Ceramic Waste Research Articles

Influence of different waste-derived fillers in extruded geopolymeric matrix for 3D printing

One of the key challenges for the development of 3D printing in construction is the optimization of proper mix design in the fresh and hardened state. It is well known that the incorporation of nano- or micro-sized fillers generally improves thixotropic properties of the mixtures, having a great influence on the performance of extruded geopolymers by 3D printing.This work reports the preliminary results related to the optimization of geopolymer mix design for extrusion purpose. The effect of different fillers on fresh and hardened properties was assessed by manually extrusion of different geopolymeric mixes. Geopolymers and alkali activated materials are innovative binders with comparable and sometimes superior properties compared to traditional cementitious materials. The setting time of these materials is generally quite fast and usually occurs at room or at low (less than100 °C) temperature. In addition, they exhibit satisfying mechanical properties, hydraulicity and mesoporous microstructure.In this study, micro-sized fillers, sourced from different industrial wastes, such as fly ash and ceramic waste from porcelain tile grinding and lapping processes, were tested. For comparisons’ purpose, calcium carbonate was also tested as reference filler. The microstructure of the investigated materials as fillers was analyzed by particle size distribution, X-ray diffraction (XRD) and scanning electron microscopy (SEM). Then, geopolymers were prepared by mixing metakaolin and the selected fillers with sodium hydroxide and sodium silicate solutions, considering the following molar ratios: SiO2/Al2O3 = 2.24, Na2O/Al2O3 = 0.64, Na2O/SiO2 = 0.28. All the samples were cured at room temperature in sealed conditions. The optimized filler concentration was selected by investigating the workability of the fresh mixes using a mini-cone slump tester. Preliminary attempts of extrusion process were manually carried out using a 5 mm-conical nozzle in air at room temperature. Moreover, the setting time was evaluated by Vicat test, while physical properties of hardened samples were analyzed by hydrostatic weighing. The preliminary results exhibited that the particle size and shape of the fillers strongly influence the fresh properties of the mix and thus the suitability of the selected mixes for extrusion in the final 3D printing application.

“Fresh characteristics and compressive strength evaluation of self-compacting concrete prepared with ceramic waste tile and fly ash”

This study aims to use fly ash as cement substitute and ceramic waste tile (CWT) as substitute for fine aggregate (FA), for creating self-compacting concrete (SCC). Fly ash content is kept constant at 30%, and CWT is used in varying proportions of 0%, 10%, 20%, 30% and 40% to create the self-compacting concrete mixtures. Total of five mixtures were cast along with one control mixture. The fresh characteristics were assessed using slump flow, U-box, T500 time, V-funnel and L-box experiments, while the mechanical characteristics was assessed using the compressive strength. The outcomes indicate that the fly ash has a positive impact on the fresh characteristics, whereas CWT affects the fresh characteristics of SCC negatively.In ceramic based SCC mixture, use of fly ash as a partial substitute to cement reduced the harmful effects of the CWT particles to a certain extent on the fresh characteristics. SCC mixture created with combined use of 30% fly ash and 30% CWT (i.e. F30C30 mix) exhibited the highest compressive strength.

Effects of microsilica and polypropylene fibers on the rheological properties, mechanical parameters and durability characteristics of green self-compacting concrete containing ceramic wastes

In the developing countries, since a major part of the urban wastes is related to the construction sector, this study has used ceramic waste (CW) as a partial substitute for natural coarse aggregates to produce self-compacting concrete (SCC), and since the latter should have enough strength and durability, effort has been made to not only examine its rheological properties and mechanical parameters, but also study the effects of microsilica (M) and polypropylene fibers (PP fibers) on its durability characteristics (electrical resistivity, ultrasonic pulse speed and volumetric and capillary water absorption). According to the results, increasing the percent CW decreases the SCC efficiency, and increasing M and PP fibers increases its viscosity and, hence, decreases its flowability and passability, but increases its resistance against segregation. In this research, CW50M10P0.15 had the highest compressive strength – an increase of about 21% compared to the control sample – and CW25M5P0.3 showed the highest tensile and flexural strengths compared to the control sample. Adding CW reduced the durability of the SCC samples slightly, but adding M and PP fibers increased it. In the electrical resistivity test, CW25M10P0.3 showed an increase of about 168% compared to the control sample. Analyzing the scanning electron microscope (SEM) images revealed that mix designs containing ceramic wastes had a stronger ITZ, and adding M made the samples denser and more coherent.

