Non-fired Brick Research Articles

Sustainable Utilization of Stabilized Dredged Material for Coastal Infrastructure: Innovations in Non-Fired Brick Production and Erosion Control

The deterioration of dams and levees is an increasing concern for both infrastructure integrity and environmental sustainability. The extensive repercussions, including the displacement of communities, underscore the imperative for sustainable interventions. This study addresses these challenges by investigating the stabilization of dredged material (DM) for diverse applications. Seven mixtures incorporating fly ash, lime, and cement were formulated. The Standard Compaction Test was used to determine optimal density–moisture conditions, which helped with brick fabrication. Bricks were tested for compressive strength over various curing periods, and the durability of the 28-day-cured samples was evaluated by performing water immersion tests following the New Mexico Code specifications. Scanning electron microscopy (SEM) was used to assess microstructural bonding. Results confirm that the inclusion of cementitious stabilizers modifies the material’s microstructure, resulting in enhancements of both strength and water resistance. Notably, the stabilized material demonstrates potential for use in non-fired brick manufacturing and as bridge stones for waterway erosion control. This dual-function application offers a sustainable and economically feasible approach to managing dredged materials.

NON-FIRED LATERITE SOIL BRICKS WITH NA-BASED STABILIZER ADDITION FOR SUSTAINABLE DEVELOPMENT

Fired bricks are widely used, but they are energy-intensive and non-eco-friendly. Non-fired bricks with chemical stabilisers can be the alternative solution, which is a low-energy-intensive and environmentally friendly manufacturing product. Laterite soil can be the raw material for the synthesis of non-fired clay brick in sodium hydroxide solution and sodium silicate solution. However, it may have been mixed with other laterite soils with different optimum moisture contents and grain sizes during extraction. Thus, the mixing ratio of laterite soil, Na-based stabilisers, and water for non-fired brick production is determined. Besides, two types of laterite soil, LAT 1 and LAT 2, from different locations were prepared, and another type of laterite soil, LAT 3, was prepared by mixing LAT 1 and LAT 2. Both three are compared primarily in terms of compressive strength and water absorption, which are mixed with the Na2SiO3/NaOH ratio. As a result, the new mixing ratio with increased water content was determined based on the optimum moisture content of the soil. Besides, the optimum mixing ratio of each type of brick was determined. Overall, based on the Malaysian standard, all types of brick samples from each ratio could be used as load-bearing class 1 and internal wall bricks. Additionally, LAT 2 and LAT 3-based bricks with a ratio of 1.5 Na2SiO3/NaOH ratio can be used as load-bearing brick class 2.

The Application of Coal Ash of Thermal Power Plant in Building Materials and Anti-salinity Foundation

Abstract: Fly ash (FA) and coal bottom ash (CBA) of thermal power plants is industrial wastes but can be used for many different purposes. This paper focuses on the authors’ research on using CBA to successfully produce artificial sand to replace natural sand; using FA and CBA as aggregates for producing of non-fired brick, and applying of the important properties of CBA to prevent salinization of structures based on capillary test results combined with a specialized design method. The research and application of coal ash not only contribute to solving environmental problems and natural resources but also significantly contribute to promoting sustainable development and proactively responding to climate change.
 
 

DESIGN AND RESEARCH OF ELECTRIC BRICKS TRANSPORTING CAR IN NON FIRED BRICKS FACTORY

Under the background of building energy saving, unburned bricks emerge as the time requires. The non-fired bricks need to be transported to the maintenance site by transporting equipment after being pressed and moulded, but now the transporting equipment in our country is simple and inefficient. In order to improve the production efficiency and promote the development of non-fired brick industry, the scheme of electric brick cart in this paper is put forward. This paper is centered on the design of electric brick cart. Firstly, the shortcomings of existing brick conveying equipment and the areas needing improvement are expounded, and the main research contents and the main structure scheme are put forward. Specific design includes structure design of main frame and loading car, calculation and selection of lifting system and motor, reducer and chain, calculation and selection of driving system, calculation and selection of motor and chain, selection and design of steering system and braking system. Finally, finite element analysis of bearing components is carried out and the design is summarized. The electric brick car designed in this paper has the advantages of energy saving, environmental protection, high transportation efficiency, simple operation, and can bring higher benefits to the brick factory without burning, and has broad application prospects.

