Brick Manufacturing Research Articles

Sustainable Construction through Waste Transformation: An Investigation into Bricks Made from Biomedical Waste

Abstract: This study explores the innovative use of biomedical waste, including sterilization wrap, plastic syringe components, medical glass, and mixed biomedical waste, as alternative raw materials in the production of sustainable bricks. Given the environmental and health risks associated with the disposal of biomedical waste, repurposing these materials for brick manufacturing presents a viable solution for waste management and sustainability in construction. Through chemical analysis, particle size distribution evaluation, and testing of physical and mechanical properties, this research assesses the feasibility and impact of incorporating various ratios of biomedical waste into bricks. The results indicate that certain biomedical wastes, particularly medical glass, can enhance the bricks' compressive strength and reduce water absorption, making them comparable or superior to traditional bricks. This study not only highlights the potential for reducing landfill use and environmental pollution but also contributes to the development of eco-friendly building materials. Future work will focus on optimizing material mixtures, evaluating long-term performance, and assessing the environmental impact of these sustainable bricks. This research underlines the importance of interdisciplinary approaches in addressing environmental challenges, offering a promising avenue for waste management and sustainable construction practices.

Moroccan heated clay-based geopolymer reinforced with date palm cellulose: microstructure characterization and mechanical/physical properties

AbstractThe objective of this research was to study the cellulose addition effect on the geopolymerization of heated clay. The clay, composed of illite, plagioclase and kaolinite, was heated at 700°C for 2 h and mixed with cellulose (up to 10 mass%). The mixtures were NaOH-activated, and shaped samples were aged at 83°C for 30 days. The cured samples were investigated by using X-ray diffraction, Fourier-transform infrared spectroscopy and scanning electron microscopy. The influence of the cellulose addition on the mechanical/physical properties was also evaluated. The results showed that zeolite ZK-14, hydrosodalite, sodium carbonate and a geopolymer composed of poly(sialate) units were formed in all cured samples. The relative amounts of zeolite and metakaolin evolved antagonistically, whereas that of illite slightly decreased with increasing cellulose content. Metakaolin and illite were involved in the geopolymerization process. Cellulose addition led to the improvement of the flexural strength of the samples and to porosity reduction. By contrast, water absorption was increased. The positive effect of cellulose on sample performance is explained on the basis of hydrogen bonding between the functional moieties of cellulose and the active sites of sample constituents, namely zeolites, metakaolin, illite and the geopolymer. As a filler, zeolite probably contributed to sample strengthening, and the detrimental impact of Na-carbonate was insignificant. Based on the results obtained, the composites could be used as binders for brick manufacturing or as lightweight mortars.

Eco-efficient reuse of alum-based water treatment sludge into structural sintering bricks

Water treatment sludge (WTS) disposal in landfills and estuaries has significant negative environmental effects. This study aims to produce a cleaner approach to recycling solid waste sludge from water treatment plants into eco-friendly construction materials. This approach involves the production of structural sintering clay bricks using WTS as a substitute for clay in the manufacturing process. Various mixtures of WTS content ranging from 10% to 50% and sand content of 10 and 20% were investigated. The Brick samples were shaped in the form of cubes and then fired in an oven at 700 °C for 3 h. Subsequently, several tests were conducted on the fired brick samples, including compressive strength, bulk density, water absorption, apparent porosity, efflorescence, freeze and thaw analysis, and microstructure investigation. The properties of WTS indicate a high concentration of silica, aluminum, and iron, which contribute to the improved properties of the fired bricks. It was observed that the bricks' compressive strength decreased from 29.8 to 8 MPa as the WTS content increased from 10% to 50%. In parallel, increasing the WTS content resulted in a decrease in bulk density from 1.005 to 0.75 g/cm3, an increase in apparent porosity values from 20% to 35%, and a higher water absorption from 12% to 37%. Furthermore, the addition of sand by 10 and 20% to the bricks leads to enhancements in both the mechanical and microstructure properties of the sintered bricks. Moreover, the efflorescence analysis of bricks is at a slight level. It can be concluded that WTS can be reused in the manufacturing of structural sintering clay bricks, providing a cleaner and more sustainable method of disposal for water treatment sludge.

