Manufacturing and Performance of Fly Ash Based Synthetic Lightweight Aggregate

Abstract

In South Africa, as much as 33 million tons of ash, a waste product of burning coal, are produced per year. Of the total ash produced, just over 8% is sold for utilisation, the remainder of which is disposed of in landfills or ash lagoons. Countries like the UK, USA, Germany, Poland and Russia are producing Lightweight Aggregates (LWAs) commercially by using fly ash and clay, however, this technology is not available in many developing countries. The opportunity to utilise the fly ash produced in South Africa for the production of coarse LWA for use in structural concrete has therefore been identified and investigated in this dissertation. This dissertation consists of two phases, firstly to determine a suitable method for the manufacture of a high quality LWA, and secondly to determine the manufactured aggregate’s performance and potential for use in structural concrete. In the first phase, different LWA batches were produced using fly ash as the main constituent and kaolin clay, in contents of 0%, 10%, 20% and 30% by mass, as a binder. Green aggregate particles were produced in a disc granulator and then hardened using sintering at 1200°C for one hour. It was found that the LWA batch containing 20% kaolin produced LWA with the most suitable mechanical properties for use in concrete, and was therefore mass produced for further aggregate testing and for the production of concrete specimens for concrete testing. The final LWA produced was found to have an apparent density of 1600 kg/m3 and 24 hour water absorption of 12% by mass. The produced LWA was also found to have an Aggregate Crushing Value (ACV) and 10% FACT of 24.4% and 185 kN, respectively, which indicated that it would be suitable for use in High Strength Concrete (HSC). The sintering process was found to induce liquid phase sintering and the formation of new phases, mainly mullite, which contributed to the relatively high strengths of the aggregates. In the second phase of this dissertation, the manufactured LWA was then used to produce HSC and Normal Strength Concrete (NSC) specimens for concrete testing, which were compared to control mixes made with normal weight dolomite aggregate. In the HSC testing, concrete with a density of 2300 kg/m3 and compressive strength of 90 MPa was produced with the LWA. In HSC, it was found that internal curing was improved when up to 50% of the normal weight coarse aggregate was replaced by saturated LWA for this specific concrete mix. By using different stiffness relationship models between the concrete constituents, it was found that the manufactured LWA modulus of elasticity was between 8-23 GPa, and had a compressive strength of between 49-60 MPa. The Interface Transition Zone (ITZ) in concrete produced with the LWA was found to be stronger than the LWA as a result of the impregnation of the cement paste within the aggregate, and that the LWA was reactive in an alkaline environment. This resulted in an improved early age strength development, as well as caused the concrete failure surface to occur through the LWA particles rather than at the ITZ. Finally, Lightweight Concrete (LWC), having a dry density below 2000 kg/m3, was produced with the manufactured LWA. The LWC, produced with a water-to-cement ratio of 0.75, 28 day compressive strength of 24 MPa, modulus of elasticity of 21 GPa and dry density of 1800 kg/m3, was found to be suitable for use as structural concrete when assessed in terms of EN 1992-1-1 (2004).