Concrete-Based and Mixed Waste Aggregates in Rendering Mortars

The Properties and Durability of Self-Leveling and Thixotropic Mortars with Recycled Sand

In recent decades, relevant environmental and economic reasons have driven an increasing interest in using a large amount of recycled aggregate in replacement of natural ones to produce mortar and concrete. The present study aims to investigate the effect of substituting 100% of natural sand with recycled aggregate on fresh properties, mechanical properties, and the durability of a thixotropic and a self-leveling mortar. Recycled aggregate was characterized using X-ray diffractometry and energy-dispersive X-ray spectroscopy. Its morphology was investigated using scanning electron microscopy and automated morphological imaging. Recycled aggregate mortars showed a moderate decline in initial workability, as well as higher shrinkage and porosity than the control ones. The compressive strength of self-leveling mortars produced with recycled aggregate was only 6% lower than mortars produced with natural sand. The gap increased to 40% in the case of thixotropic mortars. The self-leveling recycled aggregate mortar showed equivalent resistance to freeze–thaw cycles and better sulfate resistance than the control one. The thixotropic recycled aggregate mortar showed comparable sulphate resistance and only slightly lower resistance to freeze–thaw cycles than the control one. Their capacity to relief stresses, due to hydraulic pressures and the formation of expansive products, arises from their higher porosity. Thermal stability of the prepared mortars, after a curing period of 90 days, up to 700 °C, was also investigated. A significant decrease in ultrasonic pulse velocity is observed in the 200–400 °C interval for all the mortars, due to the dehydration–dehydroxylation of calcium silicate hydrate. The overall decline in the strength of both the recycled aggregate mortars was comparable to the control ones. The results reported in the present investigation suggest that the selection of high-quality recycled aggregate helps to obtain good-quality mortars when a large amount of natural sand is replaced.

Low-Carbon and Fundamental Properties of Eco-Efficient Mortar with Recycled Powders

Using recycled powders from solid waste is accepted as an effective strategy to realize the sustainable development of the construction industry. In our study, the cement was substituted by two kinds of recycled powders, i.e., spontaneous combustion gangue powder (SCGP) and recycled concrete powder (RCP), with a certain replacement ratio of 30%. The experimental variables were mainly the type of replacement powder (e.g., SCGP, RCP, and SCGP + RCP) and the grinding time of RCP (e.g., 25 min, 50 min, and 75 min). The fundamental properties, including mechanical properties, long-term properties, and carbon emission, were analyzed for all the mortar mixtures. Experimental results indicate that incorporation of RCP contributes to enhancing the toughness and dry shrinkage resistance of eco-efficient mortar, while SCGP positively affects the compressive strength and chloride resistance. The grinding process improves the activity of RCP to a certain extent, while a long grinding time leads to fusion and aggregation between powders. Investigation on CO₂ emission demonstrates that carbon emission from cement production accounts for the largest proportion, 80~95%, in the total emission from mortar production. Combined with the AHP model, eco-efficient mortar containing 15% RCP ground for 50 min and 15% SCGP displays optimal fundamental properties.

Reduction of the Cement Content by Incorporation of Fine Recycled Aggregates from Construction and Demolition Waste in Rendering Mortars

The construction sector is responsible for one third of the total wastes produced in the EU. Finding solutions for the reuse or recycling of these wastes is one of the major environmental concerns of modern times. The replacement of sand or cement in specific construction materials, such as concrete or mortars, is a possible solution for these wastes’ management. By using construction and demolition wastes in construction materials, namely on buildings, the cycle of circular economy is closed, increasing the life cycle of the wastes in the same sector. In this research, a reduction of cement content in rendering mortars is analysed. This reduction is achieved by a decrease of the cement/aggregate ratio simultaneously with the incorporation of very fine recycled aggregate from construction and demolition waste. Two recycled aggregates were studied: recycled concrete aggregate (RCA) and mixed recycled aggregate (MRA). The fresh and hardened state properties of the mortars were analysed. Several tests were carried out to evaluate the mortars’ performance, such as mechanical strength tests, water absorption tests, drying tests and shrinkage. It was noticed that the incorporation of RCA led to a better behaviour than in the reference mortar, in terms of mechanical strengths and protection against water.