1 Introduction
Due to environmental regulations, difficulty in quality control, and decrease in strength properties, the use of recycled concrete aggregate (RCA) has been mostly limited to nonstructural applications, especially in pavement layers despite its economical and eco-friendly benefits (Ministry of Land, Transportation and Maritime Affairs
2009; Ministry of Environment
2014; Kang et al.
2014; Yang et al.
2014; Fathifazl
2008; Fathifazl et al.
2009). In particular, if RCA concrete is proportioned according to the conventional American Concrete Institute (ACI) method, it would be difficult to enhance its properties such as the modulus of elasticity, drying shrinkage, and freeze-and-thaw resistance (Fathifazl
2008; Fathifazl et al.
2009; Abbas et al.
2009).
In the case of a military airfield on a base in Seoul, South Korea, its runway was paved with good quality concrete materials that has lasted around 30–40 years. Engineers predict (Yang et al.
2014) that a half of all the airport runaways in South Korea will undergo surface reconstruction within 5–10 years. A few air bases have already been under reconstruction, and the RCAs produced on-site on air bases have been used only for the sub-base materials, regardless of the potentially good RCA quality that the air bases can produce. It is noticeable that the RCA recycled on the air base normally contains fewer impurities than other structures and at most contains some asphalt and rubber from the patching and joint sealing areas.
In addition to the factors already mentioned that limit RCA concrete use, there is also a security regulation and financial conflict between the air base and recycling plant owners. Regarding the regulation, it would be unavoidable to take out the old paving concrete waste to an external recycling plant and bring the standard grade RCA back to the air base reconstruction site after recycling due to the strict RCA quality requirement. The Korean standard (KS) specifications require a specific gravity of 2.5 and water absorption of less than 3% of the RCA for structural and paving concrete use (Ministry of Land, Infrastructure and Transportation
2009; Korea Expressway Corporation
2011; Incheon International Airport Corporation
2012). In actuality, 4–6 steps of additional crushing processes are being carried out at the recycling plant in order to satisfy the KS specifications (see Fig.
4), resulting in a loss of time and money (Kang et al.
2014).
An innovative method to solve this problem has been introduced by Fathifazl (
2008), Fathifazl et al. (
2009) and Abbas et al. (
2009). They undertook an extensive literature review and summarized the mechanical and durability properties of RCA concrete (Fathifazl
2008). The concrete properties using the conventional RCA method are mainly affected by the volume of the residual mortar (RM) attached to the RCA. It was pointed out in 17 studies (Fathifazl
2008) that the elastic modulus of RCA concrete decreased by 0–45%, compared to that of the companion natural aggregate concrete. Other researchers also confirmed that RCA concretes had lower elastic modulus than normal aggregate one (Tavakoli and Soroushian
1996; Eguchi et al.
2007; Padmini et al.
2009; Limbachiya et al.
2012; McNeil and Kang
2013; Wardeh et al.
2015). This means that the elastic modulus of RCA concrete is a function of that of the mortar and also has a proportional relationship with the volume of the mortar (Fathifazl
2008). It was also mentioned in 11 studies (Fathifazl
2008) that the drying shrinkage of the RCA concrete exhibited a 6–111% increase, compared to that of the conventional mix concrete. Other studies also showed that RCA concrete had higher drying shrinkages than normal aggregate one (Eguchi et al.
2007; Limbachiya et al.
2012; Sagoe-Crentsil et al.
2001). This is due to the fact that the drying shrinkage is proportional to the volume of the mortar. Consequently, Fathifazl, et al. came up with the equivalent mortar volume (EMV) method, treating the residual mortar as part of the total mortar content of the RCA concrete, (i.e. residual plus fresh mortar) and demonstrating that the elastic modulus does not decrease and that the drying shrinkage does not increase.
In essence, airport pavements require very delicate riding smoothness, and this is greatly related to the low slump of the paving surface. The low slump, often under 50 mm (Korea Expressway Corporation
2011; Incheon International Airport Corporation
2012), can be achieved for paving due to the compaction of the concrete mix. A paving concrete mix is therefore typically proportioned with a marginal amount (usually less than 700 kg/m
3) of fine aggregates. It was pointed out in the previous study (Yang and Lee
2017b; Kim et al.
2016) that the nature of the EMV mix proportions leads to a far smaller amount of fine aggregates, in some case less than 600 kg/m
3, creating a harsh mix. It may have a smooth finish if the slip form paver forcibly vibrates more than 10,000 times per minute, but normally there will be a range of shortage in the amount of sand or fresh mortar. Therefore, the modified EMV mix proportioning method has been proposed (Yang and Lee
2017a,
b; Kim et al.
2016), assuming that a certain volume fraction of the residual mortar may be mathematically treated as original virgin aggregate, while the other fraction as a part of the total mortar.
This study aims to assess the effect of different mix proportioning methods (the conventional ACI method versus the modified EMV method) on the drying shrinkage and freeze-and-thaw resistance of concrete. The modified EMV method and the conventional method were used for comparison. Several RCAs were produced from the on-site plants on air bases and at a commercial recycling plant in South Korea. To verify the applicability of the modified EMV method, especially for the drying shrinkage and freeze-and-thaw of RCA concrete, two series of mixes were made using the modified EMV mix design, along with the original EMV and the conventional mix design, with various types and sources of coarse RCA.
2 Modified Equivalent Mortar Volume Method
The EMV mix design was originally proposed by Fathifazl (
2008). It was ensured in the EMV concept that the total volume of natural aggregate in recycled concrete aggregate (RCA) concrete is equal to the volume of natural aggregate in the conventional concrete with the same specified properties (Fathifazl
2008; Fathifazl et al.
2009; Abbas et al.
