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The use of fly ash and basaltic pumice as additives in the production of clay
fired brick in Turkey

Article · January 2020

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A Applied
H. Binici et al.: The use of fly ash and basaltic pumice as additives in the production of clay fired brick in Turkey

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

The use of fly ash and basaltic pumice as


Not for use in internet or intranet sites. Not for electronic distribution.

additives in the production of clay fired brick in


Turkey

Although significant quantities are being used in several in-


The main objective of this study is to investigate the suit- dustrial sectors and particularly as a substitute for cement in
ability of fly ash and basaltic pumice as additives in the pro- concrete, there is still a lot that requires disposal. Hence, the
duction of high quality clay fired bricks. Clay bricks with/ use of fly ash in the production of construction materials
without additives were produced adding equal amounts of will help to reduce environmental problems. On the other
fly ash and basaltic pumice, separately and together, with hand, almost 155 000 km2 of Turkey is covered by Tertiary
the rates of 5, 10 and 20 wt.%. Each sample was fired at and Quaternary-age volcanic rocks, among which pumice
700, 900 and 1 050 8C for 8 h. Bulk density, harmful magne- comprises significant volumes [12]. This material has not
sia and lime, shrinkage, water absorption, compressive and been used efficiently. The aim of the present study is to in-
flexural strength, freezing and thawing tests were carried vestigate the use of fly ash and basaltic pumice both to-
out. The test results were compared with the standard val- gether and separately as admixtures in clay matrix in the
ues and they were found to be satisfactory. Finally, it was production of bricks for wall materials.
concluded that both fly ash and basaltic pumice were suita-
ble admixtures and could be used efficiently in fired brick
2. Experimental program
production.

Keywords: Fly ash; Basaltic pumice; Admixtures; Fired 2.1. Materials


brick
www.ijmr.de

The basaltic pumice used in this study, which is widely


known as scoria, contains glass shards, mineral phases such
as feldspar, quartz and biotite and some volcanic rock. The
1. Introduction high porosity of basaltic pumice is an advantage for easy
and economical crushing [13]. It has dark brown/blackish
The inevitable increase in population increases the demand
color, porous structure and low crystal water. Its hardness
for new and efficient building materials [1]. To meet this
W 2010 Carl Hanser Verlag, Munich, Germany

is about 5.2 on the Mohs scale. The Afsin–Elbistan power


demand, in an environmentally friendly way, some indus-
plant consumes 18.106 metric tonnes of coal per year and
trial wastes have been used in making construction materi-
generates about 3.24.106 metric tonnes of fly ash and this
als. Huge amounts of unmanaged wastes cause serious en-
waste material are disposed of in the dumping area of the
vironmental problems. Since environmental friendliness,
mine [14]. The clay used in the present study is of two col-
low cost and light weight have become very important con-
siderations in the production of construction materials, it is
the aim of the researchers to satisfy the requirements given Table 1. Chemical composition of the materials used.
by the standards. Many recent studies [2 – 7] have found va-
Component (wt.%) Red clay Gray clay BP F
luable results for the use of waste glass in various forms of
construction materials. Also, some studies [8, 9] have in- SiO2 61.60 42.59 46.19 23.21
vestigated the use of different type of ash in the production Al2O3 17.93 11.92 17.26 12.88
of construction materials. Fe2O3 8.24 6.97 11.27 13.06
Environmental assessments of material production make CaO 1.61 13.97 8.98 22.55
it easier to make design decisions in choosing materials for MgO 1.34 6.28 5.27 3.42
a particular application [10, 11]. Brick is one of the main SO3 – – 0.05 12.16
construction materials and is mainly used for the construc- Na2O 0.63 1.33 4.06 0.60
K 2O 1.56 1.39 2.82 2.02
tion of outer and inner walls in buildings. The brick produc- P2O5 0.08 0.14 0.81 0.56
tion industry consumes large amounts of resources and TiO2 0.99 0.71 3.03 23.21
causes some environmental problems. MnO 0.31 0.12 0.18 –
The fly ash produced by coal fired power plants has al- Loss on ignition 5.71 14.58 14.42 9.10
ways been a major problem in many parts of the world.

Int. J. Mat. Res. (formerly Z. Metallkd.) 101 (2010) 7 887


A Applied
H. Binici et al.: The use of fly ash and basaltic pumice as additives in the production of clay fired brick in 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
Not for use in internet or intranet sites. Not for electronic distribution.

