Utilization of carbide slag in autoclaved aerated concrete (CS-AAC) and optimization: Foaming, hydration process, and physic-mechanical properties

Autoclaved aerated concrete (AAC), a lightweight porous material, has been widely used in the building field because of its energy savings. A solid waste called carbide slag with a high Ca(OH)2 content is a potential substitution for CaO to prepare AAC. In this study, carbide slag was used to replace quicklime to prepare carbide slag-based autoclaved aerated concrete (CS-AAC). The temperature, foaming rate, and rheological properties of the slurry during the foaming stage, the strength of the rough body, and the physical and mechanical properties of the autoclaved products were investigated. Hydration products, microstructure, and pore structure were further analyzed to investigate the mechanisms of carbide slag on the properties of AAC, and the use of sodium carbonate (SC) to improve the performance of CS-AAC was explored. The results show that the addition of carbide slag causes a degradation of the properties, including foaming rate and physic-mechanical properties. The “water locking” effect due to the irregular surface of the carbide slag results in an increase in slurry consistency. The increase in slurry consistency, as well as the decrease in slurry temperature is the main reason for the decrease in slurry foaming rate and roundness of bubbles, which are unfavorable for the strength development of AAC. Due to the alkali excitation characteristics of sodium carbonate. The addition of SC can react with Ca(OH)2 in the slurry to produce OH-, to promote cement hydration, which can accelerate the development of rough body strength, and save pre-curing time. The carbide slag-based AAC with 0.25% SC has a significant improvement in foaming properties and facilitates the generation of more C-S-H gels to form tobermorite under hydrothermal conditions, which improves the AAC properties. However, too much SC can consume a large amount of Ca(OH)2 and affects the production of tobermorite, which is not beneficial to the mechanical properties.