replacement of natural sand with efficient alternatives...

Anzar Hamid Mir Int. Journal of Engineering Research and Applications www.ijera.com

ISSN : 2248-9622, Vol. 5, Issue 3, ( Part -3) March 2015, pp.51-58

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Replacement of Natural Sand with Efficient Alternatives: Recent

Advances in Concrete Technology

Anzar Hamid Mir Student, Bachelor of Civil Engineering, IUST Awantipora, J&K, INDIA

ABSTRACT

Concrete is the most undisputable material being used in infrastructure development throughout the world. It

is a globally accepted construction material in all types of Civil Engineering structures. Natural sand is a

prime material used for the preparation of concrete and also plays an important role in Mix Design. Now a

day‟s river erosion and other environmental issues have led to the scarcity of river sand. 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 find new alternative materials to replace river sand so that excess river erosion is prevented

and high strength concrete is obtained at lower cost. Partial or full replacement of natural sand by the other

alternative materials like quarry dust, foundry sand and others are being researched from past two decades, in

view of conserving the ecological balance. This paper summarizes conclusions of experiments conducted for

the properties like strength, durability etc. It was observed the results have shown positive changes and

improvement in mechanical properties of the conventional concrete due to the addition or replacement of fine

sand with efficient alternatives.

KEYWORDS: Concrete, Natural sand, Alternative materials, Quarry dust, Foundry sand, Mechanical

properties.

I. I.INTRODUCTION Concrete is that pourable mix of cement, water,

sand, and gravel that hardens into a super-strong

building material. Aggregates are the important

constituents in the concrete composite that help in

reducing shrinkage and impart economy to concrete

production. River Sand used as fine aggregate in

concrete is derived from river banks. River sand has

been the most popular choice for the fine aggregate

component of concrete in the past, but overuse of the

material has led to environmental concerns, the

depleting of river sand deposits and an increase in the

price of the material. The developing country like

India( Authors native land) 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. The

rapid extraction of sand from the river bed causes

problems like deepening of the river beds, loss of

vegetation on the bank of rivers, disturbance to the

aquatic life as well as agriculture due to lowering the

water table in the well etc. Therefore, construction

industries of developing countries are in stress to

identify alternative materials to replace the demand

for river sand. Hence, partial or full replacement of

river sand by the other compatible materials like

crushed rock dust, quarry dust, glass powder,

recycled concrete dust, and others are being

researched from past two decades, in view of

conserving the ecological balance. The reuse of this

waste will help to save cost, conserve limited

resources and ultimately protect the environment.

Due to shortage of river sand as well as its high

the Madras High Court restrictions on sand mining in

rivers Cauvery and Thamirabarani. The facts like in

India is almost same in others countries also. So

therefore the need to find an alternative concrete and

mortar aggregate material to river sand in

construction works has assumed greater importance

now a days. Researcher and Engineers have come out

with their own ideas to decrease or fully replace the

use of river sand and use recent innovations such as

M-Sand (manufactured sand), robot silica or sand,

stone crusher dust, filtered sand, treated and sieved

silt removed from reservoirs as well as dams besides

sand from other water bodies [16].

II. EFFICIENT ALTERNATIVE

MATERIALS TO RIVER SAND Concrete is the second largest consumable

material after water, with nearly three tonnes used

annually for each person on the earth. India

consumes an estimated 450 million cubic meter of

concrete annually and which approximately comes to

1 tonne per Indian. Bureau of Indian Standards, the

National Standards Body of the country, considering

the scarcity of sand from natural sources, has evolved

number of alternatives which are ultimately aimed at

conservation of natural resources apart from

promoting use of various waste materials without

compromising in quality. use of these alternative

RESEARCH ARTICLE OPEN ACCESS




materials such as fly ash, slag, not only help in

conserving our precious natural resources but also

improve the durability of structures made using these.

2.1 COPPER SLAG

Copper slag is an abrasive blasting grit made of

granulated slag from metal smelting processes (also

called iron silicate). During the past two decades,

attempts have been made by several researchers all

over the world to explore the possible utilization of

copper slag in concrete. At present about 33 million

tonnes of copper slag is generating annually

worldwide among that India contributing 6 to 6.5

million tonnes. 50 % copper slag can be used as

replacement of natural sand in to obtain mortar and

concrete with required performance, strength and

durability. (Khalifa S. Al-Jabri et al 2011)

Fig 1: Copper slag[17]

2.2 GRANULATED BLAST FURNACE SLAG

Granulated blast-furnace slag (GBFS) is

obtained by quenching molten iron slag (a by-product

of Iron and steel-making) from a blast furnace in

Water or steam, to produce a glassy, granular product

that is then dried and ground into a fine powder.

GBFS has been adopted for its superiority in concrete

durability, extending the lifespan of buildings from

fifty years to a hundred years.

Fig 2: Granulated blast-furnace slag[17]

According to the report of the Working Group on

Cement Industry for the 12th five year plan, around

10 million tonnes blast furnace slag is currently being

generated in the country from iron and steel industry.

The compressive strength of cement mortar increases

as the replacement level of granulated blast furnace

slag (GBFS) increases. He further concludes that

from the test results it is clear that GBFS sand can be

used as an alternative to natural sand from the point

of view of strength. Use of GBFS up to 75 per cent

can be recommended [2].

2.3WASHED BOTTOM ASH (WBA)

The WBA is a waste material that is taken from

electric power plant and the source material is called

as bottom ash. Figure 3 show the typical steam

generating system that illustrated the bottom ash

dispose at the bottom furnace and fly ash is dispose

to atmosphere by very tall chimney.

Fig 3: The production of coal combustion by-

products in steam generating system. (NETL,2006).

2.4 QUARRY DUST (QD)

Quarry dust is fine rock particles. When

boulders are broken into small pieces quarry dust is

formed. It is grey in colour and it is like fine

aggregate. In concrete production it could be used as

a partial or full replacement of natural sand. Besides,

the utilization of quarry waste, which itself is a waste

material, will reduce the cost of concrete production.

2.4.1 ORIGIN OF QUARRY DUST

The quarry dust is the by-product which is

formed in the processing of the granite stones which

broken downs into the coarse aggregates of different

sizes.

FIG 4: Quarry Dust[17]

2.5 FOUNDRY SAND

Foundry sand is sand which when moistened &

compressed or oiled or heated tends to pack well and

hold its shape. It is used in the process of sand

casting. India ranks fourth in terms of total foundry

production (7.8 million tonnes) according to the 42nd

Census of World Casting Production of 2007.

Foundry sand which is very high in silica is regularly




discarded by the metal industry. Currently, there is no

mechanism for its disposal, but international studies

say that up to 50 per cent foundry sand can be

utilized for economical and sustainable development

of concrete (Vipul D. Prajapati 2013)[8].

Fig 5: Foundry sand[17]

2.6 SHEET GLASS POWDER (SGP)

Glass is amorphous material with high silica

content, thus making it potentially pozzolanic when

particle size is less than 75μm(Federio.L.M and

Chidiac S.E,2001, Jin.W, Meyer.C, and

Baxter.S,2000). The use of recycled glass as

aggregate greatly enhances the aesthetic appeal of the

concrete. Natural sand was partially replaced (10%,

20%, 30%, 40% and 50%) with SGP. Compressive

strength, Tensile strength (cubes and cylinders) and

Flexural strength up to 180 days of age were

compared with those of concrete made with natural

fine aggregates Attempts have been made for a long

time to use waste glasses as an aggregate in concrete,

but it seems that the concrete with waste glasses

always cracks .Very limited work has been conducted

for the use of ground glass as a concrete replacement.

(M. Mageswari and Dr. B.Vidivelli 2010) [9].

Fig 6: Glass powder[17]

2.7 CONSTRUCTION AND DEMOLITION

WASTE:

Construction and demolition waste is

generated whenever any construction/demolition

activity takes place, such as, building roads, bridges,

fly over, subway, remodelling etc. It consists mostly

of inert and non-biodegradable material such as

concrete, plaster, metal, wood, plastics etc. A part of

this waste comes to the municipal stream.

These wastes are heavy, having high density,

often bulky and occupy considerable storage space

either on the road or communal waste bin/container.

It is not uncommon to see huge piles of such waste,

which is heavy as well, stacked on roads especially in

large projects, resulting in traffic congestion and

disruption. Waste from small generators like

individual house construction or demolition, find its

way into the nearby municipal bin/vat/waste storage

depots, making the municipal waste heavy and

degrading its quality for further treatment like

composting or energy recovery. Often it finds its way

into surface drains, choking them. It constitutes about

10-20 % of the municipal solid waste (excluding

large construction projects).

Fig 7: Construction and demolition waste[17]

2.8 CRUSHED SPENT FIRE BRICKS (CSFB)

Fire bricks are the products manufactured (as

per IS: 6 and IS: 8 specifications) from refractory

grog, plastic, and non plastic clays of high purity.

The different raw materials are properly

homogenized and pressed in high capacity presses to

get the desired shape and size. Later, these are fired

in oil-fired kiln at a temperature of 1,300°C.

Fig 8: Fire brick samples

III. PHYSICAL AND MECHANICAL

PROPERTIES DIFFERENT

ALTERNATIVES 3.1 COPPER SLAG:

The sieve analysis for copper slag infers that the

gradation properties of fine aggregates at all the

replacement levels are similar to the specification for

sand zone II as per IS: 383.

The sieve analysis report is shown in Table 1




Table 1[1] Fineness test on copper slag

The test results of concrete were obtained by

adding copper slag to sand in various percentages

ranging from 0%, 20%, 40%, 60%, 80% and 100%.

All specimens were cured for 28 days before

compression strength test, splitting tensile test and

flexural strength. The highest compressive strength

obtained was 35.11MPa (for 40% replacement) and

the corresponding strength for control mix was

30MPa. This results of the research paper showed

that the possibility of using copper slag as fine

aggregate in concrete. The results showed the effect

of copper slag on RCC concrete elements has a

considerable amount of increase in the compressive,

split tensile, flexural strength characteristics and

energy absorption characteristics [1].

3.2 GRANULATED BLAST FURNACE SLAG

The granulated blast furnace slag (GBFS) is

glassy particle and granular materials in nature and

has a similar particle size range like sand. The

specific gravity of the slag is 2.63. The bulk density

of granulated slag varies from 1430 kg/m3 which

were almost similar to bulk density of convectional

fine aggregate.

FIG 9 shows the gradation curve for both natural

sand and GBFS.

Fig 9

Investigation was carried out on cement mortar

mix 1:3 and GBFS at 0, 25, 50, 75 and 100%

replacement to natural sand for constant w/c ratio of

0.5 is considered (Table 2). The flow characteristics

of the mix and compressive strengths at various ages

are studied. From this study it is observed that there

is a considerable increase in compressive strength

evident from Table 2 thus GBFS could be utilized

partially as alternative construction material for

natural sand in concrete but there is reduction in

workability for all replacement levels. The

workability can be increased by adding suitable

dosage of chemical admixture such as super

plasticizer

Table 2




3.3 WASHED BOTTOM ASH

The physical properties of washed bottom ash

are tabulated below in Table 3

Table 3: The physical properties of bottom ash

The fineness modulus is the summation of the

cumulative percentage retained on the sieve standard

series of 150, 300 and 600μm, 1.18, 2.36, 5.0 mm up

to the larger sieve size used. The calculated fineness

modulus of bottom ash was 3.65 which is more than

3.5 and is considered to be very coarse. For

categorization given in BS 822:1992 based on

percentage passing the 600μm sieve between 55%

to100% would defined it as fine sand. While WBA

has percentage passing 600μm of 58.99%. Therefore,

the WBA is considered as fine sand (Alexander &

Mindess, 2005)[3].

Generally, all concrete with WBA replacement

has increment in strength until long term duration i.e.

at 60 days. Different concrete mixes with constant

water to cement ratio of 0.55 were prepared with

WBA in different proportions as well as one control

mixed proportion. The mechanical properties of

special concrete with 30% WBA replacement by

weight of natural sand is found to be an optimum

usage in concrete in order to get a favourable strength

and good strength development pattern over the

increment ages [4].

3.4 QUARRY DUST: The physical properties of

quarry dust obtained by testing the sample as per the

Indian Standards are listed in the below table. Table

4: Showing the Physical properties of quarry dust and

natural sand

Quarry dust is poorly graded as compared to sand.

The particle size distribution of QD is shown in Fig

10

Fig 10

The results of the compression test are tabulated

below.

Table 5

The results show that there is an increase in the

compressive strength of the concrete [5,6] which the

increment is about 55% to 75% depending on the

replacement if the sand with the quarry dust, for the

100% replacement of the sand the compressive

strength is depending on the quarry dust location

from where the quarry dust was taken. The

workability of the concrete is decreasing when the

replacement percentage of the quarry dust is

increasing gradually; so as to increase the workability

small quantity of the fly-ash is replaced in place of

cement to increase the workability [7].

3.5 FOUNDRY SAND:

Table 6: Physical properties of foundry sand




The fine aggregate has been replaced by used

foundry sand accordingly in the range of 0%, 10%,

30% & 50% by weight for M-20 grade concrete.

Concrete mixtures were produced, tested and

compared in terms of compressive and flexural

strength with the conventional concrete. These tests

were carried out to evaluate the mechanical

properties for 7, 14 and 28 days. This research work

is to investigate the behaviour of concrete while

replacing used foundry sand in different proportion in

concrete. This low cost concrete with good strength is

used in rigid pavement for 3000 commercial vehicles

per day and Dry Lean Concrete (DLC) 100mm thick

for national highway to make it eco-friendly [8]. The

maximum compressive strength was achieved with

50% replacement of fine aggregate with waste

foundry sand and it was found that there is overall

increase in the split tensile strength and flexural

strength of plain concrete.

3.6 SHEET GLASS POWDER

Table 7: Physical properties of Sheet Glass powder

The compressive strength of cubes and cylinders

of the concrete for all mix increases as the % of SGP

increases but decreases as the age of curing increases

due to alkali silica reaction. The Tensile strength of

cubes and cylinders of the concrete for all mix

increases than that of conventional concrete age of

curing and decreases as the SGP content increases.

The Flexural strength of the beam of concrete for all

mix increases with age of curing and decreases as the

SGP content increases. 100% replacement of SGP in

concrete showed better results than that of

conventional concrete at 28 days and 45 days curing

but later it started to decrease its strength because of

its alkali silica reactions. The density of SGP

concrete is more that of conventional concrete. SGP

is available in significant quantities as a waste and

can be utilized for making concrete. This will go a

long way to reduce the quantity of waste in our

environment. The optimum replacement level in fine

aggregate with SGP is 10% [9].

3.7 CONSTRUCTION AND DEMOLISHION

WASTE

The fine aggregate was replaced with crushed

waste sandcrete block (CWSB) in various

percentages in the steps of 10 starting from 10% to a

maximum of 100%, while 0% represents the control.

The properties of the concrete were evaluated at 7, 14

and 28 days curing periods. Results showed (Table 3)

that replacing 50% of CWSB aggregate after 28 days

curing attained the designed compressive strength as

the conventional concrete (i.e., the control). Thus it is

concluded that CWSB can be used as a

supplementary aggregate material in concrete [10].

3.8 CRUSHED SPENT FIRE BRICKS

Table 8: Physical properties of Spent fire bricks [11]

An experimental investigation of strength and

durability was undertaken to use “Spent Fire Bricks”

(SFB) (i.e. waste material from foundry bed and

walls; and lining of chimney which is adopted in

many industries) for partial replacement of fine

aggregate in concrete. The compressive strength of

partial replacement of Crushed Spent Fire Bricks

(CSFB) aggregate concrete is marginally higher than

that of the river sand aggregate concrete at age of 7

days, 14 days, and 28 days, respectively. The split

tensile strength of partial replacement of CSFB

aggregate concrete is higher than that of the river

sand aggregate at all ages. The modulus of elasticity

of partial replacement of CSFB aggregate concrete is

marginally higher than that of the river sand

aggregate concrete. The partial replacement of GGBS

can be used effectively as fine aggregate in place of

conventional river sand concrete production [11].

IV. CONCLUSION COPPER SLAG: The results of compression & split-

tensile test indicated that the strength of concrete

increases with respect to the percentage of copper

slag added by weight of fine aggregate. Addition of

slag in concrete increases the density thereby the self

weight of the concrete.

GRANULATED BLAST FURNACE SLAG: There

is a considerable increase in compressive strength

thus GBFS could be utilized partially as alternative

construction material for natural sand in concrete but

there is reduction in workability for all replacement

levels. The workability can be increased by adding

suitable dosage of chemical admixture such as super

plasticizer.




WASHED BOTTOM ASH: 30% WBA replacement

is found to be the optimum amount in order to get a

favourable strength and good strength development

pattern over the increment ages. The cost of concrete

is less than conventional concrete and the concrete

becomes environment friendly.

QUARRY DUST: The study suggests that stone dust

is quite appropriate to be selected as the substitution

of fine aggregate. Quarry dust has a potential to

provide alternative to fine aggregate thus minimizing

waste products and disposal problems associated with

it. The only major limitation is the decrease in

workability which can be overcome by the use of fly

ash or chemical admixtures such as super plasticizers

which give high workability at the same water

contents.

FOUNDRY SAND: Waste foundry sand can be

effectively used as fine aggregate in place of

conventional river sand, in concrete. The maximum

compressive strength was achieved with 50%

replacement of fine aggregate with waste foundry

sand. Replacement of fine aggregate with waste

foundry sand showed increase in the split tensile

strength and flexural strength of plain concrete.

SHEET GLASS POWDER: It is observed that the

compressive strength of concrete for all mix increases

as the percentage of SGP increases, but decreases

with the age of curing increases because of alkali

silica reaction. The Tensile strength of the concrete

for all mix increases than that of conventional

concrete of same age of curing and decreases with

increase in SGP content. Similarly the Flexural

strength of the beam of concrete for all mix increases

with age of curing and decreases with increase in

SGP content.

CONSTRUCTION AND DEMOLITION WASTE:

The density of the concrete decreases as the

percentage of the CWSB content increases. Concrete

containing up to 50% CWSB as fine aggregate

compared favourably with normal concrete mixture

and therefore 50% CWSB content is taken as the

optimum for 30N/mm2 design characteristic strength.

CRUSHED SPENT FIRE BRICKS: The SFB is a

locally available, low cost, and inert industrial solid

waste whose disposal is a matter of concern likes

construction waste. On an overall, the CSFB can be

comparable to the natural river sand.

This paper shows that no material in the world is

waste and if utilized properly such materials will

improve sustainability by reducing the human

consumption of natural resources. The use of these

materials should be in such a way that the locally

available alternative materials should be selected so

as to achieve economy and required design strength.

REFERENCES [1] Arivalagan.S, Experimental study on the

flexural behavior of reinforced concrete

beams as replacement of copper slag as fine

aggregate, Journal of Civil Engineering and

Urbanism, 2013, Vol. 3, 176-182.

[2] M C Nataraja, P G Dileep Kumar, A S

Manu and M C Sanjay, Use of granulated

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cement mortar, Int. J. Struct. & Civil Engg.

Res., 2013, Vol. 2, 60-68.

[3] Alexander M. & Mindess S. (2005).

Aggregates in concrete. Taylor & Francis.

Specification for Aggregates for natural

source for concrete. British Standard BS882:

1992.

[4] Mohd Syahru, Hisyam bin Mohd Sani,

Fadhluhartini bt Muftah and Zulkifli Muda ,

The properties of special concrete using

washed bottom ash (wba) as partial sand

replacement, International Journal of

Sustainable Construction Engineering &

Technology, 2010, Vol. 1, No 2, 65-78.

[5] Comparative long term study of concrete

mix design procedure for fine aggregate

replacement with fly ash by minimum void

method and maximum density method,

A.D.Pofale and S.V.Deo, Pg.No. 759 to 764,

KSCE journal of civil Engineering (2010)

14(5).

[6] Characteristic studies on the mechanical

properties of quarry dust addition in

conventional concrete, A.Sivakumar and

Prakash M, Journal of civil engineering and

construction technology, vol. 2(10), Pg.No.

218 to 235, October 2011.

[7] Study of Properties of SCC using „Quarry

Dust‟ and „Fly Ash‟, M.V. Rama Raju,

K.V.Vivek, Dr.T.Siva Shankar Reddy and P.

