BEHAVIOUR OF CONCRETE ON THE USE

OF QUARRY DUST TO REPLACE SAND

A PROJECT WORK
BY
PRASHANTH J
SATHISH KUMAR G
UDAYA SHANKAR M
YUVARAJ SINGH K V

GUIDED BY : JAYAKARAN V
 ABSTRACT

The use of Recycle product is increasing with innovation in present scenario. The
utilization of waste product in the manufacturing of new product is a challenging
job. The Natural Resource decreases in a short period and therefore the use of
waste product is necessary.

Natural sand is a prime material used for the preparation of concrete and also
plays an important role in Mix Design. One such material is Quarry stone dust: a
by-product obtained during quarrying process.
 Attempts have been made to study the suitability of Quarry dust as sand replacing
material and it has been found that Quarry dust improves the mechanical properties of
concrete as well as elastic modulus.

This present work is an attempt to use Quarry Dust as partial replacement for Sand in
concrete.

The main object of this project is to determine the compressive strength. Various mixes
were prepared for carrying out the research by varying the proportions of cement, sand
and aggregates.

The fine aggregate is partial replacement with 10%, 20%, and 30% by sea shell in M20
grade. The compressive strength of concrete was tested in laboratory after 7, 14 and 28
days.
 INTRODUCTION
Concrete is the premier construction material across the world and the most widely used in
all types of civil engineering works, including infrastructure, low and high-rise buildings,
defense installations, environment protection and local/domestic developments. Concrete is a
manufactured product, essentially consisting of cement, aggregates, water and admixture(s).

Among these, aggregates, i.e. inert granular materials such as sand, crushed stone or gravel
form the major part. Traditionally aggregates have been readily available at economic price.
However, in recent years the wisdom of our continued wholesale extraction and use of
aggregates from natural resources has been questioned at an international level.

This is mainly because of the depletion of quality primary aggregates and greater awareness
of environmental protection. In light of this, the availability of natural resources to future
generations has also been realized. Given this background, the concept of sustainable
development put forward almost a decade ago, at the 1992 Earth Summit in Rio de Janeiro,
and it has now become a guiding principle for the construction industry worldwide.
 In fact, many governments throughout the world have now introduced various measures aimed at
reducing the use of primary aggregates and increasing reuse and recycling, where it is technically,
economically, or environmentally acceptable.

For example, the UK government has introduced a number of policies to encourage wider use of
secondary and recycled coarse aggregate (RCA- defined as minimum of 95% crushed concrete) as
an alternative to naturally occurring primary aggregates. These include landfill and future
extraction taxes to improve economic viability, support to relevant research and development work.

The developing country like India (Authors native land) facing shortage of good quality natural
sand and particularly in India, natural sand deposits are being used up and causing serious threat to
environment as well as the society.

The rapid extraction of sand from the river bed causes problems like deepening of the river beds,
loss of vegetation on the bank of rivers, disturbance to the aquatic life as well as agriculture due to
lowering the water table in the well etc. Therefore, construction industries of developing countries
are in stress to identify alternative materials to replace the demand for river sand.
Quarry dust
 OBJECTIVE
To use of the quarry dust replacement of fine aggregate reduces the environmental
pollution as well as providing an economic value for the waste material.

To improve durability, ductility using replacing fine aggregate.

To study the mechanical and physical properties of construction waste aggregate

by conducting experimental work.

To find out the % use feasible for construction.

 NEED FOR THE STUDY
To improve the structural strength.

To improve ductility behaviour of a structure, which can be used in

earthquake prone zones.

To increase the compressive strength of the concrete.

To increase the life time of the structure.

