International Journal of Civil Engineering and Technology (IJCIET)

Volume 9, Issue 3, March 2018, pp. 961–968, Article ID: IJCIET_09_03_096

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ISSN Print: 0976-6308 and ISSN Online: 0976-6316

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PARTIAL REPLACEMENT OF FINE

AGGREGATES OF FIRE BRICKS WITH FINE
AGGREGATES IN CONCRETE
Manoj Kumar
Lovely Professional university, Phagwara, (Punjab), India

Awadhesh Chandramauli
Department of Civil Engineering, Uttaranchal University, Dehradun (Uttarakhand), India

Ashutosh
Maharishi Ved Vyas Engineering College, Jagadhri, (Haryana), India

ABSTRACT
India is a developing country. Developing infrastructure leads to consumption of
concrete. Sand have big value in concrete. But natural sands are limited resources.
River sand is most common fine aggregates in concrete. Due to excessive production
of the river sand, it is banned by the government of India. Thus replacement of sand
becomes need in last decays and the partially replacement will contribute to a good
point to the research area. Number of researcher doing work on the replacement of
sand by number of material like waste glass powder, crushed fir bricks and etc. Fire
bricks are used to prevent the heat transfer in industries, lining furnace and fire
places. The waste material of fire bricks can be used as fine aggregates. Properties of
fire bricks are increases the strength of concrete. This research able to reduce the
dependency on sand and open a new option to dispose of waste fire bricks. Partial
replacement is done at 0%, 22%, 25%, 28% and 31% in this project. The test result
says the 28% replacement gives the maximum tensile strength.
Keywords: Concrete, Sand, River, Stone, Seepage, Fire Brick, India
Cite this Article: Manoj Kumar, Awadhesh Chandramauli and Ashutosh, Partial
Replacement of Fine Aggregates of Fire Bricks with Fine Aggregates in Concrete,
International Journal of Civil Engineering and Technology, 9(3), 2018, pp. 961–968.
http://iaeme.com/Home/issue/IJCIET?Volume=9&Issue=3

1. INTRODUCTION
River sand is most common fine aggregates are used in concrete. River sand is most suitable
fine aggregates in concrete. Due to the excessive production of the river sand is banned by
government in India. Thus replacement of sand becomes need in last two decays. Number of

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 Manoj Kumar, Awadhesh Chandramauli and Ashutosh

researches occurring in world on replacement of sand by number of material like waste glass
powder, spent fire bricks, crushed brick fine aggregates, crushed coarser aggregates, fly ash,
etc. Brick aggregates are very easily available at very low cost. It may be recycled from
destroyed buildings, bridges, and any other destroyed structures.
People from 7000 BCE have been using bricks. Turkey is that country where first brick is
found. On that time bricks were dried in sun light. This sun dried brick is not sufficient
strength. But fired brick were very high resistance. In any condition fire brick gave very
suitable results. That is why it used in permanent structures. In the construction of buildings,
bricks are generally used more than wood than other materials. Now these days many types of
machineries are available. With the help of these machineries many types of these bricks are
made with different shapes and with different materials. But clay is the first preference for fire
bricks. Apart from this, materials such as calcium silicate and concrete are also used much
more. Many materials are available now but most using is clay on industry level. In 2007
bricks made with fly ash. And fly ash are using for making roads on footpath and residential
areas. Fly ash are taken from thermal power plants. Bricks are the common building materials
which are used in construction these days. Crushed bricks in the form of aggregates finer or
coarser are called crushed brick aggregates. Bricks are very easy available material. Because
natural sand is limited natural resources thus a replacement need occurred. Brick aggregates
are very low and its result in concrete is very good. Researcher has tested the aggregates
bricks the got the higher compressive strength at 20% partially replaced the fine aggregate of
bricks with fine aggregates of concrete. But some researcher found the decrease in the
strength up to 40%. That is why is its great success to find the advantage of brick aggregates
in concrete. Bricks are found in number of types because it is common usable material. The
types of bricks aggregates like common burnt clay bricks aggregates, calcium silicate bricks
aggregates, engineering bricks aggregates, concrete bricks aggregates, fly ash clay bricks
aggregates, crushed spent fire bricks aggregates, fired brick aggregates, recycle bricks
aggregates. Brick aggregates directly affects the concrete properties when concrete are in
fresh state and hardened state. Fire bricks are used for inner lining of kiln meant for firing.
Due to continuous exposure to high degrees of temperature about 1,800 to2,100ºC for twelve
to eighteen days, if any brick keeps less strength or low strength which desired then let it out
and put a new brick. The usage or replacement of fire bricks is periodical in nature in
metallurgical based industries. The fire bricks disposed off after use are called as Spent Fire
Bricks. The Spent Fire Brick which are the waste should be through properly without causing
environmental problems in the vicinity of dump. Usually the waste materials are disposed by
land filling. In the similar manner the spent fire bricks are also used as land filling material.
The fire bricks so generated as waste, first of all clean it and after then crushed till get fine
aggregates. The fineness modulus of crushed spent fire brick powder is nearly equal to river
sand used in concrete. As such, the crushed spent fire brick can be used in place of river sand
partially in making the concrete. Bricks are made from the burnet fire clay. Bricks are formed
in the kiln at 1300oC for 10 to 15 days.

