J. Aust. Ceram. Soc.

44 [1] (2008) 23-30 23

A Preliminary Research On The Properties of Lightweight Expanded Clay

Aggregate
O. ARIOZ1*, K.KILINC1, B. KARASU2, G. KAYA2, G. ARSLAN1, M. TUNCAN1,
A. TUNCAN1, M. KORKUT1 and S. KIVRAK1
1
Anadolu University, Faculty of Engineering and Architecture, Department of Civil Engineering,
Iki Eylul Campus, 26555 Eskisehir, Turkey.
2
Anadolu University, Faculty of Engineering and Architecture, Department of Material Science and
Engineering, Iki Eylul Campus, 26555 Eskisehir, Turkey.
*email: oarioz@anadolu.edu.tr

ABSTRACT
In the present study, lightweight expanded clay aggregates were produced from clay, waste brick powders, albite
floatation waste, and coal at various temperatures ranged from 900 °C to 1250 °C. After the production, the
physical and microstructural properties of the aggregates were determined. The effect of clay type, treatment
(firing) temperature, amount and type of a pore forming agent on the water absorption, specific gravity, pore
structure, and surface texture of the expanded granules were examined. Test results showed that lightweight
aggregates with almost 0 % water absorption can be produced from clay by utilising albite floatation waste as a
pore forming agent. The effects of type of raw material and treatment temperature on the properties of the
aggregates were found to be significant. This was proved by microstructure and surface properties obtained by
means of optical microscope. The results also revealed that the waste brick powders can also be used in the
production of lightweight expanded granules. However, the specific gravity and water absorption values of the
aggregates produced from clay were found to be generally lower than those produced from brick powders.

KEYWORDS: Lightweight aggregate, clay, heat treatment, albite floatation waste utilisation, microstructure

INTRODUCTION
The use of lightweight aggregate (LWA) in
construction industry will increase in near future
since it offers functional and economical
advantages to the house building projects
particularly. The voids and pores in these
aggregates improve the thermal and acoustical
insulating properties [1]. Moreover, low density
products reduce self weight, foundation size, and
construction costs [2]. There are different types of
LWA suitable for construction purposes. They vary
in their composition, density, surface texture,
porosity and water absorption capacity [3]. Some
LWAs occur naturally; others are manufactured
from natural materials or from industrial by-
products. Because they are found only in some
parts of the world, natural LWAs are not
extensively used [4]. Furthermore, the physical and
microstructural properties of artificial LWAs can be
perfectly controlled since they are produced by
some treatments. The most widely used artificial
LWAs are expanded clay, expanded glass, perlite,
expanded vermiculite and sintered ash [3]. The
production of lightweight expanded clay aggregate
(LECA) becomes more popular since the raw
material is clay which is abundant all over the
world. LECA is named as Brazilian lightweight
aggregate [5] and Azerit [6] in Brazil and
Azerbaijan, respectively.
The production and use of LECA is not wide in
Turkey partly because the natural lightweight
aggregate sources are available and partly because
the use of lightweight structural elements in
constructions is not common. Expanded clay is
produced by firing natural clay, which swells at
1000-1200 °C due to the action of the gases
generated inside the mass [3, 7]. The lightweight of
this product is largely attributed to a relatively high
proportion of semi-closed pores which can account
for up to 90 % of the particle volume. LECAs are
typically manufactured from bloating clays which,
upon firing, expand or bloat into a frothy mass with
a high proportion of semi-closed pores. The porous
structure of loose expanded clay granulates is
composite and formed by the voids between
individual grains and by the air-filled opening in the
grain base [8].
The expansion occurring in the ceramic body is
caused by steam and gases, forming at different
temperatures, which for various reasons are unable
to escape from the body. This can be achieved by
organic components of the clay, water vapour, and
steam developments [9]. The admixture of
expanded glass granules is one of the most widely
used agents in pore-forming process of expanded
clay material. Pore-forming by means of expanded
glass granules can be combined with the admixture
of combustible additives. This is generally applied
due to the economic reasons in order to limit the
production costs. They may reduce the production
costs of LECA [10]. On the other hand, the use of
combustible pore-forming agents can cause the
emission of harmful gases and increase in costs
24 O. Arioz, K. Kilinci, B. Karasu, G. Kaya, G. Arslan, M. Tuncan, A. Tuncan,
M. Korkut, S. Kivrak

