Green Compression-Cast Concrete Material and Its Fiber-Reinforced Polymer (FRP)-Reinforced Concrete Structures

Concrete manufacturing is a significant contributor to carbon emission. This paper presents an extensive study on compression-casting, which is a newly developed and highly efficient concrete manufacturing technology. Compression-casting is a mechanical process that improves the properties of all types of concrete materials without using chemical additives or mineral admixtures. It is particularly suitable for producing high-quality concrete from secondary/substandard or waste/recycled aggregate materials, thereby promoting green, low-carbon, and sustainable construction. This paper introduces compression-casting and presents the experimental results of the material and relevant fiber-reinforced polymer (FRP)-reinforced structures. Various applications of the compression-casting technology on inferior concrete materials, including rubber, recycled aggregate, desert sand, and recycled powder concrete, have also been introduced. The behavior of FRP-reinforced structural members of compression-cast concrete (CCC) is evaluated and compared with that of normal concrete (NC). It is concluded that compared to NC, CCC has the following advantages: improved mechanical properties, microstructure, durability, cement saving, economy, and reduced carbon dioxide emissions. Finally, we provide recommendations for addressing CCC structure brittleness. As a result, this method can reshape the future of concrete manufacturing.