Ceramic Slab Research Articles

Characterization of Stone Waste Sludge and Preliminary Investigation on Green Materials Based on Traditional Lime Putty for Sustainable Construction

Very large quantities of stone waste sludge are disposed in exhausted quarries and have a very low reuse rate to date. The paper considers the possibility of using these types of industrial waste in partial substitution of natural aggregates for the production of lime-based plasters. Traditional materials based on lime, the only material with a carbon neutrality life cycle, have considerable potential for use as components of green materials for plastering and finishing building surfaces in both new construction and historic heritage conservation. The paper presents the preliminary results of a research activity aimed at developing pre-packaged products based on Traditional Lime Putty (TLP) by partially replacing natural aggregates with Stone Waste Sludge (SWS), with a low rate of recovery from the Apricena limestone production district in Apulia. The mineralogical and chemical analysis carried out using XRD (X-Ray Diffraction), TG-DTA (Thermo Gravimetry-Differential Thermal Analysis), and hydrochloric acid attack test showed that the SWS consisted of 98.4 % CaCO3 by mass. The particle sizes measured by laser diffraction technique are below 22.5 μm for the 92% mass of the sample. The high fineness of the stone waste was confirmed by the Blaine-specific surface method, which equals to 9273.79 cm2/gr. The behavior of three fresh mixtures for prepacked coarse plaster, fine plaster, and finishing plaster with 12.90%, 17.94%, and 18.90 by mass of SWS, respectively, was evaluated by spreading test and applicability tests on a perforated ceramic slab. The finishing plaster has the highest consistency value of 235 mm, while the fine plaster and the coarse plaster have values of 205 mm and 155 mm, respectively. The coarse plaster is suitable for use as base plaster (arriccio) or second layer rendering (tonachino) up to a thickness of approximately 1 cm. Both the fine plaster and finishing plasters can be used for the surfaces finishing with the application of layers of a few millimeters thick.

The main strength material parameters of deformable cement adhesives

The deformable cement adhesives types C2S1 and C2S2 are usually used to glue ceramic slabs onto so-called critical substrates (other than concrete), including under changing weather conditions. The declared strengths of these adhesives attached to substrates can be found in the manufacturer’s standards and declarations. The use of cement adhesives on surfaces other than concrete or in other applications, such as a lightweight heated floor system (LHFS), should meet safety standards. To determine this, basic strength parameters for deformable adhesives, which have not been specified until now, need to be set. For this purpose, many analyses were performed, such as tensile and compressive strength tests, as well as the measurement of displacements in the thermal chamber, using, for example, digital image correlation and extensometric techniques. It was possible to define the main strength parameters of deformable adhesives, such as Young’s modulus (E), Poisson’s ratio (ν) and linear thermal expansion coefficient (α). These multiple measuring techniques were able to authenticate the obtained results, determining the maximum compressive strength of deformable adhesives, as well as longitudinal and transverse deformations. The research material parameters E, ν and α can be used for the calculation of LHFS with a heating coil, as well as for other building partitions or on critical substrates (different from concrete), using some of the many numerical methods available.

Content of crystalline silica phases in porcelain stoneware

Kitchen and bathroom countertop is a demanding application, where high aesthetic standards must combine with durability, ease of maintenance, and resistance to heat, stain, scratch and chipping. The hard materials and composites used for high-end countertops usually contain crystalline silica phases that can be inhaled by workers during drilling and cutting operations. The occurrence of silicosis and other respiratory diseases in machining workers makes it important to know exactly how much crystalline silica is present in countertop materials. This paper collects over 300 quantitative determinations of quartz and cristobalite in porcelain stoneware products and compare these contents with other countertop materials. The sum of crystalline silica phases in porcelain stoneware is on average 21 ± 5 % by weight (mostly quartz). This content is lower than granite (∼30 %) and much lower than engineered stone (∼90 %). Possible ways to reduce the amount of crystalline silica phases in ceramic slabs are overviewed and critically discussed.

