INTERNATIONALJOURNALOFCIVILANDSTRUCTURALENGINEERING Volume1,No 3,2010

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ResearchArticle

ISSN0976 4399

Investigationsonstonedustandceramicscrapasaggregate replacementinconcrete
VeeraReddy.M Professor,CivilEngineeringDepartment,KakatiyaInstituteofTechnologyand ScienceWarangal 506015,AndhraPradesh. muralavreddy@gmail.com ABSTRACT Conservationofnaturalresourcesandpreservationofenvironmentistheessenceofany development. The problem arising from continuous technological and industrial development isthedisposalofwaste material.If someofthewaste materialsare found suitableinconcretemaking,notonlycostofconstructioncanbecutdown,butalsosafe disposalofwastematerialscanbeachieved.Sointhepresentpaper,anattempthasbeen madetoassessthesuitabilityofstonedustandceramicscrapinconcretemaking.Inthe laboratorystonedusthasbeentriedasfineaggregateinplaceofsandandceramicscrap has been used as partial/full substitute to conventional coarse aggregate in concrete making.Cubes,cylindersandprismswerecastandtestedforcompressivestrength,split tensile strength and modulus of rupture after a curing period of 28 days. The results indicated effectiveness of stone dust as fine aggregate and partial replacement of conventional coarse aggregate by ceramic scrap upto 20 percent, without affecting the designstrength. Keywords:Stonedust,ceramicscrap,economical,wasteproducts,disposal. 1.Introduction Inthelastdecade,constructionindustryhasbeenconductedresearchontheutilizationof waste products in concrete. Some of waste products are fly ash, rice husk, saw dust, discarded tires, plastic, glass rock, steel slugs, stone dust and ceramic. Each waste producthasitsspecificeffectonpropertiesoffreshandhardconcrete.Theuseofwaste products in concrete notonly makes it economical but also solves some of the disposal problems. The crushed rock flour can be used to replace the natural sand in concrete (NagarajandBanu,1996).Theuseofcrushedceramicaggregatecanbeusedtoproduce lightweight concrete, without affecting strength (Kanaka sabai et. al, 1992). The stone dust canbeusedasalternative material inplaceofsand inconcretebasedongrainsize data (Babu shanker et al,1992). Sand can replaced by rock flour upto 40% without affectingstrengthandworkability(Sahuetal,2003).Thesandcanbereplacedfullywith rockflour(Rao.S.Pet,2002).Howeveraslightlossinworkabilityhasbeennoticedwith increase in replacement of san by rock flour. Sand can be replaced fully by rock flour withoutmuchlossofworkability (Rao.G.Tet.al,2002). Nearly 20% of rock is converted into rock flour while crushing rock into aggregate at stonecrushingplants.Inceramicinsulatorindustry,thereisamassfailureofabout30to 50% of the total production due to improper mixing of raw materials, excess water, 661

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improper drying and too much of heating. No work has been reported using stone dust andceramicscraptogetherinconcretesofar.Hencethepresentworkhasbeenplanned toevaluatesuitabilityofthesewastematerialsinconcreteproduction. 2.ExperimentalProgram 2.1 Materials 2.1.1 Cement Thecementforthewholeworkwasprocuredinasingleconsignmentandproperlystored. The properties of cement (IS: 12269, 1987) used in the investigation are presented in Table1. 2.1.2 FineAggregate a) Sand: River sand was used as fine aggregate.The specific gravity of sand was 2.65 andfinenessmodulusoffinenesswas2.54 b) Stonedust:Stonedustusedinthelaboratoryinvestigationswasprocuredfromalocal crushingplant.Thespecificgravityofstonedustwas2.63andfinenessmoduluswas 2.67 2.1.3 CoarseAggregate a) Conventional Coarse Aggregate: Machine crushed granite obtained from a local Quarrywasusedascoarseaggregate. c) Ceramic Scrap: The ceramic scrap was obtained from a local ceramic insulator industry. The ceramic insulators are initially broken into pieces with hammer into requiredsize. ThepropertiesofConventionalaggregateandcrushedinsulatorceramicscrapareshown inTable2.andthesieveanalysisdataof fineandcoarseaggregatedataispresented in Table3 2.2PreparationofSpecimens ThequantitiesoftheconstituentsoftheconcretewereobtainedfromtheIndianStandard Mix Design method (IS: 10262,1982). The variation of strength of hardened concrete using stone dust as fine aggregate and ceramic scrap as partial / full replacement is studied by casting cubes, cylinders and prisms. The concrete was prepared in the laboratoryusing mixer. The cement, fine aggregate and coarse aggregate were first mixedindrystatetoobtainuniformcolourandcalculatedamountofwaterobtainedfrom workability test was added and the whole concrete was mixed for five minutes in wet

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state. Meanwhile the moulds are screwed tightly to avoid leakage oil was applied on innersurfaceofthe moulds.Theconcreteaftermixingwaspouredintomoulds inthree layers by poking with a tamping rod. The cast specimens were removed from moulds after24hoursandthespecimenswere immersedinacleanwatertank.Aftercuringthe specimensforaperiodof28days,thespecimenswereremovedfromthewatertankand allowedtodryundershade. Table1:Propertiesofcement
Sl.No 1 2 3 4 5 6 Specific Initial Finalsetting Standard Compressive Property Fineness gravity settingtime time consistency strength 2 Value 3.00 97.80 68min 9hours28min 30.00% 54.28N/mm

Table2:Propertiesof coarseaggregate
Sl.No 1 2 3 Property Sp.gravity Finenessmodulus Impactvalue ConventionalCoarse 2.70 6.90 16.50 aggregate Ceramicscrap 2.40 7.06 18.20 4 Crushingvalue 20.20 24.70

