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EVALUATION OF STRENGTH OF RCA USING TBC WITH FLY ASH AND GGBFS |

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY 1

CHAPTER 1 INRODUCTION

1.1 GENERAL

Construction activities in India are growing very fast as the construction and

demolition wastes are also produced in very large amount. As per survey, about millions

ton of construction and demolition wastes are generated worldwide. In India, construction

industry generates about 10 to 20 million tons of wastes every year and which will

become more and more every year. So, it becomes a severe problem because it is

hazardous to the surrounding environment and it can damage the nature cycle. It is

important to recycle such wastes to protect the nature and for reuse the material. By

which, the demand of natural material is minimize and the conservation of natural

resources is very important factor. By the reuse of wastes, the disposition land also

minimized.

The recycled aggregates obtained from the demolition of roads, buildings,

masonry walls, abutments, dams, piers, sub base foundation etc. In this study, without

changing the strength and other properties the use of recycled coarse aggregate in

concrete with the replacement of natural coarse aggregate.

It will be known that the concrete industry largely gives its share to the

environment impoverishment. Aggregates are the bigger components of concrete and

have a effective behavior on the engineering properties of final product. Natural

resources are very damaged by its maximum use due to increasing the demand of

structures. The use of such waste Construction and demolition (C & D) as alternative

aggregates for new concrete production gains priority to preserve natural resources and

reduces the need for disposal. These wastes are normally composed from rubbles,

concrete , tiles, bricks, sand, timber, dust and plastics, cardboard, metals and paper. From

all such waste concrete, rubble contributes more proportion.



Figure 1.1 Percentage of C & D waste

The maximum use of recycled materials among components of concrete is a very

remarkable approach towards sustainable construction. Aggregates results almost 80% of

concrete quantity, i.e. their replacement with recycled materials can really help to

transform ordinary concrete into an effective and sustainable material. So, the strength is

directly connected to the quality of recycled aggregate in Recycled Aggregate Concrete

(RAC).

1.2 Usefulness of Cementitious Material

There was estimate that production of cement was about 3 billion tons in 2009

and the extended production of cement is about 5.9 billion tons by 2020. Cement industry

is one of the major cautions of pollution and it takes a lot of energy in the production and

returns major quantities of carbon dioxide. As per a survey report 7% of worlds carbon

dioxide emission is only given by cement industry. Manufacture of Ordinary Portland

Cement (OPC) consumes natural resources i.e. limestone and there is a very need to

economize the use of cement. The use of various cementitious materials in the concrete

mixtures has been growing in the world. These materials are byproducts of other

industrial processes and their judicial use is not desirable only for the natural

20%

35% 10%

12%

8%

3%

12%

Major Component of Construction Waste

Concrete

Brick & Plaster

Soil

Wood

Plastic

Steel

Others



environment and energy conservation point. Although, they may be used as partial

replacement or in addition to Portland cement in concrete which depends on the

properties of the materials and the expected effect on concrete.

1.3 Theory of Ternary Blended Concrete

The replacement of cement will do by using GGBFS (by product of Iron plant)

and fly ash (byproduct of thermal power plant), which are cementitious materials. Both

products are ecofriendly. The combination of GGBFS and fly ash with cement cancelled

ternary blended concrete (TBC).

1.4 Quality of Recycled Aggregate (RA)

After current year the consumption of natural aggregates in the whole world are in

the criteria of 48.3 billion metric tons. The demolition of relatively young structures (for

approximately 15 years old or less), because their working features, does not fulfill any

longer new social and technical requirements. This kind of waste represents a better

selection for recycled high-grade concrete in new concrete structures. By this method,

made cement concrete can be broken during demolition and can be crushed into a coarse

granular segments that can be used as a substitute for crushed virgin rock. The adhered

mortar quality and its amount affects the physical properties of recycled aggregates. As it

especially depends on Adhered mortar ,which is a porous material and its porosity

depends upon the water/cement ratio (w/c) and mix design that originally adopted. The

quality of such kind of concrete is inversely proportional to the size of the aggregate.

Because of the adhered mortar and recycled aggregate concrete have a higher water

absorption and lower density, compared to natural aggregates.

1.5 Application of Recycled Aggregate Concrete in TBC

TBCs behavior with the combination of recycled coarse aggregate with the

percentage variation to obtain the desired strength. Such type of concrete is economical

and also increase in the demand of eco-friendly products and reuse of material waste. In



our country, the use of such type of concrete is in very small extent but environmental

point of view it will useful in every places.



CHAPTER 2 LITERATURE REVIEW

2.1 Description of Literature Survey Papers

1. Author: A.N.Dabhade, Dr.S.R.Choudhari, Dr.A.R.Gajbhiye

Objectives of study: At present, Reuse of waste concrete aggregate is easily available.

Conventional Coarse aggregate is changed with recycled aggregate and conventional.

Here, No. of test conduct like water absorption, workability test, impact value test,

Fineness modulus, compressive test, split tensile test, crushing value test, and bulk

density.

Methodology: There were concrete mixes no. of batches consists of every 20%

increment of recycled aggregate replacement from 0% to 100%.0.5,0.6 and 0.7

water/cement ratio are examined. The amount of recycled aggregate increased which

reduce workability of concrete.

Outcome of study: From the research, 100% RCA replace with NA can possible. And

effective ratio of RCA can be 40%.By using 40% of RA for making M20 grade concrete

of 0.5 w/c ratio and 20% replacement is efficient for 0.6 and 0.7 w/c ratio.

