EFFECT OF SOLID CERAMIC WASTE POWDER IN PARTIAL ...iaeme.com/MasterAdmin/uploadfolder/IJCIET_10_03_308/IJCIET_10_… · per tonne of cement). It has also been estimated that cement

http://www.iaeme.com/IJCIET/index.asp 3055 [email protected]

International Journal of Civil Engineering and Technology (IJCIET)

Volume 10, Issue 03, March 2019, pp. 3055–3066, Article ID: IJCIET_10_03_308

Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJCIET&VType=10&IType=3

ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication Scopus Indexed

EFFECT OF SOLID CERAMIC WASTE

POWDER IN PARTIAL REPLACEMENT OF

CEMENT ON MECHANICAL PROPERTIES AND

SORPTIVITY OF CEMENT MORTAR

Ali Hussain Ali

Assistant Professor, Building and Construction Department, Technical College of Mosul, Iraq

Dr.Aliaa Abbas Al-Attar

Assistant President of the Northern Technical University for Scientific Affairs, Iraq

Zeena Emad Kasm*

M.Sc. Students, Building and Construction Department, Technical College of Mosul, Iraq

Corresponding Author*

ABSTRACT

Some of the most serious problems of the world today concern elimination of

waste and finding a solution for reusing it. Large quantities of waste are generated

from manufacturing processes and construction destruction works. Materials waste

administration is one of the most important environmental interests in the world today

and with the reduction of space for landfilling, waste employment has become an

effective alternative to the disposal of waste. In this work, cement was replaced with

ceramic waste powder (CWP) in the range of 0%, 5%, 10%, 15%, 20%, 25%, 30%,

35%, and 40% of cement weight and the fineness of the CWP used was below 75µm.

After the moulding and curing processes, the specimen’s mortar was tested and

compared with the conventional mortar in terms of compressive, flexural and splitting

tensile strengths, and sorptivity test. The findings showed that the compressive

strength attained was up to 35% as a result of replacing cement with CWP.

Key words: Ceramic Powder, Mortar, Sorptivity, Environment, World

Cite this Article: Ali Hussain Ali, Dr. Aliaa Abbas Al-Attar, Zeena Emad Kasm,

Effect of Solid Ceramic Waste Powder in Partial Replacement of Cement on

Mechanical Properties and Sorptivity of Cement Mortar, International Journal of Civil

Engineering and Technology 10(3), 2019, pp. 3055–3066.

http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=10&IType=3

1. INTRODUCTION

Nowadays, pozzolanic materials have been used as construction materials, especially for their

effect in improving the properties and durability of concrete. At present, the concern about

Ali Hussain Ali, Dr. Aliaa Abbas Al-Attar, Zeena Emad Kasm


environmental pollution due to the environmental protection regulations has induced further

researches on the possibility of using pozzolanic materials from industrial wastes like ceramic

wastes and fly ash. Partial replacement of cement in mortar or concrete by waste materials

such as ceramic powder would assist in solving the landfill problems and lead to improving

the properties of concrete [1]. Ceramic wastes may come from two exporters; 1) ceramic

industry (classified as non-hazardous industrial waste) and 2) construction and destruction

activities [2]. Ceramic wastes are characterised as wastes that are tough and can bear the

changes and climatic conditions (sturdy), and resist biological and chemical decomposition,

making them suitable as recycling options [3]. Every year the ceramic and construction

manufacturers dump wastes (solid or powder) on large tracts of land without recycling. This

leads to environmental pollution and conquest of a large area of land. Therefore, it is

necessary to dispose of the ceramic wastes and use in the construction industry (in concrete or

mortar) [4]. Cement is a major material in the concrete and mortar industries due to abundant

raw material and relatively low cost. However, the process of the cement industry sends a

high level of carbon dioxide emissions to the atmosphere (about one tonne of carbon dioxide

per tonne of cement). It has also been estimated that cement factories are accountable for the

emission of more than two billion tonnes of carbon dioxide (CO2) yearly. The use of ceramic

waste in the concrete industry has many environmental, economic and technological benefits,

where it works by recycling ceramic waste to save energy, reduce CO2 emissions and improve

