Search Results (63)

Promoting construction waste utilization, this study explores using 30% mass fraction recycled micro powder (brick/concrete/hybrid) to replace cement in A03 foam concrete, as well as microbial foaming agents for insulation boards. The results show that hybrid micro powder foam concrete achieved higher compressive strength (0.7 MPa, 0.65 MPa) than pure brick (0.54 MPa) and concrete powder (0.61 MPa). For 30% hybrid micro powder insulation boards (brick:concrete ratios 2:8–8:2), when the ratio is 4:6, their performance meets JC/T 2200-2013 standards. At this point, the compressive strength is 0.43 MPa, the drying shrinkage is 0.29 mm, and the thermal conductivity 0.062 is W/(m·K). As the proportion of recycled brick powder increases, the material properties first improve and then decline, indicating that the proportion of recycled brick powder has a significant impact on the material’s overall performance; within an appropriate range, optimal performance can be achieved. Full article

The cement industry is a major contributor to global energy consumption and greenhouse gas emissions, motivating the development of sustainable cementitious materials through partial cement substitution. This study investigates the combined mechanical, durability-related, and environmental performance of mortars incorporating a 20% replacement of Portland cement by volume with different natural and waste-derived mineral additions, including natural pozzolan, brick waste, glass powder, recycled concrete powder, and calcined clay as pozzolanic or potentially reactive supplementary materials, while silica sand was used as an inert mineral filler. Mechanical performance was evaluated through compressive strength, while durability-related behavior was assessed using water absorption by immersion at 28 days. In parallel, a Life Cycle Assessment (LCA) was conducted to quantify the environmental impacts associated with climate change, acidification, eutrophication, photochemical oxidant formation, material resource depletion, and non-renewable energy consumption. The results show that mortars incorporating natural pozzolan and brick waste achieved compressive strengths comparable to the reference mortar, while maintaining low water absorption values, indicating effective microstructural densification. Glass powder also provided acceptable mechanical and durability-related performances, whereas silica sand, recycled concrete powder, and calcined clay exhibited reduced strength and increased absorption due to dilution effects, inherited porosity, or delayed pozzolanic activity. From an environmental perspective, all cement-substituted mortars demonstrated significant reductions across all assessed LCA impact categories, with decreases typically ranging from 15% to 20% relative to the reference mix. The most pronounced environmental benefits were observed for mortars incorporating waste-derived materials, particularly brick waste. Overall, the combined mechanical and environmental assessment demonstrates that a 20% cement substitution using supplementary materials can substantially reduce the environmental footprint of mortars without compromising essential engineering properties. Full article

Using solid waste as supplementary cementitious materials (SCMs) is an effective strategy for promoting low-carbon construction development. However, single or binary systems often exhibit mismatched reaction kinetics, thereby limiting their performance at high cement replacement rates. This study focuses on a novel low-carbon concrete designed based on reaction sequence coordination, containing recycled brick powder (RBP), ground granulated blast-furnace slag (GGBS), and self-combusting coal gangue (SCCG). The effects of RBP, GGBS, and SCCG on the hydration process and microstructure of the novel low-carbon concrete with different replacement levels have been studied by testing compressive strength, workability, and durability and observing microstructural changes. The results showed that an optimized ternary composition with an RBP:GGBS:SCCG ratio of 4:3:1 achieves a cement replacement level of 30% while exhibiting a 28-day compressive strength of 38.26 MPa, representing a 14.2% increase compared with plain cement mortar. Microstructural analyses indicate that this enhanced performance results from a time-dependent reaction sequence, in which GGBS contributes predominantly at early ages by supplying calcium, whereas RBP and SCCG mainly participate through delayed pozzolanic reactions and pore refinement at later ages. Consequently, the optimized ternary mortar exhibits a water absorption of 11.12% and a 27.2% reduction in electrical flux. This study aims to provide practical strategies for enhancing the performance of low-carbon cementitious materials through a reaction sequence coordination design approach, thereby improving the utilization efficiency of solid waste in the production of low-carbon building materials. Full article

