Sustainable utilization of mine wastes in mortar production as a part of aggregates: a case study on calcareous wastes of Angoran lead and zinc mine

This study investigated the feasibility of large-scale utilizing calcareous wastes (CW) of Angoran lead and zinc mine as aggregates in mortar production with the maximum possible substitution of natural aggregates. The main goal was to produce mortar (concrete with fine aggregates as fine as sand or smaller) from Angoran mine's calcareous wastes for maintenance in its underground spaces. Compared to concrete, such mortars with better fluidity can enter narrow spaces more easily. In addition, it can be used to build various structures around the mine. Therefore, multiple samples were prepared by replacing 0% (as the control sample), 20%, 40%, 60%, 80%, and 100% of natural aggregates with CW. Subsequently, compressive strength, flexural strength, water absorption, slump, and TCLP tests were conducted on these samples. The results revealed that the mortar sample with 80% CW exhibited significantly higher compressive strength at 3, 14, 28, and 56 days compared to both the control sample and other samples. Specifically, the compressive strength of this sample reached 35.5 MPa at 56 days, representing an 18.4% increase over the control sample. This indicates that the hydration of cement and the growth of C-S–H gel were enhanced. Analysis of the workability and slump of the samples indicated that as the percentage of natural aggregate replaced by CW increased, the fluidity of the mortar slightly decreased. In addition to mechanical properties like compressive strength, environmental aspects like heavy metal stabilization are also very important. So, TCLP tests conducted on the four heavy metals lead, zinc, copper, and cadmium demonstrated that the released amounts of these elements from all the samples were below the EPA standard limits. These findings confirm the effective stabilization of heavy metals in mortar samples. A comparison of SEM images revealed that the mortar sample made with 20% CW (with minimum compressive strength) exhibited a higher presence of ettringite compared to the sample made with 80% CW (with maximum compressive strength) after 28 days. © The Author(s), under exclusive licence to Springer-Verlag GmbH Germany, part of Springer Nature 2024.