In this project very innovative for manufacture the brick in paper and other materials. so this project name is PAPER BRICK. if u need any idea or discuss to improve this project join with my blog.
Friday, 20 June 2014
INTRODUCTION
While
taking the building materials, brick remains one of the most important building
material in India. Notably the Indian brick industry, which is the second
largest producer in the world, next only to china, has more than 1,00,000
operating units, producing about 140 billion bricks annually. The industry has
an annual turnover more than Rs.140 billion. And it is one of the largest
employment-generating industries employing millions of workers.
The
conventional brick making is an energy intensive process. In India fuel cost
alone account for almost 30 - 40% of the production cost. The conventional
brick making practice consumes huge quantities of fuel in terms of coal,
firewood, and other biomass fuel. It is estimated that the Indian brick
industry consumes more than 24 million tones of coal annually, in addition to
several million tones of biomass fuels. Kilns are also nutrious as highly
polluting establishments, affecting not just flora, fauna, but also posing
threats to human health.
In
this project, the above problems were solved by introducing an alternative,
cost effective, eco-friendly innovative building bricks. These alternative
bricks were made with papercrete. Papercrete is a tricky term. The name seems
to imply a mix of Paper and concrete, hence Papercrete. Different types of
Papercrete contain 50 – 80 % of waste paper. Papercrete additives can be
Portland cement, sand, fly ash.
In this project sand, cement, and waste
materials like paper, fly ash, were mixed in various proportions and a suitable
proportion which gave more strength, less cost, inflammable, less water
absorbance and more eco friendly was found out. And the character of that
successive proportions were analysed in this project.Objectives
The major Objective of the project
is replacing the costly and scarce conventional building bricks by an
innovative and alternative building bricks, which satisfies the following
characteristics,
o
Required strength
o
Cost effective
o
Environmental friendly
o
Less weight
o
Inflammable
o
Less Water absorbent
o
Easily available
LITERATURE REVIEW
First of all various books and
journals were collected for reference and were studied before starting the
project work for having an idea about how the project should be. In this
project an alternative building bricks are introduced. So, first the basic and
essential characteristics of bricks were studied. And the details about the new
technique what was used in this project i.e., papercrete, was collected from
the journals.
BRICKS
The
bricks are obtained by molding clay in a
rectangular blocks of uniform size and then by drying and burning the blocks.
As the bricks are of uniform size, they can be properly arranged and further,
as they are in lightweight, no lifting appliance is required for them. The
common brick is one of the oldest building material and it is extensively used
at present as a leading material in construction. In India, process of brick
making has not changed since many centuries except some minor refinements.
There has been hardly any effort in our country to improve the brick-making
process for enhancing the quality of bricks.
A
brick is generally subjected to the following tests to find out its suitability
for the construction work.
Absorption
A
brick is taken and it is weighed dry. It is then immersed in water for a period
of 16 hours. It is weighed again and the difference in weight indicates the
amount of water absorbed by the brick. It should not, in any case, exceed 20%
of weight of dry brick.
Crushing Strength
The
crushing strength of a brick is found out by placing it in a compression-testing
machine. It is compressed till it break, as per BIS: 1077-1957, the minimum
crushing strength of brick is 3.50 N/mm2 .The brick with crushing
strength of 7 –14 N/mm2 are graded as ‘A’ and those having above 14
N/mm2 are graded as ‘AA’.
Hardness
In
this test, a scratch is made on the brick surface with the help of fingernail.
If no impression is left on the surface, the brick is treated to be
sufficiently hard.
Presence of soluble salts
The
soluble salts, if presents in brick will cause efflorescence on the surface of
bricks. For finding out the presence of soluble salts in brick, it is immersed
in water for 24 hours. It is then taken out and allowed to dry sunshade. The
absence of grey or white deposits on its surface indicates absence of soluble
salts.
If
the white deposit covers about 10% surface, the efflorescence is said to be
slight and it is considered as moderate, when the white deposit cover about 50%
surface. If grey or white deposits are found on more than 50% of surface, the
efflorescence becomes heavy and it is treated as serious, when such deposits
are converted into powdery mass.
