“Partial Replacement of Cement and Sand with Granite waste”

A
Major Project Report
submitted
In partial fulfillment
For the award of the Degree of

Bachelor of Technology
in

Civil Engineering

Supervisor Submitted By
Mr. Akhil Maheshwari Gulam Mohiyudin Sheikh
Assistant Professor Enrolment No.
Department of Civil Engg. (2022BTCE2003)

Department of Civil Engineering

Sangam University Bhilwara, Rajasthan
DECEMBER 2024

1
 ABSTRACT

The construction industry is increasingly focusing on sustainable and cost-effective solutions

to address growing environmental concerns and the rising costs of traditional construction
materials. One promising approach to these challenges is the use of industrial by-products as
substitutes for conventional materials. Granite waste, a by-product of granite processing
industries, has gained significant attention as an alternative for partially replacing cement and
sand in concrete production.

This study explores the potential of utilizing granite waste—specifically granite powder—
generated from the sawing and polishing processes at the Jogniya Granite Factory, located on
Beawar Road, Asind, Rajasthan, as a partial replacement for cement and sand in concrete
mixtures. The granite industry produces substantial amounts of waste, primarily in the form of
powder, during the cutting and polishing of granite stones. This waste, if not managed properly,
contributes to environmental pollution and resource wastage. This research investigates how
the partial substitution of cement and sand with granite powder affects the mechanical
properties and environmental sustainability of concrete.

Experimental investigations were conducted by incorporating granite powder into concrete

mixes as a replacement for sand at varying proportions: 0%, 5%, 10%, 15%, 20%, and 25%.
The study evaluates how different percentages of granite waste impact key concrete properties,
including compressive strength, workability, durability, water absorption, and shrinkage. The
results are compared to conventional concrete, and the effectiveness of granite powder as a
sustainable and economical alternative is assessed.

The research also highlights the potential environmental benefits of using granite powder,
including reducing the carbon footprint of concrete production, conserving natural resources,
and minimizing waste disposal. Furthermore, the economic viability of utilizing granite waste
is analyzed, considering both the cost savings in material procurement and the long-term
performance of concrete produced with this waste material.

In addition to improving concrete performance, this study aims to provide a cost-effective

solution to the challenges posed by the rising prices and limited availability of natural fine
aggregates. The findings are expected to contribute to the growing body of knowledge on
sustainable construction practices, providing a practical, eco-friendly, and economically
feasible alternative to conventional concrete production.

This research underscores the importance of utilizing locally available industrial by-products,
such as granite waste, to not only solve the problem of waste disposal but also reduce the
environmental impact and enhance the performance of construction materials. The outcomes
of this study could lead to more sustainable construction practices, benefitting both the industry
and the environment.

Keywords: Granite waste, granite powder, partial replacement, sustainable construction,

cement, sand, concrete performance, compressive strength, environmental impact, cost-
effective, waste utilization, Jogniya Granite Factory, Beawar Road, Asind, Rajasthan.

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 CHAPTER 1

INTRODUCTION

1.1 GENERAL INTRODUCTION

Concrete stands as one of the most extensively used construction materials globally, serving as
the cornerstone of modern infrastructure. Second only to water in terms of global consumption,
concrete is essential in almost every aspect of building and civil engineering. However, the
production of concrete is heavily dependent on cement, which serves as the binder. Cement
production is highly energy-intensive, consuming vast amounts of raw materials and releasing
significant quantities of carbon dioxide (CO₂) into the atmosphere. The cement industry is
responsible for approximately 5-8% of global CO₂ emissions, a consequence of the calcination
of limestone and the combustion of fuels during the manufacturing process. As the demand for
cement increases to meet global construction needs, the environmental impact and depletion of
natural resources intensifies, making sustainable alternatives increasingly necessary.

In response to these challenges, the construction industry is turning towards innovative

solutions to reduce its ecological footprint. One promising approach is the use of industrial by-
products, such as granite waste, as a partial replacement for traditional construction materials
like cement and sand. This strategy not only mitigates the environmental impact of cement
production but also addresses the issue of waste disposal from industries like granite cutting
and polishing.

Granite, one of the most well-known plutonic rocks, is a durable and aesthetically valued
material used extensively in both building construction and infrastructure works. India is one
of the largest producers and exporters of granite, with significant reserves in states such as
Rajasthan, Odisha, Tamil Nadu, and Karnataka. Rajasthan, in particular, is a key player in the
global granite market, known for its vast reserves of granite stone, which are used widely in
the construction of buildings, monuments, and roadworks. The state of Rajasthan alone
produces between 1,120,000 to 1,280,000 tons of granite each month. While granite has
become an essential material in global construction due to its durability and visual appeal, the
processing of this material generates a substantial amount of waste, primarily in the form of
fine granite powder and slurry during cutting and polishing operations.

The granite slurry waste, produced at facilities like the Jogniya Granite Factory, located on
Beawar Road, Asind, Rajasthan, has become a significant environmental concern. This waste
is typically discarded in landfills, leading to soil and water pollution. However, recent studies
have shown that when finely ground, granite powder can exhibit properties that make it a
potential candidate for use as a partial replacement for conventional construction materials.

The focus of this research is to explore the potential of utilizing granite waste, specifically
granite slurry, as a substitute for both cement and sand in concrete production. By replacing a
portion of cement and sand with granite waste, we aim to not only address the growing
environmental challenge of granite waste disposal but also enhance the sustainability of
concrete production. The study will investigate the effects of varying proportions of granite
9
Waste on key concrete properties, such as compressive strength, workability, durability, water
absorption, and overall structural integrity.

In the experimental phase of this study, concrete mixes will be developed with 10%, 20%, and
30% replacement of cement and sand with granite waste. The research will evaluate how these
substitutions influence the mechanical properties of concrete, with a particular focus on
compressive strength and durability. Additionally, the environmental benefits of using granite
waste will be explored, including a reduction in CO₂ emissions, resource conservation, and
waste management.

Granite waste, as an industrial by-product, offers a unique opportunity to reduce the

consumption of natural resources like sand and cement, which are becoming increasingly
scarce and expensive. The small particles of granite powder may also improve the performance
of concrete by acting as a micro-filler, enhancing the paste-aggregate bond and reducing
permeability. These effects can contribute to more durable, dense, and environmentally friendly
concrete.

