PARTIAL REPLACEMENT OF FINE AGGREGATES OF FIRE BRICKS WITH FINE AGGREGATES IN CONCRETE

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1 International Journal of Civil Engineering and Technology (IJCIET) Volume 9, Issue 3, March 2018, pp , Article ID: IJCIET_09_03_096 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed PARTIAL REPLACEMENT OF FINE AGGREGATES OF FIRE BRICKS WITH FINE AGGREGATES IN CONCRETE Manoj Kumar Lovely Professional university, Phagwara, (Punjab), India Awadhesh Chandramauli Department of Civil Engineering, Uttaranchal University, Dehradun (Uttarakhand), India Ashutosh Maharishi Ved Vyas Engineering College, Jagadhri, (Haryana), India ABSTRACT India is a developing country. Developing infrastructure leads to consumption of concrete. Sand have big value in concrete. But natural sands are limited resources. River sand is most common fine aggregates in concrete. Due to excessive production of the river sand, it is banned by the government of India. Thus replacement of sand becomes need in last decays and the partially replacement will contribute to a good point to the research area. Number of researcher doing work on the replacement of sand by number of material like waste glass powder, crushed fir bricks and etc. Fire bricks are used to prevent the heat transfer in industries, lining furnace and fire places. The waste material of fire bricks can be used as fine aggregates. Properties of fire bricks are increases the strength of concrete. This research able to reduce the dependency on sand and open a new option to dispose of waste fire bricks. Partial replacement is done at 0%, 22%, 25%, 28% and 31% in this project. The test result says the 28% replacement gives the maximum tensile strength. Keywords: Concrete, Sand, River, Stone, Seepage, Fire Brick, India Cite this Article: Manoj Kumar, Awadhesh Chandramauli and Ashutosh, Partial Replacement of Fine Aggregates of Fire Bricks with Fine Aggregates in Concrete, International Journal of Civil Engineering and Technology, 9(3), 2018, pp INTRODUCTION River sand is most common fine aggregates are used in concrete. River sand is most suitable fine aggregates in concrete. Due to the excessive production of the river sand is banned by government in India. Thus replacement of sand becomes need in last two decays. Number of editor@iaeme.com

2 Manoj Kumar, Awadhesh Chandramauli and Ashutosh researches occurring in world on replacement of sand by number of material like waste glass powder, spent fire bricks, crushed brick fine aggregates, crushed coarser aggregates, fly ash, etc. Brick aggregates are very easily available at very low cost. It may be recycled from destroyed buildings, bridges, and any other destroyed structures. People from 7000 BCE have been using bricks. Turkey is that country where first brick is found. On that time bricks were dried in sun light. This sun dried brick is not sufficient strength. But fired brick were very high resistance. In any condition fire brick gave very suitable results. That is why it used in permanent structures. In the construction of buildings, bricks are generally used more than wood than other materials. Now these days many types of machineries are available. With the help of these machineries many types of these bricks are made with different shapes and with different materials. But clay is the first preference for fire bricks. Apart from this, materials such as calcium silicate and concrete are also used much more. Many materials are available now but most using is clay on industry level. In 2007 bricks made with fly ash. And fly ash are using for making roads on footpath and residential areas. Fly ash are taken from thermal power plants. Bricks are the common building materials which are used in construction these days. Crushed bricks in the form of aggregates finer or coarser are called crushed brick aggregates. Bricks are very easy available material. Because natural sand is limited natural resources thus a replacement need occurred. Brick aggregates are very low and its result in concrete is very good. Researcher has tested the aggregates bricks the got the higher compressive strength at 20% partially replaced the fine aggregate of bricks with fine aggregates of concrete. But some researcher found the decrease in the strength up to 40%. That is why is its great success to find the advantage of brick aggregates in concrete. Bricks are found in number of types because it is common usable material. The types of bricks aggregates like common burnt clay bricks aggregates, calcium silicate bricks aggregates, engineering bricks aggregates, concrete bricks aggregates, fly ash clay bricks aggregates, crushed spent fire bricks aggregates, fired brick aggregates, recycle bricks aggregates. Brick aggregates directly affects the concrete properties when concrete are in fresh state and hardened state. Fire bricks are used for inner lining of kiln meant for firing. Due to continuous exposure to high degrees of temperature about 1,800 to2,100ºc for twelve to eighteen days, if any brick keeps less strength or low strength which desired then let it out and put a new brick. The usage or replacement of fire bricks is periodical in nature in metallurgical based industries. The fire bricks disposed off after use are called as Spent Fire Bricks. The Spent Fire Brick which are the waste should be through properly without causing environmental problems in the vicinity of dump. Usually the waste materials are disposed by land filling. In the similar manner the spent fire bricks are also used as land filling material. The fire bricks so generated as waste, first of all clean it and after then crushed till get fine aggregates. The fineness modulus of crushed spent fire brick powder is nearly equal to river sand used in concrete. As such, the crushed spent fire brick can be used in place of river sand partially in making the concrete. Bricks are made from the burnet fire clay. Bricks are formed in the kiln at 1300oC for 10 to 15 days. 2. LITERATURE REVIEW A. Siva et al., 2017, bricks are easily available material. Bricks normally used as the nonbearing wall structure. In this experiment when fine aggregates are partially replaced by crushed bricks in proportion of 10%, 15%, 20%, 25% then found that the workability of concrete is decrease. Compressive strength of is obtained maximum when added 20% of crushed fire bricks. Because crushed fire brick is made of plastic and non-plastic clay. It put into kiln at 1300C for 10 to 15 days. Then its property gets totally changed. The unit weight of fire brick is 20KN/m. crushed fire brick is sieved on 4.75 mm sieve and who passed from the sieve of 4.75 mm sieve and not passed from 75 micron IS- sieve and then partially editor@iaeme.com

