In India, Hypo-Sludge (waste from paper industries) and Fly-Ash (waste from thermal power plants) are available in large quantity. The management of fly ash has been troublesome in view of its disposal because of its potential of causing pollution of air and water. The total generation of fly ash in India is about 180 million tonnes. About 20,000 hectares of land resources can be saved annually by effectively utilisation of fly ash in India.

1. A Presentation
on
Concrete made by Partially
Replacing Cement with Hypo sludge
and Fly ash.
By
“Write your name”
(Roll no.)
Under Supervision of
“Supervisor/guide name”
(Associate Professor)
Civil Engineering Department
“College name”

2. Overview of the Presentation
• Background.
• Introduction.
• Literature review.
• Objectives.
• Materials .
• Methodology.
• Results.
• Conclusions
• Scope for future research.
• References.

3. Background
• India ranks second in cement production and consumption after its
neighbour China.

4. • Major GOI programmes recently launched to contribute in development
and increase in the demand of cement.
Source: India Brand Equity Foundation report, April 2020
• This signifies that large amount of naturally occurring resources and raw
materials are utilized for the concrete.
• To produce Ordinary Portland Cement (OPC), earth resources like
limestone and coal are being used.
• This is causing load on the natural resources.

5. •The use of waste products from various processes as material for
making concrete.
•The wide availability of industrial waste makes it a suitable and
dependable alternative in concrete production wherever available.
 Benefits by inclusion of waste products into cement production.
•Problems of disposal, health hazards and aesthetics can be minimized.
•Diversion of the material from the waste streams.
• Reduction of the energy used in processing virgin materials
• Usage of virgin materials and decrease in pollution.
How to over come the problem?

6. INTRODUCTION
• In India, Hypo-Sludge (waste from paper industries) and Fly-
Ash (waste from thermal power plants) are available in large
quantity.
• The management of fly ash has been troublesome in view of
its disposal because of its potential of causing pollution of air
and water.
• The total generation of fly ash in India is about 180 million
tonnes.
• About 20,000 hectares of land resources can be saved annually
by effectively utilisation of fly ash in India.

7. Cont...
• It is estimated that about 100 tonnes of wasted sludge is
produced for making 550 tonnes of pulp and this causes
the major problem to the environment.
• Some toxic metals deriving from dyes, fillers, and toxic
pigments are present in hypo sludge which can cause
problem to environment.
• India imports about 3.5 million tonnes of paper waste,
which produces large quantity of hypo sludge.

8. Cont...
• Recycle of such type of wastes can be used as an
admixture to make the green concrete structures.
• This will reduce the quantity of cement used and
CO2 emission and reduce global warming.
• These industrial waste materials can also be used
as a partial replacement for cement in concrete.

9. Literature review
Year Author
Study parameter
considered
(hypo sludge as
replacement)
Major conclusion
2001
Ahmadi
and
Khaja
compressive strength
and
splitting tensile
strength
It was concluded that max. 5% replacement to
the fine sand can be used successfully as
construction materials and as the percentage of
waste was increased the water cement ratio for
the mix also increased as the waste has more
water absorption capacity.
2013 b
Pitroda
et al
compressive strength
increment in the compressive strength was
found by 10% replacement with hypo sludge in
cement.
2013
Pitroda
et al
utilization of hypo
sludge by eco-
efficient development
of rigid pavement in
rural roads.
This research study concludes for a CBR value
of 2% and Wheel Load (P) of 30kN; Cost of
rigid pavement decreases.

10. Year Author Study parameter
considered
(hypo sludge as
replacement)
Major conclusion
2013
Pitroda
and
Umrigar
modulus of elasticity
The strength of M40 grade concrete on
substitution with 10% hypo sludge gives
analogous modulus of elasticity as that of
conventional concrete.
2013
Solanki
and
Pitroda
studied the different
concrete mixtures to
determine the influence of
hypo sludge on modulus
of elasticity.
The test results were modulus of elasticity
decreases with increase in percentage
replacement of hypo sludge
2014
Balamur
ugan and
Karthick
raja
The tests were carried out
to evaluate the mechanical
properties like
compressive strength up to
28 days
Up to 10% of hypo sludge concrete, the
compression strength has been increased.
2014
Seyyedali
pour et al
studied the utilization of
pulp and paper industry
wastes in production of
concrete
He concluded that wastes and industrial by-
products like hypo sludge could be valuable
materials as alternative resources for building
and construction and other applications.

