REPLACEMENT OF NATURAL SAND IN CONCRETE BY WASTE … · aggregate, bottom ash, foundry sand and various by-products are replacing natural sand and gravel in most countries. This paper

Page No:498 www.jespublication.com

Vol 10, Issue 11, Nov / 2019 ISSN NO: 0377-9254

REPLACEMENT OF NATURAL SAND IN CONCRETE BY

WASTE PRODUCTS

P.Alekhya Reddy 1

, N.Harish2, N Vijay kumar

3

1PG Student Structural Engineering, Loyola Institute Of Technology And Management, Layolanagar,

Dulipalla, Guntur,Ap, India, Mail Id: 1 [email protected]

2 M.tech, Asst pro. Loyola Institute Of Technology And Management, Layolanagar, Dulipalla, Guntur,Ap,

India, Mail Id: [email protected]

3M.tech Ph.D, Asso pro. Loyola institute of technology and management, Layolanagar, dulipalla,

Guntur,Ap, India.

ABSTRACT

In this paper an attempt is made to present a state-of

the- art review of papers on replacement of natural

sand by by-products and recyclable materials. This

paper aims to deal with the current and future trends

of research on the use of Manufactured Fine

Aggregate (MFA) in Portland cement concrete. With

natural sand deposits the world over drying up, there

is an acute need for a product that matches the

properties of natural sand in concrete. In the last 15

years, it has become clear that the availability of

good quality natural sand is decreasing. With a few

local exceptions, it seems to be a global trend.

Existing natural sand deposits are being emptied at

the same rate as urbanization and new deposits are

located either underground, too close to already built-

up areas or too far away from the areas where it is

needed, that is the towns and cities where the

manufacturers of concrete are located. Environmental

concerns are also being raised against uncontrolled

extraction of natural sand. The arguments are mostly

in regards to protecting riverbeds against erosion and

the importance of having natural sand as a filter for

ground water. The above concerns, combined with

issues of preserving areas of beauty, recreational

value and biodiversity are an integral part of the

process of most local government agencies granting

permission to aggregate producers across the world.

This is the situation for the construction industry

today and most will agree that it will not change

dramatically in the foreseeable future. Crushed

aggregate, bottom ash, foundry sand and various by-

products are replacing natural sand and gravel in

most countries. This paper emphasizes on the use of

material to be replaced by natural sand which will

give new dimension in concrete mix design and if

applied on large scale would revolutionize the

construction industry by economizing the

construction cost and enable us to conserve natural

resources.

Key Words : Replacement, Natural sand, Concrete,

Manufactured Fine Aggregate (MFA)

Urbanization

I. INTRODUCTION

Cement, sand and aggregate are essential

needs for any construction industry. Sand is a

major material used for preparation of mortar

and concrete and plays a most important role in

mix design. In general consumption of natural

sand is high, due to the large use of concrete

and mortar. Hence the demand of natural sand

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is very high in developing countries to satisfy the

rapid infrastructure growth. The developing

country like India facing shortage of good quality

natural sand and particularly in India, natural

sand deposits are being used up and causing

serious threat to environment as well as the

society. Rapid extraction of sand from river bed

causing so many problems like losing water

retaining soil strata, deepening of the river beds

and causing bank slides, loss of vegetation on

the bank of rivers, disturbs the aquatic life as

well as disturbs agriculture due to lowering the

water table in the well etc are some of the

examples.

Cement

Cement may be prescribed as material with adhesive

and cohesive properties which make it capable of

bonding material fragments into a compact whole.

The most commonly used cement in construction

today is Portland cement and hence Ordinary

Portland Cement of 53 grades has been selected for

the investigation. It is dry, powdery and free of

lumps. The cement according to the Indian

specification must satisfy the IS code IS:8122- 1989

(reaffirmed 1999).

Coarse aggregate

The fractions from 20 mm to 4.75 mm are used as

coarse aggregate. Machine crushed angular granite

metal of 20 mm nominal size from the local source

was used as coarse aggregate. It was free from

impurities such as dust, clay particles and organic

matter etc. The coarse aggregate chosen for Concrete

was typically angular in shape, well graded, and

smaller than maximum size suited for conventional

concrete. The physical properties of coarse aggregate

were investigated in accordance with IS 383 -1963.

Fine aggregate

Fine aggregate is an essential component of concrete.

Those fractions from 4.75 mm to 150 microns are

termed as fine aggregate. The purpose of the fine

aggregate is to fill the voids in the coarse aggregate

and to act as a workability agent. The natural fine

aggregates are the river sand which is the most

commonly used natural material for the fine

aggregates that is used, but the recent social factor

that created a shortage of the material created a great

problem in the construction sector. For the studies the

river sand of Zone-II is used in all the references.

