EFFECT OF REPLACEMENT OF OPC BY PAPER

SLUDGE IN COMPRESSIVE STRENGTH OF CONCRETE

By
Nitin BharadwajH.R 1RV06CV008
Harinandan. B 1RV06CV009
VijethK.R 1RV06CV036
Kishore. R 1RV06CV013

Under The Guidance Of

Mr. Radhakrishna
Asst Professor
Dept Of Civil Engg, RVCE
HISTORY OF CONCRETE
 Concrete has been in use since the Egyptian and the
roman civilizations.

 During Roman empire, concrete was made from
quicklime, pozzolanic ash and pumice as aggregates
which posed problems while placing and provided
lesser strength.

 In the 1840’s Portland cement was first used in
concrete.

 Further evolution of concrete saw need for
increasing strength and other properties which was
achieved by substituting cement by additives.


 Recently, the use of waste materials as concrete

ingredients is gaining popularity because of
increasingly stringent environmental legislation.

 INTRODUCTION
Need for Replacement
 During manufacturing of 1 tones of Ordinary Portland
Cement (OPC) we need about 1-1.5 tonnes of earth
resources like limestone, etc and 3 to 6 GJ of fuel per
tonne of clinker produced.

 Further during manufacturing of 1 tonnes of Ordinary
Portland Cement an equal amount of carbon-di-oxide are
released into the atmosphere. The amount carbon dioxide
emitted by the cement industry is nearly 900 kg of
Carbon dioxide for every 1000kg of cement produced.


 The cement industry produces about 5% of global man-made

carbon dioxide emissions.

 In this Backdrop, the search for cheaper substitute to OPC
is a needful one.

 Need for Paper Sludge
Utilization

 From Paper manufacturing process three types of

sludge are obtained namely Lime sludge, ETP sludge
and De-Inking sludge. In our project we have
utilized lime sludge as a replacement for cement.


 Lime Sludge is a material obtained from the chemical

recovery process of paper production.
 Contd…
 Due to its low calcium(12mg/litre), Lime sludge is
used as a replacement to cement in concrete.

 The silica and magnesium present in Lime sludge
improves the setting of the concrete.


 Lime sludge is available abundantly worldwide but

its usage to date is very limited. Each Indian
mill produces an average 40 oven-dry tonnes of
sludge per day.


 The Lime Sludge disposed in mass level in landfill

shows increase in N, P, K, B, Cl-, and organic C
contents of the soil thus causing land pollution.

Study On Effect of paper sludge on soil
1 . In France


 In 1992, crop and woodland sites

from the Lorraine region,
France were treated with 186–
306 tons of paper sewage
sludge in order to study the
effects of waste recycling.


 An investigation of the blue

sludge layer from 1992 to 1997
showed a decrease of calcium
content, from about 23 to 10%,
and of organic matter content,
from about 35 to 20%. In 2000,
the blue sludge layer is still
clearly apparent under a fern
litter layer, as shown for the
woodland site on Fig.


 Incresing depth shows the

downward carbon transfer from
the paper sludge. Figure showing sampling of soil layers
from the wood plot in August 2000.
 2 . Nagoan Paper Mill


 This study was done in the Nagaon Pulp and Paper Mill (Assam,
India) which produces 100,000 tonnes of paper annually from
bamboo.

 Surface soil samples (0–15 cm depth) were collected in both
dry and wet seasons over a four-year period from 19 points
at different distances from the mill.

 Accumulation of Al2O3, Fe2O3, and MnO in soil near the mill due
to the dumping of fly ash and other solid wastes in the
surrounding low lying land.


 Metals Ca, Mg, Na, and Pb decreased away from the mill.

 The soil pH had a tendency to turn alkaline near the mill
owing to the discharge of highly alkaline effluent by the
mill.

 The physical characteristics of the soil, viz., water holding
capacity and bulk density increased with distance from the
mill while the hydraulic conductivity had an opposite trend.

