Production Of Ceramic Floor Tiles Research Articles

Recycling of urban glass waste in ceramic floor tiles toward sustainability

AbstractAround 21.7 million tons of urban solid waste are produced in North Africa and the Middle East. The amount of glass waste produced is 0.87 million tons. The amount of urban glass waste (UGW) produced in Egypt was 2280.8 tons per day. This paper aims to study the effect of partial replacement of UGW in the production of ceramic floor tiles to save the production cost and raw materials. The characteristics of the basic raw mixture of floor tiles and UGW were studied. The waste was collected, crushed and ground to be blended with the basic mixture in different percentages that ranged from 0 to 35%. The specimens were molded under uniaxial pressure followed by drying and firing at temperatures ranging from 1050 to 1120 °C. The characteristics of the fired specimens have been determined and compared with the International Standard Limits. The results showed that specimens containing waste ranging from 25% to 35%, fired at 1100 °C with a soaking time of 15 min have a modulus of rupture of 18.9 to 19.7 MPa, breaking strength of 600 to 613N and water absorption of 9.78% to 8.2% respectively that fulfilled the lowest requirements for the ISO 13006 for dry pressed tiles Group BIIb.

Ceramic floor tiles with yellow pigment from Kievan Rus’: A technological study

Colored glazed ceramic tiles were widely used for paving floors of the main buildings, mostly Orthodox churches, in the Kievan Rus’ (10th-13th centuries AD). The production of ceramic floor tiles was localized near the site of construction, and the date of production can be attributed to the date of construction or renovation of the church. Therefore, the study of glazed tiles makes it possible to determine the local and chronological features of their production technology.. Local production technology in Ancient Rus' was studied using thirteen yellow glazed ceramic tiles from six cities (Kiev, Galich, Polotsk, Vladimir-Volynsky, Pereslavl-Zalessky and Novgorod). Also, two samples were selected from churches in Polotsk, Vladimir-Volynsky and Vyshgorod at different times of construction or renovation to study chronological variations in tile production technology. Chemical compositions and crystalline phases of yellow glaze and ceramic body have been analyzed by X-ray diffraction, Raman and X-ray fluorescence spectroscopy. In all cases, samples of ceramic tiles were glazed with high-lead silicate glass, and lead tin yellow type II (PbSn1-xSixO3) was used as a pigment. Local production technology in Ancient Rus' was studied using thirteen yellow glazed ceramic tiles from six cities (Kiev, Galich, Polotsk, Vladimir-Volynsky, Pereslavl-Zalessky and Novgorod). Also, two samples were selected from churches in Polotsk, Vladimir-Volynsky and Vyshgorod at different times of construction or renovation to study chronological variations in tile production technology. Most likely, the glaze layer on the ceramic tile was formed using pre-synthesized glass; this technology differs from the conventional technology for pottery, uses lead oxide or a mixture of lead oxide and quartz. Data on the chemical composition of yellow lead glazed tiles dating from the 10th-13th centuries AD can be used to determine the region of glazed ceramic production.

Nested Hierarchical Design Application in Production of Ceramic Glazed Floor Tiles

The challenges of using locally available materials in Nigeria to meet the tiles demand that will be affordable and compete favourably with imported products will no doubt not only contribute to our Gross Domestic Product but also meet the yearning of the Federal Government on her local content policy. This necessitated this study to aim at the production of ceramic floor tiles with clays modified with naturally occurring materials. An experimental method was adopted to carry out this research work. Different clay samples were purposively gotten from Mbaukwu town, Anambra State, Nigeria. Rice husk, silt, feldspar, quartz was obtained to serve as modifiers. An elaborate nested experimental design, structured as an analytical hierarchy process, and festooned with three base materials, 4-modifiers, and with replications, facilitated the achievement of the production. The nested design was developed to guide in the optimum combination of materials that will give the best yield of tiles. The base materials were used in combination with the four modifiers at different percentage levels. The tiles produced were subjected to same test in order to ascertain their behavior in terms of weather, resistance to abrasion, compatibility with mortar, water absorption, dilute acid, Sodium Hydroxide and detergent. The experimental tiles produced compete favorably with any foreign product as it was seen to match up with “Vetrified tiles” and “Gomex tile” from Italy and satisfies NIS 427: 2000. Glazed ceramic floor tiles have been successfully manufactured locally using clay and other naturally occurring materials and it has given excellent performance characteristics.

