20320130405014 2

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308

(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME

130

HYPO SLUDGE: OPPORTUNITIES FOR SUSTAINABLE DEVELOPMENT

OF LOW COST RURAL ROADS

Prof. Jayeshkumar Pitroda1, Dr. L.B.Zala

2, Dr. F.S.Umrigar

3

1Assistant Professor & Research Scholar, Civil Engg Department, B.V.M. Engineering College,

Vallabh Vidhyanagar 2Head & professor, Civil Engineering Department, B.V.M. Engineering College, Vallabh Vidhyanagar.

3Principal, B.V.M. Engineering College, Vallabh Vidhyanagar – Gujarat – India.

ABSTRACT

Hypo Sludge, a waste derived from paper industry is plentiful in India causing severe health, environment and dumping problems. Utilization of Hypo Sludge in bulk quantities, ways and means is being discovered all over the world to use it for the construction of embankments and roads. This way the Hypo Sludge concrete are made a 'greener' building material and the discarded natural wastes can be re-utilized, avoiding otherwise wasteful landfill and harmful open incineration.To make value added concrete for development of sustainable infrastructure there is a great need to study the technical details concerned with various industrial wastes in concrete and to reduce environmental hazards. It is also needed to reduce the cost of concrete for rural development in India. A cement concrete pavement is designed for a Rural Road in Gujarat State having a traffic volume of up to 500 vehicles per day. The soil has a soaked CBR value of 2%, 4% and 6% and design wheel load 30kN. So our study is concerned with eco-efficient utilization of hypo sludge as partial replacement of cement in concrete.The aim of the present study is to investigate the low cost rural roads made of Hypo Sludge. The Hypo Sludgewas replaced within the range of 10-40% by weight of cement. In the present study, 5 different mixes of Hypo Sludgeconcretes are tested for parameters like: compressive strength, flexural strength, modulus of elasticityand cost. KEYWORDS : Hypo Sludge, Concrete, CBR, Rural Roads, Cost

INTRODUCTION

Transportation has serious impacts on the lives and welfare of the rural people. The

transportation system in a developing nation is one of its most essential assetsof its future development. Since accessibility and mobility are involved in almost everything that developing

INTERNATIONAL JOURNAL OF CIVIL ENGINEERING AND

TECHNOLOGY (IJCIET)

ISSN 0976 – 6308 (Print)

ISSN 0976 – 6316(Online)

Volume 4, Issue 5, September – October, pp. 130-142

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131

countries are striving to accomplish, transport can be a key factor in the success or failure of the entire development effort. In India, a special drive has been taken at the beginning of the new millennium to improve the road and highway systems in the country. This will require huge quantities of pavement construction materials. It has been observed that it would be economical to use industrial wastes in the construction of low cost roads.Rural roads are vital for area development. They serve as one of the key infrastructure in rural development. Agricultural productivity as well as marketability depends to a large enormousness on road development. The agriculture based industries are also predisposed by the provision of rural roads. Roads also have a socioeconomic impression on the lives of rural populations. The studies in India and overseas have clearly demonstrated the impact of accessibility on socioeconomic variables. The utilization of these waste materials can be an economical and eco-friendly alternative in nearby areas for rural road construction.

The problem of hypo sludge utilization is not confined to India alone but is being experienced all over the world. However this problem is particularly acute in India. Where utilization of hypo sludge has not received much attention. Hypo sludge properties make it very suitable for all construction activities including roads, embankments and reclamation of low lying areas. Hypo sludge based construction materials are becoming favourite of the construction industry, being durable, economical, eco-friendly, easy to use and of consistent quality. Its effective use in concrete as partial replacement of cement will lead to reduce its disposal problems and also to enhance properties of concrete. In concrete roads, a part of cement can be replaced by hypo sludge to the extent of 10% to 30% . This would result in lowering the cost of resultant concrete without any loss of strength and with increased durability.

