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Quarry dust, a by-product from the crushing process during quarrying activities is one of the materials being studied. Properties of quarry dust that were determined are aggregate crushing value, flakiness index, pH value, soundness, specific gravity, absorption and fineness modulus. Results obtained indicate that the incorporation of quarry dust into the concrete mix as Partial Replacement Material to river sand resulted in lower 28 th day compressive strength.
Quarry dust, a by-product from the crushing process during quarrying activities is one of the materials being studied. Properties of quarry dust that were determined are aggregate crushing value, flakiness index, pH value, soundness, specific gravity, absorption and fineness modulus. Results obtained indicate that the incorporation of quarry dust into the concrete mix as Partial Replacement Material to river sand resulted in lower 28 th day compressive strength.
Quarry dust, a by-product from the crushing process during quarrying activities is one of the materials being studied. Properties of quarry dust that were determined are aggregate crushing value, flakiness index, pH value, soundness, specific gravity, absorption and fineness modulus. Results obtained indicate that the incorporation of quarry dust into the concrete mix as Partial Replacement Material to river sand resulted in lower 28 th day compressive strength.
S. N. Raman a , M. F. M. Zain b , H. B. Mahmud a , K. S. Tan b
a Department of Civil Engineering, Faculty of Engineering, Universiti Malaya, 50603 Kuala Lumpur, Malaysia Tel. No : 03 7967 4492; Fax No. : 03 7967 5318; Email : snraman@um.edu.my b Department of Civil and Structural Engineering, Faculty of Engineering, Universiti Kebangsaan Malaysia, 43600 UKM Bangi, Selangor, Malaysia
ABSTRACT
The reduction in the sources of natural sand and the requirement for reduction in the cost of concrete production has resulted in the increased need to identify substitute material to sand as fine aggregates in the production of concretes. Quarry dust, a by-product from the crushing process during quarrying activities is one of the materials being studied. This paper reports the experimental study undertaken to investigate some properties of quarry dust and discusses the suitability of those properties to enable quarry dust to be used as partial replacement material for sand in concrete. The properties of quarry dust that were determined are aggregate crushing value, flakiness index, pH value, soundness, specific gravity, absorption and fineness modulus. Besides, the 28 th day compressive strength of concrete specimens, in which partial replacement of river sand with quarry dust were practiced, is also reported for comparison purposes. Results obtained indicate that the incorporation of quarry dust into the concrete mix as partial replacement material to river sand resulted in lower 28 th day compressive strength. This can partly be attributed to the properties of the quarry dust which might contribute to the negative effects in the strength of the concrete. The results of the study also indicates that quarry dust can be utilised as partial replacement material to sand, in the presence of silica fume or fly ash, to produce concretes with fair ranges of compressive strength.
The reduction in the sources of natural sand and the requirement for reduction in the cost of concrete production has resulted in the increased need to identify substitute material to constituent materials as aggregates in the production of concretes. Several types of materials have been investigated for this purpose both in developing and developed countries and the outcome of success has been varying. The materials usually researched for this purpose are either by-product materials or even sometimes manufactured aggregates. Manufactured aggregates are mostly used to produce concretes to meet specific purposes such concrete with superior properties or structural lightweight concrete. On the other hand, the advantages of utilisation of by- products or aggregates obtained as waste materials are pronounced in the aspects of reduction in environmental load and waste management cost, reduction concrete production cost and enhancement in some properties of concrete. Quarry dust, a by-product from the crushing process during quarrying activities is one of those materials being studied, especially as substitute material to sand as fine aggregates. Quarry dust have been used for different activities in the construction industry such as for road construction and manufacture of building materials such as lightweight aggregates, bricks, tiles and autoclave blocks [1]. Researches have also been conducted to study the effects of partial replacement of sand with quarry dust in the properties of freshly mixed [2-3] and hardened concrete applications [3-5]. It was deduced from those studies that partial replacement of sand with quarry dust without the inclusion of other admixtures resulted in enhanced workability in the concrete mixes [2-3], but in a reduced compressive strength and durability [3-5]. Besides, Ho et al. [6] have also researched quarry dust for self-compacting concrete applications. It is noted that there are numerous publications available in the area of utilisation of by-product and waste materials as well as different types manufactured aggregates in concrete mixes. On contrary, publications discussing the physical and chemical properties of the by-product and waste materials, and the suitability of those properties to enable these materials to be utilised in concrete mixes is limited and tends to be scattered in many publications. The present study is an experimental study which attempts to investigate some properties of quarry dust and discusses the suitability of those properties to enable quarry dust to be used as partial replacement material for sand in concrete. For comparison purposes, the 28 th day compressive strength of concrete specimens, in which partial replacement of sand with quarry dust were practiced, is also reported.
