COMPOSITION OF CONSTRUCTION WASTE BRICKS

Technical Field
The invention generally relates to the composition and process
5 of making construction waste bricks, cement, river sand and
construction wastes such as steel bars, crushed tiles, bent nails, and
tie wires as alternative building materials.

Background of the Invention

10 Natural disasters, demolition projects, and construction projects
generate massive waste. Despite increased efforts to recycle and
reuse construction and demolition waste, approximately 35% of the
amount produced globally is estimated to be sent to landfills without
further treatment (Menegaki & Damigos, 2018). Materials from
15 demolition, roadwork, and excavation are included in the “construction
wastes” category, as well as more complicated wastes, including
cardboard, plastic, metal, and ceramic. Moreover, the cost of housing
structural components is a contributing factor that leads to
homelessness and a lack of suitable housing. According to national
20 reports, a minimum of 150 million individuals, or around 2% of the
world’s population, are thought to be homeless. However, about 1.6
billion, more than 20% of the world’s population, lack adequate housing
(Chamie, 2017). The built environment consumes more natural
resources than necessary, generating a large amount of waste
25 (Osmani, 2011). Various studies proved that construction wastes are
effective replacement for aggregates. According to Rao et al. (2007),
using recycled aggregates in concrete provides a promising solution to
the problem of construction and demolition waste management
problem. Batayneh et al. (2007) studied the selected waste materials in
30 concrete mixes and proved that demolished concrete, glass, and

1
 plastic could be reused successfully as partial substitutes for sand or
coarse aggregates in concrete mixtures. The addition of agricultural
waste or construction waste in concrete indicates positive and
satisfactory strength when compared to normal concrete (Tambichik et
5 al., 2018). In the study of Silva et al. (2021) stated that the mechanical
strengths of recycled aggregate concrete produced with recycled fine
aggregate were equal or higher than those from the reference
concrete.
The invention with patent number CN117069443A discloses a
10 high-strength baking-free brick prepared from the construction waste
and a preparation method thereof, wherein the high-strength baking-
free brick comprises the following raw materials in parts by weight: 60-
70 parts of building rubbish aggregate, 20-30 parts of cement, 6-10
parts of polyurea resin, 1-5 parts of water reducer and 5-10 parts of
15 water; the polyurea resin comprises a component A and a component
B in a mass ratio of 1-3:1, wherein the component A is a secondary
amine component, and the component B is an isocyanate curing agent.
The baking-free brick prepared by taking the construction waste as the
aggregate, taking the cement as the cementing material and adding the
20 polyurea resin as the reinforcing agent has excellent mechanical
properties, water resistance and other properties, and can realize the
reduction and recycling of the construction waste.
The high-strength baking-free brick prepared from construction
waste as described has several advantages, such as recycling waste
25 materials, and having excellent mechanical properties and water
resistance due to the inclusion of polyurea resin. However, it may also
have some potential drawbacks: Polyurea resins can be expensive,
which might increase the overall cost of the bricks compared to
traditional bricks or other types of eco-friendly bricks. The specific
30 types of construction waste suitable for use as aggregate may not

2
 always be readily available in all areas, potentially limiting the
scalability of this solution. The preparation method might require
precise measurement and mixing of the polyurea resin components,
which adds complexity to the production process. While the addition of
5 polyurea resin is intended to improve mechanical properties, if not
properly prepared or cured, the bricks may not be as durable as
expected. The production and use of polyurea resins may have
environmental impacts that need to be assessed, especially if the
resins are not biodegradable.
10 Thus, this invention focuses on the possibility of utilizing cement,
sand, and construction wastes such as steel bars, crushed tiles, bent
nails, and tie wires that has a great possibility in employing alternative
building and construction material for a load-bearing wall as well as an
effective solution in fighting the problem on construction wastes.
15

Detailed Description
The construction waste bricks consisting of cement, river sand,
and construction wastes such as steel bars, crushed tiles, bent nails,
20 and tie wires as an alternative building and construction material for a
load-bearing wall. Likewise, emphasizes simplicity, reinforcement, and
localized waste utilization, which can be advantageous in terms of cost,
scalability, and environmental impact.
In this invention, cement is 33.33% by weight; sand ranges from
25 46.67% to 56.67% by weight; steel bars range from 5% to 10% by
weight; crushed tiles range from 2.5% to 5% by weight; bent nails
range from 1.25% to 2.5% by weight; and tie wires range from 1.25%
to 2.5% by weight.

