This research proposed the modular prefabricated permanent formwork system made of ultra-high-performance concrete (UHPC). Two kinds of modular formwork shapes were designed: the flat formwork and the ribbed. The experimental investigation on the axial compression performance of the composite columns that consist of the normal strength concrete (NSC) core and the modular UHPC permanent formwork was demonstrated. Compared with the flat formwork, the ribbed formwork exhibited better bonding with the NSC core. As observed from the test results, the composite column with the ribbed formwork presented a similar axial behavior as the NSC column with a slight improvement in ultimate loads. Therefore, the modular UHPC ribbed permanent formwork could be regarded as the additional cover to the conventional NSC column. In addition, the finite element analysis (FEA) model was also developed to simulate the composite columns numerically. The predicted capacities agreed with the experimental results, which validated the numerical models. The crack pattern estimated by the FEA model revealed that the interaction between the permanent formwork and the inner concrete introduced many tiny cracks to the concrete core. However, as protected by the UHPC permanent formwork, the overall durability of the composite columns can still be enhanced.

The undesirable properties of conventional recycled fine aggregate (RFA) often limit its application in the construction industry. To overcome this challenge, a method for preparing completely recycled fine aggregate (CRFA), which crushes all concrete waste only into fine aggregate, was proposed. The obtained CRFA had high apparent density, and its water absorption was lower than that of the conventional RFA. To take advantage of the CRFA, this paper introduced the modified packing density method for the CRFA concrete mix design. The modified packing density method took account of the powder with a particle size of smaller than 75 μm in the CRFA and balanced both the void ratio and the specific surface area of the aggregate system. Concrete (grade C55) was prepared using the CRFA to validate the feasibility of the proposed method. The unit price of the prepared CRFA concrete was around 12.7% lower than that of the natural aggregate concrete. Additionally, the proposed procedure for the concrete mixture design could recycle all concrete waste into the new concrete and replace all the natural fine aggregate in the concrete mixture.

To reduce the cost of lightweight concrete (LWC) partition panels and to address recycling concrete waste, this work utilized completely recycled fine aggregate (CRFA) to replace the natural fine aggregate and ceramsite in the preparation of LWC and LWC partition panels. To this end, an autoclave-free curing process and an air-entraining agent were used to prepare the CRFA-LWC. The workability, compressive strength, drying shrinkage, and pore structure of the CRFA-LWC and the performance of the CRFA-LWC partition panels were then investigated. The results show that the optimal ratio of the CRFA to the cement is 2.2 for the lightweight concrete, and the optimal panel cross section is a rounded rectangular one. All the pores in the CRFA-LWC have a diameter of smaller than 0.17 mm, and the diameter of 89% of them is less than 0.05 mm. In order to satisfy the drying shrinkage requirements stipulated by Chinese code JC/T 169-2016, the CRFA-LWC should be cured for at least 10 days. The economic analysis concludes that the material cost of CRFA-LWC is 40% lower than that of the autoclaved ceramsite concrete. In addition, utilizing CRFA in lightweight concrete can ease the shortage of natural aggregate.