Research Paper Volume 3 Issue 3 November 2015 ... Journal of Informative & Futuristic ... A concrete...

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Available online through - http://ijifr.com/searchjournal.aspx Published Online On: November 30, 2015

Copyright©IJIFR 2015

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

Volume 3 Issue 3 November 2015 Research Paper

Abstract

Due to ever increasing quantities of waste materials and industrial by-products, solid waste management is the prime concern in the world. Scarcity of land-filling space and because of its

ever increasing cost, recycling and utilization of industrial by-products and waste materials has

become an attractive proposition to disposal. There are several types of industrial by -products and waste materials. The utilization of such materials in concrete not only makes it economical,

but also helps in reducing disposal concerns. Two such industrial by-products are Foundry

Waste Sand and Quarry Dust. FWS is major by-product of metal casting industry and QD is a by-product obtained during crushing of granite rocks and successfully used as a land filling

material for many years. But use of this for land filling is becoming a problem due to rapid

increase in disposal cost. In an effort to use the FWS & QD in construction materials, research has being carried out for its possible utilization in making concrete as partial rep lacement of

fine aggregate. This experimental investigation was performed to evaluate the strength properties of M20 (20 MPa) grade of concrete mix, in which natural sand was partially and

fully replaced with foundry waste sand (FWS) and quarry dust (QD). Natural sand was replaced

with five percentage (0%, 25 %( 12.5% FWS+ 12.5% QD), 50 %( 25% FWS+ 25% QD), 75 %( 37.5% FWS+ 37.5% QD), 100 % FWS and 100% QD by weight. A total of six concrete mix

proportions for M20 grade of concrete were developed. Compression test, splitting tensile

strength test and flexural strength test were carried out to evaluate the strength properties of concrete at the age of 28 and 56 days. Test results showed that there is increase in compressive

strength, splitting tensile strength and flexural strength for all replacement levels as compared to normal concrete (100% river sand) mix. Results showed that there was better enhancement in

strength properties at 25 % replacement of fine aggregate with FWS & QD, and better

enhancement in saving environment and reducing the cost at 75% replacement.

A Feasibility Study On Manufacture Of Concrete

With Partial Replacement Of Fine Aggregate By

Foundry Waste Sand & Quarry Dust Paper ID IJIFR/ V3/ E3/ 088 Page No. 1144-1154 Research Area

Concrete

Technology

Keywords Quarry Dust, Foundry Waste Sand, Compressive Strength, Split Tensile

Strength, Flexural Strength.

1st

Basavaraj Saunshi

Assistant Professor,

Department of Civil Engineering,

KLS Gogte Institute of Technology, Belgaum( Karnataka)

2nd

Arshad Nerli B.E. Final Year Student,

Department of Civil Engineering,

KLS Gogte Institute of Technology, Belgaum( Karnataka)

3rd

Kiran Chougala

4th

Sapna Rathod

5th

Akshay Kadam

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

Volume - 3, Issue -3, November 2015 Continuous 27th Edition, Page No.:1144-1154

Basavaraj Saunshi, Arshad Nerli, Kiran Chougala, Sapna Rathod, Akshay Kadam :: A Feasibility Study On Manufacture Of Concrete With Partial

Replacem ent Of Fine Aggregate By Foundry Waste Sand & Quarry Dust

1. Introduction

General Sustainability is a global concern and hence the goal of human kind should be to

create a sustainable world. In order to achieve sustainability, methods that are to be employed are

effective utilization of currently available resources for a prolonged period of overuse, and ensuring

that there are reserves kept for future generations without complete exhaustion. But the man's greed

has influenced his oneself to over-utilize, pollute and destroy the natural resources around him

without giving a thought for future generations or for the existence of other species. By 2050,

humanity could con some an estimated 140 billion tons of minerals, ores, fossil fuels and biomass

per year (three times its current amount) . Urban sprawl and building construction industry are the

main causes of environ- by waste mental pollution leading to severe sustainable issues This

