Mechanical Behavior of Masonry Mortars Made with Recycled Mortar Aggregate

Recycled Aggregates Influence on the Mechanical Properties of Cement Lime-Based Mortars

The current framework for managing construction waste, guided by European Union regulations, calls for an integrated waste management system. However, the reuse of old plaster waste, particularly from deteriorated facades, remains underexplored. This study investigates the potential of repurposing old plaster waste as a substitute for aggregates and cement in mortars, with the aim of promoting environmental sustainability and resource efficiency. Three mortar mixes were analyzed: a control mix, a mix with 45% waste replacing aggregates, and a mix with 10% waste replacing cement. Results show that replacing 45% of aggregates with plaster waste led to a 30% reduction in flexural strength, while the 10% cement replacement increased flexural strength by 6%. Compressive strength dropped by 27% and 38% for cement and aggregate replacements, respectively. Despite these reductions, the waste replacement remained within acceptable limits for structural integrity. Further microscopic analysis revealed that the incomplete integration of portlandite particles from the waste contributed to non-uniform bonding and crystal formation, weakening the mortar's structure. This research demonstrates the feasibility of reusing old plaster waste, offering a novel approach to reducing construction waste and promoting a circular economy. It contributes to filling the knowledge gap on the reuse of plaster mortars while aligning with sustainable construction goals.

Second Life for Recycled Concrete and Other Construction and Demolition Waste in Mortars for Masonry: Full Scope of Material Properties, Performance, and Environmental Aspects

This review presents the scope of current efforts to utilize recycled construction and demolition waste in mortars for masonry. More than 100 articles are divided into groups pertaining to the type of mortar, different binder systems, the type of construction and demolition waste (CDW), and its utilization specifics. Cement-based mortars dominate this research domain, whereas recycled concrete is the main material employed to replace virgin aggregates, followed by recycled masonry and recycled mixed waste aggregates. Such application in cement-based mortars could increase water demand by 20-34% and reduce strength by 11-50%, with recycled concrete aggregates being the most favorable. Natural aggregate substitution is disadvantageous in strong mortars, whereas weaker ones, such as lime-based mortars, could benefit from this incorporation. The extent of this topic also suggests possibilities for different recycled material use cases in mortars for masonry, although the available literature is largely insufficient to infer meaningful trends. Nonetheless, the most relevant knowledge synthesized in this review offers promising and environment-conscious utilization pathways for recycled concrete and other construction and demolition waste, which brings opportunities for further research on their use in mortars for masonry and industrial-scale applications.

Recycled Fine Aggregates from Mortar Debris and Red Clay Brick to Fabricate Masonry Mortars: Mechanical Analysis

In this research, the mechanical behavior of masonry mortars made with partial substitution of sand by recycled fine aggregates (RFAs) of mortar (MT) and recycled clay brick (RCB) was compared. Mortar specimens were built in two groups (MT and RCB) considering different replacement proportions by dry weight. To reduce the water absorption of RFAs during mortar making, the prewetting method was utilized. All the mixtures were assembled with a volumetric cement-to-aggregate ratio of 1:4 and a consistency of 175 ± 5 mm. The properties in the fresh and hardening state of mortars were analyzed separately. The experimental results showed that the properties of mortars in a fresh state (bulk density and air content) were affected if RFA was added to the mixture; however, mortars assembled with up to 40% and 50% of MT and RCB, respectively, accomplished a compressive strength value of reference for new mixtures. Both mortar groups showed good results in adhesive strength values, with the RCB mortars standing up as they achieved greater adherence than the control mortar with substitution percentages of up to 30%. Therefore, the reutilization of both RFAs is feasible, notably in rendering and bonding functions.

Use of Carbonated Water as Kneading in Mortars Made with Recycled Aggregates

The increased concern about climate change is revolutionising the building materials sector, making sustainability and environmental friendliness increasingly important. This study evaluates the feasibility of incorporating recycled masonry aggregate (construction and demolition waste) in porous cement-based materials using carbonated water in mixing followed (or not) by curing in a CO2 atmosphere. The use of carbonated water can be very revolutionary in cement-based materials, as it allows hydration and carbonation to occur simultaneously. Calcite and portlandite in the recycled masonry aggregate and act as a buffer for the low-pH carbonated water. Carbonated water produced better mechanical properties and increased accessible water porosity and dry bulk density. The same behaviour was observed with natural aggregates. Carbonated water results in an interlaced shape of carbonate ettringite (needles) and fills the microcracks in the recycled masonry aggregate. Curing in CO2 together with the use of carbonated water (concomitantly) is not beneficial. This study provides innovative solutions for a circular economy in the construction sector using carbonated water in mixing (adsorbing CO2), which is very revolutionary as it allows carbonation to be applied to in-situ products.

