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.
Tuprakay et al. (Sat,) studied this question.