UTILIZATION OF CERAMIC TILE WASTE AS REPLACEMENT FOR AGGREGATES IN CONCRETE - ssrg-journals
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SSRG International
International Journal
Conference of CivilResearch
on Current Engineering (SSRG-IJCE)
in Engineering - Special
Science and Issue ICCREST
Technology - April 2018
(ICCREST-2018)
UTILIZATION OF CERAMIC TILE
WASTE AS REPLACEMENT FOR
AGGREGATES IN CONCRETE
RAJKUMAR RAMESH#1 MUTHURAJ RAMALINGAM2,
2
#1 Assistant Professor, B.E Final year student, Department Of Civil
Department Of Civil Engineering, Engineering, A.C.T. College of Engineering &
A.C.T. College of Engineering & Technology, Technology, Chengalpet, India.
Chengalpet, India. REVATHI KOMAGAN3
3
rrajkumarrao@gmail.com Assistant Professor,
A.C.T. College of Engineering & Technology,
Abstract— Ceramic generated during its production Chengalpet, India.
can cause severe problems in environmental pollution
due to its dumping and disposal methods. On the other of construction industries to attain the strength,
hand demand of natural sand were increased which economical and durability requirements. In which,
increases its cost of procurement and decreases its aggregate is one of the most essential materials in use
general availability. This study investigates the for concrete production as it strongly influences
effective utilization of ceramic waste as partial concrete properties. Very few research has been done
replacement for fine aggregates and coarse aggregates on using ceramic tiles waste as the partial replacement
in concrete. A total of 9 different mix proportions were of fine aggregates and coarse aggregates in the
casted, in which the control mix reflects the production of structural concrete. Ceramic production
conventional concrete, and other mixes containing in India contributes million tonnes per year and it also
cement, water and partial replacement of coarse ranks in the top list of countries for tile production in
aggregate and fine aggregate by crushed and powdered the world. Thus huge amount of production in ceramic
tile (in 25%, 50%, 75% and 100% proportions). These industries satisfy its high demand but it failed to
different mix proportions were cast, cubed, cured and effectively reuse its waste and these waste from this
crushed to find out the effective mix. The specimens industries also causes severe environmental pollution.
were tested on the 7th, 14th, 21st and 28th days of curing Hence, the need for its reuse in other industries is
for to find out the compressive, split tensile and becoming unavoidable issue. Building construction
flexural strengths of concrete. Based on results of industry can be the end user of all types of ceramic
mechanical properties it was found that ceramic tile wastes and it also positively reflects on environmental
wastes can be replaced up to only 25% as waste tiles problem. From structural point of view, ceramic
in concrete and replacing above this limit shows wastes were found to be performing better than
negative effects on mechanical properties of the conventional concrete, in various properties such as
concrete and slump value. durability, density, compressive strength, and
Keywords— Conventional concrete, Compressive permeability [1]. From economic point of view, now a
strength, Split tensile strength, Flexural strength, day’s fine and coarse aggregates contribute a bigger
Mix proportions. portion of costs in the construction industry. Thus
concrete made by tile aggregate is more economical as
I. INTRODUCTION compared to conventional concrete. As an estimate for
making 1m3 of concrete by replacing 20% normal 20
Conventional concrete is a compound material
mm aggregates with tile aggregates about 16% money
consists of coarse aggregate (crushed stones or
can be saved on total amount of 20 mm aggregates [2].
gravels), fine aggregate (sand) and binder (hydrated
Replacing a waste material of similar characteristics is
cement). Its use has been found for over a centuries in
all types of construction works. Now a days, variety of a major economic gain, while being more eco-friendly.
