Analysis of Concrete for Optimum Use of Waste Material in Cement Concrete Precast Products

Due to industrialization, consumption of construction materials is increased which causes the decrease of natural resources day by day. It creates environmental imbalance, so it is necessary to find alternative materials such as industrial waste or agricultural waste which can be replaced with construction materials completely or partially. Pavement blocks, which are industrial products of pre-fabricated unarmed concrete, having various dimensions and special morphology are used for pavement lying of residential project carrying pedestrian and vehicular traffic. Cement concrete paving blocks are precast solid products made out of cement concrete. The product is made in various sizes and shapes viz. rectangular, square and round blocks of different dimensions with designs for interlocking of adjacent tiles blocks. The raw materials required for manufacture of the product are Portland cement and aggregates which are available locally in every part of the country. A concrete paving block is an accurately dimensioned combination of well-graded aggregates and hydrated Portland cement which fits closely together with other paving blocks to form a pavement surface. The blocks are manufactured in wide variety of shapes, some of which are shown in figure. The blocks are then compacted with a manually operated vibratory plate compacted which seats the blocks in the sand layer, compacts the sand layer, and forces some sand into the joints between the blocks. Additional sand is then applied to the surface and swept into the joints between the blocks. More passes are made with the vibratory plate compactor to compact and wedge the sand into the joints. A base and sub- base course under the leveling course provides structural support similar to that of a conventional flexible pavement. CBP provides low-maintenance, high-strength pavement surface that resists heavy, concentrated or abrasive loads and chemical spills involving fuel, hydraulic fluid, and other materials. Their modular nature and potential for reuse allow easy removal and replacement for access to bury utilities or to correct settlement. A block pavements unique

Cement concrete paving blocks find applications in pavements, footpaths, gardens, passenger waiting sheds, bus-stops, industry and other public places. The product is commonly used in urban areas for the above applications. Hence, the unit may be set up in urban and semi urban areas, near the market. A lot of face-lift can be being given to roads, footpaths along the roadside. Concrete paving blocks are ideal materials on the footpaths for easy laying, better look and finish. Whereas the pavement blocks find extensive use outside the large building and houses, lots of these materials are also used in flooring in the open areas of public offices and commercial buildings and residential apartments

Concrete block pavements differ from other forms of pavement in that the wearing surface is made from small paving units bedded and jointed in sand rather than continuous paving. Beneath the bedding sand, the substructure is similar to that of a conventional flexible pavement. In concrete block pavement the blocks are a major load-spreading component. The blocks are available in a variety of shapes and are installed in a number of patterns, such as stretcher bond, herringbone bond, etc. A review of existing literature revealed considerable differences in findings regarding the contribution of various block parameters to the structural capacity of pavement. The surface of concrete block paving comprises concrete blocks bedded and jointed in sand. It transfers the traffic loads to the substructure of the pavement.

Fly ash is a waste produced in coal-fired thermal power stations. It has pozzolonic properties and can therefore be stabilized with either cement or lime to achieve the strength required for use as base courses in pavements. Agencies such as the Electric Power Research Institute (EPRI) have specified criteria and guidelines for the determination of the stabilizer content. This requires carrying out unconfined compression tests on stabilized fly ash specimens prepared and cured as per standard procedures. The stabilizer content is the minimum amount of the stabilizer for which the unconfined compressive strength of the specimens complies with the specified values. The actual curing conditions of the stabilized fly ash bases in the field, however, will differ from those of the laboratory specimens. This Most thermal power stations use coal as fuel in the furnaces to produce steam. The fuel gas carries along with it the fine residue of the burnt coal, which is deposited in a field of hoppers called electrostatic precipitators (ESP) This residue, called fly ash, and is generally considered to be an industrial waste. The utilization of fly ash has engaged the attention of experts from various fields for several decades. However, even today, there is a significant gap between the rates of utilization and production of fly ash, as the data in the situation in four major fly ash producing countries. The combined data for both dry type ash disposed of as collected (ESP) and wet type ash disposed of in slurry form in ash ponds and lagoons fly ash disposal systems. Fly ash is a fine-grained material of mostly silt size 0.075– 0.002 mm particles. It is non-plastic and can therefore be handled easily. Further, because of its pozzolanic properties, it can be stabilized with cement or lime to achieve the strength required for use as base and sub base courses in pavements. In Great Britain and France, pavement sections with cement-stabilized fly ash have been constructed for more than 35 years Glogowski et al. 1992. A survey made in 1992 Collins and Ciesielski1994, Coal 2001 indicated that at least 22 states in the United States have made some use of fly ash in stabilized base or sub base applications.

