Friday, 28 April 2017

use of waste material as partial replacement for concrete mix design and Estimation for partial replacement

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“USE OF WASTE MATERIALS AS A PARTIAL REPLACEMENT OF SAND AND COARSE AGGREGATES IN CONCRETE MIX”
Submitted in partial fulfillment of the requirements of the degree of
“BACHLOR OF ENGINEERING”
Submitted by-
                                            
SHOAIB GHORI
  BASIT CHAUHAN
                 ABDUL AZEEZ CHOUHAN
POOJA KAMBLE


Under the guidance of
PROF. Faizan Shaikh













Chapter 1
Introduction
At present no construction activity is possible without Using concrete. It is the most common material used in construction worldwide. The main reason behind this is because of its high strength, durability and workability. The total world consumption of concrete per year is about one ton for every living human being. Man consumes no materials except water in such tremendous quantities. Due to privatization and globalization, the construction of important


Infrastructure projects like Highways, Airports, Nuclear plants, Bridges, Dams etc. in India is increasing year after year. Such developmental activities consume large quantity of precious natural resources. This leads not only faster depletion of natural.
Resources but also increase the cost of construction of structures. In view of this, people have started searching for suitable other viable alternative materials which could be used either as an additive or as a partial replacement to the conventional ingredients of concrete so that the existing natural resources could be saved to the possible extent, and could


be made available for the future generation. In this process, different industrial waste materials such as fly ash, blast furnace slag, quarry dust, tile waste, brick bats, broken glass waste, waste aggregate from demolition of structures, ceramic tiles, electronic waste of discarded old computers, TVs, refrigerators, radios, waste paper mill pulp, iron filling, waste coconut shell, rice husk ash, marble dust powder, hypo sludge, machine crushed animal bones, chicken feather, eggs shell, granite quarry sludge, palm oil fuel ash, copper dust, human hair etc have been tried as a viable substitute material to the conventional materials in concrete.
1.1 Basic relationship
• Workability: The property of the concrete that determines its capacity to be placed and consolidated properly and be finished without harmful segregation.
• Consistency: It is the relative mobility of the concrete mixture, and measured in terms of the slump; the greater the slump value the more mobile the mixture.
• Strength: The capacity of the concrete to resist compression at the age of 28 days.
• Water-cement (w/c) ratio: Defined as the ratio of weight of water to the weight of cement, or the ratio of weight of water to the weight of cement plus added pozzolanic. Either of these ratios is used in mix design and considerably controls concrete strength.
• Durability: Concrete must be able to endure severe weather conditions such as freezing and thawing, wetting and drying, heating and cooling, chemicals, deicing agents, and the like. An increase of concrete durability will enhance concrete resistance to severe weather conditions.
  • Density: For certain applications concrete may be used primarily for its weight characteristics. Examples are counterweights, weights for sinking pipelines under water, shielding from radiation, and insulation from sound.
  • Generation of heat: If the temperature rise of the concrete mass is not held to a minimum and the heat is allowed to dissipate at a reasonable rate, or if the concrete is subjected to severe differential or thermal gradient, cracking is likely to occur."
1.2 Effects of Chemical Admixtures on Concrete
"Chemical admixtures, pozzolanic, and other materials can be added to concrete mix to alter some properties or to produce desired characteristics. Additives are used to affect the workability, consistency, density, strength, and durability of the concrete."
1.3 Construction waste
  • It include the unwanted residue resulting from the alteration, construction, demolition or repair of any buildings or other structures.
  • These include roofing, concrete block, plaster, structural steel, plumbing fixtures, electrical fixtures, heating and ventilation equipment, windows and doors.
  • Construction waste consists of unwanted material produce directly or incidentally by the construction or industries.
  • CONSTRUCTION WASTE DOES NOT INCLUDE MATERIALS IDENTIFIED AS SOLID WASTE, INFECTIOUS WASTE OR HAZARDOUS WASTE.
1.4 Use of waste in concrete
  • Research efforts has been done to match society need for safe and economic disposal of waste materials.
  • The use of waste materials saves natural resources and dumping spaces, and helps to maintain a clean environment.
  • The current concrete construction practice is through unsustainable because, not only it is consuming enormous quantities of STONE, SAND, and DRINKING WATER, but also two billion tons a year of PORTLAND CEMENT, which releases green-house gases leading to global warming.
  • Experiment has been conducted for waste materials
  • Construction waste recycle plants are now installed in various countries but they are PARTLY SOLUTION to the waste problems.
    1. Replacement materials
There are various waste that can be replaced by concrete ingredients, some are summarized here;
Waste in replacement of CEMENT are;
  1. Fly-ash
  2. Ground-granulated blast-furnace(GGBS)
  3. Marble powder
  4. Timber waste
  5. Ceramic waste
  6. Grit powder
Waste in replacement of FINE AGGREGATE;
  1. Rice husk
  2. Waste iron
  3. Ceramic waste
  4. Sheet glass powder
  5. Crushed granite powder
  6. Demolition waste
Waste in replacement of COARSE AGGREGATE;
  1. Rubber tire waste
  2. Coconut shell waste
  3. Building demolition waste
  4. Iron powder
  5. Granite powder



Chapter 2
Literature Review
Dr. Haider.K. Ammash;
Dr. Haider.K.Ammash   the possibilities Waste Glass of size up to 5mm as a fine aggregate in concrete. The waste glass was used as a partial weight replacement of sand with percentages of 10, 20, 30 and 40 %. They found that, waste glass aggregate can be satisfactorily substituted for natural fine aggregate at replacement levels up to 20%.
M. Iqbal Malik;
M. Iqbal Malik studied the use of Waste Glass as partial replacement of fine aggregates in concrete. Fine aggregates were replaced by waste glass powder as 10%, 20%, 30% and 40% by weight for M-25 mix. The concrete specimens were tested for compressive strength, splitting tensile strength, durability and density at 28 days of age and the results obtained were compared with those of normal concrete. They discovered that 20% replacement of fine aggregates by waste glass showed 15% increase in compressive strength at 7 days and 25%


