1

A MNI-PROJECT REPORT ON PREPARING & TESTING OF FLY ASH SOIL BLOCKS A Mini-Project Report submitted in partial fulfillment of the Requirement for the award of degree of Bachelor of Technology In Civil Engineering By R. KRISHNA REDDY M. JOSHNA RANI S. RAMUKUMAR M.RAJU M. PULLA REDDY (08091A0121) (08091A0114) (09095A0104) (08091A0140) (08091A0137)

UNDER THE ESTEEMED GUIDENCE OF

Mr. C. KRISHNAMA RAJU, M.E. Associate Professor

Department of Civil Engineering R.G.M College of Engineering & Technology, Nandyal-5180501 (Affiliated to J.N.T UNIVERSITY, ANANTAPUR, A.P INDIA) (Approved by AICTE, Accredited by N.B.A New Delhi) (Participated in World Bank Aided TEQIP-I) YEAR (2008-2012)

R.G.M College of Engineering & Technology, Nandyal-5180501 (Affiliated to J.N.T UNIVERSITY, ANANTAPUR, A.P INDIA) (Approved by AICTE, Accredited by N.B.A New Delhi) (Participated in World Bank Aided TEQIP-I)

DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE This is to Certify that the Mini-Project entitled PREPARING & TESTING OF FLY ASH SOIL BLOCKS that is being submitted by R.KRISHNA REDDY (08091A0121), M.JOSHNA RANI (08091A0114), S. RAMUKUMAR (09095A0104), M.RAJU (08091A0140) and M.PULLA REDDY (08091A0137) in partial fulfillment for the award of degree of Bachelor of Technology In Civil engineering to the Rajeev Gandhi Memorial College of Engineering & Technology, Nandyal (Affiliated to J.N.T UNIVERSITY, ANANTAPUR.) is a record of bonafide work carried out by them under our guidance and supervision. The results embodied in this Mini-Project have not been submitted to any other University or Institute for the award of any degree.

GUIDE Mr. C. KRISHNAMA RAJU Associate Professor

Head of the Department Mr. C. KRISHNAMA RAJU Associate Professor

Acknowledgement We express our deep sense of gratitude and honor to our MiniProject guide and HOD Sri C. Krishnama Raju
M.E.,

Associate

Professor for his encouragement and inspired guidance throughout the Mini-Project work for successful completion. We are also highly grateful to our Principal Dr. T. Jayachandra Prasad,
Ph.D.

for his kind help, inspiration & encouragement in

completing the Mini-Project work. We would like to thank our Chairman Dr. M.

Santhiramudu, and our M.D.

Sri M. Sivaram, for encouragement

and providing various facilities in completing the Mini-Project work.

R. KRISHNA REDDY M. JOSHNA RANI S. RAMUKUMAR M.RAJU M. PULLA REDDY

(08091A0121) (08091A0114) (09095A0104) (08091A0140) (08091A0137)

CONTENTS CHAPTER1: INTROUCTION CHAPTER2: PROPERTIES OF SOME BUILDING MATERIALS 2.1: Properties of fly ash 2.2: Properties of clay 2.3: Properties of silica 2.4: Properties of lime 2.5: Properties of Ordinary Portland cement CHAPTER3: TYPE OF BRICKS 3.1: Common Burnt Clay Bricks 3.2: Sand Lime Bricks (Calcium Silicate Bricks) 3.3: Concrete Bricks 3.4: Fire Clay Bricks 3.5: Fly ash soil bricks CHAPTER 4: 4.1: 4.2: 4.3: 4.4: PREPARATION OF FLY ASH BLOCKS Preparation of mould Procurement & Testing of Raw Material Different Proportions of raw materials Preparation of blocks

CHAPTER 5: RESULTS CHAPTER 6: COMPARISION OF RESULTS CHAPTER 7: CONCLUSION CHAPTER 8: SCOPE OF FEATURE WORK CHAPTER 9: REFERENCES

TABLE N0:

Page No.

