International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number1–Nov 2012
EXPERIMENTAL RESEARCH ON FLY ASH BRICK
J.Chamundeswari, N.Kiroth Kumar, K.Kirubkaran ,S.L.Rajesh
(Department of Civil Engineering, Bharath University, Chennai-73)
ABSTRACT
The discharge of waste of materials causes many problems. The main problems are the
place occupied by sites of storage, importance of costs and the environmental impact. The
main aim of this groundwork is to examine the utilization potential of stone waste as
alternative raw materials in the production of Fly ash bricks. To safeguard the environment,
efforts are being made for recycling different wastes and utilize them invaluable applications.
Stone waste is a widespread by product of industrial processes in India. These wastes pollute
and damage the environment due to sawing and polishing processes. The mixture was
prepared with amounts of 0%,2%, 4%, 6%, 8%, and 10% by weight is replaced with lime
Compressive strength was determined. Results showed that stone waste can be added to Fly
ash bricks
KEYWORDS
Stone Sludge, Natural Resources, Eco-Construction Bricks Sustainability, Waste Re-Use,
Cost Feasibility
INTRODUCTION
Today industry's disposal of the stone waste/Granite powder material is one of the
environmental problems around the world. Stone waste/Granite blocks are cut into smaller
blocks in order to give them the desired shape and size. The principle waste coming into the
stone industry is the stone itself, specifically in the forms of overburden, screening residual,
stone fragments. Stone wastes are generated as a waste during the process of cutting and
polishing. It is estimated that 175 million tons of quarrying waste are produced each year, and
although a portion of this waste may be utilized on-site, such as for excavation pit refill
construction, The disposals of these waste materials acquire large land areas and remain
scattered all around spoiling the aesthetic of the entire region. It is very difficult to find a use
ISSN: 2231-5381
http://www.ijettjournal.org
Page 32
International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number1–Nov 2012
for all scrap stone and fines produced.During the process of cutting, in that original stone
waste/Granite mass is lost by 30% in the form of dust. Every year 250-400 tons of stone
waste/Granite waste are generated on site. So it is necessary to dispose the stone
waste/Granite waste quickly and use in the construction industry.
EXPERIMENTAL MATERIALS
Fly ash
The burning of harder, older anthracite and bituminous coal typically produces Class F fly
ash. This fly ash is pozzolanic in nature, and contains less than 20% lime (CaO). Possessing
pozzolanic properties, the glassy silica and alumina of Class F fly ash requires a cementing
agent, such as Portland cement quicklime, or hydrated lime, with the presence of water in
order to react and produce cementitious compounds
Stone Dust
Stone waste/Granite has been commonly used as a building material. Today industry's
disposal of the stone waste/Granite powder material is one of the environmental problems
around the world. Stone waste/Granite blocks are cut into smaller blocks in order to give them
the desired shape and size. During the process of cutting, in that original stone waste/Granite
mass is lost by 30% in the form of dust Every year 250-400 tons of stone waste/Granite wastes
are generated on site
Lime
Sludge lime which is a by- product of acetylene gas plant can also be used with precautions
as Cao content in this type of lime varies between 25-50% and is available in wet conditions
having lumps. Therefore, each lot of sludge lime should be tested for Cao content and
accordingly its quantity in raw material mix should be adjusted
Gypsum
Commonest of the sulphate minerals ,gypsum is found in marine evaporates ,in caves where the
air is dry enough to allow it to be deposited and remain, at furnaroles ,and in the oxidized zones of
sulfide deposits on occasion.
ISSN: 2231-5381
http://www.ijettjournal.org
Page 33
International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number1–Nov 2012
Water
Water is an important ingredient of brick as it actually used for manufacturing of brick.
Since it helps to bind all the raw materials for giving proper mix. Water used for making brick
should be free from impurities
EXPERIMENTAL METHODOLOGY
The evaluation of lime for use as a replacement of fly ash material begins with the brick
testing. Brick contains fly ash, Lime, Gypsum, sand, water, and stone waste. With the control
brick, i.e. 2%, 4%,6%,8%, and 10% of the lime is replaced with stone waste ,the data from
the stone waste fly ash brick is compared with data from a standard fly ash brick without stone
waste. Five bricks samples were cast having size standard fly ash brick without stone waste.
Five bricks samples were cast having size of 400x100x100mm. The manufacturing process of
bricks broadly consists of three operations viz. Mixing the ingredients mix in the pan and
curing the bricks for a stipulated period.
