Experimental investigation of lightweight concrete by complete replacement of recycled brick as coarse

aggregate

Abstract

In this study, the feasibility of employing recycled crushed bricks as a complete replacement for
conventional coarse aggregates in lightweight concrete was examined. It investigated the
structural, mechanical, and thermal properties of this concrete while evaluating its sustainability
benefits. Experimental testing compared the workability, compressive strength, tensile strength,
and durability of lightweight concrete with conventional concrete over various curing periods.
The results indicate that the strength properties, reduced density, and better thermal insulation of
lightweight concrete made with crushed bricks render it a viable option for sustainable
construction as finally the comparison was made with regular concrete. Additionally, recycled
brick aggregates help conserve the environment by minimizing construction waste and reducing
reliance on natural resources. The conclusion of the study proposed good potential applicability
of lightweight concrete with recycled bricks for structural and non-structural elements in energy-
efficient building systems.

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Chapter-1
INTRODUCTION
Lightweight concrete is a specialized concrete mixture made with lightweight coarse
aggregates, and sometimes lightweight fine aggregates, instead of traditional
aggregates. This type of concrete possesses an in-place density (unit weight) typically
ranging from 90 to 115 lb/ft³ (1440 to 1840 kg/m³), in contrast to the density of
normal weight concrete, which falls within the range of 140 to 150 lb/ft³ (2240 to
2400 kg/m³). For structural applications, lightweight concrete must exhibit a
compressive strength greater than 2500 psi (17.0 MPa). The lightweight
aggregates used in structural lightweight concrete are usually materials such as
expanded shale, clay, or slate, which undergo a firing process in a rotary kiln to
develop a porous structure. Additionally, products like air-cooled blast furnace slag
are also utilized.
Lightweight Aggregate Concrete: Utilizes porous lightweight aggregates with a low
apparent specific gravity, typically lower than 2.6.
Aerated Concrete: Incorporates large voids within the concrete or mortar mass,
achieved through methods such as aeration with stabilized foam or air entrainment.
No-Fines Concrete: Opts to omit fine aggregate from the mix, resulting in a large
number of interstitial voids. Normal weight coarse aggregate is generally used in this
concrete type.
Lightweight concrete can also be classified according to its intended use,
distinguishing between structural lightweight concrete (ASTM C 330-82a), concrete
used in masonry units (ASTM C 331-81), and insulating concrete (ASTM C 332-83).
This classification of structural lightweight concrete is based on a minimum strength
requirement, as per ASTM standards.
1.1 Characteristics of Lightweight Aggregate Concrete
There should be uniformity in properties and composition.
The aggregate should have a low specific weight to ensure worthwhile savings in the
structure, in accordance with the appropriate ASTM specifications.
Notwithstanding the desirability of having surface characteristics to provide a good

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bond, the aggregate should have a minimum of large external voids but a large
number of smaller well-dispersed voids throughout the particles.

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Individual pieces of aggregate should be strong enough to withstand handling and

mixing.
The particles should bond well with cement and not react chemically to cement.
The aggregate should be suitably graded for the intended use, in accordance with the
appropriate ASTM specification.
1.2 DIFFERENCE BETWEEN LIGHTWEIGHT CONCRETE
AND CONVENTIONAL CONCRETE

Properties Lightweight Concrete Conventional Concrete

Weight 20- 115 pounds per cubic foot 130- 150 pounds per cubic foot

Compressive
7000+ psi 8000 psi
Strength

65,000 psi for the ultra light weights

Modulus of 2 - 6 million psi for the conventional
to 3 million psi for the medium
Elasticity concretes
lightweight concretes

Perilite - 0.1 to 0.2%, Vermiculite-

0.1 to 0.7%
Shrinkage 0.04 to 0.08 %
Slag - 0.04 to 0.06%Shale, Slate
and Clay - 0.02 to 0.08%

BTU per hour per square foot per

degree F. per inch
BTU per hour per square foot per
Perilite - 0.1 to 0.2%, Vermiculite-
Thermal degree F. per inch
0.1 to 0.7%
Conductivity Sand and gravel thermal conductivity
Slag - 0.04 to 0.06%
ranges from 8.0 to 12.0 %
Shale, Slate and Clay - 0.02 to
0.08%

3- hour rating for 6-inch slabs made

4-hour rating for 4.5"
Fire Resistance of trap rock, crushed, limestone and
slabs with lightweight aggregate.
gravel aggregate.

1.3 PROPERTIES OF THE LIGHTWEIGHT CONCRETE

Durability of Lightweight Concrete
 There is a better bonding of lightweight aggregate and cement paste. Therefore,
it shows good homogeneous properties. Thus, there is less possibility of
cracking of concrete due to shrinkage, creep, thermal deformations, or

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loads.
 Lightweight concrete has higher fire resistance.

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Water Tightness
 During the construction, it absorbs more water. Therefore, we soak the
aggregate before making the concrete. However, these types of concrete show
better water tightness performance when compared to the normal weight
concrete.
 An increase in the lightweight aggregate concrete content leads to an increase
in water permeability.
 Higher water depths could lead to water penetration into the concrete.
Chloride Attack
 Different studies have shown both the similar and lesser penetration of chloride
ions into the lightweight concrete compared to the normal weight concrete.
 Further, no significant corrosion of reinforcement has been shown compared to
the normal weight concrete
Carbonation
 This type of concrete has higher gas permeability due to its higher porosity.
 Coronation of concrete occurs by penetrating carbon dioxide into the concrete.
 Due to the higher porosity, carbon dioxide penetrates into the concrete easily
compared to the normal weight concrete. Therefore, there is a higher depth
of carbonation of concrete when compared to the normal weight concrete.
 In addition, the higher moisture content of the lightweight concrete caused due
to the higher porosity of the concrete leads to an increase in the carbonation of
concrete.
1.4 Advantage of Lightweight Concrete
 Easy to transport
 Low thermal conductivity
 High heat resistance
 It has good workability
 Unlikely to collapse though it is lightweight
 Though it takes longer to dry due to the higher water content, it does not affect
the properties significantly.
 It can be used as an alternative material
 Due to the less weight of the structure, it reduces the structural member sizes

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and foundation sizers.

 The use of lightweight concrete provides an outlet for industrial wastes such as fly
ash, clinkers, slag, and so on, which cause problems in landfills.

1.5 Disadvantages Of Lightweight Concrete

 Lightweight concrete is often particularly sensitive to the amount of water in

the mix.

 Because of the porosity and angularity of the aggregate, placement and finishing
are difficult, necessitating the use of experienced labour.

 In rare situations, cement mortar may separate the aggregates and cause them
to float on the surface.

 To ensure the correct mixing of concrete, the mixing period is longer than that
of standard concrete.

 Lightweight concrete is porous and has a low resistance.

1.6 Applications Of Lightweight Concrete

1. Because LWC has a low strength, it is utilized in the building of roof slabs, tiny
houses with load-bearing walls, and so on.

2. It is also employed in the construction of staircases, windows, and garden walls,

among other things.
3. This is utilized in the construction of partition walls in large buildings.
4. These are formed into slabs and utilized as thermal insulators throughout the building.
1.7 The Benefits Of Using Lightweight Aggregate Concrete Include:
 Reduction in dead loads making savings in foundations and reinforcement.
 Improved thermal properties.
 Improved fire resistance.
 Savings in transporting and handling precast units on site.

