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Cite this Article: Abdullah Anwar, Sabih Ahmad, S. Mohd. Ashraf Husain
and Syed Aqeel Ahmad. Salvage of Ceramic Waste and Marble Dust for the
Refinement of Sustainable Concrete. International Journal of Civil
Engineering and Technology, 6(9), 2015, pp. 79-92.
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Abdullah Anwar, Sabih Ahmad, S. Mohd. Ashraf Husain and Syed Aqeel Ahmad
1. INTRODUCTION
Sustainability in concrete production can be achieved by innovations in substitutions
of material used. Innovations are much needed to meet the increasing demand for new
and quality materials. Concrete is a widely used construction material consisting of
cementing material, fine aggregate, coarse aggregate and required quantity of water,
where the fine aggregate is usually natural sand. Cement based material are the most
abundant materials in the world. Due to the high in demand of natural resources our
engineers & architect has growing interest in sustainable development by choosing
the material which is more sustainable that is why the green building concept is
emerging in our country. It is very eco-friendly & save the environment by using
waste products generated by industries. It is realistic that a technology can be
developed which can reduced the carbon dioxide emission related to concrete
production. In India the marble & ceramic are the most thriving industries.
The global consumption of natural sand is too high due to its extensive use in
concrete. The use of sand in construction results in excessive sand mining which is
objectionable. Due to rapid growth in construction industry, the available sources of
natural sand are getting exhausted, causing depletion of natural resources resulting
increase in scour depth and sometimes flood possibility. Also, good quality sand may
have to be transported from long distance, which adds to the cost of construction.
Therefore, it is necessary to replace natural sand in concrete by an alternate material
either partially or completely without compromising the quality of concrete. Waste
marble dust is one such material which can be used to replace sand as fine aggregate.
The present study is aimed at utilizing waste marble powder as fine aggregate in
concrete, replacing natural sand. Marble is a metamorphic rock produced from
limestone by pressure and heat in the earth's crust due to geological process [1]. In
INDIA, the marble processing is one of the most booming industries. Marble
industries in India grow more than 3500 metric tons of marble powder slurry per day.
India is among the top world exporters of marble rock. The Indian marble industry
has been rising steadily at an annual pace of about 10% per year. 20 to 30% of marble
blocks are changed into powder. 3,172 M tons of marble dusts were produced in year
2009-10. Marble is one of the most important materials used in buildings since
ancient times, especially for decorative purposes. The marble is widely used in
buildings due to its beauty, strength & resistance to fire.
Marble waste powder is produced from processing plants during the sawing and
polishing of marble blocks and about 25% of the processed marble is turn into powder
form. Marble waste when dumped on open land affects adversely the productivity of
land as it reduces the porosity and affects ground water recharge. Disposal of the
waste marble powder from the marble industry is one of the environmental problems
worldwide today. Recently, marble dust powder has been employed in the
construction industry and research has been carried on to examine their fruitful result.
The production of cheaper and more durable concrete using this waste can solve to
some extent the ecological and environmental problems. The various applications of
Marble Powder are as follows:
1.
2.
3.
4.
Detergent applications
5.
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Salvage of Ceramic Waste and Marble Dust For The Refinement of Sustainable Concrete
Marble powder can be used as filler in concrete and paving materials and helps to
reduce total void content in concrete.
2.
3.
We can reduce the environmental pollution by utilizing this marble powder for
producing the other products.
4.
Marble dust is mixed with concrete, cement or synthetic resins to make counters,
building stones, sculptures, floors and many other objects.
5.
Marble dust gives an iridescent feel to the object because of the crystallized
particles present in the dust from the marble. These cultured marble objects are
often seen in luxury settings. Synthetic marble objects made with marble dust are
more commonly used than 100 percent solid marble objects.
6.
Marble dust is also used to make paint primer for canvas paintings, and as paint
filler.
7.
8.
The marble powder is also used to create carbonic acid gases which are used in
the bottling of beverages.
In addition to marble powder, silica fume, fly ash, pumice powder and ground
granulated blast furnace slag are widely used in the construction sector as a mineral
admixtures instead of cement (Demirel and Yazicioglu,2008, 2006, 2007) [2]-[4].
Marble dust can be used either to produce new products or as an admixture so that the
natural sources are used more efficiently and the environment is saved from
dumpsites of marble waste (Hameed and Sekar, 2009) [5]. Many studies have been
conducted in literature on the performance of the concrete containing waste marble
dust or waste marble aggregate, such as its addition into self compacting concrete as
an admixture or sand (Corinaldesi et al., 2010; Alyamac and Ince, 2009; Guneyisi et
al., 2009; Unal and Uygunoglu, 2003) [6]-[9], as well as its utilization in the mixture
of asphaltic concrete (Karasahin and Terzi, 2007; Akbulut and Gurer, 2007; Binici et
al., 2008) [10]-[12] and its utilization as an additive in cement production (Aruntas et
al., 010) [13]. Hanifi Binici et al (2007) [14] found that marble-dust concrete has
higher compressive strength than that of the corresponding lime stone -dust concrete
having equal w/c and mix proportion. The results indicated that the Marble dust
concrete would probably have lower water permeability than the lime stone concrete.
