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Materials Today: Proceedings 5 (2018) 17540–17547 www.materialstoday.com/proceedings

ICMPC_2018

An Experimental study on Crushed Stone Dust as Fine Aggregate in

Cement Concrete
Sarvesh P.S Rajput
Civil Engineering, Maluna Azad National Institute of Technology Bhopal, India

Abstract

The deficit of natural sand arise the need of alternative materials for replacement of natural sand. This experimental study
explores in detail the crushed stone dust which is locally available industrial solid waste material in India as alternative material
to natural sand that is being conventionally used as fine aggregate in cement concrete. The nominal mixes were prepared for
grades M-20 and M-30 of cement concrete as per Indian Standards codes using natural sand (NS) and replacement of NS sand to
crushed stone dust (CSD) in different proportions. In each case proportion the slump cone test, compaction factor test, density
test, compressive strength test and Ultra-sonic pulse velocity test were carried out. The results of the study show that, the strength
properties of cement concrete using crushed rock sand is higher and homogeneous to the conventional concrete. The study has
present that crushed stone dust can be used as readily available solid waste as an alternative to natural sand in cement concrete
construction work and it can reduce the cost of material and construction cost and can helpful to mend the environment issues.

© 2018 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of Materials Processing and characterization.

Keywords: Cement concrete; Natural sand; Crushed stone dust; Environment

In developing nation the main source of fine aggregate is natural sand (NS) and it is main constituent of cement
concrete works. So the need of good natural sand (NS) is quite high to satiate the rapid growth of cement concrete
infrastructure. Huge demand of good natural sand for cement concrete works arise the scarce of resources good
quality NS. The resources of NS are being depleted and have serious environmental and social consequences such
as loosing water retaining sand strata, bank slides, loss of vegetation on the bank of rivers, exposing the intake
well of water supply schemes, lowering the underground water table disturbance of aquatic life etc.[1]. Thus,
there is urgent need of find out the alternative materials to fulfil the need of fine aggregate. Despite scarcity of good
quality natural sand, there are huge industrial solid wastes materials available locally in construction industry

* Corresponding author.
E-mail address: Sarveshpsrajput25@gmail.com

2214-7853 © 2018 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of Materials Processing and characterization.
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. Again this solid waste management is difficult task, it requires landfill area, high transportation cost and
efficient technologies for recycling process or disposal of Solid Waste material and it also have adverse effect on
environment. So, reduction of waste from industrial processes has become more complex and costly. Therefore one
of the logical methods for reduction of their negative effects is the application of these materials in other industries
[2]. Present days, mineral additives are attracting a great deal of attention as materials that contribute to the
improvement of specific properties of concrete, as well as alleviating some of the problems of solid waste
management. Many researchers [3-10] have been find out the solid wastes as an alternative materials as fine
aggregate i.e. Fly ash ,Slag limestone ,waste plastic and Crushed stone dust etc. A critical literature review also
suggest that Crushed stone dust (CSD) can be used as an alternative of cement concrete materials and most of earlier
studies are based on strength parameters of cement concrete made-up with CSD as an alternative of fine aggregate.
Thus, a detail investigation is to be needed for evaluation of CSD as alternative of natural sand or fine aggregate.
This study is focused on the nominal mixes were prepared for grades M-20 and M-30 of concrete basic of Indian
Standards codes using natural sand (NS) and replacement of NS sand with crushed stone dust (CSD) in different
proportions. In each case, Slump cone test, Compressive strength test and Ultra-sonic pulse velocity test were carried
out.The results of this detail investigation justifies the CSD as alternative of NS in cement concrete works and also
previous studies provide support to our work.

2 Experimental works

2.1 Material used in the study

The material used in this study are cement, course aggregate, fine aggregate (NS and CSD) and water. No plasticizer
has been used in this study. The Cement (43 grade OPC, Bangur-Buland) used for making concrete was
characterised for its suitability as per IS: 8112-1989 [11] and the course aggregate is crushed stone with maximum
12.5 mm graded aggregates (nominal size) was tested for its suitability for this study. Properties of cement and
coarse aggregate shown in Table 1.

