
mixture conventional
mixture
mixture design
design design concrete
parameters
parameters
parameters isofmainly
of of
SFRCAC
SFRCAC composed
SFRCAC to to to of
achieve natural
achieve thethe
achieve thecoarse
targettarget aggregate,
targetstrength
strengthstrength
and sand,
and and cement and
workability.
workability.
workability. water.
Generally, The
thethe
Generally,
Generally, key mixture
conventional
the conventional
conventional design parameters
concrete
concrete is is is
concrete
mainly
mainly for
mainly concrete
composed
composedcomposed include
of of of
natural water-cement
natural
natural coarse
coarsecoarse ratio
aggregate,(W/C),
aggregate,
aggregate, sand,
sand, water
sand,
cement content
cement
cement
and and (m
and
water. ) and
water.
wwater.
TheThesand
The
keykey ratio
key (βs ).design
mixture
mixturemixture Once
design these
design
parameters
parameters
parameters
parameters forfor are
for
concrete determined,
concrete
concrete include
include each
include component
water-cement
water-cement
water-cement ratio can
ratio be
ratio
(W/C),calculated
(W/C), water
(W/C),
water waterby forecast
content
content (m(m
content quality
w) (m
w ) wand
and method
sand
) sand
and sand
ratio or
ratio absolute
(βs(β
ratio). s).
(βs).
Once
Once volume
Once these
these these method
parameters
parameters
parameters [32].
areare determined,
are determined,
determined, each
each eachcomponent
component
component cancan be
can
be calculated
be byby
calculated
calculated forecast
by forecast
forecast quality
quality quality method
method method
or or absolute
or Compared
absolute
absolute volume
volume volume with
method
method methodconventional
[32].
[32]. [32]. concrete, the properties and amounts of RCA and steel fiber will
inevitably
Compared
Compared
Compared affect
with
with with the
conventionalmechanical
conventional
conventional properties
concrete, thethe
concrete,
concrete, and
the workability
properties
properties
properties andand of
and SFRCAC.
amounts
amountsamountsof ofRCATherefore,
RCA
of RCA
and and andhow
steel
steel steel
fiberto fiber
determine
fiber
will willwill
the effect
inevitably
inevitably
inevitably affect of
theRCA
affect the
affect the and
mechanical
mechanical steel
mechanical fiber on the
properties
properties
properties and mixture
andand design
workability
workability
workability parameters
of of SFRCAC.
of SFRCAC.
SFRCAC. is the first
Therefore,
Therefore,
Therefore, how problem
how how
to totodetermine
be solved.
to determine
determine
thethe The
effect
the
effect experiments
effect
of of
RCA RCA
of RCA
and and insteel
and
steel this paper
fiber
steel
fiber onon
fiber was
the the
on divided
mixture
the
mixturemixtureinto
design four
design
design parts andisthe
parameters
parameters
parameters is test
the the parameters
first
isfirst
the problem
first
problem problemused
to to
beto inbe
be thesolved.
solved.
solved. test are
TheThe listed
The
experiments in Table
experiments
experiments in in 3.this
thisinpaperthispaperpaper
waswas wasdivided
divided divided
intointo four
into
four parts
four
parts and
parts
and and
the the test
the
test parameters
test parameters
parameters usedusedin in
usedthethe
intesttest
the areare
test
are
listed
listed in in
listed Table
in
Table 3. 3. 3.
Table
Table 3. Test plan and parameters.
Table
TableTable3.
3. Test
Material Test plan
3.plan
Test
Parameters and
plan
and parameters.
and parameters.
parameters. Mixture Design Parameters
Assessment
Test Parameters Steel Fiber
Material
Material
Material Parameters
Parameters
Parameters Vf Mixture
rg MixtureMixture Design
Design
W/C mParameters
Design Parametersβs
Parameters
w
Criteria
Type Assessment
Assessment
Assessment
Test
Test Parameters
Test Parameters
Parameters Steel Fiber
Steel
Steel Fiber Fiber
Steel fiber content Vf Vf Vf 0–2%rg rg rg0, 100%W/C
MF/WF/HF W/CW/C0.48 mwm164–196
wmw βs βs β36%
s Criteria
Criteria Criteriaf ftm
Type
Type Type
Water-cement ratio none – 0, 50%, 100% 0.30–0.55 180 36% f cu
Steel
Steel fiber
Steel
fiber
Waterfiber
content MF/HF
MF/WF/HF
MF/WF/HF
MF/WF/HF 0–2% 0–2%0–2%
0–2% 0, 100% 0, 0,
0, 100% 50%, 100%
100% 0.48
0.48 0.40
0.48 160–220 36%
164–196
164–196
164–196 36% 36%
36% fftmfftmfslump
ftm
content
content
content Sand content MF 0–2% 0, 50%, 100% 0.40 190 New method f cu , slump
Water-cement
Water-cement
Water-cement
nonenone
none – – –0, 50%, 0, 50%,
0, 100%
50%,100%100% 0.30–0.55
0.30–0.55 180180180 36%
0.30–0.55 36% 36% fcu fcu fcu
ratio
ratio ratio
Water
Water Watercontent
content MF/HF
content MF/HF MF/HF0–2% 0–2%
0–2% 0, 50%,
0, 50%,0, 100%
50%,100%100% 0.400.40 160–220
0.40 160–220
160–220 36%36% 36% slump slump
slump
NewNewNew
SandSand
Sandcontent
content content MFMFMF 0–2% 0–2%
0–2% 0, 50%,
0, 50%,0, 100%
50%,100%100% 0.400.40
0.40 190190190 cu, fslump
fcu, fslumpcu, slump
method
methodmethod
Materials 2019, 12, 375 4 of 16

According to the test purpose, the whole test was divided into the following four parts:

1. The purpose of the first part was the determination of the steel fiber content. Steel fibers have
more significant effect on the flexural strength than compressive strength [33], hence, the volume
fraction of steel fiber (V f ) can be determined by the flexural strength achieved. In order to ensure
the workability of SFRCAC, for each increase in V f of 0.5%, the water content is increased by
8 kg/m3 and the sand ratio by 3% [34]. To accurately determine the reinforcement effect of steel
fibers on flexural strength, one mixture of the plain concrete without steel fibers made with the
same mixture proportion corresponding to each V f group of SFRCAC was also prepared. The
mixture designs used in this part are listed in Table 4.

Table 4. Mixture design (kg/m3 ) and flexural strength of steel fiber reinforced recycled coarse aggregate
concrete (SFRCAC) with different steel fiber.

