Sustainable Materials from Waste and Renewable Sources

Commercial sodium hydroxide (NaOH) and sodium silicate (SS) are commonly used as alkaline activators in geopolymer concrete production despite concerns about their availability and associated CO₂ emissions. This study employs an alternative alkaline activator (AA) synthesized from a sodium silicate alternative (SSA) solution derived from rice husk ash (RHA) and a 10 M sodium hydroxide solution. The initial phase established an optimal water-to-binder (W/B) ratio of 0.50, balancing workability and structural performance. Subsequent investigations explored the influence of the alkali/precursor (A/P) ratio on geopolymer concrete properties. A control mix uses ordinary Portland cement (OPC), while ground granulated blast-furnace slag (GGBS)-based geopolymer concrete—GPC mixes (GPC1, GPC2, GPC3, GPC4) vary the A/P ratios (0.2, 0.4, 0.6, 0.8) with a 1:1 ratio of sodium silicate to sodium hydroxide (SS: SH). The engineering performance was evaluated through a slump test, and unconfined compressive strength (UCS) and tensile splitting (TS) tests in accordance with the appropriate standards. The geopolymer mixes, excluding GPC3, offer suitable workability; UCS and TS, though lower than the control mix, peak at an A/P ratio of 0.4. Despite lower mechanical strength than OPC, geopolymers’ environmental benefits make them a valuable alternative. GPC2, with a 0.4 A/P ratio and 0.5 W/B (water to binder) ratio, is recommended for balanced workability and structural performance. Future research should focus on enhancing the mechanical properties of geopolymer concrete for sustainable, high-performance mixtures. Full article

With the advent of the COVID-19 pandemic, the global consumption of single-use surgical masks has risen immensely, and it is expected to grow in the coming years. Simultaneously, the disposal of surgical masks in the environment has caused plastic pollution, and therefore, it is exigent to find innovative ways to handle this problem. In this study, surgical masks were processed in a laboratory using the mechanical grinding method to obtain recycled surgical masks (RSM). The RSM was added in doses of 0%, 1%, 2%, 3%, and 4% by volume of geopolymer bricks, which were synthesized with ground granulated blast furnace slag (GGBS), rice husk ash (RHA), sand, and sodium silicate (Na₂SiO₃) at ambient conditions for a duration of 28 days. The developed bricks were tested for compressive strength, flexural strength, density, water absorption, efflorescence, and drying shrinkage. The results of the study reveal that compressive strength and flexural strength improved with the inclusion of RSM in the bricks. The highest values of compressive strength and flexural strength were 5.97 MPa and 1.62 MPa for bricks with 4% RSM, respectively. Further, a reduction in the self-weight of the bricks was noticed with an increase in RSM. There was no pronounced effect of RSM on the water absorption and efflorescence properties. However, the RSM played a role in reducing the drying shrinkage of the bricks. The sustainability analysis divulges the catalytic role of RSM in improving material performance, thereby proving to be a potential candidate for low-carbon material in the construction industry. Full article

Ecological materials have been implemented in different industrial sectors due to their good performance as thermal insulators and the fact that they are 100% natural, recyclable, and biodegradable, contributing to environmental sustainability. The main objective of this article is to compare the thermal conductivity coefficients of three natural insulators with that of expanded polystyrene (a non-biodegradable material). Expanded polystyrene is one of the materials which is most often used to maintain cold temperatures in containers built for this purpose in the fishing industry; it is used for this purpose because of its properties, including a light weight and a high thermal insulation capacity and resistance. Almost all insulators have the ecological disadvantage of being environmentally unfriendly materials because they are made up of oil particles, which are not recyclable and are harmful to ecosystems. The natural insulator materials were evaluated and subjected to a drying process to reduce the humidity coefficient; then, the containers were built with an adequate insulation thickness of 25 mm. Three filling tests were carried out (at 100, 70, and 50%) to evaluate the thermal conductivity, using the Mann–Whitney U statistical analysis process to determine insulator differences. The results show that the expanded polystyrene had the lowest thermal conductivity of 0.032 W/m K, followed by the rice husk, which had a value of 0.036 W/m K. Finally, a comparative study of conservation costs was carried out in the different containers built with the natural insulators; the lowest value found was for the expanded polystyrene (COP 159.57 around USD 0.040). This allowed to conclude that rice husk is the material that comes closest to the insulating characteristics of expanded polystyrene. Full article

