Search Results (480)

This study comprehensively evaluates the mechanical properties, shrinkage behavior, and durability of concrete prepared with limestone- and granite-manufactured sands under standard-curing and steam-curing conditions. The results indicate that limestone-manufactured sand concrete consistently exhibits superior compressive strength and splitting tensile strength across all curing ages, outperforming granite-modified counterparts. The introduction of granite-manufactured sand significantly degrades these mechanical properties, with deterioration intensifying as granite content increases. Dynamic elastic modulus and damping ratio analyses reveal that limestone-based concrete maintains the highest dynamic stiffness and lowest energy dissipation under both curing regimes, suggesting fewer internal defects. In contrast, granite incorporation reduces the dynamic elastic modulus and increases the damping ratio, reflecting structural deterioration and enhanced energy loss. Drying shrinkage tests demonstrate that limestone concrete achieves the lowest shrinkage deformation throughout the testing period, even under steam-curing conditions. Conversely, granite addition markedly elevates shrinkage, particularly under steam-curing conditions, leading to compromised volumetric stability. Durability assessments highlight that manufactured sand concrete exhibits higher capillary absorption, electrical flux, and porosity, attributed to inherent material defects and the surface characteristics of manufactured sand. Granite-modified concrete further weakens interfacial shear strength between aggregates and cement paste, indicating poor interfacial bonding. Steam curing exacerbates microstructural defects, emphasizing the need to optimize curing protocols. The findings propose strategies for enhancing manufactured sand concrete performance: improving interfacial adhesion between aggregates and cement paste, rationalizing supplementary material dosages, and refining steam curing regimes. These measures offer potential pathways to develop high-performance manufactured sand concrete with balanced mechanical and durability properties. Full article

The cement industry is a major contributor to global carbon emissions. Therefore, reducing emissions while utilizing industrial wastes is critical for its sustainable development. Red mud, a solid waste byproduct of alumina smelting with main components like SiO₂, Al₂O₃, and CaO, can partially replace limestone as a raw material in cement production. TG-DSC thermal analysis clarified red mud’s three-stage weight loss characteristic during calcination (total weight loss rate of 22.11%), and orthogonal experiments identified calcination temperature as the core factor for its CaO content, with the optimal calcination pretreatment process confirmed (0.075–0.09 mm particle size, 1373 K, 1 h residence time, CaO content up to 21.1%). Based on the results, this study uses ANSYS Fluent 2021 R1 to simulate a TTF-type precalciner, establishing a validated multi-physical field model (all relative errors < 5%) to explore red mud blending ratios of 0%, 2.5%, 5%, 7.5% and 10%. Unlike previous experimental studies, this work uses a CFD model to quantify how red mud blending ratios affect the coupled thermo-chemical environment in a TTF precalciner, revealing a mechanism-driven trade-off among decomposition rate, CO₂, and NO_x that experiments alone cannot capture. Results show red mud slightly alters the internal temperature field and reduces the raw meal decomposition rate. The decomposition rate remains within the industrial acceptable range of 85–95% when the red mud blending ratio is no more than 5%, while further increasing the blending ratio to 7.5% and 10% causes the decomposition rate to drop below 85%. Therefore, a blending ratio of 5% is recommended, which balances waste utilization, decomposition rate, and emission reduction, providing solid technical support for red mud’s large-scale use in cement production. Full article

