Production of lightweight bricks using saw dust.

Rakash Kumer Mondal Md. Sal-Shabil

Reg. no. : 2014333059 Reg. no. : 2014333062
Supervisor Co-Supervisor
Dr. Mushtaq Ahmed Dr. H M A Mahzuz
Professor, Associate Professor,
CEE, SUST CEE, SUST

1. Background of the study and statement of the problem : Bricks is an

important equipment in the sector of construction. In building construction, clay
bricks are widely used in Bangladesh. Every year large amount of topsoil is
excavated to collect soil from a depth of about 1-2m from agricultural lands for
producing clay bricks. Brick making consumes large amount of clay which leads
to the top soil removal and land degradation [1]. The removal of topsoil threatens
the fertility of the agricultural lands and the availability of irrigation water. If it
continues scarcity of cultivable lands will be severe at the near future.
 Fig 1: different types of bricks

Now-a-days to meet the demand of habitation and infrastructure of the increasing

population, brick manufacturing industries are growing rapidly. In Bangladesh,
every year about 4500 brick kilns are in operation, producing about 9 billion bricks.
Among the active kilns, more than 4000 kilns are of the Bull’s trench kiln (BTK)
type. These units employ an extremely crude technology and use low-grade coal to
fire bricks [2]. In the Greater Dhaka region, from six nearby districts about 1000
brick kilns in total emit 23,300 tons of PM2.5, 15,500 tons of sulfur dioxide (SO2),
302,000 tons of carbon monoxide (CO), 6,000 tons of black carbon, and 1.8 million
tons of CO2, to produce 3.5 billion bricks per year [3].
Generally conventional clay bricks weigh about 2.5 to 3 Kg. The higher weight of
conventional clay bricks adds an extra dead load to the building frame. With the
increasing dead load, building frames become more vulnerable to earthquake. To
sustain the additional building loads, sections of beams and columns need to be
larger. It also adds an extra foundation and material cost.

In consideration of the weight of the brick and the material cost many works been
done regarding lightweight Styrofoam brick for decrease the weight with
maintaining the desire strength of the brick. For example,

A study published in the year 2003 shows that, at 1000ºC firing temperature,
compressive strength, density and absorption rate of lightweight bricks with 1.5
wt.% polystyrene foam varies with the used form of polystyrene foam. For the form
virgin EPS, recycled EPS and recycled EPS passing 3.35 mm sieve, the compressive
strength varies from 4.61-9.51 MPa, densities from 890-980 Kg/m3 and water
absorption rate from 25.5-28.5% [4].

In the same year, another study was conducted which explores the behavior of
lightweight expanded polystyrene(EPS) concrete containing silica fume. Results
show that with increasing percentage of silica fume, the strength development rate
increases and marginally increases with the decreasing of the bead size. It is also
found to be directly proportional to the concrete density. The study shows that the
resulting concrete density varies from 1500-2000 Kg/m3 and the corresponding
compressive strength varies from 10-21 MPa. With the silica replacements of 3%,
5% and 9% the corresponding 28-day strengths are about 75%, 85% and 95%. The
water absorption rate for all the mix proportions are below 3% which indicates the
good quality concrete [5].

A research on lightweight concrete reinforced with steel fiber concludes that,

replacing the coarse and fine aggregate partially by EPS beads the compressive
strength of EPS concrete can be gained up to 10–25 MPa, at densities from about
800–1800 kg/m3. Fine silica fume can increase the strength of EPS concrete (at most
15%) by improving the dispersion of EPS beads in the cement matrix and then the
bonding between EPS beads and cement paste. A significant improvement of
shrinkage resistance properties can be obtained adding steel fiber [6].

Another study focuses on the mechanical properties of EPS aggregate concrete

containing fly ash instead of binding material like cement. The EPS concretes
continuously gain strength even up to 90 days. These concretes undergo gradual
failure both in compression and split tension. The compressive strength varies from
about 1.1-43 MPa for 28-day curing and 1.5-44.5 MPa for 90-day curing. The
density differs from 582-2578 Kg/m3 for 8 different mix ratios [7].

In the year 2011, a study [8] conducted by Yi Xu, Linhua Jiang, Jinxia Xu and Yang
Li represents that, the density of lightweight concrete varies from about 1700-2100
Kg/m3 saving 10-30% of the building dead load. For different mix proportions,
compressive strength varies from about 7-21 MPa.

