The document discusses a research study investigating the feasibility of making low-cost, lightweight bricks using recycled paper mill waste from the Punalur Paper Mill. The study aims to compare the strength properties of bricks made with recycled paper mill waste-cement and recycled paper mill waste-laterite combinations to conventional clay bricks. Various tests were conducted on the raw materials and finished bricks to evaluate their properties. The recycled paper mill waste was found to contain silica and calcium which provide cementitious properties when used to make bricks.

2. FEASIBILITY OF MAKING LOW
COST, LOW ENERGY, LIGHT
WEIGHT BRICKS USING RECYCLE
PAPER MILL WASTE
FROM PUNALUR PAPER MILL
2
Student Investigators
Anandalekshmi B
Jeswin John
Nayana D
Parvathi G Vijayan
Siju P
Guided by,
Mrs. Deepa R,HOD
Mrs. Manju R,
Assistant Professors,CE
College of engineering
,Pathanapuram

3. INTRODUCTION
Brick is the most widely used construction material.
The increasing demand for the construction materials lead to
exploitation of the natural resources in large extent.
Utilisation of industrial by-products for making construction
materials has gained significant attention across the world.
This project investigated the use of recycle paper mill waste
(RPMW) from Punalur Paper Mills as a raw material for
manufacture of bricks.
3

4. With 85% average efficiency of RPM, around 5% (by weight) of total
pulp and paper mill production is generated as RPMW annual.
As a by-product, the RPMW is usually land filled, incinerated etc.
Bricks using different RPMW-cement combination and RPMW-laterite
combination are made and their properties are evaluated.
Variation of compressive strength with variation of particle size of
RPMW is studied.
4

5. NEED OF STUDY
 Shortfall of conventional building construction material can be reduced
by utilizing industrial wastes.
 Reduction of natural recourses as well as energy.
 Better way of managing industrial wastes.
5

6. OBJECTIVE OF THE STUDY
 To compare strength characteristics of RPMW-cement bricks and
RPMW-laterite bricks with conventional clay bricks.
To compare the strength of RPMW-cement bricks by varying the
particle size of the RPMW.
6

7. LITERATURE REVIEW
1. S P Raut et al (2011) conducted studies on “Reuse of recycle paper mill
waste on energy absorbing light weight bricks”. This study was to
investigate the use of Recycle paper mill waste (RPMW) in construction
bricks.
2. S P Raut ,D Rajput et al(2011) conducted studies on “Reuse of cotton
mill and recycle paper mill waste as a building material” .In this study
they used recycle paper mill waste(PW) and cotton mill waste (CW) to
make waste create bricks
3. S Raut et al(2013) conducted a study on “Utilisation of recycle paper
mill residue and rice husk ash in production of light weight bricks “.In
this research study, recycle paper mill residue (RPMR) and rice husk ash
(RHA) are utilized to improve the properties of bricks.
7

8. 4. 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”.
5. Mucahit Sutcu and Sedat Akkurt (2009) studied on “The use of recycled paper
processing residue in making porous brick with reduced thermal
conductivity”.
6. Reddy Babu and N.Venkataraman (2013) studied bricks on the paper titled
“Durability of Bricks cast with industrial sludge”.
7. Ashwin Narendra Raut and Christy Pathrose Gomez (2016) studied the
wastecrete bricks in the paper titled “Utilization of Waste as a Constituent
Ingredient for Enhancing Thermal Performance of Bricks – A Review
Paper”.
8

9. 8. Ismail Demir et al studied on the “utilisation of kraft pulp production
residue in clay brick production “.
9. J.E. Oti and J.M. Kinuthia studied on “Stabilised unfired clay bricks for
environmental and sustainable use”.
10. Sivakumar Naganathan, Almamon Yousef Omer Mohamed and Kamal
Nasharudd Mustapha studied on ” Performance of bricks made using fly
ash and bottom ash”.
9

10. 1. The research that was carried out over the last years that many
successful attempts to incorporate different types of waste in
production of bricks.
2. The compressive strength and various other properties of the brick
was also improved on using RPMW.
3. Utilisation of RPMW can be a cost-effective alternative.
10
SUMMARY

