This research investigates the mechanical activation of kaolin as a supplementary cementitious material at the laboratory scale, aiming to optimize milling parameters using the response surface methodology. The study evaluated the effects of rotation speed and milling time on the amorphous phase content, the reduction in crystalline kaolinite, and impurity incorporation into the activated clay through the Rietveld method. The results demonstrated that adjusting milling parameters effectively enhanced clay activation, which is crucial for its use in low-carbon cements. High rotation speeds (300/350 rpm) and prolonged grinding times (90/120 min) in a planetary ball mill increased the pozzolanic activity by boosting the formation of amorphous phases from kaolinite and illite and reducing the particle size. However, the results evidenced that intermediate milling parameters are sufficient for reaching substantial degrees of amorphization and pozzolanic activity, avoiding the need for intensive grinding. Exceedingly aggressive milling introduced impurities like ZrO₂ from the milling equipment wear, underscoring the need for a balanced approach to optimizing reactivity while minimizing impurities, energy consumption, and equipment wear. Achieving this balance is essential for efficient mechanical activation, ensuring the prepared clay’s suitability as supplementary cementitious materials without excessive costs or compromised equipment integrity.

Innovative approaches in the Portland cement industry, aligned with circular economy principles, offer a promising solution to reduce the environmental impacts. These methods can initially target the architectural elements with lower structural demands, such as urban furniture and paving, before being applied to areas with higher cement usage. Alkali-activated binders (AABs) made from secondary resources present a sustainable alternative to Portland cement (PC), promoting resource recovery, conservation, and a low-carbon economy. Incinerator bottom ash (IBA), traditionally landfilled, has shown potential as a precursor for AABs due to its aluminosilicate content. Repurposing IBA for urban furniture and paving transforms it into a valuable secondary resource. Accordingly, this is the first study to utilize IBA as the sole precursor for urban furniture or paving applications. Research, including state-of-the-art studies and proof of concept developed in this work, demonstrates that IBA-based AABs can produce cast concrete suitable for non-structural urban elements, meeting the technical, environmental, and ecotoxicological standards. Using IBA in AAB formulations not only reduces the reliance on primary raw materials but also contributes to significant energy savings in binder production and lowers greenhouse gas (GHG) emissions, resulting in a reduced carbon footprint. Furthermore, producing concrete from local residual resources, such as IBA, facilitates the reintegration of municipal waste into the production cycle at its point of origin, fostering a sustainable approach to urban development and supporting the circular economy.

Magnesium potassium phosphate cement (MKPC), a type of chemically bonded phosphate ceramic (CBPC), presents a promising alternative to ordinary Portland cement (OPC). This study focuses on developing sustainable MKPC (sust-MKPC) as a thermally passive material for building applications. A low-grade magnesium oxide (LG-MgO) industrial by-product was utilized to formulate sust-MKPC, with hydrogen peroxide employed as an air-entraining agent (AEA) to induce high porosity and enhance thermal insulation while supporting sustainability goals by reducing energy consumption in climate control systems. Seven formulations incorporating varying hydrogen peroxide contents (0, 1, 2, 3, 5, 7.5, and 10 wt.%) were prepared to evaluate the impact of AEA on the thermal and physicomechanical properties. Comprehensive characterization, including porosity and thermal conductivity measurements, revealed that increasing the AEA content significantly improved thermal inertia and lowered thermal conductivity due to porosity. However, this enhancement was accompanied by a marked reduction in mechanical strength and density, highlighting the trade-off between thermal performance and structural integrity in porous sust-MKPC formulations.