Red Ceramic Waste Research Articles

In situ formation of supported metallic iron on red ceramic waste and its reactivity

The in situ formation of metals has grown in recent years with the aim of applying the obtained metals in various fields of knowledge, ranging from catalysis to healthcare, by obtaining materials capable of replacing implants such as platinum or titanium. Part of this pursuit requires understanding and obtaining metals in general. The metallic iron in question has been relatively less obtained, and its application is promising and cost-effective due to the involved metal.In this study, we demonstrate the synthesis of metallic iron supported on red ceramic waste (RCW) and its reactivity in an atmosphere containing sulfur. The objective of this research is to showcase the synthesis of metallic iron associated with an unconventional support (waste) and its application in reacting with a sulfur-containing gas atmosphere. This was achieved through particles synthesized using the hydrothermal method, and the measurements were conducted through in situ X-ray absorption spectroscopy with temporal resolution in the XANES region at the Brazilian Synchrotron Light Laboratory (LNLS). In situ DXAS measurements allowed the monitoring of the reactivity of the corresponding metallic iron particles during activation and sulfidation processes. The obtained results demonstrated satisfactory metallic formation, effective adhesion of the support, and successfully achieved reactivity.

Integrated approach to assess the environmental suitability of red ceramic waste as a supplementary cementitious material in structural concrete

Integrated approach to assess the environmental suitability of red ceramic waste as a supplementary cementitious material in structural concrete

Characteristics and utilization prospects of red ceramic waste in lightweight aggregates: a systematic review

Red ceramic waste (RCW) is one of the main by-products generated by the production of ceramic materials. Its application in lightweight aggregates (LWAs) has not yet been tested. Thus, this review intends to evaluate the perspectives of using RCW in the manufacture of LWAs. The search was carried out in the ScienceDirect database. 47 articles were selected. A significant amount of data on the chemical, physical, mineralogical, and morphological properties of RCW are discussed. In most studies, the chemical constituents of RCW complied with the swelling parameters. The mineralogy of the residue usually has constituents capable of controlling the viscosity and aiding gas formation. The data of granulometry, microstructure, and loss of mass denote the need for special care with the methodology adopted for grinding and sintering of the residue. This review indicates that there is a high potential for the use of RCW in the manufacture of LWAs.

Analysis of Measured Parameters in Relation to the Amount of Fibre in Lightweight Red Ceramic Waste Aggregate Concrete

The present study provides a correlation and regression analysis of lightweight waste aggregate concretes with varying degrees of fibre reinforcement. The concrete mix contains pre-soaked red ceramic waste aggregate, expanded clay coarse aggregate and Portland cement. Copper-coated crimped steel fibre was used as the reinforcement. The experimental results included properties measured by destructive test methods—compressive strength, splitting tensile strength, static modulus of elasticity, the limit of proportionality, shear strength; and by non-destructive test methods—dynamic modulus of elasticity and surface electrical resistivity. These properties were analysed to study the relevancy and significance between non-destructive and destructive methods of measurement in the case of different amounts of fibre. The results show differences in the degree of fit to the linear and quadratic regression curves for pairs of destructive and non-destructive test results. As expected, the linear relationship can be applied in a few cases, but the quadratic curve must be used for a few pairs. Another observation is that it is not possible to neglect the amount of fibre in the correlation analyses of the measured properties.

A literature review on the effect of using ceramic waste as supplementary cementitious material in cement composites on workability and compressive strength

This study reports the amalgamation of ceramic waste procured from various sources such as waste from ceramic products manufacturing, construction and demolition waste etc. as an alternative of cement up to certain substitution percentage. The prime motive of this study is to evaluate the effect of ceramic waste on fresh and mechanical properties of various cement composites like cement paste, cement mortar, hardened concrete and self-compacting concrete. Previous studies prove the promising pozzolanic behaviour of ceramic waste, thus defending the feasibility of its utilization in cementitious materials. The consumption of ceramic waste at smaller replacement levels displays suitable workability. At higher incorporation ratios, the water content required to maintain the necessary workability increased for both vibrated and self-compacting concrete. Based on the surface area of the ceramic waste particles, the cement pastes developed can have higher or lower yield stress. With regard to mechanical properties, compressive strength of the mixes up to a substitution level of 10 to 20% is either higher or nearly equal to reference mix. White ceramic waste has shown better pozzolanic properties when compared to red ceramic waste. When combined with other alternate supplementary cementitious materials like rice husk ash and fly ash, compressive strength improved further. On examination of the microstructure using scanning electron microscopy, X-ray diffraction etc., ceramic wastes’ pozzolanic properties were retrospectively proved. Utilization of ceramic waste beyond the 20% level led to the dilution of CSH forming compounds and hence retardation in setting and hardening of the cement composites. This was also accompanied by a fall in compressive strength was noted. Assessing the utilization of ceramic waste presents a sustainable approach in the construction industry while simultaneously comprehending ecological benefits. As a future scope of work, combination of ceramic waste along with nano particles shows a promising domain that can be explored.

