International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 05 | May 2025
p-ISSN: 2395-0072
www.irjet.net
Performance and Optimization of Sustainable Concrete Incorporating Iron Ore Sludge, Brick-Mortar Waste, and Ceramic Waste Using Response Surface Methodology Navdeep Singh Phougat1 and Nitu2 Civil Engineering Department, Matu Ram Institute of Engineering & Management, Model Town, Rohtak, Haryana 124001 ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - This study investigates the sustainable
concrete to promote sustainable construction. Iron Ore Sludge (IOS), a waste by-product of iron mining, BrickMortar Waste (BMW) from demolition activities, and Ceramic Waste (CW) derived from unused or broken tiles and ceramics are among the promising materials that can serve as partial replacements in concrete.
development of M30 grade concrete by incorporating industrial and construction wastes as partial replacements for traditional constituents. Iron Ore Sludge (IOS) was used as a cement replacement in the range of 0–20%, Brick-Mortar Waste (BMW) replaced fine aggregates at 0–50%, and Ceramic Waste (CW) substituted coarse aggregates from 0– 100%. A total of 25 concrete mixes were developed based on Response Surface Methodology (RSM) to analyze and optimize their effects on key properties such as workability, compressive strength, flexural strength, and water absorption.
Recent literature underscores the increasing role of waste materials and advanced modeling in sustainable concrete. Adamu and Ibrahim (2024) highlighted the environmental benefits of combining Date Palm Ash (DPA) and Eggshell Powder (ESP), optimizing the mix using RSM to reduce CO₂ emissions and improve concrete performance. Similarly, Adamu et al. (2021) demonstrated the effective use of plastic waste and graphene nanoplatelets (GNPs) in high-volume fly ash concrete, showing how GNPs significantly improved mechanical strength and reduced water absorption. Their work, along with later findings by Adamu et al. (2024), revealed that optimal blends of DPA and ESP can boost compressive strength and reduce permeability, although excessive dosages can impact workability. Aghajanzadeh et al. (2024) optimized alkali-activated slag concrete incorporating recycled aggregates and silica fume, achieving high mechanical and durability properties with minimal environmental and economic drawbacks. Ahmed et al. (2022) used waste glass and condensed milk can fiber to address fine aggregate depletion, reporting optimal replacement values that maintained strength while emphasizing the need for further workability enhancements. Amiri et al. (2022) investigated coal waste as a partial cement replacement and achieved significant improvements in compressive strength and water absorption with optimized proportions. Studies like those by Awolusi et al. (2019) and Azeez et al. (2023) emphasized the mechanical benefits of integrating waste tyre fibers, steel slag, and waste glass into concrete. Awolusi’s work validated the effectiveness of RSM in predicting concrete performance, while Azeez reported substantial strength gains with full steel slag replacement. Similarly, Chashm Khavari et al. (2023) showed that sulfur concrete reinforced with steel fibers demonstrated remarkable strength improvements, though recyclability reduced performance slightly.
Experimental results demonstrated that moderate replacement levels led to significant performance improvements. The best mix, C5S12A0 (5% IOS, 12.5% BMW, 0% CW), exhibited a compressive strength of 40.25 MPa, flexural strength of 4.45 MPa, slump of 109 mm, and low water absorption of 2.8%. Mixes with higher CW content negatively impacted strength and durability due to increased porosity. RSM analysis confirmed the adequacy of predictive models with high R² values for all responses. The interaction of IOS with BMW and CW significantly influenced the concrete’s mechanical behavior, and the desirability function identified C5S12A0 as the optimal mix. This study highlights the potential of waste-based materials in concrete, promoting environmental conservation and costeffective construction. The use of RSM provided reliable optimization, offering valuable insights for practical applications in green construction Key Words: Sustainable concrete, Iron Ore Sludge, BrickMortar Waste, Ceramic Waste, Optimization
1.INTRODUCTION The growing demand for infrastructure and urban development has led to an unsustainable rate of natural resource consumption and waste generation. Traditional concrete production consumes large quantities of virgin materials such as cement, sand, and aggregates, while simultaneously contributing to environmental degradation through mining and CO₂ emissions. In response, researchers and industry professionals are increasingly exploring the incorporation of industrial and construction waste in
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Nano-modified concrete has also received attention, with Dahish and Almutairi (2023) optimizing mixes containing
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