properties of pepper waste bricks holson yu shen
TRANSCRIPT
PROPERTIES OF PEPPER WASTE BRICKS
HOLSON YU SHEN
Thesis is submitted to Faculty of Engineering,Universiti Malaysia Sarawak as a partial fulfilment of
the requirements for the Degree of Bachelor of Engineering with Honours(Mechanical and Manufacturing Engineering)
2009
UNIVERSITI MALAYSIA SARAWAK
R13a
BORANG PENGESAHAN STATUS TESIS
Judul: PROPERTIES OF PEPPER WASTE BRICKS
SESI PENGAJIAN: 2008/2009
Saya HOLSON YU SHEN (HURUF BESAR)
mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Malaysia Sarawak.2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk
tujuan pengajian sahaja. 3. Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan.4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini
sebagai bahan pertukaran antara institusi pengajian tinggi. 5. ** Sila tandakan ( ) di kotak yang berkenaan
SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan).
TIDAK TERHAD
Disahkan oleh
(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat tetap: No. 12, Jalan Jelutong Barat,
96100 Sarikei, SarawakNama Penyelia
Tarikh: Tarikh:
CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda.** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT dan TERHAD.
Approval Page
The Final Year Project attached here:
Title : Properties of Pepper Waste Bricks
Student Name : Holson Yu Shen
Matric No : 14136
has been read and approved by:
__________________________ ______________________
Ms Siti Nor Ain Musa Date
(Supervisor)
Dedicated to my family and friends.
ACKNOWLEDGEMENT
I would like to express my sincere appreciation to my supportive Final Year
Project supervisor, Ms Siti Nor Ain. I am very thankful for her advices, comments
and guidance all this while.
I also want to take this opportunity to thanks Mr Sabariman Bakar and Ms
Fazilah for giving me technical support for the project. Thanks to Mr Wong Liong
Pin, MD of Kitang Brick Work for providing the clay for the research.
Last but not least, I would like to thanks my family and friends for their
support and encouragement that helped me to overcome much hardship in my life.
i
ABSTRAK
Sisa lada boleh diproses semula dengan tanah liat untuk menghasilkan bahan yang berguna
untuk tujuan aspalan. Objektif kajian ini adalah bagi menyiasat ciri-ciri mekanikal bata
pernembusan air yang dibuat daripada sisa lada. Disebabkan sifat semulajadi bahan tersebut,
keupayaan sisa lada untuk membentuk liang telah disiasat. Dengan tujuan membandingkan
keputusan kajian, nisbah yang berbeza bagi sisa lada (0%, 2%, 5%, dan 10% oleh jisim)
telah diadunkan dengan tanah liat dan ‘abu terbang’. Kemudian, semua sampel bata yang
berbeza komposisi telah dibentuk, dikeringkan dan dibakar pada suhu 900 ºC. Penyerapan
air, ketertembusan dan kekuatan mampatan batu-bata yang telah siap diuji dan dibandingkan
dengan spesifikasi berkaitan. Sampel batu-bata didapati mempunyai penyerapan air antara
18.41% – 29.05%, ketertembusan pada kadar 5.278×10-10 m3s-1 dan kekuatan mampatan
antara 6.17 MPa – 30.81 MPa. Kekuatan kemampatan untuk sampel batu bata adalah
melebihi keperluan minimum standard Malaysia untuk batu bata yang berkualiti biasa, iaitu
tidak kurang dari 5.2 MPa. Keputusan kajian menunjukkan tambahan sisa lada akan
menghasilkan batu bata yang berliang dengan ciri-ciri mekanikal yang memuaskan.
ii
ABSTRACT
Pepper waste can be reprocessed with clay to produce useful materials for pavement
purpose. The objective of this study is to investigate the mechanical properties of water
penetrable bricks made from pepper waste. Due to the nature of the material, pore-forming
ability of pepper waste was investigated. In order to compare the results, different ratios of
the pepper waste (0%, 2%, 5%, and 10% by mass) were mixed with clay and fly ash. Then,
all the brick samples of different compositions were moulded, dried and lastly, fired at 900
ºC. The water absorption, penetrability and compressive strength of the fired bricks were
tested and compared with standard specifications. The brick samples have water absorption
between 18.41% – 29.05%, penetrability rate as fast as 5.278×10-10 m3s-1 and compressive
strength between 6.17 MPa – 30.81 MPa. The compressive strength for all samples passed
the minimum requirement by Malaysian Standard for the ordinary quality clay brick, which
is not less than 5.2 MPa. The results showed that pepper waste addition would produce
porous bricks with satisfactory mechanical properties.
