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FIRST 2019 IOP Publishing
Journal of Physics: Conference Series 1500 (2020) 012070 doi:10.1088/1742-6596/1500/1/012070

The Utilization of Crushed Clay Brick as Coarse Aggregate on

Eco-Green Lightweight Foamed Concrete

Sumiati1, Mahmuda2, Sukarman3, Siswa Indra4, and Darma prabudi5

Civil Engineering Departement, State Polytechnic Sriwijaya, Srijaya Negara street,

Bukit Besar Plg, 30139, Indonesia
Email : sumiati@polsri.ac.id, mahmuda@polsri.ac.id, siswaindra@gmail.com,
Sukarman@polsri.ac.id, darma_prabudi@yahoo.com

Abstract. Lightweight Concrete has advantages in its weight, so as to minimize bending moment
and mitigate earthquakes. Lightweight Concrete can be made by changing its aggregate with a
lightweight aggregate or foaming the mortar, so that the concrete becomes porous and
lightweight. But, porosity, density and compression strength concrete have relation. This
research aims to obtain the value of density, porosity and compression strength from Lightweight
foamed concrete that use crushed clay bricks as coarse aggregate.
Testing was conducted to 96 samples of concrete with diameter of 15 cm and height of 30 cm.
Foam Agent added is varied 0%-3.5% to the water weight. Before compressive strength testing,
the samples were first cured and tested after age 7; 14; 21 and 28 days.
From the testing result, it is obtained that crushed clay bricks can be made as coarse aggregate
in eco-green lightweight concrete. If foam agent added are 2-3.5% then it is categorized as
Moderate Strength Concrete, while if foam agent added is < 2% it is categorized as Structural
Concrete, based on specification of Indonesian National Standard (SNI 03-3449-2002)
Keywords: crushed clay brick, lightweight foamed concrete

INTRODUCTION
Concrete is a mixture consists of large portion of aggregate mixed with cement paste/mortar made of
cement and water, so that it is forming a mass like rock. Concrete has a weakness that is the strength per
unit weight of concrete is low that is ranged around 2300 kg/m³, his will really influence the structure
that has a long span, where the weight of a large concrete dead load will really influence the bending
moment and earthquake.
Lightweight Concrete can be made by changing its aggregate with lightweight aggregate or add foam in
its mortar. Lightweight aggregate can be natural and artificial, such as: pumice, scoria, while artificial
light aggregates are aggregates made by brewing through material heating process, such as: clays,
diatoms, fly ash, slate ash, shale stone, clay stone, pearlite and vermiculite.
Based on the level of concrete density and strength resulted also type of lightweight aggregate used,
then Lightweight Concrete can be divided into three categories that are: 1) Insulating Lightweight
Concrete has density of 300 Kg/m3-800 Kg/m3 and compression strength around 0.69-6.89 MPa, used
for insulation, because it has low thermal conductivity and sound dampening capabilities. Type of
aggregate that usually used are Perlite and Vermiculite. 2) Moderate Strength Concrete, has density of

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FIRST 2019 IOP Publishing
Journal of Physics: Conference Series 1500 (2020) 012070 doi:10.1088/1742-6596/1500/1/012070

