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that addition of GCB do not produce any detrimental effect
on performance of the binder in terms of normal consistency process. As per WBSCDs Cement Sustainability
(NC), setting time and soundness. The compressive strength Initiative (CSI) progress report 2005, one ton of
of the binder is reducing with increasing replacement of cement production is responsible for one ton of CO2
OPC with GCB at all ages. The reduction in 28-D emission: half of the CO2 is from the chemical process
compressive strength is not very significant upto 15% of clinker production, 40% from burning fuel, and the
cement replacement level, but is significant at 35% cement remaining 10% is split between electricity use and
replacement level compared to OPC and fly ash based transportation. According to the recent data of the
binders. Gain of strength from 28 to 56 days for all the GCB WBSCD, globally, cement industry produces 5% of
based binders is higher than that of OPC and fly ash based
binders indicating good pozzolanic activity of GCB. Based
global man-made CO2 [2].
on the results of the study we can conclude that ground clay
bricks can be used as supplementary cementitious material. Annual global cement production as of 2012 is
over 3.6 billion tons, and is expected to be increased
Keywords: Ground clay brick powder, binder, paste, mortar, soon to over 4 billion tons per year, nevertheless, the
compressive strength. cement industry is confronting with the continuous
increase in cost for energy supplies, the obligations to
INTRODUCTION reduce CO2 emission and the need of appropriate
supply of raw materials both in quality and quantity.
Concrete is everywhere. It is the second most Cement cannot be recycled. The cement content in
consumed material after water and it shapes our built concrete cannot be viably separated and reused or
environment. Concrete is extremely durable and can recycled into new cement and thus carbon reductions
last for hundreds of years in many applications. cannot be achieved by recycling concrete [1].
Popularity of concrete as construction material is on
three counts, i) excellent mouldability, ii) adequate Materials containing calcium, aluminates, and
(compressive) strength, and iii) amenable to the amorphous phases of silica, in addition to other phases,
utilization of local materials as ingredients. Another can react within the environment of hydrating cement
reason for its popularity is that it can be manufactured to provide a product which shares some of the
at site maintaining requisite quality without much properties of Portland cement through a secondary
elaborate production process. It is estimated that reaction known as the pozzolanic reaction. The use of
roughly 25 billion tonnes of concrete is manufactured supplementary cementitious materials (SCMs) to
globally each year. This means over 3.8 tonnes per offset a portion of the cement powder in concrete is a
person in the world each year. According to the promising method for reducing the environmental
concrete recycling report of World Business Council impact of the industry. If an alternative material can
for Sustainable Development (WBSCD), China and be substituted for at least a portion of the cement
India are now producing and using over 50% of the powder that does not contribute additional green house
worlds concrete, their waste generation will also be gasses to the atmosphere, conserves natural resources,
significant as development continues [1]. and does not negatively affect the properties of the
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resulting concrete, then the environmental impact of Santorin Island in Aegean Sea was used in lime
the industry can be reduced [3, 4]. As an added mortars to build durable structures [11]. Baronia and
incentive, researchers and manufacturers of cement Binda report that the successors of the Greeks, the
and concrete have explored ways to not only offset the Romans, refined the practice and discovered new
use of cement powder, but to improve the properties pozzolana sources one of which is brick powder.
of the resulting concrete, reduce the cost of the When the natural pozzolanic material was not
materials, and further reduce environmental damage available the Romans used powdered brick to mix
by utilizing streams of waste material as SCMs [5]. with lime to obtain a strong, durable binding material
[12].
Several industrial by-products have been used
successfully as SCMs, including silica fume (SF), The results of the study done by the authors on
ground granulated blast furnace slag (GGBFS), and cementitious pastes where cement was replaced by
fly ash (FA). These materials are used to create blends ground clay bricks (GCB) up to 25% showed that the
of cement which can improve concrete durability, effect on normal consistency and time of setting was
early and long term strength, workability, and insignificant; the temperature rise during hydration
economy [6, 7]. was reduced; and the calcium hydroxide production
was decreased. The mechanical properties of concrete
The present work aims at examining the possibility have values low at early age but higher or comparable
of using ground clay bricks as a supplementary at later ages and the resistance to chloride penetration
cementitious material. The scope of work will include was improved. These results suggested a pozzolanic
studying the performance binders composed with activity provided by finely ground brick [13].
