Batch 2 Project Report 2022

An Experimental Study on Properties of Concrete Using Over Burnt Bricks as Partial Replacement to Coarse Aggregates
2021-22
CHAPTER 1
INTRODUCTION
1.1 General
Concrete is one of the most widely used construction materials in modern days. It has
attained a status of the most preferred material in the modern constructions. Whenever
there is a requirement of Strength, Fire resistance, and durability, concrete is always
preferred and considered as the best material. Concrete Is created by blending cement,
sand, coarse aggregate and water to delivered material that can be formed into any shape.
The significant volume concrete is loaded with aggregate. The consideration of aggregate
in concrete decreases its drying shrinkage properties and enhances numerous different
properties, for example, compressive quality and so on. In any case, it is exorbitant to
transport, so neighborhood sources are expected to decrease the cost of transport, yet
because of land requirements this is not accessible at all spots, in this manner it requires
finding different sources and option from nearby sources. The numerous materials are
utilized as an option hotspot for common coarse aggregate, for example, reused low
quality smashed brick, reused coarse aggregate, coconut shell, reused plastic aggregate,
well consumed brick and so on. For this work select a over brunt brick as an option
hotspot for course aggregate Aggregates are the basic constituents in the concrete
composite that help with diminishing shrinkage and allow the economy to concrete
creation. An extensive segment of the aggregates used are ordinarily happening
aggregates, for instance, squash shake, shake and sand which is for the most part
misleadingly instinctive or latent when strengthened together with concrete.
Concrete is the base material for construction industries. coarse aggregate is filled almost
70% of volume in concrete. The cost of coarse aggregate is rapidly increasing also the
availability of aggregates is getting reduced. The over burnt brick wastes replaced with
concrete this over burnt brick maintain strength and performance to the concrete also
reduce the weight of the concrete. In environmental aspects replacement of over burnt
bricks in concrete is reduced the conservation in the natural resources. Over burnt bricks
are one of the types of aggregates used in certain places where natural aggregates are not
DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

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available. Due to its distorted shape over burnt bricks are considered as wastage but there
is a scope of using the over burnt bricks as a source of aggregates for construction. The
over burnt brick can solve the problem of shortage of aggregates and it is economically
feasible. The brick bats which are made from over burnt brick used as coarse aggregate
which is hard and absorb less water. The use brick aggregate instead of stone aggregate in
various components of building structure result in a significant reduction of dead load on
the columns and foundations.
Fig 1- OVER BURNT BRICK KILN

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1.2 OVER BURNT BRICKS
Class IV bricks are called as over burnt bricks are formed by uneven heating of bricks in kilns.
which are burnt upto temperature of 800 to 900 degree centigrade
Advantages of Over Burnt Bricks:
i. Use of burnt bricks helps to preserve natural aggregates as well as reduce waste
storage.
ii. It is also used as coarse aggregate in some places where the stone aggregates is not
easily available.
iii. It is also used as a lime concrete for the foundation.
iv. The absorption capacity is high.
Fig 2- Over burnt brick

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CHAPTER 2
LITRATURE REVIEW
G.S. Patil and P. B. Autade (2015) has performed that effect of partial replacement of
coarse aggregate by brunt brick in concrete. This project presents the effects of brunt Brick in
clusion on the mechanical properties of the concrete matrix in wet and hardened state properties.
For checking mechanical properties of brunt Brick bat based concrete used partially replacement
brunt brick to coarse aggregate ratios 20%, 40%, 60% and 80% in M40 grade of concrete. It is
observed that workability decreased with the replacement of coarse aggregate. The Compaction
factor observed as 0.92, 0.899, 0.88,
0.87 and 0.85 with varying percentage replacement of coarse aggregate by brunt brick bat as 0%,
20%, 40%, 60% and 80% respectively. The compressive strength brunt brick bat based concrete
used with partially replacement brunt brick to coarse aggregate ratios 20%, 40%, increased over
conventional concrete about 6.08%, 10.02% and 9.23%, 12.08% for7days and 10.02%, 11.95%
for 28 days. If further increased in the percentage of replacement up to 60% and 80%, the
strength was decreased by 3.73% and 8.16% respectively for 3 days and 5.69%, 9.25% for 7
days and 2.72%, 6.87% for 28 days cured cube specimen respectively. The Split Tensile and
Flexural Strength of this concrete increases with 5.26%, 8.68%, and 2.74%, 4.76% increased
with 3.94%, 12.1% and 3.16%, 7.5% for the replacement 60% and 80%.
Apebo, et. al. (2014) environs. The results indicate that crushed over burnt bricks–sand
concrete is medium light weight concrete having a density between 2000-2200 kg/m3 and
compressive strength of up to 29.5 N/mm2 compared to grave l – sand concrete having a density
between 2300-2400 kg/m3 and compressive strength of up to 30.8 N/mm2. It was concluded that
by reducing the water-cement ratio from 0.60 to 0.40 the compressive strength of crushed over
burnt bricks – sand concrete and gravel – sand concrete increased by more than 30%. Use of
broken over burnt bricks as coarse aggregate for structural concrete was recommended when

