Clay Brick Waste Research Articles

New insights into the effects of silicate modulus, alkali content and modification on multi-properties of recycled brick powder-based geopolymer

Utilizing recycled brick powder (RBP) as a green precursor to prepare alkali-activated RBP-based geopolymer (AABG) not only broadens the existing system of alkali-activated materials but also achieves the high-value and low-carbon utilization of clay brick waste. This paper aims to systematically investigate the influence of silicate modulus and alkali content of the alkali-activator on the multi-properties of AABG, while proposing multi-path modification methods to optimize AABG performance. Substituting an appropriate amount of metakaolin with RBP contributes to optimizing the performance of metakaolin-based geopolymers. However, the micro-macro properties of AABG are significantly inferior to those of metakaolin-based geopolymer. Under the same silicate modulus, the micro-macro properties of AABG first improve and then deteriorate with the increase in alkali content. With the alkali content of 8 %, the AABG owns the best microstructure and macro properties. When the alkali content remains constant, an appropriate increase in the silicate modulus of alkali-activator contributes to the performance enhancement of AABG mortar. The average pore diameter of AABG-1.2M-8%, AABG-1.4M-8%, and AABG-1.4M-4% paste is 69.4 nm, 61.8 nm and 111.9 nm. Overall, the AABG with 1.6M silicate modulus and 8 % alkali content shows good performance. For the multi-path modification methods of AABG, decreasing the w/b ratio of AABG can enhance its compressive strength and permeability resistance. Besides, increasing the curing temperature of AABG can optimize its micro-pore structure and macro-properties, achieving optimal performance at a curing temperature of 80 °C. Finally, mixing Ca(OH)2 into AABG promotes the formation of more C-A-S-H, thereby further enhancing the AABG performance. Optimizing the silicate modulus, alkaline content and modification methods, it is feasible to produce AABG with superior micro-macro properties.

Performance and Life Cycle Cost Analysis of Recycled Concrete Utilising Waste Clay Brick

Performance and Life Cycle Cost Analysis of Recycled Concrete Utilising Waste Clay Brick

Early-age structural build-up and rheological assessment of alkali-activated slag-red clay brick waste pastes: Influence of silica modulus and precursors proportions

Sustainability plays a crucial role in the current context of the cement industry, and alkali-activated materials (AAMs) are emerging as eco-efficient alternative binders. On the other hand, the massive generation of red brick waste worldwide and its lack of a defined destination emphasizes this material as an alternative precursor that has been insufficiently explored in the literature. Based on this context, the present study aims to investigate the structural build-up, reaction kinetics, and rheological properties of alkali-activated pastes based on blast furnace slag (BFS) and red clay brick waste (RBCW). Fresh properties such as structural build-up, rheology, and reaction kinetics are lacking in the literature on RCBW-based AAMs, highlighting these properties as a research gap to be filled and discussed in depth in this paper. The flow sweep test was performed, linked to yield stress and viscosity properties. The structural build-up was evaluated by strain sweep and small amplitude oscillatory shear (SAOS) tests based on viscoelastic parameters: storage modulus, loss modulus, and phase angle. Isothermal calorimetry and in-situ FTIR were also conducted to complement the analysis and provide insight into the reaction kinetics, chemical structure, and product formation. Higher silica modulus (Ms) resulted in a lower structural build-up rate and a delayed reaction. Higher content of RCBW resulted in a delayed structuration process, which was linked to a delay in the precipitation of aluminosilicate gels. Early increase in the structural build-up in 25 % and 50 % RCBW blends (Ms = 1.0) is associated with the early formation of a well-percolated network.

