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<p>The growing demand for sustainable construction materials has spurred interest in the use of industrial waste in ceramic production. This study examines ceramic tiles fabricated from iron-rust-contaminated soil, focusing on their microstructural, mechanical, and aesthetic properties. The material referred to as iron-rust-contaminated soil in this study is an industrial waste-like soil generated during steel recycling processes, rather than a natural soil affected by environmental contamination. It was repurposed as a secondary raw material in the production of ceramic tiles. Chemical characterization revealed hematite (Fe<sub>2</sub>O<sub>3</sub>) as the dominant oxide (72.04–78.85 wt%), which imparts the reddish-brown coloration to both raw soil and fired tiles. Various mixing ratios of iron-rich soil with conventional raw materials were evaluated to optimize performance at high-temperature firing (up to 1100&#xa0;°C). The highest shrinkage (8.97%) was observed in the P 60 formulation at 1100&#xa0;°C, indicating significant densification. SEM analysis revealed rust particles adhering to soil grains, influencing sintering behavior and microstructural evolution. Mechanical testing showed that increasing iron-rust content reduced flexural strength due to increased porosity, whereas higher firing temperatures improved densification and mechanical properties. The maximum flexural strength recorded was 77.07&#xa0;kg/cm<sup>2</sup> for the P 80 sample fired at 1100 ° C. Water absorption values exceeded 10%, with a modulus of rupture below 7&#xa0;kg/cm<sup>2</sup>, conforming to the TIS 2508–2555 standards. The integration of iron-rust-contaminated soil into ceramic tile manufacturing resulted in a 38.3% reduction in greenhouse gas emissions, demonstrating improved environmental performance. This strategy promotes circular-economy products by valorizing industrial waste into sustainable construction materials as a green construction material. Additionally, these tiles feature a decorative, sandstone-like surface, underscoring their potential for architectural applications. These findings demonstrate the feasibility of repurposing iron-rust-contaminated soil as a sustainable raw material for ceramics, thereby promoting eco-friendly waste recycling in the construction industry. Further refinement of composition and firing conditions is recommended to enhance mechanical performance.</p> Graphical abstract <p></p>

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Circular Economy-Driven Sustainable Ceramics: Development and Evaluation of Tiles from Iron Rust-Contaminated Soil for Green Building Applications

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年3月21日

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  • Sirawan R. Tuprakay,
  • Seree Tuprakay,
  • Neeranut Kuanchertchoo,
  • Parinda Suksabye,
  • Sivapan Choo-in,
  • Bhuvaneswari Kandasamy,
  • Surachai Wongcharee,
  • Pitsanu Pannaracha,
  • Kowit Suwannahong

摘要

The growing demand for sustainable construction materials has spurred interest in the use of industrial waste in ceramic production. This study examines ceramic tiles fabricated from iron-rust-contaminated soil, focusing on their microstructural, mechanical, and aesthetic properties. The material referred to as iron-rust-contaminated soil in this study is an industrial waste-like soil generated during steel recycling processes, rather than a natural soil affected by environmental contamination. It was repurposed as a secondary raw material in the production of ceramic tiles. Chemical characterization revealed hematite (Fe2O3) as the dominant oxide (72.04–78.85 wt%), which imparts the reddish-brown coloration to both raw soil and fired tiles. Various mixing ratios of iron-rich soil with conventional raw materials were evaluated to optimize performance at high-temperature firing (up to 1100 °C). The highest shrinkage (8.97%) was observed in the P 60 formulation at 1100 °C, indicating significant densification. SEM analysis revealed rust particles adhering to soil grains, influencing sintering behavior and microstructural evolution. Mechanical testing showed that increasing iron-rust content reduced flexural strength due to increased porosity, whereas higher firing temperatures improved densification and mechanical properties. The maximum flexural strength recorded was 77.07 kg/cm2 for the P 80 sample fired at 1100 ° C. Water absorption values exceeded 10%, with a modulus of rupture below 7 kg/cm2, conforming to the TIS 2508–2555 standards. The integration of iron-rust-contaminated soil into ceramic tile manufacturing resulted in a 38.3% reduction in greenhouse gas emissions, demonstrating improved environmental performance. This strategy promotes circular-economy products by valorizing industrial waste into sustainable construction materials as a green construction material. Additionally, these tiles feature a decorative, sandstone-like surface, underscoring their potential for architectural applications. These findings demonstrate the feasibility of repurposing iron-rust-contaminated soil as a sustainable raw material for ceramics, thereby promoting eco-friendly waste recycling in the construction industry. Further refinement of composition and firing conditions is recommended to enhance mechanical performance.

Graphical abstract