VALLUR,PRAKASAM(Dt). · Crushed waste ceramic tiles, crushed waste ceramic tile powder and Granite powder are used as a replacement to the coarse aggregates and fine aggregate. The

A PROJECT REPORT

ON

“PARTIAL REPLACEMENT OF AGGREGATE WITH CERAMIC

TILE IN CONCRETE”

SUBMITTED TO

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA

IN PARTIAL FULLFILLMENT OF THE REQUIREMENT FOR THE AWARD OF THE DEGREE

MASTER OF TECHNOLOGY

IN

STRUCTURAL ENGINEERING

BY

G.SAI CHAND

(15KQ1D8705)

Under The Esteemed Guidance Of

Mr. P.RAVI KUMAR, M.Tech

ASST.PROFESSOR, DEPT OF CE.

DEPARTMENT OF CIVIL ENGINEERING

PACE INSTITUTE OF TECHNOLOGY AND SCIENCES(AFFLIATED TO JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA & ACCRIDATED BY

NAAC ‘A’ GRADE & AN ISO 9001-2008 CERTIFIED INSTITUTION)

VALLUR,PRAKASAM(Dt).

2015-2017

PACE INSTITUTE OF TECHNOLOGY AND SCIENCES, VALLUR

DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE

This is to certify that the project work “PARTIAL REPLACEMENT OF AGGREGATE WITH CERAMIC TILE IN CONCRETE” Submitted by G.SAI CHAND

, is examined and adjusted as sufficient as a partial requirement for the MASTER DEGREE IN STRUCTURAL ENGINEERING at Jawaharlal Nehru Technological university, Kakinada is a bonafide record of the work done by student under my guidance and supervision.

Project Guide Head of the DepartmentP.RAVI KUMAR , M.Tech, G.GANESH NAIDU,M.Tech,(P.hd)Asst. Professor Asst. Professor & HOD,DEPARTMENT OF CE DEPARTMENT OF CE

PrincipalDr. C.V.SUBBA RAO, M.Tech , Phd. PROJECT EXTERNAL EXAMINER

ACKNOWLEDGEMENT

I would like to take this opportunity to express my heartiest concern of words to all

those people who have helped me in various ways to complete my project.

I express my profound gratitude to my Project guide Mr.P.RAVI KUMAR, M.Tech,

Asst.Professor, Department of CE for his valuable and inspiring guidance, comments, and

encouragements throughout the course of this project.

We are highly indebted to Mr.G.GANESH NAIDU, M.Tech,Ph.d, Assistant

Professor and Head of Civil Engineering Department. He has been a constant source of

encouragement and has inspired me in completing the project and helped us at various stages

of project work.

First and foremost I express my heartfelt gratitude to our principal Dr.C.V.SUBBA

RAO, M.Tech,Ph.d,Department of Mechanical Engineering of our institution for

forecasting an excellent academic environment which made my project work possible.

Sincerely thanks to our Secretary and Correspondent Sri.M.SRIDHAR, M.Tech, for

his kind support and encouragement.

I extend my sincere thanks to our faculty members and lab technicians for their help

in completing the project work.

G.SAI CHAND(15KQ1D8705)

DECLARATION

I, hereby declare that the work which is being presented in this dissertation entitled

“PARTIAL REPLACEMENT OF AGGREGATE WITH CERAMIC TILE IN

CONCRETE’’, submitted towards the partial fulfillment of requirements for the award of the

degree of Master of Technology in STRUCTURAL ENGINEERING at Pace institute of technology and

sciences, Vallur is an authentic record of my work carried out under the supervision of

Mr.P.RAVIKUMAR M.Tech, Assistant Professor Department of C.E,. at Pace institute of technology

and sciences, Vallur.

The matter embodied in this dissertation report has not been submitted by me for the

award of any other degree. Further the technical details furnished in the various chapters in

this report are purely relevant to the above project and there is no deviation from the

theoretical point of view for design, development and implementation.

G.SAI CHAND(15KQ1D8705)

i

Abstract

Due to the day to day innovations and development in construction field, the

use of natural aggregates is increased tremendously and at the same time, the

production of solid wastes from the demolitions of constructions is also quite high.

Because of these reasons the reuse of demolished constructional wastes like ceramic

tile and granite powder came into the picture to reduce the solid waste and to reduce

the scarcity of natural aggregates for making concrete. The ceramic tile waste is not

only occurring from the demolition of structures but also from the manufacturing unit.

Studies show that about 20-30% of material prepared in the tile manufacturing

plants are transforming into waste. This waste material should have to be reused in

order to deal with the limited resource of natural aggregate and to reduce the

construction wastes.

Crushed waste ceramic tiles, crushed waste ceramic tile powder and Granite

powder are used as a replacement to the coarse aggregates and fine aggregate. The

ceramic waste crushed tiles were partially replaced in place of coarse aggregates by

10%, 20%, 30%, 40% and 50%. Granite powder and ceramic tile powder were

replaced in place of fine aggregate by 10% along with the ceramic coarse tile. M25

grade of concrete was designed and tested. The mix design for different types of

mixes were prepared by replacing the coarse aggregates and fine aggregate at

different percentages of crushed tiles and granite powder. Experimental investigations

like workability, Compressive strength test, Split tensile strength test, Flexural

strength test for different concrete mixes with different percentages of waste crushed

and granite powder after 7, 14 and 28 days curing period has done. It has been

observed that the workability increases with increase in the percentage of replacement

of granite powder and crushed tiles increases. The strength of concrete also increases

with the ceramic coarse tile aggregate up to 30% percentage.

Keywords: Crushed tiles, Compressive strength, Flexural strength, Granite powder,

Split Tensile strength.

ii

CONTENTS

Page No.

ABSTRACT i

CONTENTS ii

LIST OF TABLES v

LIST OF FIGURES vi

SYMBOLS vii

1. INTRODUCTION

1.1 CONCRETE 2

1.2 HISTORICAL BACKGROUND 2

1.3 PROPERTIES OF CONCRETE 3

1.4 LIGHT WEIGHT CONCRETE 4

1.5 CONSTRUCTION WASTE IN INDIA 4

1.6 TILE AGGREGATE CONCRETE 5

1.6.1 ENVIRONMENTAL AND ECONOMIC BENEFITS OF TILE

AGGREGATE CONCRETE 5

2. LITERATURE REVIEW

2.1 GENERAL 7

2.2 LITERATURE REVIEW 7

3. MATERIALS AND PROPERTIES

3.1 MATERIALS USED 12

3.1.1 CEMENT 12

3.1.2 FINE AGGREGATE 13

3.1.3 COARSE AGGREGATE 13

3.1.4 WATER 14

iii

3.1.5 CERAMIC TILE AGGREGATE 15

3.1.6 CERAMIC TILE FINE AGGREGATE 15

3.1.7 GRANITE POWDER 16

4. CONCRETE MIX DESIGN

4.1 MIX DESIGN FOR M25 GRADE OF CONCRETE 18

5. EXPERIMENTAL DETAILS

5.1 GENERAL 24

5.2 WORKABILITY 25

5.2.1 SLUMP CONE TEST 25

5.2.2 COMPACTION FACTOR TEST 27

5.3 COMPRESSIVE STRENGTH TEST 28

5.4 SPLIT TENSILE TEST 29

5.5 FLEXURAL TEST 30

6. TEST RESULTS

6.1 WORKABILITY



6.2 COMPRESSIVE STRENGTH 34

6.3 SPLIT TENSILE STRENGTH 37

6.4 FLEXURAL STRENGTH 39

7. DISCUSSION

7.1 WORKABILITY


iv


7.2 COMPRESSIVE STRENGTH 42

7.3 SPLIT TENSILE STRENGTH 43

7.4 FLEXURAL STRENGTH 44

8. SUMMARY AND CONCLUSION

8.1 GENERAL 46

8.2 CONCLUSIONS 46

FUTURE SCOPE OF WORK 47

REFERENCES 48

v

LIST OF TABLES

Table No Description Page No

1 Properties of Cement 13

2 Properties of Fine Aggregate 13

3 Properties of Coarse Aggregate 14

4 Properties of Ceramic Tile Aggregate 15

5 Properties of Granite Powder 16

6 Details of Mix Designations and replacement values 24

7 Slump Cone Test Results 33

8 Compaction Factor Test Results 34

9 Compression Test Results of M25 Grade 35

10 Split Tensile Test Results of M25 Grade 37

11 Flexural Test Results 39

vi

LIST OF FIGURES

Figure No Description Page No

1 Ceramic Tile Aggregate sample 15

2 Slump Cone Test Procedure 26

3 Types of Slump/Slump Pattern 26

4 Compaction Factor Apparatus 28

5 Compression Testing of Cube Specimen 29

6 Compression Testing Machine 30

7 Split Tensile Testing of Cylinder Specimen 30

8 Flexural Testing of Beam 31

9 Comparison of compressive strength at 7days for M25 35



12 Comparison of Split Tensile strength at 7days for M25 37



15 Comparison of Workability for M25 grade by Slump Cone Test

41

16 Comparison of Workability for M25 grade by Compaction Factor Test

41

17 Comparison of Compressive Strength Gain of M25 concrete at 7, 14 and 28 days

42

18 Comparison of split tensile strength of M25 grade of concrete

43

19 Comparison of Flexural strength of M3 mix and CC of M25 grade.

44

vii

SYMBOLS

C -Cement

CC -Conventional Concrete

CCA -Ceramic Coarse Aggregate

CFA -Ceramic Fine Aggregate

GP -Granite Powder

CA - Coarse Aggregate

FA - Fine Aggregate

NCA – Natural Coarse Aggregate

NFA – Natural Fine Aggregate

M -Mix

OPC – Ordinary Portland Cement

Fck - Characteristic Compressive strength

1

Chapter-1

…………………………………..INTRODUCTION

2

1. INTRODUCTION

1.1 CONCRETE

Concrete is a composite material consist of mainly water, aggregate, and

cement. The physical properties desired for the finished material can be attained by

adding additives and reinforcements to the concrete mixture. A solid mass that can be

easily moulded into desired shape can be formed by mixing these ingredients in certain

proportions. Over the time, a hard matrix formed by cement binds the rest of the

ingredients together into a single hard (rigid) durable material with many uses such as

buildings, pavements etc., The technology of using concrete was adopted earlier on

large-scale by the ancient Romans, and the major part of concrete technology was

highly used in the Roman Empire. The colosseum in Rome was built largely of

concrete and the dome of the pantheon is the World’s largest unreinforced concrete

structure. After the collapse of Roman Empire in the mid-18th century, the technology

was re-pioneered as the usage of concrete has become rare. Today, the widely used

man made material is concrete in terms of tonnage.

