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International Journal of Scientific Research in Knowledge, 4(1), pp. 020-027, 2016

Available online at http://www.ijsrpub.com/ijsrk

ISSN: 2322-4541; ©2016; Author(s) retain the copyright of this article

http://dx.doi.org/10.12983/ijsrk-2016-p0020-0027

20

Full Length Research Paper

Utilization of Different Industrial Wastes in Concrete as a Cement Replacement

Material and Its Effects on Strength

Muhammad Taqui*, Syed Ahmed Uzair, Anwar ul Hasson

Karachi Institute of Power Engineering, Karachi, Pakistan

*Corresponding Author: Email: [email protected]

Received 13 November 2015; Accepted 26 January 2016

Abstract. Approximately 50% of marble production becomes wastage during quarrying process, and in Pakistan this figure

reaches to 73%. According to projected statistics, 37.26 million m3 fuel-wood is being consumed in 2015 only in Pakistan.

Industrial by-products are commonly used in concrete production as cement replacement materials (CRMs) to enhance both

fresh and hardened properties of concrete as well as to save the environment from the negative effects caused by their disposal.

A little investigative effort is made to utilize the wood ash (WA) and marble dust (MD) as CRM in concrete; and to evaluate

their effects on strength of concrete. It has been done by preparing the WA and MD samples by some physical means. After

the formation of proper usable material, it is partially replaced with cement (5%, 10%, 20% and 40%) in concrete specimens to

analyze the impact on its compressive strength. From the experimental work it has been found that by incorporating 10% wood

ash (WA) the strength of concrete cube increases up to 4 to 5%, by incorporating 10% marble dust (MD), the strength of

concrete increases 16 to 17%. Higher concentration of WA or MD leads to the decrement in strength. The porosity of concrete

specimen also decreased at 10% inclusion of wood ash.

Keywords: Cement Replacement, Compressive Strength, Concrete, Marble Dust, Wood Ash

1. INTRODUCTION

All the technological advancements in the world are

due to finding or producing new materials. Mainly

researcher’s concern is the cost and environment. The

increment in population and industries, both are

resulting large increase in waste. All over the world

efforts are being made to keep environment clean. The

key point in waste management is that, “generate less

and manage more”. The less generation can be

controlled at domestic level. In case of industries,

huge cost is required to improve the efficiency by

modifying the systems. But this will be done up to a

limit to keep optimized state of all constraints. On the

other side management of the waste requires also a

cost, especially when the large amount of waste is to

be dumped. So the best way to meet the above stated

key point of waste management is that, “convert

liabilities into assets” by making best use of wastes.

Concrete is basic construction material and used in

many structures including nuclear power plants

(NPPs). In NPPs where it is basic structural

component it also provides radiological shielding to

keep public and environment safe. Where concrete is

most important material, it has a negative impact on

environment. Concrete industry is one of two largest

producers of carbon dioxide (CO2), creating up to 5%

of worldwide man-made emissions of this gas (The

cement sustainability initiative: Progress report, June,

2002). The CO2 emission from the concrete

production is directly proportional to the cement

content used in the concrete mix; 900 kg of CO2 are

emitted for the fabrication of every ton of cement.

Carbon dioxide CO2 produced for the manufacture of

one tonne of structural concrete (using ~14% cement)

is 410 kg/m3 that is 180 kg/tonne @ density of 2.3

g/cm3 (Samarin, 1999). Moreover it is mentioned that

120 kg/m3 of CO2 emissions reduced by replacing

30% fly ash with cement. So, trying new materials in

concrete like fly ash is one of many solutions to

minimize excessive CO2 emissions.

The scope of this study is to develop a new basic

construction material, which may serve many

purposes not limited to:

1. Reduce the CO2 emissions from concrete;

2. Produce the new eco-friendly material;

3. Convert liabilities into assets, and reduce the

waste management cost;

4. Provide the cheap material, as cement requires

cost and high energy for production.

mailto:[email protected]

Taqui et al.

Utilization of Different Industrial Wastes in Concrete as a Cement Replacement Material and its Effects on Strength

21

1.1. Choice of Material

Selection of material (to be used in concrete) depends

upon many factors. The most important factors are;

suitability, availability and economy. The suitability

means compatibility of material to be used in concrete

as cement replacement material (CRM). It can be

easily determined; it has been evaluated by several

authors. They have used different test methods and

techniques to find CRMs. These evaluation methods

are based on the chemical composition analysis of

materials and their behaviour of reaction (when

combined with cement) to complete the process of

hydration in the concrete. Mostly referred or materials

used by researchers are those, which contain

pozzolanic activity and commonly called as pozzolans

or pozzolanic materials.

