Effects of sand addition on production of lightweight aggregates from Tunisian smectite-rich clayey rocks

Smectite-rich claystone–marlstone samples from 12 outcrops located in the Southern Atlas domain of Tunisia were investigated with regard to manufacture of lightweight aggregates (LWAs). The clayey materials mainly consist of smectite, kaolinite and illite, together with quartz, calcite, dolomite and feldspars as accessory components. 10–12 mm pellets were prepared from wet paste and initially heated to 600 °C, 700 °C or 800 °C (depending on the raw material) for at least 2 h in order to avoid any explosion of the aggregate. The pellets were then subjected to a quick firing process at 1180 °C. The addition of 15% of quartz sand (< 250 μm grain size) to the raw materials was found to improve some required pre-treatments and give better expansion properties to some of the aggregates. The addition of 1% used automobile oil to the clay and quartz sand mixtures caused the formation of more gas and a drop in bloating temperature. The obtained LWAs were characterized by physical properties such as apparent density, mechanical resistance, water absorption and expansion. The laboratory results were comparable to those of two commercial LWAs from France (Argidécor®) and Portugal (LECA®) and provide new openings for the utilization of Tunisian claystone in civil engineering work or in agricultural applications.