This paper presents an attempt to obtain technically valuable lightweight aggregate produced from a mixture of fluidized bed fly ash and post-mining residues. The motivation to take up this study is a problem with the reasonable utilization of huge amounts of ashes produced by power plants in Poland. The ashes still produced and those stored in heaps amount to a tonnage of millions, and new ways to utilize them are desired. A real lack of mineral aggregates (non-renewable resources) demands the search for alternative materials. Using the industrial ashes as aggregates is a possible solution to the two above-mentioned problems. The aim of the study was to produce the lightweight aggregate components and to assess them in terms of their physical and mechanical properties. The components were prepared by mixing, granulation, and sintering at the temperature of over 1170 °C. Evaluation of physical parameters was based on parameters such as bulk density and water absorption. The study of mechanical properties was carried out on the basis of aggregates' resistance to crushing. The obtained results revealed that using a mixture of the combustion and post-mining residues in the production of a lightweight aggregate is beneficial and results in the formation of a porous and durable structure. The measured resistance to the crushing of the produced aggregates varied from 5.9 MPa to 7.5 MPa. They also showed a high freeze-thaw resistance and good resistance to aggressive environments (bases, acids, salt). The registered properties indicate that the aggregates meet the basic requirements for materials used in construction and road-building. This study has a scientific and didactic value in that it describes the step-by-step process of planning and implementing the production of synthetic mineral aggregates.
Keywords: fluidized bed ash; lightweight aggregate; mechanical properties; mining by-products; physical properties.