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Keywords = C-(A)-S-H gels

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12 pages, 1362 KB  
Article
Thermostable Collagenase Derived from Streptomyces scabies Demonstrates Selective Antibacterial Activity Against Infections in Diabetic Foot Ulcers
by Manal Al-Kattan, Afra Baghdadi and Afnan Sahloli
Appl. Microbiol. 2025, 5(4), 122; https://doi.org/10.3390/applmicrobiol5040122 - 31 Oct 2025
Viewed by 76
Abstract
Diabetic foot ulcers (DFUs) and other chronic wounds are major global health challenges, often complicated by infections and delayed healing due to excessive collagen accumulation. Microbial collagenases offer an enzymatic alternative to surgical debridement by selectively degrading collagen and potentially limiting microbial colonization. [...] Read more.
Diabetic foot ulcers (DFUs) and other chronic wounds are major global health challenges, often complicated by infections and delayed healing due to excessive collagen accumulation. Microbial collagenases offer an enzymatic alternative to surgical debridement by selectively degrading collagen and potentially limiting microbial colonization. In this study, an isolated and characterized thermostable collagenase from Streptomyces scabies from rhizospheric soil in Al-Lith thermal springs, Saudi Arabia, is investigated. Identification was confirmed via 16S rRNA sequencing, and enzyme production was optimized on gelatin agar. Partial purification was achieved through ammonium sulfate precipitation and dialysis, and molecular weight (~25 kDa) was determined by Sodium dodecyl sulfate–polyacrylamide gel electrophoresis. Activity was assessed under varying temperatures, pH, substrates, and metal ions, while antibacterial potential was tested against Staphylococcus aureus, Klebsiella pneumoniae, and Pseudomonas aeruginosa. The collagenase exhibited optimal activity at 80 °C and pH 9, stability under thermophilic and alkaline conditions, activation by Fe2+, and notable antibacterial effects at higher concentrations. These results demonstrate that S. scabies collagenase exhibits selective antibacterial activity in vitro, suggesting its potential as an enzymatic tool for further evaluation in diabetic foot debridement and infection control. Full article
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14 pages, 3683 KB  
Article
Strength, Microstructural, and Environmental Performance of Phosphogypsum–GGBS–Carbide Slag Ternary Blended Cement
by Yunzhi Tan, Joseph Roland Atenga Essama, Chong Wang, Jun Wu and Huajun Ming
Materials 2025, 18(21), 4953; https://doi.org/10.3390/ma18214953 - 30 Oct 2025
Viewed by 145
Abstract
Phosphogypsum (PG) and Carbide Slag (CS) are two industrial byproducts that can be used as cementitious materials, and their synergistic effect provides excellent activation of ground granulated blast furnace slag (GGBS), which is traditionally activated by lime (LM). However, the behavior of PG-GGBS-CS [...] Read more.
Phosphogypsum (PG) and Carbide Slag (CS) are two industrial byproducts that can be used as cementitious materials, and their synergistic effect provides excellent activation of ground granulated blast furnace slag (GGBS), which is traditionally activated by lime (LM). However, the behavior of PG-GGBS-CS ternary blended cement remains largely unexplored. In this study, the mechanical performance, hydration mechanisms, and environmental profile of PG–GGBS–CS binders in comparison with PG–GGBS–LM were evaluated by unconfined compressive strength (UCS), XRD, SEM, and TGA analyses. The optimum formulation containing 30% PG achieved 24.88 ± 1.24 MPa at 28 d, statistically comparable to 25.6 ± 1.28 MPa for PG–GGBS–LM. The synergistic activation of PG and CS/LM on GGBS has been identified as a crucial factor in the strengthening of UCS in ternary blended cement. Hydration products consisted mainly of calcium silicate hydrate (C–S–H) gels and Ettringite (AFt). Importantly, the CO2 footprint of PG–GGBS–CS was reduced by 3.2% compared to that of PG–GGBS–LM. These findings establish CS as an effective substitute for lime in eco-binders, combining technical efficiency with carbon mitigation and offering a viable pathway for large-scale valorization of hazardous industrial residues. Full article
(This article belongs to the Section Construction and Building Materials)
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15 pages, 4930 KB  
Article
Effect of Sodium Silicate and Sodium Hydroxide Ratios on Compressive Strength of Ceramic Brick and Metakaolin Waste-Based Geopolymer Binder
by Martynas Statkauskas, Danutė Vaičiukynienė, Audrius Grinys and Diana Bajare
Materials 2025, 18(21), 4947; https://doi.org/10.3390/ma18214947 - 29 Oct 2025
Viewed by 161
Abstract
The construction industry’s growth is causing a surge in CO2 emissions, driven by increased demand for concrete and other building materials. There is a growing demand for more sustainable building materials, including alkali-activated materials. This study investigates the impact of varying ratios [...] Read more.
