EXPERIMENTAL STUDIES ON BRICKS BY

REPLACEMENT OF SCBA AND RICE HUSK ASH

A PROJECT REPORT 2016-2017

Submitted by

D.JEYABASKARAN (912313103010)

M.RAJKARAN (912313103033)

P.SRIRAMAMOORTHY (912313103041)

S.DINESHWARAN (912313103304)

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

IN

CIVIL ENGINEERING

SACS MAVMM ENGINEERING COLLEGE - MADURAI

ANNA UNIVERSITY CHENNAI-600 025

APRIL 2017

1
 ANNA UNIVERSITY CHENNAI-600 025

BONAFIDE CERTIFICATE

Certified that this project report “EXPERIMENTAL STUDIES ON BRICKS

BY REPLACEMENT OF SCBA AND RICE HUSK ASH” is the bonafide
work of “D.JEYABASKARAN (912313103010), M.RAJKARAN
(912313103033), P.SRIRAMAMOORTHY (912313103041),
S.DINESHWARAN (912313103304)” who carried out the project work
under my supervision.

SIGNATURE SIGNATURE

DR.B. SELVA KOODALINGAM, MR.R.RAJESH KUMAR M.E

HEAD OF THE DEPARTMENT ASSISTANT PROFESSOR

DEPARTMENT OF CIVIL ENGINEERING DEPARTMENT OF CIVIL ENGINEERING

SACS M.A.V.M.M ENGINEERING COLLEGE SACS M.A.V.M.M ENGINEERING COLLEGE

ALAGARKOVIL, MADURAI (D). ALAGARKOVIL, MADURAI (D).

Submitted for the project viva-voce examination held on ……………..

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT
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 We would like to praise and thank our lord almighty without whose
blessings this work would not have been done.

We express our sincere thanks to Dr.S.NAVANEETHA KRISHNAN M.E

PhD.., principal of our college for giving as the permission to carry out this
project.

I would like to special thanks to head of the department

Dr.B.SELVAKOODALINGAM M.E.., PhD.., for this enthusiastic
encouragement and involvement.

We express our deep sense of graduate to our guide

Mr.R.Rajeshkumar M.E…, civil engineering department for his

initiative suggestions, valuable advice, everlasting encouragement for the
progress and successful completion of this project and all staff members and
technicians of civil engineering department for their consistent help for the
project work successfully.

It is my privilege to thanks to MR.R.BENHUR M.E…, Department of civil

engineering for his constant encouragement throughout my research period.

I would like to express my sincere gratitude to my parent. At last would like to

thank all my batch mates and friends for their support.

ABSTRACT

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 It is an innovation technique in manufacturing the bricks. In this project
an attempt has been made to study the characteristic strength of the bricks
prepared by using sugarcane waste ash and rice husk ash. Sugarcane waste ash
is a fibrous waste material from sugar industry and is obtained after the
sugarcane waste is used for the generation of electricity by turbine. Rice husk
ash is a material from the burning of rice husk at some factories. In this study,
rice husk ash and sugarcane waste has been utilized for the preparation of bricks
in partial of clay. In this we are preparing bricks using both rice husk ash and
sugarcane waste ash both are same ratio in five different types of bricks such as
5%, 10% and 15% of replacement in sand. Based on this study it is found that
the maximum utilization of rice husk ash and sugarcane waste ash in bricks. The
best among these bricks is found and the same is used thereby. The substantial
usage will fall over the land protection and tend to make the utilization
meaningful. Moreover, clay which is the natural resource could be recouped for
the future, by the usage of rice husk ash and sugarcane waste ash. The
compressive strength and the water content is comparatively less than the
normal clay bricks as be the code the percentage of water absorbed by the bricks
should not exceed 20% of dry weight of the bricks.

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 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

ACKNOWLEDGEMENT iii

ABSTRACT iv

TABLE OF CONTENTS v

LIST OF TABLES viii

LIST OF FIGURES ix

LIST OF SYMBOLS x

1 INTRODUCTION 1
1.2 Need 2
1.3 Scope 2
1.4 Objective 2
2 LITERATURE REVIEW 3
2.1 General 3
3 STUDY OF MATERIALS 9
3.1 Clay 9

3.2 Rice Husk Ash 9

3.3 Sugarcane Waste Ash 9

3.4 Sugarcane Bagasse Ash 10

3.5 Lime 11

3.6 Types of Bricks 12

3.7 Environmental Benefits 15

4 METHODOLOGY 18
4.1 General 18

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4.2 Mix proportion 18

4.3 Requirements of Good Bricks 19

4.4 Qualities of Good Bricks 19

4.4.1 Size and Shape 20

4.4.2 Structure 20

4.4.3 Soundness 20

4.4.4 Hardness 20

4.4.5 Porosity 21

4.4.6 Strength 21

4.4.7 Resistance to fire 21

4.4.8 Efflorescence 21

4.4.9 Durability 21

4.4.10 Size of Bricks 21

4.5 Flow Chart of Methodology 22

4.6 Mixing 23

4.7 Casting 24

4.7.1 Preparation of Bricks 24

4.7.2 Moulding 25

4.7.3 Drying 28

4.7.4 Burning 29

4.8 Properties of Materials 30

4.8.1 Properties of Sugarcane 30

4.8.2.1 Physical Properties 32

4.8.2.2 Chemical Properties 32

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5 TESTING ON BRICKS 34
5.1 Compressive Strength Test 34

5.2 Procedure 34

5.2.1 Formula 35

5.3 Water Absorption Test 37

6 SUMMARY AND CONCLUSION 39

REFERENCES 40

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 LIST OF TABLES

Table no Title Page no

3.1 Chemical Composition of SCBA 11
4.2 Mix Proportions of Materials 18

4.3 Physical Properties of SWA 30
4.4 Chemical Properties of SWA 31

4.5 Chemical Properties of RHA 32

5.1 Compressive Strength of Various Mix  35
Proportions
5.2 Water Absorption of Mix Proportions 37

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 LIST OF FIGURES

Fig No. Title Page No.