Specimen No. Water Cement Sand NCA RCA Steel Fiber f ftm /MPa
R0 164 342 721 1283 0 0 5.90
R100 164 342 721 0 1283 0 4.46
R0MF0.5 172 358 749 1171 0 39 6.67
R0NF0.5-C 172 358 749 1171 0 0 5.71
R100MF0.5 172 358 749 0 1171 39 5.00
R100NF0.5-C 172 358 749 0 1171 0 4.79
R0MF1.0 180 375 796 1099 0 78 7.28
R0HF1.0 180 375 796 1099 0 78 16.25
R0WF1.0 180 375 796 1099 0 78 8.13
R0NF1.0-C 180 375 796 1099 0 0 5.78
R100MF1.0 180 375 796 0 1099 78 5.44
R100HF1.0 180 375 796 0 1099 78 14.07
R100WF1.0 180 375 796 0 1099 78 5.73
R100NF1.0-C 180 375 796 0 1099 0 4.79
R0MF1.5 188 392 842 1029 0 117 8.76
R0NF1.5-C 188 392 842 1029 0 0 6.59
R100MF1.5 188 392 842 0 1029 117 7.36
R100NF1.5-C 188 392 842 0 1029 0 5.53
R0MF2.0 196 408 886 960 0 156 9.27
R0NF2.0-C 196 408 886 960 0 0 5.65
R100MF 2.0 196 408 886 0 960 156 8.54
R100NF2.0-C 196 408 886 0 960 0 4.34
Note: R100MF1.0 stands for the specimen with rg of 100%, milling steel fiber and V f of 1.0%; R100NF1.0-C is the
plain concrete which has the same mix proportion with R100F1.0.

2. The water-cement ratio (W/C) is the parameter influence concrete strength in mixture design.
Previous research has shown that using the same W/C, the addition of the steel fiber does
significantly improve the compressive strength of concrete after 28 days [35], but RCA may lead
to 20–25% decreasing of compressive strength [15]. The properties and replacement ratio of RCA
have significant effect on the strength of SFRCAC. The relation between compressive strength
(f cu ) and W/C was studied in this part; RCA replacement ratio (rg ), which is the mass ratio of
the RCA to the total coarse aggregate, was taken as 0%, 50% and 100%. Due to the differences in
density of NCA and RCA, the quantity of aggregate and sand was increasing with the increase of
W/C in the mixing process. The mixture designs used in this part are listed in Table 5.
Materials 2019, 12, 375 5 of 16

Table 5. Mixture design (kg/m3 ) and compressive strength of recycled coarse aggregate concrete
(RCAC) with different water-cement ratio (W/C).

Specimen No. Water Cement Sand NCA RCA f cu /MPa

W/C0.3R0 180 600 603 1073 0 75.2
W/C 0.3R50 180 600 590 525 525 58.4
W/C0.3R100 180 600 579 0 1030 55.3
W/C0.35R0 180 514 630 1121 0 62.0
W/C0.35R50 180 514 617 549 549 59.6
W/C0.35R100 180 514 605 0 1076 55.9
W/C0.4R0 180 450 650 1157 0 56.4
W/C0.4R50 180 450 636 566 566 51.3
W/C0.4R100 180 450 624 0 1111 49.2
W/C0.45R0 180 400 666 1185 0 47.5
W/C0.45R50 180 400 652 580 580 45.7
W/C0.45R100 180 400 639 0 1138 41.6
W/C0.5R0 180 360 678 1207 0 43.6
W/C0.5R50 180 360 664 591 591 41.2
W/C0.5R100 180 360 651 0 1160 37.4
W/C0.55R0 180 327 689 1226 0 38.2
W/C0.55R50 180 327 674 600 600 35.3
W/C0.55R100 180 327 661 0 1177 34.2
Note: W/C0.45R50 stands for the specimen with W/C of 0.45 and rg of 50%.

3. Slump is an index reflecting the workability of concrete, which mainly was affected by the water
content of concrete. The accurate determination for the water content of SFRCAC with different
RCA and steel fibers to achieve target slump is the objective of this part. More water is required
in the batching process to obtain the similar slump for RCAC as NCAC due to the higher water
absorption of RCA [21,36,37]. The slump of concrete has been found to decrease with the increase
of aspect ratio and volume fraction of steel fiber [38]. In this part, the several mixtures were made
at each water content varying both rg and V f , as shown in Table 6.

Table 6. Mixture design (kg/m3 ) and compressive strength of steel fiber reinforced recycled coarse
aggregate concrete (SFRCAC) with different water content.

Specimen No. Water Cement Sand NCA RCA Steel Fiber Slump/mm f cu /MPa
W16R0 160 400 685 1210 0 0 6 47.8
W16R50 160 400 671 597 597 0 4 45.5
W16R100 160 400 658 0 1171 0 2 45.0
W17R0 170 425 668 1187 0 0 13 51.9
W17R50 170 425 654 582 582 0 7 48.2
W17R100 170 425 642 0 1141 0 5 45.7
W18R0 180 450 650 1157 0 0 32 56.4
W18R50 180 450 636 566 566 0 21 51.3
W18R100 180 450 624 0 1111 0 13 49.2
W19R0 190 475 632 1126 0 0 60 49.6
W19R0MF1.0 190 475 632 1126 0 78 53 48.9
W19R0HF1.0 190 475 632 1126 0 78 42 50.6
W19R0MF2.0 190 475 632 1126 0 156 44 51.0
W19R0HF2.0 190 475 632 1126 0 156 25 52.2
W19R50 190 475 619 551 551 0 46 48.1
W19R50MF1.0 190 475 619 551 551 78 40 49.2
W19R50HF1.0 190 475 619 551 551 78 32 50.5
W19R50MF2.0 190 475 619 551 551 156 34 50.7
W19R50HF2.0 190 475 619 551 551 156 18 50.2
W19R100 190 475 607.3 0 1081 0 29 47.2
W19R100MF1.0 190 475 607 0 1081 78 25 48.6
W19R100HF1.0 190 475 607 0 1081 78 20 49.0
Materials 2019, 12, 375 6 of 16

Table 6. Cont.

Specimen No. Water Cement Sand NCA RCA Steel Fiber Slump/mm f cu /MPa
W19R100MF2.0 190 475 607 0 1081 156 22 50.1
W19R100HF2.0 190 475 607 0 1081 156 10 51.3
W20R0 200 500 615 1094 0 0 96 50.2
W20R50 200 500 602 536 536 0 78 48.7
W20R100 200 500 590 0 1051 0 49 51.2
W21R0 210 525 597 1063 0 0 130 47.4
W21R50 210 525 585 521 521 0 121 46.4
W21R100 210 525 574 0/0 1020 0 106 46.0
W22R0 220 550 580 1032 0 0 175 47.2
W22R50 220 550 568 505 505 0 168 44.5
W22R100 220 550 557 0 991 0 159 42.8
Note: W19R50HF1.0 stands for the specimen with water content of 190 (kg/ m3 ), rg of 50%, hooked at both ends
steel fiber, and V f of 1.0%.

