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CHAPTER 3

MIX COMBINATIONS AND CASTING OF BRICKS

3.1 GENERAL

In the manufacturing of fly ash glass bricks, it is necessary to select

suitable raw materials and evaluate their properties. The performance
requirements of fly ash glass brick involve their mechanical properties and
durability performance.

3.2 MATERIALS USED FOR MAKING OF FLY ASH GLASS

BRICKS

Selecting and controlling the proportions of all the ingredients is

used for making fly ash glass bricks with the above qualities is accomplished.
The ingredients used for making of fly ash glass powder bricks are fly ash,
glass powders, GGBS, lime, gypsum, crusher dust and water.

3.2.1 Fly ash

Class F fly ash is used in this study for the manufacturing of the fly
ash glass brick specimens. It is obtained from Mettur Thermal Power Station,
Tamil Nadu, India. The sample of fly ash is shown in Figure 3.1. The physical
properties and chemical composition of fly ash are tabulated in Tables 3.1 and
3.2 respectively.
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Figure 3.1 Sample of fly ash

Table 3.1 Physical properties of Class F fly ash

Constituents Values
Particle Size 75-100 µm
Specific Gravity 2.25

Table 3.2 Chemical compositions of Class F fly ash

Constituents Percentage (%)

Silicon dioxide (SiO2) 59.08
Calcium oxide (CaO) 2.08
Aluminum oxide (Al2O3) 36.46
Iron oxide (Fe2O3) 2.38

3.2.2 GGBS

Ground Granulated Blast furnace Slag is obtained from iron blast -

furnace. It is collected from Jason Slag Cement (JSW) factory at Salem,
Tamilnadu.
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Figure 3.2, shows the sample of GGBS. Tables 3.3 and 3.4 show the physical
properties and chemical composition of GGBS.

Figure 3.2 Sample of GGBS

Table 3.3 Physical properties of GGBS

Constituents Value
Specific Gravity 2.25
Fineness 2%
Particle Size < 76 μm

Table 3.4 Chemical compositions of GGBS

Constituents Percentage (%)

Silicon Dioxide (SiO2) 39.36
Calcium Oxide (CaO) 34.67
Aluminium Oxide(Al2O3) 20.22
Magnesium Oxide (MgO) 5.73
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3.2.3 Glass powder

Glass powders are widely used in the construction industry

worldwide and utilized as a part of different development in construction
activities. In this research, glass powders are collected from locally available
industries. Soda glass powder, Boron glass powder and Coloured glass
powder were used for the manufacturing of fly ash glass brick.

The glass powder particle size is smaller than fly ash. So, the
strength of the brick is increased. The glass powders are collected from
locally available industries and passed through IS sieve, 75 μm is used in this
study. Glass powders are used in this work to study the mechanical and
durability properties of the brick. The sample of the glass powder is shown in
Figure 3.3.

The physical properties and chemical compositions of glass

powders are tabulated in Tables 3.5 and 3.6 respectively.

Figure 3.3 Sample of glass powder

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Table 3.5 Specific gravity of glass powders

S. No. Type Observed Values

1. Soda glass powder 2.69
2 Boron glass powder 2.63
3 Coloured glass powder 2.52

Table 3.6 Chemical composition of glass powders

Soda glass Boron glass Coloured

Constituents powder powder glass powder
Percentage (%)
Silicon dioxide (SiO2) 75.70 80.53 75.50
Calcium oxide (CaO) 6.56 1.98 5.93
Aluminium oxide (Al2O3) 1.23 1.06 3.65
Sodium oxide (Na2O) 12.15 13.90 11.15
Magnesium oxide (MgO) 1.63 0.23 2.12
Potassium oxide (K2O) 1.95 1.39 1.14
Iron oxide (Fe2O3) 0.78 0.91 0.51

3.2.4 Gypsum

The gypsum is brought from Tuticorin, Tamilnadu, India and it is

shown in Figure 3.4. The role of gypsum is to control the initial setting time
of mixes. The gypsum has a minimum purity of 35 % and should be free of
lumps and impurities. If any lumps or impurities are found in the bags, it
should be removed by screening and then used for the manufacturing process
of fly ash glass bricks.
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Figure 3.4 Sample of gypsum

3.2.5 Lime

Locally available lime is used to prepare the fly ash glass brick
specimen and it is shown in Figure 3.5. It contributes to obtain strength and
hardness of the specimen. With reference to literature, 25 % of lime is used in
the total mass of the specimen. The main advantage of lime is to propagate
high degree of plasticity and contributes the major part of the strength. At
room temperature, lime reacts with fly ash and forms a compound possessing
cementitious properties. Calcium silicate hydrates (C - S - H) were formed
due to the reaction between the lime and fly ash. It is responsible for
increasing the strength.

