Development of ceramic floor tile compositions based on quartzite and granite sludges

In the present work, industrial sludges derived from cutting and polishing natural stones (granite and quartzite) were characterised in terms of particles size distribution, chemical and mineralogical composition, and thermal behaviour and their potential to be incorporated as main components in red-clay-based stoneware tiles was evaluated. High levels (60–70 wt.%) of incorporation were attempted aiming at designing new formulations intended to be less expensive and possess better final properties (lower water absorption and higher flexural strength) in comparison to an industrial reference body used in the production of rustic tiles by extrusion, characterised 8–9% water absorption and a flexural strength of 17–18 MPa. Extruded rods of different formulations were produced and fired at 1100 °C, 1125 °C, 1150 °C and 1200 °C. The experimental results showed that all the new formulations performed better with the most significant improvements being obtained with incorporation of granite sludge. Flexural strength values more than triplicate and water absorption decreased by more than one order of magnitude in comparison to the reference paste. The new products fulfil the requirements of the ISO 13006 standard, group BIa (porcelain tiles).