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BRIEF HISTORY OF BRICKS
All over the world, bricks are the most widely used construction materials for the
construction of buildings.
The bricks are obtained by moulding clay in blocks of uniform size and then by drying
and burning the blocks.
As the bricks are of uniform size, they can be properly arranged.
The common brick is one of the oldest building materials and it is extensively used at
present as a leading material in construction.
In India, the process of brick making has not changed since many centuries except in
some minor refinements.
There has been hardly any effort in our country to improve the brick-making process
for enhancing the quality of bricks.
Also the structures in view of their compressive strength, structural stability and
relative low cost have not undergone any drastic change.
But it has two major drawbacks, namely selfweight and brittleness.
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II. MATERIALS & PROPERTIES
The constituents used in preparing the papercrete mixtures and their properties. To attain
these goals, materials were collected from various sources. Material collection is the basic
and important step in any project. Yet, the material that is used in a project should not
cause any damage to the environment.
The various materials include:
ORDINARY PORTLAND CEMENT
FLYASH
FINE AGGREGATE
COARSE AGGREGATE
PAPER
WATER
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Flyash
Fly ash, is also known as fuel-ash, is one of the residues generated in combustion, and
comprises the fine particles that rise with the flue gases.
In an industrial context, fly ash usually refers to ash produced during combustion of
coal. Fly ash is generally captured by electrostatic precipitators or other particle
filtration equipment before the flue gases reach the chimneys of coal-fired power
plants, and together with bottom ash removed from the bottom of the furnace is in this
case jointly known as coal ash.
Depending upon the source and process of the coal being burned, the components of
fly ash vary considerably, but all fly ash
includes substantial amounts of silicon dioxide (SiO2) and calcium oxide (CaO), both
being endemic ingredients in many coal-bearing rock strata.
Fly ash often replaces up to 30% by mass of Portland cement, but can be used in
higher dosages in certain applications.
In some cases, fly ash can add to the concrete's final strength andincrease its
chemical resistance and durability.
Cement production requires huge amounts of energy and Partial replacement of
cement with fly ash is economical. In the case of
mass concreting and large scale works, it is proved to be most economical.
It is practically revealed that up to 40 to 50% cement replaced and the designed
strengths are achieved.
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Fine Aggregate
Concrete produced from a mixture of fine aggregate (sand), a binder (cement), and water.
Fine aggregate concrete is similar to building mortars in its composition and certain
properties. The sand particle consists of small grains of silica (SiO2). It is formed by the
decomposition of sand stones due to various effects of weather According to the natural
resources from which the sand is obtained. The absence of coarse aggregate (crushed stone or
gravel) substantially facilitates the preparation, transport, and placing of the concrete,
particularly when concrete pumps are used. A disadvantage of fine-aggregate concrete is the
increased consumption of binder compared to other types of concrete and the associated
greater shrinkage and creep.
The quantity of binder in the concrete can be reduced by pulverizing some of the sand, by the
use of plasticizers, or by autoclaving of products.
The sand which was locally available and passing through
4.75mm IS sieve is used. The specific gravity of Fine aggregate was 2.60.
The sand particle consists of small grains of silica (SiO2).
It is formed by the decomposition of sand stones due to various effects of weather.
According to the natural resources from which the sand is obtained, it is termed as
Pit sand, River sand and Sea sand.
According to the size of grains, the sand is classified as fine, coarse and gravel.
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Coarse Aggregate
Locally available crushed blue granite stones conforming to graded aggregate of nominal
size 12.5 mm as per IS: 383 –1970.
Crushed granite aggregate with specific gravity of 2.77 and passing through 4.75 mm
sieve and will be used for casting all specimens.
Several investigations concluded that maximum size of coarse aggregate should be
restricted in strength of the composite.
In addition to cement paste – aggregate ratio, aggregate type has a great influence on
concrete dimensional stability.
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Paper
Paper is a natural polymer which consists of wood cellulose, which is the most abundant
organic compound in the planet.Cellulose is made of units of monomer glucose
(polysaccharide).The links in the cellulose chain are a type of sugar as ß-D-glucose.
