Sanitary Ceramics Research Articles

Analysis of NQI technology integration and application status of building sanitary ceramics industry

Based on the National Quality (National Quality Infrastructure, NQI) theoretical connotation as the instruction, this paper analyzes the domestic building sanitary ceramics industry key generic NQI technology integration and application of the status quo, the results show that the current domestic building sanitary ceramics industry NQI key generic technology integration and application level is not high, it is difficult to meet the demand of industry transformation and upgrading of the green, in urgent need of research to support green building sanitary ceramics industry upgrade of key generic NQI technology,to form a scientific and rational green building sanitary ceramics key testing equipment measuring standard, high quality green building sanitary ceramics standards, certification evaluation standard, and green standards in key areas (energy saving, water saving, low carbon), implementation contains measuring, testing, standards, certification and accreditation whole chain NQI technology system and carry out application demonstration, to accelerate the transformation and upgrading of domestic green building sanitary ceramics industry form the standard support and high quality development.

Machine vision based edge detection method for toilet seat

Trajectory planning plays a vital role in the stability and accuracy of the robot when working. Using the edge detection principle of machine vision for trajectory planning can provide high reliability for polishing the robot. Grinding the trajectory, which is more stable when grinding the edges of sanitary ceramics and can make the manipulator get rid of the harm caused by the strange posture and excessive working amplitude. According to the practical application characteristics of the toilet seat trimming process, this paper proposes a new method of toilet edge detection. When there is a reflective area for edge detection, the method can eliminate the false edge of the image caused by the reflection. There are high precision and strong robustness in this new edge detection algorithm, which has a high guiding significance to assist the toilet seat processing industry.

Machine vision based edge detection method for toilet seat

Trajectory planning plays a vital role in the stability and accuracy of the robot when working. Using the edge detection principle of machine vision for trajectory planning can provide high reliability for polishing the robot. Grinding the trajectory, which is more stable when grinding the edges of sanitary ceramics and can make the manipulator get rid of the harm caused by the strange posture and excessive working amplitude. According to the practical application characteristics of the toilet seat trimming process, this paper proposes a new method of toilet edge detection. When there is a reflective area for edge detection, the method can eliminate the false edge of the image caused by the reflection. There are high precision and strong robustness in this new edge detection algorithm, which has a high guiding significance to assist the toilet seat processing industry.

Investigation of natural radioactivity and associated radiological hazards in ceramic sanitary ware products commercially sold in Turkey

ABSTRACT All ceramic products used in the construction of buildings contain natural radioisotopes at various rates. These radioisotopes are the main source of outdoor radiation to which people living in houses or workplaces are exposed. Therefore, it is important to determine the radioactivity levels in ceramic products used in buildings. In this study, the natural radioactivity levels (226Ra, 232Th and 40K) in forty ceramic sanitary ware products (17 closets and 23 sinks) of twelve different brands produced in Turkey were determined using a high-purity germanium detector (HPGe). In order to evaluate the radiological hazards originating from natural radionuclides of examined ceramic sanitary ware samples, radium equivalent activity (Raeq), gamma index (Iγ), external hazard index (Hex), absorbed dose rate (D), annual effective dose (AED) and excess life time cancer risk (ELCR) values were also calculated. The average activity concentrations of 226Ra, 232Th and 40K radionuclides in the investigated ceramic sanitary ware products were found as 35.47 ± 2.35, 48.80 ± 2.53, 230.44 ± 10.49 Bq/kg for closet samples and 34.64 ± 2.34, 51.25 ± 2.61, 256.23 ± 10.95 Bq/kg for sink samples, respectively. These values are less than the world average values (50, 50, 500 Bq/kg) except for the average 232Th concentration of sink samples. The average of radiological hazard parameters (Raeq, Iγ, Hex, D, AEDE and ELCR) calculated for all ceramic sanitary ware samples were found lower than the limit values recommended by international organisations.

Experimental Investigation of Concrete with Recycled Aggregates for Suitability in Concrete Structures

This paper presents the experimental tests of concrete made on the recycled aggregates basis. Tests were carried out to determine the concrete suitability for construction purposes. The physical and strength properties were determined for three types of recycling aggregates. The aggregates were obtained from sanitary ceramics ‘SC’ (washbasins and toilet bowls), building ceramics ‘BC’ (solid bricks), and concrete rubble ‘CR’. The results obtained in tests of compressive strength, bending tensile strength, water absorption, total shrinkage, watertightness, and frost resistance of concrete made of SC and CR aggregates gave grounds for stating its suitability for structural purposes. Concrete based on the BC aggregates is not recommended for structural applications.

