Rubber Powder As a Partial Replacement To Fine Aggregate in Geopolymer Ferrocement

Rubber Powder As a Partial Replacement To Fine Aggregate in Geopolymer Ferrocement

1Mr. Ranjeet R.Karle, 2

M.E Civil (Structural Engineering), Department of Civil Engineering 1PG Student, Department of Civil Engineering, D.V. Vikhe Patil College of engineering Ahmednagar 2Professor, Department of Civil Engineering,. D. V. Vikhe Patil College of engineering Ahmednagar , India

Abstract Tyre manufacturing over the world has increased as the automobile industry has rapidly grown. The waste tyre disposal is very time consuming and environmentally damaging process. Even though it is frequently disposed of in landfills, issues with supply and demand mean that the shortage and lack of available landfill space is very big concern. The fundamentals ferrocrete is used in the construction of structures. Mix of sandandcementthemanufactureofaggregatesfromstone Quarries are also a major source of environmental degradation. Thus, the goal of the project; the purpose of this research is to investigate the effects of varying the quantities of crumb rubber replacing sand content in ferrocretemixes.Inordertoenhancedifferentpercentages ofglassfibrehaveacompressivestrengthincludedintothe mix of cement. In this study, the primary objective is to discover replacing the old rubber with a new type of rubberCementferrocreteaggregatesaremixedwithglass fibres. Finally, the product will have excellent engineering qualities.

Ferrocement is a flexible building material with unique structuralfeatures.It'sacompositemadeoftightlywound wiremesharoundskeletalsteelandrichcementmortar.

It is made of welded mesh, mild steel angles or bars, and reinforced by chicken mesh, square mesh or expanded metal.1:1.5to1:4mortarmixbyvolumeFerrocementcan beusedto buildfoundations,wallpanels,floors,roofpanel, ornamental structures,shells, etc. They are thin walled, durable,ductile, light weight, strong, and impermeable. It combines the strength of steel with the mouldability of ferrocrete, is lightweight and easy to work with, and has high tensile strength of pre stressed ferrocrete and crack control. Ferrocement requires no formwork or shuttering. Ferrocement has transformed RCC into a homogenous, ductile composite. This is because continuous meshes of fine steel wires replace steel bars. It has strengthened the link between wires and mortar such that wires break but are not pulled out of the matrix. Steel and mortar are boundtogetheruntilsteelyields,providingductilitytothe composite. The structure may flex or deflect but will not fail.

Keywords Waste tyre crumb rubber in Geopolymer ferrocrete, , replacement

I. INTRODUCTION

Thenumberofunusablewastetiresfromdifferentkinds of vehicles is rapidly growing and is in fact turning out as oneofthemajorecologicalandenvironmentalproblemsof the present day. Nearly one billion waste tires are discarded each year and are predicted to be almost 1.3 billion per year by 2025. Large amount of waste tyre rubber accumulate in the world every year ,and the easy process to decompose the rubber is by burning but because of burningof rubberalargeamount ofsmokeand pollution is generated. Another method to dispose waste rubberisbylandfill,butnowdaysavailabilityandcapacity oflandfillplacesdecreases

A expanding global automobile industry and a growing preference for automobiles as a mode of transportation haveresultedinadramaticincreaseintyremanufacturing over the last several decades. As a result, massive stockpiles of old tyres have been created. In the early 2010s,extensiveresearchwasconductedonthenumerous applicationsof recycledtyres.Atroomtemperature,scrap tyre is composed of non biodegradable components. They almostalwayshaveanegativeimpactontheenvironment. One way to put these resources to use is to incorporate themintoferrocreteandotherbuildingmaterials.

The following macroeconomic aspects should be contrasted and considered when evaluating the use of these materials in ferrocrete. The cost of collecting, processing, and transporting scrap tyres reduced environmentalexpensesandincreasedlandfillvoidsresult inanincreaseinlandfillvoids.Bysubstitutingtyrerubber for original materials in the manufacture of ferrocrete; rubber waste is extremely durable and resistant to most natural environments. As a result, proper tyre recycling is critical, as improper disposal can have serious environmentalandaestheticconsequences.

