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Concrete mixing can lead to mechanical degradation of aggregates, particularly when dealing with recycled concrete aggregates. In this work, the attrition of such materials during mixing is studied by means of experiments and simulations. The effect of the presence of fines, water addition, flow configuration of the mixer (co- or counter-current) and impeller frequency is discussed. Experiments were performed in a laboratory Eirich mixer. Discrete element numerical simulations (DEM) were performed on the same geometry by mimicking the behaviour of the material and, in particular, the cohesion induced by water and the cement paste using either Hertz–Mindlin or Hertz–Mindlin with Johnson–Kendall–Roberts (JKR) contact laws. The combination of the collision energy spectra extracted from the DEM simulations and an attrition model allowed the prediction of the mass loss due to attrition in 1-min experiments. Semi-quantitative agreement was observed between experiments and simulations, with a mean relative error of 26.4%. These showed that higher mass losses resulted from operation at the highest impeller speeds, co-current operation, and also with the wet aggregate. Mixing of the agglomerate in the concrete mix resulted in a significant reduction in attrition when compared to mixing aggregates alone. With further validation, the proposed simulation approach can become a valuable tool in the optimization of mixing by allowing the effects of material, machine and process variables to be studied on the mass loss due to attrition.

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