DESIGN AND INNOVATION HUB PROJECT ON

OPTIMISATION OF FRESH BUILDING MATERIAL TO

ACHIEVE SPECIFIC STRENGTH OF CEMENT
CONCRETE
BY MIX DESIGN OF DIFFERENT GRADE OF CEMENT
CONCRETE WITH USE OF RECYCLED AGGREGATE
AND SCRAP OF MILD STEEL AND LIMESTONE
SLURRY OR STONE DUST
DESIGN AND INNOVATION HUB (DIH) PROJECT ON

IMPROVEMENT OF COMPRESSIVE STRENGTH OF

RECYCLED AGGREGATE BASED CONCRETE WITH MILD
STEEL SCRAP AND STONE DUST
 GROUP MEMBERS

• Abhishek Chawala (16065001)

• Avinash Kumar (16065018)
• Suraj Soni (16065064)
• Vinayak Chaturvedi (16064020)

MENTOR
Dr. K. K. Pathak

Professor
Civil Engg., IIT BHU
 C & D PLANT IN BURARI, NEW DELHI
THE MATERIAL USED IN THE PROJECT WERE BROUGHT FROM THIS PLANT SITUATED IN NEW
DELHI
 INTRODUCTION / PROBLEMS FACED

• Concrete is the most commonly used man made material and the second most consumed substance in the world
behind water.
• At present time the demand of concrete is about 3 tonne per person per annum.
• Concrete contains about 60% of coarse aggregate and about 20-25% of sand. Due to high demand both of the
above resources are depleting very rapidly.
• Along with this the waste created due to demolition of buildings is increasing day by day and it’s dumping has
become a big problem.
• Stone powder produced from stone crushing zones appears as a problem for effective disposal.
 DISADVANTAGES OF RECYCLED AGGREGATE

One of the answers to the problems raised above is using recycled aggregate instead of virgin aggregate but it
raises certain problems
• Downgrading of quality of concrete.
• Increase in water absorption capacity ranging from 3% to 9%
• Decrease in compressive strength of concrete (10-30%)
• Reduces workability of concrete.
• Lack of specifications and guidelines.
• Less durability of RAC
• PEARMIBILITY OF RECYCLE AGGREGATE INCREASES
 OBJECTIVE

• Using recycled aggregate instead of fresh aggregate and adding mild steel to it to compensate the lost compressive
strength.
• Replacing some amount of sand with stone dust to find the max compressive strength at the optimum value of
stone dust in the above noted materials.
• Decreasing the permeability of recycled aggregate concrete by using stone dust.
• Comparing the results obtained here to those obtained using fresh aggregate to assess the strength of the cement
concrete.
• Designing the composition of materials after keeping the situation in mind.
 MATERIALS USED

• Recycled aggregate along with mild steel scrap instead of Fresh aggregate as course aggregate
• Sand as fine aggregate
• Stone dust partially substituting sand
• PPC Cement
• Water (pH 6.5-8.5)

Cement Stone Dust Recycled Concrete

 RECYCLED AGGREGATE AND MILD STEEL

• It is obtained by breaking, removing, and crushing demolition

waste into a material with a specified size and quality.
• Recycled aggregates used were from demolition waste from
IL & FS, Burari, New Delhi.
• Mild steel scrap used here strengthens the recycled aggregate
and compensates for the lost strength.
• Mild steel is very strong due to the low amount of carbon it
contains. Mild steel has a high resistance to breakage.
 SAND AND STONE DUST

• Sand used in the experiments was of Grade Zone II

• Stone powder is formed during the process of comminution
of rock into crushed sand which act as an alternative of sand.
• Substitution of normal sand by stone powder will
serve both solid waste minimization and waste recovery.
 CEMENT AND WATER

• Portland Pozzolana Cement (PPC) was used

in the casting of the concrete blocks.
• Bulk Density = 1.3
• Sp. Gravity = 2.97
• The water used for curing and mixing must be
free from high quantities of alkalis, acid, oils, salt,
sugar, organic materials, vegetable growth, etc
that might be deleterious to bricks, concrete or iron
 TESTS PERFORMED

