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ProjectonPartialReplacementofCementwithMarblePowder
Advanceconcretetechnologycanreducetheconsumptionofnaturalresourcesandenergysourcestherebylessentheburdenofpollutantson
environment.Wedescribesthefeasibilityofusingthemarblesludgedustinconcreteproductionaspartialreplacementofcement.
PresentedbyRahul,Jamsheed,Shanil,Geo,andJagdeesh,undertheguidanceofMissDIVYARAJANguidancetowardsthepartialfulfilmentof
therequirementsfortheawardofbacheloroftechnologydegreeincivilengineering,oftheuniversityofCalicutduringtheyear2011.
ABSTRACT
Leavingthewastematerialstotheenvironmentdirectlycancauseenvironmentalproblem.Hencethereuseofwastematerialhasbeen
emphasized.Wastecanbeusedtoproducenewproductsorcanbeusedasadmixturessothatnaturalresourcesareusedmoreefficientlyandthe
environmentisprotectedfromwastedeposits.Marblestoneindustrygeneratesbothsolidwasteandstoneslurry.Whereassolidwasteresultsfrom
therejectsattheminesitesorattheprocessingunits,stoneslurryisasemiliquidsubstanceconsistingofparticlesoriginatingfromthesawingand
thepolishingprocessesandwaterusedtocoolandlubricatethesawingandpolishingmachines.Stoneslurrygeneratedduringprocessing
correspondstoaround40%ofthefinalproductfromstoneindustry.Thisisrelevantbecausethestoneindustrypresentsanannualoutputof68
milliontonnesofprocessedproducts.Thereforethescientificandindustrialcommunitymustcommittowardsmoresustainablepractices.Thereare
severalreuseandrecyclingsolutionsforthisindustrialbyproduct,bothatanexperimentalphaseandinpracticalapplications.Theseindustrial
wastesaredumpedinthenearbylandandthenaturalfertilityofthesoilisspoiled.Thephysical,chemicalandmechanicalpropertiesofthewaste
areanalyzed.
(1.1)INTRODUCTION
INFLUENCEOFMARBLEDUSTASPARTIALREPLACEMENTOFCEMENTINCONCRETE
Theadvancementofconcretetechnologycanreducetheconsumptionofnaturalresourcesandenergysourcesandlessentheburdenofpollutants
onenvironment.Presentlylargeamountsofmarbledustaregeneratedinnaturalstoneprocessingplantswithanimportantimpactonenvironment
andhumans.Thisprojectdescribesthefeasibilityofusingthemarblesludgedustinconcreteproductionaspartialreplacementofcement.InINDIA,
themarbleandgranitestoneprocessingisoneofthemostthrivingindustrytheeffectsifvaryingmarbledustcontentsonthephysicaland
mechanicalpropertiesoffreshandhardenedconcretehavebeeninvestigated.Slumpandaircontentoffreshconcreteandabsorptionand
compressivestrengthofhardenedconcretewerealsoinvestigated.Testresultsshowthatthisindustrialbiproductiscapableofimprovinghardened
concreteperformanceupto10%,Enhancingfreshconcretebehaviourandcanbeusedinarchitecturalconcretemixturescontainingwhitecement.
Thecompressivestrengthofconcretewasmeasuredfor7and28days.Inordertoevaluatetheeffectsofmarbledustonmechanicalbehaviour,
manydifferentmortarmixesweretested.
(1.2)OBJECTIVES
Inthisprojectourmainobjectiveistostudytheinfluenceofpartialreplacementofcementwithmarblepowder,andtocompareitwiththe
compressiveandtensilestrengthofordinaryM20concrete.Wearealsotryingtofindthepercentageofmarblepowderreplacedinconcretethat
makesthestrengthoftheconcretemaximum.
Nowadaysmarblepowderhasbecomeapollutant.So,bypartiallyreplacingcementwithmarblepowder,weareproposingamethodthatcanbeof
greatuseinreducingpollutiontoagreatextent.
(2)TESTINGONPHYSICALPROPERTIESOFMATERIALS
(2.1)INITIALSETTINGTIME=84minutes
(2.2)FINENESSMODULUS=6%
(2.3)SPECIFICGRAVITYOFCEMENT(LECHATLIERFLASK)
Weightofcementused=60gm
Initialreadingonflask=0ml
Finalreadingonflask=23ml
Specificgravityofcement=weightofcementused
Weightofequalvolumeofwater
Specificgravityofcement=2.608
(2.4)SPECIFICGRAVITYOFFINEAGGREGATE
(A)SAND
SLNO