new and innovative materials have been developed in The present study is an attempt towards find out the
the field of concrete technology to fulfill the demand possibility of incorporating ceramic wastes as partial
ISSN: 2348
Seventh Sense- 8352
Research Group www.internationaljournalssrg.org
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211SSRG International
International Journal
Conference of Civil Research
on Current Engineering (SSRG-IJCE)
in Engineering - Special
Science and Issue ICCREST
Technology - April 2018
(ICCREST-2018)
substitute of aggregates in the making of concrete. The conventional concrete. The physical properties of
core objective of the study is to effectively utilize the coarse aggregates were investigated in accordance
ceramic waste in concrete and to replace the fine and
coarse aggregate with various percentages in M25 D. Ceramic waste
grade concrete and also to find the compressive, split In general, ceramic waste is available from large
tensile, flexural strength of concrete made by ceramic ceramic product manufacturing units and from routine
tile waste. construction activities. Roughly 550 - 650 kg of tile
wastes were procured from an Indian ceramic
II. MATERIALS AND METHODS company (Aravind Ceramics Tiles Industries Pvt. Ltd.,
Chengalpattu). Ceramic wastes were reduced up to 20
A. Cement mm size by manually using steel hammer which used
as a replacement material for coarse aggregate. Some
Cement is fine material having very high cohesive and part of ceramic tile wastes were reduced to less than 4
adhesive properties which makes the capable of mm size and it can sieved by using 4.75 mm sieve and
bonding material fragments into an entirely compact. tile wastes which are passing through this sieve can be
The most commonly used cement in construction used directly as a replacement material for fine
industry is Portland cement and hence Ordinary aggregate without any additional work. Physical
Portland Cement of 43 grade has been selected for the properties of fine, coarse, ceramic fine and ceramic
study. The properties of cement was summarized in coarse aggregate shown in Table.2
Table.1. It is entirely dry, powdery (very fine) and free
from lumps. The cement used in the study according E. Water
to the Indian specification must satisfy the IS code IS: Water is an important element for concreting and
8122 - 1989 (restated 1999) [3]. curing because it enhances chemical reaction with
cement and it also gives the strength to cement
concrete. Therefore the quantity and quality of water
Table 1 Properties of Cement are needed to be looked into very sensibly. Potable
Cement test bore water free from any such type of foreign matters
Sl. No Material Properties
results (acids, alkalies, organic and inorganic materials) and
1
Initial Setting time 30 Minutes having pH value of 7.0 ± 1 was used. Water which is
2 Final setting time 520 minutes used need to confirm the requirements of IS: 456 -
Standard Consistency 2000 [5] and the same water will be used for mixing
3 40%
Test of concrete and curing of specimens as well.
4 Specific Gravity 2.70
5 Fineness 5% F. Concrete Mix Proportions
M25 grade of concrete was designed by following the
B. Fine aggregate
specification given in the IS 10262: 2009 [6]. A total
Fine aggregate is a vital component of concrete. Those of nine concrete mix proportions were cast, including
sizes from 4.75 mm to 150 microns are named as fine a control concrete mix (CC) and four replacement
aggregate. The purpose of the using fine aggregate is concrete mixes, each using ceramic fine aggregates
to fill the voids in the concrete and to act as a (CFA) concrete: CFA-25, CFA-50, CFA-75 and CFA-
workability agent. In general fine aggregates are the 100 for river sand replacements and four replacement
river sand which is the commonly used material for the concrete mixes, each using ceramic coarse aggregate
fine aggregates but the shortage of the material created (CCA) concrete; and CCA-25, CCA-50, CCA-75 and
a great problem in the construction industries.
