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

TL;DR

This study shows how optimizing the mix of cement and fine aggregates can improve mortar strength and reduce emissions.

Contribution

An integrated approach combining D-optimal design and particle packing techniques optimizes multi-component binder systems for performance and sustainability.

Findings

Optimized MCB and fine aggregate gradation improve packing density and pozzolanic activity.

MCB systems reduce energy consumption by 35–40% and CO2 emissions by 34–48%.

Maximum packing density is a reliable indicator for mechanical and durability properties.

Abstract

What are the main findings?
The D-optimal mixture design (DOD) method is used to determine the optimal material proportions.Proportioning of fine aggregate using the MTM method achieves max. packing density and min. void ratio.MCB-based mortars are able to attain their maximum strengths after 90 days.

The D-optimal mixture design (DOD) method is used to determine the optimal material proportions.

Proportioning of fine aggregate using the MTM method achieves max. packing density and min. void ratio.

MCB-based mortars are able to attain their maximum strengths after 90 days.

What are the implications of the main findings?
Maximum packing density is a reliable indicator for achieving mechanical and durability properties.Statistical mixture design and particle packing provide a systematic, optimized pathway.MCB systems substantially reduce energy consumption and CO2 emissions.

Maximum packing density is a reliable indicator for achieving mechanical and durability properties.

Statistical mixture design and particle packing provide a systematic, optimized pathway.

MCB systems substantially reduce energy consumption and CO2 emissions.

The use of a multi-component binder (MCB), consisting of Ordinary Portland Cement (OPC) combined with one or more supplementary cementitious materials (SCMs), has gained prominence for enhancing sustainability and improving the performance of cementitious systems. This study provides an integrated approach to optimize both binder composition and aggregate gradation through advanced mixture design and particle packing techniques. The MCB system consists of OPC partially replaced with SCMs such as fly ash (FA), Ground Granulated Blast Furnace Slag (GGBFS), metakaolin (MK), and silica fume (SF), with particle sizes ranging from micron to sub-micron scale. The D-optimal mixture design (DOD) method is used to determine the optimal material proportions by evaluating the relation between binder composition and wet packing density measured through the wet packing method (WPM). To further enhance packing efficiency, the Modified Toufar Model (MTM) is employed to optimize fine aggregate gradation. The maximum packing density is considered the primary criterion for identifying the optimal mix design, as it reflects the minimum void ratio and the most efficient particle size distribution. The optimized mortar mixes are evaluated for mechanical strength, pozzolanic reactivity, capillary water sorptivity, and drying shrinkage. Results indicate that the optimized MCB and optimized fine aggregate gradation improve the packing density and pozzolanic activity, significantly enhancing strength and durability performance. The incorporation of SCMs offers an effective strategy to improve performance while mitigating carbon emissions. Compared with C100, CFGMS-based systems achieved energy reductions of 35–40% and CO2 emission reductions of 34–48%.

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