The construction industry’s growth is causing a surge in CO2 emissions, driven by increased demand for concrete and other building materials. There is a growing demand for more sustainable building materials, including alkali-activated materials. This study investigates the impact of varying ratios of Na2SiO3 and NaOH on the mechanical properties and microstructure of metakaolin (MKW) and ceramic brick waste (CBW) based geopolymer binder. Geopolymer binder precursors were made of three main CBW/MKW ratios: 100/0%wt. (C100), 50/50%wt. (C50M50), and 0/100%wt. (M100). Alkaline activator solutions had three different Na2SiO3/NaOH ratios: 0.5, 1.0, and 2.0. The investigation into the geopolymer binder mechanical properties was conducted using a range of analytical methods, including compressive strength, scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FT-IR). The findings of the study indicate that the Na2SiO3/NaOH ratio alone is inadequate for evaluating geopolymer mechanical properties when different AS/P ratios are employed, given its influence on other parameters, such as the W/S ratio and the total Na2O content. CBW-based geopolymer binders demonstrate limited capacity to attain substantial compressive strengths because they contain high amounts of unreacted CBW particles, as shown by XRD analysis. The incorporation of MKW precursor resulted in enhanced reactivity and intensified geopolymerization reaction. After the evaluation of all essential ratios, the most favorable Na2SiO3/NaOH ratio is 1.0. This determination was based on the highest strengths observed in designs that contained ≥50% of MKW precursor, attributed to predominance of goosecreekite and N-A-S-H gels, as evidenced by XRD and FT-IR analysis. Full article
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22 pages, 8757 KB  
Article
Multi-Variable Optimization of Sustainable Alkali-Activated Mortar with High Waste Concrete Powder Dosage for Enhanced Drying Shrinkage Resistance
by Zhen Zou, Han Gao, Yingda Zhang, Jiehong Li, Miao Li and Yang Yu
Buildings 2025, 15(21), 3903; https://doi.org/10.3390/buildings15213903 - 28 Oct 2025
Viewed by 215
Abstract
This study presents a comprehensive strategy for mitigating drying shrinkage of alkali-activated slag mortar (AASM) with the high-dosage incorporation of waste concrete powder (WCP). Response surface methodology (RSM) coupled with microstructural analysis is used to investigate the synergistic effects of WCP particle size [...] Read more.