Ternary combined industrial wastes for non-fired brick

ABSTRACT The demand for bricks in South Asia is increasing significantly due to growth in the construction sector. Bricks produced using traditional firing technique and fertile clay contribute significantly to some of the worst air pollution in the world. Therefore, the utilisation of other environment-friendly alternative to conventional bricks is considered an urgent need to conserve a clean environment and help in saving its fertile soil. This research aimed to explore geopolymerisation technique with ternary combined industrial waste/by-products as binders including high volume Ladle Furnace Slag (LFS), Fly ash and Ground Granulated Blast Furnace Slag (GGBS) to produce non-fired and clay-free brick alternatives. The first two byproducts are locally produced in the related iron and power industry while GGBS are being imported by the cement industry. The results indicated that all the prepared samples conform to the minimum compressive strength requirement of 20.7 MPa and maximum water absorption rate of 17% for common brick with severe weathering as per ASTM C62. This highly promising performance pronounced the use of locally available high volume LFS and other industrial waste/by-products materials in non-fired building block production to achieve a cleaner, environmental-friendly sustainable society as well as a sustainable route for industrial waste management.

Non-Fired Building Blocks Using Industrial Wastes

Bricks produced from traditional techniques and agricultural clay contribute considerably to the air pollutions in the world. Therefore, an urgent need to start using an environment-friendly alternative material/approach to save the fertile topsoil and conserve a clean environment. This research is aimed to produce non-fired bricks incorporating industrial solid waste from steel and power plants, including Fly ash and Ladle Furnace Slag (LFS), as a partial replacement of CEM I and lime. Induction Furnace Slag (IFS) is used as a partial/full replacement of natural fine aggregate (local sand) in the laboratory scale manufacturing process. The prepared building blocks conform to the minimum compressive strength requirement of 10.3 MPa per ASTM C62 and BDS 208 while the maximum compressive strength was 40.6 MPa. This highly promising performance pronounced the use of industrial waste materials in non-fired brick production to achieve a cleaner environment for a sustainable society. ournal of Engineering Science 12(3), 2021, 1-10

Development and Application of a High-Volume Recycled Powder Solidifying Material for Waterworks Sludge

Recycled powder (RP) is produced as a by-product during the process of recycling construction and demolition (C&D) wastes, presenting a low additional value. Using RP-based solidifying material can not only improve its utilization efficiency, but also reduce the cost of commercial solidifying materials. To date, this is the best solidifying material utilized to dispose the original waterworks sludge (OWS) with high moisture contents (60%), and the product could be used to fabricate non-fired bricks. This has become a new environment-friendly technology of “using waste to treat waste”. In this paper, the influence of different particle sizes and dosages of RP on the prepared solidifying material was studied. Besides, unconfined compression strength (UCS), volume stability, chemical composition, and heat of hydration, pore structure of the solidifying material were characterized. Then, non-fired bricks were prepared by using the solidifying material, recycled aggregate, and original waterworks sludge. The UCS and softing coefficient (SC) of the non-fired bricks were evaluated. As a result, the 28-day UCS of the solidifying material with optimal (M30) was 35.40 MPa, which could reach 84.37% of Portland cement (PC). The addition of RP increased the volume stability of the solidifying material. The addition of a large amount of RP reduced the heat flux and cumulative heat release of the solidifying material, while its porosity increased. The UCS of non-fired brick (NF20) in 28 days was 15.19 MPa and the SC after 28 days was 78.35%. In conclusion, the preparation of solidifying material using RP could be a promising approach and has a great potential in disposal of original waterworks sludge.