• Sieve analysis
• Water absorption test
• Slump test
• Compressive Strength Test

Pycnometer Wetted Aggregate

Water absorption Test Slump Test
 SIEVE ANALYSIS

• It is a procedure used to assess the particle size distribution

of a granular material by allowing the material to pass through
a series of sieves of progressively smaller mesh size and weighing
the amount of material that is stopped by each sieve as a
fraction of the whole mass.
• The fine aggregates are graded according to the
IS code 2386 :Part I into different zones.
• From the analysis shown below we obtain that the
Sand and the stone dust used both are of Grade Zone II. Sieve Shaker
 ALL THE VALUES ARE IN % PASSING

Sieve Size 20 mm Aggregate 10 mm Aggregate Sand Stone Dust

20mm 92.4 100 100 100
10mm 0.05 94.65 100 100
4.75mm - 41.5 98 98.4
2.36mm - 4.15 95 90.8
1.18mm - 0.1 84.6 72.6
600µm - - 52 57.4
300µm - - 10.8 28.6
150µm - - 1.0 2.02
Bulk Density 1.68g/cc 1.60g/cc 1.75g/cc
Sp. Gravity 2.84 2.83 2.62 1.55
Fineness Modulus 7.076 5.596 2.596
 WATER ABSORPTION TEST

• Coarse aggregates (using buoyancy)

Absorption (For 10mm) : 0.55%
Absorption (For 20mm) : 0.50%
• Fine aggregate (Pycnometer test)
Bulk Specific Gravity (G):
• G = A / (B-C)
• Where: A = Oven dry wt., B = SSD(Saturated, Surface Dry) wt., C = Wt. in water
• Absorption (% A) = [ (B-A) / A] x 100
Absorption (for Sand) : 2.5% Absorption (for Stone dust) : 3%
 MIX DESIGN DATA

• Target strength = 20+1.65*4.6=27.59 kN/mm2

• W/C ratio = 0.45
• Water (for 75 mm slump) = 186*1.06 = 197.16 lit
• Cement = 438.13 kg
• Required Sand = 35%
• Air Entrapped = 2%
• Fine Aggregate = 568.68 kg
• Coarse aggregate = 1145.95 kg (10mm:20mm = 43:57) Casting acc. to the given data
Amount of concrete material ( IS10262: 1982)
Water,
197.16 kg
Cement, Coarse Aggregate (20mm),
( 8.40% )
438.13 kg 658.13 kg
( 18.64% ) ( 28.00% )

Fine Aggregate, Coarse Aggregate (10mm),

568.68 kg 487.83 kg
( 24.20% ) ( 20.76% )
 RATIO OF THE MATERIALS USED

• Ratio by mass
Water : Cement : Sand : CA (10mm) : CA (20mm)
0.45 : 1.0 : 1.3 : 1.1135 : 1.502
• Ratio by volume
Water : Cement : Sand : CA (10mm) : CA (20mm)
1.34 : 1.0 : 1.47 : 1.17 : 1.571
 EXPERIMENT

• In the experiment performed we have added mild steel scrap step by step by replacing coarse aggregate.
• Initially the specimen do not contain any mild steel , then we replace 1% ,2% and 3% of coarse aggregate with mild
steel.
• Along with change in mild steel scrap we will vary the amount of the stone dust added to the specimen which
replaces fine aggregate.
• First the specimens are made without any stone dust and then we increase the %age of stone dust to 5%, 10%,
15% and 20% and record the readings.
• We will try to get the value of the additives at which the compressive strength of concrete equals the fresh
concrete strength.
 SLUMP TEST

• Slump is a measurement of concrete's workability, or fluidity.

• It's an indirect measurement of concrete consistency or stiffness
• The concrete slump test measures the consistency of fresh concrete
before it sets. It is performed to check the workability of freshly
made concrete, and therefore the ease with which concrete flows.
• Slump obtained from the concrete used was around 75 mm.
 COMPRESSIVE STRENGTH TEST

• Concrete designed is of M20 Grade.

