GOVERNMENT ENGINEERING COLLEGE LAKHISARAI

CELLULAR LIGHT WEIGHT BRICKS BY USING FOAMING

AGENT AND INDUSTRIAL WASTE
 Project Members
Under the guidance of Assistant Prof. Vikash Kumar
S.NO Name Registration no.

• 1 Sundram Anand 20101158049

• 2 Niraj Kumar 20101158026

• 3 Abhishek Kumar Goswami 20101158055

• 4 Abhishek kumar 20101158015

• 5 Abhishek kumar 20101158066

• 6 Saurav Kumar 20101158035

• 7 Vishwajeet Verma 20101158083

• 8 Arpit kumar 20101158022

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 OVERVIEW

• INTRODUCTION
• LITERATURE REVIEW
• OBJECTIVE
• MATERIAL REQUIRED
• PROJECT SURVEY
• METHODOLOGY
• ADVANTAGES
• DISADVANTAGES

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 INTRODUCTION
• CLC(Cellular Lightweight concrete) brick is a material composition for wall building made of Portland cement
water and fine aggregate blended with foaming agent

• Global warming and environmental pollution is now a global concern cellular light weight technology block can
be used as an alternative to the red brick.

• The weight of brick is light due to the air cavities formed is CLC brick.

• The index properties of CLC brick , such as density , depend on microstructure and mixture composition and the
treatment of the specimen.

• Foamed concrete has self compacting property wherein no compaction is required and it steadily flow out of a
pump outlet to fill mould.

• In CLC block air pockets are present which not interconnected so the water absorption of CLC brick lower than
any other material.

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 LITERATURE REVIEW
• R.Venkatesh, K.Venkatesh, M.Sathyavathi Civil Department, Narayana Engineering College, Nellore, Andra pradesh
[ CLC brick by using foaming agent and industrial waste]

 In this thesis an attempt is made to study regarding the properties of the brick. Which is manufactured using
cement ,fly ash , rice husk ash , foaming agent , water. They made four type of mix proportion M1:(1:1.2) without
rice husk ash , M2:(1:1.2) with rice husk ash , M3:(1:2) without rice husk ash , M4:(1:3) with rice husk ash and check
different properties of these four sample.
Properties Mix proportion
M1 M2 M3 M4

Avg dry 1508.19 1451.80 1472 886.67

density(kg/m^3)

Compressive strength 223.37 260 302.5 190.5

of 21 days(KN/m^2)
Avg water absorption 5.07 6.3 13.14 8.62

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 Dr.R.Ramesh Pandian, Dr.M.C.Sashikumar , Dr.S.Robert Ravi Dept of Civil Engg University College of
Engineering, Dindigul,Tamilnadu,India

This paper mainly focused on making cellular light weight concrete based on fly ash. This paper also focused on
the innovative idea of using fibers as a partial replacement of cement in fly ash based cellular light weight
concrete.
GRADE-A : These are used as load bearing units and have a block density in the range of 1200kg/m3 to
1800kg/m3 Dizhen Dizhi Journal ( ISSN:0253-4967)
GRADE-B : These are used as non-load bearing units and have a block density in the range of 800kg/m3 to
1000kg/m3
GRADE-C : These are used for providing thermal insulation and have block density in the range of 400kg/m3 to
600kg/m

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• H Maizir1 , R Suryanita2 and R Arditama3 1 Civil Engineering Department, Sekolah Tinggi Teknologi Pekanbaru,
Indonesia [Study on performance of lightweight concrete bricks with a ratio of sand and cement composition]

 The studies show the possibility of using CLC block in construction work. This research used two different
compositions of cement and sand ratio of mass. The first composition is called Variation 1, with a ratio of cement
and sand of 1:2, and the second composition is called Variation 2, with the ratio of cement and sand as 2 : 3. The
variable composition of the CLC bricks is presented in table 2. The research tested 24 specimens to obtain strength
and density of lightweight brick. The mass ratio of the foaming agent and water was 1:30. The CLC paste was made
with a mass ratio of cement to water of 0.5. The material consisted of cement, sand, water, and foam agent, while
the leading equipment used in this research included foam generator with a capacity of 200 liters per minute and a
compression testing machine with capacity of 100kN

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 OBJECTIVE
• To convert waste material into useful construction material such as brick , building block , tiles etc.

