Concrete Batch Research Articles

Pavement Flexural Fatigue Capacity, and the influence of Mix Charging Sequence

The durability of concrete pavements is greatly dictated by their capacity to resist fatigue induced by flexural stresses. Known to be a critical factor in fatigue behaviour is the quality (or deterioration under loading) of the bond between the cement paste and aggregate. This paper reports on lab and large-scale trial applications of a range of modified mix charging sequences in terms of their ability to improve the flexural fatigue life of concrete pavements, and also on conventional concrete plastic and hardened properties. Flexural fatigue resistance was assessed using the ASTM C1550 round panel loading test over a range of target failure loads, eg 10² to 106 cycles. Whilst source research was initially focussed on improved distribution of SCMs, this paper demonstrates that similar techniques significantly affect rheology, setting, strength and, in some cases, fatigue capacity and bond quality – all thought to be the result of a modified transition zone (between aggregate and mortar). Importantly, each modified charging sequence was selected or adapted on the basis that such new charging techniques, if shown to be beneficial, could be readily adapted to the common dry batch concrete plants already in use in readymix batching and on-site batching or mixing plants. This study will show that, for a matched mix design, the RILEM method of batching improves the fatigue resistance (and life) of a typical Australian pavement quality concrete by 23% when compared with the conventional batching sequence presently used by premixed and typical on-site concrete batch plants.

Experimental Study on Properties of Portland Cement Concrete Containing Recycled Asphalt Pavements

Although recycled asphalt pavement (RAP) are widely used in the construction of new, and reconstruction of old, hot mix asphalt (HMA) pavements, little research has been done to examine the potential of incorporating RAP into Portland cement concrete to replace virgin aggregate. Because RAP consists of aggregates coated by asphalt cement, the toughness of concrete made with RAP could be improved. In this paper, the mechanical properties of portland cement concrete containing RAP were investigated through laboratory experiments. Two types of RAP (coarse and fine RAP) materials were used to replace the equal amount of virgin coarse and/or fine aggregate. Silica fume and high-range water reducing agent (HRWRA) were also added into concrete mixtures to minimize the strength loss due to the incorporation of RAP. A total of 17 concrete batches were cast and tested for compressive and split tensile strengths, static compressive modulus of elasticity, and toughness index in accordance with ASTM standards. Test results indicated that there was a systematic reduction in the strengths and elastic modulus as well as an increase in the toughness index with the increase in RAP content. While the addition of HRWRA into the matrix improved the mechanical properties of concretes containing RAP, addition of silica fume unexpectedly did not.

Analysis of engineering performance of concrete comprising recycled crushed plastic waste and fly ash

This study investigated the attributes of blending of recycled crushed polypropylene plastic coarse aggregates (PPCA) and fly ash (FA) towards the fresh and hardened properties of concrete. Natural coarse aggregate was partially replaced with PPCA at volumetric replacement levels up to 30% and cement was replaced with FA up to 20%. Initially, the performance of PPCA and FA in concrete was investigated distinctly. The incorporation of 30% of PPCA in concrete rather impaired the workability (from 95 mm – 50 mm: 47%) and the compressive strength (from 44.6 MPa to 31.4 MPa: 29.7%). By appropriate using of a superplasticizer, the loss in the workability could be recovered. Microstructural investigation was conducted employing scanning electron microscope analysis; it showed that the formation of a weak interfacial transition zone between PPCA and cement paste to be the reason for strength reduction in PPCA concrete. In contrast, the addition of 10 – 20% of FA in concrete improved the workability by 63.2% – 100%, but yet again, the 28-day compressive strength reduced by 15.8 – 35.6%. Meanwhile, thermal conductivity results and constitutive relationships proved that the use of PPCA enhanced the thermal insulation property and ductility of PPCA concrete, respectively. Eventually, a total of six concrete batches with binary blended PPCA and FA were cast to find the optimum replacement levels. The optimum binary combination with reasonable strength and workability at a minimal cost was achieved to be 10% PPCA and 20% FA.

