Manufacture Of Blocks Research Articles

Study on the Usage of Ceramic Tile Waste as a Partial Replacement for Sand in Block Manufacturing

Study on the Usage of Ceramic Tile Waste as a Partial Replacement for Sand in Block Manufacturing

Time Prediction in Ship Block Manufacturing Based on Transfer Learning

Accurate time prediction is critical to the success of ship block manufacturing. However, the emergence of new ship types with limited historical data poses challenges to existing prediction methods. In response, this paper proposes a novel framework for ship block manufacturing time prediction, integrating clustering and the transfer learning algorithm. Firstly, the concept of distributed centroids was innovatively adopted to achieve the clustering of categorical attribute features. Secondly, abundant historical data from other types of blocks (source domain) were incorporated into the neural network model to explore the effects of block features on manufacturing time, and the model was further transferred to blocks with limited data (target domain). Leveraging the similarities and differences between source and target domain blocks, actions involving freezing and fine-tuning parameters were adopted for the predictive model development. Despite a small sample size of only 80, our proposed block time prediction method achieves an impressive mean absolute percentage error (MAPE) of 8.62%. In contrast, the MAPE for the predictive model without a transfer learning algorithm is notably higher at 14.97%. Experimental validation demonstrates the superior performance of our approach compared to alternative methods in scenarios with small sample datasets. This research addresses a critical gap in ship block manufacturing time prediction.

Thermal Performance Of Termite Mold Bricks Reinforced With Empty Fruit Bunch Spikelet And Coconut Fibers

The use of natural fibers to enhance the thermal properties of earth bricks has become increasingly popular. This study investigates the thermal performance of termite mold soil (TMS) reinforced with two types of fibers: coconut fibers (CF) and empty fruit bunch spikelet fibers (EFBSF). Various fiber compositions (0%, 0.5%, 1%, 1.5%, 2%, and 2.5%) were combined with sodium hydroxide (NaOH) treatments at concentrations of 1%, 2%, 3%, and 4%. Laboratory results reveal that TMS exhibits promising physical properties, including a moisture content of 23.64%, a maximum dry density of 1.63 g/cm³, and a plasticity index of 20%, indicating its structural stability and suitability for earth block production. The study also analyzes the chemical properties of EFBSF and CF fibers, noting that CF has a higher holocellulose content (88.0%) compared to EFBSF (33.5%), which impacts moisture retention and structural integrity. Thermal analysis demonstrates that incorporating these natural fibers significantly enhances the thermal performance of TMS. With a 2.5% fiber content, CF reduces thermal effusivity from 1771.43 J/m²Ks^1/2 to 1079.39 J/m²Ks^1/2 and thermal conductivity from 0.86 W/mK to 0.38 W/mK, making it particularly effective in improving insulation in hot conditions. EFBSF also lowers thermal effusivity and conductivity, but to a lesser extent than CF. Additionally, the presence of these fibers reduces volumetric calorific capacity, with CF showing a more pronounced effect. Overall, TMS reinforced with coconut fibers, especially at 1% NaOH and 2.5% fiber content, offers the best thermal performance, suggesting its potential for sustainable construction. This research promotes the use of locally sourced, natural fibers in earth block manufacturing, contributing to the development of more energy-efficient and environmentally friendly building materials.

A heuristic method for multi-objective hybrid flow shop scheduling problem with parent-child relationships and space constraints

ABSTRACT In modern ship manufacturing, a ship is divided into hundreds of blocks in the design stage, and the productivity of the block manufacturing process is vital to ship delivery. This paper investigates the production scheduling problem of ship blocks with the parent-child relationship; this relationship is characterised by the fact that sibling jobs at the same BOM layer must be processed on adjacent machines at their assembly stages. We formulate this problem as a multi-objective hybrid flow shop scheduling problem: the first objective is to minimise the total deviation from the target time of the jobs and the second one is to minimise the total processing time. To solve this problem, we propose a heuristic method based on the multi-objective genetic algorithm, in which an adjacent machine priority method is first proposed to generate feasible solutions that satisfy the space constraints. Then, we improve the individual quality in crossover and mutation of the algorithm via tabu search. We verify the performance of our algorithm by test instances generated from real manufacturing data of a shipbuilding company. Results show that the proposed method outperforms the existing algorithms when identifying the Pareto optimal solutions, especially for large-sized problems.

