LOWCOST CONCRETE FROM PAPER INDUSTRY

I.V.P.RAVI CHANDRAA.V.PRANAY KUMAR REDDY

M.A.ASIMM.VENKATESH

PROJECT GUIDE: SRI. NARENDRA KUMAR BOPPANA (Ph.D)Designation : Sr.Asst.Professor, Department of Civil Engineering

ABSTRACT

• Over 300 million tones of industrial wastes are being produced per annum by chemical and agricultural process in India.

• Out of several wastes being produced at present, the use of phosphogypsum, fluorogypsum, lime sludge, hypo sludge, red mud are significant in protecting the environment.

• low-quality paper fibers are separated out to become waste sludge classically called as Hypo sludge.

CONTENTS

• Introduction• Need for hypo sludge utilization.• Objectives.• Scope.• Mix design.• Analysis and results.• Conclusion.

INTRODUCTION• Paper making generally produces a large amount of

solid waste• This paper mill sludge consumes a large percentage

of local landfill space for each and every year.• To reduce disposal and pollution problems

emanating from these industrial wastes, it is most essential to develop profitable building materials from them.

• Investigations suggest replacing various ratios of cement with hypo sludge produces low cost concrete.

NEED FOR HYPO SLUDGE UTILIZATION

• Production of 4 million tones of cement involves in emission of 1 million tones green house gases.

• To reduce environmental degradation i.e. preventing land filling.

• Utilizing this waste the strength will be increased and also cost reduction in the concrete is achieved.

HYPO SLUDGE

• Hypo sludge behaves like cement because of silica and magnesium properties in improving the setting of concrete.

• It is the preliminary waste from the paper industry.

PROPERTIES OF RAW HYPOSLUDGE

S.NO CONSTITUENT % PRESENT IN HYPOSLUDGE

1. Moisture 56.8

2. Magnesium oxide (MgO) 3.3

3. Calcium oxide (CaO) 46.2

4. Loss of ignescent 27

5. Acid insoluble 11.1

6. Silica(SiO2) 9

7. R2O3 3.6

COMPARISON OF CEMENT AND HYPO SLUDGE

S.NO CONSTITUENT CEMENT (in %) % PRESENT INHYPOSLUDGE

1. Lime(CaO) 62 46.2

2. Silica (SiO2) 22 9

3. Alumina 5 3.6

4. Magnesium 1 3.33

5. Calcium sulphate 4 4.05

OBJECTIVES To investigate the utilization of hypo sludge as

supplementary cementitious materials and influence of hypo sludge on the strength on concrete made with different cement replacement levels.

Scope

• To provide a most economical concrete.• It should be easily adopted in field.• Using the wastes in useful manner.• To reduce the cost of the construction.• To promote the low cost housing to the L.I.G

group people.• To find the optimum strength of the partial

replacement of concrete.

Scope

• Minimize the maximum demand for cement.• Minimize the maximum degradation in

environment due to cement and safeguard the ozone layer from green house gases.

• To study the crack development in hardened concrete.

MATERIALS TO BE USED

1.Cement 2.Aggregate a) coarse aggregate b) fine aggregate3.Water4.Hypo sludge

MIX DESIGN

• A mix of M25 grade was designed as per Indian standard method and the same is used to prepare the test samples .

• The design mix proportion is done as follows .

WATER CEMENT F.A C.A

By volume 0.35 1 0.834 2.29

Mix Proportions

Conventional Concrete 1:0.834 :2.29

10% replacement 0.9:0.834 :2.29

20% replacement 0.8:0.834 :2.29

30% replacement 0.7:0.834 :2.29

40% replacement 0.6:0.834 :2.29

50% replacement 0.5:0.834 :2.29

60% replacement 0.4:0.834 :2.29

70% replacement 0.3:0.834 :2.29

Details of the Experimental Study

• 150 mm × 150 mm × 150 mm concrete cubes were casting using M25 grade concrete.

• Specimens with ordinary Portland cement (OPC) and OPC replaced with hypo sludge at 10%, 20%, 30%, 40%, 50%, 60% and 70% levels were cast.