Effect of work life balance and supervisor support on employee retention in Ceramic manufacturing industries in India -An empirical evidence

Retention of talented employees has become a serious concern to organizations irrespective of their size and special attention being given to the factors motivating retention. Extant literature predicts that work life balance and supervisor support are the most relevant factors related to employee’s retention. This study examines the impact of above factors over employees of unattended ceramic sanitary ware factories in India. Statistical tools were used for analysis. Key findings reveals that work life balance and supervisor support are the factors having positive influence on retention and supervisor support gives more impact on retention. Implications to organization and suggestion for future research are also incorporated.

Influence of postsintered wastes incorporation on physico‐mechanical and structural evolution of vitreous ceramics

AbstractDue to high consumption of conventional materials such as quartz and feldspar in most ceramic products processing, the recent practice has been targeted at exploration and utilization of some industrial wastes with similar characteristics to solely or partially replace these conventional materials to reduce cost of production, and serves as a means of solid wastes management. In this regard, this work aims at incorporating postsintered wastes as partial and sole alternatives to quartz and feldspar in the production of vitreous sanitary ceramics. Vitreous sanitary ware bodies containing discarded sanitary wares and waste soda‐lime glasses as substitute to quartz and feldspar respectively were prepared using slip casting process. Several samples measuring 120 × 50 × 10 mm were cast, left to dry at ambient temperature for 24 hours followed by oven‐drying at 105°C for another 12 hours. The cast samples were then subjected to sintering at temperatures of 1150 and 1200°C, respectively, and then soaked for 90 minutes. Physico‐mechanical, phase, and structural evaluations were carried out to assess the performance of the vitreous sanitary bodies. The results showed that samples containing postsintered wastes displayed better physical, mechanical, and structural properties, while the chemical compositions of the prepared samples showed close similarity to standard Twyford sanitary ware. However, better properties were observed for samples sintered at 1200°C which might be attributed to high vitrification at elevated temperature.

Zeolite Tuff and Recycled Ceramic Sanitary Ware Aggregate in Production of Concrete

The article presents the results of research on the use of ceramic ware waste as aggregate in concrete production. Four concrete mixtures with aluminous cement were prepared, each with a different admixture of clinoptilolite. The only used aggregate was crushed waste ceramic sanitary ware obtained from a Polish sanitary fixture production plant. As part of the studies, a compressive test of cubic samples at different curing times ranging from 7 to 90 days was performed. Prior to the preparation of the samples, a sieve analysis and an elemental analysis of the obtained aggregate were conducted. In the framework of the testing, the bimodal distribution of clinoptilolite grains was determined, as well as its chemical composition. The conducted compressive tests demonstrated high strength of concrete containing ceramic aggregate and aluminous cement with an addition of clinoptilolite. In order to determine the impact that adding zeolite exerts on the phase composition and the structure of concrete samples, an analysis of the phase composition (XRD) and scanning electron microscopy examination (SEM) were performed. Furthermore, tests of abrasion, water penetration under pressure and frost resistance were conducted, determining particular properties of the designed mixtures. The abrasion tests have confirmed that the mixtures are highly abrasion-resistant and can be used as a topcoat concrete layer. The conducted tests of selected properties have confirmed the possibility of using waste ceramic cullet and a mineral addition of clinoptilolite in concrete production.

Influence of Lampang pottery stone: local materials in Thailand on C-Q-F ratio, key properties, mullite formation and glaze-body fit of vitreous ceramic sanitary ware

This study was aimed to investigate the key properties, mullite formation and glaze-body fit of sanitary ware bodies, by using pottery stone from Lampang, Thailand as a substitute for kaolin, feldspar, and silica. Seven samples of formulated bodies were prepared by wet milling, formed by plaster mold casting, and fired at 1175 °C, 1200 °C, and 1225 °C. Testings were carried out in accordance with ASTM C373-88, ASTM C326-09, ASTM C689-09, and ASTM C372-94. Phase analysis and microstructure of selected formulations were analyzed by using XRD and SEM. For the formulation having 37.7-20.7-41.6 of C-Q-F ratio and pottery stone in substitute for 100% silica, after firing at 1200 °C showed 9.27% total shrinkage, 0.17% water absorption, and 60 MPa flexure stress. The crystal structure resulted in higher amount of mullite. The linear thermal expansion and thermal expansion coefficient were lower to 0.34 and 7.07 × 10−6/°C, respectively. The difference of linear thermal expansion between the formulated body and commercial white-opaque glaze was − 0.02 at 500 °C. The shrinkage difference of body and glaze showed that the glaze-body fit was under slightly amount of compression. As a result, the formulation with the substitute for 100% silica could be vitrificated at lower temperature and indicated positive trends towards lower dunting during firing.

