Clay Ceramics Research Articles

Utilization of Marble Wastes in Clay Bricks: A Step towards Lightweight Energy Efficient Construction Materials

Marble dust is one of the hazardous byproducts of marble-processing factories and requires planned disposal. Its beneficial use as a construction material will add to the sustainability, and most importantly, might overcome the burden of marble waste disposal. However, the use of marble dust in concrete has a negative impact. Therefore, this research examines various properties related to the utilization of such material in ceramic clay, and therefore its effects on the use of clay bricks are investigated. The research activity covers the categorization of marble dust powder from three different sources: Ziarat in Mohmand Agency, Buneer, and Mullagori (Pakistan). Its utilization in different proportions preparation of bricks is also addressed. Through the partial replacement of clay with marble dust from 0 to 30% by weight with amplification of 5%, seven mix designs are examined. The test result includes Bulk density, water absorption, porosity, thermal insulation, and strength. The partial replacement of clay with marble dust reduced its weight, strength and increased its porosity, water absorption, and thermal insulation. Furthermore, the utilization of marble powder in bricks minimizes soil erosion and reduces pollution to the environment. Doi: 10.28991/cej-2021-03091738 Full Text: PDF

White Clay Ceramic Tableware Waste as Coarse Aggregate in Concrete - Some Mechanical Properties and Durability against Fire and Sulfate Attack

The aim of study is to produce durable structural concrete by using waste ceramics with specified type (white clay ceramics) as coarse aggregates in concrete. Mechanical properties were studied, the study also show good resistance to fire resistance for concrete contains ceramics as coarse aggregates compared with normal aggregates concrete, good mechanical properties such as compressive, tensile, and flexural strength. Results of study gave 17.5% increment in compressive strength by using 100% replacement of waste ceramic, flexural strength increased with 27.8% increment. Study also show less reduction in strength due to fire resistance by using waste ceramics compared to ordinary concrete, and also more durable concrete for salty water effects by using ceramic.

INVESTIGATION OF THE EFFECTS OF PAPER ADDITIVE TO AVANOS POTTERY CLAY AND ARTISTIC CERAMIC APPLICATIONS

The lands of Anatolia we have been embracing as our homeland with the history of thousands of years hosted many cultures throughout the centuries. Art of ceramics inherited by us from these cultures has been revealed as various materials in every period of our lives. Archaeological excavations show that our history of ceramics dated to the Neolithic period. In Anatolia, embracing such a rich cultural history, many manufacturing centers in the field of traditional pottery still do exist. Avanos, among those centers, is a district of the province of Nevşehir located in the Central Anatolia region. Established on both shores of Kızılırmak, the district is one of the substantial settlements of the region known as Cappadocia. Due to the red soil of Kızılırmak, it contributed to the birth and development to the greatest extent of pottery within the region. The red soil of Avanos region provides opportunities for various research within the field of ceramics technology. In the study “paperclay”, which is also the subject matter of this study, the clay of Avanos region has been used. The paper containing clay is named as “paperclay” in English and takes part in the ceramic terminology with the same nomenclature. It is obtained by adding certain ratios of paper into the ceramic clay upon processing through various stages. In comparison of the paper containing clay with the traditional clay, it reveals numerous superior features. Based on the fact that cellulose, the raw material of the paper, forms a reticular structure in the clay, it eliminates the adverse effects such as fissures and cracking that may occur during drying. Paper containing clays are preferred by ceramic artists due to their positive features such as the large-sized ceramic form work facilitating the works and lightweight after kilned. The natural clay used in the Avanos pottery does not allow large-sized works as it results in fissures and cracking particularly as a result of rapid kilning during the artistic practices. Therefore, various tests have been conducted by adding paper in different ratios into the red clay used in Avanos pottery. Artistic practices have been performed based on the outcomes of the tests. Keywords: Art ceramics, clay, papercaly

Microstructural characterization of ceramic artifacts made using the raku technique

This study was carried out at the atelier “Adamas”, located in the city of Cunha, in the state of São Paulo, Brazil. The objective is to characterize the physical and mechanical properties of ceramics made using the raku technique in the Adamas atelier. As a methodology, the specimens were submitted to the following tests: Scanning Electron Microscopy (SEM), X-ray Energy Dispersion Spectroscopy (EDS), mass loss and linear shrinkage. It was observed that the specimens were mainly composed of silicon and aluminum, which is typical of ceramics made with kaolinitic clays, possessing a plastic behavior for molding and after firing refractory. Therefore, ceramic artifacts made through the raku technique have typical chemical and physical characteristics of clay ceramics, proper adhesion of the glaze even when there are crackles originated purposely from the process, which causes the artistic artifact appropriate characteristics for use and appreciation.

