The aim of this paper is to promote the use of mine clay washing residues for the preparation of alkali activated materials (AAMs). In particular, the influence of the calcination temperature of the clayey by-product on the geopolymerization process was investigated in terms of chemical stability and durability in water. The halloysitic clay, a mining by-product, has been used after calcination and mixed with an alkaline solution to form alkali activated binders. Attention was focused on the influence of the clay’s calcination treatment (450–500–600 °C) on the geopolymers’ microstructure of samples, remaining in the lower limit indicated by the literature for kaolinite or illite calcination. The mixtures of clay and alkali activators (NaOH 8M and Na-silicate) were cured at room temperature for 28 days. The influence of solid to liquid ratio in the mix formulation was also tested in terms of chemical stability measuring the pH and the ionic conductivity of the eluate after 24-h immersion time in water. The results reported values of ionic conductivity higher for samples made with untreated clay or with low temperature of calcination (≥756 mS/m) compared with values of samples made with calcined clay (292 mS/m). This result suggests that without a proper calcination of the as-received clay it was not possible to obtain 25 °C-consolidated AAMs with good chemical stability and dense microstructure. The measures of integrity test, pH, and ionic conductivity in water confirmed that the best sample is made with calcined clay at 600 °C, being similar (53% higher ionic conductivity of the eluate) or equal (integrity test and pH) to values recorded for the metakaolin-based geopolymer considered the reference material. These results were reflected in term of reticulation and morphology of samples through the analysis with scanning electron microscope (SEM) and X-ray diffraction (XRD), which show a dense and homogeneous microstructure predominantly amorphous with minor amounts of quartz, halloysite, and illite crystalline phases. Special attention was dedicated to this by-product to promote its use, given that kaolinite (and metakaolin), as primary mineral product, has a strong impact on the environment. The results obtained led us to consider this halloysite clay very interesting as an aluminosilicate precursor, and extensively deepening its properties and reactivity for the alkaline activation. In fact, the heart of this work is to study the possibility of reusing this by-product of an industrial process to obtain more sustainable high-performance binders.

The aim of this research was to evaluate the possibility of reusing waste foundry sands derived from the production of cast iron as a secondary raw material for the production of building materials obtained both by high-temperature (ceramic tiles and bricks) and room-temperature (binders such as geopolymers) consolidation. This approach can reduce the current demand for quarry sand and/or aluminosilicate precursors from the construction materials industries. Samples for porcelain stoneware and bricks were produced, replacing the standard sand contained in the mixtures with waste foundry sand in percentages of 10%, 50%, and 100% by weight. For geopolymers, the sand was used as a substitution for metakaolin (30, 50, 70 wt%) as an aluminosilicate precursor rather than as an aggregate to obtain geopolymer pastes. Ceramic samples obtained using waste foundry sand were characterized by tests for linear shrinkage, water absorption, and colorimetry. Geopolymers formulations, produced with a Si/Al ratio of 1.8 and Na/Al = 1, were characterized to evaluate their chemical stability through measurements of pH and ionic conductivity, integrity in water, compressive strength, and microstructural analysis. The results show that the addition of foundry sand up to 50% did not significantly affect the chemical-physical properties of the ceramic materials. However, for geopolymers, acceptable levels of chemical stability and mechanical strength were only achieved when using samples made with 30% foundry sand as a replacement for metakaolin.

In this study, the role of two reactive fillers, specifically a sand from a clay washing process as an alternative to waste glass powder and a commercial metakaolin (MK), into the geopolymerization process of waste clay-based materials was assessed. Three kinds of clayey wastes from mining operations—halloysitic, kaolinitic and smectitic clays—were tested as potential precursor of geopolymeric materials in view of a potential valorisation of these by-products. A mix-design based on the addition of low percentages (20%) of these fillers or MK to improve the mechanical and chemico-physical properties of geopolymeric formulations was evaluated. All the clays were thermally treated at a temperature of 650 °C, while the geopolymeric pastes were cured at room temperature. In particular, the chemical stability in water (pH and ionic conductivity of leachate water, weight loss), the variations in the microstructure (XRD, SEM), and in the mechanical performance (compressive strength) were analysed. The most reactive additive was MK, followed by sand and waste glass at very similar levels—1:1 or 2:1—depending upon the type of the clay but not strictly related to the clay type. The increase of geopolymeric gel densification due to the presence of MK and sand was replaced by a crack deflection mechanism in the case of the WG grains. The worst performance (chemical stability and mechanical properties) was found for the halloysitic clay, while kaolinitic and smectitic clays developed strengths slightly below 30 MPa.