related to utilisation of technical plants for the
processing and dosing of the pore-forming agents,
suction extraction units for gases, costs for the
pore-forming agents [11]. Furthermore, as a
consequence of burning out pore-forming agents,
the local temperature in clay body often increases
leading to a decrease in the pores with small
volume that precisely represents the essential factor
for improving the thermal insulation [11]. In this
experimental investigation, albite floatation waste
was used as a pore-forming agent and different
LECA granules were produced from two different
clays at different firing temperatures ranged
between 900 to 1250 °C. The effects of clay
properties, amount of pore-forming agent, and level
of firing temperature on the physical and
microstructural properties of LECA granules were
examined.
RESEARCH SIGNIFICANCE
The production of artificial lightweight aggregates
(LWA) becomes popular due to the scarcity of
natural sources. Among artificial LWA, the
lightweight expanded clay aggregate (LECA) is
more important since it is manufactured from a
widely available material, clay. On the other hand,
the properties of final product depend largely on the
type of clay, the type and amount of pore-forming
agents, and the firing temperature during heat
treatment. The main objectives of this experimental
study is to examine the effects of the albite
floatation waste usage as a pore-forming agent on
the physical and microstructural properties of
LECA produced from different clays at different
firing temperatures.
EXPERIMENTAL STUDY
Materials
In the current study, lightweight expanded clay
aggregates (LECA) were produced from two types
of clays having different chemical compositions.
One type was obtained from a pottery production
industry (CLAY-A) and the second one from waste
brick powder (CLAY-B). The chemical
compositions of the clays are given in Table 1.

Table 1: Chemical compositions of raw materials

Type of Clay SiO2 Al2O3 Fe2O3 CaO MgO TiO2 Na2O K2O
CLAY-A 58.0 27.0 1.0 0.2 0.4 1.3 0.3 2.3
CLAY-B 51.8 15.6 13.0 9.3 6.1 1.7 1.2 1.3

Albite floatation waste, which is obtained from ore
preparation process of albite especially at the stage
of quartz floatation, was also used as a pore-
forming agent. Its chemical composition is given in
Table 2 [12]. It is clear from the chemical analysis
that this waste consists of high amounts of fluxing
oxides such as CaO, Na2O, and P2O5. X-ray
diffraction (XRD) analysis can be seen in Fig. 1
which indicates that this floatation waste was
composed of albite, rutile, and hydroxyl apatite
phases [12].

Table 2: Chemical composition of albite floatation waste [12]

SiO2 Al2O3 Fe2O3 CaO MgO TiO2 Na2O K2O P2O5 L.O.I
34.7 10.3 0.40 11.0 22.2 0.20 5.20 0.20 15.1 0.70
*LOI: losses on ignition.

A: Albite
R: Rutile
Ha: Hydroxyapatite

Fig. 1: XRD pattern of albite floatation waste [12]

 J. Aust. Ceram. Soc. 44 [1] (2008) 23-30 25

Preparation of the samples
CLAY-A and CLAY-B were mixed with albite
floatation waste in different ratios ranging from 10
to 40 % and a plastic mud was prepared. In one of
the mixtures, coal was used as a pore forming
agent. The raw material was first ground in a ring
mill and then mixed homogenously in a ball mill.
The prepared mud was dried in porous stone in
order to achieve proper plasticity. Finally, the mud
was rounded by shaping operation. After
preparation, the rounded mud aggregates were first
dried in an oven for 24 hours at 67 °C and then, the
products are treated for 10 minutes in different
firing temperatures ranging from 900 to 1250 °C in
an electrically heated furnace. The rate of
temperature increase in furnace was kept constant
as 10 °C/min. Totally 38 different recipes were
prepared and tested in the present study. The
mixtures and corresponding firing temperatures are
presented in Table 3.

