Experimental Study on the Strength of Concrete using Quarry Dust and Marble Powder

IJSRD - International Journal for Scientific Research & Development| Vol. 4, Issue 04, 2016 | ISSN (online): 2321-0613

Experimental Study on The Strength of Concrete using Quarry Dust and Marble Powder Praveen kumar.R1 Iyappan.G.R2 Iyappan.A.P3 Antony Francis.V4 1,3 P.G. Student 2,4Assistant Professor 1,3,4 Mohamed sathak AJ Collegeof Engineering, Siruseri-603103, India 2 Valliammai Engineering College, Potheri-603203, India Abstract— The present study involves the replacement of the fine aggregate by using the quarry dust and the waste marble dust in the concrete. In this process the natural sand were replaced by artificial sands. The quarry dust and the marble dust were replaced as an fine aggregate in different levels (0%,25%,50% and 100% ) to find the compressive strength and (0%,25%,50% and100%) to find the flexural strength of the concrete. The concrete mix which was made for this concrete was M25 grade of concrete. The specimens were casted for both quarry dust and marble powder at different levels of replacement of fine aggregates. The cubes and the beams were casted at each level of replacement. The cubes were casted and the process of curing was done on 14 days and 28 days. And the specimens were tested to find the compressive strength of the concrete cube. The beams were casted (1mX150mmX180mm) for each levels of replacement of fine aggregate by quarry dust and marble powder. The specimens were cured and then the flexural strength of each beams were tested. Then the values of the both quarry dust and marble powder results were compared with each other.

The load deflection curve was done for each specimen. Then finally these results will compared with each other and then suggestions and recommendations will be provided Key words: Quarry dust, marble powder, sand, cement, concrete, compressive strength, flexural strength I. INTRODUCTION Nowadays there is a lack of natural sand reserves. Urban expansion, local legislation and environmental constraints have made the extraction of natural sand and gravel an expensive activity. Application processes for green field sand and gravel extraction are often long, expensive affairs with a high chance of site applications being rejected. The increasing difficulty in extraction has had a negative effect on the bottom line for many producers. Concrete plants require a consistent, quality sand to optimize their production and minimize their cement usage. In many regions of the world, the extraction of sand and gravel is heavily taxed or banned completely to try to preserve remaining deposits. The industry must find alternatives to meet the growing demand for fine aggregates. Urban expansion, local legislation and environmental constraints have made the extraction of natural sand and gravel an expensive activity. Application processes for green field sand and gravel extraction are often long, expensive affairs with a high chance of site applications being rejected.

The increasing difficulty in extraction has had a negative effect on the bottom line for many producers.

Concrete plants require a consistent, quality sand to optimize their production and minimize their cement usage. In many regions of the world, the extraction of sand and gravel is heavily taxed or banned completely to try to preserve

remaining deposits. The industry must find alternatives to meet the growing demand for fine aggregates.

II. EXPERIMENTAL PROGRAMME A. Materials Used: 1) Cement: Portland cement is composed of calcium silicates and aluminate and aluminaferrite It is obtained by blending predetermined proportions limestone clay and other minerals in small quantities which is pulverized and heated at high temperature – around 1500 deg centigrade to produce ‘clinker’. The clinker is then ground with small quantities of gypsum to produce a fine powder called Ordinary Portland Cement (OPC). When mixed with water, sand and stone, it combines slowly with the water to form a hard mass called concrete. Therefore cement remains in good condition as long as it does not come in contact with moisture. The Bureau of Indian Standards (BIS) has classified OPC in three different grades The classification is mainly based on the compressive strength of cement-sand mortar cubes of face area 50 cm2 composed of 1 part of cement to 3 parts of standard sand by weight with a water-cement ratio arrived at by a specified procedure. The grades are (i) 33 grade(ii) 43 grade(iii) 53 grade. The specific gravity of cement was tested according to IS 455:1980[10] and the obtained value was about 3.14.

2) Aggregate: Aggregate is a collective term for the mineral materials such as sand, gravel and crushed stone that are used with a binding medium (such as water, bitumen, Portland cement, lime, etc.) to form compound materials (such as asphalt concrete and Portland cement concrete). Aggregate is also used for base and sub base courses for both flexible and rigid pavements.

