Sewage Sludge as an Alternative to Ordinary Soil in Manufacturing of Bricks

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1 Sewage Sludge as an Alternative to Ordinary Soil in Manufacturing of Bricks Prof. K. T. Phalak 1, Prof. K. L. Bidkar 2, Prof. R. T. Pardeshi 3 1 Associate Professor, SIEM Nashik, India, 2 HOD, Associate Professor, SIEM Nashik, 3 Assistant Professor, SIEM Nashik, India, Abstract: Waste is an unwanted material generated after the manufacturing process of industrial, or from house hold activity, or from agricultural. It is very essential to reuse it or dispose it. This paper represents the most suitability of replacement of sewage treatment dry sludge in brick with ordinary soil. The compressive strength, water absorption, weight and other aspects were studied. Keywords Bricks, Sewage Sludge, Dry Sludge, Fly Ash I. INTRODUCTION 1 The construction industry is dynamic in nature due to the increase in new technology, budget, and development processes. As we all know that waste is being generated on large quantity and many problems have been occurred on disposal of waste. Waste may be defined as an unwanted material generated after the manufacturing process of industrial, or from agricultural, or from house hold activity. It is the discarded material which essential requirement of disposal. Waste causes many nuisances in the environment. It produces many types of viral or bacterial infection for the human and animal which create bad effects on health. In this paper we studied, the feasibility of sewage sludge as ingredient in brick making, conservation of natural resources like clay, How to solve the problem of disposal of sewage sludge in urban region and how to make eco-friendly low cost and durable construction material. The dry sludge samples used in this work is to be brought from Bara Bungalow Sewage Treatment Plant. The dry sludge was dried at natural sun light. The dry sludge used to produce different type brick by adding 10% incremental sewage sludge up to 50% rise. The use of dry sludge in several types of mixes was investigated. II. LITERATUR REVIEW There have been various methods to be performed on the topic of use of water treatment sludge for brick manufacturing some of the studies are performed in this and field are studied and presented in the following literature review. Mary Lissy P N, Dr. M S Sreeja (2014) [6], the bricks are obtained by moulding clay in rectangular blocks of uniform size and then by drying and burning these blocks. Burnt clay bricks have good resistance to moisture, insects and erosion and create a good room environment. They are medium in DOI : /IJRTER WFBAT 194

2 cost and have medium to high compressive strength. In brick making the major input is fuel followed by labour. Bricks manufactured from dried sludge collected from textile wastewater treatment plant were investigated. Results of tests indicated that the sludge proportion and the firing temperature were the two key factors determining the brick quality. Results showed that the brick weight loss on ignition was mainly attributed to the organic matter content in the sludge being burnt off during the firing process. With up to 6.66% sludge added to the bricks, the strength measured at temperatures 5000C met the requirements of the National Standards. This study showed that the pulverized sludge could be used as a brick material in reducing the firing temperature for the production of energy efficient bricks. The bonding strength can be further enhanced by controlling operating conditions [6]. Aeslina Binti Abdul Kadir (2014) [7], Brick is one of the most common masonry units used as building material. Due to the demand, different types of waste have been investigated to be incorporated into the bricks. Many types of sludge have been incorporated in fired clay brick for example marble sludge, stone sludge, water sludge, sewage sludge, and ceramic sludge. The utilization of these waste materials in fired clay bricks usually has positive effects on the properties such as lightweight bricks with improved shrinkage, porosity, and strength. This paper reviews on utilization of different types of sludge wastes into fired clay bricks. Previous investigations have demonstrated positive effects on the physical and mechanical properties as well as less impact towards the environment. Thus, the utilizations of sludge waste could produce a good quality of brick and could be one of alternative disposal methods for the sludge wastes [7]. Vivek Chaudhary and K.S. Gumaste (2015) [8], Rapid urbanization all over the world has resulted in an increase of water and wastewater treatment plant sludge. In cities, sludge disposal by land filling may not be suitable solution now due to land scarcity. In order to sort out the disposal problem of the sludge, sludge management towards the minimization and reutilization of sludge as a useful resource is one of the solutions. Properties of sludge resemble the properties of the construction materials. So, sludge can be utilized as raw material for manufacturing bricks. Moreover in western Maharashtra region, the engineering properties of bricks are not meeting the requirements, as laid by IS code. This Paper reviews the study of various research works that had been done, in order to find the suitable type of sludge for brick manufacturing in western Maharashtra region. This study emphasis on producing bricks manufactured from clay blended with sludge, having properties as per IS code [8]. Literature review shows that the bricks in Maharashtra do not possess engineering properties as per IS code. Variation in the soil is required so as to produce bricks having engineering properties as per IS code. In addition literature shows that the chemical composition of the water treatment plant sludge is similar to the clay. STP sludge is a suitable material for mixing in the clay for brick manufacturing. III. METHODOLOGY Based on the collected data, analysis has been made to find out the most suitable methodology that can be applied for replacement of dry sludge in brick as soil. For this, water absorption and compressive strength test were conducted by using different % of sludge soil (10% to 50% by 10% All Rights Reserved 195

3 IV. EXPERIMENTAL MATERIALS The properties and the detail of the all kind of material to be used in the concrete mix design are as given bellow. 1) Dry Sludge Now a day, disposal of sewage has become a necessity for societies. The construction of treatment plants has caused problems with huge content of dry sludge. It has been found that each person produce 35 to 85 grams of solid sludge per day. In recent years, waste production has increased dramatically in developing nations such as India. There are two methods to solve the problem such as disposal of solid waste (dry sludge) including land filling and using dry sludge as fertilizers. But by both these methods some harmful material remains in sludge which causes harm to environment including land, air and water as a whole. In the sense grit sludge may be generated in a grit channel or chamber. Grit particles are removed because they may damage pumps and other equipment. Here, we try dry sludge too replace as a soil. 2) Soil Clay and sludge were blended thoroughly to form a homogenous mixture. Different varieties of bricks were cast by changing the proportion in the bricks. Each mixture should be kept undisturbed 24hrs after addition of water, to allow clay partials to absorb water and soften. For brick casting standard size of mould should be used. 3) Fly Ash 10% fly Ash has been use for all All Rights Reserved 196

