Experimental Study on Flyash Bubble Bricks of burnt clay bricks requires consumption of coal leading...

International Journal of Recent Advances in Engineering & Technology (IJRAET)

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ISSN (Online): 2347 - 2812, Volume-4, Issue -7, 2016

90

An Approach – Experimental Study on Fly Ash Bricks with Hollow

Balls

1Arati Shetkar,

2Nagesh Hanche,

3Shashishankar A

1Civil Engineer, SGHIC, Kalaburagi, Karnataka India.

2Assitant Professor, Department of Civil Engineering, School of Engineering, Central University of Karnataka,

affiliated to MHRD, Government of India, New Delhi, India. 3Professor & Head, School of Engineering, Jain University, Bangalore.

Abstract : Bricks whose solid ingredients are cement, fly

ash and polyethylene hollow spheres have been

manufactured. The manufacturing process and techniques

uses similar to those used in clay bricks plants. The bricks

produced were 33 % lighter than solid bricks. The bricks

given considerable increase in compressive strength also

and are several times better than acceptable commercially

available clay bricks. The bricks have been produced with

natural colour. The strength and weight parameters have

been compared with the normal solid bricks and the results

are presented. This paper presents the testing and

advantages of the fly ash bubble bricks over the

conventional clay bricks.

Keywords: fly ash, polymer spheres, quarry dust, solid

bricks, pozzoloan.

I. INTRODUCTION

Production of burnt clay bricks requires consumption of

coal leading to green house gas emissions. The primary

raw material used for bricks is the soil, which is often

taken from prime agricultural land, causing land

degradation as well as economic loss due to diversion of

agricultural land. Use of traditional technologies in

firing the bricks results in significant local air pollution.

The burnt clay brick industry in India produces over 180

billion clay bricks annually with a strong impact on soil

erosion and unprocessed emissions. At the same time,

the thermal power plants in India continue to produce a

huge amount of fly ash, disposal of which poses

significant challenges for the power plants.

Cement Concrete dense/hollow bricks & blocks are very

popular & are extensively used in building construction

throughout the country because of the many advantages

such as durability, strength,& structural stability, fire

resistance, thermal insulation & sound absorption it

possess.

These bricks have an attractive appearance & are readily

adaptable to any style of architecture. It lends itself to a

wide variety of surface finishes for both exterior &

interior walls.

The hilly states of India have high humidity, dampness

& rainfall, so the bricks are much useful for the N.E.

Region, Himachal Pradesh, J&K, U.P etc.

High density polyethylene hollow spheres replace the

ineffective concrete in the centre of the slab, thus

decreasing dead weight and increasing efficiency of the

floor. This saving, therefore, brings down the cost of

construction considerably

These slabs have many advantages over a conventional

solid concrete slab: lower total cost, reduced material

use, enhanced structural efficiency, decreased

construction time and is a green technology.

The dominant advantages of a bubble deck slab are that

it uses 30-50% less concrete than normal solid slabs.

Hence an attempt is made to manufacture the fly ash

based bubble bricks to replace the ineffective concrete at

the centre by poly ethylene hollow spheres which are the

by products of recycled plastic.

II. REVIEW OF LITERATURE

“The satisfactory performance of a fly ash bricks as a

load bearing elememts. This types of bricks uses 100%

fly ash without mixing with clay and shale. It, therefore

provides a large venue for the disposal of fly ash in a

very efficient, useful and profitable way. Compressive

strength was 24% better than good quality clay bricks

(N. Bhanumathidas and N. Kalidas 2003).”

“The hollow concrete block masonry and comparative

study is executed with respect to brick masonry

construction and strength parameter, economy, light

weight character and insulation property are studied and

compared (Gupta P.C, Ray S. C. 1993).”

“Voided slab eliminate concrete where it is not needed,

the reduced weight of the slab allows for longer slabs

between columns without beams and a reduction in

concrete and steel in floors, columns and footings,

saving money and reducing the total building weight,

allowing lighter foundation also using recycled material

(Sengupta J. 1984).”


