Innovative Solutions for Concrete Applications

A special issue of Infrastructures (ISSN 2412-3811).

Deadline for manuscript submissions: closed (31 October 2024) | Viewed by 34739

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Guest Editor
Faculty of Applied Engineering, University of Antwerp, 171 Groenenborgerlaan, 2020 Antwerp, Belgium
Interests: fiber Bragg grating (FBG) sensor monitoring systems; concrete technology; asphalt and bitumen; recycling of industrial wastes and byproducts
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Dear Colleagues,

Concrete is an incredible human-made material which has been evolving for more than 2000 years and will continue to transform from self-healing to Martian in the years to come. Concrete is the second most used material after water on Earth, and this material may become the best building material in the Solar System.

Concrete was used by the Romans, made from lime, pozzolan, and aggregate. John Smeaton used such material in 1756 to rebuild the Eddystone Lighthouse in England, and several others independently discovered the usefulness of such material to make concrete during the following years. Joseph Aspdin is credited with the invention of Portland cement, which he patented in 1824. He gave it its name because the product of Portland cement and aggregate resembled the stone that came from the Isle of Portland on the south coast of England. Portland cement subsequently came to be manufactured in many European countries and eventually all over the world. It was imported to the United States from England for a number of years before the first American plant was built in Pennsylvania in 1850. Today there are many companies manufacturing Portland cement under many brand names worldwide, and the total production volume is ~4.2 billion tons worldwide yearly in the last 5 years. There are also slag cements, modified Portland cements, and lately, there has been a tendency to use Alkali Activated Materials (AAMs).

The production of AAMs as an alternative to Portland cement started in Germany in 1908. For the following years, its production was mainly focused on the former Soviet Union and China, where cement shortages were experienced which led to the need for alternative materials; alkali activation was developed in both regions as a means of overcoming this problem by utilizing the materials at hand, specifically metallurgical slags. Fundamental research on AAMs has blossomed internationally only since the 1990s, and most of this work has been focused on AAMs microstructure, with little emphasis on the prediction of service life, durability, and engineering properties.

The last decade has brought a splendid innovation into concrete development. It is known that no matter how carefully concrete is designed and mixed or reinforced, all concrete eventually cracks — and those cracks lead to structural collapse sooner or later. As a solution to seal cracks in concrete, several researchers from TU Delft (The Netherlands) and UGent (Belgium) have been working on bio-concrete or self-healing concrete using bacteria. Innovative development has also recently been seen in 3D printing to quickly produce different structures, and this technology can often handle geometries that traditional construction techniques cannot. Traditional concrete is not an environmentally friendly material to make or use and is also impervious; therefore, eco-friendly forms of concrete are currently being developed. Starting in the 1920s, sulfur concrete has been reported to be utilized as a construction material. Various researchers and engineers studied and succeeded in obtaining high-strength and acid-resistant sulfur concretes. In the 1970s, researchers developed techniques to modify sulfur with additives and stabilizers to improve the durability of the product. These days, in response to scientific interest in building on Mars, a research team at Northwestern University (USA) created a form of concrete that can be made with materials native to the Red Planet.

This Special Issue, “Innovative Solutions for Concrete Applications”, aims to provide an overview of current innovative tendencies in concrete technology and structures, which have the potential to be implemented in the industry in the future, covering all recent developments in the construction sector.

Patricia Kara De Maeijer
Guest Editor

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Keywords

  • concrete
  • AAMs
  • mix design
  • waste and byproduct recycling in construction materials
  • 3D printed concrete
  • real-time monitoring
  • structures
  • survey

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Published Papers (11 papers)

