A COMPARATIVE STUDY

A rc h i t H a l di a
OF FLY ASH BRICKS 1 10 9 0 43 34
M N I T, J a i p u r

MADE BY DIFFERENT
GUIDELINES WITH
UTILIZATION OF WASTE
AGGREGATES Under the
s u p e r v ision o f :

D r. Sa n de e p
Choudhary
D r. Sa n de e p
S h ri va st ava

M s . Sum a ra j
 OVERVIEW

Introduction
Objective
Review of Literature
Motivation
Methodology and Experimental Setup
Results and Discussion
Conclusion
References
 INTRODUCTION

Bricks have been mainly produced from clay and shale since
decades. The continuous extraction of clay and the removal of
the topsoil for brick manufacturing cause substantial
depletion of natural resources.
It is estimated that nearly 8 -10% of the total production of
fired clay bricks is discarded and thus there is a need to use
this waste resourcefully. The production of these bricks not
only consumes natural resources but are also a significant
source of air pollution.
Indian Construction Industry generates nearly 10-12 million
tonnes of waste annually [IL&FS ].
Owing to all these shortcomings we need an alternate and
eco-friendly method of producing bricks.
 INTRODUCTION

There have been numerous attempts to incorporate wastes

into the production of bricks for example, saw dust ash, fly
ash, rice husk ash, sludge, limestone dust etc.
One such way is the use of Compressed Fly Ash Bricks which
is present scope of study.
Fly ash is the fine residue composed
of unburned particles that get
solidified while they are suspended
in exhaust gases. Currently more
than 100 million tonnes of fly ash
is produced annually and 65000
acres of land is used to dispose
using ash ponds.
 OBJECTIVES

The present study analyses production of bricks by compression

with the use of fly ash with stone dust while replacing stone dust
with Crushed Brick Aggregates in different proportions thus,
making a comparative study between NTPC standard bricks,
Commercial Bricks and bricks made by a combination of fly ash,
brick dust and stone dust.
Commercial bricks which are being made do not follow the NTPC
guidelines given but have an altogether different approach while
making these fly ash bricks.
The guidelines followed commercially have also been discussed
as well as the change in properties of bricks made commercially
and 100% replacement of stone dust in these bricks have been
analysed in the present study.
Tests such as compressive test, warpage test, water absorption
test, Efflorescence Test, Hardness Test, Soundness Test, SEM and
EDS tests were carried out in the present research.
 REVIEW OF LITERATURE

Sl.No. Title of the Paper Author Key Points

1. Reuse of waste Ismail Demir explored the outcome of reusing
bricks in the and Mehmet of waste brick material on the
production line. Orhan (2003) durability and mechanical
qualities of the bricks.
Different ratios of the waste (0,
10, 20 and 30 % by mass) were
utilised to the raw-brick clay.
The findings indicate that at a
mass of 30 % fine-waste
material additive, sintered at
900 0C , the test specimen has
an adequate compressive
strength of 7.85 MPa and Water
Absorption of 18.4 %.
 REVIEW OF LITERATURE

Sl.No. Title of the Paper Author Key Points

2. Effect of fly ash and Kute and studied the bricks
temperature on Deodhar manufactured in laboratory
properties of burnt (2003) using class F y ash and clay.
clay bricks The results showed that the
addition of y ash augmented
the compressive strength and
reduced the water absorption of
bricks.
The highest compressive
strength of 12.4 MPa (an
average of eight samples) was
gained at 40 % y ash content,
with the parallel water
absorption being 13.8 % at
1000 C.
 REVIEW OF LITERATURE

Sl.No. Title of the Paper Author Key Points

3. High performance Obada Kayali manufactured bricks whose
bricks from fly ash (2005) solid component is 100% fly ash
firing temperature was between
1000 C and 1300C
they possessed excellent
compressive strength greater
than 40 MPa and Water
Absorption Capacity of 10 %
4. Study on fired Xu Lingling et examined the outcome of y
bricks with al., (2005) ash with higher substituting
replacing clay by fly ratio of clay on ring factors and
ash in high volume quality of bricks.
ratio a maximum compressive
strength of 50 MPa at 1000C
with composition of 50:50 Fly
ash to clay.
 MOTIVATION

The reason behind carrying out this research is

Recycling of waste brick aggregates
Production of eco - friendly bricks by curbing the use of natural
resources
Utilization of fly ash
Reducing air pollution and other wastages during firing
Reduction in the usage of mortar due to uniform shape
Extensive research hasnt been done in this sector while these bricks
are being used commercially.
 METHODOLOGY AND EXPERIMENTAL
SETUP
MATERIAL PROPERTIES
Fly Ash - Large quantities of fly ash are generated as an unwanted
secondary product in thermal power stations which use pulverized
coal as a fuel source. The current formation of fly ash is around 140
million tons every year and with the commissioning of super thermal
power plants and with the expanding utilization of poor quality coal
of high ash substance, the fly ash production is probable to stretch to
around 170 million tons by 2020 A.D.
 Sl Sieve Weight Percentage Percentage Cumulative

