Recycled materials in concrete:

projects, specifications, risks and benefits

29 May, 2013
Mohamed A Mahgoub, PhD. PE
Assistant Professor and Program Director
Concrete Industry Management
Department of Engineering Technology
New Jersey Institute of Technology, Newark, NJ
ACI 555 “Concrete with Recycled Materials”
Committee Chair
 THANK YOU

M. en I. Donato Figueroa Gallo

Gerente de Enseñanza
IMCYC
Recycled Aggregate Concrete
(RAC)
Recycling concrete provides sustainability in
several different ways:
• Saving natural resources

1250 million tons

44% x 1250=550 million
tons was used for concrete

Annual production of sand and gravel in the US

• Construction and Demolition Debris

25% increase in 7 years!

 • Construction and Demolition Debris
Brick
Landfill debris
Scrap iron

Roofing

400 ft
Wood 66%

Roofing Concrete

2000 ft
Average composition of demolition debris

170 x 66%= 112 million tons! (net concrete waste in 2003)

• Elimination of the need to use landfills

• More than 52% of the C&D is discarded in landfills;

• Landfills are limited and expensive (1889 in 1994 &

1500 landfills in 2006 “EPA”); Fees = $100 per ton

• Substantial increase in concrete waste from US

infrastructures renovation and demolition is expected.
Recycled Aggregate Concrete (RAC)?
• RAC is a concrete made of reclaimed aggregates;
• Quality of RAC is dependent on the quality of RCA;
• Care must be taken to prevent contaminations such as
asphalt and gypsum.

Natural RCA
 Why Recycle Concrete?

Sustainable practices are desirable

Reuse and conserve natural resources
Cost savings over traditional methods
Use of RA in concrete and asphalt showed
comparable performance over virgin
aggregates.
 Challenges for using Recycled
Concrete Aggregates

 Resistance to change
 Lack of experience
 Inadequate codes, specifications
and standards
 Inconsistent aggregate grading
 Lower and variable quality
Current uses of RCA:
• Mostly road sub-base
• erosion control
• pipe and drain ducts
• parking lots
• filter material

States recycling concrete as road base

Problem Statement and Objective
of current RAC research at NJIT:
• Widespread application of RAC, such as
structure and seismic, requires knowledge of
RAC behavior (unconfined and confined)

• The main objective of this research was to

develop stress-strain models for use in
structure and seismic analysis (confined and
unconfined).
Scope:
• Experimental approach was employed.

• 45 Reinforced RAC columns (10x10x32 inches)

were tested under axial load (monotonic and cyclic).

• Different reinforcement configurations were

considered.

• There were several test variables:

- steel and unconfined concrete strengths
- pattern, size and distribution of the ties
 Literature Review on
RAC Properties

Mechanical Prop. and Models for Confined

Durability of Plain RAC NAC

Beams made of RAC

Mechanical Properties
Compressive Strength
• Majority of researchers reported up to 30% decrease in the
compressive strength of RAC made of coarse RCA.

• The reduction in the strength is generally attributed to the

old paste adhered to the surface of reclaimed aggregates.

• The use of fine RCA can further reduce the strength.

• Fly ash and small w/c ratio can improve the strength.
Compressive Strength

Ravindrarajah
and Tam (1985)
Tensile Strength
• RAC made with coarse RCA exhibits less than 10%
reduction in tensile strength.

• RAC made with coarse and fine RCA shows 10-20%

reductions in tensile strength.

• In general, the effect of RCA on tensile strength is

insignificant.
Modulus of Elasticity
• E of RAC reduces with the increase of RCA.

• E of RAC made with fine and coarse RCA is 25%-40%

less that of NAC.

• E of a RAC made with only coarse RCA is 10%-33% less

that of NAC.

Bond Strength
• The bond strength of the RAC is equal to the bond
strength of the normal concrete.
Drying Shrinkage and Creep
• RAC shows approximately 50% higher shrinkage and
creep compared with NAC.
• The use of small w/c ratio and fly ash can significantly
reduce the creep and shrinkage of RAC.
Durability:
Freeze-Thaw Resistance
• The freeze-thaw resistance of RAC is higher than
NAC.