Potential of Pressmud Waste from Sugar Industry in Brick Manufacturing for Green Business and Sustainability

The construction industry in Malaysia is currently witnessing sustained expansion, as seen by the rising demand for residential properties, commercial structures, and other infrastructures throughout our country. Therefore, the present study seeks to identify suitable materials and proportions for manufacturing lightweight bricks utilizing industrial waste materials. This study investigates the feasibility of using pressmud, a sugarcane refinery waste, as a fine bio-aggregate for the production of construction materials. Binary blended cement-pressmud bricks were formed by mixing Ordinary Portland cement with pressmud at various weights percentages (50%, 40%, 30%, 20%, and 10%). Various experiments were undertaken to investigate and compare the characteristics of pressmud bricks and commercial sand bricks. The experiments focused on density determination and compression tests (standard brick). The compression tests demonstrated that cement-pressmud bricks with a weight ratio of up to 20% exhibited a compatible strength to standard brick, with values ranging from 17.16 MPa to 23.01 MPa. The pressmud bricks exhibited reduced weight, with 10% and 20% variants weighing 17-23% less than the standard brick. Thus, it can be concluded that pressmud possesses significant potential as a bio-aggregate for producing lightweight and cost-effective construction materials when used in appropriate proportions.

Factors Affecting the Recession of Construction Brick Industry: A Case of Moklan Brick Kiln Factory Nakhon Si Thammarat, Thailand

Purpose of the Study: Construction brick industry has generated high income and it is the main revenue of Moklan city residents for a long time. However, recently, there has been a huge decrease of demand due to several reasons both from internal and external factors. The output of this research can be used to solve the problem and revive Moklan city economy. The purpose are 1) To study factors affecting the recession of the construction brick manufacturing industry in Nakhon Si Thammarat Province. 2) To propose a guideline for solving the recession problems. Methodology: This is qualitative research using in-depth interview as a research tool. The data were collected from 40 owners of the Moklan brick kiln factory in Nakhon Si Thammarat, Thailand selected by purposive method. Data were analyzed by content and thematic analysis. Main Findings: 1) Factors affecting to the recession of the industry consist of technology changes, environmental concerns, domestic economy, and product quality. 2) The guideline for solving this recession, the product must be environmentally friendly products, correspond to personal demand of customers, durable, and comprehensive usage. Applications: The output of this research can be applied in construction brick companies to improve their competitive advantage and production design and process. Novelty/Originality: This study reveal the factors to revive construction brick companies in Nakhon Si Thammarat , Thailand.

Environmental Impact of Brick Manufacturing Process in Rajshahi Region, Bangladesh

Environmental Impact of Brick Manufacturing Process in Rajshahi Region, Bangladesh

Molding properties of clay mixtures in the soft mud brick manufacture

The article reveals physical and mechanical characteristics of clay mixtures in the soft mud brick manifacture. Considering that currently Russia has no advisory or regulatory documents on the selection of raw materials for soft mud bricks and requirements for their physical and mechanical properties, this issue is quite relevant. The authors, based on their extensive practical experience, present data on acceptable ranges of clay mixtures deformation and critical compressive stress in the soft mud brick manufacture, as well as the results of studies on the influence of electrolyte additives on these indicators. The findings of how the mineral composition of clay raw materials and moisture con-tent influence the critical compressive stress and stickiness of clay mixtures are also presented. Thus, it has been experimentally established that the critical compressive stress of clay mixtures for soft mud bricks should be in the range of 0.2 – 0.8 kg/cm2, and the deformation degree of raw bricks should be in the range of 3 – 5 units. Moreover, even within such narrow limits, depending on their variation as well as on the method of molding and the composition of clay mixtures, it is possible to obtain differ-ent structures of the brick front surface: granular, tuberculate, grooved, wavy, corrugated, spotted, scaly, and their combinations. The moisture content of clay mixtures, depending on the type of clay raw material, can vary within very wide limits: from 20 to 38 per cent. The data obtained will make it possible to develop methods for selecting raw materials for soft mud bricks, which in turn will con-tribute to the organization of its wide production in various regions.

Neutronic Activation of Amazon Technogenic Deposit Soil Used as Raw Material in Brick Manufacture

Considering the extraction of soil from Technogenic Deposits, may result in the risk, this article investigated whether in the brick making process, there is a possibility that chemical elements, considered linked to human illness, may have evidence of release to the environment. The adopted strategy was to subject both the soil, as well as the brick manufactured with this soil, to the Neutronic Activation test, later, through the mass balance, to verify the variations in the global concentrations of chemical elements. The results show that of the 27 elements analyzed, 25 showed a reduction in their concentrations after the burning of the soil. As the systematic literature review points out, the release of these chemical elements to the environment, is intrinsically linked to the decrease in the environmental quality of the built environment, therefore, it is an indication of possible risks for human health.

