Waste marble powder/dust

Bahar Demirel and Kürşat E. Alyamaç

Firat University, Elaziğ, Turkey
6
6.1 Introduction
Scientifically, marbles are the natural stones that come into being a new structure
as a result of recrystallization of limestone (CaCO3) and dolomite (CaMg(CO3)2)
under high temperature and pressure. Commercially, all natural stones that can be
processed, polished, used for decorative purposes and are of market value are called
marble (Aydin, 2013). In practice, marble is used as the traditional name of natural
stones. The marble, which has many types, has an extensive usage area (Alyamaç
and Ince, 2007). Using various marbles has built many structures and made lots of
works of art from ancient times to nowadays in different parts of the world (Sadek
et al., 2016).
Marbles are extracted from quarries in the form of blocks by various techniques
used in mining. These blocks, which are transported to the marble factories, are first
cut into slabs. Cutting operations are performed by Gang Saw machine which cut
out the marble blocks into large slabs with certain and specific thickness. Then, the
surfaces of the slabs are brightly polished by bridge cutting machine. Lastly,
polished slabs are cut down to the final sizes requested by the customers. During
the cutting and polishing process, water is used to avoid overheating of the saw and
to prevent dust resulted from cutting. The marbles, which have an extensive range
of colors and patterns, reflect their natural beauties after cutting and polishing and
also show decorative feature (Alyamaç and Aydin, 2015).
The countries that produce marble abundantly at present are China, Italy, Spain,
India, Turkey, Korea, and Brazil. Besides, the United States, Saudi Arabia, Egypt,
Pakistan, Germany, France, Portugal, Greece, and Norway are among the countries
that have a say in natural stone processing and importation (Awol, 2011). When the
population and economic size of these countries take into account, the size of the
marble industry is readily apparent. The marble industry is one of the most impor-
tant subcategories of the mining sector. This sector is gradually developing to
respond to growing demand, and it increases production capacity. However, as
development and production increases, the amount of waste of the marble, one of
the most significant problems of this sector, is also increasing (Alyamaç and
Tugrul, 2014).
At the end of the cutting and polishing processes in marble factories, two types
of waste material are obtained. First is the marble waste slurry (MWS) that consists
of the marble dust mixed with water during the cutting and polishing process, sec-
ond is the broken marble pieces that rupture from marble blocks and slabs.

Waste and Supplementary Cementitious Materials in Concrete. DOI: [Link]

Copyright © 2018 Elsevier Ltd. All rights reserved.
182 Waste and Supplementary Cementitious Materials in Concrete

Figure 6.1 Formation process of marble waste sludge.

This process is illustrated in Fig. 6.1. The total amount of wastes that obtained as a
result of the processing of the marble blocks and slabs vary depending on para-
meters such as saw type, cutting method, and marble type and is between 30% and
50% of the volume of all processed blocks (Rana et al., 2016).
Waste marble powder/dust 183

These wastes cause both economic losses and adverse effects on the environ-
ment. The solid wastes which are obtained after marble processing are stored in the
huge warehouses of the factories for use in different sectors. The marble slurry that
emerged during the processing is refined from the water by treatment unit as much
as possible, and the marble waste sludge is obtained. This amount of waste is too
big to be able to store by the marble firms. For this reason, the marble firms dump
this waste into the nature with controlled or uncontrolled access. As a result, this
waste causes great environmental pollution. Utilization of waste marble powder
(WMP) in other sectors than the marble sector both decreases the environmental
pollution caused by these wastes and provides economic advantages.
The marble waste sludge is easily powdered by being applied a little mechanical
force or by grinding after it is completely dried. This waste material is commonly
called as WMP. WMP is used in the fields of construction, paper, paint, plastic,
glass, agriculture, production of the animal feed and lime. Among these sectors, the
construction industry has the greatest potential for utilization. In addition, marble
wastes are mostly utilized in normal and self-compacting concretes (SCCs) in the
construction industry (Alyamaç and Ince, 2009). Therefore the use of WMP in con-
crete has been examined in detail in Section 6.3. WMP has been used for the pro-
duction of red-clay ceramics (Sutcu et al., 2015), asphalt mixture (Karaşahin and
Terzi, 2007), paving block (Gencel et al., 2012), and brick (Saboya et al., 2007) as
well as for the concrete, and researchers have reported positive results (Vardhan
et al., 2015).