Corrosion Resistance
• High alkaline reserve in RAC delays the corrosion.

• RAC has higher chloride ion penetration depth. The

use of low w/c ratio and pozzolans enhances the
corrosion resistance.
Workability
• High RCA content reduces the workability (due to
the rougher surface texture and high water absorption).

• The use of SSD aggregates is suggested (Hansen

1986). On the contrary, Poon et al. (2004) suggested
that air-dried aggregate.

• ACI555R-01 recommends adding 5% more free

water.
• The use of plasticizers is recommended.
Summary of RAC Properties:
 Issues to Consider for RAC
 Minimize old mortar attached to aggregate
 Aggregate grain size distribution and proportions
 Aggregate Absorption Capacity
 RA should be nearly-saturated conditions to avoid
loss in slump and excessive shrinkage.
 Two-Stage Mixing Approach (TSMA) and pre-soaking
treatment method for the production of RAC are
encouraged
 Can 10,000 psi
Concrete be made from
100% 3000 psi
Recycled Concrete
Aggregate?
 Sustainability in the
Concrete Lab
• Year after year students study ACI 211 design
• Every semester 3 to 4 classes
• 2000, 3000, 4000, 5000, 6000 psi mixes made and tested
• We make almost 1 cubic yard a semester just in the basic
ACI 211 design labs
• We know how strong the concrete is
• Traditionally, the cylinders are trashed
• Why not reuse them to make more concrete?
• Can we make 10,000 psi concrete from 100% recycled
concrete aggregates?
• Can we make 10,000 psi concrete from 100% recycled 3000
psi aggregate?
 10,000 psi Concrete Design
• Done for various student and research projects
• w/c = 0.35
• Include microsilica
• Lots of polycarboxolate admixture
• Quantities are in lbs
Natural Agg Mix
Water 15
Cement 38
Micro Silica 5
Coarse A 75
Fine A 36
Poly Carb 300 ml
 Experimental Concept
• Collect concretes with f’c less than 3000 psi
• Collect concretes with f’c over 6000 psi
• Collect WTC concrete f’c over 12,000 psi
• Crush to Nominal Agg. Size 1 inch
• Sieve analysis of natural aggregate
• Sieve RCAs
• Recombine RCA to match natural gradation
• Measure relative density (SG) of natural stone (2.79)
• Measure relative density of RCA (2.5 to 2.6)
• Replace natural stone on a volumetric basis
• Mass of natural aggregate multiplied by rdRCA/rdNA
• Mix natural aggregate at SSD
• Soak oven dry RCA ½ hour and mix
 Student Results 28-days
RCA Strengths Compared to Natural Aggregate Concrete Strength at
28 Days
100%

90%

80%
Percentage of Natural Aggregate Concrete

70%

60%

50%

40%

30%

20%

10%

0%
0% 3000 psi RCA 6000 psi RCA 12000 psi RCA
 Student Conclusion
• “Although the compressive strength obtained
didn’t achieve the target strength; but it was
so close to the target strength which proves
that with the right concrete mix proportions
and the right aggregate gradation, the target
strength can be achieved.”
 Testing at 2.75 years

• Found HS RCA cylinders cleaning out curing

room
• Heading for Trash
• Why not test anyway
• Too few specimens to form definitive
conclusions
• Labels on some specimens could not be read
 Testing Results

High Strength RCA Testing at 2.75 years

Sample Natural 3000 psi RCA 10,000 psi RCA
1 13640 10470 10320
2 13860 10430 9900
3 13780 10470 9540
4 10270

avg 13760 10410 9920

range 220 400 467
est sd 132 240 279
Coef of V 0.96% 2.31% 2.81%
 Can 10,000 psi
Concrete be made from
100% 3000 psi
Recycled Concrete
Aggregate?

YES
Using RAC as Structural Members:
General Findings:
• The idea of using RAC for structural applications is
quite new and the literature is limited.

