Civil construction has become a prominent consumer of natural resources, among all economic activities, due to its constant growth, mainly associated with urban areas. Many researchers have attempted to develop viable solutions to reduce the environmental impact of civil construction. Among these solutions, the use of (industrial) solid wastes for replacing natural raw materials for manufacturing construction materials can be pointed out. However, industrial solid waste needs particular care in its management and disposal since it is often associated with potentially polluting substances [18], [29] To reduce the generation of industrial solid wastes, it is essential to maintain proper management of the manufacturing processes, including destination and final disposal of those which sustainable principles should drive [22].
Among industrial solid waste, phosphogypsum (PG) is the subproduct of the primary raw material used by the fertilizer industry: phosphoric acid [11]. According to [12] and [2], PG can be classified as a Naturally Occurring Radioactive Material (NORM), which means that its reuse may pose risks to humans and the environment from the radiological protection point of view. PG (which is mainly composed of calcium sulfate dihydrate) consists of a waste that is generated by the production of phosphoric acid by wet processing of the phosphoric rock, formed mainly by apatite mineral (Ca5(PO4)3OH)) with sulphuric acid. The PG is taken to a suspension with water and pumped to storage rafts, where it decants and dries out. The chemical equation of phosphoric acid production is as follows [26] [2]:
Ca5F(PO4)3+5H2SO4 + 10H2O → 3H3PO4 + 5CaSO4.2H2O + HF (1)
Based on this equation, nearly 5 tons of PG (CaSO4.2H2O) are produced from 1 ton of phosphoric acid (H3PO4) [14][17] [30] [23]. PG consists of a powdery material with little or no plasticity, with particle density between 22.7 and 24.0 kN m− 3 and bulk density varying among 9.0 and 17 kN m− 3 [28]. From the morphological point of view, PG is characterized by a crystal structure, mostly in rhombic and hexagonal forms. PG also contains impurities as H3PO4, Ca(H2PO4) H2O, CaHPO42H2O and Ca3(PO4)2, residual acids, fluorides (NaF, NaF2SiF6, Na3AlF6, Na3FeF6, and CaF2), sulfate ions, trace metals, and organic matter as aliphatic compounds of carbonic acids, amines, and ketones, adhered to the surface of gypsum crystals [23].
Due to its low economic value for companies, PG usually ends up being landfilled or discharged into the environment without any prior treatment, thus resulting in environmental contamination and pollution of soil and water, including seawater [3]. An estimated 100–280 million tons of PG are generated worldwide per year. Only 15% of these are recycled as soil stabilization amendments, fertilizers, and building materials, mainly due to their strong acidity (pH < 3) and high moisture content [3] [2] [30][28] [23]. Approximately 3 billion tons of PG are stored in deposits of different sizes in over 50 countries [12]. Due to the possible acid and heavy metals infiltration, storage of PG may cause pollution of soils and waters [1]. The storage and management of PG are considered the main challenges facing the phosphoric acid production industries worldwide. They require the mobilization of significant resources and occupy large land areas [3].
In Brazil, PG is a severe environmental liability. The amount of PG generated as waste is about 4 to 6 times higher than the amount of phosphoric acid produced, making the storage and disposal of this waste product a challenge, especially for fertilizer industries. According to [12], Brazilian production of PG reaches 12 million tons per year. The industrial complex of the city of Uberaba/Brazil, the biggest producer of phosphoric acid in Brazil, generates more than 3 million tons of PG per year: the PG waste is stored in a 1 million m2 area, in piles that are 30 m high [13]. Another fertilizer industry in the city of Catalão produced in 2008 an amount of 600.000 tons of PG that is disposed of in landfills. [13] comments that paper and cement industries and agriculture have reused only 10% of the PG produced by this industry.
The interest in PG as a source of secondary raw materials has increased over the past decade [15]. Initially, PG was considered mainly a component for construction, cement, road-building, and agricultural industries [17] [[29] [30]. However, over the past 10–20 years, the focus has shifted, given the increase of anthropogenic pressure on the environment and the resulting shortage of natural sources of raw materials. PG, which has many valuable elements, is considered a source of calcium, phosphorus, rare-earth elements, trace elements, and a mineral resource in technological, environmental protection processes. Research increasingly focuses on finding reliable and efficient ways to manage and reuse PG, especially civil construction [3] [17]. An assessment of its radiological impact is required, mainly due to the radionuclides content and radon exhalation [12]. [13] points out that the use of PG for civil construction purposes can be a valuable way to reduce the environmental impacts caused by this economic sector. Like [18], many authors point out that PG can be used for alternative construction materials manufacturing, including bricks, tiles, and mortar.
Several studies have explored the use of PG in the base and sub-base of roads and embankments and as a final layer of earthworks to improve soil properties, minimize the possible environmental impacts caused by the disposal, and insert a new material on the market. However, the primary use of PG remains in cement manufacturing, where it substitutes natural gypsum (about 5%) [1] [16]. Researchers have studied the possibility of using PG in construction materials such as raw blocks and fired bricks, and promising results have been found [1] [30]. PG can be reused with fly ash and Portland Cement in the building industry [29]. Such results suggest that PG can become an alternative raw material for the civil construction sector, reducing the impact of landfills close to the chemical industries.
For such applications, the natural radioactivity of PG, mainly from 226Ra, remains a challenge [19]. Other radioactive elements derived from phosphate rocks may be present, such as Pb210, Po210, U238, and U234 [20]. PG that exceeds 370 Bq kg− 1 (10pCig− 1) of radioactivity has been banned from all uses by the USA Environmental Protection Agency (EPA) since 1992 [20]. The European Atomic Commission (EURATOM) prescribed a limit of 500 Bq kg− 1 (13.5 pCig− 1). Despite such characteristics, however, [20] points out that PG cannot be classified as toxic waste since PG elements are not corrosive and the average total concentration of elements classified as toxic (e.g., Ba, As, Cr, Cd, Hg, Pb, Se, and Ag) by the USA Environmental Protection Agency is lower than the EPA allowable limits for toxic, hazardous waste.
This study characterizes the physical parameters of fired and non-fired bricks produced with PG in their dosage. It also studies the influence of PG dosage on these physical characteristics. The main objective is to evaluate the potential use of PG as an alternative construction material, thus reducing the environmental impacts caused by this solid waste and civil construction activities.