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UTILIZATION OF STONE SLURRY POWDER IN PRODUCTION OF ARTIFICIAL

STONES

Article  in  Research Journal of Applied Sciences, Engineering and Technology · July 2014

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Rjeas Research Journal in Engineering and Applied Sciences 3(4) 245-249 Rjeas
© Emerging Academy Resources (2014) (ISSN: 2276-8467)
www.emergingresource.org

UTILIZATION OF STONE SLURRY POWDER IN PRODUCTION OF ARTIFICIAL

STONES

Nabil Al-Joulani
Palestine Polytechnic University
College of Engineering and Technology, Hebron – West Bank – P.O. Box 198
________________________________________________________________________________
ABSTRACT
In Palestine, quarrying and stone cutting industry generates a huge amount of stone slurry waste. The stone slurry waste
is usually disposed indiscriminately in open areas and sewage network causing several health and environmental
problems. This study aims to investigate the potential utilization of stone slurry powder in artificial stone production.
This utilization will help toward environmental protection, sustainable stone industry by reducing natural stone
exploitation, and will create new jobs. This study comes in line with many proposals currently under consideration for
utilization of stone slurry waste as construction materials in Palestine. Result indicated that the slurry waste powder
generated from stone cutting industry could be used in producing artificial stones with reasonable compressive strength
and absorption compared to natural stones. The tests results indicated that the compressive strength increased with
cement ratio, level of compaction pressure and curing time. The natural absorption increased at low compaction
pressure and cement ratio.
© Emerging Academy Resources

KEYWORDS: Environmental Protection, Recycling; Stone Industry; Construction Materials

INTRODUCTION OBJECTIVES AND IMPORTANCE

In accordance with conservation efforts, this research The subject matter of this paper is the production of
focuses on prevention of environmental pollution and artificial stones from stone slurry waste powder generated
considers the utilization of by product solid waste by stone cutting and processing. This experimental study
materials as construction materials. Huge volumes of expects to be contributing toward environmental
stone slurry waste from stone industry in Palestine are protection by utilization of stone slurry powder as
generated and dumped at the facilities surroundings of construction materials, maintain sustainable stone
most factories of stone cutting. industry in Palestine by reducing exploitation of the
natural stones from quarries and will generate new jobs
A recent study by the Union of Stone and Marble [USM, for artificial stone production.
2004]- about the stone cutting industry, states that there
are more than 247 quarries and 470 stone cutting LITERATURE REVIEW
facilities. These facilities utilize approximately 0.5 Several studies and reports have documented the potential
Million m3 of fresh water per year and generate nearly use of stone slurry waste as construction materials are
700,000 - 1000,000 tons of slurry waste. Almeida et al. shown in table1.
(2007) has reported that the global stone industry is
responsible for generating about 1 ton of stone slurry per Table 1: Usage of stone slurry waste in different
2.5 ton of final product. Stone slurry waste contains applications
heavy metals and suspension solids that vary within the Usage of Stone Main Conclusion Reference
range of 5000 to 12000 mg/l which mainly consist of Slurry
Reusing of stone Successful incorporation of Shirazi
Calcium Carbonate (CaCO3). waste in various stone slurry waste in cement, Elham,
industrial activities tiles, Mortars; concrete and 2011
The amount of waste accumulating at quarries, stone self-compact concrete (SCC),
cutting plants and open areas, is a pressing problem Production of The results indicated that the Souza et al,
vitrified floor tile gneiss rock waste could be (2010)
facing the stone industry in Palestine. In addition to products used for vitrified floor tile
depleting mineral resources, it causes serious production.
environmental impact to water, air, soil, the landscape, Concrete The use of stone sludge as Alzboon &
biodiversity and human communities. In general, the Production water source in concrete Mahasneh ,
production has insignificant (2009)
main issues associated with quarrying and stone effect on compression
production are: high impact on air quality, ground water strength, and sharp effect on
and surface water; increase in pH-value and impact of the slump
flora, fauna and soil; consumption of large amounts of In clinker, soil The authors reviewed Mirsa et al,
fresh water; slurry waste disposal reduces the area of stabilization, bricks, different articles about using (2008)
tiles, mortars and stone slurry powder as
fertile land; heavy metals in stone slurry are not soluble self compacting construction materials.
in water; fine suspended solids cause respiration concrete (SCC).
problems

