A Pilot Study on Upcycling of Lithium-Ion Battery Waste in Greener Cementitious Construction Material

Lithium-ion batteries (LIBs) are essential for electric vehicles, consumer electronics, and grid storage, but their rapidly increasing demand is paralleled by growing waste volumes. Current disposal methods remain costly, complex, energy-intensive, and environmentally unsustainable. This pilot study investigates a scalable, low-impact disposal method by incorporating LIB waste into concrete, evaluating both the structural and environmental effects of LIB waste on concrete performance. Several cement–mortar cube specimens were cast and tested under compression using the cement–mortar mix with varying battery waste components, such as black mass and varied metals. All mortar mixes maintained an identical water-to-cement ratio. The compressive strength of the cubes was measured at 3, 7, 14, 21, and 28 days after casting and compared. The mix containing black mass exhibited a 35% reduction in compressive strength on day 28, whereas the mix containing varied metals showed a 55% reduction relative to the control mix without LIB waste. A case study was conducted to evaluate the combined structural and environmental performance of a concrete specimen incorporating LIB waste by estimating the embodied carbon (EC) for each mix and comparing the strength-to-net EC ratio. Selective incorporation of LIB waste into concrete provides a practical, low-carbon upcycling pathway, reducing both embodied carbon and landfill burden while enabling greener, non-structural construction materials. This sustainable approach simultaneously mitigates battery waste and lowers cement-related CO2 emissions, delivering usable concrete for non-structural and low-strength structural applications.