Experimental investigations on mechanical performance, synergy assessment, and microstructure of pozzolanic and non‐pozzolanic hybrid steel fiber reinforced concrete

This paper investigates the effects of pozzolanic substitutions for ordinary Portland cement (OPC) with silica fume (SF) and metakaolin (MK) on the mechanical and toughness performances of steel fiber reinforced concrete (SFRC). Initially, a reference concrete mix with a water‐to‐binder ratio of 0.4 is blended with different volume fractions of steel fibers with varying geometry: crimped steel (CS) and straight steel (SS), both individually and in combination, to examine their mechanical properties. In the subsequent phase, the study investigates the impact of combining macro‐ and microsteel fibers on flexural toughness, to determine potential synergy for suitable combinations. Also, the possible influence of pozzolans in the variation of flexural toughness of hybrid steel fiber reinforced concrete (Hy‐SFRC) was evaluated. Hybridization of steel fibers was found effective in improving the workability of the concrete mix up to 11%. SFRC mixes containing pozzolans exhibited a significant enhancement in compressive strength, modulus of rupture, and modulus of elasticity compared to non‐pozzolanic SFRC. The hybrid combination of CS 1.5% and SS 0.5% was considered the best in terms of mechanical properties. Additionally, the results of synergy assessment showed that hybridization of steel fibers in the pozzolanic concrete mix was particularly effective in the post‐cracking stages with a positive 14% compared to a negative 8% in the pre‐cracking stage. The pozzolanic addition improved the flexural toughness of Hy‐SFRC to about 10%–20%. Blending of SF and MK in Hy‐SFRC was found effective in enhancing the toughness mechanism of concrete compared to Hy‐SFRC mixes containing binary SF and MK, indicating a stronger bond between the fibers and the matrix resulting from the pore refinement and hydration products developed at the interface. Hy‐SFRC containing a ternary pozzolanic mix of SF 10% and MK 10% gave the best results in flexural toughness, and the corresponding synergy values were found to be the maximum. The results were consistent with the morphology analysis, which revealed an increase in hydration products at the interface between the aggregate and concrete matrix, as well as between the steel fiber and concrete matrix, due to the ternary blending of SF and MK.