Vol. 1 (2025)
Inaugural Issue 2025

Articles

Mechanical and Microstructural Characterization of Cold-Bonded Geopolymer Aggregates from Industrial and Agricultural By-Products for Sustainable Concrete Applications

Published 2025-10-29

  • Abdul Aleem Mohamed Ismail
    • ,
  • Arun Murugesan
    • ,
  • Nidhya Rathinavel

Abdul Aleem Mohamed Ismail
Department of Civil Engineering, PSG Institute of Technology and Applied Research, Neelambur, Coimbatore - 641 062, India

Arun Murugesan
Department of Civil Engineering, PSG Institute of Technology and Applied Research, Neelambur, Coimbatore - 641 062, India

Nidhya Rathinavel
Department of Civil Engineering, PSG Institute of Technology and Applied Research, Neelambur, Coimbatore - 641 062, India

Abstract

The exhaustion of natural resources increases the demand for sustainable substitutes for use in concrete production is becoming prevalent. The present research evaluated the eco-production of synthetic aggregates by means utilizing industrial and agricultural by-products which are, ground granulated blast furnace slag (GGBS) and rice husk ash (RHA). The synthetic aggregates were developed by means of cold-bonding methods. By eliminating the high-temperature sintering stage typical of conventional lightweight aggregate production, the cold-bonding process achieves up to 90–95% energy savings and an estimated reduction of approximately 75 kg CO₂ per ton of aggregate and divert up to 1.2 tons of industrial/agricultural waste per ton of aggregate produced. The developed aggregates were used in concrete and workability was evaluated through slump test, and compressive strength was evaluated at 7, 14, and 28 days. The findings revealed that the optimum density, ideal strength and adequate microstructural characteristics were derived from using 90% GGBS and 10% RHA. This research emphasizes an eco-friendly alternative in the production of aggregates and provides practical strategies in conventional materials for sustainable concrete applications which ultimately replaces the construction practices into greener processes.

Keywords

Circular Economy, Waste Valorization, Low-Carbon Concrete, Geopolymer Aggregates, Cold-Bonding, Sustainable Construction, Industrial By-Products