• Enables faster construction.

• To reduce overall cost of construction.

• Facilitates construction of unplanned wall anywhere anytime.

• To make brick lightweight , fire resistant ,thermal insulation.

• To make construction work environmental friendly and sustainable development.

• To reduce overall weight of structure.

• To contributes toward sustainable building practices and green construction initiatives.

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 MATERIAL REQUIRED
• CEMENT
 in general, adhesive substances of all kinds, but, in a narrower sense, the binding materials used
in building and civil engineering construction. Cements of this kind are finely ground powders
that, when mixed with water, set to a hard mass. Setting and hardening result from hydration.
 There are eight major ingredients in cement. The following image is showing the ingredients of cement:

Ingredient Percentage in cement

Lime 60-65
Silica 17-25
Alumina 3-8
Magnesia 1-3
Iron oxide 0.5-6
Calcium Sulfate 0.1-0.5
Sulfur Trioxide 1-3
Alkaline 0-1

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• SAND
 Sand is a mixture of small grains of rock and granular materials which is mainly defined by
size, being finer than gravel and coarser than silt. And ranging in size from 0.06 mm to 2
mm.

 It is mainly made of silicate minerals and silicate rock granular particles and the most
common mineral in the sand is quartz–also known as silicon dioxide. This is formed when
silicon and oxygen combine..

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• FLY ASH
 Fly ash is a finely divided residue made from the combustion of pulverized coal that can be used to
increase concrete durability and workability, while reducing permeability.
 The government of India has issued guidelines to use at least 25% ash in the
manufacture of clay bricks, blocks, or tiles within a radius of 50 km from coal or
lignite based thermal power plants.

• Chemical composition of Fly Ash

Component Bituminous Coal Sub-Bituminous Coal Lignite Coal

SiO2 (%) 20-60 40-60 15-45

Al2O3 (%) 5-35 20-30 20-25
Fe2O3 (%) 10-40 4-10 4-15
CaO (%) 1-12 5-30 15-40
LOI (%) 0-15 0-3 0-5 GEC LAKHISARAI
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• FIBER

 fibers is a class of material which are having continuous filaments or having discrete elongated
pieces similar to the length of thread.
 Fiber are usually used in concrete to control cracking due to plastic shrinkage and to drying
shrinkage.
 A variety of synthetic fiber and plant fiber such as polyolefin ,glass, carbon, jute fiber , and coconut
fiber are used as reinforcement in concrete .

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.

 In CLC we generally prefer polypropylene fiber. It is a thin matte white fiber. This type of fiber is
produced by forcing a hot mass of polypropylene through a very small holes . After thermal drying,
the resulting fiber are cut into pieces of required length and a special chemical treatment is
performed , which further contributes to the uniform distribution of fiber in the foamed.
 Micro cracking is much more less when we used polypropylene fiber.

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• Foaming agent

 A foaming agent is a material such as surfactant or blowing agent that facilitates the formation of
foam.
 A foaming agent reduces surface tension of a liquid which helps in creation of foam.

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 PROJECT SURVEY
1. Equipment at manufacturing site

foam generator wire cutter

slurry trolley

mould Mixture machine

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Conveyor belt
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 1. material at manufacturing site

Foaming agent Poly propylene fiber

water

flyash GEC LAKHISARAI

cement
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 quantity of material
• for preparation one cubic meter of slurry material requierd

1. Cement—250 kg
2. Fly ash—500 kg
3. Water—250 kg
4. Foaming agent—1 to 1.2 ( for one cubic meter of slurry)
CLC Blocks Size Blocks per Cum
600mm x 200mm x
Rs. 50
600mm x 200mm x 100mm
83 Blocks
100mm
600mm x 200mm x
Rs. 70
600mm x 200mm x 150mm
55 Blocks
150mm
600mm x 200mm x
Rs. 90
600mm x 200mm x 200mm
41 Blocks
200mm
600mm x 200mm x
Rs. 110
600mm x 200mm x 250mm
33 Blocks
250mm
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 Manufacturing process
Step 1 –add water into mixture machine.
Step 2 –add cement into mixture machine.
Step 3 –add fly ash and also Poly propylene fiber
into mixture machine .

