International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Special Issue, ISSN 2349-4476

Investigation on ceramic waste and stone dust as aggregate

replacement in concrete
Amir Javed1, Salman Siddique2, Ram Prasad V S3
1
Assistant Professor, Integral University, Lucknow
2
Research Scholar, Department of Civil Engineering, Malaviya National Institute of Technology
Jaipur
3
Graduate Student, Department of Civil Engineering, Malaviya National Institute of Technology
Jaipur
Abstract The sanitary and stone cutting
industry inevitably generates wastes. This paper
presents the use of stone dusta byproduct of
crushers as replacement of fine aggregate and
ceramic waste as a replacement of coarse
aggregate.
This study was conducted to analyse the
compressive and flexural strength of concrete
when natural sand was replaced with stone dust
at 20%, 40 %, 60%, 80 % and 100% along with
20 % stone aggregate replacement with ceramic
waste. For conducting the study 21 cubes
(150mmx150mmx150mm) and 21 Beams
(500x100x100mm) were tested To increase the
workability of concrete Lyconicsulphate
plasticizer was used as an admixture. The
plasticizer was used as 2% by weight of cement.
The percentage of ceramic waste is kept 20% for
all specimens.
It is found that at 40 % replacements of natural
sand with stone dust along with 20%
replacement of stone aggregate with ceramic
waste, the compressive strength and flexural
strength is maximum.
The study concludes that the stone dust with 20
% of ceramic waste as a coarse aggregate can be
used effectively as an alternative to natural sand
for nominal concreting.
Keywords Ceramic Waste, Stone Dust,
Compressive Strength, Flexural Strength

127

1. Introduction
For Past many years construction industry has
been making some progress in the utilisation of
waste materials in concrete. Some of waste
products are fly ash, rice husk, saw dust,
discarded tires, e-waste, glass, bagasse ash,
stone dust and ceramic. Proper use of waste
products provides viable economy and healthy
environment. Each waste product has its specific
effect on properties of fresh and hard concrete.
There has been a long-term growing demand for
aggregates to produce concrete and this has
presented increased problems of supplying of
sand and gravel [10]. Previous researches have
shown crushed stone dust can be used to replace
the natural sand in concrete [2,4]. Recycle
aggregates are also being studied though some
loss in workability and mechanical property is
reported [11,12]. The ceramic industry has about
30% to 50% failed products due to improper
mixing or heating conditions [6]. Present study
has been done to evaluate the suitability of such
waste materials in concrete production.
2. Experimental Work
2.1 Materials
I.
Cement
The cement used in all mixtures was
commercially available Portland Pozzolana
cement of 43 grade manufactured by Jaypee
cement company confirming to IS 8112:1989
was used in this study.

Amir Javed, Salman Siddique, Ram Prasad V S

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Special Issue, ISSN 2349-4476

II.

Fine Aggregates
a)
Locally available river sand passed
through 4.75mm IS sieve is used as fine
aggregate. The specific gravity of sand is 2.61
and fineness modulus of 2.21.
b)
Stone dust used in the laboratory investig
ations was procured from a local crushing
plant. The specific gravity of stone dust was 2.5
and fineness modulus was 2.67.
III.
Coarse Aggregates
a)
The Coarse aggregate are obtained from
a local quarry is used. The coarse aggregate with
a maximum size 10mm having a specific gravity
2.64 and fineness modulus of 6.90.
b)
The ceramic wastes are obtained from a
pottery industry waste. The waste ceramics are
crushed into pieces with crushing machine in
laboratory. The specific gravity of ceramic
aggregates is 2.27 and fineness modulus of 5.64.
2.2 Preparation of specimen
The quantities of the constituents of the concrete
were obtained from the Indian Standard Mix
Design method (IS: 10262- 2009). The variation
of strength of hardened concrete using stone
dust as fine aggregate (partial replacement) is
studied by casting cubes, cylinders and beams.
The concrete was prepared in the laboratory
using hand mixing. The cement, fine aggregate
and coarse aggregate were first mixed in dry
state to obtain uniform colour and calculated
amount of water obtained from workability test
was added and the whole concrete was mixed
for five minutes in wet state. Meanwhile the
moulds are screwed tightly to avoid leakage Oil
was applied on inner surface of the moulds. The
cast specimens were removed from moulds after
24 hours and the specimens were immersed in a
clean water tank. After curing the specimens for
a period of 28 days, the specimens were
removed from the water tank and allowed to dry
under shade.
3. Experimental Work

128

3.1 Tests
For each batch of concrete, three cubes of
150mmX150mmX150mm size were tested to
determine compressive strength. Three beams of
100mmX100mmX500mm size were tested to
determine the flexure strength.
SI No. 1
2
3
4
Prope
rty

Specific
Gravity

Initial
setting
Time

Final
Setting
Time

Compressiv
e Strength

Value

3.13

32
min

216
min

44.28 MPa

SI
No
.