Tactical Activities to Improve the Effectiveness of Concrete Batching Plant Based on Overall Equipment Effectiveness Analysis

The growth of infrastructure projects has led to an increased demand for ready-mix concrete. A company that produces ready-mix concrete using a batching plant encountered difficulties in fulfilling customer orders due to the high rate of machine downtime. Overall equipment effectiveness (OEE) was employed to examine these issues at the tactical activities, where the root causes of losses that occur in the OEE components of availability, performance, and quality were addressed. The OEE analysis was extended to encompass maintenance effectiveness measures, as the anticipated solution to the problem was not the replacement of the machine, but rather an enhancement of its operational efficacy. The effectiveness of maintenance activities was measured using MTTF (mean time to failure), MTTR (mean time to repair), and MTBF (mean time between failure). A review of the OEE components revealed a necessity to reduce losses, as evidenced by the availability and performance rates. Although the performance rate has the lowest value, based on the frequent occurrence of failures to the availability component, the improvement process was carried out to overcome problems in the availability variable. The implementation of scheduled maintenance at the beginning of each month and the implementation of daily checks before and after the machine was used resulted in an increase in the OEE value from 56.62% to 71.15%. The incorporation of maintenance analysis into OEE has been shown to result in increased OEE values, as evidenced by a longer mean time between failures, a reduced time for process adjustments, and a decreased asset repair time.

Comparative study on the performance of fresh concrete comprising manufactured sand vs. river sand during full-scale long-distance pumping

The shift from river sand (RS) to manufactured sand (MS) as a fine aggregate in concrete is driven by environmental sustainability concerns. However, negative impacts of MS on concrete workability have raised doubts about its suitability for long-distance pumping in construction projects. This study evaluates the performance of MS concrete compared to RS concrete of the same strength grade during long-distance pumping. A full-scale coiled pipeline with measured length of 348 m was built, twelve batches of C30 and C60 concrete were prepared, and pumping tests were conducted at discharge rates of 2.5–18.9 liter per second (L/s). The workability and rheological parameters were assessed before and after pumping. The measured and predicted pumping pressure were analyzed and calculated based on rheological parameters and lubricating layer (LL) parameters. Results indicate that MS increased the yield stress and decreased the LL thickness index of C30 concrete, while it decreased the viscosity coefficient of C60 concrete. Post-pumping, the change in yield stress was similar for both MS and RS concrete, but MS reduced the plastic viscosity change in C60 concrete. MS did not significantly affect the pumping pressure loss, but influenced the pumping pressure prediction deviation by influencing the thixotropy. The classic pumping pressure prediction model developed by Kapan obviously overestimated the pumping pressure during long-distance pumping, and the deviation was more prominent in high-strength concrete pumping. MS increased the thixotropy of C30 concrete and reduced the prediction deviation of pumping pressure, but had the opposite effect on C60 concrete.

Optimum Use of Recycled Waste Materials as Partial Replacement of Fine Aggregate in Portland Cement Concrete Mixes

This study explored the independent utilization of five common waste materials - rubber, plastic, glass, slag, and sewage sludge ash (SSA) - as partial replacement of fine aggregate in Portland cement concrete (PCC) mixes. The main objective was to determine an optimum substitution range for each waste material that would offer well performing concrete in terms of workability, compressive strength, and durability. To this end, multiple concrete batches were prepared, incorporating each waste material at four different levels: 5%, 10%, 15%, and 20% by weight of fine aggregate. Then, concrete samples (100-mm diameter × 200-mm tall cylinders) were cast from each batch and were moisture-cured for 7, 14, and 28 days prior to testing. Also, the chemical composition of each waste material was identified using FTIR spectroscopy to understand its impact on the development of concrete strength. While most waste led to the diminished strength gains at all substitution rates, the addition of glass, slag, and SSA contributed positively to the strength development at specific replacement levels: 5% for glass, 10 - 15% for slag, and 5 – 15% for SSA. Furthermore, these additions of glass and slag exhibited comparable workability and durability although SSA did not exhibit comparable workability and durability. The findings of this study can hold significant implications for environmental sustainability and cost effectiveness in construction projects.