The present investigation reports the results of experiments related to the conversion of low-density polyethylene (LDPE) waste carry bags to fuel through an economic catalytic pyrolysis method in a batch reactor using zinc oxide (ZnO) as the catalyst. Plastics are highly beneficial for the day-to-day activities of human beings; however, their decomposition is limited due to their strong covalent bonding. Degradation of these big molecules into smaller ones or monomers has been attempted by several researchers in recent decades, with limited success. Pyrolysis is one of the ideas used to convert plastics, with the crowded structure of polymers, into fuel rather than small molecules. Among these plastics, LDPE is widely used as carry bags throughout the world, and, herein, the results of catalytic pyrolysis of the conversion of LDPE into fuel are reported. A compact laboratory-scale batch reactor, specially designed at our laboratory, was used to carry out the pyrolysis process. Different dosages of ZnO were used as a catalyst to carry out the pyrolysis at a specific temperature. The optimal dosage of ZnO for a 50 g waste LDPE batch was found to be 0.6 g to get the maximum oil yield. The yielded oil was analyzed chemically through Fourier transform infrared spectroscopy (FTIR) and a Reformulyzer M4 Hydrocarbon Group Type Analyzer. Evaluation of physical and chemical exergy along with exergetic efficiency of the process was carried out. The described experiments and the results represent a small but significant step toward curbing the menace of plastic solid wastes, which are degrading the environment and human life worryingly, and allowing them to be utilized for generating low-cost fuel for transportation and other applications. Full article

The search for ways to utilize and recycle industrial by-products is the basic principle that governs rational environmental management, synthesis of “green” materials, and appears as one of the main criteria for sustainable development in most countries of the world. Gypsum-containing waste (GCW) derived from industries, represents a large-tonnage product. The production of gypsum materials could be one of the ways to recycle GCW products. GCW from various industries can be used as an alternative to natural raw materials when producing gypsum binders. However, the features of GCW do not allow the production of a high-quality binder when traditional technologies are applied, so it requires the development of additional methods or the introduction of various modifiers to the binder system. One of the ways to increase the efficiency of GCW as a raw material for the production of gypsum binders is to apply a semi-dry pressing method, at reduced values of the W/S ratio of the binder. The objective of this research was to study the possibility of increasing the efficiency of GCW using citrogypsum for production of gypsum materials, by optimization of the mix design and by applying a semi-dry pressing method, using a lower pressure load at the molding stage. The mix design and technological parameters were optimized using mathematical planning of the experimental method. Parameters such as the amount of citrogypsum as an additive in the raw mixture, molding pressure, and water–solid (W/S) ratio were taken as input parameters of variation. To plot the relationship of the input–output parameters, the SigmaPlot software was applied, to analyze and demonstrate scientific and statistical data in the form of nomograms. It has been established that the use of the semi-dry pressing method with the optimal mix design and technological parameters, makes it possible to obtain gypsum samples with demolding strengths up to 2 MPa, and final compressive strengths up to 26 MPa. The incorporation of citrogypsum and the optimal W/S ratio of 0.25, results in positive effects, such as a reduction in the sticking properties of the mix during the demolding stage, and the homogeneity of compaction and visual appearance of the samples were also improved. Full article

