Mechanical Properties of Fly Ash Ceramsite Concrete Produced in a Single-Cylinder Rotary Kiln

Fly ash, as the main solid waste of coal-fired power plants, is an environmental problem that needs to be solved due to its massive accumulation. The mechanical properties and optimization mechanism of lightweight aggregate concrete prepared by using new single-cylinder rotary kiln fly ash ceramic granules as aggregate were systematically investigated. Through orthogonal experimental design, combined with macro-mechanical testing and microscopic characterization techniques, the effects of cement admixture and ceramic granule admixture on the properties of concrete, such as compressive strength, split tensile strength, and modulus of elasticity, were analyzed, and the optimization scheme of key parameters was proposed. The results show that the new single rotary kiln fly ash ceramic particles significantly improve the mechanical properties of concrete by optimizing the porosity (water absorption ≤ 5%), and its 28-day compressive strength reaches 46~50.9 MPa, which is 53.3~69.7% higher than that of the ordinary ceramic concrete, and the apparent density is ≤1900 kg/m3, showing lightweight and high-strength characteristics. X-ray diffraction (XRD) analysis shows that the new ceramic grains form a more uniform, dense structure through the synergistic effect of internal mullite crystals and dense glass phase; computed tomography (CT) scanning shows that the total volume rate of cracks of the new ceramic concrete was reduced by up to 63.8% compared with that of ordinary ceramic concrete. This study provides technical support for the utilization of fly ash resources, and the prepared vitrified concrete meets the demand of green building while reducing structural deadweight (20~30%), which has significant environmental and economic benefits.