Search Results (55)

This study treated the NaOH component in red mud sludge, an industrial by-product generated at 300,000 tons annually in Korea, with sulfuric and nitric acids to produce NaSO₄ and NaNO₃, respectively. The effects of acid-treated liquid red mud (LRM) on the hydration reactions and early strength development in cement mortar were investigated. Properties such as flow, setting time, hydration heat, and compressive strength were evaluated alongside hydration product analysis using X-ray diffraction (XRD) and scanning electron microscopy (SEM). The neutralization of LRM stabilized the pH between 7 and 8. Mortars containing neutralized red mud (NRM) and sulfuric-treated red mud (SRM) exhibited shorter initial setting times and similar final setting times compared to untreated red mud (LM). After one day, XRD confirmed the presence of Ca(OH)₂ in NRM and SRM but not in LM, while SEM revealed reduced pore sizes in NRM and SRM. Depending on dosage, the compressive strength of SRM increased by 35–60% compared to Plain mortar. These results demonstrate that LRM treated with nitric or sulfuric acid has significant potential as a setting accelerator for cement mortar. Full article

This research aims to address the environmental and economic challenges associated with conventional concrete by partially replacing cement—the most polluting, expensive, and energy-intensive ingredient—with industrial paint sludge ash (PSA), a highly contaminated industrial waste that is typically landfilled. Mortar mixtures were prepared with PSA replacement levels ranging from 0% to 20% in 5% increments while maintaining a constant water-to-binder ratio of 0.48. This study comprehensively evaluated the fresh, mechanical, durability, and microstructural properties of the PSA-modified mortar to assess its potential as an ecofriendly construction material. Results showed that as PSA content increased, the fresh properties, such as workability/slump flow and setting time, decreased, while the water demand for attaining normal consistency increased. Soundness tests indicated expansion up to 15% PSA replacement, beyond which expansion became more pronounced. Compressive strength improved significantly with PSA replacements of 5% to 15% compared to the control sample, with a slight decline at 15% relative to 5% and 10%. This trend was consistent with bulk density and ultrasonic pulse velocity measurements. Furthermore, the incorporation of PSA enhanced key durability properties, including water absorption, sulfate resistance, and porosity reduction, up to 15% PSA replacement. Microstructural analysis using SEM, XRD, TGA/DTA, and FTIR confirmed that PSA inclusion led to increased mortar densification, with the 10% PSA mix exhibiting thermal stability and minimal mass loss at elevated temperatures. FTIR spectra further indicated improved composition with higher PSA content. Overall, PSA proved to be a viable partial cement replacement, offering enhanced mortar properties without compromising performance. Its use contributes to sustainability by reducing reliance on cement, lowering construction costs, and eliminating the environmental and logistical burdens of paint sludge disposal. Full article

Electric arc furnace oxidizing slag (EAFOS) represents 80% of the electric arc furnace slag generated. Recently, EAFOS has been utilized as high value-added functional aggregate in a growing number of cases for the construction of air-cooling technology that turns EAFOS into fine aggregate-sized particles by spraying it into the air using high-pressure compressed air. Ladle furnace slag (LFS) is a product of the reduction process, accounting for approximately 20% of the steel slag enerated; however, LFS is predominantly landfilled without being utilized. This is mainly because LFS changes into sludge as it is turned into powder during water spray cooling. Therefore, in this study, spherical particles cooled at room temperature were fabricated as fine aggregates using LFS by applying atomization technology that uses high-pressure air in the molten state for the value-added utilization of LFS. Various experiments were performed to examine whether this aggregate can be used as a construction material. The experimental results showed that the air-cooled LFS (ALFS) fine aggregate generated from two different processes met the physical and chemical properties of the fine aggregate required for concrete despite its slightly lower spherical ratio compared to EAFOS aggregate. The volumetric stability experiment results also showed that ALFS fine aggregate is more stable than river sand and standard sand. In addition, the autoclave test results revealed that the mortar produced using ALFS fine aggregate was more stable for expansion than that of comparison groups. These results confirm the applicability of ALFS as an aggregate for construction. However, because the pop-out phenomenon caused by MgO was observed on the surface of some specimens, further research is required for improvement. Full article

