Alternative material recommendation for facade cladding: High silica-containing stonepaste ceramics

Abstract

This study investigated the potential of using stonepaste ceramics, which were widely preferred as a coating and decoration material on the facades of architectural buildings in ancient times and continues to be produced on a workshop scale today as a cladding material on building facades. Stonepaste ceramics, made from a mixture prepared with a high amount of crystalline quartz as well as frit, plastic clay, and bentonite raw materials, were hand-shaped and sintered at 930 °C after glazing. The physico-mechanical properties of stonepaste ceramics, their behaviour under various environmental conditions (resistance to chemicals, frost, and thermal shock), and their microstructures have been characterized. The characterization results were compared with the properties of commonly used facade cladding materials. It was determined that stonepaste ceramics had a very low firing shrinkage value (2.84 %) compared to that of other ceramic cladding materials, a higher water absorption value (11.79 %) than that of porcelain tiles and floor tiles, and close to wall tiles, and a flexural strength value (33.64MPa) higher than wall tiles and close to porcelain tiles despite the high-water absorption value. Ten cycles of thermal shock resistance showed that the body and glaze layer of the stonepaste ceramic material are well bonded to each other, and there is no significant thermal expansion mismatch between them. One hundred cycles of freeze-thaw conditions indicated that the stonepaste ceramic had good adhesion and thermal expansion compatibility between the glaze and the body but only chipping damage under the action of tensile forces caused by the freezing of water entering the pores of the body. In terms of behaviour against various chemicals, stonepaste ceramics were found to be highly resistant to high and low concentrations of household chemicals, swimming pool salts, and alkalis but less resistant to low concentrations of HCl and citric acid and high concentrations of HCl and lactic acid compared to other chemicals. The results show that stonepaste ceramics, despite their high-water absorption potential, have properties close to those of traditional ceramic tiles and, like these materials, can serve for significant periods in various environmental conditions when used as facade cladding. Consequently, it has been revealed that stonepaste ceramics can be used as a facade cladding material in sustainable, long-lasting, contemporary architectural facades thanks to their technical and protective properties.