replacement of natural sand with efficient alternatives...
TRANSCRIPT
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Replacement of Natural Sand with Efficient Alternatives: Recent
Advances in Concrete Technology
Anzar Hamid Mir Student, Bachelor of Civil Engineering, IUST Awantipora, J&K, INDIA
ABSTRACT
Concrete is the most undisputable material being used in infrastructure development throughout the world. It
is a globally accepted construction material in all types of Civil Engineering structures. Natural sand is a
prime material used for the preparation of concrete and also plays an important role in Mix Design. Now a
day‟s river erosion and other environmental issues have led to the scarcity of river sand. The reduction in the
sources of natural sand and the requirement for reduction in the cost of concrete production has resulted in the
increased need to find new alternative materials to replace river sand so that excess river erosion is prevented
and high strength concrete is obtained at lower cost. Partial or full replacement of natural sand by the other
alternative materials like quarry dust, foundry sand and others are being researched from past two decades, in
view of conserving the ecological balance. This paper summarizes conclusions of experiments conducted for
the properties like strength, durability etc. It was observed the results have shown positive changes and
improvement in mechanical properties of the conventional concrete due to the addition or replacement of fine
sand with efficient alternatives.
KEYWORDS: Concrete, Natural sand, Alternative materials, Quarry dust, Foundry sand, Mechanical
properties.
I. I.INTRODUCTION Concrete is that pourable mix of cement, water,
sand, and gravel that hardens into a super-strong
building material. Aggregates are the important
constituents in the concrete composite that help in
reducing shrinkage and impart economy to concrete
production. River Sand used as fine aggregate in
concrete is derived from river banks. River sand has
been the most popular choice for the fine aggregate
component of concrete in the past, but overuse of the
material has led to environmental concerns, the
depleting of river sand deposits and an increase in the
price of the material. The developing country like
India( Authors native land) facing shortage of good
quality natural sand and particularly in India, natural
sand deposits are being used up and causing serious
threat to environment as well as the society. The
rapid extraction of sand from the river bed causes
problems like deepening of the river beds, loss of
vegetation on the bank of rivers, disturbance to the
aquatic life as well as agriculture due to lowering the
water table in the well etc. Therefore, construction
industries of developing countries are in stress to
identify alternative materials to replace the demand
for river sand. Hence, partial or full replacement of
river sand by the other compatible materials like
crushed rock dust, quarry dust, glass powder,
recycled concrete dust, and others are being
researched from past two decades, in view of
conserving the ecological balance. The reuse of this
waste will help to save cost, conserve limited
resources and ultimately protect the environment.
Due to shortage of river sand as well as its high
the Madras High Court restrictions on sand mining in
rivers Cauvery and Thamirabarani. The facts like in
India is almost same in others countries also. So
therefore the need to find an alternative concrete and
mortar aggregate material to river sand in
construction works has assumed greater importance
now a days. Researcher and Engineers have come out
with their own ideas to decrease or fully replace the
use of river sand and use recent innovations such as
M-Sand (manufactured sand), robot silica or sand,
stone crusher dust, filtered sand, treated and sieved
silt removed from reservoirs as well as dams besides
sand from other water bodies [16].
II. EFFICIENT ALTERNATIVE
MATERIALS TO RIVER SAND Concrete is the second largest consumable
material after water, with nearly three tonnes used
annually for each person on the earth. India
consumes an estimated 450 million cubic meter of
concrete annually and which approximately comes to
1 tonne per Indian. Bureau of Indian Standards, the
National Standards Body of the country, considering
the scarcity of sand from natural sources, has evolved
number of alternatives which are ultimately aimed at
conservation of natural resources apart from
promoting use of various waste materials without
compromising in quality. use of these alternative
RESEARCH ARTICLE OPEN ACCESS
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materials such as fly ash, slag, not only help in
conserving our precious natural resources but also
improve the durability of structures made using these.
2.1 COPPER SLAG
Copper slag is an abrasive blasting grit made of
granulated slag from metal smelting processes (also
called iron silicate). During the past two decades,
attempts have been made by several researchers all
over the world to explore the possible utilization of
copper slag in concrete. At present about 33 million
tonnes of copper slag is generating annually
worldwide among that India contributing 6 to 6.5
million tonnes. 50 % copper slag can be used as
replacement of natural sand in to obtain mortar and
concrete with required performance, strength and
durability. (Khalifa S. Al-Jabri et al 2011)
Fig 1: Copper slag[17]
2.2 GRANULATED BLAST FURNACE SLAG
Granulated blast-furnace slag (GBFS) is
obtained by quenching molten iron slag (a by-product
of Iron and steel-making) from a blast furnace in
Water or steam, to produce a glassy, granular product
that is then dried and ground into a fine powder.
GBFS has been adopted for its superiority in concrete
durability, extending the lifespan of buildings from
fifty years to a hundred years.
Fig 2: Granulated blast-furnace slag[17]
According to the report of the Working Group on
Cement Industry for the 12th five year plan, around
10 million tonnes blast furnace slag is currently being
generated in the country from iron and steel industry.
The compressive strength of cement mortar increases
as the replacement level of granulated blast furnace
slag (GBFS) increases. He further concludes that
from the test results it is clear that GBFS sand can be
used as an alternative to natural sand from the point
of view of strength. Use of GBFS up to 75 per cent
can be recommended [2].
2.3WASHED BOTTOM ASH (WBA)
The WBA is a waste material that is taken from
electric power plant and the source material is called
as bottom ash. Figure 3 show the typical steam
generating system that illustrated the bottom ash
dispose at the bottom furnace and fly ash is dispose
to atmosphere by very tall chimney.
Fig 3: The production of coal combustion by-
products in steam generating system. (NETL,2006).
2.4 QUARRY DUST (QD)
Quarry dust is fine rock particles. When
boulders are broken into small pieces quarry dust is
formed. It is grey in colour and it is like fine
aggregate. In concrete production it could be used as
a partial or full replacement of natural sand. Besides,
the utilization of quarry waste, which itself is a waste
material, will reduce the cost of concrete production.
2.4.1 ORIGIN OF QUARRY DUST
The quarry dust is the by-product which is
formed in the processing of the granite stones which
broken downs into the coarse aggregates of different
sizes.
FIG 4: Quarry Dust[17]
2.5 FOUNDRY SAND
Foundry sand is sand which when moistened &
compressed or oiled or heated tends to pack well and
hold its shape. It is used in the process of sand
casting. India ranks fourth in terms of total foundry
production (7.8 million tonnes) according to the 42nd
Census of World Casting Production of 2007.
Foundry sand which is very high in silica is regularly
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discarded by the metal industry. Currently, there is no
mechanism for its disposal, but international studies
say that up to 50 per cent foundry sand can be
utilized for economical and sustainable development
of concrete (Vipul D. Prajapati 2013)[8].
Fig 5: Foundry sand[17]
2.6 SHEET GLASS POWDER (SGP)
Glass is amorphous material with high silica
content, thus making it potentially pozzolanic when
particle size is less than 75μm(Federio.L.M and
Chidiac S.E,2001, Jin.W, Meyer.C, and
Baxter.S,2000). The use of recycled glass as
aggregate greatly enhances the aesthetic appeal of the
concrete. Natural sand was partially replaced (10%,
20%, 30%, 40% and 50%) with SGP. Compressive
strength, Tensile strength (cubes and cylinders) and
Flexural strength up to 180 days of age were
compared with those of concrete made with natural
fine aggregates Attempts have been made for a long
time to use waste glasses as an aggregate in concrete,
but it seems that the concrete with waste glasses
always cracks .Very limited work has been conducted
for the use of ground glass as a concrete replacement.
(M. Mageswari and Dr. B.Vidivelli 2010) [9].
Fig 6: Glass powder[17]
2.7 CONSTRUCTION AND DEMOLITION
WASTE:
Construction and demolition waste is
generated whenever any construction/demolition
activity takes place, such as, building roads, bridges,
fly over, subway, remodelling etc. It consists mostly
of inert and non-biodegradable material such as
concrete, plaster, metal, wood, plastics etc. A part of
this waste comes to the municipal stream.
These wastes are heavy, having high density,
often bulky and occupy considerable storage space
either on the road or communal waste bin/container.
It is not uncommon to see huge piles of such waste,
which is heavy as well, stacked on roads especially in
large projects, resulting in traffic congestion and
disruption. Waste from small generators like
individual house construction or demolition, find its
way into the nearby municipal bin/vat/waste storage
depots, making the municipal waste heavy and
degrading its quality for further treatment like
composting or energy recovery. Often it finds its way
into surface drains, choking them. It constitutes about
10-20 % of the municipal solid waste (excluding
large construction projects).
Fig 7: Construction and demolition waste[17]
2.8 CRUSHED SPENT FIRE BRICKS (CSFB)
Fire bricks are the products manufactured (as
per IS: 6 and IS: 8 specifications) from refractory
grog, plastic, and non plastic clays of high purity.
The different raw materials are properly
homogenized and pressed in high capacity presses to
get the desired shape and size. Later, these are fired
in oil-fired kiln at a temperature of 1,300°C.
Fig 8: Fire brick samples
III. PHYSICAL AND MECHANICAL
PROPERTIES DIFFERENT
ALTERNATIVES 3.1 COPPER SLAG:
The sieve analysis for copper slag infers that the
gradation properties of fine aggregates at all the
replacement levels are similar to the specification for
sand zone II as per IS: 383.
The sieve analysis report is shown in Table 1
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Table 1[1] Fineness test on copper slag
The test results of concrete were obtained by
adding copper slag to sand in various percentages
ranging from 0%, 20%, 40%, 60%, 80% and 100%.
All specimens were cured for 28 days before
compression strength test, splitting tensile test and
flexural strength. The highest compressive strength
obtained was 35.11MPa (for 40% replacement) and
the corresponding strength for control mix was
30MPa. This results of the research paper showed
that the possibility of using copper slag as fine
aggregate in concrete. The results showed the effect
of copper slag on RCC concrete elements has a
considerable amount of increase in the compressive,
split tensile, flexural strength characteristics and
energy absorption characteristics [1].
3.2 GRANULATED BLAST FURNACE SLAG
The granulated blast furnace slag (GBFS) is
glassy particle and granular materials in nature and
has a similar particle size range like sand. The
specific gravity of the slag is 2.63. The bulk density
of granulated slag varies from 1430 kg/m3 which
were almost similar to bulk density of convectional
fine aggregate.
FIG 9 shows the gradation curve for both natural
sand and GBFS.
Fig 9
Investigation was carried out on cement mortar
mix 1:3 and GBFS at 0, 25, 50, 75 and 100%
replacement to natural sand for constant w/c ratio of
0.5 is considered (Table 2). The flow characteristics
of the mix and compressive strengths at various ages
are studied. From this study it is observed that there
is a considerable increase in compressive strength
evident from Table 2 thus GBFS could be utilized
partially as alternative construction material for
natural sand in concrete but there is reduction in
workability for all replacement levels. The
workability can be increased by adding suitable
dosage of chemical admixture such as super
plasticizer
Table 2
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3.3 WASHED BOTTOM ASH
The physical properties of washed bottom ash
are tabulated below in Table 3
Table 3: The physical properties of bottom ash
The fineness modulus is the summation of the
cumulative percentage retained on the sieve standard
series of 150, 300 and 600μm, 1.18, 2.36, 5.0 mm up
to the larger sieve size used. The calculated fineness
modulus of bottom ash was 3.65 which is more than
3.5 and is considered to be very coarse. For
categorization given in BS 822:1992 based on
percentage passing the 600μm sieve between 55%
to100% would defined it as fine sand. While WBA
has percentage passing 600μm of 58.99%. Therefore,
the WBA is considered as fine sand (Alexander &
Mindess, 2005)[3].
Generally, all concrete with WBA replacement
has increment in strength until long term duration i.e.
at 60 days. Different concrete mixes with constant
water to cement ratio of 0.55 were prepared with
WBA in different proportions as well as one control
mixed proportion. The mechanical properties of
special concrete with 30% WBA replacement by
weight of natural sand is found to be an optimum
usage in concrete in order to get a favourable strength
and good strength development pattern over the
increment ages [4].
3.4 QUARRY DUST: The physical properties of
quarry dust obtained by testing the sample as per the
Indian Standards are listed in the below table. Table
4: Showing the Physical properties of quarry dust and
natural sand
Quarry dust is poorly graded as compared to sand.
The particle size distribution of QD is shown in Fig
10
Fig 10
The results of the compression test are tabulated
below.
Table 5
The results show that there is an increase in the
compressive strength of the concrete [5,6] which the
increment is about 55% to 75% depending on the
replacement if the sand with the quarry dust, for the
100% replacement of the sand the compressive
strength is depending on the quarry dust location
from where the quarry dust was taken. The
workability of the concrete is decreasing when the
replacement percentage of the quarry dust is
increasing gradually; so as to increase the workability
small quantity of the fly-ash is replaced in place of
cement to increase the workability [7].
3.5 FOUNDRY SAND:
Table 6: Physical properties of foundry sand
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The fine aggregate has been replaced by used
foundry sand accordingly in the range of 0%, 10%,
30% & 50% by weight for M-20 grade concrete.
Concrete mixtures were produced, tested and
compared in terms of compressive and flexural
strength with the conventional concrete. These tests
were carried out to evaluate the mechanical
properties for 7, 14 and 28 days. This research work
is to investigate the behaviour of concrete while
replacing used foundry sand in different proportion in
concrete. This low cost concrete with good strength is
used in rigid pavement for 3000 commercial vehicles
per day and Dry Lean Concrete (DLC) 100mm thick
for national highway to make it eco-friendly [8]. The
maximum compressive strength was achieved with
50% replacement of fine aggregate with waste
foundry sand and it was found that there is overall
increase in the split tensile strength and flexural
strength of plain concrete.
3.6 SHEET GLASS POWDER
Table 7: Physical properties of Sheet Glass powder
The compressive strength of cubes and cylinders
of the concrete for all mix increases as the % of SGP
increases but decreases as the age of curing increases
due to alkali silica reaction. The Tensile strength of
cubes and cylinders of the concrete for all mix
increases than that of conventional concrete age of
curing and decreases as the SGP content increases.
The Flexural strength of the beam of concrete for all
mix increases with age of curing and decreases as the
SGP content increases. 100% replacement of SGP in
concrete showed better results than that of
conventional concrete at 28 days and 45 days curing
but later it started to decrease its strength because of
its alkali silica reactions. The density of SGP
concrete is more that of conventional concrete. SGP
is available in significant quantities as a waste and
can be utilized for making concrete. This will go a
long way to reduce the quantity of waste in our
environment. The optimum replacement level in fine
aggregate with SGP is 10% [9].
3.7 CONSTRUCTION AND DEMOLISHION
WASTE
The fine aggregate was replaced with crushed
waste sandcrete block (CWSB) in various
percentages in the steps of 10 starting from 10% to a
maximum of 100%, while 0% represents the control.
The properties of the concrete were evaluated at 7, 14
and 28 days curing periods. Results showed (Table 3)
that replacing 50% of CWSB aggregate after 28 days
curing attained the designed compressive strength as
the conventional concrete (i.e., the control). Thus it is
concluded that CWSB can be used as a
supplementary aggregate material in concrete [10].
3.8 CRUSHED SPENT FIRE BRICKS
Table 8: Physical properties of Spent fire bricks [11]
An experimental investigation of strength and
durability was undertaken to use “Spent Fire Bricks”
(SFB) (i.e. waste material from foundry bed and
walls; and lining of chimney which is adopted in
many industries) for partial replacement of fine
aggregate in concrete. The compressive strength of
partial replacement of Crushed Spent Fire Bricks
(CSFB) aggregate concrete is marginally higher than
that of the river sand aggregate concrete at age of 7
days, 14 days, and 28 days, respectively. The split
tensile strength of partial replacement of CSFB
aggregate concrete is higher than that of the river
sand aggregate at all ages. The modulus of elasticity
of partial replacement of CSFB aggregate concrete is
marginally higher than that of the river sand
aggregate concrete. The partial replacement of GGBS
can be used effectively as fine aggregate in place of
conventional river sand concrete production [11].
IV. CONCLUSION COPPER SLAG: The results of compression & split-
tensile test indicated that the strength of concrete
increases with respect to the percentage of copper
slag added by weight of fine aggregate. Addition of
slag in concrete increases the density thereby the self
weight of the concrete.
GRANULATED BLAST FURNACE SLAG: There
is a considerable increase in compressive strength
thus GBFS could be utilized partially as alternative
construction material for natural sand in concrete but
there is reduction in workability for all replacement
levels. The workability can be increased by adding
suitable dosage of chemical admixture such as super
plasticizer.
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WASHED BOTTOM ASH: 30% WBA replacement
is found to be the optimum amount in order to get a
favourable strength and good strength development
pattern over the increment ages. The cost of concrete
is less than conventional concrete and the concrete
becomes environment friendly.
QUARRY DUST: The study suggests that stone dust
is quite appropriate to be selected as the substitution
of fine aggregate. Quarry dust has a potential to
provide alternative to fine aggregate thus minimizing
waste products and disposal problems associated with
it. The only major limitation is the decrease in
workability which can be overcome by the use of fly
ash or chemical admixtures such as super plasticizers
which give high workability at the same water
contents.
FOUNDRY SAND: Waste foundry sand can be
effectively used as fine aggregate in place of
conventional river sand, in concrete. The maximum
compressive strength was achieved with 50%
replacement of fine aggregate with waste foundry
sand. Replacement of fine aggregate with waste
foundry sand showed increase in the split tensile
strength and flexural strength of plain concrete.
SHEET GLASS POWDER: It is observed that the
compressive strength of concrete for all mix increases
as the percentage of SGP increases, but decreases
with the age of curing increases because of alkali
silica reaction. The Tensile strength of the concrete
for all mix increases than that of conventional
concrete of same age of curing and decreases with
increase in SGP content. Similarly the Flexural
strength of the beam of concrete for all mix increases
with age of curing and decreases with increase in
SGP content.
CONSTRUCTION AND DEMOLITION WASTE:
The density of the concrete decreases as the
percentage of the CWSB content increases. Concrete
containing up to 50% CWSB as fine aggregate
compared favourably with normal concrete mixture
and therefore 50% CWSB content is taken as the
optimum for 30N/mm2 design characteristic strength.
CRUSHED SPENT FIRE BRICKS: The SFB is a
locally available, low cost, and inert industrial solid
waste whose disposal is a matter of concern likes
construction waste. On an overall, the CSFB can be
comparable to the natural river sand.
This paper shows that no material in the world is
waste and if utilized properly such materials will
improve sustainability by reducing the human
consumption of natural resources. The use of these
materials should be in such a way that the locally
available alternative materials should be selected so
as to achieve economy and required design strength.
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[12] Recent Trends in Replacement of Natural
Sand With Different Alternatives Akshay C.
Sankh1, Praveen M. Biradar1, Prof. S. J
Naghathan1, Manjunath B. Ishwargol1
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by partial replacement of fine aggregate
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keerthinarayana and *r. srinivasan
[14] Studies on Glass Powder as Partial
Replacement of Cement in Concrete
Production Dr. G.Vijayakumar1, Ms H.
Vishaliny2, Dr. D. Govindarajulu3
[15] Utilization of Copper Slag as a Partial
Replacement of Fine Aggregate in Concrete
D. BRINDHA and S. NAGAN
[16] http://www.thehindu.com/todays-paper/tp
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e-ISSN: 2278-1684, p-ISSN: 2320-334X
PP 59-66
www.iosrjournals.org
International Conference on Advances in Engineering & Technology – 2014 (ICAET-2014) 59 | Page
Recent Trends in Replacement of Natural Sand With Different
Alternatives
Akshay C. Sankh1, Praveen M. Biradar
1, Prof. S. J Naghathan
1, Manjunath B.
Ishwargol1
1(Department of Civil Engineering, B.L.D.E.A’s V P Dr. P G Halakatti college of engineering and Technology,
Bijapur-586 101, India)
ABSTRACT : Cement, sand and aggregate are basic needs for any construction industry. Sand is a prime
material used for preparation of mortar and concrete and which plays a major role in mix design. Now a day’s
erosion of rivers and considering environmental issues, there is a scarcity of river sand. The non-availability or
shortage of river sand will affect the construction industry, hence there is a need to find the new alternative
material to replace the river sand, such that excess river erosion and harm to environment is prevented. Many
researchers are finding different materials to replace sand and one of the major materials is quarry stone dust.