The strength of concrete depend upon percentage of RA when percentage

increases than the strength of concrete will decrease. More water use as admixture

required for using RA. It also help to reduce damage of our natural landscape.

The compressive strength of recycled concrete depend upon w/c ratio. At lower

w/c ratios, the compressive strength of recycled concrete is much lower than that of

normal concrete and also higher w/c ratio give similar strength of conventional concrete.

2. Author: Praveen Mathew, Jeevan Jacob, Leni Stephen, Thomas Paul

Objectives of study: In this study, Natural aggregate replaced by recycled aggrades, after

is examined behavior concrete for its structural property. Compressive strength, splitting

tensile strength, flexural strength and modulus of elasticity of recycled aggregate concrete



(RAC) such as were examined. This gives a correct perception of RAC comparison with

the natural aggregate concrete (NAC) which used as a structural material.

Methodology: The mix ratio was done as per the Indian standards. The Portland

Pozzolana cement is used with specific gravity 2.6.The mechanical properties of

conventional concrete and RAC and concluded that the RAC has a compressive strength

of at least 76% and modulus of elasticity from 60% to 100% of the control mix. The

strength of recycled aggregate concrete is affect by the strength of original concrete,

percentage of coarse aggregate in original concrete and the ratio of top size of aggregate

in original concrete to that of recycled aggregate. After examined that full replacement of

natural aggregates with recycle coarse aggregate, a part replacement that offers a better

structural property in comparison with the conventional concrete. Here no. of

replacements were selected i.e. 0% (NAC), 20% (RAC 20), 30% (RAC 30) and 40%

(RAC 40) to behavior the various tests on its property.

Outcome of study:

Workability and modulus of elasticity will be decreased and also

mechanical properties will be increased by using the w/c ratio 0.45 and increment the

percentage of RAC. Various properties of RAC were comparing with NAC. At 30%

replacement of RAC obtained maximum strength. In this research, at 40% replacement

obtained maximum strength.

3. Author: Prof. D.K. Bhagat, J.P. Parmar, Y.R. Tank, D.H. Gadhiya, J.S. Goyani

Objectives of study: Material properties for concrete of M25 grade made with various

percentages of recycled coarse aggregates with replacement percentage of 0, 20, 40 and

60. The basic properties like workability and compressive strength etc. observe with

NAC with RCA. The goal of this study is to develop the economical and sustainable

concrete by using the concrete waste available on the site.

Methodology: Waste was collecting the near gitanjali cinema to Surat. After material

was crush by hammer to separate the aggregate and to reduce their sizes in small fraction.

As per Indian Standard Codes various tests were conducted on separated aggregate and



also results were compared to Natural aggregate. Concrete basic properties like

compressive strength, workability test was evaluated on various combinations (0%, 20%,

40%, 60%) of RCA with NA. M25 grade mix was designed as per IS 10252:2009.

Outcome of study: The water absorption of RCA concrete increased with increase in

replacement of NCA with RCA because od adhering mortar and cement paste. Specific

gravity of RCA compare to less the NA. The results of compressive strength, the use of

RCA up to 40% affect the functional requirements of concrete structure. Also the results

of slump test continuous decrease in workability of concrete mix, as the cement mortar

paste is attached to RCA.

4. Author: S.P.S.RAMYA, A.M.N.KASHYAP

Objectives of study: Concrete when subjected to severe environments its durability can

significantly decline due to degradation. Degradation of concrete structures by corrosion

is a serious problem and has major economic implications. In this study, an attempt has

been made to study the durability of concrete using the mineral admixtures like Fly Ash

& Ground Granulated Blast Furnace Slag (GGBS) for M30 grade concrete.

Methodology: In this study, an attempt has been made to study the durability of concrete

using the mineral admixtures like Fly Ash & Ground Granulated Blast Furnace Slag

(GGBS) for M30 grade concrete. Cube specimens were casted and are immersed in

normal water, sea water, H2SO4 of various concentrations and were tested after 7 days,

28 days & 60days.

Outcome of study: The results of fly ash and GGBS concretes when replaced with 20%

of cement are more than compared to 100% cement at the end of 7 days, 28 days and 60

days for normal water curing. In sea water curing the GGBS when replaced with 20% of

cement shows good response for durability criteria. In 1% H2SO4 solution curing the Fly

Ash when replaced with 20% of cement shows good response for durability criteria.



5. Author: K. Suvarna Latha, M V Seshagiri Rao, Srinivasa Reddy. V

Objectives of study: The present paper is an effort to quantify the strength of ground

granulated blast furnace slag (GGBS) and high volume fly ash (HVFA) at the various

replacement levels and evaluates their efficiencies in concrete. In recent years GGBS

when replaced with cement has emerged as a major alternative to conventional concrete

and has rapidly drawn the concrete industry attention due to its cement savings, energy

savings, and cost savings, environmental and socio-economic benefits.

Methodology: The present study reports the results of an experimental study, conducted

to evaluate the strengths and strength efficiency factors of hardened concrete, by partially

replacing the cement by various percentages of ground granulated blast furnace slag and

high volume fly ash for M20, M40 and M60 grades of concrete at different ages. Here an

effort is made towards a specific understanding of the efficiency of GGBS and HVFA in

concrete, considering the strength to water cement ratio relations, age and percentage of

replacement. The optimum GGBS and HVFA replacement as cementations material is

characterized by high compressive strength, low heat of hydration, resistance to chemical

attack, better workability, and good durability and cost-effective.

