SWAMI VIVEKANAND COLLEGE OF

ENGINEERING
(Approved by AICTE, PCI, Affiliated to DAVV, RGPV recognized by DTE, Govt. of
India)

2015-2016
MAJOR PROJECT WORK
CIVIL DEPARTMENT

DERIVING CONCRETE FROM RECYCLED

WASTE MATERIALS
Supervised by:

Submitted by:

Ms. Sonu Malviya

Shravan Mundra

Assistant Professor
Civil Engineering

RAJIV GANDHI PROUDYOGIKI VISHWAVIDLAYA,

BHOPAL (M.P.)
SWAMI VIVEKANAND COLLEGE OF ENGINEERING, INDORE
(Approved by AICTE, PCI, Affiliated to DAVV, RGPV recognized by DTE, Govt. of
India)

CERTIFICATE
2015-2016

This is to Certify that this project report Deriving concrete from recycled waste
materialsis submitted by Shravan Mundra who carried out the project work under
my supervision. I approve this project for submission of the Bachelor of Engineering in
the Department of Civil Engineering, affiliated to RGTU, Bhopal (M.P.).

INTERNAL EXAMINER
DATE:

EXTERNAL EXAMINER
DATE:

ACKNOWLEDGEMENT

It is our sincere thanks to all enlisted people as well as not enlisted people, whose help
and continuous inspiration leads to get this project done in a pleasant way; however it
will be tough to thank them enough. We will nevertheless try.
We would like to owe my gratitude and deep sense of respect towards my adviser and
guide Ms. Sonu malviya (Assistant professor) whose timing supervision and guidance
has given me the moral boost in doing this work fine and furnished. We would like to
express my thankful to him for giving me a chance to work in the field of Concrete
testing, which is really interesting and wonderful.
We are greatly indebted to his invaluable advice and support in almost every aspect of
my academic life. We are very much indebted to Prof. NIRAJ SONI (HOD, CE) for
his continuous encouragement and support. We wish to thank all the secretarial staff of
the CE Department for their sympathetic cooperation.

DECLARATION

We are the student of Bachelor of Engineering in Civil Engineering discipline, session 2015-2016,
hereby declare that the work presented in this dissertation entitled DERIVING CONCRETE
FROM RECYCLED WASTE MATERIAL is the outcome of my own work, is bonafide and correct
to the best of my knowledge and this work has been carried out taking care of Engineering
Ethics. The work presented here does not infringe any patented work and has not been
submitted to any other university or anywhere else for the award of any degree or any
professional diploma

ABSTRACT

Use of hazardous industrial wastes in concrete-making will lead to greener environment. In

ceramic industry about 30% production goes as waste, which is not recycled at present. In this
study an attempt has been made to find the suitability of the ceramic industrial wastes as a
possible substitute for conventional crushed stone coarse aggregate. Experiments were carried
out to determine the compressive, splitting tensile and flexural strengths and the modulus of
elasticity of concrete with ceramic waste coarse aggregate and to compare them with those of
conventional concrete made with crushed stone coarse aggregate. The properties of the
aggregates were also compared. Test results indicate that the workability of ceramic waste
coarse aggregate concrete is good and the strength characteristics are comparable to those of
the conventional concrete.

CONTENT

Certificate......ii
Acknowledgement......iii
Declaration..iv
Abstract....v
Content...vi-viii
List of tables...viii
List of figures.................ix

Chapter 1 INTRODUCTION

1-3

1.1 General .........................1

1.2 Types of mixes...........1
1.2.1 Nominal mixes.....1
1.2.2 Standard mixes....1
1.2.3 Designed mixes.......1
1.3 Grades of concrete........3
Chapter 2 OBJECTIVE OF STUDY

2.1 Objective......4
Chapter 3 LITERATURE REVIEW

5-7

3.1 General.......5
3.2 Study of previous research papers...5

3.2.1 Paper I.....5

3.2.2 Paper II....6
3.2.3 Paper III...6
3.2.4 Paper IV...7
3.2.5 Paper V....7
3.2.6 Paper VI7
Chapter 4 DATA COLLECTION

9-11

4.1 Prerequisite knowledge.......9

4.2 Test data for material .........9
4.3 Factors affecting design mix.......................10
4.4 Mix proportion designations.........10
4.5 Need for present study......11
Chapter 5 METHODOLOGY

