In recent years, large industrial enterprises have often been accused of damaging the environment. This is probably why now more and more business ideas began to appear, in which mass production is combined with benefits for the ecological situation on the planet. One of these business ideas can be called the manufacture of building materials from waste from other industries, or simply from waste.

Let's look at one of the existing types of production of similar building materials - bricks and blocks from recycled materials.

How you can use "trash" to make bricks
I would like to note right away that all examples of the production of bricks and blocks from waste from various industrial industries are at the level of startups. But all these are more than promising projects, each of which can grow into a highly profitable business.

And immediately I want to consider why such a business has great prospects:

Cheap raw materials. What will become raw materials for the manufacture of your products is considered by other manufacturers as waste that needs to be disposed of, spending their own resources. Offer waste disposal services to such businessmen or municipal organizations, and you will provide yourself with cheap raw materials.

Opportunity to win tenders. If you have to participate in tenders to start a business, then you will be on your side that with your production you will improve the environmental situation in the region and provide the market with affordable building materials.

Wide target audience. The building materials you produce will be interesting for low-rise construction, the creation of sewerage systems, the construction of workshops and production facilities, etc. The demand will be provided by an affordable price, which is 10-15% lower in comparison with traditional building materials.

The prospects are great. Now let's look at how they are already being implemented in practice.

Examples of brick production from recycled waste

Now let's consider several options for using waste for brick production:

Boiler ash bricks
This technology was developed at the University of Massachusetts, proved to be successful, and is now being implemented in construction works in the Indian city of Muzaffarnagar. Ash from the boiler house (70%) is used as raw material, to which clay and lime are added. Before that, boiler ash was simply buried in the ground. And now it is possible to build comfortable housing from it.

Building waste blocks
The next example is about making wall blocks, not bricks. The production was organized in Vladivostok, where a plant was created for the production of building materials from construction and industrial waste. All this waste is fed into a shredder, crushed, converted into a homogeneous mass, after which blocks are formed from them for the construction of buildings.

Paper bricks.
The last example is still under development. From paper waste and clay, a mass is created, from which bricks are formed, then fired in a furnace. The technology was developed at the University of Jaen, and according to the reports of their researchers, this material can be used to create reliable low-rise energy-efficient houses. True, such bricks have a lower strength than traditional ones, which requires additional solutions in reinforcing the walls of the future building.

The business idea of ​​making bricks from rubbish is an industry that requires research courage, technical savvy and entrepreneurial genius. But if you manage to implement such a project, then you can take a dominant position in an emerging market. And if you prefer a fully developed production of building materials, then it makes sense to start making foam concrete blocks and other traditional wall materials.
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The use of bricks as a building material has been used since ancient times. At the moment, brick is considered one of the most basic types of material for construction. But in construction work, they learned to use both solid bricks and broken bricks, which also gained wide popularity among many construction companies in Russia.

Application area

It is customary to call the waste that is obtained as a result of the production of bricks by the battle of red brick. In addition, broken brick is formed as a result of the demolition of buildings and structures. Such a battle of bricks is widely used. It is customary for them to sprinkle roads, pits, and also use them for sprinkling places intended for parking lots and asphalt areas. In addition, broken bricks are used as backfill in places such as swampy soils, which are later used for the construction of new houses.

The use of broken bricks is used in such cases as?

  1. Fighting bricks are used to cover roads in order to shape them. Fighting bricks is used both in construction work and in gardening. But mostly broken brick found its use for temporary repair of roads in the autumn-winter period.
  2. As for road works, broken brick, like broken concrete, is used as the main and indispensable tool for dealing with pits and potholes on the roads.
  3. In the event that it is planned to build in swampy places, then in this case, the broken brick will be used as a backfill for building.
  4. In summer cottages, broken brick is used as a drainage system for the construction of reservoirs or wells.

Besides, broken brick is a great way to provide heat and noise insulation. Therefore, it is very often used in construction work during the construction of walls, filling the inner part of the wall with this material.

Broken brick sales

As for the sale of broken bricks, not only firms specializing in the production of bricks themselves are engaged in it, but also other companies that directly deal with the sale of ore materials.

