High‐Performance and Low‐Carbon Concrete Solutions for Thinner, Greener, and Durable Double‐Wall Systems

Abstract

This study aimed to optimize double‐wall precast concrete systems through the use of high‐performance concrete (HPC) for the panels and low‐carbon concrete for the core. The main objective is to enhance material efficiency and environmental sustainability. In addition, the study investigated the corrosion propagation within the HPC system, with particular emphasis on rust formation of steel fibers, and evaluated potential protective measures to ensure long‐term durability. The results demonstrated that the use of HPC enabled a substantial reduction in panel thickness while maintaining the required mechanical performance, thereby significantly reducing material consumption. Corrosion was found to be confined to the near‐surface zone, limited to a depth of approximately 3–5 mm, with negligible influence on the overall mechanical behaviour. These findings indicated that rust formation was primarily an aesthetic issue rather than a structural concern. Furthermore, the assessed protective measures proved effective in mitigating surface corrosion. Overall, the optimized double‐wall system achieved reductions of 15% in concrete volume, 31% in cement content, and 24% in CO ₂ emissions, highlighting its potential as a more sustainable solution for precast concrete construction.