Construction Materials

This study investigates sustainable mortars using lightweight synthetic sand (LSS), made from dune sand and recycled PET bottles, to replace natural sand (0–100% by volume). This aligns with circular economy principles by valorizing plastic waste into a construction aggregate. LSS is produced via controlled thermal treatment (250 ± 5 °C, 50–60 rpm), crushing, and sieving (≤3.15 mm), leading to a significantly improved interfacial transition zone (ITZ) with the cement matrix. The evaluation included physico-mechanical tests (density, strength, UPV, dynamic modulus, ductility), thermal properties (conductivity, diffusivity, heat capacity), porosity, sorptivity, alkali–silica reaction (ASR), and SEM. The results show LSS incorporation reduces mortar density (4–23% for 25–100% LSS), lowering material and logistical costs. While compressive strength decreases (35–70%), these mortars remain suitable for low-stress applications. Specifically, at ≤25% LSS, composites retain 80% of their strength, making them ideal for structural uses. LSS also enhances ductility and reduces dynamic modulus (18–69%), providing beneficial flexibility. UPV decreases (8–39%), indicating improved acoustic insulation. Thermal performance improves (4–18% conductivity reduction), suggesting insulation applicability. A progressive decrease in sorptivity (up to 46%) enhances durability. Crucially, the lack of ASR susceptibility reinforces long-term durability. This research significantly contributes to the repurposing of plastic waste into sustainable cement-based materials, advancing sustainable material management in the construction sector. Full article

The significant expansion of the construction sector and corresponding depletion of natural sand resources have intensified the search for sustainable alternatives, with waste foundry sand (WFS) emerging as a promising candidate. This systematic review evaluates the environmental performance and engineering feasibility of using WFS as a substitute for natural sand in construction. A PRISMA-guided search identified 152 peer-reviewed studies published between 2001 and 2024, which were categorized into four thematic areas: material characterization, construction applications, environmental impacts, and regulatory frameworks. The findings indicate that substituting 10–30% of natural sand with WFS in concrete and asphalt can deliver compressive strength within ±5% of control mixes and reduce water absorption by 5–15% at optimal replacement levels. However, contamination risks remain a concern, as chromium and copper concentrations in raw WFS have been reported at up to 931 mg/kg and 3318 mg/kg, respectively. To address these risks and ensure responsible reuse, a six-stage framework is proposed in this study, comprising end-of-waste classification, contaminant assessment, material preprocessing, certification, and regulatory monitoring. A comprehensive decision tree is also presented to guide the feasibility assessment of WFS reuse based on contaminant levels and material performance. Full article

The integration of sustainable materials such as fly ash, blast-furnace slag, recycled aggregates, and seawater into concrete mixes offers significant potential for reducing the environmental impact of construction. However, traditional experimental methods for determining the compressive strength of these concrete mixes are time-consuming and resource-intensive. This study leverages Artificial Neural Networks (ANNs) and Machine Learning (ML) to develop a predictive model for the compressive strength of sustainable concrete, using a dataset of 768 concrete mix samples. Input variables include the concrete age as well as concrete composition, including cement, water, fine and coarse aggregates, seawater, fly ash, blast-furnace slag, and superplasticizer contents, while the output is the compressive strength. The developed model captures the non-linear relationships among these variables to predict compressive strength efficiently. The best ANN model achieved a test loss of 0.051, demonstrating its ability to accurately predict compressive strength and reduce reliance on traditional testing methods. Moreover, the model’s results were compared with those of alternative algorithms to ensure its validity. These findings highlight the potential of machine learning in advancing sustainable construction practices. A relevant future research direction is to analyze feature importance in machine learning models to identify key variables and guide more effective optimization and decision-making, in addition to extending their application to other material properties and advanced concrete mixes. Full article

