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MANUFACTURING PROCESS-II UNIT-2 LATHE MACHINE
MANUFACTURING PROCESS-II UNIT-2 LATHE MACHINE
IRJET- Performance Study on Various Industrial Waste Utilization in Concrete
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: Issue www.irjet.net p-ISSN: 2395-0072 PERFORMANCE STUDY ON VARIOUS INDUSTRIAL WASTE UTILIZATION IN CONCRETE Mr.K.Srinivasan 1 , J.Adlinkirubha 2 , R.Divyabharathi 3 , L.Hemalatha 4 , R.Kiruthika 5 1. Assistant Professor, Department of Civil Engineering, Gnanamani college of Technology, Tamilnadu, India. 2,3,4,5 UG final year Student, Department of Civil Engineering, Gnanamani college of Technology, Tamilnadu, India. ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - With the rapid growth in population, it becomes difficult to control the huge amount of residual materials generates from enormous industrial activities does not have useful disposal till now it leads to generate a pollution. Concrete is most widely used building material in world, and about 12.6 billion tons of natural resources are used to make the concrete. Hence to control environmental pollution waste materials are replaced in concrete. This project evolves on experimentally investigation of waste materials with following percentages. The tire waste crumbled and it’s immersed in epoxy resin were partially replaced to the place of coarse aggregates by 4% and 6%. Steel slag is replaced partially as fine aggregates by 15% and 30%.Copper slag is replaced partially in place of fine aggregate by 40% and Tio2 is replaced as cement by 10%. M30 grade of concrete was designed and tested. The strength of concrete with partial replacement of waste materials at various percentages had been investigated and compared with ordinary conventional concrete. Experimental investigations like workability, Compressive strength test, Split tensile strength test, Flexural strength test for different concrete mixes with different percentages of copper slag, steel slag, tire waste, and Titanium oxide after 7, 14 and 28 days curing period has done. Keyword: Copper slag1, Steel slag2, Tire waste3, Titanium oxide4, compressive strength5, flexural strength6, split tensile strength7. 1. INTRODUCTION 1.1 General In our world, the environmental pollution is one of the major problems in nowadays mainly the pollution such as land pollution due to waste are dumped in the land, air pollution due to the burning of waste, water pollution due to without any treatment the waste to dispose of in water. Recent year’s population is much more so vehicle level will increase in our country. 1.1.1 Tire Nearly 200 million tires produced in India per year. Only 60% of the tire could be replaced in the tire industry also and the remaining 40% of the tire doesn’t know how it can be disposed of these tires have to utilize in concrete. When rubber was used instead of aggregate in concrete it shows less compressive strength (Nouman Khattak, 2015) and with added tire percent increase the compressive strength of concrete decreases (Partha sika, 2016). 1.1.2 Copper Slag The Tuticorin plant of Sterlite has a capacity of 4 million tons per annum for every tone of copper metal produced, around 1.8-2.2 tons of slag is generated. The molten temperature of copper slag is above 1573k. The raw materials of copper concentrate which mainly consists of iron in copper slag are 30-45%, and sulfur. During the operation, iron is removed as iron silicate, which is commonly known as copper slag (Ferro sand). The disposal of copper slag is a major issue in recent years so that it can be used as fine aggregates in concrete. Copper slag is also used as a building industry for use in a filling material, it possess little threat to the environment. The utilization of copper slag as a partial replacement of sand, it can be applied for all construction activities (Prachi Gupta 2012). In a review (Lakshmi Narayani P 2014) the ultrasonic pulse velocity test indicates the excellent quantity of concrete at a 40% replacement level of fine aggregates. 1.1.3 Steel Slag Steel Slag is the glass-like by-product left over after the desired metal has been separated from its raw ore. There are many grades of steel that can be produced, and each grade of steel slag the properties can change. The steel slag consists of many impurities such as carbon as gaseous carbon monoxide, and environment during disposal of slag. So it can be used as a fine aggregate. It has been observed that 36%replacement of fine aggregates with steel slag to be good in compression as well as tension (G. Maheswaran 2015). Due to this replacement, can reduce the extraction of river sand and manufactured sand also. The optimum percentage of steel slag is the © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: Issue www.irjet.net p-ISSN: 2395-0072 replacement of fine aggregates is 40% and for coarse aggregates is 30% beyond which the compressive strength decreases on further replacement ( V. Subathra Devi 2014 ). 