Mechanical Properties of Pavement Quality Concrete with

secondary Aluminium Dross as partial replacement for

Ordinary Portland Cement

Panditharadhya B J
N.I.T.K. Surathkal, Karnataka - 575025, India Research Scholar
 INTRODUCTION
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 Concrete is the commonly used construction material and Concrete roads are better
alternatives to Bituminous roads in terms of strength and durability.

 Need for alternative binder materials to reduce more energy consumption due to
production of cement – Sustainability.

 Effective usage of mineral wastes and industrial wastes/byproducts – Ecological balance.

 Supplementary cementitious materials (Silica fume, Fly ash, GGBS, Marble powder, Rice
husk ash, etc.) – Increased strength, improved durability, reduced permeability and
influence on other concrete properties.

 Use of waste materials from industries and solving the landfill and disposal problems.

NITK Surathkal, Department of Civil Engineering

 Secondary Aluminium Dross
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 Secondary Aluminium dross is a by-product obtained from the aluminium resmelting

process, forming aluminium oxide as major part of composition.
 Currently, this dross is processed in rotary kilns to recover the residual Al, and the resultant
salt cake is sent to landfills, which will have lumps and powders (Primary or White dross).
 Resmelting of the primary product produces Black dross.
 Presence of leachable salts like NaCl and KCl in Aluminium dross makes it difficult to
dispose.
 Protective cover over the nuclei of Ca(OH) 2 and reduces the rate of reaction.
 Acts as diffusion barrier by adsorbing over the cement particles and retards the hydration
of cement.
 Acts as a filler material and increases the strength of concrete by filling the voids.

NITK Surathkal, Department of Civil Engineering

 MATERIALS
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Aluminium Dross

 Procured from HINDALCO, Belagavi, Karnataka, India.

 The secondary aluminium dross wastes are irregular in shape, black in color and
contain small particles.
 Particle size vary from less than 45 micron upto 150 micron. Specific surface area
is about 380 m2/kg.

NITK Surathkal, Department of Civil Engineering

 Properties of Aluminium Dross
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Particulars Value

Aluminium Oxide (Al2O3) 60 - 80 %

Silica (SiO2) 4–6%

Calcium Oxide (CaO) 4 – 20 %

Titanium Oxide (TiO2) 2.0 %

Zinc Oxide (ZnO) 0.93 %

Aluminium Nitride (AlN) 0.10 %

Gibbsite (Al(OH)3) 2.18 %

Loss on Ignition 0.05 – 5 %

Specific Gravity 2.9

Surface Area, m2/kg 380

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 Properties of Ordinary Portland Cement
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Element Percentage by weight

Silicon di oxide (SiO2) 17–25%

Ferric trioxide (Fe2O3) 0.5–0.6

Aluminium oxide (Al2O3) 4–8

Calcium oxide (CaO) 61–63

Sulphur tri-oxide (SO3) 4.3
Magnesium oxide (MgO) 0.1–4
Titanium oxide (TiO2) 0.5 %

Chlorine (Cl) 0.1

Others 0.6–1.8
Specific Gravity 3.1
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OPC

Requirements as per
SI No Tests conducted Results obtained Remarks
IS 8112-1989
1 Specific gravity 3.12 -

2 Normal consistency 30% -

Cement used satisfies
Initial – 50 Not less than 30 mins
the requirements of
3 Setting time (minutes) Not more than 600
Final -390 IS 8112-1989
mins
4 Fineness 1.90% Not more than 10%

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 Aggregates
8  Crushed stone pieces of maximum nominal size of 20 mm were used as coarse
aggregates

Tests Results Requirements IS-Codes

Specific gravity 2.690   IS-2386 Part III
Shall not exceed 30%
Crushing Value 24.50% for Wearing Surface IS-2386 Part IV
 
For aggregates to be
used in concrete for
Abrasion Value 20.25% Wearing Surface shall IS-2386 Part IV
not exceed 30 %
 
