The thermal insulation properties of building walls are critical to the overall energy efficiency and comfort of a building. One important factor that can affect these properties is the type of bricks used in construction. Bricks can vary in their geometry and thermal coefficient, which can impact their ability to transfer heat through the wall. The geometry of a brick can affect its thermal properties by altering the amount of air trapped within it and the surface area available for heat transfer. Hollow bricks or those with complex geometries may have lower thermal conductivity than regular solid bricks due to the air pockets trapped within them. Conversely, larger surface areas on the exterior of the brick can increase heat transfer. The thermal coefficient of clay, a common material used in brick production, is another important factor. Clay has relatively low thermal conductivity, meaning it is a poor conductor of heat. However, the quality of the clay, as well as the firing temperature and duration used in brick production, can impact its thermal coefficient. Higher firing temperatures and longer firing times can result in a more compact and dense clay brick, which can improve its thermal properties. In summary, the thermal insulation properties of building walls can be significantly affected by the type of bricks used in their construction. It is important to consider the geometry and thermal coefficient of the bricks when designing a building to achieve the desired level of thermal insulation. By selecting bricks with appropriate properties, designers can help to improve the energy efficiency and comfort of the building while reducing its environmental impact.

Thermal insulation is an efficient solution to reduce energy consumption. A great way to reduce the energy consumption of a building is the use of thermal insulation bricks which provide fire resistance and a remarkable thermal capacity, which make them a unique building material for energy efficient buildings. In this study, a fine grain size of expanded perlite was used as additive in a ceramic mass. Brick solid samples were produced from three different mixtures with different ratios of expanded perlite in the mass. From every mixture, three different vacuum values were used. The constructed brick samples were dried and fired in the same conditions and their properties such as bending strength, density and thermal insulation were gathered for six different peak temperatures. The thermal insulation coefficient of every constructed mixture was calculated according to EN1745. It was found that the addition of perlite when keeping the other parameters constant led to decreases in products’ density by 2.9% up to 7.1% and in the thermal conductivity coefficient by 5.4% up to 9.5%, confirming that expanded perlite is a very good porogen material. The bending strength also decreased by 18% up to 28%, but in all cases, it remained well above the minimum accepted value of 100 kp/cm². The vacuum employed during extrusion proved an important parameter affecting the results; however, its effect proved less significant as the perlite percentage in the mixture increased.

The advent of new materials and technologies in building materials has changed the way of building. New lighter materials with easier application methods and improved mechanical behaviors, have become necessary for the market. Moreover, the new environmental policy (2022) aims to transform the waste management into sustainable materials management to ensure the long-term protection and improvement of the environment. For the brick and tile industry, raw materials and the additives that compose the product mixture seem to be a key factor in this direction. Furthermore, every product type (solid or perforated brick) requires different additives to achieve the properties that are postulated by the international standards. For the study, the wide range of additives that were used have been assorted into three (3) categories: the inert materials, the lightweight materials, and the industrial remains. Totally, eight (8) different materials were used as additives into ceramic mass, in different proportions each time. Almost all additives used for this research were pore-forming agents. These burn out almost completely before reaching the full-fire temperature, and do not change the fired body. As a result of additives burnt out, the necessary pore volume is formed in the fired brick body, which, if combined with an appropriate percentage of voids, result in raw density readings. The pore structure is significant as long as the ultimate strength of lightweight bricks is acceptable. In this study, additives between 3 and 25% by weight were added to the clay mixture. The extrusion of specimens in solid form was carried out using the Laboratory’s vacuum press. Firstly, the extrusion of specimens from the original raw material was implemented. Secondly, it was made on the material mixed with the additives mentioned above. A series of experimental activities were followed to determine the variations of the mechanical and physical properties as well as their production procedures (extrusion, drying, and firing). According to five (5) key properties measured in the current study and compared with the mixture without additives, it was found that the variation in thermal conductivity improvement is between -11% and 19%. The bending strength of the fired products showed a decrease from 16% to 55% except for the addition of bauxite residue, which increased the strength by 8%. Bigot drying sensitivity decreased from 11% to 27%. The density in two cases increased from 2% to 7% while in the majority the mixtures with the additives showed a decrease in density from 1% to 14%. Finally, the addition of the necessary water for shaping during extrusion showed a variation from a 10% decreased to a 14% increased water.

