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Advances in the Design and Properties of New Ecoconcrete Formulations

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Construction and Building Materials".

Deadline for manuscript submissions: closed (20 October 2024) | Viewed by 11248

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Special Issue Editors

Prof. Dr. Francisco Agrela

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Guest Editor

Area of Construction Engineering, University of Cordoba, 14071 Córdoba, Spain
Interests: sustainable construction; recycled materials; life cycle assessment; waste and byproduct application; recycled aggregate cement-based materials
Special Issues, Collections and Topics in MDPI journals

Dr. Julia Rosales

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Guest Editor

Area of Construction Engineering, University of Cordoba, 14071 Córdoba, Spain
Interests: cathode ray tube glass; recycled aggregates; civil infrastructures; cement-treated materials; stainless steel slag; treatment; self-compacting concrete; mechanical and durability properties; seaport loading platform; structural granular layers; construction and demolition waste; soil stabilization; nanomaterial; real-scale application; mechanical behavior; life cycle assessment
Special Issues, Collections and Topics in MDPI journals

Dr. Manuel Cabrera Montenegro

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Guest Editor

Special Issue Information

Dear Colleagues,

This Special Issue , entitled “Advances in the design of new eco-concrete formulations and their properties”, aims to address the latest research in the study of recycled concrete with different types of waste and by-products. Nowadays, the construction sector continues to be one amongst those that cause the most negative effects related to the high consumption of natural resources and high production of waste, which is then transferred to landfills. The application of different waste and by-products, such as recycled concrete aggregates, mixed recycled aggregates, steel slag, biomass bottom ash, or calcined urban solid waste, is a very important field of research and application for the manufacture of new concrete.

This Special Issue aims to explore advances in the study of the properties of recycled concrete aggregates and recycled mixed aggregates considering factors such as the influence of the place of origin, plant treatment, different processes, etc. Another important aspect that is considered is the application of these two types of aggregates in new alternative construction materials.

The main topics included in this Special Issue include, but are not limited to, the following:

Advances in the study of the characterization of recycled concrete and recycled mixed aggregates;
New classification of recycled aggregates according to their properties;
Improvement of properties through different treatments;
Use of recycled concrete and recycled mixed aggregates in new construction materials;
New techniques for the study of mechanical properties and durability of different types of recycled construction materials;
Leaching properties of recycled mixed aggregates and concrete;
Evaluation of the analysis of the life cycle of the production and use of recycled aggregates.

Prof. Dr. Francisco Agrela
Dr. Julia Rosales
Dr. Manuel Cabrera Montenegro
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

recycled concrete
recycled aggregates
recycled construction materials
life cycle
characterization

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Published Papers (9 papers)

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Research

36 pages, 6837 KiB

Open AccessArticle

Life-Cycle Assessment and Environmental Costs of Cement-Based Materials Manufactured with Mixed Recycled Aggregate and Biomass Ash

by Francisco Agrela, Manuel Rosales, Mónica López Alonso, Javier Ordóñez and Gloria M. Cuenca-Moyano

