Abstract
• High- and low-calcium off-spec fly ash based lightweight aggregate (LWA) was produced. • Engineering properties and pore structure of LWA was characterized. • Small dose of NaOH as fluxing agent can result in off-spec fly ash based LWA with desired engineering properties. This study characterizes the engineering properties of lightweight aggregate (LWA) manufactured from low calcium (F-FA) and high calcium (C-FA) waste fly ash that were designed using a previously-developed thermodynamics-guided process. LWA properties that were characterized include specific gravity, vacuum water absorption, water absorption over time, water desorption, porosity, pore size distribution, and permeability. The LWA studied had a low oven dry specific gravity ranging from 1.22 to 1.45. The vacuum absorption and total open porosity of F-FA LWA decreased as the fluxing agent (NaOH) concentration increased while the values for C-FA LWA varied with increasing amounts of fluxing agent. All LWA passed the ASTM C1761 water absorption/desorption requirements for application to the internal curing of concrete. X-ray computed tomography (XCT) and dynamic vapor sorption analyzer (DVSA) techniques were used to characterize the LWA pore structure. It was found that for F-FA LWA the normalized porosity, counting only pores smaller than 50 nm (gelpores + mesopores), ranged from 4 % to 11.5 %, while for C-FA LWA, this same pore size range had porosity ranging from 1.7 % to 2.8 %. Pore size distribution measurements of F-FA LWA using XCT showed that the pores became larger and the predicted permeability coefficient increased as the fluxing agent concentration increased. For C-FA LWA, the predicted permeability increased with increasing NaOH concentration. Since the pore size distribution had greater variability and did not follow a specific increasing trend, the increase in C-FA permeability could only be due to an increase in pore connectivity.
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