© 2019 JETIR June 2019, Volume 6, Issue 6 (ISSN … · 2019. 11. 28. · JETIRDH06018 Journal of...

© 2019 JETIR June 2019, Volume 6, Issue 6 www.jetir.org (ISSN-2349-5162)

JETIRDH06018 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 112

COMPARATIVE STUDY ON PROPERTIES

OF FLY-ASH BRICKS WITH

CONVENTIONAL BRICKS BY VARYING

MATERIAL AND COMPOSITIONS Aparupa Shenoy, Jayendra Pratap Singh, Mohd Tabish Khan, Aishwary Nayak, Abhishek Sharma

Department of Civil Engineering, JSS Academy of Technical Education, APJ Abdul Kalam Technical University, Noida, India.

Abstract

Urbanization has taken control over years ago, with set up of factories and industries. This leads to the production of smoke

containing lot of harmful gasses including shoot. The quantity of this shoot varies from industry to industry and machinery

installed. If the machinery installed is based on coal, it does produce a lot of smoke with huge amount of carbon content. Talking

about India where most of the industries are coal based the amount of fly-ash produced is considerably large.

aIn aathe apresent aexperiment, athe abricks aare amainly constructed aby athe aflya-ash a (a45-a53a%), awith lime a (a20a-a28a%), agypsum a (2a%),

acement a (0a-5%) and sand (25%). It is done ain aorder to aimprove the aengineering aproperties aof the conventional bricksa. aThere are a4

samples aprepared for athe experimental process aand 1 sample is ataken afrom athe alot of aconventional aflya-ash abricks stocka. aThe results

aare being acompared awith the aclay aburnt bricks aand athe aconventional afly-aash brick aresulta. aThe results aas aare abeing acompared with

athe aIS acode for athe aclay aburnt bricksa, aia. aea., IS acodea: a3495(apart a1 ato apart 4a) aand afor the aflya-aash brick ais acodea: a12894-2002 . The

results obtained shows that the compressive strength of aall asamples at a28 adays ais afar ahead athan aconventional aclay burnt abricks aand

acomparable awith aconventional afly-aash abricksa. aThe same agoes afor ahardness aefflorescence, aimpact aand asoundness atesta.

Keywords: Fly-ash, Compressive Strength, Conventional Bricks, Water Absorption, Density, Efflorescence, Impact,

Hardness.

1. Introduction

aFlya-aash is afinely adivided residue aproduced adue ato

burning aof acoal amainly ain athermal power aplantsa. aIt is

athen acollected aby athe electrostatic aprecipitatora. aTheir

aproper disposal ahas abeen aa acause of aconcern asince

along atime, awhich aotherwise aleads to apollution aof aair.

aIndia ais afast agrowing country awith aa apopulation aof

aabout 1a. a324 abillion. aAs aper aCentral electricity

aauthority a (CEAa) athe ainstalled acapacity ain India aas aon

a28a/02a/a2017 is a (a31SGWa) aand 215GW ais aconstituted

aby thermal apower aplantsa, which ais a68a%. aAs aper

ministry aof apowera, agovta. of aIndia aestimation a1800

million atons aof acoal awill be aused aevery ayear and a600

amillion atons aof flya-aash awill be agenerated aby 2031-

2032. The total quantity of the clay burnt bricks

produced annually is approximately 180 billion.

Approximately 340 billion tons of clay, about 5000

aces of top soil is being dug out causing soil erosion,

deforestation [2]. aManufacturing of abricks arequires

agood quality aof aclay aand auses a aweight aof a3kg per

abricka. aThe total clay ataken aout from aagricultural aland

aper day ais aover a300 amillion atons for a10,000 crore

bricks. aAt apresent, afly-aash ais abeing disposed aby atwo

methods adry amethod aand awet methoda. aDry amethod is

apreferred awhen the aquantity of aflya-aash ais asmalla. aIn

this amethod aflya-aash in adry aform ais acarried aaway

apneumatically from athe aburner aand ais adeposed on athe

aopen agrounda. aIn wet amethod aflya-aash ais amixed with

awater aand asluiced ato athe asetting pond aor adumping

aareas near athe planta. aThis amethod ais widely aadopted

aas ait is acheaper abut aboth athe amethods acausing

aenvironmental adamage. aaNow athis will abe agoing ato

acreate a abig aproblem auntil athere should ahave aa aproper

asolution givena. a

a2a. Insights afrom aPrevious aStudiesa

In athe astudy aby Ra. aV. aSHINDE aeta.ala, a2016a, the aefforts

aare amade ato aunderstand the achange ain athe adifferent

aengineering aproperties of aflya-aash with aaddition aof

different aingredients ain aita. aMix aprepared as a (aia) aFlya-

ash, aclaya, asand a [a30a:40:30], (ii) aFlya-ash, cementa,

stone adust a [35a: a07:58] (iiia) Flya-aasha, alime, sanda,

gypsum [a40:30:20:10]. Result shows amax

acompressive astrength (a174 aKga/acm2) aobtained afor the

athird asample awith minimum adensity. aAll athe asamples

ashowed zero aefflorescencea, aclear aringing sound a, awith

adense and ahomogeneousa.