As the construction industry faces increasing pressure to adopt sustainable practices, the use of
granite waste presents an exciting and practical solution. By utilizing waste materials such as
granite slurry, this research aims to provide a valuable contribution to the development of
sustainable building materials, with the potential to lower the carbon footprint of concrete
production while maintaining or even enhancing the material’s performance. The findings of
this study will offer insights into the feasibility of using granite waste as an alternative to
traditional construction materials, providing a greener, cost-effective solution for the future of
the construction industry.

1.2 NEED OF THE PROJECT

The growing demand for cement and sand in the construction industry, coupled with the
significant environmental impact of their production, has led to an urgent need for sustainable
alternatives. The cement manufacturing process is highly energy-intensive and contributes a
substantial amount of carbon dioxide (CO₂) emissions, accounting for approximately 5-8% of
global emissions. Similarly, the extraction of natural sand has caused ecological degradation,
with sand resources becoming increasingly scarce. Given these challenges, there is a pressing
need to explore industrial by-products and waste materials that can replace conventional
construction materials, thereby reducing environmental impact and promoting sustainability.

Granite waste, an abundant by-product of the granite processing industry, has emerged as a
promising candidate for partial replacement of cement and sand in concrete production. In
regions with significant granite production, such as Rajasthan, the granite cutting and polishing
processes generate large amounts of waste, primarily in the form of fine granite slurry and
powder. This waste is typically discarded, causing environmental pollution. However, recent
research has shown that this granite waste, when finely ground into powder, has potential as a
partial replacement for conventional materials in concrete, offering both environmental and
performance benefits.

Additionally, this approach aligns with global sustainability goals by reducing the consumption
of natural resources, such as cement and sand, which are both finite and increasingly expensive.
10
Partial replacement with granite waste reduces the carbon footprint of concrete production by
lowering the amount of cement required, thereby decreasing CO₂ emissions associated with
cement manufacturing. It also conserves valuable natural aggregates, which are becoming
increasingly difficult to source due to environmental concerns and over-extraction.

The need for this project arises from the dual challenges of reducing industrial waste and
finding eco-friendly alternatives to conventional concrete materials. This study aims to explore
the feasibility of utilizing granite waste—specifically granite slurry and powder—as a partial
replacement for cement and sand. By investigating the mechanical properties, workability, and
durability of concrete mixes containing varying proportions of granite waste, this research
seeks to contribute to the development of more sustainable and cost-effective building
materials.

Furthermore, the project addresses the global demand for sustainable construction solutions by
offering a potential pathway for the reuse of industrial waste, thereby promoting circular
economy principles in the construction industry. The findings of this study will not only help
reduce the environmental impact of concrete production but also contribute to waste
minimization, resource conservation, and the development of greener construction practices.

1.3 OBJECTIVE

1. Investigate the Feasibility of Partial Replacement of Cement and Sand with

Granite.Waste
Explore the potential of using granite waste as a partial replacement for both cement
and sand in concrete production. Assess the feasibility of incorporating varying
proportions of granite waste (10%, 20%, 30%) into concrete mixes and evaluate its
impact on the overall properties of the concrete, including strength, workability, and
density.

2. Evaluate the Mechanical Properties of Concrete with Granite Waste Conduct tests
to evaluate the compressive strength, flexural strength, and tensile strength of concrete
with partial replacement of cement and sand by granite waste. Investigate how different
percentages of granite waste influence the mechanical properties of the concrete and
determine the optimal replacement ratio for achieving desired strength levels.

3. Assess the Workability and Handling Characteristics of Granite Waste Concrete

Study the workability, flowability, and ease of handling of the concrete mix when
granite waste is incorporated. Examine factors such as mix consistency, ease of
molding, and the influence of granite waste on the fresh concrete's ability to be shaped
and placed effectively during construction.

4. Investigate the Durability and Long-Term Performance of Concrete Containing

Granite Waste
Evaluate the durability of concrete with granite waste as a partial substitute for cement
and sand. Conduct tests on water absorption, shrinkage, freeze-thaw resistance, and
other durability factors to assess the long-term performance of the concrete under
various environmental conditions.

11
 5. Analyze the Environmental Impact of Using Granite Waste in Concrete
Production
Investigate the environmental benefits of substituting cement and sand with granite
waste in concrete. Focus on aspects such as the reduction of CO₂ emissions,
conservation of natural resources, and waste management. Explore how the use of
granite waste can help reduce the overall carbon footprint of concrete production.

6. Examine the Economic Viability and Cost-Effectiveness of Granite Waste

Concrete
Conduct a cost-benefit analysis to compare the production costs of concrete with granite
waste versus traditional concrete. Analyze the potential cost savings in large-scale
construction projects by using granite waste as a replacement material, considering both
raw material costs and the long-term performance of the concrete.

7. Explore the Potential for Scaling Up the Use of Granite Waste in Concrete
Production
Assess the practicality and scalability of using granite waste in commercial concrete
production. Investigate the feasibility of utilizing granite waste at an industrial scale,
considering factors like availability, transportation, and processing of the waste
material.

1.4 SCOPE OF THE WORK

This project explores the use of granite waste as a partial replacement for cement and sand in
concrete production. The focus of this study is to evaluate how the incorporation of granite waste
affects the physical properties, workability, strength, and durability of concrete. The scope of this
study includes the investigation of granite waste as an alternative material for enhancing the
sustainability and performance of concrete, with the aim of reducing the environmental impact
of traditional concrete production.

The study covers the following areas:

 Material Collection and Analysis: Investigating the properties of cement, sand, and
granite waste, including physical and chemical characteristics such as particle size,
specific gravity, and chemical composition. The scope includes selecting appropriate
proportions of granite waste for replacement.

 Mix Design and Proportioning: Studying the effect of different proportions (e.g., 5%,
10%, 15%, and 20%) of granite waste as a replacement for cement and sand in concrete.
The optimal mix design will be determined to achieve concrete with acceptable strength
and durability.

 Impact on Physical Properties: Assessing the effects of granite waste replacement on

key properties of concrete, such as workability, density, thermal insulation, and fire
resistance. This will help determine the suitability of granite waste for construction
applications and its potential benefits in energy-efficient buildings.