Proposal for formulation of blocks to guarantee the sustainability of buildings in the Abidjan real estate park

A recurring fall of buildings in recent years (2013-2023) in the city of Abidjan has caused enormous material and human damage. This study was initiated in order to propose a formulation for the development of concrete blocks to guarantee the sustainability of buildings in the Abidjan real estate. The raw materials used are aggregates composed of sand, granite powder and a hydraulic binder (portland cement) then water for mixing. The aggregates were characterized before being used for the manufacture of the various FSB, FPS and FPG concrete blocks. The materials were subjected to physical and mechanical tests. The results showed that the sand and granite powder aggregates have a granular class of 0/1 and 0/2 respectively. Concerning concrete blocks, the density increases with the maturation time, namely 28 days maximum and when they are composed of both sand and granite powder (FPS). This significantly reduces the number of pores in the material. The compressive strength test showed that at 28 days of maturation, the FPS are more resistant than the FPG and FSB with respective values of 6.50 MPa; 5.31 MPa and 3.10 MPa. It appears that the addition of granite powder to the composition of the concrete blocks improves the density, porosity and compressive strength of the latter. The promotion of this formulation among concrete block manufacturers would make it possible to improve real estate construction, guarantee the durability of buildings in the Abidjan real estate park and thus avoid the possible fall of buildings.

Ceramic waste powder as a cement replacement in concrete paving blocks: mechanical properties and environmental assessment

ABSTRACT In the quest for eco-friendly alternatives to ordinary Portland cement, a material extensively used in the manufacture of concrete paving blocks, this study explores the potential of ceramic waste powder. Towards this, a parametric investigation is conducted into the effects of substituting cement with ceramic waste powder on the mechanical properties and durability performance of mass-produced pressed concrete blocks. The findings reveal that the incorporation of ceramic waste powder as a partial cement replacement can markedly enhance the strength and durability of the paving blocks. Specifically, mixtures, containing 20% and 30% ceramic waste powder, demonstrated an increase in compressive and tensile strength by 30% and 19%, respectively, compared to their control counterparts. In addition, the modified blocks exhibited a decrease in water absorption and weight loss after undergoing freezing and thawing cycles by 8% and 40%, respectively. A life cycle assessment corroborates the environmental viability of ceramic waste powder as a cement substitute, indicating reductions across all environmental impact categories, with notable improvements. This research paves the way for more sustainable solutions in pedestrian pavement construction, underscoring the potential of ceramic waste powder as a significant contributor to global sustainability efforts in the construction industry.

A megaton-scale industrial demonstration study on hydrothermal mineralization enabled silty waste upcycling

The continual large-scale urbanization and urban renewal in coastal cities of China have accumulated massive silty residue (SR) that may alter the coastal lines and always exerts high stresses to local environments. To meet China’s sustainable development policy, the need for green and high-efficient industrial treatments and reuse of SR is urgent. In this work, we may, for the first time, report a megaton-scale industrial project to upcycle low-quality SR and recycled aggregate (RA) to manufacture construction materials with hydrothermal mineralization (HM). In-situ pilot tests on five batches of SR-RA blocks were conducted. Results demonstrate that the produced blocks possess the compressive strengths of 11.4–15.8 MPa, densities of 1280–1430 kg/m3, porosities of 35–44%, CO2 emissions of 170.22–187.29 kg e-CO2/m3 and costs of 126.49–156.51 CNY/m3, comparable with or superior than the commercial blocks. The silica in SR could react with lime to produce tobermorite with stable pseudohexagonal plate under HM treatment, which improved the microstructure of the material. The findings validate the industrial practicability of upcycling low-quality SR and RA with HM for valuable construction block manufacture.