(2) EXPERIMENTAL PROCEDURE
(2.1) Materials
Locally available quarry dust was the primary material used in this study. Besides that, for concrete mixing purposes, Type I ordinary Portland cement, crushed stone granite coarse aggregate, river sand, silica fume and Class F Malaysian fly ash were used. Normal tap water (pH = 6.9) was used for both concrete mixing and curing purposes. Sulfonated naphthalene formaldehyde condensate based superplaticizer (SP) and Darex air entraining admixture (AEA) were used as liquid chemical admixtures. The physical properties of the materials are shown Table 1. A more detailed representation of the physical properties of quarry dust is given in the Results and Discussion section.
Table 1 Physical Properties of the Materials Material Properties Coarse aggregate Specific gravity: 2.63; Absorption: 0.44 %; Maximum size: 10.00 mm; Fineness modulus: 6.82 River sand Specific gravity: 2.57; Absorption: 2.12 %; Maximum size: 4.75 mm; Fineness modulus: 4.20 Quarry dust Specific gravity: 2.63; Absorption: 0.60 %; Maximum size: 4.75 mm; Fineness modulus: 4.20 Cement Specific gravity: 3.15 Silica fume Specific gravity: 2.20 Fly ash Specific gravity: 2.26 SP Specific gravity: 1.21; Solid content: 40 % AEA Specific gravity: 1.02; Solid content: 8 %
(2.2) Concrete Mix Design and Preparation of Concrete Specimens
A total of 54 cubical concrete specimens of 100 mm dimensions were prepared for this study. These consist of three types of concrete, OPCQD, SFQD and FAQD, with water-binder ratio of 0.35. Two types of curing method, water curing and air curing were practiced. The concrete mix proportions were determined by using the Sherbrooke mix design method [7]. In all the three types of concrete, replacement proportion of sand with quarry dust were varied between 0 % (no quarry dust), 20 % and 40 %. Besides that, 10 % of ordinary Portland cement was replaced with silica fume and fly ash in SFQD and FAQD respectively. The content of superplaticizers and air entraining admixtures were fixed by monitoring the desired workability and entrained air content in the fresh concrete mixes. A rotating pan type mixer (capacity 0.05 m 3 ) was used to mix the constituent materials. Fresh concrete was cast into 100 mm cubical moulds in two layers. Immediately after casting, the specimens were stored in the curing room at 202 o C and covered with plastic sheets. The specimens were demoulded after 1 day and were then allowed for water curing and air curing respectively. In water curing, specimens were immersed in water in a curing tank and the water temperature was maintained at 202 o C. Similarly, for air curing, the specimens were placed in the curing room and cured by air at 202 o C. The specimens were cured for another 27 days and the compressive strength of the cubical specimens were measured at the age of 28
days.
(2.2) Testing
The properties of quarry dust that were determined for this study are aggregate crushing value, flakiness index, pH value, soundness, specific gravity, absorption and fineness modulus. For comparison purposes, the aggregate crushing value, pH value, specific gravity, absorption and fineness modulus of the river sand used in this study were also determined. The aggregate crushing value was determined based on BS 812: Part 110: 1990 [8], the flakiness index based on BS 812: Part 1: 1975 [9], pH value of aggregates based on BS 1377: Part 3: 1990 [10], soundness test based on ASTM C88- 90 [11], and specific gravity and absorption based on BS 812: Part 2: 1975 [12]. Besides that, the compressive strength of cubical concrete specimens were measured based on BS 1881: Part 116: 1983 [13].