Microstructure and Mechanical Characterization of Rice Husks from the Tolima Region of Colombia

The under-utilization of rice husk, a milling by-product, demands attention due to its widespread disposal and limited usage. This research aims to assess the physical properties and mechanical behavior of three rice husk varieties (F 2000, Orizyca, and Panorama 394), to determine their strength capacities and potential applications. Mechanical properties are evaluated through a non-standardized tension test using a universal machine. Subsequent analyses include measuring the moisture content following ASTM D1348, determining the particle size distribution through ASAE Standard S319, and establishing the bulk density using ASAE Standard S269 Method 4. Mechanical resistance in the rice husk varieties ranged from 60 MPa to 130 MPa, with a particle density exceeding 300 kg/m3 and an average apparent density of 140 kg/m3. Scanning electron microscopy revealed the husk structures, identifying epidermis, hypodermis, and sub-hypodermis layers. The mechanical stress of the Orizyca variety was 1.89 times higher than that of F 2000, and 1.18 times higher than that of Panorama 394. Potential applications include brick manufacturing and thermoformed materials for Orizyca and Panorama 394, while F 2000 could be utilized for producing fuel briquettes or cardboard, among other possibilities.

Increasing Production Capacity by Designing Facilities to Reduce Production Costs

This research discusses facility design in the lightweight brick manufacturing industry. Every year the production costs of making lightweight bricks continue to increase due to increases in raw material prices, increases in minimum wages and increases in several auxiliary materials. The increase in selling prices cannot offset the increase in production costs because price competition in the market is high. This research aims to plan to increase the production capacity of lightweight bricks from initially 679.4m³ per day to 794.7m³ per day by designing facilities at lightweight brick manufacturing companies. This research also calculated how much it costs to produce lightweight bricks before designing, namely with a capacity of 679.4 m³ per day and how much it costs to produce lightweight bricks after designing the facilities, namely 794.7 m³ per day. The results of this research are in the form of production capacity data from each production work floor, as well as production work floors where facilities were designed so that a production capacity of 794.7 m³ per day could be achieved. And also calculate how much production costs will be with a production capacity of 679.4m³ and 794.7m³ per day.

Método de mistura à quente para fabricação de tijolos areia-polímero

Abstract This manuscript presents a method to produce sand-polymer bricks motivated by the need to reuse plastic waste and to reduce the embodied energy and carbon footprint associated with manufacturing. The method is designed to be simple: it involves a custom-built apparatus that simultaneously mixes and heats dry sand and recycled polypropylene granules, until the latter melt. The hot mixture is then compressed in a mold until the polymer rehardens, thereby producing a bonded brick upon extrusion. Bricks with 10% and 20% polymer content (i.e., by mass, PCg), were prepared with either a fine sand or a coarse sand. The voids of the PCg = 10% bricks were approximately halfway filled with hardened polymer, whereas the voids of the PCg = 20% bricks were nearly entirely filled. Bricks with PCg = 20% were found to be potential candidates for replacement of fired clay bricks, as these exhibited infiltration levels well below specification thresholds for fired clay bricks and strengths comparable to those reported for fired clay bricks. Furthermore, the embodied energy associated with sand-polymer bricks was calculated to be around a third of that required for fired clay bricks. In addition, the manufacture of sand-polymer bricks requires minutes, whereas that of fired clay bricks requires hours. The results gathered suggest that bricks produced by the proposed method have potential for replacement of fired clay bricks in applications wherein replacement is favorable.

Marketing Strategy of Red Brick Manufacturers in Facing Great Competition from Alternative Products: Resource-Based View (RBV) Approach

This research investigates the challenges faced by the red brick industry, with a focus on competition from alternatives such as Hebel. Using the Resource-Based View (RBV) approach, this analysis analyzes marketing strategy, the impact of internal resources, and responses to market demand. This research aims to examine the competitive advantage of each brick factory that is the respondent in this research, identify competitive advantages and the influence of internal resources, and provide marketing strategy recommendations. The research approach used is qualitative, with a purposive sampling technique. Data collection methods used Focus Group Discussions and In-depth Interviews. Data analysis using SWOT and RBV-VRIO. The results of the SWOT analysis related to the M. Yunus brick company require internal improvements. Meanwhile, Tajir Assawani must overcome external challenges and utilize internal strengths. Zulfadhli has an advantageous position so it requires an aggressive strategy with product innovation. The results of the RBV and VRIO analysis of the brick companies M. Yunus and Tajir Assawani, these two companies have a temporary competitive advantage with a focus on creating the inimitability component. Meanwhile, Zulfadhli has an unused competitive advantage, with a focus on improving organizational aspects for factors VR and I in VRIO

“Concept of Mental Health Practices of Employees of a Brick Manufacturing Company in Bulawayo, Zimbabwe. (Case study)”