11. MATERIALS
1. RECYCLE PAPER MILL
WASTE (RPMW)
Recycle paper mill waste (RPMW)
has been obtained from Punalur
Paper Mill. This is a type of
organic material.
11
Punalur Paper Mill

12. Recycle Paper Mill Waste
(RPMW)
Recycle Paper Mills use recycled waste paper
along with virgin pulp to produce mainly packing
paper.
The pulp is made into paper by machines.
Long length fibres go into the paper sheet on the
machine while short length fibres pass through the
machine belt and are separated at the end filter from
the waste water.
This constitutes the Recycle Paper Mills waste .
12

13. 13
Grinded RPMW

14. CHEMICAL COMPOSITION OF RPMW
The chemical analysis of RPMW done by using Energy Dispersive X-
ray Fluorescence Spectrometer (XRF).
The XRF test was conducted in CSIR, Trivandrum.
RPMW mainly contains Si (20%) and Ca (28%) depicting the XRF scan
data.
The silica content in RPMW mainly gives the cementitious property.
Slight amount of metals present.
14

15. Compound Concentration
MgO 2.446 %
Al2O3 11.892 %
SiO2 19.192 %
P2O5 1.06 %
Cl 2.135 %
K2O 0.769 %
CaO 28.238 %
TiO2 2.283 %
V2O5 502.6 ppm
Cr2O5 566.3 ppm
MnO 702.8 ppm
Fe2O5 7.511 %
NiO 84.2 ppm
CuO 553.5 ppm
ZnO 0.208 %
Ga2O3 39.8 ppm
As2O3 26.4 ppm
Br 185.3 ppm
Rb2O 45.7 ppm
SrO 357.7 ppm
ZrO2 434.1 ppm
Eu2O3 214 ppm
PbO 174.3 ppm
15

16. 2. CEMENT
• A cement is a binder, a substance used in construction that
sets, hardens and adheres to other materials, binding them
together.
• Ordinary Portland cement of 53 grade was used for the project.
16

17. 3. LATERITE
 Laterite is a soil and rock type rich in iron and aluminium.
 Nearly all laterites are of rusty-red coloration, because of high
iron oxide content.
 Locally available laterite from our college was used for the
project.
 Laterite was ground and particles passing through 300 µ was
used.
17

18. TESTS CONDUCTED ON RAW
MATERIALS
1. Test on RPMW
2. Test on laterite

19. 1. SIEVE ANALYSIS
The grain size analysis of RPMW studied by conducting sieve
analysis.
19
TESTS ON RPMW

20. Sl. No. Sieve Weight
retained
gm
% weight
retained
Cum. %
of
weight
retained
% finer
1 4.75mm 70.5 14.1 14.1 85.9
2 2.36m
m
74.5 14.9 29 71
3 1.18mm 81 16.2 45.2 54.8
4 0.6mm 78 15.6 60.8 39.2
5 0.3mm 95 19 79.8 20.2
6 0.15mm 51 10.2 90 10
7 .075mm 32 6.4 96.4 3.6
8 Pan 18 3.6 100 0
20

21. 21
0
20
40
60
80
100
120
0.01 0.1 1 10
Percentagepassing%
Grain size (mm)

22. 2. SPECIFIC GRAVITY ON RPMW
Specific gravity of RPMW is the ratio of weight, in air
of a given volume; of dry soil solids to the weight of equal volume
of water at 40C.
22
W1 = empty weight of pycnometer = 581.5gm
W2 = weight of pycnometer + oven dry RPMW = 781.8gm
W3 = weight of pycnometer + oven dry RPMW + water = 1455gm
W4 = weight of water + weight of pycnometer = 1486.5gm

23.  G =
 The specific gravity of the RPMW was obtained as
0.869,which is comparatively less than conventional clay
material having specific gravity of range 2.6

24. TESTS ON LATERITE
• SIEVE ANALYSIS
24
The grain size analysis of RPMW is studied by conducting sieve
analysis.

25. Sl.
No
Sieve
(mm)
Mass of
soil
retained
Cum.
Mass
retained
Cum. %
Of
soil
retained
% finess
1 4.75 0 0 0 100
2 2.36 12.46 12.46 2.492 97.508
3 1.18 88.67 101.13 20.217 79.783
4 0.6 189.19 290.32 58.038 41.962
5 0.3 146.14 436.46 87.254 12.746
6 0.15 53.08 489.54 97.865 2.135
7 0.075 7.57 497.11 99.378 0.622
8 Pan 2.89 500 100 0
25

