A Review of Tailings Characterizations and Their Application as Aggregates in Concrete Materials

Tailings are solid waste generated during mining and mineral processing. Their tremendous accumulation not only encroaches on arable land but also pollutes the environment. Currently, tailings are considered a viable alternative to natural fine aggregates in concrete because of their suitable physicochemical properties. However, existing studies remain highly fragmented and often report inconsistent conclusions owing to the considerable variability in tailings mineralogy, particle morphology, and physicochemical characteristics. To date, a comprehensive synthesis linking these intrinsic properties to the fresh, mechanical, durable, microstructural, environmental, and economic performance of tailings concrete remains lacking. Therefore, this review provides a systematic and critical assessment of tailings as aggregate in concrete and proposes an integrated framework connecting tailings characteristics, microstructural evolution, engineering performance, and sustainability outcomes. It systematically examines the physico-mechanical properties, durability, microstructure, hydration characteristics, environmental impact, and economic benefits of the resulting tailings concrete. The results showed that although tailings varied considerably in particle size, chemical composition, and mineralogy, they typically exhibited a rough surface texture and high water absorption. Furthermore, partial substitution of fine aggregates with tailings was found to improve the physical–mechanical properties and durability. However, to prevent performance decline, the substitution ratio should not exceed 50%. These benefits originated primarily from the filling effect and optimized particle packing, which increased matrix density. Microstructural analyses indicated that moderate tailings contents refined the pore structure, strengthened the interfacial transition zone (ITZ), and promoted hydration. In contrast, excessive substitution ratios weakened bonding and increased porosity. From an environmental perspective, the use of tailings generally reduced carbon emissions (by up to ~28%) and production costs (by up to ~50%) by lowering natural resource consumption and enabling large-scale waste valorization. Overall, tailings represent a sustainable aggregate alternative, provided that substitution levels are carefully controlled to balance workability, performance, and durability.