Outcome of study: The partial replacement of cement with GGBS and HVFA in

concrete mixes has shown enhanced performance in terms of strength and durability in all

grades. This is due to the presence of reactive silica in GGBS and HVFA which offers

good compatibility. Replacement of 40% HVFA and GGBS give good strength in all

grade.

2.2 Summary of Literature Review

In concrete, Replacement of Recycled Coarse Aggregate up to 100% is

possible.

To achieve equal strength as compare to ordinary concrete by using the

industrial products.



Cementitious material like Fly Ash, GGBFS reduces cement content in

concrete and improves workability without change in strength.

There is not any maximum difference between fresh properties recycle coarse

aggregate up to 40% with natural aggregate.

Up to 40% replacement of Recycled Aggregate Concrete (RAC) the hardened

properties of concrete will remain same.

With uses of Recycled Coarse Aggregate (RCA) and the higher dosages of

super plasticizer are required to maintain workability in High Strength

Concrete.

.



CHAPTER 3 RESERCH OBJECTIVE

3.1. Cementitious materials

3.1.1 Cement

As being the Binder of the concrete, the cement is. Water by the binds the

aggregates and cement. Here use the OPC 53 grade cement of ultra tech. Cement is

greenish grey colour with a fine powder.

The physical properties of the cement of 53 grade of Ordinary Portland

Cement are given below as per to IS 1489(part 1) 1991, IS 12269 1987.

Table 3.1 Physical Properties of OPC of ULTRATECH CEMENT

TEST RESULT

Initial setting time 180 min

Final setting time 310 min

Compressive strength 3 days 27.50 N/mm2

7 days 37.70 N/mm2

28 days 53.5 N/mm2

Soundness 5.2 mm

Fineness (90 um sieve) 1.7 %

Standard consistency 29.75 %

Specific gravity 3.15

3.1.2 Fly ash

In the modern power stations of India, The production of fly ash is good

quality as it contains a very low proportion of unburnt carbon for the less loss of ignition

and low sulphur. In new thermal power stations, there is the modern type of arrangement

of dry fly ash evacuation and storage systems available. In this type of system, fly ash



from Electrostatic Precipitators [ESP] is then evaluated by the pneumatic system and

being stored in silos and then it may be transported by using truck or tankers or it can be

shifted through suitable bagging machine.

Various usage of fly ash

To manufacture the Portland Pozzolana Cement [PPC] and to improve the

performance of Ordinary Portland Cement [OPC].

To replace of OPC cement concrete partially.

To produce high volume concrete.

To Make Roller Compacted Concrete which will be used for dam and

pavement construction.

For Manufacture of Ash bricks and other building products, etc.

In the Construction of road embankments, structural fills in low-lying area

development.

To use as a soil amender in agriculture and wasteland development.

The major components of fly ashes are silica (Sio2), alumina (Al2O3),

ferric oxide (Fe2O3) and calcium oxide (CaO). The other minor components are MgO,

Na2O, K2O, SO3, MnO, TiO2 and unburnt carbon. The proportion of principal component

is Silica [2560%], Alumina [1030%]and Ferric oxide [525%]. The some of these

components is 70% or more and the reactive Calcium oxide is less than 10% then the fly

ash is considered as siliceous fly ash or class F fly ash. Such type of fly ash will be

produced by burning of the bituminous coal and it possesses the Pozzolanic properties. If

the sum of these three components is equal to or more than 50% and reactive calcium

oxide is not even less than 10%, then the fly ash will be considered as Calcareous fly ash

also called class C fly ash.

Here Class F fly ash use which is obtained from Gandhinagar thermal

power station was use in concrete. Fly ash is light grey in colour. The chemical property

of fly ash was obtained by Stallion Energy Pvt. Ltd. From Rajkot.



Table 3.2 Physical Properties of Fly ash

1 Specific Gravity 2.1

Table 3.3 Chemical Properties of Fly Ash [class-F]

Sr.

No.

TEST UNIT OBTAINED

RESULT

1 Loss on ignition % 20

Figure 3.1 Fly Ash [class F]



3.1.3 Ground granulates blast furnace slag (GGBFS or GGBS):

GGBFS or GGBS is product by the iron production process in a blast

furnace. Raw material like iron ore, coke and limestone are heated to about 1500C, blast

furnace melt in these material, there are produce molten slag and molten iron. The molten

slag is floats and lighter. So, molten slag is top on molten iron. Molten slag has alumina

and silicates in form original iron ore and also combined with some oxides from

limestone.

In India, produce 7.8 million tons of blast furnace slag. In India mostly use

of GGBFS in manufacturing of slag cement. In Britain, every year over 2 million tons of

GGBFS is used. GGBFS will add to the cement to increase properties like compressive

strength, bond strength. A main advantage of ggbfs is less heat of hydration and also

requires less water. High replacement with cement is possible. At present year in India

mostly use of ggbfs in RMC. GGBFS also resist the alkali-silica reaction. GGBFS also

attack the chemical resistance like sulphate resistance, chloride ion resistance. GGBFS

also give more strength for long period. GGBFS mostly use in high grade of concrete.