The Properties and Durability of Self-Leveling and Thixotropic Mortars with Recycled Sand

In recent decades, relevant environmental and economic reasons have driven an increasing interest in using a large amount of recycled aggregate in replacement of natural ones to produce mortar and concrete. The present study aims to investigate the effect of substituting 100% of natural sand with recycled aggregate on fresh properties, mechanical properties, and the durability of a thixotropic and a self-leveling mortar. Recycled aggregate was characterized using X-ray diffractometry and energy-dispersive X-ray spectroscopy. Its morphology was investigated using scanning electron microscopy and automated morphological imaging. Recycled aggregate mortars showed a moderate decline in initial workability, as well as higher shrinkage and porosity than the control ones. The compressive strength of self-leveling mortars produced with recycled aggregate was only 6% lower than mortars produced with natural sand. The gap increased to 40% in the case of thixotropic mortars. The self-leveling recycled aggregate mortar showed equivalent resistance to freeze–thaw cycles and better sulfate resistance than the control one. The thixotropic recycled aggregate mortar showed comparable sulphate resistance and only slightly lower resistance to freeze–thaw cycles than the control one. Their capacity to relief stresses, due to hydraulic pressures and the formation of expansive products, arises from their higher porosity. Thermal stability of the prepared mortars, after a curing period of 90 days, up to 700 °C, was also investigated. A significant decrease in ultrasonic pulse velocity is observed in the 200–400 °C interval for all the mortars, due to the dehydration–dehydroxylation of calcium silicate hydrate. The overall decline in the strength of both the recycled aggregate mortars was comparable to the control ones. The results reported in the present investigation suggest that the selection of high-quality recycled aggregate helps to obtain good-quality mortars when a large amount of natural sand is replaced.

Low-Carbon and Fundamental Properties of Eco-Efficient Mortar with Recycled Powders

Using recycled powders from solid waste is accepted as an effective strategy to realize the sustainable development of the construction industry. In our study, the cement was substituted by two kinds of recycled powders, i.e., spontaneous combustion gangue powder (SCGP) and recycled concrete powder (RCP), with a certain replacement ratio of 30%. The experimental variables were mainly the type of replacement powder (e.g., SCGP, RCP, and SCGP + RCP) and the grinding time of RCP (e.g., 25 min, 50 min, and 75 min). The fundamental properties, including mechanical properties, long-term properties, and carbon emission, were analyzed for all the mortar mixtures. Experimental results indicate that incorporation of RCP contributes to enhancing the toughness and dry shrinkage resistance of eco-efficient mortar, while SCGP positively affects the compressive strength and chloride resistance. The grinding process improves the activity of RCP to a certain extent, while a long grinding time leads to fusion and aggregation between powders. Investigation on CO₂ emission demonstrates that carbon emission from cement production accounts for the largest proportion, 80~95%, in the total emission from mortar production. Combined with the AHP model, eco-efficient mortar containing 15% RCP ground for 50 min and 15% SCGP displays optimal fundamental properties.

Effect of Pre-Wetting Recycled Mortar Aggregate on the Mechanical Properties of Masonry Mortar

In this research we evaluated the use of recycled fine mortar aggregate (RFMA) as a fine aggregate for new masonry mortar creation. The pre-wetting effect on the aggregate before creating the mixture was analyzed as a method to reduce its absorption potential. A control mixture of conventional mortar and two groups of recycled mortars were designed with a partial replacement of natural sand by RFMA (pre-wetted and not pre-wetted) performed in different proportions. The results established that the pre-wetting process allows a reduction in the amount of water required during the creation of new mixtures, regulating the water/cement (W/C) ratio and improving the properties of recycled mortars such as air content, fresh and hardened densities, and compressive and adhesive strength for all substitution levels. Mortar made with a 20% substitution and pre-wetted until it was at 67% of its absorption capacity displayed adhesive values higher than the ones shown by the reference mortar. The pre-wetting process proves to be an easy performance technique; it is inexpensive, environmentally friendly, and the most valuable fact is that specialized equipment is not necessarily needed. This process is the most profitable option for improving RFMA exploitation and reuse.

Experimental and Analytical Study of Masonry Subjected to Uniaxial Cyclic Compression

Structural evaluation of masonry against dynamic seismic actions invariably requires appropriate cyclic compression constitutive models. However, not many research studies have been dedicated to date to investigate the cyclic compression behaviour of masonry. Therefore, series of experimental investigation followed by analytical model verification were employed in this research to better understand the cyclic compression characteristics of masonry. Twelve masonry wallettes were experimentally tested under cyclic compression loading with different unit-to-mortar assemblies, which are commonly found in masonry structures. The experimental results indicated that the cyclic compression behaviour is greatly influenced by the masonry compressive strength and deformation properties. Thereafter, the ability of five literature analytical models to predict the masonry structural response under cyclic compression loading was investigated. The advantages and limitations of these models are presented and discussed, and the most appropriate analytical model to define the cyclic compression characteristics of masonry has been evaluated and reported. The suggested analytical model is shown to predict the cyclic compression characteristics of different masonry assemblies such as the envelop response, the stiffness degradation, the plastic strain history of the unloading and reloading stages.