Study on cement mortar and concrete made with sewage sludge ash

The Utilization of Recycled Sewage Sludge Ash as a Supplementary Cementitious Material in Mortar: A Review

The output of sewage sludge has been increasing in recent years in China. Traditional treatment methods, such as incineration and landfilling, cannot meet the requirement of sustainability in various industries. As one of the efficient recycling methods for sewage sludge, previous studies have proven that sewage sludge ash (SSA) can be used as a supplementary cementitious material to partly replace cement in mortar or concrete. To understand the performance of SSA comprehensively, which contributes to its better utilization, this study reviews the basic properties of SSA and the effect of SSA on the performance of mortar. Firstly, the basic properties of SSA, such as chemical composition, heavy metal content, activity, and microstructure, are investigated. Then, the effects of SSA on the workability, setting time, and mechanical properties of mortar are reviewed. The results show that the particle size distribution of SSA is in the range of 2.5–250 μm. SSA contains active oxides such as SiO2, Al2O3, Fe2O3, and CaO, which are similar to fly ash, indicating that SSA has potential pozzolanic properties. The leaching concentration of SSA is much lower than the required values in the relevant specifications, leading to an allowable environment influence. The incorporation of SSA has a negative impact on the workability, setting time, water absorption, compressive strength, and flexural strength of the mortar. The 90-day compressive strength of the SSA mortar is 71.72–98.6% of the cement mortar, when the replacement ratio of SSA is in the range of 10–30%. However, performance can be improved by increasing the grinding time or adding an admixture. The drying shrinkage and capillary water absorption of SSA mortar are higher than those of normal mortar, which is mainly related to an increase of porosity. In conclusion, it is proven that SSA can be used to partly replace cement in mortar with appropriate properties. Source and production process have a great influence on the basic properties of SSA, leading to varied, even opposite, effects on the mechanical properties and durability of mortar. In the future, the selected raw materials and a standard preparation method should be proposed for promoting the application of SSA.

Cement Mortars with Addition of Fly Ash from Thermal Transformation of Sewage Sludge and Zeolite

The aim of research was an influence evaluation of fly ash and zeolite on selected parameters of cement mortar. The scope of the research includes studies of composition and properties of fly ash itself from the thermal transformation of sewage sludge and natural zeolite (clinoptilolite). The research also included the determination of selected mechanical properties of designed mortars, both under normal conditions and after initial thermal loads. A mortar was designed based on CEM I 42.5 R Portland cement with different content of the applied additive in the amount of 5, 10 and 15% of the cement weight. In the course of experimental work, the bending strength of mortars heated at 20, 300, 500, 700 °C were tested. The resulting beam halves (40 × 40 × 160 mm) were used to test the compressive strength. The collected results made it possible to compare the properties of the mortars. The experiment confirmed the possibility of producing cement mortars modified with fly ash from thermal transformation of sewage sludge and zeolite from tuff deposits. The average compressive strength for the mortar containing 5% fly ash and zeolite was set at 28.7 and 27.1 MPa, respectively.

Fly Ash from the Thermal Transformation of Sewage Sludge as an Additive to Concrete Resistant to Environmental Influences in Communication Tunnels

Concrete is an ecological material with a high potential to adapt to specific operating conditions, and the lowest carbon footprint as it is made from local raw materials—aggregate, cement, water, admixtures, and mineral additives. It is the most widely used composite material among those that are man-made and second only to water in the entire range of materials used. The aim of this research was to assess the possibility of using fly ash from the thermal treatment of sewage sludge as an alternative additive to concretes resistant to environmental influences occurring in communication tunnels. A concrete mix based on CEM I 42.5R Portland cement with various ash content of 0–20% of the cement mass was designed for the experimental work. In the course of the experimental work, the compressive strength was measured after three maturing periods, and the influence of both high temperature and the material modification on the course of carbonation were determined. The test results confirm the possibility of producing plain concrete, modified with fly ash obtained from the thermal treatment of sewage sludge. The highest average compressive strength of 43.6 MPa, 45.6 MPa, and 51.2 MPa after 28, 56 and 720 days of maturation, respectively, was for concrete containing 10% ash.

