Each year, about 730 million tons of bottom ash is generated in coal fired power plants worldwide. This by-product can be used as partial replacement for Portland cement, favoring resource conservation and sustainability. Substantial research has explored treated and processed coal bottom ash (CBA) for possible use in the construction industry. The present research explores using local untreated and raw CBA in mitigating the alkali–silica reaction (ASR) of reactive aggregates in concrete. Mortar bar specimens incorporating various proportions of untreated CBA were tested in accordance with ASTM C1260 up to 150 days. Strength activity index (SAI) and thermal analysis were used to assess the pozzolanic activity of CBA. Specimens incorporating 20% CBA achieved SAI greater than 75%, indicating pozzolanic activity. Mixtures incorporating CBA had decreased ASR expansion. Incorporating 20% CBA in mixtures yielded 28-day ASR expansion of less than the ASTM C1260 limit value of 0.20%. Scanning electron microscopy depicted ASR induced microcracks in control specimens, while specimens incorporating CBA exhibited no microcracking. Moreover, low calcium-to-silica ratio and reduced alkali content were observed in specimens incorporating CBA owing to alkali dilution and absorption, consequently decreasing ASR expansion. The toxicity characteristics of CBA indicated the presence of heavy metals below the US-EPA limits. Therefore, using local untreated CBA in concrete as partial replacement for Portland cement can be a non-hazardous alternative for reducing the environmental overburden of cement production and CBA disposal, with the added benefit of mitigating ASR expansion and its associated costly damage, leading to sustainable infrastructure.

The utilization of waste rubber in concrete composites has gained more attention nowadays owing to its enhanced engineering properties and eco-friendly viability. This study explored the effect of waste rubber sizes and its contents on the mechanical properties of developed concrete composites. Rubber waste with various particle sizes (R1, R5 and R10) was replaced with 10%, 20% and 30% of aggregates by volume, and the workability, compressive, splitting tensile and flexural strengths and impact resistance of the developed composite were investigated. An increase in the waste rubber contents decreased the slump of the composite due to the rougher surface of the rubber particles. The reduction in the slump was more pronounced for mixtures with smaller rubber sizes. Similarly, an increase in rubber contents decreased the compressive strength, tensile strength and flexural strength because of the lower stiffness of the used rubber waste and the poor bond between the rubber particles and the matrix. For instance, an approximately 27% decrease in compressive strength was observed for the mixture incorporating 20% of R1 rubber compared to that of the control mixture without rubber. It was observed that the incorporation of rubber waste in the concrete composite led to an enhanced resilience toward impact loading due to the improved energy dissipation mechanism offered by the rubberized concrete composite. For example, 13 blows in the case of 30% of the rubber replacement were required for the final crack as compared to 5 blows for the control mixture without rubber. It can be concluded that the choice of the optimal replacement ratio and the size of the rubber yield the developed rubberized concrete composite with a desirable strength and impact resistance.

Water treatment plants produce a huge amount of sludge, which are ultimately disposed to the nearest water channel, leading to harmful effects. This unmanaged wastewater treatment plant sludge (WTS) results in social and environmental concerns. Therefore, the utilization of WTS in construction activities can be a viable option for the management of waste sludge, leading to sustainable infrastructures. The main aim of this study was to investigate the potential of WTS in the manufacturing of clay bricks at an industrial scale. WTS was procured from the Rawal Lake water treatment plant, Pakistan. Clay was collected from a local industrial brick kiln site. Brick specimens with varying percentages of WTS (i.e., 5%, 10%, 15%, 20%, 30% and 40%) were casted and their mechanical and durability characteristics were evaluated. It was observed that the bricks incorporating WTS showed higher compressive and flexural strengths compared to that of the normal clay bricks. For instance, brick specimens incorporating 5% WTS by weight of clay showed a 10% increase in compressive strength. Furthermore, brick specimens incorporating 20% of WTS by clay weight satisfied the strength requirements as per local building codes for masonry construction. Scanning electronic microscopic (SEM) images confirm the porous microstructure of brick specimens manufactured with WTS, which results in 12% lighter clay bricks as compared to conventional clay bricks. Moreover, the durability characteristics of brick specimens incorporating WTS showed better performance. It can be concluded that bricks fabricated with a high proportion of WTS (i.e., 20%) will minimize the environmental overburden and lead to more durable and economical masonry construction.

Ultrahigh-performance concrete (UHPC) is a novel material demonstrating superior mechanical, durability and sustainability performance. However, its implementation in massive structures is hampered by its high initial cost and the lack of stakeholders’ confidence, especially in developing countries. Therefore, the present study explores, for the first time, a novel application of UHPC, incorporating hybrid steel fibers in precast tunnel lining segments. Reduced scale curved tunnel lining segments were cast using UHPC incorporating hybrid 8 mm and 16 mm steel fibers at dosages of 1%, 2% and 3% by mixture volume. Flexural and thrust load tests were conducted to investigate the mechanical behavior of UHPC tunnel lining segments thus produced. It was observed that the flow of UHPC mixtures decreased due to steel fibers addition, yet steel fibers increased the mechanical and durability properties. Flexural tests on lining segments showed that both the strain hardening (multiple cracking) and strain softening (post-peak behavior) phases were enhanced due to hybrid addition of steel fibers in comparison with the control segments without fibers. Specimens incorporating 3% of hybrid steel fibers achieved 57% increase in ultimate load carrying capacity and exhibited multiple cracking patterns compared to that of identical UHPC segments with 1% fibers. Moreover, segments without fibers incurred excessive cracking and spalling of concrete at the base under the thrust load test. However, more stable behavior was observed for segments incorporating steel fibers under the thrust load, indicating its capability to resist typical thrust loads during tunnel lining field installation. This study highlights the potential use of UHPC with hybrid steel fibers for improved structural behavior. Moreover, the use of UHPC allows producing structural members with reduced cross-sectional dimensions, leading to reduced overall structural weight and increased clear space.

The construction industry strongly relies on concrete and clay bricks for various applications. The escalating demand for these materials, driven by rapid population growth, has led to resource depletion and increased construction and demolition waste (CDW). Recycling CDW into construction materials, particularly in the form of recycled concrete aggregates (RCAs) and recycled brick aggregates (RBAs), has emerged as a promising solution. This study deals with the structural performance of concrete incorporating RCAs and RBAs. The experimental program encompasses material characterization, concrete mix design, and several tests to assess density, compressive strength, bond behavior, and flexural properties. The results indicate that the replacement of fine natural aggregate (NA) with fine RCAs or RBAs has a negligible impact on density, while the partial replacement of coarse NAs with RAs yields modest reductions in compressive strength. Notably, the bond strength between steel rebar and concrete is influenced by the type and content of RA, with specimens containing RCAs exhibiting a higher bond strength than those with RBAs. Empirical models used to predict bond strength generally align with experimental results, with conservative predictions by some models, such as ACI 318, and overestimation by others, such as models proposed by AS-3600 and CEB-FIB. The flexural tests of beams highlight the variation in stiffness and load-bearing capacity with the proportion of NAs replaced by RAs. While beams with 50% NA replacement demonstrate comparable performance to control beams, those with 100% RA replacement exhibit lower cracking and yielding stiffness. Cracking patterns in beams with RAs differ from control beams, with RA-containing beams showing more cracks and an altered crack distribution. The findings underscore the feasibility of using recycled aggregates in construction, with partial NA replacement offering a balance between sustainable material usage and desired structural properties.