Using different proportion of these quarry dust along with sand the required concrete mix can be obtained. This
paper presents a review of the different alternatives to natural sand in preparation of mortar and concrete. The
paper emphasize on the physical and mechanical properties and strength aspect on mortar and concrete.
Keywords- Sand, Quarry Stone Dust, Alternative Material, Physical Properties, Mechanical Properties.
I. INTRODUCTION Cement, sand and aggregate are essential needs for any construction industry. Sand is a major material
used for preparation of mortar and concrete and plays a most important role in mix design. In general
consumption of natural sand is high, due to the large use of concrete and mortar. Hence the demand of natural
sand is very high in developing countries to satisfy the rapid infrastructure growth. The developing country like
India facing shortage of good quality natural sand and particularly in India, natural sand deposits are being used
up and causing serious threat to environment as well as the society. Rapid extraction of sand from river bed
causing so many problems like losing water retaining soil strata, deepening of the river beds and causing bank
slides, loss of vegetation on the bank of rivers, disturbs the aquatic life as well as disturbs agriculture due to
lowering the water table in the well etc are some of the examples. The heavy-exploitation of river sand for
construction purposes in Sri Lanka has led to various harmful problems [1]. Options for various river sand
alternatives, such as offshore sand, quarry dust and filtered sand have also been made (W.P.S. Dias et al
2008)[2]. Physical as well as chemical properties of fine aggregate affect the durability, workability and also
strength of concrete, so fine aggregate is a most important constituent of concrete and cement mortar. Generally
river sand or pit sand is used as fine aggregate in mortar and concrete. Together fine and coarse aggregate make
about 75- 80 % of total volume of concrete and hence it is very important to fine suitable type and good quality
aggregate nearby site (Hudson 1997). Recently natural sand is becoming a very costly material because of its
demand in the construction industry due to this condition research began for cheap and easily available
alternative material to natural sand. Some alternatives materials have already been used as a replacement of
natural sand such as fly-ash, quarry dust or limestone and siliceous stone powder, filtered sand, copper slag are
used in concrete and mortar mixtures as a partial or full replacement of natural sand (Chandana Sukesh et al
2013)[9]. Even though offshore sand is actually used in many countries such as the UK, Sri Lanka, Continental
Europe, India and Singapore, most of the records regarding use of this alternative found mainly as a lesser
extent of practice in the construction field [3].
Due to shortage of river sand as well as its high the Madras High Court restrictions on sand mining in
rivers Cauvery and Tamirabharani. The facts like in India is almost same in others countries also. So therefore
the need to find an alternative concrete and mortar aggregate material to river sand in construction works has
assumed greater importance now a days. Researcher and Engineers have come out with their own ideas to
decrease or fully replace the use of river sand and use recent innovations such as M-Sand (manufactured sand),
robot silica or sand, stone crusher dust, filtered sand, treated and sieved silt removed from reservoirs as well as
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dams besides sand from other water bodies [4]. On the other hand, lack in required quality is the major
limitation in some of the above materials. Now a day’s sustainable infrastructural growth requires the alternative
material that should satisfy technical requisites of fine aggregate as well as it should be available locally with
large amount.
II. DIFFERENT ALTERNATIVES MATERIALS TO RIVER SAND The world is resting over a landfill of waste hazardous materials which may substitutes for natural
sand. Irrespective of position, location, scale, type of any structure, concrete is the base for the construction
activity. In fact, concrete is the second largest consumable material after water, with nearly three tonnes used
annually for each person on the earth. India consumes an estimated 450 million cubic meter of concrete annually
and which approximately comes to 1 tonne per Indian. We still have a long way to go by global consumption
levels but do we have enough sand to make concrete and mortar? Value of construction industry grew at
staggering rate of 15 % annually even in the economic slowdown and has contributed to 7-8 % of the country’s
GDP (at current prices) for the past eight years. Thus, it is becoming increasingly discomforting for people like
common people who talk about greening the industry to have no practical answer to this very critical question.
In fact we have been sitting over a landfill of possible substitutes for sand. Industrial waste and by-products
from almost all industry, which have been raising hazardous problems both for the environment, agricultural and
human health can have major use in construction activity which may be useful for not only from the economy
point of view but also to preserve the environment as well. Some of the researchers did the work to find the
alternatives for natural sand and they concluded about different industrial waste and their ability to replace the
much sought after natural river bed sand.
2.1 Copper Slag-
At present about 33 million tonnes of copper slag is generating annually worldwide among that India
contributing 6 to 6.5 million tonnes. 50 % copper slag can be used as replacement of natural sand in to obtain
mortar and concrete with required performance, strength and durability. (Khalifa S. Al-Jabri et al 2011). In India
a study has been carried out by the Central Road Research Institute (CRRI) shown that copper slag may be used
as a partial replacement for river sand as fine aggregate in concrete up to 50 % in pavement concrete without
any loss of compressive and flexural strength and such concretes shown about 20 % higher strength than that of
conventional cement concrete of the same grade [5].
2.2 Granulated Blast Furnace Slag
According to the report of the Working Group on Cement Industry for the 12th five year plan, around
10 million tonnes blast furnace slag is currently being generated in the country from iron and steel industry. The
compressive strength of cement mortar increases as the replacement level of granulated blast furnace slag
(GBFS) increases. He further concludes that from the test results it is clear that GBFS sand can be used as an
alternative to natural sand from the point of view of strength. Use of GBFS up to 75 per cent can be
recommended (M C Nataraja 2013)[6].
A mix of copper slag and ferrous slag can yield higher compressive strength of 46.18MPa (100 per cent
replacement of sand) while corresponding strength for normal concrete was just 30.23MPa. Though she warns
that with higher levels of replacements (100 per cent) there might be some bleeding issues and, therefore, she
recommended that up to 80 per cent copper slag and ferrous slag can be used as replacement of sand (Meenakshi
Sudarvizhi 2011)[7].
2.3 Washed Bottom Ash (WBA)
Currently India is producing in over 100 million tons of coal ash. From which total ash produced in any
thermal power plant isapprox 15 –20 per cent of bottom ash and the rest is fly ash. Fly ash has found many users
but bottom ash still continues to pollute the environment with unsafe disposal mechanism on offer.The
mechanical properties of special concrete made with 30 per cent replacement of natural sand with washed
bottom ash by weight has an optimum usage in concrete in order to get a required strength and good strength
development pattern over the increment ages (MohdSyahrulHisyam 2010)[8].
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2.4 Quarry Dust
About 20 to 25 per cent of the total production in each crusher unit is left out as the waste material-
quarry dust. The ideal percentage of the replacement of sand with the quarry dust is 55 per cent to 75 per cent in
case of compressive strength. He further says that if combined with fly ash (another industrial waste), 100 per
cent replacement of sand can be achieved. The use of fly ash in concrete is desirable because of benefits such as
useful disposal of a byproduct, increased workability, reduction of cement consumption, increased sulfate
resistance, increased resistance to alkali-silica reaction and decreased permeability. However, the use of fly ash
leads to a reduction in early strength of concrete. Therefore, the concurrent use of quarry dust and fly ash in
concrete will lead to the benefits of using such materials being added and some of the undesirable effects being
negated (Chandana Sukesh 2013)[9].
2.5 Foundry sand
India ranks fourth in terms of total foundry production (7.8 million tonnes) according to the 42nd
Census of World Casting Production of 2007. Foundry sand which is very high in silica is regularly discarded
by the metal industry. Currently, there is no mechanism for its disposal, but international studies say that up to
50 per cent foundry sand can be utilized for economical and sustainable development of concrete (Vipul D.
Prajapati 2013)[10].
2.6 Construction and Demolition waste
There is no documented quantification of amount of construction and demolition (C&D) waste being
generated in India. Municipal Corporation of Delhi says it is collecting 4,000 tonnes of C&D waste daily from
the city which amounts to almost 1.5 million tonnes of waste annually in the city of Delhi alone. Even if we
discount all the waste which is illegally dump around the city, 1.5 million of C&D waste if recycled can
significantly substitute demand for natural sand by Delhi.
Recycled sand and aggregate from C&D waste is said to have 10-15 per cent lesser strength then
normal concrete and can be safely used in non-structural applications like flooring and filling. Delhi already has
a recycling unit in place and plans to open more to handle its disposal problem. Construction and demolition
waste generated by the construction industry and which posed an environmental challenge can only be
minimized by the reuse and recycling of the waste it generates (Akaninyene A. Umoh 2012) [11].
2.7 Spent Fire Bricks (SFB):
An experimental investigation on strength and durability was undertaken to use “Spent Fire Bricks”
(SFB) (i.e. waste material from foundry bed and walls; and lining of chimney which is adopted in many
industries) for partial replacement of fine aggregate in concrete (S. Keerthinarayana and R. Srinivasan
2010)[12].
2.8 Sheet Glass Powder (SGP)
Natural sand was partially replaced (10%, 20%, 30%, 40% and 50%) with SGP. Compressive strength,
Tensile strength (cubes and cylinders) and Flexural strength up to 180 days of age were compared with those of
concrete made with natural fine aggregates Attempts have been made for a long time to use waste glasses as an
aggregate in concrete, but it seems that the concrete with waste glasses always cracks .Very limited work has
been conducted for the use of ground glass as a concrete replacement. (M. Mageswari and Dr. B.Vidivelli 2010)
[13].
III. PHYSICAL AND MECHANICAL PROPERTIES DIFFERENT ALTERNATIVES
3.1 Copper slag:
The slag is black glassy particle and granular materials in nature and has a similar particle size range
like sand. The specific gravity of the slag is 3.91. The bulk density of granulated copper slag varies from 1.9 to
2.15 kg/m3 which is almost similar to bulk density of convectional fine aggregate. The hardness of the slag lies
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between 6 and 7 in Mohr scale. This is almost equal to the hardness of gypsum. The pH of aqueous solution of
aqueous extract as per IS 11127 varies from 6.6 to 7.2. The free moisture content present in slag was found to be
less than 0.5%.The presence of silica in slag is about 26% which is desirable because it is one of the constituents
of the natural fine aggregate used in normal concreting operations. The fineness of copper slag was calculated
as125 m2 /kg. Table 1 shows the fineness tests on copper slag.
Table 1- Fineness test on copper slag [5].
Sieve size
In (mm)
Weight
retained(b)g
Cumulative weight
retained (g)
Slag
retained(n)g
Slag passing %
of soil
4.75mm 4 0.4 0.4 99.6
2.36mm 17 1.7 2.1 97.9
1.18mm 225 22.5 24.6 75.4
600micron 433 43.3 67.9 32.1
300micron 281 28.1 96 4
150micron 37 3.7 99.7 0.3
75micron 3 0.3 100 0
Pan 0 0 100 0
The test results of concrete were obtained by adding copper slag to sand in various percentages ranging
from 0%, 20%. 40%, 60%, 80% and 100%. All specimens were cured for 28 days before compression strength
test, splitting tensile test and flexural strength. The highest compressive strength obtained was 35.11MPa (for
40% replacement) and the corresponding strength for control mix was 30MPa. This results of the research paper
showed that the possibility of using copper slag as fine aggregate in concrete. The results showed the effect of
copper slag on RCC concrete elements has a considerable amount of increase in the compressive, split tensile,
flexural strength characteristics and energy absorption characteristics [5].
3.2 Granulated Blast Furnace Slag:
The granulated blast furnace slag (GBFS) is glassy particle and granular materials in nature and has a
similar particle size range like sand. The specific gravity of the slag is 2.63. The bulk density of granulated slag
varies from 1430 kg/m3 which were almost similar to bulk density of convectional fine aggregate. The water
absorption of slag was found to be less than 2.56 %.The presence of silica in slag is about 26% which is
desirable since it is one of the constituents of the natural fine aggregate used in normal concreting operations.
The fineness of slag was 2.37.
Investigation was carried out on cement mortar mix 1:3 and GBFS at 0, 25, 50, 75 and 100%
replacement to natural sand for constant w/c ratio of 0.5 is considered. The work is extended to 100%
replacements of natural sand with GBFS for w/c ratios of 0.4 and 0.6. The flow characteristics of the various
mixes and their compressive strengths at various ages are studied. From this study it is observed that GBFS
could be utilized partially as alternative construction material for natural sand in mortar applications. Reduction
in workability expressed as flow can be compensated by adding suitable percentage of super plasticizer [6].
The strength characteristics of conventional concrete and slag concrete such as compressive strength, tensile
strength were found. Six series of concrete mixtures were prepared with different proportions of CS and FS
ranging from 0% to 100%. The test results of concrete were obtained by adding of Copper Slag (CS) and
Ferrous Slag (FS) to sand in various percentages ranging from 0%, 20%. 40%, 60%, 80% and 100%. All
specimens were cured for 7, 28, 60 & 90 days before compression strength test and splitting tensile test. The
results indicate that workability increases with increase in CS and FS percentage. The highest compressive
strength obtained was 46MPa (for 100% replacement) and the corresponding strength for control mix was
30MPa. The integrated approach of working on safe disposal and utilization can lead to advantageous effects on
the ecology and environmental also. It has been observed that upto 80% replacement, CS and FS can be
effectively used as replacement for fine aggregate. Further research work is needed to explore the effect of
CS+FS as fine aggregates on the durability properties of concrete [7].
3.3 Washed Bottom Ash (WBA):
The fineness modulus is the summation of the cumulative percentage retained on the sieve standard
series of 150, 300 and 600 μm, 1.18, 2.36, 5.0 mm up to the larger sieve size used. The calculated fineness
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modulus of bottom ash was 3.65 which is more than 3.5 and is considered to be very coarse. For categorization
given in BS 822:1992 based on percentage passing the 600μm sieve between 55% to100% would defined it as
fine sand. While WBA has percentage passing 600 μm of 58.99%. Therefore, the WBA is considered as fine
sand (Alexander & Mindess, 2005)[16].
Different concrete mixes with constant water to cement ratio of 0.55 were prepared with WBA in different
proportions as well as one control mixed proportion. The mechanical properties of special concrete with 30%
WBA replacement by weight of natural sand is found to be an optimum usage in concrete in order to get a
favorable strength and good strength development pattern over the increment ages [8].
3.4 Quarry Dust:
The results (Table 2) show that there is an increase in the compressive strength of the concrete which
the increment is about 55% to 75% depending on the replacement if the sand with the quarry dust, for the 100%
replacement of the sand the compressive strength is depending on the quarry dust location from where the
quarry dust was taken. The workability of the concrete is decreasing when the replacement percentage of the
quarry dust is increasing gradually, so as to increase the workability small quantity of the fly-ash is replaced in
place of cement to increase the workability. This show that the fly ash and quarry dust replacement showed the
desirable results which can suggest the usage of the quarry dust as replacement of sand [9].
Table2- Physical properties for the quarry dust [9]
Property Quarry Dust Natural
Sand Test method
Specific gravity 2.54 -2.60 2.60 IS2386(Part III)- 1963
Bulk density (kg/m3) 1720- 1810 1460 IS2386(Part III)- 1963
Absorption (%) 1.20- 1.50 Nil IS2386(Part III)- 1963
Moisture Content (%) Nil 1.50 IS2386(Part III)- 1963
Fine particles less than 0.075 mm (%) 12-15 6 IS2386(Part III)- 1963
Sieve analysis Zone-II Zone-II IS 383- 1970
3.5 Foundry Sand:
Foundry sand consists primarily of silica sand, coated with a thin film of burnt carbon residual binder
and dust.
The fine aggregate has been replaced by used foundry sand accordingly in the range of 0%, 10%, 30% & 50%
by weight for M-20 grade concrete. Concrete mixtures were produced, tested and compared in terms of
compressive and flexural strength with the conventional concrete. These tests were carried out to evaluate the
mechanical properties for 7, 14 and 28 days. This research work is to investigate the behaviour of concrete while
replacing used foundry sand in different proportion in concrete. This low cost concrete with good strength is
used in rigid pavement for 3000 commercial vehicles per day and Dry Lean Concrete (DLC) 100mm thick for
national highway to make it eco-friendly [10].
3.6 Construction and Demolition waste:
The fine aggregate was replaced with crushed waste sandcrete block (CWSB) in various percentages in the steps
of 10 starting from 10% to a maximum of 100%, while 0% represents the control. The properties of the concrete
were evaluated at 7, 14 and 28 days curing periods. Results showed (Table 3) that replacing 50% of CWSB
aggregate after 28 days curing attained the designed compressive strength as the conventional concrete (i.e., the
control). Thus it is concluded that CWSB can be used as a supplementary aggregate material in concrete [11].
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Table 3- Physical Properties of the Construction and Demolition waste [11]
Sl. No. Physical Properties Values
01 Compacted Bulk density, [kg/m3] 1564
02 Porosity, [%] 11.22
03 Specific gravity 2.40
04 Water absorption (%) 28.74
05 Silt content (%) 5.22
3.7 Spent Fire Bricks (SFB):
An experimental investigation of strength and durability was undertaken to use “Spent Fire Bricks”
(SFB) (i.e. waste material from foundry bed and walls; and lining of chimney which is adopted in many
industries) for partial replacement of fine aggregate in concrete. The compressive strength of partial replacement
of Crushed Spent Fire Bricks (CSFB) aggregate concrete is marginally higher than that of the river sand
aggregate concrete at age of 7 days, 14 days, and 28 days, respectively. The split tensile strength of partial
replacement of CSFB aggregate concrete is higher than that of the river sand aggregate at all ages. The modulus
of elasticity of partial replacement of CSFB aggregate concrete is marginally higher than that of the river sand
aggregate concrete. The partial replacement of GGBS can be used effectively as fine aggregate in place of
conventional river sand concrete production [12].
Table 4- Physical Properties of the spent fire bricks [12]
Sl. No. Physical Properties Values
01 Bulk density, [kg/m3] 2,000
02 Porosity, [%] 25 to 30
03 Size tolerance, [%] ±2
04 Working temperature, [°C] 1,300 to 1,400
05 Crushing strength (cold), [N/mm2] 24.5 to 27
3.8 Sheet Glass Powder (SGP):
The SGP is suitable for use in concrete making. The fineness modulus, specific gravity, moisture
content, uncompacted bulk density and compacted bulk density at 10% Sheet glass powder (SGP) were found to
be 2.25,3.27,2.57%,1510kg/ m3 and 1620kg/m
3.
The compressive strength of cubes and cylinders of the concrete for all mix increases as the % of SGP increases
but decreases as the age of curing increases due to alkali silica reaction. The Tensile strength of cubes and
cylinders of the concrete for all mix increases than that of conventional concrete age of curing and decreases as
the SGP content increases. The Flexural strength of the beam of concrete for all mix increases with age of
curing and decreases as the SGP content increases. 100% replacement of SGP in concrete showed better results
than that of conventional concrete at 28 days and 45 days curing but later it started to decrease its strength
because of its alkali silica reactions. The density of SGP concrete is more that of conventional concrete. SGP is
available in significant quantities as a waste and can be utilized for making concrete. This will go a long way to
reduce the quantity of waste in our environment. The optimum replacement level in fine aggregate with SGP is
10% [13].
IV. CONCLUSION
1. An improvement in the compressive strength, split tensile strength and flexural strength of concrete by
addition of copper slag can be seen. The density of concrete increases with replacement of copper slag in
concrete. There is increase in the flexural strength of the beam by 21% to 51% while replacement of copper
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slag. By partial replacement of sand by copper slag, the strength increase is observed up to 40% replacement.
Copper slag replacement at higher level leads to segregation and bleeding due to less water absorption capacity
of copper slag. Author was also observed that the sand replaced copper slag beams showed an increase in energy
absorption capacity.
2. It was also observed that the increase in compressive strength of cement mortar with the replacing the GGBS.
This increase is not significant. But for 100% replacement the strength decreases a little bit compared to 100%
natural sand. Author concluded that GGBS sand can be used as an alternative to natural sand from the point of
view of strength and recommended to replace up to 75%.
