STUDY ON
THE
EFFECTS OF CALCIUM
CARBONATE
ON
THE MECHANICAL PROPERTIES OF POROUS
CLAY
BRICK
Houghton Anak Eddie
QE
Bachelor of Engineering with Honours471
(Mechanical and Manufacturing Engineering) H838
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B. SUPERVISOR'S APPROVAL (To be completed by supervisor)
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Study on the Effects of Calcium Carbonate on
the Mechanical Properties of Porous Clay Brick
By
Houghton Anak Eddie
project is submitted (0 tbe
Faculty of L'lll~ll"C"IILllg. U niversiti Malaysia Sarawak in partial fulfilment of the requirements for the degree for
Bachelor of Engineering with Honours (Mechanical and Manllflcillring Engineering) 2010
PUSUI K.;liJJu~1I ~.talc.iuHlal .\kade.mk
UN1 VEk,Sfft '''II>L.A\.)~ ~,wfu
BORANG PENGESAHAN STATUS TESIS
Judul: S(ud~ on the Effects ofCaJciurTl Carbonate On the Mechanical Pro~rties of Porous Clay Brick
SESI PENGAJIAN: 200912010
Saya HOUGHTON ANAK EDDIE
(HURUF BESAR)
mengaku membenarkan tesis *" ini disimpan di Pusat Khidmat Maklurnat. Akademik, UniversiLi Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
I. Tesis 1:Idalah hakmilik Universiti Malaysia Sarawak.
2. Pusat Khidmat Maklurnal Akademik, Universitj Malaysia Sarawak dibenarkan membuat salinall untuk
1ujuan pengajian sahaja.
3. Membual pendigilan untuk membangunkan Pangkalan Data Kandungan Ternpalan.
4. Pusal Khidmal Maklumal Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan Lesis ini
sebagai bahan penukaran antara institusi pengajian tinggi.
5. H Sila landakan ( ~ ) di kotak yang berkenaan
D
SULIT (Mengandungi mak lumal yang berdmjah keselamalan atau kepenlinganMalaysia seperti yang lermaJoub di dalam AKTA RAHSIA RASMI 1972).
D
TERHAD (Mengandungi maklumal TERHAD yang telah ditentukan oleh organisasilbadan di mana penyelidikan dijalankan).
8
TIDAK TERHAD Disahkan oleh.
(
~
,
(TAI\~A)
~yANGAN PENULIS) Alamal lelap:Quarters Majlis Daerah Serian, Miss Sili Nor Ain
94700 Serian. Nama Penyelia SARAWAK
q
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0tfVc)
'JV)O
:(
(/
Tarikh: Tarikh:CATATAN
•
Tesis dimaksudkan sebagai resis bagi Tjazah Doklor Falsafah, Saljana dan Sarjana Muda .•• lila lesis rnr SULIT alau TERHAD, sila lampirkan sural daripada pihak berkuasalorganisasi
berkenaan dengan mcnyalakan sekali sebab dall tempoh tesis ini perlu dikelaskan sehagai SULIT dan TERHAD.
APPROVAL PAGE
The following final year project:
Title : Study on the Effects of Calcium Carbonate on the Mechanical Properties of Porous Clay Brick
Writer: Houghton Anak Eddie
Matrik : 16327
is being read and approved by:
Miss Siti or Ain DATE
SUPERVISOR
DEDICATION
The
study
ofthe brick project and research is dedicated
to
the
Facul~)!ofEngineering,
Universiti
Malaysia Sarawak for belter
improvement
in physical and mechanical properties
of
the brick.
ACKNOWLEDGEMENTS
I wish to acknowledge the guidance, advice and assistance gIven by my supervisor, Miss Siti Nor Ain and to thank her for her encouragement and friendship, without which this thesis would not be possible. I also greatly thankful to her for the limitless time she spent in helping through with the writing of the thesis. Appreciation is also due to Batu Kitang Brickwork Sdn Berhad for its contribution in providing the clay and brick used in this research.
To the staff of concrete laboratory of the Civil Engineering Faculty of UNIMAS, thanks are due to the technicians, Adha, and Haji Effendi for helping me with works in the laboratory and sampling activity at the factory. Special thanks are conferred to my dear friends at the Faculty of Mechanical Engineering especially Hasmiryadie and Hafiz Aliah who had given me a lot of encouragement and motivation at the beginning of the research.