3 Partial Replacement of Fine Aggregates of Fire Bricks with Fine Aggregates in Concrete replaced from fine aggregates. For test the of split tensile strength measured from cylinder is made of 150mm x 300 mm size for M30 concrete grade after partially replacement. After made this keep for 24 hours and curing done up to 28 days. Fine aggregates of fire brick gives higher compressive strength when replaced 20% with fine aggregates. This compressive strength is 1.2% in higher. But strength of split tensile is get less if percentage is increasing more than 20%. Nisha Devi. A et al., 2016, glass powder is partially replaced with cement. And fine aggregate of fire bricks are partially replaced with fine aggregates. In this experiments glass powder increase the workability and fire brick powder act as a filler in concrete and increases the flexure strength, ductility, compressive stress, tensile strength. In this project the glass powder is replaced with cement at 10%, 20% and 30%. Fire brick powder is replaced at 10%, 15%, 20%, and 25%. Ordinary Portland cement are used which having 43 grade. Fire brick powder belongs from Zone-II. Compressive strength, tensile strength and flexure strength is measured with cubes 150*150*150 mm, 150*300 mm and 100*100*500 respectively for 7days and 28 days. Crushed spent fire brick is gives higher compressive strength at 20% replaced. More than 20% it reduces the strength. Split tensile strength increases at 20 % replacement of fine aggregates of fire brick. When replacement further increases the tensile strength is decreases. S. Keerthinarayana et al., 2010, As per IS 6 and 8 specifications, the fire bricks are made from plastic and non-plastic clay. These bricks are fired in oil kiln and temperature increased up to 1350 C these are fired in oil-fired kiln at a temperature of 1,300 C. Bricks are fire brick are fired at 1750 to 2200 ºC for thirteen to twenty days. If any brick keeps less strength or low strength which desired then let it out and put a new brick. Then, the SFB is an industrial solid waste to be disposal off properly and. First of all these cleaned and crushed into fine aggregates. The concrete contains 62 to 81 percent volumes by coarse and fine aggregates. Performance is totally depend upon the properties like chemical and physical properties. Crash Spartter was compared with fire of bricks, as well as the place of aggregates, with different physical-chemical properties and sands of original creations. Test result is same as compressive test result that when CSFB is adding 25 to 30% then tensile strength also increased. Flexure strength is determine by applied the load and when crack in concrete are visible noted that values. Dimension for rupture modulus is 150*150*700 in meter are taken. If more than 600mm span then 100*500 mm with 450mm span and applied point load. Tiwari Darshita et al., 2014, as per IS-10262, cubes is formed of grade for M20, M25, and M30. The cubes were crushed in the labs and follow the criteria of IS code of The crushing strength is measure for 3days, 7days, and 28 days. And observed that for M20 grade in which sand is partially replaced by the brick powder. When added 10% brick powder the compressive strength is decreases and when added 20% brick powder the strength is increased. If increased the brick powder more than 20% then decrease the compressive strength of M20 grade concrete. 3. PROPERTIES OF MATERIALS The properties of materials are used like fine aggregates of crushed fire bricks, fine aggregates, coarse aggregates, cement and all procedures are conducted as per Indian Standard Codes Fine aggregates of crushed fire bricks Fire bricks are use as per IS: 6. Fire bricks are crushed into fine aggregates which is passed through 4.75 mm IS sieve and retained on 150 micron meter (0.150 mm) IS sieve. Crushed fire bricks satisfying zone-ii editor@iaeme.com