1.1..8 1.2..8 2.1.12 2.2.12 2.3.13 2.4.21 2.5.21 3.1.28 4.1.29 4.2.29 4.3.30 5.1.34 5.2.35 5.3.36 6.1.38 FIGURES NO: 3.124 3.2....26 3.3.27 4.1.31 4.2.31 4.3.32 4.4.32 4.5.32 4.6.32 4.7.32 5.1.33 5.2.33

GRAPHS NO: 4.1.30 5.1.34 5.2.35 5.3.36 5. 437

ABSTRACT The demand for buildings (utilized for living, offices etc) is increasing day by day with increasing population and needs of the people. Due to this the demand for bricks also increases. Steel, cement, glass, aluminum, plastics, bricks, etc. are energy intensive materials. For sustainable development energy efficient and ecofriendly materials are needed. In the present mini-project titled Preparation & Testing of Fly ash soil Blocks the Fly ash soil Blocks using soil, fly-ash, sand, quarry dust and lime in different proportions are prepared, tested & results are reported. For all the proportions the 28 day compressive strength is more than 2.5 MPa. These blocks are energy efficient and eco-friendly because blocks are water cured and fly ash is industrial waste.

1. INTRODUCTION: The demand for buildings (utilized for living, offices etc) is increasing day by day with increasing population and needs of the people. Due to this the demand for bricks also increases. Projected demand for building materials like bricks, steel and cement consumed in bulk quantities is given in table 1.1. (Ref.1). Table 1.1: Projected demand for building materials Material Bricks(Nos) Structural steel (tonnes) Cement (tonnes) 2000 150x109 11x106 96x106 2020 246x109 30x106 255x106

Steel, cement, glass, aluminum, plastics, bricks, etc. are energy intensive materials, commonly used for building construction.

Generally these materials are transported over great distances. Energy (fossil fuel energy) spent in transportation of some of these building materials using trucks is given in table 1.2. (Ref. 1). Table 1.2: Energy in transportation of Building materials Building materials Bricks Sand Cement Steel Unit m3 m3 Tonne Tonne Energy in transportation for 100km(MJ) 200 175 100 100

Extensive use of these materials can drain the energy resources and adversely affect the environment. On other hand, it is difficult to meet the ever growing demand for buildings by adopting only energy efficient traditional materials (like mud, thatch, timber etc.) and construction methods. Hence, there is a need optimum utilization of available energy resources and raw materials to produce simple, energy efficient, environment friendly and sustainable building alternatives and techniques to satisfy the increasing demand for buildings. Some of the guiding principles in developing the sustainable alternative building technologies can be summarized as follows: Energy conservation; Minimize the use of high energy materials; Concern for environment, environment friendly technologies; Minimize transportation and maximize the use of local materials and

resources; Decentralized production and maximum use of local skills; Utilization of industrial and mine wastes for the production of building materials; Recycling of building wastes, and use of Renewable energy sources. Building technologies manufactured by meeting these principles could become sustainable and facilitate sharing the resources especially energy resources more efficiently, causing minimum damage to the environment. In the light of the above, the present mini-project titled

Preparation & Testing of Fly ash Soil Blocks is considered. The Fly ash Soil Blocks are prepared using soil, fly-ash, sand, quarry dust

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and lime in different proportions, tested & results are reported. These blocks are energy efficient and eco-friendly because blocks are water curried and fly ash is industrial waste. The present work is organized into different chapters. Chapter materials. Chapter 3 discusses about different types of bricks. Chapter 4 discusses about Preparation of Fly ash Soil Blocks. Chapter 5 discusses Results. Chapter 6 compares the results with brick other blocks. Chapter 7 presents conclusions. Finally scope of future work & references are reported. 2 discusses about properties of some building

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2: PROPERTIES OF SOME BUILDING MATERIALS 2.1: Properties of fly ash: The quality of fly ash is governed by IS 3812-part 1-2003. The BIS specification limit for chemical requirement are given in table 2.1 and 2.2 (IS 3812-2003). High fineness, low carbon content and good reactivity is the essence of good fly ash. Since fly ash is produced by rapid cooling and solidification of molten ash, large portion

component comprising fly ash particles are in amorphous state. The amorphous characteristics greatly contribute to the puzzolana

reaction between cement and fly ash. One of the important characteristics of fly ash is the spherical form of the practices. This shape of particle improves the flow ability and reduces the water demand. The stability of fly ash could be decided by finding the density of fully compacted sample. ASTM broadly classifies fly ash into two classes. Class F: Fly ash normally produced by burning anthracite or bituminous coal. Usually has less than 5% coal class F fly ash has Puzzolana properties. Class C: Fly ash normally produced by burning lignite or subbituminous. Some class C fly ash may have CaO content in excess of 10% in addition to puzzolana properties. Class C fly ash also possesses cementations properties.

