Effect of Quicklime Substitution for Cement on the Physical and Mechanical Properties of Autoclaved Fly Ash Aggregates via Hydrothermal Synthesis

Herein, we synthesized fly ash aggregates (FAAs) through a hydrothermal synthesis process utilizing fly ash, quicklime, and cement under saturated steam conditions at 180 °C. We systematically investigated the influence and mechanisms governing the physical and mechanical properties of autoclaved FAAs by incrementally replacing cement with quicklime in 5% equal mass intervals. Our results revealed that the substitution of cement with quicklime yielded lightweight aggregates (LWAs) exhibiting water absorption ranging from 1.33% to 22.88% after 1 h and 1.67% to 26.22% after 24 h, loose bulk densities between 847 kg/m³ and 1043 kg/m³, apparent densities spanning from 1484 kg/m³ to 1880 kg/m³, and cylinder compressive strengths varying from 11.9 MPa to 18.5 MPa. Notably, as the proportion of quicklime substitution for cement increased, there was a corresponding augmentation in water consumption during granulation, resulting in an elevated water-cement ratio ranging from 27.5% to 51.39%. This led to an enhancement in the water absorption of the FAAs, accompanied by a decrement in cylinder compressive strength and overall density. The hydration products, including tobermorite and calcium silicate hydrate, contributed to the creation of a dense microstructure within the FAAs. However, with higher quantities of quicklime replacing cement, the content of hydration products increased while the proportion of unreacted fly ash particles decreased significantly. The resultant weakening micro-aggregate effect emerged as a pivotal factor contributing to the observed decrement in the strength of these FAAs. The findings of this research are anticipated to provide significant theoretical insights and technical support for the selection of calcareous materials in the resource-recycling process of fly ash.