DP

EVALUATION OF STRENGTH OF RCA USING TBC WITH FLY ASH AND GGBFS
CHAPTER 1
1.1
INRODUCTION
GENERAL
Construction activities in India are growing very fast as the construction and
demolition wastes are also produced in very large amount. As per survey, about millions
ton of construction and demolition wastes are generated worldwide. In India, construction
industry generates about 10 to 20 million tons of wastes every year and which will
become more and more every year. So, it becomes a severe problem because it is
hazardous to the surrounding environment and it can damage the nature cycle. It is
important to recycle such wastes to protect the nature and for reuse the material. By
which, the demand of natural material is minimize and the conservation of natural
resources is very important factor. By the reuse of wastes, the disposition land also
minimized.
The recycled aggregates obtained from the demolition of roads, buildings,
masonry walls, abutments, dams, piers, sub base foundation etc. In this study, without
changing the strength and other properties the use of recycled coarse aggregate in
concrete with the replacement of natural coarse aggregate.
It will be known that the concrete industry largely gives its share to the
environment impoverishment. Aggregates are the bigger components of concrete and
have a effective behavior on the engineering properties of final product. Natural
resources are very damaged by its maximum use due to increasing the demand of
structures. The use of such waste Construction and demolition (C & D) as alternative
aggregates for new concrete production gains priority to preserve natural resources and
reduces the need for disposal. These wastes are normally composed from rubbles,
concrete , tiles, bricks, sand, timber, dust and plastics, cardboard, metals and paper. From
all such waste concrete, rubble contributes more proportion.
DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY
Major Component of Construction Waste

12%
3%
20%
Concrete
Brick & Plaster
8%
Soil
Wood
12%
Plastic
10%
35%
Steel
Others
Figure 1.1 Percentage of C & D waste

The maximum use of recycled materials among components of concrete is a very
remarkable approach towards sustainable construction. Aggregates results almost 80% of
concrete quantity, i.e. their replacement with recycled materials can really help to
transform ordinary concrete into an effective and sustainable material. So, the strength is
directly connected to the quality of recycled aggregate in Recycled Aggregate Concrete
(RAC).
1.2
Usefulness of Cementitious Material

There was estimate that production of cement was about 3 billion tons in 2009
and the extended production of cement is about 5.9 billion tons by 2020. Cement industry
is one of the major cautions of pollution and it takes a lot of energy in the production and
returns major quantities of carbon dioxide. As per a survey report 7% of worlds carbon
dioxide emission is only given by cement industry. Manufacture of Ordinary Portland
Cement (OPC) consumes natural resources i.e. limestone and there is a very need to
economize the use of cement. The use of various cementitious materials in the concrete
mixtures has been growing in the world. These materials are byproducts of other
industrial processes and their judicial use is not desirable only for the natural
environment and energy conservation point. Although, they may be used as partial
replacement or in addition to Portland cement in concrete which depends on the
properties of the materials and the expected effect on concrete.
1.3
Theory of Ternary Blended Concrete

The replacement of cement will do by using GGBFS (by product of Iron plant)
and fly ash (byproduct of thermal power plant), which are cementitious materials. Both
products are ecofriendly. The combination of GGBFS and fly ash with cement cancelled
ternary blended concrete (TBC).
1.4
Quality of Recycled Aggregate (RA)

After current year the consumption of natural aggregates in the whole world are in
the criteria of 48.3 billion metric tons. The demolition of relatively young structures (for
approximately 15 years old or less), because their working features, does not fulfill any
longer new social and technical requirements. This kind of waste represents a better
selection for recycled high-grade concrete in new concrete structures. By this method,
made cement concrete can be broken during demolition and can be crushed into a coarse
granular segments that can be used as a substitute for crushed virgin rock. The adhered
mortar quality and its amount affects the physical properties of recycled aggregates. As it
especially depends on Adhered mortar ,which is a porous material and its porosity
depends upon the water/cement ratio (w/c) and mix design that originally adopted. The
quality of such kind of concrete is inversely proportional to the size of the aggregate.
Because of the adhered mortar and recycled aggregate concrete have a higher water
absorption and lower density, compared to natural aggregates.
1.5
Application of Recycled Aggregate Concrete in TBC

TBCs behavior with the combination of recycled coarse aggregate with the
percentage variation to obtain the desired strength. Such type of concrete is economical
and also increase in the demand of eco-friendly products and reuse of material waste. In
our country, the use of such type of concrete is in very small extent but environmental
point of view it will useful in every places.
CHAPTER 2
2.1
LITERATURE REVIEW
Description of Literature Survey Papers
1. Author: A.N.Dabhade, Dr.S.R.Choudhari, Dr.A.R.Gajbhiye

Objectives of study: At present, Reuse of waste concrete aggregate is easily available.
Conventional Coarse aggregate is changed with recycled aggregate and conventional.
Here, No. of test conduct like water absorption, workability test, impact value test,
Fineness modulus, compressive test, split tensile test, crushing value test, and bulk
density.
Methodology: There were concrete mixes no. of batches consists of every 20%
increment of recycled aggregate replacement from 0% to 100%.0.5,0.6 and 0.7
water/cement ratio are examined. The amount of recycled aggregate increased which
reduce workability of concrete.
Outcome of study: From the research, 100% RCA replace with NA can possible. And
effective ratio of RCA can be 40%.By using 40% of RA for making M20 grade concrete
of 0.5 w/c ratio and 20% replacement is efficient for 0.6 and 0.7 w/c ratio.
The strength of concrete depend upon percentage of RA when percentage
increases than the strength of concrete will decrease. More water use as admixture
required for using RA. It also help to reduce damage of our natural landscape.
The compressive strength of recycled concrete depend upon w/c ratio. At lower
w/c ratios, the compressive strength of recycled concrete is much lower than that of
normal concrete and also higher w/c ratio give similar strength of conventional concrete.
2. Author: Praveen Mathew, Jeevan Jacob, Leni Stephen, Thomas Paul