EXPERIMENTAL WORK

a) Chemical Properties of Ordinary Portland Cement (OPC) and Hypo sludge:

It is Chemical Properties of Ordinary Portland Cement (OPC) and Hypo sludgeas listed in Table 1:

TABLE 1

CHEMICAL PROPERTIES OF ORDINARY PORTLAND CEMENT (OPC) AND HYPO

SLUDGE

Chemical Properties Ordinary Portland Cement

(OPC)

Hypo Sludge

Percent by mass

Silicon Dioxide (SiO2) 21.77% 5.28%

Calcium Oxide (CaO) 57.02% 47.84%

Magnesium Oxide (MgO) 2.71% 6.41%

Sulphur Trioxide (SO3) 2.41% 0.19%

Aluminium Oxide (Al2O3) 2.59% 0.09%

Ferric Oxide (Fe2O3) 0.65% 0.73%

Loss on Ignition 2.82% 38.26%



132

b) Characterization of cement The most common cement used is an Ordinary Portland Cement (OPC). The Ordinary

Portland Cement of 53 grades is conforming to IS:8112-1989 is being used. Specific gravity, consistency tests, setting time tests, compressive strengths, etc. are conducted on cement. The results are tabulated in table 2.

TABLE 2

PROPERTIES OF ORDINARY PORTLAND CEMENT (OPC)

Sr.

No. Physical properties of cement Result

Requirements as per

IS:8112-1989

1 Specific gravity 3.15 3.10-3.15

2 Standard consistency (%) 28% 30-35

3 Initial setting time (hours, min) 35 min 30 minimum

4 Final setting time (hours, min) 178 min 600 maximum

5 Compressive strength- 7 days 38.49 N/mm2 43 N/mm2

6 Compressive strength- 28 days 52.31 N/mm2 53 N/mm2

c) Cement fly ash Mix Proportions A mix M25 grade was designed as per IS 10262:2009 and the same was used to prepare the

test samples. The design mix proportion is shown in Table 3.

TABLE 3

CONCRETE DESIGN MIX PROPORTIONS

Sr.

No.

Concrete

Mix

Concrete Design Mix Proportion

(By Weight)

Cement

Replacement

By

Hypo Sludge

W/C

Ratio C F. A. C. A.

1 A1 0.50 372.00 558.60 1251.90 -

2 C1 0.50 334.80 558.60 1251.90 37.20

3 C2 0.50 297.60 558.60 1251.90 74.40

4 C3 0.50 260.40 558.60 1251.90 111.60

5 C4 0.50 223.20 558.60 1251.90 148.80

W/C = Water/Cement , C= Cement, F. A. = Fine Aggregate, C. A. = Coarse Aggregate



133

EXPERIMENTAL RESULTS

Above 5 different concrete samples were used to find the important properties like compressive strength, flexural strength and modulus of elasticity. To make the study from an economic point of view cost of each mix was also worked out from the present market rates. The results for these properties are given in Table 4, 5 & 6.

TABLE 4

AVERAGECOMPRESSIVE STRENGTH FOR CUBES OF (150X150X150) (N/mm²)AT 7, 14,

28 DAYS FOR M25

Concrete

Mix

% Replacement

of Cement by

Hypo Sludge

Average Compressive Strength (N/mm²)

7 Days 14 Days 28 Days

A1 0 % 28.76 32.00 38.52

C1 10 % 29.24 33.63 39.70

C2 20 % 22.96 23.35 25.78

C3 30 % 20.92 22.96 23.26

C4 40 % 19.47 21.04 22.96

Figure 1: % Replacement of Cementby Hypo Sludge v/s Compressive Strength of Concrete

(N/mm2) Specimen at 7, 14 and 28 Days for M25

28.76 29.24

22.96 20.9219.47

32.00 33.63

23.35 22.96

21.04

38.5239.70

25.78

23.2622.96

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

A1 (0%) C1 (10%)C2 (20%)C3 (30%)C4 (40%)

