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<p>This study focuses on copper slag use as a partial replacement for fine aggregates in lightweight foamed mortar (LFM) to optimize its engineering characteristics. Unlike previous studies that primarily examined copper slag in traditional concrete, this research uniquely investigates its application in LFM, providing a comprehensive analysis of fresh-state properties, mechanical strength, durability, and microstructural behavior specific to this innovative system. Copper slag was used a partial replacement of sand in LFM from 0 to 25% in steps of 5% by weight of mortar. Comprehensive experimental analyses were conducted to evaluate fresh-state properties, mechanical strength, durability, and microstructural behavior. Flowability, density, and setting durations were evaluated to evaluate fresh-state performance; higher copper slag content was shown to improve workability and slightly alter hydration kinetics. Results of mechanical tests, such as compressive strength, flexural strength, and modulus of elasticity, exhibited significant improvements, particularly at 20% replacement. The material's capability for extreme environmental conditions was confirmed by the lowered permeability of durability properties such water absorption, sorptivity, and porosity. Scanning electron microscopy microstructural investigations revealed an enhanced interfacial bonding between particles, and densification of the mortar matrix, particularly at ideal replacement levels. The results underscore the two advantages of using copper slag in LFM, in terms reduction in natural sand usage and improving the material's sustainability and technical performance. The study identifies 20% copper slag replacement as the optimal level, balancing strength, durability, and environmental benefits. A framework for the large-scale application of copper slag in lightweight concrete has been provided in this study, thus aligning with the global agenda for sustainable construction and circular economy principles. Future research recommendations, such as field-scale implementations and long-term performance assessments, are included in the study's conclusion.</p>

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Sustainable use of copper slag as a partial sand replacement to optimize the fresh and hardened state properties of lightweight foamed mortar

  • 期刊论文

  • 发表日期：

    2025年7月22日

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  • Afiya Abdul Sattar,
  • Md Azree Othuman Mydin,
  • Yasin Onuralp Özkılıç,
  • Paul O. Awoyera,
  • Mohd Mustafa Al Bakri Abdullah,
  • Shuvo Dip Datta,
  • Malathy Ramalingam

摘要

This study focuses on copper slag use as a partial replacement for fine aggregates in lightweight foamed mortar (LFM) to optimize its engineering characteristics. Unlike previous studies that primarily examined copper slag in traditional concrete, this research uniquely investigates its application in LFM, providing a comprehensive analysis of fresh-state properties, mechanical strength, durability, and microstructural behavior specific to this innovative system. Copper slag was used a partial replacement of sand in LFM from 0 to 25% in steps of 5% by weight of mortar. Comprehensive experimental analyses were conducted to evaluate fresh-state properties, mechanical strength, durability, and microstructural behavior. Flowability, density, and setting durations were evaluated to evaluate fresh-state performance; higher copper slag content was shown to improve workability and slightly alter hydration kinetics. Results of mechanical tests, such as compressive strength, flexural strength, and modulus of elasticity, exhibited significant improvements, particularly at 20% replacement. The material's capability for extreme environmental conditions was confirmed by the lowered permeability of durability properties such water absorption, sorptivity, and porosity. Scanning electron microscopy microstructural investigations revealed an enhanced interfacial bonding between particles, and densification of the mortar matrix, particularly at ideal replacement levels. The results underscore the two advantages of using copper slag in LFM, in terms reduction in natural sand usage and improving the material's sustainability and technical performance. The study identifies 20% copper slag replacement as the optimal level, balancing strength, durability, and environmental benefits. A framework for the large-scale application of copper slag in lightweight concrete has been provided in this study, thus aligning with the global agenda for sustainable construction and circular economy principles. Future research recommendations, such as field-scale implementations and long-term performance assessments, are included in the study's conclusion.