• Deflection and load capacity were simply compared

to normal concrete beams.

• Cracking patterns were similar to normal concrete

beams.

• Ultimate capacity of RAC beams slightly less than

NAC beams

• Deflections at failure of RAC beams are more than

NAC beams.
Shear Strength of RAC Beams:

Average 39 MPa

Fonteboa & Abella, 2007

(shear strength was examined)
 Shear Strength of RAC Beams:

No shear Reinforcement

Tie spacing: 24cm

Tie spacing: 17cm

NAC RAC
Shear Cracking
(50% RCA-50% natural)
Note the similarity in cracking patterns…
Shear Strength of RAC Beams:

467 kN
380 kN

19% 181 kN 2%
178 kN

14% 22%

302 kN 256 kN

354 kN 328 kN

Load versus mid-span deflection

• Etxeberria et al, 2007 studied shear strength of RAC
versus normal concrete beams. The difference were less
than 16%.

• Fathifaz et al, 2009 found little difference in the shear

capacity of RAC and normal concrete beams (less than
10%)
 Strength of RAC Beams in Bending:

Normal Concrete

Ajdukiewicz & Kliszczewicz, 2007

(Flextural strength was examined)
Strength of RAC Beams in Bending:

NAC

RAC (coarse)

RAC (coarse and fine)

• None of the studies on plain and reinforced RAC refutes its use
as a structural material.

• But widespread application of RAC, such as seismic, requires

knowledge of the RAC behavior under different confinement
configurations.
 Design option 1
(expensive)

Sufficient concrete
confinement is
necessary

Design option 2
Confinement :

Sustaining branch
Parabola

A constitutive model for normal concrete (Park et al, 1982)

Effect of lateral confinement on concrete strength and
ductility (Park et al. 1982 model)
Experimental Setup
Weldon Materials crushing facilities,
New Jersey
 5
NAC Cylinder #1
NAC Cylinder #2
4

Stress (ksi)
3

0
0 0.0025 0.005 0.0075 0.01 0.0125
Strain
Mixing:

“TSMA” and normal mixing approach (Tam et al, 2005)

Improvement of ITZ by employing “TSMA” (Tam et al, 2005)

 5.00

4.00
Compressiv Strength (ksi)

3.00

2.00
Sample #1
Sample #2
1.00 Sample #3
Sample #4
Average
0.00
3 7 Age (days) 14 21

Gain in the strength Mixing arrangement

60
RAC Cylinders

61
 5.00
RAC Cylinder #1
RAC Cylinder #2
4.00 RAC Cylinder #3
Stress (ksi)

3.00 significant damage

2.00 Typical stress-strain

Testing machine used for test terminated
Curves for plain RAC
measuring strength of 1.00 cylinders
concrete cylinders
0.00
0.0000 0.0025 0.0050 0.0075 0.0100
Axial Strain
Cylinders for Stress-Strain model:
Reinforcement: 120 80

100
60
80 average yield stress= 63 ksi

Stress (ksi)
Stress (ksi)

average yield stress= 70 ksi

60 40

40 Sample 1
Sample 1
20 Sample 2
Sample 2
Sample 3
20 Sample 3
Sample 4
Sample 4
Sample 5 Sample 5
0 0
0 0.05 0.1 0.15 0.2 0.25 0 0.05 0.1 0.15 0.2
Strain Strain
9 possibilities to make columns with
different tie configuration and spacing
Tie spacing Sequence number Tie pattern
 Column Designations

quasi-static

fast rate

cyclic
Extra End confinement with GFRPs:

Installation of SikaWrap® GFRP sheets on specimen ends

 External Instrumentation:

Capping with hydro-stone® gypsum cement

DC Linear Variable Differential Transformers

(DCDT)
Internal Instrumentation:

CEA-06-240UZ-120 electrical strain gauge (4 by 9 mm)

80

70 0.41%

60
Strain gauge still functional after this point
50
Stress (ksi)
40

30 0.2% offset method

20

10

0
0.00 0.01 0.02 0.03
Strain
 Loading Unit:

