Search Results (124)

Cementitious binders have long been a keystone of construction, evolving from ancient lime mortars in Neolithic structures to the widespread use of Portland cement in the 19th century, which remains critical in modern construction. This review traces the historical development of cementitious binders and highlights how their widespread adoption has also brought significant environmental challenges, particularly carbon dioxide emissions and intensive energy consumption. To mitigate these impacts, supplementary cementitious materials (SCMs), such as fly ash, slag, and silica fume, have been adopted to reduce clinker consumption and improve sustainability. Despite these advancements, cement continues to be one of the largest industrial contributors to global emissions. In response, alternative binders have been explored. Alkali-activated binders (AABs) demonstrate considerable potential to reduce emissions while offering enhanced durability and performance. These emerging technologies provide a pathway toward more sustainable construction practices. This review is based on a structured survey of the peer-reviewed literature, conference proceedings, and technical reports up to 2025, synthesizing key themes related to historical evolution, environmental impacts, and emerging low-carbon alternatives. The findings aim to inform the development of sustainable building materials for the future. Full article

The cement industry accounts for approximately 7–8% of global CO₂ emissions, primarily due to energy-intensive clinker production and limestone calcination. With cement demand continuing to rise, particularly in emerging economies, decarbonization has become an urgent global challenge. The objective of this study is to systematically map and synthesize existing evidence on technological pathways, policy measures, and economic barriers to four core decarbonization strategies: clinker substitution, energy efficiency, alternative fuels, as well as carbon capture, utilization, and storage (CCUS) in the cement sector, with the goal of identifying practical strategies that can align industry practice with long-term climate goals. A scoping review methodology was adopted, drawing on peer-reviewed journal articles, technical reports, and policy documents to ensure a comprehensive perspective. The results demonstrate that each mitigation pathway is technically feasible but faces substantial real-world constraints. Clinker substitution delivers immediate reduction but is limited by SCM availability/quality, durability qualification, and conservative codes; LC₃ is promising where clay logistics allow. Energy-efficiency measures like waste-heat recovery and advanced controls reduce fuel use but face high capital expenditure, downtime, and diminishing returns in modern plants. Alternative fuels can reduce combustion-related emissions but face challenges of supply chains, technical integration challenges, quality, weak waste-management systems, and regulatory acceptance. CCUS, the most considerable long-term potential, addresses process CO₂ and enables deep reductions, but remains commercially unviable due to current economics, high costs, limited policy support, lack of large-scale deployment, and access to transport and storage. Cross-cutting economic challenges, regulatory gaps, skill shortages, and social resistance including NIMBYism further slow adoption, particularly in low-income regions. This study concludes that a single pathway is insufficient. An integrated portfolio supported by modernized standards, targeted policy incentives, expanded access to SCMs and waste fuels, scaled CCUS investment, and international collaboration is essential to bridge the gap between climate ambition and industrial implementation. Key recommendations include modernizing cement standards to support higher clinker replacement, providing incentives for energy-efficient upgrades, scaling CCUS through joint investment and carbon pricing and expanding access to biomass and waste-derived fuels. Full article

Foundry slag has different characteristics from blast furnace slag, such as its high SiO₂ content and low basicity (CaO/SiO₂ < 1), which prevent it from being used as a cementitious component. Lime slurry is a waste product with a high CaO content and can be used to increase the basicity of the mixture. The aim of this study is to obtain new supplementary, eco-cementitious material composed of foundry slag and lime sludge. The compositions were designed with binary basicity (molar ratio of CaO/SiO₂) ranging from 1.0 to 1.4. Clinker was replaced with the proposed material in the range of 6–34 wt% and the performance of the different cement compositions was tested. The results showed that replacing 20 wt% of clinker with the new eco-cementitious material with binary basicity of 1.2 resulted in cement with the same mechanical strength as the reference cement. The new material reacted with free CaO to generate additional calcium silicate hydrate. The initial setting time of the cement containing the new eco-cementitious material was 240 min, acting as hydration reaction retardant. The technical feature of the new eco-cementitious material allows the use of both wastes in cement composition, contributing to the requirements of circular economy. Full article

