Bull. Soc. géol. France, 2013, t. 184, no 3, pp.

267-272

Use of alumina phosphate waste to produce building materials

MABABA DIAGNE1,2

Key-words. – Fines, Alumina phosphate, Refractory materials, Sodium silicate, Formulation, Bricks.
Abstract. – The generation of a fine fraction of sedimentary alumina phosphate before the manufacturing process of
phosphoric acid –used as fertilizer– poses a crucial environmental issue related to the large quantities of fines stored for
a long time in the wildlife without treatment or recycling in the region of Thiès in Sénégal by the Industries Chimiques
du Sénégal (ICS) and the Société Sénégalaise des Phosphates de Thiès (SSPT). This work deals with the use of the fines
particles of phosphate generated by the physical processing (crushing, transport and screening) of the raw material by
the both mining companies. These fines particles of phosphates cover all the fauna and flora surrounding the sector with
whitish dust particularly during the Harmattan, a hot and dry wind, while they can be leached during the rainy season to
contaminate groundwater and then cause diseases to the populations who drink that water. Indeed, these materials,
which are stored in large quantities as “waste”, and which pollute, the space and the environment, can be recycled as re-
fractory materials useful in manufacturing such as bricks or paving blocks. The purpose of this study is to find, from
these discarded fines that are not yet processed, a good and new material in terms of physical and mechanical character-
istics that will meet a customary standard. This will allow not only to reduce their potential hazard by reducing the pol-
lution for the consumption of the fines in order to generate a useful material especially in the surrounding villages of the
mining sector, but also to employ young people in working age in this fines recycling process, to create jobs and
therefore additional economic resources that allow a better life because the majority of the youngsters from these areas
are unemployed.
The formulation of a well-known mixture containing fines of sedimentary alumina phosphate of particles size
ranging between 0.063 mm to 5 mm, with chemical composition similar to that of volcanic slag, sodium silicate called
water-glass as binder of mineral elements; and water, led to the manufacturing of geomaterials blocks with
20×10×6 cm3 size by baking them several hours on an oven at the constant temperature of 225oC. The sodium silicate
density was 1.4.
Good mechanical and physical characteristics were achieved through systematic testing. Strength splitting rup-
ture tests, total water content determination, size measurements of the blocks (length, width and thickness) as well as
the loss on ignition on ambient atmosphere were achieved on the blocks after treatment for a complete identification.
Average values of 3.03 MPa and 2.5% were obtained as results respectively for the splitting rupture strength and for the
total water content. Negative variations of –2.05 mm, –0.59 mm and 1.69 mm on average values were obtained respecti-
vely on their length, their width and their thickness for a value of 5.30% of loss on ignition. The blocks are exposed on
the fire on their upper surface whilst the heating effect falls of rapidly at the other side. The deduction of the compres-
sive resistance strength from the average value of splitting rupture gave a value of 40.5 MPa. This value testifies very
good mechanical resistance strength of the material which is made by the fines of phosphate. These characteristics ob-
tained are compared here to the European Standard values EN 1338 for paving blocks. The values obtained for all the
tests attest good manufacturing material. This new material can also be used as refractory materials in the ovens and in
pottery materials.

Utilisation de déchets de phosphate d’alumine pour produire des matériaux de construction

Mots-clés. – Fines, Phosphates d’alumine, Matériaux réfractaires, Silicate de sodium, Formulation, Briques.
Résumé. – La génération de fines de phosphate d’alumine sédimentaire avant le processus de fabrication de l’acide
phosphorique utilisé comme engrais, pose un problème environnemental crucial. En effet, dans la région de Thiès au Sé-
négal, de grandes quantités de fines sont stockées dans la nature durant de longues périodes sans traitement préalable ou
recyclage par les Industries Chimiques du Sénégal (ICS) et la Société Sénégalaise des Phosphates de Thiès (SSPT).
L’objectif de ce travail est de valoriser ces rejets par l’utilisation de ces fines de phosphate d’alumine sédimentaire gé-
nérées par le traitement physique (concassage, transport et criblage) du tout-venant de phosphate d’alumine. Pendant
l’Harmattan, un vent chaud et sec, ces particules fines recouvrent de poussière blanchâtre toute la faune et la flore envi-
ronnantes du secteur. Ces particules peuvent être lixiviées pendant la saison des pluies pour contaminer la nappe phréa-
tique et ainsi engendrer des maladies chez les populations qui utilisent ces eaux. En effet, ces matériaux stockés en très
grandes quantités comme des « déchets », qui polluent la vue, l’espace et l’environnement, sont recyclés pour produire
des blocs de matériaux réfractaires qui seront utilisés dans la construction comme des briques ou des pavés autoblo-

