Integrating ceramic wastes into concrete: Sustainable disposal and resource optimization strategies

Due to the day-to-day innovations and development in the construction field, the use of natural aggregates is increased tremendously and at the same time, the production of solid wastes from the demolitions of constructions is also quite high. Because of these reasons, the reuse of demolished constructional wastes like ceramic tile and granite powder came into the picture to reduce solid waste and to reduce the scarcity of natural aggregates for making concrete. The ceramic tile waste is not only occurring from the demolition of structures but also from the manufacturing unit. The investigation finds out with the partially replacement of fine aggregate with ceramic waste and steel fiber with coarse aggregate in the concrete mix of M30 was made and fresh and hardness tests were examined after 7 and 28 days. The investigation was achieved on cement concrete in which partial replacement of fine aggregate at percentages of 0%, 5%, 10%, 15% and 20% with ceramic waste and steel fiber with coarse aggregate at a percentage of 0%, 10%, 20% and 30% in M30 grade of concrete respectively.

With the increasing use of recycled materials from civil construction, mainly as substitute for some aggregates in concrete mixtures, it is necessary to obtain technical information on the performance of these new mixtures. National and international research on the use of ceramic waste in concrete production highlight good results of this new material’s mechanical performance in environmental situations. However, little is known about its behavior at high temperatures. In this context, we sought to verify the performance of concrete mixtures produced with aggregates from ceramic block waste at high temperatures, with evaluation of their residual mechanical strength, axial compressive strength and elastic modulus, and also their tendency to spalling in fire situations. The RILEM-129 MHT method [1] was used for the assessment of residual mechanical strength, and the tendency to spalling was evaluated according to the procedure suggested by Souza and Moreno [2]. In both these evaluations, there is no national standard, and, in the case of spalling, not even an international standard. Three concrete mixtures were used, one prepared with natural coarse basalt aggregate (reference) and the other two by replacing part of this natural aggregate with aggregate from ceramic block waste (40% and 100% of substitution in volume). In the end, it is concluded that the substitution of natural coarse aggregate for lightweight aggregate from ceramic block waste can be an excellent alternative to increase the resistance of concrete to fire. Thus, the results of mechanical strength and spalling in a fire situation, unprecedented in our country, can greatly support the decision-making about the use of this alternative material in the national construction industry.

This study focuses on how adding ceramic waste and sesame oil waste ash (SOWA) affects the characteristics of ultra-high-performance concrete (UHPC). Different UHPC mixes were made by substituting SOWA (0–40%) for some of the cement and crushed ceramic tile waste (0–100%) for sand. The concrete's fresh and hardened properties, microstructure and durability traits were assessed. Comparing the incorporated 10% SOWA and 100% crushed ceramic tile waste to the control mix, the results demonstrated an improvement in compressive strength, splitting tensile strength, and flexural strength. By decreasing the penetration of chloride and water permeability, this combination also improved durability. A denser matrix and an enhanced interfacial transition zone with the ideal mixture were found by microstructural investigation. The study shows how ceramic waste and SOWA can be used to create sustainable UHPC with improved performance. The findings demonstrated that UHPC incorporating a 10% replacement level exhibited superior performance relative to the control mix. Specifically, the blend containing 10% SOWA and 100% crushed ceramic tile waste showed notable enhancements in mechanical properties. At 28 days, this mix achieved a compressive strength of 170.1 MPa, splitting tensile strength of 18.71 MPa, flexural strength of 27.22 MPa, and an elastic modulus of 56.86 GPa representing increases of approximately 2.5%, 4.4%, 3.8%, and 1.3%, respectively, compared to the reference specimen. Moreover, this mixture exhibited the lowest permeability values, with water permeability measured at 1.52 × 10−11 cm/s, chloride ion penetration resistance at 252 coulombs, and a sorptivity coefficient of 2.47 × 10−4 mm/s0.5, indicating improvements of around 3.5%. Microstructural analysis further revealed that the incorporation of agricultural waste contributed to a refinement of pore structure, resulting in a denser matrix. This densification is likely responsible for the enhanced durability and mechanical characteristics observed in the modified UHPC.Graphical abstract