Dimensional And Mechanical Deviation Of Paving Block Type Rectangular From Several Manufacturers In Semarang City

The non-uniformity of paving block quality can result in uneven pavement, which in turn can increase the risk of traffic accidents. This study aims to determine the quality of compressive strength of paving block type Holland from several manufacturers in Semarang City area both manually and massively. As well as knowing why the physical dimensions of paving block type Holland from several producers in Semarang City are not uniform. This research was conducted by taking samples in the paving block manufacturing industry around the city of Semarang. The discussion in this study only covers the type of holland paving block in Semarang City from 4 producers namely CV Waringin Putih Banyumanik Semarang, PT Alam Daya Sakti, Anugerah Block, and Putra Alam Sari. All paving block products tested met or exceeded the minimum value of compressive strength specified in SNI 03- 0691-1998. This indicates that these products have an adequate ability to withstand the given compressive load. The compressive strength test results show that the lowest value was recorded for Anugrah Block at 17.21 MPa, while the highest value was achieved by PT Alam Daya Sakti with 20.112 MPa. The non-uniformity of the physical dimensions of Holland type paving from several producers in Semarang City can be influenced by several factors, including different production processes between producers, the use of different raw materials, and differences in the arrangement of machines or production equipment.

Comparison of the Carbon Footprint in the Manufacturing of Cast Iron and Aluminum Engine Blocks

Comparison of the Carbon Footprint in the Manufacturing of Cast Iron and Aluminum Engine Blocks

Zr as an Alternative Grain Refiner in the Novel AlSi5Cu2Mg Alloy

Al-Si-Cu-Mg alloys are among the most significant types of aluminum alloys, accounting for 85–90% of all castings used in the automotive sector. These alloys are used, for example, in the manufacturing of engine blocks and cylinder heads due to their excellent specific strength (ratio of strength to specific weight) and superior castability and thermal conductivity. This study investigated the effect of using Zr as an alternative grain refiner in the novel AlSi5Cu2Mg cylinder head alloy. The microstructure of this alloy could not be refined via common Al-Ti-B grain refiners due to its specifically designed chemical composition, which limits the maximum Ti content to 0.03 wt.%. The results showed that the addition of Zr via the AlZr20 master alloy led to a gradual increase in the solidus temperature and to the grain refinement of the microstructure with the addition of as little as 0.05 wt.% Zr. The addition of more Zr (0.10, 0.15, and 0.20 wt.%) led to a gradual grain refinement effect for the alloy. The presence of Zr in the AlSi5Cu2Mg alloy was reflected in the formation of Zr-rich intermetallic phases with acicular morphology. Such phases acted as potent nucleants for the α-Al grain.

Innovative technology and equipment for stone processing sludge recycling

The aim of the study is to substantiate the parameters of technology and equipment for the manufacture of building products using alumina sludge from stone processing as an alumina aggregate. The standard methods of setting up an experiment for laboratory washing of granular sludge from stone processing and studying its physical and mechanical characteristics, manufacturing laboratory samples of polystyrene concrete blocks with further study of their strength characteristics were used. The physical and mechanical characteristics of granular man-made material - sludge waste from the stone processing industry - were experimentally determined. The possibility of using man-made sludge in the manufacture of polystyrene concrete blocks was substantiated by its particle size distribution and mineralogical composition. Average samples of granular material were deslagged using the TurboWash unit. The particle size distribution of the material after washing was analysed. According to the standard technology, recipe and raw materials for D300 polystyrene concrete, polystyrene concrete blocks of standard sizes of three grades were produced. Primary sludge without preliminary processing, sand and dusty loess obtained from the processing of primary sludge were used as an aggregate. The numerical values of the axial compression resistance for the studied grades of polystyrene concrete blocks were determined.

Analisis Pembuatan Paving Block Menggunakan Campuran Limbah Pecahan Keramik & Pasir Silika sebagai Pengganti Sebagian Pasir terhadap Kuat Tekan (Literature Review)

This literature article details the results of a review of the latest literature which focuses on the use of ceramic shard waste and silica sand as additional materials in making paving blocks. In the context of sustainable development, this literature highlights the positive potential of utilizing ceramic waste as a contribution to waste reduction and resource efficiency. The addition of silica sand, as an additional material, apparently has a significant effect on increasing the strength and durability of paving blocks. Through a synthesis of information from various studies, this article also highlights the need for further research to optimize ingredient composition and evaluate the overall impact, both in terms of sustainability and product quality. By summarizing key findings, this article provides a holistic view of the use of ceramic shard waste and silica sand in the context of paving block manufacturing, supporting sustainable technological development in the construction sector.