6.2 Properties of waste marble powder/dust

In this section, the physical and chemical properties, and also the microstructure of
WMP, have been examined by comparing the studies in the literature. The exact
nature of the WMP depends on the structure of the marble, type of the cutting tech-
nique, and toll.

6.2.1 Physical properties of waste marble powder/dust

The physical properties of WMP which are most commonly measured are specific
gravity and finesses. Table 6.1 summarizes the physical properties of the marble
wastes investigated in the literature. Specific gravity and specific surface of the
WMPs vary between 2.39 and 3.16 and 2150 and 8889 cm2/g, respectively.
Both specific gravity and Blaine fineness values vary over a wide range. The
reason is that the structural and chemical properties of the marbles in which the
wastes are obtained are different from each other. Besides, there is no direct rela-
tionship between the specific gravity and the fineness of the studies shown in
Table 6.1. The reason for this is that both the chemical properties and the saw blade
type and thickness are different. The average specific gravity of the waste powder
184 Waste and Supplementary Cementitious Materials in Concrete

Table 6.1 Physical properties of waste marble powders

References Specific Blaine References Specific Blaine
gravity (cm2/g) gravity (cm2/g)
Agarwal and 3100 Aliabdo et al. 2.50 3996
Gulati (2006) (2014)
Alyamaç and Ince 2.71 5106 Alyamaç and 2.71 4372
(2007) Aydin (2015)
Binici et al. 3.16 Rana et al. 2.87 7358
(2007) (2015)
Binici et al. 2.72 Rodrigues et al. 2.73 2150
(2008) (2015)
Alyamaç and Ince 2.71 3924 Tennich et al. 2.42 6526
(2009) (2015)
Demirel (2010) 2.80 Baghel et al. 2.87
(2015)
Aruntaş et al. 2.60 3097 Vardhan et al. 2.60 3290
(2010) (2015)
Hebhoub et al. 2.68 Boukhelkhal 2.70 3600
(2011) et al. (2016)
Uysal and Sumer 2.71 8889 Kore and Vyas 2.70
(2011) (2016)
Ergün (2011) 2.68 5960 Mashaly et al. 2.67 6700
(2016)
Belaidi et al. 2.70 3500 Sadek et al. 2.78 2420
(2012) (2016)
Gesoğlu et al. 3.13 2870 Choudhary 2.87 2383
(2012) et al. (2016)
Vijayalakshmi 2.39 3510 Alyamaç et al. 2.71 3920
and Sekar (2017)
(2013)
Alyamaç and 2.48 Khyaliya et al. 2.56
Tugrul (2014) (2017)
Uygunoğlu et al. 2.77 Singh et al. 2.67 3500
(2014) (2017)

is between 2.60 and 2.70, and the average fineness is between 3000 and 4000 cm2/
g, as seen in Table 6.1.

6.2.2 Chemical composition of waste marble powder/dust

Chemical analysis and quantitative mineralogical characterizations of the WMP
usually are done using X-Ray Diffraction. Table 6.2 presents the chemical composi-
tions of the WMPs were used in many different studies. When the distribution of
the main components in the table is examined, it is noted that the amount of cal-
cium oxide (CaO) is almost the highest amount of each powder. When the minor
Table 6.2 Chemical components of waste marble powder
References Chemical components (%)

