Construction Materials

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34 pages, 7685 KB

Open AccessArticle

Calcium-Based Wastes as Additives or Binder Substitutes in Mortars: Experimental Research with Oyster Shells or Lime Kiln Dust, Quicklime and a Modified Vinegar Solution

by Rute Eires, Raphaele Malheiro, Thianne Peixoto and Arlen Zúniga

Constr. Mater. 2026, 6(1), 13; https://doi.org/10.3390/constrmater6010013 - 10 Feb 2026

Viewed by 1489

Abstract

Lime kiln dust (LKD), a by-product of the paper industry, generates about 100 tonnes of waste per 400,000 tonnes of kraft paper produced, while global aquaculture yields more than 16 million tonnes of oysters annually, 65–90% of which is made up of shells. [...] Read more.

Lime kiln dust (LKD), a by-product of the paper industry, generates about 100 tonnes of waste per 400,000 tonnes of kraft paper produced, while global aquaculture yields more than 16 million tonnes of oysters annually, 65–90% of which is made up of shells. This study explores their valorisation in the production of more eco-friendly mortars by partially replacing hydrated lime with LKD and oyster shell powder (OSP). In addition, a vinegar solution (VS), prepared by reacting oyster shells with white vinegar (~5% acetic acid), was used as an alternative mixing liquid instead of water. The LKD and OSP were tested at different substitution levels, showing promising mechanical performance, supporting their use as sustainable alternatives in mortar production. Replacement levels of 25%, 50% and 90% achieved compressive strengths ≥ 0.4 MPa at 28 days. At 28 days, the reference lime mortar prepared with water reached 0.83 MPa, while the use of the vinegar solution increased the compressive strength to 1.86 MPa, representing an improvement of approximately 124%. Regarding binder replacement by wastes, the most efficient mechanical performance was obtained for mixtures with 50% LKD substitution, reaching 2.04 MPa at 28 days and 3.11 MPa at 60 days, increasing by 10% and 43%, respectively, while mixtures incorporating oyster shell powder showed more stable mechanical behaviour across substitution levels. Using a hot-mixing process with quicklime in the presence of the vinegar-based solution and sand may account for the higher strengths, due to the heat/steam generated during lime hydration prior to moulding and verified by microscopy. In addition, VS-containing mixes showed higher aragonite contents and detectable phosphorus-bearing compounds, which may further contribute to matrix densification and strengthening. Overall, the results indicate that the combined use of uncalcined calcium-based wastes and a vinegar-based solution can contribute to the development of calcium-based mortars with good mechanical performance, supporting circular economy strategies and the reduction in calcined-binder use in construction materials. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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24 pages, 4356 KB

Open AccessArticle

Design of Recycled Aggregate Fiber-Reinforced Concrete for Road and Airfield Applications Using Polypropylene Fibers and Fly Ash

by Vitalii Kryzhanovskyi, Sergii Kroviakov, Pavlo Shymchenko and Inna Aksyonova

Constr. Mater. 2026, 6(1), 2; https://doi.org/10.3390/constrmater6010002 - 5 Jan 2026

Cited by 3 | Viewed by 789

Abstract

Driving the circular economy in road construction requires the effective use of secondary materials like recycled concrete aggregate (RCA) and fly ash (FA). A key obstacle is the performance trade-off in concretes incorporating both materials. This research investigates feasible mix designs for road [...] Read more.

Driving the circular economy in road construction requires the effective use of secondary materials like recycled concrete aggregate (RCA) and fly ash (FA). A key obstacle is the performance trade-off in concretes incorporating both materials. This research investigates feasible mix designs for road concrete, using RCA as a full gravel replacement and FA as a cement substitute. Polypropylene fiber (36 mm) and a superplasticizer were utilized to mitigate fresh and hardened state drawbacks. The experimental program included 15 modified mixtures with recycled aggregate and 3 control mixtures with natural aggregate. The workability of all concrete mixtures was kept constant at slump class S1. Road concretes with RCA, containing a 10–12% FA by cement replacement, at least 2 kg/m³ of polypropylene fiber (PF), and 4 kg/m³ of superplasticizer (SP), achieve compressive strength of at least 50 MPa and flexural strength of no less than 5 MPa at the design age. This performance is comparable to that of control mixtures. Furthermore, the abrasion resistance ranges between 0.48–0.50 g/cm², and the brittleness index falls within 0.095–0.100, significantly enhancing the durability of concrete for rigid pavement applications. The conducted cradle-to-gate life-cycle assessment (stages A1–A3) of the constituent materials for 1 m³ of concrete indicates the following environmental impacts: Global Warming Potential (GWP) of 195 kg CO₂ equation, Non-renewable Primary Energy Demand (PENRE) of 1140 MJ, Abiotic Depletion Potential for Fossil resources (ADPF) of 1120 MJ, Acidification Potential (AP) of 0.45 mol H⁺ equation, and Eutrophication Potential (EP) of 0.07 kg PO₄³⁻ equation It is established that the modified compositions not only meet the required performance criteria but also contribute to the goals of resource conservation in road construction. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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24 pages, 5484 KB

