SHRI LAXMANRAO MANKAR COLLEGE OF

POLYTECHNIC, RISAMA (AMGAON)

DEPARTMENT OF CIVIL ENGINEERING

A
PROJECT REPORT
ON
“Use of Sugarcane Bagasse Ash from
Sustainability Point of View in Fly Ash
Bricks”
GUIDED BY

MR. SATIS RANE

H.O.D.

MR. SATIS RANE

SUBMITTED BY

MR. ASHAY M. KAWALE MISS. DAMINI R. BELPADE

MR. VIKAS D. NAGPURE MISS. DIKSHA R. CHUTE

MISS. LAXMI R. TURKAR MISS. AAYUSHI B. BHARNE

SESSION 2020-2021

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 CERTIFICATE

I hereby certify that the work which is being presented in the diploma in
engineering Major Project Report entitled “Use of Sugarcane Bagasse Ash from
Sustainability Point of View in Fly Ash Bricks”, in partial fulfillment of the
requirements for the award of the Diploma In Civil Engineering and submitted to the
Department of Civil Engineering of Shri Laxmanrao Mankar College of polytechnic,
Amgaon is an authentic record of my own work carried out during 2020-2021 under
the supervision of Mr. Satis Rane

The matter presented in this Project Report has not been submitted by me for
the award of any other degree elsewhere.

Submitted By

MR. ASHAY M. KAWALE MISS. DAMINI R. BELPADE

MR. VIKAS D. NAGPURE MISS. DIKSHA R. CHUTE

MISS. LAXMI R. TURKAR MISS. AAYUSHI B. BHARNE

This is to certify that the above statement made by the student is correct to the best
of my knowledge.

Date: / / 20

Project Guide H.O.D.

Mr. Satis Rane Mr.Satis Rane

PrincipaL
PORF.S.C.HANUWATE

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 ACKNOWLEDGEMENT

We express our sincere gratitude to Mr. Satis Rane , Head of Department of Civil
Engineering of Shri Laxmanrao Mankar College of Polytechnic, Amgaon (M.S). India, for
his stimulating guidance, continuous encouragement and supervision throughout the
course of present work.
We also wish to extend our thanks to other colleagues for attending our seminars
and for their insightful comments and constructive suggestions to improve the quality of
this project work.
We are extremely thankful to Prof. S. C. Hanuwate, Principal, Shri Laxmanrao
Mankar College of Polytechnic and Amgaon for providing me infrastructural facilities to
work in, without which this work would not have been possible.

PROJECTEES …….

MR. ASHAY M. KAWALE

MISS. DAMINI R. BELPADE
MR. VIKAS D. NAGPURE
MISS. DIKSHA R. CHUTE
MISS. LAXMI R. TURKAR
MISS. AAYUSHI B. BHARNE

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 DECLARATION

We undersigned hereby declared that the project entitled “Use of Sugarcane

Bagasse Ash from Sustainability Point of View in Fly Ash Bricks” submitted by us
originally genuine work.

The system presented here is developed by us independently and has not

been duplicated from any sources.

We understand that any such copying is liable to be punished in any way the
board authorities deep fit.

Thanking You

STUDENT NAME SIGNATURE

MR. ASHAY M. KAWALE ………………………

MISS. DAMINI R. BELPADE ………………………
MR. VIKAS D. NAGPURE ………………………
MISS. DIKSHA R. CHUTE ………………………
MISS. LAXMI R. TURKAR ………………………
MISS. AAYUSHI B. BHARNE ………………………

DEPARTMENT OF CIVIL ENGINEERING

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 E XAMINARS CERTIFICATE

THIS IS TO CERTIFY THAT THE STUDENT OF FINAL YEAR CIVIL

ENGINEERING OF SHRI LAXMANRAO MANKAR COLLEGE OF
POLYTECHNIC, AMGAON HAVE SUCCESSFULLY COMPLETED THE
PROJECT TITLED AS....

“Use of Sugarcane Bagasse Ash from Sustainability Point of View in

Fly Ash Bricks”

Submitted By

MR. ASHAY M. KAWALE MISS. DAMINI R. BELPADE

MR. VIKAS D. NAGPURE MISS. DIKSHA R. CHUTE

MISS. LAXMI R. TURKAR MISS. AAYUSHI B. BHARNE

AS PRESCRIBED BY MAHARASHTRA STATE BOARD OF TECHNICAL

EDUCATION MUMBAI (MSBTE) AS PARTIAL FULFILLMENT FOR THE AWARD
OF CIVIL ENGINEERING DURING IN ACADEMIC YEAR 2020-2021.

DATE: - GUIDED BY
PLACE:-AMGAON MR.SATIS RANE

INTERNAL EXAMINER EXTERNAL EXAMINER

DATE: - DATE:

DEPARTMENT OF CIVIL ENGINEERING

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 F ORWARDING LETTER

Forwarded herewith is the project entitled "Use of Sugarcane

Bagasse Ash from Sustainability Point of View in Fly Ash Bricks”
submitted By Mr. Ashay M. Kawale, Miss. Damini R. Belpade, Mr. Vikas
D. Nagpure, Miss. Diksha R. Chute, Miss. Laxmi R. Turkar, Miss. Aayushi
B. Bharne was bonafied student in this institution .The project work is in
the partial fulfillment of the requirement towards the award of the Diploma
in Civil Engineering (CE) to the Maharashtra State Board of Technical
Education, Mumbai. It has been carried out under the guidance and
supervision of Mr. Satis Rane Department of Civil Engineering, Shri
Laxmanrao Mankar College of Polytechnic, Amgaon.

