Use of Waste Materials in Construction Industry

This study investigates the use of the fine fraction of Brazilian residual kaolin, a material with no pozzolanic activity according to the modified Chapelle test, as a partial cement replacement in rendering mortars. The kaolin was classified into three granulometric fractions (coarse: 150–300 µm, intermediate: 75–150 µm, and fine: <75 µm) and incorporated at two filler contents (10% and 20% by weight). Mineralogical and chemical analyses revealed that the fine fractions contained higher proportions of kaolinite and accessory oxides, while medium and coarse fractions were dominated by quartz. Intensity ratios from XRD confirmed greater structural disorder in the fine fraction, which was associated with higher water demand but also improved particle packing and pore refinement. Fresh state tests showed that mortars with fine kaolin maintained higher density and exhibited moderate increases in air content, whereas medium and coarse fractions promoted greater entrainment. In the hardened state, fine kaolin reduced water absorption by immersion and capillary rise, while medium and coarse fractions led to higher porosity. Mechanical tests confirmed these trends: although compressive and flexural strengths decreased with increasing substitution, mortars containing the fine kaolin fraction consistently exhibited more moderate strength losses than those with medium or coarse fractions, reflecting their enhanced packing efficiency and pore refinement. Tensile bond strength results further highlighted the positive contribution of the kaolin additions, as the mixtures with 10% coarse kaolin and 20% fine kaolin achieved adhesion values only about 7% and 4% lower, respectively, than the control mortar after 28 days. All mixtures surpassed the performance requirements of NBR 13281, demonstrating that the incorporation of residual kaolin—even at higher substitution levels—does not compromise adhesion and remains compatible with favorable cohesive failure modes in the mortar layer. Despite the lack of pozzolanic activity, residual kaolin was used due to its filler effect and capacity to enhance particle packing and pore refinement in rendering mortars. A life cycle assessment indicated that the partial substitution of cement with residual kaolin effectively reduces the environmental impacts of mortar production, particularly the global warming potential, when the residue is modeled as a by-product with a negligible environmental burden. This highlights the critical role of methodological choices in assessing the sustainability of industrial waste utilization. Full article

Steel consumption in the construction sector is one of the main contributors to global greenhouse gas emissions. Therefore, developing processes for the reuse of steel-based products with lower environmental impacts is essential for the sustainability of the construction sector. One example is the reuse of metal road guardrail beams on highways. This study investigated the environmental sustainability of a reconditioning process for such beams, instead of using new guardrails. The environmental impacts of the process were studied and compared with the impacts of the traditional production process using a Life Cycle Assessment (LCA) approach. This study revealed that most of the impacts of the reconditioning process derive from the use of electricity. The comparison with the traditional beam production process revealed that when primary raw materials are replaced by reused raw materials, the environmental impacts associated with the production process decrease significantly. Of the 19 impact indicators assessed, 18 were lower, and 17 had a drop of more than 90 percent compared to the traditional production process. The results indicate that the reconditioning process has the potential to significantly reduce environmental impacts by avoiding the consumption and transportation of primary raw materials, which were identified as the main sources of impacts in the traditional production process, as well as minimizing waste generation. Full article

This study investigated the mechanical performance and durability of concretes produced with varying proportions of recycled coarse aggregate from construction and demolition waste (CDW), ranging from 0% to 100% replacement of natural coarse aggregate, using recycled aggregates derived from crushed concrete and mortar debris, characterized by lower density and high water absorption (~9%) compared to natural aggregates. A key contribution of this research lies in the inclusion of intermediate replacement levels (20%, 25%, 45%, 50%, and 65%), which are less explored in the literature and allow a more refined identification of performance thresholds. Fresh-state parameters (slump), axial compressive strength (7 and 28 days), total immersion water absorption, sorptivity, and chloride ion penetration depth (after 90 days of immersion in a 3.5% NaCl solution) were evaluated. The results indicate that, up to 50% CDW content, the concrete maintains slump (≥94 mm), characteristic strength (≥37.2 MPa at 28 days), and chloride penetration (≤14.1 mm) within the limits for moderate exposure conditions, in accordance with ABNT: NBR 6118. Water absorption doubled from 4.5% (0% CDW) to 9.5% (100% CDW), reflecting the higher porosity and adhered mortar on the recycled aggregate, which necessitates adjustments to the water–cement ratio and SSD pre-conditioning to preserve workability and minimize sorptivity. Concretes with more than 65% CDW exhibited chloride penetration depths exceeding 15 mm, potentially compromising durability without additional mitigation. The judicious incorporation of CDW, combined with optimized mix design practices and the use of supplementary cementitious materials (SCMs), demonstrates technical viability for reducing environmental impacts without significantly impairing the structural performance or service life of the concrete. Full article