Use of Wastes Derived From Earthquakes for the Production of Concrete Masonry Partition Wall Blocks

7/28/2019 Use of Wastes Derived From Earthquakes for the Production of Concrete Masonry Partition Wall Blocks

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*Second author: [email protected]; [email protected] Page 1

Original citation:

Xiao, Z., Ling, T.-C., Kou, S.-C., Wang, Q.-Y., Poon, C.-S. (2011) Use of wastes derived from

earthquakes for the production of concrete masonry partition wall blocks. Waste Management; 31(8):

1859-1866. http://www.sciencedirect.com/science/article/pii/S0956053X1100208X

Use of wastes derived from earthquakesfor the production of concrete masonry partition wall blocks

Zhao Xiao1,2

, Tung-Chai Ling1, Shi-Cong Kou

1, Qingyuan Wang

2and Chi-Sun Poon

1*

1Department of Civil and Structural Engineering, The Hong Kong Polytechnic University,

Hung Hom, Kowloon, Hong Kong2Faculty of Architecture, Civil Eng & Envir Eng and Mechanics,

Sichuan University, China

Abstract

Utilization of construction and demolition (C&D) wastes as recycled aggregates in theproduction of concrete and concrete products have attracted much attention in recent years.

However, the presence of large quantities of crushed clay brick in some the C&D waste

streams (e.g. waste derived collapsed masonry buildings after an earthquake) renders the

recycled aggregates unsuitable for high grade use. One possibility is to make use of the low

grade recycled aggregates for concrete block production. In this paper, we report the results

of a comprehensive study to assess the feasibility of using crushed clay brick as coarse and

fine aggregates in concrete masonry block production. The effects of the content of crushed

coarse and fine clay brick aggregates (CBA) on the mechanical properties of non-structural

concrete block were quantified. From the experimental test results, it was observed that

incorporating the crushed clay brick aggregates had a significant influence on the properties

of blocks. The hardened density and drying shrinkage of the block specimens decreased with

an increase in CBA content. The use of CBA increased the water absorption of block

specimens. The results suggested that the amount of crushed clay brick to be used in concrete

masonry blocks should be controlled at less than 25% (coarse aggregate) and within 50% to

75% for fine aggregates.

Keyword: Construction and demolition waste, Crushed clay brick, Recycled concrete

aggregate, Partition wall blocks, strength

1. Introduction

The 12 May 2008 Sichuan earthquake, also known as Wenchuan earthquake, was one of themost destructive earthquakes in modern Chinese history causing significant economic impact

and great loss of lives (Chen et al., 2010). It has been estimated that approximately 382

millions tons of construction wastes derived mainly from collapsed buildings were generated

(Xiao et al., 2009). The quantities of the building waste generated from Wenchuan earthquake

far exceeded the annual production of building waste in China.

In Sichuan, most of the residential and low-rise public buildings such as schools, hospitals


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and governmental offices were constructed with un-reinforced or unconfined masonry

materials before or during the 1980s, and many of these building structures had practically no

efficient seismic resistance (Zhao et al., 2009). As a result, they accounted for most of the full

and partial collapses during the earthquake. The rubble mounds derived from 6.95 millions

collapsed buildings were mainly composed of waste concrete and large amount of waste

masonry materials such as clay bricks (151.6 millions tons).

Extensive studies have been undertaken over a long period by many researchesto investigate

the possibility of utilizing all kinds of waste to produce concrete blocks and brick products.

For example, in Hong Kong the use of construction wastes such as recycled concrete

aggregates and recycled crushed glass for manufacturing concrete block products has been

successfully implemented and is gaining wider acceptance (Poon et al., 2002; Poon and Chan,

2006; Poon and Chan, 2007; Poon and Lam, 2008; Poon et al., 2009).