30

3
 Table 1: Materials’ Mixing Proportion by Weight and Percentage
A B C
Brick Code
Kg % Kg % Kg %
Cement 1.00 33.33 1.00 33.33 1.00 33.33
River sand 1.70 56.67 1.55 51.67 1.40 46.67
Wastes 0.30 10.00 0.45 15.00 0.60 20.00
Total 3.00 100.00 3.00 100.00 3.00 100.00
Breakdown at 10% wastes at 15% wastes at 20% wastes
of Wastes Mass, g Mass, % Mass, g Mass, % Mass, g Mass, %
Steel bars 150.00 50.00 225.00 50.00 300.00 50.00
Crushed tiles 75.00 25.00 112.50 25.00 150.00 25.00
Bent nails 37.50 12.50 56.25 12.50 75.00 12.50
Tie Wire 37.50 12.50 56.25 12.50 75.00 12.50

5 Cement is preferably Portland cement. River sand preferably

consists of local rocks or minerals ranging in particle size from 0.05
mm to 2 mm in diameter and sieved using a mesh size of 4.75 mm to
0.075 mm.
Steel bars preferably 10 mm to 16 mm in diameter cut to 1 to 2
10 inches. Tiles, preferably ceramic, porcelain, or cement, are crushed
into fragments. Tie wires were cut to lengths ranging from 1 to 3
inches. The bent nails used range from 1 to 3 inches. The digital
weighing scale was used to weigh the materials.
The table displays the results of the compressive strength test.
15 The minimum criteria for net area compressive strength set by the
ASTM C90 - Standard Specification for Load-Bearing Masonry Units is
1,900 psi (13.10 MPa). Based on the findings, an average of three
bricks from each brick sample exceeded the 1,900 psi standard for
load-bearing masonry units. Brick C, which has an average strength of
20 3,014.51 psi, has the maximum compressive strength after 28 days of

4
 curing. However, the results show that the compressive strength of
brick dramatically increases with an increase in building waste. On the
other hand, Mixtures A and B, 2,105.05 and 2,445.93 psi, respectively,
meet the ASTM C90 criterion.
5
Table 2: Result of Compressive Strength Test
Average
No. of
Brick Code Compressive Remark
Samples
Strength in psi
A 3 2,105.05 Passed

B 3 2,445.93 Passed
C 3 3,014.51 Passed

Water absorption test revealed excellent performance on the

various concrete brick specimens. The results showed that as the
10 percentage of construction wastes increased, water absorption
decreased with decreasing sand percentage. It implies that the lower
the water absorption rate, the higher the quality of the concrete brick.
Hence, Brick A, with 10% construction waste and 56.67% sand, has a
water absorption percentage of 5.15%. Brick B, which contained 15%
15 construction waste with 51.67% sand, had a water absorption of
4.98%. The result indicated that the absorption rate increased by
0.17%. Brick C contained 20% construction waste and 46.67% sand,
with the lowest water absorption percentage of 3.10%. The result
showed an increase in the absorption rate by 1.88%. All brick
20 specimens met or exceeded the requirement set by the IS 3495 (Part
2) 1992. The acceptance criteria for the water absorption test on bricks
must not exceed 20%. As a result, construction waste improves the
performance of concrete bricks.

25

5
 Table 3: Result of Water Absorption Test
Brick Dry Mass, Wet Mass, Percentage,
Remark
Code M1 M2 %
A 1,515.50 1,591.50 5.15 Passed

B 1,546.50 1,623.50 4.98 Passed

C 1,567.00 1,615.50 3.10 Passed
5
A composition of construction waste bricks consists of:
Components Percentage (%) by Weight
Cement 33.33
River sand 46.67 - 56.67
10 Steel bars 5.00 – 10.00
Crushed tiles 2.50 – 5.00
Bent nails 1.25 – 2.50
Tie wires 1.25 – 2.50
Water 50.00 – 60.00
15
The composition is needed for the following steps of producing
construction waste bricks:
a. collecting river sand, steel bars, crushed tiles, bent nails, and
tie wires;
20 b. sorting construction waste items such as steel bars, crushed
tiles, bent nails, tie wires into separate containers for
recycling;
c. sieving the river sand through a 4.75 mm to 0.075 mm sieve;
d. washing the river sand to remove impurities;
25 e. sun-drying the river sand for optimal moisture content;
f. cutting steel bars to required lengths.