Aggregates is a general term applied to those inert materials, which when bonded together by cement, form concrete. Most aggregates used in this country are naturally occurring aggregates such as crushed rock and gravel. Artificial and processed aggregates may also be also be used for making concrete. These may be broken brick or crushed air cooled blast furnace slag. Light weight aggregates, which are usually byproducts of industries or aggregates processed from natural sources or natural materials have a high percentage of voids and are therefore, light such as pumice, furnace, clinker, coke breeze, sawdust, foamed slag, expanded clays and shale’s, expanded slates etc. These aggregates are also used for the production of concrete of low density. The workability of concrete with light weight aggregates is greatly increased with air entraining agents, and hence the use of many light weight aggregates is being made in concrete where high strength is not desired.Aggregates should be free from adherent coatings, clay lumps, coal and coal residues and should contain no organic admixtures that may cause corrosion of the reinforcement or impair the strength or durability of the concrete. The shapes and sizes of the

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Experimental Study on The Strength of Concrete using Quarry Dust and Marble Powder (IJSRD/Vol. 4/Issue 04/2016/287)

aggregates should conform to the strength and workability requirements.

Natural Coarse Particular sand aggregate Specific gravity 2.62 2.68 Water absorption 1 0.5 (%) Fineness modulus 2.67 7.32 Bulk density (g/cc) 1.49 Percentage of voids 43.43 Grading Zone II Table 1: Physical Properties of Fine and Coarse Aggregate 3) Quarry Dust: A growing number of quarry operators have found that processed, high-quality manufactured sand can improve their bottom line and significantly reduce the percentage of waste and low-value by-products. Customer requirements for production less than 20mm, especially for 7/10mm, mean that significant amounts of 0/7mm are produced as a by-product.

By utilizing the correct process equipment, low-value crusher dust can be processed into a high-value, premium product.Concrete, mortar and asphalt sand production is possible depending on the material characteristics and regional regulations. The benefits of this process are twofold: the producer secures new product offerings and reduces lowvalue product; and the customer has access to a secure supply of sand with a stable grading curve.

Production of high-quality manufactured sand requires specialist knowledge in fine crushing and separation technology to achieve end-product performance. Processing is the key to producing a marketable product. The production of quality manufactured sand, along with its process and process control, is integral to customer success. Globally, piles of manufactured sand are about to grow significantly in the near future.

The two factors that are of the greatest concern to the end users of quarry dust are compliance with local regulations and the consistency of the product.

Compliance with manufactured sand gradation is required not only at the bottom Of the curve, but throughout the product envelope. Product consistency allows a more predictable mix to be produced than is achievable with natural sand due to normal natural variations in dug sand gradation. This means that end users of quarry dust will not allow a safety factor to mitigate for natural gradation variations and can achieve binder savings.

4) Marble Powder: A powder which was obtained as a product by marble sawing and shaping was characterized from a chemical physical point of view in order to use it as mineral addition for mortars and concrete, especially for self-compacting concrete. This marble powder showed a very high fineness value of about 1500 Kg/m2, with 90% of particles finer than 50Âľm and 50% under 7Âľm. For rheological studies, several cement pastes were prepared using marble powder, with and without the addition of acrylic based super plasticizer. Water to cementious material ratio was also varied. In order to evaluate the effects of the marble powder on the mechanical behaviour, many different mortar mixtures were tested, all prepared with sand to cement ratio of 3:1 at about the same workability. Mixtures were evaluated based upon cement or sand substitution by the marble powder.

B. Mix Design: The mix proportion chosen for this study is M25 grade (1:2.01:3.56) with water-cement ratio of 0.45. Cubes of standard size 150x150x150mm of total 30 no. are casted and cured for 28 days and tested as per code IS: 516-1959 and IS: 5816-1999.The beam specimens were 150mm wide and 180mm deep in cross section. They were 1000mm in length the clear cover of the beam was 15mm high yield strength deformed steel bars of diameter 12mm and 8mm were used as the longitudinal reinforcement in the specimens. Two legged vertical stirrups of 8mm diameter at a spacing of 125mm center to center were provided as shear reinforcement. After 14 days and 28 days curing the beam is tested.

