Improvment of Concrete Strength by Using Ceramic Tile Waste Powder As Partially Replacment of Cement

MEKELLE UNIVERSITY
EIT-M
SCHOOL OF CIVIL ENGINEERING
IMPROVEMENT OF CONCRETE STRENGTH USING
CERAMIC TILE WASTES AS PARTIALLY
REPLACEMENT OF CEMENT
A THESIS SUBMITTED FOR BSc. IN

CIVIL ENGINEERING
SUBMITTED TO SCHOOL OF CIVIL ENGINEERING
STRUCTURAL ENGINEERING CHAIR
MEKELLE UNIVERSITY
JUNE, 2017
IMPROVEMENT OF CONCRETE STRENGTH USING CERAMIC TILE WASTES AS
PARTIALLY REPLACEMENT OF CEMENT
PREPARED BY
5TH YEAR
SECTION-5 NETWORK-1
GROUP MEMEBERS ID.NO
1. ASMARE MESFIN...EIT/UR0488/05
2. WELDEABRHA WELDAY.EIT/UR1833/05
3. YIRGALEM SOLOMON ....EIT/UR1959/05
4. YOHANNES ZENEBE ...EIT/UR0788/05
ADVISOR: HELEN NEGASH (MSc.)

DECLARATION
We declare that this research is our original work. The findings presented
in this paper are not found in any other previous research works.
Group Members Signature Date

1. ASMARE MESFIN .. .
2. WELDEABRHA WELDAY ... .
3. YIRGALEM SOLOMON .. .
4. YOHANNES ZENEBE .. .
ACKNOWLEDGEMENT
First of all, glory to the almighty God for helping us on every aspect during our stay at the Uni-
versity and for the completion of the thesis.
It has been a pleasure and an honor to work under the guidance of our adviser Helen Negash
(MSc.) lecturer at Ethiopian Institutes of Technology Mekelle (EIT-M). For her guidance and
continuous support during our discussions and helped us for completion of the thesis.
We would like to acknowledge Civil Engineering and Geology laboratory technicians for their
assistance during the laboratory works.
We also greatly indebted to all our family and other individuals who encouraged us during our
graduate program study.
Page I
ABSTRACT
A ceramic tile powder is a material which interacts with the ingredients of concrete and affects
the concrete properties in the fresh and hardened state. Now a days, its possible to produce con-
crete having better quality with the addition of A ceramic tile powder in different ways by saving
some amount of cement for a given mix design.
The objective of this research was to study the effects of a ceramic tile powder on concrete
properties, such as: workability, compressive strength, and flexural strength. And to Study the
recycling of real ceramic tile waste arising from different tile manufacturing companies and con-
struction and Demolition (C&D) wastes in order to partially replace pozzolanic cement on con-
crete formation.
And other objective of this research is studying the environmental and economic effects using
ceramic tile powder on concrete production
The significant of the research is Bring environmental, economic and technological benefits,
since it avoids the disposal of waste materials and minimizes the use of natural resources for
production of pozzolan cement, which implies energy savings and, therefore, fewer carbon diox-
ide emissions and it creates Job opportunity for the society by providing ceramic powder of con-
crete production.
The experiments were performed on C-30 concrete grade which have a 0.54 water to cement ra-
tio and with a slump of 75-100mm, at a dosage of 0%, 10%, 20% and 30% a ceramic tile pow-
der. To facilitate the study, the experiments have been classified into two phases, such as
Phase-I: The effect of ceramic tile waste powder on workability at a constant W/C ratio.
Phase-II: The effect of ceramic tile waste powder on concrete properties by reducing ce-
ment content at constant W/C ratio.
Based on the work results 10% ceramic tile powder has shown higher result on compressive,
and flexural. Finally, the addition of ceramic tile powder was shown improvement on
strength (compressive and flexural) from the reference concrete. And as increasing addition
of ceramic tile powder on concrete production the workability is decrease, so that we rec-
ommend adding water.
And also, the about 23% of ceramic tile powder has equal compressive strength with 0% ce-
ramic tile powder; we get that up to 23% of ceramic tile wastes can replace cement. This
great result difference shows to save too much cement till the strength become equivalent to
the reference concrete.
Similarly on flexural strength about 22% of ceramic tile powder has equal flexural strength
with 0% ceramic tile powder, so that it is safe to replace cement by ceramic tile wastes Up to
22%.
Page II
From the, analysis the carbon dioxide CO2 produced for the manufacture of one ton of struc-
tural concrete (using ~14% cement) is estimated at 410 kg/m3 (~180 kg/ton @ density of 2.3
g/cm3). Therefore from this, our research it is estimated that 23% replacement of cement with
Ceramic tile waste powder represents a 16.92% reduction in energy consumption.
Based on the market price of cement and Ceramic tile waste powder, the cost by the use of
10%, 20% and 23% Ceramic tile waste powder for a m3 concrete is about 88.34ETB,
176.92ETB and 203.36ETB more expensive than the reference concrete.
Generally replacing of cement by 23% ceramic waste tile powder can decrease the cost of
concrete by 17% from the original concrete.
Page III
CONTENTS Page
ACKNOWLEDGEMENT ............................................................................................................... I
ABSTRACT .................................................................................................................................... II
LIST OF TABLE ......................................................................................................................... VII
LIST OF FIGURE........................................................................................................................ VII
LIST OF ABBREVIATIONS .................................................................................................... VIII
CHAPTER ONE ............................................................................................................................. 1
1. INTRODUCTION ................................................................................................................... 1
1.1 GENERAL BACKGROUND .......................................................................................... 1
1.2 STATEMENT OF THE PROBLEM ............................................................................... 2
1.3 RESEARCH QUESTIONS .............................................................................................. 2
1.4 OBJECTIVES OF THE RESEARCH.............................................................................. 2
1.4.1 General Objective ..................................................................................................... 2
1.4.2 Specific Objective ..................................................................................................... 2
1.5 SIGNIFICANCES OF THE RESEARCH ....................................................................... 3
1.6 SCOPE AND LIMITATION OF THE THESIS .............................................................. 3
1.7 MATERIALS AND METHODOLOGY ......................................................................... 3
1.7.1 Materials ................................................................................................................... 3
1.8 METHODOLOGY OF THE RESEARCH ...................................................................... 4
1.9 ORGANIZATION OF THE PAPER ............................................................................... 5
CHAPTER TWO ............................................................................................................................ 6
2 LITERATURE REVIEW ........................................................................................................ 6
2.1 GENERAL ....................................................................................................................... 6
2.2 CERAMIC TILE WASTES ............................................................................................. 6
2.2.1 Ceramic Wastes Classification ................................................................................. 7
2.2.2 Ceramic Wastes Properties: ...................................................................................... 8
2.2.3 Effect of Ceramic Tile Wastes on Concrete Production ........................................... 9
2.2.4 History of Ceramic Tile Wastes on Concrete Production ....................................... 10
2.3 CONCRETE ................................................................................................................... 11
2.3.1 Composition of Concrete ........................................................................................ 11
Page IV
2.3.2 Production of Concrete ........................................................................................... 11

2.3.3 Specification of Concrete ........................................................................................ 12
2.4 MATERIALS FOR CONCRETE PRODUCTION ....................................................... 13
2.4.1 Cement .................................................................................................................... 13
2.4.2 Aggregate ................................................................................................................ 13
2.4.3 Water ....................................................................................................................... 14
2.4.4 Admixtures.............................................................................................................. 14
CHAPTER THREE ...................................................................................................................... 15
3 METHODOLOGY, MATERIAL PREPARATION, AND CONCRETE PRODUCTION . 15
3.1 INTRODUCTION .......................................................................................................... 15
3.2 METHODOLOGY OF THE RESEARCH .................................................................... 15
3.3 MATERIAL PREPARATION ....................................................................................... 16
3.3.1 Cement Used For the Experiment ........................................................................... 16
3.3.2 Aggregate Used For the Experiment....................................................................... 16
3.3.3 Water Used For the Experiment ............................................................................. 20
3.3.4 Ceramic Tile Waste Powder Used For the Experiment .......................................... 21
3.4 CONCRETE PRODUCTION ........................................................................................ 21
3.4.1 Concrete Mix Design .............................................................................................. 21
3.4.2 Concrete Production Process .................................................................................. 25
CHAPTER FOUR ......................................................................................................................... 26
4 EXPERIMENTAL RESULTS AND DISCUSSIONS .......................................................... 26
4.1 PHASE I: THE EFFECT OF CERAMIC TILE POWDER ON WORKABILITY ....... 26
4.1.1 Workability Tests for C-30 Concrete Grade ........................................................... 26
4.2 PHASE II: THE EFFECT OF CERAMIC TILE POWDER ON CONCRETE
PROPERTIES BY REDUCING CEMENT CONTENT .......................................................... 28
4.2.1 Experimental Results and Discussion on Compressive Strength of Concrete ........ 28
4.2.2 Experimental Results and Discussion on Flexural Strength of Concrete ............... 31
CHAPTER FIVE .......................................................................................................................... 35
5 ENVIRONMENTAL AND QUALITATIVE ECONOMIC ANALYSIS ............................ 35
5.1 INTRODUCTION .......................................................................................................... 35
5.2 ENVIRONMENTAL IMPACTS ................................................................................... 36
Page V
5.2.1 Carbon Dioxide Emissions and Climate Change .................................................... 36

5.3 ECONOMIC IMPACT ANALYSIS .............................................................................. 39
CHAPTER SIX ............................................................................................................................. 41
6 CONCLUSIONS AND RECOMMENDATIONS ................................................................ 41
6.1 CONCLUSIONS ............................................................................................................ 41
6.2 RECOMMENDATIONS ............................................................................................... 42
REFERENCES ............................................................................................................................. 43
APPENDIX ONE.......................................................................................................................... 44
MATERIALS TEST RESULTS ................................................................................................... 44
APPENDEX TWO........................................................................................................................ 48
STANDARDS FOR MIX DESIGN ............................................................................................. 48
APPENDIX THREE ..................................................................................................................... 53
EXPERIMENTAL RESULTS...................................................................................................... 53
APPENDIX FOUR ....................................................................................................................... 55
SAMPLE PHOTO GALLERY TAKEN DURING THE RESEARCH ....................................... 55
Page VI
LIST OF TABLE PAGE

Table 2-1 principally waste materials in construction and demolition waste ................................. 7
Table 2-2 Material composition of ceramic tile wastes .................................................................. 9
Table 2-3 Chemical analysis of ceramic tile and cement .............................................................. 9
Table 3-1 the Particle Size Distribution for Fine Aggregates ....................................................... 17
Table 3-2 Summarized test results for fine aggregate (sand) ....................................................... 19
Table 3-3 Sieve Analysis for Coarse Aggregate ........................................................................... 19
Table 3-4 Summarized Test Results for Coarse Aggregate .......................................................... 20
Table 3-5 Summarized Material Properties Used For Concrete Mix Design ............................... 23
Table 3-6 Quantity of materials in kg for 1m3 C-30 concrete grade production ......................... 24
Table 4-1 Slump Development Test Results For C-30 Concrete Grade ....................................... 27
Table 4-2 Quantity of Materials in Kg for 1m3 C-30 Concrete Grade Production at Constant Water ....... 28
Table 4-3 Effect Of Ceramic Tile Waste Powder on Compressive Strength by Cement Reduction .......... 29
Table 4-4 Mean Value of Compressive Strength Test .................................................................. 33
Table 5-1 Amount of Cement Saving and Carbon Dioxide Emission Relation ........................... 37
Table 5-2 Cost Comparisons between Cement Saved and Ceramic Tile Waste Powder Used .... 39
LIST OF FIGURE PAGE