1. Institut des Sciences de la Terre, Faculté des Sciences et Techniques Université Cheikh Anta DIOP de Dakar, BP. 5396 Dakar-Fann, Sénégal, Tél.: +221
33 825 25 30, Fax: +221 33 824 63 18, Sénégal, Email: mababad@yahoo.fr
2. Université Paris-Est Marne-la-Vallée, Laboratoire Géomatériaux et Environnement, 5 Boulevard Descartes, Champs-sur-Marne, 77454 Marne-la-Vallée
cedex 2, Fax: +33 1 49 32 91 37 France, Email: mababa.diagne@univ-mlv.fr
Manuscript received on November 3rd, 2011 ; accepted on April 28, 2012.

Bull. Soc. géol. Fr., 2013, no 3

268 DIAGNE M.

quants. Le but de cette étude est donc de trouver à partir des ces fines rejetées avant traitement, un nouveau matériau qui
répondra à une norme bien connue en termes de caractéristiques physiques et mécaniques et permettant: (1) d’une part
la réduction de leur degré de nuisance par leur consommation pour générer un matériau utile surtout au niveau des villa-
ges environnants du site minier et (2) d’autre part de faire travailler les jeunes dans ce processus de recyclage des fines
pour générer des emplois et par la même occasion des ressources additionnelles leur permettant de vivre dans de meil-
leures conditions.
Ainsi, une formulation d’un mélange bien défini contenant ces fines de phosphate d’alumine sédimentaire de
composition chimique variée mais semblable à celle de scories volcaniques du point de vue chimique (taille des particu-
les comprise entre 0,063 mm et 5 mm), du silicate de sodium (comme liant d’éléments minéraux) et de l’eau, a permis
la confection de blocs de matériaux de 20×10×6 cm3 de dimensions par cuisson durant plusieurs heures au four pour une
température constante de 225 oC. La densité du silicate de sodium est de 1.4.
De bonnes caractéristiques mécaniques et physiques ont été obtenues grâce à des essais sur ces matériaux. Des es-
sais de résistance à la traction par fendage, des mesures de la teneur en eau d’absorption totale, des mesures des dimen-
sions des blocs (longueur, largueur et épaisseur) ainsi que de perte au feu en milieu ambiant ont été réalisés sur ces
blocs après leur cure pour une caractérisation complète. Des valeurs moyennes de 3,03 MPa et 2,5 % ont été respective-
ment obtenues en résistance à la traction et en teneur en eau d’absorption totale. Des variations négatives de –2,05 mm,
–0,59 mm et –1,69 mm en moyenne ont été obtenues respectivement sur la longueur, l’épaisseur et la largeur des blocs
pour une valeur moyenne de perte au feu de 5,30 %.
La déduction de la résistance à la compression à partir de la valeur moyenne obtenue au fendage donne une valeur
de 40,5 MPa, ce qui se traduit par une très bonne résistance mécanique du matériau. Ces caractéristiques ont été compa-
rées aux valeurs standards données par la Norme Européenne EN 1338 sur les pavés. Ces valeurs obtenues témoignent
d’un bon matériau. Ce nouveau matériau peut également être utilisé comme matériau réfractaire dans les fours et dans la
poterie.