1.1.4 Titanium In this research work, titanium is used to replace cement by a certain percentage. Titanium is a light meta composed of 60% iron, 4.5g/cc. Recently, titanium is being used as many good, such as building materials, medical applications, and accessories. This amount to about 30% of domestic consumption. In 2017, world titanium metal production was a mere 170,000 tons (according to the US geological survey). 1.2 OBJECTIVES 1. To study the feasibility on usage of waste materials in concrete. 2. To preserve the natural properties. 3. By using waste materials in concrete, it an reduce the pollution such as land, water and air and minimize the environmental degradation in our country. 4. To study experimentally the compressive strength, flexural test and split tensile strength of concrete elements with tire, copper slag, steel slag, titanium. 1.3 SCOPE AND SIGNIFICANCE In order to decrease the cost of construction and make a building free from environmental effluence, the waste materials are to be used in the construction. The materials are added with concrete to attain a required strength. 1. Durable and corrosion resistant. 2. Good isolation for cold, heat and sound saving energy and reducing noise pollution. 3. It is efficient and has a longer life. 4. Keep free 5. Hygienic and fresh. 1.4 METHODOLOGY Being the major component of structure, many researchers have been done on concrete to improve its properties in every possible manner to develop a sustainable concrete mass. The concrete can be strengthened only by the replacements of its ingredients by better ones. Waste materials used in concrete which gives environment friendly at the same time more suitable to construction. In this aspect lot of researches have been done on using the tire, copper slag and steel slag as aggregates in concrete and finding the strength by using compressive testing machine and universal testing machine then compared the strength in control mixes. 2. MATERIALS PROPERTIES AND MIX DESIGN 2.1 Cement The emission of CO2 is reduced through using blended cement is estimated to be at least 5% of total CO2 emission form of cement making. Portland pozzolana cement (PPC) confirming to IS 1489-1 (1991) was used for the project work. The properties of cement are given in the table as 2.1. Table 2.1 Chemical properties of PPC Chemical Percentage composition Silica (SiO2) 29.07 Alumina(Al2 O3) 13.89 Iron oxide(Fe2O3) 3.10 Magnesium 1.11 Oxide (MgO) Potassium 0.46 Oxide(K2 O) 2.3 M sand Due to the scarcity of river sand, the manufactured sand is used as fine aggregates in concrete. The maximum size is 4.75mm and it was confirmed to Zone II as per IS383- 1987. The specific gravity and water absorption of M sand are. The unit weight of M sand was 1580 Kg/m3. Sieve analysis was described as a table 2.2 Fig 2.1 M Sand 2.4 Coarse aggregate Crushed granite aggregate with a maximum nominal size of 20mm and it was confirming to IS 3831987 was used as coarse aggregate in concrete. The specific gravity, fineness modulus and water absorption of coarse aggregate are referred to the table as. The bulk density of crushed granite is 1755kg/m3 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 2
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: Issue www.irjet.net p-ISSN: 2395-0072 2.5 Copper Slag Copper slag is partially replaced as fine aggregates used in concrete mixes. It was collected from Sterlite industry at Tuticorin. It is the byproduct of copper extraction by smelting. The chemical composition of the slag varies with the type of treatment process. A typical copper slag composition from the smelter. Fig 2.2 Copper Slags 2.6 Steel Slag Steel slag collected from the local steel industry and it was crushed into small pieces for replacement of fine aggregates in concrete mixes. The physical and chemical properties are in the following tables 2.4 Fig 2.3 Steel Slag 2.7 Tire Tire waste was collected from Selvam tire industry near locally available. A tire typically consists of four different kinds of rubber, natural rubber, styrene, butadiene rubber, polybutadiene rubber. The chemical properties of tire include zinc oxide as 37.8%, while 22.3% of ash consisted of silica, lime was 5.7%, the ferric oxide was 7.4%, sulfate ions were 7% of tire ash After collecting the rubber it was cut into a piece of 12mm size by using a knife or wooden cutter. The crumble tire was used in both with and without treatment of epoxy resin. The crumble waste tire is dipped in epoxy resin for 24 hours after it replaces as coarse aggregate in research work. Fig 2.4 Crumbled Tire Fig 2.5 Crumbled