Production of granilite concrete plates with recycled aggregates and ornamental rock processing sludge

ABSTRACT The ornamental rock industry generates millions of tons of waste in different stages of rock processing. These wastes are stored or disposed of inadequately, which causes environmental degradation. The objective of this study was to evaluate the concomitant use of ornamental rock processing sludge as partial replacement of Portland cement in contents of 0%, 5%, 10% and 20% and of recycled stone aggregate as total replacement of coarse natural aggregates in the production and performance of granilite concrete plates. Four concrete formulations were produced with different replacement contents and their characteristics were determined through tests of axial compression strength, flexural tensile strength, water absorption, impact strength and strength to stains. Mechanical results were inversely proportional: the higher the sludge replacement content, the higher the axial compression strength and the lower the flexural tensile strength. Water absorption tests showed a gradual decrease with an increase in sludge replacement, impact tests showed that the plates performed better at resisting shocks best up to a height of 50 cm and, in terms of stain resistance, multi-use products and butoxyethanol-based stain remover were more efficient on waterproofed granilite concretes and natural rock pieces, respectively. It was possible to conclude that it was viable to use up to 20% replacement of the aforementioned wastes in conventional concrete, with additional minimization of environmental impact associated with the extraction and processing of ornamental stones.