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Resource Recovery in Building Materials: Developing Eco-Friendly Driven Sustainable Binders or Aggregates from Solid Waste

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Construction and Building Materials".

Deadline for manuscript submissions: 20 August 2026 | Viewed by 6567

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Special Issue Editors

Dr. Fan Wang

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Guest Editor

School of Minerals Processing and Bioengineering, Central South University, Changsha 410075, China
Interests: utilization of solid waste; cement-solidified polluted soil; environmental science and health; solid waste-based cementitious material; heavy metal solidification

Dr. Gang Ma

E-Mail Website
Guest Editor

School of Civil Engineering, Central South University, Changsha 410075, China
Interests: sustainable disposal process; fractal dimension analysis of particle gradation; interfacial transition zone (ITZ) optimization; micro-crack propagation resistance; recycled aggregate concrete

Special Issue Information

Dear Colleagues,

The construction industry, while fundamental to global development, faces critical sustainability challenges stemming from the environmental impacts of conventional binders and the extraction of virgin aggregates. These processes account for 8–10% of global CO₂ emissions, alongside severe resource depletion and waste accumulation. Meanwhile, massive industrial solid waste is piled up, occupying land resources and polluting the environment, thereby affecting the sustainable development of society. In alignment with circular economy principles and the UN Sustainable Development Goals (SDGs), this Special Issue focuses on transforming solid wastes—particularly mining/metallurgical (M&M) residues, construction and demolition (C&D) waste, and industrial by-products—into next-generation eco-friendly driven sustainable binders (EDSBs) or aggregates (EDSAs) via innovative processing methods.

This Special Issue aims to advance systemic solutions that address the entire value chain of waste valorization, encompassing particle engineering and reactivity modulation, as well as performance optimization and environmental impact mitigation. We prioritize interdisciplinary advancements in mining, civil engineering, environmental science, sustainable development, and social innovation. Submissions should emphasize scientific breakthroughs in the following domains but not limited to:

(1) Sustainable Recycling Technologies: Multi-scale characterization of M&M tailings, C&D waste, and industrial by-products. Process Innovations in eco-friendly driven waste disposal: Hybrid sorting technologies, mechanochemical activation, CO₂ mineralization, and recycling for recovering high-purity materials.

(2) Waste Valorization Methods: Enhancing reactivity through physicochemical activation, amorphous phase reconstruction, and synergistic effects. Recycling into aggregates for concrete, road bases, or embankments; repurposing inert materials such as backfill or landscaping substrates; and using processed waste in precast elements further reducing contamination.

(3) EDSBs / EDSAs Recycling Science and Mechanism: For EDSBs: Chemical excitation, physical filling, and coupled microaggregate effects. For EDSAs: Fractal dimension analysis of particle gradation, interfacial transition zone (ITZ) optimization, and micro-crack propagation resistance. Heavy metal encapsulation mechanisms, pH-dependent leaching behavior, and strategies for mitigating ecotoxicity.

(4) Multi-criteria Characterization and Sustainability Validation: Machine-learning-enhanced life cycle assessment (LCA), dynamic materials flow analysis, and techno-economic modeling of industrial symbiosis networks. Regulatory barriers, long-term performance certification protocols, and circularity metrics for built environments.

We aspire to inspire the global community to reimagine waste as a resource and advance the vision of a zero-waste, low-carbon built and mining-filling environment. We invite submissions to redefine waste not as an endpoint but as the foundation of tomorrow's built and mining-filled environment. Full papers, communications, and reviews are all welcome.

We look forward to your groundbreaking contributions, which will chart the course toward carbon-neutral infrastructure and sustainable mining filling development.

Dr. Fan Wang
Dr. Gang Ma
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

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Keywords

eco-friendly driven sustainable binders
eco-friendly driven sustainable aggregates
mining/metallurgical (M&M) residue re-utilization
construction and demolition (C&D) waste re-utilization
industrial by-products re-utilization
physicochemical activation
harmless disposal
long-term stability of heavy metal
fractal dimension of waste particles
synergistic processing effect

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Published Papers (7 papers)

