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BY
RAGHAVENDRA. T
Reg. No: 1st Semester M-Tech Structures
BANGALORE -560004
CERTIFICATE
This is to certify that Mr. RAGHAVENDRA. T bearing university USN
has
Prof. K.JAYRAM
H.O.D
Dept. of Civil Engg.
Dr. M. U. ASWATH.
Dr. M. U. ASWATH
Professor
Dept. of Civil Engg.
ACKNOWLEDGEMENT
RAGHAVENDRA. T
M-TECH STRUCTURES
BANGALORE INSTITUTE OF TECHNOLOGY
CONTENTS
1. INTRODUCTION
2. EXPERIMENTAL PROGRAMME
2.1 Properties of Various Materials tested
2.1.1 Physical properties
2.2 Concrete Mixture Proportioning
3. VARIOUS TESTS AND DISCUSSIONS
3.1 Tests on Plain Concrete
3.2 Test on RC Beams
3.3 Deflections
3.4 Strains
3.5 Failure Loads
3.6 Crack Widths
3.7 Cost Analysis
4. CONCLUSIONS
5. REFERENCES
6. BIBLIOGRAPHY
ABSTRACT
Stone crusher dust, which is available abundantly from crusher units at a low cost in many areas,
provides a viable alternative for river sand in concrete.
Investigations done by Giridhar Kumar. V, Master of Engineering (SE) degree,
Osmania University, Hyderabad & Mrs. Molly John , Asst Professor & Students of
M. A. College of Engineering, Mahatma Gandhi University, Kerala, on the use of stone crusher
dust in concrete as an alternative to river sand are presented in this report.
The tests conducted pertain to concrete with river sand of strength 28.1 MPa. Tests on the
strengths of concrete, and on the flexural behaviour of RC beams under two-point loading were
conducted. Failure loads and cracking patterns of the beams with sand and with crusher dust as
fine aggregates were compared. The investigations indicate that stone crusher dust has a good
potential as fine aggregate in concrete construction.
Use of Stone crusher dust does not only reduces the cost of construction but also helps reduce the
impact on the environment by consuming the material generally considered as waste product
with few applications.
1 INTRODUCTION
The spiraling costs of river sand used as fine aggregate in concrete have increased the cost of
construction significantly in the past two decades. The increase in the cost of river sand is due to
dwindling natural resources coupled with the restrictions imposed by several state government
on sand quarrying, as well as the concern to prevent further environmental degradation and
conserve ground water. These problems have led to the search for alternative materials for fine
aggregates that are eco-friendly besides being inexpensive.
Stone crusher dust, available abundantly from crusher units at a low cost in many areas, provides
a viable alternative for conventional river sand. Crusher dust from quarries, being, by and large,
a waste product, will also reduce environmental impact, if consumed by construction industry in
large quantities.
Investigation on the strength characteristics of mortars and concrete with crusher dust as partial
and full replacement of the aggregate are reported by several researchers. The test results
indicate that stone crusher dust can be used in mortar and concrete without significant difference
in strength and workability compared to mortar and concrete with conventional river sand.
However, Sahu et al investigated the use of crusher dust only as a partial replacement of fine
aggregates, and not as complete replacement, while jaffar et al investigated the performance of
high strength concrete with silica stone dust as a partial replacement of cement.
comprehensive tests on beam models are not reported so far.
Further,
Crusher dust not only reduces the cost of construction but also the impact on
environment by consuming the material generally considered as a waste product with few
applications.
Fine aggregate
River sand
Crusher dust
1157.00
660.00
Specific gravity
2.27
2.60
Fineness modulus
2.74
2.71
0.10 percent
0.60 percent
Water absorption
1.0 percent
0.90 percent
Value
20
1450.0
Compacted state
1530.0
Specific gravity
2.78
Fineness modulus
6.85
Voids, percent
Loose state
41
Compacted state
47
0.6
0.5
Sand supplied from river Godavari, and granite stone crusher dust
procured from a local granite quarry in Kesara, near Moula Ali, Hyderabad, was used.
The physical properties of the fine and coarse aggregates used are indicated in Tables1 and 2,
respectively. The crusher dust has about the same fineness modulus (2.71) as that of the
river sand (2.74), and water absorption was also similar (about 1 percent).
aggregates were falling in zone II (IS 383 : 1970) as per the particle size distribution. The
quality of crusher dust depends upon the type of stone and crusher. The properties should be
ascertained to proportion the mix for the concrete quality required.
