Project Report PDF

BUILDING BLOCKS USING FLY ASH AND STONE DUST
Chapter- 1
INTRODUCTION
1.1 GENERAL
The majority of developing countries are today facing with an ever increasing problem of providing
adequate yet affordable housing in sufficient numbers. In the last few decades, shelter conditions
have been worsening: resources have remained scare, housing demand has risen and the urgency
to provide immediate practical solutions has become more acute. Adequate shelter is one of the
most important basic human needs, yet 25% of the world population does not have any fixed
shelter, while 50% of the urban population lives in slums. Indeed 80% of the urban settlements in
developing countries consists of slums and spontaneous settlements made of temporary materials.
With the population in developing countries grooving at rates of between 2% and 4% per year and
the population in their major cities growing by double these figures, demand for low cost hosing
far outstrips the capacity to supply. No developing countries without strategies are likely to meet
its shelter target.
Developing countries planning to expand their housing stock for the low-income groups will
inevitably need to identify the lowest feasible unit housing costs. The main costs of shelter
provision are for building materials (About 60%), machinery, and manpower and loan interest
repayments [1] strategies are therefore urgently needed to develop low cost, readily available and
durable building materials.
In the case of burnt bricks the cost of fuel is considerably higher at Rs40/- per square meter mainly
due to the cost of fuel. The energy for walling from burnt brick is 495MJ. By the use of natural
materials with industrial waste and low energy requirements can be reduced 50% compared with
requirement or present production and usage.
The compressed and stabilized blocks (CSB) has been identified as low cost material with the
potential to redress the problem and reverse shelter backlogs. The principal objective of this project
is to manufacture building blocks using fly ash, sand/stone dust, lime & gypsum or cement.
Dept of Civil Engg, RITS Chevella Page 1

So we are conducting the project work on building blocks using fly ash which is available in power
plants as a waste product and cheap in cost.
The present generation fly ash in India by thermal power stations is more than 100 million tonns
per annum. One kilogram of coal of fired yields fly ash ranging from 200 to500 grams. At present
only 6% fly ash being utilized. The remaining amount of fly ash produced annually must either be
disposed in controlled landfills or waste containment facilities, or stock piled for future use or
disposal. As a result of the cost associated with disposing these vast quantities of fly ash, a
significant economical incentive exists for developing new innovative, yet environmentally safe
application for the utilization of coal as a fly ash.
Quarry waste from aggregate crushing plant has been posing disposal and environmental
problems in India. Nearly 1/3 of the crushed stone generated from the aggregate crushing plants is
quarry waste and hence majority of the investigations were directed towards its viable use in the
constructional industry. At present a very small quantity of quarry waste is being used in the
manufacture of mosaic tiles, hollow bricks, roofing tiles and in the construction of roads. But huge
quantity is disposed on a land. This posses threat to the ecology and environment region. Hence,
there is an urgent necessity to obtain safe and economic solution for the proper utilization of quarry
dust. if quarry waste can also be effectively utilized in construction industry, the objective of
reduction of cost of the construction can be met and at the same time it will help to overcome the
problems associated with its disposal including the environmental problems of the region.[2]

1.2 HISTORICAL BACKGROUND OF FLY ASH
Fly ash concrete was first used in the U.S. in 1929 for the Hoover Dam, where engineers found
that it allowed for less total cement. It is now used across the world.
Typically, concrete designers use fly ash a partial replacement for Portland cement at values up to
30 percent of the total cementitious composition.
The use of high percentages (high volumes) of fly ash has been studied extensively over the last
15 years, and the benefits of this type of concrete have been well documented. When properly
designed and constructed, the increased benefits of concrete made with 40, 50, and 60 percent fly
ash replacement include dramatically reduced concrete permeability, and excellent resistance to
all forms of premature deterioration
1.3 DIFFERENT TYPES OF BUILDING BLOCKS

The following are the various types of building blocks
➢ Stabilized mud building blocks.

➢ Steam cured lime stabilized blocks.
➢ Concrete blocks.
➢ Fine concrete blocks.
➢ Stone masonry blocks.
➢ Hollow clay blocks.

1.4 ADVANTAGES
❖ The blocks are uniform in shape and size; therefore requires less mortar in masonry.
❖ Plaster thickness required will be less compared to concrete blocks, thus saving of cement
mortar.
❖ These blocks are environmental friendly as:-
It uses fly ash, which is by product of thermal power stations. saves agricultural land which
is used for manufacturing clay blocks.
❖ Less energy intensive compared to clay blocks and helps in keeping clean environment.
❖ Improved workability
❖ Reduced permeability
❖ Reduced heat of hydration
❖ High sulphate resistance
❖ Increased long term strength
❖ High chloride corrosion resistance
❖ Grater resistance to alkali reactivity
❖ Better concrete finish
❖ Reduced shrinkage
❖ Improved water to cement ratio
❖ Reduced bleeding [1]

1.5 ENVIRONMENTAL EFFECTS
❖ Utilization of fly ash is environment friendly with improved cementitious binder

economics.
❖ Fly ash utilization reduces the requirement of clay, sand, lime stone in cement
manufacturing and hence conserves natural resources.
❖ Fly ash utilization reduces the cement requirement and hence carbon-di-oxide liberation
during cement manufacturing is reduced.
❖ Fly ash utilization reduces the top soil requirement for land filling / brick manufacturing
and saves agricultural land.
❖ Fly ash utilization achieves increased strength of the finished concrete product without
increasing the cement content [1]
1.6 OBJECTIVES OF PROJECT

This project is carried out keeping in mind the following objectives
1. Characterization of stone dust and stabilizer like cement.

