Production Of Tiles Research Articles

Potential of waste woven polypropylene fiber and textile mesh for production of gypsum-based composite

The huge production of woven polypropylene bags has led to an increase generation of plastic waste. The recycling of waste woven polypropylene bags and textiles in construction applications can be a viable option. Therefore, an attempt has been made to utilize the woven polypropylene fibers and textiles in the production of gypsum-based composite false ceiling tile for an economical and sustainable construction product. In the current research work, different water-to-powder ratios (0.6 %, 0.7 %, 0.8 %, 0.9 %) and fiber contents (0.25 %, 0.35 %, 0.45 %, 0.55 %) in the gypsum-based composite were prepared. Flexural plates with different thicknesses (18, 15, 12, and 9 mm) incorporating different recycling fibers and reinforced with different types of meshes were manufactured to produce sustainable gypsum-based plates. The physical properties, compressive and flexural strength properties of the fiber-reinforced gypsum-based composite were also evaluated. The textile and woven polypropylene fiber mesh reinforced gypsum false ceiling plates were compared with the control specimen. The results revealed that the density of gypsum-based composite decreased up to 26 % with the increase in the proportion of waste fiber contents. The compressive and flexural strength of gypsum-based composites exhibited a decrease with an increase in fiber contents and water-to-powder ratio. However, all the specimens satisfied the acceptable limit of 1 MPa and 2 MPa, respectively, according to BS EN 14246. The bending strength of all the plates incorporating different fiber content and thicknesses satisfied the minimum specified flexural strength criteria according to BS EN 14246. Moreover, the plates with different thicknesses and fiber contents also satisfied the minimum specified flexural criteria except for the plate with a thickness of 9 mm. However, all the plates with varying thicknesses and reinforced mesh have also satisfied the minimum load criteria specified by BS EN 14246. Thus, it can be envisioned that the woven polypropylene fibers and textiles can be effectively utilized to produce sustainable gypsum-based composite leading to reduce waste generation.

Using volcanic tuff wastes instead of feldspar in ceramic tile production

Using volcanic tuff wastes instead of feldspar in ceramic tile production

Fuzzy Inference System Tsukamoto–Decision Tree C 4.5 in Predicting the Amount of Roof Tile Production in Kebumen

Tile is a product that is in great demand by many people. This has become a trigger for producers to improve their management. The company's tile production management is still experiencing problems, namely frequent miscalculations in determining the agreement that must be issued in making tile production from customer requests. One of the efforts made is to predict the production that can be done to get the optimal amount obtained, to get a big profit. In this study, to obtain a prediction of the amount of tile production, computerized calculations were carried out using the Tsukamoto fuzzy logic method. This method uses the concept of rules from the C 4.5 decision tree in the building to make it easier to determine the rules that are built without having to consult an expert because C 4.5 will study existing datasets to serve as a reference in forming these rules according to conditions that often occur. The modeling results produce relevant rules after being compared with the actual results. The results of the comparison of predictions with actual production have an error percentage of 29.34%, with a truth of 70.66% (based on the calculation of the Average Forecasting Error Rate (AFER)). Therefore when implemented in the Tsukamoto Fuzzy Inference System it can produce predictions of tile production that are quite optimum. It is said to be quite optimum because all customer requests are met, either generated by the production prediction itself or the prediction results are added up with inventory data, and all predictions are close to actual production.

The Legionary Tilery of Brigetio and the Late Roman Watchtower at Kurucdomb

Modern excavations have been going on with increasing intensity for three decades in the Roman settlement complex of Brigetio (Komárom/Szőny, Hungary). Through these investigations, our knowledge about the topography and the building phases of the legionary fortress and the civil town has multiplied. However, new information can also be acquired by revisiting unpublished or poorly published past excavations. The Komárom/Szőny-Kurucdomb (Hungary) archaeological site was first explored by István Paulovics in 1934 when he found the legionary tilery of Brigetio and a Late Roman watchtower. He only published two contradictory short reports about his findings which left us with more questions than answers. By looking into the original documentation of the excavations and assessing the descriptions, drawings, and photos, valuable new data was gained about the watchtower and the legionary tilery. The study's key results are the following: contrary to former belief, tile production had not ceased before the watchtower was built but continued in the kilns beside it. Besides the two published rectangular tile kilns, another three kilns were found on the site, a rectangular and two circular ones. The more than four hundred brick stamps collected but left unpublished indeed represent all phases of the Roman settlement complex, from the end of the first century to the end of the fourth century AD. Some of them were formerly unknown, the most important of which reads VEXIL II K, which probably means Vexil(lationes) II (duae) K(arnuntinenses) and refers to the vexillations of the legio XIIII Gemina Martia Victrix and the legio XV Apollinaris.

