Project on Partial Replacement of Cement with Marble Powder

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Advance concrete technology can reduce the consumption of natural resources and energy sources thereby lessen the burden of pollutants on environment. We describes the feasibility of using the marble sludge dust in concrete production as partial replacement of cement. Presented by Rahul ,Jamsheed, Shanil , Geo, and Jagdeesh, under the guidance of Miss; DIVYA RAJAN guidance towards the partial fulfilment of the requirements for the award of bachelor of technology degree in civil engineering, of the university of Calicut during the year 2011. ABSTRACT Leaving the waste materials to the environment directly can cause environmental problem. Hence the reuse of waste material has been emphasized. Waste can be used to produce new products or can be used as admixtures so that natural resources are used more efficiently and the environment is protected from waste deposits. Marble stone industry generates both solid waste and stone slurry. Whereas solid waste results from the rejects at the mine sites or at the processing units, stone slurry is a semi liquid substance consisting of particles originating from the sawing and the polishing processes and water used to cool and lubricate the sawing and polishing machines. Stone slurry generated during processing corresponds to around 40% of the final product from stone industry. This is relevant because the stone industry presents an annual output of 68 million tonnes of processed products. Therefore the scientific and industrial community must commit towards more sustainable practices. There are several reuse and recycling solutions for this industrial by-product, both at an experimental phase and in practical applications. These industrial wastes are dumped in the nearby land and the natural fertility of the soil is spoiled. The physical, chemical and mechanical properties of the waste are analyzed. (1.1) CONCRETE The advancement of concrete technology can reduce the consumption of natural resources and energy sources and lessen the burden of pollutants on environment. Presently large amounts of marble dust are generated in natural stone processing plants with an important impact on environment and humans. INTRODUCTION

INFLUENCE OF MARBLE DUST AS PARTIAL REPLACEMENT OF CEMENT IN

This project describes the feasibility of using the marble sludge dust in concrete production as partial replacement of cement. In INDIA, the marble and granite stone processing is one of the most thriving industry the effects if varying marble dust contents on the physical and mechanical properties of fresh and hardened concrete have been investigated. Slump and air content of fresh concrete and absorption and compressive strength of hardened concrete were also investigated. Test results show that this industrial bi product is capable of improving hardened concrete performance up to 10%,Enhancing fresh concrete behaviour and can be used in architectural concrete mixtures containing white cement. The compressive strength of concrete was measured for 7 and 28 days. In order to evaluate the effects of marble dust on mechanical behaviour, many different mortar mixes were tested. (1.2)OBJECTIVES; In this project our main objective is to study the influence of partial replacement of cement with marble powder , and to compare it with the compressive and tensile strength of ordinary M20 concrete. We are also trying to find the percentage of marble powder replaced in concrete that makes the strength of the concrete maximum. Nowadays marble powder has become a pollutant. So , by partially replacing cement with marble powder, we are proposing a method that can be of great use in reducing pollution to a great extent. (2) TESTING ON PHYSICAL PROPERTIES OF MATERIALS (2.1) INITIAL GRAVITY of reading reading gravity of SETTING OF on on cement of OF = TIME CEMENT used flask flask weight cement FINE (LE = = = = of 84 CHATLIER 60 0 23 cement = minutes FLASK) gm ml ml used 2.608 AGGREGATE(2.2) FINENESS MODULUS = 6% (2.3)SPECIFIC Weight Initial Final Specific Specific (2.4)SPECIFIC (A)SANDcement

Weight of equal volume of water gravity GRAVITY

SL NO 1 2 3 4

Determination Pycnometer (M1) Pycnometer + sand (half of bottle)(M2) Pycnometer+ sand + full of water (M3) Pycnometer + full of water (M4)

gm 458.10 676 1390 1253

Gm 451 697 1405 1258

CALCULATIONS;Specific a). b) gravity (676-458.10)/ (697-451)/ = [(M2-M1)]/[(M2-M1)-(M3-M4)] = = 2.693 2.49 [(676-458.10)-(1390-1253)] [(697-451)-(1405-1258)]

Therefore, specific gravity of fine aggregate = 2.59 (2.5)SPECIFIC GRAVITY OF COARSE AGGREGATE

SL NO 1 2 3 4
Specific (a) (b)

DETERMINATION Pycnometer (M1) Pycnometer + aggregate(M2) Pycnometer+ aggregate +water(M3) Pycnometer+ water (M4)
gravity (706-458)/ (666-463) =

gm 458 706 1405 1258

Gm 463 666 1385 1253

CALCULATIONS (M2-M1)/[(M2-M1)-(M3-M4)] ] ]= = 2.45 2.859 [(706-458)-(1405-1258) /[(706-458)-(1405-1258)

Mean of these = 2.66 Therefore, specific gravity of coarse aggregate = 2.66 (2.6)SIEVE (A) Quantity of sand = 1 Time of sieving = 15 minutes ANALYSIS SAND Kg