Low water/cement ratio in use of ggbfs gives the better strength. GGBFS also improved

the resist of fire. GGBFS also give improved surface finish. By the addition of ggbfs,

reduce the permeability of concrete, high resist chloride penetration and also high

workability.

The following table is the physical and chemical properties of GGBFS or

GGBS represent and off white in colour. A chemical property of GGBFS results was

achieved from the Stallion Energy Pvt. Ltd. from Rajkot.

Table 3.4 Physical Properties of GGBFS or GGBS

1 Specific Gravity 2.85



Table 3.5 Chemical Properties of GGBFS or GGBS

Sr

No.

Test Result

Obtained

Requirement as per

IS- 12089-1987

1 Insoluble Residue (%) 0.51 5(Max)

2 Magnesia Content (%) 8.21 17(Max)

3 Sulphide Sulphur (%) 0.59 2(Max)

4 Sulfate Content (%) So3 0.22 -

5 Loss on ignition (%) 0.75 3.00(Max)

6 Maganese Content (%) 0.3 5.5(Max)

7 Chloride Content (%) 0.009 -

8 Moisture Content (%) 0.005 -

9 Glass Content (%) 96 85(Min)

Figure 3.2 GGBFS or GGBS



3.2 Natural Coarse Aggregate

Figure 3.3 Natural Coarse Aggregate

Aggregates were passing from 20mm sieve and retained from 4.75mm sieve use

as coarse aggregate. The following are the physical properties of natural aggregates,

Table 3.6 Sieve analysis of coarse aggregate

Sieve size

(mm)

Weight retain

(gms)

Cumulative

weight retain

(gms)

Cumulative

percentage

weight retain

(%)

Cumulative

percentage

weight

passing

40 0.00 0.00 0.00 100

20 410 410 8.2 91.8

10 4360 4770 95.4 4.6

4.75 165 4935 98.7 1.3



Table 3.7 Physical Properties of Natural Coarse Aggregate

Test Natural Coarse Aggregates

Specific Gravity 2.75

Water Absorption 1.40%

Moisture Content NIL

Impact Strength 10.66%

Aggregate Crushing Value 20.46%

Flakiness Value 22.18%

Elongation Value 21.26%

Abrasion Value 13.36%

3.3 Recycled Coarse Aggregate

After completing the age of building will be demolished. After the demolition the

coarse aggregate are separated from the demolition waste and the reuse of this aggregate

as a coarse aggregate in the concrete is called recycled coarse aggregates.

Maximum 20mm and minimum of 4.75mm size of aggregates use. Recycled

concrete aggregate which has been sourced from a number of demolition concretes will

have greater variability than recycled concrete aggregate from one demolition concrete

source and this is likely to have an effect on the uniformity of the physical properties of

crushed concrete differ from those of conventional concrete. In general, the crushed

concrete particles are more angular have a rougher texture surface than those of natural

aggregate. Roughly texture, angular and elongated particles require more water to

produce workable concrete than smooth rounded compact aggregate. These material were

obtained from a building which was more than 30 years old.



Table 3.8 Physical Properties of Recycled Coarse Aggregate

Properties Recycled Coarse Aggregates



Moisture Content 1.08%

Impact Strength 20.36%

Crushing Value 25.10%

Abrasion Value 17.20%

Figure 3.4 Recycled Coarse Aggregate

Chemical properties of the recycled concrete aggregate are more important because the

history of the demolition concrete is unlikely would know. For remaining concrete,

because of the properties of the parent concrete adequate to the properties of the natural

aggregate processed by a particular ready mixed concrete plant, there is less uncertainty

about the sulphates, chlorides, and alkali present than for the recycled aggregate concrete.



So, the contaminants are not the issue for remaining concrete aggregates that they are for

the recycled concrete aggregate.

3.4 Natural Fine aggregate

Figure 3.5 Natural Fine Aggregate

The aggregates size should less than 4.75mm is known as fine aggregate. The

followings are the physical properties of natural fine aggregate,

Table 3.9 Physical Properties of Natural Fine Aggregate

Natural Fine Aggregates



Moisture Content NIL



Table 3.10 IS 383-1970 Recommendation for Fine Aggregate

IS Sieve

Designation

Percentage Passing For

Grading

Zone I

Grading

Zone II

Grading

Zone III

Grading

Zone IV

10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 95-100

2.36 mm 60-95 75-100 85-100 95-100

1.18 mm 30-70 55-90 75-100 90-100

600 microns 15-34 35-59 60-79 80-100

300 microns 5-20 8-30 12-40 15-50

150 microns 0-10 0-10 0-10 0-15

3.4.1 Sieve Size Analysis

Use the fine aggregate of specific gravity 2.74 with locally available

natural river sand conforming to grading of IS 383 1970. Then as per weighing total

weight of fine aggregate is 1000 grams.

Figure 3.6 I S Sieve



Table 3.11 Sieve Analysis of Fine Aggregate

Sieve size Percentage passing from

10 mm 100

4.75mm 95%

2.36mm 82.5%

1.18mm 61.7%

600 micron 30.5%

300 micron 11.7%

150 micron 2.3%

As per IS 383:1970, table 4 above percentage of fine aggregate are zone l.

3.5 Recycled Fine Aggregate

Recycled fine aggregate size is less than 4.75 mm. That type recycled fine

aggregate not use in concrete because of that type recycled fine aggregate require

increased water demand, and related consequences.