800 kg/m3-1440 kg/m3, that is usually used as fill concrete. This concrete is made of slag, fly ash, clays,
slate, shale, and natural lightweight aggregate, such as: pumice, scoria also have compression strength
around 6,89-17.24 MPa. 3) Structural Concrete has density of 1440 kg/m 3-1850 kg/m3 and compression
strength >17.24 MPa also coarse aggregate used are in the form of: expanded shale, clays, slate, and
slag[1].
Clay brick is one of the materials that usually used in building wall making that made of clay and water
with or without other mixture through some stage of process, such as: digging, processing, printing,
drying, burning at high temperature ranges 900 oC, so that it ripens and changes color, it will then harden
like a stone if it is cooled and cannot be destroyed again when immersed in water. Clay brick has density
of 1700 kg/m3, while crushed stone that usually used in normal concrete making has density of 1900
kg/m3. If viewed from the raw material and the manufacturing process, clay-brick can be categorized as
clay stone. So clay brick can be used as an aggregate course in lightweight concrete because it has a
lighter weight than crushed stone.
Lightweight foamed concrete is usually made of silica sand, chalk, cement, water, added with a Foaming
Agent. Foaming Agent is a concentrated solution of detergent surfactant (CH 3(CH12)15OSO3-NA+).
Foaming Agent when mixed with calcium hydroxide found in sand and water will react to form
hydrogen. This hydrogen gas will form air bubbles in the concrete mixture. Based on factory licensing,
the dose suggested is for 1 L foam agent : (40 L-80 L) water, because the more foaming agents mixed,
the more foam is produced, making concrete more porous. The greater the porosity of a Lightweight
foamed concrete, the smaller the compression strength.
The preliminary research used waste clay bricks as coarse aggregate and foaming agent as a foam maker
in lightweight concrete, including: Research [2], used waste clay bricks of 20% as a substitute for coarse
aggregate will get the compressive strength of concrete which is the same as the compressive strength
of concrete using crushed stones at the age of 28 and 56 days.
Research [3], by using Foaming Agent of 0.3% from the weight of cement obtained, optimum
Compressive Strength and Tensile strength.
Research [4], used trial mix cement : sand ratio 1:1 and polycarboxylate ether super plasticizer of 1.0%
in lightweight foamed concrete, it is obtained optimum compressive strength of 24.5 MPa and density
of 1500 kg/m3.
Research [5] about Effect of Water-Cement Ratio on Pore Structure and Strength of Foam Concrete,
used Water-Cement Ratio that is varied 0.40-0.60 is obtained, the more cement used the higher the
density and compressive strength lightweight concrete. The value of Water-Cement Ratio optimum
reached on 0.55 is obtained variety of density around 400 Kg/m3-800 Kg/m3.
Research [6] by utilizing waste clay bricks waste as aggregate on fresh lightweight concrete, it is
obtained lower dry density lightweight concrete from 1850 kg/m3 and compression strength in the age
of 28 days around 40 MPa.
Research [7], utilizing crushed clay brick in concrete industry as a partial replacement for aggregate for
concrete mix, by using Cement content 250 kg/m3 and 350 kg/m3 and water cement ratio of 0.7 and
0.5, obtained the optimum compressive strength on the replacement of aggregate crushed clay bricks by
25%.
In this research, foaming agents used will vary from 0-3.5%, as a foam maker and utilize crushed clay
waste from the clay brick factory as an aggregate course, so that an eco-green lightweight concrete
design will be obtained. The main purpose of this study is to obtain the value of density, porosity and
compression strength of Lightweight concrete, so that Lightweight concrete classification will be
obtained based on the Indonesian National Standard (SNI 03-3449-2002).

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FIRST 2019 IOP Publishing
Journal of Physics: Conference Series 1500 (2020) 012070 doi:10.1088/1742-6596/1500/1/012070

METHODOLOGY
This research is based on literature review from several result of researches that has been conducted and
conduct survey to crushed clay brick that will be used as coarse aggregate. Mix design concrete planned
is based on DOE Method [8] with compressive strength of 20 Mpa at the age of 28 days. Physical testing
to properties of concrete forming material consisting of material; fine aggregate (sand) originated from
Musi river and stone ash from Lahat, coarse aggregate (crushed clay brick) from local factory of clay
brick production and Portland cement type I with brand Baturaja, includes of: Sieve Analysis of Fine
and Coarse Aggregates [9], Relative Density (Specific Gravity) and Absorption of Coarse Aggregate
[10], Relative Density (Specific Gravity) and Absorption of fine Aggregate [11], Materials Finer than
75-μm (No. 200) Sieve in Mineral Aggregates by Washing [12], Bulk Density (“Unit Weight”) and
Voids in Aggregate [13], Organic Impurities in Fine Aggregates for Concrete [14], Determination of
aggregate crushing value (ACV) [15], Abrasion and Impact in the Los Angeles Machine [16], Density
of Hydraulic Cement [17] and Standard Test Method for Soundness of Aggregates by Use of Sodium
Sulfate or Magnesium Sulfate [18].
Based on Design of Normal Concrete Mixes (DOE Method) it is obtained the composition of testing
objects, as on Table 2. The testing objects made are 96 pieces, in cylinder form with diameter of 15 cm
and height of 30 cm. Foaming agent with brand ADT in the form of liquid and green, added to vary:
0%; 0.5%; 1.0%; 1.5%; 2.0; 2.5; 3.0 and 3.5%, where each composition is made 12 testing objects. The
value of slump is still on 5 cm, so that the total water used is decreased along with the percentage
increase of foaming agent used. Slump testing is based on ASTM Standard [19]. Porosity and density
testing is conducted before compressive strength testing [20]. Compressive strength testing will be
conducted at the age of 7; 14; 21 and 28 days with Universal Testing Machine (UTM) tool by guided to
ASTM method [21].
The compressive strength test results are then calculated using the related equation and analyzed by the
regression method and described in the form of curves and histograms.