 Reduction in formwork and propping.

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1.8 Scope
The scope of this study is to determine the possibility of using crushed bricks as a replacement for
natural aggregates in making lightweight concrete. The following points outline the scope:

1. Material Innovation
Feasibility study on the use of recycled crushed bricks in lightweight concrete to reduce
dependence on natural resources and minimize waste.
2. Strength and Workability
Comparison of the strength properties (compressive, tensile) and workability of lightweight
concrete with normal concrete. This includes the testing with various curing ages.
3.Structural Use
Checking suitability of the lightweight concrete for structural uses, including the building
construction, bridges, etc. where weight can be decreased.
4. Thermal Efficiency
- It assesses lightweight concrete as having thermal insulating properties that can lead it to be
viable for many applications involving energy efficiency, such as wall panels and roof systems.
5. Environmental and Economic Gains
Its recyclable demolition waste ensures reduction in environmental impact coupled with
alternative cost-effective utilization over conventional construction materials.

1.9 Importance of the study

The study is an experimental investigation into lightweight concrete with the use of recycled
bricks as coarse aggregate. Importance of this study lies in the following aspects:
1. Environmental Sustainability
- Recycling materials such as crushed clay bricks reduce the environmental impact that
construction and demolition waste causes.
- Reduces dependence on natural aggregates, thereby conserving natural resources.
2. Economic Advantages Light weight concrete from recycled brick is cheaper than the use of
conventional concrete materials. Reduces dead loads on construction, thus saving the foundation
and reinforcement requirements

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3. Thermal and Fire Resistance Lightweight concrete has better thermal properties and fire
resistance properties, which makes it very useful for certain applications in building construction
and insulation.
4. Diverse End Uses - Capable of being used both structurally and non structurally, such as for
wall panels, roof systems, and energy-efficient insulations.
5. Strength and Workability - The research study contrasts compressive and tensile strengths
of lightweight concrete against its conventional counterpart, indicating relatively good strength
and workability.
6. Using Waste Material in New Forms - Crushed clay bricks can replace natural aggregates
and can be incorporated as cementitious materials, thereby promoting innovation in material reuse.

1.10 Relevance for the present context

The present study, which is about lightweight concrete (LWC) and coarse aggregate, made from
crushed bricks, is very relevant in the present context due to the following reasons:
1. Sustainability and Waste Management -
The use of recycled materials, such as crushed bricks, addresses environmental concerns by
minimizing construction and demolition waste.
- Using such waste fosters sustainable construction and aligns with global efforts toward
diminishing the carbon footprint of construction.
2. Economic and Resource Efficiency
- Lightweight concrete ensures economic advantages by minimizing loads on the structure,
in turn, reducing the dimension of structural members and foundation. This will lead to
reducing material costs and construction itself.
- The use of crushed brick as a natural aggregate reduces dependence on limited availability of
natural resources.
3. Structural Advantages
- LWC offers similar compressive strength but higher tensile strength compared to
conventional concrete and thus can be a viable alternative for structural purposes.
- LWC provides improved thermal insulation and fire resistance properties, hence
applicable in energy-efficient buildings.
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4. Integration with Contemporary Construction Practices -

Lightweight concrete meets the requirement for new materials for high-rise buildings and other
infrastructure projects, where minimized dead loads and enhanced seismic performance are of
utmost importance.
Its ability to cast slabs, panels, and other elements is aligned with modern modular construction
principles.
5. Energy Efficiency Possibility
The energy savings in buildings due to the lower density and better thermal insulation capabilities
of lightweight concrete are also part of green building initiatives.

1.11 OBJECTIVES
1. Create optimal mix designs for lightweight concrete with crushed brick.
2. Determine the workability of crushed brick lightweight concrete.
3. To compare the strength properties of lightweight brick concrete with the
conventional concrete.
4. Comparison study of conventional concrete and lightweight concrete.

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Chapter-2
LITERATURE REVIEW

a) Yasser M. Hussein, Mohamed Abd Elrahman, Yara Elsakhawy Bassam A. Tayeh,

Ahmed M. Tahwia (2022) “Development and performance of sustainable structural
lightweight concrete containing waste clay bricks”[1]. Utilization of waste crushed
bricks (WCB), which are obtained from brick factories and demolition waste as
coarse and fine aggregate for preparing concrete, is an adequate strategy to reuse
them and save natural resources to achieve environmental sustainability. This study
investigates the possibility of developing eco-friendly structural lightweight
concrete (SLWC) with a 100% replacement of WCB. Different contents (5%, 10%,
and 15%) of supplementary cementitious materials such as silica fume, fly
ash, metakaolin, and slag as a replacement by weight of cement were investigated.
The slump test, dry density, and mechanical properties (compressive, splitting
tensile, and flexural strengths), as well as elevated temperature resistance and water
absorption, were evaluated. Microstructure tests, including thermogravimetric
analysis, X-ray diffraction and scanning electron microscopy (SEM), were
performed. The performance of the developed concrete under high temperature
exposure of 200 °C, 400 °C, and 600 °C was evaluated. The experimental results
indicated that SLWC can be obtained using WCB as a 100% replacement of
aggregate and by using 15% metakaolin and 15% silica fume as alternatives to
cement, with a 39.5 and 41.5 MPa compressive strength, respectively.
Incorporation of 15% slag as cement replacement exhibited the best performance
after 600 °C exposure compared to other fine materials. The SEM images showed
an improvement in transition zone characteristics and increased bond between
coarse aggregate and cement paste.
b) Saad Muhammad Selman, Dr. Zena K. Abbas, (2022) “The Use of Lightweight
Aggregate in Concrete” One of the artificial lightweight aggregates with a wide
range of applications is Lightweight Expanded Clay Aggregate[2]. Clay is utilized
in the production of light aggregates. Using leftover clay from significant

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infrastructure development projects to manufacture lightweight aggregates has a

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favorable environmental impact. This research examines the expanded clay aggregate
production process and the impact of processing parameters on its physical and
mechanical qualities. It also looks at secondary components that can be used to
improve the qualities of concrete with expanded clay aggregates. The effect of the
quantity of expanded clay aggregate on the fresh, hardened, and durability qualities
of concrete is also studied. Expanded clay aggregates improve workability, fire
resistance, sound insulation, and thermal insulation in concrete. Its inclusion, on
the other hand, diminishes concrete's density, strength, elastic modulus, and
resistance to freeze-thaw action.
c) Ahmed Tareq Noaman, Ghassan Subhi Jameel , Shamil K. Ahmed, (2021)
“Producing of workable structural lightweight concrete by partial replacement of
aggregate with yellow and/or red crushed clay brick (CCB) aggregate”.[3] The
utilization of minimum natural materials content in the production of concrete
represents the main concern of many researchers. In addition, lightweight
aggregate concrete is desired for its low weight and modified physical properties.
This study aims to produce lightweight aggregate concrete with adequate strength
utilizing crushed clay brick (CCB) aggregates from discarded or broken brick
pieces. The CCB aggregates are utilized by replacement of natural aggregate at
(10%, 20% and 30%). Three types of CCB aggregate concrete series are produced.
In the first series, natural sand is replaced with similar size CCB aggregate (red and
yellow). The second series is produced by the complete replacement of coarse
aggregate with yellow, red and an equal two portions of yellow and red coarse
CCB aggregate. The third series with 100% coarse CCB aggregate is produced by
further replacement of fine aggregate up to 30% CCB aggregate. In all mixes, the
CCB aggregate is used in its dry state (without pre-wetting). The workability of
produced mixes are investigated. Investigations on density, water absorption and
compressive strength is also presented. Results indicate the possible production of
lightweight CCB aggregate concrete suitable for structural applications.
Superplasticizer (SP) significantly affect the workability of crushed brick
aggregate. A blend of yellow and red CCB aggregate is also suggested to produce
workable lightweight concrete suitable for structural applications.
d) Karl-Christian Thienel, Timo Haller, Nancy Beuntner, (2021)“Lightweight
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Concrete From Basics to Innovations”.[4]Lightweight concrete has a history of more