 PROPERTIES OF TYPICAL RAW LIME
SLUDGE
Parameters Units Average
value

pH 10.88
Moisture (%) 56.8
Conductivity (mS/cm) 0.765
Water holding capacity (%) 70.9
Organic carbon (%) 0.14
Total nitrogen (%) 0.03
Available phosphorus (mg/kg) 0.08
Potassium (mg/kg) 0.05
Calcium (mg/kg) 12.00
Magnesium (mg/kg) 26.41
Calcium carbonate (%) 67.43
Acid insoluble (%) 11.1
Silica (%) 19.0

Heavy metals Unit Average value

Zn (mg/kg) 0.463
Mn (mg/kg) 1.675
Cu (mg/kg) 0.165
Pb (mg/kg) 0.364
Ni (mg/kg) 0.268
Comparison of Cement and
typical Lime Sludge
Sl. No Constituent Lime Sludge (in %)
Cement (in %)

1. Lime(CaO) 46.2
62

2. Silica(SiO2) 19
22

3. Alumina 3.6
5

4. Magnesium 3.33
1

5. Calcium sulphate 4.05

4
 CHEMICAL REACTIONS INVOLVED IN PARTIALY REPLACED
CONCRETE


 1. Primary Hydration
 Cement + Water  C-S-H gel + Ca(OH)2


 2. Secondary Hydration
 Here Lime Sludge acts as a pozzolona
 Ca(OH)2 + Pozzolona  C-S-H gel


 Increase in amount of C-S-H gel increases

the compressive strength but only upto a
certain extent.

 Setting Time for cement
and typical Raw Lime Sludge
Sl. No Ingredients Initial (min)

Final(min)

1. Cement + 0% Lime sludge 30 600

2. Cement +10% Lime sludge 31 598

3. Cement +20% Lime sludge 33 597

4. Cement +30% Lime sludge 34 595

5. Cement +40% Lime sludge 36 593

6. Cement +50% Lime sludge 37 592

MATERIALS USED
 Portland Cement - 43 Grade


 Coarse Aggregate - 20mm downsize


 Fine Aggregate - 4.75mm passing


 Water - pH not less than 6


 Lime Sludge - dried, powdered and
 cleaned
EQUIPMENTS USED
 Sieves -IS 20mm for coarse aggregates,
 IS 4.75mm for fine aggregates


 Mortar pan and trowels


 Concrete mixer

 Slump cone apparatus

 Cube mould-150mmx150mmx150mm

 Vibrating table


 Compression testing machine

TESTS ON MATERIALS
 1 . Tests on Cement
 1.1 Normal Consistency Test


35
 30 32
30
25 28
25
20
%of water
15
P
efw
rcg
on
ta

10

0
0 1 2 3 4 5
Penetration

The consistency of cement was found to be 32%

when the penetration was 4mm from bottom.
 1.2 Initial setting time
 The initial setting time of cement used is
35 minutes


 2 . Tests on Fine aggregates

 Sieve analysis
 Sieve Size Percentage Cumulative Percentage
Retained Percentage Passing

4.75mm 00.00 00.00 100.00

2.36mm 00.70 00.70 99.30
1.18mm 17.08 17.78 82.20
600µm 32.52 50.30 49.070
300µm 31.27 81.57 18.43
150µm 16.13 97.70 2.30

The fineness modulus of sand taken is 2.48

Mix Design
Mix design is done according to IS 10262-
2004


The mix design is done for M30 grade

concrete


The parameters known



 Statistical Constant K = 1.65

 Exposure Conditions = Moderate
 Slump = 80-100mm
 Specific Gravity of FA and CA = 2.6 and
2.7 respectively
 Sand = Zone 2
 Steps :
1. Characteristic Strength, fck’ = 38.25 Mpa
2. From Table 5 of IS 456 : 2000, Exposure Condition is
moderate W/C=0.45
3. Water Content = 186Kg/m3 (for 20mm aggregates from
Table 2, IS 10262-2004 )
4. Cement Content = 413.33 kg/m3 > 300 kg/m3 (Min
Cement Content)
5. From Table 3 for 20mm aggregates and Zone 2,
 Volume of coarse aggregates per unit volume of
concentration=0.62
6. Absolute Volume of ingredients for 1m3 of concrete
 Volume of cement = 413.33/3150 = 0.132 m3
 Volume of water = 186/1000 = 0.186 m3
 Volume of total aggregates = 1 - 0.132 - 0.186 =
0.6828 m3


1.
7. Weight of all in aggregates = 0.6828 x 2.65 x 1000
 =
1809.42 kg/m3
8. Weight of coarse aggregate = 1809.42 x 0.62

 =
1121.84 kg/m3
9. Weight of fine aggregate = 1809.42 x 0.38

 =
687.57 kg/m3
10. Fresh Density = Cement + FA + CA + Water
 = 2408.75 kg/m3
11. Cement : FA : CA : Water
 1 : 1.664 : 2.714 : 0.45


For 12 cubes
Cement = 22 kgs

Sand = 41.77 kgs

Jelly = 68.15 kgs

Water = 9.723 litres

Mix Proportions

 Conventional Concrete – 1: 1.664 : 2.714

10% replacement – 0.90 : 1.664 : 2.714
20% replacement – 0.80 : 1.664 : 2.714
30% replacement – 0.70 : 1.664 : 2.714
40% replacement – 0.60 : 1.664 : 2.714
50% replacement – 0.50 : 1.664 : 2.714


 W/C ratio = 0.45 remains same for all the

replacements.
 EXPERIMENTAL STUDY
 1 . Slump Test
 For a constant W/C ratio of 0.45, concrete was found to be not workable.
Hence super plasticizer was added . The amount of super plasticizer was
arrived by slump test.