This work investigates Ferro-Rock concrete as a carbon-negative alternative to ordinary Portland cement (OPC), which accounts for 5–9% of global CO₂ emissions, and evaluates its viability as a sustainable construction material. Ferro-Rock is an iron-based binder comprising recycled iron powder, fly ash, metakaolin, limestone powder, and oxalic acid. This is enhanced by a carbonation reaction in which iron particles react with CO₂ and water to form iron (II) carbonate (FeCO₃), the main binding phase, thereby locking in atmospheric CO₂. The experimental program was divided into two groups. Group 1 studied 100% Ferro-Rock binders with different types of aggregate, specimen sizes, and CO₂ curing periods (0–6 days) with a new locally manufactured stainless steel curing chamber that provided a controlled CO₂ environment of 99.9% and 1.2–1.5 bar gauge pressure. Group 2 investigated Ferro-Rock as a partial cement replacement at 0%, 5%, 10%, 15% and 20% levels of substitution with 5% increments. The 7 and 28 days of compressive, flexural and indirect tensile strengths were determined. The results showed the Ferro-Rock with 100% iron ductile waste aggregates (Mix F4) achieved a 28-day compressive strength of 5.5 MPa, 37.5% higher than the standard Ferro-Rock reference mix. The optimum replacement range of Group 2 was 5–10% with an increase in compressive strength by 5–10%, flexural strength by 11%, and indirect tensile strength by 16% over the OPC control. When replacement exceeded 25%, the bonding was weakened, and all strength measures decreased significantly, reaching a 46% reduction in compressive strength at 50% substitution. Scanning electron microscopy–energy-dispersive X-ray spectroscopy (SEM–EDS) microstructural analysis verified the gradual formation of the iron carbonate crystalline phase and provided mechanistic insights into the observed strength trends. Fully cured Ferro-Rock specimens sequestered as much as 11% CO₂ by weight, with a verifiably carbon-negative profile that no OPC-based system can match. Full article

Punching shear failure in reinforced concrete RC slabs is one of the most significant and detrimental failure modes due to its sudden nature and its dependence on a complex interaction between concrete strength, the reinforcement, and the loading conditions. In recent years, there has been increasing interest in utilizing sustainable cementitious materials and steel fibers as a way of enhancing structural performance and improving the durability of concrete. The study aims to assess the structural behavior of RC slabs utilizing a partial cement substitution with limestone powder (LP) and granulated blast-furnace slag (GBFS), with the addition of steel fibers. Twelve RC slabs were examined under uniform concentric loading to analyze cracking behavior, load–deflection relationship, stiffness variation, and ultimate punching shear strength. The results demonstrated that using limestone powder (LP) had a significant impact on the crack distribution pattern and resulted in a slight reduction in initial stiffness, with the load-bearing capacity decreasing to approximately 55.8% of the control mixture at high replacement ratios. Due to a slower hydraulic reaction than with other mixtures, increasing additional granulated blast-furnace slag resulted in a decrease in crack resistance and relative deformation. With a load-bearing capacity of approximately 92.9% of the control mixture, a tertiary mixture of limestone powder and granulated blast-furnace slag (GBFS) demonstrated a better balance in structural behavior, leading to improved crack control while maintaining a sufficient level of load-bearing capacity. The steel fibers also significantly contributed to enhanced post-cracking behavior by decreasing crack width and improving the stress redistribution mechanism within the RC slab. This led to increased punching shear resistance and enhanced energy absorption, with the ultimate load increased to 119 kN compared to the control mixture. Overall, the findings show that combining sustainable cementitious materials with steel fibers can effectively improve punching shear performance and enhance the efficiency and durability of reinforced concrete. Full article

This study evaluates the technical feasibility, environmental sustainability, and economic viability of producing sulfoaluminate cement (SW-SAC) by co-utilizing bauxite and industrial solid wastes—phosphogypsum, calcium carbide residue (CCR), and red mud—with the solid wastes accounting for approximately 75% of the raw meal. CCR replaces limestone as the primary CaO source, releasing H₂O instead of CO₂, while phosphogypsum supplies SO₃; the raw meal is directly calcined in a single step at 1300–1350 °C, 100–150 °C below that of ordinary Portland cement (OPC). Calcination temperature and holding time were optimized through phase analysis, microstructural observation, free lime (f-CaO) determination, and strength testing. SW-SAC meeting the 42.5 strength class was then prepared using phosphogypsum as a setting regulator and phosphorus slag or limestone powder as Supplementary materials. X-ray diffraction (XRD), thermogravimetry (TG), and scanning electron microscopy (SEM) were used to examine hydration products and microstructural evolution. The optimized clinker was dominated by ye’elimite (${\mathrm{C}}_4{\mathrm{A}}_3\overline{\mathrm{S}}$) and belite (C₂S). Phosphorus slag favored the formation of gel-like products at later ages, whereas limestone powder promoted ettringite (AFt) stabilization and monocarboaluminate (Mc) formation. SW-SAC exhibited a lower carbon footprint than both Type P·I Portland cement and conventional SAC, and a lower production cost than conventional SAC. These results demonstrate a promising low-carbon route for high-value utilization of industrial solid wastes. Full article