Open AccessArticle

Performance and Environmental Assessment of Alkali-Activated Cements from Agricultural and Industrial Residues

by Rafaela Pollon, Giovani Jordi Bruschi, Suéllen Tonatto Ferrazzo, Arielle Cristina Fornari, Eduarda Razador Lazzari, Pedro Domingos Marques Prietto and Eduardo Pavan Korf

Constr. Mater. 2025, 5(4), 79; https://doi.org/10.3390/constrmater5040079 - 4 Nov 2025

Viewed by 961

Abstract

The growing concern with carbon dioxide emissions from the cement industry has driven the search for alternative binders with lower environmental impact. Among these, alkali-activated cements (AACs) stand out due to their ability to produce cementitious matrices from aluminosilicate precursors and alkaline activators. [...] Read more.

The growing concern with carbon dioxide emissions from the cement industry has driven the search for alternative binders with lower environmental impact. Among these, alkali-activated cements (AACs) stand out due to their ability to produce cementitious matrices from aluminosilicate precursors and alkaline activators. However, comparisons between One-Part and Two-Part systems remain limited. This study evaluated the technical feasibility of producing AAC using sugarcane bagasse ash (SCBA) as precursor, carbide lime (CL) as calcium source, and sodium hydroxide (NaOH) as activator. Different parameters were tested, including NaOH molarities (1.0–2.5 M), SCBA/CL ratios (9.00–1.50), curing times (3, 7, and 28 days), and preparation methods. Mortars were produced at constant water/solid ratio of 1.40 and cured at room temperature (23 °C). Unconfined compressive strength (UCS) and leaching tests were performed, along with statistical analysis and Scanning Electron Microscopy (SEM), X-ray Diffraction (XRD), and Fourier Transform Infrared Spectroscopy (FTIR) analyses. ACC synthesized by the Two-Part method (2.0 M NaOH, SCBA:CL 70:30) reached an UCS of 1.60 MPa at 28 days, compared to 1.39 MPa for the One-Part method. Curing time was identified as the most significant factor, followed by SCBA/CL ratio and activator molarity, while preparation method had minimal effect. The material developed alkali-activated gels, and leaching tests indicated no toxicity, although Ba concentrations exceeded regulatory limits for water quality. Potential applications include mine tailings stabilization, soil improvement, shallow foundations, and urban furniture production. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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13 pages, 1636 KB

Open AccessArticle

Mechanical Performance of Sustainable Asphalt Mixtures Incorporating RAP and Panasqueira Mine Waste

by Hernan Patricio Moyano-Ayala and Marisa Sofia Fernandes Dinis-Almeida

Constr. Mater. 2025, 5(3), 52; https://doi.org/10.3390/constrmater5030052 - 4 Aug 2025

Cited by 2 | Viewed by 1681

Abstract

The increasing demand for sustainable practices in road construction has prompted the search for environmentally friendly and cost-effective materials. This study explores the incorporation of reclaimed asphalt pavement (RAP) and Panasqueira mine waste (greywacke aggregates) as full replacements for virgin aggregates in hot [...] Read more.

