EXPERIMENTAL INVESTIGATION ON REPLACEMENT OF CEMENT WITH FLY-ASH, STEEL SLAG, RED MUD IN CONCRETE

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1 EXPERIMENTAL INVESTIGATION ON REPLACEMENT OF CEMENT WITH FLY-ASH, STEEL SLAG, RED MUD IN CONCRETE C.Ashokraj 1, P.Aathi kesavan 2, A.Jagadeshwaran 3, M.Karthick 4 and S.Vinothkumar 5 1,2,3,4,5 Department of Civil Engineering, The Kavery Engineering College Abstract The concept of partial of cement which is capable for reducing the emission of CO2 and sustainable development by application of industrial wastes to reduce consumption of natural resources and energy and pollution of the environment. Presently large amount of industrial wastes are generated in various industries like thermal industries, steel industries Aluminium industries etc., with an important impact on environment and humans. This research work describes the feasibility of using the industrial wastes (fly ash, steel slag, red mud) in concrete production as of cement. The cement has been replaced by industrial wastes (fly ash, steel slag, red mud) in the ratio of 30% (20%, 5%, 5%), 40%(25%,7.5%,7.5%) and 50%(30%,10%10%) by the weight of cement for M-25 mix. Concrete mixtures prepared, curried, tested and compared in terms of compressive strength, split tensile strength and flexural strength with the conventional concrete for 7,14 and 28 days.it is found that the strength obtained is comparable to the conventional concrete. Keywords Co2, fly ash, red mud, steel slag, compressive strength, split tensile strength, flexural strength. I. INTRODUCTION Environmental issues associated with the production of Ordinary Portland cement (OPC) are well known. With rapid industrialization, generation of large quantities of wastes creating environmental and ecological problems apart from occupying large tracts of valuable cultivable land. To overcome these problems it became necessary to use Industrial waste in the world s most consumed man-made material, Concrete. For its suitability and adaptability with respect to the changing environment, the concrete must be such that it can conserve resources, protect the environment and at the same time be economic too. To achieve this, major emphasis must be laid on the reuse of by-products or waste materials from industrial processes. The cement industry is held responsible for some of the carbon dioxide emission, because in the production of one ton of Portland cement, approximately one ton of carbon dioxide gas is emitted into the atmosphere. The emission of carbon dioxide will increase the effect of global warming due to the emission of greenhouse gases. Cement with fly ash reduces the permeability of concrete and dense calcium silicate hydrate (C-S-H). Research shows that adding fly ash to concrete, as a partial of cement (less than 35%), will benefit both the fresh and harden states (Jayeshkumar Pitroda et.al 2012). Among the greenhouse gases, carbon dioxide contributes about 65% of global warming. The usage of fly ash to partially replace the cement is because the production of cement emits carbon dioxide gas to the atmosphere. Using fly ash as additive in cement, admixture in concrete and cement material in concrete. Compressive strength of concrete at different proportions of cement being replaced by fly ash has been checked and results have been found effective and applicable (Padhye et.al 2016). Red Mud is a byproduct which is obtained by extracting Aluminum from Bauxite ore through Bayer s process. For every 1 tonne of Aluminium around tonne of Red Mud is generated as a by-product from 3 tonne of Bauxite ore. It covers more area to dump Red Mud which causing ground water contamination through percolation. Compressive strength of concrete produced by replacing cement by unwashed red mud and when subjected to alternative wetting and drying for 50 cycles goes on increasing up to 10% levels (Anandakumar et.al 2015) Steel slag are also the waste generated material from the manufacturing of steel industry. DOI : /IJRTER WRMMN 186

2 International Journal of Recent Trends in Engineering & Research (IJRTER) Steel slag has been observed that, the of steel slag powder to cement without changing much the compressive strength is 17% (Syed Muqueet Ali et.al 2014). 1.1 PROPERTIES OF CEMENT: Locally available Ordinary Portland Cement (OPC) of 53grade has been used and physical properties are mentioned in table below. Table 1. Properties of cement SL.NO DESCRIPTION VALUE 1 Specific gravity Standard consistency test 33% 3. Initial setting time 36.25mins Final setting time 10 hours 45mins 4. Finess test PROPERTIES OF FINE AGGREGATES: Sand was collected from nearby river Zone-III is used as a fine aggregate is passed through the sieve of 4.75mm. IS: 383(1970) is followed for fine aggregate. The various properties of sand are tabulated in table2 Table 2. Properties of fine aggregates SL.NO DESCRIPTION VALUE 1 Specific gravity Bulk density Finess test PROPERTIES OF COARSE AGGREGATE: Coarse aggregate obtained from local quarry units it 20mm aggregate it has been used for this project. As per IS2386 part (IV), the impact and crushing strength value for concrete wearing should not exceed 30% & other than wearing surface 45%.The properties of coarse aggregate are tabulated below. Table 3. Properties of coarse aggregate SL.NO DESCRIPTION VALUE 1 Specific gravity Bulk density Impact test 17% 4. Crushing strength 16% 5. Abrasion test 11% PROPERTIES OF FLY ASH: FLY ASH: Fly ash is the finely divided mineral residue resulting from the combustion of coal in electric generating plants. Fly ash consists of inorganic, incombustible matter present in the coal that has been fused during combustion into a glassy, amorphous structure. Fly ash particles are generally spherical in shape and range in size from 2μm to 10 μm. Fly ash like soil contains All Rights Reserved 187

