Recycling and reuse of waste banded iron formation as fine aggregate in the production of lightweight foamed concrete: Fresh-state, mechanical, thermal, microstructure and durability properties assessment

Abstract

This study investigates the possibility of using BIFs as sustainable fine aggregates to produce lightweight foam concrete (LWFC) by replacing sand with 5, 10, 15, 20, and 25 % banded iron formations (BIFs). The fresh concrete properties, such as slump flow, density, and setting time, as well as its mechanical properties, including compressive strength, splitting strength, and flexural strength, were investigated. The thermal conductivity, specific heat, porosity, gas permeability, pore distribution, and sorptivity were measured to determine durability and thermal performance. Microstructural analysis of the mixes was performed using SEM, energy-dispersive X-ray spectroscopy (EDX), and mapping. The results recommended a 10 % replacement ratio to achieve an increased compressive strength ratio of 55.88 % compared to the control mix at 7 days (d). The strength at later ages increased compared to that of the control mix by 33.9 %, 30 %, 42.48 %, and 42.4 % at 14, 28, 56, and 180 d, respectively. In addition, the flexure increased by 42.7 % at 7 d, 49.6 % at 14 d, and 45.6 % at 28 d compared to the control mix. In addition, the UPV also increased gradually from 2757 to 3699 km/s with increase in BIFs content. Furthermore, the porosity decreased at 7 d, 14 d, 28 d, and 90 d. Moreover, chloride penetration decreased by 2.5 %, where an improvement in thermal conductivity was achieved with BIFs to 0.342 W/mK compared to that of the control mix. In addition, a reduction in the specific heat of the material from 1042 J/kg K to 1007 J/kg K was observed. SEM showed a better arrangement of pores when BIFs were utilized compared with that of control mix without BIFs. In conclusion, the incorporation of waste BIFs as fine aggregates in lightweight foam concrete demonstrates a promising potential for enhancing the mechanical and thermal properties of construction materials, paving the way for durable building materials in the construction industry.