Red ceramic and concrete waste as replacement of portland cement: Microstructure aspect of eco-mortar in external sulfate attack

The use of red ceramic and concrete waste as a replacement for cement has great importance from an environmental point of view, and it is necessary to understand its influence on the cement matrix's performance. In this paper, mortar mixtures with partial replacement of the Portland cement by the addition of 3, 5, 12, and 20% of limestone filler (as reference), concrete waste, and red ceramic were subjected to sulfate attack. The accelerated test was monitored until the age of 98 days and microstructure analysis techniques were applied. Mortars with ceramic and concrete waste addition had greater expansion than the reference mortar. The addition of 12% of limestone filler mitigated the expansive reactions. The mortars with any type of addition had greater porosities. In this case, the aluminum oxide content in the ceramic and the calcium carbonate and calcium oxide contents in the concrete waste acted as a source for reaction with the sulfate ions. Due to the attack, the pore size distribution changed, showing that the pores in the band between 0.01 and 1 µm were filled with ettringite. The microcracks from the attack increased the pores with diameters over 1 µm. This performance reduction against sulfate attack must be considered for the use of ceramic and concrete residues in eco-efficient mortars, especially when it is inserted in environments subjected to this type of degradation.

Adsorption and desorption of phosphate onto chemically and thermochemically pre-activated red ceramic waste: Characteristics, batch studies, and mechanisms

The knowledge of adsorption and desorption mechanisms of phosphate onto construction wastes is important to minimize environmental concerns related to its discharge into water. In this study, we verified the adsorption and desorption capacity of red ceramic waste in the removal of phosphate from aqueous solution, unmodified (RC), chemically (CAC, dolomite lime) and thermochemically (TCAC, heated/dolomite lime) pre-activated. Adsorption process was best described by pseudo-first-order kinetic model for RC (1.22 mg g−1) and CAC (3.59 mg g−1) and by pseudo-second-order model for TCAC (4.57 mg g−1) at pH 5.3. Pseudo-second-order model better described desorption for RC (1.13 mg g−1) and pseudo-first-order model for CAC (0.54 mg g−1) and TCAC (0.54 mg g−1) at pH 13.3. Regarding the maximum adsorption capacities, Langmuir model best fitted to RC with 2.27 mg g−1; Freundlich model to CAC with 4.10 mg g−1; and Sips model to TCAC with 22.28 mg g−1 at pH 5.3. Sips model was best fitted to the desorption equilibrium data with 16.72 mg g−1 for RC, 15.45 mg g−1 for CAC, and 5.20 mg g−1 for TCAC at pH 13.3. The negative ΔH° showed the exothermic nature of adsorption for RC (−159.75 kJ mol−1), CAC (−108.59 kJ mol−1) and TCAC (−102.89 kJ mol−1). For desorption, the exothermic nature was verified for RC (−34.06 kJ mol−1) and TCAC (−44.11 kJ mol−1); while endothermic process was noted for CAC (9.61 kJ mol−1). Finally, the red ceramic, both unmodified and pre-activated, could be used as alternative low-cost adsorbent in the removal of phosphate.

Reuse of red ceramic waste in the production of concrete for civil construction

In search of the reuse of waste from civil construction, studies are presented as an alternative on the insertion of this waste into materials so that they become ecologically viable and at a lower cost. In this scope, there is the red ceramic waste (RCW), which is largely produced both in renovation works and in the stage of transporting construction components such as bricks, slabs, and floors. On the other hand, the use of cement is of great proportions, which raises concerns about the excessive consumption of non-renewable natural resources, especially in large-scale projects. Thus, the study aimed to evaluate the mechanical properties of compressive strength of concrete with partial replacement of cement by RCW and to verify the influence at different breakage ages (7, 14, 21, and 28 days). Five mixes were used, the first with 100% cement, and the others with crushed RCW to replace 5%, 10%, 15%, and 20% of the cement, and the resistance obtained according to percentages and ages was also verified of RCW through the uniaxial compression test. Thus, it was observed that for replacements of up to 15%, the strength losses were not significant, suggesting the feasibility of its use in works with high concrete demands, such as in dams.