Optimizing microencapsulated PCM ratios of sustainable cement mortar for energy savings in buildings

Energy efficiency improvement techniques for buildings are among the fundamental challenges to sustainable buildings. PCMs incorporation in mortar is one of the efficient techniques for improving the energy efficiency of buildings. However, the low integration ratio of PCMs into cement mortar significantly decreases its effectiveness. Using PCMs as a replacement for sand has a negative effect that leads to the deterioration of the mechanical properties of mortar. This study aims to extend using PCMs in mortar eco-friendly and study the impact PCMs up to 50% as additions of cement content with ceramic fine aggregate waste as a replacement for sand on thermal energy storage ability improvement and enhance its physicomechanical properties. Twelve specimens were prepared, four mixtures of mortars with 0%, 12.5%, 25%, and 50% PCMs, as additions to the cement content with 100% natural sand. Eight mixtures were prepared with different ceramic fine aggregate contents with 25%, 50%, 75%, and 100% as replacements from sand content with integrated 25% and 50% PCMs, respectively. SEM, thermal performance, and physical–mechanical characteristics of the mortar-integrated PCM were performed. The results showed no chemical interactions between the PCM and the cementitious components during hydration. The compressive strength and thermal performance results showed enhancement when using ceramic as a replacement for sand by increasing about 37.1% for compressive strength, with the decreased temperatures to 9.5 °C and phase peaks shifting ahead by 115 min for a mix of 50% PCM + 100CFA, compared to 7.0 °C with phase peaks shifting by 85 min for a mix of 50 %PCM + 100NS.

Adhesion of structural steel to concrete with recycled crushed sanitary ceramics aggregate

Today, the use of recyclable materials has been the focus of researchers around the world. The use of re-cycled concrete aggregates, although beneficial for environmental reasons, brings many problems. One of the basic factors is the presence of old mortar and impurities in these aggregates. Therefore, it is necessary to conduct comprehensive studies in this field. Hence, the paper presents the results of testing the adhesion of B500SP structural steel to concrete subjected to thermal loads in the range of 300–700°C. The concretes were designed exclusively based on waste aggregate made of precious waste ceramics and two types of cement: CEM I 42.5 R portland cement and Górkal 70 alumina cement. The method of direct pulling of a steel rod from the concrete cover (pull-out test) was used in the tests. The test results confirmed that the adhesion of the selected steel grade to concrete based on recycled aggregate does not differ from the results obtained for concrete with natural aggregate.

Investigation of the recycling of ceramic sludge waste from wall tile production in ceramic factory

In ceramic production, vast amount of green process waste is created. Green process waste in other words, sludge waste creates a big environmental problem. It can create water pollution as well as create environmental problems having a big physical change of the stored area., Therefore, the use of sludge waste in the process as raw material is vitally important. The research programme was carried out to use the green process wastes as raw materials in the recipes of various products in Kaleseramik Research and Development Center in Turkey. Firstly, the long term samples were taken in order to observe the fluctuation of the created waste. Then, the chemical and mineralogical characterization of sludge wastes was carried out by using XRF and XRD. Different recipes were prepared by using green process waste. The behavior and the phases of fired products were evaluated by using a double-beam optical non-contact dilatometer and XRD. SEM and EDX were carried out for microstructural and micro-chemical analysis. Finally; the physical, mechanical and color properties of waste added recipes; such as water absorption, linear shrinkage, breaking strength and chromatic coordinates were measured. The results showed that it is possible to develop wall tile body with suitable technological properties by using appropriate mixture of process wastes in the body composition. The usage of sludge waste eliminates environmental problems and also provides the cost advantages as a raw material input. The full results of the case study performed at Kaleseramik Factory is illustrated in details.