The recycling of waste clay bricks as raw materials for cement-based materials presents an effective solution to ecological pollution and resource shortages. Previous research has separately examined the effects of recycled brick fine aggregate and recycled brick powder on mortar or concrete, but few studies have investigated their combined use. This study aims to clarify the synergistic effect of recycled brick fine aggregate (RBA) and recycled brick powder (RBP) on mortar performance, quantify the influence of the RBP substitution rate on hydration characteristics and microstructural evolution, and determine the optimal mix proportion and curing system for fully recycled brick mortar. Mortar was prepared using 100% RBA and RBP at substitution rates of 0%, 10%, 20%, and 30%. The physical properties, mechanical performance, and durability of the mortar were evaluated, alongside an analysis of its microstructural morphology, mineral composition, and pore structure. The results indicate that adding an appropriate amount of RBP helped maintain the flowability of the mortar. As the RBP substitution rate increased, the mortar strength generally decreased in the early stages, but long-term curing (≥90 days) effectively mitigated this decline. The inclusion of RBP improved chloride ion permeability, with the 20% substitution rate achieving a favorable balance between compressive strength, fluidity, and durability without significantly affecting carbonation resistance. Microstructural analysis revealed that RBP regulated the morphology of hydration products and optimized the pore structure of the mortar, while the mineral composition of hydration products was similar to that of natural mortar. These findings provide a theoretical basis and technical support for the high-value utilization of construction and demolition waste in cement-based materials. Full article

This paper presents a new ceramic building material produced by the cold sintering process (CSP), as a greener and cleaner technology compared to conventional ones. The ceramic composites were made from recycled clay bricks (RCBs), a byproduct resulting from construction and demolition and waterglass (WG) as a liquid solvent, pressed at 400 MPa and sintered at a temperature of 150–200 °C. After the samples were produced, their structure and physical and mechanical properties were investigated. The internal morphology of samples shows a homogeneous structure with a low porosity (up to 3%). The compressive strength of ceramic building material produced by the CSP was up to 211 MPa, considerably higher than the reference sample whose value was 45 Mpa. This high strength is due to the internal structure of the ceramic composed of a tough amorphous phase that acts like a binder holding together the powder particles and closing most of the porosity inside the material. Full article

The growing need for a cleaner, sustainable environment has increased interest in reusing waste materials that cause pollution. In this research, the mechanical (dry density, compressive, and tensile strength) and also durability properties (sorptivity, rate of water absorption, chloride ion resistance, and resistance to freeze–thaw) of concrete were studied by partially substituting cement with brick powder (BP) and sand with quarry dust (QD). The proportions of brick powder replacement with cement were in the range of 5%, 10%, 15%, and 20% by weight. Likewise, QD was used in the range of 15%, 30%, 45%, and 60% by weight of natural sand. Both materials were used separately as well as simultaneously in concrete. Concrete mixtures were prepared, tested after curing, and then compared with conventional concrete. The water–cement (w/c) ratio was kept constant at 0.55 for all the mixes. According to experimental results, the concrete made with brick powder and quarry dust resulted in improved dry density. After curing for 28 and 56 days, the compressive and splitting tensile strengths increased by substituting cement with brick powder up to 15%. Brick powder showed a higher strength activity index than required according to the standard. Also, compressive and splitting tensile strengths significantly increased by replacing natural sand with quarry dust up to 60% at all curing ages. Combined mixes with partial replacements of cement and sand with brick powder and quarry dust, respectively, also showed improvements in the compressive and splitting tensile strength at all ages. Sorptivity and rate of water absorption decreased with the addition of BP and QD. Moreover, brick powder and quarry dust mixes showed higher resistance to chloride ion penetrability and higher resistance to freeze–thaw as the replacement level increased. Microstructural analysis of hard concrete samples also confirmed the enhanced mechanical strength and durability due to brick powder and quarry dust. Full article