Finewiremeshreinforcementisthemostbasicelementof ferrocrete,becauseitcontrolsthespecificsurface,whichis animportantfactorindesign.Theno.ofsteelmeshlayerif meshes, decided the thickness of composite structure. Varioustypesofmeshesareinuse:

Expandedwiremesh

Weldmesh

Crimpedwiremesh

In Indigent countries, where this is especially true, used tyre management is primarily governed by environmental regulations.FollowingtheimplementationofnumerousEU directives, reuse and material recovery are now regarded as the most environmentally sound waste management methods. The amount of waste glass has increased in recentyearsasaresultofincreasedindustrializationanda rapidriseinthestandardofliving.Asaresult,asignificant amount of waste glass is discarded rather than recycled, resulting in environmental and natural resource loss and pollution. Ferrocrete's brittle nature can be softened by addingfibreswithshortlengthsandsmalldiameters.

Sustainabilitycanbedefinedastheabilitytousedepleting nonrenewable resources indefinitely while also retaining depletingrenewableresources.Sustainabilityisoneof the moststudiedbutleastunderstoodconceptsontheplanet.

For the majority of countries, organizations, and individuals who consider its significance, sustainability entails the preservation of the Earth and critical issues related to development, such as stable economic growth, productive resource utilisation, poverty eradication, and consistent social advancement. In the coming years, sustainable construction expects to meet current prerequisites for a working situation, housing, and infrastructure without sacrificing people's capacity to address their issues. According to researcher’s writing, the current state of the construction industry is unsustainable. In the industry, sustainable construction could be accomplished by substituting strong recycled productsfornormalcrushedstonein ferrocrete.However, the use of conventional coarse aggregates undermines sustainability by causing additional environmental issues. According to the India Farmer's Welfare and Horticulture Ministry, over 2390 billion were formed in India in 2016 2017, which will increase farming waste accumulation. Thus, the successful use of agricultural wastes as a substitute for traditional aggregates contributes to the preservation of non renewable resources, reduces energy consumption, and lowers construction material costs. The authors used a variety of scrap materials in their ferrocrete,includingrecycledaggregate,flyash,silicafume wasteelastictyre,andGGBFSandwasteandglassplastics. They also used tobacco wastes, coconut shell, rice husk ash,palmshell,pistachioshell,andoilpalmshell.

Aside from cement, aggregate is a major component of ferrocrete.Fineaggregatesareobtainedfromriverbedsor weathering of rocks into dust, whereas coarse aggregates are formed by crushing of stones. Waste tyres are

currently a major problem all over the world. Because waste tyres decompose slowly and take over a century to disintegrateatambienttemperature,theycanbereusedin landfilling.Thesetyresrubberarecutintosmallandlarge pieces for the reduction or reuse of waste tyres. Crumb rubber(C.R.)ismade bycuttingup oldtyres.Large pieces are considered coarse crumb rubber, while small pieces are considered fine crumb rubber; in ferrocrete, these are replaced with coarse aggregate and fine aggregate, respectively. Crumb rubber from tyre waste, reduced to a veryfinesize,wasusedasafineaggregateinthisresearch paper. The amount of crumb rubber is calculated as a percentageofthefineaggregateweightas2.5percent,5.0 percent, 7.5 percent, and 10.0 percent replacement. ferrocrete mixes are used to cast cubes, beams, and cylinders & Panels for various laboratory tests. Slump variation, compressive strength, compressive strength tests are performed in the laboratory According to research, increasing the percentage of crumb rubber & glassfiberreducesstrength.

One of the most concerning issues in the early stages of GRC development was the durability of the glass fibres, whichbecamefragileovertimeduetothealkalinityofthe cement mortar. Significant progress has been made since then, and the problem is now practically solved thanks to new types of alkali resistant glass fibres and mortar additives that prevent the processes that cause GRC embrittlement. The lighter weight and higher tensile strengthofGRCcomparedtoferrocretepromptedarecent research programme to investigate its viability as a structural material. The study was conducted in collaborationwithferrocreteprecastcompanies,forwhom the improved characteristics are particularly appealing becausetheprecastelements'reducedweightiscriticalfor transportation and installation. Reinforcement systems, such as carbon or glass strands and stainless steel bars, were also investigated in order to obtain a GRC with high durability, resulting in corrosion free solutions. Although some of the average mechanical properties of GRC are known and are currently used for nonstructural elements, a much more thorough characterization is required when structural design is considered. The mechanical strength, Young's modulus, creep and shrinkage behaviour, and stress strain diagrams of GRC specimens were then determined through experimental tests. The experimental tests had to consider cementitious matrix with various plainmortarproductions,varioustypesofglassfibres,and reinforced with carbon or glass strands or steel elements, as the material characteristics were highly dependent on the production procedures. These tests resulted in a characterizationofthemanufacturingconditions,allowing fortheoptimizationofmaterialproperties.