On the Ceramic Imports from Sinope at Olbia Pontica (on the Example of Architectural Terracottas)

In the paper architectural terracottas — facade elements of building ceramics, which were imported to Olbia from Sinope for the decorative design of the roofs of public and, presumably, residential buildings, are studied. In the Olbian collection, fragments from various structurally-different parts are selected. These are frontal antefixes in the shape of multi-pelated palmettes and gorgoneions, as well as simas with ovolos and meander motifs and zoomorphic downspouts in the shape of lion protomes. It has been established that the time of the maximum spread of the Sinopean import of construction ceramics in Olbia was in the Late Classical — Early Hellenistic period. Usually, the import of such parts did not extend to the 3rd century BC, although the duration of their usage, along with tiles, was longer, which is recorded by finds. The absolute majority of Sinopean architectural terracotta finds come from the territory of the Upper City and are probably related to public buildings. Olbia, along with Istria and Bosporan centres, especially Panticapaeum and Nymphaion, was an active consumer of these products. Olbia still lacks evidence of its own production of architectural terracottas, although the tile production imitating Sinopean types is known. This distinguishes Olbia from other centres of the Northern Black Sea region, in particular Chersonesos and Panticapaeum, which are known for their own manufacturing of such products, inspired by Sinope. A significant amount of tile decor of Sinopean origin confirms the importance of the Olbian market in the trade of ceramic building materials with this South Pontic centre.

Utilization of marble waste as a sustainable replacement for calcareous in the manufacture of red-firing wall tiles

Marble waste generated in large amounts in the ornamental rock industry needs to be disposed of in a sustainable way and valorized. In this respect, this work analyzed the use of marble waste as a sustainable raw material in manufacturing red-firing wall tiles, replacing the natural calcareous material by up to 15 wt%. For this purpose, four red-firing wall tile pastes containing marble waste were pressed into rectangular pieces and fired between 1100 °C and 1180 °C using a fast-firing cycle. The red-firing wall tile specimens produced were tested to determine their technical properties (linear shrinkage, water absorption, apparent density, and three-point flexural strength), phase analysis by XRD, and microstructural analysis by SEM. The densification behavior and technical properties of these specimens were influenced by the incorporation of marble waste and firing temperature. The results showed that this waste is highly compatible for the manufacture of high-quality red-firing wall tiles, meeting the normative requirements (water absorption and flexural strength) of group-BIII of ISO 13006. The marble waste may fully replace the natural calcareous used in the manufacture of this type of tile material, contributing to its recycling and valorization with positive repercussions for both the ornamental rock and ceramic industries.

The Role of Social Capital in Socio-Economic Resistance of Tile Makers Families in Banjardowo

Professions in people's own lives are very diverse to achieve a better life, one of which is tile craftsmen. Nowadays there is a shift in the use of tiles, from what was originally traditional tiles to the main tiles in home making, the re-strengthening of social capital in building the economy of tile craftsmen through the sale of tiles is an important thing and needs to be considered. The objectives of this study are to analyze; (1) the role of social capital of tile craftsmen in tile production in Banjardowo, (2) the role of social capital of tile craftsmen in tile marketing in Banjardowo, (3) the driving and inhibiting factors of the role of tile craftsmen's social capital in the socioeconomic resilience of families, and (4) the role of social capital in the socioeconomic resilience of tile craftsmen's families in Banjardowo. This research uses qualitative research methods. The linking social capital that exists in tile craftsmen in the production process is that tile craftsmen in Dukuh Banjardowo have a direct relationship with other parties, namely the village, red soil suppliers, and capital providers (banks). Social capital linking is the cooperation of tile craftsmen with the village government and consumers. The driving factors in achieving the role of social capital are trust that is established between parties, trust in consumers and between parties, and there is support from the village government that is felt by tile craftsmen and the inhibiting factor is the transfer of land functions that provide shock to the production system.