The development of energy-efficient and sustainable construction materials is essential for reducing environmental impact and enhancing building performance. This study investigates the incorporation of coffee grounds and expanded perlite waste—two underutilized industrial byproducts—into clay-based ceramics to improve thermal insulation while maintaining mechanical integrity. Unlike previous studies that explore these additives separately or in impractically high dosages, this research focuses on their combined effect at low, industrially viable ratios to ensure large-scale feasibility. Four clay mixtures were analyzed: a reference clay (TZ), clay with coffee grounds (TZCF), clay with expanded perlite waste (TZPW), and clay with both additives (TZCFPW). Laboratory testing and computational fluid dynamics (CFD) simulations were employed to assess the physical, mechanical, and thermal properties of these formulations. The results indicated that coffee grounds increased plasticity, while expanded perlite waste reduced it, requiring adjustments in processing parameters. Both additives contributed to lower shrinkage and drying sensitivity, improving dimensional stability during production. Although mechanical strength declined due to increased porosity—most notably in the TZPW mixture—the fired bending strength remained within acceptable limits for masonry applications. The most significant finding was the substantial improvement in thermal performance, with all the modified formulations exhibiting reduced thermal conductivity and enhanced insulation. The best performance was observed in the TZPW mixture, which demonstrated the lowest thermal conductivity, highest thermal resistance, and optimal U-values in masonry wall testing, confirming its potential for energy-efficient construction. CFD simulations further validated these enhancements, providing detailed insights into heat transfer mechanisms. These findings demonstrate the feasibility of repurposing industrial waste materials to create scalable, eco-friendly building products. Future research should refine formulation ratios to optimize the balance between strength and insulation, ensuring widespread adoption in sustainable construction.

This study explores the potential benefits of incorporating Recycled Demolition Waste (RDF) as an additive in ceramic mass for the brick industry, with a focus on applications such as thermoblocks. The research underscores the significance of sustainable waste management practices and environmental conservation by diverting waste from landfills. RDF, exhibiting combustion properties above 550 °C, emerges as a valuable candidate for enhancing clay-based materials, particularly in the brick production process where firing temperatures exceed 850 °C. Conducted in two phases, the research initially concentrated on RDF preparation, RDF integration with clay materials, and its influence on extrusion and drying phases. Employing innovative techniques involving brick and tile industry machinery coupled with sand incorporation yielded promising results. The grounding of RDF particles to less than 1 mm not only facilitated the mixing process but also ensured stable grinding temperatures within the hammer mill, reducing operational costs. During extrusion, challenges associated with unprocessed RDF material were addressed by utilizing ground RDF, leading to a more efficient and cost-effective process with enhanced plasticity and reduced water requirements. Practical implications for brick plant operations were identified, promoting resource and energy savings. Drying behavior analysis revealed the positive impact of RDF integration, showcasing reduced sensitivity, decreased drying linear shrinkage, and improved density properties. RDF’s role as an inert additive resulted in a 5% reduction in density, enhancing porosity and thermal insulation properties, particularly in thermoblock applications. In the brick industry, where durability, thermal performance, and cost-efficiency are paramount, this study emphasizes the potential benefits of incorporating RDF into clay-based materials. While further research is needed to address the firing procedure of RDF as a brick mass additive, the initial findings underscore the promise of this approach for sustainable and environmentally responsible brick production. This study contributes to the literature by shedding light on the advantages and challenges of integrating RDF into clay-based products, supporting sustainability and waste reduction in construction and manufacturing. The findings provide valuable insights into the performance and feasibility of these mixtures, offering crucial information for industries striving to adopt eco-conscious production methods. This article not only outlines the applied methodology and experimental setup but also presents results related to the behavior of RDF-inclusive clay block mixtures in the production environment. Anticipated to exert considerable influence on future practices and policies, this research contributes to the growing body of knowledge concerning eco-friendly and sustainable manufacturing processes.

The thermal insulation properties of building walls are critical to the overall energy efficiency and comfort of a building. One important factor that can affect these properties is the type of bricks used in construction. Bricks can vary in their geometry and thermal coefficient, which can impact their ability to transfer heat through the wall. The geometry of a brick can affect its thermal properties by altering the amount of air trapped within it and the surface area available for heat transfer. Hollow bricks or those with complex geometries may have lower thermal conductivity than regular solid bricks due to the air pockets trapped within them. Conversely, larger surface areas on the exterior of the brick can increase heat transfer. The thermal coefficient of clay, a common material used in brick production, is another important factor. Clay has a relatively low thermal conductivity, meaning it is a poor conductor of heat. However, the quality of the clay, as well as the firing temperature and duration used in brick production, can impact its thermal coefficient. Higher firing temperatures and longer firing times can result in a more compact and dense clay brick, which can improve its thermal properties. In summary, the thermal insulation properties of building walls can be significantly affected by the type of bricks used in their construction. It is important to consider the geometry and thermal coefficient of the bricks when designing a building to achieve the desired level of thermal insulation. By selecting bricks with appropriate properties, designers can help to improve the energy efficiency and comfort of the building while reducing its environmental impact.