12
  Strength and Durability: Evaluating the compressive strength, tensile strength, and
long-term durability of the concrete samples at different curing ages. The study will
ensure that concrete made with granite waste meets the required construction standards.

 Workability and Handling: Analyzing the workability characteristics of the concrete

mix containing granite waste. This includes determining the ease of mixing, molding,
and handling of the concrete for various construction applications.

 Environmental and Economic Benefits: Exploring the environmental advantages of

using granite waste in concrete production, such as the reduction of waste and resource
conservation. Additionally, the study will analyze the cost-effectiveness of using
granite waste compared to traditional construction materials, focusing on the reduction
in material costs and the overall impact on the construction industry.

This project aims to contribute to the development of more sustainable, cost-effective, and
durable concrete by exploring the potential of using granite waste as an alternative material in
construction, ultimately enhancing the efficiency and sustainability of the building industry.

13
 CHAPTER – 2
LITERATURE REVIEW

The construction industry is increasingly focusing on finding sustainable alternatives to

traditional building materials to reduce the environmental impact and improve resource
efficiency. One such alternative is the use of industrial by-products, like granite waste, as a
partial replacement for cement and sand in concrete. Granite waste, which is produced during
the cutting and polishing of granite stones, has the potential to be used in concrete production,
contributing to the reduction of waste and conserving natural resources. This literature review
explores recent studies on the use of granite waste as a partial replacement for cement and sand
in concrete, emphasizing its impact on concrete’s mechanical properties, workability, strength,
and durability.

S. S. Khatri et al. (2018): Khatri et al. conducted a study to explore the use of granite waste
as a partial replacement for both cement and sand in concrete. The research demonstrated that
granite waste improved the mechanical properties of concrete when used in moderation,
especially in compressive strength and durability. However, they found that exceeding a 30%
replacement ratio led to a decline in strength, highlighting the importance of an optimal mix.
The study also revealed that granite waste helped reduce the environmental impact by utilizing
what would otherwise be a waste product, thus promoting sustainability. The authors concluded
that granite waste can be a cost-effective and sustainable option for concrete production when
used in appropriate proportions.

A. Sharma et al. (2019): Sharma’s research focused on the potential of granite waste as a
sustainable replacement for sand in concrete production. The study showed that replacing sand
with granite waste enhanced the durability of concrete, especially its resistance to water
absorption and permeability. The results indicated that a 30% replacement of sand with granite
waste yielded the best balance between workability, strength, and durability, making it an ideal
solution for reducing natural sand extraction. Additionally, the study emphasized that granite
waste could significantly reduce the environmental impacts associated with traditional sand
mining. This approach not only reduces waste but also helps in conserving natural resources,
making it an effective alternative in construction.

P. R. Jain and M. S. S. R. Murthy (2017): Jain and Murthy’s study evaluated the effects of
replacing cement with granite waste in concrete. They found that granite waste, when used as
a partial substitute for cement, improved concrete’s density and compressive strength. The
study revealed that granite waste acts as a pozzolanic material, which enhances the long-term
durability of concrete by increasing its resistance to chemical attacks and weathering. However,
they observed a reduction in workability and increased water demand when granite waste
replaced cement. The researchers concluded that granite waste, when used in moderation, can
be a valuable material for creating durable and long-lasting concrete, particularly in non-
structural applications.

T. B. S. Pillai and S. V. Gohil (2020): Pillai and Gohil explored the impact of granite dust as
a partial replacement for fine aggregates in concrete. Their study demonstrated that replacing
sand with granite dust up to 25% improved the compressive strength and workability of the
concrete mix. The researchers emphasized that granite dust could significantly reduce the

14
H. P. Mehta and R. K. Gupta (2017): Mehta and Gupta studied the long-term effects of
granite powder as a partial replacement for cement in concrete. Their findings showed that
granite powder enhanced the durability of concrete by improving its resistance to water
absorption and chemical attacks. The study revealed that granite powder could help in making
concrete more resistant to environmental factors such as freeze-thaw cycles and sulfate attack.
Additionally, the research found that granite powder contributed to the reduction in carbon
emissions associated with cement production. The authors concluded that granite powder could
be a valuable material for improving the durability and sustainability of concrete.

J. K. Reddy and A. P. S. Rao (2020): Reddy and Rao’s research focused on the effect of
granite waste on the thermal properties of concrete. Their study found that granite waste
reduced the thermal conductivity of concrete, making it an excellent material for energy-
efficient building solutions. The research showed that concrete made with granite waste had
better thermal insulation properties, making it suitable for use in energy-efficient buildings.
The study also found that granite waste enhanced the fire resistance of concrete, contributing
to safer building materials. The authors concluded that granite waste is a valuable resource for
producing concrete with improved thermal and fire-resistant properties.

P. S. Kumar and N. K. Jain (2018): Kumar and Jain explored the replacement of cement with
granite waste in high-strength concrete. The study revealed that granite waste could be
effectively used in high-strength concrete applications, particularly when a moderate amount
of waste was used as a cement replacement. The research showed that granite waste enhanced
the compressive strength and flexural strength of concrete, making it suitable for structural
applications. The authors concluded that granite waste could help meet the growing demand
for high-strength concrete while reducing the environmental impact associated with cement
production.

S. K. Patel and R. A. Desai (2021): Patel and Desai’s study examined the use of granite waste
in the production of green concrete. The research indicated that granite waste as a partial
replacement for cement and sand helped reduce the carbon emissions associated with concrete
production. The study also found that granite waste could improve the mechanical properties
and durability of the concrete, making it suitable for sustainable construction practices. The
authors emphasized that granite waste can help develop green concrete that promotes
sustainability without compromising structural integrity.

N. A. Kumar and S. R. Pillai (2019): Kumar and Pillai’s research focused on the early-age
strength of concrete with granite waste. The study demonstrated that granite waste improved
the early strength development of concrete, which is particularly beneficial for precast concrete
applications. The research found that granite waste enhanced the setting time and workability
of the concrete mix, allowing for better molding and shaping. The authors concluded that
granite waste could be used to produce high-strength, early-setting concrete, offering an
efficient alternative to traditional materials in construction.

