Utilization of clay residue obtained from glass
manufacturing industry in partial replacement of
fine aggregate in concrete
Mr. Asif.
Asst. Professor, Gopalan College of Engineering and
Management, Bengaluru, Karnataka, India.
Email: asifgogi@gmail.com
Abstract— Concrete is an intimate mixture of construction material
such as cement, sand, aggregate, water and chemical admixture.
All these materials are very much needs to make a good and
workable concrete. The main properties of fresh concrete are
workability, consistency, setting time etc. In concrete, fine
aggregate and coarse aggregate contributes 60% to 70% of total
volume. Therefore aggregate contributes more volume; the
selection of both fine and coarse aggregate should be done
carefully.The consumption of natural river sand is very much high,
because of more usage of concrete. To overcome the demand of
natural river sand, many research has been carried out and some of
the alternative materials have already used as the fine aggregate.
Grog clay is one of the good alternative materials to replace natural
sand. The source of grog clay is from glass manufacturing
industry.In the present study, natural sand is replaced with grog
clay by 30%, 50% and 70% along with three different water content
but the cement content was fixed constant. The mix was prepared
and test was conducted on compression beams for 7days and
28days. It has been concluded from the results that, the
compression increases with the percentage of grog clay increases.
Therefore grog clay gives satisfactory results and can be adopted as
a fine aggregate.
Keywords— Key Words: Grog.
INTRODUCTION
Concrete is the most widely used construction
material used across the world in almost all types of civil
engineering works. Concrete is a manufactured product
essentially consisting of cement, aggregates, water and
admixtures. Among these cement which is generally made by
calcining lime and clay Cement is the critical ingredient in
concrete, locking together the sand and gravel constituents in
an inert matrix. In today’s world there is a huge market
demand for cement due to which there has been a sizeable
depletion in the natural resources. At the same time disposal of
industrial waste or by-products has become a difficult task and
expensive as a result, there has been an increase in stringent
environmental regulations and shortages of suitable, nearby
disposal sites. Industrial by-products also creates
environmental hazard as they may be toxic for environment.
Therefore, taking into consideration of both these challenging
tasks there is an alarming need for an alternate solution. So the
usage of industrial by-products and solid waste materials as
aggregates in concrete and in the soil stabilization for road and
Karthik, Maruthi, Nithin kumar, Rahul kumar
Gopalan College of Engineering and Management,
Bengaluru, Karnataka, India.
other type of the construction work is the need of the hour.
Concrete is the most undisputable and indispensable material
being used in infrastructure development throughout the world.
Umpteen varieties of concretes were researched in several
laboratories and brought to the field to suit the specific needs.
Numerous waste materials are generated from manufacturing
processes, service industries and municipal solid wastes. The
increasing awareness about the environment has tremendously
contributed to the concerns related with disposal of the
generated wastes. Ceramics is a diverse industry and contains
several categories of products, including sanitary ware, cement,
advanced ceramics and ceramic tiles. The ceramic industry has
a long history, with the first instance of functional pottery
vessels being used for storing water and food, being thought to
be around since 9,000 or 10,000 BC. Solid waste management
is one of the major environmental concerns in the world. With
the scarcity of space for land filling and due to its ever
increasing cost, waste utilization has become an attractive
alternative to disposal. Investigations are being carried out to
create an economical concrete with the utilization of waste
products as substitute.Clay bricks were also made around the
same time. The ceramic industry has been modernizing
continuously, by newer innovations in product design, quality
etc. Many waste products are generated from ceramic
industries. Such waste products included in this paper are the
rejects from ceramic industries, mainly quartz and grog. Such
waste products included in this paper are the rejects from
ceramic industries, mainly quartz and grog. Each of these
waste products has provided a specific effect on the properties
of fresh and hardened concrete. The use of waste products in
concrete not only makes it economical, but also helps in
reducing disposal Problem. Reuse of bulky wastes is
considered the best environmental alternative for solving the
problem of disposal. This paper presents a detailed review
about waste and recycled materials that can be effectively used
in concrete as a sand and cement replacement.
METHODOLOGY
The methodology used in this work can be summarized into a
series of steps as below:
(1) A review on various paper on the study of the replacement
of concrete material is made.
(2) The materials are procured from various sources from
concrete mix.
(3) Characterization of materials like aggregates, cement and
grog.
(4) The specimen are moulded cured and tested for 7 and
28days
(5) Concrete mix design according to IS 10262 is been made.
II.MATERIALS
A. Coarse Aggregate
The well graded angular shaped crushed aggregates of
size 20mm as per IS 383-1970 is used as coarse aggregate.
B. Cement
53 grade Ordinary Portland cement of grade is used
in the study. The properties of cement were tabulated in table 2
C. Fine Aggregate
Natural river sand is used as fine aggregate in this
study. The properties of fine aggregate are shown in Table 3
D. Grog
Grog is obtained as by product of glass industry .Grog,
also known as firesand and chamotte, is a ceramic raw material.
It has high percentage of silica and alumina. It can be produced
by firing selected fire clays to high temperature before grinding
and screening to specific particle sizes. The particle size
distribution is generally coarser in size than the other raw
materials used to prepare clay bodies. It tends to be porous and
have low density.
Fig 1. Grog
III. MIX PROPORTIONING
The process of determining required and specifiable
characteristics of a concrete mixture is called mix design.
Characteristics can include fresh concrete properties, required
mechanical properties of hardened concrete such as strength
and durability requirements and the inclusion, exclusion, or
limits on specific ingredients. Mix design leads to the
development of a concrete specification. In the present
investigations a mix of M15 grade concrete was used and
designed as per relevant Indian Standard specifications.
Mix details for m15 concrete : 1:2:4
Weigh batching is done for all materials. All aggregates used in
the mix were weighed under surface dry conditions. Laboratory
mixer is used for mixing the components of concrete. Coarse
aggregate, fine aggregate and cement were added to the mixer
and they are mixed thoroughly. Water is then added and is
mixed for 5 minutes. Standard cubes, cylinders and beams
were casted for all mixes in concrete
RESULTS AND DISCUSSIONS
(1)The present study investigates the effect of sand
replacement by grog clay required to obtain optimum strength
with satisfying workability, strength and durability required in
the concrete. Based on the test results of compressive strength
the following conclusions are drawn.
(2)This study demonstrated that it is possible to utilize grog as
partial replacement for fine aggregate in concrete.
(3)When sand is replaced by grog the workability decreases,
hence to improve the workability we add admixtures
( superplasticisers )
(4)Result shows that concrete strength produced for all mixes
satisfy the minimum codal requirements as per Indian
Standard Codes.
(5)Better value of bulk density and water absorption gives
clear indication of dense packing of materials and less porosity
of concrete block made with addition of grog with clay.
(6)The study shows that as the replacement of grog percentage
increases the compressive strength reduces, however the
strength was still higher than that of control mix which proves
the efficiency of grog material in enhancing the characteristic
properties of concrete.
(7)The reuse of grog waste in concrete production shows
highly positive results in terms of environmental protection,
waste management, and saving of raw materials for the
production of eco-friendly building material.
REFERENCES
1) Vinayak R. supekar and popat D. kumbhar, “Properties of
Concrete by Replacement of Natural Sand with Artificial
Sand”, International Journal of Engineering Research &
Technology (IJERT), ISSN: 2278-0181, vol.1, Issue 7,
September-2012.
2) Priyanka A. Jadhav and Dilip K. Kulkarni, “Effect of
replacement of natural sand by manufactured sand on the
properties of cement mortar”, International Journal of Civil
And Structural Engineering, Volume 3, No 3, 2013.
3) Hardik K. Patel and Jayeshkumar Pitroda, “A
SUSTAINABLE APPROACH BY UTILIZATION OF
QUARRY DUST IN CONCRETE”, Journal of International
Academic Research for multidisciplinary, Impact Factor 1.393,
ISSN: 2320-5083, volume 2, Issue 4, may 2014.
4) Dammo .M. N, Deborah. J. M et al., “ Effect of Ngala Clay
on the Compressive Strength of Concrete” International
Journal of Engineering Science Invention, Volume 3 Issue 7ǁ
July 2014 ǁ PP.07-10.
5) Twubahimana Joseph Désiré and Mbereyaho Léopold,
“ Impact of clay particles on concrete compressive strength”,
International Research Journal on Engineering Vol. 1(2), pp.
049-056, December, 2013.
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of Concrete with China Clay (Kaolin) Waste” International
Journal of Latest Trends in Engineering and Technology
(IJLTET),Vol. 2 Issue 3 May 2013.
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concrete”, IGERT, ISSN 2278-1781 VOL 4 ISSUE 4 APRIL
2015.
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PARTICLES ON CONCRETE”, International Journal of
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Copernicus Value (2013): 6.14 | Impact Factor (2015): 6.391.

