A Study on Use of Ceramic Waste & Granite Waste in Concrete

A Study on Use of Ceramic Waste & Granite Waste in Concrete

1Post Graduation Student, Department of Civil Engineering, MITS Gwalior, Madhya Pradesh, India

2Professor, Department of Civil Engineering, MITS Gwalior, Madhya Pradesh, India

***

Abstract – The natural resources are depleting and construction&demolitionwastesareincreasing day-by-day. Researchersandgovernmentsofmanycountriestryingtofind outbestsolutiontodealwiththissituation.Ceramicwasteand granite waste from construction industry needed effective utilization. Many researchers have found its use for making concretewithpartiallyorfullyreplacementofaggregates.In thisstudy,wefoundouttheoptimumlevelofreplacement of such wastes by studying various previous researches and reached to conduct a detailed experimental investigation using Indian Standards. In the proposed experimental investigation, the ceramic & granite waste will be used as coarse aggregate replacement up to 30% as individual or in combination of both to study their effect on M40 grade concrete for properties such as compressive, splitting, and flexuralstrengthat7&28days.

Key Words: Ceramic Waste, Granite Waste, NonConventional Aggregates, Non-Conventional Concrete, Construction&DemolitionWaste

1. Introduction

With a size of $1 trillion by 2025, India is now the thirdlargestconstructionmarketintheworld,behindtheUnited States, China, and Japan (FE Bureau 2016). [1]. The constructionindustrymakesup10%ofIndia'sGDPandis expandingatarateofroughly9%,whichishigherthanthe global average of 5.5% [2]. Building construction and buildingdestructionhavebothgrownasaresultofgrowing urbanizationandrisinginfrastructuralactivity.Thus,thisled to an increase in the demand for concrete and the production of construction and demolition debris [3]. Significant environmental harm is being caused by the widespreaddepletionofnaturalaggregatesandthereisrise inbuildinganddemolitionwastewhichisgoingtolandfilling [4]. The necessity for sustainable and financially viable structural concrete has drawn the attention of both researchersandvariousconstructionbusinessesasaresult oftheever-increasingdemandforconcrete[5].Therefore, using alternative aggregates is a logical step towards resolvinga portionofthedepletion of natural aggregates; alternativeaggregateproducedfromwastematerialswould seemtobeanevenmorelogicaloption[6].

2. Literature Review

Numerousindustrialwastematerials,includingclassFtype ash, waste foundry sand, copper slag, imperial smelting

furnaceslag,blastfurnaceslag,ferrochromeslagandpalm oil clinker, have been used as partially or entirely fine aggregatereplacementmaterialsinconcreteproductionand theirpropertieshavebeencomparedwithcontrolconcrete [7].

Recycled concrete aggregates were used as coarse aggregatesinconcreteatratesof30%,60%,and100%byK. UshaNandhini,S.Jayakumari,andS.Kothandaraman(2017) toevaluateitsmechanicalandstructuralqualities.Awatercementratioof0.52and0.39wereusedtocreatetwosetsof mixeswithrespectivestrengthsof20MPaand40MPa.We examined the structural behaviour as well as the compressive strength, split tensile strength, flexural strength, and young's modulus. The findings indicate that recycled concrete aggregate increased the compressive strengthofconcreteoverordinaryconcrete.Higherstrength of12%forM20concreteand15%forM40gradeconcrete were obtained by replacing the aggregate with recycled concreteupto60%. Fullreplacementofrecycledconcrete aggregate produced concrete that was stronger than conventionalconcreteforM20andM40grade[8]

Wasteglasswasincorporatedintoconcreteina2019study byT.S.ThulasidharNaidu,M.V.Deepthi,ShrihariK.Naik, and S. D. Anitha Kumari. Fly ash and GGBS were used to replaceroughly30%ofthe cement,while0to25%ofthe fine aggregate was made up of recycled glass. Tests for flexural strength, split tensile strength, and compressive strength were conducted. According to research, 15% of leftoverglassistheidealamounttosubstitutefineaggregate inconcrete[9].

Recycled tyre rubber was used to a Portland cement concrete mix by Zaher K. Khatib and Fouad M. Bayomy in 1999. In mixes, they employed two different types of tyre rubber:finecrumbrubberandcoarsetyrechips.According toASTMstandards,thecompressiveandflexuralstrengthof mixtures was evaluated. According to the findings, the amountofrubberintheaggregateshouldnotbemorethan 20%.Theycametothefurtherconclusionthatrubberized concretemixtureswouldbeappropriatefornon-structural usesincludinglightweightconcretewalls,buildingfacades, andarchitecturalcomponents.Additionally,theymightbe utilized as cement aggregate bases for flexible pavements [10].

