Journal of Cleaner Production xxx (2015) 1e6

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Journal of Cleaner Production

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Use of bio-briquette ash for the development of bricks

Vishakha V. Sakhare, Rahul V. Ralegaonkar*
Department of Civil Engineering, Visvesvaraya National Institute of Technology, Nagpur, India

a r t i c l e i n f o a b s t r a c t

Article history: The issue of the ever increasing demand for construction materials and waste management has created a
Received 10 April 2015 need for the development of sustainable materials with the appropriate utilization of wastes. This paper
Received in revised form presents the study of the use of bio-briquette ash (BBA) for the development of bricks. Physico-chemical
13 July 2015
property investigations for a BBA sample were conducted, and the sample was found to be suitable as an
Accepted 15 July 2015
alternative raw material for the partial substitution of sand. For the development of the bricks, BBA was
Available online xxx
added according to the partial replacement method (5e55%) for sand, keeping the cement percentage
constant. Six compositions were prepared with 10 wt% variations. The developed product was tested
Keywords:
Bio-briquette ash
according to the Indian Standards (IS) for density, compressive strength, water absorption and efflo-
Brick development rescence along with the durability and thermal properties. The effect of the addition of the BBA on the
Compressive strength brick properties was investigated. Thirty-five weight percent BBA, 55 wt% sand and 10 wt% cement were
Physico-chemical property the optimal mix composition for the developed BBA bricks that fulfilled the desired properties of IS. The
developed BBA bricks were found to have better mechanical and thermal properties and were more
economical than commercially available fly ash and clay bricks. The developed bricks are recommended
for non-load bearing walls.
© 2015 Elsevier Ltd. All rights reserved.

1. Introduction Briquettes produced from the briquetting of biomass offer

With the rapid increase of industrialization, solid waste gener-
ation and disposal are major issues. The generated solid waste that
is otherwise land filled harms the environment and the health of
living beings. Various industries use different types of fuels for
boiler applications, resulting in the generation of several types of
waste with different characteristics. Bio-briquettes are a renewable
energy source that are used in different industrial boiler applica-
tions. Bio briquetting is the process of converting agricultural waste
(soy beans, cotton, sawdust, etc.) into high density and energy
concentrated fuel briquettes. The brick and block industry can
positively contribute to more eco-efficient construction by incor-
porating the wastes generated by other industries. This not only
prevents an increase in the area needed for waste disposal but also
avoids the exploitation of non-renewable raw materials used in the
production of masonry units, thus reducing its environmental
impact (Torgal et al., 2014). Briquettes have superior qualities and
environmental benefits in comparison with coal because they are
derived from renewable resources (Maninder et al., 2012).
* Corresponding author. Tel.: þ91 2801090.
E-mail address: sanvan28@yahoo.com (R.V. Ralegaonkar).
numerous advantages and are a fairly good substitute for coal,
lignite, and firewood. In Maharashtra (India), there are more than
350 briquetting units. Each unit produces approximately
200e250 tons of briquettes, resulting in 7000 tons of briquette ash
production per month (Visviva, 2014).
Several attempts were made to utilize waste in the development
of bricks. An experimental study was completed on the develop-
ment of masonry blocks with palm oil fuel ash (POFA) as a partial
replacement for 0%, 20%, 40% and 60% cement by mass, satisfying
the requirements of the Malaysian Standard. The compressive
strength and the breaking load of the masonry blocks were reduced
with an increasing percentage of POFA replacement (Rahman et al.,
2014). Sadek (2014) examined the effect of using air-cooled slag
(ACS) produced by the slow cooling of blast furnace slag (BFS)
under atmospheric conditions and with water-cooled slag (WCS)
produced by water quenching at 50% and 100% replacement of
natural sand (NS) in solid cement bricks. The use of ACS resulted in
greater deterioration after exposure to elevated temperatures,
although it increased the compressive strength of the unheated
specimens. However, the bricks containing WCS were thermally
more stable than NS and ACS bricks. Mutuk and Mesci (2014)
examined the utilization of boron waste (BW) and investigated
RHA as a cement additive. Five percent, 10%, and 15% RHA and 1%,