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91

2.1 Waste material/by product

The main advantage of fly ash bubble brick is the use of

waste materials/by-products produced elsewhere. The

plastic spheres of recycled plastic with different

diameters are used. The purpose of using recycled

material is to minimize the burden on the environment

through the cyclical use of resources and reduces risks to

human health. Table 1 demonstrates the comparison

between clay and bubble bricks. Disposal of fly ash in

thermal power plant and lime from paper and other

industry is a potential problem of disposal. No waste

material is generated from the fly ash bubble brick

activity. Waste materials arising from breakage of bricks

are recycled in the process itself.

Table1: Comparison of fly ash bubble bricks and burnt

clay bricks

Sl.

No

Particulars Fly ash bricks Burnt clay bricks

1 Colour Uniform

pleasing colour

like cement

Varying colour as per

soil

2 Porous Less porous More porous

3 Thermal

conductivity

1.25 to 1.35

W/m² ºC 0.9 to 1.05 W/m² ºC

4 Plastering Not required Required

5 Compressive

strength 5.21N/mm² 4.34 N/mm²

6 Water

absorption 8% to 12% 12% to 20%

7

Air Emission

Source of

Emission:

1.Storage and

handling of

raw materials;

2.Transportatio

n of bricks

Source of Emission:

1.Handling of sand

and soil;

2.Handling of coal;

3.Combustion of coal;

4.Removal of bricks

from kiln;

5.Removal and

handling of ash from

kiln;

6.Transportation of

Bricks

8

Heat

Emission Nil

1.Brick firing is

carried

Out at 1000ºC.

Residual heat of the

process is partly used

to raise the

temperature of bricks

waiting for firing and:

Emission into

atmosphere along

with gases through

stack.

9

Loss of soil /

Agriculture

Land

Nil

180 billion tones of

bricks are consumed

annually, 340 billion

tones of clay about

5000 acres of top

layer of soil dug out

for brick manufacture

Emission of carbon in

to the atmosphere.

III. SCOPE OF PRESENT WORK

Since fly ash bricks have not been used on large scale

for the construction work. But it has good scope in

future, because these bricks are being manufactured

from the waste material like fly ash, plastic bubbles and

quarry dust, manufacturing of these bricks avoid the

difficulty of dumping fly ash, plastic waste too. Since

the natural resources are becoming limit and easy way to

manufacture will increase its scope for the construction

work.

Fly ash bubble bricks also reduce the pollution during its

construction work which is not same in all the bricks

manufacturing process. High compressive strength,

better workability, fire resistance and all these quality of

the bricks will increase its future scope of masonary

construction work.

3.1 Applicability

The blocks being available in several load bearing

grades are suitable for use: -

Load bearing external walls, in low and medium

size structures.

Non - load bearing internal walls in low and

medium size structures.

Non - load bearing internal or external walls in

high-rise buildings.

3.2 Requirement of bricks as per IS 12894:2002

3.2.1 General requirement

Visually the bricks shall be sound, compact and

uniform in shape. The bricks shall be free from

visible cracks, war-page and organic matters.

Hand-moulded bricks of 90 mm or 70 mm height

shall be moulded with a frog 10 to 20 mm deep on

one of its flat sides; the shape and size of the frog

shall conform to either Fig. 3A or Fig. 3B. Bricks

of 40 or 30 mm height as well as those made by

extrusion process may not be provided with frogs.

Fig.1 shows the dimensions of the bricks.

The bricks shall be with or without frog 10 to 20

mm deep on one of its flat side. The shape and size

of the frog shall conform to either Fig. 1A or Fig.

1B.

The bricks shall have smooth rectangular faces

with sharp corners and shall be uniform in shape

and colour.