As solid waste disposal has received increasing attention, waste glass has been heavily targeted for recycling efforts, with some localities contemplating prohibitions of glass in landfills. Not all waste glass can be recycled into new glass because of impurities, prohibitive shipping costs, or mixed color waste streams that may be difficult to separate into useful raw glass stocks. Use of this waste glass in construction materials is among the most attractive options because of the volume of material involved, the capacity for use of the material in bulk, and the likely ability of construction applications to afford allowances for slight variation in composition or form. Considering waste glass not as waste but as a new resource, we crush, bake and foam it to produce Supersol, an artificial light porous foamed material. It can be used in various areas, such as greening, insulation, horticulture, water purification, architecture and civil engineering, and thus is a developing recycling societies.Waste Glass is a transparent material produced by melting a mixture of materials such as silica, soda ash, and CaCO3 at high temperature followed by cooling during which solidification occurs without crystallization. Glass is widely used in our lives through manufactured products such as sheet glass, bottles, glassware, and vacuum tubing. The amount of waste glass is gradually increased over the recent years due to an ever-growing use of glass products. Most waste glasses have been dumped into landfill sites.The Land filling of waste glasses is undesirable because they are not biodegradable, which makes them environmentally less friendly. So we use the waste glass in concrete to become the construction economical as well as eco-friendly. (Source CEA annual report)

Sisal fibre is a leaf fibre extracted from the leaves of plant which is scientifically known as Agave sisalana. The Sisal plant is one of the types of perennial shrub which grows in the tropical and subtropical regions of the world.

i) Characteristic strength 20 N/mm2 iii) Degree of quality control- Good iv) Type of exposure- Moderate

Step-1) Standard mean strength for mix design: f´ck = fck +1.65 S S = Standard deviation. Now, for M20 concrete, fck = 20 N/mm² & S = 5 N/mm². f´ck = 20 + 1.65 × 5 f´ck = 26.60 N/mm² Step-2) Selection of water/cement ratio: For maximum aggregate size of 10mm, W/C Ratio is 0.45, Adopt W/C = 0.45 Step-3) Selection of water content: Maximum water content for max agg.size 10mm, is 208 kg/m³. Let us, take it as 189 kg/m³.

W/C = 0.45, Water content = 189 kg/m³. So, cement content = 420 kg/m³

Step-5) Estimation of entrapped air:

Step-6) Selection of volume of aggregates in all-in-aggregate: For 10 mm size of aggregate (zone I)

But for every 0.1 increase in C.F. & for zone I, reduce fine aggregate volume by 0.015

V = [W+ (C/Sc) + (1/P) × (Fa/Sfa)]×(1/1000) 0.97= [188+ (417.78/3.15) + (1/0.545) × (Fa/2.62)] × (1/1000)

CA = [((1-P)/P) × Fa × (Sca/Sfa)]

CA = [((1-0.545)/0.545) × 925.24 × (2.67/2.62)]

Step No 1- All the ingredients of Concrete mixed with required quantities on GI sheet and mixing to be done by hand. Step No 2- The mould for concrete block cleaned and spreading the oil in interior sides Of mould. Step No 3- Mixed concrete now placed in mould and it get tempered by road the size of specimen will be 15*cm*15cm*15cm Step No 4-Then the specimen demounted after 24 hours and placed in water tank for required days

Step No 1- All the ingredients of Concrete mixed with required quantities on GI sheet and mixing to be done by hand. Step No 3- Mixed concrete now placed in mould and it get tempered by road the size of specimen will be 15*cm*15cm*15cm Step No 4-Then the specimen demounted after 24 hours and placed in water tank for required days

