Joudah 2021 IOP Conf. Ser. Mater. Sci. Eng. 1090 012060
Joudah 2021 IOP Conf. Ser. Mater. Sci. Eng. 1090 012060
Joudah 2021 IOP Conf. Ser. Mater. Sci. Eng. 1090 012060
Keywords: Cost effective, environment benefits, sustainable materials, tile ceramic wastes.
1. Introduction
A significant amount of greenhouse gases' (GHG) emissions and environmental pollution (both critical
drivers of climate change) are produced during the manufacturing of all types of cement. In an attempt
to minimise this environmental damage, researches are continuously looking for greener construction
materials to replace either partially or totally cement [1-3]. Cement is used for the manufacturing of
concretes and mortars, giving that one tonne of greenhouse gas is emitted when every tonne of cement
is consumed (accounting for around 8% of GHG emissions globally). The high temperature of the
cement clinker processing is the main problem. Ecological systems across the globe are thus being
strained by the continuous production of cement at its existing rate [4, 5].
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
There has been significant development in the use of promising alternatives, such as those exist in
industrial wastes from construction. The fact that these solutions are environmentally better, readily
available, and available at relatively low cost has made these alternatives attractive as replacement of
cement [6-8]. Using of the industrial wastes leads to a decrease in the depletion of the natural
resources and subsequently the sustainability is boosted and waste management is became more
effective [9-11].
A range of wastes are being used to substitute cement, and a series of core factors – from economic
viability and market stability, to material durability, environmental responsiveness and sustainability
were investigated. Sustainability as a concept practised in the construction industry, in addition to
‘green manufacturing’, require the use of alternative wastes as replacements of natural resources,
including extra-cementitious materials. The call for sustainability in construction has prompted the
emergence of new materials for a range of uses, all of them cost-reducing and environmentally geared.
Ceramic tiles, as a key example, are made at high temperatures using fire clay, feldspar and quartz
[12].
Sustainability in construction also comes into play in terms of behavioural aspects and how waste
materials are used in applied practice [13-15]. In the accessible literature, there was very limited
research pertaining to the environmental merits of using Waste Tile Ceramics (WTC) mortar as a
replacement of cement and/or natural river sand (RS).
The present study thus made a series of mortar types using ceramic waste to investigate the feasibility
of using WTC as replacement of cement and/or sand in mortars. The study sourced the ceramic waste
locally and deployed it to assess whether sustainable mortars could be developed for construction
projects. The sustainability performance metrics for the as-prepared mortar samples were assessed
using a range of analyses including greenhouse emissions, energy efficiency and cost analysis.
2. Methodology
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
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ICEST 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
Both the effects made by the feedstock and binder manufacturing processes, and the transport, must be
factored in an environmental benefit analysis. This study does not factor in the mixing, laying, curing
and emissions features of the various mortars over the entire working lifetime because they are
considered to be similar. The proposed method will likely give an analogous life cycle of effects rather
than an absolute one. The study established the various materials’ energy consumption figures,
production costs and GHG emission rates. The various phases in preparing the OPC, WCP, CFA and
RS are displayed in Table 4.
A transportation fee of 1 t/km was applied for all the materials, and these were incorporated into the
net cost. Details of the machinery and materials are provided in Table 5. An assumed price of 0
Ringgit Malaysia (RM) was assigned to the ceramic waste, which was acquired for free from industrial
sources. By factoring in the capacity of the engine and the duration of the operation, the overall cost of
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
electrical consumption for the equipment was estimated, depending on the materials’ life cycles. The
estimations were premised on Malaysian electricity price rates for October 2020, as shown in Table 6.
To calculate CO2 the equivalent amount for 1 tonne of cement, the following equation was used.
Total CO2 emissions = σୀଵ ݉݅ሾሺ݀݅ ൈ ݅ܦൈ ݇ͳ݅ሻ ሺ ݅ܧൈ ݇ʹ݅ሻሿ (2)
Where:
mi is the mass of component i (t/m3), di is the transport distance (km), Di is the diesel consumption
(L/km), k1i is the CO2 emission for 1 L of diesel (t), Ei is the total electricity consumption (kwh), and
k2i is the CO2 emission for 1 kwh electricity (t).
Total energy consumption = σୀଵ ݉݅ሾሺ݀݅ ൈ ݅ܦൈ ݇͵݅ሻ ሺ ݅ܧൈ ݇Ͷ݅ሻሿ (3)
Where:
k3i is the energy consumption for 1 L of diesel (GJ), Ei is the total electricity consumption (kwh), and
k4i is the energy consumption for 1 kwh of electricity (GJ).
where
DPi is the diesel cost (RM/L), Ti is the transport charge for 1 m3 (RM/km), and EPi is the electricity
cost (RM/kwh).
Where:
MEi is the machine capacity (t/h), and MPi is the machine power (kwh).
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
Table 6. The October 2020’ electricity cost in accordance with the consumption rate.
Consumption The unit
(Watt) (RM/kWh)
0 to 199 0.218
200 to 299 0.334
300 to 599 0.516
600 to 899 0.546
900+ 0.571
Drawn from the data (in Tables 4, 5 and 6), the study ascertained the energy consumption and
production costs for each batch. Comparisons between mortar mixtures WCP-CFAM and WCPM0
were made regarding energy consumption, costs, cost of production and GHG emissions. This was
performed to reach a compressive strength of 30 MPa to meet the requisite for Portland cement of 460
kg/m3. By ascertaining production costs, GHG emissions and energy consumption levels for WCP,
CFA, OPC and RS, the study evaluated the sustainability and environmental merits of the mortars, as
shown in Table 7. A far greater quantity of energy was required to process OPC, associated with
higher costs and higher GHG emissions, when contrasted with the WCP. A 5.13 GJ/ton energy
expenditure emerged for OPC, as contrasted with 1.12 GJ / tonne for the WCP (four times less).