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natural aggregate was not easily available, high strength of concrete was not required and the
bearing capacity of the soil was low
Tariq Ali, et. al. (2013) generated a study on concrete which incorporated Over Burnt Brick
Ballast Aggregate partially due to their abundance. 5%, 10%, 15%, and 20% (M05, M10, M15,
M20) incorporation was used as partial replacement of natural coarse aggregate in concrete.
Analysis of incorporated concrete was done in fresh state as well as hardened state to evaluate
different properties of a concrete i.e. slump, compaction factor test, unit weight, and compressive
strength are evaluated. From all the results and experimental approach, it was concluded that
concrete formed with over burnt brick ballast aggregate showed beneficial performance as
compared with the concrete made up of natural aggregate obtained from local resources. The
over burnt brick ballast aggregate showed 14.75% increase in compressive strength for 20%
replacement. The investigation discovered decline in the unit weight, the adequate gain in
compressive strength. Therefore Split Tensile strength and Flexural Strength of concrete
incorporating over burnt brick ballast aggregate need to be evaluated. The incorporated concrete
was not required any particular attention regarding mixing, placing, and finishing. It serves
economically to the constructor without compromising on the strength and behave slight in
weight because of less unit weight. After the thorough study, it was proved that to use
incorporated concrete to such structures.
Husain M (1995) studied the use as coarse aggregate of bricks untreated or treated with
cement syrups of various consistency. They found that, the compressive strengths of crushed
brick concrete are 75-80% of that of normal concrete at 28 days while the splitting tensile
strength are higher than that of normal concrete and the modulus of elasticity is lower than that
of normal concrete.
Khalaf.F.M and Devenny A.S. carried out a study to evaluate the physical and
mechanical properties of new and over burn crushed brick as aggregate for use in Portland
cement concrete. The author stated that the impact value of brick aggregate increases as the
compressive strength of the parent brick decreases. The results showed that the over burn
crushed brick aggregates can be used for producing concrete for low level civil engineering
applications.

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Farid Debib and Said Kenai: studied the effect by partially replacing the fine and coarse
aggregate with over burn crushed brick in concrete. The compressive, flexure and split tensile
tests were conducted on concrete at the replacement levels of 25, 50, 75 and 100%. The authors
reported a relatively low density for crushed brick concrete than normal concrete. The
substitution levels of 25% for coarse aggregate and 50% for fine aggregate were reported from
the test results

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CHAPTER 3
OBJECTIVES
i. To determine suitability of brick waste as replacement of coarse aggregate in concrete
production.
ii. To study the engineering properties of fresh and hardened over burnt brick based
concrete
iii. To evaluate performance of concrete with over burnt brick as partial replacement of
coarse aggregate and conventional concrete.
iv. To develop a mixture proportioning process to over burnt brick concrete.
v. To identify and study the effect of sailient parameters that affects the properties of over
burnt brick based concrete
To investigate the mechanical and physical properties of over burnt bricks concrete

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CHAPTER 4
MATERIALS AND METHODOLOGY
4.1 MATERIALS:
CEMENT
Cement, one of the most important building materials, is a binding agent that sets and
hardens to adhere to building units such as stones, bricks, tiles, etc. Cement generally
refers to a very fine powdery substance chiefly made up of limestone (calcium), sand or
clay (silicon), bauxite (aluminium) and iron ore, and may include shells, chalk, marl,
shale, clay, blast furnace slag, slate. The raw ingredients are processed in cement
manufacturing plants and heated to form a rock-hard substance, which is then ground
into a fine powder to be sold. Cement mixed with water causes a chemical reaction and
forms a paste that sets and hardens to bind individual structures of building materials.
Cement of OPC 53 grade is used.
Fig 3- cement

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FINE AGGREGATE
Fine Aggregate is the granular material used to produce concrete or mortar and when the
particles of the granular material are so fine that they pass through a 4.75mm sieve, it is
called fine aggregate. Fine aggregate is the essential ingredient in concrete that consists of
natural sand or crushed stone. The quality and fine aggregate density strongly influence
the hardened properties of the concrete.
Fig 4- Fine Aggregate
COARSE AGGREGATE
Coarse aggregates are irregular broken stones or naturally occurring round gravels that are
used to make concrete, coarse aggregates for structural concrete consist of broken stones of
hard rock like granite and limestone (angular aggregates) or river gravels (round
aggregates). Aggregates larger than 10 mm in size are termed as coarse aggregates.
These aggregates are obtained from stone quarries and stone crushers, the size between
10 mm to 20 mm. The sizes of the particles to be used for concrete depends on the type of
work and reinforcement

