A PROJECT REPORT

ON

TO STUDY THE EFFECT EGGSHELL POWDER ON THE

STRENGTH OF FLY ASH BRICK

SUBMITTED IN PARTIAL FULFILLMENT FOR THE AWARD

OF BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING

Submitted by - Ramendra Pratap Singh (1750800032)

Aditya Kumar Verma (1750800002)
Rakesh Kumar (1750800031)

BABU BANARASI DAS ENGINEERING COLLEGE

(Affiliated to Dr.A.P.J. Abdul Kalam Technical University, Lucknow)

AKTU College Code 508

1
 CERTIFICATE

This is to certify that this final year project entitled “design and analysis of to study the effect
eggshell powder on the strength of fly ash brick” is a bonafied record of work carried by
Ramendra Pratap Singh, Aditya Kumar Verma, and Rakesh Kumar, final year students
of Bachelor of technology in civil engineering.

This report is submitted to the department of civil engineering in partial fulfilment of required
for the award of bachelor degree in civil engineering in year 2021.

During development of the project they showed their sincere effort they have submitted their
project report that is very informative of general use while giving easy information.

PROJECT COORDINATOR HEAD OF DEPARTMENT

Mr. Raj Kumar Gupta Mr. Raj Kumar Gupta
(Assistant Professor) (Assistant Professor)

2
 DECLERATION

We hereby declare that the project entitled “design and analysis to study the effect eggshell
powder on the strength of fly ash brick” submitted by us in the partial fulfilment of the
requirement for the award of the degree of bachelor of technology (civil engineering) of Dr
A.P.J. Abdul Kalam Technical University, is record of our own work carried under the
supervision and guidance of Mr. Raj Kumar Gupta.

To the best knowledge this project has not been submitted to Dr.A.P.J Abdul kalam
Technical University or any other University or institute for the award of any degree.

Ramendra Pratap Singh (1750800032)

Aditya Kumar Verma (1750800002)
Rakesh Kumar (1750800031)

3
 ACKNOWLEDGEMENT

To success and final outcome of this seminar report required a lot of guidance and assistance
from many people I am extremely fortunate to have got this all along the completion of my
seminar work. Whatever I have done is only due to such guidance and assistance and I would
not forget to thank them.

I respect and thank our HOD, Prof. Mr. Raj Kumar Gupta for giving me an opportunity to
do the seminar work on study the effect eggshell powder on the strength of fly ash brick”
and providing us all support and guidance which made me complete the seminar to time. I am
extremely grateful to Mr. Raj Kumar Gupta for providing such a nice support and guidance
though she had busy schedule managing the company affairs.

I owe my profound gratitude to him who took keen interest on our seminar work and guided
us all along, till the completion of our project work by providing all the necessary
information for developing a good system.

I am thankful and fortunate enough to get constant encouragement, support and guidance
from all teaching staff of department of civil engineering which help us in successfully
completing our work. Also, I would to extend our sincere regard to all non teaching staff of
department of civil engineering and my friends for their timely support.

4
 ABSTRACT

Pulverized fuel ash commonly known as fly ash. It is a useful by-product from thermal power
stations using pulverized coal as fuel and has considerable pozzolanic activity. The national
resource has been gainfully utilized for manufacture to study the effect eggshell powder on
the strength on to study the effect eggshell powder on the strength of fly ash brick as a
supplement to common burnt clay buildings bricks leading to the conservation of natural
resources and improvement in environment quality.

These bricks are suitable for use in masonry construction just like common burnt clay bricks.
Production on to study the effect eggshell powder on the strength of fly ash bricks has already
started in the country and it is expected that this standard would encourage production and
use on mass scale. This stand lays down the essential requirements on study the effect
eggshell powder on the strength of fly ash bricks so as to achieve uniformity in the
manufacture of such bricks.

5
 TABLE OF CONTENTS
S.No Contents Page No.

1. Cover page
2. Certificate
3. Declaration
4. Acknowledgment
5. Abstract
1.1. Introduction
1.2. Type of fly ash bricks
1.3. Market demand
1.5. Fly ash
2.0. Literature review
3.1. Methodology
3.2. Clay bricks
3.3. Composition of clay bricks
3.9. Composition of fly ash brick
3.11. Fly brick uses
3.12. Various shape of brick used in construction
4.0. Experimental data analysis
4.1. To study the effect of egg shell powder on the strength of bricks
5.0. Data analysis and result
5.1. Testing
6.0. Conclusion remark and future scope
6.1. Inspection and quality control
7.0. Photo gallery
8.0. Reference

6
S. No. List of figure Page No.
3.1. Water absorption of fly ash brick
3.2. Bullnose brick
3.3. Cownose brick
3.4. Channel brick
3.5. Shaddle back brick
3.6. Hollow brick
3.7. Paving brick
3.8. Perforated brick
3.9. Cant brick
3.10. Arch brick
3.11. Water absorption clay brick and fly ash brick
3.12. Compressive strength of clay brick and fly ash brick
4.1. Pan mixer
4.2. Fully automatic fly ash brick plant
4.3. No of moulds
4.4. Fly ash brick

7
S. No. List of table Page No.
3.1. Chemical composition of fly ash of different coal
4.1. Compressive strength of bricks
5.1. Data analysis for future scope
5.2. Water absorption ratio
5.3. Difference of clay brick vs fly ash, egg shell bricks

8
CHAPTER-1

1.1 Introduction

Pulverized fuel ash commonly known as fly ash is a useful by-product from thermal power
stations using pulverized coal as fuel and has considerable pozzolonic activity. This national
resource has been gainfully utilized for manufacture of pulverized fuel ash-lime bricks as a
supplement to common burnt clay buildings bricks leading to conservation of natural
resources and improvement in environment quality.
Pulverized fly ash bricks are obtained from materials consisting of pulverized fly ash in
major quantity. Pulverized fly ash bricks are generally manufactured by intergrading blending
various raw materials are then moulded into bricks and subjected to curing cycles at different
temperatures and pressures. On occasion as and when required, crushed bottom fly ash or
sand is also used in the composition of the raw material. Crushed bottom fly ash or sand is
also used in the composition as a coarser material to control water absorption in the final
product. Thus pulverized fly ash and cement in presence of moisture form a calcium – silicate
hydrate which is binder material. Thus pulverized fly ash and egg shell brick is a chemically
ended bricks. These bricks are suitable for use in masonry construction just like common
burnt clay bricks. Production of pulverized fly ash bricks has already started in the country
and it is expected that this standard would encourage production and use on mass scale. This
stand lays down the essential requirements of pulverized fuel ash bricks so as to achieve
uniformity in the manufacture of such bricks.

Fly ash bricks manufacturing units can be set up nearby thermal power stations .Because the
main raw material is fly ash is generated by thermal power stations in big quantity. Fly ash
supplied by thermal power stations at free of cost the entrepreneur has to bare only
transportations charges from thermal power stations to the fly ash bricks manufacturing unit.

9
1.2. Type of fly ash bricks:-

1.2.1. Class F- FA normally produced by burning anthracite or bituminous coal, usually

has less than 5% CaO (calcium oxide) . Class F FA has pozzolonic properties only.

1.2.2. Class C- FA normally produce by burning lignite or sub bituminous coal. Some
class c FA may have CaO content in excess of 10%. In addition to pozzolonic properties class
c FA also possesses cementitious properties.