115 · 25 · 25 mm dimensions according to TS EN 705


ors, red and gray, and are obtained from two different re-
[15]. Prior to the moulding process, 10 – 18 % water was
gions near Kahramanmaras. The chemical and physical
added to the mix to obtain enough plasticity. After the
properties of the material used are given in Tables 1 and 2,
moulding process, specimens were obtained by uniaxial
respectively. The particle size distributions of materials
press molding at 18 MPa, dried at 110 8C for 24 h and
used are given in Tables 3 – 6.

Table 3. Particle size distribution of the gray clay.

Diameter % Passed Diameter % Passed Diameter % Passed


(lm) (mm) (mm)

200 2.34 0.2 37.97 1.6 74.69


400 5.11 0.4 43.06 1.8 80.69
500 8.11 0.5 47.62 2 87.82
600 12.53 0.75 55.30 2.2 90.34
800 20.22 1 58.54 2.4 94.28
900 25.56 1.2 64.07 2.6 97.70
1 000 32.45 1.4 71.91 2.8 100

Table 4. Particle size distribution of the red clay.

Diameter % Passed Diameter % Passed Diameter % Passed


(lm) (mm) (mm)

200 1.63 0.2 24.96 1.6 54.52


400 3.82 0.4 27.80 1.8 64.26
500 6.28 0.5 30.47 2 78.93
600 9.78 0.75 35.47 2.2 84.39
www.ijmr.de

800 14.94 1 37.88 2.4 93.03


900 18.63 1.2 42.53 2.6 97.29
1 000 21.92 1.4 50.54 2.8 100

Table 5. Particle size distribution of the fly ash.

Diameter % Passed Diameter % Passed Diameter % Passed


W 2010 Carl Hanser Verlag, Munich, Germany

(lm) (mm) (mm)

200 1.78 0.2 34.99 1.6 81.96


400 3.79 0.4 39.93 1.8 91.73
500 6.31 0.6 44.59 2 97.76
600 10.52 0.8 53.12 2.2 98.70
800 18.24 1 57.08 2.4 99.63
900 24.31 1.2 64.46 2.6 100
1 000 29.80 1.4 77.01 2.8 100

Table 6. Particle size distribution of the basaltic pumice.

Diameter % Passed Diameter % Passed Diameter % Passed


(lm) (mm) (mm)

1 0.44 25 10.80 90 36.96


2 1.09 30 12.83 120 47.63
3 1.76 35 14.85 175 66.31
5 2.83 45 18.94 200 74.14
10 4.79 50 21.03 250 86.24
15 6.72 60 25.22 320 95.01
20 8.76 80 33.21 350 100

888 Int. J. Mat. Res. (formerly Z. Metallkd.) 101 (2010) 7


A Applied
H. Binici et al.: The use of fly ash and basaltic pumice as additives in the production of clay fired brick in Turkey

Table 7. The specimen compositions.

Specimens Compositions

C (Control No replacement (pure red and gray clay)


mixture)
F5 5 % Fly ash + 95 % clay
F10 10 % Fly ash + 90 % clay
F20 20 % Fly ash + 80 % clay
Not for use in internet or intranet sites. Not for electronic distribution.

BP5 5 % Basaltic pumice + 95 % clay


BP10 10 % Basaltic pumice + 90 % clay
BP20 20 % Basaltic pumice + 80 % clay
FBP5 2.5 % Fly ash + 2.5 % Basaltic pumice + 95 % clay
FBP10 5 % Fly ash + 5 % Basaltic pumice + 90 % clay
FBP20 10 % Fly ash + 10 % Basaltic pumice + 80 % clay

were put in a vacuum machine to get the remaining air out.


Specimens were kept at room temperature for 1 day and
Fig. 1. Dried densities of bricks.
the drying shrinkage of bricks was measured by a com-
pass. Then, the specimens were fired in an electrical arc
furnace for 8 h. The different firing temperatures used
were 700 8C, 900 8C and 1 050 8C. Finally, fired specimens
were left to cool in the furnace down to room temperature.

2.3. Testing of bricks

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].
www.ijmr.de

3. Results and discussion


Fig. 2. Fired densities of bricks.
3.1. Material characterization
the fired bulk density of the control specimen as well as
Table 1 shows the chemical composition and the loss on those of the ones with fly ash and basaltic pumice display
W 2010 Carl Hanser Verlag, Munich, Germany

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-

Int. J. Mat. Res. (formerly Z. Metallkd.) 101 (2010) 7 889


A Applied
H. Binici et al.: The use of fly ash and basaltic pumice as additives in the production of clay fired brick in Turkey

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-
Not for use in internet or intranet sites. Not for electronic distribution.

