The most effective method for mitigating the adverse environmental impacts of traditional concrete involves substituting cement and natural aggregate with waste and byproduct resources. Utilizing sintered lightweight aggregate (fly ash) in geopolymer concrete emerges as an efficient solution for managing and disposing of significant amounts of fly ash. The influence of sintered aggregate size distribution on the performance of alkali-activated concrete, focusing on compressive strength improvement. The study employs sintered fly ash aggregate (SFA) as coarse aggregate, aiming to optimize packing density through proper particle distribution. The highest compressive strength is achieved with a mix featuring 75% 4-8mm and 25% 8-12mm SFA. Regression-based strength models are developed, exhibiting good alignment with conventional concrete models. Thin section techniques reveal enhanced aggregate-matrix interaction due to the porous structure of SFA. The study emphasizes the potential of SFA in geopolymer concrete for sustainable construction. Lightweight geopolymer concrete, owing to its lower density, significantly reduces the overall structural load.
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