Development and Evaluation of Kaolin, Aluminium Oxide, and Epoxy Composite Bricks for Sustainable Construction

The need for high-performance and sustainable building materials has necessitated the research of composite systems with thermal insulation and mechanical properties. This work examines the fabrication and assessment of kaolin–aluminium oxide (Al₂O₃)–epoxy composite bricks as part of sustainable construction solutions. Kaolin, a natural aluminosilicate, offers dimensional stability, thermal insulation, and eco-friendliness, and aluminium oxide adds hardness, wear resistance, and high compressive strength. Two composite systems were made based on an epoxy resin–hardener system in 5:1 volume proportion: balanced kaolin– aluminium composition and aluminium-rich composition. The samples were cast in Wood molds and cured at ambient condition, then tested for compressive strength as per IS 516 (Part-1): 2021 standards. Findings show that the balanced composite attained compressive strength of 156.2 N/mm² and the aluminium-rich composition attained 142.0 N/mm², reflecting superior load-carrying capacity. The research affirms that the kaolin-aluminium oxide-based epoxy matrix combination creates bricks that are mechanically strong and thermally insulating, superior to ordinary clay bricks. These results indicate that kaolin–aluminium oxide–epoxy composites are promising materials for energy-efficient, environmentally friendly construction, and future work should be directed at optimizing material ratios and scaling for practical use.