This study presents a comprehensive strategy for mitigating drying shrinkage of alkali-activated slag mortar (AASM) with the high-dosage incorporation of waste concrete powder (WCP). Response surface methodology (RSM) coupled with microstructural analysis is used to investigate the synergistic effects of WCP particle size (R), activator modulus (AM), activator content (AC), and water to solid ratio (W/S) on shrinkage behavior and matrix development. The optimized mix—WCP-R = 33.6 µm, AM = 1.23, AC = 6.03%. and W/S = 0.49—exhibits a 120-day drying shrinkage of only 1450.1 µε, significantly lower than that of conventional AASM. Microstructural observations reveal that coarser WCP particles act predominantly as fillers, enhancing stability, whereas finer particles promote gel formation but increase shrinkage. A high AM (1.6) refines the pore structure by reducing large pores (>0.05 µm), while a low W/S (0.46) decreases total porosity to 7.67%, collectively restricting moisture transport. The coexistence of C-(A)-S-H gel and hydrotalcite improves matrix integrity. Notably, this optimized HWAASM achieves a substantially reduced carbon footprint of 180 kg CO2-eq/t, underscoring its significant environmental advantage. The findings advance the understanding of shrinkage mechanisms in high-WCP-AASM and offer an eco-friendly route for valorizing construction waste and developing low-carbon building materials. Full article
(This article belongs to the Section Building Materials, and Repair & Renovation)
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17 pages, 2573 KB  
Article
Effect of Metakaolin and Biosilica on the Mechanical Properties of Cementitious Mortars
by Marine Kalantaryan, Nelli Muradyan, Avetik Arzumanyan, Yeghvard Melikyan, David Laroze, Manuk Barseghyan and Yeghiazar Vardanyan
Buildings 2025, 15(21), 3882; https://doi.org/10.3390/buildings15213882 - 27 Oct 2025
Viewed by 133
Abstract
The growing demand for sustainable construction materials has intensified efforts to reduce the environmental impact of Portland cement. This study investigates the effect of partial substitution of cement with metakaolin (MK, 5–15 wt.%) and biosilica (BS, 5 wt.%) on the physical, mechanical, and [...] Read more.
The growing demand for sustainable construction materials has intensified efforts to reduce the environmental impact of Portland cement. This study investigates the effect of partial substitution of cement with metakaolin (MK, 5–15 wt.%) and biosilica (BS, 5 wt.%) on the physical, mechanical, and microstructural properties of cementitious mortars. The influence of a polycarboxylate ether-based superplasticizer (Mf) and ultrasonic treatment (ULT) was also evaluated. The mortars were characterized through setting time, density, water absorption, flexural and compressive strength tests, as well as FTIR and SEM analyses. Water absorption decreased from 12.21% to 9.8%, indicating improved pore refinement and densification. Flexural strength of all modified mortars exceeded that of the control mix: from 10.0% to 89.9% at 7 days, and from 4.7% to 50.4% at 28 days. The compressive strength improved markedly with MK and BS incorporation, from 20.8% to 51.3% at 7 days and from 9.7% to 35.2% at 28 days compared to the control sample. FTIR and SEM results confirmed enhanced pozzolanic activity and formation of C–S–H gel. The synergistic use of MK, BS, and Mf—especially with ultrasonic dispersion—yielded denser, stronger, and more sustainable cementitious composites. Full article
(This article belongs to the Section Building Materials, and Repair & Renovation)
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20 pages, 5759 KB  
Article
Research on the Hydration Mechanism and Mechanical Properties of Stainless Steel Slag–Fly Ash Recycled Concrete in Pavements
by Liuyun Huang, Sixian Chen, Zhuxin Lan, Yuliang Chen and Tun Li
Materials 2025, 18(21), 4906; https://doi.org/10.3390/ma18214906 - 27 Oct 2025
Viewed by 296
Abstract
This study systematically investigates the effects of slag from the argon–oxygen decarburization (AOD) process, fly ash, and recycled aggregate (RA) replacement ratios on the mechanical properties of mortar samples and AOD slag–fly ash recycled concrete. The sustainable reuse of industrial by-products and construction [...] Read more.
This study systematically investigates the effects of slag from the argon–oxygen decarburization (AOD) process, fly ash, and recycled aggregate (RA) replacement ratios on the mechanical properties of mortar samples and AOD slag–fly ash recycled concrete. The sustainable reuse of industrial by-products and construction waste is significant for reducing environmental impact and resource consumption during pavement construction. Experimental results demonstrate that when AOD slag and fly ash are used in combination, they undergo synergistic hydration reactions, producing calcium hydroxide (CH), calcium silicate hydrate (C-S-H) gel, and ettringite (AFt), resulting in superior strength compared to the individual use of either material. This research reveals that concrete strength decreases significantly when the recycled aggregate replacement ratio exceeds 50%; therefore, RA = 50% was selected as the optimal replacement ratio for subsequent studies. On this basis, when the combined replacement ratio of AOD slag and fly ash is 10–20%, concrete performance reaches its optimum level: maximum compressive strength is 33.9 MPa, which is 8.57% and 36.2% higher than using fly ash or AOD slag alone, respectively; maximum flexural strength is 4.6 MPa, which is 6.08% and 14.44% higher than using fly ash or AOD slag alone, respectively; and peak axial compressive and splitting tensile strengths are 24.9 MPa and 3.4 MPa, respectively. These findings demonstrate that the synergistic use of AOD slag, fly ash, and recycled aggregates can produce concrete that meets pavement application requirements, while effectively promoting the resource utilization of industrial by-products and construction waste, aligning with circular economy principles. Full article
(This article belongs to the Section Construction and Building Materials)
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23 pages, 5738 KB  
Article
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 355
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 [...] Read more.
