IJSTE - International Journal of Science Technology & Engineering | Volume 3 | Issue 09 | March 2017 ISSN (online): 2349-784X
Development of Pavement Concrete Tiles using Fly Ash and ETP Lime Sludge Chitra Shijagurumayum PG Student Department of Civil Engineering KIIT University Bhubaneswar-751024, India
Saransa Sahoo Assistant Professor Department of Civil Engineering KIIT University Bhubaneswar-751024, India
Anushree Khare PG Student Department of Civil Engineering KIIT University Bhubaneswar-751024, India
Abstract Solid wastes obtained from different industries are heterogeneous, in their composition ranging from organic (in industries producing basic consumer products) to inert organic (such as generated in mining and collieries) and may include even hazardous constituents from pesticide industry. The unsystematic disposal of Effluent Treatment Plants (ETP) sludge retrograde the surface soil and contaminate with surface and ground water became a vital environmental and public health issue. Solid waste (lime sludge) generated from fertilizer industry is being used as the constituent of masonry cement, burning of lime sludge as a raw material for pavement tile production and to make building lime and compounding of fly ash with burnt lime sludge to make lime composite mortars. The idea of this research is to study the application and utilization of these industrial wastes as a pozzolanic material in pavement tile production. At very high pressure the paving stones using sand, lime sludge, fly ash, cement and aggregates are compressed to give a hard faced, strong and durable stone like product with or without bevelled edges. They do not require a solely concrete bed and need just a consolidated sand bed for the support. There is no necessary for bonding or pointing and no requirement of any cement. Keywords: Abrasion, Concrete Tiles, Durable, Effluent Treatment Plants (ETP) Sludge, Fly Ash ________________________________________________________________________________________________________ I.
INTRODUCTION
Fly ash is a waste material collected from the flue gases extracted through the burning of coal in thermal power generating sectors. About 112 million tonnes of fly ash per annum are produced by about 120 thermal power generating plants in India. Large quantities of lime sludge from water treatment plant are generated in India and across the world and they are disposed of by land filling. As existing land fill sites have limit of space for disposal and the problem waste stabilization have prompted several researches to find alternatives disposal and recycle techniques for this waste sludge. The finest way for reprocessing these solid wastes is to utilize these wastes in civil engineering construction works, as large quantities of resources are being used recently in civil engineering constructions. Materials Used Various materials used for making concrete tiles are cement, fine aggregates, coarse aggregates, fly ash & ETP lime sludge from fertilizer industry. Mix Proportion 1) 2) 3) 4)
M25 was adopted for making the concrete tiles. All the four tiles made were of different compositions. For the tile named A0, the neither cement nor sand was replaced with any waste products. For the remaining three tiles namely C1, C2 and C3, 50% of sand was replaced with 50% fly ash. For the tile C2, 5% of cement was replaced with ETP lime sludge and for the tiles C3 and C4, cement were replaced by 10% and 15% ETP lime sludge respectively. Wear Determination
The average loss in thickness of the sample gives the wear of the specimen. t = ((W1 – W2)* V1)/(W1*A) Where t = average thickness loss in mm W1 = initial weight of the sample, in gm W2 = Final weight of the specimen after abrasion test in gm
All rights reserved by www.ijste.org
87
Development of Pavement Concrete Tiles using Fly Ash and ETP Lime Sludge (IJSTE/ Volume 3 / Issue 09 / 017)
V1 = initial volume of the sample, in mm3 And A = Surface area of the sample, in mm2 II. EXPERIMENTAL PROCEDURE For each composition four tiles of size 200×200×20 mm were casted taking water-cement ratio 0.5. During casting they were vibrated manually by shaking the mold and by tampering it with the trowel. After 24hours of casting, the tiles were demolded and immersed in water for 28days. After saturation they were wiped to dry and weighed and then they were put on the hot air chamber maintained at a temperature of 1000C for 24 hours and then cooled at room temperature and reweighed. The percentage water absorption by these tiles was calculated from their saturated weight and oven-dried weight. Then from these six tiles, three tiles of each composition were selected for abrasion resistance test. The test specimen of size 70.6mm×70.6mm were sawn off from the central part of each tile. Then they were weighed to the nearest 0.1gm. After initial weighting the test specimen was placed in the thickness measuring apparatus (dial gauge) and with its wearing surface facing towards up and the dial gauge reading was noted. Aluminum oxide powder of 20gm was evenly sprinkled on the grinding path of disc of the abrasion testing machine. The test specimen was then fixed in holding device with the wearing surface facing towards the disc and a load of 300N was loaded at the centre. The grinding disc of the abrasion testing machine was then set on motion of speed 30rev/min. and aluminum oxide powder was fed back continuously on the grinding path. The grinding disc was stopped after every 22 revolutions and the abraded aluminum oxide powder and remaining abrasive powder were left out from the disc and other 20gm of aluminum oxide powder was applied in each time. The test specimen was rotated through a right angle in clockwise direction about the vertical axis after every 22 revolutions. This procedure was repeated 15 times there by giving a total number of 352 revolutions. After the test, the test specimen was again reweighed to nearest 0.1 gm and the thickness was measured with the dial gauge in a similar manner done before the test. III. RESULTS OF ABRASION RESISTANCE TEST The abrasion resistance value for the tested specimens is given below in table: Table - 1 Abrasion resistance value for the tested specimens Concrete Type Abrasion Resistance in mm A0 0.131 C1 0.067 C2 0.061 C3 0.085
Fig. 1: Abrasion resistance value for the tested tiiles
From the abrasion resistance test of the various fly ash and lime sludge composite ties it has been demonstrated as follows: 1) The concrete tiles in which 50% sand replacement with fly ash and 5% cement replacement with lime sludge showed 48.85% & 73.2% better wear resistance than the reference concrete tiles and market tile respectively. 2) The concrete tiles with 50% sand substituted with fly ash and 10% cement substituted with lime sludge showed 53.44% & 75.6% better wear resistance than the reference concrete tiles and market tile respectively. 3) The concrete tiles with 50% sand substituted with fly ash and 15% cement substituted with lime sludge showed 35.11% & 66% better wear resistance than the reference concrete tiles and market tiles respectively.