CHAPTER 4 PROCEEDING OF RECYCLED

AGGREGATE

4.1 Obtaining Process of Recycled Aggregate

4.1.1 Recycled aggregates

Figure4.1 Recycled Coarse Aggregate after process

Such kind of recycled aggregates are produced from the re processing of

construction and demolition (C&D ) waste which constitutes the largest proportion of

C&D waste. After separation from other C&D waste and sieved, a crushed concrete

rubble can be used as a substitute from the natural coarse aggregate in the concrete or as

sub base layer in the pavements.



4.2 Recycling

Material to be recycled

Manually separated debris

Waste stockpiles

Stockpiled products

Coarse friction Intermediate fraction Fine fraction

Figure 4.2: Generalized flow diagram for an aggregates recycling operation

The procedure for recycling aggregate concludes the following process:

A vibrating feeder sort out the hard portions from the inert C&D waste those are

suitable for subsequent recycling;

A jaw crusher used for reducing the sorted material of size 200 mm or smaller

which can be directed by secondary crushers;

Feed hopper

Primary Crusher

Vibrating pan

feeder

Magnetic

separator

Primary screens

Secondary crusher

Magnetic separator

Secondary screens



Magnetic separator, manual picking passage and air separator for the removal of

other impurities before the materials are filled into the secondary crusher;

Secondary crusher similar to cone crusher is useful for processing the clean

materials into sizes smaller than 40 mm;

The vibratory screens are used for separating the crushed recycled aggregate into

the different sizes;

The storage will be provided with the temporary storage of recycled aggregates.

By this facility, it is easier to separate the aggregate with various sizes as 40mm,

20mm and 10mm for coarse aggregate and less than 4.75 mm for fine aggregate.

The recycling plant has adopted the accurate quality control approach. Only

suitable materials [e.g. crushed aggregates] are processed at the plant. Bricks and tiles

will be generally not allowed. The recycled aggregates can be sampled and tested daily.

4.2.1 Recycling Plant

Recycling plants are normally located outside the towns or cities because

of the huge amount of noise pollution from the equipment that are used during recycling

process. The figure given below shows the process which is used in producing the

recycled aggregate, the process starts from the demolished waste from the construction

site, ending in ready recycled aggregate for use.



Figure4.3: Recycling process of demolition waste

Process of recycling

The processes of recycling of C&D wastes are same as production of

natural aggregates, in both processes the same crushers, equipment, screens,

transportation facilities and removal impurities.

There are two types of recycling plants are used widely all over the world:

1. On-site recycling

2. Stationary recycling plant

Both types have a same type of process, The On-site recycling type is

small and movable and it can be located in the demolished site. But the stationary plant is

located in far areas away from towns or cities and urban areas because it is very huge,

noisy and needs proper pavements for carrying heavy loads.

4.2.2 Sources of Recycled Aggregate

Produced from the breakup and crushing of existing Portland

Identify the concrete building for the demolition

Remove all exterior and interior finishes

Mechanically demolished building

Load and transport to crush plant

Crush and separate

Ready with various size



Cement concrete pavement

Concrete structures

There are mainly two sources of demolished concrete

(a). Rigid concrete pavement: In this type of pavement an asphalt concrete

surface is presented on an existing rigid pavement, the asphalt concrete must be removed

before the old Portland cement concrete pavement is first broken up.

(b). Concrete structures: By this procedure to produce the maximum amount of

Portland cement concrete which can be crushed and accepted aggregate in new Portland

cement concrete. All type of the reinforcing steel should be removed from the concrete

during the crushing operation.

4.3 Equipment used in Recycling Process

4.3.1 Break up equipment

There are various type of break up equipment.

4.3.1.1 Portland Cement Pavement break up equipment

(a) Driving hammer. It is the mounting on a motor grader that sticks in the

Portland cement pavement on around 30cm grid patterns.

(b) Horn tooth ripper It is an attached hydraulic excavator. It is used to

remove all the steel reinforcement that remains in the Portland cement pavement.

4.3.1.2 Structural Building breaks up equipment

Following methods had been use to crush the structural building:

(a) Mechanical hydraulic crusher with long boom arm:

By the crusher through the long boom arm system, the concrete and steel

reinforcements are brake. This method is suitable for the dangerous buildings.



(b) Wrecking ball:

The demolition of building will be done by the impact energy of the wrecking ball

that suspended from the crawler crane.

(c) Implosion.

Locating the placement of explosive properly and the building collapse in a safe

manner have to develop.

4.3.1.3 Crushing Plant equipment

Primary Crusher Electromagnetic Separation Process

Dry Separation Process Wet Separation Process



Screening Plant Washing Plant

Figure4.4: Crushing plant equipment

4.4 Properties of Recycled Aggregates obtained from crushed

concrete

4.4.1 Physical properties

Recycled aggregates are like a crushed stone in look. The physical

properties of such aggregates are different from ordinary concrete. The rough surface and

the angularity are more than conventional aggregate in the crushed concrete particles.

Such aggregate causes lightweight and porous cement mortar attached with recycled

aggregates have a higher water absorption and lower specific gravity than natural sized

aggregates.

4.4.1.1Specific gravity

The specific gravity of recycled aggregates is ever lower compare to the

natural aggregates. Before the recycling process starts the sample, if its specific gravity is

near about the natural coarse aggregate then only the usefulness of recycling process

could be done.

4.4.1.2 Density

The saturated surface density of recycled aggregates is lower than natural

aggregates that of, by the high density of mortar that is adhered to the recycled aggregate.