than two-thousand years and its technical development is still proceeding. This
review starts with a retrospective that gives an idea of the wide range of
applications covered by lightweight concrete during the last century. Although
lightweight concrete is well known and has proven its technical potential in a wide
range of applications over the past decades, there are still hesitations and
uncertainties in practice. For that reason, lightweight aggregate properties and the
various types of lightweight concrete are discussed in detail with a special focus on
current standards. The review is based on a background of 25 years of practical
and theoretical experience in this field. One of the main challenges in designing
lightweight concrete is to adapt most of design, production and execution rules
since they often deviate from normal weight concrete. Therefore, aspects are
highlighted that often are the cause of misunderstandings, such as nomenclature or
the informational value of certain tests. Frequently occurring problems regarding
the mix design and production of lightweight concrete are addressed and the
unintended consequences are described. A critical view is provided on some
information given in existing European concrete standards regarding the
mechanical properties of structural lightweight concrete. Finally, the latest stage of
development of very light lightweight concretes is presented. Infra-lightweight
concrete is introduced as an innovative approach for further extending the range of
applications of lightweight concrete by providing background knowledge and
experiences from case records.
e) M.N Haque, H Al-Khaiat, O Kayali (2004) “Strength and durability of lightweight
concrete”.[5] Two lightweight aggregate concretes, SLWC35 and SLWC50, of 35
and 50 MPa 28 day cube compressive strength were cast. The concrete specimens
made with lightweight coarse aggregates and a dune sand were continuously cured
in water for one or 7 days and then exposed to predominantly hot and humid
seaside ambient conditions containing air-borne salts. After 7 days of initial curing
and on subsequent exposure to hot and humid air both SLWCs attained an almost
similar strength to those continuously water cured cubes at an age of 12 months. In
contrast, the water penetrability of SLWC35 and SLWC50 after 7 days of initial
curing and subsequent exposure to the sea side was about 2 and 1.8 times the water
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penetration of those slabs which were water cured for the entire duration of 12
months.

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However, the depth of carbonation of the two sand lightweight concretes up to an

age of 12 months were negligibly small. The results suggest that compressive
strength is comparatively less sensitive to the curing regimes investigated. Both the
chloride and sulphate penetration after 12 months exposure were found to be
within tolerable limits. also replacement of lightweight fine aggregate with normal
weight sand produces a concrete that is somewhat more durable as indicated by
their water penetrability and depth of carbonation when concretes are of equal
strength.
f) Tommy Y. Lo, W.C. Tang, H.Z. Cui, (2007) “The effects of aggregate properties
on lightweight concrete”. [6] This paper describes a study of the effects of several
factors on the strength of lightweight aggregate concrete composites: aggregate
strength, w/c ratio and the porosities of the interfacial zone and within the hardened
cement paste. Concrete samples with three different water cement ratios (i.e. 0.4,
0.44, 0.48) were compared. The crushing strengths of three grades of expanded
clay lightweight aggregates (i.e. 25, 15, 5 mm) and the pore distributions of the
hardened cement pastes were measured. Increasing the water/cement ratio was
found to decrease the strength of lightweight aggregate concrete. The numbers of
pores within the cement paste and in the aggregate/cement paste interfacial zone
were found to increase.
g) Mohamed G. Mahdy, Mohamed Abd Elrahman, May M. Atyia, (2021)
“Production and properties of lightweight concrete incorporating recycled waste
crushed clay bricks”.[7] The huge amount of waste crushed clay bricks (CCB)
causes serious environmental problems worldwide. To deal with this issue and
preserve natural resources, CCB can be recycled and reused in the concrete
industry. This paper investigated the influence of CCB as substitution of cement
and aggregates on the physical, mechanical, and microstructural properties of
concrete. Eight mixtures were prepared and tested to find out the possibility of
reusing CCB as aggregate and as cementitious material for structural concrete
production. Several experiments have been performed to assess the performance of
the concrete. Concrete workability was assessed by measuring the slump of fresh
concrete. For hardened properties evaluation, dry density, compressive strength,
ultrasonic pulse velocity, porosity, thermal conductivity, water penetration test,
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and sorptivity tests have been investigated. In addition, scanning electron

microscopy, X-ray diffraction, and

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h) thermo-gravimetric analysis were implemented to analyze the morphology and

microstructure characteristics of concrete. The experimental results indicated that
CCB can be reutilized as a replacement of normal-weight aggregates to obtain
structural lightweight aggregate concrete with appropriate properties. It was also proved
that grinded CCB has a proper pozzolanic activity and can be used as supplementary
cementitious material to reduce cement content without significant deterioration of
concrete properties.
i) Yasong Zhao ,Jianming Gao, Fei Chen , Chuanbei Liu , Xuemei Chen,(2018)
“Utilization of waste clay bricks as coarse and fine aggregates for the preparation
of lightweight aggregate concrete”.[8] The amount of waste clay bricks has
been increasing as the demolition of old buildings in China, which has caused the
serious environmental problem. Utilizing waste clay bricks as lightweight
aggregates for preparing concrete is a new idea to consume them and save natural
resources. Based on this concept, an experimental study was carried out to evaluate
the feasibility of preparing lightweight aggregate concrete with waste clay bricks
by testing the properties of prepared lightweight aggregate concrete. The results
indicate that the dry densities of all mixtures are about 1700 kg/m3∼1850
kg/m3, meeting the standard requirement for lightweight aggregate concrete
(≤1950 kg/m3), the 28- day compressive strength could reach up to 40 MPa,
and corresponding static elasticity modulus is about 26 GPa. Moreover, both
freeze-thaw resistance and carbonation resistance of all mixtures could satisfy the
service requirements of Chinese standard (JGJ 51), and the chloride migration
coefficient varies from 5.0 × 10−12 m2/s and 19.0 × 10−12 m2/s, corresponding with
chloride penetration resistance of concrete from high to low. It has been proved that
consuming waste clay bricks by preparing lightweight aggregate concrete with waste clay
bricks as coarse and fine aggregates is a promising way and has application potentials.
j) Ali A. Aliabdo , Abd-Elmoaty M. Abd-Elmoaty, Hani H. Hassan, (2014)
“Utilization of crushed clay brick in concrete industry”[9] A comprehensive
experimental program regarding the use of recycled aggregates produced from
demolition of brick buildings is presented. The brick wastes were crushed, sorted
and classified into coarse and fine aggregates as well as powder (CBP). The first
phase of the research focuses on the effect of incorporating recycled aggregates on