The construction of green mines is a core strategy for promoting ecological civilization in China’s mining sector, yet its long-term ecological effects require quantitative assessment. Using a cement-grade limestone mine operated by Linyi Zhonglian Cement Co., Ltd. in Shandong Province as an illustrative case, we employed Landsat 8 OLI/TIRS imagery acquired in 2015, 2020, and 2025 to develop a five-indicator framework for assessing ecological environment quality. The selected indicators comprised greenness (NDVI), wetness, dryness (NDBSI), land surface temperature (LST), and dust concentration (MECDI). These five indicators were subsequently integrated via principal component analysis to generate the Mine Ecological Quality Index (Mine-EQI). Using this index, we applied the Theil–Sen median slope estimator alongside zonal statistics to examine ecological change trajectories across the full study area and three functional zones—the industrial square, haul roads, and active mining area—over the 2015–2025 period. The ecological outcomes attributable to the green mine policy were then quantified. The results show that (1) the mean Mine-EQI of the study area decreased from 0.3713 in 2015 to 0.3460 in 2025, exhibiting a slight overall decline. However, the rate of decline decreased from −6.1% during 2015–2020 to −0.7% during 2020–2025, yielding a Temporal Change Intensity index (TCI) of +88.5%, indicating that the ecological degradation trend has been effectively curbed. (2) Significant spatial heterogeneity was observed. The industrial square showed substantial improvement (Theil–Sen slope = +0.0726), while the haul roads (slope = −0.0705) and mining area (slope = −0.0408) continued to exhibit degradation trends. The improved areas (9.7% of the study area) were spatially coincident with green mine engineering projects. (3) The dust indicator (MECDI) decreased by 24.7% during 2020–2025, and the vegetation index (NDVI) increased by 19.5% over the decade, representing the dominant contributors to ecological improvement. This study reveals that China’s green mine policy has yielded remarkable ecological improvements in relatively stable functional zones such as industrial squares. In contrast, ecological restoration within persistently disturbed areas, including haul roads and mining pits, demands long-term sustained investment and governance. By integrating remote sensing techniques with policy analysis, this research establishes a replicable framework for evaluating progress toward sustainable mining practices. The findings directly support the monitoring of SDG 12 (Responsible Consumption and Production) and SDG 15 (Life on Land), providing a quantitative pathway to balance mineral resource extraction with ecological protection—a core sustainability challenge for resource-dependent regions. Full article

Rapid urbanization has increased the demand for building materials, depleting natural resources used in cement production and prompting the use of alternative and waste materials. This research verifies that eggshell powder waste can fully replace limestone in clinker synthesis. Five clinkers were produced using eggshell powder, aluminum sources (bentonite, zeolite, fly ash, and kaolinitic–illitic clay), Fe-slag, and quartz sand, with mechanical preprocessing (10–30 min) before sintering at 1300 °C. Experimental tests assessed the effects of mix design and mechanical activation on clinkerization, phase formation, temperature, and mechanical properties. XRD, FTIR, and SEM/EDS confirmed consistent phase compositions and primary cement minerals. Aluminum source raw materials contributed significantly to tricalcium aluminate and tetracalcium aluminoferrite formation. Eggshell and fly ash promoted tricalcium silicate and dicalcium silicate synthesis, enhancing cement strength at early and late ages. Longer mechanical pretreatments hindered clinkerization. Eggshell-based cements untreated or pretreated for 10 min are suitable for structural concrete; 20–30 min pretreatment is appropriate for low-demand or non-structural applications. The proposed methodology reduces clinker manufacturing temperature by about 100 °C from the typical range of 1400–1450 °C while maintaining mechanical properties comparable to ordinary Portland cement. Full article

