VISVESVARAYA TEHNOLOGICAL UNIVERSITY

Jnana Sangama , Belagavi-590018,Karnataka

INTERNSHIP REPORT
ON

“ PRODUCTION OF CLAY BRICKS USING

MARBLE WASTE”
Submitted in the partial fulfillment of the requirements for the award of the Degree of
Bachelor of Engineering in
ELECTRONICS AND COMMUNICATION ENGINEERING
Submitted by
ANANDITA CHALAMALASETTI 1MJ21CS016
MANASWINEE PANDA 1MJ21CS108
ESTAR R 1MJ21AE017
K SHREELEKHA 1MJ21AI024
Internship carried out in
At
Tomorrows’ Engineers Club

Internal Guide1 Internal Guide2:

Prof. JEEVA B Prof. Muralidhara R
Assistant Professor Associate Professor
Dept. of ECE Dept.of Civil
MVJCE, Bangalore Bangalore

DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING

MVJ COLLEGE OF ENGINEERING
(Affiliated to Visvesvaraya Technological University, Belagavi & Approved by AICTE, New Delhi)
Recognised by UGC under 2(f) & 12(B), Accredited by NBA and NAAC
NEAR ITPB, CHANNASANDRA, BENGALURU-560067
 2022-23

CERTIFICATE
This is to certify that the project work entitled “PRODUCTION OF CLAY
BRICK USING MARBLE WASTE” is a bonafide work carried out by
ANANDITA CHALAMALASETTI (1MJ21CS016) MANASWINEE
PANDA(1MJ21CS108)ESTAR.R(1MJ21AE017)K.SHREELEKHA
(1MJ21AI024) in partial fulfillment for the award of degree of Bachelor
of Engineering in Electronics & Communication Engineering of the
Visvesvaraya Technological University, Belagavi during the year 2020-21. It
is certified that all the corrections/suggestions indicated for Internal Assessment
have been incorporated in the Report. The project report has been approved as
it satisfies the academic requirements.

Prof. Jeeva. B Prof. Muralidhara.R Dr. P. Mahabaleswarappa

Assistant Professor Associate Professor Principal
Department of ECE Department of Civil MVJ College of Engineering
MVJ College of Engineering MVJ College of Engineering Bangalore
Bangalore Bangalore

External Examination

Name of the Examiners Signature with Date

1.
2.
 MVJ COLLEGE OF ENGINEERING
NEAR ITPB, CHANNASANDRA, BENGALURU-560067
DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING

DECLARATION

We hereby declare that the entire work of the project titled “PRODUCTION OF CLAY
BRICKS USING MARBLE WASTE” embodied in this project report has been carried out
byANANDITA.CHALAMALASETTI(1MJ21CS016)MANASWINEEPANDA
(1MJ21CS108) ESTAR.R(1MJ21AE017) K.SHREELEKHA (1MJ21AI024) during the
first internship after 2nd semester in Tomorrow’s engineering (AEC COURSE) at MVJCE,
Bangalore under the esteemed guidance of of Prof. JEEVA B, (Assistant Professor,
Department of ECE) & Prof. Muralidhara R, (Associate Professor, Department of Civil,
MVJCE), Bangalore. affiliated to Visvesvaraya Technological University, Belagavi. The
work embodied in this dissertation work is original and it has not been submitted in part or
full for any other degree in any University.

ANANDITA CHALAMALASETTI 1MJ21CS016

MANASWINEE PANDA 1MJ21CS108
ESTAR R 1MJ21AE017
K SHREELEKHA 1MJ21AI024

Place: MVJCE, Bangalore

Date:
 ABSTRACT
The main objective of this study is to obtain a gainful utilization of waste marble stone

powder as a part substitute of constituents of clay brick and to study and analyze the effects

of stone slurry on properties of bricks.

A total of 3 samples were prepared in order to assess the performance of the prepared marble
clay bricks, i.e., their water absorption, bulk density, efflorescense, hardness and compressive
strength. The obtained bricks were 1.3-19.9% lighter than conventional bricks and the bricks
with the addition of 10% of marble powder had an adequate compressive performance with
regards to the values required by international standards.

The experimental results showed acceptable performance for application in construction

activities right away. The use of marble waste in the construction industry not only lowers
project costs, but also reduces the likelihood of soil erosion and water contamination.
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any
task would be incomplete without the mention of the people who made it possible,
whose constant guidance and encouragement crowned our effort with success.

We wish to express our sincere gratitude to the Management for providing us with
the state-of-the art infrastructure and facilities. We express our sincere gratitude to
our Principal Dr. P Mahabaleshwarappa, MVJ College of Engineering for
his continuous support and guidance.

We wish to place on record our grateful thanks to, Prof. JEEVA B,

(Assistant Professor, Department of ECE MVJ College of Engineering, Bangalore)
for providing encouragement and guidance.

We consider it a privilege and honour to express our sincere gratitude to our

guide Prof. Muralidhara R, (Associate Professor, Department of Civil, MVJCE),
his valuable guidance throughout the tenure of this project work and whose
support and encouragement made this work possible.