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Editorial

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8 pages, 172 KiB  
Editorial
Innovative Solutions for Concrete Applications
by Patricia Kara De Maeijer
Infrastructures 2025, 10(3), 59; https://doi.org/10.3390/infrastructures10030059 - 10 Mar 2025
Viewed by 267
Abstract
Concrete, having evolved over the last 2000 years, is integral to modern infrastructure, with continuous innovations aiming to address sustainability challenges. From Roman concrete mixes to the invention of Portland cement (PC), concrete has evolved to meet growing infrastructure demands. As urbanization and [...] Read more.
Concrete, having evolved over the last 2000 years, is integral to modern infrastructure, with continuous innovations aiming to address sustainability challenges. From Roman concrete mixes to the invention of Portland cement (PC), concrete has evolved to meet growing infrastructure demands. As urbanization and energy consumption increase, the construction industry is focusing on high-performance materials, recycling, and minimizing harmful substances. Research on sustainable concrete alternatives shows promising reductions in global warming potential and other environmental impacts compared to traditional PC. However, challenges such as higher material costs and performance limitations remain. Alternatives such as alkali-activated concrete (AAC), self-healing concrete, and bacterial concrete (BC) have emerged in response to environmental concerns, along with fiber-reinforced AAC, waste-based concrete composites, and the reuse of construction and demolition waste (CDW), further enhancing sustainability. Foamed concrete, with its lightweight and insulating properties, offers additional potential for reducing environmental impact due to its ability to incorporate recycled materials and reduce raw material consumption. Technologies like three-dimensional concrete printing (3DCP) are improving resource efficiency and reducing carbon footprints while also lowering labor and material waste. However, concerns regarding cost-effectiveness and social sustainability persist. Overall, continued innovation is the key to balancing performance, cost, and sustainability in the development of concrete and to meet the growing demands of global infrastructure. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)

