International Journal of Engineering Trends and Technology (IJETT) Volume 4 Issue 10 - Oct 2013

ISSN: 2231-5381 http://www.ijettjournal.org Page 4484

Bagasse Ash As An Effective Replacement
In Fly Ash Bricks
Apurva Kulkarni
1
, Samruddha Raje
2
, Mamta Rajgor
3
1
Student of final year B.E. Civil, Sigma Institute of Engineering College, Vadodara
2
Student of final year B.E. Civil, Sigma Institute of Engineering College, Vadodara
3
Assistant Professor, Civil Engg. Department, Sigma Institute of Engineering College, Vadodara Gujarat-India

Abstract- Utilization of industrial and agricultural waste
products in the industry has been the focus of research for
economic, environmental, and technical reasons. Sugar-cane
bagasse is a fibrous waste-product of the sugar refining industry,
along with ethanol vapor. Huge quantity of ash which is a waste
product, available at very negligible rate. It causes the chronic
lung condition pulmonary fibrosis more specifically referred to
as bagassios. In this paper, Bagasse ash can be utilized by
replacing it with fly ash and lime in fly ash bricks. Trial bricks of
size (230x100x75) mm were tested with different proportions of
0%, 10%, 20%, 30%, 40%, 50% and 60% with replacement of
fly ash and 0%, 5%, 10%, 15% and 20% with replacement of
lime. These bricks were tested in Compression test and Water
absorption test as per Indian Standards. The aim of this research
was to make economical and green bricks to maintain
environmental balance, and avoid problem of ash disposal.
KeywordsFly ash (Class F), Bagasse ash, Sustainability,
Environment, Waste re-uses, cost feasibility, Eco friendly bricks

I. INTRODUCTION
Population scenario comes towards India by means of
increasing industries. The fruitful efforts of industries lead to
develop India. As the industries increases also the waste
coming fromthemat the end of product increases. At the end
of survey result coming that the amount of the approximately
250 to 300 million tons of industrial wastes are being
produced every year by chemical and agricultural process in
India. It is very essential to dispose these wastes safely
without affecting health of human being, environment, fertile
land, sources of water bodies; etc. Sugar cane bagasse, the
fibrous residue after crushing and juice extraction of sugar
cane, is a major industrial waste product from the sugar
industry.
Nowadays, it is commonplace to reutilize sugar cane bagasse
as a biomass fuel in boilers for vapor and power generation in
sugar factories. Depending on the incinerating conditions, the
resulting sugarcane bagasse ash (SCBA) may contain high
levels of SiO2 and Al2O3, enabling its use as a supplementary
cementious material (SCM) in blended cement systems. Uses
of Sugarcane bagasse ash waste in brick can save the
sugarcane industry disposal costs and produce a greener
bricks for construction.

II. EXPERIMENTAL MATERIALS
a) Bagasse ash

FIGURE 1: Bagasse ash
SOURCE: Shree Ganesh Khand Udhgyog

The burning of bagasse which a waste of sugarcane produces
bagasse ash. Presently in sugar factories bagasse is burnt as a
fuel so as to run their boilers. This bagasse ash is generally
spread over farms and dump in ash pond which causes
environmental problems also research states that Workplace
exposure to dusts fromthe processing of bagasse can cause
the chronic lung condition pulmonary fibrosis, more
specifically referred to as bagassosis. So there is great need
for its reuse, also it is found that bagasse ash is high in silica
and is found to have pozollinic property so it can be used as
substitute to construction material














International Journal of Engineering Trends and Technology (IJETT) Volume 4 Issue 10 - Oct 2013
ISSN: 2231-5381 http://www.ijettjournal.org Page 4485






TABLE 1
CHEMICAL PROPERTIES OF BAGASSE
SOURCE: Shree Ganesh Khand Udhayog, Sarkada

b) Flyash (Class F)
The burning of harder, older anthracite and bituminous
coal typically produces Class F fly ash. This fly ash is
pozzolanic in nature, and contains less than 20% lime
(CaO). Possessing pozzolanic properties, the glassy
silica and alumina of Class F fly ash requires a
cementing agent, such as Portland cement, quicklime, or
hydrated lime, with the presence of water in order to
react and produce cementitious compounds.