26. 0
20
40
60
80
100
120
0.01 0.1 1 10
%fineness
sieve size (mm)

27. MANUFACTURE OF RPMW BRICKS
1. Collection of RPMW from the Punalur Paper Mill
2. Pre-treatments such as drying and grinding.
3. Grinding was done by using Los Angles abrasion testing
machine by providing 500 revolutions.
27
Los Angeles abrasion testing machine

28. 4. Moulds of size 230 x 105 x 80mm.
28

29. 5. Proportioning of materials
29
Sl
No:
Cement/laterite
(%)
RPMW (%)
1 5 95
2 10 90
3 15 85
4 20 80

30. 6. Batching of raw materials
 Cement – cement of grade OPC 53 are used.
 Laterite – laterite obtained from the field is dried under the
sunlight until it is free from moisture. The dried clay is crushed
and sieved through 300 micron sieve and the laterite passed
through the sieve is collected. The collected laterite is weigh
batched according to the proportions required.
 RPMW – The grinded RPMW is sieved through 2.36mm sieve.
RPMW passes through the sieve weigh batched and used in the
required proportion
30

31. 7. Dry mixing of raw materials
8. Wet mixing of raw materials
31
Wet mixing

32. 9. Placing of mix
 After obtaining a uniform paste, the mix is placed into the mould
and proper compaction is given to the mix in order to avoid
formation of air voids.
 Now level the surface with a trowel and remove the excess paste
using trowel. The mould is kept as such for 2 minutes without any
disturbance
 Then removes the mould carefully.
32

33. 33
Casting

34. 10. Drying of brick
 Place fresh brick in shaded area to protect it from direct sunlight as
exposure to direct sunlight can accelerate crack formation.
 Place the fresh brick in shade for 3 days.
 After drying in shaded area the brick is placed for sun drying for
next 25 days.
34

35. 35
Sun drying

36. TESTS ON CONVENTIONAL BRICKS
Conventional brick was tested to determine the compressive
strength, water absorption, efflorescence, hardness, and
soundness. The testing of the burnt clay bricks are done as per
IS 3495 (Part 1to 4):1992.
36

37. 37
Compressive strength testing machine
DETERMINATION OF COMPRESSIVE STRENGTH
According to the IS 3495 (Part 1):1992

38. SL
No:
Load
(KN)
Area
(mm2)
Crushing
Strength
(N/mm2)
1. 135 22600 5.973
2. 120 22600 5.309
3. 115 22600 5.088
Average compressive strength = 5.456 N/mm2
38

39. WATER ABSORPTION (IS 3495 (Part 2):1992
39
SL
No:
Dry weight
(kg)
Wet weight (kg) Water absorption (%)
1. 2.700 3.310 22.5
2. 2.654 3.290 23.96
3. 2.746 3.322 20.97
4. 2.667 3.291 23.39
Average water absorption value = 22.705%

40. EFFLORESCENCE IS 3495 (Part 3):1992
The efflorescence test is carried according to IS 3495 (Part 3):1992.
The efflorescence is defined as the crystalline salts deposits on the
surface of bricks.
The liability to efflorescence shall be reported as ‘nil’, slight,
moderate, heavy or serious.
‘Nil’ efflorescence is present on any proportion of the brick.
40

41. HARDNESS TEST IS 3495 (Part 4):1992
Hardness of brick is the resistance to scratching or cutting.
In this test, a scratch is made on the brick surface by finger nail.
Slight impression is left on the brick surface
41

42. SOUNDNESS TEST
Two bricks are taken, one in each hand, and they are struck with
each other lightly.
A brick of good quality should not break and a clear ringing sound
should be produced.
The conventional brick tested was sound and has passed soundness
test successfully.
42

