A PROJECT REPORT ON

“PERFORMANCE EVALUATION OF BRICKS: SLUDGE BRICK OVER

CONVENTIONAL BRICK”
SUBMITTED IN FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF
BACHELOR’S IN ENGINEERING
IN
DEPARTMENT OF CIVIL ENGINEERING
SUBMITTED BY
PRATHAMESH ANAND GOSAVI (2119024)
PRAVIN DATTATRAY GURAV (2119025)
DIPAK RAMCHANDRA SAWARDE (2119032)
MUZAMMIL MOHSIN SHAIKH (2119036)

UNDER THE VALUABLE GUIDANCE OF

Er. RABIA SAMEEN

UNIVERSITY OF MUMBAI
ANJUMAN I ISLAM’S
M.H. SABOO SIDDIK COLLEGE OF ENGINEERING
8, Saboo siddik Polytechnic Rd., Byculla, Mumbai - 400 008
(2022-2023)

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2
 CERTIFICATE

This is to certify that the project entitled “PERFORMANCE EVALUATION OF BRICKS:

SLUDGE BRICK OVER CONVENTIONAL BRICK” Is bonafide work of

PRATHAMESH ANAND GOSAVI (2119024)

PRAVIN DATTATRAY GURAV (2119025)
DIPAK RAMCHANDRA SAWARDE (2119032)
MUZAMMIL MOHSIN SHAIKH (2119036)

Submitted to the University in the fulfillment of the requirement for the award of the degree of
Bachelor of Engineering in Civil Engineering.

Er. RABIA SAMEEN (GUIDE)

Prof. ZAHEER KHAN Dr. GANESH KAME

( Head of Department ) ( Principal )

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 DECLARATION

We declare that this written submission represents our ideas in our own words and
where other ideas or Words have been included, we have adequately cited and referenced the
original sources. We also declare that we have adhered to all principles of academic honesty
and integrity and have not misrepresented or fabricated or falsified any idea/data/fact/source in
our submission understand that any violation of the above will be cause for disciplinary action
by the Institute and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been taken when needed.

PRATHAMESH ANAND GOSAVI (2119024) --------------------------

PRAVIN DATTATRAY GURAV (2119025 --------------------------

DIPAK RAMCHANDRA SAWARDE (2119032) -------------------------

MUZAMMIL MOHSIN SHAIKH (2119036) --------------------------

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 ACKNOWLEDGEMENT

A project is never the outcome of a single person. It is said that “Teamwork will make
the dream work”.

It is a matter of great pleasure and privilege to have the opportunity to express our
deepest sense of gratitude profusely to Er. RABIA SAMEEN (project guide) under whose
brilliant untiring guidance, we completed this project successfully in time. Her meticulous
attention and invaluable suggestions have helped us greatly in simplifying the problems
involved in the project.

We wish to express our heartfelt and sincere gratitude to our principal Dr. GANESH
KAME, M. H. Saboo Siddik College of Engineering, Mumbai for providing the facilities to
carry out the project work.

We wish to express our gratitude thanks to our beloved Head of Department of Civil
Engineering, Prof.ZAHEER KHAN, who gave us full support and his constant
encouragement, valuable suggestions, and helping tendency which has made us carry out and
finish the project work successfully.

Last but not least Our thanks to all other faculty and non-teaching staff members of our
department for their support and to our classmates for having stood by us to complete this
project synopsis report.

PRATHAMESH ANAND GOSAVI

PRAVIN DATTATRAY GURAV
DIPAK RAMCHANDRA SAWARDE
MUZAMMIL MOHSIN SHAIKH

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 ABSTRACT

The disposal of sewage waste is the major problem in urban cities as it causes many
harmful effects to the environment. Sludge is the main product from sewage waste.
Conventional brick is mostly prepared by using clay. Chemical composition of sludge is
nearly similar to the clay. Hence sludge can be used as a replacement for a clay, soil in
manufacturing of bricks.

Recovery of waste constituents from industrial waste is a cost-effective solution in

control of environmental pollution. Present investigation deals with the feasibility of usage of
sludge obtained from sand beneficiation treatment plant in the production of bricks and their
durability. The experimental results show that the brick earth can be replaced with treatment
plant sludge up to 40% by weight without loss in strength and other brick characteristics
considered satisfactory for conventional purposes

Waste may be defined as an unwanted material generated after the manufacturing

process from industry, agriculture, or from house hold activity. Waste causes many nuisances
in the environment. It produces many types of infection, for human and animal. The sludge
from effluent plants has problem of disposal. Dewatered sludge is disposed off by land filling.
However, it is not an appropriate solution, due to the land limitation. The production of sludge
in effluent plant is about to increase every year. In addition, the constraint to treat sludge is
very high in cost and time-consuming, which is the disadvantage to the responsible parties.
Therefore, this study was carried out to utilize those sludge waste (SW) produced from the
effluent plant as a brick. The sludge brick (SB) mixtures were incorporated with many ratios
of SW. Tests were conducted such as fineness test, specific gravity, water absorption and
compressive strength. As the conclusion, brick with 20% utilization of SW is acceptable to
produce good quality of brick. This study shows that the disposal of sludge SW would act as
a suitable material for manufacturing of bricks with proportionate mix and design.

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 TABLE OF CONTENT
Abstract………………………………………………………………… v
Chapter 1
1.1 Introduction……………………………………………………………... 1
1.2 Problem Statement…………….…………………………………….….. 2
1.3 Why sludge Brick use ?............................................................................. 3
1.4 Advantages of Sludge Brick ………………………………………..…. 4
1.5 Objective of Sludge Bricks ………………………………………..…… 4
Chapter 2 History 5
2.1 History of Bricks ………………………………………………………. 5
2.2 What type of Brick is used …………………………………………….. 6
2.2.1 Properties of Good Bricks ………………………………..……... 8

2.2.2 Standard size and shape of brick………………………….……… 9

Chapter 3 Review of Literature 10
3.1 Literature ……………………………………………………………….. 10
3.2 Study of Research Papers …………………….……………..………….. 15

Chapter 4 Methodology 20
4.1 Methodology Chart ……………………………………………...……… 20
4.2 Collection of Sludge………………..…………………………………… 21

4.2.1 Sludge…………………………….……………………………. 25
4.2.2 Drying of Sludge………………….…………………………… 25
4.2.3 Sludge Brick making……….…….……………………………. 25

4.3 Treatment on Sludge…………………..………………………………… 26

4.3.1 Heat treatment……………….………………………………… 26
4.3.2 Alkaline Stabilization….………………………………………. 27
4.3.3 Incineration…………….………………………………………. 27
4.4 Material Used ……………………………………………….…….…… 28
4.4.1 Sludge…………………………………………………..……… 28
4.4.2 Clay……………………………………………………….…… 30
4.4.3 Rice Husk………………………………………………………

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 4.4.4 Water…………………………………………………………... 31
32
Chapter 5 Procedure 34
5.1 Stepswise procedure for making Sludge Bricks ……………………….. 34
5.2 Burning of Bricks ………………………………………………………. 46
Chapter 6 Tests Performed on bricks 47
6.1 Compressive strength test …………………………………………….…. 47
6.2 Water absorption test ………………………………………………….… 51
6.3 Efflorescence test ……………………………………………………….. 53
6.4 Soundness test …………………………………………………………... 54
6.5 Size,Colour and Shape test ……………………………………………… 56
6.6 Hardness test ……………………………………………………………. 57
6.7 Result ………………………………………………………………….… 58
6.8 Analysis of Result ……………………………………………………..… 59