Main Minor LOI

CaO Fe2O3 Al2O3 SiO2 MgO Na2O K2O SO3

Agarwal and Gulati (2006) 30.80 0.80 1.95 3.01 19.27 43.40
Binici et al. (2007) 50.13 1.98 0.40 5.10 2.72 35.50
Saboya et al. (2007) 49.82 1.96 0.30 4.30 2.64 40.80
Alyamaç and Ince (2009) 54.55 0.32 4.17
Topcu et al. (2009) 51.80 0.03 4.67 0.40
Demirel (2010) 40.45 9.70 0.42 38.35 16.25
Aruntaş et al. (2010) 54.43 0.08 0.12 0.67 0.59 0.14 43.40
Hebhoub et al. (2011) 54.86 0.04 0.08 0.15 1.03
Uysal and Yilmaz (2011) 55.49 0.12 0.29 0.70 0.23 42.83
Ergün (2011) 51.70 0.44 0.67 0.18 0.40 0.21 0.03 46.04
Belaidi et al. (2012) 52.60 0.20 0.20 1.00 2.10 0.06 0.07 43.63
Gesoğlu et al. (2012) 52.45 0.78 0.39 1.29 0.54 43.90
Uygunoğlu et al. (2014) 51.80 0.03 4.67 0.40 41.16
Aliabdo et al. (2014) 83.22 0.05 0.73 0.52 1.12 0.09 0.56 2.50
Rana et al. (2015) 42.13 2.98 2.20 44.10 3.72 0.08 3.50
Rodrigues et al. (2015) 54.20 0.14 0.32 1.39 0.64 0.04 42.60
Tennich et al. (2015) 49.46 0.66 0.46 7.36 0.23 0.08
Baghel et al. (2015) 49.07 0.21 1.04 1.69 4.47 43.46
Sutcu et al. (2015) 52.90 0.87 3.72 0.76 0.27 41.30
Boukhelkhal et al. (2016) 56.01 0.06 0.13 0.20 0.12 0.43 0.01 42.78
(Continued)
Table 6.2 (Continued)
References Chemical components (%)

Main Minor LOI

CaO Fe2O3 Al2O3 SiO2 MgO Na2O K2O SO3

Kore and Vyas (2016) 33.12 0.13 Traces 3.75 17.91 45.07
Mashaly et al. (2016) 55.32 0.04 0.10 0.15 0.11 0.07 0.13 43.00
El-Alfi and Gado (2016) 55.32 0.04 0.01 0.15 0.11 0.70 0.01 0.13 43.30
Choudhary et al. (2016) 30.41 0.58 0.28 0.61 21.67 0.08 0.03 44.26
Alyamaç et al. (2017) 40.45 9.70 0.17 28.35 16.25 0.04 4.84
Tennich et al. (2017) 49.46 0.66 0.46 7.36 0.23 0.08
Khyaliya et al. (2017) 33.12 0.13 Traces 3.75 17.91 45.07
Singh et al. (2017) 28.63 0.78 4.62 3.86 16.90 43.30
Tekin et al. (2017) 52.20 0.10 0.10 1.80 46.20
Yazicioglu and Kara (2017) 34.20 7.65 15.20 39.40 0.65
LOI, loss on ignition.
Waste marble powder/dust 187

components are examined, it is seen that MgO is dominant. These results are nor-
mal because the marble consist of calcite (CaCO3) and dolomite (CaMg(CO3)2).
Calcium oxide is around 50% of all components for many WMPs.
If wastes are obtained from only one type of marble, the chemical composition
of the waste and the marble will be the same. However, if the waste belongs to
more than one type of marble, then the chemical compositions of the wastes do not
reflect the chemical compositions of the marble blocks individually.

6.2.3 Scanning electron microscope analysis of waste marble

powder/dust
Scanning electron microscope (SEM) is used to analyze the morphology, particle
size, and shape of the materials. The texture and shape of the WMPs obtained from
different marble factories in Turkey are illustrated through scanning electron micro-
graphs as shown in Fig. 6.2. After cutting and polishing of different colored marble
blocks, samples of the marble waste sludge were taken individually for each marble
block, and then WMP/dust was obtained separately for each color. That is why the
marble powders seen in SEM images are named gold, cherry, and white.

Figure 6.2 Scanning electron microscope images of three different waste marble powder:
(A) gold, (B) cherry, and (C) white.
188 Waste and Supplementary Cementitious Materials in Concrete

The WMP has an irregular particle structure and a rough texture (Singh et al.,
2017). Therefore the increased water requirement in the concrete may also be owing
to this characteristic of the WMP. When the WMP compares to river sand that is
used for the concrete, the particle of the sand is smoother (Khyaliya et al., 2017).