Dispersion of steel wire:

Ferrocrete is formed by tying together a no. of layers of continuous wire meshes. Volume of steel Per cent is very

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large, may be upto 8%. Also the mortar cover over the meshesisupto3 5mm.Hencethroughoutthebodyofthe composite, the wire reinforcement is fully dispersed. This leadsferrocrete4tobecomemorehomogeneous.Itresults in improving the properties of ferrocrete in tension, flexure,impactresistanceandcrackresistance.

Crack control:

Closely spaced fine wires, very near to the surface of ferrocrete, act as crack arrestors. In conventional reinforced ferrocrete the bars are spaced some distance apart and the ferrocrete in between them is prone to temperature expansion and contraction. This tendency is overcome by the tension taking member fully bonded to mortarandspacedverytothesurfaceofferrocrete.

Equal strength in both directions:

Thecontinuityandplacementofequalmeshreinforcement in both directions make ferrocrete to achieve equal strength in two direction and become strong in resisting diagonaltensionsduetoshear.

Containment off mortar matrix in mesh layers:

In ferrocrete, layers of wire meshes tightly tied together areimpregnatedwithcementmortar.Thematrixisheldby the meshes in between and is contained by them. In RCC, steel bars are encased in ferrocrete while in ferrocrete layers of wire meshes encase the mortar and hold it bonded strongly. Thus there would not be sudden brittle failureofferrocreteelement.Incaseoftestuptofailureor in the case of sudden shock loading like earthquake, the member will undergo large deflection with adequate warning.

Formless construction:

Tightly tied meshes in ferrocrete can hold wet cement mortar when it is press filled in them. The consistency of cement mortar is very thick with very low water cement ratio.Itwon’toutofthemeshes.Thuscastingofferrocrete does not need any formwork or shuttering. The other advantage of this aspect is that no honeycombing in press fillingasthemortaringisdoneinfrontofyoureyes.

Self quality conscious material:

If the steel wire mesh is tied loosely or water to cement ratio is not maintained to thick consistency, or over sandingis, the mortarwill flowdownandwill notbeheld by the meshes. Thus the ferrocrete may be characterized asaself qualityconsciousmaterialandwilldoesnotallow lesscement,moresandormorewaterinthemortarmix.

Strength through shape:

Ferrocretestructureisthinwalledandmaybehardly25to 50mm in thickness. Hence to take care of slenderness and

buckling,ferrocreteisshapedindifferentformstoachieve itsstrength.

II. LITERATURE REVIEW

Camile B. George Saleem 2021

As waste accumulates and landfill capacity diminishes, agencies are expanding application and use of recycled resources such as crumb rubber from tyres in building. Ferrocreteismadeupofgravelandcement.Usingrecycled materials wisely may reduce costs and improve performance; however, not all recycled materials are suitable for ferrocrete construction. The primary reasons fornotusingreusedmaterialare(1)performancelossand high cost. This study investigates the effectiveness of recycled crumb rubber as a 0 80% fine aggregate replacementforcrushedsandinferrocretemixtures.Using crumb rubber to replace up to 25% of fine aggregates improvedcompressionstrength.