Figure 1-1 Methodology of the Research ....................................................................................... 5
Figure 3-1 Fine aggregate gradation chart .................................................................................... 17
Figure 3-2 Coarse aggregate gradation chart ................................................................................ 20
Figure 4-1 effect of ceramic tile powder on workability .............................................................. 27
Figure 4-2 Effects of ceramic tile powder on compressive strength ............................................ 29
Figure 4-3 allowable percentage of ceramic tile powder which replace cement .......................... 30
Figure 5-1 reduction in CO2 emission (Kg/m3) ............................................................................ 38
Figure 5-2 reduction of cost per m3 .............................................................................................. 40
Page VII
LIST OF ABBREVIATIONS
ACI American Concrete Institute P2O5 Phosphorus Pentoxide
Cm Centimeter SO3 Sulfur Trioxide
Kg Kilogram K2O Potassium Oxide
Kg/m3 Kilogram Per Cubic Meter CaO Calcium Oxide
BS British Standard TiO2 Titanium Dioxide
ASTM American Society For Testing Material ZnO Zinc Oxide
kN Kilo Newton Fe2O3 Iron Oxide
Lit Liter ZrO2 Zirconium Dioxide
m3 Meter Cubic BaO Barium Oxide
Max Maximum P2O5 Phosphorus Pentoxide
Min Minimum
mm Millimeter
MPa Mega Pascal
MPa/s Mega Pascal per Second
SSD Saturated Surface Dry
W/c Water to Cement Ratio
% Percentage
Al Aluminum
Ca Calcium
Na2O Sodium Oxide
MgO Magnesium Oxide
Al2O3 Aluminum Oxide
SiO2 Silicon Dioxide
Page VIII
CHAPTER ONE
1. INTRODUCTION
1.1 GENERAL BACKGROUND
According to information obtained from different sources written by experienced professionals,

the qualities of being constructed infrastructures are not as such strong and durable; crack and
failure is frequent and the cost incur for construction is very high; this is due to less
advancement of construction technology and materials usage. However, ceramic tile waste pow-
der can substantially reduce those problems, because they allowing increasing early and
ultimate strengths with partially replaced of cement and reduce concrete permeability and there-
by reduce aggressive penetration, like: chloride, carbonation, and sulphate, etc. and reduce crack
and enhance durability [1].
Construction and Demolition (C&D) wastes contribute the highest percentage of wastes world-
wide (75%). Furthermore, ceramic materials contribute the highest percentage of
wastes within the C&D wastes (54%). The current option for disposal of ceramic wastes is land-
fill. This is due to unavailability of standards, avoidance of risk, lack of knowledge and experi-
ence in using ceramic wastes in construction. The ability of ceramic wastes to act as a pozzolanic
material in the production of cement has been effectively explored [2].
Nowadays, a great problem for this world is global warming which is caused by depletion of
natural resources and emission of gases during cement production. But, ceramic tile waste pow-
der are sensitized or wastes which has ability to save cement consumption with some percentage,
this helps to reduces environmental problems caused by too much cement production.
In Ethiopia ceramic wastes are a problematic material in its substances. In our society wastage of
ceramic tiles disposed as landfill. However, using ceramic wastes, as landfill may not be the best
option, depending on whether there can be leaching of chemicals that can be detrimental
to the environment. This also negates the concept of sustainable development, and hence
the need to investigate alternative beneficial use of these wastes. There for, our research
will be the best solution for this problem.
Therefore, this research has investigated some benefits which are obtained by the use of ceramic
tile waste powder as a construction material. In order to show the effects of ceramic tile waste
powder on concrete properties, such as: workability, and strength, laboratory experimentations
were performed by adding dosages of 0%, 10%, 20% and 30% ceramic tile waste powder in con-
crete mixes and results are conducted. Then, based on the experimental results conclusion are
drawn and recommendations have been forwarded.
Page 1
1.2 STATEMENT OF THE PROBLEM
The qualities of being constructed infrastructures are not as such strong and durable; crack and
failure is frequent and the cost incur for construction is very high; this is due to less
advancement of construction technology and materials usage However, ceramic tile waste pow-
der can substantially reduce those problems
Every production system creates by-products and waste products which can affect the
environment. In Ethiopia this problem is becoming increasingly acute due to the growing
quantity of industrial, construction and demolition waste generated despite the measures The
need to manage these wastes has become one of the most pressing issues of our times, requiring
specific actions aimed at preventing waste generation.
1.3 RESEARCH QUESTIONS
In light of the above statement of the problem, the study tries to answer the following basic re-
search questions.
1. Is ceramic tile waste powder partially replacing cement?
2. Is ceramic tile waste powder improving the strength of concrete?
3. In how much percentage can ceramic tile waste powder replace cement?
4. Is there any effect on environmental and economic when we use ceramic tile waste pow-
der in concrete production?
1.4 OBJECTIVES OF THE RESEARCH
1.4.1 General Objective
The general objective of this research is to study the effects of ceramic tile waste powder
on the properties of concrete.
1.4.2 Specific Objective
The specific objectives of this research will explore the following points:
Improving the strength of concrete by partially replaced of cement content by ceramic tile
waste powder.
Studying the effects of ceramic tile waste powder on concrete properties by reducing ce-
ment content
Studying of the effect of ceramic tile powder on concrete production
Examining the effects of different dosage of ceramic tile waste powder on workability,
strength concrete
Determination of the percentage replacement of ceramic tile powder for cement content
Page 2
Study the recycling of real ceramic tile waste arising from different tile manufacturing
companies and construction and Demolition (C&D) wastes in order to partially
replace pozzolanic cement on concrete formation.
Studying the environmental and economic effects using ceramic tile powder on concrete
production
1.5 SIGNIFICANCES OF THE RESEARCH
Production of concrete with high strength and low cost concrete.

Brings environmental, economic and technological benefits, since it avoids the disposal
of waste materials and minimizes the use of natural resources for production of pozzolan
cement, which implies energy savings and, therefore, fewer carbon dioxide emissions
It creates Job opportunity for the society
1.6 SCOPE AND LIMITATION OF THE THESIS
The main focus of this research is to study the effects of ceramic tile waste powder on
concrete properties. Currently, in the developed countries the concrete technology has reached
on the high level and remarkable successes have achieved by the development of materials
for production of quality concrete. However, in our country the use of such materials are less
recognized and the local construction parties that participate in the construction industry have
little information and awareness about the uses and effects of such materials on the production of
quality concrete.
This research finally helps to create awareness and shows the benefits obtained by the use of
ceramic tile waste powder as partially replacement of cement.
1.7 MATERIALS AND METHODOLOGY
1.7.1 Materials
To achieve the objective of the research different materials will be used. The following are the
main ones:
Cement
Fine and coarse aggregates
Ceramic tile waste powder
Water
Page 3
1.8 METHODOLOGY OF THE RESEARCH
For the objectivity of the research the following are the methodologies followed
1) Literature Survey
The first activity in this research was review literatures related to the research from different
sources like: text books, research papers, journals, magazine, internet, etc.
2) Material Preparation
Concrete making materials (Cement, fine aggregate, Coarse aggregate, and Water) and ceramic
tile powder used for the research were prepared
3) Material Testing
The physical characteristics of concrete making materials (Cement, fine aggregate, Coarse ag-
gregate, and Water used for the research were examined and
4) Appropriate Mix Design Was Made
Based on the test results concrete making materials proportioning have been executed and mix-
design was prepared for C-30 concrete grades.
5) Casting The Specimen
After that, concrete sample preparations at different dosages of ceramic tile waste powder have
been performed. for this thesis about 48 control specimens (36 cubes and 12beams) for a nominal
mix have been cast in laboratory of C-30 grade of concrete having proportion of materials calcu-
lated in the mix design used as base for this.
6) Loading Test
Then, the prepared concrete samples have been tested for both in the fresh and hardened states.
For the fresh state workability properties of concrete has been checked and for hardened concrete
compressive and flexural tests have been carried out. For compressive strength tests concrete
samples have been checked at the age of 7, 14 and 28 days. For flexural strength concrete sam-
ples are tested at 14 day.
7) Studying And Discussion Of The Result
The results obtained from experiment are discussed and presented in tables and figures.
8) Conclusion And Recommendations
Finally, conclusions are drawn and recommendations have been forwarded.
Page 4
Litrature Material
Material
servey collection Mix design
testing
Conclusion
Casting the Studying and
and
specimen Loading test discussion of
recomendation
the result
s
Figure 1-1 Methodology of the Research
1.9 ORGANIZATION OF THE PAPER
This thesis has been organized in six chapters. The first chapter is devoted to bring about the
general background of the partially replacement of cement by ceramic tile waste powder objec-
tive of the study, statement of the problem, research questions and significance of the study.
The second chapter reviews the theoretical framework (literature) of the study. The third chapter
of this research is methodology, material preparation, and concrete production.
The fourth chapter of the study focuses on experimental results and discussions on the improve-
ment. And the fifth chapter discusses on environmental and qualitative economic analysis .Based
on these results, suitable recommendations and suggestions are forwarded in the six chapter.
Lastly, the references and appendixes are listed.
Page 5
CHAPTER TWO
2 LITERATURE REVIEW
2.1 GENERAL
Concrete is a composite material composed of coarse granular material (the aggregate or filler)
embedded in hard matrix of material (the cement of binder) that fills the space between the ag-
gregate particles and glue them together [3]. In concrete the binder or matrix is a combination of
cement and water; it is commonly called the "cement paste. Aggregates are essentially filler ma-
terials that can be separated into fine and coarse aggregates. In addition to aggregates and bind-
ers, there is another material called additive which may be used in concretes to improve certain
of its properties [4]
Concrete is by far the most versatile and most widely used construction material worldwide. It is
used in different structures, such as: dam, building, bridge, tunnels, highway etc. It can be engi-
neered to satisfy a wide range of performance specifications, unlike other building materials,
such as natural stone or steel, which generally have to be used as they are.
Ceramic tile waste powder is a type of high range cement reducing material. This type of materi-
al will provide high quality improvement for concrete in both fresh and hardened states. General-
ly, ceramic tile waste powder improves strength, of concrete [9]. Therefore, the main discussion
of this chapter focus on reviewing Ceramic tile waste powder, particularly on ceramic tile waste
powder used to produce quality concrete.
2.2 CERAMIC TILE WASTES
Ceramic tile Wastes are waste products which are released directly into the environmental and
can cause environmental pollution. Numerous waste materials are generated from manufacturing
processes, service industries, and construction and demolition works and municipal solid wastes.
Ceramic waste may come from two sources.
1. The first source is the ceramics industry

2. The second source of ceramic waste is associated with construction and demolition
activity, and constitutes a significant fraction of construction and demolition waste
(CDW).
In our country Ethiopia, there are a lot of ceramic wastes during construction and
demolishing activities. So that by reusing these ceramic wastes as partially replacement
of cement, our research would be more interesting.
Page 6
A construction and demolition waste principally consists of two fractions: the stony fraction
and the rest (see Table below). The most important fraction is the stony fraction, comprising
ceramic materials (bricks, wall tiles, sanitary ware, etc.), concrete, sand, gravel and other
aggregates [9].
Table 2-1 principally waste materials in construction and demolition waste
MATERIALS COMPOSITION (%)

STONY FRACTION 75
Bricks, wall tiles and other ceram-
ic 54
materials
Concrete 12
Stone 5
Sand, gravel and other aggregates 4
REST 25
Wood 4
Glass 0,5
Plastic 1,5
Metals 2,5
Asphalt 5
Plaster 0,2
Rubbish 7
Paper 0,3
Others 4
As can be seen, more than half (54%) corresponds to the ceramic fraction, representing the
highest percentage of all materials shown, followed by concrete waste (12%). This illustrates
the importance of the treatment and recovery of this kind of waste. In many cases, the
possibility of reuse or recycling will depend on the existence of previous studies into the
viability of this waste fraction, such as that proposed by this present research.
2.2.1 Ceramic Wastes Classification
Ceramic wastes are classified as recyclable and non-recyclable wastes. Non-recyclable used for
the normal use as filling material. And based on research regarding recyclable Construction and
Demolition (C&D) wastes, ceramic wastes have the potential to be used in concrete production.
However, there are no guidelines and standards to the usage of these wastes in concrete. In addi-
tion, the local construction industry does not have knowledge and experience to utilize the mate-
rial [9].
Page 7
2.2.2 Ceramic Wastes Properties:
Ceramic products are made from natural materials which contain a high proportion of clay
minerals. These, through a process of dehydration followed by controlled firing at
temperatures of between 700C and 1000C, acquire the characteristic properties of fired
clay. Thus, the manufacturing process involved in ceramic materials requires high firing
temperatures which may activate the clay minerals, endowing them with pozzolanic
properties and forming hydrated products similar to those obtained with other active
materials [9].
Research carried out into the influence of firing temperatures on waste product properties
has found that the chemical and mineralogical composition of ceramic masonry rubble
resulting from incorrect firing temperatures (over- or under-firing) varies significantly from
that of products obtained from optimal firing conditions. However, the temperature
applied (around 900C) is sufficient to activate the clay minerals, with the result that the
different rejects acquire similar pozzolanic properties. Furthermore, studies have been
carried out into the viability of substituting cement by using ceramic rejects or masonry
rubble as raw materials in prefabricated concrete, exploiting their pozzolanic properties.
Ceramic masonry rubble must be suitably fine in order to be used as a pozzolanic additive
in cement, and thus must be crushed and ground until reaching the specific surface, or
Blaine value, of around 3500 cm2/g. This material presents a chemical composition similar
to other pozzolanic materials, with a strongly acid nature where silica, aluminium oxide and
iron oxide predominate (75.97%), and with a CaO content of 12.41% and an alkali content of
4.22%. Loss through calcination is 3.44% and sulphate content, expressed as SO3, is 0.79%.
Mineralogical composition, determined by X-ray diffraction, mainly comprises the

crystalline compounds quartz, muscovite, calcite, microcline and anorthite. In order to assess
pozzolanic activity, an accelerated method is used in which the materials reaction over time
with a lime-saturated solution is studied. The percentage of lime fixed by the sample is obtained
through calculating the difference between the concentration of the initial lime-saturated solution
and the CaO present in the solution in contact with the material at the end of each pre-determined
period [9].
The Materials composition of ceramic tile wastes and the Chemical analysis of ceramic tile and
cement are shown on the table below [10].
Page 8
Table 2-2 Material composition of ceramic tile wastes
Ceramic tile waste Ceramic tile waste