Srinivas Reddy, Pg.No. 323 to 332,

International Journal if Engineering Science

Research, Vol 02, Issue 04, August-

September 2011.

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Jayeshkumar Pitroda, Techno- economical

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foundry sand, International Journal of

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(IJETT),2013,Vol. 4, 1620-28.

[9] M. Mageswari, and Dr. B.Vidivelli, The use

of sheet glass powder as fine aggregate

replacement in concrete, The Open Civil

Engineering Journal, 2010, Vol. 4, 65-71




[10] Akaninyene A. Umoh, Recycling demolition

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[11] S. Keerthinarayana and R. Srinivasan, Study

on strength and durability of concrete by

partial replacement of fine aggregate using

crushed spent fire bricks, Bul. Inst. Polit.

Iaşi, 2010.

[12] Recent Trends in Replacement of Natural

Sand With Different Alternatives Akshay C.

Sankh1, Praveen M. Biradar1, Prof. S. J

Naghathan1, Manjunath B. Ishwargol1

[13] Study on strength and durability of concrete

by partial replacement of fine aggregate

using crushed spent fire bricksby s.

keerthinarayana and *r. srinivasan

[14] Studies on Glass Powder as Partial

Replacement of Cement in Concrete

Production Dr. G.Vijayakumar1, Ms H.

Vishaliny2, Dr. D. Govindarajulu3

[15] Utilization of Copper Slag as a Partial

Replacement of Fine Aggregate in Concrete

D. BRINDHA and S. NAGAN

[16] http://www.thehindu.com/todays-paper/tp

national/tp-tamilnadu/msand-thrown-up-as-

analternative-to-river-sand/article3752772.

ece

[17] Wikepedia and Google.

http://www.thehindu.com/todays-paper/tp%20national/tp-tamilnadu/msand-thrown-up-as-analternative-to-river-sand/article3752772



IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)

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International Conference on Advances in Engineering & Technology – 2014 (ICAET-2014) 59 | Page

Recent Trends in Replacement of Natural Sand With Different

Alternatives

Akshay C. Sankh1, Praveen M. Biradar

1, Prof. S. J Naghathan

1, Manjunath B.

Ishwargol1

1(Department of Civil Engineering, B.L.D.E.A’s V P Dr. P G Halakatti college of engineering and Technology,

Bijapur-586 101, India)

ABSTRACT : Cement, sand and aggregate are basic needs for any construction industry. Sand is a prime

material used for preparation of mortar and concrete and which plays a major role in mix design. Now a day’s

erosion of rivers and considering environmental issues, there is a scarcity of river sand. The non-availability or

shortage of river sand will affect the construction industry, hence there is a need to find the new alternative

material to replace the river sand, such that excess river erosion and harm to environment is prevented. Many

researchers are finding different materials to replace sand and one of the major materials is quarry stone dust.

Using different proportion of these quarry dust along with sand the required concrete mix can be obtained. This

paper presents a review of the different alternatives to natural sand in preparation of mortar and concrete. The

paper emphasize on the physical and mechanical properties and strength aspect on mortar and concrete.

Keywords- Sand, Quarry Stone Dust, Alternative Material, Physical Properties, Mechanical Properties.

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 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. The heavy-exploitation of river sand for

construction purposes in Sri Lanka has led to various harmful problems [1]. Options for various river sand

alternatives, such as offshore sand, quarry dust and filtered sand have also been made (W.P.S. Dias et al

2008)[2]. Physical as well as chemical properties of fine aggregate affect the durability, workability and also

strength of concrete, so fine aggregate is a most important constituent of concrete and cement mortar. Generally

river sand or pit sand is used as fine aggregate in mortar and concrete. Together fine and coarse aggregate make

about 75- 80 % of total volume of concrete and hence it is very important to fine suitable type and good quality

aggregate nearby site (Hudson 1997). Recently natural sand is becoming a very costly material because of its

demand in the construction industry due to this condition research began for cheap and easily available

alternative material to natural sand. Some alternatives materials have already been used as a replacement of

natural sand such as fly-ash, quarry dust or limestone and siliceous stone powder, filtered sand, copper slag are

used in concrete and mortar mixtures as a partial or full replacement of natural sand (Chandana Sukesh et al

2013)[9]. Even though offshore sand is actually used in many countries such as the UK, Sri Lanka, Continental

Europe, India and Singapore, most of the records regarding use of this alternative found mainly as a lesser

extent of practice in the construction field [3].

Due to shortage of river sand as well as its high the Madras High Court restrictions on sand mining in

rivers Cauvery and Tamirabharani. The facts like in India is almost same in others countries also. So therefore

the need to find an alternative concrete and mortar aggregate material to river sand in construction works has

assumed greater importance now a days. Researcher and Engineers have come out with their own ideas to

decrease or fully replace the use of river sand and use recent innovations such as M-Sand (manufactured sand),

robot silica or sand, stone crusher dust, filtered sand, treated and sieved silt removed from reservoirs as well as


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PP 59-66



dams besides sand from other water bodies [4]. On the other hand, lack in required quality is the major

limitation in some of the above materials. Now a day’s sustainable infrastructural growth requires the alternative

material that should satisfy technical requisites of fine aggregate as well as it should be available locally with

large amount.

II. DIFFERENT ALTERNATIVES MATERIALS TO RIVER SAND The world is resting over a landfill of waste hazardous materials which may substitutes for natural

sand. Irrespective of position, location, scale, type of any structure, concrete is the base for the construction

activity. In fact, concrete is the second largest consumable material after water, with nearly three tonnes used

annually for each person on the earth. India consumes an estimated 450 million cubic meter of concrete annually

and which approximately comes to 1 tonne per Indian. We still have a long way to go by global consumption

levels but do we have enough sand to make concrete and mortar? Value of construction industry grew at

staggering rate of 15 % annually even in the economic slowdown and has contributed to 7-8 % of the country’s

GDP (at current prices) for the past eight years. Thus, it is becoming increasingly discomforting for people like

common people who talk about greening the industry to have no practical answer to this very critical question.

In fact we have been sitting over a landfill of possible substitutes for sand. Industrial waste and by-products

from almost all industry, which have been raising hazardous problems both for the environment, agricultural and

human health can have major use in construction activity which may be useful for not only from the economy

point of view but also to preserve the environment as well. Some of the researchers did the work to find the

alternatives for natural sand and they concluded about different industrial waste and their ability to replace the

much sought after natural river bed sand.

2.1 Copper Slag-

At present about 33 million tonnes of copper slag is generating annually worldwide among that India

contributing 6 to 6.5 million tonnes. 50 % copper slag can be used as replacement of natural sand in to obtain

mortar and concrete with required performance, strength and durability. (Khalifa S. Al-Jabri et al 2011). In India

a study has been carried out by the Central Road Research Institute (CRRI) shown that copper slag may be used

as a partial replacement for river sand as fine aggregate in concrete up to 50 % in pavement concrete without

any loss of compressive and flexural strength and such concretes shown about 20 % higher strength than that of

conventional cement concrete of the same grade [5].

2.2 Granulated Blast Furnace Slag

According to the report of the Working Group on Cement Industry for the 12th five year plan, around

10 million tonnes blast furnace slag is currently being generated in the country from iron and steel industry. The

compressive strength of cement mortar increases as the replacement level of granulated blast furnace slag

(GBFS) increases. He further concludes that from the test results it is clear that GBFS sand can be used as an

alternative to natural sand from the point of view of strength. Use of GBFS up to 75 per cent can be

recommended (M C Nataraja 2013)[6].

A mix of copper slag and ferrous slag can yield higher compressive strength of 46.18MPa (100 per cent

replacement of sand) while corresponding strength for normal concrete was just 30.23MPa. Though she warns

that with higher levels of replacements (100 per cent) there might be some bleeding issues and, therefore, she

recommended that up to 80 per cent copper slag and ferrous slag can be used as replacement of sand (Meenakshi

Sudarvizhi 2011)[7].

2.3 Washed Bottom Ash (WBA)

Currently India is producing in over 100 million tons of coal ash. From which total ash produced in any

thermal power plant isapprox 15 –20 per cent of bottom ash and the rest is fly ash. Fly ash has found many users

but bottom ash still continues to pollute the environment with unsafe disposal mechanism on offer.The

mechanical properties of special concrete made with 30 per cent replacement of natural sand with washed

bottom ash by weight has an optimum usage in concrete in order to get a required strength and good strength

development pattern over the increment ages (MohdSyahrulHisyam 2010)[8].

http://penerbit.uthm.edu.my/ojs/index.php/IJSCET/article/viewFile/64/20


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2.4 Quarry Dust

About 20 to 25 per cent of the total production in each crusher unit is left out as the waste material-

quarry dust. The ideal percentage of the replacement of sand with the quarry dust is 55 per cent to 75 per cent in

case of compressive strength. He further says that if combined with fly ash (another industrial waste), 100 per

cent replacement of sand can be achieved. The use of fly ash in concrete is desirable because of benefits such as

useful disposal of a byproduct, increased workability, reduction of cement consumption, increased sulfate

resistance, increased resistance to alkali-silica reaction and decreased permeability. However, the use of fly ash

leads to a reduction in early strength of concrete. Therefore, the concurrent use of quarry dust and fly ash in

concrete will lead to the benefits of using such materials being added and some of the undesirable effects being

negated (Chandana Sukesh 2013)[9].

2.5 Foundry sand

India ranks fourth in terms of total foundry production (7.8 million tonnes) according to the 42nd

Census of World Casting Production of 2007. Foundry sand which is very high in silica is regularly discarded

by the metal industry. Currently, there is no mechanism for its disposal, but international studies say that up to

50 per cent foundry sand can be utilized for economical and sustainable development of concrete (Vipul D.

Prajapati 2013)[10].

2.6 Construction and Demolition waste

There is no documented quantification of amount of construction and demolition (C&D) waste being

generated in India. Municipal Corporation of Delhi says it is collecting 4,000 tonnes of C&D waste daily from

the city which amounts to almost 1.5 million tonnes of waste annually in the city of Delhi alone. Even if we

discount all the waste which is illegally dump around the city, 1.5 million of C&D waste if recycled can

significantly substitute demand for natural sand by Delhi.

Recycled sand and aggregate from C&D waste is said to have 10-15 per cent lesser strength then

normal concrete and can be safely used in non-structural applications like flooring and filling. Delhi already has

a recycling unit in place and plans to open more to handle its disposal problem. Construction and demolition

waste generated by the construction industry and which posed an environmental challenge can only be

minimized by the reuse and recycling of the waste it generates (Akaninyene A. Umoh 2012) [11].

2.7 Spent Fire Bricks (SFB):

An experimental investigation on strength and durability was undertaken to use “Spent Fire Bricks”

(SFB) (i.e. waste material from foundry bed and walls; and lining of chimney which is adopted in many

industries) for partial replacement of fine aggregate in concrete (S. Keerthinarayana and R. Srinivasan

2010)[12].

2.8 Sheet Glass Powder (SGP)

Natural sand was partially replaced (10%, 20%, 30%, 40% and 50%) with SGP. Compressive strength,

Tensile strength (cubes and cylinders) and Flexural strength up to 180 days of age were compared with those of

concrete made with natural fine aggregates Attempts have been made for a long time to use waste glasses as an

aggregate in concrete, but it seems that the concrete with waste glasses always cracks .Very limited work has

been conducted for the use of ground glass as a concrete replacement. (M. Mageswari and Dr. B.Vidivelli 2010)

[13].

III. PHYSICAL AND MECHANICAL PROPERTIES DIFFERENT ALTERNATIVES

3.1 Copper slag:

The slag is black glassy particle and granular materials in nature and has a similar particle size range

like sand. The specific gravity of the slag is 3.91. The bulk density of granulated copper slag varies from 1.9 to

2.15 kg/m3 which is almost similar to bulk density of convectional fine aggregate. The hardness of the slag lies


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between 6 and 7 in Mohr scale. This is almost equal to the hardness of gypsum. The pH of aqueous solution of

aqueous extract as per IS 11127 varies from 6.6 to 7.2. The free moisture content present in slag was found to be

less than 0.5%.The presence of silica in slag is about 26% which is desirable because it is one of the constituents

of the natural fine aggregate used in normal concreting operations. The fineness of copper slag was calculated

as125 m2 /kg. Table 1 shows the fineness tests on copper slag.

Table 1- Fineness test on copper slag [5].

Sieve size

In (mm)

Weight

retained(b)g

Cumulative weight

retained (g)

Slag

retained(n)g

Slag passing %

of soil

4.75mm 4 0.4 0.4 99.6

2.36mm 17 1.7 2.1 97.9

1.18mm 225 22.5 24.6 75.4

600micron 433 43.3 67.9 32.1

300micron 281 28.1 96 4

150micron 37 3.7 99.7 0.3

75micron 3 0.3 100 0

Pan 0 0 100 0

The test results of concrete were obtained by adding copper slag to sand in various percentages ranging

from 0%, 20%. 40%, 60%, 80% and 100%. All specimens were cured for 28 days before compression strength

test, splitting tensile test and flexural strength. The highest compressive strength obtained was 35.11MPa (for

40% replacement) and the corresponding strength for control mix was 30MPa. This results of the research paper

showed that the possibility of using copper slag as fine aggregate in concrete. The results showed the effect of

copper slag on RCC concrete elements has a considerable amount of increase in the compressive, split tensile,

flexural strength characteristics and energy absorption characteristics [5].

3.2 Granulated Blast Furnace Slag:

The granulated blast furnace slag (GBFS) is glassy particle and granular materials in nature and has a

similar particle size range like sand. The specific gravity of the slag is 2.63. The bulk density of granulated slag

varies from 1430 kg/m3 which were almost similar to bulk density of convectional fine aggregate. The water

absorption of slag was found to be less than 2.56 %.The presence of silica in slag is about 26% which is

desirable since it is one of the constituents of the natural fine aggregate used in normal concreting operations.

The fineness of slag was 2.37.

Investigation was carried out on cement mortar mix 1:3 and GBFS at 0, 25, 50, 75 and 100%

replacement to natural sand for constant w/c ratio of 0.5 is considered. The work is extended to 100%

replacements of natural sand with GBFS for w/c ratios of 0.4 and 0.6. The flow characteristics of the various

mixes and their compressive strengths at various ages are studied. From this study it is observed that GBFS

could be utilized partially as alternative construction material for natural sand in mortar applications. Reduction

in workability expressed as flow can be compensated by adding suitable percentage of super plasticizer [6].

The strength characteristics of conventional concrete and slag concrete such as compressive strength, tensile

strength were found. Six series of concrete mixtures were prepared with different proportions of CS and FS

ranging from 0% to 100%. The test results of concrete were obtained by adding of Copper Slag (CS) and

Ferrous Slag (FS) to sand in various percentages ranging from 0%, 20%. 40%, 60%, 80% and 100%. All

specimens were cured for 7, 28, 60 & 90 days before compression strength test and splitting tensile test. The

results indicate that workability increases with increase in CS and FS percentage. The highest compressive

strength obtained was 46MPa (for 100% replacement) and the corresponding strength for control mix was

30MPa. The integrated approach of working on safe disposal and utilization can lead to advantageous effects on

the ecology and environmental also. It has been observed that upto 80% replacement, CS and FS can be

effectively used as replacement for fine aggregate. Further research work is needed to explore the effect of

CS+FS as fine aggregates on the durability properties of concrete [7].

3.3 Washed Bottom Ash (WBA):

The fineness modulus is the summation of the cumulative percentage retained on the sieve standard

series of 150, 300 and 600 μm, 1.18, 2.36, 5.0 mm up to the larger sieve size used. The calculated fineness


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modulus of bottom ash was 3.65 which is more than 3.5 and is considered to be very coarse. For categorization

given in BS 822:1992 based on percentage passing the 600μm sieve between 55% to100% would defined it as

fine sand. While WBA has percentage passing 600 μm of 58.99%. Therefore, the WBA is considered as fine

sand (Alexander & Mindess, 2005)[16].

Different concrete mixes with constant water to cement ratio of 0.55 were prepared with WBA in different

proportions as well as one control mixed proportion. The mechanical properties of special concrete with 30%

WBA replacement by weight of natural sand is found to be an optimum usage in concrete in order to get a

favorable strength and good strength development pattern over the increment ages [8].

3.4 Quarry Dust:

The results (Table 2) show that there is an increase in the compressive strength of the concrete which

the increment is about 55% to 75% depending on the replacement if the sand with the quarry dust, for the 100%

replacement of the sand the compressive strength is depending on the quarry dust location from where the

quarry dust was taken. The workability of the concrete is decreasing when the replacement percentage of the

quarry dust is increasing gradually, so as to increase the workability small quantity of the fly-ash is replaced in

place of cement to increase the workability. This show that the fly ash and quarry dust replacement showed the

desirable results which can suggest the usage of the quarry dust as replacement of sand [9].

Table2- Physical properties for the quarry dust [9]

Property Quarry Dust Natural

Sand Test method

Specific gravity 2.54 -2.60 2.60 IS2386(Part III)- 1963

Bulk density (kg/m3) 1720- 1810 1460 IS2386(Part III)- 1963

Absorption (%) 1.20- 1.50 Nil IS2386(Part III)- 1963

Moisture Content (%) Nil 1.50 IS2386(Part III)- 1963

Fine particles less than 0.075 mm (%) 12-15 6 IS2386(Part III)- 1963

Sieve analysis Zone-II Zone-II IS 383- 1970

3.5 Foundry Sand:

Foundry sand consists primarily of silica sand, coated with a thin film of burnt carbon residual binder

and dust.

The fine aggregate has been replaced by used foundry sand accordingly in the range of 0%, 10%, 30% & 50%

by weight for M-20 grade concrete. Concrete mixtures were produced, tested and compared in terms of

compressive and flexural strength with the conventional concrete. These tests were carried out to evaluate the

mechanical properties for 7, 14 and 28 days. This research work is to investigate the behaviour of concrete while

replacing used foundry sand in different proportion in concrete. This low cost concrete with good strength is

used in rigid pavement for 3000 commercial vehicles per day and Dry Lean Concrete (DLC) 100mm thick for

national highway to make it eco-friendly [10].

3.6 Construction and Demolition waste:

The fine aggregate was replaced with crushed waste sandcrete block (CWSB) in various percentages in the steps

of 10 starting from 10% to a maximum of 100%, while 0% represents the control. The properties of the concrete

were evaluated at 7, 14 and 28 days curing periods. Results showed (Table 3) that replacing 50% of CWSB

aggregate after 28 days curing attained the designed compressive strength as the conventional concrete (i.e., the

control). Thus it is concluded that CWSB can be used as a supplementary aggregate material in concrete [11].


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Table 3- Physical Properties of the Construction and Demolition waste [11]

Sl. No. Physical Properties Values

01 Compacted Bulk density, [kg/m3] 1564

02 Porosity, [%] 11.22

03 Specific gravity 2.40

04 Water absorption (%) 28.74

05 Silt content (%) 5.22

3.7 Spent Fire Bricks (SFB):

An experimental investigation of strength and durability was undertaken to use “Spent Fire Bricks”

(SFB) (i.e. waste material from foundry bed and walls; and lining of chimney which is adopted in many

industries) for partial replacement of fine aggregate in concrete. The compressive strength of partial replacement

of Crushed Spent Fire Bricks (CSFB) aggregate concrete is marginally higher than that of the river sand

aggregate concrete at age of 7 days, 14 days, and 28 days, respectively. The split tensile strength of partial

replacement of CSFB aggregate concrete is higher than that of the river sand aggregate at all ages. The modulus

of elasticity of partial replacement of CSFB aggregate concrete is marginally higher than that of the river sand

aggregate concrete. The partial replacement of GGBS can be used effectively as fine aggregate in place of

conventional river sand concrete production [12].

Table 4- Physical Properties of the spent fire bricks [12]

Sl. No. Physical Properties Values

01 Bulk density, [kg/m3] 2,000

02 Porosity, [%] 25 to 30

03 Size tolerance, [%] ±2

04 Working temperature, [°C] 1,300 to 1,400

05 Crushing strength (cold), [N/mm2] 24.5 to 27

3.8 Sheet Glass Powder (SGP):

The SGP is suitable for use in concrete making. The fineness modulus, specific gravity, moisture

content, uncompacted bulk density and compacted bulk density at 10% Sheet glass powder (SGP) were found to

be 2.25,3.27,2.57%,1510kg/ m3 and 1620kg/m

3.