4 Percentage of Finner (%) Percentage of Finner (%) Manoj Kumar, Awadhesh Chandramauli and Ashutosh Table 1 Properties of Crushed fire aggregates S.N. Properties of Crushed fire bricks Values 1 Specific gravity Net water absorption 0.70% 3 Fineness modulus Grading Zone II IS Sieve size (mm) Figure 1 Particle size distribution curve of crushed fire bricks 3.2. Fine aggregates Aggregates who passed through 4.75 mm sieve and retained on 15µm (0.150 mm) IS sieve. Specifications of fine aggregates are followed as per IS 383: Fine aggregates are used satisfied zone-ii. Following tests are conducted on fine aggregates. Table 2 Properties of fine aggregates S.N. Properties of fine aggregates Values 1 Specific gravity Net water absorption 0.81% 3 Fineness modulus Grading Zone II Chart Title IS Sieve size (mm) Figure 2 Particle size distribution curve for sand editor@iaeme.com

5 Percentage of Finner (%) Partial Replacement of Fine Aggregates of Fire Bricks with Fine Aggregates in Concrete 3.3. Coarse aggregates The aggregates which is passed through the 20 mm IS sieve and retained on 4.75 mm IS sieve are called coarse aggregates. Specifications of coarse aggregates are as per IS 383: 2016 (clause 6.1.1). Angular shapes of coarse aggregates are used. Following tests are made on coarse aggregates. Table 3 Properties of coarse aggregates S.N. Properties of coarse aggregates Values 1 Specific gravity Net water absorption 1.41% 3 Fineness modulus IS Sieve size (mm) Figure 3 Particle size distribution curve of coarse aggregates 3.4. Cement Ordinary Portland cement of grade 43 are used as per IS 8112: Cement used as a binding material in constructions. It becomes harden when comes with the contact of water. Cement used to bind the building materials. Cement names comes from ancient roman emperor. Opus caementicium is called Roman concrete. Roman concrete is based on the hydraulic setting. But modern cement is based on the Portland cement which are using in this project. Following test are conducted which result are given below. Table 4 Properties of cement S.N. Properties of fine aggregates Values 1 Specific gravity Normal consistency 33% 3 Fineness modulus 85% 4 Minimum cement content (Kgm./m 3 ) 280 Maximum cement content (Kgm./m 3 ) Water Water for construction of concrete structure should be same quality as drinkable water. The strength of concrete is totally depend upon the water thus water should be free from impurities. Impurities like suspended solids, dissolved salts organic matter. Which affect properties of concrete. These impurities can be changed setting time, hardening, strength, editor@iaeme.com

6 Manoj Kumar, Awadhesh Chandramauli and Ashutosh durability and etc. Water should be tested from an approved lab and should be checked regularly and ph value of water is Mix design of Concrete for M25 Design mix of concrete for 25 grade are made as per IS 10262: Water cement ratio and minimum cement content is taken as per IS 456: 2000 (Table 5). Size of nominal maximum of aggregates is 20 mm used. Minimum water content as per IS 10262: Proportion of mix design are given below. Table 5 Mix design proportion of M25 Cement Sand Coarse aggregates Water EXPERIMENTAL STUDY In this project the mechanical properties of concrete is improved by the partially replace of fine aggregates of fire brick aggregates with fine aggregates in concrete. The replacement is done at the varying percentage of 0%, 22%, 25%, 28% and 31% percent. Crushed fire brick s mechanical properties are similar as river sand. Mechanical properties of fine aggregates and fine aggregates of crushed fire brick are followings SPLIT TENSILE STRENGTH Split tensile strength is a most important properties of concrete. Split tensile strength is measured by standard size of plain cylinder 100 mm (diameter) and 200 mm length. M25 grade of plain concrete cylinder are used. After24 hours of moulding of cylinders made curing for 7 days and 14 days. During the moulding of cylinder vibrating table are used. 5. RESULT AND DISCUSSION As per design mix of concrete M25 and according to IS 10262: Split tensile strength is measured for partial replacement of fine aggregate of crushed fire brick (IS: 6) with fine aggregates in concrete at various percentages such as 0%, 22%, 25%, 28%, 31% after 7 days and 14 days curing and found that the optimum tensile strength is gained at 28% partial replacement editor@iaeme.com