3 International Journal of Recent Trends in Engineering & Research (IJRTER) concentration of the following heavy metal; Nickel, vanadium, cadmium, barium, chromium. Copper, molybdenum, zinc and lead. In this project 20%-30% of fly ash are replaced as cement The percentages of composition are mentioned in table A. S.NO DESCRIPTION RESULT 1. Bulk density 0.994g/cm 3 2. Color Whitish grey 3. Sp. Gravity Moisture 3.14% 5. Avg. particle size 6.92μm RED MUD: Red mud is produced during the Bayer process for alumina production. It is the insoluble product after bauxite digestion with sodium hydroxide at elevated temperature and pressure. It is a mixture of compounds originally present in the parent mineral, bauxite and of compounds formed (or) introduced during the Bayer cycle. It is disposed as a slurry having a solid concentration in the range of 10 to 30%, ph in the range of 13 and ionic strength. In this project 5%-10% of red mud are replaced as cement the percentages of composition are mentioned in table A S.NO DESCRIPTION VALUE 1 Sp. Gravity Finess 2000 STEEL SLAG: Steel slag are the industrial by-products from a greatest interest to the pavement construction industry but minimum of slag will be introduced in concrete as cement. In this project 5%-10% of steel slag are replaced as cement. The chemical composition is mentioned below in table A. S.NO DESCRIPTION VALUE 1 Sp. Gravity Water Absorption 4.6% Table A. The composition of steel slag, red mud and fly ash SL.NO COMPOSITION RED MUD STEEL SLAG FLY ASH 1. Al 2 O SiO CaO MgO Fe 2 O MnO S K 2 O LoI TiO Na 2 O SO All Rights Reserved 188

4 International Journal of Recent Trends in Engineering & Research (IJRTER) II. MATERIALS AND EXPERIMENTAL METHODOLOGY: The concrete mix design was done in accordance IS In this project M25 grades are used. The mix ratio of M25 grade is Water ratio (ml) Cement [kg/m 3 ] Fine aggregate [kg/m 3 ] Coarse aggregate [kg/m 3 ] By the use of this proportion the value of cement, sand (fine aggregate), coarse aggregate are estimated. The Ordinary Portland Cement are used, good stone aggregate and natural sand of zone III was used as coarse aggregate and fine aggregate. For this study cubes, cylinder and beam were casted by of cement with steel slag (5-10%), red mud (5-10%) and fly ash (20-30%). After that testing of fresh concrete to determine the workability of concrete. 2.1 TESTING ON FRESH CONCRETE: 1) Slump cone test. 2) Compaction factor test. 1) Slump cone test: To determine the consistency of concrete, Slump test was conducted with varying water content and a particular w/c ratio is fixed according to the slump of 120mm. 2) Compaction factor test: The cube specimen was tested for compressive strength at the end of 7 days, 14 days and 28 days. The specimen was tested after the surface gets dried. The load applied on the smooth sides without shock and increased continuously till the specimen failed. The mean compressive strength is calculated. The value of compaction factor test is 60mm. 2.2 CASTING OF SPECIMEN: As the aggregate of size is about 20mm are used, Cube mould of mm are used for casting specimen for compressive strength. Cylindrical mould of size 150mm diameter and 300mm height and beam mould of size mm are used for casting specimen for split tensile strength and flexural strength respectively. 2.3 CURING OF CONCRETE: The method used for curing in this work is the total immersion of the cubes, cylinders and beams in water for specific age of 7 days, 14 days and 28 days from the day of casting. III. RESULTS AND TABLES The various strength results are compiled in following tables with respect to curing time for a particular of fly ash, red mud and steel sag. They show the behavior of concrete with the various time intervals. The results are shown graphically in figure. The compressive strength of cubes are having the strength for various curing as follows; for 7 days curing the strength occur MPa, for days of curing the strength occur 30 MPa and for All Rights Reserved 189

5 International Journal of Recent Trends in Engineering & Research (IJRTER) days of curing the strength occur 38 MPa. Thus for the first set of special concrete (replacing the cement for 30%), the strength obtained is little higher than the conventional concrete. For the second set of special concrete (replacing the cement for 40%), the strength obtained is higher than the conventional concrete strength. For the third set of special concrete (replacing the cement for 50%), it gives greater than the conventional concrete. However it gives greater strength, comparing to the second set of special concrete the strength gradually decreases. Table 4. Compressive strength of Cubes at 7, 14, 28 days for M25 grades. Curing Age in Days Normal concrete M-25 30% (20% fly ash, 5% red mud, 5% steel 40% (25% fly ash, 7.5% red mud, 7.5% steel 50% (30% fly ash, 10% red mud, 10% steel Compressive strength in MPa 7 days days days Fig 1. Compressive strength of cubes at 7, 14, 28 days for M-25 grades. A measure of the ability of material to resist a force that tends to pull it apart. It is expressed as the minimum tensile stress (Force per unit area) needed to split the material All Rights Reserved 190