Rapid population growth and accelerating urbanization are intensifying the demand for construction materials, particularly concrete, which is predominantly produced with Portland cement and natural aggregates. This reliance imposes substantial environmental burdens through resource depletion and greenhouse gas emissions. Within the framework of sustainable construction, recycled aggregates and industrial by-products such as fly ash, slags, crushed glass, and other secondary raw materials have emerged as viable substitutes in concrete production. At the same time, three-dimensional concrete printing (3DCP) offers opportunities to optimize material use and minimize waste, yet it requires tailored mix designs with controlled rheological and mechanical performance. This review synthesizes current knowledge on the use of recycled construction and demolition waste, industrial by-products, and geopolymers in concrete mixtures for 3D printing applications. Particular attention is given to pozzolanic activity, particle size effects, mechanical strength, rheology, thermal conductivity, and fire resistance of recycled-based composites. The environmental assessment is considered through life-cycle analysis (LCA), emphasizing carbon footprint reduction strategies enabled by recycled constituents and low-clinker formulations. The analysis demonstrates that recycled-based 3D printable concretes can maintain or enhance structural performance while mix-level (cradle-to-gate, A1–A3) LCAs of printable mixes report CO₂ reductions typically in the range of ~20–50% depending on clinker substitution and recycled constituents—with up to ~48% for fine recycled aggregates when accompanied by cement reduction and up to ~62% for mixes with recycled concrete powder, subject to preserved printability. This work highlights both opportunities and challenges, outlining pathways for advancing durable, energy-efficient, and environmentally responsible 3D-printed construction materials. Full article

Supplementary cementitious materials (SCMs) provide a practical solution for reducing greenhouse gas emissions associated with Portland cement production while enhancing the economy, performance, and service life of concrete and mortar. Currently, there is a significant disparity in the availability, supply, and utilisation levels of SCMs worldwide, particularly in South Africa. This paper presents an in-depth analysis of the characteristics and performance of various SCMs, including local availability, factors driving demand, production, and utilisation. The findings indicate that fly ash and limestone calcined clay are the most widely available SCM resources in South Africa, with deposits exceeding 1 billion tonnes each. Fly ash stockpiles continuously increase due to the reliance on coal-fired power plants for 85% of generated electricity and a low fly ash utilisation rate of 7%, significantly below international utilisation levels of 10–98%. Conversely, slag resources are depleting due to the steady decline of local steel production caused by energy and input costs, alongside the growing importation of steel products. Combined, the estimated production of slag and silica fume is about 1.4 million tonnes per annum, leading to their limited availability and utilisation in niche applications such as high-performance concrete and marine environments. Furthermore, 216,450 tonnes of SCM could potentially be processed annually from agricultural waste. In addition to quality, logistics, costs, and other challenges, this quantity can only replace 1.5% of clinker in South Africa, raising concerns about the viability of SCMs from agricultural waste. Based on its findings, this study recommends future research areas to enhance the performance, future availability, and sustainability of SCMs. Full article

Cement production significantly contributes to global CO₂ emissions. Limestone Calcined Clay Cement (LC³)—a mixture of limestone, calcined clay, cement clinker, and gypsum—offers a promising alternative by significantly reducing clinker contents without compromising mechanical performance. This study assesses the environmental and social hotspots of various LC³ mortars produced in Germany, a context not yet explored in previous research. While prior studies have mostly focused on LC³ in concrete applications and in low- to middle-income countries, this is the first to evaluate LC³-based mortar in a high-income, highly industrialized context using both Life Cycle Assessment (LCA) and Social Risk Assessment (SRA) to determine the main environmental and social drivers of this material. The LCA revealed that LC³ mixtures achieve substantial reductions in key impact categories compared to conventional Ordinary Portland Cement (OPC) mixes, including Climate Change (up to 42.6% reduction) and Particulate Matter (up to 15.8% reduction). The SRA highlights significant social risks related to corruption, fair competition, and workers’ rights, including fair wages, discrimination, and safe working conditions. This study underscores LC³ as a promising sustainable solution in cement applications while emphasizing the importance of region-specific assessments to address unique environmental and social considerations. Full article

