RECYCLED AGGREGATE CONCRETE

IIT
Kharagpur
M.Chakradhara Rao
Research Scholar

Department of Civil Engineering

Indian Institute of Technology, Kharagpur
 OVERVIEW

IIT Definitions
Kharagpur
Necessity
Benefits
Applications
Case Histories
Experimental Programme
Results and Discussion
Closing Remarks

4/4/2009 2
 DEFINITIONS

IIT Recycled Concrete Aggregates (RCA/RA)

Kharagpur
Recycled Aggregate Concrete (RAC)
Coarse Aggregate Replacement Ratio (CRR)

4/4/2009 3
 NECESSITY

IIT Demolition of structures in Urban areas

Kharagpur
Demolition of old bridges
Natural disasters
Shortage of dumping sites
Cost of Transportation
Depletion of natural resources
Sustainable developments
Shortage of Aggregates in Housing Sector

4/4/2009 4
 BENEFITS

IIT Economic Aspect

Kharagpur
Reducing Environmental Impact
Saving Resources

4/4/2009 5
 ECONOMIC ASPECT

IIT Natural Aggregates

Kharagpur

Excavation Transportation Processing

Recycled Aggregates

Additional
Dumping (-ve)
Processing at site

Transport to Transport to
Dumping site (-ve) Plant

Processing
4/4/2009 6
 CONSTRAINTS

IIT Management Problems

Kharagpur
 Lack of suitable regulations
 Lack of codes, specifications, standards
and guidelines
 Lack of experience

Technology problems
 Weak Interfacial transition zone
 High porosity of RA
 Traverse crack generated
4/4/2009 7
 CONSTRAINTS Contd.

IIT
Kharagpur  High impurity
 Cement portion attached to aggregate
 Poor grading
 Low quality
 Variations in quality

4/4/2009 8
 APPLICATIONS

IIT Applications without any processing

Kharagpur
Many types of general bulk fills
Bank protection
Base or fill for drainage structures
Road construction
Noise barriers and embankments

4/4/2009 9
 FLOW CHART for RCA PREPARATION

IIT
Kharagpur

4/4/2009 10
 PRODUCTION PROCESS of RCA

IIT
Kharagpur

4/4/2009 11
 APPLICATIONS Contd.

IIT After Removal of Contaminants

Kharagpur
New concrete for pavements, shoulders, median
barriers, sidewalks, curbs and gutters, and bridge
foundations

Structural grade concrete

Soil-cement pavement bases

Lean-concrete and

Bituminous concrete

4/4/2009 12
 CASE HISTORIES

IIT
•A 41-year-old pavement was crushed and used as
Kharagpur
aggregate in production of concrete for a new one mile
long and 22.5cm thick highway pavement. This was the
first project in 1976 at Lowa.

• In Lowa ,1978, crushed old concrete was used as

aggregate for production of a new 17 mile long and
20cm thick highway pavement.

• In Connecticut, in 1980, a 1000ft long section of 24

years old reinforced concrete pavement was recycled in
to a new 22.5cm thick reinforced concrete pavement.

• Kerb and gutter in the Lenthall Street project in

Sdyney (Stone,1999)
4/4/2009 13
 CASE HISTORIES Contd.

IIT
• Construction of Vilbeler Wag building at Darmstadt in
Germany in 1996
Kharagpur

• Construction of Waldspirale Building at Darmstadt in

Germany in1998

• Construction of a new high school building in

Norway, in which 35% recycled coarse aggregates are
used in foundations, basement walls and columns
(Mehus, 2002).

• Construction of 60L green building in Carlton and ii)

CH2 new council building in Melbourne.

4/4/2009 14
 CASE HISTORIES Contd.

Projects in Germany
IIT
Kharagpur Project Name Concrete Grade % of RFA % of RCA

Vilbeler Weg Office B 35 100 100

and Carpark
Waldspirale B 25, B35 In accordance In accordance
Darmstadt- residential with Richtline with Richtline
building
Federal environmental B 35 0 100
foundation
Headquarters,
Osnabruck
Wohnpark B 35 0 100
Klosterforst, Itzehoe
Healthy Homes, B 25 0 35
Munster
Highway A1 Viaduct, B 15 as concrete 0 Not precisely
concrete filing filling given

4/4/2009 15
 CASE HISTORIES Contd.

