The impact of waste brick and geo-cement aggregates as sand replacement on the mechanical and durability properties of alkali–activated mortar composites

This study explores the potential of waste brick and geo-cement aggregates as substitutes for natural sand in alkali-activated materials (AAMs) for mortar production. With a focus on achieving net-zero construction and mitigating environmental impact, the study replaces Portland Cement (OPC) and virgin aggregates with waste materials and by-products. The investigation evaluates the substitution of sand (up to 100 % by weight) in AAMs with waste brick aggregates (WBA) and waste geo-cement aggregates (WGA) obtained from demolished construction and research lab waste, respectively. The research methodology involves assessing mechanical, durability, and microstructure properties to assess the performance of the developed AAMs with waste aggregates. Notably, AAM composites containing waste brick and geo-cement aggregates surpass natural aggregate composites in terms of mechanical strength, water absorption, freeze-thaw resistance, acid ingress, and chloride attack. The 7-day 50 % waste brick mixture achieved a maximum compressive strength of 61 MPa, while a 70 % waste geo-cement mortar mixture attained a maximum flexural strength of 12 MPa. Combinations, whether comprising waste brick or geo-cement mortar aggregates, demonstrate compressive strengths well over 40 MPa, rendering them suitable for heavy load-bearing structures. The 50 % waste geo-cement mortar mixture stands out with the lowest water absorption rate of 6 % and the least compressive strength loss of 13 % after the freeze-thaw test, with reductions of 6 % and 18 %, respectively, compared to the control. Additionally, 100 % waste brick AAMs exhibit the lowest compressive strength loss after chloride and acid attack tests, with reductions of 13 % and 2.5 %, respectively. When compared to all other mixtures, the 50 % waste brick aggregates mortar mixture obtained the best overall performance. The composites developed in this study affirm their suitability for use in heavy-load structural components, showcasing favourable mechanical and durable properties. These findings underscore the need for additional exploration in this direction to advance sustainable construction practices.