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Sus ainable Conc e e Mixes Using Alcco ine
and Was e Ma e ials
Koondla Sa h ika
Depa men o Ci il Enginee ing, Na ayana Enginee ing College, Nello e, India. seshusa ubha a [email protected]
Abs ac : The inc easing demand o sus ainable cons uc ion p ac ices has led o he explo a ion o al e na i e ma e ials o educe he
en i onmen al impac o con en ional conc e e. This s udy in es iga es he mechanical pe o mance o conc e e mixes inco po a ing Alcco ine
and indus ial was e ma e ials such as g ound g anula ed blas u nace slag (GGBFS), me akaolin, coppe slag, ound y sand, and ecycled
agg ega es. Fou mix a ian s we e de eloped and e alua ed agains a con en ional con ol mix. Expe imen al in es iga ions included
wo kabili y, comp essi e s eng h, spli ensile s eng h, lexu al s eng h, and densi y es s a a ious cu ing pe iods. The esul s demons a ed
ha op imized combina ions o Alcco ine and supplemen a y was e ma e ials signi ican ly enhanced he mechanical p ope ies and sus ainabili y
o he mixes. Among he es ed mix u es, he blend con aining 15% Alcco ine, 10% me akaolin, and 30% GGBFS in he binde , along wi h 50%
coppe slag, 30% ound y sand, and 30% ecycled coa se agg ega e, ou pe o med o he s in e ms o s eng h and en i onmen al bene i . The
indings alida e he easibili y o inco po a ing such ma e ials in s uc u al conc e e o sus ainable cons uc ion.
Keywo ds: Alcco ine, Comp essi e s eng h, Recycled agg ega es, Sus ainable conc e e, Was e ma e ials.
1 INTRODUCTION
Conc e e is he mos ex ensi ely used cons uc ion ma e ial globally, p ima ily due o i s e sa ili y and du abili y. Howe e ,
i s sus ainabili y has been inc easingly ques ioned owing o he en i onmen al bu den associa ed wi h cemen p oduc ion. Cemen
manu ac u ing con ibu es nea ly 7–8% o global CO₂ emissions, alongside he deple ion o non- enewable na u al esou ces. As
he cons uc ion indus y seeks g eene al e na i es, he e has been a g owing in e es in inco po a ing indus ial by-p oduc s and
ad anced ma e ials in o conc e e o educe i s en i onmen al oo p in wi hou comp omising pe o mance [1], [2].
Among a ious supplemen a y cemen i ious ma e ials (SCMs), Alcco ine 1203 has eme ged as a nex -gene a ion ul a ine
ma e ial known o i s supe io pozzolanic eac i i y and abili y o enhance ea ly s eng h and du abili y cha ac e is ics o conc e e
[1]. I s high con en o calcium oxide (CaO) and silica (SiO₂) con ibu es o an accele a ed hyd a ion p ocess, imp o ed
mic os uc u e, and educed pe meabili y. Se e al s udies ha e demons a ed ha he pa ial eplacemen o cemen wi h Alcco ine,
ypically in he ange o 8–15%, can signi ican ly imp o e he mechanical pe o mance o conc e e [3], [1]. Simul aneously, he
euse o indus ial was es such as coppe slag, ound y sand, and ecycled coa se agg ega es in conc e e p oduc ion has a ac ed
a en ion as a sus ainable s a egy. These ma e ials se e as al e na i es o na u al ine and coa se agg ega es, helping o educe
ex ac ion p essu es on i e sand and c ushed s one while add essing solid was e disposal issues [4], [5], [6]. Fo ins ance, he use
o coppe slag and ound y sand as pa ial sand eplacemen s has been ound o enhance he densi y and s eng h o conc e e
mix u es [4]. Simila ly, ecycled agg ega es ob ained om cons uc ion and demoli ion was e a e being in eg a ed in o new
conc e e applica ions, albei wi h ca e ul mix adjus men s o main ain quali y and pe o mance [7].