An Overview Study of Concrete with Partial Replacementof Crushed Sand with Ceramic Tile Waste

An Overview Study of Concrete with Partial Replacementof Crushed Sand with Ceramic Tile Waste

Exploring the effects of Sr/Ce/Nd co-incorporation on the phase evolution and chemical stability of Sr0.5Zr2(PO4)3-(Ce, Nd)PO4 multiphase ceramics designed for nuclear waste forms

In this work, 0.6Sr0.5Zr2(PO4)3-0.4Ce1-xNdxPO4 (x = 0–1) multiphase ceramics were fabricated using a one-step microwave sintering technique, where Sr and Ce/Nd were utilized as the substitutes for the fission products 90Sr and actinide nuclides in high-level radionuclide wastes, respectively. The influences of Sr/Ce/Nd co-incorporation on the phase evolution, crystal structure, micromorphology, densification, and chemical stability of the as-prepared multiphase ceramic waste forms were systematically investigated. It was detected that the multiphase ceramics were composed of Sr0.5Zr2(PO4)3 (SrZP) phase and monazite phase regardless of x value, and (Ce, Nd)PO4 monazite solid solution was formed with Ce/Nd substitution. Rietveld refinement results further verified the cell parameters of (Ce, Nd)PO4 monazite solid solution regularly decreased with increasing Nd replacement, and the structural change of crystalline monazite did not affect the structure of SrZP phase. All samples presented a well-compacted and homogeneous microstructure, and their micromorphology did not change significantly with the replacement of Ce by Nd. Moreover, the relative density of the as-prepared multiphase ceramics all reached more than approximately 94.5 %, demonstrating excellent densification. Importantly, the good compatibility of SrZP and (Ce, Nd)PO4 monazite phases brought out superior chemical stability. The normalized elemental leaching rate showed no significant change for different Ce/Nd substituted samples, whose normalized leaching rates of Sr, Ce, and Nd were about 10−4 g/(m2·d), 10−7 g/(m2·d), and 10−6 g/(m2·d) order of magnitude, respectively. It is demonstrated that SrZP-(Ce, Nd)PO4 multiphase ceramics can be used as candidate materials for simultaneously immobilizing fission products and actinide nuclides of high-level nuclear wastes.

Experimental Investigation of Bitumen Concrete mix with Use of Ceramic Waste and Rise Husk Ash as a Partial Replacement of Filler and Aggregate

Bituminous concrete are most widely used in present era. The cost of bitumen is increase day by day and lack of availability of natural resources increased . for that reason there are an opportunity to use local material resources such as ceramic waste (CW) silica flumes, slag, plastic,rise husk ash (ash) are by product which is a bad Environmental hazard causing damage destroy the land and surrounding area in which it is dumped .To deal with this problem,we are studying and test of material in lab of the mechanical performance of bituminous concrete using ceramic waste and rise husk ash a different proportion 4%,6%,8% and 3%,4%,5% respectively at a different bitumen content as a partial replacement of filler and aggregate material .In this lab test marshal stability test and tensile strength test considered as a design and evaluation of bituminous paving mixes . The mechanical property of these material will be check whether it is good or bad for bituminous concrete .Ceramic waste and rise husk ash is a good replacement for medium and small traffic roads.

Waste Not, Want Not: Sustainable Use of Anti-Stripping-Treated Waste Ceramic in Superpave Asphalt Mixtures

This research studied the sustainable utilization of waste ceramic in asphalt mixtures by substituting fine aggregate with treated and untreated waste ceramic produced from construction and demolition activities. To improve its adhesion to the asphalt binder and lower the moisture susceptibility of Superpave asphalt mixes, the waste ceramic was treated with a silane anti-stripping agent. The Marshall quotient (MQ), Marshall stability (MS), indirect tensile strength (ITS), retained Marshall stability (RMS), and tensile strength ratio (TSR) were used to assess the mechanical performance and moisture susceptibility of all mixes. The changes in the chemical composition, synergy, physical state, and microstructure of the studied composites were also investigated using Fourier transform infrared spectroscopy (FTIR) and scanning electron microscopy (SEM). The results revealed that substituting fine aggregate with 50% silane-treated waste ceramics reduced permanent deformation by 46%. Moreover, integrating silane-treated ceramics reduced asphalt mixture moisture susceptibility, with an RMS value of 87.7% obtained for asphalt containing 75% treated ceramic particles. The application of a silane anti-stripping agent resulted in high adhesion between the ceramic particles and bitumen as well as the production of fewer air voids in the mixes due to the formation of strong CH aromatic linkages, as well as Si-O and Si-O-Si bonds. The possibility of employing waste ceramics in asphalt mixes as a sustainable alternative to virgin aggregates while decreasing environmental impacts and improving resource efficiency is highlighted in this paper.