Materials 2024, 17(17), 4357; https://doi.org/10.3390/ma17174357 - 3 Sep 2024

Viewed by 1103

Abstract

The development of new building elements, such as concrete and mortar with sustainable materials, which produce a lower carbon footprint, is an achievable milestone in the short term. The need to reduce the environmental impact of the production of cement-based materials is of vital importance. This work focuses on the evaluation of the life-cycle assessment, production costs, mechanical performance, and durability of three mortars and three concrete mixtures in which mixed recycled aggregates (MRAs) and biomass bottom ash from olive waste (oBBA) were included to replace cement and aggregates. Powdered MRA and oBBA were also applied as complementary cementitious materials with a reduced environmental footprint. Chemical and physical tests were performed on the materials, and mechanical performance properties, life-cycle assessment, and life-cycle cost analysis were applied to demonstrate the technical and environmental benefits of using these materials in mortar and concrete mixtures. This research showed that the application of MRA and oBBA produced a small reduction in mechanical strength but a significant benefit in terms of life-cycle population and environmental costs. The results demonstrated that finding long-term mechanical strength decreases between 2.7% and 14% for mortar mixes and between 1.7% and 10.4% for concrete mixes. Although there were small reductions in mechanical performance, the savings in environmental and monetary terms make the feasibility of manufacturing these cement-based materials feasible and interesting for both society and the business world. CO₂ emissions are reduced by 25% for mortar mixes and 12% for concrete mixes with recycled materials, and it is possible to reduce the cost per cubic meter of mortar production by 20%, and the savings in the cost of production of a cubic meter of concrete is 13.8%. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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18 pages, 4517 KiB

Open AccessArticle

A Comprehensive Approach for Designing Low Carbon Wood Bio-Concretes

by M’hamed Y. R. da Gloria, Lucas R. Caldas, Joaquim A. O. Barros and Romildo D. Toledo Filho

Materials 2024, 17(11), 2742; https://doi.org/10.3390/ma17112742 - 4 Jun 2024

Viewed by 672

Abstract

This paper presents a method for designing low carbon bio-based building materials, also named bio-concretes, produced with wood wastes in shavings form (WS) and cementitious pastes. As the aggregates phase of bio-concretes is composed of plant-based particles, known as porous and high water-absorbing materials, the bio-concretes cannot be designed by using the traditional design rules used for conventional mortar or concrete. Then, the method used in the current paper is an adaptation of a previous one that has been developed in a recent paper where bio-concretes were produced with a cement matrix, three types of bio-aggregates, and a proposal of a design abacus. However, when that abacus is used for designing WBC with low cement content in the matrix, the target compressive strength is not reached. In the present paper, the method is extended to low cement content matrix (up to 70% of cement substitution) and also considering the greenhouse gas (GHG) emission of the WBC. To obtain data for proposing a new design abacus, an experimental program was carried out by producing nine workable WBCs, varying wood volumetric fractions (40–45–50%), and water-to-binder ratios. The bio-concretes produced presented adequate consistency, lightness (density between 715 and 1207 kg/m³), and compressive strength ranging from 0.64 to 12.27 MPa. In addition, the GHG emissions of the WBC were analysed through the Life Cycle Assessment methodology. From the relationships obtained between density, compressive strength, water-to-binder ratio, cement consumption, and GHG emissions of the WBC, calibration constants were proposed for developing the updated and more complete abacus regarding an integrated mix design methodology. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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14 pages, 1122 KiB

Open AccessArticle

Sustainable Hybrid Lightweight Aggregate Concrete Using Recycled Expanded Polystyrene

by D. González-Betancur, Ary A. Hoyos-Montilla and Jorge I. Tobón

Materials 2024, 17(10), 2368; https://doi.org/10.3390/ma17102368 - 15 May 2024

Viewed by 1186

Abstract

Global concrete production, reaching

14 \times 10^{13}

m^{3} /

year, raises environmental concerns due to the resource-intensive nature of ordinary Portland cement (OPC) manufacturing. Simultaneously,

32.7 \times 10^{9}

kg/year of expanded polystyrene (EPS) waste poses ecological threats. This research explores [...] Read more.

Global concrete production, reaching

14 \times 10^{13}

m^{3} /

year, raises environmental concerns due to the resource-intensive nature of ordinary Portland cement (OPC) manufacturing. Simultaneously,

32.7 \times 10^{9}

kg/year of expanded polystyrene (EPS) waste poses ecological threats. This research explores the mechanical behavior of lightweight concrete (LWAC) using recycled EPS manufactured with a hybrid cement mixture (OPC and alkali-activated cement). These types of cement have been shown to improve the compressive strength of concrete, while recycled EPS significantly decreases concrete density. However, the impact of these two materials on the LWAC mechanical behavior is unclear. LWAC comprises

