Preliminary Research on the Physical and Mechanical Properties of Alternative Lightweight Aggregates Produced by Alkali-Activation of Waste Powders

There is growing interest in construction field issues related to environmental protection, energy saving and raw materials. Therefore, the interest in recycling waste materials to produce new construction ones is constantly increasing. This study proposes a new methodology to produce lightweight aggregates (LWAs) by alkali-activation of two different waste powders: a digested spent bentonite clay and a basalt powder. Metakaolin, as secondary precursor, was added to the mixtures according to mix-design proportions, to improve the mechanical properties of the final materials, while a specific activators mix of Sodium Silicate and Sodium Hydroxide enabled the alkali-activation. The expansion process, on the other hand, was obtained using Peroxide within the liquid mix. The experimental LWAs were analyzed and tested in compliance with the EN 13055-1 standard. A more in-depth analysis on LWAs’ air voids content and porosity was also carried out by the means of Mercury Intrusion Porosimetry and Nuclear Magnetic Resonance. The results were compared with those obtained from commercial Lightweight Expanded Clay Aggregate, which represents one of the most common LWAs in the construction field. According to the presented preliminary results, the use of alkali-activated waste powders seems to be a suitable solution for the production of eco-friendly LWAs by allowing the recycling of waste materials and energy saving for their production.