Study of Fine Artificial Lightweight Aggregate (ALWA) from

Sidoarjo-Mud and Fly Ash with Different Calcination and

Composition

Rizqi Abdi Perdanawati

, Triwulan

and Januarti Jaya Ekaputri

Faculty of Science and Technology, UIN Sunan Ampel, Jl. Ahmad Yani, Surabaya, Indonesia

Department of Civil engineering, Institut Teknologi Sepuluh Nopember, Jl Raya ITS, Surabaya

Keywords: Sidoarjo-mud, fly-ash, fine ALWA.

Abstract: Sidoarjo mud is the result of an erupting mud volcano in Porong, Sidoarjo, Indonesia. It is the largest mud

volcano in the world. The utilization of mud is developed to increase the value of the mud so that it can create

incomes. This study investigates the characteristics of Fine Artificial Lightweight Aggregate (ALWA) from

Sidoarjo Mud and fly ash. Fine ALWA was made from 100% Sidoarjo mud FA, 70% sidoarjo mud 30% fly

ash, and 50% sidoarjo mud 50% fly ash. Every composition was calcinated at 1000°C (for 4 and 6 hours) and

at 1050°C (for 4 and 6 hours). Every composition is tested for spesific gravity, density, absorption and analys

XRay Diffraction and Scanning Electron Microscope (SEM). The result shows that the lowest spesific gravity

(1,9 kg/m

), lowest density (993.63 kg/m

), and lowest absorption (10.50%) occur in 50 sidoarjo mud of 50

fly ash 1050C and 360 mnt when calcinated. XRay Diffraction analisys shows that all of the variations are

dominated by quartz, anorthide, and hematite. Scanning Electron Microscope show the different structure of

the different composition.

1 INTRODUCTION

The eruption of Sidoarjo Mud started in May 2006.

Since then, Sidoarjo Mud has covered more than 640

hectares. With the monte carlo simulation (Rudolph,

Karlstrom, & Manga, 2011), it is estimated that there

is a 50% chance of the eruption lasting 41 years and

a 33% chance that it lasts 84 years. Various attempts

hace been made to reduce mud deposit. Efforts to

reduce sediment around the blast are also carried out

by utilizing it into ready-made products.

One effort to utilize Sidoarjo Mud is to process it

into building materials. The use of sidoarjo mud as a

building material is expected to have a major impact

on the reduction of the deposit volume. In this study,

building materials developed from Sidoarjo mud are

in the form of artificial lightweight aggregates.

There has been some previous research on the

manufacture of artificial lightweight aggregates using

explanded clay. To be a lightweight clay, aggregate

must be given additional obsidian with a certain

composition and then burned to sintering conditions

at 1150˚C (Husin & Sugiharto, 2008). Sidoarjo mud

was also being burned and given additional

ingredients form fly ash or silica sand to become

artificial lightweight aggregates (Lasino, 2007).

Lasino's study (2007) added fly ash to produce

aggregates with maximum addition of 30% fly ash

and was burned at the highest temperature, at 1000˚C.

The effect of the amount of addition of fly ash on

physical behavior such as density, spesific gravity,

and aggregate water absorption in previous studies is

unknown. Therefore, this study addressed this

question by giving additional fly ash up to 50%

artificial aggregate mixture with a higher calcination

temperature at 1050˚C. Besides, it also compares

chemical compound in every composition by Xray

Diffraction and the structure of material by scanning

electron microscope.

2 METHOD AND MATERIAL

2.1 Sidoarjo Mud

Sidoarjo Mud is a fine-grained material, blackish

gray, high plasticity, and high dry shrinkage (Lasino,

Perdanawati, R., Triwulan, . and Ekaputri, J.

Study of Fine Artiﬁcial Lightweight Aggregate (ALWA) from Sidoarjo-Mud and Fly Ash with Different Calcination and Composition.

DOI: 10.5220/0008907800002481

In Proceedings of the Built Environment, Science and Technology Inter national Conference (BEST ICON 2018), pages 177-184

ISBN: 978-989-758-414-5

177

2007). Sidoarjo-mud consists of many compounds as

presented in table 1.

Table 1: compound of Calcined Sidoarjo-Mud 800°C-2

hours (Lasino, 2007).

Compound

% weight

SiO

52.79

26.35

8.51

TiO

CaO

1.97

MgO

2.53

2.08

2.86

0.98

Lost material

1.92

The compounds of calcined Sidoarjo-mud can also be

known with XRD analysis shown in picture 1.

