INTERNATIONALJOURNALOFCIVILANDSTRUCTURALENGINEERING Volume1,No 3,2010

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Stonecrusherdust asafineaggregateinConcreteforpavingblocks
1 2 RadhikeshP.Nanda , AmiyaK.Das ,Moharana.N.C3 1AssociateProfessor,DepartmentofCivilEngineering,NITDurgapur,Durgapur 2 PGstudent,DepartmentofCivilEngineering,KIITUniversity,Bhubaneswar 3 AssistantProfessor,DepartmentofCivil Engineering,KIITUniversity,Bhubaneswar rpnanda2002@yahoo.co.in

ABSTRACT Concretepavingblocksareidealmaterialsonthefootpathsforeasy laying,betterlookand finish. In this paper, a parametric experimental study for producing paving blocks using crusherdust ispresented. Someofthe physical andmechanical properties ofpavingblocks withfine aggregate (sand) replacedbyvariouspercentages of crusher dustare investigated. The test results shows that the replacement fine aggregate by crusher dust up to 50% by weight has a negligible effect on the reduction of any physical and mechanical properties while there is a saving of 56% of money. The percentage of saving was less but highly beneficial for mass production of paving blocks. The shaving would be more if the sand availabilityisatagreaterdistance.Thisalsoreducestheburdenofdumpingcrusherduston earthwhichreducesenvironmentalpollution. Keywords: Pavingblock,Stonecrusherdust. 1Introduction A lotof facelift is being is given toroads, footpaths along with roadside. Concretepaving blocks are ideal materials on the footpaths for easy laying, better look and finish. Cement concretepavingblocksareprecastsolidproductsmadeoutofcementconcrete.Theproduct is made in various sizes and shapes viz. rectangular, square, and round blocks of different dimensions with designs for interlocking of adjacent paving blocks. The raw materials require for manufactures of the product are Portland cement and aggregates which are available locally in every part of the country. Market potential cement concretes paving blocks find applications in pavements, footpaths, gardens, passengers waiting sheds, bus stops,industryandotherpublicplaces.Theproductiscommonlyusedinurbanareasforthe above applications. Hence, the unit may be set up in urban and semiurban areas, near the market. A concrete mix of 1:2:4 (cement: sand: stone chips) by volume may be used for cement concrete paving blocks with water to cement ratioof0.60. The concrete mix should notbe richer than 1:6 by volume of cement to combined aggregates before mixing. Fineness modulesofcombinedaggregatesshouldbeintherangeof3.6to4.0.Alltherawmaterials are placed in a concrete mixer is rotated for 15 minutes. Till now Indian standard has not given anyspecification on cement concrete paving blocks. However, the specification laid down in IS 2185 (Part1) specification for concrete masonryunits: Part 1 for Hollow and solidconcreteblocks,maybeusedasgeneralguidelinesformeetingthequalityparameters. Quality parameters like actual proportion of the individual raw materials, ratio of coarse aggregatestofineaggregates,watertocementratio,goodfinish,accuracyinsizeandshape,