.No. No. Retained Retained Passing Percentage

(grams) (grams) (%) Retained (%)

1. 2.36 0 0 100 0

mm

2. 1.18 3 0.6 99.4 0.6 EDS shows that fly ash used
in this case is Class C fly
mm
ash with a min 50% SiO2
3. 600 m 3 0.6 98.8 1.2
plus Al2O3 plus Fe2O3.
Sieve analysis concludes IS
code specification for
4. 300 m 20.5 4.1 94.7 5.3
particles retained on 45
micron IS sieve - minimum
34%.
5. 150 m 38 7.6 87.1 12.9

6. 75 m 107 21.4 65.7 34.3

7. 45m 112 22.4 43.3 56.7

Pan 43.3 - -
 STONE DUST

All plants use locally available sand/ stone dust. The sand
used for the experimental works is locally procured and
conformed to grading zone 3 (IS 383 ). In the present study
stone dust was procured from The Arawali Ranges at Ghat ki
Guni mining area.
Zone of Grading : 3 Sl. No. Sieve No. Weight Percentage Percentage Cumulative

[IS 383] Retained Retained Passing Percentage

In case of stone dust the
(grams) (grams) (%) Retained (%)
permissible limit for 150
m sieve is increased to
20 % with an extra 5 % 1. 4.75 mm 17.5 1.75 98.25 1.75
allowance permitted.

2. 2.36 mm 171 17.1 81.15 18.85

3. 1.18 mm 184 18.4 62.75 37.25

4. 600 m 125 12.5 50.25 49.75

5. 300 m 98 9.8 40.45 59.55

6. 150 m 170.5 17.05 23.4 76.6

7. 75 m 156 15.6 7.8 92.2

Pan 78 7.8 - -
 SLUDGE LIME

It is a paper and pulp industry waste product which contains

high amount calcium hydroxide.
As hydrated lime is much costlier as compared to sludge lime
whereas there isnt much dif ference in the strength of fly ash
bricks, sludge lime is used in the present investigation.
There are some recommendation for the use of lime sludge
i.e. it should be free from extraneous materials, lumps etc. to
the degree imaginable which were followed in the analysis.
 WASTE BRICK AGGREGATES

The waste bricks used in this study was taken from the brick
kilns where bricks are broken during handling, drying and
transportation.
To turn these bricks into aggregates, these bricks were broken
down using a jaw crusher as shown in figure .
After passing through jaw crusher then the material was
passed through a roll crusher as shown in figure.
S.No. Sieve Weight Percentage Percentage Cumulative

No. Retained Retained Passing Percentage

(grams) (grams) (%) Retained (%)

1. 2.36 58 5.8 94.2 5.8

mm

2. 1.18 186 18.6 75.6 24.4

mm

3. 600 m 157 15.7 59.9 40.1

4. 300 m 75 7.5 52.4 47.6

5. 150 m 72.5 7.25 45.15 54.85

6. 75 m 265 26.5 18.65 81.35

7. 45m 156 15.6 3.05 96.95

Pan 30.5 3.05 - -

This provides us with fine waste
aggregates as shown and thus can be used
as a replacement of sand in the present
analysis. Sieve Analysis was also done on
the brick dust used.
 MIX COMBINATION

A total of six mix combinations were considered and tested in

the present investigation .
These bricks were produced according to NTPC standard
stating Guidelines for Manufacturing Quality Fly Ash Bricks
and the commercial guidelines.

Waste Brick
Aggregates Fly Ash Sand
Designation (%) (%) (%) Lime

NTPC 0 60 30 10
BA10S20 10 60 20 10
BA20S10 20 60 10 10
BA30S0 30 60 0 10
COMM 0 25 65 10
BA65FA25 65 25 0 10
 METHODOLOGY

It starts with grounding lime with optimum amount of water in

the pan mixer till it becomes a paste without any lumps.
Required quantity of ash and sand/stone dust are then added
to the pan-mixture and mixed until it forms a homogenous
mixture.
The raw materials are thoroughly mixed in the pan mixture
for at least 3 5 minutes to ensure uniform and homogenous
composition with consistency in colour too.
This mixture is then transferred to the moulding machinery
which is then compacted through a hydraulic press.
Finished bricks are dried for about 1 2 days. Water curing is
then done for a minimum period of 14 days to allow the
required strength to be achieved. Curing is done by sprinkling
water either physically or mechanically.
 EXPERIMENTAL TEST SET UP

Compressive Strength
Water Absorption Test
Ef florescence Test
Warpage Test
Shape and Size Test
Hardness Test
Soundness Test
FESEM and EDS test
XRD test
 FESEM AND EDS TEST

A representative portion of the samples was sprinkled onto

double-sided carbon tape mounted on a FESEM stub.
After placing the sample on the stub, it is placed inside a
plasma sputter coating machine as this helps in better
imaging during FESEM test.
These stubs are then kept inside the FESEM machine for
imaging.
 XRD TEST

XRD test is conducted in a X -RAY Dif fraction testing machine.