Mechanical Behavior of Concrete with Recycled PET Fiber/Red Ceramic Waste

The objective of this research is to analyze the mechanical resistance to compression of conventional specimens and specimens with the addition of red ceramic and waste of ethylene poly terephthalate (PET). The methodology applied has been based on the experimental dosage method of the São Paulo State Technology Research Institute (IPT). Three traces have been made: rich trace (1:0.5:3.5:0.45), medium trace (1:0.8:4.2:0.54) and poor trace (1:1.1:4.9:0.65), with percentages 0%, 2%, 3% and 4% of recycled PET fiber mixed with the red ceramic waste. For concreting, the materials have been mixed in a concrete mixer with a capacity of 120 liters in 20 min for each trace. Like this, 36 specimens have been made in cylindrical form 10 cm in diameter and 20 cm in height, with ages of initially and 28 days, both before the breaking load test, spending the first 24 hours immersed in tanks with water, remaining until the day of its rupture, according to NBR 5738 (ABNT, 2008). Slump flow tests, T500 time tests, workability have been performed, as well as the mechanical tests of Compressive strength and Compressive strength/density. PET fiber/red ceramic has offered greater workability than conventional concrete aggregate, using the same w/c ratio. A 4–12% reduction in density has been achieved with the PET fiber/red ceramic compared to the conventional aggregate concrete. With the 4% PET fiber/red ceramic replacing conventional aggregates at a 0.45 a/c ratio, compressive strength of 37.56 MPa has been obtained, the highest among all traces.

Supporting circular economy through the use of red ceramic waste as supplementary cementitious material in structural concrete

Supporting circular economy through the use of red ceramic waste as supplementary cementitious material in structural concrete

Red ceramic waste as supplementary cementitious material: Microstructure and mechanical properties

The red ceramic waste (RCW) powder has the potential to be used as supplementary cementitious material (SCM) since ceramic bricks, essentially composed of calcined low-grade kaolinitic clay, presents amorphous phases resulted from the sintering process. This paper investigates the effects of 30% Portland cement replacement by RCW in the microstructure of cementitious pastes and mortars' physical–mechanical properties. The use of RCW changed the hydrated pastes' microstructure by increasing the amount of ettringite (AFt) and stimulating the formation of monocarboaluminate (AFm). The compressive strength of the blended mortars reduced by 7 to 16% at 182 days. The apparent porosity for mortars with w/b ratio of 0.35 was equivalent to that of reference over the 182 days. The gradual increase in the w/b ratio of blended mortars tends to maximize the decrease in compressive strength and increase the apparent porosity. The use of RCW can reduce CO2 emissions by reducing the cement demand per unit of compressive strength.

Characterization of Red Ceramic Waste for Application as Mineral Addition in Portland Cement

AbstractThis paper investigated the red ceramic waste originated from damaged sintered bricks as a potential source of pozzolanic mineral addition for portland cement. Physical, chemical, and miner...

POTENTIAL FOR REPLACEMENT OF PORTLAND CEMENT BY CERAMIC RESIDUE IN THE SOIL-CEMENT MIXTURE FOR APPLICATION IN PAVING LAYER

In 2018, of a total extension of 87,563 kilometers of road network, only 34.2% of the total presented satisfactory conditions to users. One of the main reasons for this scenario is linked to the high cost of maintenance, including the need for soil stabilization, since the composition of the pavement layers is directly linked to its resistance and durability. In this scenario, the chemical stabilization technique with soil-cement emerges as an alternative for using the soil, which initially did not present corresponding parameters for the respective use. However, the growing demand for replacement of Portland Cement in engineering services, due to the carbon dioxide levels released into the atmosphere during its production, has supported research that deals with the substitution of binder by waste generated by the production sectors, namely, red ceramic waste from the ceramic block industry. This research aims to evaluate the carrying capacity of soils stabilized with cement and the partial replacement by red ceramic waste. Soil characterization tests were carried out, which provided parameters for the dosage of the materials, and subsequent performance of the compaction, expansion and penetration tests. Based on the need to stabilize the soil classified as clayey, group A-7-6, and susceptible to great variation in volume, the addition of 13% by weight of Portland Cement to the mixture was evaluated and subsequent replacement of the binder in percentages of 20 and 30%. The results demonstrated a reduction in specific mass by increasing the substitution by RCR (Red Ceramic Residue), and also for the expansion presented by the compounds. The CBR test evaluated the percentage of 20% replacement as the one with the highest load capacity. For paving purposes both percentages of substitution analyzed are within the parameters that satisfy their respective uses in sub-base layers of flexible pavement.

