Slag Mortars Research Articles

Effect of pre-wetting treatment for waste waterglass foundry sand on the properties of alkali-activated slag

Waste waterglass foundry sand (WwFS) is a solid waste generated by the foundry industries that is commonly discarded in landfills and has urgent needs for disposal and recycling. Accordingly, this study suggests using WwFS as aggregates source for the preparation of alkali-activated slag mortars (AASM). Two different pre-wetting methods (24 h pre-wetting at 20°C and 1~6 h pre-wetting at 70°C) were used to treat WwFS and compared their performances with adding quartz sand and dried WwFS mortars. Compared to WwFS mortars without pre-wetting treatment, the compressive strengths of WwFS mortars containing WwFS pre-wetting in water at 70°C at 28d were increased by 1.3~10.0%, and the C-(A)-S-H average elastic modulus was increased by 16%. This study confirmed the feasibility of using hot water pre-wetted WwFS as the single aggregate source for AASM, which is important for the large-scale utilization of WwFS.

Enhancing mechanical strength and microstructural properties of alkali-activated systems through nano graphene oxide dispersion and polycarboxylate ether admixture

The dispersion of graphene oxide (GO) nanoparticles in alkali-activated concrete with / without superplasticizers can help in understanding the effect it has on its mechanical strength and microstructural properties. The dispersion of GO in alkali activator fluid of 10(M) and 12(M) with / without polycarboxylate ether (PCE) admixture has been explored in this study. The alkali activator solution of 10(M) NaOH solution with PCE shows better dispersion than 12(M) NaOH solution, as higher alkalinity leads to agglomeration of GO. The study investigated the effect of incorporating PCE in GO-based alkali-activated slag (AAS) mortar with 8(M), 10(M) and 12(M) of alkaline activator solution. The mechanical strength and microstructural characteristics of conventional AAS (without both GO and PCE), GO-based AAS (without PCE) and GO-based AAS with PCE of the respective molar concentration of activator fluid are analysed. The mechanical strength of the AAS mortars has been evaluated using compressive, flexural, and splitting tensile strength testing. The micro-structural and mineralogical characteristics of the binders are evaluated using Field Emission Scanning Electron Microscopy (FESEM with EDS), X-ray Diffraction (XRD), and Fourier Transform Infrared Spectroscopy (FTIR) analysis. The addition of only GO (0.06 % of binder w/w) and the addition of both GO and PCE in AAS have shown up to 30 % and 40 % mechanical strength improvement with respect to conventional AAS, respectively. The effectiveness of PCE and percentages of strength improvement are higher with a lower molarity of activator fluid, and vice versa. Adding GO and PCE to the AAS system improves its hydration rate and denser microstructure, enhancing its strength.

Investigating the impact of foundry by-product sand as an activator on workability improvement and strength development in alkali-activated blast furnace slag mortar

The substitution of alkali-activated furnace slag significantly reduces the necessity of cement manufacture and mitigates the continuous growth of carbon emissions. In addition, it shows superior mechanical properties compared to traditional concrete materials. However, rapid setting issues hinder its widespread applications. This study investigated the innovative use of zero-carbon waste sodium silicate-bonded sand as a substitute for the fine aggregate and sodium silicate in traditional alkali-activated blast furnace slag mortar. The primary objective is to analyze the impact of waste sodium silicate-bonded sand on the workability and mechanical properties of the mortar. The key properties such as flowability, setting time, temperature measurement, compressive strength, and microstructural were analyzed to determine the improvement in workability and the strength development of alkali-activated blast furnace slag mortar resulting from the use of waste sodium silicate-bonded sand. The research showed the integration of waste sodium silicate-bonded sand results in an eco-friendly and cost-effective material, which addresses limitations in traditional activated blast furnace slag mortars. The finding revealed that substituting fine aggregate and sodium silicate with waste sodium silicate-bonded sand significantly improved the mechanical and workability properties of alkali-activated mortars. Notably, the compressive strength of mortars incorporating waste sodium silicate-bonded sand exceeded that of traditional Portland cement and effectively mitigated rapid setting issues. In addition, this approach led to an environmentally friendly mortar with satisfactory workability. The research emphasizes the practical benefits of utilizing waste sodium silicate-bonded sand and offers new insights into its effects on mortar performance. This has provided more details for future exploration and refinement in the field of alkali-activated materials.

