Hypo Sludge Concrete
Hypo Sludge Concrete
Hypo Sludge Concrete
Cement manufacturing industry is one of the main contributors of greenhouse gases like carbon dioxide. The
use of cement also makes concrete costlier. Due to these reasons, the concept of alternative binders which
can partially replace cement in concrete gains importance. Hypo sludge is an example of alternative binder.
It is the preliminary waste generated from the paper producing industry. It also helps in controlling serious
environmental pollution caused due to use of paper pulp in landfill disposal. Waste paper pulp, in the range
of 5% to 50% by weight for M20 and M30 mixes, can replace cement.
By using adequate amount of hypo sludge and waste, concrete mixtures were produced and compared with
conventional concrete in terms of slump and strengths by doing tests in both fresh and hardened concrete. As
a result, it was seen that slump, compressive strength, splitting tensile strength and flexural strength
increased upto 10% addition of waste paper pulp and further increase in waste paper pulp, decreases
strengths gradually. Thus the use of waste paper pulp in concrete can save the pulp and paper industry
disposal costs and produce a greener concrete for construction.
Partial replacement of cement in concrete by hypo sludge
1. INTRODUCTION
Tremendous amount of waste are being generated every year from the paper mill industries and are being
dumped at nearby places creating serious problems. Various kinds of wastes are produced from different
industries such as mining wastes, biomedical wastes, paper industry wastes, coal ash from thermal power
plants, iron manufacturing industry produce blast furnace slag, lignin which is a constituent of wood is the
waste produced from wood based industry, even the food industries produces different types of wastes too,
etc. Some companies burn their sludge in incinerators, contributing to serious air pollution problems.
Cement manufacturing industry is one of the main industries contributing to the greenhouse gases like
carbon dioxide. To produce 1 tons of Ordinary Portland Cement, manufacturers use earth resources like
limestone, etc and during manufacturing of 1 ton of Ordinary Portland Cement an equal amount of carbon
dioxide is released into the atmosphere which is harmful to the environment.
One solution to reduce the disposal and pollution problems arising from these industrial wastes is to develop
profitable building materials from them. To save energy and to earn carbon credit is very much essential for
the betterment of mankind, so the disposal of waste should now be done in smarter ways. The waste instead
of disposing in environment which again is hazardous, we should use them where they can be used as a raw
material. One such waste produced from the paper mill industries is the paper sludge ash also known as the
hypo sludge ash, which can be used as a partial replacement of cement in concrete.
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Partial replacement of cement in concrete by hypo sludge
While producing paper the various wastes come out from the various processes in paper industries. Some of
the major problems encountered due to this waste are as follows:
Since bulk of wastes is being disposed in wet state, arrangements have to made for extraction and
supply of these wastes in dry state, which involves lot of expenditure.
Transportation of waste in dry form in open wagons results in huge transit losses.
Limitation in distance over which the wastes can be economically transported.
Variation in the quality of wastes is one of the major problems related to its bulk utilization.
Primary waste named as hypo sludge, which contains due low calcium and maximum calcium chloride and
minimum amount of silica. Hypo sludge behaves like cement because of silica and magnesium properties.
This silica and magnesium improves the setting of the concrete. Cement production industries emit
greenhouse gases in the atmosphere. For producing 4 million tons of cement, 1 million ton of greenhouse
gases are emitted. To eliminate the ozone layer depletion, production of cement should be reduced. For this,
the hypo sludge is used as partial replacement of cement in the concrete. By utilizing this waste the strength
of concrete is maintained up to a limit and also cost reduction is achieved.
LIME 62 46.2
SILICA 22 9
ALUMINA 5 3.6
MAGNESIUM 1 3.33
CALCIUM SULPHATE 4 4.05
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Partial replacement of cement in concrete by hypo sludge
The cement has been replaced by waste paper sludge accordingly in the range of 5% to 20% and also in
some cases up to 40% by weight. Paper sludge behaves like cement because of silica and magnesium
properties which improves the setting of the concrete. By using adequate amount of the waste paper pulp and
water, concrete mixtures were produced and compared in terms of slump and strength with the conventional
concrete. The slump decreased when a higher amount of paper pulp content was included. The received pulp
exhibited a high water-absorption capability. Consequently, when a higher amount of paper pulp was
included in the mixture, it required more water to achieve a given slump. The slump increased up to 5%
replacement of cement and above 5%, the slump decreased as the paper pulp content in the concrete
mixtures was increased.