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Fig 5- Coarse Aggregate
OVER BURNT BRICKS
In modern construction industry number of materials are used and one of the material is
bricks, regular bricks are generally used in building or in some engineering application. In
manufacturing of these bricks, a lot of waste is produced in the form of over burnt bricks,
the bricks being nearer to the fire in the furnace receives a temperature more heat and even
usually shrink and loose its shape. its color becomes reddish, these bricks can’t be used in
construction, the primary goal of this paper is to assess the suitability of incorporating
over-burnt bricks in concrete, by the partial replacement of coarse aggregate(NCA) with
over burnt bricks aggregate (OBBA) in a ratio of 10%,20%,30%,40% with mix proportion
of 1:2:4 .
Fig 6-Over Burnt brick Aggregate

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WATER
Water is one of the most important elements in construction and is required for the
preparation of mortar, mixing of cement concrete and for curing work etc. The quality of
water used has a direct impact on the strength of the motor and cement concrete in the
construction work. The water used for curing and mixing must be free from high quantities
of alkalis, acid, oils, salt, sugar, organic materials, vegetable growth, etc that might be
deleterious to bricks, concrete or iron. Impurities in water can cause metal corrosion,
introduce unwanted silt and clay into the concrete, adversely affect the hardening process
of concrete and also reduce the strength by even 25%. Thus, the need to ensure the quality
of water used during construction is vital. IS 456:2000 standards lay certain parameters for
which quality of water must be tested.
Fig 7- Water

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4.2 METHODOLOGY
1. Tests were conducted to determine the properties of the material.

2. Test on Fresh concrete using standard size of slump moulds as per IS;1199-1999.slump
test was performed for each percentage of replacement of coarse aggregate
i.e.0%,10%,20%and 30%.
3. Mix design, Casting and curing.
4. Test on hardened concrete:
a) Compressive strength: The cube specimen of the size 150 x 150 x 150 mm was
tested after curing for period of 7 and 28 days.
b) Split tensile strength: The tensile strength of concrete is tested by using test
specimens 150mm height and 10mm dia. Tensile strength is determine by using
compression testing machine.
c) Rebound Hammer test: conducted to measure the elastic properties or strength of
concrete.

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4.2.1 TESTS ON CEMENT

To know the properties of cement, the following tests are conducted in the laboratory
1. Standard consistency test

a. Initial setting time
b. Final setting time
2. Specific gravity
1. STANDARD CONSISTENCY TEST
The standard consistency of a cement paste is defined as that consistency which

will permit the vicat plunger to penetrate to a point 5 to 7mm from the bottom of
the vicat mould.
APPARATUS: vicat apparatus, weighing balance, gauging trowel
PROCEDURE:
1. Prepare a paste of weighed quantity of cement (400gms) with weighed quantity of

potable or distilled water (27%) taking care that the time of gauging is less than
neither 3 minutes nor more than 5 minutes and the gauging is completed before
any sign of setting occurs.
2. The gauging is counted from the time of adding water to the dry cement until
commencing to fill the mould.
3. Fill the vicat mould with this paste resting upon a non- porous plate. Smooth the
surface of the paste, making it level with top of the mould. Slightly shake the
mould to expel the air
4. Lower the plunger gently to touch the surface of the test block and quickly release,
allowing it sink into the paste as shown in figure. Record the depth of penetration.
5. Prepare trial pastes with varying percentages of water and test as described above
until the plunger is 5mm to 7mm from the bottom of the vicat mould.

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6. In filling the mould operator’s hands and the blade of the gauging trowel shall
only be used. Immediately place the test block with the non-porous resting plate,
under the rod bearing the plunger.
Observation and Readings:
Weight of Cement Sample: 500g
SL NO. % of water added Initial Final Penetration

reading reading
01 24% of water by weight of cement 40 38 02
Table 1. Standard consistency test readings

RESULT: Normal consistency of cement obtained for 34mm penetration is 30%
a) INITIAL SETTING TIME
Initial setting time is a time at which paste of cement starts losing its plasticity
after the addition of water
APPARATUS: vicat apparatus, needle for initial setting time, stop watch.
PROCEDURE
a) Take 400gms of cement in a pan. Prepare a neat cement paste by adding

0.85 times the water required to give a paste of standard consistency by the
previous test. Start a stop watch at the instant when water is added to the
cement.
b) Keep the vicat mould on a non-porous plate and fill the cement paste in it

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After completely filling the mould, it should be shaken slightly to expel the
air. Smooth off the surface of the paste making it level with the top of the
mould
c) Place the test block and the non- porous plate under the rod bearing the
needle having 1 sq.mm. cross section.
d) Lower the needle gently tills in contact with the surface of the test block
and quickly release allowing it to penetrate in to the test block. When vicat
apparatus with dash pot is used, place the mould filled with cement paste
and the nonabsorbent plate on the base of the vicat apparatus.
e) In the beginning the needle will completely pierce the block. Repeat the
procedure until the needle fails to pierce block for 5+-0.5mm measured
from the bottom of the mould. The period elapsing between the time when
water is added to the cement and the time at which the needle fails to
pierce the test block by 5+-0.5mm is the initial testing time.
Observation and reading:
Weight of cement sample = 400g
Sl.no. Quantity of time Initial Final penetration

water reading reading
01 0 40 0 0
02 05 40 0 0
03 10 40 2 38
04 15 40 3 37
105ml
05 20 40 4 36
06 25 40 4 36
07 30 40 6 32
Table 2. Initial setting time readings
RESULT: Initial setting time of cement is 30 minutes

b. FINAL SETTING TIME

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Final setting time is a time at which paste of cement completely losses its plasticity
and attains hardness.
APPARATUS: vicat apparatus, needle for initial setting time, stopwatch.
PROCEDURE:
1. Take 400gm of cement in a pan. Prepare a neat cement paste by adding

