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1. INTRODUCTION
One solution to reduce the disposal and pollution problems arising from these industrial
wastes is to develop profitable building materials from them. To save energy and to earn
carbon credit is very much essential for the betterment of mankind, so the disposal of
waste should now be done in smarter ways. The waste instead of disposing in
environment which again is hazardous, we should use them where they can be used as a
raw material. One such waste produced from the paper mill industries is the paper sludge
ash also known as the hypo sludge ash, which can be used as a partial replacement of
cement in concrete.
While producing paper the various wastes come out from the various processes in paper
industries. Some of the major problems encountered due to this waste are as follows:
Since bulk of wastes is being disposed in wet state, arrangements have to made
for extraction and supply of these wastes in dry state, which involves lot of
expenditure.
Transportation of waste in dry form in open wagons results in huge transit losses.
Limitation in distance over which the wastes can be economically transported.
Variation in the quality of wastes is one of the major problems related to its bulk
utilization.
Primary waste named as hypo sludge, which contains due low calcium and maximum
calcium chloride and minimum amount of silica. Hypo sludge behaves like cement
because of silica and magnesium properties. This silica and magnesium improves the
setting of the concrete. Cement production industries emit greenhouse gases in the
atmosphere. For producing 4 million tons of cement, 1 million ton of greenhouse gases
are emitted. To eliminate the ozone layer depletion, production of cement should be
reduced. For this, the hypo sludge is used as partial replacement of cement in the
concrete. By utilizing this waste the strength of concrete is maintained up to a limit and
also cost reduction is achieved.
LIME 62 46.2
SILICA 22 9
ALUMINA 5 3.6
MAGNESIUM 1 3.33
The cement has been replaced by waste paper sludge accordingly in the range of 5% to
20% and also in some cases up to 40% by weight. Paper sludge behaves like cement
because of silica and magnesium properties which improves the setting of the concrete.
By using adequate amount of the waste paper pulp and water, concrete mixtures were
produced and compared in terms of slump and strength with the conventional concrete.
The slump decreased when a higher amount of paper pulp content was included. The
received pulp exhibited a high water-absorption capability. Consequently, when a higher
amount of paper pulp was included in the mixture, it required more water to achieve a
given slump. The slump increased up to 5% replacement of cement and above 5%, the
slump decreased as the paper pulp content in the concrete mixtures was increased.
The workability of concrete containing paper-mill residual was improved by the addition
of excessive water instead of admixtures as they have to achieve economy. Several
factors could lead to adverse effects on the workability of paper pulp concrete. The
amount of paper pulp would be the main reasons for the reduction of concrete
workability. The compressive strength developed of paper-mill residual concrete
mixtures shows similarity to the reference mixtures with a high early strength gain. The
compressive, splitting, tensile and flexural strength of concrete mixtures with paper pulp
become less when higher paper pulp contents were included in the concrete mixtures.
The paper pulp content in the concrete mixtures played a great role in the mechanical
properties. The splitting tensile and flexural strength decreased when the paper pulp
content was increased in the mixtures. Generally, the compressive, splitting tensile and
flexural strength increased up to 10% addition of waste paper pulp and further increase in
waste paper pulp reduces the strengths gradually. So the most suitable mix proportion is
the 5% to 10% replacement of waste paper pulp to cement. Cement blended with 10%
and 20% paper sludge exhibits a smaller reduction in compressive strength than the
control cement. Concrete containing an average of 15% residuals had lower 28- day’s
compressive strength than the reference concrete and showed either equivalent or
somewhat lower chloride-ion penetration resistance than the reference concrete.
Thus behaviour of concrete with the waste paper pulp by replacement of cement in the
range of 5%, 10%, 15%, 20%, 30%, and 40% is carried out which may help to reduce the
disposal problems of sludge and enhance the properties of concrete.