3.1 Sugarcane Waste Ash  9
3.2 Sugarcane Bagasse Ash 10
3.3 Lime 11
3.4 Application of Rice Husk Ash 16
3.5 Application of Sugarcane Bagasse Ash 17
4.1 Flow Chart of Methodology 22
4.2 Mixing 23
4.3 Moulding 27
4.4 Drying 28
4.5 Burning 29
4.6 Graphical Representation of Chemical Composition of 31
SWA
4.7 Chemical Composition of RHA 33
5.1 Graphical Representations of Compressive Strength Test 36
5.2 Graphical Representations of Water Absorption Test 38

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LIST OF SYMBOLS

SIO2 - SILICA

CAO - CALCIUM OXIDE

FE2O3 - FERRIC OXIDE

K2O - POTTASIUM OXIDE

C - CARBON

MGO - MAGNESIUM OXIDE

N/mm2 - NEWTON PER MILLIMETER SQUARE

SWA - SUGARCANE WASTE ASH

UM - MICRO METER

BIS - BUREAU OF INDIAN STANDARD

AL2O3 - ALUMINIUM TRIOXIDE

IS - INDIAN STANDARD

RHA - RICE HUSK ASH

CTM - COMPRESSION TESTING MACJINE

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 CHAPTER 01
INTRODUCTION
1.1 General

Since the large demand has been placed on building material owing to
increasing population which causes a shortage of building materials, the civil
engineers have been challenged to convert the industrial wastes to useful
building materials. Brick is the simplest and most ancient of all building
materials. More than 80 billion bricks required per year in India. SCBA is a
fibrous waste product of the sugar waste product of the sugar refining industry
and Rice husk is a waste material from the burning of rice husk at some
factories huge quantity of ash which is a waste product available at very
negligible rate. Uses of SCBA and rice husk ash waste in brick can save the
sugarcane and rice husk ash industry disposal costs and produce a greener
bricks for construction. The utilization of industrial and agricultural
waste produced by industrial processes has been the focus of waste
reduction research for economical, environmental, and technical reasons.
Sugar-cane bagasse is a fibrous waste-product of the sugar refining industry,
along with ethanol vapor. This waste product (Sugar-cane Bagasse ash) is
already causing serious environmental pollution, which calls for urgent ways of
handling the waste. Bagasse ash mainly contains aluminum ion and silica.
Bagasse ash has been chemically and physically characterized, and partially
replaced in the ratio of 0%, 5% and15% by weight of cement in fly ash bricks a
Rick is a block made of clay burnt in a kiln. It is one of the primary building
materials known to mankind. Bricks are composed of inorganic non-metallic
material and are widely used as building components all over the world. Over
time, bricks have appeared, gained prominence, lost importance and then come
to the forefront again with various styles of Architecture. Burnt bricks were
used in ancient Indian, Babylon, Egypt and Roman civilizations. Bricks find
mention in the Bible; the tower of Babel was built with burnt bricks the need
for a locally manufactured building material has been emphasized in many

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countries of the world because of their easy availability and low cost. Bricks
also have been regarded as one of the longest lasting and strongest building
materials, made from locally available sources, used throughout history.

1.2 Need of the project

 To compensate an alternate material for sand
 The disposal of SWA and RHA contaminates the surface and
underground water.
 It is the efficient way to utilize the RHA and SWA.
 To improve the durability of bricks.
1.3 Scope of the project
 The SWA and RHA property was compared with fly ash properly
then it is suggested that the SWA and RHA can be utilized as a building
material.
 Strength should be attained.
 Inspiring and innovative material should be used.

1.4 Objective
 The main objective of the present investigation is to be provide an
improved process for the production of bricks using rice husk ash and
sugarcane waste ash.
 To study the characteristics of the rice husk ash and sugarcane
waste ash.
 To produce economical bricks instead of ordinary brick production.
 To find the compressive strength, water absorption test.

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 CHAPTER 02
LITERATURE REVIEW

1. AkshaySatish More, AhadTarade, AshwaniAnant

THE EXPERIMENTAL INVESTIGATION OF EFFECT OF

FLY ASH AND RICE HUSK ASH ON THE PROPERTIES OF
BURNT CLAY BRICKS.
.

The proposed study involves the experimental investigation of effect of

fly ash and rice husk ash on the properties of burnt clay bricks. Determination
of properties of the bricks casted with varying proportions of admixtures is
taken up to ascertain whether the admixtures can be used for the production of
clay bricks. On seeing the present day demand for bricks, an attempt is made to
study the behavior of bricks manufactured using, different waste materials like
rice husk ash and fly ash The main aim of this research was to compare the
compressive strength of the bricks, so for this purpose different percentage of
materials were separately added 5%, 10%, 15%, 20% and 25% by weight and
then the compressive strength of the bricks was established, and then with the
help of graph a comparison between compressive strength of bricks, made out
of clay, Fly Ash, Rice husk ash and combination of all these was determined.
The bricks were made, sun dried and burnt in a kiln, and then with the help of
Compression Testing Machine (C.T.M.) finely their compressive strength was
calculated. From this test in this research work it was concluded that the bricks
with fly ash as the waste material admixture, gave the highest compressive
strength. The fly ash admixture, in line with its pozzolanic nature, was able to
contribute in attaining denser products with higher compressive strength, higher
water absorption rates, better durability and better overall performance. The
effects of the addition of rice husk ash and combination of fly ash and rice husk
ash by percentage-clay mix was also investigated from the experimental results
obtained, it can be concluded that The clay burnt bricks manufactured with fly

13
ash and rice husk ash had similar appearance when compared to the
conventional clay bricks. The clay bricks having fly ash as an admixture showed
the best performance, having a compressive strength of about 23% greater than
that of conventional bricks. The percentage of water absorption for these bricks
was found to be more than that of conventional bricks but still within the
prescribed maximum limit as per Indian Standards.(Maximum allowable water
absorption as per Indian Standards is 20%)Hence fly ash can be used as an
admixture with clay bricks.