(a) (b)

Figure 2: SEM Micrograph from dry Sidoarjo-mud and

Calcined Sidoarjo-Mud (800°C-2hours).

Figure 1: Xray Diffraction Calcined Sidoarjo-Mud 800°C-2 hours (Ekaputri & Triwulan, 2013).

From Figure 1, it is known that the dominant

compounds in Calcined mud are Quartz (SiO

Anorthite ordered (CaAl

) dan Hematite

(Fe

). (Rafiza, 2013) stated that the material

(Sidoarjo-mud) changed from semi crystaline pattern

in dry-mud to amorphous pattern in calcined-mud

with domminant compound is SiO

. SEM Analysis of

dry Sidoarjo Mud and calcined Sidoarjo Mud are

shown in Figure 2. The structure of Mud even in dry

or calcined looks flat shape, similar to caolin. The

bigger flat-layered structure (dry mud) changed to

smaller flat-layered structur when calcined.

2.2 Fly Ash

Fly-ash is the ﬁnely divided residue resulted from the

combustion of ground or powdered coal, which is

transported by ﬂue gasses. (ASTM & C618). Fly ash

is devided into 3 classes: class N, Class F, and class

C. The chemical compounds of fly ash are shown in

table 2.

Table 2: Compound of fly Ash in 3 classification

Compound

Class

SiO

+ Al

+ Fe

(Min. %)

SO3,( Maks %)

4.0

5.0

Water content, (Maks %)

3.0

Lost material ((Maks %)

10.0

6.0

Scanning Electron Microscopy photo from fly ash

class F, taken from Paiton Java Power Probolinggo is

shown in figure 4. From figure 4, the structure of

flyash looks spherical in a diameter of less than

45µm. (Ekaputri & Triwulan, 2013).

BEST ICON 2018 - Built Environment, Science and Technology International Conference 2018

178

Figure 4: SEM Fly-ash class F (Ekaputri & Triwulan,

2013).

2.3 Producing ALWA

Fine ALWA was produced in various compositions.

The first composition is 100% from Sidoarjo mud; the

second is mix from 70% Sidoarjo mud and 30% fly

ash; and the third is mix from 50% Sidoarjo mud and

50%. After the base material was blended perfectly,

the material was burned for 240 and 360 minutes as

presented in table 3.

Table 3: Sample of fine ALWA

Code

composition

Temperature (°C)

/duration (hours)

Sidoarjo

Mud

Fly Ash

FA-0-x-z

100

1000/2

1050/6

FA-30-x-z

1000/2

1050/6

FA-50-x-z

1000/2

1050/6

2.4 Testing ALWA

2.4.1 Physical Properties

Fine ALWA analysis is adjusted to specifications on

lightweight aggregates for structural lightweight

concrete as required in ASTM C 330-03 as shown in

table 4.

Table 4: Physics Requirement of lighweight

aggregate for structural lightweigt concrete (ASTM

C330)

Physical properties

Requirement

Density (gr/cm

)

1,0 – 1,8

Maksimum Water absorption after 24

hours (%)

Maximum Dry Loose Bulk Density

(kg/m

)

1120

(ASTM, Standard Specification for Lightweight

Aggregates for Structural Concrete, 2013)

2.4.2 Xray Diffraction

XRD testing is intended to determine the compounds

contained in fine ALWA. XRD (X-ray Diffraction)

tests carried out in the Energy laboratory - LPPM ITS.

The XRD test was carried out at angle of 2Theta

between 5 ° to 90 °. After getting the X-ray

Diffraction pattern, the Xpowder program and Match!

were used to find out the types of minerals and global

amorphous fine ALWA, as well as to find out changes

in minerals that occur due to the addition of fuel

temperature, duration of calcination, and the addition

of fly ash.

2.4.3 Scanning Electron Microscopy

SEM (Scanning Electron Microscopy) was done to

obtain micrographs from fine ALWA.

3 RESULT AND DISCUSSION

3.1 Physical properties analysis of fine

ALWA

Physical testing of fine ALWA included spesific

gravity, density, and water absorption in every

composition and calcination. Figure 5 shows the

picture of fine ALWA : FA-0-1000-4, FA-30-1000-4,

FA-50-1000-4, FA-0-1000-6, FA-30-1000-6, FA-50-1000-

4, FA-0-1050-4, FA-30-1050-4, FA-50-1050-4, FA-0-

1050-6, FA-30-1050-6, FA-50-1050-6.