The compressive strength of cubes and cylinders of the concrete for all mix increases as the % of SGP increases

but decreases as the age of curing increases due to alkali silica reaction. The Tensile strength of cubes and

cylinders of the concrete for all mix increases than that of conventional concrete age of curing and decreases as

the SGP content increases. The Flexural strength of the beam of concrete for all mix increases with age of

curing and decreases as the SGP content increases. 100% replacement of SGP in concrete showed better results

than that of conventional concrete at 28 days and 45 days curing but later it started to decrease its strength

because of its alkali silica reactions. The density of SGP concrete is more that of conventional concrete. SGP is

available in significant quantities as a waste and can be utilized for making concrete. This will go a long way to

reduce the quantity of waste in our environment. The optimum replacement level in fine aggregate with SGP is

10% [13].

IV. CONCLUSION

1. An improvement in the compressive strength, split tensile strength and flexural strength of concrete by

addition of copper slag can be seen. The density of concrete increases with replacement of copper slag in

concrete. There is increase in the flexural strength of the beam by 21% to 51% while replacement of copper


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slag. By partial replacement of sand by copper slag, the strength increase is observed up to 40% replacement.

Copper slag replacement at higher level leads to segregation and bleeding due to less water absorption capacity

of copper slag. Author was also observed that the sand replaced copper slag beams showed an increase in energy

absorption capacity.

2. It was also observed that the increase in compressive strength of cement mortar with the replacing the GGBS.

This increase is not significant. But for 100% replacement the strength decreases a little bit compared to 100%

natural sand. Author concluded that GGBS sand can be used as an alternative to natural sand from the point of

view of strength and recommended to replace up to 75%.

3. It can be concluded that 30% of Washed Bottom Ash (WBA) can be replaced with sand in concrete is the

optimum amount to get favorable strength, saving in environment and reducing the cost.

4. There is improvement in the compressive strength of the concrete by partial replacement of quarry dust with

sand. Due to absorption of the water by the quarry dust, decreases the workability of concrete with increase in

quarry dust quantity. The recommended percentage of the replacement of sand with the quarry dust is between

55% to 75% in case of compressive strength. The 100% replacement of sand can be achieved by addition of fly

ash along with quarry dust. For mortar, stone powder is well suitable to choose it as an alternative of sand. The

availability of the stone powder is depends on the locality and its price is mar vary. If the stone powder is

available in the market, it can be used as an alternative to sand and it is observed that concrete made stone chip

will have higher compressive strength compared with that of concrete made with brick chips. This may be due

to inferior quality brick chip, poor workmanship, and improper proportions of mixing. Since brick chip is

inexpensive and normally available, hence used for the low strength structures.

5. There is improvement in the compressive strength and flexural strength of the concrete by partial replacement

of foundry sand with sand. It is observed that there is increase in compressive and flexural strength with increase

in foundry sand replacing natural sand. The maximum compressive strength and flexural strength obtained at

50% replacement of natural fine aggregate with used foundry sand.

6. It is observed that increase in CWSB content in concrete, there is decrease in the density of concrete.

Concrete containing up to 50% CWSB as fine aggregate compared suitably with normal concrete mix and hence

50% CWSB content is adopted as the optimum for design characteristic strength of 30N/mm2.

7. There is improvement in the compressive strength of the concrete by partial replacement of Crushed Spent

Fire Bricks (CSFB) in concrete. The maximum strength is attained by 25% of CSFB replacement in concrete.

There is no increase in strength observed with 30% and more of CSFB replacement in concrete. Test results

shown that the compressive strength of partial replacement of CSFB aggregate concrete is a little bit higher than

that of the river sand aggregate concrete at age of 7, 14 , and 28 days, respectively.

8. The sheet glass powder (SGP) is available in substantial quantity as a waste and it can be used for making

concrete. This will help to reduce the quantity of waste in our environment. It is observed that the compressive

strength of concrete for all mix increases as the percentage of SGP increases, but decreases with the age of

curing increases because of alkali silica reaction. The Tensile strength of the concrete for all mix increases than

that of conventional concrete of same age of curing and decreases with increase in SGP content. Similarly the

Flexural strength of the beam of concrete for all mix increases with age of curing and decreases with increase in

SGP content. SGP replacing by 100% showed improved results than that of conventional concrete at 28 days

and 45 days but later it is observed decrease in strength due to alkali silica reactions. The density of SGP

concrete is little bit higher that of conventional concrete. For the best results the optimum replacement level in

fine aggregate with SGP is 10%.

This paper presented in view of alternatives available in place of natural sand in mortar and concrete.

There are various materials available, which are recognized as waste product of industry or from Domestic. But

from the above conclusion shows that many researchers have recognized these materials and spent their valuable

time and shared their knowledge to make aware of these materials for the construction industry. They showed

that no material in the world is waste, but one has to see it in different way to recognize, how best the waste can


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be handled. Few alternative materials discussed in this paper are from hard work of various research scholars.

But those materials can be utilized effectively for concrete mix and building mortar and awareness should be

spread to society. The utilization of these materials should be in such a way that the locally available such

alternative materials should be selected so as to achieve economy and required design strength.

REFERENCES [1] National sand study for Sri Lanka, vols. 1 and 2. Final Report, Phase 1, Delft Hydraulics, 1992.

[2] Dias WPS. The analysis of proposed change and stakeholder response– a case study, Civil Environ Eng Syst, 2000, Vol. 17,1–17.

[3] National practices and regulations in the extraction of marine sand and gravel, Ch. 3 in Sandpit Book.

<http://sandpit.wldelft.nl/reportpage/reportpage.htm>. [4] http://www.thehindu.com/todays-paper/tp-national/tp-tamilnadu/msand-thrown-up-as-an-alternative-to-river-

sand/article3752772.ece

[5] Arivalagan.S, Experimental study on the flexural behavior of reinforced concrete beams as replacement of copper slag as fine aggregate, Journal of Civil Engineering and Urbanism, 2013, Vol. 3, 176-182.

[6] M C Nataraja, P G Dileep Kumar, A S Manu and M C Sanjay, Use of granulated blast furnace slag as fine aggregate in cement

mortar, Int. J. Struct. & Civil Engg. Res., 2013, Vol. 2, 60-68. [7] Meenakshi Sudarvizhi and S. Ilangovan , Performance of copper slag and ferrous slag as partial replacement of sand in concrete

International Journal of Civil & Structural Engineering, 2011, Vol. 1, 918-27.

[8] Mohd Syahru, Hisyam bin Mohd Sani, Fadhluhartini bt Muftah and Zulkifli Muda , The properties of special concrete using washed bottom ash (wba) as partial sand replacement, International Journal of Sustainable Construction Engineering &

Technology, 2010, Vol. 1, No 2, 65-78.

[9] Chandana Sukesh, Katakam Bala Krishna, P.Sri Lakshmi Sai Teja and S.Kanakambara Rao, Partial replacement of sand with quarry dust in concrete, International Journal of Innovative Technology and Exploring Engineering (IJITEE), 2013, Vol. 2, 254-

58.

[10] Vipul D. Prajapati, Nilay Joshi and Prof. Jayeshkumar Pitroda, Techno- economical study of rigid pavement by using the used foundry sand, International Journal of Engineering Trends and Technology (IJETT),2013,Vol. 4, 1620-28.

[11] Akaninyene A. Umoh, Recycling demolition waste sandcrete blocks as aggregate in concrete, ARPN Journal of Engineering and

Applied Sciences, 2012, Vol. 7, 1111-18.

[12] S. Keerthinarayana and R. Srinivasan, Study on strength and durability of concrete by partial replacement of fine aggregate using

crushed spent fire bricks, Bul. Inst. Polit. Iaşi, 2010.

[13] M. Mageswari, and Dr. B.Vidivelli, The use of sheet glass powder as fine aggregate replacement in concrete, The Open Civil Engineering Journal, 2010, Vol. 4, 65-71

[14] Lohani T.K., Padhi M., Dash K.P. and Jena S., Optimum utilization of quarry dust as partial replacement of sand in concrete, Int.

Journal of Applied Sciences and Engineering Research, 2012, Vol. 1, 391-404. [15] W.P.S. Dias , G.A.P.S.N. Seneviratne and S.M.A. Nanayakkara, Offshore sand for reinforced concrete, Construction and

Building Materials, 2008, Vol. 22, 1377–1384.

[16] Alexander M. & Mindess S. (2005). Aggregates in concrete. Taylor & Francis. Specification for Aggregates for natural source for concrete. British Standard BS882: 1992.

[17] H. M. A. Mahzuz, A. A. M. Ahmed and M. A. Yusuf, Use of stone powder in concrete and mortar as an alternative of sand,

African Journal of Environmental Science and Technology, 2011, Vol. 5, 381-388.

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International Journal of Innovative Research in Engineering & Management (IJIREM) ISSN: 2350-0557, Volume-3, Special Issue-1, April-2015

Fifth National Conference on Innovative Practice in Construction Waste Management (IPCWM’15) On 8th & 9th April, 2015 Organized by Department of CIVIL Engineering, Sri Ramakrishna Institute of Technology, Coimbatore, India

Studies on Alternative Solution for Sand in Concrete

S.Karthik1 Assistant Professor,

Department of Civil Engineering, Jay Shriram Group of Institutions,

Avinashipalayam, Tirupur. Tamilnadu, India.

P. Gowtham2, R.Balaji3, S.Thangaraj4, D.Gowtham5

Under Graduate Student, Department of Civil Engineering, Jay Shriram Group of Institutions,

Avinashipalayam, Tirupur. Tamilnadu, India.

ABSTRACT At present days infrastructure is the backbone of the country. Infrastructure can be developed by several ways such as steel structure, concrete structure, and wooden structure. Among these structure, wooden structure are not used widely, because rapid use of wood leads to cause deforestation. Steel structures are economic and efficient in case of high rise buildings but in case of small structure it is little costlier than concrete. Therefore, concrete structure are mostly used for such type of buildings. Generally concrete compose of cement, coarse aggregate, fine aggregate and water. Nowadays concrete is used widely. It may cause scarcity of certain materials like fine aggregate. So, our main aim of the project is, to overcome the scarcity of the fine aggregate by reducing the usage. This have been achieved by replacing the rice husk based precipitated silica in the concrete at various proportion mixes (0%, 10%, 20%, 30%, 40%, 50%, 60%, 70% and 80%)replacement

KEYWORD: precipitated silica, cement, river sand.

INTRODUCTION Concrete is considered as the most widely used and

versatile material of construction all over the world. In recent years, concrete technology has made significant advances which have resulted in economical `improvements in strength of concretes. This economic development depends upon the intelligent use of locally available materials. One of the important ingredients of conventional concrete is natural sand or river sand, which is expensive and scarce. In India, the conventional concrete is produced by using natural sand obtained from riverbeds as fine aggregate. However, due to the increased use of concrete in almost all types of construction works, the demand of natural or river sand has been increased. To meet this demand of construction industry excessive quarrying of sand from river beds is taking place causing the depletion of sand resources.

The dwindling sand resources have not only posed the environmental problems but also have caused the rivers to change their flow direction. This fact has forced the

Government to lay down restrictions on sand quarrying process resulting in the scarcity and significant increase in its cost. Thus the scarcity of natural sand has forced to find the suitable substitute. There are the lot of materials available to substitute fine aggregate in making concrete such as fly ash, bottom ash, glass powder-sand ,crushed sand, copper slag, tyre rubber, foundry sand, off shore sand, sugar cane bases ash, marble powder, quarry dust, rice husk, sand extraction from soil & saw dust ash. But rice husk based precipitated silica is the one of the eco-friendly materials and it is taken from oil refining industries. This is a waste product, it is directly dumped to the land, it cause to environment pollution and land occupations. In this way we had to use the rice husk based precipitated silica as a fine aggregate in concrete to reduce the usage of river sand and environmental defects. In this waste materials have higher silica content from 80-85%. This is better choice to replacement of fine aggregate.

The standard mix with 100% manufactured sand has exhibited much higher compressive strength 53 MPa. The standard mix with 100% of river sand has exhibited compressive strength of 49MPa, 7.5% lower than that of manufactured sand. The improved properties of MS by the entire process of manufacturing could have resulted in reduced surface area and better particle packing. This contributed to the better binding effect with the available cement paste and improved the compressive strength. The mix with Ms Sand as 100% fine aggregate gives initial workability of 170mm, which is much higher than that of the mixes with 100% river sand (RS) and crusher dust. Higher fineness modulus, particles grading, shape, texture and control of micro fines have contributed to better workability of manufactured sand. The good physical properties of manufactured sand has enabled in reduction of free water as well. Research findings concluded that, Compared to concrete made from river sand, high fines concrete generally had higher flexural strength, improved abrasion resistance, and higher unit weight & lower permeability due to fillings the pores with micro fines. [1] The variation of compressive strength with respect to type of concrete block made by using natural sand and artificial sand are observed. Result shows that the mixes with the artificial sand with dust as fine aggregate gives consistently higher



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strength than the mixes with natural sand. The sharp edges of the particles in artificial sand provide better bond with the cement than the rounded part of the natural sand. It was found that the weight loss of artificial sand block is considerably same with respect to natural sand blocks at 20, 40, and 60 and 90 days, immersed in sulphuric acid solution during the experimental period and maintain pH 4 across it. Both concrete made using artificial sand and natural sand are moderate to chloride permeability. In water absorption test we observed after 24 hours curing, the increase in weight of both natural sand and artificial sand blocks are less than 3% that means both concrete are low absorber hence concretes are good quality. The test result obtained from well planned and carefully performed experimental program encourage the full replacement of natural sand by artificial sand with dust considering the technical, environmental and commercial factor.[2] Manufactured sand is featured with deficiency in medium size, and has poorer shape and surface texture than natural river sand. Use of manufactured sand will increase water demand, and impair pump ability and finish ability of concrete mix. These effects will become more significant in lean mix. It is feasible to use admixture approach to overcome problems resulting from use of manufactured sand in concrete mix. For the particular case in this paper, MIRA 91 works well in concrete mix with 100% replacement of natural river sand by manufactured sand MS2.However, as manufactured sand has great variety in properties from source to source, and concrete mixes have different cement content from mix to mix, it is hardly to use single admixture for all kinds of manufactured sand and concrete mix. Customized admixture approach with particular manufactured sand would be better solution for use of manufactured sand in concrete mix. [3] Blended cement concrete is developed with the mixture of Ordinary Portland cement, High Alumina cement, M-sand, coarse aggregate with complots SP430 super plasticizer for the purpose of accelerating early strength and prolonged setting time. The initial setting time of this blended cement is extended to 100 minutes permitting enough time for batching, placing and finishing of concrete perfectly at site. This blended cement will set fastly that the time between initial and final set is found to be about 10-12 minutes. Strength development rate after hardening is fast and after 3 days of curing, compressive strength exceeding 28.8 MPa and 26.51 MPa for cube and cylindrical specimens were obtained. This is similar to what the conventional concrete achieves in 28 days. Nearly 20% of compressive strength of Portland cement is increased by using M-Sand for river sand in conventional concrete. [4] Compressive strength, splitting tensile strength, flexural strength, and modulus of elasticity of fine aggregate (sand) replaced fly ash concrete specimens were higher than the plain concrete (control mix) specimens at all the ages. The strength differential between the fly ash concrete specimens and plain concrete specimens became more distinct after 28 days. Compressive strength, splitting tensile strength, flexural strength, and modulus of elasticity of fine aggregate (sand) replaced fly ash concrete continued to increase with age for all fly ash percentages. The maximum compressive strength

occurs with 50% fly ash content at all ages. It is 40.0 MPa at 28 days, 51.4 MPa at 91 days, and 54.8 MPa at 365 days. At all the ages, the maximum splitting tensile strength was observed with 50% fly ash content. It is 3.5 MPa at 28 days, 4.3 MPa at 91 days, and 4.4 MPa at 365 days. The maximum flexural strength has been found to occur with 50% fly ash content at all ages. It is 4.3 MPa at 28 days, 5.2 MPa at 91 days, and 5.4 MPa at 365 days. At all ages, the maximum value of modulus of elasticity occurs with 50% fly ash content. It is 24.5 GPA at 28 days, 28.0 GPa at 91 days, and 29.0 GPa at 365 days. Results of this investigation suggest that Class F fly ash could be very conveniently used in structural concrete. [5] The review of research work shows that the replacement of natural sand with artificial sand is fissile and behavior and strength of reinforced concrete will improved. Also the use of polypropylene fiber will enhance strength and behavior of reinforced concrete also improves resistance against impact loading and fire. Polypropylene fibers have a positive impact on ultimate strength of heated beams. For a heating duration of 4.5 hours, the residual ultimate strength is larger than the corresponding strength of beams without polypropylene fibers by more than 60 %. No sudden failures are observed in all beams containing polypropylene fibers. [6] In this project Metakaolin is added by replacing the cement of about 10%, 20%, 30%,40% and 50%. From this case of adding the various mixing of Metakaolin with glass Fibres the strength of the concrete is more than the conventional concrete thus we preferred this project to have more strength and the durability. Thus the structure built using the Metakaolin by replacing would be of good attractiveness to building and also strength to it. The conclusions arrived from the study of the above research work are as follows The use of Metakaolin in concrete as replacement of cement resulted in Pozzlonic materials like Metakaolin when used as cement replacement materials in concrete improves the properties of concrete due to the Early gain of strength, higher pozzolanic reaction and also helps in reducing the consumption of cement. This leads to saving of natural resources and reduction in the emission of green gases like CO2. The main conclusion arrived from this research work is replacement of Metakaolin at 30% would give more strength in 7 days and also 28 days. After that the compressive strength of concrete sample could be decreased. So the optimum percentage of Metakaolin is 30%. [7] MATERIALS PROPERTIES: A. Cement: Portland pozzlonic cement (Ultra tech

cement) of 43 grade confirming to IS: 12269-1987 was used. It was tested for its physical properties as per IS 4031 (part II)-1988.

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Table.1 Properties of PPC 43 grade cement S.no Descriptions Value

1 Fineness of cement 98%

2 Consistency of cement 33%

3 Initial setting time 18 mins

4 Final setting time 465 mins

B. Fine Aggregate: The locally available river sand was used as fine aggregate in the present investigation. The sand was free from clayey matter, salt and organic impurities. The sand was tested for various properties like specific gravity, bulk density etc., and in accordance with IS 2386-1963.

Table.2 Properties of Fine Aggregate S.no Descriptions Value

1 Specific Gravity 2.6 2 Zone Of Sand II 3 Fineness Modulus 3.923 4 D60 0.967 5 D10 0.236 6 Co efficient of uniformity 4.099 7 Bulk density 1600kg/m3

C. Coarse Aggregate: Machine crushed angular granite metal of 20mm 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 physical properties of coarse aggregate were investigated in accordance with IS 2386 -1963.

Table.3 Properties of coarse Aggregate S.no Descriptions value

1 Impact value 12.17% 2 Abrasion value 31.20% 3 Attrition value 6.12% 4 Specific gravity 2.44 5 Bulk density 1652kg /m3 6 Water absorption 1% 7 Grade of Aggregate ‘C’

D. Precipitated Silica: Waste Precipitated Silica was obtained locally from Orchard oil extractions Pvt ltd, Kangayam, and Tamilnadu, India. It was used as a replacement of fine aggregate (natural river sand).The precipitated silica was tested for various properties like specific gravity, bulk density etc., and in accordance with IS 2386-1963. The fine aggregate was conforming to standard specification.

Table.4 physical Properties of precipitated silica S.no Descriptions Value

1 Specific Gravity 2.3

2 Fineness modulus 3.638 4 D60 1.785 5 D10 0.810

6 Co efficient of uniformity 2.2

7 Bulk density 1020kg/m3

Table.5 chemical properties of precipitated silica S.no Descriptions Percentage

1 SIO2 90.16

2 Fe2o3 0.41 4 Al2o3 0.11 5 Cao 1.0 6 Mgo 0.27 7 So3 0.12 8 Al2o3+fe203 0.52 9 Sio2+al2o3+fe2o3 0.93 10 Na2o 0.01 11 K2o 0.65

E. Water: Chloride free water is used for mixing the concrete in which is potable and is free from injurious amounts of oils, acids, alkalis, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel.