2. To study the compressive strength of block.
3. To study the effect of stabilizer (cement) on strength of blocks.
4. Comparison of economy with bricks and conventional blocks.
5. To make recommendation for improving the specification, testing and protection of
block for the duration of their service life.
6. To achieve value addition of fly ash through their effective utilization, rather than
viewing this as waste utilization to contain environmental degradation.

Chapter-2
LITERATURE REVIEW
2.1 General
Now a day, the rate of increase in economy combined with population growth has put the
pressure on the demand for housing. In addition, the main component of building is construction
materials. In developing countries, there are many natural resources and rural labors, who are low
educated and unskilled, and have low income. Traditional building materials are firedintensive or
energy- intensive such as brick, ceramic, glass, concrete, polymer etc. manufacturing these
products increase the presence of carbon dioxide, which is harmful to human health and creates
greenhouse gases in the atmosphere. There is considerable lack of awareness and appreciation
about the possibility of use of fly ash in partial replacement of cement to the extent of 15 to 20%
without affecting in any way the strength of the structure adversely or producing any other
detrimental affect. This report is intended to give the essential technical information and data
regarding the use of in building construction and the process and feasibility of making lime fly ash
mix which can be used in variety of works. This is a major waste by-product of pulverized coal
fired in Thermal Power Stations.
Curing in steam for predetermined period is employed to enable the blocks to gain desired strength.
Thus, fly ash blocks satisfy the basic parameters of building units, moreover the blocks are also
suitable for the construction of building in coastal areas where normal red clay burnt bricks are
found to be affected.

2.2 Research works
M.Shukla and A.K.Sachan[2]: Studied stone dust environmentally hazardous waste; its
utilization in building construction. It is found that (i) partial replacement will not affect
the strength and thus, solve the problem of disposal of stone dust and also reduce the cost
of construction. (ii) The workability of concrete reduce with increase in stone dust and this
can be improved by adding suitable admixtures.
Ambalavanan and Roja (1996)[3]: Investigated the potential of fly ash, waste lime and
waste gypsum to obtain a binder for using it in bricks/ blocks and as masonry cement. Low-
calcium fly ash (from Ennore thermal plant, located near Chennai, India); four types of
waste limes, each obtained from a processing stage of a petrochemical industry and waste
gypsum from a fluoride industry (5-10%, by wt.)were used. Based on their investigations,
they have reported that only the F-L-G mix (68:23:9) containing milk of lime-reject, gives
adequate strength (it. about 4 N/mm2) for making bricks and blocks, without any
beneficiation; (ii) grinding has improved the strength of the above mix only considerably
(i.e. 4 N / mm2 to 10 4 N / mm2)
Naik and et al., (1992)[4]: Have shown that with a 40% Class F fly ash mixture with a
super-plasticizer and W/CM=0.4, compressive strength of 24MPa at 2 days, has been
obtained.
Langley and et al., (1984)[5]:have reported using 56% of Class F fly ash (by wt.) of total
cementatious materials In concrete for structural applications. They have concluded that
high-volumes of Class F fly ash and low cement content provide economical material for
strength of the order of 60 MPa at 120 days
Shashiprakash and Thomas (2001): Investigated the use of high-calcium fly ash (ca0
content 20 to 23%) and silica fume to improve the sulfate resistance of mortars.
.

Chapter-3
MATERIALS AND METHODS
3.1 Raw materials
3.1.1 Fly Ash
Fly ash forms the major component of the raw material for fly ash blocks. Therefore it
controls to a large extent the properties of the finished product. As the ash is non-plastic, a binder
must be added either plastic clay or Portland cement. Fly ash content ranges from 30-40%. The
physical appearance of fly ash is as shown in Fig 3.1.1
Fig 3.1.1 fly ash
Fly ash is a fine residue obtained from thermal power stations using ground or powered coal as
boiler fuel. It can be utilized in various forms as building material. The thermal power stations in
the country throw large quantities of fly ash which goes as waste but which could be effectively
used as partial replacement of cement. Siliceous fly ash (class F) is collected from Raichur thermal
power station. The chemical composition of fly ash is shown in Table 3.1.1

Table NO 3.1.1: Chemical composition of fly ash

Type Constituent
SiO2 61.1
Al2O3 28
TiO2 1.3
Fe2O3 4.2
MgO 0.8
CaO 1.7
K2O 0.18
Na2O 0.18
L.O.I 1.4
3.1.1.1 Characteristics of fly ash
Fly ash is composed of fine grained particles that have a variable morphology and consist
primarily of an amorphous glassy material. The element composition of fly ash is highly variable
and directly related to compositional variations in parent coal, and to the operational characteristics
of the individual power plant. The molten minerals such as clay, quartz, and feldspar solidify in
the moving air stream, giving approximately 60% of fly ash particle a spherical shape. The specific
surface area of fly ash commonly falls between 2000 to 8000 cm2/gm and it’s possess pozzolanic
properties. The particles are generally grey in colour, abrasive 3refractory in nature. It consist of
mineral constituents of coal and other organic matter, which is not fully burnt. Some elements are
concentrated in fly ash particle. While glass like particles is essentially in soluble in water, the
enriched surface particles are soluble. In one study of fly ash obtained from the burning of pine
wood, the pH was found to be about 13 and the ash contained 18% to 26% of Ca, 6% to 9% Mg,
0.4% to 11% and 1.7% to 2.5% P. the temperature at which the waste was burn influenced the
composition of the ash. Another study with hardwood ash found that they contained about 6%
potash, 2% phosphoric acid and 30% lime.

