Search Results (67)

Phosphogypsum (PG) is an industrial solid waste whose use in cementitious materials is limited by strength reduction at high dosages. This study evaluated a clinker-free multi-solid-waste binder containing 40 wt.% PG for cemented paste backfill using steel slag powder (SSP) and granulated blast-furnace slag (GBFS) as co-binders, with phosphate mine tailings and slime as aggregates. Uniaxial compressive strength (UCS), X-ray diffraction, scanning electron microscopy, and nuclear magnetic resonance were combined with image-based pore-structure sensitivity analysis to examine the relationships among hydration products, pore evolution, and strength development. The results showed that AFt and C–S–H-like gels were associated with pore refinement and strength gain. All mixtures reached UCS values above 0.5 MPa at 7 days and 1.0 MPa at 28 days. The A2 mixture achieved the highest 7-day UCS of 0.8 MPa, whereas A1 showed the highest 28-day UCS of 1.6 MPa. Porosity, pore probability entropy, and fractal dimension were negatively correlated with UCS, with pore probability entropy showing the highest sensitivity to 7-day strength. These findings support the use of high-PG clinker-free binders for targeted phosphate-mine backfill. Full article

Silicomanganese slag (SiMnS), a Mn-bearing by-product from silicomanganese alloy production, is often stockpiled in large quantities and may pose environmental concerns due to potential metal leaching. This study develops an OPC-rich hybrid SiMnS–steel slag–fly ash–OPC-activated composite binder, referred to as SMSAB, in which OPC accounts for 55% of the solid precursor mass. Different alkali contents and sodium silicate moduli were investigated, and the optimised paste was characterised in terms of mechanical strength, reaction products, pore structure, carbon-footprint and heavy-metal leaching. The best performance was obtained at an alkali content of 4% and a sodium silicate modulus of 1.0, giving 28-day compressive and flexural strengths of 65.13 MPa and 3.37 MPa, respectively. XRD, SEM-EDS, FTIR and MIP results showed that the main reaction products were C-(A)-S-H, N-A-S-H and C-N-A-S-H gels, which refined the pore structure and produced a dense matrix. The reduction in Mn leaching may be associated with physical encapsulation, possible charge-balancing interactions within gel structures, changes in Mn-related bonding environments and the presence of Mn-bearing phases. Leaching concentrations of Zn, Mn, Cr, Cu and Ni satisfied the Grade III groundwater limits used in China. The calculated carbon intensity of SMSAB was 3.97 kg·(m³·MPa)⁻¹, indicating a favourable strength-to-emission balance compared with the reference systems considered. It should be noted that the present work examines paste specimens only; aggregate skeleton, traffic loading, freeze–thaw cycling and wet–dry/moisture cycling were not included. Therefore, the results demonstrate binder-level potential rather than direct qualification of SMSAB as a pavement base or subbase material. Full article

Asphalt pavements are essential to modern transport infrastructure but remain highly dependent on virgin aggregates and petroleum-based binders, resulting in high energy demand and significant greenhouse gas emissions. In response, research has advanced recycled-material solutions and low-temperature asphalt technologies. However, sustainability is still often inferred from isolated environmental indicators, without consistent consideration of mechanical durability or economic feasibility throughout the life cycle. This review provides an integrated synthesis of sustainable asphalt mixtures by jointly examining recycling strategies, temperature-reduction processes (warm-mix, half-warm-mix, and cold-mix asphalt technologies), and their combined applications through an integrated performance–cost–environment perspective. The literature reveals substantial methodological fragmentation, with limited harmonisation of functional units, system boundaries, and allocation rules, which constrains cross-study comparability. Evidence indicates that reclaimed asphalt, recycled concrete aggregates, and steel slag can maintain or improve rutting resistance, stiffness, and moisture durability while enabling material cost savings of approximately 5–68%. Temperature-reduction technologies further achieve significant energy and GHG reductions in the production phase (20–70%), with integrated recycling–temperature-reduction systems showing the most consistent combined benefits. Overall, this review demonstrates that asphalt sustainability cannot be established through single-dimensional assessments but requires harmonised life-cycle frameworks that explicitly link environmental gains to mechanical performance, durability, and economic viability. Full article

