Structural Performance of Concrete by Partial Replacement of Cement with Hypo Sludge (paper waste)

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1 Volume Issue 7, August 4, ISSN 48 8 Structural Performance of Concrete by Partial Replacement of Cement with Hypo Sludge (paper waste) Abdullah shahbaz khan, Ram panth, Gagan Krishna R.R, Suresh G. Patil 4 PG student, Assistant professor, Associate professor, 4 Professor, Srinivas School of Engineering, Suratkal Mangalore, Guru Nanak Dev Engineering College Bidar, Srinivas School of Engineering, Suratkal Mangalore, 4 PDAC Gulbarga ABSTRACT The rapid increase in construction activities leads to active shortage of conventional construction materials such as cement, fine aggregate and coarse aggregate. Researches were searching for cheaper materials that can be used as substitute for these materials. In the world of concrete many artificial pozzolans are found by research such as fly ash, blast furnace slag, silica fume, rice husk ash, etc other than this the recent studies has show that the waste from paper industries has pazzolanic property termed as hypo sludge hypo sludge contains low calcium and minimum amount of silica. behaves like cement because of silica and magnesium properties. The silica and magnesium improve the setting of concrete. By utilizing hypo sludge the strength will be increased and also cost reduction in the concrete is achieved. The present dissertation work is directed towards developing low cost concrete from paper industry waste. Dissertation work is carried out with M & M grade concrete with W/c ratio of. &.4 respectively as a control specimen and hypo sludge is replaced in different percentages such as %, %, and % by weight of cement. Cubes of mm x mm size, Cylinders of mm dia and mm height, and prisms of mm x mm x mm are casted for conventional concrete and RPH (Replacement of hypo sludge by weight of cement) test specimen respectively. Test was conducted to study the mechanical properties of concrete, such as compressive strength, split tensile strength and flexural strength. The curing period should be, 7 and. Key words : Hypo Sludge, M and M grade concrete, cubes, cylinders, prisms. I. INTRODUCTION Concrete, is most widely used man made construction material and is the largest production of all the materials used in construction industry. Concrete is basically made of cementitious materials which have to properly bind themselves together, as well as with other materials to form a solid mass. Concrete or mortar is made up of cement, water and aggregates (Coarse and Fine Aggregate) and sometimes with necessary admixtures. 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 and absorption resistance are required. Compressive strength is considered as an index to assess the overall quality of concrete and it is generally assumed that an improvement in the compressive strength results in improvement of all other properties. Hence strength investigations are generally centered on compressive strength. Even though concrete mixes are proportioned on the basis of achieving the desired compressive strength at the specified age, flexural strength often play a vital role in concrete making. (paper industry waste) has a tremendous potential in this context and it is well documented that the use of hypo sludge in concrete results in a significant improvement is the rheological prosperities. is a recent arrival among cementitions materials. It was originally introduced as artificial pozzolana while producing paper the various wastes are comes out from the various processes in paper industries. From the preliminary waste named as hypo sludge due to its low calcium is taken out for our project to replace the cement utilization in concrete. Paper making industries generally produces a large amount of solid waste. Paper fibers can be recycled only a limited number of time before they become too short or weak to make high quality paper. From paper manufacturing process three types of sludge are obtained namely lime sludge (), ETP 7