Recently, a number of researchers have studied the possible use of crushed clay brick to

produce concrete (Akhtaruzzaman and Hasnat, 1983; Khaloo, 1994; Padmini et al., 2001;

Kibriyi and Speare, 1996; Cachim, 2009). Akhtaruzzaman and Hasnat (1983) studied the use

of crushed brick as a 100% replacement of coarse natural aggregates in concrete. It was found

that the compressive strength of the brick concrete was lower than that of normal concrete,

but the tensile strength of brick concrete was higher. Kibriya and Speare (1996) used three

different types of brick aggregates to assess the impacts on long-term durability and strengths

properties of the concrete. The results showed that the brick concrete had comparable

compressive, tensile and flexural strengths to those of normal concrete but the modulus of

elasticity was drastically reduced. An attempt was made by Corinaldesi (2009) and

Carinaldesi et al. (2002) to use different kinds of recycled aggregate in preparing

environmentally-friendly mortars. The results showed that the mechanical strength decreased

when natural sand was substituted by the recycled aggregates (Corinaldesi and Moriconi,2009). Nevertheless, the bond strength at the interface between the mortar and the brick

aggregates seemed to be higher, mainly due to its improved rheological properties (Moriconi

and Corinaldesi, 2003).

Due to the potential problems of using crushed clay brick in concrete, the amount of crushed

clay brick used has been restricted, which hinders the recycling of this masonry waste. On the

other hand, some preliminary results have already shown that it is feasible to use crushed

brick in non-structural paving block productions. Poon and Lam (2008) found that it was

feasible to produce concrete blocks with 25% crushed clay brick incorporation that satisfied

the compressive strength requirement for paving blocks to be used in trafficked areas

prescribed by the Hong Kong government. Furthermore, the paving blocks with 50% crushed

clay brick content satisfied the requirements specified by AS/NZS 4455 (1997) and Hong

Kong government for pedestrian pavement applications. Schuur (2000) also proved that it is

possible to use crushed clay brick derived from masonry waste to entirely replace sand for the

production of calcium silicate products. However, there is currently limited data on the effect

of higher percentages (>50%) of crushed clay brick on the production of concrete products.


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This paper presents a recent study at the Hong Kong Polytechnic University on the feasibility

of using crushed clay brick as replacement for recycled concrete aggregates and natural river

sand for the production of partition wall blocks. The main objective of this study was to

develop appropriate technologies for the use of waste derived from demolished or collapsed

masonry buildings as a contribution to manage the huge quantities of waste generated from

the Wenchuan earthquake.

2. Experimental details

2.1. Materials

2.1.1. Ordinary Portland cement

Ordinary Portland cement (OPC) was used as the cementing material to produce the block

specimens. The OPC used was equivalent to BS 12 (1996) with a density of 3,160 kg/m3

and

was commercially available in Hong Kong.

2.1.2. Recycled concrete aggregate

Recycled concrete aggregate (RCA) was obtained from a recycling facility located in Tuen

Mun, Hong Kong. The recycling facility processed mainly concrete rubble sourced from

demolition projects by crushing and sieving. The crushed concrete rubble was processed to

pass through a mechanical sieving system to produce coarse and fine recycled aggregates

with particle sizes of 10/5 mm (C-RCA) and less than 5 mm (F-RCA), respectively,

according to the requirements of BS 812 (1995). The properties of RCA were tested

according to BS 882 (1992) and the results are presented in Table 1. Fig. 1 shows the grading

curves of the RCA.

Table 1: Properties of recycled coarse and fine aggregates used in this study

Properties Coarse aggregate Fine aggregate5-10mm < 5mm < 2.36mm

C-RCA C-CBA F-RCA F1-CBA F2-CBA Sand

Density-SSD* (kg/m3) 2366 2036 1932 1839 1609 2620

Density-oven-dry (kg/m3) 2186 1764 1502 1358 1043 -

Water absorption (%) 8.22 15.43 28.71 35.56 54.23 0.88

*SSD Saturated Surface Dry


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0

10

20

30

40

50

60

70

80

90

100

0.15 0.3 0.6 1.18 2.36 5 10 15

Sieve size (mm)

Percentpassing(%)

C-RCAC-CBAF-RCAF1-CBAF2-CBAB S 8 8 2 (1 0 mm)B S 8 8 2

5 mm

Fig. 1. Grading curves of recycled coarse and fine aggregates.

2.1.3. Crushed clay brick

The clay brick used in this study was solid red brick sourced from a local supplier, which was

normally used for wall partition applications. The clay brick was crushed and sieved in the

laboratory into different particle sizes (see Fig. 2). The crushed clay bricks were sorted into

three groups according to their particle sizes: 10/5 mm (C-CBA) was used as coarse

aggregate; whereas the


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Fig. 2. Photographs of the coarse and fine recycled aggregates.