We wish to thank the faculty of Civil Engineering department whose suggestions

have enabled us to surpass many of the seemingly impossible hurdles.

-
 TABLE OF CONTENTS
INTRODUCTION
1.1 CLAY BRICKS
1.2 CLAY BRICKS USING MARBLE WASTE
1.3 MARBLE’S HISTORY AND ORIGIN
1.4 STUDY ON MARBLE WASTE IN INDIA
1.5 MARBLE WASTE AND ITS EFFECTS
1.6 OTHER APPLICATIONS OF MARBLE WASTE

LITERATURE SURVEY
2.1 PAPER REVIEWS AND CONCLUSIONS MADE

MATERIALS USED
3.1 MATERIALS USED
3.1.1 Alumina
3.1.2 Silica
3.1.3 Lime
3.1.4 Red Oxide
3.1.5 Marble waste
3.2 AMOUNT OF MATERIALS REQUIRED (CLAY BRICKS)
CALCULATION
3.3 AMOUNT OF MATERIALS REQUIRED (CLAY BRICKS WITH MARBLE WASTE)
CALCULATION

METHOD AND MANUFACTURING PROCESS

4.1 FOR NORMAL CLAY BRICK
4.2 FOR CLAY BRICKS USING MARBLE WASTE
4.3 MANUFACTURING PROCESS

TESTS AND RESULTS

5.1 COMPRESSION STRENGTH TEST
5.2 WATER ABSORPTION TEST
5.3 EFFLORESCENCE TEST
5.4 SOUNDNESS TEST

COMPARISON OF CLAY BRICKS AND CLAY BRICKS USING MARBLE

WASTE

CONCLUSION

REFERENCES

Page6
 LIST OF FIGURES

1.2 Clay bricks using marble waste

1.4 Marble waste in India

3.1 Alumina/clay

3.2 Silica/sand

3.3 Lime

3.4 Red oxide

3.5 Marble waste

4.1 Clay

4.2 Hand moulding ( ground moulding )

4.3 Machine moulding ( plastic method)

4.4 Natural drying of bricks

4.5 Block diagram of the manufacturing process

5.1 compression strength test

5.2 Water absorption test

5.3 Efflorescence test

5.4 Soundness test

Page7
 LIST OF TABLES

3.2 quantity of materials required for one normal clay brick.

3.3 quantity of materials required for one clay brick with marble waste.

5.3 efflorescence test

6. comparison of clay bricks and clay bricks using marble waste.

Page8
 LIST OF GRAPHS

5.1 Compression strength test

5.2 Water absorption test

Page9
CHAPTER 1

INTRODUCTION
1.1 CLAY BRICKS

Brick is one of the important materials for construction industry. The conventional
method of manufacturing bricks has left this important material aloof in advancement.
The infrastructure such as buildings for housing and industry, and the facilities for
handling water and sewage will require large amounts of construction materials. Since
the large demand has been placed on building material industry especially in the last
decade owing to the increasing population, there is a mismatch between demand-supply
management of these materials.

Hence to meet the continuously increasing demand, researchers are attempting to

design and develop sustainable alternative solutions for the construction material. The
increase in the popularity of using environmental friendly, low cost and lightweight
construction materials in building industry has brought about the need to investigate
how this can be achieved by benefiting to the environment as well as maintaining the
material requirements affirmed in the standards.

Brick is one of the most accommodating masonry units as a building material due to its
properties. Attempts have been made to incorporate waste in the production of bricks,
for instance, the use of paper processing residues, cigarette butts, fly ash, textile effluent
treatment plant (ETP) sludge, polystyrene foam, plastic fiber straw, polystyrene fabric,
cotton waste, dried sludge collected from industrial wastewater treatment plant, rice
husk ash, granulated powder mixtures were compressed in a hydraulic press, and the
green bodies were dried before firing at 1100°C.

Brick making is as ancient as human civilization itself. Great architectural wonders and
the immortal monuments built in the antique past had been built with bricks besides
stones and mortar. Ever since man realized the housing as basic need, he started using
bricks in various forms like green bricks, sun dried bricks and the fired bricks.

1.2 CLAY BRICKS USING MARBLE WASTE

In the marble industry about 7 million of the waste is generated in the form of powder
mainly in India in the process of sawing and polishing. When on exposure they can
pollute and even damage the environment. During this cutting process, 20-30% of a
marble block becomes waste marble powder. Marble dust gives high durability, high
workability, increase 10% weight of the water absorption. However, the utilization of
waste material like wood ash, marble dust and ceramic powder in the production of
bricks can help in the conservation of natural resources like clay. The main objective is

Page10
to investigate the properties of bricks produced by partial replacement of clay with
ceramic powder, marble powder and wood ash.

The main objective of this study is to obtain a gainful utilization of waste marble stone
powder as a part substitute of constituents of Clay brick and to study and analyze the
effects of stone slurry on properties of bricks. Also, this study assesses the properties of
the final product after incorporating waste marble stone powder. Ultimately, the
incorporation of waste powder in clay bricks.