2. N.VamsiMohan Prof.P.V.V.Satyanarayana, Dr.K.SrinivasaRao

PERFORMANCE OF RICE HUSK ASH BRICKS

In this study, rice husk ash has been utilized for the preparation of bricks
in partial and full replacement of clay. Engineering properties like compressive
strength, water absorption and size and shape have been studied. From the
studies, it is observed that optimum proportion for (RHA + Clay) bricks
observed as 30% RHA and 70% Clay (Maximum of 30% RHA) as the bricks
exhibited high compressive strength and low brick weight. In full replacement
of clay with 40% RHA, 40% Lime and 20% gypsum and 50% RHA, 30% lime
and 20% gypsum gives more strength (41 kg/ cm2) when compared to all other
possible proportions after 28 days curing period. By the addition of RHA up to
40% to clay, the strength gradually decreased and beyond the addition of 40%
RHA the compressive strengths decreased rapidly. Optimum proportion for
(RHA+ Clay) bricks was observed as 30% RHAand70% Clay (Maximum of
30% RHA) as the bricks exhibited high compressive strength and low brick
weight. As the percentage of RHA increased, water absorption of RHA-Clay
bricks also increased. In full replacement of clay with 0% RHA, 40%Lime and
20%gypsum and 50% RHA, 30% lime and 20%gypsumgivesmore strength
(41kg/ cm2)when compared to all other possible proportionsafter28 days curing
period.50% RHA,30% lime and 20% gypsum is optimum proportion due to its
light weight at that proportion. As the percentage of lime and gypsum increased,
Water absorption of RHA + Lime + Gypsum bricks decreased.

14
3. Apurva Kulkarni, SamruddhaRaje, and MamtaRajgor Bagasse Ash As
An Effective Replacement In Fly Ash Bricks.

Sugar-cane bagasse is a fibrous waste-product of the sugar refining industry,

along with ethanol vapor. In this paper, Bagasse ash can be utilized by replacing
it with fly ash and lime in fly ash bricks. Trial bricks of size (230x100x75) mm
were tested with different proportions of 0%, 10%, 20%, 30%, 40%, 50% and
60% with replacement of fly ash and 0%, 5%, 10%, 15% and 20% with
replacement of lime. These bricks were tested in Compression test and Water
absorption test as per Indian Standards. Compressive strength increases on
increase in percentage of Bagasse ash as compare to fly ash.

4. Piyush Kumar, Anil pratap Singh. Studies on Partial Replacement of

Cement by rice husk Ash

This paper carried out partial replacement of cement by rice husk ash in
order to reduce industrial waste and to save cement and by saving cement
reduced greenhouse gases emission and makes environmental green. Rice husk
ash partially replaced in the ratio of 0%, 5%, 10%, 15% and 20%by weight of
cement in four different experiment to find out maximum compressive strength.
Compare it with the strength of normal concrete by using grade M-30 at 7days
and 28 days. It is found that the cement could be advantageous replaced with
bagasse up to maximum limit of 10%.Replacement of cement by rice husk ash
reduce industrial waste and to save cement. By saving cement reduced
greenhouse gases emission and makes environmental green.OPC replacement
by rice husk ash results in reduction of cost of production of concrete in the
range of 5 to 10%.Using rice husk as replacement of OPC in concrete, the
emission of greenhouse gases can be reduced up to a greater extent.

5.AnilPratapSingh, Piyush Kumar - Light Weight Cement-Sand And rice

husk Ash Bricks. IJIRST –International Journal for Innovative Research in
Science & Technology| Volume 1 | Issue 12 | May 2015.

15
 Rice husk ash, is utilized to developed light weight bricks-that serve a
purpose of solid waste management and energy efficient alternative low cost
construction material. To replacing the clay bricks, with that in mind a research
was conducted by utilizing with cement and sand. The research involved the
preparation of five mix proportion, which are (15% rha+65% sand+20%
cement, 20% rha+60% sand+20% cement,25% rha,+55%sand+20%cement,
30% rha+50% sand+20% cement,35%rha+45% sand+20% cement) and bricks
are casted. After casting the series of test carried out in accordance with
recommended Indian standards to determine water absorption capacity (I.S
3495(part-2)(BIS-1992-b)) , compressive strength as per (I.S 3495(part-1) BIS-
1992-a)and efflorescence (I.S3495(part-3) (BIS1992-c)).

Sagar W. Dhengare, Dr.S.P.Raut, N.V.Bandwal, AnandKhangan –

Investigation into Utilization of Sugarcane Bagasse Ash as
Supplementary Cementations Material. International Journal of
Emerging Engineering Research and Technology.

This paper presents the use of sugarcane bagasse ash (SCBA) as apozzolanic
material for producing high- strength concrete. In this research physical
characteristics, chemical combination (XRF test), TG-DTA were investigated
and compared with cement. The concrete mixtures, in part, are replaced with
0%, 10%, 15%, 20%, 25% and 30% of BA respectively. In addition the
compressive strength, the flexural strength, the split tensile tests were
determined. The bagasse ash was sieved through No. 600sieve. The mix design
used for making the concrete specimens was based on previous research work
from literature. The water – cement ratios variedfrom0.44to 0.63.Thetestswere
performedat7, 28,56and90 days of again order to evaluate the effects of the
addition SCBA on the concrete. The test result indicate that the strength of
concrete increase up to15% SCBA replacement with cement.

Amrita Kumari, Prof. SheoKumar Experimental Study on Partial

Replacement of Cement by Sugarcane Bagasse Ash

This experimental study investigates the strength performance of

concrete using Portland pozzolanic Cement and Sugarcane Bagasse Ash.

16
Initially, bagasse ash samples were collected and its properties were
investigated. Normal consistency and setting time of the pastes containing
Portland pozzolanic cement and sugarcane bagasse ash at 5%,10%,15%&20%
replacement were investigated. The compressive strength of mortars containing
Portland pozzolana cement with bagasse ash at 5%, 10%, 15% & 20%
replacements were also investigated. Compressive strength, flexural strength,
split tensile strength and density of M25concretecontaining Portland pozzolana
cement with sugarcane bagasse ash at 5%, 10%, 15% and 20% replacements
were also investigated at water cement ratio 0.44, 0.45, 0.46. The result shows
that consistency, initial setting time, final setting time increases with increase
in percentage of sugarcane bagasse ash whereas soundness sand compressive
strength of mortar decreases with increase in percentage of sugarcane bagasse
ash. Compressive strength, flexural strength, split tensile strength and density
of concrete containing Portland pozzolana cement with sugarcane bagasse ash
decreases with increase in percentage of sugarcane bagasse ash.