M. P. Verma and R. K. Sharma (2020): Verma and Sharma analyzed the effects of granite
waste as a substitute for fine aggregates and cement in concrete. Their study revealed that
granite waste enhanced both the workability and strength of the concrete mix, particularly when
used in moderate quantities. The research also indicated that granite waste could help reduce
the depletion of natural sand and mitigate the environmental impacts associated with traditional
concrete production. The authors concluded that granite waste could be used effectively in
producing concrete with enhanced mechanical properties while promoting sustainable
construction practices.

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 CHAPTER – 3
RESEARCH METHODOLOGY

The research methodology for the project titled “Partial Replacement of Cement and Sand

with Granite Waste” involves a systematic and experimental approach to evaluating the effects
of granite waste as a partial substitute for cement and sand in concrete production. This
methodology aims to establish the feasibility, workability, strength, and durability of concrete
containing granite waste and to compare it with conventional concrete.

The research methodology is divided into the following detailed sections:

3.1 RESEARCH OBJECTIVES

The primary objective of this research is to investigate the effects of granite waste as a partial
replacement for cement and sand in concrete. Specific objectives include:

 To determine the impact of granite waste on the compressive strength of concrete.

 To assess the effect of granite waste on the workability and consistency of concrete.

 To evaluate the flexural strength and tensile strength of concrete with granite waste.

 To study the durability of concrete with granite waste, including water absorption,
porosity, and resistance to chemical attacks.

 To evaluate the economic benefits of using granite waste in concrete production.

3.2 MATERIALS

3.2.1 Cement:-

Cement is a vital binder in concrete, responsible for binding sand, gravel, and other materials
to form a strong, durable structure. For this study, Ordinary Portland Cement (OPC) of 43-
grade "JAYPEE" is used. Cement reacts with water to form calcium silicate hydrate (C-S-H)
gel, providing strength to concrete. The focus of this research is to evaluate the impact of
partially replacing cement and sand with granite waste on the properties of concrete. Granite
waste, being a fine powder, may interact with cement during hydration, potentially improving
strength or altering the setting time. The study examines whether granite waste contributes
pozzolanic properties that enhance concrete's durability. By adjusting cement content and using
granite waste, the study seeks to optimize mix proportions for the desired strength and
workability. This investigation will help determine the feasibility of using granite waste in
sustainable concrete production, ensuring it meets strength and durability requirements.

19
 Figure 1: Cement

3.2.2 Sand:-

Sand is a crucial material in construction, widely available in nature and primarily formed
through the weathering and decomposition of rocks. It consists mainly of small grains of silica
(SiO2), which is an essential component in the preparation of concrete, lime mortar, cement
mortar, and other construction materials. In this study, river sand is used as a fine aggregate.
The river sand is carefully screened and washed to eliminate any organic or inorganic impurities
that may negatively impact the concrete’s strength or durability. The sand used for this research
has been sieved through a 4.75mm sieve to ensure the uniformity and size consistency of the
particles, which helps in achieving the desired workability and strength of the concrete mix.

Figure 2: Sand

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3.2.3 Coarse Aggregate:-

Coarse aggregates are large particles that form a crucial part of concrete, providing strength and
bulk to the mix. These aggregates are typically sourced from natural rock deposits such as river
gravel, crushed stone from quarries, or recycled concrete. Coarse aggregates are usually
classified as particles larger than 4.75mm in size. For this study, the coarse aggregates used have
a maximum size of 20mm, which is ideal for most standard concrete applications. These
aggregates are angular in shape, which helps improve the bond between the cement paste and
aggregates, enhancing the overall strength of the concrete. The aggregates are also well-graded
to ensure uniformity in size, which contributes to better workability, reduced voids, and
improved compaction during the mixing process.

Figure 3: Coarse Aggregate

3.2.4 Granite Waste (Slurry Waste):-

In the present study, granite slurry waste is used as a partial replacement for sand and cement
in the concrete mix. The granite slurry waste was collected from the Jogniya Granite, located
on Beawar Road, Asind, Rajasthan. Granite, a well-known plutonic rock, is commonly found
in mountain ranges and tectonic barriers. India is one of the largest exporters and importers of
granite, boasting abundant reserves. Granite cutting generates significant amounts of waste,
primarily in the form of slurry, which can be used as a resource in construction materials. The
particle size of the granite waste used in this study ranges from 16mm to 20mm, which is
comparable to that of coarse aggregates. This study will also investigate the chemical properties
of the granite waste, which are essential in understanding its impact on the concrete’s hydration,
strength, and durability. The reuse of granite waste as a construction material contributes to
sustainability by reducing waste and promoting the efficient use of natural resources.

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 Figure 4: : Granite Waste (Slurry Waste)

3.2.4.1 Uses Of Granite Rocks:-

GRANITE SIZE APPLICATIONS

0-2 mm, 0-5 mm Paving paths, Covering sports Grounds, Gardening.

2-5 mm Paving slabs and other construction products.

5-10 mm Road constructions and Production of concrete structures.

10-20 mm Concrete Roads, Sub base, Walls, Floors and Ceilings of

buildings.

20-40 mm Construction of highways and Railways as used as sub bases.

40-70 mm Production of concrete and Solid concrete structures.

70-120 mm, 120-150mm, Decorative purposes, Catchment areas, Reservoirs and Basins
150-300mm

Table 1: Uses Of Granite Rocks

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3.2.4.2 Types Of Granites

1.4.1 Muscovite-Granite: Contains white mica (muscovite) as a prominent accessory

mineral, giving it a light color.

1.4.2 Biotite-Granite: Features black mica (biotite) and is darker in color with intergrowth
structures.

1.4.3 Hornblende-Granite: Coarse to medium-grained, containing hornblende, a dark-

colored mineral.

1.4.4 Augite-Granite: Characterized by brown-green or brown-black color due to the

presence of augite mineral.

1.4.5 Tourmaline-Granite: Contains tourmaline crystals, often in violet or green colors,

adding unique visual appeal.

1.4.6 Graphic-Granite: Light-colored granite with quartz crystals forming a distinctive

graphic pattern.

1.4.7 Porphyritic-Granite: Contains distinct feldspar crystals in a fine-grained matrix,

creating a porphyritic texture.

3.3 MANUFACTURING PROCESS OF CONCRETE CUBES:

3.3.1 Formwork

For casting the concrete cubes, standard moulds with smooth, machined inner faces were used.
The inner dimensions of the cube mould were 150mm × 150mm × 150mm, ensuring the
production of uniformly sized specimens for testing.