Preparation of Low-Dielectric-Constant Kaolin Clay Ceramics by Chemical Cleaning Method

Kaolin clay is an inexpensive and abundant material with potential for use as a low-dielectric-constant ceramic; however, the natural metallic oxides the clay contains hinder such applications. In this study, kaolin clay ceramics with excellent physical and dielectric properties were synthesized using kaolin clay as the raw material by chemical cleaning and sintering. Characterization of the resulting samples showed that the sulfuric acid treatment has a significant influence on the metallic oxide content and dielectric properties of the kaolin clay ceramics. When the kaolin clay raw material was treated with sulfuric acid three times, the dielectric constant decreased from 5.12 to 3.75 and the Vickers hardness increased from 946 to 1,214 kg/mm2 relative to the ceramic prepared from the untreated clay. Therefore, these ceramics exhibit significant potential for use in the microelectronics industry.

Clay Ceramic Waste as Pozzolan Constituent in Cement for Structural Concrete.

Ceramic-based wastes generated from different industrial activities have increasingly been reused as construction material incorporated into concrete. In general, these wastes just replace common concrete aggregates such as sand and gravel. In the present work, waste from clay brick industries composted of kaolinite minerals were for the first time evaluated for their potential to be reused as the pozzolan constituent of a cement for structural concrete. Initial standard testes revealed that the clay ceramic waste (CCW) displays high pozzolanicity. Concrete was then produced with 10 and 20 wt.% of CCW mixed with ordinary Portland cement (OPC) as its pozzolan constituent. Compression strength of these concretes and of pure OPC as a control sample were determined in standard tests after 14 and 28 days of curing. In addition, the corresponding density, water absorption, capillarity and percentage of voids were measured together with the evaluation of microstructural indices by scanning electron microscopy. The initial tests confirmed that the CCW is indeed an effective pozzolanic potential due to a chemical effect by reacting with CH to generate C–S–H. Moreover, the technological results proved that CCW might effectively replace the pozzolan cement constituent for structural concrete.

Kaolinite‐based clay ceramics blended with residual fique fibers for potential plastic soil applications

AbstractThe high content of clay minerals within the soil has a significant effect on its engineering behavior; water affects the interaction of their minerals, which influences their plasticity and deformability. Structures made with or on plastic materials can experience problems due to the high deformations presented in soil. Therefore, decreasing the deformability of plastic soils contributes to the stability and serviceability of the structures supported by this kind of soils. This investigation is about the effect of fique fibers contents in the mechanical behavior of a plastic soil based on a kaolinite‐type clay. Fique fiber is natural fiber from Colombia. Soil with additions of 0.0 wt%, 0.2 wt%, 0.7 wt%, and 1.0 wt% of fique fibers was fabricated. The goals by adding the fibers are to increase the compressive strength of the soil and to add a green reinforcement to the soil targeting a circular economy solution. Density, optimal water content, and unconfined compression tests were conducted. The microstructure was characterized with scanning electron microscopy and X‐ray diffraction. Results showed that fique fibers improved not only the compressive strength by almost three times for sample with 1.0 wt% of fibers with respect to the reference soil without fibers but also the ductility increased.

Colorimetric evaluation of the presence of efflorescence in red clay ceramics with calcium and sulfate ions

Efflorescence is a pathology quite frequently observed in ceramics. However, it has not yet been developed a methodology capable of quantifying this process's advance or its onset manifestation with precision. In this context, this paper proposed a method that uses colorimetry measurements to identify the presence and also quantify the efflorescence phenomenon. For the proposed methodology validation, red clay samples with added amounts of calcium sulfate (5; 10 and 15 % wt.) as an efflorescence agent were prepared by uniaxial pressing, following heat treatment at 900, 1000, or 1100 °C. To produce the efflorescence phenomenon, samples were then immersed in ultrapure water, only half of their height, for 21 days and then dried in the open air. After the heat treatment, the samples were also characterized by apparent porosity, water absorption, the presence of soluble salts in the fired clay, and water penetration capacity. It was possible not only to identify with precision the onset of the superficial efflorescence phenomenon but also to quantify it in a reliable way using the colorimetry method proposed since even small amounts of calcium sulfate crystals are capable of changing the light reflectance index of the original surface, which is easily detected by a colorimeter.