http://www.jetir.org/



aAkash aSuresh Pawar aeta.ala, a2014 worked awith afly-aash

abricks aby varying apercentage aof flya-aash a (a100 – 90%)

and silica a (a0- a10%). The acompressive strength aof athe

samples aare afound aabout a40% aabove athen the aclay

burnt aand alime abricksa. While aworking awith flya-aash,

asilica, alime ahe aobserved awater absorption aas a20a% of

aself aweighta. Sample aalso ashowed azero aefflorescence

with asharp aedgesa. aThe brick aobtained awere a10. a6a%

lighter than aclay abricksa. The amanufacturing aprocess

showed athat athere ais much asaving ato be adone aduring

the amaking of athe abricks. aFrom aall samples athe

asamples acontaining 15a% aflya-ash aand 85a% clay

showed the abest aresult and awere abeneficial athan the

normal aclay bricksa, aflya-ash lime abricks & aflya-ash

abagasse abricks.

The astudy aof Mamta aRajgor aet. aala, a2013 was focused

aon athe use aof awaste material awith athe afly-aash ato

aimprove its aphysical aquality aparameters like astone

awaste aand ato examine athe autilization potential ait aas

athe aalternative raw amaterial ain the aproduction aof afly-

ash bricks. aThe amixture were aprepared awith a0a%, 2a%,

a4a%, 6%, 8% and 10% by weight by replacing awith

alime and ahence athe compressive astrength ais

adetermined a. The aresults shows that as athe apercentage

of astone waste aincreases acompressive strength

adecreasesa. Result ashows abest aoutcome for a60% fly-

ash, 15% sand,10% sludge lime, 0% stone waste,

15% kheda dust.

The study performed by A Sumathi et.al, 2014-2015

has involved experimental investigation to find the

optimum mix percentage of the fly-ash bricks with

specimen size 230x110x90 mm, casted for different

proportion of the mix with fly ash (15-50%), gypsum

(2%), lime (5-30%) and quarry dust (45-55%) for

acompressive strength determination. This study

revealed that out of different mix percentage, the

sample containing fly-ash 15% lime-30%, gypsum

2% and quarry dust 53% showed the best result for

the Compressive strength as 3.38 kg/ cm2. Water

absorption result have been found as minimum as

10% which is the least among all the samples of the

test.

aIn this paper aof aRavi aKumar eta. aal, a2014 the

aexperiments ahave abeen conducted ato atest the

properties aof Flya-ash abricks aincluding compressive

astrength, awater aabsorption and aefflorescencea. The

amix ais prepared aby ausing adifferent percentage aof afly-

aasha, acement, alime, agypsum and asand. aOn athe abasis aof

his experiments the aconclusion was agiven aas athe

compressive astrength aof fly ash abrick awith a0% of

acement is a27% amore athan that of the aclass-1

conventional brick abut when a3% acement ais added ain

athe flya-aash brick athen athe compressive astrength ais

increased aup ato a51.8% more than athat aof aclass I

aconventional bricks aand afor a5a% aof cement athe

compressive astrength increases a63% more than that

of aclassa-aI conventional bricks aafter 28 adays acuringa. aIt

was analyzed athat the asample awith a0a% of acement had

awater absorption a27a% athan the aconventional abricks

aand a42% aless when athe acement content ais a3a% aand

48a% aless aas compared ato conventional abricks awhen

the acement acontent ais a5%. aThe aefflorescence test

areveals athat athe sample ahaving acement acontent 0a%

ahas agreya/white apatch aover aless than a10a% aon surface

aarea aand sample awith a3% acement acontent ahas aless

than a8a% aon the asurface aarea and athe asample awith 5a%

acement acontent has aless athan a7% on athe surface aarea.

aThis apaper by aSa. aShankranath aeta. aal, 2016 presents

aexperimental astudy by autilization aof aglass powdera,

aGGBS ain aflya- aash brick amanufacturing aprocessa.

aGlass powder aand aperlite aore are ataken ato abe aconstant

aof 2a%, a10a% aand GGBS ais aused awith a10%, a20a%, aand

30a% afor each aproportion athat have abeen acalculated.