environmental imbalance has created a situation for the people to focus on adoption of newer

technologies and environmentally preferable materials, which will not only preserve the natural

resources but also create a productive environment in which human and nature can certainly a good

potential resource and lot of energy can be recovered from it; and the terminology 'green' in the

present context refers to use of sustainable materials like stone dust or recycled stone, recycled

metal/gravel and other products that are non-toxic, reusable, renewable, and/or recyclable building

material, and the world consumption of sand in concrete generation alone is around 1000 million

tons per year, making it scarce and limited. The excessive and non-scientific methods of mining sand

from the river beds has led to lowering of water table and sinking of bridge piers. Further, it has

caused environmental degradation like removal of minerals from top-soil due to erosion and change

in vegetative properties leading to soil infertility problems thereby affecting agricultural

productivity, change in river- courses leading to floods, and alteration of river eco-system affecting

flora and fauna. Hence, the current focus of construction industry should be to partially or

completely replace natural sand in concrete material or a material that is obtained through recycling,

without compromising the quality of the end product. In the recent years, the construction industries

have identified some waste materials like fly ash, slag, limestone powder, foundry sand and siliceous

stone powder and quarry dust for use in traditional concrete. In its simplest form, concrete is a

mixture of paste and aggregates. The paste composed of Portland cement and water, coats the

surface of the fine coarse aggregates. Through a chemical reaction called hydration, the paste

hardens and gains strength to form the rock- like mass known as concrete. Within this process lies a

key to remarkable trait of concrete: its plastic, malleable and can be shaped when newly mixed,

strong, retains shape and durable when hardened. These qualities explain why one material,

concrete, can build skyscrapers, bridges, sidewalks and super highways, houses and dams. The key

to achieving a strong, durable concrete rest in the careful proportioning and mixing of the

ingredients. A concrete mixture which does not have enough paste to fill all the voids between the

aggregates will be difficult to place and will produce rough,, honeycombed surfaces and porous

concrete. A mixture with an excess of cement paste will be easy to place and will produce a smooth

surface: however, the resulting concrete is likely to shrink more and be uneconomical. A properly

designed concrete mixture will possess the desired work ability for the fresh concrete and the

required durability and strength for the hardened concrete. Typically, a mix is about 15 to 20 percent

cement, 60 to 75 percent aggregates and 5 to 10 percent water.

1.1 Objectives Of The Study The main objective of testing was to know the behaviour of concrete with replacement of

ordinary sand by quarry dust and foundry waste sand at room temperature. The main parameters

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studied were cube compressive strength and split tensile strength. The materials used for casting

concrete samples along with tested results are described. Test specimens were prepared by replacing

natural sand by quarry dust and foundry sand in varying percentage and various curing periods.

1.2 Necessity Of Replacement Of Natural Sand By Quarry Dust And Foundry Waste Sand Availability of natural sand near the site of construction in most of the areas has reduced. Sand is available in few areas hence the cost of transportation has increased. Cost of quarry dust is comparatively less when compared to natural sand. The use of quarry dust is eco-friendly. It reduces the sand mining.

1.3 Scope Of The Study

Characterization of ingredient materials including fine aggregates, Quarry dust, Waste Foundry sand, coarse aggregate and cement.

Design of Concrete mixes with different percentages (0%, 25%, 75% and 100%) with a target slump of 100mm and design strength of 20 MPa.

Assessment of fresh concrete properties.

Study on hardened concrete properties like Compressive strength and Split tensile strength.