This study investigates the deterioration of skid resistance and surface macrotexture following preventive maintenance using micro-milling techniques. Field data were collected from 31 asphalt pavement sections located across four climatic zones in Texas. The data encompasses a variety of surface types, milling depths, operational speeds, and drum configurations. A standardized data collection protocol was followed, with measurements taken before milling, immediately after treatment, and at 3, 6, 12, and 18 months post-treatment. Skid number and Mean Profile Depth (MPD) were used to evaluate surface friction and texture characteristics. The dataset was reformatted into a time-series structure with 930 observations, including contextual variables such as climatic zone, treatment parameters, and baseline surface condition. A comparative modeling framework was applied to predict the deterioration trends of both skid resistance and macrotexture over time. Eight regression models, including linear, tree-based, and ensemble methods, were evaluated alongside a time series Transformer model. The results show that the Transformer model achieved the highest prediction accuracy for skid resistance (R² = 0.981), while Random Forest performed best for macrotexture prediction (R² = 0.838). The findings indicate that the degradation of surface characteristics after preventive maintenance is non-linear and influenced by a combination of environmental and operational factors. This study demonstrates the effectiveness of data-driven modeling in supporting transportation agencies with pavement performance forecasting and maintenance planning. Full article

Coal is still China’s primary energy source, and the production process of coal produces industrial byproduct coal gangue. This study explores the possibility of using industrial byproducts of thermal power generation, fly ash (FA) and calcined coal gangue (CCG), as a partial (10% and 20%) substitute for cement in construction materials. Methodical research was conducted to determine how these two substances affect the microstructure and macroscopic characteristics of cement-based materials. Macroscopic performance test findings indicate that replacing 20% of cement with CCG had no discernible effect on the specimens’ performance. At the same time, adding FA required 28 days to be comparable to the control group. Mercury intrusion porosimetry (MIP) test results show that using CCG can refine microscopic pores. Additional hydration products could be produced by these materials, according to analyses using Fourier transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD). The production of hydration products by CCG to fill the microscopic pores was further demonstrated by scanning electron microscopy (SEM) pictures. After 28 days of hydration, a layer of hydration products developed on the surface of FA. When supplementary cementitious materials (SCMs) were added, calcium hydroxide (CH) was consumed by interacting with FA and CCG to form additional hydration products, according to thermogravimetric analysis (TG) data after 28 days. Furthermore, an evaluation of FA and CCG’s effects on the environment revealed that their use performed well in terms of sustainable development. Full article

The study is motivated by the application of dry finish milling for post-build processing of additive Ti6Al4V blanks, since the use of neither lubricant nor coolants has been attracting increasing attention due to its environmental benefits, non-toxicity, and the elimination of the need for additional cleaning processes. For end mills, wear patterns were investigated upon finish milling of the SLM Ti6Al4V samples under various machining conditions (by varying the values of radial depth of cut and feed values at a constant level of axial depth of cut and cutting speed). When using all the applied milling modes, the identical tool wear mechanism was revealed. Built-up edges mainly developed on the leading surfaces, increasing the surface roughness on the SLM Ti6Al4V samples but protecting the cutting edges. However, abrasive wear was mainly characteristic of the flank surfaces that accelerated peeling of the protective coatings and increased wear of the end mills. The following milling parameters have been established as being close to rational ones: Vc = 60 m/min, Vf = 400 mm/min, a_p = 4 mm, and a_e = 0.4 mm. They affected the surface roughness of the SLM Ti6Al4V samples in the following way: max cutting thickness—8 μm; built-up edge at rake surface—50 ± 3 μm; max wear of flank surface—15 ± 1 μm; maximum adherence of workpiece. Mode III provided the maximum MRR value and negligible wear of the end mill, but its main disadvantage was the high average surface roughness on the SLM Ti6Al4V sample. Mode II was characterized by both the lowest average surface roughness and the lowest wear of the end mill, as well as an insufficient MRR value. Since these two modes differed only in their feed rates, their values should be optimized in the range from 200 to 400 mm/min. Full article

