A Novel Method for Preparing Lightweight and High-Strength Ceramisite Coarse Aggregates from Solid Waste Materials

A novel method is introduced in this study for producing ceramisite coarse aggregates that are both lightweight and possess high strength. The process involves utilizing fly ash as the primary material, along with coal ash floating beads (CAFBs) that have high softening temperature and a spherical hollow structure serving as the template for forming pores. This study examined the impact of varying particle size and quantity of floating beads on the composition and characteristics of ceramisite aggregates. Results showed that the high softening temperature of floating beads provided stability to the spherical cavity structure throughout the sintering process. Furthermore, the pore structure could be effectively tailored by manipulating the size and quantity of the floating beads in the manufacturing procedure. The obtained ceramisite aggregates feature a compact outer shell and a cellular inner core with uniformly distributed pores that are isolated from each other and mostly spherical in form. They achieve a low density ranging from 723 to 855 kg/m³, a high cylinder compressive strength between 8.7 and 13.5 MPa, and minimal water absorption rates of 3.00 to 4.09%. The performance metrics of these coarse aggregates significantly exceeded the parameters specified in GB/T 17431.1-2010 standards.