I would also like to express my gratefulness to Mr. Awangko from Faculty of Applied and Creative Arts for his assistance and my friend, Allen for his help in the Kiln Laboratory. Last but not least, I would like to thank all members of my family especially my girlfriend who had given me moral support and help needed such as helping on some computer works.
ABSTRACT
The aim of this study is to detennine the effect of adding calcium carbonate into clay brick by comparing the mechanical properties of the brick. Hand molding process was used to produce the brick samples. All samples contained 5wt% pepper
wastes in the clay brick according to weight fraction. To characterize the mechanical
properties of the brick, compressive strength test were performed using the brick
with calcium carbonate and without calcium carbonate. The compressive test was performed in accordance to MS 76: 1972. The results of sample with and without
calcium carbonate were compared to differentiate the effects of the calcium
carbonate to the mechanical properties of the brick. The resu It showed that adding
calcium carbonate to clay brick improved the compressive strength properties of the brick. The compressive strength for sample without calcium carbonate sintered at
700°C is 16.02% lower than clay brick containing 50wt% calcium carbonate. Hence, adding calcium carbonate increased the compression strength of porous clay brick.
ABSTRAK
Tujuan utama kajian ini adalah untuk mengenalpasti kesan penambahan batu kapur ke dalam bata tanah liat. Ini dapat dilakukan dengan membandingkan sifat fizikal dan mekanikal batu-bata berkenaan. Proses pembentukan bata menggunakan tangan atau secara manual digunakan dalam kajian ini. Semua sampel bata mengandungi 5% beban bah an buangan lada dengan peratusan berat yang berbeza bagi setiap sampel. Ujian tahan mampat dilakukan ke alas bala untuk mengenalpasti ciri-ciri mekanikal sampel-sampel tersebul yang tidak mengandungi dan yang mengandungi batu kapur. Ujian dilakukan berdasarkan kepada MS 76: 1972. Perbandingan terhadap keputusan ujian ke atas sampel bala yang mengandungi batu kapur dilakukan untuk mengenalpasti kesan penambahan balu kapur terhadap sifat mekanikal sampel batao Keputusan daripada ujian menunjukkan bahawa penambahan batu kapur ke dalam bata mampu memperbaiki daya tahan mampal bata-bata tersebut
secara keseluruhan. Daya lahan mampat sampel bata tanpa balu kapur yang dibakar pada suhu 700°C adalah 16.02% lebih rendah berbanding sal11pel bala yang l11engandungi 50% beban batu kapur. Jadi penal11bahan kalsiul11 karbonale l11eningkatkan daya tahan l11al11pat berliang rongga batu tanah liat.
PUSJl h.ll:1;:....J( •• I41.k..1t.UuU( ,-.i4~~UH~ UNlVERSm MALAYSIA SAllAWAK
TABLE
OF CONTENTS
CONTENTS PAGE
TITLE
CERTlFICATlO FORM OF THESIS STATUS ii
APPROVAL PAGE iii
DEDICATION iv
ACKNOWLEDGEMENT v
ABSTRACT VI
ABSTRAK VII
LIST OF FIGURES XII
LIST OF TABLES xiv
CHAPTER 1: INTRODUCTION
1.1 Background of Brick
1.2 Problem Statement 2
1.3 Objectives 3
CHAPTER 2: LITERATURE REVIEW 2. I Introduction to Brick 4 2.2 Types of Brick 5 2.2.1 Common Brick 5 2.2.2 Facing Brick 6 2.2.3 Engineering Brick 7
2.3 Brick Manufacturing Process 8
2.3.1 The Difference between the Molding 10
Process and Extrusion Process
2.4 Clay 11
2.5 Calcium Carbonate 11
2.6 Pepper Waste 13
2.7 Overview of Previous Research by 14 mixing Various Additives in Brick
2.8 Production of Porous Brick by adding I7
Pepper Waste and Calcium Carbonate into Clay Brick
2.9 Brick Properties 18 2.9.1 Brick Firing Shrinkage 18 2.9.2 Plasticity 18 2.9.3 Initial Rate of Suction 19 2.9.4 Absorption 20 2.9.5 Compressive Strength 21
CHAPTER
3: METHODOLOGY
3.1 Introduction
3.2 Material Preparation
3.2.1 Pepper Waste Fibre
3.2.2 Clay
3.2.3 Calci urn Carbonate