35 %

lightweight aggregates (LWA)—a combination of EPS and expanded clays (EC) — and

65 %

normal-weight aggregates. As a cementitious matrix, this LWAC employs

30 %

OPC and

70 %

alkaline-activated cement (AAC) based on fly ash (FA) and lime. Compressive strength tests after 28 curing days show a remarkable

48.8 %

improvement, surpassing the ACI 213R-03 standard requirement, which would allow this sustainable hybrid lightweight aggregate concrete to be used as structural lightweight concrete. Also obtained was a

21.5 %

reduction in density; this implies potential cost savings through downsizing structural elements and enhancing thermal and acoustic insulation. X-ray diffraction (XRD) and Fourier transform infrared (FTIR) spectroscopy reveal the presence of C-S-H, C-(A)-S-H, and N-A-S-H gels. However, anhydrous products in the hybrid LWAC suggest a slower reaction rate. Further investigation into activator solution dosage and curing temperature is recommended for improved mechanical performance on the 28th day of curing. This research highlights the potential for sustainable construction incorporating waste and underscores the importance of refining activation parameters for optimal performance. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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13 pages, 3121 KiB

Open AccessArticle

Strength and Durability Characterization of Structural Concrete Made of Recycled Plastic

by Jonathan Oti, Blessing O. Adeleke, Mihiri Rathnayake, John M. Kinuthia and Emma Ekwulo

Materials 2024, 17(8), 1841; https://doi.org/10.3390/ma17081841 - 17 Apr 2024

Cited by 2 | Viewed by 1708

Abstract

This study investigates the feasibility of utilizing recycled plastic waste as a partial substitute for sand in concrete production. Reprocessing used plastic items or materials involves collecting, cleaning, shredding, and melting, resulting in reprocessed plastic particles. Incorporating these recycled plastic particles into concrete addresses environmental concerns related to plastic disposal and the growing scarcity and increasing cost of natural sand. To evaluate the sand replacement capacity of recycled plastic, four types of mixtures were created with varying levels of recycled plastic replacement (5%, 10%, 15%, and 20%). All mixtures maintained a water-to-binding ratio of 0.55 and were tested at 7, 28, and 56 days. The testing regimen encompassed determining the slump value, density, compressive strength, tensile strength, and resistance to freezing and thawing. The findings revealed that replacing sand in the concrete mix with recycled plastic enhanced workability, which was attributed to the hydrophobic nature of the plastic particles. However, both compressive and tensile strength exhibited a declining trend. Additionally, after undergoing multiple freezing and thawing cycles, the concrete mix exhibited poor durability properties and brittleness. These issues may arise due to factors such as incompatibility, non-uniformity, reduced cohesion, and the lower density of plastic particles. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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9 pages, 1875 KiB

Open AccessArticle

Influence of Accelerators on Cement Mortars Using Fluid Catalytic Cracking Catalyst Residue (FCC): Enhanced Mechanical Properties at Early Curing Ages

by Lourdes Soriano, María Victoria Borrachero, Ester Giménez-Carbo, Mauro M. Tashima, José María Monzó and Jordi Payá

Materials 2024, 17(5), 1219; https://doi.org/10.3390/ma17051219 - 6 Mar 2024

Viewed by 844

Abstract

Supplementary cementitious materials (SCMs) have been used in the construction industry to mainly reduce the greenhouse gas emissions associated with Portland cement. Of SCMs, the petrochemical industry waste known as fluid catalytic cracking catalyst residue (FCC) is recognized for its high reactivity. Nevertheless, the binders produced using SCMs usually present low mechanical strength at early curing ages. This study aims to assess the effect of different accelerating additives (KOH, sodium silicate SIL, commercial additive SKR) on the mechanical strength of mortars containing FCC. The results show that after only 8 curing hours, the compressive strength gain of the FCC mortars containing SKR was over 100% compared to the FCC mortar with no additive (26.0 vs. 12.8 MPa). Comparing the compressive strength of FCC mortar containing SKR to the control mortar, the enhancement is spetacular (6.85 vs. 26.03 MPa). The effectiveness of the tested accelerators at 8–24 curing hours was KOH ≈ SIL < SKR, whereas it was KOH < SIL < SKR for 48 h–28 days. The thermogravimetric data confirmed the good compatibility of FCC and the commercial accelerator. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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18 pages, 7657 KiB