Materials Materials
(%) (%)
SiO2 63.29 Na2O 0.75
Al2O3 18.29 SO3 0.10
Fe2O3 4.32 CL- 0.005
CaO 4.46 TiO2 0.61
MgO 0.72 SrO2 0.02
P2O5 0.16 Mn2O3 0.05
K2O 2.18 L.O.I 1.61
Table 2-3 Chemical analysis of ceramic tile and cement
Ceramic Tile Ceramic Tile

Materials waste Cement (%) Materials waste Cement (%)
(%) (%)
SiO2 63.29 20.52 Na2O 0.75 0.17
Al2O3 18.29 5.46 SO3 0.10 2.18
Fe2O3 4.32 3.64 Cl- 0.005 0.002
CaO 4.46 65.04 TiO2 0.61 0.27
MgO 0.72 1.35 SrO2 0.02 0.03
P2O5 0.16 0.04 K2O 2.18 0.68
2.2.3 Effect of Ceramic Tile Wastes on Concrete Production
The advancement of concrete technology can reduce the consumption of natural resources.
They have forced to focus on recovery, reuse of natural resources and find other alternatives. The
use of the replacement materials offer cost reduction, energy savings, arguably superior
products, and fewer hazards in the environment.
Many of the construction projects utilize concrete as the main material for the structures. Con-
crete contains about 75% (by volume) of aggregates, which are in most areas abundant. Howev-
er, in most cases where there is a need for large supply of concrete, the natural environment ends
up being sacrificed for economic reasons. Due to the rise in environmental awareness, there has
been substantial amount of research in incorporating wastes, especially C&D wastes, into the
making of concrete.
The principle waste coming into the ceramic industry is the ceramic powder,
specifically in the powder forms. Ceramic wastes are generated as a waste during the process of
dressing and polishing. It is estimated that 15 to 30% waste are produced of total raw material
used, and although a portion of this waste may be utilized on-site, such as for excavation pit re-
fill,
Page 9
The disposals of these waste materials acquire large land areas and remain scattered all around,
spoiling the aesthetic of the entire region. It is very difficult to find a use of ceramic waste pro-
duced. Ceramic waste can be used in concrete to improve its strength and other durability fac-
tors. Ceramic waste can be used as a partial replacement of cement to achieve different proper-
ties of concrete [9].
These wastes create a problem in present-day society, requiring a suitable form of management
in order to achieve sustainable development. In this thesis it illustrates about the behavior of con-
crete with partial replacement of tile powder in cement accordingly in the range of 0%, 10%,
20%, and 30% by weight for C-30 grade of concrete.
For this purpose the concrete with ceramic tile waste powder adding samples are tested and
compared with the conventional concrete. The following tests are carried out, i.e., compressive
strength for 7, 14, and 28 days and flexural strength for 14 day. The test results are going to be
discussed.
2.2.4 History of Ceramic Tile Wastes on Concrete Production
Amitkumar D. Raval, Indrajit N. Patel, JayeshkumarPitroda Use of Ceramic Powder As

A Partial Replacement of Cement the OPC cement has been replaced by ceramic waste powder
Accordingly in the range of 0%, 10%, 20%, 30% 40% & 50% by weight for C-25 grade
concrete. The Compressive Strength of C-25 grade concrete increased when the replacement of
cement with ceramic waste up to 30% by weight of cement and further replacement of cement
with ceramic powder the compressive strength decreased.
D.Tavakolia, A. Heidari*, b and M. Karimianb conducted by using ceramic wastage in

concrete production causes no remarkable negative effect in the properties of concrete. The
optimal case of using tile wastage as sand are amounts of 25 to 50 percent, besides, the best case
of their use as coarse aggregate are as amounts of 10 to20 percent.
R. Malathy, Kongu Engineering College, India K. Subramanian, CIT, Coimbatore, India has
proposed that efficiency factor for silica fume and metakaoline at various replacement levels and
conclude that the proposed method of mix proportioning combined the use of super plasticizer
and cement replacing material for obtaining economical HPC mix.
Dr.M.Swaroopa Rani Study the ordinary Portland cement replaced by ceramic waste powder
accordingly in the range of 0%, 10%, 20%, 30%, 40%, and 50% by weight for C-40 grade
concrete and the compressive strength is calculated. The Compressive Strength of C-40 grade
concrete increased when the replacement of cement with ceramic waste up to 10% by weight of
cement and further replacement of cement with ceramic powder the compressive strength
decreased.
Page 10
2.3 CONCRETE
Concrete is a composite material composed of coarse granular material (the aggregate or filler)
embedded in hard matrix of material (the cement of binder) that fills the space between the ag-
gregate particles and glue them together [3]. In concrete the binder or matrix is a combination of
cement and water; it is commonly called the "cement paste. Aggregates are essentially filler ma-
terials that can be separated into fine and coarse aggregates. In addition to aggregates and bind-
ers, there is another material called additive which may be used in concretes to improve certain
of its properties [4]
Concrete is by far the most versatile and most widely used construction material worldwide. It
can be engineered to satisfy a wide range of performance specifications, unlike other building
materials, such as natural stone or steel, which generally have to be used as they are.
It is used in different structures, such as: dam, building, bridge, tunnels, highway etc. It can be
engineered to satisfy a wide range of performance specifications, unlike other building materials,
such as natural stone or steel, which generally have to be used as they are.
2.3.1 Composition of Concrete
Concrete is basically a mixture of two components: aggregates and paste. The paste binds the
aggregate into rocklike mass because of the chemical reaction between cement and water,
sometimes mineral and chemical admixtures may also be included in the paste [5]. The quality of
the concrete depends upon the quality of the paste and aggregate, and the bond between them. In
properly made concrete, each and every particle of aggregate is completely coated with paste and
all of the spaces between aggregates are completely filled with paste [5].
2.3.2 Production of Concrete
Its obvious that, concrete can be produced by anybody through mixing of concrete ingredients,
but the important point bear in mind is producing acceptable concrete quality with a reasonable
economy. To produce acceptable quality, its important to make physical characteristic tests on
materials used for the investigation before any concrete experiments are carryout.
The production of concrete involves two distinct but equally important activities. One is related
to material required for concrete production such as selection and proportioning of ingredients
and the other is the process involved in its production such as batching, mixing, transportation,
placement, compaction and curing [3].
A good and a bad concrete may be made from exactly the same ingredients if there is a differ-
ence on the quality control during production. The importance of quality of concrete is being in-
creasingly realized to derive the optimum benefit from the materials employed.
Page 11
Quality control does not merely signify testing of concrete cubes at 28 days; rather it actually
permeates all aspects of the choice of materials, design, and workmanship it commences much
before any concrete is available for testing at 28 days [5].
According to EBCS 2, 1995, Quality control is defined as an action and decisions taken to ensure
the compliance of works with the specification. It consists of two distinct, but interconnected
parts, namely, production control and compliance control. Production control is a measure taken
during production to obtain a reasonable assurance that the specifications will be satisfied which
compliance control is a check is made to ensure the compliance of the product with the
specification.
2.3.3 Specification of Concrete
Mixture proportioning refers to the process of determining the quantities of concrete ingredients,
using local materials, to achieve the specified characteristics of the concrete such as acceptable
workability of the freshly mixed concrete, durability, strength, and uniform appearance of the
hardened concrete & Economy. As a result, various standards have set mix their own design
procedures for instance the American (ACI) and the British method of mix design, commonly
called DOE method and India standard of mix design (IS), but ACI and DOE are the most
common.
According to EBCS 2, 1995 and BS 5328 part II-1997 concrete specifications classified in to
three but Indian standard IS 456:2000 recommend Designed mixes for concrete grades above C-
20 and Nominal mix for concrete grades C-20 or lower.
1. Designed mixes: With this method the required compressive strength is specified, together
with any other limits that may be required in fresh as well as hardened concrete, such as
workability and finishing characteristics in fresh concrete and durability in hardened
concrete by specifying maximum aggregate size and minimum cement content. The mini-
mum cement content requirements serve to ensure satisfactory durability and
finishability, to improve wear resistance of slabs, and to guarantee a suitable appearance
of vertical surfaces [6].
2. Prescription mixes: With this method the designer assumes responsibility for designing
the mix and stipulates to the producer the mix proportions and the materials which shall be
employed.
3. Standard (or Nominal) mixes: Those standard mixes are rich in cement and are intended for
use, where the cost of trial mixes or of acceptance cure testing is not justified may be used
without verification of compressive strength by testing. Ethiopian standard EBCS 2, 1995
specify nominal mix proportion for grades C5 to C30 may be taken from Table 2.10 but Indi-
an standard recommended nominal mix for concrete having grade of C-20 or lower.
Page 12
2.4 MATERIALS FOR CONCRETE PRODUCTION
2.4.1 Cement
There are many different kinds of cements. In concrete, the most commonly used is Portland ce-
ment, hydraulic cement which sets and hardens by chemical reaction with water and is capable of
doing so under water. Cement is the glue that binds the concrete ingredients together and is
instrumental for the strength of the composite. Although cements and concrete have been around
for thousands of years, modern Portland cement was invented in 1824 by Joseph Aspdin of
Leeds, England. The name derives from its resemblance of the natural building stone quarried in
Portland, England [7].
Portland cement is made up primarily of four mineral components (tricalcium silicate, dicalcium
silicate, tricalcium aluminate, and tetracalcium aluminoferrite), each of which has its own hydra-
tion characteristics. By changing the relative proportions of these components, cement manufac-
turers can control the properties of the product. The primary product of cement hydration is a
complex and poorly crystalline calcium-silicate hydroxide gel (or CSH). A secondary product of
hydration is calcium hydroxide, a highly crystalline material.
A category of siliceous materials known as pozzolans have little or no cementations value, but
in finely divided form and in the presence of moisture will react chemically with calcium hy-
droxide to form additional CSH. This secondary hydration process has a generally beneficial ef-
fect on the final concrete properties. Examples of pozzolans are fly ash, ground granulated blast-
furnace slag, and micro silica or silica fume. The American Society for Testing and Materials
(ASTM) defines five types of cement, specifying for each the mineral composition and chemical
and physical characteristics such as fineness.
The most common cement is Type I. Type III cement is used if more rapid strength development
is required. The other types are characterized by either lower heat of hydration or better sulfate
resistance than that of Type I cement.
2.4.2 Aggregate
Aggregates are the materials basically used as filler with binding material in the production of
concrete and provide concrete with better dimensional stability and wear resistance. They are
derived naturally from igneous, sedimentary and metamorphic rocks or manufactured from blast
furnace slag, etc. [5]. It is therefore significantly important to obtain right type and quality of
aggregates (fine and coarse) because aggregates occupy 60% to 75% of the concrete volume
(70% to 85% by mass) and strongly influence the concretes freshly mixed and hardened proper-
ties, mixture proportions, and economy [5]. So that to proportion suitable concrete mixes, certain
properties of aggregate which influence the paste requirement of fresh concrete such as shape
and texture, size graduation, moisture content, specific gravity and bulk unit weight must be
Page 13
known [6]. In addition to these, aggregates should be hard, strong, dense, durable, clear and free
from veins and adherent coating; and free from injurious amounts of disintegrated pieces, alkali,
vegetable matter and other deleterious substances. As far as possible, flaky and elongated pieces
should be avoided [8].
All standards specify their own requirements for aggregate used for concrete production, for
instance ES 81:2001, SABS 1083 specify aggregate requirements by limiting on their grading,
soundness, fineness and amount of deleterious matter in addition to these requirements, Indian
standard [IS: 383- 1970] included aggregate crushing value, aggregate impact value. On other
hand British standard [882:1992] consider flakiness index, shell content and acid soluble sulfate
as requirement.
Aggregates can be classify based on their origin, based on their size, based on their shape and
based on their unit weight [5] but most specifications such as Ethiopian, Indian and South Afri-
can standards classified aggregates based on their sizes as fine and course aggregate depends on
their most particles retained or passed on 4.75 mm sieve. But British standard uses 5 mm sieve
size for classification. In addition to this, aggregates can be classified as light weight, normal
weight and heavy weight depending on their unit weight [3].
2.4.3 Water
The purpose of using water with cement is to cause hydration of the cement. Water in excess of
that required for hydration acts as a lubricant between coarse and fine aggregates and produces a
workable and economical concrete [5]. In addition to this water is also used for washing
aggregates and curing.
The amount of water must therefore be limited to produce quality concrete required for a job. For
instance excess water weakens bond between the successive lifts of concrete, produce
honeycombed concrete and make concrete porous. On the other hand lesser water makes it
difficult to work with concrete.
2.4.4 Admixtures
While aggregate, cement, and water are the main ingredients of concrete, there are a large
number of mineral and chemical admixtures that may be added to the concrete.
According to Neil and Ravindra (1992), numerous benefits are available through the use of
admixtures, such as: improved quality, acceleration or retardation of setting time, coloring,
greater concrete strength, increased flow for the same water-to-cement ratio, enhanced frost and
sulfate resistance, improved fire resistance, improved workability, cracking control and
enhanced finishability. The specific effects of an admixture generally vary with the type of
cement, mix proportion, ambient conditions (particularly temperature) and dosage [13].
Page 14
CHAPTER THREE
3 METHODOLOGY, MATERIAL PREPARATION, AND CONCRETE

