WASTE & RECYCLED MATERIAL

IN CONCRETE TECHNOLOGY
 CONTENTS
 NEED OF RECYCLING OF WASTE MATERIALS
 ROLE OF WASTE MATERIALS IN CEMENT CLINKER
PRODUCTION
 PORTLAND CEMENT MANUFACTURE FROM WASTE
MATERIALS
 RECYCLING OF CONCRETE.
 MINING & QUARRYING WASTES
 APPLICATION OF MISCELLANEOUS WASTES
 ROLE OF WASTE MATERIAL AS AGGREGATES
 ABSTRACT
• World wide consumption of concrete amounts to more than
1000 Kgs/person
• The demand is expected to increase in future
• Concrete comprises in quantity the largest of man made
material
 INTRODUCTION
Concrete made with Portland cement ,water admixtures and
aggregates comprises in quantity the largest of all man made material

Historically whenever new compounds were produced ,or waste

materials accumulated in industries ,they were incorporated as one of
ingredients of concrete. Typical examples are fly ash phosphogypsum,blast
furnace slag, saw mil waste, rice husk, cotton etc.The wide spread need for
conserving resources & environment will be reflected major emphasis on the
use of wastes & by products.

Recycling of concrete materials also offers some promise. Attempts

are already being made to use municipal refuse & waste oil as partial
substitutes for the fuel in the production of cement clinker
 NEED OF RECYCLING OF WASTE MATERIALS

 Rise in population
 Large scale demand for housing
 Over stressing the reserves of traditional building
materials
 Cement material presently not in a position to cope
the millions of the country
 The enormous amount of waste materials
 Recycling becoming imperative & mandatory
 ROLE OF WASTE MATERIAL IN CEMENT
CLINKER PRODUCTION

 Many waste materials contain basic ingredients that are

needed for the manufacturing of cement clinker

 Fly ash can also be used as a source of raw material

 Lime sludge can be used as a substitutes for lime stone

 Red mud a waste material from the production of alumina

used as a raw material for cement clinker production

 Phosphogypsum as a mineralizer for making clinker

COMPRESSIVE STRENGTH OF MORTAR(MPA)

Cement 1 day 3 days 7 days 28 days

Phosphogypsum 17.3 26.2 37.4 53.7

Minerals

Normal Cement 8.2 22.0 37.4 50.0

 PORTLAND CEMENT MANUFACTURED
FROM WASTE MATERIALS
FLY ASH CEMENT
BLAST FURNACE SLAG CEMENT
RICE HUSK ASH CEMENT
 FLY ASH CEMENT
 Fly ash is the ash component of Coal liberated during
combustion .
 Fly ash can be incorporated into Portland cement in one of
the three ways.
 Fly ash can be used as a admixture or as replacement of
Portland cement.
 Fly ash addition to Portland cement results in increased
workability.
 In fly ash cement development of compressive strength is
slow
 At longer periods of curing Fly ash concrete develops higher
strengths than the normal concrete
WHY CHARACTERISTICS?
 Not a specially manufactured product governed by
strict rules

 Variation in carbon, particle shape & size distribution,

presence of minerals etc..

 Exhibits different characteristics with different

compounds.

 No proper processing is available.

 Change in the behavior of concrete.

MACROSCOPIC VIEW OF FLY ASH
 FLY ASH
 Finely divided residue resulting from combustion of
powdered coal.

 Common ingredient in concrete.

 First used in construction of Hungry Horse Dam in USA

 In India, first used in Rihad Dam.

 High volume fly ash is of current interest.

 Quality of fly ash is governed by IS:3812-1981

INFLUENCE OF FLY ASH ON STRENGTH
DEVELOPMENT IN CONCRETE
PERMEABILITY OF FLY ASH CONCRETE
Hungry Horse Dam, Montana,
is a thick-arch structure
that was built between 1948 and 1953
with concrete containing
120,000 metric tons of fly ash.
The use of coal fly ash in cement
and concrete displaces Portland
cement.
Fly ash used in the construction of buildings at Chennai
Fly ash used in Delhi Metro
Roman Coliseum: An classic example of Roman
structures which was build with fly ash concrete.
 COMPRESSIVE STRENGTH

ASH 3 7 DAYS 28 DAYS 90 DAYS

CEMENT DAYS
70:30 31.9 45.4 58.7 63.9

50:50
WELCOME
26.1 39.0 57.6 60.7

30:70 24.0 35.4 42.7 50.1

0:100 22.4 32.5 42,4 47.4

 ADVANTAGES OF FLY ASH CONCRETE

 Addition of fly ash to concrete minimize or eliminates

the expansion due to alkali aggregate reaction
 WORKABILITY
 TIME OF SETTING
 DURABILITY OF FLY ASH CONCRETE

Sufficiently cured fly ash concrete has dense structure &

hence more resistance to deleterious substances.