11. Year Author
Study parameter
considered
(hypo sludge as
replacement)
Major conclusion
2014
Yousuf et
al
The study was performed
by replacing 5%, 10%, 15%
and 20% of cement by hypo
sludge in concrete for M15
mix .
It was inferred that the compressive strength
of concrete increases up to 17% compared to
ordinary concrete for 15% replacement for
cube. On 15% substitution there is an
increment of 15% splitting strength.
2015
Alam and
Berera
some important indicators
such as workability, cube
strength, stress-strain
characteristics (cylinder),
modulus of elasticity for
M20 was considered.
10% replacement of cement by hypo sludge
gives 11% higher strength than pure
concrete

12. Year Author Study parameter
considered
(fly ash as replacement)
Major conclusion
2001 Gopalakr
ishnan et
al
investigated a quantitative
assessment of different
cement replacement levels
with fly ash on the strength
and durability properties
The results showed a compressive strength
of 80 MPa at 28 days was achieved by
using 25% replacement of cement with fly
ash.
2003 Siddique utilization of high proportion
of Class F fly ash as a partial
replacement of cement in
normal concrete.
It was noted that fly ash can be
effectively used as 50% proportion of
cement replacement in normal concrete.
2010 Reddy et
al
studied the strength and
workability properties of fly
ash based geopolymer
concrete.
. It was observed that the compressive
strength of concrete samples was
increased with the increase in molar
concentration of NaOH solution
2014 Adam
and
Harianto
studied the change in
compressive strength of fly
ash based geopolymer mortar
with respect to temperature
and curing period.
The results showed that with the increase in
temperature and curing period, compressive
strength increases

13. Year Author Study parameter
considered
(fly ash as replacement)
Major conclusion
2014 Usman
and
Pandian
studied the effect of fly ash
and rice husk ash-based
geopolymer concrete
incorporated with steel
fiber on the properties of
concrete
The addition of steel fibre did not affect the
compressive strength of the geopolymer
concrete
2014 Yellaiah
et al
conducted the evaluation of
mechanical properties of fly
ash based geopolymer mortar.
It was found that the increase in mechanical
strength with respect to alkaline liquid to
fly ash ratio was due to the availability of
sufficient alkaline activator solution to
undergo complete polymerization.
2015 Rao and
Rao
experimentally investigated
the compressive strength
and final setting time of fly
ash and ground granulated
blast furnace slag (GGBS)
based geopolymer paste and
mortar
The compressive strength was increased
with the increase in molar concentration of
alkaline solution as well as GGBS
proportion in fly ash based geopolymer
mortar.

14. Objectives
The objectives of this study conducted are as
follows:
• To study the compressive and tensile strength of
concrete using hypo sludge and fly ash (as partial
replacement of cement).
• To check the economic feasibility of the partially
replaced concrete mix over the conventional M20
concrete mix.

15. Materials
 Cement
• OPC 43 grade cement confirming to IS 8112-2013 was used. (ultra tech )
 Sand (fine Aggregates)
• Fine aggregates used throughout this work was comprised of clean river
sand with max. size of 4.75 mm confirming to IS 383
 Coarse Aggregates
• Coarse aggregates used in this work were equal fractions of 20mm and
10mm confirming to IS 383
 Fly Ash
• Fly Ash used in this investigation was obtained from Panki Thermal Power
Station, Panki Kanpur.
• The fly ash was oven dried for 24 hours then sieved through 90 micron
sieve, then it was used for the experimental purpose.
 Hypo Sludge
• Hypo sludge was obtained by Mahadev Paper mill, Kanpur
• The waste was oven dried then it was pulverized to get it in usable form.

16. Fly ash
accumulation in
Panki thermal
power plant,
Kanpur in fig 1
and fig 2.
Fig.1
Fig. 2

17. Fig. 3
Fig. 4
Shaping it into useable
form for sieving in Fig
3 and 4.

18. Fig. 7 Pulverisation of hypo
Sludge.
Fig. 8 Oven drying Hypo sludge.

19. Methodology
Procurement of Materials.
Material Testing.
Sampling of materials for casting in
varied proportions.
Preparation of Mix design and
casting.
Testing of samples after curing.