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
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29 pages, 4966 KB  
Article
Structure–Property Relationships in Epoxy–Anhydride Systems: A Comprehensive Comparative Study of Cycloaliphatic, Novolac, and Aromatic Prepolymers
by Stephane Patry, Alban Asseray, Mickaël Berne, Valéry Loriot, Luc Loriot and Jean-Pierre Habas
Polymers 2025, 17(21), 2843; https://doi.org/10.3390/polym17212843 - 24 Oct 2025
Viewed by 387
Abstract
This study provides a comprehensive quantitative comparison of three structurally distinct epoxy prepolymers—cycloaliphatic, novolac, and bis-aromatic (BADGE)—cured with a single hardener, methyl nadic anhydride (MNA), and catalyzed by 1-methylimidazole under strictly identical stoichiometric and thermal conditions. Each formulation was optimized in terms of [...] Read more.
This study provides a comprehensive quantitative comparison of three structurally distinct epoxy prepolymers—cycloaliphatic, novolac, and bis-aromatic (BADGE)—cured with a single hardener, methyl nadic anhydride (MNA), and catalyzed by 1-methylimidazole under strictly identical stoichiometric and thermal conditions. Each formulation was optimized in terms of epoxy/anhydride ratio and catalyst concentration to ensure meaningful cross-comparison under representative cure conditions. A multi-technique approach combining differential scanning calorimetry (DSC), dynamic rheometry, and thermogravimetric analysis (TGA) was employed to jointly assess cure kinetics, network build-up, and long-term thermal stability. DSC analyses provided reaction enthalpies and glass transition temperatures (Tg) ranging from 145 °C (BADGE-MNA) to 253 °C (cycloaliphatic ECy-MNA) after stabilization of the curing reaction under the chosen thermal protocol, enabling experimental fine-tuning of stoichiometry beyond the theoretical 1:1 ratio. Isothermal rheology revealed gel times of approximately 14 s for novolac, 16 s for BADGE, and 20 s for the cycloaliphatic system at 200 °C, defining a clear hierarchy of reactivity (Novolac > BADGE > ECy). Post-cure thermomechanical performance and thermal aging resistance (100 h at 250 °C) were assessed via rheometry and TGA under both dynamic and isothermal conditions. They demonstrated that the novolac-based resin retained approximately 93.7% of its initial mass, confirming its outstanding thermo-oxidative stability. The three systems exhibited distinct trade-offs between reactivity and thermal resistance: the novolac resin showed superior thermal endurance but, owing to its highly aromatic and rigid structure, limited flowability, while the cycloaliphatic resin exhibited greater molecular mobility and longer pot life but reduced stability. Overall, this work provides a comprehensive and quantitatively consistent benchmark, consolidating stoichiometric control, DSC and rheological reactivity, Tg evolution, thermomechanical stability, and degradation behavior within a single unified experimental framework. The results offer reliable reference data for modeling, formulation, and possible use of epoxy–anhydride thermosets at temperatures above 200 °C. Full article
(This article belongs to the Special Issue Epoxy Resins and Epoxy-Based Composites: Research and Development)
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33 pages, 5634 KB  
Article
Electrical Curing of Metakaolin- and GBFS-Based Geopolymers: A Sustainable Technology Aligned with the European Green Deal
by Yusuf Gokcegoz, Mucteba Uysal, Orhan Canpolat, Oktay Arikan, Hasan Dilbas and Beyza Aygun
Materials 2025, 18(20), 4811; https://doi.org/10.3390/ma18204811 - 21 Oct 2025
Viewed by 275
Abstract
On-site curing of metakaolin (MK)- and granulated blast furnace slag (GBFS)-based geopolymer mortars remains a major bottleneck compared to thermal treatment for early strength development, and electrical curing is proposed here as a highly scalable and energy-efficient alternative technology. Geopolymer mortars with 0–100% [...] Read more.