Table 1 Properties of Materials

S. No. Test Name Test Values Codal Provision

1. Cement (confirming IS :8112-1989)

Fineness, (m2/kg) 250 > 225

Setting time (min) 80 <30

Initial

Final 240 <600

Soundness, (mm) 1 10

2. Course Aggregate (Confirming IS : 383- 1970)

Aggregate Abrasion Value 18.30 % <50%

Aggregate Impact Value 13.42 % <45%

Aggregate Crushing Value 16.35 % < 45%

Fineness Modulus 06.35 5.50-8.00

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There are two materials used as a fine aggregate: (i) Natural Sand is a naturally occurring granular material
composed of finely divided rock and mineral particles. The composition of sand is highly variable, depending on the
local rock sources and conditions. The Narmada River sand is used as NS. (ii) Crushed Stone dust is a fine material
formed during the process of conversion of rock into aggregate and has particle size ranging from 4 mm to dust size
(> 0.075mm). It was procured from stone crusher plant producing 20 mm downgraded aggregate, M/s Maa
Pitambara Stone situated at Neelbad, Bhopal (India). Physical properties (bulk density, specific gravity and fineness
modulus, water absorption and grain size distribution) of NS proposed alternative material CSD was determined and
the comparative evaluation of NS and CSD presented in Fig.2 (a) and sieve analysis of NS and CSD confirms IS:
383-1970 requirement of Zone II. Then, chemical analysis also carried out for assessment of surface morphology
and elemental composition of NS and CSD. For assessment of surface morphology SEM analysis was done. JEOL,
Japan made SEM model JSM 5600 / LINK ISIS 300 was used. Its resolution was 3.5 nm/138 eV and magnification
limit was 0.1 million times. SEM image of NS and CSD are presented Fig.1 (a) and (b).

(a) (b)
Fig. 1. SEM analysis (a) SEM image of NS (b) SEM image of CSD

EDX analysis was done for the study of elemental composition of the NS and CSD. Elemental composition of NS
and CSD is presented in Fig. 2(b). In Fig.1 SEM analysis clearly shows that the morphology of NS and CSD are
closer to each other.The Fig.2 explicitly shows comparative evaluation of physio-chemical properties, it shows that
physical and chemical characteristic of CSD has analogous to NS. The water is used in this study was characterized
on account of its pH, Acidity, Alkalinity, Suspended Solids, Organic Solids, Inorganic Solids, Chlorides and
Sulphates as prescribed in IS 456: 2000 Reaffirmed 2005 [12].

Fig.2. Comparative evaluation of properties of NS and CSD (a) Physical properties (b) Elemental composition
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2.2 Study of cement concrete mix

The details of cement concrete material used in this experimental study has been discussed previous section. Further
for the detail study of CSD an alternative of NS in cement concrete, the mix proportioning of cement concrete cubes
(Standard size: 15 cm ×15 cm ×15 cm) of M-20 and M-30 grades are 1: 2: 4 and 1:1.67:1.94 respectively has been
considered is this study. For the comparative evaluation of NS with CSD as fine aggregate in cement concrete mix
of M-20 and M-30 grades, prepared with NS and replacement of NS to CSD with percentage of 20, 40, 60, 80 and
100 by weight and their 7 and 28 days compressive strength was determined. To check the homogeneity of concrete
prepared using CSD, the cement concrete slabs are also prepared for ultra-sonic pulse velocity test. Three cement
concrete cubes are prepared each percentage of NS and CSD for both M20 and M30 grades and three slabs also
prepared for each by using NS and CSD in present study. In this study casting, compaction and curing accomplished
according to IS: 516-1959 [13], slump cone test as per IS: 1199 – 1959 [14] compaction factor test as per IS: 1199 –
1959, density determination of prepared cement concrete cubes as per standard volume and their weight,
compressive strength test as per IS: 516-1959 and ultra-sonic pulse velocity test as per IS 13311- Part I [15] were
performed (see Table 2).

