Utilisation of Sulphur By-Products in Diverse Civil Engineering Applications: A Systematic Review

TL;DR

Sulphur by-products from oil and gas can be turned into durable, recyclable construction materials like concrete and asphalt, offering environmental and economic benefits.

Contribution

This systematic review highlights sulphur-based materials' properties, applications, and sustainability potential in civil engineering.

Findings

Sulphur concrete achieves high strength (up to 50 MPa) and resists corrosion and extreme environments.

Polymer-modified sulphur systems reduce brittleness and temperature sensitivity.

Sulphur asphalt improves pavement stiffness and offers cost savings with 20–40% sulphur replacement.

Abstract

What are the main findings?

Research on sulphur application in civil materials has grown significantly.

Sulphur concrete and sulphur asphalt exhibit durability, strength, and recyclability.

Modified sulphur systems help overcome brittleness and temperature sensitivity.

What are the implications of the main findings?

Sulphur waste streams can support sustainable construction and a circular economy.

Sulphur materials offer techno-economic and environmental benefits for industry.

Future work may validate in situ applications of sulphur concrete.

Sulphur, a major by-product of the oil and gas industry, has emerged as a promising construction material in both sulphur concrete (SC) and sulphur-extended asphalt (SEA) applications. This review examines the development, properties, and uses of these sulphur-based construction materials over a century by following PRISMA guidelines for systematic literature selection. A bibliometric analysis highlights a surge in research activity over the last two decades. The key advantages of sulphur concrete include rapid strength gain (achieving ~50 MPa within 1–2 days) and exceptional chemical durability in extreme environments. Sulphur-bound materials exhibit high corrosion resistance, low water permeability, and full recyclability upon reheating. Challenges such as thermal shrinkage-induced brittleness and temperature sensitivity have been mitigated by using polymer-modified sulphur and mix design optimisation. Sulphur-extended asphalts benefit from increased stiffness, stability, and cost savings compared to conventional mixtures. Enhanced performance has been observed at sulphur replacement levels of 20–40% in asphalt binders. The review also summarises mixed formulations, mechanical properties, durability metrics, and innovative applications ranging from acid-resistant industrial structures to sustainable pavement materials and even extraterrestrial construction. The environmental benefits, such as up to 40% GHG reduction and complete recyclability of sulphur-based concretes, align with circular economy goals. Future research directions include improving ductility, advancing 3D printing techniques, and field validation of long-term performance. Overall, sulphur by-products can be transformed into valuable construction materials that address waste management and infrastructure durability.

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