This presentation is pertaining to Chittorgarh area of Rajasthan. There are are around 10 Limestone ( Cement Grade) mining leases currently working, with huge waste dumps of low grade limestone not fit for cement manufacture with current technology. This waste can be used for crushing into contraction aggregates and replace river sand with crushed rock fines.
Effect of Waste Foundry Sand on Durability Properties of ConcreteIEI GSC
Presentation on Effect of Waste Foundry Sand on Durability Properties of Concrete by Tirth Doshi guided by Dr Urmil Dave & Prof Tejas Joshi at #33NCCE 33rd National Convention of Civil Engineers at #IEIGSC
Effect of Crusher Dust, Stone and Tire Wastes as Granular Pavement Materialsinventionjournals
The scarcity of soil which suits for construction activities by fulfilling geotechnical characteristics is forcing the pavement engineers to look for alternative materials for construction activity. On the other hand due to the rapid industrialization there is sharp increase in the number of crushing units in so many states and the country as well. There is also a sharp increase the quantum of another industrial waste namely discarded tires due to increase in the number of vehicles year after year. Hence an attempt is made in this paper to suggest a viable solution for the above mentioned industrial wastes to use the same in an optimum manner in order to help in reducing the excessive usage of conventional soil.
Effect of Waste Foundry Sand on Durability Properties of ConcreteIEI GSC
Presentation on Effect of Waste Foundry Sand on Durability Properties of Concrete by Tirth Doshi guided by Dr Urmil Dave & Prof Tejas Joshi at #33NCCE 33rd National Convention of Civil Engineers at #IEIGSC
Effect of Crusher Dust, Stone and Tire Wastes as Granular Pavement Materialsinventionjournals
The scarcity of soil which suits for construction activities by fulfilling geotechnical characteristics is forcing the pavement engineers to look for alternative materials for construction activity. On the other hand due to the rapid industrialization there is sharp increase in the number of crushing units in so many states and the country as well. There is also a sharp increase the quantum of another industrial waste namely discarded tires due to increase in the number of vehicles year after year. Hence an attempt is made in this paper to suggest a viable solution for the above mentioned industrial wastes to use the same in an optimum manner in order to help in reducing the excessive usage of conventional soil.
Analytical and Experimental Studieson Fracture Behaviour of Foundry Sand Conc...IJERA Editor
Concrete is a widely used as vital material in the construction world. We can do partial substitution of industrial
waste such as foundry sand like material in sand. Foundry sand is not only the economical material also
improves the properties of the concrete. Foundry sand has emerged as construction material in its own right.
This type of concrete normally contains around (30%, 40%) by mass of total sand materials. It improves the
workability, minimizes cracking due to thermal and drying shrinkage, and enhances durability to reinforcement
corrosion, sulphateattack, and alkali-silica expansion. Fracture mechanics is the field of mechanics concerned
with the study of the formation of cracks in materials. It uses methods of analytical Solid mechanics to calculate
the driving force on a crack and those of experimental Solid mechanics to characterize the material's resistance
to fracture. J-integral and critical stress intensity factor is the fracture parameter. The fracture parameters
calculated in our study are stress intensity factor, Critical j-integral. Three point bending test is used to find the
fracture parameter. The study is carried out on beams of grade M20 with 0%, 30%, & 40% foundry sand. The
test is conducted for normal beams and pre-cracked beams of having a notch to depth ratio (A/W) of 0.2. This
study concludes that the critical j-integral and stress intensity factors increases by comparing the 0%, 30%, 40%
foundry sand concrete.
Experimental Study on Use of Waste Marble Dust in ConcreteIJERA Editor
Concrete is the most important component used in the construction industry throughout the world, where the
fine aggregate is generally natural sand. The use of sand in construction activities results in the excessive
mining. Due to excessive mining, natural resources are getting exhausted, results in increase in scour depth and
sometimes flood possibility. Thus, it is becoming inevitable to use alternative material in concrete.Marble is one
of the important materials used in the construction industry. Marble powder is produced from processing plants
during the sawing and polishing of marble blocks and about 20 - 25% of the processed marble is turn into
powder form. Disposal of the marble powder material from the marble industry is one of the environmental
problems worldwide today.The present study is aimed at utilizing Waste marble powder construction industry
itself as fine aggregate in concrete, replacing natural sand. The replacement is done partially and fully in the
proportion 0%, 25%, 50% and 100% and its effect on properties of concrete were investigated.
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This presentation is based on quality control lab at Road construction .
