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13-Safeer Abbass
13-Safeer Abbass
Production of sustainable clay bricks using waste fly ash: Mechanical and MARK
durability properties
⁎,1
Safeer Abbasa,1, Muhammad A. Saleema, Syed M.S. Kazmib,c, Muhammad J. Munirb,c,
a
Department of Civil Engineering, University of Engineering and Technology, Lahore 54000, Punjab, Pakistan
b
School of Engineering, RMIT University, 376-392 Swanston Street, Melbourne, Victoria 3001, Australia
c
Department of Civil Engineering, Mirpur University of Science and Technology (MUST), Mirpur 10250, AJK, Pakistan
A R T I C L E I N F O A B S T R A C T
Keywords: Burnt clay brick is one of the ancient building material. The use of waste materials in bricks can lessen the
Brick consumption of clay material and reduce the environmental burden due to accumulation of waste materials.
Clay Furthermore, addition of recycled materials can decrease the high carbon footprint. In the current study, bricks
Fly ash were manufactured using fly ash (by-product of coal) and conventional earthen materials. Fly ash was acquired
Mechanical properties
from the coal power plant. Manufacturing of brick specimens was done in a local brick industry. The main
Durability
variable in this study was the percentage of fly ash (i.e. 0–25% of clay). Results indicate that the compressive
strength of bricks incorporating fly ash was lower as compared to that of clay bricks without fly ash. However,
compressive strength of bricks incorporating up to 20% of fly ash satisfied the minimum requirements of the
Pakistan Building Code. Reduction in weight was also observed in the fly ash bricks which would lead to overall
weight reduction of the structures. Furthermore, less efflorescence was observed in bricks incorporating fly ash.
Therefore, it can be concluded that clay bricks incorporating fly ash can be helpful in producing more sustainable
bricks leading to economical solution.
1. Introduction problem, some countries like China are now limiting the use of clay for
brick production [9,10].
Brick manufacturing is one of the oldest industry having traces since Burnt clay bricks usually have higher strength than sun dried bricks.
8000 BCE [1]. Brick is a burnt block obtained after burning of clay in a However, in terms of strength and durability, these bricks are observed
kiln. Earth bricks used in the construction of shelters accommodate weaker than cement blocks [5]. To overcome these deficiencies, dif-
30% of world population, which is living in earthen structures [2]. ferent pozzolanic materials are added in clay bricks as admixtures.
Burnt clay bricks are made after subjecting clay mixture through These materials not only increase the bond between particles but also
molding, sun drying and burning processes. The properties of burnt clay help in lowering the melting temperature by acting as a flux [4]. As a
bricks depend upon the nature of material and manufacturing process result, strength of the clay brick increases [11].
[3]. Temperature also plays a key role in development of brick prop- Various researchers have explored the use of different waste mate-
erties [4]. Temperature melts the naturally occurring oxides of silica in rials in burnt clay bricks. Waste glass can be used as an additive in burnt
clay. After cooling, bond develops between the clay particles. clay bricks. By using waste glass, bricks with improved compressive
In many parts of the world, burnt clay bricks are still commonly strength and water absorption can be produced [12]. Agro-wastes like
utilized as a building material. China is the largest brick producing sugarcane bagasse ash and rice husk ash can also be utilized in clay
country [5]. India is the second largest country in brick production bricks [3,13,14]. Although, these wastes reduce the strength and in-
having an annual consumption of 180 billion tons of bricks [6]. Fertile crease the water absorption of clay bricks; however, they result in
soil is being rapidly consumed for brick manufacturing. In India, 300 lighter and energy efficient structures by improving insulation proper-
million tons of fertile soil is consumed per day for brick manufacturing ties of bricks [3,5]. Lighter bricks are also preferred in earth quake
[7]. In Ontario (Canada), production of clay bricks is approximately affected areas [15,16].
700 million per year [8]. It is also considerable that clay deposits are Fly ash (FA) is a fine waste material of power generation plant. It is
under depletion in many parts of the world. Therefore, to overcome this obtained after coal combustion. The FA usually possesses pozzolanic
⁎
Corresponding author at: School of Engineering, RMIT University, 376-392 Swanston Street, Melbourne, Victoria 3001, Australia.
E-mail address: junaidmunir17@gmail.com (M.J. Munir).
1
Joint first author.
http://dx.doi.org/10.1016/j.jobe.2017.09.008
Received 29 November 2016; Received in revised form 7 June 2017; Accepted 15 September 2017
Available online 19 September 2017
2352-7102/ © 2017 Elsevier Ltd. All rights reserved.
