Potential of Industrial Wastes and by Products in Concrete An Innovative Embodiment

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308
INTERNATIONAL
JOURNAL
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(Print), ISSN 0976 6316(Online),
Volume 5, Issue OF
8, August
(2014), pp.
101-113 IAEME
AND TECHNOLOGY (IJCIET)
IJCIET
ISSN 0976 6308 (Print)

ISSN 0976 6316(Online)
Volume 5, Issue 8, August (2014), pp. 101-113
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POTENTIAL OF INDUSTRIAL WASTES AND BY- PRODUCTS IN

CONCRETE: AN INNOVATIVE EMBODIMENT TO SUSTAINABILITY
Arvind Prakash Srivastava1,
Vasu Krishna2
Assistant Professor, Department of Civil Engineering, SRM University

Estate Officer, BabaSaheb BhimRao Ambedkar Central University, Lucknow
ABSTRACT
In the 21st Century, we have been using the natural resources at a rate that cannot be
sustained indefinitely. Exploiting these resources and estent of energy used in their consumptions,
results degradation of our balanced ecological system in the form of pollutants, wastes generation,
heat sink effects in the cities etc. Tremendous amount of waste materials and by-products like
Ground granulated blast furnace slag, waste glass, plastic waste etc. are generated from the industrial
sector. Various environmental problems can be resolved by utilizing the industrial wastes and by
products to create beneficial construction materials. These materials also enhance the mechanical
and durability properties of the building material in which they are added. This research paper is the
initial step to bring forward the utilization of various industrial wastes and by products in the
concrete including their influence on the properties of concrete. Various industrial wastes discussed
in this paper are Coal fly ash, Metakaolin, Ground granulated blast furnace slag, Plastic waste, Glass
waste.
Keywords: Waste Materials, By-Products, Utilization, Properties.
I. INTRODUCTION
Increasing amount of industrial by products and wastes has become a major environmental
problem. These by products and wastes are not only difficult to dispose but also cause serious health
hazards. Today, the main aim of the environmental agencies and governments is to minimize the
disposal problem and health hazards of these wastes and by products. The productive use of these
materials is one of the best ways to alleviate some of the problems of the solid waste management.
One of the key solutions is to utilize these wastes in the concrete. But the question arises: Why in
Concrete?
101
(Print), ISSN 0976 6316(Online), Volume 5, Issue 8, August (2014), pp. 101-113 IAEME
Cement consumption in the world has increased exponentially since 1926 and is continuing
to increase. Because of its scale of consumption and manufacture, Cement is only next to fossil fuel
burning contributing to about 7 % Greenhouse gas emission [19]. Thus, control of this greenhouse
gas emission is a major issue for sustainable concrete. Use of supplementary cementitious material,
especially industrial waste and by-products in concrete to reduce cement clinker consumption is
currently being considered as a major step towards achieving sustainability of concrete. Thus
utilization of industrial waste and by-products in Concrete not only minimize the GHGs emission
but also reduce the disposal problems and hazards caused by these wastes.
There are several types of industrial wastes which can be utilized in the concrete either as a
replacement of cement (or sand) or as an additive material. Some of these wastes are Coal Fly Ash,
Ground Granulated Blast Furnace Slag, Metakaolin, Waste Glass, Plastics, Wood Ash, Rice-husk ash
etc. It has been identified that utilisation of these wastes enhances some properties of the concrete.
Significant researches have been going on in various parts of the world related to these subjects.
Some waste products have established their credential in their usage in concrete while various
researches are being carried to understand their potential use in construction industry.
II. COAL FLY-ASH
Fly ash also known as pulverized fuel ash, is the ash precipitated from the exhaust of coalfired power stations, it is the most common artificial pozzolona. According to ASTM C618-94A, Fly
ash can be classified on the basis of coal from which the latter originates. Class F fly ash is the most
common fly ash derives from the bituminous coal. Sub- bituminous coal and lignite result in highlime ash, known as Class C fly ash.
Influence of fly ash on fresh properties of Concrete
The main influence of fly ash on fresh properties of concrete is reduction in water demand
and improved workability. For a constant workability, the reduction in water demand of concrete due
to introduction of fly ash is usually between 5-15 % in comparison to ordinary concrete [10].
Concrete mixtures with fly ash will require less water per cubic metre for a given slump
Influence of fly ash on hardened properties of Concrete
Strength Development
Although concrete mixtures containing fly ash tend to gain strength at retarded rate than
concrete without fly ash, the long term strength (90 days and after) is usually higher [10]. It has been
found that pozzolonic reaction of fly ash is slow. The reaction of fly ash is also affected by the
properties of Portland cement with which it is used.
Fig.1: Effect of fly ash on compressive strength