2. Literature Review

2.1 Literature on Foundry Sand Naik et al., 2001 conducted a project to evaluate performance and leaching of CLS Min

which both clean and used foundry sands were incorporated. The clean sand was obtained from a

sand mining company in Berlin, Wisconsin and the used foundry sand was obtained from a steel

company (Maynard Steel Casting Corp.)in Milwaukee, Wisconsin. For purposes of comparison,

properties of regular concrete sand (meeting ASTM C 33 requirements for use in making concrete)

were also measured. Physical properties of these three foundry sands were determined using the

appropriate ASTM standard .However a modified ASTMC88 was used to measure soundness of

foundry sands. The properties of used foundry sand vary due to the type of foundry processing

equipment used, the type of additive form old making, the number of times the sand is reused, and

the type and amount of binder used. The unit weight of the used sand was greater than that of clean

sand, which may be attributed to the finer gradation, attached particles of such materials as steel

pallets bonded to the sand during the foundry process, betonies clay binder material, etc. Both the

clean and used foundry sand was significant. The materials finer than No.200(75Pm) sieve were

slightly higher for the used foundry sand relative to the clean foundry sand. The sieve analysis

plots exhibit that both the clean and the used foundry sands are finer than regular concrete sands

and they are outside the ASTM limits for the use in making concrete. The grading curves show

that the foundry sands contain predominantly finer particles compared with those of regular

concretesand.Approx.50060% of the clean and used sand passed through the No.050 sieve.

However, when regular concrete sand was replaced with 30% foundry sand, the resulting curve

was close to the upper allowable ASTM limit.

Reddi et al., 1995 reported that compressive strength of stabilized foundry sands

decreases as the replacement proportion of foundry sand increases in the mixes and the strength is

achieved relatively faster with fly ash than with cement. Cement and flyash mixtures were

prepared using 0%, 25%, 50%, 75%, & 100% levels of replacement of silica sand by foundry

sand. Initial experiments with class F fly ash were unsuccessful because it lacked cementations

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properties to form a stable mix therefore subsequent experiments were restricted to class C fly ash

only. The ratio of water to the cementitious binder was chosen to be 1. in the case of Portland

cement and 0.35 in the case of fly ash. . The samples were founded in PVC pipes, 2.85 cm in dia.

and 5.72 cm long. The mixtures of sands and the binders were poured into these pipes and then

vibrated on a vibrating table to minimize air pockets. For each of their placement levels,

compressive strengths were obtained after 3,7,14,28,&56 days in order to evaluate the difference

due to curing time. The clay bonded foundry sand reduced the strength of the stabilized mixes

more than the resin bonded foundry sands. A similar observation is made in context of fly ash

stabilization. The drastic reduction in strength with an increase in clay bonded foundry sand

replacement is apparent in the cases of both fly ash & cement. Cement – stabilized mixes acquired

their strength considerably slower than fly ash stabilized mixes. After 7 days of curing the cement

stabilized RBS reached only 30% of peak strength where as its fly ash counterpart achieved 80%

of its peak strength.

Naiketal., 2004 conducted tests for freezing and thawing of bricks and paving stones in

accordance with ASTM C 140 for which water saturated brick and paving stone specimens, each

with a 10mm layer of one bearing surface immersed in H2O were subjected to cycles of freezing to

017°C(0°F) and thawing to 24ºC(75ºF) and the mass of each specimen was determined. The

resistance to cycles of freezing and thawing decreased with increasing amounts of the three by

product materials (fly ash, bottom ash, and used foundry sand in case of bricks. In case of paving

stones the wet0cast paving stones made with control mix showed a significant amount of mass loss

due to surface spelling between 60 and 150 cycles of freezing and thawing.

Naik et al., 2003 conducted an investigation to measure the drying shrinkage of bricks and

blocks in accordance with ASTMC426 using three specimens for each mixture. The test started

roughly at 300 days of age for bricks and at 270 days of age for blocks.The drying shrinkage

values for all specimens of bricks were about 0.023, 0.041, 0.031, 0.034, 0.041, and 0.036%,

respectively. Lower drying shrinkage of bricks implies less likelihood of development of drying

shrinkage cracks in masonry brick walls. Bricks containing FA, BA, and UFS shrunk more than

the control bricks upon drying. Overall, bricks with UFS shrunk more than those with BA.

However, all the bricks met the maximum drying shrinkage requirement of ASTM C 55 (0.065%).

