Influence of Carbonated Calcium Generated from Waste Concrete Sludge on the Strength and Microstructural Properties of Portland Cement Mortar

Influence of Carbonated Calcium Generated from Waste Concrete Sludge on the Strength and Microstructural Properties of Portland Cement Mortar

Mustapha Bamidele JAJI, Adewumi John BABAFEMI, Babatunde OLADIPO, Tunde OJUMU

Abstract. It is imperative to identify solutions to lower the carbon footprint of construction materials. One of the ways is to recycle and reuse waste concrete materials through indirect CO2 mineral carbonation. This study replaces Portland cement (PC) in mortar composites with up to 15% carbonated calcium (CC) generated from waste concrete at 5% intervals (i.e, 0%, 5%, 10%, 15%) by mass of PC. The slump and flow of the mortar composites (MC) developed (MC0, MC5, MC10, and MC15) were determined using the mini-slump cone and flow table tests. 50 × 50 ×50 mm cubes and 160 mm × 40 mm × 40 mm beam specimens were cured in a climate-controlled room at 23 ± 2 ℃ and a relative humidity of 65 ± 5% for 24 hours before being water cured for 7 and 28 days, respectively. The bulk density (BD), dry density (DD), compressive strength (CS), and flexural strength (FS) were determined. Additionally, the morphology of the hardened mortar was examined using scanning electron microscopy (SEM). The slump decreases from 8 mm in MC0 to 4 mm in MC15, and the BD is 2272–2462 kg/m3. The DD of the hardened mortar increases from 2104–2290 kg/m3. At 28 days, MC0, MC5, MC10, and MC15 exhibit CS of 16.8, 19.2, 22.8, and 24.9 MPa, respectively, and FS of 3.4, 3.7, 3.9, and 4.3 MPa. The microstructural analysis shows that the rhombohedral-shaped CC matrix is formed around the cement particles, depicting a whitish hydration product termed calcium silicate hydrate, with minimal visible porosity as CC increases in the SEM images. Conclusively, 15% CC inclusion in MC exhibited a 50% decrease in slump. Also, BD, DD, CS, and FS increased by 7.7%, 8.1%, 33%, and 2.1%, respectively, at optimum CC content due to the dense microstructure revealed in the SEM.

Keywords
Carbonation, Waste Concrete, Calcium Carbonate, Portland Cement, Mortar

Published online 4/2/2026, 10 pages
Copyright © 2026 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: Mustapha Bamidele JAJI, Adewumi John BABAFEMI, Babatunde OLADIPO, Tunde OJUMU, Influence of Carbonated Calcium Generated from Waste Concrete Sludge on the Strength and Microstructural Properties of Portland Cement Mortar, Materials Research Proceedings, Vol. 63, pp 112-121, 2026

DOI: https://doi.org/10.21741/9781644904053-13

The article was published as article 13 of the book Advances in Cement and Concrete Research

