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Volume 109
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Preparation of cold-bonded ceramsite based on particle packing theory and high-efficiency utilization of granite powder
Hongqiang Li, Hui Li, Yueyao Zhao, Hongbo Cui, Wukui Zheng *
School of Materials Science and Engineering, Xi'an University of Architecture and Technology, Xi'an, 710055, China
10.1016/j.partic.2025.12.002
Volume 109, February 2026, Pages 86-98
Received 16 October 2025, Revised 26 November 2025, Accepted 4 December 2025, Available online 9 December 2025, Version of Record 22 December 2025.
E-mail: zheng.wukui@xauat.edu.cn
Highlights

• MAA packing-curve design controls pellet porosity and strength.

• Lower RSS (better PSD fit) increases densities and reduces water uptake.

• Best window: bulk 1041 kg/m3, apparent 1669 kg/m3, water 11.86 %.

• Single-pellet crushing strength up to 5.76 MPa at optimal packing.

• Full PSD outperforms mono-sized blends in strength and absorption.


Abstract

The utilization of granite powder (GP) is substantially limited by its low pozzolanic activity and inert structure, posing a significant challenge for its high-volume incorporation. This study conducts experimental research on cold-bonded ceramsite based on the GP–fly ash–cement system, adopting the modified Andreasen–Andersen (MAA) particle packing model as a tool for mix ratio design and evaluation. By designing multiple groups of different particle size combinations, the raw material particle gradation is made to produce controllable deviations from the MAA target curve within a certain range. RSS is used to quantitatively characterize the degree of deviation of the particle gradation from the MAA target curve, and the influence mechanism of this deviation on the physical properties and pore structure of ceramsite is systematically analyzed. The results indicated that an RSS value of 6736 yielded the most compact ceramsite structure, which exhibited a cylinder compressive strength of 5.76 MPa, a bulk density of 1041 kg/m3, and a water absorption as low as 12.65 %. Further particle size fractionation experiments revealed that single-size raw material systems performed significantly worse than full-range particle distributions. The latter facilitated the formation of a skeleton–filler collaborative structure, thereby enhancing compactness and mechanical stability. Compared with existing utilization pathways of GP, the proposed structure-regulated preparation strategy for cold-bonded ceramsite enables up to 85 % incorporation of GP and delivers comprehensive performance improvement without reliance on high-temperature sintering or alkali activation. This approach demonstrates considerable engineering feasibility and application potential, providing a novel perspective and theoretical foundation for the high-efficiency valorization of low-activity solid wastes.

Graphical abstract
Keywords
Particle packing theory; Granite powder; Cold-bonded ceramsite; Performance optimization
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