6
 g. crushing tiles to the desired size;
h. cutting tie wires to specified lengths;
i. determining the cement ratio by weight: 33.33% cement,
46.67 - 56.67% river sand, 5 - 10% steel bars, 2.5 - 5%
5 crushed tiles, 1.25 - 2.5% bent nails, 1.25 - 2.5% tie wires,
and 50 - 60% water;
j. preparing steel molds measuring 15 cm x 10 cm x 5 cm.
k. Mixing cement, sun-dried river sand, steel bars, crushed
tiles, bent nails, and tie wire to form a dry blend;
10 l. adding water to the dry mix. m. Mixing the components
thoroughly to create a cohesive mixture;
m. pouring the mixture into steel molds to shape construction
waste bricks;
n. removing the bricks from the molds; and
15 o. curing the construction waste brick.

The invention, using leftover steel bars, crushed tiles, bent nails,
and tie wires for concrete bricks, offers several advantages like
resource efficiency, enhanced strength, cost savings, waste reduction,
20 localized production, and simplified process. By repurposing leftover
building materials such as steel bars, shattered tiles, bent nails, and
wires, waste that would otherwise end up in landfill can be reduced and
recycled. Steel bars and wires can reinforce the concrete bricks,
potentially providing greater tensile strength and resistance to cracking
25 compared to non-reinforced bricks. Utilizing leftover materials could
reduce the cost of raw materials for your bricks, making construction
waste brick more economically competitive. Likewise, this approach
contributes to the reduction of construction waste and encourages a
circular economy within the construction industry. Also, the method
30 uses readily available waste materials which can be adapted and

7
implemented locally without the need for specialized resins or
chemicals. Finally, the production process might be less complex,
making it easier to adopt in less industrialized settings.

8
 We claim:

1. A composition for construction waste bricks, comprising:

5 a. a granular component consisting of river sand, wherein said

river sand is collected, sieved using a 4.75 mm to 0.075 mm
sieve to remove larger particles and impurities, washed to
remove contaminants, and sun-dried to reduce moisture
content;
10 b. a metallic reinforcement component consisting of steel bars,
bent nails, and tie wires, wherein said steel bars are cut to a
specified size, said bent nails are straightened and cut if
necessary, and said tie wires are cut to a specified length;
c. an aggregate component consisting of crushed tiles, wherein
15 said tiles are collected and mechanically crushed to a
specified particle size for use in the brick composition;
d. a hydraulic binder component consisting of cement, wherein
said cement is used as the primary binding material to hold
the composition together upon hydration;
20 e. a moisture component consisting of water, wherein the
amount of water ranges from 50% to 60% by weight of the
entire composition to enable the cement to hydrate and to
form a cohesive mixture with the other components;
f. wherein the composition by weight is fixed at approximately
25 33.33% cement, 46.67% to 56.67% river sand, 5% to 10%
steel bars, 2.5% to 5% crushed tiles, 1.25% to 2.5% bent
nails, and 1.25% to 2.5% tie wires, providing a balanced mix
for the construction waste bricks.

30

9
 2. The composition of claim 1, wherein the metallic reinforcement
component provides increased tensile strength to the
construction waste bricks, thereby enhancing their structural
integrity and resistance to cracking.
5 3. The composition of claim 1, wherein the crushed tiles serve as a
partial replacement for natural aggregates, contributing to the
sustainability of the composition by reducing the demand for
virgin aggregates and recycling waste materials.
4. The composition of claim 1, wherein the proportion of the
10 components is selected to achieve desired physical and
mechanical properties in the resulting construction waste bricks,
including compressive strength, and water absorption.
5. The composition of claim 1, wherein the river sand component is
specifically prepared to ensure that it is free of organic
15 contaminants, clays, and silts that can adversely affect the
quality and performance of the construction waste bricks.
6. The composition of claim 1, wherein the water content is
carefully controlled to ensure optimal hydration of the cement
and to prevent the bricks from becoming too wet or too dry,
20 which can affect the curing process and the final strength of the
bricks.
7. The composition of claim 1, wherein the steel mold used for
shaping the bricks is designed to accommodate the cohesive
mixture and is constructed in a manner that allows for easy
25 release of the bricks after initial setting.
8. The composition of claim 1, wherein the process of curing the
construction waste bricks involves maintaining them in a
controlled environment to ensure that the hydration process is
gradual and consistent, leading to a stronger and more durable
30 final product.

