International Journal of Civil Engineering and Technology (IJCIET)

Volume 8, Issue 6, June 2017, pp. 360369, Article ID: IJCIET_08_06_040

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OVERVIEW OF ARTIFICIAL
ARTIFICIAL LIGHTWEIGHT
AGGREGATES REVIEW
AGGREGATES-A
Kolimi Shaiksha Vali
Research Scholar, Department of Structural and Geotechnical Engineering,
Engineering
School of Civil and Chemical Engineering, VIT University,
University, Vellore, Tamil Nadu, India

Bala Murugan S
Assistant Professor Sr, Department of Structural and Geotechnical Engineering,
Engineering
School of Civil and Chemical Engineering, VIT University, Vellore, Tamil Nadu, India

ABSTRACT
This article provides a review on o synthetic aggregates observes of many by-
product materials from various industries. In the present scenario, the dumping issues
of factory-made
made sources like fly ash, steel slag, paper pulp, metal sediment, quarrying
residues and bottom ash has turned into environmental problems like land, air, and
water due to the presence of heavy metals. In addition to that enormous land is
required to dispose of these materials also a problem to the industries. The
government also earmarking huge fund in the infrastructure
infrastructure development like road,
dam, bridge and smart city development. A Huge quantity of concrete being used in
the infrastructural development projects. In the total quantity of concrete, consumes
60% of natural aggregate obtained from the quarry and it disturbs the Mother Nature.
There is a need to identify the alternate material for natural aggregate to save the
nature without compromising the natural aggregate properties in the concrete. Few of
the researchers were carried out the experimental works in the manufacturing of
aggregate with industrial by-products
by products and reported that the properties of synthetic
aggregate are similar to the natural aggregate. By using of byproduct materials in the
manufacturing of aggregate process will reduce the environmental problemsp and
restricts deficiency of natural resources. In this paper discussed the light weight
aggregate preparation techniques, properties, and quality perspectives.
Keywords: Lightweight aggregates, Lightweight concrete, Different binding
materials, Characteristics
aracteristics of lightweight aggregates.
Cite this Article: KolimiShaiksha Vali and Bala Murugan S.S Overview of Artificial
Lightweight Aggregates-A A Review.
Review International Journal of Civil Engineering
Engine and
Technology,, 8(6), 2017, pp. 360369.
360
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 Kolimi Shaiksha Vali and Bala Murugan S

1. INTRODUCTION
Shortening and reusing wastage and by-products have turned into themain problem in the
twenty-first century. Advancement of latest systems for controlling wastage is one of the most
important fields of investigators in modern days. This is because of the requirement for
changing the materials to stay away from depleting ordinary resources that are used
sufficiently with developing people. Because of the effect of natural disasters like earthquake
pressure everywhere throughout the world, the requirement for lightweight structural design is
developing today, as it decreases the self-weight of the structure. Lightweight concrete
(LWC) moreover cuts down the total cost of the construction. Lightweight aggregates (LWA)
are normally produced from siliceous gravel or clays or pumice stone or volcanic cinders.
Ordinary aggregates are appropriated from naturally scouring gravels by splitting and
screening them into thedesired size. The utilization of natural aggregates has turnedinto
aserious problem, because of complete utilization of these materials in this expanding
infrastructure. Comparing natural aggregate with LWA, light weight aggregate density is less.
Because of its less density of LWA, it gives greater insulation and can be utilized to produce
lightweight concrete. LWA can also be formed by utilizing industrial sources like quarrying
residues, palm shell, huge metal sediment, paper sediment, pet bottles, sewage sediment, steel
slag, bottom ash, fly ash, and marine loam etc., several techniques utilized for manufacturing
synthetic aggregates from the above-mentioned resources and the effects of the aggregates
produced are also examined below. In this article, a few executions that are utilized by the
various investigators to produce LWA from waste and source have been reviewed in brief.
There are various LWA prepared profitable which are achieved through a valuable process of
manufacturing. Additionally, it reduces the general revenue for its raw constituents. The
greatest approach to escape this issue is to utilize the lightweight aggregates manufactured
from the different wastes as a raw material in concrete.
Fly ash is the misuse which makes double issues of dumping and ecological reduction,
because of its quality of effecting on air and water contamination on a huge scale. The fly ash
production, as well as utilization, has mostly been increasing since 1996-97. Fly ash usage has
increased from 9.63% in 1996-97 to the highest level of 62.6% was acquired in the year 2009-
10 and it was around 58.48 % in the year 2011-12, around 61.37% in the year 2012-13,
57.63% in the year 2013-14 and 55.69% in 2014-15. Along with the present time in the year
2015-16, use of fly ash is 56.04% which is following the specific target is being delivered in
India. Fly ash is being utilized by cement industry as a Pozzolana material in preparation of
Portland Pozzolana cement. It saves together valuable limestone and coal. 2.45 million-ton of
fly ash was utilized by cement industry in 1998-99 which increased to 43.33 million-ton
during 2014-15 and the maximum usage of fly ash to the extent of 41.97% of total fly ash
used during the 1st half of the year 2015-16. The usage of fly ash around 10-13% in
manufacturing fly ash occupying construction products with mine fills each, while it is fewer
than 5% in the development of roads & embankments, 2.15% in agriculture, 1% in concrete
preparation and 7.32% in others etc.,[Central Electricity Authority Report 2016]. In spite of
the fact that a couple of utilizations of fly ash remains, Portland-fly slag bond, mud fly ash
blocks, sand-lime blocks, and so on., have been produced, however, the mass quantity of the
ash is still unused. These fields have a huge possibility of fly ash usage which should be
investigated for growing total usage of fly ash in the country.
Fly ash, in any case, is a material that has several experimental profitable even when
utilized in its natural form [36, 37]. Fly ash is the main constituent to be used in the
preparation of artificial lightweight aggregates, in addition, to fly ash other cementitious
materials like slag, metakaolin, and silica fume were utilized in the preparation of artificial