12- 13

5.1 General...........12
5.2 Calculation as per IS standards .........12
5.3 Codes used................13
5.3.1 IS 10262: 2009.....13
5.3.2 IS 456: 2000.....13
Chapter 6 DATA AQUISION AND CALCULATION

14-18

6.1 General.............14
6.1.1 Material required......................14
6.1.2 Equipments required..14

6.2 Design mix calculation.15

6.2.1 Target mean strength15
6.2.2 Selection of w/c ratio..16
6.2.3 Selection of water content.16
6.2.4 Selection of cement content.16
6.2.5 Proportion of volume of coarse aggregate.17
6.2.6 Calculation of mix proportion17
6.3 Replacement chart of ceramic powder with cement...18
6.4 Replacement chart of glass dust with sand.....18

Chapter 7 RESULT AND DISCUSSION

19-20

7.1 Reference cube chart19

7.2 Glass powder replacement results.19
7.3 Ceramic powder replacement result...20
Chapter 8 CONCLUSIONS

21-22

Chapter 9 REFRENCES

23

SOME SNAPSHOTS OF OUR FIELD WORK

24

LIST OF TABLES
Table no. 1.1:- Strength percentage.....3
Table no. 3.1:- Codes used.5
Table no. 4.1:- Prerequisite knowledge.9
Table no. 4.2:- Test data for materials......9
Table no. 5.2:- Methodology of project12
Table no. 5.2:- Calculation methodology as per IS standard..12
Table no. 6.1:- IS 10262:2009 Table 1...16
Table no. 6.2:- IS 10262:2009 Table 216
Table no.6.3:- IS 10262:2009 Table 5.17
Table no.6.4:- design mix proportion...18
Table no.6.5:- Materials mixed by weight (ceramic replacement)..18
Table no.6.6:- Materials mixed by weight (glass dust replacement)..18
Table no.7.1:- Reference cube results M-25 ............19
Table no.7.2:- Glass powder replacement results.19
Table no.7.3:- Ceramic powder replacement results....20

LIST OF FIGURES
Fig no. 6.1:- Compression testing machine14
Fig no. 6.2:- Concrete cubes moulds..15
Fig no. 6.3:- Mechanical vibrator..15

DERIVING CONCRETE FROM RECYCLED WASTE MATERIALS

CHAPTER - 1
INTRODUCTION

1.1 GENERAL
Concrete is composed principally of aggregates, Portland cement, and water, and many
contain other cementious materials and/or chemical admixtures. It will contain some
amount of entrapped air and may also contain purposely entrained air obtained by use of
admixture or air-entraining cement. Chemical admixtures are frequently used to
accelerate, retard, improve workability, reduce mixing water requirements, increase
strength, or alter other properties of the concrete. The selection of concrete proportions
involves a balance between economy and requirements of place ability, strength,
durability, density, and appearance.