102
Durability of fly ash Concrete
Since reaction of fly ash is slow in concrete, initially, the concrete has higher permeability as
compared to ordinary concrete. However, with time, fly ash concrete exhibits very low permeability.
A concrete with 25% fly ash can have a coefficient of permeability at least one order of magnitude
less than a concrete without fly ash. This leads to enhanced durability as aggressive agents cannot
attack the concrete from within but are restricted to the concrete surface [2, 10]
Fig. 2: Permeability of fly ash vs. controlled mix concrete

Fly ash Concrete may contribute to the sulphate attack due to presence of lime and alumina in
the fly ash. However the use of low lime fly ash (ASTM Class F) can increase the sulphate resistance
of the concrete. The content of the fly ash should be generally between 20-40 % of the total
cementitious material [2].
Fig. 3: Expansion of the mortal in sodium sulphate solution

III. GROUND GRANULATED BLAST FURNACE SLAG (GGBS)
GGBS is a solid waste discharged by Iron and Steel industries. It is industrial by-product
obtained from pig iron through rapid cooling by water or quenching molten slag. Here, the molten
slag is produced which is instantaneously tapped and quenched by water. This rapid quenching of
molten slag facilitates the formation of Granulated slag. GGBS is processed from Granulated slag.
If slag is properly processed then it develops hydraulic property and it can effectively be used as a
pozzolonic material. However, if slag is slowly air cooled then it is hydraulically inert and such
crystallized slag cannot be used as pozzolonic material [8]. GGBS can be grounded to a fineness of
any desirable value but usually it is finer than Portland cement. Increased fineness leads to increased
activity at early ages [10,22]. Table I shows the composition of GGBS [8].
103
Table I: Composition of GGBS
Composition
Percentage
SiO2
34.4
Al2O3
21.5
Fe2O3
0.2
CaO+MgO+P2O5
43.24
SO3
0.66
Influence of GGBS on fresh properties of Concrete

The presence of GGBS improves the workability of the concrete. It improves the mobility of
the mix and makes it cohesive also. This is due to surface characteristics of the GGBS which are
smooth and absorb little water during mixing [10]. Workability of the concrete mix containing
GGBS increases with the increase in surface are of the latter [11].
Influence of GGBS on hardened properties of concrete
Concrete containing GGBS have long term strength development (generally after 56 days or
more). It is because the initial hydration of GGBS is very slow. The progressive release of alkalis by
the GGBS, together with the formation of Calcium Hydroxide by Portland cement, results in
continuing reaction of GGBS over a long period. [8] reported that concrete containing GGBS up to
30% does not show any increase in strength up to 28 days. Table 2 can illustrate the same:
Table II: Effect of GGBS (up to 30%) on the compressive strength
Mix
0%
5%
10 %
15 %
20 %
25 %
GGBS GGBS GGBS GGBS GGBS GGBS
30 %
GGBS
7 Days
21.03
20.74
20.44
19.85
18.07
16.88
15.40
14 Days
23.70
22.81
22.66
22.36
19.55
18.51
16.74
28 Days
26.9
25.00
24.59
24.49
20.88
20.74
18.81
It is found that concrete containing 20-60% GGBS does not achieve the desirable strength
after 28 days of curing, where similar or higher long term strength are obtained with that of normal
concrete. The proportions of GGBS and Portland cement influence the development of strength of
the resulting concrete. For the highest medium term strength, 50% of GGBS in the cementitious
material is advised. But the early strength is lower as compared to ordinary cement concrete.
104
Fig 4: Compressive strength of GGBS concrete of various percentages [10]

Durability
The value of Drying Shrinkage of concrete containing GGBS is always much smaller than the
Portland cement concrete. Figure 5 shows the test result of drying shrinkage of concrete with and
without GGBS [10].
Fig 5: Drying shrinkage of ggbs concrete with 0 to 180 days