Broken bricks are sold according to the approved price list. But it is always worth keeping in mind that there are times when the cost of this building material can change, usually due to the volume of the order and the availability of delivery. Broken bricks are delivered to their destination by special equipment, which must have a high carrying capacity.

1

The analysis of the state of the problem of utilization of broken ceramic bricks, formed as a waste when replacing brickwork in the course of repair work, is carried out. The absence of effective methods of mass disposal of such waste in the world practice has been revealed. The results of the study are presented that determine a new direction for recycling ceramic brick broken by returning it to the resource cycle as a raw material for the production of building composites, while simultaneously reducing the risk from environmental pollution. It is shown that, from the point of view of rational nature management, obsolete ceramic bricks are underutilized raw materials for construction purposes, capable of providing the ceramic industry with high-quality emaciated materials, like chamotte. The expediency of using such waste as a mechanically active component of the raw material mixture for producing decorative concrete of small-sized elements of road paving is substantiated, improving their physical and mechanical properties and color characteristics.

battle of ceramic bricks

construction composites

skinny supplement

thermal conductivity of material

1.Andrianov N.T., Balkevich V.L., Belyakov A.V. et al. Chemical technology of ceramics: Textbook / ed. AND I. Guzman. - M .: OOO RIF "Stroymaterialy", 2011. - 496 p.

2. Dovzhenko I.G. Investigation of the influence of metallurgical slags on the drying properties of ceramic masses for the production of facing bricks // Glass and ceramics. - 2013. - No. 12. - S. 24–27.

3.Rakhmankulov D.L. Historical aspects of the production and use of small-piece concrete wall and road products // Bashkir Chemical Journal. - 2006. - T. 13. - No. 2. - S. 77–83.

4. Semenov A.A. The state of the Russian market of ceramic wall materials // Building materials. - 2014. - No. 8. - S. 9–12.

5. Stolbushkin A.Yu., Berdov G.I., Stolbushkina O.V., Zlobin V.I. Influence of the firing temperature on the formation of the structure of ceramic wall materials from fine-dispersed waste of iron ore dressing. Izvestiya vuzov. Construction. - 2014. - No. 1. - S. 33–42.

(6) Tkachev A.G., Yatsenko E.A., Smoliy V.A. et al. Influence of coal industrial waste on molding, drying and roasting properties of ceramic mass // Tekhnika i tekhnologiya silikatov. - 2013. - No. 2. - S. 17–21.

7.Environmental, theoretical and technological principles of using phosphoric slag and ash-and-slag material in the production of high-quality ceramic bricks: monograph / V.Z. Abdrakhimov, I.V. Kovkov. - Samara: Publishing House of Center for Perspective Development, 2009. - 156 p.

8. Yushkevich M.O., Rogovoy M.I. Ceramic technology: textbook. allowance. - M .: Publishing house of literature on construction, 1969. - 350 p.

Construction waste, including brick, generated in large volumes during repair work, until now, is mainly disposed of at landfills for solid domestic waste (MSW). At the same time, not only the volumes of landfills are significantly increasing, but also irrevocably non-renewable mineral raw materials are lost, the resources of which are limited. The absence in world practice of effective methods of mass utilization of construction waste has prompted the task of finding new approaches and technologies for their involvement in the economic turnover.

This work is devoted to the study of the properties of brick waste as a technogenic mineral raw material for construction purposes. The urgency of solving such a problem is due, on the one hand, to environmental problems of reducing the resource intensity of building materials and products, on the other hand, to the issues of socio-economic development of the region. It is known that the mineral resource base is being depleted at an increasing rate and is insufficient to meet the needs of the construction industry in mineral resources, which determines the need to involve technogenic materials in the resource cycle. At the same time, the production of ceramic bricks has great opportunities for the use of technogenic raw materials. The works proved the possibility of using various man-made materials in the production of ceramic bricks as an additive, and in some compositions as the main raw material, replacing partially or completely non-renewable exhaustible resources of clay rocks. A large volume of production of ceramic bricks makes it possible to dispose of industrial waste in significant quantities and a wide range of their composition using traditional technology and equipment. In addition, the creation of raw materials using man-made materials as an additive is one of the ways to expand the use of low-grade clay rocks, improve the technical properties and reduce the cost of the resulting ceramic bricks.