0.85 times the water required to give a paste of standard consistency by the
previous test.
2. Start a stop watch at the instant when water is added to the cement. Keep
the vicat mould on a non-porous plate and fill the cement paste in it.
3. After completely filling the mould, it should be shaken slightly to expel the
air. smooth off the surface of the paste making it level with the top of the
mould.
4. Place test block and the non-porous plate under the rod bearing the needle
with the annular attachment for final setting time as shown in fig
5. Lower the needle gently till the needle makes an impression there on,
while the attachment fails to do so.
6. In the beginning the needle will completely pierce the block. Repeat the
procedure. The period elapsing between the time when water is added to
the cement and the time at which the needle fails to make an impression on
the surface of the test block shall be the setting time.
Mass of cement = 400gms
Mass of water taken = 0.85xPx400 =0.85x30x400
= 102 ml
Final setting time of cement = 390 minutes
2. SPECIFIC GRAVITY OF CEMENT

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Specific gravity is defined as the weight of substance to the weight of equal volume
of water. Specific gravity is used in design calculation of concrete mixes with the
specific gravity of each constituent.
APPARATUS: density bottle, weighing balance, kerosene (free from water)
PROCEDURE:
1. Weigh a clean and dry density bottle with its stopper (W1.
2. Add water into the bottle and then take the weight(W2).
3. Remove the water and add kerosene in to the bottle then take the weight(W3).
4. Remove some kerosene and add cement in to the bottle till it about half
full. Mix thoroughly with glass rod to remove entrapped air. Continue
stirring and add more kerosene till it is flush with the graduated mark. Dry
the outside and weigh (W4).
5. Take the weight of cement added (W5).

Observation:
Weight of empty Density bottle W1= 49.86g
Weight of empty Density bottle +Cement W2=98.83g
Weight of empty Density bottle + Cement+ Kerosene W3=165.81g
Weight of empty Density bottle + Kerosene W4=129.80g
Weight of empty Density bottle +Water W5=149.57g
w 4−w 1 (129.80−49.80 )
Specific Gravity of Kerosene= = =0.80
w 5−w 1 ( 149.57−49.80 )

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Specific Gravity of Cement=

( w 2−w 1 ) ( 98.83−49.83 ) ×0.80
×0.80=
( w 2−w 1 )−( w 3−w 4 ) ( 98.83−49.83 )−( 165.81−129.80 )
( 48.9× 0.80 )
=3.18
( 48.9−36.15 )
Result: Specific gravity of Cement: 3.18
4.2.2 TESTS ON AGGREGATES

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1. FINE AGGREGATES
a. SPECIFIC GRAVITY
Specific gravity of fine aggregates is defined as the weight of substance to the weight of
equal volume of water. Specific gravity is used in design calculation of concrete mixes
with the specific gravity of each constituent.
Fig 8:PYCNOMETER APPARATUS

APPARATUS: Pycnometer, weighing balance, fine aggregates.
PROCEDURE:
1. Weigh the empty pycnometer take it has W1gms.
2. Take about 500gms of sample and place it in the pycnometer. And weigh it take it as
W2gms.
3. Pycnometer +sample+ distilled water into it until it is full. And take it as W3gms.
4. Pycnometer +water and take it as W4gms.
Observation:

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Weight of empty Pycnometer W1= 590g
Weight of empty Pycnometer +1/3 of Sand W2=1100g
Weight of empty Pycnometer + 1/3 of Sand + Water W3=1800g
Weight of empty Pycnometer + Water W4=1490g
Specific gravity of sand=
w 2−w 1 ( 1100−590 )
=
( w 2−w 1 )−( w 3−w 4 ) ( 1100−590 ) −( 1800−1490 )
520
=2.47
( 520−310 )
Result: Specific gravity of Fine Aggregate:2.47
2. COARSE AGGREGATE