Recen expe imen al s udies ha e also explo ed hyb id conc e e sys ems combining SCMs like Alcco ine wi h a ious ecycled
ma e ials o achie e enhanced pe o mance. Fo example, mixes inco po a ing Alcco ine, Me akaolin, GGBFS, coppe slag,
ound y sand, ecycled agg ega es, and sin e ed ly ash ha e demons a ed supe io comp essi e and ensile s eng h
cha ac e is ics, wi h op imal combina ions ou pe o ming con en ional conc e e in bo h s eng h and sus ainabili y aspec s [3], [4].
Despi e hese ad ancemen s, limi ed esea ch has sys ema ically e alua ed he combined use o Alcco ine wi h mul iple ypes o
was e ma e ials in a con olled expe imen al amewo k. Addi ionally, comp ehensi e assessmen s o key pa ame e s such as
comp essi e, ensile, and lexu al s eng h, as well as wo kabili y and densi y, a e s ill equi ed o es ablish p ac ical and scalable
solu ions o sus ainable conc e e mix design [6], [1].
The p esen s udy aims o de elop and expe imen ally e alua e sus ainable conc e e mixes ha inco po a e Alcco ine as a
pa ial eplacemen o cemen , along wi h selec ed indus ial was es as pa ial eplacemen s o ine and coa se agg ega es. The
pe o mance o hese mixes will be compa ed wi h con en ional conc e e based on s eng h pa ame e s and physical p ope ies.
The objec i es o his s udy a e as ollows:
• To e alua e he mechanical p ope ies (comp essi e, ensile, and lexu al s eng h) o conc e e mixes con aining
Alcco ine and selec ed was e ma e ials.
• To assess he impac o coppe slag, ound y sand, and ecycled coa se agg ega es on he wo kabili y and densi y o
conc e e.
• To iden i y op imal mix p opo ions ha achie e bo h s eng h and sus ainabili y a ge s.
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This in es iga ion con ibu es o ongoing esea ch aimed a de eloping g eene cons uc ion ma e ials and op imizing esou ce
u iliza ion o u u e in as uc u e de elopmen .
2 LITERATURE REVIEW
2.1 Alcco ine as a Supplemen a y Cemen i ious Ma e ial (SCM)
The u iliza ion o Alcco ine 1203 in conc e e has ga ne ed a en ion due o i s ul a ine pa icle size, high silica and calcium
oxide con en , and imp o ed pozzolanic eac i i y. As an SCM, i enhances he packing densi y and accele a es hyd a ion eac ions,
he eby imp o ing he ea ly-age s eng h and du abili y o conc e e. Yada and Saman a [5] epo ed ha inco po a ing 8–12%
Alcco ine in conc e e signi ican ly enhanced comp essi e s eng h, educed pe meabili y, and minimized hea o hyd a ion
compa ed o mixes wi h o he SCMs. I s ul a ine na u e also aids in e ining he po e s uc u e, hus con ibu ing o long- e m
du abili y. The ea ly-age pe o mance bene i s make Alcco ine especially sui able in high-pe o mance and sus ainable conc e e
mixes.
Fu he , Rajkohila e al. [1] obse ed ha eplacing cemen wi h 15% Alcco ine in high-s eng h conc e e (HSC), combined
wi h he inclusion o na u al ibe s such as banana and coi , signi ican ly imp o ed he mechanical and mic os uc u al p ope ies.
The 28-day s eng h was no ably inc eased wi h banana ibe s, wi h Scanning Elec on Mic oscope (SEM) analysis con i ming
enhanced bonding and ma ix densi ica ion.
2.2 Was e-Based Fine and Coa se Agg ega es in Conc e e
Replacing na u al agg ega es wi h indus ial by-p oduc s is a key pa hway o sus ainabili y in conc e e p oduc ion. N. P. D. T
and K. S [4] p esen ed a comp ehensi e da ase on sus ainable conc e e mixes combining Alcco ine, Me akaolin, GGBFS, coppe
slag, ound y sand, ecycled agg ega es, and sin e ed ly ash agg ega es. Thei s udy concluded ha a mix using 15% Alcco ine,
10% Me akaolin, 30% GGBFS (cemen eplacemen s), 50% coppe slag, 30% ound y sand ( ine agg ega es), and 20–30%
ecycled agg ega es (coa se agg ega es) p oduced supe io comp essi e and ensile s eng h when compa ed o con en ional
conc e e.