The ceramics industry has consistently applied circular economy principles by efficiently reusing and recovering raw materials in the production process. Incorporating secondary raw materials, such as production scraps and recycled materials, reduces costs and improves sustainability. In the ceramics sector, raw materials like feldspars can be substituted with secondary raw materials from other production processes, particularly glass-based ones. This study selected waste glass, such as bottle glass or glass fiber processing scraps, to investigate its performance in a porcelain stoneware slab mixture. The behavior of this mixture was compared to a traditional porcelain stoneware mixture and a mixture containing a glass-ceramic frit, which exhibits significantly different behavior from waste glass. The study involved a comprehensive characterization of the fired samples, with a specific focus on addressing pyroplastic deformation—an issue that occurs in large slabs during the firing process. Although pyroplastic deformation has been extensively studied in the past using various waste glasses, this research work uniquely employed waste glass fiber and glass-ceramic material to mitigate pyroplastic deformation compared to the more commonly studied waste soda–lime glass. The pyroplastic deformation tests were conducted using an instrument from Expert Lab Service-MDF.

The ceramics industry has long embraced the principles of the circular economy, with a strong focus on the reuse and recovery of raw materials essential to the production cycle. This approach reduces costs by reintroducing secondary raw materials—such as production scraps and recycled materials—into the manufacturing process after appropriate recovery treatments. This study aims to contribute to the transition of the ceramic industry toward a circular economy by incorporating industrial by-products into monoporosa ceramic bodies, thereby transforming waste materials into valuable resources. Monoporosa is a porous, single-fired ceramic wall tile characterized by a high carbonate content and low bulk density. However, the role of secondary raw materials in monoporosa formulations, as well as their influence on processing behavior (e.g., during sintering) and on key technological properties, is not yet fully understood. This work investigates a standard monoporosa formulation based on conventional raw materials (sand, calcite, feldspars, and clays) and compares it with new formulations in which industrial waste materials from local and national sources—originating from other industrial processes—are used as partial or total substitutes for some of the traditional raw materials, particularly sand and calcite. The industrial by-products examined include biomass bottom ash, foundry sand, and marble cutting and processing sludge. All materials were characterized using chemical–mineralogical, thermal, and morphological analyses and were incorporated into the ceramic bodies at different substitution levels (10%, 50%, and 100%) to replace natural raw materials. Their behavior within the mixtures was evaluated to determine ceramic suitability and acceptable replacement ratios. Furthermore, the effects of these additions on water absorption, thermal expansion coefficient, and microstructural characteristics were assessed. Based on the positive results obtained, this study demonstrates the feasibility of using, in particular, two secondary raw materials—foundry sand and marble sludge—in monoporosa body formulations, allowing for the complete replacement of the original raw materials and thereby contributing to the development of more sustainable ceramic compositions.

The exploitation of different kind of clayey waste (halloysitic, smectitic/illitic, kaolinitic) for the production of geopolymers in the view of a circular economy of mines is the main goal of this study. In particular, the addition of low percentages of metakaolin (5-15%) was evaluated to improve the chemical-physical properties and the consolidation degree of geopolymeric formulations produced with clays classified as mine’s by-products. In fact, these secondary raw materials are often not sufficient alone to obtain chemically stable formulations with acceptable mechanical properties but require the addition of reactive fillers. All samples contained thermally treated clays (600°C-700°C) and metakaolin as aluminosilicate precursors, alkaline solution of NaOH and Na₂SiO₃, and were cured at room temperature. The influence on the final products with MK addition was monitored with the evaluation of the chemical stability in water (pH and ionic conductivity measures), the comparison of setting times (Vicat needle) and mechanical performance.