Abstract
Modified sulfur cake is a by-product of sulfuric acid and hydrometallurgical processes, and presents an underutilized resource in sustainable infrastructure with significant potential. This review evaluates the current technological innovations as pertaining to the use of modified sulfur cake in the manufacture of sulfur concrete and sulfur-modified bitumen. The processing strategies (thermal, chemical, and mechano-chemical processing, and effects of organic and inorganic additives to promote mechanical, chemical, and thermal behaviors) are discussed systematically. The effect of the modified sulfur cake on the workability, compressive strength, corrosion resistance, and environmental resistance of construction materials, in particular, is tested, with compression strengths beyond 40 MPa being reported, alongside the improved rutting resistance up to 40%. The most critical limitations associated with phase instability, toxic gas release during processing, compositional variability, and the absence of standardization are identified. Correspondingly, to alleviate them, new developments such as blends with sulfur, nano-reinforcements (e.g., carbon nanotubes (CNT), nano-silica), and the incorporation of formulation optimization by machine-learning are considered. The review particularly focuses on the life cycle performance, reduction in volatile organic compounds (VOC) emissions, and circular economy advantages, highlighting modified sulfur cake as an economical and low-carbon alternative to conventional concrete and bitumen. This review mainly aims to bridge the gap between waste valorization and green construction technologies, offering a roadmap for future research and industrial implementation in line with global climate and sustainability goals.