Mineral Composition and Morphological Features of Kaolinite in Ceramic Clays of the Shulepovo Deposit (Ryazan Region, Central European Russia)

This paper addresses for the first time the internal structure of lens 2 of the Shulepovo refractory clay deposit. The SEM study of representative samples from the entire lens section revealed relationships between the major minerals: kaolinite, halloysite, illite, and quartz. The lens was previously considered homogeneous, but its detailed study revealed a clear internal zonality. The structural forms of kaolinite (hexagons, vermicules, and films), halloysite (acicular or columnar and stellate crystals), and illite (intergrowths and bands) are distinguished. Their variable relationships define the vertical zonality of the lens.

Microwave hybrid fast sintering of red clay ceramics

AbstractThis work aimed to examine the performance of the hybrid sintering of clay ceramic in a microwave furnace, compared to the sintering process in a conventional furnace. The raw materials were subjected to X‐ray fluorescence, loss on ignition (LOI), X‐ray diffraction, particle size distribution, real specific mass, and thermogravimetric analyses. The red clay ceramic mass was prepared, extruded, pre‐sintered in a conventional furnace at 600°C/60 min, and sintered at temperatures between 700 °C and 1100 °C. The sintering conventional (resistive oven) was carried out for 60 min with a heating rate of 10°C/min. In the microwave furnace, the sintering times were 5, 10, and 15 min, with a heating rate of 50°C/min, with a sintering chamber coated with silicon carbide (susceptor). The sintered specimens were characterized according to linear shrinkage, water absorption, apparent porosity, apparent specific mass, X‐ray diffraction, Raman spectroscopy analysis, spectroscopy analysis in the ultraviolet and visible regions, microhardness, and scanning electron microscopy. The results showed that microwave sintering promoted an increase in the microhardness and apparent specific mass, and reduction in water absorption and apparent porosity values, due to greater densification in the microstructure. The best results occurred for specimens sintered at 1100°C.

Mechanical and structural properties of environmental green composites based on functionalized bacterial cellulose

In this work TiO2 and highly inorganic ceramic clay were successfully immobilized into Bacterial Cellulose (BC), produced by Komagataeibacter xylinus K2G30 (UMCC 2756) strain, in different proportions. The morphology, structure, and mechanical properties of the composites, fabricated by wet mechanical mixing, were investigated through a multi-technique approach: density measurement, optical and electronic microscopy, FTIR spectroscopy, contact angle measurement and mechanical tensile testing, before and after aging, under UV light exposure. Results suggest completely different behavior by using TiO2 or Clay. In fact, porous fragile structures were obtained by employing Clay, whereas more compact and plastic-like specimen by using TiO2, due to different chemical bonding developed through H-bonding, as confirmed by FTIR. Enhanced tensile resistance at break was found for a content of TiO2 equal to 20 wt% and this result was not affected by aging, under UV light exposure. This study demonstrates how ceramic inorganic fillers for BC are able to act in completely different way, becoming of interests in different fields such as hydrophilic porous membranes for Clay and compact plastic-like film for textile industry with TiO2 addition.

Находки из Межегейского городища (Республика Тыва), хранящиеся в Государственном Эрмитаже

The article describes a small collection of finds from the Mezhegei settlement with the total of 105 items which were included in the collection of the State Hermitage in 1987. The artifacts were discovered by the Tuvan archaeological expedition of Moscow State University under the leadership of L. R. Kyzlasov in 1960. The excavations showed that the buildings of the settlement were constructed in the architectural traditions of the 11th — 13th centuries. Local builders used a frame, the foundations were made of large adobe bricks, the dwellings were heated with kangs, massive bases for columns were preserved, the roof was tiled, there were many bas-reliefs to decorate the walls and the ridge of the roof. The settlement was the remains of a Mongolian city founded in the first half of the 13th century with the area of about twenty-five hectares. There were many buildings in the city, the remains of a rampart and other structures have been preserved. The finds, according to the inventories, come from a Buddhist temple and stupa. These are mainly architectural decorations, tiles and gray clay ceramics. The article describes five findings from the Mezhegey Settlement. Keywords: Mezhegey settlement, archaeology, tiles, architectural fragments

Comparison of Three Manufacturing Techniques for Sustainable Porous Clay Ceramics.