Environmental impact and optimization of lake dredged-sludge treatment and disposal technologies based on life cycle assessment (LCA) analysis

Baiyangdian Lake is the most important natural water body in North China and is having a dredging project to remediate serious endogenous pollution from sediments. How to reduce the secondary environmental impact in the process of dredged-sludge treatment and disposal is of great significance. Four typical dredged-sludge treatment technologies were evaluated based on comprehensive life cycle environmental and economic analysis in this paper, and recommendations are put forward to selecting suitable treatment technology for dredged-sludge with heterogeneous pollution. The LCA results indicated that land use process is a preferable approach for less polluted dredged-sludge due to simple steps and low cost. However, the environmental burden derived from land use will obviously increase with the extent of the dredged-sludge pollution, especially depends on the content of heavy metals. Comparatively, organochlorine pesticides in dredged-sludge generate a negligible environmental impact because of their trace concentration. Besides, the manufacture of non-fired brick or water storage clay is an effective treatment technology for dredged-sludge with high pollution to reduce toxic environmental impacts owing to the immobilization and stabilization of heavy metals, although it has high economic costs and consumes a large amount of energy and materials. Moreover, it is worth noting that polyacrylamide may be not an excellent conditioner for dredged-sludge dewatering because of the apparent contribution to human toxicity and freshwater aquatic ecotoxicity impact. Overall, this study highlighted and concluded how to select and optimize the adoption of suitable technologies to reduce environmental risks generated from the treatment and disposal of dredged-sludge.

Environmentally clean materials from contaminated marine dredged sludge, wood ashes and lime production wastes

The aim of this study was to develop environment-friendly composites from dredged sediments (DS) from the seaport of Paranaguá, Brazil (30–70 wt %), wood ashes (WA) (5–40%), and lime production wastes (LPW) (15–30%). The materials' characterization was carried out by axial compressive and water resistance, water absorption, bulk density, XRD, MEV, EDS mapping, LAMMA, and AAS. The samples' axial resistance reached 2.39 MPa on the 3rd day, and 8.77 MPa on the 180th day. The water absorption values ranged from 9.5% to 17.2% on the 28th day and from 8.1% to 14.6% on the 90th day. All these changes took place due to the synthesis of amorphous materials, mainly carbonates. The developed composites can be used as road base materials, cementless concrete, non-fired brick and similar sustainable construction materials. The widespread DS use by this ecologically clean method can significantly improve oceans and industrial regions’ environmental situation and decrease natural resource consumption for civil construction.

A study on the oil-based drilling cutting pyrolysis residue resource utilization by the exploration and development of shale gas.

Based on the requirement of national energy conservation and environmental protection, attention has been given to building an environment-friendly and resource-saving society. Shale gas oil-based drilling cutting pyrolysis residues (ODPRs) have been used as the main research object to developing new technology which can convert the residues into a harmless and recyclable material. Using the test data of ODPR, we analyze the development prospect in the building material industry and provide a scheme to utilize this particular solid-waste efficiently. Theoretically speaking, the ODPR resource utilization such as admixture of cement, making sintered brick, and non-fired brick, by the exploration and development of Fuling shale gas is feasible.

Investigation of Agro-concrete using by-products of Rice Husk in Mekong Delta of Vietnam

Agro-concrete concept seems to create interesting links between agriculture sector and building industry. Over the last years, researcher around the world have reported their investigation on such material made out of different type of agricultural by-products mixed with lime-based binder. Based on the locally use natural aggregate and good thermo-physical properties, they are considered as as eco-material for more comfortable low carbon building. Indeed, energy efficiency or thermal conform are improved from optimization of building envelopes. In this paper, we focus on producing concrete block under mechanical compaction method from two types of rice husk (natural and reusing) mixing with binder (hydrate lime and metakaolin). Physio-mechanical properties of concrete block were characterized at appropriate period of curing condition in dry air. Empirical results show that both compressive strength and splitting strength of concrete block evolve over time due to pozzolanic reactivity and natural carbonation reaction. Low thermal conductivity 0.27 W/mK with normal density 880 kg/m3 in mixed formulation deal with the purpose of using in thermal and acoustic insulating solution. In the current context of rural development in the delta region, the objective of using rice husk concrete for non-load bearing wall building as filling material or non-fired brick would be discussed.