RESULTS AND DISCUSSION

The results of testing the physical properties of concrete-forming materials can be seen in Table 1, where
coarse aggregate fulfills the Standard Specification for Lightweight Aggregates for Structural Concrete
[22], is a factory-made aggregate through the process of burning clays and has a density 1700 Kg/m3.
However, crushed clay-brick has an absorption value greater than sand and stone ash, which is around
12.87%. Aggregate crushing and aggregate abrasion crushed Clay-brick waste ranges from 16.15% and
32.56%, it can be concluded that crushed Clay-brick has brittle properties when compared to stone ash.
Table 1. Results Testing of physical properties of coarse/fine aggregates and cement

Test Result
Testing Notation
cement Sand Stone ash Clay brick
Specific gravity
3.0 2.43 2.59 1.70 Gr/m3
Bulk/density
Specific gravity saturated-
- 2.50 2.64 1.92 Gr/m3
surface-dry (SSD)
Absorption - 2.58 1.89 12.87 %
Materials Finer than
- 0.99 0.52 1.0 %
75µm
Unit Weight - 1362 1513 1200 Kg/m3
Aggregate crushing - - 10.60 16.15 %
Aggregate abrasion - - 20.36 32.56 %
Soundnees Test - - 2.8 6.7 %

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FIRST 2019 IOP Publishing
Journal of Physics: Conference Series 1500 (2020) 012070 doi:10.1088/1742-6596/1500/1/012070

Organic Impurities - non - - %

The result of Sieve Analysis testing then is mixed together, so composition coarse aggregate/crushed
clay brick is obtained: stone ash: sand that are: 50%: 25%: 25% and it is included in C zone with max
size of 38 mm also fulfills Design of Normal Concrete Mixes specification (Figure 1).

Particle -Size Distribution Curve Aggregate

100 100
90 composition:
80 crushed clay brick: stone ash: sand
Percent (%) Finer by Weight

75 50%: 25%: 25%

70 72
65
60 60
51 49
50 52 47 40 Specification Zona C
40
40 37 30
30 Specification Zona C 32
25 23
20 25 21
15
10 18 9 8
10 5
0 2
38 19 9.5 4.75 2.38 1.19 01 0.30 0.15
Particle Diameter (mm)

Figure 1. Aggregate Gradation maximum size 38 mm

Test objects were made with composition cement: crushed clay brick: Stone ash: sand, which ranged
from 1: 1: 0.5: 0.5. Water / cement ratio (W / C) plan 0.46 with a 5 cm slump plan. The added foaming
agent varies from 0-3.5% by weight of water. The more foam agent added, the more liquid fresh concrete
becomes, so as to maintain the value of slump and compression strength lightweight foamed concrete,
the reduction in water use can be seen in Table 2.
Table 2. Material Composition

Foam Agent (%)

Material Unit
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Cement kg/m3 620 620 620 620 620 620 620 620
Watercement ratio 0.46 0.44 0.42 0.40 0.38 0.36 0.34 0.32
Water kg/m3 285 273 260 248 236 223 212 198
Crushed clay brick kg/m3 620 620 620 620 620 620 620 620
Sand kg/m3 310 310 310 310 310 310 310 310
Stone ash kg/m3 310 310 310 310 310 310 310 310
slump cm 5 5 5 5 5 5 5 5
Foaming Agent kg 0 1.37 2.6 3.72 4.72 5.58 6.36 6.93

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FIRST 2019 IOP Publishing
Journal of Physics: Conference Series 1500 (2020) 012070 doi:10.1088/1742-6596/1500/1/012070

The result of compressive strength of Lightweight formed concrete testing can be seen from Figure 2.
The result of compressive strength will increase together with its age. Compressive strength of
Lightweight formed concrete at age of 28 days will decrease along with the addition of Foaming agent
of: 0%; 0.5%; 1.5%; 2.0%; 2.5%; 3.0% and 3.5% towards water weight, that are: 21.83 MPa; 19.20
MPa; 18.72 MPa; 17.72 MPa; 16.92 MPa; 14.32 MPa; 13.60 MPa and 9.7 MPa.
The result of density testing can be seen from Figure 3, density Lightweight Foamed Concrete will
decrease with the addition of foaming agent. The more foaming agents, the lighter the concrete produced
and the smaller the compressive strength. Density describes the density of a material and can describe
compressive strength concrete, the heavier the concrete, the compressive strength is higher, this is
proportional to the porosity of the concrete. Concrete porosity (Figure 4) also can illustrate the
magnitude of concrete strength in sustain a construction. The denser the concrete, the strength is greater
so that it can support heavier construction. Conversely, the more porous concrete, the strength will also
be weaker so that it can only support lightweight construction and durability is not too long. The porosity
be caused by the addition of foaming agent that aims to make pores in concrete, with the target of
obtaining lightweight concrete and has low heat conductivity also can muffle the sound.