partial replacement of ordinary Portland cement (OPC)
with ground clay bricks in terms of consistency, Calcined kaolin, or metakaolin, has been
setting time, soundness and compressive strength. The successfully used in mass concrete applications in
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results of the investigation will give the performance Brazil since 1965. The production cost was one third
of the binders made using waste clay bricks powder as of the Portland cement and it suppressed the potential
partial replacement of ordinary Portland cement as a alkali-aggregate reaction in several dams built with
cementitious material. The findings of this reactive aggregate [14]. The most kaolin-rich and the
investigation may instigate further research on effect mostly poorly crystallized clay show the best
of these materials on the hydration of the cementitious pozzolanic activity [15]. Kaolin is an essential
system, concrete microstructure and long term ingredient of clay brick manufacturing due to its
performance of concrete towards better understanding sintering behaviour [16]. Therefore, kaolin-rich clay
of these materials as supplementary cementitious brick may show pozzolanic activity in finely divided
material. form and has potential to be used as supplementary
cementitious material. Wild et al. achieved to produce
LITERATURE REVIEW pozzolan by heat treatment of Oxford clay used in
brick production [17] In their study with eight
This section reviews the research and literature different clay bricks from Britain, Denmark,
that focuses on the different aspects like workability, Lithuania, and Poland, authors carried out chemical
and strength of paste/mortar/concrete made using clay test for pozzolanicity and compression test for
brick powder as partial replacement of OPC. A strength development of mortar mixtures containing
considerable amount of effort has been undertaken by up to 30% ground brick as cement replacement; and
the research community for an intimate understanding concluded that all the ground brick types used in the
of using these materials as SCM. The evidence of study exhibit pozzolanicity [18].
usage of cementitious material in Egypt, Greek and
Italy is understood well before Christian era [8]. In Reference [19] found that ground brick
improves the resistance of mortar to aggressive
According to Campbell and Pryce in Reference environments. OFarrell et al. showed the resistance
[9], the earliest fired bricks discovered so far dates of mortar mixtures to sulfate attack is increased when
back to 50004500 BC in Mesopotamia. Despite the ground brick is added to mixture; similarly, negative
advanced technology used in nowadays clay brick effects of seawater on the mortar mixtures were
manufacturing, the significant amounts of products mitigated [20]. The study done by Bektas et al. on the
are still discarded because they do not confirm the cementitious pastes showed that the ground brick
standards. Sinton C W writes in their book that some slightly increased the water demand for normal
clay minerals possess pozzolanic property when consistency, delayed the time of setting, reduced the
thermally treated: upon heating interlayer water is temperature rise during hydration, and decreased the
removed, crystal structure is destroyed, and a new Ca(OH)2 content. The tests on concrete showed that
material with pozzolanic property is formed [10]. the mechanical properties (compressive, flexural and
Pozzolans have been known to construction industry splitting tensile strengths and modulus of elasticity)
since the ancient Greeks. The volcanic ash from of concrete containing ground brick were well
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comparable to those of the concrete without ground 4) 35-GCB = 65% OPC + 35 % GCB
brick. Furthermore, the GCB increased the resistance 5) 15-FA = 85% OPC + 15 % FA
of concrete to chloride ion penetration [21]. 6) 35-FA = 65% OPC + 35 % FA
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isolation and in combination, on hydration and
packing density of cement paste. Here the authors Table 1 Chemical Properties and Specific
have found that in a paste composing of Portland Gravity of OPC, FA and GCB
cement and ground clay brick, a small acceleration of
hydration reactions was also observed at early ages. Parameter GCB FA OPC
The reduction in the amount of Calcium Hydroxide SiO2(%) 45.72 55.94 23.91
and the increase in the amount of combined water Al2O3 21.39 32.17 5.01
indicated that the ground clay bricks had pozzolanic Fe2O3 (%) 18.41 4.89 3.70
activity. However, the packing density of the paste CaO(%) 2.45 1.38 62.15
composing of Portland cement and ground clay brick MgO(%) 3.09 0.73 0.68
was lower than that of the Portland cement paste and Na2O(%) 0.76 0.18 0.25
a decrease of compressive strength occurred [25]. K2O (%) 0.82 1.66 0.51
SO3 (%) 0.07 0.23 1.80
EXPERIMENTAL PROGRAMME Cl (%) - - -
TiO2 (%) 2.70 1.47 0.41
As part of the project ground waste clay bricks LOI (%) 3.78 0.58 3.88
will be analysed for their suitability as a IR (%) - 92.93 1.08
supplementary cementitious material. Samples of the Sp. Gr. 2.7 2.2 3.15
clay bricks will be collected from local construction
site and ground to powder having cement equivalent The analysis of PSD of OPC, FA and GCB
fineness. The performance of this powder will be indicates that the fly ash is very fine with mean
tested using binders composed of partial replacement particle diameter of almost 1/10th of that of OPC. With
of 53 grade OPC. This clay brick powder will be such a fine PSD the fly ash is likely to exhibit high
subjected to chemical analysis and particle size reactivity. GCB is the coarsest of all the three
distribution (PSD). Total six binder compositions will materials with mean particle diameter of 70.43 micron.