S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14
bricks to explore its effect on different mechanical as well as durability Mixture Fly ash (%) Clay (%) No. of specimens
properties. Although, many studies exist regarding the utilization of fly
ash in clay bricks; however, in all the studies, bricks with fly ash were 1 0 100 25
prepared in laboratory under controlled conditions. This study was 2 5 95 25
3 10 90 25
focused on the production of fly ash burnt clay bricks on large scale in
4 15 85 25
the industrial kiln. 5 20 80 25
6 25 75 25
2. Research significance and objectives
Disposal of waste materials is one of the major environmental pro- prepared at brick kiln site (Fig. 1) by varying the fly ash proportions
blems in the world. In many parts of world, dumping landfill sites are (Table 1). General hand mixing and molding technique was adopted for
limited. Therefore, dumped waste material is not only polluting the brick manufacturing. Materials were weighed according to desired
environment but also a burden on the earth. Furthermore, in some parts proportions and manually mixed (Fig. 2(a)). Afterwards, plasticity
of the world, the waste material is discharged into the rivers, which water (20.8–18.7%) was added into the dry mix and manual mixing
causes spread of various deceases. For instance, in Egypt wastes are continued until a homogenous mixture achieved (Fig. 2(b)).
discharged in River Nile [24] and as a result, aluminium concentration
in the water increases, causing the major diseases like, Alzheimer and 3.2. Brick manufacturing
mental retardation [25]. In Asia, 4.4 billion tons of solid waste is pro-
duced annually [26]. Therefore, due to environmental concerns, there For the molding of bricks, balls of clay (Fig. 2(c)) were made on a
is an urgent need to utilize these wastes, especially due to the accu- dry area and bricks were molded using these balls of clay. Brick mould
mulation of these pollutants. Moreover, natural resources of clay are was oiled from inside before putting clay ball in it. Moreover, a dry sand
also under depletion due to the continuous extraction. coating of clay ball was done to prevent sticking of clay with the mould.
In this research, the consumption of fly ash in burnt clay bricks was Brick specimens were marked with numbers according to the quantity
investigated for the manufacturing of sustainable bricks. The primary of fly ash added. General industry practice followed in Pakistan to
focus of this research was to experimentally investigate the effect of ash prepare bricks was adopted during the study. Freshly prepared wet
on the mechanical and durability properties of burnt clay bricks. bricks were allowed to dry for 4–5 days in open air (Fig. 3(a)) in sun-
Utilization of such wastes is not only helpful to address problems re- light to harden enough to transport to the kiln undamaged. Afterwards,
lated to pollution but would also reduce the number of landfill site. bricks were placed in kiln and subjected to fire for three days. The
Utilization of these wastes will reduce the depletion of natural re- temperature in the kiln was around 800 °C. After 20 days, burnt clay
sources. It will also help in the production of innovative construction bricks were removed from the kiln (Fig. 3(b)).
material.
4. Experimental methodology
3. Experimental program
4.1. Mechanical properties
3.1. Materials and mixing of raw materials
The mechanical properties of brick specimens were determined as
The materials used for the manufacturing of bricks were clay, fly ash per ASTM C67 (Standard test methods for sampling and testing brick
and water. Clay used in the present study was taken from Pak Bricks and structural clay tile). Five specimens were tested for each mix pro-
Company, Multan, Pakistan. The used fly ash was obtained from a local portion. Firstly, the unit weight of brick specimens was determined. For
coal power plant. Raw materials (clay and fly ash) were used without 24 h, brick specimens were oven dried at 100 °C and then cooled for 5 h
any processing during the study. The sieve analysis, chemical analysis at room temperature (25 °C). Afterwards, weight of brick specimens
and x-ray diffraction (XRD) of clay and fly ash was performed in order was determined using weighing balance of 0.50 g least count (Fig. 4).
to identify the chemical and mineralogical characterization. The compressive strength was determined by capping the brick
A total of 150 brick specimens of size 225 × 112 × 75 mm were specimens using plaster of paris for uniform application of load. The
8
S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14
l
3W ( 2 − x )
S=
bd 2 (1)
P
p= 4.2. Durability properties
w (2)
where, p is the breaking load per unit width, P is the transverse Durability properties like water absorption and efflorescence were
breaking load, w is the width of brick specimen. determined according to ASTM C 67. Water absorption was determined
9
S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14
102
Fly Ash
100 Clay
96
94
92
90
88
10.00 1.00 0.10 0.01
Particle Size (mm)
Table 2
Particle size distribution analysis.
Gravel 0.09 0
Coarse Sand 0.42 0
Medium Sand 1.25 0.22
Fig. 6. Brick specimens submerged in water. Fine Sand 5.47 10.12
Silt + Clay 92.77 89.6
after drying the brick specimens in oven. Afterwards, for 24 h, the oven
dried specimens were submerged in clean water at room temperature
medium size sand was present i.e., 0.22%, whereas, major percentages
(Fig. 6). The excess water was wiped off from the surface of the spe-
of particles were 10.12% of fine sand size and 89.66% of silt and clay
cimens before weighing.
size. Results indicated that the particle size distribution of both clay and
To study the efflorescence behavior of bricks, specimens were im-
fly ash is approximately the same having considerable particles of the
mersed in a constant depth of 25 mm water on one end. After 45 days,
size of fine sand, silt and clay. Particle size distribution plays an im-
water was allowed to dry till 60 days and observations were recorded
portant role to controls the porosity and strength development [3]. As a
for efflorescence (Fig. 7).
result, durability of the bricks also depends upon the particle sizes.
