Performance evaluation of green mortar comprising ceramic waste as cement and fine aggregates replacement

Abstract

Amongst the potential solutions to a cleaner environment is to minimize the solid waste generation. The application of solid wastes in sustainable construction has attracted much attention due to the potential properties and low cost. In this study, the potential use of waste ceramic as cement and a fine aggregate replacement was investigated. Two mortar mixes were made: one as control with OPC and natural sand, while in the other mix the OPC was replaced by ceramic powder by 40% and fine aggregates were replaced by fine ceramic particles by 100%. Microstructural analyses then assessed the effect of waste ceramic on the performance of mortar. The results show that ceramic powder together with fine ceramic particles reduced the workability of mortar. It has been found that mortar mix containing waste ceramic obtained higher compressive and tensile strengths. The drying shrinkage of ceramic mortar was also found to be lower than that of OPC mortar. The effects of ceramic wastes on the performance of mortar were detected to be more considerable at ultimate ages owing to the pozzolanic nature of ceramic powder. The study revealed that the waste ceramic powder and finer particles are potential to be used in a sustainable mortar by improving the mechanical and microstructural properties.

Review of the Properties of Sustainable Cementitious Systems Incorporating Ceramic Waste

“…However, the levels of absorption and moisture diffusivity remained within acceptable limits up to a ceramic powder content of 20% [43]. In contrast, the ceramic mortar exhibited a lower water absorption rate compared to the OPC mortar (Figure 9), with a difference of approximately 37% [39].…”

“…Research indicates that the drying shrinkage level of OPC mortar mixtures with CWP is lower than that of OPC mortar without CWP [39], as shown in Figure 12. More ceramic fillers were used to reduce shrinkage, although the degree of reduction decreased over time [60].…”

“…The methods employed to evaluate the chloride resistance of the mortar mixtures included natural The use of CWP in mortar increased the mortar's splitting tensile strength compared to a mortar mixture without CWP. For example, for a curing period of 90 days, a mortar mixture containing 40% CWP exhibited a splitting tensile strength of 4.45 MPa, which was approximately 15% higher than that of the OPC mortar for the same curing time [39].…”

“…This is because it reduces energy consumption and CO 2 emissions associated with binder production. Additionally, it minimizes the depletion of landscapes used for the industrial production of binders and aggregates, which in turn reduces the carbon footprint associated with mining activities that typically cause damage to landscapes and riverbeds [39]. The energy influence of producing one kilogram of cement clinker is approximately 850 k/cal.…”

“…The addition of a mixed powder (CWP and cement) to produce mortar with a lower water content led to a reduction in the water-powder ratio and a significant decrease in the workability of the mortar mixture [35]. Moreover, the larger the substitution level of CWP, the more water was required to maintain the standard consistency of the mortar, as shown in Figure 7, resulting in lower workability [39]. The partial replacement of OPC with CWP generated from red clay ceramic production resulted in a marginal decrease in the consistency of the fresh mortar [61].…”