Project Guide H.O.D.

Mr.Satis Rane Mr. Satis Rane

PRINCIPAL
Prof. S.C.HANUWATE

DEPARTMENT OF CIVIL ENGINEERING

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ABSTRACT
Sugarcane Bagasse Ash (SCBA) bricks can be extensively used in all
building constructional activities similar to that of common burnt clay bricks.
The SCBA bricks are comparatively lighter in weight and stronger than common
clay bricks. Since SCBA is being accumulated as waste material in large quantity
near Sugar industries and creating serious environmental pollution problems,
its utilization as main raw material in the manufacture of bricks will not only
create ample opportunities for its proper and useful disposal but also help in
environmental pollution control to a greater extent in the surrounding areas of
sugar industries. The object of this project is to represent the information
regarding Sugarcane Bagasse Ash, fly Ash bricks and plant, properties and their
uses in a most concise, compact and to the point manner. And also in this project
various laboratory experiments were carried out on Sugarcane bagasse ash in
fly ash bricks samples. Some of them are Compressive strength study, water
absorption study etc.

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 INDEX

CHAPTER PAGE NO.

1. INTRODUCTION 10

2. LITERATURE REVIEW 13

3. SUGAR MAP OF INDIA 20

4. MATERIAL USED 26

5. METHODOLOGY 35

6. TEST SET UP 42

7. RESULT DISCUSSION 47

8. CONCLUSION 52

9. REFERENCE 54

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CHAPTER NO. 1
INTRODUCTION

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INTRODUCTION
India is the largest area under sugarcane cultivation the world and the
world’s second largest producer of sugarcane next only to Brazil. Sugarcane
belongs to bamboo family of plants and is indigenous to India. It is long duration
crop and requires 10 to 15 and even 18 months to mature, depending upon the
geographical conditions. It requires hot and humid climate with average
temperature of 21º to 27ºC. And 75-150 cm rainfall is favorable for sugarcane
cultivation. Sugarcane today plays a major role in the global economy and Brazil
is the leading producer of sugar and alcohol, which are important international
commodities. Nowadays, it is commonplace to reutilize sugarcane bagasse as a
biomass fuel in boilers for vapor and power generation in sugar factories.
Depending on the incinerating conditions, the resulting sugarcane bagasse ash
(SCBA) may contain high levels of Sio2 and Al2o3, enabling its use as a
supplementary cementious material (SCM) in blended cement systems.
Sugarcane bagasse ash (SBA) is a multiprocessor by-product produced from the
milling of sugarcane. Bagasse is the fibrous material remaining after removing
the sugar, water and other impurities from the sugarcane delivered to the mill.
Use of sugarcane bagasse ash waste as a construction material can save the land
disposal cost and fertile land.
Sugarcane Bagasse Ash in Fly Ash bricks can be extensively used in all
building constructional activities similar to that of common burnt clay bricks.
The Sugarcane bagasse ash in fly ash bricks are comparatively lighter in weight
and stronger than common clay bricks. Since fly ash is being accumulated as
waste material in large quantity near thermal power plants and creating
serious environmental pollution problems, its utilization as main raw material

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in the manufacture of bricks will not only create ample opportunities for its
proper and useful disposal but also help in environmental pollution control to
a greater extent in the surrounding areas of power plants.

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CHAPTER NO. 2
LITERATURE
REVIEW

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LITERATURE REVIEW

 Bagasse Ash an Effective Replacement in Fly Ash Bricks Apruva

Kulkarni, Samruddha Raje, Mamta Rajgor, Utilization of industrial and
agricultural waste products in the industry has been the focus of research
for economic, environmental, and technical reasons. Sugar-cane bagasse
is a fibrous waste-product of the sugar refining industry, along with
ethanol vapor. Huge quantity of ash which is a waste product, available
at very negligible rate. It causes the chronic lung condition pulmonary
fibrosis more specifically referred to as bagasse’s. In this paper, Bagasse
ash can be utilized by replacing it with fly ash and lime in fly ash bricks.
Trial bricks of size (230x100x75) mm were tested with different
proportions of 0%, 10%, 20%, 30%, 40%, 50% and 60% with
replacement of fly ash and 0%, 5%, 10%, 15% and 20% with replacement
of lime. These bricks were tested in Compression test and Water
absorption test as per Indian Standards. The aim of this research was to
make economical and green bricks to maintain environmental balance,
and avoid problem of ash disposal. Based on limited experimental
investigations concerning compressive strength of Brick, the following
observations are made regarding the resistance of partially replaced
Bagasse ash: Compressive strength decreases on increase in percentage
of Bagasse ash as compare to fly ash. Use of bagasse ash in brick can solve
the disposal problem; reduce cost and produce a ‘greener’ Ecofriendly
bricks for construction. Environmental effects of wastes and disposal
problems of waste can be reduced through this research. A better
measure by an innovative Construction Material is formed through this

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 research .It provides innovative use of class F fly ash which contains less
than 20% lime. This study helps in converting the non-valuable bagasse
ash into bricks and makes it valuable. In this study, maximum
compressive strength is obtained at 10% replacement of fly ash as
bagasse ash. Bagasse ash bricks reduce the seismic weight of building.