The workability of concrete containing paper-mill residual was improved by the addition of excessive water
instead of admixtures as they have to achieve economy. Several factors could lead to adverse effects on the
workability of paper pulp concrete. The amount of paper pulp would be the main reasons for the reduction of
concrete workability. The compressive strength developed of paper-mill residual concrete mixtures shows
similarity to the reference mixtures with a high early strength gain. The compressive, splitting, tensile and
flexural strength of concrete mixtures with paper pulp become less when higher paper pulp contents were
included in the concrete mixtures.
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Partial replacement of cement in concrete by hypo sludge
The paper pulp content in the concrete mixtures played a great role in the mechanical properties. The
splitting tensile and flexural strength decreased when the paper pulp content was increased in the mixtures.
Generally, the compressive, splitting tensile and flexural strength increased up to 10% addition of waste
paper pulp and further increase in waste paper pulp reduces the strengths gradually. So the most suitable mix
proportion is the 5% to 10% replacement of waste paper pulp to cement. Cement blended with 10% and 20%
paper sludge exhibits a smaller reduction in compressive strength than the control cement. Concrete
containing an average of 15% residuals had lower 28- day’s compressive strength than the reference
concrete and showed either equivalent or somewhat lower chloride-ion penetration resistance than the
reference concrete.
Thus behaviour of concrete with the waste paper pulp by replacement of cement in the range of 5%, 10%,
15%, 20%, 30%, and 40% is carried out which may help to reduce the disposal problems of sludge and
enhance the properties of concrete.
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Partial replacement of cement in concrete by hypo sludge
3. LITERATURE REVIEW
Dr. L.B. Zala and Dr. F. S. Umrigar in “Utilization of Hypo Sludge by Eco-Efficient Development of
Rigid Pavement in Rural Roads” presented that Hypo Sludge Ash can be used for rigid pavement
construction in rural areas. By using this waste road construction may become cost efficient and at
the same time best utilization of waste could also be made. They found good results for the
replacement.
Apurva Kulkarni, Samruddha Raje, Juned Peerzada and Mamata Rajgor in “A Miniscule Endeavour
for Accomplishing Hypo Sludge Fly Ash Brick in Indian Context” presented that as the waste
produced out of paper industries can be recycled only a limited number of times so these low quality
fibres which are treated as a waste can be used for construction work. This waste contains a large
amount of lime so they used these Hypo sludge ash for production of Fly Ash Bricks. They replaced
lime with different proportions such as 5, 10, 15, 20% with HSA. They found good results at 5 %
replacement for production of Fly Ash Bricks.
Saveria Monosi, Daniela Sani and Maria Letizia Ruello in “Reuse of Paper Mill Ash in Plaster
Blends” presented that as paper mill ash is a waste and is light weight, it can be used in
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Partial replacement of cement in concrete by hypo sludge
manufacturing of plaster bends. This waste if used with Portland cement, limestone powder, natural
sand with a maximum diameter of 2mm, and a silane-based hydrophobic powder can be used in
manufacturing of cement mortar which can be used in the production of dry-cast concrete products
such as masonry blocks and paving stones, wet-cast precast products, structural-grade concrete. As
different paper mills produce different quality of paper there properties may vary in nature. Paper ash
used were provided by Burgo Group" paper mills (Mantova, Italy). Mechanical strength found
ranged from 4 to10MPa with specific gravity between 1150 and 1350 Kg/m3 .Paper ash being light
weight in nature can be used in various field applications such as filling of temporary joints and other
minor repair work
Sajad Ahmad, M. Iqbal Malik, Muzaffar Bashir Wani, and Rafiq Ahmad in “Study of Concrete
Involving Use of Waste Paper Sludge Ash as Partial Replacement of Cement” presented that, waste
produced from cement manufacturing industries are growing day by day so we have come to the
peak period to find out such a sources that help to produce greener concrete. It is found that cement
industries are the major sources that produce greenhouse gases leading to its emissions into
environment. So they found out one such material called Waste paper sludge ash which is used as
replacement to cement to produce concrete. Mix Design for M-25 grade concrete is used in project
work. Concrete cubes were prepared and compression tests was carried out and concrete beams were
prepared for testing flexural test along with that water absorption and dry density tests were also
carried for checking out the weight reduction and water absorption. It was found that concrete
strength increased at 5% replacement of cement with waste paper sludge ash and along with this
water absorption was also found to be increased.
Gabriele Fava, Maria Letizia Ruello and Valeria Corinaldesi in “Paper Mill Sludge Ash as
Supplementary Cementitious Material” presented that, as the waste produced out of paper industries
are on large scale now-a-days so gainful utilization should be made, so they targeted to use this waste
material as a supplementary cementitious material. Material properties of this paper mill ash were
tested and they used it for preparation of mortars and other concrete manufacturing. They found
excellent results at 10% replacement of cement with paper mill sludge ash.