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Table 2.1: Chemical requirement (Ref.2) Sl.no (1) (1) (2) (3) (4) (5) (6) (7) (8) Characteristic (2) Silicon dioxide (SiO3) plus aluminum oxide (Al2O3)plus iron oxide (FeO) percent by mass, Min Silicon dioxide (SiO3) percent by mass, Min Reactive silica in percent by mass, Min Magnesium oxide (MgO) percent by mass, Max Total sulphur as sulphur trioxide(SO3) percent by mass, Max Available alkalis, as sodium oxide (Na2O)percent by mass, Max Total chloride in present by mass, Max Loss on ignition, percent by mass, Max Requirement (3) 70.0 35.0 20.0 5.0 3.0 1.5 0.05 5.0

Limits regarding moisture content or fly ash shall be as agreed to between the purchaser and the supplier. All tests for properties specified shall, however, are carried out on over dry samples. Table 2.2: Physical requirements (Ref.2) Sl. No (1) Characteristic (2) requirement grade of fly ash (3) (4) 320 4.5 250 3.0

(1) (2) (3)

Fineness specific surface in m2/kg by Blaine s permeability method. Min Lime reactive average compressive strengths in n/mm2, min Compressive strength at 28 days n/mm2 , min

Not less than 80 percent of the strength of the corresponding plain cement cubes 0.8

(4) Soundness by autoclave test 0.8 expansion of specimens, percent, max.

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Fly ash, when tested in accordance with the methods of test specified in IS: 1727-1967, shall conform to the chemical

requirements give in table 2.3. Table 2.3: Illustrative properties of fly ash from different sources (Ref.3) Property/ source Specific gravity Wet sieve analysis (percentage retained on no 325 BS sieve) Specific surface (cm2/g balance) Lime reactivity (kg/sq.cm) Chemical analysis Loss on ignition percentage Si02 S03 P208 Fe203 Al303 Ti2 Mn2O3 CaO MgO A 1.91 16.07 2759 86.8 5.02 50.41 1.71` 0.31 3.34 0.66 0.84 0.31 3.04 0.93 B 2.12 54.65 1325 56 11.33 50.03 10.20 18.20 6.43 3.20 C 2.10 15 60 2175 40.03 1.54 63.75 30.92 2.35 0.95 D 2.25 5.00 4016 79.3 7.90 6.40 6.3 3.6 E 2.146 to 2.429 51.00(dry) 2800to3250 56.25 70.31 1-2 45-59 Trace to 2.5 0.6-4 0.5-1.5 5-16 1.5-5

60.10 45-59

18.64 23.33

Glass content: highly variable within and between the samples but generally below 35% Nearly 110 million tones of fly ash are generated in 2010 in India from thermal power plants set up at various places. Processes have been developed for production of clay fly ash bricks and bricks using fly ash and sand with addition of lime or chemical with or without autoclaving

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2.2: Properties of Clay: There are two types of clays that are recognized, the silicate clays of temperate regions and the iron and aluminum hydroxide clays found in the tropics and semi tropics. The great agricultural regions of the world are dominated in a large degree by clays of a siliceous nature. All clay particles are crystalline and not amorphous as was originally supposed. Each clay particle regardless of its individual shape is made up of sheet like molecules or units, held loosely together. Clay particles will also show considerable variation in size. These units are quite definite, usually changing in size only by lateral extension. A clay particle might be visualized by comparing it with a piece of mica as the flakes of the latter represent the plate like molecules or units. Clay particles because of their fineness of division must expose a large amount of external surface. There are also internal surfaces as well, the sum of which usually greatly exceeds that of a superficial character. It has been shown that clay particles are composed of two distinct parts, the inner, porous, and enormously larger insoluble acidosis, or micelle, and the outer and more or less dissociated swarm of cat ions with variable amounts of water of hydration. Since these absorbed cat ions are usually rather easily displaced, they are spoken of as exchangeable ions. This replacement, called ionic exchange, or more

