Wood Ash Valorisation for Sustainable Materials: Circular Manufacturing, Characterization, Digital Modelling, and Industrial Applications

The increasing generation of wood ash (WA) from biomass combustion presents both an environmental challenge and an opportunity for sustainable resource utilization. This review provides a comprehensive assessment of recent advances in the valorization of WA for the development of sustainable engineering materials within a circular economy framework. Unlike previous studies that primarily focus on isolated applications of WA, this work integrates multiple technical dimensions, including material characterization, advanced manufacturing technologies, mechanical performance evaluation, computational modelling, and industrial commercialization pathways. Wood ash typically exhibits alkaline characteristics (pH 9–13.5) and particle sizes ranging from 1 to 1000 µm, enabling its application in a wide range of material systems. In cementitious materials, partial replacement of cement with WA (0.10–20%) generally improves mechanical performance, whereas excessive incorporation may reduce structural integrity. The high silica content (>62%) in certain WA types also enables its utilization in lightweight glass systems and radiation-shielding materials. Furthermore, WA has emerged as a promising functional filler in polymeric and ceramic composites, where additions above 0.5% can enhance dynamic mechanical properties and thermal stability. The review also examines standardized inspection and testing procedures, including quality control (QC) and quality assurance (QA) frameworks based on American Society for Testing and Materials (ASTM), Canadian Standards Association (CSA), and European standards, to ensure the reliability of WA-derived materials. Recent developments in artificial intelligence, machine learning, and computational modelling are highlighted for predicting mechanical behavior, optimizing processing parameters, and enabling digitalized manufacturing systems. In addition, circular manufacturing strategies and economic evaluation models, including break-even analysis, are discussed to assess the industrial feasibility of WA-based products. By integrating circular economy principles with materials engineering, digital technologies, and economic assessment, this review establishes a holistic framework for transforming wood ash from an industrial residue into value-added sustainable materials for construction, energy, and advanced composite applications.