EFFECT OF CERAMIC WASTE POWDER IN SELF COMPACTING CONCRETE PROPERTIES Pratik D. Viramgama 1, Prof. S.R. Vaniya 2, Prof Dr. K.B. Parikh 3 1 PG student, Master of Structural Engineering, DIET- Rajkot, Gujarat, India 2 Assistant Professor, Civil Department, DIET-Rajkot, Gujarat, India. 3 Head of Department, Applied Mechanics Department, Government Engg. College, Dahod, Gujarat, India ABSTRACT: In ceramic industry about 5-10% production goes as waste in various processes while manufacturing. (This waste percentage goes down if the technology is installed in the new units.) This waste of Ceramic Industries dumped at nearby places resulting in environmental pollution causing effect to habitant and agricultural lands. Therefore using of ceramic waste powder in concrete would benefit in many ways in saving energy & protecting the environment. The cost of deposition of ceramic waste in landfills will be saved. An attempt has been made to study the behavior of SCC with ceramic waste powder and understands the effect of the mineral admixtures on fresh & hardened properties of SCC and also investigates the compatibility of ceramic waste powders in SCC along with chemical admixture such as super plasticizers. Industrial waste ceramic waste powder would be used in self-compacting concrete. Primary aim of this study is to substitute the cement with ceramic waste powder by 0%,5%,10%,15%,20%,25%,30% and Fly ash 25% by the binder contain of selfcompacting concrete for and M-35 Grade Concrete. For best result the percentage of ceramic waste powder will be decided for fresh and harden property of self-compacting concrete. The project can lead to the use of ceramic waste powder in Self compacting concrete, thus saving landfill and reduce CO2 emission by the use of less cement. Key words: Fly ash (FA), Fresh and Harden property, Durability, Ceramic Waste Powder (CP). 1 INTRODUCTION For all types of industrial and civil engineering buildings the cement concrete has been the best building material. Every years waste material deposited in huge quantity on valuable land. This problem of utilization waste material can be solved up to certain level if people start use of it. Here, they had studied about use of waste Silica Sand as partial replacement of fine aggregate in self-compacting concrete. There is decrease in the strength of concrete due to lack of trained construction labor, increase in the complexity of construction, uncongested design of reinforcement etc. Permeability of concrete is highly influenced by the lack of consolidation therefore decrease in the durability of concrete structures resulting large number of air voids affecting the performance. The invention of Self-compacting concrete (SCC) is considered as the most significant development in the construction industry due to its numerous benefits. 1.2 OBJECTIVES To evaluate the fresh properties of & M-35 (Passing ability, Filling ability and Segregation resistance) of SCC with use of Ceramic Waste Powder 0%,10%,15%,20%,25%,30% and Fly Ash 25% replaced by binder material. To evaluate the harden properties of & M-35 (Compressive strength,split tensile Strength and Flexural test) of SCC with use of Ceramic Waste Powder 0%,10%,15%,20%,25%,30% and Fly Ash 25% replaced by binder material. To evaluate the durability of & M-35 Acid attack with MgSo4 and HCL solution of SCC with use of Ceramic Waste Powder 0%,10%,15%,20%,25%,30% and Fly Ash 25% replaced by binder material. Partially replacement of Cement with Ceramic Waste Powder by weight in Self-Compacting Concrete. 