INDIAN INSTITUTE OF TECHNOLOGY

BANARAS HINDU UNIVERSITY

B-Tech UG PROJECT
ON
Potentail Of Artificially Cemented Bauxite Residue-Fly Ash Composite For Unfired Brick

Mentored by: Dr. Arun Prasad

Submitted by: Mohit

15065035

Civil Engineering

1
 Certificate

This is to certify that Mr. Mohit of B -Tech Part-III, Department of Civil Engineering have
successfully completed the project on the topic “Potential Of Artificially Cemented Bauxite
Residue-Fly Ash Composite For Unfired Brick ” under the guidance of Dr. Arun Prasad
during the Session 2017-2018.

Signature Date :

2
Dr. Arun Prasad
Professor
Department of Civil Engineering
Indian Institute of Technology, Varanasi

ACKNOWLEDGEMENT

I have immense pleasure on successful completion of project work on:

“Potential Of Artificially Cemented Bauxite Residue-FlyAsh Composite For Unfired Brick”

I express my deep sense of gratitude to Dr. Arun Prasad for his constant guidance and support as

my guide and mentor during the project work. I would also like to thank all other people who

helped and encouraged me all along the project work.

3
Potential Of Artificially Cemented Bauxite Residue-Fly Ash Composite For Unfired Brick

1. Introduction
Building construction with industrial waste based construction materials is a worldwide
technique from more than 9000 years ago, and currently is still used in most of the
developing countries. These materials success are based on the easy availability of raw
materials, their simplicity execution, their good thermal and acoustic properties and their
economy.In developed countries, this traditional construction system was virtually
abandoned since the beginning of the 20th century in favor of more modern materials
when, technological advances and economic capacity, generalized the use, for example, of
concrete or fired bricks respectively.The use of cementitious additives, is an effective and
economical way to improve the material engineering properties, due to the cementitious
gels formation which develop a resistant matrix around the soil particles.

Two types of waste solids, fly ash and red mud, are largely produced from power generation and

alumina industry, respectively. Red mud is a by-product of the Bayer process. For every tonne of

alumina produced, between 1 and 2 tonnes (dry weight) of red mud residues are produced. It is

composed primarily of fine particles of silica,aluminium, iron, calcium and titanium oxides and

hydroxides. Due to its high calcium and sodium hydroxide content, red mud is relatively toxic

and can pose a serious pollution hazard. In recent years, a great deal of research has been

4
undertaken to utilise red mud.

Fly ash has been used in brick production for quite a while. Several studies have been conducted

on fired brick made of fly ash. The use of such bricks is authorized in many countries such as

Germany, the United Kingdom and India. There are a number of patents on the use of fly ash–

lime mixtures for making unfired bricks. In addition to lime, other solidifying agents such as

slag, calcined gypsum and dextrin are added in the production.It is well known that chemically

pozzolanic reaction of fly ash and lime occurs readily under thermal treatment creating strong

structures with an increase of mechanical strength. This reaction involves the formation of

calcium silicate hydrate (CSH) and calcium alumino-silicate hydrate (CASH) and enhances the

strength of the materials. The type of CSH phases plays a crucial role in the strength

development of the final product owing to the effect of interparticle forces such as van der Waals

which are important for very small objects in the colloidal domain of hydration products. The

smaller the CSH particle, the stronger the interparticle force is obtained.

2. MATERIALS

2.1 BAUXITE RESIDUE

Bauxite residue is a major industrial solid waste residue produced by the Bayer process for the

extraction of Alumina from bauxite ores. About 120 million tons of red mud is produced

annually and the worldwide inventory reached more than 3.5 billion tons in 2014. It is mainly

composed of Fe2O3, Al2O3, SiO2, TiO2, CaO, Na2O and some trace elements such as V, K, Pb, Ga,

Zn, Cr, P, Mn, Cu, F, Cd, etc. Bauxite residue used in the present study was collected from

Hindalco Industries Limited, Renukoot (India). The physical properties of bauxite residue are

summarized in Tables 1. Commercial grade dry hydrated lime reject [Ca(OH)2] is used as the

5
cementing agent and it consists mainly of oxides of Ca and Mg. Distilled water was used for

microstructural characterization purpose whereas tap water was used for compressive strength

test.

Table 1 Geotechnical properties of bauxite residue (after Kumar and Prasad, 2017)

Properties Value

Maximum dry density (kN/m3) 1.50

Optimum moisture content (%) 30

pH 10.2

Specific gravity 3.1

Sand content (%) 28

Silt content (%) 60

Clay content (%) 12

Effective diameter, D10: (mm) 0.007

Coefficient of uniformity, Cu 8.57

Coefficient of curvature, Cc 0.69

Unified soil classification system (USCS) ML

Unconfined compressive strength (kPa) 138.6

2.2 FLY ASH

Fly ash is generated from the coal combustion process as industrial by-product.The fly ash has
been adopted widely in the construction industry as a binder replacement due to its pozzolanic
activity, low water demand, reduced bleeding, and less heat evolution. The spherical particles of

6
fly ash produce the ball bearing effect has a better particle packing and dense paste.Class F fly
ash contains a small quantity of lime. . However, due to the pozzolanic activity of fly ash, the
compressive strength increased in later stages of curing. The amorphous silica present in fly ash
undergoes a chemical reaction with the calcium hydroxide and generates calcium silicate
hydrate. This pozzolanic reaction of fly ash increases its significance not only in concrete but
also in various construction uses. Due to the pozzolanic reaction, the strength increment
continues for a longer period of time. In addition, fly ash improves its workability.