1.2. Pozzolans

ASTM C618 prescribes that a pozzolan should

contain SiO2 + Al2O3 + Fe2O3 ≥ 70% by weight. Many

pozzolans are available and under consideration to use

as CRM. Industrial wastes having pozzolanic activity

may also be used. According to (Seco et al., 2012) and

(Shasavandi et al., 2012) industrial wastes that can be

treated as CRM are; Fly Ash (FA), Silica Fume (SF),

Rice Husk Ash (RHA), Sewage Sludge Ash (SSA),

Waste Ceramics, Tungsten Mine Waste, Recycled

Glass (RG), Fluidized Bed Cracking Catalyst (FBCC),

Ground Granulate Blast Furnace Slag (GGBS),

Phosphogypsum (PG). Wood Ash (WA) is pozzolan

according to (Tarun et al., 2001) and Marble Dust is

incorporated in mortar by (Taner and Olgun, 2008).

Like many authors, properties and composition of WA

and MD are described by Tarun et al. (2001) and

Kavas et al. (2008), respectively.

1.3. Availability and Economy

Important factors of concern for developing countries

like Pakistan are availability of material and its cost.

The extraction of marble dust in Pakistan mainly

comprises boring of holes in the bedrock, filled with

explosives to blast the block, resulting not only in

high wastage but also in smaller sized stone,

substantially reducing the price. Standard quarry

wastage in the world is taken as 50% of the gross

production; however, in Pakistan this reaches upto

73% (Internet Source, URL is given in references,

2015). The marble wastage (in slurry form) during

polishing and cutting reaches upto 20% to 25% of

total quantity. This bulk waste (i.e., marble powder) is

to be utilized as CRM to keep environment clean, and

to compensate the price loss.

According to (Sumia and Ahmad, 2012) 37.26

million m3 fuel-wood is to be consumed this year

(2015) in Pakistan. Timber consumption is not

included. So, bulk availability of wood ash (WA)

should be converted into liability by utilizing it in

concrete. So, for case study the materials satisfying

above stated three factors are marble dust (MD) and

wood ash (WA).

2. METHODOLOGY

Scheme of work (methodology) adopted to carry out

the project contains six major steps, shown below.

Selected materials (WA & MD) for case study were

collected free of cost from local industry. Marble dust

(MD) was collected from Karachi marbles located at

main road, Sargodha, Punjab. The collected MD

sample (Figure 1) is mixture of two types of marble;

sunny grey and zemera, quarried from Baluchistan,

Pakistan. Wood ash was obtained from local baking

furnace, located in Gulshan-e-Hadeed (Phase 2),

Sindh. The ash obtained (Figure 2) belongs to special

type of fuel-wood, locally known as Sea wood.


22

ASTM standards are used to determine some

specific properties of samples. Concrete cube samples

are prepared, cured and finally tested for compressive

strength. Since concrete is brittle material, and its

compressive strength defines its quality, therefore

only compression test was conducted. However one

may prepare cylindrical samples, interested in tensile

strength.

3. EXPERIMENTAL WORK

The experimental work starts with processing of wood

ash (WA) and marble dust (MD), which includes oven

drying and sieving. However, for MD hammering was

also done after air drying, to break lumps. According

to ASTM C136 sample should be dried before sieve

analysis.

For both materials (WA & MD), No. 100 sieve

retain, and No. 200 sieve retain was used in concrete

cube samples. The reason behind No. 100 sieve retain

or No. 200 sieve retain is, to obtain the fineness

modulus (FM) of WA & MD less than the FM of fine

aggregates. The FM determined by standard

procedure of ASTM C33, is mentioned in Table 3

with reference value. Concrete is heterogeneous

material and it’s good to use different particle sized

materials to enhance the homogeneity. But

experiments were completed with extreme care to not

compromise the strength of (concrete cube) samples

due to factors other than the “partial replacement of

cement”.