Figure 3.5 Sample of lime

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3.2.6 Crusher dust

Crusher dust is used in various construction activities in global

level. Hence, it is in high demand in the market. It is available in a variety of
colours and grades to suit various requirements. The attributes of the crusher
dust are its fine texture, good quality and bonding strength. The sample of
crusher dust is shown in Figure 3.6.

Locally available crusher dust was passed through IS 4.75 mm

sieve and was used in this study. The crusher dust contains elements of Silica,
Alumina, Calcium, Magnesium and Sodium. The physical properties of
crusher dust are shown in Table 3.7.

Figure 3.6 Sample of crusher dust

Table 3.7 Physical properties of crusher dust

Properties Values
Water absorption 6.2 %
Bulking of sand 4.91
Fineness modulus 1.43
Specific gravity 3.02
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3.2.7 Water

Locally available potable water is used for this study with pH value
of 6.4. The quantity of water used to prepare the specimen is 20 % of total
mass of the raw materials. Required proportion of water is added to achieve
homogenous mixing.

3.3 METHODOLOGY OF RESEARCH WORK

Material Collection

Properties of Materials

Casting of fly ash glass bricks

Testing of fly ash glass bricks

Compressive Water Weight

Efflorescence Hardness
Strength Absorption Density

Finalizing Mix Proportion

Durability Properties
• Chemical Attack
• Initial Rate of Absorption
• Sorptivity

Structural Properties
• Stress-Strain behaviour of Brick
• Stress-Strain Behaviour of
Mortar
• Stress-Strain behaviour of Brick
Numerical
Prism
Investigation

Results / Discussions

Summary / Conclusion

Figure 3.7 Methodology of research work

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The ingredients used to make the fly ash glass bricks are fly ash,
glass powder, GGBS, lime, gypsum, crusher dust and water according to the
given specifications found in the literature. The main purpose of mix
proportioning is to obtain a product that will perform better in essential
requirements like the properties of bricks, durability performance of fly ash
glass bricks and brick masonry prism behaviour. Another purpose of mix
proportioning is to satisfy the performance requirements at a lower cost by
suitably selecting materials available in various industries.

3.4 MIX IDENTIFICATION

The materials used to make the fly ash glass brick mix are fly ash,
glass powder, GGBS, lime, gypsum, crusher dust and water. Various mix
combinations were formed for glass powder and GGBS added in fly ash
brick. Totally 37 mix combinations are made to find out the optimum dosage
of glass powder with GGBS in fly ash brick. Table 3.8, shows the various mix
identification and combination of fly ash glass brick. The following are the
mix identifications of fly ash glass bricks.

• SFA - Soda glass powder added in fly ash brick.

• BFA - Boron glass powder added in fly ash brick.

• CFA - Coloured glass powder added in fly ash brick.

• GSFA - Ground granulated blast furnace slag with Soda

glass powder added in fly ash brick.

• GBFA - Ground granulated blast furnace slag with Boron

glass powder added in fly ash brick.

• GCFA - Ground granulated blast furnace slag with Coloured

glass powder added in fly ash brick.
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Table 3.8 Mix Identification and combinations of fly ash glass bricks