Preparation and properties of alkali-activated fly ash-waste brick porous building materials

This study explores the development of sustainable porous building materials through the alkali-activation of fly ash and waste clay brick powder. Utilizing Class F fly ash and brick powder from demolished buildings, a series of alkali-activated mortars with varying brick powder replacements (0 % to 50 % by mass) were formulated and analyzed. The results reveal that a 10 % brick powder replacement optimizes the compressive strength, reaching 73 MPa at 28 days, attributed to enhanced nucleation and calcium-rich gel formation. However, higher brick content reduces strength due to the dilution of key reactive materials, with a 50 % replacement leading to a strength of 27 MPa. Porosity increases proportionally with brick content, achieving a maximum of 42 % at 50 % replacement, suggesting potential applications in insulation-centric scenarios. Microstructural analysis confirms the formation of a porous network and identifies the phase compositions and reaction products. This research demonstrates the potential of repurposing construction waste into efficient and environmentally friendly building materials, contributing to waste reduction and offering a greener alternative to traditional practices.

Exploring the Potential of Using Waste Clay Brick Powder in Geopolymer Applications: A Comprehensive Review

Exploring the Potential of Using Waste Clay Brick Powder in Geopolymer Applications: A Comprehensive Review

Using construction and demolition waste materials to alleviate the negative effect of pavements on the urban heat island: A laboratory, field, and numerical study

In this study, construction and demolition waste (CDW) materials, including waste clay bricks, concrete, and glass, were used as aggregates of chip seal layers to enhance the reflectivity and reduce the temperature of asphalt pavements as an urban heat island (UHI) mitigation policy. UHI is an urban area that has a higher temperature in comparison to its suburbs. As considerable parts of cities are covered with asphalt pavements, their heat absorption and heat release can directly affect the UHI. Four types of chip seal layers, containing CDW aggregates were prepared in this study. The reflectivity and cooling effects of asphalt pavement coated with the developed chip seals were then evaluated with laboratory, field experiments, and computational fluid dynamics (CFD) simulation. Regarding the laboratory methods, UV-Visible-NIR spectrometer reflectance, a trident thermal properties measurement, and solar simulation cooling effect were used. Besides, the albedo and cooling effects of the developed chip seals were evaluated with a pyranometer and thermocouples through a field experiment. The indoor reflectance test showed yellow and red brick chip seals reflected almost 136 % higher than the aged asphalt pavement, followed by concrete chip seals with 80 % higher solar reflectance. Besides, the surface temperatures of yellow brick, red brick, and concrete chip seals were 23 %, 18 %, and 15 % cooler than the hot mix asphalt (HMA) specimens. More importantly, clay brick chip seals had the lowest nighttime heat release, followed by the concrete chip seal. The field test indicated that the albedo of yellow brick was 2 and 6 times higher than the aged and new HMA, causing 17 % and 27 % lower surface temperatures. The numerical models also revealed that using the yellow brick and concrete chip seals decreased the surrounding air temperature at least by 18 % and 14 % respectively. Overall, the numerical modeling, laboratory, and field tests showed similar results, indicating the benefits of using clay bricks and concrete aggregates for chip seal development, which can mitigate the UHI effectively.

Formulation of geopolymer binder based on volcanic-scoria and clay brick wastes using rice husk ash-NaOH activator: Fresh and hardened properties

The present study investigated the influence of the replacement of waste clay bricks (WB) by volcanic scoria (Zg) on the fresh and hardened properties of geopolymer binders for potential construction applications at ambient temperature. Geopolymer paste samples were prepared using Zg as raw material blended with WB ranging from 0 to 50 wt% of total raw materials. Alternative alkaline activator used for the geopolymer synthesis was prepared by mixing rice husk ash (RHA) and 6 mol/L of NaOH solution. The geopolymers were cured at room temperature for 28 days, then subjected to mechanical property tests; microstructural and macrostructural characterization studies. Results showed that both flowability and setting time of geopolymer mixtures decreased with increases in WB content. The reduction in workability could be attributed to increase in the relatively rough surface of WB particles, which resulted in inter-particle friction. Flexural strength increased from 4 to 12 MPa while the compressive strength 24–52 MPa with the increase in WB up to 50%. The WB powders enriched Al content in mixtures, establishing the Si-O-Al bonds, confirmed by 27Al MAS NMR spectroscopy exhibiting the more Al(IV) sites integrating the N-A-S-H network. Incorporating the WB powders contributed to the development of densified matrix.