2 Volume Issue 7, August 4, ISSN 48 8 sludge and De-Inking sludge. In our project we have utilized lime sludge as a replacement for cement. Lime sludge ( is a material obtained from the chemical recovery process of paper production. Hypo sludge is available abundantly worldwide, but its usage to date is very limited. Each Indian mill produces an average 4 over-dry tones of sludge per day. The specific gravity hypo sludge is generally.8 but it is very slightly higher when the silica content is lower. This value can be compared with the specific gravity of Portland cement which is.. The particles of hypo sludge are extremely fine, most of them having a diameter ranging between.4 and. m, the median diameter is typically below. m. such a fine material as hypo sludge has a very low bulk density to kg/m handling this light powder is difficult. Chemical reactions involved in partially replaced concrete. Primary Hydration Cement + Water C-S-H (gel) + Ca (OH). Secondary Hydration Here hypo sludge acts as a pozzolana Ca (OH) + Pozzolana C-S-H (gel) Increase in amount of C-S-H gel increase the compressive strength but only up to a certain extent. Benefits of Hypo Sludge improves the properties of fresh and harden concrete. reduces degradation and bleeding. improves the durability of concrete. improves the setting of concrete due to presence of silica and magnesium. Environmental friendly. Light weight compare to conventional concrete. is the cheaper substitute to OPC. Limitations of Hypo Sludge Availability Handling problem and strength with the conventional concrete (). Over million tones of industrial wastes are being produced per annum by chemical and agricultural process in India. These materials pose problems of disposal and health hazards. The waste like phosphogypsum, flurogypsum and red mud contain obnoxious impurities which adversely affect the strength and other properties of building material based on them. Out of several wastes being produced at present, the use of phosphor gypsum, flurogypsum, lime sludge, hypo sludge, red mud and mine tailing is of paramount significance to protect the environment (). Paper fibers can be recycled only a limited number of times before they become too short or weak to make high quality paper. It means that the broken low quality paper fibers are separated out to become waste sludge. All the inks, dyes, coatings, pigments, stapes and Stickies (tape, plastic films etc) are also washed off the recycled fibers to join the waste solids ().This paper mill sludge consumes a large percentage of local land fill space for each and every year. Worse yet, some of the wastes are land spread on crop land as a disposal technique raising concerns about trace contaminants building up in soil or running off into area lakes and streams. Some companies turn their sludge in incinerators contributing to our serious air pollution problems. To reduce disposal and pollution problems emanating from these industrial wastes. It is most essential to develop profitable building materials from them. Keeping this in view investigations were under taken to produce low cost concrete by blending various ratios of cement with hypo sludge (). In Trondheim, the source factory produces 8 tons each year, with much more for the entire (4). Waste paper sludge obtained from a paper factory in Trondheim, Norway, It has bulk density 46kg/m specific gravity.6, ash content of 94% and a ph value of.4. The material is essentially composed of amorphous silicates and aluminates, mainly gehlenite (CaO.Al O SiO ) and melilite (8CaOAl O MgOSiO ); which are responsible for a pozzolanic reaction (8). II. LITRETURE REVIEW The use of paper-mill pulp in concrete formulations was investigated as an alternative to landfill disposal. The cement has been replaced by waste paper sludge accordingly in the range of %, %, % by weight for M and M mix. By using adequate amount of the waste paper pulp and water, concrete mixtures were produced and compared in terms of slump III. MATERIALS AND PROPERTIES The materials used in research are:. Portland cement ( grade). Fine aggregate (4.7 mm down). Coarse aggregate ( mm down) 4. Hypo Sludge. Water 76

3 Volume Issue 7, August 4, ISSN 48 8 Cement: Cement is a fine, grey powder. It is mixed with water and materials such as sand, pozzolanas to make mortar and concrete. The cement and water forms a paste that binds the other materials together. In this work ordinary Portland cement of grade conforming to IS: has been used and tested for physical and chemical properties. Fine Aggregate In the investigation fine aggregate is natural sand from local market is used, confirming grading zone II as per IS: The physical properties of fine aggregate like specific gravity, gradation and fineness modulus are tested in accordance with IS :86. Coarse Aggregate Coarse aggregate crushed granite of mm down size has been used as coarse aggregate. The physical properties of coarse aggregate like specific gravity, gradation and fineness modulus are tested in accordance with IS: 86. Hypo Sludge is also known as paper industry waste. It is the byproduct of the paper waste. This hypo sludge contains low calcium and minimum amount of silica. behaves like cement because of silica and magnesium properties. may be used as part replacement of cement. It is usually used in proportion of percent of cement content of the mix. obtained from Gemini Graphics (P) Ltd., Sikenpur village district Bidar. Table.: Chemical Properties of Hypo Sludge Percent in Sl.No. Constituent Hypo Sludge (%). Moisture.97. Magnesium Oxide (MgO) Calcium Oxide (CaO). 4. R O 9.. Silica (SiO ).9 6. Acid Insoluble.88 Water The water, which is used for making concrete and for curing, should be clean and free from harmful impurities such as oil, alkali, acid, etc, in general, the water, which is fit for drinking should be used for making concrete. IV. MIX DESIGN A mix M and M grade was designed as per IS 6:9 and the same was used to prepare the test samples. The design mix proportion is shown in blow table. Table 4.: Concrete Mix Design Proportion for m of concrete Sl n o Typ e of mix w/c rati o CV. C- M S-. M S-. M S- M CV C- M K- M K- M K- M Ceme nt Fine aggrega te Corse aggrega te Hypo Sludg e CVC-conventional concrete, S, S, S for M grade concrete with different Hypo Sludge percentage %, %, % respectively. K, K, K for M grade concrete with different Hypo Sludge percentage %, %, % respectively. V. EXPERIMENTAL PROGRAMME The quantity of cement, fine and coarse aggregates, hypo sludge and water each batch of proportion is prepared as mentioned in mix design. Then the mixing process is carried out. Tests for Fresh Properties of concrete Workability tests included the determination of slump cone test. 77

