Production and Evaluation of Synthetic Lightweight Aggregates Based on Mixture of Fluidized Bed Fly Ash and Post-Mining Residues

This paper presents an attempt to obtain technically valuable lightweight aggregate produced from a mixture of fluidized bed fly ash and post-mining residues. The motivation to take up this study is a problem with the reasonable utilization of huge amounts of ashes produced by power plants in Poland. The ashes still produced and those stored in heaps amount to a tonnage of millions, and new ways to utilize them are desired. A real lack of mineral aggregates (non-renewable resources) demands the search for alternative materials. Using the industrial ashes as aggregates is a possible solution to the two above-mentioned problems. The aim of the study was to produce the lightweight aggregate components and to assess them in terms of their physical and mechanical properties. The components were prepared by mixing, granulation, and sintering at the temperature of over 1170 °C. Evaluation of physical parameters was based on parameters such as bulk density and water absorption. The study of mechanical properties was carried out on the basis of aggregates’ resistance to crushing. The obtained results revealed that using a mixture of the combustion and post-mining residues in the production of a lightweight aggregate is beneficial and results in the formation of a porous and durable structure. The measured resistance to the crushing of the produced aggregates varied from 5.9 MPa to 7.5 MPa. They also showed a high freeze-thaw resistance and good resistance to aggressive environments (bases, acids, salt). The registered properties indicate that the aggregates meet the basic requirements for materials used in construction and road-building. This study has a scientific and didactic value in that it describes the step-by-step process of planning and implementing the production of synthetic mineral aggregates.

Cup Plant (Silphium perfoliatum L.) Biomass as Substitute for Expanded Polystyrene in Bonded Leveling Compounds

Biomass for non-food applications is considered as a substitute for petro-based materials such as expanded polystyrene (EPS). This research analyzes physical properties of an EPS containing commercial bonded leveling compound (BLC) which was substituted with cup plant (Silphium perfoliatum L.) biomass. Cup plant is a high-yielding biomass plant with several ecological benefits that is yet mainly used for biogas production. Furthermore, the high amount of parenchyma in senescent biomass with its EPS-like structure could be a possible substitute for petrochemical foams in lightweight aggregates. The natural variation in parenchyma content of several European cup plant accessions is promising, regarding the development of cultivars with suitable biomass properties for the proposed material use. Two binders with different proportions of cup plant and EPS were used to produce samples of BLC for thermal conductivity and compression strength tests. The compression strength of 0.92 N mm−2 and a thermal conductivity of 84 mW m−1 K−1 were analyzed and comparable to the commercial BLC. The thermal conductivity within the tested borders appears nearly independent of the biomass content. With increasing cup plant content, the shape characteristics of the lightweight aggregate mix changes towards more elongated aggregates. The mechanical strength and thermal conductivity are highly sensitive to the water demand of the biomass. Direct partial substitution of EPS by cup plant appears feasible and could be a part of the decarbonization of the construction sector.

Failure Criteria and Constitutive Relationship of Lightweight Aggregate Concrete under Triaxial Compression

This paper investigates the compression behavior and failure criteria of lightweight aggregate concrete (LAC) under triaxial loading. A total of 156 specimens were tested for three parameters: concrete strength, lateral confining pressure and aggregate immersion time, and their effects on the failure mode of LAC and the triaxial stress-strain relationship of LAC is studied. The research indicated that, as the lateral constraint of the specimen increases, the failure patterns change from vertical splitting failure to oblique shearing failure and then to indistinct traces of damage. The stress-strain curve of LAC specimens has an obvious stress plateau, and the curve no longer appears downward when the confining pressure exceeds 12 MPa. According to the experimental phenomenon and test data, the failure criterion was examined on the Mohr–Coulomb theory, octahedral shear stress theory and Rendulic plane stress theory, which well reflects the behavior of LAC under triaxial compression. For the convenience of analysis and application, the stress-strain constitutive models of LAC under triaxial compression are recommended, and these models correlate well with the test results.

Preparation of Lightweight Ceramsite from Solid Waste Using SiC as a Foaming Agent

SiC was chosen as the foaming agent, and river bottom silt, waste oil sludge, paint bucket slag, and fly ash were used as raw materials, to prepare lightweight ceramsite without adding any chemical additives. The effects of SiC dosing and sintering temperature on various properties of the ceramsite were studied, and the pore-forming mechanism of the lightweight ceramsite was clarified by thermal analysis and X-ray diffraction analysis. The results showed that the single ceramsite compressive strength, water absorption, bulk density, and porosity of ceramsite sintered at 1180 °C with 1.0% SiC were 2.15 MPa, 2.02%, 490 kg/m3, and 23.85%, respectively. The major mineralogical compositions were quartz, fayalite, and kyanite, with small amounts of albite-low from 1140 to 1190 °C. Furthermore, the concentration of all tested heavy metals from ceramsite was lower than the maximum allowable concentration of the leaching solution specified in the Chinese national standard (GB 5085.3-2007), which reveals that this solid waste ceramsite will not cause secondary environmental pollution. The prepared ceramsite, exhibiting lower bulk density, high water absorption and porosity, and effective solidification of deleterious elements, can be used to prepare green lightweight aggregate concrete. Importantly, preparation of solid waste ceramsite is an effective way to dispose of hazardous wastes.