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Article history: With an increasing interest in recycling and reusing waste, there is a need to carry out research on
Received 13 October 2014 exploring ways to transform industrial wastes into construction materials. This paper attempts to explore
Received in revised form the feasibility of reutilizing textile effluent sludge (TES) for producing concrete blocks with a pretreat-
5 March 2015
ment step. The lime-based pretreatment process was adopted to remove ammonia in TES which had
Accepted 28 March 2015
been found to lead to bad odor and strength loss of the concrete blocks. The concrete blocks were
Available online 6 April 2015
prepared with an aggregate to cement ratio of 12, 10 and 6. The pretreated TES was adopted to replace
the fine aggregate at a mass ratio ranging from 0% to 30%. The compressive strength and drying shrinkage
Keywords:
Textile effluent sludge
values were determined to evaluate the performance of concrete blocks containing TES. The results
Lime-based pretreatment indicated that the lime-based pretreatment process can lower the ammonia concentration in TES
Concrete block significantly. The concrete blocks with a lower TES content and lower ammonia concentration had higher
Ammonia compressive strength and better volume stability. When the TES content in the concrete blocks was
Leaching about 10%, the concrete blocks with an aggregate to cement ratio of 10 can satisfy the minimum strength
requirement for non-load bearing applications. Meanwhile, the result of leaching test indicated that the
toxic trace metals present in textile effluent sludge could be stabilized/solidified and metal leaching from
the concrete blocks is not a concern.
© 2015 Elsevier Ltd. All rights reserved.
1. Introduction petroleum solid waste was also investigated with cement-based S/S
process (Karamalidis and Voudrias, 2007). It was found that in-
Textile industry involves processing or converting raw material/ clusion of cement blended with pozzolanic materials increased the
fabric into finished clothing materials via several processes which leachability of most polycyclic aromatic hydrocarbons in solidified
consume large amount of water and produces polluting waste ef- sludge samples. Sewage sludge from have been studied for fired
fluents (Karthikeyan and Mohan, 1999) containing non- bricks production, but high content of this sludge resulted in a
biodegradable and toxic dissolved substances (Khatri et al., 2014). degradation of mechanical strength and absorption of fired bricks
Previous studies confirmed that the levels of pollutants in textile (Ingunza et al., 2011).
effluent were considerably higher than the discharge limits stipu- Several kinds of waste are also reused in combination with
lated by local regulations (Noorjahan, 2011; Paul et al., 2012). cement for producing concrete products, including waste marble
Therefore, treatment of the textile effluent before discharge is (Gencel et al., 2012), ferrochromium slag (Gencel et al., 2013) and
almost mandatory leading to the production of huge volumes of CRT funnel glass (Ling and Poon, 2014). Recently, reutilization of
textile effluent sludge. Besides landfill disposal of the sludge, there sewage sludge ash (SSA) was reported to manufacture blocks with
are growing interests in trying to re-utilize the sludge. best performance by replacing 10% sand with SSA (Francisco et al.,
Currently, cement based binders are extensively adopted for 2014). Even another study assessed the potential feasibility of
treating industrial solid waste containing radioactive or hazardous reusing lime-dried sludge as a replacement of limestone material
substances to prevent the leaching of contaminants to the envi- for clinker production (Xu et al., 2015). Rala et al. (2015) have
ronment (Batchelor, 2006). Stabilization of hydrocarbons in explored the feasibility of reuse the marble slurry to partially
replace cement for concrete production. They found that 10% of
cement replaced by marble slurry was the optimum content to
* Corresponding author. Tel.: þ852 2766 6024; fax: þ852 2334 6389. produce concrete with the requisite strength and enhanced
E-mail address: cecspoon@polyu.edu.hk (C.S. Poon). durability.
http://dx.doi.org/10.1016/j.jclepro.2015.03.083
0959-6526/© 2015 Elsevier Ltd. All rights reserved.
B.J. Zhan, C.S. Poon / Journal of Cleaner Production 101 (2015) 174e179 175
Table 1
Characterization of TES.
a b
Oxides Value (% dry mass) Trace metals Value (mg/Kg dry mass)
Table 2
Particle size distribution of pre-dried TES.
5 mm 0 0.0 100.0
2.36 mm 17.8 6.9 93.1
1.18 mm 47.9 18.7 74.4
600 mm 77.9 30.3 44.1
300 mm 64.3 25.0 19.0
150 mm 32.5 12.7 6.3
75 mm 10.0 3.9 2.5
<75 mm 6.3 2.5 /
B.J. Zhan, C.S. Poon / Journal of Cleaner Production 101 (2015) 174e179 177
Table 3
Mix proportions for concrete blocks prepared with TES.
Series Notation Pre-treatment % of fine aggregate Aggregate Cement Fine aggregate Coarse aggregate
method of TES substituted with TES to cement ratio
compressive strength was reduced by almost 80% while the 28-day When 5% of fine aggregate was replaced by TES, the B-05 sam-
compressive strength was reduced by 70%, compared to the refer- ples attained a satisfactory compressive strength value after 7 days
ence samples (A-00). Further increase in TES dosage in the concrete moist curing, which was considerably higher than 7 MPa. Never-
blocks had little impact on the compressive strength. However, theless, even after 28-day curing, the compressive strength of B-10
except the reference sample, the 7-day compressive strength of the and B-15 samples was still around 4.4 MPa.
samples in Series A did not meet the minimum requirement of Both two mixes in Series C were prepared with 10% fine
7 MPa according to BS 6073-1. aggregate substituted with TES, but with different aggregate to
cement ratios. Apparently, the compressive strength value for
concrete blocks (Ce10S) after 7-day and 28-day curing was
acceptable once an aggregate to cement ratio of 6 was adopted.
Table 4
Properties of concrete blocks prepared with TES.
Fig. 5. Comparison of drying shrinkage value of concrete blocks from different series.
3.3. Metal leaching Where, sr is 28-day compressive strength of concrete blocks pre-
pared with the pretreated TES, while s is 28-day compressive
Taking into account of maximizing the TES utilization in concrete strength of concrete blocks without TES (ref). Thus, f ranges from 0 to
blocks and easy operation of TES pretreatment, the sample D-10 was 100% as sr is always smaller than s for the samples in the same series.
Table 5
TCLP results of concrete blocks containing TES.
4. Conclusion
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BSI, 2008. BSI BS 6073e2: Precast Concrete Masonry Units e Part 2: Guide for
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BSI, 2009. BS EN 12390e3: Testing Hardened Concrete Part 3: Compressive Strength
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Fig. 6 plots the variation of (f) vs. the mass percentages of the
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strength of cement mortar and concrete. Furthermore, due to the mixed concrete paving blocks. J. Clean. Prod. 68, 209e215.
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ammonia in the fresh concrete mixture suppressed the formation Additives I: Production, Usage and Environmental Occurrence, in: the Hand-
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