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Utilization of mining waste as contruction aggregates -An overview
1. Utilization of Mining Waste as Construction
Aggregates – An Overview
Mrinmoy Chakraborty
Geologist - M.Sc (Applied Geology)
21/04/20181
2. Table of ContentsTable of Contents
1. Introduction
2 Geological rock types used in construction aggregates2. Geological rock types used in construction aggregates
3. Details of MiningWaste generated from Chittorgarh Area
4. Statutory constraints for utilization of mining wastey g
5. Technological considerations for preparation of
manufactured sand
6. Conclusion
21/04/20182
3. Introduction (1/2)
Construction Aggregates ( IS 383 : 1970)
Coarse Aggregates > 4 75mm (10mm 20mm 40mm GSB)
( / )
Coarse Aggregates > 4.75mm (10mm, 20mm, 40mm, GSB)
Fine Aggregates < 4.75mm ( M sand, Stone dust, Natural Sand)
Requirement of Alternative of Natural Sand around 50 -q
100 million tonnes, in state of Rajasthan
Study Area : Chittorgarh District
Mining waste from Cement grade Limestone mines in
Chittorgarh area
21/04/20183
5. Geological rock types used in construction aggregates
IGNEOUS ROCKS
Granite
Granophyre Granite Group
Granodiorite
Diorite
Syenite
Gabbro
Norite
Anorthosite
Gabbro Group
Peridotite
Pyroxenite
Epidiorite
Alpite Alphite Group Quartz reef
Porphyry
Dolerite Dolerite Group Lamprophyre
Rhyolite
Trachyte
Rhyolite Group Felsite
Pumicite
Andesite Basalt Group Basaltes te Basalt Group asa t
SEDIMENTARY ROCKS
Sandstone
Quartzite
Sandstone Group
Arkose
Graywacke
GritGrit
Limestone Limestone Group Dolomite
METAMORPHIC ROCKS
Granite gneiss
Composite gneiss
Granulite and Gneiss Groups Amphibolite
Granulitep g
Slate Schist Group Phyllite
Schist
Marble Marble Group Crystalline Limestone
6. Geology of RajasthanGeology of Rajasthan
AGE FORMATIONS
Recent to sub- Alluvium & Soil
recent
Pliestocene Laterite
Upper
cretaceous
Deccan trap
Vindhyan
Super Group
Kaimur
Group
Kaimur Sandstone
Kh i S k t Sh lKhorip
Group
Suket Shales,
Nimbhera
Limestone, Bari
Shales
21/04/20186
7. Map showing - Mining Leases in Chittorgarh Area
21/04/20187
8. Details of Mining waste generated from Chittorgarh Area,
Rajasthan, IndiaRajasthan, India
Sl No Lessee Name of the Mines
Reserves in Million tonnes as on
31.03.2016
Production 2015-16 ( Mill Tons)
Strippin
g
Waste
%
Total
( RSl No Lessee Name of the Mines
Reserves
Additional
Resource
( Reserves
+
Resources
)
ROM Waste
Sub
Grade
Total Ratio
1 Ultra Tech Cement Ltd Aditya Limestone Mines - - - 8 51 3 63 - 12 14 1:0 21 30%1 Ultra Tech Cement Ltd Aditya Limestone Mines 8.51 3.63 12.14 1:0.21 30%
2 JK Cement Works Ahirpura & Muraliya 23.78 32.82 56.60 0.88 0.07 - 0.95 1:1005 7%
3 JK Cement Works
Karunda Limestone
Mines
106.99 50.02 157.01 1.45 0.02 0.14 1.61 1:0.014 1%
4 JK Cement Works
MaliaKhera Limestone
105 60 23 57 129 17 1 39 0 02 0 05 1 46 1:0 008 1%4 JK Cement Works
Mines
105.60 23.57 129.17 1.39 0.02 0.05 1.46 1:0.008 1%
5 JK Cement Works
Mangrol Limestone
Mines
32.26 7.05 39.31 0.74 0.00 - 0.74 - -
6 JK Cement Works
Mangrol-Tilakhera
Limestone Mines
16.06 27.83 43.89 1.05 0.00 - 1.05 - -
7 Wonder Cement Ltd
Bhatkorti Limestone
Mines
487.65 0.00 487.65 4.10 0.06 - 4.16 1:0.033 1%
8
Nuvoco Vistas Corp
Ltd
Arniya Joshi Limestone
Mines
68.40 45.57 113.97 0.60 0.00 - 0.60 - -
9
Nuvoco Vistas Corp Sitaram Ji Ka Khera
82 05 33 12 115 17 1 53 0 28 - 1 81 - 15%
21/04/2018
9
Ltd Limestone Mines
82.05 33.12 115.17 1.53 0.28 1.81 15%
10 Birla Corporation Ltd Birla Cement Works 97.15 81.60 178.75 2.57 0.07 - 2.64 - -
GRAND TOTAL 1,019.94 301.58 1,321.52 22.83 4.15 0.19 27.17
*Source of data Indian Bureau of Mines- Mineral Environment & Mineral Conservation Week Magazine 2016
8
9. Statutory constraints for utilization of mining waste
IBM notification No. M-11012/1/2009 – CCOM (34%
CaO as minimum limit and 4% MgO) -Central India andCaO as minimum limit and 4% MgO) Central India and
States of Rajasthan & Gujarat
Excavation of limestone with CaO between 34 – 39%
results in generation of large quantity of limestone which
is not suitable for cement manufacturing.The details of
the various impacts are listed below:the various impacts are listed below:
Increase in mining cost
Environmental problemsp
Land degradation due to dumping and stacking within Mining
lease.