Mangesh V.Madurwar, Sachin A.Mandavgane and Rahul V.

Ralegaonkar Use of sugarcane bagasse ash as brick material.

Application of bio fuel by product sugarcane bagasse ash (SCBA)as a

principal raw material for the manufacturing of bricks was studied. The bricks
were developed using the quarry dust (QD) as a replacement to natural river
sand and lime (L) as a binder. SCBA as a principal raw material was
characterized using X-ray fluorescence (XRF), thermo – gravimetric analysis
(TGA), X-ray diffraction and scanning electron microscopy (SEM). XRF
confirms SCBA as a cementations material. TGA confirms thermal stability
till6500C, where as SEM monograph shows individual ash with a rough
surface and numerous fine pores. Elemental analysis of quarry dust and lime
was also carried out using XRF and classic wettest. The physical properties of
quarry dust and lime were determined using the laboratory test methods.
SCBA–QD–L combination bricks were designed and developed in different
mix proportions mechanical properties of the developed bricks were studied
according to recommended standards. The results of the SCBA–QD–L bricks
17
were compared with mechanical properties of commercially available burnt
clay- and fly- ash bricks. It was observed that SCBA–QD–L bricks are lighter
in weight and very effective

Richard Onchiri, Kiprotich James, Bernadette Sabuni – Use of

sugarcane bagasse ash as a partial replacement.

The provision of housing is a challenge around the world, especially in

developing countries. The spiraling growth of population, low Gross National
Product and the general lack of purchasing power are factors that contribute to
the progressive deterioration of the housing situation in developing economies.
This condition in many developing countries necessitates finding appropriate
low-cost cost building materials. Building materials such as fired clay bricks,
lime and Portland cement require enormous energy input, hence prove to be
expensive. The sugar manufacturing industries produce a lot of sugarcane
bagasse which is disposed of fin an open land (landfill). This ash has
pozzolanic properties which can be made use in the construction industry.

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 CHAPTER 03

STUDY OF MATERIAL

3.1 Clay

 Clay is the important binding material in bricks.

 Clay is a fine-grained soil that combines one or more clay minerals with
traces of metal oxides and organic matter.
 Clay minerals are hydrous aluminum phyla silicates, sometimes, with
variable amounts of iron, magnesium, alkali metals, alkaline earths and
other cautions found on or near some planetary surfaces.
3.2 Rice Husk Ash

 Rice hush ash is obtained by burning rice husk. Physical properties of

RHA are greatly affected by burning conditions.
 When the combustion is incomplete, large amount of unburnt carbon is
found in the ash.
 When combustion is completed, grey to whitish ash is obtained. The
amorphous content depends on burning temperature and holding time.
3.3 Sugarcane Waste Ash

 The sugarcane waste ash was burnt for generating steam and electricity.
 After burning process the remaining residue is called as the sugarcane
Waste Ash.

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 Fig 3.1 Sugarcane Waste Ash

Sugarcane Bagasse Ash

The burning of bagasse which i waste of sugarcane produces bagasse

ash. Presently in sugar factories bagasse is burnt as a fuel so as to run their
boilers. This bagasse ash is generally spread over farm sand dump in ash pond
which causes environmental problems also research states that Workplace
exposure to dusts from the processing of bagasse can cause the chronic lung
condition pulmonary fibrosis, more specifically referred to as bagasse. So
there is great need for its re use, also it is found that bagasse ash is high in
silica and is found to have pozzolanic property so it can be used as substitute
to construction material. The sugarcane bagasse consists of approximately
50% of cellulose, 25% of hemi cellulose and 25% of lignin. Each ton of
sugarcane generates approximately 26% of bagasse (at a moisture content of
50%) and 0.62% of residual ash. The residue after combustion presents a
chemical composition dominates by silicon dioxide (Si O2). In spite of being a
material of hard degradation and that presents few nutrients, the ash is used on
the farms as a fertilizer in the sugarcane harvests.

20
 Fig 3.2 SCBA

CHEMICAL COMPOSITION OF SCBA

SL.NO COMPONENT Mass %

1 Silica ( SiO2 ) 66.89

Alumina ( Al2O3 )
2 Ferric Oxide ( Fe2 O3 ) 29.18

3 Calcium Oxide ( CaO ) 1.92

4 Magnesium Oxide ( MgO ) 0.83

5 Sulphur Tri Oxide (SO3) 0.56

6 Loss of Ignition 0.72

7 Chloride -

Table 3.1 Chemical Composition of SCBA

3.4 LIME

Fig 3.3 Lime

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 Pure calcium oxide is fused with coke in order to render the highest yield
in the manufacture of acetylene. The quality of the resultant carbide lime is a
direct result of the excellent quality raw materials. Carbide lime is finer in
particle size, and physically, having a very finely divided particle size makes
carbide lime better. A finer particle size means faster and more reactivity.

3.5 Water

 Water is an important ingredient of brick as it actively giving cement

gel, the quantity and quality of water is required to be looked into very
carefully.
 Water is important in starting the reaction between cement and other
constituent materials. The building property of cement cannot take
effect without water.

THREE TYPES OF BRICKS

A Brick is a block or a single unit of kneaded clay – bearing soil, sand

and lime, or concrete material, fine hardened or air dried, used in masonry
construction. Lightweight bricks (also called lightweight blocks) are made from
expanded clay aggregate. Fired bricks are the most numerous types and are laid
in courses and numerous patterns known as bonds, collectively known as
brickwork, and may be laid in various kinds of mortar to hold the bricks
together to make a durable structure. Bricks are produced in numerous classes,
types, materials and sizes which vary with region and time period, and are
produced in bulk quantities. Two most categories of bricks are fired and non
fired bricks. Fired bricks are one of the longest and strongest building materials
sometimes referred to as artificial stone and have been used since circa 5000
BC. Air dried bricks have a history older than fired bricks, are known by the
synonyms mud bricks and adobe, and have an additional ingredients of a
mechanical binder such as straw.