Water

Water is an important ingredient of concrete as it

actually participates in the chemical reaction with

cement. Since it gives the strength to cement

concrete, the quantity and quality of water are

required to be looked into very carefully. Potable tap

water free from any injurious amounts of oils, acids,

alkalies, sugar, salts and organic materials available

in the laboratory with pH value of 7.0 ± 1 and

confirming to the requirements of IS:

456 -2000 was used for mixing concrete and curing

the specimens as well.




Bottom Ash

Bottom ash is a by-product of burning coal at

thermal power plants. Bottom ash particles are

much coarser than the fly ash. It is a coarse,

angular material of porous surface texture

predominantly sand-sized. This material is

composed of silica, alumina, and iron with small

amounts of calcium, magnesium, and sulfate

Grain size typically ranges from fine sand to

gravel in size. Chemical composition of bottom

ash is similar to the fly ash but typically contain

greater quantity of carbon. Bottom ash exhibits

high shear strength and low compressibility.

These engineering properties make bottom ash

an ideal material in design construction of dam

and for other civil engineering applications.

Bottom Ash

Advantages of Bottom Ash

Ash has been investigated for its suitability for

utilization in major areas as building material

and other civil engineering sectors. The areas

mentioned below have tremendous scope of

large scale use of Bottom ash. Building bricks

and block. Road construction, Drainage media

and Sound insulating walls. It is used in mining

mortar in such application as rock stabilization or

filling of cavities. It is used as a construction

material for highway and pavement It is used for

pressure grouting in concrete highways and for

other purposes viz, tunnel lining. It is used as

mineral filler in asphalt roads to minimize void

content and increase the stability of bituminous

wearing course during road construction. It is

used as a light weight synthetic aggregate in

block and concrete.

Foundry Sand

The Foundry industry in India has been growing

steadily over the T past several years despite

economic slowdown dented its demand from the

end user industry i.e. engineering and auto

component sectors. The Indian Metal Casting

(Foundry Industry) is well established &

producing estimated 9.99 Million MT of various

grades of castings as per International

standards. There are approx. 4500 units out of

which 85% can be classified as Small Scale

units & 10% as Medium & 5% as Large Scale

units. Approx. 800 units are having International

Quality Accreditation.

Foundry Sand

Objective of the study

The main objectives for this research are:

1) To determine the optimum content of bottom

ash as a substitute for fine aggregate (sand) in

concrete;

2) To evaluate the mechanical properties

(compressive strength) of concrete containing

bottom ash from power plant as sand

replacement in concrete;




3) To study the physical properties of concrete

materials.

4) To arrive a mix design summary for concrete

using IS code method. To study the workability

of fresh concrete such as slump.

5) To study the various strength of hardened

concrete such as compressive strength of

concrete cubes at 28 days and Split tensile

strength of cylinder at 28 days and Flexural

strength of prism at 28 days .

6) To compare the workability and various

strength for different percentage of partial

replacement of sand with Bottom ash, and

foundry sand.

II. LITERATURE REVIEW

Shyam Prakash Koganti1 , Kommineni

Hemanthraja2 , Satish Sajja3 et all, (2017)

Cement concrete paving blocks are precast hard

products complete out of cement concrete. The

product is made in various sizes and shapes like

square, round and rectangular blocks of different

dimensions with designs for interlocking of

adjacent tiles blocks. Several Research Works

have been carried out in the past to study the

possibility of utilizing waste materials and

industrial byproducts in the manufacturing of

paver blocks. Various industrial waste materials

like quarry dust, glass powder, ceramic dust and

coal dust are used as partial replacement of fine

aggregate and assessed the strength

parameters and compared the profit

percentages after replacement with waste

materials.

Huang et al. (1990) He investigated the shear

strength of Indiana bottom ash and boiler slag

compacted to different densities using direct

shear testing. The reported friction angles varied

in a wide range from 35 to 55% depending on

the density.

Seals etal. (1972) He presented data obtained

from West Virginia bottom ash. The standard

Proctor maximum densities varied between 11.6

and 18.4 kN/m3; the optimum water content

ranged from 12 to 34%. They also performed a

series of one-dimensional compression tests on

West Virginia bottom ash. They showed that, at

low stress levels, the compressibility of bottom

ash was comparable to natural granular soils

placed at the same relative density.

