EXPERIMENTAL INVESTIGATION ON INTERLOCKING

BRICKS USING INDUSTRIAL WASTES

Naveen Chikkayyanavar1, Maruthi Baddi2, Vishnu Raibagi3, Samreen Khazi4,Ishfaq Bashir5

Department of Civil Engineering, Students of Civil Engineering, KLE Technological University 580021, Karnataka, India

KEYWORDS ABSTRACT

Interlocking bricks This paper focuses on the utilization of industrial waste in the production of interlocking building bricks.
Zinc slag The zinc and granite powder industries generate a large amount of solid waste, which creates environmental
Granite waste powder problems and health hazards during disposal. This study involves experimental investigations into the use
Fly ash of granite waste powder and zinc slag to produce interlocking bricks with varying proportions. The
compressive strength and water absorption of the bricks were tested after casting and sun-drying. Three
different mix proportions were prepared, using zinc slag with 20% to 30% and granite waste powder at
20% as raw materials. The interlocking bricks were then tested for compressive strength and percentage of
water absorption after 21 days.

I. INTRODUCTION cost. The ultimate objective is to contribute to the development

Bricks are widely used as infill material in India due to their
structural strength, durability, resistance to climatic conditions,
sound insulation, and flexibility. They are utilized for load-
bearing and non-load-bearing walls, partition walls, foundations,
load-bearing columns, and piers. Over the next few years, India
may require a large quantity of building materials. It has been
estimated that between 2005 and 2030, the demand for bricks in
India could increase by approximately 500 billion. The growth
rate of urbanization in India was 31.3% from 1991 to 2001 and
31.8% from 2001 to 2011. During 1991, the urban population
was 217.7 million, and it grew to 377.10 million by 2011. The
increase in urban population and the number of cities and towns
has resulted in a surge in demand in the construction and
industrial sectors. The Indian construction sector contributes
about 10% to the gross domestic product (GDP) with an annual
growth rate of 9%. As the construction sector is growing
rapidly, the demand for construction materials is also increasing.
Currently, China is the largest brick producer in Asia, and India
is second in terms of brick production. During the 9th five-year
plan (1997-2002), it was estimated that US $4.5 billion in
revenues could be generated from 170 million annual demand
for bricks. During the 11th five-year plan (2007-2012), it was
estimated that about US$ 5.3 billion in revenues could be
generated from 220 million bricks.
1.1 PROBLEM STATEMENT
The traditional use of clay bricks in construction has adverse
effects on the environment due to the high energy consumption
and air pollution caused by brick kilns. Moreover, the
construction process using clay bricks is often costly and time-
consuming. To tackle these challenges, interlocking bricks have
been introduced as a more sustainable and efficient building
material. However, there is a pressing need to improve the
quality and usability of interlocking bricks.
This study aims to investigate the potential use of industrial
waste materials, such as fly ash and granite waste powder, in
various mix designs to optimize the performance of interlocking
bricks in terms of compressive strength, water absorption, and
of more sustainable and efficient building materials that benefit
both the construction industry and the environment.
II. LITERATURE SURVEY
"Investigation of interlocking compressed earth block masonry
under lateral loading" (Year: 2018) - The paper investigates the
seismic performance of interlocking compressed earth block
masonry walls using shake table testing. The results showed
that the walls had good seismic performance and that
interlocking blocks could be a viable alternative for building in
seismic areas. [1]
"A review on interlocking compressed earth blocks" (Year:
2020) - The paper provides an overview of interlocking
compressed earth blocks, including their properties,
advantages, and challenges. The review covers topics such as
production methods, testing, and design considerations. [2]
"Mechanical behaviour of interlocking stabilized earth block
masonry under axial loading" (Year: 2018) - The paper
investigates the compressive strength and deformation
behavior of interlocking stabilized earth block masonry using
experimental testing. The results showed that the walls had
good compressive strength and deformation behavior,
indicating their suitability for structural applications. [3]
"Experimental Investigation of Interlocking Compressed Earth
Blocks Masonry under Axial Loading" (Year: 2017) - The paper
investigates the compressive strength of interlocking
compressed earth block masonry using experimental testing.
The results showed that the walls had good compressive
strength and that the interlocking blocks provided additional
stability compared to non-interlocking blocks. [4]
"Interlocking Soil-Cement Bricks: Design and Development of
Low-Cost Housing" (Year: 2015) - The paper discusses the
design and development of interlocking soil-cement bricks for
low-cost housing. The study found that interlocking soil-cement
bricks were a viable alternative to traditional bricks, with good
compressive strength and durability. [5]
"Compression performance of walls of interlocking bricks made
of iron ore byproducts and cement under simple compressive

