e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:02/Issue:09/September-2020
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DESIGN & DEVELOPMENT THE SUSTAINABLE GEOPOYMER MORTAR & PAVER BLOCKS USING AAC WASTE Ms. Divya Mahale*1, Ms. Kritika Maske*2, Ms. Pooja Rathod*3, Ms. Pooja Pendane*4, Mr. Jeevan Durge*5, Prof. Laxmikant Vairagade*6 *1,2,3,45U.G. *6Assistant
Student, Civil Engineering Department, G.H.R.A.E.T Nagpur, Maharashtra, India. Professor, Civil Engineering Department, G.H.R.A.E.T Nagpur, Maharashtra, India.
ABSTRACT Concrete is the basic building element for modern society. Every major construction project uses concrete in one form or another. It keeps hot and protected; it allows us to get to job safely; it beautifies our homes and yards. Concrete is produced from some of the world's most scarce property and without poisonous by-product. The concrete material in industry is recycles and reclaims during the developed process. It has a higher duration compared to other products. From the proprietor to the largest city areas, concrete is playing a main role in defensive and maintaining our atmosphere. Due to increasing use of concrete and also its high cost material it is important to decrease its cost and make it durable by adding some% of waste materials in it so that it will achieve its strength. .The aim this research is make economic and ecofriendly paver block, and Reuse the waste of AAC waste. Autoclaved aerated concrete (AAC) is a lightweight cellular concrete which has been used more than 80 years. Currently however, no good recycling options for AAC from production and destruction waste exist. The quantity of AAC Waste which is produce can be used in the manufacture of autoclaved aerated concrete. Keywords: Mortar, AAC Waste, Super plasticizer, hardener, compressive strength.
I.
INTRODUCTION
Autoclaved aerated concrete (AAC) is a light in weight, pre-cast, foam concrete building material suitable for produce concrete masonry unit like blocks. Composed of quartz sand, gypsum, lime, cement, water and aluminum powder, are used in production of AAC blocks. AAC all together provides structure, insulation, and fire, mould-resistance. Slurry of AAC is used in making blocks, wall panels, floor and roof panels, cladding panels and lintels. AAC products may be used for both internal and external structure, and may be decorated or layered with a stucco or plaster compound to protector against the elements, or covered with siding materials.
Fig-1: AAC waste paver block 1.1. AAC Waste Blocks: Autoclaved Aerated Concrete is a Lightweight, Load-bearing; durable. AAC is quite light in mass, having lesser thermal conductivity, high heat resistance, low shrinkage. AAC includes of silica sand, cement, lime, and water and development agent. To decrease the manufacture waste, new AAC block has been developed by using recycling the AAC blocks and converted them in to the powder form. AAC powder is used in replacement of sands as well as cement. The new developed AAC was conducted by replacing cement with recycled AAC in ratio of 0% to 45%.
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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:02/Issue:09/September-2020
Impact Factor- 5.354
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1.2Cement: As per availability of cement in market we have use 43 grade OPC as per IS code. Material Admixture: Mineral admixture are used to replace the OPC with various percentage to find strength of concrete blocks. The AAC waste can be used in different following quantities. Cement is a binder, a substance used for construction that sets, hardens, and adheres to other materials to bind them together. Cement is seldom used on its own, but rather to bind sand and gravel (aggregate) together. Cement mixed with fine aggregate produces mortar .And for masonry cement mixed with sand and gravel is known concrete. Concrete is the most usually used material in existence and is only behind water as the planet's most-consumed resource.
Sr. No.
Size of AAC waste
IS Code recommended
1
75micron
IS 383
2
300 micron
IS 383
1.3 Admixture: An admixture is a material other than water, aggregates, or cement which is used as an ingredient of concrete or mortar to control setting and early hardening, workability, or to provide additional qualities to concrete. The property usually customized is the heat of hydration, accelerate or retard setting time, workability, water reduction, scattering and air-entrainment, impermeability and toughness factors. Admixture which is used in construction of mortar block should be conforming to IS 9103 it is not affecting the property of mortar block. 1.4 Water: Water is the most important elements in construction and is essential for the preparation of mortar, mixing of cement concrete and for curing etc. The quality of water used was directly impact on the strength of the mortar and cement concrete work. The water used for curing and mixing should be free from high quantities of alkalis, acidic, oils, etc that might be harmful to bricks, concrete structure and iron used in structure. Impurities in water can cause metal decomposition, establish surplus silt and clay into the concrete, harmfully affect the harden procedure of concrete and also decrease the strength by even 25%. Thus want to make sure the quality of water used throughout construction is vital. IS 456:2000 standards lays assured parameters from which quality of water must be tested. The water used in manufacture of paving block must be portable and having minimum PH value is 7 to 8. The water cement ratio is 0.45.
