utilization of ceramic waste and stone dust in concrete

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Special Issue, ISSN 2349-4476

127 Amir Javed, Salman Siddique, Ram Prasad V S

Investigation on ceramic waste and stone dust as aggregate

replacement in concrete

Amir Javed1, Salman Siddique

2, Ram Prasad V S

3

1Assistant Professor, Integral University, Lucknow

2Research Scholar, Department of Civil Engineering, Malaviya National Institute of Technology

Jaipur 3Graduate Student, Department of Civil Engineering, Malaviya National Institute of Technology

Jaipur

Abstract The sanitary and stone cutting industry inevitably generates wastes. This paper

presents the use of stone dusta byproduct of crushers as replacement of fine aggregate and

ceramic waste as a replacement of coarse

aggregate.

This study was conducted to analyse the

compressive and flexural strength of concrete

when natural sand was replaced with stone dust

at 20%, 40 %, 60%, 80 % and 100% along with

20 % stone aggregate replacement with ceramic

waste. For conducting the study 21 cubes

(150mmx150mmx150mm) and 21 Beams

(500x100x100mm) were tested To increase the

workability of concrete Lyconicsulphate

plasticizer was used as an admixture. The

plasticizer was used as 2% by weight of cement.

The percentage of ceramic waste is kept 20% for

all specimens.

It is found that at 40 % replacements of natural

sand with stone dust along with 20%

replacement of stone aggregate with ceramic

waste, the compressive strength and flexural

strength is maximum.

The study concludes that the stone dust with 20

% of ceramic waste as a coarse aggregate can be

used effectively as an alternative to natural sand

for nominal concreting.

Keywords Ceramic Waste, Stone Dust, Compressive Strength, Flexural Strength

1. Introduction

For Past many years construction industry has

been making some progress in the utilisation of

waste materials in concrete. Some of waste

products are fly ash, rice husk, saw dust,

discarded tires, e-waste, glass, bagasse ash,

stone dust and ceramic. Proper use of waste

products provides viable economy and healthy

environment. Each waste product has its specific

effect on properties of fresh and hard concrete.

There has been a long-term growing demand for

aggregates to produce concrete and this has

presented increased problems of supplying of

sand and gravel [10]. Previous researches have

shown crushed stone dust can be used to replace

the natural sand in concrete [2,4]. Recycle

aggregates are also being studied though some

loss in workability and mechanical property is

reported [11,12]. The ceramic industry has about

30% to 50% failed products due to improper

mixing or heating conditions [6]. Present study

has been done to evaluate the suitability of such

waste materials in concrete production.

2. Experimental Work

2.1 Materials

I. Cement The cement used in all mixtures was

commercially available Portland Pozzolana

cement of 43 grade manufactured by Jaypee

cement company confirming to IS 8112:1989

was used in this study.




II. Fine Aggregates a) Locally available river sand passed through 4.75mm IS sieve is used as fine

aggregate. The specific gravity of sand is 2.61

and fineness modulus of 2.21.

b) Stone dust used in the laboratory investigations was procured from a local crushing

plant. The specific gravity of stone dust was 2.5

and fineness modulus was 2.67.

III. Coarse Aggregates a) The Coarse aggregate are obtained from a local quarry is used. The coarse aggregate with

a maximum size 10mm having a specific gravity

2.64 and fineness modulus of 6.90.

b) The ceramic wastes are obtained from a pottery industry waste. The waste ceramics are

crushed into pieces with crushing machine in

laboratory. The specific gravity of ceramic

aggregates is 2.27 and fineness modulus of 5.64.

2.2 Preparation of specimen

The quantities of the constituents of the concrete

were obtained from the Indian Standard Mix

Design method (IS: 10262- 2009). The variation

of strength of hardened concrete using stone

dust as fine aggregate (partial replacement) is

studied by casting cubes, cylinders and beams.

The concrete was prepared in the laboratory

using hand mixing. The cement, fine aggregate

and coarse aggregate were first mixed in dry

state to obtain uniform colour and calculated

amount of water obtained from workability test

was added and the whole concrete was mixed

for five minutes in wet state. Meanwhile the

moulds are screwed tightly to avoid leakage Oil was applied on inner surface of the moulds. The

cast specimens were removed from moulds after

24 hours and the specimens were immersed in a

clean water tank. After curing the specimens for

a period of 28 days, the specimens were

removed from the water tank and allowed to dry

under shade.

3. Experimental Work

3.1 Tests

For each batch of concrete, three cubes of

150mmX150mmX150mm size were tested to

determine compressive strength. Three beams of

100mmX100mmX500mm size were tested to

determine the flexure strength.

SI No. 1 2 3 4

Prope

rty

Specific

Gravity

Initial

setting

Time

Final

Setting

Time

Compressiv

e Strength

Value 3.13 32

min

216

min

44.28 MPa

Table 1: Properties of cement

SI

No

.

