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3773
www.ijifr.com Copyright © IJIFR 2015
Research Paper
International Journal of Informative & Futuristic Research ISSN (Online): 2347-1697
Volume 2 Issue 10 June 2015
Abstract
Granite sludge powder generates in processing activities of granite stone, such as
cutting, polishing and finishing process. This contributes of about 30% wastage in these processes. As granite sludge powder is non- biodegradable waste, it has to be effectively disposed without creating environmental hazards. In our present study the objectives are to prepare Granite Sludge blocks of size
230×110×70(mm) for varying mix proportions such as 20%, 30%, 40%, 50%, 60%, and 70% for granite sludge powder and sand, by keeping lime 8% and
gypsum 2% as constant. To find Mechanical properties such as Compressive strength, Flexural strength and Water absorption, where maximum compressive
strength value for 7 days of 5.54 MPa, maximum flexural strength of 2.17 MPa
and maximum breaking load 4.33kN was obtained for A3 block type. Water absorption of granite sludge blocks increases with increase in addition of granite sludge powder in mix proportions, yet it is in limit as per IS code specifications. Utilizing granite sludge powder for manufacturing of granite sludge masonry blocks is one of efficient manner to minimize the disposal problems of granite sludge powder.
Experimental Study on Granite Sludge Blocks
Paper ID IJIFR/ V2/ E10/ 070 Page No. 3773-3781 Subject Area Civil
Engineering
Key Words Granite Sludge Powder, Granite Sludge Blocks, Lime
Received On 15-06-2015 Reviewed On 26-06-2015 Published On 29-06-2015
Sabarinath N 1
M.Tech. Student
Department of Civil Engineering
Vijaya Vittala Institute of Technology,
Bengaluru
Prof. Virendra Kumara K N 2
Professor & Head,
Department of Civil Engineering
Vijaya Vittala Institute of Technology,
Bengaluru
Dr. S B Anadinni 3
Principal
Department of Civil Engineering
Vijaya Vittala Institute of Technology,
Bengaluru
3774
ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781
Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks
1. Introduction
Traditionally burnt bricks constitute the basic masonry unit for the construction of houses and it is
well known that manufacturing requires significant quantities of energy to produce burnt bricks
while utilizing the topsoil. Also, continuous removal of topsoil for production of conventional
bricks creates environmental hazards. Hence, there is a strong need to adopt cost effective and
sustainable technologies using local materials to produce alternatives for burnt clay bricks
Recent development in the modern civilization has led to the increased industrial production to
meet the needs of the people. The production of every product results in some waste end products,
known as industrial waste. Leaving waste materials to the environment directly can cause
environmental problems. Hence reuse of waste materials has been incorporated with recent
techniques from past & present scholars to minimize the environmental hazards. Bulky waste, such
as the wastes from the granite industry can be utilized by the construction industry, which is one of
the most technologically active sectors. Both waste materials as resource and recycled products,
utilized by the sector reduce the cost of the project. The use of wastes as an alternative to raw
materials in the brick industry, which constitutes part of the construction activity, contributes to the
diversification of basic raw materials in the manufacturing process of bricks and tiles and reduces
the costs in a building
Generation of large amount of wastes in the granite industrial sector is in the form of fine dust and
sludge which are composed majorly of silicon dioxide, aluminum oxide, ferrous oxide and calcium
oxide due to their sawing and polishing process, they can bring about genuine harm to nature, for
example, soil and underground water defilement, if not proficiently treated before disposal.
The reusing of granite wastes in the brick industry has pulled in mechanical consideration in the
most recent years because of the likelihood of lessening the expense of creation, utilization of
residue as a secondary raw material in the production.
2. Problem Context Granite stones have vast application in the field of construction due to their nature of origin. Some
of it applications are for size stone masonry, granite flooring slabs, as coarse aggregate in concrete
etc. During the process of manufacturing granite flooring slabs which are used for flooring purpose
in commercial and residential buildings, about 30% waste is generated in various processing
activities. This granite sludge waste generated has negative impact to our environment. Hence reuse
of this material need to be considered to minimize the disposal problems of granite sludge.
3. Problem Definition
In this experimental study, strength and other required parameters are evaluated
by preparing Granit sludge masonry blocks using granite sludge powder 20% -70%, sand 70% -
20%, lime 8% and gypsum 2% of varying mix proportions, by keeping in view fly ash bricks as
principal reference. Granite sludge powder is collected from local granite stone processing unit and
other materials are purchased from local market. The tests are conducted in order to study the
strength characteristics such as compressive strength and flexural strength and water absorption.
The results obtained will be cross checked with IS code specifications.
4. Experimental materials
4.1 Granite Sludge Powder
3775
ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781
Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks
Granite sludge powder which results in processing activities of granite stone for flooring slabs such
as cutting, polishing and finishing process. This contributes of about 30% wastage in these
processes, which is non-biodegradable waste.
Figure 4.1: Granite Sludge Powder
4.2. Fine aggregate
Natural river sand which is locally available has been selected for the dissertation work.
The sand was tested for their physical characteristic according to the relevant IS code provisions.