Table 1 Coarse aggregate test observation

 SL NO TESTS VALUES SPECIFICATIONS TEST METHODS

1 SIEVE ANALYSIS 3.21 IS : 460-1962

NOT MORE THAN

0.6%
2 WATER 0.4% IS : 2386-1963 PART
ABSORPTION III

3 SPECIFIC GRAVITY IS : 2386-1963 PART

III

4 AGGREGATE 28% < 30% IS : 2386 - 1963PART

CRUSHING TEST IV

Table 2:Cement test observation.

SL NO TESTS VALUES SPECIFICATIONS TEST METHODS

1 FINENESS TEST 1% 2250 IS 269-1976

2 SPECIFIC GRAVITY 0.80 3.15 IS 269-1976

3 STD CONSISTENCY 32% 24-34 % IS 4031PART 4 -

1988

4 SETTING TIME OF 30MIN <30MIN IS 4031-1988

CEMENT

Table 3: Fine aggregate test observation

SL NO TESTS VALUES SPECIFICATIONS TEST METHODS

-
1 SIEVE ANALYSIS 3% IS 383
 2 SPECIFIC GRAVITY 2.66 2.5 – 3.0 IS : 2386 PART III

3 BULK DENSITY 1.59g/cc 1.45-1.65g/cc IS : 2386 PART III

TABLE 4: Properties of grog

Properties Grog

Specific gravity 2.525

Bulk density 970 kg / m3

Percentage of voids 61.58%

Table 5: Laboratory tests

In the study work, the number of tests to be performed is given below:

% of sand 0% 30% 50% 70%

7 days 3 3 3 3

No of moulds 28 days 3 3 3 3

Table 6: Average Compressive Strength of concrete

Grog replacement
Days
0% 30% 50% 70%

7 days 13.5 6.68 11.2 8.97

28days 20 14.71 19 16.4

 Fig 2. Grading curve for grog

Graph showing percentage of grog replacement and strength

Fig 3 Grog replacement