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The use of fly ash and basaltic pumice as additives in the production of clay
fired brick in Turkey
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Hanifi Binicia, Orhan Aksoganb, Huseyin Temizc, Hasan Kaplana, Ahmet Ulusoyc
a
Epoka University, Department of Civil Engineering, Tirana, Albania
b
Cukurova University, Department of Civil Engineering, Adana, Turkey
b
Kahramanmaras Sutcu Imam University, Department of Textile Engineering, Kahramanmaras, Turkey
Table 2. The physical properties of the materials used. 2.2. Production of bricks
Properties Clay BP F Nine types of samples were prepared by adding fly ash (F)
Bulk density (g cm )–3
1.27 1.12 1.34 and basaltic pumice (BP) each in equal proportions of 5,
Water absorption (%) 0.86 1.22 1.33 10 and 20 wt.%, as given in Table 7. The control speci-
Porosity (%) 35.20 50.32 – mens without additives were produced with equal amounts
Specific gravity (g cm–3) 1.85 2.74 3.16 of red and gray clay. Pressed brick specimens were shaped
under a load of 300 kg cm–2 in a square prism mould of
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Specimens Compositions
Both the dry and the fired bulk densities were determined
each of the specimens. Moreover, shrinkage, water absorp-
tion, dried and fired density, harmful magnesia and lime,
compressive and flexure strength tests were performed. Se-
ven specimens were tested for each group. Furthermore,
freezing and thawing resistance of the bricks was investi-
gated. In this test, the samples were placed in a freezing
and thawing machine and tested from – 20 8C to + 20 8C for
25 cycles. Brick quality was determined in accordance with
TS EN 4790 [16] and ASTM C67 [17].
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ignition (LI) of the raw materials. The chemical composi- a decreasing trend with increasing temperature. As the per-
tion of the clay is typical of a kaolinite-based material with centage of additives decreases, the bulk density of the brick
low amounts of alkaline oxides and relatively high amount decreases also, as in the dried ones.
of Al2O3. The high percentage of LI indicates an increased The porosity of bricks and their permeability and water
fraction of clay minerals. The basaltic pumice is basically absorption are very crucial factors in influencing technical
composed of high amounts of SiO2. The second major properties of bricks such as the bond between them and
chemical constituent of the basaltic pumice is Al2O3. Ac- mortar, the resistance of bricks to freezing and thawing,
cording to Figs. 3 – 6, all materials show a distribution of and their chemical stability. Basaltic pumice samples fired
fine particles with equivalent spherical diameter smaller at all temperatures were found to be within specifications.
than 28 mm. This characteristic of the materials is appropri- However, samples of the series F5, F10, F20 and FBP10,
ate for fired brick production. The real density of the mate- FBP20, fired at all temperatures, have slightly higher water
rials was measured by picnometry. absorption values than the value required by the Turkish
standard (18 % by weight). This is because an increase in
3.2. Mechanical properties sintering temperature causes a decrease in total-pore space
in the structure. The water absorption values increased by
Dried and fired densities are given in Figs. 1 and 2, respec- increasing firing temperature, amounts of fly ash and joint
tively. It is seen that although the addition of basaltic pu- fly ash + basaltic pumice additives in the mixtures.
mice causes an increase in the dried bulk density of the Lime–magnesia tests were carried out. The samples were
brick, fly ash causes a decrease. This behavior is due to the placed in a water tank at room temperature for 24 h and
coarser particle size of the basaltic pumice as compared then in a boiling water tank for 2 h. After the test, the sam-
with that of the fly ash. In Figs. 1 and 2, it is observed that ples were examined for any structural damage such as frac-
Table 8. The water absorption of bricks. ture, disintegration and decomposition and no damage was
observed (Tables 9 – 11). The samples were tested for dur-
Specimens Firing temperature (8C) ability and the results showed that the samples satisfied the
700 900 1 050 TS 705 specifications.
