Optimized Quaternary Binder Systems for Sustainable High-Performance Concrete: Insights from Taguchi Design

The use of high-volume industrial by-products in high-performance concrete (HPC) production offers a promising and sustainable strategy for reducing ordinary Portland cement (OPC) consumption. However, each pozzolanic material has a unique chemical composition and physical characteristics, making ternary and quaternary binder systems an effective approach for optimizing performance. In this study, quaternary binders comprising OPC partially replaced with Class F fly ash (FA), ground granulated blast-furnace slag (GGBFS), and silica fume (SF) were designed using the Taguchi method, and the mechanical and durability properties of fine-grained HPC were evaluated. Sixteen concrete mixtures were developed considering three factors—FA, GGBFS, and SF replacement levels—each at four dosage levels. The results show that incorporating SF significantly enhanced both mechanical performance and durability. An optimal blend containing 60% OPC, 30% GGBFS, and 10% SF exhibited superior performance compared with the 100% OPC control mix. Additionally, a mixture of 40% OPC, 40% GGBFS, 10% Class F FA, and 10% SF achieved comparable compressive strength to the control, exceeding 100 MPa at 28 days. SEM observations confirmed the dense microstructure of this HPC mix. ANOVA analysis indicated that FA and SF had a significantly greater influence on HPC strength development than GGBFS. Overall, these findings demonstrate the potential of high-volume industrial by-products to produce fine-grained HPC, providing a high-performance and environmentally friendly alternative to conventional OPC-based concrete.