GOVERNMENT ENGINEERING COLLEGE

BHARUCH

Utilization Of Sludge And Slag As A Construction

Material
Prepared By :
Godhani Krishna (150140106010)

Malek Mohammad Zaid (150140106020)

Panchal Sneha (160143106006)

Patel Rizwana (160143106011)

Rangrej Zeba (160143106015)

Guided By :
Prof. A. N. Dave
 OUT LINE
Introduction
Scope of project
Objective
Material used for paver block
Material used for concrete block
Literature review of sludge
Literature review of slag
Work done
Mix design of paver block(M 30) and concrete block(M 20)
Test result
Cost comparison
Conclusion
References
 Introduction

WHAT IS SLUDGE ?
Sludge is a semi-solid slurry and can be produced as sewage sludge from wastewater
treatment processes or as a settled suspension obtained from conventional drinking
water treatment and numerous other industrial processes.

WHAT IS WASTE WATER (SLUDGE WATER)?

Wastewater  is any water that has been affected by human use. Wastewater is
“used water from any combination of domestic, industrial, commercial or
agricultural activities, surface runoff or storm water and any sewer inflow or
sewer infiltration”.
Sewage sludge is that obtained after treatment of sewage from
sewage treatment plant (stp).

 The present scenario is that this treated sludge is used in land

fills (open and closed), soil conditioner and natural fertilizer.

 After treatment there are also some kind of impurities remains

present in treated sludge and waste water, its disposal cause harm
to environment and human. So that instead of dispose it in open
environment, we can reuse it in different construction materials.
• WHAT IS SLAG ?

• The slag is a by-product of copper or steel industry. Slag is

used in sand blasting. It is also used as a cementitious
material. One solution for slag is using it in concrete block.
 
• Copper slag is used in the concrete as one of the alternative
materials. It is the waste product of copper industry from
Birla Copper Dahej. The safe disposal of this waste is a lack,
costly and causes environmental pollution. The construction
industry is the only area where the safe use of waste material
(copper slag) is possible. When it is introduced in concrete
as a replacement material, it reduces the environmental
pollution, space problem and also reduces the cost of
concrete.
We can use sludge, sludge water and slag in following
Construction Materials:

 Concrete block

 Cement block

 Bricks (sludge ash)

 Aggregate

 Paver blocks

 Pavement construction in highway

Road base coarse material

 Scope of project

 Economical construction : achieving reduction in % of

sand by replacing it with dry sewage sludge, which

ultimately results in reduction in cost of construction.

 Admixture: we can use dry sewage sludge & Slag as

admixture.
 Objective

• To reduce the problem of sewage sludge disposal.

• To reduce the adverse effects on environment.
• To maximize the efficiency of sludge disposal by
partially minimizing the dependency on conventional
materials.
• To study the mechanical property of M20 concrete by
replacing Fine Aggregate by Means of Copper Slag.
 Materials used In paver block.

I. Cement
II. Sand
III.Course aggregate
IV.Water
V. Dry sludge
VI.Waste water
Materials used In Concrete block.

I. Cement
II. Sand
III.Course aggregate
IV.Water
V. Slag
 Cement

 The cement used is of ultratech cement of grade 43. The usual tests

carried out for cement are of chemical and physical requirements. The
chemical standards give permissible limits for insoluble residue, loss of
ignition and other compounds and impurities like magnesium oxide,
sulphate, etc. The physical requirements are for fineness, soundness,
setting time and compressive strength. 33, 43 and 53 grade in Ordinary
Portland cement indicates the compressive strength of cement after 28
days when tested. Similarly for 43 grade the 28 days compressive
strength should not be less than 43 mpa.
 Sand
Sand is a granular material composed of finely divided rock and mineral particles. It is
defined by size, being finer than gravel and coarser than silt. Sand can also refer to
a textural class of soil or soil type; i.e., A soil containing more than 85 % sand-sized
particles by mass.

The composition of sand varies, depending on the local rock sources and conditions,
but the most common constituent of sand in inland continental settings and non-
tropical coastal settings is silica (silicon dioxide, or sio2), usually in the form of quartz.
The second most common type of sand is calcium carbonate, for example, aragonite,
which has mostly been created, over the past half billion years, by various forms of life,
like coral and shellfish. For example, it is the primary form of sand apparent in areas
where reefs have dominated the ecosystem for millions of years like the Caribbean.

Sand is a non-renewable resource over human timescales, and sand suitable for making
concrete is in high demand.
Sieve analysis of fine aggregate
Wt. Cumulative Cumulative % Cumulative %
IS SIEVE retained(kg) wt. retained passing
Retained(kg)
80 mm - - - -
40 mm - - - -
20 mm - - - -
- - - 100
10 mm
0.141 0.141 14.1 85.9
4.75 mm
0.028 0.169 16.9 83.1
2.36 mm
0.069 0.289 28.9 71.1
1.18 mm
0.189 0.427 42.7 57.3
600mic
0.307 0.734 73.7 26.6
300mic
1.266 1 100 0
150mic
75mic - - - -
total 1   276  
Sieve analysis of fine aggregate
 Coarse aggregate (grit)

Coarse aggregate is commonly considered inert filler, which accounts

for 60 to 80 percent of the volume and 70 to 85 percent of the weight of
concrete. Although coarse aggregate is considered inert filler, it is a
necessary component that defines the concrete’s thermal and elastic
properties and dimensional stability.