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loading" (Year: 2015) - The paper investigates the compression
performance of walls made of interlocking bricks made of iron
ore byproducts and cement using experimental testing. The
results showed that the walls had lower strength compared to
traditional bricks, but still performed well under compression.
[6]
"Interlocking brick for sustainable housing development" (Year:
2014) - The paper investigates the compressive strength and
water absorption of interlocking bricks made using a mixture of
cement, fly ash, GFRP, stone dust, fine aggregate, and water.
The results showed that the interlocking bricks had good
compressive strength and density, with an increase in strength
with age and an increase in the amount of fly ash used. [7]
"Industrialized building system (IBS): challenges in
implementing interlocking mortarless blocks (IMB) system for
housing projects" (Year: 2014) - The paper discusses the
challenges faced in implementing the interlocking mortarless
blocks (IMB) system for housing projects, including the
reluctance of some contractors to adopt new construction
methods and the need for specialized equipment and trained
personnel for the production and installation of the blocks. [8]
"Design of a new type of interlocking brick and evaluation of its
dynamic performance" (Year: 2016) - The paper presents a new
design of interlocking brick with higher energy absorption
capacity compared to existing bricks. The study suggests that
the new design has potential for use in earthquake-resistant
buildings or blast-resistant structures. [9]
"Cyclic behaviour of mortarless brick joints with different
interlocking shapes" (Year: 2016) - The paper investigates the
cyclic behavior of mortarless brick joints with different
interlocking shapes. The study found that the compression
stress influenced the friction coefficient primarily by contact
with two bricks and that there was a significant stiffness
hardening effect for the interlocking mortarless block joints.
[10]
"Mortarless masonry with interlocking bricks" (2017) by
Sharukh S. Khan explores interlocking block masonry as a
sustainable building system that uses locally available resources
and is cost-effective, eco-friendly, easy to adopt, faster to build,
and energy-efficient. The research revealed that the
compressive stress of interlocking bricks is much less than that
given in IS 1905-1987, making it an aesthetically pleasing and
affordable option for faster construction. [11]
"Development of interlocking masonry bricks and its structural
behavior" (2017) by Amin Al-Fakih, Bashar S Mohammed, Fadhil
Nuruddin, and Ehsan Nikbakht discusses the use of interlocking
bricks in masonry structures as an alternative to conventional
bricks. The interlocking system's shape varies in complexity,
making it easy and fast to produce and assemble. [12]
"Physical properties of the rubberized interlocking masonry
brick" (2018) by Mohd. Shahir Liew and Wesam S Alaloul
examines the physical properties of stretcher interlocking
rubberized bricks, including density and water absorption.
Rubberized interlocking bricks exhibit uniform size and shape,
making them easy to lay in masonry, but they have higher
water absorption due to the presence of crumb rubber. [13]
"Mechanical behaviour of rubberized interlocking bricks for
masonry structural applications" (2018) by Amin Al-Fakih,
Bashar S. Mohammed, Mohd Shahir Liew, and Wesam S Alaloul
investigates the compressive strength of rubberized
interlocking bricks. The study found that the compressive
strength of the developed rubberized interlocking brick exceeds
the minimum requirement of the load-bearing masonry unit
(13.1 MPa) accordance to ASTM, making it suitable for
structural applications. [14]
"Performance evaluation of interlocking bricks using granite
waste powder" (2019) by Fatheali Shilar and S.S Quadri
examines the use of industrial waste (granite powder) in
making interlocking bricks. The study investigates the effect of
varying proportions of granite waste powder in fly ash-based
interlocking bricks on compressive strength and percentage of
water absorption. The research shows that interlocking bricks
require less mortar than clay bricks and are faster to construct.
[15]
"Substructural behavior of lightweight interlocking brick
system" (2020) by N.Rashidi studies the design proportion of
interlocking light brick mixtures like concrete, sand, and more.
The study investigated the substructural behavior of
lightweight interlocking bricks under vertical loads and found
that they are suitable for use in low-rise buildings. [16]
"Evaluation of strength and moisture absorption characteristics
of lime treated clay interlockings" presents a study on the
effect of lime treatment on lateritic soil interlockings. Results
showed a reduction in liquid and plastic limit, and a decrease in
water absorption up to 8% addition of lime. Compressive
strength was found to be lower than specification, making the
bricks suitable for non-structural use. [17]
"Development and performance evaluation of interlocking
bricks" focuses on the development of eco-friendly and cost-
effective interlocking bricks made from waste materials and
hydraulic lime. Results showed that the interlocking bricks had
a 30% higher compressive strength than conventional red
bricks and were almost 40% cheaper. [18]
"Strength enhancement of interlocking hollow brick masonry
wall with low-cost mortar and wire mesh" presents an
experimental investigation on the diagonal compressive
response of Cement-clay Interlocking Hollow Brick Masonry
(CCIHBM) walls. Results indicate that the use of cement mortar
and wire-mesh is practical for strengthening CCIHBM walls. [19
"Performance of interlocking brick walls against out-of-plane
excitation" presents a study on the performance of Lego-
shaped interlocking bricks in resisting out-of-plane loading
compared to rectangular bricks. Results showed that the
interlocking brick walls had a better performance in resisting
out-of-plane dynamic load due to the interlocking system if the
wall is thick enough to exert the interlocking effect. [20]
III. MATERIALS & METHODOLOGY
The materials used in the preparation of interlocking were:
3.1 Cement
3.2 Granite waste powder
3.3 Zinc slag
3.1 Cement:
Cement is used with other materials as a replacement, 43 grade
of cement (Ultratech brand) is procured from the concrete lab in
college and used for experimentation after testing. The obtained
results are specific gravity of 3.16 and a setting time of 30min.
Figure 1.0 OPC 43 grade cement
3.2 Granite waste powder: 5. Casting and Curing of Bricks: I used MM 7.5 (1:3)
mortar mix to cast the interlocking bricks. I prepared
three mixed designs according to IS 2250 (1981). I
ensured that the materials were mixed adequately
before casting them into the prepared molds (plastic
+ wooden). For curing, I used the water immersion
method, where the bricks were demoulded after 24
hours of casting and kept in the curing tank for 21
days.

