Black magic for concrete: Using biomass and industrial by-products to create innovative sustainable construction materials

Sulfur concrete (SC), recognized for its sustainability and chemical resistance, faces limitations in mechanical strength and thermal durability. This study investigates the enhancement of SC through the incorporation of biomass-derived activated carbon (BAC) from corn husk and cob, substituting 1 %, 3 %, 5 %, and 7 % of carbide lime by weight. The BAC, characterized by high porosity (91 % carbon content in cob-derived BAC, 74.5 % in husk-derived) and a 100–200 µm particle size, was synthesized via pyrolysis at 400°C. Mechanical testing revealed a 23.9 % increase in compressive strength at 7 % BAC replacement, achieving 52 MPa, outperforming prior SC formulations (25–43 MPa). SEM/EDX analyses confirmed BAC’s role in densifying the microstructure, reducing voids, and improving sulfur-aggregate adhesion. Durability assessments under 12 wet/dry cycles demonstrated enhanced resistance to moisture-induced degradation, with BAC-modified SC exhibiting negligible cracking and < 2 % mass fluctuation. The integration of agricultural waste-derived BAC not only elevates SC’s structural performance but also aligns with circular economy principles by repurposing industrial by-products (sulfur from ADNOC) and agricultural residues. These findings position BAC-SC as a viable, high-performance alternative to conventional concrete in harsh environments, offering quantifiable advancements in sustainability and resilience. • A sustainable method integrates biomass-derived activated carbon (BAC) into concrete, promoting eco-friendly construction. • Fine aggregate is partially replaced with BAC and carbide lime to study strength and durability. • Adding BAC to sulfur concrete boosts compressive strength by 23.9 %, enhancing its load-bearing performance significantly. • BAC addition improves sulfur concrete durability by reducing corrosion and cracking from thermal expansion and contraction.