As figure 5 indicates, the granules have different

colours in each composition and calcination. The

longer the duration of calcination, the colour became

darker. The higher the temperation of calcination, the

colour became darker.

Figure 5: Fine ALWA

Study of Fine Artiﬁcial Lightweight Aggregate (ALWA) from Sidoarjo-Mud and Fly Ash with Different Calcination and Composition

179

3.1.1 Spesific Gravity

The table 5 showed the spesific gravity of fine ALWA

when in saturated surface dry (SSD) condition.

Table 5: spesific gravity of fine ALWA (SSD)

Code

(FA-x-y-z)

SSD

(gr)

Spesific

Gravity

(SSD)

(gr/cm

)

FA-0-1000-4

200

1225

1345

2.500

FA-30-1000-4

200

1225

1340

2.353

FA-50-1000-4

200

1225

1340

2.212

FA-0-1050-4

200

620

735

2.353

FA-30-1050-4

200

1225

1335

2.222

FA-50-1050-4

200

620

725

2.105

FA-0-1000-6

200

1225

1335

2.262

FA-30-1000-6

500

1225

1480

2.119

FA-50-1000-6

200

1225

1320

1.916

FA-0-1050-6

200

1225

1330

2.105

FA-30-1050-6

500

1225

1480

2.041

FA-50-1050-6

200

1225

1320

1.905

Spesific gravity of fine ALWA in every

composition and calcination showed that the fine

ALWA was not in accordance with the requirement.

ASTM C330 requires that spesific gravity of

lighweight aggregate for structural lighweight

concrete must be from 1.1 – 1.8 gr/cm

. but, if

comparing with lumajang sand, spesific gravity of

fine ALWA in all sample was lighter than lumajang

sands. Spesific gravity of lumajang sand is about

2700 kg/m

. The lightest spesific gravity (1905

kg/m

) of fine ALWA occured in 1050°C calcination

for 6 hours with 50% sidoarjo mud and 50% fly ash.

If we use fine ALWA code FA-50-1050-6, the spesific

gravity of aggregate decreased for about 29.63%.

From the table 5, we can analyse the effect of

adding fly ash on spesific gravity of fine ALWA.

The addition of fly ash decreases the weight of the

fine ALWA if it is burned with a duration of 4 and 6

hours. The addition of 30% fly ash decreases the

spesific gravity by 3-6% while the addition 50% of

fly ash reduces the specific gravity by 3-11%. It is

because the specific gravity of the fly ash is lighter

than the specific gravity of burnt sidoarjo mud. Fly

ash’s spesific gravity is 2500 kg/m

. However, at the

duration of calcination of 10 minutes, the addition of

fly ash to 50% increases the specific gravity.

Based on table 5, we can also analyse the effect of

adding temperature of calcination to spesific gravity

of fine ALWA. Adding temperature (50°C) in all

duration and all composition reduced spesific gravity

of fine ALWA by 5-6%. According to the previous

study, (Arioz, Karasu, Kilinç, & Kivrak, 2008), the

LECA granules with spesific gravity between 1.5 and

2.0 can be produced in firing temperature at 1250°C.

Firing temperature lower than 1250°C cannot

produce lighter granules.

The effect of adding calcination’s duration from 4

hours to 6 hours reduce the spesific gravity.

The least spesific gravity loss occurs by 10% in 100%

Sidoarjo Mud, and the biggest is 19% in fine ALWA

with additional fly ash 50%.

3.1.2 Density

The density in every composition and calcination is

shown in Table 6.

Table 6: Density of fine ALWA

Code

(FA-x-y-z)

M (Kg/m

)

Density (ASTM)

(Kg/m

)

FA-0-1000-4

1197.45

1120

FA-30-1000-4

1171.97

1120

FA-50-1000-4

1121.02

1120

FA-0-1050-4

1171.97

1120

FA-30-1050-4

1146.50

1120

FA-50-1050-4

1121.02

1120

FA-0-1000-6

1095.54

1120

FA-30-1000-6

1019.11

1120

FA-50-1000-6

993.63

1120

FA-0-1050-6

1070.06

1120

FA-30-1050-6

993.63

1120

FA-50-1050-6

968.15

1120

In the density testing, almost all variations in

composition, calcination temperature, and duration of

calcination met the requirements. The volume weight

obtained ranged from 886-1197 kg/m

with ASTM C-

330 maximum limit of 1120 kg/m

The addition of fly ash to the fine ALWA reduced

the density of fine ALWA. It aligns with the previous

study by Huda and Astusti (2012), showing that

adding greater hush ask at brick reduces the density.