Table.6 Parameters in Water S.no Parameters Range

1 PH 6.8 2 Chloride Nill 3 Sulphate 0.3 ppm 4 conductivity 0.11 ms 5 TDS 8.655ppm

MIX DESIGN The mix proportion is very important for the strength of concrete structure. The mix design is done to find the accurate ratio of the concrete ingredients as per the IS 10262-(2009).The mix proportion of M-25 grade concrete was calculated. The following mix proportions is in our project.



227

Table.7 M-25 mix proportions S.No Description Value(Kg/m3)

1 Cement 446

2 Fine aggregate 527

3 Coarse aggregate 1085

4 Water 192

MIX RATIO We are casted the concrete in different mix proportions. First a control standard concrete specimen are casted without adding any replacement materials. Then we added the replacement materials in different percentage in each mix concrete.

Table.8 Different type of Mixes S.No Description Sand

(%) Precipitated

Silica (%) 1 Mix-1 100 0 2 Mix-2 90 10 3 Mix-3 80 20 4 Mix-4 70 30 5 Mix-5 65 35 6 Mix-6 60 40 7 Mix-7 55 45 8 Mix-8 50 50 9 Mix-9 45 55 10 Mix-10 40 60 11 Mix-11 30 70 12 Mix-12 20 80

FRESH CONCRETE PROPERTY

Slump Test The concrete slump test is an empirical test that measures the workability of fresh concrete. This help to found the concrete weather it is suitable or not for handling and placing. There are three stage of slump. Their range is 0 to 40mm represent the true slump and 40 to 90 mm represent the shear, but 90 to 240 mm represent the collapse stage of the concrete. All are done as per IS 7320(1974).

Table.9 Effect on Slump S.No MIX-ID Percentage of

Precipitated Silica Slump(mm)

1 Mix-1 0 61 2 Mix-2 10 59 3 Mix-3 20 56 4 Mix-4 30 58 5 Mix-5 35 53 6 Mix-6 40 55

7 Mix-7 45 52 8 Mix-8 50 56 9 Mix-9 55 50 10 Mix-10 60 49 11 Mix-11 70 46 12 Mix-12 80 48

COMPACTION FACTOR In this fresh concrete test found the compaction factor value. If the value compaction factor is more than 1 it represent the self-compacting. But normal concrete compaction factor value varying from 0.6 to 0.85.the test were done as per IS1199-1959.

Table.10 Effect on Compaction Factor S.No MIX -

ID Percentage of Precipitated

silica

Compaction factor

1 Mix-1 0 0.8 2 Mix-2 10 0.796 3 Mix-3 20 0.785 4 Mix-4 30 0.782 5 Mix-5 35 0.790 6 Mix-6 40 0.788 7 Mix-7 45 0.784 8 Mix-8 50 0.786 9 Mix-9 55 0.780 10 Mix-10 60 0.783 11 Mix-11 70 0.779

12 Mix-12 80 0.774

SPECIMEN CASTING AND TESTING Generally casting and testing of concrete were done as per IS 516 .we choose the dimensions of the specimens are in cube is 150x150x150mm, cylinder is 150mm x300mm and beam is 100x100x500mm.after the completion of final setting time, specimens are submerged into the water for curing. After the completion of 7, 14 and 28 days curing, the specimens were tested using compressive test machines (CTM)

228



RESULT AND DISCUSSIONS i] COMPRESSIVE STRENGTH

Figure: 1 Effect on Compressive Strength in 7 days

Figure. 2 Effect of compressive Strength in 14 Days

Figure.3 Effect of Compressive Strength in 28 Days

ii] SPLIT TENSILE STRENGTH

Figure 4: Effect on split tensile strength in 7 Days

Figure.5 Effect on split tensile strength in 14 Days

Figure.6 Effect on split tensile strength in 28 Days



229

iii) FLEXURAL STRENGTH

Figure.7 Effect of Flexural strength in7 Days Completed Curing

Figure.8 Effect of Flexural strength in14 Days

Figure.9 Effect of Flexural strength in 28 Days

CONCLUSIONS By applying the rice husk based precipitated silica at 50 percentages, the compressive strength for seven days ranges between 18.49 to 25.65 Mpa. The experiment is repeated for fourteen and 28 days are ranges between 22.51 to 28.73 Mpa and 28.31 to 39.84 Mpa respectively. Due to this increase in compressive strength, thickness of the member can be reduced and hence dead load of the member will decrease. The tensile strength of the concrete is measured at the 50 percentage replacement the values for seven, fourteen and 28

days are 1.655 to 2.567 Mpa and1.92 to 2.787Mpa and 2.37 to 3.431 Mpa respectively. Similarly the flexural strength is measured at the 50 percentage replacement the values for respective days are 2.62 to 3 Mpa and 3 to 3.75 Mpa and 3.85to 4.5 Mpa. From this the efficient and effective replacement percentage of the rice husk based precipitated silica is found. This leads to reduction in the cost of manufacturing concrete, Reduction in usage of river sand and environmental pollutions.

REFERENCES

[1].Dr.S.Elavenil,B. Vijaya,(2013)” Manufactured Sand, A Solution And An Alternative To River Sand And In Concrete Manufacturing” Journal of Engineering, Computers & Applied Sciences (JEC&AS) ,Volume 2,page No 20-24 [2]. M. G. Shaikh, S. A. Daimi,(2011),” Durability studies of concrete made by using artificial sand with dust and Natural sand” International Journal of Earth Sciences and Engineering Volume 04, page no 823-825 [3].Dr.S.Senthilkumar, (2013)” Experimental Investigation of Concrete with Combined High alumina cement, Silica fume and M-Sand” Dona Maria Joseph, Manjula Devi / International Journal of Engineering Research and Applications (IJERA) Vol. 3,page no 425-428 [4]. Rafat Siddique*(2002), “Effect of fine aggregate replacement with Class F fly ash on the Mechanical properties of concrete” Cement and Concrete Research 33 (2003), page no 539- 547 [5]. Rajendra P. Mogre,(2012) ,“ Behaviour of Polypropylene Fibre Reinforced Concrete with Artificial Sand” International Refereed Journal of Engineering and Science (IRJES) Page no.37-40 [6]. Mr. M. Shaju Pragash,”Experimental Investigation on the Effect of Metakaolin and M-SAND in Reinforced Concrete Structural Elements with Glass Fibres” book ,page no 1-12 [7]. Vinayak R.Supekar, (2012),“ Properties Of Concrete By Replacement Of Natural Sand With Artificial Sand” International Journal of Engineering Research & Technology (IJERT )vol-1, page no 1-7

ISSN: 0974-2115 www.jchps.com Journal of Chemical and Pharmaceutical Sciences

January - March 2017 261 JCPS Volume 10 Issue 1

Eco Friendly – Manufactured Sand: An Alternative Construction

Material for Concrete *S.S. Saravanan and P. Jagadeesh

School of Civil and Chemical Engineering, VIT University, Vellore, India.

*Corresponding author: E-Mail: [email protected], Cell: 9443011975

ABSTRACT

The depletion of natural sand creates scarcity of river sand near to the worksite and also increased its cost of

conveyance many folds. The non-availability of natural sand creating the major environmental issues such as

depletion of natural water table, drought of water, etc. Hence to substitute for natural river sand for the construction

industry needs an alternative material to be found out. Hence an attempt has been made in this present work to use

the eco-friendly machine made Granite rock sand from vertical shaft impact crushers called manufactured sand (M-

sand) as fine aggregates. This paper presents an experimental investigation on strength and durability properties of

the concrete made of eco-friendly sand replaced by natural sand and the results were compared with the conventional

said concrete. Concrete mix design was carried out as per Indian standard specification. From the current

investigation, strength properties shows that the compressive strength, modulus of rupture and split strength is

increases nearly 20% more than the conventional concrete. Concrete with manufactured sand possess superior

durability performance than the conventional sand concrete.

KEY WORDS: Durability Properties, Manufactured sand, Mechanical Properties, Super plasticizer.

1. INTRODUCTION

In developing countries like India, the development of infrastructural facilities such as construction of major

expressways, bridges, elevated corridors, metro Rail systems, tunnelling works, developing major ports, power

projects and industrial structures etc., are inevitable. To meet the above requirements, concrete plays a vital role to

develop infrastructural facilities for a specified life span. It is essential to make the good quality of concrete to meet

the specified life span duration of the structure under various exposure conditions. On other hand the cost component

of natural river sand in concrete is increasing due its non-availability. Hence it is very vital to search an alternative

material for concrete constructions. M-sand is used in this present experimental work for medium grade concrete and

this M-sand is manufactured with hard granite stone boulders crushed in vertical shaft impact crushers. A lot of

research works were done with crushed stone, manufactured sand Ilangovan (2008) reported that the replacement of

natural sand in quarry rock dust as full replacements is possible. Babu (1992), Nagaraj and Zahda Banu (1996) and

Narashiman (1998), reported that the consumption of cement, cost of concrete made with quarry rock dust,

compression strength of concrete were studied and reported. Sahu (2003), Ilangovan and Nagamani (2006), studied

and reported that the significant increase is compressive strength, split tensile strength with 40% replacements of

sand by quarry rock dust in concrete and full replacements is also possible in concrete with proper treatments of

quarry rock dust before use in concrete construction. Wakchaure (2012) reported that the compressive strength,

indirect split tensile strength and modulus of rupture of concrete with artificial sand as fine aggregates was increases

from 2.81% to 10%. Chitlange (2008) studied and reported that the use of admixture is necessary in all grades of

concrete to restrict water cement ratio to 0.50. Guptha (2006) studied and reported that the manufactured sand is

satisfying the requirements of fine aggregates such as strength, shape, gradation, and angularity. Jayaraman and

Senthil Kumar (2013) studied and reported that by optimization of fully replacements of natural sand by

manufactured sand with nano silica in high performance concrete had increased compressive strength, tensile

strength and modulus of rupture of concrete proportionate to increase in percentage of nano silica. The main

objectives of current study is to investigate the mechanical and durability properties of hardened concrete with

manufactured sand as fine aggregates and compared the results with conventional sand concrete, and to find out the

optimum percentage of manufacture sand replaced as fine aggregates.

2. MATERIAL AND METHODS

Materials:

Cement: Ordinary port land cement 53 Grade (Penna Super) is used for the present work confirming to IS: 12269-

1987.

Fine Aggregates:

Natural River sand: Natural river sand obtained from the river Cauvery near Karur, which is sand hub for Tamil

Nadu is used. The physical properties are reported in Table.1.

Manufactured Sand: The Manufactured sand obtained from vertical shaft Impact Crusher at Salem (SRC M-Sand),

Tamil Nadu was used. Fine aggregates are confirming to zone II of 383-1970 as per the details of Sieve analysis. The

physical properties are presented in Table.1.

mailto:[email protected]



Coarse Aggregates: Crushed natural granite stone aggregate of size 20mm and 12.50mm were used by blending the

aggregates by trial and error method to give good gradation as per standards. The physical properties of course

aggregates are presented in Table.1.

Water: Fresh potable water having the pHvalue of 7 is used for making up the concrete specimen and also for curing

the concrete samples. Super Plasticizer: Super Plasticizer is used work is CERACEM 300 RS(G) Grade Confirming to the Standards.

Mix proportions: There is no specific method of design concrete mixes with manufactured sand as fine aggregates

available. Hence the Design of mix is done using IS: IS : 456-2000 and 10262-2009. Then Natural sand was replaced

by Manufactured sand with 10% incremental increase up to 100% replacements. The mix Propertions for M30 Grade

of concrete for vaying replacements of fine aggregates with M-sand is presented in Table.2.

Specimen and Test Details:

Mechanical Properties: Concrete cubes of size 150mm x 150mm x 150mm used for compressive strength, Concrete

cylinders of size 150mm x 300mm used for indirect tensile strength of concrete and concrete prism of size 100mm

x 100mm x 500mm used for modulus of rupture study. The concrete specimens are cast for M30 grade Concrete

with 20mm graded aggregates and natural sand as fine aggregates, and this concrete is said to be the controlled

concrete and is denoted as M1.It is replaced by manufactred sand with 10% incremental increase and the mix are

denoted as M2, M3, M4, M5, M6, M7, M8, M9, M10, and M11 respectively. The workability of fresh concrete is

measured interms of slump in accordance with IS:1199-1959. The ingredients of concrete such as coarse aggregates,

fine aggregates, water and admixtures are properly mixed in the concrete mixer machine till the unifrom consistency

is achieved. For each mix specimens are casted and tested after 7, 14 & 28 days. The concrete cube specimens are

properly compacted on a Table vibrator, and the cylinders are casted and compacted with needle vibrator. Similarly

the concrete prisms are also compacted with needle vibrator. The mechanical properties such as compressive

strength, split tensile strength and modulus of rupture are calculated as per standards IS: 516-1959.

Table.1. Physical Properties of the Aggregates

S.No Property Coarse

Aggregate

Fine Aggregate

M-sand Natural Sand

1 Specific gravity 2.70 2.45 2.60

2 Bulk Density kg/m3 1510 1556 1460

3 Fineness modulus 6.67 3.54 3.44

4 Water absorption (%) 0.85 1.10 1.00

5 Moisture Content (%) 0.85 1.15 1.10

6 Fineness particles less than 150 microns - 6.80 2.60

7 Sieve analysis - Zone II Zone II

8 Aggregate Impact value 12.50 - -

Table.2. Mix Proportions details

S.No Mix

Details

Cement

(Kg/cum)

Natural

sand (Kg/cum)

M-sand

(Kg/cum)

Coarse Aggregates (Kg/cum)

Water/

Cement

SP

1 M1 390 544 0 1277 0.40 0.60%

2 M2 390 490 540 1277 0.40 0.60%

3 M3 390 435 109 1277 0.40 0.60%

4 M4 390 381 163 1277 0.40 0.60%

5 M5 390 326 218 1277 0.40 0.60%

6 M6 390 272 272 1277 0.40 0.60%

7 M7 390 218 326 1277 0.40 0.60%

8 M8 390 163 381 1277 0.40 0.60%

9 M9 390 109 435 1277 0.40 0.60%

10 M10 390 54 490 1277 0.40 0.60%

11 M11 390 0 544 1277 0.40 0.60%

Durability Properties: Durablity properties of the concrete in the present study is to test the concrete with M-sand

for water absorption, acid attack, alkaline attack, rapid chloride permeability test, and sorptivity with conventional

sand and manufactured sand. Concrete cube specimen of size 150mm x 150mm x 150mm are cast for properly

evaluate the water absorption, acid and alkaline resistence test.The 100mm diameter and 50mm thick cylinders are

cast to find out the rapid chloride permeability and sorptivity test. The concrete specimens are properly casted and

cured for the required number of days before the sample is taken for the durability tests.The durability tests are

carried out as per the standards and specifications.



3. RESULTS AND DISCUSSIONS

Workability Properties: The workability of concrete is measured using slump cone. Results for the different mixes

are measured and presented in table.3 with using super plasticizer. The slump value increases for all mixes with super

plasticizer.

Table.3. Slump cone test

S.No Mix Slump (mm)

1 M1 82

2 M2 86

3 M3 89

4 M4 89

5 M5 90

6 M6 92

7 M7 94

8 M8 96

9 M9 96

10 M10 98

11 M11 100

Mechanical Properties:

Compressive Strength: Figure.1 shows the 7 days, 14 days and 28 days compressive strength of casted concrete

specimen. Conventional concrete exhibits the target mean strength. Test results revealed that the M-sand replaced

concrete displays good results than the conventional one.

Figure.1. Compressive Strength of concrete after 7, 14 and 28 days

Split Tensile Strength: The M-sand replaced concrete displays better split tensile strength than the conventional

one. Figure 2 demonstrates the 7 days, 14 days and 28 days split tensile strength of casted concrete specimen.

Concrete with 70% M-sand replacement shows the better result than the other mixes.

Figure.2. Split Tensile Strength of concrete after 7, 14 and 28 days

Modulus of rupture: Figure 3 shows the 7 days, 14 days and 28 days Modulus of rupture of casted concrete

specimen. As demonstrated in split tensile, concrete with 70% of M-sand replacement shows the better Modulus of

rupture value than other mixes.

Figure.3. Modulus of Rupture of concrete after 7, 14 and 28 days

Durability Properties:



Water Absorption: Figure 4 shows the results obtained from water absorption test. Result revealed that the presence

of M-sand in the concrete reduces the water absorption capability.

Figure.4. Water Absorption test

Acid and Akaline Attack: To observe the behavior of M-sand replaced concrete under severe environment, acid

attack and alkaline attack test are carried out on the test specimen. Figure.5 and Figure.6 shows the weight loss results

of acid attack and alkaline attack on specimen after 30 days, 56 days and 90days acid and alkaline curing. The result

shows that the acid resistance and alkaline resistance of the manufactured sand is more than the conventional sand

concrete.

Figure.5. Acid Attack test Figure.6. Alkaline Attack test

Figure.7. RCPT Setup Figure.8. RCPT Results for M30 Grade

Concrete

Figure.9. Sorptivity Test on M-sand Specimen Figure.10. Sorptivity Test Results for M30

Grade Concrete

Rapid Chloride Penetration Test: RCPT test was made as per ASTM C 1202, on all the different mixes. Figure.7

shows the Rapid Chloride Penetration Test (RCPT) setup. RCPT test is carried out on all the different mixes and the

results are shown in the Figure.8. It is observed that charge passed in conventional mix is higher than the concrete

with manufactured sand mixes. Up to 60 % replacement of M-sand comes within the moderate permeability zone

and beyond 60% replacement gives low permeability. Hence forth the penetration of chloride ion in the conventional

sand concrete is more than the M Sand concrete, in otherwise the Manufactured sand concrete is less chloride ion

penetration values than the natural sand concrete.



Sorptivity: Figure.9 and Figure. 10 shows the sorptivity test specimen setup, and the sorptivity test results for M30

grade Concrete respectively. The results demonstrated that all the mixes are performed better. Results revealed that

the sorptivity in concrete with M sand shows lesser than the conventional sand concrete due to the fines and

microfines present in the manufactured sand.

4. CONCLUSIONS

The following are the conclusions drawn from the present investigation.

The Physical properties of manufactured sand satisfies the requirement of the specifications

for natural sand as per IS 383-1970.

Workability of the concrete increases with increase in M-sand replacement which can be kept

control by varying the chemical admixtures dosage.

The compressive strength of M30 grade concrete with M sand increases by 12.80% at 7days,

15.03% at 14 days and 19.78%at 28 days compared to conventional concrete at 70%

replacement level.

The split tensile strength of M30 grade concrete with M sand increases by 16.19% at 7days,

17.39% at 14days and 19.79% at 28days than the conventional sand concrete at 70%

replacement level.

The modules of rupture of concrete with M sand increases by 21.05% at 7 days, 20.41% at 14 days

and 23.08% at 28 days than the conventional sand concrete at 70% replacement level.

Natural sand if replaces by 100% with manufactured sand in M30 grade concrete also gives the

increase in strengths than the conventional sand concrete and the Flexural strength obtained as per

the test is more than the value as specified in IS:456-2000.

The Durability of the concrete with M-sand was assessed and the result shows the healthier

performances.

The Durability of the concrete for water absorption test results shows that the percentage water

absorption is lesser in manufactured sand than the conventional sand concrete.

The acid attack test and sulphate resistance of the M sand shows lower at all replacement level for

M30 Grade concrete than the natural sand concrete. This clearly states that the durability of M sand

concrete in acid resistance and sulphate resistance is higher than the conventional concrete.

The RCPT Values of the M-sand concrete up to 60% replacement exhibit moderate chloride ion

penetration and beyond which exhibits low chloride ion penetration

The sorptivity or the surface water absorption of concrete with manufactured sand shows good

performance up to 100% replacement level.

Aforesaid analysis clearly reveals that the manufactured sand could be used as an innovative

replacement material for fine aggregate in concrete even up to 100%.

REFERENCES

ASTM C 1202, Standard Test Method for Electrical Indication of Concrete's Ability to Resist Chloride Ion

Penetration, ASTM international, 2009.

