WELCOME

FEASIBILITY OF MAKING LOW COST, LOW ENERGY, LIGHT

WEIGHT BRICKS USING RECYCLE PAPER MILL WASTE

FROM PUNALUR PAPER MILL

2

Student InvestigatorsAnandalekshmi BJeswin JohnNayana DParvathi G VijayanSiju P

Guided by,Mrs. Deepa R,HODMrs. Manju R,Assistant Professors,CECollege of engineering ,Pathanapuram

INTRODUCTION

Brick is the most widely used construction material.

The increasing demand for the construction materials lead to

exploitation of the natural resources in large extent.

Utilisation of industrial by-products for making construction

materials has gained significant attention across the world.

This project investigated the use of recycle paper mill waste

(RPMW) from Punalur Paper Mills as a raw material for

manufacture of bricks.

3

With 85% average efficiency of RPM, around 5% (by weight) of total

pulp and paper mill production is generated as RPMW annual.

As a by-product, the RPMW is usually land filled, incinerated etc.

Bricks using different RPMW-cement combination and RPMW-laterite

combination are made and their properties are evaluated.

Variation of compressive strength with variation of particle size of

RPMW is studied.

4

NEED OF STUDY

Shortfall of conventional building construction material can be reduced

by utilizing industrial wastes.

Reduction of natural recourses as well as energy.

Better way of managing industrial wastes.

5

OBJECTIVE OF THE STUDY

To compare strength characteristics of RPMW-cement bricks and

RPMW-laterite bricks with conventional clay bricks.

To compare the strength of RPMW-cement bricks by varying the

particle size of the RPMW.

6

LITERATURE REVIEW1. S P Raut et al (2011) conducted studies on “Reuse of recycle paper mill waste

on energy absorbing light weight bricks”. This study was to investigate the

use of Recycle paper mill waste (RPMW) in construction bricks.

2. S P Raut ,D Rajput et al(2011) conducted studies on “Reuse of cotton mill and

recycle paper mill waste as a building material” .In this study they used

recycle paper mill waste(PW) and cotton mill waste (CW) to make waste create

bricks

3. S Raut et al(2013) conducted a study on “Utilisation of recycle paper mill

residue and rice husk ash in production of light weight bricks “.In this

research study, recycle paper mill residue (RPMR) and rice husk ash (RHA) are

utilized to improve the properties of bricks.

7

4. Raut et al (2011) did a review study in “Developing bricks from various industrial

and agricultural waste material like paper processed residues, cigarettes buts, fly

ash- lime gypsum, cotton waste, limestone powder waste, textile effluent

treatment plant, organic residue, kraft pulp residue, petroleum effluent

treatment plant sludge and recycled sludge welding flux”.

5. Mucahit Sutcu and Sedat Akkurt (2009) studied on “The use of recycled paper

processing residue in making porous brick with reduced thermal conductivity”.

6. Reddy Babu and N.Venkataraman (2013) studied bricks on the paper titled

“Durability of Bricks cast with industrial sludge”.

7. Ashwin Narendra Raut and Christy Pathrose Gomez (2016) studied the wastecrete

bricks in the paper titled “Utilization of Waste as a Constituent Ingredient for

Enhancing Thermal Performance of Bricks – A Review Paper”.

8

8. Ismail Demir et al studied on the “utilisation of kraft pulp production

residue in clay brick production “.

9. J.E. Oti and J.M. Kinuthia studied on “Stabilised unfired clay bricks for

environmental and sustainable use”.

10. Sivakumar Naganathan, Almamon Yousef Omer Mohamed and Kamal

Nasharudd Mustapha studied on ” Performance of bricks made using fly

ash and bottom ash”.

9

1. The research that was carried out over the last years that many

successful attempts to incorporate different types of waste in

production of bricks.

2. The compressive strength and various other properties of the brick

was also improved on using RPMW.

3. Utilisation of RPMW can be a cost-effective alternative.

10

SUMMARY

MATERIALS

1. RECYCLE PAPER MILL

WASTE (RPMW)

Recycle paper mill waste (RPMW)

has been obtained from Punalur

Paper Mill. This is a type of

organic material.