4. The sand ratio (βs ) is the mass ratio of sand to the total mass of aggregates (the mass sum of
sand and coarse aggregate). Generally, βs is chosen according to the experience for ordinary
concrete [33]. Now, there is no precise calculation formula of βs for SFRCAC. The determination
of a reasonable sand ratio for SFRCAC was studied in this part. According to the principle that
fine aggregate needs to fill the voids between coarse aggregates, the volume of sand required in
SFRCAC should be the sum of voids caused by all coarse aggregates (including NCA and RCA)
and the dispersal of steel fibers. Hence, a new calculation model of sand volume can be set up
as follows:
Vs = γ × (Vna × Pna + Vra × Pra + Vf ) (1)

where, γ is the sand rich coefficient, it is the volume ratio between the fine aggregate and the
void caused by coarse aggregate and steels fiber, the range of γ can be taken from 1.1 to 1.4 for
NCAC [39], and can also be determined by tests; Pna is the void ratio of NCA, Pra is the void
ratio of RCA, both Pna and Pra are the basic material properties of coarse aggregate and can be
obtained by tests; V f is the volume fraction of steel fibers used to represent the voids caused by
steel fibers, because the void caused by steel fibers should be less than the volume of steel fibers
in the common use range of 0–2% and rarely more than 4%. The sand content can be calculated
by Equation (1), the values of other mixture design parameters in this part are consistent with the
previous parts. Table 7 gives the mixture designs in this part.

Table 7. Mixture proportions (kg/m3 ) and test results for new sand content method.

Specimen No. Water Cement Sand NCA RCA Steel Fiber βs Slump/mm f cu /MPa
CR0MF0 190 475 622.8 1106 0 0 36 64 50.4
CR50MF0 190 475 648.3 521 521 0 38.4 58 51.6
CR100MF0 190 475 673.2 0 987.4 0 40.8 50 51.2
CR0MF0.5 190 475 629 1085 0 39 36.7 60 50.9
CR50MF0.5 190 475 655.7 511.7 511.7 39 39 57 51.1
CR100MF0.5 190 475 678 0 968.2 39 41.2 48 51.5
CR0MF1.0 190 475 634 1064 0 78 37.3 60 51.2
CR50MF1.0 190 475 660 502 502 78 39.7 53 52.3
CR100MF1.0 190 475 683.8 0 949.6 78 41.9 43 52.6
CR0MF1.5 190 475 641 1044 0 117 38 55 53.3
CR50MF1.5 190 475 667 492 492 117 40.4 50 52.1
CR100MF1.5 190 475 689.1 0 931 117 42.5 40 52.9
CR0MF2.0 190 475 647 1023 0 156 38.7 52 54.5
CR50MF2.0 190 475 670.8 482.2 482.2 156 41 45 53.7
CR100MF2.0 190 475 693.7 0 912.4 156 43.2 38 53.2
Note: CR50MF1.0 stands for the specimen with rg of 50%, milling steel fiber and V f of 1.0%.
Materials 2019, 12, 375 7 of 16

When the material and mixture design parameters were determined, the “absolute volume
method” was chosen to calculate the components of SFRCAC because the changing range of RCA
density is bigger than NCA, which leads to the weight per cubic meter of SFRCAC is difficult to
estimate. The dosage of each component of SFRCAC can be calculated by:

Vc + Vw + Vs + Vna + Vra + Vf + α = 1 (2)

mra ρra × Vra Vna (1 − rg ) × ρra

rg = = ⇒ = (3)
mra + mna ρra × Vra + ρna × Vna Vra rg × ρna
ms ρs Vs
βs = = (4)
ms + mna + mra ρs Vs + ρna Vna + ρra Vra
where, V c , V w , V s , V na , V ra and V f is the volume of cement, water, sand, NCA, RCA and steel fibers,
respectively; ms , mna and mra are the mass of sand, NCA and RCA, respectively; ρna and ρra are the
apparent density of sand, NCA and RCA, respectively; α is the air content, to non-air-entrained steel
fiber concrete, α = 0.02.

2.3. Specimen Preparation and Test

The cubic specimens with side length of 150 mm were cast for the compressive strength (f cu )
test, the prism specimens of 100 mm × 100 mm × 400 mm were cast for flexural strength (f ftm ) test,
in which the three specimens for each group were prepared. The mixing process included three steps.
Firstly, the suitable moulds were prepared and brushed inside with a release agent. Secondly, all
aggregates and steel fibers were put into a small mixer to mix for about 2 min to ensure that steel
fibers could be uniformly distributed in the aggregates. Thirdly, the cement was added, and mixing
continued for another minute. Finally, the water was added to the mixer slowly, and mixed for another
2 min.
The slump of fresh SFRCAC was tested first, then was put into the prepared moulds and vibrated
for 20 s. After 24 h curing in ambient temperature, the specimens were carefully demoulded and
placed in a curing room at approximately 95% RH and 20 ◦ C.
All the tests were conducted after the 28-days curing of specimens. The compressive tests were
performed according to the stipulation in GB/T50081 [40], and were carried on a servo-hydraulic
closed-loop testing machine with capacity of 3000 kN at the loading rate of 0.6 MPa/s. The flexural
tests were carried on a MTS810 testing machine with capacity of 500 kN, displacement control at a
rate of 0.1 mm/min, according to ASTM C1609 (Using Beam With Third-Point Loading) [41]. The test
results of each group are the mean value of test results for three specimens. The test results in this
research are listed in Tables 4–7, respectively.

3. Analysis and Discussion

3.1. Steel Fiber Content

Based on the experimental results in Table 4, the flexural strength increases as V f increases from
0 to 2%, regardless if rg = 0 or rg = 100%. This indicates that the higher the V f , the better the reinforcing
effect of steel fiber on flexural strength. Because the fibers of MF and WF have similar aspect ratios, the
effect of MF and WF on the flexural strength of RCAC and NCAC is quite similar. The aspect ratio of
HF is much higher than MF and WF, and consequently the flexural strength and reinforcement ratio of
HF is much higher.
According to the analysis mentioned above, the volume fraction (V f ) and aspect ratio (lf /df ) of
steel fibers have much influence on the flexural strength of RCAC, which can be comprehensively
reflected by steel fiber characteristic coefficient (λf ), where λf = V f lf /df . The relation of the flexural
strength ratio of SFRCAC to RCAC with steel fiber characteristic coefficient, based on the experimental
 Materials 2019, 12 FOR PEER REVIEW 8
Materials 2019, 12, 375 8 of 16

experimental data from this paper and previous literature [42], is shown in Figure 1, an equation is
putfrom
data forward as follows:
this paper and previous literature [42], is shown in Figure 1, an equation is put forward
as follows:
f / f tm = α f 2λf + β f
2
(5)
f ftm / ftm
f tm = αf λf + β f (5)
where,
where, f ftmfftm
is is
thethe flexural
flexural strength
strength of SFRCAC,
of SFRCAC, MPa;MPa;
f tm isftmthe
is flexural
the flexural strength
strength of RCAC
of RCAC whichwhich
has thehas
the same mix proportion corresponding to SFRCAC, MPa; αf and βf are the parameters related to
same mix proportion corresponding to SFRCAC, MPa; αf and βf are the parameters related to material
material properties, here, αf =2.5, βf =1.
properties, here, αf =2.5, βf =1.

Current study,rg=0
3.0
Current study,rg=100%
2.5 [42]
fftm/ftm

y=2.5x2+1
2.0
R2=0.83
1.5

1.0

0.0 0.2 0.4 0.6 0.8

λf

Figure 1. Relation between f ftm /f tm and λf .

