Ecofriendly Mortar with Paint Sludge Ash

This research aims to address the environmental and economic challenges associated with conventional concrete by partially replacing cement-the most polluting, expensive, and energy-intensive ingredient-with industrial paint sludge ash (PSA), a highly contaminated industrial waste that is typically landfilled. Mortar mixtures were prepared with PSA replacement levels ranging from 0% to 20% in 5% increments while maintaining a constant water-to-binder ratio of 0.48. This study comprehensively evaluated the fresh, mechanical, durability, and microstructural properties of the PSA-modified mortar to assess its potential as an ecofriendly construction material. Results showed that as PSA content increased, the fresh properties, such as workability/slump flow and setting time, decreased, while the water demand for attaining normal consistency increased. Soundness tests indicated expansion up to 15% PSA replacement, beyond which expansion became more pronounced. Compressive strength improved significantly with PSA replacements of 5% to 15% compared to the control sample, with a slight decline at 15% relative to 5% and 10%. This trend was consistent with bulk density and ultrasonic pulse velocity measurements. Furthermore, the incorporation of PSA enhanced key durability properties, including water absorption, sulfate resistance, and porosity reduction, up to 15% PSA replacement. Microstructural analysis using SEM, XRD, TGA/DTA, and FTIR confirmed that PSA inclusion led to increased mortar densification, with the 10% PSA mix exhibiting thermal stability and minimal mass loss at elevated temperatures. FTIR spectra further indicated improved composition with higher PSA content. Overall, PSA proved to be a viable partial cement replacement, offering enhanced mortar properties without compromising performance. Its use contributes to sustainability by reducing reliance on cement, lowering construction costs, and eliminating the environmental and logistical burdens of paint sludge disposal.