CHAPTER-I

INTRODUCTION 1.1 Need for using light weight bricks:

Light weight Bricks are an innovative product in the green building revolution. Light weight bricks are the new bricks in walling materials, substituting conventional and environmentally unsustainable materials like clay bricks, concrete and hollow bricks. Light weight brick/block is a new generation building block that helps in creating sustainable buildings and infrastructure. The unique characteristics of these bricks like light-weight, fire resistance, etc., not only grabbed the attention of construction industry, but also made users more curious about its performance. Though there is hype in the industry about this new innovation, only few are clear about what exactly Light weight is all about. So, in a view to help such folks, here is our small effort to put forward all the information related to light weight bricks. The raw materials used in the manufacture of these bricks are environmentally friendly and are certified green products. Fly ash is also used as an alternative building material which is a waste from thermal power plants. These bricks have been used in wide range of constructions which include residential, commercial, hotels, hospitals, schools etc. The edges of the bricks are such that they allow easy workability and accurate dimensioning. Light weight bricks are easier to install as opposed to the installation and usage of conventional building materials where construction deadline is short and labour scarcity is acute and mortars are to be used. The time required for the installation of Light weight Bricks is about 1/3rd as compared to the time required for the installation of conventional Building materials. Light weight bricks are available in various sizes and shapes. They are included into the category of Green Building materials because they dont emit VOC (Volatile Organic Compounds) which cause environmental pollution. Hence, it is one of the revolutionary materials that can be used to make the world a better, greener and cleaner place to live in.

1.2 Salient features:

1. The manufacturing process for the block form of AAC begins by mixing carefully measured quantities of the ingredients. 2. Light weight block is extremely light, just one-third the weight of clay bricks. They are much easier to handle on the site. 3. Light weight block covers the same area as that 14 clay bricks do enabling a faster construction results in saving of labor, time and material. 4. Light weight's excellent thermal properties help in saving recurring costs of heating and cooling. 5. 6. It is fire resistant. It is moisture resistant. It has exceptional good workability. Light weight bricks are resistant to moisture penetration. The structure being closed cells, there is less capillary action, thus providing a high level of moisture resistance. 7. Light weight bricks have exceptionally good workability and are easy to cut, shape and chase using ordinary wood working tools. 8. Light weight bricks are widely used in residential, commercial and industrial buildings. 9. The cost of building with AAC initially may be 15 to 20 percent higher that conventional (i.e., wood or concrete block) construction due to the time it takes for the trades to learn to handle the material. 10. These bricks are in range from a thickness of 75mm to 200mm respectively. They can also be made to required size. Light weight's micro cellular structure incorporates millions of pockets of trapped air which gives it characteristic light weight, high thermal insulation and excellent frost and water resistance.

1.3 Characteristics of Light weight Bricks:

It is a new generation building block that helps in creating sustainable buildings and infra structure. The following are the characteristics of light weight bricks: 1. Light weight
2

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Fire resistance Sound insulation Thermal insulation Strength and durability Perfect finish Less water absorption Weather and earthquake resistant Simple to erect Strong Easily re-locatable Moisture resistant Good workability

1.3.1 Light Weight:

1. 2. 3. 4. Its weight about 1/3rd density of clay bricks. It reduces weight of the brick and decreases the dead weight of the structure. They are ideal for load bearing soil and per seismic zones. Its less weight will not affect the stability of the structure.

1.3.2 Fire Resistance:

1. 2. 3. The fire proof resistance is up to 1100o C. With minimum thickness of brick, 100 mm can resist fire up to 4 hours. It is especially for industries and companies, which are vulnerable to fire accident.

1.3.3 Sound Insulation: (Air cell structure of Light weight bricks)

1. It can minimize the sound transmission up to 42 decibels. It is mainly useful for hotels, auditorium, and hospitals.

2.

1.3.4 Thermal Insulation:

1. Based on the temperature it changes the climatic conditions, it cools during summer and warms during winter. 2. 3. It saves electrical bills and natural sources. The thermal performance is 5 times better than clay brick and 10 times better than RCC.

1.3.5 Strength and Durability:

1. Light weight bricks made with higher weight ratio help in building stronger and economical structure. 2. As they remain unaffected by environmental condition they insure longer life for the building. 3. Its compressive strength is 4 N/mm2.

1.3.6 Perfect Finishing:

1. Auto-clawing process used in the manufacturing of light weight bricks which gives perfect dimensions to the bricks along with low tolerance. 2. Dimensionally perfect bricks help in buildings, uniform, thin walls with perfect finish.

1.3.7 Less Water Absorption:

4

1. 2.

It saves AAC charges. There will not be any moistness of walls and as a result structural strength will be increased.

3. 4.

The articles which are storedin building will not be spoiled. Insect problem will be minimized.

1.3.8 Weather and Earthquake Resistant:

1. Light weight bricks are light in weight and porous, such as they absorb shocks to a great extent and resist the building from tilting.

