Innovating rubberised eco-friendly polymer porous concrete with recycled ceramic aggregate

Permeable concrete, with its porous structure, allows water to pass through easily. It is used in floors for animal facilities, sewage plant sludge beds, swimming pools, bridge walkways, and zoo areas. Eco-friendly polymers offer a sustainable alternative to traditional ones. Traditional cement concrete uses less energy and emits less carbon dioxide by utilising industrial waste instead of Portland cement. Eco-friendly polymer concrete is made through polycondensation of alkali-activated aluminosilicates like fly ash, silica fume, metakaolin, and slag. Seven concrete mixes were prepared with rubber waste replacing 5%, 10%, 15%, 20%, 25%, and 30% of coarse aggregates (dry basis). Lime powder (rich in silica/alumina) was also tested. Both fresh and hardened properties were examined. Results showed low rubber content (≤10%) had little effect on mechanical properties, but higher amounts (10%–30%) improved strength. The 15% rubber mix (M4) performed best. Rubberised geopolymer concrete works well for medium-low strength applications and reduces environmental impact by reusing rubber waste as aggregate. The material maintains good mechanical properties while providing sustainability benefits through waste utilisation. This approach helps address construction waste challenges while developing eco-friendly building materials suitable for various infrastructure projects where high strength is not critical.