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International Journal of Modern Trends in Engineering and Research

www.ijmter.com e-ISSN No.:2349-9745, Date: 28-30 April, 2016

@IJMTER-2014, All rights Reserved

Evaluating the efficacy of the burnt clay bricks prepared using industrial waste like foundry sand and textile sludge

Avani K. Dedhia.1 Prof. Poonam I. Modi 2 1 Structural Engineering Department, PG Student, CEPT University, Ahmedabad.

[email protected] 2Applied Mechanics Department, Assistant Professor, L.D.College of Engineering,

Ahmedabad,[email protected]

Abstract – Problem statement: The study conducted is an attempt to explore the possible use of the industrial waste products like foundry sand and textile sludge in the production of burnt clay bricks. The textile sludge is collected from the Dying and Printing unit of a known textile mill in Ahmedabad and foundry sand is collected from non-metallic casting foundry unit also located in Ahmedabad. The base material for preparation of bricks is prepared by mixing the conventional base material i.e (clay + sand) with foundry sand and textile sludge. The ratio of textile sludge to foundry sand has been majorly kept as 1:2 & 1:3. Approach: The most suitable type of base material was initially prepared before mixing it with the alternative materials used in the study. The constitution of base material included 40% white soil ( 91.87% fines + 8.13% sand), 40%, red soil ( 87.92% fines + 12.08% sand), 20% black soil ( 80% fines + 20% sand).The percentage of foundry sand and textile sludge was taken as 5%, 10% and 15% so as to maintain a proportion of textile sludge: foundry sand as 1:2 & 1:3. Bricks were prepared and burnt as per the conventional process for making burnt clay bricks. The period of sun drying of bricks for 10 days and baking period of 7 days in a local kiln at a temperature of 900-1000ºC was maintained for all the batches. Results: The bricks thus prepared were tested in hardness, soundness, fall test, efflorescence and compressive strength tests. The goal was to achieve the brick with compressive strength of 3.50 MPa. The test results show that bricks prepared by mixing base material with 5% of textile sludge and 10-15% of foundry sand give a compressive strength value ranging from 3.67 to 3.87 MPa, thereby fulfilling the criteria of achieving the Class 3.5 designation bricks as per the classification of bricks in IS standard. The water absorption of the bricks was found to be less than 20%. Brick thus prepared also showed excellent physical properties in terms of ringing sound, hardness, soundness and exhibited no traces of efflorescence. Keywords – Textile sludge (TS), Foundry sand(FS) , base material, compressive strength of bricks

I. INTRODUCTION Bricks that form the small units of the building materials have been the most popular material

used for making shelter units for last 5000 years. The reasons for it being and ideal material can be attributed to its being low cost, aesthetically pleasing, durable, retains heat and resists fire. The production of bricks in India is about 140 billion bricks a year manufactured in about 100000 kilns spread throughout the country. The raw material used in the brick making consists of alluvial clay extracted from ground, which has resulted into degradation of the agricultural land and consumption of the virgin clay material thus posing a serious environment impact. On the other hand, huge deposition of industrial waste products into landfills mars the landscape, uses the land which can be utilized for better purposes.

International Journal of Modern Trends in Engineering and Research (IJMTER) Volume 3, Issue 4, [April 2016] Special Issue of ICRTET’2016

@IJMTER-2014, All rights Reserved 486

In this study, an attempt is made to prepare the burnt clay bricks using the conventional raw material in combination with foundry sand and textile sludge. Three different ratio of textile sludge: foundry sand in proportion of 1:1, 1:2 and 1:3 were taken. Some batch of bricks were also prepared by replacing certain percent of textile sludge with additives like silica fume and rice husk ash to evaluate if the addition of these additives comprising of amorphous silica enhances the compressive strength. Rice husk ash and Silica fume of about 2-5% has been used as additives. Bricks thus prepared were evaluated for different parameters like hardness, soundness, cracking, warpage, water absorption, compressive strength and efflorescence.

