Professional Documents
Culture Documents
Introduction
Traditionally, we are using burnt clay bricks for construction. It is a clay product which proved
its importance since the dawn of civilization. For production of bricks, we are using good plastic
clay as primary raw material. This clay is often obtained from prime agricultural land, causing
land degradation as well as economic loss due to diversion of agricultural land. Though clay is
easily and abundantly available in nature, its resources has a threshold limit and utilization of
clay has reached such a point in construction. Excess use of good clay caused erosion of fertile
soil and soil degradation and disturbed the ecology.
The burnt clay brick industry in India produces over 60 billion clay bricks annually resulting in
strong impact on soil erosion and unprocessed emissions. For production of these bricks about
160 million tons of top soil, making barren 7500 acres of fertile land. (1) Because of all these ill
effects, this is proper time to search an alternative of the burnt clay bricks.
Use of Cement, Fly Ash and Phosphors gypsum As An alternative for burnt Clay Bricks
This is new technology which works with the strength of fly ash, lime and gypsum chemistry.
The slow chemistry of fly ash and lime is maneuvered by tapping ettringite phase to its
threshold limits through sufficient limit of gypsum. Therefore, it does not require heavy duty
press or autoclave, which is otherwise required in case of only fly ash and lime. The process
completely eliminates the thermal treatment (except open air drying) and does not require
combustion of any fossil fuel. The ingredients of the units such as bricks and blocks, fly ash,
lime (from OPC) and gypsum are well-known minerals that are widely used in the industries. All
these minerals are available in the form of wastages and by-products from industrial activities.
In certain areas where by product lime is not available in adequate quantity, Ordinary Portland
Cement (OPC) can be used as the source of lime producing the good quality of bricks and
blocks. This technology is proved to be environmentally safe and sound.
Materials
Fly ash used for the present study is obtained from the Thermal Power Plant, Eklehara, Nashik.
As good quality of lime is not available in the vicinity OPC is used as a source of lime and
Phosphogy- psum (CaSO 2H O) is obtained from Savil Agrovates, a Kopargaon based company
producing agricultural product where phosphogypsum is available as a waste.
4
Mix Proportions
Table 1: Mix Proportion
Sr.
Mix
Constituent
materials
(Percentage)
Fly Cemen
P.G.
Ash
t
01
M-1
25
50
25
02
M-2
30
40
30
03
M-3
35
30
35
04
M-4
40
20
40
As our main intention is to search an alternative material for the conventional burnt clay bricks
by using the waste materials and to produce a low cost building material, emphasis is given to
use the waste products to the maximum extent and hence following mix proportions are used
for the present study. The mix proportions are given in the Table No.1 are in terms of dry
weights of the ingredients. Shrinkage cracking is a major weakness in gypsum based blocks.
Shrinkage cracking can be minimized by keeping the water content of the binder as low as
possible.
No. Designation
Methodology
Mixing of Raw Materials
The weighed quantity of Phosphogypsum, Cement and fly ash were thoroughly mixed in dry
state in a pan with the help of a trowel. The mixture in dry state is mixed till it attains a uniform
color. When the mixture attains uniform color weighed quantity of water is added in the mixture
of fly ash, cement and phosphogypsum. After addition of the required quantity of water the
mixture is thoroughly mixed with the help of trowel in a pan. After mixing the mix initially with
the trowel the mixture is again mixed thoroughly by kneading until the mass attained a uniform
consistency.
To calculate the quantity of water to be added Standard normal consistency test was performed
and the water content for the normal consistency was determined. The water content used in
the mix for strength tests was 90% of that required to produce the standard normal consistency.
Method of Curing
The blocks were taken out from the moulds after 24 hours. After removal from the moulds the
blocks were kept for air drying for 2 days. After sufficient strength was gained, these blocks
were transferred to water filled curing tanks.
Experimental Work
To check the feasibility of Cement, F.A. and P.G. binder as an alternative material for traditional
burnt clay bricks following tests are performed on the binder.
1.
2.
Observations
Mix M-1
Cement
50%
Fly ash
25%
Sr.N
o.
01
02
03
04
05
06
07
08
09
Ag
e
07
07
07
14
14
14
28
28
28
P.G.
25%
Observation Table
Surface Area Comp Load in Comp. Strength
in mm
Newton
in MPa
4998.49
55250
11.05
4998.49
66250
13.25
4998.49
72500
14.50
4998.49
90500
18.1
4998.49
88500
17.7
4998.49
88000
17.6
4998.49
118500
23.7
4998.49
117500
23.5
4998.49
117500
23.5
2
Mix M-2
Cement
40%
Fly ash
30%
P.G.
30%
Observation Table
Sr.N Ag
o. e
01
02
03
04
05
06
07
08
09
07
07
07
14
14
14
28
28
28
Surface
Area in
mm
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
2
Compressive
Load in Newton
Compressive
Strength in MPa
48500.00
49000.00
52500.00
85000.00
84500.00
85500.00
104000.00
104000.00
102000.00
9.70
9.80
10.50
17.00
16.90
17.10
20.80
20.80
20.40
Mix M-3
Cement
30%
Fly ash
35%
P.G.
35%
Observation Table
Sr.N Ag
o. e
01 07
02 07
Surface
Area in
mm
4998.49
4998.49
2
Compressive
Load in Newton
Compressive
Strength in MPa
49750.00
48750.00
9.90
9.75
03
04
05
06
07
08
09
07
14
14
14
28
28
28
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
50000.00
69500.00
72000.00
72500.00
91000.00
90000.00
90000.00
Mix M-4
Cement
20%
Fly ash
40%
10.00
13.90
14.40
14.50
18.20
18.00
18.20
P.G.