3.1. Preparation of Concrete Cubes

Concrete cubes of 50 mm x 50 mm x 50 mm with

1:2:4 mix ratio, were prepared for testing. For Ash-

crete samples (concrete samples containing WA) and

Mar-crete samples (concrete cubes containing MD)

cement is partially replaced 5%, 10%, 20% and 40%

by weight. Concrete (control concrete) cube

composition is given Table 1.

The composition for Ash-crete and Mar-crete

samples is same but quantity of cement changes when

replaced. For 5% replacement, quantity of cement is

51.3 g with 2.7 g wood ash (for ash-crete) or marble

dust (for mar-crete). Similarly for 10%, 20% and 40%

replacement, cement is 48.6 g, 43.2 g and 32.4 g

respectively.

3.2. Testing of Cube Samples

Concrete cubes, Ash-crete cubes and Mar-crete cubes

were tested for compression (Figure 3) after 7 days

and 28 days curing.

Fig. 1: Air Dried Marble Dust Sample Fig. 2: Wood Ash Sample

Fig. 3: Compression Test

4. RESULTS AND DISCUSSIONS

Properties of concrete may vary with slight change in

its mix ratio. Therefore, change in quantity of cement,

the compressive strength of concrete may also change.

To achieve the higher (compressive) strength, some

specific additives (according to requirement and

nature of work) may be used. In our case concrete

Taqui et al.


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strength also varies with the addition of cement

replacement materials (CRMs). The results of

experiments are discussed below one by one.

4.1. Physical Properties

Physical properties of used wood ash (WA) and

marble dust (MD) determined as per ASTM

specifications are provided in Table 2.

The values and results in Table 2, for WA & MD

are in range and comparable to the results of (Tarun et

al., 2001) and (Taner and Olgun, 2008) respectively.

For example the range of moisture content (MC) for

WA is 0.9% to 42.3% as discussed by (Naik et al.,

2001). It can be seen in Table 2, MC for WA is

approximately 0%. It’s near to lower range. The lower

limit value of MC does not matter too much

practically. Because when water will be added in

concrete preparation, MC for WA will be increase

whether it’s 0% or 0.9%. Same implies to MC of

marble dust (MD). It ranges 24% to 31% according to

(Kavas and Olgun, 2008) and the result obtained i.e.,

14% is mentioned in Table 2.

The specific gravity (SG) in Table 2 is 2.5 for WA

(which is less than the SG of natural sands i.e., 2.65),

while (Tarun et al., 2001) mentions 2.45 and range of

specific gravity by (Naik et al., 2001) is 2.32 to 2.76.

The unit weight or bulk density for WA by (Tarun et

al., 2001) is ranged from 663 to 977 kg/m3 while test

results shows 680 kg/m3 as mentioned in Table 2.

Table 1: Control Concrete Samples Composition

Constituents Quantity

Cement 54 g

Fine Aggregate 108 g

Coarse Aggregate 216 g

Water 27 ml

Table 2: Properties of Cement Replacement Materials Properties Wood Ash Marble Dust

Moisture Content (ASTM C311) 0 % 14.29 %

Specific Gravity (ASTM C188) 2.5 2

Bulk Density (ASTM C29) 680 kg/m3 900 kg/m3

Tapped Density 830 kg/m3 1200 kg/m3

Hausner Ratio (H) 1.22 1.33

Carr’s Index (I) 18.07 % 25 %

Flowability Fair Passable

Table 3: Sieve Analysis Deductions Results Wood Ash Marble Dust

Mass Loss 0.13 % < 2% 0.25 % < 2 %

Effective Size (D10) 0.15 mm 0.11 mm

Uniformity Coefficient (Cu) 5.67 < 6 2.72 < 6

Coefficient of Gradation (Cc) 0.71 < 1 1.09 > 1

Fineness Modulus (ASTM C33) 2.03 < 2.2 1.05 < 2.2

Classification Poorly Graded Poorly Graded

Table 4: Chemical Composition of Cement Replacement Materials Constituents Wood Ash Marble Dust

Si 43.45 % 4.09 %

Al 50.4 % 5.63 %

Fe 4.75 % 26.02 %

Zr 1.39 % 10.36 %

Ca Not Detected 53.9 %

4.2. Particle Size Distribution

Table 3, contains the results deduced from particle

size distribution (PSD) standard curves (semi-log

graphs) plotted as per ASTM C136 standard

specifications. The graphs plotted were normal and

mass loss (for wood ash and marble dust) during sieve

analysis was less than 2%. The effective particle size

for both materials wood ash (WA) marble dust (MD)

is less than 0.2 mm which is far lower than the

average size of fines i.e., < 4.75 mm. Both materials

WA and MD lies in poorly graded classification

because no special treatment is made to keep the

uniform size of particles.