Effect of waste clay brick powder on microstructure and properties in blended oil well cement pastes at HTHP conditions

The use of waste materials to improve the thermal stability of oil well cement (OWC) at high temperature and high pressure (HTHP) conditions has received increasing attention. This study investigated the performance of sustainable blended OWC pastes by recycling waste clay brick powder (CBP) as a partial substitute for commercial high temperature resistant additives (silica flour, SF). The main objective was to assess the impact of these substitutions on the hydration, microstructure and mechanical properties of blended OWC. CBP was incorporated at substitution rates of 25 wt%, 50 wt%, 75 wt% and 100 wt% by weight of SF. These pastes were firstly precured at 50 °C for 7 days (to simulate the primary cementing operation prior to steam injection), and then thermally cycling cured at 300 °C/13.0 MPa (to simulate the steam injection process). The study conducted comprehensive tests and analyses, including compressive strength, gas permeability, hydration products and microstructural analyses. The results showed that the suitable substitution rate of CBP in this study was 25 wt%-50 wt%. At these substitution levels, the blended OWC pastes had good compressive strength (18.5 MPa and 17.9 MPa) and low gas permeability (3.1 × 10−3 mD and 4.51 × 10−3 mD). From the environmental and economic analyses, the energy intensity and CO2 emissions of all blended OWCs were significantly lower compared to those of conventional OWC. Meanwhile, the cost of blended OWC in this study was significantly lower compared to that of the commercial SF-OWC system. Overall, this study highlighted the potential of recycling waste materials to promote raw material sustainability and improve the performance of OWC pastes at HTHP conditions.

Preparation and Performance of Ceramic Tiles with Steel Slag and Waste Clay Bricks.

Steel slag and waste clay bricks are two prevalent solid waste materials generated during industrial production. The complex chemical compositions of these materials present challenges to their utilization in conventional alumina silicate ceramics manufacturing. A new type of ceramic tile, which utilizes steel slag and waste clay brick as raw materials, has been successfully developed in order to effectively utilize these solid wastes. The optimal composition of the ceramic material was determined through orthogonal experimentation, during which the effects of the sample molding pressure, the soaking time, and the sintering temperature on the ceramic properties were studied. The results show that the optimal ceramic tile formula was 45% steel slag, 35% waste clay bricks, and 25% talc. The optimal process parameters for this composition included a molding pressure of 25 MPa, a sintering temperature of 1190 °C, and a soaking time of 60 min. The prepared ceramic tile samples had compositions in which solid waste accounted for more than 76% of the total material. Additionally, they possessed a modulus of rupture of more than 73.2 MPa and a corresponding water absorption rate of less than 0.05%.

Incorporation of clay brick wastes and calcium hydroxide into geopolymers: Compressive strength, microstructure, and efflorescence

This study aimed to evaluate the incorporation of clay brick waste (CBW) into geopolymers for the production of sustainable building materials. Eight mixtures were prepared with and without the incorporation of calcium hydroxide (CH) and with 0 %, 25 %, 50 %, and 75 % of the mass of metakaolin (MK) replaced by CBW. Physical-mechanical tests evaluated the macrostructural properties and scanning electron microscopy, energy dispersive X-ray spectroscopy, and X-ray diffraction analyses evaluated the microstructure. The results showed that the incorporation of CH significantly improved the physic-mechanical properties of the produced geopolymers due to the formation of C-A-S-H gel in the geopolymer matrix. Thus, CH produced an increase in compressive strength of 357.8 %, 157.6 %, and 95.2 % at 7, 28, and 91 days in the mixture with high CBW content. SEM/EDS analysis showed that Fe3+ partially replaced Al3+ in the geopolymer matrix with the incorporation of CBW. In addition, the partial replacement of Al3+ by Fe3+ from CBW in the N-A-S-H gel contributed to the mitigation of efflorescence with increasing CBW content. Therefore, the results showed that CH contributes to the production of CBW-based geopolymers with satisfactory compressive strength for use as construction materials.