Objectives of study: In this study, Natural aggregate replaced by recycled aggrades, after
is examined behavior concrete for its structural property. Compressive strength, splitting
tensile strength, flexural strength and modulus of elasticity of recycled aggregate concrete
(RAC) such as were examined. This gives a correct perception of RAC comparison with
the natural aggregate concrete (NAC) which used as a structural material.
Methodology: The mix ratio was done as per the Indian standards. The Portland
Pozzolana cement is used with specific gravity 2.6.The mechanical properties of
conventional concrete and RAC and concluded that the RAC has a compressive strength
of at least 76% and modulus of elasticity from 60% to 100% of the control mix. The
strength of recycled aggregate concrete is affect by the strength of original concrete,
percentage of coarse aggregate in original concrete and the ratio of top size of aggregate
in original concrete to that of recycled aggregate. After examined that full replacement of
natural aggregates with recycle coarse aggregate, a part replacement that offers a better
structural property in comparison with the conventional concrete. Here no. of
replacements were selected i.e. 0% (NAC), 20% (RAC 20), 30% (RAC 30) and 40%
(RAC 40) to behavior the various tests on its property.
Outcome of study:
Workability and modulus of elasticity will be decreased and also
mechanical properties will be increased by using the w/c ratio 0.45 and increment the
percentage of RAC. Various properties of RAC were comparing with NAC. At 30%
replacement of RAC obtained maximum strength. In this research, at 40% replacement
obtained maximum strength.
3. Author: Prof. D.K. Bhagat, J.P. Parmar, Y.R. Tank, D.H. Gadhiya, J.S. Goyani
Objectives of study: Material properties for concrete of M25 grade made with various
percentages of recycled coarse aggregates with replacement percentage of 0, 20, 40 and
60. The basic properties like workability and compressive strength etc. observe with
NAC with RCA. The goal of this study is to develop the economical and sustainable
concrete by using the concrete waste available on the site.
Methodology: Waste was collecting the near gitanjali cinema to Surat. After material
was crush by hammer to separate the aggregate and to reduce their sizes in small fraction.
As per Indian Standard Codes various tests were conducted on separated aggregate and
also results were compared to Natural aggregate. Concrete basic properties like
compressive strength, workability test was evaluated on various combinations (0%, 20%,
40%, 60%) of RCA with NA. M25 grade mix was designed as per IS 10252:2009.
Outcome of study: The water absorption of RCA concrete increased with increase in
replacement of NCA with RCA because od adhering mortar and cement paste. Specific
gravity of RCA compare to less the NA. The results of compressive strength, the use of
RCA up to 40% affect the functional requirements of concrete structure. Also the results
of slump test continuous decrease in workability of concrete mix, as the cement mortar
paste is attached to RCA.
4. Author: S.P.S.RAMYA, A.M.N.KASHYAP
Objectives of study: Concrete when subjected to severe environments its durability can
significantly decline due to degradation. Degradation of concrete structures by corrosion
is a serious problem and has major economic implications. In this study, an attempt has
been made to study the durability of concrete using the mineral admixtures like Fly Ash
& Ground Granulated Blast Furnace Slag (GGBS) for M30 grade concrete.
Methodology: In this study, an attempt has been made to study the durability of concrete
using the mineral admixtures like Fly Ash & Ground Granulated Blast Furnace Slag
(GGBS) for M30 grade concrete. Cube specimens were casted and are immersed in
normal water, sea water, H2SO4 of various concentrations and were tested after 7 days,
28 days & 60days.
Outcome of study: The results of fly ash and GGBS concretes when replaced with 20%
of cement are more than compared to 100% cement at the end of 7 days, 28 days and 60
days for normal water curing. In sea water curing the GGBS when replaced with 20% of
cement shows good response for durability criteria. In 1% H2SO4 solution curing the Fly
Ash when replaced with 20% of cement shows good response for durability criteria.
5. Author: K. Suvarna Latha, M V Seshagiri Rao, Srinivasa Reddy. V

Objectives of study: The present paper is an effort to quantify the strength of ground
granulated blast furnace slag (GGBS) and high volume fly ash (HVFA) at the various
replacement levels and evaluates their efficiencies in concrete. In recent years GGBS
when replaced with cement has emerged as a major alternative to conventional concrete
and has rapidly drawn the concrete industry attention due to its cement savings, energy
savings, and cost savings, environmental and socio-economic benefits.
Methodology: The present study reports the results of an experimental study, conducted
to evaluate the strengths and strength efficiency factors of hardened concrete, by partially
replacing the cement by various percentages of ground granulated blast furnace slag and
high volume fly ash for M20, M40 and M60 grades of concrete at different ages. Here an
effort is made towards a specific understanding of the efficiency of GGBS and HVFA in
concrete, considering the strength to water cement ratio relations, age and percentage of
replacement. The optimum GGBS and HVFA replacement as cementations material is
characterized by high compressive strength, low heat of hydration, resistance to chemical
attack, better workability, and good durability and cost-effective.
Outcome of study: The partial replacement of cement with GGBS and HVFA in
concrete mixes has shown enhanced performance in terms of strength and durability in all
grades. This is due to the presence of reactive silica in GGBS and HVFA which offers
good compatibility. Replacement of 40% HVFA and GGBS give good strength in all
grade.
2.2
Summary of Literature Review
In concrete, Replacement of Recycled Coarse Aggregate up to 100% is

possible.
To achieve equal strength as compare to ordinary concrete by using the

industrial products.
Cementitious material like Fly Ash, GGBFS reduces cement content in

concrete and improves workability without change in strength.
There is not any maximum difference between fresh properties recycle coarse
aggregate up to 40% with natural aggregate.
Up to 40% replacement of Recycled Aggregate Concrete (RAC) the hardened

properties of concrete will remain same.
With uses of Recycled Coarse Aggregate (RCA) and the higher dosages of
super plasticizer are required to maintain workability in High Strength
Concrete.
CHAPTER 3
RESERCH OBJECTIVE
3.1. Cementitious materials