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TABLE OF CONTENTS
CONTENT PAGE
ABSTRAK i
ABSTRACT ii
TABLE OF CONTENTS iii
LIST OF TABLES vii
LIST OF FIGURES viii
LIST OF EQUATIONS x
CHAPTER 1 INTRODUCTION
1.1 Background of Bricks 1
1.2 Overview of Water Penetrable Bricks 3
1.3 Application of Pepper Waste to Produce Water Penetrable Bricks 6
1.4 Objectives of the Project 8
1.5 Project Overview 8
1.6 Outline of Project Report 9
iv
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 10
2.2 Methods of Manufacturing Clay Bricks 10
2.2.1 Clay Winning 11
2.2.2 Clay Preparation 11
2.2.3 Moulding 12
2.2.4 Drying 13
2.2.5 Firing 14
2.3 Description of Clay Brick 15
2.4 Specification and Characteristics of Clay Bricks 16
2.4.1 Size Tolerance 17
2.4.2 Compressive Strength 18
2.4.3 Water Absorption 20
2.4.3.1 5-hour boiling test 21
2.4.3.2 24-hours cold immersion test 21
2.4.4 Durability 22
2.4.5 Aesthetic 24
2.5 Studies on Research Papers 26
2.5.1 Study on the Utilization of Kraft Pulp Production Residues in Clay
Brick Production 26
2.5.2 Study on the Effect of Organic Residues Addition on the Technological
Properties of Clay Bricks 28
v
CHAPTER 3 METHODOLOGY
3.1 Introduction 31
3.2 Pepper Waste 31
3.3 Composition of Pepper Waste Bricks 33
3.4 Sample Production 34
3.5 Mould for the Bricks 35
3.6 Drying and Firing Process 38
3.7 Sample Testing 39
3.7.1 Scanning Electron Microscopy Analysis 40
3.7.2 Size Tolerance 41
3.7.3 Water Absorption 42
3.7.4 Water Penetrability 43
3.7.5 Compressive Strength 44
vi
CHAPTER 4 RESULTS, ANALYSIS & DISCUSSIONS
4.1 Introduction 46
4.2 Effect of Pepper Waste Addition to Bricks Surface Texture 46
4.2.1 Surface Comparison between Brick Samples of
Different Composition 48
4.3 Effect of Pepper Waste Addition to the Size Tolerance 49
4.4 Effect of Pepper Waste Addition to the Water Absorption 51
4.5 Effect of Pepper Waste Addition to the Water Penetrability 53
4.6 Effect of Pepper Waste Addition to the Compressive Strength 54
4.6.1 Effect of Pepper Waste Addition to the Compressive
Strength of Sample Size Bricks 54
4.6.2 Effect of Pepper Waste Addition to the Compressive
Strength of Standard Size Bricks 56
4.6.3 Effect of Dimensional Differences to the Compressive
Strength for Bricks before Water Absorption Test 58
4.6.4 Effect of Dimensional Differences to the Compressive
Strength for Bricks after Water Absorption Test 59
4.7 Summary of results 61
CHAPTER 5 CONCLUSIONS & RECOMMENDATIONS
5.1 Conclusions 63
5.2 Limitations 64
5.3 Recommendations 65
REFERENCES 67
APPENDIX 70
vii
LIST OF TABLES
TABLE PAGE
2.1 Classification of bricks by compressive strength and water absorption
(BS 3921:1985) 19
2.2 Physical requirements for building bricks (ASTM C 62, 1990) 19
2.3 Classification of bricks by compressive strength and water absorption
(MS 76: 1972) 20
2.4 Levels of efflorescence in Malaysian Standard (MS 76: 1972) 23
2.5 Properties of fired samples 27
2.6 Equations used in Archimedes method 29
2.7 Physical properties of bricks sample 30
3.1 Composition of brick samples 34
4.1 Shrinkage for sample size bricks 49
4.2 Shrinkage for standard size bricks 49
4.3 Water penetrability test for sample size bricks 53
4.4 Mechanical properties table 61
viii
LIST OF FIGURES
FIGURE PAGE
1.1 Mechanism of water penetrable bricks 5
1.2 Pepper plants 7
2.1 Overall productions of clay brick 11
2.2 Extrusion machine 13
2.3 Size of a clay brick 18
2.4 Colours of water permeable brick 24
2.5 Application of water permeable brick 24
3.1 Raw pepper waste 32
3.2 Grinded pepper wastes 32
3.3 Mixer 35
3.4 Design for mould fabricated 36
3.5 Measurement for the mould 36
3.6 Standard size mould 37
3.7 Dimension of brick samples 37
3.8 Temperature graph 38
3.9 Testing sequence 39
3.10 SEM, JEOL JSM-6701F 40
3.11 Water absorption test 42
3.12 Water penetrability test 43
3.13 Shimadzu Autograph AG-IS 45
ix
4.1 SEM image for 0% of pepper waste 47
4.2 SEM image for 5% of pepper waste 47
4.3 Comparison between samples 48
4.4 Shrinkage for sample size brick with different composition
of pepper waste 50
4.5 Shrinkage for standard size brick with different composition
of pepper waste 50
4.6 Comparison of water absorption level with different composition
of pepper waste 52
4.7 Average compressive strength for dry and wet sample size
bricks with different composition of pepper waste 54
4.8 Average compressive strength for dry and wet standard size
bricks with different composition of pepper waste 56
4.9 Average compressive strength for dry sample size and
dry standard size bricks with different composition of pepper waste 58
4.10 Average compressive strength for wet sample size and
wet standard size bricks with different composition of pepper waste 59
x
LIST OF EQUATIONS
EQUATION PAGE