USE OF BASALT AND CLAY MATERIALS IN THE COMPOSITION OF CERAMIC MASSES

The article examines the chemical mineral composition, the formation of crystalline phases of minerals, the basic properties of ceramic masses with igneous rocks and the formation of minerals during the sintering process in the temperature range 950-1150°C. The results obtained indicate that the introduction of iron-containing basalts stabilizes the structure of ceramic slabs and reduces their sintering temperature. According to geological data, kaolins from the Republic of Karakalpakstan are promising for use.

Effect of Quartz and Red-Clay to Phonolite Ratios on Some Properties of Floor Tile

This research paper presents the procedure of preparing and testing of experimental ceramic slabs in order to examine and investigate some of their physical and mechanical properties. These slabs were divided into two types; type (I) includes slabs made of either Quartz, Phonolite, Red-Clay, Green-Clay or Kaoline, whereas, type (II) includes slabs various in their Quartz and Red-Clay to Phonolite ratios. Other constituents of type (II) slabs such as Green-Clay, Kaoline were intentionally kept comparable for the sake of comparisons. Methods of preparing and testing of the experimental ceramic slabs were performed according to the technical constraints and facilities available at the Investment Complex for Manufacturing Building Materials (INCOMA) at Misurata-Libya. Several tests and measurements have been done on the experimental ceramic slabs of both types. The physical properties of type (I) slabs and raw materials ceramic powder were investigated with the determination of their water absorption, thermal shrinkage, heat lose, bulk density and fluidity. The breaking strength and impact resistance of type (II) slabs were also determined. These results were enhanced with surface and cross-sectional metallographic investigations for both types of experimental slabs. It is thought that the presence of a considerable amounts of oxides such as CaO, K O and Fe O in the Red-Clay decreased significantly the fractural strength, but improved the impact resistance of the experimental ceramic slabs. Conversely, the presence of high alumina and silica contents together with trace amount of ZrO in the Phonolite probably behind the improvement of their fractural strength, and decline of the impact resistance of the experimental ceramic slabs.

High Power (~10 kW) Yb:YAG Ceramic Slab Laser Operating at 1030 nm

A high power quasi-continuous-wave (QCW) efficiently-cooled ceramic slab laser oscillator is reported. The maximum output power can reach 9.85 kW with the optical-to-optical efficiency of 60% with respect to the absorbed pump power as well as the slope efficiency up to 65.3%. To the best of our knowledge, this is the highest output power for any Yb:YAG ceramic laser oscillator. Beam aberration of the efficiently-cooled Yb:YAG ceramic slab laser is detected by a parallel probe beam along the optical path of laser beam. The peak-to-valley (PV) value of the wavefront distortion is 2.8 μm under full output power. The beam quality factor β is estimated to be about 3.7 times diffraction limit while without additional correction system. A numerical model of temperature field is constructed to analyze the wavefront distortion of the probe beam, and the calculated results are in agreement with the experimental data.

Adherence of Brazilian dimension stones by mortar adhesion: influence of temperature

The influence of temperature variation on the adherence of granite slabs was simulated by a set of TBS tensile bond strength tests carried out using three types of rocks of established commercial use and with good technological qualities, known as “Branco Desireé”, “Vermelho Capão Bonito” and “Cinza Andorinha”. Specimens of these materials were fixed with two types of adhesive mortars, one commercial and the other produced in the laboratory, with white cement CPI. After the standardized cure, 186 TBS tests were carried out in 5 temperature ranges laboratory-controlled, ranging from 23 °C to 60 °C. The test results showed the temperature increase implies the loss of tensile strength. The commercial mortar presented TBS final values lower or nearby to 1 MPa, the standard threshold for ceramic slabs. The mortar prepared with white cement showed better performance, with adherence values above the 68% mentioned limit. This expressive result recommends the continuation of research with other types of rocks fixed with mortar prepared with white cement. The microstructure behavior of the material sets subjected to adherence tests was also investigated. The inspections showed clear contact between the stone plates (with both rough and smooth contact surfaces), without the occurrence of reaction edges or pervasion of the mortar in the stone. Anchoring, therefore, took place only in the contact between the standard substrate and mortar.

