A

PROJECT REPORT

ON

A STUDY ON RECYCLED
AGGREGATE IN CONCRETE
Submitted in partial fulfillment of the requirements for the
degree of Diploma in
“Civil Engineering”

DEPARTMENT OF CIVIL ENGINEERING

UVIVERSITY POLYTECHNIC
IFTM UNIVERSITY, LODHIPUR RAJPUT,
MORADABAD-244001

Under the guidance of:

Mr.Neeraj Kumar Submitted By
Asst. Professor Siddharth Dhariwal(19045027)
Department of Civil Engineering Diploma CE 6th Semester
Department of Civil Engineering
University Polytechnic

1|Page
 DEPARTMENT OF CIVIL ENGINEERING
IFTM UNIVERSITY
LODHIPUR RAJPUT, DELHI ROAD, NH-24MBD,U.P.

Ref: Date:

CERTIFICATE

This is to certify that Project report entitled “A Study On Recycled

Aggregate In Concrete” Submitted by “Siddharth Dhariwal(19045027)”
Student of "Diploma" Civil Engineering Department of IFTM UNIVERSITY
MORADABAD is a record work carried out my guidance and supervision. The
material embodied in this Project report is original and has not been submitted
by me for the award of any other degree of any other university.

Siddharth Dhariwal(19045027)
Diploma CE 6th Semester
Department of Civil Engineering
University Polytechnic

This is to certify that the above statement made by the candidate is correct to the
best of my knowledge.

Mr. Mahavir Singh Rawat Mr. Neeraj Kumar

(Project Coordinator) (Project Guide)

Certified that the above-mentioned Dissertation report has been duly

carried out as per the norms of the college and statutes of the university.

Mr. Mahavir Singh Rawat

(Assistant Prof. & Head, CE Deptt.)

2|Page
 ACKNOWLEDGEMENT

We have made this Project report file on the topic “A Study On

Recycled Aggregate In Concrete” We have tried my best to elucidate
all the relevant detail to the topic to be included in the report. While in the
beginning we have tried to give a general view about this topic. My
efforts and wholehearted co-corporation of each and every one has ended
on a successful note. We express my sincere gratitude to “Mr. Mahavir
Singh Rawat” who assisting me throughout the preparation of this topic.
We thank him for providing me the reinforcement, confidence and most
importantly the track for the topic whenever we needed it.

SUBMITTED BY
Siddharth Dhariwal(19045027)
Diploma CE 6th Semester
Department of Civil Engineering
University Polytechnic
Date: ………………….

3|Page
 TABLE OF CONTENTS

CHAPTER PAGE NO.

Introduction……………………………………………… 7-10

Construction and Demolition Waste In India…………… 10-11

Need of the Study……………………………………….. 12-12

Objective………………………………………………… 12-12

Review of Literature…………………………………….. 13-15

Materials Used and Properties…………………………... 16-17

Cement…………………………………………………… 17-18

Fine aggregate…………………………………………… 18-19

Natural Aggregate……………………………………….. 19-20

Recycled Coarse Aggregate……………………………... 20-21

Water……………………………………………………... 22-22

Properties of Recycled Aggregates………………………. 22-24

Industrial Crushing System………………………………. 24-24

Laboratory Crushing System…………………………….. 25-25

Aggregate-Mortar Separation……………………………. 25-26

Sieving…………………………………………………… 26-26

Washing the Recycled Coarse Aggregates………………. 26-26

Presoaking the Recycled Coarse Aggregates……………. 26-26

Results and Discussion…………………………………... 27-34

Conclusion……………………………………………….. 35-35

References……………………………………………….. 36-37

4|Page
 LIST OF TABLE

Tableno. Title Page no.

1 Constituent in million kgs given by TIFAC 11
2 Physical characteristics of Portland cement 16
3 Chemical composition of Portland cement 16
4 Properties of aggregates 22
5 Cube Compressive strength 33

5|Page
 LIST OF FIGURES

Figure no. Title Page no.

1.1 Recycled Coarse Aggregate 10
1.2 Various constitutes of waste 11
3.1 Cement 18
3.2 Fine Aggregate 19
3.3 Natural Aggregate 20
3.4 Recycled Coarse Aggregate 21
3.5 Industrial crushing system 24
3.6 Laboratory crushing system 25
4.1 Casting of Concrete Cube 28
4.2 Curing of concrete 29

4.3 Figure Compression testing Machine 32

4.4 Bar Chart of Compressive strength test at 7,14 and 28 days 33
4.5 Bar Chart of Flexural strength test at 7,14 and 28 days 34
4.6 Bar Chart of Split Tensile strength test at 7,14 and 28 days 34

6|Page
 CHAPTER 1
INTRODUCTION

The need and importance of concrete in construction industry is ever increasing. Recycled
Aggregate Concrete (RAC) is concrete that using Recycled Aggregate (RA) as partially or
fully replacement in coarse and fine aggregate. It is believed RA have been used from 1945
in concrete producing and started when World War II damaged a large quantity of concrete
structures and the high demand of aggregate to rebuild the structures. Concrete is the
favourite choice as a construction material among civil engineers around the globe for
decades. It is preferred for its better performance, longer life and low maintenance cost. To
achieve rapid urbanization every year smaller structures are demolished and newer and bigger
ones are constructed. These demolished materials (majority of which is usually concrete) are
often dumped on land and is not reused for any purpose. This practice affects the fertility of
land. With the wave of sustainability also impacting the construction industry, scientist and
engineers throughout the world are looking for sustainable and reusable construction
materials. One such material is recycled aggregate concrete. Utilizing recycled aggregate is
certainly an important step toward sustainable development in the concrete industry and
management of construction waste. Recycled aggregate is variable properties. Quality of the
recycled aggregate depend upon the collected material quality and its delivery to the plants.
Recycling is the act of processing the used material for use in creating a new product. The
usage of natural aggregate is getting more and more intense with the advanced development
in infrastructure area. Recycled aggregate is comprised of crushed, graded inorganic particles
processed from the materials that have been used in the constructions and demolition debris.
Recycled aggregates are produced from the re-processing of mineral waste materials, with the
largest source being construction and demolition waste. These wastes are normally composed
of concrete rubble usually, constitutes the largest proportion of construction and demolition
waste. It has been shown that crushed concrete rubble, after separation from other
construction and demolition waste and sieved, can be used as a substitute for natural coarse
aggregates in concrete or a sub-base or a base layer in pavements.
Aggregate is one of the most vitally important materials in use for concrete production as it
profoundly influences concrete properties and performance. Regarding aggregate usage in
concrete, a conservative estimate is that at least 4.5 billion tons of concrete aggregates per
year are consumed worldwide. This figure is assumed to represent total aggregate production,
including usage in concrete and road base. Aggregate usage in concrete constitutes perhaps