Table 1: Properties of cement

Sieve Desi Percentage passing
gnation
Fine aggregates
Natura
l sand

Stone
Dust

1
2

12.5 mm
10 mm

--100

--100

4.75 mm

100

100

4
5
6
7
8

2.36 mm
1.18 mm
600
300
150

99.30
96.70
56.20
21.90
5.30

81
39.70
9.6
4.2
1.1

Coarse aggre
gates
Natura Cer
l aggre ami
gates
c
Wa
ste
100
100
98.25
97.
35
10
9.9
8
1
1
0
0
-------------

Table 2: Details of Sieve analysis of fine and co

arse aggregate
3.1 Mix Selection
The grade of concrete adopted for investigation
was M20. The mix proportion of concrete for
laboratory investigations was arrived by
designing as per Indian standard method. The
Amir Javed, Salman Siddique, Ram Prasad V S

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Special Issue, ISSN 2349-4476

Mix
Desig
nation

Fine aggregate

Sand

1
2
3
4
5
6
7

MC
MC0
MC1
MC2
MC3
MC4
MC5

100%
100%
80%
60%
40%
20%
0%

Coarse aggreg
ate

Numbe
r of spe
cimens

Stone
Dust

Conven
tion-al

Ceram
ic
Waste

Cu
bes

B
ea
m
s

0%
0%
20%
40%
60%
80%
100%

100%
80%
80%
80%
80%
80%
80%

0%
20%
20%
20%
20%
20%
20%

3
3
3
3
3
3
3

3
3
3
3
3
3
3

Table 3: Details of Mix designations and specimens

4. Results and Discussions

After comparison properties presented in Table
2, it is observed that the stone dust can be used
as conventional fine aggregate. Whereas
ceramic waste can be used in place of
conventional coarse aggregate. The Samples
were tested and analysed after curing for 28
days.
The experimental test results are presented in
Table 4. It can be observed from the Table 4 that
the strength of concrete is increased at some
point due to usage of stone dust as fine
aggregate. But strength is reducing due to usage
of ceramic waste as coarse aggregate. Hence in
concrete with ceramic waste as coarse aggregate
upto 20%, conventional fine aggregate can be
replaced partially by stone dust upto 40%.
SI No.
Mix
Designat
ion
Compres
sive
strength
(MPa)
Flexural
strength
(N/mm2)

129

25

20

Compressive strength at 28 days

SI
N
o.

Table 4: The experimental test results

15

10

0
0

20

40

60

80

100

% resplacement of stone dust as a fine aggregate

Fig 1: Variation of compressive strength with

percentage replacement of Stone dust alongwith
20 % ceramic waste as a coarse aggregate.
10

Flexural strength at 28 days

final mix used was 1:1.33:2.73 with water

cement ratio of 0.48. The details of mix
designations
and
specimens
used
in
experimental programme are given in Table 3.

0
0

20

40

60

80

100

% replacement of sand with stone dust

Fig 2: Variation of Flexural strength with

percentage replacement of Stone dust along with
20 % ceramic waste as a coarse aggregate.
5. Conclusion
The following conclusions are drawn from the
present study:
1.
The compressive and flexural strength of
concrete with 40% replacement of natural sand
by stone dust along with 20% replacement of
coarse aggregate by ceramic waste reveals
higher strength as compared to 0 % replacement
of natural sand by stone dust along with 20%
replacement of coarse aggregate by ceramic
waste.
1
2
3
4
5
6
7
2.
It is found that as compare to flexural
MC MC MC MC MC MC M
0
1
2
3
4
C
strength the compressive strength greatly
5
decreased when only ceramic waste is used as a
28. 18. 20. 22. 17. 16. 1
20% replacement of coarse aggregate (i.e.at 0%
45
44
13
00
27
17
4.
stone dust and 20 % ceramic waste).
2
3.
It is advised on the basis of present study
4
that
ceramic
waste alone could not be used as a
6.8 6.5 7.6 8.5 6.5 4.3 4.
3
8
0
8
8
0
0
replacement of coarse aggregate because it has
4
an adverse effect on the properties of concrete.
Amir Javed, Salman Siddique, Ram Prasad V S

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Special Issue, ISSN 2349-4476

On the other hand if it is used along with the

stone dust it gives satisfactory results and upto
40 % of replacement of fine aggregate with
stone dust the properties of concrete is found to
be enhanced and after that it decreases.
4.
Thus we found out the optimum
percentage for replacement of stone dust with
fine aggregate along with 20% replacement of
coarse aggregate by ceramic waste is almost
40% for both cubes and beams.
5.
Stone dust has a potential to provide
alternative to natural sand and helps in
maintaining the environment as well as
economical balance. Non-availability of Natural
sand at reasonable cost, forces to search for
alternative material. Stone dust qualifies itself as
a suitable substitute for natural sand at
reasonable cost.
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130

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Amir Javed, Salman Siddique, Ram Prasad V S