4.

0 gathering information related to the alternative material that describe their

properties, production, recycling process involved, application, advantages and
disadvantages.

4.1 Properties of Ceramic

Ceramics possess chemical, mechanical, physical, thermal, electrical, and magnetic properties
that distinguishthem from other materials, such as metal and plastics. Manufacturers
customize the properties of ceramicsby controlling the type and amount of the materials used
to make them.

4.1.1.1 Chemical Properties

Industrial ceramics are primarily oxides (compounds of oxygen), but some are carbides
(compounds of carbonand heavy metals), nitrides (compounds of nitrogen), borides
(compounds of boron) and silicides (compoundsof silicon). For example, aluminum oxide can
be the main ingredient of a ceramic – the important alumina ceramics contain 85 to 99 percent
aluminum oxide. Primary components, such as the oxides, can also be 33 chemically
combined to form complex compounds that are the main ingredient of a ceramic. Examples of
such complex compounds are barium titanate (BaTiO3) and zinc ferrite (ZnFe2O4). Another
material that may be regarded as a ceramic is the element carbon (in the form of diamond or
graphite). Ceramics are more resistant to corrosion than plastics and metals are. Ceramics
generally do not react with most liquids, gases, alkalies, and acids. Most ceramics have very
high melting points, and certain ceramics can be used up to temperatures approaching their
melting points. Ceramics also remain stable over long time periods.

4.1.1.2 Mechanical Properties

Ceramics are extremely strong, showing considerable stiffness under compression and
bending. Bend strength, the amount of pressure required to bend a material, is often used to
determine the strength of a ceramic. One of the strongest ceramics, zirconium dioxide, has a
bond strength similar to that of steel. Zirconias (ZrO2) retain their strength up to temperatures
of 900° C (1652° F), while silicon carbides and silicon nitrides retain their strength up to
temperatures of 1400° C (2552° F). These silicon materials are used in high-temperature
applications, such as to make parts for gas-turbine engines. Although ceramics are strong,
temperatureresistant, and resilient, these materials are brittle and may break when dropped or
when quickly heated and cooled.
4.1.1.3 Physical Properties

Most industrial ceramics are compounds of oxygen, carbon, or nitrogen with lighter metals or
semimetals. Thus, ceramics are less dense than most metals. As a result, a light ceramic part
may be just as strong as a heavier metal part. Ceramics are also extremely hard, resisting wear
and abrasion. The hardest known substance is diamond, followed by boron nitride in cubic-
crystal form. Aluminum oxide and silicon carbide are also extremely hard materials and are
often used to cut, grind, sand, and polish metals and other hard materials.

4.1.1.4 Thermal Properties

Most ceramics have high melting points and as result at high temperatures, these materials
resist deformation and retain strength under pressure. Silicon carbide and silicon nitride, for
example, withstand temperature changes better than most metals do. Large and sudden
changes in temperature, however, can weaken ceramics. Materials that undergo less
expansion or contraction per degree of temperature change can withstand sudden changes in
temperature better than materials that undergo greater deformation. Silicon carbide and silicon
nitride expand and contract less during temperature changes than most other ceramics do.
These materials are therefore often used to make parts, such as turbine rotors used in jet
engines that can withstand at extreme variations in temperature.

4.1.1.5 Electrical Properties

Certain ceramics conduct electricity. Chromium dioxide, for example, conducts electricity as
well as most metals do. Other ceramics, such as silicon carbide, do not conduct electricity as
well, but may still act as semiconductors. Other types of ceramics, such as aluminum oxide,
do not conduct electricity at all. These 34 ceramics are used as insulators—devices used to
separate elements in an electrical circuit to keep the current on the desired pathway. Certain
ceramics, such as porcelain, act as insulators at lower temperatures but conduct electricity at
higher temperatures.
4.1.1.6 Magnetic Properties

Ceramics containing iron oxide (Fe2O3) can have magnetic properties similar to those of iron,
nickel, and cobalt magnets. These iron oxide-based ceramics are called ferrites. Other
magnetic ceramics include oxides of nickel, manganese, and barium. Ceramic magnets, used
in electric motors and electronic circuits, can be manufactured with high resistance to
demagnetization. In ceramic magnets, when tiny &strong magnetic dipoles (formed due to
circulation of electrons about nucleous) become highly aligned, they create a powerful
magnetic field which is more difficult to disrupt (demagnetize) by breaking the alignment of
these dipoles.

Figure 4.1: Ceramic Powder Figure 4.2: Ceramic Waste

4.1.2 Properties of Ceramic Waste

Ceramic waste is one of the most active research areas that encompass a number of disciplines
including civil engineering andconstruction materials. Ceramic waste powder is settled by
sedimentation and then dumped away which results in environmental pollution, in addition to
forming dust in summer and threatening both agriculture and public health. Therefore,
utilization of the ceramic waste powder in various industrial sectors especially the
construction, agriculture, glass and paper industries would help to protect the environment. It
is most essential to develop eco-friendly concrete from ceramic waste. In this research study
the (OPC) cement has been replaced by ceramic waste powder accordingly in the range of
0%, 10%, 20%, 30% 40%, & 50% by weight of M-20 grade concrete. Concrete mixtures were
produced, tested and compared in terms of compressive strength to the conventional concrete.