1.3.9 Simple to Erect:

2. 3. 4. It can be cut easily into various shapes and sizes. Easy to be integrated into existing designs without major change. It can be easily handling, nailed, planed, drilled and sawn.

CHAPTER-II
LITERATURE REVIEW 2.1 Historical back ground:
Historically, concrete has been used to construct various structures, especially in defense structure such as retaining wall, shelter, barrier, nuclear reactor containment, offshore structures, and etc. It is not only applied for normal loads such as weight but is also subjected to impact load due to explosion, against ballistic effect or earth quakes. Currently, bunkers and command center in military application are developed as weapon systems. It is

consequently the penetrability of concrete in relation to projectile and resistance concrete against ballistic and explosion. In USA, approximately 950 million metric tons of coal is consumed annually for electrical and industries use, in which 110 million tons of ash consisting of bottom ash, boiler slag and 64 million tones of fly ash.Currently.40% of ash is reused. The rest is landified or surfaces impounded. This landified fly ash causes huge financial burden for industries, such as the foundry industry, and makes them responsible for potential environment effects far into the future. Scientists have therefore been looking for a way to reuse or recycle this waste into a productive, an environmentally friendly alternative. Alkali activation or geo polymerization is a field developed for the purpose of turning this solid waste into cost-effective solutions. Good source materials include by-products materials such as fly ash, blast furnace slag and silica fume. Alkali fly ash is now thought to have a better effect. Geo-polymers also gain strength very quickly as well, obtaining 70%strength within the first three to four hours of production. Disposal of waste products such as fly ash has been difficult because it must be stored in such a way that it does not seep into ground water and must have structural stability with respect to adverse environmental conditions. Alkali activation become the most costeffective solution to this problem and can be utilized in precast structures and concrete products that are resistant to heat and environmental decay. It can give a variety of characteristics, depending on the mix design, including high compressive strength, light weight and resistance to acid decay. It also has a significantly reduced energy requirement for manufacture of materials involving geo-polymers.

Recently, the application of many structures gets sub stained from normal concrete to light weight concrete because of its advantage and eco-friendly nature. For many years light weight concrete has been used successfully for structural purposes. Structural applications are related with foundation size and construction cost. The density of light weight concrete is often more important than the strength. Light weight concrete with the same strength level may reduce the self-weight consequence of decreased density. It has obvious advantage of high strength/weight ratio, good tensile strength, low coefficient of thermal expansion, waste utilizing, heat preservation, noise insulation characteristic, and energy saving, as well as good absorbability of impacting energy due to air void in light
6

weight aggregate. Impact resistance of light weight concrete is affected by strength, density, the lower modulus elasticity and tensile strain capacity.

2.2 Light weight bricks:

It is a new generation building block that helps in creating sustainable buildings and infra structure. Light weight bricks are autoclaved aerated bricks. Block: - A concrete masonry unit, any one of the external dimensions of which is greater than the corresponding dimensions of a brick as specified in IS: 3952 1978 and of such size and mass as to permit it to be handle by one man further more to avoid confusion with slabs and panels, the height of the block shall not exceed either its length or six times its width.

2.3 Classification of light weight bricks:

There are three types of light weight bricks. They are 1. 2. 3. Infill. Jumbo. Thermal bricks.

2.3.1 Infill bricks:

The size of the Infill Light weight brick is 600600 mm and the thickness varies in the ranges of 75,100,125,150,200 mm. The main advantage of Infill bricks is that they can easily replace 60% of the concrete in roof slabs and thus help in saving significant amounts of concrete, steel, labor, water, plaster etc. These bricks are especially suitable for building roofs in large column-free constructions.

Advantages:
1. 2. One fourth of Density of Concrete. Self weight of roof slab reduces by 27%
7

3. 4. 5. 6. 7.

Economical due to less dead loads. Provides very high insulation to roof. Ribbed slab construction. Gives flat soffits on completion. No edge & inside finishing of ribs required.

8. 9.

Enables faster construction. Saving in centering costs

Applications:
1. Any Roof with large column free constructions. 2. 3. 4. 5. Commercial and multistoried buildings. Extension of unplanned floors. Fire rated buildings. Air-conditioned buildings

2.3.2 Jumbo bricks:

Jumbo bricks are typically in the size of 600300 mm, and thickness ranges from 75,100,125,150, to 200 mm. The unique large size of Jumbo Light weight bricks results in the usage of much fewer bricks and hence less mortar is required. These bricks are more suitable for non-load bearing walls, multi-storied buildings etc.

Applications:
1) Suitable for both load-bearing and non load-bearing walls. 2) Ideal for multi-storeyed buildings. 3)Most suitable where thermal comforts at home and savings in air-conditioning cost are
8

desired. 4) Suitable for all fire-rated applications.

