The Intemational Journal of Cement Composites and Lightweight Concrete, Volume 9, Number3 August 1987

Rice husk and fly ash c o n c r e t e blocks

Julibn Salas, Marina Alvarez and Janer Veras*

Synopsis This paper forms part of a project on materials, technology and prototypes of very low cost
housing, Carried out at the Instituto Eduardo Torroja (Spain). Results are presented of 40 x 20 x 20 cm blocks,
with a concrete made up of an agricultural waste product, rice husk, and an industrial by-product, fly ash, and
formed by means of a manual placement machine. The blocks have a density of about 11 O0 kg/m 3, a K value of
0-20W/m°C and failure loads of 7000 to 8000kp.

Keywords Masonry, lightweight concrete, insulation, rice husk, fly ash, agricultural wastes, concrete
elements, compressive strength, thermal conductivity, appropriate technology, strength of materials, mix
design

INTRODUCTION manual placement variety (Figure 1)in which two speci-

Based on previous research [1-4] on the properties of
concrete with a rice-husk base, the present work which
is of an experimental nature, expounds the use of this
range of materials (lightweight, insulating, and structural)
in the form of building components that are easy to
produce even in developing countries. For the use of
these materials, the following prerequisites were estab-
lished:
(1) adequate manageability, without the need to resort
to mechanical means;
(2) technology to put this into effect that may be easily
assimilated;
(3) minimal investment in equipment;
(4) flexibility of use (neutrality of the components); and
(5) use of abundant waste materials (rice husk, and fly
ash) and those that may be easily acquired (cement).
Two basic elements, capable of satisfying the above
requirements, were selected: a hollow block measuring
40 x 20 x 20cm and a 90 x 60 x 6cm panel. The
present work describes the development and study of
the properties of the hollow blocks.
HOLLOW BLOCKS
Production equipment
The production equipment for these blocks involves
minimal investment; it is solid and easy to handle and
therefore represents an important step in the industriali-
sation and rationalisation of the building process in
developing countries. It involves a layer machine of the
* Instituto Eduardo Torroja (C.S.I.C.), Apartado 19002, Madrid, Spain.
Received 25 June 1980 Accepted 28 January 1987
(~) Longman Group UK Ltd 1987
0262-5075/87/09306177/$02.00
fic modifications have been introduced.
(1) To provide wall thicknesses that are greater than
normal so that they adapt better to the range of low
resistance concretes.
(2) Longitudinal tongue and groove, to improve behav-
iour with respect to horizontal action.
The block designed consists of a modular frame
measuring 40 x 20 x 20cm with an overall horizontal
section area of 791.3cm 2 and a net or resistant section of
448.5cm 2 giving an apparent volume of 8.521dm 3
(Figure 2).
Each placement carried out by the machine pro-
duces six blocks. The machine runs on electricity and
allows for alterations in the mould for the shape of such
elements.
Mix proportioning
Work has been conducted with three families of basic
mixes referred to as L, C and M. Later on, a further mix B
was definea; detads of these mixes are gwen later for
comparative purposes.
The basic or standard mix L is the same as that used
by the authors in making up insulating concretes [1]. In
order to obtain concretes with greater resistance and a
more homogeneous texture, a 'filler' was added; fly ash
in a natural state, originating from the Soto de Ribera
plant [2] was used in a quantity equal to 25% of the
weight of the cement (mix C) and 54% by weight (mix M)
(Table 1).
Five water/(cement + ash) ratios were used for each
mix. Since vibration time appeared to be a fundamental
parameter, all the mixes were vibrated for one minute;
and four mixes were selected to be vibrated again for
two and three minutes. Thus altogether twenty-four
mixes were tested, with six blocks being made from

177
Rice husk and fly ash concrete blocks
each mix, which were tested in pairs at 7, 28 and 60 days
respectively.
Analysis of results
Figures 3, 4 and 5 show the average compression test
results of the blocks; the tests were carried out with
layers of felt between the block and the plates so as to
regulate the load. The blocks were cured at a tem-
perature of 15 to 17°C. The figures show the breaking
loads for the blocks as well as the compressive strength
based on the net section of the block; the type of mix,
water/(cement + ash) ratio, vibration time and average
A
i!
Figure 2 Dimensions of hollow block (all dimensions in cm)
178
Salas, Alvarez and Veras
Figure 1
Typical blocks and
production equipment
weight of two blocks before testing are also marked on
each curve.
The effect of adding fly ash was evident both in the
outward appearance of the blocks, and in the results
obtained regarding resistance. Dosages M (with 54%
ash) showed marked improvements over dosages C and
these" (25% ash), comparatively speaking, surpassed
dosages L (without ash).
The results show average densities of 573-744 kg/
m 3 for mixes L, 748--813 kg/m 3 for mixes C, and 990-
1065 kg/m 3 for mixes M. It should also be pointed out
that adopting an average value of O.12 W/m °C [2] for this
material, the coefficient of total thermic transmission, K,
-I-.e
3 J. 12
Rice husk and fly ash concrete blocks Salas, Alvarez and Veras