Utilization of ceramic waste by using it as special concrete aggregate

In the article is presented the method ofutilization of ceramic waste by using it as special concrete aggregate for special high temperature resistant concentrates. The research was performed on six empirically designed concrete mixtures of three on aluminous cement with simultaneous aerification with using air entraining admixture respectively at 0, 5 and 10%. In order to compare the results, three Portland cement concrete mixes were prepared which had exactly the same aerification of the mixture. All types of samples were made using recyclable aggregates of sanitary ceramics selected and crushed to 0-4 mm and 4-8 mm. This particular type of aggregate, as proved in previous authors’ workshowed very favorable features in terms of the influence for thermal loads. Selected samples were subjected to a thermal treatment according to the standard curve “temperature-time” for 120 minutes until the furnace chamber temperature reached approximately 1050°C. With interative concrete mixture method design, assuming that the mixture substrates were limited to the commonly used cements and the appropriate amount of air entraining admixture, there were received tight concrete with high strength parameters, which also demonstrates resistance explosive concrete particles’ chipping off under conditions of high temperatures.

Analysis of the Effects of Aggressive Environments Simulating Municipal Sewage on Recycled Concretes Based on Selected Ceramic Waste.

This paper presents the results of research aimed at finding the possible ways of disposing of ceramic waste material, focusing mainly on the possibility of using it as aggregates in concretes exposed to an aggressive chemical environment (municipal sewage). The research part presents the preparation method and investigation of waste ceramic aggregates (red, glazed and sanitary ceramic aggregates). A suitable ratio of coarse to fine aggregates was selected, and their density, absorptivity and crushing strength were examined. All examined aggregates were also subjected to SEM analysis. Red ceramic aggregate is characterized by a greater degree of crushing compared to glazed and sanitary ceramic aggregate, by 205.7% and 439.4%, respectively. Another part of the research was to compare the properties of concrete with traditional aggregate (gravel, basalt) and with ceramic waste aggregate. The tested parameters included consistency, apparent density, absorptivity, flexural and compressive strengths of concretes. The study proved that the absorptivity of recycled composites is higher than that of traditional composites by 20.8–24.7%. The concrete based on sanitary ceramic waste has the highest strength parameters. Its compressive strength is higher by 10.5% and flexural strength by 5.9% compared with the basalt aggregate concrete. The compressive strength of sanitary ceramics concrete is higher by 42% and by 59% compared with concrete based on glazed ceramic and red ceramic aggregate, respectively. The last part of the research was to examine the resistance of concrete to aggressive environment. The scope of the work included the preparation of the research environment in the form of solutions with an increased concentration of aggressive agents (hydronium, sulfate, magnesium, ammonium ions). Among the concretes with ceramic aggregate, the highest decrease in the compressive strength was demonstrated by the concrete based on red ceramics (128.2%), while the smallest was demonstrated by the concrete based on sanitary ceramics (aggregate from sanitary ceramics (15.4%). The mass loss at different time intervals and compressive strength loss of samples stored in solutions were tested. The smallest weight loss caused by aggressive environment attack was recorded in the concrete based on ceramic sanitary and glazed aggregate (20.2% and 34.5%, respectively, after 120 days of aggressive environment).

The Wastes of Sanitary Ceramics as Recycling Aggregate to Special Concretes.