1.3. Market demand:

There is good demand for fly ash and egg shell bricks. The awareness among the people is
required and also same time the government has to give some special incentives for these
types of activities. The technologies are eco friendly, Reduces solid waste and dust in the
nature. Compared to hallow brick and clay brick the cost is reasonable. Construction of wall
with these bricks is very easy and cost effective. Technology is indigenously available.
180 billion tones of common burnt clay bricks are consumed annually approximately 340
billion tones of clay- about 5000 acres of top layer of soil dug out for bricks manufacture, soil
erosion, emission from coal burning or fire woods which causes deforestation are the serious
problems posed by brick industry. The above problems can be reduced some extent by using
fly ash bricks in dwelling units.
In Chennai alone 1 corer bricks are required for constructional activities in every day. But
good quality of bricks as well as required quantity are not available moreover during the
rainy seasons supply of clay bricks are very difficult.

1.4. Benefits of fly ash and eggshell brick:

1.4.1. Engineers and Architects- Engineers and architects will find that fly ash
provides the following benefits:

1. It enables engineers and architects to provide the client with a superior and more durable
finished concrete.
2. It produces a high strength concrete that accommodates the design of thinner sections.
3. It permits design flexibility accommodating curves, arches and other pleasing architectural
effects.
4. The addition of fly ash and eggshell to the mix is a built-in insurance for later-age strength
gain in concrete.
5. It ensures that the concrete will qualify as a durable building material.
6. It contributes to the aesthetic appearance of the concrete

1.4.2. Developers, Contractors, Owners-

Fly ash concrete provides the following advantages to developers, contractors and owners:
1. The workability of fly ash concrete generally ensures that the speed of construction is
faster, which translates into a quicker return on investment.
2. Fly ash in the mix accommodates more creative designs.
3. Since fly ash concrete is not as vulnerable to deterioration or disintegration as rapidly as
concrete without fly ash, it ensures low- maintenance buildings that will retain their value
over the long-term

10
1.5. Fly ash:
There are several techniques for manufacturing construction bricks from fly ash, producing a
wide variety of products. One type of fly ash brick is manufactured by mixing fly ash with an
equal amount of clay, then firing in a kiln at about 1000 degrees C. This approach has the
principal benefit of reducing the amount of clay required. Another type of fly ash brick is
made by mixing soil, plaster of Paris, fly ash and water, and allowing the mixture to dry.
Because no heat is required, this technique reduces air pollution. More modern manufacturing
processes use a greater proportion of fly ash, and a high pressure manufacturing technique,
which produces high strength bricks with environmental benefits.
In the United Kingdom, fly ash has been used for over fifty years to make concrete building
blocks. They are widely used for the inner skin of cavity walls. They are naturally more
thermally insulating than blocks made with other aggregates.
There is, however, a problem with the bricks in that they tend to fail or produce unsightly
pop-outs. This happens when the bricks come into contact with moisture and a chemical
reaction occurs causing the bricks to expand.
This produces a strong product with good insulation properties and environmental benefits.

1.5.1. Advantages of fly ash:

 It is highly economical.
 Use of Fly Ash is environmentally friendly as the waste materials from industries are
effectively being used to create quality building materials.
 Fly Ash has very small particles which makes the concrete highly dense and reduces
the permeability of concrete. It can add greater strength to the building.
 The concrete mixture generates a very low heat of hydration which prevents thermal
cracking.
 Fly Ash concrete is resistant to acid and sulphate attacks.
 The shrinkage of fly ash concrete is very less.
 The use of fly ash gives concrete good work ability, durability and finish.
1.5.2. Disadvantages of Fly Ash
Smaller builders and housing contractors may not be familiar with fly ash products, which
can have different properties depending on where and how it was obtained. Additionally, fly
ash applications may face resistance from traditional builders due to its tendency to effloresce
along with concerns about freeze/thaw performance. Other concerns about using fly ash in
concrete include:

 Slower strength gain

 Seasonal limitation
 Increased need for air-entraining admixtures
 Increase of salt scaling produced by higher proportions of fly ash
 The quality of fly ash can affect the quality and strength of Cement concrete.
 Poor quality fly ash can increase the permeability of the concrete and cause damage to
the building.

11
1.6. Benefits:
Fly ash can be a cost-effective substitute for Portland cement in many markets. Fly ash is also
recognized as an environmentally friendly material because it is a byproduct and has
low embodied energy, the measure of how much energy is consumed in producing and
shipping a building material. By contrast, Portland cement has a very high embodied energy
because its production requires a great deal of heat. Fly ash requires less water than Portland
cement and is easier to use in cold weather. Other benefits include:

 Produces various set times

 Cold weather resistance
 High strength gains, depending on use
 Can be used as an admixture
 Considered a non-shrink material
 Produces dense concrete with a smooth surface and sharp detail
 Great workability
 Reduces crack problems, permeability, and bleeding
 Reduces heat of hydration
 Allows for a lower water-cement ratio for similar slumps when compared to no-fly-
ash mixes
 Reduces CO2 emissions

12
CHAPTER -2
2.0. LITERATURE REVIEW
2.1. Pravin Gadling and M.B. Varma et.al 2017, Journal of Construction
Engineering, Technology and Management ISSN: 2249-4723 (Online),
ISSN: 2347-7253 (Print) Volume 7, Issue 2
 In this paper, Masonry walls are commonly used in partition thereby large numbers of
brick elements are required in construction of building. In this paper, various types of
manufacturing of bricks were studied. Optimum percentage of fly ash using various
combinations of material in the brick like lime, cement and clay are studied and their
effect on different properties of bricks have been discussed. The parameters
considered in this study are compressive strength, water absorption and durability of
bricks. In this paper maximum compressive strength (8.90N/mm2) find when we mix
50% FA, 10%lime, 40% stone dust.
 The manufacturing of bricks using fly ash is environment friendly. The fly ash 70 to
80% used in manufacturing bricks is beneficial to increase in compressive strength.
Lime makes good combination with fly ash which increases durability of brick
element. Using fly ash in bricks reduces manufacturing cost of brick element.

2.2. Manish Kumar Sahu and Lokesh Singh et.al 11 Nov 2017,
International Journal of Mechanical And Production Engineering, ISSN:
2320-2092, Volume- 5, Issue-11, Nov.-2017
 In this paper in India bricks are mainly composed up of clay, and are generally
produced in traditional, unorganized small scale industries. Bricks are important
building material and about 250 billion bricks are annually produced by the industries.
Red clay bricks making consumes larger amount of clay which leads to top soil
removal and land degradation. Large areas of lands are destroyed every year
especially in developing countries due to collection of soil from a depth of about 1 to
2 m from agricultural land. An important step in brick making is firing of bricks in
brick kilns which causes serious environmental pollution and health problems. Brick
burning largely influence the concentrations of greenhouse gases in the atmosphere.
To avoid all this environmental threats brick made of waste that is originated from the
waste as a residue from the different industries and factories, this types of bricks is
termed as fly ash bricks which is composed by the different materials such as lime,
gypsum, sand, fly waste etc.
 Advantage of fly ash bricks over red bricks: Ash bricks is manufactured by the
use of semi auto and automatic machines, in these types of machines there is a
arrangement of hydro pressing with a pre attached mould. Approx 10 labours are
required to use this machine and the machines outputs 10000 bricks in 8-9 hours.
After the formation 3 curing is done till 15 days to provide strength to bricks. Where
as on the other side in the formation of red clay bricks mould of dimension
20x10x10cm are used. After moulding clay bricks are dried under the sunlight than it

13
 is oven in kilns by the use of cow dung, coal and wood at 1100oC.Than the bricks are
left undisturbed for 30 days.

2.3. N.Sivalingam (Asst. Director, Guindy, Chennai) et.al, march 2011.

 In this paper, Production Capacity Per Annum: 24 lakh bricks total value Rs.
78,00,000/
 Turnover Per Annum : Excepted sale 24 lakh bricks @ 3.40 per bricks 81,60,000

2.4.Harsha Bhaskaran, Linet John, Neethu. P. M,Traisy Sebastian and Er.

Niya Eldhose, et.al 2016, International Journal of Engineering Research &
Technology (IJERT) ISSN: 2278-0181.

