Title:
Carbonated Fly Ash Alkali-Activated Aggregates: Properties, Performance, and Environmental Impact
Author(s):
Mohd Hanifa, Usha Sharma, P. C. Thapliyal, and L. P. Singh
Publication:
Materials Journal
Volume:
122
Issue:
4
Appears on pages(s):
99-110
Keywords:
alkali activation; autoclave; carbonated aggregate; CO2 emissions
DOI:
10.14359/51746810
Date:
7/1/2025
Abstract:
The production of carbonated aggregates from Class F fly ash(FA) is challenging due to its low calcium content, typically lessthan 10%. This study investigates the production of carbonatedalkali-activated aggregates using FA and calcium carbide sludge(CCS). Sodium hydroxide was used as an activator, and the effectsof autoclave treatment on the properties of these aggregates wereexamined. The optimal mixture, comprising 70% FA and 30%CCS, achieved a single aggregate strength of >5 MPa in autoclavecarbonated (AC) aggregates, comparable to the strength obtainedafter 14 days of water curing without-autoclave carbonated(WAC) aggregates. Both AC and WAC aggregates exhibited a bulkdensity of 790 to 805 kg/m3, and the CO2 uptake was 12.5% and13.3% in AC and WAC aggregates, respectively. Field-emissionscanning electron microscopy (FE-SEM) and Fourier-transforminfrared spectroscopy (FTIR) analysis indicated the formation ofcalcium-aluminum-silicate-hydrate (C-A-S-H) gel in non-carbonatedaggregates, while calcite and vaterite, along with sodiumaluminum-silicate-hydrate (N-A-S-H) gel, formed in carbonatedaggregates. Concrete incorporating AC and WAC aggregatesexhibited compressive strength of 39 and 38 MPa, with concretedensity of 2065 kg/m3 and 2085 kg/m3, respectively. Furthermore,AC and WAC aggregate concrete showed a reduction in CO2emissions of 18% and 31%, respectively, compared to autoclavenon-carbonated (ANC) aggregate concrete. These findings highlightthe potential of producing carbonated alkali-activated aggregatesfrom FA and CCS as sustainable materials for constructionapplications.