Effect of basalt cutting waste on the slip resistance of ceramic tile surfaces

Abstract

The present invention relates to the effect of basalt cutting waste on the slip resistance of ceramic tile surfaces in the ceramics and construction industry, which enables slippery floors that pose a hazard in indoor and outdoor spaces to be transformed into safer, non-slip floors, characterized in that it comprises the process steps of drying (1) basalt cutting waste by firing process, magnetizing (2) the iron powder contained in dried basalt cutting waste, milling (3) magnetized basalt cutting waste and sifting through a 32-45 micron sieve, obtaining the glaze mixture (4) by combining 15-35% milled basalt cutting waste, 3-5% albite, and 2-4% alumina (4), applying the glaze mixture to the ceramic tile surface (5) by glazing with a spraying or a glaze applicator and subjecting the obtained glaze mixture to a rapid firing process (6) at approximately 1210 °C for 43 minutes.

Description

[0001] EFFECT OF BASALT CUTTING WASTE ON THE SLIP RESISTANCE OF CERAMIC

[0002] TILE SURFACES

[0003] Technical Field:

[0004] The present invention relates to the effect of basalt cutting waste on the slip resistance of ceramic tile surfaces in the ceramics and construction industry, which enables slippery floors that pose a hazard in indoor and outdoor spaces to be transformed into safer, nonslip floors.

[0005] State of the Art:

[0006] Ceramic Tile is a floor and wall covering material produced in the form of sheets of various sizes from ceramic material. Tile is defined as "a flat surface piece with a length and a width clearly greater than its thickness".

[0007] Loss of traction between the sole of the shoe and the surface of the flooring is one of the main causes of falls. The biggest causes of traction loss are factors such as contamination of the surface with pollutants such as dust, oil, etc. over time. A floor exposed to dirt, abrasive material, or other contaminants begins to pose a hazard. Wet surfaces are the most common cause of slip-related accidents. Places with slippery surfaces such as homes, workplaces, hotels, schools, terraces, and pool sides are considered to be among the most likely places to fall. Slip-related accidents are among the leading causes of injury in many countries. For this reason, it is a crucial future for the ceramic tiles to have a non-slip surface for any flooring application to ensure safety.

[0008] The slip resistance value is expressed in "PTV (Pendulum test value)". PTV value is determined according to EN 16165 standard in accordance with the usage area of the place to be furnished. In order to obtain a non-slip surface on floor tiles, granule applications called grit and raw materials that will increase the melting points of glazes are generally used. In this context, alumina and corundum are the most widely used and costly raw materials. While the slip resistance of the surfaces increases, an increase in staining is also observed. In addition to the staining problem on the surfaces designed with these raw materials, the increase in the amount of alumina causes the glaze to fail to develop and prevents the surfaces with the desired properties from being obtained. Grit is a material produced with high energy use. Also, there are chemicals that need to be used during the application of the grit. This chemical used increases environmental pollution and poses a threat to life and nature. The need for the search for alternative raw materials is increasing in order to eliminate the problems experienced in the process applications of ceramic tiles known in the industrial sector and to increase both the slip resistance of the surfaces and to protect the surface properties of the coating materials with an environmentally friendly production process.

[0009] Basalt is a type of rock. Basalt is known to be used in construction (e.g. building stones or floor works), in the production of paving stones and in sculpture. As a result of these processes, basalt wastes are formed. A high amount of waste is generated during the cutting of basalts depending on the area of use. These wastes create problems such as storage and dust formation in stone mills, posing major threats to living and environmental health.

[0010] The application entitled “Ceramic Tile with Excellent Comprehensive Performances and Preparation Method Thereof’ was encountered in the application no. CN106007666A. The invention discloses a ceramic tile with excellent comprehensive performances and a preparation method thereof, and relates to the technical field of ceramic tiles. Ceramic tile is mainly prepared from fly ash, dredged marine clay, polished tile waste, submarine mineral sand, expanded and vitrified microbeads, calcium hyperborate, polyvinyl alcohol, titanium diboride, zinc stearate, disodium methylenebisnaphthalene sulfonate, sodium metabisulfite, antimony tin oxide, nano chromium carbide, magnesium hydroxide, basalt fibers, sorbitol, and tung oil. Solid waste pollution is also reduced and expanded and vitrified microbeads, calcium hyperborate, and magnesium hydroxide are paired with each other. Thus, the fire resistance and thermal insulation performance of the ceramic tile are improved.

