Glass in Bricks and Tiles

WRAP has sponsored work by CERAM that has focused on the use of powdered glass (<75 micron particle size) as a fluxing agent in the manufacture of bricks. The results have been impressive and have met with a keen industry response.

Main benefits

33% reduction in Hydrogen Flouride emissions
Improved frost resistance of the 'fired' brick
Energy savings of up to 20%
Reduction in CO₂ emissions due to reduced energy consumption

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Case Study: York Handmade
Case study detailing the use of recycled glass as a fluxing agent in brick manufacture. (140 kb)
Research Report: Akristos full scale operational trials involving use of recycled glass in heavy clay industry - bricks and tiles.
The heavy clay industry has been aware of the potential of recycled glass as a fluxing agent to reduce firing temperatures or to improve fired brick or tile product quality, but the use has been limited to a small number of operators with specific raw material or product requirements. Its use within the mainstream heavy clay industry has not been taken up, mainly due to the detailed development work required for each clay kiln scenario, the availability of processed finely ground glass, the technology for controlled feed rates into the brick making process, the lack of information from full scale factory trials and the difficulties in assessing the true cost benefits. This project therefore, focuses on intermittent and continuous tunnel kiln firing technology and a range of clay types across the UK. (7118 kb)
Research Report: To demonstrate commercial viability of incorporating ground glass in bricks with reduced emissions and energy savings.
Powdered recycled glass has long been identified as a potential fluxing agent in the manufacture of clay bricks. A project was undertaken, involving trials at a small works and in the laboratory to measure the degree to which the addition of glass to the brick clay reduced the energy consumption and the hydrogen fluoride emissions of the firing process. Three types of clay from three manufacturers were studied: Etruria Marl (Blockleys); Carboniferous shale (Hanson); and Quaternary Glacial Lacustrine Clay (York Handmade) and the hydrogen fluoride emissions were monitored continuously. Full report (653 kb)
Research Report: Glass Addition Trials - York Handmade Bricks Co Ltd.
The purpose of this project is to undertake a trial and testing programme that will maximise the information gathered enabling commercial decisions to be made as to whether or not the use of recycled glass powder will be economically viable for York Handmade in the future. (998 kb)
Research Report: Ibstock Brick Ltd - full scale operational trials involving the use of recycled glass additions to clay bricks fired through a tunnel kiln.
There has been general awareness in the brick industry for many years that ground, recycled glass has a potential use as a fluxing agent when added to brick clays. Many independent, small-scale laboratory trials have been carried out by a number of brick manufacturers with varying degrees of success. From previous studies, two major concerns were evident... a) the ground particle size of the glass available on the open market was generally too coarse, resulting in uneven vitrification and localised meltspots, leading to unacceptable colour variation b) the available processed glass was inconsistent in quality and often not available in sufficient quantity to be commercially viable. Summary (27 kb). Full Report (27 kb).

Documents

Commercial viability of masonry products from CRT panel glass Final Report.pdf 10089 kb