Concrete containing GGBS is highly resistance to chloride penetration. Table III depicts the
test results of same [5].
Table III: Charge passed in Coulombs
Mix
OPC
GGBS
W/C
23.C
50.C
0.4
0.5
0.4
0.5
4700
9800
1300
1700
12000
13000
1500
2200
The beneficial durability aspects of GGBS concrete is because of its dense micro-structures
as in this case pore space are filled with C-S-H rather than in Portland- cement- only paste. Due to
this Sulphate Resisting property of GGBS concrete is much better than ordinary cement concrete [10,
20, 22]. However to be effective, the content of GGBS must be at least 50% by mass of the total
cementitious material (preferably 60-70%).
105
IV. WASTE GLASS
It is estimated total solid waste generated each year in USA contain about 7% waste glass [9].
Definatly for the entire world, it would be much more. But unlike many of the other constituents, it
does not decay and is a permanent and often hazardous pollutant. Common glass contains about 70%
SiO2 and others including Al2O3, CaO, MgO etc. Crushed glass particles are generally angular in
shape and may contain some elongated and flat particles. The degree of angularity and the quantity
of flat and elongated particles depends on the degree of crushing. Recycling glass from the municipal
solid waste stream for use as a raw material in new glass products is limited because of the high cost
of collection and processing of waste glass. In addition, during collection and handling of waste
glass, high percentage of glass breakage limit the quantity of glass that can be actually recycled.
Several Researches has been carried out to utilize the waste glass in the concrete. The glass can
either be used as aggregate (coarse/fine) or as a partial replacement of cement. But the flat elongated
particle shape of crushed glass and the physical and chemical nature of the surface do not normally
make crushed glass a very suitable for any type of concrete. However, given an economic or
environmental incentive to dispose of the material, technical problems need not necessarily prevent
its successful utilization as aggregate.
Influence of Waste Glass on fresh properties of Concrete
Whether used as coarse or fine aggregate, waste glass reduce the workability of the concrete
mix. Using a high proportion of waste glass decreases the slump value due to the fact that waste
glass has poor geometry. Waste Glass aggregate has sharper and angular shape which results in less
fluidity [9].
Influence of Waste Glass on Hardened properties of Concrete
It is stated that smaller the size of the glass, the higher the strength of the concrete. Modhera
[12] showed that strength of the concrete increases with the percentage in replacement of the cement
by the glass fines but up to certain limit only. Table 4 can illustrate the same [12]
Table IV: Waste glass as a replacement of cement
Waste glass
Compressive Strength
percentage
(MPa)
0
27.33
28.87
10
30.08
15
31.85
20
33.86
25
30.82
30
24.44
35
22.72
40
19.25
106
However if waste glass are used as a Coarse aggregate (10mm-20mm), the strength obtained
are comparatively less than the ordinary mix. Nevertheless, most of the values exceed the minimum
specified value for structural plain concrete. Figure given below shows the effect of glass aggregate
on the compressive strength of concrete
Fig 6: Waste glass as a replacement of coarse aggregate (Note: size of the crushed glass is about
19mm)
Durability
Expansion is one of the major drawbacks concerned with concrete containing waste glass.
Several studies reported that all concrete with glass aggregates expands and cracks due to reaction
between glass aggregate and alkalis from cement, like traditional ASR [3]. However it is found that
use of low alkali Portland cement does not reduce the expansion of concrete made with crushed
glasses. The expansion of concrete containing glass aggregate is due to the imbibition of water by its
corrosion product N-C-S-H. In traditional ASR, reactive silica reacts with alkalis in the cement to
form N-C-S-H, which adsorb water and cause expansion [3]. It is also found that concrete containing
waste is less resistant to Sulphate attack. However according to [11], mineral additives (Silica fumes,
fly ash, glass powder) can reduce the expansion of the concrete and improves the durability of
concrete. Also size of the waste glass controls the expansion. The finer the particle size, the lesser
will be the expansion.
V. METAKAOLIN
Metakaolin (MK) is a pozzolonic material. It is manufactured from kaolin clay. Kaolin is a
fine, white, clay mineral that has been traditionally used in the manufacture of porcelain. It is silica
based product that, on reaction with calcium hydroxide, produces CSH gel. It also contains some
amount of alumina. MK is a very fine material. It is about 99.9% finer than 16m. Major
constituents of MK are SiO2 and Al2O3.
Influence of MK on fresh properties of Concrete
Workability of the concrete decreases with the inclusion of MK and decrease in workability
increases with the replacement level.[6] reported the slump of concrete containing 0, 5, 10 and 15%
MK. The results are shown in the table V.
107
Table V: Slump value of concrete containing Metakaolin
Mix
Slump(mm)
OPC
100
MK 5%
30
MK 10%
20
MK 15%
Influence of MK on hardened properties of Concrete