Table 3: Mixtures and firing temperatures of aggregates

Amount of Firing Temperature (°C)

Type of Type of Pore-
Pore-forming
Clay forming Agent 900 1000 1100 1125 1150 1200 1250
Agent (%)
10 + + + +
Albite 20 + + +
CLAY-A Floatation
Waste 30 + + + +
40 + + +
10 + + + + +
Albite 20 + + Melt
Floatation
Waste 30 + + + + Melt
CLAY-B
40 + + Melt
5 + + + Melt
Coal
7,5 + + + Melt
+: performed
Melt: aggregates melted during heat treatment.

The produced LECA granules were illustrated in black aggregates were produced from CLAY-A,
Fig. 2. The diameter of the aggregates was ranged CLAY-B, and CLAY-B with coal, respectively.
between 3 and 8 mm. The light coloured, red, and

constant weight at 105 °C and weighed. Then, they

are boiled for 5 hours and immersed in water for 24
hours and then, their surfaces are dried. The water
absorption values are calculated according to
following Eqn 1;

Wssd − Wdry
WA,% = x100 (1)
Wdry

Where, WA is the water absorption of the aggregate

in percent, Wssd is the weight of the aggregate in
saturated-surface-dry state, and Wdry is the weight
of the oven-dry aggregate.

In specific gravity test, the mass of the aggregate

Fig. 2: Produced LECA granules sample is determined in air and water. Then, the
specific gravity of the aggregate is calculated by
Tests applied to the produced aggregates using the Eqn 2 below;
After production, water absorption and specific
gravity tests were conducted on aggregate samples.
In this experiment, the aggregates are dried to a
26 O. Arioz, K. Kilinci, B. Karasu, G. Kaya, G. Arslan, M. Tuncan, A. Tuncan,
M. Korkut, S. Kivrak

Wd 5. According to the test results, the water absorption

SG = (2)
Ww − Ws
Where, SG is the bulk specific gravity of the
aggregate, Wd is the weight of the dry sample, Ww
is the weight of the saturated-surface-dry test
sample in air, and Ws is the weight of saturated test
sample in water.
Microstructures of the lightweight aggregates
produced at different temperatures were observed
by an optical microscope.
RESULTS AND DISCUSSIONS
The water absorption properties of LECA granules
produced in the present study are shown in Figs. 3-
values of the aggregates produced from CLAY-A
reduced with increase in firing temperature. The
lowest water absorption value, 0 %, was measured
on aggregates produced at 1250 °C. It seems that
this level of temperature makes a compact and
homogenous outer glassy film on the surface of the
aggregates and that makes them impervious to
water. R. de Gennaro et al. found similar results on
the expanded zeolite aggregates produced at around
1400 °C [1]. The effect of amount of floatation
waste on the water absorption can not be
generalized for the treatment (firing) temperatures
lower than 1250 °C. However, the water absorption
of the granules treated at 1250 °C decreased with
increase in albite floatation waste.