Table 2. Details of results of Slump cone test, Compaction factor test and density

Material Replacement Slump cone test value(mm) (average) Compaction factor test Density (g/cc)

(%)

M20 M30 M20 M30 M20 M30

Wet Dry Wet Dry

NS - 34 162 35 162 0.84 0.84 2.5 2.53

20 33 160 35 162 0.85 0.85 2.51 2.52

40 30 156 33 159 0.85 0.85 2.51 2.54

CSD 60 30 153 30 156 0.88 0.86 2.50 2.54

80 28 152 29 155 0.90 0.88 2.51 2.53

100 28 152 29 155 0.90 0.88 2.51 2.54

3. Results of different tests

The analysis of CSD as an alternative of fine aggregate material in cement concrete production in place of NS. The
M-20 and M-30 concrete mixes were prepared using CSD (20, 40, 60, 80 and 100% replacement of NS).For details
study cement concrete made up with NS and replacement of CSD to NS different test are performed.

3.1 .Slump Cone test

As per IS: 1199 – 1959 [14]the standard range of slump value are 150-175mm and 25-50mm for wet concrete and
dry concrete respectively. It is clear from Table 2 that slump values obtained for test specimens are acceptable and
the slump values for NS and CSD are comparable only little variations has been observed which are under the
standard range
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3.2.Compaction factor test
Compaction factor is ratio between weights of partially and fully compacted concrete. Standards range of
compaction factor test is 0.8 - 0.92 (IS: 1199 – 1959) [14] The results obtain from present study presented in table 2
and these results are within limits.
3.3.Density of prepared Concrete cubes
The density of cement concrete of prepared M 20 and M 30 cement concrete cubes comes out almost same i.e. 2.5
and 2.53 for NS and 2.51 and 2.54 for CSD as fine aggregate in prepared cement concrete.

3.4.Compressive strength test

The compressive strength of the cubes was determined specimens prepared with NS and for specimens prepared
with percentages replacement NS to CSD as fine aggregate. The compression testing machine was used for the
compression test. The average of compression strength of 3 cubes was recorded for each testing time. The results of
compressive strength cement concrete cube of M-20, M-30 made-up with as fine aggregate as NS and replacement
of NS to CSD with different percentage proportion is graphical presented in Fig.3 Fig. 3(a) and Fig 3 (b) shows the
results obtained about compressive strength of the concrete (M-20 and M-30 grade) prepared with varying
proportions of crushed stone dust. Values show that in case of 28 days compressive strength for M-20 and M-30
grade it increases with the increase in replacement of CSD and it is higher than that of the cubes prepared with
natural sand only. Similar trend is observed in the case of 7 days compressive strength of cement concrete cubes
also.

Fig.3. Compressive strength of cement concrete cubes with percentage replacement of NS to CSD (a) for M-20 grade (b) for M-30 grade

3.5. Ultrasonic Pulse Velocity Test

The ultra-sonic pulse velocity method is used to establish the homogeneity of the concrete, presence of cracks, voids
and other imperfections, changes in the structure of the concrete which may occur with time. The ultrasonic pulse
velocity of cement concrete is mainly related to its density and modulus of elasticity. Three beam of each M-20 and
M30 grade of cement concrete with NS and complete replacement of NS with CSD are prepared .Concrete Quality
Grading as per IS 13311- Part I. The results of the test are presented in Table 3.
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Table 3. Details of Ultra pulse velocity test results

Sample Mode of Testing NS CSD

UPV Grading UPV Grading

km/sec km/sec
Direct 4.6 A 4.7 A
M-20 Direct 4.7 A 4.6 A
Direct 4.6 A 4.6 A
Direct 4.6 A 4.7 A
M-30 Direct 4.7 A 4.6 A
Direct 4.6 A 4.6 A

The result of Table 3 indicate produced cement concrete have excellent quality of homogeneity.