3.1 Mass fraction of the pepper waste 34
3.2 Shrinkage during drying process 41
3.3 Shrinkage during firing process 41
3.4 Total shrinkage percentage 41
3.5 Percentage of water absorption 42
3.6 Water penetrability 43
3.7 Compressive strength 44
1
CHAPTER 1
INTRODUCTION
1.1 Background of Bricks
A brick is a block of ceramic material used in building material construction. It
is an important building block for buildings around the world. The use of bricks has
been found dated back to 7,500 B.C.[14] This shows that bricks have been existed in
our civilization long time ago. Bricks can be made from clay, shale (finely
sedimentary rock), soft slate (fine-grained metamorphic rock), calcium silicate (lime
mixed with quartz), and concrete or shaped from quarried stone. Clay is the most
common material used as it is easy to find and cheap. In the late-20th century, brick
was confined to low and medium-rise structures, as a slim decorative cladding over
concrete-steel buildings and for internal walls.
The bricks are continually use at large scale even though brick has been
restricted to low and medium size buildings as there are many constructions still
requiring it. As such, many researches had been done over the years to increase its
potential in terms of strength, thermal resistance, high melting point and porosity.
Many improvements have been done on the earlier sun-dried mud brick and the
result is the varieties of bricks with different composition these days. With the
2
advancement of bricks manufacturing methods and using different kind of materials,
the production of bricks is expected to meet the strong demand from the consumers
globally.
In year 2007, a new type of brick based on fly ash was invented by Dr. Henry
Liu, a retired civil engineer. [15] Fly ash is a residue of coal from power plants. Since
the manufacturing method uses a waste by-product rather than clay, and
solidification takes place under pressure rather than heat, it has important
environmental benefits. Meanwhile in United Kingdom, a technology company
Geofusion is producing bricks made of recycled glass and glass waste, which is
expensive to recycle. [16] The technology can also be used to make porous paving
stones and tiles. Water engineers stated that floods and water shortages caused by
urban developments would disrupt the flow of rainwater back to the land.
Geofusion's porous bricks will allow them to capture the rainwater falling on car
parks along with buildings walls and reuse it.
For the paving industry, it has been pioneered by Unilock Company, which
originally introduced the paving stone to North America back in 1972. Backed by a
commitment to quality and innovation, Unilock has grown to become the leading
manufacturer of paving stones and retaining walls in United States.[17] The company
produced different kind of pavers from classic paver like Hollandstone to permeable
pavers like Turfstone, Ecoloc and Uni Eco-Stone. However, these permeable pavers
do not function like water penetrable bricks. This is because the design of it is to
create small openings between the pavers providing drainage into the earth. Hence,
permeable refers to water moving through openings between pavers and aggregate.
3
While, porous refers to the material allowing water to move through it, as is the case
with porous bricks that has voids in the material.
1.2 Overview of Water Penetrable Bricks
Water penetrable brick is another type of bricks that is under the investigation
by many institutions. This type of brick is used for pavement purpose. Through its
porous property, water can flow into ground easily and sunshine is not necessary
needed to dry it up. This feature is considered supportive as it can minimize pooling
problem especially on pavement, parking lots, roads and ground of bazaar or wet
market. Pooling is a major setback in urban construction because for non-permeable
construction materials, such as bitumen and cement are indirectly destroying the
ability for the earth to retain water. Whenever it rains, the consequences will be
flooded rivers and during a drought, the riverbeds will be dried up.
Besides diffusing water into the earth, which providing flood assistance, these
construction materials are capable of contributing to temperature control. For normal
bricks, it can store the heat energy slowly from the sun during the day and continuing
to release heat for several hours after sunset. However, water penetrable brick have
cooling effect because of the evaporation process in the bricks. Evaporation takes
heat from the environment and thus, cools the surrounding temperature. With this
added benefit, the water penetrable bricks prove to be suitable for the hot and rainy
climate in Malaysia.
