Improving sustainability of precast concrete sandwich wall panels through stone waste aggregates and supplementary

Precast concrete sandwich wall panels offer advantages such as design flexibility, ease of installation, cost-effectiveness, and energy efficiency due to the incorporated insulation layer, but regular concrete production has sustainability issues. This study aims to improve the sustainability of these panels by utilizing stone waste aggregates as a replacement for natural aggregates and supplementary cementitious materials as a partial replacement for cement. The panels were made with two concrete wythes reinforced with steel fibers and joined using basalt fiber-reinforced polymer (BFRP) connectors, with high-density expanded polystyrene (EPS) insulation (30 kg/m3) in between. Self-compacting concrete mixes with varying proportions of stone waste aggregates and supplementary cementitious materials were used. Full-scale wall panels were cast and subjected to flexural tests per ASTM standards, analyzing load-displacement curves, ultimate bearing capacity, and failure modes. The incorporation of steel fibers and stone waste aggregates resulted in substantial increases in failure load and flexural strength compared to controlled concrete panels, with the stone waste steel fiber panels exhibiting significantly higher maximum cracking loads and improved energy absorption and ductility. The inclusion of these sustainable materials, along with basalt fiber connectors and grooves in the EPS layer for mechanical interlock, prevented brittle failure modes and enhanced the composite action, leading to more ductile behavior under flexural loading. Utilizing sustainable materials like stone waste aggregates (100% replacement) and supplementary cementitious materials (30% replacement) in these panels can contribute to eco-friendly and efficient construction practices while maintaining adequate structural performance, paving the way for more sustainable building systems