CrushedstonedustwasexaminedbySarveshP.S.Rajputin cementconcreteatratesof20%,40%,60%,80%,and100%.

According to Indian Standards, M20 and M30 of cement concreteweremanufacturedinvariousratios.Thefollowing tests were carried out: compressive strength test, compactionfactortest,slumpconetest,andultrasonicpulse velocitytest.Thefindingsdemonstratedtheeffectivenessof crushedstonedustasanalternativefineaggregatetonatural sandincementconcrete[11].

E-waste plastics were utilised as coarse aggregate in concrete along with manufactured sand by Santhanam Needhidasan, B. Ramesh, and S. Joshua Richard Prabu (2020).Inthisinvestigation,manufacturedsandwasusedto makeM20gradeconcrete,ande-wasteplasticwasusedto substitutecoarseaggregatefrom0%to12.5%.Asaresult, concretereplacinge-wastehashighercompressivestrength thanconventionalconcretewith10%replacement,higher flexural strength than conventional concrete with 10% replacement,andhighersplittensiletestthanconventional concretewith12.5%replacement,accordingtotheresults [12].

Coconutshellwasutilisedascoarseaggregateinconcreteby Apeksha Kanojia and Sarvesh K. Jain (2017) up to a 40% replacement level in multiples of 10%. Different watercement ratios of 0.55, 0.53, 0.492, 0.475, and 0.45 were designedforM20gradeconcrete.Theyconcludedthatusing scrapcoconut shell inplace of traditional aggregate made theconcretelighterandreduceditscompressivestrength. The28-daystrengthwasreducedbyaround22%andthe concrete density decreased by about 7.5% for 40% replacement,respectively[13].

Crushed,granularcoconutandpalmkernelshellswereused asanalternativefortraditionalcoarseaggregateinconcrete madebyE.A.Olanipekun,K.O.Olusola,andO.Ata(2006)in gradations of 0%, 25%, 50%, 75%, and 100%. 1:1:2 and 1:2:4mixratioswereemployed.Inthetwomixproportions, concrete made from coconut shells had a greater compressivestrengththanpalmkernelshell concrete.For concrete made from coconut and palm kernel shells, respectively,theresultslikewiseshowedcostreductionsof 30% and 42%. When employed as a replacement for traditional aggregates in the manufacturing of concrete, it wasfoundthatcoconutshellsweremoresuitedthanpalm kernelshells[14].

2.1 Construction & Demolition Waste

Only 5% of the Construction & Demolition (C&D) waste producedinIndia eachyear gets treated, whichisaround 25–30milliontons[15].AggregatesmaybemadefromC&D waste,whichisasteptowardseffectivewastemanagement anduse.Theprocessedaggregatescanbedividedintotwo categories:recycledaggregates(RA)andrecycledconcrete aggregate (RCA). Brick, tiles, granite, stone, and other materials can be used to make RA, and RCA contains hydrated cement paste with the original aggregate. Up to 25% in plain concrete, 20% in M25 or lower reinforced

cementconcrete,and100%inleanconcrete(lessthanM15 grade)cancontainrecycledaggregatesascoarseaggregates [16].

2.2 Ceramic Waste

Intheceramicssector,around30%ofoutputiswastedand not currently recycled. This trash is durable, hard, and extremelyresistanttofactorsthatwouldcauseittodegrade biologically, chemically, or physically. It has been claimed thatthequalitiesofthistrashcanbeutilizedtocreateusable coarse aggregate [17]. Concrete can employ the ceramic electricalinsulatortrashascoarseaggregate[18].

Inordertoevaluatetheimpactonfreshcharacteristicsand compressive strength, Salman Siddique, Sandeep Shrivastava,andSandeepChaudhary(2016)employedbone chinaceramicwasteasfineaggregates.Comparablevalues for compressive strength were achieved when bone china aggregate was used as fine aggregate. In the creation of concrete,ceramicbonechinaaggregatescanbeemployedas fineaggregates[19].