Babu K K, Radhakrishnan and Nambiar E.K.K, Compressive strength of Brick Masonry with alternative Aggregate

Mortar CE and CR Journal, New Delhi, 1992, 25-29.

Chitlange M.R, Pajgade P.S, Nagaranaik P.B, Experimental study of Artificial sand concrete, First International

Conference on Emerging Trends in Engineering and Technology, 2008, 1050-1054,

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Ilangovan R and Nagamani K Application of Rock dust as fine aggregate in concrete constriction, National Journal

of construction management, NICMR, Pune, 2006, 5-13.

Ilangovan R and Nagamani K, Studies on strength and behaviour of concrete by using quarry dust as fine aggregate,

CE and CR Journal, New Delhi, 2006, 40-42.

Ilangovan R, Mahendran N and Nagamani K, strength and durability properties of concrete containing quarry rock

dust as fine aggregates, ARPN Journal of Engineering and applied sciences, 3 (5), 2008, 20-26.



IS 10262, Recommended Guidelines for concrete mix Design, Bureau of Indian Standards, New Delhi, 2009.

IS 1199, Method of test for slump of concrete, Bureau of Indian Standards, New Delhi, 1959.

IS 12269, Specifications for 53 grade ordinary Portland cement, Bureau of Indian Standards, New Delhi, 1987.

IS 383, Specification for coarse and fine aggregate from natural sources for concrete, Bureau of Indian Standards,

New Delhi, 1970.

IS 456, Indian Standard Code of Practice for Plain and Reinforced Concrete, Bureau of Indian Standards, New Delhi,

2000.

IS 516, Methods of tests for strength of concrete, Bureau of Indian Standards, New Delhi, 1959.

Jayaraman. A, Senthilkumar, V. Optimization of Fully replacement of natural sand by Msand in high performance

concrete with nano silica, International Journal of Emerging Technology and Advanced Engineering, 3 (11), 2013,

497-502.

Nagaraj T.S and zahda Banu, Efficient Utilization of rock dust and pebbles as an aggregate in portland cement

concrete, The Indian concrete Journal, 1996, 53-56.

Narasimhan C, Patil B.T and Shankar H Sanni, Performance of concrete with quarry dust as fine aggregates-An

experimental study, CE&CR Journal, 1998, 19-24.

Sahu A.K, Sunilkumar and sachan A.K, Quarry stone waste as fine aggregate for concrete, The Indian concrete

Journal, 2003, 845-848.

Wakchaure M.R, Er. Shaikh A.P, Er Gile B.E, Effect of types of fine aggregate on mechanical Properties of cement

concrete, IJMER, 2 (5), 2012, 3723-3726.

Mohammed Nadeem, Dr. A. D. Pofale / International Journal of Engineering Research and

Applications (IJERA) ISSN: 2248-9622 www.ijera.com

Vol. 2, Issue 5, September- October 2012, pp.1258-1264

1258 | P a g e

Replacement Of Natural Fine Aggregate With Granular Slag - A

Waste Industrial By-Product In Cement Mortar Applications As

An Alternative Construction Materials

Mohammed Nadeem1, Dr. A. D. Pofale

2

ABSTRACT The construction industry is the largest

consumer of natural resources which led to

depletion of good quality natural sand (Fine

aggregates). This situation led us to explore

alternative materials and granular slag a waste

industrial byproduct is one such material

identified for utilization it as replacement of

natural sand. This paper highlights upon the

feasibility study for the utilization of granular

slag as replacement of natural fine aggregate in

construction applications (Masonry &

plastering). In this investigation, cement mortar

mixes 1:3, 1:4, 1:5 & 1:6 by volume were

selected for 0, 25, 50, 75 & 100% replacements of

natural sand with granular slag for w/c ratios of

0.60, 0.65, 0.70 & 0.72 respectively. The study

gave comparative results for mortar flow

behaviors, compressive & split tensile strengths,

brick mortar crushing & pulls strengths and

their co-relations. The study comprises of The

experimental results obtained show that partial

substitution of ordinary sand by slag gives better

results in both the applications i.e. masonry &

plastering. The sand replacement from 50 to

75% improved mortar flow properties by 7%,

the compressive strength improved by 11 to 15 %

for the replacement level from 25 to 75%. At the

same time brick mortar crushing & pull

strengths improved by 10 to 13% at 50 to 75%

replacement levels. The co-relation between

mortar compressive/split tensile strengths &

brick crushing/pull strengths shows linear

dependencies on each others. The study

concluded that granular could be utilized as

alternative construction material for natural

sand in masonry & plastering applications either

partially or fully.

Key words: Granular slag, compressive strength,

split tensile strength, mortar adhesion strength

INTRODUCTION In the production of iron and steel, fluxes

(limestone and/or dolomite) are charged into blast

furnace along with coke for fuel. The coke is

combusted to produce carbon monoxide, which

reduces the iron ore into a molten iron product.

Fluxing agents separate impurities and Slag is

produced during separation of molten steel. BF slag

is a nonmetallic co-product primarily consists of

silicates, aluminosilicates, and calcium-alumina-

silicates. The molten slag which absorbs much of the sulfur from the charge, comprises about 20

percent by mass of iron production. Figure 1

presents a general schematic view which depicts the

BF feedstock and the production of blast furnace co-

products (iron and slag).

Figure 1 General Schematic

view of blast furnace operation and slag

production

RESEARCH SIGNIFICANCE & SCOPE Presently, use of slag in India is to the tune

of 15 to 20 % by cement industry rest is mostly

unused. The use of industrial by-products in mortar

not only helps in reducing green house gases but

helps in making environmentally friendly

construction materials. Fine aggregates are part of

all the three major applications of construction

namely masonry, plastering & concreting. Due to

increased construction activities in India,

availability of natural fine aggregates are depleting

by each passing day due to construction of large water storage dams on the rivers. Present research

study explores the possibility of using granular slag

as replacement of natural sand in mortar (Masonry

& plastering applications). In this investigation,

cement mortar mixes 1:3, 1:4, 1:5 & 1:6 by volume

were selected for 0, 25, 50, 75 & 100%

replacements of natural sand with granular slag for

w/c ratios of 0.60, 0.65, 0.70 & 0.72 respectively.

The study gave comparative results for mortar flow

behaviors, compressive & split tensile strengths,




1259 | P a g e

brick mortar crushing & pulls strengths and their co-

relations.

EXPERIMENTAL INVESTIGATION This section describes physical & chemical

properties of materials used, mix proportioning,

mortar properties, test-setup.

Materials Granular slag from the local steel making

plant, natural sand from the local river shown in

Figure 2, satisfying IS 383-1993 was used, Portland

pozzolana cement confirming to IS 1489 (Part 1):1993 were used . All the chemical & physical

properties of the materials are given in the Table 1

Table 1 – Physical & Chemical Properties of Materials

Slag Natural Sand

Chemical Analysis Physical Properties Physical Properties

Constituents (%) Specific Gravity 2.38 2.65

Loss on Ignition 1.80 Water Absorption 0.39% 0.65%

Silica 30.20 Dry loose bulk

density(DLBD)

1058 Kg/cum 1468 Kg/cum

R2O3 20.20 Soundness 0.90% 0.90%

Fe2O3 0.60 Fineness Modulus 3.14 2.64

Al2O3 19.60 Zone I II

Cao 32.40 Silt (Volume) 1.38 % 2%

MgO 9.26 -

SO2 0.27 -

Insoluble matters 0.80 -

Cement-(Portland Pozzolana Cement)

Physical Properties Chemical Properties

Specific Surface 380 m2/kg Total Loss on Ignition 1.40%

Setting time – Initial 195 minutes Magnesia 1.40%

Setting time Final 280 minutes Sulphuric Anhydride 2.06%

Soundness test by -Le-chatelier method 0.50% Insoluble residue 26.0%

Soundness test by Auto Clave method 0.06%

Compressive strength after - 3day 34.9 Mpa

Compressive strength after - 7 days 44.2 Mpa

Compressive strength after - 28 days 61.4 Mpa

Chloride 0.04%

Fly ash 28%

Figure 2 – View of Granular slag sand & natural

sand

Mortar Properties In construction work, masonry units are

bound together with the help of cement & fine aggregates (below 4.75 mm size) paste which is

termed as Mortar. It is defined in IS 2250 – 1995 as,

Mortar is a homogeneous mixture,

produced by intimately mixing cementitious

materials, water and inert materials, such as sand to

the required consistency for use in building together

with masonry units.

The safety, strength & durability of the

resulting wall or any such structure depend on the quality of the mortar used as binding medium.

Mortar serves following functions,

It provides a binding force or cohesion between

the structural units

It act as a medium for distributing the forces

throughout the structure uniformly




1260 | P a g e

It imparts to the structure additional strength

and resistance against water penetration

The essential properties/qualities of a mortar are

listed below,

The mortar mix should be easily workable

The mortar should be sufficiently plastic

The mortar should be capable of retaining

sufficient water during its application

The mortar should not react with construction

units like bricks

Mix Proportions The study was done to find out results after

replacing natural sand with granular slag by taking

various proportions 1:3, 1:4, 1:5 & 1:6 as per the IS 2250 – 1995. In each mixes, natural sand confirming

the IS – 2116 – 1999 was replaced with granular

slag by 0% (Standard mix), 25%, 50%, 75%, &

100% given in Table 2.

Table 2 – Proportion & Replacement Details

Test-Setup

The test was carried out as per the IS code

2386 (part VI) – 1997 “measurement of mortar

making properties of fine aggregate”. The flow was

finalized for 100± 5 mm for each standard mix and

based on the flow; w/c ratios were selected given in

Figure & Table 3.

Figure & Table 3 – W/C ratio for standard flow

In masonry work, mortar needs to take compressive

strength which is essential property of mortar. For

making the mortar cubes, IS 2250-1995 (Code of

practice for preparation and use of masonry mortar)

was referred. For each proportions i.e. 1:3, 1:4, 1:5

& 1:6 total five mixes were prepared by replacing

natural sand with slag sand by 0,25,50,75 & 100 %. For each mix, set of 3 cubes of 50 mm2 were filled

and tested for compressive & split strengths after 7

& 28 days time. At the same time, mortar used in

masonry & plastering are required to take certain

amount of tensile stresses due to variation in

ambient temperatures (day night, seasonal), internal

shrinkage stresses due to plastic and drying

conditions. In order to study behavior of slag against

tensile stresses with various replacement levels,

cubes were tested for split tensile strength after 28

days time. The cubes of 50 mm2 were prepared as

per IS 4031 (part 6) – 1988 for mix proportions of 1:3,1:4,1:5 & 1:6 with replacement of slag sand with

0, 25, 50, 75 & 100 % shown in Figure 4.

Figure 4 – Testing of mortar for compressive &

split tensile strengths

Mortar is used in masonry work for binding

the two masonry units. The primary object of

masonry bond is to give strength to masonry unit but

it may also be employed to create artistic effects




1261 | P a g e

when the brickwork is exposed to view. The bond

mainly takes compressive stresses arises due to load

transferred by the above units. The brick was used

as per IS 1077 -1997 & mortar was prepared as per

the requirements of IS 2250 – 1995, IS 3495 (part

I)-1998 & 2212 – 1998. The mortar of 10 mm thick

layer was applied in between the two bricks and kept it for moist curing. A set of bricks comprises

three units for each proportion of 1:3, 1:4, 1:5 & 1:6

with slag sand replacement of 0,25,50,75 & 100 %.

Set of bricks were tested for mortar joint crushing

strength after 7 days time. The bricks were kept

under compression testing machine and uniformly

compression load was applied. The load at which

brick work gets crushed divided by the area of

mortar gave mortar joint crushing strength as shown

in Figure 5.

Figure 5 – Testing of brick joint crushing

strength

In this test, mortar joint’s pull or adhesive

capacity was tested against the force applied for

pulling mortar joint between two cross bricks of burnt clay type. The bricks were applied 10 mm

thick mortar for proportions of 1:3,1:4,1:5 & 1:6

with slag sand replacement of 0,25,50,75 & 100 %.

After 7 days of curing the mortar joint bond strength

was tested in Universal testing machine. Cross

bricks were kept in-between the jaws of UTM by

means of metal sling. Load was applied till the cross

bricks pull apart and separated completely from

each other. The load at which brick joint fails

divided by the mortar area in contact with both the

bricks gave pull/adhesive strength of brick joints as shown in Figure 6.

Figure 6 – Testing of brick joint pull strengths

RESULTS & DISCUSSION The result of the investigation for the

replacements of natural sand with granular slag

(volumetrically) was discussed. The replacement

was taken as 0, 25, 50, 75 & 100% for 1:3, 1:4, 1:5 & 1:6 mortar mixes proportions for 0.60, 0.65, 0.70

& 0.72 w/s ratios respectively are discussed below,

Mortar Flow The results indicated that in the proportions

of 1:3 & 1:4, the flow increases by 7% upto slag

replacement level of 75% & 50% respectively and at

100% replacement level, it came down to 5% & 2%

respectively. In mix proportions of 1:5 & 1:6, flow increases upto the replacement level of 50% by 2 &

1% but later decreases 3 & 5% at 100% replacement

level respectively. The study clearly indicated that

in rich mixes with finer particles, granular Slag

reduced internal particle frictions which enhanced

its flow properties at the same time with lesser

cement content, flow decreased shown in Figure 7.

Figure 7 – Mortar Flow and W/C Ratio

Mortar Compressive strength It was observed that in the mix proportions

of 1:3 & 1:4, compressive strength increased upto

the replacement level of 75% by 14.66 & 16.42%

respectively and in 1:5 & 1: 6 mix proportions the

increase in strength was observed to the tune of

11.19 & 11.7% at 50% replacement level. The

increase in strengths at 100% replacement was noted

as 5.41, 6.9 & 1.09% in 1:3, 1:4 & 1:5 mix

proportions and in 1:6 it was below 0.82% compare

to 0% replacements as shown in Figure 8.

Figure 8 – Mortar compressive strength




1262 | P a g e

Mortar Split Strength Mortar split tensile strength increased in

1:3 & 1:4 mix proportions at 75% granular slag

replacement by 15.97 & 16.0% respectively and in

1:5 & 1: 6 mix proportions the increase was observed 11.56 & 10.29 % at 50% replacement

level. The increase in strengths at 100%

replacement was noted as 6.08, 7.11 & 5.39% in

1:3, 1:4 & 1:5 mix proportions respectively and in

1:6 it was below 0.59% compare to 0%

replacements shown in Figure 9.

Figure 9 – Mortar split tensile strength

Brick Mortar Joint Crushing strength The brick mortar crushing strength in 1:3 &

1:4 proportions increased at 75% replacement level by 9.11 & 10.43% respectively compare to 0%

replacement on the other hand in 1:5 & 1:6

proportions, the strength was increased at 50%

replacement level by 9.11 & 10.43% respectively. It

was also observed that in the proportions 1:3, 1:4,

the strengths at 100% replacement was found as

6.08, 5.06% and in 1: 5 & 1:6 mix proportions it

decreased by 0.78 & 1.5% compared to 0%

replacements shown in Figure 10.

Figure 10 – Mortar joint crushing strength

Brick Mortar Pull/Adhesion Strength The brick mortar pull or adhesion strength

was found the highest in 1:3 & 1:4 mix proportions

by 12 to 13% at 75% replacements of natural sand

with granular slag at the same time strength

improvement was found by 10 to 11% in 1:4 & 1:5

mix proportions. It was also observed that in all the

mix proportions the strengths at 100% replacements

were higher or equal to standard mixes as shown in

Figure 11.

Figure 11 – Mortar joint pull strength

Co-Relations The co-relations between mortar’s

compressive/split tensile strength & crushing/pull strength of brick masonry joints for proportions

from 1:3 to 1:6 mixes and replacement level of

0,25,50,75, 100 % with slag sand were found out

which indicate linear decencies with each other. The

equations are given in Table 4 & Figure 12.

Figure 4 – Co-relations between compressive /

split & crush / pull strengths

Sr

.

N

o.

Co-

relation

paramet

ers

Compressive/

Split strength

Crushing/

Pull

strength

(1:3,1:4,1:5 & 1:6 proportions)

1 0 % slag replacem

ent

Y = 0.107 x – 0.199, R2 =

0.978

Y = 0.477 x – 0.79,

R2 = 0.926

2 25 %

slag

replacem

ent

Y = 0.095 x +

0.105, R2 =

0.982

Y = 0.401

x – 0.512,

R2 = 0.971

3 50 %

slag

replacem

ent

Y = 0.088 x +

0.304, R2 =

0.980

Y = 0.300

x – 0.105,

R2 = 0.962

4 75 %

slag

replacem

ent

Y = 0.086 x +

0.435, R2 =

0.944

Y = 0.273

x + 0.001,

R2 = 0.969

5 100 %

slag replacem

ent

Y = 0.089 x +

0.420, R2 = 0.940

Y = 0.270

x + 0.018, R2 = 0.993




1263 | P a g e

Figure 12 – Co-relations equations between compressive / split & crushing / pull strengths

CONCLUSIONS

The experimental results obtained show

that partial substitution of ordinary sand by granular

slag gives better results over the verified range from

0, 25, 50, 75 & 100 % replacement. The conclusions

are drawn as below,

In mortar, 50 to 75 % replacement was found

favorable to increase the flow properties by 7 %

in 1:3 & 1:4 mix proportions however it was

lower in 1:5 & 1:6 mix proportions. The 100 %

replacement increased flow by 3% 1:3 & 1:4 mix

proportions. However 100 % replacement level

was not feasible in 1:5 & 1:6 mix proportions

since it had reduced the flow by 4 %.

In general, the range of 25 to 75 % replacement

level was found increasing the compressive

strength by about 15 & 11 % respectively.

Mortar split tensile strength increased by about

13 % at 50 to 75 % replacement level in all the

mix proportions. It could also be generalized that

mortar split tensile strength could be 10 % of

mortar compressive strength in all the mixes.

The replacements of natural sand with granular slag by 50 to 75% improved mortar joint

crushing strength by about 10% in all the mix

proportions.

The brick pull/ adhesion strength improved by

10 to 13 % for the replacements from 50 to 75%.

The co-relation between mortar

compressive/split tensile strength & brick




1264 | P a g e

crushing/pull strength shows linear dependencies

on each other.

The study concluded that granular could be

utilized as alternative construction material for

natural sand in masonry & plastering applications

either partially or fully.

REFERENCES 1. Altan Yilmaz, Mustafa Karasahin, “

Mechanical properties of ferrochromium

slag in granular layers of flexible

pavements” Materials and structures (2010)

43:309-317, March 2009

2. Chen Meizhu, Zhou Mingkai, Wu

Shaopeng, “Optimization of blended

mortars using steel slag sand”, Journal of Wuhan University of Technology-Mater.

Sci. Ed. Dec. 2007

3. Isa Yüksel and Ayten Genç, “Properties of

concrete containing non-ground ash and

slag as fine aggregate”, ACI Materials

Journal, V. 104, No. 4, July-August 2007.

4. Isa Yüksel, Ömer Özkan, and Turhan Bilir,

“Use of Granulated Blast-Furnace Slag in

Concrete as Fine Aggregate”, ACI

Materials Journal, V. 103, No. 3, May-

June 2006. 5. Japan iron and steel federation, “ The slag

sector in the steel industry” July 2006

6. Keun Hyeook Yang, Jin Kyu Song, “

Propoerties of alkali activated mortar and

concrete using lightweight aggregates “

Materials and structures (2010)43:403-416,

April 2009

7. Li yun feng, Yao Yan, Wang, “ Recycling

of industril waste performance of steel slag

green concrete “ J cent south univ.

(2009)16:0768-0773, June 2006

8. Lun Yunxia, Zhou Mingkai，Cai

Xiao，XU Fang, “Methods for improving

volume stability of steel slag as fine aggregate”, Journal of Wuhan University of

Technology-Mater. Sci. Ed. Oct 2008.

9. Masa-aki Ozaki*, Ayako Miyamoto,

“Utilization of melt-solidified slag from

sewage sludge as construction materials” ,

Minamihara 1-6, Tsukuba, Ibaraki, 305-

8516 JAPAN – 2006.

10. M Shoya, S Sugita, Y Tsukinaga, M Aba,

K Tokuhasi, Chinchibu Onodo Corporation

, Japan, “Properties of self compacting

concrete with slag fine aggregates”,

International congress’ Creating with concrete – 1999

11. Mineral Commodity Summaries 1993.

Bureau of Mines, U.S. Department of the

Interior, Washington, DC, 1993.