Portlandite consumption by red ceramic waste due to alkali activation reaction

Abstract Red ceramics, due to the low compressive strength and high porosity, make it difficult to use it as an artificial aggregate in the production of mortars and concretes. However, since it has a silicon-rich composition, the ceramic material from blocks and tiles has been studied as a possible supplementary cementitious material in concrete and also as a raw material in alkali-activated binders. This paper aims to evaluate the content of calcium hydroxide (portlandite) fixed in the alkali activation reaction and the microstructure of red clay waste from construction and demolition waste (CDW) and hydrated lime mixtures, varying the atomic ratio between the silicon and the calcium. The results indicated that higher availability of lime is directly related to the content of hydrated compounds and its porosity. The increase in the silicon/calcium ratio resulted in a reduction of available lime content by 40% and an increase, in volume, of micropores by 7%.

Relationship of Surface and Bulk Resistivity in the Case of Mechanically Damaged Fibre Reinforced Red Ceramic Waste Aggregate Concrete.

Electrical resistivity is an important physical property of concrete, directly related to the chloride-induced corrosion process. This paper analyses the surface resistivity (SR) and bulk resistivity (BR) of structural lightweight waste aggregate concrete (SLWAC). The studied concrete mixture contained waste material—red ceramics fine aggregate and artificial expanded clay coarse aggregate. Red ceramic is a frequent waste material remaining after the demolition of buildings or unsatisfactory building material production and is among the least used construction waste. Therefore, its use is desirable in terms of sustainability; in some cases, it can reliably replace the conventional aggregate in a concrete mixture. The relationship between SR and BR was determined in the case of standard specimens and mechanically damaged specimens (to 50% and 100% of ultimate strength capacity—USC). Two different instruments were utilised for the investigation—a 4-point Wenner probe meter and an RCON tester. The results of standard specimens support the theoretically derived correction ratio, but in the case of mechanically damaged specimens, the ratio is more scattered, which is related to the mechanical damage and the amount of fibre.

Durability Characteristics of Concrete Mixture Based on Red Ceramic Waste Aggregate

The article aims to observe durability parameters of red ceramic waste aggregate concrete based on a measured chloride profile by the standardized NT Build 443 method, and to compare the results to the values measured by a test based on electrical resistivity measurements. The parameters related to the chloride ion diffusion are investigated on the new type of concrete designed in the previous project, which contains waste material–red ceramics fine aggregate, and artificial expanded clay coarse aggregate. Ceramic materials contribute to the highest percentage of the construction and demolition wastes and, in most cases, this type of waste is disposed of in landfills. Significant factors limiting the use of the studied material are the unavailability of standards, avoidance of risk, and lack of knowledge and experience in using ceramic wastes for construction purposes. The obtained results of the studied mixture are compared to a reference concrete in terms of mechanical properties and durability parameters. The calculated diffusion coefficient is a crucial input parameter for modeling of the degradation process and the prediction of concrete durability; therefore, proper identification is of interest in order to allow for a broader application of ceramic waste aggregate-based concrete. The research showed unproportionality of results measured by the two methods in the case of waste aggregate concrete (60% difference in comparison with reference concrete), therefore it was proved that the electrical resistivity measurements need correlation of the resulting diffusion coefficient for proper modeling.