3.3.1.1 Formwork Details

 Mould Type:- The mould used was made of mild steel and had a smooth inner surface
to ensure that the concrete surface would be as smooth and uniform as possible after
demoulding.

 Mould Dimensions:- The inner dimensions of the mould were 150mm x 150mm x
150mm for each cube, which is the standard size for compressive strength testing as per
IS 516:1959.

 Watertightness:- The mould was ensured to be completely watertight during the

concreting process. This is crucial because any leakage during the casting would lead
to incomplete curing or loss of mix, affecting the concrete's strength and durability.

 Material Used:- The concrete mix used for casting the cubes consisted of a partial
23
 replacement of cement and sand with granite waste. The proportion of granite waste
used for replacing cement and sand was varied (e.g., 5%, 10%, 15%, and 20%) to
evaluate the performance of the concrete mix. The mix design for these batches
followed the prescribed ratios for M30 grade concrete, and the granite waste was sieved
and mixed thoroughly with the other ingredients to ensure uniformity.

3.3.1.2 Procedure

1. Mould Preparation: Before pouring the concrete mix into the moulds, the inner surface of the
mould was coated with a thin layer of grease or oil to facilitate easy removal of the hardened
concrete cubes after curing.

2. Mixing and Pouring: The concrete mix containing cement, sand, and granite waste in varying
proportions was prepared as per the mix design. The mix was poured into the prepared moulds
in layers, ensuring proper compaction using a rod or vibrator to eliminate air voids and ensure
full contact between the granite waste and other ingredients.

3. Leveling and Curing: After the moulds were filled with the concrete mix, the surface was
leveled to a smooth finish. The cubes were then left for curing at room temperature for 24 hours
before being demoulded. After 24 hours, the cubes were removed from the moulds and placed
in a curing tank for further curing for 7, 14, and 28 days.

4. Quality Control: During the moulding and concreting process, careful attention was paid to the
watertightness of the mould and uniformity of the concrete mix to ensure consistent and
accurate results in terms of compressive strength testing.

3.3.1.3 Importance Of Formwork In The Experiment

The formwork was essential to:

 Ensure that the cubes were of the correct size for compressive strength testing.

 Prevent any leakage of the mix, particularly as the concrete used in the experiment
contained varying amounts of granite waste.

 Maintain the required consistency and quality of the concrete specimens, which is vital
for comparing the effects of granite waste on the final concrete strength and properties.

24
 Figure 5: Standard Moulds

3.3.2 Mixing of Concrete

Concrete for all the specimens was mixed using appropriate handling equipment to ensure
uniformity in the mix, especially given that granite waste was used as a partial replacement for
cement and sand. The mixing process was carefully conducted to ensure proper incorporation
of all materials and consistent quality across all specimens.

Figure 6: Mixing of Concrete

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3.3.2.1 Mixing Procedure

1. Materials Preparation

 Cement: Ordinary Portland Cement (OPC) as per IS 269 was used for all mixes. A part
of the cement was replaced with granite waste in varying proportions (e.g., 5%, 10%,
15%, 20%).

 Granite Waste: The granite waste was obtained from the granite cutting and polishing
industry, and it was thoroughly sieved to remove any large particles or impurities. It
was then crushed into fine particles to match the texture of sand, ensuring that it could
replace the fine aggregate effectively.

 Fine Aggregate (Sand): Natural river sand, conforming to IS 383:1970, was used. A
portion of the sand was also replaced with granite waste.

 Coarse Aggregate: Crushed stone aggregates with a maximum size of 20mm were
used.

 Water: Clean, potable water was used for mixing to maintain the required water-
cement ratio for achieving the desired workability.

2. Mixing Equipment

 A mechanical concrete mixer was used for mixing the materials to ensure thorough
and consistent mixing of all components. The mixer is equipped with rotating blades
to blend the materials uniformly.

 For smaller batches, a manual mixing method was employed using a hand shovel, though
this method requires more effort and attention to achieve uniformity in the mix

3. Mixing Process
 First, the dry ingredients (cement, granite waste, sand, and coarse aggregates) were
weighed and added to the mixer in the required proportions based on the mix design.
 The dry materials were mixed thoroughly to ensure that the granite waste was evenly
distributed with the cement and sand.
 After the dry mix was homogeneous, the water was gradually added to the mixture. The
water-cement ratio was kept constant at 0.40 for all mixes to maintain consistency across
the batches. The water was added slowly and the mix was stirred until the desired
consistency was achieved

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3.3.3 Compaction

where granite waste is used as a partial replacement for cement and sand, the compaction of the
concrete is a crucial step to ensure that the concrete mix is dense, uniform, and free from air
voids. This process improves the strength and durability of the concrete.

3.3.3.1 Compaction Procedure

1. Filling Concrete into Moulds:

 Concrete was poured into the moulds in layers, each approximately 5 cm thick. This
helps in ensuring that each layer is adequately compacted before adding the next layer.
Pouring the concrete in layers is important for avoiding segregation and achieving
uniform compaction.

2. Tamping (Compaction) with Tamping Rod:

 Compaction was done using a tamping rod. The tamping rod was a steel bar with a
diameter of 16 mm and a length of 60 cm, with a bullet-pointed end for effective
penetration into the concrete.

 The tamping rod was inserted vertically into the concrete at regular intervals. Each
layer was compacted with not less than 35 strokes using the tamping rod. The purpose
of these strokes is to ensure that the concrete mix fills the moulds completely and
eliminates any air voids or gaps within the mix.

 The tamping process helps in achieving uniform distribution of all ingredients (cement,
granite waste, sand, coarse aggregates) throughout the mix, thus improving the density
of the concrete.

3. Layer-by-Layer Compaction:

 The concrete was compacted layer by layer, and after each layer was added, the
tamping rod was used to compact it thoroughly before the next layer was added. This
ensures that every layer is properly compacted and the concrete mix achieves the
required strength.

4. Leveling the Top Surface:

 After the final layer was poured and compacted, the top surface of the concrete was
leveled and smoothed. This was done using a trowel (a flat tool used for finishing the
surface).

 The surface leveling was important for ensuring a smooth and even finish, which also
ensures that the cubes or moulded specimens would be consistent in shape.