FIGURE 2: Fly ash (Class F)
SOURCE: Shree Ganesh Khand Udhgyog




TABLE 2
CHEMICAL COMPOSITION OF CLASS F FLY ASH
Sr.
No.
Chemical Compound Class F


1 SiO
2
54.90
2 A1
2
O
3
25.80
3 Fe
2
O
5
6.90
4 CaO 8.70
5 MgO 1.80
6 SO
3
0.60
7 Na
2
O & K
2
O 0.60
SOURCE: http://www.flyash.com

c) Acetylene Carbide Lime
Pure calciumoxide is fused with coke in order to render the
highest yield in the manufacture of acetylene. The quality of
the resultant carbide lime is a direct result of the excellent
quality raw materials. Carbide lime is finer in particle size,
and physically, having a very finely divided particle size
makes carbide lime better. A finer particle size means faster
and more reactivity.

FIGURE 4: Lime
SOURCE: Shreeji bricks Sarkada

Sr. No. Chemical Compound Percentage
1 Nitrogen 0.2- 0.3%
2 P
2
O
5
1.5 -2%
3 K
2
+Na
2
5-10 %
4 CaO 1-2%
5 Mgo 0.07%
6 Sio
2
85-90%
7 Heavy metals NA
8 Fe 2-4%
International Journal of Engineering Trends and Technology (IJETT) Volume 4 Issue 10 - Oct 2013
ISSN: 2231-5381 http://www.ijettjournal.org Page 4486








TABLE 3
CHEMICAL COMPOSITION OF LIME

Sr.
No.
Chemical Compound Lime


1 SiO
2
5.39
2 A1
2
O
3
1.06
3 Fe
2
O
3
0.39
4 CaO 28.60
5 MgO 2.42
6 SO
3
0.93
SOURCE: GEO Test House, Gorwa, Gujarat

d) Quarry dust

FIGURE 5: Quarry dust
SOURCE: Shreeji bricks Sarkada

Quarry dust is a waste product produced during the
crushing process which is used to extract stone. It is rock
particles. When huge rocks brake in too small parts for
the construction in quarries. It is like sand but mostly grey
in colour. It is mineral particles. The density of Quarry
dust is 1650 kg/m.

e) Water
Water is an important ingredient of brick as it actually
used for manufacturing of brick. Since it helps to bind all
the raw materials for giving proper mix. Water used for
making brick should be free fromimpurities.

III. MIX DESIGN
The design mix proportion is done in Table 4.
TABLE 4
EFFECTIVE REPLACEMENT OF FLY ASH BY BAGASSE ASH

Sample
F. A
(Kg)
B.A
(Kg)
Lime
(Kg)
Q.D
(Kg)
Std 60.00 0.00 20.00 20.00
S1 50.00 10.00 20.00 20.00
S2 40.00 20.00 20.00 20.00
S3 30.00 30.00 20.00 20.00
S4 20.00 40.00 20.00 20.00
S5 10.00 50.00 20.00 20.00
S6 0.00

60.00

20.00 20.00
F.A=Fly ash, B.A=Bagasse ash, Q.D=Quarry Dust


TABLE 5
SAMPLE INFORMATION OF BAGASSE ASH IN REPLACEMENT OF
FLYASH IN BRICKS
Sample
F. A
(Kg)
B.A
(Kg)
Lime
(Kg)
Q.D
(Kg)
Std 60.00 0.00 20.00 20.00
L1 60.00 5.00 15.00 20.00
L2 60.00 10.00 10.00 20.00
L3 60.00 15.00 5.00 20.00
L4 60.00 20.00 0.00 20.00
F.A=Fly ash, B.A=Bagasse ash, Q.D=Quarry Dust

IV. EXPERIMENTAL SETUP

V. EXPERIMENTAL METHODOLOGY

The evaluation of Bagasse ash for use as a replacement of fly
ash material begins with the brick testing. Brick contains fly
ash, Lime, water, and Quarry dust. With the control brick, i.e.
International Journal of Engineering Trends and Technology (IJETT) Volume 4 Issue 10 - Oct 2013
ISSN: 2231-5381 http://www.ijettjournal.org Page 4487


10%, 20%, 30%, 40%, 50% and 60% of the fly ash is replaced
with Bagasse ash, the data fromthe Bagasse ash fly ash brick
is compared with data froma standard fly ash brick without
bagasse ash. Five bricks samples were cast having size of
230x115x75mm.The manufacturing process of bricks broadly
consists of three operations viz. mixing the ingredients,
pressing the mix in the machine and curing the bricks for a
stipulated period. Selection of machinery depends on the
bricks mix contents. For manufacturing bagasse ash fly ash
bricks, the best suited machinery is a Vibro - press machine,
which is an indigenous low cost machine and can be run by
ordinary semiskilled worker. Its production capacity is 1000
bricks per shift and can be operated in two shifts without any
operation/maintenance load. The maintenance cost is so low
that it can be ignored. 15 lakh bricks can be produced for each
machine in its life cycle.