Drinking water treatment sludge (DWTS) is a typical by-product of drinking water treatment plants. Concerns are growing about how to deal with big amounts of this sludge generated globally. One of the ways is to reuse DWTS as a supplementary material in cementitious systems and thus reduce landfill disposals. For our studies, we used DWTS containing more than 52% Fe₂O₃. The DWTS was taken from a water treatment plant in Vilnius, Lithuania. This work aimed to find potential applications of unprocessed DWTS in cementitious systems as a supplementary material that changes the physical and mechanical properties of the final product. Tests were performed with cementitious mortars where the binder was replaced with DWTS (from 0% to 12.5%). Local raw materials such as Portland cement CEM I 42.5R and sand 0/4 were used in the tests. Water absorption, absorption kinetics, and mechanical strength tests were conducted, and predictive freeze–thaw resistance was estimated. The heat release rate and open–closed porosity were also measured. The results showed that DWTS impacts the hydration of cementitious mortars, lowers their density (from 2122 kg/m³ to 1954 kg/m³), as well as compressive strength (from 41.78 MPa to 24.76 MPa) and flexural strength (from 6.24 MPa to 4.07 MPa), and increases total porosity (from 28.1% to 34.6%) and closed porosity (from 9.1% to 14.9%). The lowest toughness value of 6.08 was recorded in the 12.5% DWTS sample. From our conducted research, it could be observed that raw DWTS potentially changed the porosity parameters of cementitious mortars. This resulted in an incremental improvement in durability and an improvement in the hardness of cementitious mortars. A higher content of raw DWTS changed the colour (to reddish) of cementitious mortars, due to its higher Fe₂O₃ content (up to 53%). All of the above-mentioned properties allowed the designing of cementitious landscape products with a wider range of colours. Full article

The requirement for high-quality drinking water and the treatment of wastewater prior to discharge into the environment results in the generation of sludge. As with any high-volume materials, beneficial reuse applications are being sought to promote sustainable environmental solutions. This research examined the possibilities of producing sustainable lightweight concrete using modified solidified wastewater sludge as a partial replacement of cement. Wastewater sludge was modified by the addition of aluminum oxide and magnesium silicate hydrate. The properties of the modified wastewater sludge were examined, as well as the influence of the partial cement replacement with the sludge in lightweight concrete. Besides testing the physical and mechanical properties of four mortar mixtures, an additional analysis of the willingness of final users to accept novel material containing wastewater sludge was addressed. The results obtained for the mortar samples indicate that 20% cement replacement is the upper limit for the modified sludge’s application. The lightweight concrete prepared with the modified sludge (in the amount of 20%) was tested in a hardened state. The water permeability was reduced by 33.3% with the addition of the modified sludge. Both tested concrete mixtures showed good frost resistance. The maximal measured reduction in the compressive strengths was 7.6%. Citizens’ perceptions and responses regarding the beneficial reuse of materials emphasize the importance of comprehensive education for their future acceptance. Full article

The global construction industry faces increasing pressure to adopt sustainable practices, particularly in reducing cement-related CO₂ emissions. This study investigates the feasibility of using treated wastewater sludge (WWS) as a partial replacement for cement in repair mortars. Treated (A-WWS) and untreated (B-WWS) sludge were evaluated for their effects on workability, mechanical strength, durability, and environmental impact. Flow tests revealed that A-WWS maintained workability similar to the control mixture, while B-WWS reduced flow due to its coarser particles. Compressive strength tests showed that a 10% A-WWS substitution improved strength due to enhanced pozzolanic reactions, while untreated sludge reduced overall strength. Water absorption and bond strength tests confirmed the improved durability of A-WWS mortars. Chemical attack resistance testing demonstrated that A-WWS significantly reduced carbonation depth and chloride penetration, enhancing durability. Microstructural analysis supported these findings, showing denser hydration products in pretreated sludge mixtures. An environmental hazard analysis confirmed low heavy metal content, making sludge-based mortars environmentally safe. Although wastewater sludge shows promise as a partial cement replacement, the processing energy demand remains substantial, necessitating further investigation into energy-efficient treatment methods. This research highlights the potential of pretreated WWS as a sustainable alternative in construction, contributing to reduced cement consumption and environmental impact without compromising material performance. The findings support the viability of sludge-based repair mortars for practical applications in the construction industry. Full article

