Sustainable Paving Blocks Using Alkali-Activated Furnace Slag and Recycled Aggregates
Abstract
1. Introduction
2. Materials and Methods
2.1. Materials
2.2. Experimental Procedure
2.2.1. Mixture Proportions and Manufacturing of Paving Blocks
2.2.2. Testing Programme
2.2.3. Mercury Intrusion Porosimetry
2.2.4. Statistical Analysis
2.2.5. Ionic Leaching
2.2.6. Life Cycle Assessment
3. Results and Discussion
3.1. Mechanical Properties
3.1.1. PCA Applied to Paving Blocks with the Replacement of the Coarse Fraction of the Recycled Aggregate
3.1.2. PCA Applied to Paving Blocks with the Replacement of the Fine Fraction of the Recycled Aggregate
3.2. Water Absorption
3.3. Density, Abrasive Resistance and Slipping Resistance
3.3.1. PCA Applied to Block Density Data
3.3.2. PCA Applied to Block Abrasion Resistance Data
3.4. Mercury Intrusion Porosimetry of Some Representative Samples
3.5. Leaching Test
3.5.1. Recycled Aggregate
3.5.2. Paving Blocks
3.6. Life Cycle Analysis
4. Conclusions
- ▪
- The use of alkali-activated blast furnace slag allows for the production of paving blocks with physical properties comparable to or superior to those manufactured with conventional Portland cement, offering a viable route for reducing the environmental impact of production. Importantly, the paving blocks were produced at an industrial scale using the standard vibro-compression process, without requiring any modification to the usual manufacturing procedure, which confirms the practical feasibility of implementing this binder in existing production lines.
- ▪
- From the point of view of mechanical properties and with curing times of 90 days, the use of slag allows for the complete replacement of natural aggregate with recycled aggregates when the coarse fraction is used and up to 50% replacement when the fine fraction is used. This involves replacing significant quantities of natural aggregates with recycled ones without compromising mechanical performance.
- ▪
- The compressive strength of paving blocks made from alkaline-activated slag depends mainly on the percentage of replacement of recycled aggregate and not on the properties of the aggregate. This could mean that producers could incorporate recycled aggregates from different sources without the need for extensive pre-selection or characterisation, provided that the substitution ratios are properly controlled, which would simplify industrial implementation and reduce production costs.
- ▪
- Slag paving blocks have a similar behaviour to that observed with Portland cement in terms of water absorption. With substitutions of up to 100% of the coarse fraction of CA and RMA, as well as up to 20% substitutions with the fine fraction of MA and RMA, water absorption values of less than 6% are obtained.
- ▪
- The water absorption experienced by the block depends on the fraction of recycled aggregate used. With the coarse fraction, this absorption depends on the properties of the aggregate (density and water absorption), while with the fine fraction, it depends mainly on the percentage of substitution of the natural aggregate.
- ▪
- The physical properties of the blocks indicate that block density is slightly influenced by the degree of aggregate substitution and the density of the recycled aggregate. The values are similar to control samples, except with full substitution by fine aggregate. Abrasion resistance is slightly affected by the percentage of substitution, with lower values observed only when using RMA-C. Sliding resistance remains practically constant and is not influenced by the type, quantity, or fraction of recycled aggregate used.
- ▪
- The leaching study carried out shows that the industry can perfectly incorporate recycled aggregates in the manufacture of paving blocks, reducing the consumption of natural aggregates and without running any environmental risk, according to the Netherland Soil Quality Decree. Consequently, the combination of recycled aggregates and activated slags not only ensures environmental safety under international standards but also positions the product as a technically and economically viable solution for circular construction.