PRODUCTION
3.1 INTRODUCTION
Concrete is a building material composed of cement, sand as fine aggregate, crushed rock as
coarse aggregate, water and admixture. Its obvious that, concrete can be produced by anybody
through mixing of concrete ingredients, but the important point bear in mind is producing
acceptable concrete quality with a reasonable economy. To produce acceptable quality, its
important to make physical characteristic tests on materials used for the investigation before
any concrete experiments are carryout. So, this chapter elaborates concrete making materials
used for the research and their physical test results conducted from the experiment, mix design
and proportion, and concrete production process.
3.2 METHODOLOGY OF THE RESEARCH
The detail of this experimental investigation is for the measurement of the strength
properties (compressive strength and flexural strength) percentages of ceramic waste as
partial replacement of cement. This experimental investigation is conducted to get the
strength of specimen (cube, beam ) made up with different percentage of ceramic waste to
the respective strength of conventional concrete at the end of 14 and 28 days of moist
curing. 36 cubes and 12 beams for a nominal mix have been cast in laboratory of C-30
grade of concrete having proportion of materials calculated in the mix design used as base
for this. The coarse and fine aggregate used for this research is sieved as per ASTM.
The mixing is an extremely important aspect of concreting and it is important to follow

the recommendation, Even a small deviation can have a large influence on the workability
of the wet concrete and so the properties and appearance of final composite 48 control
specimens (36cubes + 12 beams) were being casted to determine the compressed strength at 7,
14 and 28 days and flexure strength at 14 day respectively.
In this thesis small amount of specimens of concrete was prepared in order to consume
time and materials. The casting of specimens was prepared on standard cast iron moulds of size
15x15x15cm are used in the preparation of concrete cubes for compressive strength. Whereas,
for flexural strength the standard cast iron moulds of size 50 x 10 x 10cm are used.
All the mould box of different specimens was initially clean, tightened and oiled properly. There
is no gap left where there is a possibility of leakage of slurry occurred. The coarse aggregate, fi-
ne aggregate, ceramic wastes and cement were weighted accurately. The concrete mix was
prepared by hand mixing and machine mixer.
Page 15
Proper care was taken during weighting, mixing of ingredients and vibration of specimens for
proper compaction. Ordinary Portland Cement (OPC) was used in the casting of design mixture.
Cement was partially replaced with ceramic waste compositely.
The age of specimen had been calculated from the time of curing. Concrete product was
usually being de-molded 12 to 18 hours after casting. In this process the mould was
vibrated as the concrete mix was poured into it. Vibration of specimen has two functions it ena-
bled the mix to fill the mould completely. It release air trapped in the mix and allows
compaction to take place. After mould filling removed any excess concrete which may
interfere with de molding when the concrete has set Carry out final toweling w
concrete is still green, it is easier to do this to achieve a good trowel face than grinding
when the concrete has set in the present study vibration table was used for vibration. It
was considered best to use as little release agent as possible.
Concrete products will achieve a substantial proportion of their ultimate strength when
the main cure is carried out for 7, 14 and 28, in humidity of greater than 95% RI-I and
with a minimum temperature of 20C. A suitable-curing regime will allow the remainder of the
strength to be achieved.
3.3 MATERIAL PREPARATION
The physical characteristics of concrete making materials (Cement, fine aggregate, Coarse ag-
gregate, and Water used for the research were examined and appropriate mix design was made.
3.3.1 Cement Used For the Experiment
Ordinary Portland cement (OPC) produced as per CEM-I-42.5 grade contains 95% clinker and
5% gypsum produced by MESSEBO Cement PLC was used throughout the experiment. The rea-
son to select only one cement type is due to financial and time limitation to perform experiments.
According to the tests result, the normal consistency of this hydraulic cement was of 27%. This
test is used to determine the amount of water required to prepare a standard cement paste. The
initial and final setting time was 2:13 hr. and 3:00 hr. respectively.
3.3.2 Aggregate Used For the Experiment
Aggregates are materials basically used as filler with binding material in the production of
concrete. Aggregates form the body of the concrete, reduce the shrinkage and affect economy.
Therefore, it is significantly important to obtain right type and quality of aggregates on site.
They should be clean, hard, strong, and durable and graded in size to achieve utmost economy
from the paste. Therefore, to judge the quality of the aggregate physical characteristics tests have
to be conducted. So, in this research the following physical testes are performed on the properties
of fine and coarse aggregate.
Page 16
3.3.2.1 Properties of Fine Aggregate
Normal River sand, which is extracted from river area which is found in Tigray region located
around Mekelle city, was used to prepare the concrete samples. All fine aggregate which retain
on 9.5mm sieve size were no longer relevant, and all the passing fine aggregate were used for
experimentation. Then, the following tests were conducted for fine aggregates.
Sieve Analysis
Grading requirements for fine aggregates according to ES C.D3.201 and, the particle size distri-
bution of fine aggregate used for the experiment is shown in Table 3.1 and Figure 3.1 below.
Table 3-1 the Particle Size Distribution for Fine Aggregates
Sieve weight of weight of mass of Percent of Cumulative Percentage

size sieve (Kg) retained retained retained percent of re- of passing
sand+ (Kg) (%) tained (%) (%)
sieve (Kg)
9.5mm 0.309 0.327 0.018 0.598 0.598 99.401
4.75mm 0.321 0.397 0.076 2.525 3.123 96.876
2.36mm 0.325 0.504 0.179 5.948 9.072 90.927
1.18mm 0.27 0.636 0.366 12.163 21.236 78.763
600m 0.256 1.05 0.794 26.387 47.623 52.376
300m 0.252 1.244 0.992 32.967 80.591 19.408
150m 0.26 0.707 0.447 14.855 95.446 4.553
120
100
percentage of retained
80
60
40
20
Sieve size
Fine- Figure 3-1 Fine aggregate gradation chart ness Modules
Page 17
= 2.8, this can be interpreted that the third

sieve, i.e. 600m is the average size. However, depending upon their size, sand can be
classified as coarse sand when a fineness modulus is between 2.90 to 3.20; medium sand with a
fineness modulus of 2.60 to 2.90 and; fine sand with a fineness Modulus of 2.20 to 2.60. So, the
sample was classified as medium sand.
Silt Content
Sand is a product of natural or artificial disintegration of rocks and minerals. Sand is obtained
from glacial, river, lake, residual and wind- blown (very fine sand) deposited. These deposited,
however do not provide pure sand. They often contained dust materials. The presences of such
materials in sand to make concrete or mortar decrease the bond between the materials to bind
together and hence the strength of the mixture produced resulting in fast deterioration. Therefore
it is necessary that one make a test on the silt content and checks against permissible limits.
A simple test which can be made on the site give a guide to the amount of silt content I natural
sand is the field settling test. This test should not be used for crushed rock sand.
According to the Ethiopian Standard it is recommended to wash the sand or reject if the silt
content exceeds a value of 6% [11]. From the test result obtained, the silt content of the sand
used for this experiment is 3.18%. This is less than the maximum requirement of Ethiopian
standard. Therefore no need to be wash
Unit Weight of Fine Aggregates

The unit weight is simply measured by filling a container of known volume and weighing it.
Then, dividing the aggregate weight by the volume of the container provides the unit weight of
the aggregate. The compacted unit weight of this sample fine aggregate was 1600kg/m3
Specific Gravity and Absorption Capacity of Fine Aggregates

Since aggregates generally contain pores, both permeable and impermeable, the meaning of the
term specific gravity has to be carefully defined, and there are indeed different types of specific
gravity, like: apparent specific gravity and bulk specific gravity. Bulk specific gravity refers to
total volume of the solid including pores of the aggregate, and Apparent specific gravity refers
to the volume of the solid is consider to include the impermeable pores but not the capillary
ones. The bulk specific gravity, bulk specific gravity (saturated- surface dry) and apparent
specific gravity results obtained from the experiment are 2.61, 2.76 and 2.95 respectively.
And, the absorption capacity was 3.5%.
Moisture Content of Aggregates

The moisture content of fine aggregate was determined by Oven dry 500gm of fine aggregate
(sand) for about 24hrs with a temperature of 105 C to 110 C and cool for an hour. Then,
dividing the weight difference by oven dry weight and multiplying by hundred provide the
moisture content. Therefore, the moisture content of the sample fine aggregate was 3.5%.
Page 18
Table 3-2 Summarized test results for fine aggregate (sand)
No. Physical test for fine aggregate Results

1 Silt content 3.18%
2 Fineness modulus 2.8
3 Unit weight Compacted unit weight 1600kg/m3
4 Bulk specific gravity 2.61
Bulk specific gravi-
Specific gravity 2.76
ty(SSD)
Apparent specific
2.95
gravity
5 Absorption capacity 3.5%
6 Moisture content 3.5%
3.3.2.2 Properties of Coarse Aggregate
The coarse aggregate used for this research was basaltic crushed which is located around
Mekelle city. The aggregate coming from the crusher site was washed thoroughly and dried in air
inside the laboratory room. In this study a maximum size of 37.5 mm diameter aggregate was
used in all the concrete mix design. The grading analysis of coarse aggregate is shown on the ta-
ble below.
Table 3-3 Sieve Analysis for Coarse Aggregate

aggregate+ (Kg) (%) tained (%) (%)
sieve (Kg)
37.5 mm 1.66 1.876 0.216 3.66 3.66 96.33
28 mm 1.73 1.929 0.199 3.38 7.05 92.94
20 mm 1.165 4.023 2.858 48.55 55.60 44.39
14 mm 1.357 3.158 1.801 30.59 86.20 13.79
10mm 0.751 0.972 0.221 3.75 89.95 10.04
6.3mm 0.802 1.393 0.591 10.04 100 0
Page 19
120
Percentage of passing (%)
100
80
60
40
20
0
6.3mm 10mm 14 mm 20 mm 28 mm 37.5 mm
Sieve size
Figure 3-2 Coarse aggregate gradation chart
Table 3-4 Summarized Test Results for Coarse Aggregate
No. Physical test for coarse aggregate Results

