Abstract
The valorization of industrial solid wastes into construction materials represents an important pathway toward resource efficiency and carbon reduction in the building sector. In this study, sustainable kaolinitic clay-based ceramics were developed using ternary blends of steel slag (SS), coal fly ash (CFA), and recycled waste glass bottle-derived powder (WGBP). The effects of WGBP content and firing temperature on phase evolution, microstructural development, densification behavior, and key physico-mechanical properties were systematically investigated. The results show that at intermediate temperatures (1000-1100 °C), the addition of 5 wt% WGBP promotes liquid-phase sintering, leading to enhanced densification, reduced water absorption, and compressive strengths up to 44 MPa, whereas higher glass contents at elevated temperature induce over-fluxing and pore entrapment, reducing strength despite comparable density. XRD, FTIR, and SEM analyses confirm the progressive vitrification and structural reorganization of the aluminosilicate matrix. The sustainability assessment identifies the 5 wt% WGBP formulation as the most balanced option, combining adequate mechanical performance with lower energy demand and CO(2) emissions. Overall, the proposed approach provides a technically viable and resource-efficient route for the integrated utilization of multiple industrial wastes in construction ceramics.