Concrete is the most used material worldwide, with cement as its essential component. Cement production, however, has a considerable environmental footprint contributing nearly 8% of global CO₂ emissions, largely from clinker calcination. This review aims to examine strategies for reducing these emissions, with a particular focus on alternative materials for producing magnesium phosphate cements (MPCs). Specifically, the objectives are first to summarize mitigation pathways, such as CO₂ capture, energy efficiency, and alternative raw materials, and second evaluate the feasibility of using industrial wastes and by-products, including low-grade MgO, tundish deskulling waste (TUN), boron-MgO (B-MgO), and magnesia refractory brick waste (MRB), as MgO sources for MPC. The review highlights that these materials represent a promising route to reduce the environmental impact of cement production and support the transition toward carbon neutrality by 2050. Full article

With the increasing global demand for sustainable building materials, coal gangue, as a potential supplementary cementitious material (SCM), has attracted widespread attention. Coal gangue is primarily composed of clay minerals, among which the kaolinite content can significantly enhance its cementitious properties after activation. However, there are various grades of coal gangues, which restrain their application, especially for the low kaolinite content coal gangue. This paper investigates the feasibility of using iron-rich coal gangue with low kaolinite content as a cement substitute through high-temperature activation treatment. In the current study, activated coal gangue replaced cement clinker at proportions of 10%, 15%, and 20%, which was further mixed with limestone powder to form a new cementitious material system. The mechanical attributes of the systems were assessed using compressive strength and microhardness tests. The influence of hydration products and microstructural changes on system performance was further explored through electrochemical impedance spectroscopy (EIS) and quantitative X-ray diffraction (XRD) analysis. The findings suggest that a well-balanced addition of coal gangue can effectively substitute for cement clinker, thereby enhancing both the mechanical properties and microstructure of the systems. These results demonstrate that through appropriate activation treatments, coal gangue can be utilized as an effective SCM. While traditional SCMs like fly ash (FA) and ground granulated blast-furnace slag (GGBFS) have near-zero allocated carbon footprints, their global supply is diminishing and increasingly unreliable. In contrast, our approach valorizes a vast industrial waste stream, aligning with circular economy principles and offering a scalable, sustainable, and low-carbon alternative for the construction industry. Full article

The environmental impact of cement production is strongly associated with the high clinker content and its corresponding CO₂ emissions. This study examines the performance of low-emission cement mortars incorporating supplementary cementitious materials (SCMs), such as ground granulated blast-furnace slag (GGBFS) and fly ash, which partially replace clinker and contribute to CO₂ reduction. Six cement types (CEM I, CEM II/B-V, CEM II/B-S, CEM III/A, CEM V/A (S-V), and CEM V/B (S-V)) were assessed in 104 mortar formulations using a polycarboxylate-based superplasticizer, under varied curing temperatures (10 °C, 20 °C, 29 °C, and 33 °C). The present study is an experimental analysis of the impact of different plasticising and superplasticising admixtures on the demand for admixtures to achieve high flowability and low air content in cement-standardised mortar for admixture testing. PN-EN 480-1. The results indicate that mortars containing CEM III/A and CEM V/B (S-V) exhibited compressive strengths comparable to or superior to CEM I at 28 days, with strength gains exceeding 60 MPa at 20 °C. Workability retention at elevated temperatures was most effective in slag-rich cements. The plasticizing efficiency of the admixture decreased at temperatures above 29 °C, especially in fly ash-rich systems. The incorporation of SCMs resulted in an estimated reduction of up to 60% in clinker, with a corresponding potential decrease in CO₂ emissions of 35–45%. These findings demonstrate the technical feasibility of using low-clinker, superplasticized mortars in varying thermal environments, supporting the advancement of sustainable cementitious systems. Full article