As non-pozzolanic fines it is at present the limestone and dolomite ones which are
most frequently used to increase the content of fine particles in self compacting
concretes (Billberg, 1999) [15]. Compared to normal plain concrete of the same w/c
ratio and the same cement, the concrete having high limestone filler content of
suitable particle-size-distribution generally improves the strength characteristics
(Sonerbi et al., 2000, Petersson, 2001) [16]-[17]. Sachin (2010) [18] used Marble
Powder and artificial sand or manufactured sand as partial replacement for natural
sand to conduct their study on mechanical behavior of concrete. Tests were conducted
using natural sand, manufactured sand, marble dust with equal amount of cement,
coarse aggregate and water. Sieve analysis was carried out on fine sand. A further step
Akbulut et al (2011) [19] found in their studies that the concrete containing waste
marble dust or waste marble aggregate, such as its addition into self-compacting
concrete as an admixture or sand as well as its utilization in the mixture of asphaltic
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Abdullah Anwar, Sabih Ahmad, S. Mohd. Ashraf Husain and Syed Aqeel Ahmad
concrete and its utilization as an additive in cement production, the usage of marble as
a coarse aggregate and as a fine aggregate passing through 1 mm sieve.
Ceramic waste is most commonly produce from ceramic industry, this waste is in
the form of pest and hard form, pest waste is known as the filter waste or slurry waste,
which is produced at the end of polishing and finishing of ceramic tiles. The overall
size of the Indian ceramic industry is about Rs 18,000 crores producing 100 Million
tons per year. The production during 2011-12 stood at approx. 600 million square
meters. However, the ceramic waste is durable, hard and highly resistant to biological,
chemical and physical degradation.
Different types of ceramic products are:
Ceramic wastes can be separated in two categories in accordance with the source
of raw materials. The first one are all fired wastes generated by the structural ceramic
factories that use only red pastes to manufacture their products, such as brick, blocks
and roof tiles. The second one is all fired waste produced in stoneware ceramic such
as wall, floor tiles and sanitary ware. These producers use red and white pastes;
nevertheless, the usage of white paste is more frequent and much higher in volume. In
each category the fired ceramic waste was classified according to the production
process. This classification is reported in the following diagram (Figure 1) (F.P.Torgal
and S. Jalali, 2010) [20].
In the ceramic industry, nearly 15%-30% waste material generated from the full
production. The ceramic wastes cause soil, air and groundwater pollution. The
ceramic wastes are not recycled in any course at present owning a problem in presentday society. Thus, a suitable form of management is required in society to attain
sustainable growth. The industries are dumping the wastes in any nearby pit or vacant
spaces, near their unit, although notified areas have been marked for dumping. This
contributes to severe environmental and dust pollution and occupation of a immense
expanse of solid ground, especially after the powder dries up and then it is necessary
to throw out the ceramic waste quickly and employ in the construction industry. It has
been estimated that about 30% of the daily production in the ceramic industry goes to
waste. This waste is not recycled in any form at present. However, the ceramic waste
is durable, hard and highly resistant to biological, chemical and physical degradation
forces. As the ceramic waste is piling up every day, there is pressure on the ceramic
industries to find a solution for its disposal (RM. Senthamarai and P. D. Manoharan,
2005) [21]. Thus, employment of the ceramic waste powder and marble dust powder
in various industrial sectors, especially the construction industry would help to protect
the surroundings. Thus, resulting in the growth of eco-friendly concrete.
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Salvage of Ceramic Waste and Marble Dust For The Refinement of Sustainable Concrete
Ceramic Wastes
Red Paste
White Paste
One-fired
Twice fired
One fired
Twice fired
Bricks
Blocks
Roof tiles
Porous stone ware tiles
Sanitary ware
Porous stoneware tiles
Stoneware tiles
China stoneware tiles
Figure 1 Classification of ceramic wastes by type and production process. (F. P.Torgal and S.
Jalali, 2010)
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Abdullah Anwar, Sabih Ahmad, S. Mohd. Ashraf Husain and Syed Aqeel Ahmad
2. EXPERIMENTAL MATERIALS
2.1. Cement
Commercially available Ordinary Portland Cement of 43 grades manufactured by the
JP Cement Company confirming to IS 8112:1989 was used in the field [31]
(Specification, Bureau of Indian Standards, New Delhi). The Physical Properties of
OPC Cement are shown in Table 1.
Table 1 Physical Properties of Cement
Details
OPC
(G-43)
Specific
Gravity
3.05
Final
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Salvage of Ceramic Waste and Marble Dust For The Refinement of Sustainable Concrete
Table 2 Chemical Properties of Marble Dust Powder
S.No.
1.
