Ceramics Properties of Indurated-Shale Quarry Wastes from Abakaliki, Southeastern Nigeria: Application as Raw Materials in Roofing-Tile Production

Abstract

The present study describes research carried out to evaluate the mineralogical, geochemical and technological properties of indurated shale-quarry wastes and assess the suitability of these low-cost and locally available quarry wastes generated from crushed indurated shales for possible use as alternatives to fresh raw materials in the manufacture of roofing-tile products. Firstly, the mineralogical and chemical properties of the indurated shales were investigated by X-ray diffraction (XRD) and X-ray fluorescence, while their physical properties were identified by grain-size distribution, Atterberg limits, and clay activity. Samples of indurated shale-quarry wastes (ISQWs) were subjected to heat treatment at elevated firing temperatures to provide the required strength and durability and their ceramics properties (linear shrinkage, weight loss, water absorption, bulk density, and flexural strength) were determined. From the results, the ISQWs were composed predominantly of fine particles with medium plasticity and clay activity with values generally >0.75. The mineralogy revealed a predominance of aluminosilicates (illite-kaolinite-smectite-chlorite) with large quartz contents and variable percentages of carbonate and feldspar. The oxides were dominated by SiO2 and Al2O3, small amounts of ferromagnesian minerals, and considerable amounts of alkalis (K2O and Na2O) which act as fluxes. The CaO concentrations were variable and related to carbonate contents. Characterizations based on compositional ternary (total clay mineral-carbonate-quartz + feldspar) systems, Casagrande clay workability charts, and Winkler and McNally diagrams revealed their suitability for ceramics applications as the majority of ISQW samples fell within the specifications for roofing tiles. The ISQWs fired at a high temperature of 1000°C revealed considerable weight loss, reduction in both linear shrinkage and water absorption with insignificant increase in flexural strength. In order to achieve excellent ceramics properties and further reduce sintering temperature for their suitability as raw materials in the production of roofing tiles, beneficiations of ISQWs are highly recommended.