Multi-Objective Optimization of Rigid Pavement Concrete Using Industrial By-Products and Polypropylene Fibers

This study investigates the properties of concrete incorporating recycled aggregates (RAs) for rigid pavement applications. A 15-point three-level experimental design was used to vary three composition factors: Portland cement substitution with fly ash (FA), and dosages of a superplasticizer (SP) and polypropylene fibers (PFs). A set of experimental–statistical models (ES models) was developed to predict the concrete strength, abrasion and frost resistance (FR), water absorption (WA), and global warming potential (GWP). This study aimed to develop a material that achieves both adequate mechanical performance for pavement applications and enhanced environmental sustainability by incorporating RAs and FA. The results demonstrate that replacing up to 13% of cement with FA does not compromise the splitting tensile strength or FR. For non-fibrous concrete, this substitution increases FR by approximately 50 freeze–thaw cycles. Application of PFs (2.4–3 kg/m3) enhances splitting tensile strength by 14–16% and improves FR by about 50 cycles. Using response surface methodology (RSM), optimal concrete compositions were identified that meet all target criteria: compressive strength ≥ 40 MPa, flexural strength ≥ 5 MPa, FR ≥ F200 (cycles), and abrasion resistance (AR) ≤ 0.5 g/cm2, while simultaneously minimizing GWP. An additional optimum composition was determined by imposing a constraint on splitting tensile strength of ≥4.5 MPa. This graphical optimization approach, utilizing two-factor interaction diagrams, provides an effective and visual methodology for practical concrete mixture design. The novelty of the method lies in the discretization of the factor space, which enables efficient identification of optimal concrete mixture compositions.