6.3 Utilization of waste marble powder/dust in concrete

WMP has been utilized up to now in the production of conventional concrete
(Demirel, 2010), SCC (Alyamaç and Ince, 2007), and polymer concrete (Tawfik
and Eskander, 2006). Studies on polymer concrete are very limited. The main pur-
pose of using WMP in polymer concrete is to reduce the cost of concrete and also
to obtain eco-efficient and economic polymer concrete using WMP (Martı́nez-
Barrera and Brostow, 2010). However, WMP/dust is most commonly utilized in
conventional and SCC.
WMP is used in the conventional concretes by replacing very fine aggregate,
sand or cement (Corinaldesi et al., 2010). In addition, it is utilized in SCC as a min-
eral additive by replacing either cement or aggregate. In any case, fresh and hard-
ened concrete and also durability properties vary, as the amount of the WMP
increases in the concrete. When producing the concrete, WMP can be used alone or
in combination with other powder materials such as fly ash, silica fume, and lime-
stone powder (Uysal and Sumer, 2011).

6.3.1 Fresh properties of concrete

The workability of fresh concrete decreases, as long as the amount of WMP in the
concrete increases. Since the amount of waste powder increases, the water require-
ment of the concrete increases. Therefore if the amount of the WMP increased, but
besides the amount of water remains constant, the workability decreases (Alyamaç
and Aydin, 2015). The extent of this decrease depends on many parameters, such as
water-to-cement ratio, maximum aggregate size, the amount of cement and particle
size distribution of aggregate. While conventional concrete is produced, if the
WMP is replaced with sand, the changes in the amount of slumps in the fresh con-
crete will be bigger (Fig. 6.3A). These changes are less for the concrete produced
by replacing with cement (Fig. 6.3B). The reason for this is that the amount of
WMP used in the concrete produced by replacing with sand is less than that of con-
crete produced by replacing with cement. In some researches shown in Fig. 6.3, due
to the use of chemical additives, the slumps have remained constant or have
increased.
The fresh concrete properties of the SCC almost make up the main production
purpose of this type of concretes. The most significant proof of this is the determi-
nation of fresh concrete properties by several test methods such as slump flow,
T-50 (flow time for fresh concrete to reach the diameter of 50 cm) and V-funnel.
It is hard to explain on the workability of SCC with only the amount of WMP. In
Waste marble powder/dust 189

(A)
Binici et al. Alyamaç and Vijayalakshmi and
200 (2007) Aydin (2015) Sekar (2013)
175
150
Slump (mm)

125
100
75 2
50
25
0
0 5 10 15 20 25 30
Waste marble powder/dust (%)
(B)
Rana et al. Sardinha et al. Singh et al.
160 (2015) (2016) (2017)

140
Slump (mm)

120

100

80

60
0 5 10 15 20 25 30
Waste marble powder/dust (%)

Figure 6.3 Fresh concrete behavior in conventional concrete produced with waste marble
powder by replacing (A) sand and (B) cement.

SCC, the amounts of WMP, cement, water, and chemical additives are effective
together on the workability. In addition, Alyamaç et al. (2017) have taken into
account the marble-to-cement and water-to-cement ratios and graphically have
showed how these parameters affect the fresh concrete properties (Fig. 6.4).