Determination

gm

Gm

Pycnometer(M1)

458.10

451

Pycnometer+sand(halfofbottle)(M2)

676

697

Pycnometer+sand+fullofwater(M3)

1390

1405

Pycnometer+fullofwater(M4)

1253

1258

CALCULATIONS
Specificgravity=[(M2M1)]/[(M2M1)(M3M4)]
a).(676458.10)/[(676458.10)(13901253)]=2.693
b)(697451)/[(697451)(14051258)]=2.49
Therefore,specificgravityoffineaggregate=2.59
(2.5)SPECIFICGRAVITYOFCOARSEAGGREGATE
SLNO

DETERMINATION

gm

Gm

Pycnometer(M1)

458

463

Pycnometer+aggregate(M2)

706

666

Pycnometer+aggregate+water(M3)

1405

1385

Pycnometer+water(M4)

1258

1253

CALCULATIONS
Specificgravity=(M2M1)/[(M2M1)(M3M4)]
(a)(706458)/[(706458)(14051258)]=2.45
(b)(666463)/[(706458)(14051258)]=2.859
Meanofthese=2.66
Therefore,specificgravityofcoarseaggregate=2.66
(2.6)SIEVEANALYSIS
(A)SAND
Quantityofsand=1Kg
Timeofsieving=15minutes
SLNO

SIEVESIZE

WEIGHTRETAINED

%OFWEIGHTRETAINED

CUMULATIVE%RETAINED

CUMULATIVE%PASSING

40mm

100

20mm

100

10mm

100

4.75

100

2.36

98

9.8

9.8

90.2

1.18

60

15.8

84.2

600micron

188

18.8

34.6

65.4

300micron

397

39.7

74.3

25.7

150micron

221

22.1

96.4

3.6

10

90micron

21.5

2.15

98.5

1.45

11

L.P

19.5

1.95

100

Finenessmodulus=329.4/100=3.29%
(2.7)(B)COARSEAGGREGATE
Quantityofmaterials=4kg
Timeofsieving=15minutes
SLNO

Sievesize

Weightretained(gm)

%weightretained

Cumulative%weightretained

Cumulative%weightpassing

40mm

100

20mm

585.0

14.625

14.65

85.375

10mm

3260

81.5

96.12

3.88

4.75mm

155

3.875

100

2.40mm

100

1.18mm

100

600m

100

300m

100

150m

100

710.77
Finenessmodulus=710.77/100=7.10%

(3)MIXDESIGN:
Mixdesignforconcretewasmadeusingthepropertiesofconstituentsofconcrete.GradeofconcretewastakenasM20andthemixdesignwas
doneasperIS:102621982andIS:4562000.Thewatercementratiowastakenas0.5whichshouldbethemaximumforM20gradeundermild
exposurecondition.
MIXDESIGNOFM20
(3.1)DESIGNSTIPULATIONS
SLNO

DESIGNSTIPULATIONS

QUANTITY

Characteristiccompressivestrengthrequiredinthefieldat28days

20N/mm2

Maximumsizeofaggregates

20mm(angular)

Degreeofworkability

0.90(compactingfactor)

Degreeofqualityofcontrol

Good

Typeofexposure

Mild

(3.2)TESTDATAFORMATERIAL
SLNO

TESTDATAFORMATERIAL

QUANTITY

Cementused

Portlandslagcement

Specificgravityofcement

2.608

Specificgravityoffineaggregate

2.59

Specificgravityofcoarseaggregate

2.66

Waterabsorptionoffineaggregate

Nil

Waterabsorptionofcoarseaggregate

Nil

Freemoistureoffineaggregate

Nil

Freemoistureofcoarseaggregate

Nil

Sieveanalysisoffineaggregate

Grade3

TARGETMEANSTRENGTHFORMIXDESIGN
fck=fck+1.65s
fck=20+1.654.6
=27.59N/mm2
AsperIS102621982,
Watercementratio=0.5