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92

Fig.1 Brick

3.2.2 Characteristics of bricks

The standard size of the brick is

230mmx100mmx70mm.

The bricks are manufactured and tested as per IS

12894-2002.

Fly ash bricks are sound, compact and uniform in

shape, size and colour. Smooth rectangular faces of

the bricks are accompanied with sharp and square

corners.

They are free from visible cracks, warpage, flaws

and organic matter.

Economical & environment friendly.

30-40% lighter than ordinary clay bricks.

Compressive strength.

Water absorption.

IV. EXPERIMENTAL INVESTIGATION

4.1 General

In the present investigation different gradations of bricks

are prepared by using different diameter of balls in

different numbers. The diameter of balls is not affected

on the strength but its effect on the weight and volume

of the bricks.

High density polyethylene hollow sphere replace the

ineffective mortar in centre of the bricks, thus

decreasing weight and volume of the bricks. These

bricks have many advantages over a conventional bricks

viz. reduced material use, lower total cost, reduced the

construction time, enhanced structural efficiency and

green technology.

By using less mortar, we can save up to 40% on

embodied carbon in the bricks. Carbon emission from

transportation and equipment usage will also decrease

with the use of fewer materials. Additionally, the

bubbles can be salvaged and reused for other projects, or

can be recycled. The Table 2 demonstrates the specimen

proportions with different W/C ratio.

Savings in materials - up to 50 % - 1 kg of plastic

replaces more than 100 kg of concrete. Less energy

consumption - both in production, transport and carrying

out No waste generation - 100 % recycling

Table 2: Showing bricks specimens with various proportions and with variable w/c ratio

Sl no. Cement, fly ash, dust, aggregate Gradation

60mm dia. 45mm dia. w/c ratio

4 no’s 2no’s 4no’s 2no’s

1. 15%,45% 30%,10% A 6 6 6 6 0.5

2. 20%,40% 30%,10% B 6 6 6 6 0.5

3. 20% (opc), 40% 30%, 10% C 6 6 6 6 0.5

4.2 Materials and Method

4.2.1 Materials used

4.2.1.1 Fly ash

Fly ash refers to the ash produced during combustion of

coal. Pulverized fuel ash commonly known as fly ash

shall conform to Grade 1 or Grade 2 of IS 3812. The

proportion of the Fly ash is generally in the ratio 60-

80%, depending upon the quality of raw materials. The

Fig.2 shows the fly ash particles pictorial view.

The Fly ash is From Raichur Thermal Power Plant,

Karnataka, INDIA – 400709.


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93

Fig.2 Fly ash

4.2.1.2 Cement

Portland cement conforming to IS 12262-1787 was

used. The Fig.3 shows the pictorial view of Ultra tech

cement 53 Grade procured from single source, and the

properties found in the laboratory are given in Table 3.

Table 3: Physical properties of cement

Sl. No. Properties Test results

1 Specific gravity 2.8

2 Normal consistency 33%

3 Initial setting time 45 minutes

4 Final setting time 300minutes

Fig.3 Cement

4.2.1.3 Quarry dust

The stone dust passing through IS sieve 1.18mm as

shown in Fig. 4.

Fig.4 Quarry dust

4.2.1.4 Aggregates

As per IS 383-1970[6] the aggregate shall not consist of

natural occurring (crushed or uncrushed) stones, gravel

and sand combination thereof. They shall be hard,

strong, dense, durable, clear, durable, clear, free from

adherent coating and free from injurious amounts of

disintegrated pieces, alkali, vegetable matter and

deleterious substances as possible flaky and elongated

pieces should be avoided. The Fig. 5 shows the pictorial

view of coarse aggregates.

In the present investigation the locally available

aggregate from crushers was used. The aggregate

generally used in fly ash bubble brick application

usually below 6mm sized aggregates are used. Results

of preliminary tests are presented in table 4.

Table 4: Properties of coarse aggregates

Sl.

No.