1.2 TYPES OF MIXES

1.2.1 Nominal Mixes
In the past the specifications for concrete prescribed the proportions of cement, fine and
coarse aggregates. These mixes of fixed cement-aggregate ratio which ensures
adequate strength are termed nominal mixes. These offer simplicity and under normal
circumstances, have a margin of strength above that specified. However, due to the
variability of mix ingredients the nominal concrete for a given workability varies widely in
strength.
1.2.2 Standard mixes
The nominal mixes of fixed cement-aggregate ratio (by volume) vary widely in strength
and may result in under- or over-rich mixes. For this reason, the minimum compressive
strength has been included in many specifications. These mixes are termed standard
mixes. IS 456-2000 has designated the concrete mixes into a number of grades as
M10, M15, M20, M25, M30, M35 and M40. In this designation the letter M refers to the
mix and the number to the specified 28 day cube strength of mix in N/mm2. The mixes
of grades M10, M15, M20 and M25 correspond approximately to the mix proportions
(1:3:6), (1:2:4), (1:1.5:3) and (1:1:2) respectively.
1.2.3 Designed Mixes
In these mixes the performance of the concrete is specified by the designer but the mix
proportions are determined by the producer of concrete, except that the minimum
cement content can be laid down. This is most rational approach to the selection of mix
proportions with specific materials in mind possessing more or less unique
characteristics. The approach results in the production of concrete with the appropriate
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properties most economically. However, the designed mix does not serve as a guide
since this does not guarantee the correct mix proportions for the prescribed
performance.
Concrete mix design may be defines as the art of selecting suitable ingredients
of concrete and determining their relative proportions with the object of
producing concrete of certain minimum strength & durability as economically as
possible.
At the end of the CONCRETE section, you should be able to...
Identify the four main chemical "compounds" in cement and explain what each
contributes to the behavior of the fresh and hardened cement
List the five main types of cement and distinguish between them on the basis of their
properties
Explain the terms "initial set" and "final set"
Distinguish between setting and hardening
Explain the primary purpose of the aggregate in normal-strength concrete
Summarize the procedures for performing a slump test and explain what the results
signify
Explain the term workability as it applies to Portland cement concrete
Explain the term segregation as it applies to Portland cement concrete
Explain the term bleeding as it applies to Portland cement concrete
Identify the factors that contribute to segregation and bleeding
Engineers usually specify the required compressive strength of concrete, which is
normally given as the 28 day compressive strength in N/mm2. Twenty eight days is a
long wait to determine if desired strengths are going to be obtained, so three-day and
seven-day strengths can be useful to predict the ultimate 28-day compressive strength
of the concrete. It is studied that the concrete mixture attains partial compressive
strength with certain duration of curing. A study shows the strength gain by the
concrete in specific days of curing which is shown below : Potable water can be used for manufacturing concrete. The w/c ratio (mass ratio of
water to cement) is the key factor that determines the strength of concrete. A lower w/c
ratio will yield a concrete which is stronger and more durable, while a higher w/c ratio
yields a concrete with a larger slump, so it may be placed more easily.
The water and cement paste hardens and develops strength over time. In order to
ensure an economical and practical solution, both fine and coarse aggregates are
utilized to make up the bulk of the concrete mixture.

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1.2 Grades of concrete
The Grade of concrete can be defined as the Compressive strength given by the
concrete block after the curing of 28 days .In other words the grades of concrete can be
defined as the compressive strength given by a specimen under the compression
testing machine after the curing of 28 days . It is denoted by M. For example if the
specimen gives 10N/mm2 strength after the curing period , then the grade of concrete is
M10 where The M in grade stands for the mix design and 10 is the compressive
strength of the specimen.
To caste the concrete of a specific grade, a certain proportion is given in the IS code IS
456:2000. For example If we want to cast the concrete of M10 grade we have to
prepare the mixture in the ratio of 1: 3: 6, i.e. one part of cement, 3 parts of sand and 6
parts of aggregates . As above there are following grades are given in the code which
are as follows: M10
M15
M20
M25
M30

- 1:3:6
- 1:2:4
- 1:1.5:3
- 1:1:2
- mix design

Age
1 day
3 days
7 days
14 days
28 days

Strength percent
16%
40%
65%
90%
99%

Table no. 1.1:- strength percentage

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CHAPTER 2
OBJECTIVE OF STUDY

2.1 OBJECTIVE OF PROJECT

The mix design determines the final strength, the durability, the workability, the cure time,
and the 3,7,14, 28 day strengths (which are very important if you must get high strength
quickly to build on the slab). I've done mix design testing for local ready-mix firms plenty of
times...they want information on breakout strengths, percent air, water, additives, etc so
they cant judge the performance of their concrete.
Good quality concrete as per requirements this means the concrete will have required
strength, workability, impermeability, durability, density and homogeneity.
Nominal mix concrete may suggest more cement than other materials, and a concrete mix
design gives the accurate quantity of cement consumption. Thus it is an economical
solution for large projects.
It is possible to save of cement and sand for M25 grade of concrete with the help of
concrete mix design. In fact higher the grade of concrete more are the savings. Lower
cement content also results in lower heat of hydration and hence reduces shrinkage cracks.
The nominal mix of concrete does not consider the quality of local construction materials.
The concrete mix design is based on the quality of available materials locally. Thus it is also
an economical solution to reduce the transportation cost of materials from long distance.
Desired Concrete Properties: The designed mix concrete will have desired concrete
properties based on project or construction requirements. Requirements such as durability,
strength, setting times, workability etc. can be controlled with the type of construction with
concrete mix design.