Influence of Solid Waste Material Content on the Properties of Steel Slag-Waste Clay Brick Ceramic Bricks

Steel slag and waste clay brick are two common solid wastes in industrial production, and their complex chemical compositions pose challenges to the production of traditional alumina silicate ceramics. To investigate the influence of steel slag and waste clay brick on the performance of CaO–SiO2–MgO ceramic materials, this study examined their effects on the mechanical properties, crystal composition, and microstructure of the ceramics through single-factor experiments. The results demonstrate that when keeping the dosage of waste clay brick and talcum powder constant, a 43% dosage of steel slag yields optimal performance for the ceramic materials with a modulus of rupture of 73.01 MPa and a water absorption rate as low as 0.037%. Similarly, when maintaining a constant dosage of steel slag and talcum powder, a 41% dosage of waste clay brick leads to superior performance of the ceramic materials, with a modulus of rupture reaching 82.17 MPa and a water absorption rate only at 0.071%. Furthermore, when keeping the dosage of steel slag and waste clay brick constant, employing a talcum powder dosage of 24% results in excellent performance for the ceramic materials with a modulus of rupture measuring 73.01 MPa while maintaining an extremely low water absorption rate at only 0.037%. It is noteworthy that steel slag contributes to akermanite phase formation while talcum powder and waste clay brick contribute to diopside phase formation.

Reusing waste clay brick powder for low-carbon cement concrete and alkali-activated concrete: A critical review

The utilization of the waste clay brick powder (CBP) as an alternative binder in cementitious materials is an effective approach to recycling clay brick waste. Many research articles have been published on concrete containing CBP, but a systematic review on the performance of CBP and its blended concrete has been lacking until now. Therefore, the purpose of this article is to provide a comprehensive review of the utilization of CBP for low-carbon cement concrete and alkali-activated concrete, offering readers an effective pathway to understand its performance. This review article provides a detailed introduction on the preparation technology of CBP, as well as the micro-macro properties of cement concrete and alkali-activated concrete incorporating CBP. The results showed that CBP with irregular micro-structure is rich in silicon, aluminum, and oxygen elements, and exhibits good pozzolanic activity and micro-aggregate filling effect. Optimizing CBP particle size, replacement rate and curing condition can prepare the cement concrete with good micro-macro properties. Besides, there is an optimal CBP replacement rate, alkali concentration, Na/Si and Si/Al molar ratios for the alkali-activated concrete containing CBP. The mix of CBP in concrete obviously reduces the CO2 emission and energy consumption, showing an excellent environmental benefit. The mechanical activation treatment, active admixture and nano-particle modification can improve the properties of CBP blended concrete. In the future, CBP can be widely used in 3D printed concrete, high performance and ultra-high-performance concrete, lightweight concrete, fully recycled concrete and CO2 sequestration concrete.

Evaluating Techno-Eco-Efficiency of Waste Clay Brick Powder (WCBP) in Geopolymer Binders