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] Y. Izumi, A. Iizuka, and H. J. Ho, “Calculation of greenhouse gas emissions for a carbon recycling system using mineral carbon capture and utilization technology in the cement industry,” J. Clean. Prod., vol. 312, no. December 2020, p. 127618, 2021. https://doi.org/10.1016/j.jclepro.2021.127618
[2] J. Yang et al., “Effect of steam curing on compressive strength and microstructure of high volume ultrafine fly ash cement mortar,” Constr. Build. Mater., vol. 266, p. 120894, 2021. https://doi.org/10.1016/j.conbuildmat.2020.120894
[3] P. H. C. H. Caldas, A. R. G. de Azevedo, and M. T. Marvila, “Silica fume activated by NaOH and KOH in cement mortars: Rheological and mechanical study,” Constr. Build. Mater., vol. 400, no. July, p. 132623, 2023. https://doi.org/10.1016/j.conbuildmat.2023.132623
[4] T. Y. Nojoukambari, A. Sadrmomtazi, and R. K. Khoshkbijari, “Influence of Feldspar and Ground Granulated Blast-furnace slag as a partial cement replacement on mechanical properties and thermal durability and environmental impacts of cement mortars,” J. Clean. Prod., vol. 398, no. December 2022, p. 136074, 2023. https://doi.org/10.1016/j.jclepro.2023.136074
[5] G. M. Amusan, M. O. Popoola, and M. B. Jaji, “Assessment of Cassava Peel Ash Blended Cement in Concrete Production,” Int. J. Adv. Eng. Manag., vol. 3, no. 10, p. 224, 2021. https://doi.org/10.35629/5252-0310224227
[6] M. Thiedeitz, B. Ostermaier, and T. Kr, “Resources , Conservation & Recycling Rice husk ash as an additive in mortar – Contribution to microstructural , strength and durability performance,” vol. 184, no. July 2021, 2022. https://doi.org/10.1016/j.resconrec.2022.106389
[7] M. B. Jaji, “Rheo-mechanics , Durability , and Microstructural Characterisation of Slag-modified Metakaolin-based Geopolymer Concrete for Extrusion-based 3D Printing Applications,” Unpubl. Ph.D. Diss., no. December, 2023, [Online]. Available: http://www.sun.ac.za
[8] M. B. Jaji, G. P. A. G. Van Zijl, and A. J. Babafemi, “Slag-modified metakaolin-based geopolymer for 3D concrete printing application : Evaluating fresh and hardened properties,” Clean. Eng. Technol., vol. 15, no. December 2022, p. 100665, 2023. https://doi.org/10.1016/j.clet.2023.100665
[9] M. Sandanayake, Y. Bouras, R. Haigh, and Z. Vrcelj, “Current Sustainable Trends of Using Waste Materials in Concrete — A Decade Review,” 2020.
[10] W. De Villiers, M. Mwongo, A. J. Babafemi, and G. Van Zijl, “Quantifying Recycled Construction and Demolition Waste for Use in 3D-Printed Concrete,” Recycling, vol. 9, no. 4, 2024. https://doi.org/10.3390/recycling9040055
[11] J. Waltisberg and R. Weber, “Disposal of waste-based fuels and raw materials in cement plants in Germany and Switzerland e What can be learned for global co- incineration practice and policy ?,” Emerg. Contam., vol. 6, pp. 93–102, 2020. https://doi.org/10.1016/j.emcon.2020.02.001
[12] H. J. Ho, A. Iizuka, and E. Shibata, “Chemical recycling and use of various types of concrete waste: A review,” J. Clean. Prod., vol. 284, p. 124785, 2021. https://doi.org/10.1016/j.jclepro.2020.124785
[13] A. Iizuka et al., “Pilot-Scale Operation of a Concrete Sludge Recycling Plant and Simultaneous Production of Calcium Carbonate,” Chem. Eng. Commun., vol. 204, no. 1, pp. 79–85, 2017. https://doi.org/10.1080/00986445.2016.1235564
[14] A. Iizuka, Y. Sakai, A. Yamasaki, M. Honma, Y. Hayakawa, and Y. Yanagisawa, “Bench-scale operation of a concrete sludge recycling plant,” Ind. Eng. Chem. Res., vol. 51, no. 17, pp. 6099–6104, 2012. https://doi.org/10.1021/ie300620u
[15] H. J. Ho, A. Iizuka, E. Shibata, H. Tomita, K. Takano, and T. Endo, “CO2utilization via direct aqueous carbonation of synthesized concrete fines under atmospheric pressure,” ACS Omega, vol. 5, no. 26, pp. 15877–15890, 2020. https://doi.org/10.1021/acsomega.0c00985
[16] N. Makul, Q. Hussain, A. Nawaz, P. Saingam, and G. Sua-iam, “Effect of para-wood ash and calcium carbonate on the properties of eco-friendly self-compacting mortar reinforced with electronic waste fibers,” J. Build. Eng., vol. 95, no. July, p. 110353, 2024. https://doi.org/10.1016/j.jobe.2024.110353