A Terahertz Circulator Based on Magneto Photonic Crystal Slab

In this paper, a terahertz circulator based on a magneto photonic crystal slab is envisaged. The triangular lattice photonic crystals with a line defect waveguide were constructed on an Al2O3 ceramic slab. Two cylindrical ferrites and two copper-clad plates in the junction of the Y-shaped wave-guide worked as a magneto-optical cavity resonator to approve the nonreciprocal function. In the working frequency range, 0.212–0.238 THz, the isolation of the circulator was better than 20 dB, and the insertion loss was better than 1 dB. The designed circulator based on the magneto photonic crystal slab experienced low loss and a wide bandwidth that satisfied its use in the THz application.

High power ceramic slab laser

High power ceramic slab laser

FEATTURES OF THE MANUFACTURING TECHNOLOGY OF THE ANCIENT GLAZE OF THE MAUSOLEUM OF KHOJA ACHMED YASAWI

The article discusses the technology of making clay masses, glazes of ceramic slabs of the mausoleum of Khoja Ahmed Yasawi. Descriptions of the mausoleum's design solutions, glaze varieties and their structure are given. The authors came to the conclusion that the creations of ancient masters who created a unique mausoleum building, made durable clay masses, ceramic tiles with glazed coatings during the construction of the mausoleum of Khoja Ahmed Yasawi are worthy of attention, further constant research and study for the development of the construction industry, during the construction of buildings and structures, including the manufacture of modern high-quality ceramic plates.

Fabrication and properties of multistage gradient doping Yb:YAG laser ceramics

AbstractIn order to fully pump and smoothen the temperature gradient of the gain medium, multistage gradient doping Yb:YAG laser ceramics were designed. The composite green bodies were fabricated by tape casting, and multistage gradient doping Yb:YAG ceramics with high optical quality were prepared by vacuum sintering and hot isostatic pressing. For samples pre‐sintered at 1740°C for 30 h and then HIP‐ed at 1700°C for 3 h in argon at 200 MPa, the in‐line transmission values at 1100 nm of YAG, 0.6 at.%Yb:YAG, and 1.5 at.%Yb:YAG ceramics were found to be 83.9%, 84.1%, and 83.3%, respectively. Finally, the 940 nm laser diode was used as the pump source to realize the 1030 nm laser output of multistage gradient doping Yb:YAG ceramic slab with a total energy of 3.43 J. The corresponding optical‐to‐optical conversion and slope efficiencies were 30% and 45%.

Desempenho ao ruído de impacto de laje nervurada pré-fabricada com vigotas protendidas com pisos laminados de madeira

Abstract This research aims to discuss and determine acoustic performance values for impact noise insulation (L’nT,w) for 39 floor system compositions that have different resilient materials and wooden laminate floor finishing. The methodology is organized according to ISO 16283-2, ISO 717-2 and NBR 15575-3 for classification. The results obtained demonstrate that the prefabricated ribbed slab with prestressed joists and ceramic slabs, as well as the slab and subfloor system do not meet the minimum requirements for acoustic insulation, comprising values of 91 and 84 dB, respectively. Among the other 37 samples, it is worth mentioning that wooden laminate floors with better abrasion resistance is more efficient concerning acoustic performance, comprising impact noise insulation values ranging from 60 to 62 dB, due to its surface density. In the samples that use resilient materials, the performance values vary from 55 to 46 dB.

A model based study of the drying and shrinkage behavior of a ceramic green body

This work presents a 1D diffusion model to characterize the drying procedure of a ceramic slab with respect to shrinkage. The proposed mathematical framework is comprised of a set of partial–differential and algebraic equations along with moving boundary conditions. The model predictions are compared to experimental data from the literature and a good agreement is accomplished. Afterwards, the parameters of a desorption isotherm equation are estimated based on experimental data from three drying tests, to characterize an industrially used clay material. A parametric analysis is conducted to study the impact of the drying-induced shrinkage on the drying kinetics of the ceramic body. The results indicate that the scale of shrinkage affects the porosity change which in turn, has a great impact on the drying kinetics and the properties distribution along the material. Finally, the drying dynamics of the green ceramic material is studied for a realistic shrinkage scenario, followed by the discussion of the results.