In place of coarse aggregate in concrete, Zahra Keshavarz andDavoodMostofinejad(2019)utilised redceramicand porcelaintrash.Inordertoevaluatethecompressive,tensile, flexural,andwaterabsorptionstrengths,65specimenswere cast. It was discovered that red ceramic waste enhanced concretecompressivestrengthbyupto29%andporcelain tile trash raised it by up to 41%. Additionally, it was discovered that porcelain might boost tensile and flexural strengths by as much as 41% and 67%, respectively. Accordingtoexperimentsonwaterabsorption,redceramic waste boosted water absorption by concrete by 91% whereasporcelainincreaseditbyupto54%[20]

Khuram Rashid, Afia Razzaq, Madiha Ahmad, Tabasam Rashid, and Samia Tariq (2017) used ceramic waste aggregateaspartialsubstitutionofcoarseaggregateatrate of10%,20%and30%.Compressivestrengthispredictedby usingACImodelandveryclosecorrespondenceisobserved betweenexperimentalandanalyticalvaluesatdifferentages. Bothtechniques,analyticalhierarchyprocessandtechnique for order preference by similarity to ideal solution are appliedtoselectthemostsustainableconcrete.Application ofbothtechniquesjustifiestheresultsbyselectingsimilar mixturesasthemostsustainableconcrete.Andconcluded that concrete made by replacing 30% of conventional aggregatebyceramicwasteisthebestsustainableconcrete at age of 63 days whereas the worst case from both techniquesisconventionalaggregateatbothages,28and63 days[21]

2.3 Granite Waste

Asignificantamountofwastegranitepowder,alsoknownas graniteindustryby-product(GIB),isproducedbythegranite processingindustryasaresultofitssawingandpolishing

operations.SinceGIBisadangerouspollutantthatthreatens ecosystems,thereisanurgentneedtodiscoverasustainable and technologically feasible approach to use it, therefore reducingitshazards.Thepositivefindingsdemonstratedthe viabilityofGIBconcreteasasustainablebuildingmaterial. 25%wasfoundtobetheideallevelforGIBtoreplaceriver sand[35].

Granitepowderwasutilizedasapartialsubstituteforfine aggregateatratesof5%,10%,15%,20%,and 25%by M. Vijayalakshmi,A.S.S.Sekar,andG.GaneshPrabhu(2013)to create concrete with a strength of 30 MPa and a watercement ratio of 0.40. There were tests for slump, compressive strength, splitting tensile strength, flexural strength, elastic modulus, chloride permeability, water permeability, carbonation depth, sulphate resistance, and electricalresistivity.However,itisadvisedthattheGPwaste besubjectedtoachemicalbleachingprocesspriortoblend intheconcretetoincreasethedurabilityandstrengthofthe concrete. The obtained test results indicated that the replacementofnaturalsandbyGPwasteupto15%ofany formulationisfavorablefortheconcretemaking[22]

Crushed limestone was combined with river sand, granulated blast furnace slag, and granite and marble as coarse aggregate by Hanifi Binici, Tahir Shah, Orhan Aksogan,andHasanKaplan(2008).Thisresearchincluded testingforfreshandhardeneddensity,slump,settingtime, compressive strength at different ages, flexural strength, splitting tensile strength, young's modulus, abrasion resistance, sulphate resistance, and chloride penetration. According to the findings of this investigation, discarded marbleandgraniteaggregatesmaybeemployedtoenhance the mechanical characteristics, usability, and chemical resistanceoftypicalconcretemixes[23].

In concrete of M25 grade, Sarbjeet Singh, Shahrukh Khan, Ravindra Khandelwal, Arun Chugh, and Ravindra Nagar (2016)substitutedgranitecuttingwasteforfineaggregateat rates of 10%, 20%, 30%, and 50%. In addition to SEM analysis and XRD analysis, workability, compressive strength, flexural strength, abrasion resistance, water permeability, and other tests were performed. The study demonstrates that concrete produced by partially substitutinggranitecuttingdebrisforsandhasstrongerand more durable properties than control mix. Concrete's compressivestrengthwasatitspeak at30%replacement whileat50%replacement,itwasequivalenttothestrength ofthecontrolmix.Concrete'sflexuralstrengthlikewiserises whenGCW(%)increases[24].

WastegraniteandglasspowderwereemployedbyKishan LalJain,GauravSancheti,andLalitKumarGupta(2020)to investigatetheimpactonconcretedurability.Glasspowder wasutilizedasapartialreplacementforcementandwaste granitepowderwasusedasapartialreplacementforsand. Inordertopartiallysupplementthecementandsandinthe concretemixtures,glasspowderwasaddedinamountsof

5%,10%,15%,20%,and25%,andgranitepowderin10%, 20%, 30%, 40%, and 50%, respectively. The combined impactofglassandgranitesuggestedimproveddurability performanceofconcrete[25].

