This study investigates the addition of 10%, 20%, and 30% crushed brick waste (CBW) to Zurbatiya clay and firing the mixture at 1000°C for 8 hours to produce sustainable and energy-efficient bricks. The results showed that the overall density increased to 1.85 g/cm3 at 10% CBW, yet decreased to 1.4 g/cm3 at 30% due to the increase in porosity from 18% to over 30%. Consequently, thermal conductivity decreased from 0.5 to less than 0.3 W/m· K, enhancing thermal insulation. Also, Shear strength decreased from 15 MPa to 5 MPa but remained acceptable at the 10–20% ratios. Shrinkage improved significantly, decreasing from 5% to less than 2%, indicating improved dimensional stability. The optimal CBW content is between 10% and 20% for durable bricks with improved thermal properties. At 30%, the bricks are suitable for insulating applications or light loads. The high calcium oxide content in the clay affects sintering and crystalline phase formation, but it does not prevent the formation of the mineral mullite, which enhances durability. The secondary phases resulting from calcium alter the physical and mechanical properties. Using CBW reduces reliance on raw materials and minimizes industrial waste, thus reducing the environmental impact. These results support sustainable industrial practices and resource conservation. Overall, CBW improves the physical, mechanical, and thermal properties of Zurbatiya bricks while reducing the environmental impact, supporting the production of lightweight, energy-efficient, and environmentally friendly bricks, which subsequently reducing the need for imports.
Hanoos et al. (Wed,) studied this question.