Development of interlocking flyash brick machine and study of brick structural efficiency

Selvapriya, Rajendran; Thanigaivelan, Rajasekaran

doi:10.1590/1517-7076-RMAT-2023-0350

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Articles • Matéria (Rio J.) 29 (2) • 2024 • https://doi.org/10.1590/1517-7076-RMAT-2023-0350 copy

Development of interlocking flyash brick machine and study of brick structural efficiency

Authorship SCIMAGO INSTITUTIONS RANKINGS

ABSTRACT

Eco friendly manner fly ash management and utilization is the need of the hour and one of the possible ways of using it is by fabrication of interlocking bricks out of it. This research focus on the development of interlocking brick machine and bricks manufactured is tested for dimension stability, water absorption, compressibility strength and efflorescence test. The machine setup was successfully fabricated and used for production of interlocking flyash bricks. The setup mainly consists of machine structure, hydraulic system and pan mixer. Two varieties of interlocking bricks were produced with the size of 12” × 6” × 5” and 12” × 8” × 5”. Based on the results of the test the interlocking bricks are found suitable for better replacement of the ordinary bricks.

Keywords
Dimension stability; Water absorption; Compressibility strength; Efflorescence test; Environment; Solid waste management

FEATURES	SPECIFICATION
Power	5 Phases 7.5 Hp
RPM	1450
Machine weight	1850 (Approximately)
Production capacity	1400 to 1500 (Approximately)
Production timing	30 Sec Per Block
Pressure load	40 Tonnes
Motor	Havells
Hydraulics	All heavy branded materials
Hydraulic tank capacity	260 Litres
Die plates	JSW En8HHCR/EN31
Brick size	Standard 12 × 8 × 5, 12 × 6 × 5 [inches]
Groove size	Standard 15 mm
Raw materials	Cement, Flyash, M Sand, Lubricants, Dr. Fixit, Pidiproof
Pan mixer capacity	400 Kgs
Bolt, nuts	TVS Brand
Flow handling capacity	High pressure max. – 60 l/min Low pressure max. – 160 l/min

SYMBOL	DESCRIPTION
HP	High pressure pump connection
LP	Low pressure pump connection
P	Outlet connection
HPG	Gauge connection on high pressure pump line
LPG	Gauge connection on low pressure pump line
Pt	Pilot pressure connection [Optional]
T1	Tank connection of high pressure relief valve
T2	Tank connection of low pressure unloading valve
F	Filter port connection [T1&T2]
R	Outlet connection [Reduced Pressure]

FEATURES	SPECIFICATION
Power	3 Phases (7.5 + 5) – 12.5 Hp
Weight	1150 Kgs (Approximately)
Drum Dia Meter	1350 mm
Drum Height	550 mm
Motor	Havells
Cell Plate Thickness	10 mm Thick and Additional 8 mm
Drum Plate Thickness	6 mm Thick and Additional 6 mm Half Drum
Cycle Time	8 to 10 Minutes
Hopper Loading Capacity	250 to 300 Kgs

S. NO	PROPERTIES	RESULT
1.	Fineness	300 m²/kg
2.	Normal Consistency	33%
3.	Initial Setting Time	30 Mins
4.	Final Setting Time	600 Mins
5.	Compressive Strength 3 Days 7 Days 28 Days	27 MPa 37 MPa 53 MPa

S. NO	PROPERTIES	RESULT
1.	Specific Gravity	2.15
2.	Initial Setting Time	130 Mins
3.	Final Setting Time	290 Mins
4.	Retained on 45 Micron	2.66 %
5.	Specific Surface	320 m²/kg
6.	Soundness	0.15%
7.	Water Requirements	96%

S. NO	PROPERTIES	RESULT
1.	Specific Gravity	2.5
2.	Fineness Modulus	2.75
3.	Water Absorption	0.26%

	6"				8"
Trail	L^# L# length in mm, W# width in mm, H# height in mm h# web height in mm.	W^# L# length in mm, W# width in mm, H# height in mm h# web height in mm.	H^# L# length in mm, W# width in mm, H# height in mm h# web height in mm.	h^# L# length in mm, W# width in mm, H# height in mm h# web height in mm.	L^# L# length in mm, W# width in mm, H# height in mm h# web height in mm.	W^# L# length in mm, W# width in mm, H# height in mm h# web height in mm.	H^# L# length in mm, W# width in mm, H# height in mm h# web height in mm.	h^# L# length in mm, W# width in mm, H# height in mm h# web height in mm.
1	296	148	124	123	297	197	123	124
2	298	147	123	124	296	197	123	124
3	298	148	124	123	297	198	124	124
4	295	148	123	124	296	199	124	123
5	296	147	124	124	297	198	123	124
6	295	149	124	123	295	197	124	124
7	295	147	123	123	294	197	123	123
8	298	148	123	124	297	199	124	123
9	298	147	124	123	296	198	124	123
10	295	149	123	124	295	197	123	124

	TOLERANCE IN % FOR 6"				TOLERANCE IN % FOR 8"
Trail	L^#	W^#	H^#	h^#	L^#	W^#	H^#	h^#
1	–1.33	–1.33	–0.80	–1.60	–1.00	–1.50	–1.60	–0.80
2	–0.67	–2.00	–1.60	–0.80	–1.33	–1.50	–1.60	–0.80
3	–0.67	–1.33	–0.80	–1.60	–1.00	–1.00	–0.80	–0.80
4	–1.67	–1.33	–1.60	–0.80	–1.33	–0.50	–0.80	–1.60
5	–1.33	–2.00	–0.80	–0.80	–1.00	–1.00	–1.60	–0.80
6	–1.67	–0.67	–0.80	–1.60	–1.67	–1.50	–0.80	–0.80
7	–1.67	–2.00	–1.60	–1.60	–2.00	–1.50	–1.60	–1.60
8	–0.67	–1.33	–1.60	–0.80	–1.00	–0.50	–0.80	–1.60
9	–0.67	–2.00	–0.80	–1.60	–1.33	–1.00	–0.80	–1.60
10	–1.67	–0.67	–1.60	–0.80	–1.67	–1.50	–1.60	–0.80

SPECIMEN NUMBER	SIZE OF BRICK (mm)	W₁ (KG)	W₂ (KG)	WATER ABSORPTION (%)	AVERAGE WATER ABSORPTION (%)
1	300 × 150 × 125	10.180	10.680	4.91	4.81
2		10.160	10.640	4.72
3		10.180	10.670	4.81
4	300 × 200 × 125	14.160	14.940	5.51	5.41
5		14.160	14.910	5.30
6		14.180	14.950	5.43

SPECIMEN NUMBER	SIZE OF BRICK (mm)	WEIGHT (W) (KG)	LOAD (KG)	COMPRESSIVE STRENGTH (N/mm²)	AVERAGE COMPRESSIVE STRENGTH (N/mm²)
1	300 × 150 × 125	10.460	240	5.33	5.26
2		10.450	250	5.56
3		10.420	220	4.89
4	300 × 200 × 125	13.580	430	7.17	7.22
5		13.410	420	7.00
6		13.260	450	7.50

Laboratório de Hidrogênio, Coppe - Universidade Federal do Rio de Janeiro, em cooperação com a Associação Brasileira do Hidrogênio, ABH2 Av. Moniz Aragão, 207, 21941-594, Rio de Janeiro, RJ, Brasil, Tel: +55 (21) 3938-8791 - Rio de Janeiro - RJ - Brazil
E-mail: revmateria@gmail.com

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[1] *Corresponding Author: Rajasekaran Thanigaivelan, e-mail: selvapriyarajendran96@gmail.com, tvelan10@gmail.com