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

C (Control) None Good Red


F5 None Good Brown–red
F10 None Good Brown–red
F20 None Good Brown–red
BP5 None Good Light red
BP10 None Good Light red
BP20 None Good Light red
FBP5 None Good Brown
FBP10 None Good Brown
FBP20 None Good Brown

Table 10. Physical properties of specimens fired at 900 8C.

Specimens Harmful magnesia Surface Color


www.ijmr.de

and lime brightness

C (Control) None Good Red


F5 None Good Brown–red Fig. 3. Compressive strength of bricks.
F10 None Good Brown–red
F20 None Good Brown–red
BP5 None Good Light red
W 2010 Carl Hanser Verlag, Munich, Germany

BP10 None Good Light red


BP20 None Good Light red
FBP5 None Good Brown
FBP10 None Good Brown
FBP20 None Good Brown

Table 11. Physical properties of specimens fired at 1 050 8C.

Specimens Harmful magnesia Surface Color


and lime brightness

C (Control) None Good Red


F5 None Good Brown–red
F10 None Good Brown–red
F20 None Good Brown–red
BP5 None Good Light red
BP10 None Good Light red
BP20 None Good Light red
FBP5 None Good Brown
FBP10 None Good Brown
FBP20 None Good Brown
Fig. 4. Flexure strength of bricks.

890 Int. J. Mat. Res. (formerly Z. Metallkd.) 101 (2010) 7


A Applied
H. Binici et al.: The use of fly ash and basaltic pumice as additives in the production of clay fired brick in Turkey

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
Not for use in internet or intranet sites. Not for electronic distribution.

the increase in the firing temperature. At all firing tempera-


tures, the control specimens had the highest flexural
strength. The flexural strength, generally, decreases with
the amount of added fly ash and basaltic pumice.

3.3. Shrinkages

The linear variation of specimen dimensions is shown in


Table 12. It can be seen that the specimens fired at 700 8C,
900 8C and 1 050 8C have shown similar behavior, where a
very small decrease in linear variation between 0 % and
5 % of additive content is noticeable. Table 12 indicates a Fig. 5. The samples in the freezing and thawing machine.
straight tendency for BP group, that the linear shrinkage de-
creases with basaltic pumice content, but the decreasing
gradient is not directly related to the firing temperature in
any way. Maximum shrinkage must be under 10 % in accor-
dance with the Turkish Standard. All specimens satisfied
this requirement. The inert action of the fly ash and basaltic
pumice may have caused this decrease in the shrinkage.

3.4. Freezing and thawing tests

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
www.ijmr.de

specimens showed no significant signs of deterioration.


After the foregoing procedure, compressive strength tests
were performed according to TS 705 and the results are
shown in Table 13. Mass loss ratio of the bricks after freez-
ing and thawing cycles is given in Fig. 7. These results
show that there is an obvious decrease in the freezing and
W 2010 Carl Hanser Verlag, Munich, Germany

thawing resistance of the bricks with an increase in the per-


centage of the additives. Firing temperature is the most sig-
nificant property causing specimens to have longer dormant
periods (the period in which freezing and thawing have no

Table 12. Shrinkage of fired bricks (wt.%).

Specimens Dried Fired shrinkage


shrinkage

110 8C 700 8C 900 8C 1 050 8C

C (Control) 6.55 5.56 5.01 4.23


F5 8.25 8.23 6.46 7.17
F10 8.66 8.36 7.33 8.06
F20 8.87 8.88 8.21 8.36
BP5 1.72 1.88 7.55 7.52
BP10 1.63 1.69 8.42 8.43
BP20 1.49 1.47 9.30 9.32
FBP5 5.15 4.12 5.10 5.19
FBP10 5.11 4.08 5.53 5.55
FBP20 5.03 4.33 6.11 6.18 Fig. 6. The appearances of fired bricks exposed to freezing and thaw-
ing test.

Int. J. Mat. Res. (formerly Z. Metallkd.) 101 (2010) 7 891


A Applied
H. Binici et al.: The use of fly ash and basaltic pumice as additives in the production of clay fired brick in Turkey

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
Not for use in internet or intranet sites. Not for electronic distribution.

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
www.ijmr.de

lower than that of the control specimen.


5. The freezing and thawing resistance of fired bricks is
significantly improved with the addition of basaltic pu-
mice and fly ash
Finally, since fly ash and basaltic pumice are available in
vast amounts in Turkey, taking into account the results of
the present study, these materials should preferably be used
W 2010 Carl Hanser Verlag, Munich, Germany

as additives in fired brick production.

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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W 2010 Carl Hanser Verlag, Munich, Germany

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