aThe asamples aare tested afor acompressive astrengtha,

awater aabsorption, aefflorescencea, density aand

asoundness aafter a21 days aof acuring. aThe atest

aperformed concludes athat asample awith a20a% aof

GGBSa, a10a% of aperlitea, a2a% of aglass powder agives a

acompressive astrength aof 16a.186 aN/mm2 which is

greater than athe Firsta-aclass abricks. aAt athe percentage

aof aGGBS above20a% athe acompressive strength aof athe

abricks ais decreasesa. aThe adensities aof the abricks aare

aall between a1300-1500 kg/m3. As the percentage of

aGGBS ais aincreased high aefflorescence is found a.

aWhen these awere astuck ait agives a aclear aringing

asound.

aThis apaper by aArati aShekhar aet.al ,2016 comprises

the aspecification afor the amanufacture aof FaL-G (Fly

aash aLime Gypsuma) amortar acompressed abricks with

alow acalcium a (Class aFa) aand adry aash as athe abase

amaterial. aFaLa-aG bricks are aprepared awithout use aof

aconventional cementa. aQuarry dust aand asand awere

aused aas fine aaggregate aas sustainable amateriala. aThe

aexperimental studies areveal that athe percentage aof

awater was afound ato be less than 12% for aboth types

aagainst athe maximum limit of a20% aas per IS-a3495-

1976a. Howevera, it has been observed athat that athe

compressive astrength increases awith time aadue to

acontinuous aareaction abetween aFaL-aG abinder aand

watera. The acompressive strength was around 5MPa at

the age of 28 days and mix strength at 28 days is

more than 3MPa in most of the cases and that

strength would be enough for its permissibility to be

used as masonry units as per IS - 3495-1976.

This paper by aK. aVidhya aeta.ala, a2013 aemphasis athe

use aof afly aash aand pond aash ain the abuilding

aconstructiona. aThey possess asuitable apozzolanic

propertiesa. aDifferent mix proportions aare prepared aby




adifferent aproportion of aFly asha, apond aash, alimeaa,

agypsum and asanda. aThe amicro structure aand

composition of acoal ash abrick awere astudied by usinga

ascanning athrough aelectron amicroscope and aX a-Raya.

aDiffraction aanalysis aand atest were aconducted afor

acompressive astrengtha, water aabsorptiona, awet adensitya,

efflorescence aand aIRAa. The acompressive astrength aof

bricks awas aincreased awith increase ain alime acontenta.

aWet density adecreases awith aincrease in athe apond aash

apercentagea. There awere ano awhite patches aobserved ain

aany aof the abricksa. aThe acost reduced aup ato 20a% athan

athe conventional aclay abricks amanufacturing. aThusa,

athe autilization aof pond aash aand aflya-aash ain the abrick

amanufacturing acan agreatly diminish athe avolume aof

alandfill awaste. a

3.1. Materials

3.1.1. Fly-ash:

aIt is aproduced aas athe aend aproduct aduring the aburning

aof athe pulverized acoal ain athe process aof aelectric

apower agenerationa. During athe acombustion aprocess

athe aimpurities in athe acoal alike aclaya, feldspara, aquartz

and ashale afuses ain athe aatmosphere in asuspensiona, aout

aof the acombustion achambera. aNow as athese afused

amaterials arises athese agets cool adown aand asolidifies

ainto irregular aparticles acalled aas aflya-asha. aAnd athese

are acollected amainly awith athe ahelp of aelectrostatic

aprecipitator aor abag afilters. aFlya-aash areacts awith athe

calcium ahydroxidesa, awhich ais obtained aas athe by

aproduct afrom athe reaction abetween awater aand

acementa. This aflya-aash aalso acontains acementitious

aproperties awhich amainly adepend aupon the atype aof

athe aflya-aash and acementa. aHowever the areaction

abetween afly-aash aand acement ais aquite slower athan athe

acement aand awater aresulting ain the adelay afor athe

ahardening aof the acement a

3.1.2. Lime:

It is an inorganic material containing calcium in

which carbonates, oxides and hydroxide

predominates. In scientific term, lime is known as

calcium oxide and calcium hydroxide. It occurs

naturally (native lime) as the product of coal seam

fires and in altered limestone xenoliths in volcanic

eject. This word originates from its character of

acting as adhering agent since early time. in the

beginning these are used as the binding material in

the roads construction.

3.1.3. Gypsum:

aThisa amaterial ais mined amainly aand aused as aa

afertilizera, aand aas athe amain constituent ain amany forms

aof aplaster, ablackboard achalk aand wallboard. Gypsum

is a soft sulfate mineral composed of calcium sulfate

di-hydrate, with the chemical formula CaSO4·2H2O.

