Search Results (1,227)

The growing need to improve the management of end-of-life vehicle (ELV) waste and mitigate its environmental impact is a global concern. One promising approach to enhancing the recyclability of these vehicles is leveraging synergies between the automotive and construction industries as part of a circular economy strategy. In this context, ELV waste emerges as a valuable source of secondary raw materials, enabling the development of sustainable innovations that capitalize on its physical and mechanical properties. This paper aims to develop and evaluate construction industry composites incorporating waste from ELV carpets, with a focus on maintaining or enhancing performance compared to conventional materials. To achieve this, an experimental program was designed to assess cementitious composites, specifically subfloor mortars, incorporating automotive carpet waste (ACW). The results demonstrate that, beyond the physical and mechanical properties of the developed composites, the dynamic stiffness significantly improved across all tested waste incorporation levels. This finding highlights the potential of these composites as an alternative material for impact noise insulation in flooring systems. From an academic perspective, this research advances knowledge on the application of ACW in cement-based composites for construction. In terms of managerial contributions, two key market opportunities emerge: (1) the commercial exploitation of composites produced with ELV carpet waste and (2) the development of a network of environmental service providers to ensure a stable waste supply chain for innovative and sustainable products. Both strategies contribute to reducing landfill disposal and mitigating the environmental impact of ELV waste, reinforcing the principles of the circular economy. Full article

The global cement industry remains a significant contributor to carbon dioxide (CO₂) emissions, prompting substantial research efforts toward sustainable construction materials. Lithium slag (LS), a by-product of lithium extraction, has attracted attention as a supplementary cementitious material (SCM). This review synthesizes experimental findings on LS replacement levels, fresh-state behavior, mechanical performance (compressive, tensile, and flexural strengths), time-dependent deformation (shrinkage and creep), and durability (sulfate, acid, abrasion, and thermal) of LS-modified concretes. Statistical analysis identifies an optimal LS dosage of 20–30% (average 24%) for maximizing compressive strength and long-term durability, with 40% as a practical upper limit for tensile and flexural performance. Fresh-state tests show that workability losses at high LS content can be mitigated via superplasticizers. Drying shrinkage and creep strains decrease in a dose-dependent manner with up to 30% LS. High-volume (40%) LS blends achieve up to an 18% gain in 180-day compressive strength and >30% reduction in permeability metrics. Under elevated temperatures, 20% LS mixes retain up to 50% more residual strength than controls. In advanced systems—autoclaved aerated concrete (AAC), one-part geopolymers, and recycled aggregate composites—LS further enhances both microstructural densification and durability. In particular, LS emerges as a versatile SCM that optimizes mechanical and durability performance, supports material circularity, and reduces the carbon footprint. 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

This study investigates the feasibility of using volcanic lapillus as a supplementary cementitious material (SCM) in mortar production to improve the sustainability of the cement industry. Cement production is one of the main sources of CO₂ emissions, mainly due to clinker production. Replacing clinker with SCMs, such as volcanic lapillus, can reduce the environmental impact while maintaining adequate mechanical properties. Experiments were conducted to replace up to 20 wt% of limestone Portland cement with volcanic lapillus. Workability, compressive strength, microstructure, resistance to alkali-silica reaction (ASR), sulfate, and chloride penetration were analyzed. The results showed that up to 10% replacement had a minimal effect on mechanical properties, while higher percentages resulted in reduced strength but still improved some durability features. The control sample cured 28 days showed a compressive strength of 43.05 MPa compared with 36.89 MPa for the sample containing 10% lapillus. After 90 days the respective values for the above samples were 44.76 MPa and 44.57 MPa. Scanning electron microscopy (SEM) revealed good gel–aggregate adhesion, and thermogravimetric analysis (TGA) confirmed reduced calcium hydroxide content, indicating pozzolanic activity. Overall, volcanic lapillus shows promise as a sustainable SCM, offering CO₂ reduction and durability benefits, although higher replacement rates require further optimization. Full article

