review · Journal of Cleaner Production
Processing iron ore generates substantial quantities of mine tailings, creating an opportunity for their repurposing in construction materials. Iron ore tailings can serve as supplementary cementitious materials or as aggregate replacements in cementitious composites. When used as a cement alternative, the material requires activation because of its inert crystalline structure. Conversely, utilising iron ore tailings as fine aggregates directly enhances the mechanical and durability characteristics of the resulting mixtures. However, aggregate substitution must remain capped at 25 per cent to avoid performance degradation. Beyond technical performance, evaluating these tailings covers environmental, economic, and social impacts alongside key implementation challenges. Overall, iron ore tailings provide an effective substitute for natural aggregates in infrastructure materials without causing significant property losses.
Large volumes of mining waste present ongoing environmental and disposal challenges for ore processing industries. Repurposing iron ore tailings into concrete and cement offers a route to reduce industrial waste while lowering the demand for virgin aggregates. Understanding the precise substitution limits helps the construction sector adopt more sustainable materials without compromising structural durability or performance.
This review informs concrete producers, construction contractors, and mining companies seeking to valorise industrial waste. Incorporating iron ore tailings at up to 25 per cent as fine aggregates offers an immediate pathway for aggregate replacement in concrete manufacturing. Because the synthesis reviews existing experimental data alongside economic and environmental assessments, the approach appears applied and tested at laboratory scale, though industrial adoption depends on addressing documented activation and processing challenges.
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The incorporation of mine tailings in cement mixtures is receiving continuous attention due to the considerable amount being produced during ore processing. Iron ore tailings (IOT) show great potential in this regard. Numerous studies have evaluated their use both as supplementary cementitious material (SCM) and as aggregates. This paper provides a comprehensive overview of the utilisation of IOT in cementitious composites, focusing on the various methods used to activate IOT and examining the durability along with mechanical properties of IOT-based cement mixtures. The findings indicate that while IOT has potential as a cement alternative, its inert crystalline structure requires activation. On the other hand, substituting IOT as fine aggregates enhances mechanical and durability properties. However, to avoid performance degradation, its replacement should be limited to 25%. Additionally, it summarises the environmental, economic, and social viability of using IOT in construction and presents current challenges and future research recommendations. Overall, IOT can be effectively utilised in cementitious composites, particularly as a replacement for natural aggregates, without significant losses.
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DOI: 10.1016/j.jclepro.2025.144853
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