This article presents the results of research on the wastes of sanitary ceramics as an aggregate to concretes. The case of high temperature load was taken into account. Six concrete mixes were designed on Portland and calcium aluminate cement with various content of aerating admixture. Only the ground waste ceramics were used as an aggregate from one of the Polish sanitary ceramics plants. The abrasion test by Boehme blade of the designed concrete was conducted within the frame of study and compression strength tests on the cylindrical samples were performed as well. Some samples were initially annealed at 400 or 800 °C prior to strength tests. In order to determine the impact of annealing on the phase content and the concrete sample structure, the analyses on phase content (XRD—X-ray diffraction) and scanning electron microscopy (SEM) were conducted. The tests on compression strength demonstrated that there is considerable resistance of concrete containing ceramic aggregate and calcium aluminate cement to high temperatures. Abrasion tests confirmed that selected mixes have a high resistance to abrasion and they can be applied as a concrete coating. The possibility of ceramic cullet use as an aggregate to special concretes has been confirmed by the conducted research on specific features. Taking into consideration the available literature, the article presents widely conducted research in the area of the internal structure of concrete designed on the basis of recycled ceramic aggregate, the phase content of individual components, and basic mechanical tests both in normal temperatures and under thermal stress.

The Assessment of Possibility of Using Sanitary Ceramic Waste as Concrete Aggregate—Determination of the Basic Material Characteristics

This article presents the possibilities of using soft clay pottery waste as concrete aggregate. There is shown a new approach of complete exchange natural aggregate in concrete with recycled aggregate, i.e., crushed ceramic of two fractions 0–4 and 4–8 mm. Basic characteristics of aggregate were evaluated, i.e., phase composition and crush strength. Drawing on past experiences, two concrete mixes were designed that were based on Portland cement 32.5 R used for ordinary concrete and aluminous Górkal 70, which is characterized by high initial strength and the fact that Al2O3 is the binding factor. The prepared concrete samples were subjected to maintenance for the next 28 days, and then tests started. A series of tests were performed on the properties of concrete obtained, including a compressive strength and bending strength, an abrasion resistance, frost resistance, water absorption, depth of penetration of water under pressure, and bulk density of concrete. The research confirmed assumptions that it is possible to completely replace the natural aggregate with aggregate made of soft clay pottery waste. Both designed concretes showed high compressive and bending strength, as well as low absorbability and abrasiveness. It was also found that soaking in water, as well as its duration, adversely affects the strength properties of the designed concretes. Regarding concrete based on Portland cement, it was also demonstrated that the concrete has a high frost resistance and resistance to penetration of water under pressure.

Microstructural Differences in Response of Thermoresistant (Ceramic) and Standard (Granite) Concretes on Heating. Studies Using SEM and Nonstandard Approaches to Microtomography and Mercury Intrusion Porosimetry Data.

The microstructure of concretes containing ceramic sanitary ware waste and granite aggregates was studied using scanning electron microscopy, mercury intrusion porosimetry and computer microtomography, before and after cyclic heating of the concretes to 1000 °C. All methods showed an increase in porosities in the concretes after heating. The proposed new approach to microtomography data analysis detected a much higher increase in the number of cracks in granite than in ceramic concrete after heating. This new approach to combining mercury intrusion and microtomography data showed that heating led to the narrowing of throats connecting smaller pore voids and a broadening of throats connecting larger pore voids, in both concretes.

Examination of granulometry of ceramic dust which derogations while disposing waste sanitary ceramics for the use of their as addition to the concrete

The purpose of the research presented in this article was to assess the granulometry of ceramic dust in terms of their use as an additive to concrete. The material for testing came from postindustrial sanitary ceramic waste, which was subjected to a crushing process in jaw crushers. A research stand consisting of a Horoir LA-300 laser particle analyzer connected to a computer equipped with appropriate software was used to study the granulometric characteristics. As a side feature, the dust density was examined using a Le Chatelier flask. The results of the tests carried out were compared with the data obtained for the traditionally used concrete additive - silica volatile dusts.

Gahnite white colour glazes in ZnO–R2O–RO–Al2O3–SiO2 system

The paper focuses on the results of research on the development of newly designed white glazes without the addition of traditional opacifiers such as ZrO2 or ZrSiO4, intended for use in ceramic sanitary products. The effect of opacity was obtained by introducing ZnO in quantities of 4–8 wt% to the sets of glazes. ZnO introduced to the glaze compositions resulted in crystallization of gahnite, and gahnite caused the glaze to become opaque and white. Measurements of the whiteness of glazes confirmed its high level, over 90 units were noticed according to the CIE Lab scale. The microstructure and structure of the glazes were measured by scanning electron microscopy and X-ray diffractometry. The colour and gloss of the glazes were measured using a spectrophotometer and a gloss meter. The topography of the glaze surfaces, as well as the roughness level (Ra), were measured using a confocal microscope.