Tire with Epoxy Table 2.2 Sieve analysis of M sand Sieve Weight Weight Cumulative size retained of % (mm) % in gm passing By weight % retained 4.75 0 0 0 2.36 0 0 0 600 24.6 25.4 50.85 300 17.2 8.2 16.4 150 6.2 2.0 4 Grading Zone II IS383-1970 (Table 4) 2.8 Titanium It is also known as a transition metal on the periodic table of elements denotes by symbol Ti. Titanium occurs below the earth surface now 12 countries are manufacture in recent years It is lightweight, Silver gray material. It can be replaced as PPC cement. Since titanium has good corrosion resistance. The Specific gravity is 4.5 Fig 2.6 Titanium 3. MIX PROPORTION Various replaceable waste materials and different mix percentage are used to be prepared as concrete with water-cement of 0.4. The specimen is casting by using M30 grade of concrete. The cement content of this mix is 480kg/m3. The cement, fine aggregates, and coarse aggregates are in the ratio of 1:1.44:2.39 as per IS 383- 1970 and IS 4562000 specifications. The various test program is conducted for this research work. The mixture proportions of concrete with specimen were tire, copper slag, steel slag, titanium are mixed. 4. EXPERIMENTAL PROCEDURE In this project, the concrete mixes are prepared by using various materials. The cube specimen is prepared by 150X150X150 mm. The cylinder molds are prepared by using 150X300 mm. Before molding the specimen the workability is to be checked by using the slump cone test in the value of 15mm. Some mix is in SS and CS as fine aggregates and tire are added without treatment and with © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: Issue www.irjet.net p-ISSN: 2395-0072 the treatment of epoxy resin as replace of coarse aggregates. After molding the specimen, these are curing temperature of 20+2ºC which is the specific period of 7, 14, 28 days. Curing has been done the molds are removed and take the dry weight after these specimens are tested by using compression testing and universal testing machine which has a capacity of 2000 KN. In this test results are compared with ordinary conventional concrete. 4.1 TESTING ON FRESH CONCRETE 4.1.1 Slump Test The concrete slump test is an empirical test that measure the workability of fresh concrete. More specifically, it is also used to determined consistency of between individual batches. The test is popular due to the simplicity of apparatus used and simple unfortunately, the simplicity of the test often allows a wide variability in the manner that the test is performed. The slump measured should be recorded in mm of subsidence of the specimen during the test. The slump concrete takes various shapes, and according to the profile of slumped concrete the slump is termed as true slump shear slump or collapse slump. If a shear or collapse slump is achieved a fresh sample should be taken and the test procedure. Unfortunately, the simplicity of the test often allows a wide variability in the manner that the test is performed. The slump measured should be recorded in mm of subsidence of the specimen during the test. The slump concrete takes various shapes, and according to the profile of slumped concrete the slump is termed as true slump shear repeated. A collapse slump is an indication of too wet a mix. Only a true slump is of any use in the test. A collapse slump will generally mean that the mix is too wet or that it is a high workability mix, for which slump test is not appropriates. Very dry mixes; having slump 0-25 mm are used making low workability mixes; having slump 10-40 mm are used for foundations with light reinforced medium workability mixes;50-90 for normal reinforced concrete placed with vibrated high workability concrete >100mm. 4.1.2 Compaction Factor Test The compacting factor test is designed primarily for use in the laboratory but it can also be used in the field. It is more precious and sensitive then the slump test. The compaction factor test gives the behavior of fresh concrete under the action of external force. In this test the compaction achieved through a free fall of concrete determines its workability. It is more accurate than slump test for concrete mixes and value of compaction factor of 0.75 to 0.8 is suggested as per IS 456- 2000. It is not suitable for concrete of very low workability of 0.7 or below. The concrete sample is placed in the upper hopper. Then the hopper is opened. The sample drops into lower hopper filling it to over flowing. The trap door of the lower hopper is then opened and the sample falls into the cylinder. The surplus concrete is removed from the top of the cylinder with the help of a trowel. The outside surface of the cylinder is wiped and cleaned. The cylinder is then weighed and it is recorded as weight of partially compacted concrete. The cylinder is again filled with concrete in