3. It can be concluded that 30% of Washed Bottom Ash (WBA) can be replaced with sand in concrete is the
optimum amount to get favorable strength, saving in environment and reducing the cost.
4. There is improvement in the compressive strength of the concrete by partial replacement of quarry dust with
sand. Due to absorption of the water by the quarry dust, decreases the workability of concrete with increase in
quarry dust quantity. The recommended percentage of the replacement of sand with the quarry dust is between
55% to 75% in case of compressive strength. The 100% replacement of sand can be achieved by addition of fly
ash along with quarry dust. For mortar, stone powder is well suitable to choose it as an alternative of sand. The
availability of the stone powder is depends on the locality and its price is mar vary. If the stone powder is
available in the market, it can be used as an alternative to sand and it is observed that concrete made stone chip
will have higher compressive strength compared with that of concrete made with brick chips. This may be due
to inferior quality brick chip, poor workmanship, and improper proportions of mixing. Since brick chip is
inexpensive and normally available, hence used for the low strength structures.
5. There is improvement in the compressive strength and flexural strength of the concrete by partial replacement
of foundry sand with sand. It is observed that there is increase in compressive and flexural strength with increase
in foundry sand replacing natural sand. The maximum compressive strength and flexural strength obtained at
50% replacement of natural fine aggregate with used foundry sand.
6. It is observed that increase in CWSB content in concrete, there is decrease in the density of concrete.
Concrete containing up to 50% CWSB as fine aggregate compared suitably with normal concrete mix and hence
50% CWSB content is adopted as the optimum for design characteristic strength of 30N/mm2.
7. There is improvement in the compressive strength of the concrete by partial replacement of Crushed Spent
Fire Bricks (CSFB) in concrete. The maximum strength is attained by 25% of CSFB replacement in concrete.
There is no increase in strength observed with 30% and more of CSFB replacement in concrete. Test results
shown that the compressive strength of partial replacement of CSFB aggregate concrete is a little bit higher than
that of the river sand aggregate concrete at age of 7, 14 , and 28 days, respectively.
8. The sheet glass powder (SGP) is available in substantial quantity as a waste and it can be used for making
concrete. This will help to reduce the quantity of waste in our environment. It is observed that the compressive
strength of concrete for all mix increases as the percentage of SGP increases, but decreases with the age of
curing increases because of alkali silica reaction. The Tensile strength of the concrete for all mix increases than
that of conventional concrete of same age of curing and decreases with increase in SGP content. Similarly the
Flexural strength of the beam of concrete for all mix increases with age of curing and decreases with increase in
SGP content. SGP replacing by 100% showed improved results than that of conventional concrete at 28 days
and 45 days but later it is observed decrease in strength due to alkali silica reactions. The density of SGP
concrete is little bit higher that of conventional concrete. For the best results the optimum replacement level in
fine aggregate with SGP is 10%.
This paper presented in view of alternatives available in place of natural sand in mortar and concrete.
There are various materials available, which are recognized as waste product of industry or from Domestic. But
from the above conclusion shows that many researchers have recognized these materials and spent their valuable
time and shared their knowledge to make aware of these materials for the construction industry. They showed
that no material in the world is waste, but one has to see it in different way to recognize, how best the waste can
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be handled. Few alternative materials discussed in this paper are from hard work of various research scholars.
But those materials can be utilized effectively for concrete mix and building mortar and awareness should be
spread to society. The utilization of these materials should be in such a way that the locally available such
alternative materials should be selected so as to achieve economy and required design strength.
REFERENCES [1] National sand study for Sri Lanka, vols. 1 and 2. Final Report, Phase 1, Delft Hydraulics, 1992.
[2] Dias WPS. The analysis of proposed change and stakeholder response– a case study, Civil Environ Eng Syst, 2000, Vol. 17,1–17.
[3] National practices and regulations in the extraction of marine sand and gravel, Ch. 3 in Sandpit Book.
<http://sandpit.wldelft.nl/reportpage/reportpage.htm>. [4] http://www.thehindu.com/todays-paper/tp-national/tp-tamilnadu/msand-thrown-up-as-an-alternative-to-river-
sand/article3752772.ece
[5] Arivalagan.S, Experimental study on the flexural behavior of reinforced concrete beams as replacement of copper slag as fine aggregate, Journal of Civil Engineering and Urbanism, 2013, Vol. 3, 176-182.
[6] M C Nataraja, P G Dileep Kumar, A S Manu and M C Sanjay, Use of granulated blast furnace slag as fine aggregate in cement
mortar, Int. J. Struct. & Civil Engg. Res., 2013, Vol. 2, 60-68. [7] Meenakshi Sudarvizhi and S. Ilangovan , Performance of copper slag and ferrous slag as partial replacement of sand in concrete
International Journal of Civil & Structural Engineering, 2011, Vol. 1, 918-27.
[8] Mohd Syahru, Hisyam bin Mohd Sani, Fadhluhartini bt Muftah and Zulkifli Muda , The properties of special concrete using washed bottom ash (wba) as partial sand replacement, International Journal of Sustainable Construction Engineering &
Technology, 2010, Vol. 1, No 2, 65-78.
[9] Chandana Sukesh, Katakam Bala Krishna, P.Sri Lakshmi Sai Teja and S.Kanakambara Rao, Partial replacement of sand with quarry dust in concrete, International Journal of Innovative Technology and Exploring Engineering (IJITEE), 2013, Vol. 2, 254-
58.
[10] Vipul D. Prajapati, Nilay Joshi and Prof. Jayeshkumar Pitroda, Techno- economical study of rigid pavement by using the used foundry sand, International Journal of Engineering Trends and Technology (IJETT),2013,Vol. 4, 1620-28.
[11] Akaninyene A. Umoh, Recycling demolition waste sandcrete blocks as aggregate in concrete, ARPN Journal of Engineering and
Applied Sciences, 2012, Vol. 7, 1111-18.
[12] S. Keerthinarayana and R. Srinivasan, Study on strength and durability of concrete by partial replacement of fine aggregate using
crushed spent fire bricks, Bul. Inst. Polit. Iaşi, 2010.
[13] M. Mageswari, and Dr. B.Vidivelli, The use of sheet glass powder as fine aggregate replacement in concrete, The Open Civil Engineering Journal, 2010, Vol. 4, 65-71
[14] Lohani T.K., Padhi M., Dash K.P. and Jena S., Optimum utilization of quarry dust as partial replacement of sand in concrete, Int.
Journal of Applied Sciences and Engineering Research, 2012, Vol. 1, 391-404. [15] W.P.S. Dias , G.A.P.S.N. Seneviratne and S.M.A. Nanayakkara, Offshore sand for reinforced concrete, Construction and
Building Materials, 2008, Vol. 22, 1377–1384.
[16] Alexander M. & Mindess S. (2005). Aggregates in concrete. Taylor & Francis. Specification for Aggregates for natural source for concrete. British Standard BS882: 1992.
[17] H. M. A. Mahzuz, A. A. M. Ahmed and M. A. Yusuf, Use of stone powder in concrete and mortar as an alternative of sand,
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International Journal of Innovative Research in Engineering & Management (IJIREM) ISSN: 2350-0557, Volume-3, Special Issue-1, April-2015
Fifth National Conference on Innovative Practice in Construction Waste Management (IPCWM’15) On 8th & 9th April, 2015 Organized by Department of CIVIL Engineering, Sri Ramakrishna Institute of Technology, Coimbatore, India
Studies on Alternative Solution for Sand in Concrete
S.Karthik1 Assistant Professor,
Department of Civil Engineering, Jay Shriram Group of Institutions,
Avinashipalayam, Tirupur. Tamilnadu, India.
P. Gowtham2, R.Balaji3, S.Thangaraj4, D.Gowtham5
Under Graduate Student, Department of Civil Engineering, Jay Shriram Group of Institutions,
Avinashipalayam, Tirupur. Tamilnadu, India.
ABSTRACT At present days infrastructure is the backbone of the country. Infrastructure can be developed by several ways such as steel structure, concrete structure, and wooden structure. Among these structure, wooden structure are not used widely, because rapid use of wood leads to cause deforestation. Steel structures are economic and efficient in case of high rise buildings but in case of small structure it is little costlier than concrete. Therefore, concrete structure are mostly used for such type of buildings. Generally concrete compose of cement, coarse aggregate, fine aggregate and water. Nowadays concrete is used widely. It may cause scarcity of certain materials like fine aggregate. So, our main aim of the project is, to overcome the scarcity of the fine aggregate by reducing the usage. This have been achieved by replacing the rice husk based precipitated silica in the concrete at various proportion mixes (0%, 10%, 20%, 30%, 40%, 50%, 60%, 70% and 80%)replacement
KEYWORD: precipitated silica, cement, river sand.
INTRODUCTION Concrete is considered as the most widely used and
versatile material of construction all over the world. In recent years, concrete technology has made significant advances which have resulted in economical `improvements in strength of concretes. This economic development depends upon the intelligent use of locally available materials. One of the important ingredients of conventional concrete is natural sand or river sand, which is expensive and scarce. In India, the conventional concrete is produced by using natural sand obtained from riverbeds as fine aggregate. However, due to the increased use of concrete in almost all types of construction works, the demand of natural or river sand has been increased. To meet this demand of construction industry excessive quarrying of sand from river beds is taking place causing the depletion of sand resources.
The dwindling sand resources have not only posed the environmental problems but also have caused the rivers to change their flow direction. This fact has forced the
Government to lay down restrictions on sand quarrying process resulting in the scarcity and significant increase in its cost. Thus the scarcity of natural sand has forced to find the suitable substitute. There are the lot of materials available to substitute fine aggregate in making concrete such as fly ash, bottom ash, glass powder-sand ,crushed sand, copper slag, tyre rubber, foundry sand, off shore sand, sugar cane bases ash, marble powder, quarry dust, rice husk, sand extraction from soil & saw dust ash. But rice husk based precipitated silica is the one of the eco-friendly materials and it is taken from oil refining industries. This is a waste product, it is directly dumped to the land, it cause to environment pollution and land occupations. In this way we had to use the rice husk based precipitated silica as a fine aggregate in concrete to reduce the usage of river sand and environmental defects. In this waste materials have higher silica content from 80-85%. This is better choice to replacement of fine aggregate.
The standard mix with 100% manufactured sand has exhibited much higher compressive strength 53 MPa. The standard mix with 100% of river sand has exhibited compressive strength of 49MPa, 7.5% lower than that of manufactured sand. The improved properties of MS by the entire process of manufacturing could have resulted in reduced surface area and better particle packing. This contributed to the better binding effect with the available cement paste and improved the compressive strength. The mix with Ms Sand as 100% fine aggregate gives initial workability of 170mm, which is much higher than that of the mixes with 100% river sand (RS) and crusher dust. Higher fineness modulus, particles grading, shape, texture and control of micro fines have contributed to better workability of manufactured sand. The good physical properties of manufactured sand has enabled in reduction of free water as well. Research findings concluded that, Compared to concrete made from river sand, high fines concrete generally had higher flexural strength, improved abrasion resistance, and higher unit weight & lower permeability due to fillings the pores with micro fines. [1] The variation of compressive strength with respect to type of concrete block made by using natural sand and artificial sand are observed. Result shows that the mixes with the artificial sand with dust as fine aggregate gives consistently higher
International Journal of Innovative Research in Engineering & Management (IJIREM) ISSN: 2350-0557, Volume-3, Special Issue-1, April-2015
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strength than the mixes with natural sand. The sharp edges of the particles in artificial sand provide better bond with the cement than the rounded part of the natural sand. It was found that the weight loss of artificial sand block is considerably same with respect to natural sand blocks at 20, 40, and 60 and 90 days, immersed in sulphuric acid solution during the experimental period and maintain pH 4 across it. Both concrete made using artificial sand and natural sand are moderate to chloride permeability. In water absorption test we observed after 24 hours curing, the increase in weight of both natural sand and artificial sand blocks are less than 3% that means both concrete are low absorber hence concretes are good quality. The test result obtained from well planned and carefully performed experimental program encourage the full replacement of natural sand by artificial sand with dust considering the technical, environmental and commercial factor.[2] Manufactured sand is featured with deficiency in medium size, and has poorer shape and surface texture than natural river sand. Use of manufactured sand will increase water demand, and impair pump ability and finish ability of concrete mix. These effects will become more significant in lean mix. It is feasible to use admixture approach to overcome problems resulting from use of manufactured sand in concrete mix. For the particular case in this paper, MIRA 91 works well in concrete mix with 100% replacement of natural river sand by manufactured sand MS2.However, as manufactured sand has great variety in properties from source to source, and concrete mixes have different cement content from mix to mix, it is hardly to use single admixture for all kinds of manufactured sand and concrete mix. Customized admixture approach with particular manufactured sand would be better solution for use of manufactured sand in concrete mix. [3] Blended cement concrete is developed with the mixture of Ordinary Portland cement, High Alumina cement, M-sand, coarse aggregate with complots SP430 super plasticizer for the purpose of accelerating early strength and prolonged setting time. The initial setting time of this blended cement is extended to 100 minutes permitting enough time for batching, placing and finishing of concrete perfectly at site. This blended cement will set fastly that the time between initial and final set is found to be about 10-12 minutes. Strength development rate after hardening is fast and after 3 days of curing, compressive strength exceeding 28.8 MPa and 26.51 MPa for cube and cylindrical specimens were obtained. This is similar to what the conventional concrete achieves in 28 days. Nearly 20% of compressive strength of Portland cement is increased by using M-Sand for river sand in conventional concrete. [4] Compressive strength, splitting tensile strength, flexural strength, and modulus of elasticity of fine aggregate (sand) replaced fly ash concrete specimens were higher than the plain concrete (control mix) specimens at all the ages. The strength differential between the fly ash concrete specimens and plain concrete specimens became more distinct after 28 days. Compressive strength, splitting tensile strength, flexural strength, and modulus of elasticity of fine aggregate (sand) replaced fly ash concrete continued to increase with age for all fly ash percentages. The maximum compressive strength
occurs with 50% fly ash content at all ages. It is 40.0 MPa at 28 days, 51.4 MPa at 91 days, and 54.8 MPa at 365 days. At all the ages, the maximum splitting tensile strength was observed with 50% fly ash content. It is 3.5 MPa at 28 days, 4.3 MPa at 91 days, and 4.4 MPa at 365 days. The maximum flexural strength has been found to occur with 50% fly ash content at all ages. It is 4.3 MPa at 28 days, 5.2 MPa at 91 days, and 5.4 MPa at 365 days. At all ages, the maximum value of modulus of elasticity occurs with 50% fly ash content. It is 24.5 GPA at 28 days, 28.0 GPa at 91 days, and 29.0 GPa at 365 days. Results of this investigation suggest that Class F fly ash could be very conveniently used in structural concrete. [5] The review of research work shows that the replacement of natural sand with artificial sand is fissile and behavior and strength of reinforced concrete will improved. Also the use of polypropylene fiber will enhance strength and behavior of reinforced concrete also improves resistance against impact loading and fire. Polypropylene fibers have a positive impact on ultimate strength of heated beams. For a heating duration of 4.5 hours, the residual ultimate strength is larger than the corresponding strength of beams without polypropylene fibers by more than 60 %. No sudden failures are observed in all beams containing polypropylene fibers. [6] In this project Metakaolin is added by replacing the cement of about 10%, 20%, 30%,40% and 50%. From this case of adding the various mixing of Metakaolin with glass Fibres the strength of the concrete is more than the conventional concrete thus we preferred this project to have more strength and the durability. Thus the structure built using the Metakaolin by replacing would be of good attractiveness to building and also strength to it. The conclusions arrived from the study of the above research work are as follows The use of Metakaolin in concrete as replacement of cement resulted in Pozzlonic materials like Metakaolin when used as cement replacement materials in concrete improves the properties of concrete due to the Early gain of strength, higher pozzolanic reaction and also helps in reducing the consumption of cement. This leads to saving of natural resources and reduction in the emission of green gases like CO2. The main conclusion arrived from this research work is replacement of Metakaolin at 30% would give more strength in 7 days and also 28 days. After that the compressive strength of concrete sample could be decreased. So the optimum percentage of Metakaolin is 30%. [7] MATERIALS PROPERTIES: A. Cement: Portland pozzlonic cement (Ultra tech
cement) of 43 grade confirming to IS: 12269-1987 was used. It was tested for its physical properties as per IS 4031 (part II)-1988.
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Table.1 Properties of PPC 43 grade cement S.no Descriptions Value
1 Fineness of cement 98%
2 Consistency of cement 33%
3 Initial setting time 18 mins
4 Final setting time 465 mins
B. Fine Aggregate: The locally available river sand was used as fine aggregate in the present investigation. The sand was free from clayey matter, salt and organic impurities. The sand was tested for various properties like specific gravity, bulk density etc., and in accordance with IS 2386-1963.
Table.2 Properties of Fine Aggregate S.no Descriptions Value
1 Specific Gravity 2.6 2 Zone Of Sand II 3 Fineness Modulus 3.923 4 D60 0.967 5 D10 0.236 6 Co efficient of uniformity 4.099 7 Bulk density 1600kg/m3
C. Coarse Aggregate: Machine crushed angular granite metal of 20mm nominal size from the local source was used as Coarse aggregate. It was free from impurities such as dust, clay particles and organic matter etc. The physical properties of coarse aggregate were investigated in accordance with IS 2386 -1963.
Table.3 Properties of coarse Aggregate S.no Descriptions value
1 Impact value 12.17% 2 Abrasion value 31.20% 3 Attrition value 6.12% 4 Specific gravity 2.44 5 Bulk density 1652kg /m3 6 Water absorption 1% 7 Grade of Aggregate ‘C’
D. Precipitated Silica: Waste Precipitated Silica was obtained locally from Orchard oil extractions Pvt ltd, Kangayam, and Tamilnadu, India. It was used as a replacement of fine aggregate (natural river sand).The precipitated silica was tested for various properties like specific gravity, bulk density etc., and in accordance with IS 2386-1963. The fine aggregate was conforming to standard specification.
Table.4 physical Properties of precipitated silica S.no Descriptions Value
1 Specific Gravity 2.3
2 Fineness modulus 3.638 4 D60 1.785 5 D10 0.810
6 Co efficient of uniformity 2.2
7 Bulk density 1020kg/m3
Table.5 chemical properties of precipitated silica S.no Descriptions Percentage
1 SIO2 90.16
2 Fe2o3 0.41 4 Al2o3 0.11 5 Cao 1.0 6 Mgo 0.27 7 So3 0.12 8 Al2o3+fe203 0.52 9 Sio2+al2o3+fe2o3 0.93 10 Na2o 0.01 11 K2o 0.65
E. Water: Chloride free water is used for mixing the concrete in which is potable and is free from injurious amounts of oils, acids, alkalis, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel.
Table.6 Parameters in Water S.no Parameters Range
1 PH 6.8 2 Chloride Nill 3 Sulphate 0.3 ppm 4 conductivity 0.11 ms 5 TDS 8.655ppm
MIX DESIGN The mix proportion is very important for the strength of concrete structure. The mix design is done to find the accurate ratio of the concrete ingredients as per the IS 10262-(2009).The mix proportion of M-25 grade concrete was calculated. The following mix proportions is in our project.
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Table.7 M-25 mix proportions S.No Description Value(Kg/m3)
1 Cement 446
2 Fine aggregate 527
3 Coarse aggregate 1085
4 Water 192
MIX RATIO We are casted the concrete in different mix proportions. First a control standard concrete specimen are casted without adding any replacement materials. Then we added the replacement materials in different percentage in each mix concrete.
Table.8 Different type of Mixes S.No Description Sand
(%) Precipitated
Silica (%) 1 Mix-1 100 0 2 Mix-2 90 10 3 Mix-3 80 20 4 Mix-4 70 30 5 Mix-5 65 35 6 Mix-6 60 40 7 Mix-7 55 45 8 Mix-8 50 50 9 Mix-9 45 55 10 Mix-10 40 60 11 Mix-11 30 70 12 Mix-12 20 80
FRESH CONCRETE PROPERTY
Slump Test The concrete slump test is an empirical test that measures the workability of fresh concrete. This help to found the concrete weather it is suitable or not for handling and placing. There are three stage of slump. Their range is 0 to 40mm represent the true slump and 40 to 90 mm represent the shear, but 90 to 240 mm represent the collapse stage of the concrete. All are done as per IS 7320(1974).