2. LITERATURE REVIEW
A. Siva et al., 2017, bricks are easily available material. Bricks normally used as the non-
bearing wall structure. In this experiment when fine aggregates are partially replaced by
crushed bricks in proportion of 10%, 15%, 20%, 25% then found that the workability of
concrete is decrease. Compressive strength of is obtained maximum when added 20% of
crushed fire bricks. Because crushed fire brick is made of plastic and non-plastic clay. It put
into kiln at 1300C for 10 to 15 days. Then its property gets totally changed. The unit weight
of fire brick is 20KN/m. crushed fire brick is sieved on 4.75 mm sieve and who passed from
the sieve of 4.75 mm sieve and not passed from 75 micron IS- sieve and then partially

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 Partial Replacement of Fine Aggregates of Fire Bricks with Fine Aggregates in Concrete

replaced from fine aggregates. For test the of split tensile strength measured from cylinder is
made of 150mm x 300 mm size for M30 concrete grade after partially replacement. After
made this keep for 24 hours and curing done up to 28 days. Fine aggregates of fire brick gives
higher compressive strength when replaced 20% with fine aggregates. This compressive
strength is 1.2% in higher. But strength of split tensile is get less if percentage is increasing
more than 20%.
Nisha Devi. A et al., 2016, glass powder is partially replaced with cement. And fine
aggregate of fire bricks are partially replaced with fine aggregates. In this experiments glass
powder increase the workability and fire brick powder act as a filler in concrete and increases
the flexure strength, ductility, compressive stress, tensile strength. In this project the glass
powder is replaced with cement at 10%, 20% and 30%. Fire brick powder is replaced at 10%,
15%, 20%, and 25%. Ordinary Portland cement are used which having 43 grade. Fire brick
powder belongs from Zone-II. Compressive strength, tensile strength and flexure strength is
measured with cubes 150*150*150 mm, 150*300 mm and 100*100*500 respectively for
7days and 28 days. Crushed spent fire brick is gives higher compressive strength at 20%
replaced. More than 20% it reduces the strength. Split tensile strength increases at 20 %
replacement of fine aggregates of fire brick. When replacement further increases the tensile
strength is decreases.
S. Keerthinarayana et al., 2010, As per IS 6 and 8 specifications, the fire bricks are
made from plastic and non-plastic clay. These bricks are fired in oil kiln and temperature
increased up to 1350°C these are fired in oil-fired kiln at a temperature of 1,300°C. Bricks are
fire brick are fired at 1750 to 2200 ºC for thirteen to twenty days. If any brick keeps less
strength or low strength which desired then let it out and put a new brick. Then, the SFB is an
industrial solid waste to be disposal off properly and. First of all these cleaned and crushed
into fine aggregates. The concrete contains 62 to 81 percent volumes by coarse and fine
aggregates. Performance is totally depend upon the properties like chemical and physical
properties. Crash Spartter was compared with fire of bricks, as well as the place of aggregates,
with different physical-chemical properties and sands of original creations. Test result is same
as compressive test result that when CSFB is adding 25 to 30% then tensile strength also
increased. Flexure strength is determine by applied the load and when crack in concrete are
visible noted that values. Dimension for rupture modulus is 150*150*700 in meter are taken.
If more than 600mm span then 100*500 mm with 450mm span and applied point load.
Tiwari Darshita et al., 2014, as per IS-10262, cubes is formed of grade for M20, M25,
and M30. The cubes were crushed in the labs and follow the criteria of IS code of 1343. The
crushing strength is measure for 3days, 7days, and 28 days. And observed that for M20 grade
in which sand is partially replaced by the brick powder. When added 10% brick powder the
compressive strength is decreases and when added 20% brick powder the strength is
increased. If increased the brick powder more than 20% then decrease the compressive
strength of M20 grade concrete.

3. PROPERTIES OF MATERIALS
The properties of materials are used like fine aggregates of crushed fire bricks, fine
aggregates, coarse aggregates, cement and all procedures are conducted as per Indian
Standard Codes.