The aggregates with the higher amount of adhered mortar will have lower density. The

density of recycled aggregate concrete will reduce with the smaller sizes of aggregates.



4.4.1.3 Water absorption

As the size of aggregate is smaller the water absorption of aggregate will

increases. The smaller sizes of aggregates have a good water absorption capacity. The

higher amount of adhered mortar in recycled aggregates will decrease the density. It has

been accepted that the absorption capacity was not ever dependent on the strength of the

natural concrete. The water absorption capacity of recycled aggregates is in proportion

with the quality and quantity of adhered mortar. Recycled aggregates with the adhered

mortar have lower density higher water absorption capacity.

4.4.1.4 Moisture content

Because of adhered mortar in recycled aggregates, moisture content of

recycled aggregates is always higher than that of natural aggregates. It directly deals with

the water cement ratio of the mix design.

4.5 Application of Recycled Aggregate Concrete

Initially in various countries, the application of recycled aggregate was to use as

landfill. Nowadays, it has been changed towards directly in construction areas widely.

This is as giving below:

1 - Granular Base Coarse Materials

2 Production of Recycled Concrete Paving Blocks

3 - Concrete Kerbs and Gutter Mix

4 - Embankment Fill Materials

5 - Building Blocks.

6 - Backfill Materials.

7 - Reinforced concrete building



CHAPTER 5 PROCESS OF RECYCLED AGGREGATE

AND EXPERIMENTAL TEST

Manufacturing process of recycled aggregate concrete is important for good

quality production. At every stage in carefulness is most require in recycled aggregate

concrete. So, proper car require otherwise concrete not give obtained results. Therefore

proper car is mostly requiring in all stages.

5.1 Process of Manufacturing

The following are the main stage of the manufacturing process of Recycled

Aggregate Concrete.

(1) Batching

(2) Mixing

(3) Transporting

(4) Placing

(5) Curing

(1) Batching

The material measurement process is known as batching. Availability of material

and quality of material, batching is divided in two method.

1. Weigh batching

2. Volume batching

1. Weigh Batching

Weigh batching is more accurate method compare to volume batching because of

the perfection of the proportion has been measured by weight. Concrete which will made

by the process of weight batching gives the good quality and also a material as per the



design always considered as the weight. For the construction of the heavy structures, this

method is more suitable.

2. Volume Batching

This method is not an accurate method of batching. In concrete, the material,

which is used in the manufacturing of concrete, which is of different characteristics.

Sometimes, the material have environmental effects like in the dry condition the material

volume can decrease as well as the in wet condition the material volume can increases.

So, using the volume batching this type of error may produce lower quality concrete and

the proportion as per the design shall not maintain.

(2). Mixing

Mixing is process of concrete mix perfectly and behaves uniform material after

concrete place in specimen. Generally mixing of concrete has two methods.

Hand mixing

Machine mixing

Hand mixing

Hand mixing in concrete is done by the manually. Mixing cannot be

possessed the uniformity as well the mixing cannot be mixed thoroughly. So, this type of

mixing is use in temporary work and small work. Hand mixing in more proportion of

cement require because cement particles floats in the atmosphere. In hand mixing around

10% more cement will take in concrete.

Machine mixing

Machine mixing is the classic method for mixing. Different capacity types

of mixture are available in market. Machine mixing is more amount of concrete produce

with the thoroughly equality. This mixing is economical and good effective for

manufacturing of more amount of concrete.



Here 0.5 m capacity of miller use for portable concrete. Proper proportion

is use the mixing every batch in miller.

Figure 5.1 Process of Concrete Mixing

(3). Transporting

There are many methods by the transporting concrete. Truck miller, pumping,

trolley, lift and other methods are useful for transporting the concrete.

Here the miller was available in the laboratory, so the concrete was been placed

directly in the mould.

Figure 5.2 Process of Transporting Concrete



(4). Placing

Different sizes of mouls in place the concrete. The below table is various size of

concrete mould use in concrete placing.

Table 5.1 Moulds dimension Use for Concreting

Mould Name Size of mould

Cube 150mm x 150mm x 150mm

Cylinder Dia of 150mm and height of 300 mm

Beam 100mm x 100mm x 500mm

Remove the air voids and surfacing of concrete is done by the vibrator. So, mould

placing on vibrator and concrete in remove the air voids and concrete surfacing done.

Figure 5.3 Vibrating Table



Figure 5.4 Placing of Concrete in Mould

(5). Curing

Hardening process completing after, the specimen occupies initial hardened state

and also the moulds are allowed to open. The moulds were casting after 24 hours, moulds

for cure in curing tank. A curing time of each moulds was 28 days and also curing tank

placed in laboratory. Each batch specimens of curing time were 7 days and 28 days after

testing procedure. The curing tank water was maintained the temperature and pure.

Figure 5.5 Curing Tank



5.2 Tests for fresh properties of concrete

5.2.1 Slump Test

Fresh concrete properties measure by the workability test. Consistency of

fresh concrete is checking by this test. Degree of wetness measures by the consistency.

The slump test is perform about 6 liter of concrete will need. This test is

procedure is very easy and very easy to perform due to ease in the apparatus. As per IS

code every batches in use of slump test to produce uniformity and suggested the of super

plasticizers dosage opportunity for the concrete.