Shall not exceed 30 %
by weight for concrete
Impact Value 22.30% IS-2386 Part IV
for Wearing Surface
 
Should be in the range
Water Absorption 0.45% IS-2386 Part III
of 0.1 % to 2.0 %

NITK Surathkal, Department of Civil Engineering

 Fine aggregates

9  Locally available river Sand conforming to IS used for the present investigation as fine
aggregate..
 Tests on sand as per IS 383 specifications are conducted and results are as shown in
Table

Sl. No. Characteristics Value

1. Specific gravity 2.78

2. Water absorption (%) 0.8

3. % voids 43.73

4. Fineness modulus 2.64

5. Grading zone Zone II

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 RESULTS AND DISCUSSION
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NORMAL CONSISTENCY

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 OPC SETTING TIME
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 12 COMPRESSIVE STRENGTH RESULTS

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 SPLIT TENSILE STRENGTH RESULTS
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 FLEXURAL STRENGTH RESULTS
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 CONCLUSIONS
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• Initial setting time is increased and final setting time decreased with higher aluminium
dross replacement, which can be considered as positive sign for construction of pavements
in hot weather conditions.
• Because of high surface area, the water absorption increases and thereby decreasing the
hydration reaction.
• Workability is reduced and demands for more water. Admixtures may solve this issue.
• The addition of Al dross as partial replacement of cement slightly reduced the mechanical
properties.
• It can be concluded that up to 15% replacement of cement by Al dross, the strength
properties of concrete is comparable with control concrete mix.
• Reduced energy consumption and carbon foot print.

NITK Surathkal, Department of Civil Engineering

 REFERENCES
16  Arimanwa, J., Onwuka, D., Arimanwa, M. and Onwuka, U. (2011). “Prediction of the compressive strength of aluminum
waste-cement concrete using Scheffe’s theory.” Journal of Materials in Civil Engineering, 24(2), 177–183.
 Elinwa, A.U., and Mbadike, E. (2011). “The use of aluminum waste for concrete production.” J. Asian Architecture
Building Engineering, 10(1), 217–220.
 Ewais, E., Khalil, N., Amin, M., Ahmed, Y. and Barakat, M. (2009). “Utilization of aluminum sludge and aluminum slag
(dross) for the manufacture of calcium aluminate cement.” Ceram. Int., 35(8), 3381–3388.
 Gaurav, S., Souvik, D., Abdulaziz, A.A., Showmen, S. and Somnath, K. (2015). “Study of Granulated Blast Furnace Slag
as Fine Aggregates in Concrete for Sustainable Infrastructure.” World Conference on Technology, Innovation and
Entrepreneurship, Procedia - Social and Behavioural Sciences, 195, 2272 – 2279.
 Girish, M., Sujay, R.N., Sreedhara, B.M., Manu, D.S., Parameshwar, H. and Jayakesh, K. (2016). “Investigation of
concrete produced using recycled aluminium dross for hot weather concreting conditions.” Resource Efficient
Technologies, 2, 68-80.
 IS 10262 – 2009. “Concrete Mix Proportioning – Guidelines.” Bureau of Indian Standards, New Delhi, India.
 IRC: 44 – 2008. “Guidelines for Cement Concrete Mix Design for Pavements.” Bureau of Indian Standards, New
Delhi, India.
 Manfredi, O., Wuth, W. and Bohlinger, I. (1997). “Characterizing the Physical and Chemical Properties of
Aluminum Dross.” JOM.
 Mbadike, E.M. (2014). “Effect of incorporation of aluminium waste in a concrete matrix using different mix ratio
and water cement ratio.” J. Advanced Biotechnology, 2(1), 58–74.
 Petavratzi, E. and Wilson, S. (2007). “A case study: Residues from aluminium dross recycling in cement.”
WRT177/WR0115, 1–8.
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Thank You

NITK Surathkal, Department of Civil Engineering