In the same year, on a paper I.H. Ling and D.C.L. Teo reported on the use of
expanded polystyrene (EPS) beads and rice husk ash (RHA) in producing
lightweight concrete bricks and their engineering properties were investigated under
different curing conditions. Under different curing conditions all the samples of
RHA and EPS content have densities less than 2000 Kg/m3. With the cement
replacement of 5%, 10%, 15% and 20% by RHA, the densities decrease about 0.9%,
2%, 3% and 4.5% respectively. The compressive strength of EPS RHA concrete
bricks increased with increasing age under different curing conditions. The highest
compressive strength is 17.51 MPa and 18.4 MPa at 28 and 90 days respectively
under full water curing regime. The water absorption rate decreases with the
increasing replacement of RHA with cement [9].

Another study shows that, for producing lightweight concrete 4 different mix ratios
have been prepared using new coarse aggregate which consists of 25%, 50%, 75%,
and 100% waste clay. Among them the lightweight concrete produced substituting
25% of waste clay brick showed the highest compressive strength of 25 MPa with a
density of 1647 Kg/m3 [10].

But this Styrofoam bricks will responsible for huge damage of property and life
when the building will caught on fire. Cause this Styrofoam bricks are very much
sensitive on fire.It normaly melt at 240 ⁰C[11] ,And when building caught on fire it
produce huge heat and that will damage the Styrofoam bricks.

For prevent this damage saw dust will be a good replacement of Styrofoam. Saw
dust is very much available in our country and light in weight. Bricks with saw dust
may prevent the fire effect that happened on Styrofoam bricks. If fire caught on the
building which built with saw dust brick, saw dust in the bricks will burnt in heat
and produce carbon and that carbon is not harmful for concrete. And so saw dust
will be a good replacement of Styrofoam.

2. Rational of the study

i) Relationship of the objectives to existing scientific knowledge on the subject:

Based on the above discussion, in this study an attempt is made to compare
the overall load taking ability and physical property of bricks having
a. Normal clay bricks, where bricks are burnt in the kiln in high
temperature.Stems are use as burning material.

b. Saw dust bricks, where fine aggregate, saw dust,cement, water will use to
production of bricks.Fine aggregate and saw dust will use in same ratio.
ii) Relevance of the proposed study to national or regional priorities:

Out of the extensive literature review, almost no full research in Bangladesh/

in abroad is seen to be conducted to find out the strength of saw dust bricks and it’s
stability.
If the expected outcome of the research is achieved and after that if it is
practiced in construction than it will certainly reduce the load on the building
structure and which will also reduce the material purchase cost as well. Thus this
will save the natural resources of Bangladesh.

3. Objectives of the Study:

The major objectives of this study are given below:

 To make eco-friendly lightweight brick using saw dust.

 To determine the compressive strength of the saw dust brick.
 To determine the water absorption rate of the saw dust brick.
 To conduct the cost-benefit analysis for production of the saw dust brick.
 To compare the strength, water absorption rate and cost with conventional
brick
 To analyze the trending graphs and develop representative equations for
making bricks
 To form a guideline for making eco-friendly bricks with zero emission to
environment
4. Methodology:

The study can be conducted in 5 phases. The steps of the study are given
bellow,
STEP I
SELECTION AND COLLECTING OF MATERIALS & FINDING MATERIAL PROPERTIES

STEP II
TAKING DIFFERENT MIX RATIOS & CUSTING BRICKSUSING WOODEN MOLD

STEP III
UNMOLDING SAW DUST BRICKS, OBTAINING DRY WEIGHTS & CURING FOR 28
DAYS

STEP IV
CONDUCTING ABSORPTION TEST, COMPRESSIVE STRENGTH TEST

STEP V
MATERIAL COST ESTIMATION, DERIVATION OF REPRESENTATIVE EQUATIONS &
COMPARE TO CONVENTIONAL BRICKS

7.1. Determination of Fineness Modulus

Fineness modulus of both sand and saw dust will be determined by sieve analysis.
Standard sieves will be used to perform the sieve analysis.