Dr. L.B. Zala and Dr. F. S. Umrigar in “Utilization of Hypo Sludge by Eco-
Efficient Development of Rigid Pavement in Rural Roads” presented that Hypo
Sludge Ash can be used for rigid pavement construction in rural areas. By using
this waste road construction may become cost efficient and at the same time best
utilization of waste could also be made. They found good results for the
replacement.
Apurva Kulkarni, Samruddha Raje, Juned Peerzada and Mamata Rajgor in “A
Miniscule Endeavour for Accomplishing Hypo Sludge Fly Ash Brick in Indian
Context” presented that as the waste produced out of paper industries can be
recycled only a limited number of times so these low quality fibres which are
treated as a waste can be used for construction work. This waste contains a large
amount of lime so they used these Hypo sludge ash for production of Fly Ash
Bricks. They replaced lime with different proportions such as 5, 10, 15, 20% with
HSA. They found good results at 5 % replacement for production of Fly Ash
Bricks.
Saveria Monosi, Daniela Sani and Maria Letizia Ruello in “Reuse of Paper Mill
Ash in Plaster Blends” presented that as paper mill ash is a waste and is light
weight, it can be used in manufacturing of plaster bends. This waste if used with
Portland cement, limestone powder, natural sand with a maximum diameter of
2mm, and a silane-based hydrophobic powder can be used in manufacturing of
cement mortar which can be used in the production of dry-cast concrete products
such as masonry blocks and paving stones, wet-cast precast products, structural-
grade concrete. As different paper mills produce different quality of paper there
properties may vary in nature. Paper ash used were provided by Burgo Group"
paper mills (Mantova, Italy). Mechanical strength found ranged from 4 to10MPa
with specific gravity between 1150 and 1350 Kg/𝑚3 .Paper ash being light weight
in nature can be used in various field applications such as filling of temporary
joints and other minor repair work
Sajad Ahmad, M. Iqbal Malik, Muzaffar Bashir Wani, and Rafiq Ahmad in
“Study of Concrete Involving Use of Waste Paper Sludge Ash as Partial
Replacement of Cement” presented that, waste produced from cement
manufacturing industries are growing day by day so we have come to the peak
period to find out such a sources that help to produce greener concrete. It is found
that cement industries are the major sources that produce greenhouse gases
leading to its emissions into environment. So they found out one such material
called Waste paper sludge ash which is used as replacement to cement to produce
concrete. Mix Design for M-25 grade concrete is used in project work. Concrete
cubes were prepared and compression tests was carried out and concrete beams
were prepared for testing flexural test along with that water absorption and dry
density tests were also carried for checking out the weight reduction and water
absorption. It was found that concrete strength increased at 5% replacement of
cement with waste paper sludge ash and along with this water absorption was also
found to be increased.
Gabriele Fava, Maria Letizia Ruello and Valeria Corinaldesi in “Paper Mill
Sludge Ash as Supplementary Cementitious Material” presented that, as the waste
produced out of paper industries are on large scale now-a-days so gainful
The various materials used in the preparation of concrete are cement, sand, coarse
aggregates, hypo sludge and water.
Hypo Sludge:- The paper fibres which are broken and of poor quality are
separated out as sludge during the formation of paper from the pulp and this
sludge can be called as the hypo sludge. It is collected from the paper mill.
Cement:- The most common cement used is an Ordinary Portland Cement (OPC).
The Ordinary Portland Cement of 53 grade conforming to IS:8112-1989 is
used. Many tests were conducted on cement; some of them are specific gravity,
consistency tests, setting time tests, compressive strengths, etc.
Fine Aggregate:- The natural river sand available in local market which passes
through 4.75mm sieve with specific gravity of 2.62. Conforming to Zone II.
Coarse Aggregate:- Crushed granite conforming to IS 383 - 1987 is used. Coarse
aggregate passing through 20mm and retained on 16 mm sieve and specific
gravity 2.82 was used.