Ordinary portland cement (OPC) Grade 53 cement (strength of standard mortar cubes = 55.6
MPa with 28 percent normal consistency) conforming to IS 12 269 : 1987 was used in the test
specimen.
Table3 Concrete mix proportions
Mixture
Material
Cement. Kg/m3
River sand. Kg/m3
Coarse aggregate. Kg/m3
Water cement ratio
Slump mm
Compaction factor
(1 : 1.4 : 3.5 )
360.0
504.0
1 260.0
0.54
( 1 : 1.6 : 3.5 )
360.0
1 260.0
0.53
28
0.92
25
0.87
Fine
Compressive strength.N/mm2
Aggregate
Sand
3-days
15.0
7-days
18.9
28- days
28.1
18.8
23.0
32.8
B Crusher dust
Percentage increase
3-days
25.3
7-days
21.7
28-days
16.8
Sand
Crusher dust
2.90
Percentage increase
7 days
28 days
21.6
6.6
Table6 Flexural tensile strength of 100 x 100 x 500 prisms (average of 3 prisms)
Mix
Fine aggregate
Percentage increase
7 days
28 days
Sand
2.85
3.70
Crusher dust
3.72
4.45
30.5
20.3
removed after 24 hours, and the specimens cured for 28 days before testing. A steel frame with
inner dimensions of 600 mm x 180 mm x 220 mm with bolts at top and bottom to hold dial
guages was fixed to the beam to measure strains over a 200.0 mm guage length, Fig 2.. three
dial guages were fixed at the top and three at the bottom to record strains at the mid-span and
one-third span sections. The beam deflections were measured by means of three dial guages set
below the beam at mid-span and one-third span sections, Fig 3. the dial guages used had a least
count of 0.01 mm.
Table7 Beam deflections at 60.0 KN load
Sl
Beam
Deflection, mm
No
1/3 span
Mean value
mid-span
Su 1
12.99
14.62
Su 2
9.72
11.30
Su 3
12.12
CDU 1
13.60
14.28
CDU 2
10.10
11.16
CDU 3
9.45
11.61
11.05
14.05
10.40
Mean value
13.32
11.95
The beams were tested on a Universal testing machine (2000 KN-capacity) under two-point
loading at one-third points of the span as indicated in Fig 1 . Dial guage reading were recorded
for every incremental load of 2.5 KN distributed equally over two points. Deflections, strains
and cracks were monitored during the tests, and the results on flexural behaviour (deflections,
strains and moment curvature relations) were compared.
3.3 Deflections
The mean deflections of the beams at one-third span sections are indicated in Fig 4 (a), while
Fig (b) indicates the mean
Table8 Failure loads of the beams
Sl
Beams
Failure load, kN
SU 1
62.5
SU 2
66.5
SU 3
60.5
CDU 1
66.0
CDU 2
67.5
CDU 3
68.5
Mean value,kN
No
63.2
67.3
Values of the mid-span deflections of the beams. The behaviour of the beams with river sand
and with crusher dust does not differ significantly. Table 7 indicates the bean deflections at a
load of 60.0 kN. The mean deflection of the SU series (river sand) was 11.61 mm at one-third
span section, while that of CDU (stone dust) series was 11.05 mm; the difference being about 5
percent. The corresponding values at the mid-span section were 13.32 mm and 11.95 mm,
respectively; the difference being about 10 percent. The differences in the mean deflections of
the test beams were not significant; however, the beams with crusher dust as fine aggregate
developed smaller deflections than those with river sand. The deflections were not measured up
to the failure load to avoid damage to dial guages.
3.4 Strains
The beams with crusher dust developed smaller strains generally, the difference up to a load of
30.0 kN was about 20 percent. However, the strains in the beams with crusher dust increased
suddenly at load beyond 50.0 kN at one-third span sections, possibly due to crushing of the
concrete at the loaded section.
Crack width,mm
Sl No
Beam
Maximum
Mean
SU 1
1.50
0.17
SU 2
1.55
0.29
SU 3
2.05
0.52
CDU 1
2.10
0.24
CDU 2
1.55
0.25
CDY 3
0.50
0.15
Cost of Mix A works out to be Rs 3,036.66, while that of Mix B to be Rs 2,531.57, indicating a
saving of about 20 percent.
