Page 1 of 3
Journal for Studies in Management and Planning
Available at http://internationaljournalofresearch.org/index.php/JSMaP
e-ISSN: 2395-0463
Volume 01 Issue 03
April 2015
Available online: http://internationaljournalofresearch.org/ P a g e | 381
Feasibility Study of Acid Resistant Brick Using
Raw and Waste Materials
Tamil selvan.P1, Gokulnath.C2, Satheesh Kumar3, Suresh Kumar.S4,uma shankar.K5, Arun
Prakash.K6
1,2,3,4 Final Year Civil Engineering students, Knowledge Institute of Technology, Civil Engineering Department,
Salem, Tamil Nadu, India-638183
5,6Assistant Professor, Knowledge Institute of Technology, Civil Engineering Department, Salem, Tamil Nadu,
India-638183
ABSTRACT:
The disposal of industrial wastes comprises one of the
major worldwide environmental problems as these
wastes render the environment unfriendly. The growing
demand for waste utilization has made solid wastes like
materials from granite processing industry, and blast
furnace slag to be absorbed into the ceramic composition
of bricks. The possibility of reduction of the production
costs provides a strong logic for use of this waste.Blast
furnace slag is a non-metallic by-product from ironand
steel industry which is generated during the conversion
ofiron ore or scarp iron to steel, along with coke for fuel.
Presence of hazardous elements such as Pb, Cd, Ni and
Cr are common in some steel slags which make the slag
environmentally harmful.
In this work, attempt has been made to develop Acid
Resistant Bricks from waste materials i.e. granite saw
dust derived during cutting and grinding of granite
blocks and blast furnace slag along with clay. The
different body formulations have been made in order to
study the effect of these three raw materials on the fired
properties of the acid resistant bricks. The body made
with the variation of raw materials have been fired at
three different temperatures and their behaviours with
respect to Apparent Porosity, Water Absorption, Bulk
Density and Firing Volume Changes as a function of
both temperature and granite:slag ratio was studied. It
has been observed that the vitrificationof the body
increased with the increase in granite content. This
increase is attributed to the increase in Feldpar content
which accompanies the increase of granite.
Keywords: Clay brick, Granite waste powder,
compressive strength, water absorption, Acid mass
loss.
1.INTRODUCTION
The disposal of industrial wastes comprises one of the
major worldwide environmental problems. In numerous
countries,the limitation of number of dumping landfill
sites and the general disposal methods has rendered the
environment unfriendly. Furthermore, as aconsequence
of environmental and financial considerations, there is a
growing clamour for wastes to be re-used or recycled.
Waste recycling, generated by the industries, as an
alternative to raw materials is not a new thing and has
been carried out successfully. The prime focus on waste
material utilisation is due to the exhaustion of the natural
resources, the conservation of not renewable
resources,and reduction in wastes disposal costs.
Solid wastes, such as the wastes from the granite industry
can be absorbed by the construction industry which is
listed as the most technologically active sector.Large
quantity of raw materials is used by the sector as well as
by the large volume of final products is used in
construction. The use of wastes as an alternative to raw
materials in the ceramic industry, which embodies part of
the construction industry, contributes to the
diversification of raw materials in the production of
ceramic bricks and tiles and reduces the costs in a
building.
The most promising business areas of the mining sector
are the Granite mining and process industry, with a mean
growth in the world production reported at 6% per year in
the last 10 years. The international trading is
approximately US$ 6 billion per year and around US$ 13
billion, taking into account tools, equipment,
etc.Generationof large amount of wastes in the industrial
sector is in the form of a mud which is basically
composed of SiO2, Al2O3, F2O3 and CaO, due to the
sawing and polishing processes, can cause serious
damages to the environment, such as soil and
underground water contamination, if not efficiently
treated before disposal.
2.EXPERIMENTAL PROCEDURE
The The raw materials that were used in sample
preparation for the production of acid resistant bricks are
• Clay
• Blast Furnace Slag
• Granite
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Journal for Studies in Management and Planning
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e-ISSN: 2395-0463
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April 2015
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FIGURE 1 : GRANITE AND GGBS POWDER
The three raw materials were ground into fine powder
form and mixed in different proportions to obtain
different ratios of the samples. The samples were then
pressed into pellets with the help of additives and fired at
three different temperatures i.e. 1050°C, 1100°C and
1150°C. The different fired compositions were studied
for different characterizations
2.MIXING AND FABRICATION OF BRICKS
Powders were dry mixed in different compositions to
make a dry mix. The batches were dry mixed in a mortar
pestle to ensure homogenisation.
