Circular Economy-Driven Sustainable Ceramics: Development and Evaluation of Tiles from Iron Rust-Contaminated Soil for Green Building Applications

The growing demand for sustainable construction materials has spurred interest in the use of industrial waste in ceramic production. This study examines ceramic tiles fabricated from iron-rust-contaminated soil, focusing on their microstructural, mechanical, and aesthetic properties. The material referred to as iron-rust-contaminated soil in this study is an industrial waste-like soil generated during steel recycling processes, rather than a natural soil affected by environmental contamination. It was repurposed as a secondary raw material in the production of ceramic tiles. Chemical characterization revealed hematite (Fe2O3) as the dominant oxide (72.04–78.85 wt%), which imparts the reddish-brown coloration to both raw soil and fired tiles. Various mixing ratios of iron-rich soil with conventional raw materials were evaluated to optimize performance at high-temperature firing (up to 1100 °C). The highest shrinkage (8.97%) was observed in the P 60 formulation at 1100 °C, indicating significant densification. SEM analysis revealed rust particles adhering to soil grains, influencing sintering behavior and microstructural evolution. Mechanical testing showed that increasing iron-rust content reduced flexural strength due to increased porosity, whereas higher firing temperatures improved densification and mechanical properties. The maximum flexural strength recorded was 77.07 kg/cm2 for the P 80 sample fired at 1100 ° C. Water absorption values exceeded 10%, with a modulus of rupture below 7 kg/cm2, conforming to the TIS 2508–2555 standards. The integration of iron-rust-contaminated soil into ceramic tile manufacturing resulted in a 38.3% reduction in greenhouse gas emissions, demonstrating improved environmental performance. This strategy promotes circular-economy products by valorizing industrial waste into sustainable construction materials as a green construction material. Additionally, these tiles feature a decorative, sandstone-like surface, underscoring their potential for architectural applications. These findings demonstrate the feasibility of repurposing iron-rust-contaminated soil as a sustainable raw material for ceramics, thereby promoting eco-friendly waste recycling in the construction industry. Further refinement of composition and firing conditions is recommended to enhance mechanical performance. Iron rust-contaminated soil is used as a sustainable ceramic raw material. The high Fe2O3 content influenced both the color and sintering behavior. Densification and strength are achieved at 1100 °C. Tiles met TIS 2508–2555 standards with a decorative finish. Carbon footprint of a product as a green construction material.