Fabrication and Mechanical Testing of Eco-friendly bricks using Fly Ash and Marble Dust as a Partial Cement Replacements

Abstract

This study focuses on the fabrication and testing of eco-friendly bricks using fly ash and marble dust as partial replacements for cement. These industrial waste materials were used in varying proportions (10%, 20%, and 30%) to evaluate their effects on the strength and durability of the bricks. A control mix with 100% cement was also prepared for comparison. All brick samples were cast, cured, and tested for compressive strength, water absorption, and density. The results showed that up to 20% replacement achieved comparable or better strength than conventional bricks while improving sustainability and reducing cost. This study highlights the potential of using fly ash and marble dust in construction as a step toward greener and more efficient building practices.

Introduction

The construction industry is a major source of environmental pollution, particularly due to cement usage, which contributes significantly to CO? emissions. To reduce environmental impact and material costs, the study explores using fly ash (a byproduct of coal combustion) and marble dust (a byproduct of marble processing) as partial replacements for cement in brick manufacturing.

2. Objective

The study aimed to develop eco-friendly bricks by replacing cement with fly ash and marble dust in 10%, 20%, and 30% proportions. These bricks were compared against a control brick with 100% cement for:

• Compressive strength

• Water absorption

• Density

3. Literature Review Highlights

• Fly Ash: Enhances strength and durability due to its pozzolanic properties.

• Marble Dust: Improves mix workability and density due to high calcium carbonate content.

• Studies have shown individual benefits of both materials, but few have examined their combined effect in cement-based bricks.

4. Materials and Methodology

• Materials: OPC (43-grade), Class F fly ash, marble dust, river sand, and clean water.

• Mix Design:

  • M0 (Control): 100% Cement

  • M10: 10% Fly Ash + 10% Marble Dust

  • M20: 20% Fly Ash + 20% Marble Dust

  • M30: 30% Fly Ash + 30% Marble Dust

• Procedure: Materials were mixed, molded (190×90×90 mm), and cured for 7 days. Bricks were tested per IS standards.

5. Results and Discussion

???? Compressive Strength

• Strength decreased as cement replacement increased.

• M10 and M20 retained acceptable strength for non-load-bearing applications.

• M30 showed reduced strength but maintained structural integrity.

???? Water Absorption

• Increased with higher cement replacement due to greater porosity.

• All samples remained within IS standards.

???? Density

• Decreased with increased fly ash and marble dust.

• Lower density bricks (especially M10, M20) may benefit thermal insulation and reduced dead load.

Conclusion

This study successfully demonstrated the feasibility of fabricating eco-friendly bricks using fly ash and marble dust as partial cement replacements. Mechanical testing revealed that bricks with up to 20% replacement exhibits compressive strength and durability characteristics comparable to those of conventional cement bricks. Although higher replacement levels led to slight reductions in strength and density, the overall performance remained within acceptable limits for general-purpose construction applications. From a mechanical engineering perspective, the experimental results confirmed that the inclusion of industrial waste materials can yield bricks with adequate load-bearing capacity, reduced density, and acceptable water absorption. These properties make these bricks suitable for lightweight and non-load-bearing structures. Furthermore, the reuse of waste materials promotes environmental sustainability, reduces construction costs, and aligns with the principles of green engineering The findings of this study support the broader adoption of industrial byproducts in building materials, particularly in the development of sustainable construction solutions. Future work can explore the long-term durability, thermal insulation, and lifecycle analysis of such bricks under different environmental conditions.

References

[1] R. Sharma and D. Dutta, “Performance of Bricks Using Fly Ash and Marble Dust as Partial Replacements for Cement,” Materials, vol. 15, no. 3, p. 1157, 2022 [2] M. Khan, A. Rehman, and F. Khan, “Utilization of Marble Dust and Fly Ash in the Manufacturing of Bricks: A Sustainable Approach,” ACS Omega, vol. 6, no. 12, pp. 8504–8511, 2021. [3] V. Kumar and S. Yadav, “Development of Geopolymer Bricks Using Fly Ash and Marble Dust,” Preprints, 2023. [4] A. Prasad, P. Mishra, and R. Singh, “Mechanical Properties of Bricks Using Fly Ash, Marble Dust and Lime Sludge,” South Asian Journal of Engineering and Technology, vol. 5, no. 3, pp. 12–18, 2019. [5] A. Joshi and N. Verma, “Statistical Analysis of Strength Variation in Fly Ash Bricks,” Journal of Materials in Civil Engineering, vol. 32, no. 9, p. 04020312, 2020.

Copyright

Copyright © 2025 Aswin Ram A P . This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.