1.0

Problem Statement

1.1

Background

Waste materials have been burden earth since long time ago, the amount of solid waste are enormously such as plastic bottles, papers, white goods, kitchen waste, and moreover the huge size of waste like concrete waste from construction activities. This kind of material may affect the environment which comes out with result of pollution. Poor managing of waste like plastics may result huge bad effect to environment. Burning out of plastics without any treatment may release a huge amount of gasses. It is not the only causes to environmental pollution, but yet also to human health. Besides, non-dispose waste plastic that didn’t manage properly may clog drainage as it is non-carbonaceous material naturally. This is some factor that causes flash flood, especially in rural area. Other than plastics, construction waste materials also contributing a large factor of environmental pollution. High demand of construction of material like aggregate, lime and some other materials that used for concrete may result an environmental extinction. It is due to over harvesting of natural result. Rock is taking a long time period to form from magma. But it consumes by human every day for construction purpose. Besides, consuming natural resources need a lot amount of money to proceed. Usually, construction waste such as concrete are used as backfilled soil on site. It is because the characteristic of waste concrete is stronger than soil. However, it consumes lots of money compare than recycling it. Therefore, in order to decrease or prevent this kind of problem, our group decided to do some research and produce new product called “4R BRICK”. In this project, we are focusing on 4R concept which are Reduced, Recycle, Reuse and Recreate. Our main concern is about the environmental pollution and extinction that rarely happen now days. So, in order to fulfil that goal, we used to reduce that problem by recycling construction waste, then recreate it by combining with plastic to form new brick to reuse it in the construction sector. This brick is made from mixing plastics and waste concrete to form new brick that can be used in construction. Plastics are used as bonding agent for the waste concrete and even makes brick are lighter than present clay and concrete brick without affecting the strength of the brick.

2.2

Objectives      

2.3

Decreased environmental pollution. To decrease waste material in construction. Decrease over harvesting of natural resources. Changing waste material to the new product. Making new brand of brick that using of 4R concept. Saving money and generate some income from waste, construction materials.

Research

Approximately of 41% of the total solid waste was generated by the construction industry in Malaysia (MHLG, 2012). 28.34% of construction are generated from Central and Southern part of Malaysia. According to Fauziah and Agamuthu (2003), construction and demolition waste was estimated to generate 161.19 tons per day by 2009, increasing to 299.69 tons per day by 2015. It is projected that 368.31 tons per day by 2023 (Fauziah & Agamuthu, 2003). Infrastructure in Malaysia has undergone a rapid development over the last decade. Therefore, demolition of existing has to carry out to provide the 1

site for construction of new buildings. A study compared between construction and refurbishment, and the result was that construction activity generated more 80% of waste then refurbishment. More waste generates from historical places. Besides that, total waste generated of data have been collected from several countries and the results showed that construction and demolition waste have roughly taken up 20% to 30% of the total waste in landfill. Construction wastes have become an issue that needs highly concern and cooperation from everyone, especially in many developing countries because it has an adverse impact on environmental health.

2.0

Idea Generation and Refinement (Innovation Process)

3.1

Idea Generation

The course, Creativity and Innovation assessment required students to form a team consisted of 5 persons. A team then created a suitable name with the tagline for the group. Besides, team also appointed a project manager and secretary. The command from our lecturer for each team to come out with 15 ideas (3 ideas for each member in the team) in the first session of our project. This process based on Brainstorming technique. Brainstorming developed by Madison Avenue advertising executive, Alex Osborn and published it in his book 1953 “Applied Imagination”. Brainstorming blends up a relaxed, informal approach to problem solving with sidelong of thinking. It boosts up people to come up with views and ideas, at first those ideas might seem a bit out of mind. But further analysis of some of these ideas can be worked into original, creative solutions to a problem, while others can spark even more ideas. This helps to get people think out of box. Therefore, during brainstorming sessions, people should avoid criticizing or rewarding ideas because to open up possibilities and break down incorrect assumptions about the problem's limits. Negative press and analysis at this stage stunts idea generation and limit creativity. Ideas then only being evaluated at the end of the session.

3.2

Idea Screening

The Ideas came from the experiences of everyone, some to improve and some to invent. However, the best idea has to contain its original to prevent any duplicates, even though some references from outsourcing is allowed. Our ideas do not have limits, this to prevent the creativity blackout during the process of Brainstorming. Brainstorming is conducted in a fun way, this is to encourage ideas production of everyone and helped issuing the ideas besides tackling their stage fright. From the fifteen ideas, a discussion had done in the class to choose only three best ideas based on the vote of in the group. Before the three ideas, every member will then have to introduce their ideas together with an explanation. Each idea is chosen based on the possibility of local materials for the making process and economic along with the originals of an idea. All ideas can refer to appendices attached together with this report. Lastly, the group decided to create a new brick that made from 100% wasted materials.

3.3

Refinement Few improvements can be made to our idea generation process as below:   

Shut off the network such as Wi-Fi connection and browsing hand phone (browser) because this will limit the way of students produce their creativity, also prevent plagiarism of idea. Guide about the access of equipment for students use in their production because lack of apparatus and equipment will affect the quality of product and safety of students. Responding in the group is very important to arrange suitable schedule and gain more solutions.

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Three sample of our products (4R Brick), each of their size are not standardized. This could have been better if we do more research. The sample used for Compressive strength test is 175mm length, 105mm width, 58mm depth, and capable to withstand the load of 83.88 kN with the strength of 4.8 MPa.