1.2 HISTORICAL BACKGROUND

Although high strength concrete is considered as relatively a new material, its

development has been gradually increasing over years. In 1950s, USA considered the

concrete with a compressive strength of 34mpa as high strength. In 1960’s, the

concrete with compressive strength 41mpa to 52mpa was used commercially. In the

early 1970’s, 62mpa concrete was been made. With in the world state of affairs,

however, within the last fifteen years, concrete of terribly high strength entered into the

construction sector of high-rise buildings and long span bridges. The compressive

strength over 110mpa has been thought-about by IS 456-2000 for the applications in

pre-stressed concrete members and cast-in-place buildings.

However, recently reactive concrete could be the one that having a compressive

strength of nearly 250mpa. It is fully supported by pozzolanic materials. The first

distinction between high-strength concrete and nominal-strength concrete refers to the

relation of utmost resistance offered by compressive strength of the concrete sample

for the application of any type of load. Though there is no correct separation between

3

high-strength concrete and normal-strength concrete, the Yankee Concrete Institute

defined the compressive strength greater than 42mpa as high strength concrete.

1.3 PROPERTIES OF CONCRETE

Generally the Concrete is a material having high compressive strength than to

tensile strength. As it has lower tensile stress it is generally reinforced with some

materials that are strong in tension like steel. The elastic behavior of concrete at low

stress levels is relatively constant but at higher stress levels start decreasing as matrix

cracking develops. Concrete has a low coefficient of thermal expansion and its

maturity leads to shrinkage.

Due to the shrinkage and tension, all concrete structures crack to some extent.

Concrete prone to creep when it is subjected to long-duration forces. For the

applications various tests be performed to ensure the properties of concrete correspond

to the specifications. Different strengths of concrete are attained by different mixes of

concrete ingredients, which are measured in psi or Mpa. Different strengths of concrete

are used for different purposes of constructions. If the concrete must be light weight a

very low-strength concrete may be used. The Lightweight concrete is achieved by the

addition of lightweight aggregates, air or foam, the side effect is that the strength of

concrete will get reduced. The concrete with 3000-psi to 4000-psi is oftenly used for

routine works. Although the concrete with 5000-psi is more expensive option is

commercially available as a more durable one. For larger civil projects the concrete

with 5000-psi is oftenly used. The concrete strength above 5000 psi was often used for

specific building elements. For example, the high-rise concrete buildings composed of

the lower floor columns may use 12,000 psi or more strength concrete, to keep the

columns sizes small.

Bridges may use concrete of strength 10,000 psi in long beams to minimize the

number of spans required. The other structural needs may occasionally require high-

strength concrete. The concrete of very high strength may be specified if the structure

must be very rigid, even much stronger than required to bear the service loads. For

these commercial reasons the concrete of strength as high as 19000-psi has been used.

4

1.4 LIGHT WEIGHT CONCRETE

One of the disadvantages of concrete is its high self weight. Density of normal

concrete will be in the range of order of 2200 to 2600 kg/m3. This heavy self weight

will make the concrete to some extent as an uneconomical structural material.

Attempts have been done in the past to reduce the self weight of concrete to increase

its efficiency of concrete as a structural material. The light weight concrete density

varies from 300 to 1850 kg/m3 by the use of various ingredients.

Basically there is only one method for making lightweight concrete, by

inclusion of air in concrete. This is achieved in actual practice by three different ways.

(i) By replacing the usual mineral aggregate by cellular porous or lightweight

aggregate.

(ii) Introducing the gas or air bubbles in mortar, known as aerated concrete.

(iii) Omitting the sand from the aggregates, called as No-fines concrete.

Lightweight concrete has become more popular in recent years and have more

advantages over the conventional concrete.

1.5 CONSTRUCTION WASTE IN INDIA:

In the present construction world, the solid waste is increasing day by day from

the demolitions of constructions. There is a huge usage of ceramic tiles in the present

constructions is going on and it is increasing in day by day construction field. Ceramic

products are part of the essential construction materials used in most buildings. Some

common manufactured ceramics include wall tiles, floor tiles, sanitary ware, household

ceramics and technical ceramics. They are mostly produced using natural materials that

contain high content of clay minerals. However, despite the ornamental benefits of

ceramics, its wastes among others cause a lot of nuisance to the environment. And also

in other side waste tile is also producing from demolished wastes from construction.

Indian tiles production is 100 million ton per year in the ceramic industry, about 15%-

30% waste material generated from the total production. This waste is not recycled in

any form at present, however the ceramic waste is durable, hard and highly resistant to

biological, chemical and physical degradation forces so, we selected these waste tiles

as a replacement material to the basic natural aggregate to reuse them and to decrease

the solid waste produced from demolitions of construction. Waste tiles and granite

5

powder were collected from the surroundings. There are some researchers are also

going on solid waste from construction to reuse them again in the construction to

reduce the solid waste and to preserve the natural basic aggregates. These researches

promotes to use the recycled aggregates in the concrete mix and they got good result

when adding some extent percentages of recycled aggregates in place of natural coarse

aggregate.

1.6 TILE AGGREGATE CONCRETE:

Crushed tiles are replaced in place of coarse aggregate and granite powder in

place of fine aggregate by the percentage of 10%. The fine and coarse aggregates were

replaced individually by these crushed tiles and granite powder and also in

combinations that is replacement of coarse and fine aggregates at a time in single mix.

For analyzing the suitability of these crushed waste tiles and granite powder in

the concrete mix, workability test was conducted for different mixes having different

percentages of these materials. Slump cone test is used for performing workability tests

on fresh concrete. And compressive strength test is also conducted for 3, 7 and 28 days

curing periods by casting cubes to analyze the strength variation by different

percentage of this waste materials. This present study is to understand the behavior and

performance of ceramic solid waste in concrete. The waste crushed tiles are used to

partially replace coarse aggregate by 10%, 20%, 30%, 40% and 50%. Granite powder

is also used partial replace fine aggregate by 10%.

1.6.1 ENVIRONMENTAL AND ECONOMIC BENEFITS OF TILE

AGGREGATE CONCRETE:

The usage of tile aggregate as replacement to coarse aggregate in concrete has

the benefits in the aspects of cost and reduction of pollution from construction

industry. The cost of concrete manufacturing will reduce considerably over

conventional concrete by including tile aggregate and granite powder since it is readily

available at very low cost and there-by reducing the construction pollution or effective

usage of construction waste.

6

CHAPTER – 2

………………………………LITERATURE REVIEW

7

2. LITERATURE REVIEW

2.1 General:

Being the major component of structure, many researches have been done on

concrete to improve its properties in every possible manner to develop a sustainable

concrete mass. The concrete can be strengthened only by the replacement of its

ingredients by better ones. Not only replacing by some material but using an waste

material makes the environment friendly at the same time more suitable to

construction. In this aspect lot of researches have been done on using the tile aggregate

in concrete which is a waste material directly from industry or indirectly from

demolition of a structure. The present study is focused only on the literature related to

usage of tile aggregate in concrete as a replacement to coarse aggregate. The details of

literature review are given below.

2.2 Literature Review:

Aruna D (2015)[1]: For tile waste based concrete, coarse aggregates were

replaced by 20mm down size, tile wastes by 0% , 5%, 10%, 15%, 20% and 25% and

also the cement is partially replaced by fly-ash. The average maximum compressive

strength of roof tile aggregate concrete is obtained at a replacement of 25%. A

reduction of 10-15% of strength is observed compared to conventional concrete at 25%

of roof tile aggregate replacement. The workability of roof tile waste concrete is in the

range of medium. Overall, the replacement of tiles in concrete is satisfactory for small

constructions.

Batriti Monhun R. Marwein (2016)[2]: The ceramic waste adopted is broken

tiles. Ceramic waste concrete (CWC)made with these tiles at 0%, 15%, 20%, 25% and

30%. M20 grade concrete is adopted; a constant water cement ratio of 0.48 is

maintained for all the concrete mixes. The characteristics properties of concrete such

as workability for fresh concrete, also Compressive Strength, Split Tensile Strength are

found at 3, 7 and 28 days. The paper suggests that the replacement of waste tile

aggregate should be in the range of 5-30% and also it is suitable to ordinary mixes like

M15 and M20.

8

B. TOPÇU AND M. CANBAZ (2010)[3]: The amount of tile waste generation

is enough to use in concrete as a replacement to coarse aggregate. The use of ceramic

tile waste has a positive effect on environment and in the cost aspects too. By the use

of tile aggregate, the self weight of concrete is reduced about 4% which makes the

structure economical. Coming to the strength aspect, the tile aggregate replacement has

a negative effect on both the compressive and split tensile strength of concrete. But this

paper studied maximum replacements of tile waste which can be further divided into

smaller percentages and can be utilized in concrete with desirable properties.

Julia García-González, Desirée Rodríguez-Robles, Andrés Juan-Valdés,

Julia Ma Morán-del Pozo and M. Ignacio Guerra-Romero (2014)[4]: The study

concentrates on the ceramic waste from industries in Spain. The concrete design is

done as per the Spanish concrete code and the recycled ceramic aggregates met all the

technical requirements imposed by current Spanish legislation. The ceramic aggregates

are replaced up to 100% replacement of coarse aggregate. Appropriate tests were

conducted to compare the mechanical properties with conventional concrete. The

ceramic ware aggregate concrete was exhibited a feasible concrete properties as like

the normal gravel concrete.

Md Daniyal and Shakeel Ahmad(2015)[5]: A large quantity of ceramic

materials goes into wastage during processing, transporting and fixing due to its brittle

nature. The crushed waste ceramic tiles were used in concrete as a replacement for

natural coarse aggregates with 10%, 20%, 30%, 40% and 50% of substitution in

concrete. The study states that the use of ceramic tile aggregate in concrete enhances

its properties and it has been observed an increase in both compression and flexural

strength.

N.Naveen Prasad (2016)[6]: Crushed waste tiles and Granite powder were used

as a replacement to the coarse aggregates and fine aggregate. The combustion of waste

crushed tiles were replaced in place of coarse aggregates by 10%, 20%, 30% and 40%

and Granite powder was replaced in place of fine aggregate by 10%, 20%, 30% and

40% without changing the mix design. M25 grade of concrete was designed to prepare

the conventional mix. Without changing the mix design different types of mixes were

prepared by replacing the coarse aggregates and fine aggregate at different percentages

of crushed tiles and granite powder. Experimental investigation is carried out. The

9

workability of concrete increased with increase in granite powder and it has been

observed that the compressive strength is maximum at 30% of coarse aggregate

replacement.

Parminder Singh and Dr. Rakesh Kumar Singla (2015)[7]: A research paper

on utilization of ceramic waste tiles from industries. A partial replacement to coarse

aggregate has been studied. Three different grades of concrete has been prepared and

tested. The results are not appropriate with the conventional but considering the

strength properties, it is advisable to use ceramic tile aggregate in concrete. It is finally

concluded that, about 20% of ceramic tile usage in M20 grade of concrete is

preferable.

Paul O. Awoyera (2016)[8]: The usage of ceramic tiles in concrete was

observed in this paper. In this, both the coarse and fine aggregates are replaced with

ceramic fine and ceramic coarse aggregates obtained from construction sites of Ota,

Lagos and Nigeria in various percentages. The ceramic fine and coarse aggregates are

replaced in conventional concrete individually and the strength parameters are studied.