Chemical Name Value(%)

SiO2 76.34

Al2O3 14.72

Fe2O3 3.69

MgO 0.54

SO3 0.11

CaO 0.6

Na2O 0.19

K2O 0.96

Cr2O3 -

P2O5 0.1

SrO -

TiO2 0.61

ZnO -

2.3 LIME

7
The lime (L) used was a commercially available lime typically used for construction
purposes.Lime is usually made by burning of limestone. Chemically, lime is calcium oxide (CaO)
and is made by roasting calcite (CaCO3) to wipe off carbon dioxide (CO2).Lime used in building
materials is broadly classified as "pure", "hydraulic", and "poor" lime; can be natural or artificial;
and may be further identified by its magnesium content such as dolomitic or magnesium lime.
Lime has many complex qualities as a building product including workability which includes
cohesion, adhesion, air content, water content, bond strength; comprehensive strength; setting
time; free lime content; vapor permeability; flexibility; and resistance to sulfates. Hydraulic lime
has silicates that are predominantely in the di-calcium silicate form (belite), with only trace
amounts of highly reactive tri-calcium silicate (alite), hence hydraulic lime has slower setting
time and gain strength overtime.

The chemical and physical properties of lime are presented in Table:-

Chemical Name Value(%)

CaO >83.3

MgO <0.5

Fe2O3 <2

Al2O3 <1.25

SiO2 <2.5

SO3 <0.5

Na2O 0.4-0.5

CO2 <5

CaCO3 <10

SrO -

TiO2 0.61

8
ZnO -

3. SAMPLE PREPARATION PROCEDURE:-

For the determiantion of compressive strength, firstly the required amount of red mud , flyash

and lime was mixed in dry state to a uniform consistency. Water was then added while

continuing the mixing process until a consistent and homogeneous mixture was obtained.After

mixing, it was compacted in the brick mould to a targeted dry unit weight of the mix.After the

moulding process, the sample was extracted from the mould and placed in a airtight polythene

bag and It was the cured at different curing time. After the moulding and curing process, the

sample was tested in an automatic load compression device of 50 KN capacity with a proving

ring. The strain rate adopted was 1.2 mm per minute.And noted down the dial gauze and proving

ring readings and find the results.

-
9
4. TESTS TO BE PERFORMED

4.1 Compressive Strength:-

The compressive strength of bauxite residue flyash brick is three times greater than the normal

clay brick. The minimum compressive strength of clay brick is 3.5 N/mm².So as the bauxite

residue flyash brick has compressive strength of 10-12 N/mm². Bricks to be used for different

works should not have compressive strength less than as mentioned above. The universal testing

machine is used for testing the compressive strength of bricks.After the curing period gets over

bricks are kept for testing. . The load at failure is the maximum load at which specimen fails to

produce any further increase in the indicator reading on the testing machine. .

4.2 Water Absorption:-

Fly ash Bricks should not absorb water more than 12%. The bricks to be tested should be dried in

an oven at a temperature of 105 to 115C till attains constant weight cool the bricks to room

temperature and weight (W1). Immerse completely dried and weighed W1 brick in clean water

for 24 hrs at a temperature of 27±20. Degree Celsius. Remove the bricks and wipe out any traces

of water and weigh immediately (W2). Water absorption in % by weight = (W2 – W1/W1) x

100.

4.3 Thawing And Freezing Test:-

Freeze Thaw is a mechanical weathering process where water penetrates the concrete or masonry

then repeated freezing and thawing force the breakup the concrete or masonry as the ice expands

in the cracks. Freeze Thaw action is responsible for a lot of external damage to masonary and

concrete in areas where the temperature regularly drops down to zero.Most concrete or masonry,
10
be it bricks, blocks or stone, have tiny fissures (cracks) in their composition. These cracks,

however tiny, will fill with water when it is wet. As the weather gets colder this water freezes.

Frozen water expands as it becomes ice and exerts a great deal of pressure within the crack. As

the crack is already a weak point in the masonry, it expands a little under the pressure from the

frozen water.When the water melts and runs away or evaporates, it leaves a slightly larger crack

which fills with water when it rains…. and so on until the face of the brick is more crack than

brick and simply falls off.

Freeze-thaw tests are usually considered an indicator of durability, it was imperative that the

selection of the test mix considered mechanical properties before and after 24 h of immersion in

water.After the 25 freeze-thaw, the test samples were visually inspected for any surface damage.