Coppe slag, a by-p oduc om he coppe -smel ing indus y, has shown p omise as a sand eplacemen . I s high speci ic
g a i y and angula i y imp o e he densi y and mechanical pe o mance o conc e e, al hough wo kabili y may educe sligh ly a
highe eplacemen le els. Found y sand, wi h i s ine g ading and silica- ich composi ion, is ano he sui able ine agg ega e
eplacemen [1]. Howe e , ca e ul p opo ioning is equi ed o a oid excessi e wa e demand and loss o slump.
Recycled coa se agg ega es (RCA) om cons uc ion and demoli ion was e a e inc easingly being conside ed o s uc u al
applica ions. While RCAs may educe comp essi e s eng h sligh ly due o he p esence o adhe ed mo a , his can be
compensa ed h ough he use o Alcco ine and o he SCMs ha e ine he ma ix and enhance bonding [7].
2.3 Hyb id and Op imized Mix Designs
Hyb id mixes using mul iple was e cons i uen s and pe o mance-enhancing ma e ials a e being ac i ely explo ed. Baho ia e
al. [7] p oposed a machine lea ning-based op imiza ion model o sus ainable conc e e inco po a ing nano-silica, basal ibe s, and
ecycled agg ega es. Thei hyb id Con olu ional Neu al Ne wo k and Long Sho -Te m Memo y (CNN-LSTM) model p edic ed
comp essi e s eng h wi h high accu acy (R² = 0.92–0.95). Mo eo e , he model-op imized mixes demons a ed 5–8% highe
comp essi e s eng h and be e cos -e ec i eness compa ed o baseline mixes. Al hough his s udy ocused mo e on AI modeling,
i unde sco ed he po en ial o hyb id mixes o balancing s eng h and sus ainabili y.
Simila ly, P. Halda and S. Ka maka [4] examined Alcco ine-based c umb ubbe conc e e unde quasi-s a ic cyclic loading.
Thei s udy e ealed signi ican enhancemen s in a igue esis ance, duc ili y, and ene gy dissipa ion capaci y due o he syne gis ic
e ec o Alcco ine and c umb ubbe . These esul s alida e he pe o mance bene i s o hyb id composi e sys ems, especially o
s uc u es subjec ed o dynamic loads.
2.4 Sel -Compac ing and Ligh weigh Sus ainable Conc e e
In ano he s udy, Najm e al. [6] analyzed he pe o mance o sel -compac ing conc e e (SCC) using GGBFS, ly ash, and silica
ume as sus ainable cemen i ious ma e ials. A mul i-c i e ia decision-making ool (TOPSIS) was employed o balance comp essi e
s eng h, global wa ming po en ial (GWP), and p oduc ion cos . Resul s showed op imal pe o mance wi h 60% GGBFS as cemen
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eplacemen . While Alcco ine was no pa o his s udy, he amewo k is use ul o e alua ing mul i-pa ame e pe o mance in
sus ainable mixes.
Swa hi and Vidjeap iya [8] e iewed he in luence o p ecu so s and mola a ios in no mal, high, and ul a-high pe o mance
geopolyme conc e e. Though no ocused on Alcco ine, he e iew emphasized he po en ial o al e na i e binde s o ully eplace
OPC in low-ca bon conc e e sys ems. Recycled was es we e also highligh ed as unc ional addi i es o enhance sus ainabili y and
educe embodied ene gy.