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CHAPTER 3
LITERATURE REVIEW
3.1 GENERAL
Generally speaking, building codes are developed by well intentioned people who are
Actively involved in the construction industry. Their original purpose, as stated in the
CABO One and Two Family Dwelling Code, is "to provide minimum standards for the
protection of life, limb, property, and environment and for the safety and welfare of the
consumer, general public and the owners and occupants of residential buildings regulated
by this code." However, it is important to keep in mind that building codes are adopted,
modified and enforced by local politicians and government officials. Something else to
remember about building codes is the fact that they "are not intended to limit the
appropriate use of materials, appliances, equipment or methods of design or construction
not specifically prescribed by the code, provided the building official determines that the
proposed alternate materials, appliances, equipment or methods of design or construction
are at least equivalent of that prescribed in this code

For design of concrete mix following codes are used

IS-10262:2009
IS 383:1970
IS-456:2000
Table no. 3.1:- Codes used

3.2 Study of previous research papers

To get the better results and make our project successful we took help from research
papers. Various research paper which are followed in doing this project are as follows3.2.1 ChandanaSukesh, Bala Krishna Katakam, P Saha and K. Shyam Chamberlin, A
Study of Sustainable Industrial Waste Materials as Partial Replacement of
Cement, IPCSIT vol. 28 (2012) (2012) IACSIT Press, Singapore.
They have studied about the partial replacement of cement in concrete by use of
waste materials like cement kiln dust (CKD), ceramic waste, palm oil fuel ash
(POFA) and plastic. All of these materials are industrial waste materials and termed
as hazardous waste to environment. Several concrete mixes possessing a target
mean compressive strength of 30 MPa were prepared with 20% cement
replacement by ceramic powder. Results show that concrete with partial cement
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replacement by ceramic powder although it has minor strength loss possess
increase durability performance. Experiments have been conducted by replacing
10%, 20%, 30%, 40% and 50% of POFA by weight of Ordinary Portland Cement.
The properties of concrete, such as setting time, compressive strength, and
expansion due to magnesium sulfate attack were investigated. They have observed
that they have added 5% plastic by weight, the strength and found to be two times
greater than the plain cement concrete. With these results it is very clear that we
can effectively use these eco-friendly materials in partial replacement of cement.
3.2.2

A.M. Mustafa Al Bakri, M.N. Norazian, H. Kamarudin1, M.A.A. MohdSalleh, and A.

Alida, Strength of Concrete Based Cement Using Recycle Ceramic Waste As
Aggregate, Advanced Materials Research Vol. 740 (2013) 734-738 (2013) Trans
Tech Publications, Switzerland
They have investigated the strength of concrete with ceramic waste as replacement
of coarse aggregate in concrete. The sources of ceramic waste are obtained from
the industrial in Malaysia. Presently, in ceramics industries the production goes as
waste, which is not undergoing the recycle process yet. The recycle ceramic waste
as aggregate was used. Concrete mixes with a 28 days characteristic strength of 20
MPa had prepared using water/cement ratio of 0.4, 0.5 and 0.7. The strength
development of the concrete mixes containing recycled ceramic waste aggregates
was compared to that of conventional concrete. They have resulted that the
concrete mixes containing recycled ceramic waste aggregates achieve strength
levels between 80 to 95 % compared to the conventional concrete. They have
concluded that ceramic waste can be effectively replaced partially by cement in
concrete.

3.2.3 3. M. Iqbal Malik, Muzafar Bashir, Sajad Ahmad, Tabish Tariq, Umar Chowdhary,
Study of Concrete Involving Use of Waste Glass as Partial Replacement of Fine
Aggregates, IOSR Journal of Engineering (IOSRJEN),Vol. 3, Issue 7 (July. 2013).
They have studied on the issues of environmental and economic concern had
addressed by the use of waste glass as partial replacement of fine aggregates in
concrete. Fine aggregates had replaced by waste glass powder as 10%, 20%, 30%
and 40% by weight for M-25 mix. The concrete specimens had tested for
compressive strength, splitting tensile strength, durability (water absorption) and
density at 28 days of age and the results obtained had compared with those of
normal concrete. They have resulted permissibility of using waste glass powder as
partial replacement of fine aggregates up to 30% by weight for particle size of range
0-1.18mm.