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a. SPECIFIC GRAVITY TEST: BY WIRE BASKET METHOD
PROCEDURE:
1. About 2kg of coarse aggregate sample is washed thoroughly to remove fines, drained and
then placed in the wire basket and immersed in distilled water and cover a at least 5 cm of
water above the top of basket
2. Immediately after immersion in the entrapped is removed from the sample by lifting the
basket containing it 25 mm above the base of the tank and allowing it to drop 25 times at
the rate of 1 drop per sec
3. The basket and the aggregate should remain completely immersed in water for a period of
24+ 30 min afterwards
4. The basket and the sample are weighed while suspended in water at a temperature of 22
degree c to 32 degree c in case it is necessary to transfer the basket and the sample to a
different tank for weighing,there should be jolted 25 times as described above in the new
tank to remove air before weighing.
5. The weight is noted while suspended in water W1 gms
6. The empty basket is then returned to the tank of water jolted 25 times and weighed in
water W2 gms
7. The surface dried aggregates then weighed W3.
8. The aggregates are placed in oven at a temperature of 110degree C for 24hrs and weighed
W4gms.
Observation:
Weight of saturated aggregate suspended in water with the basket A1=1327g
Weight of wire basket in water A2=9g
Weight of oven dried sample is C = 1995g
Weight of saturated aggregates is B = 2050g
1995
Specific gravity = C/B-A=
( 2050−1327 )
Result: specific gravity of coarse aggregate = 2.75
3. TEST ON OVER BURNT BRICKS

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a. WATER ABSORPTION TEST

Procedure:
1. Weight the dry over burnt brick W1
2. Immerse completely dried specimen in clean water for 24 hours.
3. Remove the specimen and wipe out any traces of water with damp cloth and
weigh the specimen after it has been removed from water (W2).
4. Perform the calculations.
Observation:
Weight of Over burnt brick under room temperature M1=3420g
Weight of over burnt brick after removed from water M2=3675
( M 2−M 1 )
W= ×100
M1
( 3675−3420 )
¿ ×100
3420
=7.456
Result: The percent of water absorption is 7.45%
4.2.3 TEST ON FRESH CONCRETE

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SLUMP CONE TEST
Procedure:
1. Initially a known volume of cement concrete is prepared with a required proportion of

ingredients and W/C ratio.
2. Slump mould is cleaned for any remaining cement particles or impurities and properly
oiled at the inner surface.
3. Then the prepared concrete sample is put into the mould which is placed on a non porous
plate in 3 layers with a tapping of 25times for each layer by a standard tamping rod.
Tamping rod of size 16mm dia. and 600 mm length.
4. The extra heap of concrete present on the top of mould is cut off or leveled off.
5. Then the mould is lifted up vertically by taking care not to disturb the cast cement in the
mould.
6. The nature of slump is analysed to get the workability of the given cement concrete
sample.
a. M20 Concrete consist of 0% over burnt brick Aggregate(conventional concrete).
Observation:
Density of concrete=2370kg/m3
Proportion: 1:1.5:3
SL.NO CEMEN F.A C.A OVERBURNT W/C WATER SLUMP

T Kg kg kg BRICK RATO ADDED OBSERVED
AGGREGATE ml mm
01 8 12 25 0 0.5 4000 10
02 8 12 25 0 0.55 4400 30
03 8 12 25 0 0.6 4800 50
Table 3. Slump cone test readings for 0% over burnt brick aggregate concrete
b. M20 Concrete consist of 10% over burnt brick Aggregate.

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Observation:
Proportion: 1:1.5:3
SL.NO CEMEN F.A C.A OVERBURNT W/C WATER SLUMP

T Kg kg kg BRICK RATO ADDED OBSERVED
AGGREGATE ml mm
01 8 12 22.5 2.5 kg 0.45 3600 0

02 8 12 22.5 2.5 kg 0.55 4400 50
03 8 12 22.5 2.5 kg 0.60 4800 120
c. M20 Concrete consist of 20% over burnt brick Aggregate.
Observation:
Proportion :1:1.5:3
SL.NO CEMENT F.A C.A OVERBURNT W/C WATER SLUMP

Kg kg kg BRICK RATO ADDED OBSERVED
AGGREGATE ml mm
01 8 12 20 5kg 0.45 3600 0

02 8 12 20 5kg 0.55 4400 20
03 8 12 20 5kg 0.60 4800 180
d. M20 Concrete consist of 30% over burnt brick Aggregate.

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Observation:
Proportion: 1:1.5:3

AGGREGATE ml mm
01 8 12 17.5 7.5 kg 0.45 3600 0

02 8 12 17.5 7.5 kg 0.55 4400 20
03 8 12 17.5 7.5 kg 0.60 4800 180
e. M20 Concrete consist of 40% over burnt brick Aggregate.
Observation:
Proportion: 1:1.5:3

AGGREGATE ml mm
01 8 12 15 10 kg 0.45 3600 0
02 8 12 15 10 kg 0.55 4400 20
03 8 12 15 10 kg 0.60 4800 180
4.2.4 MIX DESIGN