II.
METHODOLOGY MORTAR BLOCKS
2.1. Size of Mould: The square mould is given in IS 45658:2006, this mould is in the form of rubber the concrete directly put into it for final shape.
Fig-2: Mould Size 70mm X 70mm X 70mm
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A base line is needed to set up an experimental design to conduct testing an observation for future development and research. All the baseline mortar material used in this study is shown in table. Table-2 : Specification of Material Sr. No.
Baseline Element
Type
1.
Cement
53 grade OPC
2.
Sand
Fine particle
3.
Autoclaved Aerated Concrete
Fine particle
2.2 Weighing of Material: Weighing different types of material before it’s used for mixing. Weighing is important for small type of mixing.
Fig.3: Weighing of Material
2.3 Mixing of Material: Manual mixing procedures have to be carrying out for small amount of work. Manual mixing procedures have to be carrying out for small amount of work. The whole mixing must be done neatly and uniformly.
Fig.-4: Mixing of materials 2.4 Placing of mortar in moulds: Mortar is placed in the moulds using a trowel in two layers, first layer is up to 10mm and second layer is 30mm. The primary level of concrete placed in mould and in second layer slurry of concrete is placed .
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Fig-5: Placing of concrete in mould 2.5 Vibration Machine: In the vibration machine we have placed the concrete mould in vibration table for settling the concrete and compacting also remove the air voids into mortar. The inclination angle of machine is 20 for sliding the block into another table.
Fig-6: Vibration Machine 2.6 Testing of Mortar Block: Strength of mortar blocks was tested on CTM (Compression Testing Machine). Compressive Strength is calculated by the formula: (
III.
)
PAVER BLOCKS DESIGN
3.1. Size of Mould: The rectangular mould shall conform to IS-45658:2006, this mould is in the form of rubber the concrete directly place in it for final shape.
Fig-7: MouldSize240mmX120mmX60mm A base line is considered essential to set up an experimental design to conduct testing an observation for future development and research. All the base line concrete material used in this study is shown in table.
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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:02/Issue:09/September-2020
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Table-3: Specification of Material Sr .No.
Base line Element
Type
1.
Cement
53grade OPC
2.
Sand
Fine particles
3.
Coarse Aggregates
10mm
5.
Autoclaved Aerated Concrete Waste
Fine particles
3.2 Weighing of Material: Weighing different types of material before it’s used for mixing. Weighing is important for small type of mixing.
Fig-8: Weighing of Material 3.3 Mixing of Material: Manual mixing procedures have to be carrying out for small amount of work. This means we must not mix large quantities at the similar time. The whole mixer mix properly.
Fig-9: Mixing of materials 3.4 Placing of Concrete in Mould Concrete is placed in the mould using a trowel in two layers, first layer is up to 10mm and second layer is 30mm.The first layer of mould is concrete slurry for proper combination of second layer in the mould.
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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:02/Issue:09/September-2020
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Fig.10. Placing of concrete in mould 3.4. Vibration Machine: In the vibration machine we have placed the concrete mould in vibration table for settling the concrete and compacting also remove the air voids from concrete. The inclination angle of machine is 20 for sliding the block into another table.
Fig.11. Vibration Machine 3.5 Placing of Block: Block is placed in 7to8 layers for drying purpose on wooden plank of 25mm thickness.
Fig.12. Placing of Block 3.6. Testing of Paver Block: Strength of paver blocks was done on CTM (Compression Testing Machine). Compressive Strength is calculated by the formula: (
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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:02/Issue:09/September-2020
IV.
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MODELING AND ANALYSIS
Fig-13: Mortar Blocks
Fig-14: Compression test on paver blocks
V.
