Experimental study on concrete using waste ceramic as partial replacement of aggregate

Abstract

This research paper explains an experimental study on the utilization of waste material extracted from the Ceramic manufacturing plants and reused in concrete by replacing natural fine aggregate. Due to this ceramic waste, the natural fine aggregate extraction may be reduced, and the nominal cost of the river sand is high; compared to all the other alternate fine aggregate materials. Pulverized and granulated waste powder ceramic tiles are varies from 0%, 5%, 10%, 15%, and 20% replacement material for fine aggregate. The mix designs were prepared by replacing fine aggregate with different percentages of 0% to 20% pottery (crushed tiles) with M30 grade of concrete. Experimental investigations were conducted on fresh concrete for workability. In hardened concrete with various tests conducted like a Compression test, Young’s modulus, and Flexural strength on concrete beam with different percentages of waste crushed ceramic tiles at different stages of curing time at 7 28 days.

Full text

Experimental study on concrete using waste ceramic as partial
replacement of aggregate
R. Johnson Daniel
⇑
, S.P. Sangeetha
Department of Civil Engineering, Aarupadai Veedu Institute of Technology, Vinayaka Mission’s Research Foundation, India
article info
Article history:
Received 29 October 2020
Received in revised form 16 November 2020
Accepted 21 November 2020
Available online 13 January 2021
Keywords:
Concrete
Ceramic waste
Eco-friendly
Compressive strength
Tensile strength
abstract
This research paper explains an experimental study on the utilization of waste material extracted from
the Ceramic manufacturing plants and reused in concrete by replacing natural fine aggregate. Due to this
ceramic waste, the natural fine aggregate extraction may be reduced, and the nominal cost of the river
sand is high; compared to all the other alternate fine aggregate materials. Pulverized and granulated
waste powder ceramic tiles are varies from 0%, 5%, 10%, 15%, and 20% replacement material for fine aggre-
gate. The mix designs were prepared by replacing fine aggregate with different percentages of 0% to 20%
pottery (crushed tiles) with M30 grade of concrete. Experimental investigations were conducted on fresh
concrete for workability. In hardened concrete with various tests conducted like a Compression test,
Young’s modulus, and Flexural strength on concrete beam with different percentages of waste crushed
ceramic tiles at different stages of curing time at 7 28 days.
Ó2020 Elsevier Ltd.2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Mechanical, Electronics and Computer Engineering 2020: Materials Science.
1. Introduction
In the present-day development method, utilization of earthen-
ware materials has developed step by step as tiles, clean fittings,
and other electrical products like separators. This separator shrub
was utilized in assembling transformers [3]. This kind of Ceramic
waste from enterprises is mounting step by step in handling, ship-
ping, and fixing because of its fragile nature. Compressive quality
was unaltered when artistic waste is utilized mostly to supplement
the ordinary squashed stone course [4]. To decrease the quantity of
earthenware squander stored in landfills or anyplace and help the
common assets, reusing the artistic waste to use as totals in con-
crete has been researched. The principal target of this examination
is to consider the presentation of cement with the earthenware
squander total [5]. The Earthenware chambers are used as storage
for massive and medium-sized towns; a considerable progression
about the assortment, stockpiling and all other more as of late
treatment of local waste for the longer period [6].Correspondingly,
there has been a developing social and political familiarity with
natural issues [7].
1.1. Ceramic waste
Rapid development in industries causes significant issues
everywhere throughout the world, such as exhaustion of regular
natural minerals (river sand) and makes a gigantic measure of
waste material from development and destruction exercises. One
of the best approaches to lessen this issue is to use the squanders
[8]. The structure rubbles gathered from demolished structures
consist of squander solid, tiles, block, steel, and wood. Among
these, the clay tiles are utilized in this task. Because of removing
earthenware squanders from building destruction in a landfill,
the pottery interacts with groundwater and sand and causes harm-
ful impacts [9]. The use of squashed tile total cement is delivered
by total supplants technique, powerful in decreasing both expense
and condition sway.
1.2. Applications of ceramic waste
The need to deal with this waste has got one of the most prob-
lems that need to be addressed for our occasions, requires explicit
activities planned for forestalling wastage. The advancement of
asset recuperation frameworks is a method for misusing the assets
contained inside waste, making some way or another is lost,
diminishing ecological effect [10]. Despite securing the earth,
https://doi.org/10.1016/j.matpr.2020.11.772
2214-7853/Ó2020 Elsevier Ltd.2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Mechanical, Electronics and Computer Engineering 2020:
Materials Science.