In the inverted cone the performance of compacted concrete under the gravity

action by the slump results shows. The mould shape is like an inverted cone. Inverted

cone is a handle to hold with open at both ends. The height of cone is 300 mm and top

diameter of cone is 100 mm and bottom diameter is 200 mm. A metal rod 16 mm

diameter and 600 mm height and measure the slump is use numbering.

Figure 5.6 Slump Test

Procedure:

The mould internal surface cleaned carefully and put on rigid and non-absorbent

horizontal surface. Placing of Concrete mix is placing in a slump cone with four layer and

each layer on apply 25 times tamping. After cone outside remove extra concrete and

instantly remove the cone in upward direction without damage on concrete. After the



settlement of the concrete completely and measure the variation that called slump. Slump

can measure in cm or mm.

Generally Slump can be defined in three types,

Collapse: In this type of slump in concrete is completely collapses

Shear: In this type of slump in concrete failure in one side.

True slump: In this of slump in concrete is completely subsides.

5.3 Various tests for hardened properties of concrete

5.3.1 Compressive strength of concrete

The capacity to resist an effective load on hardened (28 days curing after)

concrete is measure by the compressive strength test. In the laboratory the capacity of

compression testing machine is 2000 KN. A machine is operated by the electrically. The

design of any structure in most important is compressive strength of concrete. The best

compression strength of Concrete achieve by the perfect conditions of concrete. In

hardened state in measures the compression test. Compression test for 150 mm x 150 mm

x 150 mm size of concrete cube are used. First concrete outer surface drying and clean by

the cloth after the specimen use for testing. Proper manufacturing process, grade of

concrete and proper curing are the factors affecting of compressive strength. Every batch

cast after 7 days and 28 days curing after this test done. Three cubes mean value

considered as result in every curing batch.

Figure 5.7 Compressive Strength Test



5.3.2 Split Tensile strength of concrete

The cylindrical mould of size 30 cm height and 15 cm diameter is use for

Split tensile strength of concrete. 28 days curing of cylinder after this test carryout. Split

tensile strength of concrete test will perform on compression testing machine. The

compressive force acts on the length of cylinder that type arrangement of cylinder in

machine and also both side plate provide on cylinder. Diametric compressive force

applied along the length of cylindrical span by this method. The below formula is use for

find out split tensile strength.

Split Tensile Strength = 2P/ ld

Where, P= load value in N

l = length in mm

d = diameter in mm

Figure 5.8 Split Tensile Strength Test

5.3.3 Flexural strength of concrete

Beam specimen in flexure strength finding by this test. 10 cm x 10 cm x

50 cm size of beam specimen for tested. After 28 days curing after beam specimen use

for testing. Testing of Beam is arrangement on Universal Testing Machine [UTM] to give

the loading on beam. The beam length on making three part and put on Universal Testing

Machine and the two point loading method by the achieve the flexural strength. The loads

apply without any shock and without sudden otherwise the fails specimen directly.

Generally universal testing machine obtain the strength range from 10KN to 500KN. The



specimen surface on create cracks by the apply loading and this loading is maximum

loading of specimen. After that value use for following formula,

Flexural strength= Pl/bd

Where, P= load in N.

l= clear length in mm

b= width in mm

d= depth in mm

Figure 5.9 Flexural Strength Test



CHAPTER 6 NEED OF THE STUDY

The natural resources can be protected by the use of demolished building

material.

Demolished waste of old building is used in new building construction which

protects natural resources.

From the demolished concrete the aggregates are crushed by hammering or by

crusher with the specific size of >4.75 mm and



CHAPTER 7 OBJECTIVES OF STUDY

The strength of recycled coarse aggregate is depends on w/c ratio with partial

replacement.

The ternary blended concrete requires the percentage replacement of cement by

using percentage variation of fly ash and GGBFS.

Experimental study on various replacement of RCA, GGBFS and fly ash, when

mixed with the changes in W/C ratio and calculate workability, compressive,

tensile, and flexural strength.

By this study maximum and minimum strength is achieved.



CHAPTER 8 INDUSTRIAL VISIT

Visited the following industries are for the recycling process of aggregates and for the materials properties and samples.

Name of company and

address

Concerned person Contact No. Date of visit

Shree Ganesh crushing

plant

Mr. Mansukh Ahir 98984 43040 28/11/2015

Lafarge aggregate &

concrete India pvt.ltd.

Rajkot

Mr. Ganesh Sahu (Q/A &

Q/C Manager)

97140 07644 29/09/2015

Stallion Energy Pvt. ltd.

Rajkot.

Mr. Kuldipsinh Basiya

(M.D.)

99099 52004 10/09/2015



CHAPTER 9 WORK PLAN

Sr.

No.

Task July

Aug.

Sep.

Oct.

Nov.

Dec.

Jan.

Feb.

Mar.

April

May

June

1. Literature

review

2. Decided the

topic name and

material

3. Testing of

material

4. Pilot test (Trial

mix)

5. Experimental

and Analysis

6. Interpretation

of results

7. Thesis writing



CHAPTER 10 RESULTS

10.1 Fresh Properties Results

10.1.1 Slump test results

While increasing the percentage replacement of fly ash and GGBFS with the 0%

replacement the slump value was increased. When the recycled coarse aggregates were

replaced with increment in percentage the slump value was decreased.