A. Compression Test

The brick specimens are immersed in water for 24 hours. The
frog of the brick is filled flush with 1:3 cement mortars and
the specimen are stored in damp jute bag for 24 hours and
then immersed in clean water for 24 hours. The specimen is
placed in compression testing machine with 6 mmplywood
on top and bottomof it to get uniformload on the specimen.
Then load is applied axially at a uniformrate of 14 N/mm
2
.
The crushing load is noted. Then the crushing strength is the
ratio of crushing load to the area of brick loaded. Average of
five specimens is taken as the crushing strength.

















FIGURE: - 6 Compression strength test for Brick
TABLE 6
COMPRESSION STRENGTH OF BRICKS (230X115X75) AT 7, 14 AND
21 DAYS FOR BAGASSE ASH FLY BRICKS
Sample 7 Days 14 Days 21 Days
STD 4.43 4.70 7.55
S1 3.38 4.35 7.43
S2 3.13 4.17 6.09
S3 3.03 4.08 5.57
S4 2.94 3.94 5.07
S5 2.77 3.77 4.02
S6 NA NA NA
L1 3.39 4.00 5.99
L2 3.12 3.74 5.81
L3 3.08 3.65 5.20
L4 2.83 3.61 4.92


GRAPH 5: Percentage replacement(X axis) Vs Compressive Stress


VI. ECONOMIC FEASIBILITY

TABLE 7
COST OF MATERIALS
Material Rupees/Kg
Bagasse Ash 0.20
Flyash 0.55
Quarry Dust 0.35
Lime 1.50

TABLE 8
TOTAL COST OF BRICKS OF DIFFERENT PROPORTION
Samples Cost
STD 3.36
S1
3.25
S2 3.14
S3 3.03
S4 2.92
S5 2.81
S6 2.70
L1 3.28
L2 3.21
L3 3.13
0
2
4
6
8
7 DAYS
STRENGTH
(N/mm2)
14 DAYS
STRENGTH
(N/mm2)
21 DAYS
STRENGTH
(N/mm2)
STD
SI
S2
S3
S4
S5
L1
L2
L3
L4
L5
International Journal of Engineering Trends and Technology (IJETT) Volume 4 Issue 10 - Oct 2013
ISSN: 2231-5381 http://www.ijettjournal.org Page 4488


L4 3.06






TABLE 9
COMPARISON BETWEEN BAGASSE ASH FLYASH BRICKS AND
ORDINARY CLAY BRICKS
Sr. No Description Clay Bricks
Bagasse Ash Fly ash
Bricks
1 Size, mm 215x100x70 230x100x75
2 Volume, cm
3
1505 1725
3
Bricks in 1 Cum
Masonry
664 500
4 Density, Kg /m
3
1600 1668
5 Cost in Rupees 4000/1000 2420/1000
6
Compressive
Strength, Kg/cm
2

30-50 30-50
7
Water
Absorption,%
20-25 8-12



VII. CONCLUSION

Based on limited experimental investigations concerning
compressive strength of Brick, the following observations are
made regarding the resistance of partially replaced Bagasse
ash:
(a) Compressive strength decreases on increase in percentage
of Bagasse ash as compare to fly ash.
(b) Use of bagasse ash in brick can solve the disposal
problem; reduce cost and produce a greener Eco-
friendly bricks for construction.
(d) Environmental effects of wastes and disposal problems of
waste can be reduced through this research.
(e) A better measure by an innovative Construction Material
is formed through this research.
(f) It provides innovative use of class F fly ash which
contains less than 20% lime.
(g) This study helps in converting the non-valuable bagasse
ash into bricks and makes it valuable.
(h) In this study, maximumcompressive strength is obtained
at 10% replacement of fly ash as bagasse ash.
(i) Bagasse ash bricks reduce the seismic weight of building.
(j) It reduces the density of bricks from20 (clay bricks) to
11(bagasse ash bricks)
(k) It reduces the cost of material per brick.


VIII. ACKNOWLEDGEMENT

The author thankfully acknowledge to Dr.F.S.Umrigar,
Principal, Prof. Jayeshkumar Pitroda, Prof.J.J.Bhavsar,
Associate Professor and PG (Construction Engineering and
Management) Coordinator, B.V.M. Engineering College, Mr.
Sailesh Shah Chairman of Sigma Institute of Engg. Asst.
Professor Patel Ankit, Asst. Professor Rajgor Mamta, Lab
Asst. Dinubhai . G . Desai, Sigma Institute of Engineering,
Vadodara, Gujarat.

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