Design and Characterization of Ceramic Bricks with Industrial Waste and Silica–Carbon-Based Additives

Kengesbekov A. Sabitova A. Bayandinova M. Sharipkhan Z. Bexoltanova D. Mukhamediarov N.
January 2026 Multidisciplinary Digital Publishing Institute (MDPI)

Buildings
2026 #16 Issue 1

This study investigates ceramic bricks produced by partially replacing clay with Pb–Zn metallurgical residues (lead furnace dust and cyclone dust), fly ash, and carbonaceous additives. The novelty lies in the integrated multi-waste formulation and the combined FTIR–TGA–XRD analytical approach used to elucidate phase-formation mechanisms. The results show that firing promotes the development of quartz, mullite, iron oxides, and an extensive Fe–Pb–Zn–Si–O amorphous network, while higher residue contents enhance amorphization and suppress mullite crystallization. These microstructural changes correlate with reduced compressive strength (1.6–3.1 MPa) and high water absorption (32–36%), although all samples completed 15 freeze–thaw cycles. Heavy-metal leaching assessed by atomic absorption spectroscopy (AAS) revealed very low Pb (0.08–0.20 mg/L) and Zn (0.25–0.45 mg/L) release, well below international safety limits, demonstrating effective immobilization of hazardous ions within the glassy matrix. Overall, the study provides new insight into multi-waste interactions during sintering and confirms that controlled residue incorporation enables environmentally safe, non-load-bearing ceramic materials with reduced clay consumption.

ceramic brick , fly ash , heavy metal immobilization , industrial waste , lead–zinc production dust

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Institute of Composite Materials, Ust-Kamenogorsk, 070000, Kazakhstan
Department of Chemistry and Ecology, Shakarim University, Semey, 071412, Kazakhstan
Department of Physics, Sarsen Amanzholov East Kazakhstan University, Ust-Kamenogorsk, 070000, Kazakhstan

Institute of Composite Materials
Department of Chemistry and Ecology
Department of Physics

10 лет помогаем публиковать статьи Международный издатель

Книга Публикация научной статьи Волощук 2026 Book Publication of a scientific article 2026