20 CLAY-A

15
Water
Absorption 10
(%)
5
10
20
0 30 Floatation
900 1100 40
1200 1250 Waste (%)

o
Firing Temperature ( C)
Fig. 3: Water absorption values of LECA granules produced from CLAY-A and floatation waste

20 CLAY-B

15
Water
Absorption 10
(%)
5

0 10
20
900
1000

30
1100
1125

40 Floatation
1150
1200

Waste (%)
o
Firing Temperature ( C)
Fig. 4: Water absorption values of LECA granules produced from CLAY-B and floatation waste
 J. Aust. Ceram. Soc. 44 [1] (2008) 23-30 27

30 CLAY-B
25
20
Water
Absorption 15
(%) 10
5
0
5
900
1000 7.5
1125 Coal (%)
1150
o
Firing Temperature ( C)
Fig. 5: Water absorption values of LECA granules produced from CLAY-B and coal

The effect of firing temperature on the water
absorption values of LECA granules produced from
CLAY-B can not be generalized. Even for the heat
treatment at 1200 °C, the water absorption values
were found between 10 and 15 % (Fig. 4.)
However, almost 0 % water absorption was
obtained at the temperature of 1125 °C. It can be
seen that the water absorption values of the
aggregates produced from CLAY-A were found to
be generally lower than those produced from
CLAY-B.
Fig. 5 presents the water absorption values of
aggregates produced from CLAY-B with coal.
Similar to Fig.4, very low water absorption values
were obtained at the temperatures of 1125 and 1150
°C. It was interesting that the water absorption
values of LECA granules produced at 1125 °C was
significantly lower than those produced at 1000 °C.
It seems that the temperatures of 1125 and 1150 °C
are proper to reduce the water absorption of
aggregates produced from CLAY-B, irrespective to
the pore forming agent.
One of the most important properties of lightweight
aggregate (LWA) granules is the specific gravity.
This property plays an important role on the design
of concrete structures and insulation properties of
the building members. The specific gravity (SG)
values of the light weight expanded clay aggregate
(LECA) granules produced in the present study are
given in Figs.6-8. It is clear from Fig. 6 that LECA
granules with specific gravity between 1.5 and 2.0
can be produced from CLAY-A at 1250 °C. The
heat treatment temperatures lower than 1250 °C
were not found to be sufficient to produce lighter
granules. Test results revealed that SG values
decreased with increase in albite floatation waste.
For example, the SG values were 1.55 and 1.95 for
the aggregates produced with 40 and 10 %
floatation waste, respectively (Fig. 6).

2.5
CLAY-A

Specific
2.0
Gravity

10
20
1.5 30 Floatation
900 1100 40
1200 1250 Waste (%)

o
Firing Temperature ( C)
Fig. 6: Specific gravity values of LECA granules produced from CLAY-A and floatation waste
28 O. Arioz, K. Kilinci, B. Karasu, G. Kaya, G. Arslan, M. Tuncan, A. Tuncan,
M. Korkut, S. Kivrak

2.5
CLAY-B

Specific 2.0
Gravity

1.5 10
20

900
1000
30

1100
1125
40 Floatation

1150
1200
Waste (%)
o
Firing Temperature ( C)
Fig.7: Specific gravity values of LECA granules produced from CLAY-B and floatation waste

2.5 CLAY-B

Specific 2.0
Gravity

1.5
5
900
1000 7.5
1125 Coal (%)
1150
o
Firing Temperature ( C)
Fig.8: Specific gravity values of LECA granules produced from CLAY-B and coal