This study proposes different manufacturing techniques (manual pelletization, powder pressing, and “shell scaffold”) to obtain lightweight clay ceramics containing recovery raw materials. The sintering in an electrical furnace (1000 °C, 1 h processing time) was conducted by traditional firing from room temperature, for pressed and shell-scaffold samples, while the flash heating (i.e., samples directly put at 1000 °C) was used only for the pellets. The porous materials (porosity 40–80%), functionalized with nutrients (K and P) in amounts to confer the fertilizer capability, gave suitable results in terms of pH (6.7–8.15) and electrical conductivity (0.29–1.33 mS/cm). Thus, such materials can be considered as feasible lightweight clay ceramics, with a positive effect on the soil. These findings permit us to hypothesize a potential use in green roofs or in agronomic applications.

What is the most relevant method for water absorption determination in ceramic tiles produced by illitic-kaolinitic clays? The mystery behind the gresification diagram

This study presents the 51 mixtures of ceramic clays characterized by using XRF, XRD, granulometry, and dilatometry analyses. After firing in a 1000–1250°C range, water absorption (WA) according to EN standards by boiling in water, under vacuum, and by 24h soaking is determined. The results indicated that there was a high and statistically significant correlation between the standard methods, but the testing under vacuum gave the highest saturation of the samples fired at 1200°C and 1250°C. It is determined that these illitic-kaolinitic clays can be used to produce floor ceramic tiles belonging to the BIIa group (water absorption between 3% and 6%).The study also aimed to reveal which method of WA determination is suitable to read the sintering interval from the gresification diagrams, which is compared to the beginning of sintering as read from dilatometry curves.

A Study on the Utilization of Coal Fly Ash Derived Grog in Clay Ceramics.

Grog is an additive material that plays important roles in ceramic making. It improves the fabrication process of green bodies as well as the physical properties of fired bodies. Few low-cost materials and wastes have found their application as grog in recent years, thus encouraging the replacement of commercial grogs with cost-saving materials. Coal fly ash, a combustion waste produced by coal-fired power plant, has the potential to be converted into grog owing to its small particle sizes and high content of silica and alumina. In this study, grog was derived from coal fly ash and mixed with kaolin clay to produce ceramics. Effects of the grog addition on the resultant ceramics were investigated. It was found that, to a certain extent, the grog addition reduced the firing shrinkage and increased the total porosity of the ceramics. The dimensional stability of the ceramics at a firing temperature of 1200 °C was also not noticeably affected by the grog. However, the grog addition in general had negative effects on the biaxial flexural strength and refractoriness of the ceramics.

CLASSIFICATION OF ARTISTIC GLAZED CERAMICS OF DERBENT OF THE END VIII-X CENTURIES.
 (on the example of materials from excavations XXVII and XXXIII)

The article is devoted to the classification analysis of the glazed ceramics of Derbent, originating from the materials of archaeological excavations (excavations XXVII and XXXIII), carried out in 2014-2015. in the city. The chronological framework of the study was presumably determined by the end of the VIII-X centuries. The relevance of the topic is characterized by the importance of studying the glazed ceramics of Derbent as a source of a large set of information (historical, cultural and socio-economic interactions of Derbent with a wide range of countries of the Near and Far Abroad).Typology of glazed ceramics in Derbent at the end of the 8th-10th centuries is considered in the article on the basis of modern methodological developments based on three main approaches to the study of any ceramics: the study of technology together with the morphology and decor of the dishes. All investigated ceramics, consisting of fragments of rims, bodies, bases and handles of vessels, are included in one large Section - Household ceramics. This section includes three sections, which are based on the analysis of the clay color of the shard (red clay, brown clay, beige clay ceramics), which determines the technology for the production of dishes. Based on the presence or absence of engobe on ceramics, two subsections are allocated in each department. The next division is the groups that are formed according to the degree of transparency of the opaque glaze. There are three of them: ceramics with transparent, translucent, opaque (dull) glaze. Within some groups, four subgroups are additionally distinguished, determined by the color of the glaze. According to the peculiarities of the additional decor, the types (overglaze, underglaze ornament) and subtypes (painting, engraving, combination of painting with engraving, relief ornament) of ceramics are distinguished. Thus, the characteristics of the glazed ceramics of Derbent from these excavations include: Section, department, sub-department, group, subgroup, type, subtype.