Table 4.1: Properties of Fine Aggregate
Sl. No.
Physical properties of fine
aggregates
Results
1 Specific gravity 2.67
2 Fines modulus 2.507
3 Grading zone 3
4.3. Lime
Lime as binding material has been made use since ancient times in our country. But at present, the
cement revolutionary has replaced usage of lime to great extent. And on other hand, scholars say
that the manufacture of cement leads to Global warming, in this present study locally available lime
of class-C (hydrated lime)
4.4. Gypsum
Gypsum is a naturally occurring mineral of sedimentary rock category which constitute of hydrated
sulphate of calcium. Property of gypsum is such it has very poor solubility in water, which sets and
hardens quickly. Gypsum of high purity is generally used as fertilizer in our country, such as
ammonium sulphate fertilizer and low purity in manufacturing of ordinary Portland cement to act as
a retarder, controlling setting time of cement. Here low purity gypsum is used as retarding agent in
the mix proportions of granite sludge blocks.
3776
ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781
Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks
5. Methodology
5.1. Mix Proportions Keeping in view with fly ash bricks, granite sludge blocks are produced by varying percentage of
granite sludge powder by 20%, 30%, 40%, 50%, 60% & 70%.Table 5.1 shows Mix proportions for
various blocks to analyse in our study.
Table 5.1: Mix Proportions for various block types
Sl.No Type G.S.P Sand Lime Gypsum
1 A1 20% 70% 8% 2%
2 A2 30% 60% 8% 2%
3 A3 40% 50% 8% 2%
4 A4 50% 40% 8% 2%
5 A5 60% 30% 8% 2%
6 A6 70% 20% 8% 2%
Quantity of ingredients required for one Granite sludge block
Size of granite sludge blocks = 230 × 110 × 70 (mm)
Volume of block moulds = 0.23 × 0.11 × 0.07 (m)
= 1.771 × 10-3
m3
Mass = Density × Volume
Mass of one Granite sludge block = 1800 kg/m3 × 1.771X10
-3 m
3
= 3.18 kg + 10% wastage
= 3.5 kg
For A1 block type
Quantity of Granite sludge powder = Mass of solids × % of granite sludge powder
requirement
= 3.5 × 0.2 = 0.7 kg
Quantity of sand = Mass of solids × % of sand requirement
= 3.5 × 0.7 = 2.45 kg
Quantity of Lime = Mass of solids × % of Lime requirement
= 3.5 × 0.08 = 0.28 kg
Quantity of Gypsum = Mass of solids × % of Gypsum requirement
= 3.5 × 0.02 = 0.07 kg
Above mix proportion method is followed for various mix proportions of Granite Sludge
5.3 Mixing
The granite sludge powder is ensured its dry and by visual examination any gravels or debris are
removed if any, the granite sludge powder, sand and gypsum are mixed dry till it attains uniformity.
Then the hydrated fat lime which is sand drained over night to remove excess water from lime is
also mixed along with water for about 3- 4 minutes till the mix becomes cohesive.
3777
ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781
Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks
5.4 Casting
The mixture is filled in 230 x 110 x 70 (mm) wooden mould in three layers and compacted by
tamping 25 times each layer by using tamping rod. And the top layer is smooth finished by using a
trowel. After which the specimen is allowed to dry for 24hrs in the mould itself.
5.5 Curing
The granite sludge blocks are de-moulded after 24hrs from the wooden moulds after casting and are
water cured for 7 days by covering wet gunny bags.
5.6 Testing
After 7 days of water curing granite sludge blocks are tested to know its compressive strength,
flexural strength, percentage of water absorption.
6. Results and Discussions
6.1 Compressive Strength Test 7 days compressive strength test for Granite sludge masonry blocks of mix proportions of 20%,
30%, 40%, 50%, 60%, and 70% were carried out as per IS code 3495:1992.
Table 6.1: Compressive strength test values
Sl. No Type 7 days Compressive load in (kN) Avg Compressive strength
in (N/mm2)
1 A1 70 71 67 2.74
2 A2 92 83 90 3.41
3 A3 138 144 139 5.54
4 A4 114 119 108 4.49
5 A5 94 88 88 3.55
6 A6 66 62 66 2.55
Length of Granite sludge block, l=230(mm)
Breadth of Granite sludge block, b= 110 (mm)
Area of the Granite sludge block, A=l x b=25300(mm)2
6.1.1 Observation and Discussion on Compressive Strength Test
Figure 6.1: Bar chart representation of compressive strength (MPa) v/s Block Types
0
1
2
3
4
5
6
A1 A2 A3 A4 A5 A67 d
ay
s C
om
pre
ssio
n
Str
eng
th
in M
Pa
Block Type
3778
ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781
Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks
The compressive test result shows that, A3 block type has obtained maximum compressive strength
value of 5.54 N/mm2 after which the compressive strength drops down due to the increase in
powder content and particle size distribution of granite sludge powder in the mix proportions. Since
maximum compressive strength obtained is 5.54 N/mm2, it belongs to class 5 designation as per IS
code 1077:1992.