3.1.1 Cement
As being the Binder of the concrete, the cement is. Water by the binds the
aggregates and cement. Here use the OPC 53 grade cement of ultra tech. Cement is
greenish grey colour with a fine powder.
The physical properties of the cement of 53 grade of Ordinary Portland
Cement are given below as per to IS 1489(part 1) 1991, IS 12269 1987.
Table 3.1 Physical Properties of OPC of ULTRATECH CEMENT
TEST
RESULT
Initial setting time
180 min
Final setting time
310 min
Compressive strength
3 days
27.50 N/mm2
7 days
37.70 N/mm2
28 days
53.5 N/mm2
Soundness
5.2 mm
Fineness (90 um sieve)
1.7 %
Standard consistency
29.75 %
Specific gravity
3.15
3.1.2
Fly ash
In the modern power stations of India, The production of fly ash is good
quality as it contains a very low proportion of unburnt carbon for the less loss of ignition
and low sulphur. In new thermal power stations, there is the modern type of arrangement
of dry fly ash evacuation and storage systems available. In this type of system, fly ash
10
from Electrostatic Precipitators [ESP] is then evaluated by the pneumatic system and
being stored in silos and then it may be transported by using truck or tankers or it can be
shifted through suitable bagging machine.
Various usage of fly ash
To manufacture the Portland Pozzolana Cement [PPC] and to improve the

performance of Ordinary Portland Cement [OPC].
To replace of OPC cement concrete partially.
To produce high volume concrete.
To Make Roller Compacted Concrete which will be used for dam and
pavement construction.
For Manufacture of Ash bricks and other building products, etc.
In the Construction of road embankments, structural fills in low-lying area

development.
To use as a soil amender in agriculture and wasteland development.

The major components of fly ashes are silica (Sio2), alumina (Al2O3),
ferric oxide (Fe2O3) and calcium oxide (CaO). The other minor components are MgO,
Na2O, K2O, SO3, MnO, TiO2 and unburnt carbon. The proportion of principal component
is Silica [2560%], Alumina [1030%]and Ferric oxide [525%]. The some of these
components is 70% or more and the reactive Calcium oxide is less than 10% then the fly
ash is considered as siliceous fly ash or class F fly ash. Such type of fly ash will be
produced by burning of the bituminous coal and it possesses the Pozzolanic properties. If
the sum of these three components is equal to or more than 50% and reactive calcium
oxide is not even less than 10%, then the fly ash will be considered as Calcareous fly ash
also called class C fly ash.
Here Class F fly ash use which is obtained from Gandhinagar thermal
power station was use in concrete. Fly ash is light grey in colour. The chemical property
of fly ash was obtained by Stallion Energy Pvt. Ltd. From Rajkot.
11
Table 3.2 Physical Properties of Fly ash

1
Specific Gravity
2.1
Table 3.3 Chemical Properties of Fly Ash [class-F]

Sr.
TEST
UNIT OBTAINED
No.
RESULT
Loss on ignition
<1
Silica as SiO2
62.57
Alumina as Al2O3
12.11
Magnesium as MgO
0.85
Sulphur Trioxide SO3
N/A
Calcium as Cao
8.16
Iron Oxide as Fe2O3
N/A
Alkalies
0.007
Reactive Silica
>20
Figure 3.1 Fly Ash [class F]
12
3.1.3
Ground granulates blast furnace slag (GGBFS or GGBS):

GGBFS or GGBS is product by the iron production process in a blast
furnace. Raw material like iron ore, coke and limestone are heated to about 1500C, blast
furnace melt in these material, there are produce molten slag and molten iron. The molten
slag is floats and lighter. So, molten slag is top on molten iron. Molten slag has alumina
and silicates in form original iron ore and also combined with some oxides from
limestone.
In India, produce 7.8 million tons of blast furnace slag. In India mostly use
of GGBFS in manufacturing of slag cement. In Britain, every year over 2 million tons of
GGBFS is used. GGBFS will add to the cement to increase properties like compressive
strength, bond strength. A main advantage of ggbfs is less heat of hydration and also
requires less water. High replacement with cement is possible. At present year in India
mostly use of ggbfs in RMC. GGBFS also resist the alkali-silica reaction. GGBFS also
attack the chemical resistance like sulphate resistance, chloride ion resistance. GGBFS
also give more strength for long period. GGBFS mostly use in high grade of concrete.
Low water/cement ratio in use of ggbfs gives the better strength. GGBFS also improved
the resist of fire. GGBFS also give improved surface finish. By the addition of ggbfs,
reduce the permeability of concrete, high resist chloride penetration and also high
workability.
The following table is the physical and chemical properties of GGBFS or
GGBS represent and off white in colour. A chemical property of GGBFS results was
achieved from the Stallion Energy Pvt. Ltd. from Rajkot.
Table 3.4 Physical Properties of GGBFS or GGBS
1
Specific Gravity
2.85
13
Table 3.5 Chemical Properties of GGBFS or GGBS

Sr
Test
No.
Result
Requirement as per
Obtained
IS- 12089-1987
Insoluble Residue (%)
0.51
5(Max)
Magnesia Content (%)
8.21
17(Max)
Sulphide Sulphur (%)
0.59
2(Max)
Sulfate Content (%) So3
0.22
Loss on ignition (%)
0.75
3.00(Max)
Maganese Content (%)
0.3
5.5(Max)
Chloride Content (%)
0.009
Moisture Content (%)
0.005
Glass Content (%)
96
85(Min)
Figure 3.2 GGBFS or GGBS
14
3.2
Natural Coarse Aggregate
Figure 3.3 Natural Coarse Aggregate

Aggregates were passing from 20mm sieve and retained from 4.75mm sieve use
as coarse aggregate. The following are the physical properties of natural aggregates,
Table 3.6 Sieve analysis of coarse aggregate
Sieve size
Weight retain
Cumulative
Cumulative
Cumulative
(mm)
(gms)
weight retain
percentage
percentage
(gms)
weight retain
weight
(%)
passing
40
0.00
0.00
0.00
100
20
410
410
8.2
91.8
10
4360
4770
95.4
4.6
4.75
165
4935
98.7
1.3
15
Table 3.7 Physical Properties of Natural Coarse Aggregate
3.3
Test
Natural Coarse Aggregates
Specific Gravity
2.75
Water Absorption
1.40%
Moisture Content
NIL
Impact Strength
10.66%
Aggregate Crushing Value
20.46%
Flakiness Value
22.18%
Elongation Value
21.26%
Abrasion Value
13.36%
Recycled Coarse Aggregate

