IJSRD - International Journal for Scientific Research & Development Vol. 3, Issue 04, 2015 ISSN (online): 2321-0613 Utilization of Ceramic Waste and used Foundry Sand in Concrete Shyam J. Makwana 1 Prof. Yashwantsinh M. Zala 2 1 M.E Student 2 Assistant Professor 1,2 Department of Civil Engineering 1,2 Marwadi education foundation s group of institutions, Rajkot-Gujarat-India Abstract In the world, there are large amounts of calcinedclay wastes and used foundry sand to generate from the industry each year. So, these wastes are used in landfills. Reusing these wastes in concrete could be a very beneficial situation for society. Therefore, at one side, we can solve the problems of industries and at the other side, we can make more sustainable concrete by reducing nonrenewable resources like cement and aggregates and also solve environmental problems related to land filled wastes. This research paper examines the feasibility of using ceramic waste powder and used foundry sand in concrete. Ceramic waste powder is replaced with cement at a rate of 0%, 10%, 20%, 30% and 40% and used foundry sand is replaced with natural sand at a rate of 0%, 10%, 20% and 30%. From this research to find out the strength and durability of concrete like compressive strength and slump of concrete. Key words: Waste Utilization, Ceramic Waste Powder, Used Foundry Sand, Slump, Compressive Strength I. INTRODUCTION A. Ceramics Ceramics are defined that it is a class of non-metallic and inorganic solids which are subjected to high temperature in manufacturing of ceramics product in industry. Most of ceramics are composed of carbides, nitrides and oxides. In the ceramic industry, there is generally a high temperature and therefore the producing materials are heat resistant. Ceramic products are generally produced from combinations of refined clay and granulated non-plastic minerals or unrefined clay. In ceramic products, the clay content exceeds 20%. Advanced ceramics are defined that it is a ceramic products which are made from highly refined natural or synthetic compositions to have special properties. According to application, advanced ceramics can be classified as optical, magnetic, chemical, electrical, mechanical, thermal, biological and nuclear. Most of ceramic products are produced from clay and are made from single clay or one or more clay mixed with mineral modifiers like quartz and feldspar. Kaolin and ball clay are the types of commercial clay which are used for ceramics products. Indian ceramic production is 100 Million ton per year. In ceramic industry, about 15%-30% waste material generated from the total production. This waste is not recycled in any form at present. The Ceramic industries are dumping the waste in any nearby pit or vacant spaces, near their unit although notified areas have been marked for dumping. This leads to serious environmental and dust pollution and occupation of a vast area of land, especially after the powder dries up so it is necessary to dispose the Ceramic waste quickly and use in the construction industry. B. Foundry Sand Foundry sand is very high quality silica sand which is a byproduct of ferrous and nonferrous metal casting industries. It has been used as a moulding material due to its thermal conductivity in these industries. The physical and chemical characteristics of foundry sand is different and it is depend on the types of casting process and the industrial area from which it originates. Sand is typically recycled and reused through many production cycles in modern foundry practice. There are approximately 100 million tons of sand is used in production of ferrous and nonferrous metal casting each year from that 6-10 million tons are discarded annually and are available to be recycled into other products and in industry. The major generators of foundry sand are the automotive industries. The raw sand is very highly quality sand than the natural sand which is used at construction sites. This sand forms the outer shape of the mould cavity. It is normally depend upon a small amount of bentonite clay to act as the binder materials. Sometimes, chemical binders are also used to create sand cores. Depending upon the geometry of the casting, sands cores are inserted into the mould cavity for the molten metal to form internal passages. When the metal has solidified, the casting is separated from the moulding. Moulding sands are reused many times in the casting process and when this reused sand degrades to the point that it can no longer be reused in this casting process, at that point, the old sand is disposed from the cycle as a byproduct and then new sand is introduced and the cycle begins again. There are two types of foundry sand. First one is green sand in which natural materials are blended together. And another is chemically bonded sand in which chemicals are used as binding materials. Both types of sands are used in industries but they have different physical and environmental characteristics. There are about 50,909 foundries in the world from which 6 10 million tons of foundry sand is totally discarded on to the ground. The Indian Metal Casting (Foundry Industry) is well established & producing estimated 9.344 MT (Million Tons) of various grades of Castings as per International standards. So, these wastages generate environmental and disposal problems. A. Cement (OPC) II. EXPERIMENTAL MATERIALS The ordinary Portland cement of 53 grade conforming to IS: 12269 2013 is being used. Initial setting time of cement is 140 minutes, final setting time is 215 minutes, standard consistency is 31.5% and specific gravity of cement is 3.15. All rights reserved by www.ijsrd.com 1608