6.2 Flexural Strength The flexural test on granite sludge blocks was conducted as per IS 15658: 2006 code specifications,
which specifies breaking load and flexural strength for pre-cast concrete blocks for paving. Table
6.2 shows flexural strength values for different granite sludge block types.
Table 6.2: Flexural strength test values
Sl.No Type Breaking load (kN)
Avg
Breaking
load (kN)
Flexural strength
fb
(N/mm2)
1 A1 3 2 3 2.67 1.33
2 A2 4 3 3 3.33 1.67
3 A3 4 5 4 4.33 2.17
4 A4 5 4 2 3.67 1.83
5 A5 2 2 2 2 1
6 A6 1 2 1 1.33 0.67
fb= flexural strength, in N/mm2.
P = Breaking load, in N.
l = distance between central lines of supporting rollers. ie, overall length of the specimen minus
50mm (230 – 50 = 180mm)
b = width of the block, 110mm.
d = thickness of the block, 70mm
6.2.1 Observation and Discussion on Flexural Strength
Figure 6.2 Flexural strength (MPa)
v/s Block Types
0
0.5
1
1.5
2
2.5
A1 A2 A3 A4 A5 A6
Fle
xu
ral
stre
ng
th i
n N
/mm
2
Block types
3779
ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781
Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks
IS code 15658: 2006 specifies following minimum breaking load values to be considered for
using in pavers for different aspects of application such as
For residential and public pedestrian pathways, minimum breaking load of 2kN
Residential driveways, minimum breaking load of 3kN
Commercial vehicle pathway, minimum breaking load of 5kN
For trafficked roads, minimum breaking load of 6kN
Heavy duty industrial roads, minimum breaking load of 7kN
By considering specifications, the average maximum breaking load of 4.3kN was achieved in
our present study. Hence granite sludge block concept can be adopted in manufacturing of precast
paver blocks of required size/ shape and used as paver block for residential driveways.
As with flexural strength of granite sludge blocks, the maximum strength value of 2.17 N/mm2
was observed for A3 block type, after which the flexural strength reduces significantly. Where it is
also noted that flexural strength as low as 0.67 N/mm2 for A6 block type which might be due to the
high granite sludge powder content and insufficient binding agent in the mix proportion.
6.3 Water Absorption Test Water absorption test for different mix proportions of Granite sludge blocks were carried out as per
IS code 3495:1992 and are tabulated in table 6.3.
Table 6.3 Water absorption test test values
Sl.No Type M1 in kg M2 in kg
Average
(%)
1 A1 3.89 3.77 3.94 4.22 4.06 4.25 8.01
2 A2 3.8 3.77 3.72 4.12 4.097 4.06 8.48
3 A3 3.67 3.56 3.83 4.022 3.89 4.17 9.2
4 A4 3.79 3.92 3.69 4.169 4.35 4.05 10.23
5 A5 3.73 3.98 3.79 4.12 4.43 4.21 10.94
6 A6 3.82 3.68 3.73 4.26 4.10 4.19 11.51
6.3.1 Observation and Discussion on Water Absorption
From fig 6.3 it can be
clearly seen that
percentage of water
absorption increases
with increase in
addition of granite
sludge powder for
various block types.
The maximum water
absorption rate is for
A6 block type which
Figure 6.3: Shows percentage of water absorption for different Block Types
3780
ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781
Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks
constitutes 70% of granite sludge powder in mix. But none of the granite sludge blocks from A1 –
A6 as water absorption rate beyond IS code 1077:1992 specification, which specifies water
absorption rate not to be more than 20% by weight for blocks up to 12.5 class designation. Where
as in our study, the maximum water absorption rate is 11.74% for class 5 masonry block, which is
well within the limiting value of 20%.
7. Conclusion
The following conclusions can be drawn from the results of the present study;
1. By using granite sludge powder as prime material granite sludge masonry blocks of size
230×110×70 (mm) is casted for varying mix proportions of 20%,30%,40%,50%,60% and 70%
for granite sludge powder and sand, by keeping lime 8% and 2% gypsum as constant.
2. Maximum Compression strength value for 7 days of 5.54 MPa was obtained for A3 block type,
which conforms to class 5 masonry blocks according to IS 3495:1992, which specifies
minimum compressive strength of 3.5MPa for masonry blocks.
3. Maximum Flexural strength of 2.17MPa for A3 block type is observed. The maximum breaking
load 4.33kN was noted for A3 block type, while conducting flexural strength test.
4. Water absorption in granite sludge blocks increases with increase in addition of granite sludge
powder in mix proportions. But the water absorption values of all the granite sludge blocks A1-
A6 are within the limit as specified by IS code 1077:1992, which specifies maximum
percentage of water content should not exceed 20% by weight of the specimen.
5. Utilizing granite sludge powder for manufacturing of granite sludge masonry blocks is one of
efficient manner to minimize the disposal problems of granite sludge powder.
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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 10, June 2015 22ndEdition, Page No: 3773-3781
Sabarinath N, Prof. Virendra Kumara K N , Dr. S B Anadinni : Experimental Study on Granite Sludge Blocks
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