Compressive strength of Concrete increases if the MK is replaced up to 30 % only [15]. It
also contributes to the high early age strength development. Table VI shows the strength
development of concrete containing Metakaolin.
Table VI: 28 days test result of MK Concrete
Percentage of
Replacement
Compressive
Strength (MPa)
87.0
91.5
10
104.0
15
103.5
The higher surface area Metakaolin yielded the highest strength and the fastest rate of
strength gain. The positive influence of the Metakaolin fineness on compressive strength was more
apparent at the later ages (i.e. 7 days or more). Furthermore, the 3 days compressive strength at 10%
and 15% Metakaolin replacement observed to be larger than the 28 days strength without
Metakaolin, confirming that Metakaolin has a pronounced influence on early age strength [15].
Durability
Sulphate attack is one of the most aggressive deterioration that affects the durability of
concrete structures. MK increases the sulphate resistance of the concrete structure. [7] evaluated the
effect of MK on the sulphate resistance of the mortar. Cement were replaced with 0%, 5%, 10%,
15%, 20% and 25% of Metakaolin. The specimens were tested for Sulphate attack (using 5% of
Sodium Sulphate soln.). It was observed that expansion decreased with increase in MK content.
Metakaolin reduces the chloride ion permeability of the concrete structures. According [14],
the amount of chloride charge passes through MK concrete is lower than the ordinary concrete. Also
at higher w/b ratio, MK is more effective than SF in improving the resistance of concrete to chloride
ion penetration.
108
Table VII: Charge passed (Coulombs) through samples
w/b ratio
0.30
0.50
Mix
0
3 Days
2461
7 Days
2151
28 Days
1035
5% MK
1327
1244
862
10% MK
417
347
199
20% MK
406
395
240
5% SF
1060
945
665
10% SF
567
445
360
5312
4054
2971
5% MK
4215
3765
2079
10% MK
1580
1247
918
20% MK
751
740
640
5% SF
3156
2047
1641
10% SF
3140
1877
1223
VI. WOOD ASH