It also helps in delaying the initial setting time for the

bricks.

3.1.4. Sand:

It is granular material composed of finely devided

rock and mineral. The composition of the sand

mainly depends upon the source and the conditions.

The main constituent of sand is mainly silica and

occurs mainly in form of quartz. The other most

common type of sand is calcium carbonate.

3.1.5 Cement:

aIta ais aused as athe abinder amaterial aand aused aunder the

aconstruction aprocessa. aMainly acomposed aof lime

asilicaa, agypsuma, airon oxide aetc. aFor the aproduction aof

concrete amortara, cement ais abeing mixed awith athe

afine aggregates aand acoarse aaggregates awith adequate

aamount aof awater ain aita. Gypsum ais aadded ain ait ato

delay athe ainitial asetting atime. The aconstituent of

acement mixed atogether to form the aBogues

compounda. aFor acomplete hydration aa atotal aof a38%

awater aby aweight ais required ain which 23% is used for

the hydration process and the rest 15% gets

aentrapped abetween the avoids aand ado anot aparticipate

ain athe ahydration processa.

3.2. Methodology

3.2.1 Sample Preparation

aBy varying mix proportions of conventional fly ash

brick, four samples awere aprepared afor aexperimental

aanalysis of acompressive astrengtha, ahardnessa,

aefflorescencea, aimpact aand asoundness awith respect aato

conventional afly aash abrick.

Table a1a. aMix proportionsa

Sl.

No

Conte

nt

Sample

1

Sample

2

Sample

3

Sample

4

1 Sand 25% 25% 25% 25%

2 Lime 20% 20% 23% 28%

3 Gypsu

m 2% 2% 2% 2%

4 Fly-ash 53% 50% 50% 45%

5 Cemen

t 0% 3% 0% 0%

3.2.2 Manufacturing Process




aManufacturing aprocess ais shown awith athe ahelp aof

aflow chart in Fig.1.

Fig. 1. Manufacturing process of fly-ash brick

4. Experimental Analysis

aCompressive astrength, aHardnessa, aImpacta,

aEfflorescence aand aSoundness atests awere conducted

aon athe abricks amanufactured a. aExperiments were

aconducted aafter a14th a, 21st aand a28th days of acuring.

aAll athe test ahas abeen aperformed aas aper the aguidelines

aof athe aIS aCODE- 3495 (PART 1 TO 4) and IS CODE

12894. Results observed for Compressive strength,

Impact and Soundness tests are shown in tabular

form in table 2 and 3 respectively. Rate of Increment

in Compressive Strength of Various Mix Proportions

with different days of curing has been represented in

Fif. 2 where as rate of Increment in Compressive

Strength of Various Mix Proportions with days has

been represented in Fig. 3. No impression was

observed on any of the manufactured samples while

checking the hardness. Efflorescence for all the

samples was found as nil.

Table 2. Compressive strength of different

samples in N/mm2

TABLE 3. Result of Impact, Hardness, Soundness

and Efflorescence of Different Samples

Samples

Impact Soundness

14

Days

21

Days

28

Days

14

Days

21

Days

28

Days

Sample

1 Fail Fail Pass

Clear

Sound

Clear

Sound Clear

Sound

Sample

2 Pass Fail Pass

Fail Clear

Sound Clear

Sound

Sample

3 Pass Pass Pass

Clear

Sound Fail Clear

Sound

Sample

4 Fail Pass Pass

Clear

Sound Fail Clear

Sound

Sample

5 Fail Pass Pass

Fail Clear

Sound Clear

Sound

Fig. 2. Rate of Increment in Compressive Strength

of Various Mix Proportions with Days

0

2

4

6

8

10

12

Sample1

Sample2

Sample3

Sample4

Sample5

com

pre

ssiv

e st

ren

gth

(N

/mm

2)

Axis Title

14 days 21 days 28 days

Samples 14 Days 21 Days 28 Days

Sample 1 3.97 8.76 11.11

Sample 2 4.68 8.77 8.96

Sample 3 3.99 8.96 9.45

Sample 4 4.07 7.98 9.35

Sample 5 5.83 8.5 11.0




Fig 3. Comparison of Compressive Strength for

Various Mix Proportion

5. Conclusion

The results obtained certainly proves that

fly-ash bricks are far above the conventional

clay burnt brick with respect to different

engineering properties which are

compressive ,strength ,hardness

,efflorescence ,soundness and impact.