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 Overview of Artificial Lightweight Aggregates-A Review

lightweight aggregates by palletization process. As well as in the concrete production by the

substitution of cement and fine aggregate.
The utility of lightweight aggregate in concrete has various advantages [39-41, 45]. These
consist of: (a). Minimization of self-weight that may result in decreased footings sizes and
lesser with smaller top structure. This may bring about decrement in the volume of cement
and probable lessening in reinforcement. (b) Lighter and shorter pre-cast components
requiring littler and less costly taking for transporting things. (c) Reductions in the sizes of
structural elements like abeam, column and slab measurements that outcome in more space
accessibility. (d) Great thermal insulation. (e) Increase fire protection. Besides, certain
structures, particularly seaward structures which are generally utilized for oil reproduction,
require lightweight components which can be pushed quickly and have the highest buoyancy
[38].

1.1. Artificial Aggregates

1.1.1. Chemical Composition
The chemical compositions of several of the waste resources that can be utilized as a raw
material for the manufacturing of synthetic aggregates are given in Table 1. The majority of
the resources, among all the constituent silica, are the main constituent to impart strength to
concrete and energizepozzolanic reaction by serving in the development of calcium-silicate-
hydrate (C-S-H) gel.

1.1.2. LWA Preparation

One of the general ways while manufacturing the lightweight aggregates is through
agglomeration. In this technique the pellet is produced in two ways one is by agitation
granulation and other is by compaction. The first technic is no more taking any exterior force
rather than revolving force. The development of cohesive force of the particles with an
increase in the quantity of water in the binder. After the technique of agglomeration by
pelletization as shown in figure1 and figure2 (Bijen, 1986; Gokhan Baykal and Ata Gurhan
Doven, 2000; Geetha and Ramamurthy, 2010, 2011; Cheeseman and Virdi, 2005; Mun, 2007;
Chin-Tson Liaw et al., 1998; Su-hen Huang et al., 2007), the manufactured green pellets used
to go through post-processing to achieve strength, so as to utilize as aggregate in concrete.
Various methods for hardening of manufactured aggregates which consist of, cold bonding,
sintering and autoclaving. From the above three processes, the cold bonding method is
cheaper compared to other two methods, in sintering causes various disadvantages like more
production cost, as it absorbs the utilization of energy (Gokhan Baykal and Ata Gurhan
Doven, 2000). The difference of 1% compressive strength was observed by partial
substitution of natural aggregate is 20 to 40% of the amount of artificial aggregate (Behera et
al., 2004). Hence, cold bonded technique is utilized, to avoid the sintering process and it gave
similar results (Bijen, 1986; Niyazi UgurKockal and Turan Ozturan, 2010, 2011a, 2011b).

Figure 1 Growing path of pellets (Bijen, 1986). Figure 2 Disc pelletizer machine(Bijen, 1986).