12. Sean Monkman; Yixin Shao; and Caijun

Shi, “Carbonated Ladle Slag Fines for

Carbon Uptake\and Sand Substitute”,

Journal of Materials in Civil Engineering ©

ASCE, November -2009.

13. S I Pavlenko, V I Malyshkin, “Fine grained

cementless concrete containing slag from

foundry”, International congress’ Russia,

Creating with concrete – 1999. 14. Saud Al-Otaibi, “Recycling steel mill scale

as fine aggregate in cement mortars”,

European Journal of Scientific Research

ISSN 1450-216X Vol.24 No.3-2008

15. Tahir Sofilic , Delko Barisic, Alenka

Rastovcan Mioc, Una Sofilic,

“Radionuclides in steel slag intended for

road construction” J Radioanal Nucl Chem

,284:73–77 – 2010.

16. Tarun R Naik, Shiw S Singh, Robert B

Wendfort, “Application of foundry by

product materials in manufacture of concrete and masonry products”, ACI

Materials Journal, V.93, No.1 January-

February 1996.

17. Xu Delong, Li hui, “ Future resources for

eco building materials – Metallurgical

slag” Journal of wuhan university of

technology, sci edi June 2009

1Mohammed Nadeem is a research scholar from

civil engineering department Visvesvaraya National Institute of Technology, Nagpur-India. His research

interest includes prefab construction, advance

construction materials and concrete technology.

2Prof. Dr. Arun D. Pofale is a professor in civil

engineering department, Visvesvaraya National

Institute of Technology, Nagpur-India. He did his

graduation in civil engineering from Visvesvaraya

regional engineering college, Nagpur-India, post

graduation (M.Tech.) in structures from IIT,

Mumbai-India and Ph.D. in civil engineering from

Nagpur university-India. His research interests include advance construction materials, concrete

technology, pre-stressed concrete and RCC

structures under fire. Currently he is chairman of

Indian Concrete Institute, Nagpur center, India.

CASE STUDY: Foundry Sand as an Alternative Raw Material in the Manufacturing of Cement

Geocycle US (Holcim)

Mason City, Iowa Geocycle US, based in Dundee, Michigan, is a subsidiary of Holcim (US) Inc. focused on offering customers solutions to their waste management needs by utilizing the co-processing capabilities of cement manufacturing. Co-processing is the substitution of fossil fuels and naturally occurring materials with waste in a manufacturing process. The recoverable materials are diverted from other disposal options such as landfills and incinerators, which preserves natural resources for future generations. Holcim is one of the largest suppliers of Portland cement and related mineral components in the United States. Founded in 1908, Holcim’s Mason City plant has been continuously producing cement for 100 years. Portland cement is made from four elements: silica, aluminum, iron, and calcium. The cement manufactured at Mason City is transported to several regional states to be used as a main ingredient in concrete. The site receives about 75,000 tons per year of foundry sand, which replaces naturally occurring, virgin silica in the cement production process. Geocycle US currently receives the spent foundry sand from eight regional foundries located in Iowa, Minnesota, Wisconsin, and Illinois, with over half of the foundry sand coming from Grede Foundries, Inc. in St. Cloud, Minnesota. In most cases, Geocycle US and the foundry share the cost of transporting the sand from the foundry’s location to the Mason City plant.

Figure 1. Unprocessed core pile. Depending on the generator, Geocycle US receives the sand in one of two forms: spent dry sand or sand cores. The dry sand may immediately be used in the production of cement, but the core sand contains hard chunks of solid sand that must be ground, screened, and processed before use. What makes the Mason City site unique is not only the amount of foundry sand it receives for co-processing, but also the site’s ability to crush and process sand cores on site. Geocycle US at Mason City allows some small foundries the opportunity to re-use their foundry sand, as these foundries may not have the resources to crush and screen their cores before sending them off for co-processing.

Figure 2. Machine that crushes and screens the core sand.

Holcim’s use of spent foundry sand in cement production results in several mutual benefits. The foundries avoid landfilling their spent foundry sands, and the Mason City plant reduces the use of a naturally occurring material like virgin sand. Also, the cement manufactured with foundry sand is a sustainable product that meets applicable quality standards and contributes to environmentally friendly applications. In addition, due to the use of recycled sand and other alternative raw materials in its cement products, the Mason City plant has a favorable relationship with the Iowa Division of Solid Waste Management and various other stakeholders.

Both Geocycle US and its source foundries are pleased with their relationship because it results in sustainable development gains for both parties. Several other foundries have expressed interest in working with Geocycle US and Holcim’s Mason City plant in the near future.

Figure 3. Machine that dries crushed and screened core sand.

Case Study: Geocycle US: Foundry Sand as an Alternative Raw Material in the

Manufacturing of Cement

Personnel End User: Geocycle US (Holcim US) Foundry: Grede Foundries, Inc.

Site

Recycling Location: Mason City, IA Site Description: Holcim’s Mason City plant uses spent sand from several foundries for its cement production process. The cement is used as a main ingredient in concrete.

Materials Utilized 75,000 tons per year of spent foundry sand in the form of dry sand or sand cores.

Project Costs and Benefits

Costs Include: • Transportation of the sand from

foundries to the Mason City plant. • Geocycle US conducts chemical

and physical analysis on the sand. • Geocycle US crushes and

processes sand cores on site. Benefits Include:

• The foundries forgo the cost to landfill spent sand.

• The Mason City plant avoids the use of naturally occurring materials like virgin sand.

• Cement made with recycled foundry sand is a viable option to reduce the environmental footprint for both parties.

• Cement manufactured with foundry sand is a sustainable product that meets applicable quality requirements and contributes to environmentally friendly applications.

• The Mason City plant has a favorable relationship with environmental regulators and stakeholders.

International Journal of Engineering Research ISSN:2319-6890)(online),2347-5013(print)

Volume No.5, Issue Special 1, pp 225-228 8-9 Jan. 2016

NCICE@2016 doi : 10.17950/ijer/v5is1/067 Page 225

Effect of Replacement of Natural Sand by Grit on Workability of Concrete

K. B. Thombre1, A. B. More

2, S. R. Bhagat

3

1,2Department of Civil Engineering, PVPIT, Bavdhan, Pune (Maharashtra)

3Department of Civil Engineering, Dr. Babasaheb Ambedkar Technological University Lonere Raigad

(Maharashtra) Email: [email protected]; [email protected]

Abstract - Globally the construction industry is facing a

major difficulty in obtaining natural river sand for making

concrete. At national level the scenario is not different than

global problem of natural sand. Day by day the sources of

natural sand is depleting at a very fast rate and at the other

end requirement of concrete is increasing tremendously due

to infrastructure developments taking place worldwide.

Government has also taken a serious note of the depleting

sources of natural sand and is taking a corrective step to

protect the environment. River sand is expensive because it is

rare to find at every location, at the same time it is required to

be transported from long distances ultimately increasing its

final cost. Environmental issues and other constraints pose

difficulties in availability and use of river sand. To cope up

with this global problem and to reduce the pressure on

natural resources, one of the alternatives is to replace the

natural sand partially or fully by other such materials

without compromising the quality of concrete. This has led to

a search for different substitute materials for natural sand.

Either partial or full replacement of natural sand by other

alternative materials like grit, stone dust, manufactured sand,

foundry sand or other such materials are being researched.

One of the easily available materials is grit which can be

obtained from stone crushers and can be used as a substitute

material to natural river sand. Natural sand plays an

important role in the performance behaviour of concrete

which directly affects the mix design. Natural sand is

rounded and smooth which improves the workability of

concrete. However, the grit is angular and rough which

adversely affects the workability. There is a challenge before

construction industry to use such material without

compromising on properties of concrete. In this paper an

attempt has been made to propose a mix proportion for

producing concrete using grit as a substitute material to

natural sand. The experimental work was carried out to study

the effect of grit on workability characteristics of concrete.

The results obtained from the study shows that grit can be

used successfully by partially replacing the natural sand thus

effectively reducing the load on environment.

Key words: Concrete, Natural sand, Grit, workability

I. Int roduct ion

Concrete is the second largest consumable material after water.

The use of concrete is increasing tremendously due to

infrastructure developments taking place worldwide. India

consumes 450 million cubic meter of concrete per annum

which is approximately 1 ton per Indian. The consumption is

much more for the developed nations than the Indian

continent. The use of concrete in India is due to infrastructure

growth such as new highways, railway projects, airports,

docks and harbours, power projects, dams, etc. For

production of concrete, 70-75% aggregates are required. Out

of this 60-67% is coarse aggregate and 33-40% is fine

aggregate. Rising demand of construction sector cannot be

fulfilled by natural sand as it is scarce and hence it is highly

expensive. It takes millions of years to form natural sand.

This bleak condition creates large demand for alternative

materials and makes the use of grit inevitable. Natural sand

contains excessive silt and the grading is not proper whereas

grit is free from organic impurities and meets the requirement

of gradation. The gradation of grit can be tailor-made

whereas it is difficult to get particular sizes and hence the

grading of natural sand. The major target before a Civil

Engineer is to produce a good quality concrete. One of the

properties required to produce a good quality concrete is its

workability. Workability plays an important role in the

production of concrete. Workability depends on many

factors; one such factor is the shape and size of fine

aggregate. Natural sand is normally of round shape and with

smooth surface, whereas grit is angular and have rough

surface. The main difficulty in achieving desired workability

of concrete with use of grit is shape and surface of grit. The

use of grit in concrete reduces the workability of concrete;

hence the proportioning of ingredients of concrete is an

important task. An attempt has been made by conducting

experiments to study the workability characteristics of

concrete produced by using grit.

II. Material and Methodology

II (A) Experimental program

The aim of this work is to study the behaviour of the concrete

by using grit as a replacement of natural sand. In this work

study has been done on the trial mixes in which the natural

sand has been replaced by grit. After carrying out trials a mix

for 100% replacement of natural sand is achieved for M 20

grade of concrete. For different concrete mixes slump values

were found and comparison is done in terms of workability.

For designing the M 20 grade of concrete W/C ratio of 0.50

is taken which is further modified up to 0.55 for meeting the

value of required workability. For the assessment of

gradation, sieve analysis of natural sand as well as grit is

conducted. For the assessment, mix designs were made using

natural sand and grit. The tests were conducted on the trials






made from using natural sand, grit and combination of grit and

fly ash with varying amount of cement, Coarse aggregate and

water. In some mixes the admixtures are added for improving

workability of concrete. Table 1.1 shows the comparative

properties of natural sand and grit.

Table no. 1 General properties of Natural Sand and Grit

S.N. Property Natural Sand Grit

1 Shape Spherical Cubical

2 Grading Cannot be

controlled

Can be

controlled

3 Specific Gravity 2.6 to 2.8 2.5 to 2.9

4 Water Absorption 2 to 3% 3 to 4%

5 Ability to hold

moisture Up to 7% Up to10%

II (B) Materials

The following paragraphs explain the details of materials used

for conducting the experiments. The natural sand was obtained

from nearby river, whereas coarse aggregate and grit was

obtained from local crusher. A total of 7 concrete samples with

different proportions were studied to find the workability

characteristics of concrete.

II (B-1) Cement

In this experimental work OPC 53 grade cement was used. The

tests conducted on the cement were fineness test conforming to

IS 12269 : 1987, standard consistency test, compression test

conforming to IS 650 : 1991. Table no. 2 shows the test results

of cement used for producing concrete.

Table no. 2 Test results of cement

S.N. Test Result

1 Soundness ( Le Chatelier ) 8 mm

2 Initial setting time 50 minutes

3 Final setting time 560 minutes

4 Compressive strength (28 days) 51 MPa

5 Fineness 235 m2/kg

II (B-2) Natural sand and grit

For the present work four types of fine aggregate are used for

making concrete which includes natural sand and three

different samples of grit. Initially, trials were carried out on the

mix made from the natural sand which is free from the organic

impurities. Following which trials were made by replacing

natural sand by three different samples of grit. The sieve

analysis was conducted for determination of gradation of

natural sand as well as grit. For sieve analysis 1 kg of material

was taken and sieved through sieves which were mounted one

over another in decreasing order of their sizes i.e. 4.75 mm,

3.35 mm, 2 mm, 600 micron, 90 micron and grading pattern

was found. Results of sieve analysis for natural sand are shown

in table no. 3. Whereas, table no. 4 shows the results of sieve

analysis for grit. Table no. 5 shows the test results of fineness

modulus and specific gravity of natural sand and grit samples

used in the experimental work.

Table no. 3 Sieve analysis of natural sand

S.

N.

Sieve

sizes

Retained

(gm)

Retained

(%)

Cum.

(%)

%

Passing

1 4.75 mm 29.5 2.95 2.95 97.05

2 3.35 mm 19.1 1.91 4.86 95.14

3 2.36 mm 26.1 2.61 7.47 92.53

4 2.00 mm 30.1 3.01 10.48 89.52

5 1.0 mm 145.2 14.52 25 75

6 600 µ 125.3 12.53 37.53 62.47

7 90 µ 611.5 61.15 98.68 1.32

8 Pan 11.9 1.19 99.87 0.13

Table no. 4 Sieve analysis of grit (sample 1)

S.

N. Sieve sizes

Retained

(gm)

Retained

(%)

Cum.

(%)

%

Passing

1 10 mm 5.0 0.5 0.5 99.5

2 4.75 mm 82.3 8.23 8.73 91.27

3 2.36 mm 292.1 29.21 37.94 62.06

4 1.18 mm 299.3 29.93 67.87 32.13

5 600 µ 93 9.3 77.17 22.83

6 300 µ 70.9 7.09 84.26 15.74

7 150 µ 73.2 7.32 91.58 8.42

8 Pan 84.9 8.49 100.07 - 0.07

Table no. 5 Test results of fine aggregate

S.N. Test

Results

Nat

ura

l sa

nd

Gri

t (s

amp

le 1

)

Gri

t (s

amp

le 2

)

Gri

t (s

amp

le 3

)

1 Specific

gravity 2.66 2.6

2.3

5 2.52

2 Fineness

modulus 2.86

4.6

8

4.5

7 4.51

II (B-3) Coarse aggregate

Coarse aggregate occupies the maximum volume in concrete,

hence it is plays an important role in performance of

concrete. It occupies nearly 70 to 80 percent by volume of the

concrete and hence their properties are vital. Plastic and

hardened concrete properties are largely depends upon the

type of coarse aggregate. In this work coarse aggregate

conforming to IS 383 : 1970 was used having maximum size

of aggregate of 20 mm. the particle size of coarse aggregate

varied from 4.75 mm to 20 mm.

II (B-4) Super plasticizer

In the present investigation Conplast SP 430 super

plasticizing admixture was used, which complies with IS

9103 : 1999. Conplast SP 430 is based on sulphonated




naphthalene polymers and is supplied as a brown liquid

instantly dispersible in water. It has been specially formulated

to give high water reduction up to 25% without loss of

workability. Its specific gravity is 1.145 (at 30 °C) and chloride

content is Nil. Air entrainment is approximately 1%.

II (B-5) Water

Water plays an important role in modifying the plastic and

hardened properties of concrete. It reacts with cement and

helps in setting and hardening the cement by evolving heat of

hydration. The workability of concrete directly depends on the

water-cement ratio and hence the quantity of water used for

making concrete. The water-cement ratio affects directly the

workability and strength of hardened concrete. For making the

concrete potable water was used.

II (C) Mix design of concrete

Concrete mix was designed in accordance with IS 456 : 2000

and IS 10262 : 1982. A total of four concrete mix were

designed to obtain M 20 grade of concrete. Out of the four

concrete mix, one mix was prepared from 100% natural sand

and the other three mix were by replacement of natural sand

with grit. Table no. 6 shows the proportions of ingredients for

different mix of concrete:

Table no. 6 Concrete mix proportions for M 20 grade (kg/m3)

S.N. Materials Cement Water

Sand (fine

aggregate)

Coarse

Aggregate

1 Quantity 394.32 197.9 635.74 1147.45

2 Proportion 1 0.50 1.6 2.90

Table no. 7 Trial Mix Design for replacement of natural sand

by grit (Sample 1) (kg/m3)

S.N

.

Cem

ent

w/c

rat

io

Fine aggregates

Co

arse

agg

reg

ates

Su

per

-

Pla

stic

izer

Fly

ash

Nat

ura

l

san

d

Gri

t

(sam

ple

1)

1 340 0.50 662.34 - 1155.42 - -

2 325 0.50 - 652.6 1116.8 - -

3 370 0.50 - 696.5 1114.8 0.60% -

4 330 0.55 - 541.00 1085 0.80% 132

5 330 0.55 - 568.058 1085 0.80% 99

Table no. 8 Trial Mix Design for replacement of natural sand

by grit (Sample 2, 3) (kg/m3)

S.N.

Cem

ent

w/c

rat

io

Fine

Aggregates

Co

arse

agg

reg

ates

Su

per

-

-pla

stic

izer

Fly

ash

Sam

ple

2

Sam

ple

3

1 330 0.55 548.8 - 1080.35 0.80% 99.06

2 330 0.55 - 583.92 1080.00 0.80% 99.06

Based on the results of 1st trial mix, adjustments were made

for the further trial mix. Each trial mix was designed to

obtain a target mean strength of 26.6 N/mm2. Different

concrete mix were designed with a variable water-cement

ratio and cement content varying from 330 kg/m3 to 370

kg/m3.

III. Results and Tables

III (A) Measurement of workability

The 1st trial mix of concrete tested had a water-cement ratio

of 0.50 with 100% natural sand as fine aggregate. The

workability measured on a slump cone for this 1st trail mix

was 50 mm. The compressive strength obtained for the 1st

trail was more than the desired target mean strength. Hence a

2nd

trail mix of concrete with natural sand was made by

reducing cement content and as expected the required target

mean strength was achieved. The 3rd

trial mix was made with

replacement of natural sand by grit with an increased water-

cement ratio of 0.55. For this sample of concrete mix the

observed slump was shear slump. So the 4th

trial was carried

out with addition of SP-430 super plasticizer. The concrete

obtained was honeycombed for this mix and it became

difficult to finish the concrete in cubes. To improve the

workability and ease in finishing the concrete, mix was

designed for another trial with addition of fly ash. The

difficulty in achieving a smooth finish and target workability

was achieved by addition of 30% fly ash and 0.8% SP 430

super plasticizer. Table no. 9 shows the workability of

concrete obtained for different mix.

Table no. 9 Workability results of various mixes

S.N. W/C

ratio Fine Aggregate Admixture

Workability

(mm)

1 0.50 Natural sand - 50

2 0.50 Natural sand - 40

3 0.55 Grit (sample 1) - 50

4 0.55 Grit (sample 1) 0.8% SP 430 100

5 0.55 Grit (sample 1)

+ 40% Fly ash

0.8% SP 430 110


+ 30% Fly ash

0.8% SP 430 150


+ 30% Fly ash

0.8% SP 430 150

8 0.55 Grit (sample 1) 0.8% SP 430 30

IV. Conclusion

Natural sand as fine aggregate in concrete plays an important

role in modifying the workability characteristics of concrete.

However, the sources of natural sand are depleting day-by-

day and it becomes essential to find other alternative

materials which can be used as replacement of natural sand.

One such material which can be used as replacement of

natural sand is grit. According to the findings of this present

work, due to the irregular particle shape of the grit and




limitations imposed by code on water-cement ratio, achieving a

good workable concrete without super plasticizer was

practically difficult. From the study carried out, it can be

concluded that concrete of M 20 grade can be produced by

100% replacing natural sand with grit in presence of fly ash

and super plasticizer.

Acknowledgement

The aouthers of this paper are highly obliged to the

Department of Civil Engineering, Dr. Babasaheb Ambedkar

Technological University, Lonere. We would solemnly like to

expess our deep sence of gratitude towards Head of the

Department and the staff of the concrete technology lab of the

University.

References i. Ankit Nileshchandra Patel, Jayeshkumar Pitroda (2013). Stone

Waste: Effective Replacement of Cement for Establishing Green Concrete.

