Mechanical, microstructural and durable characteristics of foam concrete ceramic mixes exposed to H2SO4 and HCl solution

Abstract

The soaring quantity of solid garbage resulting from fast population expansion requires immediate sustainable waste management strategies. A viable strategy is to reutilise solid waste products as alternative resources in construction, thereby preserving limited raw materials. The study evaluates the prospects of substituting ceramic waste tile powder (CWTP) partially for cement in foam concrete (FC) to improve environmental sustainability while satisfying essential concrete performance criteria. The study investigates the composition, morphology, and pozzolanic activity of CWTP, together with its impact on the mechanical, microstructural, and durability characteristics of FC. CWTP replaced cement at 10 %, 30 %, 50 %, 70 %, and 90 %, and its effects on compressive, flexural, tensile strengths, porosity, and water absorption were evaluated over time. This study tackles several of significant challenges, including how to integrate waste materials—which frequently degrade performance—while maintaining strength and durability of Foam Concrete. Significant findings indicate that substituting up to 50 % of cement with CWTP yields mechanical qualities that conform to ACI 523 R 2014 criteria, while simultaneously enhancing durability, including improved resistance to sulphates, chlorides, and abrasion. Microstructural study by SEM and XRD validated the advantageous pozzolanic response of CWTP, especially during the later phases of curing. This study presents a new durability index (DI) for evaluating FC mixtures in harsh environments, determining that 50 % CWTP substitution maximises both strength and durability. The results highlight the promise of CWTP as a sustainable substitute for cement, providing environmental advantages and technological viability in foam concrete applications.