 In this paper, influence in properties of concrete when cement is replaced by 5%, 10%
and 15% of egg shell powder it is found that egg shell powder can be used as cement
replacement material. Compressive strength was higher than control concrete for 5 %
Egg Shell Powder replacement at 7 days of curing ages. Egg Shell Powder
replacements greater than 10 % had lower strength than control concrete. Optimum
replacement of cement is up to 5%.Further strength can be improved in addition of
flyash.

2.5. Okonkwo, U. N; Odiong, I. C. and Akpabio, E. E.et.al april 2012,

International Journal of Sustainable Construction Engineering &
Technology (ISSN: 2180-3242) Vol 3, Issue 1, 2012

 In this paper to increase the eggshell ash content increased the Optimum Moisture
Content but reduced the Maximum Dry Density of the soil-cement eggshell ash
mixtures. Also the increase in eggshell ash content considerably increased the strength
properties of the soil-cement eggshell ash mixtures up to 35%.

2.6. Neeranuch Wangrungroj, Nussara Soontorntepwarakul, Surarit

Samattai and Nuchnapa Tangboriboon,et.al January 2018, ISSN: 1662-
9507, Vol. 382, pp 342-346 ,2018 Trans Tech Publications, Switzerland.

 The main composition of eggshell membrane is fibrous proteins as collagen type I, II,
III, IV, and V.The average collagen content is equal to 12.09 ± 0.42 g/100 g eggshell
membrane. The eggshell membrane composed of the chemical groups i.e. –NH3 +
and –CO-N+H2- namely amino acid. The highest amino acid content in eggshell
membrane is proline 17552 ± 745 mg/100 g. The zeta potential is a key indicator of
the stability of colloidal dispersions depending on pH. The magnitude of the zeta
potential indicates the degree of electrostatic repulsion between adjacent, similarly
charged particles in dispersion. The raw eggshell membrane was started at pH 7.82 (-
17.1 mV). It means the eggshell membrane particle is incipient instability and begins
to agglomerate. In addition, the XRD peak patterns of eggshell membrane will
transform from semi-crystalline to crystalline at high temperature.

2.7. K. Gourav and B. V. Venkatarama Reddy,et.al 2014 Journal of

Structural Engineering Vol. 41, No. 2, June - July 2014
14
  In this paper, Fly ash is used for the manufacture of masonry units such as fly ash
bricks and concrete blocks. This paper deals with results of an experimental
investigation on the characteristics of fly ash-lime-gypsum bricks and their masonry.
Characteristics (strength, absorption and durability) of compacted fly ash – lime
bricks with and without gypsum additive were examined. Compressive strength,
flexure bond strength and stress strain characteristics of fly ash brick masonry using
four types of fly ash bricks and cement-lime mortar were investigated. The results
reveal that (1) it is possible to achieve 8 – 10 MPa compressive strength in saturated
state, reasonably low values of water absorption, good dimensional stability and
durability characteristics for fly ash lime gypsum bricks using 10% lime and 2%
gypsum, (2) fly ash bricks of higher density can be produced using fly ash-sand
mixture, instead of fly ash alone and (3) fly ash brick masonry shows higher flexure
bond strength when compared with that of burnt clay brick masonry.
 These investigations clearly show the possibility of producing good quality bricks
using compacted fly ash-lime-gypsum mixtures. There is scope for selecting
optimum mix ratios of fly ash, sand, lime and other additives to obtain any specific
designed strength for the brick.

2.8. P.P. Gadling and Dr. M.B. Varma et.al January 2016, International
Journal for Scientific Research & Development| Vol. 4, Issue 09, 2016 |
ISSN (online): 2321-0613

 This paper presents Fly Ash brick properties, manufacturing process material
required for preparing the clay bricks and fly ash bricks as per Indian standard code
provisions, inspection and quality control. The textures of the bricks with Fly Ash
were very similar to that of clay bricks; the sample with the additive contains
spherical Fly Ash particles. These particles of Fly Ash led to a reduction in the
density of the bricks and a substantial improvement in their durability. Use of this
additive could have practical implications as a means of recycling and for achieving
cost savings in brick production. The absorption coefficient, shape and size, density,
weight, porosity, thermal conductivity and compressive strength of Fly Ash bricks
compare with normal clay bricks that delivered good results. From the present study,
it can be concluded that Fly Ash bricks used as an alternative to clay bricks.

 Fly ash used as wasted product and environment is directly protected by reducing
solid waste disposal. The average compressive strength of fly ash brick is (9 N/mm2)
In clay bricks, fly ash can also be used for the manufacturing process. The result of
40% fly ash with 60% Clay will be the good combination. Fly ash used as raw
material replacing of clay to make fired bricks is an effective measure of saving land
and decreasing pollution. The properties of the bricks improved with the firing
temperature. Fly ash does not modify the hydric properties of the bricks but it does
make them lighter. In fact, all the bricks with fly ash have a lower density. Fly ash
bricks show less damage than conventional bricks when exposed to salt
crystallization cycles. This improvement is due to the reduction of the surface area of
the bricks.

2.9. Md. Mainuddin, Md. Ruhul Amin, Sourav Sarkhel, Prasenjit

Bhowmick, Azharuddin Ahmed et.al December 2019, International Journal

15
of Innovative Technology and Exploring Engineering (IJITEE) ISSN:
2278-3075, Volume-9, Issue-2, December 2019

 The dead load of any structure varies depending on the type of bricks and its weight.
Due to the increased numbers of high rise buildings, lighter materials than normal
clay bricks are preferred. Fly-ash bricks are more popular presently since it weighs
28% less than clay bricks as well as shows higher strength .The strength is higher by
25% than commonly available bricks. Besides strength other characteristics such as
absorption capacity, modulus of rupture, initial rate of absorption, durability and bond
strength. The values thus obtained from the test shows excellent results as compared
to that of brick clay. The latest type of bricks has been given the name fly-ash bricks.
The key objective of the paper is to study the strength of fly ash brick using different
material proportion and also to improve the compressive stress and also to determine
the durability along with stability of the bricks.
 Fly ash based brick develop sufficient strength using both the hydride lime and the
cement as a binder material. By different trial ratios it is observed that fly ash based
bricks achieve more compressive strength for slug lime (cement) then hydride lime
even if using fifty percent of fly ash. Also it can be concluded that with a lesser
percent of cement a good strength of fly ash based brick can be prepared. Practically
the average weight of standard brick is 3.5 kg whereas the average weight of fly ash
brick is found to 2.58 kg which is more or less 26-30% lighter than the standard
modular brick. Due to less weight fly ash bricks the self-weight over the structure will
be reduced.

2.10. Nitin S. Naik1, B.M.Bahadure, C.L.Jejurkar et.al,march 2014,

International Journal of Computational Engineering Research (IJCER)

 In this paper, Burnt clay brick is an age old building material which is used for
housing in urban area as well as rural part of India. These bricks are manufactured
from good plastic clay, which is obtained from agricultural land. Excess use of
agricultural land for this clay results in loss of good fertile soil and diversion of
agricultural land for brick manufacturing. Manufacturing of bricks involved burning
of bricks using coal. Burning of bricks using coal produces green house gases leading
to environmental pollution. Fly Ash bricks are an alternative for the conventional
bricks which can be used effectively to replace the conventional bricks. Various
properties of these bricks were studied by different researchers and they found that
these bricks can be used for construction of low cost houses in the area in the vicinity
of thermal power plant.

