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<p>The production of Lightweight Expanded Clay Aggregate (LECA) is a very energy-consuming process as well as depletes natural resources. Therefore, there is a need for alternative lightweight aggregates with lesser impact on the environment. This study intends to examine the possibility of using Expanded Shale (ES) instead of LECA in concrete. ES was produced via a thermal treatment process, and concrete mixtures containing ES were compared to LECA concrete in terms of mechanical performance. The methodology included compressive, tensile, and flexural strength tests, as well as petrographic analysis for alkali-silica reaction (ASR) assessment. Quantitative results showed that ES concrete achieved 28-day compressive, tensile, and flexural strengths of 19.1 MPa, 2.62 MPa, and 3 MPa, respectively, compared to 13.9 MPa, 1.64 MPa, and 2 MPa for LECA concrete. However, petrographic examination revealed ASR gel formation around volcanic aggregates in ES concrete, indicating that ASR potential requires further mitigation rather than being negligible. ES exhibits superior mechanical properties compared to LECA; however, requires life-cycle assessment and quantification of carbon footprint to qualify as a sustainable alternative. The findings suggest that ES is a promising high-performance lightweight aggregate, provided that ASR risks are addressed through mix optimization or supplementary materials.</p>

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Mechanical and sustainability assessment of expanded shale as an alternative to lightweight expanded clay aggregate in concrete production

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Mehdi Torabi-Kaveh,
  • Zeynab Esmaeili,
  • Enayatollah Emami Meybodi,
  • Reza Morshed

摘要

The production of Lightweight Expanded Clay Aggregate (LECA) is a very energy-consuming process as well as depletes natural resources. Therefore, there is a need for alternative lightweight aggregates with lesser impact on the environment. This study intends to examine the possibility of using Expanded Shale (ES) instead of LECA in concrete. ES was produced via a thermal treatment process, and concrete mixtures containing ES were compared to LECA concrete in terms of mechanical performance. The methodology included compressive, tensile, and flexural strength tests, as well as petrographic analysis for alkali-silica reaction (ASR) assessment. Quantitative results showed that ES concrete achieved 28-day compressive, tensile, and flexural strengths of 19.1 MPa, 2.62 MPa, and 3 MPa, respectively, compared to 13.9 MPa, 1.64 MPa, and 2 MPa for LECA concrete. However, petrographic examination revealed ASR gel formation around volcanic aggregates in ES concrete, indicating that ASR potential requires further mitigation rather than being negligible. ES exhibits superior mechanical properties compared to LECA; however, requires life-cycle assessment and quantification of carbon footprint to qualify as a sustainable alternative. The findings suggest that ES is a promising high-performance lightweight aggregate, provided that ASR risks are addressed through mix optimization or supplementary materials.