 Sugarcane Bagasse Ash for Eco-friendly Fly Ash Bricks BhavyaRana,

Prof. JayeshkumarPitroda, Dr F S Umrigar, Agriculture is the most
important economic activity of India with 60% rural population and
which has caused sustainable increase in the volume of residues of
different types. Agra waste has proven to be among the most versatile
and cost effective modification of building material for construction and
their uses are expanding rapidly into nearly all areas of construction. Day
by day utilization of quality fly ash is increasing in the construction
industry, so there is a need for a new material for partial replacement of
fly ash, agro waste like sugarcane bagasse ash is having potential of such
material. Such aspects might also be helpful in gaining LEED
(Leadership in Energy and Environmental Design) points. Use of fertile
land in conventional brick production can also be saved by sugarcane
bagasse fly ash bricks. The current research study was carried out to
explore the potential of using Sugarcane Bagasse in brick production, We
can say that if fly ash is replaced by Sugarcane Bagasse Ash in fly ash brick
by using 10%, 20%, 30%, 40%, 50%, 60% Sugarcane Bagasse Ash; we
can save 0.0993m², 0.1987m² 0.2981 m², 0.3975m², 0.4968 m²,
0.5962m² in 1m depth of fertile agricultural land, respectively. This
enables us to retain our available resources. There by keeping the earth

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 excavated. Use of Sugarcane Bagasse Ash help in environmental
prevention by prevention of fertile land utilized in brick production. Uses
of Sugarcane Bagasse Ash in brick can save the agriculture industry’s
disposal costs and produce a ‘greener’ bricks for construction. An
innovative supplementary cementations Construction Material is formed
through this study.

 Reuse of Sugarcane Bagasse Ash (SCBA) for Clay Brick Production G.

Viruthagir, S. Sathiyapriya, N. Shanmugam, The utilization of
industrial waste produced by industrial process has been the focus of
waste reduction research for economic, environmental and technical
reasons. Sugarcane bagasse ash (SCBA) is a fibrous waste - product of the
sugar mill industry. Sugarcane bagasse ash (SCBA) mainly contains silica,
ion, calcium and aluminium. In this paper, bagasse ash has been
chemically and physically characterized, and partially replaced in the
ratio of 0 %, 5 %, 10 %, 15 % and 20 % ash by weight of weight in Clay
brick. The samples were fired at temperatures between 800 ºC and 1100
ºC. X-ray fluorescence, thermal analysis (differential thermal analysis,
thermo gravimetric analysis), and test for texture (particle size analysis),
compressive strength, porosity, water absorption and shrinkage were
carried out to characterize the samples. The results showed that the
amount of ash to be incorporated will depend on mainly the composition
of clay but also ash, and indicated that the clay used in this work can
incorporate up to 15% weight of ash to produce solid bricks. The results
also showed an improvement in clay/ash properties at sintering
temperature 1000 ºC. Although the incorporation of ash inhibits the

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 formation of mullite during sintering of the clay material, SCBA behaves
like non- plastic material and decreases the linear shrinkage of clay bricks
during drying and firing. The sugarcane bagasse ash waste used in this
study is a low-cost material, rich in crystalline silica (SiO2), which
behaves as a filler material, and reduces the clayey formulations
plasticity. The temperature of 1000 °C is a target for changes in the
sintering process. Below this temperature, the properties of the clay
bricks are little affected by the different concentrations of ash. For
temperatures above 1000 °C, the additive (ash) participates in the liquid
phase and the formation of new phases (mullite and cristobalite). The
results show that for temperatures up to 1000 °C, 15 wt.% ash can be
incorporated in brick making clay used to produce bricks. Therefore, the
ash (SCBA) may be used as an additive to produce clay bricks that meet
the Indian standards. Hence, this process can lower the volume of solid
residues disposed on the environment and to increase the lifetime of the
reserves of raw materials.

 Study of Properties of Light Weight Fly Ash Bricks. Ravi Kumar,

Vandana Patyal , Balwinder Lallotraand Deepankar Kumar Ashish,
In this paper, efforts has been made to study the behavior of fly ash bricks
by taking different proportions of fly ash, cement, lime, gypsum and sand.
Three types of fly ash bricks in the different percentage of cement such
as 3%, 5% and without cement are designed and then various tests such
as compressive strength test, water absorption test, efflorescence, weight
test, structural test were performed in order to have comparison with
conventional bricks. In the experimental study it is found that the

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compressive strength of fly ash brick containing 5% cement is 152.1
kg/cm2 which is more than that of class I conventional bricks by 40%
approximately. Effort has been made by making different proportions of
ingredients having composition of fly ash, cement, lime, gypsum, and
sand. On the basis of the experimental work it is concluded that the
compressive strength of fly ash brick with 0% cement is 27% more than
that of class I conventional brick but when 3% cement is added in the fly
ash brick then compressive strength is 51.8% more than that of class I
conventional brick and also when 5% cement added in fly ash brick then
the compressive strength is more than 63%. It is also analyzed that water
absorption of fly ash brick with 0% cement is 27% less as compared to
that of conventional bricks and 42% less as compared to conventional
brick when 3% cement is added and 48% less as compared to
conventional brick when 5% cement is added. The Efflorescence test of
conventional brick, fly ash brick without cement, fly ash brick with 3%
cement & fly ash brick with 5% cement and the result were compared in
which grey or white deposits are slight to moderate in conventional brick,
less than 10% on surface area in fly ash brick without cement, less than
8% on surface area in fly ash brick with 3% cement and less than 7% on
surface area in fly ash brick with 5% cement. Fly-Ash bricks are
ecofriendly as it protects environment though conservation of top soil
and utilization of waste products of coal or lignite used in thermal power
plants. It is three times stronger than the conventional burnt clay bricks.
It plays a vital role in the abatement of carbon dioxide a harmful
greenhouse gas mass emission of which is threatening to throw the
earth’s atmosphere out of balance. Being lighter in weight as compared

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to conventional bricks, dead load on the structure is reduced and hence
saving is overall cost of construction. The possibility of using innovative
building materials and eco-friendly technologies, more so covering waste
material like fly ash is the need of the hour. Fly ash affects the plastic
properties of concrete by improving workability, reducing water
demand, reducing segregation and bleeding, and lowering heat of
hydration. It also increases strength, reduces permeability, reduces
corrosion of reinforcing steel, increases sulphate, resistance, and reduces
alkali aggregate reaction.

