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1 s2.0 S0950061822039125 Main PDF
1 s2.0 S0950061822039125 Main PDF
A R T I C L E I N F O A B S T R A C T
Keywords: The construction sector is constantly growing and, consequently, the increase in the use of building materials. In
Construction sector view of this, the red ceramic industry is responsible for a large amount of waste, through failures in its process
Building materials and thus generating defective parts. Therefore, this work aims to reuse these wastes generated by the red ceramic
Red ceramics
industry in mortars, as a partial substitute for natural sand. The ceramic waste was ground in a crusher mill-type
Ceramic waste
Mortar
crusher for one hour. Mortars were made, in the mix proportion 1:6 (cement: sand) in mass, replacing the sand
with ceramic waste in replacing of 10, 20 and 30% and the mixture reference (0%), using the ordinary portland
cement. The mortars were subjected to tests of workability, water retention, density, incorporated air content,
density in the hardened state, water absorption, flexural strength in bending and compressive strength. Soon
after, microstructural characterization techniques were performed in mixtures, such as isothermal calorimetry,
mercury intrusion porosimetry and X-ray diffraction. The results show that the mixture with 10% improved the
flexural strength in bending and compressive strength, indicating a lower coefficient of capillarity, as they have
fewer pores and a greater amorphous halo. The ceramic waste caused an increase in density in the fresh and
hardened state and a decrease in the content of incorporated air. In the mixtures with 20% and 30% of ceramic
waste, there was a loss in the properties, mainly in the strength. Therefore, the most satisfactory mixtures were
with 10% ceramic waste.
1. Introduction the atmosphere also grows, being responsible for up to 20 % of the total
emission of CO2 [5].
The population has gone through great challenges of how to This fact can be reflected in environmental concerns, where indus
correctly discard everything that it generates and reuse everything that trial production is high, with greater associated impacts, whether by
has no final destination. In the last years the world production of extraction of raw materials, atmospheric emissions or eventual genera
different types of ceramic tiles was around 13.7 billion m2 [1]. Typically, tion of waste [5,6].
about 30 % of the materials in the ceramic industry are wasted. In Brazil, In this way, the destination of waste is, therefore, one of the main
ceramics are responsible for 10 % of the production loss [2], which is problems that the world faces today, whether for economic, political or
often improperly deposited, generating some types of contamination, ecological reasons. In recent years, waste recycling has been encouraged
which can be transformed into raw material and solve many industrial as one of the most effective alternatives to reduce the impact of large-
problems [3,4]. scale extraction of raw materials and waste [7,8].
In recent years, due to the development of cities and easy real estate An alternative is the incorporation of waste in construction mate
investments, there has been a growth in demand for fence blocks rials, which has great potential to minimize environmental impacts,
(bricks). With the increase in civil construction, the emission of CO2 in reduce the amount of waste to be discarded, which most of the times
* Corresponding author.
E-mail address: marianagpc1@yahoo.com.br (M.G.P. Cherene).
https://doi.org/10.1016/j.conbuildmat.2022.130256
Received 23 August 2022; Received in revised form 6 December 2022; Accepted 27 December 2022
Available online 12 January 2023
0950-0618/© 2022 Elsevier Ltd. All rights reserved.
M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
Fig. 2. Ceramic waste process: (a) Ceramic waste (b) Milling (c) Post grinding.
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M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
Table 1
Proportions.
Elements SiO2 Al2O3 Fe2O3 K2O MgO CaO P2O5 SO3 Cl
Ceramic waste (%) 51,85 29,37 12,89 2,43 0,79 1,07 0,40 1,10 0,11
Cement (%) 15,75 4,42 4,760 0,97 1,07 67,62 0,39 4,88 0,14
Fig. 3. Result of XRD test of ceramic waste and cement, M (mica); Q (quartz); H (Hematite); F (Feldspar); G (Gypsum); A (C3S); B (C2S); C (C3A).
