International Journal of Informative & Futuristic Research...

3773

www.ijifr.com Copyright © IJIFR 2015

Research Paper

International Journal of Informative & Futuristic Research ISSN (Online): 2347-1697

Volume 2 Issue 10 June 2015

Abstract

Granite sludge powder generates in processing activities of granite stone, such as

cutting, polishing and finishing process. This contributes of about 30% wastage in these processes. As granite sludge powder is non- biodegradable waste, it has to be effectively disposed without creating environmental hazards. In our present study the objectives are to prepare Granite Sludge blocks of size

230×110×70(mm) for varying mix proportions such as 20%, 30%, 40%, 50%, 60%, and 70% for granite sludge powder and sand, by keeping lime 8% and

gypsum 2% as constant. To find Mechanical properties such as Compressive strength, Flexural strength and Water absorption, where maximum compressive

strength value for 7 days of 5.54 MPa, maximum flexural strength of 2.17 MPa

and maximum breaking load 4.33kN was obtained for A3 block type. Water absorption of granite sludge blocks increases with increase in addition of granite sludge powder in mix proportions, yet it is in limit as per IS code specifications. Utilizing granite sludge powder for manufacturing of granite sludge masonry blocks is one of efficient manner to minimize the disposal problems of granite sludge powder.

Experimental Study on Granite Sludge Blocks

Paper ID IJIFR/ V2/ E10/ 070 Page No. 3773-3781 Subject Area Civil

Engineering

Key Words Granite Sludge Powder, Granite Sludge Blocks, Lime

Received On 15-06-2015 Reviewed On 26-06-2015 Published On 29-06-2015

Sabarinath N 1

M.Tech. Student

Department of Civil Engineering

Vijaya Vittala Institute of Technology,

Bengaluru

Prof. Virendra Kumara K N 2

Professor & Head,



Bengaluru

Dr. S B Anadinni 3

Principal



Bengaluru

3774

ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)

Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781

Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks

1. Introduction

Traditionally burnt bricks constitute the basic masonry unit for the construction of houses and it is

well known that manufacturing requires significant quantities of energy to produce burnt bricks

while utilizing the topsoil. Also, continuous removal of topsoil for production of conventional

bricks creates environmental hazards. Hence, there is a strong need to adopt cost effective and

sustainable technologies using local materials to produce alternatives for burnt clay bricks

Recent development in the modern civilization has led to the increased industrial production to

meet the needs of the people. The production of every product results in some waste end products,

known as industrial waste. Leaving waste materials to the environment directly can cause

environmental problems. Hence reuse of waste materials has been incorporated with recent

techniques from past & present scholars to minimize the environmental hazards. Bulky waste, such

as the wastes from the granite industry can be utilized by the construction industry, which is one of

the most technologically active sectors. Both waste materials as resource and recycled products,

utilized by the sector reduce the cost of the project. The use of wastes as an alternative to raw

materials in the brick industry, which constitutes part of the construction activity, contributes to the

diversification of basic raw materials in the manufacturing process of bricks and tiles and reduces

the costs in a building

Generation of large amount of wastes in the granite industrial sector is in the form of fine dust and

sludge which are composed majorly of silicon dioxide, aluminum oxide, ferrous oxide and calcium

oxide due to their sawing and polishing process, they can bring about genuine harm to nature, for

example, soil and underground water defilement, if not proficiently treated before disposal.

The reusing of granite wastes in the brick industry has pulled in mechanical consideration in the

most recent years because of the likelihood of lessening the expense of creation, utilization of

residue as a secondary raw material in the production.

2. Problem Context Granite stones have vast application in the field of construction due to their nature of origin. Some

of it applications are for size stone masonry, granite flooring slabs, as coarse aggregate in concrete

etc. During the process of manufacturing granite flooring slabs which are used for flooring purpose

in commercial and residential buildings, about 30% waste is generated in various processing

activities. This granite sludge waste generated has negative impact to our environment. Hence reuse

of this material need to be considered to minimize the disposal problems of granite sludge.