Concrete is still the most common building material used across the globe, but the extensive production of concrete has put tremendous pressure on natural resources, including river sand and crushed stone. At the same time, the rapid expansion of both construction and manufacturing industries has led to an increased amount of solid waste generated, specifically from ceramic debris and waste glass due to either demolition or industrial processes. Many of these types of waste materials are deposited into landfills, which adds to the degradation of our environment as well as presents challenges in their disposal. In response to this issue, recent research has expanded significantly in terms of utilizing recycled ceramic and glass waste in the development of concrete mixtures, as a means of creating a more sustainable alternative to traditional fine and coarse aggregate. The purpose of this study was to demonstrate the viability of using ceramic waste and crushed glass as a partial replacement for conventional aggregates and how these two types of waste materials affect concrete's mechanical, physical, and durability properties. The goal of using ceramic waste and crushed glass is to reduce the need for extracting natural resources, limit the negative environmental impacts from the accumulation of waste in landfills, and promote sustainable construction practices. The results of this study will provide additional insight into the performance of concrete produced with ceramic waste and glass waste and how these types of materials can help to create a more sustainable construction material.

Purpose In concrete manufacturing industry, utilisation of ceramic waste from various sources was increased in context of producing sustainable concrete. It was observed from previous studies that, the use of ceramic electrical insulator waste as concrete ingredients was unexplored. The study aims to develop a sustainable thermal resistance concrete using Ceramic insulator industry waste. Design/methodology/approach The study explores the thermal efficiency of concrete made with ceramic waste. Concrete cubes were casted with different mixes, namely, ceramic binder standard strength concrete (CB-SSC, 70% cement + 30% CW and 100% natural aggregates), ceramic binder-filler standard strength concrete (CBF- SSC, 70% cement + 30% CW and 100% CW aggregates) and ceramic filler standard strength concrete (CF-SSC, 100% cement + 100% CW aggregates). Scanning electron microscopy (SEM), X-ray diffraction (XRD) and X-ray florescence (XRF) analysis were done. Findings The concrete samples were tested under the elevated temperatures of 800°C and 1,000°C. The drop down in the compressive strength was observed in all the mix specimens when the temperature rises from 800 °C to 1,000 °C. An increase in the compressive strengths of CB-SSC and CBF-SSC was observed to be 10% compared to C-SSC subjected to 800 °C. At 1,000°C, the increase in compressive strengths of CB-SSC and CBF-SSC was around 9%–12% when compared with C-SSC. XRD analysis shows C-A-S-H and calcium silicate hydrate gel presence was predominant in CBF-SSC sample even at 1,000°C which are responsible for strength achievement of concrete. Practical implications Replacing natural aggregates and cement with recycled ceramic insulator waste in concrete improves the pozzolanic properties, workability and compressive strength. This reduces the environmental impacts and aligns with sustainable development goal (SDG-9). The better performance under higher temperatures makes it as sustainable materials that can be used in concrete in real world applications. The SEM shows, adding ceramic waste makes the microstructure denser and more uniform. Almost 26% reduction in cost was estimated for CBF-SSC mix when compared with conventional SSC mix in the present study. Originality/value The study highlights the possible usage of ceramic electrical insulator waste as a partial replacement of cement, fine as well as coarse aggregates.

Effect of ceramic tile waste on strength parameters of concrete-a review

Improving thermal and mechanical properties of concrete by using ceramic electrical insulator waste as aggregates