that the ceramic residue is mainly composed of silica (51.85 %) and their sum represents almost 80 %, also presenting other elements such as
alumina (29.37 %). It also has other elements such as iron oxide, po alumina, iron oxide, potassium oxide, magnesium oxide, silver oxide,
tassium oxide, magnesium oxide, calcium oxide, silver oxide, phos phosphorus pentoxide, sulfuric oxide and chloride [17,23,24].
phorus pentoxide, sulfuric oxide and chloride [3,12,17,21,22]. There is Fig. 3 shows the results found by X-ray Diffraction of ceramic waste
also a high percentage of iron oxide that gives the reddish color to the and cement. The X-ray Diffraction (XRD) was performed in a Proto
blocks that gave rise to the ceramic waste. The composition of Portland Manufacturing AXRD Powder Diffraction System diffraction meter
cement has silica and calcium oxide as the main components, where operating with a voltage of 30 kV, current of 20 mA and Cu-Kα radiation,
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M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
4
M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
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M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
mixture with the highest density was the CPV10 with 1.99 g/m3. It is be greater than 95 %, as there may be poor adhesion between the mortar
also possible to observe that the density decreased as the amount of and the substrate [44]. However, all mixtures are within the re
ceramic waste increased, since the specific mass of the waste (2.59 g/ quirements established by the references, it is a positive result, since
cm3) is smaller than that of the sand (2.64 g/cm3). Density reduction is a water retention is a property that is directly related to the ability of fresh
positive point as long as it does not affect the other properties [4,43]. mortar to maintain its workability when subjected to requests that cause
The amount of incorporated air decreased as the amount of ceramic loss of mixing water, either through evaporation or absorption of water
waste increased, as there are more pozzolanic reactions of finer parti [45]. It is also observed that the reference mixture has a higher value
cles, with nucleation occurring. This is also related to the fact that the than the CPV10 and CPV20 mixtures, indicating that mixtures with
residue has a filler effect, that is, it fills the voids between the grains. higher percentages of ceramic waste are more recommended. The
Observing the values found, the mixture with the highest content of CPV30 mix has better water retention with 94.50 %. A possible expla
incorporated air is the CPV00 with 10 % and the lowest content of nation for the improvement caused by mortars with ceramic waste is
incorporated air is the CPV30 mixture with 4.2 %. As the granulometry attributed to the fact that the ceramic waste comes from the burning of
of the waste at 1.73 µm in d10, 12.74 µm in d50 and 47.20 µm in d90, that clay and the clay presents surface activity due to the clay minerals that
is, fine particles, filled the existing voids, consequently reducing the compose it, which makes this material present electrical attraction to the
content of incorporated air, shown in Fig. 7, and as the waste consumed water particles [46,47].
a lot of water, there was a drop in density, as the specific mass of water is Fig. 9 shows the results of calorimetry through the released heat. It
lower than that of the ceramic waste, as shown in Fig. 6. can be seen that the main hydration of all mortar mixtures occurs in the
Fig. 8 shows the water retention results. It is possible to observe that first 15 h [48]. In stage I, where it occurs in the first minutes, it presents
there is an increase in water retention, as the amount of ceramic waste the first peak of the evolution of the heat of hydration, whose main re
increases. The water retention of mortars must not be lower than 75 %, action is the dissolution of tricalcium aluminate (C3A) and calcium
as it can impair the mortar’s strength [21]. However, retention cannot sulfate (CaSO4), forming ettringite. The CPV30 mixture has a higher
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M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
release. This is due to the filer effect resulting from the low granulometry
of the ceramic waste, responsible for providing nucleation points [49].
In stage II, during the dormancy period, the mixtures present very close
values of released heat, which shows that the ceramic waste did not
affect the induction period. In stage III, where the second exothermic
peak occurs, the CPV10 mixture had a large peak at 7.5 h, while the
CPV20 had a large peak between 5.5 and 6 h, thus presenting greater
heat released. In this phase, tricalcium silicate (C3S) and dicalcium sil
icate (C2S) react with water and rapidly form amorphous hydrated
calcium silicate (C–S–H) and calcium hydroxide (Ca(OH)2) [50]. After
this step, the mixtures entered the final stage of hydration, with low
reactivity, but with gain in strength.