⇑
Corresponding author.
E-mail address: johnsondaniel76@gmail.com (R. Johnson Daniel).
Materials Today: Proceedings 45 (2021) 6603–6608
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utilization of such waste offers a progression of focal points.
Besides, reuse likewise offers benefits as far as vitality, principally
when the waste is from oven enterprises where profoundly
endothermic deterioration responses have just occurred, in this
manner recouping the vitality recently joined during the creation
[11].
2. Research significances
The ceramic industry is another rapidly rising industry that pro-
duces more waste in India. Ceramic materials are manufactured
from clay by the following process: molding, drying, and subse-
quent burning. It has been estimated that about 30% of the daily
production in the ceramic industry goes to waste [12]. This waste
is not recycled in any form at present. However, ceramic waste is
durable, challenging, and highly resistant to biological, chemical,
and physical degradation forces. As the ceramic waste is piling
up every day, there is pressure on the ceramic industries to find
a solution for its disposal, if this can be used in concrete, making
it an ideal solution for disposal [13]. Meanwhile, conventional
crushed stone aggregate reserves are depleting fast, particularly
in some desert regions of the world use of inorganic industrial
residual products in making concrete will lead to sustainable con-
crete design and a greener environment [14].
3. Materials and properties
3.1. Ceramic waste
The principal waste coming into the ceramic industry is ceramic
waste, specifically in the powdered form. Ceramic waste is gener-
ated during the process of dressing and polishing [15]. It is also
estimated that 15 to 30% of wastes are produced from the total
raw material used. Although a portion of this ceramic waste may
be utilized in-site, such as excavation pit refill, therefore disposals
of these waste materials acquire large land areas and remain scat-
tered all around, spoiling the aesthetic of the entire region [16].Itis
challenging to find a use for ceramic waste produced Ceramic
waste in concrete to improve its strength and other durability fac-
tors. Ceramic waste can be used as a partial replacement of cement
or partial replacement of fine aggregate sand as a supplementary
addition to achieve different properties of concrete (Fig. 1).
3.2. Aggregate
An aggregate that plays an essential role in concrete occupies
70% to 80% of the concrete mass. The aggregate will reduce the
air voids in the concrete and gets more strength of the concrete
Fig. 1. Ceramic fine aggregate.
Table 1
Specific gravity of coarse aggregate and water absorption.
S. No Observation Trial
1 Weight of empty metal drum (W
1
) 870
2 Weight of empty metal drum + broken stone (W
2
) 2870
3 Weight of metal + water (W
3
) 900
4 Weight of broken stone (W
2
W
1
) 2000
5 Weight of water in the metal (W
3
W
1
)30
Fig. 2. Specific gravity of coarse aggregate and water absorption test.
Fig. 3. Specific gravity of fine aggregate test.
Table 2
Specific gravity of fine aggregate.
S. No Observation Trial
1 Empty weight of the pycnometer (w
1
) 200 g
2 Weight of pycnometer + sand (w
2
) 0.6536 g
3 Weight of pycnometer + sand + water (w
3
) 0.8536 g
4 Weight of pycnometer + full of water (w
4
) 1.638 g
R. Johnson Daniel and S.P. Sangeetha Materials Today: Proceedings 45 (2021) 6603–6608
6604

[17]. So, that concrete will reduce shrinkage and become more
cost-efficient.
3.3. Coarse aggregate
The coarse aggregate quality will fall on the requirement of
Indian Standards (IS):383 codal provisions retain on sieve from
20 mm to 4.75 mm [1]. The Specific gravity of coarse aggregate
and water absorption are tabulated in Table 1, and Fig. 2 shows
the water absorption.
3.4. Fine aggregate
The fractions from 4.75 mm to 150microns are termed as fine
aggregate. The river sand is used in combination as fine aggregate
conforming to the requirements of IS: 383. The river sand is
washed and screened to eliminate harmful materials and oversize
particles [18] (Fig. 3.Table 2.Table 3).
3.5. Water
Water is an essential ingredient of concrete as it participates in
the heat of hydration reaction with cement. Since it helps to form
from the strength giving cement-gel; the quantity and quality of
water must be looked into very carefully.
