OPTIMUM UTILIZATION OF QUARRY DUST AS PARTIAL...

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


Quarry Dust


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)


Flexural Strength (70% Quarry Dust)


Tensile Split Strength (0% Quarry Dust)


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


92

F(C) Compressive Strength Test Results for Concrete


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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