INTRODUCTION
The study area is located in the western part of Senegal
(West of Africa). The geology is dominated by two major
sets: a Precambrian basement in the extreme southeast and
sedimentary formations of the Tertiary and Quaternary in
the centre and the west of the country. This alumina phos-
phate was defined as the wavelite [Flicoteaux, 1982;
Geoter, 2009]. Among these tertiary formations, it can be
noted the existence of a number of phosphate deposits dat-
ing from the Eocene in Matam region in the North-East
[Pascal and Faye, 1989], the phosphate deposits of
Ndendouri-Wali-Diala and the deposits of Lam-Lam and
Taïba in the west of the country [CSE, 2012] (fig. 1). The
exploitation of the latter has been taking place since 1949
and 1960 respectively.
In the area of Lam-Lam, located at 14 km in the
north-east of the region of Thiès, there are also alumina
phosphate deposits, which are the products of lime phos-
phate weathering. This alumina phosphate was exploited re-
spectively by the Société Sénégalaise des Phosphates de
Thiès (SSPT) and the Industries Chimiques du Sénégal (ICS)
in open-pit mine [Pascal and Sustrac, 1989]. Mineable ore
had an average thickness of 10 m for a stripping of 3 m. It
is crushed, calcined to increase the P2O5 content from
28.5% to 34% in situ. Raw alumina phosphate production
was estimated between 180,000 and 280,000 tons between
1949 and 1983. This product is sold under the name of
“Phospal” as fertilizer [Flicoteaux and Hameh, 1989]. Its
chemical formula is Al3(OH)3(PO4)2.5H2O with several im-
purities related to the presence of organic matter and other
chemical elements [Poon and Dixon, 2007]. The material
density is 1.24 g.cm-3 and its pH is 6.8.
Physical processing (crushing or grinding, transport,
braking and screening) of alumina phosphate ore results in
a very large quantity of fine fraction, about 20% of raw mate-
rial. These fines are still stored with no prospective of pro-
cessing or valorization. They cause significant environmental
damages due to the space itself they occupy, but they are
also sources of air pollution, especially during the Harmattan
period characterized by hot, dry and dust-laden winds.
The purpose of this paper is to study how to enhance
the value of these fines of alumina phosphate by making
refractory materials that can be used in construction (bricks
or pottery materials). Many studies have been made on the
enhancement of the value of phosphate waste or recycled
aggregates in construction [Poon and Dixon, 2006; Figueroa
et al., 1987; Ghafoori and Wen, 1993; Negm and Abouzeid,
2008; Tara and Umesh, 2010].
The fines of alumina phosphate recycling can also be a
source of youth employment.
MATERIALS AND METHODS
Materials
Fines of fines of alumina phosphate
Figure 2 shows the size distribution of fines of alumina
phosphate in its zone size according to the European Stan-
dard EN 933-10 [EN 933-10, 2009]. It shows the size distri-
bution of the fines of alumina phosphate. The curve fits
correctly into its size zone. It is obvious that only 10% of
the particles are finer than 0.063 mm, 40% lie in the field
0.063 mm – 0.8 mm and 60% are coarser than 0.8 mm.
From the viewpoint of characterization, physico-chemi-
cal analysis showed a variable composition with the pres-
ence of several major chemical elements. Table I gives the
results of physico-chemical properties compared to those
obtained from slag [Karl, 1952] (table I). The composition
found for these fines is similar to that of aluminous slag
with the exception of P2O5, F2 and organic matter (OM) that
have not been analyzed. The reaction in aqueous solution is
neutral.

Bull. Soc. géol. Fr., 2013, no 3

 USE OF ALUMINA PHOSPHATE WASTE TO PRODUCE BUILDING MATERIALS 269

TABLE I. – Results of the chemical properties of the sample compared to Methods

aluminous slags.
Chemical Aluminous slags Fines of alumina
Element [Karl, 1952] (%) phosphate (%) A mixture consisting of 2 kg of fines of alumina phosphate
P2O5 -- 29.5
smaller than 1.5 mm in diameter, 10% by weight of sodium
silicate (200 g) and 14% of water content (308 g) was vig-
Al2O3 64.5 30.9
orously mixed by a mixer fitted with small blades to obtain
CaO 4.5 9.2 a homogeneous mixture. The material larger than 1.5 mm
Fe2O3 6.75 7.9 was removed to be cleared up of coarse elements. The mix-
SiO2 2.5 2.5 ture was put into molds of 20×10×6 cm3 size in order to
F2 -- 0.7 make the objects similar to bricks or paving blocks. After
MgO 4.5 -- five minutes of casting, the wet bricks were carefully re-
Organic Matter -- 15
moved from the mold and placed in an oven at a tempera-
ture of 225 oC for 24 hours for a good heat distribution
throughout the material. This duration will allow good reac-
tivity of the various components of the mixture to form a re-
fractory material of good quality. Then, these refractory
Sodium silicate materials are cooled for one hour and exposed to the ambi-
ent air of the laboratory. The laboratory ambient tempera-
Sodium silicate also called disodium of metasilicate
ture was 26oC (fig. 3).
(Na2SiO3) of high purity 95% was mixed with the fines of
alumina phosphate with a water content that gives to the
material a plastic consistency for easy handling. It is a com- Tests of tensile splitting failure, water absorption and
pound consisting of crystalline solids soluble in water. So- loss on ignition were carried out on the sample pieces ob-
dium silicate solubility is equal to 200 g.l-1 at 20oC [INRS, tained in order to see their reactivity to mechanical stress,
2006]. It is widely used as a binder in grindstones industry. soaking in water and exposure to fire. The size of the bricks
Its density is 2.6 g.cm -3 and its reaction in aqueous solution was also measured to see the percentage of shrinkage after
is lightly acid (pH = 6.7). the baking phase of our mixture.