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Please cite this article in press as: Sakhare, V.V., Ralegaonkar, R.V., Use of bio-briquette ash for the development of bricks, Journal of Cleaner
Production (2015), http://dx.doi.org/10.1016/j.jclepro.2015.07.088
2 V.V. Sakhare, R.V. Ralegaonkar / Journal of Cleaner Production xxx (2015) 1e6

3%, and 5% BW were added to mortar instead of cement. The results
showed that 10% rice husk ash additive specimens gave the highest
result with respect to the full factorial experimental design. The
effect of substituting the bottom ash for Portland cement in pro-
portions ranging from 10 to 90 wt% demonstrated that the addition
of ash increased the block porosity, thereby decreasing its thermal
conductivity and compressive strength (Carrasco et al., 2014).
Torkaman et al. (2014) investigated the effects of the partial
replacement of Portland cement by wood fiber waste (WFW), rice
husk ash (RHA) and limestone powder waste (LPW) for producing a
lightweight concrete block as a building material. The optimum
replacement level of WFW, LPW, and RHA was 25 wt%, which
resulted in good mechanical properties. Rajput et al. (2012) utilized
recycled paper mill waste and cotton waste to manufacture waste-
create bricks (WCB). WCBs with a varying content of cotton waste
from 1 to 5 wt%, recycled paper mill waste from 89 to 85 wt% and a
fixed content of Portland cement (10 wt%) were prepared and
tested as per the IS 3495 (Part 1e3): 1992 standards. The results
indicated that the bricks were thermally stable and conformed to
the recommended compressive strength test. Raut et al. (2012)
developed bricks with the addition of 5e20% cement to recycle
paper mill waste (RPMW), which exhibited a compressive strength
of 9 MPa, and found the strength to be three times greater than
conventional clay bricks (3 MPa). Ling and Teo (2011) developed
bricks from the waste rice husk ash (RHA) and expanded poly-
styrene (EPS) beads. RHA was used as a partial replacement for
cement, while EPS was used as a partial aggregate replacement in
the mixes. It was found that the properties of the bricks were
mainly influenced by the content of EPS and RHA in the mix and
also the curing conditions. Ismail et al. (2010) developed bricks by
incorporating 20% paper sludge and 20% palm oil fuel ash into
cement. Sales and Lima (2010) prepared mortar and concrete with
sugarcane bagasse ash (SBA) as a sand replacement and perfor-
mance tests were conducted. The results indicated that the SBA
samples had properties that were similar to those of natural sand.
The mortars produced with SBA in place of sand showed better
mechanical results than the conventional mortar.
Lertsatitthanakorn et al. (2009) developed rice husk ash-based
sand-cement bricks and compared them with standard commer-
cial clay bricks. For a wall of 2.5 m length  2 m height  0.09 m
thick, it was estimated that the RHA-based sand-cement bricks
reduce solar heat transfer by 46 W. Celik et al. (2008) characterized
different types of fly ash and investigated their effect on the
compressive strength properties of ordinary Portland cement.
Chiang et al. (2009) produced lightweight bricks by sintering mixes
of rice husk ash and dried water treatment sludge. The blending
ratio and sintering temperature effects on the properties and
micro-structure of the produced materials was reported.
The studied literature implied that agro-industrial waste has the
potential to be used as the principal raw material for manufacturing
bricks. Researchers used the recommended standards to evaluate
the conformance of newly designed masonry products. The po-
tential application of bio-briquette ash (BBA) for the development
of novel products has not been investigated. Due to the availability
of BBA over the study area, the present paper evaluates its possible
application as an alternate raw material for the development of
bricks. The physico-chemical properties of BBA were characterized
and analyzed. Various mix proportions were designed using BBA,
cement and sand. Then, the performance of the mechanical, dura-
bility and thermal properties of the developed bricks was analyzed.
 53 grade ordinary Portland cement conforming to IS
12269:2013.
 Bio-briquette ash samples (Fig. 1): identified and collected from
locally available industrial sources (Shree Baidyanath Ayurved
Bhawan Pvt. Ltd., Nagpur).
 Sand conforming to IS 650:1991.
2.1. Tests on the raw materials
The BBA underwent physical tests (sieve analysis, specific
gravity and soundness tests), chemical characterization, X-ray
diffraction (XRD), thermogravimetric differential thermal analysis
(TG/DTA), and scanning electron microscope (SEM) examinations
to determine its nature and constituent compounds.
Specific gravity testing for BBA, cement and sand was conducted
as per IS 2720 (3): 1980. The particle size distribution of the BBA
was determined as per IS 2720 (4): 1985. The soundness test was
performed by the autoclave expansion method for the BBA samples
(IS 3812 (1): 2003). An X-ray fluorescence spectrometer (XRF,
Philips, PW 1840) was used for chemical characterization. The X-ray
diffraction pattern was recorded on a model XRD-Philips X'Pert Pro
with a scan rate of 2 /min. XRD patterns were scanned in steps of
0.0170 in a diffraction angle range from 10 to 100 of 2q using
copper (Cu) as an X-ray source. The microstructural analysis of the
BBA sample was analyzed using a JSM-6380A scanning electron
microscope. The thermogravimetric differential thermal analysis
was conducted using Mettler, TA 4000 apparatus to verify the
thermal stability of the material.
2.2. Brick development
The automated brick plant was used to make building bricks of
dimensions 230  100  85 mm3. Mixes of bio-briquette ash, sand
and cement with various compositions were prepared. The BBA
share in the composition mix varied from 5 to 55% (Table 1). The
sand (S) share in the composition mix varied from 85 to 35%. The
cement (OPC 53 grade) percentage in the composition mix was
kept constant at 10% by weight. Twenty samples for each compo-
sition (BBA: S: C) were prepared. First, BBA, sand and cement were
mixed for approximately 30 s in a mixing unit of an automated
plant. To obtain more homogenous mixes, water (0.20 water to mix
ratio) was added into the cement slurry while the mixer was

