Glass Bottle Earth Bricks for Wall Constructions

Abstract

Many countries such as Brazil, have a low percentage of recycled container glass due to multiple factors, such as inadequate waste collection and recycling infrastructure, low public awareness about recycling’s significance, and insufficient laws to promote it. In addition, the country faces high levels of homelessness and inadequate housing. As a result, an increasing number of builders are exploring repurposing glass bottles as a construction material for walls, occasionally incorporating them into traditional earthen building techniques. Therefore, this thesis investigates the potential of repurposing glass container bottles for the construction of load-bearing walls for affordable housing in Brazil while at the same time reducing pollution, enhancing aesthetics, and promoting environmental friendliness.

The main research question is formulated as follows:
How can the structural feasibility of re-purposing beer bottles in Glass Bottle Earth Bricks (GBEB) for wall constructions be ensured?

The report consists of four parts, which are created for each research area: state of the art, experimental investigations, numerical investigations, and finally the discussion, conclusion and recommendations section.

The literature review underscores a rising trend of incorporating glass bottles into earth-based constructions, driven by their shared advantages of environmental friendliness and affordability. Nevertheless, challenges emerge in connecting glass bottles when constructing walls with mortar due to their irregular shapes. To enhance construction efficiency and quality, innovative methods entail pouring mortar between the bottles rather than applying it manually. This approach is complemented by creating bricks while using molds where the bottles are placed inside, facilitating easier stacking and faster execution. The
direct integration of glass bottles into bricks further expedites the process. Prefabricating these blocks with pre-placed glass bottles in controlled environments further optimizes efficiency.

During experimental investigations, a self-compacting earth-based mortar mixture is formulated using local Dutch soil from Emmen. Five different mixture designs are explored, utilizing both artificial and natural soil. The mechanical properties of the earth-based mortar mixtures are evaluated through compressive and flexural strength tests, as well as a mini slump flow test to assess workability. The selected earth mixture is anticipated to achieve an average compressive strength of 12.1 MPa after 28 days, an average flexural strength of 3.67 MPa after 7 days, and a flow diameter of 23.05 mm.

Subsequently, a prototype glass bottle earth brick containing a horizontally aligned longneck beer bottle is produced, revealing a compressive strength ranging between 8.21 and 11.40 MPa after 28 days of casting. Upon failure, a fracture analysis indicated that the origin of failure lies at the bottom of the bottle, with breaking stresses at failure measuring 608 kg/cm² and 431 kg/cm² for two samples.

Results from SEM-EDS analyses reveal iron and aluminum residue at the fracture origin in the glass bottle. The earth mortar cast around the bottle showcases a similar composition, suggesting that scratches were likely introduced during brick manufacturing by the earth mixture. Additionally, an initial evaluation of the thermal behavior of the Glass Bottle Earth Brick (GBEB) indicates that the mortar acts as a heat sink, suggesting that the GBEB could contribute to thermal comfort.

Through numerical investigations employing Finite Element Methods (FEM), a comprehensive understanding of stress propagation and behavior within a Glass Bottle Earth Brick is achieved. Modeling the brick with the bottle from laboratory experiments aligns with expected peak stresses. However, the Finite Element Method (FEM) model's simplification disregards knurls, the ribbed patterns commonly present on the outer bottom surface of the bottle. Simplifying the model by removing the knurls lowers the computational complexity but potentially overestimates the strength of the GBEB. This underscores the importance of considering knurls to accurately predict peak stresses.

Based on these findings, it is inferred that repurposing glass bottles for constructing walls capable of supporting small-scale structures is feasible. However, since this represents a novel building approach, it demonstrates potential while also highlighting the need for further investigation and clarification. Increasing the number of samples tested and expanding the range of factors examined can enhance confidence and provide insights into the material results and assumptions made.