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 Kolimi Shaiksha Vali and Bala Murugan S

Table 1 Chemical Composition of Source Materials

Heavy Hydrated
Oxide Mining Marine Palm Paper Sewage Steel Bottom Silica Portland
Metal Fly ash Metakaolin lime
(%) residues clay shell sludge sludge slag ash fume cement
Sludge (Dry)
18.71- 1.21- 37.8- 85.2-
SiO2 45.8 55.3 55.2 17.87 51 54.8 51.84 22.1 <1.3
38.9 18.32 62.9 97.1
10.24- 19.9-
Al2O3 13.2 13.9 12.8 4.77 21.2 2.7-3 19 0.06 41.95 6.9 0.4-0.8
52 30.61
0.55-
Fe2O3 4.9 6.8 3.7 2.66 9 89.2 3-11.4 7.8 0.45 0.52 3 <0.3
3.27
35.4-
CaO 20.1 5.4 2.87 64.39 4.48-20 4.43 1.67-17 1.74 0.50 0.34 63 >88
40.8
8.9- 0.54-
MgO 0.9 4.3 0.85 2.28 3-3.37 2.26 0.49 - - 2.5 <0.8
11.6 2.88
SO3 - - 1.8 4.65 0.39 - - 0.27-8 0.2 - - 1.7 -
0.07- 0.05-
Na2O 2.5 1.4 0.45 - 0.35 1.32 0.76 - - - -
0.24 0.87
0.11-
K2O 1.5 1.7 1.32 0.38 0.27 3.18 - - - - - -
2.77
0.56-
P2O5 - - - 0.07 0.1 5.35 0.5 - - - - -
0.75
TiO2 - - 0.5 - 0.28 0.98 - 0.8 - - - - -
Cl - - 0.14 0.015 0.04 - 0.006 0.0124 - - - - -
47.67- 0.86-
LOI - - 20.6 1.47 - - 8.35 - 0.72 2.41 -
70.36 8.95
CaCO3 - - - - - - 10 - - - - - -
73.09-
Moisture - - - - 83.09 - - - - - - -
77.8
Carbon - - - - - - - - 5.55 - - - -
Specific 2.4-
1.11 - 2.67 1.36 2.6 1.58 2.97 2.2-2.9 2.22 2.5 3.15 2.2
gravity 2.67

As demand continued to increase, new technologies were developed to discover and apply
manufactured materials as lightweight aggregate. This has included materials such as fly ash,
colliery waste, and blast furnace slag (Shafigh et al. 2010). Due to its promising qualities, the
use of lightweight concrete and various forms of lightweight aggregate have only increased
worldwide over time. However, for the use of lightweight concrete to be economically viable
in developing countries, it is necessary to identify contextually-based materials that can be
used as lightweight aggregate.
Lightweight concrete maintains its large voids and not forming laitance layers or cement
films when placed on the wall. This research was based on the performance of aerated
lightweight concrete. However, sufficient water cement ratio is vital to produce adequate
cohesion between cement and water. Insufficient water can cause lack of cohesion between
particles, thus a loss in strength of concrete. Likewise too much water can cause the cement to
run off aggregate to form laitance layers, subsequently, weakens in strength. Therefore, this
fundamental research report is prepared to show activities and progress of the lightweight
concrete.

1.1.3. Pelletizing Process

The preferred pellet size appropriation of a synthetic aggregate is either squashed or by the
process of agglomeration. The manufacturing of artificial coarse aggregates mainly by
pelletization process, for the efficiency of the manufacturing of pellet some of the parameters
to be studied such as speed and angle of pelletizer disc, time of pelletization and moisture
content (Harikrishnan and Ramamurthy, 2006). Disc or pan type, cone, drum and mixture
type are used in the manufacturing of pellets. Among the different types of the pelletizer, disc
type gives the pellet size distribution is simple to manage than drum type. By using mixer

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 Overview of Artificial Lightweight Aggregates-A Review

type pelletizer for manufacturing of pellets initially the minute grains are produced and are
later improved in grain size through disc type pelletization as appeared in Fig 1 and Fig 2
(Bijen, 1986). The disc type pelletizer is having dimensions 570mm in diameter with side
depth as 250mm, it is set in an adjustable system with modifying the angle as 35 to 550 and to
manage the speed of revolving disc in a transverse way must differing as 35 to 55rpm as
appeared in Fig 2 (Manikandan and Ramamurthy, 2007). Yang, 1997 investigated strength of
the pellet increases when the fly ash/cement percentage as 0.2 and above in the case of the
cold bonding process. Another important factor to be considered for the preparation of
artificial aggregates is a binding agent. Bijen, 1986 studied that binding agent approximately
20 to 25% by the total mass of binders was considered as optimum range for the effective
preparation of artificial lightweight aggregates. At the beginning some proportion of water is
added to the binder and then poured in a disc, left over water is sprinkled at the time of
rotation because while revolving lacking water in the disc the fly ash residue tends to form
lumps which do not raise the division of particle size. The pellets are produced roughly in the
duration of 20min.