Finally, it states that usage of ceramic waste in concrete gives considerable increase in

strength compared to conventional concrete.

P. Rajalakshmi (2016)[9]: Use of ceramic waste will ensure an effective

measure in maintaining environment and improving properties of concrete. The

replacement of aggregates in concrete by ceramic wastes will have major

environmental benefits. In ceramic industry about 30% production goes as waste. The

ceramic waste aggregate is hard and durable material than the conventional coarse

aggregate. It has good thermal resistance. The durability properties of ceramic waste

aggregate are also good. This research studied the fine aggregate replacement by

ceramic tiles fine aggregate accordingly in the range of 10% and coarse aggregate

accordingly in the range of 30%, 60%,100% by weight of M-30 grade concrete. This

paper recommends that waste ceramic tiles can be used as an alternate construction

material to coarse and fine aggregate in concrete irrespective of the conventional

concrete, it has good strength properties i.e., 10% CFA and 60% CCA being the

maximum strength.

10

Prof. Shruthi H. G. (2016)[10]: Ceramic tiles were obtained from

manufacturing industries, from construction and demolition sites, this cause’s

environmental pollution. The utilization of crushed tile as a coarse aggregate in

concrete would also have a positive effect on the economy. study, Ceramic tile waste

were used in concrete as a replacement for natural coarse aggregate with 0%, 10%,

20% and 30% of the substitution and M20 grade concrete were used. The concrete

moulds were casted and tested for Compressive Strength and Split Tensile Strength

after a curing period of 3, 7 & 28 days. The results indicate that, the maximum

compressive strength is obtained for the 30% replacement of ceramic tile aggregate

with natural coarse aggregate.

Wadhah M.Tawfeeq (2016)[11]: This study investigated the effects of using

crushed tiles (CT) as coarse aggregates in the concrete mix. The technology of

concrete recycling is well established in the U.S. Recycling of Portland cement

concrete, as well as asphaltic concrete, has been shown to be a cost-effective

alternative for road, street and highway construction. It includes not only the water

content and tiles but also the gravel/sand ratio. They concluded that as the water-

cement ratio decrease, the compressive strength increases. The paper consists of

replacement of crushed tiles to 50% and 100% only. The results show that replacement

of crushed tiles as coarse aggregate below 50% will have considerable properties.

11

CHAPTER – 3

…………..……………….MATERIALS AND PROPERTIES

12

3. MATERIALS AND PROPERTIES

3.1 MATERIALS USED

In this investigation, the following materials were used:

ÿ Ordinary Portland Cement of 53 Grade cement conforming to IS:

169-1989

ÿ Fine aggregate and coarse aggregate conforming to IS: 2386-1963.

ÿ Water.

3.1.1 CEMENT:

Ordinary Portland cement is the most common type of cement in general use

around the world as a basic ingredient of concrete, mortar, stucco, and most non-

specialty grout. It developed from other types of hydraulic lime in England in mid 19th

century and usually originates from limestone. It is a fine powder produced by heating

materials to form clinker. After grinding the clinker we will add small amounts of

remaining ingredients. Many types of cements are available in market. When it comes

to different grades of cement, the 53 Grade OPC Cement provides consistently higher

strength compared to others. As per the Bureau of Indian Standards (BIS), the grade

number of a cement highlights the minimum compressive strength that the cement is

expected to attain within 28 days. For 53 Grade OPC Cement, the minimum

compressive strength achieved by the cement at the end of the 28th day shouldn’t be

less than 53MPa or 530 kg/cm2. The color of OPC is grey color and by eliminating

ferrous oxide during manufacturing process of cement we will get white cement also.

Ordinary Portland Cement of 53 Grade of brand name Ultra Tech Company,

available in the local market was used for the investigation. Care has been taken to see

that the procurement was made from single batching in air tight containers to prevent it

from being effected by atmospheric conditions. The cement thus procured was tested

for physical requirements in accordance with IS: 169-1989 and for chemical

requirement in accordance IS: 4032-1988. The physical properties of the cement are

listed in Table – 1

13

Table-1 Properties of cement

3.1.2 FINE AGGREGATES:

Sand is a natural granular material which is mainly composed of finely divided

rocky material and mineral particles. The most common constituent of sand is silica

(silicon dioxide, or SiO2), usually in the form of quartz, because of its chemical

inertness and considerable hardness, is the most common weathering resistant mineral.

Hence, it is used as fine aggregate in concrete.

River sand locally available in the market was used in the investigation. The

aggregate was tested for its physical requirements such as gradation, fineness modulus,

specific gravity in accordance with IS: 2386-1963.The sand was surface dried before

use.

Table 2: Properties of Fine Aggregate

S.No Description Test Result

1 Sand zone Zone- III

2 Specific gravity 2.59

3 Free Moisture 1%4 Bulk density of fine aggregate (poured density)

Bulk density of fine aggregate (tapped density)

1385.16 kg/m3

1606.23 kg/m3

SL.NO Properties Test results IS: 169-1989

1. Normal consistency 0.32

2. Initial setting time 50min Minimum of 30min

3. Final setting time 320min Maximum of 600min

4. Specific gravity 3.14

5. Compressive strength

3days strength 29.2 Mpa Minimum of 27Mpa



14

3.1.3 COARSE AGGREGATES:

Crushed aggregates of less than 12.5mm size produced from local crushing

plants were used. The aggregate exclusively passing through 12.5mm sieve size and

retained on 10mm sieve is selected. The aggregates were tested for their physical

requirements such as gradation, fineness modulus, specific gravity and bulk density in

accordance with IS: 2386-1963. The individual aggregates were mixed to induce the

required combined grading. The particular specific gravity and water absorption of the

mixture are given in table.

Table 3: Properties of Coarse Aggregate

S.No Description Test Results

1 Nominal size used 20mm2 Specific gravity 2.9

3 Impact value 10.5

4 Water absorption 0.15%5 Sieve analysis 20mm

6 Aggregate crushing value 20.19%

7 Bulk density of coarse aggregate (Poured density) Bulk density of coarse aggregate (Tapped density)

1687.31kg/m31935.3 kg/m3

3.1.4 WATER:

Water plays a vital role in achieving the strength of concrete. For complete

hydration it requires about 3/10th of its weight of water. It is practically proved that

minimum water-cement ratio 0.35 is required for conventional concrete. Water

participates in chemical reaction with cement and cement paste is formed and binds

with coarse aggregate and fine aggregates. If more water is used, segregation and

bleeding takes place, so that the concrete becomes weak, but most of the water will

absorb by the fibers. Hence it may avoid bleeding. If water content exceeds

permissible limits it may cause bleeding. If less water is used, the required workability

is not achieved. Potable water fit for drinking is required to be used in the concrete and

it should have pH value ranges between 6 to 9

15

3.1.5 CERAMIC TILE AGGREGATE:

Broken tiles were collected from the solid waste of ceramic manufacturing unit

and from demolished building. The waste tiles were crushed into small pieces by

manually and by using crusher. The required size of crushed tile aggregate was

separated to use them as partial replacement to the natural coarse aggregate. The tile

waste which is lesser than 4.75 mm size was neglected. The crushed tile aggregate

passing through 16.5mm sieve and retained on 12mm sieve are used. Crushed tiles

were partially replaced in place of coarse aggregate by the percentages of 10%, 20%

and 30%, 40% and 50% individually and along with replacement of fine aggregate

with granite powder also.

Figure 1: Ceramic Tile Aggregate Sample

3.1.6 CERAMIC TILE-FINE AGGREGATE:

The tile aggregate after crushing results in some material which is finer in size.

This material is also included in concrete as replacement to fine aggregate since it is

also a waste and similar to that of sand. The aggregate which passes through the

4.75mm sieve is used as a partial replacement to fine aggregate of 10% in combination

with the coarse aggregate replacement.

Table4: Properties of Ceramic tile aggregate


1 Origin Rock Feldspar

2 Impact value of crushed tiles 12.5%

3 Specific gravity of crushed tiles 2.6

4 Specific gravity of tile powder (C.F.A) 2.5

5 Water absorption of crushed tiles 0.19%

6 Water absorption of Tile powder(C.F.A) 0.13%

16

3.1.7 GRANITE POWDER:

Since granite powder is obtained from crushing of granite rocks, the chemical

and mineral composition of granite is similar to that in cement and natural aggregates.

It is chosen to test the behavior of concrete along with the ceramic tile waste.

Table 5: Properties of Granite Powder


1 Specific gravity of granite powder 2.4

2 Water absorption of granite powder 0.10%

From Industry granite powder will be collect; 4.75 mm passed materials was

separated to use it as a partial replacement to the fine aggregate. Granite powder was

partially replaced in place of fine aggregate by the percentages of 10% along with

replacement of coarse aggregate with crushed tiles also.

17

CHAPTER-4

…………………………………………MIX DESIGN

18

4. CONCRETE MIX DESIGN (AS PER IS:10262-2009)

4.1 MIX DESIGN FOR M25 GRADE CONCRETE:

Characteristic compressive strength required in the field at 28 days: 20 Mpa

a) The mean strength , f1ck= fck + ks

=25 + (1.65x4)

= 31.6 Mpa

b) For OPC, adopting a water-cement ratio of 0.44

c) Form table 2 of IS: 10262-2009, maximum water content for 20 mm

aggregates is 186 liters.

Adopting a water content of 170 liters

d) Water-cement ratio=0.44

Cement Content, C= . =380 kg/m3

From IS: 456-2000, the minimum cement content is 300 kg/m3for severe

exposure.

Hence O.K.

e) From table 3 of IS:10262-2009, volume of coarse aggregate corresponding

to 20 mm size aggregate and fine aggregate (Zone III) for water-cement

ratio of 0.50 =0.64 %

In the present case water-cement ratio is 0.44. Therefore, volume of

coarse aggregate is required to be increased to decrease the fine aggregate

content. Thus, corrected proportion of volume of coarse aggregate for the

water-cement ratio of 0.44 = 0.652.

Volume of Fine Aggregates = 1- volume of C.A.

= 1- 0.652

= 0.348%

f) Volume of cement = . * =0.121%

Volume of water = * =0.17%

Volume of all in aggregates = 1- volume of (cement + water)

= 1- (0.121+0.17)

= 0.71 %

19

Mass of Coarse aggregate (C.A.) =e x Vol. of C.A. x Sp. gravity of C.A. x 1000

= 0.71*0.652*2.9*1000= 1340.57 kg/m3

Mass of Fine aggregate (F.A.) =e x Vol. of F.A. x Sp. gravity of F.A. x 1000

= 0.71*0.348*2.59*1000= 640 kg/m3

g) Mix proportions:C : FA : CA : WATER

380 : 640 : 1340.57 : 170

h) Site Corrections:

Water Absorption of C.A. = 1340.57 *.