• Compressive strength of concrete cube test provides
an idea about all the characteristics of concrete.
• Compressive strength of concrete depends on many factors
such as water-cement ratio, cement strength, quality of
concrete material, quality control during production of
concrete etc.
Variation of Compressive Strength with change
in amount Recycled Aggregate and Steel Scrap
(0% Stone Dust and 100% Fine Aggregate )

100% R.A. + 0% Steel Scrap 99% R.A. + 1% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at 28
Days 28 Days Days
Days
Sample 1 11.81 18.4 Sample 1 14.63 23.67
Sample 2 12.61 21.6 Sample 2 13.47 21.38
Sample 3 11.66 20.18 Sample 3 11.02 19.30
Average 13.04 21.45
Average 12.02 20.06
CONTINUE…

98% R.A. + 2% Steel Scrap 97% R.A. + 3% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 15.87 18.15 Sample 1 13.92 22.87

Sample 2 11.72 25.62 Sample 2 17.36 21.63
Sample 3 13.69 24.27 Sample 3 11.98 26.81
Average 13.76 22.68 Average 14.42 23.77
 Variation of Concrete Strength with change in amount of Recycled Aggregate and Mild
Steel (All other materials remain constant)
25
23.77
22.68
21.45
20.06
20
Strength (N/mm² )

15 14.42
13.76
13.04
12.02

10

0
100% Recycled Aggregate + 99% Recycled Aggregate + 98% Recycled Aggregate + 97% Recycled Aggregate +
0% Mild Steel 1% Mild Steel 2% Mild Steel 3% Mild Steel

7 Days Strength ( N/mm² ) 28 Days Strength ( N/mm² )

Variation of Compressive Strength with change
in amount Recycled Aggregate and Steel Scrap
(5% Stone Dust and 95% Fine Aggregate )

100% R.A. + 0% Steel Scrap 99% R.A. + 1% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 14.20 21.2 Sample 1 14.98 22.42

Sample 2 12.97 20.67 Sample 2 16.81 24.32
Sample 3 14.08 23.74 Sample 3 14.83 22.98
Average 13.75 21.87 Average 15.54 23.24
CONTINUE…

98% R.A. + 2% Steel Scrap 97% R.A. + 3% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 15.95 23.21 Sample 1 18.20 27.20

Sample 2 17.87 24.50 Sample 2 16.87 25.10
Sample 3 16.22 27.14 Sample 3 17.37 26.14
Average 16.68 24.95 Average 17.48 26.15
 Variation of Concrete Strength with change in amount of Recycled Aggregate and Mild
Steel ( 5% Stone Dust + 95% Fine Aggregate + All other materials remain constant)
30

26.15
24.95
25
23.24
21.87
Strength (N/mm² )

20
17.48
16.68
15.54
15 13.75

10

0
100% Recycled Aggregate + 99% Recycled Aggregate + 98% Recycled Aggregate + 97% Recycled Aggregate +
0% Mild Steel 1% Mild Steel 2% Mild Steel 3% Mild Steel

7 Days Strength ( N/mm² ) 28 Days Strength ( N/mm² )

Variation of Compressive Strength with change
in amount Recycled Aggregate and Steel Scrap
(10% Stone Dust and 90% Fine Aggregate )

100% R.A. + 0% Steel Scrap 99% R.A. + 1% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 13.70 21.07 Sample 1 14.77 24.70

Sample 2 15.10 24.6 Sample 2 15.6 23.69
Sample 3 15.75 20.82 Sample 3 15.59 22.35
Average 14.85 22.16 Average 15.32 23.56
CONTINUE…

98% R.A. + 2% Steel Scrap 97% R.A. + 3% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 15.71 23.71 Sample 1 18.87 26.13