It is because of the silicate-alumna in husk ash

evaporates when heated at high temperatures, so that

more cavities occur in the brick.

BEST ICON 2018 - Built Environment, Science and Technology International Conference 2018

180

The increase of temperature from 1000°C to

1050°C reduced the density for about 2%. It aligns

with the previous study by Huda and Astuti (2012),

showing that adding 20°C heating temperature

reduced the brick density. The effect of adding

duration of calcination temperature reduced the

density.

3.1.3 Water Absorption

The density in every composition and calcination is

shown in Table 7.

Table 7: Water Absorption of fine ALWA

Code

(FA-x-y-z)

Water

absorption (%)

Water absorption

(ASTM) (%)

FA-0-1000-4

20.48

FA-30-1000-4

19.05

FA-50-1000-4

16.96

FA-0-1050-4

15.38

FA-30-1050-4

12.50

FA-50-1050-4

11.40

FA-0-1000-6

20.48

FA-30-1000-6

18.34

FA-50-1000-6

16.28

FA-0-1050-6

12.36

FA-30-1050-6

11.73

FA-50-1050-6

10.50

The water absorption value is shown in Table 7

shows that almost all of the values meet the

requirement (ASTM C 330-04) less than 20%. The

water absorption value is in the range of 11-20.5%.

The smallest water absorption occurs at calcination

temperature of 1050 °C for 6 hours by 11-12.5%.

The addition of fly ash to water absorption of fine

ALWA reduces the water absorption of fine ALWA.

The addition of calcination temperature from 1000°C

to 1050°C reduces water absorption of fine ALWA.

The addition of duration of calcination temperature

reduces water absorption of fine ALWA

3.2 X-Ray Diffraction Analysis

Xray diffraction analysis for fine ALWA FA-0-1000-

6, fine ALWA FA-0-1050-6, fine ALWA FA-30-

1050-6, fine ALWA FA-50-1050-6, fine ALWA FA-

0-1050-4, analysis fine ALWA FA-30-1050-4, fine

ALWA FA-50-1050-4 discribe below.

The diffraction pattern is shown in figure 6 forms

scattered and peaked. It shows that in temperature

1000°C duration 6 hours, the minerals that appeared

are quartz (SiO2), anorthite (Al2CaO8Si2), hematite.,

calcite (CaCO3), indialite (Al4Mg2O18Si5) and

silimanite (Al2SiO5).

Xray diffraction of fine ALWA 100% Sidoarjo

mud, with calcination temperature 1050°C for 6 hours

is shown in figure 7.

The diffraction pattern presented in figure 7

shows that mineral occure are anorthite

(Al2CaO8Si2), quartz (SiO2), hematite (Fe2O3),

Indialite (Al2Mg2O18Si5), Calcite (CaCO3).

Silimanite has not been detected in this sample.

Xray diffraction of fine ALWA 70% Sidoarjo

mud-30% Fly Ash, with calcination temperature

1050°C for 6 hours is shown in figure 8.

The diffraction pattern presented in figure 8

shows that minerals occuref in higher peak are quartz

(SiO2), anorthite (Al2CaO8Si2) and hematite

(Fe2O3). In the short peak, calcite, silimanie, and a

little indialite can be found.

Xray diffraction of fine ALWA 50% Sidoarjo

mud-50% Fly Ash, with calcination temperature

1050°C for 6 hours shown in figure 9.

Xray diffraction of fine ALWA 100% Sidoarjo

mud, with calcination temperature 1050°C for 4 hours

shown in figure 10.

The diffraction pattern shown in figure 10 show

that mineral occure in higher peak are anorthite

(Al2CaO8Si2) quartz (SiO2), and hematite (Fe2O3).

The short peak occur calcite and indialite.

Xray diffraction of fine ALWA 70% Sidoarjo

mud-30% Fly ash, with calcination temperature

1050°C for 4 hours shown in figure 12.

The diffraction pattern shown in figure 12 show

that mineral occure in higher peak are anorthite

(Al2CaO8Si2) quartz (SiO2), and hematite (Fe2O3).

The short peak occur calcite, silimanite and indialite.

Xray diffraction of fine ALWA 50% Sidoarjo

mud-50% Fly ash, with calcination temperature

1050°C for 4 hours shown in figure 13.

The diffraction pattern shown in figure 13 show

that mineral occure in FA-50-1050-4 same with FA-

30-1050-4.

