Flexural and Fracture Behaviors of Ultra-High-Performance Manufactured Sand Concrete Beams with Steel Fibers and Steel Rebars Based on Acoustic Emission

The use of manufactured sand (MS) as a substitute for natural sand or quartz sand in the production of ultra-high-performance manufactured sand concrete (UHPMC) represents a critical approach to alleviating the shortage of high-quality aggregates and promoting low-carbon development. However, after steel fibers and steel rebars are introduced into this material system, the synergistic working mechanism and damage evolution characteristics of the resulting ultra-high-performance manufactured sand-reinforced concrete (UHPMRC) beams under flexural loading remain largely unexplored. Acoustic emission (AE) technology, owing to its high sensitivity to the initiation and propagation of microcracks, enables real-time dynamic monitoring of UHPMRC beams throughout the entire process from the elastic stage to fracture failure, thereby providing an effective means to reveal the internal performance degradation law. Accordingly, this study conducted simultaneous AE monitoring on small-scale reinforced beams under four-point bending and investigated the effects of MS replacement ratios (0%, 50%, 100%) and steel fiber contents (1.0%, 1.5%, 2.0%). Results show that UHPMRC beams with 100% MS replacement and 1.5% steel fiber content achieve optimal performance. Compared to 0% MS specimens, those with 100% MS exhibit superior early stiffness, ductility, and flexural capacity due to the combined effects of steel fibers and MS. Beams with 2% steel fiber content experienced fiber clustering, reducing bridging capability and promoting earlier cracking relative to those with 1.5% fibers. AE energy parameters accurately identified cracking and characterized crack propagation in UHPMRC beams. Increasing MS content raised the proportion of shear cracks while reducing tensile cracks. The highest shear signal proportion occurred at 1.0% steel fiber content. These findings provide a valuable reference for the design of sustainable high-performance reinforced-concrete structures using manufactured sand.