While the drying shrinkage values for all blocks were 0.023, 0.020, 0.031, 0.028, 0.038, and

0.040%, respectively. Blocks containing either BAor UFS shrunk more than the control upon

drying. As in the case of bricks, blocks with UFS shrunk more than those with BA. However, all

the blocks met the maximum drying shrinkage requirement of ASTMC90 (0.065%).

Naik et al., 2003 conducted the tests for abrasion of paving stones and bricks according to

ASTM C 418 using three specimens for each mixture at about 350 days of age. The abrasion

coefficient values for all specimens of paving stones were about 4.8, 3.7, 5.7, 7.3,6.8, and

8.5mm3/mm

2or(mm), respectively. All these values exceeded the limit of 3 mm specified in

ASTMC936 for concrete interlocking paving units. This might be due to the use of the brick mold

and casting method in manufacturing the paving stones in this research. However, the test results

were still considered valuable in comparing the performance of different paving stone mixtures.

Partial replacement of cement with FA, sand with BA, and sand with UFS resulted in considerable

reduction, large increase, and very large increase in depth of cavity on paving stones upon abrasion

by sand blasting.

2.2 Literature On Quarry Dust

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Ahmed et al (1989) considered the influence of natural and crushed stone sand of particle size less than 75 micron on the performance of fresh concrete. The ordinary stone dust obtained from crushers does not comply with IS: 383-1970. The presence of flaky, badly graded and rough textured particles resulted in harsh concrete

ICAR 102 test results indicated that good quality concrete could be produced using micro

fine levels up to 18 percent, when the chemical admixtures are used to increase the

workability of the concrete at a fixed w/c ratio.

Zain et al (2000) inferred that the partial replacement of sand with quarry dust without the

inclusion of other admixtures resulted in enhanced workability of the concrete mixes

3. Materials

3.1 Cement

In this experiment 43 grade ordinary Portland cement (OPC) with brand name ACC cement was

used for all concrete mixes. The cement used was fresh and without any lumps. The testing of

cement was done as per IS: 8112-1989. Table -1: Physical properties of cement

Properties Results Standard value

Normal consistency 34% -

Initial setting time (minutes) 48 min. Not less than 30

Final setting time (minutes) 240 min. Nit greater than 600

Fineness (% ) 3.5% <10

Specific gravity 3.07 -

Compression strength (MPa)

3 Days 34 23 MPa

7 Days 44 33 MPa

28 Days 58 43 MPa

3.2 Fine Aggregates

3.2.1 River sand

Locally available sand collected from the bed of river Ghataprabha was used as fine aggregate. Sand

used was having fineness modulus 2.507 and conformed to grading zone-II as per IS: 383-1970

specification .The specific gravity of fine aggregate was found to be 2.60. Moisture content was

0.19%. Table 2: Physical properties of River sand

Properties Results

Type Uncrushed (natural)(River sand)

Specific gravity 2.60

Moisture content 0.19%

Fineness modulus 2.507

Grading zone II

3.2.2 Quarry Dust

The Quarry dust is collected from the local quarry. It’s a waste product obtained from coarse

aggregate crushing site. Following are the properties of quarry dust.

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Table 3: Physical properties of Quarry Dust

Properties Results

Fineness Modulus 3.11

Specific Gravity 2.58

Silt Content 4%

Moisture Content 1.58%

3.2.3 Foundry waste sand

Investigations were made on foundry sand procured from waste dumping site at industrial area

Udyambag, Belagavi, Karnataka. The physical properties of the foundry sand used in this

investigation are listed in Table 4.

Table 4: Physical properties of Foundry waste sand

Properties Results


Specific gravity 2.3

Silt content 7%

Moisture content 1.49

3.3 Coarse aggregate

The crushed stone aggregate were collected from the local quarry. Coarse aggregates used in the

experimentation were 20mm and 10mm down size and tested as per IS:2386-1963 specifications.