Chapter 7 Costing 60
7.1 Cost Analysis …………………..………………………………………... 60
Chapter 8 Future Scope and Conclusion 61
8.1 Future Scope …………………………………………………………..… 61
8.2 Conclusion……………………………………………………………..… 61
Chapter 9 References 63

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Fig. No Caption Page No
2.1 Standard Size and Weight of Brick 9

4.1 Methodology Chart 20

4.2 College letter head for sludge collection 21
4.3 Location of sludge collection 22
4.4 LIST OF FIGURE
Sludge in original form 23
4.5 Sludge removal space 23
4.6 Aeration tank 24
4.7 Executive Engineer team ,Ulwe Water Plant 24
4.8 Sludge 29
4.9 Clay 30
4.10 Rice Husk 31

5.1 Preparing of Clay 34

5.2 Clay for mixing in sludge 35

5.3 Sludge sieving 35

5.4 Sludge sieving 36

5.5 Sludge 36

5.6 (i),(ii),(iii) Mixing of sludge and water 37

5.7 Proportion of sludge and clay 38

5.8 Proportion of sludge and clay (20 : 80) 39

5.9 Proportion of sludge and clay (40 : 60) 39

5.10 Mixing 40

5.11 (20 : 80) Proportion mixing for moulding of bricks 40

5.12 Filling of Mould 41

5.13 Moulding of Bricks 42

5.14 Filling of another mould 42

5.15 (i),(ii)Moulded bricks 43

5.16 Sun drying of bricks 44

5.17 Kiln burning 45

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5.18 Structure of kiln 46

5.19 Preparation of kiln structure 46

 List of Tables

Table. No Caption Page No

6.1 Compressive test result 50

6.2 Water absorption test result 52
6.3 Result analysis 58

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 CHAPTER 1

1.1 INTRODUCTION
Brick is one of the most important construction elements. The history of brick
manufacturing goes back 8000 years when the fabrication of the earliest sun-dried clay bricks
was discovered. Main ingredient of brick is soil but now a days soil is precious and not easily
available due to large scale deforestation and erosion. As it becomes cost prohibitive to obtain
soil for brick manufacturing is costly affair and problem arises in erosion control. Hence to
reduce percentage of soil it is necessary to find out alternative option. Dry sewage sludge is a
byproduct of sewage treatment plant and it is mostly used as manure in the agricultural fields.
The use of sludge (obtained from the drying beds of ‘Sewage Treatment Plant’) as one of the
ingredients in brick manufacturing , thus replacing soil partially has been in practice in the
Construction Industries for quite some time. However, the percentage of soil replacement by
dry sludge depends on the sludge quality which is expected to have been fully biodegraded
with no reservations for handling.
A large quantity of sludge is generated each year from various industries. Large amount
of waste water is produced from various processes within the industry like manufacturing
processes, cleaning processes, kitchen wastes etc. for discharging this wastewater into the
specified water bodies, certain standard specified by the Regulatory Authorities have to be
met. For this purpose. The wastewater has to be subjected to various treatment processes. As a
result of these treatment processes, sludge is produced. The quantity of the sludge produced

1
depends upon the amount of wastewater and the type of treatment adopted for treating the
wastewater. Common method adopted for disposing the sludge is land filling. Landfill
disposal of the sludge has drawbacks like high cost of transportation, difficulty in getting
suitable sites for land filling, heavy metal contamination of the land, emission of foul gases
etc. so, disposal of sludge has become a major issue. Efforts are being made to utilize the
sludge for making useful materials. This is a win-win strategy because it not only converts the
wastes into useful materials but it also alleviates the disposal problem. The use of sludge in
construction industry is considered to be the most economic and environmentally sound
option. This study focuses on the possibility of using sludge as a brick material.
Rapid Industrialization and Urbanization is causing serious environmental problems.
One of the major concerns amongst these is safe and sound disposal of solid wastes. There is a
strong demand for environmentally safe reuse and effective disposal methods for sludge due to
the increasing amount of sludge generated by the wastewater treatment plants.
The present study focuses on utilization of dry sludge from sludge drying . bed of
Sewage Treatment plant for use in manufacturing of bricks thus exploring possibility of
replacing higher percentage of soil with dry sludge than the prevailing practice in the
construction industry. The aspect of reduction in cost of the brick provides a strong logic for
use of dry sludge for partial soil replacement in the manufacturing process of the bricks. The
dry sludge to be used for the purpose is checked for its physical properties like bulk density,
percentage water absorption and mechanical properties like compressive strength.
In recent years, waste production has increased dramatically in developing nations such
as India. There are two methods to solve the problem such as disposal of solid waste (dry
sludge) including land filling and using dry sludge as fertilizers. However success of these
method depend highly on quality of the dry sludge and in some instances not so fully dried
sludge may create land ,air and water pollution. A fully dried sludge from sludge drying beds
of sewage treatment plant is used to replace soil in various places.

1.2 PROBLEM STATEMNENT

Now a day, disposal of sewage has become a necessity for societies. The construction
of treatment plants has caused problems with huge content of dry sludge. It has been found
2
that each person produces 35 to 85 grams of solid sludge per day. In recent years, waste
production has increased dramatically in developing nations such as India. There are two
methods to solve the problem such as disposal of solid waste (dry sludge) including land
filling and using dry sludge as fertilizers. However, success of these method depends highly
on quality of the dry sludge and in some instances not so fully dried sludge may create
land ,air and water pollution. A fully dried sludge from sludge drying beds of sewage
treatment plant is used to replace soil in various places.

1.3 WHY SLUDGE BRICK USE ?

Sludge brick is a sustainable and eco-friendly building material that is gaining
popularity in the construction industry. It is made from sludge, a semi-solid residue that is
generated during the wastewater treatment process. Sludge brick offers several advantages over
traditional clay bricks, which are made by firing clay in high-temperature kilns. Here are some
reasons why sludge brick is being used:
1. Eco-friendly: Sludge brick is an environmentally friendly building material
because it uses a waste material that would otherwise be discarded. By repurposing sludge, we
can reduce the amount of waste that goes into landfills and conserve natural resources.
2. Low Carbon Footprint: Sludge brick has a lower carbon footprint than
traditional clay bricks because it does not require high-temperature firing. The production
process of sludge brick involves mixing sludge with a small amount of cement and other
additives, and then compressing the mixture into brick shapes. This process consumes less
energy and emits fewer greenhouse gases.
3. High Insulation Properties: Sludge brick has excellent insulation properties,
which can help reduce energy consumption in buildings. The brick's insulation properties can
help keep the building cool in summer and warm in winter, reducing the need for air
conditioning and heating.
4. Durable and Resistant: Sludge brick is strong, durable, and resistant to
weathering, making it a suitable alternative to traditional clay bricks. It can withstand harsh
weather conditions and has a longer lifespan than traditional bricks.
5. Cost-effective: Sludge brick is a cost-effective building material because it uses a
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waste material that is readily available and inexpensive. The production process is also simple
and requires minimal equipment, making it a cost-effective alternative to traditional brick
manufacturing processes.
Overall, sludge brick is a sustainable and innovative building material that offers
several benefits over traditional clay brick.