2.5 Was e-Based Conc e e in Block and P ecas Applica ions
The applica ion o was e-based mixes in non-s uc u al and p ecas componen s is also being in es iga ed. Kuma e al. [9]
conduc ed an expe imen al s udy on eco- iendly conc e e blocks made using coconu shell as pa ial coa se agg ega e eplacemen
and 5% Alcco ine as a binde enhance . While he s eng h dec eased wi h inc eased shell con en , he blocks emained sui able
o ligh weigh applica ions.
Anand e al. [10] explo ed accele a ed cu ing echniques in ae a ed conc e e inco po a ing cons uc ion and demoli ion was e
(CDW) and glass powde . Thei indings showed ha blocks wi h 50% CDW and hea cu ing in an Accele a ed Cu ing Tank
(ACT) yielded imp o ed ea ly s eng h and du abili y, sugges ing iable pa hways o ecycling solid was es in block
manu ac u ing.
2.6 En i onmen al Sus ainabili y and Li e Cycle Pe spec i es
F om a li e cycle s andpoin , Rasheed e al. [11] pe o med an en i onmen al impac analysis o p ecas conc e e poles using
he Li e Cycle Assessmen (LCA) me hod. The s udy e ealed high emissions associa ed wi h con en ional p ecas pole
p oduc ion, p ima ily due o cemen usage and ma e ial anspo . This unde lines he impo ance o inco po a ing low-ca bon
SCMs like Alcco ine and ecycled agg ega es o educe en i onmen al bu dens in p ecas elemen s.
Summa y o Li e a u e Insigh s
• Alcco ine enhances s eng h, du abili y, and wo kabili y a ea ly s ages [3], [1].
• Indus ial was e ma e ials like coppe slag, ound y sand, and ecycled agg ega es imp o e sus ainabili y and can
eplace na u al agg ega es [4], [6].
• Hyb id mixes wi h Alcco ine and was e componen s pe o m be e when op imized [5], [7].
• Sus ainable SCC and ligh weigh conc e es can bene i om SCMs and ecycled ma e ials [6], [10], [8].
• En i onmen al analysis suppo s he need o low-ca bon al e na i es [2].
3 MATERIALS AND METHODS
3.1 Ma e ials Used
Cemen
O dina y Po land Cemen (OPC) o 53 g ade con o ming o IS 12269:2013 was used as he p ima y binde .
Alcco ine 1203
Alcco ine 1203, an ul a ine slag-based supplemen a y cemen i ious ma e ial, was used as a pa ial cemen eplacemen . I is
known o i s high calcium oxide (CaO) and silica (SiO₂) con en , signi ican ly imp o ing ea ly s eng h and wo kabili y [3], [1].
Fine Agg ega es
• Na u al i e sand was used as he e e ence ine agg ega e.
• Coppe slag and ound y sand we e used as pa ial eplacemen s, based on he p opo ions adop ed in p e ious
esea ch [4], [6].
Coa se Agg ega es
• C ushed s one agg ega es (20 mm downsize) we e used as he p ima y coa se agg ega e.
• Recycled coa se agg ega es ob ained om p ocessed cons uc ion and demoli ion was e we e used as pa ial
eplacemen s [4], [7].
Wa e
Po able wa e ee om o ganic ma e and ha m ul impu i ies was used o mixing and cu ing.
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3.2 Mix Design
A o al o i e mixes we e designed:
• One con ol mix (CC) wi h 100% OPC, na u al agg ega es.
• Fou sus ainable mixes (M1–M4) wi h a ying pe cen ages o Alcco ine and was e ma e ial subs i u ions.
Table 1 shows he composi ion o each mix.
Table 1. Mix P opo ions o Sus ainable Conc e e (by weigh %)
Mix ID
Cemen
(%)
Alcco ine
(%)
Coppe Slag
(% FA)
Found y Sand
(% FA)
Recycled Agg ega es
(% CA)
CC
100
0
0
0
0
M1
90
10
30
20
20
M2
85
15
40
30
30
M3
80
20
50
30
30
M4
85
15
50
30
30
All mixes we e designed o a a ge s eng h o 30 MPa a 28 days and wa e -cemen a io o 0.42. Supe plas icize
(polyca boxyla e-based) was added a 1% by weigh o binde o wo kabili y.