II. PILOT STUDY AND TECHNICAL REQUIREMENT In order to ascertain the technical viability of the bricks prepared using industrial waste

products, a pilot study was carried out. The percentage of textile sludge and foundry sand was taken as 8% of the total raw material. The base material which was taken from local brick manufacturing unit had 61% of fines and remaining content of sand. Raw material thus used in pilot study was made of 92% Base material + 4% textile sludge + 4% foundry sand. The same was confirmed by performing the wet sieve analysis of the base material. A total set of 12 bricks were hand-made using this raw material. The bricks were sundried for a period of 10 days. Bricks were then stacked in the kiln and were burnt at a temperature of about 900-1000 degree Celsius. In order to study the effect of firing temperature and firing period on the bricks, a set of 4 bricks each were removed from the kiln at the end of 24 hours, 3 days and 7 days. It was inferred from the result analysis that the bricks subjected to an exposure of 7 days firing period gave better results in terms of density, water absorption, compressive strength and the physical properties like hardness and soundness. Based on the pilot study, it was deduced that all the batches of bricks will be baked in the kiln for a period of 7 days. The aim of the study was to produce the bricks that could give the compressive strength of 3.5 N/mm2 or more. Compressive strength of the bricks at the end of 7 days was 4 MPa. Another batch of bricks were prepared by increasing the percentage of textile sludge varying it from 5 to 15%, however the compressive strength of bricks thus formed were less than 3 MPa. It was thus decided to restrict the percentage of textile sludge to about 5% for the rest of the study. The pilot study thus helped to evaluate the technical feasibility of preparing hand-made clay burnt bricks using base material and industrial wastes. It also revealed that the base material for the brick preparation must have good content of clay rather than sand. Hence for the actual program, the base material from different sites was collected and subjected to wet sieve analysis. The base material with higher clay content i.e. the mix with the percentage of fines more than 60% was prepared as the raw material for casting of bricks. The test results of the pilot study indicated that irrespective of the content of foundry sand and textile sludge, the bricks prepared using base material with total content of fines up to 61% gives compressive strength values less than 3 MPa. Any addition of additives like silica fume or rice husk ash showed no remarkable difference in the values of compressive strength.

III. EXPERIMENTAL PROGRAM

3.1. Materials and its characterization

Semi-dry textile sludge was collected from a renowned mill in Ahmedabad. Foundry sand was collected from a local non-metallic casting unit. The chemical analysis of both the samples was done using the SEM method (EDS technology), in order to determine the presence of the major chemicals. The chemical analysis and the petrographic image are shown below. Silica content in textile sludge was found to be below the required limits, hence the samples of both the industrial waste products were then investigated.



The base material for the bricks was prepared by mixing the white soil, red soil and black soil. These soils were collected from special factories who delt with the three kind of soils. Wet sieve analysis as per IS standard was carried out to determine the content of fines i.e silt and clay and sand that was present. The results of wet sieve analysis are tabulated in Table1. This base material in form of 40% White soil + 40% red soil + 20% black soil was then mixed with foundry sand and textile sludge. 3.2. Sample Preparation The raw material that was prepared by mixing the different types of soil was then mixed with foundry sand and textile sludge. The material was taken by weight and all the ingredients were then thoroughly mixed together. Required quantity of water was added until the required consistency was achieved. The workable mixture of base material, foundry sand and textile sludge was then kept for the whole day. The moulds for the bricks were dusted with river sand and then the prepared mix with dough like consistency was dashed into prepared moulds with force. Extra remaining soil is then scraped and mould is inverted to remove the bricks. Bricks so made were sun dried for about 10 days. The sun dried bricks were then transferred to the kiln where they were baked at a temperature of about 900-1000ºC for a period of 7 days. The weight of the bricks post firing was recorded to estimate the loss on ignition. The experimental batches of bricks that were made had the proportions of the base material, foundry sand, textile sludge and other additives as follows: (1) M1 – 87%O.B.M. +12% Fly Ash+1% Rice Husk (2) O1 – 78% O.B.M. + 15% F.S. +5% T.S. + 2% S.F. (3) O2 – 78% O.B.M. + 15% F.S. +5% T.S. + 2% R.H.A. (4) N1 – 80% N.B.M. + 15% F.S. + 5% T.S. (5) N2 – 80% N.B.M. + 10% F.S. + 10% T.S. (6) N3 – 85% N.B.M. + 10% F.S. + 5% T.S. (7) N4 – 80% N.B.M. + 10% F.S. + 5% T.S. +5% S.F. (8) N5 – 80% N.B.M. + 10% F.S. + 5% T.S. + 5% R.H.A. Note: Where M1 is the control mix and O1, O2, N1, N2, N3, N4, N5 are the experimental batches. Acronyms - T.S. – Textile Sludge

