optimum utilization of quarry dust as partial...
TRANSCRIPT
OPTIMUM UTILIZATION OF QUARRY DUST AS PARTIAL REPLACEMENT
OF SAND IN GREEN CONCRETE
JAHARATUL DINI KAREN LEE BINTI ABDULLAH
UNIVERSITI TEKNOLOGI MALAYSIA
OPTIMUM UTILIZATION OF QUARRY DUST AS PARTIAL REPLACEMENT
OF SAND IN GREEN CONCRETE
JAHARATUL DINI KAREN LEE BINTI ABDULLAH
A project report submitted in partial fulfilment of the
requirements for the award degree of
Master of Engineering (Civil-Geotechnics)
Faculty of Civil Engineering
Universiti Teknologi Malaysia
JUNE 2015
iii
In the Name of Allah, the Beneficent, the merciful,
I dedicate this thesis to Allah S.W.T who has endowed me with the capacity to
Increase
In knowledge and wisdom and has guided my path this far.
This thesis is also dedicated to my beloved husband and my parents,
For their endless love, understanding, support and encouragement.
And not forgotten to
All my family members, lecturers and friends.
v
ABSTRACT
The reduction in the source of natural sand and the requirement for reduction
in the cost of concrete production has resulted poor quality sand sources supplied
and thus increased need to identify substitute material to sand as fine aggregates in
the production especially in concrete. To overcome from this crisis, partial
replacement of sand with quarry dust can be economical alternative. Quarry dust, a
by-product from the crushing process during the quarrying activities is one of such
materials. In the Peninsular of Malaysia there were also been many attempts to use
quarry dust as partial replacement but only up to 50% on the lower grades concrete
with different construction purposes. This paper present mix design of higher grade
60 that develop with a replacement of 0% (100% of natural sand), 50% and up to a
maximum of 70% of quarry dust usage. Tests were conducted on cubes to determine
the properties and strength of concrete made of quarry dust and the results were
compared with natural sand concrete. An attempt has also been made to conduct the
slump test to determine the fresh concrete workability and also to obtain the
compressive strength (cubes), spilt tensile strength, flexural strength and water
absorption of hardened concrete for laboratory analysis.
vi
ABSTRAK
Pengurangan sumber pasir semulajadi dan keperluan bagi pengurangan
dalam kos pengeluaran konkrit telah menyebabkan sumber pasir berkualiti rendah
dibekalkan dan dengan itu secara tidak langsung telah meningkatkan keperluan
untuk mengenal pasti bahan pengganti pasir sebagai agregat halus dalam
pengeluaran bahan binaan terutamanya dalam penggunaan bancuhan konkrit. Bagi
mengatasi krisis ini, penggantian sebahagian pasir dengan debu kuari boleh menjadi
alternatif yang menjimatkan. Debu kuari, yang yang merupakan produk bahan
terbuang atau sekunder daripada proses penghancuran semasa aktiviti kuari adalah
salah satu daripada bahan-bahan tersebut. Di Semenanjung Malaysia terdapat juga
banyak percubaan untuk menggunakan debu kuari sebagai pengganti separa tetapi
hanya sehingga 50% ke atas gred konkrit yang lebih rendah kekuatannya dengan
tujuan pembinaan dan rekabentuk struktur bangunan yang berbeza. Penghasilan reka
bentuk bancuhan konkrit yang bergred lebih tinggi seperti gred 60 dengan
penggantian 0% (100% pasir semula jadi), 50% dan sehingga maksimum 70%
daripada debu kuari dimanfaatkan. Ujian dijalankan ke atas kiub untuk menentukan
sifat-sifat dan kekuatan konkrit yang diperbuat daripada debu kuari dan kemudian
keputusan tersebut dibandingkan dengan bancuhan konkrit yang menggunakan pasir
semula jadi. Percubaan juga dibuat untuk menjalankan ujian kemerosotan untuk
menentukan kebolehkerjaan konkrit segar dan juga untuk mendapatkan kekuatan
mampatan (kiub), kekuatan tegangan, kekuatan lenturan dan penyerapan air konkrit
untuk penganalisaan data-data makmal.
