Investigation of use of coal fly ash in eco-friendly construction materials: fired clay bricks and silica-calcareous non fired bricks

The use of coal fly ash (CFA) as raw material for the manufacture of two construction materials, fired clay bricks and silica-calcareous non-fired bricks, was investigated. Fired clay bricks were manufactured using a commercial clay and different waste ratios (0-50 wt%), moulded at 10 MPa and fired at 1000 degrees C (4 h). Silica-calcareous non fired bricks were prepared using two wastes as raw material: CFA and "geosilex"(G), a hidrated lime residue which comes entirely from acetylene industry waste. Different proportions CFA (80-30 wt%) G (20-70 wt%) were investigated. Raw materials were moulded at 10 MPa and cured in water at room temperature during 28 days. The results indicated that the incorporation of up to 20 wt% of CFA produced fired clay bricks with physical and mechanical properties similar to control bricks without waste. However, additions of a higher amount (30-50 wt%) of residue resulted in a more pronounced decrease in mechanical properties (between 25-50%) due to an increase in open porosity. The technological characterization of the silica-calcareous non fired bricks showed a reduction in the values of bulk density and water absorption when the coal fly ash content decreases. Silica-calcareous non-fired bricks containing between 40 and 60 wt% of CFA had the highest values of compressive strength in the range 46-43 MPa. These silica-calcareous non-fired bricks, 60CFA-40 G, 50CFA-50 G and 40CFA-60 G, presented the optimum amount of pozzolanic materials (SiO2 and Al2O3) in the coal fly ash and calcium hydroxide in the geosilex to give rise to the formation of calcium silicate hydrates and calcium aluminate hydrates, the phases responsible for the mechanical resistance increase of the construction materials. Therefore, CFA-clay fired bricks and silica-calcareous CFA-Geosilex non-fired bricks presented optimal technological properties that attain the quality standards.