Fig. 10 shows the accumulated heat, the CPV20 and CPV00 mixtures
have more accumulated heat, with 380 and 350 J/g, respectively. As the
Fig. 10. Calorimetry results. amount of ceramic waste increased, there was a decrease in the accu
mulated heat. This can also be explained by the consistency index test,
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M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
[52]. In the study by Gayarre et al. (2017), found a range of 1.5 MPa to
2.5 MPa for flexural strength and a range of 5.5 MPa to 8.5 MPa for
compressive strength. Mohit and Sharifi (2021) was in the range of 2.86
MPa to 3.84 MPa for flexural strength and the best strength was with the
use of 10 % of the waste, a result that corroborates with what was found
in this research.
Fig. 14 presents the results of the capillarity coefficient, indicating
that the mixture with the highest capillarity coefficient is the reference
mixture (CPV00), with 9.33 g/dm2.min1/2, results also found by For
migoni et al. (2019). As the amount of ceramic waste increased, so did
the capillarity coefficient. The increase in the coefficient may be asso
ciated with the linear increase in the fine material (ceramic waste), as its
density is lower than the fine aggregate. The fact that the reference
mixtures have higher capillarity coefficients may be associated with the
fact that these mixtures have larger capillary pores and, consequently,
the water can infiltrate more easily and, thus, absorb a greater amount of
water.
Fig. 14. Capillarity coefficient results.
Fig. 15 presents the results of Mercury intrusion (a), Cumulative pore
volume (b) and Pore volume fractions (c). Through Fig. 15 (a) it is
where the mixtures with the highest amount of ceramic waste had the
possible to notice that the mixtures presented pores in the range of 0.1 to
highest water consumption, the highest amount of water or the increase
40.0 µm. The mixtures CPV10, CPV20 and CVP30 had higher mercury
in water contente amount of ceramic waste may be causing the reduc
intrusion in the smaller pore diameters, while the reference mixture
tion of heat release. It is also possible to notice the exothermic peaks,
(CPV00) had higher mercury intrusion in the pore diameters between 1
indicating that nucleation of the finest particles occurs, converging with
and 10 µm. The CPV20 and CVP30 mixtures had greater mercury
the 11 % clay fraction of the ceramic waste.
intrusion than the CPV10 mixture in pore diameters between 1 and 10
Fig. 11 shows the results found for the bulk density in the hardened
µm. In the pore diameter range between 10 and 100 µm, the mixtures do
state. The mixture with the highest density value is CPV10, with 1.86 g/
not show significant differences. The CPV10 mixture had its highest
m3. The mixture with the lowest density is CPV30, with 1.64 g/m3.
peak in mercury intrusion at 1 µm at 0.12 mL/g. The reference mixture
Values that corroborate with those obtained by Cabrera-Covarrubias et
has larger average pores than the mixtures containing ceramic residue,
al. (2016) e Gayarre et al. (2017). One explanation for the reduction in
that is, the reference mixture is more porous and the CPV20 and CPV30
the values of this test is the density of recycled aggregates being lower
mixtures are more porous in relation to the CPV10 mixture. This can be
than that of natural sand. However, this is not a property that limits the
explained by the fact that the ceramic residue is filling the mortar. The
use of recycled aggregates in the manufacture of mortars [41,42].
decrease in porosity with the increase in the amount of ceramic waste
Fig. 12 presents the flexural strength in bending results, while Fig. 13
may also be associated with the firing temperature of the blocks, as the
presents the compressive strength results. The highest strengths were
high temperature leads to a decrease in porosity [53]. When comparing
with 10 % of the ceramic waste, reaching 3.24 MPa of flexural strength
with the results of water absorption by capillarity and water absorption
and 11.22 MPa of compressive strength, with higher percentages of
by immersion and void index, where the mixtures with waste use had
waste there was a decrease in strength. In general, the behavior of the
higher absorptions, it can be explained, because higher percentages of
loss of flexural and compressive strength related to the increase of the
small pores increase absorption [10]. In the study by Torres et al. (2020),
ceramic waste may be caused by the physical characteristics of the
the reference mortar had a greater volume of pores, staying in a size
ceramic waste, such as lower densities than sand and higher absorptions
range of approximately 10 to 80 µm, while the mortars with ceramic
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M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
Fig. 15. (a) Mercury intrusion; (b) Cumulative pore volume; (c) Pore volume fractions.