All rights reserved by www.ijste.org
88
Development of Pavement Concrete Tiles using Fly Ash and ETP Lime Sludge (IJSTE/ Volume 3 / Issue 09 / 017)
IV. CONCLUSION The wear resistance of the concrete tiles should not exceed 1mm. All the fly ash and lime sludge composite tiles showed wear resistance less than 1mm. The results obtained from the abrasion resistance showed superior wear resistance than the market tiles. Pavement tiles are widely used as building components and adoptable at low cost. The pavement tiles find their applications for laying hard, durable and to make attractive flooring in the courtyards, walk ways, pavements, car parking and in similar locations. REFERENCES [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25]
Ravindra Kumar, (2013), “effect of partial replacement of cement by fly ash and lime sludge on strength characteristics of concrete”, pp:61-68. IS 1237-2012, CEMENT CONCRETE FLOORING TILES Manas Kumar Sahoo, (2010-11), “Strength Characteristics study of fly ash composite material”, to Department of mining engineering National Institute of Technology, Rourkela. Satyajeet Kumar, (2014),” Investigation of fly ash polymer composite”. Department of Metallurgical and material engineering National Institute of Technology, Rourkela, 2014. Noolu Venkatashi , “An experimental study on effect of reinforcement on stress-stain behavior of fly ash”. Department of Civil Engineering, National Institute of Technology, Rourkela. Sirish V. deo, (2015), “Mix design approach for high 28 days’ strength, high-volume, low-lime fly ash concrete”. Singh M and Garg M, “Utilization of waste lime sludge as building materials”. Journal of scientific and industrial research, February 2008. Singh M and Garg M, “Utilization of waste lime sludge as building materials”. Journal of scientific and industrial research, February 2008. Dean Patrick Wenzek, Mortana University, “Fly ash concrete blocks”. Thesis Paper Sen, S. and Kumar, A. (1995): “NTPC’s experience in utilization of coal ash”, Proc. of the Workshop on fly ash Utilization, pp: 103-121. Kumar, V. (2006): “Fly ash: A resource for sustainable development’, “Proc. of the International Coal Congress & Expo”, 191-199. Helmath, R. (1987): “Fly Ash in Cement and Concrete”, Portland cements Association, Research and Development Laboratories, Skokie, IL. Ambarish G. and Utpal D., “Bearing ratio of reinforced fly ash overlying soft soil and defomation modulus of fly ash,” Geotextiles and Geomembranes, vol. 27, no. 4, pp. 313-320, 2009. Das A., Jayashree C., and Viswanadham B.V.S., “Effect of randomly distributed geofibers on the piping behaviour of embankments constructed with fly ash as a fill material,” Geotextiles and Geomembranes, vol. 27, no. 5, pp. 341-349, 2007. Senol A., Edil T. B., Md.Sazzad B. S., Acosta H. A. and Benson C. H., “Soft subgrades stabilization by using various fly ashes,” Resources, Conservation and Recycling, vol. 46, no. 4, pp. 365-376, 2006. Shafique S. B., Edil T. B., Benson C. H. and Senol A., “Incorporating a fly ash stabilized layer into pavement design,” Proceedings of the ICE - Geotechnical Engineering, vol. 157, no. 4, pp. 239–249, 2004. Bou E., Quereda M. F., Lever D., Boccaccini A. R., and Cheeseman C. R., “Production of pulverised fuel ash tiles using conventional ceramic production processes,” Advances in Applied Ceramics, vol. 108, no. 1, pp. 44-49, 2009. . CPCB, “Assessment of utilization of industrial solid wastes in cement manufacturing,” Central Pollution Control Board, New Delhi, 2007. CPCB, “Fly ash generation at coal/lignite based thermal power stations and its utilization in the country for 1st half of the year 2011-2012,” Central Electricity Authority, 2011. Ravikumar D., Peethamparan S., and Neithalath N., “Structure and strength of NaOH activated concretes containing fly ash or GGBFS as the sole binder,” Cement and Concrete Composites, vol. 32, no. 6, pp. 399-410, 2010. A. Ghosh and C. Subbarao, “Tensile strength bearing ratio and slake durability of class F fly ash stabilized with lime and gypsum,” Journal of Materials in Civil Engineering, vol. 18, no. 1, pp. 18-27, 2006. Berry E.E., Hemmings R.T., Cornelius B.J., “Mechanism of hydration reactions in high volume fly ash pastes and mortars”, Cem. Concr. Compos. 12 (1990) 253–261. Naik, T. R., 2002. “Use of Residual Solids from Pulp and Paper Mills for Enhancing Strength and Durability of Ready-Mixed Concrete”. Singh G. B. 1998. “Cellular Light Weight Concrete”, The Construction Journal of India, Vol. 1 issue 4. Naik T.R., and Ramme B.W., 1987. "Low Cement Content High Strength Structural Grade Concrete with fly ash." International Journal of Cement and Concrete Research. Vol. 17, pp. 283-294.
All rights reserved by www.ijste.org
89