43. TESTS ON RPMW-CEMENT BRICKS
43
Compression testing of RPMW- cement brick

44. Proportion
(RPMW:
Cement)
Sample
No:
Breaking
Load
(KN)
Area of
Surface
(mm2)
Compressi
ve
Strength
(N/mm2)
Average
compressive
strength
(N/mm2)
80:20 1 75 24150 3.10
2.96
2 70 24150 2.89
3 70 24150 2.89
85:15 1 50 24150 2.07
1.77
2 40 24150 1.65
3 40 24150 1.65
90:10 1 20 24150 0.83
0.83
2 20 24150 0.83
3 20 24150 0.83
95:5 1 20 24150 0.83
0.83
2 20 24150 0.83
3 20 24150 0.83
44

45. 45
Compressive strength of RPMW-cement bricks
0
0.5
1
1.5
2
2.5
3
3.5
75 80 85 90 95 100
Compressivestrength(N/mm2)
Percentage of RPMW

46. WATER ABSORPTION
 Water absorption is a major
factor which determines the
strength and durability of bricks.
 The void fraction imparts water
absorption property to bricks.
 Because of the fibrous nature the
RPMW has high water retention
capacity
46
Water absorption Test

47. Proporti
on
(RPMW :
Cement)
Sample
No:
Dry
weight
(M1)
(kg)
Wet
weight
(M2)
(kg)
Average
water
absorpti
on
(%)
80:20
1 1.688 2.496 47.93
47.382 1.708 2.505 46.73
3 1.703 2.510 47.48
85:15
1 1.493 2.223 48.96
48.182 1.511 2.231 47.78
3 1.506 2.225 47.8
90:10
1 1.512 2.258 49.43
49.092 1.607 2.389 48.78
3 1.546 2.300 48.88
95:5
1 1.470 2.220 51.08
52.322 1.488 2.272 52.76
47

48. The water absorption of RPMW-cement brick is increasing with
increase in percentage of RPMW.
Proportion 80:20 is found to have lesser water absorption.
On increasing the RPMW content by 5%, water absorption was
found to be increased on an average of 2%.
High water absorption can be reduced by applying water proof
coating over the brick surface without compromising other
physical and mechanical properties of brick material.
48

49. EFFLORESCENCE
.
• After placing the end of the bricks in the dish, at the depth of
25mm immersion in water until all the water in the dish is
absorbed by the specimen and the surface water evaporate.
• But no efflorescence is present on any proportion of the brick.
49

50. HARDNESS TEST
.
• Slight impressions are left on the bricks after scratching by
fingernails.
50

51. SOUNDNESS TEST
 The RPMW – cement bricks tested was sound and has passed
soundness test successfully.
51

52. TESTS ON RPMW-LATERITE BRICKS
52
COMPRESSION TEST

53. Proportion
(RPMW :
laterite)
Sample
No:
Breakin
g
Load
(KN)
Area
of
Surfac
e
(mm2)
Compressive
Strength
(N/mm2)
Average
compressive
strength
(N/mm2)
80:20 1 40 24150 1.656
2 45 24150 1.863 1.725
3 40 24150 1.656
85:15 1 20 24150 0.828
2 30 24150 1.242 0.966
3 20 24150 0.828
90:10 1 20 24150 0.828
0.897
2 20 24150 0.828
3 25 24150 1.035
95:5 1 20 24150 0.828
0.828
2 20 24150 0.828
3 20 24150 0.828
53

54. Compressive strength variation with percentage of RPMW
54
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0 1 2 3 4 5
Averagecompressivestrength(N/mm2)
Proportion RPMW %

55. It is observed that the compressive strength of RPMW-laterite
bricks is less than the RPMW-cement bricks.
It is also observed that the increase in compressive strength is
proportional to amount of the laterite.
55

56. WATER ABSORPTION
Water absorption is a major factor which determines the strength
and durability of bricks.
After conducting the test in accordance with IS specification the
results are studied
56
M1= Dry weight ; M2 = Wet weight

57. 57Sample
No:
Dry
weight
(M1)
(kg)
Wet
weight
(M2)
(kg)
Average
water
absorpti
on
(%)
80:20
1 1.688 2.666 57.93
57.382 1.708 2.677 56.73
3 1.703 2.682 57.48
85:15
1 1.493 2.538 69.99
67.182 1.511 2.495 65.22
3 1.506 2.505 66.33
90:10
1 1.512 2.575 70.30
68.032 1.607 2.676 66.52
3 1.546 2.586 67.27
95:5
1 1.470 2.531 72.17
70.322 1.488 2.525 69.69
3 1.571 2.657 69.12