the properties of concrete [5]. There are a few studies around the world that explore the

potential use of ceramic waste in the industrialisation of concrete as a partial replacement of

cement or aggregates. For example, one research had replaced a part of cement with ceramic

roofing waste (replacement rates ranged from 25% to 40% of cement). The results indicated

that waste possessed pozzolanic properties and had some similarities with the chemical and

physical properties of cement [6]. Many researches and studies have confirmed the prospect

of using ceramic waste in the construction industry in addition to its use as a partial

replacement for cement or aggregates in concrete or mortar; ceramic waste may be used as

fillers in ceramic bricks and solid bricks (a mixture of soil-cement and ceramic waste) [7].

This research is part of an experimental work that focuses on a mixture of solid ceramic

wastes that are abundant and widespread in Iraq due to the destruction of buildings in the

recent events. In the laboratory, a mixture of ceramic wastes was ground to obtain fine

powder. Then, the CWP was sieved to produce particle size of less than 75 µm and used for

the partial replacement of cement [8]. A chemical analysis was performed and some physical

properties were studied.

2. SCOPE AND OBJECTIVE

This study aims to investigate the use of CWP as a replacement for cement in mortar

mixtures, and study the behaviour of this type of mortar after curing the specimens in plain

(normal) water. It also aims to study the effect of CWP when used as a partial replacement of

cement (0 to 40% of cement weight) on the fresh and solid properties of mortar mixtures. The

commensurable objectives are as follows:

1. Evaluate CWP for reconciliation to be used in mortar as a replacement of cement.

2. Use CWP as supplementary cementing material in mortar mixtures with different

replacement ratios.

3. Evaluate mortar properties by using mechanical tests (compressive strength, splitting

tensile strength, flexural strength and sorptivity).

Effect of Solid Ceramic Waste Powder in Partial Replacement of Cement on Mechanical

Properties and Sorptivity of Cement Mortar


3. PRACTICAL INVESTIGATION

3.1. Materials

3.1.1. Cement

Ordinary Portland Cement (OPC) was used as it satisfied the Iraqi standard specification

No.5/1984 [9]. Table (1) and Table (2) show the chemical and physical properties of such

cement.

Table 1 Physical properties of OPC.

characteristics Test Values Limit of Iraq specification No.5/

1984

Blain Fineness, (m2/kg) 270 Min. 230

Initial setting time, (minutes) 220 Min. 45

Final setting time, (hrs) 5.1 Max. 10

3-day compressive strength, MPa 23.57 Min 15

7-day compressive strength, MPa 31.25 Min 23

Table 2 Chemical properties of OPC.

Limit of Iraq specification )%(Test Values Oxides

........ 65.06 CaO

........ 20.91 SiO2

........ 6.32 Al2O3

5%≤ 2.75 MgO

........ 2.8 Fe2O3

2.8%≤ 2.06 SO3

4%≤ 1.56 Loss of ignition

1.02-0.66 0.93 L.S.F.

3.1.2. Ceramic waste powder (CWP)

The grinding of solid ceramic waste was carried out in the laboratory. After sieving, the CWP

had particle size of less than 75 µm with specific gravity of 2.752. The chemical compositions

of the CWP are shown in Table (3).

Figure 1 Ceramic waste material before and after grinding.



Table 3 Chemical compositions of ceramic waste material.

3.1.3. Fine aggregate

Local sand was used with specific gravity of 2.63 and fineness modulus of 2.69. The sand

satisfied the limit of Iraq standard specification No. 45/1984 [10]. Table (4) shows the sieve

analysis of the sand.

Table 4 Sieve analysis of sand.

Sieve No. (mm) percentage Passing Iraqi limitation No. 5/1984

No.4 (4.75) 100 95-100

No.8 (2.36) 94.31 80-100

No.16 (1.18) 76.11 50-85

No.30 (0.6) 44.11 25-60

No.50 (0.3) 10.42 5-30

No.100 (0.15) 0.46 0-10

3.1.4. Water

Ordinary tap water was used for all mixtures.

