FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULE, 2003
COMPLETE SPECIFICATION
(See Section 10, Rule 13)
"ECOFRIENDLY GREEN BRICK PRODUCTION USING RECLAIMED SAND
DUST WASTE"

Field of Invention
Industrial solid waste (ISW) is risky to manage in future due to rapid industrialization and also causes degradation of environment. Rapid increase of population in the country has resulted in rapid growth of construction industry. Since natural materials are limited, there will be impact on supply and demand of building materials. Shortage of the precious materials results in high cost. Recycling has always been a matter of obtaining an economic benefit or of helping the environment. The main objective of the recycling industrial waste is to reduce usage of natural construction material, reuse and recycling of industrial waste. Several researchers investigated several green materials technologies that reduce environmental effects and reuse Industrial solid waste materials in production of eco-friendly construction materials which can be used for infrastructures applications.
Background / Prior Art
Following work is considered as background.
Algin et al. (2007) had used cotton waste (CW) and lime stone powder waste (LPW) in the production of lighter and economical new brick material. Results of the studies revealed that that the effect of 10-40% CW replacements in CW-LPW matrix does not exhibit a sudden brittle fracture even beyond the failure loads and indicates high energy absorption capacity by allowing lower labouring cost. These bricks are 60% lighter than the conventional concrete bricks having better flexural strength and compressive strength.
Dondi et al. (2009) investigated the utilization of funnel and panel glass of TV and PC glass waste mixed with clay, Sample was dried at 100°C and then fired at 900°C. It was demonstrated that adding of 2% of glass waste to clay body doesn't bring about significant changes in the technological performance of fired bricks. However, adding more than 5% of the waste may have deleterious effects on mechanical properties and efflorescence. Results for leaching test demonstrated no significant environmental pollutant emission.
Oti et al. (2008) carried out study on production of unfired clay brick by recycling a ground granulated blast furnace Slag (GGBS) activated with an alkaline lime and Portland cement combined with clay soil. The mixed materials were manually pressed with 140 bars. Mechanical properties and durability assessment were all within the acceptable engineering standards for clay masonry units.

Vorrada et al. (2009) studied Effects of Recycled Glass Substitution on the Physical and Mechanical Properties of Clay Bricks. Results of the study revealed that the compressive of bricks as high as (26-41) MPa and water absorption as low as (2-3) % were achieved for bricks containing (15-30) % by weight of glass content and fired at 1100°C. When the glass waste content was 45 % by weight, apparent porosity and water absorption was rapidly increased.
Ismail et al. (2010) experimented to explore Properties of Bricks Produced with Recycled Fine Aggregate. It was observed that the replacement of natural sand by recycled fine aggregates at the levels of 50% and 75% has good effects on the compressive strength of the cement bricks but flexural strength of the specimen's increases as the percentage level of the replacement increases to 50%. Hence, recycled fine aggregates produced from demolition waste can be utilized in brick mixtures as a good substitute for natural sand. This helps in reduction of demolition waste.
Chee Ming et al. (2011) examined the mechanical properties of clay: brick made by adding two natural fibers like oil palm fruit (OF), and pineapple eaves (PF) to clay-water mixture with baked and non-baked conditions. Compressive strength, water absorption and efflorescence tests were performed according to British standard BS3921:1985. Results indicated that the compressive strength of the bricks were similar to compressive strength of conventional bricks about 5.2 MPa.
Rania et al. (2011) recycled marble and granite waste of different sizes in the manufacturing of concrete bricks, with full replacement of conventional coarse and fine aggregates with marble waste scrapes and slurry powder. Results on the physical and mechanical properties of bricks qualified them to be used in the building sector as non-load bearing spacing construction materials, where all cement brick samples tested in this study complied with the Egyptian code requirement for structural bricks.
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. Water absorption and compressive strength of bricks developed from those waste were reviewed. It was concluded that the bricks developed from paper processing