The increasing demand for sustainable practices in road construction has prompted the search for environmentally friendly and cost-effective materials. This study explores the incorporation of reclaimed asphalt pavement (RAP) and Panasqueira mine waste (greywacke aggregates) as full replacements for virgin aggregates in hot mix asphalt (HMA), aligning with the objectives of UN Sustainable Development Goal 9. Three asphalt mixtures were prepared: a reference mixture (MR) with granite aggregates, and two modified mixtures (M15 and M20) with 15% and 20% RAP, respectively. All mixtures were evaluated through Marshall stability, stiffness modulus, water sensitivity, and wheel tracking tests. The results demonstrated that mixtures containing RAP and mine waste met Portuguese specifications for surface courses. Specifically, the M20 mixture showed the highest stiffness modulus, improved moisture resistance, and the best performance against permanent deformation. These improvements are attributed to the presence of stiff aged binder in RAP and the mechanical characteristics of the greywacke aggregates. Overall, the findings confirm that the combined use of RAP and mining waste provides a technically viable and sustainable alternative for asphalt pavement construction, contributing to resource efficiency and circular economy goals. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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18 pages, 3231 KB

Open AccessArticle

Investigation into the Properties of Alkali-Activated Fiber-Reinforced Slabs, Produced with Marginal By-Products and Recycled Plastic Aggregates

by Fotini Kesikidou, Kyriakos Koktsidis and Eleftherios K. Anastasiou

Constr. Mater. 2025, 5(3), 48; https://doi.org/10.3390/constrmater5030048 - 24 Jul 2025

Viewed by 963

Abstract

Alkali-activated building materials have attracted the interest of many researchers due to their low cost and eco-efficiency. Different binders with different chemical compositions can be used for their production, so the reaction mechanism can become complex and the results of studies can vary [...] Read more.

Alkali-activated building materials have attracted the interest of many researchers due to their low cost and eco-efficiency. Different binders with different chemical compositions can be used for their production, so the reaction mechanism can become complex and the results of studies can vary widely. In this work, several alkali-activated mortars based on marginal by-products as binders, such as high calcium fly ash and ladle furnace slag, are investigated. Their mechanical (flexural and compressive strength, ultrasonic pulse velocity, and modulus of elasticity) and physical (porosity, absorption, specific gravity, and pH) properties were determined. After evaluating the mechanical performance of the mortars, the optimum mixture containing fly ash, which reached 15 MPa under compression at 90 days, was selected for the production of precast compressed slabs. Steel or glass fibers were also incorporated to improve their ductility. To reduce the density of the slabs, 60% of the siliceous sand aggregate was also replaced with recycled polyethylene terephthalate (PET) plastic aggregate. The homogeneity, density, porosity, and capillary absorption of the slabs were measured, as well as their flexural strength and fracture energy. The results showed that alkali activation can be used to improve the mechanical properties of weak secondary binders such as ladle furnace slag and hydrated fly ash. The incorporation of recycled PET aggregates produced slabs that could be classified as lightweight, with similar porosity and capillary absorption values, and over 65% achieved strength compared to the normal weight slabs. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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16 pages, 4284 KB

Open AccessArticle

Monitoring of Corrosion in Reinforced E-Waste Concrete Subjected to Chloride-Laden Environment Using Embedded Piezo Sensor

by Gaurav Kumar, Tushar Bansal and Dayanand Sharma

Constr. Mater. 2025, 5(3), 46; https://doi.org/10.3390/constrmater5030046 - 16 Jul 2025

Cited by 3 | Viewed by 1710

Abstract

This study explores the use of embedded piezo sensor (EPS) employing the Electro-Mechanical Impedance (EMI) technique for real-time corrosion monitoring in reinforced E-waste concrete exposed to chloride-laden environments. With the growing environmental concerns over electronic waste (E-waste) and the demand for sustainable construction [...] Read more.

This study explores the use of embedded piezo sensor (EPS) employing the Electro-Mechanical Impedance (EMI) technique for real-time corrosion monitoring in reinforced E-waste concrete exposed to chloride-laden environments. With the growing environmental concerns over electronic waste (E-waste) and the demand for sustainable construction practices, printed circuit board (PCB) materials were incorporated as partial replacements for coarse aggregates in concrete. The experiment utilized M30-grade concrete mixes, substituting 15% of natural coarse aggregates with E-waste, aiming to assess both sustainability and structural performance without compromising durability. EPS configured with Lead Zirconate Titanate (PZT) patches were embedded into both conventional and E-waste concrete specimens. The EPS monitored the changes in the form of conductance and susceptance signatures across a 100–400 kHz frequency range during accelerated corrosion exposure over a 60-day period in a 3.5% NaCl solution. The corrosion progression was evaluated qualitatively through electrical impedance signatures, visually via rust formation and cracking, and quantitatively using the Root Mean Square Deviation (RMSD) of EMI signatures. The results showed that the EMI technique effectively captured the initiation and propagation stages of corrosion. E-waste concrete exhibited earlier and more severe signs of corrosion compared to conventional concrete, indicated by faster increases and subsequent declines in conductance and susceptance and higher RMSD values during the initiation phase. The EMI-based system demonstrated its capability to detect microstructural changes at early stages, making it a promising method for Structural Health Monitoring (SHM) of sustainable concretes. The study concludes that while the use of E-waste in concrete contributes positively to sustainability, it may compromise long-term durability in aggressive environments. However, the integration of EPS and EMI offers a reliable, non-destructive, and sensitive technique for real-time corrosion monitoring, supporting preventive maintenance and improved infrastructure longevity. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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20 pages, 5406 KB