 This paper is an attempt to study the strength and durability aspect of bricks prepared
using Fly Ash, Cement and Phosphogypsum. Based on the experimental investigation
reported in this study, following conclusions are drawn: Unique possibility exists for
the bulk utilization of fly ash in producing bricks in the proximity of thermal power
plants, phosphoric acid and fertilizer industries. The test cubes are having sufficient
strength and have potential as a replacement for conventional burnt clay bricks.
Cementitious binder with fly ash and phosphogypsum content equal to 90% gives
better compressive strength and 28.22 % water absorption and thus suitable for use in
construction industry. Being lighter in weight, it will reduce the dead weight and
material handling cost in multi storied constructions. When subjected to higher

16
 Sulphate concentration, the cementitious binders which gave low water absorption
exhibited a very low strength loss. From the testing of bricks for compression and
water absorption it can be concluded that such bricks are having sufficient strength to
be used as a replacement for traditional bricks. The water absorption of fly ash,
cement and phosphogypsum bricks is found more than 20%, but such bricks can be
used at places where water absorption is not a problem i.e. for curtain walls.

2.11. MAITI, D.PRASAD, B.et.al february 2016.

 Uninterrupted generation of fly ash by the coal based thermal power plants and its
dumping has lead to steady encroachment of useful land in India.
 The deleterious effects of fly ash on the nearby environment are inevitable due to its
fine texture and presence of toxic metals.
 In this paper emphasizes on an efficient reclamation strategy of FA disposal sites
which are a foremost challenge now adays to check land and environment
degradation. Above discussion on FA characteristics, enrichment and geo-
accumulation index of toxic metals can be considered before initiating technical
restoration on the site. A prior survey on the FA properties such as pH, texture, metal
leaching should be carried out before selecting the type of amendment application,
rate of application and type of plant species to be used. This would also help in
reducing ground water contamination. Use of geotextiles is also recommended in
certain cases to curtail erosion of FA during monsoon.

2.12. Hakan Cengizler et.al, January 2012.

Celal Bayar University, Manisa, Turkey.

Tayfun Çiçek et.al, January 2012.

Dokuz Eylül University, İzmir, Turkey.

Mehmet Tanrıverdi et.al, January 2012.

Dokuz Eylül University, İzmir, Turkey.

 In this paper, the brick industry of Turkey was briefly presented in general terms. The
methods of Fly Ash brick production and the leaching behaviours of heavy metals
were discussed. The methods of producing non-fired fly ash bricks seems to be an
advantageous way to confront the challenges for environment and ecologically
sustainable development. Additional economical benefits will also contribute to the
Turkish economy while increasing demand for greener building products will be met
locally and also globally.

2.13. Hunton et.al, may 2005 .

(Past Presidence, World Poultry Science Association):Research on eggshell
structure and quality.

17
  The eggshell is an important structure for two reasons. Firstly it forms an embryonic
chamber for the developing chick, providing mechanical protection and a controlled
gas exchange medium. Secondly it is a container for the market egg, providing
protection of the contents and a unique package for a valuable food.
 The superficial structure of the shell has been known for over 100 years. The shell
consists of 97% calcium carbonate, and this is provided to the hen in the diet.
However, the chemical must be broken down in the digestive system and then re-
synthesized in the shell gland to form the shell. This results in a turnover of blood Ca
of ~ 100 times each 24 hours.
 Provision of calcium to layers has been researched at length, but the key work,
conducted at Cornell University in the 1960, showed the necessity for sources with
large particle size, for example, oyster shells. Subsequent research has defined
guidelines that, if correctly followed, will yield reliable and optimum eggshell quality.
 Breaking or cracking of eggshell in market channels is a serious concern. Cracks
result from a combination of shell strength and integrity, and the extent of the “insult”
received by the egg during handling. Measurement of shell strength, and assessment
of “insults” is important to the poultry industry.
 Most recent research has identified the ultra-structure of the shell, with resulting
opportunities for industrial remedies, and possible new selection criteria, to ensure
maximum shell quality throughout the egg industry.

2.14. Stephen Owuamanam and Duncan Cree et al (University of

Saskatchewan, 57 Campus Drive, Saskatoon, SK S7N 5A9,Canada):

 In this paper reviews eggshell and seashell production by country and provides a
perspective on the quantity of bio-calcium carbonate that could be produced annually
from these wastes. The achievements obtained from the addition of recycled bio-
calcium carbonate fillers (uncoated/unmodified) in polymer composites with a focus
on tensile strength, flexural strength and impact toughness are discussed. To improve
compatibility between calcium carbonate (mineral and bio-based) fillers and
polymers, studies on surface modifiers are reviewed. Knowledge gaps and future
research and development thoughts are outlined. Developing novel and innovative
composites for this waste material could bring additional revenue to egg.
 The chemical composition of eggshells are calcium carbonate in the form of calcite
ranging from 94–97% and 3–4.5% organic matter . In addition, minor traces of other
elements have been detected such as; MgO (0.83%), SO3 (0.66%), P2O5 (0.43%),
Al2O3 (0.15%), K2O (0.08%), SiO2 (0.07%), Cl2O3 (0.06%) and SrO (0.04%).

2.15. Budsaraphorn Moonlek & Kiadtisak Saenboonruang et al (2019),

Published online: 21 Mar 2019.

 In this paper, waste eggshell was collected from local cafeterias in Bangkok,
Thailand, washed in running water for 20 min, and air-dried for 2 days. Its membrane
was manually removed, and the remainders were initially ground using a laboratory
ceramic mortar and pestle. It should be noted that, in industrial scales, the membranes
could be separated using the dissolved air-flotation separation unit or using water and
acetic acid.
 The waste eggshell powder with coarse particle sizes were ground again using a
stainless-steel ball mill (Petchkasem Commercial Co., Ltd.; Thailand) with a rotation

18
speed of 147 rpm for 2 h in order to obtain smaller waste eggshell powder particles.
The waste eggshell powder was then sieved through a 100-mesh sieve and oven-dried
at 80°C for 12 h until constant weight was achieved. The average particle size of
waste eggshell powder was 1.1μm.

19
CHAPTER-3

3.1. Methodology
FA, sand/stone dust, cement, egg shell are manually feed into a pan mixture where water is
added two the required proportion for homogeneous mixing. The proportion of raw material
may vary depending upon quality of raw materials. After mixing, the mixture are allowed two
belt conveyer through fed in to automatic brick making machine where the bricks are pressed
automatically. Then the brick are placed on wooden pallets and kept as it is for two days there
after transported to open area where they are water cured for 10 to 15 days. The brick are
shorted and tasted before dispatch.
 The manufacturing process of brick requires fly ash, sand/stone dust, cement, eggshell
to be mixed in a appropriate proportion .
 Fly ash and cement are first added to the hydraulic mixer machine where it is ground
finely as a dry mixture.
 While the mixture is mixed thoroughly and uniformly the grinding of the machine is
stopped.
 After the above process, the fly ash and the sand/stone dust are taken in the required
quantity.
 Fly ash and sand/stone dust are then added into the pan –mixture to form uniform
mixture.
 First fly ash and sand/stone dust is mixed in pan-mixture and then cement is added
into pan-mixture to have uniform dry mixture.
 Now the mixer machine is made in ON condition and the above mixture is ground
uniformly in the dry condition.
 After this Water is added into the pan-mixture once the uniform dry mixture of fly
ash, sand/stone dust and cement is achieved.
 The water content must be added in a required quantity as the mixture must be in a
concentration that they should be capable of moulded into the brick.
 It is to be carefully noted that the quantity of water must not be more and for per Kg
of cement the water content ratio must not exceed 0.6%.
 When the quantity of the materials are less they are needed to be transferred through
the labours.
 When the quantity of the mixture is more, then the process of transferring to the
mould could be done by a conveyor belt.
 Hydraulic machine consists of four pairs of brick mould.
 Moulds can be differ according to the machines available.
 After the quantity of the mixture content is transferred to the place of the location of
brick mould, it is needed to be filled into the holes provided in the machine which
represents the brick mould.
 The mould is mostly provided at the circular table which is capable of rotating in
clockwise direction.
 After the mould is filled with the materials, the table is allowed to rotate in clockwise
direction and then it remains under the part of closed portion of the machine.