245
 Research Journal in Engineering and Applied Sciences 3(4) 245-249
Utilization Of Stone Slurry Powder In Production Of Artificial Stones

Production of high The performance of hardened Almeida et Portland cement with some additives to improve its
performance concrete improved by 16%, al, (2007) properties.
concrete and the behavior of fresh
concrete enhanced.
Production of The stone slurry powder was Nabil Al- The compressive strength at 28 days aging is 65 N/mm2
different used in production of PVC Joulani and its hardness upon drying is 7 on moh’s scale.
construction Pipes, tiles, blocks, pottery (2007) The stone slurry waste taken from stone cutting plant was
materials by using and other applications.
stone slurry powder dried, grounded to fine particles and then incorporated in
Stone slurry powder Results showed that, the Felekoglu the batch formulations of artificial stones.
was used to limestone powder in Burak,
enhance viscosity of producing normal-strength of (2007) The Moulds
self-compacting self-compacting concrete
concrete (SCC)
The moulds used for specimen preparation were designed
Applications in To effectively utilize these Pappu et and fabricated to produce specimens with cross sectional
road construction, wastes as a raw material, al., (2007) area of 64 cm2 and height of 8 cm. The specimen’s height
concrete, asphalt filler, binder and additive in will vary from 5 to 8 cm depending on compaction
aggregates, cement developing alternative
and polymer building material..
pressure. Figure 1 show the steel mould used to fabricate
composites the artificial stone specimens.
Production of Compressive strength and Binici et al.
concrete. Sulphate resistance of (2007)
concrete increased with
increasing percentage of
marble dusts replacement
with fine sand aggregates.
Incorporation of Results showed that the Silva et al.
marble and granite granite and marble sludge (2006)
sludge in clay can be added to the clay
material material with no detrimental
effect on the properties of the
sintered red-clay products.
Production of CSLM was made with Katz and
controlled low significant amounts of stone Kovler
strength materials powder (25-50%), with some (2004)
(CLSM) cementing or pozzolanic
potentials as do fly ash and
cement kiln dust. Figure 1: Steel mould parts
Utilizing of granite The produced porcelain tiles Torres et al,
cutting sludge in have superior properties in (2004) Specimens Preparation
industrial porcelain terms of water absorption
tile formulations. and bending strength. Different percentages of cements to stone powder were
used in the production of artificial stones. The stone
EXPERIMENTAL WORK slurry powder and cement were mixed and homogenized
Materials and Specimens Preparation in the laboratory rod mill. The mixture was humidified by
The study variables included three cementing materials, spraying an adequate amount of water. An adequate
three cement ratios, three levels of compaction and three compression force was applied in order to achieve the
curing times. Tests carried out on artificial stones predetermined values of compaction pressure using a
specimens included compressive strength, natural compression machine (ELE 90 KN). The fabricated
absorption and apparent density. specimens were removed from the mould by using an
extruder jack; the specimens were cured in a closed steel
The materials used for specimen preparation were stone storage cabinet in room temperature for 7, 14 and 28
slurry waste, Portland cement and two types of days.
commercial cement. The stone slurry waste was collected
from the discharge point of a stone cutting plant in Table 2: Chemical analysis of stone slurry
Hebron city in the West Bank, was oven dried, grinded, powder (Al-Juolani, 2007)
Properties Test Value (%)
and sieved on #80 sieves. The chemical analysis results
SiO2 1.21
and the engineering properties of stone slurry powder in CaCO3 50.15
Palestine are presented in table 2. , and table 3, MgO 3.12
respectively. AL2O3 2.12
Fe2O3 0.30
The second type of cement used in the study is the SO3 0.20
Loss on Ignition 42.90
Conbextra HF, which used in machine foundations and PH 6.8
can be used for repairing concrete cracks and
deterioration. This type is available as powder and mixed
with water to achieve the required strength. The
compressive and tensile strengths at aging of 28 days is
64 N/mm2 and 10 N/mm2 respectively. The third type of
cement used is the Nitroflor Quartztop, it is consist of