Sample 2 16.82 25.41 Sample 2 17.03 23.12
Sample 3 15.59 25.67 Sample 3 16.23 28.21
Average 16.04 24.93 Average 17.37 25.82
 Variation of Concrete Strength with change in amount of Recycled Aggregate and Mild
Steel ( 10% Stone Dust + 90% Fine Aggregate + All other materials remain constant)
30

25.82
24.93
25
23.58
22.166
Strength (N/mm² )

20
17.377
16.44
14.85 15.32
15

10

0
100% Recycled Aggregate + 99% Recycled Aggregate + 98% Recycled Aggregate + 97% Recycled Aggregate +
0% Mild Steel 1% Mild Steel 2% Mild Steel 3% Mild Steel

7 Days Strength ( N/mm² ) 28 Days Strength ( N/mm² )

Variation of Compressive Strength with change
in amount Recycled Aggregate and Steel Scrap
(15% Stone Dust and 85% Fine Aggregate )

100% R.A. + 0% Steel Scrap 99% R.A. + 1% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 14.87 24.67 Sample 1 16.87 23.51

Sample 2 16.21 21.90 Sample 2 14.20 24.7
Sample 3 14.10 23.63 Sample 3 16.78 26.24
Average 15.06 23.40 Average 15.95 24.82
CONTINUE…

98% R.A. + 2% Steel Scrap 97% R.A. + 3% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 15.87 25.17 Sample 1 17.34 29.12

Sample 2 16.71 26.97 Sample 2 19.17 26.99
Sample 3 17.96 26.46 Sample 3 18.36 29.23
Average 16.85 26.20 Average 18.29 28.44
 Variation of Concrete Strength with change in amount of Recycled Aggregate and Mild
Steel ( 15% Stone Dust + 85% Fine Aggregate + All other materials remain constant)
30
28.44

26.2
24.82
25
23.4
Strength (N/mm² )

20
18.29
16.846
15.95
15.06
15

10

0
100% Recycled Aggregate + 99% Recycled Aggregate + 98% Recycled Aggregate + 97% Recycled Aggregate +
0% Mild Steel 1% Mild Steel 2% Mild Steel 3% Mild Steel

7 Days Strength ( N/mm² ) 28 Days Strength ( N/mm² )

Variation of Compressive Strength with change
in amount Recycled Aggregate and Steel Scrap
(20% Stone Dust and 80% Fine Aggregate)

100% R.A. + 0% Steel Scrap 99% R.A. + 1% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 11.86 20.02 Sample 1 12.95 20.87

Sample 2 13.40 17.60 Sample 2 13.97 19.67
Sample 3 10.89 17.7 Sample 3 12.14 19.52
Average 12.05 18.44 Average 1302 20.20
CONTINUE…

98% R.A. + 2% Steel Scrap 97% R.A. + 3% Steel Scrap

Compressive Compressive Compressive Compressive

Strength at 7 Strength at Strength at 7 Strength at
Days 28 Days Days 28 Days

Sample 1 13.60 20.70 Sample 1 15.21 21.96

Sample 2 15.87 21.86 Sample 2 13.67 22.87
Sample 3 12.55 21.58 Sample 3 15.16 22.24
Average 14.07 21.38 Average 14.68 22.36
 Variation of Concrete Strength with change in amount of Recycled Aggregate and Mild
Steel ( 20% Stone Dust + 80% Fine Aggregate + All other materials remain constant)
25

22.36
21.38
20.2
20
18.44
Strength (N/mm² )

14.68
15 14.06
13.02

11.05

10

0
100% Recycled Aggregate + 99% Recycled Aggregate + 98% Recycled Aggregate + 97% Recycled Aggregate +
0% Mild Steel 1% Mild Steel 2% Mild Steel 3% Mild Steel

7 Days Strength ( N/mm² ) 28 Days Strength ( N/mm² )

 RESULTS

• We can easily observe that the compressive strength of the specimens is max at 15% stone dust and 3% mild steel
• The maximum compressive strength of the specimen sample
At 7 Days : 18.29 N/mm2 At 28 Days :28.44 N/mm2
• The compressive strength of the specimen with fresh aggregate
At 7 Days : 18.9 N/mm2 At 28 Days : 28.78 N/mm2
COMPARISON OF MAX ACHIEVED STRENGTH AND
STRENGTH OF VIRGIN AGGREGATE
Comparison of the recycled with virgin aggregate concrete