Figure 1. Relation between fftm/ftm and λf.
The steel fiber characteristic coefficient can be calculated by Equation (5) for the required flexural
The steel fiber characteristic coefficient can be calculated by Equation (5) for the required flexural
strength of SFRCAC, then the steel fiber volume fraction can be determined after choosing the
strength of SFRCAC, then the steel fiber volume fraction can be determined after choosing the
appropriate steel fiber type and aspect ratio.
appropriate steel fiber type and aspect ratio.
3.2. Water-Cement Ratio
3.2. Water-Cement Ratio
The compressive strength test results of RCAC with different W/C are listed in Table 5. Obviously,
The compressive
the compressive strength fstrength test results of RCAC with different W/C are listed in Table 5.
cu of RCAC decreases with the increase of rg at the same W/C because the
quality of the RCA is lower than NCA asfcustated
Obviously, the compressive strength of RCAC in many decreases
previouswith the increase
studies of rg at the same W/C
[6,15,43,44].
because
For thethe quality
RCAC of the
with rg ofRCA50%isorlower
100%than andNCA W/Cas ofstated
abovein many
0.35, f cu previous
increasesstudies [6,15,43,44].
continuously with
For the RCAC with r g of 50% or 100% and W/C of above 0.35, fcu increases continuously with the
the decrease of W/C, but for the RCAC with W/C of below 0.35, f cu decreases slightly with the
decrease
decrease of of W/C,This
W/C. butisfor the RCAC
different from with
the W/C NCAC of with
belowrg0.35,
of 0%,fcu where
decreases slightly with
f cu decreases the decrease
continuously
of W/C.
with This isofdifferent
the increase W/C. This from is the NCAC
because thatwith rg of 0%,
the failure of where
RCAC fis cu decreases continuously with the
caused by the damage of weak
increase of W/C. This is because that the failure
point inherited from crushed RCA rather than the damage of cement mortar of RCAC is caused by the when
damage W/Cof weak point
is below
inherited
0.35 from crushed
and compressive RCAisrather
strength higher than
than the50damage of cementthe
MPa. Therefore, mortar when W/C
compressive is below
strength 0.35 and
of RCAC
compressive strength is higher than 50 MPa. Therefore, the compressive
is mainly limited by the strength of RCA instead of W/C. Previous studies have had the similar strength of RCAC is mainly
limited by the strength of RCA instead of W/C. Previous studies
conclusions [3,16]. Consequently, the weakest point in concretes made with RCA of medium–high have had the similar conclusions
[3,16]. (45–60
strength Consequently,
MPa) couldthe weakest point in
be determined byconcretes
the strength made with or
of RCA RCAtheofadhered
medium–high strength (45–
mortar [3,16].
60 Based
MPa) could be determined by the strength of RCA or the adhered mortar
on the stipulation in Chinese Standards JGJ55 [32], the first step in mixture design is to [3,16].
Based
determine theon W/Ctheaccording
stipulation tointheChinese Standards JGJ55
target compressive [32],by
strength theusing
first the
stepfollowing
in mixture design is to
equation:
determine the W/C according to the target compressive strength by using the following equation:
f cu,0 = αa f ce (C/W − αb ) (6)
f cu, 0 = α a f ce ( C / W − α b ) (6)
where
wheref cu,0
fcu,0isisthe
thecubic
cubiccompressive
compressive strength
strength of of
concrete
concrete at 28 days,
at 28 MPa;
days, MPa;f cefis the
ce is compressive
the compressive strength
strength
of of
cement at 28 days, MPa; W/C is the cement-water ratio; α is the
cement at 28 days, MPa; W/C is the cement-water ratio; αa is the cement strength conversion
a cement strength conversion
coefficient;
coefficient; αb αisb the virtual
is the cement-water
virtual cement-water ratio. αa αand
ratio. αbαare
a and dependent
b are dependent onon thethe
quality and
quality andtype of of
type
coarse aggregate.
coarse aggregate. WhenWhenthethe
coarse aggregate
coarse aggregateis gravel, αa =α0.53,
is gravel, αb =α0.2;
a = 0.53, when
b = 0.2; whenthe coarse aggregate
the coarse is
aggregate
pebble, α = 0.49,
is pebble, αa = 0.49,
a α = 0.13.
b αb = 0.13.
When
When W/C W/Cchanges
changesfrom
from0.35
0.35toto0.55,
0.55,thethe
relation between
relation between thetheratio
ratio of of
RCACRCAC compressive
compressive
strength to cement compressive strength f /f and C/W is shown in
strength to cement compressive strength fcu/fce and C/W is shown in Figure 2, in which the solid
cu ce Figure 2, in which the solid
points
Materials 2019, 12, 375 9 of 16
Materials 2019, 12 FOR PEER REVIEW 9

stand stand
points for thefortest
theresults. It is clear
test results. It is that
clearfcuthat
/fce is
f cuproportional to C/W to
/f ce is proportional forC/W
the RCAC
for thewith
RCAC thewith
constant
the
of rg, which
constant of rgabides
, whichby the principle
abides of Equation
by the principle (6). The (6).
of Equation values
Theofvalues
αa andofααb afor
andSFRCAC with different
αb for SFRCAC with
rg can bergobtained
different throughthrough
can be obtained the regression analysisanalysis
the regression of the experimental data, that
of the experimental is αthat
data, a = 0.53
is αaand αb =
= 0.53
0.2 αfor
and rg = 0%; αa = 0.502 and αb = 0.217 for rg = 50%; αa = 0.476 and αb = 0.244 for rg = 100%.
b = 0.2 for rg = 0%; αa = 0.502 and αb = 0.217 for rg = 50%; αa = 0.476 and αb = 0.244 for rg = 100%.