The increasing demand for sustainable practices in road construction has prompted the search for environmentally friendly and cost-effective materials. This study explores the incorporation of reclaimed asphalt pavement (RAP) and Panasqueira mine waste (greywacke aggregates) as full replacements for virgin aggregates in hot mix asphalt (HMA), aligning with the objectives of UN Sustainable Development Goal 9. Three asphalt mixtures were prepared: a reference mixture (MR) with granite aggregates, and two modified mixtures (M15 and M20) with 15% and 20% RAP, respectively. All mixtures were evaluated through Marshall stability, stiffness modulus, water sensitivity, and wheel tracking tests. The results demonstrated that mixtures containing RAP and mine waste met Portuguese specifications for surface courses. Specifically, the M20 mixture showed the highest stiffness modulus, improved moisture resistance, and the best performance against permanent deformation. These improvements are attributed to the presence of stiff aged binder in RAP and the mechanical characteristics of the greywacke aggregates. Overall, the findings confirm that the combined use of RAP and mining waste provides a technically viable and sustainable alternative for asphalt pavement construction, contributing to resource efficiency and circular economy goals. Full article

Reinforced concrete (RC) deep beams constructed with low-strength concrete are susceptible to sudden splitting failures in the strut region due to shear–compression stresses. To mitigate this vulnerability, various strengthening techniques, including steel plates, fiber-reinforced polymer sheets, and cementitious composites, have been explored to confine the strut area. This study investigates the structural performance of RC deep beams with low-strength concrete, strengthened externally using an Engineered Cementitious Composite (ECC) layer. To ensure effective confinement and uniform shear distribution, shear reinforcement was provided at equal intervals with configurations of zero, one, and two vertical shear reinforcements. Four-point bending tests revealed that the ECC layer significantly enhanced the shear capacity, increasing load-carrying capacity by 51.6%, 54.7%, and 46.7% for beams with zero, one, and two shear reinforcements, respectively. Failure analysis through non-linear finite element modeling corroborated experimental observations, confirming shear–compression failure characterized by damage in the concrete struts. The strut-and-tie method, modified to incorporate the tensile strength of ECC and shear reinforcement actual stress values taken from the FE analysis, was used to predict the shear capacity. The predicted values were within 10% of the experimental results, underscoring the reliability of the analytical approach. Overall, this study demonstrates the effectiveness of ECC in improving shear performance and mitigating strut failure in RC deep beams made with low-strength concrete. Full article

This study evaluates the influence of fiber type, geometry, and interfacial behavior on the physical and mechanical performance of cementitious composites reinforced with recycled pulp from beverage cartons (RPBC), bamboo fiber (BF), and eucalyptus fiber (EF) as the sole reinforcing agents. The BF was rounded in shape and had the highest aspect ratio, while the ribbon-shaped EF exhibited the highest tensile strength index. The RPBC fibers were fibrillated and the shortest, with a ribbon shape. Flexural strength results showed that RPBCC achieved a maximum strength that was 47.6% higher than the control specimen (0% fiber), outperforming both BF- and EF-reinforced counterparts. This superior performance is attributed to the higher fibrillation level of the ribbon-shaped RPBC fibers, which promoted better fiber–matrix bonding. As the fiber content increased, the bulk density of EFC and BFC decreased linearly, while RPBC composites showed only a modest decrease in density. Porosity steadily increased in EFC and BFC, whereas a non-linear trend was observed in RPBCC, likely due to its unique morphology and fibrillation. Conversely, EFC exhibited significantly higher maximum fracture toughness (3600 J/m² at 10 wt.%) compared to PBFCC (1600 J/m² at 14 wt.%) and BFC (1400 J/m² at 14 wt.%). This enhancement is attributed to extensive fiber pullout mechanisms and increased energy absorption during crack propagation. Overall, all composite types demonstrated flexural strength values above 4 MPa, placing them in the Grade I category. Those reinforced with 10–14% RPBC exhibited strengths of 11–12 MPa, categorizing them as Grade II according to ASTM C1186-02. Full article