4. Discussions on Results

The experimental investigation carried out in this study showed that successive partial replacement of natural sand
to Crushed stone dust in cement concrete is enhances its properties. The Fig. 2 shows the comparative evaluation of
physio –chemical characteristic was of NS and CSD has been carried, it explicit that composition with respect to
Silica, Aluminium, Oxygen and Calcium are nearest to natural sand in crushed stone dust, also the morphology of
CSD and NS is much close shown in Fig. 1.Therefore, it is direct justification of CSD is quite good choice of
alternative material as fine aggregate in cement concrete in place of NS .Further , cement concrete nominal mix of
M-20 and M-30 in proportion of 1: 2: 4 and 1:1.67:1.94 respectively. It is noted down that any admixture not used
this experimental study. The nominal mixes of cement concrete exacting the study results. The details study of
slump cone test, compaction factor test and density values of cement concrete prepared by successive replacement
of NS with CSD as fine aggregate are figuring almost same. The trends of results in Table 2 explicit Slump value
and compaction factor value of cement prepared by CSD have very little deviation with results of NS and the values
for both NS, CSD are under expected limits of Indian Standard; whereas density of cement concrete made up with
NS and complete replacement with CSD as an alternative of fine aggregate have almost same values .So it can be
justify that CSD could be Suitable alternative of NS for cement concrete works. Moreover compressive strength of
concrete cubes made up with successive replacement i.e. 20 %, 40%, 60% , 80 %and 100% of natural sand with
crushed stone dust of M -20 and M-30 showing higher compressive strength at 7 days and 28 days. Fig. 3 shows
the comparable results compressive strength of the cement concrete cubes. The bar trends show that in case of 28
days compressive strength for M-20 and M-30 grade concrete cubes, it increases with the increase in replacement of
CSD and it is higher than that of the cubes prepared with natural sand only. Similar trend is observed in the case of 7
days compressive strength of cement concrete cubes also. Actually, cement concrete prepared by complete replacing
of NS to CSD significant different in Compressive strength so , it may be possible that quantity need to be of CSD
for desire strength will be lesser as compare to NS. The ultra-sonic pulse velocity test was performed to check the
homogeneity of prepared cement concrete. Table 3 shows that produce cement concrete have excellent quality of
homogeneity for both M-20 and M-30. In economic point view the cost of CSD is 500 INR/ton whereas cost of
natural sand is 4500 INR/ton at current location Bhopal, Madhya Pradesh (India) so, CSD much cheaper than NS, it
can suggested that CSD is economical, have higher compressive strength and it also reduces the diminishing effect
on surrounding [16] .Hence, This further justify the choice of crushed stone dust as an alternative of natural sand as
fine aggregate for cement concrete works in developing nations.
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5. Conclusion

This study insures that crushed stone dust a solid industrial waste of the construction industry as a natural sand-
substitution as fine aggregate in cement concrete gives a good approach to reduce the scare good quality of fine
aggregate, increase compressive strength and solve some of the solid waste problems posed by crushed stone dust.
Some of important findings are as follows:
 Physio-chemically natural sand and crush stone dust is almost similar.

 The results indicated that slump cone test, compaction factor test and density test of prepared cement
concrete mixes of M-20 and M-30 grades are analogous for NS and CSD. Compressive strength of
concrete cubes prepared with successive percentage replacement of NS to CSD shows that it increases
with the increase in replacement and also its values are higher in almost in all cases than cubes prepared
with natural sand only.

 Ultrasonic pulse velocity test results for the M-20 and M-30 both concrete mix, which was prepared using
crushed stone dust completely replacing natural sand shows excellent results.

Thus, this investigation presents the crushed stone dust as suitable material for cement concrete works as alternative
fine aggregate to replace the natural sand. The crushed stone dust is economical also in Indian condition. The
limitation of the study is that it is applicable in developing countries where crushed stone dust readily available in
substantially only. The all test results of cement concrete are as per Indian Standards so results may vary with
different standard practices. The comparative evaluation with other industrial solid waste like copper slag, blast
furnace slag etc. is needed to the compare the suitability of CSD as fine aggregate in cement concrete.
Environmental impact assessment of crush stone dust is not discussed in detail.
It is expected that this study may be useful for augment the use of crushed stone dust as an alternative of natural
sand as fine aggregate in cement concrete work where scare good quality of natural sand in developing nation. It
may helpful to increase research orientation toward finding out the alternative solid industrial waste material for
cement concrete works.

References

[1] S. Elavenil and B Vijaya, “Manufactured Sand, A Solution And An Alternative to River Sand and in Concrete Manufacturing,” Journal of
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[9] S. Ahmad and S. Mahmood. “Effects of Crushed and Natural Sand on the Properties of Fresh and Hardened Concrete,” 33rd Conference on
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[10] L. Nagpal, A. Dewangan, S Dhiman, and Kumar, S. (), “Evaluation of Strength Characteristics of Concrete Using Crushed Stone Dust as
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