A group of international researchers have developed a new type of cement made from ceramic waste that could prove to be stronger than traditional cement while using less energy in the manufacturing process.
Photo Credit: RUVID Association

The results of a study published by a group from the Institute of Science and Concrete Technology at the Polytechnic University of Valencia (UPV-ICITECH), the Universitat Jaume I of Castellón, Imperial College London and the Universidade Estadual Paulista in Sao Paulo, Brazil, in the journal Construction and Building Materials could open new opportunities for hardscapers and the ceramic industry.

Researchers have worked with waste bricks, sanitary products like sinks and toilets, and porcelain tile as base materials so far. Ceramic waste is ground up and mixed with an activator solution – in this case sodium hydroxide, sodium silicate or rice husk ash – and water. The mix is poured into a mold and baked under high temperatures. Tests on a mixture made with red clay brick show it to be stronger than some common types of cement.

"This is a completely new material," UPV-ICITECH researcher Maria Victoria Borrachero said through a translator. "The main feature is that it contains Portland cement, making it a more sustainable material than currently employed. The cement is composed only of the ceramic residue, a chemical activator and water."

Researchers focused on the performance of the products with residues of bathroom ceramic or porcelain tiles, and are analyzing new activating substances in search of a more sustainable final product.

"We have already done tests with rice husk ash and the results are very positive. Its use would yield an even more sustainable and cheaper final product, because it would be composed almost entirely of reused waste," Barracho said.