Investigating the Effect of Steel Wire and Carbon Black from Worn Out Tyre on the Strength of Concrete

Technology in concrete is rapidly developing to improve the quality and properties of concrete. One of the many recycled materials is worn-out tyres. Currently, the use of tires is very widespread considering the use of vehicles that increase from time to time. Piles of discarded tires can cause a lot of damage to the environment. So, by using steel wire waste (SWW) as new fiber reinforcement in concrete and with the combination with carbon black (CB), it is hoped that, by doing this, not only it could improve the quality of concrete, but also preserves the environment. Therefore, the objective of this research was, to identify the properties of fresh concrete with the addition of SWW and CB, and also to investigate the physical and mechanical properties of hardened concrete, incorporating of SWW as additional fiber reinforcement and CB. For fresh concrete, workability using a slump test was conducted. Several tests were carried out on the properties of hardened concrete. Among them were compressive strength, flexural strength, splitting tensile strength, and water absorption. The physical appearance of the concrete has also been examined and recorded. There are four batches of concrete which consist of one control batch and three batches of concrete with various weights of SWW which are in the portion of 300 g, 600 g, and 900 g, and the weight of CB is maintained at 300 g for all batches. For workability, all concrete batches with the addition of SWW and CB show acceptable workability. For the case of the density of fresh concrete, samples containing 900 g addition of SWW have the highest density which was 2520 kg/m³, as expected. Results for water absorption show that the lowest value is contributed by the control sample which was 7.6%. For compressive and flexural strength, 300 g addition of SWW has the highest value which was 28.52 MPa for compressive strength and 7.52 MPa for flexural strength. Lastly, for splitting tensile strength, the highest value was also obtained when 300 g addition of SW was added which was 5.4 MPa. To conclude, SWW and CB can be added to concrete to obtain comparable strength of concrete. However, some modifications could be made to both recycle materials to improve concrete performance.

Metode Pelaksanaan Pembuatan PC Spun Pile dengan Mutu F'c 52 MPa Pada PT. Wijaya Karya Beton Tbk PPB Majalengka

A concrete plant, also known as a batch plant or batching plant or a concrete batching plant, is equipment that combines various ingredients to form concrete. This implementation aims to determine the manufacturing process and quality control of concrete product production. The method used in this implementation is descriptive quantitative. Steps include operational variables to determine the problem and indicators of the cause of the problem. Data collection through observation and documentation. The results of this implementation show that the implementation of manufacturing at PT WIKA Beton Tbk PPB Majalengka aims to make good concrete products, the factors for making PC Spun Pile products are made based on work instructions or standard operational procedures.

Cooperative game theory approach towards capital equipment procurement in construction projects: a concrete batch plant case study

This study explores how contractors can benefit from joint resource procurement in construction projects, particularly in case with capital-intensive ones. Capital equipment is costly and has a long beneficial life compared to other resources; hence, minimizing its long-term costs is pivotal. Also, the lack of open dialogue under a legal structure in projects may deprive project participants from many beneficial partnering opportunities. Given this background, a comprehensive framework based on cooperative game theory is introduced to form a systematic partnership among contracting parties to share their capital equipment. Cooperative game theory is suggested as the basis for increase the gains to all parties and fair and efficient allocation of the incremental benefits of cooperation. The proposed flowchart is then applied to a real-world project and various coalitional cooperative game theory solutions for dividing gains equitably, from sharing a site-located concrete batch plant among three contractors are evaluated and the most stable cost allocation is identified. Results reveal that with the application of this cooperative procurement, the three contractors can achieve an average of twenty three percent considerable savings through practical alliance that deliver vast improvements in project productivity and performance.

The influence of graphene nanoplatelet content on the mechanical properties and microstructure of sustainable concrete

The effects of the content of graphene nanoplatelets (GNPs) on the mechanical properties and microstructure of sustainable concrete were investigated. Aqueous solutions were prepared, using a wet-dispersion technique to disperse GNPs in the mixing water. Concrete batches were prepared using different GNP fractions (0.05, 0.1, 0.25, 0.5, 1 and 2% by weight of cement), and their compressive, flexural and tensile strengths were determined at 28 days. Qualitative microstructural analyses were performed using scanning electron microscopy and energy dispersive X-ray analysis. The results obtained were analysed using analysis of variance (Anova), which demonstrated improvements in all strength properties when using GNP filaments regardless of their weight fraction. The batch containing 0.5% GNPs showed the largest strength improvements, with improvements in compressive, flexural and tensile strength properties of 22.6%, 23.9% and 255.4%, respectively. Microstructural analysis showed a good dispersion of nanofilaments inside the concrete matrix through the dispersion technique used in this study. Finally, Anova revealed statistically significant relationships between the GNP content and the compressive, flexural and tensile strengths of the concrete specimens. The results highlight the importance of the GNP content in influencing the concrete's mechanical properties.