From the point of view of rational use of natural resources, ceramic bricks are underutilized raw materials for construction purposes, capable of providing the ceramic industry with high-quality emaciated materials like chamotte. It is known that chamotte is one of the highest quality clay softeners. Chamotte, unlike other weakening agents, does not reduce the refractoriness of the ceramic mass, but it is an expensive material, and therefore it is not used for the manufacture of cheap ceramic products, in particular, ceramic bricks.

The purpose The research carried out was to assess the applicability of obsolete ceramic bricks for use as a component of the raw material charge of building composites.

Materials and research methods

The studies used the breakage of ceramic bricks formed as a waste when replacing brickwork in the course of repair work at a heat power plant. The studied waste was considered as a thinning additive in the composition of the ceramic mass for obtaining a ceramic shard for construction purposes. Clay rocks of local deposits were used as the main raw material. Clay raw materials were tested in accordance with the requirements of GOST 9169-75 "Clay raw materials for ceramic bricks" and standard procedures GOST 21216-2014 "Clay raw materials. Test methods ". According to their physical and mechanical properties, determined by the number of plasticity and the index of refractoriness, they are classified as medium-plastic and low-melting clay raw materials, and in terms of particle size distribution, they are classified as low- and medium-dispersed ones. According to the mineral composition, the samples of clay rocks studied in the experiment belong to polymineral, mainly montmorillonite clays. In terms of chemical composition, they met the requirements of GOST 32026-2012, GOST 9169-75 and OST 21-78-88 for raw materials for the ceramic industry.

Experimental studies in the work included the development of the composition of the raw material charge and the manufacture of samples of ceramic shards. The compositions of ceramic masses were developed using the methods of building materials science and mathematical modeling. Raw materials, mixtures, samples were prepared according to the standard procedure.

At the stage of preparation, the broken brick was crushed by dry grinding in a ball mill to the fineness of grinding with a residue on a sieve No. 008 of no more than 5mass. %. Brick powder sifted out on a sieve No. 008 (bulk density ρн = 1256 kg / m3) in an amount of 5-35 wt. % was mixed with clay until a homogeneous mass was obtained. The raw charge was mixed with water until a plastic dough was formed. From the prepared ceramic mass by the method of plastic molding, laboratory samples-cubes with a size of 70 × 70 × 70 mm were made. The manufactured samples were kept at a temperature of (20 ± 5) ° C for 24 hours. The deformed samples were dried in a drying oven for 4 h at a temperature of (105 ± 2) ° С. The samples were fired in an SNOL6.7 / 1300 muffle furnace. The firing mode was set taking into account the component composition of the raw material charge. The maximum firing temperature was calculated by the formula

where are the mass fractions in the charge of oxides of silicon, aluminum, calcium, magnesium, iron, wt. %.

For the investigated compositions of the raw material mixture in the selected intervals of variation of the mass fraction of the powder of brick broken, the maximum firing temperature was determined in the range of 900-950 ° C.

The quality assessment of the samples made in laboratory conditions was carried out for compliance with the standard requirements of GOST 530-2012 “Ceramic bricks and stones. General specifications "in terms of: water absorption, average density, volumetric air and fire shrinkage (GOST 7025-91" Bricks and ceramic and silicate stones. Methods for determining water absorption, density and frost resistance control "), mechanical strength in compression (GOST 8462-85 "Wall materials. Methods for determining the ultimate strength in compression and bending"), coefficient of thermal conductivity (GOST 7076-99 "Building materials and products. Method for determining thermal conductivity and thermal resistance in a stationary thermal regime"), grade for the average strength of samples. The samples were tested under laboratory conditions.