Table 1 Mix proportions by weight for six blocks

Mixes with substituion of Mix with substitution of cement

fly ash by fly ash
Dosages L C M B
P-ARI-450 cement (kg) 26.46 26.46 26.46 20.33
Husk treated with lime
(saturated surface dry) (kg) 10.17 10.17 10.17 10.17
Fly ash from Soto de
-- 6.61 14.27 20,33
Ribera (kg)
% cement 100 80 66.6 50
% fly ash 0 20 33.3 50
Water/(cement + ash) ratios 0.45 0.50 0.55 0.60 0.65

should correspond to an approximate value of 0.20W/
m 2 oC.
Mixes type L
The average unit densities of all the mixes were low,
falling within the region of 800 + 50kg/m 3, with the
exception of L (0.65) (3'), (573kg/m3). As can be seen
from Figure 3, the most suitable w a t e r - c e m e n t ratio is
0.60. The w a t e r - c e m e n t ratio of 0.65 was clearly
excessive, especially for three minutes' vibration time,
since it caused the mortar to segregate considerably,
reducing the weight of the block and lowering its
strength.
Mixes type C
The average densities of all the C dosages involved
hardly any increase over the L mixes, remaining within
the region of 800 + 50 kg/m 3. The most suitable water/
(cement + ash) ratios were within the range 0.50 to 0.65
for one minute's vibration time, giving resistances at 28
days of 4000 to 4500 kp. The increase in vibration time for
the dosage with a water/(cement + ash) ratio of 0.65 was
obviously counterproductive, and dropped noticeably
between one and two minutes and, most appreciably
(around 50%) when vibration time is increased from one
to three minutes.
Mixes type M
The average densities of all the mixes were in the region
of 950 + 100kg/m 3, with appreciable compressive
strengths being achieved in comparison to the previous
mixes. The most suitable water/(cement + ash) ratio
turned out to be 0.60.
An attempt was made to determine the influence of
vibration time on the two extreme mixes M(0.45) and

kp
Figure 3 Compressive
6000 13,2 strengths of blocks of
different L-type mixes and
L(0,60)(]')(7292} vibration times
5000 ll,O
n

c~
4000 B,8 II
L [0,55)( I')(6555]
"13
0 300( 6,6
CD ](1'}(S431
¢-

I II F / 4,4 ._>
L(0,751(1'1165151
Q.
,ooo ., %.-- 2,2 ~:
0
(..}
L(O,eS)(3')(4aee:

Days

179
Rice husk and fly ash concrete blocks Salas, A lvarez and Veras

kp Figure 4 Compressive
strengths of blocks of
6000 --13,2 different C-type mixes and
C(O, 50)(1')(6535)
.______J.
vibration times
C(0,55}(1')(6608)
50001.--- 11,0 CL

C (0,65)(1')(7428)
C)
tl
4000 - - 8,8 "E
.,Q C(0,60)(1')(S701)/ C (0,65)(2')(6726)
o
3000 -- 6,6
c (0,45) (I')(6373 )
oo
C (0,65)( 3' ) (6930) >
2000 4,4

Q.
E
0
1000 - - 2,2 (J

Days

kp J
Figure 5 Compressive
strengths of blocks of
90001 - - 19,8
different M-type mixes and
vibration times

80001 - - __ __ M(o,6o~(-~(8~-~-~1;7,6
0
M(O,60)(1')(SlS5)
.-...ao
7000 - - ~ ' ~ .... - - . - 15,4

D-

6000 - - " ~:4"~(3~e6 ~"~T 13,2

O
M(0,651(3~(9074)

"o 5000 . . . . )(1')(7993)

00 I1,0
0
{D'
t- }
(0
4OO0 8,8
¢n
.>
3000 • M!Or65)(]'l166151 6,6
M 10,4j~)(2') ( 7 2 0 3 E
O
(_)
M(0,651(2'1162031
2000 4,4

