Mitigating the brittle behavior of compression cast concrete using polypropylene fibers

Compression casting enhances mechanical properties, durability, and microstructure of concrete while reducing cement usage and carbon emissions. However, its brittleness restricts its widespread use. This study aims to mitigate the brittleness of compression cast concrete (CCC) through fiber reinforcement. Eleven concrete mixes with varied volumetric ratios (0, 0.05, 0.1, 0.15, 0.2, and 2 %) and aspect ratios (250, 313, and 396) of polypropylene fibers were prepared. Both compressed and uncompressed specimens were analyzed for compressive stress-strain behavior, compressive strength, modulus of elasticity, toughness, specific toughness, and microstructure. Results show that CCC specimens have steeper and shorter descending segments on their compressive stress-strain curves than uncompressed concrete, indicating brittleness. Adding polypropylene fibers significantly reduces this brittleness by enhancing the post-peak compressive stress-strain behavior of CCC. Fiber reinforced CCC specimens exhibit significant enhancements in compressive strength, modulus of elasticity, and toughness (up to 68 %, 34 %, and 38 % respectively) compared to uncompressed plain concrete. Mercury intrusion porosimetry, scanning electron microscopy, and backscattered electron imaging confirm that compression casting strengthens the interfacial transition zone of both plain and fiber reinforced CCC. Proposed empirical models accurately forecast the modulus of elasticity, compressive strength, and peak compression strain for both types of CCC. Comparisons with existing models show that Nematzadeh and GB50010-2010 models effectively predict the ascending part of the compressive stress-strain curves of plain and fiber reinforced CCC. These findings affirm that polypropylene fibers effectively reduce the brittleness of CCC, promoting its practical application.