Turning waste into value: sustainable utilization of dam sediments in porcelain stoneware tiles

The increasing demand for sustainable construction materials has driven the exploration of innovative approaches to utilize secondary raw materials in the building sector. This study investigates the potential of dam sediments from the Mignano Lake reservoir (Northern Apennines, Italy) for use in the production of porcelain stoneware tiles aligning with the principles of circular economy and sustainable development. Comprehensive characterization of the sediments, including X-ray diffraction (XRD), X-ray fluorescence (XRF), particle size analysis, plasticity and thermogravimetric analysis (TGA), was performed to evaluate their suitability for construction applications. The analysis revealed that the dam sediments primarily consist of carbonates (22–25%), quartz (31–33%), and clay minerals (42–45%). Based on these findings, a feasibility study was conducted to evaluate the potential of utilizing these sediments in the ceramic industry. The study specifically explored their application as partial substitutes in porcelain stoneware tiles, leveraging their composition to serve as corrective plastic clay to enhance plasticity in the formulations. The effects of firing temperatures on the physical, mechanical, and microstructural properties of porcelain stoneware tiles were examined, identifying optimal conditions for density, strength, and pore structure. The optimal firing temperature was determined to be 1200℃, achieving a bulk density between 3.370-2.390 g/cm3, the mechanical strength of 37-48 MPa and water absorption value <0.5 %, depending on the percentage of waste addition. These results confirm the feasibility of utilizing dam sediments in porcelain stoneware tiles production, contributing to sustainable and high-performing ceramic materials. This approach highlights the potential to transform dam sediments into high-value construction materials. By integrating waste management with material innovation, the research provides a sustainable pathway to address environmental challenges and advance resource efficiency in the construction industry.