58.  It is observed that the water absorption of laterite– RPMW
brick is increasing with increase in percentage of RPMW.
 From the results obtained the water absorption corresponding
to proportion 80:20 is found to have lesser water absorption.
58

59. EFFLORESCENCE
 No efflorescence is present on any proportion of the brick.
59
 Slight impressions are left on the bricks after scratching by
fingernails.
HARDNESS TEST
SOUNDNESS TEST
 The RPMW-laterite bricks tested were sound and has passed
soundness test successfully.

60.  Different type of bricks like conventional clay brick, cement-
RPMW brick, cement-laterite bricks were compared in their
compressive strength.
 Compressive strength of conventional clay brick is
comparatively high with other types of bricks.
 The low compressive strength of RPMW brick is due to low
silica content, thus results in low binding capacity.
60
COMPARISON BETWEEN
DIFFERENT TYPES OF BRICKS

61. 61
Comparison of RPMW-cement and RPMW -laterite
0
0.5
1
1.5
2
2.5
3
3.5
75 80 85 90 95 100
Compressivestrength(N/mm2)
Percentage of RPMW %
RPMW-cement
RPMW-laterite

62. 62
Comparison of RPMW bricks with conventional bricks
0
1
2
3
4
5
6
7
0 1 2 3 4
compressivestrength(N/mm²)
clay brick
RPMW-cement brick
RPMW-laterite brick

63. STUDY OF VARIATION OF
PARTICLE SIZE OF RPMW
The compressive strength obtained for the RPMW bricks were found to be
less than the standards.
Thus study was further extended by changing the particle size of the RPMW.
The particle sizes of RPMW was decreased as 4.56,2.36,1.18,0.150 mm .
As the particle size is reduced, the strength of the bricks get increased.
The maximum compressive strength was observed for 80:20 ratio brick for
both the cement and laterite brick. Thus, particle variation was done for this
proportion.
The 14th day compressive strength was tested and tabulated
63

64. Sieve
size
(mm)
Breaki
ng
Load
(KN)
Area of
Surface
(mm2)
Compre
ssive
Strengt
h
(N/mm2
)
Proportion
(RPMW:cement
)
80:20
4.56 25 24150 1.035
2.36 30 24150 1.242
1.18 40 24150 1.656
0.150 45 24150 1.863
Proportion
(RPMW:lateri
te)
4.56 20 24150 0.828
2.36 30 24150 1.242
1.18 30 24150 1.242
0.150 40 24150 1.656
64

65. 65
Strength characteristics on changing particle size
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0 1 2 3 4 5
Compressivestrength(N/mm²)
Particle size(mm)
RPMW-cement
RPMW-laterite

66. COST ESTIMATION OF RPMW
BRICK
The cost of the RPMW bricks is comparatively less than the
conventional bricks
As the raw material is obtained free of cost from the Punalur Paper
Mills, the cost of only transportation is considered.
The manufacturing can be under taken by unskilled labours.
The cost of fabrication of the mould is a onetime cost.
The cost of manufacture includes transportation charge of RPMW,
labour cost and cost for cement.
66

67. Cost of conventional bricks = 9 Rs
Proportion of brick (RPMW-cement) = 80:20
Total weight of one brick = 1.700 kg
Weight of materials used for one brick is;
RPMW = 1.360 kg
Cement = 0.340 kg
Cost calculation of each materials
RPMW = 0.60 Rs /kg = 1.36 x 0.6 = 0.816 Rs/brick
Cement (bag) = 400 Rs/bag = 8 Rs/kg = .340 x 8 = 2.72 Rs/brick
Labour cost = 600/1000 bricks = 0.6 Rs /brick
Other expenses = 0.5 Rs /brick
Total cost = Cost of (RPMW + cement + labour cost + other cost)
= 0.816 + 2.72 + 0.6 + 0.5 = 4.636 Rs
67