Feng shi Guiuan Chen, Liuan Li Yoshugchan Guo 2018

Using chosen rubber particles of 0.175 mm, 1.15 mm, and 2 mm, and steel fibre of upto 25 mm in length and 0.5 percent volume percentage, he studied the impact resistance of rubber reinforced and rubber/steel fibre reinforcedferrocrete.Ferrocretecontaining5%,10%,15% and 20% rubber particles was tested dynamically under 0.2MPa,0.3MPa,0.4MPaand0.5MPaimpactloads.These curves were then utilised to depict the strain rate levels connectedwiththerubberreinforcedferrocrete.Basedon the findings, the impact resistance of rubber reinforced ferrocretewasstudied.TheimprovedHolmquist Johnson Cook dynamic constitutive model was developed by finding the parameters of the improved Holmquist Johnson Cook constitutive model. The constitutive model of rubber reinforced ferrocrete was created, with parametersgivenforvariousstrainrates.

Ding 2018

The volume of polymeric wastes like tyre rubber and PET bottles is rapidly growing. Every year, an estimated 1000 milliontyresarewasted,with5000millionmoreprojected by 2030.Currently, only a small percentage gets recycled, whilemillionsaredumpedorburied.TheyearlyPETbottle use is above 300 million units. The majority is dumped. Research on ferrocrete including tyre rubber and PET wastes is reviewed. It also addresses the impact of waste treatments, waste particle size, and waste replacement volumeonferrocrete'sfreshandhardenedcharacteristics.

Waung Her Yung a, Lin Chhin Yung 2020

Themixingofregularsandwithwastetyrerubberpowder of varying fineness is described. The results revealed that adding 5% waste tyre rubber powder sieved #50 increased the 91 day compressive strength by 10% over

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the control group. The shrinkage increased with the amount of discarded rubber and peaked at 20%. The ultrasonic pulse velocity dropped as additional powder was added, and the 56 day electrical resistance rose from 20 kX cm to over 30 kX cm. Meanwhile, the ultrasonic pulsevelocityandelectricalresistancecorrelatedwellwith compressive strength. The addition of 5% waste tyre rubber powder improved anti sulfate corrosion. Leaky self compacting rubber ferrocrete can benefit from waste tyrerubberpowder.

P Paramasivam (et.al, 2018):

Ferrocementisideallysuitedforthinwallstructuresasthe uniform distribution and dispersion of reinforcement provide better cracking resistance, higher tensile strength to weight ratio, ductility and impact resistance. By adapting available mechanized production methods and properchoiceofreinforcementsitcanbe costcompetitive in industrialized countries. Research and development works of ferrocement, at the National University of Singapore, since early 1970's, has resulted in several applications such as sunscreens, secondary roofing slabs, watertanks,andrepairmaterialinthebuildingindustries.

Aim

“This study's goal is to substitute sand in ferrocrete with crumbrubberinvaryingquantities.TheGeopolymerinthe cement is to be tried to increase flexural and impact strength”.

Objectives

 Study on its use in cement ferrocrete is limited. Rubberized Portland cement ferrocrete strength and hardnesstests



To study goal is to substitute sand in ferrocrete with crumb rubber in varying quantities. The proportion of geopolymer in the ferrocrete is to be tried to increase flexureandimpactstrength.

The study uses varied percentages of rubber waste in ferrocrete.

III. RESEARCH METHODOLOGY

Research Work



To check flexure strength Up to 5%, 10%, 15%, 20% replacementofrubberaggregatetofineaggregateand

Problem Statement

“Study on Flexural strength Up to 5%,10%, 15%, 20% replacement rubber aggregate to fine aggregate in GeopolymerFerrocement

Scope of the Study

Rubberized ferrocrete has many applications in construction, further research is needed to determine its elasticconstantsandmechanicalpropertiesbyvaryingthe rubber volume proportions, water cement ratios, aspect ratios, and rubber forms such as fibre chips, powder, etc.

Studyforliteraturereviewsurvey 



Tostudytheconstructiontechniquesofferrocrete,we have gone through various research papers, books, andsomefieldworks 

TocastPanelforconfigurationsizeLength 1000mm, Width .300mm, Thickness. 30mm and to study after 28dayscuring 

To check flexure strength Up to 5%, 10%, 15%, 20% replacementofsandtotirerubberaggregate

Impacttest

Test

Analysisresult

Resultanddiscussion

IV. EXPERIMENTAL CONSIDERATION

Material

Cement

Collection

OrdinaryIS:269 1976Portlandcement,40grade.Allofthe specimenswerecastwithordinaryPortlandcement,grade53. To produce pastes of uniform consistency, different types of cementrequiredifferentamountsofwater.Differenttypesof cementwillresultindifferentratesofstrengthdevelopmentin ferrocrete. The most important factor in producing high quality ferrocrete is choosing the right brand and type of cement. Because the type of cement used affects the rate of hydration,thestrengthoftheferrocreteatanearlyagecanbe significantlyinfluenced.It'salsocrucialtomakesurethatthe chemicalandmineraladmixturesarecompatiblewithcement.

