Mechanical and Microstructural Analysis of Lightweight Subgrade Bricks Synthesized from Mixtures of Coal Fly Ash and Sewage Sludge

Abstract

Abstract The massive discharge of coal fly ash and sewage sludge has placed great pressure on the environment and society. This study proposes a feasible method for producing lightweight subgrade bricks from coal fly ash and sewage sludge. The results show that the lightweight subgrade bricks mainly consist of mullite (3Al2O3·2SiO2), hematite (Fe2O3), sillimanite (Al2SiO5), aluminum phosphate (AlPO4), and a small amount of cristobalite (SiO2). The formation of AlPO4 improved the sintering and mechanical properties of the sintered samples. The formation of voids and cracks in the sintered samples was primarily attributable to the combustion and sintering shrinkage of the organic matter in the mixture. The maximum compressive and flexural strengths were observed when the sewage sludge content was 40 wt. %, and the corresponding compressive strength and flexural strength were 19.86 and 8.57 MPa, respectively. An appropriate amount of sewage sludge improves the connections between coal fly ash particles and promotes the densification of the lightweight subgrade bricks. These results provide a direction for the development of applications for coal fly ash and sewage sludge in the field of building materials.