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CHAPTER NO. 3
SUGAR MAP OF
INDIA

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SUGAR MAP OF INDIA

Variation in burning temperature and duration of burning, size of

particle, chemical composition has been studied rigorously. Aim of this study
was to evaluate the potential use of SCBA as partial replacement of cement and
fly ash in bricks.

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OBJECTIVES
The objectives of the study are:

 Producing light weight but of required strength.

 To manage the disposal of waste product into construction raw material.

 To make the bricks which are energy efficient which is the only viable

solution to the environmental concerns and natural resources

conservation for future generation.

 Production of an ecofriendly brick with agricultural waste i.e. SCBA

having physical and chemical behavior better than conventional one.

 To investigate the mechanical properties such as compressive strength,

density (Lightweight).

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Sugarcane Bagasse Ash (SCBA)
For this Research Work Sugarcane bagasse ash used in fly ash brick. The
burning of bagasse which a waste of sugarcane produces bagasse ash. Presently
in sugar factories bagasse is burnt as a fuel so as to run their boilers. This
bagasse ash is generally spread over farms and dump in ash pond which causes
environmental problems also research states that Workplace exposure to dusts
from the processing of bagasse can cause the chronic lung condition pulmonary
fibrosis, more specifically referred to as bagassosis. So there is great need for
its reuse, also it is found that bagasse ash is high in silica and is found to have
pozollinic property so it can be used as substitute to construction material.
Sugarcane bagasse ash is a byproduct of sugar factories and it is produced by
burning sugarcane bagasse where it is formed by extracting all sugar from
sugarcane, for the use of SCBA as a partial replacement cement in fly ash brick,
it is tested in various part of the world. SCBA was found that it improves the
properties of brick such as compressive strength and water absorption. The
main parameter responsible for this improvement was higher silica content.
The silica content may vary from ash to ash and this content is depending on
the burning condition of sugarcane bagasse. SCBA is a valueless agricultural
waste product but is has a pozzolanic property which can be used to replace -

Fig. Raw Sugaracane bagasse Fig. Sugarcane bagasse ash

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-cement and fly ash in bricks. Initiative are taken worldwide to control and to
manage the agricultural waste to prevent environment pollution. The solution
is found out to burn these waste materials.

Fly Ash
Fly ash is the by-product of coal combustion collected by the mechanical
or electrostatic precipitator (ESP) before the flue gases reach the chimneys of
thermal power stations in very large volumes. All fly ash contain significant
amounts of silicon dioxide (SiO2), aluminum oxide (Al2O3), iron oxide (Fe2O3),
calcium oxide (CaO), and magnesium oxide (MgO) however, the actual
composition varies from plant to plant depending on the coal burned and the
type of burner employed. Fly ash also contains trace elements such as mercury,
arsenic, antimony, chromium, selenium, lead, cadmium, nickel, and zinc. These
particles solidify as microscopic, glassy spheres (see fig.1) that are collected
from the power plant‘s exhaust before they can ―fly‖ away — hence the
product‘s name: Fly Ash. Chemically, fly ash is a pozzolana. When mixed with
lime (calcium hydroxide), pozzolans combine to form cementations
compounds. The power requirement of the country is rapidly increasing with
increase in growth of the industrial sectors. India depends on Thermal power
as its main source (around 65% of power produced is thermal power), as a
result the quantity of Ash produced shall also increase. Indian coal on an
average has 30% to 40% Ash and this is one of the prime factors which shall
lead to increased ash production and hence, Ash utilization problems for the
country. Fly ash is one of the numerous substances that cause air, water and
soil pollution, disrupt ecological cycles and set off environmental hazards. It‘s
also contains trace amounts of toxic metals which may have negative effect on

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human health and on plants and the land where the fly ash decomposed not
gets reused.
The disposal of this waste material is a matter of great concern from the
environmental and ecological point of view. The safest and gainful utilization of
this material has been one of the topics of research over the last few decades.
The advantages of fly ash utilization are:
 Saving of space for disposal and natural resources
 Energy saving and Protection of environment The options of ash utilization
including the ash based products are at development stage and need to be made
more environments friendly by bringing ash revolution.

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CHAPTER NO. 4
MATERIAL USED

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Material Properties
The project “Use of Sugarcane Bagasse Ash from Sustainability Point of
View in Fly Ash Bricks” is an innovative concept in civil engineering. In
construction industries civil engineers are always interested in long term
performance of construction materials by using ordinary Portland cement and
waste SCBA for making bricks.
Material Selection
The materials given below are used for bricks:
1) Ordinary Portland Cement (53 Grade)
2) Sugarcane Bagasse Ash
3) Fly Ash
4) Crushed Sand
5) Admixture
6) Water

Materials:
1) Cement
Ordinary Portland Cement (OPC), ULTRATECH 53 grade was used for
bricks. Cement may be prescribed as a material with adhesive and cohesive
properties which make it capable of bonding
Mineral fragments into a compact whole. For constructional purpose the
meaning of the term cement is restricted to the bonding material used with
stones, sand, bricks, building blocks, etc. The principle constituents of this type
of cement compounds of lime, so that in building and civil engineering we are
connected with calcareous cement.