residues and waste paper pulp showed the highest compressive strength greater than 12 times from the minimum recommended by Indian Standard IS 1007:1992.
Kartini et al. (2012) experimented on Development of Lightweight Sand Cement Bricks Using Quarry dust,; Rice husk and Kenaf Powder for Sustainability. They found that Sand-Quarry Dust Cement (SQDC) Bricks give enough compressive strength so that it is suitable to be used as an in-filled in frame structures. Also, it was observed that SQDC Bricks and Sand-Rice Husk Cement (SRHC) Bricks have higher water absorption hence can be used as an in-filled in masonry wall. Normally this wall is plastered but compressive strength decreases as percentage of rice husk increases.
Luciana C.S et al. (2012) carried out characterization of ceramic bricks incorporated with Textile Laundry Sludge. Results of the study revealed that maximum 20% (mass basis) of * sludge can be replaced in bricks without affecting its mechanical properties. All bricks were fabricated by extrusion method, dried at 100°C and then fired at 900°C. Mechanical properties of ceramics as flexural strength and water absorption were satisfactory within the Brazilian legislation.
Paki et al. (2012) investigated the potential use of crumb rubber-concrete combination for producing a low cost and lightweight composite brick with improved thermal resistance. The obtained compressive strength, flexural strength, splitting strength, freezing-thawing resistance, unit weight and water absorption values satisfy with the relevant international standards. The experimental observations reveal that high level replacement of crumb rubber with conventional sand aggregate does not exhibit a sudden brittle fracture even beyond the failure loads. Indicating high energy absorption capacity with reduced unit weight dramatically and smoother surface compared to the current concrete bricks in the market. Thermal insulation performance is improved by introducing various amount of crumb rubber add in to the cementitious mixes.
Sivakumar et al. (2012) manufactured bricks from thermal power plant bottom ash, fly ash mixed along with water and cement. The bricks were produced by making flow-able mix with high w/c ranged in (1.5-5.5). Results for compressive strength ranged in (5-10) MPa, water absorption varied from 7 to 14:%.
Jahagirdar et al. (2013) carried out study on Utilization of Textile mill sludge in Brunt Clay Bricks. Results of the studies show that Textile mill sludge can be used up to 15% without

compromising on the compressive strength of 3.5 N/mm2 and water absorption of 20% as per the IS code requirements. Organic matter present in the sludge gets burnt at temperature more than 550°C, because of which large number of voids are created in the body of the bricks which results in greater water absorption capacity and make brick lighter in weight compare to clay bricks. Use of Textile mill sludge helps in reducing pollution load on environment.
Kulkarni et al. (2013) identified that Compressive strength obtained at 10% replacement of fly ash as bagasse ash in fly ash bricks is almost; same compared to normal fly ash bricks and It reduces the density and cost of bricks. Main benefit of Bagasse ash bricks is that it reduces the seismic weight of building. It reduces load for disposal of fly ash.
Miqueleiz et al. (2013) carried out study on Alumina Filler Waste as Clay Replacement Material for Unfired Brick Production. It was observed that using the Alumina filler waste as clay replacement material for unfired bricks tends to shows slight increase in compressive strength compare to normal unfired bricks. And hence the use of bio-energy waste materials such as AF waste is recommended, especially when the materials add obvious advantages of environmental benefits.
Pitroda J. R. et al. (2013) explored use of foundry sand in concrete. They found that compressive strength increases on increase in percentage of waste foundry sand as compare to traditional concrete. In this study, maximum compressive strength is obtained at 60% replacement of fine aggregate by waste foundry sand. The result of percentage cost change reduces up to 3.5 for 60% replacement of waste foundry sand. This shows that the concrete produced is economical.
Pawade et al. (2014) found out that 20%; addition of coconut waste in fly ash brick gave compressive strength up to 4.65 N/mm2 which is more than 20% addition of orange peels waste and paper mill residue waste.
Prasad et al. (2014) tried to find Alternative Solution in Brick Manufacturing. Fly ash and Granite dust were added to replace natural clay material for manufacturing of clay bricks. Results of the study show that compressive strength of clay bricks was increased with addition of Fly ash and Granite dust by 55% and 25% respectively. Water Absorption Capacity of these Bricks are relatively lower compared to the Clay Bricks. The study aimed towards a "Greener Eco-friendly Bricks for Construction".