7 Partial Replacement of Fine Aggregates of Fire Bricks with Fine Aggregates in Concrete S.No. Replacement Table 6 7 days Split Tensile Strength of M25 Concrete 7 Days Split tensile Strength Cylinder (100*200) mm Peak Load (KN) Tensile strength (KN/mm 2 ) Increase (+) /Decrease (-) strength (%) 1 0% % 2 22% % 3 25% % 4 28% % 5 31% % Figure 4 7 Days split tensile strength of M25 6. FUTURE SCOPE 1. It will slightly reduce the dependency on natural sand. 2. High strength gives in tension as compare to conventional concrete. 3. Accidental fire bricks or fire bricks who has deformed or recycled bricks are easily available in India when partially replaced with sand then cost will be reduced. 4. Natural aggregates are the natural resources and which are limited. Thus fire bricks aggregates concrete can be best cheap material instead of natural sand. 5. This project will open the new benchmark in research. 7. CONCLUSION 1. The maximum size of aggregates should not be greater than 10 mm to 20 mm. 2. Angular shapes of coarse aggregates are used. 3. Slump of concrete is 60 mm. 4. Split tensile strength is increased when 25% to 31% replacement is done. 5. Optimum split tensile strength of M25 is achieved at 28% replacement 6. All procedures are done as per Indian standards. 7. Water absorption for coarse aggregates and fine aggregates are less than 2%. 8. Both fine aggregates are satisfying Zone-II editor@iaeme.com

8 Manoj Kumar, Awadhesh Chandramauli and Ashutosh REFERENCES [1] A.Siva, Thamilselvi, A. Nisha Devi1 and B. Ashvini (2017), Experimental Investigation on Partial Replacement of Fine Aggregate Using Crushed Spent Fire Bricks, American Journal of Engineering Research (AJER), e-issn: p-issn: , Volume-6, Issue-2, pp [2] Nisha Devi. A (2016), Study of Partial Replacement by Glass Powder and Crushed Spent Fir Bricks in Concrete, International Journal of Engineering Research & Technology (IJERT), ISSN: , Vol. 5 Issue 03, March [3] Veerni Lakshmi (2016), An Investigation on Flexural Behavior of Concrete with Fine Aggregate Partially Replaced with Grog, International Journal of Innovations in Engineering and Technology (IJIET), Volume 7 Issue 4 December 2016, ISSN: [4] Tiwari Darshita, Patel Anoop (2014), Study of Strength and Workability of Different Grades of Concrete by Partial Replacement of Fine Aggregate by Crushed Brick and Recycled Glass Powder, Volume 3 Issue 6, June 2014, International Journal of Science and Research (IJSR) ISSN (Online): [5] Keerthinarayana S. and Srinivasan R. (2010), Study on Strength and Durability of Concrete by Partial Replacement of Fine Aggregate using Crushed Spent Fire Bricks, Journal of construction and building materials vol-1, pp [6] M. Usha Rani and J. Martina Jenifer (2016), An Experimental Study on Partial Replacement of Sand with Crushed Brick in Concrete, IJSTE - International Journal of Science Technology & Engineering, Volume 2, Issue 08, February 2016 ISSN (online): X. [7] Gopinandan Dey and Joyanta Pal (2013), Use of Brick Aggregate in Standard Concrete and Its Performance in Elevated Temperature, IACSIT International Journal of Engineering and Technology, Vol. 5, No. 4, August BIOGRAPHY: Corresponding Author Er. Manoj Kumar, Lovely Professional University, Phagwara Punjab (India). Three year teaching experience Co-Author Er. Awadhesh Chandramauli Astt. Professor in Department of Civil Engineering Uttaranchal University, Dehradun (Uttrakhand) He has more than six years teaching experiences and has done his M.tech. in civil Engineering (Structural Engineering). Co-Author Er. Ashutosh, Maharishi Ved Vyas Engineering College, Jagadhri Distt. Yamuna agar Jagadhri, Haryana, India editor@iaeme.com