increase in compressive strength at 28 days. Fine aggregates can be replaced by waste glass up to 30% by weight showing 9.8% increase in compressive strength at 28 days. With increase in waste glass content, percentage water absorption decreases. With increase in waste glass content, average weight decreases by 5% for mixture with 40% waste glass content thus making waste glass concrete light weight. Splitting tensile strength decreases with increase in waste glass content.
Gunalaan Vasudevan, Seri Ganis KanapathyPillay;
Gunalaan Vasudevan, Seri Ganis KanapathyPillay studied to investigate the effect of using Waste Glass Powder in concrete. Laboratory work was conducted to determine the performance of control sample and concrete with used waste glass powder. They concluded that concrete with using waste glass powder averagely had higher strength at 14 days but once the concrete reached at 28 days the control mix give more higher value compare to mix that contained waste glass powder but still give high value of the M 30 grade.
G.Murali;
G.Murali concluded that the concrete with Steel Powder as waste material was found to be good in compression which had the compressive strength of 41.25% more than the conventional concrete. Better split tensile strength was achieved with the addition of the steel powder waste in concrete. The strength has increased up to 40.87% when compared to that of the conventional concrete specimen. In flexure the specimen with soft drink bottle caps as waste material was found to be good. While adding the soft drink bottle caps the flexural strength increased by 25.88% that of the conventional concrete.
Mostafa Jalal;
Mostafa Jalal investigated the mechanical behavior of concrete reinforced with Recycle Steel Fibers (RSF) recovered from milling and machining process. He observed that the compressive strength of the specimens was significantly increased. By increasing the waste fibers percentage, workability of concrete decreased. In some cases, water must be added so that the workability increases and as a result, the compressive strength decreases a little. By using waste fibers, cracks distribution got much more uniform during failure. The desired


amount of fibers from the compressive strength point of view was turned out to be between 2-3 percent.
Dr. G.Vijayakumar ;
Dr. G.Vijayakumar conducted and experiment concrete prepared by partial replacement of cement by waste Glass Powder of particle size 75μm. The waste glass powder was replaced by 10%, 20%, 30% and 40% of the binder and the mix design was prepared. Before adding glass powder in the concrete it had to be powdered to desired size. In this studies glass powder ground in ball/pulverize for a period of 30 to 6o minutes resulted in particle sizes less than size 150 μm and sieved in 75 μm. The concrete mix design was proposed by using Indian Standard for control concrete of grade M20. The mixture was prepared with the cement content of 330kg/m3 and water to cement ratio of 0.53.At 28 days the glass powder shows a compressive strength of 41.96N/mm2, strength at 30% cement replacement. The pH value observed from the alkalinity test showed that the specimen tested found to be more alkaline and hence more resistant towards corrosion.
Ali N. Alzaed;
Ali N. Alzaed observed that Iron Filings are very small pieces of iron that look like a light powder. He used four different percentage of iron filing and was added to concrete mix to measure the variation 0% (control), 10%, 20% and 30% which may be obtained in compression and tensile concrete strengths after 28 days. Ordinary locally-available Portland cement having a specific gravity of 3.15, Locally available sand having a fineness modulus of 2.54 and a specific gravity of 2.62 was used. Crushed granite coarse aggregate of 20 mm maximum size having a fineness modulus of 7.94 and specific gravity of 2.94 was used. Water conforming to the requirements of water for concreting and curing as per IS: 456–2000. He concluded that compressive strength of concrete was increased by 17% when 30% of iron filling added to the concrete mix. Concrete tensile strength had a minor effect if the percentage of iron filing used more than 10%. Concrete tensile strength increased by 13% when 10% of iron filling added to concrete mix.
Kabiru Usman Rogo and Saleh Abubakar ;
Kabiru Usman Rogo and Saleh Abubakar studied on the Coconut Shell which can be a substitute for aggregates. The shell of the coconut is mostly used as an ornament and as a source of activated carbon. The powdered shell is also used in the industries of plastics, glues, and abrasive materials. The use of coconut shells can also help the prevention of the environment and also help economically. The coconut shells are obtained from a local coconut field. They were sun dried for 1 month before being crushed manually with particle sizes of the coconut shell range from 5 to 20 mm. They prepared about 72 concrete cubes size 150x150 x150mm with different mixed ratios1:2:4, 1:11/2:3 and 1:3:6 were casted and tested. They concluded that compressive strength in N/mm2 of coconut shell at 7, 14 21, and 28 days with mix ratios of 1:2:4, 1:1.5:3 and1:3:6 are (8.6, 8.9, 6.4), (9.6, 11.2, 8.7), (13.6, 13.1, 10.7) and (15.1, 16, 5, 11)respectively for gravel (19.1, 18.5, 9.6) (22.5, 23.0, 10.4) (26.7, 24.9, 12.9) and (28.1,30.0, 15) respectively. Since the concrete strength of coconut shell with mix ratio 1:1.5:3attained 16.5N/mm2 at 28 days it can be used as plain concrete. Hence cost reduction of48% was obtained.
Mohammed Monish;
Mohammed Monish investigated that huge quantities of construction and demolition wastes are generated every year in developing countries like India. The disposal of this waste is a very serious problem because it requires huge space for its disposal and very little demolished waste is recycled or reused. The paper deals with the effect of partial replacement of coarse aggregate by demolished waste on workability and compressive strength of 7 and 28 days.
The concrete mix design was done in accordance with IS:10262 (1982). The cement content in the mix design was taken as 380 kg/m3 which satisfies minimum requirement of 300 kg/m3 . Three specimens each having 0%, 10%, 20%, and 30% demolished waste as coarse aggregate replacement for mix of 1:1.67:3.33were cast and tested after 7 and 28 days in order to have a comparative study. They concluded that up to 30% replacement of coarse aggregate with recycled aggregate concrete was comparable to conventional concrete. Up to 30% of coarse aggregate replaced by demolished waste gave strength closer to the strength of plain concrete cubes and strength retention is in the range of86.84-94.74% as compared to conventional concrete.
P.Krishna Prasanna and M.Kanta Rao;
P.Krishna Prasanna and M.Kanta Rao they carried out an experimental study by utilizing E- waste particles as coarse aggregates in concrete with a percentage replacement from 0% to 20% i.e. (5%, 10%, 15% and 20%). Similarly, conventional specimens were also prepared for M30grade concrete without using E- waste aggregates. By conducting tests for both the specimens the hardened properties of concrete were studied. The e-waste contents were calculated on weight basis as coarse aggregate in the conventional mix. The fineness modulus of coarse aggregate with various E- waste contents was observed as 6.937.Compressive strength test was conducted to evaluate the strength development of concrete containing various E- waste contentsat the age of 7, 14, 28 days respectively. It was also observed that the compressive strength of concrete was found to be optimum when coarse aggregate was replaced by 15% with E-Waste. Beyond it the compressive strength is decreasing.
Conclusion;
From the research discussed it is clear that these various wastes are suitable in the construction industry especially in concrete making. Industrial and agricultural waste materials such as fly ash, blast furnace slag, quarry dust, tile waste, broken glass waste, waste aggregate from demolition of structures, ceramic tiles, E-waste, waste paper mill pulp, iron filling, waste coconut shell, rice husk ash, marble dust powder, hypo sludge, machine crushed animal bones, chicken feather, eggs shell, granite quarry sludge, palm oil fuel ash, copper dust, human hair etc are used in varying proportion as a partial replacement of concrete ingredients. Researchers have indicated their potential for usage in both structural and non-structural concrete. They were found to be performing better than normal concrete, in properties such as workability, durability, permeability and compressive strength. As disposal of wastes, by-products is a major problem in todays world due to limited landfill space as well as its escalating prices for disposal, utilization of these wastes in concrete will not only provide economy but also help in reducing disposal problems.
Chapter 3
METHODOLGY
3.1 Tests Performed on Normal Concrete Materials;
Test on Cement;
  • Specific gravity test
Tests on Fine Aggregate;
  • Specific gravity test
  • Water Absorption Test
  • Sieve Analysis
Tests on Coarse Aggregate;
  • Specific gravity test
  • Water absorption test
3.1.1 Tests on Cement;
Determination of specific gravity of cement
Apparatus: 1. Specific Gravity Bottle
                  2. Balance capable of weight accurately up to 0.1gm
Procedure:
  1. Weigh a clean and dry Specific gravity bottle with its stopper (W1).
  2. Place a sample of cement upto half of the flask and weight with its stopper (W2).
  3. Add kerosene (polar liquid) to cement in flask till it is about half full. Mix thoroughly with glass rod to remove entrapped air. Continue stirring and add more kerosene till it is flush with the graduated mark. Dry the outside and weigh (W3).
  4. Empty the flask, clean it refills with kerosene flush with the graduated mark wipe dry the outside and weigh (W4).
Conclusion: (W2-W1)/[((W2-W1)-(W3-W4))x0.79]
                  Where, W1 = weight of empty bottle.
                               W2 = weight of bottle + cement.
                               W3 = weight of bottle + cement + kerosene.
                               W4 = weight of bottle + kerosene.
                              0.79 = Specific Gravity of kerosene.
Result: Specific gravity of cement = 3.14
3.1.1.1 Observation table
Mass of empty bottle (g) (W1)
23.47
Mass of cement (g) (W2)
32.5
Mass of bottle + cement + kerosene (g) (W3)
48.4
Mass of bottle + kerosene (g) (W4)
43
Specific gravity of kerosene
0.79
Specific Gravity of cement
3.14
3.1.2 Tests on Fine Aggregate;
Determination of specific gravity and water absorption on fine aggregates
Apparatus :- 1. Weighing balance of capacity not less than 5kg
2. Thermostatically controlled oven
                    3. Pycnometer, Enamel tray, Air tight container, Glass
                      rod, Wash bottle, Filter paper and Funnel.
Procedure:
  1. Take approximately 2kg of fine aggregate in saturated surface dry condition and weigh it. Take 500g of this sample for test and record it in observation sheet as (C).
  2. This sample is then place in the pycnometer. Fill the pycnometer partly with distilled water. Entrapped air is eliminated by stirring the contents of the pycnometer with glass rod.
  3. Then the pycnometer is completely filled distill water. The hole of the apex of the cone is now covered with finger and assembly is shaken to remove any Entrapped air. Fill the cone of pycnometer with distill water using wash bottle. Now its weight recorded as (A)
  4. Empty the content of pycnometer in enamel tray and refill the pycnometer with distill water to the same level as before using the same procedure. Weigh the entire assembly and record this reading as (B).
  5. The water from the sample in the enamel tray is then removed by decantation. This water collected after decantation is then filtered and the material retained on the filter paper is returned to the sample after drawing.
  6. The sample is then placed in the oven at a temperature of 100’C for 24hours. After 24hours the sample is taken out from the oven.
  7. The sample should then be cooled in the air tight container. Note down the oven dried weight of the sample and record the reading as (D).
Conclusion: Specific gravity can be defined as the ratio of the weight of aggregate in air to the weight of equal volume of water displaced by saturated surface dry aggregate.
Specific gravity of fine aggregate = D/(C-(A-B))
Water Absorption of fine aggregate = [(C-D)/D] x 100      
3.1.2.1 Observation table:
DESCRIPTION
SAMPLE NO.
TEST 1                  TEST 2
  1. Weight of sample taken (g)
2000
2000
  1. Weight of saturated and surface dry aggregates (C) (g)