1000-kip MTS815 loading unit and data

acquisition hardware and software
 Test Results:
Observations and Discussions
Test Observations
Plain RAC Cylinders
5
Strain at maximum stress=0.0026
Strain at maximum stress=0.0020 Ec=2060 ksi
Ec=3600 ksi
4

3
Stress (ksi)

2
RAC Cylinder (fc=4.19 ksi)

Todeschini (1964)
1
Popovic (1973)

Kent-park (1971)
0
0.0000 0.0010 0.0020 0.0030 0.0040 0.0050
Strain
Reinforced RAC Columns
The differences between the readings were insignificant, due to:
• The concentric nature of the loading;
• Precision in fabrication of the reinforcement cage;
• Thorough consolidation.
600

500
Axial Load (Kips)

400

300
B1-2-DCDT-South
200 B1-2-DCDT-West
B1-2-DCDT-East
100 B1-2-DCDT-North
Average
0
0 0.1 0.2 0.3 0.4 0.5
Axial Deformation (in)
 Failure Sequence
• Vertical hair cracks (strain=0.0020)

• Cracks widening (strain=0.0035)-Cover gradually becomes

ineffective

• Crushing of core

• Cover complete spall (strain=varying, depending on the tie

configuration and spacing).

• Tie fracture + hook slippage + buckling of longitudinal rebars

Typical failure

South and East sides North and West sides

South and East sides North and West sides
Effect of Reinforcement Variables:
600

C1-1
500
B1-1

400 C3-1 C2-1

Axial Load (kips)

B3-1
300

B2-1
200 A1-1

A2-1
A3-1
100
Increase in volumetric ratio
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Axial Deformation (in)
Tie Spacing
600

500
C1-1 ( =2.10, s=1 in)
fc=4.23 ksi
400
Axial Load (kips)

`
C2-1 ( =1.05, s=2 in)
300
fc=4.34 ksi

200 C3-1 ( =0.70, s=3 in)

fc=4.45 ksi

100

0
0 0.005 0.01 0.015 0.02
Axial Strain
Effect of Tie Configuration
600
C3-1 ( =0.70, s=3 in)
f c=4.26 ksi
500

400
Axial Load (kips)

`
300 B2-1 ( =0.75, s=2 in)
f c=4.18 ksi

200

100 A1-1 ( =0.88, s=1 in)

f c=4.45 ksi

0
0 0.005 0.01 0.015 0.02
Axial Strain
Effect of Loading Rate

700
B2-4
600 B2-1

500
Axial Load (kips)

400

300

200

100

0
0 0.1 0.2 0.3 0.4 0.5
Axial Deformation (in)
Effect of Loading Rate
 Effect of Loading Rate

Plain: Dilger et al. (1984)

0.016

Shah (1985) 1,2 or 3 in

Confined: 63 ksi

8.0 in

Steel: Soroushian and Sim (1986)

70 ksi
Effect of Loading Rate
 Effect of Cyclic Loading

Specimen with small confinement

undergoes considerable degradation
of stiffness. However, when effectively
confined, it can maintain its stiffness.
800 600

600

Axial Load (kips)

Axial Load (kips)

400

400

200

200
A1-4
A1-5
B1-5 0
0 0 0.1 0.2 0.3
0 0.1 0.2 0.3 Axial Deformation (in)
Axial Deformation (in)
Analytical Prediction of RAC
Stress-Strain Behavior
 8

5
Stress (ksi)

4
A18 (fc=6.08 ksi)
A18 (predicted)
3
A13 (fc=5.02 ksi)
A13 (predicted)
2 A8 (fc=3.61 ksi)
A8 (predicted)
1 A3 (fc=2.4 ksi)
A3 (predicted)
0
0.000 0.002 0.004 0.006 0.008
Strain
• The proposed model for ascending portion follows the
equation suggested by Popovic (1973) to predict the entire
stress-strain range of normal concrete:
• The descending branch, then, can be expressed as:

where is the strain corresponding to the maximum stress.