(3) RESULTS AND DISCUSSION
(3.1) Aggregate Crushing Value
The Aggregate Crushing Value (ACV) is a measure of aggregate resistance to pulverization [14]. The ACV of quarry dust used in this study is in the range of 47.70 % to 50.28 %, with an average value of 49.38 % as shown in Table 2.
Table 2 Aggregate Crushing Value (ACV) of Quarry Dust and River Sand Specimen ACV (%) Quarry dust 1 47.70 Quarry dust 2 50.16 Quarry dust 3 50.28 Average 49.38
River sand 18.0
When compared to the ACV of river sand used in this study which has a value of 18.0 %, it can be deduced that the river sand is a stronger and harder aggregate compared to the quarry dust. The higher ACV value for the quarry dust might be caused by the particle shape of quarry dust used in this study which is flaky and angular. The aggregate with such shape have the possibility to be crushed when load is applied on them. Neville has stated that even though there are no physical relation between the ACV and the compressive strength, but the results of the two are usually in agreement [14].
(3.2) Flakiness Index
Table 3 Flakiness Index of Quarry Dust Specimen Flakiness Index Quarry dust 1 48.86 Quarry dust 2 53.19 Quarry dust 3 61.70 Average 54.58
Flakiness index is a measure of the mass of the flaky particles expressed as percentage of the mass of the sample [14]. It can be observed from Table 3 that the flakiness index of quarry dust used in this study ranged between 48.86 % and 61.70 % with an average value of 54.58 %. This result implies that half of the quarry dust used in this study is flaky. The bond strength in concrete is dependent on the strength of the mix and the surface characteristics of aggregates. Especially in the case of fine aggregates, the surface texture of the aggregate affects its bond to the cement paste and also influences the water demand of the mix [14]. The substantial amount of flaky particles in the quarry dust will influence the bond between the aggregate and cement paste, thus resulting in the negative effects in the strength of the concrete matrix. Besides, aggregates with flaky particle shape tends to be oriented in one plane, with air voids and bleeding water forming underneath [14], which may result in adverse effects to the compressive strength and durability of concrete.
(3.3) pH Value
Table 4 pH Value of Quarry Dust and River Sand Specimen pH Value Quarry dust 1 8.14 Quarry dust 2 8.37 Quarry dust 3 8.64 Average 8.38
River sand 6.20
Referring to the results shown in Table 4, it can be deduced that quarry dust used in this study is a material with alkali characteristics. The average pH value for quarry dust was 8.38 and compared to the river sand used in this study which exhibited a pH value of 6.20, it can be deduced that river sand is more inclined to neutral condition compared to the quarry dust. The weak alkali characteristic of the quarry dust might induce the hydroxide ion (OH) into the concrete mix which might influence the hydration of cement in the mix and thus result in a slight decrease of the compressive strength. Anyway, the alkali influence of the quarry dust onto the concrete mix is only minimal since the properties of concrete are more influenced by the shape, surface texture, strength and hardness of quarry dust particles.
(3.4) Soundness Test
Table 5 Results of Soundness Test on Quarry Dust Maximum Size of Quarry Dust Soundness (%) 4.75 mm 3.2 2.36 mm 1.4 1.18 mm 4.6 600 m 6.0 300 m 36.8
Soundness of aggregate is a term used to describe the ability of aggregate to resist excessive changes in volume as a result of changes in physical conditions [14]. The results in Table 5 shows that quarry dust used in this study exhibited soundness values in the range of 1.4 % to 36.8 %. The wide range in the soundness value is due to the size of the quarry dust particles, where as the size of the quarry dust particle decreases, its ability to resist changes in volume also decreases. It can be deduced that low ability of the quarry dust to resist changes in volume might result in reduced ability of strength and durability of concrete when exposed to excessive conditions.