Sieve Desi

gnation

Percentage passing

Fine aggregates Coarse aggre

gates

Natura

l sand

Stone

Dust

Natura

l aggre

gates

Cer

ami

c

Wa

ste

1 12.5 mm --- --- 100 100

2 10 mm 100 100 98.25 97.

35

3 4.75 mm 100 100 10 9.9

8

4 2.36 mm 99.30 81 1 1

5 1.18 mm 96.70 39.70 0 0

6 600 56.20 9.6 --- ---

7 300 21.90 4.2 --- ---

8 150 5.30 1.1 --- ---

Table 2: Details of Sieve analysis of fine and co

arse aggregate

3.1 Mix Selection

The grade of concrete adopted for investigation

was M20. The mix proportion of concrete for

laboratory investigations was arrived by

designing as per Indian standard method. The




final mix used was 1:1.33:2.73 with water

cement ratio of 0.48. The details of mix

designations and specimens used in

experimental programme are given in Table 3. SI

N

o.

Mix

Desig

nation

Fine aggregate Coarse aggreg

ate

Numbe

r of spe

c-

imens

Sand Stone Dust

Conven

tion-al

Ceram

ic

Waste

Cu

bes

B

ea

ms

1 MC 100% 0% 100% 0% 3 3

2 MC0 100% 0% 80% 20% 3 3

3 MC1 80% 20% 80% 20% 3 3

4 MC2 60% 40% 80% 20% 3 3

5 MC3 40% 60% 80% 20% 3 3

6 MC4 20% 80% 80% 20% 3 3

7 MC5 0% 100% 80% 20% 3 3

Table 3: Details of Mix designations and specimens

4. Results and Discussions

After comparison properties presented in Table

2, it is observed that the stone dust can be used

as conventional fine aggregate. Whereas

ceramic waste can be used in place of

conventional coarse aggregate. The Samples

were tested and analysed after curing for 28

days.

The experimental test results are presented in

Table 4. It can be observed from the Table 4 that

the strength of concrete is increased at some

point due to usage of stone dust as fine

aggregate. But strength is reducing due to usage

of ceramic waste as coarse aggregate. Hence in

concrete with ceramic waste as coarse aggregate

upto 20%, conventional fine aggregate can be

replaced partially by stone dust upto 40%. SI No. 1 2 3 4 5 6 7

Mix

Designat

ion

MC MC

0

MC

1

MC

2

MC

3

MC

4

M

C

5

Compres

sive

strength

(MPa)

28.

45

18.

44

20.

13

22.

00

17.

27

16.

17

1

4.

2

4

Flexural

strength

(N/mm2)

6.8

3

6.5

8

7.6

0

8.5

8

6.5

8

4.3

0

4.

0

4

Table 4: The experimental test results

% resplacement of stone dust as a fine aggregate

0 20 40 60 80 100

Comp

ressiv

e stre

ngth

at 28

days

0

5

10

15

20

25

Fig 1: Variation of compressive strength with

percentage replacement of Stone dust alongwith

20 % ceramic waste as a coarse aggregate.

% replacement of sand with stone dust

0 20 40 60 80 100

Flex

ural st

reng

th at

28 da

ys

0

2

4

6

8

10

Fig 2: Variation of Flexural strength with

percentage replacement of Stone dust along with

20 % ceramic waste as a coarse aggregate.

5. Conclusion

The following conclusions are drawn from the

present study:

1. The compressive and flexural strength of concrete with 40% replacement of natural sand

by stone dust along with 20% replacement of

coarse aggregate by ceramic waste reveals

higher strength as compared to 0 % replacement

of natural sand by stone dust along with 20%

replacement of coarse aggregate by ceramic

waste.

2. It is found that as compare to flexural strength the compressive strength greatly

decreased when only ceramic waste is used as a

20% replacement of coarse aggregate (i.e.at 0%

stone dust and 20 % ceramic waste).

3. It is advised on the basis of present study that ceramic waste alone could not be used as a

replacement of coarse aggregate because it has

an adverse effect on the properties of concrete.




On the other hand if it is used along with the

stone dust it gives satisfactory results and upto

40 % of replacement of fine aggregate with

stone dust the properties of concrete is found to

be enhanced and after that it decreases.

4. Thus we found out the optimum percentage for replacement of stone dust with

fine aggregate along with 20% replacement of

coarse aggregate by ceramic waste is almost

40% for both cubes and beams.

5. Stone dust has a potential to provide alternative to natural sand and helps in

maintaining the environment as well as

economical balance. Non-availability of Natural

sand at reasonable cost, forces to search for

alternative material. Stone dust qualifies itself as

a suitable substitute for natural sand at

reasonable cost.

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utilization of ceramic waste and stone dust in concrete