Fromtable4
Watercontent=186kg/m3
Sandcontent=35%
Forchangeinvalueofwatercementratio,compactingfactorandsandbelongingtoZone3,thefollowingadjustmentisrequired.
Changeincondition
1)Fordecreaseinwatercementratioby(0.600.50)thatis0.1
AdjustmentsrequiredinWatercontentpercent=0
Adjustmentsrequiredinpercentagesandintotalaggregate=2.0
2)Forincreaseincompactingfactor(0.90.8)thatis0.10
AdjustmentsrequiredinWatercontentpercent=+3
Adjustmentsrequiredinpercentagesandintotalaggregate=0
3)ForsandconformingtozoneIIIoftable4OfIS3831970
AdjustmentsrequiredinWatercontentpercent=0
Adjustmentsrequiredinpercentagesandintotalaggregate=1.5
Addingtheseadjustmentsweget
TotalAdjustmentsrequiredinWatercontentpercent=+3%
TotalAdjustmentsrequiredinpercentagesandintotalaggregate=3.5
Therefore,requiredsandcontentaspercentageoftotalaggregatebyabsolutevolume=353.5=31.5%
Requiredwatercontent=186+(186x3)/100=186+5.58=191.6litre/m3
(3.3)DETERMINATIONOFCEMENTCONTENT
Watercementratio=0.50
Water=191.61
Cement=191.6/0.50=383kg/m3
Thiscementcontentisadequateformildexposurecondition,accordingtoAppendixAofIS4561978.
(3.4)DETERMINATIONOFCOARSEANDFINEAGGREGATECONTENT
FromTable3,forthespecifiedmaximumsizeof20mm,theamountofentrappedairinthewetconcreteis2%.Takingthisintoaccountand
applyingequationsfrom3.5.1ofIS102621982.
Therefore,
Forfineaggregate
0.98=[191.58+(383.16/2.608)+(1/0.315)x(fa/2.59)]x(1/1000)
fa=525.82
Forcoarseaggregate
0.98=[191.58+(383.16/2.608)+(1/(10.315)x(Ca/2.83)]x(1/1000)
Ca=1139.43kg/m3
Themixproportionsthenbecomes
Water:Cement:Fineaggregate:Coarseaggregate
191.61:383kg:525.82:1139.43kg
or
0.50:1:1.372:2.97
VOLUMES
Volumeofcube=15x15x15=3375cm3
Volumeofcylinder=?x7.52x30=5301.44
Totalvolume=8676.44
Add10%extravolume=9544.084
Volumeofconcrete=(1/2.602)+(1.372/2.59)+(2.97/2.66)+(0.5/1)=2.529
Weightofcement=(1/V)xvolume=(1/2.529)x9544.084)=3.77kg
Weightoffineaggregate=1.372x3773.85=5.177kg
Weightofcoarseaggregate=2.97x3773.85=11.208kg
Requiredamountofwater=0.5x3773.85=1886.92litre

FORTWOSPECIMEN

Weightofcement=7.547kg
Weightoffineaggregate=10.355kg
Weightofcoarseaggregate=22.41kg
Requiredwater=377litre
(3.5)MIXPROPORTIONS:
Fiveconcretemixeswithstonedustwereproduced,replacing0%(referencemixture),5%,10%,15%,and20%,Cement,intermsofweight.The
concretemixproportionforM20gradewasdesignedinaccordancewithI.S.code.
QUANTITYOFMARBLEPOWDER
5%ofcementreplacedbymarblepowder=377.38gm
10%ofmarblepowder=754.7gm
15%ofmarblepowder=1.13kg
20%ofmarblepowder=1.5094kg
Experimentalconditions:
Compressivestrengthofconcretewasundertakenon15cmcubicspecimens.at7daysand28daysofage.Regardingsplittingtensilestrength,
cylinderswith30cmofheightand15cmofdiameterwerecastedandtestedat28daysofage.Allspecimenswereremoved48hoursaftercasting,
andthentransferredtoregularconditions(interiorofthelaboratory)tilltesting.
(4)PREPARATIONANDCURINGOFSPECIMEN:
Standardcubicspecimensof150mmsizewerecast.Concretecubeswerecastforcompressivestrength.Thestandardcylindricalspecimenof
100mmdiameterand300mmheightcylindricalspecimenswerecastefortensilestrength.
(5)TESTINGOFHARDENEDCONCRETE
(5.1)COMPRESSIVESTRENGTH7DAYS
%