High water-content silty soft soils are widely distributed across coastal regions. Their low strength and high compressibility render them unsuitable for direct use as foundation or subgrade materials. While ordinary Portland cement is the most prevalent chemical stabilizer for ground improvement, its manufacturing process generates substantial CO₂ emissions, significantly exacerbating global climate change. While limestone calcined clay cement (LC³) has emerged as a promising low-carbon alternative in concrete engineering, its multicomponent hydration mechanisms and engineering applicability for geotechnical soft soil stabilization remain a critical knowledge gap. To address this, this study investigates the application of LC³ in ground improvement by systematically evaluating and comparing three novel LC³ blends formulated with distinct types of calcined clay. The mechanical properties of LC³-stabilized soft soil were investigated through unconfined compressive strength and direct shear tests. Furthermore, the underlying stabilization mechanisms and microstructural evolution were revealed using X-ray diffraction and supplementary microanalytical techniques. The results demonstrated that LC³ significantly enhanced the mechanical properties of soft soils by generating abundant C-S-H and C-A-S-H gels, which bound soil particles into a stable, interlocking network. Among the evaluate variants, the calcined kaolin-based cement (LC³-K) exhibited the highest pozzolanic activity, providing to be the optimal stabilizer. However, this stabilization effect was dosage dependent; while an appropriate LC³ application markedly improved soil strength, excessive dosage or elevated clinker proportions induced a highly alkaline environment. This led to charge over-neutralization and deflocculation, ultimately compromising the structural integrity and mechanical performance of the solidified soil. The findings of this study provide a solid theoretical foundation for the application of eco-friendly LC³ in soft soil stabilization, promoting the broader adoption of sustainable, low carbon geomaterials in geotechnical engineering. Full article

The cement industry has been seeking strategies to ensure the circularity of materials through the incorporation of solid waste into its processes, driven by the environmental challenges associated with cement production, such as high CO₂ emissions and resource consumption. In this context, marble residue (MR) has been investigated for application in cementitious materials, including as a partial cement substitute, which also mitigates MR deposition as an inert waste in landfills. Although its technical feasibility has shown promising results, environmental justification is still necessary to validate this technology. This research presents a Life Cycle Assessment (LCA) of MR as a substitute for limestone filler in ternary cement production, promoting circular economy principles. The environmental impacts of three formulations were compared: Ordinary Portland Cement (OPC), used as the reference; limestone calcined clay cement (LC³), composed of calcined clay and limestone filler; and LC³-R, which incorporates 15% MR in place of limestone filler. The cradle-to-gate LCA included raw material extraction through to cement production, using OpenLCA (v2.3) and the Ecoinvent database (v3.6). The impact categories analyzed included abiotic depletion (ADP), abiotic depletion of fossil fuels (ADP-ff), global warming potential (GWP 100a), ozone layer depletion (ODP), human toxicity potential (HTP), and acidification potential (AP). Results showed that LC³-R had the lowest environmental impacts, with reductions up to 39% compared to OPC and 11% compared to LC³. A sensitivity analysis was conducted for environmental and economic dimensions to assess the influence of MR transportation distances in the LC³-R context. The LC³-R formulation remained environmentally viable up to an additional 400 km compared to OPC, and up to 100 km compared to LC³, being also competitive in the economic dimension. The results highlight the benefits of incorporating marble residue into LC³ cement, contributing to environmental impact reduction and promoting resource efficiency within a circular economy approach. Full article