Water:- Water is an important ingredient of concrete as it actively participated in
chemical reaction with cement, clean portable water which is readily available is
used.
4.1 METHODOLOGY
The sludge was initially dried at room temperature for about 48 hours, grinded
and sieved. It was sieved using 150 micron sieve.
Chemical analysis of hypo sludge and cement as per IS 1727:1967.
Replacement levels of OPC by Hypo Sludge of 5%, 10%, 15%, 20% was carried
out.
Batching was carried out by weighing as per calculated amount of each concrete
constituent and a concrete mix of M25 and M40 was designed as per IS
10262:2009.
Hypo sludge and the aggregates were mixed for 3-5 minutes in a rotary mixing
machine. Water was then added to the dry mix and the mix was repeated.
The concrete was then poured into the moulds of size 150mm and compacted with
the help of vibrating machines and the top surface was well finished.
The cast specimens were demoulded after 24 hours of casting and were kept in
different curing regimes. The specimens were cured in water for 28 days.
Different tests were then performed on the concrete which are discussed below.
A concrete mix M25 and M40 grade was designed as per IS10262:2009
Different tests are performed on cement concrete in order to find its properties. Tests are
done in two stages if concrete, in fresh concrete and in hardened concrete. Test performed
in fresh concrete is slump test and in hardened concrete are compression test, flexural
strength test and water absorption test.
Mr. R Balamurugan (April 2014) conducted an experimental study for the innovative use
of hypo sludge in concrete formulations as a supplementary cementations material was
tested as an alternative to traditional concrete. The cement has been replaced by waste
paper sludge accordingly in the range of 0% (without hypo sludge), 5%, 10%, 15%, 20%
by weight for M25. Slump test is used to determine the workability of fresh concrete.
Slump test as per IS1199 – 1959 is followed. The apparatus used for doing slump test are
Slump cone and tamping rod. Fig 5.4 shows the slump cone. Table 5.1 represents the
slump values as performed by Mr. R Balamurugan for M25 concrete mix.
The slump initially increases (5%) and then decreases when a higher amount of paper
pulp content was included. The received pulp exhibited a high water- absorption
capability. Several factors could lead to adverse effects on the workability of paper pulp
concrete. The amount of paper pulp replacement, paper pulp physical properties, and the
carbon content of the paper pulp would be the main reasons for the reduction of concrete
workability.
99
98
97
96
Slump (mm)
95
94
% of HypoSludge
93
92
91
90
89
0% 5% 10% 15% 20%
% of Hyposludge
150 mm × 150 mm × 150 mm concrete cubes were casted using M25 and M40 grade
concrete. Specimens with Ordinary Portland Cement (OPC) and OPC replaced with hypo
sludge at 10%, 20%, 30%, 40% levels were cast. During casting, the cubes were
mechanically vibrated by using a table vibrator. After 24 hours, the specimens were
removed from the mould and subjected to water curing for 14 and 28 days. After curing,
the specimens were tested for compressive strength using calibrated compression testing
machine of 2000kN capacity.
The compressive strength for M25 and M40 are represented in table 5.2. It is observed
that the average compressive strength increased up to 10% addition of hypo sludge and
further increased addition of hypo sludge reduces the strengths gradually in both M25
and M40. Figure 4.3 shows the variation of compressive strength of cubes at 28 days for
M25 and M40.
Average Compressive
% Replacement of cement by
Type of concrete strength
hypo sludge
(N/mm𝟐 ) at 28 days
A1 0 36.52
C1 10 39.70
M25 C2 20 25.78
C3 30 23.26
C4 40 22.96
A2 0 50.81
C5 10 52.26
M40 C6 20 40.74
C7 30 28.74
C8 40 24.00
60
50
Compressive Strenth (N/mm2)
40
30 M25
M40
20
10
0
0% 5% 10% 15% 20%
Replacement of Hypo Sludge
The flexural strength is determined by the central point method. Standard metallic beam
moulds (100 mm × 100 mm × 500 mm) were used for the preparation of concrete
specimens for flexural strength. A table vibrator was used for compaction of hand filled
concrete beams. The specimens were de moulded after 24 hours and subsequently
immersed in water for different age of testing. For each age, three specimens were used
for the determination of average flexural strength. The test was performed on Universal
Testing Machine (UTM). The schematic: set up of Universal Testing Machine for
flexural strength is represented below.