Advantages:
1) Savings in mortar. 2) Faster construction. 3) Enhanced thermal and sound performance due to less joints. 4) Economic design -Savings in cement and steel. 5) Easy handling even jumbo size due to lower density. 6) Light-weight -1/3rd the density of clay bricks.

2.3.3 Thermal bricks:

These bricks are also called as aero cool thermal bricks whose size and thickness is 300200 mm and 50 mm respectively. These bricks are ideal for roofing since they delay the transmission of heat flow and also help interiors remain warm during winters and cool during summers.

2.4 Advantages of light weight bricks:

1. Saves approximately 20% in construction cost (Steel, sand, cement) 50% labour and

also saves 70% time in construction of walls. 2. 3. 4. A single large size block can replace almost 16 bricks. So, speed in construction. Accuracy with uniform size (i.e, easy, faster and excellent workability). Reduces the deadweight of a structure, bring light weight with high compressive strength. 5. 6. 7. 8. Bricks available in various sizes (24inch8inch4inch, 6 inch, 8 inch and 9 inch). High thermal insulation (natural cooling and power saving). High resistant to fire, sound, weather and earth quakes. Can be cut easily into various shapes and sizes, easy to machine can even be carved to murals. 9. Easy to be integrated into existing designs without major change.
9

10.

Easy to cut conduits, boxes, for concealing pipes, electrical etc.

CHAPTER - III
EXPERIMENTAL PROCEDURE 3.1 Materials required for fabrication of light weight bricks:
For fabrication of light weight bricks, the following materials are taken with suitable proportions. They are:1. 2. 3. 4. 5. 6. Water Fly ash Gypsum Cement Lime Aluminium

3.1.1 Properties of Fly ash:

Fly ash is a fine, glass powder recovered from the gases of burning coal through the production of electricity. These micron-sized earth elements consist mainly of silica, alumina and iron. When mixed with lime and water the fly ash form a cementations compound with property very similar to that of Portland cement. Because of this similarity, fly ash can be used to replace a portion of cement in the concrete, providing some discrete quality advantages. The concrete is denser resulting in a tighter, smoother surface with less bleeding. Fly ash concrete offers a distinct architectural benefit with better textural consistency and sharper detail. Fly Ash is also known as Coal Ash, Pulverized Flue Ash, and Pozzolona. Fly ash closely resembles volcanic ashes used in production of the earliest known hydraulic cements about 2,300 years ago. Those cements were made near the small Italian town of Pozzuoli - which later gave its name to the term "pozzolan." A pozzolan is a siliceous or siliceous/aluminous material that, when mixed with lime and water, forms a cementations compound. Fly ash is the best known, and one of the
10

most commonly used, pozzolans in the world. Instead of volcanoes, today's fly ash comes primarily from coal-fired electricity generating power plants. These power plants grind coal to powder fineness before it is burned. Fly ash - the mineral residue produced by burning coal - is captured from the power plant's exhaust gases and collected for use. Fly ash is a fine, glass powder recovered from the gases of burning coal during the production of electricity. These micron-sized earth elements consist primarily of silica, alumina and iron. The difference between fly ash and Portland cement becomes apparent under a microscope.

11

Increased use as a partial cement or lime replacement would also correspond to savings in energy since fly ash has been called a high-energy-based material (Hausmann, 1990). Fly ash utilization, in particular in concrete, has significant environmental benefits.

Chemical Composition and Classification:

Fly ash particles are in general spherical in shape and range in size from 0.5 m to 100 m. They consist mainly of silicon dioxide (SiO2), which is present in two forms: amorphous, which is rounded and smooth, and crystalline, which is sharp, pointed and hazardous; aluminium oxide (Al2O3) and iron oxide (Fe2O3). Fly ashes are in general highly heterogeneous, consisting of a concoction of glassy particles with various exacting crystalline phases such as quartz, mullite, and various iron oxides. Fly ash also contain environmental toxins in major amounts, jointly with arsenic -43.4 ppm, barium -806 ppm, beryllium -5 ppm, boron -311 ppm, cadmium -3.4 ppm, chromium -136 ppm, chromium VI -90 ppm, cobalt -35.9 ppm, copper- 112 ppm, fluorine -29 ppm, lead 56 ppm, manganese -250 ppm, nickel- 77.6 ppm, selenium -7.7 ppm, strontium -775 ppm; thallium -9 ppm, vanadium -252 ppm, and zinc -178 ppm. Two classes of fly ash are defined by ASTM C618: Class F fly ash and Class C fly ash. The chief difference between these classes is the amount of calcium, silica, alumina, and iron content in the ash. The chemical properties of the fly ash are largely subjective by the chemical content of the coal burned (i.e., anthracite, bituminous, and lignite).

