Physical, Mechanical and Environmental Assessment of Fly Ash Bricks Manufactured from Dhanbad, Jharkhand

Physical, Mechanical and Environmental Assessment of Fly Ash Bricks Manufactured from Dhanbad, Jharkhand

Vivek Raj

B.Tech, Sitamarhi Institute of Technology, Sitamarhi, Bihar.

Abstract: Dhanbad Coalfield region is one of the major coal-producing areas of India, where large quantities of fly ash are generated from coal washeries and thermal power plants. Fly ash is an important raw material for brick manufacturing due to its availability, fine particle size, and pozzolanic properties. In the Dhanbad region, fly ash is easily available in bulk quantity, which reduces transportation cost and supports sustainable construction practices.

The quality and density of fly ash produced in this region are comparatively better due to the high-grade coal used in washeries and thermal power plants. This makes it suitable for manufacturing high-quality bricks used in building and construction works. Utilization of fly ash in brick production not only improves compressive strength and durability but also reduces the use of natural clay, thereby minimizing environmental degradation.

Key words: Coal washeries, Portland Cement, fly ash, environmental.

INTRODUCTION:

This study focuses on analyzing the physical properties, density, and strength characteristics of fly ash-based bricks produced using materials from the Dhanbad coalfield area. The research also evaluates cost effectiveness and environmental benefits compared to conventional clay bricks. The results are expected to demonstrate that fly ash bricks made from Dhanbad coalfield ash are economical, durable, and environmentally sustainable, making them a suitable alternative for modern construction.

Materials and Methods

The following materials were used for manufacturing fly ash bricks:

Fly Ash

Fly ash was collected from coal washeries and nearby thermal power plants in the Dhanbad coalfield region. The ash is fine, grey in color, and possesses good pozzolanic properties. It was used as the primary raw material for brick production.

Cement

Ordinary Portland Cement (OPC 43 grade) was used as a binding material to improve strength and durability.

Sand / Stone Dust

Locally available river sand or stone dust was used as filler material to enhance density and reduce shrinkage.

Water

Clean potable water was used for mixing and curing purposes.

Testing Methods and Brick Quality Analysis Method Compressive Strength Test

• Conducted using Compression Testing Machine (CTM) as per IS 3495 (Part 1).

• Brick placed flat between plates.

• Load applied gradually until failure.

• Record maximum load.

  Compressive Strength=Maximum Load Loaded Area Compressive\ Strength = \frac {Maximum\ Load} {Loaded\ Area} Compressive Strength=Loaded Area Maximum Load

  Water Absorption Test Method.

• Dry brick in oven at 105°C for 24 hours.

• Record dry weight (W1).

• Immerse brick in water for 24 hours.

• Record wet weight (W2).

  Water Absorption (%) =W2W1W1×100Water\ Absorption (\%) = \frac {W2 – W1} {W1} \times 100Water Absorption (%)

  =W1W2W1×100

  Bulk Density Test Method:

• Measure dimensions of brick.

• Calculate volume.

• Weigh the brick.

Density=Mass Volume Density = \frac {Mass}{Volume}Density=Volume Mass.

Table 01. Bulk Density Test

Brick Quality Analysis.

Table 02 Brick Quality Analysis.

Data Analysis

The efflorescence test shows slight salt deposits, which are within permissible limits according to IS standards. Slight efflorescence does not significantly affect strength or durability and is considered acceptable for construction purposes.

Overall Data Interpretation

All tested parameters satisfy IS code requirements. The compressive strength is higher than the minimum limit, water absorption is well below the maximum allowable value, density is within the ideal range, and efflorescence is acceptable.

Therefore, the fly ash bricks produced using Dhanbad coalfield ash demonstrate good mechanical properties, durability, and structural stability. These bricks are suitable for high-quality civil construction work and can be considered a cost-effective and sustainable alternative to conventional clay bricks.

Finding Research Result and benefit.

The experimental results of compressive strength, water absorption, bulk density, and efflorescence tests confirm that bricks produced using Dhanbad fly ash meet and exceed IS standard requirements. The higher strength and lower water absorption indicate improved durability and structural stability, making these bricks suitable for civil construction wrks, including residential and commercial buildings.