6. Testing of Bricks: I tested the interlocking mortar

bricks for two physical properties: Compressive
strength test - I tested the cured bricks for
compressive strength according to IS 3495-1992
part-1. I took an average value of 3 specimens for
each mix. Water absorption test - I carried out this
test according to IS 3495-1992 part-2.

V. COST ANALYSIS

Table 1.0
Granite waste powder is industrial waste, procured from Ilakal
quarry in Hubli, The specific gravity of the Granite waste
powder obtained was 2.43 physical and chemical tests were
conducted on procured Granite Waste powder details are given

3.3 Zinc slag:

Zinc slag possesses properties such as high compressive

strength, good durability, low permeability, high specific
gravity, and excellent wear resistance. It also has a relatively Table 2.0
low rate of water absorption, making it an ideal material for use
in construction with a specific gravity of 3.

METHODOLOGY
Figure 2.0 Methodology Chart

1. Brick Design: I designed a new 2D and 3D model of

interlocking brick using AutoCAD. The size and Table 3.0
volume of the brick were 230x150x150mm and
5175x10³ mm³, respectively.

2. Mix Designs: I prepared three different mix designs,

namely Cement + Fine aggregate, Cement(80%)+
Granite Powder (20%) + Fine aggregate, Cement +
Fine aggregate (70%) + Zinc slag (30%).

3. Mould Preparation: In this phase, We prepared

moulds to cast the interlocking bricks as per the
finalized design and made the moulds by gluing
together plastic boxes and wooden pieces. VI. RESULTS AND DISCUSSION

4. Material Tests: I procured materials from local • The compressive strength of design 1, design 2, and design
2 2
suppliers and conducted tests on their physical 3 respectively is 5.68 N/mm , 4.40 N/mm , and 3.83 N/m
2
properties such as standard consistency of cement, m.
specific gravity, fineness, setting time, and sieve
• The optimum compressive strength was obtained by design
analysis of cement, fine aggregates, granite powder, 2
2 i.e. 4.40 N/mm .
and zinc slag.

