Ceramsite used in construction and building are typically limited by high water absorption rates, the contradiction between lightweight and high strength, and severe performance fluctuations. This can be attributed to the fact that ceramsites are currently prepared by high-temperature sintering expansion, wherein viscosity and surface tension of the liquid phases shall perfectly match with the gas generation rate. On the other hand, sand washing sludge and fly ash are common solid wastes in construction and building and their environmentally friendly disposal are of great significance. In this study, honeycombed pomegranate-like sludge ceramsites with low density (packing density = 733.2–968.3 kg/m3), high strength (cylinder compressive strength = 11.2–18.8 MPa), and low water absorption rate (one-hour water absorption rate = 1.2–2.8 %) were prepared with sand washing sludge and fly ash floating beads as the raw material and the pore-forming template, respectively. Also, the effects of particle size and content of fly ash floating beads on the structure and performance of the as-prepared ceramsite were investigated. The results indicated that the pore structure of the as-prepared ceramsite was directly dependent on size and content of the fly ash floating beads, suggesting that the performance of the as-prepared ceramsite can be customized by tuning size and content of the beads. Additionally, lightweight aggregate concrete prepared by using the as-prepared ceramsites exhibited improved 7-day and 28-day compressive strengths and reduced thermal conductivity compared with concrete prepared by using commercially available ceramsites. Overall, this study presents the preparation of ceramsite particles with both high strength and low density by using fly ash and sand washing sludge, both of which are abundant solid wastes in constructions, thus contributing to solid waste recycling in construction.
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