The microstructure-property correlation of synthetic granite tiles developed from sand garnet

In the present study, garnet sand which is a by-product of beach sand minerals, was utilized as a major raw material to develop single fired "synthetic granite" tiles. A series of compositions containing garnet sand, clay and feldspar were studied by heating at different temperatures. A hard vitrified product with dense microstructure and low porosity was obtained in the temperature range of 1100o-1150°C from an optimum combination. XRD study on the vitrified samples showed the presence of mullite, ferrite spinel and monticellite as major phases. Presence of these phases contributed towards superior hardness, abrasion resistance and strength development. SEM studies revealed the presence of strongly interlocked crystals of mullite and feroan spinel embedded in an amorphous glassy phase. Superior physicomechanical properties of the presently developed synthetic granite tiles may suitably replace costly natural granite tiles for application in building industries