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 The Raw materials used for the production of cement are lime, silica,
Alumina and Iron Oxide. These oxides interact in the kiln at very high
temperatures to form complex compounds. The Relative proportions of this
oxides in the cement are responsible for influencing various properties to the
cement. Table 3.1 shows various oxide composition of the cement. This oxide
influence in the production of four important compounds C2S, C3S, C3A and
C4AF. The first two are responsible for strength in brick. High Alumina and high
ferric oxide content are responsible for high early strength in cement. The
major composition of cement content about 60% of CaO, SiO2 is about 19%,
Fe2O3 is about 3.7% and Al2O3 of about 5.2%.

Chemical Composition of Cement

Sr. No Oxides Mass%
1 SiO2 19.71
2 Al2O3 5.20
3 Fe2O3 3.70
4 CaO 62.91
5 MgO 2.54
6 LOI 0.96
7 SO3 2.72
8 K2O 0.90
9 Na2O3 0.25

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2) Sugarcane Bagasse Ash
Sugarcane bagasse ash is a byproduct of sugar factories and it is produced
by burning sugarcane for this Research Work Sugarcane bagasse ash used to
make fly ash brick. The burning of bagasse which a waste of sugarcane produces
bagasse ash. Presently in sugar factories bagasse is burnt as a fuel so as to run
their boilers. This bagasse ash is generally spread over farms and dump in ash
pond which causes environmental problems also research states that
Workplace exposure to dusts from the processing of bagasse can cause the
chronic lung condition pulmonary fibrosis. So there is great need for its reuse,
also it is found that bagasse ash is high in silica and is found to have pozollanic
property so it can be used as substitute to construction material. Sugarcane
bagasse ash is a byproduct of sugar factories and it is produced by burning
sugarcane bagasse where it is formed by extracting all sugar from sugarcane,
for the use of SCBA as a partial replacement cement in fly ash brick, it is tested
in various part of the world. SCBA was found that it improves the properties of
brick such as compressive strength and water absorption. The main parameter
responsible for this improvement was higher silica content. The silica content
may vary from ash to ash and this content is depending on the burning
condition of sugarcane bagasse. SCBA is a valueless agricultural waste product
but is has a pozzalanic property which can be used to replace cement and fly
ash in bricks. Initiative are taken worldwide to control and to manage the
agricultural waste to prevent environment pollution. The solution is found out
to burn these waste materials. Variation in burning temperature and duration
of burning, size of particle, chemical composition has been studied rigorously.
Aim of this study was to evaluate the potential use of SCBA as partial
replacement of cement and fly ash in bricks.

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Chemical Composition of Sugarcane Bagasse Ash

Composition (% by mass) property Bagasse Ash(% by mass)

Sio2 78.34
Al2o3 8.55
Fe2o3 3.61
CaO 2.15
Na2O 0.28
K2O 3.46
MnO 0.13
TiO2 0.50
P2O 1.07
Loss on ignition 0.42

3) Fly Ash
A waste material extracted from the gases emanating from coal fired
furnaces, generally of a thermal power plant is called fly ash. One of the chief
usages of volcanic ashes in the ancient ages were the use of its hydraulic
cements, and fly ash bears close resemblances to these in the around the globe.
The demand of powder supply has exponentially heightened these days due to
increasing urbanization and industrialization phenomena. Subsequently this
growth has resulted in the increase in the number of power supplying thermal
power plant that coal as a burning fuel to produce electricity. The mineral
reduces that is left behind after the burning of coal is the fly ash. The electro
static precipitator (ESP) of the powder plants collect these fly ash.
Fly ash is a fine powder that is a byproduct of burning pulverized coal in electric
generation power plants. Fly ash is a pozzolanic , a substance containing
aluminous and siliceous material that forms cement in the presence of water.

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When mixed with lime and water, fly ash forms a compound similar to Portland
cement. This makes fly ash suitable as a prime material in blended cement,
mosaic tiles, and hollow blocks, among other building materials. When used in
concrete mixes, fly ash improves the strength and segregation of the concrete
and makes it easier to pump. It is unanimously suggested that coal, which has
been the dominant source of fuel for power generation in India (almost three-
fourths is currently coal-based), will continue to be a critical source for
generating base load electricity. Various estimates indicate that electricity
generated from coal is expected to grow twofold to threefold by 2030.With an
average of 730 MT of coal consumed by the power plants in our country by the
end of financial year 2018 which tuned to an average of 210 MT of fly ash
generated by then with efforts of ash utilization had resulted in achieving just
59% by the same year end. The Indian government has been pushing for a
target of 1.5 billion tons of coal production annually by 2020, most of which will
be used in the power sector. In this context, current issues-status, policies,
regulations, and bottlenecks-regarding the disposal of fly ash generated by
thermal power plants are to be examined. As far as the mode of utilization was
concerned, the CEA's report indicates that the utilization of fly ash is the highest
in the cement sector with 24.04 per cent of the total fly ash used, followed by
bricks and tiles at 7.37 per cent. The concrete industry segment has the lowest
level of utilization at 0.6 per cent.
For the purposes of quantitative analysis, 951 MT of cement production and
1,340 MT of coal in electricity generation by 2030 have been considered. At
average ash content in coal of 33%, this implies that the annual fly ash
generation by 2030 will be approximately 437 MT. If the current trends in
utilization of fly ash were to continue, overall the utilization will tune up to 310

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MT by 2030, with cement's share in utilization, as a percentage of total fly ash
generated, increasing from 25% to 35% by 2030. While cement's fly ash
requirement will grow fourfold, to 151 MT in 2030, approximately 128 MT of
fly ash will still remain unutilized. This will require an additional 2,300 hectares
of land and 1.3 billion cubic meters of water for ash ponds, exacerbating the
existing problems concerning fly ash disposal. A waste material extracted from
the gases emanating from coal fired furnaces, generally of a thermal power
plant is called fly ash.