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3.2.4 Amitkumar
D.
Raval,
Indrajit
N.
Patel,
JayeshkumarPitroda,
bco-Efficient Concretes: Use of Ceramic Powder As A Partial Replacement Of
Cement, IJITEE, ISSN: 2278-3075, Volume-3, Issue-2, July 2013.
They have studied about the (OPC) cement has been replaced by ceramic waste
powder accordingly in the range of 0%, 10%, 20%, 30% 40%, & 50% by weight for
M-25 grade concrete. The wastes employed came from ceramic industry which had
been deemed unfit for sale due to a variety of reasons, including dimensional or
mechanical defects, or defects in the firing process. They have resulted
demonstrate that the use ceramic masonry rubble as active addition endows
cement with positive characteristics as major mechanical strength and the economic
advantages. Reuse of this kind of waste has advantages economic and
environmental, reduction in the number of natural spaces employed as refuse
dumps.
3.2.5 Dr. G.Vijayakumar, Ms H. Vishaliny, Dr. D. Govindarajulu, Studies on Glass
Powder as Partial Replacement of Cement in Concrete Production, ISSN 22502459, ISO 9001:2008 Certified Journal, Volume 3, Issue 2, February 2013.
They have instigated about the use of cement replacements, using many waste
materials and industrial by products. Efforts have been made in the concrete
industry to use waste glass as partial replacement of coarse or fine aggregates and
cement. They have studied on finely powdered waste glasses are used as a partial
replacement of cement in concrete and compared it with conventional concrete.
Glass powder was partially replaced as 10%, 20%, 30% and 40% and tested for its
compressive, Tensile and flexural strength up to 60 days of age and had compared
with those of conventional concrete; from the results obtained, they have stated that
the glass powder can be used as cement replacement material up to particle size
less than 75m to prevent alkali silica reaction.
3.2.6 Yogendra O Patil, Prof.P.N. Patil, Dr. Arun Kumar Dwived, GGBS As Partial
Replacement of OPC Cement Concrete-An Experimental study, International
Journal Of Scientific Research Volume : 2 | Issue : 11 | November 2013 ISSN No
2277 - 8179
They have investigated on currently focused on use of waste material having
cementing properties, which can be added in cement concrete as partial replacement
of cement, without compromising on its strength and durability, which will result in
decrease of cement production thus reduction in emission in green house gases, in
addition to sustainable management of the waste. They have represented an
experimental study of compressive and flexural strength of concrete prepared with
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Ordinary Portland Cement, partially replaced by ground granulated blast furnace slag
in different proportions varying from 0% to 40%. It is observed from the investigation
that the strength of concrete is inversely proportional to the % of replacement of
cement with ground granulated blast furnace slag. They have also concluded that the
20% replacement of cement is possible without compromising the strength with 90
days curing.

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CHAPTER 4
DATA COLLECTION

4.1 Prerequisite knowledge

Grade Designation

M-25

Type of cement

OPC 53

Max. Nominal size of aggregate

20mm

Mini. Cement content

300 Kg/m3

Max. w/c ratio

0.40

Exposure condition

Severe

Degree of supervision

Good

Type of Aggregate

Crushed angular aggregate

Chemical admixture

No chemical admixture

Table no. 4.1:- Prerequisite knowledge

4.2 Test Data for Materials

Cement used

OPC 53

Specific Gravity of cement

3.15
Specific gravity of

Coarse aggregate

2.5

Fine aggregate

1.7

Glass dust

2.66

Ceramic powder

2.33
Water absorption

Coarse aggregate

1.08%

Fine aggregate

3.4%

Ceramic powder

2.44%

Table no. 4.2:- Test data for materials

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4.3 Factors affecting design mix
The various factors affecting the mix design are:
4.3.1 Compressive strength
It is one of the most important properties of concrete and influences many other describable
properties of the hardened concrete. The mean compressive strength required at a specific age,
usually 28 days, determines the nominal water-cement ratio of the mix. The other factor affecting
the strength of concrete at a given age and cured at a prescribed temperature is the degree of
compaction.
4.3.2 Workability
The degree of workability required depends on three factors. These are the size of the section to be
concreted, the amount of reinforcement, and the method of compaction to be used. For the narrow
and complicated section with numerous corners or inaccessible parts, the concrete must have a
high workability so that full compaction can be achieved with a reasonable amount of effort. This
also applies to the embedded steel sections. The desired workability depends on the compacting
equipment available at the site.
4.3.3 Durability
The durability of concrete is its resistance to the aggressive environmental conditions. High
strength concrete is generally more durable than low strength concrete. In the situations when the
high strength is not necessary but the conditions of exposure are such that high durability is vital,
the durability requirement will determine the water-cement ratio to be used.
4.3.4 Maximum nominal size of aggregate
In general, larger the maximum size of aggregate, smaller is the cement requirement for a
particular water-cement ratio, because the workability of concrete increases with increase in
maximum size of the aggregate. However, the compressive strength tends to increase with the
decrease in size of aggregate. IS 456:2000 recommend that the nominal size of the aggregate .
4.3.5 Grading and type of aggregate
The grading of aggregate influences the mix proportions for a specified workability and watercement ratio. Coarser the grading leaner will be mix which can be used. Very lean mix is not
desirable since it does not contain enough finer material to make the concrete cohesive.The type of
aggregate influences strongly the aggregate-cement ratio for the desired workability and stipulated
water cement ratio.
4.3.6 Quality Control
The degree of control can be estimated statistically by the variations in test results. The variation in
strength results from the variations in the properties of the mix ingredients and lack of control of
accuracy in batching, mixing, placing, curing and testing. The lower the difference between the
mean and minimum strengths of the mix lower will be the cement-content required. The factor
controlling this difference is termed as quality control.

