RECYCLED AGGREGATES

R.MANOJ K.ARUN PRAKASH

Dr.SIVANTHI ADITANAR COLLEGE OF ENGINEERING

AGGREGATE
Aggregate is the component of a composite material used to resist compressive stress and provide bulk to the composite material. For efficient filling, aggregate should be much smaller than the finished item.

NEED FOR AGGREGATE

Global use of concrete 2nd to that of Water Concrete is a heterogenous material made with cement, aggregate, sand and water Widely preferred due to its longer life, low maintenance, better performance Mainly used in Structures, Highways and Railroads and other infrastructure development 50% of concrete constitutes of coarse aggregate And the problem is these natural resource ie aggregates are not available in plenty

PROBLEMS IN AVAILABILITY OF FRESH AGGREGATE

Currently construction industry requires large quantity of aggregates for infrastructures development Fresh Aggregates
Breaking of Stones from Hillocks River Beds

Cost of construction increases with increase in cost of aggregates Environment is affected indirectly by deforestation, flood, etc Cost of material transportation is very high At this rate there will be shortage of these resource in few years.

PROBLEMS OF DEMOLISHING WASTE

Delhi produces 6500 tons of garbage everyday Central Pollution control board report states of the 48million tons of Solid waste produced 35% is from construction Industry Most of these solid waste are dumped or used in landfill which pollutes the ground water and cause enviromental hazards and the no scrap value for the solid waste is obtained It is a Herculean task for need of space of dumping and the energy consumption in transportation to dumping yard. Dumping yards are generally present far outside the city limits

COMPOSITION OF SOLID WASTE

50% 45% 40% 35% 30% 25% 20% 15% 10% 5% 0% SOLID WASTE

DEMOLISION WASTE

SOIL & DUST

ORGANIC MATTER PLASTIC METAL WOOD OTHERS

ADVANTAGE OF RECYCLING AGGREGATES

It is the best solution to growing waste disposal problem It is the best solution to growing needs of aggregate for construction Conserve natural resource like hillocks, Fuels, etc Protection the environment from pollution and other hazards Meet the increasing demand for aggregates Value for the solid waste is obtained Creates a Ecological Balance

NEED FOR PRESENT STUDY AND IMPLEMENTATION

Flyash is used as a partial substitute for cement due to its impermeability record and better concrete Similarly, large scale recycling of demolished waste will provide solution to
Natural resource depletion Waste disposal Energy Requirement Full or Partial replacement of Conventional aggregate

RECYCLING PROCEDURE
Initially the demolished waste is brought to the site of recycling the aggregate The steps followed are
HAMMERING PRIMARY CRUSHING
STEEL EXTRACTION MAKE TO WORKABLE SIZE

SECONDARY CRUSHING
SELECTION OF SUITABLE MATERIAL SCREENING PROCESS ENERGY EFFICIENY ( LEAVING CORRECT SIZE AGGREGATES ) PAPER AND PLASTIC REMOVED BY AIR JET

FINISHED MATERIAL
EVENLY GRADED WELL SHAPED FINAL PRODUCT 70000 TONS/YEAR

EXPERIMENTAL INVESTIGATION
A comparative study is made between
Fresh conventional aggregate (Dolomite Stone) Fresh Local aggregate (Sand Stone) Recycled Aggregate

Specific Gravity of recycled aggregates is about 72% of fresh aggregate and 80% of local aggregate A study is also done on the use of recycled aggregate in making
Conventional Bricks/Blocks General Concrete Construction Highway Construction

Recycled aggregates of 20mm and 10mm are used for experiments The results obtained are as follows :

COMPARATIVE TABULATION
DESCRIPTION SPECIFIC WATER AIV% AVERAGE BULK

OF
MATERIALS

GRAVITY ABSORPTION%

FM
20mm 10mm

DENSITY
(gm/cc)

Fresh aggregate
Local aggregate Recycled aggregates

2.78
2.50 2.21

0.31
1.93 1.26

10.50
31.36 25.97

7.20
7.42 7.28

6.37
6.08 6.28

1.66
1.45 1.20

CONVENTIONAL BRICK/BLOCK
15cubic.cm cubes were casted based the below mix design Cured in open grounds The bricks were weighed and concrete density was calculated Comparative study is made between these bricks and 1st class burnt clay Bricks
Description Cement Aggregate Aggregate Sand (Kg) 20mm 10mm (Kg) Cement Water W/C

Aggregate (Kg)

(Kg)
Recycled aggregates 160 502

(Kg)
502 867

Ratio %
8.11 96 0.6

DISCUSSIONS AND RESULT

Compression Strength:DESCRIPTION Recycled agg concrete brick 1st class Burnt Clay Brick AV. STRENGTH (MPa) 15.27 14.65 DENSITY OF BRICK (g/cc) 2.218 1.503