F.S. – Foundry Sand O.B.M. – Old Base Material N.B.M. – New Base Material – 40%Red Soil + 40% White Soil + 20% Black Soil F.A. – Fly Ash R.H. – Rice Husk S.F. – Silica Fume R.H.A. – Rice Husk Ash

200g soil samples were tested for grain size analysis using the wet sieving method as per IS 2720 – 4 (1985). The amount of sand & fines (clay + silt) in the percentage is as below:

Table1. Grain Size Distribution of all the soil samples. Sr. No. O.B.M. Red Soil White Soil Black Soil

1. Sand (%) 39 12.08 8.13 20 2. Fines (%) 61 87.92 91.87 80

Also the chemical analysis of the all the soils, the two industrial wastes and the additives were carried out. Their results are as follows:



Table2. Chemical Analysis of the soil samples Sr. No Compound O.B.M. Red Soil White Soil Black Soil

1 SiO2 61.60 49.28 54.45 56.77 2 FeO 10.81 16.61 2.94 14.30 3 Al2O3 19.23 26.27 28.00 17.92 4 CaO 2.13 2.75 6.33 3.95 5 MgO 2.75 1.05 3.12 3.41 6 TiO2 - 2.20 1.86 2.28 7 K2O 2.51 0.64 1.16 1.37 8 Na2O 0.96 0.66 - -

Table3. Chemical Analysis of the two experimental industrial wastes

Sr. No Compound F.S. T.S. 1 SiO2 66.75 12.03 2 FeO - 0.99 3 Al2O3 7.54 51.56 4 MgO 7.99 3.56 5 Na2O - 3.94 6 SO3 - 22.73 7 CaO 17.71 -

Figure 1: Petrographic image of foundry sand Figure 2: Petrographic image of textile sludge

Table4. Chemical Analysis of the two additives Sr. No Compound S.F R.H.A

1 SiO2 99 31.17 2 K2O 1 - 3 CO2 - 68.83



Figure 3: Final experimental bricks (batch O1, O2, N1, N2, N3)

3.3 Tests on final end product i.e. bricks

3.3.1 Water absorption – durability test Bricks were withdrawn from the kiln at the end of 7 days of baking period. Water absorption test as per IS 3495 – 2 (1992) was performed on the bricks. Bricks removed from the kiln were submerged in water for 24 hours. The increase in weight of the bricks was noted and water absorption was calculated. The water absorption values were found to be in range of 14.5-16.5%, which was less than 20% as per the requirement of the IS standard.