CCA-100 for gravel replacements. Mix proportion
C. Coarse aggregate ratios by weight are summarized in Table 3. Mix
proportions like 25%, 50%, 75% and 100% by weight
The sizes from 20 mm to 4.75 mm are used as coarse of river sand and gravel were replaced by ceramic fine
aggregate. Mechanically crushed angular granite of 20 and coarse aggregates respectively. A constant
mm nominal size from the nearby source was used as
water/cement (w/c) ratio of 0.5 by weight was
coarse aggregate. It was free from impurities such as
clay particles, dust, organic matter, inorganic matter adopted, to ensure workability and durability of the
and other inert matter etc. The coarse aggregate concrete. Concrete mix containing, ceramic waste
preferred for Concrete was typically angular in shape, aggregates were mixed in air dry condition to control
well graded, and smaller than maximum size suited for mixed in saturated surface-dry condition. The ceramic
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212International Conference
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- Special Technology (ICCREST-2018)
ICCREST - April 2018
Table 2 Properties of aggregates
Natural Natural Ceramic fine Ceramic coarse
Property
fine aggregate coarse aggregate aggregate aggregate
4.75 mm to 20 mm to 4.75 mm to 20 mm to
Size
150 micron 4.75 mm 150 micron 4.75 mm
Fineness modulus 3.36 2.26 3.10 1.28
Bulk density
1749 1597 1721 1580
(kg/ m3)
Water absorption
2.2 1.66 6 4.7
(%)
Specific gravity 2.65 2.78 2.63 2.54
Table 3 Mix proportions of control and ceramic concrete
Fine Aggregate Coarse Aggregate
Mix Cement (kg/m3) (kg/m3)
W/C (%)
Proportions (kg/m3) River
CFA Gravel CCA
sand
CC 472.5 660.65 0 1106.6 0 0.5
CFA-25 472.5 495.49 165.16 1106.6 0 0.5
CFA-50 472.5 330.32 330.32 1106.6 0 0.5
CFA-75 472.5 165.16 495.49 1106.6 0 0.5
CFA-100 472.5 0 660.65 1106.6 0 0.5
CCA-25 472.5 660.65 0 829.95 276.65 0.5
CCA-50 472.5 660.65 0 553.3 553.3 0.5
CCA-75 472.5 660.65 0 276.65 829.95 0.5
CCA-100 472.5 660.65 0 0 1106.6 0.5
Seventh Sense
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Civil Engineering Engineering Science andIssue
- Special Technology
ICCREST(ICCREST-2018)
- April 2018
tile wastes and natural aggregates were thoroughly specimen between the loading surfaces of a CTM and
washed to get rid of debris from the materials. A 1:1:2 the uniform rate of load was applied until the specimen
concrete mix of cement, fine and coarse aggregates was fails. The maximum load to failure at which the
adopted, and batching was conducted by weight. For all specimen breaks and the pointer starts moving back is
mixes, one hundred and eight (108) concrete cubes of 150 noted. The average mean value of compressive
mm dimensions, cylindrical specimens of 150 mm strength of 3 specimens for each mix proportions at the
diameter and 300 mm height were cast and prism age of 7 days, 14 days, 21 days and 28 days are shown
specimens of 150 mm height, 150 mm width and 700 mm in Fig. 2. Results clearly shows that, compressive
length were cast respectively. Thus, following the strength of cubes were increased by cube age and 25%
procedures of IS: 516-1959 [8] for determining the replacement of waste tiles in both fine (33.97 N/mm2)
compressive strength, split tensile strength and flexural and coarse aggregate (32.33 N/mm2) shows maximum
strength respectively, cubes, cylinders and prism were compressive strength compared to other mix
tested in triplicates, after 7, 14, 21 and 28 days of curing. proportions. Increasing percentage of waste tile in
The specimens were demolded after 24 hours of casting concrete shows less compressive strength. Replacing
and cured in water at room temperature until respective of aggregates over 25% of waste tile negatively
curing age. Compression Testing machine (CTM) of influences on compressive strength which may be due
1500 kN capacity was used for the strength determination to lack of moisture in concrete. Outcomes from this
of Cubes and cylinders. For the strength determination of study was supported by [10].