Study on cutting performance of ceramic rock slab machined by rotating ultrasonic vibration

Study on cutting performance of ceramic rock slab machined by rotating ultrasonic vibration

Violin Ceramic Joist Slabs: Evaluation and Proposal for Intervention with Duplex-Type Stainless Steel

Due to the present significant need to repair and maintain our buildings and the building repair sector’s minimal experience in special structural elements, we here describe a study on the repair of ceramic violin joist slabs in an actual intervention on a building erected in the 1950s that had been unsuccessfully repaired several times. Due to damp and being close to the sea, the main reinforcement elements had undergone considerable corrosion causing a significant risk to the building’s safety. The intervention necessarily involved replacing the affected steel rebars with appropriate elements with mechanical and corrosion resistance properties, as required by the latest building codes. An appropriate strengthening and repair system was developed with a stainless steel prosthesis fitted to the lower third of the joists that almost tripled their resistance, gave them 120 min of fire resistance, and increased their durability against corrosion at a cost of less than 50% of the current repair systems with minimum generation of construction waste. One of the most appealing characteristics of this new repair system is its avoidance of the full replacement of the joists, which can be considered as a relevant contribution to the sustainability of the construction industry.

Non-Vascular Ceramic Sherds Coming from Two Italian Etruscan Settlements: Peculiarities and Interpretation of Their Possible Use

Peculiar non-vascular ceramic slabs of uncertain use were found in two different Etruscan settlements of the Po Delta region (San Basilio di Ariano nel Polesine and Adria, North-East Italy) dated back to the first millennium BC. Different interpretations concerning the primary role of these fragments have been suggested by previous scholars. To bring to light an understanding of the construction processes that appear to be unique to the San Basilio and Adria settlements, a multi-analytical approach has been carried out. Macroscopic observations enabled these materials to be preliminary subdivided into groups based on chromatic features, followed by the identification of their chemical composition through FTIR-ATR spectroscopy. Moreover, the open porosity was estimated by the total water absorption test, and the superficial morphology and elemental composition of specific samples were analyzed using SEM-EDS. Furthermore, the firing temperature of a few selected fragments was evaluated by the TGA-DSC technique in order to investigate ancient production techniques. The results of the research lead us to consider the role of these peculiar non-vascular ceramic slabs as building materials due to their specific protective properties, considering the environmental conditions of the Po Delta region.

Numerical Analysis of Thermal Shock Cracking Behaviors of Ceramics Based on the Force-Heat Equivalence Energy Density Principle

Thermal shock is one of the main causes for the fracture of ceramic materials due to their inherent brittleness. Aiming to explore the mechanism of thermal shock cracking behavior of ceramics under different thermal shock conditions, a novel temperature-dependent failure criterion of thermal shock fracture of the ceramic materials was deduced based on the force-heat equivalence energy density principle. Combining this failure criterion and the finite element method, the thermal shock cracking behaviors of the thin circular and rectangular ceramic slabs under different thermal shock initial temperature were simulated. Results show that the morphology, periodicity, hierarchy, and number of thermal shock cracks obtained by numerical simulation are in good agreement with the experimental results. These essential characteristics verify the validity of the temperature-dependent failure criterion for thermal shock fracture. Furthermore, the strain energy of tension produced by thermal shock is proved to be the dominated mechanism for thermal shock-induced fracture.