This paper examines the properties of sewage sludge ashes (SSAs) from the incineration of sewage sludge with added limestone for toxic gas treatment. It also evaluates the potential valorization of SSA in cement composites as supplementary cementitious materials (SCMs). The work involves a thorough characterization of four SSAs, including physical, chemical, and mineralogical properties. It also includes assessing the behavior of SSA in water solution through electrical conductivity measurements. The reactivity of ashes was evaluated using the R³ method and mechanical properties. The results revealed that all SSAs present comparable mineralogical and chemical properties, with varying proportions. Major elements such as Ca, Si, Fe, P, and S are predominant in the ashes, with traces of heavy metals. In an aqueous solution, a gradual formation of ettringite was detected only for two SSA. The heavy metal leachability was negligible, confirming that SSA is a non-hazardous waste. Finally, the reactivity and strength activity index assessments revealed a low and slow reactivity of SSA compared to metakaolin or slag. The SSA that favored ettringite formation in aqueous solution presented the lowest compressive strength at 28 days after incorporation in mortar. Despite originating from different incineration sites, these ashes fall under the same category of SCM reactivity. Full article

The paper presents an analysis of the effective use of a mixture of steel sludge (S1) and slag (S2) from the converter process of steel production for the production of cement mortars. Metallurgical waste used in the research, which is currently deposited in waste landfills and heaps near plants, posing a threat to groundwater (possibility of leaching metal ions present in the waste), was used as a substitute for natural sand in the range of 0–20% by weight of cement (each). The obtained test results and their numerical analysis made it possible to determine the conditions for replacing part of the sand in cement mortars with a mixture of sludge and slag from a basic oxygen furnace (BOF) and to determine the effects of such modification. For the numerical analysis, a full quadratic Response Surface Model (RSM) was utilized for two controlled factors. This model was subsequently optimized through backward stepwise regression, ensuring the inclusion of only statistically significant components and verifying the consistency of residual distribution with the normal distribution (tested via Ryan-Joiner’s test, p > 0.1). The designated material models are helpful in designing ecological cement mortars using difficult-to-recycle waste (i.e., sludge and converter slag), which is important for a circular economy. Mortars modified with a mixture of metallurgical waste (up to 20% each) are characterized by a slightly lower consistency, compressive and flexural strength, and water absorption. However, they show a lower decrease in mechanical strength after the freezing–thawing process (frost resistance) compared to control mortars. Mortars modified with metallurgical waste do not have a negative impact on the environment in terms of leaching heavy metal ions. The use of a mixture of sludge and steel slag in the amount of 40% (slag/sludge in a 20/20 ratio) allows you to save 200 kg of sand when producing 1 m³ of cement mortar (cost reduction by approx. EUR 5.1/Mg) and will also reduce the costs of the environmental fee for depositing waste. Full article

Sludge ceramsite (SC) can be utilized as a lightweight aggregate in concrete, especially in external wall materials, due to the increasing volume of polluted sludge, which contributes to water system deterioration and poses greater threats to human health. The influence of the fresh mortar’s slump flow on the dispersion of ceramsite was studied. The ultrasonic sound velocity, capillary water absorption rate, compressive strength, and coefficient of variation (CV) were measured in this study. Thermogravimetric (TG) analysis, ultra depth-of-field microscope scanning, X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectrometry (EDS) were used to analyze the performance mechanism of the ceramsite concrete. The results indicated that adding SC could reduce the fluidity of the fresh concrete, with a reduction by rates of up to 2.04%. The addition of WRA could improve the fluidity by rates of up to 60.77%. The relationship between the ultrasonic sound speed and the increasing fluidity could be deduced as a negative correlation. The water absorption was negatively correlated with the compressive strength. The concrete with a slump flow of 12.35 and 12.5 cm reached the maximum compressive strength, which had the lowest water absorption, and demonstrated internal homogeneity. The optimum slump flow was 12.35 and 12.5 cm. With the slump flow of 12.5 cm, the corresponding CV was the lowest, showing the optimum SC’s dispersion. Through TG, XRD, and SEM analyses, it was verified that the addition of 0.6% WRA promoted the hydration of cement. In addition, SC increased the hydration products. Full article