2009). Thus, the new fresh mortar volume in the RCA concrete (RAC) mix is required to be reduced as much as the residual mortar content (RMC). The RMC was obtained using the following equation:
$$ {\text{RMC }} = \, \left( {W_{\text{RCA}} - W_{\text{OVA}} } \right)/W_{\text{RCA}} \times { 1}00 $$
(1)
where
W
RCA is the initial oven-dry weight of the RCA samples before the test and
W
OVA is the final oven-dry weight of the original virgin aggregate (OVA) after complete removal of the residual mortar (RM). However, it was noted earlier that in the typical paving concrete mix the EMV concept leads to too little mortar content. It was also previously mentioned that the lack of fillers causes slump loss and a detrimental shape due to too much reduction in the amount of cement, water, and sand (Yang and Lee
2017b).
Therefore, it was assumed in the modified EMV model (Yang and Lee
2017b) that the RM attached to RCA works as aggregate in fresh concrete, and works as mortar after it is hardened. Considering this treatment, the RM volume in RAC was represented as the sum of the volume fraction of mortar
\( V_{RMa}^{RAC} \) and the other volume faction of aggregate
\( V_{RMb}^{RAC} \), as follows:
$$ V_{RM}^{RAC} = V_{RMa}^{RAC} + V_{RMb}^{RAC} $$
(2)
where
$$ V_{RMa}^{RAC} = V_{RCA}^{RAC} \times \left[ {1 - \left( {1 - \frac{1}{S} \times RMC} \right) \times \frac{{SG_{b}^{RCA} }}{{SG_{b}^{OVA} }}} \right] $$
(3)
where
\( V_{RCA}^{RAC} \) is the RCA volume in the RAC;
\( SG_{b}^{RCA} \) and
\( SG_{b}^{OVA} \) are the bulk specific gravities of RCA and the original virgin aggregate (OVA), respectively; and, S is a scale factor that determines the volume fraction.
Now, the parameter
R, which was defined as the ratio of the fresh natural aggregate content of RAC to the fresh natural aggregate content of the companion conventional mix, was modified (Yang and Lee
2017b) as follows:
$$ R = 1 - \frac{{V_{RCA}^{RAC} }}{{V_{NA}^{NAC} }} \times \left( {1 - \frac{1}{S} \times RMC} \right) \times \frac{{SG_{b}^{RCA} }}{{SG_{b}^{OVA} }} $$
(4)
where the volume of fresh NA in the natural aggregate concrete (NAC) is represented by
\( V_{NA}^{NAC} \) and the volume of RCA in the RCA concrete by
\( V_{RCA}^{RAC} \);
\( SG_{b}^{RCA} \),
\( SG_{b}^{OVA} \) as the bulk specific gravities of RCA and the OVA, respectively. Note that the original definition of the parameter
R was proposed by Fathifazl (
2008).
Then, the volume of new mortar in RAC mix
\( V_{ NM}^{RAC} \) is calculated from the volume of mortar in NAC mix
\( V_{ M}^{NAC} \), and the volume of natural aggregate (NA) in NAC mix
\( V_{ NA}^{NAC} \) as follows:
$$ V_{ NM}^{RAC} = V_{ M}^{NAC} - V_{ RMa}^{RAC} $$
(5)
$$ V_{ M}^{NAC} = 1 - V_{ NA}^{NAC} $$
(6)
$$ V_{ NA}^{NAC} = \frac{{W_{ OD \cdot NA}^{NAC} }}{{SG_{ b}^{NA} \times 1,000}} $$
(7)
where the oven-dry weight of NA in NAC mix is represented as
\( W_{ OD.NA}^{NAC} \).
The oven-dry weight of RCA in RAC mix
\( W_{ OD.RCA}^{RAC} \) and oven-dry weight of NA in RAC mix
\( W_{ OD.NA}^{RAC} \) can be determined as follows:
$$ W_{ OD \cdot RCA}^{RAC} = V_{ RCA}^{RAC} \times SG_{ b}^{RCA} \times 1000 $$
(8)
$$ W_{ OD \cdot NA}^{RAC} = V_{ NA}^{RAC} \times SG_{ b}^{NA} \times 1000 $$
(9)
where the volume of RCA in RAC mix
\( V_{ RCA}^{RAC} \) is represented by rearranging Eq. (
4),
$$ V_{ RCA}^{RAC} = \frac{{V_{ NA}^{NAC} \times \left( {1 - R} \right)}}{{\left( {1 - RMC \times \frac{1}{S}} \right) \times \frac{{SG_{ b}^{RCA} }}{{SG_{ b}^{OVA} }}}} $$
(10)
By multiplying the quantities of the ingredients of the mortar in the companion NAC by the
\( \frac{{V_{ NM}^{RAC} }}{{V_{ M}^{NAC} }} \) ratio, the corresponding quantities of water, cement, and fine aggregate in RCA concrete can be calculated as follows:
$$ W_{ w}^{RAC} = W_{ w}^{NAC} \times \frac{{V_{ NM}^{RAC} }}{{V_{ M}^{NAC} }} $$
(11)
$$ W_{ c}^{RAC} = W_{ c}^{NAC} \times \frac{{V_{ NM}^{RAC} }}{{V_{ M}^{NAC} }} $$
(12)
$$ W_{ OD \cdot FA}^{RAC} = W_{ FA}^{NAC} \times \frac{{V_{ NM}^{RAC} }}{{V_{ M}^{NAC} }} $$
(13)
where the weights of water and cement are represented as
\( W_{ w}^{RAC} \) and
\( W_{ c}^{RAC} \), respectively, and the oven-dry weight of fine aggregate as
\( W_{ OD \cdot FA}^{RAC} \). A sample mix proportioning can be found in Ref. (Yang and Lee
2017b).