IIT The Netherlands

Kharagpur
• A viaduct in RW32 near Meppel where 500m3
recycled concrete was used in side walls

• About 2000m3 of recycled concrete was used in an

under-water concrete slab in the De Haandrik navigation
lock

• About 3000 m3 of RAC was used in an under-water

concrete slab in a lock/barrage combination at Statenziji

•A second viaduct in RW 32 near Meppel where 11,000

m3 recycled concrete was used

4/4/2009 16
 CASE HISTORIES Contd.

IIT
Kharagpur • Recent example: Delftse Zoom Housing project –
272 two-storey dwelling units. Recycled concrete was
used in the construction of precast load bearing
walls, façade elements and floors

RAC Pavements in Shanhai Ecological building in Shanghai

(2004) (50% RCA) (2006) (100% RCA in
foundations and Walls)
4/4/2009 17
 CASE HISTORIES

IIT
Kharagpur

Environmental building at BRE (1995-96) Berendrecht lock in Belgium (1987-88)

Source: W.K.Fang. SCCT Annual conference Source: W.K.Fang. SCCT Annual
seminar, 3rd Feb, 2005 conference seminar, 3 Feb, 2005
rd

New high school building in

Norawy ( Mehus, 2002)

4/4/2009 18
 WORLD SCENARIO

IIT UK: (Capita Symonds Ltd. Report, 2007).

Kharagpur

Item 2001 2005

Total C&DW (Mt) 90 90
C&DW in 1999 is 69Mt + 21mt
Recycled (%) 49 52
Landfill (%) 26 31
Exempt Sites (%) 25 17

4/4/2009 19
 WORLD SCENARIO Contd.

IIT Denmark: (Waldo Montecions, 2006)

Kharagpur

Total C&DW in 2003 : 3.785 Mt

31% of the total Solid Waste
70-75% from Demolition
20-25% from renovation
5-10% from new building developments
Total recycling : 94%

4/4/2009 20
 WORLD SCENARIO Contd.

IIT
Kharagpur
Scotland: (National Waste Strategy, 2005)

Total C&DW in 2000 6.29 Mt

Usage of primary aggregates 33 Mt
C&DW recycled: 2.31
(37%)

4/4/2009 21
 WORLD SCENARIO Contd.

IIT USA (Franklin Associates, 1998)

Kharagpur

Total C&DW in 1996 136 Mt

Residential 58 Mt
Nonresidential 78 Mt
Total recycling 20-30%
Total C&DW in 2002 250-300 Mt(Brickner,
2002)

4/4/2009 22
 WORLD SCENARIO Contd.

IIT Germany (Destatis 2005a and 2005b, 2006)

Kharagpur

Item 2002 2003

Total C&DW 241 233 Mt
Total recycling 85.6% 86.2%

4/4/2009 23
 WORLD SCENARIO Contd.

Rest of the European Countries

IIT C&DW arisings Reused/recycled Landfilled
Kharagpur Member state
(Mt) (%) (%)
France 24 15 85
Italy 20 9 91
Spain 13 5 95
Netherlands 11 90 10
Belgium 7 87 13
Australia 5 41 59
Portugal 3 5 95
Greece 2 5 95
Sweden 2 21 79
Finland 1 45 55
Ireland 1 5 95
Luxemburg 0
4/4/2009 24
 WORLD SCENARIO Contd.

IIT India
Kharagpur

Constituent Quantity generated in million

tonnes per annum
Soil, Sand & gravel 4.20 to 5.14
Bricks & Masonry 3.60 to 4.40
Concrete 2.40 to 3.67
Metals 0.60 to 0.73
Bitumen 0.25 to 0.30
Wood 0.25 to 0.30
Others 0.10 to 0.15
Recycling NIL

4/4/2009 25
 CLASSIFICATION

IIT RILEM (1989)

Kharagpur

Type I Aggregates originate primarily from

masonry rubble
Type II Aggregates originate primarily from
Concrete rubble
Type III A blend of recycled aggregates (20%
RCA) and normal aggregates (80%).