Brick industry could lead to a viable, environmentally friendly material with attractive
shelter , bricks are being used in the development of infrastructure such as construction
of dams, canals and business houses which are needed for improvement in the levels of
living of the people everywhere.

Fig 1.2 Clay bricks using marble waste

1.3 MARBLE’S HISTORY AND ORIGIN

Marble is a metamorphic rock composed of recrystallized carbonate minerals, most

commonly calcite or dolomite. Marble is typically not foliated (layered), although there
are exceptions. In geology, the term marble refers to metamorphosed limestone, but its
use in stonemasonry more broadly encompasses un-metamorphosed limestone. Marble
is commonly used for sculpture and as a building material.

The name "marble" is used in a different way in the dimension stone trade. Any
crystalline carbonate rock that has an ability to accept a polish is called "marble." The
name is sometimes used for other soft rocks such as travertine, verd antique, serpentine,
and some limestones

Marble is a stone extracted from ancient times. The history of marble quarries goes
back to the 3th century BC in Greece, the 7th century in Turkey (Anatolia), and the
1st century in Italy. We can see historical monuments, sculptures, temples, mosques
Page11
made from marble. The first reference for marble extraction can be dated back to
3rd century BC in islands of Paros and Naxos in the Aegean Sea. And marble extraction
in those islands became popular and got a dominant position in the ancient world when
we look at Anatolia -the cradle of civilization - we see that marble was utilized for
construction of homes, tombs, temples, and sculptures during the Roman and
Byzantium era. And these quarries have been used during Seljuk and Ottoman periods.

Nowadays, in quarries high technology equipment and tools are used. This enables
more marble production with less labour work. In 2009, a total 107 million ton of
marble were produced in the whole world. When it comes to export, Turkey is the
leader in marble export with a 42% share in the global market.

Marble is a rock resulting from metamorphism of sedimentary carbonate rocks, most

commonly limestone or dolomite. Metamorphism causes variable recrystallization of
the original carbonate mineral grains. The resulting marble rock is typically composed
of an interlocking mosaic of carbonate crystals. Primary sedimentary textures and
structures of the original carbonate rock have typically been modified or destroyed.
Pure white marble is the result of metamorphism of a very pure (silicate - poor)
limestone or dolomite. The characteristic swirls and veins of many colored marble
varieties are usually due to various mineral impurities such as clay silt sand iron oxides,
or  which were originally present as grains or layers in the limestone. Green coloration
is often due to serpentine resulting from originally magnesium-rich limestone or
dolomite with silica impurities. These various impurities have been mobilized and
recrystallized by the intense pressure and heat of the metamorphism.

1.4 STUDY ON MARBLE WASTE IN INDIA

In India, million tons of wastes from marble industries are being released from marble
cutting, polishing, processing and grinding. Exposing the waste material to the
environment directly can cause environmental problems. Therefore, many countries
have still been working on how to re-use the waste materials.
Marble ranks the largest produced natural stone in the world and it accounts for 50% of
the world's natural stone production. Around 90% of the world's production of marble
comes from India and approx 85% of India's production is received from Rajasthan and
almost all mining and processing activities are concentrated around Udaipur, where the
proposed study is planned to undertake. The marble mining industry has come up
significantly in recent past. Rajasthan has around 4000 marble mines and about 1100
marble gang saws (processing plants). The industry involves Mines, Processing plants,
Cutters for the production of tiles for walls and floors, articles, waste reproduction and
other ancillary works.
The marble waste generation varies widely from 30% by weight (in mechanized mines
using wire saw cutting methods for extraction of marble blocks) to 65% by weight (at

Page12
mines where manual mining is resorted to and the rocks are fractured). Waste during
quarrying by mechanized processes can be estimated at 30% to 40% of the production.

The Conventional quarrying techniques of blasting leads to a waste percentage of 60%

to 70% and subsequent soil erosion. Dust generated during quarrying can also blanket
surrounding areas leading to vegetation die-off and adversely affecting the fertility and
quality of top soil. However, since m of the quarries in India are ill equipped as far as
mechanization is concerned, the percentage of marble waste, as generated during
quarrying of marble blocks can be estimated at 60%. This waste includes odd blocks of
various sizes and shapes, unwanted blocks and rock fragments produced during
trimming and shaping of mined out blocks before dispatch to processing units.

Figure 1.4 Marble waste in India

1.5 MARBLE WASTE AND ITS EFFECTS

The marble when quarried from natural stones gives its waste in two form: solid and
semi-liquid slurry .Waste slurry after drying results in environmental pollution in dust
form and land pollution by making soil infertile .Thus it proves that due to marble
waste air and land pollution generated. When marble is extracted from ores 30% of
marble is in waste form due to its non-uniformshape and size.