1.3 MATERIALS A. CEMENT IS 12269, 1987 conforming of Ordinary Portland Cement (OPC) of Sanghi 53 grade cement was used. B. FINE AGGREGATE AND COARSE AGGREGATE Fine Aggregate used for study as conforming to zone I of IS: 383, 1987.Fine aggregate size less than 4.75mm. Coarse aggregate size is maximum 20mm used for study as conforming to IS: 383, 1970. FINE AGGREGATES COARSE AGGREGATES Specific gravity 2.56 2.77 Water absorption 1.0% 0.40% Moisture content Nil Nil C. WATER Casting and curing in potable water available in the college was used. D. FLY ASH Class F fly ash which satisfies ASTM C618 & 92a, 1994, obtained from Gandhinagar thermal power station was used for JETIR1606011 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 50
Production of SCC. E. SUPER PLASTICIZER The important admixtures are the SP, used with a water reduction greater than 20%. Admixture conforming to IS 9103. Admixture is most important constitute of SCC to achieving flow ability and passing ability. In this experimental study, Glenium sky 8784 is used. This admixture of older name is Glenium sky 784. F. CERAMIC WASTE POWDER Ceramic waste powder is directly obtained from ceramic wall tiles industries, while finishing process of tiles (sizing). The Fineness of CWP is same like cement used in this experiment. CWP used in this experiment is obtained from WALLSTONE CERAMIC PVT LTD, Morbi. CWP is ready to use waste in place of cement, therefore it can be a cost effective factor. Specific gravity of ceramic waste powder is 2.76. 1.3 Mix Design of Grade Concrete Total Sr. W/P Type of Mix Binder No. ratio 1 2 3 4 5 6 7 Chemical Test Result of Ceramic Waste Powder Sr. No. Test Name Test Result 1 CaO 5.82% 2 SiO2 59.50% 3 Fe2O3 1.12% 4 Al2O3 29.52% 5 MgO 0.26% 6 SO3 0.18% 7 Loss on Ignition 0.90% Cement Fly ash Ceramic powder Coarse aggregate Fine aggregate Water (litre/ ) S.P (1%) VMA (0.25%) MIX-1 (0% CP+ 25% FA) 500 375 125 0 741.69 955.12 180 5 1.25 MIX-2 (5% CP+ 25% FA) 500 350 125 25 741.69 955.12 180 5 1.25 MIX-3 (10% CP+ 25% FA) 500 325 125 50 741.69 955.12 180 5 1.25 MIX-4 (15% CP+ 25% FA) 500 300 125 75 741.69 955.12 180 5 1.25 MIX-5 (20% CP+ 25% FA) 500 275 125 100 741.69 955.12 180 5 1.25 MIX-6 (25% CP+ 25% FA) 500 250 125 125 741.69 955.12 180 5 1.25 MIX-7 (30% CP+ 25% FA) 500 225 125 150 741.69 955.12 180 5 1.25 1.4 Mix Design of M-35 Grade Concrete Sr. No. 1 2 3 4 5 6 Type of Mix W/P ratio Total Binder Fly Cement ash Ceramic powder Coarse aggregate Fine aggregate Water (litre/ ) S.P (1.2%) VMA (0.25%) MIX-1 (0% CP+ 25% FA) 0.35 540 405 135 0 741.69 955.12 191.4 6.48 1.35 MIX-2 (5% CP+ 25% FA) 0.35 540 378 135 27 741.69 955.12 191.4 6.48 1.35 MIX-3 (10% CP+ 25% FA) 0.35 540 351 135 54 741.69 955.12 191.4 6.48 1.35 MIX-4 (15% CP+ 25% FA) 0.35 540 324 135 81 741.69 955.12 191.4 6.48 1.35 MIX-5 (20% CP+ 25% FA) 0.35 540 297 135 108 741.69 955.12 191.4 6.48 1.35 MIX-6 (25% CP+ 25% FA) 0.35 540 270 135 135 741.69 955.12 191.4 6.48 1.35 JETIR1606011 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 52