4/4/2009 26
 CLASSIFICATION Contd.

IIT MOC (1997): based on water absorption, for

Kharagpur
Concrete for Buildings and public works.

Item Recycled Coarse Recycled Fine

Aggregate (RCA) Aggregate
Type Type II Type Type Type II
I III I
Absorption ≤3 3 to 5 5 to 7 ≤5 5 to 10
(%)

4/4/2009 27
 CLASSIFICATION Contd.

IIT Building Research Establishment (1998):

Kharagpur Old concrete and brick masonry

Class Origin Brick content Strength

by weight (by 10%
fines test)
RA (I) Brick 0 – 100 % 70 kN
Work
RA (II) Concrete 0 – 10 % > 100 kN

RA (III) Concrete 0 – 50 % 70 kN
and Brick

4/4/2009 28
 CLASSIFICATION Contd.

IIT
Kharagpur DIN 4226-100 (2000): Source of waste

Type I Gravel of concrete/ Sand of Concrete

Type II Gravel of Construction/ Sand of
Construction
Type III Gravel of masonry/ Sand of masonry
Type IV Gravel of mixture/ Sand of mixture

4/4/2009 29
 SPECIFICATIONS

RILEM (1989)
IIT Mandatory requirements Type I Type II Type III
Kharagpur
Min. dry density of particles (kg/m3) 1500 2000 2400

Max. Water absorption (% by mass) 20 10 3

Max. content of materials with SSD<2000 kg/m3 10 10

(% m/m)
Max. content of materials with SSD<1800 kg/m3 10 1 1
(% m/m)
Max. content of materials with SSD<1000 kg/m3 1 0.5 0.5
(% m/m)
Max. Content of foreign materials (% m/m) 5 1 1
Max. Content of metals (% m/m) 1 1 1

Max. content of organic materials (% m/m) 1 0.5 0.5

(Max. content of filler < 0.063mm (% m/m) 3 2 2

Max. content of sand (<4mm) (% m/m) 5 5 5

4/4/2009 30
 SPECIFICATIONS Contd.

BRE (1998)
IIT
Kharagpur
Use of coarse recycled aggregates in concrete:
BS: 882 “ Specifications for aggregates from natural
sources for concrete”
Use of fine recycled concrete aggregates in concrete:
•less than 5mm ---- not recommended

Recommended Maximum Grade of Concrete:

Type I Dry density < 2000 kg/m3 C 20
Type I Dry density > 2000 kg/m3 C 35
Type II Dry density < 2000 kg/m3 C 50
20% RCA + 80% NA No limit
4/4/2009 31
 SPECIFICATIONS Contd.

Japanese Specifications
IIT Type of RAC and suggested uses in Public Works
Kharagpur
RA Applications Coarse Fine Aggregate Strength
C Aggregate (MPa)
I Reinforced or plain Recycled coarse Normal 18 – 21
concrete, low aggregates 1st aggregates
structures of bridges, Class
tunnel lining, retaining
walls etc.
II Plain concrete, Recycled coarse Normal 16 – 18
masonry units, gutters, aggregates 2nd aggregates or
gravity type retaining Class recycled 1st
walls etc. class
III Sub slab concrete, Recycled coarse Recycled fine < 16
back filling concrete, aggregate 3rd aggregate 2nd
leveling concrete class class

4/4/2009 32
 SPECIFICATIONS Contd.

Proposed types of RAC and suggested uses

IIT in Buildings (Tomosawa, 1998)
Kharagpur
Concrete CA FA Suggested Design Suggested Uses
Type Strength (MPa)

A Type I Natural 18 or more Ordinary reinforced concrete

Fine buildings
B Type II Natural 18 or more Concrete attached to ground:
Fine foundations, cast-in-place
concrete piles, concrete slabs
on steel decks
C Type III Type I 18 or more Foundation slabs, earthen
floor slabs, subslab concrete,
back filling concrete, leveling
concrete. Etc.
D Type III Type II 18 or more Subslab concrete, back filling
concrete, leveling concrete ,
etc.

4/4/2009 33
 SPECIFICATIONS Contd.

