Manufacture Of Concrete Blocks Research Articles

Analysis of environmental performance indicators for concrete block manufacturing: embodied energy, CO2 emissions, and water consumption.

Concrete block production significantly contributes to environmental degradation. A thorough understanding of its ecological implications is critical for sustainable development. This study investigates concrete block manufacturing's environmental impact by quantifying embodied energy, CO2 emissions, and water consumption via a comprehensive life cycle assessment. An extended life cycle assessment methodology is utilized to quantify the environmental indicators throughout the concrete block production lifecycle. Primary industry data and secondary research data ensure accuracy and reliability. Findings showed that concrete block manufacturing requires 2.5-4.1 times more embodied energy than equal clinker mass. Cement and aggregate production and transportation account for substantial energy needs. Limestone calcination during cement production causes significant CO2 emissions, 2.3-3.3 times higher than the minimum. Water consumption is concerning during curing and washing. Exploring alternative cementitious materials, optimized processes, and water recycling can reduce embodied energy by up to 75%, CO2 emissions by up to 67%, and water consumption by up to 80%. Concrete block manufacturing necessitates considerable energy and generates significant emissions. Implementing sustainable measures can minimize embodied energy, CO2 emissions, and water consumption, enabling environmentally responsible manufacturing. This research emphasizes adopting sustainability practices to mitigate environmental impact. Policymakers, industry professionals, and researchers can employ these insights to develop effective strategies promoting green manufacturing. The concrete block industry can contribute to a sustainable future through sustainable practices.

Sustainable strategies for reducing environmental impact in concrete block manufacturing: a comprehensive life cycle assessment

ABSTRACT This study delves into the environmental impact of concrete block manufacturing, focusing on embodied energy, CO2 emissions, and water consumption. The research addresses the pressing need to understand the ecological implications of concrete block production for sustainable development. We use a comprehensive life cycle assessment (LCA) methodology to assess embodied energy, CO2 emissions, and water consumption throughout the concrete block production lifecycle. The study draws upon primary data from industry sources and secondary data from research studies to ensure accuracy and reliability. Findings reveal that concrete block manufacturing demands significant energy, primarily attributed to cement and aggregate production and transportation. The process generates substantial CO2 emissions from limestone calcination during cement production. Water consumption is a critical concern during the curing and washing stages. The study explores diverse strategies and technologies aimed at mitigating the environmental impact. Implications of this research highlight the importance of adopting sustainable practices within the concrete block industry to address environmental impact. This study emphasizes the concrete block industry's potential to contribute to a greener and more sustainable future by implementing environmentally friendly measures. This study's comprehensive analysis and actionable recommendations aim to attract readers and stakeholders, encouraging further interest and investment in sustainable practices.

Mechanical and Structural Behavior of Concrete Blocks with Granulated Polystyrene (PS) and Recycled Polypropylene (PP) Fibres and Their Use in Low and Medium Height Frames

ABSTRACT This research proposes to include different percentages of recycled polypropylene (PP) fibers and polystyrene (PS) granules in the manufacture of concrete blocks. They are thermoplastic materials widely used in industry and are characterized by their lightness, their low thermal and electrical conductivity, and their low humidity absorption coefficient, factors that improve the efficiency of constructions. The results of this study show improvements in the mechanical behavior of the blocks with these plastic additives compared to the traditional ones, along with improvements in the structural behavior of the low (2-story) and medium-height (8-story) frames.

Manufacture of Load Bearing Concrete Masonry Units Using Waste Demolishing Material

The presence of construction wastes such as clay bricks, glass, wood, plastic, and others in large quantities causes serious environmental problems in the world. Where these wastes can be used to preserve the natural resources used in construction and reduce the impact of this problem on the environment, it also works to reduce the problem of high loads of concrete blocks. Clay bricks aggregate (AB) can be recycled as coarse aggregate and replaced with volumetric proportions of coarse aggregate by ( 5% and 10%), as well as the use of clay brick powder (PB) by replacing its weight of cement (5% and 10%) and reduced in the manufacture of concrete blocks (blocks). Four mixtures will be prepared and tested to learn how to reuse the brick coarse aggregate ACB and PB powder brick as substitute materials for producing concrete blocks, use the water spray method to treat concrete building blocks (blocks) and check the Dimensions and compressive strength, and absorption.