The effect of copper slag as a precursor on the mechanical properties, shrinkage and pore structure of alkali-activated slag-copper slag mortar

Copper slag, an industrial by-product produced in large quantities during copper smelting and refining, has the potential to be used as an alternative precursor for alkali-activated materials. This approach not only reduces the environmental impact of copper slag but also addresses the growing scarcity of conventional precursors, such as ground granulated blast furnace slag. In this research, copper slag was used as an alternative precursor for alkali-activated slag-copper slag mortars. Sodium hydroxide and water glass served as the activators. The workability, mechanical properties, autogenous shrinkage and drying shrinkage were investigated to evaluate the influence of copper slag content. Furthermore, the reaction products and pore structure of hardened mortar were analysed to gain deeper insights into its performance. The results show that the incorporation of copper slag effectively prolongs the setting time and increases the fluidity. Copper slag reduces the autogenous shrinkage, but it also results in an undesirable increase in drying shrinkage. While copper slag delays strength development and reduces the strength, incorporating copper slag at a 50 % ratio still results in strength comparable to that of mortars utilizing 100 % ground granulated blast furnace slag as the precursor. The incorporation of copper slag alters the composition of calcium aluminosilicate hydrate and promotes the formation of ferro-silicate. Although it reduces the proportion of macropores in the total pore volume, it simultaneously increases the amount of capillary pores. Copper slag alters pore solution, and although heavy metal leaching remains minimal, risks in complex environments require further study.

Improving the Performance of Mortar under Carbonization Curing by Adjusting the Composition of Ternary Binders

As the most widely used building material, cement has attracted the attention of scholars because of its large carbon emission. To alleviate the problems of carbon emission and limited resource use caused by cement production, this study focuses on the performance of mortar after carbonization curing by regulating the composition of ternary binders. Testing involved mechanical parameters, carbon shrinkage, water absorption, hydration product, microstructure, adsorption of carbon dioxide, calcium carbonate content, and carbonization degree of mortar, as well as comparisons with the effect of calcium carbide slag and sintered red mud. We carried out several studies which demonstrated that carbonization curing and adjusting the content of calcium carbide slag and sintered red mud were beneficial to improve the mechanical properties, peak load displacement, slope, elastic energy, plastic energy, carbon shrinkage, carbon dioxide adsorption, calcium carbonate content, and carbonization degree of mortar, while the addition of calcium carbide slag and sintered red mud increased the water absorption of mortar, and the greater the dosage, the greater the water absorption. Meanwhile, adding 25%–50% calcium carbide slag and sintered red mud still had negative effects on the mechanical properties of mortar. But carbonation curing and the addition of calcium carbide slag and sintered red mud could promote the hydration reaction and consume calcium hydroxide formed by hydration to form calcium carbonate. When the dosage was 50%, the carbon dioxide adsorption capacity, calcium carbonate content, and carbonization degree of calcium carbide slag mortar were higher than those of sintered red mud mortar, which increased by 29.56%, 102.73%, and 28.84%, respectively. By comparison, calcium carbide slag and sintered red mud still showed superior carbon sequestration capacity, which was higher than fly ash and Bayer red mud. From the experiment, we came to realize that adjusting the composition of cementitious materials could realize the carbon sequestration of cement-based materials and promote the road toward low-carbon sustainable development of cement.

Changes in the structure of alkali activated slag mortars subjected to accelerated leaching

The chemically induced degradation of alkali-activated materials exposed to the surrounding environment is a critical concern for durability. In this study, the leaching of alkali activated slag mortars (AASs) subjected to a 6M NH4NO3 solution was investigated by integrating techniques including ICP-OES, XRD/QXRD, TGA/DSC, ATR-FTIR, and 29Si MAS-NMR. The results revealed that the main leachable elements from the AASs and their leaching rates decreased in the following order: Na, K, Ca, and Mg. In contrast, Si and Al, the key elements in the C-A-S-H gel, displayed a remarkable resistance to leaching. Upon NH4NO3 attack, the primary phase (C-A-S-H) becomes more siliceous and has a greater mean chain length through decalcification and dealumination. The second phase, Mg, Al-layered double hydroxide (Mg, Al-LDH, or hydrotalcite), incorporated nitrate from the surrounding solution, sulfate from precursor dissolution, and Ca from gel decalcification to form nitrate/sulfate-bearing Ca, Al-LDH phases. Remarkably, the water-to-binder ratio exerted a nuanced influence, dictating the pace of element leaching, while exhibiting a relatively modest impact on the stability of the solid phases after 28 days of exposure. This work proposes a leaching mechanism for understanding the leaching process occurring in AASs based on an in-depth experimental exploration of mineralogical alterations.