3.2. Strength activity index (SAI)

To estimate the activity of the CWP used, the activity index test was used (20% replacement

ratio with CWP according to ASTM C311 [11]).The SAI for 28 days was 84%.

3.3. Mixture proportion

A mixing ratio of 1:2.75 with water cement ratio of 0.5 was used in the present work. The

effects of CWP on the compressive, flexural and splitting tensile strengths were examined.

Cement was replaced with CWP by 5%, 10%, 15%, 20%25%, 30%, 35%, and 40% of cement

weight.

Oxide composition Abbreviation Content Percent %

Lime CaO 11.064

Silica oxide SiO₂ 55.325

Alumina oxide Al₂O₃ 18.342

Magnesia oxide MgO 0.395

Ferro oxide Fe2O₃ 6.235

Sulphate SO₃ 0.013

Sodium oxide Na₂O 0.687

Potash oxide K₂O 1.201

Titanium Dioxide TiO2 0.642

Phosphorus Pent oxide P2o5 0.162

Manganous Oxide MnO 0.0713

Loss on ignition L.O.I 4.3%

http://www.endmemo.com/chem/chemsearch.php?q=P2O5




Table 5 Proportions of mortar.

Mortar mix

Replacement ratio 0

(M0)

5%

(M1)

10%

(M2)

15%

(M3)

20%

(M4)

25%

(M5)

30%

(M6)

35%

(M7)

40%

(M8)

Materials (kg/m3)

OPC 550 522.5 495 467.5 550 412.5 385 375.5 330

Ceramic Powder

(kg/m3)

0 27.5 55 82.5 110 137.5 165 192.5 220

Sand 1660 1660 1660 1660 1660 1660 1660 1660 1600

w/c 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.5

4. TESTING PROGRAMMES

4.1. Flow test according to ASTM C1437-01 [12].

4.2 Fresh density test according to ASTM C 138 [13].

4.3 Compressive strength for 7, 28, and 90 days of using 50×50 mm cube specimen according

to ASTM C109 [14].

4.4 Flexural strength for 28 and 90 days of using 40×40×160 mm prism according to ASTM

C348 [15].

4.5 Splitting tensile strength for 28 and 56 days of using 200×100 mm cylinder according to

ASTM C496 [16].

4.6 Sorptivity test for 90 days of using 100×50 mm cylinder according to ASTM C1585 [17].

5. MIX PREPARATION AND CASTING

5.1. Mix preparation and casting for flexural, compressive and tensile strengths

In the beginning, cement and sand were blended manually until the dry components were

homogenous; the reference blend proportion was 1:2.75 (cement:sand). Water was

progressively added to ensure that all components were well-mixed. According to ASTM

C1437, the flowability of the mortar was measured up to the designed flow (110±5%). After

24 hr from casting, the specimens were removed and cured in water at the laboratory at a

temperature of between 21–23 °C until the time of testing.

5.2. Sorptivity

5.2.1. Sorptivity test

Sorptivity can be defined as a material’s capacity to absorb and transfer water via capillary

suction [18]. In this investigation, the sorptivity test conformed to ASTM C1585 that assesses

the sorptivity of a mortar specimen (sample used was a 100×50 mm cylinder).

5.2.2. Test procedure

After casting the cylinder sample, it was cured in water at the laboratory at a temperature of

between 21–23 °C for 90 days. Then, the specimen was dried in an oven at a temperature of

100 + 10 °C until the mass became constant. After drying, the sample was placed in an

aquarium as shown in Figure (2) with water level not more than 3–5 mm above the base of the

cylindrical sample. The flow from the peripheral surface was blocked by sealing it properly

with a non-absorbent coating. The quantity of water absorbed in time interval of 30 min was

measured by weighting the specimen. Surface water on the sample was wiped off with a

moisten fabric and each weighting operation was completed within 30 sec.



Figure 2 Sorptivity test schematic representation.

The calculated capillary suction depth versus the square root of time was used to estimate

the sorptivity index as follows:

Sorptivity (mm)=I/ time0.5

Where,

I= change in weight/area exposed × water density [19].