500

500
  1. Weight of pycnometer + sample + water (A) (g)
1834
1834
  1. Weight of pycnometer + water (B) (g)
1514
1514
  1. Weight of oven dry sample (D) (g)
484
484
  1. Specific gravity = D/( C-(A-B))
2.69
2.69
  1. Water absorption percentage dry weight = [(C-D)/D] x 100 (%)
3.31
3.31
Average Specific gravity
2.69

Average Water absorption (%)
3.31
3.1.3 Sieve analysis on fine aggregate 1000g
Apparatus:- 1. A set of IS Sieves of sizes – 4.75mm, 2.36mm, 1.18mm, 600µm, 300µm,                     150µm and 75µm.
 2. Balance or scale with an accuracy to measure 0.1
                       percent of the weight of the test sample.
Procedure:
1. The test sample is dried to a constant weight at a temperature of 110 + 5oC and weighed.
2. The sample is sieved by using a set of IS Sieves.
3. On completion of sieving, the material on each sieve is weighed.
4. Cumulative weight passing through each sieve is calculated as a percentage of the total sample weight.
5. Fineness modulus is obtained by adding cumulative percentage of aggregates retained on each sieve and dividing the sum by 100.
Reporting of result:
The results should be calculated and reported as:
i) the cumulative percentage by weight of the total sample
ii) the percentage by weight of the total sample passing through one sieve and retained on the next smaller sieve, to the nearest 0.1 percent.
3.1.3.1 Observation table
IS sieve size
Weight retaining (gm)
Cumulative weight retaining (gm)
Cumulative % of weight retaining
4.75 mm
66.18
66.18
6.62
2.36 mm
72.13
138.31
13.83
1.18 mm
329
467.31
46.73
600 u
399.78
767.09
76.71
300 u
206.93
973.92
97.39
150 u
21.38
994.05
99.41
75 u
4.90
997.34
99.73
Pan
2.16
1000
100
3.1.4 Tests on Coarse Aggregates
Determination of specific gravity and water absorption on Coarse aggregates
Apparatus: 1. Weighing balance of capacity not less than 5kg
                  2. Thermostatically Controlled oven
                  3. Glass vessel of sufficient capacity, Air-tight container
                  4. 10mm IS sieve
Procedure:
  1. Take approximately 1kg sample of coarse aggregate in its natural state (The quantity of sample to be taken depends upon the size of the aggregate)
  2. Now sieve the sample to 10mm IS sieve to remove the finer particles. Placed the sieved sample in the glass vessel and partly fill the vessel with distill water. Keep the aggregate immersed for 24hours so that they are completely saturated.
  3. At the end of the soaking period the vessel is then over filled with water. Cover this vessel with plane glass disc to ensure that no air is trap in the vessel. The vessel is then dried from the outside. Now take the weight of this assembly and note this reading as (A)
  4. The vessel is now empty and the aggregate allowed to drain out. The aggregates are then placed on a dried cloth, till its comes in completely surface dry condition.
  5. Refill the vessel with distilled water and slide the glass disc in position as before to ensure that no entrapped air is present in the vessel. Weigh the entire assembly and record the reading as (B)
  6. After the aggregate appeared to be in saturated surface dry condition their weight is taken as (C).
  7. Now the aggregates are placed in enamel tray to be kept in oven at a temperature of 100’C for 24hours. After 24hours the aggregates are taken out from the oven and cooled in an air tight container. Note down the oven dried weight of aggregate as (D).
Conclusion; Specific gravity cane be defined as the ratio of the weight of aggregate in air to the weight of equal volume of water displaced by saturated surface dry aggregate.
Specific gravity of Coarse aggregate = D/(C-(A-B))
Water Absorption of Coarse aggregate = [(C-D)/D] x 100