Properties Test results

1 Shape of course aggregate Angular

2 Specific gravity 2.63

3 Free surface moisture Nil

Fig.5 Coarse aggregate

4.2.1.5 Water

Generally, water that is suitable for drinking is

satisfactory for bricks. Water from lakes and streams

that contain marine life also usually is suitable. When

water is obtained from sources mentioned above, no

sampling is necessary. When it is suspected that water

may contain sewage, mine water, or wastes from

industrial plants or canneries, it should not be used in

bricks unless tests indicate that it is satisfactory. Water

from such sources should be avoided since the quality of


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94

the water could change due to low water or by

intermittent tap water is used for casting.

4.3 Manufacturing process

The normal hand mould is used to cast the bricks with

standard size of 23cmX10cmX7cm. Fly ash, cement,

quarry dust and aggregates are manually fed into a pan

mixer where water is added in the required proportion

for intimate mixing.

The proportion of the raw material is generally in the

different ratios in different gradation, depending upon

the quality of raw materials. The Fig. 6,7 & 8 show the

weighing of fly ash, pouring of mortar into mould and

manufactured bricks after demoulding respectively.

The materials are mixed in pan mixture. After mixing,

the mixture is poured into the mould and placing the

bubbles in between the mortar like sandwich, conveyed

through belt conveyor to the hydraulic/mechanical

presses.

The homogenized mortar taken out of roller mixer is put

into the mould boxes. Depending on the type of

machine, the product is compacted under vibration /

hydraulic compression etc.

The fly ash bubble bricks are dried up under sun from 2

to 4 days, depending whether lime route or cement

route; the dried up bricks are stacked and subjected for

water spray curing once or twice a day, for 28 days,

depending on ambience. The bricks are tested and sorted

before dispatch.

Fig. 6 Weighting raw material Fig.7 Mixed Material Filling Into The mould

Fig.8 Demoulded Bricks

V. RESULTS AND DISCUSSIONS

5.1 Tests conducted

a. Compressive strength test

5.1.1Specimen

The fly ash bubble bricks of mould 23cm x 10cm x 7cm

size with varying mix proportions of Fly ash, cement,

quarry dust, aggregates ratio, inserting plastic bubbles

like sandwich and constant water to cement ratio of 0.5

were casted in the lab. A total of 48 bricks specimens

were casted & tested for each diameter of the bubbles. in

the laboratory. The Fig. 9 shows the test conducted on

bricks and brick after failure in CTM.


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Fig.9 After Failure

5.1.2 Calculation:

𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡𝑕 𝑁

𝑚𝑚2 =

𝑀𝑎𝑥. 𝑙𝑜𝑎𝑑 𝑎𝑡 𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑖𝑛 𝑁

𝐴𝑣𝑔.𝐴𝑟𝑒𝑎 𝑜𝑓 𝑏𝑒𝑑 𝑓𝑎𝑐𝑒 𝑖𝑛 𝑚𝑚2

Table 5: Showing the compressive strength

Gradation Ball diameter

Proportion Curing in days

Compressive Strength

4 no’s

A.

15% PPC

45% FA

30%Dust

10%CA

60mm

1:3:2:0.6

7 days 1.325 N/mm2

21 days 1.855 N/mm2

28 days 2.6 N/mm2

B.

20%PPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.65 N/mm2

21 days 2.31 N/mm2

28 days 3.3 N/mm2

C.

20%OPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.765 N/mm2

21 days 2.471 N/mm2

28 days 3.53 N/mm2


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96

Fig.10 :fcm of Gradation A, 60mm dia (4 no.)

Fig.11 :fcm of Gradation B , 60mm dia (4 no.) Fig.12: fcm Gradation C, 60mm dia (4 no.)


0

0.5

1

1.5

2

2.5

3

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days

compressive strength in Mpa


0

0.5

1

1.5

2

2.5

3

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



00.5

11.5

22.5

33.5

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



Ball diameter



2 no’s

A.