Table.9 Effect on Slump S.No MIX-ID Percentage of
Precipitated Silica Slump(mm)
1 Mix-1 0 61 2 Mix-2 10 59 3 Mix-3 20 56 4 Mix-4 30 58 5 Mix-5 35 53 6 Mix-6 40 55
7 Mix-7 45 52 8 Mix-8 50 56 9 Mix-9 55 50 10 Mix-10 60 49 11 Mix-11 70 46 12 Mix-12 80 48
COMPACTION FACTOR In this fresh concrete test found the compaction factor value. If the value compaction factor is more than 1 it represent the self-compacting. But normal concrete compaction factor value varying from 0.6 to 0.85.the test were done as per IS1199-1959.
Table.10 Effect on Compaction Factor S.No MIX -
ID Percentage of Precipitated
silica
Compaction factor
1 Mix-1 0 0.8 2 Mix-2 10 0.796 3 Mix-3 20 0.785 4 Mix-4 30 0.782 5 Mix-5 35 0.790 6 Mix-6 40 0.788 7 Mix-7 45 0.784 8 Mix-8 50 0.786 9 Mix-9 55 0.780 10 Mix-10 60 0.783 11 Mix-11 70 0.779
12 Mix-12 80 0.774
SPECIMEN CASTING AND TESTING Generally casting and testing of concrete were done as per IS 516 .we choose the dimensions of the specimens are in cube is 150x150x150mm, cylinder is 150mm x300mm and beam is 100x100x500mm.after the completion of final setting time, specimens are submerged into the water for curing. After the completion of 7, 14 and 28 days curing, the specimens were tested using compressive test machines (CTM)
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RESULT AND DISCUSSIONS i] COMPRESSIVE STRENGTH
Figure: 1 Effect on Compressive Strength in 7 days
Figure. 2 Effect of compressive Strength in 14 Days
Figure.3 Effect of Compressive Strength in 28 Days
ii] SPLIT TENSILE STRENGTH
Figure 4: Effect on split tensile strength in 7 Days
Figure.5 Effect on split tensile strength in 14 Days
Figure.6 Effect on split tensile strength in 28 Days
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iii) FLEXURAL STRENGTH
Figure.7 Effect of Flexural strength in7 Days Completed Curing
Figure.8 Effect of Flexural strength in14 Days
Figure.9 Effect of Flexural strength in 28 Days
CONCLUSIONS By applying the rice husk based precipitated silica at 50 percentages, the compressive strength for seven days ranges between 18.49 to 25.65 Mpa. The experiment is repeated for fourteen and 28 days are ranges between 22.51 to 28.73 Mpa and 28.31 to 39.84 Mpa respectively. Due to this increase in compressive strength, thickness of the member can be reduced and hence dead load of the member will decrease. The tensile strength of the concrete is measured at the 50 percentage replacement the values for seven, fourteen and 28
days are 1.655 to 2.567 Mpa and1.92 to 2.787Mpa and 2.37 to 3.431 Mpa respectively. Similarly the flexural strength is measured at the 50 percentage replacement the values for respective days are 2.62 to 3 Mpa and 3 to 3.75 Mpa and 3.85to 4.5 Mpa. From this the efficient and effective replacement percentage of the rice husk based precipitated silica is found. This leads to reduction in the cost of manufacturing concrete, Reduction in usage of river sand and environmental pollutions.
REFERENCES
[1].Dr.S.Elavenil,B. Vijaya,(2013)” Manufactured Sand, A Solution And An Alternative To River Sand And In Concrete Manufacturing” Journal of Engineering, Computers & Applied Sciences (JEC&AS) ,Volume 2,page No 20-24 [2]. M. G. Shaikh, S. A. Daimi,(2011),” Durability studies of concrete made by using artificial sand with dust and Natural sand” International Journal of Earth Sciences and Engineering Volume 04, page no 823-825 [3].Dr.S.Senthilkumar, (2013)” Experimental Investigation of Concrete with Combined High alumina cement, Silica fume and M-Sand” Dona Maria Joseph, Manjula Devi / International Journal of Engineering Research and Applications (IJERA) Vol. 3,page no 425-428 [4]. Rafat Siddique*(2002), “Effect of fine aggregate replacement with Class F fly ash on the Mechanical properties of concrete” Cement and Concrete Research 33 (2003), page no 539- 547 [5]. Rajendra P. Mogre,(2012) ,“ Behaviour of Polypropylene Fibre Reinforced Concrete with Artificial Sand” International Refereed Journal of Engineering and Science (IRJES) Page no.37-40 [6]. Mr. M. Shaju Pragash,”Experimental Investigation on the Effect of Metakaolin and M-SAND in Reinforced Concrete Structural Elements with Glass Fibres” book ,page no 1-12 [7]. Vinayak R.Supekar, (2012),“ Properties Of Concrete By Replacement Of Natural Sand With Artificial Sand” International Journal of Engineering Research & Technology (IJERT )vol-1, page no 1-7
ISSN: 0974-2115 www.jchps.com Journal of Chemical and Pharmaceutical Sciences
January - March 2017 261 JCPS Volume 10 Issue 1
Eco Friendly – Manufactured Sand: An Alternative Construction
Material for Concrete *S.S. Saravanan and P. Jagadeesh
School of Civil and Chemical Engineering, VIT University, Vellore, India.
*Corresponding author: E-Mail: [email protected], Cell: 9443011975
ABSTRACT
The depletion of natural sand creates scarcity of river sand near to the worksite and also increased its cost of
conveyance many folds. The non-availability of natural sand creating the major environmental issues such as
depletion of natural water table, drought of water, etc. Hence to substitute for natural river sand for the construction
industry needs an alternative material to be found out. Hence an attempt has been made in this present work to use
the eco-friendly machine made Granite rock sand from vertical shaft impact crushers called manufactured sand (M-
sand) as fine aggregates. This paper presents an experimental investigation on strength and durability properties of
the concrete made of eco-friendly sand replaced by natural sand and the results were compared with the conventional
said concrete. Concrete mix design was carried out as per Indian standard specification. From the current
investigation, strength properties shows that the compressive strength, modulus of rupture and split strength is
increases nearly 20% more than the conventional concrete. Concrete with manufactured sand possess superior
durability performance than the conventional sand concrete.
KEY WORDS: Durability Properties, Manufactured sand, Mechanical Properties, Super plasticizer.
1. INTRODUCTION
In developing countries like India, the development of infrastructural facilities such as construction of major
expressways, bridges, elevated corridors, metro Rail systems, tunnelling works, developing major ports, power
projects and industrial structures etc., are inevitable. To meet the above requirements, concrete plays a vital role to
develop infrastructural facilities for a specified life span. It is essential to make the good quality of concrete to meet
the specified life span duration of the structure under various exposure conditions. On other hand the cost component
of natural river sand in concrete is increasing due its non-availability. Hence it is very vital to search an alternative
material for concrete constructions. M-sand is used in this present experimental work for medium grade concrete and
this M-sand is manufactured with hard granite stone boulders crushed in vertical shaft impact crushers. A lot of
research works were done with crushed stone, manufactured sand Ilangovan (2008) reported that the replacement of
natural sand in quarry rock dust as full replacements is possible. Babu (1992), Nagaraj and Zahda Banu (1996) and
Narashiman (1998), reported that the consumption of cement, cost of concrete made with quarry rock dust,
compression strength of concrete were studied and reported. Sahu (2003), Ilangovan and Nagamani (2006), studied
and reported that the significant increase is compressive strength, split tensile strength with 40% replacements of
sand by quarry rock dust in concrete and full replacements is also possible in concrete with proper treatments of
quarry rock dust before use in concrete construction. Wakchaure (2012) reported that the compressive strength,
indirect split tensile strength and modulus of rupture of concrete with artificial sand as fine aggregates was increases
from 2.81% to 10%. Chitlange (2008) studied and reported that the use of admixture is necessary in all grades of
concrete to restrict water cement ratio to 0.50. Guptha (2006) studied and reported that the manufactured sand is
satisfying the requirements of fine aggregates such as strength, shape, gradation, and angularity. Jayaraman and
Senthil Kumar (2013) studied and reported that by optimization of fully replacements of natural sand by
manufactured sand with nano silica in high performance concrete had increased compressive strength, tensile
strength and modulus of rupture of concrete proportionate to increase in percentage of nano silica. The main
objectives of current study is to investigate the mechanical and durability properties of hardened concrete with
manufactured sand as fine aggregates and compared the results with conventional sand concrete, and to find out the
optimum percentage of manufacture sand replaced as fine aggregates.
2. MATERIAL AND METHODS
Materials:
Cement: Ordinary port land cement 53 Grade (Penna Super) is used for the present work confirming to IS: 12269-
1987.
Fine Aggregates:
Natural River sand: Natural river sand obtained from the river Cauvery near Karur, which is sand hub for Tamil
Nadu is used. The physical properties are reported in Table.1.
Manufactured Sand: The Manufactured sand obtained from vertical shaft Impact Crusher at Salem (SRC M-Sand),
Tamil Nadu was used. Fine aggregates are confirming to zone II of 383-1970 as per the details of Sieve analysis. The
physical properties are presented in Table.1.
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Coarse Aggregates: Crushed natural granite stone aggregate of size 20mm and 12.50mm were used by blending the
aggregates by trial and error method to give good gradation as per standards. The physical properties of course
aggregates are presented in Table.1.
Water: Fresh potable water having the pHvalue of 7 is used for making up the concrete specimen and also for curing
the concrete samples. Super Plasticizer: Super Plasticizer is used work is CERACEM 300 RS(G) Grade Confirming to the Standards.
Mix proportions: There is no specific method of design concrete mixes with manufactured sand as fine aggregates
available. Hence the Design of mix is done using IS: IS : 456-2000 and 10262-2009. Then Natural sand was replaced
by Manufactured sand with 10% incremental increase up to 100% replacements. The mix Propertions for M30 Grade
of concrete for vaying replacements of fine aggregates with M-sand is presented in Table.2.
Specimen and Test Details:
Mechanical Properties: Concrete cubes of size 150mm x 150mm x 150mm used for compressive strength, Concrete
cylinders of size 150mm x 300mm used for indirect tensile strength of concrete and concrete prism of size 100mm
x 100mm x 500mm used for modulus of rupture study. The concrete specimens are cast for M30 grade Concrete
with 20mm graded aggregates and natural sand as fine aggregates, and this concrete is said to be the controlled
concrete and is denoted as M1.It is replaced by manufactred sand with 10% incremental increase and the mix are
denoted as M2, M3, M4, M5, M6, M7, M8, M9, M10, and M11 respectively. The workability of fresh concrete is
measured interms of slump in accordance with IS:1199-1959. The ingredients of concrete such as coarse aggregates,
fine aggregates, water and admixtures are properly mixed in the concrete mixer machine till the unifrom consistency
is achieved. For each mix specimens are casted and tested after 7, 14 & 28 days. The concrete cube specimens are
properly compacted on a Table vibrator, and the cylinders are casted and compacted with needle vibrator. Similarly
the concrete prisms are also compacted with needle vibrator. The mechanical properties such as compressive
strength, split tensile strength and modulus of rupture are calculated as per standards IS: 516-1959.
Table.1. Physical Properties of the Aggregates
S.No Property Coarse
Aggregate
Fine Aggregate
M-sand Natural Sand
1 Specific gravity 2.70 2.45 2.60
2 Bulk Density kg/m3 1510 1556 1460
3 Fineness modulus 6.67 3.54 3.44
4 Water absorption (%) 0.85 1.10 1.00
5 Moisture Content (%) 0.85 1.15 1.10
6 Fineness particles less than 150 microns - 6.80 2.60
7 Sieve analysis - Zone II Zone II
8 Aggregate Impact value 12.50 - -
Table.2. Mix Proportions details
S.No Mix
Details
Cement
(Kg/cum)
Natural
sand (Kg/cum)
M-sand
(Kg/cum)
Coarse Aggregates (Kg/cum)
Water/
Cement
SP
1 M1 390 544 0 1277 0.40 0.60%
2 M2 390 490 540 1277 0.40 0.60%
3 M3 390 435 109 1277 0.40 0.60%
4 M4 390 381 163 1277 0.40 0.60%
5 M5 390 326 218 1277 0.40 0.60%
6 M6 390 272 272 1277 0.40 0.60%
7 M7 390 218 326 1277 0.40 0.60%
8 M8 390 163 381 1277 0.40 0.60%
9 M9 390 109 435 1277 0.40 0.60%
10 M10 390 54 490 1277 0.40 0.60%
11 M11 390 0 544 1277 0.40 0.60%
Durability Properties: Durablity properties of the concrete in the present study is to test the concrete with M-sand
for water absorption, acid attack, alkaline attack, rapid chloride permeability test, and sorptivity with conventional
sand and manufactured sand. Concrete cube specimen of size 150mm x 150mm x 150mm are cast for properly
evaluate the water absorption, acid and alkaline resistence test.The 100mm diameter and 50mm thick cylinders are
cast to find out the rapid chloride permeability and sorptivity test. The concrete specimens are properly casted and
cured for the required number of days before the sample is taken for the durability tests.The durability tests are
carried out as per the standards and specifications.
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3. RESULTS AND DISCUSSIONS
Workability Properties: The workability of concrete is measured using slump cone. Results for the different mixes
are measured and presented in table.3 with using super plasticizer. The slump value increases for all mixes with super
plasticizer.
Table.3. Slump cone test
S.No Mix Slump (mm)
1 M1 82
2 M2 86
3 M3 89
4 M4 89
5 M5 90
6 M6 92
7 M7 94
8 M8 96
9 M9 96
10 M10 98
11 M11 100
Mechanical Properties:
Compressive Strength: Figure.1 shows the 7 days, 14 days and 28 days compressive strength of casted concrete
specimen. Conventional concrete exhibits the target mean strength. Test results revealed that the M-sand replaced
concrete displays good results than the conventional one.
Figure.1. Compressive Strength of concrete after 7, 14 and 28 days
Split Tensile Strength: The M-sand replaced concrete displays better split tensile strength than the conventional
one. Figure 2 demonstrates the 7 days, 14 days and 28 days split tensile strength of casted concrete specimen.
Concrete with 70% M-sand replacement shows the better result than the other mixes.
Figure.2. Split Tensile Strength of concrete after 7, 14 and 28 days
Modulus of rupture: Figure 3 shows the 7 days, 14 days and 28 days Modulus of rupture of casted concrete
specimen. As demonstrated in split tensile, concrete with 70% of M-sand replacement shows the better Modulus of
rupture value than other mixes.
Figure.3. Modulus of Rupture of concrete after 7, 14 and 28 days
Durability Properties:
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Water Absorption: Figure 4 shows the results obtained from water absorption test. Result revealed that the presence
of M-sand in the concrete reduces the water absorption capability.
Figure.4. Water Absorption test
Acid and Akaline Attack: To observe the behavior of M-sand replaced concrete under severe environment, acid
attack and alkaline attack test are carried out on the test specimen. Figure.5 and Figure.6 shows the weight loss results
of acid attack and alkaline attack on specimen after 30 days, 56 days and 90days acid and alkaline curing. The result
shows that the acid resistance and alkaline resistance of the manufactured sand is more than the conventional sand
concrete.
Figure.5. Acid Attack test Figure.6. Alkaline Attack test
Figure.7. RCPT Setup Figure.8. RCPT Results for M30 Grade
Concrete
Figure.9. Sorptivity Test on M-sand Specimen Figure.10. Sorptivity Test Results for M30
Grade Concrete
Rapid Chloride Penetration Test: RCPT test was made as per ASTM C 1202, on all the different mixes. Figure.7
shows the Rapid Chloride Penetration Test (RCPT) setup. RCPT test is carried out on all the different mixes and the
results are shown in the Figure.8. It is observed that charge passed in conventional mix is higher than the concrete
with manufactured sand mixes. Up to 60 % replacement of M-sand comes within the moderate permeability zone
and beyond 60% replacement gives low permeability. Hence forth the penetration of chloride ion in the conventional
sand concrete is more than the M Sand concrete, in otherwise the Manufactured sand concrete is less chloride ion
penetration values than the natural sand concrete.
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Sorptivity: Figure.9 and Figure. 10 shows the sorptivity test specimen setup, and the sorptivity test results for M30
grade Concrete respectively. The results demonstrated that all the mixes are performed better. Results revealed that
the sorptivity in concrete with M sand shows lesser than the conventional sand concrete due to the fines and
microfines present in the manufactured sand.
4. CONCLUSIONS
The following are the conclusions drawn from the present investigation.
The Physical properties of manufactured sand satisfies the requirement of the specifications
for natural sand as per IS 383-1970.
Workability of the concrete increases with increase in M-sand replacement which can be kept
control by varying the chemical admixtures dosage.
The compressive strength of M30 grade concrete with M sand increases by 12.80% at 7days,
15.03% at 14 days and 19.78%at 28 days compared to conventional concrete at 70%
replacement level.
The split tensile strength of M30 grade concrete with M sand increases by 16.19% at 7days,
17.39% at 14days and 19.79% at 28days than the conventional sand concrete at 70%
replacement level.
The modules of rupture of concrete with M sand increases by 21.05% at 7 days, 20.41% at 14 days
and 23.08% at 28 days than the conventional sand concrete at 70% replacement level.
Natural sand if replaces by 100% with manufactured sand in M30 grade concrete also gives the
increase in strengths than the conventional sand concrete and the Flexural strength obtained as per
the test is more than the value as specified in IS:456-2000.
The Durability of the concrete with M-sand was assessed and the result shows the healthier
performances.
The Durability of the concrete for water absorption test results shows that the percentage water
absorption is lesser in manufactured sand than the conventional sand concrete.
The acid attack test and sulphate resistance of the M sand shows lower at all replacement level for
M30 Grade concrete than the natural sand concrete. This clearly states that the durability of M sand
concrete in acid resistance and sulphate resistance is higher than the conventional concrete.
The RCPT Values of the M-sand concrete up to 60% replacement exhibit moderate chloride ion
penetration and beyond which exhibits low chloride ion penetration
The sorptivity or the surface water absorption of concrete with manufactured sand shows good
performance up to 100% replacement level.
Aforesaid analysis clearly reveals that the manufactured sand could be used as an innovative
replacement material for fine aggregate in concrete even up to 100%.
REFERENCES
ASTM C 1202, Standard Test Method for Electrical Indication of Concrete's Ability to Resist Chloride Ion
Penetration, ASTM international, 2009.
Babu K K, Radhakrishnan and Nambiar E.K.K, Compressive strength of Brick Masonry with alternative Aggregate
Mortar CE and CR Journal, New Delhi, 1992, 25-29.
Chitlange M.R, Pajgade P.S, Nagaranaik P.B, Experimental study of Artificial sand concrete, First International
Conference on Emerging Trends in Engineering and Technology, 2008, 1050-1054,
Guptha R, Strength of concrete by Partially replacing the fine aggregate using M sand, Scholors Journal of
Engineering and technology (SJET),1(4), 2006, 238-246.
Ilangovan R and Nagamani K Application of Rock dust as fine aggregate in concrete constriction, National Journal
of construction management, NICMR, Pune, 2006, 5-13.
Ilangovan R and Nagamani K, Studies on strength and behaviour of concrete by using quarry dust as fine aggregate,
CE and CR Journal, New Delhi, 2006, 40-42.
Ilangovan R, Mahendran N and Nagamani K, strength and durability properties of concrete containing quarry rock
dust as fine aggregates, ARPN Journal of Engineering and applied sciences, 3 (5), 2008, 20-26.
ISSN: 0974-2115 www.jchps.com Journal of Chemical and Pharmaceutical Sciences
January - March 2017 266 JCPS Volume 10 Issue 1
IS 10262, Recommended Guidelines for concrete mix Design, Bureau of Indian Standards, New Delhi, 2009.
IS 1199, Method of test for slump of concrete, Bureau of Indian Standards, New Delhi, 1959.
IS 12269, Specifications for 53 grade ordinary Portland cement, Bureau of Indian Standards, New Delhi, 1987.