PDF

References

  1. N. Sahu, V. Sahu, M. Dhruw, K. Paikra, A.K. Garg, S. Panda, Review on Advancements in the Production of Artificial Aggregates from Industrial Byproducts: A Sustainable Solution for Infrastructure Development, (n.d.).
  2. M. Alharthai, K.C. Onyelowe, T. Ali, M.Z. Qureshi, A. Rezzoug, A. Deifalla, K. Alharthi, Enhancing concrete strength and durability through incorporation of rice husk ash and high recycled aggregate, Case Stud. Constr. Mater. 22 (2025) e04152. https://doi.org/10.1016/j.cscm.2024.e04152
  3. N.R. Mohanta, M. Murmu, Alternative coarse aggregate for sustainable and eco-friendly concrete-A review, J. Build. Eng. 59 (2022) 105079. https://doi.org/10.1016/j.jobe.2022.105079
  4. B. Basheer, G. Antherjanam, Effect of silica fume in the mechanical properties of ambient cured GGBS based geopolymer concrete, in: Natl. Conf. Struct. Eng. Constr. Manag., Springer, 2019: pp. 155-164. https://doi.org/10.1007/978-3-030-26365-2_15
  5. J. Oti, B.O. Adeleke, P.R. Mudiyanselage, J. Kinuthia, A comprehensive performance evaluation of GGBS-based geopolymer concrete activated by a rice husk ash-synthesised sodium silicate solution and sodium hydroxide, Recycling 9 (2024) 23. https://doi.org/10.3390/recycling9020023
  6. S.R. Prusty, D. Murmu, R. Panigrahi, S. Jena, Assessment of strength and microstructural properties of GGBS based sustainable geopolymer concrete with parametric variations in alkaline solutions, (2023). https://doi.org/10.21203/rs.3.rs-3194834/v1
  7. M. Almadani, R.A. Razak, M.M.A.B. Abdullah, R. Mohamed, Geopolymer-based artificial aggregates: A review on methods of producing, properties, and improving techniques, Materials (Basel). 15 (2022) 5516. https://doi.org/10.3390/ma15165516
  8. G.B. Bekkeri, K.K. Shetty, G. Nayak, Effects of cold-bonded artificial aggregate properties on the behaviour of concrete, Mater. Res. Express 11 (2024) 85202. https://doi.org/10.1088/2053-1591/ad6ef2
  9. T.-P. Huynh, T.-B. Pham, T.-K. Lam, T.-D. Tran, V.-T. Nguyen, Feasibility of producing artificial aggregates by alkaline activation of fly ash-slag blends, in: 2020 Appl. New Technol. Green Build., IEEE, 2021: pp. 1-5. https://doi.org/10.1109/ATiGB50996.2021.9423427
  10. M.A.H. Pasaribu, B.B. Adhitya, A. Costa, B. Nayobi, Effect of Curing Time and Variations in Na2SiO3: NaOH Ratio on the Mechanical Properties of Fly Ash-Based Geopolymer Artificial Aggregates Using the Crushing Method, J. Adv. Res. Appl. Mech. 117 (2024) 107-117. https://doi.org/10.37934/aram.117.1.107117
  11. J.P. Zaniewski, L. Bessette, H. Rashidi, R. Bikya, Evaluation of Methods for Measuring Aggregate Specific Gravity, (2012).
  12. Y.S. Deshpande, J.E. Hiller, Pore characterization of manufactured aggregates: recycled concrete aggregates and lightweight aggregates, Mater. Struct. 45 (2012) 67=79. https://doi.org/10.1617/s11527-011-9749-2
  13. R.W. Earle Sr, E.T. Garz, P.O. Lee, M.D. Lockwood, J.J. Schmitt, Method and apparatus for determining liquid absorption of aggregate, (2002). https://doi.org/10.1016/S1350-4789(02)80119-2
  14. A.Z. Bendimerad, E. Roziere, A. Loukili, Combined experimental methods to assess absorption rate of natural and recycled aggregates, Mater. Struct. 48 (2015) 3557=3569. https://doi.org/10.1617/s11527-014-0421-5
  15. J.K. Das, S. Deb, B. Bharali, Prediction of Aggregate Impact Values and Aggregate Crushing Values Using Light Compaction Test., J. Appl. Eng. Sci. 11 (2021). https://doi.org/10.2478/jaes-2021-0012
  16. G.B. Bekkeri, K.K. Shetty, G. Nayak, Production of artificial aggregates and their impact on properties of concrete, in: Int. Conf. Cem. Build. Koncrete a Sustain. Resilient Infrastruct., Springer, 2023: pp. 359-370. https://doi.org/10.1007/978-981-99-7464-1_26
  17. N. Raj, S.G. Patil, B. Bhattacharjee, Concrete mix design by packing density method, IOSR J. Mech. Civ. Eng 11 (2014) 34-46. https://doi.org/10.9790/1684-11213446
  18. J. Raza, N. Singh, F. Colangelo, I. Farina, Sustainability Assessment of Lightweight Artificial Aggregates Made from Industrial Waste Using a Double-Step Cold Bonding Palletization Process, Adv. Sci. Technol. 149 (2024) 15-19. https://doi.org/10.4028/p-4UL6hC
  19. S. Zou, C.K. Chau, L.M. Leung, Z. Duan, J. Xiao, M.L. Sham, C.S. Poon, Developing low-carbon high-strength core-shell aggregates using solid waste by cold-bonding techniques, Constr. Build. Mater. 416 (2024) 135116. https://doi.org/10.1016/j.conbuildmat.2024.135116
  20. G.B. Bekkeri, K.K. Shetty, G. Nayak, Synthesis of artificial aggregates and their impact on performance of concrete: a review, J. Mater. Cycles Waste Manag. 25 (2023) 1988-2011. https://doi.org/10.1007/s10163-023-01713-9
  21. S.Y. Kwek, H. Awang, Utilization of industrial waste materials for the production of lightweight aggregates: a review, J. Sustain. Cem. Mater. 10 (2021) 353-381. https://doi.org/10.1080/21650373.2021.1891583
  22. H. Özkan, N. Kabay, N. Miyan, Properties of cold-bonded and sintered aggregate using washing aggregate sludge and their incorporation in concrete: a promising material, Sustainability 14 (2022) 4205. https://doi.org/10.3390/su14074205
  23. M.F.K. Al-Shamaa, A.A. Ali, I.F. Ahmed Al-Mulla, Mechanical characteristics of structural concrete using building rubbles as recycled coarse aggregate, J. Mech. Behav. Mater. 33 (2024) 20240001. https://doi.org/10.1515/jmbm-2024-0001
  24. D.Y. Osei, Compressive strength of concrete using recycled concrete aggregate as complete replacement of natural aggregate, J. Eng. Comput. Appl. Sci. 2 (2013) 26-30.