Green Disposal of Domestic Wastewater in Alkali-Activated Slag Mortar: Enhancing Performance and Sustainability

Green Disposal of Domestic Wastewater in Alkali-Activated Slag Mortar: Enhancing Performance and Sustainability

Microstructural evolution and its impact on the mechanical strength of typical alkali-activated slag subjected to accelerated carbonation

This study aims to comprehensively investigate the evolution of microstructure, mechanical strength, and their correlation in alkali-activated slag (AAS) mortars, designed for application in the immobilization of liquid radioactive waste, under accelerated carbonation conditions (1% CO2, 20 °C and 60% RH). To gain insights into the underlying microstructural changes, CO2 uptake and decalcification of C-A-S-H were analyzed using TGA/DSC and EDS. The pore structure of AASs was systematically assessed across nano- to macro-scales, employing N2-adsorption, MIP, and SEM segmentation. Generally, carbonation led to a decrease in total porosity, primarily attributed to the reduction in meso-macropore volume. However, the pore size distribution of AAS exhibited a complex alteration over varying carbonation durations. Carbonation significantly reduced flexural strength, whereas its effect on compressive strength was comparatively milder. Notably, an evident linear correlation emerged between porosity and compressive strength in both reference and carbonated AASs.

Inhibiting efflorescence of alkali-activated slag mortar by improving its hydrophobicity with methyl-terminated polydimethylsiloxane (PDMS): Evidences showing the remained PDMS

This paper proposes to prepare hydrophobic alkali-activated slag (AAS) mortars with methyl-terminated polydimethylsiloxane (PDMS), a hydrophobic polymer with low surface energy, to minimize its water sorptivity and efflorescence. To depict the efflorescence process of PDMS-modified AAS mortars, visual inspections of efflorescence features, the leaching behavior of sodium ions, water absorption characteristics of mortars and contact angle tests were conducted. Additionally, the hydration process, microscopic morphology, and chemical structure of PDMS-modified AAS mortars and pastes were examined by compressive strength, isothermal calorimetry, TEM, SEM, FT-IR, 29Si NMR, enabling the explanation of PDMS working mechanisms. The results demonstrated that the addition of PDMS successfully mitigated esthetic issues and the spalling of mortars caused by efflorescence. Furthermore, PDMS reduced the risk of long-term durability issues of AAS mortars by restricting the loss of sodium ions after efflorescence. At the same time, the introduction of PDMS with dosage below 5 % did not significant retarder the hydration reaction process or the development of strength of AAS. However, it did alter the micromorphology and chemical structure of the hydration product. PDMS linked to the hydration products through covalent bonds and acted as a bridging role to alter the micromorphology of the hydration products. The resulting multi-structured material exhibited micropapillary and nano-coating layers with hydrophobic methyl functional groups, imparting hydrophobicity to the PDMS-AAS hydration product.

Crack-healing and rheological properties of high content fly ash/slag/silica fume green and sustainable cement-based materials incorporating crystalline admixture and calcium alginate biomass hydrogel

Cracking is an important factor affecting the durability of concrete. Rheological properties are important performance indicators of the workability of fresh concrete. Ion chelator (CA) is one kind of crystalline admixture, which can enhance crack-healing of concrete by promoting the formation of calcium carbonate in wet environment. Calcium alginate hydrogel (CaAlg) can maintain the humidity of cementitious matrix and promote the crystallization of inorganic minerals. Therefore, in this study, CaAlg bead was prepared to further improve the crack-healing of cementitious materials containing CA. Self-healing performance was evaluated by visual crack closure and water permeability test. Rheological property was measured by rotor rheometer. Healing mechanism of cementitious materials with CA and CaAlg was analyzed. Results showed that with the increase of CaAlg dosage, yield stress and plastic viscosity of paste decreased gradually. Meanwhile, fly ash and slag reduced viscosity of pastes, while silica fume increased the viscosity of pastes. CA could evidently improve the permeability and mechanical properties of mortar, especially for slag mortar. Self-healing performance test and characterization showed that CaAlg could further enhance crack-healing process of mortar with CA, especially for pure cement and slag mortar. Microscopic testing indicates that CaAlg could induce the formation of vaterite and calcite on its surface to further improve crack-healing efficiency.