The weight of the fly-ash brick is reduced by

20% compared to conventional clay burnt

brick.

In the conventional fly-ash brick the content

for the lime+gypsum vary from 13-15% but

in our experiment the lime+gypsum varied

from 22-30%. It is basically to replace it

from sand and reduce its weight further.

Most importantly experimental results

shows that there should not be any major

change in the conventional composition of

fly-ash brick. Our sample 1 reached the

strength of 11.11 N/mm2 at 28 days is better

than the conventional fly ash brick while

other samples were below the strength of

conventional fly ash brick at 28 days.

All the samples were found far superior than

clay burnt bricks in compressive strength.

There are few samples that show the result

which are not satisfactory in the aspect of

compressive strength while compared with

the conventional fly-ash bricks.

Coming to the variation of result from what

we had expected and what we have achieved

is not up to our expectation but this variation

of the result is due to improper mixing of

material and improper storing of bricks. This

leads to the formation of lumps of lime in

the samples. Lumps of lime interrupt the

aggregate to aggregate transfer of the load

and hence affects the load bearing capacity

of the sample. Also leads to the sudden

fracture of the sample at the time of the load

application, hence increases the brittleness

of the sample. This excess of lime leads the

melting of the bricks at the time of load

application.

However, there is very remarkable result

found when considering efflorescence, there

is no sign of efflorescence found.

Surface of the sample bricks found to be

quite smooth and surface roughness is

almost negligible.

As per the IS code 3495, all the samples

passed the hardness test.

Summarizing the overall project work,

results found are satisfactory but better

result could have been achieved if there

would have been proper mixing of material

and proper storing of bricks.

6. References

[1] R.V.Shinde et al. “Study of Engineering

Properties of Fly-Ash Bricks for Construction”,

International Journal of Innovative Research in

Science, Engineering and Technology, Volume 5,

Issue 5, May 2016.

[2] Akash Suresh Pawar and Devendra Bhimrao

Garud “Engineering Properties of Clay Bricks with

Use of Fly-Ash”, International Journal of Research

in Engineering and Technology (IJRET), Volume: 03

special issue :09, NCETCE-2014,

June2014,ISSN:2319-1163/pISSN:2321-7308..

[3] Mamta Rajgor, Prof. Jayesh Kumar Pitroda” A

Miniature Ground for Setting Industrial Waste”,

Journal of International Academic Research for

Multidisciplinary Volume 1, Issue 3, April 2013

ISSN:2320-5083

[4] A. Sumathi, K. Saravana Raj Mohan”

Compressive Strength of Fly- ash Brick with

Addition of Lime, Gypsum and Quarry Dust”

International Journal of Chemical Technology

Research, Coden(USA), IJCRGG, Volume 7,

Number1, pp 28 -36, issn:0974-4290,2014-2015.

[5] Ravi Kumar et al. “Study of Properties of Light

Weight Fly-ash Bricks”, International Journal of

Engineering Research and Application (IJERA)

ISSN: 2248-9622, National Conference on Advances

in Engineering and Technology, AET -29 March

2014.

2

4

6

8

10

12

14 days 21 days 28 days

Co

mp

ress

ive

Str

en

gth

N/

mm

2

sample1 sample2 sample3

sample4 sample5




[6] S. Shankarnath and B. Jaivignesh ,” Experimental

Study on The Use of Glass Powder, GGBS and

Perlite in fly- ash brick” International Journal of

Advanced Research, (2016) Volume 4, Issue 4, 1381-

1387,ISSN 2320-5407.,

[7] Arati Shetkar et al.” Experimental Study on Fly

Ash Based Lime Bricks”, International journal of

Recent Advances in Engineering & technology

(IJRAET), ISSN:2347-2812, volume 4, issue 7 ,2016

[8] K. Vidhya et al.” Experimental Studies on Pond

Ash Bricks” International Journal of Engineering

Research and Development E ISSN:2278-067X, p

-IISN: 2278-800X, volume 6, issue 5, pp06-11,

March 2013.

[9] IS CODE: 2180-1988: Specification for heavy-

duty burnt clay building bricks (second revision)

[10] IS CODE: 2248-1992: Glossary of terms relating

to structural clay products for buildings (second

revision)

[11] IS CODE:3495 (PART-1)-1992: Methods of

tests of burnt clay building bricks: Part I

Determination of compressive strength (third

revision)

[12] IS CODE:3495(PART-3)-1992: Methods of tests

of burnt clay building bricks: Part 3 Determination of

efflorescence (third revision).


© 2019 JETIR June 2019, Volume 6, Issue 6 (ISSN … · 2019. 11. 28. · JETIRDH06018 Journal of...

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