Life Cycle Impact Assessment of Solid Concrete Blocks Incorporating Recycled Fine and Coarse Crushed Ceramic Aggregates

• Published in: Journal of architectural engineering 2025-03, Vol.31 (1)
• Main Authors: Shaqour, Eman N., Seddik Hassan, Ahmed M., Abo Alela, Aimen H., Mohamed, Ayman S.
• Format: Article
• Language: English
• Subjects: Case Studies; Case Study; Ceramics; Compressive strength; Concrete aggregates; Concrete blocks; Crushing; Cycle ratio; Efflorescence; Manufacturing; Mechanical properties; Physical properties; Plant layout; Recycled materials; Thermal conductivity; Thermal resistance; Water absorption
• ISSN: 1076-0431; 1943-5568
• DOI: 10.1061/JAEIED.AEENG-1812

Abstract This study investigates the influence of substituting crushed and fine ceramics for natural aggregates in the production of solid concrete blocks. The aim is to determine the impact on the physical and mechanical properties of the materials. Test specimens were prepared by replacing fine and coarse aggregates with finely and coarsely crushed ceramics, respectively, at varying weight percentages. The study focuses on utilizing ceramic waste as an alternative additive in concrete block manufacturing and examines the performance of the blocks throughout their life cycles. A comprehensive set of tests, including compressive strength, flexure, water absorption, efflorescence, unit weight, resistance to wet/dry cycles, and thermal conductivity tests, were conducted to evaluate the physiomechanical properties of the blocks. Concrete block manufacturing was assessed at different time intervals. By comparing the properties of the ceramic-replaced blocks with those of the standard blocks, the optimal replacement ratio of crushed ceramic was determined. The findings reveal that incorporating fine and coarse crushed ceramics significantly impacts the life cycle of concrete blocks while reducing environmental impact in both production and usage stages. This study emphasizes the value of waste materials as sustainable alternatives in concrete production and calls for further research to explore their long-term structural implications and scalability in construction systems Practical Applications This research goes somewhere along the lines of exploring the possibility of integrating the ground waste of ceramic materials into the manufacturing process of concrete blocks, in an attempt to make construction sustainable. The study reveals that when natural aggregates are replaced with the coarsely and finely crushed ceramics, there are significant improvements in the physical and mechanical properties of the blocks. The highlights include higher compressive and flexural strengths, and lower water absorption as well as improved thermal insulation properties. All these outcomes put forward promising hints for the construction sector and help conduct studies on the possibility of improving the construction properties of load-bearing buildings built of cement bricks by increasing the number of floors or reducing the thickness of the walls allowed in the codes. According to this study, there is an increase in the percentage of ceramic waste in factories during productio