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physico-mechanical properties of paste, mortar and concrete. Non-traditional tests

including X-ray diffraction (XRD), thermo-gravimetric analysis (TGA) and micro-
structural analysis (MSA) were performed. The second phase of the program
explores the effect of using recycled aggregates on properties of concrete masonry
units. A total of 44 mixtures were utilized throughout the program. Results show
cement paste when modified with 25% CBP achieves smaller pore size and lower
weight loss under high temperature than reference paste. Furthermore, the use of
recycled aggregates reduces the overall unit weight of concrete masonry units.
Actually, modified concrete masonry units incorporating recycled aggregates
achieve lower unit weight, higher thermal resistance and absorption rate than
reference units. Although considerable strength reduction is noticeable by
substitution, compressive strength levels meet the Egyptian specifications
limitations. Critical replacement ratios are suggested to produce load bearing-
concrete masonry units. Based on experimental evidences, it can be stated that the
use of recycled aggregate and dust made of clay bricks is promising in many
applications where the thermal resistance, cost and environmental aspects are
imperative.
k) Fouad M. Khalaf [email protected] Affiliations, (2006) “Using
Crushed Clay Brick as Coarse Aggregate in Concrete” .[10] This paper provides
the results of an experimental investigation into the use of crushed new clay brick
as coarse aggregate in producing concrete. The present investigation is the first
phase of a two-phase program to study the effects of using recycled masonry
aggregate (predominately made of clay brick) with its impurities on the properties
of fresh and hardened concrete. Four different types of new clay bricks with
different compressive strengths were used in the investigation. Several physical
and mechanical properties of fresh and hardened concrete produced from crushed
clay brick aggregates were determined and compared to concrete produced using
granite as a proven aggregate.
l) Shiren Osman Ahmed, (2024) “Study Properties of Eco-Friendly Lightweight
Concrete Made with Crushed Clay Bricks”.[11] Recycling crushed clay bricks
(CCB) in concrete is a sustainable and cost-effective process. Huge quantities of
crushed clay bricks waste cause many serious environmental problems around the

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world. To

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deal with this problem, crushed bricks were recycled in the concrete industry as an
alternative to natural resources, and the brick powder was reused as a partial
replacement for cement. The objective of this paper is to study the effect of crushed
clay bricks on the characteristics of concrete. 7 concrete mixtures containing coarse
crushed brick aggregate (CCBA) and fine crushed brick aggregate (FCBA) were
prepared as a complete substitute for sand and dolomite, respectively. Clay brick powder
(CBP) and silica fume were used as a partial substitute for cement by 5%, 10%, and
15% of its weight. The water-to-cement ratio was 0.35. For comparison, a control
mixture was prepared. Various tests were conducted to evaluate the performance of
concrete. The results showed that the workability of the different mixtures containing
CCB decreased compared to that of the reference mixture. The compressive strength
values of mixtures containing CCBA had a clear decrease compared to the reference
mix at 7, 28, and 56 days of curing. The modulus of rupture results had the same path
as compressive strength results. The thermal conductivity coefficient for mixtures
including CCBA decreased compared to the control mix. Scanning Electron
Microscope images indicated crystals of calcium silicate hydrate because of the
pozzolanic interaction between the brick powder and the fine crushed clay bricks with
calcium hydroxide.
m) H Adem, E Athab, S Thamer , AT Jasim4 (2019) “The behavior of Lightweight
Aggregate Concrete Made with Different Types of Crushed Bricks “.[12] Lightweight
concrete can significantly reduce a dead load of structural concrete elements
compared to normal weight concrete. The reuse of construction and demolition
wastes, especially crushed clay bricks, represents a major contribution to the
environment. Due to the nature of clay bricks, it can be considered as source of fine
and coarse aggregate to produce lightweight structural concrete .In this study, used
three types of crushed clay brick as coarse aggregate for concrete aiming to produce
structural lightweight concrete. Density, compressive and flexural strengths were
tested. Results show that the 28-day air-dry density, compressive and flexural
strengths values of the concrete made with Iso crushed brick were higher than that for
concrete made with crushed Iranian and Nahrawan bricks. Results of 28 air-dry
density and compressive strength show that the lightweight concretes used were
complied with the requirements for lightweight structural concrete
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environment, reduce energy consumption, reduce the cost of concrete, improve the
properties of concrete, and obtain lightweight concrete for high buildings with more
fluidity for narrow places. Also, it discusses the best replacement ratios because the
knowledge about them is still lake. Three mixes of concrete were used and tested. Mix-1was
the standard, where the replacement of coarse aggregate with crushed brick aggregate
has been used in mix-2, the mix-3 was to study the replacement of fine aggregate by
powder brick. In this analysis, only two factors were taken into account: the
percentage of coarse aggregate replaced by brick aggregate (from 0 to 50%) and the
percentage of fine aggregate replaced by brick aggregate (from 0 to 75%).
Compressive strength was tested after curing at ages (7, and 28) days. The results
showed that concrete with crushed brick aggregate reduces unit weight and increases
of compressive strength of concrete. Using mix-2 increased the compressive strength
by about 9.7%, and 7% at ages (7, 28) days respectively, and reduced the weight by
11%. Also, using mix-3 increased the compressive strength with high percentages of
about 59%, and 61% at ages (7, and 28) days respectively, with a little percentage of
reducing the weight by 2%.
n) Md. Emran Ali , Moustakem Khondaker Moin , Md. Rashedul Haque, Shakil Bin
Aziz3,(2022) “Performance Evaluation of Structural Lightweight Concrete Using
Jhama Brick as a Partial Replacement of Coarse Aggregate”.[14] Through the
ancient time structural lightweight concrete has been used successfully all over the
world due to having its pleasant property of reducing dead load of multi-storied
buildings which is very much important for high rising structures. This research
represents the experimental works on the structural lightweight concrete to observe
the cost and the physical properties using jhama brick (also known as over burnt
brick) chips as partial replacement of coarse aggregate. For producing C-35 grade
concrete, jhama brick chips was used for the partial replacement of coarse
aggregate by 0%, 5%, 10%, 15%, 20%, 25%, and 30% weight of coarse aggregate.
For this purpose, 21 sets of cylinders (100 mm x 200 mm) were prepared. Slump
tests were carried out for each mix in the fresh state and 3, 7 and 28 days of
compressive strength tests were also performed in the hardened state.
o) M. A. Mansur, T. H. Wee, and S. C. Lee (1999) “ Crushed Bricks as Coarse Aggregate for
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Concrete”.[15] The suitability of crushed clay bricks as coarse aggregate for concrete has
been assessed by making a direct comparison of the basic properties with those of
equivalent conventional concrete. Four basic mixes were chosen for crushed granite to
achieve concrete with grades ranging from 30 to 60 .
MPa. The equivalent brick-aggregate concrete for each mix was obtained by
replacing granite with an equal volume of crushed bricks; everything else
remaining the same. Test results indicate that brick-aggregate concrete can attain
the same compressive strength, a higher tensile strength, a lower drying
shrinkage, and almost identical specific creep when compared to conventional
concrete