6. RESULTS AND DISCUSSIONS

6.1. Flowability

The results for flowability (workability) of mortar cement are shown in Figure (3). The figure

shows the flowability of all mortar mixtures with different substitution ratios. The flow test

results showed that the operating capacity increased slightly with the increase of cement

substitution ratio of ceramic powder. There were no significant differences between the

reference mortar and the mortar containing CWP as a partial replacement. The increase in the

flow measurement may be due to two factors: 1) ceramic powder had lower fineness than

cement, therefore, it had a lower surface area, causing the reduction in water absorption; 2)

ceramic powder is initially an inert powder because the process of the pozzolanic reaction

usually takes time [20].

6.1. Strength activity index (SAI)

The results showed that the SAI for 28 days of CWP was equal to 84% (greater than 75%

according to ASTM C618 [21]), which proved that the CWP had the pozzolanic property.

Therefore, the CWP is suitable for use as a replacement for cement in concrete mortar mixes.

6.2. Compressive strength

Table (6) and Figure (4) show the compressive strength of mortar mixes for 28 and 90 days.

The use of CWP as a partial replacement for cement via the compressive strength test showed

that with the increase in the percentage of replacement, the compressive strength gradually

decreased (decreased slightly) to a replacement ratio of 25%. This may be due to the

pozzolanic reaction that happened between silicon oxide (SiO2) and calcium hydroxide

Ca(OH)2 from the hydration process [22]. Then, the value of compressive strength started to

decrease as compared to the reference mortar. Table (7) explains the percentage change in the

mortar mixture strength when compared with the control mix (when the replacement ratio was

0%) at different ages, i.e. 7, 28 and 90 days and CWP percentages from 5% to 40%.




6.3. Flexural strength

The results of the flexural strength test are shown in Figure (5). The value obtained for 28

days showed that the percentages of replacement (5%, 10% and 15% down to 20%) showed

no considerable differences in flexural strength compared to the normal mortar. The result can

be assigned to the activity index of CWP.

6.4. Tensile strength

Figure (6) explains the tensile strength values of mortar mixes. The results showed that even

with the replacement of CWP with cement up to 30%, the acceptable results and the resulting

mortar retained their properties compared to the control mix. The pozzolanic effects of the

CWP were the main reasons for the results.

6.5. Sorptivity test

Figure (7) explains the tensile strength values of mortar mixes. The sorptivity at 15%, 20%

and 25% of replacement with CWP showed a decrease in value compared to the reading of

the reference mortar. Then, the absorption rate started to rise with the increase of the

replacement ratio.

6.6. Fresh density

Figure (8) shows the fresh density of the cement mortar for all cement percentages with CWP.

The fresh density of mortar mixes varied depending on the replacement ratios. From the

figure, it can be noted that with the increase in replacement ratio, the reference density of the

cement mortar at zero replacement ratio was 2.25 gm/cm3. The fresh density decreased

gradually; the higher the percentage of the cement substrate, the less the density of the CWP.

The decrease in fresh density was due to the increase in the amount of CWP in the mortar

mixture to the specific weight of the CWP, which was 0.4 times the value of the specific

weight of the cement [23].

Figure 3 Flowability results of mortar.

0

20

40

60

80

100

120

140

Flo

w (

%)



Table 6 Results of compressive strength.

Figure 4 Compressive strength of different mixes.

Figure 5 Flexural strength of different mixes.

0

5

10

15

20

25

30

35

40

45

50

M0% M5% M10% M15% M20% M25% M30% M35% M40%

Co

mp

resi

ve s

tre

ngh

t M

Pa

7 days

28 days

90 days

3.5

4

4.5

5

5.5

6

6.5

7

7.5

8

M%0 M%5 M%10 M%15 M%20 M%25 M30% M%35 M%40

Fle

xtu

ral S

tre

ngh

Mp

a

Ceramic Waste Powder Content%

Modulus of Rupture

Mix no 7 days (MPa) 28 days (MPa) 90 days (MPa)

M0 33.45 42.32 45.35

M1 33.87 43.62 45.75

M2 32.42 41.21 43.52

M3 30.21 38.68 40.68

M4 28.76 35.45 37.92

M5 26.57 33.26 35.36

M6 23.92 30.75 32.32

M7 21.25 29.61 30.52

M8 19.42 25.35 27.34




Table 7 Percentage change in strength of mortar mixtures relative to reference mix.

