Flyash Bricks

CRACKS IN BUILDINGS :
THE ROLE OF FLYASH

BRICKS AND THE
REMEDIES
PROF. (DR.) ANANTA KUMAR DAS
DEPARTMENT OF CHEMICAL ENGINEERING,
DURGAPUR INSTITUTE OF ADVANCED
TECHNOLOGY AND MANAGEMENT, DURGAPUR
INTRODUCTION
Cracks in buildings are of common occurrence and are

developed whenever stress in the component exceeds its
strength. This stress caused by external forces such as
dead, live, wind, seismic loads and foundation settlement;
or induced internally due to thermal movements, moisture
changes, chemical actions, weathering actions resulting in
shrinkage or expansion of the bricks, mortar, concrete or
due to corrosion of reinforcement etc. render the structure
unsafe. The other causes may be due to fault of structural
design. Fly ash brick, a building component has a little
effect on these cracks that can be avoided if it is
manufactured and used properly.
CLASSIFICATION OF CRACKS
VERTICAL CRACKS
Develops
due
to
shrinkage, expansion or
thermal movement of
brick,
mortar
and
concrete.
Do not endanger the
safety of the building
but unsightly
Impression of
workmanship
faulty
HORIZONTAL CRACKS
Develops mainly at the
junction
of
brick
masonry with RCC slab
Weakens
the
construction
and
requires
heavy
repairing resulting high
cost involvement
STRUCTURAL
Faulty construction
NON STRUCTURAL
Internal induced stress
building materials
in
Overload
Penetration of moisture and

weather actions through the
masonry works
Extensive cracking of RCC

beam
Resulting in shrinkage
bricks, mortar, concrete
Incorrect Design
Resulting
corrosion
of
reinforcement
&
hence
increase in volume
in
PATTERN OF CRACKS
CLASSIFICATIONS:
Straight
Toothed
Stepped
Random
Crazing - Occurrence of closely spaced
fine cracks at surface of a material
STRAIGHT
CRACKS
TOOTHED
CRACKS
STEPPED
CRACKS
RANDOM
CRACKS
CRAZING
CAUSES OF CRACKS
A building component develops cracks

whenever stress developed in the component
exceeds its strength.
External applied force
Due to dead,
seismic load
live,
Formation of settlement
wind
Internal induced stress

or
Due
to
thermal
movements
moisture change and chemical
actions
In building component leading to
dimensional changes
Horizontal movements.
Due to volume change within a
component
resulting
either
expansion or contraction
Compressive Tensile
Building composition
Shear
in
SUBJECT TO CRACKING
Masonry
Concrete
Mortar
WIDTH OF CRACKS
Thin <1mm
Medium 1 to
2 mm
Wide
>2mm
PRINCIPAL CAUSES OF CRACKS IN

BUILDING (Non structural)
Thermal variation
Chemical reaction
Moisture movement
Elastic deformation
Creep
Foundation movement & settlement of soil
Vegetation
Manufacturing defects
Details in next few slides
THERMAL MOVEMENTS
FACTORS AFFECTING
Temperature variation
Dimensions
Coefficient of expansion
Physical properties of the materials
COEFFICIENT OF THERMAL
EXPANSION (10-6 / C)
Clay Brick & Brick work 5-7
Cement mortar & concrete 10-14
Sand lime bricks 11-14
Fly ash bricks 13-17
SOME FACTORS INFLUENCING IN

THERMAL CRACKING
a.Color & surface characterization (high
reflectivity coefficient) reduces heat load on
the roof
b.Thermal conductivity
c.Provision of an insulating or protective layer
d.Internally generated heat
OTHER FACTORS INFLUENCING IN

THERMAL CRACKING
Loss of heat by radiation into the atmosphere depends on the proportion of
exposed surface to volume of the component. For instance, if under certain
conditions in a 15 cm thick fly ash brick wall, 95% of heat is lost to the air in 1.5
hours under similar circumstances; same amount of heat will be lost in about one
week when the wall is 1.5 m thick .
Generally speaking thermal variations in the internal walls are not much and this
does not cause cracking. It is mainly the external walls, especially thin walls
exposed to distinct solar radiation and the roof which are subject to substantial
thermal variations and are this liable to cracking.
Horizontal crack at the support of an RCC Roof slab due to Thermal movement of
slabs.
CHEMICAL REACTIONS
MOVEMENT DUE TO CHEMICAL

REACTION
Soluble sulphates, which are sometimes present in ground water react with excess lime of fly ash
bricks, form gypsum and calcium aluminate sulphate which occupy much bigger volume than that of
the original constituents. This expansion reaction results in weakening of masonry & plaster and
then formation of cracks.
The severity of sulphate attack depends upon amount of soluble sulphate present, permeability of
fly ash bricks, concrete mortar, proportion of C 3A present and duration for which the building
components in quantity remains damp. If pure water free of sulphate is used for manufacturing of fly
ash bricks then sulphate attack can be avoided. Similarly chloride content in water enhances the
cell formation in case of RCC and again propagates the cracks due to increase in volume of Fe 3O4.
The chemical reaction proceeds very slowly and it may take about two to more years before the
effect of this reaction becomes apparent.
SEVERITY OF SULPHATE /CHLORIDE

