Using volcanic tuff wastes instead of feldspar in ceramic tile production

The present study investigated the potential of utilizing the cutting dust waste generated in the sizing process of volcanic tuff stones as an alternative to the traditional raw materials of industrial floor tile formulations. Within the scope of the research, Döger region (Afyonkarahisar, Turkey) tuff waste was used in varying amounts (up to 7 wt. %) to substitute feldspar (albite) in the industrial formulation partially. The ceramic tiles, which were shaped at 20 MPa pressure by uniaxial pressing from the mixtures obtained by partial substitution of albite by tuff waste, were fired in an industrial furnace at 1180 °C for 50 min. When the pre- and post-firing properties of the tuff waste-incorporated tiles were compared, one could find that 5 wt. % tuff waste incorporation to the industrial formulation provided the highest green (9.83 MPa) and fired (26.77 MPa) strength values, as well as the lowest water absorption (5.77%) value. The results indicated that 5 wt. % substitution of albite with tuff-stone cutting waste could improve the densification and fired strength of ceramic tiles. Furthermore, although it has the potential to be converted into more valuable materials, the use of tuff wastes, which are still disposed of in landfills, in ceramic tile production, will contribute to environmentally friendly solutions and protect the rare natural feldspar deposits.