The global focus on geopolymer binder production has increased due to the adoption of waste materials and industrial byproducts. Given the gradual decline in the availability of fly ash and ground granular blast furnace slag (GGBFS) resulting from the decarbonization process in electricity and steel production, waste clay brick powder (WCBP) could be a viable substitute for these pozzolanic by-products. This study presents the economic and environmental benefits of the use of WCBP as a replacement for conventional pozzolanic by-products in geopolymer binder production by assessing its techno-eco-efficiency, environmental impact, and cost-effectiveness performances. The favorable mechanical characteristics exhibited by the fly ash–GGBFS–WCBP-based geopolymer binder emphasize the importance of assessing its sustainability alongside its technical viability. The study employed life cycle analysis (LCA), following ISO framework, and using the Simapro software 9.2, to evaluate the environmental implications of the use of WCBP-based geopolymer mixtures. Human toxicity emerged as the primary impact. Moreover, the analysis of life cycle costs highlighted key financial factors, with around 65–70% attributed to alkaline activators of the total cost. The production of alkaline activators was identified as a critical point for both environmental impact and economic considerations due to energy consumption. While WCBP-rich samples exhibit a 1.7–0.7% higher environmental impact compared to the control mix (CM), their high mechanical strength and cost-effectiveness make them technologically and economically efficient geopolymer mixes. In conclusion, the portfolio analysis for techno-eco-efficiency affirms that mixes containing 40%, 30%, and 20% WCBP are more efficient than those using 10% and 0% WCBP, respectively.

Development of nano-silica modification to enhance the micro-macro properties of cement-based materials with recycled clay brick powder

Utilizing recycled clay brick powder (RCBP) as alternative binder provides an effective method for reducing the amount of the clay brick waste and the need for cement, but incorporating high volume of RCBP generally causes a reduction in the performance of cement-based materials. Considering that the nano-SiO2 (NS) is commonly used and highly efficient modification materials for cement-based materials, this paper developed the NS modification to enhance the performance of cement-based materials containing RCBP. Mixing RCBP negatively impacts the hydration reaction and hydration products, but adding NS accelerates the hydration process and the formation of hydration products in RCBP paste. Adding 0.5% and 2.0% NS causes 27.3% and 43.3% increase in the cumulative heat of 30% RCBP blended paste. The mix of NS can refine the pore structure of RCBP paste, and causes a distinct reduction in the percentage of the most harmful pore. The nanoindentation results show that adding NS can raise the elasticity modulus and indentation hardness of RCBP paste. Substituting RCBP for partial cement reduces the drying shrinkage, but mixing NS increases the drying shrinkage of RCBP paste. Incorporating RCBP leads to a decline in mechanical strength, nonetheless, the mechanical strength of RCBP paste rises with the increasing dosage of NS. Adding 2.0% NS results in 44.2% and 18.8% enhancement on the 1-d and 28-day compressive strength of 30% RCBP blended paste. By optimizing the dosage of RCBP, NS and mineral admixtures, it is possible to fabricate sustainable cement-based materials exhibiting good strength and permeability resistance.

Effect of Waste Brick Clay Powder on Self Compacted Concrete

This research investigates the effect of waste clay bricks powder in producing self-compacting concrete by partial replacement of cement. Bricks were crushed to particle sizes smaller than 75 microns. Percentages of cement of 5, 10 and 12.5 % by weight were replaced by the power at w/c ratios of 0.4, 0.425 and 0.45. Fresh concrete workability then measured and hard concrete properties were determined at 28 days. The results show that waste bricks powder can be utilized partially instead of cement to produce concrete with self leveling fresh properties and good hard properties. Consequently, this proves that waste bricks can be recycled to minimize both the effect of waste material on the environment and the heat needed for cement production.

POROUS FLY ASH-BASED GEOPOLYMER USABLE AS AN UNCONVENTIONAL CONSTRUCTION MATERIAL

Geopolymer foam with thermal insulation properties was made by foaming the alumino-silicate mixture composed of fly ash and clay brick waste activated with alkaline activator (water glass and sodium hydroxide in aqueous solution). Other mixture components were expanded perlite as siliceous additive, usual fine aggregate (quartz sand), and less frequently used surfactant (olive oil). The main characteristics of the geopolymer foam were: low density, low thermal conductivity, and relatively high compressive strength. The residual materials contributed to low costs and the complete replacement of ordinary cement led to the significant reduction of CO2 emissions.

