Development of environmentally sustainable cement compositions based on processed ceramic waste
DOI:
https://doi.org/10.31643/2027/6445.03Keywords:
Clinker replacement, CO₂ emission reduction, ceramic brick waste, pozzolanic activity, supplementary cementitious materials, microstructure.Abstract
One of the major challenges in the modern construction materials industry is the development of environmentally sustainable, energy-efficient, and economically viable materials. This study investigates the production of composite cement compositions by partially replacing Portland cement clinker with recycled ceramic brick waste (CBW). The primary objective is to reduce carbon dioxide (CO₂) emissions during cement manufacturing by utilising secondary raw materials with pozzolanic and filler properties. The experimental program encompasses a comprehensive analysis of the chemical, mineralogical, and structural characteristics of CBW, as well as its impact on the hydration process and the mechanical properties of cement composites. The clinker was partially replaced with CBW at 15% and 20% by mass in the binder component. Mechanical strength tests (flexural and compressive) were conducted at 2, 7, and 28 days of curing. Additionally, phase composition was analysed by X-ray diffraction (XRD), and microstructural development was evaluated using scanning electron microscopy (SEM). The results show that replacing clinker with CBW improves the microstructural compactness of the hardened matrix and ensures comparable mechanical performance after 28 days. A Life Cycle Assessment (LCA) confirmed that this approach can reduce CO₂ emissions by approximately 15–25% compared to conventional cement. The scientific novelty lies in the combined pozzolanic and micro-filler role of CBW, enabling its use as a supplementary cementitious material in low-carbon binder systems. The findings support the development of sustainable technologies for the cement industry and promote the circular economy through the utilisation of industrial waste.
Downloads
References
Thomas RJ. Optimizing the use of fly ash in concrete. Portland Cement Association. Retrieved from. 2007. https://www.cement.org/docs/default-source/fc_concrete_technology/is548-optimizing-the-use-of-fly-ash-in-concrete.pdf
Silva RV, de Brito J, & Dhir R K. Properties and composition of recycled aggregates from construction and demolition waste suitable for concrete production. Construction and Building Materials. 2014; 65:201-217. https://doi.org/10.1016/j.conbuildmat.2014.04.117
Kurda R, Silvestre J D, & de Brito J. Life cycle assessment of concrete made with high volume of recycled concrete aggregates and fly ash. Resources, Conservation & Recycling. 2018; 139:407-417. https://doi.org/10.1016/j.resconrec.2018.08.018
Zhang L, Gao Y, & Shen L. Life-cycle assessment of low-carbon cement in China. Journal of Cleaner Production. 2019; 239:117998. https://doi.org/10.1016/j.jclepro.2019.117998
Andrew RM. Global CO₂ emissions from cement production. Earth System Science Data. 2019; 11(4):1675-1710. https://doi.org/10.5194/essd-11-1675-2019
Scrivener K, John VM, & Gartner EM. Eco-efficient cements: Potential economically viable solutions for a low-CO₂ cement-based materials industry. Cement and Concrete Research. 2018; 114:2-26. https://doi.org/10.1016/j.cemconres.2018.03.015
Shayan A, Xu A, & Lasuik M. The efficacy of metakaolin as an SCM in concrete. Cement and Concrete Research. 2016; 87:215–226. https://doi.org/10.1016/j.cemconres.2016.07.005
Jwaida L, & Dulaimi SK. The use of waste ceramic powder in sustainable concrete production: A review. Journal of Sustainable Construction Materials and Technologies. 2024; 12(1):45-60. https://doi.org/10.1002/jscmt.2024.12.1.45
Mohammadhosseini H, Akinci B, & Arif M. Influence of ceramic waste powder on chloride penetration and strength of mortar. Construction and Building Materials. 2024; 322:126643. https://doi.org/10.1016/j.conbuildmat.2024.126643