4 SLUMP VALUES IN mm International Journal of Emerging Technologies and Engineering (IJETE) Volume Issue 7, August 4, ISSN 48 8 Casting of Moulds Once the workability tests are over, concrete is filled into the moulds (cubes, cylinders and beams) and compaction process has to be carried out. Then casted moulds are de-moulded and the specimens are kept inside the water for curing till test day (, 7 and 8 days). Mechanical Properties Tests To determine the hardened properties of concrete standard tests were carried out at standard ages (,7days and of curing) i.e., compression test on cubes for compressive strength (three cubes of xxmm size), split tensile test on cylinders for tensile strength (three cylinders of mm dia with mm height) and flexural test on beams for flexural strength (three beams xxmm) of concrete for each grade with different mix proportions of hypo sludge. VI. RESULTS AND DISCUSSION Setting time for cement and hypo sludge Table:6. Setting Time for Cement and Sl. No. Ingredients Cement + % Cement + % Cement + % Initial time (min) Final time (min) Table:6. Results of Slump Cone Test M and M Mix designation M Slump cone (mm) M Slump cone (mm) 6 4 CVC M M 4 4 M 4 8 SLUMP VALUES cvc M M M Fig.6. Slump values for various mixes (M, M ) Table:6. Mechanical Properties of Concrete with Different mix Proportions Mix s Compressive strength (N/mm ) Split tensile strength (N/mm ) M M DIFFERENT MIX PROPORTIONS Flexural strength (N/mm ) days 7 8 days days CVC Cement + % Cement + 4% Cement + % Slump Cone Test results Workability tests, slump cone tests conducted on fresh concrete and the results are shown in table. S S S CVC K K K

5 Volume Issue 7, August 4, ISSN 48 8 Here CVC, CVC Conventional Concrete for M, M Grade concrete Respectively S, S and S are %, % and % RPH for M, Grade concrete Respectively K, K and K are %, % and % RPH for M, Grade concrete Respectively 4 Fig.6. Compressive strength results for different curing period for M Grade Concrete 4 4 CVC S S S CVC K K K days 7 days days 7 days Fig.6. Compressive strength results for different curing period for M Grade Concrete.... Fig.6.4 Split tensile strength results for of curing for M Grade Concrete CVC S S S Fig.6. Split tensile strength results for of curing for M Grade Concrete... CVC K K K CVC S S S Fig.6.6 Flexural strength results for of curing for M Grade Concrete 79