24

Fig. 4: Porosity of 7 Days Cured Cube Samples

Fig. 5: Porosity of 28 Days Cured Cube Samples

Fig. 6: Compressive Strength of Ash-crete Cubes

Taqui et al.


25

Fig. 7: Compressive Strength of Mar-crete Cubes

Fig. 8: 7 Days Compressive Strength of Ash-crete and Mar-crete

The reason to use non-uniform sizes is

heterogeneity of concrete already discussed in section

3. However, one interested in uniform sizes of

particles may use other techniques like ball mill

apparatus before analyzing the particles.

4.3. Chemical Composition

The chemical composition of wood ash (WA) and

marble dust (MD) determined by x-ray fluorescence

(XRF analysis) in terms of silicon (Si), aluminum

(Al), iron (Fe) and zirconium (Zr) is described in

Table 4. According to (Tarun R. Naik et al., June,

2001), range for Si, Al, and Fe for WA is 4 to 59.3%,

5 to 17% and 1 to 16.7% respectively. Si and Fe are

exactly in range but Al not.

The presence of Al, Fe and Si cumulatively greater

than 70% by weight in wood ash (WA) cent per cent

satisfies the standard ASTM C618 discussed earlier in

section 1.2, and hence can be called pozzolan. Marble

dust somehow deviates from it, but presence of Ca in

satisfactory amount makes it eligible to be used with

cement, since Ca is also core element in cement. The

MD alone shows good binding properties with water.

It forms hard lumps that cannot be broken without

hammering. It definitely enhances the binding of

cement when used with it.

4.4. Porosity Test

Porosity of cube samples was determined and graphs

are generated for 7 days cured samples (Figure 4) as

well as for 28 days cured samples (Figure 5).


26

Fig. 9: 28 Days Compressive Strength of Ash-crete and Mar-crete

The true porosity for both wood ash (WA) and

marble dust (MD) is higher than the apparent porosity,

since true porosity includes the volume of the sealed

or closed pores. The difference between the true

porosity and apparent porosity represents the percent

volume of closed pores. The test results exhibit

maximum percentage of apparent porosity for samples

containing 20% replacement, whether WA or MD. It’s

true for 7 days cured as well as 28 days cured

samples. For true porosity maximum percentage is

observed for cube samples containing 20%

replacement of marble dust and 10% replacement of

WA. It’s valid for 7 days as well as 28 days cured

samples.

4.5. Compression Test

Compression test was conducted as per ASTM C109

specifications. Bar graph for compressive strength of

ash-crete samples is shown in Figure 6. It also

contains 0% concentration of wood ash (WA), which

means compressive strength of control concrete

sample. It is incorporated to observe the variation in

compressive strength by varying WA concentration.

The composition of samples for each concentration is

already described in section 3.1. The 5%

concentration of WA means, 5% by weight of cement

WA is added in concrete and 5% cement is removed.

Bar graph for compressive strength of Mar-crete

samples is shown in Figure 7. It also contains 0%

concentration of marble dust (MD), which means

compressive strength of control concrete sample. It is

incorporated to observe the variation in compressive

strength by varying MD concentration. The 5%

concentration of MD means, 5% by weight of cement

MD is added in concrete and 5% cement is removed.

Similarly, 10% concentration of MD means, 10% by

weight of cement MD is added in concrete and 10%

cement is removed and so on.

Comparison between compressive strength of ash-

crete and mar-crete samples is done by producing line

graphs. Two graphs are plotted for 7 days curing and

28 days curing separately. Figure 8 is comparison of

compressive strength of 7 days cured samples and

Figure 9 is comparison of compressive strength of 28

days cured samples. The trend followed by line graphs

is common and deductions are summarized in

conclusion.

5. CONCLUSIONS

1. Marble dust (MD) is excellent cement replacement

material (CRM) while wood ash (WA) is good.

2. MD gives relatively high strength even at higher

concentration.

3. Rapid decrease in strength is observed as wood ash

concentration in concrete increases more than 10%.