20. Varying percentage of fly ash and
hypo sludge for different concrete mix
Mix Replacement
Hypo sludge
percentage
Fly ash
percentage
M0 0% 0 0
M1 10% 5% 5%
M2 20% 10% 10%
M3 30% 15% 15%
M4 40% 20% 20%

21. Weight of ingredients in gm for 6
cubes for each percentage replacement
% replacement of
cement with fly ash
and hypo sludge
0% +
0%
5 % + 5% 10% + 10%
15% +
15%
20% +
20%
Material
Cement 2.5 kg 2.25 kg 2 kg 1.75 kg 1.5 kg
Hypo Sludge 0 125 gm 250 gm 375 gm 500 gm
Fly Ash 0 125 gm 250 gm 375 gm 500 gm
Fine Aggregates 4.23 kg 4.23 kg 4.23 kg 4.23 kg 4.23 kg
Coarse Aggregates 7.5 kg 7.5 kg 7.5 kg 7.5 kg 7.5 kg
Water cement ratio 0.5 0.5 0.5 0.5 0.5

22. Fig. Materials used. Fig. 6 Preparing dry mix

23. Fig. 7 Wet mix Fig. 8 Casted cubes.

24. Results
• Tests on cement
Sr. No. Characteristics
Experimental
Value
Values specified as per IS-
8112:2013
1 Fineness 1% ≤ 10% by weight
2 Specific Gravity 3.14 -
3 Standard consistency 32% -
4 Initial Setting time 78 mins 30 mins (min)
5 Final Setting time 600 mins 600 mins (min)
6
Compressive Strength
3 days
7 days
17.4 N/mm2
28.5 N/mm2
16 N/mm2
22 N/mm2

25. Tests on coarse Aggregates
Parameters Results/observations
Crushing strength 28%
Shape Angular
Impact value 13%
Maximum Size 20 mm
Specific Gravity 2.67
Water Absorption 0.80%
Fineness Modulus 6.60
Colour Grey

26. Tests on Fine Aggregates
Parameters Results/observations
Specific gravity 2.72
Fineness modulus 2.70
Water absorption 1.10

27. Properties of hypo sludge vs. cement
Serial No. Constituents Cement (%) Hypo sludge (%)
1 Lime (CaO) 60 – 67 37 – 48
2 Silica (SiO2) 17 – 25 3 – 12
3
Magnesium oxide
(MgO)
0.1 – 4 0.1 – 4
4
Aluminum
(Al2O3)
3 – 8 2 – 7
5
Calcium sulphate
(Ca2SO4)
1.5 – 4 0.5 – 4.5
(Reference: Shah and Pitroda, 2013)

28. Chemical properties of fly ash from Panki
Thermal Power Station
Sr. No. Chemical component Percentage (%)
Requirements as per IS: 3812
(Part 1) 2003
1
(SiO2) + (Al2O3)
+(Fe2O3)
94.36 Min 70
2 Silicon dioxide (SiO2) 52.66 Min 35
3 Calcium Oxide (CaO) 1.64 -
4
Magnesium Oxide
(MgO)
0.84 Max 5
5 Sodium Oxide (Na2O3) 0.02 Max 1.5
6 Loss on ignition 2.35 Max 5
Source: (Environmental Stress: Indication, Mitigation and Eco-conservation,
Yunus et al.)

29. Physical properties of fly ash from Panki
Thermal Power Station
Sr. No. Physical Properties Experimental Values
1 Colour Light Grey
2 Class F
3
Particles retained on 45 micron IS
sieve in %
31

30. Economic Feasibility
a) Cost of Materials
• Cost of cement per bag = Rs. 450 per bag
(Ultra Teach grade 43) = Rs 9.4 per kg
• Cost of sand per m3 = 2200
• Cost of hypo sludge per kg = Rs. 0.35
• Cost of fly ash per kg = Rs. 0.12
• Cost of coarse aggregates in per m3 = 1800

31. Cost of concreting for Conventional M20
mix in Concrete/m3
Material
Quantity in [kg
or m3]
Cost in [Rs]
Cost of material
in [Rs]
cement 260 kg 9.40 2444/-
hypo sludge - - -
fly ash - - -
sand 0.36 m3 2200 792/-
coarse aggregate 0.54 m3 1800 972/-
Total 4208/-