Naik et al. (2014) carried out study on Stability of Fly Ash, Cement and Gypsum Bricks. Results of the study show that fly ash, cement and phosphor-gypsum bricks are having sufficient strength up to23.56 N/mm2 when fly ash, cement, phosphorus proportion was used 25, 50 and 25% respectively. These bricks can used as a replacement for traditional bricks but water absorption this brick was found more than 20%. Such bricks can be used at places where water absorption is not a problem, i.e., for curtain walls.
Swarna et al. (2014) carried out study on Manufacturing of Bricks Using Tannery Effluent sludge. They investigated that the percentage of tannery sludge, Quarry dust and cement were 20, 50 and 30 respectively used in cement bricks gave favorable compressive up to 6 N/mm2 and desired flexural strength. This makes use of these bricks suitable for structural applications.
Sumathi et al. (2014) studied Compressive Strength of Fly Ash Brick with Addition of Lime, Gypsum and Quarry Dust, Results of the study revealed that the addition of Flyash-15% Lime-30% Gypsum-2% Quarry dust-53% in flyash brick gave compressive strength 7.91 N/mm2 which is comparable to normal fly ash brick and also it reduced particulate air pollution by uses of Quarry dust.
Watile et al. (2015) carried out study on Utilization of Rice Husk for Production of Clay Brick. They found that replacement of 2 percent of rice husk by weight increase the compressive strength up to 6.59 MPa and lower density in normal clay brick. Also, 14.01 percent of water absorption in bricks was found that is favourable to normal clay brick.
Chih-Huang Weng et al. (2016) studied that 10% addition of sewage treatment plant sludge in to clay brunt brick as a clay substitute gave compressive strength 230 kg/cm2 which is desirable and also beneficial to environment for disposal of treatment plant sludge.
Nithiya R.: et al. (2016) investigated that Brunt clay bricks made with 3% addition of egg shell powder gave compressive strength 5.26 N/mm2 which is fulfil requirement for clay bricks and also bricks made with 3% addition of granite powder gave resultant compressive strength 6.73 N/mm2.

Table 1: Waste Material Used in Different studies and Review of Different Test
Results Found out from Studies

Sr.
No Author Year Utilization Area Material Used Addition/ Replacement Tests Increase/ Desirable
1 Nithiya R. 2016 Clay Burnt Brick Egg Shell Powder Addition Compressive strength Desirable
2 Chih Huang Weng 2016 Clay Burnt Brick Treatment
Plant
Sludge Addition Compressive strength Desirable
3 Watile 2015 Clay Burnt Brick Rice Husk Replacement Compressive
strength
Water
Absorption Desirable Desirable
4 Sumathi 2015 Clay Burnt Brick Sludge Addition Compressive
strength
Water
Absorption Decrease Increase
5 Swarna 2014 Cement Brick Tannery Sludge Addition Compressive strength Flexural Strength Desirable Increase
6 Sumathi 2014 Fly Ash Brick Quarry Dust Replacement Compressive Strength Desirable
7 Prasad 2014 Clay Brunt Brick Fly Ash
Granite
Dust Addition Water Absorption. Desirable
8 Pawade 2014 Fly Ash Brick Coconut Waste Addition Compressive Strength Desirable
9 Pitroda J. R 2013 Concrete Foundry Sand Replacement Compressive Strength Increase
10 Miqueleiz 2013 Clay Brunt Brick Alumina Filler Waste Replacement Compressive Strength Increase
11 Kulkarni 2013 Fly Ash Brick Bagasse Ash Replacement Compressive strength Desirable
12 Luciana 2012 Clay Brunt Brick Textile Sludge Addition Compressive
Strength
Water
Absorption
Flexural
Strength Desirable Desirable Desirable
13 Karthini 2012 Cement Brick Quarry
Dust Addition Compressive Strength Desirable
14 Rania 2011 Concrete. Marble
Waste
Granite
Waste Replacement Compressive Strength Desirable
15 Chee Ming 2011 Clay Brunt Brick Natural Fibre Addition Compressive Strength Desirable