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Research

21 pages, 8716 KB

Open AccessArticle

Synergistic Sintering of Multi-Source Petrochemical Wastes for High-Strength Ceramsite: Process Optimization and Environmental Safety

by Yang Liu, Teng Wang, Jiayan Dang, Siwei Liu, Jiawei Hu and Yongjie Xue

Materials 2026, 19(4), 787; https://doi.org/10.3390/ma19040787 - 18 Feb 2026

Cited by 1 | Viewed by 296

Abstract

The sustainable management of typical petrochemical hazardous wastes, such as oil sludge (OS), spent fluid catalytic cracking catalysts (SFCCs), and petrochemical-contaminated soil (PCS), poses a significant challenge. This study developed a synergistic sintering strategy that utilizes the complementary properties of these materials, with OS serving as an organic source, SFCCs and PCS providing an aluminosilicate framework, and waste glass powder (GP) acting as a fluxing agent to produce an environmentally friendly, high-strength ceramsite (OSPG-Opt). Single-factor experiments were first conducted to investigate the effects of OS content, sintering temperature, and duration. Subsequently, the Box–Behnken design was employed to optimize the process for maximizing aggregate strength. The optimal conditions were determined to be 30.5% OS content, a sintering temperature of 1142 °C, and a sintering time of 32 min. Under these conditions, the resulting ceramsite demonstrated a compressive strength of 23.12 MPa, along with a bulk density of 1012.50 kg/m³ and low water absorption of 1.61%, meeting the requirements of the Chinese standard T/CSTM 00548-2022 for structural materials. Microstructural analysis identified the presence of quartz, anorthite solid solution, hematite, and albite. The remarkable mechanical strength is attributed to an interlocking structure of anorthite solid solution within a glassy matrix, which also contributes to effective heavy metal immobilization, ensuring the excellent environmental performance of the final product. Full article

(This article belongs to the Special Issue Resource Recovery in Building Materials: Developing Eco-Friendly Driven Sustainable Binders or Aggregates from Solid Waste)

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33 pages, 21812 KB

Open AccessArticle

Assessment of the Mechanical Properties and Durability of Cement Mortars Modified with Polyurethane Foam Waste

by Gabriela Rutkowska, Barbara Francke, Filip Chyliński, Mariusz Żółtowski, Hanna Michalak, Agnieszka Starzyk, Michał Musiał and Oskar Sierakowski

Materials 2026, 19(3), 491; https://doi.org/10.3390/ma19030491 - 26 Jan 2026

Cited by 2 | Viewed by 754

Abstract

In the era of growing demand for sustainable solutions in construction, increasing attention is being paid to the potential use of waste materials as components of building composites. This article presents the results of a study on the impact of ground polyurethane foam waste on the mechanical properties and durability of cement mortars. The waste, derived from industrial production processes, was used as a partial replacement for fine aggregates in various proportions. The analysis included bulk density, compressive and flexural strengths, water absorption, and resistance to freeze–thaw cycles. The results indicate that adding waste reduces the density of the mortar, which can be advantageous in applications requiring lightweight materials. The most favourable balance of strength retention, density reduction, and frost resistance was observed with a 1% addition, as the mortar maintained good mechanical performance and freeze–thaw durability while achieving reduced weight. Higher waste content (2–3%) led to significant deterioration of the mechanical properties due to increased porosity. All samples exhibited increased strength after 25 freeze–thaw cycles, possibly due to continued hydration under moist low-temperature conditions. The analysis of the microstructure of cement coatings with the addition of polyurethane foam enabled the explanation of the causes of the observed changes in physico-mechanical properties resulting from ageing factors. This study suggests that small amounts of waste can be effectively used to produce lightweight and environmentally friendly construction materials, supporting circular economy practices. Full article

(This article belongs to the Special Issue Resource Recovery in Building Materials: Developing Eco-Friendly Driven Sustainable Binders or Aggregates from Solid Waste)

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34 pages, 71927 KB

Open AccessArticle

Residual Flexural Strength of Concrete Reinforced with Recycled Carbon Fibers from Wind Turbine Blades