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1. Grade designation = M20

2. Type of cement = OPC53 grade
3. Maximum size of coarse aggregate = 20mm
1. Target mean strength:-
f’ck = fck+1.65S
From IS 10262-2019,Table-2 pg no.3
f’ck = 20+1.65X4 = 26.6N/mm2
2. Selection of W/C ratio:
From IS-456-2000, Table-5
W/C=0.5
3. Selection of water content:
From 10262, Table-4
50mm slump=186ltr
for 100mm slump=186+6/100x186=197.16ltr
4. Calculation of cement content
w/c =0.5
197.16/0.5=394.32kg/m3
5. Calculation of coarse and fine aggregate
IS 10262, Table 5 volume of coarse aggregate 20mm size aggregate zone-1=0.6
Since w/c ratio is 0.5 therefore volume of CA =0.6
Volume of fine aggregate = 0.4=(1-0.6)
6. Mix calculation

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Volume of concrete =1m3
Volume of cement =(mass/SG)x(1/1000)
=(394.32/3.15)x(1/1000)
=0.125m3
Volume of water = 197.16/1000
= 0.197m3
Volume of aggregates e = {a-(b + c)}
= {1-(0.197+0.125)}
=0.678m3
Mass of coarse aggregate =0.678xSGx0.6x1000
=0.678x2.75x0.6x1000
=1073.95kg/m3
Mass of FA =0.678xSGx0.4x1000
=678kg/m3
4.2.5 QUANTITY OF MATERIALS REQUIRED AND CASTING OF MOULDS

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% OF CEMENT F.A C.A OVERBURNT W/C WATER

REPLACEMENT Kg kg kg BRICK RATO ADDED
OF C.A AGGREGATE ml
0 8 12 25 0 kg 0.5 4000
10 8 12 22.5 2.5 kg 0.5 4000
20 8 12 20 5 kg 0.5 4000
30 8 12 17.5 7.5 kg 0.5 4000
40 8 12 15 10 kg 0.5 4000
Total 40 60 100 25 - -
Table 8. Quantity of materials
We casted moulds in which coarse aggregates are partial replaced by Over burnt brick
Aggregates. The casted moulds are demoulded and allowed for curing. The curing process is
carried in Material testing laboratory curing tank of SIET Tumkuru.

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Fig 9: Slump cone test and Casting
Fig 10: Moulding

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Fig 11: Demoulding
Fig 12: Curing

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CHAPTER 5
RESULTS AND DISCUSSION
5.1 Test conducted on hardened conventional concrete.
We conducted Compression test and split tensile test for 7 days and 28 days.
Rebound hammer test is conducted for 28 days.
a. Compression test results on moulds cured for 7days.
Trial Weight of Dimension of Area in mm2 Peak load Peak stress

no. mould in kg mould in mm kN/m m2
1 8.550 150X150X150 22500 646.32 25.3
2 8.600 150X150X150 22500 683.80 27.1
Table 9. compression test readings.
Result: Compression test results on moulds cured for 7days is 26 N/mm2
b. Split tensile test results on moulds cured for 7 days.
Dimension of circular mould,100mm dia. and 200mm length.
Trial. No. Weight in kg Area mm2 Peak Load kN Peak Stress N/mm2
1 3.980 7853.98 87.3 11.00

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Table 10. Split tensile test readings.
Result: Split tensile test results on moulds cured for 7 days is 11.00 N/ mm2
a. Compression test results on moulds cured for 28 days.

1 8.700 150X150X150 22500 744.7 33.09
2 8.650 150X150X150 22500 660.6 29.36
3 2560 100X100X100 10000 369.5 36.95
Result: Compression test results on moulds cured for 28 days is 33.1 N/mm2
Dimension of circular mould,100mm dia. And 200mm length.
1 3.850 7853.98 89.2 12.63

2 3.800 7853.98 90.3 12.87
Result: Split tensile test results on moulds cured for 7days is 12.8 N/mm2

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a. Rebound hammer test results on moulds cured for 28 days
Trial.no. Mould 1 rebound Mould 1 Mould 1 rebound Mould 2

hammer reading strength hammer reading strength
1 35 34
2 30 30
3 36 28
4 28 30
5 27 30
6 31 34
7 31 33
8 24 25
9 34
Result Average Average
Table 13. Rebound hammer test readings.

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5.2 Test conducted on hardened concrete consist of 10% over burnt brick
aggregate.
a. Compression test results on moulds cured for 7days.

1 8.210 150X150X150 22500 513.4 22.81
2 8.300 150X150X150 22500 600.1 26.67
Result: Compression test results on moulds cured for 7days is 24.77 N/mm2
Dimension of circular mould,100mm dia. and 200mm length.
1 3.790 7853.98 73.9 9.41

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c. Compression test results on moulds cured for 28 days.

1 8.320 150X150X150 22500 867.3 30.2
2 8.425 150X150X150 22500 635.9 28.6
3 2.450 100X100X100 10000 220.1 22.01
Result: Compression test results on moulds cured for 28 days is 26.77N/mm2
d. Split tensile test results on moulds cured for 28 days.
1 8.44 7853.98 104.7 13.33

2 8.43 7853.98 90.3 11.50

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e. Rebound hammer test results on moulds cured for 28 days

1 30 28 29 28
2 26 22 25 22
3 24 20 21 18
4 25 22 26 22
5 22 20 25 22
6 27 26 22 18
7 22 20 26 22
8 24 22 25 22
9 22 20 24 20
Result Average 23 Average 23

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5.3Test conducted on hardened concrete consist of 20% over burnt brick

aggregate.
a) Compression test results on moulds cured for 7days.