2.2. Mix proportions of blocks

A total of four series of blocks mixtures was designed in this study (see Table 2). The block

specimens produced aimed to meet the requirements stipulated by BS 6073 (1981)

(specification for partition wall block). All the mixtures were proportioned with a fixed total

aggregate/cement ratio of 11.5, and 65% of the total aggregate was fine aggregates (


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Table 2: Descriptions of block mixtures

Series Description

1 Coarse aggregate: fixed C-RCA/C-CBA ratio of 3

Fine aggregate: Sand, Replacement of sand with F1-CBA at 0%, 25%, 50%,

75% and 100% by weight

2 Coarse aggregate: fixed C-RCA/ C-CBA ratio of 1Fine aggregate: Sand, Replacement of sand with F1-CBA at 0%, 25%, 50%,

75% and 100% by weight

3 Coarse aggregate: C-RCA, Replacement of C-RCA by C-CBA at 0%, 25%,

50%, 75% and 100% by weight

Fine aggregate: fixed sand/F1-CBA ratio of 1

4 Coarse aggregate: C-RCA

Fine aggregate: F-RCA, Replacement of F-RCA with F2-CBA at 0%, 25%,

50%, 75% and 100% by weight

2.3. Preparation of block specimens

The block specimens was fabricated in the laboratory using a dry-mixed method that had

been described in our previous research studies (Poon et al., 2002; Poon and Chan, 2006;

Poon and Chan, 2007; Poon and Lam, 2008; Poon et al., 2009). Initially, cement, coarse and

fine aggregates, were mixed in a pan mixer for approximately 3 minutes. After mixing, water

was incrementally added to the mixtures until the desired moisture content for these dry

mixtures was obtained. For fabrication of block specimens, only a small amount of water was

required to prepare a cohesive mix but with zero slump (non-workability, which simulated the

actual industrial production process of concrete blocks). Throughout the study, the amount of

water required varied depending on the types of aggregate used. For example, in the case of

using crushed clay brick (high water absorption capacity) in the mixture, the total amount of

water needed was relatively higher (see Table 3).

Steel moulds with internal dimensions of 200 mm in length, 100 mm in width, and 60 mm in

depth were used to produce the block specimens. For each block, approximately 2.8 kg mixed

materials were used. The materials were put into the mould in three layers of approximately

equal depth. After filling each of the first two layers, a consistent manual compaction was

applied using a hammer and a wooden stem. After the third layer was filled, a compression

force at a rate of 600 kN/min was applied until the force reached 500 kN. Excess materials

were then removed with a trowel. The fabricated block specimens were kept in the steel

moulds, covered by a plastic sheet and left at room temperature of 233 C and 755 relative

humidity (RH) for 24 hours. The block specimens were then remoulded from the steel

moulds and cured (covered by a hemp bag to maintain a RH of over 90%) at room

temperature of 233 C until the date of testing at 7 and 28 days.


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Table 3: Mix proportions of block mixtures

Notation Cement

Coarse

aggregate

Fine aggregateAdded

Watera

< 5mm < 2.36mm

C-RCA C-CBA F-RCA F1-CBA F2-CBA Sand

Series 1

S1-0 1 3 1 - 0 - 7.500 0.16S1-25 1 3 1 - 1.875 - 5.625 0.26

S1-50 1 3 1 - 3.750 - 3.750 0.34

S1-75 1 3 1 - 5.625 - 1.875 0.45

S1-100 1 3 1 - 7.500 - 0 0.47

Series 2

S2-0 1 2 2 - 0 - 7.500 0.22

S2-25 1 2 2 - 1.875 - 5.625 0.30

S2-50 1 2 2 - 3.750 - 3.750 0.37

S2-75 1 2 2 - 5.625 - 1.875 0.44

S2-100 1 2 2 - 7.500 - 0 0.58

Series 3

S3-0 1 4 0 - 3.750 - 3.750 0.33

S3-25 1 3 1 - 3.750 - 3.750 0.35

S3-50 1 2 2 - 3.750 - 3.750 0.37

S3-75 1 1 3 - 3.750 - 3.750 0.39

S3-100 1 0 4 - 3.750 - 3.750 0.40

Series 4

S4-0 1 4 - 7.500 - 0 - 0.22

S4-25 1 4 - 5.625 - 1.875 - 0.24

S4-50 1 4 - 3.750 - 3.750 - 0.43

S4-75 1 4 - 1.875 - 5.625 - 0.41S4-100 1 4 - 0 - 7.500 - 0.49

aAdded water is the total mass of water added per cement weight

2.4. Test methods

2.4.1. Hardened density

The density of block specimens was determined using a water displacement method as per

