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<p>The article presents a method for producing high-strength artificial aggregates for structural concrete, developed in accordance with the principles of the circular economy. The aggregates were manufactured using dredged sediments, municipal solid waste incineration residues, as well as fine fractions of construction and demolition waste obtained from ceiling milling. The waste mixtures were subjected to alkali activation and subsequently sintered at temperatures of 1000–1050&#xa0;°C. Increasing the sintering temperature to 1050&#xa0;°C promoted the crystallization of albite and wollastonite, which resulted in an increase in aggregate crushing strength from 2.6 to 9&#xa0;MPa and a 27% reduction in total water absorption. The concrete produced with the developed aggregate (AAC) exhibited an apparent density of 1.99&#xa0;g/cm³, water absorption of 6.1%, and compressive strength of 38&#xa0;MPa. Compared to the reference concrete made with lightweight expanded clay aggregate, an increase in density and strength of 17% and 41%, respectively, was observed, along with a 32% reduction in water absorption. Microstructural analyses (SEM, µCT) revealed a more compact structure and a denser interfacial transition zone in AAC, explaining its improved durability and enhanced frost resistance. The life cycle assessment results confirmed a 41% reduction in total environmental impact and a 12% decrease in CO<sub>2</sub> emissions in wall applications. The developed waste-based artificial aggregates constitute a sustainable alternative to conventional materials, supporting decarbonization and the advancement of circular economy practices in construction.</p> Graphical abstract <p></p>

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High-strength artificial aggregates for structural concrete: a study of physical-mechanical properties, itz morphology, frost resistance and environmental impact

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年6月15日

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  • Małgorzata Franus,
  • Danuta Barnat-Hunek,
  • Małgorzata Grzegorczyk-Frańczak,
  • Rafał Panek,
  • Katarzyna Kalinowska-Wichrowska,
  • Adam Masłoń,
  • Agnieszka Żelazna,
  • Martyna Janek

摘要

The article presents a method for producing high-strength artificial aggregates for structural concrete, developed in accordance with the principles of the circular economy. The aggregates were manufactured using dredged sediments, municipal solid waste incineration residues, as well as fine fractions of construction and demolition waste obtained from ceiling milling. The waste mixtures were subjected to alkali activation and subsequently sintered at temperatures of 1000–1050 °C. Increasing the sintering temperature to 1050 °C promoted the crystallization of albite and wollastonite, which resulted in an increase in aggregate crushing strength from 2.6 to 9 MPa and a 27% reduction in total water absorption. The concrete produced with the developed aggregate (AAC) exhibited an apparent density of 1.99 g/cm³, water absorption of 6.1%, and compressive strength of 38 MPa. Compared to the reference concrete made with lightweight expanded clay aggregate, an increase in density and strength of 17% and 41%, respectively, was observed, along with a 32% reduction in water absorption. Microstructural analyses (SEM, µCT) revealed a more compact structure and a denser interfacial transition zone in AAC, explaining its improved durability and enhanced frost resistance. The life cycle assessment results confirmed a 41% reduction in total environmental impact and a 12% decrease in CO2 emissions in wall applications. The developed waste-based artificial aggregates constitute a sustainable alternative to conventional materials, supporting decarbonization and the advancement of circular economy practices in construction.

Graphical abstract