CO

MP

RE

SS

IVE

ST

RE

NG

HT

OF

CO

NC

RE

TE

(N

/mm

2)

% REPLACEMENT OF CEMENT BY HYPO SLUDGE

% REPLACEMENT OF CEMENT BY HYPO SLUDGE V/S

COMPRESSIVE STRENGTH OF CONCRETE (N/mm2)

SPECIMEN AT 7, 14, 28, FOR M25

7 DAYS

14 DAYS

28 DAYS



134

TABLE 5

AVERAGE FLEXURAL STRENGTH FOR BEAMS OF(100X100X500)(N/mm²) AT 28 AND

90 DAYS FOR M25

Concrete

Mix

% Replacement of

Cement by

Hypo Sludge

Average Flexural Strength (N/mm²)

28 Days 90 Days

A1 0 % 4.71 5.26

C1 10 % 4.49 4.94

C2 20 % 2.93 3.31

C3 30 % 2.74 3.27

C4 40 % 2.62 2.93

Figure2:% Replacement of Cement by Hypo Sludge v/s Flexural Strength of Concrete (N/mm2)

Specimen at 28 Days and 90 Days for M25

4.714.49

2.93 2.742.62

5.264.94

3.31 3.27 2.93

0

1

2

3

4

5

6

A1 (0%) C1 (10%) C2 (20%) C3 (30%) C4 (40%)

FL

EX

UR

AL

S

TR

EN

GH

T O

F

CO

NC

RE

TE

(N

/mm

2)



FLEXURAL STRENGTH OF CONCRETE (N/mm2) SPECIMEN

AT 28 DAYS AND 90 DAYS FOR M25

28 DAYS

90 DAYS



135

TABLE 6

MODULUS OF ELASTICITY (150X300 DIA.) (N/mm²) AT 28 DAYS FOR M25

Concrete Mix

% Replacement of

Cement by

Hypo Sludge

Modulus of Elasticity (N/mm²)

28 Days

A1 0 % 24958

C1 10 % 27500

C2 20 % 23167

C3 30 % 17875

C4 40 % 15750

Figure3:% Replacement of Cementby Hypo Sludge v/s Modulus of Elasticity of Concrete

(N/mm2) Specimen at 28 Days for M25

DESIGN OF A CEMENT CONCRETE PAVEMENT FOR RURAL ROAD

(IRC:SP:20-2002 / IRC:SP:62-2004) A cement concrete pavement is to be designed for a Rural Road in Gujarat State having a

traffic volume of upto 500 vehicles per day consisting vehicles, like, agricultural tractors/trailers, light goods vehicles, heavy trucks, buses, animal drawn vehicles, motorized two-wheels and cycles. The soil has a soaked CBR value of 2%,4%,6%. For 30kN wheel load.

24958 27500

23167

1787515750

0

5000

10000

15000

20000

25000

30000

A1 (0%) C1 (10%)C2 (20%)C3 (30%)C4 (40%)

MO

DU

LU

S O

F

EL

AS

TIC

ITY

OF

CO

NC

RE

TE

(N

/mm

2)



MODULUS OF ELASTICITY OF CONCRETE (N/mm2)

SPECIMEN AT 28 DAYS FOR M25

28 DAYS



136

TABLE 7

DESIGN OF CC PAVEMENT FOR RURAL ROADS

Design Parameters: Sample C1 (6% CBR)

Trial Thickness for Slab, h = 150mm.

Check for Temperature Stresses: Assuming a contraction joint spacing of 3.75 m and 3.75m width.

1. Temperature Stress (σte):

The temperature differential (∆t) for Gujarat for a slab thickness of 150mm is 12.5˚C.