4.4 Mix proportion designations

The common method of expressing the proportions of ingredients of a concrete mix is in the terms
of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of proportions
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1:2:4 means that cement, fine and coarse aggregate are in the ratio 1:2:4 or the mix contains one
part of cement, two parts of fine aggregate and four parts of coarse aggregate. The proportions are
either by volume or by mass. The water-cement ratio is usually expressed in mass

4.5 Need for present study

Leaving the waste materials to the environment directly can cause environmental problem. Hence
the reuse of waste material has been emphasized. Waste can be used to produce new products or
can be used as admixtures so that natural resources are used more efficiently and the environment
is protected from waste deposits.
Marble and ceramic stone industry generates both solid waste and stone slurry. Whereas solid
waste results from the rejects at the mine sites or at the processing units, stone slurry is a semi
liquid substance consisting of particles originating from the sawing and the polishing processes and
water used to cool and lubricate the sawing and polishing machines. Stone slurry generated during
processing corresponds to around 40% of the final product from stone industry.
There are several reuse and recycling solutions for this industrial by-product, both at an
experimental phase and in practical applications. These industrial wastes are dumped in the nearby
land and the natural fertility of the soil is spoiled. The physical, chemical and mechanical properties
of the waste are analyzed.
The advancement of concrete technology can reduce the consumption of natural resources and
energy sources and lessen the burden of pollutants on environment. Presently large amounts of
marble dust are generated in natural stone processing plants with an important impact on
environment and humans. This project describes the feasibility of using the marble sludge dust in
concrete production as partial replacement of cement.
In INDIA, the marble and porcelain stone processing is one of the most thriving industry the effects
if varying marble dust contents on the physical and mechanical properties of fresh and hardened
concrete have been investigated. Slump and air content of fresh concrete and absorption and
compressive strength of hardened concrete were also investigated. Test results show that this
industrial bi product is capable of improving hardened concrete performance up to 10%,Enhancing
fresh concrete behavior and can be used in architectural concrete mixtures containing white
cement. The compressive strength of concrete was measured for 7 and 28 days. In order to
evaluate the effects of marble dust on mechanical behavior, many different mortar mixes were
tested.

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CHAPTER 5
METHODOLOGY

5.1 GENERAL
SELECTION OF CONCRETE GRADES.
SERCHING IS CODES AND REFRENCES.
STUDY OF JOURNELS ALREDY WORKED OVER MIX DESIGN.
SELECTION OF RECYCLED WASTE MATERIALS.
SELECTION OF PERCENTAGE RATIO OF CONCRETE INGEDIENTS.
CALCULATIONS AS PER IS STANDARDS.
CONCRETE CUBES MAKING
COMPRESSION TEST AT 7, 14 AND 28 DAYS
DRAWINGS COMPRESSION GRAPHSFROM RESULTS.

Table no. 5.1:- Methodology of project

5.2 CALCULATIONS AS PER IS STANDARDS

Design specification.
Testing of materials.
Calculating target strength for mix proportioning
Selecting water/cement ratio
Calculating water content
Calculating water content
Calculating cement content.
Finding out volume proportions for Coarse aggregate & fine aggregate.
Mix calculations

Table no. 5.2:- Calculation methodology as per IS standard

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5.3 CODES USED
5.3.1 IS 10262:2009
IS: 10262 is the code specified by Bureau of Indian Standards for Concrete Mix
Design. The code came to existence in the year 1982. Keeping pace with the
advancing technology the code has been revised in December 2009. Significant
changes have been made in the revised version and a brief discussion is presented in
this paper comparing the two versions of IS: 10262. The basic points where the
guidelines have been modified are discussed. Besides one numerical example have
been solved using guidelines of both the versions to understand the differences.
Though the 2009 version encourages mixing of mineral admixtures to meet greater
challenges of modern concreting, a simple example is considered with use of no
additives.