[0011] The application summarized above describes a ceramic tile with excellent comprehensive performances and the preparation method thereof. It is seen in the specification that the ceramic tiles intended to be obtained in this invention are subjected to a firing period of 13-14 hours. It is known that the maximum firing time known in the ceramic tile industry is 40-70 minutes in production. Ingredients such as expanded vitrified microbeads, calcium hyperborate, polyvinyl alcohol, titanium diboride, zinc stearate, disodium methylenebisnaphthalenesulfonate, sodium metabisulfite, antimony tin oxide, nano chromium carbide, magnesium hydroxide, sorbitol, and tung oil are not materials used in traditional ceramic tiles but are raw materials of the present application. However, considering this long firing time and the raw materials used, the application is disadvantageous.

[0012] Application no. CN107382373A discloses "Wear Resistant Non-Slip Ceramic Tile and Preparation Method Thereof. The invention discloses a wear resistant and non-slip ceramic tile. A mixed glaze layer of wear resistant and non-slip particles and a primer is applied to the surface of the molded ceramic tile-based clay raw material. Here, a mixed glaze layer consisting of wear resistant and non-slip particles and a primer is prepared. It comprises a glaze slurry and a mixed glaze slurry of high-temperature wear resistant and non-slip particles. The invention also discloses a method of preparing a wear resistant and non-slip ceramic tile. In wear resistant and non-slip ceramic tile, wear resistant and non-slip dry particles are placed inside the glaze layer and positioned under the ceramic tile patterned decoration layer. Thus, the particle components and transparency of the wear resistant and non-slip dry particles do not affect the color effect of a product pattern, and the wear resistant and non-slip dry particles are unlikely to be worn or scraped during actual use. The particle size of wear resistant and non-slip dry particles is relatively large, so that the surface of the product achieves a better non-slip and anti-fouling effect.

[0013] The application, which is summarized above, describes a wear resistant non-slip ceramic tile and the preparation method thereof. A glaze slurry is prepared for the slipperiness mentioned in this application. The description of this glaze slurry of the present application states that “the structure of the glaze slurry contains the following components by weight: SIO2 50%, Ai?O321%, Fe?O3 0.3%, CaO + MgO 2.7%, K2O + Na2O 6.5%, ZnO 1%, BaO 10% , ZrC>2 8%, T1O2 0.5%”. It is a disadvantageous invention in terms of features such as the creation of a glaze slurry to ensure non-slip, passing this glaze mixture through another stage to ensure its integration into the product, and the increased cost of raw materials.

[0014] As a result, there is a need for a new production method that can overcome the above- mentioned disadvantages, which can be used to increase the slip resistance of ceramic tiles and reduce costs, while ensuring the advantageous utilization of basalt wastes, which are hazardous for living and environmental health when found in free form.

[0015] Definition of the Invention:

[0016] This invention is the effect of basalt cutting wastes on the slip resistance of ceramic tile surfaces, characterized in that it is a new production method used to increase the slip resistance of ceramic tiles and reduce the cost, while ensuring the advantageous utilization of basalt wastes, which are hazardous for living and environmental health when found in free form, in the industry.

[0017] In order to achieve all objectives mentioned above and which will arise from the detailed explanation below; the invention is directed to obtaining surfaces with low slip potential by using in the glaze recipe basalt powder wastes, which are released during the cutting of basalt stone, and are very harmful to living and environmental health and difficult to dispose of.

[0018] This invention provides many positive features such as reduced cost, use of chemicals, and environmental damage by incorporating a waste material instead of the expensive raw materials commonly used in the industry. As basalt waste creates storage and dusting problems in operations, it is utilized thanks to this invention, and provides increased anti-slip resistance in ceramic tiles.

[0019] The invention utilizes waste sludge created during basalt cutting. The high iron content in the basalt cutting waste is magnetized before it is added to the recipe. This waste sludge is dried and ground to pass through a 32 - 45 micron sieve. It is added to the matte glaze formulation in the operation at certain ratios (up to 35%). 2-4% alumina is also added to the recipes. The created glazes are applied to the surfaces by glazing with spraying or a glaze applicator. Here, the need to add alumina to the glaze recipe is for adjusting the glaze melting interval and to provide glaze surface control with albite addition. The data shown in the table below are obtained based on these recipes.