(3.5) Specific Gravity, Absorption and Fineness Modulus
Table 6 Specific Gravity, Absorption and Fineness Modulus of Quarry Dust and River Sand Properties Quarry Dust River Sand Specific gravity 2.63 2.57 Absorption 0.60 % 2.12 % Fineness modulus 4.20 4.20
When compared to river sand, the quarry dust used in this study exhibited a higher specific gravity, lower absorption and a similar fineness modulus. It can be mentioned that there are no direct relationship between these properties and the strength and durability of concrete, but they might have minimal effects to the bond strength between cement paste and aggregate. It should be noted that the slightly higher fineness modulus of both quarry dust and river sand indicate the presence of coarser particles in the samples of quarry dust and river sand used in this study.
(3.6) 28 th Day Compressive Strength
60 61 62 63 64 65 66 67 68 69 70 0% 20% 40% Percentage of Quarry Dust as Fine Aggregates C o m p r e s s i v e
S t r e n g t h
( M P a ) OPCQD SFQD FAQD
Fig. 1 28 th Day Compressive Strength of Water Cured Concrete Specimens (Water-Binder Ratio = 0.35)
Figure 1 and Figure 2 shows the 28 th day compressive strength of concrete with different ratios of partial replacement of river sand with quarry dust. Figure 1 represents the 28 th day compressive strength of water cured concrete specimens with water-binder ratio of 0.35, whereas Figure 2 represents the 28 th day compressive strength of air cured concrete specimens with water-binder ratio of 0.35.
54 55 56 57 58 59 60 61 62 0% 20% 40% Percentage of Quarry Dust as Fine Aggregates C o m p r e s s i v e
S t r e n g t h
( M P a ) OPCQD SFQD FAQD
Fig. 2 28 th Day Compressive Strength of Air Cured Concrete Specimens (Water-Binder Ratio = 0.35)
The 28 th day compressive strength of the water cured specimen ranged between 64.0 MPa and 67.8 MPa, whereas for air cured specimen, the 28 th day compressive strength ranged between 57.8 MPa and 60.7 MPa. It can be observed that for both curing methods, the partial replacement of river sand with quarry dust, and cement with mineral admixtures resulted in significant effects in the concrete compressive strength. For both cases with or without the inclusion of mineral admixtures, the partial replacement of sand with quarry dust resulted in a reduced compressive strength compared to the control concrete with no quarry dust. Similar findings have been reported is earlier studies [1,4]. It is also quite evident for both curing conditions that the compressive strength is further decreased as the replacement proportion of sand with quarry dust is increased. The high portion of flaky particles in the quarry dust sample used in this study might have caused the detrimental effects to the concrete compressive strength. As mentioned earlier, aggregates with flaky particle shape tends to be oriented in one plane, with air voids and bleeding water forming underneath [14], thus contributing to the negative effects to the compressive strength of concrete. The incorporation of mineral admixtures, especially silica fume was beneficial to overcome the negative effects in the compressive strength of the quarry dust concrete. It can be observed that SFQD concrete recorded the highest compressive strengths under all conditions. The beneficial effects of silica fume in concrete mixes in pronounced and have been widely accepted. The ultrafine particles of silica fume are able to fill the microvoids in the concrete matrix resulting in a much denser concrete matrix. Besides that, the chemical reaction between silica fume and calcium hydroxide produces calcium silicate hydrate (CSH), which occupies the larger spaces between the two reagents and reduces the porosity of concrete [1]. Similarly, the inclusion of fly ash into the concrete mix also resulted in beneficial effects in the concrete compressive strength even though it was not as effective as silica fume. Fly ash is a common artificial pozzolana which has been widely used in concrete production and it has the physical effect of improving the microstructure of the hydrated cement paste [14]. When comparing the different types of curing method practiced, it is quite evident that water cured specimens exhibited higher compressive strength than the air cured specimens, which is inline with the theoretical understanding. The lower degree of hydration in concrete when the vapour pressure is lower than 0.8 of the saturation pressure might be one the causes for this situation [14].
