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In this study, low-carbon recycled cement (RC) was produced from thermally activated concrete and cement paste wastes and its incorporation in mortars, as cement replacement, was investigated. The calcination temperatures were defined based on thermogravimetric and X-ray diffraction analysis. Mortars were characterized in terms of their main fresh and mechanical properties (compressive and flexural strength, ultrasonic pulse velocity and dynamic modulus of elasticity). The influence of RC replacement ratio (20%, 50%, 75% and 100%), RC treatment temperature and RC fineness were analyzed. In all tested properties, RC from concrete waste showed significant lower efficiency than that from cement paste waste. The RC rehydration capacity was improved by increasing its fineness and pre-heating temperature. Mortars produced with 100% of 650 °C pre-heated RC were able to attain as high as 8.3 MPa of compressive strength at 28 days, corresponding to about 20% of that found in reference mortars without RC. In addition, mechanical properties were little affected by RC replacement ratios up to 20%. This study shows the efficient rehydration capacity of thermal activated RC and suggests its high potential for the construction industry.

Separation is a fundamental step for concrete recycling, enabling not only the achievement of reliable and cleaner recycled aggregates but also the better re-use of the remaining concrete constituents. Recently, a new hydraulic binder produced from the hydrated cement paste contained in waste concrete, which is associated with lower processing temperatures and carbon dioxide emissions, has gained momentum in the history of concrete recycling. However, a decisive turning point for its application lies in the successful individualisation of the cement paste and aggregate initially contained in concrete debris. This paper describes a new patented method involving a mechanical comminution stage and a high-intensity magnetic separation process to obtain the cementitious fraction in concrete and retrieve cleaner fine aggregate. The efficiency of the proposed method was assessed through image analysis, thermogravimetry, X-ray diffraction and acid attack. In addition, cement pastes produced with the obtained recycled cement after thermal activation were characterised in terms of mechanical strength. Findings suggest that the proposed method effectively separated the main concrete constituents, especially when the waste material was reduced to the size range 150–500 μm. It was possible to obtain a recycled binder at the current laboratory scale with up to about 80% cement content by weight (nearly 90% in volume). Furthermore, a cleaner recycled fine aggregate, with minimal cement paste contamination, as low as less than 3 wt%, was also obtained. The mechanical strength of pastes with recycled cement retrieved from waste concrete was about 70% of that of reference pastes of equal water/binder produced with recycled cement from non-contaminated waste cement pastes.

Considerable amounts of municipal solid waste incinerator bottom ashes are produced yearly without an adequate outlet. Given the established reactivity of the ash when subjected to an alkali medium, there is considerable scope to valorize it within the Construction industry in an alkali-activated material, thereby reducing the significant environmental pressure of the cement industry. This study assesses the optimization of alkali-activated mortars, using milled municipal solid waste incinerator bottom ash as a precursor, from mechanical and durability behaviour perspectives, many properties of which have never been analysed. The alkaline solution is comprised of either NaOH or Na2SiO3 (Na2O/precursor ratio varying between 9.1% and 24.2% and SiO2/Na2O ratios of 0 or 1.0); fly ash from a coal-fired power plant was also used as control precursor. X-ray fluorescence and powder X-ray diffraction analyses of cement, fly ash, bottom ash and of the resulting pastes were carried out. All specimens were evaluated in terms of their mechanical and durability-related performance (i.e. flexural and compressive strength, carbonation, water absorption by capillary action, and shrinkage). Considerable generation of H2 gas was observed during production, resulting from the reaction between the bottom ashes’ metallic aluminium fraction and the NaOH solution, leading to significant expansion and an overall increase in porosity and thus a strong decline in performance. Alkali-activated bottom ash specimens presented fast carbonation, resulting in a considerable strength increase. Despite the low performance of most of these mixes, the strength enhancement of specimens subjected to some conditions infers that there is significant scope for further mix design optimization (e.g. aluminium reduction, mixing time, Na2O/precursor and SiO2/Na2O ratios) that can lead to the manufacture of fit-for-industry construction materials.

Milled municipal solid waste incinerator bottom ash was used as a precursor in the production of alkali-activated mortars with recycled concrete aggregates as a sand substitute. Fly ash was used as control precursor and sodium hydroxide as an alkaline activator. Different thermal curing regimens were used: 24 h in ambient conditions; 24 h/70 °C; 48 h/70 °C; and 24 h/90 °C. Mechanical and durability-related performances were evaluated (i.e. flexural and compressive strength, modulus of elasticity, ultrasonic pulse velocity, carbonation, capillary water absorption, and shrinkage). The reaction between metallic aluminium from municipal solid waste incinerator bottom ash and OH− ions produced hydrogen gas, causing expansion, porosity increase and thus decline in performance. Low stability in high relative humidity settings due to leaching of highly soluble compounds was also observed. A further decline in performance was observed in mixes containing recycled aggregates. Alkali activated municipal solid waste incinerator bottom ash presented fast carbonation but also a considerable strength enhancement.