Recycling of Glass Waste on the Concrete Properties as a Partial Binding Material Substitute

Concrete is a significant construction material that is utilized extensively worldwide. A research study on the properties of concrete was conducted using Glass Waste (GW), which was readily available locally. As broken glass is difficult to sort, it is possible to positively utilize this waste particulate matter to reduce its detrimental impacts on both human health and the environment. Besides crushing or grinding, glass can transform into a natural pozzolan which enhances the fresh and hardened properties of concrete. This study also intends to reduce the amount of binding material used in the manufacturing of concrete blocks by making the best use of cement with Glass Waste. Therefore, an attempt has been made by using GW from 5-20% by weight as cement replacement for concrete blocks. When 5% crushed glass waste was added to the concrete mix (1:2:4), maximum compressive strength was 25.90 N/mm2, as opposed to Ordinary Cement Concrete's 21.09 N/mm2 strength, according to workability and laboratory testing. The 5% Glass Waste Mixed Cube and 5% Glass Waste Mixed Cylinder had the lowest water absorption test values at 2.22% and 3.58% respectively. In comparison to Ordinary Cement Concrete, Glass Waste Concrete has higher tensile strength. The maximum splitting tensile strength for 5% crushed Glass Waste Concrete was 2.115 N/mm2, compared to 1.815 N/mm2 for an Ordinary Cement Concrete Cylinder. The concrete with 20% glass waste content had the highest density, which was 2380.4 kg/m3 that defines good quality concrete.

Characteristics, as a shield against ionizing photons, of concrete blocks used in the construction industry

INEGI reports that 81% of new constructions are built with durable materials, such as concrete blocks, including rooms where ionizing radiation is used, such as clinics and hospitals. The volume ratios used in the manufacture of concrete blocks have a 1: 5: 2 ratio of: portland cement, sand and crushed gravel. The percentage mass content of each atom in the sample is obtained with the energy-dispersed X-ray fluorescence, these results are used to calculate the characteristics such as shielding of the concrete blocks, which have been partially reported, in this work several characteristics are presented for photons from 1 keV to 100 GeV, such as linear attenuation coefficients, the hemireductive layer, the effective, atomic and electronic sections, the effective atomic number (Zef). The exposure of accumulation and energy absorption factors (EBF, EABF) of 0.5–40 mfp are reported, using the Photon Shielding and Dosimetry (PSD) software. These characteristics are compared to those of NBS concrete. The concrete blocks have an attenuation capacity for energies used in radiological equipment such as mammography, 20–35 keV; dental, 50–90 keV and for conventional radiography equipment, 70–150 keV, so the block and lightened concrete block must be considered in the calculations of primary and secondary shielding walls.

Use of bottom ash as part replacement of sand for making concrete blocks

Coal-based thermal power plants all over the world facing serious problems of handling and disposal of the ash produced. The productive use of coal Bottom Ash (BA) is the best way to alleviate the problems associated with its disposal. This paper covers the studies on laboratory scale evaluation of vibro compaction concrete blocks using BA I, BA II & BA III collected from three different location of Coal Fed Thermal Power Station. In the present investigation laboratory investigation have been carried to utilize BA as part replacement of sand in concrete. This study cover manufacture of concrete blocks without flyash & with BA using for making solid block as per specification laid down in IS:2185 using vibro compaction machine. Three different sources of BA were used in concrete mix each @ 30%, 40% & 50% replacement by weight of sand were adopted in making concrete blocks. Comparative study of compressive strength of concrete at different age of curing, wet density, drying shrinkage is reported in this study. Wet density is found to be lower in blocks containing BA & dry shrinkage values are found well within the limits of specifications. Concrete Blocks having BA @ 30% by weight of sand are found suitable for use in the manufacture of concrete blocks.

Use of bottom ash as part replacement of sand for making concrete blocks

Coal-based thermal power plants all over the world facing serious problems of handling and disposal of the ash produced. The productive use of coal Bottom Ash (BA) is the best way to alleviate the problems associated with its disposal. This paper covers the studies on laboratory scale evaluation of vibro compaction concrete blocks using BA I, BA II & BA III collected from three different location of Coal Fed Thermal Power Station. In the present investigation laboratory investigation have been carried to utilize BA as part replacement of sand in concrete. This study cover manufacture of concrete blocks without flyash & with BA using for making solid block as per specification laid down in IS:2185 using vibro compaction machine. Three different sources of BA were used in concrete mix each @ 30%, 40% & 50% replacement by weight of sand were adopted in making concrete blocks. Comparative study of compressive strength of concrete at different age of curing, wet density, drying shrinkage is reported in this study. Wet density is found to be lower in blocks containing BA & dry shrinkage values are found well within the limits of specifications. Concrete Blocks having BA @ 30% by weight of sand are found suitable for use in the manufacture of concrete blocks.