M40%

M35%

M30%

M25%

M20%

M15

%

M10%

M5%

Mixture Age

-41.9 36.4% -28.4% 20.5%- -14% -9.6% -3% 1.25% 7-Days

-40% -30% -27.3 -21% -16.2 -8.6% -2.6% 3% 28-Days

-39.7 -32% -28% -22 -16.3% -10% -4% 0.8% 90-Days

Figure 6 Splitting tensile strength of different mixes.

Figure 7 Sorptivity test values for 90 days.

0

0.5

1

1.5

2

2.5

3

3.5

Split

tin

g te

nsi

le s

tre

ngh

t

Ceramic waste powder content %

Splitting Tensile Strenght

28 days (Mpa)

58 days (Mpa)

0

1

2

3

4

5

6

0 10 20 30 40 50

sorp

tivi

ty(m

m/m

in0

.5)

Ceramic waste powder content %

Sorptivity Test (Rate Of Absorption Of Water)



Figure 8 Fresh density for mortar mixtures in (g/cm3).

6. CONCLUSIONS

The feasibility of using CWP as a replacement for cement in the production of mortar at eight

different cement replacement levels of 0%, 5%, 10%, 15%, 20%, 25%, 30%, 35% and 40%

CWP by cement mass and its contribution to sustainable mortar mixtures were investigated in

this research. This research also examined the viability of using recycled CWP that partially

replaced cement in concrete mixtures. Based on the results of this laboratory work, the

following conclusions can be drawn:

1. Increase in ceramic powder lead to the increase in the workability of cement mortar, where

the workability at the replacement ratios of 15%, 20%, 25%, 30%, 35% and 40% increased by

about 9.5%, 11%, 14%, 19%, 23%, and 28% respectively, for the reference mixture, M0%.

2. Mortar that contained ceramic powder as the partial replacement of cement had less

compressive strength than the normal mortar. The results showed that replacement of less

than 20% had no considerable effect on the compression strength, and at M20%, the decreases

in the compressive resistance were 14%, 16.2%, and 16.3% for 7, 28, and 90 days,

respectively. After replacement ratio of 40% of cement weight, the compression strength

started to decrease significantly and affected the properties of the mortar.

3. With the addition of CWP, the splitting tensile and flexural strengths of cement mortar will

reduce gradually without any significant impact on their values so that they remain within the

safe limit.

4. The sorptivity values decreased by 9%, 27%, and 54% at 20%, 25%, and 30% replacement

ratios, respectively, as compared to the control mixture. The reduction of water absorption

rate indicated the reduction in the capillary porosity and connectivity of capillary pores. The

pozzolanic effects of the CWP were the main reasons for the reduction.

5. The use of CWP as a partial replacement of cement is an effective waste disposal solution

and it reduces cost without compromising the strength of concretes.

1.5

1.6

1.7

1.8

1.9

2

2.1

2.2

2.3

2.4

2.5

0 5 10 15 20 25 30 35 40

De

nsi

ty(g

/cm

3)

Percentage of ceramic powder(%)




REFERENCES

[1] Samadi, M., Hussin, M. W., Lee, H. S., Sam, A. R. M., Ismail, M. A., Lim, N. H. A. S., .. & Khalid, N. H. A.. "Properties of Mortar Containing Ceramic Powder Waste as Cement

Replacement". Jurnal Teknologi, 2015 Nov 12; 77(12):93-7.

[2] Rani, M, S," A Study on Ceramic Waste Powder" SSRG International Journal of Civil Engineering (SSRG-IJCE) – volume 3 Issue 7 – July 2016

[3] Raval, A. D., Patel, I. N., & Pitroda, J.," Ceramic waste: Effective replacement of cement for establishing sustainable concrete". International Journal of Engineering Trends and

Technology (IJETT), 2013; 4(6):2324-9.