BS 1881 Part 114 (1983) for hardened concrete.

2.4.2. Water absorption

The cold water absorption values of the block specimens were determined in accordance withAS/NZS 4455 (1997). The water absorption was measured by immersing the oven dried

block specimens in cold water at room temperature for 24 hours. The values were expressed

as a ratio of the mass of the absorbed water of an immersed block to the oven dried mass of

the same specimen.

2.4.3. Compressive strength

The compressive strength was determined by using a universal testing machine with a


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maximum capacity of 3000 kN. The loading rate of 450 kN/min was applied to the nominal

area of the block specimen. Prior to the loading test, the block was soft capped with two

pieces of plywood. Three samples were tested for each mix proportion.

2.4.4. Flexural strength

The flexural strength of the block specimens was determined by a three-point bending testwith a supporting span of 180 mm. For this test, test machine with a maximum load capacity

of 50 kN was used and a displacement of 0.10 mm/min was set.Two samples were tested for

each mix proportion.

2.4.5. Drying shrinkage

The drying shrinkage of the block specimens was determined according to BS 6073 (1981).

Many other researchers used this method and obtained reliable results (Poon et al., 2009;

Gunduz, 2008). After 28 days of room temperature curing, the block specimens were

immersed in water at room temperature for 24 h, and the initial length of the specimens were

measured. After the initial reading, the specimens were conveyed to a drying chamber with a

temperature of 23C and a relative humidity of 55% until further measurement at 1st, 3rd, 7th,

14th

day. Each value represents the average of two measurements.

3. Results and discussion

The hardened density, water absorption, compressive and flexural strengths as well as drying

shrinkage test results of the block specimens are tabulated in Table 4.

3.1. Hardened density

Fig. 3 shows the results of the hardened density of the block specimens. For Series 1 and 2, it

shows that the hardened density of block specimens decreased with the increase of F-RCAcontent, reflecting the lower density of F-RCA as compared to river sand (see Table1). The

results of Series 3 indicate that the hardened density of the block specimens decreased with

increasing C-CBA content due to the lower density of C-CBA. Therefore, as expected, when

the F2-CBA was used to replace F-RCA, the density of the block specimens was also lower

than those made with F-RCA.

3.2. Water absorption

Fig. 4 shows the results of the water absorbed test. In all cases, block specimens containing

recycled coarse and fine clay bricks aggregates had higher water absorption values when

compared to the blocks specimens prepared with recycled concrete aggregates or river sand.

This is because crushed clay brick aggregates had higher water absorption capacity (see Table

1).


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Table 4: Test results of Series 1, 2, 3 and 4 block specimens

Notation Density

(kg/m3)

Water

absorption

(%)

Compressive

strength (MPa)

Flexural strength

(MPa)