prism, Universal Testing Machine (UTM) of 2000 kN
was used. Workability of each mix proportions was C. Split tensile strength test
measured through slump cone test according to IS 1199- The split tensile test is another method for
1959 (Reaffirmed 2004) [9]. determining strength and performance of concrete
under tensile stress and also gives its progressive
III. RESULTS
cracking pattern [11]. The average mean value of split
A. Slump value test tensile strength results of control concrete mixes with
ceramic fine aggregate and ceramic coarse aggregate
The effect of waste ceramic tile aggregates content substitution are shown in Fig. 3. The split tensile
into the concrete mix on the workability of the fresh strength of concrete cubes was tested by using 150 mm
concrete mix expressed as the slump value for x 300 mm cylinder specimens. The test was carried out
different mix proportions were shown in Fig. 1. by placing a cylinder specimen between the loading
Results shows that different mix proportions like CC, surfaces of a CTM and the uniform rate of load was
CFA-25, CFA-50, CFA-75, CFA-100, CCA-25, CCA- applied until the specimen cracks. The extreme load to
50, and CCA-75 were ranged from 82 to 120 mm failure at which the specimen breaks and the pointer
where CCA-100 shows very poor slump value less starts moving back is noted. Results clearly shows
than 50 mm. Poor slump value in CCA-100 endorsed that, tensile strength of cylinders were increased by
by glazy surfaces of ceramic coarse aggregate. Thus, number of curing days and 25% replacement of waste
glazy surface fail to bind with other materials in tiles in both fine and coarse aggregate shows
concrete which sufficiently reflects on low slump maximum tensile strength (3.7 N/mm2) when
value. Increasing proportions of ceramic waste tile as compared to other mix proportions . Increasing the
aggregates leads into poor slump value when percentage of waste tile in concrete shows less tensile
compared to control concrete. Mix proportions like strength. Substituting of aggregates over 25% by using
CFA-25 and CCA-25 were found to be better in slump waste tile negatively influences on tensile strength
value when compared to control and other mix which may be due to lack of moisture in concrete.
proportions. Increasing proportions of waste tile in concrete reflects
decreasing in strength and this results are from this
B. Compressive strength study supported by author [12].
The finding of compressive strength has received a
D. Flexural strength test
large amount of attention because the concrete is
mainly meant to withstand compressive stresses. Flexural strength is a measurement that indicates the
Compression Testing Machine (CTM) of 2000 kN resistance of a material to failure when placed under a
capacity was used to find out the Compressive strength load. Rectangular concrete samples were placed under a
of cubes. The compressive strength of concrete cubes two point loading testing setup and the tests were carried
was tested by using 150 mm x 150 mm x 150 mm cube out confirming to IS: 516-1959. The specimens were
specimens. The test was carried out by placing a cube tested for flexural strength and the average mean value
ISSN: 2348
Seventh Sense- 8352
Research Group www.internationaljournalssrg.org
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214SSRG International
International Journal
Conference of CivilResearch
on Current Engineering (SSRG-IJCE)
in Engineering - Special
Science Issue ICCREST
and Technology - April 2018
(ICCREST-2018)
140 40
Compressive Strngth (N/mm2)
120 7th day 14th day 21th day 28th day
Slump Value (mm) 35
100 30
80 25
60 20
40 15
20
10
5
0
0
Mix proportions
Mix proportions
Fig 3.1 Slump test for all mix proportions Fig 3.2 Compressive strength test results
4 6
7th day 14th day 21th day 28th day 7th day 14th day 21th day 28th day
3.5
Flexural Strength (N/mm2)
Split Tensile strength (N/mm2)
5
3
4
2.5
2 3
1.5
2
1
1
0.5
0 0
Mix proportions Mix proportions
Fig 3.3 Split tensile test results Fig 3.4 Flexural strength test results
ISSN: 2348 - 8352 www.internationaljournalssrg.org Page 23SSRG International
International Journal
Conference of CivilResearch
on Current Engineering (SSRG-IJCE)
in Engineering - Special
Science Issue ICCREST
and Technology - April 2018
(ICCREST-2018)
of three specimens for each mix proportions were [5] IS: 456 -2000: Indian Standard “Plain and
recorded at the age of 7 days, 14 days, 21 days and 28 reinforced concrete” –code of practice.