IS 383, Specification for coarse and fine aggregate from natural sources for concrete, Bureau of Indian Standards,
New Delhi, 1970.
IS 456, Indian Standard Code of Practice for Plain and Reinforced Concrete, Bureau of Indian Standards, New Delhi,
2000.
IS 516, Methods of tests for strength of concrete, Bureau of Indian Standards, New Delhi, 1959.
Jayaraman. A, Senthilkumar, V. Optimization of Fully replacement of natural sand by Msand in high performance
concrete with nano silica, International Journal of Emerging Technology and Advanced Engineering, 3 (11), 2013,
497-502.
Nagaraj T.S and zahda Banu, Efficient Utilization of rock dust and pebbles as an aggregate in portland cement
concrete, The Indian concrete Journal, 1996, 53-56.
Narasimhan C, Patil B.T and Shankar H Sanni, Performance of concrete with quarry dust as fine aggregates-An
experimental study, CE&CR Journal, 1998, 19-24.
Sahu A.K, Sunilkumar and sachan A.K, Quarry stone waste as fine aggregate for concrete, The Indian concrete
Journal, 2003, 845-848.
Wakchaure M.R, Er. Shaikh A.P, Er Gile B.E, Effect of types of fine aggregate on mechanical Properties of cement
concrete, IJMER, 2 (5), 2012, 3723-3726.
Mohammed Nadeem, Dr. A. D. Pofale / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 5, September- October 2012, pp.1258-1264
1258 | P a g e
Replacement Of Natural Fine Aggregate With Granular Slag - A
Waste Industrial By-Product In Cement Mortar Applications As
An Alternative Construction Materials
Mohammed Nadeem1, Dr. A. D. Pofale
2
ABSTRACT The construction industry is the largest
consumer of natural resources which led to
depletion of good quality natural sand (Fine
aggregates). This situation led us to explore
alternative materials and granular slag a waste
industrial byproduct is one such material
identified for utilization it as replacement of
natural sand. This paper highlights upon the
feasibility study for the utilization of granular
slag as replacement of natural fine aggregate in
construction applications (Masonry &
plastering). In this investigation, cement mortar
mixes 1:3, 1:4, 1:5 & 1:6 by volume were
selected for 0, 25, 50, 75 & 100% replacements of
natural sand with granular slag for w/c ratios of
0.60, 0.65, 0.70 & 0.72 respectively. The study
gave comparative results for mortar flow
behaviors, compressive & split tensile strengths,
brick mortar crushing & pulls strengths and
their co-relations. The study comprises of The
experimental results obtained show that partial
substitution of ordinary sand by slag gives better
results in both the applications i.e. masonry &
plastering. The sand replacement from 50 to
75% improved mortar flow properties by 7%,
the compressive strength improved by 11 to 15 %
for the replacement level from 25 to 75%. At the
same time brick mortar crushing & pull
strengths improved by 10 to 13% at 50 to 75%
replacement levels. The co-relation between
mortar compressive/split tensile strengths &
brick crushing/pull strengths shows linear
dependencies on each others. The study
concluded that granular could be utilized as
alternative construction material for natural
sand in masonry & plastering applications either
partially or fully.
Key words: Granular slag, compressive strength,
split tensile strength, mortar adhesion strength
INTRODUCTION In the production of iron and steel, fluxes
(limestone and/or dolomite) are charged into blast
furnace along with coke for fuel. The coke is
combusted to produce carbon monoxide, which
reduces the iron ore into a molten iron product.
Fluxing agents separate impurities and Slag is
produced during separation of molten steel. BF slag
is a nonmetallic co-product primarily consists of
silicates, aluminosilicates, and calcium-alumina-
silicates. The molten slag which absorbs much of the sulfur from the charge, comprises about 20
percent by mass of iron production. Figure 1
presents a general schematic view which depicts the
BF feedstock and the production of blast furnace co-
products (iron and slag).
Figure 1 General Schematic
view of blast furnace operation and slag
production
RESEARCH SIGNIFICANCE & SCOPE Presently, use of slag in India is to the tune
of 15 to 20 % by cement industry rest is mostly
unused. The use of industrial by-products in mortar
not only helps in reducing green house gases but
helps in making environmentally friendly
construction materials. Fine aggregates are part of
all the three major applications of construction
namely masonry, plastering & concreting. Due to
increased construction activities in India,
availability of natural fine aggregates are depleting
by each passing day due to construction of large water storage dams on the rivers. Present research
study explores the possibility of using granular slag
as replacement of natural sand in mortar (Masonry
& plastering applications). In this investigation,
cement mortar mixes 1:3, 1:4, 1:5 & 1:6 by volume
were selected for 0, 25, 50, 75 & 100%
replacements of natural sand with granular slag for
w/c ratios of 0.60, 0.65, 0.70 & 0.72 respectively.
The study gave comparative results for mortar flow
behaviors, compressive & split tensile strengths,
Mohammed Nadeem, Dr. A. D. Pofale / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 5, September- October 2012, pp.1258-1264
1259 | P a g e
brick mortar crushing & pulls strengths and their co-
relations.
EXPERIMENTAL INVESTIGATION This section describes physical & chemical
properties of materials used, mix proportioning,
mortar properties, test-setup.
Materials Granular slag from the local steel making
plant, natural sand from the local river shown in
Figure 2, satisfying IS 383-1993 was used, Portland
pozzolana cement confirming to IS 1489 (Part 1):1993 were used . All the chemical & physical
properties of the materials are given in the Table 1
Table 1 – Physical & Chemical Properties of Materials
Slag Natural Sand
Chemical Analysis Physical Properties Physical Properties
Constituents (%) Specific Gravity 2.38 2.65
Loss on Ignition 1.80 Water Absorption 0.39% 0.65%
Silica 30.20 Dry loose bulk
density(DLBD)
1058 Kg/cum 1468 Kg/cum
R2O3 20.20 Soundness 0.90% 0.90%
Fe2O3 0.60 Fineness Modulus 3.14 2.64
Al2O3 19.60 Zone I II
Cao 32.40 Silt (Volume) 1.38 % 2%
MgO 9.26 -
SO2 0.27 -
Insoluble matters 0.80 -
Cement-(Portland Pozzolana Cement)
Physical Properties Chemical Properties
Specific Surface 380 m2/kg Total Loss on Ignition 1.40%
Setting time – Initial 195 minutes Magnesia 1.40%
Setting time Final 280 minutes Sulphuric Anhydride 2.06%
Soundness test by -Le-chatelier method 0.50% Insoluble residue 26.0%
Soundness test by Auto Clave method 0.06%
Compressive strength after - 3day 34.9 Mpa
Compressive strength after - 7 days 44.2 Mpa
Compressive strength after - 28 days 61.4 Mpa
Chloride 0.04%
Fly ash 28%
Figure 2 – View of Granular slag sand & natural
sand
Mortar Properties In construction work, masonry units are
bound together with the help of cement & fine aggregates (below 4.75 mm size) paste which is
termed as Mortar. It is defined in IS 2250 – 1995 as,
Mortar is a homogeneous mixture,
produced by intimately mixing cementitious
materials, water and inert materials, such as sand to
the required consistency for use in building together
with masonry units.
The safety, strength & durability of the
resulting wall or any such structure depend on the quality of the mortar used as binding medium.
Mortar serves following functions,
It provides a binding force or cohesion between
the structural units
It act as a medium for distributing the forces
throughout the structure uniformly
Mohammed Nadeem, Dr. A. D. Pofale / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 5, September- October 2012, pp.1258-1264
1260 | P a g e
It imparts to the structure additional strength
and resistance against water penetration
The essential properties/qualities of a mortar are
listed below,
The mortar mix should be easily workable
The mortar should be sufficiently plastic
The mortar should be capable of retaining
sufficient water during its application
The mortar should not react with construction
units like bricks
Mix Proportions The study was done to find out results after
replacing natural sand with granular slag by taking
various proportions 1:3, 1:4, 1:5 & 1:6 as per the IS 2250 – 1995. In each mixes, natural sand confirming
the IS – 2116 – 1999 was replaced with granular
slag by 0% (Standard mix), 25%, 50%, 75%, &
100% given in Table 2.
Table 2 – Proportion & Replacement Details
Test-Setup
The test was carried out as per the IS code
2386 (part VI) – 1997 “measurement of mortar
making properties of fine aggregate”. The flow was
finalized for 100± 5 mm for each standard mix and
based on the flow; w/c ratios were selected given in
Figure & Table 3.
Figure & Table 3 – W/C ratio for standard flow
In masonry work, mortar needs to take compressive
strength which is essential property of mortar. For
making the mortar cubes, IS 2250-1995 (Code of
practice for preparation and use of masonry mortar)
was referred. For each proportions i.e. 1:3, 1:4, 1:5
& 1:6 total five mixes were prepared by replacing
natural sand with slag sand by 0,25,50,75 & 100 %. For each mix, set of 3 cubes of 50 mm2 were filled
and tested for compressive & split strengths after 7
& 28 days time. At the same time, mortar used in
masonry & plastering are required to take certain
amount of tensile stresses due to variation in
ambient temperatures (day night, seasonal), internal
shrinkage stresses due to plastic and drying
conditions. In order to study behavior of slag against
tensile stresses with various replacement levels,
cubes were tested for split tensile strength after 28
days time. The cubes of 50 mm2 were prepared as
per IS 4031 (part 6) – 1988 for mix proportions of 1:3,1:4,1:5 & 1:6 with replacement of slag sand with
0, 25, 50, 75 & 100 % shown in Figure 4.
Figure 4 – Testing of mortar for compressive &
split tensile strengths
Mortar is used in masonry work for binding
the two masonry units. The primary object of
masonry bond is to give strength to masonry unit but
it may also be employed to create artistic effects
Mohammed Nadeem, Dr. A. D. Pofale / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 5, September- October 2012, pp.1258-1264
1261 | P a g e
when the brickwork is exposed to view. The bond
mainly takes compressive stresses arises due to load
transferred by the above units. The brick was used
as per IS 1077 -1997 & mortar was prepared as per
the requirements of IS 2250 – 1995, IS 3495 (part
I)-1998 & 2212 – 1998. The mortar of 10 mm thick
layer was applied in between the two bricks and kept it for moist curing. A set of bricks comprises
three units for each proportion of 1:3, 1:4, 1:5 & 1:6
with slag sand replacement of 0,25,50,75 & 100 %.
Set of bricks were tested for mortar joint crushing
strength after 7 days time. The bricks were kept
under compression testing machine and uniformly
compression load was applied. The load at which
brick work gets crushed divided by the area of
mortar gave mortar joint crushing strength as shown
in Figure 5.
Figure 5 – Testing of brick joint crushing
strength
In this test, mortar joint’s pull or adhesive
capacity was tested against the force applied for
pulling mortar joint between two cross bricks of burnt clay type. The bricks were applied 10 mm
thick mortar for proportions of 1:3,1:4,1:5 & 1:6
with slag sand replacement of 0,25,50,75 & 100 %.
After 7 days of curing the mortar joint bond strength
was tested in Universal testing machine. Cross
bricks were kept in-between the jaws of UTM by
means of metal sling. Load was applied till the cross
bricks pull apart and separated completely from
each other. The load at which brick joint fails
divided by the mortar area in contact with both the
bricks gave pull/adhesive strength of brick joints as shown in Figure 6.
Figure 6 – Testing of brick joint pull strengths
RESULTS & DISCUSSION The result of the investigation for the
replacements of natural sand with granular slag
(volumetrically) was discussed. The replacement
was taken as 0, 25, 50, 75 & 100% for 1:3, 1:4, 1:5 & 1:6 mortar mixes proportions for 0.60, 0.65, 0.70
& 0.72 w/s ratios respectively are discussed below,
Mortar Flow The results indicated that in the proportions
of 1:3 & 1:4, the flow increases by 7% upto slag
replacement level of 75% & 50% respectively and at
100% replacement level, it came down to 5% & 2%
respectively. In mix proportions of 1:5 & 1:6, flow increases upto the replacement level of 50% by 2 &
1% but later decreases 3 & 5% at 100% replacement
level respectively. The study clearly indicated that
in rich mixes with finer particles, granular Slag
reduced internal particle frictions which enhanced
its flow properties at the same time with lesser
cement content, flow decreased shown in Figure 7.
Figure 7 – Mortar Flow and W/C Ratio
Mortar Compressive strength It was observed that in the mix proportions
of 1:3 & 1:4, compressive strength increased upto
the replacement level of 75% by 14.66 & 16.42%
respectively and in 1:5 & 1: 6 mix proportions the
increase in strength was observed to the tune of
11.19 & 11.7% at 50% replacement level. The
increase in strengths at 100% replacement was noted
as 5.41, 6.9 & 1.09% in 1:3, 1:4 & 1:5 mix
proportions and in 1:6 it was below 0.82% compare
to 0% replacements as shown in Figure 8.
Figure 8 – Mortar compressive strength
Mohammed Nadeem, Dr. A. D. Pofale / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 5, September- October 2012, pp.1258-1264
1262 | P a g e
Mortar Split Strength Mortar split tensile strength increased in
1:3 & 1:4 mix proportions at 75% granular slag
replacement by 15.97 & 16.0% respectively and in
1:5 & 1: 6 mix proportions the increase was observed 11.56 & 10.29 % at 50% replacement
level. The increase in strengths at 100%
replacement was noted as 6.08, 7.11 & 5.39% in
1:3, 1:4 & 1:5 mix proportions respectively and in
1:6 it was below 0.59% compare to 0%
replacements shown in Figure 9.
Figure 9 – Mortar split tensile strength
Brick Mortar Joint Crushing strength The brick mortar crushing strength in 1:3 &
1:4 proportions increased at 75% replacement level by 9.11 & 10.43% respectively compare to 0%
replacement on the other hand in 1:5 & 1:6
proportions, the strength was increased at 50%
replacement level by 9.11 & 10.43% respectively. It
was also observed that in the proportions 1:3, 1:4,
the strengths at 100% replacement was found as
6.08, 5.06% and in 1: 5 & 1:6 mix proportions it
decreased by 0.78 & 1.5% compared to 0%
replacements shown in Figure 10.
Figure 10 – Mortar joint crushing strength
Brick Mortar Pull/Adhesion Strength The brick mortar pull or adhesion strength
was found the highest in 1:3 & 1:4 mix proportions
by 12 to 13% at 75% replacements of natural sand
with granular slag at the same time strength
improvement was found by 10 to 11% in 1:4 & 1:5
mix proportions. It was also observed that in all the
mix proportions the strengths at 100% replacements
were higher or equal to standard mixes as shown in
Figure 11.
Figure 11 – Mortar joint pull strength
Co-Relations The co-relations between mortar’s
compressive/split tensile strength & crushing/pull strength of brick masonry joints for proportions
from 1:3 to 1:6 mixes and replacement level of
0,25,50,75, 100 % with slag sand were found out
which indicate linear decencies with each other. The
equations are given in Table 4 & Figure 12.
Figure 4 – Co-relations between compressive /
split & crush / pull strengths
Sr
.
N
o.
Co-
relation
paramet
ers
Compressive/
Split strength
Crushing/
Pull
strength
(1:3,1:4,1:5 & 1:6 proportions)
1 0 % slag replacem
ent
Y = 0.107 x – 0.199, R2 =
0.978
Y = 0.477 x – 0.79,
R2 = 0.926
2 25 %
slag
replacem
ent
Y = 0.095 x +
0.105, R2 =
0.982
Y = 0.401
x – 0.512,
R2 = 0.971
3 50 %
slag
replacem
ent
Y = 0.088 x +
0.304, R2 =
0.980
Y = 0.300
x – 0.105,
R2 = 0.962
4 75 %
slag
replacem
ent
Y = 0.086 x +
0.435, R2 =
0.944
Y = 0.273
x + 0.001,
R2 = 0.969
5 100 %
slag replacem
ent
Y = 0.089 x +
0.420, R2 = 0.940
Y = 0.270
x + 0.018, R2 = 0.993
Mohammed Nadeem, Dr. A. D. Pofale / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 5, September- October 2012, pp.1258-1264
1263 | P a g e
Figure 12 – Co-relations equations between compressive / split & crushing / pull strengths
CONCLUSIONS
The experimental results obtained show
that partial substitution of ordinary sand by granular
slag gives better results over the verified range from
0, 25, 50, 75 & 100 % replacement. The conclusions
are drawn as below,
In mortar, 50 to 75 % replacement was found
favorable to increase the flow properties by 7 %
in 1:3 & 1:4 mix proportions however it was
lower in 1:5 & 1:6 mix proportions. The 100 %
replacement increased flow by 3% 1:3 & 1:4 mix
proportions. However 100 % replacement level
was not feasible in 1:5 & 1:6 mix proportions
since it had reduced the flow by 4 %.
In general, the range of 25 to 75 % replacement
level was found increasing the compressive
strength by about 15 & 11 % respectively.
Mortar split tensile strength increased by about
13 % at 50 to 75 % replacement level in all the
mix proportions. It could also be generalized that
mortar split tensile strength could be 10 % of
mortar compressive strength in all the mixes.
The replacements of natural sand with granular slag by 50 to 75% improved mortar joint
crushing strength by about 10% in all the mix
proportions.
The brick pull/ adhesion strength improved by
10 to 13 % for the replacements from 50 to 75%.
The co-relation between mortar
compressive/split tensile strength & brick
Mohammed Nadeem, Dr. A. D. Pofale / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 5, September- October 2012, pp.1258-1264
1264 | P a g e
crushing/pull strength shows linear dependencies
on each other.
The study concluded that granular could be
utilized as alternative construction material for
natural sand in masonry & plastering applications
either partially or fully.
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Mechanical properties of ferrochromium
slag in granular layers of flexible
pavements” Materials and structures (2010)
43:309-317, March 2009
2. Chen Meizhu, Zhou Mingkai, Wu
Shaopeng, “Optimization of blended
mortars using steel slag sand”, Journal of Wuhan University of Technology-Mater.
Sci. Ed. Dec. 2007
3. Isa Yüksel and Ayten Genç, “Properties of
concrete containing non-ground ash and
slag as fine aggregate”, ACI Materials
Journal, V. 104, No. 4, July-August 2007.
4. Isa Yüksel, Ömer Özkan, and Turhan Bilir,
“Use of Granulated Blast-Furnace Slag in
Concrete as Fine Aggregate”, ACI
Materials Journal, V. 103, No. 3, May-
June 2006. 5. Japan iron and steel federation, “ The slag
sector in the steel industry” July 2006
6. Keun Hyeook Yang, Jin Kyu Song, “
Propoerties of alkali activated mortar and
concrete using lightweight aggregates “
Materials and structures (2010)43:403-416,
April 2009
7. Li yun feng, Yao Yan, Wang, “ Recycling
of industril waste performance of steel slag
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(2009)16:0768-0773, June 2006
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Xiao,XU Fang, “Methods for improving
volume stability of steel slag as fine aggregate”, Journal of Wuhan University of
Technology-Mater. Sci. Ed. Oct 2008.
9. Masa-aki Ozaki*, Ayako Miyamoto,
“Utilization of melt-solidified slag from
sewage sludge as construction materials” ,
Minamihara 1-6, Tsukuba, Ibaraki, 305-
8516 JAPAN – 2006.
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K Tokuhasi, Chinchibu Onodo Corporation
, Japan, “Properties of self compacting
concrete with slag fine aggregates”,
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Bureau of Mines, U.S. Department of the
Interior, Washington, DC, 1993.
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Shi, “Carbonated Ladle Slag Fines for
Carbon Uptake\and Sand Substitute”,
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ASCE, November -2009.
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cementless concrete containing slag from
foundry”, International congress’ Russia,
Creating with concrete – 1999. 14. Saud Al-Otaibi, “Recycling steel mill scale
as fine aggregate in cement mortars”,
European Journal of Scientific Research
ISSN 1450-216X Vol.24 No.3-2008
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Rastovcan Mioc, Una Sofilic,
“Radionuclides in steel slag intended for
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Wendfort, “Application of foundry by
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1Mohammed Nadeem is a research scholar from
civil engineering department Visvesvaraya National Institute of Technology, Nagpur-India. His research
interest includes prefab construction, advance
construction materials and concrete technology.