SL NO 1 2 3 4 5 6 7 8 9 10 11

SIEVE WEIGHT SIZE RETAINED 40mm 0 20mm 0 10mm 0 4.75 0 2.36 98 1.18 60 600micron 188 300micron 397 150micron 221 90micron 21.5 L.P 19.5

%OF WEIGHT CUMULATIVE % RETAINED RETAINED 0 0 0 0 0 0 0 0 9.8 9.8 6 15.8 18.8 34.6 39.7 74.3 22.1 96.4 2.15 98.5 1.95 100

CUMULATIVE % PASSING 100 100 100 100 90.2 84.2 65.4 25.7 3.6 1.45 0

Fineness modulus = 329.4 / 100 = 3.29%

(2.7)(B)COARSE Quantity of materials = 4 Time of sieving = 15 minutes

AGGREGATE kg

SL NO 1 2 3 4 5 6 7 8 9

Sieve size 40mm 20mm 10mm 4.75mm 2.40mm 1.18mm 600m 300m 150m

Weight retained(gm) 0 585.0 3260 155 0 0 0 0 0

%weight retained 0 14.625 81.5 3.875 0 0 0 0 0

Cumulative % weight retained 0 14.65 96.12 100 100 100 100 100 100 710.77

Cumulative %weight passing 100 85.375 3.88 0 0 0 0 0 0

Fineness modulus = 710.77/100 = 7.10%

(3)

MIX

DESIGN:

Mix design for concrete was made using the properties of constituents of concrete. Grade of concrete was taken as M20 and the mix design was done as per IS:10262-1982 and IS:456-2000. The water cement ratio was taken as 0.5 which should be the maximum for M20 grade under mild exposure condition.

MIX

DESIGN

OF

20

(3.1) DESIGN STIPULATIONS

SL NO 1 2 3 4 5

DESIGN STIPULATIONS Characteristic compressive strength required in the field at 28 days Maximum size of aggregates Degree of workability Degree of quality of control Type of exposure

QUANTITY 20N/mm2 20mm(angular) 0.90 (compacting factor) Good Mild

(3.2) TEST DATA FOR MATERIAL

SL NO 1 2 3 4 5 6 7 8 9
TARGET

TEST DATA FOR MATERIAL Cement used Specific gravity of cement Specific gravity of fine aggregate Specific gravity of coarse aggregate Water absorption of fine aggregate Water absorption of coarse aggregate Free moisture of fine aggregate Free moisture of coarse aggregate Sieve analysis of fine aggregate
MEAN STRENGTH FOR

QUANTITY Portland slag cement 2.608 2.59 2.66 Nil Nil Nil Nil Grade 3
MIX DESIGN

fck =fck +1.65s fck =20+1.654.6 = 27.59N/mm2 As Water cement ratio = 0.5 per IS;10262-1982,

From Water content Sand content = 35%

table = 186

4 kg/m3

For change in value of water cement ratio, compacting factor and sand belonging to Zone 3 ,the following adjustment is required. Change 1) For decrease in water in Adjustments 2) For required increase in in cement Water ratio by content factor percent is = condition (0.60-0.50)that is = 0.1 0 0.10 +3

Adjustments required in percentage sand in total aggregate = -2.0 compacting in to in Water zone III (0.9-0.8)that percent 4 Of IS Adjustments 3) For sand required conforming required these Adjustments required content of table content

Adjustments required in percentage sand in total aggregate = 0 ;383-1970 = 0 get =+3% Adjustments Adding Total Water percent we content percent

Adjustments required in percentage sand in total aggregate = -1.5 adjustments in Water

Total Adjustments required in percentage sand in total aggregate = -3.5 Therefore, required sand content as percentage of total aggregate by absolute volume= 35 OF ratio =
3

3.5

= CEMENT =

31.5
3

% CONTENT 0.50 191.61

Required water content =186 + (186x 3) / 100 = 186 + 5.58 =191.6 litre /m (3.3)DETERMINATION Water Water Cement = 191.6/0.50 = 383 kg/m Appendix A of IS ; 456-1978. (3.4)DETERMINATION OF COARSE AND FINE AGGREGATE cement

This cement content is adequate for mild exposure condition, according to

CONTENT

From Table 3, for the specified maximum size of 20mm , the amount of entrapped air in the wet concrete is 2%. Taking this into account and applying equations from 3.5.1 of IS ; 10262 -1982. Therefore, For fa = 525.82 For Ca = 1139.43 kg/m3 coarse aggregate ;0.98 = [ 191.58 + (383.16/2.608) + (1/(1-0.315) x (C a / 2.83)] x (1/1000) fine aggregate ;0.98 = [191.58 + (383.16/2.608)+(1/0.315) x (fa / 2.59) ] x (1/1000)