1.4 ADVANTAGES OF SLUDGE BRICK

1) Good strength.
2) Environmentally friendly bricks.
3) Reduce the cost of construction.
4) Load bearing bricks.
5) Low price high quality.

1.5 OBJECTIVES:-
1) Partial replacement of more than 50% of soil by dry sludge as one of the ingredients in
brick manufacturing process and to find if the sludge replacement is feasible on account of
aesthetic and stigma aspect.

2) Substitute soil by dry sludge and to utilize dry sludge as ingredient of brick for
construction.

3) Reduce in cost of brick and reduction in impact on environment.

4) To find if the compressive strength of bricks made using sludge is compatible with
conventional brick.

5) To examine the effect of dry sludge in brick properties

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 CHAPTER 2

2.1 HISTORY OF BRICKS

The use of bricks in India can be traced back to the Indus Valley Civilization,
which dates back to 2500 BCE. The Indus Valley Civilization, which was spread across
present-day India, Pakistan, and Afghanistan, was one of the earliest urban civilizations in the
world. The cities of the Indus Valley Civilization, such as Harappa and Mohenjo-daro, were
built using fired bricks.
The bricks used in the Indus Valley Civilization were of a uniform size and shape,
and were made using a mixture of clay and straw. The bricks were baked in kilns at high
temperatures, which made them durable and strong. The use of fired bricks allowed for the
construction of buildings that were taller and more structurally complex than those made using
only sun-dried bricks.
During the Mauryan Empire (321-185 BCE), brick-making techniques became
even more advanced. The Mauryan Empire, which was one of the largest and most powerful
empires in Indian history, was known for its impressive architecture. The city of Pataliputra,
the capital of the Mauryan Empire, was built using high-quality fired bricks.
The bricks used in Pataliputra were made using a mixture of clay, sand, and lime. The
bricks were molded into shape using wooden frames, and then left to dry in the sun. Once
dried, the bricks were fired in kilns at high temperatures. The fired bricks were then used
to construct buildings such as palaces, temples, and administrative buildings.

5
 The use of bricks in architecture continued throughout the centuries, and many
notable structures were constructed using bricks. The Red Fort in Delhi, which was built by
the Mughal Emperor Shah Jahan in the 17th century, is one such example. The Red Fort,
which is now a UNESCO World Heritage Site, was constructed using red sandstone and red
bricks.
The Taj Mahal in Agra, which was built in the 17th century by the Mughal
Emperor Shah Jahan as a mausoleum for his beloved wife Mumtaz Mahal, is another notable
structure that was constructed using bricks. The Taj Mahal, which is also a UNESCO World
Heritage Site, was built using white marble and red sandstone, as well as bricks.
Brick-making in India traditionally involved using clay from nearby rivers or ponds.
The clay was mixed with water, then formed into bricks using wooden molds. The bricks were
then left to dry in the sun for several days before being fired in kilns, which were often built
on-site.
In recent years, brick-making in India has become more mechanized, with the use of
machines to mix and mold the clay, and modern kilns to fire the bricks. However, traditional
brick-making techniques are still used in some parts of the country.
Today, India is the second-largest brick producer in the world, after China, with an
estimated 300 billion bricks produced annually. Brick-making is an important source of
employment for millions of people in India, particularly in rural areas where other job
opportunities may be limited. However, the industry also has significant environmental
impacts, including air pollution from kilns and deforestation for fuel.
In conclusion, the use of bricks in India has a long and rich history dating back to the
Indus Valley Civilization. The use of fired bricks allowed for the construction of impressive
structures, and the tradition of brick-making has continued to this day. While the industry has
provided important economic opportunities, it also has significant environmental impacts that
must be addressed.

2.2 WHAT TYPE OF BRICK IS USED

Sun-dried bricks
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 Also known as unburnt bricks, these types of bricks are mostly used for decorative
purposes because they are the weakest. They are made from clay that is molded and dried
directly under the sun

Burnt bricks
These bricks are divided into four categories:
First-class bricks: These are the best quality bricks because they are made
through table molding before they are put in a kiln. They are also strong and, therefore, more
durable than all the other types.
Second-class bricks: These are ground-molded and, as such, don’t have the
perfect shape or texture. They are also burnt in kilns, making them the second-strongest type
of bricks.
Third-class bricks: These are like unburnt bricks and should only be used in
temporary structures. Their weakness also means they can be damaged easily by water. They
are ground-molded and burnt in clamps instead of kilns.
Fourth-class bricks: These are of low quality and are, therefore, not suitable for
use in any construction. They are crushed and mixed with concrete before they are used.

Concrete bricks
These are made using sand, cement, coarse aggregates, and water. They can be
custom-made into different sized and can be manufactured at the construction site

Lime bricks
These are made with sand and lime and are perfect for improving the visual aesthetics
of a building.

Engineering bricks
These bricks are engineered to increase strength and resist damaging elements
like fire and water. They are ideal for basements or other areas likely to deal with a lot of
moisture.

Fly ash bricks

Made using fly ash and water, these bricks have better resistance to thawing and

7
freezing cycles. They are lightweight but strong and have lower water penetration, which
makes them great for insulation.

BRICK
Brick is one of the oldest building materials and it is extensively used even at present
because of its durability, strength, reliability, low cost, easy availability etc. Bricks are
obtained by moulding clay in rectangular blocks of uniform size then by drying and burning
these blocks in brick kilns

2.2.1 PROPERTIES OF GOOD BRICKS

 good brick should have the following properties:

 Bricks should have perfect edges, well burnt in kilns, copper coloured, free from cracks
with sharp and square edges

 It should be uniform in shape and of standard size.

 Colour should be uniform and bright.

 The brick when broken should show a bright homogeneous and uniform compact structure
free from voids.

 It should produce clear ringing sound when struck with each other.

 ater absorption should not be greater than 20% for first class bricks and 22% for second
class bricks when soaked in water for 24 hours.

 Bricks should be sufficiently hard, i.e., no nail impression must be present when scratched

 It should not break when dropped from a height of one metre

 It should have low thermal conductivity and should be sound proof

 Good brick should not show any white or grey deposits of salts when immersed in water
and dried. i.e., it should not have any efflorescence.

 Good brick should have crushed strength above 5.5N/mm².

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2.2.2 STANDARD SIZE AND WEIGHT OF BRICK

Fig 2.1
Size of standard bricks is 19 X 9 X 9cm. Such brick is known as Modular Bricks. The
size of bricks including mortar thickness is 20 X 10 X 10cm. Average weight of brick is
about 3 to 3.5kg

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 CHAPTER 3

3.1 LITERATURE REVIEW:-

Aeslina Binti Abdul Kadir, et Al (2009) “An Overview of Sludge Utilization into Fired
Clay Brick”
Brick is one of the most common masonry units used as building material. Due to the
demand, different types of waste have been investigated to be incorporated into the bricks.
Many types of sludge have been incorporated in fired clay brick for example marble sludge,
stone sludge, water sludge, sewage sludge, and ceramic sludge. The utilization of these waste
materials in fired clay bricks usually has positive effects on the properties such as lightweight
bricks with improved shrinkage, porosity, and strength. This paper reviews on utilization of
different types of sludge wastes into fired clay bricks. Previous investigations have
demonstrated positive effects on the physical and mechanical properties as well as less impact
towards the environment. Thus, the utilizations of sludge waste could produce a good quality
of brick and could be one of alternative disposal methods for the sludge wastes.
Keywords - Fired Clay Brick, Sludge waste, Compressive strength, Shrinkage, Water
absorption.