6.3.2 Strength properties of concrete

WMP affects the compressive strength of the concrete due to the filler effect
(Demirel, 2010). In conventional concrete, this effect is not significant when the
WMP is replaced with sand (Fig. 6.5A), but it is bigger when it is replaced with
cement (Fig. 6.5B). In the concretes produced by replacing cement with WMP, the
amount of binder decreases as the amount of WMP increases, so the compressive
strength declines significantly. Because WMP is an inert material, there is no poz-
zolanic effect of WMP on the first and following age of compressive strength of the
concrete. Generally, as the amount of WMP increases, the compressive strength
Figure 6.4 3D plot indicating interaction effects of W/C and M/C on (A) Slump flow, (B) T-50, and (C) V-funnel (Alyamaç et al., 2017).
Waste marble powder/dust 191

(A)
Binici et al. (2007) Demirel (2010) Ural et al. (2014)
Alyamaç and Vijayalakshmi and Aliabdo et al. (2014)
Aydin (2015) Sekar (2013)
Compressive strength (Mpa)

55
50
45
40
35
30
25
20
15
0 5 10 15 20 25 30 35
Waste marble powder/dust (%)
(B)
Rana et al. (2015) Rodrigues et al. Ergün (2011)
(2015)
Bacarji et al. Aliabdo et al. Singh et al. (2017)
Compressive strength (Mpa)

45 (2013) (2014)

40
35
30
25
20
0 5 10 15 20 25 30
Waste marble powder/dust (%)

Figure 6.5 Hardened concrete behavior in conventional concrete produced with WMP by
replacing (A) sand and (B) cement.

also increases up to a certain amount, then the strength decreases. This WMP value,
in which is obtained the maximum compressive strength, is expressed as the opti-
mum value. However, this behavior and optimum value vary according to the
amounts of the concrete mixture. In addition, the splitting and bending strengths’
behaviors of the concretes produced using WMP are similar to those of the com-
pressive strength behaviors (Uygunoğlu et al., 2014).
In SCC, WMP is not effective on the strength of the concrete as much as on the
properties of the fresh concrete. The efficiency of WMP is generally expressed
regards marble-to-cement ratio. Alyamaç et al. (2017) have emphasized the
marble-to-cement and water-to-cement ratios are the most efficient parameters on
the compressive strength of SCC, and graphically have showed how these para-
meters affect the hardened concrete (Fig. 6.6). When this graph is taken into
account, it seems to be an optimum zone, not just an optimum point, for WMP to
utilize in SCC.
192 Waste and Supplementary Cementitious Materials in Concrete

Figure 6.6 3D plot indicating interaction effects of W/C and M/C on the 28-day
compressive strength (Alyamaç et al., 2017).

While WMP is utilized in the SCC, following important points should not be
overlooked. There is no significant contribution of WMP to the increase of the
compressive strength of the concrete. Besides, even when too much WMP is used
in SCC, it does not affect substantially of reducing the compressive strength. As a
result, an eco-efficient concrete which has aimed fresh and hardened properties, can
be produced using WMP.

6.3.3 Durability properties of concrete

The highly popular performance measure that is used by civil engineers to deter-
mine hardened property of concrete is the compressive strength. Technically, there
is an assumption that the high values of the compressive strength of concrete usu-
ally denote proper or at least adequate durability properties of concrete, and the
researchers have supported this (Binici et al., 2008; Topcu et al., 2009). However,
the durability properties, such as sulfate resistance (Sadek et al., 2016), abrasion
resistance (Alyamaç and Aydin, 2015), water permeability (Sardinha et al., 2016),
porosity (Demirel, 2010), sorptivity (Gesoğlu et al., 2012), chloride penetration,
corrosion (Rana et al., 2015), carbonation depth, and electrical resistivity (Gesoğlu
et al., 2012) have been examined for the concrete produced with WMP by the
researchers.
The researchers produced the concrete that contained WMP with different ratios,
and these were compared with the reference concrete without WMP. For almost all
concretes, the durability increased as the compressive strength increased. The
Waste marble powder/dust 193

majority of researchers utilized WMP in the concrete by replacing sand or cement

between 20% and 30% (Arel, 2016). These amounts are very close to optimum
values for the rate of filler material used in concrete. For this reason, the common
opinion of the literature is that the durability values of concrete produced using
WMP at optimum quantities are better than those of reference concrete.
As the amount of WMP used in the concrete increases, the air void ratio in the
concrete decreases. After the optimum value, the WMP begins to lose its positive
effect due to the increase of the air void ratio (Alyamaç and Aydin, 2015).
However, this positive effect continues until the value of the property being investi-
gated reaches the value of the reference concrete. The decrease in the air void ratio
means that the water permeability is reduced. When the water permeability of con-
crete decreases, the freeze thaw resistance increases. Likewise, when the air void
ratio decreases and the compressive strength increases, the sulfate and abrasion
resistance increase. As a result, at optimum amounts, WMP positively affects the
durability properties of the concrete (Gameiro et al., 2014).