RESULTS AND DISCUSSION
Size of mortar block we casted is 70mm x 70mm x 70mm. We have used various machines such as weighting machine, Vibration table, Compression testing machine, Universal testing machine.
Results: Table-4: Comparison of compressive strength of mortar blocks Sr. No
Mortar Ratio
Material Used
1
1:1
2
Compressive Strength (N/mm2) Material Combination
7 Days
14 Days
28 Days
Cement, Sand
Conventional
13.86
20.40
31.89
1:1.5
Cement, Sand
Conventional
12.61
18.6
28.44
3
1:1
Cement, Sand ,AAC Waste
10% replacement by AAC Waste
14.28
28.36
34.49
4
1:1
Cement, Sand ,AAC Waste
20% replacement by AAC Waste
10.18
19.55
33.78
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5
1:5
Cement, Sand ,AAC Waste
10% replacement by AAC Waste
13.26
24.88
30.53
6
1:5
Cement, Sand ,AAC Waste
20% replacement by AAC Waste
12.24
23.11
29.57
40 35
Compressive Strength (N/mm2)
30 25 7 Days 14 Days 28 Days
20 15 10 5 0
Days
Table-5: Compressive Strength of Paver Block 7, 14 & 28 Days Compressive Strength (N/mm2)
Sr. No
Grade of Concrete
Material Used
1
M25
2
Percent replacement of AAC Waste
7 Days
14 Days
28 Days
Cement, Sand, & Aggregate
Conventional
14.9
20.86
25.86
M25
Cement, Sand, Aggregate, Autoclaved Aerated Concrete (AAC) waste
25%
17.91
23.84
30.48
3
M25
Cement, Sand, & Aggregate AAC Waste
50%
12.17
15.43
22.41
4
M25
Cement, Sand, & Aggregate AAC Waste
100%
8.69
11.86
17.24
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35 30 25 7 Days 14 Days 28 Days
20 15 10 5 0 Conventional
25% Replacement
50% Replacement
100%Rplacement
Days
VI.
CONCLUSION
From experimental results we conclude that AAC Waste give good compressive strength then convention Mortar blocks. Therefore, AAC waste Mortar blocks can replace conventional mortar blocks. AAC Waste is cheaply and readily available and it is economical in construction. Quality of structure is improved by using AAC Waste mortar Block rather than Conventional Mortar Block. AAC Mortar block is lightweight precast building materials that provide equally construction economy and speed. It is an eco-friendly product.
VII. [1] [2]
[3] [4]
[5] [6]
[7] [8] [9] [10]
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Ahmed A., Fried A., Flexural strength of low-density blockwork, Construction and Building Materials, 35:516–520,2012. Bisceglie F., GiganteE., BergonzoniM., Utilization of waste auto claved aerated concrete as alighting material in the structure of a green roof, Construction and Building Materials, 69:351– 361,2014. UNI11235, Criteria for design, execution, testing and maintenance of roof garden, by UNI– Ente Nazionale Italiano di Unificazione(UNI),May2007. Drochytka R., Zach J., Korjenic A., HroudovaJ. ´, Improving the energy efficiency in buildings while reducing the waste using auto claved aerated concrete made from power industry waste, Energy and Buildings, 58:319–323,2013. YardimY., Waleed A.M.T. , Jaafar M., Laseima S., AAC-concrete light weight precast composite floors lab, Construction and Building Materials, 40:405–410,2013. British Standards, BS-5628:Part1:–structural use of unreinforced masonry, 1992. British Standards,BSEN-1052:Part2: determination of flexural strength,1999(now in corporate intoEurocode6). JermanM.,KeppertM.,Vyborn´yJ.,´CernˇyR.´,Hygric, thermal and durability of auto claved aerated concrete, Construction and Building Materials, 41:352–359,2013. Rezende L.R., Camapum de CarvalhJ., The use of quarry waste in pavement construction, Resources, Conservation and Recycling, 39(1):91–105,2003. Nasly M.A, Yassin A.A.M., Sustainable housing using aninnovative inter locking block building system, [in:] Proceedings of the 5thNational Conference on Civil Engineering (AWAM’09): TowardSustainableDevelopment,KualaLumpur,Malysia,pp.130–138,2009. AhmedA, Frieda., Flexural strength of low-density blockwork, Construction and Building Materials, 35:516–520,2012.
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