Effect of Mechanically Activated Nepheline-Syenite Additive on the Physical–Mechanical Properties and Frost Resistance of Ceramic Materials Composed of Illite Clay and Mineral Wool Waste

Abstract

This study investigates the coupling effect of mechanically activated nepheline-syenite (NS) and mineral wool melt waste (MWMW) on the physical–mechanical properties of a ceramic body. The results indicate that an optimal amount (10–20%) of NS additive promotes the formation of the smallest pore size from 0.001 to 0.01 µm, as well as improves physical, mechanical, and durability properties of the ceramic samples with MWMW, when fired at temperatures between 1000 and 1080 °C. As the NS content increases, the composition becomes more alkaline, leading to enhanced vitrification and the formation of a glass phase during firing. This reduces open porosity, modifies pore size distribution, and enhances compressive strength and frost resistance. An NS content of 15% produces the best results, increasing the smallest pore fraction and yielding favourable properties, such as reduced open porosity, water absorption and density, increased compressive strength, and does not affect the linear shrinkage. The frost resistance test demonstrates that the coupling effect of NS additive and MWMW improves the samples’ resistance to freeze–thaw cycles, with the best performance observed at 15% NS content. The study also highlights the usefulness of structural parameters and ultrasound testing for assessing and predicting the frost resistance of ceramic samples.