After completing the age of building will be demolished. After the demolition the
coarse aggregate are separated from the demolition waste and the reuse of this aggregate
as a coarse aggregate in the concrete is called recycled coarse aggregates.
Maximum 20mm and minimum of 4.75mm size of aggregates use. Recycled
concrete aggregate which has been sourced from a number of demolition concretes will
have greater variability than recycled concrete aggregate from one demolition concrete
source and this is likely to have an effect on the uniformity of the physical properties of
crushed concrete differ from those of conventional concrete. In general, the crushed
concrete particles are more angular have a rougher texture surface than those of natural
aggregate. Roughly texture, angular and elongated particles require more water to
produce workable concrete than smooth rounded compact aggregate. These material were
obtained from a building which was more than 30 years old.
16
Table 3.8 Physical Properties of Recycled Coarse Aggregate

Properties
Recycled Coarse Aggregates
Specific Gravity
2.52
Water Absorption
4.40%
Moisture Content
1.08%
Impact Strength
20.36%
Crushing Value
25.10%
Abrasion Value
17.20%
Figure 3.4 Recycled Coarse Aggregate

Chemical properties of the recycled concrete aggregate are more important because the
history of the demolition concrete is unlikely would know. For remaining concrete,
because of the properties of the parent concrete adequate to the properties of the natural
aggregate processed by a particular ready mixed concrete plant, there is less uncertainty
about the sulphates, chlorides, and alkali present than for the recycled aggregate concrete.
17
So, the contaminants are not the issue for remaining concrete aggregates that they are for
the recycled concrete aggregate.
3.4
Natural Fine aggregate
Figure 3.5 Natural Fine Aggregate

The aggregates size should less than 4.75mm is known as fine aggregate. The
followings are the physical properties of natural fine aggregate,
Table 3.9 Physical Properties of Natural Fine Aggregate
Natural Fine Aggregates
Specific Gravity
2.74
Water Absorption
1.0%
Moisture Content
NIL
18
Table 3.10 IS 383-1970 Recommendation for Fine Aggregate

Percentage Passing For
IS Sieve
Grading
Grading
Grading
Grading
Zone I
Zone II
Zone III
Zone IV
10 mm
100
100
100
100
4.75 mm
90-100
90-100
90-100
95-100
2.36 mm
60-95
75-100
85-100
95-100
1.18 mm
30-70
55-90
75-100
90-100
600 microns
15-34
35-59
60-79
80-100
300 microns
5-20
8-30
12-40
15-50
150 microns
0-10
0-10
0-10
0-15
Designation
3.4.1
Sieve Size Analysis

Use the fine aggregate of specific gravity 2.74 with locally available
natural river sand conforming to grading of IS 383 1970. Then as per weighing total
weight of fine aggregate is 1000 grams.
Figure 3.6 I S Sieve

19
Table 3.11 Sieve Analysis of Fine Aggregate

Sieve size
Percentage passing from
10 mm
100
4.75mm
95%
2.36mm
82.5%
1.18mm
61.7%
600 micron
30.5%
300 micron
11.7%
150 micron
2.3%
As per IS 383:1970, table 4 above percentage of fine aggregate are zone l.

3.5
Recycled Fine Aggregate

Recycled fine aggregate size is less than 4.75 mm. That type recycled fine
aggregate not use in concrete because of that type recycled fine aggregate require
increased water demand, and related consequences.
20
CHAPTER 4
PROCEEDING OF RECYCLED
AGGREGATE
4.1
Obtaining Process of Recycled Aggregate

4.1.1
Recycled aggregates
Figure4.1 Recycled Coarse Aggregate after process
Such kind of recycled aggregates are produced from the re processing of

construction and demolition (C&D ) waste which constitutes the largest proportion of
C&D waste. After separation from other C&D waste and sieved, a crushed concrete
rubble can be used as a substitute from the natural coarse aggregate in the concrete or as
sub base layer in the pavements.
21
4.2
Recycling
Material to be recycled
Feed hopper
Manually separated debris
Primary Crusher
Vibrating pan
feeder
Magnetic
separator
Waste stockpiles
Primary screens
Secondary crusher
Magnetic separator
Secondary screens
Stockpiled products
Coarse friction
Intermediate fraction
Fine fraction
Figure 4.2: Generalized flow diagram for an aggregates recycling operation

The procedure for recycling aggregate concludes the following process:
A vibrating feeder sort out the hard portions from the inert C&D waste those are
suitable for subsequent recycling;
A jaw crusher used for reducing the sorted material of size 200 mm or smaller
which can be directed by secondary crushers;
22
Magnetic separator, manual picking passage and air separator for the removal of
other impurities before the materials are filled into the secondary crusher;
Secondary crusher similar to cone crusher is useful for processing the clean
materials into sizes smaller than 40 mm;
The vibratory screens are used for separating the crushed recycled aggregate into
the different sizes;
The storage will be provided with the temporary storage of recycled aggregates.
By this facility, it is easier to separate the aggregate with various sizes as 40mm,
20mm and 10mm for coarse aggregate and less than 4.75 mm for fine aggregate.
The recycling plant has adopted the accurate quality control approach. Only
suitable materials [e.g. crushed aggregates] are processed at the plant. Bricks and tiles
will be generally not allowed. The recycled aggregates can be sampled and tested daily.
4.2.1
Recycling Plant
Recycling plants are normally located outside the towns or cities because
of the huge amount of noise pollution from the equipment that are used during recycling
process. The figure given below shows the process which is used in producing the
recycled aggregate, the process starts from the demolished waste from the construction
site, ending in ready recycled aggregate for use.
23
Identify the concrete building for the demolition

Remove all exterior and interior finishes
Mechanically demolished building
Load and transport to crush plant

Crush and separate
Ready with various size

Figure4.3: Recycling process of demolition waste
Process of recycling
The processes of recycling of C&D wastes are same as production of
natural aggregates, in both processes the same crushers, equipment, screens,
transportation facilities and removal impurities.
There are two types of recycling plants are used widely all over the world:
1. On-site recycling
2. Stationary recycling plant
Both types have a same type of process, The On-site recycling type is
small and movable and it can be located in the demolished site. But the stationary plant is
located in far areas away from towns or cities and urban areas because it is very huge,
noisy and needs proper pavements for carrying heavy loads.
4.2.2
Sources of Recycled Aggregate
Produced from the breakup and crushing of existing Portland
24
Cement concrete pavement
Concrete structures
There are mainly two sources of demolished concrete