- ▪
- Replacing Portland cement with slag reduces the environmental impact by around 15%, representing another advantage in the use of AAS. This implies that the industry could drastically reduce its carbon footprint by reusing steel by-products as substitutes for cement, turning an industrial waste into a high-value construction resource.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
| CA | Concrete recycled aggregate |
| MA | Masonry recycled aggregate |
| RMA | Recycled mixed aggregate |
| PCA | Principal component analysis |
| LCA | Life cycle assessment |
| IEA | International Energy Agency |
| WBCSD | World Business Council for Sustainable Development |
| C&DW | Construction and demolition waste |
| OPC | Ordinary Portland cement |
| CO2 | Carbon dioxide |
| C | Coarse |
| S | Fine |
| NaOH | Sodium hydroxide |
| AAS | Alkali-activated blast furnace slag |
| MIP | Mercury intrusion porosimetry |
| NSQD | Netherland Soil Quality Decree |
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| Oxides | Cement Type I | Blast Furnace Slag |
|---|---|---|
| CaO | 66.10 | 46.19 |
| SiO2 | 17.64 | 32.36 |
| Al2O3 | 4.09 | 9.93 |
| Fe2O3 | 3.16 | 0.44 |
| MgO | 2.41 | 6.41 |
| SO3 | 4.01 | 1.89 |
| Na2O | 0.35 | 0.28 |
| K2O | 1.22 | 0.58 |
| TiO2 | 0.34 | 0.70 |
| MnO | 0.09 | 0.19 |
| LOI | 0.87 | 0.67 |
| Mixture | CA | MA | RMA |
|---|---|---|---|
| Concrete | 78.0% | - | 22.0% |
| Masonry | - | 100.0% | 17.2% |
| Unbound aggregate | 19.0% | - | 52.7% |
| Floating particles | 3.0% | - | 6.6% |
| Asphalt | - | - | 1.0% |
| Other | - | - | 0.5% |
| Properties | Concrete Aggregate (CA-C) | Masonry Aggregate (MA-S) | Masonry Aggregate (MA-C) | Recycled Mixed Aggregate (RMA-S) | Recycled Mixed Aggregate (RMA-C) | Natural Aggregate 0–4 mm | Natural Aggregate 4–12 mm |
|---|---|---|---|---|---|---|---|
| Water absorption (%) | 4.8 | 9.8 | 9.7 | 6.3 | 6.0 | 1.4 | 1.1 |
| Dry surface density (g/cm3) | 2.39 | 2.15 | 2.15 | 2.32 | 2.32 | 2.67 | 2.70 |
| Resistance to fragmentation | 28 | 30 | 30 | 30 | 30 | 24 | 24 |
| Fine value (<0.063 mm) (%) | 1 | 46 | 2 | 15 | 1 | 7 | 1 |
| Mixture | Cement (kg/m3) | Slag (kg/m3) | NaOH (kg/m3) | Effective Water (L/m3) | Natural Aggregate S (kg/m3) | Natural Aggregate C (kg/m3) | Recycled Aggregate S (kg/m3) | Recycled Aggregate C (kg/m3) |
|---|---|---|---|---|---|---|---|---|
| OPC control | 280 | - | - | 132 | 1155 | 945 | - | - |
| AAS control | - | 320 | 20.6 | 146 | 1118 | 914 | - | - |
| CA-C-20 | - | 320 | 20.6 | 146 | 1118 | 731 | - | 162 |
| CA-C-50 | - | 320 | 20.6 | 146 | 1118 | 457 | - | 405 |
| CA-C-100 | - | 320 | 20.6 | 146 | 1118 | - | - | 809 |
| MA-S-20 | - | 320 | 20.6 | 146 | 894 | 914 | 180 | - |
| MA-S-50 | - | 320 | 20.6 | 146 | 559 | 914 | 450 | - |
| MA-S-100 | - | 320 | 20.6 | 146 | - | 914 | 900 | - |
| MA-C-20 | - | 320 | 20.6 | 146 | 1118 | 731 | - | 146 |
| MA-C-50 | - | 320 | 20.6 | 146 | 1118 | 457 | - | 364 |
| MA-C-100 | - | 320 | 20.6 | 146 | 1118 | - | - | 728 |
| RMA-S-20 | - | 320 | 20.6 | 146 | 894 | 914 | 194 | - |
| RMA-S-50 | - | 320 | 20.6 | 146 | 559 | 914 | 486 | - |
| RMA-S-100 | - | 320 | 20.6 | 146 | - | 914 | 971 | - |
| RMA-C-20 | - | 320 | 20.6 | 146 | 1118 | 731 | - | 157 |
| RMA-C-50 | - | 320 | 20.6 | 146 | 1118 | 457 | - | 393 |
| RMA-C-100 | - | 320 | 20.6 | 146 | 1118 | - | - | 785 |
| Test | Procedure | Age (Days) | Number of Specimens |
|---|---|---|---|
| Water absorption | UNE-EN 1338 Annex E [31] | 90 | 6 |
| Dry surface density | UNE-EN 12390-7 [32] | 90 | 8 |
| Mechanical strength | UNE-EN 1338 Annex F [31] | 28 and 90 | 8 |
| Abrasion resistance | UNE-EN 1338 Annex G [31] | 90 | 7 |