𝑀 𝑓 𝑀 𝑀
The flexural strength is calculated by using bending equation = or × y or f =
𝐼 𝑦 𝐼 𝑍
The flexural strength for M25 and M40 are represented in the following table. It is
observed that the flexural strength increased up to 10% addition of hypo sludge and
further increase in hypo sludge reduces the strength gradually in both M25 and M40.
Flexural
% Replacement of
Concrete mix Strength(N/𝐦𝐦𝟐 ) at 28
cement by hypo sludge
days
A1 0 4.71
C1 10 4.49
M25 C2 20 2.93
C3 30 2.74
C4 40 2.62
A2 0 6.10
C5 10 6.20
M40 C6 20 4.73
C7 30 3.41
C8 40 2.70
6
Flexural Strength (N/mm2)
5
M40
3
M25
2
0
0% 5% 10% 15% 20%
Replacement of Hypo Sludge
The 100 mm diameter 50 mm height cylinder after casing were immersed in water for
90 days curing. These specimens were then oven dried for 24 hours at the temperature
110˚C until the mass became constant and again weighed. This weight was noted as the
weight (W1) of the cylinder. After that the specimen was kept in hot water at 85˚C for
3.5 hours. Then this weight was noted as the wet weight (W2) of the cylinder. % water
𝑊2−𝑊1
absorption = × 100 where, W1 = oven dry weight of cylinder in grams, W2 =
𝑊1
after 3.5 hours wet weight of cylinder in grams.
It has been observed that the % of water absorption increases with increase in % of hypo
sludge. Table gives the water absorption result of % replacement of paper industry waste
(hypo sludge) in concrete for 90 days curing.
As Per IS: 4031 (Part 5) – 1988. Initial and final setting time of cement is calculated
using VICAT apparatus conforming to IS: 5513 – 1976
400g of cement were taken and water of quantity 0.85P (where P is the standard
consistency of cement) was added. The stopwatch was started at the moment when the
water was added. The Vicat mould was filled with the mix and any excess paste found
was taken off using a trowel. Then the mould was placed on a non porous plate such that
the plunger touched the surface of Vicat mould. Plunger was then released and it was
allowed to sink into the test mould. The penetration of the plunger from the bottom of the
mould was noted. The same experiment was repeated at different positions on the mould
until the plunger stopped penetrating 5mm from the bottom of the mould.
The initial and final setting time for concrete with different replacement of hypo sludge is
represented in Table 2. It is observed that the initial setting time increases with the
increase in percentage of hypo sludge and final setting time decreases as the percentage
of hypo sludge increases.
CEMENT+0%HYPOSLUDGE 30 600
CEMENT+10%HYPOSLUDGE 31 598
CEMENT+20%HYPOSLUDGE 33 597
CEMENT+30%HYPOSLUDGE 34 595
CEMENT+40%HYPOSLUDGE 36 593
6. APPLICATIONS
7. ECONOMIC ANALYSIS
The addition of hypo sludge reduces strength of concrete. Still there are some benefits of
the hypo sludge addition. Firstly it provides an environmentally consistent way of hypo
sludge disposal. Secondly in overall it reduces the cost of the structural element. Of
course due to lesser strength of hypo sludge blended concrete, sectional area of structural
element required will be more. But, addition of fly ash shall reduce the quantity of
cement required and hence the overall cost.
8. CONCLUSIONS
This report concludes that hypo sludge can be used as a construction material.
9. REFERENCES