The construction sector heavily relies on natural resources and significantly impacts environmental degradation, underscoring the urgent need for sustainable building materials. Recent efforts prioritize enhancing the performance of cement-based products while reducing their ecological footprint. Sustainable High-Strength Cement Mortar (SHSCM) has gained prominence due to its superior mechanical properties, yet traditional formulations often rely heavily on non-renewable resources, resulting in substantial carbon emissions. This research addresses the dual objective of optimizing the mechanical properties of SHSCM while promoting sustainability through the innovative use of waste materials. Specifically, this study investigates the incorporation of ceramic waste (CW) as a partial replacement for fine aggregates, alongside the reinforcement of glass fibers (GF), to explore their synergistic effects on the mechanical performance of the mortar. By examining various combinations of CW (10%, 20%, and 30%) and GF (2%, 4%, and 6%). Preliminary results indicate that the inclusion of up to 30% CW not only enhances compressive and flexural strengths but also highlights the challenges posed by increased fiber content on workability. According to the multi criteria decision making (MCDM) framework, that is represented by technique for order of preference by similarity to ideal solution (TOPSIS). This method helps decision-makers assess options by comparing how close they are to the best possible solution and how far they are from the worst possible outcome, providing a well-rounded evaluation of each choice. TOPSIS identified mix M7 (30% CW and 2% GF) was the optimal formulation confirming it achieved the highest compressive and flexural strength while maximizing CW efficiency. This paper ultimately seeks to contribute to the field of sustainable construction materials by demonstrating that effective valorization of waste materials can lead to the development of high-performance, environmentally friendly cement mortars, paving the way for more sustainable building practices.

The increasing global demand for sustainable construction materials has led to the exploration of alternative resources in concrete production. This study investigated the potential of using crushed ceramic waste as a partial replacement for conventional aggregates to reduce environmental impact, minimize waste, and enhance resource efficiency. Concrete mixtures were prepared with ceramic waste replacing natural coarse aggregates at 0%, 5%, 10%, 15%, 20%, and 25% by weight. The compressive strength, split tensile strength, water absorption, and bulk density of the concrete were assessed at curing ages of 7, 14, and 28 days. The results show that replacing up to 20% of natural aggregates with ceramic waste improves the mechanical properties of concrete. At 28 days, compressive strength increased by 22% (from 27.27 to 33.27 MPa), and split tensile strength reached a maximum of 4.20 MPa with 20% ceramic waste. However, beyond 20%, performance declined, with compressive and tensile strengths dropping at 25% ceramic waste. Water absorption increased, and bulk density decreased with higher ceramic waste content. These findings suggest that while ceramic waste enhances concrete strength up to 20%, higher replacement levels lead to poor bonding and reduced performance. This research supports the use of ceramic waste as an eco-friendly alternative for sustainable concrete production, promoting a circular economy and environmentally conscious construction practices.

Plastic is used in many forms in day-to-day life. Since Plastic is non-biodegradable, landfills do not provide an environment friendly solution. Hence, there is strong need to utilize waste plastic. This creates a large quantity of garbage every day which is unhealthy and pollutes the environment. In present scenario solid waste management is a challenge in our country. The production of solid waste is increasing day to day and causes serious concerns to the environment. In this study, the recycled plastics are used in the concrete as a partial replacement of fine aggregate in concrete. The main purpose of this study is to investigate the mechanical properties of concrete such as workability, compressive, flexural and split tensile strengths of concrete mixes with partial replacement of conventional fine aggregate with aggregate produced from plastic waste. The use of plastic aggregate as replacement for fine aggregate enhances workability and fresh bulk density of concrete mixes. The mechanical properties of concrete such as compressive, flexural, and tensile strengths of concrete reduced marginally up to 10% replacement levels.Plastic is used in many forms in day-to-day life. Since Plastic is non-biodegradable, landfills do not provide an environment friendly solution. Hence, there is strong need to utilize waste plastic. This creates a large quantity of garbage every day which is unhealthy and pollutes the environment. In present scenario solid waste management is a challenge in our country. The production of solid waste is increasing day to day and causes serious concerns to the environment. In this study, the recycled plastics are used in the concrete as a partial replacement of fine aggregate in concrete. The main purpose of this study is to investigate the mechanical properties of concrete such as workability, compressive, flexural and split tensile strengths of concrete mixes with partial replacement of conventional fine aggregate with aggregate produced from plastic waste. The use of plastic aggregate as replacement for fine aggregate enhances workability and fresh bulk density of concrete mixes. The mechanical properties of concrete such as compressive, flexural, and tensile strengths of concrete reduced marginally up to 10% replacement levels.