4 Table No. 1 PHYSICAL PROPERTIES OF SLUDGE SR. NO PROPERTIES RESULTS 1 Specific Gravity Bulk Density Kg/M Water Absorption% Clay And Sulphate Content% Softening Coefficient Grain Type Coefficient Moisture Content% V. MIX DESIGN FOR BRICKS MANUFACTURING PROCESS 1) Preparation of Raw Material (excavated & ground) 2) Forming or shaping (mixing with water to a plastic condition to obtain the desired shape) Stiff-mud, Soft-mud, dry press processes 3) Setting and drying 4) Glazing provides a thin & smooth coat on the surface. Firing or burning in kilns above 950 C 5) Cooling rate of cooling affects brittleness, colour & shape. FIGURE NO.1 MANUFACTURING PROCESS Different Percentage of sludge Table No. 2MIX DESIGN FOR BRICKS Soil Sand Fly Ash (Murrum) Water 10% 52% 26% 12% 40lit 20% 45% 23% 12% 42lit 30% 38% 20% 12% 44lit 40% 31% 17% 12% 42lit 50% 24% 14% 12% All Rights Reserved 197

5 VI. TESTING AND RESULTS Test To Be Conducted On Dry Sludge 1. Sieve Analysis of Dry Sludge Table No Dry Sludge Specific Gravity Table No Dry Sludge Liquid Limit Table No. All Rights Reserved 198

6 4. Proctor Compaction Test Table No. 6 Table No. 7 shows water absorption and compressive strength test results of conventional brick and bricks with using different % of sludge soil (10% to 50% by 10% increments). Average water absorption Compresive Strenght Table No. 7 %WATER ABSORPTION OF BRICKS Conventional Brick 10% 20% 30% 40% 50% 19.86% 22.30% 25.75% 32.04% 35.49% 31.12% 3.53N/mm N/mm N/mm N/mm N/mm N/mm 2 VII. CONCLUSION Dry sludge is available free of cost so it reduces cost of brick by using sludge soil. Some properties of sludge soil are match with ordinary soil. In this project we have incorporated the use of Dry Sludge in brick up to 50% by replacing Soil. (Dry Sludge 10%, 20%, 30%, 40% and 50%).Based on limited experimental investigation concerning the water absorption and compressive strength of brick, the following observations are made regarding the resistance of partially replaced dry Sludge. The water absorption increases with replacement of soil by dry Sludge. Compressive strength decreases with replacement of dry Sludge with ordinary soil as compare to traditional Brick. The replacement of soil with this Dry Sludge material reduces the weight of brick. And it s become light weight product. Use of Dry Sludge in brick can save the ferrous and non-ferrous metal industries disposal, land pollution, cost and produces a greener brick for construction. Environmental effects from wastes and disposal problems of waste can be reduced or controlled through this research. A better measure by an innovative Construction Material is formed through this project. REFERENCES 1. Mohammed O. Ramadan (2008) Reuse of Water Treatment Plant Sludge in Brick Manufacturing Journal of Applied Sciences Research, 4(10): , , INSI net All Rights Reserved 199

7 2. A.A.Mageed (2011) Utilization of Water Treatment Plants Sludge In Brick Making Journal of Engineering Sciences, Assiut University, Vol. 39, No 1, Pp , January Badr El-Din E. Hegazy (2012) Brick Manufacturing From Water Treatment Sludge and Rice Husk Ash Australian Journal of Basic and Applied Sciences, 6(3): , 2012 Issn G.Reddy Babu(2013) Durability Of Bricks Cast With Industrial Sludge IOSR Journal of Mechanical And Civil Engineering (IOSR-JMCE) E-Issn: ,P-Issn: x, Volume 6, Issue 4 (May. - Jun. 2013), Pp Anyakora Nkolika Victoria (2013) Characterization and Performance Evaluation of Water Works Sludge As Bricks Material IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) May Vol. 3, No. 3 Issn Mary Lissy P N1, Dr. M S Sreeja (2014) Utilization Of Sludge In Manufacturing Energy Efficient Bricks IOSR Journal of Mechanical And Civil Engineering (IOSR-JMCE) E-Issn: ,P-Issn: x, Volume 11, Issue 4 Ver. Iii (Jul- Aug. 2014), Pp Aeslina Binti Abdul Kadir (2014) World Academy of Science, Engineering and Technology International Journal of Environmental, Chemical, Ecological, Geological and Geophysical Engineering Vol: 8, No: 8, Vivek Chaudhary and K.S. Gumaste (2015) Effective Utilization of Water Treatment Plant Sludge for Brick Manufacturing Journal of Civil Engineering and Environmental Technology, Print ISSN: ; Online ISSN: X; Volume 2, Number 3; January-March, 2015 pp IS: (Reaffirmed 2007) Indian Standard Classification and Identification of Soils for General Engineering Purposes (First Revision) Bureau of Indian Standard. 10. Books: i. Dr.K.R.Arora, Soil Mechanics and Foundation Engineering. ii. Gopal Ranjan & A.S.R. Rao, Basic and Apply Soil All Rights Reserved 200