DIN EN 4226 – 100 (2000)

IIT
Constituents Composition of the material proportion (% by
Kharagpur mass)
Type I Type II Type III Type IV

Concrete and natural aggregates ≥ 90 ≥ 70 ≤20 ≥ 80

according to DIN 4226 – 1
Clinker, non-pored bricks ≤10 ≤30 ≥80 ≥80
Sand – lime bricks ≤5
Other mineral materials such as ≤2 ≤3 ≤5 ≤20
pored brick, light weight concrete,
no fines concrete, mortar etc.
Foreign substances such as glass, ≤ 0.2 ≤ 0.5 ≤ 0.5 ≤1
gypsum, plastic, wood, paper etc.
OD density (kg/m3) ≥2000 ≥2000 ≥1800 ≥1500

Maximum water absorption after 10 15 20 No

10 min (%) requirement

4/4/2009 34
 SPECIFICATIONS Contd.

Hong Kong Specifications

IIT Mandatory Requirements Limits Testing Method
Kharagpur Minimum dry particle density 2000 BS 812: Part 2
(kg/m3)
Max. water absorption (%) 10 BS 812: Part 2
Max. content of wood and other 0.5% Manual sorting in
material less dense than water accordance with BRE Digest
433
Max. content of other foreign 1%
materials (e.g. metals, plastics,
asphalt, glass, etc.)
Max. content of sand ( <4mm) (% 5 BS 812: section 103.1
m/m)
Max. fines 4% BS 812: section103.1
Max. content of sulphate (% m/m) 1 BS 812 : Part 111
Flakiness Index 40% BS 812: Section 105.1
10% fines test 100kN BS 812 : Part 111
Grading Table 3 of BS 882:1992
Max. chloride content Table 7 of BS 882 – 0.05% by mass of
4/4/2009
chloride ion of combined aggregate 35
 EXPERIMENTAL PROGRAMME

IIT Materials
Kharagpur
OPC (43 grade):Confirming to IS: 8112 (1989)
Fine Aggregate: Zone II of IS: 383 (1970)
Natural Coarse Aggregate: Locally available
crushed stones of maximum size 20mm
Recycled Coarse Aggregate: Demolished RCC
culvert
Superplastisizers

4/4/2009 36
 PRODUCTION OF RCA

IIT
Kharagpur
Demolished > 20mm Crushing by < 4.75mm
Transported Crushing
culvert jaw crusher
to lab Manually
material
> 4.75mm

>4.75mm
< 20mm Combined

< 4.75mm

4/4/2009 37
 END PRODUCT (RCA)

IIT
Kharagpur

Recycled Coarse Aggregates

4/4/2009 38
 DETAILS OF CONCRETE MIXES

IIT
Kharagpur
Mix Designation RCA (%)
MCRR 0.0 0
MCRR 0.25 25
MCRR 0.50 50
MCRR 1.0 100

4/4/2009 39
 MIXTURE PROPORTION

IIT
Kharagpur Mix Cemen Natural Natural RCA Total Super
Designa t (kg) FA (kg) CA (kg) Water Plasticiz
tion (kg) (l) er *
MCRR 401 574 1261 0 178 0.05
0.0
MCRR 401 574 911 303 184.83 0.05
0.25
MCRR 401 574 585 585 195.13 0.175
0.50
MCRR 401 574 0 1119 206.86 0.225
1.0
* % by weight of cement

4/4/2009 40
 RESULTS AND DISCUSSION

Properties of Aggregates
IIT % Replacement of Coarse IS:383
Kharagpur Aggregates (1970)
Property
CRR CRR CRR
CRR 0 Limits
0.25 0.50 1.0
Fineness Modulus 6.781 6.697 6.693 6.692
Bulk density (Compact) in kg/l 1.581 1.56 1.5 1.413
Specific gravity 2.75 2.661 2.602 2.51
Water absorption (%) 1.129 1.911 2.63 3.92
Los Angeles Abrasion resistance 50,
21.56 38.8
(%) 30%
Impact value (%) 17.37 35.81 45%
Crushing Strength (10% fines) and
231.3 115.3 30%
KN
Flakiness Index (%) 24.37 6.27 25%
Elongation Index (%) 20.06 11.63 30%

4/4/2009 41
 RESULTS AND DISCUSSION Contd.