Evaluation of the possibility of improving the durability of tools made of X153CrMoV12 steel used in the extrusion of a clay band in ceramic roof tile production

Abstract The article presents the results of a complex comparative analysis of the abrasive wear resistance of tools made of X153CrMoV12 steel after different heat treatment variants. These investigations aimed to select the most durable material for application in tools forming a mass band in the production of ceramic roof tiles. The tests included the determination of resistance to abrasive wear in ball-on-disc tests, hardness measurements, and microstructure analysis, including the assessment of changes occurring in the subsurface area, as well as impact tests (at a working temperature for the tools of 50°C). The comprehensive test results showed that the best effects of increasing the resistance to abrasive wear can be obtained through a heat treatment that consists of hardening at 1020°C and then tempering at 200°C for about 2 hours. The next stage of research will be to compare the results obtained with another popular material for tools for the production of roof tiles - Hardox steel, which is characterized by high resistance to abrasive wear.

Application of plastic wastes as construction material for sustainable development: A review

The development of a sustainable ecosystem in the present period is seriously threatened by the effective disposal of plastic waste. This work aims to reduce the burning issue that leads to environmental pollution by reusing plastic waste bags as building materials for sustainable development. In this review study, a modified plastic mixer is created by combining shredded plastic waste bags with hot aggregates, and sand. Comprehensive research has been done on the use of plastic waste as a binder, aggregate, fine aggregate, modifier, or replacement for cement and sand in the production of bricks, tiles, concrete, and roadways. Additionally, the review of impact of plastic waste addition on tensile characteristics, water absorption, durability, etc. has been extensively examined.

A Review Paper on Reuse of Plastic Waste as Pavement Construction Material

Abstract: The exponential rise in the production of plastic and the consequential surge in plastic waste have led the scientists and researchers look out for innovative and sustainable means to reuse/recycle the plastic waste in order to reduce its negative impact on environment. Construction material, converting waste plastic into fuel, household goods, fabric and clothing are some of the sectors where waste plastic is emerging as a viable option. Out of these, construction material modified with plastic waste has garnered lot of attention. Modification of construction material with plastic waste serves a dual purpose. It reduces the amount of plastic waste going to landfills or litter and secondly lessens the use of mined construction materials, thereby mitigating the negative impact of construction industry on environment. This article summarizes advances related to the use of plastic waste as a component of building materials. The inclusion of plastic waste as a binder, aggregate, fine aggregate, modifier or substitute for cement and sand in the production of bricks, tiles, concrete and roads has been comprehensively considered. The effect of the addition of plastic waste on strength properties, water absorption, durability, etc. was also discussed in detail. Studies reviewed for this review were categorized according to whether they used plastic waste to produce bricks and tiles or concrete for road construction.

The use of rheologically problematic Turkish clays with dry granulation technology in porcelain tile production

The use of rheologically problematic Turkish clays with dry granulation technology in porcelain tile production

Evaluation of Linamon Red Clay, Salvador Black Cinder and Kapatagan Diatomaceous Earth of the Southern Philippines

The southern island of the Philippines is abundant in silicate minerals, including the province of Lanao del Norte. However, some of these resources in the region are untapped for use as raw materials in the production of various ceramic products for industrial, pharmaceutical, and nanotechnology applications. These could include tiles, sanitary ware, dinnerware, insulating bricks, porcelain, membranes and coatings. Some of the explored minerals are the red clay in the municipality of Linamon, diatomaceous earth in Kapatagan and black cinder in Salvador. It is the aim of this study that these minerals are evaluated in terms of their physical and chemical properties so that these will be used for optimum application. The properties that were determined were their specific gravities, raw and fired surface colors, Atterberg limits, particle size distribution, thermal properties, morphologies and mineralogical compositions. Pellets were formed for each raw material and fired at two temperature levels 1000 °C and 1200 °C to evaluate their physical properties. Linamon red clay has a 38.88% cumulative passing size of 150 µm, and the black cinder of Salvador and diatomaceous earth of Kapatagan have cumulative passing sizes of 96.53% and 60.12% at 150-micron sieve, respectively. The common mineral contents of the three samples are montmorillonite, quartz and andesine. Black cinder fired at 1200 °C has the darkest shade of red with a greasy quasi-submetallic luster. It attained the highest fusion coverage on the platform among the three materials, which makes it a potential supplement or replacement for feldspar in clay-based triaxial materials for ceramic production. The diatomaceous earth has the potential to be a secondary clay content source and a good source of flux for a certain temperature range. Both the red clay and diatomaceous earth were classified as plastic materials that are suitable for brick production, and the red clay is also feasible for pottery production. These are a few of the features of the clay minerals in the region that present suitable properties for application as raw materials in the production of ceramic tiles and hollow ceramic products.