1.5
rg=0
1.4 y=0.53*(x-0.2)
rg=50%
1.3 R2=0.98
rg=100%
fcu/fce

1.2
1.1
1.0 y=0.502*(x-0.217)
R2=0.99
0.9
0.8 y=0.476*(x-0.244)
R2=0.99
0.7
1.8 2.0 2.2 2.4 2.6 2.8 3.0
C/W
Figure 2. Relation between f cu /f ce and C/W.
Figure 2. Relation between fcu/fce and C/W.
The quality of the coarse aggregate used in RCAC is not only related to the property of RCA, but
The quality of the coarse aggregate used in RCAC is not only related to the property of RCA,
also rg . Generally, the quality of the RCA is weaker than NCA, αa decreases and αb increases with the
but also rg. Generally, the quality of the RCA is weaker than NCA, αa decreases and αb increases with
increase of rg , respectively. Therefore, the relation of αa , αb with rg can be expressed as follows:
the increase of rg, respectively. Therefore, the relation ofαa, αb with rg can be expressed as follows:
αa α= =0.53 (1 −−ααc ×
0.53(1 × rrgg))
a c (7)
αb = 0.2(1 + αd × rg ) (7)
α b = 0.2(1 + α d × rg )
where, αc and αd are the coefficient related to the quality of recycled aggregate. Putting the values of
αwhere, αc and αd are the coefficient related to the quality of recycled aggregate. Putting the values of
a and αb gotten from test results into the Equation (7), the value of αc and αd for the RCA has been
αa and αb gotten from test results into the Equation (7), the value of αc and αd for the RCA has been
determined to be 0.1 and 0.2, resulting in the following equations:
determined to be 0.1 and 0.2, resulting in the following equations:
αa = 0.53(1 − 0.1 × rg )
α = 0.53(1 − 0.1 × r ) (8)
αb =a 0.2(1 + 0.2 × rgg ) (8)
α b = 0.2(1 + 0.2 × rg )
When RCA belongs to category II and the target compressive strength is below 50 MPa, Equation
(8) canWhen RCA
be used to belongs to category
determine αa and αbIIfor
and the target
RCAC. compressive
For other kinds ofstrength is below
RCA, the 50αMPa,
value of c andEquation
αd may
(8) can be used to determine α and α for RCAC. For other kinds of RCA, the value of α
be different, and the suitable value must be determined through the regression analysis of experimental
a b c and αd may
be different, and the suitable value must be determined through the regression
data by Equation (7), then put αa and αb into Equation (6) to calculate the water–cement ratio. analysis of
experimental data by Equation (7), then put αa and αb into Equation (6) to calculate the water–cement
3.3. Water Content
ratio.

3.3.1. Influence
3.3. Water of Recycled Coarse Aggregate
Content
According to the experimental results in Table 6, the relation between the water content and
slump Influence
3.3.1. of RCAC is ofshown
Recycled Coarse3.Aggregate
in Figure It can be seen that when rg is kept constant, the slump of RCAC
increases with the rise of water content.
According to the experimental results Withinthe same
Table 6, water content,
the relation the slump
between the of RCAC
water reduces
content and
with theof
slump increase
RCAC of rg . Thisin
is shown is Figure
because3.RCA
It canhas
be higher water
seen that absorption
when rg is keptthan NCA,the
constant, andslump
absorbs more
of RCAC
water in concrete
increases with thebatching, whichcontent.
rise of water leads theWith
reduction of effective
the same water and
water content, thethe decreasing
slump of RCAC of slump.
reduces
with the increase of rg. This is because RCA has higher water absorption than NCA, and absorbs more
water in concrete batching, which leads the reduction of effective water and the decreasing of slump.
Generally, the water content is determined by the maximum size of coarse aggregate and the
desired range of slump. In China, the water content of ordinary concrete is generally estimated
through table look-up or calculated with equation as follows [39]:
where mw is the water content, kg/m3; T is the desired slump, mm; K is the constant determined by
the type and maximum size of coarse aggregate. With the different type of aggregate, the value of K
can be obtained by test or look-up table, K = 53 for the coarse aggregate of rubble with the maximum
size of 20 mm, and K = 48.5 for the coarse aggregate of rubble with the maximum size of 40 mm. It
Materials 2019, 12, 375 10 of 16
can be seen that the larger the particle diameter, the smaller the K value.

220

Water content(kg/m3)
210
200
rg=0%
190
y=0.334x+165.6,R2=0.95
180 rg=50%
y=0.336x+168.8,R2=0.91
170
rg=100%
160 y=0.337x+172.6,R2=0.82

0 40 80 120 160 200

Slump(mm)
Figure3.3.Relation
Figure Relationbetween
betweenwater
watercontent
contentand
andslump
slumpofofRCAC.
RCAC.

Generally,
Based on thethetest
water
datacontent is determined
in this paper, by the
the formulas formaximum size can
water content of coarse aggregate
be obtained and the
by regression
desired range of slump. In China, the water content of ordinary concrete is generally estimated through
and represented in Figure 3. It indicates the relation of water content with slump is a linear function
table look-up
for the or calculated
SFRCAC with equation
with different as follows
rg, the slopes [39]:linear functions are similar, but the constant
of these
terms increase with the increasing of rg. Therefore, the relation between water content and slump can
mw = 3.33 × (0.1 × T + K ) (9)
be expressed as follows:
where mw is the water content, kg/m3 ; m T is= the
w (
3.33desired
× 0.1× Tslump,
0 )
+ K g mm; K is the constant determined(10) by
the type and maximum size of coarse aggregate. With the different type of aggregate, the value of K
can
wherebe obtained by test of
T0 is the slump or RCAC;
look-upKtable, K parameter
g is the = 53 for therelative
coarse to aggregate
the typeofand
rubble with the
maximum maximum
size of coarse
size of 20 mm,
aggregate. and K = 48.5
According to theforregression
the coarseanalysis
aggregate of of rubble
test data with
in this the maximum
paper, size of 40 as
Kg is obtained mm. It can
49.7, 50.7
be
andseen that
51.8 forthe larger
rg of 0, 50%theand
particle
100%, diameter, the smaller
respectively. Kg is nothe K value.
longer a constant like K in Equation (9), but
Based on
it increases the the
with testincreasing
data in thisofpaper, the
rg. This is formulas
consistentfor water
with thatcontent cancontent
the water be obtained by regression
of RCAC increases
and
withrepresented
the increasingin Figure 3. Itdifference
of rg. The indicates the relation
of water of water between
absorption content withRCAslump
and NCAis a linear function
is an important
for the SFRCAC
factor affecting with
water contentrgof
different , the slopesHence,
RCAC. of thesethe
linear functionsformula
calculation are similar,
of Kbut thebe
g can constant terms
expressed as
follows: with the increasing of rg . Therefore, the relation between water content and slump can be
increase
expressed as follows:
K = K [1 + (ωra −×ωTna )+
mw =g 3.33 × 0.1
× rKg ]
(11)
(10)
0 g

whereTω
where is is
0 ra thethe water
slump of absorption
RCAC; Kg isofthe RCA; ωna is the
parameter water
relative toabsorption
the type and ofmaximum
NCA; K issize theofconstant
coarse
dependingAccording
aggregate. on the typetoand
the maximum
regression size of NCA,
analysis its data
of test valueincan
thisbepaper,
obtained
Kg isbyobtained
test or look-up
as 49.7,table.
50.7
In this study, the value of K is 49.7 from the test results, and ω = 1.4%, ω = 4.85%,
and 51.8 for rg of 0, 50% and 100%, respectively. Kg is no longer a constant like K in Equation (9), but it
na ra as shown in
Table.1. Putting
increases with thethe value of these
increasing of rg . parameters into Equation
This is consistent with that (11),
thegetting Kg = 50.6offor
water content rg = 50%
RCAC and Kg
increases
= 51.4
with thefor rg = 100%.ofThe
increasing value
rg . The of Kg with
difference the different
of water rg calculated
absorption between by RCAEquation
and NCA (11)iswas very close
an important
to theaffecting
factor test results. Therefore,
water content the water content
of RCAC. Hence, of theRCAC can beformula
calculation determined
of Kgby Equations
can (10) and
be expressed as
(11).
follows:
Kg = K [1 + (ωra − ωna ) × rg ] (11)
3.3.2. Influence of Steel Fibers
where ω ra is the water absorption of RCA; ω na is the water absorption of NCA; K is the constant
Basedon
depending onthe
thetype
test results, the relation
and maximum size between
of NCA, the slumpcan
its value of be
SFRCAC and
obtained byVtest
f can be seen in Table
or look-up table.
7. Obviously, the slump decreases with the increasing of V f. For each type of steel fiber, the slump of
In this study, the value of K is 49.7 from the test results, and ω na = 1.4%, ω ra = 4.85%, as shown in
SFRCAC decreases with the increasing of rg. Due
intotoEquation
the larger(11),
aspect ratio K
of HF, the slump reduction
Table 1. Putting the value of these parameters getting g = 50.6 for rg = 50% and
Kg = 51.4 for rg = 100%. The value of Kg with the different rg calculated by Equation (11) was very close
to the test results. Therefore, the water content of RCAC can be determined by Equations (10) and (11).