Impact of exposure conditions on alkali-silica reaction in alkali-activated material systems

The influence of different testing methods on alkali-silica reaction (ASR) behavior is a result of the difference in the effect of exposure conditions on it. This study investigated the impact of temperature and the addition of alkali on ASR behavior in an alkali-activated material (AAM) system and compared it with an ordinary Portland cement (OPC) system. The results showed that the ASR in the AAM system was more independent of the exposure conditions than that in the OPC system because of its inherently high alkalinity and dense microstructure. More ASR products with higher Na:Si ratios were evident in the alkali-activated slag (AAS) mortars than in the OPC mortars. The accelerated test conditions developed for OPC systems could be applied to AAM systems. However, owing to the difference in the acceleration effect, comparing the ASR-induced expansion in OPC and AAM systems using the accelerated test method was misleading to some extent. This study contributes to the understanding of the ASR in AAM systems and is of considerable importance for the industrial application of AAMs.

Effect of glass and nylon fibers on drying shrinkage of alkali activated blast furnace slag mortars

The environmental consequences of Portland cement (PC) manufacturing have prompted the exploration of alternative binders, such as the alkali activation of blast furnace slag (BFS), which is generated as a byproduct during the extraction of iron. While alkali-activated blast furnace slag (AAS) binders have some benefits over regular PC binders, they also suffer from disadvantages such as significant drying shrinkage. The study investigated the impact of Na dosage and curing conditions on alkali-activated blast furnace slag mortar (AASM). The consistency of the specimens was tested for fresh, hardened properties, and was conducted. The optimum Na dosage and curing conditions were selected. In the second stage, 0.1% and 0.2% glass and nylon fibers were added to the selected optimum mortar. Consistency, fresh, mechanical, and durability properties tests were conducted on the fiber mortars. The results showed that increasing the Na content increased the compressive and flexural strengths of AASM specimens. Thermal curing provided high compressive and flexural strengths, whereas fiber addition reduced water absorption and drying shrinkage. The drying shrinkage value was reduced by 26.82 % for AASM specimens with 0.2 % nylon fibers by volume compared to AASM without fibers.

CO2-Driven Additive Manufacturing of Sustainable Steel Slag Mortars

CO₂-Driven Additive Manufacturing of Sustainable Steel Slag Mortars

Effect of curing condition on mechanical properties and durability of alkali-activated slag mortar

While alkali-activated slag (AAS) has emerged as a promising alternative binder in construction engineering, a consensus on the optimal curing condition for this material has not been reached yet. It is well known that AAS can harden at ambient temperatures, but the influence of humidity on its properties remains poorly understood. Herein, we considered five curing conditions with different relative humidities (RH), including ambient/dry condition (RH=55 %), sealed condition (RH=80–95 %), fog condition (RH>95 %), water immersion condition (RH=100 %), and saturated limewater immersion condition (RH=100 %). Various properties have been examined, including flexural and compressive strengths, elastic modulus, shrinkage, pore structure, carbonation resistance, and freeze-thaw resistance of AAS mortars (AASM). Two types of activators, sodium hydroxide and sodium silicate (modulus at 1) solutions were used. The experimental results indicate that drying at early ages is detrimental to almost all the properties investigated. Sealed curing can deliver desirable mechanical properties and durability, but considerable shrinkage. Fog and water curings are highly effective at mitigating early shrinkage in AASM, but the problem of leaching adversely affects its long-term properties. Generally, limewater curing offers limited benefits compared to other high-humidity curing methods.