3.3 Fabrication of Brick 3.3. 1 Mixing Process 3.3.2 Molding Process 3.3.3 Drying Process 3.3.4 Firing Process 3.4 Sample Testing 3.4.1 Firing Shrinkage 3.4.2 Plasticity
3.4.3 Initial Rate of Suction
3.4.4 Absorption
3.4.5 Compressive Strength
CHAPTER 4: RESULTS & DISCUSSIONS
4.1 Introduction
4.2 Brick Firing Shrinkage
4.3 Plasticity
4.4 Initial Rate of Suction
23 25 25 26 26 27 28 29 30 31 33 33 34 35 36 37 38 39 41 43 x
4.5 Water Absorption 45
4.6 Compressive Strength 47
4.7 Overall Properties 49
CHAPTER 5: CONCLUSIONS & RECOMMENDATIONS
5.1 Conclusions 51
5.2 Recommendations 52
REFERENCES 53
APPENDICES 57
LIST OF FIGURES
CONTENT Figure 2.1: Figure 2.2: Figure 2.3: Figure 2.4: Figure 3.0: Figure 3.1: Figure 3.2: Figure 3.3: Figure 3.4: Common Brick Facing Brick Engineering BrickFlow Chart for the Brick Manufacturing Process
Flow Chart for the Brick Manufacturing Process
(a) Raw Pepper Waste
(b) Pepper Waste after cleaning Process (c) Grinded Pepper Waste
Clay
Calcium Carbonate Powder
Production Process of the Brick
PAGE 6 6 7 8 24 25 26 26 27 XII
29 Figure 3.5: (a) Rectangle Shape (b) Clay Mixture in Mold
(c) Hurling- down Procedure
(d) Molded Brick
Figure 3.6: Drying Process 30
Figure 3.7: (a) Kiln (b) Arrangement of Brick in Kiln 31
(c) Controller
Figure 3.8: Firing Process of the Brick 32
Figure 3.9: Measuring the Length of the Brick 33
Figure 3.10 Weighing Process of the Dried and Wet Bricks 34
Figure 3.11: 24 hours Water Absorption Process 36
Figure 3.12: Compressive Strength Test 37
Figure 4.0: Chart of Firing Shrinkage Result 39
Figure 4.1: Plasticity Chart of the Brick Specimen 41
of the Brick Specimen
43 Figure 4.2: Chart of Initial Rate of Suction
Figure 4.3:
Figure 4.4:
Figure 4.5
of the Brick Specimen
Chart Water Absorption Percentage
of the Brick Specimen
45
Compressive Strength of the Brick 47
Result of Overall Physical and
Mechanical Properties of the Brick
49
LIST OF TABLES
CONTENT
PAGETable 2.0 Average Compressive Strength and 7
Water Absorption of Engineering Brick
Table 3.0 Composition of Clay, Calcium Carbonate and 28
Pepper Waste Powder
CHAPTER!
INTRODUCTION
1.1 Background of Bricks
Nowadays, scientist, engineers and material scientists are striving to produce green
technology product either by improving the existing materials or producing new
materials. Bricks are not a new construction material available in the market. The
most primitive construction materials comprised straw and mud were used by the
Egyptians in the last 2000 years. Scientists have predicted that this construction material will have increase in demand steadily along with metal, polymer and
ceramic materials. Today, bricks have become one of the ma.ior materials used 111 construction and are still improving to fulfill the needs [or better material.
There are numerous researches on brick have been carried out towards creating cleaner environment and reducing the natural depletion. Natural fiber wastes product
used as reinforcements or substitute for clay in brick is not a new fact but it is widely
used and has increased dramatically during the last few years. Due to lower strength
provided by the natural fiber after firing process, the usages of calcium carbcnate for
clay brick have been seriously acknowledged. Calciwn carbonate are not only less expensive compared to clay, it can also provide extra strength to the mixture [24). In
addition to this, the low density of the calcium carbonate can produce brick with low specific mass.
The low-density property allows the production of bricks with good mechanical properties with low specific mass. There are various types of natural fibers can be found in the market today and the list is still increasing. There are many potential natural fiber sources in Malaysia alone and among them is a pepper waste fiber.
