Development of sintered artificial coarse aggregate by employing the Taguchi optimization technique

The construction industry necessitates the creation of new materials due to the scarcity of conventional aggregates and the abundance of industrial byproducts. This study investigates the production of sintered artificial coarse aggregate (SACA) employing the Taguchi optimization technique. Red mud (RM) is the main component, supplemented by fly ash (FA) and waste glass powder (WGP). The experimental design included four variables: RM content, FA content, WGP content, and sintering temperature, each examined at four separate levels. The effectiveness of the produced SACA was assessed by measuring compressive strength, water absorption, and density. Microstructural and compositional characterization was performed using Scanning Electron Microscopy (SEM), X-ray Diffraction (XRD), and Energy Dispersive X-ray Analysis (EDAX). Taguchi analysis identified an ideal composition, labeled T4, which prioritized compressive strength and maximized RM usage. The T4 mixture displayed a compressive strength of 23.79 MPa, a water absorption rate of 1.29%, and a density of 1334.58 kg/m³, while incorporating 79% RM. Moreover, an Analysis of Variance (ANOVA) was performed to ascertain the relative importance of each variable on the measured outcomes.