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Partial replacement of cement in concrete by hypo sludge
Material:- The various materials used in the preparation of concrete are cement, sand, coarse aggregates,
hypo sludge and water.
Hypo Sludge:- Hypo Sludge is a waste material collected from the Paper Industry. It is used as
cement replacement in producing concrete and was investigated on its chemical and physical
properties. Construction material with natural resources now become limited and causes of air
pollution and environmental problems. It becomes a new innovation material that can be used as
material to support the green technology. It behaves like cement because of silica and magnesium
properties. This silica and magnesium improve the setting of the concrete and the hypo sludge is
collected from the paper mill.
Cement:- The most common cement used is an Ordinary Portland Cement (OPC). The Ordinary
Portland Cement of 53 grade conforming to IS:8112-1989 is used. Many tests were conducted on
cement; some of them are specific gravity, consistency tests, setting time tests, compressive
strengths, etc.
Fine Aggregate:- The natural river sand available in local market which passes through 4.75mm sieve
with specific gravity of 2.62. Conforming to Zone II.
Coarse Aggregate:- Crushed granite conforming to IS 383 - 1987 is used. Coarse aggregate passing
through 20mm and retained on 16 mm sieve and specific gravity 2.82 was used.
Water:- Water is an important ingredient of concrete as it actively participated in chemical reaction
with cement, clean portable water which is readily available is used.
Methodology:- Replacement levels of OPC by Hypo Sludge of 5%, 10%, 15%, 20% were done . Batching
was carried out by weighing as per calculated amount of each concrete constituent and a concrete mix of
M25 and M40 was designed as per IS10262:2009.
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Partial replacement of cement in concrete by hypo sludge
The constituents were then mixed thoroughly until a uniform mix was obtained. Water was then added and
the mix was repeated. The fresh concrete mix was then placed in a mould of size 150 mm, compacted, and
left for 24 h before testing Compressive specimens were tested at the ages of 7 and 28 days. Different tests
were then performed on the concrete which are discussed below.
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Partial replacement of cement in concrete by hypo sludge
Different tests are performed on cement concrete in order to find its properties. Tests are done in two stages
if concrete, in fresh concrete and in hardened concrete. Test performed in fresh concrete is slump test and in
hardened concrete are compression test, flexural strength test and water absorption test.
Mr. R Balamurugan (April2014) conducted an experimental study for the innovative use of hypo sludge in
concrete formulations as a supplementary cementations material was tested as an alternative to traditional
concrete. The cement has been replaced by waste paper sludge accordingly in the range of 0% (without hypo
sludge), 5%, 10%, 15%, 20% by weight for M25. Slump test is used to determine the workability of fresh
concrete. Slump test as per IS1199 – 1959 is followed. The apparatus used for doing slump test are Slump
cone and tamping rod. Fig 5.4 shows the slump cone. Table 5.1 represents the slump values as performed by
Mr. R Balamurugan for M25 concrete mix.
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Partial replacement of cement in concrete by hypo sludge
Test Results: The slump initially increases (5%) and then decreases when a higher amount of paper pulp
content was included. The received pulp exhibited a high water- absorption capability. Several factors could
lead to adverse effects on the workability of paper pulp concrete. The amount of paper pulp replacement,
paper pulp physical properties, and the carbon content of the paper pulp would be the main reasons for the
reduction of concrete workability.
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99
98
97
96
Slump (mm)
95
94
% of HypoSludge
93
92
91
90
89
0% 5% 10% 15% 20%
% of Hyposludge
150 mm × 150 mm × 150 mm concrete cubes were casted using M25 and M40 grade concrete. Specimens
with Ordinary Portland Cement (OPC) and OPC replaced with hypo sludge at 10%, 20%, 30%, 40% levels
were cast. During casting, the cubes were mechanically vibrated by using a table vibrator. After 24 hours,
the specimens were removed from the mould and subjected to water curing for 14 and 28 days. After curing,
the specimens were tested for compressive strength using calibrated compression testing machine of 2000kN
capacity.
Test results:
The compressive strength for M25 and M40 are represented in table 4.2. It is observed that the average
compressive strength increased up to 10% addition of hypo sludge and further increased addition of hypo
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Partial replacement of cement in concrete by hypo sludge
sludge reduces the strengths gradually in both M25 and M40. Figure 4.3 shows the variation of
compressive strength of cubes at 28 days for M25 and M40.