On-site curing of metakaolin (MK)- and granulated blast furnace slag (GBFS)-based geopolymer mortars remains a major bottleneck compared to thermal treatment for early strength development, and electrical curing is proposed here as a highly scalable and energy-efficient alternative technology. Geopolymer mortars with 0–100% MK/GBFS binder ratios were activated using sodium silicate (SS) and sodium hydroxide (SH) solutions of the following molarities: 6, 8, 10, 12, and 14 M. Steel fiber (SF), carbon fiber (CF), waste erosion wire (EW), and carbon black (CB) microfiller were incorporated to enhance the electro-conductive efficiency of the geopolymer matrix. Specimens were subjected to electrical curing under 10 V and 20 V AC and were compared with benchmarking under ambient conditions of 23 °C and thermal conditions of 70 °C. The findings established that the incorporation of fibers substantially boosted the level of conductivity and mechanical performance, with 28-day compressive strengths of up to 88.30 MPa (0.50% EW, 20 V) and flexural strengths of up to 22.24 MPa (0.50% CF, 7 days), exceeding the results of conventional curing in various instances. Microstructural studies based on well-bonded geopolymer gels with fibers indicated uniform geopolymerization through electrical curing without deleterious fiber–matrix interactions. A multi-criteria decision support approach (the HD method) based on 273 parameters established 0.50% CF, 0.75% SF, 0.75% EW, and 1.00% CB as the group-wise optima and chose 0.75% EW as the single-best performing combination. The findings confirm that electrical curing is a low-carbon, cost-effective, and field-adjustable curing technology with the potential to achieve target strength ratings, in line with the European Green Deal’s climate-neutral building material goals. Full article
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19 pages, 4576 KB  
Article
Study on Engineering Geopolymer Composites (EGCs) Under Sustained Thermal Environment: Linking Strain-Hardening Characteristics, Static/Impact Load Mechanical Properties, and Evolution Mechanism
by Shuo Wang, Wei Wang, Haoxing Liu, Ao Huang and Hongqiang Ma
Buildings 2025, 15(20), 3792; https://doi.org/10.3390/buildings15203792 - 21 Oct 2025
Viewed by 322
Abstract
This study focuses on the performance evolution of Engineering Geopolymer Composites (EGCs) in long-term thermal environments, investigating the mechanical properties and microstructural evolution of alkali-activated fly ash–slag composites under sustained 60 °C thermal conditions. The research results indicate that sustained exposure to 60 [...] Read more.
This study focuses on the performance evolution of Engineering Geopolymer Composites (EGCs) in long-term thermal environments, investigating the mechanical properties and microstructural evolution of alkali-activated fly ash–slag composites under sustained 60 °C thermal conditions. The research results indicate that sustained exposure to 60 °C significantly enhances the static and impact loading compressive strength of EGCs; however, single-slag or high-alkalinity systems exhibit strength retrogression due to insufficient long-term thermal stability. After exposure to elevated temperatures, the tensile strain-hardening curve of EGCs becomes smoother, with a reduced number of cracks but increased crack width, leading to a transition from a distributed multicrack propagation pattern to rapid widening of primary cracks. Due to the bridging effect of PVA fibers, sustained elevated temperature significantly enhances the peak impact load stress of the S50-6 sample. Microscopic analysis attributes this improvement to the matrix-strengthening effect caused by accelerated C-(A)-S-H gel polymerization and refined pore structure under continuous heat, as well as the energy dissipation role of the fiber system. The study recommends an optimal EGC system formulation with a fly ash–slag mass ratio of 1:1 and a Na2O concentration of 4–6%. This research provides a theoretical foundation for understanding the performance evolution and strength stability of EGC materials under sustained elevated temperature. Full article
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19 pages, 4177 KB  
Article
Macroscopic Mechanical Properties and Mesoscopic Structure Evolution of Steel Slag–MSWIBA-Improved Soil Mixture
by Guosheng Xiang, Feiyang Shao, Hongri Zhang, Yunze Bai and Youjun Li
Appl. Sci. 2025, 15(20), 11033; https://doi.org/10.3390/app152011033 - 14 Oct 2025
Viewed by 231
Abstract
Taking municipal solid waste incineration bottom ash (MSWIBA) and natural soil as raw materials, this study incorporated steel slag to prepare MSWIBA mixed soil for pavement base courses. The modified soil was subjected to a 7-day unconfined compressive strength (UCS) test, California Bearing [...] Read more.