The construction industry strives for sustainable solutions to tackle environmental challenges and optimize resource use. One such focus area is the management of industrial byproducts and waste materials, including fugitive dust control through wheel washers. While wheel washers play a pivotal role in dust management, they generate a challenging byproduct known as wheel washer sludge (WWS). The disposal of WWS is complicated due to its composition and potential hazards. Recent research explores reusing WWS in construction materials, particularly in repair mortar, aiming for sustainability and circular economy principles. This study investigates the incorporation of WWS into repair mortar formulations, evaluating mechanical properties, durability, and environmental implications. Results show that WWS enhances workability but prolongs setting time. Mechanical strength tests reveal improvements with WWS addition, especially when pretreated. Water absorption rates decrease with pretreated WWS, indicating enhanced durability. Chemical attack tests demonstrate resistance to carbonation and chloride penetration, especially with modified WWS. Freeze–thaw tests reveal improved resistance with WWS addition, particularly modified. Microstructure analysis confirms hydration products and denser matrices with WWS inclusion. Environmental hazard analysis shows WWS contains no harmful heavy metals, indicating its suitability for use in repairs. Overall, this study highlights the technical feasibility and environmental benefits of incorporating WWS into repair mortar, contributing to sustainable construction practices. Full article

This research presented, for the first time, the results of the successful application of the waste press sludges, WSLP (plant for lacquer and paint) and WSEP (powdery enamel plant), from a wastewater treatment plant generated during heating device production in the construction industry. The results of WSEP characterization and its influence on cement paste, mortar, and concrete properties showed that this material could be used as a cement replacement (with a maximum replacement amount of 20%) in producing mortar and concrete. Although waste WSLP sludge does not possess pozzolanic properties and does not meet the criteria prescribed by the standards for application in mortar and concrete due to its chemical inertness and fineness, as well as its extended setting time, it can be used as a replacement for stone filler or other powdered mineral admixture in the production of self-compacting concrete (SCC) in amounts up to 100%, with a maximum quantity of up to 100 kg/m³. The obtained results indicate that with the appropriate conversion, waste sludges, despite representing hazardous waste, can be used as safe products in the construction industry; i.e., the waste material can become a useful and valuable raw material by applying (respecting) all of the principles of the green economy. Full article

With the significant pace of industrialization, the emission of carbon dioxide (CO₂) through cement manufacture, as well as from developed environments, will undoubtedly rise yearly. Biochar as a byproduct of biomass pyrolysis can be utilized in concrete to partially replace cement. Because of its ecological and economic benefits, such as carbon sinks or carbon capture, low thermal conductivity, chemical resistance, and low thermal properties, biochar has risen in popularity in recent years. On the other hand, the possibility of using sludge ash as a cement substitute in the process of making mortar has recently attracted increasing interest. The effectiveness and acceptability of using pine cones as a byproduct of biochar and sludge ash, a byproduct of wastewater treatment, to produce mortar in place of cement are being intensively explored. The integration of biochar and sludge ash into cementitious materials is a possible approach for pollution reduction by replacing Portland cement and reducing collection and disposal in landfills. In order to create high-performance mortar, this study experimentally explores the impacts of combining biochar at an optimal of 6% and sludge ash at optimal of 10%. It analyzes the rheological, mechanical, and durability attributes across curing times of 7 and 28 days in both wet and dry environments, while keeping a constant temperature of 20 °C. As a result, at 28 days, every blend was higher compared to baseline mixture at 7 days. Increases of 19.52% and 13.78%, as well as 24.76% and 21.68%, were seen in the mixtures with 5% and 10% sludge ash (SA) at 28 days compressive strength. With percentage increments for both 7 days and 28 days of 6.6% and 30.9% and 2.2% and 14.1%, the binary blend utilizing BC₃SA₁₀ and BC₃SA₅ significantly outperformed the reference mix. In mortar, the use of biochar could reduce capillary absorption. In addition, its inclusion fastens the rate of hydration of the cement and prevents shrinkage cracks in the mix. The current study concentrates on the significant features of biochar and sludge ash that have an impact on cementitious materials performance. The fresh as well as hardened properties of various concrete and mortar mixes after the replacement of cement with biochar and sludge ash components have been extensively reviewed based on the research results. In a nutshell, biochar and sludge ash materials are an excellent alternative for cement in construction. Full article

