article · Buildings
This research assesses ceramic fine dust, an industrial waste from spray dryer cyclones used in ceramic tile production, as a partial replacement for cement in concrete. Chemical tests confirmed the dust qualifies as a pozzolanic material under ASTM standards. Concrete mixtures were prepared with cement replacement levels ranging from 0 to 30 percent by weight, maintaining a constant water-to-binder ratio of 0.45 across various curing periods. Test results revealed that compressive strength increased with replacements of up to 10 percent, while remaining within acceptable structural standards up to 30 percent. A 7 percent replacement yielded an 8 percent gain in flexural tensile strength and a 5 percent increase in splitting strength over standard concrete. While mix workability decreased, water absorption fell by 15 percent at a 10 percent substitution. Exposure to sulfuric acid reduced compressive strength, yet the material proved viable for manufacturing standard quality concrete.
Cement manufacturing contributes heavily to global carbon emissions. Repurposing industrial ceramic waste directly into concrete formulations helps lower the reliance on traditional cement. This approach simultaneously diverts fine industrial dust from landfills and produces concrete that meets standard structural benchmarks, offering a pathway toward more sustainable and cost-effective construction practices.
This research provides laboratory-tested formulation data that could be used by concrete producers, precast manufacturers, and ceramic tile makers seeking waste utilisation partnerships. Because the testing covers standard structural metrics such as compressive and tensile strength, the material is applied and tested in laboratory conditions, though operational testing in production environments is needed to confirm handling and workability adjustments.
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Researchers and engineers have been exploring alternative materials to partially substitute for cement in concrete to decrease carbon emissions and promote sustainability. Industrial pozzolanic waste is one such material that has gained attention as a potential substitute for cement. This research paper investigates the use of industrial pozzolanic waste materials, ceramic fine dust from the cyclones installed onto spray dryers in the process of manufacturing ceramic tiles, as a partial replacement for cement in concrete. Chemical analysis showed that ceramic dust could be used as pozzolana as ASTM C 618:2019. The study aims to evaluate the properties of fresh and hardened concrete; compressive strength; tensile splitting; and flexural strength of concrete mixtures. Additionally, specimens were subjected to durability performance: an acidic environment and water absorption tests. The cement was replaced in the concrete mix in proportions of 0, 5, 7, 10, 15, 20, and 30% by weight with a water-to-binder ratio of 0.45 at different curing periods. The results showed an increase in compressive strength of up to 10% replacement over time; fortunately, even with up to 30% replacement, it is still within the characteristic value of 30 MPa. The workability of the concrete decreases with replacement. The flexural tensile strength improved by 8% and the splitting strength by 5% with a replacement of 7% set against the control sample. The water absorption of concrete decreased by up to 10% replacement level, which was 15% less than that of the control mix. Concrete subjected to a 2% sulfuric acid solution (acid attack) revealed a loss in compressive strength when set against those not subjected to acid attacks. Based on the present research, ceramic dust as pozzolanic waste material can be used as a partial substitute for cement in the manufacture of good quality concrete under standard conditions.
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DOI: 10.3390/buildings13082067
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