3. Problem Definition

In this experimental study, strength and other required parameters are evaluated

by preparing Granit sludge masonry blocks using granite sludge powder 20% -70%, sand 70% -

20%, lime 8% and gypsum 2% of varying mix proportions, by keeping in view fly ash bricks as

principal reference. Granite sludge powder is collected from local granite stone processing unit and

other materials are purchased from local market. The tests are conducted in order to study the

strength characteristics such as compressive strength and flexural strength and water absorption.

The results obtained will be cross checked with IS code specifications.

4. Experimental materials

4.1 Granite Sludge Powder

3775




Granite sludge powder which results in processing activities of granite stone for flooring slabs such

as cutting, polishing and finishing process. This contributes of about 30% wastage in these

processes, which is non-biodegradable waste.

Figure 4.1: Granite Sludge Powder

4.2. Fine aggregate

Natural river sand which is locally available has been selected for the dissertation work.

The sand was tested for their physical characteristic according to the relevant IS code provisions.

Table 4.1: Properties of Fine Aggregate

Sl. No.

Physical properties of fine

aggregates

Results

1 Specific gravity 2.67

2 Fines modulus 2.507

3 Grading zone 3

4.3. Lime

Lime as binding material has been made use since ancient times in our country. But at present, the

cement revolutionary has replaced usage of lime to great extent. And on other hand, scholars say

that the manufacture of cement leads to Global warming, in this present study locally available lime

of class-C (hydrated lime)

4.4. Gypsum

Gypsum is a naturally occurring mineral of sedimentary rock category which constitute of hydrated

sulphate of calcium. Property of gypsum is such it has very poor solubility in water, which sets and

hardens quickly. Gypsum of high purity is generally used as fertilizer in our country, such as

ammonium sulphate fertilizer and low purity in manufacturing of ordinary Portland cement to act as

a retarder, controlling setting time of cement. Here low purity gypsum is used as retarding agent in

the mix proportions of granite sludge blocks.

3776




5. Methodology

5.1. Mix Proportions Keeping in view with fly ash bricks, granite sludge blocks are produced by varying percentage of

granite sludge powder by 20%, 30%, 40%, 50%, 60% & 70%.Table 5.1 shows Mix proportions for

various blocks to analyse in our study.

Table 5.1: Mix Proportions for various block types

Sl.No Type G.S.P Sand Lime Gypsum

1 A1 20% 70% 8% 2%

2 A2 30% 60% 8% 2%

3 A3 40% 50% 8% 2%

4 A4 50% 40% 8% 2%

5 A5 60% 30% 8% 2%

6 A6 70% 20% 8% 2%

Quantity of ingredients required for one Granite sludge block

Size of granite sludge blocks = 230 × 110 × 70 (mm)

Volume of block moulds = 0.23 × 0.11 × 0.07 (m)

= 1.771 × 10-3

m3

Mass = Density × Volume

Mass of one Granite sludge block = 1800 kg/m3 × 1.771X10

-3 m

3

= 3.18 kg + 10% wastage

= 3.5 kg

For A1 block type

Quantity of Granite sludge powder = Mass of solids × % of granite sludge powder

requirement

= 3.5 × 0.2 = 0.7 kg

Quantity of sand = Mass of solids × % of sand requirement

= 3.5 × 0.7 = 2.45 kg

Quantity of Lime = Mass of solids × % of Lime requirement

= 3.5 × 0.08 = 0.28 kg

Quantity of Gypsum = Mass of solids × % of Gypsum requirement

= 3.5 × 0.02 = 0.07 kg

Above mix proportion method is followed for various mix proportions of Granite Sludge

5.3 Mixing

The granite sludge powder is ensured its dry and by visual examination any gravels or debris are

removed if any, the granite sludge powder, sand and gypsum are mixed dry till it attains uniformity.