7 MIX-7 (30% CP+ 25% FA) 0.35 540 243 135 162 741.69 955.12 191.4 6.48 1.35 1.5 RESULTS OF FRESH PROPERTIES OF M30 & M35 GRADE CONCRETE A. Fresh Properties of & M-35 Grade Concrete Sr. No. 1 2 3 4 5 6 7 Type of Mix (0% CP + 25% FA) (5%CP + 25% FA) (10%CP + 25% FA) (15%CP + 25% FA) (20%CP + 25% FA) (25%CP + 25% FA) (30%CP+25%FA) Slump (mm) 650-800 mm V-Funnel (sec) M-35 L- Box J-Ring Slump V-Funnel (h2/h1) (mm) (mm) (sec) 0 to 650-800 10mm mm 8-12 sec. 0.8-1 L- Box (h2/h1) 8-12 sec. 0.8-1 J-Ring (mm) 0 to 10mm 655 10.8 0.82 9.5 690 11.2 0.86 9.1 665 10.5 0.84 9.3 710 10.5 0.88 8.9 675 9.6 0.86 9.1 725 9.2 0.89 8.7 685 9.1 0.89 8.8 730 8.8 0.91 8.4 690 8.8 0.91 8.5 735 8.7 0.92 8.1 705 8.4 0.93 8.3 745 8.1 0.94 7.8 710 8.2 0.94 8.1 750 7.9 0.96 7.7 Fig. 1.5(a) SLUMP TEST Fig. 1.5(b) V-FUNNEL TEST JETIR1606011 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 53
Fig. 1.5(c) L-BOX TEST Fig. 1.5(d) J-RING TEST 1.6 RESULTS OF HARDENED PROPERTIES OF M30 & M35 GRADE CONCRETE A. Compressive Strength of & M-35 Grade Concrete Compressive Strength of cubes in MPa Sr.No. Type Of Mixes M-35 7 days 14 days 28 days 7 days 14 days 28 days 1 Mix-1(0%CP+25%FA) 28.89 35.78 43.78 31.56 39.56 48.89 2 Mix-2(5%CP+25%FA) 27.56 34.00 42.00 30.67 38.22 47.78 3 Mix-3(10%CP+25%FA) 25.78 31.11 38.67 29.78 36.67 45.33 4 Mix-4(15%CP+25%FA) 23.33 28.44 36.89 28.22 34.22 43.11 5 Mix-5(20%CP+25%FA) 22.89 27.56 34.67 25.56 32.44 40.67 6 Mix-6(25%CP+25%FA) 20.44 25.33 32.00 24.44 31.78 38.89 7 Mix-7(30%CP+25%FA) 19.33 24.22 31.56 22.89 30.22 37.56 Fig. 1.6(a) Compressive Strength () Fig. 1.6(b) Compressive Strength (M-35) B. Flexural Strength of & M-35 Grade Concrete Flexural Strength of beam in MPa Sr.No. Type Of Mixes M-35 7 days 14 days 28 days 7 days 14 days 28 days 1 Mix-1(0%CP+25%FA) 2.80 3.45 4.26 3.19 3.95 4.87 2 Mix-2(5%CP+25%FA) 2.68 3.27 4.05 2.97 3.62 4.66 3 Mix-3(10%CP+25%FA) 2.34 2.91 3.75 2.74 3.47 4.41 4 Mix-4(15%CP+25%FA) 2.20 2.72 3.46 2.63 3.26 3.98 5 Mix-5(20%CP+25%FA) 1.91 2.48 3.18 2.52 2.95 3.70 JETIR1606011 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 54
6 Mix-6(25%CP+25%FA) 1.76 2.27 2.93 2.34 2.77 3.42 7 Mix-7(30%CP+25%FA) 1.54 2.13 2.38 2.15 2.43 3.25 Fig. 1.6(c) Flexural Strength () Fig. 1.6(d) Flexural Strength (M-35) C. Split Tensile Strength of & M-35 Grade Concrete Split Tensile Strength of Cylinder in MPa Sr.No. Type Of Mixes M-35 7 days 14 days 28 days 7 days 14 days 28 days 1 Mix-1(0%CP+25%FA) 2.53 3.01 3.85 2.88 3.54 4.32 2 Mix-2(5%CP+25%FA) 2.27 2.78 3.58 2.67 3.15 3.95 3 Mix-3(10%CP+25%FA) 2.03 2.56 3.26 2.39 2.91 3.72 4 Mix-4(15%CP+25%FA) 1.86 2.35 3.06 1.96 2.30 2.97 5 Mix-5(20%CP+25%FA) 1.53 1.98 2.78 1.82 2.28 2.72 6 Mix-6(25%CP+25%FA) 1.31 1.58 2.59 1.64 2.05 2.53 7 Mix-7(30%CP+25%FA) 1.16 1.29 2.23 1.28 1.75 2.30 Fig. 1.6(e) Split Tensile Strength () Fig. 1.6(f) Split Tensile Strength (M-35) JETIR1606011 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 55
1.7 DURABILITY TEST RESULTS A. Average Loss of Comp. Strength of Grade Concrete Due to Acid & Base Attack Test Average loss of Comp. Strength (%) For Grade Concrete Sr.No. Type Of Mixes ACID ATTACK(HCl) SULPHATE ATTACK(MgS ) 7 days 28 days 91 days 7 days 28 days 91 days 1 Mix-1(0%CP+25%FA) 2.15 5.63 13.37 2.34 6.1 14.41 2 Mix-2(5%CP+25%FA) 1.98 4.37 12.35 2.1 5.9 13.57 3 Mix-3(10%CP+25%FA) 2.73 5.9 14.73 2.71 6.72 15.56 4 Mix-4(15%CP+25%FA) 3.01 5.43 15.23 3.21 5.95 16.83 5 Mix-5(20%CP+25%FA) 2.56 5.86 14.19 3.47 7.57 15.91 6 Mix-6(25%CP+25%FA) 3.15 6.71 15.86 3.56 6.43 17.15 7 Mix-7(30%CP+25%FA) 