1.1.4. Hardening Process in LWA

After manufacturing pellets, it allows to air dry for 24hrs then hardening the pellets is carried
out by different techniques cold bonding, sintering and autoclaving. From the above
hardening process cold-bonded may be done by ordinary water curing, autoclaving and steam
curing. From the past investigations, it was concluded that autoclave and steam curing process
is less efficient to enhance the aggregate properties as a contrast to ordinary water curing.
Cold bonded aggregate results poor properties compared to sintered aggregates (Niyazi Ugur
Kockaland Turan Ozturan, 2010, 2011a, 2011b). In autoclaving process do not show more
difference in strength and durability properties compared to normal water curing method
(Manikandan and Ramamurthy, 2008). When aggregates are prepared with C-Type of fly ash
and cured in accelerated curing, it has properties nearly equal to ordinary water curing
because of packed microstructure development. The curing process plays a significant role to
increase the strength of the aggregate. Consequently, an ordinary water curing can be opted
and autoclaving can be opted for high-early strength (Manikandan and Ramamurthy, 2008). A
greater strength of the aggregate can be attained at 8 to 10h in autoclave curing method (Bekir
and Tayfun, 2007).
Sintering method can be explained as heated the cold bonded pellet at a temperature range
of 800 to 1300oC with muffle furnace, normally sintering at elevated temperatures more than
1200oC (Su-Chen Huang et al., 2007; Cheeseman and Viridi, 2005; Mun, 2007; Geetha and
Ramamurthy, 2010, 2011; Bijen, 1986, Peter Neumann et al., 1991, Gokhan Baykal et al.,
2000, Niyazi et al., 2010, Manikandan et al., 2008). Crystalline structure (CSH) may form
when mineral particles in the binder combine together which results in greater strength of the
aggregate. In this way, sintered aggregate manufacturing is more suitable during substitution
of ordinary weight aggregate to lightweight aggregate (Verma et al., 1998).A sintered
aggregate improves durability properties(Niyazi Ugur Kockal and Turan Ozturan, 2010,
2011a, 2011b).

2. REVIEW OF STATUS OF RESEARCH AND DEVELOPMENT ON

THE SUBJECT
Besides decreasing the total expenditure, this also gives an idea to use these waste materials
that create ecological issues. Various investigations are carried out in these fields from prior
1980s (Van der Wegen and Bijen, 1985). A different process is utilized for generating
variously manufactured aggregates of various sources are shown in Table 2. In the preparation

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 Kolimi Shaiksha Vali and Bala Murugan S

of artificial aggregates pelletization is the accurate method followed by curing with different
methods cold bonding, sintering and autoclaving. Among the three methods, cold bonding is
the cheapest one where as sintering and autoclaving method that orderly produces the problem
of huge energy use. Part of the investigators utilized heavy metal sediment and quarrying
residues in the preparation of artificial aggregates (Su-Chen Huang et al., 2007), marine loam
(Laursen et al., 2006), palm shell (Okpala et al., 1990; Mannan and Ganapathy, 2002; Payam
Shafigh et al., 2011), paper sludge (Chin-TsonLiaw et al., 1998; Ahmadi and Al-Khaja, 2001;
Garcia et al., 2008), pet bottles (Yun-Wang Choi et al., 2005), sewage sludge (Cheeseman and
Virdi, 2005; Mun, 2007), steel slag (Maslehuddin et al., 2003; George Wang, 2010), fly ash
(Bijen, 1986; Peter Neumann et al., 1991; Gokhan Baykal and Ata GurhanDoven, 2000;
Ramamurthy and Harikrishnan, 2006; Manikandan and Ramamurthy, 2007, 2008; Niyazi
Ugur Kockal and Turan Ozturan, 2010, 2011a, 2011b; Ioanna Kourti et al., 2010; Verma et
al., 1998), bottom ash (Geetha and Ramamurthy, 2010, 2011; Kim and Lee, 2010) Numerous
works are carried out in fly ash aggregates compared to alternative synthetic aggregates, may
be because of its possibility in huge amount and high quantity of dumping. A partial usage of
these residues is recognized universally as cement substituent material. However,
investigations are in search of large utilization of these residues because of availability in
huge volume (Peter Neumann et al., 1991; Ramamurthy and Harikrishnan, 2006; Manikandan
and Ramamurthy, 2007). Therefore, the fly ash is treated as a substituent of ordinary
aggregates in concrete. The manufacturing of synthetic aggregates from fly ash achieved
globe attention because of the decreasing resources of ordinary aggregates caused by the
increasing infrastructure improvement.