3.1.1.2 Cost benefit of fly ash
Since it is byproduct, the initial cost of fly ash is minimum compared that of Portland cement.
There are some costs associated with the handling of fly ash and possibly with any special
operations required to ensure proper quality control of material. However, for the cement, the cost
of fly ash will depend mainly on the cost of its transportation from thermal power plant.
Consequently, in areas close to power station producing good quality of fly ash, there should be
cost benefits associated with the use of fly ash in concrete or in production of blended cement.
Thus, the making use of appropriate technologies, fly ash concrete of equivalent quality to that of
conventional concrete could be produced at lower cost. Therefore there is some immediate
economic benefit potential in using fly ash in concrete
3.1.1.3 Application of fly ash
1. Use of fly ash in Portland cement manufacture

Approximately 50 tons of fly ash which was about 6% of kiln fed was added to the kiln
during the manufacture. It was observed that the kiln operation ran in a more efficient,
stable and predictable manner. As a result, the cement plant achieved fuel saving of
approximately 3.9%, the production increased by approximately 9.7% and several key
processing parameters were improved. Microscopically and analytical examination of
clinkers confirmed the presence and normal distribution of major clinker phases cement
produced during demonstration tested as per specification, performed similarly to that of
cement produced before and after the demonstration.
2. Use of fly ash in concrete:

Fly ash is a finally divided siliceous material having pozzolanic property that is it form into a
binding material in presence of water and lime at ordinary temperatures.
It is well established that in production of concrete, fly ash could be used as replacement of
cement.
Use of fly ash in concrete is found to have many beneficial effects viz., improved
workability, improved water tightness, less heat of hydration etc. Thus making it suitable
for all types of structures especially hydraulic structures, mass concreting works etc. use

of fly ash is also found to improve the resistance of the concrete from chemical attack
especially sulphate attack.
3. Use of fly ash in road construction:
fly ash can be used in the road construction in various ways. The sub-grade can be stabilized
with ash. Coarse ash can be used in the base and sub-base courses. Fly ash can be used in rigid
concrete pavement.
4. Use in building materials:

The pozzolanic properties of fly ash can be usefully applied in the manufacture of bricks,
building blocks, aggregates and other such building products. There are numerous technologies
available starting from low tech applications of fly ash in kiln burnt clay fly ash bricks to highly
sophisticated and mechanized plants producing aerated cellular concrete blocks.
3.1.1.4 Classification of fly ash
1. Class C fly ash: It is the residue collected from the smoke stacks of coal-fired power plants
generally using lignite and sub-bituminous coals. class C fly ash are themselves mildly
cementitious, and have combined with lime or even calcium carbonate soils to produce
moderately strong concrete.
2. Class F fly ash: It is residue collected from coal-fired power plants generally using anthrax
site and bituminous coals. Generally less effective than the Class C fly ashes, Class F fly
ash is nevertheless an abundant and useful pozzolana. Generally it contains less than 10%
CaO.
3.1.2 Cement
Many pilot plants faced difficulty in regular supply of consistent quality sludge lime. Some NTPC
projects have switched over to cement as the binding materials in place of sludge lime. When
cement is used, use of gypsum can be avoided. Ordinary Portland cement confirming to IS-269,
IS-8112 or IS-12269 should be used.

3.1.3 Jelly
10mm down size aggregates are used. The physical appearance of stone dust is as shown in Fig
3.1.3
Fig 3.1.3 Jelly (10mm down size aggregates)
3.1.4 Water
Generally potable water from a well or a river is required. Sea-water should be avoided as far as
possible. Soluble salts or organic matter in water should not exceed 0.25%. Water is an essential
but temporary constituent of fly ash blocks.

3.1.5 Stone dust
For the present study, 2000gms of stone dust was collected. Various physical & mechanical
properties stone dust was determined in laboratory. The physical appearance of stone dust is as
shown in Fig 3.1.5
Fig 3.1.5 stone dust
All plants use locally available stone dust which is used for concreting works.