The construction of concrete pavements has increased due to their better durability, lifespan, and lower maintenance costs. However, this has resulted in the increased consumption of Portland cement, which is one of the major contributors to carbon emissions. Consequently, the research on alternative binders such as geopolymer concrete has increased in recent times. There are several research studies that investigate the feasibility of geopolymer concrete as a construction material, with limited studies exploring its application in concrete pavements. Therefore, this review study explores the material properties of geopolymer concrete pertinent to the performance of concrete pavements. It also discusses the potential of various industrial and agricultural waste as precursor material in geopolymer concrete. The findings of this paper show that most of the studies used fly ash and ground granulated blast furnace slag (GGBFS) as precursor material in geopolymer pavement-quality concrete, and there is a vast scope in the exploration of other industrial and agricultural waste as precursor material. The mechanical and durability properties of geopolymer pavement-quality concrete are superior to conventional pavement concrete. It is also observed that the drying shrinkage and coefficient of thermal expansion of geopolymer pavement-quality concrete are lower than those of conventional pavement concrete, and this will positively benefit the long-term performance of concrete pavements. The results of fatigue analysis and mechanical load test on the geopolymer pavement-quality concrete indicate its improved performance when compared to the conventional pavement concrete. Full article

Alkali-activated building materials have attracted the interest of many researchers due to their low cost and eco-efficiency. Different binders with different chemical compositions can be used for their production, so the reaction mechanism can become complex and the results of studies can vary widely. In this work, several alkali-activated mortars based on marginal by-products as binders, such as high calcium fly ash and ladle furnace slag, are investigated. Their mechanical (flexural and compressive strength, ultrasonic pulse velocity, and modulus of elasticity) and physical (porosity, absorption, specific gravity, and pH) properties were determined. After evaluating the mechanical performance of the mortars, the optimum mixture containing fly ash, which reached 15 MPa under compression at 90 days, was selected for the production of precast compressed slabs. Steel or glass fibers were also incorporated to improve their ductility. To reduce the density of the slabs, 60% of the siliceous sand aggregate was also replaced with recycled polyethylene terephthalate (PET) plastic aggregate. The homogeneity, density, porosity, and capillary absorption of the slabs were measured, as well as their flexural strength and fracture energy. The results showed that alkali activation can be used to improve the mechanical properties of weak secondary binders such as ladle furnace slag and hydrated fly ash. The incorporation of recycled PET aggregates produced slabs that could be classified as lightweight, with similar porosity and capillary absorption values, and over 65% achieved strength compared to the normal weight slabs. Full article

This study presents a detailed and comprehensive investigation into the macro-scale performance, strength gain mechanisms, environment and economic performance of graphene oxide (GO)-enhanced low-emission concrete. A comprehensive experimental program evaluated fresh and hardened properties, including slump retention, bleeding, air content, compressive, flexural, and tensile strength, drying shrinkage, and elastic modulus. Scanning Electron Microscopy (SEM), energy-dispersive spectroscopy (EDS), Thermogravimetric analysis (TGA) and proton nuclear magnetic resonance (¹H-NMR) was employed to examine microstructural evolution and early age water retention, confirming GO’s role in accelerating cement hydration and promoting C-S-H formation. Optimal performance was achieved at 0.05% GO (by binder weight), resulting in a 25% increase in 28-day compressive strength without compromising workability. This outcome is attributed to a tailored, non-invasive mixing strategy, wherein GO was pre-dispersed during synthesis and subsequently blended without the use of invasive mixing methods such as high shear mixing or ultrasonication. Fourier-transform infrared (FTIR) spectroscopy further validated the chemical compatibility of GO and PCE and confirmed the compatibility and efficiency of the admixture. Sustainability metrics, including embodied carbon and strength-normalized cost indices (USD/MPa), indicated that, although GO increased material cost, the overall cost-performance ratio remained competitive at breakeven GO prices. Enhanced efficiency also led to lower net embodied CO₂ emissions. By integrating mechanical, microstructural, and environmental analyses, this study demonstrates GO’s multifunctional benefits and provides a robust basis for its industrial implementation in sustainable infrastructure. Full article