ATTACK
a.Amount of soluble sulphate/Chloride present
b.Permeability of bricks, concrete mortar
c.Proportion of C3A present
d.Duration for which the building components
in quantity remains damp.
MOISTURE MOVEMENT
Initial shrinkage:- Initial shrinkage in fly ash sand-lime

bricks is about 50% greater than that due to subsequent
wetting and drying from saturation to dry state.
Reversible
In the first instance, moisture
present in the intermolecular
space (absorbed moisture) dries
out, causes some reduction in
volume & shrinkage. This is
reversible in nature.
Irreversible
After capillary water is lost, CaSiO3
gel crystallizes and gives up some
moisture (absorbed moisture) and
individual
molecules
undergo
reduction in size, resulting in
shrinkage which is irreversible
nature.
Most of the cracking in these
materials occurs due to shrinkage at
the time of initial drying.
DRY
SHRINKAGE
VS FLY ASH
SAND-LIME
COMPOSITIO
N
FLY ASH-SAND-LIME BRICKS VS CLAY

BRICKS
ELASTIC DEFORMATION
Hydration of lime after brick formation causes

a reduction in the volume of the system of
silica lime water to an extent of 0.5% of
the volume of the dry compact. This is the
plastic strain which aggravates due to loss of
water by evaporation that causes surface
cracks. If the proportions of each components
are properly mixed this problem will be
negligible for making fly ash bricks.
CREEP
The increase of strain of a compact with time

under sustained stress is termed creep, the
shrinkage and creep occurs simultaneously.
The rate of creep decreases with time and
the factors influencing creep are similar to
shrinkage which are described later. In case
of fly ash bricks Creep is negligible if the
bricks are matured .
FOUNDATION MOVEMENT &

SETTLEMENT
Fly ash bricks are not responsible for this type

of failure
VEGETATIONThe growth of unwanted plants in the

construction makes the construction
weak. So any growth of plant is to be
stopped.
Not related to fly ash bricks
SHRINKAGE
SHRINKAGE OF FLY-ASH BRICKS:

The Factors
a)
b)
c)
d)
e)
f)
g)
h)
i)
LIME / FLY ASH CONTENT

WATER CONTENT
AGGREGATES
ACCELERATORS
CURING
PRESENCE OF EXCESSIVE FINES
HUMIDITY
CEMENT AS A COMPONENT
TEMPERATURE
DETAILS GIVEN IN THE NEXT FEW SLIDES
LIME/ FLY ASH CONTENT

Higher the lime, greater the drying shrinkage.
Conversely larger the volume of aggregate,
lesser the shrinkage for bricks, increasing the
volume of aggregates by 10%, reduction of
shrinkage by 50%.So proper composition to
be maintained.
WATER CONTENT
Greater the quantity of water used in the mix,
greater the shrinkage. Thus a wet mix has
more shrinkage than a dry mix which is
otherwise similar. So better vibration / high
pressure gives less shrinkage. On the other
hand variation in the strength will occure.
AGGREGATES
By using largest possible maximum size of
aggregate in brick and ensuring good grading
requirement of water is reduced. Aggregates
that are porous and shrink on drying result in
higher shrinkage
ACCELERATORS
Accelerators like CaCl2, MgCl2 is added for
faster reaction towards silicate bonding but
use in high percentage over 0.5 to 2,
shrinkage could be more. In case of steam
curing the addition of accelerators has no
noticeable impact.
CURING
Proper curing should be done started as soon as
initial set has taken place and it is to be continued
for at least for 7 days, then drying shrinkage will be
less, because when hardening takes place under
moist environments, then there is initially some
expansion which offsets a part of subsequent
shrinkage. Steam curing at the time of
manufacturing reduces the liability to shrinkage as
high lime results in pre-carbonation
PRESENCE OF EXCESSIVE FOREIGN

FINES
Like Silt, clay, dust should not be more than 24% in aggregates because it increase surface
area resulting high water requirement and
resistant to bonding in chemical reaction.
HUMIDITY
Shrinkage is much less in coastal areas where
relative humidity remains high. Low relative
humidity causes plastic shrinkage.
CEMENT AS A COMPONENT
Rapid hardening cement to be avoided because it has
greater shrinkage than ordinary Portland cement of
higher proportion of CaSiO3 & lower proportion of
alkalis like sodium oxide and potassium oxide to be
used. PPC cement is preferable.
Otherwise difference in strength development
between fly ash bricks and cement mortar will cause
cracks.
TEMPERATURE
If the temperature of the mix is lowered from
38C to 10C, it would results reduction of water
requirements and hence lower shrinkage. It is
thus follows that in a tropical countries like India,
brick work done by fly ash bricks in mild winter
would have much less tendency for cracking
than that done in hot summer. So the aggregates
and mixing water should be shaded from direct
sun.
MEASURES FOR CONTROLLING

