Utilization of waste materials for ultra-lightweight and thermal insulating concrete blocks

Abstract

This study investigates the feasibility of utilizing waste materials—specifically fly ash, residual fuel catalytic cracking catalyst (RFCC), and honeycomb briquette ash—in the production of ultra-lightweight concrete blocks for thermal insulation applications. Physical properties such as dry density, water absorption, and compressive strength were evaluated alongside thermal conductivity and microstructural analysis. Additionally, the materials' compliance with hazardous substance regulations and fire resistance were examined. Economic analysis demonstrated substantial cost savings compared to conventional materials. Results indicate that while higher cement replacement ratios with waste materials generally reduce compressive strength, they enhance thermal insulation properties. The study concludes that these materials offer a viable solution for sustainable building construction, aligning environmental benefits with economic advantages.