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Journal of Building Engineering 14 (2017) 7–14

Contents lists available at ScienceDirect

Journal of Building Engineering


journal homepage: www.elsevier.com/locate/jobe

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

properties and helps in improving the strength of concrete [17,18].


Different researchers [19,20] have studied the utilization of fly ash in
burnt clay bricks. Fly ash can be utilized in production of 10% lighter
bricks as compared to clay bricks [6]. Fly ash also increases the strength
and reduces water absorption [19]. Leiva et al. [21], observed the in-
crease in compressive strength of fly ash bricks at firing temperature of
1000 °C. However, clay bricks showed decrease in compressive strength
with increasing fly ash content at firing temperature lower than
1000 °C. Çiçek and Çinçin reported the superior thermal conductivity of
fly ash bricks as compared to conventional clay bricks [22] Fly ash
bricks usually have smooth edges than burnt clay bricks [6]. The uti-
lization of fly ash is less as compared to its production. It is estimated
that approximately 0.16 billion tons of fly ash is produced every year
[5]. In many parts of the world, fly ash is used to replace cement [23].
Environmental problems exist with respect to coal in countries where
coal is the main source of power generation [7]. Moreover, the cost of
production of fly ash bricks is 2% less as compared to burnt clay bricks
[20].
Fig. 1. Brick manufacturing industry.
In this study, the use of FA was focused for brick manufacturing.
Utilization of FA not only improved the brick performance but also
reduced the environmental pollution and landfill burden. FA was used Table 1
in different dosages (5%, 10%, 15%, 20%, 25% by clay weight) in clay Test matrix for brick specimens.

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

Fig. 2. Mixing of raw material.

specimens were tested after 24 h of capping. For flexural test, bricks


were placed on flat support with frog on top (compression) side. Load
was applied in the middle of brick specimen using flat loading plate in
the direction of brick depth. The displacement rate was 1.25 mm/min.
The span of tested brick specimens was 200 mm. The modulus of rup-
ture for tested bricks can be calculated as follows:

l
3W ( 2 − x )
S=
bd 2 (1)

where, S is the modulus of rupture, W is the maximum load, l is the span


length, x is the average distance from failure plane to the middle of
brick specimen, b and d are the width and depth of brick specimen,
respectively.
To find out the breaking load, brick specimens were supported flat
on the solid rods of 25 mm diameter, placed at 12.7 mm from edges of
the specimen. The support was extended to the entire width of the
brick. The load was applied at the mid span of the specimens, with frog
on the bottom (tension) side. Load was applied through steel plate
having 6.5 mm thickness and 38 mm width extended to the entire width
of the specimen (Fig. 5). The displacement rate was 1.27 mm/min. The
breaking load per width of brick is calculated as Fig. 4. Brick specimen during weight determination.

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

Fig. 3. Process of brick manufacturing.

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S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14

Fig. 7. Efflorescence results on brick specimens after 60 days.

102
Fly Ash
100 Clay

Percentage Finer (%)


Fig. 5. Brick specimen under breaking load test setup.
98

96

94

92

90

88
10.00 1.00 0.10 0.01
Particle Size (mm)

Fig. 8. Particle size distribution of raw materials.

Table 2
Particle size distribution analysis.

Particle content Clay (%) FA (%)

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.

5. Results and discussion 5.1.2. Chemical analysis


The chemical composition of clay and fly ash is presented in Table 3.
5.1. Properties of materials used for the manufacturing of bricks It was observed that SiO2 content in fly ash (54.90%) was lower than
that of the clay (81.10%). However, Al2O3 and Fe2O3 contents were
5.1.1. Sieve analysis higher in fly ash compared to clay. Normally, it is preferred that clay
The particle size analysis of clay and fly ash was performed in ac- which is used for the brick production should have silica in the range of
cordance with ASTM D422 (Standard test method for particle-size 50–60% and CaO more than 6% referred as calcareous [4]. If the
analysis of soils) and results are shown in Fig. 8. Results showed that concentration of iron, calcium and magnesium oxides are greater than
raw materials have variety of particle sizes. The major percentages of 9%, the clay is classified as low refractory material [27]. Clay used in
particles for soil were 0.09% of gravel size, 0.42% of coarse sand size, this study has the amount of silica greater than required and on the
1.25% of medium sand size, 5.47% of fine sand size and 92.77% of silt basis of composition, it is refereed as non-calcareous with high re-
and clay size together (Table 2). In fly ash, a very small amount of fractory properties.

