The effect of replacing sand with aggregate from sanitary ceramic waste on the durability of stucco mortars

Beata Klimek,Paweł Ogrodnik,Jacek Szulej

doi:10.1007/s10098-020-01932-w

Beata Klimek, Paweł Ogrodnik + Show 1 more

Open Access

https://doi.org/10.1007/s10098-020-01932-w

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Abstract

During processing and transport, the ceramic industry generates big amounts of waste. In order to limit the number of landfills and to minimise consequences of such waste that is clearly noxious for the environment, this industry remains under great pressure to find effective recycling methods for its waste and by-products. What is more, given the limited resources of traditional aggregate, energy savings and protection of the environment, the construction industry is seeking for new sources of aggregate. For this reason, ceramic waste is increasingly frequently used as coarse and fine aggregate, both in mortars and in concrete mixtures. The goal of studies presented in the paper was to analyse the impact of recycled ceramic aggregate on the frost and salt spray resistance of stucco mortar used in the construction industry. Mortar recipes also contained admixtures that modify properties of the mixture and of the hardened product, such as copolymer of vinyl acetate and methylcellulose with a hydrophobic admixture. Elementary testing was performed related to mechanical and physical parameters of mortars. Among others tests were carried out of compressive strength and flexural strength, a determination was made of density, open and total porosity, absorbability, resistance to salt spray corrosion and frost resistance after 25 freeze–thaw cycles of samples. Replacement of sand by recycled ceramic aggregate causes a change in physical parameters of mortars. It has a positive impact on strength parameters of mortars with concurrent reduction in absorbability and capillary action. Testing of mortar with the addition of ceramic aggregate has proved better frost resistance and resistance to salt crystallisation as compared to mortar to which sand had been added.Graphic abstract

Highlights

The rapid increase in global population and the ever-developing economy cause the generation of large volumes of waste
Results of strength tests before and after 25 freeze–thaw cycles clearly speak to the favour of ceramic aggregate
Average values of compressive strength for the group of mortars based on ceramic aggregate amounted to 6.42 N/mm2 while mortar containing sand—4.49 N/mm2

Summary

Introduction

The rapid increase in global population and the ever-developing economy cause the generation of large volumes of waste. European countries place emphasis on the rational use of waste in an effort at limiting the need for traditional raw materials, reducing the environmental degradation by decreasing air and water pollution, reducing the energy consumption and creating new jobs. The European “Zero Waste” programme (European Commission 2014) assumes taking up measures aimed at transition onto a closed circle economy, which to a large extent has been based on the reuse and high quality of recycling, and much less on primary raw materials. Systems of closed circle economy retain the value added of products for a long time and allow elimination of wasting. Waste generated during the production of sanitary ware requires over 4000 years to decompose in a natural process, which is not acceptable (Correia et al 2006). The annual usage of aggregate in Poland equals to ca. 4–4.5 tonnes/persons and leads to the exploitation of 3 billion tonnes of non-renewable natural resources annually, at an average annual increase by 7% (Uzunow 2014)

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