Effects of Heavy-Metal-Sludge Sintered Aggregates on the Mechanical Properties of Ultra-High-Strength Concrete

To investigate the effects of heavy-metal-sludge sintered aggregates on the workability, mechanical properties, and fracture toughness of ultra-high-strength concrete (UHSC), this study systematically evaluated the influence of different aggregate replacement ratios and particle gradations on the fluidity, flexural strength, compressive strength, and fracture energy of UHSC. Microstructural characterization techniques including SEM, XRD, TG, and FTIR were employed to analyze the hydration mechanism and interfacial transition zone evolution. The results demonstrated the following: Fluidity continuously improved with the increase in the sintered aggregate replacement ratio, with coarse aggregates exhibiting the most significant enhancement due to the "ball-bearing effect" and paste enrichment. The mechanical properties followed a trend of an initial increase followed by a decrease, peaking at 15-20% replacement ratio, at which flexural strength, compressive strength, and fracture energy were optimally enhanced; excessive replacement led to strength reduction owing to skeletal structure weakening, with coarse aggregates providing superior improvement. Microstructural analysis revealed that the sintered aggregates accelerated hydration reactions, promoting the formation of C-S-H gel and Ca(OH)₂, thereby densifying the ITZ. This study identified 15-20% of coarse sintered aggregates as the optimal replacement ratio, which synergistically improved the workability, mechanical properties, and fracture toughness of UHSC.