3.3 Cas ing and Cu ing
Conc e e specimens we e cas in s anda d moulds:
• Cubes o size 150 mm × 150 mm × 150 mm o comp essi e s eng h es s.
• Cylinde s o 150 mm diame e and 300 mm heigh o spli ensile s eng h.
• P isms o 100 mm × 100 mm × 500 mm o lexu al s eng h.
All specimens we e demoulded a e 24 hou s and cu ed in wa e a 27 ± 2°C un il es ing a 7, 14, and 28 days.
3.4 Tes ing P ocedu es
All es s we e conduc ed in acco dance wi h Bu eau o Indian S anda ds (BIS) p ocedu es.
• Comp essi e S eng h: IS 516 (Pa 1/Sec 1): 2021
• Spli Tensile S eng h: IS 5816:1999
• Flexu al S eng h: IS 516 (Pa 2/Sec 2): 2021
• Slump Tes (Wo kabili y): IS 1199:1959
• Densi y Measu emen : Based on uni weigh a e 28 days
3.5 Me ics o E alua ion
Each mix was e alua ed using he ollowing me ics:
• Mechanical p ope ies:
o Comp essi e s eng h (MPa) a 7, 14, 28 days
o Spli ensile s eng h (MPa) a 28 days
o Flexu al s eng h (MPa) a 28 days
• Wo kabili y:
o Measu ed using slump es (mm)
• Densi y:
o Measu ed in kg/m³ a 28 days
• Sus ainabili y Index (Quali a i e):
o Based on ma e ial eplacemen le els and ca bon oo p in po en ial, adap ed om [4], [6]
4. RESULTS AND DISCUSSION
4.1 Wo kabili y
The slump es esul s o all mixes a e p esen ed in Table 2.
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Table 2. Slump Values o All Mixes
Mix ID
Slump (mm)
CC
90
M1
100
M2
95
M3
85
M4
88
The addi ion o Alcco ine imp o ed wo kabili y in M1 and M2 due o i s ine pa icles and be e low cha ac e is ics [5], [6].
Howe e , in M3, he wo kabili y dec eased sligh ly wi h highe was e agg ega e con en , especially coppe slag and ecycled
coa se agg ega es, which end o abso b mo e wa e [4], [7]. O e all, all mixes main ained accep able slump alues, sui able o
con en ional conc e e applica ions.
4.2 Comp essi e S eng h
The esul s o he comp essi e s eng h es s a 7, 14, and 28 days a e summa ized in Table 3.
Table 3. Comp essi e S eng h o Conc e e (MPa)
Mix ID
7 Days
14 Days
28 Days
CC
24.1
28.7
32.5
M1
25.8
30.4
34.9
M2
26.7
32.2
36.5
M3
25.2
29.7
33.2
M4
27.0
32.8
37.1
The sus ainable mixes M1–M4 consis en ly ou pe o med he con ol mix (CC), wi h M4 showing he highes 28-day s eng h
o 37.1 MPa, a 14% imp o emen o e he con ol. This gain is p ima ily due o he syne gis ic e ec o Alcco ine wi h GGBFS
and Me akaolin (as seen in [4], [1]) and imp o ed packing densi y due o he ine pa icles o coppe slag and Alcco ine. These
indings a e consis en wi h he da a analysis in [4], which iden i ied simila ma e ial combina ions yielding supe io pe o mance.
4.3 Spli Tensile S eng h
The 28-day spli ensile s eng h is p esen ed in Table 4.
Table 4. Spli Tensile S eng h a 28 Days
Mix ID
Spli Tensile S eng h (MPa)
CC
2.9
M1
3.2
M2
3.5
M3
3.1
M4
3.6
Mixes con aining Alcco ine showed highe ensile s eng h, consis en wi h p io indings [3]. The inc eased bonding and
dense mic os uc u e con ibu ed o imp o ed c ack esis ance. Mix M4 again achie ed he highes ensile s eng h, which may
be a ibu ed o he op imized combina ion o SCMs and he imp o ed in e acial ansi ion zone due o ul a ine pa icles [1].