average

Compressivestrength(MPa)

0%

380

340

360

16

5%

355

405

380

16.88

10%

390

430

410

18.22

15%

275

325

300

13.33

20%

290

270

280

12.44

(5.2)COMPRESSIVESTRENGTH28DAYS
%

average

Compressivestrength(MPa)

0%

535

565

550

24.40

5%

580

620

600

26.67

10%

675

645

660

29.33

15%

470

435

452.5

20.11

20%

420

440

420

18.67

5.3)GRAPHICALREPRESENTATIONOFCOMPRESSIVESTRENGTH

(5.4)TENSILESTRENGTH7DAYS
%marblepowder

Specimen1

Specimen2

mean

Tensilestrength

tensileload

tensileload

0%

111

129

120

1.69

5%

130

136

133

1.88

10%

125

151

138

1.95

15%

100

128

114

1.61

20%

108

84

96

1.35

(MPa)

(5.5)TENSILESTRENGTH28DAYS
%marblepowder

Specimen1,

Specimen2,

mean

Tensilestrength

tensileload

tensileload

0%

170

178

174

2.461

5%

182

185

183.5

2.59

10%

197

201

199

2.84

15%

165

170

167.5

2.36

20%

141

162

151.5

2.14

(MPa)

(5.6)GRAPHICALREPRESENTATIONOFTENSILESTRENGTH

(6)RESULTSANDDISCUSSION:
CompressionTest:
Mechanicalbehaviourofconcretecubespreparedwithoutchemicaladmixtureswasstudiedbycompressivetests(GradeM20andcuringtimeof7
daysand28days.Itcanbenoticedthat5%replacementofcementwithmarbledustinmildconditionand10%replacementofcementwithmarble
dustinmildcondition,areshowingincreaseincompressivestrength.
TensileStrengthtest
Mechanicalbehaviourofcylindricalspecimenspreparedwithoutchemicaladmixtureswasstudiedbytensilestrengthtest.(GradeM20),curingtimes
of7daysand28daysandtheresultsobtainedarereported.Itisnoticedthat5%replacementofcementwithmarbledustinmildconditionand10%
replacementofcementwithmarbledustinsevereconditions,areshowingincreaseintensilestrength.
(7)CONCLUSIONS:
Duetomarbledust,itprovedtobeveryeffectiveinassuringverygoodcohesivenessofmortarandconcrete.Fromtheabovestudy,itisconcluded
thatthemarbledustcanbeusedasareplacementmaterialforcementand10%replacementofmarbledustgivesanexcellentresultinstrength
aspectandqualityaspectanditisbetterthanthecontrolconcrete.Theresultsshowedthatthesubstitutionof10%ofthecementcontentbymarble
stonedustinducedhighercompressivestrength,highersplittingtensilestrength,andimprovementofpropertiesrelatedtodurability.
Testresultsshowthatthisindustrialwasteiscapableofimprovinghardenedconcreteperformanceupto15%,enhancingfreshconcretebehaviour
andcanbeusedinplainconcrete.
(8)REFERENCES:
1)CONCRETETECHNOLOGYM.S.SHETTY
2)DESIGNOFCONCRETEMIXESN.KRISHNARAJU
Weatengineeringcivil.comareverythankfultoEr.Rahulforsubmittingthisprojectreporttous.WehopethiswillbeofgreathelptootherfellowCivil
Engineers.