2.1 Points to be observed

 Several studies have demonstrated the feasibility of using waste crushed bricks
(WCB) as a replacement for natural aggregates in lightweight concrete.
 Concrete incorporating crushed bricks has comparable compressive strength to
conventional concrete, especially with supplementary materials like silica fume
and metakaolin.
 Workability is slightly reduced when using recycled bricks due to their high water
absorption, which affects slump values.
 Lightweight concrete with crushed bricks provides better thermal insulation,
making it ideal for energy-efficient building applications such as roof slabs and
partition walls.
 The use of waste materials like crushed bricks helps in reducing landfill waste and
environmental pollution.
 Reducing reliance on natural aggregates makes this method a cost-effective
alternative for sustainable construction.
 Due to the porosity and angularity of crushed bricks, mixing and finishing
processes require experienced labour.

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Chapter 3
MATERIALS AND METHODOLOGY
3.1 Introduction to Materials
The concrete mix is prepared using the normal materials i.e., cement, fine
aggregate coarse aggregate apart from this experimental point of view the
replacements of natural ingredients for cement and fine aggregate the use of
waste material such as Recycled Brick

 Cement
Portland cement is the most common type of cement in general use around the
world and bean used as the basic material in concrete, mortar, stucco. It was
firstly developed from other type of hydraulic lime England in the mid 19th and
usually originates from the lime stones. It is a fine powder produced by heating
materials in a kiln to form clinker, grinding clinker and adding small amounts of
other materials final product so formed is called as CEMENT. The low cost and
wide spread availability of lime stone, shale and other naturally Occurring
materials used in Portland cement make it one of the lowest-cost Materials
widely used over the last century throughout the world. Ordinary Portland
cement of 43 grades with brand name ultra tech shall confirm (IS 8112-1989)
standards have been used in the preparation of the concrete mix for casting
different specimen.

Fig 3. 1 Cement (43 Grade)

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 AGGREGATE
Aggregates are defined as the inert, granular and inorganic materials that normally
consist of stone or stone like solids. Aggregates can be used alone (in road bases and
various types of fill) or can be used with cementing materials (such as Portland cement
or asphalt cement) to form a composite material or concrete. Approximately 3/4th of
volume of Portland cement concrete is occupied by aggregates

 Classification of aggregates: -
Aggregates can be divided into several categories according to different criteria
 Fine aggregate (sand)
The aggregates passing through 4.75MM sieve and retained75MM sieve is
known as the fine aggregate. The use of fine aggregates free from any organic
particles and less amount of silt has been used. The used material be shall
confirming the IS code 383-2016
 Coarse aggregate: -
Aggregates predominately retained on the IS sieve 4.75mm size are usually
termed as the coarse aggregate, the maximum size of the coarse aggregate shall
not exceed 20mm. The used material be shall confirming the IS code 383-1970
a crushed natural stone from local crushers has been used. The test of natural
aggregate are conducted as per IS 383-2016

Figure 3. 2 Aggregate
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 CRUSHED BRICK
Crushed brick is a recycled aggregate made from old bricks that are left over
from construction and demolition sites. It's created by grinding up the bricks
into small and medium sized aggregates, as well as fine particles called cracker
dust. The pieces are then screened for dirt, put through an impactor, and
divided by size .
Crushed brick is popular because it's cheaper to manufacture than other
aggregates, and it's sustainable. Recycling and reusing bricks reduce the strain
on landfill sites, which helps to reduce greenhouse gas emissions

Figure 3.3 Crushed Bricks

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3.2 METHODOLOGY
 Testing of concrete
Workability refers to the ease with which a fresh concrete mix can be handled, and it can
be measured using the slump test. Slump test was conducted for each batch of fresh
concrete according to the requirements of Indian Standards IS 516: 1959 . The bulk
densities of the hardened samples were obtained in accordance with Indian Standards IS
516: 1959 . for
concrete at 7, 14, 21, and 28 days of curing respectively. On the day of testing, the cubes
were removed from the curing tank and subjected to room temperature for about three
hours before their densities were determined prior to crushing. A compressive testing
machine was used to conduct the compressive strength test on the concrete cubes at 7, 14,
21, and 28 days respectively in accordance with Indian Standards IS 516: 1959 . . The
mean values of the bulk density and compressive strength of twelve concrete cubes for
each curing age and coarse aggregate group were calculated and recorded.

 Workability
The slump of fresh concrete mixes of NAC and RAC were 90 mm and 100
mm. The slump of different concrete samples fell within the range of 25-100 mm,
indicating medium workability (Dhir and Jackson, 1996). Based on workability, both
NAC and RAC using the given concrete mix and water/cement ratios can be applied in
construction work involving heavily reinforced concrete sections with vibration, and
simply reinforced concrete sections without vibration. Fresh concrete mix of RAC showed
lower workability than NAC for 1:2:4 mix ratio of and water/cement ratio of 0.5.

 Compressive strength

The test results of the 7-, 14-, 21-, and 28-days compressive strength of concrete are
presented in Figure 4. Both NAC and RAC concrete types had similar compressive
strength development with increase in time. As expected, the compressive strength of each
concrete mix increased with age with the 7-day concrete cube attaining the lowest
compressive strength while the 28-day concrete had the highest strength. This is due to
increased amount of hydration products with the longer curing age. Both NAC and RAC

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types had approximately similar compressive strength development with time. The 7-day
compressive strength of concrete generally ranges from 60-80% of the 28-day
compressive strength for

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traditional concrete under standard curing conditions

(Neville and Brooks, 2010). The 7-day compressive strength of NAC obtained in this
study was 85.1% of its 28-day compressive strength, while the 7-day compressive
strength of RAC was 76.4% of its 28-day compressive strength. The compressive
strength of 7-day NAC was slightly higher than the expected range probably due to
higher cement content. High cement content contributes to produce a greater early-age
compressive strength (Safiuddin et al., 2011). The recommended percentage of cement
in a structural concrete mix is 10.2% (Ettu et al., 2013) while the 1:2:4 concrete mix
used in this study represents 14.2% cement content. Table 3 shows the reduction in
compressive strength of RAC in comparison with NAC. The reduction in compressive
strength of RAC ranged from 30-40%. The compressive strength of RAC for 28 days
represents 32.9% reduction of the 28-day compressive strength of NAC. The reduction
in compressive strength of RAC could be attributed to the lower quality of the recycled
aggregate in comparison with virgin coarse aggregate. It should be noted that the RCA
was obtained from a demolished concrete structure of unknown compressive strength.

3.3 PRILIMINARY INVESTIGATION

 The Tests on Materials Conducted Are As Follows: -
1. Test on cement.
2. Test on fine aggregate.
3. Test on coarse aggregate.
4. Test on recycled brick.