12

Table: 3.1.1

PARAMETERS

RANGE

Specific Gravity

1.90 2.55

Plasticity

Non plastic

Maximum dry density (gm/cc)

0.9 1.6

Optimum moisture content (%)

38.0 18.0

Cohesion (KN/m2)

Negligible

Angle of internal friction (j)

300 400

Coefficient of consolidation Cv (cm2/sec)

1.75 x 10-5 2.01 x 10-12

13

Compression index Cc

0.05 0.4

Permeability (cm/sec)

8 x 10-6 7 x 10-4

Coefficient of uniformity

3.1 10.7

14

Uses of Fly Ash:

1. Portland cement. 2. Embankments and structural fill. 3. Waste stabilization and solidification. 4. Raw feed for cement clinkers. 5. Mine reclamation. 6. Stabilization of soft soils. 7. Road sub base. 8. Aggregate. 9. Flow able fill. 10. Mineral filler in asphaltic concrete. 11. Application on rivers to melt ice. 12. Used as a sub-base product in pavement design. Environmental benefits: - Fly ash utilization has significant environmental benefits. They are:1. 2. 3. 4. 5. It increases the life of concrete roads and structures by improving concrete durability. It helps in net reduction in energy use and green house gas. It can be used to replace or displace manufacturedcement. Reduction in amount of coal combustion products as it is used in other purposes. Conservation of other natural resources and materials.

Advantages of Addition of Fly Ash in light weight bricks:

15

1. 2. 3.

Increased (later) Compressive Strength Increased Workability Reduced the heat of hydration (CANMET, Canada found that 10 ft cubes had a temperature rise of only 35 deg Celsius vs. 65 deg using Portland cement)

4.

No leaching of Calcium Hydroxide crystals occurs on to the surface (those white patches)

5.

Increased Durability -(low Chloride Ion penetration, i.e. very low coulomb rating that further decreases with time).

6. 7. 8. 9.

Decreased Permeability Reduced Sulfate Attack Decreased Bleeding & Segregation Reduced Drying Shrinkage

3.1.2 Properties of gypsum:

Gypsum is an evaporate mineral most commonly found in layeredsedimentary deposits in association with halite, anhydrite, sulfur, calcite and dolomite. Gypsum (CaSO4.2H2O) is very similar to Anhydrite (CaSO4). The chemical difference is that gypsum contains two waters and anhydrite is without water. Gypsum is the most common sulfate mineral. Table: 3.1.2

Physical Properties of Gypsum

Color Streak Luster Diaphaneity Cleavage clear, colorless, white, gray, yellow, red, brown White Vitreous transparent to translucent Perfect
16

Mohs Hardness Specific Gravity Distinguishing Characteristics Chemical Composition Crystal System

2 2.3 cleavage, specific gravity, low hardness hydrous calcium sulfate, CaSO4.2H2O Monoclinic

Uses of Gypsum uses include: manufacture of wallboard, cement, plaster of Paris, soil conditioning, a hardening retarder in Portland cement. Varieties of gypsum known as "satin spar" and "alabaster" are used for a variety of ornamental purposes, however their low hardness limits their durability.

Gypsum from Grand Rapids, Michigan. Specimen is approximately 4 inches (10 centimeters) across.

17

Gypsum from North Holston, Virginia. Specimen is approximately 1-1/2 inches (3.8 centimeters) across.

3.1.3 Properties of Aluminium:

Aluminium has a unique and unbeatable combination of properties that make it into a versatile, highly usable and attractive construction material. Weight: - Aluminium is light with a density one third that of steel, 2.700 kg/m3. Strength: - Aluminium is strong with a tensile strength of 70 to 700 MPa depending on the alloy and manufacturing process. Extrusions of the right alloy and design are as strong as structural steel. Elasticity:-The Youngs modulus for aluminium is a third that of steel (E = 70,000 MPa). This means that the moment of inertia has to be three times as great for an aluminium extrusion to achieve the same deflection as a steel profile. Formability: - Aluminium has a good formability, a characteristic that is used to the full in extruding. Aluminium can also be cast, drawn and milled. Machining: - Aluminium is very easy to machine. Ordinary machining equipment can be used such as saws and drills. Aluminium is also suitable for forming in both the hot and the cold condition. Joining:- Aluminium can be joined using all the normal methods available such as welding, soldering, adhesive bonding and riveting. Corrosion resistance: - A thin layer of oxide is formed in contact with air, which provides very good protection against corrosion even in corrosive environments. This layer can be
18

further strengthened by surface treatments such as anodizing or powder coating. Conductivity: - The thermal and electrical conductivities are very good even when compared with copper. Furthermore, an aluminium conductor has only half the weight of an equivalent copper conductor. Linear expansion: - Aluminium has a relatively high coefficient of linear expansion compared to other metals. This should be taken into account at the design stage to compensate for differences in expansion. Non-toxic:- Aluminium is not poisonous and is therefore highly suitable for the preparation and storage of food. Reflectivity:-Aluminium is a good reflector of both light and heat.