The construction industry is responsible for 39% of global CO₂ emissions related to energy use, with cement responsible for 5–8% of it. Limestone calcined clay cement (LC³), a ternary blended binder system, offers a low-carbon alternative by partially substituting clinker with calcined clay and limestone. This study investigated the use of waste clay brick powder (WBP), a waste material, as a source of calcined clay in LC³ formulations, addressing both environmental concerns and SCM scarcity. Two LC³ mixtures containing 15% limestone, 5% gypsum, and either 15% or 30% WBP, corresponding to clinker contents of 65% (LC³-65) or 50% (LC³-50), were evaluated against general purpose (GP) cement mortar. Tests included setting time, flowability, soundness, compressive and flexural strengths, drying shrinkage, isothermal calorimetry, and scanning electron microscopy (SEM). Isothermal calorimetry showed peak heat flow reductions of 26% and 49% for LC³-65 and LC³-50, respectively, indicating a slower reactivity of LC³. The initial and final setting times of the LC³ mixtures were 10–30 min and 30–60 min longer, respectively, due to the slower hydration kinetics caused by the reduced clinker content. Flowability increased in LC³-50, which is attributed to the lower clinker content and higher water availability. At 7 days, LC³-65 retained 98% of the control’s compressive strength, while LC³-50 showed a 47% reduction. At 28 days, the compressive strengths of mixtures LC³-65 and LC³-50 were 7% and 46% lower than the control, with flexural strength reductions being 8% and 40%, respectively. The porosity calculated from the SEM images was found to be 7%, 11%, and 15% in the control, LC³-65, and LC³-50, respectively. Thus, the reduction in strength is attributed to the slower reaction rate and increased porosity associated with the reduced clinker content in LC³ mixtures. However, the results indicate that the performance of LC³-65 was close to that of the control mix, supporting the viability of WBP as a low-carbon partial replacement of clinker in LC³. Full article

The cement industry is a significant contributor to global carbon dioxide emissions, primarily due to the energy demands of its production process and its reliance on clinker, a material formed through the high-temperature calcination of limestone. Strategies to reduce emissions include the adoption of low-carbon fuels, the use of carbon capture and storage (CCS) technologies, and the integration of supplementary cementitious materials (SCMs) to reduce the clinker content. The effectiveness of these measures depends on a complex set of interactions involving technological feasibility, market dynamics, and regulatory frameworks. This study presents a system dynamics model designed to assess how various decarbonization approaches influence long-term emission trends within the cement industry. The model accounts for supply chains, production technologies, market adoption rates, and changes in cement production costs. This study then analyzes a number of scenarios where there is large-scale sustained investment in each of three carbon mitigation strategies. The results show that CCS by itself allows the cement industry to achieve carbon neutrality, but the high capital investment results in a large cost increase for cement. A combined approach using alternative fuels and SCMs was found to achieve a large carbon reduction without a sustained increase in cement prices, highlighting the trade-offs between cost, effectiveness, and system-wide interactions. Full article

This paper presents a comprehensive review of dealuminated metakaolin (DK), a hazardous industrial by-product generated by the aluminium sulphate (alum) industry and evaluates its potential as a component in cementitious systems for the partial or full replacement of Portland cement (PC). Positioned within the context of waste valorisation in concrete, the review aims to establish a critical understanding of DK formation, properties, and reactivity, particularly its pozzolanic potential, to assess its suitability for use as a supplementary cementitious material (SCM), or as a precursor in alkali-activated cement (AAC) systems for concrete. A systematic methodology is used to extract and synthesise relevant data from existing literature concerning DK and its potential applications in cement and concrete. The collected information is organised into thematic sections exploring key aspects of DK, beginning with its formation from kaolinite ores, followed by studies on its pozzolanic reactivity. Applications of DK are then reviewed, focusing on its integration into SCMs and alkali-activated cement (AAC) systems. The review consolidates existing knowledge related to DK, identifying scientific gaps and practical challenges that limit its broader adoption for cement and concrete applications, and outlines future research directions to provide a solid foundation for future studies. Overall, this review highlights the potential of DK as a low-carbon, circular-economy material and promotes its integration into efforts to enhance the sustainability of construction practices. The findings aim to support researchers’ and industry stakeholders’ strategies to reduce cement clinker content and mitigate the environmental footprint of concrete in a circular-economy context. Full article