Table 1: Test Results Of Ordinary Portland cement

SL NO PROPERTIES RESULTS
1. Specific gravity 3.15
2. Standard consistency 33%
3. Initial setting time 32min
4. Final setting time. 500min

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Table 2: Test Result of Natural Sand

SL NO PROPERTIES RESULTS
1 Specific gravity 2.60
2 Fineness modulus 3.07
3 Water absorption 1.5%
4 Zone grade 2

Table 3: Test Results of Coarse Aggregate

SLNO PROPERTIES RESULTS
1. Specific gravity 2.65
2. Water absorption 1.03%

Table 4: Test Results of Brick Aggregate

SL NO PROPERTIES RESULTS
1. Specific gravity 2.17
2. Fineness modulus 4.3
3. Water absorption 12%

TEST ON FRESH AND HARDENED CONCRETE

 Mix design of M30 grade concrete :
 Grade of designation = M30
 Type of cement = OPC 53 Grade
 Maximum nominal size of aggregate = 20mm
 Minimum cement content = 310Kg/m³
 Workability = 100 Slump
 Exposure condition = Severe condition
 Type of aggregate = Crushed angular aggregate
 Cement used = OPC 53 Grade

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 Specific gravity of cement = 3.15

 Specific gravity of water = 1
 Specific gravity of sand = 2.605
 Sieve analysis of fine aggregate = Zone Ⅱ
 Specific gravity of coarse aggregate = 2.17
( crushed brick)
Soln :
Step 1: Target mean strength
F’ck = fck + 1.65xS
= 30 +1.65 x 5
=38.25 N/mm²

Step 2: Selection of water cement ratio: -

From IS 456 table 5 page 2 with respect to severe condition max water cement ratio
is 0.5, fck = 30N/mm²
Adopting w/c ratio =0.40
Step 3: Selection of water content: -
From IS 10262 table 7 nominal mixed aggregate 20mm
= 186 Kg/m³
= 186 +6/100*186
= 197.16 Kg/m³

Max w/c = (1-20/100) (197.16)

= 157.728 Kg/m³
Step 4: Calculation of cement content:-
Water cement ratio = 0.40
157.728/0.40 = C/C
Cement content = 394.32
kg/𝑚3 540 kg/𝑚3> 310
kg/𝑚3
(HENCE OK)
Step 5: Proportion of volume of fine aggregate and coarse aggregate:- From
table 3 volume of coarse aggregate corresponding to 20mm size aggregate

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and fine aggregate confirming zone 2 for w/c ratio 0.40

CA = 62+1+1 = 64%
FA = 100-64 = 36%
Step 6: Mix calculations: -
a) Volume of concrete = 1𝑚

b) Volume of cement = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑐𝑒𝑚𝑒𝑛𝑡 / 𝑠𝑝. 𝑔𝑟𝑎𝑣𝑖𝑡𝑦 𝑜𝑓 𝑐𝑒𝑚𝑒𝑛𝑡 x 1 /

1000
= 394.32/3.15 x 1/1000 = 0.125kg/𝑚³
c) volume of water = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 / 𝑠𝑝 𝑔𝑟𝑎𝑣𝑖𝑡𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑥 1/1000
= 157.728/1 x 1/1000 =0.157kg/𝑚3
d) volume of all in aggregate = a-(b+c) =1-(0.125+0.157)
= 0.718 m³
e) Volume of crushed brick = e x vol CB
= 0.718 x 0.64
= 0.459 m³
f) Volume of FA = e X VOL FA
= 0.7198 X 0.36
= 0.258 m³
g) Mass of CB = e x vol CB x Sp. Gr x 1000
= 0.718 x 0.54 x 2.17 x 1000
= 997.158kg/ m³
h) Mass of FB = e x vol FB x Sp. Gr x 1000
= 0.718 x 0.36 x 2.605 x 1000
= 673.340 kg/ m³
Step 7: Mix proportions
 Cement = 394.32 kg/ m³
 Water = 157.728 liters
 w/c = 0.40
 Crushed brick = 997.158 kg/ m³
 Fine aggregate = 673.340 kg/ m³
Mix proportion = 1:1.70:
2.52
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Cement Fine aggregate Crushed brick

1 1.70 2.52

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3.5 Test on Fresh Concrete:-

3.5.1 Slump cone test (workability test)
 To determine the optimum water content many test such as Vee-Bee consist
meter, compaction factor, flow table, are conducted among all the slump cone test
is commonly used
 The apparatus used for conducting this procedure consist of a non porous metal
tray, slump cone (300 MM height, 200MM dia at bottom, 100MM dia at top),
tamping rod, trowel, measuring scale.
 Before carrying out this procedure the inner surface of the slump cone is cleaned
and made free from any sort of moisture content and presence of any old set
concrete before commencing the test.
 PROCEDURE :
 The test is carried out using a slump cone which is also known as Abram’s cone.
 The cone is placed on hard non absorbent surface such as metal tray
 This cone is filled with the concrete mix of different water content in 3 layers
(layer by layer). During placing Layer is compacted for 25 times using tamping
rod for the removal of any presence of the air voids.
 At the end of 3rd layer the surface is finished, leveled and any excess material on
outside of cone is removed.
 Then the mould is carefully lifted without disturbing the concrete fill with
twisting motion. Concrete subsides.
 Thus subsidence is termed as slump.
 And is measured to nearest 5MM if the slump is less then 100MM and if the
slump is greater the 100MM it is measured near to 10MM.

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Figure 3.5.1 Slump Test

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3.6 TEST ON HARDEN CONCRETE

The following test were conducted on the concrete specimens casted with 100% of
replacement of natural sand by M-Sand and egg shell powder replaced to cement at
0%, 5%,10%,15%
The different specimen of cube, cylinder and prism were casted for different mix
percentage and cured for 3days, 7days, and 28days and tested respectively. The
following tests were conducted on different specimen at different curing periods:-

3.6.1 Compressive Strength Test:-

To calculate the compressive strength test of concrete cubes (150MM x 150MM x
150MM) the compression testing machine (CTM) of loading capacity 2000KN
was used shown in fig 6.1
Compressive strength of concrete can be defined as the processes of the
mechanical test measuring the maximum amount of compressive load a material
can bear before fracturing. The test specimen is usually in shape of the cube or
cylinder placed between plates of loading frame and is subjected to gradually
applied load.
It is a well known fact that the brittle material such as Rock, and concrete may
exhibit the greater compressive strength but ultimately they fail and the failure
mode is fracture one
The compressive strength of the brittle material varied from 3tonnes per square inch
for the cube and 10tonnes per square inch for the granite stone.
Some ductile material such as mild steel also poses some the compressive strength
but the measuring of actual values is difficult due its elastic failure nature. When
the load on ductile material is applied it deforms elastically up to certain point
which is followed up with the plastic deformation when the load is future
increased the flattening of the plats may take place without any definite fracture
occurring.