15

commonly Base Exchange, is one of the most important of all soil phenomena. Calcium and magnesium are the absorbed metallic cat ions held in the largest amounts by the siliceous clays of most natural soils. Since so much of the total calcium is replaceable, its activity is assured. The main concern, therefore, is the amount present thus we use the practice of liming. With potash the total amount is often ample, but the proportion active is exceedingly small. Two groups of clay are commonly recognized, the kaolin and the montmorillonite. The molecules of the kaolin are thought to be composed of two sheets or plates, one of silica and one of alumina. The second group, the montmorillonite, is composed molecularly of two silica sheets and one of alumina. The molecules of these clays are less firmly linked together than those of the kaolin group and are usually further apart. In discussing the mineralogical nature of silicate clay, it must not be forgotten that other minerals besides the ones mentioned are present, either as mere accessories or as an important part of the colloidal complex. Of these, the hydrated oxides of silicon, iron, and aluminum should be mentioned. While these probably occur but sparingly in temperate-region soils, the latter two are especially important in tropical and semitropical regions, giving rise to what are spoken of as late rite soils. The silicate clays often contain a larger

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and larger admixture of colloidal iron and aluminum oxides. The red and yellow soils of our southern states are very good evidence of this transition. 2.3: Properties of silica: SILICA is the most abundant mineral found in the crust of the earth. It forms an important constituent of practically all rock-forming minerals. It is found in a variety of forms, as quartz crystals, massive forming hills, quartz sand (silica sand), sandstone, quartzite, Tripoli, diatomite, flint, opal, chalcedonic forms like agate etc., and in with numerous other forms depending upon color such as purple quartz (amethyst), smoky quartz, yellow quartz or false topaz (citrine), rose quartz and milky quartz. Only pure quartz crystal or rock crystal, untwined, clear, free from any inclusion, has an important property.

It expands (mechanically) under the influence of electric current and conversely pressure induces a measurable electric current. This property is known as piezoelectricity. The current thus developed is called piezoelectric current. This property resulting from the asymmetry of its atomic groups makes quartz an effective transducer for converting electrical energy into mechanical energy and vice-versa. This property in quartz crystals was discovered in 1880-82 by Pierre and Jacques Curie and remained a laboratory curiosity till in 1921 when W.G. Cady, a physicist, discovered that quartz plates could be used to control the frequency of wireless transmission circuits.

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This discovery marked the dawn of quartz crystal application in modern communication equipments. A very thin plate of quartz is so cut that the frequency of the oscillating circuit corresponds with the quartz plate and when such plate is inserted in a radio receiving set or radio transmitter it prevents frequencies from wandering and deviation and greatly reduces interference. Quartz plate is used in controlling frequencies in air and water media as well. It is largely used in radio circuit, radar, ultrasonic and in multiple telephone lines. Quartz plates keep the broadcast on the right beam. Quartz crystals cut into prisms, wedges and lenses are used for microscopes and other optical instruments. Quartz wedge is the commonest accessory which students use in the petro logical microscope. A number of other crystals giving piezoelectricity are known but none compares with quartz. Chemically prepared Rochelle salt and Barium titan ate have been found good substitutes for piezoelectric quartz. However, the crystal - quartz because of its chemical and physical stability and high elasticity has remained indispensable so far. The consumption of quartz plate pieces has tremendously increased with the increase in the manufacture of modern receiving sets.

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2.4: Properties of lime: Lime: Lime is a generic term, but by strict definition it only embraces manufactured forms of lime quicklime (CaO) and hydrated lime (Ca (OH)2). It is, however, sometimes used to describe limestone products which might be a cause of confusion. The raw material for all lime-based products is a natural stone: limestone, which is composed almost exclusively of calcium carbonate (CaCO3). When limestone contains a certain proportion of magnesium, it is called dolomite, or dolomites limestone (CaMg (CO3)2). It is widely geographically available all over the world (the Earths crust contains more than 4% calcium carbonate) and also widely used for many different purposes. In the lime or dolomite production processes, the blocks of limestone or dolomite obtained after blasting in the quarry are crushed and sorted by size in screening plants. At this stage: Part is used directly, for example as aggregates for road construction, for concrete or other applications. Part is ground to lime fertilizer or pulverized into limestone powder, used in applications such as flue, Gas-cleaning, animal feed or as fillers in many products (concrete, asphalt, carpetbacking). The rest, high quality limestone with a defined particle size is calcinated in a lime burning plant at a temperature of 900-1200C, at which temperature it is decarbonated in either vertical or rotary kilns