7|Page
between 25 and 35 per cent of the total aggregate production. The above inevitably impacts
on the environment due to the great huge quantity of general and construction waste materials
or from building demolition sites generated in developed countries. The research conducted
for the Industry Commission Report indicated that about 3 million tons of waste aggregate
has been created in the India alone. The disposal of all this waste has become a harsh social
and environmental problem. This is a large burden on the world’s natural resources and an
increasingly expensive problem for solid waste management. Therefore, a possible alternative
aggregate method to overcome this issue may be using recycled concrete aggregates instead
of natural aggregate in construction tasks. This solution not only can help to conserve and
extend natural resources but also can reduce the cost of waste treatment and the demand on
landfill sites for disposing the waste. In this project, the other most important issue is to
determine the best solution to make the recycled concrete aggregate economical for most
infrastructure tasks especially in structural concrete around India. The recycled concrete
aggregate can be defined as crushed concrete composed of aggregate fragments coated with
cement paste or cement mortar from the demolition of the old structures or pavements that
has been processed to produce aggregates suitable for use in new concrete. The processing, as
with many natural aggregates, generally involves crushing, grading and washing. This
removes contaminant materials such as reinforcing steel, remnants of formwork, gypsum
board, and other foreign materials. The resulting coarse aggregate is then suitable for use in
concrete. The fine aggregate, however, generally contains a considerable amount of old
cement paste and mortar. This tends to increase the drying shrinkage and creep properties of
the new concrete, as well as leading to problems with unworkable mix and strength.
Therefore, many transportation departments have found that using 100% coarse recycled
aggregate but with only about 10% to 20% recycled fines works well. Regarding the results
of most of the previous research that has been done so far, the application of Recycled
Aggregate is mostly currently in low quality/strength concrete, for example, pavement base
and slab rather than used in structural concrete. The most common application of Recycled
Concrete Aggregate is the use in concrete sub-base in road construction, bank protection,
noise barriers and embankments, many types of general bulk fills and fill materials for
drainage structures. After the removal of contaminants through selective demolition,
screening, and/or air separation and size reduction in a crusher to aggregate sizes, crushed
concrete can be used as new concrete for pavements, shoulders, median barriers, sidewalks,
curbs and gutters, and bridge foundations; structural grade concrete; soil-cement pavement
bases; moulded concrete bricks and blocks; bituminous concrete etc. However, there is an

8|Page
example of recycled concrete being used for part of the structural slabs in a high-rise building
in Japan but there was no too much detail available on this project. According to research that
has been conducted in Australia, current use of recycled aggregates is still only around 7% of
road construction material in South Australia. Victoria Road also use recycled aggregate for
construction projects. The aim of this project is to determine the characteristic strength and
durability properties of 100% recycled aggregate used in structural concrete, compared with
natural aggregate, as well as to find the most economical solution and quality of the recycled
concrete aggregate
Recycled aggregates (RA) are produced from the re-processing of mineral waste materials, with the
largest source being the construction and demolition waste. In general, the quality of RA is inferior to
those of natural aggregates. The density of the RA is lower than natural aggregates and RA have a
greater water absorption value compared to natural aggregates. As a result, proper mix design is
required for obtaining the desired qualities for concrete made with RA. Experimental studies on
properties of RA with NC have been contributed by the several researchers.
The brief literature reviews of some of the latest studies are as follows: studied the fresh and
hardened properties of NC using recycled concrete aggregates as both coarse and fine
aggregates states. Three series of NC mixtures were prepared with 100% coarse recycled
aggregates, and different levels of fine recycled aggregates were used to replace river sand.
The cement content was kept constant for all concrete mixtures. Studied on the potential
usage of RCA obtained from crushed concrete for making of NC, and additionally
emphasizing its ecological value. In their experiment, three types of concrete mixtures were
made, where the percentage of substitution of coarse aggregate by recycled aggregate was
0%, 50% and 100%. In the process of mixing, equal consistence of all concrete mixtures was
achieved determined the influence of different curing conditions on the mechanical
performance of concrete made with coarse recycled aggregate from crushed concrete.
The properties analyzed include compressive strength, split tensile strength, modulus of
elasticity and abrasion resistance studied the benefits of limestone powder, basalt powder and
marble powder as partial replacement of Portland cement and used directly in the production
of NC. The water to binder ratio was maintained at 0.33 for all mixture studied on the effect
of coarse aggregate gradation on the properties of NC. Four NC mixtures with A/B (size 5-10
mm coarse aggregate weight/size 10- 20 mm coarse aggregate weight) ratio 4/6, 5/5, 6/4 and
7/3 were prepared; the bulk density of aggregates with various A/B ratios was investigated.
The effectiveness of various types of coarse aggregates on fresh and hardened properties of
NC was investigated.

9|Page
 Figure No. 1.1: Recycled Coarse Aggregate

Construction and Demolition Waste in India:

According to the estimation of (CPCB) the Central Pollution Control Board of India the
approximate solid waste generated is in the range of 48 million tons per annum. In which the
waste generated from construction industry is more than 25%. Therefore there is great need
for proper management of such a high quantity of waste. According to (Gaikwad and Kumar,
2004) the quantity of waste will reach at least 65 million tons per annum. Worldwide there is
use of 10 billion tons of natural rock and sand by concrete industry and production of waste
materials is more than 10 billion tons per year (Mehta, 2002). Table No. 1 showing different
values of constituents in million kgs per year and Figure no.1 showing various constitutes of
waste according to (TIFAC, Department of science and technology, GOVT. OF INDIA).
Construction and demolition waste produced by The Europe
European
an Union approximately 200 –
300 million tons per year that is approximately equal to 0.5 – 1 per capita per year ( Zega C J
and Maio, 2011). Construction and demolition is mainly main source of aggregates because
74% of concrete is made from aggregates if this can be reused or recycled then there will be
reduction in transpor
transportation
tation cost and landfills also.