Open AccessArticle

Sintering Behavior and Chlorine Volatilization Mechanism of Cl-Containing Solid Waste in Clay Brick Production: Implications for Tunnel Kiln Applications

by Zhu Liu, Shupeng Wen, Jian Wang, Yi Li, Linqiang Mao, Yang Yang and Zhongquan Liu

Constr. Mater. 2025, 5(2), 34; https://doi.org/10.3390/constrmater5020034 - 27 May 2025

Cited by 3 | Viewed by 2914

Abstract

The use of tunnel kiln firing in clay brick production offers a promising approach for disposing of Cl-containing solid waste, with lower chlorine (Cl) and heavy metal volatilization compared to cement kiln processes. However, the effects of Cl salts on brick properties and [...] Read more.

The use of tunnel kiln firing in clay brick production offers a promising approach for disposing of Cl-containing solid waste, with lower chlorine (Cl) and heavy metal volatilization compared to cement kiln processes. However, the effects of Cl salts on brick properties and the volatilization mechanisms remain unclear. This study investigates the behaviors of NaCl, KCl, and CaCl₂ during sintering. Adding 15 wt% Cl salts significantly alters pore structure, increasing water absorption by 80–100% and reducing compressive strength by 70–80%. At 1050 °C, 10.8–16.4% of Cl volatilizes mainly as HCl (g), 24.4–26.2% remains in original salt form, and over half is immobilized within the brick matrix. Thermodynamic and TG-MS analyses reveal Cl salts are stable below 800 °C but release HCl (g) at higher temperatures due to lower reaction energy barriers than Cl₂ (g). Density functional theory (DFT) calculations show that H⁺ for HCl (g) formation primarily originates from water vapor (H₂O), with organic decomposition having minimal effect. The presence of Cl salts promotes feldspar and silicate phase formation, enhancing densification but increasing porosity from HCl release. To reduce HCl emissions, a two-stage temperature control strategy is proposed: organic decomposition and moisture removal below 600 °C, followed by sintering at 800–1000 °C. This work clarifies the volatilization mechanisms of Cl salts and provides guidance for optimizing industrial brick production using Cl-containing waste. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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18 pages, 6152 KB

Open AccessArticle

Development of Thermally Insulating Gypsum Boards Blended with Quartzite and Fiberglass Waste

by Rosana M. R. Mol, Marialaura H. Rosas, Keoma D. C. e Silva and Ricardo A. F. Peixoto

Constr. Mater. 2025, 5(2), 30; https://doi.org/10.3390/constrmater5020030 - 29 Apr 2025

Viewed by 1613

Abstract

The construction industry generates approximately 45% of the world’s total waste, highlighting the need for sustainable solutions. This study investigates the incorporation of quartzite waste (QW) and fiberglass waste (FW) into the production of gypsum plasterboard to reduce its environmental impact while maintaining [...] Read more.

