To improve the greenness and deformability of engineered cementitious composites (ECC), recycled powder (RP) from construction and demolition waste with an average size of 45 μm and crumb rubber (CR) of two particle sizes (40CR and 80CR) were used as supplements in the mix. In the present study, fly ash and silica sand used in ECC were replaced by RP (50% and 100% by weight) and CR (13% and 30% by weight), respectively. The tension test and compression test demonstrated that RP and CR incorporation has a positive effect on the deformability of ECC, especially on the tensile strain capacity. The highest tensile strain capacity was up to 12%, which is almost 3 times that of the average ECC. The fiber bridging capacity obtained from a single crack tension test and the matrix fracture toughness obtained from 3-point bending were used to analyze the influence of RP and CR at the meso-scale. It is indicated that the replacement of sand by CR lowers the matrix fracture toughness without decreasing the fiber bridging capacity. Accordingly, an explanation was achieved for the exceeding deformability of ECC incorporated with RP and CR based on the pseudo-strain hardening (PSH) index.

External sulfate attack is an important factor causing a decrease in the mechanical properties of cement-based materials. In this paper, a computational prediction model of elastic modulus, considering the characteristics of sulfate corrosion from outside to inside and the influence of the interface transition zone (ITZ), was established to predict the elastic modulus of mortar under the external sulfate attack. Firstly, the backscattered electron (BSE) images of mortar and the algorithm of image threshold segmenting were used to determine a reasonable thickness of corroded ITZ. Secondly, the nanoindentation test was adopted to acquire the microscopic elastic parameters of phases (sand, cement, and ITZ) in corroded mortar. Moreover, the mortar mix proportion and Lu and Torquato’s model were adopted to calculate the volume fractions of phases. Finally, a computational prediction model of elastic modulus of mortar under sulfate attack was proposed with homogenization methods. The results indicate that the thickness of corroded ITZ is 20 mm, and the error values of elastic modulus between the theoretical prediction results and the experimental results are within 8%, indicating that the macroscopic elastic modulus of corroded mortar can be precisely predicted by the computational prediction model of elastic modulus.

In this paper, a 2D mesoscale finite element (FE) numerical model of mortar, considering the influence of the ITZ, was proposed to evaluate the corrosion of mortar in sodium sulfate. On the mesoscale, the corroded mortar was regarded as a three-phase composite material composed of sand, cement paste, and an interface transition zone (ITZ). Firstly, the volume fractions and mechanical parameters (elastic modulus, Poisson’s ratio, and strength) of the mesoscale phases were obtained. Then, the cement paste and the ITZ were combined to form an equivalent matrix by homogenization methods, and the calibrated constitutive relations of the equivalent matrix were established. Subsequently, a two-dimensional (2D) random circular aggregate (RCA) model and a 2D random polygonal aggregate (RPA) model of corroded mortar were established using the random aggregate model. The failure process of corroded mortar specimens under uniaxial compression was simulated by the mesoscale FE numerical model. Comparing the simulation results with the measured stress–strain curves of the uniaxial compression test, it was found that the simulation results of the 2D RP model were closer to the experimental results than those of the 2D RC model. Meanwhile, the numerical simulation results were in good agreement with the experimental results, and the error values of peak stress between the simulation results and the measured results were within 7%, which showed that the 2D mesoscale FE model could accurately predict the results of a uniaxial compression test of a mortar specimen under sulfate attack.