10 | P a g e
 Table No. -1 Constituent in million kgs given by TIFAC
Constituent Million Kgs per year
Soil gravel and sand 4200 to 5140
Bricks and masonry 3600 to 4400

Concrete 2400 to 3670

Metals 600 to 730
Bitumen 250 to 300
Wood 250 to 300

Others 100 to 150

There is approximate 12 to 14.7 million tons waste from construction industry out of which there is
7 to 8 million tons are concrete and brick waste. Figure No. 1 shows the various constitutes of waste

and out of which 25 % is concrete

concrete.
Figure No. 1.2: Various constitutes of waste

11 | P a g e
Need of the Study:
Due to fast growth in infrastructural development and increasing demand for housing there is
shortage in the construction materials and also increase in cost of the materials. Generally
materials which are produced by demolished structures are thrown away as a land fill. There
is shortage in dumping place in city areas. Therefore it is essential to reuse and recycle the
demolished materials to save environment, cost and energy. It is well known that naturally
occurring aggregates used for construction are depleting rapidly. Therefore there is need to
find substitutes for it. Recycled aggregates can be used in place of normal aggregates in
construction of low volume roads. For economical environmental reasons, and due to the
increased amount of recycled aggregates at the present time as a result of advancesin crushing
technologies, there has been a growing global interest in maximizing the use of recycled
aggregates in construction. Till today the research of recycled aggregates are mostly carried
out in countries like Europe, Japan and United States etc. In India its research is at very initial
stage. So there is wide scope of using recycled aggregates in construction work. The research
work is mainly done on the use of recycled concrete in concrete structures. To Study the
physical and mechanical performance of recycled aggregate used in concrete in place of
natural aggregate.

Recycled concrete aggregate presents numerous benefits:

 Increased protection from seepage.
 Reduced costs, since it doesn't need to be mined.
 Reduced environmental impact, more appealing to governments and customers.
 Preserves natural resources such as gravel, water, coal, and oil.
 Reduced space wastage in landfills.

Objective:
 To Study the physical and mechanical performance of recycled aggregate
used in concrete in place of natural aggregate.

 To utilize the recycled aggregate as a partial or full replacement of virgin

aggregates inconcrete. .

12 | P a g e
 CHAPTER 2
Review of Literature
The applications of recycled aggregate in construction as a road base materials are very broad
and have been in use for almost 100 years. There has been much research based on the use of
recycled aggregate that has been carried out all around the world. The research on recycled
aggregate that has been carried out indicated that the successful application of crushed
aggregate in concrete can be achieved. This successful research has been achieved in many
countries, in particular in Europe; United States; Japan and China. This chapter presents
literature reviews on the effects of various factors on the recycled aggregate from research
from those countries. The major objective of most of the experiments or research on recycled
aggregate is to find out the results in the strength characteristic area and what is the best
method to achieve high strength concrete with recycled aggregate.
K C Panda (2013) in this paper presents the influence of different amounts of recycled
coarse aggregate (RCA) obtained from a demolished Town Club building of Banka, N.A.C of
Cuttack region, about 25 years old on the properties of Normal Concrete(NC) and
compared the results with normal vibrated concrete (NVC) containing 100% natural coarse
aggregate (NCA). Important properties such as physical and mechanical properties of natural
and recycled aggregates are carried out. NCA is partially replaced with RCA by an amount
10%, 20%, 30% and 40%. The effect of RCA on the properties of NC in green state (e.g.,
Slump flow test, V-Funnel test, and L-Box Test) and properties of concrete in hardened state
(e.g., compressive strength, flexural strength, and Split tensile Strength) are studied. The mix
design was carried out for M25 grade of concrete. The experimental results indicate that the
compressive strength, flexural strength, and split tensile strength of the NC with 100%
natural aggregate is less than the normal vibrated concrete (NVC) with 100% natural
aggregate and the strength of NC decreases with an increase in recycled aggregate2 (RA)
replacement ratios. The present study recommends NC marginally achieves required
compressive strength up to 30% replacement of RCA.
W.C. Tang (2016) utilization of recycled concrete aggregate (RCA) in Normal Concrete
(NC) has the potential to reduce both the environmental impact and financial cost associated
with this increasingly popular concrete type. However, to date limited research exists
exploring the use of coarse RCA in NC. The work presented in this paper seeks to build on
the existing knowledge in this area by examining the workability, strength, and fracture
properties of NCs containing 0%, 25%, 50%, 75%, and 100% coarse RCA. The experimental
programme indicated that at RCA utilization levels of 25% to 50% little or no negative

13
impact was observed for strength, workability, or fracture properties, except for a slight
reduction in young’s modulus.
S Vijaya (2015) Construction and Demolition waste management issues have attracted
researchers around the world. The boom in construction sector and large-scale mechanization
in concrete production has led to setting up of several ready-mixed-concrete (RMC) plants.
The present study aimed at producing fine and coarse aggregates from the hardened concrete
waste available at the RMC plant on the outskirts of Bangalore. The material characterization
for both fine and coarse aggregates was carried out as per IS: 2386 (Part IV) – 1963. The test
results have shown that the properties of recycled aggregates satisfy the codal provisions
specified for natural aggregates. The M-20 Normal Concretemix with 0%, 25%, 50%, 75%
and 100% replacement of fine and coarse aggregates were done separately in two batches.
Third batch mixes consist of both fine and coarse aggregates replacement of 0%, 25%, 50%,
75% and 100%. Further the fresh and hardened properties of M-20 Normal Concretemix has
been carried out systematically. It was observed that 50% replacements in all the three
batches of M-20 concrete mix have exhibited satisfactory flow and compressive strength
values.
Prof. Sarah Anil (2018) Self Compacting Concrete is a flowing concrete mixture that can
consolidate under its own weight. Use of NC can also help in minimize hearing damage on
the work site that is induced by vibration of concrete. The use of recycled concrete aggregates
from demolition waste and rubble in combination with cementitious additions in concrete has
several advantages. In this paper experimental studies are carried out to understand the fresh
and hardened properties of NC in which natural coarse aggregate is replaced by recycled
coarse aggregate at 15%, 30% and 45%. The cement content was also partially replaced by
Ground Granulated Blast Furnace Slag and Fly Ash. The mix design was carried out for M30
grade of concrete. The fresh properties of NC were determined. The strength behavior,
flexural behavior, split tensile strength, modulus of elasticity and shear strength behavior of
NC are studied. The compressive strength, flexural strength and split tensile strength was
measured at the ages of 7, 28, and 56 days. The mechanical properties were reduced with the
incorporation of recycled coarse aggregate due to the poor adhesion between the mortar and
aggregate. The results indicate that compressive strength, flexural strength, split tensile
strength Modulus of Elasticity, and shear strength of NC decreases with increase in the
amount of RCA. The present study recommends NC marginally achieves required
compressive strength up to 30% replacement of RCA.

