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Optimization and Performance Evaluation of Multi-Component Binder-Based Mortars Using Particle Packing Techniques.

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Title: Optimization and Performance Evaluation of Multi-Component Binder-Based Mortars Using Particle Packing Techniques.
Authors: Renuka, Vanga1 (AUTHOR), Rao, Sarella Venkateswara1,2 (AUTHOR) tezeswi@nitw.ac.in, Tadepalli, Tezeswi1,3 (AUTHOR), Kalinowska-Wichrowska, Katarzyna2,4 (AUTHOR), Granatyr, Krzysztof1,2 (AUTHOR), Kosior-Kazberuk, Marta2 (AUTHOR), Franus, Małgorzata3 (AUTHOR), Masłoń, Adam4 (AUTHOR)
Source: Materials (1996-1944). Mar2026, Vol. 19 Issue 5, p1024. 33p.
Subjects: Binding agents, Packing problem (Mathematics), Carbon dioxide mitigation, Cement composites, Density, Cement admixtures, Tensile strength
Abstract: Highlights: What are the main findings? The D-optimal mixture design (DOD) method is used to determine the optimal material proportions. Proportioning of fine aggregate using the MTM method achieves max. packing density and min. void ratio. MCB-based mortars are able to attain their maximum strengths after 90 days. What are the implications of the main findings? Maximum packing density is a reliable indicator for achieving mechanical and durability properties. Statistical mixture design and particle packing provide a systematic, optimized pathway. MCB systems substantially reduce energy consumption and CO2 emissions. The use of a multi-component binder (MCB), consisting of Ordinary Portland Cement (OPC) combined with one or more supplementary cementitious materials (SCMs), has gained prominence for enhancing sustainability and improving the performance of cementitious systems. This study provides an integrated approach to optimize both binder composition and aggregate gradation through advanced mixture design and particle packing techniques. The MCB system consists of OPC partially replaced with SCMs such as fly ash (FA), Ground Granulated Blast Furnace Slag (GGBFS), metakaolin (MK), and silica fume (SF), with particle sizes ranging from micron to sub-micron scale. The D-optimal mixture design (DOD) method is used to determine the optimal material proportions by evaluating the relation between binder composition and wet packing density measured through the wet packing method (WPM). To further enhance packing efficiency, the Modified Toufar Model (MTM) is employed to optimize fine aggregate gradation. The maximum packing density is considered the primary criterion for identifying the optimal mix design, as it reflects the minimum void ratio and the most efficient particle size distribution. The optimized mortar mixes are evaluated for mechanical strength, pozzolanic reactivity, capillary water sorptivity, and drying shrinkage. Results indicate that the optimized MCB and optimized fine aggregate gradation improve the packing density and pozzolanic activity, significantly enhancing strength and durability performance. The incorporation of SCMs offers an effective strategy to improve performance while mitigating carbon emissions. Compared with C100, CFGMS-based systems achieved energy reductions of 35–40% and CO2 emission reductions of 34–48%. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Optimization and Performance Evaluation of Multi-Component Binder-Based Mortars Using Particle Packing Techniques.
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  Data: <searchLink fieldCode="AR" term="%22Renuka%2C+Vanga%22">Renuka, Vanga</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Rao%2C+Sarella+Venkateswara%22">Rao, Sarella Venkateswara</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> tezeswi@nitw.ac.in</i><br /><searchLink fieldCode="AR" term="%22Tadepalli%2C+Tezeswi%22">Tadepalli, Tezeswi</searchLink><relatesTo>1,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kalinowska-Wichrowska%2C+Katarzyna%22">Kalinowska-Wichrowska, Katarzyna</searchLink><relatesTo>2,4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Granatyr%2C+Krzysztof%22">Granatyr, Krzysztof</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kosior-Kazberuk%2C+Marta%22">Kosior-Kazberuk, Marta</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Franus%2C+Małgorzata%22">Franus, Małgorzata</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Masłoń%2C+Adam%22">Masłoń, Adam</searchLink><relatesTo>4</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Mar2026, Vol. 19 Issue 5, p1024. 33p.
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  Data: <searchLink fieldCode="DE" term="%22Binding+agents%22">Binding agents</searchLink><br /><searchLink fieldCode="DE" term="%22Packing+problem+%28Mathematics%29%22">Packing problem (Mathematics)</searchLink><br /><searchLink fieldCode="DE" term="%22Carbon+dioxide+mitigation%22">Carbon dioxide mitigation</searchLink><br /><searchLink fieldCode="DE" term="%22Cement+composites%22">Cement composites</searchLink><br /><searchLink fieldCode="DE" term="%22Density%22">Density</searchLink><br /><searchLink fieldCode="DE" term="%22Cement+admixtures%22">Cement admixtures</searchLink><br /><searchLink fieldCode="DE" term="%22Tensile+strength%22">Tensile strength</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Highlights: What are the main findings? The D-optimal mixture design (DOD) method is used to determine the optimal material proportions. Proportioning of fine aggregate using the MTM method achieves max. packing density and min. void ratio. MCB-based mortars are able to attain their maximum strengths after 90 days. What are the implications of the main findings? Maximum packing density is a reliable indicator for achieving mechanical and durability properties. Statistical mixture design and particle packing provide a systematic, optimized pathway. MCB systems substantially reduce energy consumption and CO2 emissions. The use of a multi-component binder (MCB), consisting of Ordinary Portland Cement (OPC) combined with one or more supplementary cementitious materials (SCMs), has gained prominence for enhancing sustainability and improving the performance of cementitious systems. This study provides an integrated approach to optimize both binder composition and aggregate gradation through advanced mixture design and particle packing techniques. The MCB system consists of OPC partially replaced with SCMs such as fly ash (FA), Ground Granulated Blast Furnace Slag (GGBFS), metakaolin (MK), and silica fume (SF), with particle sizes ranging from micron to sub-micron scale. The D-optimal mixture design (DOD) method is used to determine the optimal material proportions by evaluating the relation between binder composition and wet packing density measured through the wet packing method (WPM). To further enhance packing efficiency, the Modified Toufar Model (MTM) is employed to optimize fine aggregate gradation. The maximum packing density is considered the primary criterion for identifying the optimal mix design, as it reflects the minimum void ratio and the most efficient particle size distribution. The optimized mortar mixes are evaluated for mechanical strength, pozzolanic reactivity, capillary water sorptivity, and drying shrinkage. Results indicate that the optimized MCB and optimized fine aggregate gradation improve the packing density and pozzolanic activity, significantly enhancing strength and durability performance. The incorporation of SCMs offers an effective strategy to improve performance while mitigating carbon emissions. Compared with C100, CFGMS-based systems achieved energy reductions of 35–40% and CO2 emission reductions of 34–48%. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
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  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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      – Type: doi
        Value: 10.3390/ma19051024
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 33
        StartPage: 1024
    Subjects:
      – SubjectFull: Binding agents
        Type: general
      – SubjectFull: Packing problem (Mathematics)
        Type: general
      – SubjectFull: Carbon dioxide mitigation
        Type: general
      – SubjectFull: Cement composites
        Type: general
      – SubjectFull: Density
        Type: general
      – SubjectFull: Cement admixtures
        Type: general
      – SubjectFull: Tensile strength
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      – TitleFull: Optimization and Performance Evaluation of Multi-Component Binder-Based Mortars Using Particle Packing Techniques.
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              Text: Mar2026
              Type: published
              Y: 2026
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