Then the hydrated fat lime which is sand drained over night to remove excess water from lime is

also mixed along with water for about 3- 4 minutes till the mix becomes cohesive.

3777




5.4 Casting

The mixture is filled in 230 x 110 x 70 (mm) wooden mould in three layers and compacted by

tamping 25 times each layer by using tamping rod. And the top layer is smooth finished by using a

trowel. After which the specimen is allowed to dry for 24hrs in the mould itself.

5.5 Curing

The granite sludge blocks are de-moulded after 24hrs from the wooden moulds after casting and are

water cured for 7 days by covering wet gunny bags.

5.6 Testing

After 7 days of water curing granite sludge blocks are tested to know its compressive strength,

flexural strength, percentage of water absorption.

6. Results and Discussions

6.1 Compressive Strength Test 7 days compressive strength test for Granite sludge masonry blocks of mix proportions of 20%,

30%, 40%, 50%, 60%, and 70% were carried out as per IS code 3495:1992.

Table 6.1: Compressive strength test values

Sl. No Type 7 days Compressive load in (kN) Avg Compressive strength

in (N/mm2)

1 A1 70 71 67 2.74

2 A2 92 83 90 3.41

3 A3 138 144 139 5.54

4 A4 114 119 108 4.49

5 A5 94 88 88 3.55

6 A6 66 62 66 2.55

Length of Granite sludge block, l=230(mm)

Breadth of Granite sludge block, b= 110 (mm)

Area of the Granite sludge block, A=l x b=25300(mm)2

6.1.1 Observation and Discussion on Compressive Strength Test

Figure 6.1: Bar chart representation of compressive strength (MPa) v/s Block Types

0

1

2

3

4

5

6

A1 A2 A3 A4 A5 A67 d

ay

s C

om

pre

ssio

n

Str

eng

th

in M

Pa

Block Type

3778




The compressive test result shows that, A3 block type has obtained maximum compressive strength

value of 5.54 N/mm2 after which the compressive strength drops down due to the increase in

powder content and particle size distribution of granite sludge powder in the mix proportions. Since

maximum compressive strength obtained is 5.54 N/mm2, it belongs to class 5 designation as per IS

code 1077:1992.

6.2 Flexural Strength The flexural test on granite sludge blocks was conducted as per IS 15658: 2006 code specifications,

which specifies breaking load and flexural strength for pre-cast concrete blocks for paving. Table

6.2 shows flexural strength values for different granite sludge block types.

Table 6.2: Flexural strength test values

Sl.No Type Breaking load (kN)

Avg

Breaking

load (kN)

Flexural strength

fb

(N/mm2)

1 A1 3 2 3 2.67 1.33

2 A2 4 3 3 3.33 1.67

3 A3 4 5 4 4.33 2.17

4 A4 5 4 2 3.67 1.83

5 A5 2 2 2 2 1

6 A6 1 2 1 1.33 0.67

fb= flexural strength, in N/mm2.

P = Breaking load, in N.

l = distance between central lines of supporting rollers. ie, overall length of the specimen minus

50mm (230 – 50 = 180mm)

b = width of the block, 110mm.

d = thickness of the block, 70mm

6.2.1 Observation and Discussion on Flexural Strength

Figure 6.2 Flexural strength (MPa)

v/s Block Types

0

0.5

1

1.5

2

2.5

A1 A2 A3 A4 A5 A6

Fle

xu

ral

stre

ng

th i

n N

/mm

2

Block types

3779




IS code 15658: 2006 specifies following minimum breaking load values to be considered for

using in pavers for different aspects of application such as

For residential and public pedestrian pathways, minimum breaking load of 2kN

Residential driveways, minimum breaking load of 3kN

Commercial vehicle pathway, minimum breaking load of 5kN

For trafficked roads, minimum breaking load of 6kN

Heavy duty industrial roads, minimum breaking load of 7kN

By considering specifications, the average maximum breaking load of 4.3kN was achieved in

our present study. Hence granite sludge block concept can be adopted in manufacturing of precast

paver blocks of required size/ shape and used as paver block for residential driveways.