29
27
25
23
21
19
17
15
7 Days 28 Days
Fresh aggregate Recycled aggregate Column1
 COST EVALUATION

• The cost for concrete with virgin aggregate is calculated as below

Coarse aggregate : Rs. 2400 / m3
Sand : Rs.1235 / m3
Cement : Rs. 17820 / m3
Transportation : Rs. 400 Total cost for 1 cubic metre of concrete: Rs. 4400
• Cost for concrete with recycled coarse aggregate , stone dust and metal scrap
Sand : Rs.1235 / m3
Cement : Rs. 17820 / m3 Total cost for 1 cubic metre of concrete: Rs. 2995
 EFFECTS ON CONCRETE DUE TO STONE DUST

• Change in Slump : As the %age of dust in the concrete increases, the slump of concrete decreases. As the
percentage of dust increases, the fineness of aggregate increases and in turn, the specific surface of aggregate
particles increases. So, more water was required to wet the concrete and consequently, workability decreases.
• Absorption : Crushed stone dust acts as a filler in the concrete and reduces the absorption of concrete.
• Water Permeability : The addition of dust to the concrete improves the impermeability of concrete because it
blocks the passages connecting capillary pores and the water channels. This blockage is affected by the amount of
dust content, and the more water passages were blocked, the more reduction in the permeability of concrete
specimens is observed.
 BENEFITS OF USING RECYCLED AGGREGATE

• The use of recycled aggregate can save money for local governments and other purchasers
• Save energy when recycling is done on site
• Conserve diminishing resources of urban aggregates.
• Creates more employment opportunities is recycling industry.
• While being crushed into smaller particles a large amount of carbon dioxide is absorbed. This reduces the amount
of CO2 is the atmosphere.
• Conserves landfill space, reduces the need for new landfills and hence saving more costs.
RECYCLED AGGREGATE IN INDIA

• Currently India has a severe shortage of infrastructural facilities. Nonetheless India is

constructing its foundation at a very fast rate. In this process of construction and
reconstruction it has become the second largest producer of cement in the world only
after China. Though it is not even in top ten when it comes to production of recycled
aggregate concrete. One of the main reasons for it is the lack of proper source concrete
in India. But if willed, the demand can be fulfilled with the help of Gulf Cooperation
Council (GCC) countries like UAE, Saudi Arabia, etc.
• Now as the govt. is gearing up for development of new cities, buildings, roads etc., the
gates are wide open for production of more RAC.
SCOPE FOR FUTURE EXTENSION OF THE PROJECT:

• A series of tests could be done about the use of wastes such as stone dust, metal scrap,
brick chips, broken tiles, marble dust etc. by first adding them separately and then
combining them to check the properties of concrete such as Water Absorption, Water
Penetration, Compressive Strength, Flexural Strength, Impact Resistance, Water
Permeability, Drying Shrinkage, Durability etc.
• Since the increasing demand of concrete and rapid depletion in its materials used and
environmental hazards are troublesome problems and it are crying out loud for
replacements of the present way and we have to provide it, as soon as possible.
REFERENCES: -

• Tahir Celik and Khaled Marar Department of Civil Engineering, Eastern Mediterranean
University, Magusa, Mersin 10 Turkey
• Scrap Specifications Revised March 2012 Contacts: Mike Russ & Marty Wallace
• ISHER C, WERGE M. EU AS A RECYCLING SOCIETY. ETC./SCP WORKING PAPER
2/2009. AVAILABLE ON
• IS : 383-1970 Specifications for coarse and fine aggregates from natural sources for
concrete (second revision) BIS, New Delhi
• IS CODE: 10262-1982 CONCRETE MIX DESIGN.