Effectiveness of the Concrete Equivalent Mortar Method for the Prediction of Fresh and Hardened Properties of Concrete

Modern concrete mix design is a complex process involving superplasticisers, fine powders, and fibres, requiring time and energy due to the high number of trial tests needed to achieve rheological properties in the fresh state. Concrete batching involves the extensive use of materials, time, and the testing of chemical admixtures, with various methodologies proposed. Therefore, in some instances, the required design properties (physical and mechanical) are not achieved, leading to the loss of resources. The concrete equivalent mortar (CEM) method was introduced to anticipate concrete behaviour at fresh and hardened states. Moreover, the CEM method saves time and costs by replacing coarse aggregates with an equivalent sand mass, resulting in an equivalent specific surface area at the mortar scale. This study aims to evaluate the performance of fibre in CEM and concrete and determine the relationships between the CEM and the concrete in fresh and hardened states. Steel and polypropylene fibres were used to design three series of mixtures (CEM and concrete): normal-strength concrete (NSC), high-strength concrete (HSC), high-strength concrete with fly ash (HSCFA), and equivalent normal-strength mortar (NSM), high-strength mortar (HSM), and high-strength mortar with fly ash (HSMFA). This study used three-point bending tests and digital image correlation to evaluate load and crack mouth opening displacement (CMOD) curves. An analytical mode I crack propagation model was developed using a tri-linear stress–crack opening relationship. Post-cracking parameters were optimised using inverse analysis and compared to actual MC2010 characteristic values. The concrete slump is approximately half of the CEM flow; its compressive strength ranges between 78% and 82% of CEM strength, while its flexural strength is 60% of CEM strength. The post-cracking behaviour showed a significant difference attributed to the presence of aggregates in concrete. The fracture energy of concrete is 28.6% of the CEM fracture energy, while the critical crack opening of the concrete is 60% of that of the CEM.

Mechanical Properties of a Sustainable Low-Carbon Geopolymer Concrete Using a Pumice-Derived Sodium Silicate Solution.

A geopolymer is an inorganic amorphous cementitious material, emerging as an alternative sustainable binder for greener concrete production over Ordinary Portland Cement (OPC). Geopolymer concrete production promotes waste reuse since the applicable precursor materials include agricultural and industrial waste that requires disposal, helping to reduce waste in landfills and ensuring sustainable environmental protection. This study investigates the development of an environmentally friendly sodium silicate alternative (SSA) derived from pumice powder (PP) in place of a commercial Na2SiO3 solution at a 10 M concentration. Six concrete batches were produced at alkaline/precursor (A/P) ratios of 0.1, 0.2, 0.3, 0.4, and 0.5. The geopolymer mix AF4, with an A/P ratio of 0.4, became the optimum geopolymer concrete design; however, it recorded lower compressive, tensile splitting, and flexural strengths, respectively, against the control OPC concrete. The geopolymer formulations, however, obtained 28-day-hardened concrete densities comparable to the control concrete. The 28-day compressive strength of the OPC concrete was 29.4 MPa, higher than the 18.8 MPa recorded for AF4. However, the 56-day strength of AF4 improved to 22.4 MPa, an around 19% increase compared to the 30.8 MPa achieved by the control mix on day 56, having experienced only a 5% strength increase. The low mechanical performances of the geopolymer formulation could be attributed to extra water added to the original geopolymer design to improve the workability of the geopolymer mix. Therefore, the SSA alkaline solution using PP showed some potential for developing geopolymer concrete for low-strength construction applications.

Verification Test and Research on Fitting Curve of Shear and Tensile Synthesis Method

Based on the recommended curve of concrete compressive strength tested by shear and tensile composite method, this paper combined with concrete specimens of different strength grades, ages and batches produced by several test verification units, adopted the in vitro shear and tensile test method introduced by the regulations, and used basically the same test equipment to collect the single shear and tensile strength and the compressive strength of cube specimens under the same conditions. Each batch was divided into 15 or 30 specimens. Through the collected test data, the conversion strength of the single shear, pull-out and shear tensile composite methods were calculated respectively. The relative error of a single specimen was calculated based on the average strength of each batch of concrete. The error distribution types and errors of each company were systematically studied, and finally the relative error data of each company were summarized, and the probability distribution parameters of the error of the Shear and tensile synthesis method were understood through probability distribution analysis, and the relationship between the error of the shear and tensile synthesis method, the single shear method and the pull method, and the influence degree on the conversion strength of the shear and tensile synthesis method were shown by using three-dimensional coordinates. Using the test data of "shear and tensile synthesis method", "single shear method" and "pull-out method", the scatter plot is drawn, and the error size is compared to explore the direction of further improving the detection accuracy of "shear and tensile synthesis method".