3.1.4.1 Observation table
DESCRIPTION
SAMPLE NO.
 TEST 1
      TEST 2
  1. Weight of sample taken (g)
1000
1000
  1. Weight of vessel + sample + water (A) (g)
3404
3408
  1. Weight of vessel + water (B) (g)
2754
2754
  1. Weight of saturated and surface dry Sample (C) (g)
990
992
  1. Weight of oven dry sample (D) (g)
962
963
  1. Specific gravity = D/( C-(A-B))
2.83
2.85
  1. Water absorption percentage dry weight = [(C-D)/D] x 100 (%)
2.91
3.01
Average Specific gravity
2.84
Average water absorption
2.96


3.2 Concrete Mix Calculation
  1. TARGET STRENGTH FOR MIX PROPORTIONING
f'ck = fck + 1.65 s
where
f'ck = target average compressive strength at 28 days,
fck = characteristic compressive strength at 28 days, and
s = standard deviation.
From IS 10262:2009 Table I, standard deviation, s =5 N/mm2 for M30
Therefore, target strength =30 + 1.65 x 5 =38.25 N/mm2
  1. SELECTION OF WATER-CEMENT RATIO
From Table 5 of IS 456:2000, maximum water-cement ratio = 0.45
Based on experience, adopt water-cement ratio as 0.40
0.40 < 0.45, hence O.K.
  1. SELECTION OF WATER CONTENT
From IS 456:2000 Table 2, maximum water content for
20mm aggregate =186 liter (for 100 to 90 mm slump range)
Estimated water content = 186+ (6/100)x 186 = 197 liter
As super plasticizer is used, the water content can be reduced up 20 percent.
Based on trials with super plasticizer water content reduction of 20 percent has been achieved. Hence, the arrived water content
= 197 x 0.8 = 157.6 liter
  1. CALCULATION OF CEMENT CONTENT
Water-cement ratio = 0.40
Cement content = 157.6/0.40 = 394 kg/m3
From Table 5 of IS 456:2000,  minimum cement
content for severe exposure condition = 320 kg/m3
394 kg/m3  > 320 kg/ m3, hence O.K.
  1. PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT
When we increase coarse aggregate by 2 %
Water content should be lowered by 0.1 %
Coarse aggregate = 60% = 0.6
Fine aggregate = 40% = 0.4
Increase in volume of coarse aggregate by 2 %


Therefore % increase of Coarse aggregate = 0.6 + 0.02 = 0.62
For pumpable concrete the volume of coarse aggregate should be reduced by 10% volume of aggregate.
Therefore Coarse aggregate = 0.62x0.9 = 0.56
Therefore fine aggregate= 1-0.56 = 0.44
  1. MIX CALCULATIONS
The mix calculations per unit volume of concrete shall be as follows:
a)Volume of concrete = 1 m3
b) Volume of cement = (Mass of cement/sp.gravity of cement) x 1/1000
                                  = (394/3.14) x 1/1000
                                  = 0.1254 m3
  
c) Volume of water = (Mass of water/sp.gravity of water) x 1/1000
                               = (157.6/1) x 1/1000
                               = 0.1576 m3    
d) Volume of chemical admixture = (Mass of admixture/sp.gravity) x 1/1000
(Chemsons super plasticizer) (@ 1.2% by mass of cementitious material)
                       Mass of admixture  = 4.728 kg
                    Volume of admixture = (4.728/1.281) x 1/1000
                                                       = 0.0037 m3
e) Volume of all in aggregate = [a-(b+c+d)]
                                               = [1-(0.1254+0.1576+0.0037)]
                                               = 0.7133 m3
f) Mass of coarse aggregate = e x Vol of  CA x sp.gravity of CA x 1000
                                            = 0.7133 x (0.56x2.84) x 1000
                                            = 1134.43 kg
g) Mass of fine aggregate = e x Vol of FA x sp.gravity of FA x 1000
                                         = 0.7133 x (0.44x2.69) x 1000
                                         = 844.26 kg
  1. MIX CALCULATED
  • Volume of Concrete = 1 m3
  • Mass of Cement = 394 kg/m3
  • Mass of Water = 157.6 kg/m3
  • Mass of Fine aggregate = 844.26 kg/m3
  • Mass of Coarse aggregate = 1134.43 kg/m3
  • Chemical admixture = 4.728 kg/m3
  • Water-cement ratio = 0.40
Mix proportion,
1 : 2.14 : 2.88 (C : FA : CA)
3.3 Batching
Weight batching method is adopted for batching
  • No. of cubes casted = 6
  • Volume of One cube = 0.15x0.15x0.15 = 0.003375 m3
  • Volume of Six cubes = 0.003375x6 = 0.02025 m3
  • Increased volume of concrete by 52% = 0.03078 m3
  • Quantity of cement = 12.12 kg
  • Quantity of Coarse Aggregate = 34.91 kg
  • Quantity of Fine aggregate = 25.98 kg
  • Quantity of water = 4.85 kg
  • Quantity of Admixture (Super plasticizer) = 0.1455 kg
3.4 Concrete Compressive Strength Test Results
At 7 days
Cube Size (mm):150x150x150             Date of Casting:20/09/2016
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
7
150
150
22500
8.261
590
26.22
2.
7
150
150
22500
8.242
600
26.67
3.
7
150
150
22500
8.294
580
25.78

Average Value
26.23
Grade of Concrete:M30                        Date of testing:27/09/2016
At 28 days
Cube Size (mm):150x150x150             Date of Casting:20/09/2016
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
28
150
150
22500
8.288
840
37.33
2.
28
150
150
22500
8.309
830
36.89
3.
28
150
150
22500
8.206
840
37.33

Average Value
37.18
Grade of Concrete:M30                        Date of testing:18/10/2016
Chapter 4
Waste Materials
4.1 Material used as partial replacement of cement, sand and coarse aggregates
Ingredients Of Concrete
Replacement  Of  Waste Materials
1. Cement - Cement is the binding material, ordinary portland cement is the Standard cement used for many purpose.