(a). Rigid concrete pavement: In this type of pavement an asphalt concrete
surface is presented on an existing rigid pavement, the asphalt concrete must be removed
before the old Portland cement concrete pavement is first broken up.
(b). Concrete structures: By this procedure to produce the maximum amount of

Portland cement concrete which can be crushed and accepted aggregate in new Portland
cement concrete. All type of the reinforcing steel should be removed from the concrete
during the crushing operation.
4.3
Equipment used in Recycling Process
4.3.1
Break up equipment
There are various type of break up equipment.
4.3.1.1 Portland Cement Pavement break up equipment

(a) Driving hammer. It is the mounting on a motor grader that sticks in the
Portland cement pavement on around 30cm grid patterns.
(b) Horn tooth ripper It is an attached hydraulic excavator. It is used to
remove all the steel reinforcement that remains in the Portland cement pavement.
4.3.1.2 Structural Building breaks up equipment

Following methods had been use to crush the structural building:
(a) Mechanical hydraulic crusher with long boom arm:
By the crusher through the long boom arm system, the concrete and steel
reinforcements are brake. This method is suitable for the dangerous buildings.
25
(b) Wrecking ball:

The demolition of building will be done by the impact energy of the wrecking ball
that suspended from the crawler crane.
(c) Implosion.
Locating the placement of explosive properly and the building collapse in a safe
manner have to develop.
4.3.1.3 Crushing Plant equipment
Primary Crusher
Dry Separation Process
Electromagnetic Separation Process
Wet Separation Process
26
Screening Plant
Washing Plant
Figure4.4: Crushing plant equipment
4.4
Properties of Recycled Aggregates obtained from crushed
concrete
4.4.1
Physical properties
Recycled aggregates are like a crushed stone in look. The physical
properties of such aggregates are different from ordinary concrete. The rough surface and
the angularity are more than conventional aggregate in the crushed concrete particles.
Such aggregate causes lightweight and porous cement mortar attached with recycled
aggregates have a higher water absorption and lower specific gravity than natural sized
aggregates.
4.4.1.1Specific gravity
The specific gravity of recycled aggregates is ever lower compare to the
natural aggregates. Before the recycling process starts the sample, if its specific gravity is
near about the natural coarse aggregate then only the usefulness of recycling process
could be done.
4.4.1.2 Density
The saturated surface density of recycled aggregates is lower than natural
aggregates that of, by the high density of mortar that is adhered to the recycled aggregate.
The aggregates with the higher amount of adhered mortar will have lower density. The
density of recycled aggregate concrete will reduce with the smaller sizes of aggregates.
27
4.4.1.3 Water absorption

As the size of aggregate is smaller the water absorption of aggregate will
increases. The smaller sizes of aggregates have a good water absorption capacity. The
higher amount of adhered mortar in recycled aggregates will decrease the density. It has
been accepted that the absorption capacity was not ever dependent on the strength of the
natural concrete. The water absorption capacity of recycled aggregates is in proportion
with the quality and quantity of adhered mortar. Recycled aggregates with the adhered
mortar have lower density higher water absorption capacity.
4.4.1.4 Moisture content
Because of adhered mortar in recycled aggregates, moisture content of
recycled aggregates is always higher than that of natural aggregates. It directly deals with
the water cement ratio of the mix design.
4.5
Application of Recycled Aggregate Concrete

Initially in various countries, the application of recycled aggregate was to use as
landfill. Nowadays, it has been changed towards directly in construction areas widely.
This is as giving below:
1 - Granular Base Coarse Materials

2 Production of Recycled Concrete Paving Blocks
3 - Concrete Kerbs and Gutter Mix
4 - Embankment Fill Materials
5 - Building Blocks.
6 - Backfill Materials.
7 - Reinforced concrete building
28
CHAPTER 5
PROCESS OF RECYCLED AGGREGATE

AND EXPERIMENTAL TEST
Manufacturing process of recycled aggregate concrete is important for good

quality production. At every stage in carefulness is most require in recycled aggregate
concrete. So, proper car require otherwise concrete not give obtained results. Therefore
proper car is mostly requiring in all stages.
5.1
Process of Manufacturing
The following are the main stage of the manufacturing process of Recycled
Aggregate Concrete.
(1) Batching
(2) Mixing
(3) Transporting
(4) Placing
(5) Curing
(1) Batching
The material measurement process is known as batching. Availability of material
and quality of material, batching is divided in two method.
1. Weigh batching
2. Volume batching
1. Weigh Batching
Weigh batching is more accurate method compare to volume batching because of
the perfection of the proportion has been measured by weight. Concrete which will made
by the process of weight batching gives the good quality and also a material as per the
29
design always considered as the weight. For the construction of the heavy structures, this
method is more suitable.
2. Volume Batching
This method is not an accurate method of batching. In concrete, the material,
which is used in the manufacturing of concrete, which is of different characteristics.
Sometimes, the material have environmental effects like in the dry condition the material
volume can decrease as well as the in wet condition the material volume can increases.
So, using the volume batching this type of error may produce lower quality concrete and
the proportion as per the design shall not maintain.
(2). Mixing
Mixing is process of concrete mix perfectly and behaves uniform material after
concrete place in specimen. Generally mixing of concrete has two methods.
Hand mixing
Machine mixing
Hand mixing
Hand mixing in concrete is done by the manually. Mixing cannot be
possessed the uniformity as well the mixing cannot be mixed thoroughly. So, this type of
mixing is use in temporary work and small work. Hand mixing in more proportion of
cement require because cement particles floats in the atmosphere. In hand mixing around
10% more cement will take in concrete.
Machine mixing
Machine mixing is the classic method for mixing. Different capacity types
of mixture are available in market. Machine mixing is more amount of concrete produce
with the thoroughly equality. This mixing is economical and good effective for
manufacturing of more amount of concrete.
30
Here 0.5 m capacity of miller use for portable concrete. Proper proportion
is use the mixing every batch in miller.
Figure 5.1 Process of Concrete Mixing