3.1.6 TESTING OF INGREDIENTS

3.1.6.1 Sieve analysis of stone dust: Appearance of collected stone dust sample indicates that the
particle size lies between sand and cement. For determining the fineness modulus of stone dust,
dry sieve analysis was conducted as per IS method and result are given in the table 3.1.6.1
Weight of stone dust sample: 2000gms
Table No 3.1.6.1 Sieve analysis of stone dust
SI. Empty Empty Weight of

NO IS sieve weight of weight of stone dust % of retained Cumulative %
no sieve sieve + retained [W3/2000]X1
(gm) W1 stone dust (gm) 00
retained W3=W2-W1
(gm) W2
1 4.75mm 415 435 20 1 1
2 2.36mm 365 385 15 0.75 1.75
3 1.18mm 305 670 365 18.25 20.00
4 600 µ 330 715 385 19.25 39.25
5 300 µ 345 1190 845 42.25 81.5
6 150µ 321 630 320 16 97.5
7 Pan 275 325 50 2.5 _______
∑F=240.75
Hence Fineness modulus =∑F/100= sum of cumulative % /100
i.e F.M = 240.75/100=2.4075≈2.5
Average size of stone dust = 450µ and type of stone dust is coarse stone dust

3.1.6.2 Sieve analysis test on jelly: Appearance of collected jelly sample indicates that the particle
size lies between coarse aggregate and fine aggregate. For determining the fineness modulus of
jelly, dry sieve analysis was conducted as per IS method and result are given in the table 3.1.6.2
Weight of Jelly sample: 5000g
Table No 3.1.6.2 SIEVE ANALYSIS TEST ON JELLY

SI. No Empty Empty
weight weight of Weight of stone % of retained Cumulative
IS of sieve sieve + stone dust retained(gm) [W3/5000]X1 %
sieve (gm) dust W3=W2-W1 00
no W1 retained
(gm)W2
1 40mm 855 855 0 0 0
2 20mm 980 980 0 0 0
4 10mm 970 1675 705 14.1 14.1
5 4.75m 985 5025 4040 80.8 94.9

m
6 Pan 975 1215 240 4.8 99.7
∑F=208.7
Fineness modulus = sum of cumulative %/100
i.e F.M = 208.7/100=2.087≈2
Hence the average size of an aggregate is 10mm.

3.2 METHODOLOGY: [7]

The fly ash blocks are prepared by process which involves following steps.
1) Selection and preparation of raw materials which are suitable for fly ash blocks.
2) Mixing raw materials and water.
3) Pressing the blocks in machine.
4) Curing of blocks
Preparation of raw materials which is suitable for fly ash blocks.
Fly ash is said to be used for production of blocks should preferably take from the nearest thermal
plant. This reduces the transportation cost of fly ash
3.2.1 Mixing process

Mixing is done in two stages
1) Dry mixing:-Measure out the stone dust, fly ash, jelly and cement required for the
production of required number of block. Preferably 5 blocks per batch. Mixing of these
ingredients can be done manually or in the concrete mixer. Mixing should be done till the
color of the mixture become homogeneous.
2) Wet mixing: add the water to the dry mix by sprinkling with hand or garden rose can.
Water should be added to the dry mix till the field optimum moisture is obtained. The wet
mixing equipment is as shown in fig 3.2.1.
Fig 3.2.1 Concrete Machine

This can be identified by making the ball of wet mix in hand and this mix should not adhere to the
palm of the hand.
3.2.2 Pressing the blocks in machine
The following steps are to be followed in sequence for pressing the blocks.
A) Proportioning of raw material: The mixture of fly ash, stone dust, jelly, cement and water
may now be taken in appropriate proportion. Pour the mixture into the mould.
B) Compaction: The lid of machine is now closed and locks the lid. Pull the lever down with
two persons till the compaction stroke is completed. The pressing machine is as shown in fig
3.2.2
Fig 3.2.2 Hydraulic pressing machine
C) Ejecting the block: Bring lever back into near vertical and lock into a simple lever. Move it
down slightly to open the lid. Simple lever may be now pressed further down to eject the block.
D) Removing the block: The block may now be removed along with the thin base plate and taken
for stacking and machine is ready for the next block.
E) The stacking of blocks: The blocks have to be stacked on a level ground preferably in a shaded
area. The blocks may be stacked one above the other up to six layers.

3.2.3 Curing of blocks

The blocks must be cured for 14,21,28 days by gentle sprinkling of water; preferably using
garden rose can.
Fig 3.2.3 Curing of blocks using Gunny bags.
The top of the blocks must be covered with straw or gunny cloth to prevent evaporation

3.3 Percentage of ingredients used for block production

400mm x 200mm x 150mm sized blocks are prepared with stone dust, fly ash, jelly with different
percentage of stabilizer cement. The combinations are used for block production is shown in table
no 3.3
Table no 3.3 Percentage of ingredients used for block production

SERIAL NO COMBINATIONS DESIGNATION
FLY ASH 20 %
STONE DUST 30 %
1 CEMENT 20% 1
JELLY 30%
FLY ASH 30%
STONE DUST 30%
2 CEMENT 10% 2
JELLY 30 %
FLY ASH 40%

STONE DUST 25%
3 CEMENT 05% 3
JELLY 30%
FLY ASH 20%

STONE DUST 35%
4 CEMENT 05% 4
JELLY 40%

% OF INGRADIENTS
FLY ASH
JELLY 20%
30%
STONE
DUST
CEMENT 30%
20%
Fig No 3.3.1 % of ingredients for combination 1
% OF INGRADIENTS
JELLY FLY ASH