The enormous amount of wastes produced during wood processing operations in many
countries provides challenging opportunities for the use wood wastes as a construction material. The
physical and the chemical properties of wood ash depend upon several factors such as species of
wood, combustion temperature etc. The average particle size of wood ash is about 230 m [11]. The
major chemical components present in wood ash are SiO2, CaO, and Fe2O3. Wood ashes have very
less and slow pozzolonic activity however from strength point of view, they are quite satisfactory.
Influence of Wood ash on fresh properties of Concrete
Strictly speaking, Wood ash reduces the workability of the concrete whatever the percentage
of replacement is. [4] reported the slump test of concrete containing different percentage (5,
10,15,20,25 and 30 by weight of cement) of waste wood ash used as an additive in concrete. The
values of slump are given in the table VIII.
Table VIII: Value of slump for different percentage of wood ash replacement
Percentage of
Slump (mm)
Replacement
0
62
5
10
15
20
25
30
0
109
Influence of Wood ash on Hardened properties of Concrete
[4] determined the compressive strength of concrete made with various percentage of waste
wood ash. They reported that compressive strength generally increased with the age but decreased
with the increase in wood ash content. A possible explanation for this trend is that wood ash acts
more like filler in the matrix than as a binder. However there is a improvement in strength of wood
ash concrete (up to 20% replacement level) after 90 days. This is due to weak pozzolonic activity and
fine filler effect.
Durability
[13] investigated the drying shrinkage of concrete mixture made with wood ash. Wood ash
percentage was 5, 8 and 12. They concluded that mix containing more wood ash has more drying
shrinkage. However there is not much effect on the wood ash concrete due to freezing and thawing.
VII. RICE HUSK ASH (RHA)
Rice Husk Ash is a by-product from agriculture industry. It is obtained by burning the rise
husk at controlled temperature and pressure. Completely burnt rise husk ash is grey to white in
colour. Rise husk ash contain significant amount of silica and thus it shows very good pozzolonic
properties. However, silica content in RHA depends on the temperature and duration of combustion
of rice husk. Well burnt and well- grounded RHA is very active and considerably improves the
strength and durability of cement and concrete.
Influence of RHA on fresh properties of Concrete
[16] studied the effect of RHA on the workability of Concrete. Cement was partially replaced
with 0, 20, 25 and 30% of RHA. Slump and Compaction factor results are given in the table IX.
Table IX: Workability of Concrete containing RHA
RHA %
Slump (mm)
Compaction
Factor
40
0.926
30
33
0.93
40
30
0.92
It is clear that slump decreases with the increase in RHA content however this decrement is
not too much, thus RHA can be utilized as a cement replacement in concrete.
Influence of RHA on hardened properties of Concrete
It has been observed that RHA concrete exhibits higher compressive strength than the
ordinary cement concrete. However, early age strength development of RHA concrete is
comparatively low. [17] investigated the influence of 10% RHA on the concrete. The results were
compared with 10% Silica fume concrete and ordinary concrete. They concluded that RHA concrete,
110
in general, achieved higher strength than ordinary concrete but lower than that of Silica fume
concrete. It is also suggested to replace the RHA up to 30% of the cement only [16].
Durability
Chloride-ion penetration of concrete containing RHA is significantly less than the ordinary
concrete [17]. Table X illustrates the chloride-ion permeability of RHA concrete
Table X: Chloride-ion Penetration test results
Chloride Ion Resistance (Coulombs)
Type of
Concrete
W/C
Control
0.40
3175
1875
10% RHA
0.40
875
525
10% SF
0.40
410
360
7 Days
28 Days
Concrete containing RHA shows excellent performance in the freezing-thawing test. The
RHA concrete shows good durability factor and very small changes in length, mass, pulse velocity
after 300 cycles of freezing-thawing [17]. RHA concrete shows resistance to Sulphate attack also.
[18] determined the Sulphate resistance of mortars made from ordinary Portland cement containing
fly-ash and rice husk ash (RHA). It was observed that expansion of ordinary cement mortars, in
Na2SO4 solution, was much larger than those made with blended cements.
CONCLUSION
1. Utilization of Industrial waste and by-products in concrete helps in waste disposal, reduction of
Greenhouse gases and thus contribute to Sustainable development.
2. Fly ash improves the workability of the concrete and contributes to the high later strength
development.
3. GGBS improves the workability of the concrete mix. Up to 30% GGBS does not show much
improvement in strength but more than 30% significant long term strength is developed.
4. Metakaolin decreases the workability of concrete. It increases the strength of concrete
especially after 7 days. Metakaolin up to 15% is sufficient to increase the strength and
durability.
5. Waste glass reduces the workability of the concrete. Glass fines can increase the strength but
up to certain percentage of replacement of cement only. Durability of concrete containing
waste glass can be affected due to expansion.
6. Wood ash lowers the workability of the concrete. Strength is also lowered with increase in
percentage of the wood ash. However wood ash concrete is not much affected by freezingthawing
7. Rice husk shows pozzolonic properties. It improves the strength and durability of the concrete
provided that Rice husk should be burnt properly. Upto 30% utilization of the Rice husk ash is
recommended.
111
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112
AUTHORS DETAIL
Vasu Krishna is a graduate in civil engineering from SRM University. He is member of ACI
committee on Sustainability of the Concrete. He has published various research paper related to the
field of Sustainability of the Concrete. He is member of ASCE, IRC, ICE-UK. Presently he is posted
as Estate Officer of Bhimrao Ambedkar Central University, MHRD, Govt of India.
Arvind Srivastava is Assistant Professor at SRM University. His areas of interest include
Sustainable Concrete Structures, Construction and Project Planning. He has published various papers
in different journals and conferences.
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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308

ISSN 0976 6308 (Print)

POTENTIAL OF INDUSTRIAL WASTES AND BY- PRODUCTS IN

Assistant Professor, Department of Civil Engineering, SRM University

Fig.1: Effect of fly ash on compressive strength

Fig. 2: Permeability of fly ash vs. controlled mix concrete

Fig. 3: Expansion of the mortal in sodium sulphate solution

Influence of GGBS on fresh properties of Concrete

Fig 4: Compressive strength of GGBS concrete of various percentages [10]

Fig 5: Drying shrinkage of ggbs concrete with 0 to 180 days

Influence of MK on hardened properties of Concrete

VI. WOOD ASH

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