Table3:DetailsofSieveanalysisoffineandcoarseaggregate. Percentagepassing Fineaggregates Coarseaggregates Natural Ceramic aggregates scrap 100 93.20 11.20 5.20 100 87.20 5.20 1.20

Sl.no

Sieve Design Natural Rock ation sand flour 40mm 20mm 10mm 4.75mm 2.36mm 1.18mm 600microns 300microns 150microns 100 100 98.40 77.20 45.50 12.60 8.8

1 2 3 4 5 6 7 8 9

100 100 98.20 75.60 46.60 8.40 4.20

ConformingIS383 1970

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3.Tests Foreachbatchofconcrete,threecubesof150mmX150mmX150mmsizeweretestedto determine compressive strength (IS: 516, 1959). Three prisms of 100mmX100mmX500mm sizeweretestedin flexure(IS:9399,1979)underthreepoint loading to determine modulus of rupture. And three cylinders of 150mmdia.X300mm heightsizeweretestedforsplittensilestrength (IS:5816,1999). 3.1 MixSelection ThegradeofconcreteadoptedforinvestigationwasM25.Themixproportionofconcrete for laboratory investigations was arrived by designing as per Indian standard method. Thefinalmixusedwas1:1.62:3.24withwatercementratioof0.48.Thedetailsofmix designationsandspecimensusedinexperimentalprogrammearegiveninTable4. Table4:DetailsofMixdesignationsandspecimens Sl. Mix Fine Coarseaggregate Numberofspecimens NoDesignation aggregate Conventional Ceramicscrap CubesCylindersPrisms 1. MC Sand 100% 3 3 3 2. 3. 4. 5. 6. 7. 8. M0 M1 M2 M3 M4 M5 M6 Stonedust Stonedust Stonedust Stonedust Stonedust Stonedust Stonedust 100% 90% 80% 70% 60% 50% 10% 20% 30% 40% 50% 100% 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

4.ResultsandDiscussions AftercomparisonpropertiespresentedinTable3,itisobservedthatthestonedustcanbe used as conventional fine aggregate. By comparing the properties of ceramic scrap and conventionalcoarseaggregatepresentedinTable2,itcanbeconcludedthattheceramic scrapcanbeusedinplaceofconventionalcoarseaggregate. TheexperimentaltestresultsarepresentedinTable5.ItcanbeobservedfromtheTable 5thatthestrengthofconcreteis increasedduetousageofstonedustasfineaggregate. Butstrengthisreducingduetousageofceramicscrapascoarseaggregate.AndItisclear

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from the fig. 1 that replacement of coarse aggregate by ceramic scrap in excess of 20 percent,leadstoreductionofstrengthbelowconventionalmix(MC).Henceinconcrete withstonedustasfineaggregate,conventionalcoarseaggregatecanbereplacedpartially byceramicscrapupto20percent. Table5:Theexperimentaltestresults
Sl.No MixDesignation 2 Compressivestrength(N/mm ) 2 Splittensilestrength(N/mm ) 2 Modulusofrupture(N/mm ) 1 2 3 4 5 6 7 8 MC M0 M1 M2 M3 M4 M5 M6 33.93 35.85 34.52 33.93 33.78 33.34 33.19 32.59 3.25 3.35 3.28 3.26 2.97 2.93 2.88 2.83 4.98 5.16 5.06 4.98 4.80 4.74 4.56 4.40

Figure1:Imageshowingthevariationofstrengthvs%ceramicscrap 5.Conclusions Thefollowingconclusionsaredrawnfromthepresentinvestigationscarriedout: Stonedustcanbeeffectivelyusedas fineaggregateinplaceofconventionalriversand, inconcrete.

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Ceramic scrap can be partially used to replace conventional coarse aggregates (10 to 20%),withoutaffectingitsstructuralsignificance. 6.References 1. Babu Shankar, N. and Md.Ali,1992., Engineering Properties of Rock Flour. National Conference on Cement and Building Materials from Industrial Waste., pp167172. 2. Nagaraj, T. S. and Zahida Banu.1996, Efficient utilization of rock dust and pebbles as aggregate in Portland cement concrete. The Indian Concrete Journal, Vol70,No1,pp14. 3. Sahu. A. K., Sunil Kumar and Sachin. A. K, 2003, Crushed stone waste as fine aggregateforConcrete.TheIndianconcretejournal. 4. Kanaka Sabai, V. and Raja Shekaran A.,1992, Ceramic insulator scrap as Light Weight Concrete. National Conference on Cement and Building Materials from IndustrialWastes.pp815. 5. Rao.S.P.,SeshagiriRao.M.VandSravana,2002,Effectofcrusherstoneduston some properties of concrete. National conference on advances in construction materials,ACIM,Harmipur,H.P,Pp196201. 6. Rao G.T and Andal T.,2002, A study of behaviour of concrete with stone sand replacing river sand. National conference on advances in construction materials, ACIM,Harmipur,H.P,Pp196201. 7. IS: 122691987,Specification for 53 Gradeordinary Portland cement. BIS New Delhi 8. IS:3831970,SpecificationforCoarseandFineAggregatesfromnaturalsources forconcrete(Secondrevision). 9. IS: 9399 1979, Specification for apparatus for flexural testing of concrete. BISNewDelhi 10. IS:5161959,methodoftestforstrengthofconcreteBureauofIndianstandards. NewDelhi,India 11. IS: 10262 1982 recommended guidelines for concrete mix Design, BIS. New Delhi,India,1982. 12. IS: 58161999 method of test for splitting tensile strength of concrete BIS New Delhi.

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