A low-titanium-slag-based multi-solid-waste cementitious system was developed for cemented paste backfill. The cementitious binder was prepared from low-titanium slag (LTS), steel slag (SS), municipal solid waste incineration (MSWI) fly ash, and flue gas desulfurization gypsum (FGDG), while lead–zinc tailings were used as the aggregate for backfill materials preparation. The activation of low-titanium slag, proportion optimization, and strength development mechanisms were systematically investigated. Mechanical grinding effectively activated low-titanium slag, and its activity index reached 108% after 90 min of grinding at 28 d. Steel slag alone could not fully activate low-titanium slag in the ternary system, whereas the incorporation of MSWI fly ash significantly enhanced the synergistic activation effect. The quaternary system with 40% MSWI fly ash replacement showed higher cumulative heat release and better later-age strength. The optimum backfill proportion was a solid mass concentration of 81% with a binder-to-tailings ratio of 1:4, yielding a 28 d compressive strength of 11.07 MPa with satisfactory flowability and setting behavior. Microstructural results indicated that the continuous formation of ettringite and gel phases promoted pore refinement and matrix densification. Moreover, the leaching concentrations of Pb, Zn, Cr, and soluble Cl were all below the relevant groundwater quality limits. These results demonstrate a feasible route for the high-value co-utilization of low-titanium slag and MSWI fly ash in cemented backfill materials. Full article

Iron tailings, steel slag (SS), and desulfurization ash (DA) are industrial solid wastes with high annual output and large stockpiles. To enhance their utilization rate in concrete and fully utilize the synergistic effect of iron tailings powder (ITP), SS, and DA, a multi-solid-waste ISD (ITP-SS-DA) concrete was prepared. In this study, ITP, SS, and DA were used as composite mineral admixtures to replace 30% of the cement, and iron tailings sand (ITS) and iron tailings waste rock (ITR) were used as aggregates. The effects of water/binder ratio (w/b), ITP fineness, and mineral admixture proportion on the compressive strength of ISD concrete were investigated. The influence of ITP fineness on the microstructure was analyzed based on mercury intrusion porosimetry (MIP) and backscattered electron (BSE) tests. The results show that the w/b has a significant effect on the early-age compressive strength, but its effect diminishes at mid-to-late ages. ISD composite mineral admixtures with properly ball-milled ITP enhance compressive strength, refine the pore structure, and increase the compactness of the interfacial transition zone (ITZ). Appropriately increasing the proportion of SS and adjusting the ratio of ITP to DA can promote the synergistic effect of mineral admixtures, thus enhancing compressive strength. Compared with cement concrete, ISD concrete exhibits slightly lower compressive strength but still meets the design requirements and presents a significantly superior microstructure when the w/b, ITP fineness, and admixture proportion are suitable. Full article

This study aims to systematically synthesize and critically evaluate the characteristics of electric arc furnace slag (EAFS) and ladle furnace slag (LFS) when applied as an alternative paving material. A systematic literature review was conducted following the PRISMA methodology, with research published between 2000 and 2024. Three major databases were searched, considering only Q1–Q2 and English articles. After independent, blinded screening by two reviewers, a total of 177 papers met the selection criteria. The results were qualitatively synthesized through bibliometric analysis, slag characteristics, and application type. Results show that asphalt concrete (AC) is the most common application of EAFS, representing 61% of studies, with many studies exploring 100% substitution of natural aggregates. Overall, EAFS and LFS demonstrate favorable mechanical properties, including high toughness, hardness, and adequate soundness, largely attributed to their iron-rich composition, supporting their use in base layers, AC, and Portland cement concrete (PCC). However, significant chemical and mineralogical variability influences swelling potential and reactivity, highlighting the need for case-specific characterization. While swelling concerns limit its use as an unbound base material, these issues are reduced when EAFS and LFS are used as a soil binder or encapsulated within AC or PCC matrices. Environmental assessments show that most EAFS and LFS samples meet the regulatory thresholds for their respective local leaching limits, though behavior varies with steel type (low-alloy vs. stainless), particle size and pH. Significant gaps remain in long-term performance and testing standards. This review proposes guidelines for selecting appropriate tests according to the intended pavement application, aiming to facilitate the safe and effective use of EAFS and LFS in road infrastructure. Full article