The question of disposal of the residue on sieve No. 008, represented by a fraction of brick powder with an admixture of masonry mortar on its surface, remained open. In the present work, this residue was investigated as a mechanically active component of the raw material mixture for the production of decorative concrete for small-sized road paving elements (sidewalk slabs and figured paving elements). The main task of the research was to determine the possibility of using such a fraction of brick powder in the composition of the raw charge to obtain concretes for road elements with operational properties that meet the requirements of GOST for the corresponding types of products and improved color characteristics.

At the present stage of development of building technologies, much attention is paid to small-sized paving elements. In contrast to continuous asphalt pavements, the use of prefabricated elements of a relatively small size for the construction of sidewalks, pedestrian paths and squares is considered more appropriate due to their flexibility. With temperature drops, these clothes are subject to less deformation, are more maintainable and less resource-intensive, do not cause imbalance in the atmosphere - soil - hydrosphere system, and contribute to an increase in the sanitary and hygienic conditions of the urban environment. A characteristic modern feature of paving slabs is the ability to manufacture them using various technologies and methods of modifying the structure and properties of concrete, providing increased resistance to aggressive environments and mechanical stress. Various pigments are used to give architectural expressiveness.

The compositions of the raw mixes were developed by the calculation and experimental method using Portland cement, quartz sand with a fineness modulus of more than 2.5 and the addition of brick powder. Relamix T-2 was used as a plasticizing additive. The water consumption was determined from the calculation of the water-cement ratio in the range of 0.37-0.47. The component composition of the raw material mixture varied within, wt. %: 23 - Portland cement, 52-77 - quartz sand, 0-25 - brick breakage powder.

The experiment used the method of volumetric staining of concrete. The concrete preparation technology provided for the separation of the process. At the first stage, a homogeneous mixture of cement was prepared with the addition of brick-broken powder. Subsequent operations for preparing concrete solution and making samples were carried out in accordance with the requirements of GOST. For testing, from the prepared mass, samples-cubes with an edge size of 70 × 70 × 70 mm were made by vibration molding.

The assessment of the decorative qualities of concrete textures and color fastness was carried out visually in natural conditions. To assess the conformity of the quality of concrete samples to the regulatory requirements of GOST 17608-91 “Concrete paving slabs. Technical conditions "tests were carried out for compressive strength (GOST 10180-2012" Concrete. Methods for determining the strength of control samples ") and determined the grade of concrete (GOST 26633-2012" Concrete heavy and fine-grained. Technical conditions "), water absorption (GOST 12730.3- 2012), average density (GOST 12730.1-2012), frost resistance (GOST 10060.4). Compressive strength was determined by testing specimens on a hydraulic press. The samples were tested in laboratory conditions at the age of 28 days. Testing the material for water absorption was carried out by saturating standard concrete samples with water. The frost resistance of the material was determined in accordance with the requirements of GOST 10060.4 by alternating freezing and thawing of standard concrete specimens in a state saturated with water.

Research results and their discussion

In the study of the relationship between the content of the powder of brick scraps in the composition of the raw charge and the main physical and mechanical characteristics of the ceramic shard samples (water absorption, average density, volumetric air and fire shrinkage, thermal conductivity, ultimate strength in compression), the linear regression method was used. The degree of nonlinearity of the considered dependences was established by determining the value of the coefficient of determination R2 when approximating the parameters уi (water absorption, average density, volumetric shrinkage, thermal conductivity, ultimate strength in compression) by a linear model

The model was built on the basis of the results of an actual experiment and analytically describes the dependences obtained in the experiments (figure).

The high value of the coefficient R2 for the dependences of the determined indicators on the content of the powder of brick broken in the charge is due to an almost linear nature.