1. Fly ash replacement = (15%, 30%, 45% of weight of cement) 2. Waste glass replacement = (15%, 30%, 45% of weight of fine aggregates) 3. Sisal addition = (1%, 1.5%, 2% of weight of cement)

Cubes are casted and tested of M 20 grade of concrete for conventional concrete without any replacement result as follows:

From the Experimental results we can conclude that, 1. The properties of ingredients of concrete which are using for conventional concrete are as per limit of IS code, so it can be used for further process. 2. The properties of fly ash, sisal fibers, and glass powder examined carefully , then we conclude that due to some similar properties

3. By the comparative study we can conclude that i) Incorporating 15% Fly ash in place of cement helps to reduce the cost and thereby achieve economy with increase in compressive strength 30% waste glass in place of fine aggregate, gives acceptable mechanical properties with increased compressive strength at an age of 28 days. Additional sisal fiber (0.5% by weight of cement) increases compressive strength of concrete pavement block. ii) Compressive strength increases with increasing the glass percentages from 15% to 30%, replacement of glass to the fine aggregate ,which helps to reduce cost and after 30% waste glass replacement onward, the strength decreases as the internal void of waste glass increases. 4. Fly ash can replace the cement up to 15%, which will help to reduce the cost & thereby bring economy. Cost of paving blocks decreases with increase in glass content. Sisal fiber will develop the strength in the concrete paving blocks which helps to give a long lasting performance by the paving blocks. 5. The value of abrasion resistance for paving block with addition of waste is minimum which is within limit of IS code. 6. Manufacturing cost of paving block can be reduced by using waste material up to 10%.

1. Basihar Taha& Ghassan Nounu (2009) ―Utilizing wastere cycled glass as sand/cementreplacement in concrete” ASCE Journal of Materials in Civil Engineering/Vol.21Issue12December-2009. 2. ShiCong Kou, Chisun Poon &Dixon Chan (2007) “Influence of fly ash as cement replacement on the properties of recycled aggregate concrete” ASCE Journal of Materials in Civil Engineering / Vol.19Issue 9 september-2007. 3. Diego Alejandro Gutiérrez-Orrego; Edwin Fabián Garcia-Aristizabal; and Maryory Astrizabal and Maryory Astrid ―Mechanical and Physical Properties of soil-cement blocks reinforced with mineral wool and sisal fiber‖ Journal of material in civil engg. ASCE, ISSN 0899-1561. proportions and different percentage of fiber addition” International Journal of Research in Engineering and Technology Vol.4(3), pp.474-477. 5. Anuj Kumar, Sanjay Kumar (2013) “Development of paving blocks from synergistic use of red mud and fly ash using geopolymerization”, Construction and Building Materials, Vol.38, pp.865-871. 6. Balasubramanian, J. Chandrashekaran, (2015) “Experimental Investigation of Natural Fiber Reinforced Concrete in Construction Industry”, International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 02 (01), pp. 179-182. 7. Darshan Narayana1, Prof. Gireesh Mailar (2015) “Experimental Investigation On the Properties and Durability Of Partially Replaced Recycled,” IJREAT International Journal of Research in Engineering & Advanced Technology, Volume 2, (6) pp. 135- 141. 8. Ganjian, Jalull, Sadeghi-Pouya (2015) “Using waste materials and by-products to produce concrete paving blocks”. Construction and Building Materials, Vol.77, pp.270-275. 9. Ganjian, Jalull, Sadeghi-Pouya (2014) ―Reducing Cement Contents of Paving Blocks by Using Mineral Waste and by-Product Materials” Journal of Materials in Civil Engineering, Vol.27(1), pp.1-13. 10. Gencel, Ozel, Koksal, Erdogmus, Martínez-Barrera, Witold Brostow (2012) “Properties of concrete paving blocks made with waste marble” Journal of Cleaner Production, Vol.21, pp.62-70. 11. Giordano Penteado, Carvalho, Cecche Lintz (2015) “Reusing ceramic tile polishing waste in paving blocks manufacturing”. Journal of Cleaner Production, Vol.30, pp1- 7.

Department of Civil Engineering, Padmabhooshan Vasantdada Patil Institute of Technology (PVPIT)