Utilization of Recyclable Concrete and Ceramic Waste as Filling Material in Hot Mix Asphalt

A significant issue that researchers have been addressing recently is the recycling of various waste materials from different industries. Annually, millions of tons of waste are released. Pollution and safe, cost-effective disposal are critical issues with these waste materials. This study aims to investigate usability of concrete waste (COW) and ceramic waste (CEW) as filler material in Hot Mix Asphalt (HMA). Firstly, in this direction, a series of tests were conducted to determine the optimum bitumen content. Five different bitumen contents (i.e., 4.5%, 5%, 5.5%, 6%, and 6.5%) were used to prepare asphalt concrete samples. The Marshall Stability (MS) test was then performed on the prepared samples using various filler ratios, including limestone (LS), concrete waste (COW), and/or ceramic waste (CEW). Selecting the series of asphalt with 4% filler that has provided the maximum stability, COW or CEW was replaced with LS filler at rates of 25%, 50%, 75%, and 100%. Consequently, the use of COW or CEW as a mineral filler in HMA was found to be suitable.

Study of concrete behavior by partial replacement of cement with Ceramic Waste Powder in the presence of Sisal fiber

Concrete is the most prevalent building material, needing massive amounts of cement, coarse and fine aggregate. A substitute material needs to be used as a partial replacement for cement, fine or coarse aggregates or admixtures in concrete, as the widespread use of concrete may lead to an increase in the cost of resources. In order to minimize the budget for concrete and environmental degradation, experimental research is conducted by substituting cement with Ceramic Waste Powder (CWP) in varying proportions and incorporating an effective proportion of sisal fiber. A practical solution to problems is to incorporate ceramic waste into building materials for recycling. In this project, 25% of the cement is replaced with ceramic waste, and sisal fiber is added. Ceramic waste powder is used to replace 5%, 10%, 15%, 20%, and 25% of the cement, along with an effective percentage of sisal fiber. The project's design mix is M30, with a W/C ratio of 0.45. Ordinary concrete made by substituting cement with CWP and along in presence of sisal fiber as an admixture was cast and tested for compressive strength, flexural strength, and split tensile strength at 7 and 28 days and also for workability. Utilizing 10% ceramic waste and 1% sisal fiber as concrete additives produces optimal strength values. Utilization and use of ceramic waste contribute to the growth of the construction industry.

Effect of waste stream materials on properties of cement mortars when used as supplementary binding materials

The present study focuses on the effect of waste stream materials on various properties of cement mortar when the waste materials are used as supplementary binding/cementitious materials (SCMs) for partial replacement of binding material. The effect and properties of various types of SCMs that are commonly used in mortar preparation replacing a part of cement (%) like limestone dust (LS), cement kiln dust (CKD), ground granulated blast furnace slag (GGBS), dolomitic limestone (DLS), ladle furnace slag (LDF), silica fume (SF), ceramic wastes (CW), fly ash (FA), pulverized fuel ash (PFA), waste glass sludge (WGS), etc. are studied and presented. Effects and characteristics of various combinations of different supplementary binding materials like the combination of FA with LS, an amalgamation of FA with DLS, the compatibility of FA with WGS, the mixture of GGBS with PFA, blending of GGBS with CKD, etc. are studied and reported. The elemental composition, pore size distribution system and microstructural composition were studied through X-ray diffraction (XRD), mercury intrusion porosimetry (MIP) and scanning electron microscope (SEM) and discussed. The results of the study revealed that a combination of GGBS and PFA yields better results than the reference mixes made of cement and other blended mixes made of SCMs. The performance of CW and WGS is found good at the later age. The performance of fly ash on mortar properties depended on the dosage and fineness of fly ash. Apart from their better solo performance, a combination of limestone dust and silica fume not only enhances the strength but also the sulphate resistance of mortar. The study revealed that the use of SCMs in mortar contributes to a reduction in cement production and carbon emission.