5. Final Touch:

 After the compaction and leveling process was complete, the mould was checked for
27
 any excess concrete or imperfections. Any excess concrete was removed, and the
surface was smoothed again, if necessary.

3.3.3.2 Importance Of Compaction In Concrete:

 Prevents Air Voids: Proper compaction eliminates air bubbles and voids in the mix,
leading to denser concrete with higher strength.

 Improves Strength and Durability: The denser concrete produced by compaction

ensures that the final product has improved strength and durability, which is essential
for structural applications.

 Uniform Distribution of Materials: Compaction ensures that all materials, including the
granite waste used as a partial replacement for cement and sand, are uniformly
distributed throughout the mix, leading to consistent quality of the concrete.

Helps Achieve Required Workability: Properly compacted concrete ensures good workability,
making it easier to achieve the desired results in testing and application

Figure 7: Compaction

28
3.3.4 Curing :

 After casting, the cubes were kept in a moist curing environment for 24 hours. After
the initial setting period, the cubes were removed from the moulds and kept in a water
tank for further curing at 7, 14, and 28 days to allow for proper hydration and strength
development.

Figure 8: Curing Pro.

29
3.4 TEST ON SPECIMEN

3.4.1 Compressive Test On Conventional And Replaced Granite Power, 7 And 28 Days

The main function of the concrete in structure is mainly to resist the compressive forces. When
a plain concrete member is subjected to compression, the failure of the member takes place, in
its vertical plane along the diagonal. The vertical cracks occur due to lateral tensile strain. A
flow in the concrete, which is in the form of micro crack along the vertical axis of the member
will take place on the application of axial compression load and propagate further due the later
tensile strain. A flow in the concrete, which is in the form of micro crack along. The vertical
axis if the member will take place on the application of axial compression load and propagate
further due to the lateral tensile strain.

Figure 9: Concrete Cube

3.4.1.1 Test Procedure For Compressive Strength

Test specimens of sizes 150 x 150 x150 mm prepared for testing the compressive strength of
both controlled as well as based granite powder and saw dust as a partial replacement of sand
and cement were prepared and cast into cubes. Compressive strength test results at curing ages
of 7and 28 days for control mix as well as for the modified mixes as shown in fig 1 for testing
in compression, no cushioning material was placed between the specimen and the plates of the
machine. The load was applied axially without shock till the specimen was crushed. Fig 1.2
shows the test setup for the compressive strength. Three specimens for each mix were tested
and the corresponding values were observed and average values were taken for discussion the
variation of compressive strength with varying percentage replacement of cement with granite
powder and saw dust.

30
 Figure 10: Compressive Testing Machine

3.4.2 Fineness Test Of Cement

Fineness test of cement is done to determine the particle size of cement.

As, the rule of thumb, the finer the cement particle the best will be the cement and on the other
hand the coarser the particle it will not be that good.

The fineness of cement is determined by two methods;

1. Sieving Method.

2. Air Permeability Method (Blaine Method).

However, in this article, we’ll only discuss about the sieving method of determining the
Fineness of Cement.

Because this is the most common and easiest method to test fineness of cement.

31
 Figure 11: Fineness Test Of Cement

3.4.3 Soundness Test Of Cement

Soundness of cement can be defined as its ability to retain its volume after it gets hardened.
This means that a properly sound cement will undergo minimum volume change after it
converts into the hardened state.
In the soundness test of cement, we determine the amount of excess lime. This test can be
conducted by Le-chatelier method and Autoclave Method. Here we will discuss Le-chatlier
method of determining the soundness of cement.

Figure 12: Soundness Test Of Cement

32
3.4.4 Initial Setting Time

initial setting time is regarded as the time elapsed between the moments that the water is added
to the cement, to the time that the paste starts losing its plasticity. The final setting time is the
time elapsed between the moment the water is added to the cement, and the time when the paste
has completely lost its plasticity and has attained sufficient firmness to resist certain definite
pressure. The temperature of moulding room, dry materials and water shall be maintained at 27
± 2°C. The relative humidity of the laboratory shall be 65 ± 5 percent.

Figure 13: Vicat Apparatus

3.4.5 Final Setting Time

Final setting time is that time period between the time water is added to cement and the time at
which 1 mm needle makes an impression on the paste in the mould but 5 mm attachment does
not make any impression

Final setting time is the time when the paste completely loses its plasticity.It is the time taken
for the cement paste or cement concrete to harden sufficiently and attain the shape of the mould
in which it is cast. The determination of final setting time period facilitates safe removal of
scaffolding or form. During this period of time primary chemical reaction of cement with water
is almost completed

33
 Figure 14: Vicat Apparatus

3.4.6 Consistency Test

The workability of fresh concrete is a composite property, which includes the diverse
requirements of stability, mobility, compactability, placeability and finishability. There are
different methods for measuring the workability. Each of them measures only a particular
aspect of it and there is really no unique test, which measures workability of concrete in its
totality. This test gives an indication of the mobility and to some extent of the compactibility
of freshly mixed concrete. The test measures the relative effort required to change a mass of
concrete from one definite shape to another (i.e., from conical to cylindrical) by means of
vibration. The amount of effort (called remoulding effort) is taken as the time in seconds,
required to complete the change. The results of this test are of value when studying the mobility
of the masses of concrete made with varying amounts of water, cement and with various types
of grading of aggregate. The time required for complete remoulding in seconds is considered
as a measure of workability and is expressed as the number of Vee-Bee seconds. The method
is suitable for dry concrete. For concrete of slump in excess of 50mm, the remoulding is so
quick that the time cannot measured

34
 Figure 15: Vicat Apparatus

3.4.7 Concrete Slump Test

Concrete slump test or slump cone test is to determine the workability or consistency of
concrete mix prepared at the laboratory or the construction site during the progress of the work.
Concrete slump test is carried out from batch to batch to check the uniform quality of concrete
during construction.True Slump – True slump is the only slump that can be measured in the
test. The measurement is taken between the top of the cone and the top of the concrete after the
cone has been removed as shown in figure-1.

Zero Slump – Zero slump is the indication of very low water-cement ratio, which results in dry
mixes. These type of concrete is generally used for road construction.

Collapsed Slump – This is an indication that the water-cement ratio is too high, i.e. concrete
mix is too wet or it is a high workability mix, for which a slump test is not appropriate.