This reduces the corrosion of reinforcement.

Class F fly ash reduces alkali-silica reactivity because of the

dense structure & hence expansion is reduced which
increases durability.

 Because of the reduced permeability the chloride ingress

is reduced.
 STRUCTURES USED FLY ASH ASH
Structures State Cement replaced Source of fly
Sl. No
(%) ash
1. Gurgoan 15 Delhi
Haryana
tunnel
2. Jawar sagar Rajasth Delhi
Dam an 20
3. Kakki Dam Neyveli
Kerala
20
4. Navora U.P. Harduaganj
15
barrage
5. Rihad Dam 15 Bokaro
UP
6. Bihar 15 Bokhara
Sone Barrage
7. Umium Durgapur
Assam Not available
Project
8. 25 Talcher
Chandil dam Bihar
FLY ASH MISSION PROJECT SITES
 BLAST FURNACE SLAG CEMENT
 Portland blast furnace slag cement can replace Portland
cement where high strength is not required.
 It is produced by intergrinding Portland cement clinker &
granulated blast furnace slag.
 The workability of this cement is as good as Portland cement
concrete.
 This is resistant to a number of aggressive agents including
sulphates of Al,Mg,NH4 etc…
 The rate of hardening is slower than the normal Portland
cement concrete.
 The 90 days strength is ≤ of Portland cement concrete.
 More resistant to sea water &other chemical agents than
Portland cement.
RICE HUSK
 RICE HUSK ASH CEMENT

In the rice milling operation one ton of rice paddy

produces 400 kg of husk. Burning of the husk results in 20% by
a weight of ash. Blending this ash with cement produces a
suitable blended cement
 ADVANTAGE

The rice husk ash cement on hydration

produces practically no Ca(OH)2 &hence is
superior to Portland.
 RECYCLING OF CONCRETE

 Except structures which have to be preserved as moments a

great number of them have to be demolished sooner or later.
 Concrete accounts of nearly 75% by weight of all construction
material.
 Millions of tons of concrete debris are generated by natural
disaster.
 Depletion of normal aggregate sources, stricter environmental
laws & waste disposal problems make recycling of concrete.
 WHAT IS CONCRETE RECYCLING…?

Breaking , removing & crushing hardened concrete from

an acceptable source. Old concrete pavements often
are excellent sources of material for producing RCA
RECYCLING PROCESS
 USES OF RECYCLED CONCRETE

 Smaller pieces of concrete are used as gravel for new

construction projects.
 Sub base gravels laid down as the lowest layer in a road.
 Recycled concrete can also be used as the dry aggregate for
brand new concrete.
 Larger pieces can be used for erosion control.
 DISADVANTAGES

Lead paint contamination.

CONCRETE RECYCLING MACHINE
 MINING & QUARRYING WASTES

 Large amount of wastes produced in mining & quarrying

operations.
 Mineral mining wastes are “waste rock” or “mill tailings”.
 Manufacturing of bricks ,light weight aggregates & autoclaved
concrete blocks.
APPLICATION OF MISCELLANEOUS WASTES

 Collier spoil

 Waste glass

 Red mud

 Burnt clay

 Saw dust
 COLLIERY SOIL

 In coal operations about one half of the material is separated

& discarded as colliery soil.
 This soil is used to fill in road embankments.
 It can also be used to produce light weight concrete.
 WASTE GLASS

 Millions of tons of waste glass are generated annually..

 The strength of concrete less than with gravel aggregate.
 This is used to make light weight aggregates.
 RED MUD

 Red mud is a waste product resulting from the extraction of

alumina from bauxite ore.

 It is sufficiently plastic to be moulded into balls.

 Firing at about 1260 to 1310 c produces a strong dense

aggregate.
 BURNT CLAY

 High permeability.
 Concrete contains burnt clay has high fire resisting capacity.
 SAW DUST

 Saw dust concrete is used only to a limited extent because of

its low strengths.
 The addition of sand can improve strength.
 Saw dust cement has a good insulation value .
 Low thermal conductivity.
 Concrete containing large amounts of saw dust is flammable.
 ROLE OF WASTE MATERIALS AS
AGGREGATES
 Use of waste & byproducts as aggregates has greater
potential because 75% of concrete is composed of aggregates.
 Various aggregates examined includes reclaimed concrete
mining & quarrying wastes, colliery soil, waste glass, red mud,
burnt clay & saw dust.
 CONCLUSION
In the coming future Recycling of Waste Materials
& by production for concrete technology will achieve new
heights, as attempts are already being made to use
municipal refuse & waste oil as partial substitutes for
production of cement clinker. We have to promote &
development in the area of utilization of waste materials.

Variability of the physical & chemical characteristics

& availability at locations far removed from populations
areas may inhibit the wide spread use of many types of
wastes. Future work will have to be directed to study of
the long term durability of concretes containing these
materials.