Development of sustainable masonry solid blocks by the incorporation of industrial and agro waste.

<p>Bricks have been extensively adopted for centuries and continue to play a vital role in the construction industry. Nevertheless of its dependable workability and accessibility, fired clay brick production has been recognized for its comparatively high energy and resource requirements. Traditional clay bricks, widely used in construction for centuries, pose significant environmental challenges. The extraction of clay for brick production can result in habitat destruction and landscape alteration. The firing process in brick kilns consumes substantial amounts of energy, often derived from non-renewable sources, contributing to greenhouse gas emissions. The development of sustainable masonry solid blocks signifies a revolutionary change in the construction sector, providing a sustainable substitute for conventional building materials. These blocks, typically made from reused or locally obtained materials, demonstrate a dedication to environmental stewardship and the efficient use of resources. This innovative idea of utilizing some industrial waste such as fly ash, bagasse ash, marble dust and stone dust in solid block manufacture significantly reduces the environmental pollution problem, offers an alternative construction material source, and makes the solid blocks economical. Different types of trail mixes have been developed, and the produced masonry solid blocks underwent a series of experimental investigations. The solid bricks are being compared to conventional cement blocks. The developed sustainable solid block (MB6) exhibits a strength that is 43.78% greater than that of conventional cement solid blocks. The present study attempts to determine the optimal material proportion for innovative solid block production. Key words: Carbon footprint, Eco-friendly building blocks, Bagasse ash, Marble dust and Industrial waste</p>

Changes in Functional Groups and Crystal Structure of Coal Tar Pitch with Respect to Carbonization Temperature

In this study, changes in the microstructure of coal-tar pitch (CTP) during successive processes, including pyrolysis, polycondensation, and crystallization, were examined in connection with the resulting variations in structure factors, as measured by X-ray diffraction (XRD) analysis, and functional groups, as confirmed by Fourier transform infrared (FTIR) spectroscopy. To this end, four zones were defined based on variations in crystallinity, which were indicated by d002 and Lc. Each zone was further characterized by interpreting crystallinity development in relation to changes in functional groups and specimen height. At around 400 °C, polycondensation occurred as the C-Har and C-Hal peaks decreased in intensity. These peak reductions coincided with the formation of mesophase spheres, resulting in enhanced crystallinity. Subsequently, at around 500 °C, the peak intensity of C-H and COOH decreased, which was attributed to the release of large amounts of gases. This led to sharp volume changes and a temporary reduction in crystallinity. All these results suggest that changes in the functional groups of CTP at lower temperatures (600 °C or less) during the carbonization process are closely associated with variations in its crystallinity. The major findings of the present study provide valuable insights for designing highly effective processes in the manufacturing of synthetic graphite blocks using CTP as a binder material, including by selecting appropriate temperature ranges to minimize volume expansion and crystallinity degradation and determining the lowest possible carbonization temperature to ensure adequate binder strength.

Dry ice sublimation performance as affected by binding agent, density, and age

AbstractDry ice is one of the world's most in‐demand commodities for cold chain distribution of temperature sensitive products in insulated shippers. A commonly used rule of thumb is that dry ice sublimates about 8% every 24 h, without consideration for dry ice type, size, or geometry. This study explored sublimation rates of dry ice composition (binding agent and density), age, and geometry (size and shape). Dry ice block manufacturing often involves dosing propylene glycol‐water “binder” solution to liquid carbon dioxide. Tests performed in this study revealed that the binding agent did not influence the dry ice sublimation rate. Dry ice density was found to impact sublimation rate. Fresh and aged blocks of similar dimensions and mass were found to have similar performance outcomes. Mass loss curves for pellets and various sized dry ice blocks showed a dependence on surface area and volume. Chunked blocks and pellets with and without binding agent sublimated at similar rates of 2.84 and 2.53% h−1 (w/w), respectively, whereas block varieties with significantly lower surface area to volume ratios had lower sublimation rates of 0.98–1.60% h−1.