G. Esakki Muthu et. al. [2016] investigated the

micro formation of cement mixture with green sand

and copper slag like a substitute of fine aggregate.

The replacement of green sand and copper slag will

be regularly from 10%, 20%, and 30% by the weight

of fine collection. The results obtained in this

research point to that the main function of copper

scum and green sand in mortar as alternate material

for river Sand gives options for the consumption of

this huge waste materials as an alternative material

that is environmentally sustainable and appropriate

for the building manufacturing.

III. COLLECTION OF MATERIALS

1.CEMENT AND ITS PROPERTIES

The cement is an important constitute of

concrete. The cement is a binder can bind other

materials together. The word cement derived

from the Romans. Different brands of cement

have been found to possess different strength

development characteristics and behavior due to

the variations in the compound composition and

fineness. For the present investigation, Ordinary

Portland Cement of 53 Grade conforming to IS

269-1986 was used. The cement sample was




tested as per the procedure given in IS: 4031-

1988 and IS: 4032-1985.

OPC 53 GRADE CEMENT

2. AGGREGATESAND ITS PROPERTIES

The most popular use of aggregates is to form

Portland cement concrete. Approximately three-

fourths of the volume of Portland cement

concrete is occupied by aggregate. Aggregates

typically make up 70-80% of the volume of

Portland cement concretes and over 90% of

asphalt concretes. Thus, their properties play

important roles in determining the properties of

the composite materials in which they are to be

used. Knowledge of relative density/specific

gravity, absorption, unit weight and voids

content are necessary for the proper design of

both Portland cement and bituminous concretes.

Fine Aggregates, And Coarse Aggregates

3.WATER

Water is one of the important ingredients in

construction but in present day quality of water

is not given such big importance. during

construction work. The quality and quantity of

water plays a major role in determining the

strength of mortar and cement concrete in

construction work.

4. BOTTOM ASH

Bottom ash [normally recognized as coal

combustion residues (CCRs) from pulverized

fuel power stations] has been categorized as

solid garbage. But, CCRs are increasingly being

regarded as a useful substitute material

resource. They had an appearance similar to

dark gray coarse sand, and its particles are

clusters of micron sized granules, up to 10mm in

diameter (60%-70% smaller than 2 mm. and

l0%-20% smaller than 75 microns).

5.FOUNDRY SAND

Most of the metal industries prefer sand casting

system. In this system mould made of uniform

sized, clean, high silica sand is used. After

casting process foundries recycle and reuse the

sand several times but after sometime it is

discarded from the foundries known as waste

foundry sand. The application of waste foundry

sand to various engineering sector can solve the

problems of its disposal and harmful effect to

environment. Foundry sand is clean, uniformly

sized, high-quality silica sand that is bounded to

form moulds for ferrous (iron and steel) and non-

ferrous

(copper, aluminum, brass) metals. Type of

foundry sand depends on the casting process in

foundries. Foundry sand is generally of two

types: Green sand, chemically bounded sand.

Additive in sand depends on type of metal

casting. Use of waste foundry sand as full or

partial replacement by fine aggregate helps to

achieve different properties or behavior of

concrete.

6. MIX DESIGN




6.1 TRAIL MIX OF M30 GRADE OF

CONCRETE

Final trial mix for M30 grade concrete is

1:1.64:2.55 at w/c of 0.45

IV EXPERIMENTAL PROCEDURES

1) SLUMP CONE TEST

Types of Concrete Slump Test Results :

o True Slump – True slump is the only slump that can

be measured in the test. The measurement is taken

between the top of the cone and the top of the

concrete after the cone has been removed as shown in

figure-1.

o Zero Slump – Zero slump is the indication of very

low water-cement ratio, which results in dry mixes.

These type of concrete is generally used for road

construction.

o Collapsed Slump – This is an indication that the

water-cement ratio is too high, i.e. concrete mix is

too wet or it is a high workability mix, for which a

slump test is not appropriate.

o Shear Slump – The shear slump indicates that the

result is incomplete, and concrete to be retested.

Procedure for Concrete Slump Cone Test

1. Clean the internal surface of the mould and apply oil.

2. Place the mould on a smooth horizontal non- porous

base plate.

3. Fill the mould with the prepared concrete mix in 4

approximately equal layers.

4. Tamp each layer with 25 strokes of the rounded end

of the tamping rod in a uniform manner over the

cross section of the mould. For the subsequent layers,

the tamping should penetrate into the underlying

layer.

5. Remove the excess concrete and level the surface

with a trowel.

6. Clean away the mortar or water leaked out between

the mould and the base plate.

