Sustainable use of industrial waste materials as raw material replacement in lightweight concrete

Sustainable Use of Industrial Waste

Raw Material Replacement in Lightweight Concrete

Piti Sukontasukkul, PhD Prof., KMUTNB, Thailand

Vice President, TCA, Thailand

Concrete is Everywhere in Thailand

From local production to plant production

From bucket to chute, to pump, and to precast

From small units to large and complex units

Clinker and Cement Production

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Portland Cement 16.0 17.5 19.6 19.1 20.9 23.7 25.6 22.1 20.2 21.1 23.4 23.5 27.9

Mixed Cement 8.96 10.0 11.1 12.5 14.0 13.3 12.9 11.5 10.9 10.3 10.5 10.3 10.3

Clinker 28.6 32.6 37.5 32.9 35.3 38.7 40.9 40.7 38.1 37.6 38.8 37.8 39.8

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5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

Qu

an

tity

(m

illi

on

to

ns)

Cement Production- Thailand

Source: The office of Industrial

Workshop on Concrete Sustainability, Kagawa University, Japan

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Portland Cement 9.31 10.1 12.9 13.6 16.0 17.7 17.8 15.9 15.1 15.4 17.4 18.1 21.1

Mixed Cement 7.91 8.40 9.39 9.99 11.1 11.3 11.3 9.63 9.03 9.20 9.36 9.92 10.2

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5.00

10.00

15.00

20.00

25.00

Qu

an

tity

(m

illi

on

to

ns)

Domestic Usage

Source: The office of Industrial

Concrete Consumption

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Ready-mixed Concrete

5.14 7.52 8.91 9.61 12.2 11.4 10.8 10.6 11.0 10.5 10.8 11.0 13.4

0

2

4

6

8

10

12

14

16Q

uan

tity

(mil

lion

cu

.m)

Ready-mixed Concrete

Source: The office of Industrial Economy

Limestone Reserve and Consumption

At the current consumption rate of 145 million tons per year, the available resource will run out in 21.2 years

PROPERTIES OF CONCRETE MIXED WITH LIGHTWEIGHT AGGREGATES FROM INDUSTRIAL WASTE

Source of Aggregates

Aluminum Waste

Aerated Block Manufacturing Waste

Abandoned Tires

Aggregate Properties

Aggregate - Crumb Rubber (CR)

Physical Properties

Specific Gravity (Dry) 0.96

Specific Gravity (SSD) 0.97

Specific Gravity (Apparent) 0.97

Absorption (%) 0.92

Fineness Modulus 4.93

Composition

Natural Rubber 23.1%

Synthetic Rubber 17.9%

Carbon Black 28.0%

Ash Content 5.1%

Others 16.5%

Aggregate - Aerated Block Waste (AB)

Dry Specific Gravity 0.75 kg/cu.m

SSD Specific Gravity 1.27 kg/cu.m

Absorption 71 %

Compressive Strength >3 MPa

Modulus of Rupture 0.45 MPa

Elastic Modulus 1530 MPa

Aggregate -Aluminum Waste (AW)

Dry Specific Gravity 0.73

Bulk Specific Gravity 1.08

SSD Specific Gravity 1.25

Percent Void 72 %

Percent Absorption 16 %

GENERAL APPLICATIONS

Concrete Properties-Specific Gravity

Concrete Properties: Percentage Absorption

Compressive Strength

Flexural Strength

SOUND AND THERMAL APPLICATIONS

Aerated Waste Concrete Panel

Aluminum Waste Concrete Panel

Crumb Rubber-Rubberized Concrete

Thermal Insulation Applications

Paraffin Impregnated in Aggregate (PIA) from

Aluminum Waste

Degree of Impregnation vs. Time

Thermal Properties of Concrete Panel mixed with PIA

MILITARY APPLICATION

Ability to Absorb Energy of

Rubberized Concrete

Low strength but high energy absorption

Rubberized Concrete as a Cushion Layer for Bulletproof Concrete Panel

T1

T2

Rubberized Concrete

Steel Fiber Reinforced Concrete

Failure Patterns : Double Layer Panel

Typical Failure Patterns Partially Energy Dissipation

Ideal Failure Patterns Full Energy Dissipation

Typical Acceleration Response SFRC (9 mm)

Typical Acceleration Response Double Layer (9 mm Bul.)

Comparison

Single Layer Plate Double Layer Plate Responding time: Slower in Double layer plate

Acceleration Value: Lower in Double layer plate

Conclusion • In order to sustain our natural resource availability and

prolong its depletion, the search for alternative materials for concrete production is necessary.

• The use of industrial waste to produce aggregates not only can reduce waste and pollution, it also can help reduce the use of virgin materials (slow down natural resource depletion).

• Some industrial wastes may not exhibit good mechanical properties to suit structural purposes, BUT there are some properties that allow them to be used extremely well on other applications such as sound and thermal insulation, or even bulletproof panel.

Thank you Prof. Koji Sakai for 15 years of friendship