use of waste material in concrete
TRANSCRIPT
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WASTE & RECYCLED MATERIAL
IN CONCRETE TECHNOLOGY
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CONTENTS NEED OF RECYCLING OF WASTE MATERIALS
ROLE OF WASTE MATERIALS IN CEMENT CLINKER
PRODUCTION
PORTLAND CEMENT MANUFACTURE FROM WASTEMATERIALS
RECYCLING OF CONCRETE.
MINING & QUARRYING WASTES
APPLICATION OF MISCELLANEOUS WASTES ROLE OF WASTE MATERIAL AS AGGREGATES
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ABSTRACT
World wide consumption of concrete amounts to more than
1000 Kgs/person
The demand is expected to increase in future
Concrete comprises in quantity the largest of man madematerial
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INTRODUCTION
Concrete made with Portland cement ,water admixtures and
aggregates comprises in quantity the largest of all man made material
Historically whenever new compounds were produced ,or waste
materials accumulated in industries ,they were incorporated as one ofingredients of concrete. Typical examples are fly ash phosphogypsum,blastfurnace slag, saw mil waste, rice husk, cotton etc.The wide spread need forconserving resources & environment will be reflected major emphasis on theuse of wastes & by products.
Recycling of concrete materials also offers some promise. Attemptsare already being made to use municipal refuse & waste oil as partialsubstitutes for the fuel in the production of cement clinker
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NEED OF RECYCLING OF WASTE MATERIALS
Rise in population
Large scale demand for housing
Over stressing the reserves of traditional building
materials
Cement material presently not in a position to cope
the millions of the country
The enormous amount of waste materials Recycling becoming imperative & mandatory
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ROLE OF WASTE MATERIAL IN CEMENT
CLINKER PRODUCTION
Many waste materials contain basic ingredients that areneeded for the manufacturing of cement clinker
Fly ash can also be used as a source of raw material
Lime sludge can be used as a substitutes for lime stone
Red mud a waste material from the production of aluminaused as a raw material for cement clinker production
Phosphogypsum as a mineralizer for making clinker
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COMPRESSIVE STRENGTH OF MORTAR(MPA)
Cement 1 day 3 days 7 days 28 days
Phosphogypsum
Minerals
17.3 26.2 37.4 53.7
Normal Cement 8.2 22.0 37.4 50.0
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PORTLAND CEMENT MANUFACTURED
FROM WASTE MATERIALS
FLY ASH CEMENT
BLAST FURNACE SLAG CEMENT
RICE HUSK ASH CEMENT
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FLY ASH CEMENT
Fly ash is the ash component of Coal liberated duringcombustion .
Fly ash can be incorporated into Portland cement in one ofthe three ways.
Fly ash can be used as a admixture or as replacement ofPortland cement.
Fly ash addition to Portland cement results in increasedworkability.
In fly ash cement development of compressive strength isslow
At longer periods of curing Fly ash concrete develops higherstrengths than the normal concrete
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WHY CHARACTERISTICS?
Not a specially manufactured product governed by
strict rules
Variation in carbon, particle shape & size distribution,
presence of minerals etc..
Exhibits different characteristics with different
compounds.
No proper processing is available.
Change in the behavior of concrete.
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MACROSCOPIC VIEW OF FLY ASH
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FLY ASH
Finely divided residue resulting from combustion of
powdered coal.
Common ingredient in concrete.
First used in construction of Hungry Horse Dam in USA
In India, first used in Rihad Dam.
High volume fly ash is of current interest.
Quality of fly ash is governed by IS:3812-1981
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INFLUENCE OF FLY ASH ON STRENGTH
DEVELOPMENT IN CONCRETE
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PERMEABILITY OF FLY ASH CONCRETE
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Hungry Horse Dam, Montana,is a thick-arch structure
that was built between 1948 and 1953with concrete containing120,000 metric tons of fly ash.The use of coal fly ash in cementand concrete displaces Portlandcement.
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Fly ash used in the construction of buildings at Chennai
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Fly ash used in Delhi Metro
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Roman Coliseum: An classic example of Romanstructures which was build with fly ash concrete.
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WELCOME
ASH
CEMENT
3
DAYS
7 DAYS 28 DAYS 90 DAYS
70:30 31.9 45.4 58.7 63.9
50:50 26.1 39.0 57.6 60.7
30:70 24.0 35.4 42.7 50.1
0:100 22.4 32.5 42,4 47.4
COMPRESSIVE STRENGTH
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ADVANTAGES OF FLY ASH CONCRETE
Addition of fly ash to concrete minimize or eliminates
the expansion due to alkali aggregate reaction
WORKABILITY
TIME OF SETTING
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DURABILITY OF FLY ASH CONCRETE
Sufficiently cured fly ash concrete has dense structure &hence more resistance to deleterious substances.