As with flexural strength of granite sludge blocks, the maximum strength value of 2.17 N/mm2

was observed for A3 block type, after which the flexural strength reduces significantly. Where it is

also noted that flexural strength as low as 0.67 N/mm2 for A6 block type which might be due to the

high granite sludge powder content and insufficient binding agent in the mix proportion.

6.3 Water Absorption Test Water absorption test for different mix proportions of Granite sludge blocks were carried out as per

IS code 3495:1992 and are tabulated in table 6.3.

Table 6.3 Water absorption test test values

Sl.No Type M1 in kg M2 in kg

Average

(%)

1 A1 3.89 3.77 3.94 4.22 4.06 4.25 8.01

2 A2 3.8 3.77 3.72 4.12 4.097 4.06 8.48

3 A3 3.67 3.56 3.83 4.022 3.89 4.17 9.2

4 A4 3.79 3.92 3.69 4.169 4.35 4.05 10.23

5 A5 3.73 3.98 3.79 4.12 4.43 4.21 10.94

6 A6 3.82 3.68 3.73 4.26 4.10 4.19 11.51

6.3.1 Observation and Discussion on Water Absorption

From fig 6.3 it can be

clearly seen that

percentage of water

absorption increases

with increase in

addition of granite

sludge powder for

various block types.

The maximum water

absorption rate is for

A6 block type which

Figure 6.3: Shows percentage of water absorption for different Block Types

3780




constitutes 70% of granite sludge powder in mix. But none of the granite sludge blocks from A1 –

A6 as water absorption rate beyond IS code 1077:1992 specification, which specifies water

absorption rate not to be more than 20% by weight for blocks up to 12.5 class designation. Where

as in our study, the maximum water absorption rate is 11.74% for class 5 masonry block, which is

well within the limiting value of 20%.

7. Conclusion

The following conclusions can be drawn from the results of the present study;

1. By using granite sludge powder as prime material granite sludge masonry blocks of size

230×110×70 (mm) is casted for varying mix proportions of 20%,30%,40%,50%,60% and 70%

for granite sludge powder and sand, by keeping lime 8% and 2% gypsum as constant.

2. Maximum Compression strength value for 7 days of 5.54 MPa was obtained for A3 block type,

which conforms to class 5 masonry blocks according to IS 3495:1992, which specifies

minimum compressive strength of 3.5MPa for masonry blocks.

3. Maximum Flexural strength of 2.17MPa for A3 block type is observed. The maximum breaking

load 4.33kN was noted for A3 block type, while conducting flexural strength test.

4. Water absorption in granite sludge blocks increases with increase in addition of granite sludge

powder in mix proportions. But the water absorption values of all the granite sludge blocks A1-

A6 are within the limit as specified by IS code 1077:1992, which specifies maximum

percentage of water content should not exceed 20% by weight of the specimen.

5. Utilizing granite sludge powder for manufacturing of granite sludge masonry blocks is one of

efficient manner to minimize the disposal problems of granite sludge powder.

References

[1] Mamta. B. Rajgor and Jayeshkumar Pitroda, “A Study of Utilization Aspect of Stone Waste Indian

Context.” Global Journal for Research Analysis;Vol.2, Issue 1,Jan.2013

[2] Rania A. Hamza, Salah El-Haggar, and Safwan Khedr, “Marble and Granite Waste: Characterization

and Utilization in Concrete Bricks”. International Journal of Bioscience, Biochemistry and

Bioinformatics, Vol. 1, No. 4, November 2011

[3] ZHANG Ji-ru and CAO Xing , “Stabilization of Expansive Soil by Lime and Fly Ash”, Journal of

Wuhan University of Technology – Materials Science Edition, 17(4)

[4] V. Karthikeyan and M. Ponni, “An Experimental Study of Utilization of Fly Ash for Manufacturing

of Bricks”, 22nd National Conference of Architectural Engineers Trichur

[5] Tabin Rushad.S, Abhishek Kumar, Duggal.S.K and Metha.P.K, “Experimental Studies on Lime-

Soil-Fly Ash Bricks”, International Journal of Civil and Structural Engineering Vol 1, No 4, 2011

[6] Veena G. Pathan and Md. Gulfam Pathan “Feasibility and Need of use of Waste Marble Powder in

Concrete Production”, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) 2014.

