Use Of Red Sand (Bauxite Residue)

As A Green Material With

Replacement To Natural Sand In

Concrete

Team Id - :

1300011133

Internal Guide - :

Prof. Amar salariya

Submitted by - :

Patel Parth R.

(100780106028)

Patel Parth H.

(100780106027)

Patel Darshan N.

(100780106021)

Bhavsar Chintan B.

(100780106002)

Content

Introduction

Objectives

Methodology

Literature review

Procedure

Conclusion form references

Conclusion from our project

References

Introduction Why we choose this topic? One of the waste materials that is available in

large quantities and requiring alternative methods of disposal is the Bauxite Reside (Red Sand) from the Bayer process used to extract alumina from bauxite.

Enormous quantity of Red Sand is generated worldwide every year posing a very serious and alarming environmental problem.

So that it is very essential to find some applications of this waste material to reduce the health hazardous effects to biological life and environment in a most suitable economical way.

Objectives

An investigation will be carried out to establish its application potential as a natural yellow sand replacement material in concrete.

Properties of fresh concrete containing Red Sand up to 100% by mass of fine aggregate, mechanical and durability properties will be determined.

Applications will be determined where concretes containing Red Sand can be used.

Methodology

Literature Review Kavehsoltaninaveh (2008),“The Properties Of Geo

Polymer Concrete Incorporating Red Sand As Fine Aggregate”

This thesis concluded that the moisture content of red sand prior to use has a great influence on the workability of geopolymer concrete mixture: in order to achieve the desired workability, red sand must be in SD condition.

MajidGhiafehDavood (2008),“Long Term Stability Of Concrete Made From Red Sand”

the main objective of this research was to investigate the possibility of using the coarse fraction of bauxite residue (red sand) as a fine aggregate substitution in concrete mix design suitable for marine environment.

Procedure Concrete Mix Design - M20 ( 1: 1.5 : 3 )

Replacement Criteria-:

(% Replacement With Respect To Fine Aggregate)

0 %

25 %

50 %

75 %

100 %

Sample Are Tested After Curing Period Of 3 Days, 7 Days And 28 Days.

Cement

• Cement is a fine, grey powder. Cement is mixed with water and materials such as sand, gravel, and crushed stone to make concrete.

• The cement and water form a paste that binds the other materials together as the concrete hardens.

• The most commonly used cement is called ordinary Portland cement.

• Ordinary Portland cement of different grades OPC-33, OPC-43 and OPC-53 are available in the market and are generally used.

• In this work cement of 53 grade was used for casting cubes for all concrete mixes.

PROPERTIES OF RED MUD

PHYSICAL PROPERTIES OF RED MUD:

The following tests were conducted to evaluate physical properties.

•Generally Fineness of red mud is varies in between 1000-3000

cm2/gm.

•In our study we have taken red mud passing through 1.18mm I.S.

Sieve.

• Specific gravity of red mud is found to be 2.41.

CHEMICAL PROPERTIES OF RED MUD

•Chemical properties of red mud are shown in Table. it indicates that

percentage of Cao is very less hence it has no cementitious

properties but when it react with water and cements it starts gaining

cementitious properties. Also Percentage of silica available,

contributes to strength.

Visual identification And Specific

gravity

Chemical Composition Of RED MUD

Ingredients Red mud in %

Fe2o3 38.3

Al2o3 21.6

Sio2 11.4

Cao 1.47

Na2o 6.87

Following test will be conducted on

cement -:

1. Standard Consistency

2. Initial and final Setting Time

3. Soundness

Standard Consistency test

Aim-For a given sample of cement

determine the percentage of water for

normal consistency.

Main Equipments-

1. Vicat needle apparel with plunger.

2. Simple balance.

3. Trowel.

4. Non-porous plate.

Test results

Sr No. Quantity of

water added

% by mass of

cement

Penetration

from bottom of

mould(mm)

1 25 5 40

2 100 20 36

3 125 25 28

4 150 30 15

5 160 32 7

•Cement grade-53 OPC- 500gm

• From this experiment we get standard consistency for cement is

32%.

OBSERVATION TABLE

Initial and Final Setting Time Test

Aim-For a given sample of cement

determine the initial and final setting time

for cement.

Main Equipments-

1. Vicat needle apparel with plunger.

2. Simple balance.

3. Trowel.

4. Non-porous plate.

Test results

Sr No. Time

(Min)

Penetration from

bottom of

mould(mm)

Initial Setting Time

1 5 7

2 20 18

3 25 30

4 30 36

5 32 42

•Cement grade-53 OPC- 500gm

• Initial and Final setting time 32 minutes and 600 minutes maximum

respectively.

OBSERVATION TABLE

Soundness Test

Aim- Determination of soundness of cement with le-chatelier apparatus.

Main Equipment-

1. Le-Chatelier apparatus.

2. Two glass plate

OBSERVATION TABLE

Initial distance

between

indicator

(mm)

(1)

Distance

between

indicator after

submerging in

water for 24hrs

(2)

Distance

between

indicator after

submerging in

boiling water

for 3 hrs

(3)

Expansion of

cement

mm(4)=(3)-(2)

(4)

14 14 17 3

14 14 18 4

14 14 16 2

Following test will be conducted on

Red Sand -:

1. Pycnometer bottle test

2. Moisture content measurement of RS

3. pH test

Test On RED MUD(RED

SAND) Specific gravity

Aim-To determine the specific gravity of soil fraction passing 4.75mm sieve by density bottle/pycnometer.