25 Compression Strength of Lightweight Foamed Concrete

20
15
Compression Strength (MPa)

10
5
0
7 days 14 days 21 days 28 days
F0 14.19 18.55 20.30 21.83
F0.5 12.67 17.09 17.66 19.20
F1.0 12.54 16.66 18.16 18.72
F1.5 11.34 15.24 16.13 17.72
F2.0 10.49 14.72 16.41 16.92
F2.5 9.74 12.75 13.32 14.32
F3.0 8.70 11.42 13.19 13.60
F3.5 6.69 8.24 9.12 9.70

Figure 2. compressive strength of Lightweight formed concrete

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FIRST 2019 IOP Publishing
Journal of Physics: Conference Series 1500 (2020) 012070 doi:10.1088/1742-6596/1500/1/012070

25 1850
21.83 Structural Concrete
Classification Limit
Compressive Strength 28 days (MPa)
20 1825 180919.20 1800
18.72 Moderate Strength Concrete
1754 17.72 16.92

Density(Kg/m3)
1750
15 14.32 13.60
1703 1700
10 1675 9.70
1650
1633
5 1603 1600
1580
0 1550
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Foaming(%) by Weight Water
Compression Strength Density

Figure 3. Compressive Strength Concrete VS Density

Based on specification of Indonesian National Standard (SNI 03-3449-2002), Lightweight Concrete can
be categorized as: structural concrete with density of 1440-1850 Kg/m3 and compressive strength >
17.24 MPa, moderate concrete has density of 800-1440 Kg/m3 and compressive strength 6.98-17.24
MPa also Insulating Lightweight Concrete has density of 300 Kg/m3-800 Kg/m3 and compression
strength around 0,69-6,89 MPa. The result of research, from Figure 3, it can be seen that density
Lightweight Concrete is around 1580 Kg/m3-1825 Kg/m3, but it is smaller than density of normal
concrete that is 2300 Kg/m3. Whereas, its compression strength is greater than 9.7 MPa. So if the foam
agent added is 2-3.5% to water weight, concrete resulted can be categorize as Moderate Strength
Concrete even though for its density still does not fulfill the standard specification. While if the foam
agent yang added is < 2% to the water weight, then concrete resulted can be categorized as Structural
Concrete. Crushed clay brick can be made as course aggregate on lightweigh concrete because it has
density of 1825 Kg/m3 and compression strength of 21.83 MPa and it can be categorized as Structural
Concrete.

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FIRST 2019 IOP Publishing
Journal of Physics: Conference Series 1500 (2020) 012070 doi:10.1088/1742-6596/1500/1/012070

5.0 4.88 25

Compressive Strength 28 days(MPa)

4.5
21.83 4.37
4.0 19.20 20
18.72 3.69 3.78
3.5 16.92
Porosity (%)

3.0 2.98 17.72

3.04 15
14.32
2.64 13.60
2.5
2.0 2.31 9.70 10
1.5
1.0 5
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Foaming(%) by Weight Water
Porosity Compression Strength

Figure 4. Compressive Strength Concrete VS Porosity

CONCLUSION
Based on testing result, that materials used for the mixture of Lightweight Foamed Concrete, to obtain
result that is compatible with plan, then first testing of material physic characteristic must be conducted
and it must fulfill Standard Specification for Lightweight Aggregates for Structural Concrete.
The testing result is obtained, if foam agent added is 2-3.5% to water weight then it is categorized as
Moderate Strength Concrete, while if foam agent added is < 2% it is categorized as Structural Concrete,
based on specification of Indonesian National Standard (SNI 03-3449-2002).
Crushed clay brick is one of the materials that can be used as course aggregate on eco-green Lightweight
Concrete.

REFERENCES
[ 1 ] Indonesian National Standard, 2002, (SNI 03-3449-2002), “The Procedure for Planning a
Lightweight Concrete Mixture with Light Aggregate”.
[ 2 ] Chaocan Zheng, Cong Lou, Geng Du, Xiaozhen Li, Zhiwu Liu, Liqin Li, 2018, “Mechanical
properties of recycled concrete with demolished waste concrete aggregate and clay brick
aggregate”, Results in Physics 9 pp. 1317–1322.
[ 3 ] Puput Risdanareni, Aldi Hilmi & Prijono Bagus Susanto, 2017, “The Effect of Foaming Agent
Doses on Lightweight Geopolymer Concrete Metakaolin Based”, AIP Conference Proceedings
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[ 4 ] Philip Chie Hui Ling, Kan Chyau Shim, Lemba Anak Bennet, Cher Siang Tan, and Ee Ling Yong,
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[ 5] Zhongwei Liu, Kang Zhao, Chi Hu, and Yufei Tang, “Effect of Water-Cement Ratio on Pore
Structure and Strength of Foam Concrete”, Advances in Materials Science and Engineering,
Volume 2016, 9 pages.

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FIRST 2019 IOP Publishing
Journal of Physics: Conference Series 1500 (2020) 012070 doi:10.1088/1742-6596/1500/1/012070

[ 6 ] Y Zhao, J Gao, F Chen, C Liu, X Chen, 2018, “Utilization of waste clay bricks as coarse and fine
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