2Prof. Dr. Arun D. Pofale is a professor in civil
engineering department, Visvesvaraya National
Institute of Technology, Nagpur-India. He did his
graduation in civil engineering from Visvesvaraya
regional engineering college, Nagpur-India, post
graduation (M.Tech.) in structures from IIT,
Mumbai-India and Ph.D. in civil engineering from
Nagpur university-India. His research interests include advance construction materials, concrete
technology, pre-stressed concrete and RCC
structures under fire. Currently he is chairman of
Indian Concrete Institute, Nagpur center, India.
CASE STUDY: Foundry Sand as an Alternative Raw Material in the Manufacturing of Cement
Geocycle US (Holcim)
Mason City, Iowa Geocycle US, based in Dundee, Michigan, is a subsidiary of Holcim (US) Inc. focused on offering customers solutions to their waste management needs by utilizing the co-processing capabilities of cement manufacturing. Co-processing is the substitution of fossil fuels and naturally occurring materials with waste in a manufacturing process. The recoverable materials are diverted from other disposal options such as landfills and incinerators, which preserves natural resources for future generations. Holcim is one of the largest suppliers of Portland cement and related mineral components in the United States. Founded in 1908, Holcim’s Mason City plant has been continuously producing cement for 100 years. Portland cement is made from four elements: silica, aluminum, iron, and calcium. The cement manufactured at Mason City is transported to several regional states to be used as a main ingredient in concrete. The site receives about 75,000 tons per year of foundry sand, which replaces naturally occurring, virgin silica in the cement production process. Geocycle US currently receives the spent foundry sand from eight regional foundries located in Iowa, Minnesota, Wisconsin, and Illinois, with over half of the foundry sand coming from Grede Foundries, Inc. in St. Cloud, Minnesota. In most cases, Geocycle US and the foundry share the cost of transporting the sand from the foundry’s location to the Mason City plant.
Figure 1. Unprocessed core pile. Depending on the generator, Geocycle US receives the sand in one of two forms: spent dry sand or sand cores. The dry sand may immediately be used in the production of cement, but the core sand contains hard chunks of solid sand that must be ground, screened, and processed before use. What makes the Mason City site unique is not only the amount of foundry sand it receives for co-processing, but also the site’s ability to crush and process sand cores on site. Geocycle US at Mason City allows some small foundries the opportunity to re-use their foundry sand, as these foundries may not have the resources to crush and screen their cores before sending them off for co-processing.
Figure 2. Machine that crushes and screens the core sand.
Holcim’s use of spent foundry sand in cement production results in several mutual benefits. The foundries avoid landfilling their spent foundry sands, and the Mason City plant reduces the use of a naturally occurring material like virgin sand. Also, the cement manufactured with foundry sand is a sustainable product that meets applicable quality standards and contributes to environmentally friendly applications. In addition, due to the use of recycled sand and other alternative raw materials in its cement products, the Mason City plant has a favorable relationship with the Iowa Division of Solid Waste Management and various other stakeholders.
Both Geocycle US and its source foundries are pleased with their relationship because it results in sustainable development gains for both parties. Several other foundries have expressed interest in working with Geocycle US and Holcim’s Mason City plant in the near future.
Figure 3. Machine that dries crushed and screened core sand.
Case Study: Geocycle US: Foundry Sand as an Alternative Raw Material in the
Manufacturing of Cement
Personnel End User: Geocycle US (Holcim US) Foundry: Grede Foundries, Inc.
Site
Recycling Location: Mason City, IA Site Description: Holcim’s Mason City plant uses spent sand from several foundries for its cement production process. The cement is used as a main ingredient in concrete.
Materials Utilized 75,000 tons per year of spent foundry sand in the form of dry sand or sand cores.
Project Costs and Benefits
Costs Include: • Transportation of the sand from
foundries to the Mason City plant. • Geocycle US conducts chemical
and physical analysis on the sand. • Geocycle US crushes and
processes sand cores on site. Benefits Include:
• The foundries forgo the cost to landfill spent sand.
• The Mason City plant avoids the use of naturally occurring materials like virgin sand.
• Cement made with recycled foundry sand is a viable option to reduce the environmental footprint for both parties.
• Cement manufactured with foundry sand is a sustainable product that meets applicable quality requirements and contributes to environmentally friendly applications.
• The Mason City plant has a favorable relationship with environmental regulators and stakeholders.
International Journal of Engineering Research ISSN:2319-6890)(online),2347-5013(print)
Volume No.5, Issue Special 1, pp 225-228 8-9 Jan. 2016
NCICE@2016 doi : 10.17950/ijer/v5is1/067 Page 225
Effect of Replacement of Natural Sand by Grit on Workability of Concrete
K. B. Thombre1, A. B. More
2, S. R. Bhagat
3
1,2Department of Civil Engineering, PVPIT, Bavdhan, Pune (Maharashtra)
3Department of Civil Engineering, Dr. Babasaheb Ambedkar Technological University Lonere Raigad
(Maharashtra) Email: [email protected]; [email protected]
Abstract - Globally the construction industry is facing a
major difficulty in obtaining natural river sand for making
concrete. At national level the scenario is not different than
global problem of natural sand. Day by day the sources of
natural sand is depleting at a very fast rate and at the other
end requirement of concrete is increasing tremendously due
to infrastructure developments taking place worldwide.
Government has also taken a serious note of the depleting
sources of natural sand and is taking a corrective step to
protect the environment. River sand is expensive because it is
rare to find at every location, at the same time it is required to
be transported from long distances ultimately increasing its
final cost. Environmental issues and other constraints pose
difficulties in availability and use of river sand. To cope up
with this global problem and to reduce the pressure on
natural resources, one of the alternatives is to replace the
natural sand partially or fully by other such materials
without compromising the quality of concrete. This has led to
a search for different substitute materials for natural sand.
Either partial or full replacement of natural sand by other
alternative materials like grit, stone dust, manufactured sand,
foundry sand or other such materials are being researched.
One of the easily available materials is grit which can be
obtained from stone crushers and can be used as a substitute
material to natural river sand. Natural sand plays an
important role in the performance behaviour of concrete
which directly affects the mix design. Natural sand is
rounded and smooth which improves the workability of
concrete. However, the grit is angular and rough which
adversely affects the workability. There is a challenge before
construction industry to use such material without
compromising on properties of concrete. In this paper an
attempt has been made to propose a mix proportion for
producing concrete using grit as a substitute material to
natural sand. The experimental work was carried out to study
the effect of grit on workability characteristics of concrete.
The results obtained from the study shows that grit can be
used successfully by partially replacing the natural sand thus
effectively reducing the load on environment.
Key words: Concrete, Natural sand, Grit, workability
I. Int roduct ion
Concrete is the second largest consumable material after water.
The use of concrete is increasing tremendously due to
infrastructure developments taking place worldwide. India
consumes 450 million cubic meter of concrete per annum
which is approximately 1 ton per Indian. The consumption is
much more for the developed nations than the Indian
continent. The use of concrete in India is due to infrastructure
growth such as new highways, railway projects, airports,
docks and harbours, power projects, dams, etc. For
production of concrete, 70-75% aggregates are required. Out
of this 60-67% is coarse aggregate and 33-40% is fine
aggregate. Rising demand of construction sector cannot be
fulfilled by natural sand as it is scarce and hence it is highly
expensive. It takes millions of years to form natural sand.
This bleak condition creates large demand for alternative
materials and makes the use of grit inevitable. Natural sand
contains excessive silt and the grading is not proper whereas
grit is free from organic impurities and meets the requirement
of gradation. The gradation of grit can be tailor-made
whereas it is difficult to get particular sizes and hence the
grading of natural sand. The major target before a Civil
Engineer is to produce a good quality concrete. One of the
properties required to produce a good quality concrete is its
workability. Workability plays an important role in the
production of concrete. Workability depends on many
factors; one such factor is the shape and size of fine
aggregate. Natural sand is normally of round shape and with
smooth surface, whereas grit is angular and have rough
surface. The main difficulty in achieving desired workability
of concrete with use of grit is shape and surface of grit. The
use of grit in concrete reduces the workability of concrete;
hence the proportioning of ingredients of concrete is an
important task. An attempt has been made by conducting
experiments to study the workability characteristics of
concrete produced by using grit.
II. Material and Methodology
II (A) Experimental program
The aim of this work is to study the behaviour of the concrete
by using grit as a replacement of natural sand. In this work
study has been done on the trial mixes in which the natural
sand has been replaced by grit. After carrying out trials a mix
for 100% replacement of natural sand is achieved for M 20
grade of concrete. For different concrete mixes slump values
were found and comparison is done in terms of workability.
For designing the M 20 grade of concrete W/C ratio of 0.50
is taken which is further modified up to 0.55 for meeting the
value of required workability. For the assessment of
gradation, sieve analysis of natural sand as well as grit is
conducted. For the assessment, mix designs were made using
natural sand and grit. The tests were conducted on the trials
International Journal of Engineering Research ISSN:2319-6890)(online),2347-5013(print)
Volume No.5, Issue Special 1, pp 225-228 8-9 Jan. 2016
NCICE@2016 doi : 10.17950/ijer/v5is1/067 Page 226
made from using natural sand, grit and combination of grit and
fly ash with varying amount of cement, Coarse aggregate and
water. In some mixes the admixtures are added for improving
workability of concrete. Table 1.1 shows the comparative
properties of natural sand and grit.
Table no. 1 General properties of Natural Sand and Grit
S.N. Property Natural Sand Grit
1 Shape Spherical Cubical
2 Grading Cannot be
controlled
Can be
controlled
3 Specific Gravity 2.6 to 2.8 2.5 to 2.9
4 Water Absorption 2 to 3% 3 to 4%
5 Ability to hold
moisture Up to 7% Up to10%
II (B) Materials
The following paragraphs explain the details of materials used
for conducting the experiments. The natural sand was obtained
from nearby river, whereas coarse aggregate and grit was
obtained from local crusher. A total of 7 concrete samples with
different proportions were studied to find the workability
characteristics of concrete.
II (B-1) Cement
In this experimental work OPC 53 grade cement was used. The
tests conducted on the cement were fineness test conforming to
IS 12269 : 1987, standard consistency test, compression test
conforming to IS 650 : 1991. Table no. 2 shows the test results
of cement used for producing concrete.
Table no. 2 Test results of cement
S.N. Test Result
1 Soundness ( Le Chatelier ) 8 mm
2 Initial setting time 50 minutes
3 Final setting time 560 minutes
4 Compressive strength (28 days) 51 MPa
5 Fineness 235 m2/kg
II (B-2) Natural sand and grit
For the present work four types of fine aggregate are used for
making concrete which includes natural sand and three
different samples of grit. Initially, trials were carried out on the
mix made from the natural sand which is free from the organic
impurities. Following which trials were made by replacing
natural sand by three different samples of grit. The sieve
analysis was conducted for determination of gradation of
natural sand as well as grit. For sieve analysis 1 kg of material
was taken and sieved through sieves which were mounted one
over another in decreasing order of their sizes i.e. 4.75 mm,
3.35 mm, 2 mm, 600 micron, 90 micron and grading pattern
was found. Results of sieve analysis for natural sand are shown
in table no. 3. Whereas, table no. 4 shows the results of sieve
analysis for grit. Table no. 5 shows the test results of fineness
modulus and specific gravity of natural sand and grit samples
used in the experimental work.
Table no. 3 Sieve analysis of natural sand
S.
N.
Sieve
sizes
Retained
(gm)
Retained
(%)
Cum.
(%)
%
Passing
1 4.75 mm 29.5 2.95 2.95 97.05
2 3.35 mm 19.1 1.91 4.86 95.14
3 2.36 mm 26.1 2.61 7.47 92.53
4 2.00 mm 30.1 3.01 10.48 89.52
5 1.0 mm 145.2 14.52 25 75
6 600 µ 125.3 12.53 37.53 62.47
7 90 µ 611.5 61.15 98.68 1.32
8 Pan 11.9 1.19 99.87 0.13
Table no. 4 Sieve analysis of grit (sample 1)
S.
N. Sieve sizes
Retained
(gm)
Retained
(%)
Cum.
(%)
%
Passing
1 10 mm 5.0 0.5 0.5 99.5
2 4.75 mm 82.3 8.23 8.73 91.27
3 2.36 mm 292.1 29.21 37.94 62.06
4 1.18 mm 299.3 29.93 67.87 32.13
5 600 µ 93 9.3 77.17 22.83
6 300 µ 70.9 7.09 84.26 15.74
7 150 µ 73.2 7.32 91.58 8.42
8 Pan 84.9 8.49 100.07 - 0.07
Table no. 5 Test results of fine aggregate
S.N. Test
Results
Nat
ura
l sa
nd
Gri
t (s
amp
le 1
)
Gri
t (s
amp
le 2
)
Gri
t (s
amp
le 3
)
1 Specific
gravity 2.66 2.6
2.3
5 2.52
2 Fineness
modulus 2.86
4.6
8
4.5
7 4.51
II (B-3) Coarse aggregate
Coarse aggregate occupies the maximum volume in concrete,
hence it is plays an important role in performance of
concrete. It occupies nearly 70 to 80 percent by volume of the
concrete and hence their properties are vital. Plastic and
hardened concrete properties are largely depends upon the
type of coarse aggregate. In this work coarse aggregate
conforming to IS 383 : 1970 was used having maximum size
of aggregate of 20 mm. the particle size of coarse aggregate
varied from 4.75 mm to 20 mm.
II (B-4) Super plasticizer
In the present investigation Conplast SP 430 super
plasticizing admixture was used, which complies with IS
9103 : 1999. Conplast SP 430 is based on sulphonated
International Journal of Engineering Research ISSN:2319-6890)(online),2347-5013(print)
Volume No.5, Issue Special 1, pp 225-228 8-9 Jan. 2016
NCICE@2016 doi : 10.17950/ijer/v5is1/067 Page 227
naphthalene polymers and is supplied as a brown liquid
instantly dispersible in water. It has been specially formulated
to give high water reduction up to 25% without loss of
workability. Its specific gravity is 1.145 (at 30 °C) and chloride
content is Nil. Air entrainment is approximately 1%.
II (B-5) Water
Water plays an important role in modifying the plastic and
hardened properties of concrete. It reacts with cement and
helps in setting and hardening the cement by evolving heat of
hydration. The workability of concrete directly depends on the
water-cement ratio and hence the quantity of water used for
making concrete. The water-cement ratio affects directly the
workability and strength of hardened concrete. For making the
concrete potable water was used.
II (C) Mix design of concrete
Concrete mix was designed in accordance with IS 456 : 2000
and IS 10262 : 1982. A total of four concrete mix were
designed to obtain M 20 grade of concrete. Out of the four
concrete mix, one mix was prepared from 100% natural sand
and the other three mix were by replacement of natural sand
with grit. Table no. 6 shows the proportions of ingredients for
different mix of concrete:
Table no. 6 Concrete mix proportions for M 20 grade (kg/m3)
S.N. Materials Cement Water
Sand (fine
aggregate)
Coarse
Aggregate
1 Quantity 394.32 197.9 635.74 1147.45
2 Proportion 1 0.50 1.6 2.90
Table no. 7 Trial Mix Design for replacement of natural sand
by grit (Sample 1) (kg/m3)
S.N
.
Cem
ent
w/c
rat
io
Fine aggregates
Co
arse
agg
reg
ates
Su
per
-
Pla
stic
izer
Fly
ash
Nat
ura
l
san
d
Gri
t
(sam
ple
1)
1 340 0.50 662.34 - 1155.42 - -
2 325 0.50 - 652.6 1116.8 - -
3 370 0.50 - 696.5 1114.8 0.60% -
4 330 0.55 - 541.00 1085 0.80% 132
5 330 0.55 - 568.058 1085 0.80% 99
Table no. 8 Trial Mix Design for replacement of natural sand
by grit (Sample 2, 3) (kg/m3)
S.N.
Cem
ent
w/c
rat
io
Fine
Aggregates
Co
arse
agg
reg
ates
Su
per
-
-pla
stic
izer
Fly
ash
Sam
ple
2
Sam
ple
3
1 330 0.55 548.8 - 1080.35 0.80% 99.06
2 330 0.55 - 583.92 1080.00 0.80% 99.06
Based on the results of 1st trial mix, adjustments were made
for the further trial mix. Each trial mix was designed to
obtain a target mean strength of 26.6 N/mm2. Different
concrete mix were designed with a variable water-cement
ratio and cement content varying from 330 kg/m3 to 370
kg/m3.
III. Results and Tables
III (A) Measurement of workability
The 1st trial mix of concrete tested had a water-cement ratio
of 0.50 with 100% natural sand as fine aggregate. The
workability measured on a slump cone for this 1st trail mix
was 50 mm. The compressive strength obtained for the 1st
trail was more than the desired target mean strength. Hence a
2nd
trail mix of concrete with natural sand was made by
reducing cement content and as expected the required target
mean strength was achieved. The 3rd
trial mix was made with
replacement of natural sand by grit with an increased water-
cement ratio of 0.55. For this sample of concrete mix the
observed slump was shear slump. So the 4th
trial was carried
out with addition of SP-430 super plasticizer. The concrete
obtained was honeycombed for this mix and it became
difficult to finish the concrete in cubes. To improve the
workability and ease in finishing the concrete, mix was
designed for another trial with addition of fly ash. The
difficulty in achieving a smooth finish and target workability
was achieved by addition of 30% fly ash and 0.8% SP 430
super plasticizer. Table no. 9 shows the workability of
concrete obtained for different mix.
Table no. 9 Workability results of various mixes
S.N. W/C
ratio Fine Aggregate Admixture
Workability
(mm)
1 0.50 Natural sand - 50
2 0.50 Natural sand - 40
3 0.55 Grit (sample 1) - 50
4 0.55 Grit (sample 1) 0.8% SP 430 100
5 0.55 Grit (sample 1)
+ 40% Fly ash
0.8% SP 430 110
6 0.55 Grit (sample 2)
+ 30% Fly ash
0.8% SP 430 150
7 0.55 Grit (sample 3)
+ 30% Fly ash
0.8% SP 430 150
8 0.55 Grit (sample 1) 0.8% SP 430 30
IV. Conclusion
Natural sand as fine aggregate in concrete plays an important
role in modifying the workability characteristics of concrete.
However, the sources of natural sand are depleting day-by-
day and it becomes essential to find other alternative
materials which can be used as replacement of natural sand.
One such material which can be used as replacement of
natural sand is grit. According to the findings of this present
work, due to the irregular particle shape of the grit and
International Journal of Engineering Research ISSN:2319-6890)(online),2347-5013(print)
Volume No.5, Issue Special 1, pp 225-228 8-9 Jan. 2016
NCICE@2016 doi : 10.17950/ijer/v5is1/067 Page 228
limitations imposed by code on water-cement ratio, achieving a
good workable concrete without super plasticizer was
practically difficult. From the study carried out, it can be
concluded that concrete of M 20 grade can be produced by
100% replacing natural sand with grit in presence of fly ash
and super plasticizer.
Acknowledgement
The aouthers of this paper are highly obliged to the
Department of Civil Engineering, Dr. Babasaheb Ambedkar
Technological University, Lonere. We would solemnly like to
expess our deep sence of gratitude towards Head of the
Department and the staff of the concrete technology lab of the
University.
References i. Ankit Nileshchandra Patel, Jayeshkumar Pitroda (2013). Stone
Waste: Effective Replacement of Cement for Establishing Green Concrete.
International Journal of Innovative Technology and Exploring Engineering
(IJITEE) ISSN: 2278-3075, Volume-2, Issue-5
ii. Anzar Hamid Mir (2015). Replacement of Natural Sand with
Efficient Alternatives: Recent Advances in Concrete Technology. International
Journal of Engineering Research and Applications ISSN : 2248-9622, Vol. 5,
Issue 3, ( Part -3)
iii. Dushyant R. Bhimani, Jayeshkumar Pitroda, Jaydev J. Bhavsar
(2013). Innovative Ideas for Manufacturing of the Green Concrete by Utilizing
the Used Foundry Sand and Pozzocrete. International Journal of Emerging
Science and Engineering (IJESE) ISSN: 2319–6378, Volume-1, Issue-6
iv. Mahendra R. Chitlange and Prakash S. Pachgade. (2010).