Uses of aluminium powder in light weight bricks:

1. It is make up flakes solvent water surface, and it has active and scatter, and it is mainly used air entrapping beton and air-entrapping brick. 2. 3. 4. Good hydrophilic and dispersion in water. Stable bubbles. Uniform particle size, small distribution range.

Specifications:
Grade:-GLY-75. Solid Content:-70 D50:-From 20 to70 um Type:-Aluminum flake powder.

3.1.4 Properties of Lime:

The use of lime as a cementing material has been made since ancient times. Even in India, the various engineering structures such as big palaces, bridges, monuments etc. were constructed with lime as a cementing material and some of these structures still exist in perfectly good condition.

Sources of lime:
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The lime is not usually available in nature in Free State. It is produced by burning one of following materials. 1. 2. Lime stones from the stone hills, Boulders of lime stones from the beds of old rivers, 3) Kankar found below the ground, and 4) Shells of sea animals. It may be noted that white chalk is pure lime stone and kankar is an impure lime stone.

Specifications of lime:
The building limes according to BIS:712-1984 are classified under six categories, namely, Class A, Class B, Class C, Class D, Class E and Class F. Class A:-Class A lime is the eminently hydraulic lime which is used for structural purpose and it is to be supplied in the hydrated form only. Class B:-Class B lime is the semi hydraulic lime which is used for mortars for masonry work and it can be supplied either as quick lime or as hydrated lime. Class C:-Class C lime is the fate lime which is used mainly for finishing coat in plastering, whitewashing and with suitable admixture such as surkhi or any other pozzolanic material to produce artificial hydraulic mortars. Class D:-Class D lime is the magnesium or dolomitic lime which is used for finishing coat in plastering, whitewashing, etc. It is to be supplied in hydrated or quick form. Class E:-Class E lime is the kankar lime which is used for the masonry mortars and it is to be supplied in the hydrated form only. Class F:-Class F is the siliceous dolomitic lime which is used for undercoat and finishing coat of plaster. It is to be supplied in hydrated or quick form.

Uses of lime:-The lime is an important engineering material and its uses can be enumerated
as follows: 1. It is used as chemical raw material in the purification of water and for sewage treatment.
20

2. 3. 4. 5. 6. 7. 8.

It is used as flux in the metallurgical industry. It is used as matrix for concrete and mortar. It is used as refractory material for lining open-hearth furnaces. It is used in the production of glass. It is used for making mortar for masonry work. It is used for plastering of walls and ceilings. It is used for production of artificial stone, lime-sand brick, foam silicate products, etc.

3.1.5 Properties of cement:

The natural cement is obtained by burning and crushing the stones containing clay, carbonate of lime and some amount of carbonate of magnesia. The clay content in such stones is about 20 to 40%. The natural cement is brown in colour and its best variety is known as The Roman Cement. Following points of differences may be noted between ordinary cement and lime: 1) The cement can be used under conditions and circumstances which are not favourable for lime. 2) The cement, when converted into paste form, sets quickly. 3) The colours of cement and lime are different. 4) When water is added to the cement, no heat is produced and there is no slaking action. Following are the important properties of good cement which primarily dependent upon its chemical position, thoroughness of burning and fineness of grinding. 1. 2. 3. 4. It gives strength to masonry. It is an excellent binding material. It is workable. It offers good resistance to the moisture.
21

5. 6.

It possesses a good plasticity. Its stiffness or hardness early.

3.2 Mix proportions:

The following are the various proportions are taken into account for fabrication of light weight bricks. Table : 3.2

S.NO

MIX IDENTIFICATION

CEMENT (gm)

LIME (gm)

FLYASH (gm)

GYPSUM (gm)

ALUMINIUM (gm)

WATER (ml)

M1

1200

1500

750

350

12.5

1000

M2

2000

1500

750

350

12.5

1000

3.3 Casting and curing procedure:

During the production, fly ash and water are mixed together to form a slurry. This mixture is then heated and transferred to a high speed mixer, to which the rest of the ingredients like lime, cement, and aluminum powder are added. During mixing process, a chemical reaction takes place between the ingredients and as a result small bubbles are formed in the mixture which form the characteristic cellular or aircrete structure. A little later, when the mixture is partially set, it is wire cut into pre-determined sizes. These cut bricks are then transferred into autoclaves for high pressure steam AAC. This autoclaving assisted by aeration process is what gives the unique, light-weight cellular structure as well as dimensional stability to the Light weight block.