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andcompressionstrengthaftercuringarethesomeoftheimportantparametersthatshouldbe checkedperiodicallytoensuregoodqualityoftheproduct. Ramanetal.,2005studiedtheeffectofquarrydustandfoundthatthepartialreplacementof river sand with quarry dust without the inclusion of fly ash resulted in a reduction in the compressivestrengthofconcretespecimen.Ithasalsobeenreportedthatthereductioninthe compressivestrengthofquarrydustconcretewascompensatedbytheinclusionofflyasinto theconcretemix.ReddyandReddy,2007reportedan increasingcompressivestrengthbyuse ofrockflourasfineaggregateinsteadofriversand.Ilangovanaetal.,2008reportedstrength of quarry rock dust concrete was comparably 1012 % more than that of similar mix of conventionalconcrete. Hameed and Sekar, 2009 studied effect of crushed stone dust as fine sand and found the flexural strength increases than the concrete with natural sand but the values decreases as percentage ofcrusher dust increases. It has been reportedby Reddy and Reddy, 2007from theirexperimentalstudyonuseofrockflowandinsulatorceramicscrapinconcretethatthe rock flow when used as fine aggregate increases the modulus of rapture thus the flexural strength. Fromthestudyofgreenconcretepossescontainingquarrydustandmarblesludge powder it has been reported that the split tensile strength of green concrete was 14.62% higherat7daysand8.66%higherat28days.Butsplittensilestrengthwasfoundtobelesser by10.41%at3daysthancontrolledconcrete. Hameed and Sekar, 2009 also reported the resistance of Green concrete containingcrusher dust againstsulfateattack (Mg SO4 and Na2SO4 ) ishigher than the conventional concrete. Also they have reported acidresistance( H2SO4 ) is higher than the conventional concrete. Thedurabilityofquarryrockdustconcreteundersulphateandacidactionishigherthanthe conventionalconcret.
2 Similarlywater Absorption found to be more in the concrete containing crusher dust . The overall workability value of quarry rock dust concrete in terms of slump as well as compactionfactorwaslessincomparisontoconventionalconcrete(Ilangovanaetal.,2008). Asreportedby (HameedandSekar,2009)theslumpvalueincreases(Workabilityincreases), if concrete is mixed with quarrydust as well as marble sludge due to presence of marble sludgepowder

2ExperimentalProgramme Paving block specimens (figure 1) of sizes 0.25mx0.20mx0.05m, made of concrete with cement,fineaggregate(sand/coarserdust)andcoarseaggregateintheratio(1:2:4)byweight arecastedwithfollowingreplacementsofsand. ConcretePavingbockSand100%andcrusherdust0% ConcretePavingbockSand75%andcrusherdust25% ConcretePavingbockSand50%andcrusherdust50% ConcretePavingbockSand25%andcrusherdust 75% ConcretePavingbockSand0%andcrusherdust100% (FC0) (FC25) (FC50) (FC75) (FC100)

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Figure1: Concretepavingblockspecimens 3.TestResultsandDiscussion Samples are prepared for calculating the different mechanical and physical properties of cementaswellasfineaggregateinthelaboratoryandarementionedbelow. 3.1Testresultsforcementandsand: StandardConsistency33% InitialSettingtime2Hrs20Minutes FinalSettingTime5Hrs10Minutes. Specificgravity 2.85 2 Strengthofcement38.32N/mm (for28Days) Sand:FinenessModulus:2.01,SpecificGravity=2.62 Crusherdust:FinenessModulus:3.13,SpecificGravity=2.62

3.2Testresultsforpavingblocks: 6 sets of samples from each category are prepared for calculating the average vales of differentmechanicalandphysicalpropertiesofpavingandmentionedinTable1.

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Table1:Differentmechanicalandphysicalpropertiesofpavingblockswithvariationof crusherdustreplacementwithsand Test 28dayscompressivestrength 2 (N/mm ) 2 28daysflexurestrength(N/mm ) 28dayssplittensileStrength 2 (N/mm ) 28daysabrasionvalue(mm) (FC0) 35.0 8.4 3.36 2.12 (FC25) 35.0 8.01 3.12 2.10 1.55 2576.9 94.0 2.0 1.60 (FC50) (FC75) 34.0 33.9 7.95 3.05 2.11 5.55 3.36 2.11 (FC100) 33.7 6.45 2.44 2.27 1.33 2550.0 80.0 1.94 1.57

24hr.waterabsorption(%) 1.60 3 Density(kg/m ) 2574.4 Slumpvalue(mm) 95.0 30 days weight loss (%) in acid 2.01 solution(H2So4) 30 days weight loss(%) in alkali 1.59 solution(NaOH)