Particle size distribution of natural and

IIT
Kharagpur recycled coarse aggregates

100
Cum. percentage passing

90
80
RCA 25
70 RCA 50
60
50 RCA 100
40
30
RCA 0
20 Min - IS:383
10
0 Max - IS:383
0 10 20 30 40
Sieve size in mm

4/4/2009 42
 RESULTS AND DISCUSSION Contd.

IIT Compressive Strength

Kharagpur

60
Compressive Strength

55 MCRR 0.0
50
45
in MPa

MCRR 0.25
40
35
30 MCRR 0.50
25
20 MCRR 1.0
0 14 28 42 56 70 84 98
Age in Days

4/4/2009 43
 RESULTS AND DISCUSSION Contd.

IIT Influence of Type of Curing

Kharagpur

48
Compressive Strength

47
46
45
in MPa

44
43 Moist Cured
42
Partial moist curing
41 + Air dried
40
0.25 0.5 1
Coarse Aggregate Replacement Ratio (CRR)

4/4/2009 44
 RESULTS AND DISCUSSION Contd.

IIT
Compressive Strength of RAC reported by
Kharagpur different researchers

Topcu et al (16MPa) (2004)

60
Compressive Strength (MPa)

Topcu et al (16MPa)(2004)
50 Present Work
Bairagi et al (w/c 0.43)(1993)
40
Bairagi et al (w/c 0.5)(1993)
30 Bairagi et al (w/c 0.57)(1993)
Poon et al (2004)
20
Limbachiya et al (fck 45)
10 Limbachiya et al (fck 35)
0 Limbachiya et al (fck 20)
0 0.25 0.5 0.75 1
Coarse Aggregate Replacement Ratio (CRR)

4/4/2009 45
 RESULTS AND DISCUSSION Contd.

IIT Compressive Strength Reduction

Kharagpur
Author(s) % Reduction
Present work 13
Ravindrarajah and Tam (1985) 8-24
Bairagi et al. (1993) 6-16
Poon et al. (2004) 15
Etxeberria et al. (2007) 20-25
Rahal (2007) 10

4/4/2009 46
 RESULTS AND DISCUSSION Contd.

IIT
Kharagpur

4/4/2009 47
 RESULTS AND DISCUSSION Contd.

IIT
Kharagpur

4/4/2009 48
 RESULTS AND DISCUSSION Contd.

IIT
Kharagpur

4/4/2009 49
 RESULTS AND DISCUSSION Contd.

IIT
Kharagpur

4/4/2009 50
 RESULTS AND DISCUSSION Contd.

IIT Stress-Strain Variation

Kharagpur
40.00
35.00
30.00
Stress (MPa)

25.00 MCRR 0.0

20.00 MCRR 0.25
15.00 MCRR 0.5
10.00 MCRR 1.0
5.00
0.00
0 0.001 0.002 0.003
Strain (mm/mm)

4/4/2009 51
 RESULTS AND DISCUSSION Contd.

IIT
Modulus of Elasticity
Kharagpur
Present Work
4
Modulus of Elasticity (×

Bairagi et al. (1993) (w/c=0.43)

3 Bairagi et al. (1993) (w/c=0.5)
104 MPa)

2 Bairagi et al. (1993) (w/c=0.53)

Xiao et al. (2005)
1
Etxeberria et al. (2007)
0
0 0.25 0.5 0.75 1
Coarse aggregate replcement ratio (CRR)

4/4/2009 52
 RESULTS AND DISCUSSION Contd.

IIT Reduction in Modulus of Elasticity

Kharagpur
Author(s) % Reduction
Present work 34.8
Frondistou – Yannas (1977) 40
Bairagi et al. (1993) 39
Khedar (2005) 20-25
Xiao et al. (2005) 45

4/4/2009 53
 RESULTS AND DISCUSSION Contd.

IIT
Variation in Modulus of Elasticity
Kharagpur
4 Present work
Modulus of elasticity (× 104

IS: 456
3
Ravindrarajah and
MPa)

Tam
2 ACI

Xiao et al.
1
Kakizaki et al.