Steps involved in fabrication of light weight bricks:

The following are the various steps involved for the fabrication of light weight bricks. They are:
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1) Purchasing of materials. 2) Weighing of materials. 3) Mixing of materials in variable proportions. 4) Placing of mixture into moulds. 5) Removal of excess material in sample bricks. 1) Purchasing of materials: - Raw materials like fly ash, cement, lime, gypsum and aluminium are purchased into desired proportions. 2) Weighing of materials: - After purchasing of materials, it is weighed in weighing machine accurately as per requirement. 3) Mixing of materials in variable proportions: - Generally mixing of materials can be performed by either hand mixing or by using equipment (Generally Concrete Mixture). Various proportions are taken accordingly by requirements and it is mixed by using both processes. 4) Placing of mixture into moulds: - After mixing of materials, obtained mixture is placed on required moulds (Depending on dimensions of mould boxes). About three-fourth of mould is filled with mixture and the remaining material is expended due to the reason that there is formation of bubbles. 5) Removal of excess material in sample bricks: - For perfect finishing of bricks, the excess material in the mould are removed by using hacksaw, metallic wire etc. After removal of excess material, it is placed at room temperature for 24 hours. Lastly, Light weight bricks are placed in muffle furnace at the temperature around 2000C by supplying continuous amount of electric current about 8 hours.

23

24

FIGURE: 1 MOULD

25

FIGURE: 2 MIXER

26

FIGURE: 3 WEIGHING MACHINES

27

FIGURE: 4 MUFFLE FURNENCE

28

FIGURE: 5 COMPRESSION TESTING MACHINE

29

FIGURE: 6 SWELLING OF CEMENT

30

FIGURE: 7 MOULD AFTER CUTTING THE SWELLED PART

31

FIGURE: 8 LIGHT WEIGHT BRICKS

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3.4 Testing of Bricks as per is 3495-1966:

Before using the bricks for any important engineering work, they should be tested to know their suitability of for the work. For testing the bricks, generally 50 No. are selected for every consignment or from a stack of 50,000 bricks. The selection of samples of bricks may be by any one of the following two methods:i: Sampling in motion:- In this method, some samples of bricks shall be taken when bricks are being moved as in the case of loading or unloading at regular intervals so as to get a true ii. Sampling from a Stack:- In this method, samples shall be takes out at random from a stack of bricks. The number of bricks requiredfor the test shall be selected from the top, the sides and interior of the stack. The samples, taken by either of two methods, shall be storedin a dry place until the tests are completed. The following tests are generally performed for testing the common building bricks: 3.4.1 Dimensions and Tolerance test 3.4.2 Compressive strength test 3.4.3 Water absorption test. 3.4.4 Density test

3.4.1 Dimensions and Tolerances Test:

Purpose: - This test is performed to know the accuracy of the dimensions of the bricks which should be within the specified limits. Method: - In this test, twenty bricks out of the samples already taken, are selected at random. All blisters, loose particles of clay and small projections shall be removed. They shall be then arranged upon a level surface in contact with each other and in a straight line according to the dimensions to be measured. The overall length of the assembled bricks shall be measured at one stretch by means of a steel tape. If for any reason, it is found impracticable to measure 20 bricks in one row, the sample may be divided into two rows of 10 bricks each, and shall be measured separately to the nearest millimeter. All these dimensions shall be added together and checked.
33

3.4.2 Compressive Strength:

Purpose: - This test is performed to know the crushing strength of bricks which should not be less than the specified limit. Method: - In this test, five bricks out of the samples already taken, are selected at random. They are immersed in water at room temperature for 24 hours. Then, the bricks are taken out from water and wiped free from surplus moisture at room temperature. After this, their frogs and all voids in the bed and face shall be filled with cement mortar 1:1 (1 cement, 1clean coarse sand of grain size 3 mm and down). The bricks shall then be storedunder damp stacks for 24 hours. After the expiry of this period, they shall be immersed in water for three days. At the end of t here days, the samples of bricks shall be taken, out, wiped dry. Then, each brick shall be placed between two or three thin ply wood sheets, each approximately 3 mm thick, with flat surfaces horizontal and the mortar filled face upward. This arrangement shall be carefully centered between the plates of compression testing machine. The load shall be applied at a uniform rate of 104 kg/sq/cm (14N/sq.cm) per minute until failure occurs. The maximum load at failure divided by the area of the brick is taken as its compressive strength. Result: The arithmetic mean of the compressive strength of five such tests shall be taken as the compressive strength of the lot or stacks where from the samples have been taken. Note: The compressive strength of any individual brick shall not fall below average compressive strength specified for the corresponding class of brick by more than 20% Common building brick shall have a minimum compressive strength of 35 kg/cm2

3.4.3 Water Absorption Test:

Purpose:-The strength of a bricks also depends upon its water absorption capacity. If the bricks have more water absorption capacity, it will loose its strength earlier. Before using the brick, it should, therefore be tested for its water absorption capacity. This should not be move than 20% by weight for 1st class bricks.

