Development of eco friendly brick using water treatment plant sludge and processed tea waste

Purpose: This paper aims to study the effect of the addition of water treatment plant sludge (WTPS) and processed tea waste (PTW) on the properties of burnt clay bricks. The reuse of WTP sludge as a raw material for brick production is a long-term approach, to sludge disposal, for economic and environmental sustainability. Sludge have been added at 10, 20, 30 and 40% and processed tea waste at 5% (by weight) in replacement of clay for brick manufacturing. Each batch of hand-moulded bricks was fired in a heat controlled furnace at a temperature of 990°C. The compressive strength has been found to increase with the sludge content, however, a slight decrease in compressive strength was observed with tea waste addition. Further, PTW addition has improved the thermal insulation of bricks as compared to controlled bricks. The study shows that 40% WTPS, 5% PTW and 55% natural clayey soil can be considered as an optimum mix for bricks with good compressive strength as well as improved thermal insulation property. Design/methodology/approach: Four different mixing ratios of sludge at 10, 20, 30 and 40% of the total weight of sludge-clay mixtures were used to make bricks. Similarly, PTW was investigated as a substitute of natural clayey soil in brick manufacturing. Each batch of hand-moulded bricks was fired in a heat controlled furnace at a temperature of 990°C. The physical, mechanical and engineering properties of the produced WTPS bricks and PTW bricks were determined and evaluated according to various Indian Standard Codes of Specification for burnt clay bricks and certain reference books. Findings: The results exhibited that WTP sludge and PTW can be used to produce good quality brick for various engineering applications in construction and building. Increasing the sludge content increases the compressive strength. Moreover, thermal insulation of PTW bricks depicted an upward trend when compared to controlled bricks. Hence, an optimum mixture of 40% WTPS, 5% PTW and 55% natural clayey soil was found, at which bricks showed good compressive strength as well as improved thermal insulation property of the building material. Research limitations/implications: The present work provides a sustainable solution for disposal of WTP sludge and tea waste. Utilization of these waste materials in brick manufacturing is viable and economic solution. Practical implications: Bricks with 40% WTP sludge and 5% processed tea waste proved to be economic, technically sound for construction purposes with added thermal insulation properties. Social implications: Bulk amount of waste such as WTP sludge is a threat to society owing to its environmental implications of disposal. Authors propose to use WTP sludge and tea waste for brick manufacturing and provide a solution to its disposal. Originality/value: Water treatment plant sludge along with tea waste have not been tried for brick manufacturing so far. Hence, the composition is new in itself and also have resulted into good performance.