The marble slurry could lead in the long run to water clogging of the soil, to increasing
soil alkalinity, and to disruption of photosynthesis and transpiration. The net effect is a
reduction of soil fertility and plant productivity. Many animal species are exclusively
herbivores. Even if those plants did not die out, their internal chemistry will have been
altered and their nutritional value poisoned by gases emitted by the industry. The Inter-
dependence of the parts of the ecosystem does not seem to be greatly emphasized in
environmental public policy. It should also be realized that animal health, like human
health, can be adversely impacted by inferior environment quality.

Page13
1.6 OTHER APPLICATIONS OF MARBLE WASTE

 In paper production where it is the most important filler and coating pigment in

the manufacturing process. The fillers and pigments give paper a range of uses
including asphalt, ceramics, glass, concrete, detergents, tiles and bricks.

 For the environment, from flue gas desulfurization, drinking water treatment,

liming operations in forests and lakes, and acid rain neutralization.

 In agriculture, it is an additive for pesticide high degree of whiteness, opacity,

gloss and high printing quality at attractive prices.

 In plastics is used as a mineral modifier, which greatly improve processes and

mechanical properties in many plastics applications.

 In construction, as it has a multitude of characteristics that make it an ideal raw

material for a wide and animal feed production, suitable for sustainable eco-
friendly agriculture.

 In food and pharmaceuticals, where its chemical properties make it an

attractive filler and the right carrier for various blends. It is also a white pigment
and a technical aid in rice refining and other applications.

Page14
CHAPTER 2

LITERATURE SURVEY/REVIEW
2.1 PAPER REVIEWS AND CONCLUSIONS

“UTILIZATION OF MARBLE WASTES IN CLAY BRICKS: A

STEPTOWARDS LIGHTWEIGHT ENERGY EFFICIENT
CONSTRUCTION MATERIALS”.

AUTHORS: Zeeshan Khan, Akhtar Gul, Syed Azmat Ali Shah, Samiullah Qazi,
Nauman Wahab, Eid Badshah, Tayyab Naqash, Khan Shahzada.

 Proposed a beneficial use as a construction material will add to the

sustainability, and most importantly, might overcome the burden of marble waste
disposal.

 The partial replacement of clay with marble dust reduced its weight, strength and
increased its porosity, water absorption, and thermal insulation.
 The utilization of marble powder in bricks minimizes soil erosion and reduces
pollution to the environment.

CONCLUSION - Bricks produced by incorporating optimum replacement of marble

dust can be used in parapet walls, roof tiles and parition walls and other non lad bearing
walls. these bricks can be used for insulation purpose in buildings as the thermal
conductivity decrreases by increasing marble waste content.

“CHARACTERISTICS OF FIRED CLAY BRICKS WITH WASTE MARBLE

POWDER ADDITION AS BUILDING MATERIALS”.

AUTHOR: Sutcu, Mucahit, Hande Alptekin, Ertugrul Erdogmus, Yusuf Er, and
Osman Gencel.

 Bulk density of bricks with the waste marble decreases. Compressive strength
of bricks decreases depending on increment in waste marble content in the
brick body.

 Brick samples with 35% waste marble additive gives the lowest thermal
conductivity value .The highest thermal conductivity value was
obtained ,which belong to reference brick samples without waste marble
additive.

CONCLUSION- Waste marble powder at certain ratios can be utilized to lighten and to
Page15
make porous the body in production of fired clay bricks. Consequently, these bricks
produced with addition of waste marble can be used as a heat insulation construction
material. Wide scale application of waste marble in brick can significantly improve the
environmental situation in industrial regions. The application of waste marble can
significantly reduce the waste marble disposal cost as a component of brick.

“PRODUCTION OF BRICKS FROM WASTE MATERIALS”.

AUTHORS- Lianyang Zhang.

 A wide variety of waste materials have been researched for production of

bricks, including mainly fly ash and slags.

 Methods for producing bricks from waste materials can be divided into 3
categories: firing, cementing and geopolymerization.

 Commercial production of bricks from waste materials is still very limited due
to different reasons.

 Further research and development is needed to promote wide production and

application of bricks from waste materials.

“SUSTAINABLE USE OF MARBLE WASTE IN INDUSTRIAL

PRODUCTION OF FIRED CLAY BRICKS AND ITS EMPLOYMENT
FOR TREATMENT OF FLUE GASES”.

AUTHORS-Shehbaz Ahmad, Mansoor Ul Hassan Shah, Asmat Ullah, Syed Nasir Shah,
Muhammad Saad Rehan, Irfan Ahmed Khan, and Muhammad Imran Ahmad.

 Marble waste powder used in clay bricks and flue gas treatment was collected
from local marble processing plants, and its chemical composition was
analyzed using energy-dispersive X-ray analysis and X-ray fluorescence.

 The porosity of clay bricks increases with an increase in marble waste

percentage, and due to an increase in porosity, water absorption of clay bricks
also increases, while compressive strength and bulk density decrease.

 Clay bricks with 10% uncalcined marble waste and 20% calcined marble
waste satisfy the required compressive strength standard.

