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International Journal of Recent Advances in Engineering & Technology (IJRAET)
_______________________________________________________________________________________________
_______________________________________________________________________________________________
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).”
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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ISSN (Online): 2347 - 2812, Volume-4, Issue -7, 2016
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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.
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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ISSN (Online): 2347 - 2812, Volume-4, Issue -7, 2016
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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.
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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ISSN (Online): 2347 - 2812, Volume-4, Issue -7, 2016
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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
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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ISSN (Online): 2347 - 2812, Volume-4, Issue -7, 2016
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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.
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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ISSN (Online): 2347 - 2812, Volume-4, Issue -7, 2016
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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
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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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.)
Table 6: Showing the compressive strength
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
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
compressive strength in Mpa
compressive strength in Mpa
00.5
11.5
22.5
33.5
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa
Ball diameter
Proportion Curing in days
Compressive Strength
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
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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ISSN (Online): 2347 - 2812, Volume-4, Issue -7, 2016
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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.)
Table 7: Showing the compressive strength
0
0.5
1
1.5
2
2.5
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa
0
1
2
3
4
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa
0
1
2
3
4
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa
Gradation Ball diameter
Proportion Curing in days
Compressive Strength
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
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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ISSN (Online): 2347 - 2812, Volume-4, Issue -7, 2016
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Fig.16: fcm of Gradation A, 45mm dia (4 no.)
Fig.17: fcm of Gradation B, 45mm dia (4 no.) Fig.18 fcm of Gradation C, 45mm dia (4 no.)
Table 8: Showing the compressive strength
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
compressive strength in Mpa
0
1
2
3
4
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa 0
1
2
3
4
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa
Gradation Ball diameter
Proportion Curing in days
Compressive Strength
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
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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Fig.19: fcm of Gradation A, 45mm dia (2 no.)
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
compressive strength in Mpa
compressive strength in Mpa
0
1
2
3
4
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa 0
1
2
3
4
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa
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
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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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
compressive strength in Mpa
compressive strength in Mpa 0
1
2
3
4
7 21 28
Co
mp
ress
ive
str
en
gth
in M
pa
Days
compressive strength in Mpa
compressive strength in Mpa
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
International Journal of Recent Advances in Engineering & Technology (IJRAET)
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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
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