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fired with gas, oil, coal, coke or other fuels. During that process, carbonate is converted into oxide (Cao or CaMgO) and CO2 is released. The combustion phase is essential for obtaining a quality lime that satisfies the required characteristics. First it is important to adjust reactivity because the various applications require reaction times (reaction of oxide with water) that can vary from a few seconds to more than thirty minutes. In addition the products must possess precise physical and chemical characteristics because of different standards for certain applications. The quicklime obtained can be used as such, or can be crushed, finely ground, or micronized depending on its intended use. Quicklime can also be hydrated, i.e. combined with water in a hydrator. The quantity of water added is about twice the stoichiometric amount required for the hydration reaction. The excess water is added to moderate the temperature generated by the heat of reaction by conversion to steam. The end product is hydrated lime or slaked lime (Ca (OH)2) in the form of a very fine powder suitable for a variety of applications. Milk of lime and lime putty is produced by slaking of lime with excess water. Slaking is done in both batch and continuous slackers. The term milk of lime is used to describe a fluid suspension of slaked lime in water. Milks of lime may contain up to 40% by weight of solids. Milk of lime with high solids content is sometimes called lime slurry. Lime putty is a thick dispersion of 55 to 70% by weight of slaked lime in water. Lime paste is sometimes used to describe semi-fluid putty.

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Multiple properties manifold uses Lime can be used for a wide range of purposes because of its different characteristics: Alkaline reaction of lime with water (neutralization,

coagulation, flocculation) Forming of water insoluble calcium salts (precipitation of heavy metals and sulphates) Re-carbonation reaction with CO2 (hardening of plaster, increase of acid capacity) Pozzolanic silicates) Heat generation by contact of quicklime with water (drying, pasteurization, disinfection) While lime is one of the earliest industrial commodities known to man, its production and uses have grown with the times, and it continues to be one of the essential building blocks of modern industry. Properties of Ordinary Portland cement (OPC): It is the most type of cement. Prior to 1987, there was only one grade of OPC which was governed by IS 269-1976. After 1987 higher grade cements were introduced in India. The OPC was classified in to 3 grades, namely 33 grade, 43 grade and 53 grade depending upon the strength of cement at 28 days when tested as per IS 4031-1988. If the 28 days strength is not less than 33Mpa, it is called 33grade reaction with silicates (forming of calcium

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cement, if the strength is not less than 43Mpa, it is called 43grade cement and if the strength is not less than 53Mpa, it is called 53grade cement. But the actual strength obtained by these cements at the factory is much higher than the BIS specifications. The physical and chemical properties of 33, 43 and 53 grade OPC are shown in table Table2.4: Physical properties (Ref.4) Sl. Type of no cement (OPC) Fineness (m2/kg) Min. Soundness by Le chatelier (mm) max. 10 10 10 Auto clave (%) Max. 0.8 0.8 0.8 Setting time (mts) Initia l min Fina l max. 600 600 600 Compressive strength (min. Mpa) 3 7 28 days days days

1 2 3

33 grade 43 grade 53 grade

225 225 225

30 30 30

16 23 27

22 33 37

33 43 53

Table2.5: Chemical properties (Ref.4) Sl. Type of Lime no cement saturatio n factor (%) Alumi na iron Ratio (%) Min. 0.66 Insolu Magne Sulphuric ble sia (%) Anhydride Resid Max. ue (%) Max. 4 6 2.5% max. When C3A is 5 or less 3% max. when C3A > 5 2.5% max. When C3A is 5 or less 3% max. when C3A > 5 2.5% max. When C3A is 5 or less 3% max. when C3A > 5 Loss of magnesi a (%) Max.

33 grade 43 grade 53 grade

0.66 min. 1.02max. 0.66 min. 1.02max 0.8 min 1.02max.