Analysis of the experimental data shown in the figure shows that an increase in the proportion of brick powder in the charge leads to a slight increase in water absorption. At the same time, the dynamics of a decrease in the values ​​of total shrinkage, average density, thermal conductivity, and compressive strength of samples is clearly traced. In accordance with the normative documents for different types of building ceramics, water absorption is standardized, which should not exceed 20mass. % and is a qualitative characteristic of the sintering process. On the water absorption graph (figure, a), this value is limiting when optimizing a ceramic mixture and allows us to determine, taking into account the obtained values ​​of shrinkage deformations, average density, thermal conductivity and compressive strength, a rational range of changes in the content of brick powder in a two-component mixture based on low-melting clay at a certain firing temperature. The results obtained indicate the possibility of using brick waste in the current technology of ceramic bricks of the M125, M150 brands with a brick powder content of up to 30 wt. % at a firing temperature of up to 950 ° C, which meets the regulatory requirements of GOST 530-2012 “Ceramic bricks and stones. General technical conditions ". The optimum content of crushed ceramic bricks is 10-30mass. %. With an increase of more than 30mas. %, the compressive strength decreases below the rated value and the water absorption of the samples increases, and when its content decreases to less than 10 wt. % there is no significant decrease in the thermal conductivity coefficient. Products made of low-melting clay with an additive within the limits of variation in the composition of the ceramic mass of the mass fraction of the ceramic brick breakage powder have sufficient color saturation and purity of color tone. The influence of the effect of the interaction of the components of the raw material charge on the indices of the determined physical and mechanical characteristics of the samples of the ceramic shard made under the experimental conditions has not been established.

The type of experimental dependences of indicators on the content of powder of brick scraps in the composition of the raw charge: a - water absorption; b - average density; c - volumetric shrinkage; g - thermal conductivity; d - compressive strength; e - experimental data; - calculation data for the model in the MS Excell program

Samples of concrete products of small-sized paving elements, made with the addition of brick powder in the range of up to 20mass. %, in terms of brand compressive strength and average density, they met the requirements of GOST 17608-91. The introduction of brick powder into the raw mix in large quantities causes a decrease in the strength characteristics of concrete and an increase in water absorption. Frost resistance of the manufactured test batches of concrete samples in the investigated range of the component composition is relatively high and corresponds to the value regulated by GOST 17608-91. Products made on the basis of a raw material mixture with the addition of brick broken powder had sufficient color saturation and purity of color tone.

Conclusion

The research results showed that the utilization of obsolete ceramic bricks as a lean additive in the composition of the ceramic mass to obtain a ceramic shard for construction purposes and for partial replacement of natural sand in the production of concrete for small-sized paving elements is a promising direction of its use. In addition, the creation of raw materials with the use of waste as an additive is one of the ways to reduce the cost of the resulting products and prevent their placement at storage facilities, which is essential to ensure the rational use of raw materials.

The data obtained are of an evaluative, preliminary nature, but they allow us to focus on the existing problem and the need for a comprehensive study that requires further theoretical study and deepening of technological studies.

Bibliographic reference

Fomenko A.I., Gryzlov V.S., Kaptyushina A.G. CERAMIC BRICK WASTE AS AN EFFECTIVE COMPONENT OF BUILDING COMPOSITES // Modern science-intensive technologies. - 2016. - No. 2-2. - S. 260-264;
URL: http://top-technologies.ru/ru/article/view?id=35613 (date accessed: 02/26/2020). We bring to your attention the journals published by the "Academy of Natural Sciences"

Building from Waste is a book that won't make it on your weekend or vacation reading list, but some might find it quite curious. Every year, settlements generate 1.3 billion tons of solid waste. The book claims that they simply need to be used as cheap and durable building materials. Thanks to this, humanity can significantly reduce the level of environmental pollution.

Co-authors Dirk Hebel, Martha Vishnevskaya, and Felix Hayes took a close look at the construction industry and came up with a waste management system designed to find new and interesting building materials that can usually be found in landfills. The book argues that in the future, we would be able to reuse almost everything, just as we once did when all waste was organic.

This approach will be especially useful in the future, when the population increases and the level of waste doubles. Below is a list of the building materials that are most popular with the authors of the book.

Newspaper tree

This development came from Norway, where more than 1 million tons of paper and cardboard are recycled annually. Wood is created by rolling paper with insoluble glue. Next, you get something that looks like a log, which is cut into workable boards. The wood can later be additionally protected in order to make it moisture and fire resistant. As a result, planks can be used in the same way as regular wood.

Newspaper tree

Diaper roof

The good news is that you can still do something about the many diapers and hygiene products that we throw away all the time, even if they are dirty and disgusting. A dedicated recycling plant is capable of separating polymers from organic waste and can be used to create building materials such as the tiles in the photo above.

