AN EXPERIMENTAL STUDY ON CLAY

BRICK INCROPORATED WITH EGG SHELL

POWDER,WASTE GLASS POWDER AND
WOOD SAW DUST- Review

A.Kalyani K.Vijai Srei K.Haritha

Assistant Professor,Civil depatrment Civil department, Civil department,
Sri Manakula Vinayagar Engineeering Sri Manakula Vinayagar Engineeering Sri Manakula Vinayagar Engineeering
College, College, College,
Pondicherry,india. Pondicherry,india. Pondicherry,india.
kalyanicivil83@gmail.com vijaisrei@gmail.com kharitha726@gmail.com

R.Nandini
Civil department,
Sri Manakula Vinayagar Engineeering
College,
Pondicherry,india
nandhinir486@gmail.com

Abstract— The growing demand for building materials,
as well as environmental concerns associates with energy
consumption and natural resources depletion, prompted
a search for sustainable alternatives for clay including
natural and waste materials. In order to minimize these
problems, techniques must be innovated for the
production of low cost light weight, low thermal
conductivity and eco-friendly bricks. Consequently, this
work is an attempt to develop a modified masonry brick,
as a replacement of egg shell powder, wood saw dust,
waste glass powder. The optimum value of egg shell
powder is kept as 20%. Different ratios of wood saw dust
and waste glass powder starting from 5% is added. For
this purpose, the egg shell is oven dried for 110 0 C for 20
minutes and grinded to fine powder by grinders, wood
saw dust is collected, dried in sunlight to remove the
moisture content. Different proportion of the mixture is
added to the clay with required amount of water and the
mixture is poured into the mould and dried for about two
weeks.In the process of burning, the dried bricks are
burned either in clamps (small scale) or kilns (large scale)
up to certain degree temperature. After manufacturing
process, the brick are analysed regarding the
compressive strength, water absorption, hardness test,
soundness test, unit weight values satisfies the relevant
Indian Standards. Thus the effective use of egg shell
powder, wood saw dust and waste glass powder has been
provided.
Keywords— Egg shell powder, Wood saw dust, Waste glass
powder, Light weight, compressive strength.
1.INTRODUCTION
1 .1 CLAY BRICK
Clays used today are more varied than those used
by the first brick makers. The process of making bricks
invloves mixing clay with other materials such as sand, straw
and water to form a homogeneous mixture. The mixture is
then shaped into a rectangular mold or form, either by hand
or using a press or machine. The molded clay is then dried in
the sun or in a klin to harden it into a durable and solid
structure.
Digging, mining, and various methods of grinding
enable the modern manufacturer to utilize many raw
materials.Surface clays are typically recovered by means of
power shovels, bulldozers with scraper blades, and dragline
operations. Shales are recovered by blasting and power
shovels. Fireclays are mined by conventional techniques.
Raw clays are often blended to obtain a more uniform
consistency. In many cases the material is ground to reduce
large rocks or clumps of clay to usable size and is placed in
storage sheds. As additional material is stored, samples are
blended from a cross section of the storage pile. The material
is then transferred to secondary grinders and screens to secure
the optimum particle size for mixing with water. In certain
processes the clay is transferred directly to the mixing area,
eliminating all grinding, screening, and blending.
 A minimum of water is added, the material is placed
in steel molds, and pressures up to 1,500 pounds per square
inch are applied.After the bricks are formed, they must be
dried to remove as much free water as possible. Drying, apart
from sun drying, is done in drier kilns with controlled
temperature, draft, and humidity.Bricks are fired and cooled
in a kiln, an oven-type chamber capable of producing
temperatures of 870° to 1100° C depending on the type of raw
material.
Since the development of the tunnel kiln, brick
Fig 1: Waste glass powder
makers have sought to increase automation in their plants.
Handling of the finished product has been automated to the
point that bricks emerging from the kiln are now
2.2. EGG SHELL POWDER:
automatically stacked in packages of approximately 500,
strapped with metal bands, and stored, shipped, and delivered
by mechanical equipment. Many eggshells are dumped as waste from the food
industries, causing environmental issues that lead to health
risks, pollution, and environmental harm due to incorrect
2.MATERIALS disposal. On average, a chicken eggshell weighs 5–6 g and
involves 85–95% calcium carbonate (CaCO3), which make
2.1. WASTE GLASS POWDER: up the majority of eggshells together with 1.4% magnesium,
carbon and other elements in trace amounts. Eggshell wastes
The disposal of waste glass has become a major are composed of two basic components: calcified eggshell
environmental concern due to the increasing demand for and protein-rich shell membrane. Calcite (CaCO3) which is
landfill space and natural resources, and a greater emphasis the main component in the egg shell powder, can be
on reducing the carbon footprint of the construction industry. employed in a variety of applications, including
Although the total amount of waste glass recovered may be pharmaceuticals, paints, plastics, fertilizers and construction
high, only a fraction of this amount may be remanufactured applications. However, the inappropriate disposal of eggshell
due to the strict limitations of glass remanufacturing. wastes has become a source of worry for food industries.
Traditionally, glass needs to be collected and sorted into Despite the promising application of egg shell powder in
different colours. Glass that cannot be sorted is broken or building materials, very few studies have been reported on
mixed during the collection phase along with glass that the use of egg shell powder in ceramic brick making. The
contains composite materials or contaminants that are not effect of integrating egg shell powder into clay-based bricks
economical or technically impossible to remanufacture. The to improve their thermal and physico mechanical properties
remanufacturing of waste glass is environmentally friendly as was reported. The obtained result shows that incorporating
it reduces the amount of raw materials required and decreases 20% egg shell powder to clay bricks exhibited good thermal
the total amount of energy consumed during the and mechanical characteristics.
manufacturing process. Waste glass is estimated to account
for 7% of the global municipal solid waste generated in 2021
with recycling rates varying globally and within regions. For
every 10% of glass cullet used (by weight) in the production
of glass, carbon emissions and energy consumption are
reduced by 5% and 3%, respectively. The cost of
manufacturing is also reduced in attaining the weight of the
altered brick equal to the normal brick. Waste glass bottles
(also called fused silica glass) are rich in silica, SiO2 which is
in the range of 70–75%. It also contains a considerable Fig 2: Egg shell powder
amount of alkaline earth oxides like Na2O, CaO, and MgO in
the range of 12–16%, 5–11%, and 1–3%, respectively. 2.3. WOOD SAW DUST:

Green building materials have attracted attention

recently due to sustainability issues. Sawdust is one of the
organic waste products being tested in a bid to produce bricks
with enhanced heat insulation properties.The addition of

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sawdust to clay mixtures also seems to reduce the
interconnection between the pores in fired bricks. When
different concentrations of sawdust were tested, the best
physical and mechanical results were obtained with low
percentages of waste. The organic additives tested in the
production of roof tiles, solid bricks and hollow bricks led to
a higher water absorption capacity and less mechanical
resistance and that the best results with sawdust were
obtained when it was used in the production of solid bricks.
Fig 1: Wood saw dust
3. LITERATURE REVEIW
The basic processes to be carried out for
manufacturing of brick using egg shell powder, wood saw
dust and waste glass powder as a partial replacement of clay
is studied from literature. The basic steps for preparing the
brick are studied from the collected literatures. For the better
replacement in clay several alternatives were considered and
finally egg shell powder, wood saw dust and waste glass
powder was chosen as the best alternatives after studying the
literatures. Egg shell is made almost entirely of calcium
carbonate crystals. The use of eggshell as a bio filler and flux
to enhance the technological properties of fired clay bricks is
promising and can be considered as an effective alternative
method to reduce environmental concerns caused by
inappropriate discarding and landfill construction to dispose
of eggshell waste. Glass powder is mainly composed of silica.
The replacement of waste glass powder has equalised the
compressive strength and other properties of normal fired
clay brick. Wood saw dust also acts as an effective
replacement material as studies reveal that it showed higher
compressive strength than fly ash cement based and burnt
clay bricks. First of all the raw materials required for the
manufacturing of brick is collected and stored. Next the
appropriate mix design is calculated from the results obtained
in preliminary test made for clay and raw materials. 9 number
of bricks is casted for each different mix ratios. tottaly 36
bricks are casted. Then, using the mix design different
proportions of clay, egg shell powder, wood saw dust and
waste glass powder are mixed and clay bricks are casted. The
casted clay bricks are dried in sunlight for 5 days and then
burnt in klins at 900 to 12000C. The burnt bricks are then
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tested for compressive strength, efflorescence test, shape and
size test, water absorption and soundness test.
4. CONCLUSION
This review paper explored the recycling of egg
shell, waste glass and wood saw dust. In summary, the
following conclusions have been derived from this
investigation:
 The bricks with 20 wt.% addition of egg shell powder
fired at 1000 °C for 5 h displayed excellent physical-
mechanical and thermal properties. The compressive
strength of 7 MPa the hardness of 6.0 HV, and water
absorption value less than 25 wt.%.
 Initially 15%, 20% and 25% replacement of egg shell
powder in clay is done and the bricks are produced.
 These bricks are tested to obtain the percentage of egg
shell which gives high strength.
 This obtained percentage is set as optimum value and
the other two raw materials ie, wood saw dust and waste
glass powder is mixed in different proportions and
moulded as bricks.
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