CRACKS DUE TO SHRINKAGE
On account of drying out of moisture content in building materials/
components.
Shrinkage in a material induces tensile stress when there is some
restraint to movement where the stress exceeds the strength,
cracking occurs, this relating the stress. Cracks get localized at weak
sections such as door and window opening or staircase walls.
Avoiding use of rich cement mortar in masonry made of fly ash
bricks. Delaying plaster work till masonry has dried after proper
curing. Shrinkage is made to take place without any restraint.
MEASURES FOR CONTROLLING

CRACKS DUE TO SHRINKAGE(Cont.)
Coat of plastering on masonry is restrained from shrinkage to some extent
by its adhesive bond to non shrinking background, the later having already
undergone shrinkage.
Shrinkage of a rich and strong mortar is known to extent sufficient force to
tear off the surface layer of weak bricks.
In summer 1 cement: 6 sand
In winter 1 cement: 5 sand
If a wall exceeds 5-7m length, provide control joints at weak sections.
Curing of masonry should be done sparingly to avoid body of the blocks
getting wet.
Avoid excessive welting of masonry at the time of plastering so that
moisture doesnt reach the body of the blocks.
DRYING SHRINING OF FLY ASHSAND-LIME BRICKS(Comparison)

FRESH MIXTURE BRICK
STRENGTH
40-50
kg/cm2
3 days
15 days
52-55
kg/cm2
15 days
30 days
55-60
kg/cm2
30 days
56-62
kg/cm2
45 days
75-85 kg/cm2
3 days
95-105
kg/cm2
107-112
kg/cm2
DRYING
SHRINKAGE
0.084%
SORPTION
21%
DEAD MIXTURE BRICK

STRENGTH
DRYING
SHRINKAGE
0.128%
SORPTION
34%
MORTOR SHRINKAGE
MORTOR SHRINKAGE
(sand: cement=5:1)
Rate of
SHRINAGE
MORTOR SHRINKAGE
(sand: cement=6:1)
190.585
10 days
190.535
190.275
10 days
16 days
190.155
15 days
190.500
18 days
190.160
18 days
190.465
21 days
190.130
25 days
190.455
23 days
190.090
30 days
190.435
30 days
0.079%
SRENGTH
SHRINAGE
0.097%
MANUFACTURING DEFECTS
SOURCES OF SUCH DEFECTS Role of fly ash bricks

To use proper and standard raw materials
Heterogeneity in mixing causes unequal stress
subsequently cracks in bricks and in structure
development
and
If moisture is high in the mixture the coarse aggregate will settle down
and lime will come up on the surface during compaction resulting less
strength development
If the filling of the materials in the mould box is not proper, unequal
pressure will develop on the brick mixture and improper compact will be
formed. So crack will develop in the brick itself and in the construction
If numbers of bricks are more in one cycle then deviations in compaction
will be much more resulting different quality bricks
Old mixture in manufacturing bricks to be avoided
SOME CONSTRUCTIONS
CONSTRUCTION
ON PROCESS WITH
FLY ASH BRICKS
COMPLETE
CONTRUCTION
WITH FLY ASH
BRICKS
A 3-Storied
building
constructed
by Fly ash
bricks
A BEAUTIFUL
CONSTRUCTION
WITH FLY ASH
BRICKS
CONCLUSION
It is found that fly ash-sand-lime bricks are the

only alternative to burnt clay bricks to avoid
pollution in the atmosphere, to save huge
energy consumed in brick kiln by burning coal
and to save huge fertile land. If the product is
manufactured with proper technological method
and construction is done with proper way it will
be the only alternative to conventional clay
brick. This is the prime importance of the
manufacturers, users and engineers to find out
the solution how the ecofriendly bricks can be
consumed for all construction purposes for the
sustainability of the Society and our Earth.
THANK YOU

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CRACKS IN BUILDINGS :

THE ROLE OF FLYASH

Cracks in buildings are of common occurrence and are

Penetration of moisture and

Extensive cracking of RCC

A building component develops cracks

Internal induced stress

PRINCIPAL CAUSES OF CRACKS IN

SOME FACTORS INFLUENCING IN

OTHER FACTORS INFLUENCING IN

MOVEMENT DUE TO CHEMICAL

SEVERITY OF SULPHATE /CHLORIDE

Initial shrinkage:- Initial shrinkage in fly ash sand-lime

FLY ASH-SAND-LIME BRICKS VS CLAY

Hydration of lime after brick formation causes

The increase of strain of a compact with time

FOUNDATION MOVEMENT &

Fly ash bricks are not responsible for this type

VEGETATIONThe growth of unwanted plants in the

SHRINKAGE OF FLY-ASH BRICKS:

LIME / FLY ASH CONTENT

DETAILS GIVEN IN THE NEXT FEW SLIDES

LIME/ FLY ASH CONTENT

PRESENCE OF EXCESSIVE FOREIGN

MEASURES FOR CONTROLLING

MEASURES FOR CONTROLLING

DRYING SHRINING OF FLY ASHSAND-LIME BRICKS(Comparison)

DEAD MIXTURE BRICK

SOURCES OF SUCH DEFECTS Role of fly ash bricks

It is found that fly ash-sand-lime bricks are the

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