layers not exceeding 50mm in thickness. Each layer is fully compacted with tamping rod. The cylinder is again weighed and it recorded as a weight of fully compacted concrete. Compaction factor =Wp/Wf Table 4.1 Fresh concrete test Fresh Concrete Test No of Mix of materials Sets Slump Compaction Flow Factor Mix A Conventional concrete Shear 0.83 Mix B Cement + [FA+SS(15%)] +[CA+T(6%)] Collapse 0.82 Mix C Cement + [FA+SS(15%) + CS(40%)] + [CA+T (4%)] Shear 0.86 Mix D Cement + [FA+SS(30%) + CS(40%)] +[CA+ TE(4%)] Shear 0.85 Mix E [Cement+TiO2(10%)] + [FA+CS(40%)] + [CA+ Shear 0.875 TE (4%)] 4.2 TESTING OF HARDENED CONCRTE Concrete specimens of cube, cylinder, prism is casted for conventional and modifier mix in various percentages of by the weight to the sand, coarse aggregate and cement with the optimum percentage of concrete specimens. The various tests are listed in below tables 4.2.1 Compressive Strength Test Compressive test is the most common test conducted on hardened concrete; partly it is easy test to perform because of most desirable characteristic properties of concrete and qualitatively related to its compressive strength. The compression test is carried out on specimen cubical or cylindrical in shape. Prism is also sometimes used, but it is not common. Compressive strength = (P/A) (N/mm2) Where, P=Applied load (N) A=Area of the specimen (mm2) D=diameter in mm L=length in mm Fig 4.1 Compressive test machine © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4 L=length in mm
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: Issue www.irjet.net p-ISSN: 2395-0072 4.2.2 Split Tensile Strength The split tensile strength of concrete cylinder was determined as per IS 5816-1999. The load shall be applied nominal rate within the range 1.2N/mm2/min to 2.4N/mm2/min. Split tensile strength is = 2P/ 3.14DL (N/mm2) Where, P=load in N L=length in mm D=diameter in mm The tensile strength of concrete is one of the basic and important properties. Split tensile strength test on concrete cylinder is a method to determine the tensile strength of concrete. The concrete is very weak in tension due to its brittle nature and is not expected to resist the direct tension. Table 5.1 Compressive Strength of Cube Compressive strength No. Mix of materials (N/mm2) of Sets 7days 14days 28days Mix A Conventional concrete 21.66 31.66 33.33 Mix B Cement+[FA+SS(15)] + [CA+T (6%)] 19.64 28.71 30.22 Mix C Cement+[FA+SS(15%)+CS (40%)]+[CA+T(4%)] 21.57 31.52 33.18 Mix D Cement + [FA+SS(30%) CS(40%)]+[CA+TE(4%)] 20.22 29.55 31.11 Mix E [Cement+TiO2(10%)] +[FA+CS(40%)]+[CA+TE 35.34 45.94 47.77 (4%)] Fig 4.2 Split Tensile test machine 4.2.3 Flexural Strength This test method is used to determine the modulus of rupture of specimens prepared and cured. The strength determined will vary where there are differences in specimen size, preparation, moisture condition or curing. This test method covers the determination of the flexural strength of concrete specimens by the use of the sample beam with center-point loading. Fig 4.3 Flexural Test machine Flexural Strength = PL/bd2 Where, P=load in N L=length in mm D=diameter in mm 5. RESULTS AND DISCUSSIONS 5.1 Compressive Strength Analysis The compressive strength tested on cube for different materials and percentage for M30 concrete for 7days, 14days and 28days having better result achieved. 5.2 SPLIT TENSILE STRENGTH ANALYSIS The split tensile strength tested on cylinders for different percentage of Copper Slag, Steel Slag, Tire and Titanium for M30 concrete for 7days, 14days and 28days having better result achieved. The below tables shows the split tensile strength of cylinders at different percentage of No. of Split tensile strength Sets Mix of materials 7days 14days 28days Mix A Conventional concrete 2.57 3.76 3.96 Mix B Cement+ [FA+SS(15%)] 2.23 3.22 3.39 + [CA+T (6%)] Mix C Cement+ [FA+SS (15%)+ 2.27 3.33 3.5 CS (40%)] +[CA+T (4%)] Cement+ [FA+SS (30%) 2.28 3.33 3.5 Mix D +CS (40%)] +[CA+ TE (4%)] material mixes. Table 5.2 Split Tensile Strength of Cylinder 5.3 Flexural strength In this method to find the flexural value of prism and taking the results of 7, 14, 28 days after curing the specimen. © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: Issue www.irjet.net p-ISSN: 2395-0072 Table 5.3 Flexural Strength Of Prism NUMBR FLEXURAL OF SETS MIX OF MATERIALS STRENGTH AT 28 DAYS(N/mm2) Mix A Conventional concrete 3 Cement+ [FA+SS (15%)] + Mix B [CA+T (6%)] 2.4 Cement+ [FA+SS (15%) + Mix C CS (40%)] + [CA+T (4%)] 2.9 DISCUSSION Compressive Strength Comparison between Various Mixes At 7 Days, 14 Days & 28 Days 50 47.36 40.6445 40 33.33 33.18 35.34 35 31.66 31.52 31.11 N/ 30.22 29.55 30 m2 25 21.66 20.71 21.57 20.22 7 days m 20 19.64 14 days 15 10 28 days 5 0 CC ST CST CSTE TCTE Fig 5.1 Compressive Strength Analysis 