Performance evaluation of artificial aggregates on the mechanical, microstructure and durability properties of concrete

Abstract The production of artificial aggregates has emerged as a promising research trend, offering a sustainable alternative to natural aggregates by converting waste materials into value-added construction materials. The current study aimed to incorporate the optimized angular-shaped artificial aggregates in the production of concrete and analyse their behavior through detailed experimental investigations. Concrete mixes were designed and cast with natural coarse aggregates partially replaced by artificial aggregates at incremental levels of 25%, ranging from 0% to 100% replacement. The experimental analysis of various concrete mixes’ physical, mechanical, microstructure, and durability characteristics was carried out. The replaced concrete mixes exhibited dry density of 2000–2322 kg m −3 and compressive strength of 32–39 MPa. Split tensile strength (2.7–3.31 MPa) and flexural strength (3.29–4.46 MPa) decreased with higher replacement levels. Microstructural analysis showed a stronger aggregate–matrix interface with minor microcracks near the interfacial transition zone. The findings indicate that replacing 50% natural coarse aggregates with produced artificial aggregates produces concrete suitable for structural use, demonstrating comparable performance and potential for sustainable construction practices.