10
 9. The composition of claim 1, wherein the construction waste
bricks are designed to meet or exceed the performance
standards set by relevant building codes, ensuring that the
bricks are not only sustainable but also safe and reliable
5 meeting the compressive strength (>1,900 psi), and water
absorption (≤ 20%).
10. The composition of claim 1, wherein the entire method for
producing the construction waste bricks, from the collection of
materials to the curing of the final product, is designed to be
10 implemented with minimal specialized equipment or advanced
technology, making it accessible for widespread adoption in
various regions and economic contexts.
11. The composition of claim 1, wherein the construction waste
bricks are subject to quality control measures throughout the
15 manufacturing process, ensuring a consistent and reliable
product that contributes to the circular economy and promotes
sustainable construction practices.
12. A method for creating construction waste bricks, comprising the
steps of:
20 a. collecting raw materials, including river sand, steel bars,
crushed tiles, bent nails, and tie wires;
b. segregating construction waste materials such as steel bars,
crushed tiles, bent nails, and tie wires into different containers
to facilitate processing;
25 c. sieving the collected river sand using a sieve with mesh sizes
ranging from 4.75 mm to 0.075 mm to obtain uniformly sized
sand particles;
d. washing the sieved river sand to remove impurities and
enhance the quality of the sand for use in brick making;

11
 e. sun-drying the washed river sand until the moisture content is
substantially reduced, suitable for brick formation;
f. cutting steel bars to desired lengths for incorporation into the
brick mixture as reinforcing materials;
5 g. crushing tiles to a specified size to be used as a partial
aggregate replacement in the brick mixture;
h. cutting tie wires to appropriate lengths for use as
reinforcement or binding material in the bricks;
i. determining and fixing the proportion by weight of the
10 components for the brick mixture, comprising cement
(33.33%), river sand (46.67 - 56.67%), steel bars (5 – 10%),
crushed tiles (2.5 – 5%), bent nails (1.25 – 2.5%), tie wires
(1.25 – 2.5%), and water (50 – 60%);
j. fabricating a 15 cm x 10 cm x 5 cm steel mold designed to
15 shape and form the construction waste bricks;
k. mixing the cement, sun-dried river sand, steel bars, crushed
tiles, bent nails, and tie wires to form a well-blended dry
mixture;
l. adding a predetermined amount of water to the dry materials
20 to initiate the chemical reaction of cement and to form a
cohesive mixture;
m. thoroughly mixing the components to ensure a uniform
distribution of materials and to achieve cohesion in the
mixture;
25 n. pouring the cohesive mixture into the prepared steel mold,
ensuring the mixture is appropriately settled and compacted
to form construction waste bricks;
o. removing the formed construction waste brick from the steel
mold after an initial set has been achieved;

12
 p. curing the construction waste brick for a defined period to gain
strength and durability, wherein the brick is maintained in a
controlled environment to ensure the cement hydrates
optimally and the brick achieves the desired physical
5 properties.
13. The method of claim 12, wherein the collected construction
waste, including steel bars, crushed tiles, bent nails, and tie
wires, is sourced from construction and demolition sites,
promoting recycling and sustainability.
10 14. The method of claim 12, wherein the proportions of the
components in the brick mixture can be adjusted to meet
specific strength and durability requirements for various
construction applications.
15. The method of claim 12, wherein the curing process involves
15 maintaining the construction waste bricks in a moist environment
for 28 days
16. The method of claim 12, wherein the crushed tiles used in the
brick mixture are derived from ceramic or porcelain tiles,
providing an effective use of non-biodegradable waste that
20 would otherwise contribute to environmental pollution.
17. The method of claim 12, wherein the sieving and washing of
river sand not only improve the quality of the sand but also
reduce the risk of deleterious materials affecting the final
strength and durability of the construction waste bricks.
25 18. The method of claim 12, wherein the construction waste bricks
produced by this method can be used for various construction
purposes, including but not limited to, non-load bearing walls,
garden walkways, and landscape features, thereby contributing
to the circular economy in the construction industry.

13
 19. The method of claim 12, wherein the inclusion of varying
percentages of steel bars, crushed tiles, bent nails, and tie wires
in the brick mixture not only recycles waste materials but also
contributes to the overall compressive strength, tensile strength,
5 and water absorption properties of the construction waste bricks.
20. The method of claim 12, wherein the construction waste bricks
are subjected to testing for their physical and mechanical
properties, including compressive strength, and water
absorption to ensure compliance with relevant building codes
10 and standards.

Abstract
15 This invention outlines an improved method for sustainable
construction material production by integrating the collection,
segregation, and processing of various materials like river sand, steel
bars, crushed tiles, bent nails, and tie wires. The process involves
sieving and washing river sand, sun-drying it, along with cutting steel
20 bars, crushing tiles, and cutting tie wires to specified dimensions.
Proportions by weight for cement, river sand, steel bars, crushed tiles,
bent nails, tie wires, and water are determined to create a cohesive
mixture. The mixture is then poured into steel molds to form
construction waste bricks. This innovative approach aims to streamline
25 material utilization, reduce waste, and promote environmentally friendly
practices in the construction industry.

14