6 International Journal of Recent Trends in Engineering & Research (IJRTER) Table 5 Split Tensile strength of Cylinder at 7, 14, 28 days for M25 grades. Curing Age in Days Normal concrete M-25 30% (20% fly ash,5% red mud,5% steel 40% (25% fly ash,7.5% red mud,7.5% steel 50% (30% fly ash,10% red mud,10% steel Split Tensile strength in MPa 7 days days days Fig 2. Split tensile strength of cubes at 7, 14, 28 days for M-25 grades. The flexural strength is stress at failure in bending. Flexural strength, also known as modulus of rupture, or bend strength, or transverse rupture is a material property, defined as the stress in a material just before it yields flexure test. Curing Age in Days Normal concrete M-25 30% (20% fly ash,5% red mud,5% steel 40% (25% fly ash,7.5% red mud,7.5% steel 50% (30% fly ash,10% red mud,10% steel Flexural strength in MPa 7 days days days Table 6. Flexural strength of Beam at 7, 14, 28 days for M25 All Rights Reserved 191

7 International Journal of Recent Trends in Engineering & Research (IJRTER) Fig 3. Flexural strength of cubes at 7, 14, 28 days for M-25 grades. IV. RECOMMENDATION Based on the result of the test, it is recommended that 40% (fly ash 25%, red mud 7.5%, steel slag 7.5%) is optimum for of cement it as an economical for use in concrete works. V. CONCLUSION The result obtained from compressive strength, split tensile strength and flexural strength test conducted on concrete containing various percentage of fly ash, red mud and steel slag from different industries were as follows; The strength result of special concrete the (40%) fly ash, red mud and steel slag (25%, 7.5%, 7.5%) to cement it gives better strength when compare to conventional concrete. But the of cement is increases with percentage of fly ash, red mud and steel slag simultaneously t concrete for construction. Use of fly ash, red mud& steel slag in concrete can save industry disposal cost and produce a greener concrete for construction, which has low emission of CO2 and CO directly or indirectly in the environment. The cost analysis indicates that percent cement reduction decreases cost of concrete but at the same time strength also decreases. By adding fly ash, red mud and steel slag rate of hydration get reduced therefore expected results achieve later than 100% cement is used. REFERENCES [1] R. D. Padhye and N. S. Deo, Cement Replacement by Fly Ash in Concrete, International Journal of Engineering Research, vol.5, Issue 1, pp , Jan [2] Prof.Jayeshkumar Pitroda, Dr. L.B.Zala, Dr. F.S.Umrigar, Experimental Investigation on Partial Replacement of Cement with Fly Ash in Design Mix Concrete, International Journal of Advanced Engineering Technology, E-ISSN , [3] Kedar S.Shinge and Sandeep S.Pendhari, Use of Red Mud for Partial Cement Replacement, International Journal of Modern Trends in Engineering and Research, e-issn NO: , July [4] Syed Muqueet Ali and Prof. D.N.Kakde, Partially Process Steel Slag Used as Cement Replacement in Self Compacting Concrete (S.C.C), International Journal of Civil Engineering and Technology, vol.5, Issue 9, pp , Sep [5] Rahul Bansal, Varinder Singh and Ravi Kant Pareek, Effect on Compressive Strength with Partial Replacement of Fly Ash, International Journal on Emerging Technologies, ISSN No.: , All Rights Reserved 192

8 International Journal of Recent Trends in Engineering & Research (IJRTER) [6] D.Linora Metilda, C.Selvamony, R.Anandakumar and A.Seeni, Investigations on Optimum Possibility of Replacing Cement Partially by Red Mud in Concrete, Scientific Research and Essays, vol.10 (4), pp , Feb [7] Dr.S.Sundararaman and S.Azhagarsamy, Partial Replacement of Cement with Fly Ash and Silica Fume for Sustainable Construction, International Research Journal of Engineering and Technology, vol.03, Issue:05, e-issn: , May [8] P.Vipul Naidu and Pawan Kumar Pandey, Replacement of Cement in Concrete, International Journal of Environmental Research and Development, vol.4, No. 1, pp , ISSN ,2014. [9] A.B.Sawant, Dilip B.Kamble and Triveni B.Shinde, Utilization of Industrial Waste (Red Mud) in Concrete Construction, International Journal of Innovative Research in Science and Engineering, vol. No.2, Issue 03, ISSN , March [10] M.S.Kiran kumar and Raghavendra Naik, Experimental Study on Utilization of Industrial Wastes (Red Mud and Copper Slag) in Mortar and Concrete, International Journal of Civil and Structural Engineering Research, vol.3, Issue 1, pp. ( ), ISSN , April 2015-Sep All Rights Reserved 193