1
Unit weight Compacted unit weight 1600kg/m3
2 Bulk specific gravity 2.40
Bulk specific gravi-
Specific gravity 2.78
ty(SSD)
Apparent specific
2.42
gravity
3 Absorption capacity 3.03%
4 Moisture content 3.17%
3.3.3 Water Used For the Experiment
Water is an important ingredient of concrete as it actually participates in the chemical

reaction with cement. Since it helps to from the strength giving cement gel, the quantity and
quality of water are required to be looked into very carefully. Mixing water used in this research
was drinkable water supplied by Mekelle.
Page 20
3.3.4 Ceramic Tile Waste Powder Used For the Experiment
Ceramic wastes are generated as a waste during the process of construction and demolition. It is
estimated that about 54% of construction and demolition(C&D) are Bricks, wall tiles and other
ceramic materials.
The ceramic tile wastes used for this test is comes from construction and demolition(C&D)
buildings and those ceramic tile are applicable to this test by crushing the wastes into powder as
shown on the figure below. The specific gravity of ceramic tile powder is found to be 2.62 and
the fineness is found to be 7.5%.
3.4 CONCRETE PRODUCTION
3.4.1 Concrete Mix Design
It is the process of selecting suitable ingredients of concrete and determining their relative pro-
portions with the object of producing concrete of certain minimum strength and durability as
economically as possible [11].
Variables in Proportioning
In connection with specifying a concrete mix, four variable factors to be considered are
Water-cement ratio.
Cement content or cement-aggregate ratio.
Gradation of the aggregates.
Consistency.
Usually two or three factors are specified, and the others are adjusted to give minimum workabil-
ity and economy. Water/cement ratio expresses the dilution of the paste - cement content varies
directly with the amount of paste. Gradation of aggregate is controlled by varying the amount of
given fine and coarse aggregate. Consistency is established by practical requirements of placing.
In brief, the effort in proportioning is to use a minimum amount of paste (and therefore cement)
that will lubricate the mass while fresh and after hardening will bind the aggregate particles to-
gether and fill the space between them. Any excess of paste involves greater cost, greater drying
shrinkage, greater susceptibility to percolation of water and therefore attack by aggressive waters
and weathering action. This is achieved by minimizing the voids by good gradation.
Page 21
American Method of Mix Design

Among the various standard methods of concrete mix design, the ACI recommended practice for
selecting proportions of concrete is most widely used. These design method is more or less based
on the fact that crushing strength is primarily dependent upon the water/cement ratio and that for
a given water/cement ratio, the aggregate concentration or cement-aggregate ratio, the maximum
size and grading of the aggregate.
The procedure to be followed in designing a concrete mix is detailed below:
Step1: Choice Of Slump: If slump is not specified, recommend consistencies in terms of slump
for concretes consolidated by vibration are given in the table1on the appendix.
Step2: Choice Of Maximum Size of Aggregate: The method recommends using the largest
size that is economically available and consistent with dimensions of the structure.
Step3: Estimation Of Mixing Water and Air Content: The approximate mixing water re-
quired is selected from tables 2a and b for desired workability and maximum size of aggregate.
Step 4: Selection of Water/ Cement Ratio: The water/cement ratio is selected based on the du-
al criterion of durability and strength using tables 3&4 on the appendix .The minimum of the two
being adopted for trial mix.
Step 5: Calculation of Cement Content: The cement content is calculated from the water con-
tent and the water/cement ratio required for durability or strength.
Step 6: Estimation of Coarse Aggregate Content: The coarse aggregate content is estimated
from table 5&6 on the appendix, for the maximum size of aggregate and the fineness modulus of
sand.
Step 7: Estimation of Fine Aggregate Content: The fine aggregate content is determined by
subtracting the sum of the volumes of coarse aggregate, cement, water and air content from the
unit volume of fresh concrete.
Step 8: Adjustments for Aggregate Moisture: The aggregate quantities actually to be weighed
out for the concrete must allow for moisture in the aggregate.
Step 9: Trial Batch Adjustment: The calculated mixture proportions should be checked by
means of trial batches prepared and tested for compressive and flexural resistance.
Page 22
In our thesis the concrete mix design was done to design C-30 concrete grade based on
American Method of Mix Design. The quantity of concrete materials was calculated by using
the physical properties of the materials and table 3.5. And table 3.6 shows the quantity of ma-
terials for one cubic meter for C-30 concrete grade.
Table 3-5 Summarized Material Properties Used For Concrete Mix Design
Target mean strength for M30 mix design (Ft) is given by Ft = Fck+ k.S , where Fck is
1 characteristic compressive strength, K is constant and is taken as 1.65 and S is standard
deviation. Therefore, Ft= 30 + 1.65*4.0 =36.6MPa.
2 The concrete will be non-air entrained
Cement used is ordinary Portland cement OPC and its spe-

3 Cement
cific gravity is 3.15
The coarse aggregate has of maximum nominal size of
4 Coarse Aggregate. 37.5mm and dry-rodded mass of 1600Kg/m3 and it has a
bulk specific gravity of 2.4 and absorption of 3.03%.
The fine aggregate has a bulk specific gravity of 2.67 and
5 Fine aggregate
absorption of 3.5% and a fineness modulus of 2.8.
Workability corresponding to
6 75 to 100 mm slump
compaction factor
The water- cement ratio for non-
air entrained concrete with 28-
7 0.54
day compressive strength of
30MPa
The estimated mixing water for
slump of 75 to 100mm in non-air
8 181 Kg/m3
entrained concrete made with 37.5
aggregate
From the information developed
10 above the cement content is found 335.18 Kg/m3
to be 181/0.54
For fine aggregate having a fi-
0.71 m3of coarse aggregate, on dry-rodded basis, may be
nesse modulus of 2.8 and 37.5mm
used in each cubic meter of concrete. The required dry
11 maximum nominal
mass
size of coarse aggregate, the
id therefore, 0.71*1600=1136Kg.
ASTM table indicates that
Page 23
With quantities of water, cement and coarse aggregate established, the remaining material
comprising the cubic meter of concrete must consist of fine aggregate and whatever air will
be entrapped the required fine aggregate may be determined on the basis of either mass or
absolute volume as shown below.
Mass basis
The mass of cubic meter of non-air entrained concrete made with aggregate having a nominal
maximum size of 37.5mm is estimated to be 2410KG. Mass already known are: Water (net mix-
ing) 181Kg Cement 335.18 Kg Coarse aggregate 1136 Kg Total 1652.18 Kg The mass of fine
aggregate, therefore, is estimated to be 2410-1652.18= 757.82 Kg.
Absolute Volume Basis:

With quantities of water, cement and coarse aggregate established, and the approximate en-
trapped air content (as opposed to purposely entrained air) of 1% determined from the table of
ASTM the sand content can be calculated as follows.
Volume of water = = 0.181m3
Solid volume of cement = = = 0.106m3
Solid volume of coarse aggregate =
Volume of entrapped air = 0.01*1= 0.010m3
Total volume of ingredients = 0.767m3
Then volume of fine aggregate is estimated to be 1-0.767= 0.233 m3
Therefore the mass of fine aggregate for 1m3 volume of concrete is=0.233*2.67*1000=622.11Kg
Result
Based on the above mix design, following mix proportion has been calculated
Table 3-6 Quantity of materials in kg for 1m3 C-30 concrete grade production
Materials Mass of coarse Mass of fine

Mass of cement Mass of water
aggregate aggregate
(Kg/m3) (Kg/m3)
(Kg/m3) (Kg/m3)
Quantities per m3 335.18 Kg 181Kg 1136 622.11
Ratio 1 0.54 3.38 2.26
Page 24
3.4.2 Concrete Production Process
The processes which we used to produce Concrete have the following steps:
Step-1: The concrete moulds and mixer were cleaned from all dust and coated with releasing
agent (oil) to smooth the surface and to prevent sticking of mixed concrete with the mold and
mixer.
Step-2: The ingredients, such as; cement, fine aggregate (sand), coarse aggregate water and ad-
mixture were measured by weight balance.
Step-3: After that the weighted coarse aggregate was first added to the mixer and the cement was
added after the coarse aggregate and then the fine aggregate is added next to cement and dry
mixed for a minute.
Step-4: Then, water and ceramic tile wastes was added to the dry mixed concrete ingredients
mixture and thoroughly mixed for two more minute. The mixed concrete was checked for work-
ability by filling the standard slump cone with three layers by rodding each layer with 25 times.
Step-5: Then, after checked the slump the mixed concrete was placed in the mould and was well
compacted in two layers with the help of a table vibrator for 45 and 30 seconds for double and
single cast iron moulds respectively.
Step-6: The concrete moulds are kept for 24 hours and then the casted concrete cubes were re-
moved from the mould and placed inside water for curing to take place until the testing age was
reached.
Page 25
CHAPTER FOUR
4 EXPERIMENTAL RESULTS AND DISCUSSIONS
According to the research objectives and methodology, effect of ceramic tile waste powder on
concrete properties, such as: workability, and strength of concrete have been studied with four
different phases at dosages of 0%, 10%, 20% and 30% of the cement amount. The laboratory ex-
periments were performed in two different phases, these are:
Phase-I: The effect of ceramic tile waste powder on workability at a constant W/C ratio.
Phase-II: The effect of ceramic tile waste powder on concrete properties by reducing
cement content at constant W/C ratio.
4.1 PHASE I: THE EFFECT OF CERAMIC TILE POWDER ON WORK-

ABILITY
This phase was performed to study the effects of ceramic tile waste powder on workability at
a constant volume of liquid for convectional strength concrete (C-30) with different dosage of
ceramic tile waste powder.
The effects of ceramic tile waste admixture on workability were assessed, for this investigation
experiments is carried out for fresh concrete with and without the presence of ceramic tile waste
powder for C-30 concrete grade. For fresh concrete property, slump tests were conducted to as-
sess the workability of concrete
4.1.1 Workability Tests for C-30 Concrete Grade
The objective of workability test is to assess whether the concrete is effective enough for easy
compaction and placing. Slump test is the simplest test for workability.
For the C-30 concrete, workability and strength tests were conducted. The slump test results
were conducted to investigate the impact of ceramic tile waste dosage on workability, while the
strength development and strength of concrete with dosage of ceramic tile waste to determine the
hardness of concrete. Table 4.1 below shows slump development test results for C-30 concrete
grade with different dosage of ceramic tile waste powder.
Page 26
Table 4-1 Slump Development Test Results For C-30 Concrete Grade
Effect of ceramic tile waste powder on workability and compression
ceramic tile waste powder W*/C ratio Slump (mm)
0% 0.54 79
10% 0.54 52
20% 0.54 35
30% 0.54 22
The value of slump test for C-30 with different dosages of ceramic tile waste powder are shown
as a graph below
80
Slump value (mm)
70
60
50
40
30
20
10
0
0.0% 10.0% 20.0% 30.0%
slump value 75 52 35 22
Figure 4-1 effect of ceramic tile powder on workability

According to the observed test results, the slump of concrete produced without adding
ceramic tile waste admixture was measured 75mm. similarly, for 10%, 20%, 30% are 52mm,
35mm, 22mm respectively. This shows that as increasing ceramic tile powder the slump is de-
creasing, so that workability is decreasing. To increase the workability we should add some
amount of water.
Page 27
4.2 PHASE II: THE EFFECT OF CERAMIC TILE POWDER ON CON-

CRETE PROPERTIES BY REDUCING CEMENT CONTENT
4.2.1 Experimental Results and Discussion on Compressive Strength of Con-

crete
The compressive strength of concrete was determined by testing the cubes in a compression test-
ing machine at a rate of 0.28MPa/s. For every cube the compressive strength is recorded in Mpa
and, then the mean values of three samples were taken as their compressive strength value for
7rd, 14th and 28th days.
To check the effect of ceramic tile waste powder on concrete properties by reducing cement
content, laboratory tests were performed on concrete compressive strength at the age of 7th, 14th
and 28th days.
4.2.1.1 Experimental Results Compressive Strength of Concrete
In this test only cement was reduced based on the percentage of ceramic tile waste powder added
with respect to the weight of total cement content, but water and the water to cement ratio was
kept constant for all mixes. Table 4.2 shown the quantity of materials used to produce 1 m3 con-
crete at a constant water to cement ratio and the compressive strength results observed from the
experiments are shown in the table 4.3 below.
Table 4-2 Quantity of Materials in Kg for 1m3 C-30 Concrete Grade Production at Constant Wa-
ter
For C-30 concrete grade ceramic tile powder
ceramic tile
Cement fine aggre- Coarse aggre-
Materials Water(lt) waste powder
(kg) gate (kg) gate(kg)
(Kg)
Quantities per m3 335.18 181 0 622.11 1136
For C-30 concrete grade by 10% ceramic tile powder
ceramic tile
(Kg)
Quantities per m3 301.66 181 33.52 622.11 1136
ceramic tile
(Kg)
Quantities per m3 268.14 181 67.04 622.11 1136
Page 28

ceramic tile
(Kg)
Quantities
234.62 181 100.56 622.11 1136
per m3
Table 4-3 Effect Of Ceramic Tile Waste Powder on Compressive Strength by Cement Reduction
mean value of compressive strength test for cement saving
7th days 14th days 28th days