This study explores the use of embedded piezo sensor (EPS) employing the Electro-Mechanical Impedance (EMI) technique for real-time corrosion monitoring in reinforced E-waste concrete exposed to chloride-laden environments. With the growing environmental concerns over electronic waste (E-waste) and the demand for sustainable construction practices, printed circuit board (PCB) materials were incorporated as partial replacements for coarse aggregates in concrete. The experiment utilized M30-grade concrete mixes, substituting 15% of natural coarse aggregates with E-waste, aiming to assess both sustainability and structural performance without compromising durability. EPS configured with Lead Zirconate Titanate (PZT) patches were embedded into both conventional and E-waste concrete specimens. The EPS monitored the changes in the form of conductance and susceptance signatures across a 100–400 kHz frequency range during accelerated corrosion exposure over a 60-day period in a 3.5% NaCl solution. The corrosion progression was evaluated qualitatively through electrical impedance signatures, visually via rust formation and cracking, and quantitatively using the Root Mean Square Deviation (RMSD) of EMI signatures. The results showed that the EMI technique effectively captured the initiation and propagation stages of corrosion. E-waste concrete exhibited earlier and more severe signs of corrosion compared to conventional concrete, indicated by faster increases and subsequent declines in conductance and susceptance and higher RMSD values during the initiation phase. The EMI-based system demonstrated its capability to detect microstructural changes at early stages, making it a promising method for Structural Health Monitoring (SHM) of sustainable concretes. The study concludes that while the use of E-waste in concrete contributes positively to sustainability, it may compromise long-term durability in aggressive environments. However, the integration of EPS and EMI offers a reliable, non-destructive, and sensitive technique for real-time corrosion monitoring, supporting preventive maintenance and improved infrastructure longevity. Full article

The present study concerns the utilization of spent coffee grounds (SCGs) as an alternative bio-based modifier for a petroleum-based penetration grade 70/100 bitumen at 5%, 10% and 15% by weight of bitumen. The conventional properties of the binders were examined with a series of penetration, ring and ball, elastic recovery, dynamic viscosity and storage stability tests. Their rheological properties were assessed with a Dynamic Shear Rheometer. The aforementioned tests were conducted before and after applying a short-term ageing protocol to quantify the ageing susceptibility of the binders using different rheological ageing metrics. Furthermore, a statistical analysis was conducted to discover whether any correlations exist between the conventional and rheological properties of the binders. It was observed that spent coffee grounds can be incorporated into bitumen at an optimal content of up to 5% without downgrading the binder’s rheological properties or its structural integrity. Additionally, the bio-modifier slightly improved the ageing resistance of bitumen. Finally, the ring and ball test’s results had the strongest correlation with the DSR findings. Full article

Lime plaster has historically been a key material in the preservation of architectural heritage in Peru; however, its availability has been restricted by state regulations that limit its production and commercialization. This study evaluates the performance of paints formulated with inorganic pigments extracted from soils in the Cusco valley, combined with natural and synthetic binders, as a sustainable alternative for the protection of heritage buildings in this Andean region characterized by high altitude, wide thermal variations, and high solar radiation. Adhesion, hardness, drying time, and weather resistance tests were conducted according to applicable ASTM standards for architectural coatings. The results show that these formulations exhibit good adhesion to historic surfaces and greater durability against extreme environmental conditions compared to traditional lime plaster. Their potential compatibility with historic substrates and lower environmental impact suggest that these paints represent a viable alternative in sustainable conservation strategies; however, further studies are needed to more accurately characterize the mineralogical composition of the pigments used. Full article

This research aims to investigate the possibility of measuring dielectric constant as an alternative proxy for estimating E* through a non-destructive procedure. An experimental program was conducted on dense-graded (DG) and open-graded (OG) asphalt mixtures, where variable asphalt contents and compaction levels were controlled to achieve different air voids. The measurements of dielectric constant were performed with a Percometer, and E* values were obtained using standard laboratory tests. For DG mixtures, a clear correlation was observed between dielectric constant, air void content and effective binder ratio. The less consistent relationships for OG mixtures were likely due to the more heterogeneous structure of the OG mixtures, the conductive slag aggregates and a limited dataset. Using dielectric values, two predictive models were developed (DIME_DG and DIME_OG), with the former showing higher reliability. Verification with independent specimens confirmed model robustness. This dielectric-based approach offers a practical, cost-effective alternative to traditional modulus testing. The key innovation of this study is the integration of the asphalt mix dielectric constant into established dynamic modulus predictive models, offering a novel approach that enhances the sensitivity of these models to mixture-specific characteristics beyond traditional volumetric and binder properties. Full article