It is standard test, to determine the compressive strength of concrete in an

indirect way. This test is conducted in accordance to IS 5816-1970A standard
test cube of concrete specimen (150mm x150mm x 150mm) is placed

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horizontally between loading surface of compression testing machine

Figure 3.6.1
The compressive strength of cube is determined using relation

Compressive strength = 𝑃 𝐴 N/𝒎𝒎𝟐

Where:-P= ultimate compressive strength.
(N) A= cross sectional area (𝑚𝑚2 )
3.6.2 Split Tensile Strength: -
It is the standard test, to determine the tensile strength of concrete. This test can be
Performed in accordance width IS 5816-1970.
A standard test cylinder of concrete specimen (300MM x 150MM diameter) is placed
horizontally between the loading surfaces of compression testing machine. The
compression load is applied diametrically and uniformly along the length of the
cylinder until the failure of the cylinder specimen along the vertical axis
Due to this compression loading along the vertical diameter of the cylinder it is
subjected to a vertical compressive stress and a horizontal stress.
The loading condition produces a high compressive stress immediately below loading
points but the larger portion of cylinder, corresponding to its depth is subjected to

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uniform tensile stress acting horizontally. It is estimated that the compressive

stress is acting for about 1/6 depth and the remaining portion 5/6 depth is
subjected to tension.
The split tensile strength of specimen is determined by the following relation:- Split
tensile strength = 2𝑃 𝜋𝐷2 (N/𝒎𝒎𝟐 )
Where:-
P =compressive load. (KN)
D= diameter of cylinder. (MM).

L= length of cylinder. (MM)

The split tensile strength of the concrete varies from 1/8th to 1/12th of the
compressive strength of cube

Figure 3.6.2 Compression Test

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Chapter 4
RESULT AND DISCUSSION
4.1Test on Fresh Concrete
4.1.1 Test Result of Slump cone test

Water / Cement Ratio Slump (mm)

0.36 85
0.38 92
0.40 110
0.42 96
0.44 94

Slump Test
120
110.00
Slump value

100 96.0
92 94
80 85

60
40

20
0
0.36 0.38 0.40 0.42 0.44

Water / Cement Ratio

Fig No 4.1.1: Graph b/w Slump V/S Water/Cement Ratio

The graph illustrates the slump test result, which is used to determine the
workability or consistency of the concrete. For further explanation, X-
Axis: Water/Cement Ratio:
The water-to-cement (W/C) ratio is the horizontal axis, ranging between
0.36 and 0.44. This ratio is one of the critical factors that determines the
workability and strength of the concrete.

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y-axis: Slump Value: The vertical axis is the slump value in millimeters
(mm) that

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describes the consistency of a concrete mix. Generally speaking, the higher

 The slump value begins at about 80 mm when the W/C ratio is 0.36.

It rises straight, reaching a maximum slump value of about 120 mm when the W/C
ratio is 0.40. After this maximum, the slump value does decrease with an increase
to a W/C ratio of 0.44.
 Interpretation: It increases with the slump value at around up to a W/C ratio of
0.40 that when water content is increased then increasing that amount enhances
the workability of concrete so easy mixes could be placed.
 After having peak values of slump drop, it might mean too much water dilutes
cohesion or reduces the stability, giving poor mix segregation
4.1.2 TEST RESULT OF COMPACTION FACTOR VALUES
SL Description Sample Sam Sam Sample Sam
p p p
NO 1 4
l l l
e e e
2 3 5
1 Weight of Empty Cylinder 10 10 10 10 10
(W1)
2Weight of Empty Cylinder + 18 18.6 19.01 18.5 18.8
Free Fall Concrete (W2)
3 Weight of Empty Cylinder + 19.5 20 20.3 20.1 20
Hand Compacted Concrete
(W3)
4 Weight of Partially 8 8.4 9 8.6 8.8
Compacted
Concrete
(Wp =W2 -W1)
5 Weight of Fully Compacted 9.5 10 10.3 10.2 10
Concrete (Wf =W3 -W1)

6 Water / Cement Ratio 0.36 0.38 0.40 0.42 0.44

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10.4
Compaction Factor

Compaction
10.2
10.
10.
10 10 10
9.8

9.6 9.5
9.
4

9.2
0.36 0.38 0.40 0.42 0.44
Water / Cement
Fig No 4.1.2: Graph b/w Compaction factor V/S Water/Cement Ratio

This graph depicts the relationship of the water-to-cement ratio (W/C ratio) and the
compaction factor of lightweight concrete utilizing recycled brick as coarse aggregate.
An expanded discussion on the trend in the curve is shown hereunder:
1. Rising Compaction Factor between 0.36 and 0.40 W/C Ratio: The compaction
factor will increase with the water-to-cement ratio, reaching the peak at a W/C ratio of
0.40 This means that until this point, the workability of the concrete increases,
presumably because of the higher water content that increases lubrication and
facilitates better compaction.
2. Peak at 0.40 W/C Ratio: Maximum compaction factor is noted at 0.40 W/C ratio. This
could be the best balance of water and cementitious material for recycled brick
aggregate in order to reach maximum density.
3. Deteriorating Compaction Factor (0.40 to 0.44 W/C Ratio): At this point, beyond 0.40
W/C ratio, the compaction factor begins to deteriorate. It is supposed that excessive
water content segregates the mixture, lowering its cohesiveness. Because of this, its
ability to compaction becomes lesser and is expected to degrade.
4. Lightweight concrete design implication: Peak W/C ratio has to be known to reach
a point to achieve the best density coupled with best strength properties maintaining
reasonable workability.
For this analysis, the optimal W/C ratio is about 0.40, where the maximum compaction
factor is attained.

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4.2 TEST ON HARDEN CONCRETE

TABLE 4.2.1 COMPRESSIVE STRENGTH TEST
Mix Curing Surface Load Compressive Average
age area (KN) strength compressive
(days) (mm2) (N/mm2) strength
(N/mm2)
3 150x150 515 22.9
AOZ1 3 150x150 519 23.08 23.55
3 150x150 555 24.67
7 150x150 562 25.01
AOZ2 7 150x150 538 23.92 24.51
7 150x150 553 24.62
28 150x150 807 35.91
36.70
AOZ3 28 150x150 823 36.60
28 150x150 846 37.60
Table 4.2.2 CONVENTIONAL CONCRETE TEST

Mix Curing Surface Load Compressive Average

age area (KN) strength compressive
(days) (mm2) (N/mm2) strength
(N/mm2)
3 150x150 320 14.24
AOZ1 3 150x150 357 15.87 15
3 150x150 335 14.89
7 150x150 532 23.68
AOZ2 7 150x150 540 24.01 24.17
7 150x150 558 24.82
28 150x150 792 35.20
AOZ3 28 150x150 810 36.02
36.06
28 150x150 832 36.98

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Compressive
Strength

Strenght(N/mm²)
40
Compressive
20

L…
0

3 Days 7 Days 28 Days

Curing Days
Normal concrete Light Weight Concrete

Figure 4.2.1 Compressive Test Graph

This bar chart shows a comparison of compressive strength of two different types of
concrete: normal concrete and lightweight concrete, over three curing periods: 3 days, 7
days, and 28 days. In this explanation:
Y-axis (Compressive Strength in N/mm²): This is the compressive strength of the
samples in Newtons per square millimetre (N/mm²).
X-axis (Curing Days): Represents the number of days that the concrete has been cured,
with data available at 3 days, 7 days, and 28 days.
Bars:
Blue bars indicate normal concrete. Orange bars indicate lightweight concrete.
Observations:
At 3 days: Lightweight concrete has a higher compressive strength than normal concrete.
At 7 days: The compressive strengths of both normal and lightweight concrete are almost
the same.
At 28 days: Both types of concrete have almost the same compressive strength, although
lightweight concrete has a higher value than normal concrete.