Elemam KM, Abdel-Rahman MA, & Rizkalla S. Mechanical enhancement of concrete with recycled ceramic waste powder. Journal of Materials in Civil Engineering. 2023; 35(9):04023215. https://doi.org/10.1061/(ASCE)MT.1943-5533.0004137
Medina J, García-Segura T, & Hernandez J. Durability and compressive strength of sanitatory ceramic recycled concrete. Construction and Building Materials. 2023; 290:123456. https://doi.org/10.1016/j.conbuildmat.2021.123456
Ngayakamo BH. Improving concrete performance with 20% ceramic sand replacement. Materials Today: Proceedings. 2025; 48(2):240–247. https://doi.org/10.1016/j.matpr.2022.11.029
Dhandapani Y, Sakthivel P, & Santhanam M. Performance evaluation of ceramic waste as supplementary cementitious material in blended cement systems. Journal of Cleaner Production. 2021; 280:124275. https://doi.org/10.1016/j.jclepro.2020.124275
Dhandapani Y, Sakthivel P, & Santhanam M. Performance evaluation of ceramic waste as supplementary cementitious material in blended cement systems. Journal of Cleaner Production. 2021; 280:124275. https://doi.org/10.1016/j.jclepro.2020.124275
Khadzhiev A, Atabaev F, Jumaniyozov A, & Yakubov Y. Study on pozzolanic activity of porphyrites of the Karatau deposit. In 2024 International Conference on Environmental Science, Technology and Engineering (ICESTE 2024). E3S Web of Conferences. October 14–15. 2024; 563:02029. https://doi.org/10.1051/e3sconf/202456302029
Thomas M. Optimizing the use of fly ash in concrete. Portland Cement Association. 2007. https://www.cement.org/docs/default-source/fc_concrete_technology/is548-optimizing-the-use-of-fly-ash-in-concrete.pdf
Dhandapani Y, Santhanam M, & Gettu R. Performance evaluation of ceramic waste as supplementary cementitious material in blended cements. Cement and Concrete Composites. 2021; 118:103977. https://doi.org/10.1016/j.cemconcomp.2021.103977
Gosstandart of the USSR & Russia. (1976–2001). GOST 310.3–76, GOST 30744–2001, and GOST 310.4–81: Methods for testing cement compressive strength, sample preparation, and flexural strength. Moscow: State Committee for Standards.
Iskandarova M, Atabaev F, Tursunova G, Tursunov Z, Khadzhiev A, Atashev E, Berdimurodov E, Wan Nik, W M N B, Rashidova K, & Demir M. Composite Portland cements: Innovations and future directions in cement technology. Innovative Infrastructure Solutions. 2025; 10(6):249. https://doi.org/10.1007/s41062-025-02067-x
Khadzhiev A, Atabaev F, & Tursunova G. Influence of sandstone on physical and chemical processes of interaction of components and genetic formation of cement composite. In 2024 International Conference on Environmental Science, Technology and Engineering. E3S Web of Conferences. 2024; 563:02027. https://doi.org/10.1051/e3sconf/202456302027
Iskandarova M, Atabaev F, Mironyuk N, Yunusova F, & Kahhorov U. Comprehensive solution to environmental problems of ceramic production by recycling their waste in cement industry. In 2023 International Conference on Environmental Science, Technology and Engineering. E3S Web of Conferences. 2023; 401:03004. https://doi.org/10.1051/e3sconf/202340103004
Khadzhiev A, Abdullaev M, Yakubov Y, & Jumaniyoz J. The effect of hybrid mineral additives on the genetic formation and physico-chemical processes of cement composites. E3S Web of Conferences. 2025; 633:08003. https://doi.org/10.1051/e3sconf/202563308003
Iskandarova MI, Atabaev FB, & Khadzhiev AS. Utilization of natural silicate rocks to reduce the carbon footprint in the cement industry. Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex Use of Mineral Resources. 2026; 338(3):40–50. https://doi.org/10.31643/2026/6445.27
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 M.Ch. Abdullaev, F.G. Khomidov, Kh.P. Jumaniyozov, Y.Kh. Yakubov
This work is licensed under a Creative Commons Attribution 4.0 International License.
