Evaluation of strength, durability, and microstructural properties of concrete with ceramic waste aggregates

The escalating demand for coarse aggregates in concrete production is critically depleting natural resources, necessitating sustainable alternatives. As a leading global producer of ceramic tiles, India generates substantial waste, particularly in Morbi, Gujarat, where manufacturing defects contribute significantly to environmental burdens through landfilling. This study investigates the feasibility of replacing natural aggregates with ceramic tile waste (CTW), emphasizing those with 0 % water absorption to optimize water efficiency in concrete production. Ceramic aggregates with 0 % and 18 % water absorption were characterized for specific gravity, flakiness, and abrasion resistance and utilized as coarse aggregate replacements at varying proportions (0–100 %). Comprehensive mechanical, durability, and microstructural (Field Emission Scanning Electron Microscope) analyses were conducted to evaluate performance. The results indicate that a 60 % CTW replacement yields superior mechanical properties, with compressive, split tensile, and flexural strengths increasing by 31.5 %, 20.4 %, and 10.8 %, respectively. Furthermore, 0 % water absorption CTW significantly enhances durability by reducing chloride permeability and refining the interfacial transition zone (ITZ), contributing to superior microstructural integrity. A slight reduction in workability was noted due to the flaky nature of CTW aggregates; however, their partial replacement supports sustainable construction practices by enabling the beneficial reuse of ceramic waste in performance-enhanced concrete.