This study investigates the impact of partially replacing cement with fly ash (FA) on the mechanical performance of fiber-reinforced rubberized concrete (FRRC) incorporating waste tyre rubber and recycled macro-synthetic fibers (MSF). FRRC mixtures were prepared with varying fly ash replacement levels (0%, 25%, and 50%), rubber aggregate contents (0%, 10%, and 20% by volume of fine aggregate), and macro-synthetic fiber dosages (0% to 1% by total volume). The fresh properties were evaluated through slump tests, while hardened properties including compressive strength, splitting tensile strength, and flexural strength were systematically assessed. Results demonstrated that fly ash substitution up to 25% improved the interfacial bonding between rubber particles, fibers, and the cementitious matrix, leading to enhanced tensile and flexural performance without significantly compromising compressive strength. However, at 50% replacement, strength reductions were more pronounced due to slower pozzolanic reactions and reduced cement content. The inclusion of MSF effectively mitigated strength loss induced by rubber aggregates, improving post-cracking behavior and toughness. Overall, an optimal balance was achieved at 25% fly ash replacement combined with 10% rubber and 0.5% fiber content, producing a more sustainable composite with favorable mechanical properties while reducing carbon and ecological footprints. These findings highlight the potential of integrating industrial by-products and waste materials to develop eco-friendly, high-performance FRRC for structural applications, supporting circular economy principles and reducing the carbon footprint of concrete infrastructure. Full article

The use of 3D printing holds significant promise to transform the construction industry by enabling automation and customization, although key challenges remain—particularly the control of fresh-state rheology. This study presents a novel formulation that combines potassium-rich biomass fly ash (BFAK) with an air-entraining plasticizer (APA) to optimize the rheological behavior, hydration kinetics, and structural performance of mortars tailored for extrusion-based 3D printing. The results demonstrate that BFAK enhances the yield stress and thixotropy increases, contributing to improved structural stability after extrusion. In parallel, the APA adjusts the viscosity and facilitates material flow through the nozzle. Isothermal calorimetry reveals that BFAK modifies the hydration kinetics, increasing the intensity and delaying the occurrence of the main hydration peak due to the formation of secondary sulfate phases such as Aphthitalite [(K₃Na(SO₄)₂)]. This behavior leads to an extended setting time, which can be modulated by APA to ensure a controlled processing window. Flowability tests show that BFAK reduces the spread diameter, improving cohesion without causing excessive dispersion. Calibration cylinder tests confirm that the formulation with 1.5% APA and 2% BFAK achieves the maximum printable height (35 cm), reflecting superior buildability and load-bearing capacity. These findings underscore the novelty of combining BFAK and APA as a strategy to overcome current rheological limitations in digital construction. The synergistic effect between both additives provides tailored fresh-state properties and structural reliability, advancing the development of a sustainable SMC and printable cementitious materials. Full article

Additive manufacturing (AM) has brought significant breakthroughs to the construction sector, such as the ability to fabricate complex geometries, enhance efficiency, and reduce both material usage and construction waste. However, several challenges must still be addressed to fully transition from conventional construction practices to innovative and sustainable green alternatives. This study investigates the use of non-cementitious traditional mixtures for green construction applications through 3D printing using Liquid Deposition Modeling (LDM) technology. To explore the development of mixtures with enhanced physical and mechanical properties, natural pine and cypress wood shavings were added in varying proportions (1%, 3%, and 5%) as sustainable additives. The aim of this study is twofold: first, to demonstrate the printability of these eco-friendly mortars that can be used for conservation purposes and overcome the challenges of incorporating bio-products in 3D printing; and second, to develop sustainable composites that align with the objectives of the European Green Deal, offering low-emission construction solutions. The proposed mortars use hydrated lime and natural pozzolan as binders, river sand as an aggregate, and a polycarboxylate superplasticizer. While most studies with bio-products focus on traditional methods, this research provides proof of concept for their use in 3D printing. The study results indicate that, at low percentages, both additives had minimal effect on the physical and mechanical properties of the tested mortars, whereas higher percentages led to progressively more significant deterioration. Additionally, compared to molded specimens, the 3D-printed mortars exhibited slightly reduced mechanical strength and increased porosity, attributable to insufficient compaction during the printing process. Full article

The construction sector makes a major contribution to global greenhouse gas emissions, in which cement alone produces approximately 7–8% of global CO₂ emissions. To abate environmental impact and promote sustainable construction, alternative low-carbon cementitious materials are gaining attention. Biochar (BC), a carbon-rich material obtained from biomass sources through the process of pyrolysis, has surfaced as a capable supplementary cementitious material due to its carbon capture capabilities and positive impact on the characteristics of cement composites. This review investigates the role of BC in cement composites, including its effects on hydration kinetics, microstructural development, fresh-state properties, and its optimal utilisation. The study also highlights the internal curing capabilities of BC when used in cement composites, its role in promoting hydration product formation, and its dual function in enhancing mechanical performance while facilitating carbon capture. Despite the benefits, there are some challenges such as variable BC properties, optimal dosage, and scalability. The review highlights the need for standardisation and further research to fully harness BC’s potential as a sustainable component in low-carbon construction technologies. Full article

