Deformation Behavior and Low-Carbon Assessment of Large-Span Beam with Fully Recycled Concrete

Jianzhuang Xiao, Yupo Pan, Chunhui Wang, Haibo Fang, Ruming Liang, Xuyao Ge, Pujin Wang, Xiangshuo Guan, Haolin Xu, Jiaqian Ning, Yao He, Tao Ding, Xuwen Xiao

Strategic Study of CAE ›› 2025

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Strategic Study of CAE ›› 2025 DOI: 10.15302/J-SSCAE-2025.04.013

Deformation Behavior and Low-Carbon Assessment of Large-Span Beam with Fully Recycled Concrete

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Abstract

As global construction solid wastes surged and to achieve the carbon peak and carbon neutrality goals, the application of fully recycled coarse aggregate concrete (FRCAC, 100% replacement rate) in structural engineering has emerged as a breakthrough solution to addressing resource-environmental constraints and reshaping low-carbon structural systems. However, current codes and standards lack long-term empirical data under actual service conditions, constraining technological updates and large-scale application. This study aims to break technological bottlenecks, drive code upgrades, and promote low-carbon application. It explores the service performance of FRCAC structures using a 30-m-span simply supported beam as the engineering prototype. Under self-weight loading, the maximum compressive stress at the edge of the compression zone of FRCAC is approximately 50% of its axial compressive strength, simulating the stress state under actual loading conditions, thus enabling quantitative analysis of performance evolution mechanisms and low-carbon benefits under long-term coupled effects of mechanical loading and environmental exposure. Through designing comparative beams with equivalent reinforcement and water-to-binder ratios between FRCAC and conventional concrete, we established a comprehensive framework covering material preparation, component behaviors, and carbon benefit quantification. We tracked deformations, crack patterns, and carbonation depth evolution over 4-year service periods, and quantified carbon absorption effects using life cycle assessment models. Results demonstrate that although FRCAC exhibits 7.8%~14% reduced elastic modulus under the same-condition curing, pre-cambering completely compensates deformation discrepancies, satisfying structural requirements. While bending cracks increased by 8% and the crack length increased by 15%, the average width remained comparable to conventional concrete. Considering service-period carbon absorption, FRCAC beams achieved 7.69% reduction in net carbon emissions. This study pioneers engineering prototype validation of FRCAC's feasibility under actual load-environment coupling conditions. The findings are expected to advance the transformation of construction wastes from extensive landfilling to high-value utilization, providing a forward-looking solution for low-carbon structural engineering.

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Keywords

fully recycled coarse aggregate concrete (FRCAC) / 30-m-span engineering prototype beam / dynamic monitoring / life cycle assessment / carbon emissions

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Jianzhuang Xiao, Yupo Pan, Chunhui Wang, Haibo Fang, Ruming Liang, Xuyao Ge, Pujin Wang, Xiangshuo Guan, Haolin Xu, Jiaqian Ning, Yao He, Tao Ding, Xuwen Xiao. Deformation Behavior and Low-Carbon Assessment of Large-Span Beam with Fully Recycled Concrete. Strategic Study of CAE, 2025 https://doi.org/10.15302/J-SSCAE-2025.04.013

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Funding
National Key R&D Program of China(2022YFC3803401); Chinese Academy of Engineering project "Research on Green Construction Development Strategy"(2022-XZ-21)
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