32. Cost of concreting for 10% Partially
Replacing cement in Concrete/m3
Material
Quantity in [kg
or m3]
Cost in [Rs]
Cost of
material in
[Rs]
cement 234 kg 9.40 2200/-
hypo sludge 5% 13 kg 0.35 4.55/-
fly ash 5% 13 kg 0.12 1.56/-
sand 0.36 m3 2200 792/-
coarse aggregate 0.54 m3 1800 972/-
Total 3970.11/-

33. Cost of concreting for 20% Partially
Replacing cement in Concrete/m3
Material
Quantity in [kg
or m3]
Cost in [Rs]
Cost of material
in [Rs]
cement 208 kg 9.40 1955.2/-
hypo sludge 10% 26 kg 0.35 9.1/-
fly ash 10% 26 kg 0.12 3.12/-
sand 0.36 m3 2200 792/-
coarse aggregate 0.54 m3 1800 972/-
Total 3731.42/-

34. Cost of concreting for 30% Partially
Replacing cement in Concrete/m3
Material
Quantity in [kg
or m3]
Cost in [Rs]
Cost of material
in [Rs]
cement 182 kg 9.40 1710.8/-
hypo sludge 15% 39 kg 0.35 13.65/-
fly ash 15% 39 kg 0.12 4.68/-
Sand 0.36 m3 2200 792/-
coarse aggregate 0.54 m3 1800 972/-
Total 3493.13/-

35. Cost of concreting for 40% Partially
Replacing cement in Concrete/m3
Material
Quantity in [kg
or m3]
Cost in [Rs]
Cost of material
in [Rs]
Cement 156 kg 9.40 1466.4/-
hypo sludge 20% 52 kg 0.35 18.2/-
fly ash 20% 52 kg 0.12 6.24/-
Sand 0.36 m3 2200 792/-
coarse aggregate 0.54 m3 1800 972/-
Total 3254.84/-

36. 4208
3970.11
3731.42
3493.13
3254.84
0
500
1000
1500
2000
2500
3000
3500
4000
4500
0% replacement 10% replacement 20% replacement 30% replacement 40% replacement
Cost of concreting for 1 cubic metre wrt. to percentage replacement.
cost of concreting for 1 cubic metre
Graph showing comparison of cost with percentage replacement of
cement.

37. Reviewed results from other researchers
Strength characteristics of concrete mix by replacing cement with Fly
ash.
S.No. Title Author Test result
1
Effects of fly ash
on compressive
strength of M20
mix design
concrete.
Shantmurtiupad
hyaya,
Dr.R.Chandake
The addition of fly ash up to 10% there is
negligible change in the strength of concrete, and
up to 30% replacement, a fly ash block has shown
very low compressive strength in comparison to
concrete containing no fly ash.
2
Assessment of
concrete strength
using fly ash and
rice husk ash.
SatishD.Kene,
PravinV.Domke,
SandeshD.Desh
mukh, R.S.
Deotale.
The compressive strength increases with the
increases % of fly ash and rice husk ash up to
replacement (21% fly ash and 9% rice husk ash)
in concrete.
3
Utilization of fly
ash as cement
replacement to
produce high-
performance
concrete.
J.A. Peter, M
Neelameyam,
J.K. Dattatreya,
N.P. Rajamane,
S.
Gopalakrishnan.
The strength at seven days of the fly ash based
HPC has marginally decreased whereas the
strength at 28 days was observed to be greater
than that of the reference HPC mix as compared
with 90 days it is also greater than seven days, 28
days and reference HPC mix.

38. S.No. Title Author Test result
4
A research paper
on partial
replacement in
M30 concrete
from silica fume
and fly ash.
Alok Kumar,
Shobha Jain,
Shobha Gupta,
Sonaram,
Sanjay
Merawat.
the tensile strength 2.573 N/MM2 was which
is obtained at replacement level of 7.5% by
weight of silica fume (SF) and replacement
level of 20% by weight of fly ash with
cement.
5
Use of high
volumes of class
C and class F fly
ash in concrete
Tarun R. Naik,
Bruce W.
Ramme, John
H. Tews.
Tensile strength was lower at all age for high
fly ash content concrete mixture that is
expected when compared with higher %
Portland cement content mixture
6
Utilization of fly
ash as cement
replacement to
produce high-
performance
concrete.
J.A. Peter, M
Neelameyam,
J.K.
Dattatreya,
N.P.
Rajamane, S.
Gopalakrishna
n.
The tensile and flexural strength of mixes
(except C5) with fly ash always a higher
tensile strength than the control mix without
fly ash.

