IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 15, Issue 2 Ver. V (Mar. - Apr. 2018), PP 66-72 www.iosrjournals.org DOI: 10.9790/1684-1502056672 www.iosrjournals.org 66 | Page Recycled refractory brick and Kaolin in Green concrete production Kamal G. Sharobim 1 1 , M. El Gendy 2, Nesreen ELawadly 3 1 (Professor of Properties and Strength of Materials Ismailia Faculty of Engineering, Suez Canal University, Ismailia, Egypt) 2 (Professor of Geotechnical and Foundation Engineering, Port Said Faculty of Engineering, Port Said University, Egypt) 3 (Civil Engineering Department, New Damietta Higher Institute of Engineering and Technology, Egypt) Abstract : The paper presents results of three studies on concrete mixes containing calcined clay to produce green concrete. The first type (Type I) was Metakaolin (600° K Calcination), second type (Type II) was calcined kaolin in high temperature (1000°K) and (Type III) was a waste crushed refractory brick. The first study was to replace 20% of Portland cement by (Type I) and also with (Type II). In the second study fine aggregate was replaced by 20% (Type I) and (Type II). The last study was with crushed refractory brick. Fine and coarse aggregate were replaced by 20% (Type III). Normal grade of concretes containing calcined clay were prepared in six mixes. The Setting times and normal consistency of pastes were determined. Workability, Compressive strength, tensile splitting and flexural strength were checked against the control concrete mix. The study recommended calcined clay as a worthwhile alternative material instead of Portland cement with consideration of water requirement. The research recommends using recycled refractory crushed brick as a green aggregate for production of concrete with recycled materials Keywords - Green concrete, Calcined Clay, kaolin, Meta kaolin, recycled refractory Clay brick. -------------------------------------------------------------------------------------------------------------------------------------- Date of Submission: 19-04-2018 Date of acceptance: 07-05-2018 --------------------------------------------------------------------------------------------------------------------------------------- I Introduction It is now known that cement manufacturing process is one of the most effectual reasons that cause the problem of CO2 emission in atmosphere. Researchers are interested in Green Concrete as a suggested solution. Bambang Suhendro[1] summarized the definition of Green Concrete as a concrete which uses waste materials, or its production process does not lead to environmental impact, or it has high performance. Obla [2] noted that reuse / recycling of materials can help in CO2 emission reduction. Tarun R. Naik were agree with the previous results [3] M.Shahul &Sekar[4] showed an excellent result in them research about Quarry rock dust and marble sludge powder as fine aggregate. Also Micheal Berry [5] tried to produce green concrete with 100% fly ash instead of ordinary Portland cement and he examines its properties. C. Meyer [6] pointed out that the economic factors in using recycled materials in Green concrete production. Imbabi [7] reviewed some benefits of green alternatives of cement. Rajwala D.B [8] and others concluded that each of compressive, split tensile and flexural strength increases about 40% when use flies ash instead of ordinary Portland cement .Al Bakri. [9] Agreed with the previous conclusion. Amankwah and others [10] studied partial replacement of ordinary Portland cement with (0 -25) % calcined clay. It will be good if the developing countries can use the refractory brick which came out from rebuilding the furnaces in many factories. The paper represents an experimental work in green concrete production from waste refractory brick and also from kaolin calcined clay. II Materials Three calcined clay types were selected, the first and second were Metakaolin and kaolin respectively produced by ” Asfour factory for mining and refractories” located in Helwan city in Egypt. Kaolin fired up to the temperature of 1000 o C and Metakaolin fired up to the temperature of 500 o C depending on Asfour factory datasheets. third type of calcined clay was waste crushed refractory brick obtained from” Helwan cement factory” for Portland cement production which locat ed in Helwan city in Egypt . The samples of kaolin and Metakaolin were labeled as Type I and Type II and the sample of waste refractory brick was labeled as Type III. The physical and chemical properties of kaolin and Metakaolin were shown in table (1) to table (3). The admixtures used were super plasticizing named X-Mix GTA produced by NCC construction chemicals Egypt. Cement was (Type52.5 N) produced by the Sinai cement factory respecting the requirements of the Egyptian Standards [(ESS. 4657-1/2009)] [11]. Coarse aggregate was crushed dolomite from North Sinai quarry, has maximum size and specific gravity of 12.5 mm, and 2.70 respectively, which satisfies the Egyptian Standard