 LITERATURE REVIEW
CHARACTERISTIC STUDIES ON THE MECHANICAL PROPERTIES OF
QUARRY DUST ADDITION IN CONVENTIONAL CONCRETE
A. Sivakumar et al. (2011) investigated, Quarry dust is a waste obtained during
quarrying process. It has very recently gained good attention to be used as an
effective filler material instead of fine aggregate. In the present study, the hardened
and durable properties of concrete using quarry dust were investigated. Also, the use
of quarry dust as the fine aggregate decreases the cost of concrete production in
terms of the complete replacement for natural river sand. This paper reports the
experimental study which investigated the influence of 100% replacement of sand
with quarry dust. Initially cement mortar cube was studied with various proportions
of quarry dust (CM 1:3, CM 1:2, and CM 1:1). The experimental results showed
that the addition of quarry dust for a fine to coarse aggregate ratio of 0.6 was found
to enhance the compressive properties as well as elastic modulus.
IMPROVED CONCRETE PROPERTIES USING QUARRY DUST AS
REPLACEMENT FOR NATURAL SAND
Anzar Hamid Mir (2015) investigated, Concrete plays a major role in the
construction industry. Natural sand is a prime material used for the preparation of
concrete and also plays an important role in Mix Design. Now a days river erosion
and other environmental issues have led to the scarcity of river sand. The reduction
in the sources of natural sand and the requirement for reduction in the cost of
concrete production has resulted in the increased need to find new alternative
materials to replace river sand so that excess river erosion is prevented and high
strength concrete is obtained at lower cost. One such material is Quarry stone dust: a
by-product obtained during quarrying process. Attempts have been made to study the
suitability of Quarry dust as sand replacing material and it has been found that
Quarry dust improves the mechanical properties of concrete as well as elastic
modulus. The optimum compressive strength is achieved at the proportion of fine to
coarse with 60:40 ratio.
USE OF QUARRY DUST TO REPLACE SAND IN CONCRETE AN
EXPERIMENTAL STUDY
G.Balamurugan et al. (2013) investigated, this experimental study presents the
variation in the strength of concrete when replacing sand by quarry dust from 0% to
100% in steps of 10%. M20 and M25 grades of concrete were taken for study
keeping a constant slump of 60mm. The compressive strength of concrete cubes at
the age of 7 and 28 days were obtained at room temperature. Also the temperature
effect on concrete cubes at 100oC on 28th day of casting was carried out to check
the loss of strength. From test results it was found that the maximum compressive
strength is obtained only at 50% replacement at room temperature and net strength
after loss due to hike in temperature was above the recommended strength value due
to 50% replacement itself. This result gives a clear picture that quarry dust can be
utilized in concrete mixtures as a good substitute for natural river sand giving higher
strength at 50% replacement.
PARTIAL REPLACEMENT OF SAND WITH QUARRY DUST IN CONCRETE
Chandana Sukesh et al. (2013) investigated, the reduction in the sources of natural sand
and the requirement for reduction in the cost of concrete production has resulted in the
increased need to identify substitute material to sand as fine aggregates in the production
of concretes especially in Concrete. Quarry dust, a by-product from the crushing process
during quarrying activities is one of such materials. Granite fines or rock dust is a by-
product obtained during crushing of granite rocks and is also called quarry dust. In recent
days, there were also been many attempts to use Fly Ash, an industrial by product as
partial replacement for cement to have higher workability, long term strength and to make
the concrete more economically available. This present work is an attempt to use Quarry
Dust as partial replacement for Sand in concrete. Attempts have been made to study the
properties of concrete and to investigate some properties of Quarry Dust the suitability of
those properties to enable them to be used as partial replacement materials for sand in
concrete.
PHASE OF EXPERIMENTAL WORK
Materials collection Study of physical characteristics
(Quarry dust and River sand) (Quarry dust and River Sand)

Mix proportion M20 and M30

Study of compressive, Flexural and Split tensile strength M20 and

M30

Analysis of results M20 and M30

Conclusion
MATERIALS USED
cement
Fine aggregate
coarse aggregate
 EXPERIMENTAL TESTS ON
CONCRETE
MATERIAL TESTING:
Specific gravity test
Water absorption

FRESH CONCRETE TEST (WORKABILITY TEST)

Slump cone Test

HARDEN CONCRETE TEST

Compressive test
MATERIAL TESTING
SPECIFIC GRAVITY
Specific gravity of soil grains is
used in calculating void ratio,
porosity and degree of
saturation, by knowing moisture
content and density.
Specific gravity test is used to
determine the gravity value of
cement, fine aggregate and
coarse aggregate.
 SPECIFIC GRAVITY
TEST RESULTS
S.No Cement Fine Coarse aggregate
aggregate (20mm)

1 3.15 2.64 2.76

WATER ABSORPTION

Water absorption test is used to

determine the absorption content
of water by fine aggregate and
coarse aggregate.
 WATER ABSORPTION
TEST RESULTS
S.No Fine Coarse aggregate
aggregate (20mm)
(%) (%)

1 1.24 0.54
PREPARATION AND CASTING OF TEST SPECIMENS
All the concrete mixtures were mixed in the laboratory. For each concrete mix
specimens having size 150x150x150-mm cubes were casted for the determination
of compressive.

A design mix of M-20 was used and quarry dust was added at 10%, 20%and 30%
respectively by the weight of cement.