30% 30%
CEMENT
STONE DUST
10%
30%

% OF INGRADIENTS
JELLY
30%
FLY ASH
40%
CEMENT
5%
STONE DUST
25%
% OF INGRADIENTS
FLY ASH
20%
JELLY
40%
STONE
DUST
CEMENT
35%
5%

3.4 WATER CEMENT RATIO AND QUANTITIES FOR EACH

COMBINATION:
The mass for block size of 400mmX200mmX150mm is given by its volume and density of
concrete.
i.e Mass = Density X Volume.
Then quantity of cement = Mass/sum of material proportion. After that we can easily find out w/c
ratio. The following Table 3.4 gives the quantities of material required per block.
Table no 3.4 Quantities of materials required per block.
QUANTATIES PER BLOCK(Kg)

IN GRADIENTS PROPORTION CEMENT FLY STONE JELLY W/C RATIO
C:F:S:J kgs ASH kgs DUST(kgs) (kgs)
COMBINATION 2:2:3:3 5.4 5.4 8.1 8.1 0.5
1
COMBINATION 1:3:3:3 2.7 8.1 8.1 8.1 0.41
2
COMBINATION 0.5:4:2.5:3 1.35 10.8 6.75 8.1 0.43
3
COMBINATION 0.5:2:3.5:4 1.35 5.4 9.45 10.8 0.55
4

Chapter-4
TEST RESULT AND DISCUSSION

4.1 General
In this chapter, the results of the studies on the strength characteristics of fly ash blocks(
fully/ partially replacement of cement and sand by fly ash and stone dust respectively) are
presented and are discussed. The salient conclusions based on the present study are given in the
chapter 5.
4.2 Discussion of results
Here the results of properties of fly ash and stone dust are discussed. The compressive
strength test results of fly ash blocks are given and discussed. Water absorption and dry density
tests of the fly ash blocks also been considered and results are discussed.
4.1 Dry density
The density of fly ash Block of size: 40cmX20cmX15cm (LXBXD) for different combinations
are as fallows. Three blocks shall be dried for 1 day to constant mass. The dimensions of each
block shall be measured in centimeters and overall volume computed in cubic centimeter. The
blocks shall then be weighted in kilograms to the nearest 10 gram. The density of each block is
calculated as follows [8]
Density in kg/m3 =Mass of block in kg/Volume of block in cm3*106

4.1.1 Dry density of 14 days cured blocks

The dry density of blocks is as shown in table 4.1.1 for 14 days curing
Table No 4.1.1 Dry density of 14 days cured blocks

Combination sample Weight of block Volume of block Dry density
(gm) (cm3) (gm/cm3)
1 1 25120 12000 2.093
2 24950 12000 2.080
3 24650 12000 2.054
2 1 24580 12000 2.048
2 24130 12000 2.010
3 23950 12000 2.00
3 1 22260 12000 1.855
2 21840 12000 1.820
3 22190 12000 1.850
4 1 27570 12000 2.29
2 26850 12000 2.24
3 27780 12000 2.27


. The dry density of blocks is as shown in table 4.1.2 for 21 days curing

(gm) (cm3) (gm/cm3)
1 1 28420 12000 2.37
2 27850 12000 2.32
3 27730 12000 2.31
2 1 27910 12000 2.32
2 27800 12000 2.31
3 28030 12000 2.33
3 1 23125 12000 1.92
2 22960 12000 1.91
3 22140 12000 1.84
4 1 28650 12000 2.38
2 27780 12000 2.31
3 27540 12000 2.29

The dry density of blocks is as shown in table 4.1.3 for 28 days curing

(gm) (cm3) (gm/cm3)
1 1 28550 12000 2.38
2 28280 12000 2.35
3 27950 12000 2.29
2 1 27865 12000 2.32
2 27470 12000 2.29
3 27285 12000 2.27
3 1 22650 12000 1.88
2 22880 12000 1.90
3 22740 12000 1.89
4 1 27850 12000 2.32
2 27780 12000 2.31
3 27640 12000 2.30
4.2 Water absorption test

Three full size blocks shall be completely immersed in clean water at room temperature for 24
hour. The block shall then be removed from water and allow to drain for 1 minute by placing
them on a 10 mm or coarser wire mess, visible surface water being removed with a damp cloth,

the saturated and surface dry blocks immediately weighed. After weighing all blocks shall be dry
for not less than 24 hours. Table 4.2 shows the percentage of water absorbed by each block for 28
days curing. And Fig 4.2 shows curing of blocks for 24 hour.[8]
The water absorption calculates as given below:
Absorption,% = (A-B)/B*100
Where,
A= Wet mass of unit in kg. B=Dry mass of unit in kg
Fig 4.2 Water absorption of blocks

Table 4.2 Shows the percentage of water absorbed by each block after 28 days of curing.
Designation Dry weight Wet weight Weight of water % of water

(1) (kg) (kg) (kg) absorption
(2) (3) (4) [(4)/(2)]X 100
Combinatin1
1 28.550 29.240 0.690 2.416
2 28.285 28.900 0.615 2.200
3 27.950 28.530 0.580 2.075
Average 2.230
Combination2
1 27.865 28.850 0.985 3.530
2 27.470 28.550 1.080 3.930
3 27.285 28.370 1.085 3.976
Average 3.812
Combination3
1 22.650 24.066 1.416 6.250
2 22.880 23.453 1.465 6.402
3 22.740 24.200 1.460 6.420
Average 6.357
Combination4
1 27.850 28.983 1.133 4.068
2 27.780 28.790 1.010 3.635
3 27.640 28.751 1.111 4.019
Average 3.907