Phosphorous slag is an industrial by-product generated in the process of producing yellow phosphorus by electric furnace, which occupies a substantial number of land resources and causes serious environmental pollution. The comprehensive utilization of phosphorous slag is a major topic relevant to the sustainability of the yellow phosphorus industry. In this paper, we attempted to utilize phosphorous slag as a supplementary cementing material to prepare silica-aluminum based cementitious material (SAC-PHS). To determine how phosphorus influences the early-age hydration reaction process of silica-aluminum based cementitious material, three groups of samples, PHS₂₀, PHS₂₅, and PHS₃₀, with better mechanical properties were selected to deeply investigate their one-week hydration characteristics. Characterization results showed that the main hydration products of SAC-PHS were C-A-S-H gels and ettringite. PHS₂₅ specimen produced more C-A-S-H gels and ettringite than the other two samples after one-week hydration. Interestingly, the P/Si atomic ratio indicated that chemical bonds were formed between Si and P during the formation of C-A-S-H gels, which improved the strength of SAC-PHS. Our findings offer valuable insights for the application of phosphorous slag in construction and building materials and promote the efficient resource utilization of phosphorous residue. Full article

This study focuses on the development of high-performance composite cementitious materials for offshore engineering applications, addressing the critical challenges of durability, environmental degradation, and carbon emissions. By incorporating polycarboxylate superplasticizers (PCE) and combining fly ash (FA), ground granulated blast furnace slag (GGBS), and silica fume (SF) in various proportions, composite mortars were designed and evaluated. A series of laboratory tests were conducted to assess workability, mechanical properties, volume stability, and durability under simulated marine conditions. The results demonstrate that the optimized composite exhibits superior performance in terms of strength development, shrinkage control, and resistance to chloride penetration and freeze–thaw cycles. Microstructural analysis further reveals that the enhanced performance is attributed to the formation of additional calcium silicate hydrate (C–S–H) gel and a denser internal matrix resulting from secondary hydration. These findings suggest that the proposed material holds significant potential for enhancing the long-term durability and sustainability of marine infrastructure. Full article

Traditional cementitious coating materials struggle to meet the performance criteria for protective coatings in complex environments. This study developed a polymer-modified cement-based coating material with polymer, silica fume (SF), and quartz sand (QS) as the principal admixtures. It also investigated the influence of material composition on the coating’s mechanical properties, durability, interfacial bond characteristics with concrete, and the durability enhancement of coated concrete. The results demonstrated that compared with ordinary cementitious coating material (OCCM), the interfacial bonding performance between 3% Styrene Butadiene Rubber Powder (SBR) coating material and concrete was improved by 42%; the frost resistance and sulfate erosion resistance of concrete protected by 6% polyurethane (PU) coating material were improved by 31.5% and 69.6%. The inclusion of polymers reduces the mechanical properties. The re-addition of silica fume can lower the porosity while increasing durability and strength. The coating material, mixed with 12% SF and 6% PU, exhibits mechanical properties not lower than those of OCCM. Meanwhile, the interfacial bonding performance and durability of the coated concrete have been improved by 45% and 48%, respectively. The grey relational analysis indicated that the coating material with the best comprehensive performance is the one mixed with 12% SF + 6% PU, and the grey correlation degree is 0.84. Full article

In this study, sodium hydroxide and calcium hydroxide are employed as activators to enhance the properties of foam concrete with hybrid alkali-activated cementitious material as the base mix. The effect of the activators on the properties of foam concrete is studied. The experimental results reveal that the presence of sodium hydroxide can also enhance the hydration rate of the base mix and increase the density of the pore wall in foamed concrete, thus enhancing the compressive strength of foamed concrete. Meanwhile, the addition of excessive sodium hydroxide may introduce too much water and increase the settlement of foamed concrete, thus resulting in a coarse and uneven pore structure. The settlement of the foam concrete with calcium hydroxide as an activator can be significantly increased, which is more related to the settlement of the matrix. The presence of calcium hydroxide could enhance dense pore walls, thus increasing the compressive strength and lowering water absorption. Full article