Specimens were casted in three layers and were compacted using a vibrator. They
were unmolded after 24 hours, and were transferred to a water tank for 7, 14 and
28 days of testing.
 Concrete mix proportions
The mixture proportioning was done according the Indian Standard Recommended Method IS
10262-2009:

MIX DESIGN FOR M20 GRADE CONCRETE (Standard)

STIPULATING FOR PROPORTIONING:
1. Grade designation = M20
2. Type of cement = OPC 53 Grade
3. Maximum size of aggregate = 20mm
4. Minimum cement content = 250kg/m3
5. Maximum water - cement ratio = 0.5
6. Workability = 100mm(slump)
7. Exposure condition = Severe
8.Type of aggregate = Crushed angular aggregate
9. Maximum cement content = 400kg/m3
TEST DATA FOR MATERIALS:
1. Cement used = OPC 53 Grade
2. Specific gravity of cement = 3.15
3. Specific gravity of coarse aggregate = 2.76
4. Specific gravity of fine aggregate = 2.64
5. Water absorption of coarse aggregate = 0.54%
6. Water absorption of fine aggregate = 1.24%
7. i) Free (surface) moisture coarse aggregate = Nil
ii) Free (surface) moisture fine aggregate = Nil
TARGET STRENGTH FOR MIX PROPORTIONING:
f'ck=fck+1.65s
Standard deviation, s = 04.00 N/mm2
Target strength = 26.6 N/mm2
Characteristic Strength @ 28 days = 20N/ mmm2

SEELCTION OF WATER-CEMENT RATIO:

Maximum w/c ratio = 0.5
Assume w/c ratio = 0.5

SELECTION OF WATER CONTENT:

For , maximum water content = 186 litres
Estimated water content for 100mm slump = 197 litres
Water content = 197 litres
CALCULATION OF CEMENT CONTENT:
Adopted w/c ratio = 0.50
Cementitious material content = 394 kg/m3 (197/0.5)
Water content = 197 litres
W/C ratio = 0.5
Cement (OPC) = 394 kg/m3 (Which is greater then 250 kg/m3 )

PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE

AGGRAGATE:
Volume of coarse aggregate = 0.64
Volume of fine aggregate = 0.36
MIX CALCULATION:

1. Volume of concrete = 1 m3
2. Volume of cement = 0.125 m3
3. Volume of water = 0.197 m3
4. Volume of all in aggregate = 0. 322 m3
5. Mass of coarse aggregate = 1197.61 kg/ m3
6. Mass of fine aggregate = 644.37 kg/ m3
MIX PROPORTIONS FOR TRIAL:

1. Cement = 394 kg/ m3

2. Water = 197.000 kg/ m3
3. Fine aggregate = 644.37 kg/ m3
4. Coarse aggregate = 1197.61kg/ m3
5. Water cement ratio = 0.5
Mix proportion for standard concrete (1m3)

Cement Fine Coarse Water

aggregate aggregate

Quantity 394 644.37 1197.61 197

(kg/m3)

Mix Proportions 1 1.63 3.03 0.5

 Mix proportion for 150mm X 150mm X 150mm

Calculation for cubes :

Volume of cube = 0.15*0.15*0.15 = 0.00375 m3
For 0.003375 m3
Cement content = 0.003375*394 = 1.32 kg
Coarse aggregate content = 0.003375*1197.61 = 4.044 kg
Fine aggregate content = 0.003375* 644.37 kg =2.17 kg
Water content = 0.003375*197 = 0.66 liters
 EXPERIMENTAL PROCEDURE

1. For strength requirements, select the water to cement ratio by weight.

2. Before mixing concrete, be sure that the mixer has been "buttered" with a
mixture of cement, sand, and water.

3. Divide a water into two buckets, one with about 3/4 of the water. Put about
half the coarse aggregate and the 3/4-bucket of water.

4. Start the mixer.

5. Add about half the fine aggregate.

6. Carefully add all the cement with the mixer. Mix until all the cement
is blended in.

8. Add the rest of the coarse and fine aggregate.

9. Mix for a while.

10. Add enough water from the final quarter of the water to produce a
workable mix.
Concrete mixture
Slump cone test for standard concrete
 Slump test
Percentage of quarry dust Slump Value (mm)
(%)
0 70

10 75

20 80

30 90
Casting for concrete
Compressive strength (7 days test results)
Percentage of quarry 7 days (N/mm2) Average
dust (%) Specimens compressive
Strength (N/mm
)
CUBE 1 16.3 16.9
0 CUBE 2 17.3
CUBE 3 16.8
CUBE 4 17.9 17.3
10 CUBE 5 17.7
CUBE 6 16.4
CUBE 7 17.9 17.6
20 CUBE 8 17.3
CUBE 9 17.5
CUBE 10 18.4 18.1
30 CUBE 11 18.2
CUBE 12 17.7
Compressive strength (14 days test results)
Percentage of quarry 14 days (N/mm2) Average
dust (%) Specimens compressive
Strength (N/mm
)
CUBE 1 20.8 20.5
0 CUBE 2 20.4
CUBE 3 20.2
CUBE 4 20.9 21.6
10 CUBE 5 21.8
CUBE 6 22.2
CUBE 7 22.6 22.2
20 CUBE 8 22.1
CUBE 9 21.8
CUBE 10 22.8 23.4
30 CUBE 11 23.7
CUBE 12 23.6
Compressive strength test
Thank you