x
LIST OF TABLES
TABLE NO. TITLE PAGE
2.1 Typical Slag Chemical Composition 15
2.2 The Relationship Between Particle Size, Volume and
Surface Area of Particles
22
2.3 The Grading of Fine Aggregate Calculated using
Exponent
24
2.4 Empirical Surface and Specific Surface Values 31
2.5 Properties of Concrete Incorporating Natural Sand
and Quarry Dust
35
3.1 The Number of Trial Samples for the Research 42
3.2 Concrete Mix Design Form 48
3.3 Concrete Composition 50
3.4 Degree of Workability Based on Slump Value (mm) 54
4.1 Slump Test Results 60
4.2 Compressive Strength of Concrete Specimens at 7
days Curing
63
4.3 Summary Results of Average Compressive Strength 64
4.4 The Percentage of Strength Increase for 50%,70%
and 0% Quarry Dust
67
4.5 Flexural Strength of Concrete Specimens at 7 days
curing
69
xi
4.6
4.7
4.8
Summary Results of Average Flexural Strength
Concrete
Tensile Strength of Concrete Specimen at 7 days
curing
Average Tensile Strength with Different Percentages
of Mix
71
73
74
xii
LIST OF FIGURES
FIGURE NO. TITLE PAGE
1.1
2.1
Sand Distribution and Location Map
The Process of Getting the Slag
03
14
2.2 Type of Various Shapes and Categories of Particles 20
2.3 Cumulative Percentage Passing using Exponent 25
2.4 Relationship between Void Content in Percentage
with Volume Mass of Materials
29
2.5 The Water Required for Constant Mortar Flow in
Relation to Percentage of Minus 75 micron
30
2.6 Compressive Strength in the Concrete with Higher
Amount of Minus 75 micron
36
2.7 The Effect of Permeability in a Higher Percentage
of Minus 75 micron
38
3.1 Flow Chart for Research Methodology 41
3.2 Specimens Used in the Research and Cured 42
3.3 Dry Sieve Analysis of Fine Aggregate 43
3.4 Dry Sieve Analysis of Coarse Aggregate 44
3.5
3.6
3.7
Picture of Mixer Used in the Research
Concrete that Poured into Wheelbarrow and Slump
Test
The Cracking Pattern of the Specimen at Failure
50
52
55
3.8
3.9
Shape of Beam Specimen after Failure
Shape of Cylindrical Specimen after Splitting
57
58
xii
4.1 Variation of Slump Value of Fresh Concrete with
Quarry Dust Content
61
4.2
4.3(a)
4.3(b)
4.3(c)
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
Average of Compressive Strength of Mixes with
different Age
Compressive Strength versus Curing Age for 0%
Quarry Dust
Compressive Strength versus Curing Age for 50%
Quarry Dust
Compressive Strength versus Curing Age for 70%
Quarry Dust
The Percentage of Compressive Strength for the
Concrete
Flexural Strength of Mixes with Different Age
Tensile Strength Mixes with Different Age
Tensile Strength versus Curing Age
Relationship Between Compressive Strength and
Tensile Split Strength (70% Quarry Dust)
Relationship Between Compressive Strength and
Flexural Strength (70% Quarry Dust)
Relationship Between Compressive Strength and
Tensile Split Strength (0% Quarry Dust)
Relationship Between Compressive Strength and
Flexural Strength (0% Quarry Dust)
High Rise Building Using the Quarry Dust Sand
64
65
66
66
67
70
73
74
76
77
78
78
79
xiv
LIST OF SYMBOLS
CaO - Lime
SiO2 - Silicate
Al2O3 - Aluminate
Fe2O3 - Iron Oxide
Ca (OH)2 - Calcium Hydroxide
(C-S-H
gel)
- Calcium Silicate Hydrate
R - Flexural Strength, MPA
P - Maximum Applied Load, N
L - Span Length , mm
b - Average Width of Specimen, m
d - Average Depth of the Specimen, m
Fct - Tensile Splitting Strength (N/mm2)
F - Ultimate Load at Failure (N)
D - Diameter of the Specimen (mm)
π
F
q
n
-
-
-
-
3.14
Shape Factor
Elongation Ratio
Coefficient (exponent)
GGBS - Ground Granulated Blast Furnace Slag
xv
LIST OF APPENDICE
APPENDIX NO. TITLE PAGE
A(1) Chemical Properties of OPC Cement Used 85
A(2) Chemical Properties of GGBS Cement Used 85
B(1) Physical Properties of Quarry Dust and Natural Sand
Used
86
B(2) Chemical Properties of Quarry Dust and Natural
Sand Used
86
C Recorded Sieve Analysis Data for Fine Aggregate 87
D Recorded Sieve Analysis Data for Coarse Aggregate 88
E Recorded Wet Sieve Analysis Data for OPC and
GGBS
90
F(A) Compressive Strength Test Results for Concrete