Taking municipal solid waste incineration bottom ash (MSWIBA) and natural soil as raw materials, this study incorporated steel slag to prepare MSWIBA mixed soil for pavement base courses. The modified soil was subjected to a 7-day unconfined compressive strength (UCS) test, California Bearing Ratio (CBR) test, water stability test, and freeze–thaw cycle test. The results demonstrate that the incorporation of steel slag and MSWIBA greatly boosts the modified soil’s performance. The 7-day UCS and CBR first increase and then decrease with the increase in steel slag content and MSWIBA proportion. Based on this, the optimal mix ratio of MSWIBA mixed soil was determined as 50% MSWIBA + 50% natural soil (mass ratio) with an additional 15% steel slag (relative to the total mass of MSWIBA and soil). Under this optimal ratio, the 7-day UCS of the mixed soil reaches 0.82 MPa, the 5-day water stability coefficient is 0.91, and the strength retention rate after 11 freeze–thaw cycles is 65.3%, all meeting the technical requirements for pavement base course materials. A freeze–thaw resistance study based on the optimal ratio revealed that the sample with the optimal mix ratio exhibits better freeze–thaw resistance than other ratios; its strength first decreases and then tends to stabilize with increasing freeze–thaw cycles. It was found through XRD and SEM experiments that the incorporation of steel slag promoted the progress of the hydration reaction and generated gelation products. The stacking and friction between MSWIBA and soil particles enhance the structural stability. Meanwhile, in the alkaline environment produced by the hydration of steel slag, MSWIBA further promotes hydration, increasing the total amount of cementitious substances. The C-S-H and other gels generated by hydration fill the pores, resulting in fewer cracks between the matrices and a denser matrix. It should be noted that this study focuses on short-term performance and microscopic mechanisms, and discussions on long-term heavy metal leaching behavior remain hypothetical—long-term leaching experiments have not been conducted, and the long-term environmental safety of the mixture still needs to be verified by subsequent experimental data. Full article
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17 pages, 1782 KB  
Article
Mechanical and Environmental Properties of Cemented Paste Backfill Prepared with Bayer Red Mud as an Alkali-Activator Substitute
by Lihui Gao, Haicheng Zhao, Nan Guo, Xinmeng Jiang and Yijing Zhang
Materials 2025, 18(20), 4712; https://doi.org/10.3390/ma18204712 - 14 Oct 2025
Viewed by 396
Abstract
This study developed a sustainable high-strength coal gangue backfill material for underground mining applications using coal gangue, fly ash, and cement as primary raw materials, with red mud (RM) as an alternative alkali activator. The mechanical properties of the backfill material were systematically [...] Read more.