Continuous monitoring of composite vital signs and biomarkers for highly specific ICU alarms

Reusing calcium carbide slag (CCS) and ceramic polishing waste (CPW) as mineral admixtures can reduce the consumption of cement and the stockpiles of CCS and CPW. Studies on CCS improving the pozzolanic reaction of CPW have yet to be published. In this work, CCS was added to cement-based composites to provide sufficient CH for the pozzolanic reaction of CPW. The influence of CCS and CPW on the hydration, mechanical performance, and autogenous shrinkage of composite pastes or mortars was studied. The hydration kinetics, hydration products, and microstructures of the composite pastes were characterized using isothermal conduction calorimetry, thermogravimetric analysis (TGA), X-ray diffraction (XRD), and mercury intrusion porosimetry (MIP). The results showed that the CH contents of the composite pastes at 28 d are lower than those at 7 d, that is, the pozzolanic reaction of CPW consumes a considerable amount of Ca(OH)2 in the system. Meanwhile, CCS supplies sufficient CH for this reaction and improves the CPW reaction degree. Macroscopically, the pozzolanic reaction of CPW promotes the strength development of composite mortars at a late age. Nonetheless, most composite mortars have lower compressive and flexural strengths than cement mortars, especially at an early age. In addition, the composite pastes have more micropores, which enhance the capillary pressure and further increase the autogenous shrinkage. This work contributes to the recycling of CPW and CCS, potentially lowering construction costs and increasing sustainability.

Engineering attributes of alkali-activated mortars containing ceramic tiles waste as aggregates replacement: Effect of high-volume fly ash inclusion

Fast depletion of the natural aggregates and an ever-increasing carbon footprint in environment has enforced humanity to take an immediate remedial measure. Meanwhile, the wastes generated from ceramic materials by various industries worldwide became responsible for growing landfill problems. Several alkali-activated mortars mortars containing ceramic tiles waste as natural aggregates replacement have been designed and evaluated to assess the effectiveness of such waste on the engineering characteristics, such as compressive strength, drying shrinkage, abrasion resistance and water absorption performance of the obtained mortars. The prepared mortars enclosed high volume Fly Ash (FA), Ceramic Tiles Waste (CTW) and Ground Blast Furnace Slag (GBFS). It has been observed that the use of 100% of CTW as fine aggregates replacement was shown to achieve strengths comparable to the control specimen, whereas the inclusion of high volume of FA contents as GBFS substitute in the proposed mix design was discerned to affect significantly on their early strength, thus enhanced the durability performance in term of reducing the total drying shrinkage. However, the results showed that the porosity and abrasion resistance are negatively affected due to increasing FA level. The grinding depth and waster absorption percentage of the mortars was found to increase with the increase of FA content as GBFS replacement.

Effect of partial replacement of cement with alkali activated Ceramic Waste Powder

Ceramic waste powder (CWP) is a remnant of the ceramic industry that is utilized in a variety of industries, including construction, agriculture, glass, and paper, due to its resistance to biological, chemical, and physical forces as a Pozzolanic material. In this research, CWP is combined with an alkali activating solution to partially supplant cement in concrete. The primary objective of using alkali activating solution is to increase the CWP's reactivity. This investigation employs a fluid binder ratio of 0.45, which is typically between 0.40 and 0.60 (IS: 456–2000). A study is conducted to evaluate the strengths of hardened M30 grade concrete with partial replacement of cement of 0%, 10%s, 20%s, 30%s, 40%s, and 50%s with CWP at ages of 7 days and 28 days for constant fluid binder ratio and normal curing. Cubes, cylinders, and beam specimens are cast, cured, and evaluated to determine the effect of replacing cement with CWP. In accordance with the experimental findings, the compressive strength, modulus of elasticity andsplit tensile strengthof concrete containing CWP as a replacement for cement decrease linearly with percentage increase inCWP.