20
  At that portion the mixture is hydraulically pressed to obtain bricks and then the
pressed bricks are pushed outside the brick mould automatically.
 Once bricks are taken out from the mould, they are transferred to the Planck.
 The transferring of the bricks must be carried out carefully as it is possible to get
broken due to the pressure applied over it.
 When the certain ratios of the bricks are completed for the purpose of reference they
are to be noted over the brick.
 When the Planck is filled by the bricks then they are to be taken by the Planck lifter
for the purpose of air drying process where the bricks are air dried for 2 to 3 days.
 Water curing is done for required days and to achieve the required strength.

3.2. Clay bricks

Made of clay and shale, the final composition of clay brick includes the four natural
elements: earth, wind, fire and water. Therefore, they contain no pollutants or allergens and
are resistant to noxious insects. They are also known to have a benign effect on the
environment.
Clay brick’s soundproof effect is poor. When outside sound spreads into clay brick, because
it doesn't have a lot of air holes, it can't isolate the sound very well.
Clay brick’s main raw material is soil, and that will do harm to the environment. Clay brick
manufacturing easily leads to the loss of soil and water.
According to production process, fire clay brick is divided into machine made brick and
handmade brick. According to structures, fire clay brick is divided into solid brick and hollow
brick, and hollow brick can be divided into load-bearing brick and nonbearing brick. Fire clay
brick is made at different shapes according to different using requirements.
3.2.1. Advantages of fire clay brick：
 Fire clay brick is environmentally friendly and belongs to resource recycling bricks,
so we can rest assured use fire clay brick. Fire clay bricks won’t be harmful to our
health.
 Fire clay brick has advantages of fireproof and heat insulation. Used clay brick can be
used as concrete so that to save a lot of resources.
 The price of fire clay brick is not as expensive as that of other fire bricks. Light
weight brick is more expensive than fire clay brick. Besides, fire clay brick is very
cheap and very durable
 Fire clay brick has good moisture-proof function, it also has the advantages of fire
insulation, heat insulation and moisture absorption.
3.2.2. Disadvantages of fire clay brick：
 Clay brick is made of concrete and is much heavier than other masonry materials. It
will make the whole building bear more weight, and it will increase the cost of the
whole project.
 Clay brick’s soundproof effect is poor. When outside sound spreads into clay brick,
because it doesn't have a lot of air holes, it can't isolate the sound very well.

21
  Clay brick’s main raw material is soil, and that will do harm to the environment. Clay
brick manufacturing easily lead to the loss of soil and water. For this reason in China
caly brick is being forbidden gradually.

3.3. Composition of clay brick:

For the preparation of bricks, clay or other suitable earth is moulded to the desired shape.
After drying, the brick should not shrink and no crack should be develop the clay used for
making of the brick consist mainly of Silica, Alumina it also contain small amount of Lime,
Magnesia, Sulphur etc.

Silica- 50 to 60%

Alumina- 20 to 30%

Lime- 10%

Magnesia < 1%

Ferric oxide- < 7%

Alkalis < 10%

CO2, SO3 and water(H2O){very small %}

3.4. Functions of various ingredient:

1. Silica (SIO2) –Silica enables the brick to retain its shape, impart durability and prevent
shrinkage warping (bend out of shape due to heat and pressure).

Excess of Silica- It make the brick brittle and weak on burning.

2. Alumina (AL2O3)- It absorb water and make the clay plastic, if alumina is present in
excess the brick will crack.

3. Lime (CaO) - Lime normally constitute less than 10%. Lime reduces shrinkage on
drying. If excess of lime, it causes the brick to melt and lose its shape.

22
4. Magnesia (Mg(OH)2)- A small amount of magnesia give yellow color to the brick.
Excess of magnesia lead to the decay of brick.

5. Oxides of Iron(Fe2O3)- It give red colour to the brick on burning. Excess of iron
oxide make the brick dark blue or black

3.5. Fly ash

Fly ash is a heterogeneous by-product material produced in the combustion process of coal
used in power stations. It is a fine grey coloured powder having spherical glassy particles that
rise with the flue gases. As fly ash contains pozzolanic materials components which reach
with lime to form cementitious materials. Thus Fly ash is used in concrete, mines, landfills
and dams.

3.6. Coal:

Coal is a combustible black or brownish-black sedimentary rock with a high amount of

carbon and hydro carbons. Coal is classified as a non renewable energy source because it
takes million of year to form. Coal contains the energy stored by plants that lived 100 f
millions of year ago in swampy forest.
Types of coal: coal is classified into four main types, or ranks:

 Anthracite: The highest rank of coal. It is a hard, brittle, and black lustrous coal,
often referred to as hard coal, containing a high percentage of fixed carbon and a low
percentage of volatile matter.
 Bituminous: Bituminous coal is a middle rank coal between subbituminous and
anthracite. Bituminous coal usually has a high heating (Btu) value and is used in
electricity generation and steel making in the United States. Bituminous coal is blocky
and appears shiny and smooth when you first see it, but look closer and you might see
it has thin, alternating, shiny and dull layers.
 Subbituminous: Subbituminous coal is black in color and is mainly dull (not shiny).
Subbituminous coal has low-to-moderate heating values and is mainly used in
electricity generation.
 Lignite: Lignite coal, aka brown coal, is the lowest grade coal with the least
concentration of carbon. Lignite has a low heating value and a high moisture content
and is mainly used in electricity generation.

Bituminous coal in india, it is a medium grade of coal having high heating capacity. It is the
most commonly used type of coal for electricity generation in India. Most of bituminous coal
is found in Jharkhand, Odisha, West Bengal, Chhattisgarh, and Madhya Pradesh. Steam coal,
also known as thermal coal, is used in power stations to generate electricity. First coal is
milled to a fine powder, which increases the surface area and allows it to burn more quickly.

23
 Water absorption of fly-ash bricks
25

20

15
Water absorption (%)

10

0
0 20 30 40 50 60 70

% Fly-ash

Fig. No. 3.1. water absorption of fly ash bricks

3.7. Chemical Composition of Fly Ash

The chemical composition of fly ash depends upon the type of coal used and the methods
used for combustion of coal.

Table No 1: Chemical composition of fly ash of different coals.

Component Bituminous Coal Sub bituminous Coal Lignite Coal

SiO2 (%) 20-60 40-60 15-45

Al2O3 (%) 5-35 20-30 20-25

Fe2O3 (%) 10-40 4-10 4-15

CaO (%) 1-12 5-30 15-40

LOI (%) 0-15 0-3 0-5

Table No. 3.1. Chemical composition of fly ash bricks

3.8. Physical Properties of Fly Ash

The physical properties of fly ash are,

1. Fineness of Fly Ash

24
As per ASTM, the fineness of the fly ash is to be checked in both dry n wet sieving. The fly
ash sample is sieved in 45 micron sieve and the percentage of retained on the 45 micron sieve
is calculated. Further fineness is also measured by LeChatelier method and Blaine Specific
Surface method.

2. Specific Gravity of Fly Ash

The specific gravity of fly ash ranges from a low value of 1.90 for a sub-bituminous ash to a high
value of 2.96 for an iron-rich bituminous ash.

3. Size and Shape of Fly Ash

As the flyash is a very fine material, the particle size ranges in between 10 to 100 micron.
The shape of the fly ash is usually spherical glassy shaped.

4. Colour

The colour of the fly ash depends upon the chemical and mineral constituents. Lime content
in the fly ash gives tan and light colours where as brownish colour is imparted by the
presence of iron content. A dark grey to black colour is typically attributed to an elevated un-
burned content.