• Visual examination of the experimental stress-strain curves
showed that up to a strain of 0.004, assuming a straight line for
the descending
8
branch was reasonable.
7
0.004-.0025=0.0015

5
Stress (ksi)

4
A19 (fc=6.61 ksi)
A19 (predicted)
3
A14 (fc=5.16 ksi)
A14 (predicted)
2 A9 (fc=4.19 ksi)
A9 (predicted)
1 A4 (fc=2.57 ksi)
A4 (predicted)
0
0.000 0.002 0.004 0.006 0.008
Strain
 8

5 A21 (fc=7.17 ksi)

Stress (ksi)

A21 (predicted)
4 A16 (fc=5.70 ksi)
A16 (predicted)
3 A11 (fc=4.62 ksi)
A11 (predicted)
2 A6 (fc=3.12 ksi)
A6 (predicted)
1 A1 (fc=1.92 ksi)
A1 (predicted)
0
0.000 0.002 0.004 0.006 0.008
Strain
 Stress

0.0025

Strain
 30
Xiao et al. (2008)
Proposed model
25

20

Stress 15
(MPa)
10

0
0 0.002 0.004 0.006
Strain
Variables required to define the stress-strain relationship of confined RAC

1
Acc: area of the core
Ac: total area of the concrete

B core concrete stress (Pconc / Acc)

Stress (ksi)

C
A

gross concrete stress (Pconc / Ac)

strain at onset of spalling (Table 4.1)

strain at complete spalling (Table 4.1)

0O
hair cracks Axial Strain
0 1
Concrete Contribution:
600
A1-1-total
longitudinal steel transverse steel concrete
specimen A1-2-total
As (in2)  gross (%)  core (%) s (in) s (%) fc (ksi)
500 A1-1-concrete
A1-1 1.76 .018 .028 1 .88 4.26

A1-2 1.76 .018 .028 1 .88 4.41

A1-2-concrete
steel
400
Axial Load (kips)

total load
` concrete contribution
300

200

100 contribution of longitudinal

steel

0
0 0.005 0.01 0.015 0.02
Axial Strain
Initial cracks (hair-cracks)
0.002
A1-1
0.0018 A2-1
A3-1
0.0016
B1-1
0.0014 B2-1
B3-1
0.0012 C1-1
Tie Strain

C2-1
0.001
C3-1
0.0008

0.0006
The average strain at which
local slippage
vertical hair cracks appear on
0.0004 the RAC columns=0.0020

0.0002

0
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
Axial Strain
Transition Strains :
Column (ksi) (%) Crack Initiation Complete Spall

A1-1* 4.26 0.88 0.0019 0.0037

A1-2 4.41 0.88 0.0019 0.0035
A2-1* 4.12 0.44 0.0021 0.0033
A2-2 4.35 0.44 0.0021 0.0036
A3-1* 4.26 0.29 0.0018 0.0031
A3-2 4.05 0.29 0.0018 0.0033
B1-1* 4.23 1.51 0.0022 0.0058
B1-2 4.42 1.51 0.0022 0.0053
B2-1* 4.18 0.75 0.0019 0.0052
B2-2 4.32 0.75 0.0019 0.0048
B3-1* 4.36 0.50 0.0016 0.0042
B3-2 4.23 0.50 0.0016 0.0038
C1-1* 4.23 2.10 0.0023 0.0070
C1-2 4.06 2.10 0.0023 0.0053
C2-1* 4.34 1.05 0.0019 0.0047
C2-2 4.09 1.05 0.0019 0.0043
C3-1* 4.45 0.70 0.0021 0.0043
C3-2 4.13 0.70 0.0021 0.0046

Average: 0.0020 .0040

Calculation of
• Estimated, experimental and Calculated
7
A1-1-gross
A1-1-core
6
A1-1 cylinder fc=4.26 ksi
fcc=4.61 ksi cover spall-off
5
hair cracks
B
Stress (ksi)