11

Punalur Paper Mill

Recycle Paper Mill Waste (RPMW)

Recycle Paper Mills use recycled waste paper

along with virgin pulp to produce mainly packing

paper.

The pulp is made into paper by machines.

Long length fibres go into the paper sheet on the

machine while short length fibres pass through the

machine belt and are separated at the end filter from

the waste water.

This constitutes the Recycle Paper Mills waste .

12

13

Grinded RPMW

CHEMICAL COMPOSITION OF RPMW

The chemical analysis of RPMW done by using Energy Dispersive X-

ray Fluorescence Spectrometer (XRF).

The XRF test was conducted in CSIR, Trivandrum.

RPMW mainly contains Si (20%) and Ca (28%) depicting the XRF scan

data.

The silica content in RPMW mainly gives the cementitious property.

Slight amount of metals present.

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Compound ConcentrationMgO 2.446 %

Al2O3 11.892 %

SiO2 19.192 %

P2O5 1.06 %

Cl 2.135 %

K2O 0.769 %

CaO 28.238 %

TiO2 2.283 %

V2O5 502.6 ppm

Cr2O5 566.3 ppm

MnO 702.8 ppm

Fe2O5 7.511 %

NiO 84.2 ppm

CuO 553.5 ppm

ZnO 0.208 %

Ga2O3 39.8 ppm

As2O3 26.4 ppm

Br 185.3 ppm

Rb2O 45.7 ppm

SrO 357.7 ppm

ZrO2 434.1 ppm

Eu2O3 214 ppm

PbO 174.3 ppm

15

2. CEMENT

• A cement is a binder, a substance used in construction that

sets, hardens and adheres to other materials, binding them

together.

• Ordinary Portland cement of 53 grade was used for the

project.

16

3. LATERITE

Laterite is a soil and rock type rich in iron and aluminium.

Nearly all laterites are of rusty-red coloration, because of high

iron oxide content.

Locally available laterite from our college was used for the

project.

Laterite was ground and particles passing through 300 µ was

used.

17

TESTS CONDUCTED ON RAW MATERIALS

1. Test on RPMW

2. Test on laterite

1. SIEVE ANALYSIS

The grain size analysis of RPMW studied by conducting sieve

analysis.

19

TESTS ON RPMW

Sl. No. Sieve Weight retainedgm

% weight retained

Cum. %of weight retained

% finer

1 4.75mm

70.5 14.1 14.1 85.9

2 2.36mm

74.5 14.9 29 71

3 1.18mm

81 16.2 45.2 54.8

4 0.6mm 78 15.6 60.8 39.2

5 0.3mm 95 19 79.8 20.2

6 0.15mm

51 10.2 90 10

7 .075mm

32 6.4 96.4 3.6

8 Pan 18 3.6 100 0

20

21

0.01 0.1 1 100

20

40

60

80

100

120

Grain size (mm)

Perc

enta

ge p

assi

ng %

2. SPECIFIC GRAVITY ON RPMW

Specific gravity of RPMW is the ratio of weight, in air

of a given volume; of dry soil solids to the weight of equal volume

of water at 40C.

22

W1 = empty weight of pycnometer = 581.5gm

W2 = weight of pycnometer + oven dry RPMW = 781.8gm

W3 = weight of pycnometer + oven dry RPMW + water = 1455gm

W4 = weight of water + weight of pycnometer = 1486.5gm

G = The specific gravity of the RPMW was obtained as

0.869,which is comparatively less than conventional clay

material having specific gravity of range 2.6

TESTS ON LATERITE

• SIEVE ANALYSIS

24

The grain size analysis of RPMW is studied by conducting sieve

analysis.

