Experimental investigation of face mask fiber-reinforced fully recycled coarse aggregate concrete

To address the challenges associated with the disposal of construction and demolition waste (C&DW) and discarded personal protective equipment, this study investigates the feasibility of using face mask (FM) fibers to enhance fully recycled coarse aggregate (FRCA) concrete. The current study uses six FM fiber volume fractions (0, 0.1 %, 0.2 %, 0.3 %, 0.4 %, 0.5 %) for FRCA concrete reinforcement. According to the mechanical performance test results, adding FM fibers can enhance the splitting tensile strength (up to 8.22 % contents 0.1 % FM fiber) and flexural strength (up to 26.92 % contents 0.2 % FM fiber) of FRCA concrete. While excessive FM fibers (over 0.3 %) affect compressive strength negatively, the damaged concrete retains integrity due to the bridging action of FM fibers combined with scanning electron microscopy (SEM) analysis. Comparatively, the hydrophilic inner layer of disposable medical masks features a better microstructural fiber arrangement, increasing tensile strength by 14.51 % and 111.68 % compared to the filter and outer layers, respectively, making it ideal for enhancing FRCA concrete. All samples achieved a "Good" rating in the UPV tests, confirming the feasibility of FM fiber-reinforced FRCA concrete. The calculation method for FRCA concrete mechanical properties prediction considers the contribution of fibers in addressing the disparate effects of FM fiber incorporation, with correlation coefficients of 0.904 and 0.827 for splitting tensile strength and flexural strength, respectively. Environmental and economic impact analysis indicates that FM fiber-reinforced FRCA concrete can reduce carbon emissions by 71.25 % and save 29.05 % of economic costs. • Face mask fibers were added to reinforce fully recycled coarse aggregate concrete. • Test setups were used to investigate the properties of concrete and face mask fiber. • SEM analysis revealed FM fibers' three-layer structure effect on concrete. • Concrete strength prediction formulas considering fiber contribution were proposed. • FM fiber-reinforced FRCA concrete has good environmental and economic benefits.