0.66

0.66

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3. TYPE OF BRICKS There are various type of bricks used in masonry. 1. Common Burnt Clay Bricks 2. Sand Lime Bricks (Calcium Silicate Bricks) 3. Concrete Bricks 4. Fire Clay Bricks 5. Flay ash soil bricks 3.1: Common Burnt Clay Bricks Clay bricks are fired bricks. These are formed by pressing in moulds or by an extrusion and wire cutting process. Then these bricks are dried and fired in a kiln. 3.2: Sand lime bricks In the early 'eighties of the 19th century, Dr Michaels of Berlin patented a new process for hardening blocks made of a mixture of sand and lime by treating them with high-pressure steam for a few hours, and the so-called sand-lime bricks are now made on a very extensive scale in many countries. There are many differences of detail in the manufacture, but the general method is in all cases the same. Dry sand is intimately mixed with about one-tenth of its weight of powdered slaked lime; the mixture is then slightly moistened with water and afterwards moulded into bricks under powerful presses, capable of exerting a pressure of about 60 tons per sq. in. After removal from the press the bricks are immediately placed in huge steel cylinders usually 60 to 80 ft. long and about 7 ft. in diameter, and are there subjected to the action of high-pressure steam (120 lb to

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150 lb per sq. in.) for from ten to fifteen hours. The proportion of slaked lime to sand varies according to the nature of the lime and the purity and character of the sand, one of lime to ten of sand being a fair average. The following is an analysis of a typical German sand-lime brick: silica (SiO), 84%; lime (Cao), 7%; alumina and oxide of iron, 2%; water, magnesia and alkalis, 7%. Under the action of the highpressure steam the lime attacks the particles of sand, and a chemical compound of water, lime and silica is produced which forms a strong bond between the larger particles of sand. This bond of hydrated calcium silicate is evidently different from, and of better type than, the filling of calcium carbonate produced in the mortar-brick, and the sand-lime brick is consequently much stronger than the ordinary mortar-brick, however the latter may be made. The sand-lime brick is simple in manufacture, and with reasonable care is of constant quality. It is usually of a light-grey color, but may be stained by the addition of suitable coloring oxides or pigments unaffected by lime and the conditions of manufacture. Fig 3.1 shows the sand lime bricks.

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Fig: 3.1sand lime bicks

3.3: Concrete bricks Concrete brick is made from solid concrete. These bricks are used to cover the facade of a home, build fences, and enhance the overall beauty of a home's exterior. Bricks that are made from concrete come in a number of styles and colors making them extremely popular amongst homeowners. Concrete bricks also have many other

appealing attributes. While regular brick does a fine job of insulating a home, concrete brick tends to be a better insulation option. Traffic, airplanes, and other outside noises are effectively muted, thanks to the solid concrete that these bricks are made from. Other benefits of concrete brick include better fire protection, less exterior home maintenance, and lower energy bills. Bricks that are fashioned from concrete are available in a number of different styles. Consumers can select from a smooth, rough, textured, glossy, sandblasted, or stone finish. Various manufacturers may also offer customized bricks according to a consumer's specifications. In addition, hundreds of different color

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options are available -- most manufacturers will customize bricks to meet a homeowner's needs. Concrete bricks are quickly becoming a popular alternative to other home facade materials. While the cost of installing this type of brick may be higher than the cost of installing other materials, concrete brick will last a lot longer than most other substances. In fact, concrete brick tends to mature with age creating a desired timeless look. While durable and attractive, these bricks are not indestructible. Bricks made from concrete will generally last up to twelve years. After this length of time has passed, small bits of brick may begin to break off of each piece. At this point, certain bricks will have to be replaced, though this can be done on an individual brick basis. There are many positive aspects of these bricks, but there are also some negative aspects. Concrete may shrink once it has been installed. This often results in gaps between bricks, which can allow outside water to seep into a home. Also, there is no way to prevent color from leaking out of concrete, which may result in faded bricks. Concrete brick is a very effective way to make a strong first impression. When people walk up or drive by a home with concrete brick, second glances are common reactions. If you own a home with concrete brick as your exterior veneer, you already know this. If you are planning on using it, be prepared to have your neighbors ask

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questions while admiring the beauty of your

concrete brick.

Concrete brick has more benefits than its striking visual qualities. They deaden exterior noise, giving you and your family a buffer from traffic noise, airplanes flying overhead and other various disruptions. Fire protection is another benefit of concrete brick. Giving your family, and the fire department, extra time is never a bad thing. You won't have to worry about maintenance with concrete bricks finally; concrete brick walls can improve the thermal mass qualities of your exterior walls, thus improving your energy bills. Fig: 3.2shows the Concrete brick. Fig: 3.2 concrete bricks

3.4: Fire clay bricks Fire clay exists at much depth below the surface and is usually mined. Generally, Fire clays contain metallic oxides less than surface clays and have more uniform chemical and physical properties. Fire clay bricks are produced from Fire clay is used for manufacturing of all sorts of refractory materials and due to its alumina and silica content, it leads to the formation of highly heat