Expansive or soft soils cause significant geotechnical issues for foundations and subgrades because they show swell–shrink behaviour under wet and dry conditions. These volume changes can result in cracking, heaving, uneven settlement, and structural or pavement damage, ultimately increasing maintenance and repair costs. While traditional Portland cement and lime stabilisers effectively enhance soil strength and reduce swell–shrink behaviour, the cement production process is responsible for only approximately 7%–8% of global CO₂ emissions, prompting a transition toward sustainable alternatives. This comprehensive review consolidates recent advancements in soil stabilisation using industrial by-products, such as fly ash, ground granulated blast furnace slag (GGBS), steel slag, cement kiln dust, silica fume, bottom ash, red mud, waste foundry sand, brick dust, calcium carbide residue, water treatment sludge, etc. These materials leverage pozzolanic and latent hydraulic properties to form C-A-H, C-S-H, and N-A-S-H gels, thereby densifying the soil microstructure, improving CBR (%), UCS, and reducing plasticity and swelling potential. Optimisation studies indicate that industrial waste stabilisers often match or exceed conventional binder performance, GGBS-steel slag combinations yielding 105% higher UCS than ordinary Portland cement, and silica fume enhances cement-stabilised soils by 22% at reduced dosages. However, inherent compositional variability, long-term durability concerns including sulfate attack and freeze–thaw degradation, and the absence of standardised design guidelines restrict large-scale implementation. This review integrates mechanistic, microstructural, and sustainability insights, highlighting the need for durability research, standardised methods, and large-scale field validation to advance industrial waste-based stabilisation within circular construction practices in geotechnical engineering. Full article

The high environmental impact associated with ordinary Portland cement production has driven increasing interest in alternative low-carbon binder systems based on alkali-activated materials. In this context, geopolymers synthesized from metakaolin and supplemented with natural or industrial by-products represent a promising route toward more sustainable construction materials. In this study, the partial substitution of metakaolin (MK) with stainless steel slag (SSS, calcium rich) or volcanic ash (VA, silica-rich) in alkali-activated cements (AACs) synthesis was investigated by analyzing their physical, mechanical, and thermal properties. The structural evolution associated with alkali activation was assessed using X-ray diffraction (XRD) and ²⁹Si and ²⁷Al magic angle spinning nuclear magnetic resonance (MAS NMR). Fourier transform infrared spectroscopy (FTIR) revealed a shift in the main Si–O–T (T = Si, Al) asymmetric stretching band toward lower wavenumbers (≈1000 cm⁻¹), indicating changes in the aluminosilicate network consistent with geopolymer formation. Scanning electron microscopy (SEM) was used to examine the microstructural features of the hardened matrices. The results showed that samples containing 50 wt.% MK and 50 wt.% VA achieved the highest mechanical performance, with compressive and flexural strengths of 46.29 MPa and 16.2 MPa at 7 days, increasing to 56.66 MPa and 17.58 MPa at 28 days of curing, respectively. In contrast, the samples containing 50 wt.% MK and 50 wt.% SSS displayed lower strength development, reaching compressive and flexural strengths of 27.7 MPa and 9.6 MPa at 7 days and 41.01 MPa and 13.68 MPa at 28 days. Additionally, thermal conductivity decreased with increasing porosity and decreasing bulk density, highlighting the potential of these AACs as structurally efficient materials with improved thermal insulation performance. Full article

This study documents the development of a clinker-free cementitious material based on circulating fluidized bed fly ash (CFBFA), red mud (RM), and steel slag (SS) without external alkaline activators. The thermal self-curing mechanism was elucidated through hydration heat–temperature field coupling simulations and microstructural characterization. Results indicate that the CFBFA-RM-SS ternary system achieved a 28-day compressive strength of 7.65 MPa (meeting the design strength of 3–5 MPa for the filling design area of Jinxinda Coal Industry in the article background) under a water-to-binder ratio of 0.6 by mass, along with a certain degree of fluidity (slump of 215 mm) and reasonable setting times (initial setting time of 12.1 h, final setting time of 14.0 h). Thermal self-curing significantly enhanced early strength, yielding a 1-day strength of 1.88 MPa with a 1837.5% improvement over ambient curing. Numerical simulations based on a coupled hydration heat–temperature field model (MIDAS Civil) revealed that backfill volumes ≥ 1 m³ can sustain a core temperature of 40–60 °C for over 72 h. This elevated temperature self-curing mainly accelerates early hydration and promotes faster formation of binding hydration products (hydrated aluminosilicate gels and ettringite), leading to a denser microstructure and improved early strength; this trend is supported by XRD, FTIR, and SEM-EDS observations. This work provides theoretical and technical foundations for large-scale utilization of industrial solid waste in mine backfill engineering. Full article