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Chart 1.0 [4]P. Torres, H. Fernandes, S. Olhero, and J. Ferreira.
―Incorporation of Wastes from Granite Rock Cutting and
Polishing Industries to Produce Roof Tiles‖. Journal of the
European Ceramic Society, 29, 23-30, 2009.

[6]Almeida, F. Branco, and J. Santos. ―Recycling of Stone

The Slurry in Industrial Activities: Application to Concrete
Mixtures‖. Building and Environment, 42, 810-819, 2007

[7] Abhinandan R. Gupta, Dr. S.K. Deshmukh -

―Interlocking brick design – a paradigm for sustainable
construction‖ Vol 3, Issue 1, Jan 2016.

[8] Bansal Deepak - ―Interlocking dry stacked masonry‖,

8th International Masonry Conference 2010 in Dresden.

[9] Sajad Ahmed, Saddam Hussain, Mohd Awais -

• The minimum compressive strength of Interlocking brick Behaviour of interlocking of masonry units/blocks‖,2012
2
available in the market is 3 N/m m . Design 2 has 68.18 %
[11] S. Pareek. ―Gainful Utilization of Marble Waste – An
more than the minimum strength.
Effort towards Protection of Ecology & Environment‖.
• Compressive strength of the interlocking brick was found Centre for Development of Stones. Retrieved May 5, 2007.
greater than that of an ordinary solid brick of
[12] Swapnil H Patil – ―Interlocking stabilized soil bricks‖,
approximately the same size, Compressive strength of the
2 Vol 2, Issue 2, 2016.
interlocking brick and normal brick were 4.40 N/m m and
2
5.68N/mm respectively. [13] R.K. Watile, S.K. Deshmukh, H.C. Muley -
―Interlocking bricks for sustainable housing
• The pattern of interlock, provides better matrix
development‖,2009.
strengthening, and wall stability, disallows movements, and
reduces mortar. [14] R. K. Watile, S. K. Deshmukh, H.C.Muley
―Interlocking Brick for Sustainable Housing Development
• Therefore, interlocking block masonry can be adopted as a
suitable substitute for traditional masonry. And in [15] M. Celik and E. Sabah, ―Geological and Technical
conclusion, interlocking masonry can be recommended for Characterisation of Iscehisar (Afyon-Turkey) Marble
housing projects as an alternative method that is cheaper Deposits and the Impact of Marble Waste on the
than the conventional. Environment Pollution‖. Journal of Environmental
Management, 87, 106-116, 2008.
VII. CONCLUSION
[16] F. Saboya, G. Xavier, and J. Alexandre. ―The Use of
• Interlocking bricks were cast successfully as per code
Powder Marble By-product to Enhance the Properties
2185:2005 (part 1) in the mould made of wood.
ofBrick Ceramic‖. Construction and Building Materials, 21,
• Compressive strength of the interlocking brick was found 1950-1960, 2007.
greater than that of an ordinary solid brick of
[17]M. Kumar, K. Suryanarayana, and T. Venkatesh.
approximately the same size, Compressive strength of the
2 ―Value Added Products from Marble Slurry Waste‖.
interlocking brick and Normal brick were 5.68 N/mm and
2 Centre for Development of Stones, 2003. Retrieved January
4.40N/mm respectively
3, 2010 from the World Wide Web.
• Faster is construction of masonry units when we use
[18] Carrasco, E.V.M, Mantilla - ―Compression
interlocking brick then burnt clay bricks.
performance of walls of interlocking brick made of iron ore
VIII. REFERENCE by-product and cement‖,2014.

[1] Amana Ocholi, Manasseh Joel – ―Effect of variation in

temperature on some properties of cement stabilized laterite
interlocking bricks‖, 2014

[2] G. Rizzo, F. D‘Agostino, and L. Ercoli. ―Problems of

Soil and Groundwater Pollution in the Disposal of
―Marble‖ Slurries in NW Sicily‖. Environmental Geology,
55, 929-935. 2008.

[3] Jain A K, ― ―Fly Ash Utilization in Indian Cement

Industry: Current Status and Future Prospects‖, Indian
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