Global objectives to mitigate climate change in the construction industry have led to increasing geopolymer development as an alternative to carbon-intensive cement. Geopolymers can have similar mechanical properties and a lower carbon footprint. However, geopolymer production is not as homogeneous as cement because it is produced by synthesizing alkali solutions with different aluminosilicate precursors. This study assessed the feasibility of using conventional (fly ash, blast furnace slag, and metakaolin) and alternative precursors (steel slag, mine tailings, glass waste, sewage sludge ashes, and municipal solid waste incineration bottom ashes (MSWI BA)) in geopolymer mixes for different European regions (Belgium and Finland) from a sustainability perspective, using environmental, economic, and resource availability indicators as the criteria. A multi-objective optimization technique was applied to identify optimal precursors for geopolymer mixes using two scenarios: (1) considering both conventional and alternative precursors; (2) only considering alternative precursors. The results from the first scenario show that one of the most optimal precursor combinations for the geopolymer mix is 50% fly ash, 25% MSWI BA, and 25% sewage sludge ash for Belgium. For Finland, it is 19% fly ash, 27% mine tailings, and 45% MSWI BA. For the second scenario, one of the most optimal precursor combinations for Belgium is 87% MSWI BA and 13% steel slag. For Finland, it is 25% mine tailings and 75% MSWI BA. Subsequently, linear regression analysis was applied to predict the compressive strength of the identified optimal mixes, and the results for Belgium and Finland were between 31–55 MPa and 31–50 MPa for the first scenario and between 50–59 MPa and 50–55 Mpa for the second scenario, respectively. Full article

In the last decades, gypsum-bearing industrial wastes become one of the common globally produced industrial and domestic wastes that are currently recycled and further utilized. In this study, the gypsum-bearing waste citrogypsum was used as a Ca²⁺-containing component to modify the properties of alkali-activated cement (AAC) based on granulated blast-furnace slag (GBFS). Citrogypsum was used in different AAC mixes activated with three different alkaline components: Na₂CO₃, NaOH, and Na₂SiO₃. Laser granulometry was applied to assess the granulometric characteristics of citrogypsum and GBFS. Specific gravity (SG), compressive strength, and water resistance were tested to evaluate the effect of citrogypsum on the physical and strength performance of AAC. Experimental results obtained over 4-day to 28-day time periods for the studied AACs showed that the addition of citrogypsum had a detrimental effect on the properties of AAC mixes, where decreases in compressive strength between 1 and 100%, decreases in specific gravity between 4 and 30%, and decreases in water resistance between 12 and 100% were observed. It was determined that AAC mixes modified with citrogypsum cured in ambient conditions had compressive strength values 61% to 90% lower than those cured in hydrothermal conditions. In terms of strength performance, specific gravity and water resistance, citrogypsum showed the greatest effect on AAC mixes activated with NaOH, and to a lesser extent, on mixes activated with Na₂CO₃. The highest water resistance value of 0.77 was observed for the AAC mixes activated with Na₂CO₃ cured in ambient conditions, and when cured in hydrothermal conditions, the highest water resistance reached up to 0.84 for the AAC mixes activated with NaOH. It was observed that the type of alkaline activator and curing conditions are both crucial factors that govern the response of citrogypsum as a supplementary mineral additive in GBFS-based AAC mixes in regard to compressive strength, specific gravity and water resistance. Full article

Up to now, primary resources have been the main choice of raw material selection for production. Now, global market tendencies have brought significant attention to secondary resources as the price has been raised for primary materials, and there is a shortage of their delivery. This could bring an additional effort to increase the recycling level of construction and demolition waste, including expanded polystyrene (EPS). Efforts have been made to develop new efficient building materials with a high content of recycled EPS. In this paper, composite insulation material made of gypsum hemihydrate and recycled EPS beads by casting and compression methods were evaluated, and properties were compared. Thermal and sound insulation properties were characterized. Density from 48 to 793 kg/m³ was obtained and the thermal conductivity coefficient from 0.039 to 0.246 W/(m·K) was measured. Compression strength was from 18 kPa to 2.5 MPa. Composites produced with the compression method have a sound absorption coefficient α > 0.9 in the range from 600 to 700 Hz, while the samples produced by casting showed poor sound absorption with wide deviation. Compression methods had an advantage over the casting method as more homogenous and lightweight materials were produced with improved insulation properties. Full article