(4) CONCLUSIONS
Based on the results and discussion mentioned above, the following conclusions can be derived: 1. The quarry dust used in this study was a relatively weaker fine aggregate when compared to the river sand used in this study. 2. The aggregate crushing value, flakiness index, soundness and pH value of the quarry dust used in this study could contribute significant effects to the strength and durability of concrete. 3. The incorporation of quarry dust as partial replacement material to sand in concrete resulted in a reduction in the compressive strength, and this was more evident when the replacement proportion was increased. 4. The reduction in the compressive strength of the quarry dust concrete was compensated by the inclusion of mineral admixtures into the concrete mix. 5. In the presence of silica fume or fly ash, quarry dust can be a suitable partial replacement material to sand to produce concretes with fair ranges of compressive strength.
(5) REFERENCES
[1] M. Safiuddin, M.F.M. Zain, M.F. Mahmud and R.S. Naidu, Effect of quarry dust and mineral admixtures on the strength and elasticity of concrete, Proceedings of the Conference on Construction Technology, Kota Kinabalu, Sabah, Malaysia, pp. 68-80, 2001. [2] M.F.M. Zain, S.N. Raman and M. Safiuddin, Influence of partial replacement of sand with quarry dust on the properties of fresh high performance concrete (in Malay), Jurnal Kejuruteraan 12, pp. 21- 30, 2000. [3] K.S. Tan, M.F.M. Zain, K.M. Yusof, M. Safiuddin, T.Y. Chang and K.S. Lee, Influence of quarry dust and silica fume on the properties of high performance concrete, Proceedings of the Second International Conference on Advances in Strategic Technologies, Bangi, Selangor, Malaysia, pp. 1563-1572, 2000. [4] R.S. Naidu, M.F.M. Zain and K.S. Tan, Strength and elasticity of concrete incorporating quarry dust and mineral admixtures, Proceedings of the 3 rd
International Conference on Advances in Strategic Technologies, Kuala Lumpur, Malaysia, pp. 1179-1184, 2003. [5] S.N. Raman, M.F.M. Zain and H.B. Mahmud, Influence of quarry dust and mineral admixtures on the 28 th day initial surface absorption of concrete, in Sustainable Development in Concrete Technology: Proceedings of the Seventh International Conference on Concrete Technology in Developing Countries, Kuala Lumpur, Malaysia, pp. 33-42, 2004. [6] D.W.S. Ho, A.M.M. Sheinn, C.C. Ng and C.T. Tam, The use of quarry dust for SCC applications, Cement and Concrete Research 32 (4), pp. 505-511, 2002. [7] P.-C. Aitcin, Sherbrooke mix design method, Proceedings of the One-Day Short Course on Concrete Technology and High Performance Concrete: Properties and Durability, Kuala Lumpur, Malaysia, 1997. [8] BS 812: Part 110: 1990, Methods of determination of aggregate crushing value (ACV), Testing Aggregates, British Standards Institution, London, 1990. [9] BS 812: Part 1: 1975, Sampling, shape, size and classification, Testing Aggregates, British Standards Institution, London, 1975. [10] BS 1377: Part 3: 1990 [11] ASTM C88-90, Test for soundness of aggregates by use of sodium sulphate or magnesium sulphate, American Society of Testing and Materials, Philadelphia, 1990. [12] BS 812: Part 2: 1975, Methods for determination of physical properties, Testing Aggregates, British Standards Institution, London, 1975. [13] BS 1881: Part 116: 1983, Method for determination of compressive strength of concrete cubes, Testing Concrete, British Standards Institution, London, 1983. [14] A.M. Neville, Properties of Concrete: Fourth and Final Edition, Pearson Education Limited, Essex, 2002.