The potential use of drinking water sludge ash as supplementary cementitious material in the manufacture of concrete blocks

The effect of drinking water sludge ash (DWSA) on the properties of DWSA-cement pastes is investigated in this study using x-ray diffraction, scanning electron microscopy coupled with energy-dispersive spectrometry, and thermogravimetry techniques. The pozzolanic reactivity of DWSA is confirmed; the filler effect of DWSA can significantly and rapidly accelerate the hydration reaction at an early curing age. The presence of DWSA in blended pastes promotes the incorporation of aluminum into the C-(A)-S-H gel; the original ‘Al-minor’ C-(A)-S-H gel in pure cement paste is converted to ‘Al-rich’ C-(A)-S-H gel. The added DWSA leads to the formation of aluminum-bearing hydrates, such as ettringite and calcium aluminate hydrates (C-A-H). The compressive strength of sludge-derived concrete blocks is studied; blocks containing 10% DWSA exhibited higher compressive strength at a curing age of 90 d than the reference samples. Such benefits are not observed in block samples with 20 and 30% DWSA, which is attributed mainly to the physical effect of unreacted DWSA particles.

APPLICATION OF FGC BLOCKS FOR SUSTAINABLE INFRASTRUCTURE DEVELOPMENT

The use of conventional materials in building construction results in increased emission of carbon dioxide and consumption of more energy. The replacement of sustainable materials with conventional materials can help in reducing the overall energy consumed while making it more eco-friendly. The aim of the study is to replace the cement used in manufacturing of concrete blocks with sustainable and waste materials such as fly ash, ground granulated blast furnace slag and calcined clay. The compressive strength of these blocks were slightly lesser than the conventional blocks while satisfying the standards’ minimum criteria. The blocks showed 50% reduced thermal conductivity and 35% reduced carbon emission, which suggests that these blocks could be an excellent replacement for conventional materials since it increases the thermal comfort of the building while reducing the environmental impact.

Properties and microstructure of concrete blocks incorporating drinking water treatment sludge exposed to early-age carbonation curing

In recent decades, industrial by-products have gained significant attention for their potential as components of more environmentally friendly construction materials. In this context, this paper presents the manufacture of concrete blocks (CB), in which sand was replaced with oven-dried drinking water treatment sludge (DWTS). In addition, CB with DWTS contents ranging from 0% to 30% by weight were exposed to early-age carbonation curing. Experiments were conducted to determine the compressive strength, splitting tensile strength, and water capillary absorption of CB subjected to normal or early-age carbonation curing. The results indicated that DWTS degraded durability and mechanical properties of CB because of the high-water absorption and high organic content of DWTS. However, early-age carbonation curing was found to improve the overall performance of CB with DWTS, such that the carbonated CB mixtures satisfied the strength requirement of load-bearing blocks. The pH values of CB after carbonation curing increased with increasing content of DWTS. Microstructural analyses showed that the addition of DWTS into CB caused the formation of ettringites because of the presence of alum and gypsum in DWTS, and early-age carbonation curing decomposed these ettringite into calcium carbonates. The results also showed that the production of crystalline CaCO3 under carbonation had a filling effect that refined the pore sizes. Thus, the findings of this study indicate that utilisation of DWTS in CB offers significant environmental and health benefits via increased greenhouse gas absorption, as well as reduced DWTS disposal in landfills and unsustainable sand extraction.

Evaluation of overall equipment effectiveness in concrete block manufacturing

Companies are required to integrate a set of critical dimensions in order to measure and evaluate their performance to compete in globally competitive markets. Overall Equipment Effectiveness (OEE) is a quantitative metric, in the context of the total productive maintenance (TPM), attempts to measure and improve the effectiveness of manufacturing operations in three dimensions namely: availability, performance rate and quality rate. This study applies OEE to evaluate and improve the performance of a concrete block manufacturing system at Dler Company in Iraq. The study was conducted in two years of operation during 2016 and 2017. Results from 2016 show that the level of effectiveness was lower than the world class. An improvement in the average value of the OEE for 2017 was recorded, where the OEE value is increased in 2017 to 75% in comparison with its value in 2016 at 67%. It was also found that the reasons for this improvement are due to the enhancement that are made in the availability and quality.