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 Alaa.A. Shakir, et Al (2014) “Development of Bricks from Waste Material”
Large demand has been placed on building material industry especially in the last
decade owing to the increasing population which causes a chronic shortage of building
materials, the civil engineers have been challenged to convert waste to useful building and
construction material. Recycling of such waste as raw material alternatives may contribute to
the exhaustion of the natural resources; the conservation of not renewable resources;
improvement of the population health and security preoccupation with environmental matters
and reduction in waste disposal costs. In the review of utilization of those waste, this paper
reviewed recycling various waste material in bricks production. The effects of those wastes on
the bricks properties as physical, mechanical properties will be reviewed and
recommendations for future research as out comings of this review will be given. This
reviewed approach on bricks making from waste is useful to provide potential and sustainable
solution.
Key words: bricks, waste material, bricks properties

Shrikant S Jahagirdar et.al (2013) represented a paper ‘Utilization of Textile Mill Sludge
in Burnt Clay Bricks.’
In this paper they are introducing the Textile mill sludge in the manufacturing of the
bricks my mixing the clay soil and textile mill sludge together. He took the sludge for bricks
by mixing with the clay soilas 0% to 35% by weight. Different samples of each percentage
undergone through the various tests like compressive strength test, water absorption test,
efflorescence as per the procedures of Bureau of Indian Standards. After the testing, the author
conclude that the dry sludge can be used in the bricks as the partial replacement for the clay in
the well burnt bricks. Hence it may reduce some cost of brick also. Textile mill sludge can be
used up to 15% without compromising the chemical and physical properties of the bricks as
per the IS code. As the organic matter is present in the sludge, when the brick is burnt at the

11
5500 o C temperature, it created the voids in the bricks. Which reduces the compressive
strength of the brick and it increases the water absorption capacity as well. Anyakora Nkolika
Victoriaet.al (2013) represented a paper ‘characterisation and performance evaluation of water
works sludge as bricks material.’ In this paper they are saying that the use of sludge in the well
burnt bricks is a long term approach as point of view of the disposal, economy, and
environmental sustainability. The physical, mechanical and chemical properties of the sludge
was determined as per the Nigerian Standard specifications (NIS 74:1976) and British
Standard Specifications (BS 3921:1985). For the evaluation of the well burnt bricks using
Sludge, Five different ratios of the Sludge and clay were taken as 0%, 5%,10%, 15% & 20%
by weight. Each and every mixed batch was hand 10 moulded to the standard size and shape
of the brick. All the brick samples were heated in the kiln at 850oC temperature to the 1050
oC temperature. At the end of the study the author concluded that sludge-clay bricks can be
used successfully without any failure.

“Use of sludge waste as an ingredient in making of bricks , April 2021”

In this study the bricks were produced with sewage sludge additions ranging from 10,
20, 30, 40 and 50 % by dry weight and compared the produced brick with conventional
brick.In this work, raw materials namely sludge, Fly Ash, and clay are as the major
ingredients. They are mix with each other in proportion produce brick.

Study on Effect of Partial Replacement of Sludge in Bricks Keerthana. S, Kavya. K,

Pradeep.T, Sharmila.S
The present scenario shows, every day in Tamil Nadu 2.5 to 3 tonnes of waste sludge
generated and there is no place to dump this solid waste because it contains many toxic
constituents (copper, manganese, cadmium, chromium, potassium, sodium, etc.,) which may
cause pollution of water sources and other problem; hence an attempt is made to reduce the
pollution by manufacture eco-friendly bricks. Brick is the constituent material in construction
industry. The main component of the brick includes clay, sand and water. Sludge is the waste
product which is collected from the industries. The collected sludge is dried at open

12
atmosphere for 40 days and powdered. The powdered sludge is replaced by clay (10%, 20%,
30%, and 40%) and sand (10% and 20%). The performance was found good when the various
tests such as water absorption (30% replacement by clay and 10% by sand), compressive
strength (by 10% in both clay and sand) and basic characteristics test for bricks are examined
and determined.
Key words: Sludge, Water absorption, Compressive strength, Eco-friendly bricks.

Durability of Bricks Cast with Industrial Sludge G. Reddy Babu1, N. Venkata Ramana
Recovery of waste constituents from industrial waste is a cost-effective solution in
control of environmental pollution. Present investigation deals with the feasibility of usage of
sludge obtained from sand beneficiation treatment plant in the production of bricks and their
durability. The experimental results show that the brick earth can be replaced with treatment
plant sludge up to 40% by weight without loss in strength and other brick characteristics
considered satisfactory for conventional purposes. Apart from that when reference specimens
and test bricks (5% Sludge) were immersed in various concentrations of hydrochloric acid
(HCl) solution at different immersed ages, the loss of weight is found to be less in test bricks
than that in reference bricks. Hence, at 5% of replacement, the quality of bricks is superior to
the bricks made from earth alone and can be used for superior work of permanent nature.
Keywords-Brick, Sludge from sand beneficiation treatment plant, Compressive strength, HCL,
weight loss.

Utilization of Waste Sludge in Brick Making, Miss. Shrutakirti A. Mahajan, Dr. M.

Husain
The Indian automotive industry has emerged as a 'sunrise sector' in the Indian economy
with an annual production of 23.37 million vehicles in 2014- 15. Even it is a value adding
industry, it has several environmental impacts causing land and water pollution with toxicity.
Effluent sludge waste management becomes a big problem nowadays. Except engineered
landfills, rest of the methods for dumping, leads ground water contamination and there by
other socio-economic impacts. Many studies have been conducted in this area and reported
that the pollution level is high in ground water and nuisance due to dumping in the treatment
13
plant area premises. There is a growing need to find alternative solutions for the sludge
management. In the present study, an attempt has been made to utilize the automotive ETP
sludge (dry) in making of construction materials, which is produced from TATA MOTARS,
PUNE. Evento analyse the sludge, have been studied. For inducing strength materials like fly
ash, lime, sand, cement, CaCl2, have been used. Sludge bricks show better compressive
strength when compared with normal fly bricks or building bricks. Keywords— Brick, Sludge,
Compressive Strength.