Strength appraisal of artificial sand as fine aggregate in SFRC. ARPN
journal of engineering and applied sciences. Vol. 5 no. 10
v. Manguriu, G.N., Karugu, C.K., Oyawa, W.O., Abuodha, S.O. and
Mulu, PU. (2013). Partial replacement of natural river sand with Crushed
rock sand in concrete production. Global engineers & technologists review.
vi. Sachin Balkrishna Kandekar, Amol Jagannath Mehetre,
Vijayshree A. Auti (2012). Strength of concrete containing different types of
fine aggregate. International Journal of Scientific & Engineering Research
Volume 3, Issue 9, September- 2012 ISSN 2229-5518
vii. Tushar R Sonawane, Sunil S. Pimplikar. Use of Recycled
Aggregate Concrete. IOSR Journal of Mechanical and Civil Engineering
(IOSR-JMCE) ISSN: 2278-1684, PP: 52-59
viii. IS 12269 : 1987 Specification for 53 grade ordinary Portland
cement.
ix. IS 650 : 1991 Specification for standard sand for testing of
cement.
x. IS 383 : 1970 Specification for course and fine aggregates from
natural sources for concrete.
xi. IS 9103 : 1999 Specification for admixtures for concrete.
xii. IS 456 : 2000 Code of practice for plain and reinforced concrete.
xiii. IS 10262 : 1982 Recommended guidelines for concrete mix
design.
International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol. 2, Issue. 5, Sept.-Oct. 2012 pp-3006-3012 ISSN: 2249-6645
www.ijmer.com 3006 | Page
Prof. R. Sathish Kumar Sr. Associate Professor
National Institute of Construction Management and Research, Hyderabad
Abstract: Rapid increase in construction activities leads
to active shortage of conventional construction materials
due to various regions. Concrete is most widely used
construction material. Cement, sand & granite stone are
the constituents of the concrete. Researches were
researching for cheaper materials that can be used as
substitute for these materials. In this context an
experimental study was carried out to find the suitability of
the alternate construction materials such as, rice husk ash, sawdust , recycled aggregate and brickbats as a partial
replacement for cement and conventional aggregates .For
this concrete cubes of sixe 150mm x150mm were casted
with various alternate construction materials in different
mix proportion and with different water cement ratios.
Their density, workability and compressive strengths were
determined and a comparative analysis was done in terms
of their physical properties and also cost savings. Test
results indicated that the compressive strength of the
OPC/RHA concrete cube blocks increases with age of
curing and decreases as the percentage of RHA content
increases.It was also found that the other alternate construction materials like saw dust, recycled aggregates
and brick bats can be effectively used as a partial
replacement for cement and conventional aggregates. The
results showed that the compressive strength, of recycled
aggregate are on average 70% to 80% of the natural
aggregate concrete and the compressive strength of brick
bat concrete and saw dust concrete was found to be in the
range of 30-35% and 8-10% respectively. The compressive
strength of rice husk ash concrete was found to be in the
range of 70-80% of conventional concrete for a
replacement of cement up to 20%.
I. Introduction Concrete is most widely used construction material today.
Concrete has attained the status of a major building
material in all the branches of modern construction. It is
difficult to point out another material of construction which is as variable as concrete. Concrete is the best material of
choice where strength, durability, impermeability, fire
resistance & absorption resistance are required. Rice husk
& saw dust are the waste products which are abundantly
available & which can be used as a substitute for white
cement.
I.1 Rice husk ash (RHA) concrete
Rice husk is an agro-waste material which is produced in
about 100 million of tons. Approximately, 20 Kg of rice
husk are obtained from 100 Kg of rice. Rice husks contain organic substances and 20% of inorganic material. Rice
husk ash (RHA) is obtained by the combustion of rice
husk. The burning temperature must be within the range of
600 to 8000C. The ash obtained has to be grounded in a
ball mill for 30 minutes and its appearance in colour will
be grey. The most important property of RHA that
determines pozzolanic activity is the amorphous phase
content. RHA is a highly reactive pozzolanic material
suitable for use in lime-pozzolana mixes and for Portland
cement replacement. RHA contains a high amount of
silicon dioxide, and its reactivity related to lime depends on
a combination of two factors, namely the non-crystalline
silica content and its specific surface. Research on
producing rice husk ash (RHA) that can be incorporated to concrete and mortars are not recent. In 1973, investigations
were done on the effect of pyroprocessing on the
pozzolanic reactivity of RHA. Since then, a lot of studies
have been developed to improve the mechanical and
durability properties of concrete.
I.2 Previous Research Efforts
The following research efforts shed light on the research
works on the utilization of rice husk and rice husk ash as a
partial replacement material or stabilizing agent in building
works. Tests were carried out on some characteristics of acha husk ash/ordinary Portland cement concrete. Test
results indicated that the compressive strength for all the
mixes containing AHA increases with age up to the 14-day
hydration period but decreases to the 28-day hydration
period while the conventional concrete increases steadily
up to 28-day hydration period[1]. Tests were also carried
on the use of rice husk ash in concrete. Test results
indicated that the most convenient and economical
temperature required for conversion of rice husk into ash is
500°C. Water requirement decreases as the fineness of
RHA increases. The higher the percentage of RHA
contents, the lower the compressive strengths [3]
I.3 Saw dust concrete
It is sometimes required to make nailing concrete & this
may be achieved by using saw dust as an aggregate.
Nailing concrete is a material into which nails can be
driven & in which they are firmly held. The last stipulation
is made because, for instance in some of the lighter light
weight concrete nails, although easily driven, fail to hold.
The nailing properties are required in some types of roof
construction & pre cast unit for houses etc. because of its
very large moisture movement, saw dust concrete should not be used in the situation where it is exposed to moistures
(4).
I.4 Recycled aggregate concrete
“Experimental study on the properties of concrete made
with alternate construction materials”
International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol. 2, Issue. 5, Sept.-Oct. 2012 pp-3006-3012 ISSN: 2249-6645
www.ijmer.com 3007 | Page
Lots of construction activities are going on in & around the
world & lots of demolition of old concrete works are also
taking place. This demolished concrete, if it can be
recycled & used as recycled aggregate concrete their disposal which is gigantic task can never be problem.
Shanker and Ali(5) have studied engineering properties of
rock flour and reported that the rock flour can be used as
alternative material in place of sand in concrete based on
grain size data. Nagaraj and Banu(9) have studied the
effect of rock dust and pebble as aggregate in cement and
concrete. It has been reported that crushed stone dust can
be used to replace the natural sand in concrete. Sahu, et al
(2) have reported that sand can be replaced by rock flour
up to40% without affecting strength and workability.
Kanakasabai and Rajashekaran(10)investigated the
potential of ceramic insulator scrap as coarse aggregate in concrete. It has been reported that the crushed ceramic
aggregate can be used to produce lightweight concrete,
without affecting strength
I.5 Obstacles in Use of recycled aggregate
The acceptability of recycled aggregate is impeded for
structural applications due to the technical problems
associated with it such as weak interfacial transition zones
between cement paste and aggregate, porosity and
transverse cracks within demolished concrete, high level of
sulphate and chloride contents, impurity, cement remains, poor grading, and large variation in quality (8). Although,
it is environmentally & economically beneficial to use
RCA in construction, however the current legislation and
experience are not adequate to support and encourage
recycling of construction & demolished waste in India.
Lack of awareness, guidelines, specifications, standards,
data base of utilization of RCA in concrete and lack of
confidence in engineers, researchers and user agencies is
major cause for poor utilization of RCA in construction. (7)
I.6 Brick bat aggregate concrete
Bricks bats one of the types of aggregates used in certain places where natural aggregates are not available or costly.
Where ever brick bats aggregates are used the aggregates
are made from slightly over burnt bricks. This will be hard
& absorb less water.
II. Experimental Investigations
II.1 Introduction
The experimental investigations includes the casting of cube with various alternative construction materials & the
tests were conducted to study the various physical
properties such as density, slump, 7days & 28 days
compressive strength. A total of 168 specimens were cast
& tested in the laboratory to evaluate their compressive
strength.
II.2 Materials and Methods
II.2.1 Materials
Cement- Cement used in this study is “43 Grade” which is available under the commercial name “ Rajashree
Cement”.
Sand - River sand confirming to zone -2 and with a
fineness modulus of 2.4 was used in this study.
Rice Husk Ash -The rice husk ash was obtained from
N.K.Enterprises ,Jharsuguda, Orissa, India . Here rice
husk was burnt approximately 48 hours under
uncontrolled combustion process. The burning temperature was within the range of 600 to 8000C. The
ash obtained was grounded in a ball mill for 30 minutes
and its appearance in colour was grey.
Coarse aggregate - From near by quarry.
Saw dust - from nearby saw mill
Brick bats –Collected locally and then broken into
pieces of 40mm size, mechanically sieved through
4.75mm sieve to remove the finer particles.
Recycled aggregates The recycled aggregate are
collected from the source demolished structures. The
concrete debris were collected locally from different sources and broken into the pieces of approximately 80
mm size with the help of hammer .The foreign matters
were sorted out from the pieces. Further, those pieces
were mechanically sieved through sieve of 4.75 mm to
remove the finer particles. The recycled coarse
aggregates were washed to remove dirt, dust etc. and
collected for use in concrete mix.
II.3 Material tests (As per I S 456-2000)
II.3.1 Cement and rice husk ash
Initial setting time of cement – 95 min
Final setting time of cement – 420 min
Specific gravity of cement – 3.12
Specific gravity of rice husk ash -2.14
Fineness of cement – 1.35%
Setting Times-The comparison of setting times of
cement and rice husk ash is presented in table -1
The initial and final setting times increases with increase in
rice husk ash content. The reaction between cement and
water is exothermic leading to liberation of heat and evaporation of moisture and consequently stiffening of the
paste. As rice husk ash replaces cement, the rate of reaction
reduces, and the quantity of heat liberated also reduces
leading to late stiffening of the paste. As the hydration
process requires water, greater amount of water was also
required for the process to continue.
II.3.2 Chemical analysis of rice husk ash as supplied by
the supplier
Table shows the chemical composition of rice husk ash.
The total percentage composition was found to be 73.77%
This value is within the range of required value of 70% minimum for pozzolonas. The loss of ignition obtained was
17.71% which is slightly more than 12%max required for
pozzolonas. It means that rice husk ash contains little
unburnt carbon and this reduces the pozzolonic activity of
ash.
Content % age
composition
Fe2O3 0.91%
SiO2 65.3%
CaO 1.31%
Al2O3 4.4%
MgO 1.85%
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Loss of ignition 17.71%
The specific gravity of rice husk ash was found to be
2.14.The value is well within the range of pulverised fuel
ash which is in between 1.9 and 2.4 as reported in (6)
II.3.3 Fine aggregate tests
Specific gravity of sand – 2.61
Fineness modulus of sand – 2.54
Fineness modulus of saw dust – 2.67
Specific gravity of saw dust -2.12
II.3.4 Coarse aggregates tests
II.3.4.1 Conventional aggregate
Specific gravity of coarse aggregate – 2.70
Fineness modulus of coarse aggregate – 7.133
Crushing strength – 16.1% Specific gravity of brick bats -2.34
II.3.4.2 Recycled Concrete Aggregate
(a) Specific Gravity and Water Absorption
The specific gravity (saturated surface dry condition) of
recycled concrete aggregate was found to be 2.28 which is
lower as compared to natural aggregates. Since the RCA
from demolished concrete consist of crushed stone
aggregate with old mortar adhering to it, the water
absorption found to be 2.95% which is relatively higher
than that of the natural aggregates.
(b) Bulk Density
The rodded & loose bulk density of recycled aggregate is
lower than that of natural aggregate. The lower value of
loose bulk density of recycled aggregate may be attributed
to its higher porosity than that of natural aggregate.
(c)Crushing and Impact Values
The recycled aggregate is relatively weaker than the natural
aggregate against mechanical actions. As per IS 2386, the
crushing and impact values for concrete wearing surfaces should not exceed 45% and 50% respectively. The
crushing & impact values of recycled aggregate satisfy the
BIS specifications
II.4.4.3 Super plasticizer
Product - Roff block master
Description – It is an admixture for making concrete blocks
and pre cast concrete products- to achieve homogeneous
highly workable mix to give high early strength & to
reduce breakages.
Typical applications – For manufacture of concrete blocks,
products such as pipes, pole, manhole covers, concrete jails etc.
Consumption – 140ml/bag of 50 Kg cement
Application – Dry mix cement & aggregate, add 140ml roff
block master in gauging water, mix thoroughly & cast as
per standard practice, permits use of leaner mixes.
II.5 Specimens
A total of 168 specimens of size 15cm x 15cm x 15cm
were casted with different alternative construction
materials with varying mix proportion & water cement
ratio is given in table -2
III. Comparison of results
III.1.Rice husk ash concrete with conventional concrete
Nearly 60 specimens were casted with the mix proportion
of 1:2:4 with different water cement ratios 0.56,0.58,0.60
and 0.62 and with different percentages of Cement and rice
husk ash .It was found from that when the rice husk ash
percentage was increased from 50% onwards the mix was
becoming harsh ,so a higher water cement ratio was
adopted for the mixes with increased rice husk ash
percentages The comparison of compressive strength of conventional and rice husk ash concrete cubes are given in
table -3
III. 2. Saw dust concrete with conventional concrete
Some properties of concrete with sawdust ash (SDA) as a
replacement for conventional fine aggregate are
investigated The cube specimens were casted under 2 mix
proportions.1:2:4 and 1:1.5:3.Sawdust and river sand were
taken in the ratio 1.5:0.5 for 1:2:4 concrete and 1:0.5 and
1.25:0.25 for 1:1.5:3 concrete. The water cement ratio
adopted earlier was found harsh for this concrete. So the
mixes are made in a water cement ratio of 0.7,0.75 and 0.8 respectively.. The compressive strength of specimens with
replacement levels shown above cured for periods of 7-28
days showed a decreasing strength with higher saw dust
content. The comparison of compressive strength of
conventional and saw dust concrete cubes are given in
table -4
III.3. Recycled aggregate concrete with conventional
concrete
Three different mix proportions 1:1.5:3, 1:2:4, and 1:3:6
with water cement ratio 0.5 & 0.6 and 0.7 were made with natural aggregate concrete and recycled aggregate concrete
with and without plasticizer. Due to the higher water
absorption capacity of RCA as compared to natural
aggregate, both the aggregates are maintained at saturated
surface dry (SSD) conditions before mixing operations.
The ordinary Portland cement of 43 grade and natural river
sand were used throughout the casting work. The
maximum size of coarse aggregate used was 20 mm in both
recycled and natural aggregate concrete.
A total of 54 cube specimens were casted . The comparison
of compressive strength of conventional and recycled
aggregate concrete cubes are given in table -5
III.4 Brickbat concrete with conventional concrete
Here the conventional stone aggregates were replaced with
brickbats and the specimens were casted in the ratio
1:2:4.1:1.5:3 and 1:3:6. The comparison of compressive
strength of conventional and brick bat aggregate concrete
cubes are given in table -6
IV. Cost analysis A cost comparison was done with concrete made up of
alternate construction materials and conventional concrete
was done the same was presented in table 7 &8
IV.1 Analysis of results obtained
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IV.1.1 Suitability of Material Used
The rice husk ash used was found to be pozzolonic in
nature.The specific gravity of rice husk ash was found to
be 2.14.The setting time of Ordinary Portland cement and rice husk ash paste increases as rice husk ash content
increases
The fineness modulus of saw dust was 2.67 and that of
sand was 2.54. This infers that the saw dust contains
more coarse particles in comparison to sand. Hence, saw
dust may be considered as fine aggregate in concrete.
The specific gravity of the brick bat aggregates (2.34) is
about 0.86 times as that of conventional aggregate (2.7).
As the specific gravity of brick bat aggregates is less
than that of the conventional aggregates, the concrete
produced using the brick bat aggregate will be of low density.
Recycled aggregate and brick bat aggregates can be
partially used to replace conventional coarse aggregates
(10% to 20%), without affecting its structural
significance
V. Conclusion
The compressive strength of rice husk ash concrete was
found to be in the range of 70-80% of conventional
concrete for a replacement of cement up to 20%.
The study shows that the early strength of rice husk ash
concrete was found to be less and the strength increased
with age.
The rice husk ash concrete occupies more volume than
cement for the same weight. So the total volume of the
rice husk ash concrete increases for a particular weight
as compared to conventional concrete which results in
economy.
Due to the lower density of RHA concrete the self
weight of structure gets reduced which results in overall
savings.
From the cost analysis it was found that the cost of RHA
concrete was less compared to conventional concrete
Recycled aggregate posses relatively lower bulk density,
crushing and impact values and higher water absorption
as compared to natural aggregate.
The compressive strength of recycled aggregate
concrete was found to be in the range of 70 to 80 % of
conventional concrete..
The compressive strength of brick bat concrete was
found to be nearly 35 % of conventional concrete... The
compressive strength of saw dust concrete was found to be nearly 10 to 15% of conventional concrete. So the
concrete made with alternate construction materials like
brick bats and saw dust can be used for partition &
filling purposes & nailing purposes where the strength is
not the criteria.
Wherever compressive strength is not a criteria, the
concrete made with alternate construction materials can
always be preferred.
Referances
1. Al –Khalaf M.N.and Yousuf H.A ,Use of rice husk
ash in concrete, The international journal of cement
composite and light weight concrete ,6(11),p.241-
245,1984
2. A K Sahu, S Kumar and A K Sachin. „Crushed Stone
Waste as Fine Aggregate for Concrete‟. The Indian
Concrete Journal, January 2003
3. Dashan .I.IB and Kamang E.E.I.,Some characteristics
of RHA/OPC concrete, A preliminary assessment
,Nigerian journal of Construction Technology and
Management,2(1),P.22-28,1999
4. Felix F. Udoeyo1 and Philibus U. Dashibil,J. Mat. in
Civ. Engrg. Volume 14, Issue 2, pp. 173-176 (March/April 2002)
5. N B Shankar and Md Ali. „Engineering Properties of
Rock Flour‟. National conference on Cement and
Building Materials from Industrial Waste, July 24-25,
1992, pp 167-172.
6. Neville AM.,Properties of concrete, John&Wiley and
sons,Malasia,1981 &1985 composites and light
weight concrete,6(4).P.241-248,1984.
7. Rahal, K. (2007) “Mechanical Properties of Concrete with Recycled Coarse Aggregate,” Building &
Environment, Vol. 42, pp 407-415.
8. Sharma, P.C., Nagraj, N.(1999), “Recycled
Aggregate Concrete and Its Importance in Indian
Conditions”– All India Seminar on Indian Cement
Industries : Challenges and Prospects of Cement”
Chandrapur (Maharashtra)
9. T S Nagaraj and Z Banu. „Efficient Utilization of
Rock Dust and Pebbles as Aggregate in Portland
Cement Concrete‟. The Indian Concrete Journal, vol
70, no 1, 1996, pp 1-4
10. VK Sabai and AR Shekaran. „Ceramic Insulator
Scrap as Light Weight Concrete‟.National
Conference on Cement and Building Materials from
Industrial Wastes, July 4-25, 1992, pp 8-15
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Table -1 Comparison of setting times of cement and rice husk ash under various replacement levels.
Table -2 Specimens casted with different alternate construction materials and with different water
Cement ratios.
Table -3 Comparisons of compressive strength of conventional and rha concrete cubes.