Sl.No

Sieve (mm)

Mass ofsoilretained

Cum.Massretained

Cum. %Ofsoil retained

% finess

1 4.75 0 0 0 100

2 2.36 12.46 12.46 2.492 97.508

3 1.18 88.67 101.13 20.217 79.783

4 0.6 189.19 290.32 58.038 41.962

5 0.3 146.14 436.46 87.254 12.746

6 0.15 53.08 489.54 97.865 2.135

7 0.075 7.57 497.11 99.378 0.622

8 Pan 2.89 500 100 0

25

0.01 0.1 1 100

20

40

60

80

100

120

sieve size (mm)

% fi

nene

ss

MANUFACTURE OF RPMW BRICKS

1. Collection of RPMW from the Punalur Paper Mill

2. Pre-treatments such as drying and grinding.

3. Grinding was done by using Los Angles abrasion testing

machine by providing 500 revolutions.

27

Los Angeles abrasion testing machine

4. Moulds of size 230 x 105 x 80mm.

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5. Proportioning of materials

29

Sl No:

Cement/laterite (%)

RPMW (%)

1 5 95

2 10 90

3 15 85

4 20 80

6. Batching of raw materials

Cement – cement of grade OPC 53 are used.

Laterite – laterite obtained from the field is dried under the sunlight

until it is free from moisture. The dried clay is crushed and sieved

through 300 micron sieve and the laterite passed through the sieve

is collected. The collected laterite is weigh batched according to the

proportions required.

RPMW – The grinded RPMW is sieved through 2.36mm sieve.

RPMW passes through the sieve weigh batched and used in the

required proportion

30

7. Dry mixing of raw materials

8. Wet mixing of raw materials

31

Wet mixing

9. Placing of mix

After obtaining a uniform paste, the mix is placed into the mould

and proper compaction is given to the mix in order to avoid

formation of air voids.

Now level the surface with a trowel and remove the excess paste

using trowel. The mould is kept as such for 2 minutes without any

disturbance

Then removes the mould carefully.

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33

Casting

10. Drying of brick

Place fresh brick in shaded area to protect it from direct sunlight as

exposure to direct sunlight can accelerate crack formation.

Place the fresh brick in shade for 3 days.

After drying in shaded area the brick is placed for sun drying for

next 25 days.

34

35

Sun drying

TESTS ON CONVENTIONAL BRICKS

Conventional brick was tested to determine the compressive

strength, water absorption, efflorescence, hardness, and

soundness. The testing of the burnt clay bricks are done as per

IS 3495 (Part 1to 4):1992.

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37

Compressive strength testing machine

DETERMINATION OF COMPRESSIVE STRENGTH According to the IS 3495 (Part 1):1992

 SLNo:

Load(KN)

Area(mm2)

Crushing Strength(N/mm2)

1. 135 22600 5.973

2. 120 22600 5.309

3. 115 22600 5.088

Average compressive strength = 5.456 N/mm2

38

WATER ABSORPTION (IS 3495 (Part 2):1992

39

SL No:

Dry weight (kg)

Wet weight (kg) Water absorption (%)

1. 2.700 3.310 22.5

2. 2.654 3.290 23.96

3. 2.746 3.322 20.97

4. 2.667 3.291 23.39

Average water absorption value = 22.705%

EFFLORESCENCE IS 3495 (Part 3):1992

The efflorescence test is carried according to IS 3495 (Part 3):1992.

The efflorescence is defined as the crystalline salts deposits on the

surface of bricks.

The liability to efflorescence shall be reported as ‘nil’, slight,

moderate, heavy or serious.

‘Nil’ efflorescence is present on any proportion of the brick.

40

HARDNESS TEST IS 3495 (Part 4):1992

Hardness of brick is the resistance to scratching or cutting.

In this test, a scratch is made on the brick surface by finger nail.

Slight impression is left on the brick surface

41

SOUNDNESS TEST

Two bricks are taken, one in each hand, and they are struck with

each other lightly.

A brick of good quality should not break and a clear ringing sound

should be produced.

The conventional brick tested was sound and has passed soundness

test successfully.