In light of the increasing global recognition of workplace mental health, this study examines employees’ knowledge and perceptions of mental health practices within a brick manufacturing company in Bulawayo, Zimbabwe. Despite the growing adoption of mental health policies aimed at improving employee well-being, a gap persists between the implementation of these practices and employees’ understanding of them. This research employs a qualitative phenomenological approach, utilizing semi-structured interviews with 15 employees to explore their awareness, perceptions and experiences related to mental health policies. Findings reveal that while employees are generally aware of the existence of mental health policies, their knowledge of specific resources and services remains limited. Mixed perceptions of the effectiveness of these policies suggest that, although well-intentioned, their practical impact often falls short. Barriers such as stigma, insufficient awareness, and confidentiality concerns hinder the utilization of available mental health resources, whereas supportive management and visible resources act as facilitators. The study highlights critical areas for improvement, including the need for better communication, increased training and enhanced confidentiality measures. Recommendations include implementing awareness campaigns, providing comprehensive support services, and conducting regular workshops. Addressing these issues is essential for creating a more effective mental health support system within the company, thereby enhancing employee well-being and productivity.

Parametric study of brick manufacturing by replacing clay with landfill waste soil

Parametric study of brick manufacturing by replacing clay with landfill waste soil

Status of Occupational Health and Safety in Nepal: Current Scenario and Strategies for Improvement

Occupational health is a vital aspect of public health that aims to ensure the well-being of workers in various occupations. It encompasses multiple academic fields, such as occupational medicine, nursing, ergonomics, psychology, hygiene, and safety. Despite global efforts to improve occupational health, access to occupational health and safety (OHS) services remains low in many countries, including South Africa, Zimbabwe, Zambia, Botswana, China, and Nepal. This review paper was conducted through an extensive literature review. Databases such as Science Direct, Springer, NepJol, PubMed, and Google Scholar were searched to access a wide range of scholarly articles, research papers, and reports. The findings reveal that occupational workers face various hazards, including exposure to infectious diseases, radiation, hazardous chemicals, noise, and psychosocial risks. In Nepal, workers in industries such as agriculture, construction, and brick manufacturing are particularly vulnerable to these hazards. Lack of proper safety measures, inadequate access to clean drinking water and sanitation, child labor, and physical strain contribute to the high incidence of work-related diseases and injuries among workers. The study also highlights the policies and initiatives undertaken by the government of Nepal to improve occupational health and safety, including the Labor Act of 1992, the Occupational Safety and Health Project, and the Nepal National Building Code. The study emphasizes the urgent need to improve occupational health and safety conditions in Nepal. It highlights the importance of implementing preventive measures, raising awareness, providing training and education, and establishing standards to protect the health and well-being of workers.

Study of clay raw materials with Korolek technogenic waste for the production of ceramic bricks

The use of industrial waste in the production of building materials is an urgent task at present. Studies on the use of mineral wool waste in the manufacture of ceramic bricks have been carried out. For the preparation of experimental samples of ceramic bricks used clay deposit, as heaters and intensifiers of sintering – waste production of mineral wool. Chemical composition of investigated components is given. The study of mineralogical and phase composition of raw materials was carried out by petrographic, X-ray phase, IR-spectroscopic, electron-microscopic methods of analysis and DTA. During the experiment such properties of samples as cracking temperature; end shrinkage moisture; relative shrinkage; drying time to residual moisture content of 8%; mechanical strength in compression were tested. As a result of the tests, the influence of Korolek on the drying properties of ceramic samples was established. Thus, an increase in the content of Korolek in the samples, improved the crack resistance, relative shrinkage, drying time to residual moisture. The results of the research showed a non-linear dependence of physical and mechanical properties of the samples on the content of Korolek. The best values of mechanical strength were achieved when the Korolek content was 40% of the total mass of the manufactured sample. The proposed composition corresponds to the properties of ceramic bricks above grade M150-175.

Use of recycled carbon fibre as an additive in the manufacture of porous bricks more durable against salt crystallization

Within the framework of the Sustainable Development Goals of the Agenda 2030, the circular economy is being promoted as a means of ensuring a sustainable use of resources and a reduction in the amount of waste produced. The aim is to reduce the demand for often scarce raw materials through the continuous reuse, recycling and regeneration of materials and products. This paper explores the use of carbon fibre from wind turbine blades as an additive in the production of new efficient bricks. Clay mixes with 0, 5 and 10 wt% additive were fired at three temperatures (800, 950 and 1100 °C) and the fired bricks were analysed from mineralogical and physical points of view to determine their suitability for use in the construction industry. The results show that carbon fibre improves the durability of the bricks, which became 16 % more porous as the firing temperature increased. However, the compressive strength of the bricks with 10 wt% carbon fibre was about 50 % lower than that of the control bricks made without additive. It is interesting to note that the distribution of the carbon fibres within the brick varies considerably and that they are shorter and wider in the core of the samples. These results could offer an alternative line for new product development in the brick industry. The bricks tested here are an example of a circular economy in which waste from one industrial process (wind turbine blades) is reused as an input in another (brick manufacture). The environmental benefits achieved are twofold: reduced demand for clay and recycling of decommissioned turbine blades, which are currently amassed in wind turbine graveyards.