14
Frank Stephen. S (2019) In recent years, sustainable construction materials are highly
recommended in construction projects due to reduce the degradation of natural resources. An
experimental investigation with varying percentages of coarse recycled concrete aggregate
was conducted on self-compacting concrete.
The primary goal was to explore the suitability and impact of coarse recycled aggregate in
concrete fresh generation. The demand for building products has risen tremendously in latest
years, so the quantity of building and demolition waste has increased, placing enormous
stress to the atmosphere. The use of recycled aggregate in concrete is a suitable solution to
extend the lifetime of natural resources and thereby lead to sustainable developments in
construction field. In this investigation, NC is modified by recycled coarse aggregate (RCA)
in various percentages of natural coarse aggregate (NCA) substitutes from 0 percent to 100
percent with a 20 percent increase. Durability and the mechanical properties of modified NC
was determined. From the results it is revealed that the substitution of RCA in the place of
NCA significantly improved the durability properties.

Aljassar et al., 2005 had studied asphalt mixture prepared by recycled coarse aggregates
and found its performance in terms of volume, residual Marshall Stability and rutting
resistance well satisfied the related technique requirements of Kuwait.

15
 CHAPTER 3
Materials Used and Properties

1. EXPERIMENTAL INVESTIGATION
1.1 Materials
1.1.1 Cement
In this present study 43 grade Ordinary Portland Cement (OPC) was used
Table No 2: Physical characteristics of Portland cement
Min. Compressive
Fineness Soundness by Setting time
Type of strength (mp)
m2/kg
cement Lechatelierite Initial Final 3 7 28
(min)
(%) max. (min) (min) days days day
43 Grade
OPC
225 10 30 600 23 33 43
(IS 8112-
1989)

Table No 3: chemical composition of Portland cement

S
r. Name of Oxide
Abbreviation Approx. % Function
N compound composition
o
Tricalcium Mainly responsible for early
1 3CaO.SiO2 C3 S 45-55
silicate strength (1 to 7 days)
Dicalcium Mainly responsible for later
2 2CaO.SiO2 C2 S 20-30
silicate strength (7 days and beyond)
C3A increases rate of
Tricalcium hydration of C3S. C3A gives
3 3CaO.Al2O3 C3 A 6-10
aluminate flash set in absence of
gypsum
It hydrates rapidly but Its
Tetra calcium 4CaO.Al2O3. contribution to strength is
4 C4AF 15-20
luminometries Fe2O3 uncertain and generally very
low.

The sand is brought from the river Gagan Moradabad which is about 35 km from the
Institute. Sand is used as fine aggregate which is passing through IS 4.75 mm sieve. NCA

16
consists of rock fragments that are used in their natural state or are used after mechanical
processing such as crushing, washing, and sizing. The size of aggregate used in this study
was between 10 mm to 20 mm. The source of NCA is crushed stone. It is brought from
Tapang granite quarry in the district of Moradabad. RCA used in this study are brought from
Moradabad N.A.C., which is about 10 kms from the Institute. The source of aggregate was a
25 years old town club building whose roof slab was demolished. The aggregates were
separated by crushing the demolished debris manually and were then cleaned. The size of
aggregate was kept between 10 mm to 20 mm which were used for casting. The debris are
manually broken down. The properties of fine and coarse aggregates obtained experimentally
as per IS: 383-1970 is presented in Table 3.2.

CEMENT:
A cement is any substance which binds together other materials by a combination of chemical
processes known collectively as setting. Cements are dry powders and should not be confused
with concretes or mortars, but they are an important constituent of both of these materials, in
which they act as the 'glue' that gives strength to structures. Mortar is a mixture of cement
and sand whereas concrete also includes rough aggregates.
Because it is a major component of both of these building materials, cement is an extremely
important construction material. It is used in the production of the many structures that make
up the modern world including buildings, bridges, harbours, runways and roads. It is also
used for facades and other decorative features on buildings. The constant demand for all of
these structures, increasingly from the developing world, means that cement is the second
most consumed commodity in the world after water. The cementitious properties of lime in
mortars and concrete have been known since early historic times. The Romans made
extensive use of lime concretes and developed pozzolanic cements of lime and certain
volcanic earths. Lime mortars and concretes continued to be used in the middle Ages. The
rise of modern civil engineering in the 18th Century promoted serious efforts to develop
improved cement. In 1824, the first step was made in producing the cement, which we are
familiar today. The inventor of Portland cement (PC) is Joseph Aspdin from Leeds city UK.

17
 Figure No 3.1: Cement

Fine aggregate:
Fine aggregate is the essential ingredient in concrete that consists of natural sand or crushed
stone. The quality and fine aggregate density strongly influence the hardened properties of
the concrete. The concrete or mortar mixture can be made more durable, stronger and cheaper
if you made the selection of fine aggregate on basis of grading zone, particle shape and
surface texture, abrasion and skid resistance and absorption and surface moisture. Fine
aggregates are the structural filler that occupies most of the volume of the concrete mix
formulas. Depending on composition, shape, size and other properties of fine aggregate you
can have a significant impact on the output. The role of fine aggregate can be described in
few points:
Fine aggregates provide dimensional stability to the mixture. The elastic modulus and
abrasion resistance of the concrete can be influenced with fine aggregate. Fine aggregates
quality also influence the mixture proportions and hardening properties The properties of fine
aggregates also have a significant impact on the shrinkage of the concrete.