 % of Super plasticizer added Slump Obtained ( in mm)

0.2 10
0.4 27
0.6 42
0.8 50
0.9 58
1.0 75

Therefore 1% addition of complast super plasticizer is done on partially

replaced concrete and checked for slump.
% replacement Slump Obtained ( in mm)
Slump obtained for all replacements
10 70
20 70
30 66
40 62
50 55
2 . Preparation of Mould
 Cement, course aggregate, fine aggregates, water and Super
plasticizer are calculated and weighed depending upon the
volume and number of moulds to be cast.


 The moulds are prepared for water content ratio of 0.45 and 1%
addition of super plasticizer.


 The mixer is initially cleaned then cement and course aggregate

is poured into it and required rotation is given for 1 min to
mix.


 The inner surface of all the moulds is greased before pouring the
concrete and is then leveled.


 The moulds are placed on the vibrating table and allowed to
RESULTS
Compressive Strength on Cubes at 7 Days
 Partial Replacement in Number of Ultimate Load(kN) Ultimate Compressive Strength
% Specimen (N/mm2)

0 3 405.00 18.00
10 3 571.67 25.40
20 3 756.67 33.62
30 3 796.67 35.40
40 3 500.00 21.96
50 3 350.00 15.55

Compressive Strength on Cubes at 14 Days

Partial Replacement Number of Ultimate Ultimate Compressive Strength
in % Specimen Load(kN) (N/mm2)

0 3 526.67 23.40
10 3 696.67 30.96
20 3 873.33 38.81
30 3 896.67 39.85
40 3 600.00 26.66
50 3 450.00 20.88
Compressive Strength on Cubes at 28 Days

Partial Replacement in % Number of Ultimate Load(kN) Ultimate Compressive Strength

Specimen (N/mm2)

0 3 951.67 42.29

10 3 1000.00 44.44

20 3 1370.00 60.88

30 3 1403.33 62.36

40 3 990.00 44.00

50 3 515.25 22.90
Analysis of graphs
Graph of Compressive Strength Vs Age in Days


For 0 % Replacement

For 10 % Replacement
For 20 % Replacement

For 30 % Replacement
For 40 % Replacement

For 50 % Replacement
Graph of Compressive Strength Vs %
Replacement

At 7 Days At 14 Days

At 28 Days
DISCUSSIONS
1 . Economic Feasibility
 The calculations show cost values up to 50% replacement
 Total Cost of concrete mix for normal concrete/m3 = 3187.05 Rs
 Total Cost of concrete mix for 10% replacement/m3 = 2980.38 Rs

 Total Cost of concrete mix for 20% replacement/m3 = 2773.70 Rs

 Total Cost of concrete mix for 30% replacement/m3 = 2567.06 Rs
 Total Cost of concrete mix for 40% replacement/m3 = 2360.39 Rs
 Total Cost of concrete mix for 50% replacement/m3 = 2153.72 Rs


 2 . Comparison of strengths between

conventional concrete and partially replaced
concrete
Age of Concrete
(In Days) .
Compressive Strength(MPa)

Conventional Concrete 30% replaced Concrete


7 17.99 35.40

14 23.40 39.85

28 42.29 62.36

The difference in cost from normal concrete to partially

replaced concrete at 30% was Rs . 620 . 00 / m 3
CONCLUSIONS

 Compressive strength of the concrete,

increases as percentage of replacement is
increased up to 30%. Further increase in
replacement reduces compressive strength.


 Economy can be achieved with the replacement


 Environmental effects from lime sludge
disposal and cement manufacturing is reduced
through replacement.

SCOPE FOR FUTURE WORK
 Split tensile strength.

 Effect of Super plasticizer on compressive
strength can be studied by keeping other test
parameters such as mix composition, curing
period, curing time etc. constant.

 Effect of curing time can be further studied by
curing for 56 days.


 Admixtures could be used to give better

workability, higher strengths and provide ease
while laying of concrete.
  We as Civil Engineers must be
responsible for a better environment
for future generations by reducing
environmental degradation through use
of wastes that are generated from
various industrial processes.



THANK YOU