Specimen of 0% Quarry Dust
91
F(B) Compressive Strength Test Results for Concrete
Specimen of 50% Quarry Dust
92
F(C) Compressive Strength Test Results for Concrete
Specimen of 70% Quarry Dust
93
G(A) Tensile Splitting Test Results for Concrete Specimen
of 0% Quarry Dust
94
G(B) Tensile Splitting Test Results for Concrete Specimen
of 50% Quarry Dust
95
xvi
G(C) Tensile Splitting Test Results for Concrete Specimen
of 70% Quarry Dust
96
H(A) Flexural Test Results for Concrete Specimen of 0%
Quarry Dust
97
H(B) Flexural Test Results for Concrete Specimen of 50%
Quarry Dust
98
H(C) Flexural Test Results for Concrete Specimen of 70%
Quarry Dust
99
CHAPTER 1
INTRODUCTION
1.1 Background
As part of the normal production of crushed aggregate up to 30% (rock
dependant) of the material recovered from the quarry is reduced to a size that is not
suitable as coarse aggregate. Typically, this material will pass the 4.75mm screen.
As the supplies of suitable natural sand near the point of consumption are
becoming exhausted, the cost of this sand is increasing. A replacement material was
sought and the fines from crushing operations were identified as a possible substitute
material. Early attempts by the quarry industry to market this material as
manufactured sand resulted in failure. This was due to the material having been
produced as a waste product; no thought having been given to the properties that are
crucial to its performance in concrete. The manufactured sand also failed due to
noncompliance with the existing sand specifications. Criteria such as misshapen
particles increasing the water demand, gradation not falling within the prescribed
envelope, micro fines (material passing a 75micron sieve) content too high, sands
equivalent and fineness modulus out of specifications; to name but a few, have
limited the general acceptance of manufactured sand. Attempts to modify the
2
properties of the manufactured sand to conform to the specifications brought with
them new problem such as increased production costs and disposal of the waste
micro fines from the washing process.
These problems were recognised by the aggregate and concrete industries and
together with the specifying authorities, revised the sand specifications to include
manufactured sand as a construction material in its own right. However, since
manufactured sand is so different to natural sand, new testing and proportioning
methods need to be developed. In 1997, a report was commissioned to quantify the
status of the fitness produced by aggregate quarrying operations in the USA. The
report identified that, although 80% of the fitness produced are used for
constructions and agricultural purpose, there is in excess of 300 million tons of
minus 9.5mm and 400 million tons of minus 75micron material already stockpiled.
This amount is increasing by 180 million tons per year. The balance of the material is
stockpiled, creating a financial and environmental drain on the quarry industry. One
of the main causes is the limit being placed on the amount of minus 75micron
material allowed in the aggregates and sand.
Concrete is the most popular building material in the world. However, the
production of cement has diminished the limestone reserve in the world and requires
a great consumption of energy. River sand has been the most popular choice for the
fine aggregate component of concrete in the past, but overuse of the material has led
to environmental concerns the depleting of securable river sand deposits and a
concomitant price increase in the material. Therefore, it is desirable to obtain cheap,
environmentally friendly substitutes for cement and river sand that are preferably by
products. GGBS (pulverized GGBS) is used extensively as a partial replacement of
cement. However, though the inclusion of GGBS in concrete gives many benefits,
such inclusion causes a significant reduction in early strength due to the relatively
slow hydration of GGBS. Nevertheless, GGBS causes an increase in workability of
concrete.