(3). Transporting
There are many methods by the transporting concrete. Truck miller, pumping,
trolley, lift and other methods are useful for transporting the concrete.
Here the miller was available in the laboratory, so the concrete was been placed
directly in the mould.
Figure 5.2 Process of Transporting Concrete
31
(4). Placing
Different sizes of mouls in place the concrete. The below table is various size of
concrete mould use in concrete placing.
Table 5.1 Moulds dimension Use for Concreting
Mould Name
Size of mould
Cube
150mm x 150mm x 150mm
Cylinder
Dia of 150mm and height of 300 mm
Beam
100mm x 100mm x 500mm
Remove the air voids and surfacing of concrete is done by the vibrator. So, mould
placing on vibrator and concrete in remove the air voids and concrete surfacing done.
Figure 5.3 Vibrating Table
32
Figure 5.4 Placing of Concrete in Mould

(5). Curing
Hardening process completing after, the specimen occupies initial hardened state
and also the moulds are allowed to open. The moulds were casting after 24 hours, moulds
for cure in curing tank. A curing time of each moulds was 28 days and also curing tank
placed in laboratory. Each batch specimens of curing time were 7 days and 28 days after
testing procedure. The curing tank water was maintained the temperature and pure.
Figure 5.5 Curing Tank
33
5.2
Tests for fresh properties of concrete

5.2.1
Slump Test
Fresh concrete properties measure by the workability test. Consistency of

fresh concrete is checking by this test. Degree of wetness measures by the consistency.
The slump test is perform about 6 liter of concrete will need. This test is
procedure is very easy and very easy to perform due to ease in the apparatus. As per IS
code every batches in use of slump test to produce uniformity and suggested the of super
plasticizers dosage opportunity for the concrete.
In the inverted cone the performance of compacted concrete under the gravity
action by the slump results shows. The mould shape is like an inverted cone. Inverted
cone is a handle to hold with open at both ends. The height of cone is 300 mm and top
diameter of cone is 100 mm and bottom diameter is 200 mm. A metal rod 16 mm
diameter and 600 mm height and measure the slump is use numbering.
Figure 5.6 Slump Test

Procedure:
The mould internal surface cleaned carefully and put on rigid and non-absorbent
horizontal surface. Placing of Concrete mix is placing in a slump cone with four layer and
each layer on apply 25 times tamping. After cone outside remove extra concrete and
instantly remove the cone in upward direction without damage on concrete. After the
34
settlement of the concrete completely and measure the variation that called slump. Slump
can measure in cm or mm.
Generally Slump can be defined in three types,
Collapse: In this type of slump in concrete is completely collapses
Shear: In this type of slump in concrete failure in one side.
True slump: In this of slump in concrete is completely subsides.
5.3
Various tests for hardened properties of concrete

5.3.1
Compressive strength of concrete

The capacity to resist an effective load on hardened (28 days curing after)
concrete is measure by the compressive strength test. In the laboratory the capacity of
compression testing machine is 2000 KN. A machine is operated by the electrically. The
design of any structure in most important is compressive strength of concrete. The best
compression strength of Concrete achieve by the perfect conditions of concrete. In
hardened state in measures the compression test. Compression test for 150 mm x 150 mm
x 150 mm size of concrete cube are used. First concrete outer surface drying and clean by
the cloth after the specimen use for testing. Proper manufacturing process, grade of
concrete and proper curing are the factors affecting of compressive strength. Every batch
cast after 7 days and 28 days curing after this test done. Three cubes mean value
considered as result in every curing batch.
Figure 5.7 Compressive Strength Test

35
5.3.2
Split Tensile strength of concrete

The cylindrical mould of size 30 cm height and 15 cm diameter is use for
Split tensile strength of concrete. 28 days curing of cylinder after this test carryout. Split
tensile strength of concrete test will perform on compression testing machine. The
compressive force acts on the length of cylinder that type arrangement of cylinder in
machine and also both side plate provide on cylinder. Diametric compressive force
applied along the length of cylindrical span by this method. The below formula is use for
find out split tensile strength.
Split Tensile Strength = 2P/ ld
Where, P= load value in N
l = length in mm
d = diameter in mm
Figure 5.8 Split Tensile Strength Test
5.3.3
Flexural strength of concrete

Beam specimen in flexure strength finding by this test. 10 cm x 10 cm x
50 cm size of beam specimen for tested. After 28 days curing after beam specimen use
for testing. Testing of Beam is arrangement on Universal Testing Machine [UTM] to give
the loading on beam. The beam length on making three part and put on Universal Testing
Machine and the two point loading method by the achieve the flexural strength. The loads
apply without any shock and without sudden otherwise the fails specimen directly.
Generally universal testing machine obtain the strength range from 10KN to 500KN. The
36
specimen surface on create cracks by the apply loading and this loading is maximum
loading of specimen. After that value use for following formula,
Flexural strength= Pl/bd
Where, P= load in N.
l= clear length in mm
b= width in mm
d= depth in mm
Figure 5.9 Flexural Strength Test
37
CHAPTER 6
NEED OF THE STUDY
The natural resources can be protected by the use of demolished building

material.
Demolished waste of old building is used in new building construction which

protects natural resources.
From the demolished concrete the aggregates are crushed by hammering or by

crusher with the specific size of >4.75 mm and <20mm sieve. Then division of
aggregates passed from 20mm sieve and retained from 10mm sieve and also
retained 4.75 microns sieve and passed from 10mm sieve.
Recycled coarse aggregates are wash properly and dry fully before use. These are
obtained from demolished waste of concrete and also from tested samples in the
laboratory.
Fly ash is directly available from thermal power plant in loose state and used with
cement, GGBFS is also available from industrial plant. Both material are
available in 30KG and 50KG bags in the market.
By mixing all the above material with cement and fine aggregate in concrete is
same as normal concrete so it is same as conventional concrete in mixing.
38
CHAPTER 7
OBJECTIVES OF STUDY
The strength of recycled coarse aggregate is depends on w/c ratio with partial
replacement.
The ternary blended concrete requires the percentage replacement of cement by

using percentage variation of fly ash and GGBFS.
Experimental study on various replacement of RCA, GGBFS and fly ash, when
mixed with the changes in W/C ratio and calculate workability, compressive,
tensile, and flexural strength.
By this study maximum and minimum strength is achieved.
39
CHAPTER 8
INDUSTRIAL VISIT
Visited the following industries are for the recycling process of aggregates and for
the materials properties and samples.
Name of company and

address
Concerned person
Contact No.
Date of visit
Shree Ganesh crushing

plant
Mr. Mansukh Ahir
98984 43040
28/11/2015
Lafarge aggregate &

concrete India pvt.ltd.
Rajkot
Mr. Ganesh Sahu (Q/A &

Q/C Manager)
97140 07644
29/09/2015
Stallion Energy Pvt. ltd.