This study developed a sustainable high-strength coal gangue backfill material for underground mining applications using coal gangue, fly ash, and cement as primary raw materials, with red mud (RM) as an alternative alkali activator. The mechanical properties of the backfill material were systematically optimized by adjusting coal gangue particle size and alkali activator dosage. The optimized formulation (coal gangue/fly ash/cement = 5:4:1, 3–6 mm coal gangue particle size, 5% RM, which named BF-6-5RM) achieved superior compressive strengths of 8.23 MPa (7 days) and 10.5 MPa (28 days), significantly exceeding conventional backfill requirements and outperforming a CaO-activated reference system (coal gangue/fly ash/cement = 5:4:1, 3–6 mm coal gangue particle size, 2% CaO, which named BF-6-2CaO). Microstructural and physicochemical analyses revealed that both formulations produced calcium silicate hydrate gels (C-S-H gels) and ettringite (AFt) as key hydration products, though BF-6-5RM exhibited a denser microstructure with well-developed ettringite networks and no detectable portlandite (CH), explaining its enhanced early-age strength. Environmental assessments confirmed effective heavy metal immobilization via encapsulation, adsorption, precipitation and substitution, except for arsenic (As), which exceeded Class III groundwater thresholds (DZ/T 0290-2015) due to elevated raw material content, displaying “surface wash-off, diffusion and depletion” leaching behavior. The findings confirm that red mud-based alkali activation is a viable technology for underground backfilling, provided it is coupled with arsenic control strategies like chemical stabilization or the selection of low-arsenic raw materials. This approach not only enables the resource utilization of hazardous industrial waste but also facilitates the production of backfill materials that combine both mechanical strength and environmental compatibility, thereby delivering dual economic and ecological benefits for sustainable mining practices. Full article
(This article belongs to the Section Construction and Building Materials)
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20 pages, 8359 KB  
Article
Unveiling Synergistic Hydration in a Multi-Waste Binder: Co-Processing Electrolytic Manganese Residue and Red Mud with Steel Slag for Enhanced Performance
by Yingchun Sun, Xinglan Cui, Xiaobin Gu, Xinyue Shi, Hongxia Li and Lei Wang
Materials 2025, 18(20), 4711; https://doi.org/10.3390/ma18204711 - 14 Oct 2025
Viewed by 399
Abstract
In response to the pressing environmental challenges posed by electrolytic manganese residue (EMR) and red mud (RM), this study proposes an innovative cementitious material technology for the synergistic co-utilization of these industrial wastes. By employing steel slag (SS) as a calcium-rich skeleton, the [...] Read more.
In response to the pressing environmental challenges posed by electrolytic manganese residue (EMR) and red mud (RM), this study proposes an innovative cementitious material technology for the synergistic co-utilization of these industrial wastes. By employing steel slag (SS) as a calcium-rich skeleton, the system effectively immobilizes sulfates from EMR and alkalinity from RM, converting hazardous wastes into value-added construction materials. Through orthogonal experimentation, an optimal mix proportion was established—30% RM, 20% EMR, and 50% SS at a water-to-binder ratio of 0.28—which achieved a 28-day compressive strength of 20.40 MPa, meeting relevant industry standards for auxiliary cementitious materials. Microstructural analysis unveiled a multi-stage alkali-sulfate synergistic activation mechanism: (1) the high alkalinity derived from RM rapidly activates the dissolution of aluminosilicate phases in both SS and EMR; (2) sulfate ions released from EMR promote extensive formation of ettringite (AFt), enhancing early-age structural integrity; and (3) calcium ions from SS facilitate the development of a dense C-S-H gel matrix, which serves as the primary binding phase. More profoundly, this process exemplifies a self-stabilizing waste-to-resource conversion mechanism, whereby harmful constituents (sulfates and free alkalis) are constructively incorporated into stable hydration products. This work not only elucidates a coherent scientific framework for the safe and efficient reclamation of multi-source solid wastes, but also demonstrates a scalable and ecologically viable pathway for million-ton-scale valorization of EMR and RM. Furthermore, it presents feasibility insights for the application of high-dosage steel slag-based material systems, thereby unifying significant environmental and economic advantages. Full article
(This article belongs to the Section Construction and Building Materials)
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19 pages, 3824 KB  
Article
Effects of Incorporating Iron-Rich Slag on the Performance of Calcium Sulfoaluminate Cement: Strength Development, Hydration Mechanisms and Microstructure
by Rong Wang, Haixing Liu, Xiaohua Yang, Chao Peng, Taibing Wei and Huawei Li
Buildings 2025, 15(20), 3654; https://doi.org/10.3390/buildings15203654 - 11 Oct 2025
Viewed by 317
Abstract
Using solid waste from the non-ferrous metal industry as non-traditional supplementary cementitious material has attracted increasing attention. In this study, iron-rich slag (IRS) was incorporated into calcium sulfoaluminate cement (CSC) to improve its properties, and its strength development and hydration mechanism were systematically [...] Read more.
