JOURNAL OF INTERNATIONAL ACADEMIC RESEARCH FOR MULTIDISCIPLINARY

Impact Factor 1.393, ISSN: 2320-5083, Volume 2, Issue 4, May 2014

TECHNO ECONOMICAL DEVELOPMENT OF LOW-COST INTERLOCKING

PAVERBLOCK BY PARTIALLY REPLACEMENT OF PORTLAND POZZOLANA
CEMENT WITH USED FOUNDRY SAND WASTE
DIXIT N. PATEL*
JAYESHKUMAR R. PITRODA**
*Final Year M.E C E & M, B.V.M. Engineering College, VallabhVidyanagar, Gujarat, India
**Assistant Professor& Research Scholar, Dept. of Civil Engineering B.V.M. Engineering College, VallabhVidyanagar, Gujarat, India

ABSTRACT
Foundries for the metal-casting industry generate by- products such as used foundry
sand. Applications of foundry sand, which is technically, sound, environmentally safe for
sustainable development. In this study, partially replacement of Cement (PPC 53 grade
cement) in paver block by used foundry sand for determining the change in the compressive
strength of paver blocks and cost of paver block. Partial replacement of cement (PPC 53
grade cement) in bottom layer in different percentage as like 10%, 20%, 30%, 40% and 50%.
The compressive strength, flexural strength has been determined at the end of 7, 14 and 28
days and water absorption test has been determined at 28 days. The paper also shows the cost
comparison per block for the paver block mix proportion.
KEYWORDS: Various Test, Portland Pozzolana Cement (PPC) Used Foundry Sand, Paver
Block, Cost
INTRODUCTION
Interlocking Concrete Paver Block (ICPB) has been extensively used in a number of
countries for quite some time as a specialized problem-solving technique for providing
pavement in areas where conventional types of construction are less durable due to many
operational and environmental constraints. Paver block is solid, unreinforced pre-cast cement
concrete paving units used in the surface course of pavement.. By improving its compressive
strength it can be used in heavy traffic area also. Interlocking pavers are manufactured
concrete product that is individually placed in a variety of patterns and shapes as per the requirement.

The objective of the present study is

1. To study the effect on the properties of paver block by partially replacement of
cement (PPC 53 grade) by used foundry sand the different percentage.
2. To study the effect on compressive strength and water absorption by partial
replacement of cement in paver blocks.
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3. To development of low-cost interlocking concrete paver block.

DESIGN MIX MATERIALS

In paver block different types of material are used. In top layer cement, dolomite powder and
pigment are used and in bottom layer cement, fine aggregate, semi grit, quarry dust is used.

Figure 1: Layer Distribution of Paver Block

Source: Jalaram Ceramic Industry, Baroda
CEMENT
Cement basically acts as a binding material that holds all the other components of the block.
For making paver block ordinary Portland cement is used. It also imparts strength necessary
to the blocks. Cement is added to semi grit, sand and quarry dust in the required ratio and the
final mixture is thus made and water is added only for the wetness of mixture.

FOUNDRY SAND
Foundry sand is high-quality uniform silica sand that is used to make moulds and cores for
ferrous and nonferrous metal castings. Foundry sand consists primarily of silica sand, coated
with a thin film of burnt carbon, residue and dust. Foundry Sand can be used as a partial
replacement of cement or as a partial replacement of fine aggregates or total replacement of
fine aggregate and as a supplementary addition to achieve different properties of concrete
Foundry sand can be used in concrete to improve its strength and other durability factors. The
foundry sand is a mixture of several elements that combine features of giving perfect
workability of the mixture that comprises the molding box.

Figure 2: Used Foundry Sand

Source: Vithhal Udyognagar, Anand, Gujarat

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Impact Factor 1.393, ISSN: 2320-5083, Volume 2, Issue 4, May 2014

TABLE: 1 PHYSICAL PROPERTIES OF SPENT GREEN FOUNDRY SAND

Property
Specific Gravity

Results
2.39-2.55

Bulk Relative Density, kg/m3 (lb/ft3)

2589(160)

Absorption, %

0.45

Moisture content, %

0.1-10.1

Clay Lumps and Friable Particles

1-44

Coefficient of Permeability (cm/Sec)