2. Materials and methods

The main ingredients proportioned on the basis of wt% for brick

development were: Fig. 1. Pictorial appearance of bio-briquette ash.

Please cite this article in press as: Sakhare, V.V., Ralegaonkar, R.V., Use of bio-briquette ash for the development of bricks, Journal of Cleaner
Production (2015), http://dx.doi.org/10.1016/j.jclepro.2015.07.088
 V.V. Sakhare, R.V. Ralegaonkar / Journal of Cleaner Production xxx (2015) 1e6 3

Table 1
Compositions of prepared brick samples.

Sr. no. Ingredients by wt%

Cement Sand BBA

1 10 85 5
2 10 75 15
3 10 65 25
4 10 55 35
5 10 45 45
6 10 35 55

operated for 2 min. Then, the fresh mixes were fed through a
conveyor into the squeezing unit. The mix was pressed into molds
until the adjustable pressure reached approximately 14 MPa. After Fig. 2. Particle size distribution of BBA.
pressing, the bricks were automatically removed from the molds,
and the casting of each of the brick samples were completed
Table 3
following the same procedure. All of the brick samples were dried Particle size distribution analysis.
for 3 days, followed by 7 days of continuous curing and 7 days of
sun drying. % Distribution Gravel Sand Silt Clay

Specification size (mm) >2 0.05e2 0.002e0.05 <0.002

BBA 0.00 85.26 13.64 1.10
2.3. Tests on the developed product

Various tests on the developed product were conducted as per

The TGA/DTA (Fig. 5) results confirm the thermal stability until
the recommendations given by IS 3495 (Part IeIII): 1992 for dry
666  C. The TG curve indicates first mass loss of approximately 3.2%
density, compressive strength, water absorption and efflorescence;
due to the presence of moisture in the sample. Later, the material
the results were analyzed as per IS 1077:1992 (d). The compressive
exhibits stable behavior with minimal weight loss. Another weight
test was completed using a compression-testing machine. The
loss of 1.005% occurs due to organic matter burn off, and the organic
average of three samples was considered for analysis. The durability
compound degrades in this range. In the DTA curve, an endo-
tests were conducted in terms of the chloride and sulfate contents
thermic peak occurs because the moisture loss requires some
and carbonation. The chloride and sulfate present in the brick
amount of heat energy.
samples was experimentally estimated by the laboratory titration
Table 5 demonstrates the results of the physical (density and
method (ASTM C1218 (ASTM, 2008)) and the spectrophotometer
water absorption) and mechanical (compressive strength) test
test as per IS: 3025 (Part 24): 2003, respectively. The effect of
completed on the developed BBA bricks (Fig. 6). It was observed
carbonation was measured by a phenolphthalein test, and Lee's disc
that as the BBA percentage increases, the dry density decreases. The
apparatus was used to estimate the thermal conductivity for all of
bricks, when examined in accordance with the process specified in
the compositions.
IS 3495 (Part I): 1992 for compressive strength, had values above
the minimum average compressive strength of 3.5 MPa (IS
3. Results and discussion 1077:1992 (d)), except for the 55 wt% ash replacement. The test