FIG. 1. – Geologic map of Senegal, modified (Centre de Suivi Ecologique, 2012).

Bull. Soc. géol. Fr., 2013, no 3

270 DIAGNE M.

– 0.05 mm is obtained compared to the recommended one

that is ± 2 mm.

Water absorption
The refractory blocks were immersed for three days and
then put into the oven for three days to determine the maxi-
mum water that can clog the finished products. Thus, tests
were conducted on a series of eight refractory blocks. The
data are compiled in table III.
The average water content of refractory blocks is
2.95%; this value is less than that required by the standard
EN 1338 which is 6%. It reflects a very low porosity due to
fineness of the phosphate material. The average dry density
of blocks obtained is 2.084 g.cm-3.

FIG. 2. – Particle size distribution curve of the sample in its zone size
(䊏 zone size distribution, 䉱 curve of the sample).
RESULTS AND DISCUSSIONS
Resistance to splitting failure
Tests of tensile strength and size measurements were con-
ducted on a series of four blocks of 20×10×6 cm-3 sizes.
The results are compiled in table II.
In the bottom line they are compared to the reference
value given by the European Standard [EN 1338, 2004,
Tabl. II, page 8] which sets a value normalized to the hy-
draulic concrete paving blocks of the same size. This com-
parison is just indicative. The results in table II show that
the average resistance to splitting of 3.03 MPa was obtained
and it is below the value required by EN 1338. However,
this standard EN 1338 can tolerate up to a limit value of
2.9 MPa. The values of the average found in the splitting
failure can be correlated to the compressive strength
through the equation 1 [BAEL 91, 2000] (Eq. 1).
Rt = 0.6 + 0.06×Rc Eq.1
Rc gives the compressive strength and Rt the tensile
strength. Thus, a theoretical value of 40.5 MPa must be ob-
tained by compression. This value is indicative of the com-
pressive strength we should get in these refractory products.
Table II also shows that variations in the sizes of the
bricks are within the limits required in terms of thickness
and width. An absolute variation value in length of
Loss on ignition
This test was performed to show the behavior of the blocks
produced if used in civil engineering among other uses. A
series of eight samples was submitted to fire in ordinary at-
mosphere. The moisture content of samples was zero. The
results obtained are given in table IV. They show an average
value of loss on ignition of 5.30%. This value is quite high
due to the high amount of phosphate present in the material
(29.5%). Indeed, the phosphorus element is very reactive to
fire, this value of loss on ignition found can be ascribed to
the presence of phosphorus in the new material.
DISCUSSION
Visual, space and environmental pollutions from fines of
alumina phosphate generated by extraction, transportation,
crushing and screening of raw alumina phosphate materials
pose a serious problem in the mining sites of Lam-Lam and
Taïba (Senegal). Nevertheless, the 2003-36 Act of Novem-
ber 24, 2003 of the Senegalese Mining Code in Chapter 82
Clause V [Loi no 2003-36, 2003] requires that “every holder
of mining rights must conduct site rehabilitation at the end
of each mining title...”. This rehabilitation has not been
done since the opening of the mine in the early 50s generat-
ing the storage of fines in large areas from mechanical ac-
tivity but also a dumping of phosphogypsum, a waste of the
phosphoric acid process.
Recycling of mining waste in refractory blocks has
shown promising results. Thus, these results obtained with
splitting failure tests show that these fines material recycled
in blocks, can be used as construction material because the
standard requires that only one value may fall below
2.90 MPa. Table II shows that all values are higher than the
latter.