The SGs of LECA granules produced from CLAY-
B ranged between 2.2 and 2.4 even the firing
temperature increased up to 1200 °C (Fig. 7). It was
not possible to produce LECA granules with a SG
less than 2.0 with CLAY-B and floatation waste in
the present study. On the other hand, LECA
granules with SG value of less than 2.0 can be
produced at 1150 °C by using coal as a pore
forming agent (Fig. 8).
The pore structures and surface textures of the
aggregates were illustrated in Figs. 9 and 10,
respectively. It is clear that the pore structure and
surface properties of the aggregates are
significantly affected by the type of raw material
and treatment temperature. The distribution,
amount and size of the pores become very suitable
as the pore forming agent is 40 % and the treatment
temperature is 1250 °C with CLAY-A (Fig. 9b).
The size of the pores ranged from 0.2 and 1 mm
and there was no connection between the pores.
This may reduce the specific gravity of the
aggregate and also provide perfect insulation. It can
be seen from Fig. 6 that the smallest specific
gravity value was measured in aggregates produced
from CLAY-A with 40 % albite floatation addition
at a treatment temperature of 1250 °C. This was not
obtained by using CLAY-B even though the pore
forming agent was 40 % and the treatment
temperature 1200 °C (Fig. 9c). The pores of these
aggregates were found to be small and
discontinuous. It is also clear that the treatment
temperature of 1100 °C is not enough for CLAY-A
to form a suitable pore structure even the pore
forming agent is 40 % (Fig. 9a).
 J. Aust. Ceram. Soc. 44 [1] (2008) 23-30
(a)
(b)
(c)
Fig. 9: Pore structures of the aggregates
(a) CLAY-A, 40 % albite floatation, 1100 °C,
(b) CLAY-A, 40 % albite floatation, 1250 °C,
(c) CLAY-B, 40 % albite floatation, 1200 °C
The surface properties of the aggregates are
important for water absorption capacity of the
aggregates. Re. de Gennaro et al. state that the
expanded aggregates have a compact and
homogenous outer glassy film that makes them
impervious to water [1]. It was found that the heat
treatment and type of clay played an important role
in the surface properties of LECA granules. The
surface of the aggregates seemed smooth and
impervious in case of CLAY-A usage treated at
1250 °C (Fig. 10b). This will reduce the water
absorption capacity of the aggregate. It can be seen
from Fig. 3 that the smallest water absorption value
was observed in aggregates produced from CLAY-
A with 40 % albite floatation at 1250 °C. On the
other hand, the surface texture was rough and
29
(a)
(b)
(c)
Fig. 10: Surface textures of the aggregates
(a) CLAY-A, 40 % albite floatation, 1100 °C,
(b) CLAY-A, 40 % albite floatation, 1250 °C,
(c) CLAY-B, 40 % albite floatation, 1200 °C
seemed to be pervious when CLAY-A was treated
at 1100 °C (Fig. 10a). The surface of the aggregates
produced from CLAY-B was rough and pervious
even though the treatment temperature increased to
1200 °C.
CONCLUSIONS
The following conclusions may be drawn from this
experimental study;
1. The water absorption values of aggregates
produced from pottery clay (CLAY-A) at 1250
°C decreased with increase in the amount of
floatation waste.
2. The water absorption values of aggregates
produced from waste brick powders (CLAY-B)
were found to be almost 0 % when they are
30 O. Arioz, K. Kilinci, B. Karasu, G. Kaya, G. Arslan, M. Tuncan, A. Tuncan,
M. Korkut, S. Kivrak
treated at a temperature of 1125 °C irrespective
to the type of pore forming agent.
3. The water absorption values of aggregates
produced from CLAY-A were found to be
generally lower than those of aggregates
produced from CLAY-B.
4. Lightweight expanded clay aggregates with
specific gravity between 1.5 and 2.0 and almost 0
% water absorption can be produced from
CLAY-B by using albite floatation wastes.
Specific gravities of the aggregates generally
decreased with increase in the amount of
floatation waste.
5. The waste brick powders can also be used in the
production of LECA granules but the specific
gravity values were very high even the treatment
(firing) temperature increased to 1200 °C when
the pores were obtained by floatation waste. On
