Structural Monitoring and Maintenance

Volume 12, Number 4, 2025, pages 417-435

DOI: 10.12989/smm.2026.12.4.417

The effectiveness of substrate roughness and bond angle between old and new concrete in improving the flexural performance of hybrid concrete prisms

Abeer F. Hussein , Thaer Jasim Mohammed , Saadiyah M. Ismael , Sabreen Ali Abed

Abstract

This study aimed to evaluate the structural behavior of sustainable hybrid concrete produced using recycled plastic as a partial sand replacement at percentages of 0%, 5%, 10% and 15% with the addition of 2% recycled steel wire fibers by volume. The focus was on improving the bond performance between old and new concrete under bending loads. The experimental program included compressive strength tests cubes, split tensile strength tests cylinders and slump tests for fresh concrete. Additionally, bending tests were conducted on prisms measuring 10 x 10 x 40 cm at contact angles of 30, 45 and 60 with various surface treatments applied to increase the roughness of the face. The results showed a gradual decrease in mechanical properties with increasing plastic content. The compressive strength decreased by 16% when 15% of the sand was replaced with a compressive strength of 19.24 MPa recorded at 28 days. The bond angle also significantly affected flexural strength and failure mode 60 angle reduced strength by 17%-20% compared to smaller angles. Conversely, surface treatments applying horizontal and radial roughening of 1 cm improved bond strength by 16% -26%, while reducing the likelihood of surface bond failure in samples with high plastic content. These results suggest the possibility of producing sustainable concrete using recycled materials without significantly impacting structural performance and in an environmentally friendly manner, provided that the concrete's surface bonding properties are improved to ensure effective structural behavior.

Key Words

bond angle; flexural load; hybrid concrete; recycled plastic; recycled wire steel; roughness surface

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