15% PPC

45% FA

30%Dust

10%CA

60mm

1:3:2:0.6

7 days 1.17 N/mm2

21 days 1.638 N/mm2

28 days 2.34 N/mm2

B.

20%PPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.55 N/mm2

21 days 2.17 N/mm2

28 days 3.10 N/mm2

C.

20%OPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.654 N/mm2

21 days 2.317 N/mm2

28 days 3.310 N/mm2


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Fig.13: fcm of Gradation A, 60mm dia (2 no.)

Fig.14: fcm of Gradation B, 60mm dia (2 no.)Fig.15: fcm of Gradation C, 60mm dia (2 no.)


0

0.5

1

1.5

2

2.5

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



0

1

2

3

4

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



0

1

2

3

4

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days






3 no’s

A.

15% PPC

45% FA

30%Dust

10%CA

45mm

1:3:2:0.6

7 days 1.305 N/mm2

21 days 1.827 N/mm2

28 days 2.61 N/mm2

B.

20%PPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.455 N/mm2

21 days 2.037 N/mm2

28 days 2.91 N/mm2

C.

20%OPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.715 N/mm2

21 days 2.401 N/mm2

28 days 3.43 N/mm2


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Fig.17: fcm of Gradation B, 45mm dia (4 no.) Fig.18 fcm of Gradation C, 45mm dia (4 no.)


0

0.5

1

1.5

2

2.5

3

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



0

1

2

3

4

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days


compressive strength in Mpa 0

1

2

3

4

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days






2 no’s

A.

15% PPC

45% FA

30%Dust

10%CA

45mm

1:3:2:0.6

7 days 1.225 N/mm2

21 days 1.715 N/mm2

28 days 2.45 N/mm2

B.

20%PPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.505 N/mm2

21 days 2.107 N/mm2

28 days 3.010 N/mm2

C.

20%OPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.565 N/mm2

21 days 2.191 N/mm2

28 days 3.130 N/mm2


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Fig.20: fcm of Gradation B, 45mm dia (2 no.) Fig.21: fcm of Gradation C, 45mm dia (2 no.)

Table 9: Showing the compressive strength of solid bricks

0

0.5

1

1.5

2

2.5

3

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



0

1

2

3

4

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



1

2

3

4

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



Gradation Proportion Curing in days Compressive Strength

A.

15% PPC

45% FA

30%Dust

10%CA

1:3:2:0.6

7 days 1.375 N/mm2

21 days 1.925 N/mm2

28 days 2.750 N/mm2

B.

20%PPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.465 N/mm2

21 days 2.051 N/mm2

28 days 2.930 N/mm2

C.

20%OPC

40%FA

30%Dust

10%CA

1:2:1.5:1

7 days 1.575 N/mm2

21 days 2.205 N/mm2

28 days 3.150 N/mm2


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100

Fig.22: fcm of Solid brick, Gradation A

Fig.23 fcm Solid brick, Gradation B Fig.24: fcm of Solid brick, Gradation C

Table 10: Showing the weight of solid bricks

5.2 Discussions

As per the results shown in graphs from Fig. 10 to Fig.

24 and the test results tabulated reveals that the bubble

bricks shown considerable increase in strength with the

increase in no. of bubbles for the gradation B & C with

the increase in diameter of the bubbles. From Table 5 to

Table 9 demonstrates the compressive strengths of

different gradations with different diameters and no. of

balls. Similarly the Table 10 demonstrates the weight

comparison of different gradations with different

diameter and no. of balls.

0

1

2

3

4

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



1

2

3

4

7 21 28

Co

mp

ress

ive

str

en

gth

in M

pa

Days



Gradation Proportion

Weight of bricks(60mm) Weight of bricks(45mm) Solid bricks

4 no’s 2 no’s 4 no’s 2 no’s

A.