After mixing these three material

Step 4 – add foam in mixture.

Mixture is stop after when slurry attend its homogeneity.

Step 5 –put all slurry into the trolley. After that with the help of trolley
slurry is transported to the casting area.

Step 6—slurry is put into the mould frame. And extra slurry is removed.

Step 7– after 24 hours of settling start curing for minimum 15 days.

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 • equipment required
METHODOLOGY
 mixer—a mixer has a rotatory blade which helps to mix required material for preparation of slurry.

 Belt conveyor—a belt conveyor is a system designed to transport or move physical items .such as
cement sand fly ash etc.

 Foam generator—foam generator for CLC blocks is famous for making high quality ,stable and constant
flow of foam.

 Slurry trolley—it is used to transport slurry from mixing plant to mould.

 Mould—a mould is used to make particular shape of clc blocks.

 Wire cutting machine—this machine used for create precise pattern.

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.
 It is produced by initially making slurry of Cement + Fly Ash +Water, which is further mixed with the
addition of pre-formed stable foam in anordinary concrete mixer under ambient conditions.
• Raw material preparation
• The raw materials required for CLC bricks include cement, fly ash, water, foam generator, and
additives. In order to manufacture one cubic metre of CLC bricks, you need approximately five bags of
OPC 53 grade cement and 500 kg of fly ash.
• Foaming
• A foam generator is used to produce stable foam from a foaming agent. About 1.2 kg of foaming agent
and 30 litres of water are mixed and then added to the concrete mixture. The foam creates air bubbles
in the mixture, resulting in lightweight bricks.
• Weighing
• A litre of slurry is taken from the mixer and weighed for density. If the right density is attained, the
slurry goes to the next stage of casting into moulds.

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• Casting
• The foamed concrete mixture is poured into pre-designed moulds or formwork. The moulds are
typically made of steel or plastic and have the desired shape and size of the bricks.
• Curing
• After casting, the bricks are left to cure for 28 days to gain strength and stability. Curing can be done
through natural curing or by using steam curing.
• Demoulding
• Once the curing process is complete, the bricks are removed from the moulds. Care should be taken
to ensure that the bricks are not damaged during demoulding.
• Drying
• The demoulded bricks are then left to dry in a controlled environment. This helps in further
strengthening the bricks and reducing moisture content.
• Quality control
• Before the CLC bricks are ready for use, they undergo quality control checks. These checks ensure
that the bricks meet the required standards and specifications.
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 ADVANTAGES
•Light in Weight: The density of CLC blocks vary from 600 to 800 Kg/cum. This is almost three times less
than the traditional clay bricks or flyash brciks.

•Reduced Construction Cost: The overall dead load of structure is decreased when CLC blocks are used
in construction. By optimizing the design accordingly house owners can save money on major construction
materials like cement and steel.

•Eco friendly: CLC blocks are made of material such as fly ash and other industrial wastes. The production
process of CLC blocks don’t release any harmful effluents that affects ground, water or air.

•Sound and Thermal Insulation: CLC Blocks are excellent for both Sound insulation and Heat
Insulation. This decreases the energy spent on heating and cooling the houses thereby decreasing the
electricity costs for the house owners.

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•Lower Water Absorption: Due to the presence of air pockets which are not interconnected, the water absorption of
CLC blocks are relatively lower than any other materials. This compares much better than concrete 50% and ordinary
brick, which has water absorption of around 50% to 80%. The low water absorption property of these blocks will help
to reduce the cracks in the walls.

•Fire Protection: Foam concrete blocks offers grate fire protection. With a just 100mm thickness of wall with density
of 1000 kg/m3, offers fire endurance for heat transmission for 4 hours without releasing any toxic fumes during the
fire. Fire rating of cellular concrete is far superior to that of brickwork or dense concrete.

•Ease to Handling: Due to its less weight CLC blocks are easy to handle and install, thus minimizing the construction
costs. They also require lesser materials like cement and sand during construction for bonding.

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 DISADVANTAGES
• Less strength than regular concrete .

• Required careful handling.

• Not suitable for load bearing structures.

• Limited availability in some reason.

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THANK YOU

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