3.3.2. Influence of Steel Fibers

Based on the test results, the relation between the slump of SFRCAC and V f can be seen in Table 7.
Obviously, the slump decreases with the increasing of V f . For each type of steel fiber, the slump of
SFRCAC decreases with the increasing of rg . Due to the larger aspect ratio of HF, the slump reduction
Materials 2019, 12, 375 11 of 16
Materials 2019, 12 FOR PEER REVIEW 11

ofofRCAC
RCACwith withHFHFisismuch
muchhigher
higherthan
thanthat
thatof
ofMF,
MF,and
andhashaslittle
littletotodo
dowithwithrgr.g.Besides,
Besides,the
thesimilar
similar
slumpreduction
slump reductionwas wasobserved
observedirrespective
irrespectiveofofthe
theaggregate
aggregatetype.
type.
Therelation
The relationbetween
betweenthe theslump
slump reduction
reduction ratio
ratio andand
thethe characteristic
characteristic coefficient
coefficient of steel
of steel fiberfiber
(λf )
is(λshown
f) is shown in Figure
in Figure 4, in4,which
in which
thethe points
points areare drawn
drawn from
from thethe test
test resultsininthis
results thispaper
paperand
andprevious
previous
literature[44].
literature [44]. Obviously,
Obviously,the theslump
slumpreduction
reductionratio
ratioisisapproximately
approximatelylinear linearwith
withthethecharacteristic
characteristic
coefficientof
coefficient ofsteel
steelfiber,
fiber,aaformula
formulacan canbe
bedetermined
determinedbasedbasedon onthe
thetest
testresults:
results:

T 0/ T=
T/T 0
=11−
− 0.38λf f
0.38λ (12)
(12)

where TT isis the

where thedesired
desiredslump
slumpofofSFRCAC,
SFRCAC,mm;mm; TT0 isis the
the slump
slump of
of the
the plain
plain concrete
concrete which
which isis
0
correspondingto
corresponding toSFRCAC
SFRCACin insame
samemixture
mixtureproportion,
proportion,mm.mm.When
Whenthe
thedesired
desiredslump
slumpofofSFRCAC
SFRCAC(T) (T)
is determined, T 0 can be calculated by Equation (12), then using Equation (10), the water content of
is determined, T0 can be calculated by Equation (12), then using Equation (10), the water content of
SFRCACcan
SFRCAC canbe bedetermined.
determined.

1.0 y=1-0.38x,R2=0.93
0.8
T/T0

0.6
[44]
0.4
Current study,rg=0
0.2 Current study,rg=50%
Current study,rg=100%
0.0
0.0 0.3 0.6 0.9 1.2 1.5 1.8
λf

Figure4.4.Relation
Figure betweenT/T
Relationbetween T/T00and
andλλff..

3.4. Sand Ratio

3.4. Sand Ratio
The test results by using the new sand content method determined by Equation (1) are shown in
The test results by using the new sand content method determined by Equation (1) are shown
Table 7. It can be seen that sand ratio βs increases regularly with the increasing of V f and rg . For the
in Table 7. It can be seen that sand ratio βs increases regularly with the increasing of Vf and rg. For the
SFRCAC with the same V f , βs increases by 2.2% as rg increases by 50%. For the SFRCAC with the same
SFRCAC with the same Vf, βs increases by 2.2% as rg increases by 50%. For the SFRCAC with the same
rg , βs increases by 0.7% as V f increases by 0.5%. This result is very close to that for the SFNCAC [45],
rg, βs increases by 0.7% as Vf increases by 0.5%. This result is very close to that for the SFNCAC [45],
where steel fiber was treated as part of the coarse aggregate used in sand ratio calculation, and it was
where steel fiber was treated as part of the coarse aggregate used in sand ratio calculation, and it was
concluded that βs increases by 0.8% as V f increases by 0.5%.
concluded that βs increases by 0.8% as Vf increases by 0.5%.
In the test of this paper, the water content is kept constant, and the slump still decreases obviously
In the test of this paper, the water content is kept constant, and the slump still decreases
with the increasing of V f and rg although the sand ratio increases with the increasing of V f and rg .
obviously with the increasing of Vf and rg although the sand ratio increases with the increasing of Vf
However, the slump in Table 7 using the new sand ratio method is much higher than that in Table 6,
and rg. However, the slump in Table 7 using the new sand ratio method is much higher than that in
where the sand ratio was a constant of 36%. The comparison of these test results is shown in Figure 5.
Table 6, where the sand ratio was a constant of 36%. The comparison of these test results is shown in
Obviously, the slump of SFRCAC using the new sand ratio method is much higher than that by using
Figure 5. Obviously, the slump of SFRCAC using the new sand ratio method is much higher than
the old method, especially for SFRCAC with rg of 100%. This indicates that the workability of SFRCAC
that by using the old method, especially for SFRCAC with rg of 100%. This indicates that the
can be improved by using the new sand ratio method.
workability of SFRCAC can be improved by using the new sand ratio method.
The comparison of measured compressive strength of SFRCAC designed by the new and old sand
The comparison of measured compressive strength of SFRCAC designed by the new and old
ratio method is shown in Figure 6. It can be seen from Figure 6 that for the SFRCAC with a constant
sand ratio method is shown in Figure 6. It can be seen from Figure 6 that for the SFRCAC with a
of rg , its compressive strength increases with the increasing of V f . When rg increases from 0 to 100%,
constant of rg, its compressive strength increases with the increasing of Vf. When rg increases from 0
the compressive strength of SFRCAC designed by using the old sand ratio method decreases, but that
to 100%, the compressive strength of SFRCAC designed by using the old sand ratio method decreases,
designed by using the new sand ratio method increases slightly. For SFRCAC with rg of 100%, the
but that designed by using the new sand ratio method increases slightly. For SFRCAC with rg of 100%,
difference of the compressive strength of SFRCAC designed by the new and old sand ratio method is
the difference of the compressive strength of SFRCAC designed by the new and old sand ratio
more remarkable.
method is more remarkable.
Materials 2019,
Materials 12, 12
2019, 375FOR PEER REVIEW 12 of 16 12
Materials 2019, 12 FOR PEER REVIEW 12

New method Old method

70 New method Old method
70 rg=0 rg=50% rg=100%
rg=0 rg=50% r =100%
60 g
60

Slump(mm)
50

Slump(mm)
50
40
40
30
30
20
20
10
10
0
0 0 1 2 0 1 2 0 1 2
0 1 Steel
2 0
fiber 1 0 1
2 ratio(%)
volume 2
Steel fiber volume ratio(%)
Figure
Figure 5. Comparison
Comparison
5. 5. of slump
ofof
slump by
byby using
using different
different sand
sand ratio
ratio method.
method.
Figure Comparison slump using different sand ratio method.