Research

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20 pages, 2491 KiB  
Article
Quantifying Anisotropic Properties of Old–New Concrete Interfaces Using X-Ray Computed Tomography and Homogenization
by Guanming Zhang and Yang Lu
Infrastructures 2025, 10(1), 20; https://doi.org/10.3390/infrastructures10010020 - 14 Jan 2025
Viewed by 701
Abstract
The interface between old and new concrete is a critical component in many construction practices, including concrete pavements, bridge decks, hydraulic dams, and buildings undergoing rehabilitation. Despite various treatments to enhance bonding, this interface often remains a weak layer that compromises overall structural [...] Read more.
The interface between old and new concrete is a critical component in many construction practices, including concrete pavements, bridge decks, hydraulic dams, and buildings undergoing rehabilitation. Despite various treatments to enhance bonding, this interface often remains a weak layer that compromises overall structural performance. Traditional design methods typically oversimplify the interface as a homogeneous or empirically adjusted factor, resulting in significant uncertainties. This paper introduces a novel framework for quantifying the anisotropic properties of old–new concrete interfaces using X-ray computed tomography (CT) and finite element-based numerical homogenization. The elastic coefficient matrix reveals that specimens away from the interface exhibit higher values in both normal and shear directions, with normal direction values averaging 33.15% higher and shear direction values 39.96% higher than those at the interface. A total of 10 sampling units along the interface were collected and analyzed to identify the “weakest vectors” in normal and shear directions. The “weakest vectors” at the interface show consistent orientations with an average cosine similarity of 0.62, compared with an average cosine similarity of 0.23 at the non-interface, which demonstrates directional features. Conversely, the result of average cosine similarity at the interface shows randomness that originates from the anisotropy of materials. The average angle between normal and shear stresses was found to be 88.64°, indicating a predominantly orthogonal relationship, though local stress distributions introduced slight deviations. These findings highlight the importance of understanding the anisotropic properties of old–new concrete interfaces to improve design and rehabilitation practices in concrete and structural engineering. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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24 pages, 10210 KiB  
Article
Collision Milling of Oil Shale Ash as Constituent Pretreatment in Concrete 3D Printing
by Lucija Hanžič, Mateja Štefančič, Katarina Šter, Vesna Zalar Serjun, Māris Šinka, Alise Sapata, Genādijs Šahmenko, Evaldas Šerelis, Baiba Migliniece and Lidija Korat Bensa
Infrastructures 2025, 10(1), 18; https://doi.org/10.3390/infrastructures10010018 - 13 Jan 2025
Viewed by 763
Abstract
Concrete is an essential construction material, and infrastructures, such as bridges, tunnels, and power plants, consume large quantities of it. Future infrastructure demands and sustainability issues necessitate the adoption of non-conventional supplementary cementitious materials (SCMs). At the same time, global labor shortages are [...] Read more.
Concrete is an essential construction material, and infrastructures, such as bridges, tunnels, and power plants, consume large quantities of it. Future infrastructure demands and sustainability issues necessitate the adoption of non-conventional supplementary cementitious materials (SCMs). At the same time, global labor shortages are compelling the conservative construction sector to implement autonomous and digital fabrication methods, such as 3D printing. This paper thus investigates the feasibility of using oil shale ash (OSA) as an SCM in concrete suitable for 3D printing, and collision milling is examined as a possible ash pretreatment. OSA from four different sources was collected and analyzed for its physical, chemical, and mineralogical composition. Concrete formulations containing ash were tested for mechanical performance, and the two best-performing formulations were assessed for printability. It was found that ash extracted from flue gases by the novel integrated desulfurizer has the greatest potential as an SCM due to globular particles that contain β-calcium silicate. The 56-day compression strength of concrete containing this type of ash is ~60 MPa, the same as in the reference composition. Overall, collision milling is effective in reducing the size of particles larger than 10 μm but does not seem beneficial for ash extracted from flue gasses. However, milling bottom ash may unlock its potential as an SCM, with the optimal milling frequency being ~100 Hz. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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14 pages, 4082 KiB  
Article
The Impact of Production Techniques on Pore Size Distribution in High-Strength Foam Concrete
by Slava Markin, Genadijs Sahmenko, Aleksandrs Korjakins and Viktor Mechtcherine
Infrastructures 2025, 10(1), 14; https://doi.org/10.3390/infrastructures10010014 - 9 Jan 2025