18
 Figure No 3.2: Fine Aggregate

Natural Aggregate:
This natural aggregate is characterized by its chemical composition, physical stability and
granulometric size. The use of this raw material is essential to the socio-economic
development and infrastructure of a country, and is reflected in the quality of life.
These are inert solid materials of assorted sizes, used in formulations with other binders in the
production of concrete, asphalts and mortars. They are also directly used in fillers, road
surfaces and railway ballast.
Calcinor has units dedicated to aggregate washing as well as grinding and for particle
classification, minimizing the presence of impurities that exist in the raw material, ensuring a
constant and homogeneous composition.
All of this gives rise to a wide range of products, from unbound aggregates for fillers to
minerals classified for more specific applications – including colour variations – the most
important being the white aggregate from Cales de la Plana. This range also includes
concretes with different technical characteristics, resistances and typologies of the matrials
used in their production, as well as mortars and asphalts.

19
 Figure No 3.3: Natural Aggregate

Recycled Coarse Aggregate

Recycling is the act of processing the used material for use in creating a new product. The
usage of natural aggregate is getting more and more intense with the advanced development
in infrastructure area. Recycled aggregate is comprised of crushed, graded inorganic particles
processed from the materials that have been used in the constructions and demolition debris.
Recycled aggregates
gates are produced from the re-processing of mineral
neral waste materials, with the
largest source being construction and demolition waste.
These wastes are normally
lly composed of concrete rubble usually, constitutes the largest
larg
proportion of C&D waste. It has been shown that crushed concrete
ncrete rubble, after separation
from other C&D waste and siev
sieved, can be used as a substitute for natural coarse aggregates in
concrete or a sub-base or a base layer in pavements. The need and importance of concrete in

20
construction industry is ever increasing. Recyc
Recycled
led Aggregate Concrete (RAC) is concrete that
using Recycled Aggregate (RA) as partially or fully replacement in coarse
arse and fine aggregate.
It is believed RA have been used from 1945 in concrete producing and started when World
War II damaged a large quantity of concrete structures and the high demand of aggregate to
rebuild the structures. Concrete is the favourite choice as a construction material among
a civil
engineers around the globe for decades. It is prefer
preferred
red for its better performance, longer life
and low maintenance cost.
To achieve rapid urbanization every year sm
smaller
aller structures are demolished and newer and
bigger
ger ones are constructed. These demolished materialss (majority of which is usually
concrete) are often dumpedd on land and is not reused for any purpose. This practice affects
the fertility of land. With the wave of sustainability also impacting the construction industry,
scientist and engineers
ineers throughout the world are looking for sustainable and reusable
r
construction materials. One such material is recycled aggregate concrete.

. Figure No 3.4: Recycled Coarse Aggregate

21
Water-
The amount of water in concrete controls many fresh and hardened properties in concrete
including workability, compressive strengths, permeability and water tightness, durability and
weathering, drying shrinkage and potential for cracking.
Table No 4. Properties of aggregates
Value obtained explain mentally as per
Characteristics Fine Aggregate
Coarse Recycled
Aggregate Aggregate
Specific gravity 2.69 2.83 2.42
Fineness modulus 3.214 6.80 7.840
Water absorption 0.14 0.34 1.25
Bulk density(kg/m2) 1598 1428 1377
Abrasion value (%) - 27.08 26.65
Impact value (%) - 26.41 24.45
Crushing value (%) - 31.78 37.14

Properties of Recycled Aggregates:

Raw materials for production of the natural aggregates and recycled concrete aggregate
contribute to some differences and variations of aggregate properties. Recycled
concrete aggregate consists of natural aggregate coated with cement paste residue,
pieces of natural aggregate, or just cement paste and some impurities. Relative amounts
of these components, as well as grading, affect aggregate properties and classify the
aggregate as suitable for production of better mix.
Physical Properties: The various physical properties of recycled aggregate are
presented below.
Shape and Surface Texture: In particular, the shape of the coarse aggregate is an
important characteristic that can affect the mechanical properties of concrete. The
shape and surface texture of the coarse aggregate influence the strength of concrete by
providing an adequate surface area for bonding with the paste or creating unfavorable
high internal stresses. The surface texture of aggregate contributes significantly to

thedevelopment of a physical bond between aggregate and cement paste. Tasong

et al.(1998) identified that the rough surface texture of the aggregate as contributing to
a betterbonding between aggregate and cement paste in concrete.
22
Bulk Density: The bulk density or unit weight of an aggregate gives valuable information
regarding the shape and grading of the aggregates. For a given specific gravity the angular
aggregates shows a lower bulk density. Bulk density of aggregates is of interest when dealt
with light weight aggregates and heavy weight aggregates. In general, the saturated surface
density of recycled aggregates is lower than that of natural aggregates, due to the low density
of the mortar that is adhered to the original aggregate. It depends on the strength of original
concrete and size of original aggregates. Gonzalez et al. (2008) concluded that recycled
aggregate concrete shows less dense than conventional concrete.

Specific Gravity: Hansen et al. (1983) investigated that the specific gravity decreases
from 4.5 to7.6% when compared with specific gravity of natural aggregate. Topcu et al.
(2004) investigated that the specific gravity of Waste Concrete Aggregates (WCA) was
lower than normal crushed aggregates. The reason for this was thought to be the fact that
there was a certain proportion of mortar over these aggregates. Prasad et al. (2007) noted
that the specific gravity of demolished concrete aggregates is lower than that of natural
aggregate. The average specific gravity of aggregate usually varies from 2.6 to 2.8.
Water Absorption: It is demonstrated by Ravindraraja (2000) that the average value of
water absorption in recycled aggregate was 6.35%, where as in natural aggregate it was
0.9%. The absorption capacity of recycled aggregates depends on the quality and quantity
of attached mortar. There was dependence between density and water absorptioncapacity.
Recycle aggregates with adhered motor have lower density and higher water absorption
capacity. Topcu et al. (2004) investigated that the water absorption ratio was found to be
much higher compared with that of normal crushed aggregates. This was attributable to
mortar over these aggregates.

Mechanical Properties: - The various mechanical properties of recycled aggregatesare

as follows.
Abrasion Value: Los - Angeles abrasion value changes depends on the strength of the
original concrete, the amount of adhered mortar and the original aggregate quality.
Hansen et al. (1983) found that the Los - Angeles abrasion loss value is 22.4% for
aggregates sized 16 to 32mm and 41.4% for aggregates sized 4-8mm.
Impact Value: Aggregate impact value also depends upon the way in which recycled
aggregates produced and strength of original concrete. The mortar which is still left on the
surface of aggregates also influences the impact value. Aggregate impact value of recycled

23
aggregates is generally higher than the virgin aggregates.
Recycled Aggregate Production: The recycled coarse aggregates classified for this
study was crushed by two different systems. One was an industrial crushing operation
that incorporated a primary jaw crusher and a secondary cone crusher. The second type of
crusherwas a small laboratory jaw crusher.