4) Crushed Sand
In India, river sand is used as
fine aggregate in mortar over a
period of millions of years. In
general, the demand of river sand is
very high in developing countries to
satisfy the rapid infrastructure
growth. In this situation developing country like India facing shortage in good
quality of river sand. Properties of sand affect the durability and performance
of mortar, so fine aggregate is an essential component of cement mortar. Now
a day’s sand is becoming a very costly material, in this situation research began
for cheap and easily available alternative material than river sand. Thus
Manufactured sand (Crushed stone dust), as a fine aggregate, is an attractive
alternative of river sand for cement mortars. It is purpose made fine aggregate
produced by crushing and screening or further processing i.e. washing, grading,
classifying of quarried rock, cobbles, boulders or gravels from which natural
fine aggregate had been removed.

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5) Admixture
Admixture is defined as material other than cement, water and aggregate
it’s used as ingredient of concert and is added to the batch before or during
mixing. Admixture is used to modify different properties of concrete so as to
make it sustainable for any situation the various type of admixture are as
follows,
 Plasticizer
 Super Plasticizer
 Retarders and retarding plasticizer
 Accelatetors and accelerating plasticizer
 Air entraining admixtures
 Pozzolanic or mineral admixture
 Damp proofing and water proofing admixture
 Gas forming admixture
Air Entraining Admixtures (Foaming Agent)
The foaming agent is such chemical
which is highly used in the field of
construction for making bricks which are
simply made up with the proper amount
of cement, fly ash and foaming agent
finely mix with water in particular
compressed air.
Stable Air Foaming Agent is a liquid air-
entraining admixture that provides freeze-thaw resistance enhances the finish
ability characteristics of concrete, and allows concrete producers to accurately
control yield. Foaming agent is recommended for use in all ready-mix, precast,

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prestress and other concrete products where the intentional entrainment of the
specified level of air is required.

6) Water
Water is an important ingredient of a brick as it actually used for
manufacturing of brick. Since it helps to bind all the raw materials for giving
proper mix. Water used for making brick should be free from impurities. Since
it helps to from the strength giving cement gel, the quantity and quality of water
is required to be looked into very carefully. Water is the most important and
least expensive ingredient of brick. A part of mixing water is utilized in the
hydration of cement to the binding matrix in which the inner aggregates are
held in suspension until the matrix has hardened. The remaining water serve
as lubricant between the fine and coarse aggregate with recycled coarse
aggregates and makes concrete workable ,i.e. readily peaceable in forms.
Generally cement requires about three tenth of its weight of water for
hydration. Hence the minimum water-cement ratio 0.30. But the brick
containing water in this proportion will be very harsh and difficult to place.
Additional water is required to the lubricate the mix, which makes the brick
workable. This additional water must kept to minimum, since too much water
reduces the strength of brick. The water cement ratio is influenced by the grade
of concrete, nature and type of concrete, the workability and durability etc.

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CHAPTER NO. 5
METHODOLOGY

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Preparation of Sugarcane bagasse ash bricks
Sugarcane bagasse Ash and fly ash, crushed sand and are manually fed
into a pan mixer where water is added in the required proportion for intimate
mixing. The proportion of the raw material is generally in the ratio SCBA 40-
70% of fly ash 20-54%, Cement 4-8%, and Crushed sand 1-4%, depending upon
the quality of raw materials. The materials are mixed in pan mixture. After
mixing, the mixture is conveyed through belt conveyor to the
hydraulic/mechanical presses. The homogenized mortar taken out of roller
mixer is put into the mould boxes. Depending on the type of machine, the
product is compacted under vibration or hydraulic compression etc. The

Fig. Schematic Diagram of manufacturing of fly ash bricks

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green bricks are dried up under sun from 24 to 48 hours, depending whether
lime route or cement route; the dried up bricks are stacked and subjected for
water spray curing once or twice a day, for 7-14 days, depending on ambience.
The bricks are tested and sorted before dispatch.

Batching of Material
Weigh batching of all raw materials is idelly suited for the
process.batching is the process measuring mix ingredients either by volume or
by mass and introducing them inti the mixture. Tradionally batching is done by
volume but most specifications require that batching be done by mass rather
than volume.

Mixing of material
Methods of grinding and mixing
depend upon the composition of the fly
ash and the layout of the plant. To get a
high strength calcium silicate materials, it
is advantageous to mix and grind lime and
sand for a greater period and then mix the
remaining quantity of fly ash and mix for a further short period so that only a
portion of the ingredients receive such grinding. Mixing and proportioning may
be done either by batch or continuous process. Generally batch methods are
preferred for the primary stage to achieve a good control on the operation. Raw
materials, water stains and other chemicals are properly mixed in a double -
shaft or U-shaped mixer or counter-current mixer (costlier) till the semi-dry
mix is uniform and ready for pressing. Trolleys: Each trolley carries about 750

36 | P a g e
to 1500 bricks and an autoclave may hold up to 20 such trolleys or more
depending upon its length.