Novel applications of waste foundry sand in conventional and dry-mix concretes

The use of waste materials in the building industry is a major challenge for eco-efficient construction. Brazil generates more than 3 million tons of waste foundry sand (WFS) annually, making it one of the largest industrial wastes produced in the country. This work proposes the use of WFS in two novel ways: in conventional concrete by WFS calcination, and in dry-mix concrete for the production of concrete blocks. For the conventional mixture study, mortars with 0, 50 and 100% replacement of natural sand by WFS and calcined WFS (CFS) were produced. The fresh state properties, volumetric variation, cement hydration and 28-days compressive strength of the mortars were evaluated. For the dry-mix concrete study, compositions with two densities (2.20 and 2.25 g/cm3), three cement contents and 0, 50 and 100% WFS in natural sand replacement were produced in the laboratory. Furthermore, concrete blocks of different strength ranges and 0 and 100% WFS in natural sand replacement were produced in a concrete block manufacturing plant for full-scale testing. The results showed that the use of WFS led to reductions in flowability and compressive strength of the mortars, but did not cause expansion as initially expected. In contrast, the use of up to 100% CFS resulted in mortars with flowability and compressive strength similar to those of the reference. WFS calcination removed the pulverized coal and may have formed pozzolanic phases in the clay material. As a result, the CFS presented performance similar to that of natural sand. In dry-mix concrete, the laboratory results showed that the use of 100% WFS resulted in similar strengths to the reference for concretes of up to 20 MPa. Finally, full-scale tests showed that it was possible to produce concrete blocks with 100% WFS and strengths compatible to the reference.

Use of crushed clay brick and pumice aggregates in lightweight geopolymer concrete

The study aimed to examine the properties of lightweight high-calcium fly ash geopolymer concrete (LWGC) containing crushed clay brick and pumice aggregates. A high-calcium fly ash activated by sodium silicate and sodium hydroxide solutions was used as the geopolymer binder. The properties of LWGCs including workability, compressive strength, splitting tensile strength, surface abrasion resistance, density, thermal conductivity, ultrasonic pulse velocity, and fire resistance were investigated and compared with those of the normal density control geopolymer concrete. Temperatures corresponding to 400 °C, 600 °C, and 800 °C were used to test the fire resistance of the concretes. The results indicated that both crushed clay brick and pumice LWGCs exhibited better thermal insulation and fire resistance characteristics when compared to that of the geopolymer containing natural aggregates (CGCs). The results suggested that the LWGCs produced with crushed clay brick aggregate are suitable for structural lightweight concrete. With respect to LWGCs produced with pumice aggregate, the compressive strength was significantly lower, and is sutiable for the manufacture of concrete blocks.

Use of recycled tires in non-structural concrete

This research addresses the issue of tire waste management and natural aggregate resource depletion. It investigates use of commercially produced recycled tire rubber as replacement for fine and coarse aggregate in non-structural concrete. Two replacement levels of 10% and 20% were considered for fine aggregate with 0% or 10% of coarse aggregate. The study employed a mix proportion of 1:5:4 (cement: fine aggregate: coarse aggregate) with a water-to-cement ratio of 0.25, which is normally utilized in concrete block manufacturing in Oman. The mixes were tested for their thermal conductivity, water absorption and compressive strength. The behavior of mixes exposed to 100 and 200°C was also studied and the samples were later tested for compressive strength. The results showed improvements in compressive strength after exposure to heat. Thermal conductivity was reduced as the percentage replacement increased for both fine and coarse aggregate. During heat exposure, the temperature rise was faster in rubberized mixes, and the compressive strength of all mixes improved after the exposure to heat. Water absorption and void content increased with increase in replacement percentage. The compressive strength did not show a clear trend with the replacement and this is due to the sensitivity of the stiff mix used in the study and its inherent lean nature. The results indicate that the lean nature of the mix makes it insensitive to small replacement investigated in this research.