Besides the savings in costs, since crusher dust is a waste material from the stone quarries, its use
will lead to eco-friendly green concrete.
4 CONCLUSIONS
It can be seen that stone crusher dust as fine aggregate has in general no detrimental effect on the
strength and performance of concrete when designed correctly.
The concrete cubes with crusher dust developed about 17 percent higher strength in compression,
7 percent more split tensile strength and 20 percent more flexural strength (modulus of rupture)
than the concrete cubes/beams with river sand as fine aggregate. The differences in strengths are
possibly due to the sharp edges of stone dust providing stronger bond with cement compared to
the rounded shape of river sand.
Similarly, the RC beams with crusher dust sustained about 6 percent more load under two point
loading, and developed smaller deflections and smaller strains than the beams with river sand.
The cracks were also fewer, and the crack widths were smaller. The better performance of the
beams with stone dust may be due to the higher strength of concrete.
The test results pertain to concrete with river sand (as fine aggregate) of strength 28.1 MPa, and
for concrete with granite stone crusher dust of strength 32.8 MPa. The results for other strengths
may be different for other grades of concrete, and for crusher dust of other types of stones
(basalt, trap and lime stone).
Based on the test results presented by Giridhar Kumar. V, it can be concluded that crusher stone
dust can be adopted as fine aggregates in concrete structures.
Fine
Mix
Description
Quantity
M3
Rate per m3
Rs
Rs
Aggregate
A
River sand
Crusher dust
Cost
Cement
0.266
6,600.00
1755.60
Sand
0.436
1,250.00
545.00
Coarse aggregate
0.868
848.00
736.06
Cement
0.266
Total
6,600.00
3,036.66
1755.60
Crusher dust
0.347
115.00
39.91
Coarse aggregate
0.868
848.00
736.06
Total
2,531.57
The dwindling sources of natural sand, and its high cost could encourage the adoption of crusher
dust as fine aggregate in concrete, a waste material from stone quarries, in present & future
constructions.
REFERENCES
GIRIDHAR KUMAR. V, Strength characteristics of concrete with crusher dust as fine
aggregate, Dissertation submitted in partial fulfillment of the requirements of the Master of
Engineering (SE) degree, Osmania University, Hyderabad, 2003.
PRABIN PAUL. K, SOUMYA SAIRA JOY, AMITA ABRAHAM, SMITHA. K,
KURIACHAN SIMON & NAVEEN. J An alternative to natural sand Project report submitted
in partial fulfillment for the award of the B. Tech. degree in Civil Engineering, under the
guidance of Mrs. Molly John , Asst Professor, Department of Civil Engineering, M. A. College
of Engineering, Mahatma Gandhi University, KERALA, 2003.
Web page www.schubert-env.com
Progressive Review - website
CSA - website
BIBLIOGRAPHY
MISHRA, V. N Use of stone dust from crushers in cement-sand mortars. The Indian Concrete
journal, August 1984, Vol 58, Nos 58,No,pp.219-223.
BABU, K. K. RADHAKRISHNA,R. and NAMBIAR, E.K.K. Compressive strength and
Construction review, September 1997, vol 10,No 9,pp 25-29.
SAHU, A.K.,KUMAR, SUNIL and SACHAN, A.K.Crushed stone waste as fine aggregate for
concrete, The Indian concrete Journal, January 2003, Vol 77,N0 1, pp.845-847.
JAAFAR,M.S.,THANOON,W.A.,KADIR,M.R.A and TRIKHA,D.N. Strength and durability
characteristics of high strength autoclaved stone dust concrete, The Indian Concrete Journal,
December 2002, Vol 77,No1,pp.771-775.
Recommended guidelines for concrete mix design, IS 10262 : 1982, Bureau of Indian Standards,
New Delhi.
Handbook on concrete mixes, SP 23: 1982 Bureau of Indian Standards, New Delhi.
Indian standard specifications for coarse and fine aggregate from natural source for concrete, IS
1983: 1970, Bureau of Indian Standards, New Delhi.
Specifications for 53 grade ordinary Portland cement, IS 12269 : 1987, Bureau of Indian
Standards, New Delhi.
Indian standard code of practice for plain and reinforced concrete, IS 456 : 2000, fourth revision,
Bureau of Indian Standards, New Delhi.