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Structural concretes with waste-based lightweight aggregates: from landfill to engineered materials.
Roberto De'Gennaro1, Sossio Fabio Graziano, Piergiulio Cappelletti
1Centro Interdipartimentale di Servizio per Analisi Geomineralogiche, Federico II University, Via Mezzocannone 8, 80134 Naples, Italy. robdegen@unina.it
Environmental Science & Technology
|October 8, 2009
Summary
Waste muds from stone and ceramic production can be reused to create lightweight aggregates. These aggregates can be used to manufacture high-performance lightweight structural concretes, offering sustainable construction solutions.
Area of Science:
- Materials Science
- Waste Management
- Sustainable Construction
Background:
- Industrial waste, specifically sludges from granite and ceramic tile production, presents disposal challenges.
- Valorization of these waste streams can lead to innovative construction materials and reduced environmental impact.
Purpose of the Study:
- To investigate the feasibility of reusing ornamental stone and ceramic production sludges for manufacturing lightweight aggregates.
- To characterize the physicomechanical properties of the synthesized lightweight aggregates.
- To produce and test lightweight structural concretes using the optimized aggregate formulation.
Main Methods:
- Lab-scale simulation of aggregate manufacturing via pelletizing and firing waste mixes up to 1300°C in a rotary furnace.
- Determination of aggregate composition and physicomechanical properties (particle density, particle strength).
- Production and testing of lightweight structural concretes according to standard procedures, evaluating compressive strength and bulk density.
Main Results:
- Both granite and porcelain stoneware sludges showed suitable firing behavior, with silicon carbide (SiC) decomposition promoting bloating and resulting in aggregates with particle density < 1 Mg/m³.
- Aggregate properties varied with mixture composition, ranging from expanded clay-like (density 0.68 Mg/m³, strength 1.2 MPa) to high-strength products (density 1.25 Mg/m³, strength 6.9 MPa).
- The optimal mix (50 wt.% porcelain stoneware sludge + 50 wt.% granite sludge) yielded lightweight structural concretes with compressive strength > 20 MPa and bulk density of 1.4-2.0 Mg/m³.
Conclusions:
- Waste sludges from granite and ceramic tile industries are viable precursors for producing lightweight aggregates.
- The developed lightweight aggregates can be successfully used to manufacture structural concretes with desirable mechanical properties.
- This research demonstrates a sustainable approach to waste valorization in the construction materials sector.
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