7.2. Mix Proportions

5 ratios of Cement: saw dust and 11 ratios of Cement: Sand: saw dust are chosen for
the study. To achieve maximum strength, some mix ratios are chosen deviating from
the standard practice. The mix ratio calculations will be done by volume basis (ft 3).
The w/c ratio of 0.485 will be used for all mix ratio. The mix ratios are given in
tabulated form.
 Table 1. Different Mix Ratios of Styrofoam Bricks

Mix Ratio
Mix Ratio No.
Cement Saw dust Sand
1 1 1 0
2 1 1.5 0
3 1 2 0
4 1 2.5 0
5 1 3 0
6 1 3.9 1.3
7 1 3.3 1.3
8 1 3 1.4
9 1 2.7 1.4
10 1 2.5 1.4
11 1 2.3 1.4
12 1 2.3 1.4
13 1 1.8 1.3
14 1 1.7 1.3
15 1 1.3 1.3
16 1 1 1.5

7.3. Mixing and Molding

Appropriate mix ratios will be taken based on the volume (ft3). The water/cement
ratio of 0.485 will be maintained properly to achieve proper consistency and
workability.
After the proper mixing of cement, sand and saw dust, the fabrication steps will be
done using wooden molds having cells of standard brick size (9.5″×4.5″×2.75″). The
casted bricks will be kept in a room temperature for 1-2 days till unmolding.

7.4.Curing
After unmolding the bricks, 28 days long curing process will be conducted in a room
temperature. During the 28 days long curing term, the weight of the bricks will be
measured after 7, 14, 21 and 28 days to determine water absorption rate of the bricks.
7.5. Compressive Strength Test
According to the ASTM standard the compressive strength test will be done. 2 brick
samples will be tested for each mix ratio and then the corresponding results will be
averaged to obtain the final compressive strength of each mix ratio.

7.6. Absorption Test

Using the recorded dry weight of the saw dust bricks after 7, 14, 21 and 28 days, the
absorption rates will be determined for all 16 mix ratios. The percentage of
absorption can be calculated using the following equation:

(𝑾−𝑾𝒅 )
% Absorption = ×100%
𝑾𝒅

7.8. Material Cost Estimation

The local market price of the saw dust, cement and sand will be taken to estimate
the material cost. Then a graphical relation will be formed between material cost and
compressive strength of saw dust bricks.

7.9. Derivation of Equation

Representative equations will be derived using obtained data with the help of
Microsoft Excel and SPSS software. These equations will represent the mix ratios
of saw dust bricks and the compressive strength found for corresponding mix ratio.

7.10. Comparison
Comparison between the conventional and saw dust brick will be done using the
experimental data found from the study. The compressive strength, absorption rate,
material cost etc. of saw dust brick will be compared to the conventional clay brick.

Following research materials will be used to conduct the whole research work:

 Coarse Sand
Two types of sand are very available in Sylhet region. One is ‘Volagonji Balu’ and
‘the other is ‘Sari Balu’. In this study Sari Balu will be used as one of the coarse
aggregate.
  Cement
The Supercrete brand Portland Limestone Cement will be used as a binder material.
The chemical composition of this cement is Clinker 65-79%, Limestone 21-35%,
Gypsum 0-5% and BDS EN 197-1:2003 CEM II/B-L 42.5 N.

 Saw dust

Saw dust is very much available in our country. Saw dust will be collected
from the nearby saw mile.

Fig 2: Saw dust.

5. Expected Outputs:
The following major results must/ could be extracted by conducting the research-

 Reduce the weight of the bricks with kipping approximately constant strength
of as conventional bricks.
 By this saw dust bricks will reduce the dead load on beam and column.
 Reduce the construction cost.
6. Work Plan:
The total duration of the research is one year, starting from April 2018 to the end
of March 2019. The following time schedule (Table-02) will be maintained in
conducting the study:

Table 02: Work plan of the proposed project:

Start Date End Date
Name of the Task
(D/M/YY) (D/M//YY)
Task-1: Selecting and collecting materials and
finding material properties.
15-Apr-18 20-Jun-18
Task-2: Preparation of mould
21-Jun-18 22-Aug-18
Task-3: Preparation of Samples and curing.
23-Aug-18 31-Oct-18
Task-4: Test of the prepared Samples
1-Nov-18 31-Dec-19
Task-5: Report writing, review and submission.
1-Jan-19 30-Mar-19
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