Study of Fine Artiﬁcial Lightweight Aggregate (ALWA) from Sidoarjo-Mud and Fly Ash with Different Calcination and Composition

181

Figure 6: XRD analysis fine ALWA FA-0-1000-6

Figure 7: XRD analysis fine ALWA FA-0-1050-6

Figure 8: XRD analysis fine ALWA FA-30-1050-6

Figure 9: XRD analysis fine ALWA FA-50-1050-6

BEST ICON 2018 - Built Environment, Science and Technology International Conference 2018

182

Xray diffraction analysis for fine ALWA FA-0-

1000-6, fine ALWA FA-0-1050-6, fine ALWA FA-

30-1050-6, fine ALWA FA-50-1050-6, fine ALWA

FA-0-1050-4, fine ALWA FA-30-1050-4, fine

ALWA FA-50-1050-4 mineral occure domminantly

anorthite (Al2CaO8Si2), quartz (SiO2), and hematite

(Fe2O3).

3.3 Scanning Electron Microscopy

Photo SEM (Scanning Electron Microscopy) aims to

determine the shape of the microstructure found in the

composition of fine ALWA. The fine ALWA

composition carried out by SEM photos is without the

addition of fly ash and 50% additional fly ash shown

in figure 14.

Figure 10: XRD analysis fine ALWA FA-0-1050-4

Figure 11: XRD analysis fine ALWA FA-30-1050-4

Figure 12: XRD analysis fine ALWA FA-50-1050-4

Study of Fine Artiﬁcial Lightweight Aggregate (ALWA) from Sidoarjo-Mud and Fly Ash with Different Calcination and Composition

183

From the figure 14 show micro structure of fone

ALWA. Fine ALWA FA-0-1050-6 occur irregular

particle and angled. Fine ALWA FA-50-1050-6 occur

solid particle.

Figure 14: Photo SEM Fine ALWA FA-0-1050-6 and

FA-50-1050-6

4 CONCLUSSION

Spesific gravity of fine ALWA in all variation (1,905-

2,5gr/cm

) not in accordance with the requirements of

ASTM C 330 (1,1-1,8 gr/cm

). Density of fine

ALWA in all variation (886-1197 kg/m

) meet with

the requirement of ASTM C 330 (1120 kg/m

Water Absorption of fine ALWA in all variation meet

with the requirement of ASTM C 330. (less than

20%). Xray diffraction analysis in all variation of fine

ALWA domminantly quartz. Anorthide, and

hematite, and Photo SEM of fine ALWA show that

adding fly ash increase solidity of particle.

REFERENCES

Arioz, O., Karasu, B., Kilinç, K., & Kivrak, S. 2008.

A Preliminary Research On The Properties

of Lightweight Expanded Clay Aggregate. J.

Aust. Ceram. Soc. 44 [1] , 23-30.

ASTM. 2013. Standard Specification for Lightweight

Aggregates for Structural Concrete. West

Conshohocken, Uinted States: ASTM

international.

ASTM, & C618. n.d.. Standard Specification for

Coal Fly Ash and Raw or Calcined Natural

Pozzolan for Use in Concrete. West

Conshohocken, United States: ASTM

International.

Ekaputri, J. J., & Triwulan. 2013. Sodium sebagai

aktifator F;y Ash, Trass dan Lumpur

Sidoarjo dalam Beton Geopolimer. Jurnal

Teoretis dan Terapan Bidang Rekayasa Sipil

Vol 20, No.1.

Husin, A. A., & Sugiharto, B. 2008. Peningkatan

Mutu Agregat Ringan Buatan Untuk Beton

Ringan Struktural. Jurnal Permukiman

Volume 3 No. 1, 1-14.

Lasino. 2007. Penelitian Pemanfaatan Lumpur

Sidoarjo Untuk Agregat Buatan. jurnal

Permukiman, Vol.2, no.1.

Perdanawati, R. A., Nasir, F. R., & Januarti Jaya

Ekaputri, T. 2013. PERILAKU LUMPUR

SIDOARJO LUSI SEBAGAI AGREGAT

RINGAN BUATAN UNTUK BAHAN

DASAR BETON RINGAN AAC., pp. 129-

138.

Rafiza, A. R. 2013. Review on the Properties of

Aggregates Made with or without

Geopolymerisation Method. Advanced

Material Research, Vol 626, 892-895.

Rudolph, M. L., Karlstrom, L., & Manga, M. 2011. A

prediction of the longevity of the Lusi mud

eruption, Indonesia. Earth and Planetary

Science, 124–130.

BEST ICON 2018 - Built Environment, Science and Technology International Conference 2018

184