Using solid waste from the non-ferrous metal industry as non-traditional supplementary cementitious material has attracted increasing attention. In this study, iron-rich slag (IRS) was incorporated into calcium sulfoaluminate cement (CSC) to improve its properties, and its strength development and hydration mechanism were systematically evaluated. Three types of IRS with distinct particle size characteristics were fabricated through mechanical grinding, and their effects on the strength development and hydration heat evolution of CSC-based materials were investigated. Furthermore, several solid-phase analysis methods were employed to characterize the hydration mechanisms and microstructural characteristics of IRS-containing CSC-based materials. The results show that mechanical grinding enhances the reactivity of IRS in CSC-based systems, which in turn facilitates the generation of hydrates like ettringite (AFt), AH3, and C–S–H gel, thereby improving their strength. The incorporation of IRS effectively decreases the total hydration heat released by CSC-based materials within 24 h. Furthermore, evidence from EDS analysis suggests the possible isomorphic substitution of Al3+ by Fe3+ in AFt, which, along with the slower reaction kinetics of Fe-AFt, may contribute to the improved late-age strength development of CSC-based materials. This study proposes a sustainable strategy for producing high-performance CSC-based materials and offers a potential approach for the high-value use of non-ferrous metal industry solid waste in construction materials, thereby demonstrating both scientific value and practical engineering significance. Full article
(This article belongs to the Section Building Materials, and Repair & Renovation)
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Article
Temperature-Dependent Effects of Hydroxyethyl Methyl Cellulose on Rheological Properties and Microstructural Evolution of Robotic Plastering Mortars
by Guangjie Ling, Hongbin Yang and Sifeng Liu
Materials 2025, 18(20), 4664; https://doi.org/10.3390/ma18204664 - 10 Oct 2025
Viewed by 394
Abstract
Temperature-induced instability in early-age rheology poses a major challenge to the pumpability and application of robotic plastering mortars. This study systematically investigates the temperature-dependent effects of a high-viscosity (75,000 mPa·s) hydroxyethyl methyl cellulose (HEMC) on the rheological properties and early microstructural evolution of [...] Read more.
Temperature-induced instability in early-age rheology poses a major challenge to the pumpability and application of robotic plastering mortars. This study systematically investigates the temperature-dependent effects of a high-viscosity (75,000 mPa·s) hydroxyethyl methyl cellulose (HEMC) on the rheological properties and early microstructural evolution of mortars at 5 °C, 20 °C, and 40 °C. Mortars with HEMC dosages from 0 to 0.25 wt% were tested using rheological measurements, ultrasonic pulse velocity (UPV), and complementary microstructural analyses (XRD, FTIR, and SEM–EDS). Results show that HEMC reduced the initial static yield stress while monotonically increasing plastic viscosity, with the thickening effect more pronounced at higher temperatures. Notably, at 40 °C, the initial plastic viscosity of a 0.25% HEMC mix reached 14.4 Pa·s, a 133% increase compared to the control group. HEMC also effectively retarded the time-dependent increase in yield stress and stabilized plastic viscosity, thereby mitigating the adverse influence of elevated temperature. UPV confirmed that HEMC delayed microstructural formation, in agreement with the observed retardation of hydration reactions. At 40 °C, a 0.10% HEMC dosage postponed the percolation threshold from 67 min to 150 min, highlighting its strong retardation effect. Microstructural tests further revealed that HEMC delayed CH formation, refined C–S–H gels, and reduced the crystallinity of AFt, supporting the rheological and ultrasonic findings. A statistically significant, moderate-to-strong correlation (r = 0.88, R2 = 0.77, p < 0.001) was established between static yield stress and UPV, indicating that macroscopic rheological resistance responds to microstructural evolution. Based on these results, the recommended HEMC dosages to achieve stable rheological performance are 0.05–0.10% at 5 °C, 0.10–0.15% at 20 °C, and 0.15–0.20% at 40 °C. Full article
(This article belongs to the Special Issue Eco-Friendly Materials for Sustainable Buildings)
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