= 2 kg/m3

Moisture content of F.A. = 640 *

= 6.4 kgWeight of C.A. = 1340.57-2

= 1338.57 kg/m3

Weight of F.A. = 640+6.4= 633.6 kg/m3

Adjusted water content = 170-2+6.4= 174.4 liters

i) Final quantities of materials after corrections/adjustments according to the

site:

Cement = 380 kg/m3

Fine aggregates = 634 kg/m3

Coarse aggregates = 1339 kg/m3

Water = 175 kg/m3

Final Mix Proportions:

C : FA : CA : WATER380 : 634 : 1339 : 175

1 : 1.67 : 3.52 : 0.44

20

For 10% CCA Aggregates:

Mix Proportions:

C : NFA : NCA : CCA : WATER

380 : 640 : 1207 : 120 : 174.5

1 : 1.7 : 3.18 : 0.31 : 0.44


Mix Proportions:


380 : 640 : 1074 : 241 : 174.5

1 : 1.7 : 2.83 : 0.63 : 0.44


Mix Proportions:


380 : 640 : 939 : 359 : 174.5

1 : 1.7 : 2.47 : 0.95 : 0.44


Mix Proportions:


380 : 640 : 804 : 481 : 174

1 : 1.7 : 2.12 : 1.26 : 0.44


Mix Proportions:


380 : 640 : 671 : 603 : 174

1 : 1.7 : 1.77 : 1.59 : 0.44

21

For 10% CCA+10%CFA Aggregates:

Mix Proportions:

C : NFA : CFA : NCA : CCA : WATER

380 : 574 : 62 : 1207 : 120 : 174

1 : 1.51 : 0.16 : 3.18 : 0.31 : 0.44


Mix Proportions:


380 : 574 : 62 : 1074 : 240.7 : 174

1 : 1.51 : 0.16 : 2.83 : 0.63 : 0.44


Mix Proportions:


380 : 574 : 62 : 939 : 359 : 174.5

1 : 1.51 : 0.16 : 2.47 : 0.95 : 0.44


Mix Proportions:


380 : 574 : 62 : 804 : 481 : 174

1 : 1.51 : 0.16 : 2.12 : 1.26 : 0.44

For 10% CCA+10%GP Aggregates:

Mix Proportions:

C : NFA : GP : NCA : CCA : WATER

380 : 574 : 59 : 1207 : 120 : 173.5

1 : 1.51 : 0.15 : 3.18 : 0.31 : 0.44

22


Mix Proportions:


380 : 574 : 59 : 1074 : 240.7 : 173.5

1 : 1.51 : 0.15 : 2.83 : 0.63 : 0.44


Mix Proportions:


380 : 574 : 59 : 939 : 359 : 173.5

1 : 1.51 : 0.15 : 2.47 : 0.95 : 0.44


Mix Proportions:


380 : 574 : 59 : 804 : 481 : 173.5

1 : 1.51 : 0.15 : 2.12 : 1.26 : 0.44

In this project the concrete grades M25 is designed with a suitable water-

cement ratio at which the desired concrete strength attained and also for various mix

replacements of both fine and coarse aggregate.

23

CHAPTER -5

………………………….EXPERIMENTAL DETAILS

24

5. EXPERIMENTAL DETAILS

This chapter deals with the various mix proportions adopted in carrying out the

experiments and experimental results obtained with respect to their workability, compressive

strength, split tensile strength, flexural strength and durability test.

5.1 GENERAL:

Different types of mixes were prepared by changing the percentage of replacement of

coarse and fine aggregates with crushed tiles, crushed tile powder and granite powder. Total

14 types of mixes are prepared along with conventional mixes. The coarse aggregates are

replaced by 10%, 20%, 30%, 40% and 50% of crushed tiles and the fine aggregate is replaced

by 10% of both crushed tile powder and granite powder individually but along with the coarse

aggregate. The details of mix designations are as follows:

Table 6: Details of aggregate replacement for mix codes

S.noMix

Code

Cement

(%)

Coarse Aggregate (%) Fine Aggregate (%)

Natural

Coarse

Aggregate

Crushed

TilesSand

Crushed

tile

powder

Granite

Powder

1 M0 100 100 0 100 0 0

2 M1 100 90 10 100 0 0

3 M2 100 80 20 100 0 0

4 M3 100 70 30 100 0 0

5 M4 100 60 40 100 0 0

6 M5 100 50 50 100 0 0

7 M6 100 90 10 90 10 0

8 M7 100 80 20 90 10 0

9 M8 100 70 30 90 10 0

10 M9 100 60 40 90 10 0

11 M10 100 90 10 90 0 10

12 M11 100 80 20 90 0 10

13 M12 100 70 30 90 0 10

14 M13 100 60 40 90 0 10

25

5.2 WORKABILITY:

The property of fresh concrete which is indicated by the amount of useful

internal work required to fully compact the concrete without bleeding or segregation in

the finished product. Workability is one of the physical parameters of concrete which

affects the strength and durability as well as the cost of labor and appearance of the

finished product. Concrete is said to be workable when it is easily placed and

compacted homogeneously i.e without bleeding or Segregation. Unworkable concrete

needs more work or effort to be compacted in place, also honeycombs &/or pockets

may also be visible in finished concrete.

DIFFERENT TEST METHODS FOR WORKABILITY MEASUREMENT:

Depending upon the water cement ratio in the concrete mix, the workability may

be determined by the following three methods.

1. Slump Test

2. Compaction Factor Test

3. Vee-bee Consistometer Test

In this study, the slump-cone test and compaction factor tests were carried out to

determine the workability of concrete. The test procedures are given below:

5.2.1 DETERMINATION OF WORKABILITY BY SLUMP-CONE TEST:

To find the workability of concrete thoroughly mix cement, sand And coarse

aggregate according to designed mix proportions to form a homogenous mix of

concrete.

Equipments Required for Concrete Slump Test:

Mould for slump test, non porous base plate, measuring scale, temping rod. The

mould for the test is in the form of the frustum of a cone having height 30 cm, bottom

diameter 20 cm and top diameter 10 cm. The tamping rod is of steel 16 mm diameter

and 60cm long and rounded at one end.

ß Clean the internal surface of the mould and apply oil.

ß Place the mould on a smooth horizontal non- porous base plate.

ß Fill the mould with the prepared concrete mix in 3 approximately equal layers.

26

ß Tamp each layer with 25 strokes of the rounded end of the tamping rod in a

uniform manner over the cross section of the mould. For the subsequent layers,

the tamping should penetrate into the underlying layer.

ß Remove the excess concrete and level the surface with a trowel.

ß Clean away the mortar or water leaked out between the mould and the base

plate.

ß Raise the mould from the concrete immediately and slowly in vertical

direction.

ß Measure the slump as the difference between the height of the mould and that

of height point of the specimen being tested.

Figure-2: Concrete Slump Test Procedure

Slump for the given sample= _____mm

When the slump test is carried out, following are the shape of the concrete slump that

can be observed:

Figure-3: Types of Concrete Slump Test Results∑ True Slump – True slump is the only slump that can be measured in the test.

The measurement is taken between the top of the cone and the top of the concrete

after the cone has been removed as shown in figure-1.

27

∑ Zero Slump – Zero slump is the indication of very low water-cement ratio,

which results in dry mixes. These type of concrete is generally used for road

construction.

∑ Collapsed Slump – This is an indication that the water-cement ratio is too

high, i.e. concrete mix is too wet or it is a high workability mix, for which a slump

test is not appropriate.

∑ Shear Slump – The shear slump indicates that the result is incomplete, and

concrete to be retested.

5.2.2 DETERMINATION OF WORKABILITY BY COMPACION

FACTOR TEST:

APPARATUS

Compaction factor apparatus’ trowels, hand scoop (15.2 cm long), a rod of steel

or other suitable material (1.6 cm diameter, 61 cm long rounded at one end) and a

balance.

Procedure:

ÿ To find the workability of concrete thoroughly mix cement, sand And coarse

aggregate according to designed mix proportions to form a homogenous mix of

concrete.

ÿ Find the Weight of empty cylinder (W1).

ÿ Fill the upper hopper with the freshly prepared concrete and after 2 minutes,

release the trap door of the hopper. Immediately after the concrete has come to

rest, open the trap door of the lower hopper and allow the concrete to fall into

the cylinder which brings the concrete to a partially compacted state.

ÿ Remove the excess concrete over the top of the cylinder by a trowel.

ÿ Clean the cylinder properly and weigh it with the partially compacted concrete

(W2).

ÿ Empty the cylinder and refill it with the same sample of concrete in four layers,

compaction of each layer by giving 25 blows with the tamping rod.

ÿ Level up the mi and weigh the cylinder with the fully compacted concrete

(W3).

28

COMPACTION FACTOR= (W2 - W1)/( W3 - W1)

Figure 4: Compaction factor Assembly

5.3 COMPRESSIVE STRENGTH PROCEDURE:Prepare the concrete in the required proportions and make the specimen

by filling the concrete in the desired mould shape of 15cm x 15cm x 15cm cube with

proper compaction, after 24 hrs place the specimen in water for curing.

∑ Take away the specimen from water when such as natural process time and

wipe out excess water from the surface.

∑ Take the dimension of the specimen to the closest 0.2m

∑ Clean the bearing surface of the testing machine

∑ Place the specimen within the machine in such a fashion that the load shall be

applied to the other sides of the cube forged.

∑ Align the specimen centrally on the bottom plate of the machine.

∑ Rotate the movable portion gently by hand so it touches the highest surface of

the specimen.

∑ Apply the load step by step while not shock and incessantly at the speed of

140kg/cm2/minute until the specimen fails

∑ Record the utmost load and note any uncommon options within the form of

failure.

COMPRESSIVE STRENGTH = (LOAD / AREA) in N/sq.mm

29

Figure 5: Compression testing of Cube Specimen

5.4 SPLIT TUBE TENSILE STRENGTH PROCEDURE:

Prepare the concrete in the required proportions and make the specimen

by filling the concrete in the desired mould shape of 10 cm x 30 cm cylinder with

proper compaction, after 24 hrs place the specimen in water for curing.

ÿ Take the wet specimen from water when seven days of natural process

ÿ Wipe out water from the surface of specimen

ÿ Draw diametrical lines on the 2 ends of the specimen to make sure that they're

on a similar axial place.

ÿ Note the weight and dimension of the specimen.

ÿ Set the compression testing machine for the specified vary.

ÿ Keep are plywood strip on the lower plate and place the specimen.

ÿ Align the specimen so the lines marked on the ends square measure vertical and

targeted over very cheap plate.

ÿ Place the other plywood strip above the specimen.

ÿ Bring down the upper plate to touch the plywood strip.