Results:
Bricks made with recycled aggregates have good compressive strength

sufficient of normal construction and shoulder construction of roadsides Density of Bricks made with recycled aggregates is also high Hence they are widely used for construction activities

RECYCLED AGGREGATE IN GENERAL CONCRETE CONSTRUCTION

A concrete mix with fresh aggregate & recycled aggregate was designed in grade of M25 with cement content of 300Kg/ m3. The ingredients are tabulated below
Description Cement Aggregate Aggregate River of Aggregates (Kg) 20 mm (Kg) 10 mm (Kg) sand (Kg) Ratio of Water W/C CA/FA (Kg)

Fresh aggregate Recycled aggregate

300

545

545

841

56:44

150

0.5

300

428

428

802

58:42

150

0.5

PROCEDURE
Taken for smaller batch and weighed as for design requirements Gives the quantity of other materials used in concrete Materials were casted in laboratory and cubes were casted Tested and results are obtained for 7 and 28days Compressive Strength is determined Weight and Dry density is calculated

DISCUSSIONS AND RESULTS

1. Compressive Strength 2. Density of Concrete

COMPRESSIVE STRENGTH
Test results were obtained for 7 and 28 days and it is summarized the below table
MATERIALS 7 DAYS AV.COM 28 DAYS AV.COM STRENGTH(MPA) STRENGTH(MPA) 28.30 AVG. WEIGHT OF CUBES(KG) 8.25 CONCRETE DENSITY(G/CC) 2.44

FRESH 20.33 AGGREGATE RECYCLED 19.81 AGGREGATE

26.81

7.58

2.25

Compressive Strength obtained is more than 25Mpa

DENSITY OF CONCRETE
Density of Concrete
Each cube is weighed and concrete density is calculated Density is maximum when fresh aggregates is used Density obtained by using recycled aggregate is less than that of the fresh aggregate The density obtained for
Fresh aggregate is 2.44g/cc, is maximum Recycled aggregate is 2.25g/cc, is minimum

Density of concrete with recycled aggregate is 93% of the density obtained by fresh aggregates

RECYCLED AGGREGATE IN HIGHWAY CONSTRUCTION

The following components in Highway were tried
DLC (Dry Lean Concrete) Use of recycled aggregate in Embankment drainage components

Dry Lean Concrete

Parameters of recycled aggregate along with two other materials were determined for the concrete mix for DLC grade requiring a minimum strength of 10Mpa at 7 days Local and Recycled Aggregate are the main parameters are determined to compare the usefulness of these from strength and compacted density consideration

CONCRETE MIX DESIGN AND RESULT

Conventional Design Method Results on MDD & OMC & compressive strength of DLC Mix were found out
Cubes filled with vibratory hammer at different moisture content Weight of cubes were taken Density & moisture content was found to good within the required limits

Compressive Strength
Cubes were tested after 7 days Attains strength more than the design Strength , 10 MPa

TABULATION
OBSERVATIONS UNITS FRESH AGGREGATES Average 7day strength Avg.weight of cubes Density of concrete OMC Maximum Dry Density % g/cc 4.30 2.44 5.50 2.20 5.52 2.21 g/cc 2.52 2.45 2.39 Kg 8.51 8.28 8.07 MPa 17.03 LOCAL AGGREGATES 12.53 RECYCLED AGGREGATE 13.37

EMBANKMENT DRAINAGE COMPONENT

With success in DLC, recycled aggregate were tried in Casting Curve Chute drain Median drain Side drain components

WHAT SHOULD BE DONE?

To have Sustainable Building concept Minimize cement/concrete consumption innovation architecture and structural design Maximum use of recycled aggregate and pozzolanic materials(fly ash) in concrete Tax breaks for sustainable building during approval Govt must make compulsory norms of using recycled materials during new construction The cost of making concrete is increasing rapidly and the use of recycled aggregate will make it cheaper

CONCLUSION
Disposal of Garbage becomes easier Replacing conventional brick with recycled aggregate blocks will prevent the exploitation of top soil suitable for agriculture Concrete of M25 grade can be made of recycled aggregate, useful in PCC, foundation, retaining wall, panel wall. Highway highest user of aggregate, economical Finer material passing 4.75mm IS sieve can be used for embankment refilling RMC can prepare concrete at very low cost Saves the natural resource such as Hillocks, River beds, etc. Natural Hazards such as flood, drought, deforestation can be prevented Roads and Streets can be kept clean of demolished waste Generate employment oppurtunities

REFERENCE
Trends in Concrete Construction (online newsletter, Aug 2010) Engineering Materials R.K.Rajput IS 10262: 1982 (Guidelines of concrete mix design) ICI Journal (January 2010) Website
www.howstuffswork.com www.capebricks.com www.cement.org www.eoearth.org www.sprinkler.com

Project report on recycled aggregates