Effects of fly ash additions on the mechanical and other properties of porcelainised stoneware tiles

The effect of fly ash additions on the mechanical properties of porcelainised stoneware tile composition has been investigated. Fly ash additions in the range of 0–40 wt% have been added in to the tile body composition, wet milled, spray dried, shaped and fired at 1250°C. The MOR strength improved with increasing fly ash content and reached maximum when 25–30 wt% fly ash used, and with greater additions it decreased. A linear correlation between strength development and mullite formation was found. The tiles with 25 wt% fly ash had improved bending strength, abrasion resistance and hardness compared to the conventional tiles and conform to all other properties at an EN standard specification.