ÿ Apply the load incessantly while not shock at a rate of roughly 14-

21kg/cm2/minute (Which corresponds to a complete load of 9900kg/minute to

14850kg/minute)

ÿ Note the breaking load(P)

The splitting tensile strength is calculated using the formula=ଶగ

Where, P = applied load

D = diameter of the specimen

L = length of the specimen

30

Figure 6: Compression testing machine

Figure 7: Split Tensile Testing and Specimen (Cylinders)

5.5 FLEXURAL STRENGTH TEST:

Prepare the concrete in the required proportions and make the specimen

by filling the concrete in the desired mould shape of 10x10x50cm prism with proper

compaction, after 24 hrs place the specimen in water for curing.

ÿ Remove the specimens from water after specified curing time and wipe out

excess from the surface.

ÿ Leave the specimen in the atmosphere from 24hours before testing.

ÿ The specimen is then placed in the machine in such a manner that the load is

applied to the uppermost surface as cast in the mould, along the two lines

spaced 20.0cm a part. The axis of the specimen is carefully aligned with the

axis of loading devices.

ÿ The load is then applied without shock and increasing continuously at a rate of

400kg/min.

ÿ Since a < 20.0cm but > 17.0 for 15.0cm specimen or < 13.3 cm but > 11.0cm for 10.0cm

specimen.

31

The Flexural strength or the modulus of rupture is calculated using the

formula:

= ଷୢమ

Where,

P=load applied at failure

b=Width of specimen

d=Depth of the specimen

a= the distance between the line of fracture and the nearer support,

measured on the center line of the tensile side of the specimen

Figure 8: Flexural Testing of Beam Specimen

32

CHAPTER – 6

………………………..……………..TEST RESULTS

33

6. TEST RESULTS

6.1 WORKABILTY:

The ideal concrete is the one which is workable in all conditions i.e, can

prepared easily placed, compacted and moulded. In this chapter, the workability is

assessed by two methods as follows:

6.1.1 Slump Cone Test:. The test was conducted for fresh concrete prepared before

the moulding process. A total of 14 concrete mixes are prepared at different times.

Workability Results obtained from slump cone test for M25 grade of concrete is

shown in table 7.

Table 7: Test results from slump cone test for workability in mm

The workability from the slump cone test is in increasing manner as the mix

proportion replacement increasing. The workability range of concrete increasing as

mentioned while being in medium range overall.

S.NoMix

Designation

Aggregate Replacements % (CCA+CFA+GP )

Workability (mm)

M25

1 M0 0+0+0 62

2 M1 10+0+0 65

3 M2 20+0+0 68

4 M3 30+0+0 73

5 M4 40+0+0 78

6 M5 50+0+0 81

7 M6 10+10+0 63

8 M7 20+10+0 67

9 M8 30+10+0 71

10 M9 40+10+0 76

11 M10 10+0+10 72

12 M11 20+0+10 79

13 M12 30+0+10 86

14 M13 40+0+10 102

34

6.1.2 Compaction Factor Test:

The compaction factor test was conducted to the same mix that tested for

workability by slump cone. The results obtained from the compaction factor test for

the workability of various mixes of replacements of M25 grade of concrete are

tabulated as follows:

Table 8: Test results of compaction factor test for workability

The workability of M25 grade of concrete by compaction factor test is similar

to that of slump cone test. The pattern of increment for the mixes is quite same which

will be discussed in detail further.

6.2 Compressive strength:

A total of 42 cubes of size 150 x 150 x 150mm were casted and tested for 7

days, 14 days and 28 days testing each of 13 specimens after conducting the

workability tests. The results are tabulated below:

S.NoMix

Designation


Compaction Factor

M25

1 M0 0+0+0 0.82

2 M1 10+0+0 0.84

3 M2 20+0+0 0.855

4 M3 30+0+0 0.87

5 M4 40+0+0 0.89

6 M5 50+0+0 0.93

7 M6 10+10+0 0.83

8 M7 20+10+0 0.86

9 M8 30+10+0 0.88

10 M9 40+10+0 0.91

11 M10 10+0+10 0.85

12 M11 20+0+10 0.90

13 M12 30+0+10 0.93

14 M13 40+0+10 0.95

35

Table: 09: Compressive strength results of M25 grade of concrete for 7, 24 and 28 days

Figure 9: Comparison of Compressive strength of M25 at 7 days

0

5

10

15

20

25

30

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13

Mix Designation

CC

7 days

S.NoMix

Designation


Compressive strength of M25 grade in N/mm2

7 days 14 days 28 days

1 M0 0+0+0 20.57 28.54 33.18

2 M1 10+0+0 24.09 31.39 36.5

3 M2 20+0+0 26.27 32.8 39.5

4 M3 30+0+0 28.05 37.53 43.14

5 M4 40+0+0 23.96 31.77 37.16

6 M5 50+0+0 22.22 28.88 34.18

7 M6 10+10+0 21.98 29 35.17

8 M7 20+10+0 23.41 31.6 37.169 M8 30+10+0 26.5 34.4 39.510 M9 40+10+0 20.01 26.65 32.9

11 M10 10+0+10 21.05 28.64 34.5

12 M11 20+0+10 24.6 33.58 39.5

13 M12 30+0+10 28.1 38.4 42.14

14 M13 40+0+10 21.32 28.09 33.84

36

Figure 10: Compressive strength of M25 concrete at 14 days

Figure 11: Compressive strength of M25 concrete at 28 days

The results obtained from compression testing gives comprehensive outcome of

the project as the replacement the replacement of tile aggregates produces a concrete

with suitable properties as conventional.

0

5

10

15

20

25

30

35

40

45

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13

Mix designation

CC

14 days

0

5

10

15

20

25

30

35

40

45

50

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13

Mix Designation

CC

28 days

37

6.3 Split Tensile strength:

The split tensile strength obtained by testing the cylindrical specimen for M25

grade of concrete to all the mixes designed for various replacements are given below:

Table 10: Split tensile strength results for M25 grade of concrete

Figure 12: Split tensile strength for M25 at 7days

1.6

1.62

1.64

1.66

1.68

1.7

1.72

1.74

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13

CC

Series 2

S.NoMix

Designation


Split Tensile Strength of M25 grade in N/mm2

7 days 14 days 28 days1 M0 0+0+0 1.67 2.18 2.562 M1 10+0+0 1.67 2.19 2.613 M2 20+0+0 1.69 2.24 2.615

4 M3 30+0+0 1.71 2.26 2.65

5 M4 40+0+0 1.69 2.21 2.59

6 M5 50+0+0 1.67 2.16 2.52

7 M6 10+10+0 1.69 2.18 2.57

8 M7 20+10+0 1.69 2.21 2.619 M8 30+10+0 1.70 2.23 2.64

10 M9 40+10+0 1.65 2.19 2.50

11 M10 10+0+10 1.68 2.20 2.5812 M11 20+0+10 1.71 2.21 2.6513 M12 30+0+10 1.72 2.24 2.6614 M13 40+0+10 1.69 2.20 2.62

38

Figure 13: Split tensile strength of M25 concrete at 14days

Figure 14: Split tensile strength of M25 concrete at 28days

The strength i.e., the tensile strength, from the results is clearly in an increment way

compared to the conventional concrete at all the curing ages of 7days, 14 days and 28 days.

The replacement of aggregates by various proportions has positive effect on the strength of

the concrete.

2.12

2.14

2.16

2.18

2.2

2.22

2.24

2.26

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13

CC

Series 2

2.4

2.45

2.5

2.55

2.6

2.65

2.7

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13

CC

Series 2

39

6.4 Flexural Strength:

The flexural test was conducted for M3 mix only since it has the highest compressive and split tensile strength to compare it with conventional i.e.,M0. A Total of 6 beams were casted and tested as follows:

Table 11:Flexural test results for 7, 14 and 28 days

S.No Grade of concrete Mix CodeFlexural Strength in N/mm2

7 days 14 days 28 days

2 M25 M0 7.92 8.98 9.95

3 M25 M3 8.88 9.15 10.28

40

CHAPTER – 7

…………………………………………..DISCUSSION

41

7. DISCUSSION

7.1 Workability:

7.1.1 Slump Cone Test:

Figure 15: Comparison of workability for different mixes of M25 Grade

From the results it is observed that the workability is increased by an amount of

4.8%, 9.6%, 17.7%, 25.8%, 30.6%, 1.6%, 8%, 14.5%, 22.5%, 16.1%, 27.4%, 38.7%

and 64.5% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 mixes

respectively over conventional M25 concrete grade(M0).

7.1.2 Compaction Factor Test:

Figure 16: Comparison of compaction factor for various mixes with conventional concrete for M25 grade

0

20

40

60

80

100

120

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13

Mix Codes

C.C

C.C.A

C.C.A+C.F.A

C.C.A+G.P

0.75

0.8

0.85

0.9

0.95

1

M0 M1 M2 M3 M4 M5 M6 M7 M8 M9 M10M11M12M13mix Designations

CC

CCA

CCA+CFA

CCA+GPCC

42

From the results it is observed that the workability is increased by an amount of

2.4%, 4.3%, 6.1%, 8.5%, 13.4%, 1.2%, 4.9%, 7.3%, 10.9%, 3.6%, 9.7%, 13.4% and

15.8% and 64.5% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13

mixes respectively over conventional M25 concrete grade(M0).

The workability from both slump cone and compaction factor tests is similar in

increasing manner. The workability increases with increase in ceramic coarse tile

aggregate but a little deviation with the addition of ceramic fine aggregate. The

addition of granite powder has significant improvement on the workability of concrete.

7.2 Compressive strength:

Figure 17: Strength comparison at 7, 14 and 28 days for M25 concrete

The Compressive strength of concrete varies as 17.11%, 27.7%, 36.36%,

16.4%, 8.02%, 6.85%, 13.8%, 28.82%, -2.72%, 2.33%, 19.59%, 36.6% and 3.64% for

M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12 and M13 compared with

the conventional concrete after 7days of curing.

The Compressive strength of concrete varies as 9.99%, 14.92%, 31.49%,

11.31%, 1.19%, 1.61%, 10.72%, 20.53%, -6.62%, 0.3%, 17.65%, 34.54% and -1.57%

for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12 and M13 compared

with the conventional concrete after 14days of curing.

The Compressive strength of concrete varies as 10%, 19.04%, 30%, 11.99%,

3.01%, 5.99%, 11.99%, 19.04%, 0.8%, 3.97%, 19.04%, 27% and 1.98% for M1, M2,

05

10

1520

2530

354045

50

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13

Mix Codes

7days

14days

28days

43

M3, M4, M5, M6, M7, M8, M9, M10, M11, M12 and M13 compared with the

conventional concrete after 28days of curing.

On comparing the strengths of all mixes, M3, M8 and M12 has the highest i.e.,

30% replacement of coarse aggregate. The addition of granite powder has positive

effect on strength while improving the workability also.

7.3 SPLIT TENSILE STRENGTH:

Figure 18: Split tensile strength for M25 concrete mixes

The split tensile strength of concrete varies as 0%, 1.2%, 2.4%, 1.2%, 0%,

1.2%, 1.2%, 1.8%, -1.2%, 0.59%, 2.4%, 3.0% and 1.2% for M1, M2, M3, M4,

M5,M6,M7,M8,M9,M10,M11,M12,M13 compared with the conventional concrete

after 7days of curing.