Fast drying for the manufacturing of clay ceramics using natural clays

In this work, the feasibility of using natural clays for the manufacture of clay ceramics processed by fast drying was studied using mixture design (DoE). Three clays were selected and their chemical (XRF), mineralogical (XRD) and particle size characteristics (laser diffraction) were determined. A plastic clay, a sandy clay and a claystone were used in a simplex centroid mixture design resulting in 10 compositions that were processed by extrusion. The extruded samples were subjected to forced drying in fast cycles of 180 min. The performance of the process, content of coarser particles, moisture loss and drying shrinkage were evaluated by response surfaces. As a result, the plastic clay was the most significant factor for the properties under analysis, since mixtures using above 33% of this clay resulted in losses of moisture by drying greater than 50%. The plastic clay showed low content of coarser particles (>45 μm), therefore hindering the diffusion of water between capillaries, resulting in high shrinkage and causing cracks during drying. The use of claystone could stabilize the shrinkage in the neutral zone of drying, minimizing the number of defective samples during drying caused by cracking.

Effect of the Incorporation of Marble Waste in the Properties of Clay Ceramic Bricks

Residues incorporation into construction building materials is a promising sustainable alternative for the correct disposal of this kind of material. Brazil is one of the largest world producers of ornamental stones. Nevertheless, the disposal of these residues usually is made outside the industry, which contributes to environmental pollution. This work aimed to evaluate the incorporation of residues from the marble industry into ceramic bricks. Specimens of clay ceramic containing 10, 20, 30 and 40 wt.% of marble residue were prepared and fired at 900oC. The evaluation of the ceramic bricks added with marble residue was based on linear shrinkage, water absorption and mechanical resistance. These properties were compared with Brazilian standards. It was concluded that the incorporation of marble residues, with up to 20 wt%, into the ceramic body is technically feasible and positively influences the properties of the material.

Valorization of Spent Coffee Grounds, Biochar and other residues to Produce Lightweight Clay Ceramic Aggregates Suitable for Nursery Grapevine Production

The valorization of agro-industrial by-products is one of the key strategies to improve agricultural sustainability. In the present study, spent coffee grounds and biochar were used as pore forming agents in the realization of lightweight clay ceramic aggregates that were used as sustainable fertilizers, in addition to tailored glass fertilizer containing phosphorous (P) and potassium (K) and nitrogen (N) synthetic fertilizer, for nursery grapevine production. The obtained fertilizers were assessed in a pot experiment for the fertilization of bare-rooted vines. Unfertilized (T0) and fertilized plants (T1, using NPK-containing commercial fertilizer) were used as controls. Plants fertilized by spent coffee grounds and spent coffee grounds + biochar-containing lightweight aggregates and added with 30 wt% of the above-mentioned glass and N fertilizers (T2 and T3, respectively) recorded higher values of plant height, shoot diameter, leaf and node numbers. Moreover, T2 treatment induced the highest chlorophyll content, shoot and root dry weights. The present study shows that lightweight clay ceramic aggregates containing spent coffee grounds and glass and N fertilizers can be used for nursery grapevine production, in turn improving the agricultural sustainability.

Firing behaviour of Tertiary, Cretaceous and Permo-Triassic clays from Castellon ceramic cluster (Spain)

This study is focused on the knowledge of clays historically used in manufacturing of ceramic pavement and coatings from the province of Castellon (NE, Spain) with a large ceramic industry. This research began in the early 1980s in the research group led by Professor T. Sanfeliu and continues today. This review paper and the last advances in knowledge have been written in honor of Professor E. Galán, one of the pioneers in the study of ceramic clays and kaolin in Spain. The objective of this paper is to extract conclusions about mineralogy, porosity and bending strength in ceramic test bodies manufactured using Tertiary-age, Cretaceous and Permo–Triassic local clays. Tertiary clays show a high CaO content and their predominant mineral phases are calcite and quartz. Cretaceous clays show a scarce CaO content. These Cretaceous raw materials are clays with high quartz and illite percentages. Permo–Triassic clays present a difference in the K2O and Fe2O3 content. The mineralogical composition is mainly formed by quartz, clay minerals and hematites. Ceramic test bodies were molded by extrusion and undergoing a firing process. Characterization of the fired clays was accomplished by TOM and XRD. Granular texture and porphyry structure, quartz phenocrysts and opaque hematite crystals were observed. Illitic clays rich in carbonates form plagioclases, wollastonite and gehlenite from 950 °C. In samples with low content in calcite and dolomite, the predominant mineral phases are quartz and hematite from 1000 °C onwards. A mercury porosimeter was used for determining the porous texture of ceramic matrix. A progressive reduction in open porosity and an increase of bending strength are observed with increasing temperature. The essays for bending strength were carried out by an INSTRON. A decline in porosity was observed when temperature rise associated with an increase in bending strength. Establishing relations between bending strength and the seven parameters studied link to the porous behaviour of the ceramic tests it was not possible because empirical equations do not fit experimental results.