Valorization of Construction and Demolition Wastes and Industrial By-Products in Sustainable Concrete: Comparative Mechanical Performance of Slag Slurry-Treated Recycled Aggregate Concretes

This study investigates the valorization of construction and demolition (C&D) waste streams and an industrial by-product for sustainable concrete production. Recycled concrete aggregates (RCA) and recycled brick aggregates (RBA), derived from C&D wastes, together with pelletized recycled fly ash aggregates (FAA) produced from thermal power plant fly ash, were used as total replacements for natural coarse aggregates. Six concrete mixtures were prepared at a constant water-to-cement ratio of 0.50 using untreated and slag slurry–treated aggregates. A slag slurry-based two-stage mixing approach (TSMA), incorporating ground granulated blast furnace slag (GGBFS), was applied as a practical and potentially scalable treatment method to enhance aggregate quality and interfacial bonding. The results show that complete replacement of natural aggregates reduced fresh concrete unit weight by up to 17%, while meeting the minimum compressive strength requirements for structural applications. Slag slurry treatment led to statistically significant improvements in mechanical properties, reduced variability, and enhanced overall reliability. In addition, widely used code-based prediction models (TS500, ACI, Eurocode-2, NZS 3101-1:2006, and CSA A23.3-04), originally developed for conventional concrete, were evaluated for their applicability in estimating key mechanical properties of recycled and by-product aggregate concretes, and alternative regression-based models were developed to improve prediction accuracy. Overall, the findings demonstrate the potential for effective utilization of C&D wastes and industrial by-products in structural concrete, contributing to resource efficiency and reduced reliance on natural aggregates.