Automatic concrete slump prediction of concrete batching plant by deep learning

The workability of fresh concrete is highly important in terms of construction quality and safety. Slump tests are required every 120 m³, yet automated monitoring for each concrete batch remains unavailable in the actual concrete batching plant. To mitigate this issue, we propose an automatic slump prediction method based on the VGG16 neural network by analyzing the video from the final discharge hopper of the batching plant. Additionally, Explainable AI (XAI) is adopted to evaluate and validate our automatic concrete quality inspection approach. Iteratively examining XAI outputs and applying necessary adjustments in data preprocessing helps to achieve better overall performance. The proposed video classification method performed by averaging over the image-level predictions can classify the concrete into four slump classes with an average precision of 85% and an average F1 score of 87%. This demonstrates the possibility of continuous quality evaluation for all concrete produced in the concrete batching plant.

Mechanical and Microstructural Investigation of Geopolymer Concrete Incorporating Recycled Waste Plastic Aggregate.

The effective use of waste materials is one of the key drivers in ensuring sustainability within the construction industry. This paper investigates the viability and efficacy of sustainably incorporating a polylactic acid-type plastic (WP) as a 10 mm natural coarse aggregate (NA) replacement in geopolymer concrete. Two types of concrete (ordinary Portland cement-OPC and geopolymer) were produced for completeness using a concrete formulation ratio of 1:2:3. The ordinary concrete binder control was prepared using 100% OPC at a water/binder ratio of 0.55, while the geopolymer concrete control used an optimum alkaline activator/precursor-A/P ratio (0.5) and sodium silicate to sodium hydroxide-SS/SH volume ratio (1.2/0.8). Using the same binder quantity as the control, four concrete batches were developed by replacing 10 mm NA with WP at 30 and 70 wt% for ordinary and geopolymer concrete. The mechanical performance of the developed concrete was assessed according to their appropriate standards, while a microstructural investigation was employed after 28 days of curing to identify any morphological changes and hydrated phases. The results illustrate the viability of incorporating WP in geopolymer concrete production at up to 70 wt% replacement despite some negative impacts on concrete performance. From a mechanical perspective, geopolymer concrete indicated a 46.7-58.3% strength development superiority over ordinary concrete with or without WP. The sample composition and texture quantified using automated scanning electron microscopy indicated that adding WP reduced the presence of pores within the microstructure of both concrete types. However, this was detrimental to the ordinary concrete due to the low interfacial zone (ITZ) between calcium silicate hydrate (CSH) gel and WP, resulting in the formation of cracks.

The influence of methods of concrete quality control by physical and mechanical parameters on the reliability of building structures

Introduction. The construction technical control system evaluates the physical and mechanical properties of concrete on the base of testing a series of samples taken from a batch of concrete. It is necessary to take into account the influence of the control method on the quality of concrete structures and their reliability.
 
 Aim. Creation of a technical control system that should eliminate the causes of the identified risks by reducing the impact of the identified causes.
 
 Materials and methods. The control method affects the reliability of concrete structures being built and is evaluated from the point of view of choosing the number of samples and discarding the minimum strength values in the series. The results of the control of a series of concrete samples for 6 samples selected in such a way as to ensure compliance with the declared class when discarding 2 minimum sample values are compared.
 
 Results. As a result of the analysis of the impact of the methodology on quality and reliability: class B turns out to be 2 steps lower than the prescribed one, the in-series coefficient of variation exceeds the permissible one by 8 %, and the reliability level is significantly lower by 36 %.
 
 Conclusions. The conducted research shows an underestimation of the methodological component of material control, which can leave significant gaps in the system of technical control of construction products and does not allow to ensure the required level of reliability of structures.