Electrical curing is a viable alternative to traditional thermal curing for geopolymer materials due to its capability for rapid and internal geopolymerization. In this research, reinforced geopolymer-based composite beams were successfully fabricated at a macroscale using a binary system of fly ash (FA) and granulated blast furnace slag (GBFS). The mixture was activated with a solution of sodium silicate (Na₂SiO₃) and sodium hydroxide (NaOH) with a fixed molar ratio of 2:1 for both, and aggregate-to-binder and activator-to-binder (A/B) ratios of 2.5 and 0.7, respectively. To ensure electrical conductivity, individual fiber systems were employed, including carbon fiber (CF), steel fiber (SF), and waste wire erosion (WWE), each incorporated at a dosage of 0.5 vol.% of the total mix volume. In addition, carbon black (CB) was introduced as a conductive filler at a constant dosage of 2.0 vol.% of the binder content in selected specimens. Each beam specimen contained only one type of conductive reinforcement or filler. A total of twelve reinforced geopolymer-based composite beams with a 150 mm square section and a span of 1300 mm, with a clear span of 1200 mm, were successfully cast and reinforced based on reinforced concrete beam designs and standards, with a dominant goal of enhancing beam behavior under flexure. The beams were cured in ambient curing conditions, or using thermal curing at 80 °C for 24 h, and using electrical curing from the fresh states with a fixed voltage of 25 V. Notwithstanding a common beam size and reinforcement pattern, distinct curing methods significantly influenced beam structure properties. Peak loads were between 20.8 and 31.5 kN, initial stiffness between 1.75 and 6.09 kN/mm, and total energy absorption between 690 and 1550 kN/mm, with a post-peak energy component of between 0.12 and 0.55. Displacement-based ductility measures spanned from 3.2 to 8.1 units with a distinct improvement in electrical curing regimes, especially in the SF-reinforced specimens; this indicates that electrical curing in reinforced geopolymer composite materials works as a governing mechanism in performance rather than simply a method for enhancing the strength of materials. Full article

This study systematically examines the fluidity, setting time, mechanical properties, and microstructural evolution of metakaolin-based geopolymer grouting materials with a relatively high water-to-solid (W/S) ratio window. A four-factor, three-level orthogonal experimental design was employed to identify the dominant factors and main effect trends of W/S ratio, alkali dosage, water glass modulus (Ms, molar ratio of SiO₂ to Na₂O in alkali solution), and steel slag content on the material’s performance. The results indicated that the W/S ratio predominantly governed fluidity, while the alkali content was the primary controlling factor for setting time and early-age strength. An intermediate range of water glass modulus with a value of 1.6 provided balanced performance. The incorporation of steel slag with a range of 10–20% showed an age-dependent contribution: it not only tended to improve the rheology of the paste but also the later-age strength. XRD, FTIR, and SEM/EDS results suggested that the hardened binders were dominated by amorphous products, where alumimosilicate gel (N-A-S-H) and Ca-containing gel (C-S-H/C-A-S-H) may coexist depending on calcium availability and activator chemistry. The proposed parameter ranges are valid within the studied design space and provide guidance for the mix design of high-W/S geopolymer grout. Full article

This study prepares solid-waste-based alkali-activated material (AAM) concrete using ground granulated blast furnace slag (GGBFS), fly ash (FA), steel slag (SS), and desulfurized gypsum (DG) as primary raw materials, with Na₂SiO₃ as the activator. Taking the GGBFS content (X₁), Na₂SiO₃ content (X₂), and water-to-binder ratio (X₃) as independent variables and the 3-day, 7-day, and 28-day compressive strengths and slump as response values, it investigates the influence of each factor and their interactions, constructs a response surface prediction model, screens for the optimal mix proportion with comprehensive performance, and explores the microstructural characterization and strength formation mechanism of the AAM concrete via SEM and EDS. The results indicate the following: (1) compared with binary and ternary mixtures, the use of the quaternary solid waste mixture not only enhances strength and optimizes the microstructure but also increases the utilization rate of low-quality solid wastes; (2) the regression coefficients (R²) of the response surface models are all greater than 0.98, exhibiting good goodness of fit and rationality. Experimental validation confirms that each model shows excellent predictive capability; (3) AAM concrete exhibits comprehensively superior mechanical properties to ordinary cement, with leading early- and late-stage compressive strengths and splitting strengths, albeit with a slightly lower slump; (4) the performance synergy is prominent. Combined with microscopic analysis (highly polymerized C-S-H gels and a dense structure), the superiority of its macroscopic mechanical properties stems from the optimization of the microstructure, reflecting the intrinsic correlation of the “microscopic densification-macroscopic high strength. Full article

