International Journal of Informative & Futuristic Research ISSN (Online): 2347-1697
Volume 2 Issue 10 June 2015
Abstract
Experiments were conducted to determine the strength of iron ore tailing (IOT) as a replacement fine aggregate (FA) of river sand (RS) for concrete used for pre-stressed concrete (PSC) sleepers. The present experimental investigation is aimed to study the static behaviour of a pre-tensioned pre-stressed concrete sleeper using river sand and iron ore tailings. PSC sleeper is used in the experimental studies in accordance with Research Design Standard Organisation (RDSO), IRS; T-39-85. The test programme consists of the static bending test and electrical resistance test to obtain load deflection behaviour, on 4 standard PSC sleepers
with regards to different percentage mix of IOT (25%, 50%, 75%, and 100%) proportions for M-55 grade concrete. Replacement of 50% IOT gives maximum compressive strength and for replacement of 100% IOT gives the less compressive strength as compare to 50% IOT, but 100% IOT gives more compressive strength than specified load as per RDSO.
Utilization of Iron Ore Tailings as a Replacement to
Fine Aggregates in Pre-Stressed Concrete Sleepers Paper ID IJIFR/ V2/ E10/ 076 Page No. 3802-3812 Subject Area
Civil
Engineering
Key Words Pre-Stressed Concrete (PSC), River Sand (RS), Iron Ore Tailing (IOT),
Spheriodical Graphical Cast Iron (SGCI) Inserts, High Tensile Steel (HTS) Wire,
Compressive Strength, Static Bending Test and Electrical Resistance Test
Received On 18-06-2015 Reviewed On 27-06-2015 Published On 29-06-2015
Manjula 1 Assistant Professor,
Department of Civil Engineering
Rajeev Institute of Technology, Hassan
Sachin H. S. 2 B.E. Student, Department of Civil Engineering
Rajeev Institute of Technology, Hassan
Shivakumar K. M. 3 B.E. Student, Department of Civil Engineering
Rajeev Institute of Technology, Hassan
Ranjitha D. R. 4 B.E. Student, Department of Civil Engineering
Rajeev Institute of Technology, Hassan
Santhosh B. M. 5 B.E. Student, Department of Civil Engineering
Rajeev Institute of Technology, Hassan
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
1. Introduction
Railway companies worldwide have used timber sleepers, steel sleeper, reinforced for nearly two
centuries and there are millions of old timber sleepers in railway range throughout the world that
need to be replaced by concrete sleeper. Now a day‟s PSC sleepers are using widely which was
experimented in U.K. (Johansen, 1944, Hanna, 1979). Both „Twin block‟ and „Mono block‟
varieties were tried, and the latter was found to be more successful. Most suitable types of sleeper
are mono block sleeper and now a day‟s mostly mono block sleeper is being used. The concrete
sleeper with trapezoidal cross section at rail seat the average dimensions of 150X210X250mm,
gradually gets smaller up to the centre as 150X180X220mm of the sleeper, sleeper having a span of
2750mm and a weight of 282.64 kg are tested under static loading and electrical resistivity.
1.1 Iron Ore Tailings
In India, there is great demand of aggregates mainly from civil engineering industry for
concrete constructions. But now days it is very difficult problem for available of fine aggregates. So
researchers developed waste management strategies to apply for replacement of fine aggregates for
specific need. Natural resources are depleting worldwide, so the sustainable development for
construction involves the use of river sand and innovative materials, and recycling of waste
materials in order to compensate the lack of natural resources and to find alternative ways
conserving the environment. Iron Ore Tailings (IOT) is one of the materials that is considered as a
waste material which could have a promising future in construction industry as partial or full
replacement of fine aggregates. It is a by-product obtained during the process of separating the
valuable fraction from the worthless fraction of an ore. The waste/tailings that are ultra-fines having
diameter less than 150 μm, are not useful and hence are discarded. In India approximately 10 – 12
million tons of such mined ore is lost as tailings. The Iron Ore Tailings used in the present project
purpose are taken from Kudremukh Iron Ore Company Limited (KIOCL), Kudremukh, Mudigere
Taluk, Chikkamagaluru District, which was a leading company in India in the mining activities of
iron ore has dumped about 200 million metric tons of iron ore tailings at Lakya Dam. Campany
stopped mining in 2005 in the process of beneficiation; it has dumped iron ore tailings in Lakya
Dam, which was constructed as an ecological dam for this purpose.