1. The foundry sand can be applicable as building material in concrete which results in reduction of 3.5% of cost for 60 % replacement of waste foundry sand and the foundry sand can be successively used in bricks as filler at small substitution rates (2.5 and 5%primary sand substitution.) and also it is envisaged that higher replacement can be feasible.
2. The compressive strength of brick can be increased by using fiber (1%) up to 5.86 N/mm2 after 21 days.
3. The bricks developed from paper processing residues and waste paper pulp showed the highest compressive strength greater than 12 times from the minimum recommended by Indian Standard IS1007:1992.
4. Crumb rubber-concrete combination for producing a low cost and lightweight brick with improved thermal resistance. The obtained compressive strength, flexural strength, splitting strength, freezing-thawing resistance, unit weight and water absorption values satisfy with the relevant international standards.
5. Compressive strength obtained at 10% replacement of fly ash as bagasse ash in fly ash bricks is almost same compared to normal fly ash bricks and It reduces the density and cost of bricks main benefit is Bagasse ash bricks reduce the seismic weight of building.
6. The percentage of tannery sludge, Quarry dust and cement were 20, 50 and 30 respectively used in cement bricks gave favourable compressive and flexural strength.
7. Replacement of 2 % of rice husk by weight increase the compressive strength and lower density in normal clay brick so that 2 % of rice husk by weight obtain 6.59MPa of compressive loading and 14.01 % of water absorption in bricks that was favourable to normal day brick.
Brief Description of the Drawings
Fig. 1 Compressive Strength of Brick Mixes with Replacement of RSDW at 7, 14 and 21
Days Fig. 2 Conventional Fly Ash Brick and Fly ash with Replacement of RSDW in Different
Proportion at 21 Days Fig. 3 Percentage Water Absorption in Fly ash Brick Mixes: Conventional fly ash brick and
Fly ash with replacement of RSDW in Different Proportions Fig. 4 Cost of Brick per 1000 Nos. Mixes: Conventional Brick and Brick with RSDW in
Different Proportions

Objective of the invention
Following are the main objectives of the research work.
1. To study Physical, Chemical properties and mechanical properties of reclaimed sand dust waste (RSDW) in Indian contexts and compare with properties of fly ash.
2. To find reclaimed sand dust waste behaviour in fly ash brick by replacing fly ash with reclaimed sand dust waste in different proportions of 20%, 40%, 60%, 80% and 100% with comparison of conventional fly ash brick.
3. To assess economy of RSDW brick mixes with compared to conventional fly ash brick for the replacement in different proportion.
4. To reduce load of industrial solid waste on environment and prevent environmental degradation.
Detailed Description
Raw Material Testing
The following materials are selected for study purpose.
1. Fly Ash;
2. Reclaimed Sand Dust Waste
3. Lime
4. Sand/ Stone dust
The following table 2 indicates the various experimental raw materials to be used and their respective sources from where these raw materials are collected for this research work.
Table: 2 Source of Materials

Experimental Materials Source
Fly Ash Classs F Fly Ash of Wanakbori Thermal Power Plant
Lime Gaytri Brick Manufaturing Industry, V.U. Nagar, Anand
Sand / Stone dust Locally available 20mm
(having characteristics according to
IS 383-1963)
Water Gaytri Brick Manufaturing Industry, ■. V.U. Nagar, Anand
Reclaimed Sand Dust Waste Rhino Machines Pvt Ltd.

In above table 2 shows that which raw materials are require for fly ash brick manufacturing and this research work. Before, this raw material used for this research work sample of raw material should be given for testing of their physical and chemical properties. So that sample of fly ash, lime and reclaimed sand dust waste are given in Geo Test House, Gorwa Estate, Vadodara, Gujarat. Following are the physical and chemical properties of raw material which are used for this research work.
Physical Properties Requirement for Fly Ash
The following table 3 indicates the different physical requirement of fly ash compare to IS standards.
Table 3: Physical Requirement of Fly Ash

Sr.
NO. : Physical Requirement for Fly Result Requirements as per IS:3812
1 Fineness — Specific surface in m2/kg by Blaine's permeability method 300 200 Minimum
2 Particles retained on 45 microns IS sieve (wet sieving) in percent 1) 42.. 50 Maximum
3 Soundness by autoclave test — Expansion of specimen in percent 0.5 0.8 Maximum
(Source: Gaytri Brick Manufacturing Industry, V.U. Nagar, Anand) Chemical Composition Requirement for Fly Ash
Following table 4 shows different chemical composition require for fly ash using for brick with compare to IS standards. • :
Table 4: Chemical Composition Requirement for Fly Ash

