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<p>Cement production accounts for approximately 8% of global CO₂ emissions, driving urgent demand for low-carbon supplementary cementitious materials. Sugarcane bagasse ash (SCBA), a by-product of sugar mill cogeneration, offers well-established pozzolanic potential; however, most existing studies employ energy-intensive calcination at 600–900&#xa0;°C, which substantially offsets the environmental benefit of waste valorisation. No prior study has employed ultra-minimal single-step sieving — without grinding, classification, or calcination — as the sole processing method for SCBA under Indian industrial conditions, nor evaluated cement-replacement performance at extended curing ages within an integrated mechanical-environmental framework. This study characterises SCBA from Triveni Sugar Mill, Muzaffarnagar, India, processed solely by 300&#xa0;μm sieving, and evaluates its performance as cement replacement at 10%, 15%, and 20% by mass in mortar. Compressive, split tensile, and flexural strengths and ultrasonic pulse velocity were assessed at 7, 28, 90, and 120 days (<i>n</i> = 3 replicates per mix per age; all reported differences significant at <i>p</i> &lt; 0.05). A cradle-to-gate life cycle assessment quantified global warming potential, embodied energy, water footprint, and acidification potential per 1&#xa0;m³ of mortar. A Modified Multi-Criteria Sustainability Index (MCSI) was developed to integrate normalised environmental indicators against mechanical performance, enabling objective ranking of mix designs. The 15% replacement mix consistently outperformed the control and higher replacement levels across all mechanical properties at extended curing ages, attributable to progressive pozzolanic densification and C–S–H gel formation. All SCBA mixes reduced GWP, embodied energy, water footprint, and acidification potential relative to the control, with the 15% mix achieving the most favourable balance. Sieving-only processing delivered a processing GWP offset ratio of 27.3 relative to calcination. Strong empirical correlations were established between UPV and compressive strength (R² = 0.962) and between compressive and tensile and flexural strengths. MCSI identified 15% replacement as optimal, representing a 38.4% improvement over the control. These results demonstrate that minimally processed SCBA offers a scalable, low-energy pathway for sustainable mortar production in developing-country sugar-producing regions.</p>

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Mechanical properties and environmental impact of minimally processed sugarcane bagasse ash in cement mortar

  • 期刊论文

  • 发表日期：

    2026年6月2日

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  • Mohammad Tabish,
  • Mohd Moonis Zaheer,
  • Abdul Baqi,
  • Salim Barbhuiya

摘要

Cement production accounts for approximately 8% of global CO₂ emissions, driving urgent demand for low-carbon supplementary cementitious materials. Sugarcane bagasse ash (SCBA), a by-product of sugar mill cogeneration, offers well-established pozzolanic potential; however, most existing studies employ energy-intensive calcination at 600–900 °C, which substantially offsets the environmental benefit of waste valorisation. No prior study has employed ultra-minimal single-step sieving — without grinding, classification, or calcination — as the sole processing method for SCBA under Indian industrial conditions, nor evaluated cement-replacement performance at extended curing ages within an integrated mechanical-environmental framework. This study characterises SCBA from Triveni Sugar Mill, Muzaffarnagar, India, processed solely by 300 μm sieving, and evaluates its performance as cement replacement at 10%, 15%, and 20% by mass in mortar. Compressive, split tensile, and flexural strengths and ultrasonic pulse velocity were assessed at 7, 28, 90, and 120 days (n = 3 replicates per mix per age; all reported differences significant at p < 0.05). A cradle-to-gate life cycle assessment quantified global warming potential, embodied energy, water footprint, and acidification potential per 1 m³ of mortar. A Modified Multi-Criteria Sustainability Index (MCSI) was developed to integrate normalised environmental indicators against mechanical performance, enabling objective ranking of mix designs. The 15% replacement mix consistently outperformed the control and higher replacement levels across all mechanical properties at extended curing ages, attributable to progressive pozzolanic densification and C–S–H gel formation. All SCBA mixes reduced GWP, embodied energy, water footprint, and acidification potential relative to the control, with the 15% mix achieving the most favourable balance. Sieving-only processing delivered a processing GWP offset ratio of 27.3 relative to calcination. Strong empirical correlations were established between UPV and compressive strength (R² = 0.962) and between compressive and tensile and flexural strengths. MCSI identified 15% replacement as optimal, representing a 38.4% improvement over the control. These results demonstrate that minimally processed SCBA offers a scalable, low-energy pathway for sustainable mortar production in developing-country sugar-producing regions.