Viewed by 635
Abstract
This study examined the impact of various foam concrete production techniques on pore size distribution and its water absorption properties. Techniques such as the use of a cavitation disintegrator and a turbulent mixer were employed to produce foam concrete. Six foam concrete compositions, [...] Read more.
This study examined the impact of various foam concrete production techniques on pore size distribution and its water absorption properties. Techniques such as the use of a cavitation disintegrator and a turbulent mixer were employed to produce foam concrete. Six foam concrete compositions, with dry densities ranging from 820 to 1480 kg/m3 and compressive strength up to 47 MPa, were prepared. A novel method for digital image correlation was applied to analyse the pore size distribution within the foam concrete specimens. The manufactured foam concrete specimens’ porosity and water absorption indices were determined. The experimental results, including compression strength and water absorption, indicated that the production technique significantly affects the pore size distribution in foam concrete, impacting its mechanical and durability properties. Compressive strength was assessed at curing intervals of 7, 28, and 180 days. Cavitation technology was found to promote the formation of a finer porous structure in foam concrete, resulting in enhanced strength properties. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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22 pages, 8967 KiB  
Article
Physical, Mechanical and Durability Properties of Eco-Friendly Engineered Geopolymer Composites
by Ahmed M. Tahwia, Duaa S. Aldulaimi, Mohamed Abdellatief and Osama Youssf
Infrastructures 2024, 9(11), 191; https://doi.org/10.3390/infrastructures9110191 - 25 Oct 2024
Cited by 6 | Viewed by 1543
Abstract
Engineered geopolymer composite (EGC) is a high-performance material with enhanced mechanical and durability capabilities. Ground granulated blast furnace slag (GGBFS) and silica fume (SF) are common binder materials in producing EGC. However, due to the scarcity and high cost of these materials in [...] Read more.
Engineered geopolymer composite (EGC) is a high-performance material with enhanced mechanical and durability capabilities. Ground granulated blast furnace slag (GGBFS) and silica fume (SF) are common binder materials in producing EGC. However, due to the scarcity and high cost of these materials in some countries, sustainable alternatives are needed. This research focused on producing eco-friendly EGC made of cheaper and more common pozzolanic waste materials that are rich in aluminum and silicon. Rice husk ash (RHA), granite waste powder (GWP), and volcanic pumice powder (VPP) were used as partial substitutions (10–50%) of GGBFS in EGC. The effects of these wastes on workability, unit weight, compressive strength, tensile strength, flexural strength, water absorption, and porosity of EGC were examined. The residual compressive strength of the proposed EGC mixtures at high elevated temperatures (200, 400, and 600 °C) was also evaluated. Additionally, scanning electron microscope (SEM) was employed to analyze the EGC microstructure characteristics. The experimental results demonstrated that replacing GGBFS with RHA and GWP at high replacement ratios decreased EGC workability by up to 23.1% and 30.8%, respectively, while 50% VPP improved EGC workability by up to 38.5%. EGC mixtures made with 30% RHA, 20% GWP, or 10% VPP showed the optimal results in which they exhibited the highest compressive, tensile, and flexural strengths, as well as the highest residual compressive strength when exposed to high elevated temperatures. The water absorption and porosity increased by up to 106.1% and 75.1%, respectively, when using RHA; increased by up to 23.2% and 18.6%, respectively, when using GWP; and decreased by up to 24.7% and 22.6%, respectively, when using VPP in EGC. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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19 pages, 493 KiB  
Article
A Path towards SDGs: Investigation of the Challenges in Adopting 3D Concrete Printing in India
by Bandoorvaragerahalli Thammannagowda Shivendra, Shahaji, Sathvik Sharath Chandra, Atul Kumar Singh, Rakesh Kumar, Nitin Kumar, Adithya Tantri and Sujay Raghavendra Naganna
Infrastructures 2024, 9(9), 166; https://doi.org/10.3390/infrastructures9090166 - 23 Sep 2024
Cited by 2 | Viewed by 1669
Abstract
In recent years, three dimensional concrete printing (3DCP) has gained traction as a promising technology to mitigate the carbon footprint associated with construction industry. However, despite its environmental benefits, studies frequently overlook its impact on social sustainability and its overall influence on project [...] Read more.