3.9. Composition of fly ash brick

The manufacturing method saves energy, reduces pollution in the environment, and often
costs 20% less than traditional clay brick manufacturing. It uses materials in the following
proportion - Fly ash (70%), Lime (10%), Gypsum (5%) and sand(15%).

3.10. Chemical Properties

Silica - 35-59 %
Alumina - 23-33%
Calcium Oxide - 10-16%
Loss on ignition - 1-2%
Sulphur - 0.5- 1.5%
Iron - 0.5- 2.0 %

1. Gypsum:
Hydrated calcium sulphate are called gypsum. (Caso4 2H2O). Gypsum should have
minimum 35% purity and 5 to 15% may be used.
2. Lime :

25
Quick Lime or hydrated lime or both can be mixed in the composition. Lime should have
minimum 40% Cao content.

3. Sand:
River sand should be clean & coarse. About 10 to 20% may used.
All the raw materials are indigenous and readily available from the manufacture or traders
4. Fly ash:
Pulverized fuel ash commonly known as fly ash is a useful by-product from thermal power
stations using pulverized coal as fuel and has considerable pozzolonic activity.

Advantage of fly ash bricks:

1. Appearance : the appearance of fly ash bricks is very attractive due to pleasing colour like
cement, uniform size, and smooth finish. Due to uniform size, mortar require for walls and
plastering reduces almost by 40-50%.
Plaster of paris (gypsum plaster), putty can be applied directly without a baking coat of
plaster. These bricks are free from crack, warp age, organic matter, pebbles, and nodules of
free lime.

2. Strength: the compressive strength of fly ash brick is very high (9-10N/mm2). Due to high
strength no breakages/wastages during transport and handling. The lower thickness of joints
and plaster reduces cracking in plaster.
These bricks do not cause any extra load for the design structures and provide better earth
quick resistance. It improves the strength over time and offers greater strength to the building.
3. Thermal properties:
They absorb less heat. The pozzolanic reaction between fly ash and lime produces less heat.
It keeps your building cooler in summer, hence most suitable for Indian climates.

4. Durability:
These bricks are highly durable and less permeable. The lower permeability can efficiently
reduce the effect of efflorescence of bricks.
These bricks are less pores, absorb less water, and reduce dampness on the walls. It is also
highly resistant to attack by mild acid, water, and sulphate.

26
5. Sound insulation:
Construction with these bricks provides decent sound insulation to the buildings.

6. Fire resistance:
These bricks are highly fired resistant compared to normally clay bricks.

7. Sustainability:
Fly ash bricks are environmentally friendly as they are made of waste materials that come
from combustion of coal in thermal power plants. There is no pollution or environmental
damage.

8. Buildability:
This bricks have easy workability and absorb less water. Unlike clay bricks, they don’t
requires soaking in water for 24 hours. The sprinkle of water before use is enough. The
construction technique is same as clay brick construction and does not require any extra
training for masons.

9. Availability:
these bricks are generally available closer to the thermal power plants. However, finding
dealers in all major cities and towns would not be a problem.

10. Cost:
the same number of fly ash bricks will cover more areas than clay bricks. Consumption of
mortar is also low. Requires less labour. The cost is approximately 30% lower than clay
bricks.

11. Applicability:
due to lightweight, these bricks are suitable for multi-storey structures. Less weight means
less stress on the buildings. These bricks can be used in load bearing external walls in low
/mid structures, known load bearing internal walls in low/mid structures, and non – load
bearing internal or external walls in high rise buildings.

Disadvantage of fly ash bricks:

27
  Not all fly ash suitable for construction, those are produce in power plants usually
compatible with concrete, while others may need beneficiation.
 It is very important to use only high-quality fly ash to negative effect on the structure.
 If not made properly, it has no strength and not suitable for construction. Poor quality
of brick have negative impact on concrete. It can increase permeability, resulting in
damage to the structure.
 Bonding with concrete is lower due to smooth finish. Limitation in size. Only
modular size of bricks can be produced. The large size will have more breakage.
 It is only suitable for sub tropical areas, or where the climate is warm because these
break do not absorb heat. But it in winter season it is not helpful.

3.11. Fly ash bricks uses: Fly ash brick used in-
 Multi-storey structures.
 High rise buildings.
 Houses construction.
 Factories
 Ware houses.

3.12. Various Shape of bricks used in construction:

Bullnose Bricks: A brick moulded with a rounded angle is known as a Bullnose. These
types of bricks are used for a rounded quoin (round corner). An external corner of a wall is
known as quoin. The centre of the curved position is situated on the long centre-line of brick.
Uses: It is commonly used in the rounded edge for staircase steps, building corners,
verandahs, etc.

Fig. No. 3.2. Bullnose Brick

28
Cownose Bricks:A brick which is manufactured with a double Bullnose on end is known
as a cownose brick.

Fig. No.3.3. Cownose Brick

Channel Bricks: Channel bricks are moulded to the shape of a gutter or a channel and
they are often glazed.

Uses: Channel bricks are used as drains.

Fig. No.3.4. Channel Brick

Coping Bricks: Coping bricks are used where the coping is to be provided. The shapes of
brick can be chamfered, half round or saddle-back.
Uses: Coping bricks are used as topmost direction on parapets.

29
 Fig. no .3.5. Saddle Back Brick

Hollow Bricks: Hollow bricks are also known as the cellular or cavity bricks. They are
made up of special homogeneous clay. Hollow bricks are light in weight about one-third the
weight of the ordinary brick of the same size. These types of bricks can be laid almost about
four times as fast as the ordinary bricks. Therefore the use of such bricks leads to speedy
construction. They also reduce the transmission of heat, sound and damp.
Uses: Hollow bricks are used in the partition wall.

Fig. No.3.6. Hollow Brick

Paving Bricks: Paving bricks are made up of clay with a higher percentage of iron. Such
bricks resist better the abrasive action of traffic. The paving bricks may be plain or
chequered. These types of bricks make the floor less slippery.
Uses: Paving bricks are most commonly used for street pavements, garden walks, stable
floors, etc.
30
 Fig. No.3.7. Paving Brick

Perforated Bricks: Perforated bricks have cylindrical holes throughout their thickness.
These bricks are light in weight and they require less quantity of clay for their preparation.
The shapes of brick may be circular, square, rectangular or any other shape in cross-section.
Uses: The perforated bricks are used in the panel of lightweight structures and multi-storeyed
framed structures.

Fig. No.3.8. Perforated Brick

31
Purpose-made Bricks:There are various shapes of brick which are made in order to
achieve certain purposes.
1. The splay or cant bricks are prepared for door and window jambs
.

Fig. No3.9. Cant Bricks

2. The arch bricks are made of a wedge shape to keep mortar joint in the uniform thickness.

Fig. No.3.10. Arch Bricks

3. The ornamental bricks are prepared for corbels, cornices, etc.

4. Similarly, engineering bricks are made for construction where high durability, compression
strength and adequate resistance to sudden shocks are required.

32
Engineering bricks are usually more costly than the ordinary bricks. But they provide safe
and quick construction. Hence, their cost is justified by their excellent performance in the
situation for which they are purposefully made.