1 7.920 150X150X150 22500 427.5 19
2 7.980 150X150X150 22500 443.9 19.72
Result: Compression test results on moulds cured for 7days is 19.37N/mm2
b) Split tensile test results on moulds cured for 7 days.
1 3.665 7853.98 69.4 8.84

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c) Compression test results on moulds cured for 28 days.

1 8.085 150X150X150 22500 642.2 28.63
2 8.000 150X150X150 22500 612.6 27.22
3 2.365 100X100X100 10000 266.3 26.63
Result: Compression test results on moulds cured for 28 days is 27.49N/mm2
d) Split tensile test results on moulds cured for 28 days.
1 3.700 7853.98 84.5 8.84

2 3.700 7853.98 69.4 10.76
Result: Split tensile test results on moulds cured for 28 days is 12.41 N/mm2

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e) Rebound hammer test results on moulds cured for 28 days.

1 22 18 23 21
2 20 14 25 22
3 21 18 22 18
4 24 20 23 20
5 23 20 20 16
6 26 22 22 18
7 21 18 21 18
8 22 18 26 22
9 25 22 22 18
Result Average 18 Average 19.2

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aggregate.

1 8.035 150X150X150 22500 364.4 16.18
2 8.000 150X150X150 22500 395.1 17.56
3 2.330 100X100X100 10000 184.7 18.47
1 3.770 7853.98 59.7 7.6

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1 7.960 150X150X150 22500 552.9 24.57
2 8.090 150X150X150 22500 635.3 28.23
3 2.265 100X100X100 10000 132.6 21.26
1 3.715 7853.98 72.5 9.23

2 3.725 7853.98 72.4 9.22

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e) Rebound hammer test results on moulds cured for 28 days

1 20 16 21 18
2 24 20 24 20
3 21 18 22 18
4 24 20 22 18
5 22 18 24 20
6 20 16 25 22
7 24 20 20 20
8 24 20 21 18
9 24 20 20 16
Result Average 18.6 Average 19

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aggregate.

1 7.915 150X150X150 22500 337.5 15
2 8.070 150X150X150 22500 336.1 16.27
3 2.225 100X100X100 10000 115.57 11.57
1 3.650 7853.98 60.8 7.74

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1 8.010 150X150X150 22500 503.3 22.36
2 7.960 150X150X150 22500 427.7 18.92
3 2.320 100X100X100 10000 173 17.3
1 3.695 7853.98 69 8.78

2 3.690 7853.98 54 6.87

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e) Rebound hammer test results on moulds cured for 28 days

1 21 18 20 16
2 20 16 21 18
3 24 20 22 18
4 24 20 20 16
5 24 20 22 18
6 25 22 21 18
7 21 18 21 18
8 20 16 20 16
9 24 20 22 18
Result Average 18 Average 18

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COMPRESSIVE STRENGTH OF MOULDS CURED FOR 7 &28

DAYS
35 33.1
29.4
30 27.49
26
24.77 24.68
25
19.75 19.52
20 17.4
14.5
15
10
0
conventional 10% of aggregate 20% of aggregate 30% of aggregate 40% of aggregate
concrete replacement replacement replacement replacement
compressive strength for 7 days of curing compressive strength for 28 days of curing
Series3
G.1.GRAPH SHOWING COMPRESSIVE STRENGTH OF M20 CONCRETE
TENSILE STRENGTH OF MOULDS CURED FOR 7 &28 DAYS
14
12.8 12.41
12 11
9.41 9.8 9.52
10 9.23
8.84
8 7.6 7.74
0
conventional 10% of aggregate 20% of aggregate 30% of aggregate 40% of aggregate
concrete replacement replacement replacement replacement
Tensile strength for 7 days of curing Tensile strength for 28 days of curing
G.2.GRAPH SHOWING TENSILE STRENGTH OF M20 CONCRETE

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CHAPTER 6
CONCLUSION
Based on the experimental work done in this study, the following conclusions were drawn,
a) Over burnt bricks can be suitably used for partial replacement of coarse aggregate in
concrete production as they adhere to the various specifications of aggregate as specified.
b) But with the replacement of coarse aggregates by 10% 20% 30% over burnt bricks, the
variations of strength between conventional concrete is within the targeted or allowable
strength.
c) Comparing to the conventional concrete the replacement of the coarse aggregate that is
10%,20%,30% and 40% by the over burnt bricks, the strength will reduces 5%,24%34%
and 44% respectively in compression for 7 days. For 28 days the compression strength is
reduced to 2%,8.3%,17.73% and 34.93%.
d) Comparing to the conventional concrete the replacement of the coarse aggregate that is
10%,20%,30% and 40% by the over burnt bricks, the tensile strength will reduces
14%,19%,30% and 32% respectively for 7 days. For 28 days the tensile strength is reduced
to 3%,23%,27% and 25%.
e) Further replacement of coarse aggregates by 40% of over burnt bricks, the variations of
strength between conventional concrete is not within the targeted or allowable strength.
By considering the above points, we can say that the over burnt bricks with 10to30%
replacement to coarse aggregate can be used to produce concrete with lower weight and hence
lower dead loads as such can be used on low bearing capacity soils.