Pellets of each batch were prepared by uniaxial pressing
at 970.8 kg/cm2. Pellets were oven dried at 80°C/24
hours.
The pellets were then fired in a furnace at 1050°C,
1100°C and 1150°C with a soaking time of 4 hours. The
fired pellets were then characterised for Apparent
Porosity, Water Absorption, Firing Shrinkage, Bulk
Density, Dimetral Compressive Strength and Acid Mass
Loss.
FIGURE 2 : CURING AND TESTING
3.TESTING AND RESULTS
Apparent Porosity depict the variation of apparent
porosity of the samples as a function of Granite: Slag
ratio and sintering temperature, wherein samples
prepared with (a) 40% clay, (b)50% clay, (c) 60% clay
and (d) samples sintered at 1100oC as a function of clay
content.
It could be observedfrom the figurethat with increase in
the firing temperature apparent porosity was found to
decrease for all the samples studied. It can also be
observed thatincrease in the granite content decreases the
apparent porosity of the samples. Granite is consists of
three minerals namely feldspar, mica and quartz
Density could be observed that all the samples studied
have an increase in the bulk density values with increase
in the firing temperature. It can also be observed that
increase in the granite content increases the bulk density
of the samples. Feldspar, mica and quartz are three
minerals which constitute the granite.
Water Absorption occurs with increase in the firing
temperature for all the samples studied. The inverse
correlation could be observed between the granite content
with the water absorption of the samples. Feldspar, mica
and quartz are three minerals which constitute the
granite. The increase in granite content correlates to an
increase in the amount of feldspar in the samples.
Acid mass loss could be observed that the mass loss %
decreases with increase in granite content for 40% clay,
50% clay and 60% clay. It is observed that the porosity of
the samples is more when formulated with low granite to
slag ration. However it decreases with the increase in
granite to slag ratio irrespective to the clay content in the
formulation
Compressive Strength values of all the samples are found
to be quite high in the range of 10 to 15 MPa. This higher
value can be attributed with the achievement of enhanced
vitrification in the sample. It is interesting to note that
these measured strength values does not show any
particular trend as a function of granite;slag ratio or the
clay content in the body.
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Journal for Studies in Management and Planning
Available at http://internationaljournalofresearch.org/index.php/JSMaP
e-ISSN: 2395-0463
Volume 01 Issue 03
April 2015
Available online: http://internationaljournalofresearch.org/ P a g e | 383
Granite:Slag
30
D.
11000C
40% Clay
50% Clay
20 60% Clay
A.P. %
10
0
-1 0 1 2 3 4 5 6
Granite:Slag
FIGURE 3 : LINEAR REPRESENTATION.
4.RESULT AND DISCUSSION
The experimental results carried out during the present
work would lead to the following discussion.
• The samples with higher granite content found
to be vritrified completely and could be
correlated with the granite content of the
sample.
• The samples with Water Absorption <2%, and
Acid Mass Loss <1.5% confirm to the IS 4860-
1968 to be used as acid resistant brick. The
study suggests that body formulations with
Clay-Granite-Slag ratio as 40-30-30, 40-40-20
and 40-50-10; 50-30-20 and 50-40-10; 60-30-
10 has a potential to be used as acid resistance
bricks.
5.CONCLUSIONS
• It can be observed thatincrease in the
granite content decreases the apparent
porosity of the samples. Granite isconsists of
three minerals namely feldspar, mica and
quartz. The increase in granite
contentcorresponds to an increase in the
amount of feldspar, mica and quartz.
• It could be observed that all the samples
studied have an increase in the bulk density
values with increase in the firing
temperature. It can also be observed that
increase in the granite content increases the
bulk density of the samples
• Samples prepared with higher amount of
clay are observed to have higher water
absorption as compared to that prepared with
low amount of clay.
• The sample surface area exposed to the acid
solution is expected to increase with the
porosity of the sample. Dissolution of brick
into the acid solution will increase with the
increase in exposed area of the sample.
Hence the samples prepared with low
granite:slag ratio showed higher dissolution
as compared to that prepared with high
granite to slag ratio.
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