Industrial Crushing System: In the industrial crushing process, concrete pieces near
about of 12 to 16 inches are fed into the primary jaw crusher. The jaw crusher jaws are
distanced to regulatee the maximum aggregate size produced. The jaw crusher produces good
recycled aggregate size and an expected gradation for concrete production. The cone crusher
is used as secondary crusher to further remove the mortar from the natural aggregates. The
additional removal of mortar from the aggregates produces less angular or shaped pieces and
aggregate with lower absorption capacity. This suggests that the mortar content on the
recycled aggregates determines the overall qualities of that aggregate. While higher cost is
incurred, the additional crushing removes attached mortar and thus produces a higher quality
of recycled aggregate. The cone crusher must be used as a secondary crusher because it
cannot hold materials greater than 200 mm. A cone crusher sq
squeezes
ueezes material between an
eccentrically gyrating spindle and a bowl below. As the pieces are broken they fall to the
lower, more closely spaced part of the crusher and are further crushed until small enough to
fall through the bottom opening.

Figure No 3.5: Industrial crushing system



24
Laboratory Crushing System: The smaller laboratory crusher is commonly used in the
study of recycle coarse aggregates as large quantities of materials are needed to be properly
crushed and collected by an industrial crushing system. The laboratory crusher is a jaw
crusher and uses the
he same mechanism as the jaw crusher but can crush smaller quantities of
material and fit in a laboratory. Due to the closeness of the jaws and smaller
s quantity of
material, the crusher tends to break both the mortar and aggregate. This produces more
angular
ar pieces with a higher percent of attached mortar.


Figure No 3.6: Laboratory crushing system


Mortar Separation: The aggregate matrix bond is still important with recycle
Aggregate-Mortar
coarse aggregates as it is with natural aggregates. The strength of the bond is determined by
the aggregate surface. The recycle coarse aggregates properties are determined by the
attached mortar content and the natural aggregate, which affects the aggregate-mortar
separation and new recycle coarse aggregates shape. An aggregate with a rough surface, such
as crushed aggregate, will have a stronger bond with the mortar than a sawn or smooth-
smooth
surface aggregate. The crushed rock has higher bond strength and for that reason is less likely
to initiate cracking at the interface
interface. The crushed rock tends to be weaker and is for that reason
more likely to fracture through the aggregate rather than at the interface if the matrix is
sufficiently strong. Recycle coarse aggregates production generally uses concrete in a

25
structure at the end of its valuable life. Good mortar- aggregate separation is needed because
the removal of this mortar improves the concrete properties and therefore should be
considered when determining the cost of additional processing and aggregate choice.
Sieving: After the crushing of concrete it is sieved to remove finer particles and grade the
final product. Sieving equipment is already part of an industrial crushing system so no
additional costs are incurred. The fine aggregate resulting from concrete crushing and recycle
coarse aggregates production must be removed from the coarse aggregate pieces. The fine
aggregate portion of crushed concrete is generally taken as particles passing the 4 no. sieve.
Coarse aggregates are most resourcefully sorted with inclined, low frequency vibrating
screens. Material that is smaller than 2 mm is removed because most of the loss in strength
comes from these particles.
Washing the Recycled Coarse Aggregates: There is not consent on the necessity of
washing coarse aggregates prior to using them in concrete. Fine particles increase cohesion
between cement and fine aggregate particles which influences the ability of the cement paste
to cling to it and the aggregates. A lately published paper on the treatment of recycled
concrete aggregates indicates that for RCA to be used inconcrete the RCA must be washed to
lower the fine particle content. One another study accomplished that washing RCA increased
the strength and permeability, whereas havingno effect on the drying shrinkage.
Presoaking the Recycled Coarse Aggregates: The coarse Recycled aggregates should be
integrated into concrete in a saturated surface dry state in order to moderate the irregular
water demand created by the residual mortar attached to aggregates. Presoaking to the point
of saturation is the best method because it ensures consistent moisture content and makes the
high absorption capacity unrelated. The suggested length of presoaking time varies between
researchers

26
 CHAPTER-4
Results and Discussion

Fresh Concrete Properties

Water Absorption of RCA
The increased porosity of RCA, when compared to natural aggregates, results in a greater
water absorption capacity in the RCA. This enhances the potential for water interchange with
the surrounding paste in the RCA concretes, meaning RCA particles can have a greater role
in absorbing water from or providing water to the NC mortar. As stated by Casuccio et al.
This is an unwanted source of variation when comparing RCA concretes and concretes
containing only natural aggregates, as RCA used in the dry condition may absorb some water
from the mortar phase, and RCA used in the saturated phase may slightly increase water
content.

Fresh Concrete Test Results

The test results of slump flow, blocking ratio, and sieve segregation for the control NC and
the NCs with various levels of RCA utilization and illustrated respectively. Firstly,
considering the slump flow test results, displayed graphically that the initial measurements
indicated that the addition of RCA up to 100% did not impact upon slump flow diameter;
however, the times increased with increasing RCA content. This result indicates similar flow
ability across all NCs but increased viscosity with increasing RCA content. A similar pattern
was observed in the slump flow tests conducted one hour after concrete mixing; however, the
times experienced a greater percentage increase with increasing RCA content; that is, from
control to 100% RCA increases by 48% at initial measurement and 94% after 1 hour. The
one-hour slump flow diameter for the 100% RCA is also notably smaller than the control NC.
The increase in viscosity with increasing RCA content may be due to the angular shape of the
RCA, while it is possible that the time dependent change in the slump flow results was
caused by continued water absorption of the recycled aggregate, despite having been
presoaked and dried for one hour before use. The RCA had approximately seven times more
absorption capacity than the natural aggregates, meaning even though both aggregate types
were soaked for 24 hours and subsequently dried for 1 hour, the RCAs are likely to have had
a greater capacity to absorb free water after this process.

27
Casting of specimen
 The mounds are cleaned and applied a layer of oil.
 The concrete is filled in layers into the moulds approx. 5cm thick.
 Each layer is given at least 35 strokes to compact the concrete with the help of tampering
rod.
 The top surface smoothened and lleveled with a trowel.

