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ABSTRACT
The problem arising from continuous technological and industrial
development is disposal of waste material. Conservation of natural
resources and sustainable development
INTRODUCTION :
In modern way of construction, the consumption of ceramic materials
has building up day by day in the form of tiles, sanitary fittings and other
electrical goods like insulators. Crushed Insulator and bush scrap was
used as a coarse aggregate in the present study.
Conventional Concrete is being used in bulk quantity. Therefore, doing
research about using modern technologies in production concrete is of
great importance. Furthermore, one of the most critical problems of the
world
This experimental study is related to remove the wastage and reusing of
it. In all countries, large amount of wastage is produced annually. most
of these wastage are not reusable or if they are, their recycling leads to
wasting energy and pollution which is turn increase the risk of these
materials for the environment. Moreover, a good strategy to achieve the
two purposes of removing the wastage material and also obtaining the
positive qualities of concrete.
The wastage related to tile, ceramic insulators and sanitary ware are
created in different forms some of which are produced in companies
during and after production process due to errors in either construction,
human activities, and also inappropriate raw materials. Some others are
produced in transportation and distribution procedures and finally, the
most bulk of them are created as a result of destroying constructions. It
is predicted that almost 3 to 7 percent of daily production of ceramic in
Europe change into wastage and this amount reaches to millions ton per
year .
The properties of these materials are in a way that they are unusable in
other cycles of production. Therefore, they are useless in practiced and
cause damages to environment. All in all, the hard physical structure of
these materials and also their chemical structure make them a good and
suitable choice to be used in concrete.
However, no comprehensive study has yet done in which the use of the
materials as sand and coarse aggregate in wide ranges and then
determining the ideal percent of substation have not been achieved
either.
Therefore, in this experimental study, first the grinded waste ceramic
ceramic insulator and then its grading were done in a way that the tile
grading curve of the natural aggregates used in control concrete was
completely in compatible with the ceramic aggregates. After that, a
range of experiments including chemical analysis, unit weight, water
absorption, and Crushing strength test were done on ceramic
aggregates. Waste ceramic material in 0, 25, 30, 35 and 40 percent is
substituted for coarse aggregates.
The experimental studied is done of concrete made with replacement of
stone coarse aggregate by ceramic waste aggregate with conventional
stone coarse aggregate, coarse sand of kolayat, Bikaner and OPC 43
grade Make: JK cement. The ceramic waste aggregate is taken at 25%,
30%, 35% and 40%.
GREEN CONCRETE :
Green concrete can be defined as the concrete with material as a partial
or complete replacement for cement or fine or coarse aggregates. The
substitution material can be of waste or residual product in the
manufacturing process. The substituted materials could be a waste
material that remain unused, that may be harmful (material that contains
TESTING OF CEMENT :
Specific gravity
: 3.15.
Initial Setting Time : 75 minutes
Final Setting Time : 186 minutes
Soundness
: 2.00 mm
Compressive
: 345 Kg/cm2
Strength
Materials
Percent
Percent
Materials
Percent
SiO2
68.85
Na2O
2.01
MnO
Al2O3
18.53
K2O
1.63
P2O5
Fe2O3
4.81
MgO
0.72
SO3
CaO
1.57
TiO2
0.737
Materials
0.078
0.034
0.06
TESTS
STONE
AGGREGATE
CERAMIC
WASTE COARSE
AGGREGATE
COARSE
SAND
(Zone-II)
IMPACT VALUE
As per
IS:2386
13.60%
20.00%
--
CRUSHING
VALUE As per
15.75%
22.00%
--
IS:2386
3
4
5
6
WATER
ABSORPTION
MOISTURE
CONTENT
SPECIFIC
GRAVITY
FLAKINESS
INDEX
As per
IS:2386
0.50%
0.21%
1.25%
NIL
NIL
0.10%
2.45
2.71
2.60
17.50%
21.36 %
--
SIEVE SIZE
% PASSING Of Sand
10 mm
100
4.75 mm
95.26
2.36 mm
88.53
1.18 mm
68.30
600 micron
40.21
300 micron
8.15
150 micron
1.45
COARSE AGGREGATES :
SN.
SIEVE SIZE
% PASSING
% PASSING
20 mm
10 mm
1.
40 mm
100
--
2.
20 mm
92.87
--
12.5 mm
--
100
10 mm
1.64
95.56
4.75 mm
1.11
2.36 mm
--
0.13
SIEVE
SIZE
% PASSING
% PASSING
Combined
20 mm
10 mm
100 %
(60 %)
(40 %)
1.
40 mm
60
40
100
2.
20 mm
55.72
40
95.72
3.
10 mm
0.98
38.22
39.20
4.
