In the heart of Giza, Egypt, a groundbreaking study led by Esraa K. Fayed of the Pyramids Higher Institution for Engineering and Technology is turning the tables on construction waste, transforming it into a high-performance shield for steel reinforcement. The research, published in the journal “Developments in the Built Environment” (translated as “Advances in Construction and Building”), is paving the way for a more sustainable and efficient future in construction and energy sectors.
Concrete waste is a global challenge, with millions of tons generated annually. Traditional recycling methods often fall short of maximizing its potential. Fayed’s research, however, has unlocked a new avenue: using concrete waste powder (CWP) to create alkali-activated coatings for steel, significantly enhancing its resistance to chloride-induced corrosion.
The secret lies in the ratio of CWP to sodium silicate (Na2SiO3) and the silica modulus (Ms). “We found that the optimal ratio of CWP to Na2SiO3 is 40/60 wt%, with a silica modulus of 2,” Fayed explains. This combination significantly boosts the coating’s performance, increasing chloride corrosion resistance from 3.5 to 19.8 kΩ·cm² and reducing corrosion current density from 45 to 1.1 μA/cm².
The implications for the energy sector are substantial. Steel reinforcement is a critical component in energy infrastructure, from power plants to renewable energy installations. Enhanced corrosion resistance means longer lifespan and reduced maintenance costs, making energy production and distribution more efficient and sustainable.
Moreover, this innovation contributes to circular economy principles, reducing the environmental impact of construction waste. “This study proposes a viable method for CWP valorization in demanding applications,” Fayed states, highlighting the potential for widespread adoption in the construction industry.
The research also opens doors for further exploration. The binding phase and hardness of the coating, along with the role of silica gel, present avenues for future investigation. As the construction and energy sectors strive for sustainability and efficiency, Fayed’s work offers a promising path forward, turning waste into a valuable resource and shaping the future of material science in construction.