Thaumasite sulfate attack (TSA) under elevated water pressure has important implications for the durability of deep underground concrete structures, yet the deterioration process and the coupled effect of water pressure and carbonate supply remain insufficiently understood. In this study, laboratory pressurized sulfate exposure tests were conducted to investigate the evolution of macroscopic performance and microstructure of cement mortars with different limestone powder contents (0%, 15%, and 30%) under water pressures of 0, 2.5, and 5.0 MPa. The results show that elevated water pressure promotes sulfate ingress into the mortar and accelerates later-stage strength loss; this interpretation is supported by the depth-dependent distribution of soluble SO₄²⁻ measured in mortars without limestone powder. Two-way ANOVA indicates that both water pressure and limestone powder content have significant effects on compressive strength, and their interaction becomes statistically significant at 120 d. XRD, FT-IR, and SEM/EDS results show that, under elevated water pressure and high limestone powder content, the corrosion products gradually evolve from gypsum-related products to ettringite- and thaumasite-related products, with a certain spatial differentiation. Specifically, the gray–white, mud-like surface products are consistent with thaumasite-rich assemblages, whereas the needle- and column-like crystals in the interior are consistent with ettringite-rich assemblages. Overall, elevated water pressure mainly promotes sulfate transport, while limestone powder mainly increases carbonate availability. These two factors may jointly intensify TSA deterioration in mortar through a pathway involving transport enhancement, carbonate supply, corrosion product evolution, and aggravated macroscopic damage. This study provides a reference for understanding the sulfate deterioration mechanism of limestone powder-containing cement-based materials in deep underground environments under elevated water pressure. Full article

Environmental targets towards net-zero carbon concrete are increasing the demand for eco-efficiency in concrete production. Promising measures to increase sustainability include the combination of high levels of limestone fillers (LFs) and the use of advanced mix-design techniques, such as particle packing models (PPMs). However, there is still a limited understanding of the fresh and hardened state properties of eco-efficient mixtures; the literature suggests that mobility parameters (MPs; interparticle separation distance—IPS; maximum paste thickness—MPT) can help explain the fresh behaviour of concrete mixtures. Yet, the impact of MP values on fresh properties is still not fully understood. To address this gap, this study evaluates a reduced-complexity system comprising twelve concrete mortar fractions developed with distinct MP ranges and high LF contents (up to 52%). The use of mortar mixtures was intended to reduce the number of variables in the system and provide a clearer assessment of the role of mobility parameters. Time-dependent rheological behaviour (flow behaviour factor, torque, and viscosity) is analyzed and correlated with MP ranges to identify governing fresh state mechanisms. In addition, the relationships of IPS and MPT with compressive strength and porosity are evaluated to examine their relevance to the hardened state behaviour of low-carbon mixtures with reduced cement content. Results indicate that MPT and IPS can be used as practical indicators of rheological behaviour, with MPT showing the strongest influence on rheological response across all mixtures. Based on compressive strength and porosity measurements, empirical models are proposed to describe the effect of mobility parameter-based spacing concepts on hardened properties. Finally, the environmental performance of the optimized mixtures is assessed, confirming the potential of LF-rich, MP-tailored mixtures to contribute to low-carbon, net-zero concrete production. Full article

Replacing clinker with mixtures of calcined clay and limestone is one of the most sustainable strategies for decarbonizing the cement industry. However, the kinetic patterns governing the grinding behavior of these materials are not yet fully understood. This study developed a kinetic model based on particle population balance to simulate this process. Experiments were conducted using a standard Bond ball mill, and the samples were characterized by X-ray diffraction. The results show that the grinding of calcined clay and its mixtures with limestone follows first-order kinetics. The proposed model simulates the process with a high degree of accuracy, with residual errors below 1.5% and a coefficient of determination exceeding 99%. Full article