The split tensile strength of concrete varies as 0.46%, 2.7%, 4.6%, 1.4%, -2.7%,

0%, 1.37%, 2.3%, 0.46%, 0.92%, 1.37%, 2.75% and 0.92% for M1, M2, M3, M4,



The split tensile strength of concrete varies as 1.95%, 5%, 7%, 1.18%, -1.6%,

0.39%, 1.9%, 3.1%, -2.3%, 0.78%, 3.5%, 3.9% and 2.3% for M1, M2, M3, M4,



0

0.5

1

1.5

2

2.5

3

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13Mix Codes

7days

14days

28days

44

7.4 Flexural Test:

The flexural test is conducted for the mixe, which has maximum

compressive strength and split tensile strength i.e., M3 (30% of CCA) and the results

are plotted below:

Figure 19: Flexural strength comparison M25 grades for M3 mix with conventional

The strength gaining of beam is linearly increasing. The strength variation for

three grades is in increasing manner. The flexural strength of conventional varies as

12.6%, 1.8% and 3.32% of increment at 7, 14 and 28 days respectively for M3 mix.

The 7days strength gain is quite same for three grades but after 14 days M25 has the

rapid growth of strength. Even though we are not comparing with the conventional

concrete but the attainment of strength for is satisfactory.

0

2

4

6

8

10

12

7Days 14 Days 28 DaysAge Of Concrete

CC

M3

45

CHAPTER -8

……………………SUMMARY AND CONCLUSION

46

8. SUMMARY AND CONCLUSION

8.1 General:

The basic objective of the study is to prepare a concrete much more stable and

durable than the conventional by replacing aggregates both coarse and fine. Mix

designs for all the replacements of materials has done and a total of 90 specimens (42

cubes, 42 cylinders, 6 beams) are prepared and tested in the aspect of strength

calculation and also comparisons has done.

8.2 Conclusions:

The following conclusions are made based on the experimental investigations

on compressive strength, split tensile strength and flexural strength considering

the―environmental aspects also:

ÿ The workability of concrete increases with the increase in tile aggregate

replacement. The workability is further increased with the addition of granite

powder which acts as admixture due to its chemical properties.

ÿ The properties of concrete increased linearly with the increase in ceramic

aggregate up to 30% replacement later it is decreased linearly.

ÿ M3 mix of concrete produced a better concrete in terms of compressive

strength, split tensile strength and flexural strength than the other mixes. But

the mixes up to 50% of ceramic coarse aggregate can be used.

ÿ The usage of ceramic fine aggregate has some effect on the properties of

concrete in decrement manner.

ÿ Granite powder using as fine aggregate has more influence on the concrete

than the ceramic fine because of chemical composition it is made of and works

as admixture.

ÿ The addition of granite powder along with the ceramic coarse aggregate

improves the mechanical properties of concrete slightly since mineral and

chemical properties are of granite.

ÿ The split tensile strength of ceramic tile aggregate is very much in a straighter

path compared to the conventional grades of concrete.

47

FUTURE SCOPE OF WORK

There is a vast scope of research in the recycled aggregate usage in concrete

especially ceramic tile wastes in the future. The possible research investigations that

can be done are mentioned below:

∑ The usage of marble floor tiles can be studied as it is similar to that of tile

waste generation and also it is quite hard compared to the natural crushed stones using

in conventional concrete.

∑ The usage of granite powder in concrete as an admixture to improve the

workability of concrete and the strength parameters can also be studied at various

percentages.

∑ A combination of different tiles (based on their usage) in different proportions

in concrete and their effects on concrete properties like strength, workability etc can be

determined.

∑ By the use of ceramic tile aggregate in concrete, the physical properties like

durability, permeability etc., can be analyzed to prepare a concrete with more

advantageous than conventional concrete.

∑ A study on properties of concrete made with combination of recycled aggregate

and tile aggregate in different proportions can be investigated to enhance the concrete

properties and also to reduce the pollution or waste generation from construction

industry.

∑ A further investigation on the use of granite powder alone as a replacement to

fine aggregate can be carried out the possibility of using such waste generation from

industries.

∑ The mechanical properties of concrete with marble aggregate (waste) either

from manufacturing units or from construction demolition can be investigated to

improve the properties like permeability; resistance to sound can also be studied.

∑ Ceramic tile aggregate in high strength concrete can be studied further to check

the possibility of its use in high rise buildings.

48

REFERENCES

1. Aruna D, Rajendra Prabhu, Subhash C Yaragal, Katta Venkataramana

IJRET:eISSN: 2319-1163 | pISSN: 2321-7308.

2. Batriti Monhun R. Marwein, M. Sneha, I. Bharathidasan International Journal

of Scientific & Engineering Research, Volume 7, Issue 4, April-2016 ISSN 2229-5518.

3. Iranian Journal of Science & Technology, Transaction B, Engineering, Vol. 31,

No. B5, pp 561-565 Printed in The Islamic Republic of Iran, 2007

4. Department of Engineering and Agricultural Sciences, University of Leon,

Avenida Portugal 41, Leon 24071, Spain.

5. International Journal of Innovative Research in Science,Engineering and

TechnologyISSN(Online): 2319-8753 ISSN (Print): 2347-6710.

6. N.Naveen Prasad, P.Hanitha, N.C.Anil IOSR Journal of Mechanical and

Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 13,

Issue 6 Ver. V (Nov. - Dec. 2016), PP 168-176.

7. Journal of Multidisciplinary Engineering Science and Technology (JMEST)

ISSN: 3159-0040 Vol. 2 Issue 11, November - 2015

8. Paul O. Awoyera , Julius M. Ndambuki , Joseph O. Akinmusuru , David O.

Omole-4048 2016 Housing and Building National Research Center. Production and

hosting by Elsevier B.V. 15 November 2016)

9. P.Rajalakshmi, Dr.D.Suji, M. Perarasan, E.Niranjani International Journal of

Civil and Structural Engineering Research ISSN 2348-7607 (Online) Vol. 4, Issue 1,

pp: (114-125), Month: April 2016 - September 2016.

10. Prof. Shruthi. H. G, Prof. Gowtham Prasad. M. E Samreen Taj, Syed Ruman

Pasha International Research Journal of Engineering and Technology (IRJET) e-ISSN:

2395 -0056 Volume: 03 Issue: 07 | July-2016 p-ISSN: 2395-0072)

11. Int'l Journal of Research in Chemical, Metallurgical and Civil Engg. (IJRCMCE)

Vol. 3, Issue 2 (2016) ISSN 2349-1442 EISSN 2349-1450 .

International Journal of Engineering Research-OnlineA Peer Reviewed International Journal

Articles available online http://www.ijoer.in; [email protected]

Vol.5., Issue.3, 2017May-June

RESEARCH ARTICLE ISSN: 2321-7758

PARTIAL REPLACEMENT OF AGGREGATE WITH CERAMIC TILE IN CONCRETE

G.SAI CHAND1, P.RAVI KUMAR2

1 M.Tech student, IV semester, PACE Institute of technology and sciences, Ongole 2Assistant Professor, Department of Civil Engineering, PACE Institute of technology

ABSTRACTDue to the day to day innovations and development in construction field, the use of natural aggregates is increased tremendously and at the same time, the production of solid wastes from the demolitions of constructions is also quite high. Because of thesereasons the reuse of demolished constructional wastes like ceramic tile and granite powder came into the picture to reduce the solid waste and to reduce the scarcity of natural aggregates for making concrete. The ceramic tile waste is not only occurring from the demolition of structures but also from the manufacturing unit. Studies show that about 20-30% of material prepared in the tile manufacturing plants are transforming into waste. This waste material should have to be reused in order to deal with the limited resource of natural aggregate and to reduce the construction wastes.

Crushed waste ceramic tiles, crushed waste ceramic tile powder and Granite powder are used as a replacement to the coarse aggregates and fine aggregate. The ceramic waste crushed tiles were partially replaced in place of coarse aggregates by 10%, 20%, 30%, 40% and 50%. Granite powder and ceramic tile powder were replaced in place of fine aggregate by 10% along with the ceramic coarse tile. M15, M20 and M25 grades of concrete were designed and tested. The mix design for different types of mixes were prepared by replacing the coarse aggregates and fine aggregate at different percentages of crushed tiles and granite powder. Experimental investigations like workability, Compressive strength test, Split tensile strength test, Flexural strength test for different concrete mixes with different percentages of waste crushed and granite powder after 7, 14 and 28 days curing period has done. It has been observed that the workability increases with increase in the percentage of replacement of granite powder and crushed tiles increases. The strength of concrete also increases with the ceramic coarse tile aggregate up to 30% percentage.

Keywords: Crushed tiles, Compressive strength, Flexural strength, Granite powder,Split Tensile strength.

1. Introduction

1.1 General: In the present construction world, the solid waste is increasing day by day from the demolitions of constructions. There is a huge usage of ceramic tiles in the present constructions is going on and it is increasing in day by day construction field. Ceramic products are part of the essential

construction materials used in most buildings. Some common manufactured ceramics include wall tiles, floor tiles, sanitary ware, household ceramics and technical ceramics. They are mostly produced using natural materials that contain high content of clay minerals. However, despite the ornamental benefits of ceramics, its wastes among others cause a lot of

173 G.SAI CHAND, P.RAVI KUMAR




disturbance to the environment. And also in other side waste tile is also producing from demolished wastes from construction. Indian tiles production is 100 million ton per year in the ceramic industry, about 15%-30% waste material generated from the total production. This waste is not recycled in any form at present, however the ceramic waste is durable, hard and highly resistant to biological, chemical and physical degradation forces so, we selected these waste tiles as a replacement material to the basic natural aggregate to reuse them and to decrease the solid waste produced from demolitions of construction. Waste tiles and granite powder were collected from the surroundings.

1.2 Crushed Tile Concrete: Crushed tiles arereplaced in place of coarse aggregate and granite powder in place of fine aggregate by the percentage of 10%. The fine and coarse aggregates were replaced individually by these crushed tiles and granite powder and also in combinations that is replacement of coarse and fine aggregates at a time in single mix.

For analyzing the suitability of these crushed waste tiles and granite powder in the concrete mix, workability test was conducted for different mixes having different percentages of these materials. Slump cone test is used for performing workability tests on fresh concrete. And compressive strength test is also conducted for 3, 7 and 28 days curing periods by casting cubes to analyze the strength variation by different percentage of this waste materials. This present study is to understand the behavior and performance of ceramic solid waste in concrete. The waste crushed tiles are used to partially replace coarse aggregate by 10%. Granite powder is also used partial replace fine aggregate by 10%.