Aggregate

LocalriversandconformingtoIS:383 1970GradingzoneII. Localriversandwillbeused.Allthe specimenswillbecastin IS4.75mmsand.

Rubber

Thecrumbrubberparticlesrangingfrom75μto2.36mm withdifferentdifferentshape.

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Fly ash

Fly ash used in this study is low calcium class F unprocessed fly ash from thermal power plant. Quantity and fineness of fly ash plays an important role in the activation process of geo polymer. It was already pointed outthatthestrengthofgeo polymerferrocementincreases withincreaseinquantityandfinenessofflyash

GGBS

Ground granulated blast furnace slag is a hydraulic binder,acquirebyquenchingmoltenironslagfromablast furnace in water or steam to create a glazey, granular productthatisthendriedandgroundintoafinepowder.

Alkaline Solution

SodiumHydroxideSolution(NaOH)

Sodiumsilicatesolution(Na2SiO3)

Steel Mesh

Wirediameterofacross0.5mm to5mm shouldadopted. Sizeofmeshopeningisbetween7mmto35mm.Maximum utilization of upto 3 layers of work for various thickness There should maximum 10% volume portion in both bearings Steelcover1.5to5millimeters

Constituent Materials Used Materials that are used for making ferrocrete for this study will be tested before casting the specimens. The preliminary tests will be conductedforthefollowingmaterials.

Cement

Aggregate

Water

Methodology and preparation

Cement

Cement used in construction is categorized as hydraulic ornon hydraulic.Hydrauliccement(e.g.,Portlandcement) harden because of heat of hydration, chemical reactions that occur independently of the mixture's water content; they can harden even underwater or when constantly exposedtowetweather.Thechemicalreactionthatresults when the anhydrous cement powder is mixed with water produces hydrates that are not water soluble. Non hydrauliccements(e.g.,limeandgypsumplaster)must be kept dry in order to retain their strength. The most important use of cement is the production of mortar and ferrocrete. The bonding of natural or artificial aggregates to form a strong building material that is durable in the faceofnormalenvironmentaleffects.

Aggregates

“Fine aggregate” is defined as material that will pass through 4.75mm sieve and will, for the most part, be retainedona1.18mmsieve.Forincreasedworkabilityand for economy as reflected by use of less cement, the fine aggregateshouldhavearoundedshape.

Mix Proportion

Ordinary portland cement and river sand passing through No. 8 (2.38 mm) sieve and having a fineness modulus of 2.72 were used for casting. In design mix proportion 40% cement replace with combination of fly ash and GGBS with different proportion. The geopolymer mortar used in this study is composed of low calcium fly ash and alkaline solution composed of NaOH and sodium silicatecombinations.NaOHismixedwithdeionizedwater atarequiredconcentration(12M)andkeptforatleast24h prior to casting. All geopolymer mortar specimens were madewithsand to geopolymerratioinequalproportion.

The cement, fly ash and fine aggregate were dry mixed together in a mixer machine for 5 min. W/c ratio is taken as 0.46 followed by the addition of activator solution containing hydroxide and silicate to the mixture, and mixedforanother10min.Themixingwascarriedoutata roomtemperatureofapproximately27 30°C

The crumb rubber is immersed in 1N NaOH solution for 30 minutes. After that the rubbers are water washed to removethepresenceofNaOHresidue.Themoistrubberis free dried under sun light with ambient condition. 1lit of NaOHsolutionmayrequirefortreatingupto1kgofcrumb rubber.

The Ferro cement panel is made by using expanded chicken mesh and geopolymer mortar. The panel mold is made of wooden base with the size of 1000mmX300mmX30mmwithopentopandbottomisrest on base plate & cubes of 150x150mm are prepared to checkcompressivestrengthofmixture.