40%
Observation Table
Sr.N Ag
o. e
01
02
03
04
05
06
07
08
09
07
07
07
14
14
14
28
28
28
Surface
Area in
mm
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
4998.49
2
Compressive
Load in Newton
Compressive
Strength in MPa
28500.00
28000.00
28000.00
50000.00
50500.00
49000.00
88000.00
87000.00
87000.00
5.70
5.60
5.60
10.00
10.10
9.80
17.60
17.40
17.40
Density Test
After 28 days of casting, the cubes was dried to a constant mass in an oven at 1050C they were
cooled to room temperature and their density was obtained
Observations: (For density and Water absorption)
Dry
Dry
Sr. Age in Saturated
% water
Mass
density
No. days Mass ( Kg)
absorption
(Kg)
Kn/m3
01
02
03
01
02
03
01
02
03
28
28
28
Mix M-1
0.660
0.510
0.665
0.510
0.665
0.512
Average values
29.41
30.39
29.88
29.89
14.44
14.44
14.50
14.46
28
28
28
Mix M-2
0.650
0.498
0.645
0.495
0.645
0.495
Average values
30.52
30.30
30.30
30.37
14.10
14.02
14.02
14.048
28
28
28
Mix M-3
0.640
0.515
0.645
0.515
0.645
0.515
Average values
24.27
25.24
25.24
24.91
14.58
14.58
14.58
14.58
Mix M-4
01
02
03
28
28
28
0.625
0.520
0.620
0.515
0.625
0.520
Average values
20.19
20.38
20.19
20.25
14.73
14.58
14.73
14.68
Mix
M-1
M-2
M-3
M-4
Conclusion
Based on the experimental investigation reported in this study, following conclusions are
drawn.
Unique possibility exists for the bulk utilization of fly ash in producing bricks from Cement, F.A.
and P.G. in the proximity of thermal power plants, phosphoric acid and fertilizer industries.
The test cubes are having sufficient strength and have potential as a replacement for
conventional burnt clay bricks.
Cementitious binder with fly ash and phosphogypsum content equal to 80% gives better
compressive strength and 20.25% water absorption and thus suitable for use in construction
industry.
Being lighter in weight, Cement, F.A. and P.G. mix will reduce the dead weight and material
handling cost in multi storied constructions. The utilization of wastes in making cementitious
binder will help in solving the disposal and health hazard problems. It is further needed to
develop awareness among users, professionals and financial supporters for using these waste
materials for techno-economic reasons in addition to balance economy and achieve energy
conservation. The use of these wastes for building industries will definitely reduce the
environmental pollution which will be there because of use of burnt clay bricks. Such products
can be used for low cost construction practices.
References
N. Bhanumathidas and N. Kalidas, The role of Fal-G, The Indian Concrete Journal, July 1992, pp.389-391.
R. Ambalavanam and A. Roja, Feasibility studies on utilization of waste lime and gypsum with fly ash, The
Indian Concrete Journal, Nov.1996,pp.611-616.
Kumar Sunil, Utilization of Fal-G bricks in buildings, The Indian Concrete Journal, July 2001, pp.463-466.
Kumar Sunil, Utilization of Fal-G bricks and blocks, Construction and Building Materials,.
Dr. D. Sree Rama Chandra Murthy et. Al., Conventionally reinforced concrete beams with Fal-G cement in
flexure, CE and CR, Sept.2006,pp.47-53.
S.Marinkovic and A. Kostic-Pulek, Examination of the system fly ash-lime-calcined gypsum water, Science
Direct Journal of Physics and Chemistry of solids, 2007,pp.28-30.
Shiqun Li, Jishan Hu, et.al, Study on the weathering resistance of fly ash-lime compacts, Science Direct,
Cement and Concrete Research,34,2004,pp.753-758.
Luciano Santoro and Ignazio Aletta, Hydration of mixtures containing Fly ash, lime and phosphogypsum,
Thermochimia Acta,98 ,1986, pp.71-80.
A.K.Choudhary and J.N. Jha, Characteristics evaluation of fly ash for the stabilization of an expansive soil,
proceeding of National conference at Ludhiana, CEMCT-2006,Nov.2006,pp.199-203.
Jagroop Singh, Effect of fly ash, cement and randomly distributed fibers on compressive strength of
Kaolinite, proceeding of National conference at Ludhiana, CEMCT-2006,Nov.2006,pp.207-210.
Ismail Demir et al., Effece of Silica fume and expanded perlite addition on the technical properties of the fly
ash-lime-gypsum mixture, construction and Building Materials, 2007
Stefania Grzeszczyk et al., Effect of Super Plasticizers on the reheological properties of fly ash suspensions
containing activators of the pozzolanic reaction, Cement and Concrete Research, June 2000,pp.1263-1266.
Amit Mittal et al., Parametric Study on Use of Pozzolanic Materials in Concrete, New Building Materials and
Construction World, October 2006,pp94-112.
Environmental and Social Review for Fal-G bricks projects, Eco Carbon Private Limited, Jan 2006, pp.6-14.
Manjit Singh, Dr. Mridul Garg, Environment Friendly Building Materials from Waste Gypsum, NBM&CW, June
2007, pp.116-126.
www.Science direct.com
www.fal-G projects.com
I.S.4031-1968, Method of physical tests of hydraulic cement ( Part-I), Bureau of Indian Standards, New
Delhi.
I.S.269-1976, Specification for Ordinary Portland Cement and low heat cement, Bureau of Indian Standards,
New Delhi.
I.S.1077-1976, Specifications for common burnt clay building bricks, Bureau of Indian Standards, New Delhi.
T.T.T.I., Chandigarh, Civil Engineering Materials, Tata McGraw- Hill Publishing Company Limited, New Delhi.