Pressing
In general, after the mixing and grinding, the material is placed in an
instant stripping mould with a high powered external vibrator of 180 112
frequency. During compaction the top surface is pressed at a 300 kg/cm2 on
each brick. A wooden plate is then set on the top surface and the mould is
turned upside down. Finally the mould is stripped by lifting it up. It is necessary
to use high pressure moulding because the mixers are non-plastic in nature.
The press required for this purpose has to be sufficiently robust to withstand
the high chemical strains and wear and tear to which it is to be subjected.

Removal Stacking for Curing

The pressed bricks are removed from the press either manually or by an
Automatic press off loading and brick stacking machine, designed to work in
conjunction with the brick making press, and amonged on trolleys. Each trolley
carries about 750 to 1500 bricks and an autoclave may hold up to 20 such
trolleys or more depending upon its length.

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 Fig. Removal of Sugarcane Bagasse ash bricks

Drying
Green bricks contain about 7–30% moisture depending upon the
method of manufacture. The object of drying is to remove the moisture to

Fig. drying of Bricks

38 | P a g e
Control the shrinkage. The moisture content is brought down to about 3 per
cent under exposed conditions within three to four days. Thus, the strength of
the green bricks is increased and the bricks can be handled safely bricks are
normally dried in natural open air driers (Fig They are stacked on raised
ground and are protected from bad weather and direct sunlight. A gap of
about 1.0 m is left in the adjacent layers of the stacks so as to allow free
movement for the workers.

39 | P a g e
Flow sheet for the manufacture process of SCBA Bricks

SCBA+Fly Ash+Cement+Admixture+Water

Homogeneous Mixing in Rotary machine

Conveying the mix through belt convyers

Formation of fly ash bricks at high pressure

Stackling and Curing

SCBA in fly ash bricks ready for use

40 | P a g e
CHAPTER NO. 6
TEST SET UP

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TEST SET UP
To know the quality of bricks following 8 tests can be performed. In these
tests some are performed in laboratory and the rest are on field.

1. Size, Shape and Colour Test

2. Soundness Test

3. Water Absorption

4. Hardness t Test

5. Compressive strength Test

1. Size, Shape and Colour Test

In this test randomly collected 20 bricks are staked along lengthwise,

widthwise and height wise and then those are measured to know the variation
of sizes as per standard. Bricks are closely viewed to check if its edges are sharp
and straight and uniform in shape. A good quality brick should have bright and
uniform color throughout.

2. Soundness Test

In this test two bricks are held by both hands and struck with one
another. If the bricks give clear metallic ringing sound and don't break then
those are good quality bricks.

3. Water Absorption Test

In this test bricks are weighed in dry condition and let them immersed in
fresh water for 24 hours. After 24 hours of immersion those are taken out from

42 | P a g e
water and wipe out with cloth. Then brick is weighed in wet condition. The
difference between weights is the water absorbed by brick. The percentage of
water absorption is then calculated. The less water absorbed by brick the
greater its quality. Good quality brick doesn't absorb more than 20% water of
its own weight.

4. Hardness Test

In this test a scratch is made on brick surface with a hard thing. If that
doesn't left any impression on brick then that is good quality brick.

5. Compressive strength Test

This test is done to know the compressive strength of brick. It is also

called crushing strength of brick. Generally 5 specimens of bricks are taken to
laboratory for testing and tested one by one. In this test a brick specimen is put
on crushing machine and applied pressure till it breaks. The ultimate pressure
at which brick is crushed is taken into account. All five brick specimens are
tested one by one and average result is taken as brick's compressive/crushing
strength.

COMPRESSIVE STRENGTH TEST FOR BRICKS (IS 3495-

PART-1:1992)

Apparatus

A compression testing machine, the compression plate of which shall

have a ball seating in the form of portion of a sphere the center of which
coincides with the center of the plate, shall be used.

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Preconditioning

Remove unevenness observed in the bed faces to provide two smooth

and parallel faces by grinding. Immerse in water at room temperature for 21
hours. Remove the specimen and drain out any surplus moisture at room
temperature. Fill the frog ( where provided ) and all voids in the bed face flush
with cement mortar ( 1 cement, clean coarse sand of grade 3 mm and down ).
Store under the damp jute bags for 24 hours followed by immersion in clean
water for 3 days. Remove, and wipe out any traces of moisture.

Procedure

Place the specimen with flat faces horizontal, and mortar filled face facing
upwards between two to 3 plywood sheets each of 3 mm thickness and
carefully centered between plates of the testing machine. Apply load axially at
a uniform rate of 14 N/mm² (140 kg/cm²) per minute till failure occurs and
note the maximum load at failure. The load at failure shall be the maximum load
at which the specimen fails to produce any testing machine. NOTE - In place of
plywood sheets plaster of Paris may be used to ensure a uniform surface for
application of load.

𝐍 𝐌𝐚𝐱𝐢𝐦𝐮𝐦 𝐥𝐨𝐚𝐝 𝐚𝐭 𝐟𝐚𝐢𝐥𝐮𝐫𝐞 𝐢𝐧 𝐍

𝐂𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐯𝐞 𝐬𝐭𝐫𝐞𝐧𝐠𝐭𝐡 𝐢𝐧 =
𝐦𝐦𝟐 𝐀𝐯𝐞𝐫𝐚𝐠𝐞 𝐚𝐫𝐞𝐚 𝐨𝐟 𝐭𝐡𝐞 𝐛𝐞𝐝 𝐟𝐚𝐜𝐞𝐬 𝐢𝐧 𝐦𝐦²

44 | P a g e
WATER ABSORPTION TEST FOR BRICK (IS 3495–PART
2)
How to calculate water absorption value for bricks (IS 3495 part 2) Water
absorption value of bricks largely influences the bond between brick and
mortar. If water absorption in bricks is more and bricks are not soaked before
the masonry work, the water from freshly laid mortar is likely to be absorbed
by bricks. This results into poor mortar strength as the sufficient quantity of
water will not be available for hydration process. This article describes the
details procedure for water absorption test For bricks as per IS 3495,P-2

1. Sensitive weigh balance

2. Ventilated oven

Test Procedure for Water Absorption for Bricks:

1. The specimen is dried in a ventilated oven at a temperature of 105 to 1150C;

till it attains substantially constant mass. The specimen is cooled to room
temperature and its weight is recorded as M1

2. The dried test specimen is immersed completely in clean water at a room

temperature of 27±20C for 24 hours.