Effect of Pouring Time on the Integrity of Pulverized Fuel Ash Concrete

The effects of pouring time intervals on the integrity of pulverized fuel ash (PFA) concrete were evaluated by measuring ultrasonic pulse velocity and compressive strength. Concrete was poured progressively at different time intervals (30 min, 45 min, and 60 min) under similar conditions after the first batch of concrete was vibrated. The effects of the water–cement ratio (w/c) on ultrasonic pulse velocity were also compared and analyzed. Both compressive strength and ultrasonic pulse velocity decreased as the pouring time interval increased. When the water–cement ratio was 0.55, the pouring time interval had little effect on compressive strength, but when the w/c was reduced to 0.45, improvements in the compressive strength of concrete with different pouring time intervals were as high as 10 MPa. Under the condition of the same w/c and the same pouring time interval, improvements in the compressive strength of the interface were as high as 15 MPa, and the prolongation of the aging period could reduce the difference in strength to 8 MPa. The formula Fc=0.63e0.95Vc was used to infer the compressive strength of fly ash concrete at different ages by ultrasonic pulse velocity.

Construction quality control of concrete structures in architectural engineering—A case in Shanghai, China

<p>Architectural concrete provides diverse patterns, colors, and forms, offering extensive structural and aesthetic possibilities. In China, advanced techniques such as prefabricated and precast concrete structures are increasingly utilized, delivering benefits like faster construction, reduced resource use, and improved quality control. Recent studies in China have highlighted the environmental benefits and practical considerations of incorporating recycled materials and moderate-heat Portland cement into concrete, which offer promising sustainability advantages. This study, through a case analysis in China, explored the usability, durability, manufacturing costs, and economic implications of architectural concrete. It emphasizes the critical role of architectural concrete in modern structural engineering, financial planning, and design, aiming to reduce variability in strength and uniformity between concrete batches, ensure consistent material quality, and lower maintenance costs while accelerating production. Focusing on quality control in concrete construction in Heqing, Pudong, Shanghai, this research identified unique challenges and provided insights. In Shanghai's architectural context, continuous monitoring of concrete quality is essential for structural stability and durability. This study also addressed the resilience of concrete structures in saltwater and freeze-thaw conditions, underscoring the need to consider environmental factors in quality assurance. Laboratory experiments demonstrated that composite members and deep beams of steel and concrete exhibit notable deformation and shear resistance, highlighting the importance of meticulous material selection and structural design for effective quality control.</p>

Compressive Strength Prediction of Concrete Containing Used Cooking Oil Using Ann

To mitigate the detrimental impacts of disposing of used cooking oil (UCO) into the environment, which adversely affects marine life, human health, and agricultural outputs, this research proposes a novel approach incorporating this waste material into the concrete industry as a chemical admixture. To investigate this, an initial experimental program is designed to examine how used cooking oil affects various fresh properties and compressive strength at 3, 7, and 28 days of age of concrete. Concrete batches of M40 grade are meticulously prepared with varying proportions (ranging from 0% to 2%) of used cooking oil. To predict strength characteristics, an Artificial Neural Network (ANN) is employed, consisting of three layers. The input layer comprising quantities of cement, coarse aggregate, fine aggregate, water content, super plasticizer, and the percentage of the chemical admixture (UCO), hidden layer for predicting the network system and the output layer providing the concrete's compressive strength.

Mechanical characterisation and small-scale life-cycle assessment of polypropylene macro-fibre blended recycled cardboard concrete

This paper presents an experimental study and findings on the requalification of waste cardboard as a fine-aggregate replacement in the development of waste-based concrete. The design of eco-efficient and green-star concrete has become a significant focus, driven by the impact of industrial and municipal waste on both the environment and the global economy. The study aimed to utilise materials such as waste cardboard, polypropylene, and ground-granulated blast furnace slag as partial replacements for Ordinary Portland Cement and fine natural aggregate. It specifically focused on developing techniques for processing recycled cardboard into an aggregate suitable for this study. Six concrete batches were cast with incremental dosages of finely processed recycled cardboard and a fixed dosage of recycled polypropylene macro-fibres. An experimental program was conducted to determine fresh and mechanical properties at 7 and 28 days. The results were used to identify an optimal dosage level of waste cardboard suitable for commercial use. Additionally, a small-scale life-cycle assessment was performed to evaluate the environmental impact of the hybrid concrete mix. The processed cardboard exhibited desirable rheological and mechanical properties, making it a suitable fine-aggregate replacement. The addition of recycled polypropylene fibres enhanced flexural and tensile strength, establishing the blend as a suitable concrete mixture design for real-world applications. Furthermore, the life-cycle assessment highlighted the effectiveness of the mixture designs when compared to benchmark concrete mixtures.