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Hybrid Fiber-Reinforced Lightweight Concrete with EPS and Perlite: Density-Driven Mechanical and Structural Performance, Schmidt Hammer Calibration, and Microplane Modeling for Construction Applications |
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PP: 575-605 |
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Author(s) |
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Ahmed M. Yassin,
Omar M. Abu Seada,
Mohamed M. Badawi,
Ibrahim H. El-Rashidi,
Mariam S. Elsayed,
Mostafa R. Nassar,
Mohamed H. Sarhan,
Mohamed Ahmed Hafez,
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Abstract |
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| In this study, the Egyptian sources are used to analyze the mechanical and flexural capabilities of a lightweight fibre reinforced concrete (LWFRC) integrating hybrid steel and polypropylene fibres at various concrete densities with expanded polystyrene (EPS) and perlite. Three LWFRC density classes exist: 1200, 1500, and 1800 kg/m3. To achieve the target density, the EPS (20-40% volume) and perlite (0-20% volume) ratios were modified, together with fly ash and silica fume as cementitious ingredients. Workability, density, compressive strength, splitting tensile strength, and flexural behavior were tested in this study. Non-destructive Schmidt hammer calibration curves were constructed to forecast compressive and splitting tensile strengths in three orientations (downward, horizontal, and upward). The coupled damage-plasticity microplane model in ANSYS Workbench 2023 R2 was used to compare advanced finite element modelling findings with experimental data. Lowering EPS and perlite ratios from 50% to 30% increases density from 1200 to 1800 kg/m3 and compressive force from 5 to 27 MPa, a 5-fold increase. The ratios of fsp/√(fcu) and fctr/√(fcu) rise from 0.55 to 0.91 and 0.72 to 1.04, respectively, as density increases. These values exceed Egyptian Code ECP 203-2025s normal-weight concrete restrictions (0.42 and 0.60). Finite element analysis properly predicted maximum load and flexural strengths. The economic analysis found that LWFRC costs 132-to-281 times more than normal concrete and has 24-52 times less material density. Weight-reducing EPS is cheaper and more efficient than perlite. To optimize LWFRC blending with Egyptian materials, the paper presents crucial design equations, calibration curves, and proven numerical modelling methods. This will boost resilient building and lightweight concrete requirements. |
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