3
Quarry dust has been proposed as an alternative to river sand that gives
additional benefit to concrete. Quarry dust is known to increase the strength of
concrete over concrete made with equal quantities of river sand, but is causes a
reduction in the workability of concrete. When examining the above qualities of
GGBS and quarry dust it becomes apparent that if both are used together, the loss in
early strength due to one may be alleviated by the gain in strength due to the other
and the loss of workability due to the one maybe partially negated by the
improvement in workability caused by the inclusion of the other.
The use of GGBS in concrete is desirable because of benefits such as useful
disposal of a by-product, increased workability, reduction of cement consumption,
increase sulphate resistance, increased resistance to alkali-silica reaction and
decreased permeability. However the use of GGBS leads to a reduction in early
strength of concrete. Therefore the concurrent use of quarry dust and GGBS in
concrete will lead to the benefits of using such materials being added and some of the
undesirable effects being negated. The concurrent use of the two by-products will
lead to arrange of economics and environmental benefits.
Figure 1.1: Sand Distribution and Location Map
4
1.2 Problem Statement
The construction industry in Peninsular of Malaysia facing a serious shortage
of sand and expected worst in future due to over exploitation of natural river sand.
River sand has been used as the major building material component. Hence, the
entire construction industry will be paralyzed if there are no alternative sources
instead of river sand.
The depleting of securable river sand deposit has causes the rapid price
increase in the material. Higher demand may cause the price increase up to the
maximum and unreasonable costing and thus benefits the bigger domain. Besides
manipulating the pricing, the inconsistency of the sand river quality was neglected
thus causing failures in achieving the higher strength in concrete. Common river sand
is expensive due to excessive cost transportation from natural sources. Also large
scale depletion of these sources creates environmental problems. As environmental
transportation and over constraints make the availability and use of the river sand
less attractive, an environmentally friendly substitutes or replacement product for
concrete industry needs to be found.
1.3 Objective of the Study
The objective of this research is related to a set of aims or targets to be
achieved through the completion of the research. The objective of the study
comprises of the following:
(i) To design high strength and performance green concrete of Grade 60 with
higher percentage of quarry dust as partial replacement of sand.
5
(ii) To determine the effect of different percentages of quarry dust as partial
replacement of sand by 0 %, 50 % and 70 % on concrete strength and
performance.
(iii) To determine the properties of quarry dust in concrete.
1.4 Scope of the Study
The scope of work covers the mechanical and physical properties of high
strength concrete incorporates with high percentage of quarry dust replacement. The
high strength and performance green concrete of grade 60 will be design by
incorporating with quarry dust. The application of the Department of Environment in
designing the mix concrete are referring to the ASTM C94-86, Standard
Specification for Ready Mixed Concrete, BS 146 and BS 4246.
The scope of this study is to incorporate with high percentage of quarry dust
replacement. The fresh and harden concrete properties of the high strength concrete
will be tested with specific ranging of 0%, 50% and 70% quarry dust as partial
replacement of sand. The fresh properties of the concrete are determine through the
slump test only whereas the mechanical properties of the harden concrete are tested
through the few tests such as compressive strength test with cubes (150x150x150)
mm, tensile strength test with cylinders (diameter, 100xlong, 200) mm, flexural test
with beams (100x100x500) mm and water absorption test at the age mature of 7
days, 14 days, 28 days and 56 days after the wet curing process at the tank. These
tests were conducted on 3 samples for every individual age of curing period for the
earlier of trial mix and 50 sets of samplings. Data of the results collected will be
reviewed and evaluated.
6
1.5 Significance of the Study
In the construction industry, river sand is used as important building material
and world consumption of sand in concrete generation alone is around 1000 million
tonnes per year, making it scarce and limited. Further, it has caused environmental
degradation and affecting flora and fauna.
The significance of this study is to ensure the current focus of construction
industry should be to partially replace natural sand in concrete by waste material or
by-product without comprising the quality of the end product. Besides to ensure the
partial replacement for the sand will protect the natural sources and friendly
environmental to be utilized. Quarry dust was used and availability almost free of
cost, hence this study may significantly show reducing of the usage of river sand in
the concrete design and also will cut down the cost of construction with economical
concrete production.
The choice of quarry dust as replacement for sand has been supported in the
previous study and obtained the positive results. Therefore, with the application of
70% quarry dust as partial replacement as sand in higher grade of 60 green concrete,
the results of the strength will be predicted showing positive and optimum results.
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