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<p>High-value utilisation of solid waste and the development of green building materials are vital for achieving carbon emission reduction and resource recycling. To overcome the high energy consumption, considerable carbon emissions, and poor performance of traditional concrete in deep mine applications, this study examined the performance regulation and optimal mix design of solid waste-based lightweight concrete using coal gangue, fly ash, ceramsite, and basalt fibre. Single-factor experiments clarified the effects of water-to-binder ratio, coal gangue content, fly ash content, basalt fibre dosage, and ceramsite volume fraction on compressive strength and thermal diffusivity. Multi-factor optimisation via response surface methodology established regression models capable of accurately predicting both properties and revealed significant main and interaction effects. For compressive strength, the influence order was: water-to-binder ratio &gt; fly ash content &gt; ceramsite volume fraction &gt; coal gangue content; for thermal diffusivity: water-to-binder ratio &gt; ceramsite volume fraction &gt; fly ash content &gt; coal gangue content. The final optimal mix proportion was a water-to-binder ratio of 0.4, coal gangue content of 18.87%, fly ash content of 19.7%, ceramsite volume content of 45%, and basalt fibre content of 0.24%. With this mix, the 28-day compressive strength of 21.25&#xa0;MPa, and the thermal diffusivity was as low as 1.86 × 10<sup>− 7</sup> m<sup>2</sup>/s, meeting the standards for both structural insulation and high-performance concrete. The results of this research provide a theoretical foundation and practical reference for the high-performance design of solid waste-based lightweight concrete and the green and safe mining of underground resources.</p>

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Study on the Performance Modulation and Optimal Mix Design of Solid Waste-based Lightweight Concrete Using Response Surface Methodology

  • 期刊论文

  • 发表日期：

    2026年3月2日

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  • Bowen Fan,
  • Ping Chang,
  • Zhijun Wan,
  • Yuan Zhang,
  • Weifan Wu

摘要

High-value utilisation of solid waste and the development of green building materials are vital for achieving carbon emission reduction and resource recycling. To overcome the high energy consumption, considerable carbon emissions, and poor performance of traditional concrete in deep mine applications, this study examined the performance regulation and optimal mix design of solid waste-based lightweight concrete using coal gangue, fly ash, ceramsite, and basalt fibre. Single-factor experiments clarified the effects of water-to-binder ratio, coal gangue content, fly ash content, basalt fibre dosage, and ceramsite volume fraction on compressive strength and thermal diffusivity. Multi-factor optimisation via response surface methodology established regression models capable of accurately predicting both properties and revealed significant main and interaction effects. For compressive strength, the influence order was: water-to-binder ratio > fly ash content > ceramsite volume fraction > coal gangue content; for thermal diffusivity: water-to-binder ratio > ceramsite volume fraction > fly ash content > coal gangue content. The final optimal mix proportion was a water-to-binder ratio of 0.4, coal gangue content of 18.87%, fly ash content of 19.7%, ceramsite volume content of 45%, and basalt fibre content of 0.24%. With this mix, the 28-day compressive strength of 21.25 MPa, and the thermal diffusivity was as low as 1.86 × 10− 7 m2/s, meeting the standards for both structural insulation and high-performance concrete. The results of this research provide a theoretical foundation and practical reference for the high-performance design of solid waste-based lightweight concrete and the green and safe mining of underground resources.