4.75 mm
0.44
0.44
2.36 mm
--
0.05
EXPERIMENTAL PROGRAM :
Experimentation was done for verdict of following
1. Effect of replacement of coarse aggregate with Ceramic waste
aggregate on compressive strength, flexural strength and
workability of concrete.
W/C RATIO :
As per IS: 456 maximum W/C ratio is 0.55 for M-20 grade of concrete.
So 0.55 W/C ratio is taken for better workability of concrete for all six
trials.
MIX PROPORTION :
Based on the ingredient properties of concrete, M-20 concrete mix
design as per IS 10262-2009 was prepared and its proportion was
0.55: 1: 1.96: (1.91,1.27) (W: C: FA: CA) by weight.
TEST PROCEDURE
Compressive strength:
Six cube specimens for each replacement percentage were casted
according to the design mix. The size of cubes is 150x150x150mm. To
study the workability, slump cone test is performed. Specimens were
compacted in table vibrator and de-molded after 24 hrs and cured in
water curing tank @ temperature of 27 2 for a period of 7 and 28
days. After completion of curing period, specimens were removed from
curing tank kept for drying and then tested in compression testing
machine of 2000 KN Capacity.
OBSERVATION:
TRIAL NO. 1 :
Procedure :
After trial with different cement and w/c ratio final and suitable concrete
for for M-20 grade of concrete design mix of concrete conventional
material OPC 43 grade cement, fine aggregate, coarse aggregate and
water mixed with concrete mixture and cubes are prepared. Compaction
is done with the help of vibrating table. The compressive strength of 7
and 28 days are found as per target mean strength.
W/C
CEMENT
0.55
S
N
MATERIAL
CCCUBES
(M-20)
FINE AGGREGATE
CONVENTIONAL CONVENTIONAL
C. A.
C. A.
1.96
COMPRESSIVE
STRENGTH FOR
7 DAYS CURING
Kg/cm2
SAMPLES
1. 197.25
2. 192.77
3. 195.90
20 mm
(60%)
10 mm
(40%)
1.91
1.27
COMPRESSIVE
STRENGTH FOR
28 DAYS CURING
Kg/cm2
RESULT
195.30
SAMPLES
4. 298.43
5. 297.74
6. 298.36
RESULT
298.17
TRIAL NO. 2 :
Procedure :
For M-20 grade of concrete design mix with 60% of conventional coarse
aggregate and 40% of ceramic waste material, OPC 43 grade cement,
fine aggregate and water mixed with concrete mixture and six cubes are
casted. Compaction is done with the help of vibrating table.The
compressive strength of 7 and 28 days are found satisfactory. The target
mean strength has been achieved but lower compressive strength
found.
W/C
CEMENT
FINE AGGREGATE
C. A.
0.55
S
N
MATERIAL
CCCUBES
(M-20)
1.96
COMPRESSIVE
STRENGTH
FOR
7 DAYS CURING
Kg/cm2
SAMPLES
1. 186.90
2. 188.03
3. 187.70
RESULT
187.54
C. A.
20 mm
(60%)
10 mm
(40%)
1.91
1.27
COMPRESSIVE STRENGTH
FOR
28 DAYS CURING
Kg/cm2
SAMPLES
4. 267.24
5. 266.90
6. 267.29
RESULT
267.15
TRIAL NO. 3 :
Procedure :
For M-20 grade of concrete design mix with 65% of conventional coarse
aggregate and 35% of ceramic waste material, OPC 43 grade cement,
fine aggregate and water mixed with concrete mixture and six cubes are
casted. Compaction is done with the help of vibrating table.The
compressive strength of 7 and 28 days are found satisfactory. The target
mean strength has been achieved but lower compressive strength
found.
W/C
0.55
S
N
CEMENT
MATERIAL
CCCUBES
(M-20)
FINE AGGREGATE
1.96
COMPRESSIVE
STRENGTH FOR
7 DAYS CURING
Kg/cm2
SAMPLES
1. 190.20
2. 192.77
3. 192.70
RESULT
191.89
20 mm
(65%)
10 mm
(35%)
2.06
1.11
COMPRESSIVE STRENGTH
FOR
28 DAYS CURING
Kg/cm2
SAMPLES
4. 270.90
5. 274.89
6. 276.76
RESULT
274.18
TRIAL NO. 4 :
Procedure :
For M-20 grade of concrete design mix with 70% of conventional coarse
aggregate and 30% of ceramic waste material, OPC 43 grade cement,
fine aggregate and water mixed with concrete mixture and six cubes are
casted. Compaction is done with the help of vibrating table.The
compressive strength of 7 and 28 days are found satisfactory. The target
mean strength has been achieved but average compressive strength
found.