Materials
Loss of Ignition (L.O.I)
2.
CaO
43.20
3.
Fe2O3
1.90
4.
Al2O3
2.50
5.
SiO2
13.8
6.
MgO
2.70
7.
SO3
0.07
8.
K2O
0.60
9.
Na2 O
0.90
10.
CL
0.03
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Abdullah Anwar, Sabih Ahmad, S. Mohd. Ashraf Husain and Syed Aqeel Ahmad
Table 3 Chemical Properties of Ceramic Waste Powder
S.No.
Materials
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
SiO2
Al2O3
Fe2O3
CaO
K 2O
Na2 O
MgO
P2O5
Mn2O3
CL
SO3
Loss of Ignition (L.O.I)
63.29
18.29
4.32
4.46
2.18
0.75
0.72
0.16
0.05
0.005
0.10
1.61
2.6. Water
Water is an important factor of concrete as it actually participates in the chemical
reaction with cement. Portable water is employed in fusing of concrete.
3. ECONOMIC FEASIBILITY
The Economic Feasibility of materials is tabulated as below in Table 4.
Table 4 Cost of Materials
S.No.
1.
2.
3.
4.
5.
Materials
Rate (Rs/Kg)
8.00
0.65
0.70
2.00
12.00
4. NOMINAL PROPORTIONS
The concrete mix is designed as per IS: 10262-1982 [35], IS: 456-2000 [36] for the
normal concrete. The grade of concrete, which we adopted, is M20. The concrete mix
proportion (cement: fine aggregate: coarse aggregate) is 1:1.5: 3 by volume and a
water cement ratio of 0.50.
5. EXPERIMENTAL METHODOLOGY
The evaluation of Ceramic Waste Powder as a replacement of cement material and
Marble Dust Powder as a replacement of fine aggregate begins with the concrete
testing. The study is conducted to analyze the compressive strength of concrete when
the base materials, i.e. Cement is replaced with ceramic waste powder and fine
aggregate is replaced with Marble Dust Powder respectively. Compressive strength
tests were done on compression testing machine using cube samples. Firstly, the
ceramic waste powder replacement was made at proportions 0%, 5%, 10%, 15%,
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Salvage of Ceramic Waste and Marble Dust For The Refinement of Sustainable Concrete
20%, 25%, 30%, 35%, 40%, 45% and 50% by weight of M-20 grade concrete. Three
samples per batch were tested with the average strength values reported in this paper.
The maximum average value of compressive strength at a certain definite replacement
proportion of cement with ceramic waste powder was noted. Now, the ceramic waste
powder replacement is kept at the constant proportion (proportion attaining maximum
average value of compressive strength) and marble dust powder replacement was
made at proportions 0%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45% and 50%
by weight of M-20 grade concrete. Again, three samples per batch were tested with
the average strength values reported in this paper. In all total 66 cubes of OPC
(150mm 150mm 150mm) were examined and results were analyzed after curing
28 days. Result obtained from the replacement is compared with data from a
Conventional concrete.
6. EXPERIMENTAL SET-UP
Subsequently, on a detailed study we have obtained the following outcomes for the
compression tests as shown in the Table 5 and Table 6
Table 5 Ceramic Waste Powder Replacement; Compressive Strength of Concrete (M 20)
(Partial Replacement of Cement)
S.No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Specimen
Conventional Concrete
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
30
25
20
15
10
0
0
10
20
30
40
50
60
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Abdullah Anwar, Sabih Ahmad, S. Mohd. Ashraf Husain and Syed Aqeel Ahmad
Table 6 Marble Dust Powder Replacement; Compressive Strength of Concrete (M 20)
Specimen
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Conventional Concrete
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
30.50
31.44
32.08
33.60
34.16
32.40
30.75
28.50
26.29
23.08
20.54
30
20
10
0
0
10
20
30
40
50
60
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Salvage of Ceramic Waste and Marble Dust For The Refinement of Sustainable Concrete
30
20
10
0
0
10
20
30
40
50
Figure 6 (BAR GRAPH) Percentage Replacement of both Ceramic Waste and Marble Dust
Powder vs Compressive Strength (N/mm2) of Concrete for M 20
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Abdullah Anwar, Sabih Ahmad, S. Mohd. Ashraf Husain and Syed Aqeel Ahmad
8. CONCLUSION
The compressive strength have increased with the increase of marble dust powder
content till 20% replacement of fine aggregate and after that there is a decrease in its
strength. With the inclusion of marble dust powder up to 20%, there is 10.71%
increase in compressive strength for 28days curing as compared to conventional
concrete (without marble dust powder). (Fig. 5 and 6)
Utilization of ceramic waste or marble dust and its application for the sustainable
development of the construction industry is the most effective solution and also speak
the high value application of such waste.
It is the possible alternative solution of safe disposal of the Ceramic waste powder
and Marble dust powder thus stepping into a realm of solving the environmental
pollution by cement production; being one of the primary objectives of Civil
Engineers.
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