by Julita Krassowska

Materials 2025, 18(22), 5195; https://doi.org/10.3390/ma18225195 - 15 Nov 2025

Viewed by 1000

Abstract

The study aims to assess the potential of recycled carbon fibers recovered from end-of-life wind turbine blades as a sustainable reinforcement material for concrete and to establish correlations between fiber parameters and the mechanical behavior of fiber-reinforced concrete. The research focuses on how fiber length, content, and cement type affect the residual flexural strength and cracking behavior of FRC. The experimental program included 48 concrete mix series with varying fibre lengths (25, 38, and 50 mm), dosages (0, 2, 4, and 8 kg/m³), cement types (CEM I 42.5 and CEM II 42.5R/A-V), and water-to-cement ratios (0.50 and 0.40). Mechanical properties such as compressive strength, tensile strength, modulus of elasticity, and residual flexural strength were evaluated. Notched beams underwent three-point bending tests, and the progression of cracks was tracked using the digital image correlation method. The analysis revealed that enhancing both the fiber content and length generally bolstered the toughness and post-cracking characteristics of concrete, with a notable effect observed for fibers ranging from 38 to 50 mm in length when used at a dosage of 8 kg/m³. However, the effects depend on the fiber recovery technology and the base concrete strength, which may influence the results and should be considered as a limitation of this study. Full article

(This article belongs to the Special Issue Resource Recovery in Building Materials: Developing Eco-Friendly Driven Sustainable Binders or Aggregates from Solid Waste)

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23 pages, 5738 KB

Open AccessFeature PaperArticle

Study on Alkali-Activated Slag Mortar Based on Co-Modified Recycled Fine Aggregate with Nano-SiO₂ and Sodium Silicate Integrating Waste Liquid Recycling

by Qiushi Su, Changbai Wang, Jimin Liu and Qinghua Liu

Materials 2025, 18(21), 4889; https://doi.org/10.3390/ma18214889 - 25 Oct 2025

Viewed by 976

Abstract

The widespread use of recycled fine aggregate (RFA) is hindered by its porous and weak adhered mortar. In this study, a nano-SiO₂–sodium silicate mixed solution (NMS) was used to soak and strengthen the adhered mortar. Alkali-activated slag was adopted as the cementitious material, and the resulting treated waste liquid (RNMS) was recycled as a sodium silicate source for the alkali activator. The effects of modified RFA (MRFA) incorporation and RNMS use on the performance, economic, and environmental benefits of alkali-activated slag recycled fine aggregate mortar (AASRM) were evaluated. Compared with the control group, mortars using only MRFA showed significantly improved performance, with a 28-day compressive strength increase of 57.6% (reaching 38.3 MPa) and enhanced workability. The capillary water absorption and 90-day drying shrinkage rates decreased by 49.5% and 40.2%, respectively. Microstructural analysis revealed that NMS treatment promoted the formation of additional C-(N)-A-S-H gel, thereby densifying the surface of the RFA and strengthening the interfacial transition zone (ITZ). More importantly, using RNMS as the alkali activator source maintained the excellent performance of the AASRM mortar, with the compressive strength reaching 95.6% of that prepared with a fresh alkali activator, while effectively reducing material costs and embodied carbon. This study not only successfully applies MRFA in alkali-activated mortar systems but also provides an effective approach for the in situ recycling of treated waste liquid. Full article

(This article belongs to the Special Issue Resource Recovery in Building Materials: Developing Eco-Friendly Driven Sustainable Binders or Aggregates from Solid Waste)

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23 pages, 10416 KB

Open AccessArticle

Effect of Expansive Agent on Properties and Microstructure of Coal Gangue-Slag-Fly Ash Based Geopolymer

by Qi Wang, Mei Zhou, Xinyi Wang, Yang Han, Lei Peng and Gang Ma

Materials 2025, 18(19), 4607; https://doi.org/10.3390/ma18194607 - 4 Oct 2025

Cited by 1 | Viewed by 921

Abstract

Expansive agents (CaO, MgO, C₄A₃Š) were incorporated into coal gangue-slag-fly ash based geopolymer (CSFG). The influence of expansive agents on the properties and microstructure of CSFG was investigated by macroscopic tests including setting time, compressive strength, and shrinkage values, along with microstructural tests including XRD, FTIR, SEM-EDS, and BET. Results showed that CaO and MgO added separately and their combination exhibited similar trends, with CaO added separately yielding the most favorable outcome. In comparison to the control group, the sample with 7% CaO reduced initial and final setting times by 43.6% and 52.8%, increased 28 d compressive strength by 12.6%, and decreased 28 d drying shrinkage and autogenous shrinkage values by 43.5% and 29.9%, respectively. Moderate MgO and CaO enhanced dissolution of precursors (e.g., coal gangue, fly ash), promoting formation of C-A-S-H gel, CaCO₃, and periclase. Incorporating 3% C₄A₃Š shortened initial and final setting times by 41.3% and 17.8%, improved 28 d compressive strength by 32.2%, but increased 28 d drying and autogenous shrinkage values by 58.3% and 12.8%. Exceeding 3% content significantly reduced 3 d strength. Excessive C₄A₃Š promoted rapid ettringite (AFt) formation, leading to microcracking. Correction prediction models for drying shrinkage strain and autogenous shrinkage strain of CSFG were developed, demonstrating good agreement between predictive and actual values. Full article

