- This study valorizes granite sawing waste and kaolin through production of durable ceramics tiles. FactSage (8.4) thermochemical software was integrated with petrography, XRD, XRF, DTA-TGA, SEM-EDX, physico-mechanical, hot-stage microscopy, dilatometry, chemical durability tests and Raman spectroscopy to investigate the green materials and ceramics sintered at 900-1250 °C/h. Results show that Al/Si, Ca/Si, and Ca/Al ratios and impurities levels control feldspar crystallization, glassy phase formation, and the development of silicate melt with variable viscosities. The optimum composition (40 wt% granite waste at 1200 °C/h) has a compact, interlocked microstructure with ∼47 wt% melt and suitable viscosity (2.41 × 105 PaS), yielding negligible water absorption (0.19%), low porosity (0.46%), high flexural strength (52 MPa), controlled thermal expansion (5.42 × 10−6 C−1), and excellent acidic/alkali durability (0.48, 0.06 wt%) as well as acceptable geometric stability. However, 50 wt% granite waste involvement caused deformation at 1200This study valorizes granite sawing waste and kaolin through production of durable ceramics tiles. FactSage (8.4) thermochemical software was integrated with petrography, XRD, XRF, DTA-TGA, SEM-EDX, physico-mechanical, hot-stage microscopy, dilatometry, chemical durability tests and Raman spectroscopy to investigate the green materials and ceramics sintered at 900-1250 °C/h. Results show that Al/Si, Ca/Si, and Ca/Al ratios and impurities levels control feldspar crystallization, glassy phase formation, and the development of silicate melt with variable viscosities. The optimum composition (40 wt% granite waste at 1200 °C/h) has a compact, interlocked microstructure with ∼47 wt% melt and suitable viscosity (2.41 × 105 PaS), yielding negligible water absorption (0.19%), low porosity (0.46%), high flexural strength (52 MPa), controlled thermal expansion (5.42 × 10−6 C−1), and excellent acidic/alkali durability (0.48, 0.06 wt%) as well as acceptable geometric stability. However, 50 wt% granite waste involvement caused deformation at 1200 °C, and bloating occurring at 1250 °C. Ceramic tiles at 1200 °C are promising for heavy-duty industrial flooring applications.…