Valorizing construction and demolition waste (CDW) via alkaline activation enables low-carbon binders. This study assesses binary geopolymers formulated with recycled brick powder (PLR) and recycled concrete powder (PCR) in seven precursor ratios (0–100% PCR), activated with a ternary NaOH/Na₂SiO₃/KOH solution (silicate modulus M_s ≈ 3.2) at L/B = 0.15, and cured for 7, 14, and 28 days. Compressive strength (fc), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS) were used to link microstructure–phases–properties. A local maximum in fc at ~30% PCR (16.2 MPa at 28 d) was observed versus 0% PCR (14.2 MPa) and ≥50% PCR (13.8 → 10.1 MPa at 28 d). XRD indicated a reduction in inherited crystalline phases and an increased amorphous fraction at ~30% PCR; FTIR (normalized peak position and FWHM of the T–O–Si band, not absolute intensity) suggested higher network extension; SEM-EDS (local/semiquantitative) showed a moderate rise in Ca that supports C-A-S-H domains bridging the N-A-S-H network. At a high PCR, excess Ca simplified mineralogy (quartz/portlandite dominance), promoted competitive routes (C-S-H/carbonation), reintroduced microdefects, and reduced fc. A theoretical oxide balance per mix identified a compositional window where Ca/(Si + Al) ≈ 0.35–0.45 coincides with the mechanical optimum and with XRD/FTIR tracers. Overall, a ~30% PCR window maximizes co-reticulation of N-A-S-H/C-A-S-H and densification without compromising aluminosilicate continuity, providing transferrable design and process-control criteria for CDW-based geopolymer binders. Full article

Recycled powder (RP), a by-product with a particle size smaller than 150 μm, is generated during the processing of construction and demolition waste (CDW) for recycled aggregate production. RP mainly consists of recycled concrete powder and recycled brick powder. Previous studies have demonstrated that RP can serve as a supplementary cementitious material (SCM) in concrete production. Due to the heterogeneity of parent materials with different ages, service environments, and compositions, the physicochemical properties and reactivity of RP vary significantly, which largely accounts for the inconsistent results reported in the literature. This paper presents a critical review of the application of RP as an SCM in construction. The preparation technologies, chemical and physical properties, microstructural characteristics, and activation methods of RP are systematically examined. Owing to its irregular and rough surface morphology, RP tends to reduce workability and increase water demand when incorporated as an SCM. Nevertheless, when the replacement level and median particle size are limited (typically below 30% and 20 μm, respectively), RP can contribute through micro-filling, nucleation, and limited pozzolanic effects, thereby mitigating adverse impacts on mechanical and durability properties. The mechanisms and effectiveness of mechanical grinding, thermal activation, chemical activation, and CO₂ treatment are comparatively evaluated. Moreover, the incorporation of RP in cement-based materials offers significant economic and environmental benefits. Full article

Geopolymer mortars were produced from construction and demolition waste using a binary binder of recycled brick powder/recycled concrete powder (RBP/RCP = 70/30 wt%), activated with a hybrid alkaline solution (NaOH/Na₂SiO₃/KOH) and reinforced with sisal fibres at 0–2 wt%. Mechanical performance (compression and three-point bending) and microstructure–phase evolution (XRD, FTIR, SEM-EDS) were assessed after low-temperature curing. Sisal addition delivered a strength–toughness trade-off with a reproducible optimum at ~1.0–1.5 wt%; at 2.0 wt%, fibre clustering and connected porosity reduced the effective load-bearing section, penalising flexure more than compression. Microstructural evidence indicates coexistence and co-crosslinking of N-A-S-H and C-(A)-S-H gels—enabled by Ca from RCP—leading to matrix densification and improved fibre–matrix anchorage. Fractographic features (tortuous crack paths, bridging, and extensive pull-out at ~1.5 wt%) are consistent with an extended post-peak response and higher fracture work without compromising early-age strength. This study achieves the following: (i) it identifies a practical reinforcement window for sisal in RBP/RCP geopolymers, (ii) it links gel chemistry and interfacial phenomena to macroscopic behaviour, and (iii) it distils processing guidelines (gradual addition, workability control, gentle deaeration, and constant A/S) that support reproducibility. These outcomes provide a replicable, low-embodied-CO₂ route to fibre-reinforced geopolymer mortars derived from CDW for non-structural and semi-structural applications where flexural performance and post-peak behaviour are critical. Full article