The Radius of Relative Stiffness, l = � � �� µ� �

�

Hence, l = 618.70 mm. L/l = 3750 / 618.70= 6.1 W/l = 3750 / 618.70 = 6.1 Both values are same, if not then adopt greater one. Bradbury’s Coefficient, C = 0.923 (from figure 1, pg. 9) [Value of C can be ascertained directly from Bradbury’s chart against values of L/l and W/l]

Temperature Stress in edge region, σte = � ∆��

Hence, σte = 1.59 N/mm2.

2. Edge Load Stress (σle):

From Page: 12, Edge Load Stress, Radius of equivalent distribution of pressure (b), b = a (if (a/h >= 1.724);

(b) =√1.6 �� - 0.675 h if (a/h < 1.724), For slab thickness of 150mm; Edge Load Stress, σte, is 3.32 N/mm

2 (3.32 MPa).

Total Stress = Edge Load Stress + Temperature Stress = 3.32 + 1.59 = 4.91 N/mm2, which is less than the allowable flexural strength of 4.94 N/mm2. Hence, assumed thickness of slab = 150mm, is OK. [As per Temperature Stress Criteria]

Check for Corner Stresses (σlc):

Traffic Volume (A) = UP TO 500 cvpd (Assume)

Concrete Grade (fc) = 25 N/mm2

Characteristic Compressive Cube Strength = 39.70 N/mm2at 28 Days Actual Compressive Strength

Flexural Strength ( ff ) = 4.49 N/mm2[44.9kg/cm2]

90 days Flexural strength = 4.94 N/mm2[49.4 kg/cm2]

Soaked CBR Value (%) = 0.06 (6%)

Modulus of Subgrade Reaction (k) = 45 (N/mm2/mm)*10-3

Effective K Value (20% more) = 54 (N/mm2/mm)*10-3

Elastic modulus of Concrete (Ec) (As per Actual Calculation)

= 27,500 N/mm2

Poisson’s ratio (µ) = 0.15

Coefficient of thermal coefficient of concrete (α) = 0.00001/˚C

Design Wheel Load (P) = 30 kN

Tyre pressure (q) = 0.5 N/mm2 [5 kg/cm2]

Spacing of Contraction Joints (L) = 3.75m [3750 mm]

Width of Slab (W) = 3.75m [3750 mm]

Radius of load contact (assumed circular), (a) =13.82 cm



137

From Fig. 5 (Page 12), Corner Load Stress for wheel load of 30kN, for k = 54.0(N/mm2/mm)*10-3 = 0.054 N/mm2/mm = 0.054 N/mm2/mm (Approx.) and slab thickness of 150mm is 3.08 N/mm

2 (3.08 MPa).

[Temperature Stress in the corner region is negligible, as the corners are relatively free to warp, hence it can be ignored.]

Hence, σlc = 3.08 N/mm2, which is less than the allowable flexural strength of 4.94 N/mm

2.

So, the slab thickness of 150mm is Safe. The calculations presented above are sample calculations. Similar calculations are done using various values of flexural strengths of concrete.

ECONOMIC ANALYSIS

TABLE- 8

COST OF MATERIALS

Sr. No. Materials Rate (Rs/Kg)

1 Cement (OPC 53 grade) 6.40

2 Hypo Sludge 0.60

3 Fine aggregate 0.60

4 Coarse aggregate 0.65

5 Grit 0.65

TABLE-9

MATERIALS FOR DESIGNED M25 CONCRETE

Concret

eMix

%

Reducti

on in

Cement

by Hypo

Sludge

Materials Total

Cost

[m3]

% Change

in Cost Ceme

nt

[kg/m3]

Fine

aggrega

te

[kg/m3]

Coarse

aggrega

te

[kg/m3]

Grit

[kg/m3]

Hypo

Sludge

[kg/m3]

A1 0 % 479.00 485.75 718.22 478.8

1 0.0 4135.12 0

C1 10 % 431.10 485.75 718.22 478.8

1 47.90 3857.30 (-) 6.71

C2 20 % 383.20 485.75 718.22 478.8

1 95.80 3579.48 (-) 13.43

C3 30 % 335.30 485.75 718.22 478.8

1 143.70 3301.66 (-) 20.15

C4 40 % 287.40 485.75 718.22 478.8

1 191.60 3023.84 (-) 26.87



138

TABLE 10

COST OF 1m X 1m SLAB (Rs.)