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Table 4.2.1 Split Tensile strength Test

Mix Curing Surface Load Compressive Average

age area (KN) strength compressive
(days) (mm2) (N/mm2) strength
(N/mm2)
3 150x300 22 1.250
AOZ1 3 150x300 20 1.149 1.273
3 150x300 25 1.42
7 150x300 41 2.34
AOZ2 7 150x300 43 2.47 2.42
7 150x300 43 2.45
28 150x300 57 3.23
AOZ3 28 150x300 63 3.57
3.47
28 150x300 65 3.68

Table 4.2.2 CONVENTIONAL CONCRETE

Mix Curing Surface Load Compressive Average

age area (KN) strength compressive
(days) (mm2) (N/mm2) strength
(N/mm2)
3 150x300 20 1.150
AOZ1 3 150x300 18 1.049 1.13
3 150x300 21 1.21
7 150x300 38 2.19
AOZ2 7 150x300 40 2.29 2.24
7 150x300 39 2.26
28 150x300 55 3.12
AOZ3 28 150x300 59 3.35
3.27
28 150x300 59 3.34

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Split Tensile Strenght

4
3.5

Strenght(N/mm²)
Split Tensile 3
2.5
2
1.5
1
0.5
0
3 Days 7 Days 28 Days

Curing Days
Normal Concrete Lightweight Concrete

Figure 4.2.2
This bar chart compares split tensile strength of regular concrete and lightweight concrete
through three curing periods: 3 days, 7 days, and 28 days. Here's a detailed analysis:
Axes: Y-axis (Split Tensile Strength in N/mm²):
This axis represents split tensile strength of concrete samples measured in Newtons per
square millimetre, N/mm².
X- axis (Curing Days): This axis indicates the period of curing in days where data is
available for 3 days, 7 days, and 28 days.
Bars:
Blue bars: Splits tensile strength of normal concrete.
Orange bars: Splits tensile strength of lightweight concrete.
At 3 days: Split tensile strength of lightweight concrete is marginally greater than that of
normal concrete.
At 7 days: Split tensile strength of lightweight concrete is slightly lesser than that of
normal concrete, however the difference is minimal.
At 28 days: Both concrete types attain comparable split tensile strength values, although
lightweight concrete is marginally equal to or slightly greater than normal concrete.

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Chapter 5
CONCLUSION

1. Performance of Lightweight Concrete (LWC):

o The experimental study demonstrates that lightweight concrete using recycled

crushed brick aggregate achieves comparable compressive and tensile strength to
conventional concrete.

o Results indicate better or similar performance in terms of strength over curing

periods (3, 7, and 28 days).

2. Advantages of Using Recycled Materials:

o Using crushed brick as a coarse aggregate in LWC reduces the unit weight of
concrete, offering advantages like reduced structural loads.

o Enhances sustainability by effectively utilizing construction and demolition waste.

3. Workability and Durability:

o The LWC mix displayed acceptable workability and could meet the design mix
requirements while being easier to handle and transport.

4. Environmental and Economic Benefits:

o This approach is environmentally friendly and cost-effective, offering potential

savings in material and construction costs.

5. Scope for Structural Applications:

o The findings suggest that lightweight concrete with recycled materials can be used
in a variety of structural and non-structural applications, including energy-efficient
and sustainable construction.

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FUTURE SCOPE

 Lightweight concrete (LWC) has a wide range of potential applications, including

in construction, insulation, and energy efficiency. Here are some ways that LWC
can be used with bricks
 Crushed bricks can be used to produce structural LWC. LWC can be used in a
variety of construction projects, including buildings, bridges, and infrastructure.
 LWC can be used in wall panels, roof systems, and insulation blocks. Perlite, a
lightweight a g g r e g a t e , i s o f t e n used as loose-fill insulation in
masonry construction.
 LWC's lower density and higher thermal insulation make it ideal for energy-
efficient applications. Vermiculite is a lightweight aggregate that can be used to
improve thermal efficiency and act as an acoustic buffer
 LWC's decreased density makes it easier to handle and carry during construction
 LWC reduces dead loads on structures, which can save money on foundations and
reinforcement
 LWC is over half the weight of regular concrete, so it can be installed more quickly
and easily.

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REFERENCES
1. Yasser M. Hussein, Mohamed Abd Elrahman, Yara Elsakhawy Bassam A. Tayeh,
Ahmed M. Tahwia (2022) “Development and performance of sustainable
structural lightweight concrete containing waste clay bricks”.
2. Saad Muhammad Selman, Dr. Zena K. Abbas, (2022) “The Use of Lightweight
Aggregate in Concrete”
3. Ahmed Tareq Noaman, Ghassan Subhi Jameel, Shamil K. Ahmed, (2021)
“Producing of workable structural lightweight concrete by partial replacement of
aggregate with yellow and/or red crushed clay brick (CCB) aggregate
4. Karl-Christian Thienel, Timo Haller, Nancy Beuntner, (2021) “Lightweight
Concrete—From Basics to Innovations”.
5. M.N Haque, H Al-Khaiat, O Kayali (2004) “Strength and durability of lightweight
concrete”.
6. Tommy Y. Lo, W.C. Tang, H.Z. Cui, (2007) “The effects of aggregate properties
on lightweight concrete”.
7. Mohamed G. Mahdy, Mohamed Abd Elrahman, May M. Atyia, (2021)
“Production and properties of lightweight concrete incorporating recycled waste
crushed clay bricks”.
8. Yasong Zhao, Jianming Gao, Fei Chen , Chuanbei Liu , Xuemei Chen,(2018)
“Utilization of waste clay bricks as coarse and fine aggregates for the preparation
of lightweight aggregate concrete”.
9. Ali A. Aliabdo , Abd-Elmoaty M. Abd-Elmoaty, Hani H. Hassan, (2014)
“Utilization of crushed clay brick in concrete industry”
10. Fouad M. Khalaf [email protected] Affiliations, (2006) “Using
Crushed Clay Brick as Coarse Aggregate in Concrete”.
11. Shiren Osman Ahmed, (2024) “Study Properties of Eco-Friendly Lightweight
Concrete Made with Crushed Clay Bricks”.
12. H Adem, E Athab, S Thamer, AT Jasim4 (2019) “The behavior of Lightweight
Aggregate Concrete Made with Different Types of Crushed Bricks
13. Hajer Satih Abbas, Shaima Sabri Ali, Alaa Hassoon,(2023) “Using recycled bricks

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to improve the compressive strength of concrete and produce lightweight concrete

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14. Md. Emran Ali , Moustakem Khondaker Moin , Md. Rashedul Haque, Shakil Bin
Aziz3,(2022) “Performance Evaluation of Structural Lightweight Concrete Using
Jhama Brick as a Partial Replacement of Coarse Aggregate”.
15. M. A. Mansur, T. H. Wee, and S. C. Lee (1999) “ Crushed Bricks as Coarse
Aggregate for Concrete”

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PHOTO GALLERY

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