Transforming Waste into Value: The Role of Recovered Carbon Fibre and Oil Shale Ash in Enhancing Cement-Based...

Economic and technological factors necessitate the use of alternative fuels during oil shale combustion, a process that generates substantial amounts of solid waste with varying ash compositions. This study evaluates the potential of two such waste materials: (i) fly ash derived from the combustion of oil shale (a fine particulate residue from burning crushed shale rock, sometimes combined with biomass), and (ii) short carbon fibres recovered from the pyrolysis (a process of decomposing materials at high temperatures in the absence of oxygen) of waste wind turbine blades. Oil shale ash from two different sources was investigated as a partial cement replacement, while recycled short carbon fibres (rCFs) were incorporated to enhance the functional properties of mortar composites. Results showed that carbonate-rich ash promoted the formation of higher amounts of monocarboaluminate (a crystalline hydration product in cement chemistry), leading to a refined pore structure and increased volumes of reaction products-primarily calcium silicate hydrates (C-S-H, critical compounds for cement strength). The findings indicate that the mineralogical composition of the modified binder (the mixture that holds solid particles together in mortar), rather than the fibre content, is the dominant factor in achieving a dense microstructure. This, in turn, enhances resistance to water ingress and improves mechanical performance under long-term hydration and freeze-thaw exposure. Life cycle assessment (LCA, a method to evaluate environmental impacts across a product's lifespan) further demonstrated that combining complex binders with rCFs can significantly reduce the environmental impacts of cement production, particularly in terms of global warming potential (-4225 kg CO₂ eq), terrestrial ecotoxicity (-1651 kg 1,4-DCB), human non-carcinogenic toxicity (-2280 kg 1,4-DCB), and fossil resource scarcity (-422 kg oil eq). Overall, the integrative use of OSA and rCF presents a sustainable alternative to conventional cement, aligning with principles of waste recovery and reuse, while providing a foundation for the development of next-generation binder systems.