The Influence of Incinerated Sewage Sludge as an Aggregate on the Selected Properties of Cement Mortars

In line with the trend of using waste raw materials in the technology of building materials, experimental studies of cement mortars containing various amounts of fine-grained waste aggregate were carried out. The waste aggregate was based on an incinerated municipal sewage sludge which was mechanically crushed to an appropriate grading. Chemical and physical properties of the waste aggregate are presented. Mortars with varying amounts of waste aggregate as a replacement for natural sand were prepared. Study determines compressive strength and flexural strength up to 56 days. Properties such as capillary action, air content and thermal conductivity were determined. The results of the tests has shown that the incinerated waste sludge can be used as a partial or total replacement for natural aggregate. In mortars with waste aggregate, a favorable relation between flexural and compressive strengths was observed, which translates into increased strength of the interfacial transition zone. A significant increase in water absorption was observed for mortars containing high amounts of waste aggregate, which is directly related to its porous structure. Conducted studied prove that the aggregate obtained from incineration of the municipal sewage sludge can a feasible alternative for natural aggregates in production of masonry and rendering mortars for construction purposes.

The Use of Modal Analysis in Addition Percentage Differentiation, and Mechanical Properties of Ordinary Concretes with the Addition of Fly Ash from Sewage Sludge

Production cost reduction and constraints on natural resources cause the use of waste materials as substitutes of traditional raw materials to become increasingly important. The dynamic development of sewerage systems and sewage treatment plants leads to increases in the produced sewage sludge. According to the Waste Law, municipal sewage sludge can be used if it is properly stabilized. This process results in significant quantities of fly ash that must be utilized. This paper presents investigation results of partial cement replacement influence by the fly ash from sewage sludge on concrete parameters. The results confirm the possibility of fly ash waste applications as a cement substitute in concrete manufacturing. In the later parts of the publication, a pilot study was conducted using the modal analysis methodology and aimed at checking the hypothesis of whether vibration methods can be used in the assessment of the amount of the admixture used in concrete and the effect it has on concrete properties. This is the first time that vibration tests have been used to determine the diversity of the concrete mix composition and to distinguish the percentage of ash added. There are no studies using modal analysis to distinguish the composition of a concrete mix in the scientific literature. The article shows that the vibration test results show the differentiation of concrete composition and can be further improved as a method for determining the composition of mixtures and for distinguishing their mechanical properties. These are only pilot studies, which, in order to develop the target cognitive inference, should be performed in the future on a significantly enlarged number of the studied samples.

Land application of sewage sludge incinerator ash for phosphorus recovery: A review

Phosphorus (P) is essential for all living things and an integral part of food production. However, significant amounts of P are functionally lost when wastewater byproducts, such as biosolids or sewage sludge incinerator ash (SSA), are not beneficially reused. Around 20% of sewage sludge produced in the US is incinerated and nearly 25% of sewage sludge is incinerated in European Union member countries. SSA contains significant amounts of P (up to 14% total P) and other beneficial elements but is typically sent to landfills for disposal. However, SSA has also been explored as one method of capturing and redirecting P back into the food system. Research investigating SSA characterization, P availability, and contaminant concentrations and behavior in soil is required to understand the effects of SSA land application on soil chemical properties and crop production. Several approaches for recovering P from SSA have been investigated that consider these factors. Ultimately, the opportunity for land application of SSA depends on the individual characteristics of a given SSA, ex. total P and contaminant concentrations, and the requirements and regulations of the region where it is produced and applied. In this review, we address the history of P recovery from SSA and discuss research regarding characterization, contaminants, P availability, and land application of SSA.

Fly Ash from Thermal Conversion of Sludge as a Cement Substitute in Concrete Manufacturing

Striving for reduction of production costs and constraints on natural resources cause the use of waste materials as substitutes of traditional raw materials to become increasingly important. Dynamic development of sewerage systems and sewage treatment plants observed over the recent years leads to increase of mass of the produced sewage sludge. According to the Waste Law, the municipal sewage sludge can be used if it is properly stabilized, e.g., through thermal processing. This process results in significant quantities of fly ash which must be properly utilized. The paper presents results of investigations of influence of partial replacement of cement by the fly ash from sewage sludge on concrete parameters. It was designed as a C20/25 class concrete mix, based on the Portland cement CEM I 42.5R with various ash content. Physical and chemical properties of the ash as well as frost resistance and the compressive strength of the concrete after 28, 56 and 365 days of curing were investigated. The obtained results of investigations confirm the possibility of application of fly ash wastes as a cement substitute in the concrete manufacturing. If a predefined quantity of cement is replaced by the fly ash, then one can obtain cement composite with good strength parameters.