4. The optimum concentration for both materials is

10%. However, for marble dust, 20% concentration is

also appreciable.

5. Maximum increase in compressive strength is

16.24% for 10% replacement of marble dust.

6. For 40% replacement of marble dust maximum loss

of compressive strength is 18.81%.

7. Maximum gain in compressive strength for 10%

replacement of wood ash is 4.22%.

8. Lowest strength was observed for 40% replacement

of wood ash and maximum reduction in compressive

strength is 68.35%.

9. Wood ash is light in weight and it’s suitable for

light weight concrete with reasonable strength.

10. The concrete samples containing wood ash have

excellent finishing on removal of moulds.

Taqui et al.


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11. Mar-crete samples require more temping during

cast.

5.1. Way Forward

1. Addition of both materials (wood ash and marble

dust) at a time, as CRM, may be tested to get higher

strength at high concentration by making suitable

combinations.

2. The CO2 emission for optimum concentration of

CRMs, i.e., 10% may be tested.

3. Detailed micro-structure study or chemical analysis

for 10% replacement may open new doors of research.

REFERENCES

Samarin A (1999). Wastes in Concrete :Converting

Liabilities into Assets. in Ravindra K. Dhir,

Trevor G. Jappy, Exploiting wastes in concrete:

proceedings of the international seminar held at

the University of Dundee, Scotland, UK,

Thomas Telford, p. 8

Seco A, Ramirez F, L. Miqueleiz, Urmeneta P, García

B, Prieto E, Oroz V (2012). Types of Waste for

the Production of Pozzolanic Materials – A

Review. Department of Projects and Rural

Engineering, Public University of Navarre,

Spain.

Shasavandi A, Pacheco-Torgal F, Jalali S (2012). Eco-

Efficient Concrete Using Industrial Wastes: A

Review. Research Unit C-TAC, Sustainable

Construction Group, University of Minho,

Guimarães, Portugal.

Sumia ZB, Ahmad S (2012). Wood Supply and

Demand Analysis in Pakistan – Key Issues.

Research Briefings, 4(22).

Tarun RN, Kraus RN, Kumar R (2001). Wood Ash: A

new source of pozzolanic material. Report No.

CBU-2001-10, REP-435

Kavas T, Olgun A (2008). Properties of Cement and

Mortar Incorporating Marble Dust And Crushed

Brick. Ceramics – Silikáty, 52(1): 24-28.

[URL]:http://www.stonefairasia.com/potentialofmarbl

es.htm (Visited on November 2, 2015)

WBCSD-CSI (June 01, 2002), the cement

sustainability initiative: Progress report, World

business council for sustainable development.


Muhammad Taqui is MS candidate in Nuclear Power Engineering at Karachi Institute of Power

Engineering (affiliated with PIEAS, Islamabad) and recipient of PAEC fellowship. He received his

first degree from Sir Syed University of Engineering and Technology Karachi in 2013 and awarded

with Bachelor of Science in Civil Engineering. His current research focuses on conversion of

liabilities into assets.

Senior Engineer Syed Ahmed Uzair obtained his first class degree from NED University of

Engineering and Technology Karachi in Materials Engineering in 2010. He received scholarship

from PAEC and pursued master degree in Nuclear Power Engineering from Pakistan Institute of

Engineering and Applied Sciences Islamabad and graduated in 2012. Currently S. A. Uzair is

serving PAEC as Assistant Professor at Karachi Institute of Power Engineering. Engineer Uzair’s

field of expertise is Nuclear Reactor Materials.

Dr. Anwar ul Hasson (Deputy Chief Engineer) is Professor and Head Program Development at

Karachi Institute of Power Engineering Pakistan. He received his first degree in Mechanical

Engineering in 1992 from N.E.D. University, Karachi and M.Sc .(Eng) in Nuclear Power

Engineering in 1997 from the same university. Dr. Anwar received his Ph.D. in mechanical

engineering from KAIST, Korea. His research focus was flow control and the operation of a fuel

cell in a subzero temperature environment. Dr. Anwar has published numerous refereed articles in

professional journals. His main area of interest is thermal hydraulics of a nuclear power plant.

Documents

Full Length Research Paper - IJSRPUB Husk Ash (RHA), Sewage Sludge Ash ... incorporated in mortar by (Taner and Olgun, 2008). ... the project contains six major steps,