Nested Hierarchical Design Application in Production of Ceramic Glazed Floor Tiles

The challenges of using locally available materials in Nigeria to meet the tiles demand that will be affordable and compete favourably with imported products will no doubt not only contribute to our Gross Domestic Product but also meet the yearning of the Federal Government on her local content policy. This necessitated this study to aim at the production of ceramic floor tiles with clays modified with naturally occurring materials. An experimental method was adopted to carry out this research work. Different clay samples were purposively gotten from Mbaukwu town, Anambra State, Nigeria. Rice husk, silt, feldspar, quartz was obtained to serve as modifiers. An elaborate nested experimental design, structured as an analytical hierarchy process, and festooned with three base materials, 4-modifiers, and with replications, facilitated the achievement of the production. The nested design was developed to guide in the optimum combination of materials that will give the best yield of tiles. The base materials were used in combination with the four modifiers at different percentage levels. The tiles produced were subjected to same test in order to ascertain their behavior in terms of weather, resistance to abrasion, compatibility with mortar, water absorption, dilute acid, Sodium Hydroxide and detergent. The experimental tiles produced compete favorably with any foreign product as it was seen to match up with “Vetrified tiles” and “Gomex tile” from Italy and satisfies NIS 427: 2000. Glazed ceramic floor tiles have been successfully manufactured locally using clay and other naturally occurring materials and it has given excellent performance characteristics.

Valorization of Municipal Waterworks Sludge to Produce Ceramic Floor Tiles

In municipal waterworks large amounts of waste in the form of sludge have to be discarded. This investigation focuses on the processing of ceramic floor tiles incorporated with a municipal waterworks sludge. Four floor tile formulations containing up to 10 wt. % of the municipal waterworks sludge were prepared in order to replace the kaolin. The floor tile processing route consisted of dry powder granulation, uniaxial pressing, and firing between 1190 and 1250 °C using a fast-firing cycle (<60 min). The densification behavior and technological properties of the floor tile pieces as function of the sludge addition and firing temperature were determined. The development of the microstructure was followed by XRD and SEM/EDS. The results show that the replacement of kaolin with municipal waterworks sludge, in the range up to 10 wt. %, allows the production of ceramic floor tiles (group BIb and group BIIa, ISO 13006 Standard) at lower firing temperatures. These results suggest a new possibility of valorization of municipal waterworks sludge in order to bring economic and environmental benefits.

Utilization of leonardite and coal bottom ash for production of ceramic floor tiles

The aim of this research was to exploit leonardite and coal bottom ash (CBA), which are waste products from coal power plants, for investigating their potential as raw materials in the production of ceramic floor tiles. The developments of ceramic body were mixed with traditional raw materials. Different proportions of ceramic materials were studied in order to explore the proper composition with a variety of wastes containing leonardite and coal bottom ash from 20% up to 80%. Unglazed tiles were produced by shaping through dry pressing and single firing. The physical, chemical, and mechanical properties of the samples were investigated. The total waste (CBA and leonardite) contained in the production was close to 42.8%, and it presented properties that are adequate for it to be classified in groups within the ISO 13006 standard, and yielded the highest flexural strength which enabled the obtained ceramic floor tile bodies to satisfy the requirement to be classified in group BIIa. The chemical resistances of the products were classified in the category UA group which passed the minimum requirement for classification as chemical attack, set by standard EN 14411.

The use of sewage sludge in the production of ceramic floor tiles

Scientists proved that municipal sewage sludge contains many dangerous pathogens, toxic heavy metals, endocrine disruptors, drains, storm water runoff, hospitals, and industrial plants. Sewage sludge represents an extremely high ecological hazard to the environment. Due to the increasing amount of sludge generated from the wastewater treatments plants a strong demand for environmentally and effective safe reuse has arisen. One potential use of that waste is its incorporation in the production of ceramic tiles. The main aim of present work was to study the possibility of usage of this hazardous waste in floor ceramic tiles industry. A dried sludge waste was added in percentages from 5% up to 35% to a standard floor tile mix, molded, pressed uniaxially at 30MPa and then fired at temperatures reaching 1150°C for 15 min soaking time. The properties of both green and fired tiles were investigated as function of percent waste added. The vitrification parameters, which are linear firing shrinkage, water absorption, apparent porosity, and mechanical property, were determined and compared with ISO standards. Fired samples of the proposed mixtures were investigated by scanning electron microscope (SEM). It was possible to obtain tiles that abided by ISO standards for maximum addition of 7% sludge fired at 1150°C (for water absorption<10%), and 10% sludge or 5% sludge for tiles fired at 1150°C and 1100°C, respectively (for water absorption>10%), which are recommended for both their economic and environmental benefits.

