Preparation and application of gangue-based artificial aggregate using silicone mold casting method
Year: 2025
Type: article
Abstract: In response to the ongoing demand for natural aggregates in the construction industry and the urgent need for green utilization of solid wastes, a preparation method for multi-source solid waste-based artificial lightweight aggregates using a silicone mold casting technique is proposed. The artificial lightweight aggregates were composed primarily of coal gangue, slag, fly ash, basalt fibers, a small amount of cement, and water, with quartz sand, waste glass, and a superplasticizer as supplementary components. They were fabricated via a process of mixing, cold-bonding, and subsequent natural water curing, successfully obtaining products with a specified particle shape coefficient.The physical and mechanical properties of the aggregates under seven different mix proportions were systematically evaluated: apparent density 800–900 kg/m³, water absorption around 10 %, and crushing index 9.27 %–15.18 %, along with the compressive strength of the resulting concrete. Experimental results demonstrate that even with 100 % replacement of natural aggregates, the concrete can achieve C30-grade strength, exhibiting high structural integrity and good aggregate–matrix synergy in failure mode. XRD and SEM analyses indicate that the aggregates possess a dense internal structure and complete hydration reactions. LCA-based environmental assessment shows that the production of these aggregates can achieve significant carbon reduction, with optimized groups (G4–G7) even exhibiting net negative carbon emissions, while simultaneously enabling large-scale solid waste utilization and energy savings. This study provides a technically feasible, environmentally friendly, and economically viable solution for valorizing coal gangue and other solid wastes, contributing to the green and low-carbon transformation of the construction materials industry.
Source: Results in Engineering
Authors: Xinqi Zhang, Chenghua Zhang, Xiang Ren, Yuchen Wang, Qianhui Xiao, Liang Cheng, Qing Qin, Zhigang Gao, Yubo Sun, Liyun Tang, Guanghong Xiong, Chunlin Shang
Institution: Xi'an University of Science and Technology
Language: English
Subfield: Civil and Structural Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,940
Funder: Innovation Fund
Award: G4044759079
OpenAlex ID: W7114769161