Physical and Mechanical Properties of Fired Industrial Waste-Clay Brick from Sugarcane Bagasse

Fired industrial clay brick depletes clay soil, wastes energy and wastes money. Population growth has increased agricultural waste. Many studies have been conducted on the production of fired industrial waste clay brick from sugarcane bagasse ash. This research reviews the physical and mechanical properties of sugarcane bagasse fired industrial waste clay brick. Fired industrial waste clay brick- filled with sugarcane bagasse ash provide better mechanical and physical properties than normal fired bricks. Reduce clay soil mining, agricultural waste, and fired industrial bricks reduces energy and costs. This supports sustainable development and helps the environment (SDG).

Characterization of Waste Clay Brick Powder and its Effect on the Mechanical Properties and Microstructure of Geopolymer Mortar

Fly ash is known as a common geopolymer precursor. However, it is important to search for suitable alternatives as the availability of fly ash will reduce with the move to more renewable energies. This paper evaluates the feasibility of using waste clay brick powder (WCBP) as a partial alternative for fly ash in geopolymer mortars with ground granulated blast furnace slag (GGBFS), under ambient and heat curing conditions. The physical, mechanical, and mineralogical properties of geopolymer mortar with 10 to 40% WCBP were investigated. Microstructural properties of WCBP and geopolymer mortars were investigated using X-ray fluorescence (XRF), X-ray diffraction (XRD), tescan integrated mineral analyzer (TIMA), scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS). Reductions of the flow of fresh mortar were observed with the increase of WCBP. The highest 28 days compressive strengths were obtained in the mortars containing 40% WCBP, both at ambient and heat curing conditions. Microstructural analysis highlighted compact structure and reduced porosity, which are attributed to the role of WCBP in enhancing fly ash-GGBFS mortar properties by promoting geopolymer gel formation.

Optimization of the Impact of Dune Sand, Recycled Rubber Aggregates, and Clay Brick Waste on Eco-Mortar Mechanical Strength by the Taguchi Method

Utilizing local materials and recycling waste has the potential to yield both ecological and economic advantages in the field of construction materials. In this context, the object of this work is to apply Taguchi's design of experiments on cement eco-mortar, which were designed using an L-9 orthogonal array, to optimize and model the effect of dune sand of the El Oued region, rubber aggregates, and crushed clay brick waste on the mechanical strength at 28 days. The different interactions were also investigated between the factors targeted in our study, namely: dune sand (DS) content, rubber aggregates (RA) content, and brick waste (BW) content. The results of the analysis of variation (ANOVA) as well as the mathematical models developed in this study showed that the BW factor content has a positive effect on compressive strength and a negative effect on flexural strength. In addition, the interactions between DS and BW contents and between RA and BW contents have a negative effect on the compressive strength of eco-mortar. With regard to flexural strength, the results showed that the interaction between the factors DS and RA contents has a negative effect on flexural strength, in contrast to the interaction between the RA and BW contents, which has a positive effect.

Investigating the Ability of producing Sustainable Blocks using Recycled Waste

The primary objective of this study is to manage price market items in the construction of walls for affordable structures with load-bearing hollow masonry units using the ACI 211.1 blend design with a slump range of 25-50 mm that follows the specification limits of IQS 1077. It was difficult to reach a suitable cement weight to minimum content (economic and environmental goal), so many trail mixtures were cast. A portion (10-20%) of the coarse aggregates was replaced with concrete, tile, and clay-brick waste. Finally, two curing methods were used: immersion under water as normal curing, and water spraying as it is closer to the field conditions. The recommendation in IQS 1077 to increase the curing period from 14 to 28 days was taken into account. The results proved that the compressive strength of the blocks of cured immersion under water increased by 2.63%-0.63% and 5.12%-7.88% for 10% and 20% concrete waste aggregates, decreased by 0,3.84% and 4.22%,6.41% for 10% and 20% tile waste aggregates, and decrease by 5.71%-6.10% and 12.1%-11.4% for 10% and 20% brick waste aggregates, respectively at 14 and 28 days, and beams that were cured by spraying performed a little worse than those immersed under water.