High-Strength, Cement-Free Concrete of Flue Gas Desulfurization Gypsum-Based Non-Fired Brick

High-Strength, Cement-Free Concrete of Flue Gas Desulfurization Gypsum-Based Non-Fired Brick

Study on the Preparation of Non-Fired Bricks by Solidified Dredged Soil

A non-fired brick were manufactured by solidification of modified dredged soils. A novel solidified agent based on industrial wastes was prepared. A typical manufacture process of the non-fired brick comprised of mixing, stirring, tamping and maintaining. Several tests and measurements were conducted according to Chinese Professional Standard and National Standard. The results showed that the non-fired brick exhibited excellent performances and low toxicity. The non-fired brick was found to be a suitable material for use in the civil architecture.

Utilization of waste phosphogypsum to prepare non-fired bricks by a novel Hydration–Recrystallization process

Phosphogypsum is a solid waste generated in phosphoric acid production. Currently, a large number of phosphogypsum are discarded without any treatment, leading to considerable land occupation and serious environmental contamination. In this study, a novel process of preparing non-fired bricks from waste phosphogypsum, named as “the Hydration–Recrystallization process”, is proposed and tested. In this process, the press-formed green bricks are hot-dried at 180°C to dehydrate gypsum (CaSO4·2H2O) into semi-hydrated gypsum (CaSO4·0.5H2O), and then water-immersed to in situ recrystallize gypsum (CaSO4·2H2O) crystals, and finally air-dried naturally to obtain the non-fired brick products. A series of the experiments were conducted according to the novel process, and results showed that the optimal mix designation composes of 75.0% phosphogypsum, 19.5% river sand, 4.0% Portland cement and 1.5% hydrated lime, and the corresponding compressive strength, water-saturated compressive strength and bending strength of the as-prepared bricks are 21.8MPa, 13.7MPa and 5.2MPa, respectively. Microstructural characteristics of the bricks were investigated by XRD and ESEM, and the results indicated that the in situ recrystallized gypsum (CaSO4·2H2O) crystals presents regular, dense and interlock crystalline microstructure, which contributes to the high mechanical strength of the non-fired bricks prepared from the waste phosphogypsum. The industrial application of the new process can help to significantly reduce the environmental impacts of waste phosphogypsum.

Non-fired dinas brick

Non-fired dinas brick

Experiments in use of non-fired siphon brick

It is advisable to continue experiments on manufacturing and using non-fired siphon brick for steel casting1). Its moisture content after drying should not be greater than 0.5%.

Magnesite brick for open-hearth furnace regenerator checkers

Investigation and service tests showed that in gas regenerator checkers for open-hearth furnaces magnesium parts made of metallurgical powder with a small iron oxide content do not frumble and are marked by good wear resistance. The technology of making dense magnesite fired and nonfired checker brick of small dimensions has been tested at the Panteleymonovo Plant. The tests on fired and non-fired checker brick in gas regenerators in 370-ton furnaces using oxygen showed their good wear resistance, the absence of wear and tear from the second and third courses upward and the possibility of keeping them for additional runs in the basic arch.

Production and service testing of small-size fired and non-fired forsterite brick

The use of small-size fired forsterite bricks for regenerator checkers in open-hearth furnaces is tantamount to using large-size fired bricks and provides the same wear resistance, making it possible to increase the output of forsterite checker bricks and reduce the cost of production for sterite checker bricks and reduce the cost of production simultaneously.