10
S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14
Table 3 160
Clay + Fly Ash Bricks Clay Bricks
Chemical composition of materials used for brick manufacturing.
140
0
Fly ash was composed essentially of SiO2, CaO and Al2O3 with 5% 10% 15% 20% 25%
oxides of iron, sulfur and magnesium in small quantity. The con- Percentage replacement
centration of SiO2 plus Al2O3 plus Fe2O3 was 75.46% and sulfur trioxide
Fig. 10. Weight per unit area incorporating various fly ash dosages.
was less than 4%. Moisture and loss of ignition (LOI) were also less than
3% and 6% respectively. LOI for clay and fly ash at 1000 °C was de-
termined as 2.27% and 0.47%, respectively. Therefore, as per ASTM [34]. Results are similar as reported in previous studies [35,36]. As a
C618 (Standard specification for coal fly ash and raw or calcined nat- result of weight reduction, transportation and labor cost reduces. Light
ural pozzolan for use as a mineral admixture in concrete), fly ash is weight bricks are also helpful in overall weight reduction of structures,
classified as class F pozzolan. Chemical composition of fly ash mainly which improves the performance of structures in earthquake affected
depends upon the composition of coal and the combustion technique areas.
used [28]. LOI was observed higher for clay as compared to fly ash,
which is the indication of the presence of organic matter [29–31].
Plasticity of mixture is easily achieved if organic matter is present [32]. 5.2.2. Compressive strength
Compressive strength results of burnt clay bricks incorporating fly
ash are shown in Fig. 11. Average of five brick specimens were reported
5.1.3. XRD analysis in the results having coefficient of variation (COV) lesser than 10%.
Fig. 9 depicts the results of XRD analysis of the clay and fly ash. XRD Results depict that the burnt clay bricks without fly ash had higher
analysis shows that major mineral phases in clay were quartz (SiO2) compressive strength. It was observed that compressive strength de-
with small amount of calcite (CaCO3); while, quartz (SiO2) and hema- creased with increasing percentage of fly ash. For instance, compressive
tite (Fe2O3) phases were observed in fly ash with traces of calcite strength of brick specimen incorporating 5% (by weight) fly ash was
(CaCO3). Results are in accordance with chemical analysis. Clay bricks decrease by approximately 17% in comparison with control clay bricks.
incorporating fly ash have different properties as compared to clay The compressive strength reduced by more than 50% for 20% and 25%
bricks because of different chemical compositions and mineral phases addition of fly ash. This may be because the clay bricks incorporating
[33]. fly ash need high calcination temperature of 1050 °C to attain higher
strength [37]. Normally, variation in compressive strength depends on
5.2. Mechanical properties the soil type, kiln type and the process of manufacturing [38]. Porosity
increases with increase in the amount of fly ash resulting in to increased
5.2.1. Weight per unit area water absorption and decreased compressive strength [21]. Similar
Fig. 10 depicts the weight per unit area results after incorporating behavior is observed during the study. Results are similar to those re-
fly ash in burnt clay bricks. Decrease in weight per unit area of speci- ported by some of the previous studies [36,37]. According to Pakistan
mens was observed as the fly ash percentage was increased, resulting in Building Code, minimum requirement of compressive strength for
light weight bricks. For instance, 15% replacement of clay with fly ash bricks is 8.25 MPa [39]. Similarly, in many parts of the world, the
results in 13% lighter bricks. This phenomenon was more prominent minimum strength requirement for burnt clay bricks ranges from 5 to
with 25% fly ash, which in turn reduced the weight of the bricks up to 10 MPa [40–42]. Therefore, it can be concluded that up to 20% of clay
18%. This can be attributed to lighter weight of fly ash than the clay can be effectively replaced with fly ash.
11
S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14
25 120
5
20
0 0
5% 10% 15% 20% 25% 5% 10% 15% 20% 25%
Percentage replacement Percentage replacement
Fig. 11. Effect of FA dosages on compressive strength. Fig. 13. Effect of FA dosages on breaking load.
7 30
Clay + Fly Ash Bricks
6 Clay Bricks
Clay + Fly Ash Bricks 25
Modulus of Rupture (MPa)
Water Absorption(%)
5 Clay Bricks
20
4
15
3
10
2
5
1
0 0
5% 10% 15% 20% 25% 5% 10% 15% 20% 25%
Percentage replacement Percentage replacement
Fig. 12. Effect of FA dosages on modulus of rupture. Fig. 14. Effect of FA dosages on water absorption.
12
S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14
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