Manufacturing of Clay Bricks Using Hybrid Waste Marble Powder and Sugarcane Bagasse Ash: A Sustainable Building Unit

In masonry construction, the most commonly used building unit all over the world is the burnt clay brick. Adding waste materials in certain percentages to these bricks helps in eliminating the environmental burden occurring in the form of excessive waste accumulation on open land sites, leading to sustainable and economical construction. This research program aimed to examine the feasibility of using waste marble powder (WMP) and sugarcane bagasse ash (SBA) in the manufacturing of clay bricks. WMP was collected from local marble cutting workshops, whereas SBA was prepared by burning the waste sugarcane obtained from various sugar mills in the local area. Brick specimens incorporating 5%, 10%, 15%, and 20% of hybrid WMP and SBA were prepared at a local brick kiln. Burnt clay bricks were transported to the laboratory, and their mechanical and durability properties were evaluated. A reduction in weight per unit area of brick specimens incorporating waste materials was observed, allowing them to be easily handled and transported. Decreased compressive strength was due to the addition of waste materials in comparison with conventional clay bricks. However, waste percentages up to 15% satisfied the criteria for the minimum compressive strength as per the Building Code of Pakistan (BCP). All tested samples showed flexural strength greater than 0.65 MPa. Tested bricks incorporating 10% and 20% of waste materials had water absorption values of 18% and 21%, respectively, which are higher than that of conventional clay bricks. Moreover, bricks incorporating waste materials exhibited a higher initial rate of absorption than conventional clay brick; therefore, such bricks need to be wet well before use in masonry construction. Brick specimens showed less than 1% weight loss, and bricks exhibited no signs of distress and cracking after 50 freeze-thaw cycles. A decrease in compressive strength was observed due to sulphate exposure. However, specimens with 10% waste materials still satisfied the minimum compressive strength requirement of BCP. Based on this study, it can be concluded that bricks with up to 10% hybrid waste materials (WMP and SBA) will assist in the environmental issues of these wastes, leading to more sustainable and economical masonry construction.