2.97 7.26 16.61 2.77 7.33 16.65 B. Average Loss of Comp. Strength of M-35 Grade Concrete Due to Acid & Base Attack Test Average loss of Comp. Strength (%) For M-35 Grade Concrete Sr.No. Type Of Mixes ACID ATTACK(HCl) SULPHATE ATTACK(MgS ) 7 days 28 days 91 days 7 days 28 days 91 days 1 Mix-1(0%CP+25%FA) 2.69 5.86 15.17 2.27 6.83 15.24 2 Mix-2(5%CP+25%FA) 1.87 5.31 13.68 1.86 6.32 12.96 3 Mix-3(10%CP+25%FA) 2.32 6.84 14.47 2.51 7.18 14.62 4 Mix-4(15%CP+25%FA) 3.27 5.48 16.82 3.21 6.55 13.66 5 Mix-5(20%CP+25%FA) 2.95 6.22 16.13 3.05 6.84 17.43 6 Mix-6(25%CP+25%FA) 3.18 6.77 15.9 2.91 7.31 16.16 7 Mix-7(30%CP+25%FA) 3.43 7.14 17.77 3.58 7.69 18.57 Fig. 1.7(a) AVERAGE LOSS IN % VARIATION FOR 7- DAYS Fig. 1.7(b) AVERAGE LOSS IN % VARIATION FOR 28-DAYS JETIR1606011 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 56
Fig. 1.7(c) AVERAGE LOSS IN % VARIATION FOR 91-DAYS 1.8 CONCLUSION Various tests were carried out on different mixes of concrete containing ceramic powder and fly ash along with control mixes in self compacting concrete. Based on experimental investigation, following observations are made on the fresh property, hardened properties and durability of SCC : The Use of Ceramic powder and fly ash by substitution to binder has no negative effect on Fresh Properties of SCC. In Slump flow test, the result shows that by replacing the ceramic powder to 10% by binder contain there will be increase in the slump flow by 3.05% in and 5.07 % in M-35 Grade of Concrete. In V-Funnel Test, the result shows that by replacing the ceramic powder to 10% by binder contain there will be decrease in the time of V-Funnel test by 11.11% in and 17.85% in M-35 Grade of Concrete. In L-Box test, the result shows that by replacing the ceramic powder to 10% by binder contain there will be increase in the ratio (H2/H1) of L-box test by 4.88% in and 3.49 % in M-35 Grade of Concrete. In J-Ring Test, the result shows that by replacing the ceramic powder to 10% by binder contain there will be decrease in the height of concrete of J-Ring test by 4.21% in and 4.4% in M-35 Grade of Concrete. In Hardened property such as Compressive strength, Flexural strength and Split tensile, there is decrease in the strength of SCC with increase in the percentage of ceramic waste powder. In Hardened property such as Compressive strength, Flexural strength and Split tensile strength would be put together, Ceramic powder can apply up to 10% and Fly ash 25% to achieve target mean strength of concrete. In Durability test using HCL Solution and MgSO4 Solution in and M-35 grade of concrete, Results for 7 Days, 28 Days and 91 Days shows that there is minimum average loss of compressive strength in percentage of decreasing at Mix 2(5% Ceramic powder and 25% fly ash) in self-compacting concrete. Than significantly increase in the average loss of compressive strength percentage at 15%, 20%, 25% and 30% ceramic powder and 25% fly ash. 1.9 REFERENCES [1] A.S.E. Belaidi, L Azzous, E. Kadri, S. Kenai, Effect of natural pozzolana and marble powder on the property of the self-compacting concrete Construction building material, January 2011. [2] Bouziani Tayeb Benmounah Abdelbaki, Bederina madani and lamara Mohamed, Effect on marble powder on the properties of self-compacting sand concrete, Construction and building technology journal, 2011, 5, 25-29. [3] B.H.V. Pai, M. Nandy, A. Krishnamoorthy, P.K Sarkar, Philip George, Comparative study of self-compacting concrete mixes containing fly ash and rice husk ash, American journal of engineering research (AJER), 2014 [4] Dhiyaneshwaran, Ramanathan, Baskar and Venkatasubramani, Study on durability of self-compacting concrete with fly ash, Jordan journal of civil engineering, 2013 JETIR1606011 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 57