The pursuit of sustainable alternatives to portland cement has become a global imperative within the construction sector, driven by the need to reduce carbon dioxide emissions and energy consumption. Among the promising alternatives, agricultural ashes have garnered attention for their potential as alternative supplementary cementitious materials (ASCMs), owing to their inherent pozzolanic properties when appropriately processed. However, the availability and utilization of these ashes have predominantly been concentrated in tropical and subtropical regions, where such biomass is more abundant. This review offers a comprehensive bibliometric analysis to identify and assess agricultural ashes (specifically switchgrass, barley, sunflower, and oat husks) that are cultivated in temperate and cold climates and exhibit potential for SCM application. The analysis aims to bridge the knowledge gap by systematically mapping the existing research landscape and highlighting underexplored resources suitable for cold-region implementation. Key processing parameters, including incineration temperature, retention duration, and post-combustion grinding techniques, are critically examined for their influence on the resulting ash’s physicochemical characteristics and pozzolanic reactivity. In addition, the effect on fresh, hardened, and durability properties was evaluated. Findings reveal that several crops grown in colder regions may produce ashes rich in reactive silica, thereby qualifying them as viable ASCM candidates and bioenergy sources. Notably, the ashes derived from switchgrass, barley, oats, and sunflowers demonstrate significant reactive silica content, reinforcing their potential in sustainable construction practices. Hence, this study underscores the multifaceted benefits of contributing to the decarbonization of the cement industry and circular economy, while addressing environmental challenges associated with biomass waste disposal and uncontrolled open-air combustion. Full article

The bond interface is the weakest part of the repair system, and its performance is a key factor impacting the repair effectiveness of damaged concrete constructions. However, the research on the damage law and the mechanism of repair of the bonded interface in the cold region marine environment is not in-depth. In this study, the influence of polyvinyl alcohol (PVA) fibers and crystalline admixtures (CAs) on the mechanical properties and volumetric deformation performance of cementitious repair materials was researched. Furthermore, the deterioration patterns of the bond strength and chloride ion diffusion characteristics of the repair interface under the coupling of seawater-freeze-thaw cycles were investigated. Combined with the composition, micro-morphology, and micro-hardness of hydration products before and after erosion, the damage mechanism of the repaired bonding interface was revealed. The results indicate that the synergistic use of PVA fibers and CAs can significantly improve the compressive strength, bond strength and volume stability of the repair materials. The compressive strength and 40° shear strength of S0.6CA at 28 d were 101.7 MPa and 45.95 MPa, respectively. Under the seawater-freeze-thaw cycle action, the relationship between the contents of free and bound chloride ions in the bonded interface can be better fitted by the Langmuir equation. The deterioration process of the bonding interface and the penetration rate of chloride ions can be effectively delayed by PVA fiber and CAs. After 700 seawater-freeze-thaw cycles, the loss rates of bond strength and chloride diffusion coefficient of S0.6CA were reduced by 26.34% and 52.5%, respectively, compared with S0. Full article

This study focuses on developing a novel clinker-free cement, specifically comprising phosphorus slag-based cementitious materials (PSCMs), by utilizing lime and industrial byproducts, including granulated electric furnace phosphorus slag and fluidized bed combustion bottom ash. The optimal composition of PSCM was determined by investigating the effects of different proportions of activators (water glass and sodium sulfate) and retarder (potassium fluoride) on the setting time and the mechanical strength of PSCMs. Performance evaluations demonstrated that the compressive and flexural strengths of the optimal PSCM formulation at 28 days were 64.1 MPa and 7.5 MPa, respectively. Notably, concrete prepared with the optimal PSCM exhibited superior freeze–thaw resistance and sulfate resistance compared to Portland cement concrete of equivalent strength grades. The comprehensive characterization of selected PSCM compositions, conducted using X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and scanning electron microscope–energy-dispersive spectrometry (SEM-EDS), provided in-depth insights into the interrelationship among mechanical properties, durability, and microstructural characteristics. SEM-EDS analysis confirmed that calcium aluminosilicate hydrate and sodium aluminosilicate hydrate are the predominant hydration products of PSCMs. FTIR and TG analyses elucidated the continuous hydration behavior of PSCMs during the curing process, while SEM observations revealed a densely compact microstructure in the hardened PSCM paste. Full article