1.3 ENVIRONMENTAL AND ECONOMIC BENEFITS OF TILE AGGREGATE CONCRETE: The usage of tileaggregate as replacement to coarse aggregate in concrete has the benefits in the aspects of cost and reduction of pollution from construction industry. The cost of concrete manufacturing will reduce considerably over conventional concrete by including tile aggregate and granite powder since it is readily available at very low cost and there-by reducing the construction pollution or effective usage of construction waste.

2. MATERIALS AND PROPERTIES2.1 MATERIALS USED

In this study, the following materials wereused:

∑ OPC of 53 Grade cement conforming to IS: 169-1989

∑ Fine aggregate and coarse aggregate conforming to IS: 2386-1963.

∑ Water. 2.1.1 CEMENT: Ordinary Portland Cement of 53

Grade of brand name Ultra Tech Company, available in the local market was used for the investigation. Care has been taken to see that the procurement was made from single batching in air tight containers to prevent it from being effected by atmospheric conditions. The cement thus procured was tested for physical requirements in accordance with IS: 169-1989 and for chemical requirement in accordance IS: 4032-1988. The physical properties of the cement are listed in Table – 1Table-1 Properties of cement

IS: 169-results 1989

Normal

Initialsetting time

320min oftime

600minSpecific

Mpa

Mpa28days

Mpa

2.1.2 FINE AGGREGATES: River sand locally availablein the market was used in the investigation. The aggregate was tested for its physical requirements such as gradation, fineness modulus, specific gravity in accordance with IS: 2386-1963.The sand was surface dried before use.





Table 2: Properties of Fine AggregateS.No Description Test Result

1 Sand zone Zone- III


3 Free Moisture 1%

4 Bulk density of fine 1385.16aggregate (poured density) kg/m3

Bulk density of fine 1606.23aggregate (tapped density) kg/m3

2.1.3 COARSE AGGREGATES: Crushed aggregates of20mm size produced from local crushing plants were used. The aggregate exclusively passing through 25mm sieve size and retained on 10mm sieve is selected. The aggregates were tested for their physical requirements such as gradation, fineness modulus, specific gravity and bulk density in accordance with IS: 2386-1963. The individual aggregates were mixed to induce the required combined grading. The particular specific gravity and water absorption of the mixture are given in table.

Table 3: Properties of Coarse AggregateS.No Description Test Results

1 Nominal size used 20mm


3 Impact value 10.5

4 Water absorption 0.15%5 Sieve analysis 20mm

6 Aggregate crushing value 20.19%

7 Bulk density coarse 1687.31kg/m3aggregate (Poured 1935.3 kg/m3density)Bulk density coarseaggregatedensity)

2.1.4 WATER: Water plays a vital role in achievingthe strength of concrete. It is practically proved that minimum water-cement ratio 0.35 is required for conventional concrete. Water participates in chemical reaction with cement and cement paste is formed and binds with coarse aggregate and fine

aggregates. If more water is used, segregation and bleeding takes place, so that the concrete becomes weak, but most of the water will absorb by the fibers Potable water fit for drinking is required to be used in the concrete and it should have pH value ranges between 6 to 9

2.1.5 CERAMIC TILE AGGREGATE: Broken tiles werecollected from the solid waste of ceramic manufacturing unit and from demolished building. The waste tiles were crushed into small pieces by manually and by using crusher. The required size of crushed tile aggregate was separated to use them as partial replacement to the natural coarse aggregate. The tile waste which is lesser than 4.75mm size was neglected. The crushed tile aggregate passing through 16mm sieve and retained on 12.5mm sieve are used. Crushed tiles were partially replaced in place of coarse aggregate by the percentages of 10%, 20% and 30%, 40% and 50% individually and along with replacement of fine aggregate with granite powder also.

Figure 1: Ceramic Tile Aggregate Sample 2.1.6 CERAMIC TILE-FINE AGGREGATE: The tile aggregate after crushing results in some material which is finer in size. This material is also included in concrete as replacement to fine aggregate since it is also a waste and similar to that of sand. The aggregate which passes through the 4.75mm sieve is used as a partial replacement to fine aggregate of 10% in combination with the coarse aggregate replacement.Table4: Properties of Ceramic tile aggregate

Results

of crushed 12.50%tiles





Specific3

Specific

4

(C.F.A)

5 absorption of 0.19%

6 absorption of 0.13%

2.1.7 GRANITE POWDER: Since granite powder isobtained from crushing of granite rocks, the chemical and mineral composition of granite is similar to that in cement and natural aggregates. It is chosen to test the behaviour of concrete along with the ceramic tile waste.

Table 5: Properties of Granite Powder

S.No DescriptionTestResults

1Specific gravity of granite

2.4powder

2Water absorption of granite

0.10%powder

From Industry granite powder will be collect; 4.75 mm passed materials was separated to use it as a partial replacement to the fine aggregate. Granite powder was partially replaced in place of fine aggregate by the percentages of 10% along with replacement of coarse aggregate with crushed tiles also.

3. Methodology: The methodology of research includes the collection of required materials from the various sources and determining the properties of all the materials gathered. Designing the concrete mix proportions for all types of replacements and Preparation of the concrete mix, Moulding and curing. The testing of concrete includes Slump cone test, compaction factor test for determining workability of concrete in fresh state and compressive strength, split tensile test and flexural test for determining the strength of concrete in hardened state.

Total 13 types of mixes are prepared along with conventional mixes. The coarse aggregates are replaced by 10%, 20%, 30%, 40% and 50% of

crushed tiles and the fine aggregate is replaced by 10% of both crushed tile powder and granite powder individually but along with the coarse aggregate. The details of mix designations are as follows:Details of aggregate replacement for mix codes

Coarse Aggregate (%) Fine Aggregate (%)Cement Crushed

(%) tilepowder

1 M0 100 0 0 02 M1 10 0 03 M2 20 0 04 M3 30 0 05 M4 40 0 06 M5 50 0 07 M6 10 90 08 M7 20 90 09 M8 30 90 0

10 M9 40 90 011 10 90 012 20 90 013 30 90 014 40 90 0

4. CONCRETE MIX DESIGN

Since, the properties of concrete are dependent on the quantities of materials used, the concrete mixes for desired strength are calculated. The mix design for M15, M20 and M25 grades of concrete for all the replacements are determined as per the IS: 10262-2009 code.4.1 MIX DESIGN FOR M15 GRADE CONCRETE:

Final Mix Proportions:

4.2 MIX DESIGN FOR M20 GRADE CONCRETE: Final Mix Proportions:

4.3 MIX DESIGN FOR M25 GRADE CONCRETE: Final Mix Proportions:

5. TEST RESULTS5.1 WORKABILTY

5.1.1 Slump Cone Test: The pattern of workabilityobtained is True Slump. Workability Results obtained from slump cone test for various grades of concrete are shown in following





Table 7: Test results from slump cone test for workability in mm

Aggregate

Workability (mm)S.No Designat

ion

A+GP )

10+10+020+10+030+10+040+10+010+0+1020+0+1030+0+1040+0+10 102

5.1.2 Compaction Factor Test: The results obtainedfrom the compaction factor test for the workability of various mixes of replacements of M15, M20 and M25 grades of concrete are tabulated as follows:

Table 8: Test results of compaction factor test for workability

Aggregate

Compaction FactorS.No Designat

ion

A+GP )

0.820.82 0.840.820.85 0.870.86 0.890.87 0.93

10+10+0 0.82 0.8320+10+0 0.82 0.8630+10+0 0.84 0.8840+10+0 0.84 0.9110+0+10 0.84 0.8520+0+10 0.87 0.930+0+10 0.91 0.9340+0+10 0.92 0.95

Comparison of workability for different mixes of all Grade

5.2 Compressive strength: A total of 126 cubes ofsize 150 x 150 x 150 mm were cast for 7 days, 14

days and 28 days testing. For each grade of concrete 42 cubes are tested, 14 each for 7, 14 and 28 days and the results are tabulated below:S.No MIX Grade Compressive strength at

Code Of 7 days 14 28Conc days days

1 M0 M15 12.96 18.06 21.252 M0 M20 16.56 22.87 28.03 M0 M25 20.57 28.54 33.18

Strength gain and comparison of M15 concrete at 7, 14 and 25 days

Strength gain and comparison of M20 concrete at 7, 14 and 25 days

Strength comparison at 7, 14 and 28 days for M25 concrete

5.3 Split Tensile strength: The split tensile strengthobtained by testing the cylindrical specimen for M15, M20 and M25 grades of concrete to all the mixes designed for various replacements are given in graphical representation as follows:





S.No MIX Grade Compressive strength 6. DISCUSSIONCode Of at

Conc 7 14 28days days days

1 M0 M15 1.19 1.44 1.732 M0 M20 1.33 1.76 2.143 M0 M25 1.67 2.18 2.56

Comparison of split tensile strength variation for M15 concrete


From the graph it is observed that the workability is increased by an amount of 5.4%, 12.7%, 21.8%, 30.9%, 41.8%, 3.6%, 10.9%, 18.2%, 25.5%,21.8%, 34.5%, 47.27%, 60% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 mixes respectively over conventional M15 concrete grade(M0).

Split tensile strength development for M20 concrete mixes

Split tensile strength for M25 concrete mixes 5.4 Flexural Test:

The flexural test is conducted for the mixes, which has maximum compressive strength and split tensile strength i.e., M3 (30% of CCA) and the results are plotted below:Table 15: Flexural test results for 7, 14 and 28 days

Grade of Mix Flexural Strength in N/mm2

S.No 14concrete Code 7 days 28 days

days

1 M15 M3 3.78 4.67 5.182 M20 M3 6.69 6.95 7.36

3 M25 M3 8.88 9.15 10.28

Figure 28: Comparison of workability for different mixes of M20 Grade with the conventional concrete

From the graph it is observed that the workability is increased by an amount of 5.1%, 8.6%, 15.5%, 24.1%, 34.5%, 0%, 5.1%, 12%, 18.9%, 15.5%, 31%, 46.5% and 63.8% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12, M13 mixes respectively over conventional M20 concrete grade(M0).






From the results it is observed that the workability is increased by an amount of 4.8%, 9.6%, 17.7%, 25.8%, 30.6%, 1.6%, 8%, 14.5%, 22.5%, 16.1%, 27.4%, 38.7% and 64.5% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 mixes respectively over conventional M25 concrete grade(M0).6.1.2 Compaction Factor Test


From the results it is observed that the workability is increased by an amount of 2.5%, 2.5%, 6.25%, 7.5%, 8.75%, 2.5%, 2.5%, 5%, 5%, 5%, 8.75%, 13.75% and 15% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 mixes respectively over conventional M15 concrete grade(M0).


From the results it is observed that the workability is increased by an amount of 0.61%, 2.4%, 3.66%, 7.3%, 10.9%, 1.2%, 3.65%, 4.8%, 8.5%, 2.4%, 8.5%, 12.2% and 15.8% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 mixes respectively over conventional M20 concrete grade(M0).