2. Objectives
The objectives are as follows:
Determining the properties of iron ore tailings and comparing the results with the river sand and
partial replacement of iron ore tailings with the river sand.
Determining the strength properties of concrete for steam curing 11 ½ hours, 3, 7 and 14 days.
To conduct detailed investigation of conventional PSC sleeper and modifying the PSC sleeper
with Iron ore tailings as an alternative to river sand.
To understand the behaviour of modified PSC sleeper with Iron ore tailings under static loading
behaviour and electrical résistance test.
3. Materials and Methods
3.1 Materials
3.1.1 Cement::Ordinary Portland Cement 53-S grade (Dalmia) shall confirm to code of IS: 12269-
1987 with amendment No.6 of June 2000.Cement shall confirm to Indian Railway Specification
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
No. T-40.While the minimum fineness of cement has to be 3700 cm2/g, the 7 days compressive
strength needs to be 375 kg/cm2 (min) and minimum C3S content 45% is summarized in table 3.1
Table 3.1: Properties of Cement
Sl. No. Characteristics Results As per IS:12269-1987
1. Standard consistency 32% -
2.
Setting time
129 minutes
286 minutes
Not less than 30 Min.
Not more than 600 Min.
Initial setting time
Final setting time
3. Specific gravity 3.15 -
4. Fineness modulus 7.5% < 10%
3.1.2 Fine Aggregate
The aggregate size is lesser than 4.75 mm is considered as fine aggregate. The sand used
for the experimental programmers was locally procured and conformed to grading zone II as per IS:
383-1970. The properties of the fine aggregate are indicated in table 3.2
Table 3.2: Physical Properties of Natural Sand
Property Results
Specific gravity 2.65
Fineness modulus 2.672
Zone II
3.1.3 Iron Ore Tailings (IOT)
Tailings are the materials left over, after the process of separating the valuable fraction
from the worthless fraction of an ore. Tests on Iron Ore Tailings procured from Kudremukh Lakya
Dam. The properties of the IOTs are indicated in table 3.3
Table 3.3: Physical Properties of Iron Ore Tailings
Property Results
Specific gravity 2.90
Fineness modulus 2.0
Zone II
Colour Dark tan (Brown)
Figure 3.1: Iron Ore Tailings
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
3.1.4 Coarse Aggregate
According to RDSO specifications aggregates shall conform to IS-383 and shall before use,
be got tested through an approved testing institute and results submitted accordance with
“Appendex A” of IS-383 to the inspecting officer for approval. The aggregates are tested flakiness
index, elongation index, crushing, impact and abrasion values shall not exceed 30% when tested
accordance with IS-2386(PART-1)
Coarse aggregates shall crushed stone, angular in shape and gravel shall not be used.
Table 3.4: Tests of Coarse Aggregate
Sl. No. Particular of test Results
1. Type Size of aggregates Crushed
2. Specific gravity 10mm & 20mm 2.65
3. Fineness modulus
a.20mm
b.10mm
1.86
5.58
4. Elongation Index a.20mm
b.10mm
21.9%
28.08%
5. Flakiness Index a.20mm
b.10mm
21.22%
27.52%
6. Crushing value a.20mm
b.10mm
24.29%
25.66%
7. Impact value a.20mm
b.10mm
22.19%
20.50%
8. Abrasion value a.20mm
b.10mm
27.34%
27.59%
3.1.5 High Tensile Steel (HTS) Wire and End Plates
High tensile steel in the form of plain wire or strand shall conform to IS: 1785 Part-I and
IS: 6006 respectively. It shall be procured only from BIS approved manufacturers, HTS wire which
has 3 numbers of 3mm in diameter each, which is twisted to form a single wire of 6mm diameter.
18 numbers of wires are inserted to the mould of end plate, wires are stretched by the
hydraulic jacks on either sides to the 243kN.
Figure 3.2: High Tensile Steel Wires and End Plates
3.1.6 Spheriodical Graphical Cast Iron (SGCI) Inserts
Spheriodical Graphical Cast iron (SGCI) inserts are to be provided in a proper position,
every inserts to be checked in the gauge before fixing the mould. Grease to be provided in a every
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
inserts and fixed with PIN in a eye of inserts so that it should be loosed/ shifted during vibration /
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
4. Mix Design of M-55 Concrete
4.1 Introduction
Mix design can be defined as the process of selecting suitable ingredients of concrete and
determining their relative proportion with object of producing concrete of certain minimum strength
and durability as economically as possible. For the present work a grade of concretem-55 suggested
to be used in RDSO specifications.