6.4 Role of waste marble management for sustainable

environment and construction
The disposal of industrial wastes to nature causes environmental pollution. Marble
wastes both cause significant economic losses and have a great role in environmen-
tal pollution. This pollution is seen in Fig. 6.7. WMP has a broad range of industrial
uses. The WMP is utilized not only as a component of the concrete but also as a
component of other types of construction materials. When the WMP is used to pro-
duce SCC as an additive, this special concrete is more economical, feasible, and
eco-efficient (Alyamaç et al., 2017).
For a sustainable environment, wastes generated as a result of production must
not dispose uncontrollably to the nature. Wastes should be either warehoused or
recycled/reused to prevent environmental pollution. The use of a waste material
such as WMP in the production of another material has two significant contribu-
tions, which are direct and indirect, to the sustainable environment. The direct con-
tribution is the prevention of environmental pollution by consuming waste. The
indirect contribution is to reduce the CO2 emission and the need for natural
resources. WMP is used by replacing with the sand or aggregate. Therefore as the
use of WMP increases in the concrete, the amount of aggregates, i.e., the use of nat-
ural resources, decreases. WMP is also used in concrete by replacing with cement.
Cement is indispensable for construction activity, so it is tightly linked to the global
economy. Cement production accounts for about 5% of global CO2 emissions from
human sources. Decreasing cement requirement means decreasing CO2 release
(Aruntaş et al., 2010).
The use of wastes in the production of new materials to create a sustainable
environment means the production of eco-efficient materials. Eco-efficiency can
be defined as maximizing the efficiency while minimizing the impact on the
194 Waste and Supplementary Cementitious Materials in Concrete

Figure 6.7 Environmental pollution caused by marble wastes.

environment. When WMP is used in the concrete, an eco-efficient concrete is

obtained. Even as the amount of WMP in the concrete increases, the eco-efficient
level also increases (Alyamaç et al., 2017).
The construction sector is constantly developing and using new materials. The
primary reason for this development is the production of sustainable construction
materials. The goal is both to develop new materials and to improve the properties
of existing materials. If the produced or developed materials are economical, the
sector provides significant advantages (Alyamaç and Aydin, 2015). For this reason,
manufacturers prefer the use of waste materials in their present production and new
material research. Materials produced or developed using waste materials are both
economical and eco-efficient.
WMP is usually utilized to improve the properties of existing products in the con-
struction industry and to obtain more economical products. The most important
usage field of WMP is the concrete. If the concrete is considered as a liquid, it is the
most consumed material in the world after water (Alyamaç and Ince, 2007). In fact,
even this amount is an indication for the concrete how much eco-efficient can be.
Concretes produced using WMP prevent environmental pollution and are produced
using less natural resources and energy. For this reason, the concretes produced with
WMP are expressed as eco-efficient in the literature.
Waste marble powder/dust 195

6.5 Conclusions
When considering the total amount of waste produced, marble industry is one of
the sectors that are obtained the most waste from raw materials. In this industry, the
amount of waste produced during marble processing is almost 50% of the volume
of a marble block. For a sustainable environment, waste product of marble indus-
trial has to be used as raw material in other industries. Taking into account the
amount of the waste how big it is, the concrete industry is the most appropriate sec-
tor for reusing of WMP.
The usage of WMP in the concrete at optimum ratios positively affects the fresh and
hardened properties of the concrete. In addition, since both natural resources and
energy are used little, a more economical concrete is obtained. Finally, the use of WMP
in the construction industry will help to decrease environmental pollution and economic
costs. Thus the utilization of WMP in the concrete has the huge potential to be highly
beneficial for sustainable construction technologies and eco-efficient concrete.

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