METHOD OF EXPERIMENT
Before testing the brick specimens are immersed in water for 24 hours. After that prepare
cement mortar (1:1) and fill the frog and all void in bed faces with it. Store the sample under
damp jute bag after 3 days remove and wipe out a trace of moisture and measure the area of two
horizontal faces. For testing place the specimen with flat faces horizontal and mortar filled
facing upwards between two plywood sheets and center carefully between plates of testing
machine.Load is applied axially at a uniform rate 14 N/mm2 per minute till failure occurs;
Note the maximum load at failure.Find the Compressive Strength (N/mm2) using the following
formula
Max.load at Failure in N
Compressive Strength (N/mm2) =
ISSN: 2231-5381
Avg.Area of Bed Face
http://www.ijettjournal.org
Page 34
International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number1–Nov 2012
Observation Table:
Sample
Dimension of Fly ash Bricks
Avg.
Max
Compressive
Area of
load at
strength
(N/mm2)
Length
Width
Height
bed
failure
(mm)
(mm)
(mm)
surface
(KN)
(mm2)
A
230
100
78
2300
118
5.153
B
228
100
80
22800
104
4.582
C
228
100
76
22800
132
5.815
D
230
102
78
23000
127
5.546
E
230
100
80
23000
138
6.026
AVERAGE
5.425
≈5.43
N/mm2
From the result average compressive strength is 5.425 N/mm2 which is higher than normal clay
bricks.
ISSN: 2231-5381
http://www.ijettjournal.org
Page 35
International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number1–Nov 2012
RESULTS AND ANALYSIS:
From the measurement done on 10 bricks, the total length, width and height obtained
were 4000 mm,1000 mm and 1000 mm.
Comparison Of Fly Ash Brick And Burnt Clay Brick Units:
Loss of soil/Agriculture land, heat emission are nil, solid waste generation and disposal is
negligible in Fly Ash Brick Unit.
TABLE :1 Comparison of Fly ash bricks and ordinary red clay bricks
Properties
Red Bricks
Fly Ash Bricks
Remarks
Colour
Very
Uniform
Good Appearance
Density
1600 - 1750 kg/m3
1700 - 1850 kg/m3
Higher Load
Bearing
Compressive
30 - 35 kg/cm2
55 - 100 kg/cm2
Strength
Water
Absorption
Bearing
15 - 25 %
Very Low
Dimensional
Tolerance
10 - 14 %
Less Dampness
High Tolerance
Saving in Mortar
Stability
Wastage
During Transit
Plastering
Higher Load
Up to 25 %
Up to 10 %
Thickness Vary on
the Both Sides of
Walls
ISSN: 2231-5381
Less than 2 %
Even on Both
Sides
of Walls
Saving in Cost Up
to 8 %
Saving in Plaster
Up to 15 %
http://www.ijettjournal.org
Page 36
International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number1–Nov 2012
CONCLUSION
Fly ash utilization in the country has remained less than 30% during the past 5 years and it
might take several years to reach the final goal of cent percent utilization. It is estimated at
present nearly 160 million ton fly ash is produced every year, out of which hardly 40- 50 % is
used in all possible applications.To utilize such a huge quantity of ash, we have to take
necessary actions from government side and from nongovernment side for utilisation point of
view. Based on the results for the experiments done on Fly ash lime brick,Compressive strength
= 54.25 kg/cm2 ,% Water absorption = 19.26 %.The results shows the Fly ash bricks are more
safe, economical and having higher strength compare to conventional bricks.
REFERENCES:
1. Bhanumathidas.N and N.Kalidas( April 2003) ‗Fly ash: The resource for construction
industry', ,The Indian Concrete Journal, PP. 997-1004
2. Bhanumathidas.N and N. Kalidas, Inswareb,( Jan 2005) ‗Sustainable Development
through use of Fly Ash', Keynote Paper presented at National Seminar on Building
Materials & Technology for Sustainable Development; Ahmadabad
3. Environmental and Social Review (ESR) for FaL-G Bricks/Blocks Project
prepared by Eco Carbon Private Limited, Visakhapatnam.
4. Fly Ash Bricks Masonry: An Experimental Study, National Conference on Recent
Trends in Engineering & Technology.
5. Jain A.K. (Technical Advisor) Ultratech Cement Ltd, ‗Fly Ash Utilization in
Indian Cements Industry: Current Status And Future Prospects', ICI Update February 2011, PP. 03-11
6. Malaviya S.K, B. Chatterjee And K. K. Singh, ‗Fly Ash - An Emerging
Alternative Building Material', National Metallurgical Laboratory, Jamshedpur, PP. 59-67
7. Sharda Dhadse, Pramila Kumari and L. J. Bhagia, Fly ash Characterization,Utilization and
Government Initiatives in India - A review', Journal
/ Scientific and Industrial Research,. (Vol. 67,
January 2008, PP. 11-18 )
ISSN: 2231-5381
http://www.ijettjournal.org
Page 37