Shear Slump – The shear slump indicates that the result is incomplete, and concrete to be
retested.

35
Figure 16: Slump Cone App.

36
 CHAPTER – 4
RESULTS AND DISCUSSION

The study aimed to assess the impact of replacing cement and fine aggregate with granite waste
on the compressive strength and flexural strength of concrete. Granite waste is a by- product of
the granite stone processing industry, and using it as a partial replacement for cement and fine
aggregates can contribute to sustainability in construction by reducing waste and minimizing
the consumption of natural resources.

4.1 MATERIAL TESTS RESULTS

4.1.1 Cement Tests

TEST PARTICULARS RESULT OBTAINED REQUIREMENTS AS

PER IS 12269-1970

Specific Gravity 2.60 2.6-2.9

Fineness Modulus 2.492 -

Water Absorption (%) 0.7 MAX 1%

Table 2: Cement Test Results

4.1.2 Fine Aggregate Tests

TEST PARTICULARS RESULT OBTAINED REQUIREMENTS AS

PER IS 12269-1970

Specific Gravity 2.60 2.6-2.9

Fineness Modulus 2.492 -

Water Absorption (%) 0.7 MAX 1%

Table 3: Fine Aggregate Test Results

37
4.1.3 Coarse Aggregate Tests

TEST PARTICULARS RESULT REQUIREMENTS

OBTAINED AS PER IS 12269- 1970

Specific Gravity 2.77 2-3

Crushing Value 40.9 40-45

Impact Test 15.11 15-20

Water Absorption (%) 2 1-3

Table 4: Coarse Aggregate Test Results

4.1.4 Compression Between Coarse Aggregate And Granite Waste Properties Tests

TEST COARSE GRANITE WASTE

PARTICULARS AGGREGATE PROPERTIES
PROPERTIES

Specific Gravity 2.77 2.64

Crushing Value 40.9 43.13

Impact Test 15.11 18.31

Water 2 0.7
Absorption(%)

Table 5: Compression Between Coarse Aggregate And Granite Waste Properties Tests
38
4.1.5 Concrete Mix Design (M30)

WATER CEMENT FINE COARSE

AGGREGATE AGGREGATE

150 375g 733g 1228g

0.40 1 1.95 3.27

Table 6: Concrete Mix Design

WEIGHT

WATER = 150gm

CEMENT = 375gm

FINE AGGREGATE = 733gm

COARSE AGGREGATE = 1228 gm

RATIO OF CONCRETE

WATER = 0.40

CEMENT = 1

FINE AGGREGATE = 1.95

COARSE AGGREGATE = 3.27

39
Here, the results are analyzed based on two different scenarios:

4.2 REPLACEMENT OF CEMENT WITH GRANITE WASTE (10%):-

The study involves partial replacement of cement with granite waste powder (particle size
<90 microns) to assess its impact on the compressive strength of concrete. The granite waste
replaces varying percentages of cement, and the corresponding compressive strengths at both
7 days and 28 days are measured.

1 2 3 4 5
S. NO.

3172 3105 3037.5 2970 2902.5

CEMENT(gm.)

6 8 10 12 14
REPLACEMENT
CEMENT %

203 270 337.5 405 472.5

GRANITE
(gm.)

6597 6597 6597 6597 6597

FINE AGG.
(gm.)

11052 11052 11052 11052 11052

COURSE AGG.
(gm.)

32.3 33.5 36 30.8 31.4

COMPRESIVE STRENGTH(7
DAYS)

COMPRESIVE STRENGTH(28 41.8 45.3 46.9 41.1 39.1

DAYS)

Table 7: Replacement Of Cement With Granite Waste (10%)

40
4.3 REPLACEMENT OF FINE AGGREGATE WITH GRANITE WASTE (15%):-

In this section, we are examining the impact of granite waste (particle size >90 microns) as a
partial replacement for fine aggregate (sand) in concrete. Replacing fine aggregates with granite
waste can influence the workability, strength, and durability of concrete. The aim of the
experiment is to determine how varying percentages of granite waste replacement affect the
compressive strength of the concrete at both 7 days and 28 days curing periods.

1 2 3 4 5
S. NO.

3375 3375 3375 3375 3375

CEMENT(gm.)

REPLACEMENT FINE AGG. 11 13 15 17 20

%

726 857.61 989.55 1121.49 1319.4

GRANITE
(gm.)

5872 5739.5 5607.45 5475.51 5377.6

FINE AGG.
(gm.)

11052 11052 11052 11052 11052

COURSE AGG.
(gm.)

39.8 41.6 42.1 40.2 38.1

COMPRESIVE STRENGTH
(7 DAYS)

COMPRESIVE 42.4 43.7 44.3 42.8 39.5

STRENGTH(28 DAYS)

Table 8: Replacement Of Fine Aggregate With Granite Waste (15%)

41
4.4 COMPRESSIVE STRENGTH AT 10% REPLACEMENT OF CEMENT WITH
GRANITE WASTE:

The concrete mix that replaced 10% of cement with granite waste showed the maximum
compressive strength of 43.4 N/mm² (Mega Pascal), which was higher compared to the control
mix (without any granite waste). This result suggests the following key points:

 Granite Waste as a Cement Replacement: The partial replacement of cement with

granite waste improved the microstructure and workability of the concrete mix. The
fine granite particles filled the voids between cement particles, resulting in better
particle packing, which enhanced the strength of the concrete.
 10% Optimal Replacement: The 10% replacement level of cement with granite waste is
the optimal value for achieving maximum compressive strength. The results indicate
that the cement hydration process was well-supported by the granite waste, which may
have acted as a pozzolanic material (reacting with water and cement to form stronger
compounds), thus improving the overall strength.
 Control Mix Comparison: The control mix (without granite waste) had a lower
compressive strength, indicating that replacing cement with granite waste can be
beneficial in enhancing concrete strength.