The construction industry generates approximately 45% of the world’s total waste, highlighting the need for sustainable solutions. This study investigates the incorporation of quartzite waste (QW) and fiberglass waste (FW) into the production of gypsum plasterboard to reduce its environmental impact while maintaining its structural performance. The optimum formulation (MQ-20) was determined by replacing 20% of the gypsum with QW, based on the observed free water loss and crystallization water. The physical, mechanical, and thermal properties of the reference and modified boards were evaluated. The results showed that the MQ-20 samples exhibited a 30% reduction in flexural strength compared to the reference, while still exceeding regulatory standards. In addition, the MQ-20 samples had a lower thermal conductivity (0.54 W/(m∙K)) than the reference (0.58 W/(m∙K)). Fire-resistance tests showed that the inclusion of QW and FW reduced the size and number of cracks, improving the structural stability of the plasterboard at high temperatures. This research demonstrates that the incorporation of industrial waste into plasterboard is a viable and environmentally friendly approach, providing both mechanical and thermal performance benefits. These findings provide a basis for future studies aimed at developing sustainable building materials with improved functional properties. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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Review

Jump to: Research

29 pages, 754 KB

Open AccessReview

Sustainability: A Comprehensive Overview of Palm Oil Waste Upcycling in Civil Engineering Applications

by Nura Shehu Aliyu Yaro, Jacob Adedayo Adedeji, Zesizwe Ngubane and Jacob Olumuyiwa Ikotun

Constr. Mater. 2026, 6(2), 23; https://doi.org/10.3390/constrmater6020023 - 15 Apr 2026

Viewed by 250

Abstract

Palm oil waste (POW) is generated during the production of palm oil, and a large quantity of this waste often travels to landfills for disposal. This review aims to provide a comprehensive understanding of the circular economy approach to sustainable engineering and environmental [...] Read more.

Palm oil waste (POW) is generated during the production of palm oil, and a large quantity of this waste often travels to landfills for disposal. This review aims to provide a comprehensive understanding of the circular economy approach to sustainable engineering and environmental applications of POW, including its generation, disposal concerns, challenges, and prospects. This review provides an overview of the features, composition, and prospective applications of several POWs, including palm oil clinkers (POCs), palm oil fuel ashes (POFAs), palm oil kernel shells (POKSs), and palm oil fibres (POFs). Furthermore, this overview describes the different applications that POW has found, such as sustainable construction materials, renewable energy production, and environmental remediation. Moreover, this review discusses the leaching and risk assessment of POW. The overview also discusses the circular economy implications of using POW. The results showed that while some wastes are reused and recycled, a good quantity are still discarded in environmentally harmful ways. With this overview of a wide circular economy approach to the sustainable use of POW, there will be a rallying call to experts and researchers to identify research gaps that could contribute to the sustainable use of POW. The results of this overview of the sustainable engineering and environmental applications of POW with a circular economy approach indicate that cleaner production technologies and better environmental sustainability of the palm oil industry are feasible through proper waste management, renewable energy generation, resulting in minimal environmental impacts. Furthermore, this analysis will be very useful in providing tools to engineers, environmentalists, and other relevant stakeholders to enable the efficient and sustainable use of POW in the global circular economy. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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21 pages, 641 KB

Open AccessReview

Towards Sustainable Concrete: Current Trends and Future Projections of Supplementary Cementitious Materials in South Africa

by Ichebadu George Amadi and Jeffrey Mahachi

Constr. Mater. 2025, 5(3), 70; https://doi.org/10.3390/constrmater5030070 - 20 Sep 2025

Cited by 4 | Viewed by 3085

Abstract

Supplementary cementitious materials (SCMs) provide a practical solution for reducing greenhouse gas emissions associated with Portland cement production while enhancing the economy, performance, and service life of concrete and mortar. Currently, there is a significant disparity in the availability, supply, and utilisation levels [...] Read more.

Supplementary cementitious materials (SCMs) provide a practical solution for reducing greenhouse gas emissions associated with Portland cement production while enhancing the economy, performance, and service life of concrete and mortar. Currently, there is a significant disparity in the availability, supply, and utilisation levels of SCMs worldwide, particularly in South Africa. This paper presents an in-depth analysis of the characteristics and performance of various SCMs, including local availability, factors driving demand, production, and utilisation. The findings indicate that fly ash and limestone calcined clay are the most widely available SCM resources in South Africa, with deposits exceeding 1 billion tonnes each. Fly ash stockpiles continuously increase due to the reliance on coal-fired power plants for 85% of generated electricity and a low fly ash utilisation rate of 7%, significantly below international utilisation levels of 10–98%. Conversely, slag resources are depleting due to the steady decline of local steel production caused by energy and input costs, alongside the growing importation of steel products. Combined, the estimated production of slag and silica fume is about 1.4 million tonnes per annum, leading to their limited availability and utilisation in niche applications such as high-performance concrete and marine environments. Furthermore, 216,450 tonnes of SCM could potentially be processed annually from agricultural waste. In addition to quality, logistics, costs, and other challenges, this quantity can only replace 1.5% of clinker in South Africa, raising concerns about the viability of SCMs from agricultural waste. Based on its findings, this study recommends future research areas to enhance the performance, future availability, and sustainability of SCMs. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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33 pages, 4522 KB