4.4 Flexu al S eng h
The 28-day lexu al s eng h esul s a e shown in Table 5.
Table 5. Flexu al S eng h a 28 Days
Mix ID
Flexu al S eng h (MPa)
CC
4.5
M1
4.9
M2
5.2
M3
4.7
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M4
5.3
Again, M2 and M4 demons a ed imp o ed lexu al pe o mance. These indings suppo he esul s o P. Halda and S.
Ka maka [5], who showed ha Alcco ine con ibu es o enhanced duc ili y and ene gy dissipa ion unde load, pa icula ly when
used wi h o he sus ainable ma e ials.
4.5 Densi y
The densi y alues measu ed a 28 days a e shown in Table 6.
Table 6. Densi y o Ha dened Conc e e (kg/m³)
Mix ID
Densi y (kg/m³)
CC
2430
M1
2450
M2
2462
M3
2415
M4
2470
The use o coppe slag, which has a highe speci ic g a i y han na u al sand, inc eased he densi y in M1, M2, and M4 [1]. In
M3, sligh ly educed densi y was obse ed due o he highe pe cen age o ecycled agg ega es, which gene ally ha e mo e oids
and adhe ed mo a [7].
4.6 Discussion on Sus ainabili y
F om a sus ainabili y iewpoin , mixes M2 and M4 achie e a balanced pe o mance:
• Mechanical p ope ies exceeded he con ol mix.
• Wo kabili y and densi y emained wi hin accep able limi s.
• Ma e ial subs i u ion le els educed cemen and na u al agg ega e usage signi ican ly.
These mixes align wi h he sus ainabili y amewo k highligh ed in [4], [6], and [2], suppo ing a educed ca bon oo p in and
p omo ing ci cula economy p inciples h ough was e u iliza ion [13]-[17].
5. CONCLUSIONS
This s udy in es iga ed he mechanical pe o mance and sus ainabili y aspec s o conc e e mixes inco po a ing Alcco ine and
selec ed indus ial was e ma e ials such as coppe slag, ound y sand, and ecycled agg ega es. A o al o ou sus ainable mixes
we e e alua ed agains a con en ional con ol mix, wi h a ia ions in binde composi ion and agg ega e eplacemen le els. The
expe imen al esul s e ealed ha he pa ial eplacemen o cemen wi h 15% Alcco ine, combined wi h 50% coppe slag, 30%
ound y sand as ine agg ega es, and 30% ecycled coa se agg ega es (Mix M4), achie ed supe io pe o mance in e ms o
comp essi e, spli ensile, and lexu al s eng hs. The inclusion o Alcco ine enhanced ea ly-age s eng h and imp o ed
mic os uc u al densi y, aligning wi h p io indings. Al hough mino educ ions in wo kabili y and densi y we e obse ed a highe
was e con en , he mixes emained wi hin accep able p ac ical limi s. The obse ed imp o emen s in s eng h, coupled wi h
educed eliance on na u al ma e ials and cemen , demons a e he po en ial o such mixes o suppo sus ainable cons uc ion
p ac ices. Mo eo e , he indings a e consis en wi h p e ious esea ch emphasizing he mechanical and en i onmen al bene i s o
using indus ial byp oduc s and SCMs. Fu u e wo k may ocus on du abili y aspec s, li e cycle assessmen , and he in eg a ion o
op imiza ion echniques such as AI-based mix design models o u he enhance he e iciency and sus ainabili y o such conc e e
sys ems.
FUNDING INFORMATION
This esea ch ecei ed no speci ic g an om any unding agency in he public, comme cial, o no - o -p o i sec o s.
ETHICS STATEMENT
This s udy did no in ol e human o animal subjec s and, he e o e, did no equi e e hical app o al.
STATEMENT OF CONFLICT OF INTERESTS
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