4. 3 Effect of water absorption on dry density

The results of water absorption and dry density are obtained from above test are compared
and effects of water on dry density is as shown in Table no 4.3 and in Graph 4.3
Table no 4.3 Effect of water absorption on dry density

AVG % OF WATER ABSORPTION DRY DENSITY (gm/cc)
2.230 2.34
3.812 2.29
6.357 1.89
3.907 2.31
AVG % OF WATER ABSORPTION 6.357
DRY DENSITY (gm/cc)
3.812 3.907
2.23 2.34 2.29 2.31

1.89
1 2 3 4
Combination No
Graph 4.3 Effect of water absorption on dry density

4.4 Compressive strength test of blocks: [8][9]

The compression testing machine (CTM) should be as per IS: 516-1959 and
I.S:14858-2000. The load capacity, platens sizes, vertical space between platens and
horizontal space between machine columns shall be as per the requirement of the specimen
to be tested.
However, IS : 2185 (part-I)- 1979 specified that when the bearing area of the steel
blocks is not sufficient to cover the bearing are of the blocks, steel bearing plates shall be
placed between the bearing blocks and the capped specimen after the centroid of the
masonry bearing surface has been aligned with the center of thrust of bearing blocks. It is
desirable that the bearing faces of blocks and plates used for compression testing of concrete
masonry have hardness of not less than 60.
When steel plates are employed between the steel bearing blocks and masonry
specimen, the plate shall have thickness equal to at least 1/3 of the distance from the edge
of the bearing block to the most distant corner of the specimen. In no case shall the plate
thickness be less than 12mm.
ASTM: C140-03 specified that when the bearing area of the upper platen or lower
platen is not sufficient to cover the area of the specimen, a single steel bearing plate with a
thickness equal to at least the distance from the edge of platen to the most distant corner of
the specimen shall be placed between the platen and capped specimen. The length and width
of steel plates shall be at least 6.3mm greater than length and width of the unit.
Thickness of bearing plate has significant effect on the tested compressive strength of the
masonry units when the bearing area of the platen is not sufficient to cover the area of the
specimen. Tested compressive strength will typically increase with increased plate
thickness and reduce distance to the further corner of the specimen. Accordingly the CTM
platens shall have the required dimensions with respect to the specimens to be tested on it.
Test specimens
Eight full size units shall be tested within 72 hours after delivery to the laboratory,
during which time they shall be stored continuously in normal room air.
For purpose of acceptance, age of testing the specimens shall be 28 days. The age shall
be reckoned from the time of addition of water to the dry ingredients.

PROCEDURE
Specimens shall be tested with the centroid of the bearing surface aligned vertically
with the centre of thrust of spherically seated steel bearing blocks of the testing machine
The load up to one half of the expected maximum load may be applied at any convenient
rate, after which the control of the machine shall be adjusted as required to give a uniform
rate of travel of the moving head such that the remaining load is applied in not less than one
nor more than two minutes.
The compressive strength of concrete masonry units shall be taken as the maximum
load in Newtones divided by the gross cross sectional area of the unit in square millimeters.
Report to the nearest 0.1 N/mm2 separately for each unit and average for the 8 full units.
The testing machine and results are shown in following fig 4.4 and Table
4.4.1
Fig 4.4 Compression testing machine with sample

4.4.1 COMPRESSIVE STRENGTH OF BLOCKS AFTER 14 DAYS CURING

Results of compressive strength test on blocks for 14 days curing are as shown in table 4.4.1
Table No: 4.4.1 Compressive strength of blocks after 14 days curing

Designation Load (kg) Load (N) Area (mm2) Compressive
(1) strength (N/mm2)
Combination1
1 76000 745560 80000 9.3195
2 74000 725940 80000 9.0743
3 76000 745560 80000 9.3195
Average 9.2377
Combination2
1 55000 539550 80000 6.7444

2 49000 480690 80000 6.0086
3 53000 519930 80000 6.4991
Average 6.4173
Combination3
1 13000 127530 80000 1.5941
2 14000 137340 80000 1.7167

3 13000 127530 80000 1.5941
Average 1.6349
Combination4
1 12000 117720 80000 1.4715
2 13000 127530 80000 1.5941
3 13000 127530 80000 1.5941

Average 1.5532
Sample 18000 176580 80000 2.2073

Results of compressive strength test on blocks for 21days curing are as shown in table 4.4.2

(1) strength
(N/mm2)
Combination1
1 84000 824040 80000 10.3005
2 81000 794610 80000 9.9326
3 82000 804420 80000 10.0552
Average 10.0961
Combination2
1 58000 568980 80000 7.1122
2 59000 578790 80000 7.2348
3 59000 578790 80000 7.2348
Average 7.1939
Combination3
1 17000 166770 80000 2.0846
2 16000 156960 80000 1.9620
3 14000 137340 80000 1.7167
Average 1.9209
Combination4
1 18000 176580 80000 2.2072
2 20000 196200 80000 2.4525
3 22000 215820 80000 2.6978
Average 2.4525
Sample 19000 186390 80000 2.3298