A Study on Modified Clay Bricks with Paper sludge and Laterite Soil Arya K C, Alester
Joseph Vanreyk
Clay bricks have been used in the construction for thousands of years. Paper sludge is also a
waste material that is produced from paper printing press. This residue sludge is generally deposited in
landfills causing disposal and environmental pollution problems. Laterite soil is used for many
construction activities due to their high clay content. They are also energy efficient and environment
friendly material. In this study 5%, 10%, 15%, 20% of paper sludge was added along with the clay and
a combination of 15% of laterite soil with paper sludge is also added to the clay bricks. The properties
such as compressive strength, water absorption, efflorescence and thermal conductivity of those bricks
are analyzed and reported. It was found that all clay bricks made with these materials shows higher
compressive strength than that of control bricks whereas the water absorption increases with increase
in percentage of added material. All the bricks showed only slight efflorescence. The thermal
conductivity of the entire bricks shows a decreasing pattern with increase in percentage addition when
compared with control bricks. Based on the observations made it is clear that 10 class designation
bricks (second class) with improved properties and light in weight developed by using these industrial
byproducts. Index Terms— Paper sludge, Laterite soil, compressive strength, water absorption,
efflorescence, thermal conductivity

14
3.2 STUDY OF RESEARCH PAPERS

15
16
17
18
19
 CHAPTER 4

4 METHODOLOGY

4.1 METHODOLOGY CHART:-

Fig

4.1Methodology chart

20
4.2 COLLECTION OF SLUDGE

Collection of waste sludge from sewage treatment plant which is located at

sector-6,ulwe,
navi Mumbai-400206
Water Treatment Plant - Ulwe
https://maps.app.goo.gl/9DiqLDRLhGHiuKgK9

Fig 4.2 College letter head

21
LOCATION :-

Fig 4.3 Locatio

SLUDGE :-

22
Fig 4.4 sludge in original form

Fig 4.

23
 Fig 4.6 Aeration tank

Fig 4.7 Executive Engineer , Ulwe water treatment plan

24
4.2.1 SLUDGE
Sludge from municipalities (often called sewage sludge) is a byproduct of wastewater
treatment. It is normally a mix of organic matter from human waste, food waste particles,
microorganisms, trace chemicals and inorganic solids from products and medicine we use,
together with water bound to these materials. In the United States, sewage sludge is also called
wastewater solids.
After any form of treatment, sludge is often referred to as “biosolids”. In line with this,
we can say that sludge treatment turns sludge into biosolids. "Biosolids" are usually either
applied on land, incinerated, or landfilled.
Sludge can also come from industrial facilities (food manufacturers, pulp and paper
factories, chemical and fuel factories, etc.). Industrial sludge is a byproduct of specific factory
processes and differs widely in content in each industry. Certain types of industrial sludge are
permitted to enter a municipal sewer network for treatment with municipal sludge or be
delivered to a sludge treatment plant to be mixed with sewage sludge for treatment.

4.2.2 DRYING OF SLUDGE

The waste sludge which is collected from sewage treatment plant is allowed to dry for
7 to 10 days.
The drying method is completely natural. Natural solar energy is used for three drying
purpose.Available water in sludge is evaporated in atmosphere by the heat of sun.

4.2.2 SLUDGE BRICK MAKING

For the given study proper solidification of brick is necessary essential. Selection of
suitable proportion of different kind of material for achieving good strength is essential. After
selection of proper proportion for brick the dry homogenous mixture is done. With adding the
appropriate water wet homogenous mixture is done and finally the mortar is allowed to
making brick sample

25
4.3 TREATMENT ON SLUDGE
4.3.1 HEAT TREATMENT
Heat treatment is a process that has been used for the conditioning and stabilization of
sludge, but it is seldom used in new installations. Heat treatment involves heating the sludge
for short periods of time under pressure. The treatment coagulates the solids, breaks down the
gel structure, and reduces the water affinity of sludge solids. As a result, the sludge is
sterilized and is dewatered readily. Supernatant from the heat-treatment unit is high in BOD
and may require special side stream treatment before it is introduced into the mainstream
wastewater treatment process.
Advantages cited for heat treatment are
(1) the solids content of the dewatered sludge can range from 30 to 50 percent, depending on
the degree of oxidation achieved,
(2) the processed sludge does not normally require chemical conditioning,
(3) the pro- cess stabilizes sludge and will destroy most pathogenic organisms,
(4) the processed sludge will have a heating value of 28 to 30 kJ/g (12,000 to 13,000 Btu/lb) of
volatile solids, and
(5) the process is relatively insensitive to changes in sludge composition.
The major disadvantages associated with heat treatment are
(1) high capital cost due to its mechanical complexity and the use of corrosion-resistant
materials; (2) close supervision, skilled operators, and a strong preventive maintenance
program are required; (3) the process produces sidestreams with high concentrations of
organics, ammonia nitrogen, and color:
(4) significant odorous gases are produced that require extensive containment, treatment,
and/or destruction
(5) scale formation in the heat exchangers, pipes, and reactor requires acid washing or high-
pressure water jets. Because of these disadvantages, interest in heat treatment has declined
significantly and few new facilities have been constructed

26
 4.3.2 ALKALINE STABILIZATION
A method to eliminate nuisance conditions in sludge is through the use of alkaline
material to render the sludge unsuitable for the survival of microorganisms.
In the lime stabilization process, lime is added to untreated sludge in sufficient quantity to
raise the pH to 12 or higher.
The high pH creates an environment that halts or substantially retards the microbial reactions
that can otherwise lead to odor production and vector attraction.
The sludge will not putrefy, create odors, or pose a health hazard so long as the pH is
maintained at this level. The process can also inactivate virus, bacteria, and other
microorganisms present.

Note:- GOING WITH INCINERATION EFFECT OF CARBON CONTENT WE SHOULD

NOT DECREASE IN THE STRENGTH OF BRICK.

4.3.3 INCINERATION
Incineration of sludge involves the total conversion of organic solids to oxidized end
products, primarily carbon dioxide, water, and ash.

Incineration is not a common method for clay brick making as it is not an efficient or cost-
effective process for producing bricks. The traditional method for producing clay bricks
involves mixing clay and water to form a plastic mass, which is then molded into the desired
shape and fired at high temperatures in a kiln. The firing process hardens the bricks and gives
them their strength and durability.

Incineration is a process of burning waste materials at high temperatures to convert

them into ash, gas, and other byproducts. While it may be possible to use incineration to
process clay into a usable material for brick making, the process is not cost-effective or
efficient compared to traditional brick-making methods. Additionally, the use of incineration
can generate harmful emissions and waste products, which can have negative environmental
impacts.

27
 The major advantages of incineration are

(1) maximum volume reduction thereby lessening disposal requirements

(2) destruction of pathogens and toxic compounds, and

(3) energy recovery potential (U.S. EPA, 1985a).

Disadvantages include

(1) high capital and operating cost,

(2) highly skilled operating and maintenance staffs are required,

(3) the residuals produced (air emissions and ash) may have adverse environmental effects

(4) disposal of resid uals, which may be classified as hazardous wastes, if they exceed
prescribed maximum pollutant concentrations. Incineration is used most commonly by
medium- to large sized plants with limited disposal options.

Sludges processed by incineration are usually dewatered, untreated sludges. It is normally

unnecessary to stabilize sludge before incineration. In fact, such practice may be detrimental
because stabilization, specifically aerobic and anaerobic digestion. decreases the volatile
content of the sludge and consequently increases the requirement for an auxiliary fuel. Sludges
may be incinerated separately or in combination with municipal solid wastes. The incineration
processes considered in the following discussion include multiple hearth incineration,
fluidized bed incineration, and coincineration with municipal solid.

In summary, incineration is not a viable option for clay brick making as it is not an efficient or
cost-effective method for producing high-quality bricks. Traditional brick-making methods are
still the most widely used and effective method for producing clay bricks.