Ceramic Weight
Slump
tile waste of cube Failure Comp. Failure Comp. Failure Comp.
(mm)
powder (%) (Kg) Load strength Load strength Load strength
(KN) (MPa) (KN) (MPa) (KN) (MPa)
8.35 75
0% 519.75 23.10 678.32 30.15 746.5 33.17
8.26 52
10% 634.10 28.18 823.50 36.60 905.85 40.26
8.13 35
20% 566.02 25.16 735.08 32.67 808.60 35.94
8.01 22
30% 453.42 20.15 588.87 26.17 647.74 28.79
The values of compressive strength test for C-30 with different dosage of ceramic tile waste
powder by reducing amount of cement content at a constant water to cement ratio has shown
as a graph in Figure below.
45
Compressive Strength
40
35 0% ceramic tile
30 powder
25 10% ceramic tile
20 powder
15 20% ceramic tile
10 powder
5 30% ceramic tile
0 powder
0 7 14 28
Age/Days
Figure 4-2 Effects of ceramic tile powder on compressive strength
Page 29
45
40
Compressive Strength
35
30
25
20
23%
15
10
0
0% 10% 20% 30%
at 28 day compressive
33.17 40.26 35.94 28.79
strength
reference line 33.17 33.17 33.17 33.17
percentage of ceramic tile powder
Figure 4-3 allowable percentage of ceramic tile powder which replace cement
4.2.1.2 Discussion on Compressive Strength of Concrete
It clear that better strength can be obtained by addition of more cement .It is obvious that reduc-
tion of cement amount can reduce the concrete strength, but in same extent the addition of ce-
ramic tile powder can improve the strength of concrete. The results obtained from the experiment
by reduction of cement content and addition of ceramic tile waste powder was discussed as fol-
lows.
During the seventh day, the compressive strength of concrete without ceramic tile waste
powder was 23.10Mpa. For 10%, 20% and 30% of ceramic tile waste powder added concrete
were 28.18Mpa, 25.16Mpa, and 20.15Mpa.
This shows the compressive strength of 10% ceramic tile waste powder added concrete
was higher than the reference concrete by 5.08MPa or 21.99%,
The compressive strength of 20% ceramic tile waste powder added concrete was im-
proved by 2.24MPa or 8.97.
The compressive strength of 30% ceramic tile waste powder added concrete was de-
creased by 3MPa or 12.98%.
At the fourteen day, the compressive strength of concrete without ceramic tile waste powder
was 30.15Mpa. For 10%, 20% and 30% of ceramic tile waste powder added concrete were
36.60MPa, 32.67MPa, 26.17MPa.
Page 30
This shows the compressive strength of 10% ceramic tile waste powder added con-
crete was 6.45MPa or 21.39.
The compressive strength of 20% ceramic tile waste powder added concrete
was improved by 2.52MPa or 8.38.
The compressive strength of 30% ceramic tile waste powder added concrete
was decreased by 3.98MPa or 15.21.
At the twenty eighth day, the compressive strength of concrete without ceramic tile waste
powder added was 33.17Mpa. For 10%, 20% and 30% of ceramic tile waste powder added
concrete were 40.26MPa, 35.94MPa, 28.79MPa.
The compressive strength of 10% ceramic tile waste powder
added concrete was improved by 7.09MPa or 21.37%.
And the compressive strength of 20% ceramic tile waste powder added concrete is
higher by 2.77MPa or 8.3%
The compressive strength of 30 % ceramic tile waste powder
added concrete was decreased its strength by 4.38MPa or 15.21%.
Therefore, optimum dosage of ceramic tile waste powder is found based on the highest ulti-
mate strength that they provide at age 28 days. i.e., 10% ceramic tile waste powder added
concrete was provided the highest optimum compressive strength by 7.09MPa or 21.37%.
And also, the 23% of ceramic tile powder has equal compressive strength with 0% ceramic
tile powder. We can conclude that up to 23% of ceramic tile wastes can replace cement. This
And as we can see from weight of specimens, adding of ceramic tile powder does not in-
crease the weight of concrete, rather it decrease in small amount
4.2.2 Experimental Results and Discussion on Flexural Strength of Concrete
The flexural strength test is used to determine the tensile strength of the concrete. When point
load is applied at the center of the sample concrete, the member is subjected to bending
moment. In this test, the concrete sample to be tested was supported at 6cm towards its both ends
and loaded at the interior (center) location by a gradually failure load as illustrated in the figure
below. The failure load at which the concrete cracks was then recorded in KN as follows
and by using formula, calculations were carried out to determine the flexural strength in MPa.
Then, the flexural strength for center point loading has been calculated by using the following
general formula.
Flexural strength= 3FL/2BD2
Where F= total load, L= the distance between the lower supporting rollers, B= breadth of the
beam, D= depth of the beam
Page 31
4.2.2.1 Experimental Results on Flexural Strength of Concrete
This test was performed for fourteen days for 0 %, 10%, 20% and 30% ceramic tile powder add-
ed concrete. The quantity of materials used to produce 1 m3 concrete by reducing cement content
is the same with the quantity of compressive strength test quantity. And the results obtained from
the experiment and through calculation are recorded in the table below.
Table 4-4 Mean Value of Compressive Strength Test
Mean value of compressive strength test
L B D
14th days
(cm) (cm) (cm)
Slump
Admixture Flexural
(mm) Failure
strength
Load
(MPa)
(KN)
38 10 10 75 6.2985
0% 11.05
38 10 10 52 7.4442
10% 13.06
38 10 10 35 6.4011
20% 11.23
38 10 10 22 5.8938
30% 10.34
14 day flexural strength

8
flexural strength
7
6
5
4
3
2
1
0
0.0% 10.0% 20.0% 30.0%
14 day flexural
6.2985 7.4442 6.4011 5.8938
strength
Figure 4-4 effect of ceramic tile powder on flexural strength for 14 day
Page 33
8
7
flexural strength
6
5
4 22%
3
2
1
0
0.0% 10.0% 20.0% 30.0%
14 day flexural
6.2985 7.4442 6.4011 5.8938
strength
reffernce line 6.2985 6.2985 6.2985 6.2985
Figure 4-5 allowable percentage of ceramic tile powder that replace cement for flexural strength
4.2.2.2 Discussion on Flexural Strength of Concrete
Therefore, optimum dosage of ceramic tile waste powder is found based on the highest ulti-
mate flexural strength that they provide at age 14 days. i.e., 10% ceramic tile waste powder
added concrete was provided the highest optimum flexural strength. Dosage with lower or
higher than this optimum value will reduce the strength. Since, the flexural strength of con-
crete is improved by the addition of ceramic tile waste powder by the reduction of cement;
its possible to conclude that a better improvement can also be obtained on flexural strength.
And also, the 22% of ceramic tile powder has equal flexural strength with 0% ceramic tile
powder; we can conclude that up to 22% of ceramic tile wastes can replace cement. This
Page 34
CHAPTER FIVE
5 ENVIRONMENTAL AND QUALITATIVE ECONOMIC ANALYSIS
5.1 INTRODUCTION
The advancement of concrete technology can reduce the consumption of natural resources.
They have forced to focus on recovery, reuse of natural resources and find other alternatives. The
use of the replacement materials offer cost reduction, energy savings, arguably superior
products, and fewer hazards in the environment.
Many of the construction projects utilize concrete as the main material for the structures. Con-
crete contains about 75% (by volume) of aggregates, which are in most areas abundant. Howev-
er, in most cases where there is a need for large supply of concrete, the natural environment ends
up being sacrificed for economic reasons. Due to the rise in environmental awareness, there has
been substantial amount of research in incorporating wastes, especially C&D wastes, into the
making of concrete.
The principle waste coming into the ceramic industry is the ceramic powder,
specifically in the powder forms. Ceramic wastes are generated as a waste during the process of
dressing and polishing. It is estimated that 15 to 30% waste are produced of total raw material
used, and although a portion of this waste may be utilized on-site, such as for excavation pit re-
fill, The disposals of these waste materials acquire large land areas and remain scattered all
around, spoiling the aesthetic of the entire region. It is very difficult to find a use of ceramic
waste produced. Ceramic waste can be used in concrete to improve its strength and other durabil-
ity factors. Ceramic waste can be used as a partial replacement of cement to achieve different
properties of concrete [9].
Cement is obtained by extraction of natural resources (rock) as raw materials and processing in
factory. But, the production of cement has some adverse impacts on environmental and econom-
ic points of view. However, nowadays additional materials have developed as a concrete making
material to improve concrete properties by reducing cement content. This can minimize envi-
ronmental and economic problems caused by production of huge amount cement.
Ceramic tile waste powder is one of additional materials basically come from the ceramics indus-
try and from constitutes a significant fraction of construction and demolition waste (CDW).
In our country Ethiopia, there are a lot of ceramic wastes during construction and
demolishing activities. So that by reusing these ceramic wastes as partially replacement
of cement, our research would be more interesting.
Page 35
Here, we wonder to show the effects of Ceramic tile waste powder on environmental and eco-
nomic points of view. So, based on the results of phase II (at a constant water to cement ratio), to
obtain equivalent strength as the reference concrete, the following environmental and economic
comparative analysis are made between cement and Ceramic tile waste powder.
5.2 ENVIRONMENTAL IMPACTS
Cement production is one of the most energy intensive industrial manufacturing processes
which cause severe environmental impacts at all stages of the process. These include: change of
landscape, depletion of natural resources due to quarrying and production process. According
to researchers, the mass of raw materials needed to manufacture Portland cement is assumed to
be 1.6 times as much as the mass of finished Portland cement [12]. Therefore, this can cause
environmental problems like global warming due to depletion of natural resources, dust and
noise, gas emissions, such as carbon dioxide emission from clinker production, which is nearly
estimated that the production of one ton of Portland cement is associated to release in the
environment of an equivalent amount of CO2 by the operation of kiln systems, clinker coolers,
mills, electrical energy consumption, fuel, usually coal and petroleum [12].
5.2.1 Carbon Dioxide Emissions and Climate Change

The concrete industry is one of two largest producers of carbon dioxide (CO2), creating up to 5%
of worldwide man-made emissions of this gas, of which 50% is from the chemical process and
40% from burning fuel. The carbon dioxide CO2 produced for the manufacture of one ton of
structural concrete (using ~14% cement) is estimated at 410 kg/m3 (~180 kg/ton @ density of 2.3
g/cm3). The CO2 emission from the concrete production is directly proportional to the cement
content used in the concrete mix; 900 kg of CO2 are emitted for the fabrication of every ton of
cement, accounting for 88% of the emissions associated with the average concrete mix. Cement
manufacture contributes greenhouse gases both directly through the production of carbon dioxide
when calcium carbonate is thermally decomposed, producing lime and carbon dioxide, and also
through the use of energy, particularly from the combustion of fossil fuels.
One area of the concrete life cycle worth noting is the fact that concrete has a very low embodied
energy relative to the quantity that is used. This is primarily the result of the fact that the materi-
als used in concrete construction, such as aggregates, Pozzolana, and water, are relatively plenti-
ful and can often be drawn from local sources. This means that transportation only accounts for
7% of the embodied energy of concrete, while the cement production accounts for 70% [14].
Page 36
However, Ceramic tile waste powder are obtained by crushing of ceramic tile wastes comes from
the ceramics industry and from constitutes a significant fraction of construction and demolition
waste (CDW) and which is easily renewable resource. So, reusing those wastes as a construction
material can save the environment from pollution. Since, addition of Ceramic tile waste powder
with some percentage can save cement with some percentages, this helps to save natural resource
depletion and damage of landscapes to extract too much raw materials for cement production,
this can reduces the effect of global warming caused by huge amount of CO2 emission.
In addition, using Ceramic tile waste powder obtained as wastes released directly into the envi-
ronmental and can avoid discharge of environmental pollution, which causes pollution of envi-
ronment Table 5.1 shows the amount cement saved with different dosages of Ceramic tile waste
powder at constant water to cement ratio for C-30 concrete grade based on result obtained from
this research on phase II and CO2 emission for one cubic meter concrete production.
Table 5-1 Amount of Cement Saving and Carbon Dioxide Emission Relation
Reduction
Ceramic tile
in CO2
waste pow- Water Cement
Ceramic tile emission (kg/m3).
W*/C der used used
waste powder [1Kg of cement produce
added (kg/m3) (kg/m3)
0.9Kg of CO2)
(kg/m3)
0
0% 0.54 0 181 335.18
10% 0.54 33.52 181 301.66 30.17
20% 0.54 67.04 181 268.14 60.34
0.54 181 69.39