3. The specimen is then removed and any traces of water are wiped out with a
damp cloth and the specimen is weighed. M2-M1

The weighing is completed 3 min after the specimen has removed from
water. Record the weight as M2

𝐌𝟐−𝐌𝟏
Calculation of %of Water Absorption: 𝑿𝟏𝟎𝟎
𝑴𝟏

45 | P a g e
CHAPTER NO. 7
RESULT
DISCUSSION

46 | P a g e
RESULT DISCUSSION
1. SIZE & SHAPE TEST
BAGGASE ASH LENGTH WIDTH HEIGHT
PROPORTION
0% 224.00 106.70 75.70
10% 223.00 107.00 77.00
20% 223.80 106.80 76.30
30% 223.70 107.00 76.20
50% 223.40 106.70 76.20
STANDARDS 225.00 100.00 80.00
As we can see from result size of the bricks are near the standard values
of any proportion for bagasse ash.

2. COLOUR TEST

Up to 20% proportion for bagasse ash, bricks has good red uniform
colour. But after 20% proportion, bricks have yellowish colour. Under burnt
bricks.

3. SOUNDNESS TEST FOR BRICKS

When two bricks are struck with one another, up to 20% proportion, they
give metallic sound. But 30% and 50% proportion gives dull sound.

47 | P a g e
4. WATER ABSORPTION TEST

Weight of
Weight of Weight of % water
water Average
Proportion dry brick wet brick absorbed
absorbed %
(W1 kg) (W2 kg) (kg)
(W2-W1) kg
2.702 3.099 0.397 14.69
0% 2.725 3.105 0.380 13.94 13.89
2.719 3.074 0.355 13.056
2.731 3.124 0.393 14.39
10 % 2.751 3.204 0.453 16.46 15.89
2.672 3.122 0.450 16.84
2.668 3.126 0.458 17.16
20% 2.762 3.167 0.405 14.66 15.55
2.675 3.072 0.397 14.84
2.706 3.122 0.416 15.37
30% 2.668 3.062 0.394 14.76 15.34
2.653 3.075 0.422 15.90
2.704 3.149 0.445 16.45
50% 2.654 3.088 0.434 16.35 16.26
2.686 3.116 0.430 16.00
As we can see in result, as percentage of bagasse ash increased water
absorption of bricks increased. Up to 20 % bagasse ash is adequate to
replace.

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5. HARDNESS TEST

Up to 30% proportion, bricks are hard. When scratch is made, it doesn’t

left mark. But after 30% proportions, there was scratch left on brick surface.

6. COMPRESSIVE STRENGTH TEST

Size of Compressive
Proportion Surface Load at
brick Strength
in % area Failure Average
(mm²) (P/A) in
(mm²) (P) in KN
N/mm²
224 X 127 120 4.22
10 28448 150 5.27 4.57
120 4.22
224 X 127 80 2.81
20 28448 100 3.52 3.16
90 3.16
224 X 127 80 2.81
30 28448 80 2.81 3.05
100 3.52
224 X 127 90 3.16
40 28448 80 2.81 2.81
70 2.46
224 X 127 60 2.11
50 28448 70 2.46 2.34
70 2.46

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 As per the results of compressive strength test, up to 20% bagasse ash
strength is as per requirement. After 20 % the strength reduces. It is desirable
to use only up to 20 % bagasse ash.

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CHAPTER NO. 8
CONCLUSION

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CONCLUSIONS
From the analysis of the results given above, the followings conclusions
can be made:

1. Use of bagasse ash in brick can solve the disposal problem; reduce cost and
produce a ‘greener’ Eco friendly bricks for construction.

2. Environmental effects of wastes and disposal problems of waste can be

reduced through this research.

3. A better measure by an innovative Construction Material is formed through

this research.

4. This study helps in converting the non-valuable bagasse ash into bricks and
makes it valuable.

5. It reduces the cost of material per brick. 6. From the tests conducted in
laboratory, in all tests it is observed that up to 20% bagasse ash all the
characteristics of bricks are adequate and desirable for use in building
construction.

7. As addition of bagasse ash more than 20% causes more water absorption,
reduction in compressive strength, less hardness, under burnt.

8. So we recommend that up to 20 to 25 % bagasse ash can be replaced by clay

in bricks.

52 | P a g e
CHAPTER NO. 9
REFERENCE

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REFERENCES
[1]. IS: 3102 – 1971: Classification of burnt clay solid bricks

[2]. IS: 1200 (Part-III) – 1976: Methods of measurement of buildings and

civil engineering works – Brick Work

[3]. IS: 1077 – 1992: Common burnt clay building bricks

[4]. IS: 3495-PART-1:1992: Methods of tests of burnt clay building bricks.

Part 1: determination of compressive strength

Part 2: determination of water absorption

Part 3: determination of efflorescence

Part 4: determination of war page

[5]. en.wikipedia.org/wiki/Fly ash brick

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