Additionally, the easy availability of fly ash in the Dhanbad coalfield area reduces transportation costs and overall production expenses. This results in lower market price of fly ash bricks compared to conventional clay bricks. The use of fly ash also reduces environmental pollution, minimizes topsoil consumption, and supports sustainable construction practices.

Therefore, Dhanbad coalfield fly ash can be effectively utilized as a low-cost, high-quality, and environmentally beneficial material for brick manufacturing and civil construction work.

Analysis of Table 01

Table 01 presents the experimental test results of fly ash bricks manufactured using Dhanbad coalfield fly ash. The compressive strength of 8.5 MPa exceeds the minimum IS requirement of 7.5 MPa, indicating good load-bearing capacity. Water absorption is recorded at 14%, which is significantly lower than the maximum permissible limit of 20%, showing better durability and lower porosity. The bulk density of 1750 kg/m³ lies within the recommended range, confirming proper compaction and structural stability. Slight efflorescence is observed, which is within acceptable limits.

Overall, the bricks meet IS standards and are suitable for civil construction applications.

Analysis of Table 02

Table 02 provides a comparative evaluation between observed values and IS standards. The compressive strength exceeds the required limit by 1.0 MPa, confirming structural suitability. Water absorption is 6% lower than the maximum limit, indicating improved resistance to moisture penetration. Bulk density falls within the standard range, ensuring good internal bonding and compactness. Efflorescence is within permissible limits and does not affect performance significantly.

DISCUSSION

Research Result (Based on Table 01 and Table 02)

The experimental investigation carried out on fly ash bricks manufactured using Dhanbad coalfield fly ash shows that all tested parameters satisfy the requirements of IS standards.

From Table 01, it is observed that:

1. The compressive strength of 8.5 MPa is higher than the minimum required 7.5 MPa, confirming good load-bearing capacity.

2. Water absorption is 14%, which is significantly lower than the permissible limit of 20%, indicating low porosity and enhanced durability.

3. Bulk density of 1750 kg/m³ lies within the standard range of 16001900 kg/m³, showing proper compaction and structural stability.

4. Efflorescence is slight and within acceptable limits. From Table 02, it is observed that:

He comparative analysis further confirms that:

1. Compressive strength exceeds the required standard by 1.0 MPa.

2. Water absorption is 6% lower than the maximum allowable value.

3. Density remains within the ideal construction range.

4. Surface quality is acceptable with no significant salt deposition.

Duration of study: This research work was carried out by the author in the Dhanbad Coalfield region during the period from 01 MAR 2024 to 01 SEP 2024. The study included material testing, brick manufacturing, and comparative data analysis as per IS standards.

CONCLUSION:

The fly ash bricks produced using Dhanbad coalfield ash demonstrate:

Higher compressive strength than IS minimum requirement Lower water absorption indicating better durability Adequate density ensuring structural stability

Acceptable efflorescence level

Therefore, it can be concluded that Dhanbad coalfield fly ash is a high-quality raw material suitable for manufacturing durable, cost- effective, and environmentally sustainable bricks for civil construction work. These bricks can be effectively used in residential, commercial, and infrastructure projects.

ACKNOWLEDGEMENT:

The authors sincerely acknowledge RTBT Infrastructure Developer Pvt. Ltd., Ranchi (www.rtbtltd.com; support@rtbtltd.com) and Shree Fly Ash Industries, Govind, Dhanbad, for their valuable technical support and cooperation during this research study.

REFERENCES

1. IS 3495 (Part 1 to 4): 1992. Methods of Tests on Burnt Clay Building Bricks. Bureau of Indian Standards (BIS), New Delhi.

2. IS 12894: 2002. Fly Ash Lime Bricks Specification. Bureau of Indian Standards (BIS), New Delhi.

3. IS 3812 (Part 1): 2013. Pulverized Fuel Ash Specification for Use as Pozzolana in Cement, Cement Mortar and Concrete. Bureau of Indian Standards (BIS), New Delhi.

4. ASTM C67-14. Standard Test Methods for Sampling and Testing Brick and Structural Clay Tile.

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