Rajkot.
Mr. Kuldipsinh Basiya

(M.D.)
99099 52004
10/09/2015
40
CHAPTER 9
Sr. Task
No.
1.
Literature
review
2.
Decided the
topic name and
material
3.
Testing of
material
4.
Pilot test (Trial
mix)
5.
Experimental
and Analysis
6.
Interpretation
of results
7.
WORK PLAN
July Sep.
Aug. Oct.
Nov.
Dec.
Jan.
Feb.
Mar.
April
May
June
Thesis writing
41
CHAPTER 10
RESULTS
10.1 Fresh Properties Results

10.1.1 Slump test results
While increasing the percentage replacement of fly ash and GGBFS with the 0%
replacement the slump value was increased. When the recycled coarse aggregates were
replaced with increment in percentage the slump value was decreased.
Table 10.1 Slump Value
% of RCA
w/c ratio= 0.55
+FA+GGBFS
Value (mm)
0+0+0
120
0+30+0
162
0+0+30
143
0+10+10
125
0+30+30
165
100+10+10
100
100+30+30
105
60+10+10
122
60+30+30
160
42
10.2 Hardened Properties Results

10.2.1 Compressive Strength test results
Compressive strength for 0% replacement of recycled coarse aggregate
with increasing in the fly ash content and GGBFS content can decrease the strength.
While increasing the percentage of recycled coarse aggregate with increasing the Fly ash
and GGBFS the strength was decreased.
Table 10.2 Compressive strength value of 7 days and 28 days for 0.55 w/c ratio
% of RCA
+FA+GGBFS
w/c ratio= 0.55

7 days
28 days
[MPa]
[MPa]
0+0+0
19.55
26.66
0+30+0
10.56
17.55
0+0+30
14.44
22.44
0+10+10
14.66
23.2
0+30+30
10.22
15.77
100+10+10
11.55
20.88
100+30+30
7.50
13.67
60+10+10
12.11
21.55
60+30+30
8.55
14
43
10.2.2 Split Tensile strength test results

Split tensile strength for 0% replacement of recycled coarse aggregate
with increasing in the fly ash content and GGBFS content can decrease the strength.
Table 10.3 Split Tensile strength value of 28 days for 0.55 w/c ratio
% of RCA
w/c ratio= 0.55
+FA+GGBFS
Value (MPa)
0+0+0
2.66
0+30+0
1.52
0+0+30
2.05
0+10+10
2.57
0+30+30
1.62
100+10+10
2.23
100+30+30
1.15
60+10+10
2.47
60+30+30
1.41
44
10.2.3 Flexural Strength test results

Flexural strength for 0% replacement of recycled coarse aggregate with
increasing in the fly ash content and GGBFS content can decrease the strength.
Table 10.4 Flexural strength value of 28 days for 0.55 w/c ratio
% of RCA
w/c ratio= 0.55
+FA+GGBFS
Value (MPa)
0+0+0
3.00
0+30+0
2.17
0+0+30
2.56
0+10+10
2.56
0+30+30
1.6
100+10+10
1.98
100+30+30
1.27
60+10+10
2.01
60+30+30
1.50
45
CHAPTER 11
PROPOSED OUTCOME OF STUDY
The properties of concrete can change by different material and also require
strength can achieved by the use of waste and by products.
In future the availability of natural aggregates after time want be easy as per
requirement specific properties.
The waste material also having important contribution as it helps to decrease the
pollution and saves the natural resources.
As per study, use of demolished waste will be increased by using the portable
crusher to crush the concrete waste. This requires many extensions.
This type of concrete is applicable in the construction of small houses and also for
road construction but at present this type of concrete is not used in INDIA.
46
CHAPTER 12
MIX DESIGN FOR W/C RATIO OF 0.55
W/C ratio = 0.55

Cement = OPC 53 grade
Maximum size of aggregate = 20 mm
Workability = 100 mm (Slump)
Specific gravity of Cement = 3.15
Specific gravity of Fly ash = 2.1
Specific gravity of GGBFS or GGBS = 2.85
Specific gravity of coarse aggregate = 2.75
Specific gravity of fine aggregate = 2.74
Specific gravity of recycled coarse aggregate = 2.52
Water absorption of coarse aggregate = 1.40%
Water absorption of fine aggregate = 1.0%
Water absorption of recycled coarse aggregate = 4.40%
Moisture content of coarse aggregate = Nil
Moisture content of fine aggregate = Nil
Fine aggregate of zone 1
Target strength is on w/c ratio 0.55

Water content for maximum 20 mm size of aggregate = 186 liter
Estimated water content for 100 mm slump = 186+ ((6/100)*186) = 197 liter
Cementitious material content = (197/0.55) =358.18 kg/m3
Volume of coarse aggregate is to be decreased and fine aggregate is to be
increased as the w/c ratio is greater by 0.05
Volume of coarse aggregate is decreased by 0.01
According to IS 10262, if the aggregate size is 20 mm and the fine aggregate of
zone-1 then the w/c ratio of 0.50 = 0.60
Corrected volume of coarse aggregate for the w/c ratio of 0.55 = 0.59
Volume of fine aggregate = 1- 0.59 =0.41
47
Mix Calculations (Conventional concrete):Volume of concrete = 1 m3