7. Raise the mould from the concrete immediately and

slowly in vertical direction.

8. Measure the slump as the difference between the

height of the mould and that of height point of the

specimen being tested.

Concrete Slump Test Procedure

2) COMPRESSIVE STRENGTH TEST ON

CUBES




Compression Strength Test

The compression strength of concrete is

one of the most important and useful properties of

concrete. In most structural applications concrete is

used primarily to resist compression stress. The

compression strength of the concrete is conducted on

the cube of standard dimensions of 150*150*150mm.

The compressive strength test is conducted at

7,14&28 days of curing.

Compressive Strength Formula

Compressive strength formula for any material is the

load applied at the point of failure to the cross-section

area of the face on which load was applied.

Compressive Strength = Load / Cross-sectional

Area

Procedure:

Compressive Strength Test of Concrete Cubes

For cube test two types of specimens either cubes of

15cm X 15cm X 15cm or 10cm X 10cm x 10cm

depending upon the size of aggregate are used. For

most of the works cubical moulds of size 15cm x

15cm x 15cm are commonly used.

This concrete is poured in the mould and tempered

properly so as not to have any voids. After 24 hours

these moulds are removed and test specimens are put

in water for curing. The top surface of these

specimen should be made even and smooth. This is

done by putting cement paste and spreading smoothly

on whole area of specimen.

These specimens are tested by compression testing

machine after 7 days curing or 28 days curing. Load

should be applied gradually at the rate of 140 kg/cm2

per minute till the Specimens fails. Load at the failure

divided by area of specimen gives the compressive

strength of concrete.

Procedure for Concrete Cube Test

1. Remove the specimen from water after specified

curing time and wipe out excess water from the

surface.

2. Take the dimension of the specimen to the nearest

0.2m

3. Clean the bearing surface of the testing machine

4. Place the specimen in the machine in such a manner

that the load shall be applied to the opposite sides of

the cube cast.

5. Align the specimen centrally on the base plate of the

machine.

6. Rotate the movable portion gently by hand so that it

touches the top surface of the specimen.

7. Apply the load gradually without shock and

continuously at the rate of 140 kg/cm2/minute till the

specimen fails

8. Record the maximum load and note any unusual

features in the type of failure.




compressive strength test on eps concrete

3) SPLIT TENSILE STRENGTH TEST

PROCEDURE:

1. SAMPLING OF MATERIALS –

Samples of aggregates for each batch of concrete

shall be of the desired grading and shall be in an air-

dried condition. The cement samples, on arrival at the

laboratory, shall be thoroughly mixed dry either by

hand or in a suitable mixer in such a manner as to

ensure the greatest possible blending and uniformity

in the material.

2. PROPORTIONING –

The proportions of the materials, including water, in

concrete mixes used for determining the suitability of

the materials available, shall be similar in all respects

to those to be employed in the work.

3. WEIGHING –

The quantities of cement, each size of aggregate, and

water for each batch shall be determined by weight,

to an accuracy of 0.1 percent of the total weight of

the batch.

4. MIXING CONCRETE –

The concrete shall be mixed by hand, or preferably,

in a laboratory batch mixer, in such a manner as to

avoid loss of water or other materials. Each batch of

concrete shall be of such a size as to leave about 10

percent excess after molding the desired number of

test specimens.

5. MOULD –

The cylindrical mould shall be of 150 mm diameter

and 300 mm height conforming to IS: 10086-1982.

6. COMPACTING –

The test specimens shall be made as soon as

practicable after mixing, and in such a way as to

produce full compaction of the concrete with neither

segregation nor excessive laitance.

7. CURING –

The test specimens shall be stored in a place, free

from vibration, in moist air of at least 90 percent

relative humidity and at a temperature of 27° ± 2°C

for 24 hours ± ½ hour from the time of addition of

water to the dry ingredients.

8. PLACING THE SPECIMEN IN THE

TESTING MACHINE –

The bearing surfaces of the supporting and loading

rollers shall be wiped clean, and any loose sand or

other material removed from the surfaces of the

specimen where they are to make contact with the

rollers.




9. Two bearings strips of nominal (1/8 in i.e 3.175

mm) thick plywood, free of imperfections,

approximately (25 mm) wide, and of length

equal to or slightly longer than that of the

specimen should be provided for each

specimen.

10. The bearing strips are placed between the

specimen and both upper and lower bearing

blocks of the testing machine or between the

specimen and the supplemental bars or plates.

11. Draw diametric lines an each end of the

specimen using a suitable device that will

ensure that they are in the same axial plane.