Concret

e Mix

%

Reduction

in

Cementby

Hypo

Sludge

2% CBR 4% CBR 6% CBR

Slab

Thickne

ss (mm)

Cost of

1m x

1m Slab

(Rs.)

Slab

Thickne

ss (mm)

Cost of

1m x 1m

Slab (Rs.)

Slab

Thickness

(mm)

Cost of

1m x 1m

Slab

(Rs.)

A1 0 % 190 785.67 150 620.27 150 620.27

C1 10 % 150 590.12 150 590.12 150 590.12

C2 20 % 190 680.10 190 680.10 190 680.10

C3 30 % 190 627.32 190 627.32 190 627.32

C4 40 % 200 605.17 200 605.17 200 605.17

Figure4:% Replacement of Cement by Hypo Sludge v/s Slab Thickness (mm) at 2%CBR,

4%CBR, 6% CBR [Design Wheel Load= 30kN]

190

150

190 190 200150 150

190 190200

150 150

190 190 200

0

50

100

150

200

250

0% 10% 20% 30% 40%

SL

AB

TH

ICK

NE

SS

(m

m)


% REPLACEMENT OF CEMENT BY HYPO SLUDGE V/S SLAB

THICKNESS (mm) AT 2%CBR, 4%CBR, 6% CBR [DESIGN

WHEEL LOAD= 30kN]

SLAB THICKNESS

(mm) AT 2% CBR

SLAB THICKNESS

(mm) AT 4% CBR

SLAB THICKNESS

(mm) AT 6% CBR



139

Figure5:% Replacement of Cement by Hypo Sludge v/s Cost of 1m x 1m Slab (Rs./Sq.mt)at

2%CBR, 4%CBR, 6% CBR [Design Wheel Load= 30kN]

TABLE 11

RELATIVE COST OF SLAB

Concrete

Mix

%

Reduction

in

Cement

2% CBR 4% CBR 6% CBR

Cost of

1m x 1m

Slab

(Rs.)

Relative

Cost

(%)

Cost of

1m x

1m Slab

(Rs.)

Relative

Cost

(%)

Cost of

1m x

1m Slab

(Rs.)

Relative

Cost

(%)

A1 0 % 785.67 100 620.27 100 620.27 100

C1 10 % 590.12 75.11 590.12 99.95 590.12 99.95

C2 20 % 680.10 86.57 680.10 109.64 680.10 109.64

C3 30 % 627.32 79.84 627.32 101.13 627.32 101.13

C4 40 % 605.17 77.02 605.17 97.56 605.17 97.56

785.67

590.12680.10

627.32 605.17

620.27 590.12680.10

627.32605.17

620.27590.12

680.10 627.32605.17

0.00

100.00

200.00

300.00

400.00

500.00

600.00

700.00

800.00

900.00

0% 10% 20% 30% 40%

CO

ST

OF

1m

x 1

m S

LA

B (

Rs.

/Sq

.mt)


% REPLACEMENT OF CEMENT BY HYPO SLUDGE V/S COST

OF 1m x 1m SLAB (Rs./Sq.mt) AT 2%CBR, 4%CBR, 6% CBR

[DESIGN WHEEL LOAD= 30kN]

COST OF 1m x 1m

SLAB (Rs./Sq.mt) AT

2% CBR

COST OF 1m x 1m

SLAB (Rs./Sq.mt) AT

4% CBR

COST OF 1m x 1m

SLAB (Rs./Sq.mt) AT

6% CBR



140

Figure6:% Replacement of Cement by Hypo Sludge v/s Relative Cost Slab (%) at 2%CBR,

4%CBR, 6% CBR [Design Wheel Load= 30kN]

CONCLUSIONS

Based on limited experimental investigations concerning the compressive strength, flexural strength and modulus of elasticity test of concrete (M25 Grade) for rigid pavement, the following observations are made in the ray of the objectives of the study: (a) For a CBR value of 2% and Wheel Load (P) of 30KN; Cost of rigid pavement decreases from Rs.