4
Currently, such bricks are significantly used in the construction of venue’s
paving, roads and squares in many Olympic stadiums in China for the 2008 Beijing
Olympic Games. For example, water permeable blocks make up much of the paving
at the Fengtai Softball venue. These allow rainwater to leak through to the
underground water collection systems. While, in the Olympic Media Village, at least
3,000 cubic metres of rainwater can be captured using water permeable bricks, pipes
and wells installed on roofs, roads and green areas.[18]
Water penetrable brick serves as a medium between the external surface and
the ground. From the voids of the bricks itself, it allows water from the external
surface to flow through the bricks and into the ground. Figure 1.1 illustrated the
overall concept of water penetrability using this type of brick. Besides reducing
overflow problem and heat insulation problem, water penetrable brick can prevent
raw sewage discharged into the rivers.
5
Figure 1.1 Mechanism of water penetrable bricks
The range of using water penetrable brick is within the part of urban, suburban
and metropolitan areas. In big cities where everything is congested, such brick play a
critical role in town irrigation structure. For the heat effect inside cities, using this
brick will reduce the environment warming and balancing the temperature between
the external surface and the ground.
Water penetrable bricks
Water droplets
Pores
Pores
Ground
6
1.3 Application of Pepper Waste to Produce Water Penetrable Bricks
In order to produce water penetrable bricks, organic material is required to mix
with clay brick to create pores. This is because organic material will decompose if it
is exposed to the high temperature or considerable heat, thus leaving pores. The idea
of using pepper waste totally fit the criteria and it is easy to be found locally as
pepper is mainly produced in Sarawak. Therefore, pepper waste can be manipulated
to facilitate the production of water penetrable bricks instead of being dumped or
burnt up.
Pepper that is the world most widely used spice for food seasoning is the fruit
of the tropical climbing vine, Piper nigrum L, which is illustrated in Figure 1.2. It is
native to southwestern India and is extensively cultivated there and in other tropical
regions. The commercial black peppercorn is the entire dried berry while the white
peppercorn is the seed. Peppercorn pungency is due to the presence of the alkaloids
piperine, chavicine and piperettine.
In Sarawak, pepper cultivation dates back to 1856 but more extensive planting
started in the 1900s. Nearly 98% of Malaysian pepper is produced in Sarawak. The
plantations in Sarawak are in small farms averaging 0.2 hectares, mostly planted by
rural dwellers in upland areas. Peppers from Sarawak are concentrated in certain area
of Kuching, Samarahan, Sri Aman, Betong and Sarikei Divisions. Malaysia now
ranks No. 5 after Vietnam, India, Indonesia, and Brazil in terms of pepper
production.[19]
7
About 70 % of Sarawak's pepper is exported as whole black pepper and the
remaining as white pepper, green pepper in brine, value-added pepper and pepper
products. The production in 2004 was about 20,000 tonnes.[19] This shows that the
wastes and residues from such production are also likely to be in tonnes. The waste
that was separated from the production is outer pericarp layer, damaged or broken
fruits, the unfertilized buds, dust, pepper hulls or shells removed during the
preparation of white pepper and lastly the stems or stalks of the plant.
Figure 1.2 Pepper plants [20]
8
1.4 Objectives of the Project
The objectives of this project are to:
1. Produce samples of water penetrable bricks using pepper waste for research
and testing.
2. Investigate the mechanical properties of water penetrable bricks produced.
3. Study the effect of pepper waste in the bricks produced.
4. Compare the properties of standard size bricks and sample size bricks.
1.5 Project Overview
This is a research and experimental based project, which aims to increase the
strength of pepper waste bricks. Fly ash was chosen to improve its strength
properties. This is because fly ash is pozzolanic in nature as it reacts with lime with
lime and water to form a cementitious compound. It is anticipated that the bricks
produced is more durable and have a better porosity. From this project, it validates
the draw on of pepper waste in production of porous bricks. Samples were produced
in different percentage of residue addition. Then, tests were done to determine the
bricks mechanical properties. The information and data collected can be used to
support the implementation of such bricks in the clay bricks industry. Lastly, a
review and evaluation for the overall research was carried out.
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1.6 Outline of Project Report
This Final Year Project Report is split into five chapters: Introduction, Literature
Review, Methodology, Data and Analysis, and Discussion, Conclusion and
Recommendations. The brief information of each chapter is described as below:
Chapter 1 (Introduction) will introduce the background and provide the overview and
objectives of the project. Besides that, the sequence of the final year project report is
provided in this chapter as well.
Chapter 2 (Literature Review) provides summary and overview of the studies or
researches which are related to the project done. For example, processed waste tea,
kraft pulp residues and other organic waste are used as an additive to clay bricks to
generate porosity.
Chapter 3 (Methodology) provides the information of the methods used in the
project. This chapter provides techniques apply to do the experimental works as well
as how the specimen is produced for the research.
Chapter 4 (Results, Analysis and Discussions) will show the results analyzed from
the experiment and testing approach. It includes the discussion of the results.
Chapter 5 (Conclusions and Recommendations) summarizes the overall performance
of the project and recommendations for the future works.