Drying

shrinkage

(%)7 days 28 days 7 days 28 days

Series 1

S1-0 2121 9.1 17.6 19.3 6.7 6.3 0.06S1-25 2112 9.9 19.2 23.9 5.6 8.0 0.05

S1-50 2040 11.1 19.5 21.9 5.3 7.1 0.05

S1-75 1971 13.9 16.6 17.7 5.1 8.8 0.04

S1-100 1919 14.9 14.4 16.9 5.1 7.6 0.04

Series 2

S2-0 2104 9.5 15.4 16.0 5.7 6.3 0.05

S2-25 2047 10.8 14.5 17.6 5.8 7.5 0.04

S2-50 2013 12.5 17.1 19.2 5.3 7.8 0.05

S2-75 1986 13.5 14.8 18.9 5.7 7.9 0.04

S2-100 1967 16.3 9.3 14.9 3.5 7.2 0.03

Series 3

S3-0 2110 10.3 20.0 29.8 6.8 10.1 0.06

S3-25 2040 11.1 19.5 21.9 5.3 7.1 0.05

S3-50 2013 12.5 17.1 19.2 5.3 7.8 0.05

S3-75 2008 11.9 13.8 17.3 4.6 6.5 0.05

S3-100 1956 14.0 12.6 16.3 4.4 6.4 0.04

Series 4

S4-0 2138 13.9 11.2 12.6 - 6.0 0.07

S4-25 2094 14.4 16.5 16.3 - 9.5 0.05

S4-50 2047 14.7 18.1 21.0 - 9.4 0.04

S4-75 2029 14.9 15.3 17.2 - 10.7 0.04S4-100 2017 15.5 11.2 15.3 - 10.1 0.03


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1900

1950

2000

2050

2100

2150

0 25 50 75 100

Percentage of replaceme nt

Density(kg/m3)

S er ies 1

S er ie s 2

S er ie s 3

S er ie s 4

Fig. 3. Hardened density of Series 1, 2, 3 and 4 block specimens.

8

9

10

11

12

13

14

15

16

17

0 25 50 75 100

Percentage of replacement

Waterabsorption(%)

S er ies 1

S er ie s 2

S er ie s 3

S er ie s 4

Fig. 4. Water absorption of Series 1, 2, 3 and 4 block specimens.

The results of Series 1 and 2 indicate a systematic increase in water absorption values of the

block specimens with the increase in F1-CBA content. For Series 3 and 4, as the C-RCA and


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F-RCA were entirely (100%) replaced by C-CBA and F2-CBA, the level of increase in water

absorption was very high, recording an increase of 35.3% and 11.3%, respectively.

3.3. Compressive strength

The 28-day compressive strength results of the block specimens are shown in Fig. 5. It can be

seen that the compressive strength of the block specimens in Series 1, 2 and 4 was firstincreased and then decreased with the increase in the crushed clay brick content in the fine

aggregate system. When the replacement level was increased from 0% to 25% in Series 1 and

from 0% to 50% in Series 2 and 4, the block specimens attained the highest compressive

strength. Therefore, it can be concluded that for a given type of coarse aggregate, the use of a

combination of different types in fine aggregates with different particle gradings would

provide a better compressive strength probably due to the fact that the aggregates are well

packed. Furthermore, the lower particle density of the finer CBA compared to that of the fine

RCA and sand represented a higher volume of fine particles in the mixtures when RCA or

sand was replaced by CBA. The finer CBA particles might have filled more voids and

reduced the porosity and thus enhanced the mechanical properties. This finding is consistent

with that of our previous study (Poon and Chan, 2007).

10

20

30

0 25 50 75 100


Compressivestren

gth(MPa)

S er ies 1

S er ie s 2

S er ie s 3

S er ie s 4

Fig. 5. 28-day compressive strength of Series 1, 2, 3 and 4 block specimens.

Regarding the results of the compressive strength obtained in Series 3, the compressive

strength gradually decreased with an increase in the C-CBA content. It was found that the

compressive strength of block specimens prepared with 100% C-CBA was only

approximately 54.5% of those of the prepared with pure C-RCA. Indeed this was expected

because of the lower intrinsic strength of C-CBA when compared with C-RCA. Yang et al.,


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(2011) carried out a study on concrete prepared with recycled concrete aggregate and crushed

clay brick and observed a 5.7% loss in compressive strength when the natural aggregate was

fully replaced by RCA. But loss of strength of approximately 11% and 20% were observed in

the concrete prepared with 20% and 50% crushed clay brick ratios.

3.4. Flexural strengthThe results of the flexural strength of the block specimens are shown in Fig. 6. It is important

to note that increase in crushed fine clay brick aggregate content effectively increased the

flexural strength of the block specimens in Series 1, 2 and 4, and the highest flexural

strengths was attained at the replacement level of 75%. The flexural strength of S1-75 and

S2-75 block specimens was 40.3% and 24.5% higher than that of control samples (S1-0 and

S2-0), respectively. In the case of using F2-CBA in Series 4, the increase in flexural strength

of the block specimen was 79.6% at a replacement level of 75% as compared with the control

sample (S4-0). As mentioned earlier, this was probably attributed to the better grading of the

combined use of different types of fine aggregates. In addition, since the flexural strength is

mainly governed by the properties of the ITZ, and it been suggested that the inclusion of

brick aggregates could allow the mortar to permeate the brick surface assuring a stronger

physical interlock and ITZ (Moriconi et al., 2003).