Open AccessReview

Sustainable Engineering of Recycled Aggregate Concrete: Structural Performance and Environmental Benefits Under Circular Economy Frameworks

by Bishnu Kant Shukla, Harshit Yadav, Satvik Singh, Shivam Verma, Anoop Kumar Shukla and Chetan Sharma

Constr. Mater. 2025, 5(3), 67; https://doi.org/10.3390/constrmater5030067 - 15 Sep 2025

Cited by 2 | Viewed by 4494

Abstract

The transition toward sustainable infrastructure in the construction sector necessitates the practical integration of Circular Economy (CE) principles, particularly through the valorization of recycled materials in concrete applications. This review critically synthesizes recent advancements in the use of recycled polyethylene terephthalate (PET), glass [...] Read more.

The transition toward sustainable infrastructure in the construction sector necessitates the practical integration of Circular Economy (CE) principles, particularly through the valorization of recycled materials in concrete applications. This review critically synthesizes recent advancements in the use of recycled polyethylene terephthalate (PET), glass powder, and crumb rubber as partial replacements for conventional aggregates in Ordinary Portland Cement (OPC)-based concrete. The incorporation of these secondary materials has demonstrated the ability to reduce the environmental footprint of concrete production—achieving up to 25% reductions in greenhouse gas emissions and diverting significant volumes of waste from landfills—while maintaining structural viability with compressive strength retention levels exceeding 90% in several optimized mix designs. Enhanced ductility, thermal resistance, and reduced density further support their application in specialized construction scenarios. Beyond material characterization, the review systematically examines implementation enablers, including regulatory alignment, life-cycle-based procurement, and design-for-deconstruction strategies. It also highlights critical gaps such as the absence of harmonized standards, variability in recycled material quality, and systemic barriers to market uptake. Addressing these challenges is essential for scaling CE integration and achieving measurable sustainability gains across the built environment. This study aims to inform policy, practice, and research trajectories by linking material innovation with operational frameworks that support regenerative construction systems. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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32 pages, 4492 KB

Open AccessReview

Foundry Sand in Sustainable Construction: A Systematic Review of Environmental Performance, Contamination Risks, and Regulatory Frameworks

by Ferdinand Niyonyungu, Aurobindo Ogra and Ntebo Ngcobo

Constr. Mater. 2025, 5(3), 57; https://doi.org/10.3390/constrmater5030057 - 20 Aug 2025

Cited by 3 | Viewed by 3938

Abstract

The significant expansion of the construction sector and corresponding depletion of natural sand resources have intensified the search for sustainable alternatives, with waste foundry sand (WFS) emerging as a promising candidate. This systematic review evaluates the environmental performance and engineering feasibility of using [...] Read more.

The significant expansion of the construction sector and corresponding depletion of natural sand resources have intensified the search for sustainable alternatives, with waste foundry sand (WFS) emerging as a promising candidate. This systematic review evaluates the environmental performance and engineering feasibility of using WFS as a substitute for natural sand in construction. A PRISMA-guided search identified 152 peer-reviewed studies published between 2001 and 2024, which were categorized into four thematic areas: material characterization, construction applications, environmental impacts, and regulatory frameworks. The findings indicate that substituting 10–30% of natural sand with WFS in concrete and asphalt can deliver compressive strength within ±5% of control mixes and reduce water absorption by 5–15% at optimal replacement levels. However, contamination risks remain a concern, as chromium and copper concentrations in raw WFS have been reported at up to 931 mg/kg and 3318 mg/kg, respectively. To address these risks and ensure responsible reuse, a six-stage framework is proposed in this study, comprising end-of-waste classification, contaminant assessment, material preprocessing, certification, and regulatory monitoring. A comprehensive decision tree is also presented to guide the feasibility assessment of WFS reuse based on contaminant levels and material performance. Full article

(This article belongs to the Special Issue Advances in the Sustainability and Durability of Waste-Based Construction Materials)

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