Recycling Spent Fluorescent Lamp Glass Waste in Calcium Aluminate Cement: Effects on Hydration and Mechanical Performance

Calcium aluminate cement (CAC) offers rapid strength development, chemical durability in harsh environments, and high-temperature resistance, but its long-term performance may be compromised by the conversion of metastable hexagonal hydrates into stable cubic phases. Concurrently, recycling spent fluorescent lamp glass (SFLG) is limited because of its residual mercury content. This study investigates the use of manually (MAN) and mechanically (MEC) processed SFLG as partial CAC replacements (up to 50 wt.%). Both SFLG types had irregular morphologies with mean particle sizes of ~20 µm and mercury concentrations of 3140 ± 61 ppb (MAN) and 2133 ± 119 ppb (MEC). Moreover, the addition of SFLG reduced the initial and final setting times, whilst MEC waste notably extended the plastic state duration from 20 min (reference) to 69 min (50 wt.% MEC). Furthermore, strength development was accelerated, with SFLG/CAC mortars reaching peak strengths at 7–10 days versus 28 days as in the CAC reference. CAC and 15 wt.% SFLG mortars showed strength loss over time by reason of their phase conversion, whereas mortars with 25–50 wt.% SFLG experienced significant long-term strength gains, reaching ~60 MPa (25 wt.%) and ~45 MPa (35 wt.%), respectively, after 365 days, with strength activity indexes (SAI) near 90% and 70%, respectively. These improvements are attributed to the formation of strätlingite (C2ASH8), which stabilized hexagonal CAH10 and mitigated conversion to cubic katoite (C3AH6). Mercury leaching remained below 0.01 mg/kg dry matter for all mixes and curing ages, classifying the mortars as non-hazardous and inert under Spanish Royal Decree 646/2020. The results suggest that SFLG can be safely reused as a sustainable admixture in CAC systems, enhancing long-term mechanical performance while minimizing environmental impact.