5.3.2 IS 456:2000
IS 456-2000 Plain and Reinforced Concrete - Code of Practice is an Indian
Standard code of practice for general structural use of plain and reinforced concrete.
The latest revision of this standard was done in year 2000, reaffirmed 2005. This code
uses the limit state design approach as well working stress design approach. It is
written for use in India. It gives extensive information on the various aspects of
concrete.
It contains five sections and eight annexure:
Section 1: General
Section 2: Materials, Workmanship, Inspection and Testing
Section 3: General Design Considerations
Section 4: Special Design Requirements for Structural Members and Systems
Section 5: Structural Design (Limit State Method).

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CHAPTER 6
DATA AQUISION AND CALCULATIONS
6.1 General
6.1.1 Materials Required
1) Cement
2) Sand
3) Angular aggregates
4) Waste Glass dust.
5) Waste ceramic powder
6.1.2
1)
2)
3)

Equipments required
15cm x 15cm x15cm Moulds.
Sieves.
Compression testing machine.

Fig no. 6.1:- Compression testing machine

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Fig no. 6.2:- Concrete cubes moulds

Fig no. 6.3:- Mechanical vibrator

6.2 Design mix calculation

6.2.1

Target Mean strength

fck`= fck + 1.65 s

(Here S= standard mean deviation taken from IS 10262:2009)
= 25+ (1.65 x 4)
=31.6
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6.2.2 Selection of w/c ratio
From table 5 of IS 456: 2000 and for M-25 w/c maximum= 0.50
Here we adopt w/c = 0.47

Table no: - 6.1 IS 10262:2009 Table 1

6.2.3 Selection of water content
For 20mm aggregate, From Table 2 IS 10262 max .water content = 186 for 25-30
mm slump.

Table no.6.2:- IS 10262:2009 Table 2

Our slump value is125mm so,
= 186 x (9 100) +186 = 203 liters.
6.2.4 Calculation of cement content
W/c ratio = 0.47
Cement content = 203 0.47
= 431.91 Kg
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According to IS 456:2000 minimum cement content = 300Kg.hence ok

.
Table no.6.3:- IS 10262:2009 Table 5
6.2.5 Proportion of volume of coarse aggregate
From Table3 volume of coarse aggregate corresponding to 20mm size aggregate
and fine aggregate for w/c ratio of 0.5=0.62.
Here 0.45 i.e. it is less than 0.05 by 0.50. Therefore coarse aggregate is increase at
the rate of 0.01 for every decrease in w/c ratio of 0.05
(0.010.050 x 0.03= 0.006
Therefore corrected proportion of volume of Coarse aggregate = 0.623
Since it is angular aggregate and concrete is to be pumped , coarse aggregate can
be reduced by 10%
Final volume of coarse aggregate = 0.623 x0.9
= 0.560
Fine aggregate = 0.44
6.2.6 Calculation of mix proportion
Volume of concrete = 1m3
Volume of cement = (Mass of cement sp. Gravity of cement) x (11000)
= 0.137m3
Volume of water = (Mass of water specific gravity of water) x (1 1000)
= (203/ 1) x (1/1000)
Volume of all aggregate = 1-(0.137 + 0.203)
= 0.66 m3
Volume of coarse aggregate = 0.66 x 0.560 x 2.40 x 1000
=887.04 Kg
Volume of fine aggregate = 493.68 Kg
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CEMENT

F.A.

C.A.

W/C RATIO

431.91

493.68

887.04

0.47

1.14

2.05

0.47

Table no.6.4:- design mix proportion

6.3 Replacement chart of ceramic powder with cement

REPLACEMENT %

20%

23%

25%

CEMENT

7.2 Kg

6.93 Kg

6.75 Kg

SAND

10.26 Kg

10.26 Kg

10.26 Kg

COARSE AGGREGATE

18.45 Kg

18.45 Kg

18.45 Kg

CEREMIC POWDER

1.8 Kg

2.07 Kg

2.25 Kg

W/C RATIO

0.47

0.47

0.47

Table no.6.5:- Materials mixed by weight (ceramic replacement)