1.41 1.56 2676.8 2594.4 90.0 87.0 1.96 1.95 1.60 1.61

Compressive Strength: Compressive Strength of the paving blocks are determined in accordance to IS: 2185 (PartI): 2005 as well as IS15658: 2006. Results for compressive strength of blocks FC0, FC25, FC50, FC75 & FC100 are shown in the graph (Fig.2). The compressive strength for paving block FC0 and FC25 shows higher and equal strength. But this strength for the blocks FC50, FC75 & FC100 are gradually decreasedbut the variation is very less.UptoFC50 showshigheststrengthamongtheblockscontainingcrusherdust.But all the specimen satisfy the recruitment given in IS : 15658 : 2006 forpaving blockstobe usedinnontrafficareas.AsperabovecodetheminimumgradeofconcreteasM30.Buteven M20 concreteisobservedtobesatisfyingaboverequirementwhichalsosatisfyrequirement ofcompressivestrengthofsolidblockgradeCasperIS:2185(PartI) 2005.

Figure2: Graphshowingcompressivestrengthwithvariationofcrusherdustreplacement

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Flexure Strength: The flexural strength of paving blocks can be expressed in term of flexural stress or in from of breaking load. The flexural strength(Fig.3) decreases as percentage of crusher dust increases but all the samples, FC75 as well as FC100 satisfying breakingloadspecifiedbyIS:15658:2006evenifinheavytrafficcondition.

Figure3:Graphshowingflexuralstrengthwithvariationofcrusherdustreplacement Split Tensile Strength:Splittensilestress hasbeendoneaccordingtoIS15658:2006.The split tensile stress in the normal concrete was found to be higher. Variation of split tensile stressinconcretecourtingcrusherdustbetweenFC50 andFC75 isless.ButthesampleFC100 shows much lower split tensile stress between normal concrete and concrete containing crusherdustisfoundtobe9%.AsperIS15658:2006thereisnoacceptancelimitmentioned butacceptancelimitedtothespecificationofthemanufacture.

Figure4: Graphshowingabrasionvaluewithvariationofcrusherdustreplacement

Abrasion:AbrasiontestofpavingblocksweredoneinaccordancetoIS:15658:2006.Itwas found that wearing depth increases with the increase of percentage of crusher dust. Hence

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wearingdepthisfoundtobe2.27mmforFC100 samples.AsperIS1237:1980thewearing depth should not exceed3.5mmof concreteblock usedfor general purposeand should not exceed 2mm. for heavy traffic. As the work contained to the non traffic condition wearing resistanceareseemstobesatisfactory.ThevariationuptoFC50isalmostconstant(Fig.4). Water Absorption: As per IS: 15658:2006 water absorption of concrete paving block shouldbe less than 7%. But maximum water absorption among all groups was found tobe 1.56% in FC75 which is much less than the requirement also it comply maximum water absorptionrequirementlessthan10%asperIS:2185(PartI)2005. Weight loss in Acid Solution:Fromthe Weightlossofsamplesimmersedinacidsolution (H2So4)with1%ofwaterafter30daysitwasfoundthelossinweightinthenormalconcrete wasslightlyhigherthattheconcretecontainingcrusherdustandalsoweightlossdecreasesas percentage of crusher dust increases. Difference in weight loss of normal concrete in the concretecontaining100%crusherdust(FC.100)isfoundtobe3.5%approximately.Theloss inweightuptoFC50isinsignificant. WeightLossinAlkaliSolution:Weightlossofsamplesinalkalisolution(NaOH)with4% of water after 30 days in the normal concrete was found to be smaller than the concrete containing crusher dust but differences are very small about 0.6%. It may be due to the crusherdusthavegreatertendencyofreactingwithalkalisolutionthanthe normalsandi.e. resistanceofcrusherdustagainstalkaliresistanceislessthanthenormalsand. Density:Densityofthenormalconcretewasfoundtobelessthanthedensityoftheconcrete containingcrusherdustbutspecificgravityofthesandusedforthepreparationofconcrete was found to be higher than the specific gravity of crusher dust. Density of the specimen FC100 isfoundtobelessthanthenormalconcrete.ThespecimenFC50 &FC75 showshigher densityanditmaybeduetodifferenceincompactionduringcastingormaybeduetoslight variation in homogeneous in the mix. The code IS 2185 (part 1) : 2005 specified for solid 3 concreteblockgradeCdensityshouldnotbelessthan1800Kg/m . Flow/Slump(waterrequirement):Theslumpvaluehadbeenmeasuredduringthecasting ofspecimen.Theslumpvaluedecreasesasthepercentageofcrusherdustincreases.This reflectsaspercentageofcrusherdustincreasesthewaterrequirementincreasesandthusslum valuedecreaseswhichmayduetextureofcrusherdust.Generallycrusherdusthasrough texturethansand.Theaggregatehavingroughtexturerequiresmorewaterforsurface weighting.Thussomewaterisconsumedforsurfaceweightingofcrusherdustandthenet wateravailablegetdecreasesforworkability.AspertheIS15658:2006concretepaving blockmaybepreparedwithconcretehavingzeroslumps.Ifthewaterrequirementincreases andslumpdecreases,additionofcrusherdustmaysolvetheproblemwhichwillnotaffectthe physicalproperties. 3.3Costeffectiveness: It has been seen that a replacement of up to50% shows negligible variation in mechanical andphysicalproperties.Baseuponthiscostshavingiscalculated.Costofstonecrusherdust including transportation = Rs. 100 per Cum. Cost of Sand (river 20km away) including transportation=Rs.216percum.Variationintransportationcostdependinguponlocationof site and source of sand & crusher dust. It has been seen that there is a shaving of 56% of