CONCLUSION- There is up to 43 and 65% reduction in the concentration of sulfur

dioxide and particulate matters, respectively, in flue gases, after treatment with marble
waste. The addition of marble waste to clay bricks is an effective and economical

Page16
solution for waste marble powder management. Furthermore, it can be used for the
treatment of flue gases from brick kilns before its addition to clay bricks.

“AN EXPERIMENTAL AND EMPIRICAL STUDY ON THE USE OF WASTE

MARBLE POWDER IN CONSTRUCTION MATERIAL”.

AUTHORS- Muhammad Sufian, Safi Ullah , Krzysztof Adam Ostrowski , Ayaz Ahmad
, Asad Zia , Klaudia Sliwa-Wieczorek , Muhammad Siddiq , Arsam Ahmad Awan.

 Marble waste occurs during the exploitation of deposits using shooting

technologies. The obtained elements most mainly often have an irregular
geometry and small dimensions, which excludes their use in the stone
industry.

 Different percentage proportions of marble powder were considered as a

partial substitute for clay, i.e., 5–30%. A total of 105 samples were prepared
in order to assess the performance of the prepared marble clay bricks, i.e.,
their water absorption, bulk density, apparent porosity, salt resistance, and
compressive strength.

 The obtained bricks were 1.3–19.9% lighter than conventional bricks. The
bricks with the addition of 5–20% of marble powder had an adequate
compressive strength with regards to the values required by international
standards.

CONCLUSION-The obtained empirical equations showed good agreement with the

experimental results. The use of waste marble powder in the construction industry not
only lowers project costs, but also reduces the likelihood of soil erosion and water
contamination. This can be seen to be a crucial factor for economic growth in
agricultural production.

SUMMARY OF LITERATURE REVIEW

Marble waste is used as an additive to bricks. It was proven that the marble waste had a
good impact on the chemical, physical, and mechanical strength of the resultant bricks .
Considering the mechanical properties of bricks containing wastes, it has been shown
that the addition of marble powder to a mixture has no prominent impact on their load-
bearing capacity .Marble sludge powder as a partial replacement for clay in order to
prepare modified clay bricks with enhanced durability and strength properties. It was
discovered that the use of marble sludge powder in brick manufacturing results in safe
and environmentally sustainable recycled materials .The obtained results showed that
the addition of waste marble powder reduced the density and compressive strength of
the elements, while at the same time improving their porosity.

Page17
CHAPTER 3

MATERIALS USED
The hardware requirments for making of a brick are listed below :-

3.1 MATERIALS USED

 Silica (sand): 50-60 % by weight

 Alumina clay : 20-30 % by weight
 Lime: 2-5 % by weight
 Red oxide : <=7 % by weight
 Magnesia : less than 1 % by weight
 Marble waste: <= 30% replacement of sand

3.1.1 Alumina
Alumina is the main constituent of clay. It acts as a cementing material in raw brick.
Brick clay is plastic due to the presence of alumina. This plasticity ensures that bricks
can be molded. An excess amount of alumina in clay may cause the bricks to shrink,
warp or crack on drying and burning as any other cementing material.

Figure 3.1.1 Alumina/clay

3.1.2 Silica
Good quality bricks contain 50-60% silica. It is present in both free and combined form.
As frees sand, it remains mechanically mixed with clay. In combined form, it reacts
with alumina to form aluminosilicates. Silica prevents raw bricks from cracking,
shrinking and warping. The higher the proportion of sand, the more and shapely and
uniform in texture will be the brick. Although, excess silica destroys cohesion between
the brick clay particles and makes brick brittle and weak. The durability of bricks
largely depends upon the proper proportion of silica and alumina.
Page18
 Figure 3.1.2 Silica/sand

3.1.3 Lime
Bricks should contain a little amount of finely powdered lime. It enables silica (of a
required portion) to melt at the furnace temperature of 1650oC and binds the particles
of brick together resulting in strong and durable bricks. At about 1100o C, lime acts as
a catalyst to elevate the furnace temperature to 1650oC at which silica fuses. This
slightly fused silica works as a strong cementing material. Excess lime in brick clay will
cause vitrification of bricks. It causes bricks to melt, as more than the required amount
of silica will fuse. The bricks then lose their shape and become disfigured.

Figure 3.1.3 Lime

3.1.4 Red Oxide

Bricks contain a small quantity of Red Oxide. Red Oxide acts a flux like lime, thus
helps silica to fuse at low temperature. It imparts a red color to bricks upon burning. It
also increases the durability and impermeability of the bricks.

Page19
 Figure 3.1.4 Red oxide

3.1.5 Marble waste

The partial replacement of clay with marble waste reduced its weight, strength and
increased its porosity, water absorption, and thermal insulation. Furthermore, the
utilization of marble powder in bricks minimizes soil erosion and reduces pollution to
the environment.