6.4 Replacement chart of glass dust with sand

REPLACEMENT %

10%

12%

15%

CEMENT

9 Kg

9 Kg

9 Kg

SAND

9.23 Kg

9.03 Kg

8.73 Kg

COARSE AGGREGATE

18.45 Kg

18.45 Kg

18.45 Kg

GLASS DUST

1.03 Kg

1.23 Kg

1.53 Kg

W/C RATIO

0.47

0.47

0.47

Table no.6.6:- Materials mixed by weight (glass dust replacement)

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CHAPTER 7
RESULTS AND DISCUSSIONS
7.1 REFFERANCE CUBE M25

Days

Compressive strength
(N/mm2)

18.56

14

20.9

28

23

Table no.7.1:- Reference cube results M-25

7.2 Glass powder replacement results

S.no.

% of glass
powder

Days

Compressive strength
(N/mm2)

1.

10%

20

14

21.51

28

24.93

16.55

14

21.68

28

22.22

13.05

14

15.46

28

21.95

2.

3.

12%

15%

Table no.7.2:- Glass powder replacement results

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7.3 Ceramic powder replacement results

S.no.
1.

2.

3.

% of
ceramic
powder

Days

Compressive strength
(N/mm2)

20%

15.31

14

18.02

28

22.13

24.34

14

29.84

28

32.79

11.78

14

13.89

28

15.87

23%

25%

Table no.7.3:- Ceramic powder replacement results

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CHAPTER 8
CONCLUSION

8.1 REFFERANCE CUBE M25

compressive strength (N/mm2)

25
20
15
10
5
0

compressive
strength
(N/mm2)
7 DAYS

14 DAYS

28 DAYS

8.2 Glass dust conclusion

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8.3 Ceramic powder conclusion

From the above study, it is concluded that: 10% replacement of sand with glass dust gives maximum strength as compared to 12%
and 15% but is that much effective strength as that of M-25.
15% replacement of glass dust with sand gives minimum strength.
In case of ceramic powder , we started with cement replacement with ceramic powder 20%
of replacement gives good strength but at 23% replacement of cement with sand gives
maximum compressive strength at 328 days i.e. 32.79N/mm2.
Hence from whole project we conclude that replacement of glass dust does create a huge
effect on economy and strength of concrete, further replacing cement with ceramic powder
in appropriate percentage (i.e. 23% in our project) may increase strength of concrete and
within economic cost.

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CHAPTER 9
REFFRANCES

1. Sonerbi M., Bartos PJM., ZHU W., Gibbs J., Tamimi A., (2000), Task 4properties of
hardened concrete, Final report, BriteEuRam Project No. BE96-3801/Contact BRPR-CT960366, P 73.
2. Petersson O. (2001), Limestone powder as filler in self-compacting concretefrost
resistance and compressive strength, in: K. Ozawa, M. Ouchi (Eds.), Proceedings of the
Second International Symposium on Self-Compacting Concrete, COMS Engineering
Corporation, Kochi, pp 277-28.
3. HanifiBinici, Hasan Kaplan and SalihYilmaz, (2007), Influence of marble and limestone
dusts as additives on some mechanical properties of concrete, Scientific Research and
Essay, 2(9), pp 372-379.
4. Billberg P. (1999), Fine mortar rheology in mix design of SCC, in: A. Skarendahl, O.
Petersson (Eds.), Proceedings of the first International RILEM Symposium on Self-Compacting
Concrete, RILEM, CachanCedex. pp 47-58.
5. Ali Ergun (2011), Effects of the usage of diatomite and waste marble powder as
partial replacement of cement on the mechanical properties of concrete, Construction
and Building Materials, 25(2), pp 806-812.
6. IS: 383-1970, Specification for Coarse and Fine Aggregate from Natural Sources for
ConcreteBureau of Indian Standards, New Delhi.
7. IS: 10262-1982 Recommended Guidelines for Concrete Mix DesignBureau of Indian
Standards, New Delhi.
8. IS: 456-2000, Plain and Reinforced ConcreteCode of PracticeBureau of Indian
Standards, New Delhi.
9. IS: 516-1959, Methods of Tests for Strength of ConcreteBureau of Indian Standards, New
Delhi.
10. IS: 8112-1989, 43 Grade Ordinary Portland cementSpecification, Bureau of
Indian Standards, New Delhi.

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SOME SNAPSHOTS OF OUR FIELD WORK

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