Results of compressive strength test on blocks for 28 days curing are as shown in table 4.4.3

(1) strength
(N/mm2)
Combination1
1 88000 863280 80000 10.7910
2 86000 843660 80000 10.5458
3 85000 833850 80000 10.4231
Average 10.5866
Combination2
1 70000 686700 80000 8.5837
2 68000 667080 80000 8.3385
3 66000 647460 80000 8.0933
Average 8.3385
Combination3
1 24000 235440 80000 2.9430
2 23000 225630 80000 2.8203
3 23000 225630 80000 2.8203
Average 2.8612
Combination4
1 28000 274680 80000 3.4335
2 28000 274680 80000 3.4335
3 26000 255060 80000 3.1882
Average 3.3590
Sample 25000 245250 80000 3.0656

4.5 Effect of water absorption on compressive strength

The results of water absorption and dry compressive strength are obtained from above
test are compared and effects of water on compressive strength is as shown in Table no 4.5
and in Graph 4.5
Table No 4.5 Effect of water absorption on compressive strength

Combinations Avg % of water Avg compressive strength
absorption
1 2.23 10.5866
2 3.812 8.3385
3 6.357 2.8612
4 3.907 3.359
EFFECT OF WATER ABSORPTION ON COMPRESSIVE

STRENGTH
AVG % OF WATER ABSORPTION AVG COMPRESSIVE STRENGTH (N/MM^2)
10.5866
8.3385
6.357
3.812 3.907
3.359
2.8612
2.23
1 2 3 4
Combinations
Graph 4.5 Effect of water absorption on compressive0 strength

4.6 Ingredients of blocks comparing with compressive strength
Table No 4.6.1 Ingredients of blocks compare with compressive strength for 14 days of
curing
% Of cement % of fly ash % of stone % of jelly Avg compressive

content content dust strenght(mpa)
20 20 30 30 9.2377
10 30 30 30 6.4173
5 40 25 30 1.6349
5 20 35 40 1.5532
curing
% Of cement % of fly ash % of stone dust % of jelly Avg compressive
content content strenght(mpa)
20 20 30 30 10.0961
10 30 30 30 7.1939
5 40 25 30 1.9209
5 20 35 40 2.4525
curing
% Of cement % of fly ash % of stone % of jelly Avg compressive
content content dust strenght(mpa)
20 20 30 30 10.5866
10 30 30 30 8.3385
5 40 25 30 2.8612
5 20 35 40 3.3590

4.7 Curing period of block comparing with compressive strength

Combination 1
COMPRESSIVE STRENGTH CURING PERIOD
9.2377 14
10.0961 21
10.5866 28
10.8
10.6
10.4 10.5866
10.2
10
10.0961
9.8 COMPRESSIVE STRENGTH
9.6
9.4
9.2
9 9.2377
0 5 10 15 20 25 30
Curing period
Combination 2
COMPRESSIVE STRENGTH CURING PERIOD

6.4173 14
7.1939 21
8.3385 28
9
8 8.3385
7 7.1939
6 6.4173
5
4 COMPRESSIVE STRENGTH
3
2
1
0
0 5 10 15 20 25 30
Curing period

Combination 3
CURING PERIOD COMPRESSIVE STRENGTH
14 1.6349
21 1.9209
28 2.8612
3.5
3 2.8612
2.5
2 1.9209
1.5 1.6349 COMPRESSIVE
1 STRENGTH
0.5
0
0 5 10 15 20 25 30
Curing period
Combination 4
CURING PERIOD COMPRESSIVE STRENGTH
14 6.4173
21 7.1939
28 8.3385
9
8 8.3385
7 7.1939
6 6.4173
5
4
3 COMPRESSIVE STRENGTH
2
1
0
0 5 10 15 20 25 30
Curing period

4.8 Average compressive strength of all different combinations of blocks
12
10.5866
10
8.3385
8
6
AVG COMPRESSIVE STRENGTH
(N/MM^2)
4
3.359
2.8612
0
1 2 3 4
Combinations
Graph 4.8 Average compressive strength of all different combinations of blocks

Chapter-5
CONCLUSIONS
1. Stone dust is found to be ideal for producing cement blocks for masonry construction.
2. The percentage of water absorption increases with decrease in compressive strength.
3. The percentage of water absorption increases with decrease in dry density.
4. Water absorption of block is range between 2%-6% as compared to burnt brick is range
between 10% – 20%.
5. The strength of block is in between 1.55 – 10.3N/mm2 as compared to burnt brick 3 - 4
N/mm2.
6. Solid concrete blocks are energy efficient, saves energy, less pollution and cost effective.
7. As cement quantity increase cost and strength of block increases up to some extent and
it is seem to be uneconomical after certain limit.
8. As fly ash content increases, water absorption also increases.
9. Experimental study reveals that the fly ash is not very supportive in enhancing the strength
of brick tiles but their use helps to reduce the environmental pollution and saving in energy.
10. Use of fly ash will also reduce the land required for ash dump yards. By the utilization of
60% fly ash in making brick tiles an equal volume of top soil which will otherwise be used
for making clay brick tiles can be saved.
11. The density of fly ash blocks is 28% less than that of standard clay bricks. This reduction in
the weight of blocks results in a great deal of saving amongst which are savings in raw
materials and transportation cost and savings to the consumer, that results from increased
number of units and reduction in the loads on structural elements .

Reference
[1] Techno Economic Feasibility Report On fly ash bricks (Building Materials & Technology
Promotion Council Ministry of Housing & Urban Poverty Alleviation Government of India New
Delhi) pp: 1-11
[2] M.shukla and A.K.sachan,stone dust-environmentally hazardous waste, it’s utilization in

building construction. Materials and machines for construction by L.K.Mishra and Y.P.Gupta
new age international publishers, feb 2000 page-V77-V81
[3] Ambalavanan, R, and Roja, A., (1996)," Feasibility studies on utilization of waste lime and
gypsum with fly ash Concrete Jl., Nov.'96, pp.611-616.
[4] Naik T.R. & Ramme B.W. 1989. High-strength concrete containing large quantities of fly ash,
ACI Materials Journal, Vol. 86, No. 2, Mar.-Apr. 1989.
[5] Langley W.S., Carette G.G.,and Malhotra V.M , “Structural concrete incorporating high volumes
of ASTM class F fly ash”, ACI mater J 86 (1989), pp.: 507-514.
[6] M.S.Shetty, “Concrete technology” (2012) pp: 48-53.176-183, aggregate and testing of
aggregate page-93-97
[7] NTPC Journal ASH UTILIZATION DIVISION page: 3-9.
[8] IS: 2185 (part-I) 1979 1987 1998-Specifications for concrete masonry. Unit’s part-I hollow
and solid concrete blocks (Second Revision)
[9] IS: 2185 (part-II)-1985 super seeding IS: 3590-1966 specification for concrete masonry unit’s
part-II hollow and solid light weight concrete blocks (First Revision).
[10] ASTM: C 140-03 Standard test methods for sampling and testing concrete machinery units
and related units.

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BUILDING BLOCKS USING FLY ASH AND STONE DUST

Dept of Civil Engg, RITS Chevella Page 1

Dept of Civil Engg, RITS Chevella Page 2

1.2 HISTORICAL BACKGROUND OF FLY ASH

1.3 DIFFERENT TYPES OF BUILDING BLOCKS

➢ Stabilized mud building blocks.

Dept of Civil Engg, RITS Chevella Page 3

Dept of Civil Engg, RITS Chevella Page 4

1.5 ENVIRONMENTAL EFFECTS

❖ Utilization of fly ash is environment friendly with improved cementitious binder

1.6 OBJECTIVES OF PROJECT

1. Characterization of stone dust and stabilizer like cement.

Dept of Civil Engg, RITS Chevella Page 5

Dept of Civil Engg, RITS Chevella Page 6

2.2 Research works

Dept of Civil Engg, RITS Chevella Page 7

Fig 3.1.1 fly ash

Dept of Civil Engg, RITS Chevella Page 8

Table NO 3.1.1: Chemical composition of fly ash

3.1.1.1 Characteristics of fly ash

Dept of Civil Engg, RITS Chevella Page 9

3.1.1.2 Cost benefit of fly ash

3.1.1.3 Application of fly ash

1. Use of fly ash in Portland cement manufacture

2. Use of fly ash in concrete:

Dept of Civil Engg, RITS Chevella Page 10

4. Use in building materials:

3.1.1.4 Classification of fly ash

Dept of Civil Engg, RITS Chevella Page 11

Fig 3.1.3 Jelly (10mm down size aggregates)

Dept of Civil Engg, RITS Chevella Page 12

3.1.5 Stone dust

Fig 3.1.5 stone dust

Dept of Civil Engg, RITS Chevella Page 13

3.1.6 TESTING OF INGREDIENTS

Weight of stone dust sample: 2000gms

Table No 3.1.6.1 Sieve analysis of stone dust

SI. Empty Empty Weight of

1 4.75mm 415 435 20 1 1

2 2.36mm 365 385 15 0.75 1.75

3 1.18mm 305 670 365 18.25 20.00

4 600 µ 330 715 385 19.25 39.25

5 300 µ 345 1190 845 42.25 81.5

6 150µ 321 630 320 16 97.5

7 Pan 275 325 50 2.5 _______

Hence Fineness modulus =∑F/100= sum of cumulative % /100

i.e F.M = 240.75/100=2.4075≈2.5

Dept of Civil Engg, RITS Chevella Page 14

Weight of Jelly sample: 5000g

Table No 3.1.6.2 SIEVE ANALYSIS TEST ON JELLY

2 20mm 980 980 0 0 0

4 10mm 970 1675 705 14.1 14.1

5 4.75m 985 5025 4040 80.8 94.9

Fineness modulus = sum of cumulative %/100

i.e F.M = 208.7/100=2.087≈2

Hence the average size of an aggregate is 10mm.

Dept of Civil Engg, RITS Chevella Page 15

3.2 METHODOLOGY: [7]

3.2.1 Mixing process

Fig 3.2.1 Concrete Machine

Dept of Civil Engg, RITS Chevella Page 16

3.2.2 Pressing the blocks in machine

Fig 3.2.2 Hydraulic pressing machine