2. Fine Aggregate - River Sand is used as Fine aggregate in construction work.




3. Coarse Aggregate - Aggregates are inert granular particles such as Gravel or Crushed stone.





2. Ceramic Powder- Ceramic tiles waste powder obtained from local ceramic tile Manufacturing unit will be used as a partial replacement of sand in some % in all mix composition.

3. Demolished waste- The waste of  which is obtained from the Demolished structure is crushed into the Required sizes of Aggregates as a partial replacement of Course aggregates in some % in all mix composition.
    1. Ceramic Waste
The principle waste coming into the ceramic industry is the ceramic powder, specifically in the powder forms. Ceramic wastes are generated as a waste during the process of dressing and polishing. It is estimated that 15 to 30% waste are produced of total raw material used, and although a portion of this waste may be utilized on-site, such as for excavation pit refill, The disposals of these waste materials acquire large land areas and remain scattered all around, spoiling the aesthetic of the entire region. It is very difficult to find a use of ceramic waste produced.
Ceramic waste can be used in concrete to improve its strength and other durability factors. Ceramic waste can be used as a partial replacement of cement or as a partial replacement of fine aggregate sand as a supplementary addition to achieve different properties of concrete.
Ceramic waste fragments obtained from local industry were crushed and sieved to produce fine aggregates.
      1. Crushing process
The ceramic chip were crushed manually with the use of rammer and after crushing the ceramic waste were passed from 4.75mm IS sieve and retained on 300u (micron) IS sieve.
The particle which is passed from 4.75mm IS sieve and retained on 300u (micron) IS sieve were used as Fine aggregate in replacement of River sand.
The photo of initial stage ceramic chip and crushed ceramic is as shown below,



C:\Users\basit chohan\Desktop\20170315_130527.jpg
Initial stage of Ceramic chips
C:\Users\basit chohan\Desktop\20170315_112308.jpg
Crushed Ceramic
    1. Demolition Waste
Demolition waste is waste debris from destruction of a building. The debris varies from insulation, electrical wiring, rebar, wood, concrete, and bricks. It also may contain lead, asbestos or different hazardous materials.
Certain components of demolition waste such as plasterboard are hazardous once landfilled. Plasterboard is broken down in landfill conditions releasing hydrogen sulfide, a toxic gas.
There is the potential to recycle many elements of demolition waste. Often roll-off containers are used to transport the waste. Rubble can be crushed and reused in construction projects. Waste wood can also be recovered and recycled.
Government or local authorities often make rules about how much waste should be sorted before it is hauled away to landfills or other waste treatment facilities. Some hazardous materials may not be moved, or demolition begun, before the authorities have ascertained that safety guidelines and restrictions have been followed. Among their concerns would be the proper handling and disposal of such toxic elements as lead, asbestos or radioactive materials.
4.3.1 Crushing process
The demolished waste were crushed manually with the use of rammer and after crushing the demolished waste were passed from 20mm IS sieve and retained on 10mm IS sieve.
The particle which is passed from 20mm IS sieve and retained on 10mm IS sieve were used as Coarse aggregate in replacement of Crushed Stone.
The photo of initial stage Demolished waste and crushed demolished waste is as shown below,
C:\Users\basit chohan\Desktop\20170315_130736.jpg
Demolished waste
C:\Users\basit chohan\Desktop\20170315_111827.jpg
Crushed Demolished waste
4.4 Tests on Waste Materials
Similar test to be performed on respective waste materials,
4.4.1 Tests on Ceramic Waste;
  • Specific Gravity test
  • Water Absorption test
Determination of specific gravity and water absorption on fine aggregates
Apparatus: 1. Weighing balance of capacity not less than 5kg
                  2. Thermostatically controlled oven
                  3. Pycnometer, Enamel tray, Air tight container, Glass
                      rod, Wash bottle, Filter paper and Funnel.
Procedure:
  1. Take approximately 2kg of fine aggregate in saturated surface dry condition and weigh it. Take 500g of this sample for test and record it in observation sheet as (C).
  2. This sample is then place in the pycnometer. Fill the pycnometer partly with distilled water. Entrapped air is eliminated by stirring the contents of the pycnometer with glass rod.
  3. Then the pycnometer is completely filled distill water. The hole of the apex of the cone is now covered with finger and assembly is shaken to remove any Entrapped air. Fill the cone of pycnometer with distill water using wash bottle. Now its weight recorded as (A)
  4. Empty the content of pycnometer in enamel tray and refill the pycnometer with distill water to the same level as before using the same procedure. Weigh the entire assembly and record this reading as (B).
  5. The water from the sample in the enamel tray is then removed by decantation. This water collected after decantation is then filtered and the material retained on the filter paper is returned to the sample after drawing.
  6. The sample is then placed in the oven at a temperature of 100’C for 24hours. After 24hours the sample is taken out from the oven.
  7. The sample should then be cooled in the air tight container. Note down the oven dried weight of the sample and record the reading as (D).
Conclusion: Specific gravity can be defined as the ratio of the weight of aggregate in air to the weight of equal volume of water displaced by saturated surface dry aggregate.
Specific gravity of fine aggregate = D/(C-(A-B))
Water Absorption of fine aggregate = [(C-D)/D] x 100




4.4.1.1 Observation table
DESCRIPTION
SAMPLE NO.
TEST 1
  1. Weight of sample taken (g)
2000
  1. Weight of saturated and surface dry aggregates (C) (g)

500
  1. Weight of pycnometer + sample + water (A) (g)
1796
  1. Weight of pycnometer + water (B) (g)
1506
  1. Weight of oven dry sample (D) (g)
494
  1. Specific gravity = D/( C-(A-B))
2.35
  1. Water absorption percentage dry weight = [(C-D)/D] x 100 (%)
1.21
   










4.4.2 Tests on Demolished waste
  • Specific gravity test
  • Water absorption test
Determination of specific gravity and water absorption on Coarse aggregates
Apparatus: 1. Weighing balance of capacity not less than 5kg
                  2. Thermostatically Controlled oven
                  3. Glass vessel of sufficient capacity, Air-tight container
                  4. 10mm IS sieve


