UTILIZATION OF FERROCHROME WASTE FOR

CONCRETE MANUFACTURING

T.PRIYADHARSHINI(15209007)
P.NIVETHA (15209022)

INTRODUCTION:
 Improvement in mechanical and durability properties of concrete has
already been established due to use of industrial wastes replacing the
various ingredients of concrete partially or fully.
 Concrete is the most widely used building material in the construction
sector and cement is the principal ingredient in concrete.

 Cement manufacture contributes greenhouse gases directly through the

production of carbon dioxide. In order to minimize greenhouse gases,
conserve energy and mineral resources, there is a need to reduce the
production of cement by finding alternative materials.

 Global annual production of ferrochrome is around 6.5–9.5 million

tonnes. It is increasing at the rate of 2.8–3% per year.Accordingly the
generation of ferrochrome waste is increasing parallel with the
production of ferrochrome and is currently being dumped, polluting the
environment without any attention towards prevention, control and
remedy.

 Two such wastes from the Ferroalloy industry are ferrochrome ash
(FA) and ferrochrome slag(FS). FS to the tune of 1–1.2 tonnes and FA
of 0.02–0.03 tonnes are generated during the production of each tonne
of ferrochrome product.

 FA is obtained from the gas cleaning plant of the ferrochrome

industry. The gas emitted from Ferro-alloy smelting furnaces contains
particles of dust, dirt and incomplete combustion of wood and/or coal
and coke. This gas contains harmful sulphurous, toxic metal oxide
vapours, carbon monoxide and other organic gases.

 FS is obtained as a waste material by the smelting process during the

production of stainless steel. Examining the properties of FS, the
possibility of its utilization for the preparation of low cost green concrete
by replacing natural coarse aggregates.

PURPOSE OF THE PROJECT:

  To study about the utilization of FCA reduces production of
cement ,which in turn lowers green house emission and energy
consumption.
 Concrete containing (10- 40%)FCAand 7% lime, shows strength
similar or higher to that of normal concrete.
 To make low cost effective concrete and eco-friendly.

NEED OF THE PROJECT:

 To develop the compressive and tensile strength of the concrete
by adding the ferrochrome waste material.
 The combine effect of FA and FS it gives compressive strength,
flexural strength ,split tensional strength and sorptivity were
obtained in concrete.

MATERIALS USED IN THIS PROJECT:

 OPC (43 Grade) conforming to the requirements of IS:8112 (2013)

was used in this study.

 The physical properties of OPC and FA are used. Natural sand

from the local river bed, having a maximum size of 4.5mm, was
used as fine aggregate.

 Natural granite stone aggregates of maximum 20 mm size and FS

aggregate, both conforming to IS:383 (1970) (Reaffirmed 2002)
were used as coarse aggregate.

 The properties of natural coarse aggregate, FS coarse aggregate and

fine aggregate used .

 The chemical properties of FA, FS and OPC are presented in Table

3. The particle size distribution of aggregates . .

 FA is used for partial replacement of cement along with lime. The

lime used in the experiment was commercially available and
procured from the local market the lime is rich in Ca(OH)2, while
the FA is rich in SiO2 and Al2.

PROCEDURE:

 Based on the materials and mix proportions , cubes of 15 cm

size for the compressive strength test, cylinders of 150 mm
diameter × 300 mm long for splitting tensile strength and
 beams of 100 mm × 100 mm × 500 mm for flexural strength
were cast.

 The specimens for the sorptivity test were 100 mm in diameter

and 50 mm thick concrete discs, saw-cut from 100 mm
diameter, 200 mm long cylinders.

 The specimens after casting were covered with plastic sheets

and kept at room temperature (27°C). After 24 hours the
specimens were demoulded and immersed in a water vat for
curing until their testing at the ages of 28, 91 and 180 days.

 Three samples were used for each test and the average result of
the three was considered. Workability in terms of slump was
determined as per
 IS:7320 (1974) (Reaffirmed 2008) and IS:1199 (1959)
(Reaffirmed
 2004). Compressive strength and flexural strength were
examined
 as per IS:516 (1959) (Reaffirmed 2004).
 The splitting tensile strength was determined as per IS:5816
(1999) (Reaffirmed 2004). A sorptivity test was conducted as
per ASTM C 642 (2006).

RESULTS:
Workability
 Thus, workability increased on replacement of natural coarse aggregate
by FS aggregate, but decreased on inclusion of lime and FA.

 This happened because the surface area of cementitious materials

increased on inclusion of FA and the plasticity of paste increased due to
lime.

COMPRESSIVE STRENGTH:

 Compressive strength was decreased with an increase in the dosage of

FA.

 However, at the highest substitution of 47% (M-5), the compressive

strength was observed more than in the control mixes at all ages.

 At the age of 28 days, the increase in compressive strength by concrete

mixes containing FA (10–40%), lime (7%) and FS coarse aggregate
varied between 2.12% and 14.47% over the control mix (M-1).

 The same at 91 days and 180 days varied between 13.64% and
24.63%.
  Compressive strength increased on replacement of natural aggregate by
FS aggregate.

 This may be due to higher mechanical properties of FS coarse

aggregate in comparison to natural coarse aggregate.

FLEXURAL STRENGTH:

 Increase in flexural strength on the replacement of natural coarse

aggregate by FS coarse aggregate is due to the improved mechanical
properties of FS.

 Increase in flexural strength on the inclusion of FA and lime is due to

filling of gaps and micro voids on formation of more C-S-H gel.

 The reduction in micro gaps along boundaries improved bonding

between aggregate and cement paste, which led to improvement of
flexural strength.

SORPTIVITY:
 The sorptivity of concrete is a quantity that measures the unsaturated flow
of fluids into the concrete due to capillary suction, which gives indirect
information on the continuity of the pore system in the near-surface zone.

 The uptake of water by capillary absorption was measured through the

weight gain of the specimens.

Conclusions:
The following conclusions are drawn from these investigations.

 Compressive strength, flexural strength, splitting tensile strength and

sorptivity similar to normal concrete or even more was achieved at all
ages on partial replacement of OPC up to 47% (by 40% FA and 7%
lime) and total replacement of natural coarse aggregate by FS
aggregate.

 Results of compressive strength, flexural strength, splitting tensile

strength, sorptivity, XRD study and petrography study confirm each
other.

 The TCLP test established that concrete made of FS and FA has no

significant adverse impact on the environment due to toxic metal ions.

 A huge quantity of ferrochrome waste can be managed in preparation

of good quality and sustainable green concrete that has ecological
benefits.

JOURNALS RELATED:
 BOND ,PERMEABILITY AND ACID RESISTANCE
CHARACTERISTICS OF FERROCHROME WASTE CONCRETE
PRASANNA K.ACHARYA,SANJAY KUMAR PATRO

 DEVELOPMENT OF HIGH STRENGTH CONCRETE USING

FERROCHROME SLAG AGGREGATE AS REPLACEMENT TO
COARSE AGGREGATE.SATHWIK S.R,SANJITH J,SUDHAKAR G.N