Centre one of the plywood strips along the

centre of the lower bearing block.

12. Place the specimen on the plywood strip and

align so that the lines marked on the ends of the

specimen are vertical and cantered over the

plywood strip.

13. Place a second plywood strip lengthwise on the

cylinder, cantered on the lines marked on the

ends of the cylinder. Apply the load

continuously and without shock, at a constant

rate within, the range of 689 to 1380 kPa/min

splitting tensile stress until failure of the

specimen

14. Record the maximum applied load indicated by

the testing machine at failure. Note the type of

failure and appearance of fracture.

4) Flexural strength of beam

Flexural strength, also known as modulus of

rupture, or bend strength, or transverse rupture

strength is a material property, defined as the

stress in a material just before it yields in a

flexure test.

Flexural Strength of Beams Incorporating Copper

Slag as Partial Replacement of Fine Aggregate in

Concrete.

Procedure of Flexural Test on Concrete

o The test should be conducted on the specimen

immediately after taken out of the curing condition so

as to prevent surface drying which decline flexural

strength.

o Place the specimen on the loading points. The hand

finished surface of the specimen should not be in

contact with loading points. This will ensure an

acceptable contact between the specimen and loading

points.

o Center the loading system in relation to the applied

force.

o Bring the block applying force in contact with the

specimen surface at the loading points.

o Applying loads between 2 to 6 percent of the

computed ultimate load.

o Employing 0.10 mm and 0.38 mm leaf-type feeler

gages, specify whether any space between the

specimen and the load-applying or support blocks is

greater or less than each of the gages over a length of

25 mm or more.

o Eliminate any gap greater than 0.10mm using leather

shims (6.4mm thick and 25 to 50mm long) and it

should extend the full width of the specimen.

o Capping or grinding should be considered to remove

gaps in excess of 0.38mm.

o Load the specimen continuously without shock till

the point of failure at a constant rate (Indian standard

specified loading rate of 400 Kg/min for 150mm

specimen and 180kg/min for 100mm specimen, stress

increase rate 0.06+/-0.04N/mm2.s according to

British standard).




Experimental test set up flexural strength test on

beam

VI RESULTS AND DISCUSSIONS

1 . MATERIAL PROPERTIES

CEMENT

COARSE AGGREGATES

FINE AGGREGATES

1) SLUMP CONE TEST

Graph for Slump Cone test

2) COMPRESSIVE STRENGTH

Graph for Compressive strength test

0%

2000%

4000%

6000%

8000%

10000%

1 2 3 4 5

Material

Slump (CM)

0

10

20

30

40

50

1 2 3 4 5

7 Days

14 days

21 Days

28 Days




3) SPLIT TENSILE STRENGTH

Graph for Split tensile strength test

4) FLEXURAL STRENGTH

Graph for flexural strength test on beam

VII. CONCLUSIONS

The present investigation was carried out to

evaluate the suitability of utilizing bottom ash as

a partial replacement of fine aggregates in M30

grade concrete. The study also investigated the

effect of micro silica in optimum bottom ash

concrete mix. Test results indicate that bottom

ash from Hindustan Newsprint Limited is a

suitable material to be used as fine aggregate in

partial replacement of fine aggregate along with

micro silica in production of structural concrete.

Based on the analysis of test results and

discussions following conclusions can be drawn.

SCOPE OF THE FUTURE WORK

she project can be implemented to the further

grades of the cement concrete with different

grades of the replacement of the bottom ash and

foundry sand, This project is limited to the

distractive tests can be implemented by

conducting NON DISTRACTIVE TESTS

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international journal of innovative research in

science, engineering and technology, vol4.

3. Pramod. S. patil “innovative techniques of waste

plastic used in concrete mixture” international journal

of engineering and technology.

4. Tomas.U.Ganiron. “Effect of thermoplastic as fine

aggregate to concrete mixture” international journal

of science and technology, vol 62.

5. J.N.S.Suryanarayana.Raju“mechanic al study on

concrete with waste plastic” International journal of

research in civil engineering, vol 1.

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0

2

4

6

8

1 2 3 4 5

14 days

28 days

0

2

4

6

8

1 2 3 4 5

FlexuralStrengthKN/m2 14days

FlexuralStrengthKN/m2 28days




7. Zainab.Z. Ismail “use of waste plastic in concrete

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8. Yousef Ghernouti,” use of recycled plastic bag

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Documents

REPLACEMENT OF NATURAL SAND IN CONCRETE BY WASTE … · aggregate, bottom ash, foundry sand and various by-products are replacing natural sand and gravel in most countries. This paper