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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 10 Issue: 06 | Jun 2023

p-ISSN: 2395-0072

www.irjet.net

Experimental study on fired clay brick production using waste foundry sand and fly ash Adhin Asok1, Nalanth N2 1MTech Student, Department of civil engineering, Rajadhani Institute of Engineering and Technology, Kerala, India 2Professor, Department of civil engineering, Rajadhani Institute of Engineering and Technology, Kerala, India

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Abstract - Fired clay bricks are one of the oldest and major

This serious problem of natural resource depletion can be overcome by recycling industrial wastes in the production of construction materials. So, this study focusses on utilization of industrial waste materials such as waste foundry sand (WFS) from metal casting industry and fly ash (FA) from thermal powerplant in sustainable brick production. Various studies have been conducted on the incorporation of industrial wastes in brick production. Safeer Abbas et al. (2017) [2] reported findings of bricks manufactured using FA and conventional earthen materials, concluding that about 5% of FA added bricks can be used as severe weather resistant brick. Whereas, bricks with 20% FA addition can be used as moderate weather resistant bricks and about 10% FA can be utilized effectively. Nabil Hossiney et al. (2018) [3] studied on the utilization of WFS in clay bricks by mixes 0%, 30%, 40% & 50% WFS. Found a minimum compression resistance of 3.3 MPa and maximum water absorption of 21.6% for 50% WFS incorporated bricks. Also, concluded insignificant difference in apparent porosity, and specific gravity compared to commercial bricks.

walling materials used in India. India is the second largest producer of bricks in the world after China, with about 240 260 billion bricks produced annually. Our country is now rapidly urbanizing is expected to have an annual growth rate of about 6.2% in the construction industry. So, there will be higher demands for infrastructure, thus leading to a higher demand for primary building materials like clay bricks. But one of the major disadvantages of clay bricks is the use of large amount of agricultural clay in the manufacturing it, which is a great challenge for farmers. Depletion of this fertile top soil leads to land degradation. So, the main aim of this study is to develop & evaluate the behaviour of fired clay bricks incorporating industrial waste materials such as waste foundry sand & fly ash, thus reducing soil usage. In this work, 10% to 50% by weight replacement of clay in traditional clay bricks to industrial wastes is investigated. Based on the test results, bricks with 30% addition of foundry sand and 10% fly ash are effective and has high strength. Compressive strength of unreinforced masonry of such bricks were also studied by casting prism and wall panels as per IS 1905-1987 and BS EN 1052-1: 1999.

In this work, the combination of industrial wastes (WFS and FA) on the properties of fired clay brick was studied. 5 mixes were selected with WFS varying from 0 to 40% by weight of clay, while keeping a constant proportion of 10% FA. An optimization study was then conducted by various tests as per IS 1077: 1992[4] to select the best brick specimen. The compressive strength of unreinforced masonry of such bricks were also studied by casting prism and wall panels as per IS 1905-1987[5] and BS EN 1052-1: 1999[6].

Key Words: Fired clay bricks, waste foundry sand, Fly ash, masonry prism, wall panels, compressive strength, sustainability

1.INTRODUCTION India's economy, which is currently the fifth largest in the world, is anticipated to overtake the top three in the next ten to fifteen years. Further due to increase in population growth, we have seen tremendous urban progress. The overall urban population had increased from 217.17 million in 1991 to about 377.1 million in 2011 & the number of cities & towns had increased from 3,768 to 7,951. It is estimated that by 2030, more than 400 million people will be living in cities in India [1]. These will result in major demand for infrastructure and housing, which will in turn increase the demand for construction materials. Also, the government has launched programs such as ‘Smart India Mission,’ which aims to develop 100 existing cities to smart cities, which has again boosted the construction demands. But this has major disadvantages like consumption of natural resources for material production, such as quarrying raw materials for cement, agricultural clay for brick production etc.

Impact Factor value: 8.226

2. Experiment and methods 2.1 Materials used The materials used for the study includes Waste Foundry sand (WFS), Clay and Fly ash (FA).

2.1.1 Foundry Sand Waste foundry sand (WFS) is a discarded material produced from ferrous (iron & steel) & non-ferrous (copper, aluminium & brass) metal casting industries, which is used to create moulds & cores. About 95% of the WFS is generated by suppliers of automotive industry & it’s parts. The waste foundry sand was accumulated from the metal

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