Fired bricks with high replacement ratio of fly ash and
Water absorption (%) basaltic pumice (except specimen BP20) are lighter than
conventional fired clay. The samples were fired at 700 8C,
C (Control) 17.62 17.83 18.85 900 8C and 1 050 8C and then tested to determine the com-
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F5 22.17 22.24 22.64 pressive and flexure strength of the bricks. An apparatus
F10 25.81 25.72 25.83
with a capacity of 25 kN pressure was used in the proce-
F20 27.31 27.48 26.35
BP5 15.77 17.15 17.51
dure. The minimum average crushing strength prescribed
BP10 15.37 17.26 16.79 in the Turkish code for burnt clay bricks is 5 MPa. It was
BP20 14.03 16.79 16.07 observed that in all mix proportions, even those with high
FBP5 18.04 18.58 19.43 addition content, the compressive strength of the samples
FBP10 19.12 19.38 20.32 was found to be above 5 MPa (Fig. 3).
FBP20 21.35 21.34 20.99 The compressive strength of all fired bricks is given in
Fig. 3 and variations of the flexural strength are shown in
Fig. 4. Specimen BP5 yielded the highest compressive
Table 9. Physical properties of specimens fired at 700 8C. strength at all temperatures. However, bricks with basaltic
Specimens Harmful magnesia Surface Color
and lime brightness
pumice yielded higher compressive strength than the important effect) than control specimens. The compressive
others. strength of the bricks decreases roughly 10 % showing the
At 1 050 8C firing temperature, specimens with basaltic pu- significance of freezing and thawing effect.
mice had the lowest compressive strength. This is due to the
burning of the glass minerals of the basaltic pumice, which
causes a loss of mass. Hence the optimum firing temperatures
of the bricks with basaltic pumice should be under 1 050 8C.
In general, the flexural strength of bricks increases with
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3.3. Shrinkages
After carrying out the tests, the samples were examined for
cracks, decomposition or scaling and no damage was ob-
served (Figs. 5 and 6). As seen in Fig. 6, only control and
FB20 specimens had slight cracking and fractures on the
external surfaces. However, it is seen in Fig. 6 that other
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Table 13. Compressive strengths of bricks after freezing and layer water and absorbed water at low temperatures. This
thawing cycles. caused a shrinkage in the bricks and increasing in the con-
tact areas of particles of fly ash and clay, resulting lower
Sample Firing temperature (8C)
porosity in the bricks as well. The lower porosity, in turn,
700 900 1 050 enhances the mechanical properties of the bricks and the
freezing – thawing resistance as well.
C 12.30 16.50 18.10 Basaltic pumice used in this study had a high porosity.
C 15.67 27.09 26.35 This renders it easy to crush. With clay particles filling in
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F5 6.80 19.05 23.08 the pores of pumice, a more compact brick is obtained,
F5 11.30 12.80 13.10 causing an improvement in many of its physical properties.
F10 5.60 13.18 22.78
However, firing at higher temperatures, such as 1 050 8C,
F10 10.6 10.90 11.20
F20 12.46 13.51 20.33
causes some of the pumice to melt and voids to form in the
F20 9.30 9.80 10.40 bricks. This is the reason for the low strength of bricks fired
BP5 10.40 10.20 19.97 at 1 050 8C with or without freezing – thawing.
BP5 14.60 18.60 14.50
BP10 8.80 9.50 29.37
4. Conclusions
BP10 12.80 15.30 14.60
BP20 25.00 27.50 29.40
BP20 12.40 12.80 14.20 In this work, the evaluation of the fly ash and basaltic pu-
FBP5 18.00 19.50 25.30 mice effect on the properties of fired brick led to the follow-
FBP5 17.90 18.30 19.20 ing conclusions:
FBP10 20.70 23.80 21.50 1. The basaltic pumice and fly ash are wastes predomi-
FBP10 13.50 14.70 16.20 nantly composed of a high percentage of silicon. These
FBP20 17.66 28.65 33.06 materials show a fine particle size that is appropriate
FBP20 9.80 10.40 10.60 for incorporation in fired bricks.
2. Fly ash and basaltic pumice, at certain replacement lev-
els, contribute to decreasing the bulk density of the
bricks.
3. 10 % replacement level of additives decreased the fired
shrinkage and the water absorption.
4. At 700 8C firing temperature, the highest strength was
recorded at 5 % replacement and this is approximately
28 % above the control value. However, for firing tem-
peratures around 900 8C the compressive strength is
nearly equal to that of the control specimen. Above
900 8C firing temperature the compressive strength is
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Fig. 7. Mass loss ratio of bricks after freezing and thawing cycles. This study was supported by The Scientific and Technological Re-
search Council of Turkey (TÜBITAK, Project No. 107T264).
Figure 8 depicts the test results of mass loss after the References
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