Behaviour of sewage sludge based lightweight aggregate in geopolymer concrete

Abstract

Abstract The global challenge of sewage sludge disposal has encouraged innovative solutions aimed at reducing environmental impact while simultaneously addressing the growing demand for sustainable construction materials. This study aimed to develop treated raw sewage sludge-based lightweight aggregates with strength comparable to commercially available aggregates. Two methods, namely cold bonding and sintering, were employed for the formation of aggregates. The sintering method produced well-formed and hard aggregates, while the cold bonded aggregates exhibited weakness and disintegrated under the slightest pressure. The optimal mix for quality aggregates was found to be 10%–20% sewage sludge, 70%–80% fly ash, and 10% lime using the sintering method. In the sintering method, an increase in sewage sludge content resulted in the reduction of bulk density and specific gravity by 13% and 4% respectively due to the high organic content in sewage sludge, volatile gas release, and porous structure formation. When 10% to 20% sewage sludge content was added, water absorption of the aggregates also increased by approximately 2%. Physical properties such as individual pellet strength. aggregate crushing value reduced by 18%, 20% respectively and the aggregate impact value increased by about 9%. These aggregates were then used to produce lightweight geopolymer concrete, which exceeded the design strength by 7% for the aggregate containing 20% sewage sludge and demonstrated excellent physical properties. The use of waste-based aggregates offers advantages including savings in cost, sustainability, resource conservation, waste reduction, and reduced environmental impact, making them a valuable alternative to natural crushed stone aggregates in specific applications.