Physical-chemical processes of sustainable construction materials structure formation with iron ore processing tailings and aluminum anodizing sludge

Abstract

To replace completely natural raw materials were developed new sustainable concrete-like construction composites from 10 − 40% iron ore tailings, 10–35% aluminum anodizing sludge, 25–30% concrete waste, and 15–25% lime production waste with mechanical and physical properties that meet the requirements of the Brazilian standards. The composition’s axial compression resistance reached 4.49 MPa on the 3rd day and 11.24 MPa on the 730th day of cure. All mechanical, physical, and chemical properties of newly developed composites from these industrial wastes met Brazilian standards for producing construction materials like ecological. Dilatation coefficient values varied between 0.95 and 2.35% on the 3rd day of cure, and it ranged from 1.35 to 2.05% on the 730th day. The apparent specific mass increased during two years from 3.38 − 3.67% to 3.47–3.75. Such properties met the requirements of Brazilian standards for producing sustainable road bases, bricks, and blocks. The studies of structure formation processes during 730 days of outdoor cure showed the synthesis of mainly amorphous sol–gel new formations with a slight inclusion of crystalline carbonate content. The main novelty of this research study is the scientifically and experimentally proven possibility to produce new environmentally clean construction composites only from four types of hazardous industrial waste to replace traditional natural raw materials like sand, gravel, crushed stone. The use of this laboratory study’s results at the industrial level will reduce the irreversible destruction of nature by quarries of construction materials, noticeably improving our planet’s sustainability.