Chemical Composition (in percent by mass) Result Requirements as per IS:3812
Aluminum oxide (Al2O3) 4.38 70 Minimum
Silicon dioxide (SiO2) 57.69 35 Minimum
Magnesium oxide (MgO) 5.90 5.0 Maximum
Sulphur trioxide (SO3) 0.25 5.0 Maximum
sodium oxide (Na2O) 0.36 1.5 Maximum
(Source: GEO Test House, Gorwa Estate, Vadodara, Gujarat)

Chemical Composition Requirement for Reclaimed Sand Dust Waste
Table 5 indicates the different chemical composition requirement of reclaimed sand dust waste and IS code requirement for fly ash.
Table 5: Chemical Composition of Reclaimed Sand Dust Waste

Chemical Composition (in percent by mass) Result Requirements as per
IS:3812 for Fly Ash Compare to
Reclaimed Sand Dust Waste
Aluminum oxide (AI2O3) 16.64 70 Minimum
Silicon dioxide (SiO2) 38.7 35 Minimum :
Magnesium oxide (MgO) 30.57 5.0 Maximum
sulphur trioxide (SO3) 2.67 5.0 Maximum
sodium oxide (Na2O) 0.63 1.5 Maximum
(Source: GEO Test House, Gorwa Estate, Vadodara, Gujarat)
Here chemical testing results show that all chemical compound which are useful for fly ash that are also present in reclaimed sand dust waste material. So that partial replacement of fly ash in brick can be possible by reclaimed sand dust waste.
Requirements of Fly Ash Lime Bricks [IS 12894:2002] .. !
For manufacturing of Fly ash brick there are same specifications and requirement which given IS codes.
General Requirement
1. Visually the bricks shall be sound, compact and uniform in shape. The bricks shall be free from visible cracks, war-page and organic matters.
2. Hand-moulded bricks of 90 mm or 70 mm height shall be moulded with a frog 10 to 20 mm deep on one of its flat sides; the shape and size of the frog shall conform to Indian Standards. Bricks of 40- or 30-mm height as well as those mad by extrusion process may not be provided with frogs.

3. The bricks shall be solid and with or without frog 10 to 20 mm deep on one of its flat side. The shape and size of the frog shall conform to either to Indian Standards.
4. The bricks shall have smooth rectangular faces with sharp corners and shall be uniform in shape and colour.

Dimensions and Tolerances
The standard modular and non-modular sizes of pulverized fuel ash-lime bricks shall be as following table 6.

Table 6: Sizes of Fly Ash Brick

Standard Modular Size of Brick Non-Modular size of Brick
Length (L)mm Width (W)mm Height (H) mm Length
(L)nim Width (W)mm Height (H)mm
190 90 90 230 110 70
190 90 40 230 110 : 30
Tolerances
The dimensions of bricks when tested in accordance to Indian Standards shall be within the following limits per 20 bricks:
For Modular Size
Length 3720 to 3880 mm (3800 ± 80 mm)
Width 1760 to 1840 mm (1800 ± 40 mm)
Height 1760 to 1840 mm (1800 ± 40 mm) (For 90 mm high bricks)
760 to 840 mm (800 ± 40 mm) (For 40 mm high bricks)
For Non-modular Size
Length 4520 to 4680 mm (4600 ± 80mm)
Width 2160 to 2240 mm (2200 ± 40mtn)
Height 1360 to 1440 mm (1400 ± 40mm) (For 70 mm high bricks)
560 to 640 mm (600 ± 40mm) (For 30 mm high bricks )
Mix Proportion for Fly Ash Lime Brick and Reclaimed Sand Dust Brick
Following table 7 shows raw material mix proportion in percentage by volume for Good Quality Fly Ash Lime Gypsum Brick.
Table 7: Raw Material Proportion for Standard Fly Ash Brick