This reduces the corrosion of reinforcement.
Class F fly ash reduces alkali-silica reactivity because of thedense structure & hence expansion is reduced whichincreases durability.
Because of the reduced permeability the chloride ingressis reduced.
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STRUCTURES USED FLY ASH ASH
Sl. No Structures State Cement replaced(%) Source of flyash
1. Gurgoantunnel Haryana 15 Delhi
2. Jawar sagarDam Rajasthan 20
Delhi3. Kakki Dam Kerala 20 Neyveli4. Navora
barrage U.P. 15 Harduaganj5. Rihad Dam
UP 15 Bokaro6.
Sone Barrage Bihar 15 Bokhara
7. UmiumProject Assam Not available Durgapur
8.Chandil dam Bihar 25 Talcher
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FLY ASH MISSION PROJECT SITES
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BLAST FURNACE SLAG CEMENT
Portland blast furnace slag cement can replace Portlandcement where high strength is not required.
It is produced by intergrinding Portland cement clinker &granulated blast furnace slag.
The workability of this cement is as good as Portland cementconcrete.
This is resistant to a number of aggressive agents includingsulphates of Al,Mg,NH4etc
The rate of hardening is slower than the normal Portlandcement concrete.
The 90 days strength is of Portland cement concrete.
More resistant to sea water &other chemical agents thanPortland cement.
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RICE HUSK
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RICE HUSK ASH CEMENT
In the rice milling operation one ton of rice paddy
produces 400 kg of husk. Burning of the husk results in 20% by
a weight of ash. Blending this ash with cement produces a
suitable blended cement
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ADVANTAGE
The rice husk ash cement on hydration
produces practically no Ca(OH)2 &hence is
superior to Portland.
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RECYCLING OF CONCRETE
Except structures which have to be preserved as moments a
great number of them have to be demolished sooner or later.
Concrete accounts of nearly 75% by weight of all construction
material.
Millions of tons of concrete debris are generated by natural
disaster.
Depletion of normal aggregate sources, stricter environmental
laws & waste disposal problems make recycling of concrete.
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WHAT IS CONCRETE RECYCLING?
Breaking , removing & crushing hardened concrete from
an acceptable source. Old concrete pavements often
are excellent sources of material for producing RCA
RECYCLING PROCESS
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RECYCLING PROCESS
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USES OF RECYCLED CONCRETE
Smaller pieces of concrete are used as gravel for new
construction projects.
Sub base gravels laid down as the lowest layer in a road.
Recycled concrete can also be used as the dry aggregate for
brand new concrete.
Larger pieces can be used for erosion control.
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DISADVANTAGES
Lead paint contamination.
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CONCRETE RECYCLING MACHINE
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MINING & QUARRYING WASTES
Large amount of wastes produced in mining & quarrying
operations.
Mineral mining wastes are waste rock or mill tailings.
Manufacturing of bricks ,light weight aggregates & autoclaved
concrete blocks.
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APPLICATION OF MISCELLANEOUS WASTES
Collier spoil
Waste glass
Red mud
Burnt clay
Saw dust
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COLLIERY SOIL
In coal operations about one half of the material is separated
& discarded as colliery soil.
This soil is used to fill in road embankments.
It can also be used to produce light weight concrete.
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WASTE GLASS
Millions of tons of waste glass are generated annually..
The strength of concrete less than with gravel aggregate.
This is used to make light weight aggregates.
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RED MUD
Red mud is a waste product resulting from the extraction of
alumina from bauxite ore.
It is sufficiently plastic to be moulded into balls.
Firing at about 1260 to 1310 c produces a strong dense
aggregate.
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BURNT CLAY
High permeability.
Concrete contains burnt clay has high fire resisting capacity.
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SAW DUST
Saw dust concrete is used only to a limited extent because of
its low strengths.
The addition of sand can improve strength.
Saw dust cement has a good insulation value .
Low thermal conductivity.
Concrete containing large amounts of saw dust is flammable.
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ROLE OF WASTE MATERIALS AS
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ROLE OF WASTE MATERIALS AS
AGGREGATES
Use of waste & byproducts as aggregates has greater
potential because 75% of concrete is composed of aggregates.
Various aggregates examined includes reclaimed concrete
mining & quarrying wastes, colliery soil, waste glass, red mud,
burnt clay & saw dust.
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CONCLUSION
In the coming future Recycling of Waste Materials
& by production for concrete technology will achieve new
heights, as attempts are already being made to use
municipal refuse & waste oil as partial substitutes for
production of cement clinker. We have to promote &
development in the area of utilization of waste materials.
Variability of the physical & chemical characteristics
& availability at locations far removed from populations
areas may inhibit the wide spread use of many types ofwastes. Future work will have to be directed to study of
the long term durability of concretes containing these
materials.
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