3.1. Fine aggregates of crushed fire bricks

Fire bricks are use as per IS: 6. Fire bricks are crushed into fine aggregates which is passed
through 4.75 mm IS sieve and retained on 150 micron meter (0.150 mm) IS sieve. Crushed
fire bricks satisfying zone-II.

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 Manoj Kumar, Awadhesh Chandramauli and Ashutosh

Table 1 Properties of Crushed fire aggregates

S.N. Properties of Crushed fire bricks Values
1 Specific gravity 2.31
2 Net water absorption 0.70%
3 Fineness modulus 2.57
4 Grading Zone II

110
Percentage of Finner (%)

100
90
80
70
60
50
40
30
20
10
0
100.00 10.00 1.00 0.10 0.01 0.00
IS Sieve size (mm)

Figure 1 Particle size distribution curve of crushed fire bricks

3.2. Fine aggregates

Aggregates who passed through 4.75 mm sieve and retained on 15µm (0.150 mm) IS sieve.
Specifications of fine aggregates are followed as per IS 383: 2016. Fine aggregates are
used satisfied zone-II. Following tests are conducted on fine aggregates.

Table 2 Properties of fine aggregates

S.N. Properties of fine aggregates Values
1 Specific gravity 2.56
2 Net water absorption 0.81%
3 Fineness modulus 2.18
4 Grading Zone II

Chart Title
110
Percentage of Finner (%)

100
90
80
70
60
50
40
30
20
10
0
100.000 10.000 1.000 0.100 0.010 0.001
IS Sieve size (mm)

Figure 2 Particle size distribution curve for sand

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 Partial Replacement of Fine Aggregates of Fire Bricks with Fine Aggregates in Concrete

3.3. Coarse aggregates

The aggregates which is passed through the 20 mm IS sieve and retained on 4.75 mm IS sieve
are called coarse aggregates. Specifications of coarse aggregates are as per IS 383: 2016
(clause 6.1.1). Angular shapes of coarse aggregates are used. Following tests are made on
coarse aggregates.

Table 3 Properties of coarse aggregates

S.N. Properties of coarse aggregates Values
1 Specific gravity 2.5
2 Net water absorption 1.41%
3 Fineness modulus 2.58

110
Percentage of Finner

100
90
80
70
60
(%)

50
40
30
20
10
0
100.000 10.000 1.000 0.100 0.010 0.001
IS Sieve size (mm)

Figure 3 Particle size distribution curve of coarse aggregates

3.4. Cement
Ordinary Portland cement of grade 43 are used as per IS 8112: 1989. Cement used as a
binding material in constructions. It becomes harden when comes with the contact of water.
Cement used to bind the building materials. ‘Cement’ names comes from ancient roman
emperor. Opus caementicium is called Roman concrete. Roman concrete is based on the
hydraulic setting. But modern cement is based on the Portland cement which are using in this
project. Following test are conducted which result are given below.

Table 4 Properties of cement

S.N. Properties of fine aggregates Values
1 Specific gravity 3.15
2 Normal consistency 33%
3 Fineness modulus 85%
4 Minimum cement content (Kgm./m 3) 280
Maximum cement content (Kgm./m3) 478.98

3.5. Water
Water for construction of concrete structure should be same quality as drinkable water. The
strength of concrete is totally depend upon the water thus water should be free from
impurities. Impurities like suspended solids, dissolved salts organic matter. Which affect
properties of concrete. These impurities can be changed setting time, hardening, strength,

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 Manoj Kumar, Awadhesh Chandramauli and Ashutosh

durability and etc. Water should be tested from an approved lab and should be checked
regularly and pH value of water is 7.

3.6. Mix design of Concrete for M25

Design mix of concrete for 25 grade are made as per IS 10262: 2009. Water cement ratio and
minimum cement content is taken as per IS 456: 2000 (Table 5). Size of nominal maximum of
aggregates is 20 mm used. Minimum water content as per IS 10262: 2009. Proportion of mix
design are given below.

Table 5 Mix design proportion of M25

Cement Sand Coarse aggregates Water
1 1.3 2.1 0.4

4. EXPERIMENTAL STUDY
In this project the mechanical properties of concrete is improved by the partially replace of
fine aggregates of fire brick aggregates with fine aggregates in concrete. The replacement is
done at the varying percentage of 0%, 22%, 25%, 28% and 31% percent. Crushed fire brick’s
mechanical properties are similar as river sand. Mechanical properties of fine aggregates and
fine aggregates of crushed fire brick are followings.