The Water: 191.61: or

mix Cement:Fine 383kg:

proportions 525.82

then :

becomes aggregate 1139.43kg

aggregate:Coarse

0.50 :1:1.372: 2.97 VOLUMES Volume Volume Add 2.529 Weight of cement = (1 / V) x volume = (1 / 2.529) x 9544.084) = 3.77kg Weight Weight Required FOR Weight Weight Weight (3.5)MIX of of of fine coarse of of fine coarse of aggregate aggregate water = = = TWO cement aggregate aggregate = = = 7.547 10.355 22.41 1.372 2.97 0.5 x x x 3773.85 3773.85 3773.85 = = = 5.177 11.208 1886.92 kg kg litre of of 10% cube cylinder = = extra 15 ? x x 15 7.52 x x = 15 30 =3375cm3 =5301.44 9544.084

Total volume = 8676.44 volume Volume of concrete = (1 / 2.602) + (1.372 / 2.59) + (2.97 / 2.66) + (0.5 / 1) =

amount

SPECIMEN kg kg kg

Required water = 3-77 litre PROPORTIONS: Five concrete mixes with stone dust were produced, replacing 0%(reference mixture ), 5%,10%,15%,and 20%,Cement, in terms of weight. The concrete mix proportion for M20 grade was designed in accordance with I.S. code. QUANTITY 5% 10% 15% of cement of of OF replaced marble marble by powder powder MARBLE marble powder = = = 754.7 1.13 POWDER; 377.38gm gm kg

20 %of marble powder = 1.5094 kg Experimental conditions: Compressive strength of concrete was undertaken on 15 cm cubic specimens. at 7 days and 28 days of age. Regarding splitting tensile strength, cylinders with 30 cm of height and 15 cm of diameter were casted and tested at 28 days of age. All specimens were removed 48 hours after casting, and then transferred to regular conditions (interior of the laboratory ) till testing.

(4)

PREPARATION

AND

CURING

OF

SPECIMEN:

Standard cubic specimens of 150 mm size were cast. Concrete cubes were cast for compressive strength. The standard cylindrical specimen of 100mm diameter and 300mm height cylindrical specimens were caste for tensile strength. (5)TESTING OF HARDENED CONCRETE (5.1)COMPRESSIVE STRENGTH 7 DAYS

% 0% 5% 10% 15% 20%

1 380 355 390 275 290

2 340 405 430 325 270

average 360 380 410 300 280

Compressive strength ( MPa) 16 16.88 18.22 13.33 12.44

(5.2)COMPRESSIVE STRENGTH 28 DAYS

% 0% 5% 10 % 15% 20%

1 535 580 675 470 420

2 565 620 645 435 440

average 550 600 660 452.5 420

Compressive strength(MPa) 24.40 26.67 29.33 20.11 18.67

5.3)GRAPHICAL REPRESENTATION OF COMPRESSIVE STRENGTH

(5.4)TENSILE STRENGTH 7 DAYS

% marble powder

Specimen 1 tensile load 111 130 125 100 108

Specimen 2 tensile load 129 136 151 128 84

mean

Tensile strength (MPa) 1.69 1.88 1.95 1.61 1.35

0% 5% 10% 15% 20%

120 133 138 114 96

(5.5)TENSILE STRENGTH 28 DAYS

% marble powder

Specimen 1, tensile load 170 182

Specimen 2, tensile load 178 185

mean

Tensile strength (MPa) 2.461 2.59

0% 5%

174 183.5

10% 15% 20%

197 165 141

201 170 162

199 167.5 151.5

2.84 2.36 2.14

(5.6)GRAPHICAL REPRESENTATION OF TENSILE STRENGTH

(6) Compression

RESULTS

AND

DISCUSSION: Test:

Mechanical behaviour of concrete cubes prepared without chemical admixtures was studied by compressive tests (Grade M20and curing time of 7 days and 28 days. It can be noticed that 5% replacement of cement with marble dust in mild condition and 10% replacement of cement with marble dust in mild condition, are showing increase in compressive strength. Tensile Mechanical behaviour of Strength cylindrical specimens prepared without test chemical

admixtures was studied by tensile strength test. (Grade M20),curing times of 7 days and 28 days and the results obtained are reported. It is noticed that 5% replacement of cement with marble dust in mild condition and 10% replacement

of cement with marble dust in severe conditions, are showing increase in tensile strength. (7)CONCLUSIONS: Due to marble dust, it proved to be very effective in assuring very good cohesiveness of mortar and concrete. From the above study, it is concluded that the marble dust can be used as a replacement material for cement ; and 10% replacement of marble dust gives an excellent result in strength aspect and quality aspect and it is better than the control concrete. The results showed that the substitution of 10% of the cement content by marble stone dust induced higher compressive strength, higher splitting tensile strength, and improvement of properties related to durability. Test results show that this industrial waste is capable of improving hardened concrete performance up to 15%, enhancing fresh concrete behaviour and can be used in plain concrete. (8) 1) CONCRETE TECHNOLOGY M.S. 2) DESIGN OF CONCRETE MIXES- N.KRISHNA RAJU We at engineeringcivil.com are very thankful to Er. Rahul for submitting this project report to us. We hope this will be of great help to other fellowCivil Engineers. REFERENCES: SHETTY