The preparation of construction waste into eco-friendly recycled powder (RP), partially replacing cement to produce foam concrete with thermal insulation properties, provides a new approach for the resource utilization of RP. In this study, different components of construction waste were used to prepare recycled paste powder (RPP), recycled brick powder (RBP), and recycled concrete powder (RCP). The effects of RP on the microstructural and macroscopic properties of foam concrete were investigated at replacement rates ranging from 0% to 30%. The research results indicate that the microstructure of all three types of RP exhibits irregular shapes, and their chemical compositions show significant differences. Partial replacement of cement with these RP leads to the deterioration of the matrix microstructure, which negatively affects the workability and mechanical properties of the foam concrete. However, the addition of RP effectively mitigates the drying shrinkage of the foam concrete, with RBP showing particularly outstanding performance in this regard. Specifically, the maximum drying shrinkage rate of F-30RBP is 9.33% and 11.31% lower than that of F-30RPP and F-30RCP, respectively. Furthermore, the incorporation of RP has a minimal effect on the thermal conductivity of the foam concrete, indicating that RP is well-suited for use in foam concrete. Full article

The growing demand for eco-efficient construction materials has driven the development of low-clinker cement systems incorporating recycled mineral additives. Finely ground brick powder represents one of such materials with high pozzolanic potential. This article presents an experimental study on the effect of partially replacing slag cement CEM III and ordinary rapid-hardening cement CEM I with brick powder waste of different chemical compositions and fineness levels (63, 32, and 15 µm) on the physical and mechanical properties of blended cement mortars. Compressive and flexural strengths were determined at 2, 7, and 28 days, along with the strength activity index (SAI). Additionally, the setting times and standard consistency were investigated, with the latter showing a correlation with the workability of fresh mortars. Comprehensive microstructural analysis (TGA, SEM, EDX) confirmed the pozzolanic activity of the brick powder, which was manifested by the formation of C-S-H and C-A-S-H phases. The highest strength characteristics were achieved with a 15% replacement of cement by brick powder with a fineness of 32 μm and an increased SiO₂ content (63.06%). Comparative analysis with fly ash- and silica fume-modified mortars revealed that brick powder exhibits comparable performance, confirming its suitability as an active mineral additive. Full article

The increasing demand for sustainable construction materials has prompted the recycling of construction and demolition waste in concrete manufacturing. This study investigates the feasibility of utilizing porcelain and brick waste as partial substitutes for natural sand in concrete with the objective of improving sustainability and preserving mechanical and durability characteristics. The experimental program was conducted in three consecutive phases. During the initial phase, natural sand was partially substituted with porcelain waste powder (PWP) and brick waste powder (BWP) in proportions of 25%, 50%, and 75% of the weight of the fine aggregate. During the second phase, polypropylene fibers were mixed at a dosage of 0.5% by volume fraction to enhance tensile and flexural properties. During the third phase, zinc oxide nanoparticles (ZnO-NPs) were utilized as a partial substitute for cement at concentrations of 0.5% and 1% to improve microstructure and strength progression. Concrete samples were tested at curing durations of 7, 28, and 91 days. The assessed qualities encompassed workability, density, water absorption, porosity, compressive strength, flexural strength, and splitting tensile strength. Microstructural characterization was conducted utilizing X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). The findings indicated that porcelain waste powder markedly surpassed brick waste powder in all mechanical and durability-related characteristics, particularly at 25% and 50% sand replacement ratios. The integration of polypropylene fibers enhanced fracture resistance and ductility. Moreover, the incorporation of zinc oxide nanoparticles improved hydration, optimized the pore structure, and resulted in significant enhancements in compressive and tensile strength throughout prolonged curing durations. The best results were obtained with a mix of 50% porcelain sand aggregate, 1% zinc oxide nanoparticles as cement replacement, and 0.5% polypropylene fibers, for which the improvements in compressive strength, flexural strength, and splitting tensile strength were 39.5%, 46.2%, and 60%, respectively, at 28 days. The results confirm the feasibility of using porcelain and brick waste as sand replacements in concrete, as well as polypropylene fiber-reinforced concrete and polypropylene fiber-reinforced concrete mixed with zinc oxide nanoparticles as a sustainable option for construction purposes. Full article