22
 In addition to fired bricks, some chemically set bricks also existed that do
not undergo the process of firing. Some of the chemically set bricks are calcium
silicate bricks and concrete bricks.

Calcium Silicate Bricks

Calcium Silicate bricks are also called sand lime or flint lime bricks
depending on their ingredients. Rather than being made with clay they are made
with lime binding the silicate materials. The raw materials for calcium – silicate
bricks include lime mixed in a proportion of about 1 to 1 with sand, quartz,
crushed flint or crushed siliceous rock together with mineral colorants. The
materials are mixed and left until the lime is completely hydrated; the mixture is
then passed into moulds and cured in an autoclave for three to fourteen hours to
speed the chemical hardening. The finished bricks are very accurate and
uniform, although the sharp arise need careful handling to avoid damage to
brick and bricklayer. The bricks can be made in a variety of colors; white, black,
buff and grey – blues are common and pastel shades can be achieved. This type
of bricks is known as fly ash bricks, manufactured using the FaL-G (fly ash,
lime and gypsum) process. Calcium-silicate bricks are also manufactured in
Canada and The United States, and the meet criteria set forth in ASTM C73 –
10 Standard Specification for Calcium Silicate Brick (Sand – Lime Brick). It
has lower embodied energy then cement based man – made stone and clay
brick.

Concrete Bricks

Bricks of concrete with sand aggregate can be made using a simple

machine and a basic assembly line. A conveyor belts adds the mixture to a
machine, which pours a measured amount of concrete into a form. The form is
vibrated to remove bubbles, after which it is raised to reveal wet bricks, speed

23
out on a plywood sheet. A small elevator then stacks these palettes, after which
a forklift operator moves them to the brickyard for drying.

Concrete bricks are available in many colours and as an engineering brick

made with sulphate – resisting Portland cement or equivalent. When made with
adequate amount of cement they are suitable for harsh environments such as wet
condition and retaining walls. They are made to Standard BS 6073, EN 771-3.
Concrete bricks expand and contract more than clay or sand lime bricks so they
need movement joints every 5 to 6 metres, but it similar to other bricks of
similar density in thermal and sound resistance and fire resistance.

Clay Bricks

The majority of used are made from clay and shale; they are used in the
preliminary in the construction of walls by bleeding and joining of bricks into
established bonding arrangement. Clay is an abundant raw material with a
variety of uses and properties. It is a complex of group of material that consists
of minerals commodities, geological occurrence, technology and applications.
They are natural earth fine grained materials of secondary origin and composed
of an aluminates and silicates structures with an additional iron, alkalis and
alkaline earth element. Common clays are sufficiently plastic to permit ready
moulding and when firing, they make 1000C. The clay bricks has been
traditionally manufactured by mixing the ground clay wit water forming into the
desired shape, size, drying and firing.

24
4.1.1.1 ENVIRONMENTAL IMPACTS

Environmental impacts of Fly ash as below:

 Flying fine particles of ash poses problems for living near power stations,
corrode structural surfaces and affect horticulture.
 Long inhalation of fly ash causes fibrosis of lungs, silicosis, bronchitis
etc.,
 It is very difficult to handle the material in dry state because it is very fine
and readily air borne even in mild wind.
 It disturbs the ecology of that region, as source of soil, air and water
pollution.

4.1.1.2 ENVIRONMENTAL BENEFITS

Fly ash utilization has significant environmental benefits as:

 It increases the life of concrete roads and structures by improving

concrete durability.
 It helps in net reduction in energy use and green house gas.

4.1.1.3 APPLICATIONS

Application of Clay, Rice Husk, and Sugarcane waste ash in Civil Engineering
Works are as follows:

 Clay is a raw material for cement manufacturing (for blended cement

products).
 Light weight brick manufacturing.
 It is used as Asphaltic mineral fillers.
 Rice Husk ash used for road stabilization.
 Clay is used for making light weight aggregates.
 Rice Husk used in embankment construction.
 Use of Sugarcane waste as landfill.
 Fly ash used in flexible pavements.
 Controlled low strength fills.

25
APPLICATIONS OF RICE HUSK ASH

Fig 3.4 Application of Rice Husk Ash

APPLICATIONS OF SUGARCANE ASH

26
Fig 3.5 Application of Sugarcane Bagasse Ash

CHAPTER 04

METHODOLOGY

27
4.1 General
The process of manufacturing bricks using rice husk ash and
sugarcane waste ash is done in this project. The process initiates with the
collection of resource (rice husk ash and sugarcane ash produced from the sugar
industry) collection. Secondly, the material properties are determined. Then, the
bricks are cast in the casting yard with appropriate ratios comprising of the
constituents respectively. This process needs the sole attention because; it
decides the strength of the bricks. Finally, the process ends up with the testing
of the bricks.

4.2 Mix proportion

Materials Type-1 Type-2 Type-3

CLAY 90% 80% 70%

RHA 5% 10% 15%

SWA 5% 10% 15%

4.2 Mix proportions of material

4.3 Requirements of Good Bricks

A good bricks earth should fulfill the following requirements

 It must have proper proportions of rice husk ash and sugarcane waste ash.
 It should have perfect edges, free cracks with proper rectangular shape.

28
  It should give clear ringing sound when struck with each other.
 The percentage of water absorption of water should not be greater than
20% for first class brick.
 The average weight of bricks should be 3-3.5 kg.
 It should have low thermal conductivity.
 It should be sound proof.
 The minimum crushing strength of bricks must be 3.5 N/mm^2.
 It must be homogenous and free voids.

