Valorization of Acid Mine Tailings and Polymeric Waste in Cementitious Paving Blocks: A Statistical Design and Morphological Analysis

Acid-generating mining waste and polymer waste are two of the most persistent environmental problems facing the mining and manufacturing sectors, respectively. We have investigated the co-recovery of these disparate waste streams for the production of unfired cementitious paving blocks. We established a statistically optimized formulation using response surface methodology (RSM) and a central composite design (CCD). We systematically evaluated three process variables: air-curing time (4–37 days), dosage of the waste mixture (5–68% by weight of dry solids: acid-generating mining waste, hydrated lime, and recycled polymer in a waste-to-polymer mass ratio of 1:1), and type of polymeric aggregate (recycled PET flakes versus granulated rubber). Compressive strength ranged from 4.5 to 42.1 MPa across the 40 experimental conditions. The resulting quadratic model was clearly significant (F = 186.31, p < 0.0001) with solid predictive parameters (R2 = 0.9796; R2pred = 0.9627; adequate precision = 42.47). Desirability-based optimization, which limited air curing to industrially feasible timeframes (7–28 days) and maximized waste utilization within a 10–50% by weight, identified PET with 12.4 days of curing and a 50% by weight waste mixture as the optimal configuration, predicting a compressive strength of 37.3 MPa. This value exceeds the 32 MPa threshold for Type I heavy-traffic paving blocks; however, confirmatory tests yielded 34.09 ± 1.08 MPa, indicating that production-scale use should include control of moisture content, compaction, and batch homogeneity. Scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS) and X-ray diffraction (XRD) demonstrated that PET inclusions promoted a denser and more continuous interfacial transition zone than shredded rubber, driven by physical entanglement and the pronounced microfilling effect of the fine waste particles.