the other hand, somewhat lower specific gravity
values were measured on the aggregates
produced with the addition of coal.
6. The pore structure and surface properties of the
aggregates were significantly affected by the
type of raw material and treatment temperature
applied in the granule production.
7. The distribution, amount and size of the pores
become very suitable as the pore forming agent
is 40 % and the treatment temperature is 1250 °C
with CLAY-A.
8. The surface of the aggregates seemed smooth
and impervious when CLAY-A was treated at
1250 °C
Conclusively, it was found that the type of clay, the
type and amount of pore forming agent, and the
firing temperature were very important for the
properties of lightweight expanded clay aggregate
(LECA). The test results have revealed that it is
possible to produce LECA granules from clay by
using albite floatation waste in different amounts.
Utilisation of floatation waste for pore-forming may
reduce the production costs. These wastes can be
utilised properly in this sector. Since the clay is
locally available material, it is possible to produce
lightweight aggregate with low costs. This is
advantageous for countries with low natural
lightweight aggregate sources. These LECA
granules can be used to produce lightweight
concrete and lightweight blocks or isolation brick
reducing the energy costs in buildings.
FURTHER RESEARCH
In the present investigation, albite floatation wastes
were used in the production of lightweight
expanded clay aggregate granules. However, it is
desirable to use different pore forming agents such
as perlit and glass. The results of such studies
would make enable to compare the effects of the
pore forming agent for different clay types.
ACKNOWLEDGEMENTS
The Authors would like to thank to The Research
Fund of Anadolu University for funding the present
study (Project no: 06 02 08). The Authors also very
much appreciate to Dr. I. Tore of Anadolu
University for their collaboration relating to this
experimental study. The Authors also would like to
thank to Professor N. Varcan for his invaluable
contributions to several aspects of the work
reported in this paper.
REFERENCES
1. de’Gennaro, R., Cappelletti, P., Cerri, G.,
de’Gennaro, M., Dondi, M. and Langella, A.,
“Neapolitan Yellow Tuff as Raw Material for
Lightweight Aggregates in Lightweight
Structural Concrete Production”, Applied Clay
Science, Vol. [28], (2005), 309-319.
2. Alduaij, J., Alshaleh, K., Haque, M. N. and
Ellaithy, K., “Lightweight Concrete in Hot
Coastal Areas”, Cement and Concrete
Composites, Vol. [21], (1999), 453-458.
3. Mladenovic, A., Suput, J. S., Ducman, V. and
Skapin, A. S., “Alkali-Silica Reactivity of Some
Frequently Used Lightweight Aggregates”,
Cement and Concrete Research, Vol. [34],
(2004), 1809-1816.
4. Neville, A. M., Properties of Concrete, Addison-
Wesley Longman, (1995).
5. Rossignolo, J. A., Agnesini, M. V. C. and
Morais, J. A., “Properties of High-Performance
LWAC for Precast Structures with Brazilian
Lightweight Aggregates”, Cement and Concrete
Composites, (2003), 77-82.
6. Pioro, L. S. and Pioro, I. L., “Production of
Expanded-Clay Aggregate for Lightweight
Concrete from Non-Selfbloating Clays”, Cement
and Concrete Composites, (2004), 639-643.
7. Cavaleri, L., Miraglia, N. and Papia, M.,
“Pumice Concrete for Structural Wall Panels”,
Engineering Structures, Vol. [25], (2003), 115-
125.
8. Vasina, M., Hughes, D. C., Horoshenkov, K. V.
and Lapcik, L., “The Acoustical Properties of
Consolidated Expanded Clay Granulates”,
Applied Acoustics, (2005), Article in press.
9. Toth, M. N. and Csaky, I. B., “The Role of the
Smectite Group in the Bloating Process”,
Ziegelindustrie, Vol. [5], (1989), 246-250.
10. Bettzieche, H., Schops, W. and Hohmann, H.,
“Pore-Forming in Brickmaking Clay by Means
of Expanded Glass Granules”, Ziegelindustrie,
Vol. [5], (2000), 41-53.
11. Sveda, M., Bagel, L. and Komora, L., “A New
Possibility for Pore-Forming in the Clay Body”,
Ziegelindustrie, Vol. [4], (1996), 240-245.
12. Kaya, G., Karasu, B. and Özdemir, M., “Effects
of Aydın Çine Region’s Albite Flotation Wastes
on the Properties of Floor Tile Bodies”, Key
Engineering Materials, (2004), 2429-32.