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<p>The accumulation of industrial packaging waste poses a severe environmental threat. To promote a circular economy, this study investigates valorizing extruded plastic sack (EPS) waste as a partial aggregate replacement in concrete (5–20% by volume). A dual-mitigation strategy using waste polypropylene (PP) fibers (0.5%) and microsilica (10%) was employed to offset the anticipated mechanical deficiencies of the smooth-surfaced plastic. Specimens were tested for mechanical strength, water absorption, and workability. Results indicate that increasing EPS replacement significantly decreases mechanical performance due to a weak interfacial transition zone (ITZ); at 20% replacement, compressive strength fell by approximately 78%. However, the dual-mitigation strategy proved effective: microsilica refined the bulk matrix via pore-filling and pozzolanic reactions, while PP fibers bridged microcracks initiated at the EPS surface. The optimal composite (5% EPS, 10% microsilica, 0.5% fibers) not only recovered the compressive strength loss but exceeded the control specimen’s tensile and flexural strengths by 3.6% and 15%, respectively. This approach successfully transforms a brittle, waste-laden matrix into a ductile, eco-efficient composite suitable for semi-structural applications.</p>

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Dual mitigation of extruded plastic sack waste in green concrete via microsilica and recycled polypropylene fibers

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年4月24日

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  • Sina Lotfollahi,
  • Rasoul Omranzadeh,
  • Parham Bakhtiari,
  • Hosein Khavari

摘要

The accumulation of industrial packaging waste poses a severe environmental threat. To promote a circular economy, this study investigates valorizing extruded plastic sack (EPS) waste as a partial aggregate replacement in concrete (5–20% by volume). A dual-mitigation strategy using waste polypropylene (PP) fibers (0.5%) and microsilica (10%) was employed to offset the anticipated mechanical deficiencies of the smooth-surfaced plastic. Specimens were tested for mechanical strength, water absorption, and workability. Results indicate that increasing EPS replacement significantly decreases mechanical performance due to a weak interfacial transition zone (ITZ); at 20% replacement, compressive strength fell by approximately 78%. However, the dual-mitigation strategy proved effective: microsilica refined the bulk matrix via pore-filling and pozzolanic reactions, while PP fibers bridged microcracks initiated at the EPS surface. The optimal composite (5% EPS, 10% microsilica, 0.5% fibers) not only recovered the compressive strength loss but exceeded the control specimen’s tensile and flexural strengths by 3.6% and 15%, respectively. This approach successfully transforms a brittle, waste-laden matrix into a ductile, eco-efficient composite suitable for semi-structural applications.