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money if sand is replaced by crusher dust. The percentage of saving was less but highly beneficial for mass production of paving blocks. The shaving would be more if the sand availability isat greater distance. This also reduces the burdenofdumping crusher duston earthwhichisecofriendly. 4.Conclusion Replacementfineaggregatebycrusherdustupto50%byweight hasa negligibleeffecton the reduction of any physical andmechanical properties like compressive strength, flexural strength, split tensile strength etc. Water absorption is well below the limit as per Indian codes.Durabilitytestshowsnovariationfordifferentreplacementsofcrusherdust.Thereisa shavingof56%ofmoneyifsandisreplacedbycrusherdust.Thepercentageofsavingwas lessbuthighlybeneficialformassproductionofpavingblocks.Theshavingwouldbemore if thesand availability isat greaterdistance like hilly area. This also reduces theburdenof dumpingcrusherdustonearthandhenceenvironmentalpollution. 5.References 1. AhmedA.E.K.,1989,Propertiesofconcreteincorporatingnaturalandcrushedsand veryfinesand,ACEMaterialJournal,Vol.86(4),pp417424. 2. Hameed, M. S. and Sekar A. S. S., 2009, Properties of green concrete containing quarry rock dust and Marble sludge powder as fine aggregates, ARPN journal of EngineeringandappliedScience,Vol.4(4),pp8389. 3. Ilangovana, R. Mahendrana, N. and Nagamanib, K., 2008, Strength and durability propertiesofconcretecontainingquarryrockdustasfineaggregates,ARPNJournal ofEngineeringandAppliedScience,Vol.3(5),pp2026. 4. IS15658:2006,Precastconcreteblocksforpavingpage,BureauofIndianStandard, NewDelhi 5. IS2185(part1):2005,Concretemasonryunitsspecification:Part1hollowandsolid concreteblocks,BureauofIndianStandard,NewDelhi 6. IS:15658:2006,Precastconcreteblockforpaving,BureauofIndianStandard,New Delhi 7. Jayawardhane,U.DesandDissanayake,D.M.S.,2006,Useofquarrydustinstead ofriversandforfutureconstructioninSriLanka,TheGeologicalSocietyofLondon, AEG200E,paperno38,pp14. 8. Raman, S. N. M., Zain, F. M., Mahmud H. B. & Tan, K. S., 2005. Influence of quarry dust & fly ash on the concrete compressive strength development. Proc. AEESEAPInt.Conf.2005.KualaLumpur,Malaysia,78Jun2005

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9. Reddy, M.V. and Reddy, C.N.V.S.,2007,Anexperimental study of rock flourand insulatorceramicscrapinconcrete,JournalofInstituteofEngineer(India),Vol88, August,pp4750.

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