PERFORMANCE OF RED MUD AS PARTIAL REPLACEMENT OF CEMENT IN CONCRETE

A PROJECT ON

BYG.MURALI MOHAN

INTRODUCTION

During present era use of cement became very high because of urbanization. So the natural resources are decreasing rapidly.As part of development, use of cement in buildings, many other civil engineering structures is taking place.But the sources are getting reduced very fastly because of heavy usage.In order to reduce the usage of conventional materials like cement, some experiments are done for finding out compressive strength of Cement By replacing Cement with Red mud

Red mud comprises of oxides of iron, titanium, aluminum and silica along with some other minor constituents. Presence of Alumina and Iron oxide in red mud compensates the deficiency of the same components in limestone which is the primary raw material for cement production. Experiments have been conducted under laboratory condition to assess the strength characteristics of the aluminum red mud. our project work focuses on the suitability of red mud obtained for construction. Five test groups of cubes were casted by replacing the cement with 0%, 5%, 10%, 15, & 20% of red mud. The strength of these cubes will be compared with the conventional cubes .

MATERIALS USED AND THEIR AVAILABILITY

Cement ( OPC 53 grade Cement) Ordinary Portland Cement (53 Grade) is being used throughout the project. Different tests were performed on the cement to ensure that it confirms to the requirements of Indian standards.

Fine aggregate (Locally available)Locally available sand is used as fine aggregate. The sand here used is that which is passed through 4.75mm sieve and retained on 75microns sieve

Coarse aggregate Locally available coarse aggregate is used throughout the project. Coarse aggregate of size 20mm is used throughout the project.

Red mud(locally available)The red mud is collected from the near by fields. The red mud here used is that which is passed through 90 microns.

S.NO. PROPERTY TEST RESULTS1 Consistency 30%

2 Specific gravity 3.13

3 Initial setting time 53 minutesFinal setting time 530 minutes

4Soundness (Expansion)

Lechatlier method1 mm

5 Fineness of cement 6%

PRELIMINARY TESTS A. CEMENT

B.FINE AGGREGATE• Fine aggregate is locally available. S.NO. PROPERTY TEST

RESULTS

1 Zone of sand Zone II

2 Specific gravity 2.6

S.NO. PROPERTY TEST RESULTS

1 Specific gravity 2.8

D.RED MUD

C.COARSE AGGREGATE

S.NO. PROPERTY TEST RESULTS

1 Specific gravity 2.64

MIX DESIGN OF CONCRETESTIPULATION FOR PROPORTIONGrade designation M20Type of cement OPC53 gradeMaximum size of aggregate 20mmWorkability 75mm slumpExposure condition mildType of aggregate crushed angular aggregateTEST DATA FOR MATERIALSSpecific gravity of

1)cement =3.132)coarse aggregate =2.83)fine aggregate =2.6

Fine aggregate conforming to grading zone of II of table 4 of IS 383

STEP :1 TARGET MEAN STRENGTH

Target mean strength fck = fck+ks =20 +1.65x4=26.6 N/mm2

From table 1 of IS 10262 - 2009 the standard deviation for M20 grade of concrete is 4N/mm2

STEP:2 SELECTION OF W/C RATIOFrom table 5 of IS 456-2000 maximum water cement ratio =0.55 ……(1)From the graph between w/c ratio and compressive strength,The water cement ratio is =0.50 ……..(2)The minimum of above (1)&(2) is (2)The w/c ratio is 0.50

STEP:3 SELECTION OF WATER CONTENTFrom table2 of IS 10262-2009,Maximum water content for 20mm aggregate =186 lit (For slump of 25 to 50mm)

Then for slump of 75mm,water content =

= 191.58lit

100186*3186

Cement content= =383.16 kg/m35.0

58.191

STEP :4 PROPORTION OF VOLUME OF C.A & F.AFrom table -3 of IS 10262-2009,volume of C.A corresponding to 20mm size of coarse aggregate & F.A belonging to zone -II and for w/c ratio of 0.5 is 0.62 ( as our w/c ratio is 0.5,hence there is no need increase or decrease volume of C.A).STEP:5 MIX CALCULATIONa) Volume of concrete =1 m3

b) Volume of cement =

= =0.1224 m3

c) Volume of water = =0.1915m3

d) Volume of aggregates = a-(b+c) = 1-(0.1224+0.1915) =0.6861m3

10001*

13.316.383

10001*

158.191

10001*

cement ofgravity specificcement of mass

e) Volume & weight of C.A

Volume of C.A = 0.6861x0.62 =0.42538m3

Weight of C.A = volume of C.A x specific gravity of C.A x mass density of water = 0.42538x2.8x1000 =1191.064kgf) Volume & weight of F.A

Volume of F.A = 0.6861*0.38 = 0.2607m3

Weight of F.A =volume of F.A x specific gravity of F.A. x mass density of water = 0.2607x2.6x1000 = 677.82kg

CEMENT FINE AGGREGATE

COARSE AGGREGATE

WATER

383.16(kg) 677.82(kg) 1191.064(kg) 191.58(lit)

1 1.77 3.11 0.5

CONCRETE PROPORTIONS:

PROPORTIONS OF CONTENTS FOR DIFFERENT PROPORTIONS OF RED MUDThe proportions of contents in preparation of concrete cubes for different percentages of red mud for 6 cubes is as follows:

% of red mud

Cement(kg)

Red mud(kg)

Fine aggregate(kg)

Coarse aggregate(kg)

Water(litres)

0 7.76 0 13.74 24.13 3.88

5 7.372 0.388 13.74 24.13 3.88

10 6.984 0.776 13.74 24.13 3.88

15 6.596 1.164 13.74 24.13 3.88

20 6.208 1.552 13.74 24.13 3.88

Red mud proportion (%)

Compressive strength(7 days)(Mpa)

Compressive strength(28 days)(Mpa)

0 13.5 19.3

5 13.3 19.1

10 13.0 18.7

15 12.5 18.2

20 11.9 17.6

RESULTS

0% 5% 10% 15% 20%11

11.512

12.513

13.5147 days compressive strength

7 days com-pressive strength

% of red mud

Com

pres

sive

str

engt

h (n

/mm

Progress of our project:Upto now we casted the concrete cubes with 0%,5%,10%&15% of red mud and tested the conventional cubes for their compressive strength.We will cast the cubes with other proportions(20%) and test the cubes with other proportions and compare their compressive strength with conventional cubes.

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