Despite containing several hydroxyl groups, cellulose is water insoluble.
The reason is the stiffness of the chains and hydrogen bonding between two OH groups on
adjacent chains.
The chains pack regularly in places to form hard, stable crystalline regions that give the
bundled chains even more stability and strength. This hydrogen bonding is the basis of
papercrete strength.
By applying a force on the paper the hydrogen bond between the water and the cellulose
molecule is broken. Coating cellulose fibers with Portland cement creates a cement matrix,
which encases the fibers for extra strength to the mix. The links in the cellulose chain are a
type of sugar: ß-D-glucose and the cellulose chain bristles with polar -OH groups.
These groups form many hydrogen bonds with OH groups on adjacent chains, bundling the
chains together. Viewed under a microscope, it is possible to see a network of cellulose fibers
and smaller offshoots from the fibers called fibril which becomes coated with Portland
cement. When these networks or matrices of fibers and fibrils dry, they intertwine
and cling together with the power of the hydrogen bond.
Fig 5: Paper
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Water
Water is an important ingredient of papercrete as it actively participates in the chemical
reaction with cement. Water should be free from organic matter and
the pH value should be between 6 and 7.
1. Dry the flask carefully and fill with kerosene or naphthalene point on the stem
between 0
to 1ml.
2. Record the level of the liquid in the flask as initial reading.
3. Put a weighted quantity of cement(about60gm) in to the flask so that level of
kerosene rise to about 22ml mark, care being taken to avoid splashing and to see that
cement does not
adhere to the sides of the above the liquid.
4. After putting all the cement in the flask, roll the flask gently in an inclined position
to expel air until no further air bubbler is set to the surface of the liquid.
Fig 6: Water
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PROPERTIES OF PAPERCRETE
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LITERATURE REVIEW
Clauidu aciu et al, (2014) [2] have reported a study on the recycling of paper
waste, which is frequently found in almost all activities. In order to obtain an
ecological plastering mortar, paper materials were used in four mortar recipes, as well
as the methods of preparation were presented. Paper can be recycled only 6-10 times
because with each recycling the length of the cellulose fiber was reduced. One ton of
recycled paper is equivalent to saving 17 trees. This was adopted for newspaper and
copy paper. This four mix proportions were tested for density, compression, bending,
water absorption, and adhesion behavior. Optimal proportion of the mortar recipe was
around 40%. The developed technology ensures the manufacture of a new ecological
plastering mortar with minimal embodied energy and with good thermal insulation
properties. Comparing to normal mortar the density was between 842-1147 kg and
m3.Then it is a very good fire resistance and sound absorption material.
Randhir J. Phalke et al, (2014) [3] have reported the effect of using different
numbers of wire mesh layers on the flexural strength of flat ferrocement panels and to
compare the effect by varying the number of wire mesh layers and use of steel fibers
on the ultimate strength and ductility of ferrocement slab panels. The number of
layers used are two, three and four. Slab panels of size (550 x 200) with thickness 25
mm are reinforced with welded square mesh with varying no of layers of mesh.
Panels were casted with mortar of mix proportion (1:1.75) and water cement ratio
(0.38) including super plasticizer (Perma PC-202) with dosage of 1% of total weight
of cement. Some panels were casted with steel fibers (0.5%) of total volume of
composite and aspect ratio (l/d) =57. Panels were tested under two point loading
system in UTM machine after curing period of 28 days. Based on experimental test
results the following conclusions were made. The flexural loads at first crack and
ultimate loads depend on number of reinforcing mesh layers used in ferrocement
panel. Increasing the number of layers of wire mesh from 2 to 4 layers significantly
increases the ductility and capability to absorb energy of the panels. Presence of steel
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fibers also increases the flexural strength of panels as compared to those without
fibers.