Procedure:
  1. Take approximately 1kg sample of coarse aggregate in its natural state (The quantity of sample to be taken depends upon the size of the aggregate)
  2. Now sieve the sample to 10mm IS sieve to remove the finer particles. Placed the sieved sample in the glass vessel and partly fill the vessel with distill water. Keep the aggregate immersed for 24hours so that they are completely saturated.
  3. At the end of the soaking period the vessel is then over filled with water. Cover this vessel with plane glass disc to ensure that no air is trap in the vessel. The vessel is then dried from the outside. Now take the weight of this assembly and note this reading as (A)
  4. The vessel is now empty and the aggregate allowed to drain out. The aggregates are then placed on a dried cloth, till its comes in completely surface dry condition.
  5. Refill the vessel with distilled water and slide the glass disc in position as before to ensure that no entrapped air is present in the vessel. Weigh the entire assembly and record the reading as (B)
  6. After the aggregate appeared to be in saturated surface dry condition their weight is taken as (C).
  7. Now the aggregates are placed in enamel tray to be kept in oven at a temperature of 100’C for 24hours. After 24hours the aggregates are taken out from the oven and cooled in an air tight container. Note down the oven dried weight of aggregate as (D)
Conclusion; Specific gravity cane be defined as the ratio of the weight of aggregate in air to the weight of equal volume of water displaced by saturated surface dry aggregate.
Specific gravity of Coarse aggregate = D/(C-(A-B))
Water Absorption of Coarse aggregate = [(C-D)/D] x 100






4.4.2.1 Observation table
DESCRIPTION
SAMPLE NO.
 TEST 1
  1. Weight of sample taken (g)
1000
  1. Weight of vessel + sample + water (A) (g)
1858
  1. Weight of vessel + water (B) (g)
1228
  1. Weight of saturated and surface dry Sample (C) (g)
1034
  1. Weight of oven dry sample (D) (g)
976
  1. Specific gravity = D/( C-(A-B))
2.42
  1. Water absorption percentage dry weight = [(C-D)/D] x 100 (%)
5.94











4.5 Comparison of Tests Results
Test concluded on
materials
Test results of Normal
Concrete material
Test results of Waste
material
Average Test Results
Specific Gravity



Fine Aggregate
2.69
2.35
2.52
Coarse Aggregate
2.84
2.42
2.63
Water Absorption



Fine Aggregate
3.31
1.21
2.26
Coarse Aggregate
2.96
5.94
4.45
Conclusion: On the basis of average material test result, mix design of waste replacement is calculated.
4.6 Mix Design with use of Waste Materials
Data for mix design,
  • Grade of Concrete: M 30
  • Target Strength: 38.25 N/mm2
  • Water Cement Ratio: 0.4
  • Maximum Size of Aggregate: 20 mm
  • Value of slump: 90 mm
  • Zone of Fine Aggregate: 2
  • Is concrete Pumpable: YES
Admixture specification,
  • % of Super Plasticizer: 1.2 %
  • % of water Reduction: 20.0 %
  • Specific gravity of admixture: 1.281
Specification of Materials,
  • Specific gravity of Cement: 3.14
  • Specific gravity of coarse Aggregate: 2.63
  • Specific gravity of fine Aggregate: 2.52
  • Water absorption of Coarse Aggregate: 4.45 %
  • Water absorption of Fine Aggregate: 2.26 %
  • Free Moisture of Coarse Aggregate: 0.0 %
  • Free Moisture of Fine Aggregate: 2.0 %
Mix calculated,
  • Quantity of Mix: 1 m3
  • Mass of Cement: 392.5 kg
  • Mass of Water Content: 207.179 kg
  • Mass of Fine Aggregate: 763.856 kg
  • Mass of Coarse Aggregate: 1082.988 kg
  • Mass of Chemical Admixture: 4.71 kg
Mix proportion,
1 : 1.94 : 2.75 (C : FA : CA)
Chapter 5
Replacement of Waste Material in Concrete
5.1 Trial 1: 20% of waste is replacing by Fine aggregate and Coarse aggregate in concrete in mix.
5.1.1 Batching
Weight Batching:
  • Mix proportion = 1:1.94:2.75
  • No. of cubes casted = 6
  • Volume of One cube = 0.15x0.15x0.15 = 0.003375 m3
  • Volume of Six cubes = 0.003375x6 = 0.02025 m3
  • Increased volume of concrete by 52% = 0.03078 m3
  • Quantity of cement = 12.08 kg
  • Quantity of Coarse Aggregate = 33.33 kg
Quantity of Crushed Stone = 26.66 kg
Quantity of Demolished waste = 6.67 kg
  • Quantity of Fine aggregate = 23.51 kg
Quantity of River sand = 18.8 kg
Quantity of Ceramic waste = 4.71 kg
  • Quantity of water = 6.38 kg
  • Quantity of Admixture (Super plasticizer) = 0.145 kg
5.1.2 Compressive Strength Test Results
At 7 days
Cube Size (mm):150x150x150             Date of Casting:25/01/2017
Grade of Concrete:M30                        Date of testing:01/02/2017
Percentage replacement of Waste: 20%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
7
150
150
22500
8.241
540
24
2.
7
150
150
22500
8.215
570
25.33
3.
7
150
150
22500
8.232
560
24.89

Average Value
24.74
At 28 days
Cube Size (mm):150x150x150             Date of Casting:25/01/2017
Grade of Concrete:M30                        Date of testing:22/02/2017
Percentage replacement of Waste: 20%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
28
150
150
22500
8.202
810
36
2.
28
150
150
22500
8.226
820
36.44
3.
28
150
150
22500
8.173
800
35.56

Average Value
36
5.2 Trial 2: 30% of waste is replacing by Fine aggregate and Coarse aggregate in concrete in mix.
5.2.1 Batching
Weight Batching:
  • Mix proportion = 1:1.94:2.75
  • No. of cubes casted = 6
  • Volume of One cube = 0.15x0.15x0.15 = 0.003375 m3
  • Volume of Six cubes = 0.003375x6 = 0.02025 m3
  • Increased volume of concrete by 52% = 0.03078 m3
  • Quantity of cement = 12.08 kg
  • Quantity of Coarse Aggregate = 33.33 kg
Quantity of Crushed Stone = 23.33 kg
Quantity of Demolished waste = 9.99 kg
  • Quantity of Fine aggregate = 23.51 kg
Quantity of River sand = 16.46 kg
Quantity of Ceramic waste = 7.05 kg
  • Quantity of water = 6.38 kg
  • Quantity of Admixture (Super plasticizer) = 0.145 kg







5.2.2 Compressive Strength Test Results
At 7 days
Cube Size (mm):150x150x150             Date of Casting:25/01/2017
Grade of Concrete:M30                        Date of testing:01/02/2017
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
7
150
150
22500
8.217
540
24
2.
7
150
150
22500
8.108
540
24
3.
7
150
150
22500
8.189
550
24.44

Average Value
24.14
Percentage replacement of Waste: 30%
At 28 days
Cube Size (mm):150x150x150             Date of Casting:25/01/2017
Grade of Concrete:M30                        Date of testing:22/02/2017
Percentage replacement of Waste: 30%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
28
150
150
22500
8.100
790
35.11
2.
28
150
150
22500
8.147
780
34.67
3.
28
150
150
22500
8.086
780
34.67