New method Old method

60 New method Old method
strength(MPa)

60 rg=0 rg=50% rg=100%

Compressivestrength(MPa)

rg=0 rg=50% rg=100%

50
50
40
40
30
30
Compressive

20
20
10
10
0
0 0 1 2 0 1 2 0 1 2
0 1 Steel
2 fiber 0 volume
1 2 ratio(%)
0 1 2
Steel fiber volume ratio(%)
Figure 6. Comparison
Figure of compressive
6. Comparison strength
of compressive by by
strength using different
using sand
different ratio
sand method.
ratio method.
Figure 6. Comparison of compressive strength by using different sand ratio method.
4. Experimental Verification
4. Experimental Verification
4. Experimental Verification
In order to verify the mixture proportion design method was put forward in this paper, the
In order to verify the mixture proportion design method was put forward in this paper, the
specimens In order withto theverify the mixture
different dosages proportion
of RCA (r design = 0%, 50%, method 100%) waswereputused
forward in this apaper,
to achieve desired the
specimens with the different dosages of RCAg (rg = 0%, 50%, 100%) were used to achieve a desired
specimens with the different dosages of RCA (r = 0%,
compressive strength (f cu = 40 MPa), flexural strength (f ftm = 10 MPa), and slump (T = 50 mm). The
g 50%, 100%) were used to achieve a desired
compressive strength (fcu = 40 MPa), flexural strength (fftm =10 MPa), and slump (T = 50 mm). The
compressive
design process strength
is shown (fascu follows.
= 40 MPa), flexural strength (fftm =10 MPa), and slump (T = 50 mm). The
design process is shown as follows.
design process is shown as follows.
1. 1. Determination
Determination ofofthethesteel
steelfiber
fibercontent
contentChecking whether steel fiber is necessary or not. An
1. Determination of the steel fiber content
empirical
Checking formula
whether between
steel the fiberflexural strengthor
is necessary and compressive
not. An empirical strength for normal
formula between concrete
the flexural[46]
Checking whether steel fiber 0 )0.5 , is necessary or not. An empirical formula between
0 is cylinder 0 = 0.8 the' flexural
is used here, f tm = 0.89 × ( f where f
strength and compressivec strength forcnormal concrete [46] is used here, ftm = 0.89 compressive strength and f c f
× ( f' 0.5) , The
cu
0.5. where
strength value
predicted and compressive
of f = 0.89 strength
× (0.8 × for
40)normal
0.5 = 5.03 concrete
MPa; [46] isf used
since, < here,
10 MPaftm(the
= 0.89 × ( f c c)flexural
desired , where
'
tm '
tm
f' is cylinder
strength), compressive
it is necessary to add strength
the steel andfiber f' = obtain
0.8 f .
f c c is cylinder compressive strength and fc cto= 0.8 fcucu. the desired flexural strength.
The predicted value of ftm = 0.89 ×of(0.8 × 40) = 5.03 MPa; since, ftm < 10 MPa (the desired flexural
0.5
p
2. Calculating the required content steel fibers
pThe predicted value of ftm = 0.89 × (0.8 × 40)0.5 = 5.03 MPa; since, ftmf < 10 MPaftm[Equation (5)] λ = ( f / f tm
(the − β f )/α
desired f =
flexural
strength),
(10/5.03 − it is necessary
1)necessary
/2.51 to
=to add add0.63 the steel fiber to obtain the desired
V f lf /df,theVdesired flexural strength.
strength), it is the Since λf =
steel fiber to obtain f = 0.63/34.2
flexural = 1.84% for MF;
strength.
2. V fCalculating
= 0.63/39.7 the
= required
1.6% for WF; content
V = of steel
0.63/82.3 fibers
= [Equation
0.76%
f of steel fibers [Equation (5)] for HF. (5)]
2. Calculating the required content
3. λf = ( f ftmthe
Calculating − β
/ frequired ) / αW/C = (10 / 5.03 − 1)
[Equations (6)/ and = 0.63
2.51 (8)] According to Equation (8), αa = 0.53 × (1 −
λf = ( f ftm / f tmtm− β f f) / α f f = (10 / 5.03 − 1) / 2.51 = 0.63
× rg )λand
0.1Since α = 0.2 × (1 + 0.2
f = Vflbf/df, Vf = 0.63/34.2 = 1.84%
× r g ); α = 0.53, α = 0.2
a for MF;bVf = 0.63/39.7 for rg = 0; αa = 0.503,
= 1.6% for WF; αb V=f 0.22 for rg ==50%;
= 0.63/82.3 0.76%
Since
= 0.477,
αa for λf = Vflf/df, Vf = 0.63/34.2 = 1.84% for MF; Vf = 0.63/39.7 = 1.6% for WF; Vf = 0.63/82.3 = 0.76%
α = 0.24 for r g = 100%. f cu,0 is the prepared strength, σ is the standard deviation of
HF. b
for HF.
compressive strength. According to Chinese Standard [47], for the RCAC with f cu = 40 MPa,
3. Calculating the required W/C [Equations (6) and (8)]
3. σCalculating
= 6 MPa, f cu,0 the=required
40 + 1.645 W/C ×a [Equations
6 = 50 ×MPa. (6)According
and (8)] to Equation (6), f cu,0 /f ce = αa × (C/W
According to Equation (8), α = 0.53 (1 − 0.1 × rg) and αb = 0.2 × (1 + 0.2 × rg);
According to Equation (8), α a = 0.53 × (1 − 0.1 × rg) and αb = 0.2 × (1 + 0.2 × rg);
− αb ), C/W = 1/(f cu,0 /f ce /αa + αb ), from Table 1, f ce = 45 MPa, then: W/C = 1/(50/45/0.53 +
αa = 0.53, αb = 0.2 for rg = 0; αa = 0.503, αb = 0.22 for rg = 50%; αa = 0.477, αb = 0.24 for rg = 100%.
αa = 0.53, αb = 0.2 for rg = 0; αa = 0.503, αb = 0.22 for rg = 50%; αa = 0.477, αb = 0.24 for rg = 100%.
Materials 2019, 12, 375 13 of 16

