Optimization and Performance Evaluation of Multi-Component Binder-Based Mortars Using Particle Packing Techniques.

Area of Science:

• Materials Science
• Civil Engineering
• Sustainable Construction

Background:

• Multi-component binders (MCB), combining Ordinary Portland Cement (OPC) with supplementary cementitious materials (SCMs), are crucial for sustainable and high-performance cementitious systems.
• SCMs like fly ash, slag, metakaolin, and silica fume offer particle size benefits from micron to sub-micron scales.

Purpose of the Study:

• To integrate advanced mixture design and particle packing techniques for optimizing both MCB composition and aggregate gradation.
• To enhance packing density, mechanical strength, durability, and reduce environmental impact in cementitious materials.

Main Methods:

• Utilized D-optimal mixture design (DOD) to correlate binder composition with wet packing density (WPM).
• Employed the Modified Toufar Model (MTM) to optimize fine aggregate gradation for maximum packing density.
• Evaluated optimized mortar mixes for mechanical strength, pozzolanic reactivity, capillary water sorptivity, and drying shrinkage.

Main Results:

• Optimized MCB and aggregate gradation significantly improved packing density and pozzolanic activity.
• Enhanced strength and durability performance were observed in the optimized mortar mixes.
• CFGMS-based systems demonstrated substantial energy (35-40%) and CO2 emission (34-48%) reductions compared to C100.

Conclusions:

• Integrated optimization of binder composition and aggregate gradation is effective for improving cementitious system performance.
• The use of SCMs in MCB is a viable strategy for enhancing material properties and achieving significant environmental benefits.
• Optimized systems offer a sustainable alternative to conventional cement, reducing energy consumption and carbon footprint.