4.4 MATERIAL USED

4.4.1 SLUDGE-

28
 Fig 4.8 Sludge

Biologically degradable and non-degradable organic and inorganic pollutants existing

in the wastewater in soluble, colloidal or suspended form are removed by number of methods
in waste water treatment plants. The suspended solids and some of the dissolved solids that are
present in the wastewater as well as the ones which are added or cultured by wastewater
processes, are separated in the form of settle able solids [6] Thus, sludge is the solids, liquid or
semisolids residuals (concentrated contaminants) generated as a byproduct of waste water
treatment. Usually sludge contains 0.25-12 % solids by weight, depending upon the operations
and the processes used [12] Sludge treatment/disposal represents 50 % of the capital and
operational costs of wastewater treatment plant. As mentioned above, the effluent treatment
plant consists of physical, chemical and biological unit, each unit generating different types of
sludge. The safe disposal of these types of wastes has received a considerable attention in
recent years to protect the environment. Sludge can become a problem if they are improperly
managed or disposed of. It can induce three impacts on the environment distinguishing the
gaseous, liquid and solid phase. [6] Impact on the soil composition by the input of compounds
enriched in the Sludge (potentially toxic elements and compounds, pathogens and parasites).
Impact on the percolating water and consequently on the ground water. Quality by the
immobilization of the compounds accumulated in the soil. Impact on the neighboring
environment by eventual problems of odor Nuisance.

A. Liquid sludge :-The effluent coming from the industries are treated by flocculation

29
process, during this treatment the sludge obtained is called as liquid sludge.

B. Semi solid sludge :-This is the second form of sludge, obtained by dewatering of liquid
sludge by passing through centrifuges at 1500 rpm, because of this high revolution the sludge
gets dewatered and comes out as wet cake. This wet cake is called wet sludge.

C. Dry sludge :-The sludge from the centrifuges is dried by spreading it over a large area, i.e.,
on the sludge drying beds in the presence of sunlight. Thus, wet sludge is converted into dry
sludge in a period of 40 days. All the three forms of sludge which has been discussed above
are being used as composite material and influence of each on compressive strength and other
parameters have been discussed in subsequent articles

4.4.2 CLAY-

Fig 4.9 Clay

Clay is the primary raw material used in brick making. Here's some information on the
characteristics of clay used in brick making:

Plasticity: Clay needs to be sufficiently plastic to be molded into the desired shape.
Plasticity is determined by the presence of fine particles in the clay, such as silt and clay-sized
particles.

Workability: Workability refers to how easily the clay can be molded into the desired

30
shape. Workability is influenced by the clay's plasticity, moisture content, and the amount of
organic matter present.

Firing properties: The clay should have good firing properties, which means it should
be able to withstand the high temperatures required to harden and set the brick. The clay's
ability to hold its shape and not crack or deform during firing is crucial.

Color: The color of the clay can influence the color of the finished brick. Red, yellow,
and brown are the most common colors for fired clay bricks, and they are determined by the
type of iron oxide present in the clay.

Mineral content: The mineral content of the clay can also affect its suitability for brick
making. Some minerals, such as calcium carbonate and magnesium, can cause the clay to
expand or crack during firing.

4.4.3 RICE HUSK

Fig 4.10 Rice Husk

Rice husk can be used as a supplementary material in brick making to improve the
strength, thermal insulation, and durability of the bricks. Here are some of the benefits of
using rice husk in brick making:

Strength: Rice husk ash can be used as a pozzolan, a material that reacts with lime to

31
produce cementitious compounds, which can improve the strength of the bricks.

Thermal insulation: Rice husk can be used to reduce the thermal conductivity of
bricks, which can help to reduce the energy consumption of buildings.

Durability: Rice husk ash can also help to reduce the rate of absorption of water by
bricks, which can improve their durability and resistance to weathering.

Sustainability: The use of rice husk in brick making can help to reduce waste and
promote sustainability, as rice husk is a byproduct of rice milling.

However, it's important to note that the use of rice husk in brick making requires careful
consideration of factors such as the quality and consistency of the rice husk, the amount of rice
husk that can be used in the brick mix, and the impact on the overall properties of the finished
bricks. The mix design and production process may need to be adjusted to ensure that the
desired properties of the bricks are achieved while maintaining their quality and performance.

4.4.4 WATER
Water is a critical component in the production of bricks. It is used to mix with the clay
or other raw materials to form a plastic mix that can be molded into the desired shape. Here
are some considerations when using water in brick material:

Quality: The quality of the water used in brick production can affect the quality of the
finished product. Ideally, water used in brick making should be clean and free from
contaminants such as sand, silt, and organic matter. Water with high levels of dissolved salts
or minerals can also affect the properties of the bricks, such as their color, strength, and
durability.

Quantity: The amount of water used in brick making is critical to ensure that the mix
has the right consistency for molding. Too little water can result in a mix that is too dry and
difficult to shape, while too much water can weaken the mix and cause the bricks to crack or
deform during firing.

Control: The amount of water used in brick making must be carefully controlled to
ensure consistency in the mix. This can be achieved by measuring the amount of water used

32
and adjusting it as necessary to maintain the desired consistency.

Recycling: Water used in brick making can be recycled to minimize water

consumption and reduce waste. This can be achieved by using closed-loop systems that
capture and treat water used in production, or by using techniques such as evaporation to
recover water from wastewater.

In summary, water is a critical component in the production of bricks. Its quality and
quantity should be carefully controlled to ensure that the mix has the right consistency and
properties, and to minimize waste and environmental impact.

33
 CHAPTER 5

5.1 PROCEDURE FOR MAKING BRICKS

STEP 1
Dig up clay soil and sludge with a shovel to use as the material to build the bricks. You
can identify clay soil because it is sticky and gummy when wet.

Fig 5.1 Preparing of clay

34
Fig 5.2 Clay for Mixing in sludge

Fig 5.3 (i) Sludge Sievin

35
Fig 5.4 (ii) Sludge Sieving

Fig 5.5 Sludge

36
STEP 2
Some clay soil is already at the right consistency, but grinding will generally improve
the end result of your brick building. Then after mixing up the soil with sludge in proportion .

Fig 5.6 (i) Mixing of sludge and water

Fig 5.6 (ii) mixing of sludge and wat

37
 Fig 5.6 (iii) Mixing of sludge and water

Fig 5.7 Proportion of sludge and clay

38
STEP 3
Mix the ground clay soil with water and sludge to make a thick malleable paste.
Traditionally, clay bricks were molded by hand or with wooden tools. Today, many clay
bricks are made in purpose-built molds. Whichever molding method you use, aim to produce
clay bricks of the same size and shape.

Fig 5.8 Proportion of sludge and clay (20:80)

Fig 5.9 Proportion of sludge and clay (40:60)

39
 Fig
5.10

Mixing

Fig 5.11 (20:80) Proportion mixing for Moulding the Bricks

40
STEP 4
Bricks are molded and then Leave the bricks out in the sun to dry or dry them in an
oven to remove the moisture. Traditionally, brick builders lay bricks out in the sun to dry and
this is still a method used in many countries as it does not require fuel or electricity.

Fig 5.12 Filling of mould

41
 Fig 5.13 Moulding of Bricks

Fig 5.14 Filling of another mould

42
Fig 5.15 (i) and (ii) Molded Bricks

(i)

(ii)

43
Fig 5.16 (i) Sun drying of bricks

(ii

44
STEP 5
Fire the dried bricks in a kiln. A kiln is a type of ceramic oven that heats the contents to
a very high temperature for a number of hours. This will alter the molecular bonds of clay and
bind it to the other molecules -- making very solid bricks as a result.