(This article belongs to the Special Issue Resource Recovery in Building Materials: Developing Eco-Friendly Driven Sustainable Binders or Aggregates from Solid Waste)

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32 pages, 11740 KB

Open AccessArticle

Experimental and Analytical Study on Concrete Mechanical Properties of Recycled Carbon Fibers from Wind Turbine Blades

by Julita Krassowska

Materials 2025, 18(17), 4105; https://doi.org/10.3390/ma18174105 - 1 Sep 2025

Cited by 2 | Viewed by 1340

Abstract

This study examines the effects of incorporating recycled carbon fibers obtained from decommissioned wind turbine blades into cementitious composites. An extensive experimental program was carried out, varying fiber content (0–8 kg/m³), fiber length (25, 38, 50 mm), water-to-cement ratio (0.4, 0.5), and cement type (CEM I 42.5, CEM II 42.5R/A-V). The mechanical properties of the fiber-reinforced concretes, including compressive strength, flexural strength, splitting tensile strength, and modulus of elasticity, were evaluated. The addition of recycled carbon fibers significantly improved flexural and splitting tensile strengths, with increases exceeding 60% and 100%, respectively, at the highest fiber dosage (8 kg/m³), attributed to efficient crack-bridging capability. Compressive strength was mainly influenced by the water-to-cement ratio, while the modulus of elasticity showed slight reductions in some mixes due to fiber clustering and increased micro-porosity. Regression analysis indicated that shorter fibers (25 mm) were more effective in enhancing flexural strength, whereas longer fibers (50 mm) improved splitting tensile strength. Classical predictive models generally underestimated the flexural capacity of recycled-carbon-fiber-reinforced concretes, highlighting the need for recalibration. Optical microscopy confirmed uniform fiber dispersion at lower dosages and a dominant pull-out failure mechanism. The findings demonstrate the feasibility of using recycled carbon fibers to enhance the mechanical performance of concrete while supporting sustainability through waste diversion and circular economy strategies. Full article

(This article belongs to the Special Issue Resource Recovery in Building Materials: Developing Eco-Friendly Driven Sustainable Binders or Aggregates from Solid Waste)

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17 pages, 3444 KB

Open AccessArticle

Multiphysics-Coupled Simulation of Ultrasound-Assisted Tailing Slurry Sedimentation

by Liang Peng and Congcong Zhao

Materials 2025, 18(15), 3430; https://doi.org/10.3390/ma18153430 - 22 Jul 2025

Cited by 2 | Viewed by 744

Abstract

This study establishes a multiphysics coupling model of acoustics, mechanics, and electrostatics through COMSOL, systematically explores the sound field distribution and stress–strain characteristics of tailing particles in sand silos under different frequencies of ultrasonic radiation, and proposes an optimization scheme for the sound field. The simulation results show that under 28 kHz ultrasonic radiation, the amplitude of sound pressure in the sand silo (173 Pa) is much lower than that at 40 kHz (1220 Pa), which can avoid damaging the original settlement mode of the tail mortar. At the same time, the periodic fluctuation amplitude of its longitudinal sound pressure is significantly greater than 25 kHz, which can promote settlement by enhancing particle tensile and compressive stress, achieving the best comprehensive effect. The staggered placement scheme of the transducer eliminates upward disturbance in the flow field by changing the longitudinal opposing sound field to oblique propagation, reduces energy dissipation, and increases the highest sound pressure level in the compartment to 130 dB. The sound pressure distribution density is significantly improved, further enhancing the settling effect. This study clarifies the correlation mechanism between ultrasound parameters and tailings’ settling efficiency, providing a theoretical basis for parameter optimization of ultrasound-assisted tailing treatment technology. Its results have important application value in the optimization of tailings settling in metal mine tailing filling. Full article

(This article belongs to the Special Issue Resource Recovery in Building Materials: Developing Eco-Friendly Driven Sustainable Binders or Aggregates from Solid Waste)

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