34

Method: - In this test, five bricks shall be selected at random out of the sample of bricks already taken. They are then dried in a ventilated oven at 105 to 1150C till they attain almost constant weight. The specimens shall then be cooled to room temperature and weighed. Let be W1 units. The dry and cooled specimens shall be completely immersed in clean water for 24 hours. Each specimen shall then be removed, the surface water wiped off with a damp cloth and then weighed. Weighing shall be completed within three minutes after removing the specimen form water. Let it be W1 units. Then the water absorption capacity of the specimen is found as given below: W1 = Weight of specimen W2 = Weight after soaking in water Water absorption (percentage of weight) = (W2 W1) x (100/W1) Result: - The average of the five specimens should be taken as the water absorption capacity of the lot of stack of bricks from where the samples have been taken. Note: - The average water absorption of common building bricks shall not be more than 20% up to class 125, and 15% for higher class by weight after immersion for 24 hours in coldwater

3.4.4 Density Test:

Purpose:-The strength of a bricks also depends upon its Density Test. If the bricks have more Density it will loose its strength earlier. Before using the brick, it should, therefore be tested for its Density Test. Method:-In this test, three bricks shell be selected at random out of sample of bricks already taken. Here we calculated the weight and volume of the brick and also calculate the density of the brick which is the ratio of weight and volume. And we found that light weight brick have low density when compared to conventional clay burnt brick.

35

36

CHAPTER - IV
RESULTS AND DISCUSSION For M1 Mix proportions:
In this chapter the test results were presented in the form of tables. The results of dimension and tolerance test were given in table 4.1

Table 4.1 Dimensions and Tolerance test:

S.No 1 Brick Light weight brick Length (mm) Width (mm) Height (mm) 386 178 178 Remarks 1999 cm

4.2 Water Absorption test:

In this chapter the test results were presented in the form of tables. The results of water absorption test for conventional clay burnt brick were given in table 4.2.1

4.2.1 Conventional clay burnt brick:

Table: 4.2.1 Weight of specimen S.No Brick Weight of the specimen, (W1) 1 2 3 1 2 3 2724 2663 2460 Water Absorption =

after soaking in water, (W2 - W1) 100 ( W1) (W2) 3258 3033 2912 19.60 13.89 18.37

37

In this chapter the test results were presented in the form of tables. The results of water absorption test for light weight brick were given in table 4.2.2

4.2.2 For light weight brick:

Table: 4.2.2 Weight of specimen S.No Brick Weight of the specimen, (W1) 1 2 3 1 2 3 2150 2140 2122 Water Absorption =

after soaking in water, (W2 - W1) 100 ( W1) (W2) 2350 2330 2250 9.30 8.15 6.03

4.3 Compressive Strength:

In this chapter the test results were presented in the form of tables. The results of compressive strength for conventional clay burnt brick were given in table 4.3.1.

4.3.1 Conventional clay burnt brick: Table: 4.3.1

Contact S.No Brick Weight Length Breadth (mm) 1 2 1 2 2429 2372 190 190 (mm) 95 95 Height (mm) 90 95 Area (mm2) 8550 9025 20.9 23.7 Load (KN) Compressive Strength (KN/mm2) 2.44 2.6

38

2437

190

100

95

9500

18.6

1.95

In this chapter the test results were presented in the form of tables. The results of compressive strength for light weight brick were given in table 4.3.2.

4.3.2 Light weight brick:

Table: 4.3.2 Contact S.No Brick Weight Length Breadth (mm) 1 2 3 1 2 3 1810 1955 1818 190 190 190 (mm) 95 102 105 Height (mm) 100 100 100 Area (mm2) 9500 10200 10500 15.1 21.3 16.6 Load (KN) Compressive Strength (KN/mm2) 1.59 2.08 1.58

4.4 Density Test:

In this chapter the test results were presented in the form of tables. The results ofdensity test were given in table 4.4 S.NO 1 BRICK Light weight Brick 2 Conventional Clay burnt brick 2.7 0.001995 1353 WEIGHT(Kg) 1.4 Volume(m3) 0.001624 Density 862

39

FOR M2 MIX PROPOTION

In this chapter the test results were presented in the form of tables. The results of dimension and tolerance test were given in table 4.5

4.5 Dimensions and Tolerance test:

S.No Brick Length (mm) 1 Light weight brick 386 178 178 1999 cm Width (mm) Height (mm) Remarks

4.6 Water Absorption test:

In this chapter the test results were presented in the form of tables. The results of water absorption test for conventional clay burnt brick were given in table 5.2.1

4.6.1 Conventional clay burnt brick:

Weight of the S.No Brick specimen, (W1) Weight of specimen Water Absorption =

after soaking in water, (W2 - W1) 100 ( W1) (W2)

1 2 3

1 2 3

2724 2663 2460

2350 3033 2912

9.30 13.89 18.37

In this chapter the test results were presented in the form of tables. The results of water absorption test for light weight brick were given in table 4.6.2

4.6.2 Light weight brick:

Weight of specimen S.No Brick Weight of the specimen, (W1) Water Absorption =

after soaking in water, (W2 - W1) 100 ( W1) (W2)

40

1 2 3

1 2 3

1500 1550 1450

1620 1640 1580

8.01 5.01 8.09

4.7 Compressive Strength:

In this chapter the test results were presented in the form of tables. The results of compressive strength for conventional clay burnt brick were given in table 5.6.1.

