cellular light weight bricks are a new generation building material that is highly sought after by builders as they offer a variety of benefits over traditional bricks. They are more affordable and environment friendly as they use recycled materials and have better insulation properties. Additionally, they are easier to handle and require less construction mortar than conventional bricks. This saves time and money for the contractor. Moreover, the blocks are also fire resistant, making them more durable.

The foam concrete blocks are manufactured with the help of a special mixer that mixes cement, fly ash and protein based foam together to produce the desired density. The slurry is then poured into assembled moulds of bricks of the required size and then cured in a special kiln for 18 to 24 hours. One cum of cellular lightweight concrete contains approximately 5 bags of OPC 53 grade cement and 500 kgs of fly ash.

A key advantage of cellular concrete is its lower water absorption, which is 8 to 9 % for a density of 800 kg/m3. This significantly improves the resistance against cracks in walls. It can also provide up to 37-42 dB sound reduction based on the wall thickness.

The cellular bricks developed in this research were made of recycled expanded polystyrene as aggregate and commercial Portland cement as binder. The bricks were subjected to compression and tensile tests. The results showed that the strength of the cellular bricks increases with increasing fly ash content and a decrease in the cement content. However, the tensile strength of these bricks is lower than that of the conventional clay bricks, which is expected due to the flexural behaviour of EP.