LOWCOST CONCRETE FROM PAPER INDUSTRY

I.V.P.RAVI CHANDRA A.V.PRANAY KUMAR REDDY

M.A.ASIM M.VENKATESH

PROJECT GUIDE: SRI. NARENDRA KUMAR BOPPANA (Ph.D) Designation : Sr.Asst.Professor, Department of Civil Engineering

ABSTRACT
Over 300 million tones of industrial wastes are being produced per annum by chemical and agricultural process in India. Out of several wastes being produced at present, the use of phosphogypsum, fluorogypsum, lime sludge, hypo sludge, red mud are significant in protecting the environment. low-quality paper fibers are separated out to become waste sludge classically called as Hypo sludge.

CONTENTS
Introduction Need for hypo sludge utilization. Objectives. Scope. Mix design. Analysis and results. Conclusion.

INTRODUCTION
Paper making generally produces a large amount of solid waste This paper mill sludge consumes a large percentage of local landfill space for each and every year. To reduce disposal and pollution problems emanating from these industrial wastes, it is most essential to develop profitable building materials from them. Investigations suggest replacing various ratios of cement with hypo sludge produces low cost concrete.

NEED FOR HYPO SLUDGE UTILIZATION

Production of 4 million tones of cement involves in emission of 1 million tones green house gases. To reduce environmental degradation i.e. preventing land filling. Utilizing this waste the strength will be increased and also cost reduction in the concrete is achieved.

HYPO SLUDGE
Hypo sludge behaves like cement because of silica and magnesium properties in improving the setting of concrete. It is the preliminary waste from the paper industry.

PROPERTIES OF RAW HYPOSLUDGE

S.NO 1. 2. 3. 4. 5. 6. 7. CONSTITUENT Moisture Magnesium oxide (MgO) Calcium oxide (CaO) Loss of ignescent Acid insoluble Silica(SiO2) R2O3 % PRESENT IN HYPOSLUDGE 56.8 3.3 46.2 27 11.1 9 3.6

COMPARISON OF CEMENT AND HYPO SLUDGE

S.NO 1. 2. 3. 4. 5. CONSTITUENT Lime(CaO) Silica (SiO2) Alumina Magnesium Calcium sulphate CEMENT (in %) 62 22 5 1 4 % PRESENT INHYPOSLUDGE 46.2 9 3.6 3.33 4.05

OBJECTIVES
To investigate the utilization of hypo sludge as supplementary cementitious materials and influence of hypo sludge on the strength on concrete made with different cement replacement levels.

Scope
To provide a most economical concrete. It should be easily adopted in field. Using the wastes in useful manner. To reduce the cost of the construction. To promote the low cost housing to the L.I.G group people. To find the optimum strength of the partial replacement of concrete.

Scope
Minimize the maximum demand for cement. Minimize the maximum degradation in environment due to cement and safeguard the ozone layer from green house gases. To study the crack development in hardened concrete.

MATERIALS TO BE USED
1.Cement 2.Aggregate a) coarse aggregate b) fine aggregate 3.Water 4.Hypo sludge

MIX DESIGN
A mix of M25 grade was designed as per Indian standard method and the same is used to prepare the test samples . The design mix proportion is done as follows .
WATER By volume 0.35 CEMENT 1 F.A 0.834 C.A 2.29

Mix Proportions
Conventional Concrete 10% replacement 1:0.834 :2.29 0.9:0.834 :2.29

20% replacement
30% replacement 40% replacement 50% replacement 60% replacement 70% replacement

0.8:0.834 :2.29
0.7:0.834 :2.29 0.6:0.834 :2.29 0.5:0.834 :2.29 0.4:0.834 :2.29 0.3:0.834 :2.29

Details of the Experimental Study

150 mm 150 mm 150 mm concrete cubes were casting using M25 grade concrete. Specimens with ordinary Portland cement (OPC) and OPC replaced with hypo sludge at 10%, 20%, 30%, 40%, 50%, 60% and 70% levels were cast.

Experimental Study
After 24 h the specimens were removed from the mould and subjected to water curing. The specimens were tested for compressive strength using a calibrated compression testing machine.

Results
Partial Replacement Number of specimen Ultimate load, [Kn] Ultimate compressive strength, [N/mm2] 37.33 40.37 55.69 56.11 36.95 18.335 15.87 12.94

0 10 20 30 40 50 60 70

1 1 1 1 1 1 1 1

839 908 1252 1253 898 412 357 291

Economic Feasibility
Cost analysis is carried out for the optimum proportion of percentage of hypo sludge in concrete. This project was carried out in our college campus. The cost is compared to the conventional concrete.

Cost of Materials
Cost of cement per bag = 275/Cost of sand per m3 = 955/Cost of hypo sludge per kg = 0.51/Cost of coarse of aggregate per m3=620/-

Cost of Material of Normal Concrete/ m3

Description Quantity, [kg/m3] Cost Cost of material in (Rs)

Cement Hypo sludge sand Coarse aggregate Total

450 375.3 1030.5

5.5/kg 0.51/kg 955/m3 620/m3

2475 224 290.4 2989/-

Cost of material of 10% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement Hypo sludge sand Coarse aggregate Total

405 45 375.3 1030.5

5.5/kg 0.51/kg 955/m3 620/m3

2227.5 22.95 224 290.4 2764/-rs

Cost of material of 20% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement Hypo sludge sand Coarse aggregate Total

360 90 375.3 1030.5

5.5/kg 0.51/kg 955/m3 620/m3

1980 45.9 224 290.4 2540.3

Cost of material of 30% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement Hypo sludge sand Coarse aggregate Total

315 135 375.3 1030.5

5.5/kg 0.51/kg 955/m3 620/m3

1732.5 68.85 224 290.4 2315

Cost of material of 40% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement Hypo sludge sand Coarse aggregate Total

270 180 375.3 1030.5

5.5/kg 0.51/kg 955/m3 620/m3

1485 91.8 224 290.4 2091

Cost of material of 50% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement Hypo sludge sand Coarse aggregate Total

225 225 375.3 1030.5

5.5/kg 0.51/kg 955/m3 620/m3

1237.5 114.75 224 290.4 1866

Cost of material of 60% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement Hypo sludge sand Coarse aggregate Total

180 270 375.3 1030.5

5.5/kg 0.51/kg 955/m3 620/m3

990 137.7 224 290.4 1642

Cost of material of 70% partially replaced concrete /m3

Description Quantity, [kg/m3] Cost Cost of material

Cement Hypo sludge sand Coarse aggregate Total

135 315 375.3 1030.5

5.5/kg 0.51/kg 955/m3 620/m3

742.5 903 224 290.4 1417

Conclusion
Compressive strength of the concrete is increased when the percentage of replacement is increased up to 40%. Replacement of cement with this waste of hypo sludge material provides maximum compressive strength at 30% replacement.

Cont... Used as temporary shelters during natural calamities and storage conditions. When government implement the projects for temporary shelters for affected by tsunami, E.Q., etc., this material can be used for economical feasibility. Cost of cement becomes low from this project.

Cont.
Environment effects from wastes and maximum amount of cement manufacturing is reduced through this project. A better measure by a New Construction Material is formed out through this project.

Thank you

WORK SCHEDULE
S.No 1 Activity
Literature Review

Duration
Dec 2011-Jan 2012 (4 weeks) Jan 2012-Feb2012 (2 weeks) Feb2012-March 2012 (4 weeks) March 2012-April 2012 (4 weeks) April 2012 (2 weeks)

2
3 4 5

Mix design
Experimental trials Analysis of results Documentation