| Slippage resistance | UNE-EN 1338 Annex I [31] | 90 | 7 |
| Mixture | Density (g/cm3) | Abrasive Wear (mm) | Slipping Resistance |
|---|---|---|---|
| OPC control | 2.30 | 16.9 | 86 |
| AAS control | 2.30 | 17.4 | 85 |
| CA-C-20 | 2.27 | 16.7 | 86 |
| CA-C-50 | 2.24 | 15.9 | 85 |
| CA-C-100 | 2.26 | 18.5 | 85 |
| MA-C-20 | 2.27 | 16.0 | 86 |
| MA-C-50 | 2.20 | 17.1 | 87 |
| MA-C-100 | 2.10 | 16.5 | 84 |
| MA-S-20 | 2.29 | 16.8 | 87 |
| MA-S-50 | 2.15 | 17.5 | 86 |
| MA-S-100 | 1.89 | 17.9 | 85 |
| RMA-C-20 | 2.29 | 13.8 | 87 |
| RMA-C-50 | 2.25 | 14.6 | 85 |
| RMA-C-100 | 2.21 | 15.3 | 86 |
| RMA-S-20 | 2.28 | 14.6 | 84 |
| RMA-S-50 | 2.25 | 16.7 | 87 |
| RMA-S-100 | 2.01 | 17.2 | 86 |
| Mixture | Aggregate Type | Total Porosity (%) | Hg Retained (%) |
|---|---|---|---|
| Aggregate | CA | 7.20 | 49.31 |
| Aggregate | MA | 26.87 | 66.26 |
| Concrete CA-C-100 | CA | 5.80 | 60.59 |
| Concrete MA-C-100 | MA | 28.91 | 67.05 |
| DSQ Limits (mg/m2) | OPC Control | AAS Control | Concrete Aggregates | Masonry Aggregates | Recycled Mixed Aggregates | ||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| CA-C-20 | CA-C-100 | MA-S-20 | MA-S-100 | MA-C-20 | MA-C-100 | RMA-S-20 | RMA-S-100 | RMA-C-20 | RMA-C-100 | ||||
| Cr | 120 | 0.650 | 0.217 | 0.108 | 0.217 | 0.108 | 0.542 | 0.217 | 0.542 | 0.108 | 0.325 | 0.108 | 0.217 |
| Ni | 81 | 0.000 | 0.000 | 0.000 | 0.000 | 0.108 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.108 |
| Cu | 98 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.217 | 0.000 | 0.108 |
| Zn | 800 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 |
| As | 260 | 0.108 | 0.217 | 0.433 | 2.817 | 0.433 | 1.192 | 0.542 | 2.275 | 0.433 | 1.192 | 0.325 | 1.192 |
| Se | 4.8 | 0.000 | 0.000 | 0.108 | 0.217 | 0.000 | 0.108 | 0.108 | 0.000 | 0.108 | 0.217 | 0.108 | 0.433 |
| Mo | 144 | 0.758 | 0.000 | 0.000 | 1.733 | 0.000 | 0.108 | 0.000 | 0.000 | 0.000 | 1.517 | 0.000 | 1.083 |
| Cd | 3.8 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 | 0.000 |
| Sb | 8.7 | 0.000 | 0.000 | 0.108 | 0.542 | 0.000 | 0.325 | 0.000 | 0.108 | 0.000 | 0.325 | 0.000 | 0.217 |
| Ba | 1500 | 0.758 | 0.542 | 0.650 | 0.542 | 0.975 | 23.292 | 0.758 | 2.167 | 1.083 | 0.867 | 0.217 | 0.650 |
| Chloride | 110,000 | 349.92 | 74.53 | 513.39 | 1242.69 | 129.13 | 2031.47 | 279.28 | 2107.84 | 4753.78 | 2794.03 | 5755.53 | 1680.36 |
| Sulphate | 165,000 | 88.83 | 1693.36 | 100.32 | 150.48 | 13,643.72 | 77,023.92 | 11,511.07 | 63,180.00 | 10,901.69 | 47,506.12 | 4349.04 | 22,685.11 |
| Fluoride | 2500 | 14.73 | 133.03 | 137.48 | 203.88 | 135.09 | 195.98 | 136.28 | 220.78 | 460.85 | 318.39 | 142.24 | 171.17 |
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Hernández, M.; Navarro, R.; Sánchez, I.; Sánchez, M.; Rodríguez, C. Sustainable Paving Blocks Using Alkali-Activated Furnace Slag and Recycled Aggregates. Appl. Sci. 2026, 16, 3344. https://doi.org/10.3390/app16073344
Hernández M, Navarro R, Sánchez I, Sánchez M, Rodríguez C. Sustainable Paving Blocks Using Alkali-Activated Furnace Slag and Recycled Aggregates. Applied Sciences. 2026; 16(7):3344. https://doi.org/10.3390/app16073344
Chicago/Turabian StyleHernández, Miriam, Rosa Navarro, Isidro Sánchez, Marina Sánchez, and Carlos Rodríguez. 2026. "Sustainable Paving Blocks Using Alkali-Activated Furnace Slag and Recycled Aggregates" Applied Sciences 16, no. 7: 3344. https://doi.org/10.3390/app16073344
APA StyleHernández, M., Navarro, R., Sánchez, I., Sánchez, M., & Rodríguez, C. (2026). Sustainable Paving Blocks Using Alkali-Activated Furnace Slag and Recycled Aggregates. Applied Sciences, 16(7), 3344. https://doi.org/10.3390/app16073344