The various raw material tests revealed that the specific gravity
of the collected BBA samples was lower compared to cement and
Table 4
sand (Table 2). The particle size distribution of BBA is illustrated in Chemical characterization of BBA according to XRF results in wt%.
Fig. 2, where 85% of the tested sample was observed in the category
Compound SiO2 Al2O3 Fe2O3 CaO MgO SO3
of sand (Zone II, IS 383: 1970) (Table 3). The chemical character-
ization of BBA according to the XRF results illustrated in Table 4 Share 37.54 6.84 8.62 19.98 5.81 2.1
provides an explanation of both the hydraulic and pozzolanic
properties of the material (IS 3812 (1): 2003). Hydraulic materials
react directly with water to form cementitious material, while
pozzolanic materials chemically react with calcium hydroxide, a
soluble reaction product, in the presence of moisture to form
compounds possessing cementing properties (Neuwald, 2004).
Hence, denser pore structures and higher strength resulted. Ac-
cording to the XRD pattern (Fig. 3), the crystalline nature of the BBA
was observed. The XRD pattern shows the crystalline components
as being predominantly quartz (SiO2), ferric oxide (Fe2O3), and
calcite (CaCO3). The SEM image for BBA clearly indicated plenty of
fine pores in the sample (Fig. 4).

Table 2
Specific gravity result.

Sample BBA OPC Sand

Specific gravity 2.468 3.0 2.6

Fig. 3. X-ray diffraction pattern of BBA.

Please cite this article in press as: Sakhare, V.V., Ralegaonkar, R.V., Use of bio-briquette ash for the development of bricks, Journal of Cleaner
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4 V.V. Sakhare, R.V. Ralegaonkar / Journal of Cleaner Production xxx (2015) 1e6

Table 5
Mechanical test results.

S. N. Ash replacement Density Compressive Water absorption

(wt%) (kg/m3) strength (MPa) (%)

1 5 1470 3.64 13
2 15 1430 3.67 16
3 25 1360 3.70 18
4 35 1340 4.19 19
5 45 1200 4.08 22
6 55 1170 3.20 25

results proved that the compressive strength of bricks containing

Fig. 4. Scanning electron microscope image of BBA.
BBA increases as the wt% of BBA increases. Further, the addition of
BBA above 35 wt% decreases the compressive strength because of
the presence of un-reacted silica, which further acts as a filler
material in the brick. Additionally, the percentage of water ab-
sorption, as estimated in Table 5, shows an increasing trend with
respect to the BBA wt%. Up to 35% replacement is within the
permissible limit of 20%, as recommended by IS 1077:1992 (d). The
efflorescence is observed as ‘nil’ in all cases because a perceptible
deposit of efflorescence occurs. Thus, the developed bricks pass the
physical requirements specified in the standards up to the 35 wt%
addition of BBA.

3.1. Durability test

Chloride and sulfate tests were conducted for BBA brick sam-
ples. The allowable chloride content as per IS: 456:2000 for the

Fig. 5. Thermogravimetric differential thermal analysis curve of BBA.

Fig. 7. Lee's disc apparatus.

1 1600
0.9 1400
Thermal conductivity (W/(mK))

0.8
1200
0.7
Density (kg/m )

0.6 1000

0.5 800
0.4 600
0.3
400
0.2
0.1 200

0 0
5 15 25 35 45
BBA in bricks (wt%)
Thermal conductivity (W/(mK)) Density (kg/m3)

Fig. 6. Developed BBA bricks. Fig. 8. Variation of thermal conductivity and density with respect to BBA wt%.