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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

Weight per Unit Area (Kg/m²)


Elements Clay (%) Fly ash (%)
120
Silica (SiO2) 81.10 54.90
100
Calcium Oxide (CaO) 4.20 14.28
Alumina (Al2O3) 5.80 13.50 80
Iron Oxide (Fe2O3) 3.10 7.06
SO3 2.35 3.65 60
Moisture 1.45 1.31
Magnesium Oxide (MgO) 0.20 0.40 40
Loss on Ignition 2.27 0.47
20

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.

Fig. 9. XRD analysis of materials used in brick manufacturing.

11
S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14

25 120

100 Clay + Fly Ash Bricks


20 Clay + Fly Ash Bricks
Clay Bricks
Compressive Strength (MPa)

Breaking Load (N/mm)


Clay Bricks
80
15
60
10
40

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.

5.2.3. Modulus of rupture: flexural test 5.3. Durability properties


Fig. 12 shows the results of flexural strength of burnt clay bricks
after incorporating fly ash. Average of five brick specimens were re- 5.3.1. Water absorption
ported in the results having coefficient of variation (COV) lesser than Durability of bricks is governed by water absorption [44]. Fig. 14
15%. Results showed that the burnt clay bricks without fly ash have depicts the water absorption results of brick specimens incorporating
higher flexural strength as compared to the bricks having fly ash. De- fly ash. Water absorption decreased with the increase in content of fly
crease in flexural strength was observed with increase in fly ash con- ash. For example, bricks incorporating 15% fly ash showed around 19%
tent. Minimum flexural strength was observed for bricks having 25% of water absorption; while, it was 12% for specimens without fly ash. This
fly ash (i.e. 3 MPa), which is 60% less than the control specimen. Si- can be attributed to the high absorbing capacity of fly ash [45,46].
milar results were observed in previous study [36]. According to ASTM Results are similar to those reported in previous studies [35,36]. All the
C67, the minimum requirement for flexural strength of bricks is tested brick specimen incorporating fly ash showed water absorption in
0.65 MPa. Brick specimens after incorporating fly ash showed modulus the range of 15–24%. According to ASTM C20, water absorption should
of rupture in the range of 3–6 MPa. be less than 17% and 22% for severe and moderate weather resistance,
respectively. In many parts of the world water absorption is considered
acceptable within the range of 20–30% [5,24,33]. Bricks incorporating
5.2.4. Breaking load
5% fly ash can be used as severe weather resistant bricks. Whereas,
Fig. 13 shows the results of breaking load per unit width of burnt
bricks incorporating up to 20% fly ash can be used as moderate weather
clay bricks after incorporating fly ash. Average of five brick specimens
resistant bricks. Therefore, it can be concluded that the bricks speci-
were reported in the results having coefficient of variation (COV) lesser
mens having fly ash up to 20% were within the permissible limits of
than 10%. Results depict that the burnt clay bricks without fly ash had
water absorption, which leads to durable construction.
higher breaking load. Decrease in breaking load was observed with
increase in fly ash content. For instance, breaking load of brick spe-
cimen having 5% fly ash was decreased approximately by 12% as 5.3.2. Efflorescence
compared to the specimen without fly ash. Also, 49% reduction in According to ASTM C67, efflorescence in brick specimens should be
breaking load was observed for bricks incorporating 25% fly ash. The investigated after 7 days immersion in water. No visible signs of ef-
reduction in breaking load is in agreement with previous studies florescence were observed on samples after 7 days. Therefore, test was
[36,43]. The minimum requirement for breaking strength of bricks is continued for longer period to observe any efflorescence which would
83 N/mm as per ASTM C1272 (Standard specification for heavy vehi- appear at later stage. Specimens were kept immersed in water for 45
cular paving brick). Brick specimens after incorporating fly ash ex- days. Afterwards, bricks were allowed to dry till 60 days and observa-
hibited breaking load per unit width values in the range of 58–113 N/ tions were recorded for efflorescence. Fig. 15 shows the efflorescence
mm. Therefore, it can be concluded that clay up to 10% can be effec- results for the burnt clay brick incorporating fly ash. Slight ef-
tively replaced with fly ash if breaking load is a concern. florescence (7.4% of the surface area) was observed on the clay brick

12
S. Abbas et al. Journal of Building Engineering 14 (2017) 7–14

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