Low-Carbon Concrete Reinforced with Waste Steel Rivet Fibers Utilizing Steel Slag Powder, and Processed Recycled Concrete Aggregate—Engineering Insights

The construction industry is a major source of environmental degradation as it is responsible for a significant share of global CO2 emissions, especially from cement and aggregate consumption. This study fills the need for sustainable construction materials by developing and evaluating a low-carbon fiber-reinforced concrete (FRC) made of steel slag powder (SSP), processed recycled concrete aggregates (PRCAs), and waste steel rivet fibers (WSRFs) derived from industrial waste. The research seeks to reduce dependency on virgin materials while maintaining high values of mechanical performance and durability in structural applications. Sixteen concrete mixes were used in the experimental investigations with control, SSP, SSP+RCA, and RCA, reinforced with various fiber dosages (0%, 0.2%, 0.8%, 1.4%) by concrete volume. Workability, density, compressive strength, tensile strength, and water absorption were measured according to the appropriate standards. Compressive and tensile strength increased in all mixes and the 1.4% WSRF mix had the best performance. However, it was found that a fiber content of 0.8% was optimal, which balanced the improvement in strength, durability, and workability by sustainable reuse of recycled materials and demolition waste. It was found by failure mode analysis that the transition was from brittle to ductile behavior as the fiber content increased. The relationship between compressive, tensile strength, and fiber content was visualized as a 3D response surface in order to support these mechanical trends. It is concluded in this study that 15% SSP, 40% PRCA, and 0.8% WSRF are feasible, specific solutions to improve concrete performance and advance the circular economy.