39. S.No. Title Author Test result
1
Advancement in
Physical
Properties of
Hypo Sludge
Concrete
Ram Kishore
Manchiryal
and Kiran
Kumar Poloju
30% replacement with hypo sludge was
found to be optimum
2
An experimental
study on use of
hypo sludge in
cement
Concrete
Mehtab Alam
and Vebhav
Berera
20% replacement by hyposludge in cement
provides strength equal to traditional
concrete and 10% replacement provides
about 11% higher strength than normal
concrete.
3
Effect of hypo
sludge as partial
replacement
With cement in
mortar
Rushabh A.
Shah and
Jayeshkumar
Pitroda
results indicated that the incorporation of a
Hypo
Sludge in mixed cement was not feasible for
making masonry mortars
Strength characteristics of concrete mix by replacing cement
with hypo sludge.

40. S.No. Title Author Test result
4
An Experimental
Investigation of
Partial Replacement
of Cement by
Industrial Waste
(Hypo Sludge)
R.Balamurug
an and
R.Karthickraj
a
For the 10% replacement of cement the
compressive strength was increased by
10%.
5
Hypo Sludge – An
Innovative and
Sustainable
Approach
Manmeet
Kaur, Jaspal
Singh &
Manpreet
Kaur
Replacement of 10% in cement with hypo
sludge was found to be optimum. It was
recorded as 3.79 N/mm2 at 28 days
6
Experimental Study
on Partial
Replacement of
Cement by
Hyposludge in
Concrete
Priya R. and
Hepzibah A.
The max. tensile strength was gained for
15% replacement of cement for 7 days
and 28 days. Decrease in strength was
observed in replacement from 20% to
30%.

41. S.No. Title Author Test result
1
Gainful Utilization
of Fly Ash and Hypo
Sludge in Concrete
Jayeshkumar
Pitroda
For M40 strength concrete 10%
replacement with the combination of fly
ash and hypo sludge gives the design
strength at 28 days.
Strength characteristics of concrete mix by replacing cement with
hypo sludge and fly ash.

42. Conclusions
• Better measure towards the sustainable environment can be undertaken by
effective utilization of hypo sludge and fly ash in concrete mix.
• Due to large quantity of disposal of by-products from the paper industries
and thermal power the bad effects on the environment be minimized through
this research.
• According to the papers reviewed up to 10% of hybrid mix concrete attains
the maximum compressive strength and splitting tensile strength.
• The cost analysis indicates that with incorporation of hypo sludge and fly
ash decreases the cost of concrete, but at the same time strength also
decreases.
• This innovative material is economically feasible for the structures where
strength is not considerable factor.

43. Scope for future work.
• The study of hybrid mix can be extended for
various concrete grades like M25, M30, M35 etc.
• The proportions of the replacement can be
changed to obtain the most optimum strength.
• Different industrial wastes can be used instead of
fly-ash and hypo sludge whose properties are
similar to them can be used as a replacement.

44. References
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building construction industry. Res Conserve Recycle 32: 105-13
• Alam M and Berera V (2015), “An experimental study on use of hypo
sludge in cement concrete. Int J Progr In Civil Eng 2(1): 1-23.
• Alokkumar, Shubhamjain, Shubhamgupta, Sonaram, Sanjay Merawat. “A
research paper on partial replacement in M30 concrete from silica fume and
fly ash”. SSRG International journal of civil engineering (SSRG-IJCE).
Volume-3, issue-5, May 2016.
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concrete mix design, Bureau of Indian Standard, NewDelhi-2004.

45. • BIS: 383-1970 (Reaffirmed 1997): Specification for Coarse and Fine Aggregates
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Standard, New Delhi-2000.
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of Indian Standard, New Delhi-2004.
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Cement, Bureau of Indian Standard, New Delhi-2005.
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46. • Kaur M et al.”Hypo sludge-An Innovation and sustainable approach (IJCSEIERD)”
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48. THANK YOU