Hydrothermal modification of ceramic waste: Characterization, optical properties and low-cost adsorbent agent for removal organic dyes

Hydrothermal modification of ceramic waste: Characterization, optical properties and low-cost adsorbent agent for removal organic dyes

Sustainable environment approach by the usage of ceramic pottery waste in geopolymer mortar

Sustainable environment approach by the usage of ceramic pottery waste in geopolymer mortar

Data-driven based estimation of waste-derived ceramic concrete from experimental results with its environmental assessment

The significant requirement for natural resources, specifically as ingredients of cement, is accelerating due to the considerable growth of the construction sector. Further, cement production adversely affects climate change due to the generation of bulk CO2 emissions. At the same time, a significant quantum of ceramic waste is generated either in the ceramic production process or due to the demolition of ceramic products each year. The unavailability of an adequate way to dispose of this ceramic waste negatively impacts the environment and landfills. Numerous researchers have explored the potential of utilizing this ceramic waste powder as a partial cement replacement to reduce the allied issues. Hence, in the current study, the supervised machine learning (ML) algorithms, i.e., Decision Tree (DT), AdaBoost (AdB), Bagging (Bg), Random Forest (RF), Gradient Boosting (GB) and XGBoost (XGB) are employed for predicting the Compressive Strength (CS) of ceramic waste powder concrete (CWPC). The performance of models is also assessed by using the coefficient of determination (R2), Mean Absolute Error (MAE), Root Mean Square Error (RMSE), and Nash Sutcliffe efficiency (NSE). The k-fold cross-validation technique is applied afterwards to validate the model's performance. For predicting the CS of CWPC, the RF algorithm is the most effective among the employed algorithms, with a higher R2 value of 0.97 and significantly lesser RMSE and MAE values of 1.40 and 1.13, respectively. SHAP analysis shows that the curing days feature has the highest influence on the CS of CWPC. As per quantitative Environmental Impact Assessment (EIA), the concrete with 10% CWP content can have 6.78%, 8.68%, 7.18%, and 7.19% reduced impacts on natural resources, climate change, ecosystem quality, and human health, respectively. Moreover, the effects on non-renewable energy resources, depletion of the ozone layer, and global warming can also primarily be reduced by a maximum of 7%, 6%, and 9%, respectively. The application of ML techniques for estimating the CS of CWPC would benefit the field of civil engineering in terms of conserving resources, effort, and time.

Combined Effect of Ceramic Waste Powder Additives and PVA on the Structure and Properties of Geopolymer Concrete Used for Finishing Facades of Buildings.

Currently, there is great interest in geopolymer composites as an alternative and environmentally friendly basis for compositions for restoring the facades of historical and modern buildings. Although the use of these compounds is much smaller than conventional concrete, replacing their main components with ecological geopolymer counterparts still has the potential to significantly reduce the carbon footprint and reduce the amount of greenhouse gas emitted into the atmosphere. The study aimed to obtain geopolymer concrete with improved physical, mechanical, and adhesive characteristics, designed to restore the finishing of building facades. Regulatory methods, chemical analysis, and scanning electron microscopy were applied. The most optimal dosages of additives of ceramic waste powder (PCW) and polyvinyl acetate (PVA) have been established, at which geopolymer concretes have the best characteristics: 20% PCW introduced into the geopolymer instead of a part of metakaolin, and 6% PVA. The combined use of PCW and PVA additives in optimal dosages provides the maximum increase in strength and physical characteristics. Compressive strength increased by up to 18%, bending strength increased by up to 17%, water absorption of geopolymer concretes decreased by up to 54%, and adhesion increased by up to 9%. The adhesion of the modified geopolymer composite is slightly better with a concrete base than with a ceramic one (up to 5%). Geopolymer concretes modified with PCW and PVA additives have a denser structure with fewer pores and microcracks. The developed compositions are applicable for the restoration of facades of buildings and structures.