International Journal of Innovative Technology and Exploring Engineering

(IJITEE) ISSN: 2278-3075, Volume-2, Issue-5

ii. Anzar Hamid Mir (2015). Replacement of Natural Sand with

Efficient Alternatives: Recent Advances in Concrete Technology. International

Journal of Engineering Research and Applications ISSN : 2248-9622, Vol. 5,

Issue 3, ( Part -3)

iii. Dushyant R. Bhimani, Jayeshkumar Pitroda, Jaydev J. Bhavsar

(2013). Innovative Ideas for Manufacturing of the Green Concrete by Utilizing

the Used Foundry Sand and Pozzocrete. International Journal of Emerging

Science and Engineering (IJESE) ISSN: 2319–6378, Volume-1, Issue-6

iv. Mahendra R. Chitlange and Prakash S. Pachgade. (2010).

Strength appraisal of artificial sand as fine aggregate in SFRC. ARPN

journal of engineering and applied sciences. Vol. 5 no. 10

v. Manguriu, G.N., Karugu, C.K., Oyawa, W.O., Abuodha, S.O. and

Mulu, PU. (2013). Partial replacement of natural river sand with Crushed

rock sand in concrete production. Global engineers & technologists review.

vi. Sachin Balkrishna Kandekar, Amol Jagannath Mehetre,

Vijayshree A. Auti (2012). Strength of concrete containing different types of

fine aggregate. International Journal of Scientific & Engineering Research

Volume 3, Issue 9, September- 2012 ISSN 2229-5518

vii. Tushar R Sonawane, Sunil S. Pimplikar. Use of Recycled

Aggregate Concrete. IOSR Journal of Mechanical and Civil Engineering

(IOSR-JMCE) ISSN: 2278-1684, PP: 52-59

viii. IS 12269 : 1987 Specification for 53 grade ordinary Portland

cement.

ix. IS 650 : 1991 Specification for standard sand for testing of

cement.

x. IS 383 : 1970 Specification for course and fine aggregates from

natural sources for concrete.

xi. IS 9103 : 1999 Specification for admixtures for concrete.

xii. IS 456 : 2000 Code of practice for plain and reinforced concrete.

xiii. IS 10262 : 1982 Recommended guidelines for concrete mix

design.

International Journal of Modern Engineering Research (IJMER)

www.ijmer.com Vol. 2, Issue. 5, Sept.-Oct. 2012 pp-3006-3012 ISSN: 2249-6645

www.ijmer.com 3006 | Page

Prof. R. Sathish Kumar Sr. Associate Professor

National Institute of Construction Management and Research, Hyderabad

Abstract: Rapid increase in construction activities leads

to active shortage of conventional construction materials

due to various regions. Concrete is most widely used

construction material. Cement, sand & granite stone are

the constituents of the concrete. Researches were

researching for cheaper materials that can be used as

substitute for these materials. In this context an

experimental study was carried out to find the suitability of

the alternate construction materials such as, rice husk ash, sawdust , recycled aggregate and brickbats as a partial

replacement for cement and conventional aggregates .For

this concrete cubes of sixe 150mm x150mm were casted

with various alternate construction materials in different

mix proportion and with different water cement ratios.

Their density, workability and compressive strengths were

determined and a comparative analysis was done in terms

of their physical properties and also cost savings. Test

results indicated that the compressive strength of the

OPC/RHA concrete cube blocks increases with age of

curing and decreases as the percentage of RHA content

increases.It was also found that the other alternate construction materials like saw dust, recycled aggregates

and brick bats can be effectively used as a partial

replacement for cement and conventional aggregates. The

results showed that the compressive strength, of recycled

aggregate are on average 70% to 80% of the natural

aggregate concrete and the compressive strength of brick

bat concrete and saw dust concrete was found to be in the

range of 30-35% and 8-10% respectively. The compressive

strength of rice husk ash concrete was found to be in the

range of 70-80% of conventional concrete for a

replacement of cement up to 20%.

I. Introduction Concrete is most widely used construction material today.

Concrete has attained the status of a major building

material in all the branches of modern construction. It is

difficult to point out another material of construction which is as variable as concrete. Concrete is the best material of

choice where strength, durability, impermeability, fire

resistance & absorption resistance are required. Rice husk

& saw dust are the waste products which are abundantly

available & which can be used as a substitute for white

cement.

I.1 Rice husk ash (RHA) concrete

Rice husk is an agro-waste material which is produced in

about 100 million of tons. Approximately, 20 Kg of rice

husk are obtained from 100 Kg of rice. Rice husks contain organic substances and 20% of inorganic material. Rice

husk ash (RHA) is obtained by the combustion of rice

husk. The burning temperature must be within the range of

600 to 8000C. The ash obtained has to be grounded in a

ball mill for 30 minutes and its appearance in colour will

be grey. The most important property of RHA that

determines pozzolanic activity is the amorphous phase

content. RHA is a highly reactive pozzolanic material

suitable for use in lime-pozzolana mixes and for Portland

cement replacement. RHA contains a high amount of

silicon dioxide, and its reactivity related to lime depends on

a combination of two factors, namely the non-crystalline

silica content and its specific surface. Research on

producing rice husk ash (RHA) that can be incorporated to concrete and mortars are not recent. In 1973, investigations

were done on the effect of pyroprocessing on the

pozzolanic reactivity of RHA. Since then, a lot of studies

have been developed to improve the mechanical and

durability properties of concrete.

I.2 Previous Research Efforts

The following research efforts shed light on the research

works on the utilization of rice husk and rice husk ash as a

partial replacement material or stabilizing agent in building

works. Tests were carried out on some characteristics of acha husk ash/ordinary Portland cement concrete. Test

results indicated that the compressive strength for all the

mixes containing AHA increases with age up to the 14-day

hydration period but decreases to the 28-day hydration

period while the conventional concrete increases steadily

up to 28-day hydration period[1]. Tests were also carried

on the use of rice husk ash in concrete. Test results

indicated that the most convenient and economical

temperature required for conversion of rice husk into ash is

500°C. Water requirement decreases as the fineness of

RHA increases. The higher the percentage of RHA

contents, the lower the compressive strengths [3]

I.3 Saw dust concrete

It is sometimes required to make nailing concrete & this

may be achieved by using saw dust as an aggregate.

Nailing concrete is a material into which nails can be

driven & in which they are firmly held. The last stipulation

is made because, for instance in some of the lighter light

weight concrete nails, although easily driven, fail to hold.

The nailing properties are required in some types of roof

construction & pre cast unit for houses etc. because of its

very large moisture movement, saw dust concrete should not be used in the situation where it is exposed to moistures

(4).

I.4 Recycled aggregate concrete

“Experimental study on the properties of concrete made

with alternate construction materials”




Lots of construction activities are going on in & around the

world & lots of demolition of old concrete works are also

taking place. This demolished concrete, if it can be

recycled & used as recycled aggregate concrete their disposal which is gigantic task can never be problem.

Shanker and Ali(5) have studied engineering properties of

rock flour and reported that the rock flour can be used as

alternative material in place of sand in concrete based on

grain size data. Nagaraj and Banu(9) have studied the

effect of rock dust and pebble as aggregate in cement and

concrete. It has been reported that crushed stone dust can

be used to replace the natural sand in concrete. Sahu, et al

(2) have reported that sand can be replaced by rock flour

up to40% without affecting strength and workability.

Kanakasabai and Rajashekaran(10)investigated the

potential of ceramic insulator scrap as coarse aggregate in concrete. It has been reported that the crushed ceramic

aggregate can be used to produce lightweight concrete,

without affecting strength

I.5 Obstacles in Use of recycled aggregate

The acceptability of recycled aggregate is impeded for

structural applications due to the technical problems

associated with it such as weak interfacial transition zones

between cement paste and aggregate, porosity and

transverse cracks within demolished concrete, high level of

sulphate and chloride contents, impurity, cement remains, poor grading, and large variation in quality (8). Although,

it is environmentally & economically beneficial to use

RCA in construction, however the current legislation and

experience are not adequate to support and encourage

recycling of construction & demolished waste in India.

Lack of awareness, guidelines, specifications, standards,

data base of utilization of RCA in concrete and lack of

confidence in engineers, researchers and user agencies is

major cause for poor utilization of RCA in construction. (7)

I.6 Brick bat aggregate concrete

Bricks bats one of the types of aggregates used in certain places where natural aggregates are not available or costly.

Where ever brick bats aggregates are used the aggregates

are made from slightly over burnt bricks. This will be hard

& absorb less water.

II. Experimental Investigations

II.1 Introduction

The experimental investigations includes the casting of cube with various alternative construction materials & the

tests were conducted to study the various physical

properties such as density, slump, 7days & 28 days

compressive strength. A total of 168 specimens were cast

& tested in the laboratory to evaluate their compressive

strength.

II.2 Materials and Methods

II.2.1 Materials

Cement- Cement used in this study is “43 Grade” which is available under the commercial name “ Rajashree

Cement”.

Sand - River sand confirming to zone -2 and with a

fineness modulus of 2.4 was used in this study.

Rice Husk Ash -The rice husk ash was obtained from

N.K.Enterprises ,Jharsuguda, Orissa, India . Here rice

husk was burnt approximately 48 hours under

uncontrolled combustion process. The burning temperature was within the range of 600 to 8000C. The

ash obtained was grounded in a ball mill for 30 minutes

and its appearance in colour was grey.

Coarse aggregate - From near by quarry.

Saw dust - from nearby saw mill

Brick bats –Collected locally and then broken into

pieces of 40mm size, mechanically sieved through

4.75mm sieve to remove the finer particles.

Recycled aggregates The recycled aggregate are

collected from the source demolished structures. The

concrete debris were collected locally from different sources and broken into the pieces of approximately 80

mm size with the help of hammer .The foreign matters

were sorted out from the pieces. Further, those pieces

were mechanically sieved through sieve of 4.75 mm to

remove the finer particles. The recycled coarse

aggregates were washed to remove dirt, dust etc. and

collected for use in concrete mix.

II.3 Material tests (As per I S 456-2000)

II.3.1 Cement and rice husk ash

Initial setting time of cement – 95 min

Final setting time of cement – 420 min

Specific gravity of cement – 3.12

Specific gravity of rice husk ash -2.14

Fineness of cement – 1.35%

Setting Times-The comparison of setting times of

cement and rice husk ash is presented in table -1

The initial and final setting times increases with increase in

rice husk ash content. The reaction between cement and

water is exothermic leading to liberation of heat and evaporation of moisture and consequently stiffening of the

paste. As rice husk ash replaces cement, the rate of reaction

reduces, and the quantity of heat liberated also reduces

leading to late stiffening of the paste. As the hydration

process requires water, greater amount of water was also

required for the process to continue.

II.3.2 Chemical analysis of rice husk ash as supplied by

the supplier

Table shows the chemical composition of rice husk ash.

The total percentage composition was found to be 73.77%

This value is within the range of required value of 70% minimum for pozzolonas. The loss of ignition obtained was

17.71% which is slightly more than 12%max required for

pozzolonas. It means that rice husk ash contains little

unburnt carbon and this reduces the pozzolonic activity of

ash.

Content % age

composition

Fe2O3 0.91%

SiO2 65.3%

CaO 1.31%

Al2O3 4.4%

MgO 1.85%




Loss of ignition 17.71%

The specific gravity of rice husk ash was found to be

2.14.The value is well within the range of pulverised fuel

ash which is in between 1.9 and 2.4 as reported in (6)

II.3.3 Fine aggregate tests

Specific gravity of sand – 2.61

Fineness modulus of sand – 2.54

Fineness modulus of saw dust – 2.67

Specific gravity of saw dust -2.12

II.3.4 Coarse aggregates tests

II.3.4.1 Conventional aggregate

Specific gravity of coarse aggregate – 2.70

Fineness modulus of coarse aggregate – 7.133

Crushing strength – 16.1% Specific gravity of brick bats -2.34

II.3.4.2 Recycled Concrete Aggregate

(a) Specific Gravity and Water Absorption

The specific gravity (saturated surface dry condition) of

recycled concrete aggregate was found to be 2.28 which is

lower as compared to natural aggregates. Since the RCA

from demolished concrete consist of crushed stone

aggregate with old mortar adhering to it, the water

absorption found to be 2.95% which is relatively higher

than that of the natural aggregates.

(b) Bulk Density

The rodded & loose bulk density of recycled aggregate is

lower than that of natural aggregate. The lower value of

loose bulk density of recycled aggregate may be attributed

to its higher porosity than that of natural aggregate.

(c)Crushing and Impact Values

The recycled aggregate is relatively weaker than the natural

aggregate against mechanical actions. As per IS 2386, the

crushing and impact values for concrete wearing surfaces should not exceed 45% and 50% respectively. The

crushing & impact values of recycled aggregate satisfy the

BIS specifications

II.4.4.3 Super plasticizer

Product - Roff block master

Description – It is an admixture for making concrete blocks

and pre cast concrete products- to achieve homogeneous

highly workable mix to give high early strength & to

reduce breakages.

Typical applications – For manufacture of concrete blocks,

products such as pipes, pole, manhole covers, concrete jails etc.

Consumption – 140ml/bag of 50 Kg cement

Application – Dry mix cement & aggregate, add 140ml roff

block master in gauging water, mix thoroughly & cast as

per standard practice, permits use of leaner mixes.

II.5 Specimens

A total of 168 specimens of size 15cm x 15cm x 15cm

were casted with different alternative construction

materials with varying mix proportion & water cement

ratio is given in table -2

III. Comparison of results

III.1.Rice husk ash concrete with conventional concrete

Nearly 60 specimens were casted with the mix proportion

of 1:2:4 with different water cement ratios 0.56,0.58,0.60

and 0.62 and with different percentages of Cement and rice

husk ash .It was found from that when the rice husk ash

percentage was increased from 50% onwards the mix was

becoming harsh ,so a higher water cement ratio was

adopted for the mixes with increased rice husk ash

percentages The comparison of compressive strength of conventional and rice husk ash concrete cubes are given in

table -3

III. 2. Saw dust concrete with conventional concrete

Some properties of concrete with sawdust ash (SDA) as a

replacement for conventional fine aggregate are

investigated The cube specimens were casted under 2 mix

proportions.1:2:4 and 1:1.5:3.Sawdust and river sand were

taken in the ratio 1.5:0.5 for 1:2:4 concrete and 1:0.5 and

1.25:0.25 for 1:1.5:3 concrete. The water cement ratio

adopted earlier was found harsh for this concrete. So the

mixes are made in a water cement ratio of 0.7,0.75 and 0.8 respectively.. The compressive strength of specimens with

replacement levels shown above cured for periods of 7-28

days showed a decreasing strength with higher saw dust

content. The comparison of compressive strength of

conventional and saw dust concrete cubes are given in

table -4

III.3. Recycled aggregate concrete with conventional

concrete

Three different mix proportions 1:1.5:3, 1:2:4, and 1:3:6

with water cement ratio 0.5 & 0.6 and 0.7 were made with natural aggregate concrete and recycled aggregate concrete

with and without plasticizer. Due to the higher water

absorption capacity of RCA as compared to natural

aggregate, both the aggregates are maintained at saturated

surface dry (SSD) conditions before mixing operations.

The ordinary Portland cement of 43 grade and natural river

sand were used throughout the casting work. The

maximum size of coarse aggregate used was 20 mm in both

recycled and natural aggregate concrete.

A total of 54 cube specimens were casted . The comparison

of compressive strength of conventional and recycled

aggregate concrete cubes are given in table -5

III.4 Brickbat concrete with conventional concrete

Here the conventional stone aggregates were replaced with

brickbats and the specimens were casted in the ratio

1:2:4.1:1.5:3 and 1:3:6. The comparison of compressive

strength of conventional and brick bat aggregate concrete

cubes are given in table -6

IV. Cost analysis A cost comparison was done with concrete made up of

alternate construction materials and conventional concrete

was done the same was presented in table 7 &8

IV.1 Analysis of results obtained




IV.1.1 Suitability of Material Used

The rice husk ash used was found to be pozzolonic in

nature.The specific gravity of rice husk ash was found to

be 2.14.The setting time of Ordinary Portland cement and rice husk ash paste increases as rice husk ash content

increases

The fineness modulus of saw dust was 2.67 and that of

sand was 2.54. This infers that the saw dust contains

more coarse particles in comparison to sand. Hence, saw

dust may be considered as fine aggregate in concrete.

The specific gravity of the brick bat aggregates (2.34) is

about 0.86 times as that of conventional aggregate (2.7).

As the specific gravity of brick bat aggregates is less

than that of the conventional aggregates, the concrete

produced using the brick bat aggregate will be of low density.

Recycled aggregate and brick bat aggregates can be

partially used to replace conventional coarse aggregates

(10% to 20%), without affecting its structural

significance

V. Conclusion

The compressive strength of rice husk ash concrete was

found to be in the range of 70-80% of conventional

concrete for a replacement of cement up to 20%.

The study shows that the early strength of rice husk ash

concrete was found to be less and the strength increased

with age.

The rice husk ash concrete occupies more volume than

cement for the same weight. So the total volume of the

rice husk ash concrete increases for a particular weight

as compared to conventional concrete which results in

economy.

Due to the lower density of RHA concrete the self

weight of structure gets reduced which results in overall

savings.

From the cost analysis it was found that the cost of RHA

concrete was less compared to conventional concrete

Recycled aggregate posses relatively lower bulk density,

crushing and impact values and higher water absorption

as compared to natural aggregate.

The compressive strength of recycled aggregate

concrete was found to be in the range of 70 to 80 % of

conventional concrete..

The compressive strength of brick bat concrete was

found to be nearly 35 % of conventional concrete... The

compressive strength of saw dust concrete was found to be nearly 10 to 15% of conventional concrete. So the

concrete made with alternate construction materials like

brick bats and saw dust can be used for partition &

filling purposes & nailing purposes where the strength is

not the criteria.

Wherever compressive strength is not a criteria, the

concrete made with alternate construction materials can

always be preferred.

Referances

1. Al –Khalaf M.N.and Yousuf H.A ,Use of rice husk

ash in concrete, The international journal of cement

composite and light weight concrete ,6(11),p.241-

245,1984

2. A K Sahu, S Kumar and A K Sachin. „Crushed Stone

Waste as Fine Aggregate for Concrete‟. The Indian

Concrete Journal, January 2003

3. Dashan .I.IB and Kamang E.E.I.,Some characteristics

of RHA/OPC concrete, A preliminary assessment

,Nigerian journal of Construction Technology and

Management,2(1),P.22-28,1999

4. Felix F. Udoeyo1 and Philibus U. Dashibil,J. Mat. in

Civ. Engrg. Volume 14, Issue 2, pp. 173-176 (March/April 2002)

5. N B Shankar and Md Ali. „Engineering Properties of

Rock Flour‟. National conference on Cement and

Building Materials from Industrial Waste, July 24-25,

1992, pp 167-172.

6. Neville AM.,Properties of concrete, John&Wiley and

sons,Malasia,1981 &1985 composites and light

weight concrete,6(4).P.241-248,1984.

7. Rahal, K. (2007) “Mechanical Properties of Concrete with Recycled Coarse Aggregate,” Building &

Environment, Vol. 42, pp 407-415.

8. Sharma, P.C., Nagraj, N.(1999), “Recycled

Aggregate Concrete and Its Importance in Indian

Conditions”– All India Seminar on Indian Cement

Industries : Challenges and Prospects of Cement”

Chandrapur (Maharashtra)

9. T S Nagaraj and Z Banu. „Efficient Utilization of

Rock Dust and Pebbles as Aggregate in Portland

Cement Concrete‟. The Indian Concrete Journal, vol

70, no 1, 1996, pp 1-4

10. VK Sabai and AR Shekaran. „Ceramic Insulator

Scrap as Light Weight Concrete‟.National

Conference on Cement and Building Materials from

Industrial Wastes, July 4-25, 1992, pp 8-15

http://scitation.aip.org/vsearch/servlet/VerityServlet?KEY=ASCERL&possible1=Udoeyo%2C+Felix+F.&possible1zone=author&maxdisp=25&smode=strresults&aqs=true

http://scitation.aip.org/vsearch/servlet/VerityServlet?KEY=ASCERL&possible1=Dashibil%2C+Philibus+U.&possible1zone=author&maxdisp=25&smode=strresults&aqs=true




Table -1 Comparison of setting times of cement and rice husk ash under various replacement levels.