TABLE II. – Results of splitting rupture and measurements of the size of the blocks.

N° Sample 1 2 3 4 Average ⌬ (mm) ⌬ (mm) EN 1338 Standard EN 1338

Length (mm) 199.26 197.48 197.72 197.34 197.95 -2.05 ⫾ 2 --
Thickness (mm) 59.7 58.96 59.96 59.02 59.41 -0.59 ⫾ 3 --
Width (mm) 97.93 98.30 98.84 98.17 98.31 -1.69 ⫾ 2 --
Breaking load (kN) 85 86 84.7 87.3 92.9 -- -- --
Resistance (MPa) 3.00 3.03 2.99 3.08 3.03 -0.57 -- 3.6

Bull. Soc. géol. Fr., 2013, no 3

 USE OF ALUMINA PHOSPHATE WASTE TO PRODUCE BUILDING MATERIALS 271

will allow unemployed young people to find work in the re-

cycling process. This work will involve the training of the
youth, the creation of blocks production units in villages on
a small scale in the short term.

CONCLUSION

The fines of alumina phosphate released by the ICS and the

FIG. 3. – Procedure of manufacturing blocks of refractory materials.
Poon et al. [2002] showed that the replacement of natu-
ral fines aggregates in concrete material from the waste
from house demolition allows the production of paving
blocks with a compressive strength of 49 MPa. The same
authors showed that the addition of fly ash gave a value of
compressive strength of 30 MPa for brick masonry, corre-
sponding to a value of 2.4 MPa (Equation I, Page 8) in split-
ting failure, a value below that which we obtain (3.03 MPa).
These values obtained in terms of splitting failure
strength, measurement, percentage of total water absorption
and loss on ignition of the rectangular blocks made evi-
dence of the ability to reduce the pollution of the entire area
studied by recycling these fines in creating Economic Inter-
est Groups in the villages surrounding the mining site. It
SSPT and stored in large quantities can be recycled into ma-
terials such as refractory bricks for construction etc. In-
deed, the blocks made provide good mechanical properties
including the splitting failure. A resistance value of
3.03 MPa was found, value correlated to 40.5 MPa in com-
pression and which reflects a good performance in terms of
mechanical resistance of the blocks obtained.
In terms of water absorption, the refractory blocks are
of good behavior in extreme water conditions. Indeed, after
3 days, the blocks were packed of 2.95% water in average.
This value reflects the good reactivity of the different com-
ponents of the mixture during the firing into the oven at
225°C. The reactions between the major chemical elements,
sodium silicate and water have driven the disappearance of
almost all the empty spaces despite a maximum diameter of
the initial material of 3.5 mm.
However, the loss on ignition is not negligible because
the value found is considered quite high due to the presence
of phosphorus in the raw material. These refractory materi-
als from waste phosphate show good mechanical and physi-
cal performance for their use as bricks or paving blocks or
objects in pottery but they can also be tested as refractory
materials in furnaces.

TABLE III. – Results of measurements of water content of the refractory blocks.

N° Sample 1 2 3 4 5 6 7 8 Average Density (g.cm )
3

Weight of wet blocks (g) 2,500 2,498 2,506 2,493 2,524 2,499 2,503 2,489 2,501.5 2.084
Weight of dry blocks (g) 2,436 2,435 2,439 2,419 2,438 2,437 2,415 2,420 2,429.88 2.024
Weight of total water (g) 64 63 67 74 86 62 88 69 71.63 --
Water content (%) 2.63 2.59 2.75 3.06 3.53 2.54 3.64 2.85 2.95 --

TABLE IV. – Results of loss on ignition tests on refractory blocks.