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.

Utilization of Cockle Shell Ash, Sea sand and Plastic Waste in the Manufacture of Paver Blocks

The cockle shell is categorized as industrial waste and often disposed of in open dumping zones, especially in coastal areas. Therefore, an eco-friendly solution to this disposal issue is crucial, as it can transform waste into a high-value product, such as a partial cement replacement. Also, as there is a growing interest in using alternatives to sand as a replacement for fine aggregate in concrete, in this study we used plastic coated sea sand as a partial replacement for fine aggregate. The design mix is formulated for a non-traffic application, with varying percentages of cockle shell ash and plastic-coated sea sand replacing cement and fine aggregate, respectively. Two curing methods, normal water curing and accelerated curing, are applied. The samples are then tested for compression strength and water absorption after 28 days of curing. The findings indicate that compressive strength value increased with increase in both cockle shell ash content as well as plastic coated sea sand content. The water absorption value increased with increase in cockle shell ash content and decreased with increase in plastic coated sea sand content. Hence, this composite material is suitable for use in paver blocks.

Investigation into the Mechanical Properties of Commercial Sandcrete Blocks Produced in Nigeria: A Case Study of Warri Metropolis

This study investigated the extent to which the mechanical strength of commercially produced sandcrete blocks in Delta State, Nigeria, conforms to recognized international standards. Fifty sandcrete blocks (28 curing days) were sampled from ten known sandcrete block manufacturers in Warri municipal area, five blocks from each manufacturer. The compressive strength of the blocks was determined in accordance with the American Society for Testing and Materials (ASTM) International guidelines. The results showed that the compressive strength of all the blocks failed to meet the Nigeria Industrial Standard (NIS) benchmark for load loading sandcrete block, while only 20% of the blocks attained NIS requirement for non-load bearing walls. Field observation revealed that poor mixing ratio of the sandcrete; inconsistencies in the batching method and sand used in the production of the sandcrete blocks were responsible for the poor quality (low compressive strength) of the sandcrete blocks manufactured in the region. The findings of this study underscore the importance for the Nigerian Institution of Structural Engineers, to rigorously monitor the strength of sandcrete blocks made in Nigeria to ensure that their quality meets internationally recognized standards. This will reduce the occurrence of structural damage in Nigeria, due to the use of low quality blocks for wall constriction.

Impression of ABS waste (Acrylonitrile Butadiene Strene) as an alternative material eco-friendly paving block manufacturing

Impression of ABS waste (Acrylonitrile Butadiene Strene) as an alternative material eco-friendly paving block manufacturing

Exploring Sawdust as a Sustainable Alternative in Block Production: A Study on Compressive Strength and Environmental Impact

The utilisation of sawdust in block manufacture has effectively minimised the amount of waste material being disposed of in landfills. The study aimed to examine the utilisation of sawdust as a partial substitute for sand in the manufacture of blocks and assess the compressive strength of sandcrete and sawdust blocks. The experiment utilised cement grade 32.5R, pit sand as the fine aggregate, fine particles of sawdust, and a water-cement ratio of 0.65. Control specimen 0,utilised 10%, 15%, and 20% of fine sawdust particles as partial substitutes for sand. Subsequently, the materials were combined in a proportion of 1:3 to generate sawdust and sandcrete blocks. The block samples were cured by applying water at intervals of 7, 14, and 21 days, respectively. The results indicate a significant alteration in the water-cement ratio employed during the material batching and mixing procedure of the sawdust samples. Additional results revealed differences in the compressive strength and density tests between sandcrete and sawdust blocks in the control specimens. The compressive strength of sandcrete blocks was superior to that of sawdust blocks. Sandcrete blocks are suitable for load-bearing purposes in construction projects, whilst sawdust blocks are suitable for non-load-bearing walls.