Average Compressive
% Replacement of cement by
Type of concrete strength
hypo sludge
(N/mm𝟐 ) at 28 days
A1 0 36.52
C1 10 39.70
M25 C2 20 25.78
C3 30 23.26
C4 40 22.96
A2 0 50.81
C5 10 52.26
M40 C6 20 40.74
C7 30 28.74
C8 40 24.00
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60
50
Compressive Strenth (N/mm2)
40
30 M25
M40
20
10
0
0% 5% 10% 15% 20%
Replacement of Hypo Sludge
The flexural strength is determined by the central point method. Standard metallic beam moulds (100 mm ×
100 mm × 500 mm) were used for the preparation of concrete specimens for flexural strength. A table
vibrator was used for compaction of hand filled concrete beams. The specimens were de moulded after 24
hours and subsequently immersed in water for different age of testing. For each age, three specimens were
used for the determination of average flexural strength. The test was performed on Universal Testing
Machine (UTM) having capacity of 50 BT. The schematic: set up of Universal Testing Machine for flexural
strength is represented below.
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Partial replacement of cement in concrete by hypo sludge
𝑀 𝑓 𝑀 𝑀
The flexural strength is calculated by using bending equation = 𝑦 or ( ) × y or f = where, M, I, y and
𝐼 𝐼 𝑍
Z represents respectively the bending moment, moment of inertia, distance of farthest fire and section
𝑏𝑑2
modulus. For rectangular section Z = , where b and d denote the breadth and depth of the beam
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respectively.
Test result:
The flexural strength for M25 and M40 are represented in the following table. It is observed that the flexural
strength increased up to 10% addition of hypo sludge and further increase in hypo sludge reduces the
strength gradually in both M25 and M40.
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Partial replacement of cement in concrete by hypo sludge
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Partial replacement of cement in concrete by hypo sludge
Flexural
% Replacement of
Concrete mix Strength(N/𝐦𝐦𝟐 ) at 28
cement by hypo sludge
days
A1 0 4.71
C1 10 4.49
M25 C2 20 2.93
C3 30 2.74
C4 40 2.62
A2 0 6.10
C5 10 6.20
M40 C6 20 4.73
C7 30 3.41
C8 40 2.70
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6
Flexural Strength (N/mm2)
M40
3
M25
2
0
0% 5% 10% 15% 20%
Replacement of Hypo Sludge
The 100 mm diameter 50 mm height cylinder after casing were immersed in water for 90 days curing.
These specimens were then oven dried for 24 hours at the temperature 110˚C until the mass became
constant and again weighed. This weight was noted as the weight (W1) of the cylinder. After that the
specimen was kept in hot water at 85˚C for 3.5 hours. Then this weight was noted as the wet weight (W2)
of the cylinder. % water absorption = [(W2 – W1) / W1] × 100 where, W1 = oven dry weight of cylinder in
grams, W2 = after 3.5 hours wet weight of cylinder in grams.
Test result:
It has been observed that the % of water absorption increases with increase in % of hypo sludge. Table
gives the water absorption result of % replacement of paper industry waste (hypo sludge) in concrete for 90
days curing.
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As Per IS: 4031 (Part 5) – 1988. Initial and final setting time of cement is calculated using VICAT apparatus
conforming to IS: 5513 – 1976
Procedure:-
The initial and final setting time for concrete with different replacement of hypo sludge is represented in
Table 2. It is observed that the initial setting time increases with the increase in percentage of hypo sludge
and final setting time decreases as the percentage of hypo sludge increases.
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Partial replacement of cement in concrete by hypo sludge
6. APPLICATIONS
Hypo Sludge Ash can be used as an alternative material for production of concrete of different
grades.
Waste Paper Sludge ash can also be used for making of bricks.
Hypo Sludge Ash can be used as an alternative material for plastering work and other minor repair
works.
It can also be used for temporary construction work where strength is not the major parameter.
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Partial replacement of cement in concrete by hypo sludge
7. ECONOMIC ANALYSIS
The addition of hypo sludge reduces strength of concrete. Still there are some benefits of the hypo sludge
addition. Firstly it provides an environmentally consistent way of hypo sludge disposal. Secondly in overall
it reduces the cost of the structural element. Of course due to lesser strength of hypo sludge blended
concrete, sectional area of structural element required will be more. But, addition of fly ash shall reduce the
quantity of cement required and hence the overall cost.
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8. CONCLUSIONS
This report concludes that hypo sludge can be used as a construction material.
Strength ( compressive and flexural ) is found to be increased for initial replacement of cement with
hypo sludge ash for instance up to 10% replacement
Effective utilization of Hypo Sludge in concrete can save the Paper industry’s disposal costs and
storage problems and also produces a greener concrete.
Low cost houses can be constructed
By using suitable admixtures such as superplasticizers, the problem of water absorption can be
reduced.
8. REFERENCES
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