Effect of Varying Fiber, Fly Ash, and Recycled Gypsum Contents on the Mechanical Properties of Fiber-Reinforced Ternary Concrete

A concrete mixture formulation consisting of industrial wastes such as fly ash and gypsum from ceramic mold waste as partial replacements for cement was developed in this two-part study to lessen the carbon footprint from processing the conventional materials used in the construction industry. The first part aims to determine the optimum composition of the ternary binder (cement, fly ash and recycled gypsum) and the curing period (7, 28 and 90) that will provide the highest compressive strength for the casted concrete cylinders. The second part focuses on establishing the effective polypropylene fiber (PPF) dosage, utilizing the pre-optimized binder composition. The structural integrity of the concrete cylinders was evaluated through compressive strength and split tensile tests following water curing periods of 7, 28, and 90 days. Results from the initial mechanical tests revealed that the optimum ternary binder composition was C60-F37.5-G2.5 cured for 90 days. While fiber reinforcement typically has limited impact on compressive strength, the addition of 1.5% PPF yielded better long-term compressive strength development compared with other PPF dosages. For tensile strength, 0.5%-1% PPF achieved the highest values at 28 days, whereas 1.5% PPF provided the peak performance under prolonged curing at 90 days. This shift in behavior is attributed to the progressive increase in fiber-bridging effectiveness over time. Findings from these mechanical tests were supported by the results from X-Ray Diffraction (XRD) analysis and optical microscopy.