1.2 Problem Statement
Porous brick has been studied and known as one of the new construction materials. It
is well known in the industry because of its porous nature. Porous bricks absorb high amount of water by capillarity when they are placed in contact with water. However, high percentage of porosity of the brick reduces the compressive strength of the brick.
In basic engineering material study, when materials mix together, the mechanical and physical properties of the material are expected to change, either slightly or dramatically. Perhaps, a testing method could help in determining the degree of changes in mechanical and physical level of the brick.
Studies by Tan (2008) shown that the effect of adding 2 wt%, 5 wt% and 10 wt% pepper waste fibers on mechanical and physical properties of green brick. The study showed that, the additions of pepper wastes in the brick slightly reduce the strength of the brick and the maximum composition of pepper wastes in the brick is 5 wt% in order to satisfied the MS76: 1972 strength requirement. The study proved that pepper waste has the potential to be used as pore additive material in brick but this reduced the strength of the brick. From the experiment, the strength of the brick was slightly
higher compared to the Malaysian Standard [25]. Therefore this study will focus on how to improve the strength of the bricks by adding Calcium Carbonate, CaC03 into the mixture of clay and 5 wt% pepper waste.
1.3 Objectives
The objective of this project is to investigate and to improve the mechanical and physical properties of brick produce with addition of calcium carbonate. The samples were tested in term of firing shrinkage, plasticity, initial rate of suction, water absorption and compressive strength.
CHAPTER 2
Literature Review
2.1 Introduction to Brick
The term brick refers to small units of building material such as the common brick. Brick is made from fired clay and blended with a bonding agent comprising of sand, and water [1]. Dimension of the small unit brick is usually 22cm in length, I O.S cm in
width and 6.5cm in height. Unit brick which exceed any of these dimensions are referred to as building blocks [2]. This brick is dried under sun or heated inside the furnace until it is hard and ready to be used as building material.
Drying process is usually done in hottest climate country while heating the brick
inside the kiln (furnace) is done in tropical rainforest country. However, firing process reduces the porosity of the brick and a bond is developed between the particle fusions andlor sintering of amorphous constituent. Firing is responsible for development of strength in the brick. Lt is also responsible for color and resistance to disintegration by rainwater, freezing and thawing. [3J
Today most brick manufacturing companies used the extrusion process to manufacture bricks. Bricks prepared by the extrusion process showed lower porosity and smaller pore compared to that of molding process but this may increase the
durability of the brick. Hence the absorption process is reduced due to lower porosity
and small pore between the particles. Besides that, high temperature during firing process will decrease the absorption capability. [3,17]
2.2 Types of Brick
Brick masonry units may be solid, hollow, or architectural terra cotta. All types can
serve a structural function, a decorative function, or a combination of both. The
various types differ in their formation and composition.
2.2.1 Common Brick
A common brick is suitable for general building work but having no special feature
to give an attractive appearance. Thus, the term 'common' is applied to the many
varieties of clay bricks which fall outside the categories of Facings and Engineering
bricks. Common bricks have good load bearing properties and are available in
various crushing strengths. Common bricks are usually used for found ations and are
increasingly being specified for calculated load bearing construction. Common bricks generally make an ideal backing for rendering, plaster and color wash.
Figure 2. 1: Common Brick [26)
2.2.2 Facing Brick
Facing bricks are specially made to give an attractive appearance when used without
plaster or other surface treatment of the wall. Facing bricks combine attractive
appearance with structural strength and good resistance to exposure. Facing bricks
are available in a very wide range of strengths, colors and textures.
Figure 2.2: Facing Brick [27) 6
2.2.3 Engineering Brick
Engineering bricks are sub-divided into Facings and Commons bricks according to their appearance properties. To qualify as engineering bricks, the bricks must possess both the required strength and absorption properties. The properties of the engineering brick are shown as in Table 2.0.
Table 2.0: Average Compressive Strength and Water Absorption of Engineering Brick[29].
Engineering Average Compressive Average Water Absorption Brick Strength (N/mm2) (%)
A
69
4.5B 48.5 7.0
Figure 2.3: Engineering Brick [28]
![Table 2.0: Average Compressive Strength and Water Absorption of Engineering Brick[29]](https://thumb-ap.123doks.com/thumbv2/123dok/4368987.3189308/24.918.104.815.392.1145/table-average-compressive-strength-water-absorption-engineering-brick.webp)