4.7.1 Conventional clay burnt brick:

Contact S.No Brick Weight Length Breadth (mm) 1 2 3 1 2 3 2429 2372 2437 190 190 190 (mm) 95 95 100 Height (mm) 90 90 95 Area (mm2) 8550 9025 9500 20.9 23.7 18.6 Load (KN) Compressive Strength (KN/mm2) 2.44 2.60 1.95

In this chapter the test results were presented in the form of tables. The results of compressive strength for light weight brick were given in table 4.7.2.

4.7.2 Light weight brick:

41

Contact S.No Brick Weight Length Breadth (mm) 1 2 3 1 2 3 1810 1955 1818 190 190 190 (mm) 95 102 105 Height (mm) 100 100 100 Area (mm2) 9300 10300 10400

Load (KN)

Compressive Strength (KN/mm2)

36.2 42.3 41.3

3.89 4.10 3.97

In this chapter the test results were presented in the form of tables. The results of density test were given in table 4.8

4.8 Density Test:

S.NO 1 BRICK Light weight Brick 2 Conventional Clay burnt brick 2.7 0.001995 1353 WEIGHT(Kg) 1.4 Volume(m3) 0.001624 Density 862

4.9 STASTICAL COMPARISSION B/W CLAY BRICKS AND LIGHT WEIGHT BRICKS 4.9.1 Water absorption test:
GRAPH: 1

42

M1 MIXED PROPORTION
CLAY BRICK LIGHT WEIGHT BRICK

19.6

18.37 13.89 9.3

8.15 6.03

BRICK 1

BRICK 2

BRICK 3

M2 MIXED PROPORTION
CLAY BRICK LIGHT WEIGHT BRICK 18.37

13.8

9.3 8.01 5.01 8.09

BRICK 1

BRICK 2

BRICK 3

4.9.2 Compressive strength test:

GRAPH: 2
43

M1 MIXED PROPORTION
CLAY BRICKS LIGHT WEIGHT BRICKS

2.44

2.6 2.08 1.59 1.95 1.58

BRICK 1

BRICK 2

BRICK 3

M2 MIXED PROPORTION
CLAY BRICK LIGHT WEIGHT BRICK

3.89

4.1

3.97

2.44

2.6 1.95

BRICK 1

BRICK 2

BRICK 3

4.9.3 Density test:

44

GRAPH: 3 M1 MIXED PROPORTION

CLAY BRICK LIGHT WEIGHT BRICK

1353

862

BRICK 1

M2 MIXED PROPORTION
CLAY BRICK LIGHT WEIGHT BRICK

1353

862

BRICK 1

45

CHAPTER - V
CONCLUSION AND FUTURE SCOPE 5.1 Conclusion:
The following observations were made from the test results. 1. Compressive strength increases and it is compared with conventional clay burnt brick by taking 3 different brick sizes. 2. Percentage water absorption for light weight bricks is less than conventional clay burnt brick. 3. 4. Dimensions and tolerances test also performed and remarks are noted. Density test for light weight bricks is less than conventional clay burnt brick.

Results are satisfactory therefore ordinary conventional bricks can be replaced with light weight bricks discussed in this project and can be used as building bricks with the advantage of reduced dead weight of the structure

5.2 Future scope:

The following of the points to be taken into priority for future plan of work: 1. By changing suitable proportions of materials like aluminium powder, fly ash, gypsum, cement and lime may change the characteristic properties of light weight bricks. 2. By adding of finely crushed sand material along with the following composition may increase the strength. 3. Replacing cement by Pulverized Fuel Ash and Blast Furnace Slag along with fly ash, aluminium powder and gypsum may vary the weight, fire resistant and also increases durability. 4. 5. Increasing of aluminium powder may decrease the weight of the light weight bricks. Mixing of husk ash long with cement and gypsum may vary the properties of bricks.

46

6.

Fire resistant, sound insulation, thermal insulation etc. tests can also be performed and compared with the conventional clay burnt bricks.

BIBLIOGRAPHY

1. 2. 3.

Engineering materials by Rangawala. Civilsolution.wordpress.com Concrete technology by Ms.Setty IS: 6441:1972 Part 1 IS: 6441:1972 Part 5 IS: 21985 Part 3 IS: 6011:1984 IS:6011:1985 IS: 3495(part-1):1992- method of tests of burnt clay building bricks, part: 1 determination of compressive strength.

4.
5. 6. 7. 8. 9.

10.

IS: 3495(part-2):1992- method of tests of burnt clay building bricks, part: 2 determination of water absorption.

11. 12.

High performance bricks from fly ash by O. Kayali Veisn.S The use of polystyrene in light weight brick production, Iranian plymer journal vol 12,no:4-pp.324-329,2003.

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