Table -2 Specimens casted with different alternate construction materials and with different water

Cement ratios.

Table -3 Comparisons of compressive strength of conventional and rha concrete cubes.

Sl No Types of

concrete

Mix Cement :

RHA

W/C Compressive strength in

Kg/cm2

3 days 7 days 28

days

1 Conventional

concrete

1:2:4 100% :0% 0.56 118.57 166.00 298.06

2 RHA concrete 1:2:4 90%:10% 0.56 98.69 138.57 234.39

3 RHA concrete 1:2:4 80%:20% 0.56 89.69 124.62 197.98

4 RHA concrete 1:2:4 70%:30% 0.56 71.02 104.00 157.90

5 Conventional

concrete

1:2:4 100% :0% 0.58 122.3 168.22 276.67

6 RHA concrete 1:2:4 90%:10% 0.58 100.79 144.74 237.15

7 RHA concrete 1:2:4 80%:20% 0.58 89.05 128.93 198.57

8 RHA concrete 1:2:4 70%:30% 0.58 78.50 106.26 158.12

9 Conventional

concrete

1:2:4 100% :0% 0.60 101.67 154.15 277.86

10 RHA concrete 1:2:4 90%:10% 0.60 101.12 146.15 239.33

11 RHA concrete 1:2:4 80%:20% 0.60 91.47 132.98 199.76

12 RHA concrete 1:2:4 70%:30% 0.60 79.66 108.59 161.33

13 Conventional

concrete

1:2:4 100% :0% 0.62 120.55 160.43 248.33

14 RHA concrete 1:2:4 90%:10% 0.62 84.05 112.79 216.71

15 RHA concrete 1:2:4 80%:20% 0.62 78.28 107.05 198.81

16 RHA concrete 1:2:4 70%:30% 0.62 61.26 85.09 164.62

17 RHA concrete 1:2:4 50%:50% 0.98 49.4 57.31 75.09

18 RHA concrete 1:2:4 40%:60% 1.07 35.57 55.33 59.28

19 RHA concrete 1:2:4 30%:70% 1.20 25.57 39.52 41.5

20 RHA concrete 1:2:4 20%:80% 1.35 15.81 23.71 25.69

RHA replacement of OPC (%) 0 10 20 30 40 50

Initial Setting Time (minutes) 90 172 183 285 324 389

Final Setting Time (minutes) 240 313 490 525 712 790

Sl No Types of concrete Proportions W/C ratio Density

(Kg/cum)

1. Conventional

concrete

1:2:4 0.4,0.5,0.6 2520

2. Concrete with rice

husk ash

1:2:4(80%cement and 20%rice

husk ash)

0.4,0.5,0.6 2418

4. Recycled concrete

without plasticizer

1:1.5:3,1:2:4,1:3:6 0.5,0.6,0.7 2488

6. Saw dust concrete 1:(1.5+0.5):4 0.7,0.75,0.8 1980

7. Concrete using

brick bat

1:2:4 0.5,0.6,0.7 2215




Table-4 Compressive strength test results of conventional concrete and saw dust concrete.

Sl No Types of

concrete

Prop W/C Compressive

Strength

(7days) Kg/cm2

Compressive

Strength

(28days)

Kg/cm2

Conventional

concrete

1:2:4 0.56 166 328

Saw dust

concrete

1:(1.5+0.5):4 0.7 18.89 31.11

Saw dust

concrete

1:(1.5+0.5):4 0.75 19.09 32.36

Saw dust

concrete

1:(1.5+0.5):4 0.8 17.78 30.35

Saw dust

concrete

1:(1+0.5):3 0.7 20.12 42.11

Saw dust

concrete

1:(1+0.5):3 0.75 20.26 43.22

Saw dust

concrete

1:(1+0.5):3 0.8 19.19 39.32

Saw dust

concrete

1:(1.25+0.25):3 0.7 18.11 30.33

Saw dust

concrete

1:(1.25+0.25):3 0.75 18.63 30.44

Saw dust concrete

1:(1.25+0.25):3 0.8 18.42 30.14

Table-5 Compressive strength test results of conventional concrete and recycled aggregate concrete.

Sl

No

Types of concrete Prop. W/C Compressive

Strength

(7days) Kg/cm2

Compressive

Strength

(28days)

Kg/cm2

1 Conventional concrete 1:2:4 0.5 166 296

2 Conventional concrete 1:1.5:3 0.5 198 346


4 Recycled concrete

without plasticizer

1:2:4 0.5 101.44 177.56

5

Recycled concrete

without plasticizer

1:2:4

0.6

104.67

187.78

6 Recycled concrete

without plasticizer

1:2:4 0.7 114.44 192.22

7 Recycled concrete

without plasticizer

1:1.5:3 0.5 119.23 218.11

8 Recycled concrete

without plasticizer

1:1.5:3 0.6 122.89 221.56

9 Recycled concrete

without plasticizer

1:1.5:3 0.7 129.28 228.33

10 Recycled concrete

without plasticizer

1:3:6 0.5 81.88 118.66


without plasticizer

1:3:6 0.6 87.78 121.22


without plasticizer

1:3:6 0.7 92 128.78

13 Recycled concrete with plasticizer

1:2:4 0.5 134.44 234.56

14 Recycled concrete with

plasticizer

1:2:4 0.6

136.67

241.78

15

Recycled concrete with

plasticizer

1:1.5:3

0.5

148.23 258.13





plasticizer

1:1.5:3 0.6 152.78 272.11


plasticizer

1:3:6 0.5 109.11 152.06


plasticizer

1:3:6 0.6 111.43 154.11

Table-6 Compressive strength test results of conventional concrete and brick bat concrete.

Sl

No

Types of concrete Prop. W/C Compressive

Strength

(7days) Kg/cm2

Compressive

Strength

(28days)

Kg/cm2


2 Concrete using brick bat 1:2:4 0.5 58.12 91.11



5 Concrete using brick bat 1:1.5:3 0.5 64.12 122.33






Table -7 Cost comparisons between rice husk ash concrete specimens and conventional concrete specimens.

Sl

No

Types of concrete Cement:RHA Prop. Percentage w.r.t conventional

concrete

1 Conventional concrete 100% :0% 1:2:4 --

2 RHA concrete 90%:10% 1:2:4 4.23%

3 RHA concrete 80%:20% 1:2:4 5.93%

4 RHA concrete 70%:30% 1:2:4 14.31%

5 RHA concrete 50%:50% 1:2:4 17.9%

6 RHA concrete 40%:60% 1:2:4 19.74%

7 RHA concrete 30%:70% 1:2:4 23.6%

8 RHA concrete 20%:80% 1:2:4 27.6%

Table-8 Cost comparison between other alternate construction material specimens and conventional

Concrete specimen.

Sl

No

Types of concrete Prop %age of saving w.r.t to

conventional concrete

1. Conventional concrete 1:2:4 --

2 Recycled concrete without plasticizer 1:4 28.1%

5.a Recycled concrete with plasticizer 1:4 25.2%

6.a Saw dust concrete 1:(1.5+0.5):4 30.1%

7.a Concrete using brick bat 1:2:4 15.42%

24th & 25th July 2015

Emerging Trends on Sustainable Construction – National Level Conference Christ University, Bangalore Page 1

Alternatives to Conventional Cement-Sand Mortar for

Sustainable Masonry Construction

Sumanth M Kamplimath1, Ashwin M joshi

2

1PG. Student, Infrastructure Construction and Management, RASTA-Centre for Road Technology,

Bangalore 560058 email: [email protected] 2Asst. Professor, Infrastructure Construction and Management, RASTA-Centre for Road Technology,

Bangalore 560058 email: [email protected]

Abstract

Masonry Mortar is basically a binding agent that is composed of cementitious material,

fine aggregates and water. The main purpose of the mortar is to sew masonry units

(blocks/bricks) into single integral unit. Conventionally used mortar is cement sand

mortar in the proportion 1:6 (Cement: River Sand). Over the past few decades man has

exploited the natural resources at a severe rate. Good quality Natural River Sand stands

first in the list of construction materials that are in the verge of extinction due to excessive

and unnecessary consumption in construction process. One has to adapt to alternative

materials that can be used as an effective replacement over ‘Natural River Sand’ in

Masonry Mortar without affecting its efficiency. This paper focuses on the experimental

analysis on six such alternatives that have the potential to replace Natural River Sand in

mortar. Mortars prepared from these alternatives satisfies the minimum strength

requirement as per IS code. Thus the use of such alternatives to natural sand for mortars

in masonry construction would deliver an efficient-economical and sustainable structure.

Keywords: Natural River Sand, M. Sand, LD Slag, GBFS, Quarry Dust, Granite Powder,

Cement-Lime-Soil-Paste (CLSP), Mortar, Masonry

1. Introduction

The field of Civil Engineering and Construction technology has evolved from bamboo

huts to multi storeyed sky scrapers and man-made islands. Such mega structures consume

huge amount of natural resources which may have irreversible ill-effects on the

environment. Sand being the most widely consumed material in construction is on the

verge of causing such ill-effect on environment. In the present day, sand mining is banned

and this has resulted in severe imbalance in the supply-demand chain of Natural River

Sand. Construction with River sand in the present case scenario is highly expensive.

Hence one has to adapt to alternative materials in construction process that has negligible

impact on environment.



24th & 25th July 2015


2. Earlier Investigations

Several investigations have been carried out on alternatives that can be used as partial or

total replacement of sand in conventional cement sand mortar. Rashmi S, Jagadish K S

and Nethravathi S (2014) [1] carried out studies on stabilized mud mortars. Masonry

Mortar plays a major role in the strength gaining parameters of the masonry structures.

This study focuses on the utilization of locally available and economical resources as an

alternative for conventional construction practises. Mortars were prepared with various

mix proportions of soil, brick dust, lime, sand and cement. The various mortar mix

proportions was prepared with varied percentage of water content and tested for its 28 day

cube compressive strength. The mortar proportion M5 with 50% soil and sand with 12%

cement stabilization showed a compressive strength of 4.25 MPa at 28 day which satisfies

the standards of IS 2250:1981. Hence it is clear that partial replacement of sand using soil

works out to be an economical mix. Costigan.A and S.Pavia (2005) [2] carried out

analysis on the compressive strength flexural strength and bond strength of Masonry

using Lime based mortars. Both the hydraulic Lime and Non hydraulic Lime was used as

mortar. Masonry wallettes were built using non hydraulic Lime and Hydraulic Lime as

mortar and were tested for its compressive strength and flexural strength. The mortar was

also tested for its cube compressive strength at 28 days and 56 days. The non-hydraulic

Lime had a 28 day cube compressive strength of 0.89MPa which was slightly lower from

the specified standard values of 1.20MPa; Hydraulic lime had a mortar cube compressive

strength of 4.39MPa which was satisfactory as per standards. Venkatarama Reddy and

Ajay Gupta (2006) [3] carried out tests to determine the strength and elastic properties of

stabilized mud block masonry using cement-soil mortar. Soil used in the blocks and

mortar is same. Soil being Loamy contained 16% clay. The clay content was varied by

blending the soil with natural sand. Workability was maintained constant and the

compressive strength was evaluated. It was found that the compressive strength of

cement-soil mortar and cement-lime mortar was 20% higher than pure cement mortar.

The study showed that mud mortars and lime mortars that are cheaper when compared to

pure cement mortar can be used effectively in Stabilized mud block masonry. Till date,

several alternative materials have been considered for partial replacement of sand in

conventional cement sand mortar. In the present work, an attempt is made on various

alternatives that can be used as complete replacement of sand in masonry mortar.

24th & 25th July 2015


3. Materials and Methodology

The step by step procedure followed in the present study in preparation of mortars using

alternative materials have been discussed below

3.1 Materials

The various ingredients or alternatives materials that have been used as fine aggregate for

total replacement of sand in conventional Cement Sand mortar and their description is

given below.

3.1.1 Manufactured Sand (M. Sand)

M. Sand or Manufactured sand is the latest alternative for natural river sand being used

widely in the construction process. It is derived from crushing of aggregates in a

controlled process as per required specification in terms of shape, size and surface

texture.

3.1.2 Granulated Blast Furnace Slag Sand (GBFS)

This sand is basically a slag material obtained when manufacturing Iron from its ore. The

slag is initially derived in its molten state which upon rapid cooling results in the

formation of sand sized particles. These particles are non-metallic and have surface

texture similar to that of natural river sand

3.1.3 Quarry Dust

Quarry Dust is a by-product generated during the stone quarrying process. These are

extremely fine particles with grain lesser than 75 micron. Hence it can be used effectively

as a filler material because of its tendency to occupy large surface area.

3.1.4 Granite Powder

Granite powder is initially collected as slurry in large storage tanks. When the slurry is

left undisturbed for weeks, the particles undergo sedimentation which is later collected as

Granite Powder. Granite slurry disposal has become a nuisance to the dealers and hence

its application in the field of civil engineering has been explored in the present study.

3.1.5 LD Slag

The slag gets its name from the process developed by scientists Linz and Donawitz in the

manufacture of steel. Calcium oxide comprises of 46% of the total constituent of the Slag.

Hence the slag exhibits cementitious property. Other constituents include oxides of Silica,

Magnesium, Manganese and Iron.

24th & 25th July 2015


3.1.6 Cement-Lime-Soil-Paste (CLSP)

Over the past few decades, with the advancements in the field of stabilization techniques,

we have seen the effective use of soil as partial replacement of sand in Cement-Soil

mortar [3]. Hence an attempt has been made to use locally available soil as complete

replacement to natural sand in Cement-Lime-Soil Paste (CLSP) as mortar. CLSP has been

used in two different proportions (1:1:2 and 1:1:1.5 – Cement:Lime:Soil). Soil used in the

study is locally sourced and had a clay content of about 20%. Quick Lime was procured

from Bijapur and slaked to obtain Hydrated Lime. This hydrated lime was blended

effectively with cement and soil to obtain a paste that has been used as mortar for

complete replacement of river sand in conventional cement sand mortar. 43 Grade

Cement has been used as binder for all the mortars used in the present study.

3.2 Methodology

The first step in the present study was the procurement of various alternative materials

that was intended to be used as fine aggregates in masonry mortar. The binding agent in

all these materials was cement. The alternatives considered as complete replacement of

sand in mortar was first sieved and the sand portion i.e. passing 4.75mm sieve and

retained on 75 micron sieve was collected for use in preparing mortar. The proportion of

cement and fine aggregates in the various mortars that have been studied was 1:6 (Binder:

Fine Aggregate). Mode of preparation of mortar was followed as per Standard

specifications [4]. Granite powder being extremely fine had 0% retained on 75 micron

sieve. The details of various alternatives materials used and water content maintained at

the time of preparation of mortar cubes have been tabulated in table 1.

Table 1: List of Various Mortar Cubes along with its initial water content

Sl. No Mortar Type Water Content

1 1:1:1.5 - CLSP 50%

2 1:1:2 - CLSP 50%

3 1:6 - Cement: Natural Sand 40%

4 1:6 - Cement: Quarry Dust 60%

5 1:6 - Cement: Granite Powder 80%

6 1:6 - Cement: M. Sand 60%

7 1:6 - Cement: GBFS 50%

8 1:6 - Cement: LD Slag 80%

https://www.researchgate.net/publication/245308082_Strength_and_Elastic_Properties_of_Stabilized_Mud_Block_Masonry_Using_Cement-Soil_Mortars?el=1_x_8&enrichId=rgreq-36b75349a236996fd91e54c62d3c4721-XXX&enrichSource=Y292ZXJQYWdlOzI4MDQ2MjE5MTtBUzoyNTU3MTE0NTYyNjQxOTNAMTQzNzk3Nzc3MDUwNw==

24th & 25th July 2015


4. Testing Procedure - Compressive Strength of Mortar Cubes

The various alternatives that have been mentioned above were cast in mortar cubes of

70.6mm dimension. The cubes were greased thoroughly before filling the mortar mix.

Filling of mix was done in 3 layers as per standard specifications [4]. The prepared mortar

cube was allowed to set for a period of 24 hours after which they were demoulded and

cured for 28 days and 56 days and tested for its compressive strength under Universal

Testing Machine.

5. Results and Discussion

Workability and Compressive Strength are the two important parameters that govern the

efficiency of mortar. In the present study, Workability being fairly a relative parameter

has been adopted based on trial mixes. Strength parameter has been evaluated by testing

the mortar cubes for it compressive strength at 28 days and 56 days respectively. The test

results have been comparatively analysed with respect to the strength of conventional

cement sand mortar cube compressive strength at corresponding curing period.

Compressive strength results are tabulated in table 2. The different alternatives that would

be suitable for complete replacement of sand in mortar were studied by analysing the

compressive strength results of mortar cubes over different curing periods.

Table 2: Compressive Strength of Mortar Cubes

Failure

Load (kN)

Average

(MPa)

Failure

Load (kN)

Average

(MPa)

1 1:1:1.5 - CLSP 4984.36 70.43 14.13 90.02 18.06

2 1:1:2 - CLSP 4984.36 56.27 11.29 68.63 13.77

3 1:6 - Cement: Natural Sand 4984.36 34.14 6.85 52.34 10.50

4 1:6 - Cement: Quarry Dust 4984.36 72.67 14.58 82.59 16.57

5 1:6 - Cement: Granite Powder 4984.36 10.22 2.05 17.64 3.54

6 1:6 - Cement: M.Sand 4984.36 25.27 5.07 40.82 8.19

7 1:6 - Cement: GBFS 4984.36 9.42 1.89 16.25 3.26

8 1:6 - Cement: LD Slag 4984.36 35.89 7.20 53.58 10.75

Sl.

NoMortar Type

Cube Surface

Area (mm2)

28 days

Comp. Strength

56 days

Comp. Strength

24th & 25th July 2015


Figure 1: Mortar Cube Compressive Strength

Except for Granite powder and GBFS, all the alternatives have satisfactory compressive

strength as per IS codes. However it can be seen that quarry dust and 1:1:1.5 CLSP

mortar have the highest strength. It is interesting to note that at 28days quarry dust mortar

had slightly higher strength as compared to 1:1:1.5 CLSP mortar. However at 56day the

compressive strength of 1:1:1.5 CLSP is much greater than that of mortar using Quarry

Dust. This can be attributed to the lower hydration rate of lime based mortar.

6. Conclusion

From the present study we have seen that there are several alternatives for complete

replacement of sand as fine aggregate in mortar. With advancements in technology we

have to adapt to eco-friendly alternatives rather than relying on conventional methods that

have been exploiting our environment from decades. Any advancement in field of civil

engineering should be towards exploring new innovative methods that conserve our

environment rather than developing techniques that exploit our environment at a faster

rate. Cement-Granite Powder mortar and Cement-GBFS mortar have comparatively low

compressive strengths. Such mortar can be used for works with low strength

requirements.

1:1:1.5 CLSP

1:1:2 CLSP

CM M_Sand Quarry

Dust GBFS LD SLAG

Granite Powder

28 Day 14.13 11.29 6.85 5.07 14.58 1.89 7.20 2.05

56 Day 18.06 13.77 10.50 8.19 16.57 3.26 10.75 3.54

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

20.0

Co

mp

ress

ive

Str

en

gth

in

MP

a

Mortar Cube Compressive Strength

24th & 25th July 2015


7. References

1. Rashmi S, K.S Jagadish, Nethravathi S, “Stabilized Mud Mortar”, IJRET Vol 3,

Special Issue 6, May 2014.

2. A. Costigan, S. Pavia, “Influence of the mechanical properties of lime mortar on the

strength of brick masonry”, The International Information Centre for Structural

Engineers, Vol 7, Pg 349-359, 2013.

3. B. V Venkatarama Reddy and Ajay Gupta, Strength and Elastic Properties of Stabilized

Mud Block Using Cement-Soil Mortars, Journal of Materials in Civil Engineering,

Vol.18, No.3, pp 472-476, June 2006.

4. IS: 2250-1981 “International Standard Code of Practice for Preparation and Use of

Masonry Mortars”, Bureau of Indian Standards, New Delhi

5. K.S Jagadish, B. V Venkatarama Reddy, K. S. Nanjunda Rao, “Alternative building

Materials and Technologies”, New Age International Ltd. Publishers, 2009.

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