Search Results (1,061)

The construction sector faces the dual challenge of reducing energy consumption and mitigating the environmental burden of construction and demolition waste (CDW). Geopolymers offer a low-carbon alternative to Portland cement, yet their performance depends strongly on precursor composition. This study presents an extensive investigation of precursor chemistry, mechanical performance and phase composition, focusing on the partial substitution of ground granulated blast furnace slag (GGBFS) with mechanically activated CDW powder (15% and 30% by weight) alongside fly ash (FA). The oxide composition, amorphous content and particle size distribution were analyzed, using XRF, XRD and laser diffraction to evaluate the reactivity. Mortar samples were subsequently synthesized and tested for compressive and flexural strength, ultrasonic pulse velocity, density and porosity. The results demonstrate that while mechanically activated CDW incorporation decreases early strength compared with GGBFS-rich systems, compressive strengths above 45 MPa were attained at 28 days, with continuous improvement to >69 MPa for aged composites. The relationship between precursor chemistry, precursor sizes and mechanical performance highlights the feasibility of CDW valorization in geopolymer binders, contributing to energy efficiency, circular economy strategies and sustainable construction materials. Full article

Spent garnet (SG) wastes are generated in significant quantities by several industrial activities, including abrasive waterjet cutting (AWJ), abrasive blasting, and filtration and powdered media applications. These wastes represent a promising secondary raw material for the production of sustainable construction materials, particularly green mortars and concretes, through their partial replacement of natural sand in cementitious systems. Such applications are relevant to both hydraulically setting inorganic binders (cement-based materials) and alkali-activated cementitious materials (AACMs). The valorization of SG wastes offers multiple benefits, notably a dual environmental advantage: reducing the consumption of natural aggregates and diverting industrial waste from disposal by integrating it into a new life cycle as a value-added by-product. Additional potential advantages include reduced production costs and possible improvements in the overall performance of mortars and concretes. Despite these benefits, the use of SG as an aggregate replacement remains insufficiently explored, with existing studies providing only preliminary and fragmented evidence of its feasibility. This paper presents an overview of a comprehensive four-year research program investigating SG wastes derived from single-cycle AWJ processes and their incorporation into conventional mortars as partial fine aggregate replacement in cement-based construction composites. The validation stage of the performance assessment expands the range of SG sources by including new sampling from the original suppliers, enabling verification of the repeatability and reproducibility of earlier findings. A broad set of physical, mechanical, and durability properties—particularly resistance to freeze–thaw cycles—is evaluated to achieve a robust and comprehensive material characterization. These results are further correlated with chemical and microstructural analyses, providing critical insights to support the technological transfer of SG-based construction materials to industrial applications with reduced carbon footprint. Full article

The recycling of ultralight foam concrete (ULFC), both with and without phase-change material (PCM), involves crushing it and using the resulting recycled foam concrete powder (RFCP) as a partial substitute for cement or sand in cement composites. These recycling paths remain insufficiently explored in the literature regarding practical feasibility. Since both RFCP and PCM reduce the flowability of fresh mortars, incorporating RFCP with PCM is, in practice, only feasible with the addition of a superplasticizer (SP). The primary objectives of this study were to determine: (1) the effect of RFCP with PCM, when used to replace cement or sand, on mortar properties, and (2) its influence on the performance of the superplasticizer (SP), to assess the feasibility of using RFCP with PCM in cement composites. The addition of RFCP, both without PCM (RFCP_0) and with PCM (RFCP_PCM), deteriorates the properties of fresh and hardened mortars compared to reference mortars. The negative impact of RFCP is less pronounced when it replaces sand rather than cement. Compared to RFCP_0 mortars, RFCP_PCM mortars exhibit reduced flowability. PCM delays setting and reduces heat evolution during the first 48 h of hardening. PCM does not significantly affect strength or water absorption but increases shrinkage and lowers thermal conductivity. While RFCP_PCM does not impair SP efficiency, PCM causes SP to significantly retard setting and hardening. Full article

