Hybrid Steel Fiber Design in Ultra-High-Performance Concrete Containing Coarse Aggregate Using Pore Size Distribution Within Coarse Aggregate Skeleton

To address the challenge of coarse aggregates hindering steel fiber dispersion and reducing toughening efficiency in ultra-high-performance concrete containing coarse aggregate (UHPC-CA), this study proposes a hybrid fiber design method based on reverse adaptation to the aggregate structure: a paradigm where fiber proportions are inversely designed to match the quantified void size distribution within the coarse aggregate skeleton. Industrial X-ray computed tomography (X-CT) was employed to capture the internal structure of UHPC-CA. Digital image processing techniques were used to quantitatively characterize the size distribution within the coarse aggregate skeleton gap. Based on this distribution, the blending proportions of multi-scale (3-16 mm) copper-plated steel fibers were systematically determined. Three fiber configurations were compared: mono-sized 13 mm fibers (Type A), an empirical model based on aggregate size (Type B), and a quantitatively designed blend based on skeleton gap distribution (Type C). At the same fiber volume fraction, the mechanical property test results show that the C type achieves approximately 18.6% higher flexural strength and 29.1% higher splitting tensile strength compared to the A type, while showing 5.3% and 6.7% improvements over the B type, and the compressive strength also increased slightly (about 3.0%). The microanalysis further confirms that the fiber distribution in the C-type design was more uniform, and the bridging effect and crack resistance were more sufficient. The proposed gap-adaptive fiber design paradigm offers an effective approach for optimizing reinforcement distribution in composites, providing theoretical and practical value for high-performance UHPC-CA applications.