5

7

9

11

0 25 50 75 100

Percentage of replaceme nt

Flexuralstrength(MPa)

Se rie s 1 Se rie s 2

Se rie s 3 Se rie s 4

Fig. 6. 28-day flexural strength of Series 1, 2, 3 and 4 block specimens.

It is known that the flexural strength of the block specimens is highly dependant on the type

and coarseness of aggregate content. In Series 3, as the replacement of C-RCA with C-CBA

exceeded 25%, it resulted in a significant decrease in flexural strength. The decrease of

flexural strength in the replacement level of 25%, 50%, 75% and 100% were 30.1%, 22.9%,


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35.4% and 37.1% as compared with the control sample (S3-0), respectively. Similar findings

were also reported by Corinaldesi and Moriconi (2009).

3.5. Drying shrinkage

Fig. 7 shows the drying shrinkage values obtained of the specimens at 14 days were within

the limit (

0.06%) prescribed by BS 6073 (1981), except the S4-0 mix. The higher dryingshrinkage value of S-4-0 (0.07%) was probably due to the mix contained only recycled

concrete aggregate (without any crushed clay bricks).

0.000

0.010

0.020

0.030

0.040

0.050

0.060

0.070

0.080

0 25 50 75 100


Dryingshrinkage

(%)

Series 1

Series 2

Series 3

Series 4

Fig. 7. Drying shrinkage of block specimens.

The drying shrinkage of the block specimens decreased with the increase in crushed coarse

and fine clay brick aggregates content and this is consistent with the results of a previous

study (Bektas et al., 2009). The might be primarily due to the self-curing action of the brick

aggregates in the block specimens. This beneficial effect of brick aggregates on reducing

drying shrinkage was well documented in the literature (Corinaldesi and Moriconi, 2010).

During the initial mixing, the crushed clay brick aggregates might have initially absorbed a

relatively large amount of water (see Table 3) and this water was kept in the pores before it

was released as the curing progressed. Therefore, the overall drying shrinkage was reduced

owing to the presence of this internal moisture.

4. Conclusions

The feasibility of using appropriate combination of low grade recycled aggregates for the

production of partition wall blocks has been performed through laboratory scale experiments.


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Based on the laboratory results of this study, the following conclusions can be drawn:

1. The hardened density of block specimens decreased with the increase in crushed claybrick aggregates content, thus reflecting the lower density of crushed clay brick aggregates as

compared to river sand or recycled concrete aggregates.

2. The water absorption of the block specimens increased with the increase of crushed claybrick aggregates content because the crushed clay brick aggregates had relatively higherwater absorption capacity than that of the recycled concrete aggregates and river sand.

3. The use of a combination of different types of fine aggregates is likely to provide a bettercompressive strength. As for coarse aggregate replacement, the compressive strength was

found to gradually decrease with an increase in the C-CBA content.

4. The highest flexural strength was attained when the replacement level of crushed fineclay aggregate reached the level of 75%. For coarse aggregate replacement, as the percentage

of replacement level of C-RCA with C-CBA exceeded 25%, a significant decrease in flexural

strength was observed.

5. The drying shrinkage of the block specimens decreased with the increase in the crushedcoarse and fine clay brick aggregates contents.

6. The overall results demonstrate that it is feasible to use the waste clay brick derived fromearthquakesas coarse and fine aggregates in the production of non-structural partition wall

blocks. It is suggested that the percentage of coarse clay brick aggregates should be less than

25%, whereas as far as the percentage of fine clay brick aggregate is concerned, it should

range between of 50% to 75%.

Acknowledgements

The authors wish to acknowledge the Hong Kong Polytechnic University and the State Key

Laboratory of Subtropical Building Science (2009KB22) for funding support.

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Documents

Use of Wastes Derived From Earthquakes for the Production of Concrete Masonry Partition Wall Blocks