PREPARATION OF PAPERCRETE
A total of 9 cubes of size (70 x 70) of above proportion were casted. Compressive
strength obtained to be best proportion evaluating the flexural test and compression
test specimen will be prepared. Mortar was prepared by calculating the exact amount
of cement, sand, papercrete and water. At first the cement and sand were mixed dry
with additionally added in paper pulp, fly ash and silica fume. In admixture of CERA
water proofing and water will be mixed in consider ratio. The wood mould prepared
were properly oiled before casting .At bottom a layer of mortar was applied of
thickness 20 mm followed by layer of geo grid and again followed by layer of mortar.
The mesh pieces were cut down according to the size of panel leaving a cover of 3
mm on both side of mesh. After casting of panels they were removed from mould
after a period of 24 hours. After removal the panels were dried in direct sunlight in
open surface for a period of 28 days. The panels were removed from the drying after a
period of 28 days. White wash was applied to the panels to get clear indication of the
cracks due to loads.
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Fig 7: Paper pulp preparation
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ADVANTAGES AND DISADVANTAGES OF PAPERCRETE
Papercrete can be produced by harnessing solar energy. The only power needed is for
the purpose of mixing. Papercrete is far lighter in weight and has remarkable insulating
qualities, unlike concrete which is relatively heavy. It can be easily shaped when cured and
dried. The most important benefit of papercrete is the reduction of cement in the mix. Carbon
footprint during production, the total cost and weight are reduced, resulting in an eco-friendly
and lightweight material. Paper fibers result in excellent heat and sound insulating properties.
Papercrete incentivizes the recycling of waste paper, especially in communities with no
recycling services. Papercrete is viable option for low cost housing and temporary shelters
and offices. Crises of building materials lead to high demand and need for recycling
industrial waste or finding alternative source. Wastepaper helps in low- cost, eco-friendly and
therefore, sustainable design. In India’s context only a fraction of paper is recycled annually.
This means that the rest is still disposed off, mostly ending up in landfills for slow
degradation and capacity consumption of dumpsites. Conservatively speaking, it takes about
15 trees to make 1 ton of paper. As it is recycled material, there is a benefit in embodied
energy due to reutilization. It has good thermal and sound insulation properties.
The material has certain limitations in its application. Apart from the fact that the material is
still to be recognized and researched, there are also major obvious shortfalls in the materials
mechanical and chemical properties. Lack of literature, official data or guidelines on its
preparation, structural behavior or long term viability is one of the constraints for commercial
usage of the material. Papercrete is a brittle material. It expands and contracts frequently
leading to cracks, bulging and buckling and it has very low tensile strength. It is difficult to
exercise quality control of the mix batches and obtain smooth surface. There is also a major
issues of dimensional stability. Also, it is not waterproof and flameproof and this is not
desirable for building applications. The production of papercrete units uses a large quantum
of water. Durability is another major issue owing to the tendency of paper to degrage due to
thermal, biological and chemical action.
Certain limitations in the properties can be overcome by below measures:
1. Modification of mix proportions can help achieve optimum properties.
2. Addition of reinforcement like coconut fiber (5%-10%) or fly ash can be done to improve
compressive strength of papercrete.
3. Colour and texture can be added to papercrete for better aesthetics and design versatility.
4. Addition of silicon, concrete sealer or epoxy compound can help in waterproofing of
papercrete.
5. Admixtures can also be added to improve setting and bonding properties.
6. Higher strength can be obtained by using higher grade of cement.
7. Papercrete made with certain mixes are resistant to fire, fungi, and pests to a larger extent.
8. Papercrete blocks made with a sufficient quantity of Portland cement and sand have
improved fire resistance.
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CONCLUSION
This study was conducted with an aim to learn the small scale preparation of papercrete
blocks, its design and construction skills and also had a focus on the assessment of the
properties of this building blocks. The study recognized papercrete as a sustainable building
material and emphasized on more research towards its performance parameters. The
manufacturing, processing and construction techniques are still not developed enough to
facilitate its use and this requires extensive amount of research. Papercrete can be developed
as a material which is suitable for low cost housing and temporary shelters and offices and
can help reduce carbon footprint. It is thus evident that it can be looked upon as a sustainable
building material and has a promising future.
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