These tests were carried out to evaluate the mechanical properties for 7, 14 and 28 days. As a
result, the compressive strength achieved up to 30% replacing cement with ceramic
waste.This research work is concerned with the experimental investigation on strength of
concrete and optimum percentage of the partial replacement by replacing cement via 0%,
10%, 20%, 30%, 40% and 50% of ceramic waste. Keeping all this view, the aim of the
investigation is to study the behavior of concrete while replacing theceramic waste with
different proportions in concrete.
4.2 Production and Recycling Process

The used tableware that is collected is reproduced after undergoing the processes needed to
change it into raw materials as shown in Figure 1. Mino ware has set the standard for the ratio
of combination of recycled materials at 20% because a higher combination ratio causes the
lowthermal expansion of the green body and it ruins the compatibility of the green body and
the glaze and decreases product strength. This standard also allows the use of existing
manufacturing facilities and technologies, enables all manufacturers to enter into the recycling
system and facilitates the expansion of recycling activities. The 20% of recycled materials
combination may be an initial step in the ceramic ware recycling. Studies of the plasticity of
recycled green body and the glaze that conforms to the green body (low-thermal expansion
glaze) will be essential to reaching a high combination ratio. Further collaboration with
engineers is required.

The physicality, safety and environmental burden of recycled tableware with a 20%
combination ratio are described in the following section (Hasegawa et al. 2000).

Table 4.1: The properties of recycled and conventional tableware

4.2.1 Physicality and Safety

The physicality of recycled tableware is evaluated by measurements of water absorption ratio,

specific gravity and bending strength (Table 1). In the results, water absorption ratio was a
little higher than existing porcelain tableware, but specific gravity and bending strength were
almost equivalent. It can be used without causing any problem in people’s lives. Safety was
evaluated by means of a quenching experiment with a temperature difference by 150 degrees
Celsius and a lead and cadmium elusion test using green body without glaze, into which 50%
of crushed tableware with overglaze decoration was combined. where crushed tableware that
had been painted and decorated was combined at 50%. In the results of both the quenching
experiment and elusion test, there were no anomalies and there was no problem with safety
when used as tableware.
4.2.2 Quantitative Research on the Environmental Burden

The environmental burden was evaluated by converting energy consumption into CO2
emission volume. The LCA method was used for the clay preparation and tableware
manufacturing processes of recycled tableware and existing porcelain tableware each. The
results are shown in Table 2. CO2 emission volumes per 1 ton of each product in both
processes are almost the same. Consequently, we found that it was possible to recycle
tableware without increasing theenvironmental burden.

Table 4.2: CO2 emission of recycled and conventional tableware in processes [kgC/t]

4.2.3 Reinforced Porcelain Tableware Recycling

In addition to the aforementioned recycling of general porcelain tableware, there is the

recycling of the reinforced porcelain tableware that is used in school food services. The
recycling method is technically the same as general porcelain tableware. However, reinforced
tableware is manufactured by incorporating approximately 30% of more expensive aluminum
in order to increase product strength. In the recycling of reinforced porcelain tableware, used
reinforced porcelain tableware is collected to use the aluminum that it contains in order to
reduce the volume of aluminum consumption. The advantage is to offset purchase costs,
transport costs and crushing costs by collecting used reinforced porcelain tableware as a
valuable resource to avoid the cost of using new aluminum. It can also reduce the CO2
emission volume by approximately 3% by reducing the amount of high LAC aluminum
consumption (in the case of combining recycled materials at 20%).
4.3 Application

Supplementary cementing material such as fine-ground ceramics has found the application in
concrete production couple of decades ago because of their potential to replace a part of
Portland cement in concrete. Fine-ground ceramics belongs to waste materials. Therefore,
these materials or their combinations can beconsidered as environmental friendly cement
substitutes.

Waste ceramic materials may become a cheaper but almost equivalent alternative to
metakaolin orground granulated blast furnace slag, fly ash and other materials as
supplementary binder in concrete. Theceramic industry often produces calcined clays that
result from burning illite-group clays which arecommonly used in the production of red-clay
ceramic products. A portion of these products (which amountsup to 2% depending on
producer and country) is discarded as scrap, thus constitutes industrial waste. Theresidues of
ceramic bricks and floor and roof tiles ground to a suitable fineness can though become
activepozzolans [1-3]. So, they have a potential to be used in mortar and concrete.

The measurements of properties of materials containing supplementary cementing materials

are similarlyas with many other cement based composites mostly concentrated on mechanical
properties. This may notalways be sufficient because superior mechanical properties are often
not accompanied by comparably good resistance against water or salt penetration.

This paper presents an extensive set of parameters of concrete containing different amounts of
wasteceramics as active pozzolana replacing a part of Portland cement, including basic
material characteristics, mechanical characteristics, hygric and thermal properties. The results
are also compared with those obtained for reference concrete containing only Portland cement
as binder.
4.4 Advantages and Disadvantages
Advantages
 Ceramic waste can be used as a
replacement material for producing
aggregate.
 Ceramic waste can save the cost of
producing aggregate.
 To avoid contamination as a result of
the removal of the ceramic waste.
 Use of ceramic waste can contribute
in a green program that is being
conducted by the government.
 Use of ceramic waste for making
aggregate more tidy than using coarse
aggregate and fine aggregate.
 Ceramic waste also can be used as
decoration.
Table 4.3: Advantages and Disadvantages
Disadvantages
 Less compressive strength.
 When we test by using slump test, the
result is collapse.
 Unsuitable for large construction such
as bridge.
 Using ceramic waste as an aggregate
are not stable than using common
aggregate.
 Difficult to process the material
because hard to find the ceramic
material.