Various Ingredients in Percentage

S. No Mix ID
FA SG BG CG GGBS Gypsum Lime Crusher dust
1 FA 25 0 0 0 0 25 25 25
2 SFA1 23 2 0 0 0 25 25 25
3 SFA2 22 3 0 0 0 25 25 25
4 SFA3 21 4 0 0 0 25 25 25
5 SFA4 20 5 0 0 0 25 25 25
6 SFA5 19 6 0 0 0 25 25 25
7 SFA6 18 7 0 0 0 25 25 25
8 BFA1 23 0 2 0 0 25 25 25
9 BFA2 22 0 3 0 0 25 25 25
10 BFA3 21 0 4 0 0 25 25 25
11 BFA4 20 0 5 0 0 25 25 25
12 BFA5 19 0 6 0 0 25 25 25
13 BFA6 18 0 7 0 0 25 25 25
14 CFA1 23 0 0 2 0 25 25 25
15 CFA2 22 0 0 3 0 25 25 25
16 CFA3 21 0 0 4 0 25 25 25
17 CFA4 20 0 0 5 0 25 25 25
18 CFA5 19 0 0 6 0 25 25 25
19 CFA6 18 0 0 7 0 25 25 25
20 GSFA1 16 1 0 0 8 25 25 25
21 GSFA2 15 2 0 0 8 25 25 25
22 GSFA3 14 3 0 0 8 25 25 25
23 GSFA4 13 4 0 0 8 25 25 25
24 GSFA5 12 5 0 0 8 25 25 25
25 GSFA6 11 6 0 0 8 25 25 25
26 GBFA1 16 0 1 0 8 25 25 25
27 GBFA2 15 0 2 0 8 25 25 25
28 GBFA3 14 0 3 0 8 25 25 25
29 GBFA4 13 0 4 0 8 25 25 25
30 GBFA5 12 0 5 0 8 25 25 25
31 GBFA6 11 0 6 0 8 25 25 25
32 GCFA1 16 0 0 1 8 25 25 25
33 GCFA2 15 0 0 2 8 25 25 25
34 GCFA3 14 0 0 3 8 25 25 25
35 GCFA4 13 0 0 4 8 25 25 25
36 GCFA5 12 0 0 5 8 25 25 25
37 GCFA6 11 0 0 6 8 25 25 25
FA - Fly ash, SG - Soda Glass Powder, BG - Boron Glass powder, CG - Coloured Glass Powder,
GGBS - Ground Granulated Blast furnace Slag
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3.5 CASTING OF FLY ASH GLASS BRICKS

The ingredients such as fly ash, glass powders, GGBS, gypsum,

lime, crusher dust and water were mixed thoroughly as per the given mix
combinations and required quantity of water was added for homogeneous mix
and good bonding. The following are the sequence of the casting of the fly
ash glass brick.

• Batching

• Mixing

• Belt Conveyor

• Pressing of Brick

• Removal of brick from mould

• Curing

Mixing of raw materials

Filling of mould using feeder

Pressing of brick

Removal of brick from mould

Drying the brick in

atmospheric temperature

Curing

Figure 3.8 Manufacturing process of fly ash glass bricks

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3.5.1 Batching

Ingredients were weighed as per required combinations given in

Table 3.8 by weight batching. Due to some practical difficulties, volume
batching was adopted for lime, gypsum, crusher dust and fly ash. The glass
powders and GGBS were measured by weight batching.

3.5.2 Mixing

Various ingredients like fly ash, Glass powders, GGBS, gypsum,

lime and crusher dust are thoroughly mixed by pan mixer as per the mix
combinations given in Table 3.8. For good homogeneous mix and bonding,
water was added in required quantity. For example, the preparation of mix
BFA1 is as follows:

Step 1: Required amount of lime and gypsum are grounded by using pan
mixer. Add the required amount of water till, the mix became a
paste without lumps.

Step 2: Crusher dust, Boron glass powder and fly ash were added with
required quantity of water and mixing was continued to get a
homogeneous mix. Process done in pan mixer is shown in
Figure 3.9.

Step 3: Manual or hydraulic discharge gate is provided to discharge the

mixed materials.
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Figure 3.9 Pan mixer

3.5.3 Belt conveyor

The belt conveyor is used to convey the materials from pan mixer
to next stage under the control of hydraulic. The belt conveyor is shown in
Figure 3.10.

Figure 3.10 Belt conveyor

3.5.4 Pressing of bricks

A steel mould has 12 bricks with size of 230 mm × 110 mm × 75

mm was used to cast the bricks. The hydraulic press was used to compress the
raw materials with required tonnage pressure of 36 MPa. After pressing, the
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bricks were taken manually and dried in ambient temperature. Figure 3.11 and
3.12 shows the feeder and brick moulder to cast the brick.

Figure 3.11 Feeder Figure 3.12 Brick moulder

3.5.5 Removal of brick from mould

After pressing, the bricks are de - moulded. The pressed bricks are
laid on steel pallets in four to five layers. Brick steel pallets were transported
on hydraulic trolley for curing area. Initially, the fresh bricks were dried in
open air and under shade. Figure 3.13, shows the bricks after compaction.

Figure 3.13 Bricks after compaction

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3.5.6 Curing

The moulded bricks were cured for 7 days, 14 days, 28 day.

Initially, the curing of bricks was done by covering it with gunny bags and
after a few days curing was done by sprinkling with water. The moisture in
the gunny bag is regularly maintained for the betterment of curing. Figure
3.14, shows the arrangement of bricks for curing.

Figure 3.14 Curing stage of fly ash glass brick