Optimizing ceramic waste powder ratios for cost and CO2 emission reduction in high-strength concrete to enhance efficiency and sustainability

Ceramic waste abundant in construction, is typically landfilled due to its brittleness but emerges as a promising cement substitute because of its unique chemical constitution. This investigation aims to expand the utilization of ceramic waste, exceptionally eco-friendly sanitary ceramic waste powder (SCWP) and tiles ceramic waste powder (TCWP), as a substitute for cement to produce sustainable HSC. Eleven HSC mixes incorporating ceramic waste at up to 50% were examined, assessing mechanical properties as compressive, splitting tensile, and flexural strength alongside elasticity modulus. Additionally, durability factors were conducted, including chloride penetration resistance, Sorptivity coefficient, microstructure analysis, and EDX tests. Economic and environmental evaluations encompassed cost analysis, CO2 emissions, and energy consumption. Results demonstrate that incorporating up to 50% of ceramic waste does not compromise concrete's compressive strength, exceeding 60 MPa targets. Relative tensile strength, flexural strength, and modulus of elasticity showed enhancement, notably with 40% TCWP. After 28-day curing, chloride ion penetration decreased by 6.16% compared to conventional mixes with 30% SCWP and TCWP. Economic and environmental analyses revealed significant reductions in CO2 emissions, energy consumption, and the binder OPC/ CWP cost by more than 47 %, 39 %, and 34.9 %, respectively, with 50% SCWP and TCWP. Ceramic waste proves viable as a binder material in sustainable HSC up to 40%, offering cost reductions.