[4] Patel, J., Shah, B. K., & Patel, P. J.," The potential pozzolanic activity of different ceramic waste powder as cement mortar component (strength activity index)". Int J Eng Trends

Tech (IJETT), 2014; 9(6):267-71.

[5] Abdullah Hasan Jabbar (2015) “Study Magnetic Properties And Synthesis With Characterization Of Nickel Oxide (NiO) Nanoparticles”, 6 (8): 94-98.

[6] Zimbili, O., Salim, W., & Ndambuki, M," A review on the usage of ceramic wastes in concrete production". Int. J. Civ. Archit. Struct. Constr. Eng., 2014 Jan 4; 8:91-5.

[7] AGRAWAL, A., SRIVASTAVA, V., HARISON, E. A., & SURYAVANSHI, S. "A Peer Reviewed International Journal" 2016.

[8] Pacheco-Torgal, F., & Jalali, S.," Compressive strength and durability properties of ceramic wastes based concrete". Materials and structures, 2011 Jan 1; 44(1):155-67.

[9] Iraqi Specification No. 5, "Portland Cement", 1984.

[10] S. O. Mezan, A. H. Jabbar, M. Q. Hamzah, A. N. Tuama, N. N. Hasan, and M. A. Agam, “Synthesis and Characterization of Zinc Sulphide ( ZnS ) Thin Film Nanoparticle for

Optical Properties,” Journal of Global Pharma Technology, 2018; 10(07): 369-373.

[11] ASTM C311 – 00," Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use as a Mineral Admixture in Portland-Cement Concrete", Annual Book

of ASTM Standards, 2004.

[12] ASTM C1437,"Standard test method for flow test", Annual Book of ASTM Standards, 2001.

[13] ASTM C 138, "Standard test method for density (unit weight), yield, and air content (gravimetric) of concrete", Annual book of ASTM standards, 2001

[14] ASTM C 109/C 109M – 02, "Standard Test Method for Compressive Strength of Hydraulic Cement Mortars ", Annual Book of ASTM Standards, 2002.7

[15] ASTM C348,"Standard Test Method for Flexural Strength of Hydraulic-Cement Mortars”,Annual book of ASTM Standards, 2002.

[16] ASTM C 496/C 496M – 04, "Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens", Annual Book of ASTM Standards, 2004.



[17] ASTM C 1585 – 04, "Standard Test Method for Measurement of Rate of Absorption of Water by Hydraulic Cement Concretes", Annual Book of ASTM Standards, 2004.

[18] Sabir, B. B., Wild, S., & O'farrell, M.,"A water sorptivity test for mortar and concrete", Materials and Structures, 1998 Oct 1; 31(8):568.

[19] Pitroda, J., Umrigar, D. F., Principal, B., & Anand, G. I.,"Evaluation of sorptivity and water absorption of concrete with partial replacement of cement by thermal industry waste

(Fly Ash)", International Journal of Engineering and Innovative Technology (IJEIT),

2013 Jan;2(7).

[20] S. O. Mezan, A. H. Jabbar, M. Q. Hamzah, A. N. Tuama, N. N. Hasan, and M. A. Agam, “Synthesis and Characterization of Zinc Sulphide ( ZnS ) Thin Film Nanoparticle for

Optical Properties,” Journal of Global Pharma Technology, 2018; 10(07): 369-373.

[21] ASTM C618,"Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete", Annual book of ASTM Standards, 2003.

[22] Xu, W., Lo, T. Y., Wang, W., Ouyang, D., Wang, P., & Xing, F.," Pozzolanic reactivity of silica fume and ground rice husk ash as reactive silica in a cementitious system: A

comparative study", Materials, 2016 Mar 1; 9(3):146.

[23] Manogna, Ponnapati, and M. Sri Lakshmi. "Tile powder as partial replacement of cement in concrete." International Research Journal of Engineering and Technology (IRJET) 2,

no. 4 (2015): 75-77.

Documents

EFFECT OF SOLID CERAMIC WASTE POWDER IN PARTIAL ...iaeme.com/MasterAdmin/uploadfolder/IJCIET_10_03_308/IJCIET_10_… · per tonne of cement). It has also been estimated that cement