Life cycle assessment in the ceramic tile industry: a review

This paper presents a comprehensive review of existing literature on the life cycle analysis (LCA) of ceramic tiles. By critically evaluating these studies, the paper aims to provide insights into controlling the factors that contribute to a more sustainable production of ceramic tiles. The study identifies the relationships between variables that impact the shaping process, and highlights the priority areas that require intervention for reducing the environmental impact of ceramic tile production. The results of the LCA analysis emphasize the significance of the manufacturing process and the dependence on non-renewable sources of fuels in the ceramic tile industry. This paper provides a hierarchical framework of the variables that have the most significant impact and offers a guide for reducing the environmental footprint of ceramic tile production.

:The Making of a Roman Imperial Estate: Archaeology in the Vicus at Vagnari, Puglia

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Development of Polymeric Binder from Expanded Polystyrene (EPS) Foam Waste as Construction Materials

Expanded Polystyrene (EPS) foam wastes become a huge environmental issue as most of them are non-biodegradable materials and are disposed of inappropriately. It was reported that the amount of plastic and foam wastes for food containers and other packagings was evidently increased during the past 5 years, especially since the COVID19 pandemic. This work studied the development of the polymeric foam binder from the EPS foam waste for the production of green construction blocks or pavement tiles. The types of solvent (acetone and toluene) and the amount of additional EPS foam binder were investigated. The results show that the appropriate mixtures contained EPS foam binder from 15% to 30% to achieve maximum compressive strength at approximately 10 to 12 MPa with the optimal unit weight of 1,600 to 1,900 kg/m3. Those outcomes have equally passed the strength class of Thai Industrial Standard (TIS 57 and 77) for construction brick and block. This eco-friendly technique could facilitate value-added production and reduce the environmental impact of EPS wastes disposal. Moreover, it is one of the alternative approaches to promote greener and cleaner production for environmentally friendly construction materials.

Parametric study of the correlation between location and size of superficial cracks in the deflection of traditional tiles based on finite element analysis

Superficial cracks are one of the common defects in the manufacturing of traditional ceramic tiles. Such defects do not only damage the appearance of the product, but also affect their mechanical behavior. Understanding the correlation between superficial cracks and deflection is key for the traditional ceramic tile industry. However, the related bibliography is very rare, and its importance is systematically ignored during design and manufacturing. In this work, we investigate the impact of the location and size of superficial cracks over the deflection of traditional ceramic tiles. A technique based on FEA (finite element analysis) is validated through experimental data and used to undertake a statistical, parametric research. The study shows that location and depth of the defect have an exponential cross-correlation over deflection and could be characterized together through a single surface. On the contrary, the width and sharpening of the defect barely interfere.

Evolution of azulejo glaze technology in Portugal from the 16th to the onset of the 19th century

Azulejos have been applied to architectural settings in Portugal for the last five centuries and represent one of its most unique art forms. In this article a group of representative samples regarding the chronology and typology of the majolica azulejos produced by the Lisbon workshops from the second half of the 16th century (beginning of majolica azulejos production in Portugal) up to the first quarter of the 19th century (after which more industrialized manufacturing processes were introduced) are studied. SEM-EDS was used to obtain morphological and chemical information on the glazes, ceramic bodies, and their interfaces. The results show that a major shift from lead-rich to lead-alkali glazes occurred in the transition from the 16th to the 17th century, while from then to the end of the studied period the same basic technology prevailed. The Lisbon tiles production is also considered in the European context.