An investigation was conducted to explore the freeze–thaw resistance of 60–90 MPa high-strength concrete blended with multiple industrial byproducts (limestone powder, fly ash, etc.) and mixed sand (machine-made/tailings sand), aiming to clarify freeze–thaw degradation mechanisms and build reliable damage prediction models. Three water-binder (w/b) ratios (0.30, 0.25, 0.20) and 15 mix proportions were designed, with 30–45% cement replaced by mineral admixtures and 90–100% natural sand by mixed sand. Results show lower w/b ratios improve resistance: the 0.20 ratio yields merely 0.06% mass loss and 96% relative dynamic elastic modulus retention after 400 cycles. Optimized silica fume and limestone powder refine pore structures; fly ash-slag synergy boosts durability via secondary hydration under specific dosage ratios. A 7:3 machine-made/tailings sand mix shows better frost resistance due to improved particle packing and interfacial transition zones. Three damage models were established, with Model III demonstrating high accuracy. This work’s novelty lies in multi-byproduct synergy and multi-factor models, supporting green concrete use in cold regions. Full article

Since 2007, the porosity–to–cement relationship has been widely used as a unified parameter to predict mechanical strength, durability, expansion, and stiffness of stabilized soils. In this formulation, the volumetric binder content is adjusted by an internal exponent x, typically ranging between 0 and 1, to balance the relative contributions of porosity and cementation. Traditionally, the parameters of this relationship have been obtained using manual regression procedures. This study proposes an automated calibration methodology for the porosity–binder index, where the parameters A, B, and x are determined through an iterative optimization framework based on minimization of the sum of absolute errors (SAE) combined with a Monte Carlo search algorithm. The methodology is applied to a cement-stabilized clay blended with ground glass (GG), recycled gypsum (GY), and limestone residues (CLW). The predictive capability of the calibrated model is evaluated using unconfined compressive strength (q_u) and initial shear stiffness (Go) datasets. Two calibration strategies are considered: Calibration Process No. 1, based on CLW mixtures and q_u values only, and Calibration Process No. 2, incorporating all mixtures (CLW, GG, and GY) and both q_u and Go responses. The results indicate that Calibration Process No. 2 provides a more robust and physically consistent parameter set, yielding coefficients of determination of 0.9318 and 0.9412 for q_u and Go, respectively. The proposed algorithm-driven calibration framework improves predictive capability and provides a systematic approach for determining the parameters of the porosity–binder relationship. Full article

Cement production accounts for approximately 8% of global CO₂ emissions, and while calcined clays have attracted growing attention as supplementary cementitious materials, the literature remains fragmented across clay types and performance metrics, with no unified comparative framework examining how mineralogical composition and calcination conditions jointly govern pozzolanic reactivity and downstream performance outcomes. This study addresses that gap through a PRISMA-guided systematic review of 32 peer-reviewed studies, validated by structured expert interviews, and a comparative assessment of five calcined clay categories: metakaolin (MK), limestone-calcined clay blends (LC³), illite-rich clays, montmorillonite (MM)- based clays, and ceramic waste (CW)- derived clays. Findings establish clear performance hierarchies with direct implications for the construction sector. MK at 10–15% cement replacement delivers compressive strength gains of 8–36%, chloride permeability reductions of 61–87%, and sulphate expansion reductions of up to 89%, confirming its suitability for high-performance, chemically aggressive-environment structural concrete. LC³ systems enable 30–50% clinker substitution, yielding an estimated 30–40% embodied CO₂ reduction alongside 6–10% strength gains and 64–90% reductions in chloride migration, representing the most significant decarbonisation opportunity reviewed. Illite-rich clays reduce compressive strength by 6–25%, limiting application to non-structural uses despite moderate durability gains. MM-based clays exhibit highly variable performance, ranging from a 60% strength loss to an 8% gain, with workability penalties of up to a 90% slump reduction, constraining adoption. CW-derived clays achieve 50–69% reductions in chloride diffusion while valorising industrial waste, though strength reductions of 11–20% limit structural applications. Across all clay types, superplasticiser demand increases by 1.5–3.6 times, posing a universal cost and logistics challenge for practitioners in mix design. Full article