15% PPC

45% FA

30%Dust

10%CA

1:3:2:0.6 1.626kg 1.934kg 1.946kg 2.000kg 2.350kg

B.

20%PPC

40%FA

30%Dust

10%CA

1:2:1.5:1 1.532kg 1.760kg 1.976kg 2.100kg 2.420kg

C.

20%OPC

40%FA

30%Dust

10%CA

1:2:1.5:1 1.685kg 1.710kg 2.148kg 2.259kg 2.540kg


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101

The weight of the bricks also decreased considerably

with the increase in no. of bubbles with increase in

diameter of the bubbles.

VI. CONCLUSION

The bubble bricks shown increase in compressive

strength and hence there will be less or no breakage

during transportation.

The bubble bricks are 33 % lighter in weight and

hence can utilized in construction.

The raw material required is waste by product and

hence the environmental erosion can be reduced. Waste

is converted into wealth. Eco-Friendly bricks.

These bricks masonry presents better architectural

view as compared to brick masonry.

Fly ash bubble brick masonry consumes less mortar

than brick masonry because volume of joints is less in

fly ash bubble brick masonry.

Due to uniform size of bricks mortar required for

joints & plaster reduced.

It can be understood that fly ash bricks are better

alternative to conventional burnt clay bricks in

structural, functional and economic aspects; by use of

this aspect we can convert waste into wealth.

REFERENCES

[1] N. Bhanumathidas and N.Kalidas, Fly ash: The

resource for construction industry„, April 2003,

The Indian Concrete Journal, PP. 997-1004

[2] Gupta P.C, Ray S. C. ,” Commercialization of

Fly ash”, The Indian Concrete Journal, 167,

1993, 554-560.

[3] Sengupta J. , “Availability of Fly ash and its

Application in Construction Industry”, NBO

Journal, XXXIX, 1984, 17-22

[4] Butterworth B., “Bricks made with pulverized

Fuel Ash.”, Trans. Brit. Ceram.Soc‟ ENGLAND,

53 (5), 1954, 293- 313.

[5] Gupta, R.L. , Bhagwan, Gautam, D.K., Garg,

S.P., “A Press for Sand Lime Bricks Research

and Industry”, 22(40), 1977, 246-249.

[6] Parul, R. Patel, “Use of Fly ash in Brick

Manufacturing”, National Conference On

Advances in Construction Materials, “ AICM-

India, 2004, 53-56.

[7] Peter George Kenneth Kingth, “Pulverized fuel

ash as a construction material”, proceedings of

institution of Civil Engineers, 16, 1960, 419-432.

[8] Rai, Mohan, Gupta, R. L., “Energy Conservation

in the Manufacture of sand Lime Bricks”, Proc.

of National Seminar on Energy Conservation in

Process Industries, Institution of Engineers India,

1985.

[9] I.S Code 12894-1990 for Fly ash – Lime Bricks-

Specification.

[10] I.S Code: 8112-1989, Ordinary Portland Cement,

43 Grade- Specification

[11] IS: 3495(P-I)-1976, Determination of

Compressive Strength (Second Revision).

[12] IS: 3495 (P-II) -1976, Determination of Water

Absorption (Second Revision).

[13] IS: 3495 (P-II)-1976, Determination of Effloresce

(Second Revision).

[14] S.C Rangwala, “Engineering Material”, Charotar

Publications, 15th Edition, 1991, 72-112.

[15] Bhanumathidas, N., “Fly ash in precast products-

The Indian Scenario”, 1999, 31- 35.

[16] IEEE-International Conference On Advances In

Engineering, Science and Management (lCAESM

-2012) March 30, 31, 2012

[17] N. Bhanumathidas and N. Kalidas, INSWAREB,

‗Sustainable Development through use of Fly

Ash„, Keynote Paper presented at National

Seminar on Building Materials & Technology for

Sustainable Development; Ahmadabad: Jan 2005

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