Mix design is based on absolute volume method
Calculation of batch mass
Cement = 100 kg
F.A. = 100 kg
C.A.-1 = 199.78 200 kg
C.A.-2 = 100 kg
Water = 33 liters
4.2 Final proportion
C: FA: CA
1: 1: 3
5. Results and Discussions
5.1 Tests for Fresh Concrete
5.1.1 Measurement of Workability
Tests adopted for measurement of workability in the present investigation are
Slump Test
Table 5.1: Slump Cone Test
Designation of mix Slump in mm
Normal concrete 0
Mix 25% IOT 0
Mix 50% IOT 0
Mix 75% IOT 0
Mix 100% IOT 0
5. 2 Test on Hardened Concrete
5.2.1 Compressive Test of Cubes
The cubes shall be surface dry at the time of testing. The rate of loading shall be about 400
KN/minute. As mentioned in RDSO para 5.3.4 &5.3.5
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
Table 5.2: Compressive Strength for Steam Curing and Water Curing
% Replacement of IOT Load(kN) Weight
(grams)
Strength
(N/mm2)
Std. Values As
Per RDSO
0%
Steam curing
11 & ½ hour 945 8496 42.00 >40 N/mm
2
7 days 1123 8525 49.88 >37.5 N/mm2
15 days 1282.5 8436 57.00 >55 N/mm2
25%
Steam curing
11 & ½ hour 1015 8572 45.11 >40 N/mm
2
7 days 1140 8618 50.66 >37.5 N/mm2
15 days 1300 8496 57.77 >55 N/mm2
50%
Steam curing
11 & ½ hour 985 8615 43.77 >40 N/mm
2
7 days 1190 8649 52.88 >37.5 N/mm2
15 days 1335 8619 59.33 >55 N/mm2
75%
Steam curing
11 & ½ hour 920 8637 40.88 >40 N/mm
2
7 days 1172 8526 52.08 >37.5 N/mm2
15 days 1255 8840 55.77 >55 N/mm2
100%
Steam curing
11 & ½ hour 1027 8384 45.64 >40 N/mm
2
7 days 1110 8546 49.88 >37.5 N/mm2
15 days 1310 8603 58.22 >55 N/mm2
Figure 5.1: Graph of Compressive Strength of Cubes
0
10
20
30
40
50
60
0 25 50 75 100
Co
mp
ress
ive
Str
eng
th i
n
N/m
m2
% variation of IOT
Compressive Strength of Cubes
steam curing
water curing 7days
water curing 15days
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
5.2.2 Test for 15 Day’s Modulus of Rupture of Concrete
The test for 15 day modulus of rupture of concrete shall be carried out on concrete beams of 10 x
10 x 50 cm size as specified in IS: 516. If any value falls below 5 N/sq.mm for M55 the mix design
shall be reviewed. As mentioned in RDSO Para 5.3.6
Table 5.3: Flexural Strength Results
Replacement Flexural Strength
N/mm2
Standard value as
per RDSO
100% SAND 7.3
>5 N/mm2
25% IOT & 75% FA 7.7
50% IOT & 50% FA 7.2
75% IOT & 25% FA 7.1
100% IOT 7.4
5.3 Tests on PSC Sleepers
5.3.1 Testing For Static Bending Strength of Sleeper
All sleepers tested should pass all the acceptance tests provided in clause RDSO 5.3.7.2 for the
lot to be accepted. The specified values of moment of resistance (MR) tests Load for Centre Top,
Centre bottom, Rails Seat cracking and MF test are depending on 15 day cube strength of the lot as
mentioned in para RDSO 5.3.5
Table 5.4: Moment of Resistance
Sleeper
Center Top
(kN)
(Minimum)
Center
Bottom
(kN)
(Minimum)
Rail Seat Bottom
Cracking
(kN)
(Minimum)
Failure
(kN)
(Minimum)
BG 60 52.5 230 370
MG 25 40 150 250
Figure 5.2: Static Bending Test Arrangements
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
Figure 5.3: Static Bending Test (Centre Top) & Crack at Top
Figure 5.4: Static Bending Test (Rail Seat) & Crack at Bottom
5.3.2 Test for Electrical Resistivity
All sleepers shall be tested as per Annexure-V in RDSO for electrical resistance for their
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
250
260
270
280
290
300
25 50 75 100
load
kN
% variation of IOT
Rail Seat Bottom
R.H.S
L.H.S
85
90
95
100
105
110
25 50 75 100
load
kN
% variation of IOT
Centre Top
CentreTop
fitness for use in track circuited area.