This study assesses the mechanical properties of mortars incorporating waste paper sludge-derived cellulose fibers. Compression and flexural tests were carried out on specimens prepared with cellulose fibers at different proportions, ranging from 0% to 2% of the total weight of the solid mortar constituents (cement, sand, and lime). In addition, a comparative analysis was carried out to evaluate the influence of the preparation method on the mechanical properties of the mortars. To this end, two series of mortars were studied: one prepared following a rigorous control of the preparation parameters and the other made without systematic parameter control to simulate typical on-site conditions. Finally, the applicability of both traditional and eco-friendly mortars in the construction of small-scale masonry walls was assessed through compression tests. Overall, the mechanical properties of mortars with cellulose fibers were comparable to those with 0% waste material, regardless of the production process. Regarding the compressive behavior of masonry walls, experimental tests showed significant similarities between specimens made with traditional and eco-friendly mortar. In conclusion, incorporating cellulose fibers into cement-based mortar shows considerable potential for building applications, enhancing the environmental benefits without compromising the mechanical behavior. Full article

Against the backdrop of escalating infrastructure budgets worldwide, a notable portion—up to 45%—is allocated to maintenance endeavors rather than innovative infrastructure development. A substantial fraction of this maintenance commitment involves combatting concrete degradation due to microbial attacks. In response, this study endeavors to propose a remedial strategy employing nano metals and repurposed materials within cement mortar. The methodology entails the adsorption onto eggshell membranes (ESM) of silver nitrate (ESM/AgNO₃) or silver nanoparticles (ESM/AgNPs) yielding silver–eggshell membrane composites. Subsequently, the resulting silver–eggshell membrane composites were introduced in different proportions to replace cement, resulting in the formulation of ten distinct mortar compositions. A thorough analysis encompassing a range of techniques, such as spectrophotometry, scanning electron microscopy, thermogravimetric analysis, X-ray fluorescence analysis, X-ray diffraction (XRD), and MTT assay, was performed on these composite blends. Additionally, evaluations of both compressive and tensile strengths were carried out. The mortar blends 3, 5, and 6, characterized by 2% ESM/AgNO₃, 1% ESM/AgNPs, and 2% ESM/AgNPs cement replacement, respectively, exhibited remarkable antimicrobial efficacy, manifesting in substantial reduction in microbial cell viability (up to 50%) of typical waste activated sludge. Concurrently, a marginal reduction of approximately 10% in compressive strength was noted, juxtaposed with an insignificant change in tensile strength. This investigation sheds light on a promising avenue for addressing concrete deterioration while navigating the balance between material performance and structural integrity. Full article

The study aims to increase the efficiency of mortar mixes and improve their necessary qualities such as strength, density, and durability by using wastepaper as a cement substitute in the form of wastepaper sludge ash (WPSA). Mortars with 20, 25, and 30% cement replacement were tested. Due to less use of cement and greater usage of WPSA, CO₂ and SO₂ emissions can be reduced. The chemical properties of WPSA were compared to those of Ordinary Portland Cement (OPC). Testing showed that WPSA had similar cementitious properties. Results demonstrate the potential applications of this mortar in a variety of settings where increased toughness and equivalent characteristics are needed while still preserving the environment. Full article