Fig 5.17 (i) Kiln Burning

(ii)Kiln burning structure

45
5.2 BRICK BURNING
KILN BURNING

Fig 5.18 Structure

Fig 5.19 Preparation of kiln structure

46
 CHAPTER 6

TEST PERFOMED ON BRICKS

1) Compressibility test (as per is 3495(part-1): 1992)
2) Water absorption test (as per is 3495(part-2):1992)
3) Efflorescence test (as per is 3495(part-3):1992)
4) Soundness test
5) Size, Color and Shape
6) Hardness test

6.1 COMPRESSION TEST

One of the most crucial tests carried out on bricks to ascertain their durability and
strength is the compressive strength test. The maximum load that a brick can support during
this test before collapsing or breaking under compression. Typically, a brick's compressive
strength is stated in N/mm2 or pounds per square inch (psi).
A brick is put between two plates of a testing apparatus that can apply a compressive
load to the brick at a steady rate to conduct the compressive strength test. The maximum load
that a brick can withstand is recorded after the load is applied until the brick fails. between two
plates of a testing apparatus that can apply a compressive load to the brick at a steady rate to
conduct the compressive strength test. The maximum load that a brick can withstand is
recorded after the load is applied until the brick fails

47
 Fig 6.1 Compressive Strength Machine

Apparatus

A compression testing machine, the compression plate of which shall have a ball
seating in the form of apportion of a sphere the center of which coincides with the center of
the plate shall be used.

Specimens

Six numbers of bricks from the sample to be tested are to be taken. The dimensions
shall be measured to the nearest 1mm.
Preconditioning
Remove the unevenness observed in the bed faces of the bricks to provide two smooth
and parallel faces by grinding. Immerse in water at room temperature for 24 hours. Remove
the specimen from water and drain out any surplus moisture at room temperature. Fill the frog
(if provided) and all voids in the bed and flush with cement mortar (1 cement, clean coarse
sand of grade 3mm and down).Store under damp jute bags for 24 hours followed by
immersion in clean.

Procedure

48
 Place the specimen with flat faces horizontal, and mortar filled face facing upwards
between two 3-ply plywood sheets each of thickness 3mm and carefully centered between the
plates of the testing machine. Apply load axially at a uniform rate of 14N/mm2 (140 kgf/cm²)
per minute till failure occurs and note the maximum load at failure. The load at failure shall be
themaximum load at which the specimen fails to produce any further increase in the indicator
reading of the testing machine.

Fig 6.2 Compression Testiong Machine on bricks Fig 6.3 Digital Load Indicator

49
 Fig 6.4 Compressive Strength Test on CTM

Compressive strength in N/mm²= Maximum load at failure in N

Average area of bed faces in mm²

RESULT :-

SPECIMEN W1 (GRAM) WEIGHT (KN) UTM (N/mm²)

(SLUDGE-CLAY)
10 – 90 2873 135 9.18
20 – 80 2765 91.3 6.22
30 – 70 2863 48.6 3.30
40 – 60 2696 61.6 4.19
50 – 50 2695 20.9 1.42

NORMAL BRICK 2900 150 10.2

Table 6.1( Compressive test )

50
6.2 WATER ABSORPTION TEST
Apparatus

A sensitive balance capable of weighing within 0.1 percent of the mass of the specimen
and a ventilated oven.

Test Specimen

Five numbers of bricks from the sample to be tested are to be taken. The dimensions
shall be measured to the nearest 1mm.

Preconditioning

Dry specimen in a ventilated oven at a temperature of 105 to 115°C till it attains

substantially constant mass. Cool the specimen to room temperature and obtain its
weight(W1). Specimen warm to touch shall not be used for the purpose.

Procedure

Immerse completely the dried specimen in clean water at a temperature of 27±2°C for
24 hours. Remove the specimen from water and wipe out any traces of water with a damp
cloth and weigh the specimen. Complete the weighing within 3 minutes after the specimen has
been removed from the water (W2). Water absorption, percentage by weight, after 24 hour
immersion in cold water is given by the following formula

Fig 6.5 Dry specimen in a ventilated oven

51
 Fig 6.6 after 24 hour immersion in cold water

Percentage water absorption = (W2-W1) X 100/ W1

RESULT
SPECIMEN WEIGHT OF WEIGHT OF WATER
(SLUDGE- DRY WET ABSORPTION(%)
CLAY) BRICK(W1) BRICK(W2)
(KG) (KG)
10 – 90 2135 2631 23.23
20 – 80 2033 2489.5 22.42
30 – 70 2108 2720 29.09

40 – 60 1903 2508 31.79

50 – 50 1810 1810 38.45

NORMAL 2236 2746 22.80

BRICK
Table no 6.2(Water absorption test result)

52
6.3 EFFLORESECE TEST

The efflorescence test is a method used to evaluate the potential for a brick to develop
efflorescence, a white powdery substance that forms on the surface of bricks due to the
migration of soluble salts to the surface. Efflorescence can occur when moisture is present and
can affect the appearance and durability of the brick.

Fig 6.7 White deposits seen after efflorescence test

To perform the efflorescence test on bricks, a test specimen is placed in a controlled

environment and exposed to a high humidity environment. After a period of time, the brick is
visually inspected for the presence of efflorescence.
If efflorescence is present, the amount and severity of the efflorescence are recorded,
and the brick may be classified as having a high potential for efflorescence. If no efflorescence
is present, the brick may be classified as having a low potential for efflorescence.
The efflorescence test is important because it helps to ensure that bricks used in
construction are not prone to developing efflorescence, which can affect the appearance and
durability of the brick. Efflorescence can also indicate the presence of soluble salts in the
brick, which can lead to other problems such as corrosion of steel reinforcement or
deterioration of other building materials. This test is done according to IS 3495 :1992
In case of plastic-sand bricks or plastic-fly ash bricks, NO efflorescence was found, it
typically indicates that the brick has a low level of soluble salts and is of good quality.

Apparatus

A shallow flat bottom dish containing sufficient distilled water to completely saturate

53
the specimens. The dish shall be made of glass, porcelain or glazed stoneware and of size I80
mm x 1SO mm X 40 mm depth for square shaped and 200 mm dia X 40 mm depth for
cylindrical shaped.

Procedure

Place the end of the bricks in the dish, the depth of immersion in water being 25 mm.
Place the whole arrangement in a warm ( for example, 20 to 30°C ) well-ventilated room until
all the water in the dish is absorbed by the specimens. and the surplus water evaporates. Cover
the dish containing the brick with suitable glass cylinder so’ *hat excessive evaporation from
the dish may not occur. When the water has been absorbed and bricks appear to be dry, place a
similar quantity of water in the dish and allow it to evaporate as before. Examine the bricks for
efflorescence after the second evaporation and report the results.

Result

The liability to efflorescence shall be reported as ‘nil’, ‘slight’, ‘moderate’, ‘heavy’ or

‘serious’ in accordance with the following definitions

Nil - When there is no perceptible deposit of efflorescence.

SIigltt - When not more than 10 percent of the exposed area of the brick is covered with a thin
deposit of salts.