Experimental Study

• After 24 h the specimens were removed from the mould and subjected to water curing.

• The specimens were tested for compressive strength using a calibrated compression testing machine.

ResultsPartialReplacement

Number ofspecimen

Ultimateload, [Kn]

Ultimatecompressivestrength, [N/mm2]

0 1 839 37.33

10 1 908 40.37

20 1 1252 55.69

30 1 1253 56.11

40 1 898 36.95

50 1 412 18.335

60 1 357 15.87

70 1 291 12.94

Economic Feasibility

• Cost analysis is carried out for the optimum proportion of percentage of hypo sludge in concrete.

• This project was carried out in our college campus.

• The cost is compared to the conventional concrete.

Cost of Materials

• Cost of cement per bag = 275/-• Cost of sand per m3 = 955/-• Cost of hypo sludge per kg = 0.51/-• Cost of coarse of aggregate per m3=620/-

Cost of Material of Normal Concrete/ m3

Description Quantity, [kg/m3] Cost Cost of material

in (Rs)

Cement 450 5.5/kg 2475Hypo sludge

- 0.51/kg -

sand 375.3 955/m3 224Coarse aggregate

1030.5 620/m3 290.4

Total 2989/-

Cost of material of 10% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement 405 5.5/kg 2227.5Hypo sludge

45 0.51/kg 22.95

sand 375.3 955/m3 224Coarse aggregate

1030.5 620/m3 290.4

Total 2764/-rs

Cost of material of 20% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement 360 5.5/kg 1980Hypo sludge

90 0.51/kg 45.9

sand 375.3 955/m3 224Coarse aggregate

1030.5 620/m3 290.4

Total 2540.3

Cost of material of 30% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement 315 5.5/kg 1732.5Hypo sludge

135 0.51/kg 68.85

sand 375.3 955/m3 224Coarse aggregate

1030.5 620/m3 290.4

Total 2315

Cost of material of 40% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement 270 5.5/kg 1485Hypo sludge

180 0.51/kg 91.8

sand 375.3 955/m3 224Coarse aggregate

1030.5 620/m3 290.4

Total 2091

Cost of material of 50% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement 225 5.5/kg 1237.5Hypo sludge

225 0.51/kg 114.75

sand 375.3 955/m3 224Coarse aggregate

1030.5 620/m3 290.4

Total 1866

Cost of material of 60% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement 180 5.5/kg 990Hypo sludge

270 0.51/kg 137.7

sand 375.3 955/m3 224Coarse aggregate

1030.5 620/m3 290.4

Total 1642

Cost of material of 70% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement 135 5.5/kg 742.5Hypo sludge

315 0.51/kg 903

sand 375.3 955/m3 224Coarse aggregate

1030.5 620/m3 290.4

Total 1417

Conclusion• Compressive strength of the concrete is

increased when the percentage of replacement is increased up to 40%.

• Replacement of cement with this waste of hypo sludge material provides maximum compressive strength at 30% replacement.

Cont...• Used as temporary shelters during natural

calamities and storage conditions. • When government implement the projects for

temporary shelters for affected by tsunami, E.Q., etc., this material can be used for economical feasibility.

• Cost of cement becomes low from this project.

Cont…….

• Environment effects from wastes and maximum amount of cement manufacturing is reduced through this project.

• A better measure by a New Construction Material is formed out through this project.

Thank you

WORK SCHEDULE

S.No Activity Duration

1 Literature Review Dec 2011-Jan 2012 Dec 2011-Jan 2012 (4 weeks)(4 weeks)

2 Mix design Jan 2012-Feb2012 Jan 2012-Feb2012 (2 weeks)(2 weeks)

3 Experimental trials Feb2012-March Feb2012-March 2012 (4 weeks)2012 (4 weeks)

4 Analysis of results March 2012-April March 2012-April 2012 (4 weeks)2012 (4 weeks)

5 Documentation April 2012 (2 April 2012 (2 weeks)weeks)