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 V.V. Sakhare, R.V. Ralegaonkar / Journal of Cleaner Production xxx (2015) 1e6
Table 6
Comparative analysis BBA bricks vs burnt clay, fly ashecement bricks.
Brick type Material composition (wt%) Mass
(kg)
Clay Fly ash BBA Sand Cement
BC 90 e e 10 e 3.250
FA e 40 e 50 10 3.640
BBA e e 35 55 10 2.500
concrete or mortar containing non-embedded metal is 3 kg/m3. The
observed maximum chloride concentration was 0.0076 kg/m3 for
35% ash replacement. The sulfate concentration was obtained by a
spectrophotometer test of the extracted sample as per IS: 3025
(Part 24): 2003. The total water-soluble sulfate content of the
concrete mix should not exceed 4 percent by mass of cement in the
mix in terms of SO3. The obtained result of the sulfate concentration
for extracting water is 86.8 PPM (for 35 wt%). In the carbonation
tests and according to RILEM CPC 18, 1% phenolphthalein is used in
70% ethyl alcohol. The phenolphthalein solution is lightly sprayed
onto a freshly exposed surface of the sample. If the concrete is
carbonated, it remains uncolored. The pink color indicates that
enough Ca (OH)2 is present and that it was carbonated to a lesser
extent (Shetty, 2013). The surface color of the BBA brick was pink;
therefore, it was unaffected by environmental CO2. These test re-
sults indicate that the bricks developed by BBA are durable and
resistant to weathering.
3.2. Thermal performance
The estimated thermal conductivity values using Lee's disc
apparatus (Fig. 7) are shown in Fig. 8. The developed BBA bricks
showed a decreasing trend (0.93e0.34 W/(mK)) with the wt%
replacement of BBA. As the wt% of BBA increases, the density and
thermal conductivity decrease.
The 35% BBA replacement composition was further compared
with the commercially available burnt clay (BC) and fly ash (FA)
bricks (Table 6). The properties of the BC and FA were considered
from a prior research study (Madurwar et al., 2014). The compari-
son showed that the density of BBA bricks is 16% and 25% lower
compared to the BC and FA bricks, respectively. The achieved
compressive strength is more than that of burnt clay bricks. The
maximum thermal conductivity of the developed BBA bricks (35%
BBA) was 59% and 52% lower than the commercially available burnt
clay (1.25 W/(mK)) and fly ash bricks (1.05 W/(mK)), respectively.
Although the compressive strength of the fly ash bricks is greater
compared to the BBA bricks, it fulfills the requirements of IS
1077:1992 (d); the fly ash bricks also have the additional advan-
tages of having a lower density and thermal efficiency. The water
absorption is also within the permissible limits for all of the bricks.
Overall, the developed BBA bricks resulted in better mechanical and
thermal performance.
A cost analysis for the BBA bricks and the commercially, locally
available burnt clay and fly ash bricks was completed. The cost of
BBA bricks (INR 2.01) was estimated as 55% less than that of con-
ventional bricks (INR 4.55). However, BBA bricks were found to be
63% cheaper compared to traditional burnt clay bricks (INR 5.5).
4. Conclusions
The analysis revealed significant potential for the utilization of
BBA in the development of bricks. The increase in wt% of BBA from 5
to 55 % resulted in a decrease in brick density of 20%. The bricks
developed with 35% ash replacement (35 wt% BBA: 55 wt% sand:
Please cite this article in press as: Sakhare, V.V., Ralegaonkar, R.V., Use of bio-briquette ash for the development of bricks, Journal of Cleaner
Production (2015), http://dx.doi.org/10.1016/j.jclepro.2015.07.088
5
Density Compressive Water Thermal Cost
(kg/m3) strength (MPa) absorption conductivity (INR)
(%) (W/(mK))
1600 3.5 15 1.25 5.5
1800 6.5 10 1.05 4.5
1340 4.19 19 0.51 2.01
10 wt% cement) represent the optimum mixture in view of the
compressive strength (4.19 MPa) and water absorption (19%) as per
IS 1077:1992 (d). The bricks, when examined for durability and
thermal conductivity, showed encouraging results, indicating that
bricks are durable and thermally efficient. Overall, the developed
bricks were found to be an effective and economical option instead
of commercially available burnt clay and fly ash bricks. The use of
waste makes BBA bricks a reliable solution for the environmental
pollution and waste management issues associated with traditional
bricks; it also fulfills the demand of large construction products.
The developed BBA bricks can also be utilized for non-load-bearing
walls, making them that much more suitable for construction use.
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Please cite this article in press as: Sakhare, V.V., Ralegaonkar, R.V., Use of bio-briquette ash for the development of bricks, Journal of Cleaner
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