4 A

3 1/2 fcc=2.31 ksi

C
1
0.0019

0.0037

0.0096

O
0
0 0.0025 0.005 0.0075 0.01 0.0125 0.015 0.0175 0.02
Axial Strain

Determination of experimental
2- Calculation of
• Estimated, experimental and Calculated
2- Calculation of
• Estimated, experimental and Calculated
5

y = 4.031x0.334
4 R2 = 0.9157

Experimental data
2

0
0 0.2 0.4 0.6 0.8 1 1.2 1.4
Calculation of transition strains
(hair-crack strain and )
7
A1-1-gross
A1-1-core
6
A1-1 cylinder fc=4.26 ksi
fcc=4.61 ksi cover spall-off
5
hair cracks
B
Stress (ksi)

4 A

3 1/2 fcc=2.31 ksi

C
1
0.0019

0.0037

0.0096

O
0
0 0.0025 0.005 0.0075 0.01 0.0125 0.015 0.0175 0.02
Axial Strain
 7
B2-1-gross
B2-1-core
6
fcc=5.19 ksi B2-1 cylinder fc=4.18 ksi
cover spall-off
5 hair cracks
Stress (ksi)

1/2 fcc=2.60 ksi

3

1
0.0019

0.0052

0.0119

0
0 0.0025 0.005 0.0075 0.01 0.0125 0.015 0.0175 0.02
Axial Strain
Confinement
not active

Transition of
stresses from
cover to core

Confinement
fully active
 6

4
Stress (ksi)

3 Proposed model for confined

RAC
Mander et al. (1984) model for
normal concrete
2 Sheikh and Uzumeri (1978)
model for normal concrete
Proposed model for confined
1 RAC
Experimental curves (C2-2)

0
0 0.003 0.006 0.009 0.012
Axial Strain
Examination of RAC models in
Flexure
Geometry:

Clear span L=44 inches

 10.0

8.0
Load (kips)

6.0

4.0
Calculated-Case 2
2.0 Calculated-Case1
Beam #1
Beam #2
0.0
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00
Displacement (in)
Experiment vs. Calculation:
Some observations:
• The tensile cracks appeared at a deflection of 0.017 inch and
0.021 inch for Beam-1 and Beam-2, respectively. The cracking
deflection was quite close to the calculated value of 0.022 in.

• The crushing of the compressive concrete started a deflection

of 0.205 inch and 0.240 inch for Beam-1 and Beam-2,
respectively. The calculated cracking deflection was 0.233
inch, quite close to the experimental values.
Conclusions
Conclusions:

An extensive experimental program including testing of

several plain RAC cylinders as well reinforced RAC
columns, 10 inches by 10 inches in section and 32 inches in
height, with different tie arrangements was conducted. The
following conclusions can be made:

1. RAC has a relatively smaller E than that of NAC (30% to

50% depending on the compressive strength). The higher
the strength, the less the difference is;
2. The strain corresponding to maximum strength of a RAC
cylinder is about 0.0025 (0.002 for NAC);

3. When efficiently confined, RAC can exhibit a significant

gain in strength (depending on the amount of the lateral
reinforcement) and ductility. An “efficient” confinement,
however, requires a cage in which the longitudinal and
lateral reinforcement are closely joined together;
4. Up to an axial strain about 0.0020 and regardless of the
amount of lateral reinforcement, RAC columns behave as if
they are plain. At this stage vertical hair cracks appear on the
cover;

5. The strain at which the cover spalls off is in a wide range of

0.004 to 0.007, depending on the amount of lateral
reinforcement (0.004 and 0.005 is suggested for NAC);

6. Under high straining rates, RAC column show 7% to 26%

increase in ultimate axial strength;

7. Well-confined RAC shows excellent ductility and no

insignificant degradation of stiffness under cyclic loading;
8. Plain RAC may be modeled through a set of equations as
follows:
9. Confined RAC may be modeled through a set of equations
as follows:
 Recommendations for Future
Research:

1. The applicability of the proposed model to RAC made of RCA with

different cleanliness and quality;

2. The applicability of the proposed model to spiral, rectangular and

irregular configurations of ties. The use of full-size of near-full size
specimen is recommended;

3. The applicability of the model for high-strength RAC.

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