Figure No 4.1 Casting of Concrete Cuve

Curing:
The 12 test samples are kept for 24 hours in air from the 1st batch and after this period the
mould is removed and the samples are marked. The specimen is then kept in fresh clear water
until taken out for the test. The 12 testing samples are stored for 24 hours in air from the next
batch and after this period the mould is removed and the specimen are marked. The
specimens are then submerged in fresh water, free from dirt until taken out for test. The
specimens are left in the moulds undisturbed at room tem
temperature
perature for about 24 hours after
casting. The specimens are then removed from the moulds and immediately transferred to the
different curing environment tubs i.e., cubes are cured in fresh water and 5% MGSO4 diluted
solution. The cast specimens are tested as per standard procedures, 29 immediately after they

28
are removed from curing tubs an
and wiped off the surface water, as per IS 516-1959.
516

Figure No 4.2 Curing of concrete

Precautions:
After every 7 days, the water consumed for curing should be examined and must be 27+-
27+ 2 0
c. We should also ensure that the water is free from any kind of dirt.
The results of the L-box
box test. As stated in the previous section this test measures the passing
passin
ability of the NC,, thus quantifying the suitability of the NC for use in a member with
congested reinforcement. The replacement of natural coarse aggregates with coarse RCA has
little impact on the initial blocking ratios, with only a very slight reduction
reducti in observed for
the 75% and 100% RCA utilization levels. However, for the L
L-box
box test carried out one hour
after mixing, the difference between the control NC and the NCss containing 75% RCA and
100% RCA increases. For this test the reductions in the bloc
blocking
king ratio observed, when
compared to the control NC,, are approximately 8% and 10% for the 75% and 100% RCA
NCs,
s, respectively. This results in the NC containing 100% RCA being only just inside the,
NC passing ability tolerance of 0.80. As with the slump fl
flow
ow test results, this time dependent
change in blocking ratio at the higher levels of RCA utilization may have been caused by
continued absorption of free water by the RCA after concrete mixing. Examining, the
segregation resistance of the NCs increased with
th increasing RCA content. Again, this is
likely to be due to the higher water absorption capacity of the recycled concrete aggregates.
All the NCss were deemed appropriate in accordance, with each NC mix falling into the sieve
segregation resistance class SR2.

29
Strength Properties:
The test results for concrete compressive strength, splitting tensile strength, and the static
modulus of elasticity. Facilitates the easy comparison of the control mix results and the RCA
mixes results, by presenting the RCA NC strength properties relative to the control NC
properties. The compressive strength value of RCA25 was 7% greater than the compressive
strength of the control mix, that is, relative compressive strength performance of 107%. Thus,
the RCA25 compressive strength bar lies above the 100% line. There are several possible
reasons for the increase in compressive strength with addition of RCA up to 50%. Hoffmann
et al. and Tuyen et al. have both highlighted the fact that the increased surface roughness of
recycled aggregates can increase cement aggregate bond. The role of the differing water
absorption coefficients in recycled aggregates and conventional aggregates is also likely to
have some influence. As shown herein and in other published studies, RCAs have a higher
water absorption capacity than natural aggregates. This increased water absorption may
reduce the w/c ratio in the ITZ, increasing the strength of the cement paste in improving the
bond between aggregates and cement paste. However, as pointed out by To et al., if too much
water is absorbed insufficient water content and poor hydration will reduce strength
development in the concrete. This optimal water content balance is a possible explanation for
the increase in compressive strength up to 50% RCA level, followed by the decrease in
compressive strength from 50% RCA to 100% RCA, where w/b ratio remains constant at
0.35, regardless of RCA content. It is however also noted that the decrease in compressive
strength even at 100% replacement with RCA was found to be less than 10%, indicating the
suitability of RCA utilization. Authors examining conventional vibrated concretes have
identified greater reductions in compressive strength when 100% RCA is used at replacement
level; however as pointed out by Tuyen et al. NCs are likely to experience a reduced effect of
addition of RCA due to the reduced content of coarse aggregates in NC mixes (which
typically have an aggregate content comprising more than 50% fines).

The tensile strength results exhibit a somewhat similar pattern to the compressive strength
results, with the tensile strength initially increasing at the lower levels of RCA utilization,
followed by a decrease in strength beyond 50% RCA content. The tensile strength for the
25% RCA replacement is almost 20% greater than the control NC. More subtle changes in
tensile strength occur when the RCA content is greater than 25%. In similar tests Grid et al.

30
found that the tensile strength for NCs with 50% RCA and 100% RCA coarse aggregates
resulted in approximate reductions in tensile strength of 2.5% and 14%, respectively, when
compared to a control mix. Tuyen et al. found that the splitting tensile strength reduced for
20%, 40%, and 60% RCA by 8.8%, 11.1%, and 16%, respectively, owing to the higher
porosity and lower specific gravity of the RCA when compared to the natural aggregates. It
should be noted however that, in contrast to the tests carried out herein, both Grid et al. and
Tuyen et al increased water content in mix designs with increasing RCA content. Andreu and
Miren did not increase water content with increasing RCA content in their study of vibrated
concretes containing RCA. These authors found that the use of 20% RCA increased the
splitting tensile strength by between approximately 3% and 22%, a finding consistent with
the results obtained herein.

Finally in terms, the use of RCA at any replacement level resulted in a reduction in modulus
of elasticity. The reduction in modulus of elasticity increases with increasing RCA content to
a maximum of 22.2% for the 100% RCA concrete. The reduction for the 75% RCA mix is
also substantial at 9.5%. As pointed out by Andreu and Miren, who obtained similar results
for vibrated concretes containing RCA, such reductions are to be expected given that the
modulus of elasticity of concrete is related to the modulus of elasticity of the coarse
aggregate, with studies indicating that the modulus of elasticity is proportional to the square
root of the aggregate density.
Overall considering the three strength property tests, the experimental programme indicated
that the use of RCA in proportions of 25% to 50% does not negatively impact upon the
compressive and tensile strength of NC. In fact, even up to the 100% RCA utilization level,
reductions in these parameters were less than 10% when compared to the control NC.
However, reductions in young’s modulus increased with increasing RCA utilization across all
NCs, with the modulus of elasticity for the 100% RCA NC 22% less than the control NC,
highlighting an issue relating to the brittleness of NCs constructed entirely with RCA.