10-3-10-6

Plastic Limit/Plastic Index

Non plastic

Source: Geo-Struct engineering and testing services, Baroda

TABLE:2 CHEMICAL COMPOSITION OF FOUNDRY SAND
Constituents

Value (%)

SiO2
Al2O3
Fe2O3
CaO
MgO
SO3
Na2O3
K2O
TiO2
SrO
LOI

87.91
4.70
0.94
0.14
0.30
0.09
0.19
0.25
0.15
0.03
5.15

Source: Geo-Struct engineering and testing services, Baroda

FINE AGGREGATE
Fine aggregate is a naturally occurring granular material composed of finely divided rock and
mineral particles. Those fractions from 4.75 mm to 150 microns are termed as fine aggregate.
The river sand is used as fine aggregate conforming to the requirements of IS: 383.

Figure3: Fine Aggregate

Source: Jalaram Ceramic Industry, Baroda
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SEMI GRIT
Semi grit is the heavier sand than normal sand and is very versatile sand used for many
different tasks and jobs. Semi grit is ideal for water logged areas or finely brushing beneath
flag stones during flag laying It is also ideal for building and it is one of the building sands
that building companies use, mainly as bedding material for paving. The size of the semi grit
is less than 9.5 mm.

Figure 4: Semi-grit (<9.5mm)

Source: Jalaram Ceramic Industry, Baroda
QUARRY DUST
Quarry Rock Dust can be defined as residue, tailing or other non-voluble waste material after
the extraction and processing of rocks to form fine particles less than 4.75mm. Usually,
Quarry Rock Dust is used in large scale as a surface finishing material in the highways and
also used for manufacturing of hollow blocks and lightweight concrete prefabricated
Elements.

Figure 5: Quarry Dust (<4.75 mm)

Source: Jalaram Ceramic Industry, Baroda
DOLOMITE POWDER
Dolomite is one mineral with specific gravity of 2.84 to 2.86. The main use of dolomite is to
impart the particular red or yellow colour to the surface of paver blocks. Dolomite is mixed
with cement and colour in a mixer drum and is rotated for a fixed period of time to get a
proper mixture. It is then put in the mould initially to impart the colour of the blocks.
Dolomite may be locally available or may be sometimes transported and it is cheap too.

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Source: Jalaram Ceramic Industry, Baroda

Figure 6: Dolomite Powder
DESIGN MIX METHODOLOGY
By using this standard mix (M35 Grade) 60 mm paver blocks as per IS: 15658:2006
Table 3: Mix Design Proportion for Top Layer
Sample

Cement

Dolomite Powder

TOP LAYER

156.5 gm.

469.5 gm.

RATIO

Table 4: Mix Design Proportion for Bottom Layer

Sample

Cement

Sand

Semi-Grit

Quarry-Dust

BOTTOM LAYER
RATIO

333 gm.
1

333 gm.
1

700 gm.
2.1

1250 gm.
3.75

Table 5: Partial Replacement of Cement PPC 53 Grade) By Used Foundry Sand in

Standard Concrete Paver Block
Where, B=PPC sample paver block
M-20 With P.P.C

Cement(%)

Used Foundry Sand(%)

B0
B1
B2
B3
B4
B5

100%
90%
80%
70%
60%
50%

0%
10%
20%
30%
40%
50%

EXPERIMENTAL METHODOLOGY
Testing Methodology
Paver block concrete contains cement, fine aggregate, semi grit and quarry dust in the bottom
layer of paver block and in the top layer of paver block only a mixture of cement, dolomite
powder and pigment is used. Partial replacement of cement to the different percentage 0.1%,

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0.2%, 0.3%, 0.4% and 0.5% by used foundry sand in concrete paver block. For compression
test there were four numbers of paver block has been cast and for water absorption three
blocks were cast. At the time of casting water added only for the wet purpose of the mix.
After about 24 h the specimens were placed at safe place and water curing was continued till
the respective specimens were tested after 7, 14 and 28 days for compressive strength and
water absorption tests.

Compressive Strength Test [IS 15658:2006]

Compressive strength tests were performed on compression testing machine using paver
block samples. Four samples per batch were tested with the average strength values reported
in this paper. The block has been stored for 24 4 h in water maintained at a temperature of
20 5C. The bearing plates of the testing machine shall be wiped clean. The specimens are
aligned with those of the bearing plates. The load would be applied without shock and
increased continuously at a rate of 15 3 N/mm2/min until no greater load can be sustained
by the specimen or delamination occurs. The maximum loads applied to the specimen were noted.