Utilization of coal bottom ash as raw material for production of ceramic floor tiles

The aim of this research was to produce ceramic floor tiles using coal bottom ash (CBA), which is a no-value waste from coal power plants, as the raw material. CBA was first mixed with clay at various compositions to determine the proper ratio. Shaping through the dry pressing and single-firing route was chosen for this study. The properties of these ceramic tiles were investigated. Classification of these ceramic tiles has been adopted within the international standard, ISO 13006. Investigation of the optimum conditions for producing this product showed that coal bottom ash content combined with clay in the batch samples should not be more than 40 wt% and that the temperature for sintering was 1175 °C. The addition of sand could reduce linear shrinkage and increase the whiteness of the fired body. The products had less than 3 % water absorption, which is the property in the requirement of group BIb, but flexural strength was in the range of 22–30 MPa, which is the property in the requirement of group BIIa. The results obtained indicate that coal bottom ash when mixed with traditional raw materials has potential as a raw material for production of ceramic floor tiles.

Influência da incorporação de resíduo de rocha ornamental sobre as propriedades e microestrutura sinterizada de piso cerâmico

O Brasil é um dos maiores produtores e consumidores de rochas ornamentais no mundo. No entanto, a indústria de rochas ornamentais gera enormes quantidades de resíduos sólidos na forma de pó fino não biodegradável. No século XXI o grande desafio do setor de rochas ornamentais é o descarte final deste abundante resíduo de forma ambientalmente correta. Os resíduos de rochas ornamentais são ricos em materiais fundentes, que promovem a formação de fase líquida e auxiliam na densificação de materiais cerâmicos tradicionais. Neste trabalho foi avaliada a possibilidade de utilização de resíduo de rocha ornamental como um material de fluxo em composição para fabricação de piso cerâmico vitrificado de alta qualidade. As massas cerâmicas contendo até 45 % em peso de resíduo de rocha ornamental foram preparadas pelo processo via seca. Peças cerâmicas prismáticas foram preparadas por prensagem uniaxial a 50 MPa e sinterizadas a 1230 ºC usando um ciclo de queima rápida. As seguintes propriedades física e mecânica foram determinadas: retração linear, absorção de água, massa específica aparente, porosidade aparente e tensão de ruptura a flexão. A microestrutura sinterizada foi acompanhada por microscopia eletrônica de varredura e as fases cristalinas foram identificadas por difração de raios-X. Os resultados mostram que o efeito da adição do resíduo de rocha ornamental foi o de promover maior densificação e propriedades melhoradas dos pisos cerâmicos vitrificados.

Use of Iranian steel slag for production of ceramic floor tiles

In this paper, the authors have tried to introduce the use of electric arc furnace steel slag as a raw material in the floor tile body. Experimental samples were prepared with different amounts of slag (10–50 wt-%) using the die pressing method. Fabricated samples were fired in an industrial roller kiln at 1140°C. Thermal behaviour of the samples was investigated by simultaneous thermal analysis and dilatometery. X-ray diffraction analysis identified Wustite (FeO), as the major phase in the used slag. The effect of slag addition on the strength of experimental samples was evaluated by four-point bending strength test. Sintering behaviour of different samples was investigated by measuring shrinkage, relative density and water absorption. Results showed that addition of more than 40 wt-% slag to the base body generates closed porosities in the specimens due to the bloating phenomenon which reduces the bending strength. The wear resistance test on this sample confirmed that it can be used as a standard floor tile.

Possibility of the Use of Tuff as a Potential and Cheaper Raw Material in the Production of Ceramic Floor Tiles

Possibility of the Use of Tuff as a Potential and Cheaper Raw Material in the Production of Ceramic Floor Tiles

Improved method and working conditions for the production of ceramic floor tiles

Improved method and working conditions for the production of ceramic floor tiles

The production of ceramic floor tiles from local raw materials in Latvia

The production of ceramic floor tiles from local raw materials in Latvia

Production of ceramic floor tiles in the boizenburg works

Production of ceramic floor tiles in the boizenburg works

Production of ceramic floor tiles in Czechoslovakia

Production of ceramic floor tiles in Czechoslovakia