days. The increase in the strength of various mix [6] IS 10262–2009: Indian Standard “Guidelines
proportions over the control concrete is shown in Fig. for concrete mix design proportioning” – code of
4. Results shows that, replacement of 25% of ceramic practice
fine (4.31 N/mm2) and coarse (4.78 N/mm2) mix [7] H.Higashiyama, F. Yagishita, M. Sano, O.
Takahashi, Compressive strength and resistance
concrete were found be high in flexural strength when to chloride penetration of mortars using ceramic
compared to control and other mix concrete. waste as fine aggregate. Constr. Build. Mater.
Enhancing proportions of tile waste as aggregate, 26, 96–101, (2012).
similarly results in lower flexural strength. Mix [8] IS: 516-1959: Methods of Tests for strength of
proportions like CFA-100 and CCA-100 shows very concrete.
poor flexural strength when compared to control [9] IS 1199-1959: Methods of Sampling and
concrete which is due to low binding properties of analysis of concrete.
ceramic tile. Findings from this study was supported [10] V. Lopez, B. Llamas, A. Juan, J.M. Mora´ n, I.
by [13]. Guerra, Eco-efficient concretes: impact of the
use of white ceramic powder on the
mechanical properties of concrete, Biosyst.
Eng. 96, 559–564. 2007.
IV. CONCLUSION [11] Ofonime A. Harry and Ifiok E. Ekop,
This study assessed the mechanical properties of ceramic Compressive strength characteristics of tile
waste aggregate concrete, in an effort to determine its
waste concrete, International journal of
engineering sciences & research technology,
suitability for construction. The workability of ceramic
5(8) 268-273, 2016.
waste concrete was comparable to the control concrete, [12] P.O. Awoyera, Nonlinear finite element analysis
which ranged between average to high workability in of steel fibre reinforced concrete beam under
nature. Mix proportions like CCA-100 and CFA-100 mix static loading, J. Eng. Sci. Technol. 5(8) in press.
was an exception. Slump value gets reduced when replacing 2016
higher percentage of ceramic waste aggregate. Mechanical [13] Paul O. Awoyera, Julius M. Ndambuki, Joseph
performance of the CFA-25 & CCA- 25 concretes was O. Akinmusuru, David O. Omole,
Characterization of ceramic waste aggregate
better than that of the control concrete. The highest concrete, Housing and Building National
compressive strength, split tensile strength and flexural Research Center. 1-6, 2016.
strength was achieved by replacing 25% of the natural
aggregate with CCA and CFA individually. The mechanical
properties of ceramic waste aggregate concretes improved
as the replacement percentage of natural aggregates was
only at 25% beyond this replacement it shows poor
mechanical properties of concretes. Concrete made with
ceramic waste aggregate as a replacement for some portion
of the natural aggregates can be considered a suitable
alternative for conventional concrete.
REFERENCES
[1] O. Zimbili, W. Salim, M. Ndambuki,. A Review
on the Usage of Ceramic Wastes in Concrete
Production. World Academy of Science,
Engineering and Technology International
Journal of Civil, Environmental, Structural,
Construction and Architectural Engineering, 8
(1), 91-95. 2014.
[2] P. Singh, R. K. Singla, Utilization of Waste
Ceramic Tiles as Coarse Aggregate in Concrete.
Journal of Multidisciplinary Engineering
Science and Technology (JMEST), 2(11), 3294-
3300. 2015.
[3] IS: 8122- 1989 (restated 1999): Specification for
43 grade ordinary Portland cement.
[4] IS 383 -1963: Indian Standard “Specification for
coarse and fine aggregates from natural’s
sources for concrete”.
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