Ceramic waste as a sustainable cementitious resource: pathways to cleaner and high-performance concrete
G. Murali, Najmeh Hassas, Hakim S. Abdelgader
Abstract
The growing demand for sustainable construction and the need to reduce the carbon footprint of cement production have led to the exploration of alternative cementitious materials, such as Ceramic Waste Powder (CWP). Derived from tile manufacturing, polishing, and demolition, CWP exhibits pozzolanic properties. However, existing research remains fragmented, with inconsistencies in optimal replacement ratios, early-age strength, and long-term durability, owing to variations in mineral composition, thermal processing, and particle fineness. This highlights the need for a comprehensive review to synthesize the current findings, identify performance trends, and clarify the physicochemical mechanisms influencing CWP’s behavior in concrete. This review article is organized into seven sections. The introduction outlines the rationale, objectives, and significance of using CWP in cementitious systems. The second section covers the physical, chemical, and microstructural properties of CWP. The third examines the fresh and mechanical performance of CWP-incorporated mortar and concrete, while the fourth evaluates durability aspects, such as permeability and fire resistance. The fifth section explores the microstructural changes in concrete with CWP, and the sixth discusses the economic and environmental benefits, highlighting sustainability and cost-effectiveness. From the detailed review, CWP shows significant pozzolanic activity at 5–10% replacement, enhancing calcium hydroxide consumption, calcium silicate hydrate formation, and improving strength, densification, and durability. However, replacements above 20–30% lead to increased inert silica, reduced reactivity, higher porosity, and decreased mechanical performance. Moderate CWP levels improved the mechanical strength and lowered the thermal conductivity, whereas higher levels caused strength loss, delayed setting, increased water absorption, and reduced thermal stability. Microstructural analyses confirmed active pozzolanic reactions at moderate levels and a shift to inert filler behavior at higher contents, negatively impacting hydration and durability.