Impact of Compression Casting Technique on the Mechanical Properties of 100% Recycled Aggregate Concrete

The research work presented in this manuscript focused on the comparative examination of the influence of the Compression Casting Technique (CCT) and the conventional casting method (i.e., compaction through vibration) on the performance of 100% Recycled Aggregate Concrete (RAC). The minimum target compressive strength of 100% RAC was 15 MPa keeping in view its application in the manufacturing of load-bearing concrete masonry units. A total of 28 concrete compositions were prepared by varying the coarse to fine aggregates ratio (i.e., 70:30 and 60:40), cement content (10% and 15%) by weight of total aggregates, casting technique, and applied pressure for compression casting (i.e., 25, 35, and 45 MPa). The concrete compositions were tested to determine their density, compressive strength, Elastic Modulus (EM), and Ultrasonic Pulse Velocity (UPV). For comparison, samples of Natural Aggregate Concrete (NAC) were also tested for the same properties. The results highlighted the positive impact of CCT on the properties of 100% RAC. The compressive strength and EM of fully RAC was increased by 20–80% and 15–50%, respectively, by changing casting method from vibration to CCT. At casting pressure of 35 MPa and 15% cement, compressed 100% RAC exhibited compressive strength higher than vibrated NAC. The UPV value exhibited by 100% RAC was increased by changing the casting technique. The analytical models were proposed using regression analysis of experimental results to predict compressive strength and EM of compressed 100% RAC and NAC. These proposed models were evaluated using statistical parameters, i.e., average absolute error (AAE) and mean (M) and found to be able to predict the compressive strength and EM of RAC with reasonable accuracy as compared to the analytical models already existing in the literature. This study finally concluded that through CCT, 100% RAC with low cement content could achieve minimum target compressive strength of 15 MPa. The development and use of compressed load-bearing 100% RAC construction units would help to achieve sustainability in construction.