Open AccessArticle

Enhancing Thermal Efficiency in Water Storage Tanks Using Pigmented Recycled Concrete

by Jorge López-Rebollo, Ignacio Martín Nieto, Cristina Sáez Blázquez, Susana Del Pozo and Diego González-Aguilera

Materials 2024, 17(5), 1008; https://doi.org/10.3390/ma17051008 - 22 Feb 2024

Viewed by 988

Abstract

The present work investigated the manufacture of elements such as water tanks from recycled concrete for applications where industries require water heating. This proposal leverages precast rejects for recycled concrete and incorporates colouring pigments. It is expected to contribute to the circularity of construction materials (due to the total replacement of natural aggregates by recycled aggregates) as well as to energy and emissions savings, which are attributed to improved thermal performance driven by the thermal behaviour that the coloration pigment gives to the manufactured concrete elements. To assess the efficacy of the proposed solution, on the one hand, mechanical tests were carried out in tensile, compression and modulus of elasticity, which showed a suitable concrete dosage for HA-30 structural concrete. Simultaneously, in search for a material that would increase the internal temperature of the tanks, thermal tests were carried out in a controlled laboratory environment on samples with different percentages of pigment, and an optimum concentration of 1% was obtained. It was also found that the thermal conductivity remained almost unaffected. Finally, two water tank prototypes were manufactured and tested under real environmental conditions: one with the optimised pigment concentration solution and other (the reference tank) without pigment. The results revealed that the colourised tank with the optimal concentration resulted in an average water temperature increase of 2 °C with respect to the reference tank. Finally, the economic and environmental benefits of this temperature increase were studied for industrial processes requiring water heating with a potential saving of 8625 kWh per month. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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19 pages, 2491 KiB

Open AccessArticle

Feasibility of Using New Sustainable Mineral Additions for the Manufacture of Eco-Cements

by S. Moreno, M. Rosales, J. Rosales, F. Agrela and J. L. Díaz-López

Materials 2024, 17(4), 777; https://doi.org/10.3390/ma17040777 - 6 Feb 2024

Cited by 3 | Viewed by 1223

Abstract

Due to a continuously developing population, our consumption of one of the most widely used building materials, concrete, has increased. The production of concrete involves the use of cement whose production is one of the main sources of CO₂ emissions; therefore, a challenge for today’s society is to move towards a circular economy and develop building materials with a reduced environmental footprint. This study evaluates the possibility of using new sustainable supplementary cementitious materials (SCMs) from waste such as recycled concrete aggregates (RCAs) and mixed recycled aggregates (MRAs) from construction and demolition waste, as well as bottom ash from olive biomass (BBA-OL) and eucalyptus biomass ash (BBA-EU) derived from the production of electricity. A micronisation pre-treatment was carried out by mechanical methods to achieve a suitable fineness and increase the SCMs’ specific surface area. Subsequently, an advanced characterisation of the new SCMs was carried out, and the acquired properties of the new cements manufactured with 25% cement substitution in the new SCMs were analysed in terms of pozzolanicity, mechanical behaviour, expansion and setting time tests. The results obtained demonstrate the feasibility of using these materials, which present a composition with potentially reactive hydraulic or pozzolanic elements, as well as the physical properties (fineness and grain size) that are ideal for SCMs. This implies the development of new eco-cements with suitable properties for possible use in the construction industry while reducing CO₂ emissions and the industry’s carbon footprint. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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21 pages, 4232 KiB