[5] EFNARC. 2002. Specification and guidelines for self-compacting concrete. European Federation of Producers and Applicators of Specialist Products for Structures. [6] Ilker Bekir Topçu, Turhan Billir Tayfun Uygunoglu, Effect of waste marble dust content as filler on properties of selfcompacting concrete Construction and building material, September 2008. [7] Bernardinus Herbudiman, Adhi Mulyawan Saptaji (Elsevier-2013) Self-Compacting Concrete with Recycled Traditional Roof Tile Powder [8] Khalid Najim, Ibrahim Al-Jumaily, Abdukhaliq Atea, (Elsevier, November-2015) Characterization of Sustainable High Performance/Self-Compacting Concrete Produced Using CKD as a Cement Replacement Material [9] Muhd Fadhil Nuruddin, Kok Yung Chang, Norzaireen Mohd Azmee (Elsevier, December- 2014) Workability and Compressive Strength of Ductile Self Compacting Concrete (DSCC) With Various Cement Replacement Materials [10] Chaijun Shi, Zemei Wu, KuiXi Lv, Linmei Wu (Elsevier, March-2015) A Review on Mixture Design Method for Self Compacting Concrete [11] IS: 456-2000 Plain and reinforced Concrete-Code of Practice, Fourth Revision, and July-2010, BIS, New Delhi. [12] IS: 10262-1982 Recommended Guidelines for Concrete Mix Design, Fifth Reprint, and March-1998, BIS, New Delhi [13] IS: 10262-2009, Concrete Mix Proportioning Guidelines, First Revision, July-2009, BIS, New Delhi [14] Okamura H, Ozawa K. 1994. Self-compactable high performance concrete in Japan. In International Workshop on Highperformance Concrete. 1-16. [15] Okamura H, Ouchi M. 2003b. Self-compacting concrete. Journal of Advanced Concrete Technology 1(1):5-15. [16] Okamura H, Ozawa K. 1995. Mix design for self-compacting concrete. Concrete Library of Japanese Society of Civil Engineers 25(6):107-120. [17] Okamura H. 1997. Self-compacting high-performance concrete. Concrete International 19(7):50-54. [18] Okamura H, Maekawa K, Ozawa K. 1993. High performance concrete. Giho-do Press, Tokyo. [19] Okamura H, Ouchi M. 1999. Self-compacting concrete development, present use and future. In: The 1st International RILEM Symposium on Self. [20] Okamura H, Ouchi M. 2003a. Applications of self-compacting concrete in Japan. In: The 3rd International RILEM Symposium on Self-Compacting Concrete. Wallevik OH, Nielsson I, editors, RILEM Publications S.A.R.L., Bagneux, France. 3-5. [21] Krishna Murthy, Narasimha Rao A V, Ramma Reddy I Vand, Vijay Sekhar Reddy M Mix design procedure for selfcompacting concrete IOSR Journals of Engineering 2(9), 2012, 33-41. [22] Liana Iures and Cornelu Bob, The future concrete: Self-compacting concrete, 2010 [23] M. S. Shetty, Concrete Technology (Theory and Practice), S.Chand & Company Limited, New Delhi, Seventh Edition, July-2012. [24] A M Neville, Properties of Concrete, Pearson Education, Published in India By Dorling Kindersley India Private Limited, Fourth Edition, 2007 JETIR1606011 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 58