B. Ceramic Waste Powder Ceramic waste is produced at the end process of polishing and finishing from the ceramic industries. This waste is crushed by the crusher and to make a powder form. This ceramic waste powder is collected from the Morbi region, Gujarat. It is a white dry powder which is passing through the 90 microns sieve and replaced with cement. Specific gravity of ceramic waste powder is 3.11. Its chemical investigation is done by MET-Chem laboratory, Baroda and it is shown in below table. Constituents Value (%) SiO 2 96.49 Fe 2 O 3 0.12 Al 2 O 3 0.1 CaO Absent MgO Absent TiO 2 Absent LOI 0.88 Table 1: Chemical Compositions of Ceramic Waste Powder Source: - MET Chem Laboratory, Baroda C. Used Foundry Sand Used foundry sand which is used in this experimental work was collected from Rajkot. Used ferrous foundry sand was used for casting of mild steel and it was chemically bonded sand. Specific gravity and water absorption of this foundry sand is 2.38 and 0.43 percent, respectively. Fineness modulus of used foundry sand is 2.05. Its chemical investigation is done by MET-Chem laboratory, Baroda and it is shown in below table. Constituents Value (%) SiO 2 91.84 Fe 2 O 3 0.2 Al 2 O 3 2.52 CaO 3.5 MgO Absent TiO 2 0.26 LOI 0.02 Table 2: Chemical Compositions of Used Foundry Sand Source: - MET Chem Laboratory, Baroda D. Aggregate The most important ingredient of concrete is aggregate. Good gradation of aggregate is required for workability. Good gradation aggregate minimise the voids of concrete. So, less paste is required to fill up to the voids. E. Coarse aggregate Locally available 10mm and 20mm size aggregate is used. Physical property is determined, specific gravity of coarse aggregate is 2.78, and fineness modulus is 4.70. Water absorption and natural moisture content of coarse aggregate is 0.5% and 0.21%, respectively. F. Fine Sand Locally available river sand is used. It is tested as per the IS code 383:1970, specific gravity of sand is 2.60 and fineness of modulus is 2.85. Water absorption and natural moisture content of coarse aggregate is 0.84% and 0.32%, respectively. G. Water Water is an important ingredient of concrete. It actually participates in the chemical reaction with cement. The quality and quantity of water are required to be looked into very carefully. III. DESIGN MIX A mix M25 grade of concrete is design as per the Indian Standard code 10262-2009 and design mix proportion is shown in table 3. C W (Lit.) F.A. C.A. 20 10 mm mm By Weight 394 197 669.53 700.81 467.2 By Volume 1 0.5 1.70 1.78 1.18 Table 3: Mix Design Proportion C = Cement, W = Water, F.A. = Fine Aggregate, C.A. = Coarse Aggregate IV. EXPERIMENTAL METHODOLOGY The evaluation of ceramic waste powder and used foundry sand for use as a replacement of cement and fine aggregate materials, respectively begins with the concrete testing. Concrete contains cement, water, coarse aggregate and fine aggregate. In this experiment work, ceramic waste powder is replaced with cement at a rate of 0%, 10%, 20%, 30% and 40% and used foundry sand is replaced with natural sand at a rate of 0%, 10%, 20% and 30%, the data from the ceramic waste powder and used foundry sand are compared with data from a standard concrete without ceramic waste powder and used foundry sand. Three cube samples were cast on the mould of size 150X150X150 mm for each 1:1.70:2.96 concrete mix with partial replacement of cement and fine aggregate with a w/c ratio as 0.50. After 24 h the specimens were de-moulded and water curing was continued till the respective specimens were tested after 7 and 28 days for compressive strength test. Slump test were performed for workability of concrete. A. Slump Test Slump test was performed as per IS: 1199 1959. Cone is used for slump test which has 100mm top and 200mm bottom diameter and 300mm height. Slump was measured by the difference between the height of the concrete cone and the height of the concrete cone after slump. Slump test is shown in figure 1 and the results are shown in figure 2. All rights reserved by www.ijsrd.com 1609
Fig. 1: Slump Test Fig. 2: Percentage Replacement of Ceramic Waste Powder (CWP) and Used Foundry Sand (UFS) V/S Slump (mm) of Concrete for M25 Mix B. Compressive Strength Its perform on compressive testing machine, cube is placed as shown in figure 3 and continuous loading is applied on it and its reading which is in tone is note down, as per the equation Load/Area, cube compressive stress is find out. In grade of M25 concrete, 3 cubes are casted for each batch. The average compressive strength values of three samples are reported in this paper. The results are shown in figure 4. Fig. 3: Compression Testing Machine All rights reserved by www.ijsrd.com 1610
Fig. 4: Percentage Replacement of Ceramic Waste Powder (CWP) and Used Foundry Sand (UFS) V/S Compressive Strength (N/mm 2 ) of Concrete for M25 Mix at 7 and 28 days V. CONCLUSION Based on experimental investigation, the following observations are made: 1) The slump was decreased when the replacement of cement and fine aggregate were increased with ceramic waste powder and used foundry sand in concrete, respectively. It was decreased from 6.31% to 69.47% as compare to normal concrete. 2) The compressive strength was increased from 7.12% to 10% when the replacement of natural sand with used foundry sand by 10% to 30% at 28 days with compare to normal concrete. The compressive strength was continuously decreased from 9.21% to 31.19% when the replacement of cement with ceramic waste powder by 10% to 40% at 28 days with compare to normal concrete. So, we could not use only ceramic waste powder to replace with cement in concrete. But the positive results were observed for the combination of CWP and UFS to replace with different percentages in concrete. For the replacement of both wastes in concrete together, the compressive strength was increased up to 20% CWP and 10% UFS by 2.06% at 28 days with compare to normal concrete and the maximum value of compressive strength was observed to increase 5.35% with compare to normal concrete at the replacement of 10% ceramic waste powder and 10% used foundry sand in concrete. REFERENCES [1] Eva Vejmelkova, Martin Keppert, Pavla Rovnanikova, Michal Ondracek, Zbynek Kersner, Robert C erny, Properties of high performance concrete containing fine-ground ceramics as supplementary cementitious material, Elsevier, Cement & Concrete Composites 34 (2012) 55 61. [2] C. Medina, M.I. Sanchez de Rojas, M. Frias, Properties of recycled ceramic aggregate concretes: Water resistance, Elsevier, Cement & Concrete Composites 40 (2013) 21 29. [3] Amitkumar D. Raval, Indrajit N. Patel, Jayeshkumar Pitroda, Eco-Efficient Concretes: Use Of Ceramic Powder As A Partial Replacement Of Cement, International Journal of Innovative Technology and All rights reserved by www.ijsrd.com 1611
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