In recent years, three dimensional concrete printing (3DCP) has gained traction as a promising technology to mitigate the carbon footprint associated with construction industry. However, despite its environmental benefits, studies frequently overlook its impact on social sustainability and its overall influence on project success. This research investigates how strategic decisions by firms shape the tradeoffs between economic, environmental, and social sustainability in the context of 3DCP adoption. Through interviews with 20 Indian industry leaders, it was found that companies primarily invest in 3DCP for automation and skilled workforce development, rather than solely for environmental reasons. The lack of incentives for sustainable practices in government procurement regulations emerges as a significant barrier to the widespread adoption of 3DCP. Our study identifies five key strategies firms employ to promote sustainability through 3DCP and proposes actionable measures for government intervention to stimulate its advancement. Addressing these issues is crucial for realizing the full societal and environmental benefits of 3DCP technology. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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16 pages, 3324 KiB  
Article
Mechanical Properties of Pervious Recycled Aggregate Concrete Reinforced with Sackcloth Fibers (SF)
by Arissaman Sangthongtong, Noppawan Semvimol, Thitima Rungratanaubon, Kittichai Duangmal and Panuwat Joyklad
Infrastructures 2023, 8(2), 38; https://doi.org/10.3390/infrastructures8020038 - 18 Feb 2023
Cited by 9 | Viewed by 2350
Abstract
The excessive production of construction waste is a significant concern as it requires proper disposal and may become economically unfeasible. Reusing construction waste in producing new concrete can substantially reduce the disposal requirements of construction waste. In addition, this results in a sustainable [...] Read more.
The excessive production of construction waste is a significant concern as it requires proper disposal and may become economically unfeasible. Reusing construction waste in producing new concrete can substantially reduce the disposal requirements of construction waste. In addition, this results in a sustainable solution for the rapidly depleting natural resources of concrete. Pervious concrete may contain up to 80% coarse aggregates and could be an exceptional host for reusing construction waste. This study aimed to investigate the mechanical properties of pervious concrete constructed with natural and recycled aggregates. The substandard properties of recycled aggregates were improved by adding natural fibers from sackcloth. This study presents an experimental program on 45 samples of pervious concrete with air void ratios and the size of coarse aggregates as the parameters of interest. The compressive strength of the pervious concrete decreased by increasing the air void ratio regardless of the size of the aggregates. The type of aggregates did not influence the permeability of pervious concrete, and the maximum temperature in pervious concrete increased as the quantity of air void ratios increased. The decrease in compressive strength was 40–60% as the void ratio was increased from 10–30% for all types of concrete mixes, such as natural and recycled aggregates. The permeability of small-size aggregates with 10% designed air void ratios for natural and recycled aggregates with sackcloth was 0.705 cm/s. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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21 pages, 4256 KiB  
Article
Cradle-to-Gate Life Cycle and Economic Assessment of Sustainable Concrete Mixes—Alkali-Activated Concrete (AAC) and Bacterial Concrete (BC)
by Kruthi Kiran Ramagiri, Ravali Chintha, Radha Kiranmaye Bandlamudi, Patricia Kara De Maeijer and Arkamitra Kar
Infrastructures 2021, 6(7), 104; https://doi.org/10.3390/infrastructures6070104 - 15 Jul 2021
Cited by 34 | Viewed by 5627
Abstract
The negative environmental impacts associated with the usage of Portland cement (PC) in concrete induced intensive research into finding sustainable alternative concrete mixes to obtain “green concrete”. Since the principal aim of developing such mixes is to reduce the environmental impact, it is [...] Read more.
The negative environmental impacts associated with the usage of Portland cement (PC) in concrete induced intensive research into finding sustainable alternative concrete mixes to obtain “green concrete”. Since the principal aim of developing such mixes is to reduce the environmental impact, it is imperative to conduct a comprehensive life cycle assessment (LCA). This paper examines three different types of sustainable concrete mixes, viz., alkali-activated concrete (AAC) with natural coarse aggregates, AAC with recycled coarse aggregates (RCA), and bacterial concrete (BC). A detailed environmental impact assessment of AAC with natural coarse aggregates, AAC with RCA, and BC is performed through a cradle-to-gate LCA using openLCA v.1.10.3 and compared versus PC concrete (PCC) of equivalent strength. The results show that transportation and sodium silicate in AAC mixes and PC in BC mixes contribute the most to the environmental impact. The global warming potential (GWP) of PCC is 1.4–2 times higher than other mixes. Bacterial concrete without nutrients had the lowest environmental impact of all the evaluated mixes on all damage categories, both at the midpoint (except GWP) and endpoint assessment levels. AAC and BC mixes are more expensive than PCC by 98.8–159.1% and 21.8–54.3%, respectively. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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Review