Blocks from packages

The photo shows building blocks completely made from old bags, which are rather difficult to recycle in another way. Recycled bags or plastic bags are placed in a special mold and then squeezed together under high temperature to form a block. True, they are too light to be used for load-bearing walls, but they can be used to divide rooms.

Building blocks from plastic bags

Bloody Blocks

The emergence of this idea was the result of the fact that animal blood is considered useless and is usually disposed of. However, due to its high protein content, it is one of the strongest biological adhesives.

Jack Monroe, a British student studying architecture, suggests using dehydrated blood supplied in powder form.


Then mix it with sand to form a paste. This can be especially useful in regions where there is a lot of blood left after slaughter and building materials are in short supply.

Making building blocks from animal blood

Bottle building blocks

The idea is different here, as it is based on consumer goods that can later be used as building materials. Many companies are already making cuboid bottles to make them easier to transport.

However, the practical use of such material began with the Heineken brewery in the 1960s. Alfred Heineken visited a Caribbean island where open bottles of his beer were scattered everywhere, which he was not happy about. After that, the company switched to new bottles, as shown in the photo.

The neck is inserted into a special recess on the bottom, after which a closed line of bottles is obtained.

A wall made of bottles

Smog insulators

One of the largest receptacles for waste is air, which becomes of little use for our lungs. And also the greenhouse effect, which raises the temperature on the planet to the point of being unsuitable for the human race. Dastyrelief is a system created in the city of Bangkok. The idea is to place electrically charged grids on buildings that attract smog particles and glue them together. As a result, something similar to bluish fur is formed on the buildings. It is certainly not very attractive, but anything is better than what could form inside your lungs.

"Gray fur"

Mushroom walls

The designers have found a way to grow insulation and packaging materials from mycelium. These are bacteria found in rotting organisms such as tree trunks and agricultural by-products. If they are placed in a special mold, these organic substances grow to a given shape in just a few days, and then the growth can be stopped using a hot oven.

Mushrooms as a building material for walls

Plasfalt

It sounds funny, but the thing is really interesting. Plasphalt consists of grains obtained from unsorted plastic waste, which replace the traditionally used sand and gravel. During the tests, it was found that plastic roads are much less susceptible to wear, and this is all because plastic granules are connected much better than the same sand and gravel.

Plasphalt photo

Wine cork panels

These wall or floor panels are made with a combination of recycled and whole wine corks that you can see in the photo. This is a pretty good idea as more than 31.7 billion bottles of wine are consumed annually.

Wine cork panels

Fired clay bricks, with their constantly growing production, have a number of negative environmental and social consequences. MIT students have created a brick that is 70% boiler ash and does not need to be fired at all.



The explosive growth in construction in developing countries is leading to an increase in the production of bricks as one of the most affordable building materials. This in turn creates 2 problems:

  • and environmental pollution during firing
  • the extraction of clays for this brick leads to the processing of fertile soil, or rather to its destruction on a large scale


“Clay bricks are fired at 1,000 degrees Celsius,” says Michael Laracy, a graduate student who worked on the project. "They consume a tremendous amount of energy from coal, in addition to the fact that these bricks are produced entirely from the topsoil, so they are depleting the amount of farmable land."


So Michael proposed to solve both problems by converting industrial waste into building materials.
Eco BLAC bricks are 70% composed of boiler ash from paper mills, mixed with sodium hydroxide, lime and a small amount of clay. It is produced at room temperature using "Alkaline Activation Technology" to ensure its strength.



“Currently, this ash has no practical application due to the variability of its physical and chemical properties, and it is very costly to send it to landfills, both for the environment and for breeders. For this reason, we see an opportunity in creating a robust design that can account for these variability using alkaline-activation technology. "

Ash brick turned out to be a very practical and scalable solution for all of India, where, in fact, this experiment was carried out.
Eco-BLAC was awarded a $ 100K grant as a finalist in the 2015 MIT competition and was named one of the best innovations of 2015 by Mashable.