785.67 per sq.mt. to Rs. 605.17 per sq.mt. shown in figure-5. (b) For a CBR value of 4%, 6% and Wheel Load (P) of 30KN; Cost of rigid pavement decreases

from Rs. 620.27 per sq.mt. to Rs. 605.17 per sq.mt. shown in figure-5. (c) 10% replacement of cement by hypo sludge in concrete for rural road construction gives Slab

Thickness 150mm and low cost of rigid pavement i.e Rs. 590.12 per sq.mt. for a CBR value of 2%, 4%, 6% and Design Wheel Load (P) of 30kN.

(d) For a CBR value of 2% and Wheel Load (P) of 30KN; Relative Cost of Slab decreases from 100%. to Rs. 75.11%. at 10% Replacement Cement by Hypo Sludge shown in figure-6.

(e) For a CBR value of 4%, 6% and Wheel Load (P) of 30KN; Relative Cost of Slab decreases from 100%. to Rs. 99.95%. at 10% Replacement Cement by Hypo Sludge and Rs. 97.56%. at 40% Replacement Cement by Hypo Sludge shown in figure-6.

(f) Use of hypo sludge in concrete can save the paper industry disposal costs and produce a ‘greener’ concrete for low cost rural roads.

(g) This research concludes that hypo sludgecan be an innovative Supplementary Cementitious Material useful for development oflow cost rural roads.

(h) India should aggressively identify projects that can use large amounts of hypo sludge in road construction so that harmonizing environment and ecological sustainability can be developed.

100.00

75.1186.57

79.84 77.02

100.0099.95

109.64101.13 97.56

100.00 99.95109.64

101.13 97.56

0.00

20.00

40.00

60.00

80.00

100.00

120.00

0% 10% 20% 30% 40%

RE

LA

TIV

E C

OS

T S

LA

B (

%)



RELATIVE COST SLAB (%) AT 2%CBR, 4%CBR, 6% CBR

[DESIGN WHEEL LOAD= 30kN]

RELATIVE COST SLAB

(%) AT 2% CBR

RELATIVE COST SLAB

(%) AT 4% CBR

RELATIVE COST SLAB

(%) AT 6% CBR



141

(i) Use of hypo sludge in road construction works will result in the less depletion of naturally available stone metal, gravel, sand and soil; and will save cement, which is the costliest ingredient will lead to reduction in construction cost. With adequate knowledge on the performance of hypo sludge based road pavements, a huge demand can be expected from the road sector to use hypo sludge for construction purposes, but judicious decisions are to be taken by engineers, for development of low cost rural roads.

(j) This research study concludes that there is a great scope for eco-efficient utilization of hypo sludge for sustainable development of Indian Road Network.

ACKNOWLEDGMENT

The Authors thankfully acknowledge to Dr. C. L. Patel, Chairman, Charutar Vidya Mandal,

Er.V.M.Patel, Hon.Jt. Secretary, Charutar Vidya Mandal, Prof. J. J. Bhavsar, Associate Professor and PG Coordinator of Construction Engineering and Management, B.V.M. Engineering College, Mr. Yatinbhai Desai, Jay Maharaj construction, Vallabh Vidyanagar, Gujarat, India for their motivations and infrastructural support to carry out this research.

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Technology

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charutar vidya mandal

conventional materials technologies

edge load stress

allowable flexural strength

rigid pavement decreases

design wheel load

ordinary portland cement