Physical properties of coarse aggregate are given in table 5. Table 5: Physical properties of coarse aggregate (IS: 2386-1963)

Properties Results

Type Crushed

Maximum size 20mm


Specific gravity (20mm) 2.86

Moisture content 1.49

3.4 Water

Ordinary potable water free from organic content, turbidity and salts was used for mixing and for

curing throughout the investigation.

4. Experimental Investigations

4.1 Mix Proportions

Since there is no standard method of designing concrete mixes incorporating quarry dust and waste

foundry sand as fine aggregate, the mix design method proposed by IS was first employed to design

the conventional concrete mixes and finally natural sand was partially replaced by quarry dust and

foundry sand to obtain different concrete mixes. The purpose of mix proportioning is to produce the

required properties in both plastic and hardened concrete by working out a combination of available

materials, with various economic and practical standards.

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For the present work a single grade of M20 concrete is adopted. A control concrete mix of M20 grade

was designed as per IS: 10262-2009.The mix design involved the partial replacement of fine

aggregates on the mass basis. Replacement of fine aggregates by quarry dust and foundry sand as

fine aggregate was investigated by considering different level of replacement viz. 0, 25%, 75% and

100%. Details of mix proportions for various concrete mixes with and without quarry dust and

foundry sand are given in following table 6.

Table 6: Mix proportions of concrete of grade M20

FWS – Foundry Waste Sand, QD – Quarry Dust

5. Test Results

This chapter deals with the test results of concrete in which natural sand is replaced by quarry dust

and foundry waste with varying percentages (0%, 25%, 50%, 75% and 100%).

5.1 Slump Values At Different Percentage Replacement Of Natural Sand

Table 7: variation of slump value with various replacement levels

Different replacement levels Slump value (mm)

0% 75

25% 60

50% 55

75% 55

100% 30

Figure 1: Variation of S lump with % replacement of natural sand

0

20

40

60

80

0% 25% 50% 75% 100%

0%

25%

50%

75%

100%

Mix

% replacement

of fine aggregates by

FWS & QD

Cement

kg/m3

River

sand

kg/m3

FWS

kg/m3

QD

kg/m3

Coarse

aggregate

kg/m3

Water

kg/m3

Normal

concrete

0% ( 100 % River sand) 400 750 - - 1300 198

(FWS+QD)

25%

12.5% FWS +12.5% QD 400 563 83 93 1300 198

(FWS+QD)

50%

25% FWS +25% QD 400 375 166 186 1300 198

(FWS+QD)

75%

37.5% FWS +37.5% QD 400 188 249 279 1300 198

(FWS+QD)

100%

50% FWS +50% QD 400 0% 332 372 1300 198

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5.2 Compressive Strength Test Results Of Concrete Mixes At Various Curing Days

Table 8: Overall results of 28 days compressive strength.

Different percentage

of quarry dust and

foundry waste

Compressive strength of

concrete for 28 days (mpa)

Percentage increase or decrease in

compressive strength with respect to

reference mix

0 % 33.3 -

25 % 43.7 31.23

50 % 40.4 21.32

75 % 34.2 2.70

100% 34.5 2.70

Table 9: Overall results of 56 days compressive strength.

Different percentage of

quarry dust and

foundry waste

Compressive strength of

concrete for 56 days (mpa)

Percentage increase or decrease in

compressive strength with respect

to reference mix

0 % 34.8 -

25 % 45.8 31.60

50 % 43.5 25

75 % 35.7 2.58

100% 34 2.3

Figure 2: Compressive strength of concrete after 28 & 56 days of curing

Co

mp

ress

ive

Str

en

gth

in M

pa

% Replacement of Natural sand

28 days

56 days

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5.3 Split Tensile Strength Test Results Of Concrete Mixes