The rapidly increasing in population has led to the higher of construction, repairing and renovation activity that lead to produce large amount of construction material waste. The disposal of broken ceramic tiles during construction is one of the factors which contribute to this matter and can lead to land pollution. On the other hand, the natural resource in construction such as fine aggregate also facing depletion in order to cater the current and future demand. Therefore, this paper explores the properties of concrete with ceramic tile waste used as a partial replacement for fine aggregate. About 45 cube samples, 30 prism samples and 15 control samples were casted. Various percentage of ceramic tile waste has been introduced as partial replacement for fine aggregate with proportion of 10%, 15%, 20% and 30%. Tests for mechanical and rheological properties which have been done to identify the concrete performance are compressive strength, flexural, water absorption and slump test. From the results obtained, the sample of concrete contain of 15% ceramic tile waste as fine aggregate replacement has reached the optimum strength in both compressive strength and flexural strength. However, by using 20% of ceramic tile waste as fine aggregate replacement does show higher workability and water absorption.

In pursuit of sustainable and innovative construction practices, this study investigates the combined effects of sugarcane bagasse ash (SCBA) and ceramic tile waste (CTW) as subsititue to aggregates on concrete properties, aiming to optimize their usage as eco-friendly alternatives. However, SCBA is a waste product of sugar industry. As a result of increasing recognition and understanding of sustainability and recycling in academia and industry over the past several decades, sustainability and recycling have become increasingly significant. It is also important to note that recycling construction waste and debris is one of the opportunities available for reducing construction waste. To optimize the amount of cement replaced by SCBA, the cement was partially replaced by SCBA and the ceramic waste was replaced at different dosages of 10%, 20%, and 30% by weight of coarse aggregates. Different properties such as workability and compressive strength have been evaluated during 7 and 28 days following replacement by SCBA and CTW. The results further revealed that the workability decreased with the inclusion of SCBA and CTW due to water absorption by the CTW and SCBA particles. However, the compressive strength of concrete mix was relatively higher at 10% replacement of cement by SCBA and 10% replacement of CTW, after which it decreased beyond 10% replacement. The maximum compressive strength was observed as 29.31 MPa with 10% SCBA and 10% CTW at the age of 28 days which is around 9.7% higher than the control mix concrete. It was deduced from the results of this study that 10% SCBA and 10% CTW replacement by the cement and coarse aggregates respectively, could be considered asoptimum replacement.

Recycled materials have gained extensive recognition in many industrial sectors for enhancing sustainability and reducing environmental impacts. Combining ceramic tile waste (CTW) in concrete mixes with recycled aggregate will help lower natural aggregate demand and reduce the amount sent to landfill. This paper aims to study the mechanical properties of CTW in concrete mixes as a brick aggregate replacement and its impact on concrete strength and durability. To evaluate and assess their strength and durability, three types of concrete cubes were prepared using 20%, 40%, and 70% of waste ceramic tiles as a replacement for coarse aggregate. Two kinds of concrete samples were also prepared with conventional coarse aggregate as the control specimen (CC). A 1:2:4 concrete mixed ratio was used in this research with a 0.50 water-cement ratio. The samples were tested after 14 days and 28 days to assess their mechanical properties, including strength and durability. When CTW was added to concrete mixtures instead of brick chips, the mechanical strength rose considerably, and the water absorption performance increased. Moreover, replacing brick chips with ceramic waste in concrete could have significant environmental benefits.

Reutilizing ceramic polishing waste as powder filler in mortar to reduce cement content by 33% and increase strength by 85%

Society is developing concerning the development of the infrastructure and resources the word infrastructure contains the roadways, buildings, airports, runways and taxiways, and many things that make human civilization possible. Concrete is a vital element used in infrastructure projects in other words infrastructure construction is directly correlating the concrete production. Concrete is made of four basic elements water, cement, fine aggregate, and coarse aggregate where conventional coarse and fine aggregates are derived from rock and river mining from natural source that causes the natural resource depletion. Coarse aggregate and fine aggregates are chemically inert material at operational temperature. Therefore replacement of coarse or fine aggregate is possible with other inert material possess good mechanical strength and durability. In this research work we replace the conventional fine aggregate with brick dust and ceramic waste and brick dust. This experimental analysis based on two material replacement ceramic waste and brick dust up to optimum percentage to achieve maximum utilization. In this experiment, we found the optimum percentage of ceramic waste and brick dust is 20% and 15% respectively