Fig. 14 (c) shows a refinement in the pore size for the CPV10 mixture,
containing pore sizes between 0.1 and 50 µm of 0.65 cm3/g, a smaller
value between the mixtures, being more efficient in reducing pore vol
ume, converging the results of Figs. 12, 13 and 14. This was already
expected to occur because the nucleation of finer particles in the CPV10
mortar was observed in Fig. 9 in the fresh state by calorimetry and, also
in Fig. 15, with the presence of the amorphous halo referring to the
formation of C–S–H and the disappearance of portlandite peaks,
making the CPV10 mortar denser and more resistant.
Fig. 16 shows the presence of ettringite, portlandite, quartz and
calcite [55–58]. The calcite phase, coming from the limestone filler that
composes the anhydrous OPC and the carbonation of the sample, can be
justified by the presence of OPC as a component of the formulation [23].
The amorphous halo in the diffractogram between 18◦ and 29◦ 2θ,
which does not have a well-defined crystal structure, that is, it has
characteristic peaks together with a baseline bump in the aforemen
tioned region. The ceramic residue consumed portlandite and generated
more calcite formation, the amorphous halo comparing the CPV10
mixture with the reference one (CPV00) has fewer peaks, converging
with the flexural and compression strengths, in which the mortar with
Fig. 16. XRD results. Caption: A/CPV (cement + water), CPV00 (sand +
cement + water), CPV10 (ceramic waste + cement + water), CPV20 (ceramic the highest strengths had 10 % of ceramic residue, the highest density in
waste + cement + water), CPV30 (ceramic waste + cement + water), E the fresh and hardened state, calorimetry, by porosimetry that proved
(ettringite), P (portlandite), Q (quartz), C (calcite). that it has fewer pores. On the other hand, the CPV20 and CPV30 traits
had the presence of ettringite, interfering with the decrease in
residue had a greater volume of pores in intervals of smaller diameters, resistance.
between 0.7 and 3 µm. 0.0 µm. This same trend also occurred in the
study by Grilo et al. (2014), where the reference mortar had a greater 4. Conclusions
volume of pores in the range of 0.5 to 10 µm. This same trend occurred in
Fig. 14, but with larger pore diameters. In Fig. 14 (b) The mixture CPV10 Based on the results obtained, it is possible to conclude that:
showed a lower cumulative volume of mercury intrusion of 0.11 mL/g in
pores from 0.1 to 40 µm, suggesting less pores and greater densification - The use of ceramic waste promotes an increase in water consumption
of this trace, converging with the result of Fig. 11. The other traces in the mortar and an increase in workability. The mixtures with 20 %
showed cumulative intrusion volume between 0.12 mL/g to 0.14 mL/g. and 30 % of ceramic waste showed a decrease in density both in the
fresh state and in the hardened state, proving that the specific mass of
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M.G.P. Cherene et al. Construction and Building Materials 367 (2023) 130256
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Declaration of Competing Interest [27] M.S. Morsy, H. Shoukrya, M.M. Mokhtara, A.M. Ali, S.A. El-Khodary, Facile
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interests or personal relationships that could have appeared to influence [28] S.K.B.M. Silva, C.J. Araújo, A.G.B. Lima, Numerical analysis of the dimensional
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[29] ABNT NBR 7181:1984- Determination of Granulometric Analysis of Soils; Brazilian
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[30] P.I. Moreira, J.O. Dias, G.C. Xavier, C.M. Vieira, J. Alexandre, S.N. Monteiro, R.
No data was used for the research described in the article.
P. Ribeiro, A.R.G. Azevedo, Ornamental Stone Processing Waste Incorporated in
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