Strength, Wear-Resistance, Degree of Hydration, Energy and Carbon Performance of Concrete Using Ferrochrome Waste Materials

Ferrochrome ash (FCA) and air-cooled ferrochrome slag (ACFS) are two waste materials of the ferrochromium industry. Both have excellent engineering properties to be used as building materials. FCA possesses properties of cementitious material, whereas ACFS possesses properties of coarse aggregate. This study examines some properties of concrete on the combined use of lime-activated FCA for the potential replacement of cement and ACFS for the total replacement of natural coarse aggregates. Concrete mixtures were prepared to replace cement by FCA 0–40% at an interval of 10%, using ACFS as coarse aggregates. Mechanical properties such as compressive strength and modulus of elasticity of FCA–ACFS concrete were compared to the established standards of normal concrete. The durability of such concrete as wear resistance was addressed. The microstructure of FCA–ACFS concrete was studied through the degree of hydration. Environmental impact aspects like embodied energy and carbon were studied. Besides, the sustainability of FCA–ACFS concrete was examined by comparing the environmental parameters such as embodied energy and embodied carbon with the functional parameters like compressive strength. The results related to strength, durability, microstructure, environmental impact and sustainability showed the positive effect of ACFS and FCA. Sustainable concrete with improved engineering properties can be prepared using FCA and ACFS.