Valorisation of water treatment sludge for lightweight aggregate production

Water treatment sludge is an industrial by-product which has recently been classified as a waste by the European Commission. The main goal of this work is to valorise this waste to produce lightweight aggregates. Formulations with sludge substituting expanded clay up to 50 wt% were produced. The physical properties of the lightweight aggregates such as bloating index, density and porosity were studied. The introduction of the sludge without expanding properties, reduced the expandability of the clay and the porosity of the aggregates. The density increased from 0.32 g/cm(3) in aggregates without sludge to 1.46 g/cm(3) in aggregates with 50 wt% of sludge. It is shown that lightweight aggregates can be produced using mixtures of expanded clay and water treatment sludge, with low substitution percentages (up to 15 wt% of sludge). Aggregates up to 15 wt% of sludge were further studied. The compressive strength increased with sludge wt.%, and the concentrations of heavy metals and metalloids, assessed through leaching tests, were well below the stablished limits. Two preliminary tests of lightweight aggregate concrete were produced: LWAC 1 was formulated with commercial lightweight aggregates and LWAC 2 with aggregates containing 7 wt% of the sludge and commercial lightweight aggregates. The physical, mechanical and thermal properties of LWAC 1 and LWAC 2 were found to be very similar. Our work demonstrates the feasibility in using water treatment sludge as a by-product to produce lightweight aggregates suitable for thermal insulation and lightweight applications. (C) 2020 Elsevier Ltd. All rights reserved.