3.0

Solution

3.1

Existing Solution

Bricks are the only man-made building materials that testify to their use since the early human civilization. With their attractive appearances and superior properties such as high compressive strength and durability, excellent fire and weather resistance, good thermal and sound insulation, bricks are widely used for building, civil engineering work, and landscape design. General Brick Specification as per Malaysia Standard MS 7.6: 1972 / British Standard BS 3921: 1985

3.2

The Innovation

The block made from wasted materials is named 4R Brick. 4R defined as to reduce, reuse, recycle, recreate. 4R brick is made from ashes of concrete block from demolished, project mixed with plastic bottles that cooked in the wok at maximum temperature. The technique was being adopted from cooking technique, where the stove heats fire up and the wok, then pour in the used cooking oil. When the wok gets heated up, slowly add in plastic bottles and stirred until the plastic bottle melt. Lastly, add in ashes from concrete block and continued stirring until the mixture blend into one. The mixture is ready when the texture looks same as plasticine. The concrete block chose for this project because of construction waste that commonly being used as for reclamation at the back yard, else just throw in the landfill. This is not the best solution for bulky solid waste, plus the solid waste cannot be decomposed by the microorganism and this will take a lot of space without help from mechanical energy to degrade it. Ashes from the concrete block are cohesive less material. To re-block the ashes, we used the plastic bottle. Plastic bottles also are one of the major solid waste in this country. The property of plastic when at high temperature, it behaves like cohesive and when temperature reduced, it becomes harder, which is why we choose plastic as our binder. As for the used cooking oil, this is one of the solutions to melt the plastic besides to use the chemical compound which is dangerous and costly for students like us. Cooking oil usually throws away after several uses, also the boiler temperature of the cooking oil is higher than normal water.

3.3

The Features

4R Bricks are made from wasted materials by stirred and boiled it at high temperatures. The action of heat loosens up the plastic molecules and let the concrete ashes to interrupted in between. When the temperature decreased, the process causes the plastic and concrete ashes to fuse and develops into strong concrete block.

4.3.1

Strength

The sample used for Compressive strength test is 175mm length, 105mm width, 58mm depth, and capable to withstand the load of 83.88 kN with the strength of 4.8 MPa. The strength is in average class.

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4.3.2

Flexibility in Applications

4R brick greatly simply the construction process as to save materials, time and labour. Besides, 4R Brick can be made into agreeable shape and size to suit the construction work. It is very flexible and handy in application almost everywhere.

4.3.3

Aesthetic Appeal

4R Brick possesses the natural and pleasant colors of concrete. 4R Brick color is permanent and will not be faded during weathering process. By proper control of making process factors, bricks can be made to exhibit endless variety of natural and attractive colors. Besides, proper control the ratio of plastic in mixture during production could add shine surface to the 4R Brick. 4R brick is rich in grayish color, it also can be made to various textures according to mold.

4.3.4

Porosity

To act as a wall, porosity is an important characteristic in the building. The molten plastic concealed the void in the concrete block ashes, which gives it a shining surface. Alongside, the water resistant of plastic also benefiting 4R brick.

3.4

The Functions

Our product targeting on brick wall. Consider the making process of this 4R brick and it strength, where it can be easily mold into many shapes as wanted. Therefore, 4R brick can be create not just only for brick, but also many usage:    

4.0

Brick wall Landscape pavement Interior & exterior decoration Block paving

Conclusion

Standard brick size is 210 x 100 x 65 mm compared with 4R brick size is 175 x 105 x 58 mm. The 4R brick sizes are not standardized as normal brick size on the market, however the strength we obtained from the concrete cube compressive strength test is average class compared to normal brick’s strength. The 4R brick strength obtained from the test is 4.8Mpa. The sizes of the brick are not standardized, this is due to lack of equipment and insufficient of study. Therefore, some improvement can be made to the brick size. The brick wall is a main member in a building in resisting the heat if the fire incident occurs. For 4R brick to be fully functioning as a wall, a study to improve 4R brick’s fire resistance is needed. 4R brick can be used as an interior and exterior decoration, landscaping pavement and brick wall is all suitable, although the material is from construction waste and solid waste (plastic bottle). The production of 4R brick is quite successful, our aim of making a brick from wasted material also achieved. In future, 4R brick can be one or another way of benefiting natural environmental and everyone. Besides that, this is also a good study for someone wishes to making profit. 4

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References    

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MindTools | Brainstorming | Generating Many Radical, Creative Ideas | 1996-2015 | https://www.mindtools.com/brainstm.html Small SEO Tools | Plagiarism Checker | Check for Plagiarism | 2012-2016 | http://smallseotools.com/plagiarism-checker/ THE CONSTRUCTION CIVIL | Compressive / Crushing Strength of Bricks | 2015 | http://www.theconstructioncivil.org/compressive-crushing-strength-of-bricks/ Yap Sie Horng | Compressive Strength Study of Brick Masonry Subjected to Axial Loading | April 2010 | https://www.academia.edu/9289032/Compressive_Strength_Analysisof_Brick_Masonry Kia Lim Berhad, Malaysia | Clay Bricks - Technical Data | 2000 | http://www.kialim.com.my/bricks-spec.php Claybricks & Tiles Sdn. Bhd. | General Brick Specifications | 1998-2007 | http://www.claybricks.com/more_info/brick-specifications.html wikiHow | Mediawiki | How to Make Bricks from Concrete | N/A | http://www.wikihow.com/Make-Bricks-from-Concrete

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