Abstract

The rapid advancement of construction technologies has necessitated the development of lightweight, thermally efficient, and sustainable building materials. Hollow bricks, due to their inherent voids, offer substantial reductions in dead load and enhanced insulation properties. However, their mechanical performance often falls short when compared to conventional solid bricks. To address this limitation, this study explores the synergistic integration of aerated aggregates and polymer-cement composites (PCCs) in hollow brick production. Aerated aggregates such as foamed glass and expanded clay provide the benefits of low density and thermal insulation but typically compromise compressive strength. Meanwhile, polymer additives like Styrene-Butadiene Rubber (SBR), Acrylic Emulsions, and Epoxy Resins significantly improve the bond strength, flexibility, water resistance, and crack-bridging ability of cementitious composites. This research combines these materials to produce innovative hollow bricks with improved structural and durability characteristics. Five distinct mix designs incorporating varying proportions of polymers and aerated aggregates were tested. Comprehensive laboratory evaluations included compressive strength, flexural strength, water absorption, impact resistance, thermal conductivity, and microstructural analysis using SEM and DSC/TGA techniques. The findings revealed that the optimal combination (Mix M3: 90% cement, 10% epoxy, and 20% aerated aggregates) exhibited a 26% increase in compressive strength and nearly 40% reduction in water absorption compared to the control sample. Flexural strength and impact resistance were also significantly enhanced due to polymer bridging and improved aggregate-matrix bonding. Furthermore, thermal analysis confirmed the improved insulation and thermal stability of the polymer-modified bricks. SEM images showcased a more homogeneous and denser microstructure with fewer voids and microcracks. The study concludes that polymer-modified, aerated-aggregate hollow bricks present a viable and sustainable alternative for modern masonry construction, especially in low- to mid-rise buildings. They offer a balanced performance in terms of strength, weight, durability, and energy efficiency, making them suitable for the future of eco-friendly and structurally sound architecture.

Keyword: Hollow bricks, aerated aggregates, polymer-cement composites, lightweight masonry, mechanical properties

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