23% 77.09 258.09
Page 37
Reduction in co2 (Kg/m3)

80
70
CO2 emission (Kg/m3)

60
50
40
30
20
10
0
23% 20% 10% 0%
Reduction in co2 (Kg/m3) 69.39 60.34 30.17 0
Figure 5-1 reduction in CO2 emission (Kg/m3)
The amount of cement saved per cubic meter by using 10%, 20% and 23% Ceramic tile
waste powder is 30.17kg, 60.34kg and 69.39kg from the reference concrete. On the other
hand the amount of CO2 emissions can reduce by 30.17kg, 60.34kg and 69.39kg from the
reference concrete, respectively. In addition, it is possible to reduce the depletion of natural
resources with 30.17kg, 60.34kg and 69.39kg per cubic meter respectively.
From the above analysis the carbon dioxide CO2 produced for the manufacture of one ton of
structural concrete (using ~14% cement) is estimated at 410 kg/m3 (~180 kg/ton @ density of
2.3 g/cm3). Therefore from this, our research it is estimated that 23% replacement of cement
with Ceramic tile waste powder represents a 16.92% reduction in energy consumption.
Page 38
5.3 ECONOMIC IMPACT ANALYSIS
We make an economical comparative analysis based on the cement saved and Ceramic tile waste
powder used for the experiments.
Since Ceramic tile waste powder is prepared by crushing of ceramic tile wastes, only preparing
of ceramic tile waste and crushing costs are the comparative costs with the cement cost.
This comparative analysis is carried out based on the market price during 2016/2017, when those
materials: cement, fine aggregate, coarse aggregate and water are purchased for the research. The
market prices were 282 birr per quintal, 312.5 birr per cubic meter, 350 birr per cubic meter and
21 birr per cubic meter respectively. From our cost of analysis, the cost of ceramic tile waste
powder is 400 birr per cubic meter.
According to the result which is shown in table 5.1 above, it is possible to save 33.52 kg/m3,
67.04 kg/m3, 77.09 kg/m3, cement by the addition of 10%, 20% and 23% Ceramic tile waste
powder at a constant W/C ratio for the same strength. Table 5.2 shows the cost comparisons be-
tween cement saved and Ceramic tile waste powder used for 1m3 concrete.
Table 5-2 Cost Comparisons between Cement Saved and Ceramic Tile Waste Powder Used
Total
Ceramic Amount of Ceramic tile Cost
water Sand used Gravel used
tile cement waste powder incurred
(lit/m3) (kg/m3 and (kg/m3 and
waste (kg/m3) and (kg/m3 and by per
and Cost Cost) Cost)
powder Cost Cost) 1m3
concrete
335.18
181 622.11 1136 1193.91
0% (945.20 0
(3.81 ETB) (74.65ETB ) (170.4ETB) ETB
ETB)
181
301.66 33.52 622.11 1136 1105.57
10% (3.81 ETB)
(850.68ETB) (6.03ETB) (74.65ETB ) (170.4ETB) ETB
181
268.14 67.04 622.11 1136 1016.99
20% (3.81 ETB)
(756.15ETB) (12.07ETB) (74.65ETB ) (170.4ETB) ETB
258.09 181
77.09(13.88E 622.11 1136 990.55
23% (727.81 (3.81ETB) TB) (74.65 ETB) (170.4 ETB) ETB
ETB)
Page 39
reduction of cost( birr/m3)

250
Reduction of cost(birr/M3)
200
150
100
50
0
23% 20% 10% 0%
reduction of cost( birr/m3) 203.36 176.92 88.34 0
Figure 5-2 reduction of cost per m3
Based on the market price of cement and Ceramic tile waste powder, the cost by the use of
10%, 20% and 23% Ceramic tile waste powder for a m3 concrete is about 88.34ETB,
176.92ETB and 203.36ETB more expensive than the reference concrete. This value is mainly
depending on the market price of cement and Ceramic tile waste powder during purchasing
the materials. When the price of cement is increased, it can be beneficial to use Ceramic tile
waste powder.
Page 40
CHAPTER SIX
6 CONCLUSIONS AND RECOMMENDATIONS
Based on the conducted laboratory results by using MESSEBO cement PLC and ceramic tile
waste powder conclusions and recommendations are forwarded on the effect of ceramic tile
waste powder on the properties of concrete
6.1 CONCLUSIONS
This research was investigated the effect of ceramic tile waste powder on concrete properties,
such as: workability and strength (compressive and flexural). The results obtained from the study
are summarized as follows:
1. According to the observed test results, the slump of concrete produced without adding
ceramic tile waste was measured 79 mm. similarly, for 10%, 20%, 30% are 52mm, 35mm,
22mm respectively. This shows that as increasing ceramic tile powder the slump is decreas-
ing, so that workability is decreasing. To increase the workability we should add some
amount of water.
2. The, optimum dosage of ceramic tile waste powder is found based on the highest ultimate
strength that they provide at age 28 days. i.e., 10% ceramic tile waste powder added concrete
was provided the highest optimum compressive strength. Dosage with lower or higher than
this optimum value will reduce the strength. Since, the compressive strength of concrete is
improved by the addition of ceramic tile waste powder by the reduction of cement; its possi-
ble to conclude that a better improvement can also be obtained on flexural strength.
3. And also, the 23% of ceramic tile powder has equal compressive strength with 0% ceramic
tile powder; we can conclude that up to 23% of ceramic tile wastes can replace cement. This
4. The 10% ceramic tile waste powder added concrete was provided the highest optimum flex-
ural strength. Dosage with lower or higher than this optimum value will reduce the strength.
Since, the flexural strength of concrete is improved by the addition of ceramic tile waste
powder by the reduction of cement; its possible to conclude that a better improvement can
also be obtained on flexural strength.
5. And also, the 22% of ceramic tile powder has equal flexural strength with 0% ceramic tile
powder; we can conclude that up to 22% of ceramic tile wastes can replace cement.
6. The amount of cement saved per cubic meter by using 23% Ceramic tile waste powder is
69.39kg from the reference concrete. On the other hand the amount of CO2 emissions can
reduce by 69.39kg from the reference concrete, respectively.
7. From the analysis, the carbon dioxide CO2 produced for the manufacture of one ton of struc-
tural concrete (using ~14% cement) is estimated at 410 kg/m3 (~180 kg/ton @ density of 2.3
Page 41
g/cm3). Therefore from this, our research it is estimated that 23% replacement of cement with
Ceramic tile waste powder represents a 16.92% reduction in energy consumption.
8. Based on the market price of cement and Ceramic tile waste powder, the cost by the use of
23% Ceramic tile waste powder for a m3 concrete is 203.36ETB more expensive than the
reference concrete.
9. Generally replacing of cement by 23% ceramic waste tile powder can decrease the cost of
concrete by 17% from the original concrete.
6.2 RECOMMENDATIONS
Based on the research study, the following recommendations have forwarded.
1. Before using Ceramic tile waste powder, the effect of way of Ceramic tile waste powder ad-
dition should be investigate on workability, strength, resistance to water penetration and oth-
er properties.
2. This research studied only on 0%, 10%, 20% and 30% Ceramic tile waste powder. So, fur-
ther studies are required in different dosages of Ceramic tile waste powder on different prop-
erties of concrete to obtain the maximum benefit.
3. Since as increasing ceramic tile powder the slump is decreasing, so that workability is de-
creasing. To increase the workability we should add some amount of water and we have to
use any other methodologys to increase water content like adding of admixture.
4. Since our research mainly focuses on decreasing cement content, other researchers should do
this ceramic tile waste replacement on other materials like aggregate replacement.
5. In our country investigations are not yet done on Ceramic tile waste powder, therefore, to
obtain the best benefit from Ceramic tile waste powder, further researches should have to be
done on effects of different types of Ceramic tile waste powder on different cement.
Page 42
REFERENCES
1. Kumar M. P. and Paulo M. J. M., Concrete Microstructure, Properties, and Materials,

Third Edition, University Of California at Berkeley, Department Of Civil And
Environmental Engineering, United States of America, 2006
2. International Journal of Civil, Environmental, Structural, Construction and Architectural
Engineering Vol:8, No:1, 2014 A Review on the Usage of Ceramic Wastes in Concrete
Production Prepared by o. Zimbili, w. Salim, m. Ndambuki
3. Sydney Mindess, Francis J.Young and Darwin David (2003); Concrete (2nd Edition),
Pearson Education, Inc.
4. Abebe Eshetu (2005); Concrete Production and Quality Control in Building Construction
industry of Ethiopia, Addis Ababa University press
5. Duggal S.K. (2000); Building Materials (3rd Edition), New age international publishers
6. Steven H. Kosmatka, Beatrix Kerkhoff, and William C. Panarese (2003); Design and
Control of Concrete Mixtures (14th edition) published by Portland Cement Association,
Skokie, Illinois, USA, 2003.
7. The McGraw-Hill Encyclopedia of Science & Technology, 10th Edition.
8. Indian standard IS 383-1970; specification for coarse and fine aggregates from natural
sources for concrete.
9. And Re-use of ceramic wastes in construction Pdf. www.intechopen.com
10. Ceramic Engineering Department, Anadolu University, Yunusemre Kampusu, Eskisehir,
Turkey
11. Ethiopian Institute of Technology Mekelle university, Construction Materials
Laboratory Manual, Faculty of Technology, Department of Civil Engineering,
Construction Technology and Management,
12. Monique Pag and Nelu Spiratos, the Role of admixtures in the Development of
Environmentally-Friendly Concrete, Canada, April 19-20, 2000,
http://ecosmartconcrete.com/docs/trpage99.pdf
13. Irving Kett, Engineered Concrete Mix Design and Test Methods; Second Edition.
14. Environmental impact of concrete From Wikipedia, the free encyclopedia
https://en.wikipedia.org/wiki/Environmental_impact_of_concrete
Page 43
APPENDIX ONE
MATERIALS TEST RESULTS
1. Properties Of Cement
1.2. Normal Consistency Of Cement
Wt. of cement (gm.) 500 500 500 500 500 500 500 500
% of water 26 27 28 29 30 31 32 33
Wt. of water (gm.) 130 135 140 145 150 155 160 165
Penetration depth(mm) 5 11 21 - - - - -
1.3. Initial and final setting time

Time 8: 8: 8: 9: 9: 9: 9: 9: 9: 10: 10: 10: 10:3 10: 10: 11: 11:1
(min) 10 40 50 00 10 20 30 40 50 00 10 20 0 40 50 00 0
Pene-
tra-
- 40 40 39 40 39 38 35 36 34 34 28 15 13 10 5 0
tion(m
m)
2. Properties of Fine Aggregate