Barium slag is classified as a hazardous waste due to its high content of soluble Ba²⁺. To achieve safe disposal and high-value utilization, this study developed a novel all-solid-waste road base material by synergistically combining harmlessly treated barium slag (HTBS) with steel slag, blast furnace slag, and flue-gas-desulfurization gypsum (SWB). The primary novelty of this work lies in the dual-immobilization mechanism of barium within a multi-solid-waste cementitious system. Our results showed that the mixture containing 16% binder achieved unconfined compressive strengths of 4.24 MPa (7 days) and 8.06 MPa (28 days), meeting the technical requirements for heavy-load road bases. Microstructural analyses revealed that the system evolved into a dense network composed of C–S–H gels and ettringite (AFt). Mechanistically, environmental safety is ensured by two pathways: (1) the chemical precipitation of stable BaSO₄ and (2) the physical encapsulation of ions by the dense gel matrix. Leaching tests confirmed that Ba concentration remained far below the regulatory limit, ensuring environmental safety. This work provides a scalable, eco-friendly solution for the “waste-to-resource” conversion of hazardous barium slag in road engineering. Full article

Composite geopolymer concrete (CGPC), is receiving growing attention in the construction sector for its sustainable nature, environmental benefits, and its valuable role in promoting efficient waste utilization. The strategic incorporation of reinforcing fibers into geopolymer concrete (GPC) matrices is critical for enhancing mechanical performance and meeting the durability requirements of high-performance construction applications. Although substantial research has focused on strength enhancement of fiber-reinforced geopolymer concrete (FGPC) individually, it has neglected practical considerations such as energy use for curing and life-cycle assessments. Thus, this study investigates the cost-effective aspects of FGPC cured under different regimes. Different cementitious binders were incorporated, i.e., fly ash (FA) and ground granulated blast-furnace slag (GGBS), in addition to alkaline activators (a combination of sodium hydroxide and sodium silicate), hooked-end steel fibers (HESFs), basalt fibers (BFs), and polypropylene fibers (PPFs), as well as aggregates (gravel and sand). The effect of different geopolymer-based materials, reinforcing fibers, and different curing regimes on the mechanical, durability, and economic performance were analyzed. Results showed that the applied thermal curing regimes (oven curing or steam curing) had a considerable impact on durability performance, compressive strength, and flexural strength development, especially for GPC mixes involving high FA content. Cost analysis outcomes suggested that the most affordable option is GPCM1 (100% FA without fibers), but it demonstrates low strength under ambient curing conditions; RGCM4 (100% GGBS and 0.75% HESF) provided the best strength and durability option but at higher material cost; RGCM7 (50% FA, 50% GGBS, and 0.75% HSF) exhibited a balanced choice since it offer satisfied strength and durability performance with moderate cost compared to other options. Full article

On-site curing of metakaolin (MK)- and granulated blast furnace slag (GBFS)-based geopolymer mortars remains a major bottleneck compared to thermal treatment for early strength development, and electrical curing is proposed here as a highly scalable and energy-efficient alternative technology. Geopolymer mortars with 0–100% MK/GBFS binder ratios were activated using sodium silicate (SS) and sodium hydroxide (SH) solutions of the following molarities: 6, 8, 10, 12, and 14 M. Steel fiber (SF), carbon fiber (CF), waste erosion wire (EW), and carbon black (CB) microfiller were incorporated to enhance the electro-conductive efficiency of the geopolymer matrix. Specimens were subjected to electrical curing under 10 V and 20 V AC and were compared with benchmarking under ambient conditions of 23 °C and thermal conditions of 70 °C. The findings established that the incorporation of fibers substantially boosted the level of conductivity and mechanical performance, with 28-day compressive strengths of up to 88.30 MPa (0.50% EW, 20 V) and flexural strengths of up to 22.24 MPa (0.50% CF, 7 days), exceeding the results of conventional curing in various instances. Microstructural studies based on well-bonded geopolymer gels with fibers indicated uniform geopolymerization through electrical curing without deleterious fiber–matrix interactions. A multi-criteria decision support approach (the HD method) based on 273 parameters established 0.50% CF, 0.75% SF, 0.75% EW, and 1.00% CB as the group-wise optima and chose 0.75% EW as the single-best performing combination. The findings confirm that electrical curing is a low-carbon, cost-effective, and field-adjustable curing technology with the potential to achieve target strength ratings, in line with the European Green Deal’s climate-neutral building material goals. Full article