Rubberized concrete is a more environmentally friendly material than natural concrete as it helps to reduce rubber disposal issues and has superior impact resistance. Geopolymer concrete, on the other hand, is an economical concrete with higher mechanical properties than nominal concrete that uses fly ash and slag, among other industrial solid wastes, to lower carbon footprints. Rubberized geopolymer concrete (RuGPC) combines the advantages of both concrete types, and a thorough grasp of its dynamic compressive characteristics is necessary for its use in components linked to impact resistance. Despite the advantages of RuGPC, predicting its mechanical characteristics is sometimes difficult because of variations in binder type and combination. This research investigated the combined effect of ground granulated blast furnace slag (GGBFS) and fly ash (FA) on the workability, compressive strength, and stress–strain characteristics of RuGPC with rubber at 0%, 10%, and 20% fine aggregate replacement. Thereafter, energy absorption and ductile characteristics were evaluated through the concrete toughness and ductility index. Numerical models were proposed for the cube compressive strength, modulus of elasticity, and peak strain of RuGPC at different percentages of crumb rubber. It was found that RuGPC made with GGBFS/FA had similar stress–strain characteristics to FA- and MK-based RuGPC. At 20% of crumb rubber aggregate replacement, the workability, compressive strength, modulus of elasticity, and peak stress of RuGPC reduced by 8.33%, 34.67%, 43.42%, and 44.97%, while Poisson’s ratio, peak, and ultimate strain increased by 30.34%, 8.56%, and 55.84%, respectively. The concrete toughness and ductility index increased by 22.4% and 156.67%. The proposed model’s calculated results, with R² values of 0.9508, 0.9935, and 0.9762, show high consistency with the experimental data. RuGPC demonstrates high energy absorption capacity, making it a suitable construction material for structures requiring high-impact resistance. Full article

The Palma Cathedral, a landmark of Mediterranean Gothic architecture, features some of the most structurally daring slender piers in European ecclesiastical design. This study examines the role of marés stone—a local marine calcarenite—in enabling such architectural feats despite its inherent fragility. A multi-technique, non-invasive diagnostic campaign was conducted, including visual inspection, portable microscopy, and infrared thermography, to evaluate the physical condition and behavior of the stone under structural and environmental stress. The results reveal widespread deterioration processes—granular disintegration, alveolization, biological colonization, and structural cracking—exacerbated by the stone’s high porosity and exposure to marine aerosols and thermal fluctuations. Thermographic analysis highlighted moisture retention zones and hidden material discontinuities, while crack monitoring confirmed long-standing, localized structural strain. These findings demonstrate that the Cathedral’s formal audacity was grounded in a refined empirical understanding of marés’ properties. The study underscores the importance of material-based diagnostics for the sustainable conservation of Gothic heritage architecture. Full article

Iraq’s extreme summer temperatures pose critical challenges to pavement durability, as conventional asphalt mixtures often fail under prolonged thermal stress. This paper provides a comparative evaluation of the high-temperature performance of unmodified (40/50 penetration grade) and polymer-modified (PG 76-10) asphalt mixtures for the asphalt course layer. Marshall stability, flow, and stiffness were measured at elevated temperatures of 60 °C, 65 °C, 70 °C, and 75 °C after short-term (30 min) and extended (24 h) conditioning. Results show that while both mixtures experienced performance degradation as the temperature increased, the polymer-modified mixture consistently exhibited superior thermal resistance, retaining approximately 9% higher stability and 28% higher stiffness, and displaying 18% lower flow deformation at 75 °C compared to the unmodified mixture. Stability degradation rate (SDR), stiffness degradation rate (SiDR), and flow increase rate (FIR) analyses further confirmed the enhanced resilience of PG 76-10, showing nearly 39% lower FIR under thermal stress. Importantly, PG 76-10 maintained performance within specification thresholds under all tested conditions, unlike the conventional 40/50 mixture. These findings emphasize the necessity of adapting mix design standards to regional climatic realities and support the broader adoption of polymer-modified asphalt binders to enhance pavement service life in hot-climate regions like Iraq. Full article