3.6. Cement
The cement used in all mixtures is commercially available Port-
land pozzolana cement of 53 grade confirming to IS: 12,269 were
used in this study. The specific gravity of cement is 3.15. The initial
and final setting times of cement were found as 30 and 600 min,
respectively, setting time. Cement, when mixed with water con-
crete, forms a paste, which gradually losses. Its plasticity and
results in hard mass. In this setting process, a range is reached
when cement paste is sufficiently rigid to withstand a definite
amount of pressure. The time taken to reach this stage is called
the setting (Table 4).
Table 3
Sieve analysis of fine aggregate.
S. No Sieve size (mm) Weight retained (g) Cumulative weight retained (g) Cumulative percentage retained Percentage passing
1 4.75 0 0 0 100
2 2.36 11.3 11.3 2.26 97.74
3 1.18 63.6 74.9 14.98 85.02
4 0.6 69.3 144.2 28.84 71.16
5 0.3 290.1 434.3 86.86 13.14
6 0.15 57.3 491.6 98.32 1.68
7 <0.15 8.4 500 100 0
Table 4
Physical properties of cement.
S. No. Name of the test Value
1 Consistency 35%
2 Initial Setting Time 65 min
3 Final Setting Time 450 min
4 Specific Gravity 3.1
5 Fineness of cement 4%
6 Soundness 3 mm
Table 5
Physical properties of different types of aggregate used in concrete.
S. No Property Fine aggregate Coarse aggregate Ceramic waste aggregate
1. Specific gravity 2.67 2.74 2.70
2. Water Absorption 1.5% 1.0% 2.0%
Table 6
Concrete mix proportions.
w/cRatio Cement(kg/m) Water(litre) Fine aggregate (River Sand)(kg/m
3
) Coarse aggregate (20 mm blue metal)(kg/m
3
) Mix ratio for concrete
0.5 365 191.6 686.64 1173.87 1:1.88:3.21
Fig. 4. Specimen casting.
Table 7
Workability of concrete batches using slump test.
S. NO Waste Ceramic replacement (%) Slump in (mm)
10% 52
25% 48
3 10% 45
4 15% 33
5 20% 30
R. Johnson Daniel and S.P. Sangeetha Materials Today: Proceedings 45 (2021) 6603–6608
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3.7. Physical properties of materials used in concrete
Table 5.
4. Experimental program
4.1. Experimental plan
The main aim objective of this research is to replace the waste
ceramic materials is to grain as fine particles and replaced them
with fine aggregate. This experiment has carried out to find a bet-
ter understanding of factors that can increase concrete’s strength
and properties to determine the value of ceramic waste as aggre-
gate in the concrete. The concrete cubes were tested to find the
value of compressive strength; cylinders were cast for testing split
tensile strength of the concrete cylinder, and concrete beams were
cast to determine the value for flexural strength at various age of
curing 7 days and 28 days with a concrete grade of M30.
4.2. Mix proportion
Mix design was calculated for M30 grade concrete according to
the Indian standard code provision IS 10262–2009 [2], tabulated in
Table 6. Fine aggregate was replaced with crushed ceramic waste
aggregate at different percentages as follows 0, 5, 10, 15, and 20%
in the concrete composition. To determine the value of Mechanical
properties of fine aggregate (river sand) and fine ceramic aggre-
gate, which is extracted from the waste ceramics, were obtained
through experimentation work.
4.3. Preparation of concrete and size of Specimen
The quantities of the concrete constituents were obtained from
the Indian Standard Mix Design (IS 10262:2009) [2]. The mixed
proportion of concrete was prepared in the laboratory. The follow-
ing materials were used cement, fine aggregate, and coarse aggre-
gate mixed in a particular mix ratio in the form of a dry state to
obtain uniform color and calculate the water-cement ratio, and it
is mixed with the dry mix. Concrete will be poured in the cube
mold, cylinder mold, and beam mold by tampering with the fresh
concrete to eliminate the air voids, shown in Fig. 4. After 24 h, all
molds should be unmolded and remove the concrete cubes, cylin-
ders, and beams; the cast is then kept for curing in two different
stages of the test at 7 days and 28 days in into the water tank.
Fig. 5. Slump test.
Fig. 6. Test on compressive strength.
