Mechanical Performance, Durability, and Environmental Assessment of Low-Carbon Fiber-Reinforced Reactive Powder Concrete with a High Content of Fly Ash

Reactive powder concrete (RPC) delivers outstanding mechanical performance and durability; however, it is commonly hindered by high cement consumption, elevated embodied carbon emissions, and high material costs. To mitigate these drawbacks, this study develops a low-carbon, cost-effective RPC incorporating high-volume class-F fly ash, a reduced silica fume dosage, conventional river sand, and an optimized steel fiber system. A systematic mix design framework, combining particle packing density with paste rheology optimization, was employed to balance workability, strength, and durability. The optimized mixtures were evaluated for compressive, splitting tensile, and flexural strength, as well as durability-related metrics, including water absorption rate and resistance to chloride penetration. Environmental impact and cost-effectiveness were further quantified via embodied carbon accounting and strength-normalized performance indices. The results show that well-designed high-volume fly ash RPC can achieve compressive strengths above 130 MPa while maintaining excellent impermeability, alongside substantial reductions in both material cost and carbon footprint relative to conventional RPC. In addition, mixed-size steel fibers further enhance mechanical performance through multi-scale crack bridging. Overall, this work provides a practical route to decouple ultra-high performance from high environmental burden, supporting the sustainable deployment of RPC in infrastructure engineering.