Table 5.5: Static Bending Results
Static Bending Values kN
M-55 GRADE
25% IOT
+ 75% FA
50% IOT
+ 50% FA
75% IOT
+ 25% FA
100%
IOT
Std. Values
As Per
RDSO
Centre Top 105
98
105
92.5
>60kN
Rail Seat Bottom kN
o R.H.S
o L.H.S
Moment Failure kN
o R.H.S
o L.H.S
270
280.9
-
-
290.4
287.5
-
-
286
290
-
-
275
284.7
410
424.5
>230 kN
>230 kN
>370 kN
>370 kN
Figure 5.7: Graph Rail Seat Bottom
Figure 5.8: Graph Center Top
6. Conclusion
The experimental programme deals with the study of static bending strength, electrical
resistance test. Some conclusions are given below.
1. Load carrying capacity more than the control specimen (ie centre top, rail seat , moment failure
test)
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Manjula , Sachin H. S. , Shivakumar K. M. , Ranjitha D. R. , Santhosh B. M. : Utilization of Iron Ore Tailings as a Replacement to Fine Aggregates in Pre-Stressed Concrete Sleepers
2. The electrical resistivity is good for the all the test specimens tested.
3. It is experimentally evident that from results obtained for static bending test for the material
(IRON ORE TAILINGS) chosen in present study is more than river sand used in control
specimen.
4. Replacement of 50% IOT gives maximum compressive strength and for replacement of 100%
IOT gives the less compressive strength as compare to 50% IOT, but 100% IOT gives more
compressive strength than specified load as per RDSO.
5. The static behaviour of PSC sleeper can be increased by using higher toughness and higher
fracture capacity, which can be achieved by replacement of river sand with IRON ORE
TAILINGS to concrete matrix.
References [1] J. Taherinezhad, M. Sofi, P. A. Mendis and T. Ngo, “A Review of Behaviour of Prestressed Concrete
Sleepers”, 2013
[2] G.C. Agarwal and P.C Agwekar, ”Use Of High Strength Concrete For Pre-Stressed Concrete Sleepers In
India”, Indian Concrete journal, December 1996, PP683-686.
[3] R.S.Varsheya, G.C. Agarwal and P.C Agwekar, ”An Overview of Development of Concrete Sleepers on
Indian Railway” .Indian concrete journal, june 1993,PP249-258.
[4] Sujing Zhao , Junjiang Fan, Wei Sun “Utilization of iron ore tailings as fine aggregate in ultra-high
performance concrete”, Construction and Building Materials 50, pp.540–548, (2014)
[5] Xiaoyan Huang; Ravi Ranade and Victor C. Li, F.ASCE “Feasibility Study of Developing Green ECC
Using Iron Ore Tailings Powder as Cement Replacement” Journal Of Materials In Civil Engineering 25:923-
931(2013).
[6] G R Harish, S A K Zai ,N Munnirudrappa, “behaviour of SBR-latex modified polypropylene fibre
reinforced PSC railway sleepers under static loading”, 2010.
[7] SakdiratKaewunruenand Alex M Remennikov, “Probabilistic Impact Fractures of Railway Prestressed
Concrete Sleepers”,Trans Tech Publications, 2008.
[8] Adedayo, S. M and Onitiri, M. A., (2012).Tensile Properties of Iron Ore Tailings filled Epoxy
Composites. The West Indian Journal of Engineering Vol. 35. No.1 Pp 51-59.
Code Books:
[1] IS: 456-2000 Code of practice for plain and reinforced concrete, Bureau of Indian Standards.
[2] Code book IRS: T-39-85 Third Revision Indian Railway Standard specification for Pre-tensioned pre-
stressed concrete sleepers for broad gauge and meter gauge, RDSO Lucknow. [3] For Cement: IS: 12269-1987 with amendment No.6 of June 2000.
[4] For Sand and Coarse aggregate: IS:383-1970 ( reaffirmed 1990 Indian Standard specification for coarse
and fine aggregate from natural source for concrete)
