Synthesis of a ceramic tile base based on high-alumina fly ash

To effectively utilize the industrial waste of high-alumina fly ash (HAFA), a ceramic tile base was successfully synthesized by the ceramic sintering process. In this research, the influence of HAFA addition and sintering temperature on properties were investigated. The results showed that the presence of ferruginous and calcareous minerals in HAFA decreased the inversion temperature of densification. Moreover, the optimum parameters were obtained at the sintering temperature of 1300 °C for 2 h with 70% HAFA, 15% clay and 15% quartz. In this research, the highest flexural strength reaches 67 MPa, and the corresponding bulk density and apparent porosity values are 2.43 g/cm3 and 0.13%, respectively.