Unit of batch

Wate r (liter )

Ceme nt (kg)

San d (kg)

Coarse aggregat e (kg)

Super plasticiz er

Meter cube 164 375 375 750 3.75 content Ingredie 0.45 1 1 2 1% nt ratio Table 2: Mix Proportion for M25 Grade Concrete C. Workability: Slump test is most commonly used method of measuring consistency of concrete which can be employed either in laboratory or site work. The slump test is used vary often in concrete work. It is easily performed at a job site and is useful in detecting variations in mixes of given properties.

Slump test was conducted to determine the workability of concrete. In this experimental work, as the percentage of clay/silt content increases, the workability of concrete mix also increases. The slump value obtained from different percentage of clay/silt content mixes are shown in figure 1.

Fig 1.1: Quarry Dust

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Experimental Study on The Strength of Concrete using Quarry Dust and Marble Powder (IJSRD/Vol. 4/Issue 04/2016/287)

COMPRESSIVE STRENGTH RESULTS 40 30 20 10 0 Control Quarry Quarry Quarry Quarry cube dust 25% dust 50% dust 75% dust 100% 14 days compressive strength(Mpa) 28 days compressive strength(mpa)

Fig. 1: Slump values for Different Mix Proportions D. Compressive Strength Test: For compressive strength of concrete, 150 mm x 150mm x 150 mm cubes were used. Compressive strength results consist for M25 grade of concrete on cubes with (25%, 50% and 100% replacements of quarry dust and marble powder).

The compressive test is done after the specimen has been cured for 14 and 28 days. All the cubes were tested in saturated condition, after wiping out the moisture in their surface. The compressive test is done in compressive testing machine. It has the capacity of 1000 KN. Loading was continued till the readings were revised from the increment values. The reversal in the reading value indicates the specimen has failed. The machine was stopped and the reading at that instant was the ultimate load. The ultimate load divided by the cross sectional area is the compressive strength.

Compressive strength = P/A (MPa) Where, P = Load (MPa) A = Area of the cube = Lxb 14 DAYS 28 DAYS SL.NO compressive compressive SPECIMEN Strength Strength (MPa) (MPa) 1 Cont. Cube 24.47 32.21 QUARRY 2 26.54 34.93 DUST 25% QUARRY 3 25.08 33.01 DUST50% QUARRY 4 19.45 25.67 DUST75 % QUARRY 5 16.88 22.22 DUST 100% Table 3: COMPRESSIVE STRENGTH TEST RESULTS FOR QUARRY DUST

Fig. 2: Compressive Strength results for Quarry Dust SL.NO SPECIMEN 14 DAYS 28 DAYS compressive compressive Strength Strength (MPa) (MPa) 1 Cont. Cube 24.47 32.21 2 MARBLE POWDER 25.12 33.18 25% 3 MARBLE POWDER 25.08 33.01 50% 4 MARBLE POWDER 17.32 25.67 75 % 5 MARBLE POWDER 14.88 20.02 100% Table 4: Compressive Strength Test Results for Marble Powder COMPRESSIVE STRENGTH OF MARBLE POWDER 14 days compressive strength (mpa) 28 days compressive strength (mpa) 35

32.21 33.18 33.01

30 25

24.47 25.12 25.08

25.67 20.02

20

17.32 14.88

15 10 5 0 C.c

25% M.P

50% M.P

75% 100% M.P M.P

Fig. 3: Compressive Strength Result of Marble Powder

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Experimental Study on The Strength of Concrete using Quarry Dust and Marble Powder (IJSRD/Vol. 4/Issue 04/2016/287)

1 2 3 4 5 6

0 1.011 3.37 6.74 10.11 15.165

0 0.1 0.5 0.8 1.2 1.62

7 21.568 2.45 8 23.40 3.02 9 27.97 4.5 10 28.645 4.85 11 30.33 5.26 12 32.015 5.5 Table 5: Load Vs Deflection for Control Beam LOAD Vs DEFLECTION CURVE FOR CB