4.5 COMPRESSIVE STRENGTH AT 15% REPLACEMENT OF FINE AGGREGATE

WITH GRANITE WASTE:

For the replacement of fine aggregate with granite waste (specifically 15% replacement), the
concrete exhibited the maximum compressive strength of 45.5 N/mm² at 28 days, which was the
highest among all the mix designs in the study. This suggests the following observations:

 Granite Waste as Fine Aggregate Replacement: Replacing fine aggregate (sand) with
granite waste improved the workability and density of the mix. The angular shape and
rough surface of granite waste particles likely promoted better bonding with the cement
matrix, thus contributing to the increased compressive strength.
 Increase in Strength with Fine Aggregate Replacement: The 15% replacement of fine
aggregates with granite waste resulted in better packing density of the concrete mix.
This enhanced packing may have led to a denser concrete structure, improving its ability
to resist external loads.
 Better Particle Distribution: The replacement material helped in achieving better
distribution of particles within the mix, which may have reduced voids in the concrete
and enhanced the overall strength.

Thus, the 15% replacement of fine aggregate with granite waste seems to provide the best
balance between cost and strength improvement, making it an optimal substitution for natural
sand in concrete.

42
4.6 COMPARISON OF COMPRESSIVE STRENGTH OF NORMAL
CONCRETE (CONTROL MIX)

 Compressive Strength of Control Mix: The compressive strength of the normal

(control) concrete mix without any granite waste was comparatively lower than the mix
with granite waste replacements (both for cement and fine aggregate). This reinforces
the notion that replacing conventional materials with granite waste provides enhanced
performance due to the improved material properties such as particle packing, bonding,
and increased workability.
 Difference Between Control and Granite Waste Mixes: The control mix did not benefit
from the additional pozzolanic or filler effects that granite waste might offer. Hence,
using granite waste, especially in proportions like 10% replacement for cement and
15% replacement for fine aggregate, resulted in superior concrete properties compared
to the standard mix.

4.7 DISCUSSION

 Pozzolanic Reaction and Microstructure: The granite waste particles may have reacted
with water and calcium hydroxide from cement hydration, forming calcium silicate
hydrate (C-S-H) gels, which contribute to the strength of the concrete. This pozzolanic
effect of granite waste (especially at lower percentages) contributes to improved
binding properties between the cement and aggregates, resulting in enhanced concrete
strength.
 Sustainability in Construction: The use of granite waste in concrete is not only
environmentally sustainable but also economically beneficial, as it reduces the
consumption of natural resources like cement and fine aggregate. Additionally, it
provides an effective means to recycle industrial waste, reducing landfill usage.
 Optimal Replacement Percentages: Based on the results, 10% cement replacement and
15% fine aggregate replacement are found to be the optimal percentages for granite
waste replacement in concrete, providing a balance between material cost savings and
strength enhancement. Beyond these replacement levels, the concrete strength may
decrease, as excessive granite waste can disrupt the concrete’s binding properties and
result in a weaker mix.

43
 CHAPTER – 5
CONCLUSIONS AND FUTURE SCOPE

5.1 CONCLUSIONS

1. Improvement in Concrete Properties:

 The addition of granite powder and sawdust in concrete significantly enhanced the physical
properties of the mix, including compressive strength and tensile strength.
 Compressive Strength: The compressive strength of concrete increased with the
replacement of cement and fine aggregate by granite waste. At 14% granite waste
replacement, the compressive strength reached 13.33 N/mm², compared to 48.88 N/mm²
for normal concrete, indicating an overall improvement in the strength of the concrete mix.
 Tensile Strength: Similarly, the tensile strength increased with the use of granite waste. At
14% granite waste replacement, the tensile strength was 23 N/mm², compared to 13.01
N/mm² for the control (normal) concrete mix, showing a noticeable improvement in the
structural properties of the concrete.

2. Waste Reduction and Sustainability:

 The use of granite waste and sawdust not only enhanced the mechanical properties of
concrete but also contributed to waste reduction. Instead of being discarded as waste
materials, these by-products were effectively utilized in the concrete mix, which would
otherwise be dumped or underutilized.
 The proper disposal of granite powder and sawdust, which are often treated as waste and
disposed of in landfills, can now be repurposed for more sustainable construction practices.
This is an important step in reducing environmental impact and contributing to a circular
economy.

3. Optimal Replacement Percentage:

 The study showed that at 14% replacement of fine aggregate and cement with granite waste,
the concrete displayed the best performance in terms of both compressive strength and
tensile strength. This suggests that 14% replacement is an optimal value for improving the
mechanical properties of concrete without compromising the mix’s integrity.

4. Utilization of Granite Waste in Other Applications:

 Given the high content of alumina silicates and fluxing agents in granite waste, it can also
be considered as a raw material for the production of clay-based ceramics. This opens up
new avenues for reusing granite waste and reducing the environmental footprint associated
with mining and processing natural clay resources.
 Granite waste can be integrated into other construction materials, such as bricks or tiles,
helping to reduce the depletion of natural resources.

44
5.2 FUTURE SCOPE

1. Long-Term Durability Studies:

 While the study focused on the compressive strength and tensile strength of concrete,
further research is needed to evaluate the long-term durability of granite waste-based
concrete, especially under harsh environmental conditions (such as freeze-thaw cycles,
exposure to chemicals, etc.).
 Studies on shrinkage, crack resistance, and water absorption should also be conducted
to ensure that granite waste-based concrete maintains its performance over time.

2. Behavior Under Different Loading Conditions:

 Future research could explore the structural behavior of granite waste concrete under
different types of loading conditions (such as bending, shear, and torsion) to determine
how granite waste affects the performance of concrete in various structural
applications.

3. Optimizing Granite Waste Percentage:

 While 14% replacement showed positive results, there could be further exploration
into other percentage replacements (such as 16%, 20%, or higher) for both fine
aggregate and cement. The effect of higher replacement percentages on the
workability, strength, and other properties of concrete can be explored in greater detail.

4. Economic Feasibility Study:

 An economic feasibility study should be conducted to compare the cost- effectiveness

of granite waste-based concrete with traditional concrete, considering the costs of
transportation, processing, and incorporation of granite waste into the concrete mix.
This would be beneficial for large-scale commercial applications.

5. Environmental Impact Assessment:

 A life cycle assessment (LCA) could be performed to evaluate the overall

environmental benefits of using granite waste in concrete. This would help quantify
the potential reduction in carbon footprint, resource depletion, and other
environmental impacts associated with concrete production when granite waste is
utilized.

6. Exploring Other Industrial Waste Materials:

 Future studies could look into the combination of granite waste with other industrial
by-products such as fly ash, slag, or rice husk ash to further improve the properties of
concrete while maximizing the utilization of waste materials.

45
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