Shape and size
In
this test, a brick is closely inspected. It should be of standard size and its
shape should be truly rectangular with sharp edges. For this purpose, 20 bricks
of standard size (190mm X 90mm X 90mm) are selected at random and they are
stacked length wise, along the width and along the height.
For
a good quality brick, the results should be within the following permissible
limits:
Length:
3680mm to 3920mm
Width
: 1740mm to 1860mm
Height:
1740mm to 1860 mm
Soundness
In
this test, two bricks are taken and they are struck each other. The bricks
should not break and a clear ringing sound should be produced.
Structure
A
brick is broken and its structure is examined. It should be homogeneous,
compact and free from defects such as holes, lumps etc.,.
PAPERCRETE
Papercrete
is a tricky term. The name seems to imply a mix of paper and concrete, hence
papercrete. But more accurately, only the Portland cement part of concrete is
used in the mix-if used at all. Arguably, it could have been called
“paperment”. Papercrete may be mixed in many ways. Different types of
papercrete contain 50-80% of waste paper. Up to now, there are no hard and fast
rules, but recommended standards will undoubtedly be established in future.
The
basic constituents are water nearly any kind of paper, card board, glossy
magazine stock, advertising brochure, junk mail or just about any other type of
“Mixed Grade” paper is acceptable. Some types of paper work better than others,
but all types of work, newsprint is the best. Water proofed paper and card
board, such as butcher paper, beer cartons etc., are harder to break down in
water. Catalogs, magazines and other publications are fine in and of
themselves, but some have a stringy, rubbery, sticky spine, which is also water
resistant. Breaking down this kind of material in the mixing process can’t be
done very well. Small fragments and strings of there materials are almost
always present in the final mix. When using Papercrete containing the unwanted
material in a finish, such as stucco or plaster, the unwanted fragment some
times show up on the surface, but this is not the serious problem.
Papercrete’s additives can
be,
o
Cement
o
Sand
o
Fine earth
o
Clay
o
Fly ash
o
Powdered glass
o
Rice husk ash
Papercrete is having the
following derivatives,
o Fibrous
concrete
o Padobe
o Fidobe
Fibrous concrete
Fibrous concrete
is a mixture of paper, Portland cement, water. There are no harmful by-products
or excessive energy use in the production of papercrete. While it can be argued
that the Portland cement is not environmental friendly, it is not used in all
types of papercrete, and when it represents a fairly small percentage of cured
material by volume. One of the most advantageous properties of papercrete is
the way paper fibres hold the Portland cement or perhaps the way Portland
cement adheres to paper fibres. When the water added to the paper and Portland
cement drains from the mix, it comes out almostly clear. There is no messy and
eco-unfriendly cement sediment left on the ground, running in to waterways
etc., papercrete can be produced using solar energy. The only power needed is
for mixing and pumping water. Its R-value is rated between 2.0-3.0 per inch.
Since walls in a one or two storey house will be 12-16 inches thick, the
long-term energy savings of building with papercrete will be a bonanza for the
homeowner and the environment.
Padobe
Padobe has no Portland cement. It is a mix of paper,
water, earth with clay. Here clay is the binding material instead of using
cement, earth is used in this type of brick. This earth should have clay
content more than 30%. With regular brick, if the clay content is too high the
brick may crack while drying, but adding paper fiber to the earth mix
strengthens the drying block and give some flexibility which helps to prevent
cracking.
Fidobe
Fidobe is like padobe, but it may contain other fibrous
material.
ECO – FRIENDLY
Phenomenal
growth in the construction industry that depends upon the dependable resources. Production of building materials lead to irreversible environmental impacts.
Using Eco-friendly materials is the best way to build a Eco-friendly building.
Eco-friendly, describes a product that has been designed to do the least
possible damage to the environment. US-EPA programme defines, Eco-friendly
products or services that have a lesser or reduced effect on human health and
the environment when compared with competing products or services that serve
the same purposes.
MATERIAL CHARACTERISTICS
Materials are the important
criteria to produce a product. The materials should be easily available and
eco-friendly. In this project waste materials were utilized to produce building
bricks. The following materials were used in this project
o
Paper
o
Fly ash
o
Sand
o
And ordinary Portland cement
The characteristics of these materials are as
follows.
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