LOAD IN KN

100 80 60 40 20 0 0

1

2

3

4

5

6

7

8

9

10

DEFLECTION OF BEAM AT CENTRE IN mm

Fig. 4: Load Vs Deflection Curve for Control Beam SL.NO LOAD(KN) DEFLECTION(mm) 1 0 0 2 5.055 0.50 3 11.45 1.20 4 18.87 1.64 5 25.95 2.00 6 33.7 2.24 7 41.45 2.85 8 50.55 3.15 9 54.93 4.50 10 62.00 5.50 11 65.04 6.35 12 67.40 7.75 Table 5: Load Vs Deflection For 25% of Quarry Dust LOAD Vs DEFLECTION CURVE FOR 25% QUARRY DUST 100

LOAD IN KN

E. Flexural Strength: Flexural strength is one measure of the tensile strength of concrete. It is a measure of an unreinforced concrete beam or slab to resist failure in bending. It is measured by loading 6 x 6-inch (150 x 150-mm) concrete beams with a span length at least three times the depth. The flexural strength is expressed as Modulus of Rupture (MR) in psi (MPa) and is determined by standard test methods ASTM C 78 (third-point loading) or ASTM C 293 (center-point loading).Flexural MR is about 10 to 20 percent of compressive strength depending on the type, size and volume of coarse aggregate used. However, the best correlation for specific materials is obtained by laboratory tests for given materials and mix design. The MR determined by third-point loading is lower than the MR determined by center-point loading, sometimes by as much as 15%. Beam specimens must be properly made in the field. Pavement concrete mixtures are stiff (1/2 to 21/2-inchslump).

Consolidate by vibration in accordance with ASTM C 31 and tap sides to release air pockets. For higher slump, after rodding, tap the molds to release air pockets and spade along the sides to consolidate. Never allow the beam surfaces to dry at any time .Immerse in saturated limewater for at least 20 hours before testing. Specifications and investigation of apparent low strengths should take into account the higher variability of flexural strength results. Standard deviation for concrete flexural strengths up to 800 psi (5.5 MPa) for projects with good control range from about 40 to 80 psi (0.3 to 0.6 MPa). Standard deviation values over 100 psi (0.7 MPa) may indicate testing problems. Where a correlation between flexural and compressive strength has been established in the laboratory, core strengths by ASTM C 42 can be used for compressive strength to check against the desired value using the ACI 318 criteria of 85 percent of specified strength for the average of three cores. It is impractical to saw beams from a slab for flexural testing.

Sawing beams will greatly reduce measured flexural strength and should not be done. In some instances, splitting tensile strength of cores by ASTM C 496 is used.

Test is done to find the flexural strength of the beam consists of with and without fibers. The flexural test is done in the loading frame it has the capacity of 500KN. All the beams were tested in single point loading. The load is acted at the center of the beam. The dial gauges were used to find the deflection acting on the beam. For finding the load is given to the beam through the proving ring. The dial gauge readings were recorded at different loads. The load was applied gradually until the first crack was observed.

Subsequently, the load was applied. The behavior of the beam was observed carefully. The crack development and propagation were monitored and marked during progress of the test. The crack width were measured. The deflection was recorded for respective load increments until failure. The failure mode of the beams w.

SL.NO LOAD(KN) DEFLECTION(mm)

80 60 40 20 0

0

1 2 3 4 5 6 7 8 9 10 DEFLECTION OF BEAM AT CENTRE IN mm

Fig. 5: Load Vs Deflection Curve Of 25% Quarry Dust SL.NO 1 2 3 4

LOAD(KN) 0 5.73 10.78 14.828

DEFLECTION(mm) 0 0.50 1.35 1.80

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Experimental Study on The Strength of Concrete using Quarry Dust and Marble Powder (IJSRD/Vol. 4/Issue 04/2016/287)