Table 8
Compressive Strength (N/mm
2
) of Concrete Cubes for different percentage of broken
Tiles with Mixing Ratio 1:1.88:3.21.
S.
No
Percentage of
broken tiles
replacement (%)
Average compressive
strength at 7 days in N/
mm
2
Average compressive
strength at 28 days in
N/mm
2
1 0 20.40 32.55
2 5 16.24 28.33
3 10 17.50 29.53
4 15 15.48 27.08
5 20 14.36 26.11
R. Johnson Daniel and S.P. Sangeetha Materials Today: Proceedings 45 (2021) 6603–6608
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5. Test results and discussions
5.1. Workability
A new concrete test has been conducted to determine the work-
ability of concrete. The slump cone test was conducted out in con-
crete batches for various percentages of waste ceramics, as shown
in Table 7. The water-cement ratio improves the workability of the
concrete, with the addition of ceramic waste materials as fine
aggregate. The slump value is as shown in the Fig. 5.
5.2. Compressive strength of concrete
Compression tests were conducted as per the Indian standard
code IS 516(1959), Concrete cubes of size 150mmx150m-
mx150mm for the following mix proportions of 5, 10, 15, and
20% replacement of aggregate with waste ceramic materials. The
cubes were cast and kept for curing at two different ages, 7 days
and 28 days, in the water tank. Then, the concrete cubes were
tested with a compression testing machine (CTM), which has a
capacity of 2000kN, which is shown in Fig. 6. The concrete cube
specimens were loaded until it reaches the failure mode. The
experimental value of the compression test is tabulated in Table 8,
and the comparative study of two different age of curing is shown
in Fig. 7.
5.3. Flexural strength of concrete
The test could be performed following as per code IS 516 –1959.
If the flexural strength would be the same as the tensile strength,
then the material becomes homogeneous. Most materials have
small or large defects, which act to concentrate the stresses locally,
effectively causing a localized weakness. The test was performed
on beams of dimensions 100 100 500 mm to determine the
flexural strength. The casted beams are kept in curing for 7 and
28 days by immersed underwater (Fig. 8.Fig. 9.Fig. 10.Table 9).
Fig. 7. Compressive test.
Fig. 8. Flexural strength on concrete.
Fig. 9. Flexural Strength on ceramic fine aggregate.
R. Johnson Daniel and S.P. Sangeetha Materials Today: Proceedings 45 (2021) 6603–6608
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6. Conclusion
During this research, concrete workability with various mixes
has given a good result, and hardened test on concrete also.
The compressive strength of concrete cubes for a regular con-
crete of M30 grade for two different ages of curing 7 and
28 days is 20.40 and 32.55 N/mm
2
, respectively.
The compressive strength of concrete containing ceramic tiles
of 5, 10, 15, and 20% for 7 days for M30 grade of concrete are
16.24, 17.50, 15.48, and 14.36 N/mm
2
, respectively.
The compressive strength of concrete containing ceramic tiles
of 5, 10, 15, and 20% for 28 days for M30 grade of concrete is
28.33, 29.53, 27.08, and 26.11 N/mm
2
, respectively.
The flexural strength of prism for the regular concrete of M30
grade is 7.5 N/mm
2
. The flexural strength of concrete containing
ceramic tiles of 5, 10, 15, and 20% for M30 grade of concrete are
6.2, 7.0, 5.1, and 4.3 N/mm
2
, respectively.
Overall 10% of replacing ceramic wastes has shown a good
result in all the tests conducted with fresh and hardens concrete
tests.
CRediT authorship contribution statement
R. Johnson Daniel: Conceptualization, Methodology, Writing -
original draft. S.P. Sangeetha: Supervision, Validation.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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Table 9
Flexural strength (N/mm
2
) of concrete Beam for different percentage of broken tiles
with Mixing Ratio 1:1.88:3.21.
S.
No
Various percentage
of waste tiles
replacement (%)
Flexural strength of
concrete beams at
7 days in N/mm
2
Flexural strength of
concrete beams at
28 days in N/mm
2
1 0 3.87 7.5
2 5 4.24 6.2
3 10 4.76 7.0
4 15 4.33 5.1
5 20 3.43 4.3
R. Johnson Daniel and S.P. Sangeetha Materials Today: Proceedings 45 (2021) 6603–6608
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