Sustainable Brick Using by Recycled Plastic Waste, Foundry Sand, and Crusher Waste Dust

Abstract

The increasing generation of plastic waste and industrial by-products such as foundry sand and crusher waste has created serious environmental concerns. Simultaneously, conventional brick manufacturing consumes natural resources and requires high energy for kiln firing. This study focuses on the development of sustainable bricks using recycled plastic waste as a binding material along with foundry sand and crusher waste as filler materials. The bricks were manufactured using a non-burning process with a material proportion of 30% recycled plastic, 35% foundry sand, and 35% crusher waste. Laboratory tests including compressive strength and water absorption were conducted to evaluate the performance of the developed bricks. The results indicated an average compressive strength of approximately 14 MPa and low water absorption values below 1.2%, demonstrating good durability.

Introduction

The construction industry consumes large amounts of natural resources and contributes to environmental degradation, particularly through conventional clay brick production, which uses fertile soil and high-energy kiln firing. Meanwhile, plastic waste and industrial by-products like foundry sand and crusher waste are increasing environmental hazards due to improper disposal.

To address these issues, sustainable construction practices focus on recycling waste materials to create eco-friendly building materials. Plastic waste serves as a thermoplastic binder, foundry sand improves workability and surface finish, and crusher waste enhances strength due to its angular particle shape.

Key Materials

1. Recycled Plastic Waste (PE, PP)

   • Acts as a binder when melted.

   • Water-resistant and lightweight.

   • Reduces environmental pollution by repurposing non-biodegradable waste.

2. Foundry Sand

   • Fine, uniform particles with high silica content.

   • Improves brick workability, bonding, and thermal stability.

3. Crusher Waste (Stone Dust)

   • Angular particles enhance interlocking and compressive strength.

   • Adds density and stability to bricks.

Literature Insights

• Plastic-based bricks show low water absorption, durability, and chemical resistance.

• Industrial by-products partially replace natural aggregates without compromising strength.

• Combined use of plastic, foundry sand, and crusher waste achieves adequate compressive strength suitable for non-load bearing applications.

• Eliminates kiln firing and water curing, reducing energy consumption and carbon emissions.

Objectives of the Study

1. Develop sustainable bricks using recycled plastic as a binder.

2. Utilize foundry sand and crusher waste effectively.

3. Reduce environmental pollution and conserve resources.

4. Determine compressive strength and water absorption.

5. Evaluate suitability for construction use.

Material Selection Rationale

• Chosen based on availability, engineering properties, environmental benefit, and cost-effectiveness.

• Plastic: binds particles, lightweight, water-resistant.

• Foundry sand: fine texture, high silica, thermal stability.

• Crusher waste: angular shape, mineral content, strength enhancement.

Material Proportioning

• Different trial mixes were developed based on literature, experimental results, workability, and strength performance to determine the optimal composition of sustainable bricks.

Conclusion

Based on the reviewed literature and comparative analysis, it can be concluded that bricks manufactured using waste plastic and sand provide a viable and sustainable alternative to conventional clay bricks. The findings indicate that plastic-sand bricks can achieve comparable or even higher compressive strength when produced with appropriate mix proportions. Additionally, these bricks exhibit very low or zero water absorption, which enhances their durability and resistance to moisture. The utilization of waste plastic in brick manufacturing significantly contributes to reducing environmental pollution caused by non-biodegradable plastic disposal. It also helps conserve natural clay resources and minimizes the depletion of riverbeds and soil used in traditional brick production. Furthermore, plastic-sand bricks are lightweight, cost-effective, and environmentally friendly, making them suitable for modern sustainable construction practices. Therefore, the adoption of plastic bricks can play an important role in promoting eco-friendly development and effective waste management in the construction industry.

References

[1] Siddique, R., & Kaur, G. (2019). Utilization of waste materials in concrete and construction. Journal of Cleaner Production, 231, 1222–1239. [2] Sharma, R. K., & Chandel, S. S. (2017). Plastic waste incorporation in construction materials: A review. Sustainable Materials and Technologies, 14, 15–23. [3] Abdulkareem, M. Y., et al. (2015). Recycling of waste foundry sand in concrete production: A review. Construction and Building Materials, 78, 122–131. [4] Gupta, T., & Kumar, P. (2018). Use of crusher waste for sustainable brick manufacturing. International Journal of Civil Engineering Research, 9(3), 321–328. [5] Chowdhury, S., & Paul, S. K. (2021). Environmental assessment of construction waste reuse. Journal of Environmental Management, 278, 111444. [6] Al-Jabri, K. S., et al. (2008). Effect of temperature on properties of recycled plastic concrete. Journal of Materials in Civil Engineering, 20(9), 569–577.

Copyright

Copyright © 2026 Prof. I. J. Korabu, Mr. Haval Om Manoj , Mr. Raje Ghadage Sairaj Yashwantrao, Mr. Kavade Suraj Nana, Mr. Mahasawade Dadasaheb Jalinder. 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.