Cement floor tiles based on waste ceramic and waste tires for EMI shielding

Abstract This study explores the valorization of ceramic waste (CW) and waste tire particles in the development of eco-friendly cementitious tiles for outdoor roof shielding applications. CW, sourced from industrial byproducts and demolition debris, offers promising hydraulic properties and cost-effectiveness. Two waste samples, collected during the renovation of sanitary facilities in an aged building and waste iron powder (WIP) were incorporated into cement formulations comprising Portland cement, fine aggregates, water, and recycled materials. The waste components were characterized via particle size distribution analyses which was found in the order of 34.15 μm for waste wall ceramic while it was 49.06 μm for waste floor one. The chemical composition analysis using X-ray fluorescence (XRF) was measured. The bulk density after a cure period of 28 days, water absorption was also evaluated. The compressive strength and flexural strength data revealed enhancement by the addition of WIP particles. This enhancement is attributed to the strong interfacial bonding between WIP particles and the cementitious matrix. Powder X-ray diffraction was used to measure crystalline phase composition. The results demonstrate that ceramic and rubber wastes reduce density and increase water absorption due to enhanced porosity, while the inclusion of WIP significantly improves matrix densification, mechanical strength, and electrical conductivity. Composites containing 10 wt% WIP exhibited optimal performance, achieving enhanced compressive and flexural strengths. Electrical conductivity measurements revealed values ranging from 10− 13 to 10− 11 S/cm, aligning with the requirements for antistatic applications. Consequently, the tiles are recommended for use as antistatic roof shielding materials. Besides, Electromagnetic interference (EMI) shielding tests demonstrated that samples incorporating a metal mesh achieved attenuation levels exceeding 20 dB, effectively blocking over 99% of incident electromagnetic waves. Further enhancement was observed with the addition of waste conducting particles (WIP), suggesting that composites integrating both WIP and metal mesh can achieve EMI shielding efficiencies up to 99.999%, making them suitable for industrial and commercial applications demanding high-performance shielding. The developed tiles comply with Egyptian and European standards for external cement tiles, demonstrating their suitability for sustainable construction applications, particularly for roofing and flooring in environments exposed to electromagnetic pollution. This work highlights an effective pathway for converting multiple waste streams into high-value, multifunctional building materials.