42

TESTS ON RPMW-CEMENT BRICKS

43

Compression testing of RPMW- cement brick

Proportion

(RPMW:Cement)

SampleNo:

Breaking

Load(KN)

Area ofSurface(mm2)

Compressive

Strength(N/mm2)

Average compressive

strength(N/mm2)

80:20 1 75 24150 3.10  2.962 70 24150 2.89

3 70 24150 2.89

85:15 1 50 24150 2.07  1.772 40 24150 1.65

3 40 24150 1.65

90:10 1 20 24150 0.83  0.832 20 24150 0.83

3 20 24150 0.83

95:5 1 20 24150 0.83  0.832 20 24150 0.83

3 20 24150 0.83

44

45

Compressive strength of RPMW-cement bricks

78 80 82 84 86 88 90 92 94 960

0.5

1

1.5

2

2.5

3

3.5

Percentage of RPMW

Com

pres

sive

str

engt

h (N

/mm

2)

WATER ABSORPTION

Water absorption is a major

factor which determines the

strength and durability of

bricks.

The void fraction imparts water

absorption property to bricks.

Because of the fibrous nature

the RPMW has high water

retention capacity

46

Water absorption Test

Proportion

(RPMW :

Cement)

SampleNo:

Dry weight (M1)(kg)

Wet weight (M2)(kg)

Average water

absorption(%)

 80:20

1 1.688 2.496 47.93  47.382 1.708 2.505 46.73

3 1.703 2.510 47.48

 85:15

1 1.493 2.223 48.96  48.182 1.511 2.231 47.78

3 1.506 2.225 47.8

 90:10

 

1 1.512 2.258 49.43  49.092 1.607 2.389 48.78

3 1.546 2.300 48.88

 95:5

1 1.470 2.220 51.08  52.322 1.488 2.272 52.76

3 1.571 2.391 52.22

47

The water absorption of RPMW-cement brick is increasing with

increase in percentage of RPMW.

Proportion 80:20 is found to have lesser water absorption.

On increasing the RPMW content by 5%, water absorption was

found to be increased on an average of 2%.

High water absorption can be reduced by applying water proof

coating over the brick surface without compromising other

physical and mechanical properties of brick material.

48

EFFLORESCENCE.

• After placing the end of the bricks in the dish, at the depth of

25mm immersion in water until all the water in the dish is

absorbed by the specimen and the surface water evaporate.

• But no efflorescence is present on any proportion of the brick.

49

HARDNESS TEST . • Slight impressions are left on the bricks after scratching by

fingernails.

50

SOUNDNESS TEST

The RPMW – cement bricks tested was sound and has passed soundness test successfully.

51

TESTS ON RPMW-LATERITE BRICKS

52

COMPRESSION TEST

Proportion(RPMW : laterite)

SampleNo:

Breaking

Load(KN)

Area of

Surface

(mm2)

Compressive

Strength(N/mm2)

Average compressive strength(N/mm2)

80:20 1 40 24150 1.656

  2 45 24150 1.863 1.725

  3 40 24150 1.656  

85:15 1 20 24150 0.828

  2 30 24150 1.242 0.966 

3 20 24150 0.828

90:10 1 20 24150 0.828   0.8972 20 24150 0.828

3 25 24150 1.035

95:5 1 20 24150 0.828   0.8282 20 24150 0.828

3 20 24150 0.828

53

Compressive strength variation with percentage of RPMW

54

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

Proportion RPMW %

Ave

rage

com

pres

sive

str

engt

h (N

/mm

2)

It is observed that the compressive strength of RPMW-laterite

bricks is less than the RPMW-cement bricks.

It is also observed that the increase in compressive strength is

proportional to amount of the laterite.

55

WATER ABSORPTION

Water absorption is a major factor which determines the strength

and durability of bricks.

After conducting the test in accordance with IS specification the

results are studied

56

 

M1= Dry weight ; M2 = Wet weight

57SampleNo:

Dry weight (M1)(kg)

Wet weight (M2)(kg)

Average water

absorption(%)

 80:20

1 1.688 2.666 57.93  57.382 1.708 2.677 56.73

3 1.703 2.682 57.48

 85:15

1 1.493 2.538 69.99  67.182 1.511 2.495 65.22

3 1.506 2.505 66.33

 90:10

 

1 1.512 2.575 70.30  68.032 1.607 2.676 66.52

3 1.546 2.586 67.27

 95:5

1 1.470 2.531 72.17  70.322 1.488 2.525 69.69

3 1.571 2.657 69.12

It is observed that the water absorption of laterite– RPMW

brick is increasing with increase in percentage of RPMW.

