Experimental investigation of sustainable concrete production using ceramic waste powder as partial fine aggregate replacement

This study investigates the feasibility of using ceramic waste powder as a partial replacement for fine aggregate in concrete, addressing the dual challenges of ceramic industrial waste management and sustainable development of construction materials. Ceramic waste was collected from three major industrial units (Ocean Ceramics, Ghani Ceramics, and Qiang Sheng Ceramics) at the Faisalabad Industrial Estate, Pakistan, which collectively generate approximately 1.06 million tons of ceramic waste annually. The waste was processed into a fine powder and characterized by X-ray Fluorescence (XRF), revealing a high silica content (approximately 71.4%) and significant alumina and sodium oxide phases. Concrete mixtures were prepared with ceramic powder replacement levels of 0% (control), 10%, 20%, 30%, 40%, and 50% by volume of fine aggregate. Results demonstrated that 30% replacement optimally enhanced compressive and flexural strength by 10.5% and 5.92%, respectively, compared to control concrete, while 20% replacement optimally improved tensile strength by 4.68%. XRD analysis confirmed that 30% replacement promoted beneficial pozzolanic reactions, reducing portlandite content and increasing calcium-silicate-hydrate (C-S-H) gel formation, thereby densifying the microstructure. However, workability decreased progressively with increasing ceramic content due to higher water absorption and particle angularity. Beyond 30% replacement, mechanical properties declined due to increased porosity and reduced cement hydration products. Cost analysis indicates that a 30% replacement reduces manufacturing costs by approximately 2.3% for 3 m3 of concrete incorporating ceramic waste. This study demonstrates that ceramic waste powder can be effectively used as a sustainable fine aggregate substitute in concrete up to 30%, offering both environmental benefits through waste reduction and economic advantages while maintaining or enhancing structural performance.