N° Sample 1 2 3 4 5 6 7 8 Average
Weight of blocks before calcination (g) 2,428 2,433 2,440 2,425 2,423 2,429 2,428 2,431 2,430
Weight of blocks after calcination (g) 2,300 2,302 2,297 2,306 2,279 2,306 2,310 2,306 2,301
Loss on ignition (%) 5.27 5.38 5.86 4.91 5.94 5.06 4.86 5.14 5.30

Bull. Soc. géol. Fr., 2013, no 3

272 DIAGNE M.
References
BAEL 91 (2000). – Règles techniques de conception et de calcul des ouvra-
ges et constructions en béton armé suivant la méthode des états
limites – 3e édition. – CSTB, Paris: France 190 p., France.
CENTRE DE SUIVI ECOLOGIQUE C.S.E. (2012). – Carte géologique des grands
ensembles du Sénégal à 1/150 000, modifiée. – Dakar, CSE.
FIGUEROA J.L., ZHOU L. & CHANG W.F. (1987). – Use of phosphate mining
waste in secondary road construction. – Transportation Research
Record, 1, 59-64.
FLICOTEAUX R. (1982). – Genèse des phosphates alumineux du Sénégal oc-
cidental. Etapes et guides de l’altération. – Thèse Sci., Mar-
seille, 1982. – Mém. Sci. Géol. Univ. Strasbourg, 67, 229 p
FLICOTEAUX R. & HAMEH P.M. (1989). – The aluminous phosphate deposits
of Thies, western Senegal. In: A.J.G. NOTHOLT, R.P. SHELDON &
D.F. DAVIDSON, Eds, Phosphate deposits of the world, Phosphate
rock resources. – Cambridge University Press, Cambridge, 2,
273-276.
GEOTER (2009). – Carte géologique de la zone d’activité du Cap-Vert à
1/50 000. Notice explicative de la feuille de Thiès. – 1ère édition. –
Dakar. Formations superficielles et notice explicative par R OGER
J. et al., 2009, 245p.
GHAFOORI N. & W EN F.C. (1993). – Investigation of phosphate mining
waste for construction materials. – J. Mater. Civil Engineering,
5, 249-264.
I.N.R.S. (2006). – Fiche technique. – Institut National de Recherche et de
Sécurité, 256, 4 pages.
KARL A. (1952). – Process for the production of refractory masses of bricks
from slags. – United States Patent Office, n° 2764493.
LOI No 2003-36 (2003). – Code Minier du Sénégal, Dakar, 62 p.
Bull. Soc. géol. Fr., 2013, no 3
NEGM A.A. & ABOUZEID A.Z.M. (2008). – Utilization of solid wastes from
phosphate processing plants. – Physicochem. Probl. Miner. Pro-
cess., 42, 5-16.
NF EN 933-10 (2009). – Essais pour déterminer les caractéristiques géo-
métriques des granulats – Partie 10: détermination des fines –
Granularité des fillers (tamisage dans un jet d’air), P18-622-10. –
Assoc. Franç. Normalisation, Paris, 28 p.
Norme E.N. 1338 (2004). – Pavés en béton. Prescriptions et méthodes
d’essai. – Service d’études sur les transports, les routes et leurs
aménagements. – S.E.T.R.A. Paris, 63 p.
PASCAL M. & M FAYE C. (1989). – The Matam phosphate deposits. In:
A.J.G. NOTHOLT, R.P. SHELDON & D.F. DAVIDSON, Eds., Phos-
phate deposits of the world, 2. Phosphate rock resources. – Cam-
bridge University Press, Cambridge, 2, 295-300.
PASCAL M. & SUSTRAC G. (1989). – Phosphorite deposits of Senegal. In:
A.J.G. NOTHOLT, R.P. SHELDON & D.F. DAVIDSON, Ed., Phos-
phate deposits of the world, 1. Phosphate rock resources. – Cam-
bridge University Press, Cambridge, 1, 233-246.
POON C.S. & DIXON C. (2006). – Paving blocks made with recycled con-
crete aggregate and crushed clay brick. – Construction and Buil-
ding Materials, 20, 569-577.
POON C.S. & DIXON C. (2007). – Effects of contaminants on the properties
of concrete paving blocks prepared with recycled concrete ag-
gregates. – Construction and Building Materials, 21, 164-175.
POON C.S., KOU S.C. & LAM L. (2002). – Use of recycled aggregates in
moulded concrete bricks and blocks. – Constr. Build Mater., 16,
281-289.
TARA S. & UMESH M. (2010). – Usage of industrial waste products in vil-
lage road construction. – Internat. J. Environm. Sci. Developt, 1,
122-126.