3.3.2 Compressive strength test Compressive strength tests of the bricks was carried out as per the guidelines laid out in IS 3495-1992. A set of 6 bricks for each combination was tested and average of 6 values was recorded as the compressive strength. The test results show that the combination of 85% base material + 10%FS + 5% TS gives the compressive strength values higher than 4 MPa. 3.3.3 Soundness, hardness, fall test and efflorescence test Bricks that showed no traces of indentation on being scratched with a stone or sharp substance were considered to be cleared in hardness test. For soundness test, the bricks were struck with each other. Bricks that gave a clear metallic ringing sound were recorded to be sound bricks. Bricks were dropped from height of 1.0 m to test their breakability as a part of the fall test. The test bricks showed excellent physical properties. Lastly the efflorescence test was performed on them as per IS 3495 – 4 (1992) and they showed almost no trace of white foam and hence successfully cleared the efflorescence test too. Other engineering properties of all the bricks batches like density, loss on ignition, water absorption and compressive strength have been shown graphically compared below:



Figure 3: Result summary of engineering properties of all batches

IV. TEST RESULTS AND SUMMARY OF THE FINDINGS

The following inferences were made from the experimental program: 1. The industrial waste like foundry sand and textile sludge can be successfully used in

manufacturing of handmade burnt clay bricks. 2. Foundry sand from non-metallic industries can be used up to 10-15% and textile sludge can be

used up to 5% to produce the burnt clay bricks with compressive strength values in range of 3.67 -3.87 MPa.

3. The study shows that beyond 5% of textile sludge when used in making bricks, decreases the compressive strength, however the other physical properties are only marginally affected.

4. The test results clearly indicate that the base material to be used when making bricks using industrial waste must have total content of fines i.e. clay and silt to be more than 60%.



REFERENCES

[1]. Shrikant S Jahagirdar, S. S. Utilization of Textile Mill Sludge in Burnt Clay Bricks. International Journal of Environmental Protection , 6-13. (May, 2013).

[2]. Mary Lissy P N, D. M. Utilization of sludge in manufacturing Energy Efficient Bricks. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) , 70-73. (Jul- Aug, 2014).

[3]. Hema Patel, S. P. Exploring the Reuse Potential of Chemical Sludge from Textile WastewaterTreatment Plants in India-A Hazardous Waste. American Journal of Environmental Sciences 5 , 106-110. (2009).

[4]. Eknath P.Salokhe, D. (n.d.). Application of Foundry Waste Sand In Manufacture of Concrete. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) , 43-48.

[5]. Mr. I .M. Attar, P. A. (n.d.). Application of Foundry Sand In Civil Construction. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) , 38-42.

[6]. Dr Evaggelia Petavratzi, S. W. Foundry sand in facing bricks. UK. (Nov, 2007). [7]. Dr. Krishnan Umachandran, R. REUSE OF WASTE SAND. Hyderabad. (2012). [8]. Badr El-Din Ezzat Hegazy, H. A. Incorporation of water sludge, silica fume, and rice husk ash in brick making.

Advances in Environmental Research, Vol. 1 , 83-96. (2012). [9]. Jawaid, D. S. Rice Husk Ash - Lime blended Building Bricks. International Journal of Earth Sciences and

Engineering , 302-309. (April, 2010). [10]. IS: 1077 (1992) - Common Burnt Clay Building Bricks -Specification [CED 30: Clay and Stabilized Soil

Products for Construction], Bureau of Indian Standards, New Delhi, India. [11]. IS 2117 (1991) - Guide for manufacture of hand-made common burnt-clay building bricks [CED 30: Clay and

Stabilized Soil Products for Construction], Bureau of Indian Standards, New Delhi, India. [12]. IS: 1498 (1970) - Classification and identification of soils for general engineering purposes [CED 43: Soil and

Foundation Engineering], Bureau of Indian Standards, New Delhi, India. [13]. IS: 2720-4 (1985) - Methods of test for soils, Part 4: Grain size analysis [CED 43: Soil and Foundation

Engineering], Bureau of Indian Standards, New Delhi, India. [14]. IS: 3495-1 to 4 (1992) - Methods of tests of burnt clay building bricks: Part 1 - Determination of compressive

strength, Part 2 - Determination of water absorption, Part 3 - Determination of Efflorescence, Part 4 - Determination of warpage [CED 30: Clay and Stabilized Soil Products for Construction], Bureau of Indian Standards, New Delhi, India.

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