Multi-Scale Investigation of Fly Ash Aggregates (FAAs) in Concrete: From Macroscopic Physical-Mechanical Properties to Microscopic Structure of Hydration Products.

Fly ash aggregates (FAAs) were synthesized via a hydrothermal process, involving the reaction of fly ash and cement at 180 °C under saturated steam conditions. A thorough examination was carried out to evaluate the impact of cement content on the physico-mechanical properties of the resulting FAAs. A comprehensive exploration was undertaken to decipher the mechanisms by which cement modulates the cylinder compressive strength of FAAs, encompassing mineralogical composition, microstructure, insoluble residue content, and loss on ignition. As the cement proportion increased, a concomitant rise in the amount of hydration products was observed, leading to an enhanced filling effect. This, subsequently, resulted in reduced water absorption and increased apparent density of the FAAs. The augmented filling effect of hydration products contributed to a gradual elevation in the cylinder compressive strength of FAAs as cement content escalated from 5 to 35 wt%. However, a significant transition occurred when cement content surpassed 35%, reaching 35-45 wt%. Within this range, the micro-aggregate effect was diminished, causing a decrease in cylinder compressive strength. The optimal equilibrium between the filling effect and micro-aggregate effect was attained at 35 wt% cement content, where the cylinder compressive strength of FAAs reached its peak value of 18.5 MPa. This research is expected to provide a feasible approach for solid waste reduction, with a particular emphasis on the utilization of fly ash.