From the results obtained the water absorption corresponding

to proportion 80:20 is found to have lesser water absorption.

58

EFFLORESCENCE

No efflorescence is present on any proportion of the brick.

59

Slight impressions are left on the bricks after scratching by

fingernails.

HARDNESS TEST

SOUNDNESS TEST

The RPMW-laterite bricks tested were sound and has passed

soundness test successfully.

Different type of bricks like conventional clay brick, cement-

RPMW brick, cement-laterite bricks were compared in their

compressive strength.

Compressive strength of conventional clay brick is

comparatively high with other types of bricks.

The low compressive strength of RPMW brick is due to low

silica content, thus results in low binding capacity.

60

COMPARISON BETWEEN DIFFERENT TYPES OF BRICKS

61

Comparison of RPMW-cement and RPMW -laterite

78 80 82 84 86 88 90 92 94 960

0.5

1

1.5

2

2.5

3

3.5

RPMW-cementRPMW-laterite

Percentage of RPMW %

Com

pres

sive

str

engt

h (N

/mm

2)

62

Comparison of RPMW bricks with conventional bricks

0.5 1 1.5 2 2.5 3 3.50

1

2

3

4

5

6

7

clay brickRPMW-cement brickRPMW-laterite brick

com

pres

sive

str

engt

h(N

/mm

²)

STUDY OF VARIATION OF PARTICLE SIZE OF RPMW

The compressive strength obtained for the RPMW bricks were found to be

less than the standards.

Thus study was further extended by changing the particle size of the

RPMW.

The particle sizes of RPMW was decreased as 4.56,2.36,1.18,0.150 mm .

As the particle size is reduced, the strength of the bricks get increased.

The maximum compressive strength was observed for 80:20 ratio brick for

both the cement and laterite brick. Thus, particle variation was done for

this proportion.

The 14th day compressive strength was tested and tabulated

63

 

Sieve size

(mm)

Breaking

Load

(KN)

Area of

Surface

(mm2)

Compressive

Strength

(N/mm2)

Proportion

(RPMW:cement)

80:20

4.56 25 24150 1.035

2.36 30 24150 1.242

1.18 40 24150 1.656

0.150 45 24150 1.863

Proportion

(RPMW:laterite) 

80:20

4.56 20 24150 0.828

2.36 30 24150 1.242

1.18 30 24150 1.242

0.150 40 24150 1.656

64

65

Strength characteristics on changing particle size

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

RPMW-cementRPMW-laterite

Particle size(mm)

Com

pres

sive

str

engt

h(N

/mm

²)

COST ESTIMATION OF RPMW BRICK  

The cost of the RPMW bricks is comparatively less than the

conventional bricks

As the raw material is obtained free of cost from the Punalur Paper

Mills, the cost of only transportation is considered.

The manufacturing can be under taken by unskilled labours.

The cost of fabrication of the mould is a onetime cost.

The cost of manufacture includes transportation charge of RPMW,

labour cost and cost for cement.

66

Cost of conventional bricks = 9 Rs

Proportion of brick (RPMW-cement) = 80:20

Total weight of one brick = 1.700 kg

Weight of materials used for one brick is;

RPMW = 1.360 kg

Cement = 0.340 kg

Cost calculation of each materials

RPMW = 0.60 Rs /kg = 1.36 x 0.6 = 0.816 Rs/brick

Cement (bag) = 400 Rs/bag = 8 Rs/kg = .340 x 8 = 2.72 Rs/brick

Labour cost = 600/1000 bricks = 0.6 Rs /brick

Other expenses = 0.5 Rs /brick

Total cost = Cost of (RPMW + cement + labour cost + other cost)

= 0.816 + 2.72 + 0.6 + 0.5 = 4.636 Rs

67

CONCLUSIONS

The bricks made from RPMW is found to have compressive strength

less than conventional brick.

