Feasibility and economic evaluation of grouting materials containing binary and ternary industrial waste

Abstract In this study, the feasibility and environmental impact of using zeolite powder (ZP), basalt powder (BP), and unprocessed coarse fly ash (UFA) as grouting materials were evaluated. The rheological properties, workability, and compressive strengths of cementitious systems containing cement, ZP, BP, and UFA were tested, and three-parameter models were used to characterize the relationships between these properties. The resource consumption, electricity consumption, and greenhouse (CO2) and pollution (PM, SO2, and NOx) gas emissions of different grout formulations were evaluated by combining life cycle assessment (LCA) and economic cost assessment. The results showed that the incorporation of ZP, BP, or UFA improved the cohesiveness and bleeding rate of the grout. Some formulas had adverse effects on the rheology and compressive strength. The ternary blends of these mineral admixtures effectively solved this problem. In particular, the blends of BP and UFA not only retained cohesiveness and segregation resistances but also exhibited good rheological properties and compressive strengths. LCA and the economic evaluation indicated that the utilization of ZP and BP reduced the resource and electricity consumption, harmful gas emissions, and economic costs. Among them, BP’s annual production and mining costs were better than those of ZP. The production of UFA had a negative impact on resource consumption and environmental pollution but had the best economic effect among the three waste materials. A blend with 10% BP and 10% UFA was the optimal combination, which could simultaneously meet the requirements of the grouting performance and economic cost.