Effect of structural and textural properties of a ceramic industrial sludge and kaolin on the hardened geopolymer properties

Abstract This paper presents a comparative structural and textural study of an industrial sludge and commercial kaolin, in order to explain the transformation of the industrial sludge after calcination and to correlate the raw material properties to the hardened geopolymer products structure and compressive strength. The industrial sludge used in this study comes from a local factory manufacturing ceramic sanitary products. The amorphization and the dehydroxylation of the two materials were followed by X-ray diffraction, infrared spectroscopy and thermogravimetric method. The clay morphology was verified by scanning electron and transmission electron microscopies. The textural study of materials was carried out using two techniques, the mercury porosimetry and nitrogen adsorption. The chemical composition of the newly formed geopolymers phases was followed by FTIR spectroscopy. The XRD analysis revealed that the crystallinity of the industry sludge is lower than that of commercial Kaolin. The FTIR analysis confirmed that the dehydroxylation of the ceramic industrial sludge at the chosen temperature caused a total removal of hydroxyl groups. The N2 adsorption isotherms of the calcined industry sludge (MB) and the Metakaolin (MK) showed that the texture is formed by the agglomeration of aggregates. The maximum value of the compressive strength of MB-geopolymer is too close to that of MK-geopolymer (about 29 MPa), confirming therefore the great reactivity of the ceramic industrial sludge. We conclude that the industrial ceramic sludge appears to be a very efficient material that should find a niche in a market where kaolin clay is becoming scarce.

DURABILITY OF A REPAIRED DUNE SAND MORTAR MODIFIED BY CERAMIC WASTE

The waste-modified mortars have an important place in the range of repair products. The objective of this study is to better understand and analyze, in one hand, the influence of ceramic waste in the dune sand mortars on the quality of repair concrete surfaces, in the other hand, durability of the mortars in interaction with the substrates to which they are applied. As regards the mortar layer durability, two indicators are chosen: the first is the adhesion to the substrate, and the second is the stress state in the mortar layer. For this, two types of modified mortars were made using two types of waste ceramics: sanitary ceramics and earthenware. To evaluate the quality of the adhesion to a substrate surface to be repaired, an adhesion test based on the three point bending test was implemented, taking into account the influences of the environment, the state of the surface of the substrate, the nature of the substrate defined by its water saturation degree and its porosity. The mortar composition parameters, in particular, the nature and the amount of ceramic, were studied. The results enable us to evaluate the influences of the waste ceramic incorporation in the mortar and the substrate condition on which the mortar is applied. Show that the adhesion depends on both the type and the amount of the used ceramic waste and the applied cure. It is optimized from 30% of ceramic earthenware and sanitary mortar adhesive strengths are higher than mortars based on dune sand ones.

Application of Recycled Ceramic Aggregates for the Production of Mineral-Asphalt Mixtures.

This paper describes a method of designing and producing innovative mineral–asphalt mixtures, which utilize waste aggregate from the recycling of sanitary ceramics. The work presents the basic properties of the ceramic material, the investigation concerning the microstructure of the aggregate obtained from the grinding of waste, and a comparison with the images obtained for the aggregates usually employed in mineral–asphalt mixtures. The mixtures were designed for the application in the wearing course. Four series of mixtures were prepared. In the first and second, the ceramic aggregate constituted a partial substitute for dolomite, whereas in the third, we substituted granodiorite, and the fourth series contained only dolomite. The mixtures were examined for the content of soluble binder, the bulk density of samples, the presence of voids, the space filled with binder, and the susceptibility to water and frost corrosion. The obtained results were compared with the standard requirements. The microstructure as well as the contact zone in the considered mineral–asphalt mixtures are presented based on research conducted by means of a scanning electron microscope (SEM).

Comparative Study on Energy Saving of Low-Carbon Materials in Sanitary Ware Development

In this article, the author deeply analyzed and researched the production of wollastonite base-material sanitary ware, emphatically discussed molding method of wollastonite base-material, and established a calculation formula for whole production phase carbon emission and carbon tax of wollastonite base-material sanitary ware and common ceramic sanitary ware; made a comprehensive compare on environmental performance between common ceramic and wollastonite base-material sanitary wares, and clearly put forward the advantage on carbon emission of wollastonite base-material during production process; made a comparative research on energy consumption and carbon emission between traditional ceramic sanitary ware and low-carbon sanitary ware; finally verified the application value of low-carbon sanitary ware and provided the basis for development of it.