Development of Sustainable, Low-Shrinkage Concrete Through Optimized Aggregate Gradation, Cement Reduction, and Internal Curing

The durability of concrete is compromised by early-age cracking, which provides a pathway for harmful ions and water to penetrate the material. Early-age cracking, however, is most commonly caused by concrete shrinkage. This study investigates strategies for minimizing the shrinkage of concrete by optimizing aggregate gradation via the Tarantula Curve, reducing cement content, and incorporating lightweight fine aggregates (LWFA) as internal curing agents. The commercially adopted mix design was used as a reference, with the cementitious materials-to-aggregate (C/A) ratio reduced from 0.21 (reference) to 0.15 (proposed), incorporating 0-15% LWFA replacement levels. Workability (ASTM C143), mechanical performance (ASTM C39, ASTM C78), durability (AASHTO TP 119-21), and dimensional stability (ASTM C157) were evaluated through ASTM standard tests. The results highlight that optimizing the C/A ratio cannot only improve both compressive and flexural strengths in regular concrete but also mitigate the total shrinkage by 12.68%. The introduction of LWFA further reduced shrinkage, achieving a 19.72% shrinkage reduction compared to regular concrete. In addition, the sustainability of the developed mix designs is enhanced by the reduced cement usage. A Life Cycle Assessment (LCA) based on the TRACI method confirmed the sustainability advantages of cement reduction. The optimized mix designs resulted in a 30% decrease in CO₂ emissions, emphasizing the role of mix design in developing environmentally responsible concrete. Overall, lowering the cement amount and the addition of LWFA provide an optimal combination of shrinkage control, strength retention, and sustainability for applications.