1000 - - -
2,2

7' 28' 6 'o

Days

180
Rice husk and fly ash concrete blocks Salas, Alvarez and Veras

Figure 6 Compressive
,oTol 0,60
15,6 strengths of blocks of
different M-type mixes.
Vibration time: one minute
---0 0,55 Water/(cement + fly ash)
60001-- 13,4 A
r a t i o : 0 . 4 5 ; 0.50; 0.55; 0.60;
--0 0,50
0.65
0
5000,1----- 11,2
0,45

4000 8,9
.E

3000 i 6,7
0,65
._>

20001---#4 4,5 t~
E
0

IO001"-IH-- 2,2

~'" 2~ 6b
Days

Figure 7 Compressive

'°t
8000-- B (9,460 Kg)a/(c+cv)
=0,45

--'--
M(01185 Kg)q/(c',-cv) -
17,8

15,6
strength of blocks of L, C, M
and B dosages, Vibration
time: one minute

7000 i i ~ = 0,60
O.

6000 I - - 13,4

0
L(7,292 Kg)a/c =0,60 tl
~'0
5000 ~_ - - 11,2

t~
C{6,701Kg) a/(c ÷ cv)
"O
¢D ~3 =0,60 ~v
O 4000 I 8,9
ED
E

co

CQ 3000 ._>
- - 6,7

O.
E
2000 i 4,5 0
(D

]000 - - 2,2

!
28 6'0

Days

181
Rice husk and fly ash concrete blocks
M(0.65). In both cases, the results are noticeably contra-
dictory: a reduction in resistance between one and two
minutes of vibration time, and an increase when vibration
was increased to three minutes. This phenomenon
cannot be accounted for. For the mix M and water/
(cement + fly ash) ratio = 0.60, the increase in vibration
time from one to two minutes is seen to be beneficial
from the point of view of compressive strengths at all
ages.
Mixes type B
It would be appropriate to draw attention, particularly in
the light of the results given in Figure 6, to the fundamen-
tal influence of an adequate water/(cement + fly ash)
ratio: a sharp drop in resistance when passing from 0.60
to 0.65 follows the progressive increase in resistance for
increases in such ratio from 0.45 to 0.60.
In general, it may be concluded that no appreciable
advantage of any kind is to be found in moving from mix
type L to type C; however, there is a considerable,
practical improvement when moving from the latter to
M-type mixes. This can be seen clearly in Figure 7, which
gives the results for water/(cement + fly ash) ratio =
0.60 and one minute's vibration time.
In the light of these results it was decided to
increase the quantity of ash again by an appreciable
amount in such a way that a new dosage B was produced
with the following .composition:
P-ARI-450 cement 20.33 kg (40%)
Soto de Ribera ash 20.33 kg (40%)
Treated husk (S.S.D.) 10.17 kg (20%)
Water 18.30 litres
Water/(cement + fly ash) -- 0.45
CONCLUSIONS
Comparatively speaking, the results of this new mix are
182
Salas, Alvarez and Veras
clearly satisfactory since they include the following
points:
1. An increase in compressive strengths with respect
to mix M.
2. Savings in cement amounting to roughly 30% with
respect to mix M, since 4.78kg of cement are used per
block instead of 3.38 kg.
3. A really minimal increase in weight, with respect to
mix M, of the order of 3%, since the average weight per
block increased from 9.185kg to 9.460kg.
In light of the above data, mix B has been adopted
(4/4/2 by weight of P-ARI-450 cement, fly ash, treated
husk) and water/(cement + fly ash) ratio = 0.45, as the
most suitable for blocks made up with an industrial
by-product (fly ash), an agricultural waste product (rice
husk) and a portland cement.
REFERENCES
I. Salas, J. and Veras J. 'Insulating panels with rice
husk', International Journal for Housing Science
and its Applications, Miami, U.S.A., Vol. 10, No. 1,
1986, pp. 27-32.
2. Salas, J., Alvarez, M. and Veras, J. 'Materiales de
construcci6n con propiedades aislantes a base de
c~scara de arroz', Informes de la Construcci6n,
Madrid, Spain, Vol. 37, No. 372, July 1986, pp. 1-12.
3. Salas, J., Alvarez; M. and Veras, J. 'Light/insulating
concretes with rice husk', The International Journal
of Cement Composites and Lightweight Concrete,
Vol. 8, No. 3, August 1986, pp. 171-80.
4. Salas, J., Alvarez, M. and Veras, J. 'Algunas com-
probaciones previas para un programa experimen-
tal sobre hormigones de baj0 coste', Boletin Oficial
del Colegio de Aparejadores, Madrid, Spain, No.
83, October 1985, pp. 52-7.