6 .... Fig.6.7 Flexural strength results for of curing for M Grade Concrete By this table and graphs results shows that there is an increase in compressive strength, split tensile strength and flexural strength with %, % replacement of cement with hypo sludge and it decreases with % replacement. VII. CVC K K K CONCLUSION. COMPRESSIVE STRENGTH Compressive strength of concrete with various mixes with different curing periods which are, 7, 8 days by partial replacement of cement with hypo sludge that is %, %, %, % which are noted as CVC, S, S, S and CVC, K,K,K. The compressive strength increases as the curing period increasing for M, M grade concrete, compressive strength of CVC and % are approximately same but it increase with % replacement and finally it starts decreasing in strength with % replacement.. SPLIT TENSILE STRENGTH It is observed that in split tensile strength of M and M grade concrete. The strength of concrete has increased with % replacement of hypo sludge with cement as compare to conventional concrete and with % replacement it is slightly more or we can say it as equivalent but with % its start decreasing in strength.. FLEXURAL STRENGTH It is observed that in flexural strength of M and M grade concrete the strength of concrete has increased with % replacement of hypo sludge with cement as compare to conventional concrete and with % International Journal of Emerging Technologies and Engineering (IJETE) Volume Issue 7, August 4, ISSN 48 8 replacement it is slightly more or we can say it as equivalent but with % its start decreasing in strength. The prisms which contains % of RPH breaks earlier with the influence of two point loading condition where as %, %, shows more deflection and carries higher load but CVC prisms break earlier without showing mutch cracks. REFERENCES ) Jayeshkumar Pitroda, Dr. L. B. Zala, Dr F. S. Umrigar, Hypo Sludge Management : Opportunities for Developing Low Cost Concrete with Glass Fibers, International Global Research Analysis, Dec Volume-, Issue-7, ISSN: ) Jayeshkumar Pitroda, L.B.Zala, F S Umrigar, Durability of concrete with Partial Replacement of Cement by Paper Industry Waste (Hypo Sludge) International Journal of Innovative Technology and Exploring Engineering (IJITEE) Feb, ISSN: 78-7, Volume-, Issue-. ) Jayraj Vinodsinh Solanki, Jayeshkumar Pitroda, Investigation of Low Cost Concrete Using Industrial Waste as Supplementary Cementitious Materials, International Journal of Engineering Science and Innovative Technology (IJESIT), January, Volume, Issue, ISSN: ) Mamta B. Rajgor, Jayeshkumar Pitroda, A Study on Paper Industry Waste: Opportunities for Development of Low Cost Concrete in Indian Context International Journal of Scientific Research, Feb Volume-, Issue-, ISSN: ) Mohammad Alizadeh Kharaazia and Eshmaiel Ganjianb, Use of Iranian Industrial Waste for Cement Replacement in Low Strength Concrete and CLSM, Sharif University of Technology, June, ISBN ) P.Sharmini, E.Ananthakrishnan, Partial Replacement of Cement in Concrete using Hypo Sludge from Paper Industry Waste, International Conference on Intelligent Science and Technology (IIST). 7) R.Balamurugan, R.Karthickraja, An Experimental Investigation of Partial Replacement of Cement by Industrial Waste (Hypo Sludge) International Journal of Engineering Research and Applications (IJERA) April 4, ISSN : 48 96, Vol. 4, Issue 4( Version ), pp

7 Volume Issue 7, August 4, ISSN ) R. Srinivasan, K. Sathiya and, Experimental Investigation in Developing Low Cost Concrete From Paper Industry Waste, The Bulletin of the Polytechnic Institute of Jassy, Construction. Architecture Section (Romania) Jan. 9) Ronaldo S. GALLARDO, Mary Ann Q. ADAJAR, Structural Performance of Concrete with Paper Sludge as Fine Aggregates Partial Replacement Enhanced with Admixtures Dec 6, University of the Philippines, Diliman, Quezon City, PHILIPPINES. ) Sumit A Balwaik, S P Raut, () Utilization of Waste Paper Pulp by Partial Replacement of Cement in Concrete, International Journal of Engineering Research and Applications (IJERA), Vol., Issue, pp.-9. ) Sandesh D. Deshmukh, Pravin V.Domke, Satish D. Kene, R.S.Deotale, Experimental Study on Strength of Concrete by Using Artificial Fibers with Rice Husk Ash, International Journal of Engineering Research and Applications (IJERA), Jan Vol., Issue, pp.7-8, ISSN: ) Seyyedeh Fatemeh Seyyedalipour, Ghasem Norouznejad, Study of Utilization of Pulp and Paper Industry Wastes in Production of Concrete, International Journal of Engineering Research and Applications (IJERA), January 4, Vol. 4, Issue (Version ), pp.-, ISSN : ) MS SHETTY, Concrete Technology theory and practice, ISBN:8-9--4, Edition. 4) BIS: , Bureau of Indian Standard, Grade Ordinary Portland Cement. ) BIS:4-98 Method of Chemical Analysis Of hydraulic Cement. 6) BIS:8-97 specification for coarse and fine aggregates from natural sources for concrete. 7) BIS: 46- plain and reinforced concrete code for practice. 8) SP 6, Design Aid to IS: ) BIS: 6-9, Bureau of Indian Standard, Recommended Guidelines for Concrete Mix Design. ) BIS: 6-99, Bureau of Indian Standard, Methods of Tests for Strength on Concrete. ) BIS: 86-97, Bureau of Indian Standard, Methods of Tests for split tensile strength. 8