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Process parameter design approach for pressed fly ash geopolymer brick using Box–Behnken design: influence of forming pressure, sand-to-precursor ratio and liquid-to-solid content

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Abstract

Worldwide, billions of masonry-burnt clay bricks are made each year. However, their manufacturing is not eco-friendly. The present study aims to create geopolymer brick made from fly ash, a sustainable substitute for brunt clay brick. The influence of forming pressure (FP), sand-to-precursor ratio (S/P) and liquid-to-solid ratio (L/S) were studied. Molarity (10 M), alkaline solution ratio (2.5) and curing temperature (60 °C) were kept constant in the study. Physio-mechanical properties of the developed were studied and presented in this paper. Response surface methodology (RSM)–Box–Behnken Design (BBD) was used to optimize the parameter. Multiple objective response optimizer and composite desirability were performed to get an optimum mix. Statistical analysis was carried out to identify the significance levels of variables. Surface, interaction and contour plots are presented in this paper. In addition, microstructural analysis like scanning electron microscopy (SEM)–energy-dispersive X-ray spectra (EDS), X-ray diffraction (XRD) spectra and thermal gravimetric analysis (TGA) was carried out to study morphology, mineralogy and thermal resistance of the brick specimen. The L/S ratio is a predominant factor influencing the brick properties. According to RSM-BBD, the optimum ratio to develop fly ash-based geopolymer brick was FP (2700 psi), S/P (1.16) ratio and L/S ratio (0.364).

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Acknowledgements

The authors would like to thank Material Research Centre, MNIT Jaipur and National Centre for Earth Science Studies Thiruvananthapuram for providing necessary support in conducting microstructural properties (SEM-EDX, TGA, XRD, PSA and WD-XRF) of specimens and sample.

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  1. Department of Civil Engineering, Malaviya National Institute of Technology, Jaipur, India

    Mohammed Rihan Maaze & Sandeep Shrivastava

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MRM done experimental investigation, conceptualization, methodology, writing—original draft. SS performed conceptualization, supervision, writing—review & editing.

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Maaze, M.R., Shrivastava, S. Process parameter design approach for pressed fly ash geopolymer brick using Box–Behnken design: influence of forming pressure, sand-to-precursor ratio and liquid-to-solid content. Innov. Infrastruct. Solut. 8, 116 (2023). https://doi.org/10.1007/s41062-023-01085-x

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