Most of the previous research on recycled concrete aggregates (RCA) has focused on coarse RCA (CRCA), while much less has been accomplished on the use of fine RCA particles (FRCA). Furthermore, most RCA research disregards its unique microstructure, and thus the inferior performance of concrete incorporating RCA is often reported in the fresh and hardened states. To improve the overall behaviour of RCA concrete advanced mix design techniques such as equivalent volume (EV) or particle packing models (PPMs) may be used. However, the efficiency of these procedures to proportion eco-efficient FRCA concrete still requires further investigation. This work evaluates the overall fresh (i.e., slump and rheological characterization) and hardened states (i.e., non-destructive tests, compressive strength and microscopy) performance of sustainable FRCA mixtures proportioned through distinct techniques (i.e., direct replacement, EV and PPMs) and incorporating different types of aggregates (i.e., natural and manufactured sand) and manufacturing processes (i.e., crusher fines and fully ground). Results demonstrate that the aggregate type and crushing process may influence the FRCA particles’ features. Yet, the use of advanced mix design techniques, particularly PPMs, may provide FRCA mixes with quite suitable performance in the fresh (i.e., 49% lower yield stress) and hardened states (i.e., 53% higher compressive strength) along with a low carbon footprint.

The pressure to use sustainable materials and adopt practices reducing the carbon footprint of the construction industry has risen. Such materials include recycled concrete aggregates (RCA) made from waste concrete. However, concrete made with RCA often presents poor fresh and hardened properties along with a decrease in its durability performance, especially when using its fine fraction (i.e., FRCA). Most studies involving FRCA use direct replacement methods (DRM) to proportion concrete although other techniques are available such as the Equivalent Volume (EV) and Particle Packing Models (PPMs); yet their impact on the durability performance, especially its performance against freezing and thawing (F/T), remains unknown. This work, therefore, appraises the F/T resistance of FRCA mixtures proportioned through various mix proportioning techniques (i.e., DRM, EV and PPMs), produced with distinct crushing processes (i.e., crusher’s fines vs. finely ground). The results show that the mix design technique has a significant influence on the FRCA mixture’s F/T resistance where PPM-proportioned mixtures demonstrate the best overall performance, exceeding the specified requirements while DRM-proportioned mixtures failed F/T resistance requirements. Moreover, the crushing process plays an important role in the recycled mixtures’ cracking behavior under F/T cycles, where less processing leads to fewer cracks while remaining the most sustainable option overall.

The ever-growing urgency to combat climate change has led the civil construction industry to develop and adopt sustainable construction materials and methods. The so-called recycled concrete aggregate (RCA) emerges as an alternative to decrease the carbon footprint of new concrete construction, the disposal of waste concrete, and the use of non-renewable natural resources such as cement and aggregates. RCA can be produced from crushing waste concrete; yet challenges remain when using RCA in concrete especially its fresh state behaviour due to its distinct multi-phase nature and microstructure (i.e., presence of residual mortar (RM)/residual cement paste (RCP)). In this context, this work presents a comprehensive study of the rheological behaviour of recycled concrete mixtures through the use of a planetary rheometer (IBB). The recycled mixtures were proportioned using the Equivalent Volume (EV) method, a mixture proportioning technique that accounts for the RM and RCP, respectively, and improves the recycled mixture's hardened state properties, incorporating distinct: 1) coarse RCA having various inner qualities (i.e., 25 MPa, 35 MPa and 45 MPa) and mineralogy (i.e., limestone and granite) and 2) fine RCA made from natural or manufactured sand while having different degrees of processing (i.e., crushed once vs continuously crushed). All recycled mixtures produced in this study present shear-thinning profiles, suggesting that these mixtures are suitable for applications under high torque regimes such as vibrated or pumped concrete. Additionally, they were produced with 100% recycled concrete aggregate (either fine or coarse RCA), classifying them as low embodied energy mixtures.