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resistant fireclay bricks. Normally, fireclay is clay that has higher content of Alumina. Normally, alumina content in fire clay is 24 or 34% while the silica content is 50 or 60%. Fire clay bricks are used for building construction including fire place construction and huge industrial furnace construction. These products are used in the core industries such as Steel Industry, Aluminum Industry, Cement Industry, Ceramic Industry,

Electroplating Industry, Chemicals Plants, Dairy Plants, Fertilizers Plants and Forging Plants. The fireclay bricks are highly useful in the boiler and sugar industry, boiler cupola and steel foundry, cement pre-heater cyclone, silicate furnace, boilers incinerators, cement kiln, preheating zone and preheating furnace wall. Fig: 3.3 fire clay bricks

3.5: Fly ash Soil Bricks Fly Ash soil bricks are made of fly ash, lime, soil and sand. These can be extensively used in all building constructional activities.

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Fly ash is used as main raw material to prepare fly ash soil blocks because, it is being accumulated as waste material in large quantity near thermal power plants and creating serious environmental pollution problems, its utilization as main raw material in the manufacture of bricks will not only useful in disposal but also help in environmental pollution control to a greater extent in the surrounding areas of power plants. Also there is ever increasing demand for power generation in the country. In our country major power is generated from thermal power plants which are coal based and they generate fly ash as waste product. The Table3.1 (Ref.5) shows the thermal power generation, coal consumption and ash generation in India. Table 3.1: Thermal power generation, coal consumption and ash generation in India (Ref.5) Year Thermal power Coal consumption Ash generation (MW) (MT) (MT) generation

1995 2000 2010 2020

54,000 70,000 98,000 137,000

200 250 300 350

75 90 110 140

The preparation and results of these blocks are discussed in next chapters.

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4. PREPARATION OF FLY ASH SOIL BLOCKS: 4.1 Preparation of mould The mould is prepared with fly wood flanks having inner dimensions of 305x143x100 mm. 4.2 Procurement & Testing of Raw Material Fly ash from T.G Venkatesh power plant, Kurnool; soil from

Shanthi Ram Engineering College, Nandyal; Quartz dust from stone quarry near Orvakallu, Lime from Nandyal are collected. The specific gravity of soil, sand and quartz dust is determined by using pychnometer and particle size distribution for fly ash, soil, sand, quartz dust is determined by using dry sieve analysis method. The results are shown in table 4.1, 4.2 and particle size distribution curves in Graph 4.1. Table 4.1: Specific Gravity SNo Material 1 Soil 2 Sand 3 Quartz dust Table 4.2: Sieve Analysis SNo 1 2 3 4 Material Soil Sand Quartz dust Fly Ash % Gravel 10.37 0 0 0 % Sand 88.73 99.66 93.00 96.20 % Silt & Clay 0.90 0.34 7.00 3.80 Specific Gravity 2.38 2.56 2.00

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Graph 4.1 patrical size distribution curves

4.3 Different Proportions of raw materials: Five different proportions of raw materials are considered for making the Fly ash Soil Blocks as shown in table 4.3. For first four proportions 4 blocks are prepared and for fifth proportion 2 blocks are prepared. Table 4.3: Different Proportions Sl. No Fly ash (%) Soil (%) 1 2 3 4 5 20 30 40 50 60 60 50 40 30 20 Sand (%) 7 7 7 7 7 Quartz dust (%) 7 7 7 7 7 Lime (%) 6 6 6 6 6 Water (%) 41 42.5 44 45 46

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4.4 Preparing of block: The proportion of the raw materials (i.e. Fly ash, lime, sand, Soil and quartz dust) are taken according to the table 4.3 into the pan and mixed thoroughly. Then water is added about 40- 45% to get workability and it becomes paste. The paste is poured as 3 layers in to the mould, each layer is tamped with tamping rod to avoid voids and this mould is shifted to the C.B.R (California bearing ratio) for applying load up to 200 Kg on the block. After loading, the block is removed carefully from the mould then it is kept in open air up to 24 hours for drying and the block is cured in presence of water for required days. The step by step procedure for preparation of blocks as shown figures: 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7. Fig: 4.1 Mixing of raw mateials Fig: 4.2 Block paste

