Interfacial Characteristics of a Fly Ash-Based Artificial Aggregate

A fly ash-based artificial aggregate with a compressive strength of >60 MPa was prepared via cement activation and alkali activation using >75% fly ash as the principal raw material. The mechanical properties of concrete prepared using this aggregate and the characteristics of the interfacial transition zone (ITZ) were compared with those of concrete containing natural aggregate. The results indicated that the compressive strength of concrete prepared using artificial aggregate was lower than that of concrete prepared using natural aggregate by about 19.0–27.6%. Scanning electron microscopy (SEM) revealed that the cement paste bonded tightly to the surface of the natural aggregate; the width of ITZ was 20–30 µm. The ITZ between the cement paste and the fly ash-based artificial aggregate exhibited a relatively loose structure at 28 d, with a width of 30–40 µm; however, the ITZ became narrower and denser at 90 d. EDS indicated that the principal hydration products were calcite crystals and C-S-H gel in the ITZ of natural aggregate concrete and artificial aggregate concrete. According to nanoindentation tests, for both cement pastes with natural and artificial aggregates, the elastic modulus of the ITZ at 28 d was >10 GPa, and it increased slightly at 90 d. The ITZ between the alkali-activated paste and limestone exhibited a relatively dense structure, with a width of 20–30 µm. The ITZ between the alkali-activated paste and the fly ash-based artificial aggregate exhibited a relatively loose structure with numerous pores at 28 d and had a width of 30–40 µm; however, the ITZ became narrower and denser at 90 d. The principal hydration products were N-A-S-H and C-A-S-H in the two kinds of aggregate concrete. Whether the alkali-activated paste contained natural aggregate or artificial aggregate, the elastic modulus of the ITZ at 28 d was 5–6 GPa, and it increased rapidly to >10 GPa by 90 d. The performance of ITZ is primarily influenced by the matrix materials, while also being influenced by aggregates and curing conditions. Qualitative and quantitative analyses revealed the formation mechanisms of artificial and natural aggregates in different matrices. Through continuous hydration and polymerization reactions, artificial aggregates gradually form narrower and denser interfacial transition zones with different matrices, especially in alkali-activated matrices. The continuously improved performance of the ITZ makes it less prone to forming cracks between the ITZ and the artificial aggregate. This study provides an important theoretical basis for the application of fly ash-based artificial aggregates, which can also be used to produce high-strength concrete.