Partial replacement of metakaolin with red ceramic waste in geopolymer

Metakaolin was incrementally replaced (33.3%, 50% and 66.6%) by red ceramic waste in geopolymer formulation to study the effect on geopolymerisation and its resultant properties. The geopolymer binders composed of two calcined aluminosilicates (viz. Metakaolin and Red ceramic waste), NaOH and sodium silicate. In the experimental compositions, metakaolin was replaced gradually up to 66.6% in the clay fraction, the Si/Al increased from 3.36 to 5.16 and Na/Al increased from 0.93 to 1.38. The FTIR spectroscopic studies of geopolymer pastes along with XRD analysis indicated that the red ceramic waste partly reacts with alkali and takes part in geopolymer formation. Replacement of 33.3% metakaolin by the red ceramic waste in geopolymer binder did not reduce the compressive strength with respect to the pure metakaolin geopolymer here. Additional replacement resulted in a drastic decrease in the compressive strength of the geopolymer binder. However, the compressive strength of geopolymer mortars revealed interesting synergy between the amount of binder and particle packing in the mortar. Despite having a lower amount of binder phase, mortars with 33% and 50% red ceramic waste exhibited maximum compressive strength values. This has been attributed to improved particle packing through incorporation of red ceramic waste particles.

Evaluation of the pozzolanic activity of red ceramic waste using mechanical and physicochemical methods

Abstract Alternative cementitious materials can potentially reduce the environmental impact of the extraction of lime and the hazardous production of Portland cement. Red ceramic waste can be comminuted to fine particles with both filler and pozzolanic activity and used in Portland and lime mortars. This study presents the evaluation of the pozzolanic activity of red ceramic waste by physicochemical and mechanical methods using Portland cement and lime mortars. The evaluated waste depicted high pozzolanic activity and absence of Na2O, and consumed 32% of CaO according to the adapted Chapelle test. The compressive strength recorded in the pozzolanic activity test with lime was 7.1 MPa at 7 days. Moreover, the compressive strength of mixes with 25% replacement of Portland cement by red ceramic waste was 11% higher than the reference waste-free composition. The red ceramic waste depicted adequate characteristics to be used in the production of large volumes of Portland and lime mixes commonly employed in the civil construction.

Change of Fatigue and Mechanical Fracture Properties of a Cement Composite due to Partial Replacement of Aggregate by Red Ceramic Waste

Fine-grained cement-based composites used in civil engineering and construction industry are usually made of cement-based matrix and natural aggregate (such as sand, gravel, crushed stone, etc.). Red ceramic waste aggregate is considered as a perspective replacement of a part of natural aggregate in modern environmentally oriented building materials. Fine-grained cement composite with natural aggregate partially replaced by ceramic waste aggregate usually show different mechanical fracture characteristics from ordinary fine-grained concrete. The specimens were tested at six different ages. This was the reason for conducting the research programme. Altogether, 6 fine-grained cement mixtures with various proportions of natural and red ceramic waste aggregate were prepared. The aim of this paper is to present and compare mechanical fracture properties obtained from static and fatigue tests. Bulk density, flexural and compressive cube strength, fracture toughness and fatigue properties (S−N − Wöhler curve) were of special interest. All of these tests are important for a practical application of concrete with ceramic aggregate for structures. All the results were statistically analysed and they showed that the fatigue and mechanical fracture properties were improved or at least kept up with the increasing levels of red ceramic waste aggregate. Environmental impact of application in construction industry of composites in question is discussed.

Porcelain and red ceramic wastes used as replacements for coarse aggregate in concrete

Recent advances in construction engineering have made the design of safe structures possible and attracted an increasing attention to the use of concrete for its beneficial properties. This has, in turn, instigated a lot of efforts aimed at improving the physical and chemical properties of concrete. This is while increasing numbers of industry are producing waste products that warrant to be reused in order to avoid their dumping into the environment. One way to prevent accumulation of waste products in the environment is to use them as useful substitute materials in concrete. Along these lines, the use of ceramic wastes in concrete has been widely investigated. Porcelain ceramic is a new generation of ceramics that is highly heat resistant and offers a great resistance against pressure; however, these ceramics cannot be recycled to return to the production line in factories and are inevitably dumped into the environment as waste products. In the present research, two types of porcelain and ordinary red ceramics were used as substitutes for coarse aggregates in concrete. For this purpose, 65 specimens were cast to test their compressive, tensile, and flexural strengths as well as their water absorption. It was found that porcelain tile waste was able to increase concrete compressive strength by up to 41% while the red ceramic one increased it by up to 29%. Additionally, porcelain was found capable of increasing tensile and flexural strengths by up to 41% and 67%, respectively. Water absorption tests revealed that while porcelain increased concrete water absorption by up to 54%, red ceramic waste increased it by 91%. The superior performance of porcelain over that of red ceramic waste was attributed to the high porosity of red ceramics.