As a potential strategic resource of critical metals, deep-sea cobalt-rich crusts represent one of the most promising metal reservoirs within oceanic seamount systems, and their metallogenic mechanism constitutes a frontier topic in deep-sea geoscience research. This review focuses on the cobalt-rich crusts from the Magellan Seamount region in the northwestern Pacific and synthesizes existing geological, mineralogical, and geochemical studies to systematically elucidate their mineralization processes and metal enrichment mechanisms from a microstructural perspective, with particular emphasis on cobalt enrichment and its controlling factors. Based on published observations and experimental evidence, the formation of cobalt-rich crusts is divided into three stages: (1) Mn/Fe colloid formation—At the chemical interface between oxygen-rich bottom water and the oxygen minimum zone (OMZ), Mn²⁺ and Fe²⁺ are oxidized to form hydrated oxide colloids such as δ-MnO₂ and Fe(OH)₃. (2) Key metal adsorption—Colloidal particles adsorb metal ions such as Co²⁺, Ni²⁺, and Cu²⁺ through surface complexation and oxidation–substitution reactions, among which Co²⁺ is further oxidized to Co³⁺ and stably incorporated into MnO₆ octahedral vacancies. (3) Colloid deposition and mineralization—Mn–Fe colloids aggregate, dehydrate, and cement on the exposed seamount bedrock surface to form layered cobalt-rich crusts. This process is dominated by the Fe/Mn redox cycle, representing a continuous evolution from colloidal reactions to solid-phase mineral formation. Biological processes play a crucial catalytic role in the microstructural evolution of the crusts. Mn-oxidizing bacteria and extracellular polymeric substances (EPS) accelerate Mn oxidation, regulate mineral-oriented growth, and enhance particle cementation, thereby significantly improving the oxidation and adsorption efficiency of metal ions. Tectonic and paleoceanographic evolution, seamount topography, and the circulation of Antarctic Bottom Water jointly control the metallogenic environment and metal sources, while crystal defects, redox gradients, and biological activity collectively drive metal enrichment. This review establishes a conceptual framework of a multi-level metallogenic model linking macroscopic oceanic circulation and geological evolution with microscopic chemical and biological processes, providing a theoretical basis for the exploration, prediction, and sustainable development of potential cobalt-rich crust deposits. Full article

Red mud (RM), an industrial byproduct generated during bauxite refining, has accumulated to more than 5 billion tons worldwide, posing serious environmental challenges. In response, substantial research over recent decades has focused on the sustainable utilization of RM, particularly in the field of construction materials. This review first summarizes the generation process and chemical composition of RM, and then systematically examines its potential applications in the production of artificial aggregates, partial replacement of cementitious materials, and synthesis of geopolymers. Existing studies demonstrate that RM exhibits considerable potential in construction applications: when used as an aggregate, it can reduce concrete porosity, enhance compressive strength, and improve overall mechanical performance. Moreover, RM can partially substitute cement or serve as a geopolymer precursor, contributing to the immobilization of toxic elements such as Pb and Cr while simultaneously improving the mechanical properties of both cementitious systems and geopolymers. The reactivity and performance of RM-based materials can be further enhanced through carbonation curing and other modification techniques. Finally, this review highlights the significant sustainability and economic benefits of RM-based concrete, supported by life-cycle assessment and cost–benefit analyses. Full article

Biochar, a carbon-rich material produced through the pyrolysis of wood residues and agricultural byproducts, has carbon storage capacity and potential as a low-carbon construction material. This study predicts the compressive strength of cementitious composites in which cement is partially replaced with biochar using machine learning models. A total of 716 data samples were analyzed, including 480 experimental measurements and 236 literature-derived values. Input variables included the water-to-cement ratio (W/C), biochar content, cement, sand, aggregate, silica fume, blast furnace slag, superplasticizer, and curing conditions. Predictive performance was evaluated using Multiple Linear Regression (MLR), Elastic Net Regression (ENR), Support Vector Regression (SVR), and Gradient Boosting Machine (GBM), with GBM showing the highest accuracy. Further optimization was conducted using XGBoost, Light Gradient-Boosting Machine (LightGBM), CatBoost, and NGBoost with GridSearchCV and Optuna. LightGBM achieved the best predictive performance (mean absolute error (MAE) = 3.3258, root mean squared error (RMSE) = 4.6673, mean absolute percentage error (MAPE) = 11.19%, and R² = 0.8271). SHAP analysis identified the W/C and cement content as dominant predictors, with fresh water curing and blast furnace slag also exerting strong influence. These results support the potential of biochar as a partial cement replacement in low-carbon construction material. Full article

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

Alkali-activated materials (AAMs) or geopolymers have been considered for many years as a sustainable substitution for the traditional ordinary Portland cement (OPC) binder. However, their production needs energy consumption and creates carbon emissions. Since construction and demolition waste (CDW) can become precursors for manufacturing alkali-activated materials, their use as substitutes for traditional AAM (such as metakaolin, blast furnace slag, and fly ash) can solve both the problem of their disposal and the problem of sustainability. Furthermore, CDW can also be used as aggregate replacement, avoiding the exploitation of natural river sand and gravel. A new circular economy could be created based on CDW recycling, creating a new eco-friendly building practice. Unfortunately, this process is quite difficult owing to several variables that should be taken into consideration, such as the possibility of separating and sorting the CDW, the great variability of CDW composition, the cost of the mechanical and thermal treatment, the different parameters that compose an alkali-activated mix-design, and public opinion still being skeptical about the use of recycled materials in the construction sector. This review tries to describe all these aspects, summarizing the results of the most interesting studies performed on this subject. Today, thanks to a comprehensive protocol, the use of building information modeling (BIM) software and machine learning models, a large-scale reuse of CDW in the building industry appears more feasible. Full article