be used for the project. 53 grade Ordinary Portland
cement complying with IS 12269-2013 [26] will be Table 2 Particle Size Distribution of OPC, FA
one binder. The other five binder compositions will and GCB
be with 5%, 15% and 35 % replacement of OPC with
waste brick powder (GCB), and with 15%, 35% Particle Size Distribution (
)
Material
replacement of OPC with fly ash. D10 D50 D90 Mean Diameter
GCB 2.71 41.17 178.22 70.43
The binders will be designated as follow; FA 0.27 1.70 4.68 2.13
1) 100-OPC = 100% OPC OPC 6.85 23.94 54.16 27.72
2) 5-GCB = 95% OPC + 5 % GCB
3) 15-GCB = 85% OPC + 15 % GCB Consistency, Setting Time and Soundness Test
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OPC. The FST has slightly increased from 230 smaller than 1mm greater than 0.5mm and smaller
minutes to 255minutes with 5% GCB replacement than 0.5mm greater than 0.09mm. The size of the
compared 100% OPC. Whereas, the FST has shown mortar cube will be 70.7*70.7*70.7 mm. The mortar
reducing trend with increasing addition of GCB i.e. cubes will be tested for compressive strength at 1, 7,
reduction of 15 minutes and 45 minutes for 15 and 35% 28 and 56 days. The compressive strength of the
replacement by GCB respectively compared to 100% mortar made with OPC and varying replacement level
OPC. Although, both the IST and FST are reducing of OPC with GCB from 5, 15 and 35% are given in
with the increasing replacement level of GCB, it is Figure 2. The results of the compressive strength test
well within the requirement of the code i.e. minimum indicates that the compressive strength of the binder is
30minute for IST and maximum 600minutes for FST reducing with the increasing addition of GCB as
respectively [26]. cement replacement material compared to 100% OPC,
15% FA and 35% FA binder .
The Le-Chatelier expansion has increased to 1mm
compared to 0.5mm with the 100% OPC paste. The The 1-day compressive strength of the 100% OPC
Autoclave expansion has rather reduced to 0.03% for as binder is 18.4MPa. Although 1 day compressive
the paste with 5% GCB compared to the control mix strength of the binder made with 5% replacement of
with 100% OPC; whereas it has rather reduced to 0.04% OPC with GCB is 4% more than that of 100% OPC
for the paste with 15% and 35% GCB replacement as binder; at 15 and 35% replacement of OPC with GCB
compared to the control mix with 100% OPC. it has reduced by 15 and 50% respectively as
Although, both the Le-Chatelier and Autoclave compared to that of 100% OPC binder. The 28 days
expansions are showing varying trends with addition compressive strength of the 100% OPC binder is
of GCB both the expansions are well within the 60.9MPa. The 28 days compressive strength of the
requirements of the code i.e. maximum 10mm for Le- binder composed with 5, 15 and 35% replacement of
Chatelier expansions and 0.8% for Autoclave OPC using GCB is reduced by 10, 17 and 36%
expansions respectively [26]. respectively than that of 100% OPC binder.
Results of the above tests indicate that the GCB do However, the gain of strength from 28-days to 56-
not show any harmful effect on paste performance days is 14% for 100% OPC binder whereas that for
when used as partial replacement of OPC hence can be binder composed with 5%, 15% and 35% cement
used as a cement replacement material. replacement of OPC with GCB is 18%, 17% and 24%
respectively. This indicates enhanced hydraulic
activity at later age when using GCB as a cement
replacement material in increasing replacement level
of OPC as compared to 100% OPC.
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For comparison purpose two more mortar mixes 4) Based on the above we can conclude that
were produced with same mix composition but with ground clay brick is exhibiting comparable
replacement of OPC by high grade fly ash at 15 and pozzolanic behaviour and can be used as
35 percent replacement level. The 1-day strength of supplementary cementitious material up to 35%
binder with 15% replacement of OPC by fly ash cement replacement level.
exhibited almost same strength compared to that with 5) Further research is needed to evaluate the
GCB. But, the 1-day strength of binders with 35% performance of ground clay brick in concrete
replacement of OPC by fly ash exhibited 11% higher in terms of plastic properties, strength and
strength compared to that of the binder with 35% GCB. durability performance as well as
However, at 28 days, the compressive strength of microstructural analysis of concrete made
binder with 15% fly ash is 14% higher than that of the using ground clay brick as SCM. Also, a
binder with 15% GCB; whereas the compressive further research can be undertaken towards
strength of binder with 35% fly ash is 19% higher that understanding the hydration of the binders
than with 35% GCB. The higher 28 days strength of with ground clay brick.
fly ash mixes is possibly due to high reactivity of fly
ash with very finer particle size compared to that of ACKNOWLEDGEMENT
GCB. But, the gain of strength from 28 to 56 days of
the binders with GCB is 2% more than that of binders The authors express grateful acknowledgments to
with FA at 15 CRL and is same as that of FA based Research and Development Department of UltraTech
binder at 35% CRL, indicating better pozzolanic Cement Limited, Mumbai, for their support to this
activity of the GCB compared to fly ash at 15% as research work.
well as 35% CRL.
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