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CHAPTER 7
REFERENCES
1. G S. Patil and P. B. Autade,(2015), “Effect of Partial Replacement of Coarse Aggregate
by Jhama Class Brick in Concrete, International Journal of Engineering Research and
General Science, Volume 3, Issue 4, Part-2, July-August, 2015 ISSN 2091-2730.
2. Kulkarni S ., Momin A. A., (2015), Experimental study on strength properties of concrete

using Brick Aggregates”, International Journal of Advance Engineering and Research
development,vol.2,Issue-1
3. Apebo N. S., Agunwamba J. C.(2014) “The suitability of crushed over burnt bricks as
coarse aggregates for concrete International Journal of Engineering Science and
Innovative Technology (IJESIT), Volume 3, Issue -1
4. Tariq Ali., Iqbal N.,(2013),Evaluation of compressive strength of concrete for partial

replacement of over burnt brick ballast aggregate,”, International Journal of Science And
Modern Engineering., vol-2.,Issue-1
5. Abdur Rashid Mohd., Abdus Salam Mohd., Kumar S,S., Kowsur Hasan Mohd., Effect of
Replacing Natural Coarse Aggregate by Brick Aggregate on the Properties of Concrete,
Dhaka University of Engineering & Technology, Vol.1, Issue.3, June 2012,pp.17-22.
CODE BOOKS
a) IS: 10262-2009,Recommend Guidelines for Concrete Mix Design, Bureau of Indian

Standards.
b) IS 516-1959 (reaffirmed in 1999), Methods of Tests for Strength of Concrete, Bureau

of Indian Standards.
c) IS 2386- 1963, Methods of test for aggregates for concrete, Bureau of Indian
Standards.
d) IS 1199-1959, Methods of sampling and analysis of concrete, Bureau of Indian

Standards.

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An Experimental Study on Properties of Concrete Using Over Burnt Bricks as Partial Replacement to Coarse Aggregates

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

Fig 1- OVER BURNT BRICK KILN

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

1.2 OVER BURNT BRICKS

which are burnt upto temperature of 800 to 900 degree centigrade

Advantages of Over Burnt Bricks:

iii. It is also used as a lime concrete for the foundation.

iv. The absorption capacity is high.

Fig 2- Over burnt brick

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

iv. To develop a mixture proportioning process to over burnt brick concrete.

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

MATERIALS AND METHODOLOGY

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

Fig 4- Fine Aggregate

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

Fig 5- Coarse Aggregate

OVER BURNT BRICKS

Fig 6-Over Burnt brick Aggregate

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

1. Tests were conducted to determine the properties of the material.

3. Mix design, Casting and curing.

4. Test on hardened concrete:

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

4.2.1 TESTS ON CEMENT

1. Standard consistency test

1. STANDARD CONSISTENCY TEST

The standard consistency of a cement paste is defined as that consistency which

APPARATUS: vicat apparatus, weighing balance, gauging trowel

1. Prepare a paste of weighed quantity of cement (400gms) with weighed quantity of

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

Observation and Readings:

Weight of Cement Sample: 500g

SL NO. % of water added Initial Final Penetration

01 24% of water by weight of cement 40 38 02

02 26% of water by weight of cement 40 36 04

03 28% of water by weight of cement 40 31 09

04 30% of water by weight of cement 40 06 34

Table 1. Standard consistency test readings

a) INITIAL SETTING TIME

a) Take 400gms of cement in a pan. Prepare a neat cement paste by adding

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

Observation and reading:

Weight of cement sample = 400g

Sl.no. Quantity of time Initial Final penetration

RESULT: Initial setting time of cement is 30 minutes

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

APPARATUS: vicat apparatus, needle for initial setting time, stopwatch.

1. Take 400gm of cement in a pan. Prepare a neat cement paste by adding

Mass of cement = 400gms

Mass of water taken = 0.85xPx400 =0.85x30x400

Final setting time of cement = 390 minutes

2. SPECIFIC GRAVITY OF CEMENT

DEPARTMENT OF CIVIL ENGINEERING, SIET, TUMAKURU.

APPARATUS: density bottle, weighing balance, kerosene (free from water)

5. Take the weight of cement added (W5).

Weight of empty Density bottle W1= 49.86g

Weight of empty Density bottle +Cement W2=98.83g

Weight of empty Density bottle + Cement+ Kerosene W3=165.81g