Open AccessArticle

Eco-Friendly Pavements Manufactured from Mixed Recycled Aggregates Obtained from Construction and Demolition Waste: An Industrial-Scale Validation

by Manuel Contreras-Llanes, Manuel Jesús Gázquez and Maximina Romero

Materials 2023, 16(24), 7544; https://doi.org/10.3390/ma16247544 - 7 Dec 2023

Cited by 1 | Viewed by 1414

Abstract

This study aimed to validate that laboratory-scale results could be commercially replicated when manufacturing marketable precast concrete. Construction and demolition waste (CDW) was separated into two (fine and coarse) recycled aggregates (RAs). Precast paver and kerb units were fabricated by partial or total substitution of natural aggregates (NAs) by RAs. The study involved the comprehensive characterisation of raw materials, including particle size distribution, mineral composition, and elemental composition. Paver blocks and kerbs manufactured with up to 50% RAs showed mechanical resistance (T = 3.7 ± 0.2 and B = 5.3 ± 0.6 MPa, respectively), water absorption between 5.3–5.7%, and abrasion resistance (approximately 20.2 mm), which met the standard requirements (UNE-EN 1340:2004 and UNE-EN 1338:2004). Furthermore, industrial-scale precast pavement units demonstrated strength and durability suitable for heavy traffic areas. A reduction of 13% in cement content could maintain the requirements with a partial RA substitution of 25%, offering economic and environmental benefits. Therefore, it is feasible at an industrial level to replace NAs with RAs, promoting durability and technological properties with a positive environmental impact and considerably reducing CO₂ emissions by up to 65%. Overall, pavers with RAs manufactured at the laboratory scale met mechanical standards, and the kerb stones showed improvements in abrasion resistance. On an industrial scale, kerb stones and precast blocks with specific substitutions can meet strength, water absorption, and abrasion requirements, allowing a reduction in cement content. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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17 pages, 4783 KiB

Open AccessArticle

Recycled Fine and Coarse Aggregates’ Contributions to the Fracture Energy and Mechanical Properties of Concrete

by Madumita Sadagopan, Alexander Oliva Rivera, Katarina Malaga and Agnes Nagy

Materials 2023, 16(19), 6437; https://doi.org/10.3390/ma16196437 - 27 Sep 2023

Cited by 1 | Viewed by 1222

Abstract

This paper investigates the fracture mechanical properties of concrete, using crushed concrete aggregates (CCA) and granulated blast furnace slag (GGBS) for partial cement replacement. CCAs made from prefabricated concrete replace 100% of the fine and coarse fractions in concrete recipes with w/c ratios of 0.42 and 0.48. Two pre-treatment methods, mechanical pre-processing (MPCCA) and accelerated carbonation (CO₂CCA), are investigated for quality improvements in CCA. The resulting aggregates show an increased density, contributing to an increase in the concrete’s compressive strength. The novelty of this paper is the superposition of the effects of the composite parts of concrete, the aggregate and the cement mortar, and their contributions to concrete fracture. Investigations are directed toward the influence of fine aggregates on mortar samples and the influence of the combination of coarse and fine aggregates on concrete samples. The physical and mechanical properties of the aggregates are correlated with mortar and concrete fracture properties. The results show that CCA concrete achieves 70% of the fracture energy values of concrete containing natural aggregates, and this value increases to 80% for GGBS mixes. At lower w/c ratios, MPCCA and CO₂CCA concretes show similar fracture energies. CO₂CCA fine aggregates are the most effective at strengthening the mortar phase, showing ductile concrete behavior at a w/c ratio of 0.48. MPCCA aggregates contribute to higher compressive strengths for w/c ratios of 0.42 and 0.48. Thus, mechanical pre-processing can be improved to produce CCA, which contributes to more ductile concrete behavior. Full article

(This article belongs to the Special Issue Advances in the Design and Properties of New Ecoconcrete Formulations)

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