Table 10.1 Slump Value

% of RCA

+FA+GGBFS

w/c ratio= 0.55

Value (mm)

0+0+0 120

0+30+0 162

0+0+30 143

0+10+10 125

0+30+30 165

100+10+10 100

100+30+30 105

60+10+10 122

60+30+30 160



10.2 Hardened Properties Results

10.2.1 Compressive Strength test results

Compressive strength for 0% replacement of recycled coarse aggregate

with increasing in the fly ash content and GGBFS content can decrease the strength.

While increasing the percentage of recycled coarse aggregate with increasing the Fly ash

and GGBFS the strength was decreased.

Table 10.2 Compressive strength value of 7 days and 28 days for 0.55 w/c ratio

% of RCA

+FA+GGBFS

w/c ratio= 0.55

7 days

[MPa]

28 days

[MPa]

0+0+0 19.55 26.66

0+30+0 10.56 17.55

0+0+30 14.44 22.44

0+10+10 14.66 23.2

0+30+30 10.22 15.77

100+10+10 11.55 20.88

100+30+30 7.50 13.67

60+10+10 12.11 21.55

60+30+30 8.55 14



10.2.2 Split Tensile strength test results

Split tensile strength for 0% replacement of recycled coarse aggregate

with increasing in the fly ash content and GGBFS content can decrease the strength.

Table 10.3 Split Tensile strength value of 28 days for 0.55 w/c ratio

% of RCA

+FA+GGBFS

w/c ratio= 0.55

Value (MPa)

0+0+0 2.66

0+30+0 1.52

0+0+30 2.05

0+10+10 2.57

0+30+30 1.62

100+10+10 2.23

100+30+30 1.15

60+10+10 2.47

60+30+30 1.41



10.2.3 Flexural Strength test results

Flexural strength for 0% replacement of recycled coarse aggregate with

increasing in the fly ash content and GGBFS content can decrease the strength.

Table 10.4 Flexural strength value of 28 days for 0.55 w/c ratio

% of RCA

+FA+GGBFS

w/c ratio= 0.55

Value (MPa)

0+0+0 3.00

0+30+0 2.17

0+0+30 2.56

0+10+10 2.56

0+30+30 1.6

100+10+10 1.98

100+30+30 1.27

60+10+10 2.01

60+30+30 1.50



CHAPTER 11 PROPOSED OUTCOME OF STUDY

The properties of concrete can change by different material and also require

strength can achieved by the use of waste and by products.

In future the availability of natural aggregates after time want be easy as per

requirement specific properties.

The waste material also having important contribution as it helps to decrease the

pollution and saves the natural resources.

As per study, use of demolished waste will be increased by using the portable

crusher to crush the concrete waste. This requires many extensions.

This type of concrete is applicable in the construction of small houses and also for

road construction but at present this type of concrete is not used in INDIA.



CHAPTER 12 MIX DESIGN FOR W/C RATIO OF 0.55

W/C ratio = 0.55

Cement = OPC 53 grade

Maximum size of aggregate = 20 mm

Workability = 100 mm (Slump)

Specific gravity of Cement = 3.15

Specific gravity of Fly ash = 2.1

Specific gravity of GGBFS or GGBS = 2.85

Specific gravity of coarse aggregate = 2.75

Specific gravity of fine aggregate = 2.74

Specific gravity of recycled coarse aggregate = 2.52

Water absorption of coarse aggregate = 1.40%

Water absorption of fine aggregate = 1.0%

Water absorption of recycled coarse aggregate = 4.40%

Moisture content of coarse aggregate = Nil

Moisture content of fine aggregate = Nil

Fine aggregate of zone 1

Target strength is on w/c ratio 0.55

Water content for maximum 20 mm size of aggregate = 186 liter

Estimated water content for 100 mm slump = 186+ ((6/100)*186) = 197 liter

Cementitious material content = (197/0.55) =358.18 kg/m3

Volume of coarse aggregate is to be decreased and fine aggregate is to be

increased as the w/c ratio is greater by 0.05

Volume of coarse aggregate is decreased by 0.01

According to IS 10262, if the aggregate size is 20 mm and the fine aggregate of

zone-1 then the w/c ratio of 0.50 = 0.60

Corrected volume of coarse aggregate for the w/c ratio of 0.55 = 0.59

Volume of fine aggregate = 1- 0.59 =0.41



Mix Calculations (Conventional concrete):-

a) Volume of concrete = 1 m3

b) Volume of cement = ((358.18/3.15)*(1/1000)) = 0.114 m3

c) Volume of Water = (197*(1/1000)) = 0.197 m3

d) Volume of all in aggregate = a-(b + c)

= 1-(0.114 + 0.197)

= 1-0.311

= 0.69 m3

e) Mass of coarse aggregate = 0.69*0.59*2.75*1000

= 1119.53 kg

f) Mass of fine aggregate = 0.69*0.41*2.74*1000

= 775.15 kg

Coarse aggregate = ((1.40*1119.53)/100) = 15.67

= 1119.53-15.67

= 1103.86 kg

Actual water added = 197+15.67 = 212.67



REFERENCES

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engineering research and development, volume 10, issue 11, November 2014.

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recycled desulfurization slag Wen-Ten kuo, Her-Yung Wang, Chun-Ya Shu in

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Thavasumony D, Thanappan Subash, Sheeba D in IJSER, volume 5, Issue 7, July

2014.

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10. IS 12269 1987.

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13. IS 456 2000.

14. M.S.Shetty,Concrete Technology (Theory and Practice), S.Chand & Company

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