Nowadays, the environmental impact of plastic waste is crucial, and in the energy industry, fly ash, a type of solid waste, has also prompted severe ecological and safety concerns. In this study, we synthesised composite material from two industrial wastes: recycled polyethylene terephthalate (rPET) as the matrix and fly ash as the filler. The effect of different fly ash loadings on the thermal behaviour and microstructure of the composite material using rPET were evaluated. Various loading amounts of fly ash, up to 68%, were added in the rPET mixtures, and composites were made using a single-threaded bar’s barrel extruder. The feeding zone, compression zone, and metering zone made up the three functional areas of the extruder machine with a single-flighted, stepped compression screw. The composite materials were subjected to DSC and SEM equipped with EDX spectroscopy tests to examine their thermal behaviour and microstructural development. It was found that the thermal behaviour of rPET improved with the addition of fly ash but degraded as the fly ash loading increased to 68%, as confirmed by the DSC study. The composites’ microstructural development revealed an even filler distribution within the polymer matrix. However, when the fly ash loading increased, voids and agglomeration accumulated, affecting the composites’ thermal behaviour. Full article

Clayey soils are treated with binding agents to improve their mechanical properties, as these soils are widely used in construction. The production of binding agents is an energy-intensive process and emits significant amounts of CO₂. In addition, the interest in recycling industry waste materials has increased, and the management of significant waste from biomass power plants remains an issue. We used three biomass ashes derived from pellet, olive, and grapevine combustion as stabilizing agents of a clayey soil. The mechanical effects of the treatment on clay-ash mixtures were evaluated using confined compressive tests. The mixtures’ chemo-mineralogical evolution was evaluated through X-ray powder diffraction and quantitative Rietveld analysis, Fourier transform infrared spectroscopy (FT-IR), and energy-dispersive X-ray spectroscopy coupled with scanning electron microscopy (EDS-SEM). The FT-IR spectra showed an evolution of the Si-O-Si/Al features, with shifting band positions due to polymerization of the tetrahedral units. The EDS-SEM analysis showed an evolution of the Ca/Si distribution and the growth of pozzolanic reaction products, such as C-S-H nanocrystals and gels. This evidence confirms that the pozzolanic reaction occurs by dissolution of clay minerals and/or the amorphous phase of the ash, which affects the macroscopic behavior of clayey soils in terms of stiffening and strengthening, as confirmed by mechanical tests, albeit these effects are non-homogenous and continuous. Full article

Cement is a widely used building material, with more than 4.4 billion metric tons produced in 2021. Unfortunately, the excessive use of cement raises several environmental issues, one of which is the massive amounts of CO_2e produced as a by-product. Using recycled materials in the concrete mix is widely employed to solve this problem. A method for minimizing the use of natural cement by substituting it with secondary cementitious material that consists of wood–cement board manufacturing waste has been studied in this paper. The cement in the waste stream was reactivated by a mechanical treatment method—the use of a planetary mill, allowing it to regain its cementitious properties and be used as a binder. Physical and mineralogical analysis of the binder material was performed using X-ray diffraction (XRD), thermogravimetry/differential thermal analysis (TG/DTA) and Brunauer–Emmett–Teller analysis; granulometry and compressive strength tests were also carried out. The results show that the grinding process did not significantly change the mineralogical composition and the specific surface area; it did, however, affect the compressive strength of the samples prepared by using the reactivated binding material; also, the addition of plasticizer to the mix increased compressive strength by 2.5 times. Samples were cured in high-humidity conditions. The optimal water-to-binder (W/B) ratio was found to be 0.7 because of the wood particles that absorb water in their structure. Compressive strength increased as the grinding time increased. Full article