68. CONCLUSIONS
The bricks made from RPMW is found to have compressive strength
less than conventional brick.
It is observed that when the amount of cement is increased the
strength also increases.
In our project, the maximum compressive strength was obtained for
RPMW cement brick with 80:20 proportions.
The strength effect on the particle size was also investigated to
improve the strength of brick. It showed a positive result, as the size
of the RPWM particles is reduced, strength is increased.
68

69. RPMW from Punalur paper mill are found to have silica content
only about 20%. As the silica content in the raw materials is less it
affects the binding property of the particle .
The average weight of the RPMW –cement brick was found to be
1.6 kg which is much less than that of conventional brick .This
bricks are produced without firing which is an advantage over other
manufacturing of bricks in term of low embodied energy material.
The water absorption of RPMW-cement and RPMW-laterite bricks
are increasing with increase in percentage of RPMW.
RPMW-cement and RPMW-laterite bricks passed the
efflorescence, hardness and soundness tests successfully.
69

70. RECOMENTATIONS FOR FURTHER
STUDY
1. In our project while increasing the percentage of cement we get a
positive result. Therefore, we accept an increase in compressive strength
by increasing the amount of cement.
2. Also when decreasing the particle size, the compressive strength is
increasing. This is due to the increase in binding property between the
materials.
3. Required strength can be achieved by adding proper admixtures.
4. The silica content of the RPMW collected is comparatively less. So
adding materials with high silica content may also increase the strength
of the brick.
70

71. REFERENCE
1. S.P. Raut , Rohant Sedmake , Sunil Dhunde , R.V. Ralegaonkar , Reuse of recycle
paper mill waste in energy absorbing light weight bricks, Construction and Building
Materials(2011)
2. D. Rajput, S.S. Bhagade, S.P. Raut , R.V. Ralegaonkar , Sachin A. Mandavgane, Reuse
of cotton and recycle paper mill waste as building material, Construction and Building
Materials 34 (2012) 470–475
3. S. Raut, R.Ralegaonkara,S.Mandavgane, Utilization of recycle paper mill residue and
rice husk ash in production of light weight bricks , Archives of civil and mechanical
engineering 1 3 ( 2 0 1 3 ) 2 6 9 – 2 7 5
4. S.P Rout,R.V Ralegaonkar ,S.A.Mandavgane,Development of sustainable construction
material using industrial and agricultural solid waste:A review of waste-crete bricks
71

72. 5. S.P. Raut a, R.V. Ralegaonkar , S.A. Mandavgane, Development of sustainable
construction material using industrial and agricultural solid waste: A review of waste-
create bricks , Construction and Building Materials 25 (2011) 4037–4042
6. Mucahit Sutcu 1, Sedat Akkurt ,The use of recycled paper processing residues in
making porous brick with reduced thermal conductivity, Ceramics International 35
(2009) 2625–2631
7. Alaa.A.Shakir, Sivakumar Naganathan, Kamal Nasharuddin Bin Mustapha,
Development Of Bricks From Waste Material: A Review Paper, Australian Journal of
Basic and Applied Sciences, 7(8): 812-818, 2013 ISSN 1991-8178
8. Ashwin Narendra Raut and Christy Pathrose Gomez, Utilization of Waste as a
Constituent Ingredient for Enhancing Thermal Performance of Bricks – A Review
Paper, Indian Journal of Science and Technology, Vol 9(37), DOI:
10.17485/ijst/2016/v9i37/87082, October 2016
72

73. 9. Ismail Demira,_, M. Serhat Baspınara, Mehmet Orhanb, Utilization of
kraft pulp production residues in clay brick production, Building and
Environment 40 (2005) 1533–1537
10. J E Oti,J M Kinuthia ,Stabilised unfired clay bricks for environmental and
sustainable use,Applied clay Science 58 (2012) 52-59
11. IS 3495 ( Parts 1 to 4 ) : 1992, METHODS OF TESTS OF BURNT
CLAYBUILDING BRICKS
12. IS 1077 : 1992( Reaffirmed 2002), COMMON BURNT CLAY
BUILDING
13. BRICKS – SPECIFICATION ( Fifth Revision )
73

74. THANK YOU
74