According to the study, using 25–40% of granite cutting waste(GCW)inplaceofriversandwillimprovethestrength anddurabilityofconcrete.Compressivestrengthat0.30w/c israisedbyGCWwhen25%moreriversandissubstituted. FlexuralstrengthisincreasedwhenGCWreplaces40%of river sand. Concrete's service life and durability may be considerablyincreasedbyusing55%GCW.Incomparisonto the control concrete, the use of GCW up to 25–40% as a partialsubstitutefornaturalsandresultedincomparableor superiorcorrosionresistance[36].

3. Methodology

Bystudyingtheliteraturereview,themethodologyforthe future research work can be formed. The proposed methodologyfortheexperimentalworktobeconductedhas been described in this section. All the ingredients such as fineaggregate(riversand),coarseaggregates,cement,etc., usedformakingdesiredconcretemixeswillbetestedasper specificationsofIndianStandards. IS383:2016andIS2386: 1963willbeusedforspecificationsandtestingofaggregates forvariousphysical&mechanicalpropertiestochecktheir suitabilityascoarseaggregate.IS4031:1996&IS269:2015 will be used for specifications and testing of cement for various properties to check suitability as cement. IS 456: 2000 & IS 10262: 2019 will be used for mix design of concreteasperspecificationsgiveninthem.IS9103:1999 will be used for specifications of concrete admixtures and theirsuitabledosageinconcrete.IS1199:2018(Part2)will beusedforconsistencydeterminationoffreshconcrete.IS 516:1959&IS5816:1999willbeusedforcasting,curing, andtestingofhardenedconcreteatsuitableageofcuring.

Thewastematerialssuchasceramictileswasteandpolished granite waste will be collected from tiles suppliers and construction sites. The received raw waste will get break down into pieces by manual hammering action. Then the processed material having the appearance of coarse aggregateswillbesubjectedtosievingthrough20mmand 4.75mmISsieves.Now,thisconvertedwastewillbecalled as ceramic tiles waste aggregates (CTWA) and polished granitewasteaggregates(GWA).

The experimental work will be done in three steps. First, NCA will get partially replaced by CTWA up to 30% in multiplesof10%.Second,NCAwillgetpartiallyreplacedby GWA up to 30% in multiples of 10%. Third, NCA will get partially replaced by both CTWA & GWA up to 30% in multiplesof10%.ThemixdesignofM40gradeconcreteis taken as reference concrete. The calculation of various ingredients to be used in concrete mixes will be kept constant for all mixes except coarse aggregates. The substitution of coarse aggregates will be done by volume.

The total of 10 concrete mixes must be prepared for this work.Therewillbe180specimenstocast,cure,andtestat7 & 28 days for various strength properties such as workability,concretedensity,compressivestrength,splitting tensilestrength,andflexuralstrength.Outof180specimens, 60cubesof100mmX100mmX100mmsize,60cylinders of100mmdiameter&200mmheight,and60beamsof100 mmX100mmX500mmsizewillbeusedtofindhardened properties such compressive strength, splitting tensile strength,andflexuralstrengthat7&28daystocheckthe effect on partial substitution of NCA with CTWA and/or GWA.

Thecompositionofvariousconcretemixes.

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4. Conclusion

Based on the above literature review and by studying variousresearches,itcanbeconcludedthatceramicwastes andgranitewastesareaccumulatinginhugequantitiesand thereisnopropersolutionofdisposalofsuchwastesother thanlandfilling.Manyresearchershavestudiedtheireffect onpartialorfullreplacementofsuchwasteascoarseorfine aggregate to obtain their optimum levels. Based on this study,itcanalsobeconcludedthattheceramictileswaste andpolishedgranitecanbetransformedintousefulcoarse andfineaggregatestobeuseinconcretefordesiredstrength

Researchers studied ceramic and granite waste in lower grade of concrete (less than M30) for partially or fully substitutioninconcreteascoarseand/orfineaggregatesand foundevenmorebetterresultsascomparedtoconventional concretemixes.Theliteraturereviewsuggestedthattheuse of ceramic waste and granite waste can be found to be effectiveformakingM40gradeconcretebutonlyupto30% replacementlevel.

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