Reformulation of a Roofing Tiles Body

"A ceramic body traditionally used to produce bricks and roofing tiles with kaolinitic clays was reformulated by the addition of sand and illitic clay. The objective was to obtain a ceramic product with better technological properties. Specimens were made by uniaxial press-molding at 20 MPa and then fired at 850, 900 and 950°C. The determined technological properties were: linear shrinkage, water absorption and flexural rupture strength. The results showed that both sand and illitic clay contribute to reduce the water absorption of the industrial clayey body. With respect to the flexural behavior, it was observed that the incorporation of sand decreased the mechanical strength. On the other hand, the illitic, incorporated in an amounts of 30 wt.% contributed to increase the mechanical strength of the clayey ceramic.IntroductionCeramic bodies industrially fabricated in the county of Campos, north of the State of Rio de Janeiro, in Brazil, are still empirically elaborated using a mixture of local clays. These clays are predominantly kaolinitic mineral in nature, associated with high plasticity and elevated weight loss during the firing stage. Due to the excessive plasticity of the ceramic bodies, dimensional defects, which occur after drying and firing are usually obtained. Moreover, the kaolinitic nature and the presence of aluminum hydroxide (gibbsite) confer a refractory behavior to the local clays, which impairs sintering during the firing operation. In the case of clay ceramic products for civil construction, this results in greater porosity associated with elevated values of water absorption and low mechanical strength [1,2]. To avoid these problems, it is necessary to reformulate the ceramic body composition. The addition of both non-plastic materials to reduce plasticity and fluxes to condition the refractoriness is a possible alternative.As an alternative to reduce the plasticity of clayey ceramics sand, which is predominantly constituted of silica, can be used. The incorporation of sand in amounts of up to 25 wt.% to a clayey ceramic body used for roofing tiles fabrication was studied by Vieira et al. [3]. In that work specimens were prepared by extrusion and fired at 850°C. The results indicated that in the pre-firing stages the sand improved the workability of the investigated clayey ceramic body and facilitates the drying stage. It was also observed that the incorporated sand significantly improved the physical and mechanical properties of the clayey ceramic after firing. On the other hand, the apport of flux oxides could be done by the use of illitic clays that have a higher amount of alkaline oxides in comparison with the kaolinitics clays."