21/04/20189
10. Technological considerations for preparation of
manufactured sandmanufactured sand
General Preferred specification of Crushing & Screening is as follows:
1 Jaw Crusher + Cone Crusher + Screen = 10mm 20mm 40 mm Stone dust ( Two1. Jaw Crusher + Cone Crusher + Screen 10mm, 20mm. 40 mm , Stone dust ( Two
Stage Crusher)
2. Jaw Crusher + Cone Crusher + Cone Crusher + Screen = 10mm, 20mm, 40mm, M-
Sand ( Three Stage Crusher)
3. Jaw Crusher + Cone Crusher +VSI + Screen = 10mm, 20mm, 40mm, M-Sand ( ThreeJ (
Stage Crusher)
Generally, by using suitable configuration of stone crusher produces around 60-
65% of Coarse aggregates (+4.75mm IS sieve) around 40-35% of crushed material
is screened out as Fine aggregates (-4.75mm IS sieve).There are options of even
modifying your existing crushers can result in production of manufactured sand.
Tests for Aggregates : CrushingValue AbrasiveValue Compressive strength Tests for Aggregates : CrushingValue,AbrasiveValue, Compressive strength,
Elongation Index, Flakiness Index, Soundness , Fineness Modulus etc from any
NABL approved laboratory/ NCCBM Faridabad/Shriram Institute Delhi
21/04/201810
11. Technological considerations for preparation of
manufactured sand – Sieve Analysis ( M Sand)manufactured sand Sieve Analysis ( M Sand)
SIEVE ANALYSIS ( FINE AGGREGATE) Zone -1
Limit as per
SIEVE ANALYSIS ( FINE AGGREGATE) Zone -2
Li it IS
Weight
retained
%
Retained
Cum %
Retained
Limit as per
IS 383 Zone-1
IS Sieve Size
(mm)
%
Passing
Lower
Limit
Upper
Limit
Weight
retained
%
Retained
Cum %
Retained
Limit as per IS
383 Zone-2
IS Sieve Size
(mm)
%
Passing
Lower
Limit
Upper
Limit
10 0 0 0 100 100 100
4.75 58 58 5.66 94.34 90 100
2 36 300 358 34 93 65 07 60 95
( ) ass g t t
10 0 0 0 100 100 100
4.75 58 58 5.66 94.34 90 100
2.36 300 358 34.93 65.07 60 95
1.18 251 609 59.41 40.59 30 70
0.600 74 683 66.63 33.37 15 34
0 300 76 759 74 05 25 95 5 20
2.36 245 303 29.56 70.44 75 100
1.18 330 633 61.76 38.24 55 90
0.600 50 683 66.63 33.37 35 59
0.300 76 759 74.05 25.95 5 20
0.150 80 839 81.85 18.15 0 20
Pan 186
1025 100.00 0.00
0.300 76 759 74.05 25.95 8 30
0.150 80 839 81.85 18.15 0 20
Pan 186
1025 100.00 0.00
Total = 1025.00 FM 3.23
Pan 186
Total = 1025.00 FM 3.20
21/04/201811
12. Conclusion
In near future, Indian Bureau of Mines may consider to increase the
threshold value from CaO 34% to 38%.
Based on production data of FY 2015 16 15% waste is generated Based on production data of FY 2015-16, 15% waste is generated,
even if we consider an average of 10% waste from existing limestone
mining leases, we have around more than 100 million tonnes of
limestone waste is expected which can be used as an alternative ofp
natural sand.
Mining waste resources from cement grade limestone mines can be
utilized for production construction aggregates.
C f S f Chemical analysis of M-Sand from Limestone
SiO2 Al2O3 Fe2O3 CaO MgO LOI
28.00 3.50 1.9 33.50 1.4 30.2
We can also consider various other mining wastes generated from
Dolomite, Limestone (All Grades), Granite, Marble Chips, Silica Sand
with quartz etc and various other minerals and rock types suitable
for manufacturing of sand from crushed stone
21/04/2018
for manufacturing of sand from crushed stone.
12
13. Acknowledgements & References
ACKNOWLEDGEMENTS
I would like to acknowledge Shri Madhu Sudan Palliwal ADM – Dept Mines & I would like to acknowledge Shri Madhu Sudan Palliwal ,ADM – Dept Mines &
Geology, Udaipur for providing me an opportunity present the paper in the forum
I would also like to acknowledge special thanks to Shri Raghavendrarao Jahagirdar,
Vi P id t (Pl t M ) d Sh i S th B j DGM Mi f ChittVice President (Plant Manager) and Shri Somnath Banerjee, DGM Mines of Chittor
Cement Plant (NuvocoVistas Corp Ltd) for their encouragement and support.
REFERENCES
[1].Indian Standard,“Specification for Coarse and Fine Aggregates from Natural
Sources to Concrete,” Bureau of Indian Standards, IS 383-1970 (Reaffirmed 2002),
Ninth Reprint, Sep. 1993.
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14. “Strong Forts are build using rocks and the crushed
rocks are equally stronger “
THANK YOU
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