Experimental Results and Discussions

The hardened concrete properties such as compressive strength, flexural strength and split
tensile strength were tested in the laboratory. The results are presented along with their
graphical plots and discussions. Also, a comparative study of NC using RCA and NCA is
also presented.

31
Compressive strength:
The compressive strength is measured using both cube and cylindrical specimens. The size of
the cube specimen is 150 mm × 150 mm × 150 mm and size of the cylindrical specimen is
100 mm diameter and 200 mm height. Nine concrete cubes for each concrete mix
proportions.

Figure No 4.3 Compression testing Machine

32
 Table No 5 Cube Compressive strength

Compressive strength (N/mm²)

Mix type
7day 14 days 28 days

Mix-1 18.41 24.78 37.54

Mix-2 17.72 21.18 34.42

Mix-3 14.68 18.98 28.15

Mix-4 11.58 17.94 27.12

Mix-5 11.10 17.50 25.36

40

35

30

25
7-days
20
14-days
15 28-days

10

0
Mix-1 Mix-2 Mix-3 Mix-4 Mix-5

Figure 4.4: Bar Chart of Compressive strength test at 7,14 and 28 days

33
 4

3.5

2.5
7-days
2
14-days

1.5 28-days

0.5

0
Mix-1 Mix-2 Mix-3 Mix-4 Mix-5

Figure 4.5: Bar Chart of Flexural strength test at 7,14 and 28 days

3.5

2.5

2 7-days
14-days
1.5
28-days

0.5

0
Mix-1 Mix-2 Mix-3 Mix-4 Mix-5

Figure 4.6: Bar Chart of Split Tensile strength test at 7,14 and 28 days

34
CONCLUSION

 The test results indicate that the compressive strength, flexural strength, and split tensile
strength of NC is less than the NVC.
 The compressive strength, flexural strength and split tensile strength of NC decreases
with increase in the amount of RCA
 The test result indicates that in 28 days test NC marginally achieves required compressive
strength up to 0.30 replacement ratio.
 It is observed that NVC with 100% NCA has the highest flexural strength and more than
the theoretical value at 28 days and 90 days.
 The 28 days flexural strength of NC obtained from experimental investigation is less than
the theoretical flexural strength in all the replacement ratio of RCA.
 RCA show higher water absorption compared with conventional NCA due to old mortar
attached with original concrete and has relatively lower specific gravity.

35
REFERENCES
 Kou, S.C., Poon, C.S., 2009. Properties of Normal Concreteprepared with coarse and
fine recycled concrete aggregates, Cement and Concrete Composites 31, pp. 622-627.
 Grid, Z.J., Troplicic-curcic, G.A., Despotic, I.M., Ristic, N.S., 2010. Properties of
Normal Concreteprepared with coarse recycled concrete aggregate. Construction and
Building Materials 24, pp. 1129-1133.
 Fonseca, N., Brito, J. D., Evangelista, L., 2011. The influence of curing conditions on
the mechanical performance of concrete made with recycled concrete waste. Cement
and Concrete Composites 33, pp. 637-643.
 Uysal, M., Yilmaz, K., 2011. Effect of mineral admixtures on properties of self-
compacting concrete. Cement and Concrete Composites 33, pp. 771- 776.
 Zhao, H., Sun, W., Wu, X., Gao, B. 2012. The effect of coarse aggregate gradation on
the properties of self-compacting concrete. Materials and Design, 40, pp. 109-116.
 Uysal, 2012. The influence of coarse aggregate type on mechanical properties of fly
ash additive self-compacting concrete. Construction and Building Materials 37, pp.
533-540.
 IS: 10262 (1982) (Reaffirmed 1999), Recommended Guidelines for Concrete Mix
Design. Bureau of Indian Standards, Manak Bavan, 9 Bahadur Shah Zafar Marg, New
Delhi 110002.
 SP 23 (1982), Handbook on concrete mixes (based on Indian Standards). Bureau of
Indian Standards, Manak Bavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002.
 IS: 1489 (Part I): (1991), Indian Standard, Portland Pozzolana Cement Specification,
(Third Revision). Bureau of Indian Standards, Manak Bavan, 9 Bahadur Shah Zafar
Marg, New Delhi 110002.
 IS: 383 (1970), Indian Standard specification for coarse and fine aggregates from
natural sources for concrete (second revision). Bureau of Indian Standards, Manak
Bavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002.
 EFNARC (2005), The European guidelines for self-compacting concrete; May 2005,
pp. 1-63.
 K C Panda and B C Pal Chemical, Civil and Mechanical Engineering Tracks of 3rd
Nirma University International Conference on Engineering (Nicene 2012) Procedia
Engineering 51 (2013) 159 – 164.
 W.C. Tang (2016) Novel Technologies and Applications for Construction Materials.

36
 Nischay T G, B Shiva Kumaraswamy’s Vijaya (2019) Professor and Head, Civil
Engineering Department Dr. Ambedkar Institute of Technology Bengaluru, Karnataka,
India, International Journal of Engineering Research & Technology Vol. 4 Issue 06, June-
2015.
 Femy George1, Prof. Sarah Anil2 (2018) Study on Properties of Self Compacting
Concrete Made with Recycled Coarse Aggregate International Research Journal of
Engineering and Technology (IRJET).
 Frank Stephen. S, Chockalingam. M.P, Nilantha. N (2019) Durability Properties of
Modified Self Compacting Concrete with Recycled Concrete Aggregate, International
Journal of Engineering and Advanced Technology (IJEAT) SSN: 2249 – 8958, Volume-9
Issue-1, October 2019
 Prashant O. Modani1, Vinod M Mkhitar (2014) International Journal of Modern Trends
in Engineering and Research(www.ijmter.com), Scientific Journal Impact Factor (SJIF):
1.711
 Khaleel H. Younis, Shkar Latif (2019) Mechanical Performance of Normal
ConcreteIncorporating Recycled Aggregate, INTERNATIONAL JOURNAL OF
SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 8, ISSUE 10, OCTOBER
2019.
 Junaid Ahmad, Raj Bandhu Dixit, Rahul Singh (2015) To Study the Properties of Self
Compacting Concrete Using Recycled Aggregate and Polypropylene Fiber, International
Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)

37