Volume of cement = ((358.18/3.15)*(1/1000)) = 0.114 m3
Volume of Water = (197*(1/1000)) = 0.197 m3
Volume of all in aggregate = a-(b + c)
= 1-(0.114 + 0.197)
= 1-0.311
= 0.69 m3
e) Mass of coarse aggregate = 0.69*0.59*2.75*1000
= 1119.53 kg
f) Mass of fine aggregate = 0.69*0.41*2.74*1000
= 775.15 kg
a)
b)
c)
d)
Coarse aggregate = ((1.40*1119.53)/100) = 15.67

= 1119.53-15.67
= 1103.86 kg
Actual water added = 197+15.67 = 212.67
48
REFERENCES
1. An experimental study on durability of concrete using fly ash & GGBS for M30
grade concrete S.P.S. Ramya, A.M.N. Kashyap in the International Journal of
engineering research and development, volume 10, issue 11, November 2014.
2. Destructive strength properties of recycled coarse aggregate Chetan M Vayas,
Darshna R Bhatt in international journal of innovative technology and exploring
engineering vol. 2, issue 3, Feb. 2013.
3. Engineering properties of cementless concrete produced from GGBFS and
recycled desulfurization slag Wen-Ten kuo, Her-Yung Wang, Chun-Ya Shu in
construction and building material.
4. Estimation of GGBS and HVFA strength efficiencies in concrete with age K.
Suvarna Latha, M V Seshagiri Rao, Srinivasa Reddy. V in international journal of
engineering research and advanced technology in vol. 2, issue 2, Dec. 2012.
5. Experimental study of compressive strength of recycled aggregate concrete
Prof. D K Bhagat, J P Parmar, Y R Tank, D H Gadhiya, J S Goyani in
international journal of research and technology, volume 3, issue 4, April 2014.
6. High strength concrete using ground granulated blast furnace slag
Thavasumony D, Thanappan Subash, Sheeba D in IJSER, volume 5, Issue 7, July
2014.
7. Influence of GGBS and eco sand in green concrete M Prabu, S. Logeswaran,
Dr. Sunilaa George in international journal innovative research in science,
engineering and technology, vol. 4, issue 6, June 2015.
8. Influence of recycled concrete aggregate on strength parameters of concrete
Jitender Sharma, Sandeep Singla in international journal of civil engineering in
vol. 1, issue 4, Sep. 2014.
9. IS 10262: 2009 (concrete mix proportioning)
10. IS 12269 1987.
11. IS: 2386 (part 1, 2,3,4) 1963.
12. IS 383 1970.
49
13. IS 456 2000.

14. M.S.Shetty,Concrete Technology (Theory and Practice), S.Chand & Company
Limited, New Delhi, Sixth Edition, May-2005.
15. Performance evaluation of recycled aggregate usedin concrete A N Dabhade,
Dr. S S R choudhary, Dr. A R Gajbhiye in international journal of engineering
research and application in vol.2 issue for july august 2012.
16. Recycled aggregate concrete, a sustainable option from demolition concrete
waste- a percentage replacement method Praveen Mathew, Jeevan Jacob, Leni
Stephen, Thomas Paul I international journal of innovative research in science,
engineering and technolology, vol.3, issue to, feb. 2014.
17. Strength characteristics of concrete with recycled aggregate and artificial sand
N.K. Deshpande, Dr. S.S. Kulkarni, H.Pachpande in IJERA, volumne 2, Issue 5,
sep.-oct.-2012.
18. Study of properties of sustainable concrete using slag and recycled concrete
aggregate Basil Johny, Prof. M V Geoge, Dr. Elson John in international journal
of engineering research and technology, vol. 3 issue 9 Sep 2014.
19. Studies on compression and flexural strength characteristics of triple blended
high strength recycled aggregate concrete M.V.S.S. Sastri, Dr. K. Jagannadha
Rao, Dr. V. Bhiksma in IJCIET, Vol. 5, Issue 3, March 2014.
20. Study on the permeability of the recycled aggregate concrete using fly ash V.
Bhikshma, K. Divya.-2012.
50

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EVALUATION OF STRENGTH OF RCA USING TBC WITH FLY ASH AND GGBFS

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Major Component of Construction Waste

Figure 1.1 Percentage of C & D waste

Usefulness of Cementitious Material

Theory of Ternary Blended Concrete

Quality of Recycled Aggregate (RA)

Application of Recycled Aggregate Concrete in TBC

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Description of Literature Survey Papers

1. Author: A.N.Dabhade, Dr.S.R.Choudhari, Dr.A.R.Gajbhiye

2. Author: Praveen Mathew, Jeevan Jacob, Leni Stephen, Thomas Paul

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

5. Author: K. Suvarna Latha, M V Seshagiri Rao, Srinivasa Reddy. V

Summary of Literature Review

In concrete, Replacement of Recycled Coarse Aggregate up to 100% is

To achieve equal strength as compare to ordinary concrete by using the

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Cementitious material like Fly Ash, GGBFS reduces cement content in

Up to 40% replacement of Recycled Aggregate Concrete (RAC) the hardened

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

3.1. Cementitious materials

Initial setting time

Final setting time

Fineness (90 um sieve)

To manufacture the Portland Pozzolana Cement [PPC] and to improve the

To replace of OPC cement concrete partially.

To produce high volume concrete.

For Manufacture of Ash bricks and other building products, etc.

In the Construction of road embankments, structural fills in low-lying area

To use as a soil amender in agriculture and wasteland development.

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Table 3.2 Physical Properties of Fly ash

Table 3.3 Chemical Properties of Fly Ash [class-F]

Sulphur Trioxide SO3

Iron Oxide as Fe2O3

Figure 3.1 Fly Ash [class F]

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Ground granulates blast furnace slag (GGBFS or GGBS):

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Table 3.5 Chemical Properties of GGBFS or GGBS

Insoluble Residue (%)

Magnesia Content (%)

Sulphide Sulphur (%)

Sulfate Content (%) So3

Loss on ignition (%)

Maganese Content (%)

Chloride Content (%)

Moisture Content (%)

Glass Content (%)

Figure 3.2 GGBFS or GGBS

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Natural Coarse Aggregate

Figure 3.3 Natural Coarse Aggregate

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Table 3.7 Physical Properties of Natural Coarse Aggregate

Natural Coarse Aggregates

Aggregate Crushing Value

Recycled Coarse Aggregate

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Table 3.8 Physical Properties of Recycled Coarse Aggregate