Coarse aggregate replacement ratio (CRR)

4/4/2009 54
 RESULTS AND DISCUSSION Contd.

IIT Density
Kharagpur
2450
2400
3.5%
2350
Density (kg/m3)

4.6%
2300
CRR 0.0
2250 10%
CRR 0.25
2200 CRR 0.50
2150 CRR 1.0
2100
2050
0.0 0.25 0.50 1.0
Coarse aggregate replacement ratio (CRR)

4/4/2009 55
 RESULTS AND DISCUSSION Contd.

IIT Relationship b/w Density and Comp.strength

Kharagpur

55
Compressive strength (MPa)

y = 0.026x - 13.85
50 R = 0.98

45

40 Present work
y = 0.069x - 116.1 Xiao et al.(2006)
35 R =0.92

30
2100 2200 2300 2400 2500
Density (kg/m3)

4/4/2009 56
 RESULTS AND DISCUSSION Contd.

IIT Water Absorption and Volume of Pores

Kharagpur

8 16.5
7
Water Absorption (%)

16

Volume of voids (%)

6 15.5
5
15
4
14.5
3
2 14
1 13.5
0 13
0 0.25 0.5 0.75 1
Coarse Aggregate Replaement Ratio (CRR)

Water absorption Volume of voids

4/4/2009 57
 RESULTS AND DISCUSSION Contd.

IIT Volume of Pores

Kharagpur
Volume of pores (%) 25

20
Present Work
15
Levy et al
10 (Fck=20MPa)
Levy et al
5 (Fck=30MPa)
0 Levy et al
(Fck=40MPa)
0 0.25 0.5 0.75 1
Coarse aggregate replacement ratio (CRR)

4/4/2009 58
 RESULTS AND DISCUSSION Contd.

IIT Water Absorption

Kharagpur
10
Water Absorption (%)
8
Present Work
6
Levy et al
4 (fck=20MPa)
Levy et
2 al(fck=30)
Levy et
0
al(fck=40MPa)
0 0.25 0.5 0.75 1
Coarse aggregate replacement ratio (CRR)

4/4/2009 59
 RESULTS AND DISCUSSION Contd.

IIT Relation b/w Density, Water Absorption and

Kharagpur Volume of Pores

8 17
y = -0.010x + 38.93
7.5
Water Absorption (%)

16

Volume of Voids (%)

R² = 0.925
7 15
6.5
14
6
y = -0.007x + 23.58 13
5.5 R² = 0.981
5 12
4.5 11
4 10
2100 2200 2300 2400 2500
Density (kg/m3)
water absorption Volume of voids

4/4/2009 60
 CLOSING REMARKS

IIT Benefits and Constraints

Kharagpur
Applications
Classification system
Specifications
Experimental Results

4/4/2009 61
 CLOSING REMARKS (Experimental Observations)

IIT Recycled aggregates are well within the limits of IS:383

Kharagpur
No much significant difference observed in
compressive strength up to 50% replacement
More gain in comp. strength of RAC in first 7 days
Strength gaining rate of RAC is slower after 28days
Variation of stress-strain is similar
Considerable difference is observed in case of Modulus
of Elasticity
Water absorption and volume of voids are increases
and density decreases

4/4/2009 62
 IIT
Kharagpur

4/4/2009
 METHODS to IMPROVE the PROPERTIES

IIT
Two-stage mixing approach (TSMA)
Kharagpur

120 s
mixing

60 s 60 s 30 s 120 s
mixing mixing mixing mixing

Mixing procedures for normal mixing approach and Two-

stage mixing approach (TSMA) (Source: Tam et al. 2005)
4/4/2009 64
 METHODS to IMPROVE the PROPERTIES Contd.

IIT
New treatment method
Kharagpur

Pretreatment Technique ( source: Tam et al. 2006)

4/4/2009 65
 METHODS to IMPROVE the PROPERTIES Contd.

IIT Tam and Tam (2007)

Kharagpur
• Proposed new TSMA with silica fume and cement

4/4/2009 66
 METHODS to IMPROVE the PROPERTIES Contd.

IIT
Kharagpur

Source: Otsuki et al. (2003)

4/4/2009 67