Characterization of sewage sludge incineration ashes from multi-cyclones and baghouse dust filters as possible cement substitutes

Incineration is not a final disposal method for sludge management since a significant amount of ash is generated. Although some published literature reported on the use of sewage sludge ashes (SSAs) as a cement replacement, none of them referred to the air pollution control unit of the incinerator where the SSA is collected. The properties of SSAs from different air pollution control units were investigated with the purpose of usage as a cement replacement in the present study. The SSA samples obtained from multi-cyclone units (MC-SSA), where SSA is collected at the bottom of the unit with the help of inertia and centrifugal forces, and baghouse dust filters (BHD-SSA), where SSA is collected at the fabrics of the unit, of the sludge incinerator were analyzed for chemical and physical characteristics, including heavy metal leaching, mineralogy (XRD), and particle morphology (scanning electron microscopy). Mortar samples were prepared with 15 and 30% of MC-SSA and BHD-SSA additions and analyzed for workability, strength activity, strength development, and freeze-thaw resistance. Heavy metal leaching results of both of the MC-SSA and BHD-SSA and their mortars were below the legal requirements of landfills, inferring that the toxic elements in SSA would not be of environmental concern in case SSA is used in cement matrices. The present study identified the variability of the physical and chemical properties of both SSAs over time and their differences. Incompliances of the SSAs to the pozzolanic material standards were observed, although moderate pozzolanic activity was concluded. In order to obtain the required flow value, different amounts of polycarboxylate ether-based superplasticizer were used in all of the mixtures. The levels of amorphous phases were found to be 23.3 and 39.3% for MC-SSA and BHD-SSA, respectively. MC-SSA exhibited less porosity with larger agglomerates than BHD-SSA. Ninety-day compressive strength levels of MC-SSA mortars with 15% replacement, which was found as 50.53 MPa, was higher than that of BHD-SSA mortars by 6% (47.65 MPa). The freeze-thaw resistance and water adsorption capacity of SSA mortars were comparable with that of the cement mortars. It was inferred that the contribution of SSA substitution to the strength development was influenced by hydraulic activity more than pozzolanic activity.Graphical abstract.

Modification of Ordinary Concrete Using Fly Ash from Combustion of Municipal Sewage Sludge

This article focuses on the impact of fly ash from the combustion of municipal sewage sludge (FAMSS) as a cement additive in the amounts of 5%, 10%, 15%, 20% and 25% (by mass) on selected concrete properties. In the course of the experimental work, water penetration depth and compressive strength measurements were made at various periods of curing (from 2 to 365 days). In addition, the potential impact of FAMSS on the natural environment was examined by determining the leachability of heavy metals. FAMSS-modified concretes showed small values of water penetration depth (lower than 50 mm), as well as good compressive strength (reaching minimum class C30/37 after 130 days of maturing)—similar to the compressive strength obtained for conventional concrete. In addition, the partial replacement of cement with FAMSS has environmental benefits, expressed as a reduction in CO₂ emissions. In addition, study has shown that compliance with environmental requirements is associated with heavy metal leaching.

Change in re-use value of incinerated sewage sludge ash due to chemical extraction of phosphorus

The potential of six different extractants to recover phosphorus (P) from incinerated sewage sludge ash (ISSA) was evaluated. Secondary effects such as the co-dissolution of Zn and Cu were also considered. The residual ISSA from each study was assessed in particular detail, focusing on the leachability of remaining Zn and Cu, major element composition, crystalline phases and overall degree of crystallinity and particle size distribution. The residual ISSA was also evaluated as a pozzolanic material using a Strength Activity Index (SAI) test with mortars containing Portland cement with a 20% substitution by ISSA. All results were compared to tests with untreated ISSA. Overall, the use of 3 of the 6 extractants could be ruled out due to poor P recovery potential and/or a serious compromise of the potential reuse of residual ISSA in Portland cement-based materials. The results highlight the added value of considering the potential reuse of residual ISSA when trying to optimize P recovery from ISSA by wet methods.

Utilization of municipal sewage sludge as additives for the production of eco-cement

The effects of using dried sewage sludge as additive on cement property in the process of clinker burning were investigated in this paper. The eco-cement samples were prepared by adding 0.50-15.0% of dried sewage sludge to unit raw meal, and then the mixtures were burned at 1450 °C for 2 h. The results indicated that the major components in the eco-cement clinkers were similar to those in ordinary Portland cement. Although the C(2)S phase formation increased with the increase of sewage sludge content, it was also found that the microstructure of the mixture containing 15.0% sewage sludge in raw meal was significantly different and that a larger amount of pores were distributed in the clinker. Moreover, all the eco-cement pastes had a longer initial setting time and final setting time than those of plain cement paste, which increased as the sewage sludge content in the raw meal increased. All the eco-cement pastes had lower early flexural strengths, which increased as the sewage sludge content increased, while the compressive strengths decreased slightly. However, this had no significant effect on all the strengths at later stages. Furthermore, the leaching concentrations of all the types of eco-cement clinkers met the standard of Chinese current regulatory thresholds.