Figure 3: Split Tensile strength of concrete after 28 & 56 days of curing

5.4 Flexural Strength Test Results Of Concrete

Figure 4: Flexural strength of concrete after 28 & 56 days of curing

Sp

lit

Ten

sile

str

en

gth

in

mp

a


28 days

56 days

Fle

xu

ral

Str

en

gth

in

mp

a


28 days

56 days

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6. Discussions The test results showed that there is an increase in the 28 and 56 days compressive strength of the

concrete made with 25% replacement of sand by quarry dust and foundry sand, the increase in

percentage is about 30%. And also it is observed that, as Fine aggregates replacement % increases

( i.e for 50%& 75% replacement ) there is a decrease in the 28 and 56 days compressive strength of

concrete. The decrease in compressive strength % is about 30 % to 3%. And it is also observed that

the compressive strength at 50% replacement is less than 25% replacement, but it is more than

normal concrete. The compressive strength at 75% & 100 % replacement is almost equal to normal

concrete. Also it is observed that the variation of tensile and flexural strength shows enhancement up

to 75% replacement of natural sand by quarry dust and foundry waste.

7. Conclusion

An improvement in the compressive strength, split tensile strength and flexural strength of

concrete by the addition of Quarry dust and foundry sand can be seen.

There is increase in the compressive strength at 25% replacement as compared to 50 and 75

% replacement levels. And the strength at 50% replacement is more than normal concrete &

at 75% replacement is equal to normal concrete.

It can be concluded that up to 75% of fine aggregates can be replaced with Quarry dust and

foundry sand in concrete is the optimum amount to get required strength, saving in

environment and reducing the cost.

From the strength point of view it is concluded that up to 25% we can replace the fine

aggregates with quarry dust and foundry sand.

It is also observed that compressive strength at 28 and 56 days of curing is almost similar.

8. References

[1] Albert K.H. Kwan and Henry H.C. Wong, “Durability of Reinforced Concrete Structure s, Theory

vsPractise”. Department of Civil Engineering, The University of Hong Kong, Hong Kong.

[2] Baruah and S.Talukdar , “ A comparative study of compressive , flexural , tensile and shear strength of

concrete of different originals”, The Indian Concrete Journal , July 2007.

[3] IS 10262:2009, “Concrete Mix Proportioning – Guidelines”, Indian Standards Bureau, New Delhi, India.

[4] IS 8112:1989, “Specification for 43 grade Ordinary Portland Cement (1st

revision)”, Indian Standard

Bureau, New Delhi, India.

[5] IS 2386(Part 3): 1963, “Methods for testing of aggregates for concrete: Part 3 Specific gravity, voids,

absorption and bulking”, Indian Standard Bureau, New Delhi, India.

[6] IS 383:1970, “Specifications for coarse and fine aggregate and natural sources for concrete (2nd

revision)”,

Indian Standards Bureau, New Delhi, India.

[7] IS 516-1959, “Methods of Tests for Strength of Concrete”, Ind ian Standards Bureau, New Delhi, India.

[8] IS 456-2000, “Plain and Reinforced Concrete-Code of Practice”, Indian Standards Bureau, New Delhi,

India.

[9] IS 5816:1999, “Splitting Tensile Strength of Concrete-Method of Test”, Indian Standards bureau, New

Delhi, India.

[10] IS: 383-1970, Specifications for Coarse and Fine aggregates from Natural Sources of Concrete , Bureau of

Indian Standards , New Delhi, India.

[11] IS:516-1959, Indian Standard Code of Practice – Methods of Test for Strength of Concrete , Bureau of

Indian Standards , New Delhi, India.

[12] IS: 5816-1999, Indian Standard Code of Practice –Methods of Test for tensile Strength of Concrete, Bureau

of Indian Standards, New Dehli , India.

[13] IS: 456-2000, Indian Standard Code of Practice- Plain and Reinforced Concrete.

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Basavaraj Saunshi is presently working as Assistant Professor since last 2 years

in Civil engineering department, KLS, Gogte Institute of Technology, Belagavi

Karnataka. His areas of interest in research includes Concrete Technology,

Composite Materials

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