Raw Materials Fly Ash Sand Lime Gypsum
Percentage (by Volume) 55-60% : 20-25% 15-20% 5%

Mix Proportion of Reclaimed Sand Dust Waste (RSDW) in Fly Ash Brick
Following table 8 shows mix proportion of reclaimed sand dust waste in fly ash brick with percentage replacement of fly ash:
Table 8: Mix proportion of Reclaimed sand dust Waste in Fly Ash Brick

Sample FlyAsh
(Kg) RSDW
(Kg) Quarry Dust
(Kg) Lime
(Kg)
A (Conventional) ■60.00 0.00 15.00 25.00
Bl (20%) 40.00 20.00 15.00 25.00
B2 (40%) 20.00 40.00 15.00 : 25.00
B3 (60%) 0.00 60.00 15.00 25.00
C1 (0%) 75.00 0.00 : 0.00 25.00
C2(25%) 50.00 25.00 0.00 25.00
C3 (50%) 25.00 50.00 0.00 25.00
C4 (75%) 0.00 75.00 0.00 25.00
RSDW = Reclaimed Sand Dust Waste
Manufacturing Process for Fly Ash Brick
Fly ash, lime, sand and gypsum 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 60-80% of fly ash 10-20% lime, 10% Gypsum and 10% sand, 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 homogenised mortar taken out of roller mixer is put into the mould boxes. Depending on the type of machine, the product is compacted under vibration / hydraulic compression etc. :
The 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 7-21 days, depending on ambience. The bricks are tested and sorted before despatch.

Tests on Bricks
Following are the various tests to be done on bricks in different periods of time after manufacturing of brick:
1. Compressive strength test [IS 3495:1992 Part I]
2. Water absorption test [IS 3495:1992 Part II]
Determination of Compressive strength Brick (IS 3495:1992 Part I) Apparatus:
Compression testing machine, measuring tape or scale, surface grinder, plywood sheets.
Procedure:
Preparation of Sample:
1. Remove unevenness observed in the bed faces to provide two smooth and parallel faces by grinding.
2. Immerse the sample in water at room temperature for 24 hours.
3. Prepare cement mortar (1:1) and fill the frog and all void in bed faces with it.
4. Store the sample prepared in (iii) under damp jute bag for 3 days in clean water.
5. Remove and wipe out a trace of moisture.
6. Measure the area of two horizontal faces.
Testing of Sample:
1. Place the specimen with flat faces horizontal and mortar filled facing upwards between two plywood sheets and centre carefully between plates of testing machine.
2. Load is applied axially at a uniform rate 14 N/mm2 per minute till failure occurs; Note the maximum load at failure
Calculation:


Determination of Water Absorption (IS 3495:1992 Part II) (24-hour Immersion Cold Water Test)
Apparatus:
A sensitive balance capable of weighing within 0.1 percent of the mass of the specimen and a ventilated oven.
Preconditioning:
Dry the specimen in a ventilated oven at a temperature of 105 to 115 °C till it attains substantially constant mass. Cool the specimen to room temperature and obtain its weight (Dry Weight). Specimen warm to touch shall not be used for the purpose.
Procedure: -
1. Immerse completely dried specimen in clean water at a temperature of 27 ± 2 °C for
: 24 hours.
2. Remove the specimen and wipe out any traces of water with a damp cloth and weigh
the specimen. Complete the weighing 3 minutes after the specimen has been removed
from water (wet weight). Water absorption, percent by mass, after 24-hour immersion
in cold water is given by the following formula:


Claims
We claim
1. Compressive strength of fly ash brick was increasing by replacement of RSDW in different proportion for brick mixes as compared to conventional fly ash brick mix.
2.; Highest compressive strength 21.82 N/mm2 and 2% reduction in percentage water absorption can be obtained for 20% replacement of RSDW with fly ash in brick mixes which is comparable to M20 grade concrete.
3. Bricks manufactured from RSDW replaced by fly ash costs 26.47% less than cost of conventional fly ash brick per 1000 Nos.
4. Use of these bricks can be used in Low-cost Housing schemes of India like Indira Awas Yojana, Pradhanmantri Awas Yojana etc. For achieving the economy for construction cost.