Integrated utilisation of multiple industrial byproducts in eco friendly masonry mortar development

The utilization of industrial byproducts in masonry mortar provides a sustainable measure for increased natural resource consumption and environmental pollution caused by conventional cement mortars. Studies that aim to integrate multi source industrial wastes in mortar development and simultaneous replacements of cementitious and fine aggregate component in mortar are not much explored. This study investigates the integrated utilization of multi source industrial byproducts in masonry mortar development. Mortar proportions with progressive replacements for manufactured sand (M-sand) with construction demolition waste(CDW) and waste foundry sand(WFS) upto 100% and cementitious replacement by flyash(FA) and waste marble powder(WMP) upto a maximum proportion of 30% was done. The mortar specimens were evaluated for their mechanical properties, pozzolanicity, microstructural behaviour, durability, environmental performance, cost analysis and bond behaviour with bricks. 20 mixes were formulated using industrial byproducts and the results were analysed using one-way ANOVA and linear regression. Results reveal CDW exhibited enhanced mechanical and durability performance than WFS as fine aggregate replacement due to its uniform gradation and interfacial behaviour with cement paste. FA exhibited enhanced cementitious performance than WMP because of its particle shape and enhanced pozzolanic reactivity. Mix MM6C50F50-FA30 containing cement, CDW and WFS in the proportion of 1:3:3, with cementitious replacement of FA by 30% gave compressive strength of 19.82 MPa achieving the limits for various masonry applications. Mechanical, durability and environmental parameters of the ecofriendly mortar mixes were comparable with conventional mortar. This integrated utilization of multi-source industrial byproducts in masonry mortar development fosters circular economy and enhances waste reuse in construction.