4.1. SPLIT TENSILE STRENGTH

Split tensile strength is a most important properties of concrete. Split tensile strength is
measured by standard size of plain cylinder 100 mm (diameter) and 200 mm length. M25
grade of plain concrete cylinder are used. After24 hours of moulding of cylinders made curing
for 7 days and 14 days. During the moulding of cylinder vibrating table are used.

5. RESULT AND DISCUSSION

As per design mix of concrete M25 and according to IS 10262: 2009. Split tensile strength is
measured for partial replacement of fine aggregate of crushed fire brick (IS: 6) with fine
aggregates in concrete at various percentages such as 0%, 22%, 25%, 28%, 31% after 7 days
and 14 days curing and found that the optimum tensile strength is gained at 28% partial
replacement.

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 Partial Replacement of Fine Aggregates of Fire Bricks with Fine Aggregates in Concrete

Table 6 7 days Split Tensile Strength of M25 Concrete

7 Days Split tensile Strength
Cylinder (100*200)
mm Tensile strength Increase (+) /Decrease
S.No. Replacement
(KN/mm2 ) (-) strength (%)
Peak Load (KN)
1 0% 113.8 11.38 0%
2 22% 109.7 10.97 -3.60%
3 25% 114.5 11.45 0.62%
4 28% 123.1 12.31 8.17%
5 31% 116.5 11.65 2.37%

Figure 4 7 Days split tensile strength of M25

6. FUTURE SCOPE
1. It will slightly reduce the dependency on natural sand.
2. High strength gives in tension as compare to conventional concrete.
3. Accidental fire bricks or fire bricks who has deformed or recycled bricks are easily
available in India when partially replaced with sand then cost will be reduced.
4. Natural aggregates are the natural resources and which are limited. Thus fire bricks
aggregates concrete can be best cheap material instead of natural sand.
5. This project will open the new benchmark in research.

7. CONCLUSION
1. The maximum size of aggregates should not be greater than 10 mm to 20 mm.
2. Angular shapes of coarse aggregates are used.
3. Slump of concrete is 60 mm.
4. Split tensile strength is increased when 25% to 31% replacement is done.
5. Optimum split tensile strength of M25 is achieved at 28% replacement
6. All procedures are done as per Indian standards.
7. Water absorption for coarse aggregates and fine aggregates are less than 2%.
8. Both fine aggregates are satisfying Zone-II.

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REFERENCES
[1] A.Siva, Thamilselvi, A. Nisha Devi1 and B. Ashvini (2017), Experimental Investigation
on Partial Replacement of Fine Aggregate Using Crushed Spent Fire Bricks, American
Journal of Engineering Research (AJER), e-ISSN: 2320-0847 p-ISSN: 2320-0936,
Volume-6, Issue-2, pp-01-04.
[2] Nisha Devi. A (2016), Study of Partial Replacement by Glass Powder and Crushed Spent
Fir Bricks in Concrete, International Journal of Engineering Research & Technology
(IJERT), ISSN: 2278-0181, Vol. 5 Issue 03, March-2016.
[3] Veerni Lakshmi (2016), An Investigation on Flexural Behavior of Concrete with Fine
Aggregate Partially Replaced with Grog, International Journal of Innovations in
Engineering and Technology (IJIET), Volume 7 Issue 4 December 2016, ISSN: 2319 -
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[4] Tiwari Darshita, Patel Anoop (2014), Study of Strength and Workability of Different
Grades of Concrete by Partial Replacement of Fine Aggregate by Crushed Brick and
Recycled Glass Powder, Volume 3 Issue 6, June 2014, International Journal of Science
and Research (IJSR) ISSN (Online): 2319-7064
[5] Keerthinarayana S. and Srinivasan R. (2010), Study on Strength and Durability of
Concrete by Partial Replacement of Fine Aggregate using Crushed Spent Fire Bricks,
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[6] M. Usha Rani and J. Martina Jenifer (2016), An Experimental Study on Partial
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[7] Gopinandan Dey and Joyanta Pal (2013), Use of Brick Aggregate in Standard Concrete
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BIOGRAPHY:
Corresponding Author Er. Manoj Kumar, Lovely Professional University,
Phagwara Punjab (India). Three year teaching experience

Co-Author Er. Awadhesh Chandramauli Astt. Professor in Department of

Civil Engineering Uttaranchal University, Dehradun (Uttrakhand) He has
more than six years teaching experiences and has done his M.tech. in civil
Engineering (Structural Engineering).

Co-Author Er. Ashutosh, Maharishi Ved Vyas Engineering College,

Jagadhri Distt. Yamuna agar Jagadhri, Haryana, India

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