Moderate - When there is a heavier deposit than under ‘slight’ and covering up to 50 percent
of the exposed area of the brick surface but unaccompanied by powdering or flaking of the
surface.

Heavy - When there is a heavy deposit of salts covering 50 percent or more of the exposed
area of the brick surface but unaccompanied by powdering or flaking of the surface.

Serious - When there is a heavy deposit of salts accompanied bp powdering and/or flaking of
the exposed surfaces.

6.4 SOUNDNESS TEST

One of the tests used to gauge the strength and quality of bricks is the soundness test. It
is used to assess a brick's resistance to abrupt shocks or collisions without breaking or

54
shattering. Typically, a sample of bricks taken at random from a production batch is used for
the test.
The soundness test is conducted as follows:
The soundness test is used to determine the ability of bricks to withstand weathering
and exposure to freeze-thaw cycles.

Fig 6.8 Soundness Test on Brick

Apparatus

Brick samples

Water

Oven Container

Procedure

1. Collect a representative sample of bricks for testing.

2. Measure the dimensions of each brick and record the values.

3. Weigh each brick and record the weight.

4. Soak the bricks in water for 24 hours.

5. After soaking, measure the dimensions of each brick again and record the values.

6. Place the soaked bricks in an oven set to 105°C to 115°C and dry them until they reach a
constant weight

7. Weigh each brick again and record the weight.

55
 8. Calculate the percentage weight loss for each brick using the following formula:

9. Percentage weight loss = [(Initial weight - Dry weight) / Initial weight] x 100

10. Calculate the average weight loss percentage for all of the bricks tested.

11. Compare the average weight loss percentage to the acceptable limits specified in the
relevant building code or standard. In general, the acceptable limit is typically between 3% to
5%.

If the average weight loss percentage is within the acceptable limit, the bricks are considered
to be sound and suitable for use in construction. If the percentage weight loss is higher than
the acceptable limit, the bricks may be prone to weathering and degradation and may not be
suitable for use in construction.

Fig 6.9 Measuring Dimension of Bricks

Fig 6.10 Dimension measure

RESULT :-Clear ringing sound is produced and no breakage of brick

56
6.5 SIZE ,COLOUR AND SHAPE TEST

 Result :- All are within standard limits

.

6.6 HARDNESS TEST

A nail can be used to gauge the brick's hardness. Although it shouldn't be used as the
only criterion for a brick's fitness for a certain application, this test can be an easy and rapid
approach to evaluate a brick's quality and strength.

Fig 6.11 Hardness test

The steps below should be followed to conduct the brick's nail hardness test:
1. Firmly grasp the brick with one hand.
2. Beginning at one corner, tap the nail into the brick's surface with the other hand.
3. Be careful not to damage either the nail or the brick by tapping the nail hard enough to
minimally embed it into the brick's surface.
4. Once you reach the other corner, keep hammering the nail at regular intervals along the
brick's surface, advancing down each row.
5. Check the nail indentations' depth. The brick is regarded as being hard and of high quality
if the nail only leaves minute, barely perceptible marks. The brick is regarded as soft and of
low quality if the nail leaves deep scratches or cracks the surface.

57
Result:- Bricks are sufficient har

Bricks with lower percentage of sludge have higher compressive strength than bricks
with higher percentage of sludge.

Cost of brick with higher percentage of sludge is low.

Weight of brick with higher percentage of sludge is lower than brick with lower
percentage of sludge.

SAMPLE COMPRESSIVE WATER EFFLORESCENCE

(SLUDGE- TEST ABSORPTION TEST

CLAY) (N/mm²) (%)

10 – 90 9.18 23.23 NIL

20 – 80 6.22 22.42 NIL

30 – 70 3.30 29.03 NIL

40 – 60 4.19 31.79 NIL

50 – 50 1.42 38.45 NIL

NORMAL 10.2 22.80 NIL

6.7 RESULT

Table no 6.3( Result Analysis)

58
The brick has been tested for determining the strength using universal testing machine because
it is important property required for this project.

1. Country bricks = 3.5 to 5.0 N/mm2

2. II class bricks = 5.0 to 7.5 N/mm2

3. I class bricks = 7.5 to 12.5 N/mm2

Minimum crushing strength = 3.5 N/mm

6.8 ANALYSIS OF RESULT

COMPRESSION TEST GRAPH

COMPRESSION
12
10.2
10 9.18
COMPRESSIVE STRENGTH

8
6.22
6
4.19
4 3.3

2 1.42

0
10 20 30 40 50 NORMAL
SLUDGE PROPORTION

Fig 6.12 Analysis of Compression Test

WATER ABSORPTION TEST GRAPH

59
 WATER ABSORPTION TEST
45

40 38.45

35 31.79
WATER ABSORPTION

30 29.03

25 23.23 22.42 22.8

20

15

10

0
10 20 30 40 50 normal
SLUDGE PROPORTION

Fig 6.13 Analysis of Water Absorption of Test

CHAPTER 7
7.1 COST ANALYSIS
Total Weight of One Brick = 2 kg

For % Proportion of SLUDGE : FLYASH = 20:80

Weight of Sludge = 400 gm, Weight of clay = 1.6 kg

• Cost of clay ( including Transportation )

= Rs 4 /Kg

=4*1.6

60
=Rs 6.4 per Brick

• Cost of Sludge (Including Transportation) = Rs 0 per Brick

( According to Indian Government Provisions it is mandantory for Authorities of STP to

dispose off Sludge free of cost at required places )

• Cost of Labour = Rs 300 / 1000 bricks = Rs 0.3 per Brick

• Total Cost = Cost of ( clay + Sludge+ Labour)

= 6.4 +0.0+0.3

= Rs 6.7 per Brick

= Almost under Re 1.00

Normal clay Brick = Rs 8 / brick.

HENCE , IT IS PROFITABLE.

CHAPTER 8

8.1 FUTURE SCOPE

1. To study the compressive strength and water absorption of bricks manufactured by using
sludge in different percentage (10%, 20%, 30%)

2. Higher strength should be obtained, and it should be economical.

3. Inspiring and innovative materials should be used.

4. To decide the exact ratio that will be practically feasible.

61
 5. Various chemical admixtures should be used for increasing strength and other properties.

6. Tests like compressibility test, water absorption test, efflorescence test and soundness test
should be conducted

8.2 CONCLUSION
1. The conclusion is finilised by using experimental results and tests. Brick is used as clay
and rice husk is used to achieve strength.

2. As we increase the content of sludge in the brick ,the strength of brick is lowered.

3. Also, the quantity of rice husk in the brick is also limiting.

4. At a certain percentage where the percentage of rice husk and sludge with soil gives
maximum strength it can be considered as suitable mix proportions.

5. Hence,20 – 80 proportion of sludge and clay is feasible.

6. The Water treatment plant sludge (WTP) could be a replacement in conventional brick
reinforced with sludge waste from industry, with high chrome content.

7. The researched brick type will be a big competitor to the cement

8. brick and clay brick type in the market.

9. Economical Brick can be produce.

10. Sludge waste can be reduce in environment.

11. Load of dumping will reduce of Sludge.

2)

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 CHAPTER 9

9 REFERENCE
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[2] "An Overview Of Sludge Utilization Into Fired Clay Brick." By- Aeslina Binti Abdul
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