Average Value
34.81
5.3 Trial 3: 40% of waste is replacing by Fine aggregate and Coarse aggregate in concrete in mix.
5.3.1 Batching
Weight Batching:
  • Mix proportion = 1:1.94:2.75
  • No. of cubes casted = 6
  • Volume of One cube = 0.15x0.15x0.15 = 0.003375 m3
  • Volume of Six cubes = 0.003375x6 = 0.02025 m3
  • Increased volume of concrete by 52% = 0.03078 m3
  • Quantity of cement = 12.08 kg
  • Quantity of Coarse Aggregate = 33.33 kg
Quantity of Crushed Stone = 19.998 kg
Quantity of Demolished waste = 13.332 kg
  • Quantity of Fine aggregate = 23.51 kg
Quantity of River sand = 14.11 kg
Quantity of Ceramic waste = 9.4 kg
  • Quantity of water = 6.38 kg
  • Quantity of Admixture (Super plasticizer) = 0.145 kg






5.3.2 Compressive Strength Test Results
At 7 days
Cube Size (mm):150x150x150             Date of Casting:02/02/2017
Grade of Concrete:M30                        Date of testing:09/02/2017
Percentage replacement of Waste: 40%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
7
150
150
22500
8.163
530
23.56
2.
7
150
150
22500
8.180
530
23.56
3.
7
150
150
22500
8.205
510
22.67

Average Value
23.26
At 28 days
Cube Size (mm):150x150x150             Date of Casting:02/02/2017
Grade of Concrete:M30                        Date of testing:02/03/2017
Percentage replacement of Waste: 40%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
28
150
150
22500
8.221
770
34.22
2.
28
150
150
22500
8.210
760
33.78
3.
28
150
150
22500
8.199
770
34.22

Average Value
34.07
5.4 Trial 4: 50% of waste is replacing by Fine aggregate and Coarse aggregate in concrete in mix.
5.4.1 Batching
Weight Batching:
  • Mix proportion = 1:1.94:2.75
  • No. of cubes casted = 6
  • Volume of One cube = 0.15x0.15x0.15 = 0.003375 m3
  • Volume of Six cubes = 0.003375x6 = 0.02025 m3
  • Increased volume of concrete by 52% = 0.03078 m3
  • Quantity of cement = 12.08 kg
  • Quantity of Coarse Aggregate = 33.33 kg
Quantity of Crushed Stone = 16.665 kg
Quantity of Demolished waste = 16.665 kg
  • Quantity of Fine aggregate = 23.51 kg
Quantity of River sand = 11.755 kg
Quantity of Ceramic waste = 11.755 kg
  • Quantity of water = 6.38 kg
  • Quantity of Admixture (Super plasticizer) = 0.145 kg







5.4.2 Compressive Strength Test Results
At 7 days
Cube Size (mm):150x150x150             Date of Casting:02/02/2017
Grade of Concrete:M30                        Date of testing:09/02/2017
Percentage replacement of Waste: 50%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
7
150
150
22500
8.174
490
21.77
2.
7
150
150
22500
8.143
500
22.22
3.
7
150
150
22500
8.190
490
21.77

Average Value
21.92
At 28 days
Cube Size (mm):150x150x150             Date of Casting:02/02/2017
Grade of Concrete:M30                        Date of testing:02/03/2017
Percentage replacement of Waste: 50%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
28
150
150
22500
8.182
740
32.89
2.
28
150
150
22500
8.129
730
32.44
3.
28
150
150
22500
8.150
750
33.33

Average Value
32.88


5.5 Trial 5: 60% of waste is replacing by Fine aggregate and Coarse aggregate in concrete in mix.
5.5.1 Batching
Weight Batching:
  • Mix proportion = 1:1.94:2.75
  • No. of cubes casted = 6
  • Volume of One cube = 0.15x0.15x0.15 = 0.003375 m3
  • Volume of Six cubes = 0.003375x6 = 0.02025 m3
  • Increased volume of concrete by 52% = 0.03078 m3
  • Quantity of cement = 12.08 kg
  • Quantity of Coarse Aggregate = 33.33 kg
Quantity of Crushed Stone = 13.332 kg
Quantity of Demolished waste = 19.998 kg
  • Quantity of Fine aggregate = 23.51 kg
Quantity of River sand = 9.4 kg
Quantity of Ceramic waste = 14.11 kg
  • Quantity of water = 6.38 kg
  • Quantity of Admixture (Super plasticizer) = 0.145 kg







5.5.2 Compressive Strength Test Results
At 7 days
Cube Size (mm):150x150x150             Date of Casting:02/02/2017
Grade of Concrete:M30                        Date of testing:09/02/2017
Percentage replacement of Waste: 60%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
7
150
150
22500
8.051
450
20
2.
7
150
150
22500
8.113
450
20
3.
7
150
150
22500
8.096
460
20.44

Average Value
20.14
At 28 days
Cube Size (mm):150x150x150             Date of Casting:02/02/2017
Grade of Concrete:M30                        Date of testing:02/03/2017
Percentage replacement of Waste: 60%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
28
150
150
22500
8.087
670
29.77
2.
28
150
150
22500
8.105
670
29.77
3.
28
150
150
22500
8.039
680
30.22

Average Value
29.92


5.6 Trial 6: 55% of waste is replacing by Fine aggregate and Coarse aggregate in concrete in mix.
5.6.1 Batching
Weight Batching:
  • Mix proportion = 1:1.94:2.75
  • No. of cubes casted = 6
  • Volume of One cube = 0.15x0.15x0.15 = 0.003375 m3
  • Volume of Six cubes = 0.003375x6 = 0.02025 m3
  • Increased volume of concrete by 52% = 0.03078 m3
  • Quantity of cement = 12.08 kg
  • Quantity of Coarse Aggregate = 33.33 kg
Quantity of Crushed Stone = 14.998 kg
Quantity of Demolished waste = 18.332 kg
  • Quantity of Fine aggregate = 23.51 kg
Quantity of River sand = 10.58 kg
Quantity of Ceramic waste = 12.93 kg
  • Quantity of water = 6.38 kg
  • Quantity of Admixture (Super plasticizer) = 0.145 kg







5.6.2 Compressive Strength Test Results
At 7 days
Cube Size (mm):150x150x150             Date of Casting:02/03/2017
Grade of Concrete:M30                        Date of testing:09/03/2017
Percentage replacement of Waste: 55%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
7
150
150
22500
8.141
460
20.44
2.
7
150
150
22500
8.104
470
20.89
3.
7
150
150
22500
8.122
470
20.89