Coarse aggregate is usually greater than 4.75 mm to 10 mm. The

compressive strength is an important factor in the selection of coarse
aggregate. When determining the strength of normal concrete, coarse
aggregate are several times stronger than the other components in
concrete.
Other physical and mineralogical properties of coarse aggregate include
shape and texture, size gradation, moisture content, specific gravity,
reactivity and bulk unit weight.

The shape and texture of coarse aggregate affects the properties of fresh
concrete more than hardened concrete. The surface texture of coarse
aggregate can be either smooth or rough. A smooth surface can improve
workability, yet a rough surface generates a stronger bond between the
paste and the coarse aggregate creating a higher strength.
 Sieve analysis of coarse aggregate
IS SIEVE Wt. Cumulative wt. Cumulative Cumulative %
retained(kg) Retained(kg) % retained passing

80 mm - - - -

40 mm - - - -

20 mm - - - -

- - - -
10 mm
0.719 0.719 71.9 28.1
4.75 mm
0.22 0.939 93.9 6.1
2.36 mm
0.049 0.988 98.9 1.1
1.18 mm
0.006 0.944 94.4 5.6
600mic
0.002 0.996 99.6 0.4
300mic
0.001 0.997 99.7 0.3
150mic
75mic 0.003 1 100 0

total 1   658.4  
 Water
Water is when mixed with the dry composite (cement, sand &coarse aggregate),
produces a semi-liquid that can be shaped (typically by pouring it into a form).
The concrete solidifies and hardens through a chemical process called hydration.

The water reacts with the cement, which bonds the other components together,
creating a robust stone-like material. Combining water with a cementitious
material forms a cement paste by the process of hydration. The cement paste glues
the coarse aggregate together, fills voids within it, and makes it flow more freely.

A lower water-to-cement ratio yields a stronger, more durable concrete, whereas

more water gives a free flowing concrete with a higher slump. Impure water used
to make concrete can cause problems when setting or in causing premature failure
of the structure.
 Sludge
Sewage sludge is created as solids are removed from waste water during
treatment. Over the last 20 years, the rate of sludge production has doubled.
Most of the sludge is harmless organics. Nutrients like nitrogen and
phosphorus are also present and can make for an effective fertilizer. But
sludge also contains contaminants taken from wastewater, such as heavy
metals, organic carcinogens and pathogens.

Properties of sludge
Absorption (%) 1

Specific gravity 1.96

Bulk density 638.71 kg/ cum

Physical properties
Particle size: depending on the source of some sludge may have a significant
fraction of particles greater than 0.6 mm and less than 2 mm in size. In this case, it
is introduced into the mix as a combination mineral filler.
Plasticity: sludge is a non-plastic material.
Specific gravity: specific gravity of sludge is the ratio of weight in air of the
given volume of dried sludge to the weight of equal volume of water at 4°c.
The properties of a concrete containing sludge that are of particular interest
include stability, densityand air voids and durability.
Stability: the addition of sludge in concrete mixes up to approximately 8% by
weight of sand reportedly increases the stability of the mix.
Density: the addition of sludge can be expected to decrease the density of the mix.
Air voids: an increase in sludge concentration can be expected to result in an
increase in air voids and a corresponding increase in the cement demand of the
mix.
Durability: mix durability may be slightly improved by the addition of sludge.
Sieve analysis of dry sludge

IS SIEVE Wt. Cumulative wt. Cumulative % Cumulative %

retained(kg) Retained(kg) retained passing

80 mm - - - -
40 mm - - - -
20 mm - - - -
10 mm - - - -
4.75 mm 0 0 0 100
2.36 mm 0.329 0.329 32.9 67.1
1.18 mm 0.187 0.516 51.6 48.4
600mic 0.180 0.696 69.6 30.4
300mic 0.248 0.944 94.4 5.6
150mic 0.056 1.00 100 0
75mic - -    
Total 1   348.4  
 Waste water

Secondary treatment is a treatment process for wastewater (or sewage)

to achieve a certain degree of effluent quality by using a sewage
treatment plant with physical phase separation to remove settable
solids and a biological process to remove dissolved and suspended
organic compounds. After this kind of treatment, the wastewater may
be called as secondary-treated wastewater.
 Composition of waste water sample

SR NO PARAMETER NAME RESULT

1 PH 6.83 ppm
2 TDS 1509 ppm
3 TSS 1.8 ppm
4 COD 133 ppm
5 NH₄N 4 BDL
6 TOTAL HARDNESS 502 ppm
7 CHLORIDE 503ppm
8 SULPHUR BDL
9 ARSENIC BDL
10 CHROMIUM 0.0078 ppm
11 LEAD BDL
 Copper Slag
• Copper slag is an irregular, black, glassy and granular in
nature and its properties are similar to the river sand. In this
project, Copper slag used is brought from Sterile Industries
India Ltd, