PARTIAL REPLACEMENT OF NATURAL AGGREGATE BY BRICK BALLAST AGGREGATE

A
PROJECT REPORT
ON
“PARTIAL REPLACEMENT OF NATURAL AGGREGATE BY
BRICK BALLAST AGGREGATE”
Submitted in the partial fulfillment of the requirement for,
FINAL YEAR CIVIL ENGINEERING
SUBMITTED BY,
Mr. GURAV SURAJ BAPUSAHEB [ROLL NO.45]
Mr. BHUSE AKASH RAMCHANDRA [ROLL NO.05]
Mr. DHALE UMESH RAJENDRA [ROLL NO.11]
Mr. DUDHAL DIPAK PRAKASH [ROLL NO.12]
Mr. JADHAV SUJIT KHANDU [ROLL NO.15]
Mr. JADHAV TANAJI BHARAT [ROLL NO.16]

Under The Guidance Of,

PROF. ADLINGE SIR.

DEPARTMENT OF CIVIL ENGINEERING FABTECH TECHNICAL

CAMPUS,
COLLEGE OF ENGINEERING AND RESEARCH ,SANGOLA.
2019-2020

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ABSTRACT
In this present work the study on replacement of coarse aggregate by burnt brick aggregate.
Coarse aggregate can be defined as inert granular materials such as gravel, crushed stone and sand.
Coarse aggregate is one of the essential ingredients apart of water and cement in concrete
production.
The only variable considered in this study was the volumetric replacement (0%, 10%,20%&
30%) of stone aggregate by brick aggregate. The use of brick aggregate as a replacement of stone
aggregate resulted reductions in unit weight, compressive strength of concrete. Different relations
for determination of compressive strength have been tentatively proposed.
The 20% replacement of RCBA (Reinforced Concrete Bridge Approach) is considered as the
best in view of strength and economy, hence we use it in moderately loaded structures. 30%
replacement of RCBA can be used wherever load coming chances are less. Can be rectified, but
few of them can be overcome by improving management responsibilities.

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Objectives:
 To compare the physical properties of brick ballast aggregate with natural coarse
aggregate.
 Applications and uses of brick aggregate concrete.
 To make the mix design for brick aggregate concrete.
 To provide a most economical concrete.
 Using the wastes in useful manner.

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INTRODUCTION

As the time is passing, the construction industry is growing rapidly and in the last decade
we are seeing relatively huge construction. With this rapid growth, a concern of its waste
management also growing with the same speed every annum. Regular bricks are used in
the construction of buildings either as main walls, partition walls or some other purpose.

The brick which are near the fire in kiln subjected to high heat more than 1000 degree
centigrade ultimately shrink and loose its shape,colour becomes reddish and its appearance
like reddish to blackish gradient stone.
Its constituents in gradients derive from a wide variety of naturally occuring material that
are readily available in most part of the world.
Stone or gravel which are obtained naturally either from river bed or by crushing rocks
mechanically up to the required size.
Generally aggregates are collected by cutting mountains or breaking river gravels or
boulders or by breaking clay bricks
Concrete is a versatile engineering material consisting of cementing substance,
aggregates, water and often
controlled amount of entrained air. It is initially a plastic, workable mixture which can be
molded into a wide
variety of shapes when wet. The strength is developed from the hydration due to the
reaction between cement and
water. The products, mainly calcium silicate, calcium aluminates and calcium hydroxide
are relatively insoluble
which bind the aggregate in a hardened matrix. Concrete is considerably stronger in
compression than in tension,
for structures required to carry only compressive loads such as massive gravity dams and
heavy foundations,
reinforcement is not required and the concrete is consequently called plain concrete.
When the structure is to be
subjected to tensile stresses, steel bars are embedded in the concrete.
Since seventy five (75) percent of concrete is made up of aggregates, its types, quality
and general properties
determine the quality of concrete.
At present, the most commonly used coarse aggregates for concrete production in Benue
State of Nigeria is the
river washed gravel due mainly to the presence of River Benue and its deposits. But these
are not readily available
in some local government areas which are not serviced by the river. Thus the cost of
transporting gravel to the areas
outside the catchment of the river tends to increase the cost of construction even at
relatively cheap labor. This

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necessitates the use of alternative coarse aggregates which are locally obtained. One of
such coarse aggregate is
crushed over burnt bricks obtained from the production of burnt bricks [3].
In many countries, the need for locally manufactured building materials can hardly be
overemphasized because
there is an imbalance between the demands for housing and expensive conventional
building materials coupled
with the depletion of traditional building materials. To address this situation, attention has
been focused on
low-cost alternative building materials
Bricks are a versatile and durable building and construction material, with good load-
bearing properties. Various
researches have been carried out on porosity, permeability and absorption of bricks.
Reference [7] reported the
properties of concrete which use crushed bricks as natural coarse aggregate partial
substitute. Experimental
investigation has also been done to achieve higher strength concrete using crushed brick
aggregate. It has been
found that even recycled brick can also be used as coarse aggregate in concrete.

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LITERATURE REVIEW
1)Tariq Ali, Noumanlqbal, MdZeeshan, MdZulfiqar Ali Khan
Regional conditions enforced engineers to generate a study on concrete
which incorporate Over Burnt Brick Ballast Aggregate partially due to their
abundance. 5% , 10% , 15 % , and20% (M05, M10, M15, M20) incorporation was used
as partial replacement of natural coarse aggregate in concrete. Analysis of incorporated
concrete was done in fresh state as well in hardened state to evaluate different
properties of concrete i.e. slump,compaction factor test, unit weight, and compressive
strength are evaluated. From all the results and experimental approach it is concluded
that Concrete formed with over burnt brick ballast aggregate showed beneficial
performance as compared with the concrete made up of natural aggregate obtained
from local resources. The over burnt brick ballast aggregate showed 14.75 %increase in
Compressive strength for 20 % replacement. It reduces the cost of concrete by reducing
the aggregate cost and produces economical infrastructure system.

2)Fouad M. Khalaf and Alan S. DeVenny :- The testing described in this

paper was performed to establish the physical and mechanical properties of new and
recycledcrushed clay brick aggregates for use in Portland cement concrete PCC
Various physical and mechanical properties of eight differenttypes of aggregates were
determined and compared with the limits set out in the British Standards ior aggregate
from natural sources usedin concrete. The results were also compared with granite
aggregate that has been proved to be a good natural aggregate for producingPCC. The
results showed that most of the crushed clay-brick aggregates tested can be used in
producing PCC for low-level civilengineering applications and that some kinds of
brick aggregate possess good physical and mechanical properties that qualify them
forproducing high-quality concrete.

3)A. G. S. Patil and P. B. Autade (2015) [1] has performed that effect of partial replacement of
coarse aggregate by Jhama class brick in concrete. This project presents the effects of Jhama
Class Brick inclusion on the mechanical properties of the concrete matrix in wet and hardened
state properties. For checking mechanical properties of Jhama Class Brick bat based concrete
used partially replacement Jhama class brick to coarse aggregate ratios 20%, 40%, 60% and 80%
in M40 grade of concrete. It is observed that workability decreased with the replacement of
coarse aggregate. The Compaction factor observed as 0.92, 0.899, 0.88, 0.87 and 0.85 with
varying percentage replacement of coarse aggregate by Jhama class brick bat as 0%, 20%, 40%,
60% and 80% respectively. The compressive strength of Jhama Class Brick bat based concrete
used with partially replacement Jhama class brick to coarse aggregate ratios 20%, 40%,
increased over conventional concrete about 6.08%, 10.02% for 3 days and 9.23%, 12.08% for 7
days and 10.02%, 11.95% for 28 days. If further increased in the percentage of replacement up to
60% and 80%, the strength was decreased by 3.73% and 8.16% respectively for 3 days and
5.69%, 9.25% for 7 days and 2.72%, 6.87% for 28 days cured cube specimen respectively. The
Split Tensile and Flexural Strength of this concrete increases with 5.26%, 8.68%, and 2.74%,

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4.76% respectively over plain concrete for the replacement 20% and 40% and decreased with
3.94%, 12.1% and 3.16%, 7.5% for the replacement 60% and 80%.

4)B. Apebo, et. al. (2014) [2] : reported the suitability of crushed over burnt bricks as coarse
aggregates for concrete The research was conducted to study the suitability of crushed over burnt
bricks as alternative coarse aggregates for concrete production. Tests were carried out to
determine the physical properties of the crushed over burnt bricks aggregates. Values of 22.8%,
28.2%, and 4.4% were obtained for aggregate crushing value, aggregate impact value and
aggregate water absorption respectively. The concrete mixes were prepared using crushed over
burnt bricks as coarse aggregates at water – cement ratios of 0.40, 0.50, 0.55 and 0.60. Cubes of
concrete were prepared and tested to study the compressive strength. The results were compared
with concrete made with river wash gravel as coarse aggregates which at present is the only
coarse aggregate in Makurdi, Nigeria, and its environs. The results indicate that crushed over
burnt bricks – sand concrete is medium light weight concrete having a density between 2000-
2200 kg/m3 and compressive strength of up to 29.5 N/mm2 compared to grave l – sand concrete
having a density between 2300-2400 kg/m3 and compressive strength of up to 30.8 N/mm2. It
was concluded that by reducing the water-cement ratio from 0.60 to 0.40 the compressive
strength of crushed over burnt bricks – sand concrete and gravel – sand concrete increased by
more than 30%. Use of broken over burnt bricks as coarse aggregate for structural concrete was
recommended when natural aggregate was not easily available, high strength of concrete was not
required and the bearing capacity of the soil was low.

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MATERIAL
1)Cement:

2)Fine aggregate:

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3)Coarse aggregate:

4) Over Burnt brick waste:

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5) Chemical admixture:

6)Potable water

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TEST
1)Test on brick aggregate.
A) Impact value test:

B) Water absorption test:

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2)Test on Concrete:
A)Fresh concrete:
a)Slump cone test:

b)Compaction factor test:

B)Hardened concrete:
a)Compressive strength test:

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REFERANCE

 Fouad M. Khalaf. Using crushed clay brick as coarse aggregate in concrete.Journal of

material in Civil Engineering July/August 2006
 Abul Basher. Consultant, Mirpur, Dhaka, Bangladesh.
 IS 10262-1982: Recommended guidelines for concrete mixed design.
 IS 456-2000: Code of practice for plane and reinforced concrete structures.
 IS 516-1959: Method of test for strength of concrete.
 G. S. Patil and P. B. Autade, “Effect of Partial Replacement of Coarse Aggregate by Jhama
Class Brick in Concrete, International Journal of Engineering Research and General
Science, Volume 3, Issue 4, Part-2, July-August, 2015 ISSN 2091- 2730.
 Tariq Ali, Nouman Iqbal, Md Zeeshan, Md Zulfiqar Ali Khan, Evaluation of the
Compressive strength of Concrete for partial replacement of Over Burnt Brick Ballast
Aggregate, International Journal of Science and Modern Engineering (IJISME), December
2013.

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