4.4 Qualities of Good Bricks

 The bricks should be table – moulded, well burnt in kilns, copper-
coloured, free from cracks and with sharp and square edges. The colour
should be uniform and bright.
 The bricks should be uniform in shape and should be of standard size.
 The bricks should give a clear metallic ringing sound when struck with
each other.
 The bricks when broken or fractured should show a bright homogeneous
and uniform compact structure free from voids.
 The brick should not absorbs water more than 20% by weight, for first
class bricks and 22% by weight for second class bricks, when soaked in
water for a period of 24 hours.
 The bricks should be sufficiently hard. No impression should be left on
brick surface, when it is scratched with finger nail.
 The bricks should not break into pieces when dropped flat on hard ground
from a height of about one meter.
 The bricks should have low thermal conductivity and they should be
sound proof.

4.4.1 Size and Shape

A good brick should be uniform in size (standard) and should
have rectangular plane surfaces with parallel sides and sharp straight right-
29
angled edges. Its surfaces should not be too smooth or, otherwise, the mortar
will not stick to it. Bricks are carefully monitored to verify its edges are sharp
and straight and undeviating in shape. A superior quality brick must contain
bright and unvarying color throughout.

Smooth

Velour

Rug

4.4.2 Structure
Structural brick homes in the settle, area were found to have
performed extremely well recent in the Nisqually earthquake. The elimination
of costly wood framing and the need to deal with fluctuating lumber prices is
yet another benefit of using structural brick.

Brick gives a home performance and beauty. Brick homes have

lower maintenance costs and often lower insurance rates because of their
resistance characteristics. For these reasons structural brick homes often have
higher resale values and greater curb appeal than homes constructed with
traditional methods or other siding materials.

4.4.3Soundness
A good brick should give a clear metallic ringing sound when struck
with another brick. Under the soundness test two bricks are retained with both
hands and hit with the one. If there is apparent metallic ringing sound and the
bricks don’t break then the quality of bricks is good.

4.4.4 Hardness
A good brick should be so hard that finger nails should not be able to
make any impression on its surface when scratched. Under the hardness test the
brick surface is scratched with a solid thing and the bricks is unaffected, then
the quality of the bricks is good.

4.4.5 Porosity
A good brick should not absorb more than 20 percent of its dry weight of water
when kept immersed for 24hours.

30
4.4.6 Strength
A good brick should have minimum crushing strength of
10.5N /mm^2. Ordinarily it should not break when dropped flat on hard ground
from a height of about 1m.

4.4.7 Resistance to fire

A good brick should have adequate resistance to fire. Ordinary
bricks can resist temperature up to 1200c. Bricks to be used for lining of
furnaces, etc., should be of special quality (known as fire bricks).

4.4.8 Efflorescence
A good brick not contain much alkaline salts, which may cause
efflorescence on surface and decay the brick. If the bricks contain alkalies, it is
injurious as they develop a gray or white coating on brick surface through
moisture absorption. This type of test is useful to detect the availability of
alakalis in bricks. Under this test a brick is submerged in fresh water for 24
hours and then it withdrawn from water and kept to be dried in shade.

If the whitish coat is detectable about 10% of brick surface then the
existence of alkalis in tolerable range. If it is about 50% of then it is may be
reasonable. If the alkalis are available more than 50% then the brick is
rigorously influenced with alkalies.

4.4.9 Durability
A good brick should be able to resist the effects of weathering agencies like
temperature variations, rain, frost action, etc.

4.4.10 Size of bricks

Length : 190mm

Breadth : 90mm

Depth : 90mm

4.5 Flow Chart of Methodology

COLLECTION OF MATERIALS
31
 PROPERTY STUDY ON
MATERIALS

MIXING

CASTING OF BRICKS

BURNING OF BRICKS

TESTING OF BRICKS

FIG 4.1 Flow Chart of Methodology

4.6 MIXING
 Fly ash Bricks can be manufactured using different mixing ratios of
different materials.

32
  We can select the best suitable mixing ratio according to the availability
of raw materials and market requirement.
 Profitable mixing ratio to manufacture fly ash brick at very low cost is
our project aim. At the same we should maintain the quality too; here we
come with different types of mixing ratios for manufacturing fly ash
bricks

FIG 4.2 Mixing

4.7 CASTING OF BRICKS

33
 For casting the test specimens, split-type Poly Vinyl Chloride (PVC)
moulds specially made for this purpose were used. The mixtures were poured
into the mould (180mm diameter and 25mm thickness) and then cast manually.
Immediately then, the disc was taken out from the mould and kept in open air.
After the air drying, i.e. on hearing the metallic sound when striking out the disk
surface, the specimen was coated externally with water proofing admixture
(Prime seal 604 + Rain coat) and it was dried 24 hours. At this stage, the disk
was for testing

4.7.1 BRICK MANUFACTURING PROCESS

These are the following step by step procedure of brick manufacturing
1. Preparation of bricks
2. Moulding
3. Drying
4. Burning

PREPARATION OF BRICKS

Unsoiling of clay

We need pure clay for the preparation of bricks. The top layer of soil may
contain impurities, so the clay in top layer of soil about 200mm depth is thrown
away.

Digging

After the removal of top layer, the clay is dug out from the ground and
spread on the plain ground.

Cleaning

In this stage, the clay is cleaned of stones, vegetable matter etc. if large
quantity of particulate matter is present, then the clay is washed and screened.
The lumps of clay are converted into powder with earth crushing rollers.

Weathering

34
 The cleaned clay is exposed to atmosphere for softening. The period of
weathering may be 3t o 4 weeks or a full rainy season. Generally, the clay is dug
out just before the rainy season for larger projects.

Blending

If we want to add any ingredient to the clay, it is to be added in this stage

by making the clay loose and spread the ingredient over it. Then take small
portion of clay into the hands and tuning it up and down in vertical direction.
This process is called blending.

Tempering
In this stage water is added to clay and pressed or mixed. The
pressing will be done by cattle or with feet of men or small scale
project, pug mill is used as grinder for large scale projects. So, the
clay obtains the plastic nature and now it is suitable for moulding.
4.7.2 MOULDING
The moulding process prepared into brick shape. This process can be
done in two methods.