Table 2 Different methods of manufacturing and properties of Artificial Aggregates from wastes
Manufacturing of
References Source Binder Pre-Process Post-Process
aggregate pellet
[1] Fly ash Cement, polymer - Pelletized Cold bonded
Polystyrene beads
(PB) Blast furnace Raw materials Sintered at 1300oc for
[2] Cement Pelletized
slag, mixed well 1hr
Fly ash
Paper sludge and
Granulation using Oven-dried at 100-
[3] Paper sludge Cement cement mixed
pelletizer 105oc for 7days
together in mixer
[4] [6] [7] [8]
Cold bonded for
[10] [14] [25] Fly ash Cement - Pelletized
28days
[28] [35]
Sintered at >1000oc for
[5] [19] [21] Raw materials
Fly ash Cement/Lime/Clay Pelletized an hr/Autoclaved/Cold
[22] [16] mixed well
bonded
Rapid cooling and
[9] Steel slag - - -
minimal crushing
F-Type fly ash
[11] and unscreened Cement - Pelletized Cold bonded
fly ash
Sintered at rotary
[12] [18] Sewage sludge Clay/organic binder - Pelletized furnace at 1050oc-
1150oc for 10-15mins
By cutting pet bottles
and mixed with
[13] Pet bottles Steel slag (GGBS) - GGBS in mixer at -
250oC for 20sec at
30-50rpm speed
Marine clay, Heated in kiln at
[15] - - Hand rolling
industrial sludge 1200oc for 1-2min
Heavy metal Pelletized at optimum
Pulverizing and Sintered at 1050oc-
[17] sludge, mining Water, starch temperature for
mixing 1250oc for 5-25min
residues, fly ash 15min at 15rpm speed

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 Overview of Artificial Lightweight Aggregates-A Review

Sintered at 800-1100oc
[20] [24] Bottom ash Lime/Bentonite/CementPulverized Pelletized
for 30-120mins
Breaking the palm
[23] Palm shell - - Washed in water
shell
Fly ash-F,
Bentonite,NAOH Raw materials
[32] Metakaolin, Pelletized Cold bonded
(8,10,12M),Water mixed well
Slag,
[34] Fly ash, Slag Cement - Pelletized Cold bonded
Fly ash, Quarry
[30] [33] Cement - Pelletized Cold bonded
dust
Cement, Bentonite Raw materials
[31] Fly ash Pelletized Cold bonded/Sintered
mixed well
Cement, Sodium
Fly ash, GGBS, silicate and sodium Raw materials
[26] Pelletized Cold bonded
Rice husk ash hydroxide is 1.5, mixed well

Cement, Six Na2SiO3

/Noah ratios (0.5, 1.0,
1.5, 2.0, 2.5 and 3.0)
Fly ash, Raw materials
[27] were used, Pelletized Cold bonded/Sintered
mixed well
Fly ash/Alkaline
activator ratio (1.5, 2.0,
and 2.5) were used
Fly ash,Slag, Raw materials
[29] Cement, Bentonite Pelletized Cold bonded/Sintered
Metakaolin mixed well

3. CONCLUSIONS
The main purpose of this review was to raise the use of different factory-made wastes to
protect the ordinary resources and to counteract ecological interference. The future uses of
lightweight aggregate are extraordinary regarding the utilization as modern structural
elements. Different results can be tired from this review correlated with ordinary concrete.
The overall research carried by different researchers represent that the manufactured
aggregates by pelletization process can be an efficient aggregate in concrete preparation to
examine fresh, mechanical and durability properties. Sooner rather than later the reduction of
the natural aggregate can be appropriately compensated from the artificial aggregates. The
present article will likewise inspire the usage of waste got from different industries.

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