ISSN: 2278-1684 pp 23-26

[7] F. J. Aukour, “Feasibility Study of Manufacturing Concrete Eco-Blocks Using Marble Sludge

Powder as Raw Materials”, Sustainable Development and Planning IV, Vol. 2, ISSN 1743-3541

[8] Elham Khalilzadeh Shirazi, “Reusing of Stone Waste in Various Industrial Activities”, 2nd

International Conference on Environmental Science and Development, IPCBEE Vol.4 (2011)

[9] Nutan C. Patel, “A Technical Study on Quarrying and Processing of Marble and its Waste

Incorporating with Concrete”, GRA, Vol. 2, issues 2, feb 2013

[10] Ashish Kumar Parashar and Rinku Parashar, “Comparative Study of Compressive Strength of Bricks

Made With Various Materials to Clay Bricks”, International Journal of Scientific and Research

Publications, Vol.2, Issue 7, July 2012

[11] Niranjan P S Radhakrishna, “Properties of Fal-G Hollow Masonry Blocks”, IJRET: Vol: 03 Issue:

01 | Jan-2014

3781




[12] Menezes„‟Use of Granite Sawing Wastes in the Production of Ceramic Bricks and Tiles‟‟, Journal of

the European Ceramic Society, Vol. 25, Issue 7, May 2005

[13] S.K. Malhotra and S.P. Tehri „‟Development of Bricks from Granulated Blast Furnace Slag‟‟

Construction and Building Materials, Vol. 10, Issue 3, April 1996

[14] Torres “Characteristics of Bricks Made from Waste Steel Slag‟‟, Waste Management Vol. 24, Issue

10, 2004

[15] Rajni Lakhani, Rajesh Kumar and Priyanka Tomar “Utilization of Stone Waste in the Development

of Value Added Products: A State of the Art Review” CSIR – Central Building Research Institute,

Roorkee 247667, India

[16] S.V. Ribeiroa and J.N.F. Holandaa, “Soil-Cement Bricks Incorporated with Granite Cutting Sludge”,

International Journal of Engineering Science and Innovative Technology (IJESIT) Vol. 3, Issue 2,

March 2014

[17] H.N.Rajendra Prasad, “An Approach for Alternative Solution in Brick Manufacturing”,

International Journal of Science, Environment and Technology, Vol. 3, No 3, 2014

[18] Ashish Kumar Parashar and Rinku Parashar, “Comparative Study of Compressive Strength of

Bricks Made with Various Materials to Clay Bricks”, International Journal of Scientific and

Research Publications, Vol. 2, Issue 7, July 2012

[19] Swamithan Dhanapandian, “Utilization of Granite and Marble Sawing Powder Wastes as Brick

Materials”.., Carpathian Journal of Earth & Environmental Sciences. Oct 2009, Vol. 4.

IS Codes

[20] IS 3495 ( Parts 1 to 4 ) : 1992 Methods of Tests of Burnt Clay Building Bricks

[21] IS 1290 : 1973 Specification of Mineral Gypsum

[22] IS 1077 : 1992 Common Burnt Clay Building Bricks Specification

[23] IS 383 : 1970 Specification for Coarse and Fine Aggregates

[24] IS 712 : 1984 Specification for Building Limes

[25] IS 1905 : 1987 Code of practice for structural use of unreinforced masonry

Date post:	15-Mar-2018
Category:	Documents
Upload:	haque
View:	219 times
Download:	3 times

International Journal of Informative & Futuristic Research...

Documents