Figure 3.1.5 Marble waste

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3.2 AMOUNT OF MATERIALS REQUIRED (clay brick)

CALCULATION
It is found that
Dimensions of brick mould is as follows:
Length = 23.2 cm = 0.232 m
Breadth = 10.8 cm = 0.108 m
Height = 8cm =0.08 m
Therefore volume of brick = length * breadth * height
= 23.2 * 10.8 * 8
= 2004.48 cm3
We know that density of normal clay brick = 2.5 g/cm3
Hence mass of brick = density * volume
= 2.5 * 2004.48
= 5011.2 g
= 5.0112 kg

Table 3.2 quantity of materials required for one normal clay brick.
SAND 50 – 60% 60% by 3006.72 g 3 kg
weight
CLAY 20 – 30% 30% by 1503.36 g 1.5 kg
weight
LIME 2 – 5% 4% by 200.448 g 0.2 kg
weight
RED Less than or equal to 6% by 300.672 g 0.3 kg
OXIDE 7% weight

3.3 AMOUNT OF MATERIALS REQUIRED (clay brick with marble waste )

CALCULATION
It is found that
Dimensions of brick mould is as follows:
Length = 23.2 cm = 0.232 m
Breadth = 10.8 cm = 0.108 m
Height = 8cm =0.08 m

Therefore volume of brick = length * breadth * height

= 23.2 * 10.8 * 8
= 2004.48 cm3

Assuming density of clay brick with marble waste be = 2.5 g/cm3

Page21
Hence mass of brick = density * volume
= 2.5 * 2004.48
= 5011.2 g
= 5.0112 kg

Table 3.3 quantity of materials required for one clay brick with marble waste.
SAND 50 – 60% 50% 2505.5 g 2.5 kg
CLAY 20 – 30% 30% 1503.36 g 1.5 kg
MARBLE 5- 25% 10% 501.12 g 0.5 kg
WASTE replacement
of sand
LIME 2 – 5% 4% 200.448 g 0.2 kg
RED Less than or 6% 300.672 g 0.3 kg
OXIDE equal to 7%

Page22
CHAPTER 4

METHOD AND MANUFACTURING PROCESS

4.1 FOR NORMAL CLAY BRICKS

 Based on study/ tests to be performed we have made 3 normal bricks

For which required materials are
 Sand- 9 kg
 Clay – 4.5 kg
 Lime – 0.6 kg
 Red oxide – 0.9 kg
 Water (as required)

4.2 FOR CLAY BRICKS USING MARBLE WASTE

 Based on study/ tests to be performed we have made 3 bricks using

marble waste
For which required materials are
 Sand- 7.5 kg
 Clay – 4.5 kg
 Marble waste – 1.5 kg (10% replacement of sand)
 Lime – 0.6 kg
 Red oxide – 0.9 kg
 Water (as required)
4.3 MANUFACTURING PROCESS

Manufacturing of bricks constitutes four stages i.e., preparation of soil, moulding,

drying and burning.

Preparation Of Soil

Page23
Removal of Top Soil: The removal of top soil involves the loose materials present at the
top of the soil for a depth of about 200 mm. These materials should be removed as they
contain a lot of impurities and are not used in the preparation of bricks.

Digging and Spreading: After digging the soil for about 200 mm, the soil is spread on
the level ground, and the heaps of clay are about 600 to 1200 mm.

Figure 4.1 Clay

Cleaning: After spreading the soil on the ground, it should be cleaned of stones,

vegetable matter, pebbles, etc... If excess non-clay materials are present, the clay should
be washed and screened. This whole process will become expensive and clumsy. The
lumps in soil should be crushed into a powder form.

Weathering: The soil is then exposed to the atmosphere for softening for a few weeks
depending on the nature of the soil, which imparts plasticity and strength to the soil.

Blending: To increase the quality of soil, additionally, sandy or calcareous clays may be
added in suitable proportions along with coal, ash, etc. and the whole mass is mixed
uniformly with water.

Tempering: After adding the sufficient quantity of water, the soil is kneaded under the
feet of men or cattle to make it stiff and homogeneous. In general, for handmade bricks,
the soft plastic clay could be prepared by using about 25 to 30 per cent water. For
making superior bricks on a large scale of about 20,000, the earth is tempered in a pug
mill.

Moulding of Bricks

Page24
Bricks are made in metric sizes called modular bricks, as prescribed by the Bureau of
Indian Standards. Nominal size of the bricks is 20cm X 10cm X 10cm, which include
the thickness of the mortar and the actual size of modular brick is 19cm X 9cm X 9cm.
A brick mould is a rectangular box of steel or wood, which is open at the top and
bottom of the box and inside dimensions of the mould are 20cm X 10cm X 10cm.
Moulding of bricks can be done using either hand or machine.

Hand Moulding

There are two types in hand moulding, i.e. ground moulding and table moulding. In this
type, bricks are moulded manually and preferred where only a small quantity of bricks
is needed.

Ground Moulding: The process of moulding bricks on the ground manually by labour is

called ground moulding. On an average, a moulder can mould about 750 bricks per
day. When the bricks have dried sufficiently, they are moved to the drying shed and
placed in an orderly manner.