LOAD vs DEFLECTION CURVE FOR 50% QUARRY DUST 100

LOAD Vs DEFLECTION CURVE FOR 100% of QUARRY DUST 100 90 80 70

LOAD IN KN

5 21.568 2.20 6 27.634 3.25 7 35.722 3.65 8 44.14 4.22 9 50.55 4.40 10 56.95 5.20 11 64.03 5.38 Table 6: Load Vs Deflection For 50% of Quarry Dust

50 40 30

90

20

80

10

70

0

60

0

50

1

2

3

4

5

6

7

8

9

10

DEFLECTION OF BEAM AT CENTRE IN mm

40 30

Fig. 7: Load vs Deflection curve of 100% Quarry Dust

20 10 0 0

1

2

3

4

5

6

7

8

9

10

DEFLECTION OF BEAM AT CENTRE IN mm Fig. 6: Load Vs Deflection Curve Of 50% Quarry Dust

S.NO LOAD(KN) DEFLECTION(mm) 1 0 0 2 2.022 0.05 3 5.392 0.15 4 8.088 0.70 5 17.447 1.45 6 21.90 1.90 7 28.308 2.44 8 33.77 2.80 9 45.16 3.33 10 51.56 4.20 11 56.62 4.63 12 50.77 5.65 Table 7: Load Vs Deflection For 100% of Quarry Dust

SL.NO LOAD(KN) DEFLECTION(mm) 1 0 0 2 5.73 0.50 3 10.78 1.35 4 14.828 1.80 5 18.568 2.20 6 22.95 3.25 7 24.56 3.65 8 26.55 4.22 9 27.10 4.40 10 30.18 5.20 11 32.01 5.38 TABLE 8: LOAD VS DEFLECTION FOR 25% of Marble Powder LOAD Vs DEFLECTION CURVE 25% MARBLE POWDER 100

LOAD IN KN

LOAD IN KN

60

80 60 40 20 0 0

1

2

3

4

5

6

7

8

9

10

DEFLECTION OF BEAM AT CENTRE IN mm Fig. 8: Load Vs Deflection Curve for 25% Of Marble Powder S.NO LOAD(KN) DEFLECTION(mm) 1 2 3

0 2.022 5.392

0 0.05 0.15

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Experimental Study on The Strength of Concrete using Quarry Dust and Marble Powder (IJSRD/Vol. 4/Issue 04/2016/287)

4 8.088 0.70 5 17.447 1.45 6 21.90 1.90 7 23.40 2.44 8 27.97 2.80 9 28.65 3.33 10 29.64 4.20 11 32.02 4.63 12 34.21 5.65 Table 9: Load Vs. Deflection for 50% Of Marble Powder

Fig. 9: Load Vs Deflection for 50% Of Marble Powder SL.NO

LOAD(KN)

DEFLECTION(mm)

1 0 0 2 5.055 0.50 3 11.45 1.20 4 18.87 1.64 5 20.61 2.00 6 21.54 2.24 7 22.34 2.85 8 24.12 3.15 9 26.82 3.95 10 29.46 4.31 11 31.54 5.20 12 33.7 5.89 Table 10: Load Vs. Deflection for 100% Of Marble Powder

Fig. 10: Load Vs Deflection For 100% Of Marble Powder

III. CONCLUSION In the project work, the specimens such as cubes and beams were made and the strength characteristics of the specimen such as compressive strength and flexural strength respectively were tested. The variations in the crack pattern and deflection criteria of quarry dust and marble powder in the replacement of sand are studied and compared. From the above results it is concluded that: 1) In terms of workability, the quarry dust which gives the maximum value without using any admixtures. While in the marble dust, it has very low workability.

2) In the replacement of sand by quarry dust, the concrete which acquires maximum increase in the compressive strength at the level of 50% replacement of sand by quarry dust.

3) In the replacement of sand by marble powder, the concrete which acquires the maximum increase in the compressive strength at the level of 25% of replacement of sand by marble dust.

4) The maximum flexural strength is also obtained at the level of 50% of replacement of sand by quarry dust.

5) It gives the clear suggestions that, the quarry dust has better results in workability, compressive strength and flexural strength of the concrete than the marble powder.

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