[17] P. Saingam et al., “Synergizing Portland Cement, high-volume fly ash and calcined calcium carbonate in producing self-compacting concrete: A comprehensive investigation of rheological, mechanical, and microstructural properties,” Case Stud. Constr. Mater., vol. 21, no. October, p. e03832, 2024. https://doi.org/10.1016/j.cscm.2024.e03832
[18] Antoni, L. Chandra, and D. Hardjito, “The impact of using fly ash, silica fume and calcium carbonate on the workability and compressive strength of mortar,” Procedia Eng., vol. 125, pp. 773–779, 2015. https://doi.org/10.1016/j.proeng.2015.11.132
[19] J. Zhang, C. Shi, Y. Li, X. Pan, C. S. Poon, and Z. Xie, “Influence of carbonated recycled concrete aggregate on properties of cement mortar,” Constr. Build. Mater., vol. 98, pp. 1–7, 2015. https://doi.org/10.1016/j.conbuildmat.2015.08.087
[20] B. Safaei, E. Davodian, A. M. Fattahi, and M. Asmael, “Calcium carbonate nanoparticles effects on cement plast properties,” Microsyst. Technol., vol. 27, no. 8, pp. 3059–3076, 2021. https://doi.org/10.1007/s00542-020-05136-6
[21] S. W. M. Supit and F. U. A. Shaikh, “Effect of Nano-CaCO3 on compressive strength development of high volume fly ash mortars and concretes,” 2014, Journal of Advanced Concrete Technology. doi: 10.3151/jact.12.178
[22] F. M. Nejad, M. Tolouei, H. Nazari, and A. Naderan, “Effects of calcium carbonate nanoparticles and fly ash on mechanical and permeability properties of concrete,” Adv. Civ. Eng. Mater., vol. 7, no. 1, pp. 651–668, 2018. https://doi.org/10.1520/ACEM20180066
[23] M. B. Jaji, K. A. Ibrahim, G. Pieter, A. Greeff, and A. J. Babafemi, “Materials Today : Proceedings Thixotropic characterisation of slag modified 3D printable metakaolin based geopolymer composite,” Mater. Today Proc., no. xxxx, pp. 0–6, 2024. https://doi.org/10.1016/j.matpr.2023.03.530
[24] M. B. Jaji, A. J. Babafemi, and G. P. A. G. van Zijl, “Mechanical performance of extrusion-based two-part 3D-printed geopolymer concrete: A review of advances in laboratory and real-scale construction projects,” Mater. Today Sustain., vol. 31, no. February, p. 101131, 2025. https://doi.org/10.1016/j.mtsust.2025.101131
[25] M. B. Jaji, G. P. A. G. Van Zijl, and A. J. Babafemi, “Fresh properties and strength evolution of slag modified fibre-reinforced metakaolin-based geopolymer composite for 3D concrete printing application,” Curr. Perspect. New Dir. Mech. Model. Des. Struct. Syst., pp. 1630–1634, 2022. https://doi.org/10.1201/9781003348443-267
[26] K. A. Ibrahim, M. B. Jaji, G. P. A. G. van Zijl, and A. J. Babafemi, “Influence of effective microorganisms on the rheology and fresh state properties of SCMs-based concrete for digital fabrication,” Mater. Today Proc., no. xxxx, 2023. https://doi.org/10.1016/j.matpr.2023.03.520
[27] ASTMC0230, “American Standard for Testing Materials,” ASTM Intl, vol. i, no. Reapproved, pp. 3–5, 2018. https://doi.org/10.1520/C0230
[28] M. Balcikanli Bankir, M. Ozturk, U. K. Sevim, and T. Depci, “Effect of n-CaCO3 on fresh, hardened properties and acid resistance of granulated blast furnace slag added mortar,” J. Build. Eng., vol. 29, no. January, p. 101209, 2020. https://doi.org/10.1016/j.jobe.2020.101209
[29] P. Gonnon and D. Lootens, “Toward net zero carbon for concrete and mortar: Clinker substitution with ground calcium carbonate,” Cem. Concr. Compos., vol. 142, no. June, p. 105190, 2023. https://doi.org/10.1016/j.cemconcomp.2023.105190
[30] K. De Weerdt, K. O. Kjellsen, E. Sellevold, and H. Justnes, “Synergy between fly ash and limestone powder in ternary cements,” Cem. Concr. Compos., vol. 33, no. 1, pp. 30–38, 2011. https://doi.org/10.1016/j.cemconcomp.2010.09.006
[31] W. S. H. Q. Cheng Caoa, “Analysis of Strength Fly Ash,” Cem. Concr. Res. 30 71–75, vol. 30, pp. 71–75, 2016.
[32] A. Marzouki, A. Lecomte, A. Beddey, C. Diliberto, and M. Ben Ouezdou, “The effects of grinding on the properties of Portland-limestone cement,” Constr. Build. Mater., vol. 48, pp. 1145–1155, 2013. https://doi.org/10.1016/j.conbuildmat.2013.07.053
[33] Y. Mao, S. Drissi, P. He, X. Hu, J. Zhang, and C. Shi, “Quantifying the effects of wet carbonated recycled cement paste powder on the properties of cement paste,” Cem. Concr. Res., vol. 175, no. October 2023, p. 107381, 2024. https://doi.org/10.1016/j.cemconres.2023.107381