Figure 4.2 Hand moulding ( ground moulding )

Table Moulding: This moulding is done on a table of size 2m X 1m X 0.7m instead of

on the ground. This table moulding process is almost similar to ground moulding expect
for some minor changes.

Machine Moulding

Moulding machines are used when a large scale of bricks are to be manufactured in less
time. These types of bricks are heavier and stronger than the hand moulded ones and
possess a sharp regular shape, a smoother surface and sharp edges. There are two types
in machine moulding
Page25
Plastic Method: In this method, pugged earth is used, which is placed in the machine
that contains a rectangular shape of size equal to the length and width of the brick. A
beam of the moulded earth comes out of it and is cut into strips by wires fixed in the
frames. These bricks are also called wire-cut bricks.

Figure 4.3 Machine moulding ( plastic method)

Dry Method: In this method, the machine first converts the hard earth into a powder
form and a small quantity of water is added to the powder to make it a stiff plastic
paste. This paste is placed in the mould and pressed by the machine to form hard and
correct-shaped bricks. These bricks are known as pressed bricks, which do not require
any drying and can be sent directly to the burning section.

Drying of Bricks

Moulded bricks cannot be burnt directly, as they may get damaged. So before burning
they should be dried either naturally or artificially for about two weeks.

Natural Drying: It is also called hack drying, which comprises placing moulded bricks
in rows on their edges, slightly above the ground called a hack. These bricks are air and
sun-dried that is strong enough to use for the construction of small structures.

Page26
 Figure 4.4 Natural drying of bricks

Artificial Drying: When bricks are needed to dry on a large scale, then this artificial
drying is preferred. They are dried in special dryers which receive heat from specially
made furnaces for artificial drying.

Burning of Bricks

After the process of moulding and drying, bricks are burnt in kilns to impart hardness,
strength and to increase the density of the brick. Some physical and chemical changes
take place in the burning of bricks. Heating brick to about 640°C produces only
physical changes. If a brick is heated up to 700-1,000°C, it undergoes chemical
changes. During this reaction, the materials present in brick alumina and silica fuse
together to make the brick strong and stable to prevent from cracking and crumbling.

Figure 4.5 Block diagram of the manufacturing process

Page27
CHAPTER 5
TESTS AND RESULTS
5.1 COMPRESSION STRENGTH TEST

Steps to be followed for the test are :-

1. Wet the brick by immersing it in water
2. On the horizontal surface apply mortar (1 part of cement 3 parts sand + water)
To remove uncertainities and form smooth surface.
3. Dry for 24 hours.
4. Soak the bricks in water again for 24 hours.
5. Place the brick between the plates in compressive strengh machine
6. Aplly load
7. Note the point where needle turns back (break point)
Calculations
Break point = -------------- kg
Compressive strength = (break point * 9.81) / (area of contact (l*b))
= -----------------------N/m2
= -----------------------Pascals
For normal clay bricks:
Observations:-
Dimensions of the brick:-
Length= 22.8 cm = 228mm
Breadth = 10.7 cm = 107mm
Therefore area = 228*107 = 24396mm2
Break point = 93KN(kilo Newton)

Calculations:-
Compression strength=93000/24396
= 3.81 N/mm2
Result:-
The compression strength of normal clay brick = 3.8 N/mm2
It is observed that compression strength ranges= 3.5 to 3.8 N/mm2

Page28
For clay bricks using marble waste(10% replacement of sand):
Observations:-
Dimensions of the brick:-
Length= 22.8 cm = 229mm
Breadth = 10.7 cm = 108mm
Therefore area = 228*107 = 24732mm2
Break point = 87KN(kilo Newton)

Calculations:-
Compression strength=87000/24732
= 3.52 N/mm2
Result:-
The compression strength of normal clay brick = 3.5 N/mm2
It is observed that compression strength ranges= 3.2 to 3.6 N/mm2

Graph 5.1 compression strength test

Page29
 Fig 5.1 compression strength test

5.2 WATER ABSORPTION TEST

Steps to be followed:-
1. After the break completely dries weigh the brick W1
2. Put the brick in water for 24 hours
3. Dry with cloth on the surface only
4. Weigh the brick again W2 within three minutes.
Calculations:-
Water absorption % = ((W2 – W1) * 100) / W1
= -------------------%

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 Fig 5.2 Water absorption test

For normal clay bricks:-

Observations:-
Weight of bricks before placing in water W1 = 3581grams
Weight of bricks after placing in water W2 = 4133 grams

Calculations
Water absorption %= ((4133-3581) * 100) / 3581
= 15.41%
Result
Water absortion of a normal clay brick is observed as 15.41%
i.e <= 15%

For clay bricks using marble waste:-

Clay brick contained 10% of marble waste replacing sand used

Observations:-
Weight of bricks before placing in water W1 = 3633grams
Weight of bricks after placing in water W2 = 4465 grams

Calculations
Water absorption %= ((4465-3633) * 100) / 3633
= 22.90%
Result
Page31
Water absortion of a normal clay brick is observed as 22.90%
i.e <= 20%

Graph 5.2 water absorption test

5.3 EFFLORESCENCE TEST

A good quality brick should not contain any soluble salts in it. If soluble salts are there,
then it will cause efflorescence on brick surfaces . To know the presence of soluble salts
in a brick, placed it in a water bath for 24 hours and dry it in shade. After drying,
observe the brick surface thoroughly. If there is any white or grey color deposits, then it
contains soluble salts and not useful for construction.