2.2. Sieve analysis of sand
sand+ (Kg) (%) tained (%) (%)
sieve (Kg)
9.5mm 0.309 0.327 0.018 0.598 0.598 99.401
4.75mm 0.321 0.397 0.076 2.525 3.123 96.876
2.36mm 0.325 0.504 0.179 5.948 9.072 90.927
1.18mm 0.27 0.636 0.366 12.163 21.236 78.763
600m 0.256 1.05 0.794 26.387 47.623 52.376
300m 0.252 1.244 0.992 32.967 80.591 19.408
150m 0.26 0.707 0.447 14.855 95.446 4.553
2.3. Silt content
Amount of Silt deposit Amount of clear Silt content
Sample
(A) sand (B) (%)
Sample 1 1mm 54mm 1.8
Sample 2 2mm 52.5mm 3.8
Sample 3 2.3mm 58mm 3.96
Mean 3.18
The silt content (%) = *100
Page 44
Where A= amount of silt deposited above the sand
B= amount of clean sand
2.4. Unit weight
Compacted Unit weight
Wt. of
Height Volume
Wt. of container Dia. of Wt. of Compacted
of of
Sample cylindrical + cylinder aggregate unit eight
cylinder container
metal(kg) aggregate (m) (kg) (kg/m3)
(m) (m3)
(kg)
Sample 1 4.835 27.775 0.28 0.255 22.94 0.0142925 1605
Sample 2 4.835 27.625 0.28 0.255 22.79 0.0142925 1595
mean 1600
2.5. Specific gravity
Sample Wt. of oven Weight of pycnometer Wt. of sample Wt. of saturated

dry sample in filled with water, g &water to the cali- dry sample, g
water, g (B) bration mark, g C
(S)
(A)
Sample 1 480 658 970 500
Sample 2 486 654 980 500

mean 483 656 975 500
Bulk specific gravity
Bulk Sp gr=
Bulk Sp gr=
Bulk specific gravity (saturated- surface dry)
Bulk sp. Gr. (saturated- surface dry) = =
Apparent specific gravity
Page 45
Apparent sp. Gr. = =
Absorption capacity
Absorption capacity (%) =
2.6. Moisture content
A = weight of original sample = 500gm
B= weight of oven dry sample = 483gm
W= moisture content (%) =
3. Properties Coarse aggregate
3.1. Sieve analysis

aggregate+ (Kg) (%) tained (%) (%)
sieve (Kg)
37.5 mm 1.66 1.876 0.216 3.66 3.66 96.33
28 mm 1.73 1.929 0.199 3.38 7.05 92.94
20 mm 1.165 4.023 2.858 48.55 55.60 44.39
14 mm 1.357 3.158 1.801 30.59 86.20 13.79
10mm 0.751 0.972 0.221 3.75 89.95 10.04
6.3mm 0.802 1.393 0.591 10.04 100 0
3.2. Unit weight
Compacted Unit weight/ dry rodded density
Unit weight= = 1600Kg/m3
3.3. Specific gravity
Weight of oven dry sample in air (mass A) = 2009g
Weight of saturated surface dry sample in air (mass B) = 2034g
Weight of saturated sample in water (mass C) = 1178.4g
Bulk specific gravity
Page 46
Bulk sp gr=
Bulk sp gr=
Bulk specific gravity (saturated- surface dry)
Bulk sp. gr. (saturated- surface dry) = =
Apparent specific gravity
Apparent sp. gr.= =
3.4. Absorption capacity
Absorption capacity (%) =
3.5. Moisture content
A = weight of original sample = 500gm
B= weight of oven dry sample = 491.64gm
W= moisture content (%) =
Page 47
APPENDEX TWO
STANDARDS FOR MIX DESIGN
Table 1: Recommended slumps for various Types of construction.
Types of construction Slump, cm

Maximum* Minimum
Reinforced foundation walls 8 2
and footings
Plain, footings, caissons, and 8 2
substructure walls
Beams and reinforced walls 10 2
Building columns 10 2
Pavements and slabs 8 2
Heavy mass concrete 8 2
*May be increased by 2cm for methods of consolidation other than vibration
Table 2a: Relative Mixing Water Requirements for Different Consistencies of Concrete.
Consistence Relative Water
Content,
Description Slump Compacting Vebes %
mm factor
Extremely dry _ _ 32 - 18 78
Very stiff _ 0.70 18 -10 83
Stiff 0 - 30 0.75 10 - 5 88
Stiff plastic 30 - 80 0.85 5 -3 92
Plastic(reference) 80 - 130 0.91 3-0 100
Fluid 130 - 180 0.95 _ 106
Page 48
Table 2b: Approximate Mixing Water Content for different Maximum Sizes of Aggregate.
Maximum size of ag- Non-air-entrained wa- Entrapped air content Air-entrained water
gregate (mm) ter content (Kg/m3) per cent content (Kg/m3)
10 225 3 200
12.5 215 2.5 190
20 200 2 180
25 195 1.5 175
40 175 1 160
50$ 170 0.5 155
70$ 160 0.3 150
150$ 140 0.2 135
Water contents of concretes with aggregates sizes greater than 40 mm are not given for mixes
with a slump of less than 30 mm.
Table 3: Relation between Water/Cement Ratio and Compressive Strength of Concrete Accord-
ing to ACI Standard
Compressive strength at Water/cement ratio (by weight)
28 days*MPa Non-air-entrained concrete Air-entrained concrete
48 0.33 _
41 0.41 0.32
34 0.48 0.40
28 0.57 0.48
21 0.68 0.59
14 0.82 0.74
Measured on standard cylinders. The values given are for maximum size of aggregate of 20
to 25mm.
Page 49
Table 4: Maximum Permissible Water/Cement Ratios for Different Types of Structures in Severe
Exposure, Prescribed by ACI Standard.
Exposure conditions
Structure wet continuously or Structure exposed to

Type of structure frequently and exposed to sea water or sul-
freezing and thawing* phates
Thin sections, such as railings, kerbs,

sills, ledges, ornamental work, and sec-
tions with less than 25mm cover to the 0.45 0.40$
reinforcement.
All other structures 0.50 0.45$
Air-entrained concrete should be used under all conditions involving severe exposure.
When Type II or Type V cement is used, maximum water/cement ratio may be increased by
0.05.
Table 5: Bulk Volume of Coarse Aggregate per Unit Volume of Concrete.
Maximum size of Bulk volume of rodded coarse aggregate per unit volume of concrete for
aggregate(mm) fineness modulus of sand
2.40* 2.60* 2.80* 3.00*
10 0.50 0.48 0.46 0.44
12.5 0.59 0.57 0.55 0.53
20 0.66 0.64 0.62 0.60
25 0.71 0.69 0.67 0.65
40 0.75 0.73 0.71 0.69
50 0.78 0.76 0.74 0.72
70 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81
Page 50
Page 51
Fineness Modulus of Sand
The values given will produce a mix with workability suitable for reinforced concrete construc-
tion. For less workable concrete, e.g. that used in road construction, the values may be increased
by about 10 per cent. For more workable concrete, such as may be required for placing by pump-
ing, the values may be reduced by up to 10 per cent.
Table 6: Factors to be applied to the Volume of Coarse Aggregate Calculated on the basis of Ta-
ble 3.2 for Mixes of Consistence other than Plastic.
Factor for maximum size of aggregate of _
Consistence
10mm 12.5mm 20mm 25mm 40mm
Extremely dry 1.90 1.70 1.45 1.40 1.30
Very stiff 1.60 1.45 1.30 1.25 1.25
Stiff 1.35 1.30 1.15 1.15 1.20
Stiff plastic 1.08 1.06 1.04 1.06 1.09
Plastic (reference) 1.00 1.00 1.00 1.00 1.00
Fluid 0.97 0.98 1.00 1.00 1.00
Table7. First estimate of weight of fresh concrete
First Estimate of concrete weight, kg/m3

Maximum Size of Aggregate, mm Non-air-entrained Air-entrained con-
concrete crete
10 2285 2190
12.5 2315 2235
20 2355 2260
25 2375 2315
40 2420 2355
50 2445 2375
70 2465 2400
150 2505 2435
Page 52
APPENDIX THREE
EXPERIMENTAL RESULTS
Table 1: Experimental results on workability for C-30 Concrete Grade at constant W/C ratio
Effect of ceramic tile waste powder on workability and compression
ceramic tile waste powder W*/C ratio Slump (mm)

0% 0.54 75
10% 0.54 52
20% 0.54 35
30% 0.54 22
Table 2: Experimental results on compressive strength of C-30 Concrete Grade at constant W/C
ratio
Mean Value Of Compressive Strength Test For Cement Saving
14th days
7rd days 28th days
Ceramic tile
W/C Slump
waste pow- Failure Comp. Failure Comp. Failure Comp.
ratio (mm)
der (%) Load strength Load strength Load strength
(KN) (MPa) (kN) (MPa) (kN) (MPa)
0.54 75
0% 519.75 23.10 678.32 30.15 746.5 33.17
0.54 52
10% 634.10 28.18 823.50 36.60 905.85 40.26
0.54 35
20% 566.02 25.16 735.08 32.67 808.60 35.94
0.54 22
30% 453.42 20.15 588.87 26.17 647.74 28.79
Table 3: Experimental Results on Flexural Strength of Concrete
Page 53
Mean value of compressive strength test
L B D
14th days
(cm) (cm) (cm)
Slump
Admixture Flexural
(mm) Failure
strength
Load
(MPa)
(KN)
38 10 10 75 6.2985
0% 11.05
38 10 10 52 7.4442
10% 13.06
38 10 10 35 6.4011
20% 11.23
38 10 10 22 5.8938
30% 10.34
Page 54
APPENDIX FOUR
SAMPLE PHOTO GALLERY TAKEN DURING THE RESEARCH
Investigation and Collection of Ceramic Tile Wastes
Crushing Of Ceramic Tile Wastes Ceramic Tile Powder
Page 55
Laboratory Tests on Material Used for Concrete Production
OPC Cement Used For Our Research
Page 56
Casting Of Concrete Concrete Specimen
Testing Of Concrete Specimens
Page 57

Improvment of Concrete Strength by Using Ceramic Tile Waste Powder As Partially Replacment of Cement

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MEKELLE UNIVERSITY

A THESIS SUBMITTED FOR BSc. IN

SUBMITTED TO SCHOOL OF CIVIL ENGINEERING

STRUCTURAL ENGINEERING CHAIR

ADVISOR: HELEN NEGASH (MSc.)

Group Members Signature Date

2.3.2 Production of Concrete ........................................................................................... 11

5.2.1 Carbon Dioxide Emissions and Climate Change .................................................... 36

LIST OF TABLE PAGE

LIST OF FIGURE PAGE

Cm Centimeter SO3 Sulfur Trioxide

Kg Kilogram K2O Potassium Oxide

Kg/m3 Kilogram Per Cubic Meter CaO Calcium Oxide

BS British Standard TiO2 Titanium Dioxide

ASTM American Society For Testing Material ZnO Zinc Oxide

kN Kilo Newton Fe2O3 Iron Oxide

Lit Liter ZrO2 Zirconium Dioxide

m3 Meter Cubic BaO Barium Oxide

Max Maximum P2O5 Phosphorus Pentoxide

1.1 GENERAL BACKGROUND

According to information obtained from different sources written by experienced professionals,

1.2 STATEMENT OF THE PROBLEM

1.3 RESEARCH QUESTIONS

1.4 OBJECTIVES OF THE RESEARCH

1.4.1 General Objective

1.4.2 Specific Objective

1.5 SIGNIFICANCES OF THE RESEARCH

Production of concrete with high strength and low cost concrete.

1.6 SCOPE AND LIMITATION OF THE THESIS

1.7 MATERIALS AND METHODOLOGY

1.8 METHODOLOGY OF THE RESEARCH

4) Appropriate Mix Design Was Made

5) Casting The Specimen

7) Studying And Discussion Of The Result

8) Conclusion And Recommendations

Finally, conclusions are drawn and recommendations have been forwarded.

Figure 1-1 Methodology of the Research

1.9 ORGANIZATION OF THE PAPER

2.2 CERAMIC TILE WASTES

1. The first source is the ceramics industry

Table 2-1 principally waste materials in construction and demolition waste

MATERIALS COMPOSITION (%)

2.2.1 Ceramic Wastes Classification

2.2.2 Ceramic Wastes Properties:

Mineralogical composition, determined by X-ray diffraction, mainly comprises the

Table 2-2 Material composition of ceramic tile wastes

Ceramic tile waste Ceramic tile waste

Table 2-3 Chemical analysis of ceramic tile and cement

Ceramic Tile Ceramic Tile

2.2.3 Effect of Ceramic Tile Wastes on Concrete Production

2.2.4 History of Ceramic Tile Wastes on Concrete Production

Amitkumar D. Raval, Indrajit N. Patel, JayeshkumarPitroda Use of Ceramic Powder As

D.Tavakolia, A. Heidari*, b and M. Karimianb conducted by using ceramic wastage in

2.3.1 Composition of Concrete

2.3.2 Production of Concrete

2.3.3 Specification of Concrete

2.4 MATERIALS FOR CONCRETE PRODUCTION

3 METHODOLOGY, MATERIAL PREPARATION, AND CONCRETE

3.2 METHODOLOGY OF THE RESEARCH

The mixing is an extremely important aspect of concreting and it is important to follow

3.3 MATERIAL PREPARATION

3.3.1 Cement Used For the Experiment

3.3.2 Aggregate Used For the Experiment