Average Value
20.74
At 28 days
Cube Size (mm):150x150x150             Date of Casting:02/03/2017
Grade of Concrete:M30                        Date of testing:29/03/2017
Percentage replacement of Waste: 55%
S. No.
Age of specimen (Days)
Dimension of specimen (mm)
Cross Sectional area (mm2)
Weight (kg)
Maximum load (KN)
Compressive strength (N/mm2)
Length
Width
1.
28
150
150
22500
8.127
680
30.22
2.
28
150
150
22500
8.134
700
31.11
3.
28
150
150
22500
8.148
680
30.22

Average Value
30.51
5.7 Comparison of average compression strength at 28 days;
Trials
Average Compressive Strength at 28 days (N/mm2)
Trial 1 (20% replacement)
36
Trial 2 (30% replacement)
35.55
Trial 3 (40% replacement)
34.07
Trial 4 (50% replacement)
32.88
Trial 5 (60% replacement)
29.92
Trial 6 (55% replacement)
30.51
Optimum replacement level of fine aggregate with ceramic waste and coarse aggregate with demolition waste is 50%.




Chapter 6
Cost Estimation and Comparison
Cost estimation is done to know how much amount for per M3 concrete work on construction project can be save when replacing 50% of Ceramic waste with fine aggregate and demolished waste with coarse aggregate. Estimation is done on the basis of latest market selling rates as on March 2017. Estimation is calculated only for fine aggregate and coarse aggregate required as per mix proportion in 1m3 concrete, as only these ingredients are replaced by waste materials. Following are the rate of material, per brace;
Material
Rate per Brass (₹)
Rate per m3 (₹)
River sand
6400
2261.5
Crushed sand
2500
883.4
Crushed stone (CA)
1600
565.4
Ceramic waste
1250
441.7
Demolished waste
1200
424.1
Above rates are excluding transportation charge*
6.1 Rate of waste materials
Rate of Ceramic waste and demolished waste are calculated as follows;
  • Rate of ceramic chip without crushed = ₹350/brass
  • Rate of demolished waste without crushed = ₹200/brass
  • Primary crusher (Jaw crusher) charge = ₹1000/brass
  • Secondary crusher (Roll crusher) charge = ₹900/brass
  • Rate of ceramic chip = Without crushed rate + Secondary crusher charge
                                 = 350 + 900
                                             = ₹1250/brass
  • Rate of demolished waste = without crushed rate + Primary crusher charge
                                               = 200 + 1000
                                               = ₹1200/brass
6.2 Rate of FA and CA in 1m3 concrete mix (1:1.94:2.75)
  1. Dry volume = 1m3
  2. Increased 52% of dry volume = 1.52 x 1
= 1.52m3
  1. Volume of sand = [1.52/(1+1.94+2.75)]x1.94
 = 0.518m3
  1. Volume of coarse aggregate = [1.52/(1+1.94+2.75)]x2.75
         =0.735m3
S. No.
Description
Quantity
Unit
Rate(₹)
Amount(₹)
1.
Sand
0.518
M3
2261.5
1171.5
2.
Coarse aggregate
0.735
M3
565.4
415.5

Total = ₹1587/-




6.3 Rate with Replacement of 50% Waste in FA and CA
  1. Volume of FA = 0.518m3
Therefore, Volume of Sand = 50% of 0.518m3
          = 0.259m3
Volume of Ceramic waste = 50% of 0.518m3
        = 0.259m3
  1. Volume of CA = 0.735m3
Therefore, Volume of Crushed sand = 50% of 0.735m3
         = 0.3675m3
Volume of Demolished waste = 50% of 0.735m3
= 0.3675m3


S. No.
Description
Quantity
Unit
Rate(₹)
Amount(₹)
1.
Sand
0.259
M3
2261.5
585.7
2.
Ceramic waste
0.259
M3
441.7
114.4
3.
Crushed stone
0.3675
M3
565.4
207.8
4.
Demolished waste
0.3675
M3
424.1
155.9

Total = ₹1063.8
6.4 Cost Comparison
The total cost of fine aggregate and coarse aggregate in 1m3 concrete mix = ₹1587/-
The total cost of fine aggregate and coarse aggregate with replacement of 50% of ceramic waste and demolished waste respectively = ₹1063.8/- ~ ₹1064/-
Amount saved after replacement of 50% waste = 1587 – 1064
    = ₹523/-
This shows that in 1m3 concrete ₹523/- saved in 50% replacement of waste with fine aggregate and coarse aggregate without disturbing the required compressive strength of concrete.









Chapter 7
Objectives
  • For sustainable development of structural engineering.
  • To reduce or utilize the waste generated from structures.
  • To use various waste materials in constructions units.
  • To find the alternative of basic materials which are used in construction from past many years.
  • Research efforts have been done to match society’s need for safe and economic disposal of waste materials.
  • The use of waste materials saves natural resources and dumping spaces, and helps to maintain a clean environment.
  • Construction waste recycle plants are now installed in various countries but they are partly solution to the waste problems.
Chapter 8
Conclusion
  • It is observed that, compressive strength of concrete made using ceramic waste and Demolition waste increased with replacement level (up to 50%).
  • The Compressive Strength of M30 grade Concrete does not effect when the replacement of Ceramic waste and Demolition waste up to 50% replaces by weight or volume of Fine aggregate and Coarse aggregate. Further replacement of Fine aggregate with Ceramic waste and Coarse aggregate with Demolition waste decreases the Compressive Strength.
  • Optimum replacement level of fine aggregate with ceramic waste and coarse aggregate with demolition waste is 50%.
  • In 1m3 concrete ₹523/- saved in 50% replacement of waste with fine aggregate and coarse aggregate without disturbing the required compressive strength of concrete.
  • Ceramic waste can effectively be used as alternative & supplementary materials in concrete.
  • Demolished aggregate posses relatively lower bulk crushing, density and impact standards and higher water absorption as compared to natural aggregate.
  • The compressive strength of demolished aggregate concrete is relatively lower up to 15% than natural aggregate concrete.
  • It is the possible alternative solution of safe disposal of Ceramic waste Demolition waste.
  • It is identified that all wastes used here can be disposed by using them as Construction materials.
  • Waste and recycling management plans should be developed in order to sustain environmental, economic and social development of nation.
  • The specific gravity of all these waste materials are quite smaller. Vast potential of saving the natural beds of stones and boulders which are currently used as main source of aggregates can be reduces significantly.
  • Light weight constructions units can be made by using these wastes.
  • It also reduces the cost of construction when used in bulk.














References



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1 comment:

  1. Mastermix31 January 2019 at 16:49

    Thanks for sharing such great information with us. I hope you will share some more info about CONCRETE MIX . Please keep sharing.

    Concrete Mix NZ

    ReplyDelete

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