Partnering with a local concrete block manufacturing plant to improve quality of construction materials in Haiti’s Central Plateau

This paper presents a successful ongoing partnership between Clemson Engineers for Developing Countries (CEDC) and a concrete masonry unit (CMU) manufacturing plant in rural Haiti. The infrastructure destruction and resulting loss of life of the 2010 earthquake in Haiti highlighted the need for improved building materials and codes. This partnership has helped to improve the strength of CMUs in the plant, both creating a safer local built environment and expanding the economic opportunities for this plant. Using samples of aggregate and cement from the site in Haiti, students in Clemson performed experiments to optimise the CMU mix design and made other suggestions to improve efficiency and quality of their product. Consistency continues to be a challenge for the CMU plant, and this paper also describes proposed procedures to help the plant implement quality control and quality assurance plans.

WOOD ASH AS AN EFFECTIVE RAW MATERIAL FOR CONCRETE BLOCKS

Utilization of wood ash as a partial substitution for cement is one of the promising method to increase the strength and thermal insulation for cement blocks. The present study focused to use wood ash as a partial replacement for cement material during sand cement block manufacturing. The concrete mixtures have been mixed with 10%, 15% 20% and 25% of wood ash as a partial replacement for cement with sand and tested for compressive strength, water absorption and heat release. Higher compressive strength was observed in the samples of 15% containing wood ash replacement material. All the samples other than 25% of wood ash replacement were shown lower water absorption and highest was found in 15% wood ash content. Slower heat release was observed in the samples of 15% and 20% of wood ash replacement after 21 days of curing time. Addition of 15% wood ash for the manufacturing of concrete blocks was developed and these blocks meet standard limits.

Lightweight Concrete: An Alternative for Recycling Cellulose Pulp

From the analysis of the production process of molded pulp packaging, it can be seen that one of the residues generated in the molding is “pulp”. When this waste cannot be reincorporated into the production line, is recovered by centrifugation in the effluent treatment system.With the intention of recycling this residue it was investigated the feasibility of their use in the manufacture of concrete blocks or panels lightened studying possible ways to use the material, either in the wet state (form is discharged from the process) or dry (dried in a controlled environment), analyzing the advantages and disadvantages of each alternative.For practical purposes, various dosages were proposed to maintain constant the amount of residue and varying the amounts and proportions of water and cement. Test specimens were made with various amounts of cement per m3 of concrete.

Relevance of Ornamental Stone Residues in the Manufacture of Concrete Blocks for Structural Masonry

The civil construction industry in Brazil is an ever growing sector with relevant participation in the country’s economy. On the other hand, this sector, technically, is among those that generate the largest amount of undesirable rejects, waste and residues. Some of these residues are highly detrimental to the environment not only because of landscape degradation but also the possibility of pollution to rivers and lakes as well as ground waters. A typical example is that of the ornamental stone industry, which generates granite and marble residues from the several processing stages. Therefore the aim of the present work is to investigate the effect of direct addition of this kind of residues in concrete blocks for different applications in housing masonry. It was found that blocks added with 20 wt% of residue possess relatively higher compression strength in association with convenient water absorption below those presented by residue-free traditional blocks.

Production of Concrete Blocks with Residues for Civil Construction

The Construction is recognized as one of the most important activities for the economic and social development, and on the other hand, behaves also as a major generator of environmental impacts, either by consumption of natural resources, the modification of the landscape or the generation of construction and demolition waste (CDW). Investing in an implementation of managed clean and healthy in the area of CDW is essential for the environment and for the economy of the cities, who are spending less resources on the collection, cleaning of drains and treatment of diseases. Nowadays, the amount of waste generated is considered large, occupying much space in landfills, and its transportation, depending on the volume and weight, is quite expensive. Recycling and reuse of these wastes are extremely important to control and mitigate environmental problems, as well as produce various materials value-added. Over 90% of waste can be recycled, reused and transformed into aggregates with characteristics very similar to the original product, thus creating environmentally friendly products such as sand, gravel, pebbles. This research concerns the study of the properties of concrete containing CDW, aiming its use in the manufacture of concrete blocks to seal without structural function. Blocks have been molded with partial replacement of natural aggregates by recycled aggregates and later were performed tests of compressive strength in accordance with the standards to prove the technical feasibility of the material for the trait studied.