W/C
0.55
S
N
CEMENT
MATERIAL
CCCUBES
(M-20)
FINE AGGREGATE
1.96
COMPRESSIVE STRENGTH
FOR
7 DAYS CURING
Kg/cm2
SAMPLES
1. 193.12
2. 194.46
3. 193.70
RESULT
193.76
20 mm
(70%)
10 mm
(30%)
2.22
0.95
COMPRESSIVE STRENGTH
FOR
28 DAYS CURING
Kg/cm2
SAMPLES
4. 280.20
5. 282.43
6. 282.72
RESULT
281.78
TRIAL NO. 5 :
Procedure :
For M-20 grade of concrete design mix with 75% of conventional coarse
aggregate and 25% of ceramic waste material, OPC 43 grade cement,
fine aggregate and water mixed with concrete mixture and six cubes are
casted. Compaction is done with the help of vibrating table. The
compressive strength of 7 and 28 days are found satisfactory. The target
mean strength has been achieved but better compressive strength
found.
W/C
0.55
S
N
CEMENT
MATERIAL
CCCUBES
(M-20)
FINE AGGREGATE
1.96
COMPRESSIVE STRENGTH
FOR
7 DAYS CURING
SAMPLES
1. 195.26
2. 196.70
3. 195.22
RESULT
195.72
20 mm
(75%)
10 mm
(25%)
2.38
0.79
COMPRESSIVE STRENGTH
FOR
28 DAYS CURING
SAMPLES
4. 290.20
5. 292.77
6. 291.70
RESULT
291.55
TRIAL NO. 6 :
Procedure :
For M-20 grade of concrete design mix with 75% of conventional coarse
aggregate and 25% of ceramic waste material, OPC 43 grade cement,
fine aggregate and water mixed with concrete mixture and six cubes are
casted. Compaction is done with the help of vibrating table. The
compressive strength of 7 and 28 days are found satisfactory. The target
W/C
CEMENT
0.55
S
N
MATERIAL
CCCUBES
(M-20)
FINE AGGREGATE
1.96
COMPRESSIVE STRENGTH
FOR
7 DAYS CURING
SAMPLES
1. 195.80
2. 196.77
3. 196.24
RESULT
196.27
20 mm
(80%)
10 mm
(20%)
2.54
0.63
COMPRESSIVE STRENGTH
FOR
28 DAYS CURING
SAMPLES
4. 294.24
5. 294.72
6. 295.71
RESULT
294.89
SLUMP :
1. Reduction of slump was 5.3% when recycled ceramic
aggregate was used at a replacement level of 25%.
2. Compressive strength of concrete made with ceramic insulator lower
as compared to the conventional concrete .
3. Recycled aggregate shows higher water absorption and lower density
due to the mortar adhered to the recycled aggregate and these
fired
Water absorption:
Water absorption of ceramic waste was 0.21% and that of natural
aggregate was 0.50%. Compacted and even crushing of these will not
wide opens. So, due to this reason water absorption has increased little
in ceramic scrap. Ceramic scrap has porcelain cover over the top
surface, deglazing was done partially during chiseling and crushing.
Partial deglazing of ceramic waste surface is influencing the water
absorption property. Table presents the comparison of physical
properties of ceramic waste aggregate and crushed granite coarse
aggregate. All the properties were well within the acceptable range for
coarse aggregates and hence the ceramic waste aggregate can be
safely used in concrete making.
Compressive strength:
CONCLUSION :
The substation of ceramic as a coarse aggregate and finally reported a
positive effect for the process.
Compressive Strength of non conventional concrete is gradually
increase with decrease of percentage of waste ceramic insulator in the
concrete as coarse aggregate. However compressive strength of
ceramic waste aggregate is found satisfactory with achievement of
target mean strength. Due to the influence of water absorption and
external porcelain nature, strength of ceramic concrete is declining
gradually but strength of ceramic concrete is more than the targeted
mean strength even after replacing 100% of natural coarse aggregate.
Coarse aggregate is 30% less than the natural aggregate and loss of
strength is about 30% as compared to the conventional aggregate
concrete. Similar trends were reported even for flexural strength.
1.
REFERENCES :
IS Codes :
1. IS : 383 OF 1970 : Specification for coarse and fine aggregate.
2. IS : 2386 OF 1963 : Method of test for aggregate for concrete.
3. IS : 10262 OF 2009 : Recommended guidelines for Concrete mix
design
4. IS : 456 OF 2000
: Code of practice for plain reinforced
concrete.
5. IS : SP-23 (S&T)-1982 : Concrete design mixes
6. IS : 8112 : OPC 43 grade Cement
7. IS : 1269
1.M.S. Shetty