Abstract
This study investigates ceramic bricks produced by partially replacing clay with Pb–Zn metallurgical residues (lead furnace dust and cyclone dust), fly ash, and carbonaceous additives. The novelty lies in the integrated multi-waste formulation and the combined FTIR–TGA–XRD analytical approach used to elucidate phase-formation mechanisms. The results show that firing promotes the development of quartz, mullite, iron oxides, and an extensive Fe–Pb–Zn–Si–O amorphous network, while higher residue contents enhance amorphization and suppress mullite crystallization. These microstructural changes correlate with reduced compressive strength (1.6–3.1 MPa) and high water absorption (32–36%), although all samples completed 15 freeze–thaw cycles. Heavy-metal leaching assessed by atomic absorption spectroscopy (AAS) revealed very low Pb (0.08–0.20 mg/L) and Zn (0.25–0.45 mg/L) release, well below international safety limits, demonstrating effective immobilization of hazardous ions within the glassy matrix. Overall, the study provides new insight into multi-waste interactions during sintering and confirms that controlled residue incorporation enables environmentally safe, non-load-bearing ceramic materials with reduced clay consumption.