246
 Research Journal in Engineering and Applied Sciences 3(4) 245-249
Utilization Of Stone Slurry Powder In Production Of Artificial Stones

Table 3: Engineering properties of stone slurry powder Conbextra HF Cement

(Al-Joulani, 2007) Effect of Conbextra HFcement percent and compaction
Test Result pressure on compressive strength and absorption are shown
Natural Water 63% in table 5.
Content
Sieve analysis Cu = 1.37 , Cc= 3.19 , D10= 0.091,
parameters D30 =0.19, D60=0.29 Nitoflor Quartztop Cement
Liquid Limit, Strength Effect of Nitoflor Quartiztop cement percent and
23%, ϕ =35o, C= 0.08 kg/cm2
Parameters compaction pressure on compressive strength and
Shrinkage Limit, Linear, 5.7% , 26% absorption are shown in table 6.
Volumetric
The variation of compressive strengths with compaction
Plastic limit, Specific non-plastic , 2.46
gravity pressure for the three Portland cement ratios is shown in
(AASHTO, Unified
A-2-6(0), SM (Sandy Silt figure 3. The variation of Compressive strength with
system) Mixture) cement ratio for the three levels of compaction pressure is
shown in figure 4.
Specimens Testing The variation of compressive strength with cement ratios at
After curing, the specimens were tested by using a constant compaction pressure, for the three types of cement
compression testing machine; the load was applied used in this study is shown in figure 5.
gradually at 200 N/s until failure. The natural absorption
was measured after 28 days, by oven drying the stone Table 5: Effect of cement ratio & compaction pressure on
specimens and immersing them in water for 24 hours, the Compressive Strength & absorption after 28 days curing
natural absorption was computed as the difference in Cement Compaction Compressive Flexural Absorption
moisture content. Compressive strength, absorption and Percent Pressure Strength Strength (%)
(%) (MPa) (MPa) (MPa)
density were calculated as the average of 3 specimens.
15 4.00 1.80 0.26 0.11
8.00 2.00 0.33 0.11
EXPERIMENTAL RESULTS 12.0 2.15 0.38 0.10
Illustration of natural and artificial stone specimens is 20 4.00 1.93 0.29 0.11
shown in figure 2. The compressive strength after 28 days 8.00 2.25 0.42 0.10
curing is presented in the following paragraphs. 12.0 2.48 0.44 0.11
30 4.00 2.41 0.40 0.10
8.00 2.60 0.43 0.08
12.0 2.80 0.46 0.10

Table 6: Effect of cement ratio and compaction pressure

on compressive strength and absorption after 28 days
curing
Cement Compaction Compressive Flexural Absorption
Percent Pressure Strength Strength (%)
(%) (MPa) (MPa) (MPa)
15 4.00 1.30 0.21 0.11
8.00 1.70 0.23 0.09
12.0 2.50 0.40 0.10
20 4.00 1.90 0.28 0.09
Figure 2: Natural and artificial stone specimens 8.00 2.40 0.38 0.10
12.0 3.00 0.51 0.08
Portland Cement 30 4.00 2.30 0.34 0.11
8.00 2.74 0.40 0.10
Effect of Portland cement percent and compaction 12.0 3.35 0.54 0.09
pressure on compressive strength and absorption are
shown in table 4.