Development and study of the properties of a ceramic-matrix composite material for the production of ultra-thin large-format ceramic granite slabs

The article analyzes the advantages and disadvantages of large-format ultra-thin ceramic granite slabs, shows the need and identifies ways to increase their strength. The composition of the ceramic matrix has been developed, provides the maximum level of sintering (W ≤ 0.5 %) in accordance with the requirements for ceramic plates of class ВІа, and the choice of the reinforcing filler has also been substantiated. It has been experimentally established that mullite-silica fibers have a positive effect on the physical and mechanical properties of the slabs, which makes it possible to reduce their thickness by three times, and therefore significantly reduce the weight of products. The fractional composition of the grinding products of mullitesilica fibers was determined depending on the grinding conditions, and the influence of the quantitative and qualitative characteristics of the reinforcing filler on the main properties that determine the quality of ceramic granite slabs was investigated. The conditions for the formation of densely sintered composite materials with a complex of high-performance properties have been determined. It was shown the possibility of increasing the samples bending strength up to 57 MPa by introducing 4 wt. % of finely dispersed mullitesilica fibers, most of which (~ 60 %) have a length up to 45 microns, which is achieved by 3 min grinding in a planetary mill at a speed of 300 rpm. The structural-phase features of the samples obtained under the high-speed firing conditions, which consist in the increased amount of the mullite phase formation in the presence of mullite-silica fibers, have been established. The latter not only reinforce the ceramic matrix, but also act as a precursor of new mullite formations, the crystals of which, in the presence of a melt, acquire an isometric shape and contribute to an increase in the products strength. The research results indicate the promising obtain large-format ultra-thin ceramic granite slabs using composite materials technology. The combination of excellent technical qualities, large dimensions, and reduced slabs thickness opens up the new possibilities for using composite ceramic granite in design of furniture and large rooms due to the possibility of creating a continuous seamless coating and a significant reduction in the products weight.

Cutting behaviour of porcelain stoneware slabs: A microstructural evaluation

The study concerns the characterisation of five porcelain stoneware slabs with thicknesses of 12 and 20 mm and different cutting responses. Two slabs showed a deviation from a linear cut, resulting in a poor response to the diamond disk, while the other three slabs reacted well. In order to highlight any differences between these slabs, mineralogical and microstructural analyses were carried out, including the determination of a sintering index, total porosity and pore size distribution.This approach is based on a “reverse engineering” concept whereby the cause of the cutting effect can be traced by analysing the finished product.Both the total porosity values and the sintering index can be considered as critical parameters to evaluate the cutting responses of ceramic slabs. The best compromise to obtain a good cutting response, in porcelain stoneware slabs, is reached when the total porosity is the maximum possible, pores are the smaller as possible and the sintering index is the minimum possible, without compromising the quality and technical performance of the porcelain stoneware.

Effect of different cleaning methods after surface treatment of dental ceramics on the surface characteristics and adhesion to resin-based luting agents

The aim of this study was to assess the efficacy of cleaning methods after the surface treatment of dental ceramics. Ceramic slabs (zirconia – Yz; lithium disilicate-reinforced glass – Ld; and porcelain – Pc), were submitted to different surface treatments (air abrasion for Yz and hydrofluoric acid etching for Ld and Pc), and after, six cleaning methods were tested: DW – distilled water for 60 s; AL – 70% alcohol for 60 s + DW; UDW – ultrasonic bath with distilled water for 60 s; UAL – ultrasonic bath with 70% alcohol for 60 s + DW; IVC – ivoclean for 20 s + DW; PAC – 37% phosphoric acid for 20 s + DW. Microshear bond strength to luting agent was tested after 24 h (baseline) or 6 months storage (aged) in water at 37 °C. Complementary analysis of failure pattern, surface topography and composition, and contact angle measurements were executed. The cleaning methods promoted similar bond strength for Ld and Pc, regardless of the condition (baseline and aged) and for Yz after aging. DW, AL, and PAC decreased the contact angle for Yz, while UAL decreased for Ld. Pc presented a higher wettability with UDW, UAL, and PAC. The use of IVC and PAC resulted in precipitates in the Pc surface. For Yz, more air-abrasion remnants were observed using DW; for both Ld and Pc, a higher presence of fluorine was observed in groups treated with IVC. Despite differences in surface composition, topography and contact angle measurements, after aging the bond strength to the tested ceramic materials was similar regardless of the different cleaning methods.