 Hand Moulding
 Machine Moulding
Hand Moulding
The molds are in rectangular shape made of wood or steel which
are opened at the top and bottom. The longer sides it as handles. If we
take durability in consideration steel molds are better than wooden
molds.
Generally hand molding is two types
 Ground molded bricks
 Table molded bricks
Ground Molded bricks
35
  In this process of ground molding, first level the ground and
sand or ash is sprinkled over it.
 Now place the wet mold in the ground and filled it with I,
tempered clay and press hard to fill all corners of the mold.
Extra clay is removed with metal.
 The mould is then lifted up and we have raw brick in the
ground. And again wet the mould by dipping in water and repeat
the same process.
 Sometimes, the inside surface of mould is sprinkled with sand or
ash instead of dipping in water this is called sand moulding.
 Frog marks of bricks are made by using a pair of pallet boards.
Fog mark means the mark of depth which is placed on raw brick
while moulding. The depth may be 10mm to 20mm.
 Frog mark stats the trademark of manufacturing company and
also it is useful to store mortar in it when the brick is placed
over it.
Table Moulded bricks

 This process is similar to ground moulding process, but here the

bricks on molded on the table of size 2m x 1m.
 Ground moulding is economical when compared to table
moulding.
Machine Moulding
The bricks required are in large quantity and the machine molding is
economical and also saves more time. Here also we have two types of
machines.
1. Plastic Clay Machines
2. Dry Clay Machines

Plastic Clay Machines

36
 This machine contains an opening in rectangular shape and
when we place the tempered clay in to this machine it will come out
through this opening. Now, the rectangular strips coming out the
opening are cut by wires to get required thickness of bricks. So, these
are also called wire cut bricks.
Dry Clay Machines
Dry clay machines are more time saving machines. We can put
the blended clay into these machines directly without tampering.
Means tempering is also done in the machine by adding some water.
When the required stiffness is obtained the clay is placed in mould
and pressed hard and well shaped bricks are delivered.

FIG 4.3 Moulding

4.7.3 DRYING

37
  After molding process the bricks contain some amount of
moisture in it. So, drying is to be done otherwise they may
cracked while burning. The drying of raw bricks is done by
natural process.
 The bricks are laid in stacks. A stack consist 8 to 10 stairs. The
bricks in this stacks should be arranged in such a way that
circulation of air in between the brick is free.
 The period of drying may be 3 to 10 days. It also depends upon
the weather conditions.
 The drying yards are also prepared on higher level than the
normal ground for the prevention of bricks from rain water.
 In some situations artificial drying is adopted under special
dryers or hot gases.

FIG 4.4 Drying

4.7.4 BURNING

38
  In this process of burning, the dried bricks are burned either in
clamps (small scale) or kilns (large scale) up to certain degree
temperature. In this stage, the bricks will gain hardness and
strength so it is important stage in manufacturing of bricks.
 The temperature required for burning is about 1100·C. If they
burnt beyond this limit they will be brittle and easy to break. If
they burnt under this limit, they will not gain full strength and
there is a change to absorb moisture.
 Hence burning should be done properly to meet the
requirements of good bricks.

FIG 4.5 Burning

Requirements of Good Bricks

 It must have proportions of the above mix ratio.
39
  It should have perfect edges, free from cracks with proper
rectangular shape.
 It should give clear ringing sound when struck with each other.
 The average weight of bricks should be 3 to 3.5 kg.
 It should have low thermal conductivity.
 It should be sound proof.
 The minimum crushing strength of brick must be 3.5 N/mm2.

4.8 Properties of materials

4.8.1 Sugarcane Waste Ash

The physical properties of the sugarcane waste ash were found by the
standards test procedure (IS 2720-1963). There details were shown in the table.
The purpose of finding the physical properties was to check the properties to
use the sugarcane waste ash for the replacement of cement in the concrete.

The physical and chemical characteristics of sugarcane waste ash were

obtained from the sugar industries

S.NO PROPERTY VALUE

1 Fineness of SWA by sieve 3%

2 Specific gravity 2.15g/cc

3 Standard consistency 26.75%

4 Initial setting time 95mins

5 Final setting time 776mins

Table 4.3 Physical Properties of SWA

Table 4.4 chemical Properties of SWA

40
 S.NO COMPOSITION % OF PRESENCE

1 Sio2+al2o3 + Fe2o3 42.52

2 Mg O 01.92
3 Na2O 00.69

4 K2O 01.41
5 Cao 02.57
6 Loss of ignition 49.38
7 Titanium oxide 0.0023

8 Phosphorous 01.40

% OF PRESENCE

Si o2+al 2o3+
Fe2o3
0; 0.00% 1.4; 1.40%
MgO
Na2O
42.52; 42.57%K2O
49.38; 49.43% Cao
Loss of i gni tion
Ti tani um oxi de
Phos phorous
1.41; 1.41% 0.69; 0.69% 1.92; 1.92%
2.57; 2.57%

FIG 4.6

4.8.2 Properties of Rice Husk Ash

4.8.2.1 Physical properties

41
RHA resulting from the burning of rice husks at control temperatures have
physical and chemical properties that meet ASTM (American society for testing
and materials) standard C 618-94a. At burning temperatures of 550 0c – 8000c
amorphous silica is formed, but at higher temperatures crystalline silica is
produced. The silica content is between 90 and 96%. Grinding for producing
high quality RHA was studied by (Loot al. 1984). Studies have shown that to
obtain the required particle size, the RHA needs to be grown to size 45um -
10um

4.8.2.2 Chemical Properties

Table 4.5 chemical Properties of RHA

S.NO COMPOSITION %(PERCENTAGE)

1 Silica 91.56
2 Carbon 4.8
3 Calcium oxide 1.58
4 Magnesium oxide 0.53

5 Potassium oxide 0.39

6 Hematite, Fe2O3 0.21

42
percentage (%)

4.8

Si l i ca
1.580.530.39 0.21
Ca rbon

Ca l ci um Oxide

Ma gnes i um
Oxi de

Potas s i um Oxi de

Ha ematite, Fe2O3

91.56

FIG 4.7

43
 CHAPTER 05
TESTS ON BRICKS

5.1 COMPRESSIVE STRENGTH TEST

The crushing affords a basic comparing the quality of bricks but is of little value
in determining the strength of a masonry wall since the later depends primarily
on the strength of mortar. Compressive/Crushing strength of bricks are very
variable, and may vary from 30 kg/sq.cm to 150 kg/sq.cm for handmade burnt
bricks, while crushing strength of heavy duty bricks machine pressed may have
compressive strength.