Table 4: Effect of cement ratio and compaction pressure

on compressive strength and absorption after 28 days
curing
Cement Compaction Compressive Flexural Absorption
Percent Pressure Strength Strength (%)
(%) (MPa) (MPa) (MPa)
15 4.00 1.62 0.22 0.10
8.00 2.20 0.36 0.11
12.0 3.27 0.62 0.11
20 4.00 2.86 0.41 0.10
8.00 3.47 0.67 0.11
12.0 5.00 0.84 0.09
30 4.00 3.67 0.68 0.11
8.00 5.31 0.92 0.11
12.0 6.12 1.11 0.08
Figure 3: Compressive strength versus compaction
pressure for the three Portland cement ratios

247
 Research Journal in Engineering and Applied Sciences 3(4) 245-249
Utilization Of Stone Slurry Powder In Production Of Artificial Stones
Figure 4: Compressive strength versus cement ratio for
the three compaction pressures
Figure 5: Comparison of compressive strength versus
cement ratio at constant compaction pressure (12 MPa)
Natural absorption of artificial stone specimens is
presented in tables 4, 5 and 6, for the three types of
cement used in this study. The average values of natural
absorption varied between 8% and 11%. The absorption
trend is decreased with increasing of compaction
pressure. The absorption values of artificial stones are
high compared to natural stones; because they are made
of 100% fine stone powder which has very high specific
area and, therefore, high potential for water absorption.
The amounts of cement and curing time of specimens are
critical factors which affect the natural absorption of
artificial stones. The variation of natural absorption with
compaction pressure for the three types of cements is
presented in figure 6.
Figure 6: Variation of natural absorption with compaction
pressure for artificial stones
248
DISCUSSION AND COMPARISON OF RESULTS
The artificial stones fabricated with 30 percent cement
exhibited higher strength after 28 days age for most
specimens regardless of compaction pressure. The
artificial stone specimens are characterized by rough
surfaces and high natural absorption ratio compared with
natural stones. The average apparent density varied
between 2.1 to 2.4 gm/cm3 and depends largely on
compaction pressure of the fabricated samples, the
difference between the highest and lowest values of unit
weight is 0.18 kg/cm3. Thus it can be confidently stated
that a consistent level of compaction is achieved for all
specimens of artificial stones.
The produced artificial stones are more suitable for
monuments and interior decoration. The utilization of
stone slurry powder “from stone slurry waste” will
contribute toward mitigation of the environmental
pollution caused by indiscriminately dumping of stone
slurry in open area and in sewerage systems.
CONCLUDING REMARKS
In this research, stone slurry waste generated from stone
cutting industry is utilized as raw materials for production
of artificial stone. Different percentages of Portland
cement and two commercial types cements were used at
specific percentages (0.15, 0.2 and 0.3) with the stone
slurry powder. Using static compaction pressures of 4, 8
and 12 MPa, the mixture of stone slurry powder and
cement was pressed after spraying adequate amounts of
water. The following results may be withdrawn from this
experimental study.
1- The compressive strength of the artificial stones is
largely affected by the cement to stone powder percent,
compaction pressure and curing time.
2- The maximum compressive strength was achieved
after 28 days at 30% Portland cement and compaction
pressure of 30 KN.
3- Absorption decreased by increasing cement percent
and increasing the compaction pressure
4- Absorption of artificial stones made with Portland
cement was less than the values obtained when
commercial cement was used.
5- The density of artificial stones varied between 2.1 and
2.4 gm/cm3.
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Almeida N., Branco F. and Santos J.R. (2007): Recycling
of Stone Slurry in Industrial Activities: Application to
Concrete Mixtures, Building and Environment, No. 42,
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Alzboon K.K. and Mahasneh K.N., (2009): Effect of
Using Stone Cutting Waste on the Compression Strength
and Slump Characteristics of Concrete, International
Journal of Environmental Science and Engineering 1:4,
pp 167-172.
Al-Joulani, Nabil (2007): Engineering Properties,
Industrial and Structural Applications of Stone Slurry
Waste, Jordan Journal of Applied Science, Vol. 9, No.1.
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Utilization Of Stone Slurry Powder In Production Of Artificial Stones

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