0.2) = 0.43, for rg = 0; W/C = 1/(50/45/0.503 + 0.22) = 0.41, for rg = 50%; W/C = 1/(50/45/0.477
+ 0.24) = 0.39, for rg = 100%.
4. Calculating the required water content [Equations (10)–(12)] According to Equation (11), Kg = K
× [1 + (ω ra − ω na ) × rg ], K = 49.7. From Table 1, ω na = 1.4%, ω ra = 4.85%. Kg = 49.7 × [1 + (0.0485
− 0.014) × rg ], Kg = 49.7 for rg = 0; Kg = 50.6 for rg = 0; Kg = 51.4 for rg = 100%. According to
Equation (12), T/T0 = 1 − 0.38λf , T0 = T/(1 − 0.38λf ) = 50/(1 − 0.38 × 0.63) = 66 mm. According
to Equation (10), mw = 3.33 × (0.1T + Kg ), then mw = 3.33 × (0.1 × 66 + 49.7) = 187.5 kg, for rg = 0;
mw = 3.33 × (0.1 × 66 + 50.6) = 190.5 kg, for rg = 50%; mw = 3.33 × (0.1 × 66 + 51.4) = 193 kg, for
rg = 100%.
5. Calculating the required aggregate dosage [Equations (1)–(3)]. rg = 50% and WF was taken as an
example to explain the calculation. From Table 1, Pna = 44.3%, Pra = 50.3%, ρna = 2814 kg/m3 ,
ρra = 2640 kg/m3 ; when rg = 50%, mna = mra , V na = 0.938 × V ra ; According to Step 1, V f = 1.6% for
WF; and then put these parameters in Equation (1), V f = 1.4 × (0.443 × 0.938 × V ra + 0.503 × V ra
+ 0.016) = 1.286 × V ra + 0.0224. According to Steps 2 and 3, rg = 50%, W/C = 0.41, mw = 190.5 kg;
therefore, mc = mw /(W/C) = 464.6 kg; V w = mw /ρw = 0.1905 m3 , V c = mc /ρc = 464.5/3100 = 0.15
m3 . According to Equation (2), V c + V w + V s + V na + V ra + V f + α = 1; 0.15 + 0.1905 + (1.286
× V ra + 0.0224) + 0.938 × V ra + V ra + 0.016 + 0.02 = 1, V ra = 0.187, mra = V ra × ρra = 493.7 kg;
V s = 1.286 × V ra + 0.0224 = 0.263, ms = V s × ρs = 672.3 kg.

Based on the established method, shown as above example, the mixture proportion details of
SFRCAC are represented in Table 8, and the relevant test results of compressive strength, flexural
strength and slump of SFRCAC are shown in the identical table. It can be seen that all groups of
SFRCACs have achieved the target compressive strength, flexural strength and slump.

Table 8. Mix design details of SFRCAC based on new method, test results of slump and compressive
and flexural strength.

Specimen No.
Test Value
CR0MF CR50MF CR100MF CR0WF CR50WF CR100WF CR0HF CR50HF CR50HF
W/C 0.43 0.41 0.39 0.43 0.41 0.39 0.43 0.41 0.39
Water (kg) 187.5/ 190.5/ 193/ 187.5/ 190.5/ 193/ 187.5/ 190.5/ 193/
/volume% 18.75 19.05 19.3 18.75 19.05 19.3 18.75 19.05 19.3
Cement (kg) 436/ 464.6/ 494.9/ 436/ 464.6/ 494.9/ 436/ 464.6/ 494.9/
/volume% 14.1 15 15.7 14.1 15 15.7 14.1 15 15.7
SFs (kg) 143.5/ 143.5/ 143.5/ 124.8/ 124.8/ 124.8/ 59.3/ 59.3/ 59.3/
/volume% 1.84 1.84 1.84 1.6 1.6 1.6 0.76 0.76 0.76
NCA (kg) 1054.8/ 488.4/ 0/ 1064.8/ 493.7/ 0/ 1100/ 509/ 0/
/volume% 37.5 17.3 0 37.8 17.5 0 39.1 19.3 0
Cement (kg) 436/ 464.6/ 494.9/ 436/ 464.6/ 494.9/ 436/ 464.6/ 494.9/
/volume% 14.1 15 15.7 14.1 15 15.7 14.1 15 15.7
RCA (kg) 0/ 488.4/ 907.5/ 0/ 493.7/ 916.5/ 0/ 509/ 947.7/
/volume% 0 18.5 34.4 0 18.7 34.7 0 18.1 35.9
Sand (kg) 660.4/ 674/ 685.1/ 656.5/ 672/ 681.9/ 647.1/ 661.6/ 672.3/
/volume% 25.8 26.4 26.8 25.7 26.3 26.7 25.3 25.9 26.3
βs/% 38.5 40.8 43 38.1 40.5 42.7 37 39.4 41.5
Slump (mm) 56 60 52 55 53 52 60 62 56
f cu (MPa) 50.4 52.6 49.8 51 51.8 49.6 50.6 49.9 49
f ftm (MPa) 12.3 12 10.6 11.8 11.3 10.2 10.9 12 12.5
Note: CR50MF stands for the specimen with rg of 50% and milling steel fiber.

5. Conclusions
Through the above analysis, the mixture design method of SFRCAC which is given the target
compressive strength, flexural strength and slump is following:

1. The flexural strength of RCAC can be improved by adding steel fibers. The characteristic
coefficient of steel fiber can be calculated by Equation (5). Once the steel fiber type is chosen, the
steel fiber volume fraction can be determined.
Materials 2019, 12, 375 14 of 16

2. The calculation model of water–cement ratio for normal concrete can also be used in recycled
concrete, except that the parameter αa , αb , which are connected with the quality of coarse
aggregate and the replacement ratio (rg ), should be determined by test or calculated by Equations
(6) and (7).
3. The water content of SFRCAC is related to replacement ratio (rg ) and characteristic coefficient of
steel fiber (λf ). According to the desired slump, the slump can be calculated by Equation (12).
Then, the water content can be calculated by Equations (10) and (11).
4. The sand ratio (βs ) of SFRCAC is related to void fraction and apparent density of coarse aggregate,
replacement ratio (rg ) and characteristic coefficient of steel fiber (λf ). The volume fraction of steel
fiber (V s ) can be calculated by Equation (1). Based on the material property of aggregates and
steel fiber used in the test, βs increases by a factor 2.4% when rg is increased by 50%, βs increases
by a factor 0.7% when V f is increased by 0.5%.
5. Due to the apparent density of RCA being generally less than that of NCA, the mass of RCAC is
greatly influenced by apparent density and replacement ratio (rg ), the absolute volume method is
recommended to be used to calculate the material component of the SFRCAC.

Author Contributions: Methodology, D.G. and L.Z.; Investigation, D.G. and L.Z.; Data Curation, L.Z.;
Writing—Original Draft Preparation, L.Z.; Writing—Review & Editing, M.N. and J.Z.; Funding Acquisition,
D.G. and J.Z.
Funding: This work was part of a key project financially supported by National Natural Science Foundation of
China (U1704254) and innovation team development plan of China’s Ministry of Education (IRT_16R67).
Conflicts of Interest: The authors declare no conflict of interest.

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