1. Common Building Bricks – 35 kg/sq.cm

2. Second Class Bricks – 70 kg/sq.cm

3. First Class Bricks – 105 kg/sq.cm

4. Crushing Strength of bricks not less than 140 kg/sq.cm are graded AA class.

The strength of bricks is decrease by about 25 per cent when soaked in water.

Strength of sun – dried bricks is from 15 to 25 kg/sq.cm

5.2 Procedure
Place the specimen with the flats faces horizontal and mortar filled face being
upwards between two-three ply wood sheet each of 3mm thickness and
carefully centered between plates of the testing machine. Load is applied at a
uniform rate of 14 N/mm2 per minute till failure occurs and notes the maximum
load at failure. The load failure shall be the maximum load at which the
specimen fails to produce any further increase in the indicator reading on the
testing machine. The maximum load at failure divided by the average are of bed
face gives compressive strength.

44
5.2.1 Formula

maximum load at failure

Compressive strength in N/mm2 = ¿ averagearea of the bed faces

The crushing or compressive strength of common building bricks should not be

less than 3.5 N/mm2. Bricks of high quality do not have strength less than
14N/mm2.

The strength of the bricks is affected by the following factors.

I. The composition of brick used

II. The preparation of paper and blending of ingredients/constituents
III. Type of molding adopted.

Table 5.1 compressive strength of various mix proportions

MIX SAMPLE 1 SAMPLE 2 SAMPLE 3 AVG COMPRESSIVE
RATIO STRENGTH
(N/mm2)
0%RHA 175 170 175 173.33 10.13
0%SWA
5%RHA 180 185 180 181.67 10.26

5%SWA
10%RHA 190 195 200 195 11.4

10%SWA
15%RHA 160 165 165 163.33 9.55

15%SWA

45
The Graphical Representation Of Compressive Strength Of Brick

COMPRESSIVE STRENGTH (N/mm2)

12

11.5
Compressive strength (N/mm2)

11

10.5

10

9.5

8.5
0 10 20 30

Mix ratio

FIG 5.1

46
5.3 WATER ABSORPTION TEST
 The specimen brick is first weighted dry W1
 It is then immersed in water for a period of 24 hours.
 It is weighted again w2
 The difference in weight indicates the amount of water absorbed by the
brick
 It should not in any case, exceed 20% of weight of dry brick.

5.3.1 Formula
Water absorption = (w2-w1)/w1*100

W1= Dry brick weight

W2= Wet brick weight

Table 5.2 Water absorptions of various mix proportions

MIX Dry weight Wet weight Water Average

(%) W1(kg) W2(kg) Absorption (%)
(%)
0 4.019 4.027 0.19 0.16
4.026 4.033 0.17
4.124 4.119 0.12
10 3.812 3.825 0.34 0.28
3.763 3.772 0.24
3.820 3.830 0.26
20 3.449 3.432 0.37 0.40
3.411 3.426 0.44
3.252 3.265 0.40
30 3.016 3.031 0.49 0.44
3.108 3.125 0.48

47
 3.251 3.257 0.46

The Graphical Representation of Water Absorption of Brick

AVERAGE WATER OBSORPTION

0.5
0.45
0.4
Avg. Water Absorption

0.35
0.3
0.25
0.2
0.15
0.1
0.05
0
0 10 20 30
Mix ratio

FIG 5.2

48
 CHAPTER 06
CONCLUSION

Thus, we conclude by saying that the effective utilization of Rice Husk Ash
and Sugarcane waste ash bricks of size 190*90*90mm and was casted by
using handling mould at 0%,10%,20%,30%,40%,50% of ashes utilized in
bricks and tested with normal clay bricks . Load was applied on the
specimens using 500KN hydraulic jack, and it is efficient than the normal
cement bricks and clay bricks. Hence this is one of the best ways to dispose the
Rice Husk ash and Sugarcane Waste ash .Since the weight of the brick (30%
ashes replaced 3kg) is lesser than the conventional bricks (3.5 kg).

49
 REFERENCES

 Environmental Construction and Valuation [Research - Paper] by

B.N.Purohit from the Institution of values, Gujarat zone.
 “Engineering Materials” by R. K. Rajput, S.Chand & Company Ltd.
 Madurwar, M. V., Ralegaonkar, R. V. and Mandavgane, S. A., Application
of agro-waste for sustainable construction materials: a review. Constr.
Build. Mater., 2013, 38, 872–878.
 Limam, S.A.Varum, H., Sales, A. and Neto, V. F., Analysis of the
mechanical properties of compressed earth block masonry using the
sugarcane bagasse ash. Constr. Build. Mater, 2012, 35,829–837.
 Faria, K. C. P.Gurgel, R. F. and Holanda, J.N.F., Recycling of sugarcane
bagasse ash waste in the production of clay bricks. J. Environ. Manage,
2012, 101, 7–12.
 Ken C. Onyelowe “Cement Stabilized Akwuete Lateritic Soil and the Use
of Bagasse Ash as Admixture” International Journal of Science and
Engineering Investigations, 2012 vol.1, issue 2
 Bagasse Ash As An Effective Replacement In Fly Ash Bricks- October
2013 (Apurva Kulkarni, SamruddhaRaje, MamtaRajgor)
 Use of sugarcane bagasse ash as brick material (Mangesh V. Madurwar,
Sachin A)
 Jayminkumar A. Patel, Dr. D. B. Raijiwala
 Experimental Study on Partial Replacement of Cement by Sugarcane
Bagasse Ash AmritaKumari, Prof. Sheo Kumar Effects of Fine Bagasse
Ash on the Workability and Compressive Strength of Mortars
(PiyanutMuangtong, SuvimolSujjavanich, SansaneeBoonsalee)
 Wikipedia and Google

50