Coal gangue, as a predominant solid byproduct of the global coal industry, poses severe environmental challenges because of its massive accumulation and low utilization rate. This review systematically synthesizes and analyzes published experimental and analytical studies on the dual-pathway utilization of coal gangue in concrete, including Pathway 1 (aggregate substitution) and Pathway 2 (cementitious activity activation). While the application of coal gangue aggregates is traditionally limited by their inherent high porosity and lower mechanical strength than those of natural aggregates, this review demonstrates that performance barriers can be effectively overcome. Through multiscale modification strategies—including surface densification, biological mineralization (MICP), and matrix synergy—the interfacial defects are significantly mitigated, allowing for feasible substitution in structural concrete. Conversely, for the mineral admixture pathway, controlled thermal activation is identified as a key process to optimize the phase transformation of kaolinite, thereby significantly enhancing pozzolanic reactivity and long-term durability. According to reported studies, the partial replacement of natural aggregates or cement with coal gangue can reduce CO₂ emissions by approximately tens to several hundreds of kilograms per ton of coal gangue utilized, depending on the substitution level and activation strategy, highlighting its considerable potential for carbon reduction in the construction sector. Nevertheless, challenges related to energy-intensive activation processes and variability in raw gangue composition remain. These limitations indicate the need for future research focusing on low-carbon activation technologies, standardized classification of coal gangue resources, and long-term performance validation under realistic service environments. Based on the synthesized literature, this review discusses hierarchical utilization concepts and low-carbon activation approaches as promising directions for promoting the sustainable transformation of coal gangue from an environmental liability into a carbon-reduction asset in the construction industry. Full article

Portland cement (PC) is widely regarded as a cost-effective and reliable binding material for the stabilization and solidification of municipal solid waste incineration fly ash (MSWI FA). However, the soluble salts and heavy metals present in MSWI FA retard PC hydration, thereby limiting the amount of fly ash that can be incorporated. The present study investigates the feasibility of normalizing the hydration of PC-based mixtures containing MSWI FA by applying a fly ash pre-granulation step with 25% PC, followed by coating the resulting granules with a geopolymer layer to reduce the release of harmful ions during the early stages of hydration. Isothermal calorimetry, TG/DTA, XRD, SEM, and mechanical testing were used to investigate the hydration characteristics of composites containing such granules and to assess their properties at 7, 28, and 90 days. It was found that a 20% substitution of PC with the studied FA disrupted PC hydration within the first 48 h. In contrast, both types of granules exhibited the main exothermic peak within the first 10–12 h, with hydration heat release (about 300 J/g) comparable to that of sand-containing references. Uncoated granules exhibited more active behavior with hydration kinetics similar to pure cement paste, whereas the effect of geopolymer-coated granules was close to sand. TG/DTA revealed reduced calcite content in mixtures containing granules, whereas uncoated granules promoted greater portlandite formation than the sand-based system. Hardening the samples under wet conditions resulted in the development of a dense cement matrix, firm integration of the granules, redistribution of chlorine and sulfur ions, and mechanical properties that reached at least 93% of those of the sand-containing reference, despite a lower density of ~4.5%. Full article

The advancement of reactive powder concrete (RPC) technology primarily focuses on modifications to its conventional composition. This involves substituting Portland cement (CEM I) with alternative cement types and finely ground mineral additives, as well as replacing quartz aggregate with another type of aggregate. The paper presents an analysis of the properties of RPC obtaining using waste sand and powder generated during the processing of aggregates from migmatite-amphibolite rock. Research into RPC mixtures revealed that in one scenario, replacing quartz powder with waste powder resulted in a significant increase in flexural strength by 23%, although there was a slight decrease in compressive strength by 7%. However, when both quartz powder and quartz sand were substituted with waste powder and waste sand, there was a 14% reduction in compressive strength, while flexural strength increased, albeit to a much lesser extent. The analysis of mineral composition and microstructure of migmatite-amphibolite waste powder and sand revealed that the primary factor contributing to the increase in flexural strength is the presence of biotite in a flake shape form. The microscopy images clearly show hydration products gathering mainly at the rims of biotite flakes and not on their smooth surfaces. The reason could be better availability for hydration products attachment and lower steric hindrance to the rims of single biotite flakes instead of its large packets. Conversely, the reduction in RPC compressive strength, resulting from the substitution of quartz sand with migmatite-amphibolite waste sand, can be attributed mainly to the lower compressive strength of the waste sand itself. Test results indicate that the waste powder generated during the production of migmatite-amphibolite aggregates, which contains fine flakes of biotite, can be utilised as a mineral admixture in concrete, thereby enhancing its flexural strength. Full article