Effect of fly ash and gypsum on drying shrinkage and mechanical properties of one‐part alkali‐activated slag mortar

AbstractOne‐part alkali‐activated materials can be processed into semi‐finished products by mixing a solid activator with the powder. They only require the addition of water, which greatly improves their commercial feasibility. So, we used one‐part alkali‐activated slag mortar to investigate the effects of the dosages of the activator (sodium metasilicate), fly ash (FA), and gypsum on its fluidity, flexural strength, compressive strength, and drying shrinkage. The microscopic mechanisms of the mortar were analyzed using scanning electron microscopy and x‐ray diffraction. The below conclusions were drawn. First, the drying shrinkage and compressive strength of the mortar gradually increased with the increase of the activator dosage. Second, the drying shrinkage of the mortar initially decreased and then increased as increasing FA substitution, while the compressive strength decreased gradually in the early stage and then increased and decreased in the later stage. Lastly, by increasing the gypsum dosage, the drying shrinkage of the mortar was significantly reduced. However, the compressive strength gradually decreased. Besides, when adding 20% of FA and 2.4% of gypsum, it was found that ettringite, which underwent expansion, formed in the system. This not only reduced the drying shrinkage by 25.3% but also increased the compressive strength by 1.3%. Furthermore, our investigation has led to the development of a low‐shrinkage one‐part alkali‐activated slag and FA mortar, which not only facilitates the recycling of solid waste materials but also presents commendable environmental and economic advantages.

Investigation of the Effect of Blended Aggregate on the Strength and Drying Shrinkage Characteristics of Alkali-Activated Slag Mortar.

To reduce drying shrinkage of AASC mortar (AASM), mixed aggregate mixed with river sand (RS) and silica sand in three sizes was used to investigate the effect of the physical properties of mixed aggregate on shrinkage reduction. A mixture of river sand (0.2-0.8 mm), S1 (2.5-5.0 mm), S2 (1.6-2.5 mm), and S3 (1.21-160 mm) had river sand-silica sand mean diameter ratios (dr) of 7.68 (S1/RS), 3.75 (S2/RS), and 3.02 (S3/RS). The compressive strength and drying shrinkage characteristics of mixed aggregates according to fineness modulus, surface area, bulk density, and pore space were investigated. It had the highest bulk density and lowest porosity at a substitution ratio of 50%, but the highest strength was measured at a substitution ratio of 50% or less. High mechanical properties were shown when the fineness modulus of the mixed aggregate was in the range of 2.25-3.75 and the surface area was in the range of 2.25-4.25 m2/kg. As the substitution rate of silica sand increased, drying shrinkage decreased. In particular, the drying shrinkage of RS + S1 mixed aggregate mixed with S1 silica sand, which had the largest particle size, was the smallest. When silica sand or river sand was used alone, the drying shrinkage of the sample manufactured only with S1, which has the largest particle size of silica sand, was the smallest among all mixes. Compared to RS, at a 5% activator concentration, drying shrinkage was reduced by approximately 40% for S1, 27% for S2, and 19% for S3. At a 10% concentration, S1 showed a reduction effect of 39%, S2 by 28%, and S3 by 13%. As a result of this study, it was confirmed that the drying shrinkage of AASM could be reduced simply by controlling the physical properties of the aggregate mixed with two types of aggregate. This is believed to have a synergistic effect in reducing drying shrinkage when combined with various reduction methods published in previous studies on AASM shrinkage reduction. However, additional research is needed to analyze the correlation and influencing factors between the strength, pore structure, and drying shrinkage of AASM using mixed aggregate.

Investigate the mechanical behavior of alkali-activated slag mortar using sustainable waste sodium silicate-bonded sand as an alkali activator and carbon free aggregate

Various products generate different types of industrial by-products based on their production characteristics and procedures. Therefore, an accurate classification of these characteristics would contribute significantly to achieving the goals of resource recycling and environmental protection. This study focused on Waste Alkali-Activated Slag Mortar (W-AASM). In the past, inorganic aggregation technology was successfully adopted to replace conventional concrete binding materials and reduce cement usage. Besides utilizing inorganic aggregation technology, the study has introduced a novel industrial by-product known as Waste Sodium Silicate-Bonded Sand (WSSS). WSSS not only serves as a substitute for sodium silicate in alkali-activated agents but also acts as a complete replacement for fine aggregates in mortar. The experimental findings showed that, in addition to fulfilling the original strength requirements of concrete, it results in a significant reduction in cement consumption, minimizing the extraction of natural resources, and decreasing the overall cost of Alkali-activated concrete production. The study highlighted the advantage of WSSS and showed a new dimension of waste foundry sand application in the concrete industry. This method leads to the recycling of waste materials and their optimal use, and as a result, leads to a sustainable ecosystem. The results of this study can be applied to secondary structures in civil engineering and construction projects in the future, such as precast concrete products, concrete pavements, or roads.

