In Brazil, artificial lightweight aggregates (LWAs) are predominantly produced in the Southeast Region using clay as the primary raw material. However, clay extraction has significant environmental impacts and limits access to LWAs in the North and Northeast regions, resulting in high costs and hindering sustainable construction solutions. This study addresses these challenges by developing sustainable LWAs in the Northeast Region using raw materials from the metropolitan area of João Pessoa, Paraíba, namely chamotte (CHT), which is rich in aluminosilicates, and eucalyptus firewood ash (EFA), which is rich in carbonates, combined with kaolinitic clay (KC). Sixty-four binary mixtures were produced, demonstrating diverse properties in density, water absorption, and compressive strength. EFA-rich mixtures achieved the highest expansion (80%) and lowest density (1.20 g/cm³), while CHT-rich mixtures provided superior strength (>10 MPa) and deformation (>20 GPa). These properties highlight their suitability for diverse applications, from structural uses to landscaping, enhanced by distinct color variations. Statistical optimization identified the residue content and sintering temperature as key factors, confirming the technical viability of incorporating up to 80% industrial waste into sustainable LWA production. Therefore, the results confirm the technical feasibility of producing LWAs using CHT and EFA in the metropolitan region of João Pessoa/Paraíba, achieving properties comparable to commercial LWAs. By incorporating up to 80% industrial waste, this study reduces dependence on non-renewable resources, decreases CO₂ emissions and transportation costs, and promotes sustainable practices. The findings offer a scalable, eco-friendly solution to resource-limited regions’ material scarcity.

The growing demand for lightweight aggregates (LWAs) in the construction industry is driving the development of sustainable alternatives based on the reuse of solid industrial waste. The aim of this study was to assess the technical feasibility of using red ceramic waste (RCW) as a partial or total substitute for red clay (RC) to produce lightweight expandable aggregates. Six formulations were made with different proportions of RCW and RC and sintered at four temperatures (1100, 1150, 1200 and 1250 °C). They were characterised using physical, thermal, morphological, chemical and mechanical analyses, according to standard protocols. The results showed that almost all the formulations sintered at 1200 and 1250 °C had a positive bloating index (BI > 0), particle density of less than 2.0 g/cm³, low water absorption of less than 2% and mechanical strength of more than 5.4 MPa, revealing strong potential for use in lightweight structural and non-structural concrete. The main conclusion is that RCW, even used in isolation, has physicochemical and mineralogical properties suitable for the production of lightweight aggregates under optimised thermal conditions, contributing to the development of sustainable materials with a competitive technical performance compared to commercial LWAs.

Lightweight artificial aggregates (LWAs) are widely used in civil construction, but their conventional production depends on pure clays, a finite natural resource that negatively impacts the environment. This study aims to contribute to minimizing this issue by exploring the use of sustainable ternary mixtures of kaolinitic clay (KC), chamotte residues (CHT), and eucalyptus firewood ash (EFA), promoting a more environmentally friendly approach to the manufacture of LWAs. Thus, the aim was to develop and optimize LWAs using different replacements of industrial waste. Furthermore, the Taguchi method is employed to identify the optimal manufacturing parameters, such as waste content, sintering temperature, and heating time. The research involved the production of 32 distinct mixtures with different proportions of KC, CHT, and EFA, processed through grinding and sintering at temperatures ranging from 1075 °C to 1180 °C. The samples were evaluated for density, water absorption, mechanical strength, and expansion index. Statistical analysis was conducted using ANOVA to validate the most significant factors. The results revealed that mixtures with 80% of waste presented an aggregate expansion index of up to 60%, a minimum bulk density of 1.20 g/cm³ (which aligns with requirements for structural applications but exceeds the maximum bulk density for some lightweight aggregates), and crushing strength higher than 5 MPa, satisfying the normative criteria for commercial LWAs. In addition, 63 industrial applications were identified for the developed materials, ranging from structural lightweight concretes to thermal and acoustic insulation with varied microstructures. Therefore, the partial replacement of clay by CHT and EFA waste represents a promising alternative for producing sustainable LWAs, helping to reduce environmental impacts while providing quality materials for various applications in the most diverse industrial sectors.

RESUMO O lodo de esgoto é o principal subproduto proveniente do tratamento de efluentes residuais. Sua produção é crescente em todo o mundo. Paralelamente, órgãos ambientais vêm restringindo vários métodos de deposição deste resíduo, exigindo cada vez mais a criação de práticas sustentáveis. Nesse contexto, a construção civil destaca-se como um parceiro em potencial. Diversos estudos empregaram o lodo de esgoto no desenvolvimento de novos materiais de construção, dentre os quais destaca-se o agregado leve (LWA). Assim, este estudo avaliou, a partir de uma revisão sistemática da literatura, o potencial de aplicação do lodo de esgoto no processo de fabricação de agregados leves. Dados importantes como: composição química; densidade; granulometria; resistência mecânica; absorção; temperatura de sinterização; aplicação em concretos e lixiviação, foram analisados e comparados as diretrizes internacionais e/ou a agregados comerciais. Os resultados são encorajadores, pois em todos os quesitos avaliados os agregados produzidos com lodo de esgoto atenderam aos padrões internacionais e/ou apresentaram resultados semelhantes aos de agregados comerciais. Demonstrou-se, portanto, que o lodo de esgoto possui viabilidade técnica para fabricação de LWA’s, confirmando a potencialidade da gestão sustentável deste resíduo.