The circular economy in construction requires the valorization of gypsum waste from construction and demolition. Waste from gypsum plasterboards is considerable, yet it is still viewed more as a problem than as a mineral resource. This study investigates the potential for utilizing recycled gypsum (RG) from waste plasterboards in the production of blended green binders. Four gypsum–cement–pozzolanic binders are designed with two pozzolanic additives (natural zeolite and recycled brick powder) in two ratios to cement—0.6 and 1.0. The structural mineral compounds of the binders are analyzed by XRD and DTA/TG, while the performance of both fresh and hardened paste is evaluated by standardized methods for binders to determine possible construction applications of these green binders. Results show that RG can be used to produce blended fast-setting binders with a gypsum content of above 40%. Systems with natural zeolite achieve higher strength (up to 30 MPa at 90 days) and sufficient water resistance, thus suitable even as substitutes for cement binders. The developed blended binders with recycled brick powder can be used in low-moisture environments only as substitutes for gypsum binders in plasters, masonry units, and lightweight composites. Full article

Replacing virgin raw materials with recycled waste in construction products is a key strategy for advancing sustainable development. This study explores the partial substitution of commercial gypsum with powdered waste brick (WB) in gypsum mortars, assessing its impact on mechanical performance, water absorption, and environmental footprint. Mortars were prepared with 0%, 5%, 10%, 20%, and 30% WB by weight. Results indicate that a 20% replacement level enhances flexural strength by 56% and compressive strength by 33% at 28 days, compared to the reference mix. SEM and XRD analyses revealed no formation of new crystalline phases, suggesting that the performance improvement is primarily due to physical interactions and microstructural effects. However, at 30% WB, a significant reduction in adhesion strength was observed, falling below the typical threshold for gypsum-based coatings, which may constrain practical application at higher replacement levels. Environmental assessment showed that both CO₂ emissions and energy consumption decreased by up to 20% with a 30% substitution. A 20% WB content is therefore proposed as the optimal compromise between mechanical performance and environmental benefit. This approach supports circular economy principles by promoting the reuse of ceramic construction waste in the development of new sustainable materials. Full article

To promote the large-scale utilization of construction and industrial solid waste in engineering, this study focuses on developing accurate prediction and optimization methods for the unconfined compressive strength (UCS) of composite recycled mortar. Innovatively incorporating three types of recycled powder (RP)—recycled clay brick powder (RCBS), recycled concrete powder (RCBP), and recycled gypsum powder (RCGP)—we systematically investigated the effects of RP type, replacement rate, and curing period on mortar UCS. The core objective and novelty lie in establishing and comparing three artificial intelligence models for high-precision UCS prediction. Furthermore, leveraging GA-BP’s functional extremum optimization theory, we determined the optimal UCS alongside its corresponding mix proportion and curing scheme, with experimental validation of the solution reliability. Key findings include the following: (1) Increasing total RP content significantly reduces mortar UCS; the maximum UCS is achieved with a 1:1 blend ratio of RCBP:RCGP, while a 20% RCBS replacement rate and extended curing periods markedly enhance strength. (2) Among the prediction models, GA-BP demonstrates superior performance, significantly outperforming BP models with both single and double hidden layer. (3) The functional extremum optimization results exhibit high consistency with experimental validation, showing a relative error below 10%, confirming the method’s effectiveness and engineering applicability. Full article