Application of a Mixture of Fly Ash and Solid Waste from Gas Treatment from Municipal Solid Waste Incineration in Cement Mortar

This paper analyzes the effective use of a mixture of fly ash (MSWI-FA) and solid waste from flue gas treatment (MSWI-SW), which are by-products of the municipal waste incineration process. MSWI-FA (19 01 13*) and MSWI-SW (19 01 07*) are classified as hazardous waste due to their toxic metal content and leaching potential, and currently lack practical applications, unlike slag and bottom ash (19 01 12). This study tested these wastes as partial substitutes for natural sand within a range of 0–20% of cement mass. Statistical analysis of the experimental results allowed the creation of good quality models predicting the effect of substitution additives on compressive strength and flexural strength (correlation 0.91 and 0.93, respectively). The mixture with the highest share of substitution additives (40% = 20% + 20%) was characterized by a decrease in compressive strength by 1.3% and flexural strength by 25.8%. Cement mortars synthesized with the waste mixture (up to 20% of each component) showed slightly lower consistency and water absorption than the control mortars. After the frost resistance tests (25 cycles), the flexural and compressive strength showed ambiguous behavior, showing both increases and decreases, indicating that the percentage of waste components alone is an insufficient set of factors for predicting these strength properties. The concentration of metal ions, i.e., Zn, Cu, Pb, Ni, Cu, and Cr, in the eluate after the leaching tests did not exceed the legal levels of pollutants introduced into waters, with the exception of barium. However, its content did not exceed the permissible levels required for waste intended for landfill. Using the mixing plant for this waste in the amount of 20% each, we save about EUR 10 in the cost of purchasing sand (which is 13% of the production costs of 1 m3) and EUR 8 in the cost of environmental fees when producing 1 m3 of mortar. The proposed technology is compatible with the objectives of a sustainable economy.