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Fig 4.3: Pouring paste in to the mould

Fig4.4: C.B.R (for loading)

Fig: 4.5: Block with mould

Fig 4.6: Removing the mould

Fig4.7: Fly ash soil blocks

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5. RESULTS: The cured blocks are removed from the water and dried to open air then the bricks are weighted, dimensions are noted to find density of the blocks and these blocks are tested by using Universal testing machine (U.T.M) to find the compressive strength of the fly ash soil blocks. Fig5.1: U.T.M machine Fig 5.2: Testing the block

The test results of blocks are shown in graphs 5.1, 5.2 & 5.3 for 3, 14, 28 days, and also maximum load and compressive strengths for various proportions of blocks are shown in tables: 5.1, 5.2, and 5.3.

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Table 5.1 FOR 3 DAYS Bricks with different Maximum load (KN) proportions
FSB1.1 FSB1.2 FSB2.1 FSB2.2 FSB3.1 FSB3.2 FSB4.1 FSB4.2 21.87 24.15 27.6 25.11 27.03 23.58 23.95 22.9

Compressive strength (N/mm^2)

0.5 0.56 0.64 0.58 0.6 0.55 0.56 0.54

Graph 5.1: Compressive strength for 3 days

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Table 5.2 FOR 14 DAYS Bricks with different Maximum load (KN) proportions
FSB1.3 FSB1.4 FSB2.3 FSB2.4 FSB3.3 FSB4.3 FSB5.1

Compressive strength (N/mm^2) 1.73 1.64 2.16 2.06 1.94 2.60 2.64

73.95 70.05 91.68 87.8 83.73 110.97 112.38

Graph 5.2 Compressive Strength for 14 days

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Table 5.3 FOR 28 DAYS Bricks with different Maximum load (KN) proportions
FSB3.4 FSB4.4 FSB5.2

Compressive strength (N/mm^2)

114.7 112.63 119.28

2.67 2.63 2.78

Graph 5.3 Compressive Strength for 28 days

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Graph 5.4 shows the variation of compressive strength for different proportions for 3, 14, 28 days. Graph5. 4 Variation of Compressive Strength

The following points are drawn from the above results. For 3 days the compression strength of fly ash soil blocks is 0.5

to 0.6Mpa. For 14 days the compression strength of fly ash soil blocks is

>1.7Mpa.

For 28 days the compression strength of fly ash soil blocks is >

2.5Mpa.

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6. COMPARISION OF RESULTS Table 6.1: Compressive Strengths of various bricks Sl. No 1 Type of bricks Common burnt clay bricks (Ref.6) I. II. III. 2 3 4 Class Class Class Not less than 10.5Mpa. Not less than 7.5Mpa. >3.5Mpa. 3- 4Mpa. >3Mpa. >2.5Mpa. Compressive strength

Stabilized mud Bricks (Ref.1) Fine concrete blocks (Ref.1) Fly ash soil blocks

The Fly ash soil blocks have got less compressive strength compared to bricks, stabilized mud bricks & Fine concrete blocks. Hence these blocks can be used for partition walls, parapet wall & temporary structures.

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7. CONCLUSION The maximum compressive strength is 2.78 MPa for 5th proportion (i.e. fly ash 60%, soil 20%, sand7%, quartz dust7% and lime6%). The increase in compressive strength from 3 to 14 days is about 1.1Mpa and from 14 to 28 days is about 0.8 Mpa. As the fly ash content is increased the compressive strength of fly ash soil blocks is also increases. Emphasizes the need for using alternative materials for protecting the Environment and for sustainable development.

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8. SCOPE OF FUTURE WORK 1. The work can be extended by using cement in place of lime. 2. The work can be extended by increasing lime percentage. 3. The work can be extended by increasing the compressive load during moulding of block.

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9. REFERENCES 1. Sustainable Building Technologies by B.V. Venkatarama Reddy, IISc, Bangalore; CURRENT SCIENCE, VOL.87, NO 7, 10 OCTOBER 2004. 2. IS: 3812-part-1-2003. 3. IS: 1727-1967. 4. CONCRETE TECHNOLOGY BY M.S SHETTY. 5. CURRENT SCIENCE, VOL. 100, NO. 12, 25 JUNE 2011 IS 2691989 6. BUILDING MATEIALS BY S.K DHUGGAL

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