Investigation of the durability properties of concrete incorporating iron dust and silica fume

Objective The study aims to develop a green, sustainable, and durable concrete suitable for general construction applications. In response to increasing construction activity and the need for sustainable practices, the research investigates the use of industrial waste materials—specifically iron dust and silica fume—as partial replacements for fine aggregates and cement, respectively, and evaluates their effects on the durability of concrete. Method Concrete mixes were prepared by replacing fine aggregates with 0–30% iron dust and cement with 0–15% silica fume. Durability performance was assessed through Rapid Chloride Penetration Test (RCPT), acid resistance, sorptivity, sulfate resistance, and water penetration tests at 28, 56, and 84 days of curing. Additionally, X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses were conducted to examine the microstructural changes in the modified concrete. Results The incorporation of iron dust and silica fume significantly influenced the durability properties of concrete. The mix containing 20% iron dust and 10% silica fume showed optimal performance across most durability tests, demonstrating reduced chloride penetration, improved resistance to acid and sulfate attack, lower sorptivity, and decreased water permeability. Microstructural analyses further confirmed denser matrix formation and improved bonding in the optimized mix. Conclusion The study concludes that substituting 20% of fine aggregates with iron dust and 10% of cement with silica fume enhances the durability characteristics of concrete. Utilizing these industrial byproducts provides an environmentally sustainable approach while maintaining or improving concrete performance for construction applications.