Valorisation of Aggregate-Washing Sludges in Innovative Applications in Construction

The valorisation of sludges from aggregate production into construction materials is required for full circularity in mining waste management. This study explores valorisation pathways, relevant regulatory frameworks, and End-of-Waste (EoW) criteria for specific settings in Spain and Norway. The explored valorisation routes involved the production of filler, supplementary cementitious materials (SCMs), and lightweight aggregates (LWAs) for the production of cement-based products, and precursors for 3D printed construction material. The sludge from Norway revealed a non-polluted stream and a stream contaminated with organic phases and clays. Sludge-based filler proved suitable in concrete production with contents of up to 40% of total binder, providing adequate consistency and cohesion. However, clays in the sludge increased the demand for water and superplasticizer. Clay contents were still insufficient for the applications as SCMs, as the calcined sludge demonstrated limited reactivity. The application to produce LWAs was promising, but further microstructure optimization is still required. The clay content was also relevant for the sludge from the site in Spain, as it provided 3D printing mixes with good plasticity. The dosage optimization still required the addition of enzymes, limestone, and natural fibres to improve cohesion, workability, and resistance to the cracking of the 3D printing mix.