Water absorption of clay brick and fly-ash brick

30

25

20
Water absorption (%)

15
15-25%
10

6-12%
5

0
Clay brick Fly-ash brick

24 hours

Fig. No. 3.11. Water absorption of clay brick and fly ash brick

Compressive strength of clay brick and fly-ash brick

16

14
Compressive strength (N/mm2)

12

10 7-14 N/mm2
(for superior quality)
8 minimum 3.5 N/mm2

6
3.5-10 N/mm2
4

0
Clay brick Fly-ash brick
Name of brick

Fig. No. 3.12. Compressive strength of clay brick and fly ash brick

33
CHAPTER-4
4.0. Experimental data analysis
4.1. To study the effects of egg shell powder on the strength of fly ash brick
Fly ash, eggshell, and sand/stone dust are manually feed into a pan mixer where water is
added to the required proportion for homogeneous mixing. The proportion of raw material
may vary depending upon quality of raw materials. After mixing, the mixture are allowed to
belt conveyor through feed in to automatic brick making machine were the bricks are pressed
automatically. Than the bricks are placed on wooden pallets and kept as it is for two days
thereafter transported to open area where they are water cured for 10 -15 days. The bricks are
sorted and tested before dispatch

4.2. Compressive strength of brick

Brick type Proportion Compressive strength

(N/mm2)
FA+Lime 90% FA, 10% Lime 6.74
85% FA, 15% Lime 6.95
80% FA, 20% Lime 7.39
75% FA, 25% Lime 8.36
FA+Cement 90% FA, 10% Cement 5.43
85% FA, 15% Cement 5.65
80% FA, 20% Cement 6.73
75% FA, 25% Cement 6.93
FA+Lime+Stone dust 65% FA, 10% lime, 25% stone dust 7.39
60% FA, 10% lime, 30% stone dust 7.60
55% FA, 10% lime, 35% stone dust 8.26
50% FA, 10% lime, 40% stone dust 8.90
Table No. 4.1. compressive strength of bricks

34
4.4. Chemical composition of egg shell:

The chemical composition of eggshells are calcium carbonate in the form of calcite ranging
from 94–97% and 3–4.5% organic matter. In addition, minor traces of other elements have
been detected such as; MgO (0.83%), SO3 (0.66%), P2O5 (0.43%), Al2O3 (0.15%), K2O
(0.08%), SiO2 (0.07%), Cl2O3 (0.06%) and SrO (0.04%).

The color of the shell does not dictate the amount of calcium carbonate. For example, brown
eggshells were reported to contain 96–97% calcium carbonate and 3–4% organic membrane,
while white eggshells were found to have 94% calcium carbonate content with 6% organic
membrane. Based on these findings, the calcium carbonate contents in both brown and white
eggshells were considered equivalent.

4.5. Chemical composition of stone dust:

Stone dust is a waste material obtained from crusher plants. It has potential to be used as
partial replacement of natural river sand in concrete. Use of stone dust in concrete not only
improve the quality of concrete but also conserve the natural river sand for future
generations. In the present investigation, an experimental program was carried out to study
the workability and compressive strength of concrete made using stone dust as partial
replacement of fine aggregate in the range of 10%-100%.

4.6. Chemical composition of portland cement:

Portland cement, binding material in the form of a finely ground powder, usually gray, that is
manufactured by burning and grinding a mixture of limestone and clay or limestone
and shale. The inventor Joseph Aspdin, of England, patented the basic process in 1824,
naming it for the resemblance of the cement when set to portland stone, a limestone from
the Isle of Portland.

When mixed with water, the anhydrous calcium silicates and other constituents in the
portland cement react chemically with the water, combining with it (hydration) and
decomposing in it (hydrolysis) and hardening and developing strength.

4.7. Chemical composition of lime:

Calcium oxide, CaO, also known as lime or more specifically quicklime, is a white or grayish
white solid produced in large quantities by roasting calcium carbonate so as to drive
off carbon dioxide. At room temperature, CaO will spontaneously absorb carbon dioxide
from the atmosphere, reversing the reaction.

35
 Flow Sheet Diagram

Fly ash Cement Sand Egg shell Water

Weighing

Pan Mixer

Conveyor

Fly ash brick making machine

(Hydraulic or power press)

Transported to wooden racks

Kept as it is for two days for

setting

Water curing (7 to 10 days)

Drying (1 or 2 days)

Sorting and testing

Dispatch

36
4.8. Weighing-

4.8.1. Volume:

 In volume batching the materials are measure on the basis of volume. It is less precise
method of batching.
 Measurement boxes or gauge boxes of known volume are used to measure material.

4.8.2. Weight batching-

 In this method materials are measured on the basis of weight. It is accurate method of
batching.
 Weight batcher or other types of weighting equipments are used to measure weight of
material.
 Weighing batcher used or available in two types mainly mechanical weighing batcher
and electronic weighing batcher.
 In mechanical weighing batchers, weights are measured using spring and dial gauge
arrangement and it is widely used equipments in weigh batching.
 In electronic weighing batchers electronic scales and load cells supported by hoppers
are used to measured the weight of FA, stone dust, egg shell, cement.
 Weighing batchers available are may be manual or semi automatic or fully automatic.
Manual type is used for small production job while other two types are used for large
brick production.

4.9. Pan mixer-

FA pan mixer machine can be noticed in different construction site where it is used for
uniform blending of FA. Automatic control panel of this equipment insure its error free
cooperation. It consist of necessary parts like high strength shaft with advanced sealing
technology, monitoring system to absorb its operating process and easy to remove taper
mixing arm. Hydraulic pressure system of this mixing equipment is instrumental in trouble
free opening and closing of its discharge door. Non automatic pump of this machine is utilise
to open its discharge by valve during emergency situation. We are a reliable supplier and
manufacturer of fly ash pan mixture machine.

37
Fig. No. 4.1. Pan mixer

4.10. Conveyer belt –

Conveyer belt is carrying medium of a belt conveyer system. A belt conveyer system is one
of many type of conveyer system. A belt conveyer system consists of two or more pulley
(some time referred to as drums), with a close loop of carrying medium- the conveyer belt-
that rotates about them. One or both of the pulleys are powered, moving the belt and the
material on the belt forward. The powered pulley is called the derive pulley while the
unpowered pulley is called the idler pulley.

38
4.11. Fly ash brick making machine-

Fig. No. 4.2. fully automatic fly ash brick plant

Fig.No. 4.3. Moulds

FA brick making machine with the help of hydraulic power press give size and shape of the
brick. There are different number of hydraulic press mould on the machine(4,6,8,10 moulds
are present in hydraulic power press).

4.12. Transported to wooden rack- Wooden rack is used to transport the

manufactured brick into the open areas to setting for 1 to 2 days.

39
4.13. Water curing- After the initial setting provide curing 7 to 10 days.
After the curing one to two days for drying the bricks.

Fig.No. 4.4. Fly ash brick

40
CHAPTER-5

5.0. Data analysis and result

Brick type Proportion Compressive strength

(N/mm2)
FA+ Cement+ Stone 65% FA, 10% cement, 15% stone dust, -
dust+ Egg shell 10% egg shell
60% FA, 10% cement, 25% stone dust. -
5% egg shell
55% FA, 10% cement, 20% stone dust. -
15% egg shell
50% FA, 10% cement, 30% stone dust, -
10% egg shell
Table No. 5.1. Data analysis for future scope

5.1. Testing-

5.1.1. Absorption test:

 Note dry weight of brick.

 Emerge in water for 24 hours.
 Weighted again.
 Difference in wait indicates the water absorbed.
 In case it should not be greater then 20% by dry weight of brcks.

5.1.2. Crushing strength-

 Test using compression testing machine .

 Brick is compressed till it breaks .
 Maximum load at which the brick crush is noted .
 Crushing strength = Maximum load / Area of the bearing face .
 Minimum compressive strength of the brick is 3.5N/mm2 .
 For superior quality it is 7 to 14 N/mm2

5.1.3. Hardness test-

 Scratch is made on the brick surface with the help of finger nail
 If no impression on the surface, the brick is sufficiently hard.

5.1.4. Soundness test-

41
  Two brick stuck with each other
 Brick of good quality should not break and produce the ringing sound.

5.1.5. Impact test-

 Take a brick and drop it from 1m height.
 A good quality brick should not break at all.
 If bricks are broken that’s mean its impact value is low and it should be rejected.

