Experimental Study on a New Cement-Based Grouting Material for Iron Tailings Sand.

Area of Science:

• Materials Science
• Civil Engineering
• Sustainable Construction

Background:

• Resource depletion necessitates sustainable alternatives in construction materials.
• Industrial solid waste, such as iron tailings sand (ITS), presents an opportunity for material valorization.
• Developing high-performance cementitious grouts is crucial for prefabricated construction applications.

Purpose of the Study:

• To develop a green, high-performance cement-based grout using iron tailings sand (ITS) as a partial replacement for manufactured sand.
• To evaluate the engineering feasibility of ITS-modified grout by assessing fluidity, mechanical strength, and expansion rates.
• To determine the optimal ITS replacement ratio for achieving desired grout properties and meeting industry specifications.

Main Methods:

• Cement-based grout formulations were prepared with ITS replacing manufactured sand at varying ratios (0-50%).
• Experimental evaluations included measurements of fluidity, compressive strength (at different ages), and expansion rates.
• Optimization analysis was conducted to identify the best performing ITS replacement level.

Main Results:

• ITS inclusion negatively impacted fluidity due to its particle morphology but improved compressive strength via a physical filling effect.
• The 30% ITS replacement group reached a peak 28-day compressive strength of 100.4 MPa.
• A 40% ITS replacement rate was identified as optimal, satisfying industry standards for fluidity, early strength, and volume stability.

Conclusions:

• Utilizing iron tailings sand (ITS) in cement grout is a viable strategy for sustainable construction material development.
• The developed grout with optimal ITS content demonstrates high performance suitable for prefabricated construction.
• This research highlights the practical application of industrial solid waste in producing advanced construction materials.