Compressive Strength

This test is execute to check the required compressive strengthisgainedbyRubberisedGeopolymerFerrocement mortar when compared to regular specimen. The rubberized geoplymer ferromix mortar cube and conventional specimen are water cured for 28 days at room temperature. After completion of curing, the cubes aretestedon1000KNcapacityuniversaltestingmachine.

ConventioalFerrocement 17 30

GRF(5%) 17 29

GRF(10%) 15 27 GRF(15%) 16 27 GRF(20%) 16 24

GRF : Geopolymer Rubberised Ferrocement

Flexure Test on Ferrocement

Ferrocement specimens size (1000mmx300mmx30mm) were tested in accordance with the applicable provision standard testing methods for flexural strength of ferrocement, using a fixed supported slab with uniformly distributed load. An experimental load deflection curve of ferrocementwithclearlydefinedtransitionpoint

Sr. No Sample Temperature (Celcius) %Rubber Replaced %GGBS Flexural Strength (KN)

1 A 28° 5% 20% 7.66

2 B 28° 10% 20% 7.03

3 C 28° 15% 20% 5.46

4 D 28° 20% 20% 4.73

consisted of a rigid welded steel frame square in plan and supported by short columns. The specimen was laid flat resting on four 75 mm diameter bars to provide line support along the four edges. The test setup consists of a cylindrical ball of 60mm diameter; 150mm height (the plunger) with hemispherical blunt tip to a height of 50mm.The plunger which loads the panel has a spherical tip enablinga point contact tobemade.A ropeandpulley arrangement with a pipe guide, which enables a central impactintheverticaldirection,wasusedtomanuallyraise thehammertotherequiredheightforrepeatedlydropping it on the specimen surface. Grease was applied on the rollers to reduce friction and to ensure smooth fall. The weightoftheballis3.22kganditisdroppedfromaheight of670mm.Themasswasthendroppedrepeatedlyandthe number of blows required to cause first crack was recorded. Then the number of blows required for the failureisalsorecorded

Specimenwith (%)rubber replacement

No. of Drops for First Crack

No. of Drops Failuare

Impact Energy for 1st crack (Nm)

Impact Energy at failure (Nm)

592.5 15% 6 29 141.03 620.7 20% 8 30 190.43 663.0

Impact Energy for First Crack (Joule) Impact Energy at Failuare (Joule)

Impact Energy of

Flexural Strength of Rubberised Geopolymer Ferrocement

Impact Testing

After the 28 days of curing, slabs are taken out from the curing tank and white wash was applied to the slabs surface in order to get clear indication of cracks on repetitive drops. Impact test was conducted on the geopolymer ferrocement panel slabs after 28 days of curingbyusingadropweightmethodandthetestsetupis

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056

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• Then on further impact loadings, cracks propagate and reachedtheboundariesoftheslab.

• The panel with 20% rubber aggregate has more impact resistance capacity against crack development as it take moreblowsbeforeappearanceoffirstcrack

V. CONCLUSION

1. A12%to15%sandreplacementlevelinferrocretemixes was found to be optimal for increasing strength and durabilityafter28days.

A low coefficient of permeability was found in all samples of ferrocretecontainingRubberPowder.

2. The regular controlled specimen has flex. Strength is between4.75 5.5KN,whichmeanswecangetbetterresultup to 10% to 15% replacement of fine aggregate by rubber powder.

3 Increase in the thickness and molarity concentration in the GF panels increased the load carrying capacity,ductility, energy absorption, and stiffness of the elementanddecreasedthecrackwidthandcrackspacing

4. The cracking behavior of the various specimen shows thatthecrackingregionand the cracking spaceare less in the geopolymer specimens and large number of cracks comparedwiththecontrolspecimens.

5 The rubber addition in mix increases the flexural strength of geopolymer base panel by 1.41times with lessercrackpronouncement

6 The impact resistant property of the rubberised geopolymer ferrocement is slightly more than conventionalferrocrete

7. The increased rubber powder ratio decreased the compressive strength and the modulus of rupture of the panel but delays the appearance of first crack and final failure.

REFERENCES

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