It is observed that when the amount of cement is increased the

strength also increases.

In our project, the maximum compressive strength was obtained for

RPMW cement brick with 80:20 proportions.

The strength effect on the particle size was also investigated to

improve the strength of brick. It showed a positive result, as the size

of the RPWM particles is reduced, strength is increased.

68

RPMW from Punalur paper mill are found to have silica content only

about 20%. As the silica content in the raw materials is less it affects

the binding property of the particle .

The average weight of the RPMW –cement brick was found to be 1.6

kg which is much less than that of conventional brick .This bricks

are produced without firing which is an advantage over other

manufacturing of bricks in term of low embodied energy material.

The water absorption of RPMW-cement and RPMW-laterite bricks

are increasing with increase in percentage of RPMW.

RPMW-cement and RPMW-laterite bricks passed the efflorescence,

hardness and soundness tests successfully.

69

RECOMENTATIONS FOR FURTHER STUDY

1. In our project while increasing the percentage of cement we get a positive

result. Therefore, we accept an increase in compressive strength by

increasing the amount of cement.

2. Also when decreasing the particle size, the compressive strength is

increasing. This is due to the increase in binding property between the

materials.

3. Required strength can be achieved by adding proper admixtures.

4. The silica content of the RPMW collected is comparatively less. So

adding materials with high silica content may also increase the strength of

the brick.

70

REFERENCE

1. S.P. Raut , Rohant Sedmake , Sunil Dhunde , R.V. Ralegaonkar , Reuse of recycle paper

mill waste in energy absorbing light weight bricks, Construction and Building

Materials(2011)

2. D. Rajput, S.S. Bhagade, S.P. Raut , R.V. Ralegaonkar , Sachin A. Mandavgane, Reuse

of cotton and recycle paper mill waste as building material, Construction and Building

Materials 34 (2012) 470–475

3. S. Raut, R.Ralegaonkara,S.Mandavgane, Utilization of recycle paper mill residue and

rice husk ash in production of light weight bricks , Archives of civil and mechanical

engineering 1 3 ( 2 0 1 3 ) 2 6 9 – 2 7 5

4. S.P Rout,R.V Ralegaonkar ,S.A.Mandavgane,Development of sustainable construction

material using industrial and agricultural solid waste:A review of waste-crete bricks

71

5. S.P. Raut a, R.V. Ralegaonkar , S.A. Mandavgane, Development of sustainable

construction material using industrial and agricultural solid waste: A review of

waste-create bricks , Construction and Building Materials 25 (2011) 4037–4042

6. Mucahit Sutcu 1, Sedat Akkurt ,The use of recycled paper processing residues in

making porous brick with reduced thermal conductivity, Ceramics International 35

(2009) 2625–2631 

7. Alaa.A.Shakir, Sivakumar Naganathan, Kamal Nasharuddin Bin Mustapha,

Development Of Bricks From Waste Material: A Review Paper, Australian Journal of

Basic and Applied Sciences, 7(8): 812-818, 2013 ISSN 1991-8178

8. Ashwin Narendra Raut and Christy Pathrose Gomez, Utilization of Waste as a

Constituent Ingredient for Enhancing Thermal Performance of Bricks – A Review

Paper, Indian Journal of Science and Technology, Vol 9(37), DOI:

10.17485/ijst/2016/v9i37/87082, October 2016

72

9. Ismail Demira,_, M. Serhat Baspınara, Mehmet Orhanb, Utilization of

kraft pulp production residues in clay brick production, Building and

Environment 40 (2005) 1533–1537

10. J E Oti,J M Kinuthia ,Stabilised unfired clay bricks for environmental and

sustainable use,Applied clay Science 58 (2012) 52-59

11. IS 3495 ( Parts 1 to 4 ) : 1992, METHODS OF TESTS OF BURNT

CLAYBUILDING BRICKS

12. IS 1077 : 1992( Reaffirmed 2002), COMMON BURNT CLAY

BUILDING

13. BRICKS – SPECIFICATION ( Fifth Revision )

73

THANK YOU

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