An Empirical Study for Improving the Quality of Fly Ash Added Bricks

Because of urbanization, demand for housing is increasing day by day in India. Traditional clay brick leads to resource scarcity and environmental pollution. To overwhelmed this problem, manufacturing of bricks was done using the waste of thermal power plants like Fly Ash along with Sand and Cement (FAS-C Brick) as key ingredients. Fly ash is an Industrial by-product of thermal power plant. An experimental study of mix-design was carried out to increase the quality of the FAS-C brick. This paper attempt to formulate the mix design of fly ash based brick by process planning. Laboratory tests were conducted to determine the compressive strength and water absorption of the bricks. The main objective of the research study was to design the Fly Ash, Sand, Cement (FAS-C) brick and find the compressive strength using different mix design methods as a part of quality improvement process.

Use of SCM in Manufacturing the Compressed Brick Optimizing Embodied Energy and Carbon Emission

Brick is one of the most used building materials in masonry construction. Conventionally burnt clay bricks are used. These bricks are manufactured from clay and burnt in a kiln at a higher temperature. This results in a very high amount of CO2 emission and has high embodied energy, which highly affects the environment. Compressed bricks are one of the sustainable solutions to overcome these issues of high CO2 emission and embodied energy. Adopting sustainable alter- natives, such as compressed bricks incorporating supplementary cementitious materials or envi- ronmentally friendly brick manufacturing processes, can help mitigate these issues and promote more sustainable construction practices. In this study, attempts have been made to manufacture and test the bricks with different proportions of the soil, i.e., the mix of locally available soil with sand, cement as the cementitious materials, and SCMs like fly ash & GGBS. The research methodology involves the formulation of different mixtures with varying proportions of SCMs. The specimens were then prepared using a compression molding technique and cured under controlled conditions. This research paper aims to investigate the effects of incorporating sup- plementary cementitious materials (SCMs) on the properties of compressed bricks. The study focuses on evaluating the density, compressive strength, water absorption, and efflorescence, as well as calculating the embodied energy and carbon dioxide emissions associated with the pro- duction of these bricks. Furthermore, the paper comprehensively analyzes the embodied energy and CO2 emissions associated with producing compressed bricks. These calculations consider the energy consumed and CO2 emitted in manufacturing, including raw material extraction, transportation, and brick fabrication. The study's results demonstrate the influence of SCMs on the properties of the compressed bricks. The analysis of embodied energy and CO2 emissions provided valuable insights into the environmental sustainability of the brick production process.

Reusing ceramic waste in fired brick and as cement additive

AbstractBACKGROUNDAlthough there has been considerable research on the utilization of ceramic and tile waste (CTW) in concrete production, there has been a noticeable lack of studies examining its application in fired brick manufacturing and the use of ceramic glaze powder as an additive in cement. The aim of this study is to assess the potential of reusing CTW as concrete aggregate and as part of fired brick composition. Furthermore, this research investigates the potential application of glaze powder as a novel cement additive, which has not been previously explored.RESULTSThe results indicate that bricks made from waste materials had a moisture absorption of 12.2% and flexural strengths ranging from 15.39 to 24.2 MPa. X‐ray diffraction analysis showed that quartz and kaolinite were the dominant crystalline phases in bricks made from raw glazed ceramic. The concentration of heavy metals in the toxicity characteristic leaching procedure leachate of the waste materials decreased after the firing process during the manufacturing of bricks due to oxidation, immobilization and encapsulation processes, with levels below standard limits. In concrete, the use of 20% ceramic glaze powder as a partial cement replacement resulted in a 55% increase in compressive strength. Additionally, the leaching of barium decreased by 70% and that of strontium decreased by 17%.CONCLUSIONThis study highlights the promising utilization of CTW in fired brick production and the effective incorporation of ceramic glaze powder as a cement additive. The findings suggest enhanced mechanical properties and decreased heavy metal leaching, indicating the viability of CTW reuse in sustainable construction practices. © 2023 Society of Chemical Industry (SCI).