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Sustainable Interlocking Ash Bricks with Green Waste Lime - Ceramic Fines: Improving Performance and Longevity

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초록

This study presents a comprehensive investigation into the feasibility of incorporating Ceramic Fines (CF), a calcium-richindustrial byproduct from the cement manufacturing process, as a partial replacement for Ordinary Portland Cement (OPC)in the production of fly ash-based interlocking bricks. CF was substituted at incremental levels ranging from 0% to 20%,and its influence on the physical, mechanical, and durability properties of the bricks was systematically evaluated. Theresults indicate that 10% replacement of OPC with CF yields optimal performance, achieving a peak 28-day compressivestrength of 11.72 MPa. A substantial reduction in bulk density, upto 13.36%, was observed with increasing CF content,indicating the potential for lightweight applications. Water absorption exhibited a strong inverse correlation with weightdensity and a decrease in the initial rate of absorption further confirmed the refinement of pore structure. Durability studiesunder prolonged seawater and sodium chloride immersion demonstrated superior chemical resistance, with minimal weightgain and strength degradation in CF specimens.XRD Analysis revealed dominant hexagonal crystalline phases, contributingto enhanced matrix stability and reduced ion permeability. The findings substantiate the viability of Ceramic Fines as asustainable supplementary cementations material, promoting circular economy principles while enhancing the performanceand durability of interlocking masonry units.

Abstract

This study presents a comprehensive investigation into the feasibility of incorporating Ceramic Fines (CF), a calcium-richindustrial byproduct from the cement manufacturing process, as a partial replacement for Ordinary Portland Cement (OPC)in the production of fly ash-based interlocking bricks. CF was substituted at incremental levels ranging from 0% to 20%,and its influence on the physical, mechanical, and durability properties of the bricks was systematically evaluated. Theresults indicate that 10% replacement of OPC with CF yields optimal performance, achieving a peak 28-day compressivestrength of 11.72 MPa. A substantial reduction in bulk density, upto 13.36%, was observed with increasing CF content,indicating the potential for lightweight applications. Water absorption exhibited a strong inverse correlation with weightdensity and a decrease in the initial rate of absorption further confirmed the refinement of pore structure. Durability studiesunder prolonged seawater and sodium chloride immersion demonstrated superior chemical resistance, with minimal weightgain and strength degradation in CF specimens.XRD Analysis revealed dominant hexagonal crystalline phases, contributingto enhanced matrix stability and reduced ion permeability. The findings substantiate the viability of Ceramic Fines as asustainable supplementary cementations material, promoting circular economy principles while enhancing the performanceand durability of interlocking masonry units.

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