5.2 Split Tensile Strength comparison Between Various Mixes At 7 Days, 14 Days &28 Days (N/ 4.5 3.96 4.1 4 3.7 6 3.39 3.5m 3.5 3.4 53.22 3.33 m2 3 3 2.5 7 ) 2.5 2.2 2.2 7 2 1.5 1 0.5 0 CC ST CSTE TCTE Fig 5.2 Split Tensile Analysis 5.3 Flexural Strength Comparison between Various Mixes At 7 Days, 14 Days & 28 Days N/ 5 3 2.4 2.9 m2 0 m CC ST CST Various Mixes (%) 28 DAYS Fig 5.3 Flexural Strength Analysis 6 SUMMARIES AND CONCLUSION 6.1 General The basic objectives of the study is to prepare a concrete much more stable and durable than the conventional by replacing aggregates both coarse and fine. Mix designs for all the replacements of material have done. The specimens are prepared and tested in the aspect strength calculation and also comparisons done. 6.2 Conclusion The following conclusion is made based on the experimental investigation on compressive strength, Split tensile strength and flexural strength considering the environment aspects also: In Mix E, the titanium as 10% replacement of cement, 40% of copper slag, Tire as 4% with epoxy resin dipped for 24 hours in these proportion the compressive strength and split tensile strength are greater when compared to conventional plain cement concrete. When percentage of tire increases, the strength of concrete decreases gradually so tire can adopt 4% and 6% of coarse aggregate. Copper slag as 40% and steel slag as 15% replace in fine aggregates to attain good compressive strength in concrete The split tensile strength of result as conventional in same as the Mix C so it various waste materials are suitable in construction purposes. The cost is optimum and it’s economical in all different proportion of concrete mixes when compared to ordinary cement concrete. In all mixes of specimen should be more or slightly less equal to the controlled specimen. It must be preserve the degradation of environment .Industrial waste can be effectively used in concrete and thus provide a solution for the disposal problem of the copper slag, steel slag, and tire. It will used to protect the environment and maintains a green country. © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 6
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of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: Issue www.irjet.net p-ISSN: 2395-0072 REFERENCE 1. Ali Nazari, Shadi iahi, Shirin Riahi, “Assesment of the effects of the cement paste composite in presence of Tio2 nanoparticles”. Journal of American Science 6(4). (2010), pp. 43-46. 2. Blessen Skariah Thomas, (2012), M.E thesis entitled “Application of copper slag and discarded rubber tyres in construction”, Submitted to Sreesastha Institute of Engg and Tech, Chennai, India. 3. Brindha D, Nagan S (2010) Utilization of Copper slag as a Partial Replacement of Fine Aggregates in Concrete. International Journal of Earth Sciences and Engineering 3: 579-585. 4. Deborah M.,Erinc Shay Kurt A.,Journal of Human Ecological and Risk Assessment 2002 Vol 8(4) pp681-711. 5. Fedroff, D., Ahmad. S., Savas, B.Z., 1996. Mechanical properties of concrete with ground waste tire rubber. Transportation Research Board, Report No. 1534. 6. IlkerBekirTopcu (1995) “The properties of rubberized concrete”, Cement and concrete Research, Vol.25, No. 2, pp. 304310, 1995. 7. Liuchunlin, Zha Kunpeng, Chen Deng, Possibility of concrete prepared with steel slag as fine and coarse aggregates: A preliminary study, Procedia Engineering 4(2011) 412-416. 8. Maslehuddin S.M., Alfarabri S.M., Ibrahim M., Barry M., Construction and Building Materials 2003 Vol 117 pp 105-112. 9. Mavroulidou, M. and Figueiredo,J., (2010), Paper entitled “Discarded tire rubber as concrete aggregate: A possible outlet for used tires”, Global NEST Journal. 10. N. N. Eldin and A. B. Senouci, Rubber- Tire Particles as Coarse aggregate (2015). 11. Nivason, Chingangbam, (2010), M.tech. Thesis entitled “Use of Copper tailing as partial replacement of sand in concrete”, Submitted to Malaviya National Institution of Technology, Jaipur, India. 12. Piti Sukontasukkul (2008) “Use of crumb rubber to improve thermal and sound properties of pre- cast concrete panel”, Construction and building materials 23 (2008)1084-1992. 13. Reddy SS, Kumar KM(2013) Utilization of Copper slag as a partial Replacement of Fine Aggregates in Concrete. International Journal of Mechanical Engineering and Computer Applications, 1:140-144. 14. Shadi Riahi and Ali Nazari, “The effects of Tio2 nanoparticles on properties of binary blended concrete”. Journal of Composite Mterials 45(2). (2010), pp. 1181-1188. 15. Weiwu, Weide Zhang, Guowei Ma, Optimum content of copper slag as a fine aggregate in high strength concrete. Material and design 31(2010) 2878-2883. © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7
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