Results:-
Table 5.3 efflorescence test
Normal clay bricks Nil
Clay bricks using marble Slight efflorescence
Page32
 waste(10%)

Fig 5.3 Efflorescence test

On further increase in percentage of marble waste(>10%) as a replacement to sand in

manufacturing of clay bricks efflorescence of brick also increases gradually . Hence
more percentage of marble waste containing bricks are not suitable for constructional
applications or any other applications.

5.4 SOUNDNESS TEST

Soundness test of bricks shows the nature of bricks against sudden impact. In this test, 2
bricks are chosen randomly and struck with one another. Then sound produced should
be clear bell ringing sound and brick should not break. Then it is said to be good brick.

Results :- On bringing the two normal clay bricks together and hitting them against
each other it resulted in a clear bell ringing sound and did not break .

In case of marble breaks the clear bell ringing sound was not heard properly but bricks
did not break.

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 Fig 5.4 Soundness test

CHAPTER 6

COMPARISON OF CLAY BRICKS AND CLAY

BRICKS USING MARBLE WASTE
Table 6. Comparison of clay bricks and marble waste infused clay bricks
PROPERTY CLAY BRICKS MARBLE WASTE
INFUSED BRICKS
Materials Used Sand- 9 kg Sand- 7.5 kg
Clay – 4.5 kg Clay – 4.5 kg
Lime – 0.6 kg Marble waste – 1.5 kg
Page34
 Red oxide – 0.9 kg (10% replacement of
Water (as required) sand)
Lime – 0.6 kg
Red oxide – 0.9 kg
Water (as required)
Weight of brick 3581grams
3633grams
Compressive Strength 3.81 N/mm 2
3.52 N/mm2
Water absorption (%) 15.41%
22.90%
Efflorescence Test No efflorescence was
observed. Slight efflorescence was
observed.
Soundness Test
Clear bell ringing sound
was produced and the slight bell ringing sound
bricks did not break. was produced and the
bricks did not break.

CHAPTER 7
CONCLUSION

On the basis of studies and tests carried out, the conclusions drawn are stated in this
section.

By increasing weight in percentage of marble powder, compressive strength of bricks

decreased. . These bricks can be used in areas where higher strength is not a concern
especially in shelter for people of earthquake and flood affected areas. Slight

Page35
efflorescence was observed in the marble dust bricks, but it does not affect the
appearance of building.

By increasing of the percentage of marble powder, the water absorption of bricks

increased. The addition of marble powder would result in a maximum decrease in
thermal conductivity compared to standard clay bricks.

Marble powder/dust is obtained from the marble processing plants which are the
leftovers during the cutting, shaping and polishing of marble. In this process, about
20% to 25% of the marble is turned into its powdered form. Hence, India is the topmost
exporter of marble, every year millions of tons of marble waste form processing
plants is obtained . Disposal of this marble waste into soils causes reduction in
permeability and also contaminates the ground water when deposited along the
catchment area. Thus, utilizing this marble waste in the construction industries would
help to protect the environment from dumping of marble dust. Marble is a non-
biodegradable material hence using them in bricks reduces the harmful effects of it on
the environment.

Hence these bricks are easy to make and manufacturing process is simple.

CHAPTER 8

REFERNCES

 Sutcu, Mucahit, Hande Alptekin, Ertugrul Erdogmus, Yusuf Er, and Osman Gencel.
“Characteristics of Fired Clay Bricks with Waste Marble Powder Addition as
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 Umar, Muhammad, Syed Azmat Ali Shah, Khan Shahzada, Muhammad Tayyab
Naqash, and Wajid Ali. “Assessment of Seismic Capacity for Reinforced Concrete

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 Frames with Perforated Unreinforced Brick Masonry Infill Wall.” Civil Engineering
Journal 6, no. 12 (December 1, 2020): 2397–2415. doi:10.28991/cej-2020-
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 Tozsin, Gulsen, Taskin Oztas, Ali Ihsan Arol, Ekrem Kalkan, and Omur Duyar.
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 Zhang, Lianyang. “Production of Bricks from Waste Materials – A Review.”

Construction and Building Materials 47 (October 2013): 643–655.
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 ASTM, “Standard Test Method for Dispersive Characteristics of Clay Soil by

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 ASTM, “Desidnation C67-11: Standard test methods for sampling and testing brick
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 Mehta, Dhiraj, Poonam Mondal, and Suja George. “Utilization of Marble Waste
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