Main Equipments-

1. Washed Pycnometer bottle.

2. Vacuum source.

3. Balance.

Natural sand 2.6

Red mud 2.41

Water Absorption Test

An important characteristic of the fine aggregate is the amount of

water that is absorbed by the aggregate itself. It is desirable to use the

SSD condition for aggregates when making concrete mixes. The

amount of water absorption can be found allowing adjustment to the

amount of free water and the amount of fine aggregate in the concrete

mix. This allows the fine aggregate to be oven dried and a small

amount of water added; which is more accurate than simply observing

the fine aggregate and making an assumption when it is at the surface

saturated dry (SSD) condition.

pH Test

Natural sand 7-7.5

Red mud 6.5-7

PH value

Following test will be conducted on

Concrete with Red Sand -:

1. Compressive strength test

2. Split tensile strength test

3. Flexural strength test

Mix Design

All the samples were prepared using design M20 grade

of concrete. Mix design was done based on I.S 10262-

1982. The Table below show mix proportion of concrete

(Kg/m3).

Sr. No Material Quantity (Kg/m3)

1. Cement (OPC) 383

2. Fine Aggregate 642

3. Coarse Aggregate 1142

4. Water 191.6

COMPRESSIVE STRENGTH

In the study of strength of material, the

compressive strength is the capacity of a material or structure to withstand loads tending to reduce size. It can be measured by plotting applied force against deformation in a testing machine. Some material fracture at their compressive strength limit; others deform irreversibly, so a given amount of deformation may be considered as the limit for compressive load. Compressive strength is a key value for design of structures.

Test On Concrete

SPLIT TENSILE STRENGTH

• Tensile strength is an important property of concrete

because concrete structures are highly vulnerable to

tensile cracking due to various kinds of effects and

applied loading itself.

• However, tensile strength of concrete is very low in

compared to its compressive strength. This test could

be performed in accordance with IS : 5816-1970.

FLEXURAL STRENGTH Flexural strength, also known as modulus of rupture, bend

strength, or fracture strength mechanical parameter for brittle

material, is defined as a material's ability to resist

deformation under load. The transverse bending test is most

frequently employed, in which a specimen having either a

circular or rectangular cross-section is bent until fracture or

yielding using a three point flexural strength technique. The

flexural strength represents the highest stress experienced

within the material at its moment of rupture. It is measured in

terms of stress.

COMPRESSIVE STRENGTH RESULT

RS

CONTENT

%

SAMPLE 3 DAYS

N/MM2

7 DAYS

N/MM2

28 DAYS

N/MM2

0 M1 8 13.5 21

25 M2 9 15 23

50 M3 11 16.5 25.5

75 M4 13.5 19 28

100 M5 15 21 32

Comparison Of Compressive Strength For Various

Mix

0

5

10

15

20

25

30

35

M1 M2 M3 M4 M5

3 days

7 days

28 days

Co

mp

res

siv

e S

tre

ng

th

Designatio

n

TENSILE STRENGTH RESULT

RS

CONTENT

%

SAMPLE 3 DAYS

N/MM2

7 DAYS

N/MM2

28 DAYS

N/MM2

0 M1 1.66 2.18 2.72

25 M2 1.8 2.28 2.85

50 M3 2 2.45 3

75 M4 2.3 2.62 3.24

100 M5 2.35 2.76 3.43

Comparison Of Tensile Strength For Various Mixes

0

0.5

1

1.5

2

2.5

3

3.5

4

M1 M2 M3 M4 M5

3 days

7 days

28 days

Designation

Ten

sile

str

en

gth

FLEXURE STRENGTH RESULT

RS

CONTENT

%

SAMPLE

3 DAYS

N/MM2

7 DAYS

N/MM2

28 DAYS

N/MM2

0 M1 2.03 2.55 3.15

25 M2 2.1 2.70 3.35

50 M3 2.33 2.81 3.53

75 M4 2.57 3 3.71

100 M5 2.70 3.21 4.1

Comparison Of Flexure Strength For Various Mixes

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

M1 M2 M3 M4 M5

3 days

7 days

28 days

Designation

Co

mp

res

siv

e S

tre

ng

th

Conclusion from references

Very large quantity of redsand(bauxite

residue) is generated and possesses

very serious environmental problem

for its disposal health hazardous itself.

Neutralization of redsand is also a

serious problem and uneconomical.

Disposal procedure of neutralizing red

sand with natural sea water is also

uneconomical.

Conclusion from our project

In comparison to concrete using natural sand, concrete using red sand achieved similar strength characteristics greater than that of the control mix. partially replaced red sand by the weight of natural sand also showed improved strength in the tests.

Compressive strength of concrete increased with the increase in sand replacement with different replacement levels of red sand .

Split tensile strength and flexural strength also showed an increase with increase in replacement levels of red sand with fine aggregate.

Based on the results of all of the marine grade concrete mixes, the indication is that red sand performs better as a replacement of fine aggregate.

References Cooling, DJ, ―Improving The Sustainability Of Residue

Management Practices‖— Alcoa World Alumina

Australia, 5 July 2008.

Evaluation of the properties of red mud concrete ;

Ramesh R Rathod, Nagesh T. Suryavanshi

Is 456-2000, Plain And Reinforced Concrete - Code Of

Practice ( Fourth Revision ).

Improving the sustainability of residue management

practice- alcoa world alumina Australia.by D.J.Coolling.

Neutralization of bauxite residue with acidic flyash.by

sameer khaitan, gregory p. lowry.august 2007.

THANK YOU