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20 pages, 2257 KiB  
Review
An Overview of Methods to Enhance the Environmental Performance of Cement-Based Materials
by Daniel Suarez-Riera, Luciana Restuccia, Devid Falliano, Giuseppe Andrea Ferro, Jean-Marc Tuliani, Matteo Pavese and Luca Lavagna
Infrastructures 2024, 9(6), 94; https://doi.org/10.3390/infrastructures9060094 - 11 Jun 2024
Viewed by 1993
Abstract
Urbanization and demographic growth have led to increased global energy consumption in recent years. Furthermore, construction products and materials industries have contributed significantly to this increase in fossil fuel use, due to their significant energy requirements, and consequent environmental impact, during the extraction [...] Read more.
Urbanization and demographic growth have led to increased global energy consumption in recent years. Furthermore, construction products and materials industries have contributed significantly to this increase in fossil fuel use, due to their significant energy requirements, and consequent environmental impact, during the extraction and processing of raw materials. To address this environmental problem, architectural design and civil engineering are trying to implement strategies that enable the use of high-performance materials while minimizing the usage of energy-intensive or toxic and dangerous building materials. These efforts also aim to make buildings less energy-consuming during their useful life. Using waste materials, such as Construction and Demolition Waste (CdW), is one of the most promising approaches to address this issue. In recent years, the European Union (EU) has supported recovery strategies focused on using CdW, as they account for more than 30% of the total waste production in the EU. In this regard, reuse techniques—such as incorporating concrete fragments and bricks as road floor fillers—have been the subject of targeted scientific research. This review will outline various strategies for producing green cement and concrete, particularly emphasizing the reuse of Construction and Demolition Waste (CdW). Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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32 pages, 2672 KiB  
Review
Sustainable Assessment of Concrete Repairs through Life Cycle Assessment (LCA) and Life Cycle Cost Analysis (LCCA)
by Neel Renne, Patricia Kara De Maeijer, Bart Craeye, Matthias Buyle and Amaryllis Audenaert
Infrastructures 2022, 7(10), 128; https://doi.org/10.3390/infrastructures7100128 - 26 Sep 2022
Cited by 22 | Viewed by 8283
Abstract
Nowadays, a vast number of concrete structures are approaching the end of their expected service life. The need for maintenance and repair is high due to the continued deterioration of the existing building inventory and infrastructure, resulting in a large need for concrete [...] Read more.
Nowadays, a vast number of concrete structures are approaching the end of their expected service life. The need for maintenance and repair is high due to the continued deterioration of the existing building inventory and infrastructure, resulting in a large need for concrete repair in the near future. Reinforcement corrosion is the most important deterioration mechanism, causing (i) severe concrete damage (cracking along reinforcement and the spalling of the cover concrete) and (ii) loss in steel section. Therefore, appropriate repair techniques for corrosion damage are the main focus of this review paper. With the European transition towards a circular economy and with sustainable development goals in mind, it is also important to consider the environmental impact along with the technical requirements and life cycle cost. In order to improve the sustainability of concrete structures and repairs over their life cycle, life cycle assessment (LCA) and life cycle cost analysis (LCCA) should be applied. However, more research efforts are needed in this field for further development and refinement. This literature review tries to adress this need by compiling existing knowledge and gaps in the state-of-the-art. A comprehensive literature survey about concrete repair assessment through LCA and LCCA is performed and showed a high potential for further investigation. Additionally, it was noticed that many differences are present between the studies considering LCA and/or LCCA, namely, the considered (i) structures, (ii) damage causes, (iii) repair techniques, (iv) estimated and expected life spans, (v) LCCA methods, (vi) life cycle impact assessment (LCIA) methods, etc. Therefore, due to the case specificity, mutual comparison is challenging. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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20 pages, 1854 KiB  
Review
Crumb Rubber in Concrete—The Barriers for Application in the Construction Industry
by Patricia Kara De Maeijer, Bart Craeye, Johan Blom and Lieven Bervoets
Infrastructures 2021, 6(8), 116; https://doi.org/10.3390/infrastructures6080116 - 20 Aug 2021
Cited by 40 | Viewed by 8583
Abstract
This state-of-the-art review was aimed to conduct a comprehensive literature survey to summarize experiences of crumb rubber (CR) application in concrete within the last 30 years. It shows that certain gaps prevent obtaining a coherent overview of both mechanical behaviour and environmental impact [...] Read more.
This state-of-the-art review was aimed to conduct a comprehensive literature survey to summarize experiences of crumb rubber (CR) application in concrete within the last 30 years. It shows that certain gaps prevent obtaining a coherent overview of both mechanical behaviour and environmental impact of crumb rubber concrete (CRC) to object to the stereotypes which prevent to use of CR in concrete in the construction industry. Currently, four major barriers can be distinguished for a successful CR application in the concrete industry: (1) the cost of CR recycling, (2) mechanical properties reduction, (3) insufficient research about leaching criteria and ecotoxicological risks and (4) recyclability of CRC. The application of CR in concrete has certainly its advantages and in general cannot be ignored by the construction industry. CR can be applied, for example, as an alternative material to replace natural aggregates and CRC can be used as recycled concrete aggregates (RCA) in the future. A certain diversity for the CR application can be introduced in a more efficient way when surface treatment and concrete mix design optimization are properly developed for each type of CR application in concrete for possible field applications. The role of CRC should not be limited to structures that are less dependent on strength. Full article
(This article belongs to the Special Issue Innovative Solutions for Concrete Applications)
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