The advent of new materials and technologies in building materials has changed the way of building. New lighter materials with easier application methods and improved mechanical behaviors, have become necessary for the market. Moreover, the new environmental policy (2022) aims to transform the waste management into sustainable materials management to ensure the long-term protection and improvement of the environment. For the brick and tile industry, raw materials and the additives that compose the product mixture seem to be a key factor in this direction. Furthermore, every product type (solid or perforated brick) requires different additives to achieve the properties that are postulated by the international standards. For the study, the wide range of additives that were used have been assorted into three (3) categories: the inert materials, the lightweight materials, and the industrial remains. Totally, eight (8) different materials were used as additives into ceramic mass, in different proportions each time. Almost all additives used for this research were pore-forming agents. These burn out almost completely before reaching the full-fire temperature, and do not change the fired body. As a result of additives burnt out, the necessary pore volume is formed in the fired brick body, which, if combined with an appropriate percentage of voids, result in raw density readings. The pore structure is significant as long as the ultimate strength of lightweight bricks is acceptable. In this study, additives between 3 and 25% by weight were added to the clay mixture. The extrusion of specimens in solid form was carried out using the Laboratory’s vacuum press. Firstly, the extrusion of specimens from the original raw material was implemented. Secondly, it was made on the material mixed with the additives mentioned above. A series of experimental activities were followed to determine the variations of the mechanical and physical properties as well as their production procedures (extrusion, drying, and firing). According to five (5) key properties measured in the current study and compared with the mixture without additives, it was found that the variation in thermal conductivity improvement is between -11% and 19%. The bending strength of the fired products showed a decrease from 16% to 55% except for the addition of bauxite residue, which increased the strength by 8%. Bigot drying sensitivity decreased from 11% to 27%. The density in two cases increased from 2% to 7% while in the majority the mixtures with the additives showed a decrease in density from 1% to 14%. Finally, the addition of the necessary water for shaping during extrusion showed a variation from a 10% decreased to a 14% increased water. Full article

The environmental concerns regarding the production of the most widely consumed cement construction material have led to the need for developing sustainable alternatives. Using recycled industry waste products such as fly ash and slag via geopolymerisation has led to the development of geopolymer cement—an efficient replacement for ordinary Portland cement (OPC). Adopting geopolymer cement and concrete as a construction material reduces greenhouse gas and promotes the recycling of waste products. This study explores the suitability of a unique geopolymer concrete mix made of recycled cementitious materials including industry waste products such as fly ash, micro fly ash and slag for use in aggressive environments. Sorptivity tests are conducted to assess the durability of concrete and indicate the cementitious material’s ability to transmit water through the capillary forces. This study thus reports on the sorptivity characteristics of a newly developed self-compacting geopolymer concrete and two other fibre geopolymer concrete mixes containing 1% (by weight) of 12 mm- or 30 mm-long basalt fibres. The addition of basalt fibres indicated less water absorption and moisture ingress than the mix without fibres. The study used 18 specimens from three geopolymer concrete mixes, and the results showed that adding fibres improved the durability performance in terms of resistance to moisture ingress. Finally, an artificial neural network model is developed to predict the absorption rates of geopolymer concrete specimens using MATLAB. The prediction models reported excellent agreement between experimental and simulated datasets. Full article

Geopolymer concrete (GC) has the potential to incorporate recycled concrete aggregates (RCA) obtained from construction and demolition waste. This research aims to review the current state-of-the-art knowledge of the RCA in GC and identify the existing knowledge gaps for future research direction. This paper highlights the essential factors that impact the GC’s mechanical and durability properties. Moreover, the influence of various percentages of coarse and fine RCA and the pattern of their replacement will be assessed. The effect of aluminosilicate material, alkaline activators, and curing regime also will be evaluated. Besides, the durability-related characteristics of this concrete will be analysed. The impact of exposure to a higher temperature, freeze–thaw cycles, marine environment, and acid and alkali attack will be comprehensively reviewed. A literature review revealed that increasing alumina silicate content, such as slag and metakaolin, and increasing the Na₂SiO₃/NaOH ratio and alkali-activator-to-binder ratio improve the hardened GC. However, increasing slag and metakaolin content and the Na₂SiO₃/NaOH ratio has an adverse impact on its workability. Therefore, finding the optimum mix design for using RCA in GC is vital. Moreover, there is a scope for developing a self-compacting GC cured at ambient temperature using RCA. Full article