Sl No Types of
concrete
Mix Cement :
RHA
W/C Compressive strength in
Kg/cm2
3 days 7 days 28
days
1 Conventional
concrete
1:2:4 100% :0% 0.56 118.57 166.00 298.06
2 RHA concrete 1:2:4 90%:10% 0.56 98.69 138.57 234.39
3 RHA concrete 1:2:4 80%:20% 0.56 89.69 124.62 197.98
4 RHA concrete 1:2:4 70%:30% 0.56 71.02 104.00 157.90
5 Conventional
concrete
1:2:4 100% :0% 0.58 122.3 168.22 276.67
6 RHA concrete 1:2:4 90%:10% 0.58 100.79 144.74 237.15
7 RHA concrete 1:2:4 80%:20% 0.58 89.05 128.93 198.57
8 RHA concrete 1:2:4 70%:30% 0.58 78.50 106.26 158.12
9 Conventional
concrete
1:2:4 100% :0% 0.60 101.67 154.15 277.86
10 RHA concrete 1:2:4 90%:10% 0.60 101.12 146.15 239.33
11 RHA concrete 1:2:4 80%:20% 0.60 91.47 132.98 199.76
12 RHA concrete 1:2:4 70%:30% 0.60 79.66 108.59 161.33
13 Conventional
concrete
1:2:4 100% :0% 0.62 120.55 160.43 248.33
14 RHA concrete 1:2:4 90%:10% 0.62 84.05 112.79 216.71
15 RHA concrete 1:2:4 80%:20% 0.62 78.28 107.05 198.81
16 RHA concrete 1:2:4 70%:30% 0.62 61.26 85.09 164.62
17 RHA concrete 1:2:4 50%:50% 0.98 49.4 57.31 75.09
18 RHA concrete 1:2:4 40%:60% 1.07 35.57 55.33 59.28
19 RHA concrete 1:2:4 30%:70% 1.20 25.57 39.52 41.5
20 RHA concrete 1:2:4 20%:80% 1.35 15.81 23.71 25.69
RHA replacement of OPC (%) 0 10 20 30 40 50
Initial Setting Time (minutes) 90 172 183 285 324 389
Final Setting Time (minutes) 240 313 490 525 712 790
Sl No Types of concrete Proportions W/C ratio Density
(Kg/cum)
1. Conventional
concrete
1:2:4 0.4,0.5,0.6 2520
2. Concrete with rice
husk ash
1:2:4(80%cement and 20%rice
husk ash)
0.4,0.5,0.6 2418
4. Recycled concrete
without plasticizer
1:1.5:3,1:2:4,1:3:6 0.5,0.6,0.7 2488
6. Saw dust concrete 1:(1.5+0.5):4 0.7,0.75,0.8 1980
7. Concrete using
brick bat
1:2:4 0.5,0.6,0.7 2215
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Table-4 Compressive strength test results of conventional concrete and saw dust concrete.
Sl No Types of
concrete
Prop W/C Compressive
Strength
(7days) Kg/cm2
Compressive
Strength
(28days)
Kg/cm2
Conventional
concrete
1:2:4 0.56 166 328
Saw dust
concrete
1:(1.5+0.5):4 0.7 18.89 31.11
Saw dust
concrete
1:(1.5+0.5):4 0.75 19.09 32.36
Saw dust
concrete
1:(1.5+0.5):4 0.8 17.78 30.35
Saw dust
concrete
1:(1+0.5):3 0.7 20.12 42.11
Saw dust
concrete
1:(1+0.5):3 0.75 20.26 43.22
Saw dust
concrete
1:(1+0.5):3 0.8 19.19 39.32
Saw dust
concrete
1:(1.25+0.25):3 0.7 18.11 30.33
Saw dust
concrete
1:(1.25+0.25):3 0.75 18.63 30.44
Saw dust concrete
1:(1.25+0.25):3 0.8 18.42 30.14
Table-5 Compressive strength test results of conventional concrete and recycled aggregate concrete.
Sl
No
Types of concrete Prop. W/C Compressive
Strength
(7days) Kg/cm2
Compressive
Strength
(28days)
Kg/cm2
1 Conventional concrete 1:2:4 0.5 166 296
2 Conventional concrete 1:1.5:3 0.5 198 346
3 Conventional concrete 1:3:6 0.5 136 196
4 Recycled concrete
without plasticizer
1:2:4 0.5 101.44 177.56
5
Recycled concrete
without plasticizer
1:2:4
0.6
104.67
187.78
6 Recycled concrete
without plasticizer
1:2:4 0.7 114.44 192.22
7 Recycled concrete
without plasticizer
1:1.5:3 0.5 119.23 218.11
8 Recycled concrete
without plasticizer
1:1.5:3 0.6 122.89 221.56
9 Recycled concrete
without plasticizer
1:1.5:3 0.7 129.28 228.33
10 Recycled concrete
without plasticizer
1:3:6 0.5 81.88 118.66
11 Recycled concrete
without plasticizer
1:3:6 0.6 87.78 121.22
12 Recycled concrete
without plasticizer
1:3:6 0.7 92 128.78
13 Recycled concrete with plasticizer
1:2:4 0.5 134.44 234.56
14 Recycled concrete with
plasticizer
1:2:4 0.6
136.67
241.78
15
Recycled concrete with
plasticizer
1:1.5:3
0.5
148.23 258.13
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16 Recycled concrete with
plasticizer
1:1.5:3 0.6 152.78 272.11
17 Recycled concrete with
plasticizer
1:3:6 0.5 109.11 152.06
18 Recycled concrete with
plasticizer
1:3:6 0.6 111.43 154.11
Table-6 Compressive strength test results of conventional concrete and brick bat concrete.
Sl
No
Types of concrete Prop. W/C Compressive
Strength
(7days) Kg/cm2
Compressive
Strength
(28days)
Kg/cm2
1 Conventional concrete 1:2:4 0.56 166 328
2 Concrete using brick bat 1:2:4 0.5 58.12 91.11
3 Concrete using brick bat 1:2:4 0.6 62.89 108.89
4 Concrete using brick bat 1:2:4 0.7 59.67 102.89
5 Concrete using brick bat 1:1.5:3 0.5 64.12 122.33
6 Concrete using brick bat 1:1.5:3 0.6 69.67 132.11
7 Concrete using brick bat 1:1.5:3 0.7 66.78 128.44
8 Concrete using brick bat 1:3:6 0.5 42.89 66.67
9 Concrete using brick bat 1:3:6 0.6 43.22 72.22
10 Concrete using brick bat 1:3:6 0.7 41.08 68.34
Table -7 Cost comparisons between rice husk ash concrete specimens and conventional concrete specimens.
Sl
No
Types of concrete Cement:RHA Prop. Percentage w.r.t conventional
concrete
1 Conventional concrete 100% :0% 1:2:4 --
2 RHA concrete 90%:10% 1:2:4 4.23%
3 RHA concrete 80%:20% 1:2:4 5.93%
4 RHA concrete 70%:30% 1:2:4 14.31%
5 RHA concrete 50%:50% 1:2:4 17.9%
6 RHA concrete 40%:60% 1:2:4 19.74%
7 RHA concrete 30%:70% 1:2:4 23.6%
8 RHA concrete 20%:80% 1:2:4 27.6%
Table-8 Cost comparison between other alternate construction material specimens and conventional
Concrete specimen.
Sl
No
Types of concrete Prop %age of saving w.r.t to
conventional concrete
1. Conventional concrete 1:2:4 --
2 Recycled concrete without plasticizer 1:4 28.1%
5.a Recycled concrete with plasticizer 1:4 25.2%
6.a Saw dust concrete 1:(1.5+0.5):4 30.1%
7.a Concrete using brick bat 1:2:4 15.42%
24th & 25th July 2015
Emerging Trends on Sustainable Construction – National Level Conference Christ University, Bangalore Page 1
Alternatives to Conventional Cement-Sand Mortar for
Sustainable Masonry Construction
Sumanth M Kamplimath1, Ashwin M joshi
2
1PG. Student, Infrastructure Construction and Management, RASTA-Centre for Road Technology,
Bangalore 560058 email: [email protected] 2Asst. Professor, Infrastructure Construction and Management, RASTA-Centre for Road Technology,
Bangalore 560058 email: [email protected]
Abstract
Masonry Mortar is basically a binding agent that is composed of cementitious material,
fine aggregates and water. The main purpose of the mortar is to sew masonry units
(blocks/bricks) into single integral unit. Conventionally used mortar is cement sand
mortar in the proportion 1:6 (Cement: River Sand). Over the past few decades man has
exploited the natural resources at a severe rate. Good quality Natural River Sand stands
first in the list of construction materials that are in the verge of extinction due to excessive
and unnecessary consumption in construction process. One has to adapt to alternative
materials that can be used as an effective replacement over ‘Natural River Sand’ in
Masonry Mortar without affecting its efficiency. This paper focuses on the experimental
analysis on six such alternatives that have the potential to replace Natural River Sand in
mortar. Mortars prepared from these alternatives satisfies the minimum strength
requirement as per IS code. Thus the use of such alternatives to natural sand for mortars
in masonry construction would deliver an efficient-economical and sustainable structure.
Keywords: Natural River Sand, M. Sand, LD Slag, GBFS, Quarry Dust, Granite Powder,
Cement-Lime-Soil-Paste (CLSP), Mortar, Masonry
1. Introduction
The field of Civil Engineering and Construction technology has evolved from bamboo
huts to multi storeyed sky scrapers and man-made islands. Such mega structures consume
huge amount of natural resources which may have irreversible ill-effects on the
environment. Sand being the most widely consumed material in construction is on the
verge of causing such ill-effect on environment. In the present day, sand mining is banned
and this has resulted in severe imbalance in the supply-demand chain of Natural River
Sand. Construction with River sand in the present case scenario is highly expensive.
Hence one has to adapt to alternative materials in construction process that has negligible
impact on environment.
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Emerging Trends on Sustainable Construction – National Level Conference Christ University, Bangalore Page 2
2. Earlier Investigations
Several investigations have been carried out on alternatives that can be used as partial or
total replacement of sand in conventional cement sand mortar. Rashmi S, Jagadish K S
and Nethravathi S (2014) [1] carried out studies on stabilized mud mortars. Masonry
Mortar plays a major role in the strength gaining parameters of the masonry structures.
This study focuses on the utilization of locally available and economical resources as an
alternative for conventional construction practises. Mortars were prepared with various
mix proportions of soil, brick dust, lime, sand and cement. The various mortar mix
proportions was prepared with varied percentage of water content and tested for its 28 day
cube compressive strength. The mortar proportion M5 with 50% soil and sand with 12%
cement stabilization showed a compressive strength of 4.25 MPa at 28 day which satisfies
the standards of IS 2250:1981. Hence it is clear that partial replacement of sand using soil
works out to be an economical mix. Costigan.A and S.Pavia (2005) [2] carried out
analysis on the compressive strength flexural strength and bond strength of Masonry
using Lime based mortars. Both the hydraulic Lime and Non hydraulic Lime was used as
mortar. Masonry wallettes were built using non hydraulic Lime and Hydraulic Lime as
mortar and were tested for its compressive strength and flexural strength. The mortar was
also tested for its cube compressive strength at 28 days and 56 days. The non-hydraulic
Lime had a 28 day cube compressive strength of 0.89MPa which was slightly lower from
the specified standard values of 1.20MPa; Hydraulic lime had a mortar cube compressive
strength of 4.39MPa which was satisfactory as per standards. Venkatarama Reddy and
Ajay Gupta (2006) [3] carried out tests to determine the strength and elastic properties of
stabilized mud block masonry using cement-soil mortar. Soil used in the blocks and
mortar is same. Soil being Loamy contained 16% clay. The clay content was varied by
blending the soil with natural sand. Workability was maintained constant and the
compressive strength was evaluated. It was found that the compressive strength of
cement-soil mortar and cement-lime mortar was 20% higher than pure cement mortar.
The study showed that mud mortars and lime mortars that are cheaper when compared to
pure cement mortar can be used effectively in Stabilized mud block masonry. Till date,
several alternative materials have been considered for partial replacement of sand in
conventional cement sand mortar. In the present work, an attempt is made on various
alternatives that can be used as complete replacement of sand in masonry mortar.
24th & 25th July 2015
Emerging Trends on Sustainable Construction – National Level Conference Christ University, Bangalore Page 3
3. Materials and Methodology
The step by step procedure followed in the present study in preparation of mortars using
alternative materials have been discussed below
3.1 Materials
The various ingredients or alternatives materials that have been used as fine aggregate for
total replacement of sand in conventional Cement Sand mortar and their description is
given below.
3.1.1 Manufactured Sand (M. Sand)
M. Sand or Manufactured sand is the latest alternative for natural river sand being used
widely in the construction process. It is derived from crushing of aggregates in a
controlled process as per required specification in terms of shape, size and surface
texture.
3.1.2 Granulated Blast Furnace Slag Sand (GBFS)
This sand is basically a slag material obtained when manufacturing Iron from its ore. The
slag is initially derived in its molten state which upon rapid cooling results in the
formation of sand sized particles. These particles are non-metallic and have surface
texture similar to that of natural river sand
3.1.3 Quarry Dust
Quarry Dust is a by-product generated during the stone quarrying process. These are
extremely fine particles with grain lesser than 75 micron. Hence it can be used effectively
as a filler material because of its tendency to occupy large surface area.
3.1.4 Granite Powder
Granite powder is initially collected as slurry in large storage tanks. When the slurry is
left undisturbed for weeks, the particles undergo sedimentation which is later collected as
Granite Powder. Granite slurry disposal has become a nuisance to the dealers and hence
its application in the field of civil engineering has been explored in the present study.
3.1.5 LD Slag
The slag gets its name from the process developed by scientists Linz and Donawitz in the
manufacture of steel. Calcium oxide comprises of 46% of the total constituent of the Slag.
Hence the slag exhibits cementitious property. Other constituents include oxides of Silica,
Magnesium, Manganese and Iron.
24th & 25th July 2015
Emerging Trends on Sustainable Construction – National Level Conference Christ University, Bangalore Page 4
3.1.6 Cement-Lime-Soil-Paste (CLSP)
Over the past few decades, with the advancements in the field of stabilization techniques,
we have seen the effective use of soil as partial replacement of sand in Cement-Soil
mortar [3]. Hence an attempt has been made to use locally available soil as complete
replacement to natural sand in Cement-Lime-Soil Paste (CLSP) as mortar. CLSP has been
used in two different proportions (1:1:2 and 1:1:1.5 – Cement:Lime:Soil). Soil used in the
study is locally sourced and had a clay content of about 20%. Quick Lime was procured
from Bijapur and slaked to obtain Hydrated Lime. This hydrated lime was blended
effectively with cement and soil to obtain a paste that has been used as mortar for
complete replacement of river sand in conventional cement sand mortar. 43 Grade
Cement has been used as binder for all the mortars used in the present study.
3.2 Methodology
The first step in the present study was the procurement of various alternative materials
that was intended to be used as fine aggregates in masonry mortar. The binding agent in
all these materials was cement. The alternatives considered as complete replacement of
sand in mortar was first sieved and the sand portion i.e. passing 4.75mm sieve and
retained on 75 micron sieve was collected for use in preparing mortar. The proportion of
cement and fine aggregates in the various mortars that have been studied was 1:6 (Binder:
Fine Aggregate). Mode of preparation of mortar was followed as per Standard
specifications [4]. Granite powder being extremely fine had 0% retained on 75 micron
sieve. The details of various alternatives materials used and water content maintained at
the time of preparation of mortar cubes have been tabulated in table 1.
Table 1: List of Various Mortar Cubes along with its initial water content
Sl. No Mortar Type Water Content
1 1:1:1.5 - CLSP 50%
2 1:1:2 - CLSP 50%
3 1:6 - Cement: Natural Sand 40%
4 1:6 - Cement: Quarry Dust 60%
5 1:6 - Cement: Granite Powder 80%
6 1:6 - Cement: M. Sand 60%
7 1:6 - Cement: GBFS 50%
8 1:6 - Cement: LD Slag 80%
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Emerging Trends on Sustainable Construction – National Level Conference Christ University, Bangalore Page 5
4. Testing Procedure - Compressive Strength of Mortar Cubes
The various alternatives that have been mentioned above were cast in mortar cubes of
70.6mm dimension. The cubes were greased thoroughly before filling the mortar mix.
Filling of mix was done in 3 layers as per standard specifications [4]. The prepared mortar
cube was allowed to set for a period of 24 hours after which they were demoulded and
cured for 28 days and 56 days and tested for its compressive strength under Universal
Testing Machine.
5. Results and Discussion
Workability and Compressive Strength are the two important parameters that govern the
efficiency of mortar. In the present study, Workability being fairly a relative parameter
has been adopted based on trial mixes. Strength parameter has been evaluated by testing
the mortar cubes for it compressive strength at 28 days and 56 days respectively. The test
results have been comparatively analysed with respect to the strength of conventional
cement sand mortar cube compressive strength at corresponding curing period.
Compressive strength results are tabulated in table 2. The different alternatives that would
be suitable for complete replacement of sand in mortar were studied by analysing the
compressive strength results of mortar cubes over different curing periods.
Table 2: Compressive Strength of Mortar Cubes
Failure
Load (kN)
Average
(MPa)
Failure
Load (kN)
Average
(MPa)
1 1:1:1.5 - CLSP 4984.36 70.43 14.13 90.02 18.06
2 1:1:2 - CLSP 4984.36 56.27 11.29 68.63 13.77
3 1:6 - Cement: Natural Sand 4984.36 34.14 6.85 52.34 10.50
4 1:6 - Cement: Quarry Dust 4984.36 72.67 14.58 82.59 16.57
5 1:6 - Cement: Granite Powder 4984.36 10.22 2.05 17.64 3.54
6 1:6 - Cement: M.Sand 4984.36 25.27 5.07 40.82 8.19
7 1:6 - Cement: GBFS 4984.36 9.42 1.89 16.25 3.26
8 1:6 - Cement: LD Slag 4984.36 35.89 7.20 53.58 10.75
Sl.
NoMortar Type
Cube Surface
Area (mm2)
28 days
Comp. Strength
56 days
Comp. Strength
24th & 25th July 2015
Emerging Trends on Sustainable Construction – National Level Conference Christ University, Bangalore Page 6
Figure 1: Mortar Cube Compressive Strength
Except for Granite powder and GBFS, all the alternatives have satisfactory compressive
strength as per IS codes. However it can be seen that quarry dust and 1:1:1.5 CLSP
mortar have the highest strength. It is interesting to note that at 28days quarry dust mortar
had slightly higher strength as compared to 1:1:1.5 CLSP mortar. However at 56day the
compressive strength of 1:1:1.5 CLSP is much greater than that of mortar using Quarry
Dust. This can be attributed to the lower hydration rate of lime based mortar.
6. Conclusion
From the present study we have seen that there are several alternatives for complete
replacement of sand as fine aggregate in mortar. With advancements in technology we
have to adapt to eco-friendly alternatives rather than relying on conventional methods that
have been exploiting our environment from decades. Any advancement in field of civil
engineering should be towards exploring new innovative methods that conserve our
environment rather than developing techniques that exploit our environment at a faster
rate. Cement-Granite Powder mortar and Cement-GBFS mortar have comparatively low
compressive strengths. Such mortar can be used for works with low strength
requirements.
1:1:1.5 CLSP
1:1:2 CLSP
CM M_Sand Quarry
Dust GBFS LD SLAG
Granite Powder
28 Day 14.13 11.29 6.85 5.07 14.58 1.89 7.20 2.05
56 Day 18.06 13.77 10.50 8.19 16.57 3.26 10.75 3.54
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
20.0
Co
mp
ress
ive
Str
en
gth
in
MP
a
Mortar Cube Compressive Strength
24th & 25th July 2015
Emerging Trends on Sustainable Construction – National Level Conference Christ University, Bangalore Page 7
7. References
1. Rashmi S, K.S Jagadish, Nethravathi S, “Stabilized Mud Mortar”, IJRET Vol 3,
Special Issue 6, May 2014.
2. A. Costigan, S. Pavia, “Influence of the mechanical properties of lime mortar on the
strength of brick masonry”, The International Information Centre for Structural
Engineers, Vol 7, Pg 349-359, 2013.
3. B. V Venkatarama Reddy and Ajay Gupta, Strength and Elastic Properties of Stabilized
Mud Block Using Cement-Soil Mortars, Journal of Materials in Civil Engineering,
Vol.18, No.3, pp 472-476, June 2006.
4. IS: 2250-1981 “International Standard Code of Practice for Preparation and Use of
Masonry Mortars”, Bureau of Indian Standards, New Delhi
5. K.S Jagadish, B. V Venkatarama Reddy, K. S. Nanjunda Rao, “Alternative building
Materials and Technologies”, New Age International Ltd. Publishers, 2009.
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