The test sample is poured on a metal chip with a rectangular
carbon box on one side on which sample is poured.
The powdered sample is levelled and then kept inside the
dif fraction analysis machine.
 RESULTS AND DISCUSSION

COMPRESSIVE STRENGTH : The minimum strength needed in

these bricks is 3.5 N/mm2, three brick specimens namely,
NTPC (NTPC standard), BA10S20 (10 % replacement of sand
with brick aggregates) and COMM (Commercial bricks) satisfy
the requirements set by the IS Code.
Brick Designation Average Compressive Strength of bricks

(in N/mm2)
NTPC
4.48

BA10S20
3.87
BA20S10
2.74
BA30S0
2.24
COMM
13.08
BA65FA25
3.2
 COMPRESSIVE STRENGTH

The compressive strength decreases as we increase the

percentage of brick aggregates i.e. brick dust into the mix.
 COMPRESSIVE STRENGTH

The compressive strength decreases as we increase the

percentage of brick aggregates i.e. brick dust into the mix .
As we increase the amount of Brick Aggregates in the mix i.e.
making BA20S10 and BA30S0 (100 % replacement), the
strength decreases considerably.
There was a drastic change in the compressive strength when
100 % replacement of sand was carried out in the commercial
brick samples containing 25 % fly ash and 65 % stone dust
with 10 % lime as binder. BA65FA25 fail the minimum
compressive strength requirements set by the Indian Standard
with the percentage change between the commercial bricks
and these BA65FA25 being 308.75 %.
 WATER ABSORPTION TEST

The maximum water absorption permitted through Indian

Standard is 20 %, therefore only three brick specimens qualify
this condition namely, NTPC (NTPC standard specimen),
BA10S20 (10 % replacement of brick aggregates) and COMM
(Commercial Bricks).
Brick Designation Average Water Absorption of bricks (in %)

NTPC
17.59

BA10S20
19.75

BA20S10
21.57

BA30S0
21.75

COMM
11.22

BA65FA25
17.23
 WATER ABSORPTION TEST

Water absorption increases as we increase the amount of

waste brick aggregates as these aggregates have a high water
absorption amount.
The commercial brick specimen COMM has the least water
absorption of 11 .22 % which is well below the Indian standard
maximum of 20 % and thus are considered excellent bricks .
After 100 % replacement of stone dust in this specimen by
brick aggregates, the increase in water absorption percentage
is 6.01 %.
 EFFLORESCENCE TEST

The brick specimens were tested for ef florescence by

measuring the salt deposits over the samples which were
immersed in water with the depth of immersion being 25mm .
The maximum ef florescence permitted by IS 13757 (1993)
shall not be more than moderate up to class 12.5. Therefore,
all the bricks qualify this requirement set by the Indian
Standard.
Brick Designation Average Efflorescence of bricks

NTPC
Nil

BA10S20
Nil
BA20S10
Nil
BA30S0
Slight
COMM
Nil
BA65FA25
Slight
 EXPERIMENTS

WARPAGE TEST: In all the brick samples tested, there was

neither Convex nor Concave Warpage present. This is due to
the fact that these bricks were produced using a compression
machine which compacts the molecules together in a mould
producing a smooth rectangular surface.
SHAPE AND SIZE TEST: All the brick specimens qualify this
requirement of the Indian Standard. The brick samples
namely NTPC and COMM produce the exact dimensions as
specified under IS 13757 for fly ash bricks.
SOUNDNESS TEST: All the brick specimens produce a clear
ringing sound when struck against each other expect the brick
specimens with 20 % and 30 % replacement of stone dust by
waste brick aggregates which fail in this test.
FESEM TEST
 Judgement based on four aspects: texture, porosity, bonding due to fibrous structure
There are bonds formed by Sludge Lime shown as fibrous structures present on the
figure.
As the amount of pores as well as the size of pores increases, the density of fibrous
structures due to sludge lime has decreased considerably as well resulting in its
greater water absorption and decreased strength.
Rounded fly ash particles decrease the amount of fibres present.
As we increase the amount of Brick aggregates, the porosity of the bricks increases.
 FUTURE SCOPE OF STUDY

The investigation of utilizing brick waste aggregates as 100 %

replacement of natural clay in fired bricks.
The utilization of brick waste in commercial fly ash
compressed bricks at lower substitution levels, i.e. partial
replacement of stone dust or sand.
The influence of lime at higher percentages should be
examined.
For NTPC guidelines the percentage of Fly Ash can be
substituted with Waste Brick Aggregates.