Study on the Effect of Partial Replacement of Cement by Breweries Dry Grain (Sorghum) Ash in Mortar Property

The construction industry is increasingly seeking sustainable alternatives to ordinary Portland cement (OPC) due to its high cost and the significant environmental impact of its production, particularly CO 2 emissions. This study explores the use of brewery dry grain ash (BDGA), an abundant agricultural waste byproduct rich in silica and with promising pozzolanic activity, as a partial substitute for OPC in mortar production. BDGA is generated in large quantities by breweries, making it a viable material for sustainable construction practices. Mortar mixes were prepared with BDGA replacement levels of 0%, 5%, 10%, 15%, and 20% and evaluated for their physical, chemical, thermal, and microstructural properties. Although several studies have assessed the influence of BDGA on concrete strength, this research uniquely examines its effect on cement paste soundness, the morphology of BDGA particles, and how their irregular and angular shapes impact workability, consistency, and setting time, areas previously underexplored. The results showed that increasing BDGA content reduced workability and setting time while increasing water demand. However, 5% and 10% BDGA replacements improved compressive strength (5.6% and 14.5%, respectively), bulk density, ultrasonic pulse velocity, and thermal stability, while also reducing water absorption. These findings demonstrate that BDGA, particularly at a 10% replacement level, is a promising, eco‐friendly alternative for cement in mortar applications, offering both performance benefits and environmental advantages.