5.1.6. Efflorescence test -

 In efflorescence test using oven 3000C.
 A shallow flat bottom dish containing sufficient distilled water to completely saturate
the specimens is used for the test. The ends of the bricks are placed in the dish, the
depth of immersion in water being 25 mm.
 The whole arrangement is placed in a warm (between 200C and 300C) well ventilated
room until all the water in the dish is absorbed by the specimens and the surplus water
evaporates.
 The dish containing the brick is covered with a suitable glass cylinder so that
excessive evaporation from the dish may not occur.
 When the water has been absorbed and brick appears to be dry, a similar quantity of
water is placed in the dish and it is allowed to evaporate as before. Examine the bricks
for efflorescence after the second evaporation and the results are reported.

Reports:
The liability to efflorescence shall be reported as ‘Nil’, ‘Slight’, ‘Moderate’, ‘Heavy’ or
‘Serious’ in accordance with the following definitions

Nil: When there is no perceptible deposit of efflorescence.

Slight: When not more than 10 percent of the exposed area of brick is covered with a thin
deposit of salts.

Moderate: When there is a heavier deposit than under ‘Slight’ and covering up to 50 percent
of the exposed area of the brick surface but unaccompanied by powdering or flaking of the
surface.
Heavy: When there is a heavy deposit of salts covering 50 percent or more of the exposed
area of the brick surface but unaccompanied by powdering or flaking of the surface.

Serious: When there is a heavy deposit of salts accompanied by powdering and / or flaking
of the exposed surfaces.

Safety and precautions: Use hand gloves while removing containers from oven after
switching off the oven.

 Thoroughly clean & dry the container before testing.

 Use apron & safety shoes at the time of testing.

5.1.7. Shape and size test:

Shape and size of bricks are very important are very important consideration. All bricks used
for construction should be of same size. The shape of bricks should be purely rectangular

42
with sharp edges. Standard bricks size consists length* breadth * height as 230mm* 110mm*
70mm.

5.1.8. Structure of brick:

To know the structure of brick pic one brick randomly from the group and break it. Observe
the inner portion of brick clearly. It should be free from lumps and homogeneous.

5.1.9. Color test:

A good brick should possess bright and uniform color throughout its body.

5.2. Water absorption:

Material Mass (in %) Sample-1(in%) Sample-2(in%)

Fly Ash 60 50 55
Sand/Stone dust 30 30 30
Portland Cement 10 10 10
Egg Shell No 10 05
Table No. 5.2. water absorption

For Sample-1
 Fly Ash- 2600*50/100=1300gm
 Sand-2600*30/100=780gm
 Cement-2600*10/100=260gm
 Egg Shell-2600*10/100=260gm

For Sample-2
 Fly Ash-2600*55/100=1430gm
 Sand-2600*30/100=780gm
 Cement-2600*10/100=260gm
 Egg Shell-2600*5/100=180gm

Total material used

 Fly Ash =1300+1430=2.73kg=3kg
 Sand =780+780=1.560kg=2kg
 Cement =260+260=520gm=1kg
 Egg Shell =260+130gm=390gm=500gm

Water used
W1 =440gm , w2 =820gm

Sample 1
W1=weight of dry brick=440gm
W2=weight of wet brick=470.8gm

43
W%=w2-w1/w1*100=470.8-440/440*100=7%

Sample 2
W1=weight of dry brick=820gm
W2=weight of wet brick=893.8gm
W%=w2-w1/w1*100=893.8-820/820*100=9%.

2.5kg fly ash Brick and egg shells brick making

Weight-2600gm
Dimension-230mm*110mm*70mm

Advantages of the process:

 The technology adopted is eco-friendly.

 It does not require steaming or auto-calving as the bricks are cured by water only.

 Firing process is avoided.

 There are no emissions and no effluent is discharged.

 Facial masks and dust control equipment may be provided.

 These products are low energy consumption since no need of fire operation in the
production unlike conventional bricks.

5.3. Normal clay brick Vs fly ash and eggshell bricks

Normal clay bricks Fly ash and eggshell brick

Varying colour as per soil. Uniform pleasing colour like cement.
Uneven shape as handmade. Uniform in shape and smooth in finish.
Lightly bonded. Dense composition.
Plastering required. No plastering required.

44
Heavier in weight. Light in weight.
2
Minimum compressive strength is 3.5N/mm . Maximum compressive strength____.
Maximum compressive strength is 10N/mm2. Minimum compressive strength____.
More porous. Less porous.
Water absorption 20-25%. Water absorption.
Table No. 5.3. Difference of clay brick Vs fly ash and eggshell bricks

Advantages of fly ash and eggshell bricks:

 Due to high strength, practically no breakage during transport and use.

 Due to uniform size of bricks mortar required for joints and plaster reduces almost by
50%.
 Due to lower water penetration seepage of water through bricks is considerably
reduced.
 Gypsum plaster (plaster of Paris) can be directly applied on these bricks without a
backing coat of lime plaster.
 These bricks do not require soaking in water for 24 hours. Sprinkling of water before
use is enough

45
CHAPTER-6

6.0. Conclusion remark and future scope

After doing the through study and knowing the way how the fly ash bricks are manufactured
and its importance in construction field we can say that in near future this brick is soon going
to replace all the bricks and blocks which are now a days used for construction purpose. With
decreasing natural resources and boom in construction field will definitely increase the
demand for fly ash brick as it has lots of quality and advantages than other bricks some
quality are like high compressive strength, low resistance, low mortar construction etc. Since
it also accounts 20% less cost for its construction than the clay burnt bricks. So all these and
present situation will make this brick as the most important material for the construction
work.
The manufacturing of bricks using FA and egg shell is environment friendly. The egg shell
5,10 and 15% used is beneficial to increase in compressive strength. Cement makes
combination with fly ash which increase durability of brick element. Using fly ash and egg
shell in bricks reduces manufacturing cost of brick elements. It reduces dead load on
structures due to light weight 2.6kg. due to high strength, practically no breakage during
transport and use. Due to uniform size of bricks mortar required for joints and plaster reduces
almost by 50%.
Fly ash bricks also reduce the chances of pollution during its construction work which is not
same in all the bricks manufacturing process. High compressive strength, better workability,
fire resistant and all these quality of the bricks will increase its future scope of construction
work. Soon we will find that in lots of construction work fly ash bricks are being widely
used.

6.1. Inspection and quality control

The Bureau of Indian Standards has formulated and published the specifications for
maintaining quality of product and testing purpose. IS: 12894 :2002. Compressive strength
achievable: 60-250 Kg/cm Sq. Water absorption: 5 – 12 %; Density: 1.5 gm/cc Co-efficient
of softening (depending upon water consistency factor) Unlike conventional clay bricks fly
ash bricks have high affinity to cement mortar though it has smooth surface, due to the crystal
growth between brick and the cement mortar the joint will become stronger and in due course
of time it will become monolithic and the strength will be consistent.

6.2. Pollution control

The technology adopted for making fly ash bricks is eco-friendly. It does not require
steaming or auto-calving as the bricks are cured by water only. Since firing process is
avoided. There are no emissions and no effluent is discharged. Facial masks and dust control
equipment may be provided to the employees to avoid dust pollution more over all the raw
materials are kept under covered by polythene sheet to avoid air pollution.

46
6.3. Energy conservation
General precautions for saving electricity are followed by the unit by providing energy meter.
This product are low energy consumption since no need of fire operation in the production
unlike conventional bricks. Thus considerable energy could be saved not only in
manufacturing activities but also during the construction.

47
Photo gallery :

48
49
References

1.Manish kumar sahu and Lokesh singh “critical review on types of brick type 2: fly ash
brick”. International journal of mechanical and production engineering.
2. Harsha Bhaskaran, Linet John, Neethu. P.M, Traisy Sebastian, Er. Niya Eldhose “Study on
egg shell concrete”. International journal of engineering research and technology

50