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<p>The growing demand for sustainable building materials encourages the use of industrial by-products to reduce resource depletion and environmental impact. In this context, mill scale, a waste product from the steel industry, offers an opportunity for partial replacement of fine aggregates in cement-based composites. This study investigates the effect of Waste Iron Mill Scale (WIMS) as a partial replacement for manufactured sand (M-sand) in cement mortar, with substitution levels ranging from 0 to 30% in 5% increments. Mechanical performance, microstructural behavior, durability, and functional properties were comprehensively evaluated. At 15% WIMS replacement, the mortar exhibited optimal mechanical performance, with a peak compressive strength of 44 MPa and tensile strength of 4.2 MPa compared to 42 MPa and 3.5 MPa for the control mix, respectively. The addition of WIMS also improved durability, as indicated by reduced water absorption and Ultrasonic Pulse Velocity (UPV) values of 3608 m/s, reflecting a denser cement matrix. Rapid Chloride Permeability Test (RCPT) values decreased from 3900 Coulombs (control) to 2693 Coulombs at 25% WIMS, demonstrating enhanced resistance to chloride penetration. In contrast, 30% WIMS substitution (WIMS30) achieved the highest Electromagnetic Interference Shielding Effectiveness (EMI-SE) of 26.37 dB at 11.82 GHz, while mechanical strength showed no further significant improvement. These findings highlight that 15% WIMS replacement optimizes mechanical performance, whereas higher substitution levels (up to 30%) enhance multifunctional properties such as EMI shielding, enabling a tailored approach for sustainable and functional cement mortar composites.</p>

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Sustainable dual-functional cement mortar with waste iron mill scale: mechanical, durability, and electromagnetic shielding performance

  • 期刊论文

  • 发表日期：

    2025年11月7日

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  • G. Loganathan,
  • M. Senthil Pandian

摘要

The growing demand for sustainable building materials encourages the use of industrial by-products to reduce resource depletion and environmental impact. In this context, mill scale, a waste product from the steel industry, offers an opportunity for partial replacement of fine aggregates in cement-based composites. This study investigates the effect of Waste Iron Mill Scale (WIMS) as a partial replacement for manufactured sand (M-sand) in cement mortar, with substitution levels ranging from 0 to 30% in 5% increments. Mechanical performance, microstructural behavior, durability, and functional properties were comprehensively evaluated. At 15% WIMS replacement, the mortar exhibited optimal mechanical performance, with a peak compressive strength of 44 MPa and tensile strength of 4.2 MPa compared to 42 MPa and 3.5 MPa for the control mix, respectively. The addition of WIMS also improved durability, as indicated by reduced water absorption and Ultrasonic Pulse Velocity (UPV) values of 3608 m/s, reflecting a denser cement matrix. Rapid Chloride Permeability Test (RCPT) values decreased from 3900 Coulombs (control) to 2693 Coulombs at 25% WIMS, demonstrating enhanced resistance to chloride penetration. In contrast, 30% WIMS substitution (WIMS30) achieved the highest Electromagnetic Interference Shielding Effectiveness (EMI-SE) of 26.37 dB at 11.82 GHz, while mechanical strength showed no further significant improvement. These findings highlight that 15% WIMS replacement optimizes mechanical performance, whereas higher substitution levels (up to 30%) enhance multifunctional properties such as EMI shielding, enabling a tailored approach for sustainable and functional cement mortar composites.