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

The construction sector faces pressure to decarbonise while addressing rising resource demands and agricultural waste. Ordinary Portland cement (OPC) is a major CO₂ emitter, yet biomass residues are often open-burned or landfilled. This study explores corncob ash (CCA) as a sustainable supplementary cementitious material (SCM), examining how calcination conditions influence pozzolanic potential and support circular economy and climate goals, which have not been adequately explored in literature. Ten CCA samples were produced via open-air burning (2–3.5 h) and electric-furnace calcination (400–1000 °C, 2 h), alongside a reference OPC. Mass yield, colour, XRD, XRF, LOI, and LOD were analysed within a process–structure–property–performance–sustainability framework. CCA produced in a 400–700 °C furnace window consistently achieved high amorphous contents (typically ≥80%) and combined pozzolanic oxides (SiO₂ + Al₂O₃ + Fe₂O₃) above the 70% ASTM C618 threshold, with 700 °C for 2 h emerging as an optimal condition. At 1000 °C, extensive crystallisation reduced the expected reactivity despite high total silica. Extended open-air burning (3–3.5 h) yielded chemically acceptable but more variable ashes, with lower amorphous content and higher alkalis than furnace-processed CCA. Simple industrial ecology calculations indicate that valorising a fraction of global CC residues and deploying optimally processed CCA at only 20% OPC replacement could displace 180 million tonnes CC waste and clinker avoidance on the order of 5–6 Mt CO₂ per year, while reducing uncontrolled residue burning and primary raw material extraction. The study provides an experimentally validated calcination window and quality indicators for producing reactive CCA, alongside a clear link from laboratory processing to clinker substitution, circular resource use, and alignment with SDGs 9, 12, and 13. The findings establish a materials science foundation for standardised CCA production protocols and future life cycle and performance evaluations of low-carbon CCA binders. Full article

The aim of this study is to investigate the potential use of rapidly increasing agricultural wastes in concrete production by substituting them for cement, thereby reducing their environmental impact and producing eco-friendly concrete. For this purpose, concrete samples were produced using a combination of almond shell biomass (ASB) and silica fume (SF). These samples were subjected to standard compressive strength tests as well as ultrasonic pulse velocity (UPV), porosity (P), and maturity (M) tests. In addition, the microstructure of the samples containing ASB and SF was examined using scanning electron microscopy (SEM). The test results show that the combined use of ASB and SF in concrete production significantly improves the strength properties, and the best results were obtained from the ASB6SF10 series. A significant increase of 37.7% was observed in the compressive strength values of the ASB6SF10 series from the early age between 3 and 28 days. UPV and P values were obtained as 4.46 m/s and 10%, respectively. The use of ASB and SF in concrete production has been found to be critically important in terms of the mechanical and physical properties of concrete and environmental benefits. The results of the study show that ASB and SF have potential for use in concrete production and can contribute to more sustainable concrete production, waste management, and the circular economy by reducing the negative environmental impacts arising from this production. Full article

This study investigated the effects of waste steel fiber and high-volume blast furnace slag (BFS) substitution on the mechanical and physical properties of three-dimensional printable concrete (3DPC) to improve its environmental performance. BFS was substituted for cement at 0%, 25%, 50%, and 75% by volume. Waste steel fibers were added to the mixtures at three lengths (5, 10, and 15 mm) and two volumetric ratios (0.5% and 1.0%). Twenty-eight mixtures were optimized based on extrudability, buildability, and shape stability criteria. Parameters such as compressive and flexural strength, surface moisture content, and drying shrinkage were evaluated. The results showed that using up to 0.5% waste steel fibers increased compressive strength by up to 23%, but decreased it to a level of 1%. Fiber reinforcement improved the flexural strength of all blends by up to 53% at both ages, regardless of fiber ratio or length. Increasing the BFS substitution rate generally increased surface moisture however, this value decreased in mixtures containing 75% BFS and silica fume. Furthermore, using steel fibers and in-creasing fiber length significantly improved the drying shrinkage performance of the mixtures. Full article