Accordingly, OPC produced GHG emissions of 0.904 ton / ton, relatively high compared to WCP
which was 0.045 ton/ton. The production costs for OPC were also the highest amongst the samples.
The manufacturing process for OPC required high levels of energy, and transporting the material
required far greater effort. In the case of OPC, production costs sat at 600 RM / ton, whereas for WCP
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
the cost stood at 170 RM / ton. To reduce energy consumption levels and production cost, in addition
to GHG emissions, OPC needed to be applied at lower contents for mortar samples.
Table 7. WCP, OPC, CFA, and RS production process’ greenhouse gas emissions, cost effective and
energy consumption
Greenhouse gases Cost Energy consumption
Materials
(ton/ton) (RM/ton) (GJ/ton)
In Figure 3(b), the impact of replacing RS by CFA on the costs of mortars is shown. This
replacement caused a moderate cost reduction. The preparation phases for the materials, that affect the
cost of the mixes, were used as the basis of the price calculations by weight. The figure shows that the
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
entire replacement of RS by CFA decreased the cost of the 1m3 of mortar from 380 RM to about 340
RM.
The production costs of mortar mixtures WCPM0, CFAM100, WCPM40, and WCP-CFAM were
compared as shown in Figure 3(c). It can be seen that the cost of the later mortar mixture (WCP-
CFAM), which has 40% replacement of OPC by WCP and 100% replacement of RS by CFA, was
decreased by about 35% compared to that of the control mortar mixture. In other words, the
incorporation of both materials WCP and CFA as a replacement of OPC and RS, respectively can lead
to a significant reduction in the cost of mortar. It should be noted that technical results, such as effect
of replacement dosage on mechanical properties of mortar and concrete, should be gathered with these
results to determine the optimum replacement level.
In Figure 3(b), the impact of replacing RS by CFA on the costs of mortars is shown. This
replacement caused a moderate cost reduction. The preparation phases for the materials, that affect the
cost of the mixes, were used as the basis of the price calculations by weight. The figure shows that the
entire replacement of RS by CFA decreased the cost of the 1m3 of mortar from 380 RM to about 340
RM.
The production costs of mortar mixtures WCPM0, CFAM100, WCPM40, and WCP-CFAM were
compared as shown in Figure 3(c). It can be seen that the cost of the later mortar mixture (WCP-
CFAM), which has 40% replacement of OPC by WCP and 100% replacement of RS by CFA, was
decreased by about 35% compared to that of the control mortar mixture. In other words, the
incorporation of both materials WCP and CFA as a replacement of OPC and RS, respectively can lead
to a significant reduction in the cost of mortar. It should be noted that technical results, such as effect
of replacement dosage on mechanical properties of mortar and concrete, should be gathered with these
results to determine the optimum replacement level.
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
Figure 2. GHG emission of (a) WCP as replacement of OPC, (b) CFA as replacement
of RS, (c) replacement of OPC and RS by WCP and CFA, respectively.
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
Figure 3. Proposed mortar cost of (a) WCP as OPC replacement, (b) CFA as RS
replacement, and (c) incorporation of both WCP and CFA
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
compared to the control mortar mixture. This can be partially attributed to the reduced cost of diesel
and electricity used in the preparation of WCP. Figure 4 (b) shows that the replacement of RS by CFA
has a very marginal effect on the energy consumption. This can be logically attributed to the existing
low energy usage level associated with RS.
The incorporation of both WCP and CFA as replacement of 40% OPC and 100% RS, respectively
caused a reduction in energy consumption approximately comparable to that of mortar mixture
WCPM40. This means that the use of CFA as a replacement of RS has very little effect, if any,
whether it was used alone in mortar mixture as a replacement of RS or with mortars having WCP as a
partial replacement of OPC.
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
4. Conclusions
The Carbone dioxide emission, cost and energy consumption of twelve mortar mixtures incorporating
two forms of waste ceramic tile (WCP and CFA) were calculated. Based on results of this study, the
following conclusions were drawn.
1. The GHG emission, cost and energy consumption of OPC production are approximately 20, 4
and 4 times as high as those of WCP
2. The incorporation of various levels of WCP (10 to 60% by weight) as a partial replacement of
OPC resulted in a significant decrease in GHG emission, effective cost and energy
consumption of the mortar mixtures.
3. Although the use of CFA as replacement of RS led to a decrease in the effective cost of the
mortar mixtures, the effect of the replacement was very marginal on both GHG emission and
the energy consumption of the mortar mixtures.
4. The use of WCP and CFA as replacement of OPC and RS, respectively in the same mortar
mixture had comparable effect on GHG emission and energy consumption to that of using
only WCP in the mortar mixture.
It is worthy stating that laboratory investigation on the effect of using WCP and CFA on the
mechanical properties of mortars and concrete should be carried out and gathered with those of
this study to complete the entire picture and support the decision of selecting the appropriate
replacement materials either for cement or other components of mortars or concrete.
5. References
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IOP Conf. Series: Materials Science and Engineering 1090 (2021) 012060 doi:10.1088/1757-899X/1090/1/012060
[13] Dung N T, et al. 2016 Cementitious properties and microstructure of an innovative slag eco-
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[14] Huseien G F, Shah K W and Sam A R M 2019 Sustainability of nanomaterials based self-
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[16] Huseien G F and Shah K W 2020 Durability and life cycle evaluation of self-compacting
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