Flexural fatigue properties of concrete based on different replacement percentage of natural sand with manufactured sand

Compression and flexural fatigue tests were conducted on concrete specimens with varying strengths under different replacement percentages of natural river sand (R-sand) with manufactured sand (M-sand) at 0%, 30%, 70%, and 100%. The objective was to compare and analyse differences in fatigue damage of concrete across different replacement percentages. Findings were made that when the replacement percentage of M-sand was 30% and 70%, the concrete exhibited higher fatigue life, irrespective of any variations in compressive strength. The fatigue life of concrete with a compressive strength of 30 MPa could be increased by an average of 20%–30% compared to concrete with a compressive strength of 50 MPa, and this increasing trend reached its peak when the replacement percentage of M-sand was in the range of 30%–70%. In order to enhance the prediction of fatigue life for concrete subjected to varying replacement percentages of natural sand with M-sand and to elucidate the evolution process of fatigue damage in M-sand concrete, dynamic strain gauges and DIC methods were employed. This enabled determination of the cycle-varying maximum strain and residual strain during the fatigue process across different replacement percentages. The findings indicate that the addition of M-sand can significantly delay the degradation of dynamic elastic modulus (E), with this effect being enhanced by over 15%. The fatigue damage was defined based on fatigue deformation modulus; therefore, a new fatigue damage model was established. It was observed that this new model improved accuracy by up to 6.1% compared to the traditional fitted model in this test. Finally, the effects of different replacement percentages of natural sand with M-sand on the brittle transition of concrete were analysed at the microscopic level. This analysis involved a combination of microhardness testing and examination of the interfacial transition zone and hydride map of concrete under a scanning electron microscope across different replacement percentages of natural sand with M-sand. •The effects of M-sand replacement percentage and concrete strength on the fatigue behavior of concrete were investigated.•Probabilistic analysis of the experimental fatigue data was modeled by Weibull distribution.•Analysis of concrete microanalysis considering different replacement percentage of natural sand with M-sand was conducted.•A new fatigue life prediction model was established.