4.4 Efflorescence:-

For this test, brick was placed vertically in water with one end immersed. The depth of
immersion in water being 2.5 cm, then this whole arrangement should be kept in a warm-well-
ventilated room temperature of 20-30 C until all evaporates. When the water in the dish is
absorbed by the brick and surplus water evaporates. When the water is completely absorbed and
evaporated place similar quantity of water in dish and allows it to absorb and evaporate as
before. Examine the brick after this and find out the percentage of white spots to the surface area
of brick. If any difference is observed because of presence of any salt deposit then the rating is
reported as ‘effloresced’. If no difference is noted, the rating is reported as ‘not
effloresced’.Percentage of white spot in the brick = Nil.

5. RESULTS :-

11
The investigation was carried out to determine the optimal mix percentage of bauxite residue fly

ash composite Unfired brick and also to determine the water absorption.

The effects of the addition of lime on the compressive strength is shown in figure

(a),(b),(c),(e),(f),(g),(h) and figure (d) illustrate the effect of flyash content on the compressive

strength.

.Divide the whole samples into three sections:-

Section 1:- Amount of flyash=0%

From the figure (a) and (b),it can be observed that the compressive strength of the bauxite

residue flyash mix increases non linearly with the increase in lime content at curing stages(7

days and 28 days).From the figure (c) , we can say that the compressive strength also increase

with increase in curing time(7 to 28 days) .

Section 2:- Amount of flyash=12.5%

From the figure (e) and (f),it can be observed that the compressive strength of the bauxite

residue flyash mix increases non linearly with the increase in lime content at curing stages(7

days and 28 days).

Section 3:- Amount of flyash=25%

From the figure (g) and (h),it can be observed that the compressive strength of the bauxite

residue flyash mix increases non linearly with the increase in lime content at curing stages(7

days and 28 days).

12
 4
4
3.5 14.5

Compressive Strength(MPa)
3.5 14.5 15.25 16
Compressive strength(Mpa)

3 15.25
3
2.5 16 2.5
2 2
1.5 1.5
1 1
0.5 0.5
0 0
5 10 15 5 10 15
Lime Content(%) Lime Content(%)

(a) (b)

4.5
4
Strength(Mpa)

3.5
Cmpressive

7 Days 14 days 28 days

3
2.5
2
1.5
1
0.5
0
5 10 15
Lime Content(%)

(c)

15
Strength(Mpa)
Compressive

10
14.5
5

0
0 5 10 15
Fly ash content (%) 20 25 30

13
(d)

Variation of compressive strength of red mud with (a) 7 days cured with lime and dry

density,(fly ash=0%)(b) 28 days cured with lime and dry density(fly ash=0%) (c) curing

for dry density (14.5 kN/m3) and (d) Fly ash content for 7 days cureddry density (14.5

kN/m3) and Lime content (5 %).

9 10
8 14.5 15.25 16 14.5 15.25 16
9
strength(Mpa)
Compressive

7
strength(Mpa)8
Compressive
6 7
5 6
4 5
3 4
2 3
2
1
1
0
0
5 10 15
5 10 15
Lime Content(%)
Lime Content(%)

(e) (f)

Variation of compressive strength of red mud with (e) 7 days cured with lime and dry
density,(fly ash=12.5%) (f) 28 days cured with lime and dry density(fly ash=12.5%)

14
 16 16

Compressive strength(Mpa)
14.5 15.25 16 14.5 15.25 16
14 14
12
strength(Mpa)
12
Compressive

10
10
8
8
6
4 6

2 4
0 2
5 10 15
0
Lime Content(%) 5 10 15
Lime Content(%)

(g) (h)

Variation of compressive strength of red mud with (g) 7 days cured with lime and dry
density,(fly ash=25%)(h) 28 days cured with lime and dry density(fly ash=25%)

6. CONCLUSION:-

Based on the experimental study, following conclusions can be drawn regarding the strength
behavior of bauxite residue flyash Unfired brick; The study was conducted to find the optimum
mix percentage of bauxite residue flyash Unfired brick. However the brick specimen of size
80mm x 40mm x 40mm were cast for different mix percentage of Flyash (0 to 25%), Dry density
(14.5 to 16), Lime (5 to 15%). However the specimens have been tested for several mix
proportions. The mechanical properties such as compressive strength were studied for different
mix proportions, at different curing ages(7,14 and 28 days). From the results it was inferred that,
among the proportions, the maximum optimized compressive strength is obtained for optimal
mix percentage of Flyash-25% Lime-15% dry density-16 curing time 28 days as 13.595 N/mm2.

On the basis of analyzing the above graph, we can say that compressive strength of bauxite
residue flyash composite brick always increases with increase in these parameters(flyash content,
15
Lime content, Dry density and curing time ).As it is clearly seen that our results are satisfying the
criteria for minimum compressive strength. But now we have to perform several other tests of
bauxite residue flyash Unfired brick.

7. FUTURE WORK:-

Compressive strength tests has been completed in the stipulated time. But not only on the basis
of compressive strength test, we cannot decide whether the brick is used as a building material or
not,but also we

shall do the following tests:-

1. Water absorption test

2. Freezing and Thawing test

3. Effloresecense

16