From the results it is observed that the workability is increased by an amount of 2.4%, 4.3%, 6.1%, 8.5%, 13.4%, 1.2%, 4.9%, 7.3%, 10.9%, 3.6%, 9.7%, 13.4% and 15.8% and 64.5% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 mixes respectively over conventional M25 concrete grade(M0).

The workability from both slump cone and compaction factor tests is similar in increasing manner. The workability increases with increase in ceramic coarse tile aggregate but a little deviation with the addition of ceramic fine aggregate. The addition of granite powder has significant improvement on the workability of concrete.

7.2 Compressive Strength: On comparing thestrengths of all mixes, M3, M8 and M12 has the highest i.e., 30% replacement of coarse aggregate. The addition of granite powder has positive effect on strength while improving the workability also.

M15 Grade: The Compressive strength of concrete varies as 9%, 12.8%, 24.5%, 19.1%, 5.4%, 6.7%, 13.4%, 23.1%, 11.9%, 7.4%, 15.9%,25% and 14.9% for for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12, M13 compared with the conventional concrete after 7days of curing.

The Compressive strength of concrete varies as 8%, 15.33%, 22.5%, 9.3%, -1.4%, 6.3%, 9.6%, 17.67%, -3.1%, 0.94%, 12.9%, 22.7% and 0% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 with the conventional concrete after 14 days of curing period.

The Compressive strength of concrete varies as 4.3%, 13.3%, 23.8%, 14.3%, 5%, 5%,12.9%,20.3%, 1.6%, 4%, 14%, 24.3% and4.9% forM1, M2, M3, M4,





M5,M6,M7,M8,M9,M10,M11,M12,M13 with the conventional concrete after 28 days of curing period.

M20 Grade: The Compressive strength of concretevaries as 7.6%, 14.7%, 25.4%, 13.67%, 0.25%, 4.6%, 8.4%, 20.5%, 8.6%, 8.4%, 14.3%, 24.7% and 0.06% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12, M13 compared with the conventional concrete after 7days of curing.

The Compressive strength of concrete varies as 2.1%, 6.2%, 16%, 6.9%, -3.9%, -0.5%, 8.7%, 10.8%, 0.3%, 3.4%, 11.5%, 13.8% and 0.3% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12, M13 compared with the conventional concrete after 14days of curing.

The Compressive strength of concrete varies as -3%, 2.7%, 9.5%, -0.4%, -1.4%, -1.1%, -0.3%, 7.5%, 2%, -6%, 1.8%, 9% and 2% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 compared with the conventional concrete after 28days of curing.

M25 Grade of Concrete: The Compressive strengthof concrete varies as 17.11%, 27.7%, 36.36%, 16.4%, 8.02%, 6.85%, 13.8%, 28.82%, -2.72%, 2.33%, 19.59%, 36.6% and 3.64% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12 and M13 compared with the conventional concrete after 7days of curing.

The Compressive strength of concrete varies as 9.99%, 14.92%, 31.49%, 11.31%, 1.19%, 1.61%, 10.72%, 20.53%, -6.62%, 0.3%, 17.65%, 34.54% and - 1.57% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12 and M13 compared with the conventional concrete after 14days of curing.

The Compressive strength of concrete varies as 10%, 19.04%, 30%, 11.99%, 3.01%, 5.99%, 11.99%, 19.04%, 0.8%, 3.97%, 19.04%, 27% and 1.98% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12 and M13 compared with the conventional concrete after 28days of curing.

6.3 Split Tensile: The linear development of strength can be seen from the graph. The strengths are quite good compared to the conventional concrete. M3 being the maximum of all mixes along with the M12 mix which uses the granite powder.

6.3.1 M15 Grade: The split tensile strength ofconcrete varies as 5%, 6.7%, 10%, 5.8%, -0.84%, 1.7%, 5.8%, 8.4%, 4.2%, 3.36%, 7.5%, 9.2% and 5%

for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12, M13 compared with the conventional concrete after 7days of curing.

The split tensile strength of concrete varies as 2.8%, 10.4%, 24.3%, 9%, 1.4%, 1.4%, 7.6%, 13.8%, 6.25%, 4.9%, 13.2%, 13.9% and 7.6% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 compared with the conventional concrete after 14days of curing.

The split tensile strength of concrete varies as 1.7%, 5.2%, 14.5%, 1.2%, -4.6%, 0.58%, 3.5%, 8%, 0.58%, 1.2%, 4.6%, 11.6% and 1.2% for M1, M2, M3, M4, M5, M6, M7, M8,M9,M10,M11,M12,M13 compared with the conventional concrete after 28days of curing.

M20 Concrete: The split tensile strength of concretevaries as 3%, 4.5%, 6%, 6%, 2.3%, -0.75%, 2.3%, 4.5%, 0.75%, 2.25%, 3.75%, 5.3% and 1.5% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12, M13 compared with the conventional concrete after 7days of curing.

The split tensile strength of concrete varies as 2.8%, 5.1%, 7.4%, 5.7%, 2.27%, 0%, 1.7%, 6.8%, 0.56%, 2.3%, 3.9%, 7.9% and 1.7% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12 and M13 compared with the conventional concrete after 14days of curing.

The split tensile strength of concrete varies as 0.93%, 2.3%, 3.7%, 2.8%, 2.3%, 0%, 1.4%, 2.8%, 0.46%, 1.4%, 2.8%, 4.2% and 2.3% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12 and M13 compared with the conventional concrete after 28days of curing.

M25 Concrete: The split tensile strength of concretevaries as 0%, 1.2%, 2.4%, 1.2%, 0%, 1.2%, 1.2%, 1.8%, -1.2%, 0.59%, 2.4%, 3.0% and 1.2% for M1, M2, M3, M4, M5, M6, M7, M8, M9, M10, M11, M12, M13 compared with the conventional concrete after 7days of curing.

The split tensile strength of concrete varies as 0.46%, 2.7%, 4.6%, 1.4%, -2.7%, 0%, 1.37%, 2.3%, 0.46%, 0.92%, 1.37%, 2.75% and 0.92% for M1, M2, M3, M4, M5,M6,M7,M8,M9,M10,M11,M12,M13 compared with the conventional concrete after 14days of curing.

The split tensile strength of concrete varies as 1.95%, 5%, 7%, 1.18%, -1.6%, 0.39%, 1.9%, 3.1%, -2.3%, 0.78%, 3.5%, 3.9% and 2.3% for M1, M2, M3,





M4, M5, M6, M7, M8, M9, M10, M11, M12, M13 compared with the conventional concrete after 28days of curing.6.4 Flexural Strength:

Figure 39: Flexural strength comparison of M15,M20 and M25 grades for M3 mix

The strength gaining of beam is linearly increasing. The strength variation for three grades is in increasing manner. The 7days strength gain is quite same for three grades but after 14 days M25 has the rapid growth of strength. Even though we are not comparing with the conventional concrete but the attainment of strength for three grades is satisfactory7. SUMMARY AND CONCLUSION

7.1 General: The basic objective of the study is toprepare a concrete much more stable and durable than the conventional by replacing aggregates both coarse and fine. Mix designs for all the replacements of materials has done and a total of 261 specimens (126 cubes, 126 cylinders, 9 beams) are prepared and tested in the aspect of strength calculation and also comparisons has done. 7.2 Conclusions

The following conclusions are made based on the experimental investigations on compressive strength, split tensile strength and flexural strength considering the―environmental aspects also:

∑ The workability of concrete increases with the increase in tile aggregate replacement. The workability is further increased with the addition of granite powder which acts as admixture due to its chemical properties.

∑ The properties of concrete increased linearly with the increase in ceramic aggregate up to 30% replacement later it is decreased linearly.

∑ M3 mix of concrete produced a better concrete in terms of compressive strength,

split tensile strength and flexural strength than the other mixes. But the mixes up to 50% of ceramic coarse aggregate can be used.

∑ The usage of ceramic fine aggregate has some effect on the properties of concrete in decrement manner.

∑ Granite powder using as fine aggregate has more influence on the concrete than the ceramic fine because of chemical composition it is made of and works as admixture.

∑ The addition of granite powder along with the ceramic coarse aggregate improves the mechanical properties of concrete slightly since mineral and chemical properties are of granite.

∑ The split tensile strength of ceramic tile aggregate is very much in a straighter path compared to the conventional grades of concrete.

FUTURE SCOPE OF WORK

There is a vast scope of research in the recycled aggregate usage in concrete especially ceramic tile wastes in the future. The possible research investigations that can be done are mentioned below:

∑ The usage of marble floor tiles can be studied as it is similar to that of tile waste generation and also it is quite hard compared to the natural crushed stones using in conventional concrete.

∑ The usage of granite powder in concrete as an admixture to improve the workability of concrete and the strength parameters can also be studied at various percentages.

∑ A combination of different tiles (based on their usage) in different proportions in concrete and their effects on concrete properties like strength, workability etc can be determined.

∑ By the use of ceramic tile aggregate in concrete, the physical properties like durability, permeability etc., can be analyzed to prepare a concrete with more advantageous than conventional concrete.

∑ A study on properties of concrete made with combination of recycled aggregate and tile aggregate in different proportions can be investigated to enhance the concrete properties and also to reduce the pollution or waste generation from construction industry.




∑ A further investigation on the use of granite powder alone as a replacement to fine aggregate can be carried out the possibility of using such waste generation from industries.

∑ The mechanical properties of concrete with marble aggregate (waste) either from manufacturing units or from construction demolition can be investigated to improve the properties like permeability; resistance to sound can also be studied.

∑ Ceramic tile aggregate in high strength concrete can be studied further to check the possibility of its use in high rise buildings.

REFERENCES

[1]. Aruna D, Rajendra Prabhu, Subhash C Yaragal, Katta Venkataramana IJRET:eISSN: 2319-1163 | pISSN: 2321-7308.

[2]. Batriti Monhun R. Marwein, M. Sneha, I. Bharathidasan International Journal of Scientific & Engineering Research, Volume 7, Issue 4, April-2016 ISSN 2229-5518.

[3]. N.Naveen Prasad, P.Hanitha, N.C.Anil IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 13, Issue 6 Ver. V (Nov. - Dec. 2016), PP 168-176.

[4]. Paul O. Awoyera , Julius M. Ndambuki , Joseph O. Akinmusuru , David O. Omole-4048 2016 Housing and Building National Research Center. Production and hosting by Elsevier B.V. 15 November 2016)

[5]. P.Rajalakshmi, Dr.D.Suji, M. Perarasan, E.Niranjani International Journal of Civil and Structural Engineering Research ISSN 2348-7607 (Online) Vol. 4, Issue 1, pp: (114-125), Month: April 2016 - September 2016.

[6]. Prof. Shruthi. H. G, Prof. Gowtham Prasad. M. E Samreen Taj, Syed Ruman Pasha International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 03 Issue: 07 | July-2016 p-ISSN: 2395-0072)



VALLUR,PRAKASAM(Dt). · Crushed waste ceramic tiles, crushed waste ceramic tile powder and Granite powder are used as a replacement to the coarse aggregates and fine aggregate. The

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