The physical and mechanical consequences of incorporating industrial residues into mortar and concrete mixtures for eco-friendly marine constructions

Abstract

In pursuit of a more sustainable construction material with the potential to improve bioreceptivity in marine environments, this study investigates the feasibility of incorporating three industrial residues—steel sludge (“Conox”), mytilid mussel shells, and wheat straw fibers—as partial substitutes for cement and sand. The research focuses on evaluating the physical and mechanical properties of mortar and concrete mixtures containing these residues, both individually and in combination. Additionally, it assesses the metal leaching potential of concrete incorporating Conox sludges into the environment. The results show that mixture containing 10% Conox sludges as a sand substitute exhibit the highest mechanical strength but also increased porosity, water absorption, and chloride ion diffusion. The addition of mussel shells and straw fibers generally reduced mechanical properties and increased porosity in mortars, though a 20% mussel shell substitution maintained mechanical strength and chloride ion diffusion in the concrete. The combination of mussel shells with Conox sludges allowed the concrete to retain its mechanical properties, although it also increased porosity and chloride ion penetration, which may limit its use where impermeability is key. However, this increased porosity could benefit coastal erosion control structures like breakwaters and revetments, and sea walls. Moreover, metal leaching from concrete incorporating Conox sludges remained within established safety limits. Despite these challenges, the materials show promise for non-structural applications or projects where sustainability is prioritized. Our research lays the foundation and opens new possibilities for future investigations that innovate in the combination of industrial wastes, aiming to create more sustainable construction materials with a reduced impact on biodiversity.