Manufacturing of lightweight aggregates with carbon fiber and mineral wastes

The use of carbon fiber wastes (FC) as a component to manufacture lightweight aggregates (LWAs) for concrete has been studied. Amounts of 0, 2.5, 5 and 10% (w/w) of powdered FC were added into a mineral matrix composed by 90% of granite-marble sludge (COR) plus 10% of sepiolite rejection (SEP). The mixtures were milled, kneaded with water, extruded, shaped into pellets, oven-dried and finally fired at 1100, 1125 and 1150 °C for 4, 8 and 16 min in a rotary kiln. The main technological properties of the sintered aggregates were measured. The addition of FC promoted bloating and the formation of an internal structure in which both pores and unburnt carbon fibers were present. Improvements in lightness and mechanical properties were also observed. This is the first time that carbon fibers have been embedded within aggregates, opening the way to the development of a new type of LWAs for concrete.