In order to elucidate the high-temperature reaction process of solid waste-based high belite sulphoaluminate cement containing residual gypsum in clinker (NHBSAC) and obtain the formation laws of each mineral in clinker, this article studied its high-temperature reaction kinetics. Through QXRD analysis and numerical fitting methods, the formation of C₄A₃$\overline{\mathrm{S}}$, β-C₂S, and CaSO₄ in clinker under different calcination systems was quantitatively characterized, the corresponding high-temperature reaction kinetics models were established, and the reaction activation energies of each mineral were obtained. The results indicate that the content of C₄A₃$\overline{\mathrm{S}}$ and β-C₂S increases with the prolongation of holding time and the increase in calcination temperature, while CaSO₄ is continuously consumed. Under the control mechanism of solid-state reaction, the formation and consumption of minerals follow the kinetic equation. C₄A₃$\overline{\mathrm{S}}$ and β-C₂S satisfy the D₄ equation under diffusion mechanism control, and CaSO₄ satisfies the R₃ equation under interface chemical reaction mechanism control. The activation energy required for mineral formation varies with different temperature ranges. The activation energies required to form C₄A₃$\overline{\mathrm{S}}$ at 1200–1225 °C, 1225–1275 °C, and 1275–1300 °C are 166.28 kJ/mol, 83.14 kJ/mol, and 36.58 kJ/mol, respectively. The activation energies required to form β-C₂S at 1200–1225 °C and 1225–1300 °C are 374.13 kJ/mol and 66.51 kJ/mol, respectively. This study is beneficial for achieving flexible control of the mineral composition of NHBSAC clinker, providing a theoretical basis and practical experience for the preparation of low-carbon cement and the optimization design of its mineral composition. Full article

Iron-rich bauxite residue (red mud) is a hazardous alkaline solid waste produced during the production of alumina from high-iron bauxite, which poses severe environmental challenges due to its massive stockpiling and limited utilization. In this study, metallic iron was recovered from high-iron red mud using the smelting reduction process. Thermodynamic analysis results show that an increase in temperature and sodium oxide content, along with an appropriate mass ratio of Al₂O₃ to SiO₂ (A/S) and mass ratio of CaO to SiO₂ (C/S), contribute to the enhancement of the liquid phase mass fraction of the slag. During the smelting reduction process of high-iron red mud, iron recoveries for low-alkali high-iron red mud and high-alkali high-iron red mud under optimal conditions were 98.14% and 98.36%, respectively. The metal obtained through reduction meets the industrial standard for steel-making pig iron, which is also confirmed in the pilot-scale experiment. The smelting reduction process of high-iron red mud can be divided into two stages, where the reaction is predominantly governed by interfacial chemical reaction and diffusion control, respectively. The apparent activation energy of high-alkali high-iron red mud is lower than that observed for low-alkali high-iron red mud. The reduced slag can be used as a roadside stone material or cement clinker. This proposed method represents a sustainable process for the comprehensive utilization of high-iron red mud, which also promotes the minimization of red mud. Full article

Based on a novel ternesite sulphoaluminate cement (NTSAC), the effects of various influencing factors on the calcination of clinker were studied, including mineral composition of clinker, grinding fineness of raw materials, molding technology of samples, and cooling methods of clinker. The research was carried out by taking the calcination system and mineral content of clinker as evaluation indexes, and using RSM and QXRD as analytical means. The results indicate that the optimal calcination temperature of clinker varies with the design mineral composition, while the holding time remains basically unchanged. Clinker with high CaSO₄ content has a relatively lower calcination temperature. The use of a calcination system of 1175 °C-49 min can control the mineral content error of the cement below 15%. Moreover, the molding pressure, molding methods, grinding fineness of raw materials, and cooling methods of clinker have significant effects on the clinker preparation to varying degrees, with the order of influence from high to low being molding methods, grinding fineness of raw materials, molding pressure, and cooling methods of clinker. Within the range of experimental parameters, the better preparation conditions are compression molding (molding method), 15 MPa (molding pressure), and 20 μm (grinding fineness). The above research conclusions provide reference data for cement preparation in the laboratory, offering useful guidance for developing novel types of cement. Full article