Potassium citrate-activated pure BOF slag-based mortars utilizing carbonated and autoclaved BOF slag aggregates

This study proposes novel basic oxygen furnace (BOF) slag mortars formulated with tri-potassium citrate (TPC) activated BOF slag as binder and treated BOF slag (carbonated (CB) and autoclaved (AB)) as aggregates, aiming to maximize the utilization of BOF slag in the construction industry. Untreated BOF slag (UB) and natural sand (NS) were employed as reference aggregates. The effects of carbonation and autoclaving were investigated, focusing on the interfacial transition zone (ITZ) properties through SEM-BSE greyscale thresholding and constituent segmentation analysis. Results indicate that both treatments reduce the free CaO, promote CaCO3 formation, and modify the aggregate surface. The 28 d compressive strength of pure BOF slag-based mortars with UB, CB, and AB aggregates are 25.8, 29.4, and 34.8 MPa (average at varying TPC dosages), significantly higher than that with NS (19.6 MPa). Pure BOF slag-based mortars also show narrower ITZ thicknesses and the absence of bond cracks. Mortars with CB and AB aggregates exhibit fewer unreacted particles and more hydration products within the integral binder region compared to those with UB. Overall, pure BOF slag-based mortars present a more robust aggregate/binder interface that is further enhanced by the aggregate treatments. Leaching values of all mortars are well below the Dutch legal limits. The findings suggest promising application prospects for pure BOF slag-based mortars in substituting cement mortars and valorizing BOF slag.

Alkali-silica reaction of ferronickel slag fine aggregate in Portland cement and alkali-activated slag mortars: Pessimum effect investigation

Ferronickel slag (FNS) with dense and hard nature exhibits great potential to be utilized as recycled aggregate in concrete production. This study investigated the alkali-silica reaction (ASR) and the pessimum proportion of FNS fine aggregate in Portland cement (PC) and alkali-activated ground granulated bast furnace slag (AAS) mortars as a substitute for river sand. Over a 120-day period, the accelerated mortar bar test revealed that the addition of FNS fine aggregate in both cases resulted in harmless ASR expansion. In PC mortars, the ASR expansion consistently decreased from 0.569 % to 0.114 % as the FNS content increased. In comparison, AAS mortars with higher pore solution alkalinity had the pessimum proportion of 30 % FNS. The ASR expansion values initially increased from 0.472 % to 0.554 % with an increase in FNS content from 0 % to 30 %, but then decreased to 0.146 % as the FNS content was further raised to 100 %. The amorphous ASR gel was identified as a hydrated alkali silicate gel and present within the existing veins in the river sand grain. The ASR reaction of FNS fine aggregate exhibited a self-mitigating effect on the deleterious expansion through its pessimum behavior. Additionally, the addition of FNS fine aggregate yielded a beneficial outcome by reducing the cumulative pore volume in the mortars, and thus enhanced the compressive strengths.

Effects of recycled carbon fibers on mechanical and piezoresistive properties and environmental impact in alkali-activated cementitious materials

The development of alkali-activated cementitious materials (AAM) reinforced with recycled carbon fiber (rCF) is of remarkable significance due to its cost-effectiveness compared to virgin carbon fiber, along with the sustainable reuse of solid waste serving as AAM. This study explores the integration of rCF and solid waste Ground Granulated Blast Furnace Slag (GGBS), aiming for cleaner construction practices. A novel approach involving a high-viscosity one-part GGBS slurry ensured homogeneous rCF dispersion, resulting in alkali-activated slag (AAS) mortars with outstanding overall performance at minimal dosage. At a minimum dosage of 0.1 vol%, rCF significantly enhanced flexural strength by 53.42% and reduced drying shrinkage by over 20%. The uniformly dispersed rCF acts as nucleation sites, boosting early compressive strength without compromising long-term performance. Furthermore, the connected rCF network established an exceptionally low percolation threshold (0.125 vol%) and demonstrated promising piezoelectric properties under cyclic loading, illustrating its potential as self-sensing concrete elements. Additionally, life cycle analysis (LCA) underscored the environmental benefits of rCF and GGBS, revealing their potential to remarkably cut carbon emissions (75.36%) and reduce costs (36.5%). These findings provide valuable insights into the development of rCF-reinforced self-sensing mortar with superior mechanical properties, showcasing the substantial potential of rCF in driving the construction industry toward carbon neutrality.