Application of Flowsheet Simulation Methodology to Improve Productivity and Sustainability of Porcelain Tile Manufacturing

Porcelain tile manufacturing is an energy-intensive industry that is in dire need of increasing productivity, minimizing costs, and reducing CO2 emissions, while keeping the product quality intact to remain competitive in today’s environment. In this contribution, alternative processing parameters for the porcelain tile production sequence were proposed based on simulation-based process optimization. Flowsheet simulations in the Dyssol framework were used to study the impact of the milling and firing process parameters on the electrical and thermal energy consumption, final product quality, and productivity of the entire processing sequence. For this purpose, a new model of gas flow consumption in the sintering stage was proposed and implemented. During optimization, the primary condition was to maintain the product quality by keeping the final open porosity of the tile within the specified industrial range. The proposed simulation methodology proved to be effective in predicting the influence of the processing parameters on the intermediate and final products of the manufacturing sequence, as well as in estimating the production costs for the Brazilian and Spanish economic conditions. This approach has shown great potential to promote digitalization and establish digital twins in ceramic tile manufacturing for further in-line process control.

A TRIZ-Supported Concept and Protocol Development for Roof Tile Transportation and Inspection Systems

Currently, the use of manual labour in the transportation and inspection systems of leading roof tile manufacturing companies in Indonesia is still prevalent. Manual labour is usually labour-intensive, has higher risks of musculoskeletal disorders, and produces frequent occurrences of errors and losses. Furthermore, the current studies of suitable concepts and test protocols for roof tile transportation at the manufacturing stage as well as their inspection systems are not practicable in Indonesia. There is also no study that has used the theory of inventive problem-solving (TRIZ) in the development of concepts and protocols for roof tile transportation and inspection systems. Using TRIZ as a supporting tool, this study investigated the development of a transportation system to be employed during the manufacturing of the roof tile and a test protocol for their usability in Indonesian companies to overcome this concern. The study included screening and scoring concepts and usability test protocols identified from the existing literature, with the support of TRIZ tools such as the engineering contradiction, contradiction matrix, and inventive principles. Thus, the finalised concept comprised a belt conveyor system (Inventive Principle 20: Continuity of Useful Action) with a flipping mechanism for transportation and a vision-based camera for inspection. Results of the study showed that the concept excelled in cost, durability, reliability, versatility, low risk to the product, efficiency, and safety. The t-test protocol (Inventive Principle 23: Feedback) was selected based on the results due to its versatility in testing efficiency, reliability, and productivity. It was concluded that this concept has the potential to alleviate roof tile workers of physical work and reduce the prevalence of musculoskeletal disorders.

DIGITALISASI BANK SAMPAH SEBAGAI OPTIMALISASI PENGELELOAAN SAMPAH DAN PENDAYAGUNAAN MASYARAKAT DI DESA PEJATEN, KECAMATAN KEDIRI, KABUPATEN TABANAN, BALI

Pejaten Village is one of the villages in Kediri District, Tabanan Regency, Bali Province. Pejaten Village or commonly known as Tile Village because of the production of good quality roof tiles in this Village. Behind the production of good quality roof tiles, Pejaten Village has now developed a Garbage Bank. The Garbage Banks in Pejaten Village are 5 Banjars out of 8 Banjars with 1 Main Garbage Bank which is shaded under Pejaten Village. However, the Garbage Bank that is used is still conventional, still does traditional recording and requires a lot of energy in recording and calculating this Garbage Bank. The Garbage Bank in Pejaten Village also faces inconsistent collectors who receive results from the Garbage Bank from Pejaten Village. With the existence of the Digital Waste Bank, in terms of recording and calculating the value of waste exchanged per each resident in Pejaten village, it will be more accurate and reduce the number of workers needed. The Digital Garbage Bank is an application that contains waste balances that have been exchanged by residents at the waste bank and this balance can be exchanged once every 6 months in the form of groceries and compost. As well as socialization about waste sorting and waste utilization which will be able to build Pejaten villagers to understand more about adding value to the use of waste after it has been sorted.