[0020] When developing the recipe for the invention, ratios for optimum conditions were selected. The surface of ceramic tiles is made rougher with basalt cutting waste. Within the scope of the invention, ensuring sustainability by reusing the existing waste material and adding anti-slip functionality to the surface provides added value to the product. In this process, by using basalt cutting waste, which is an environmental waste, to increase the slip resistance, problems such as the use of additional chemicals and the use of high- cost grits that arise in existing methods are also avoided. With this product, surface contamination is prevented. The result of the experiments conducted show that the slip value (PTV) of the tile with the addition of basalt cutting waste to the matte glaze was 19 under standard conditions, while this value increased up to 53 as a result of the recipe no. 3.

[0021] The prepared glazed samples are subjected to a rapid firing process at a temperature of approximately 1210 °C for 43 minutes. To determine the value of the slip resistance, this value is tested using many test methods known in the industry, such as the ramp test and the pendulum test. The ramp test is the most commonly performed slip resistance test. In general, it involves a method of walking on an inclined surface that has been contaminated with pollutants. The slip resistance values are determined based on the angle at which the tester feels unsafe.

[0022] The structural and characteristic features of the inventive product and all advantages thereof will be understood more clearly with the figures given below and the detailed description provided with reference to the these figures, therefore, evaluation must be made by taking these figures and detailed description into account.

[0023] Description of the Drawings:

[0024] The invention will be described with reference to the accompanying figures, so that the features of the invention will be more clearly understood and appreciated, however it is not intended to limit the invention to these particular embodiments. On the contrary, it is intended all alternatives, modifications and equivalences that may be included in the field of the invention as defined by the accompanying claims are within the scope. It should be understood that the details shown are for the sole purpose of illustrating preferred embodiments of the present invention and are intended to provide the most useful and easily understandable description of both the embodiment of the methods and the rules and conceptual features of the invention. In the drawings;

[0025] Fig. 1 is a schematic representation of the subject of the invention

[0026] The figures which will help understand this invention are numbered as indicated in the accompanying drawing and are given below with their names.

[0027] Description of the References:

[0028] 1 . Drying

[0029] 2. Magnetization

[0030] 3. Milling (Powder)

[0031] 4. Obtaining the Glaze Mixture

[0032] 5. Applying to Tile Surfaces

[0033] 6. Subjecting to Rapid Firing Process

[0034] Description of the Invention:

[0035] The invention comprises the process steps of drying (1) basalt cutting waste by firing process, magnetizing (2) the iron powder contained in dried basalt cutting waste, milling (3) magnetized basalt cutting waste and sifting through a 32-45 micron sieve, obtaining the glaze mixture (4) by combining 15-35% milled basalt cutting waste, 3-5% albite, and 2-4% alumina, applying the glaze mixture to the ceramic tile surface (5) by glazing with a spraying or a glaze applicator, subjecting the obtained glaze mixture to a rapid firing process (6) at approximately 1210 °C for 43 minutes.

[0036] It includes increasing the standard slip resistance value of ceramic tile from 19% to 53%.

Claims

CLAIMS1 . An effect of basalt cutting waste on the slip resistance of ceramic tile surfaces, characterized in that it comprises the process steps of:- drying (1) basalt cutting waste by firing process, magnetizing (2) the iron powder contained in dried basalt cutting waste, milling (3) magnetized basalt cutting waste and sifting through a 32-45 micron sieve,- obtaining the glaze mixture (4) by combining 15-35% milled basalt cutting waste, 3-5% albite, and 2-4% alumina (4),- applying the glaze mixture to the ceramic tile surface (5) by glazing with a spraying or a glaze applicator,- subjecting the obtained glaze mixture to a rapid firing process (6) at approximately 1210 °C for 43 minutes.

2. The effect of basalt cutting waste on the slip resistance of ceramic tile surfaces according to claim 1 , characterized in that the standard slip resistance of the ceramic tile is increased from 19% to 53%.