Figure 7: Setup of Compression Test

Source: Geo-Struct engineering and testing services, Baroda
Water Absorption Test [IS 15658:2006]
The paver blocks after casting were immersed in water for 28 days curing. They were then
weighted and this weight was noted as the wet weight of the paver block. These specimens
were then oven dried at the temperature 110 C 0until the mass became constant and again
weighed. This weight was noted as the dry weight of the paver block. % Water Absorption =
[(WW DW) / DW] x 100 Where, WW = Wet Weight of paver block, DW = Dry Weight of
paver block

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TEST RESULTS
Table 6:Compressive Strength of PPC Concrete Paver Block mix (N/mm2) at 7, 14 & 28 Days

Compressive Strength Test (PPC)

Mix-Proportions
B0

7 Days
25.732

14 Days
25.61

28 Days
28.919

B1

24.392

24.32

27.812

B2

22.142

23.31

26.437

B3

21.044

23.17

25.616

B4

20.455

22.37

25.0089

B5

19.589

21.24

23.482

Graph: 1Compressive Strength of PPC Concrete Paver Block mix (N/mm2) at 7, 14 & 28 Days

Table 7: Water Absorption of Concrete Paver Block at 28 Days

Water Absorption Test (PPC)
Mix-Proportions
B0
B1
B2
B3
B4
B5

28 Days
3.82
3.29
2.87
2.49
2.43
2.00

Graph: 2 Water absorption of PPC Concrete Paver Block mix (N/mm2) at 28 Days
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ECONOMIC FEASIBILITY
Sr No

Material

Rate (Rs/kg)

1
2
3
4
5
6

Cement PPC
Dolomite powder
Sand
Semi- Grit
Quarry Dust
Used foundry Sand

5.70
1.45
0.65
0.45
0.25
0.25

Table 8: Rate Analysis for Standard all type (P.P.C) Paver Blocks
Description
Cost (Rs/kg)
B0
Standard Paver Block mix
Qnty.
Cost
(kg/)
of material
Cement
Top
5.7
0.16
0.912
(P.P.C)
Bottom
0.33
1.881
Dolomite
1.45
0.47
0.6815
Powder
Sand
0.65
0.33
0.2145
Semi-Grit
0.45
0.7
0.315
Quarry Dust
0.25
1.25
0.3125
Used Foundry Sand
0.25
0
0
Total cost (Rs.)
4.32
So as per above all PPC 53 grade paver block mix different proportions is as below:
Paver block mix

Cost in ( Rs.) per 1 block

B0

4.32

B1

4.15

B2

3.99

B3

3.77

B4

3.61

B5

3.45

Graph: 3 %Replacement of PPC 53 grade cement with used foundry sand in paver block v/s
cost of paver block in (Rs)

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CONCLUSIONS
From this study the following conclusion can be drawn:
1.) From this test, even though at extent of 50 % replacement of cement we got
compressive strength 23.48 N/mm2. So its beneficially for general application as like
footpath, parking, and street road.
2.) By increasing proportions of replacement, Water absorptions is also decreased with
decreasing of compressive strength. At maximum replacement

50% , water

absorption is 2% & compressive strength 23.48 N/mm2

3.) Cost optimization can be achieved when Cement (PPC 53 Grade) is replaced as 10%,
20%, 30%, 40%,50% by Used Foundry Sand. At 50 % replacement of cement (B5)
the cost of paver block is 20.13% lower than standard mix proportion B0.
ACKNOWLEDGEMENTS
The Authors thankfully acknowledge to Dr.C.L.Patel, Chairman, Charutar Vidya Mandal,
Er.V.M.Patel, Hon.Jt. Secretary, Charutar Vidya Mandal, Dr. F.S. Umrigar, Principal,
B.V.M. Engineering College, Mr. Jayrajbhai Patel , owner of Jay Maharaj Tiles, Kanjari,
Anand, Prof. J.J.Bhavsar, Civil Engineering Department, B.V.M Engineering College,
Vallabh Vidyanagar, Gujarat, India for their motivations and infrastructural support to carry
out this research.
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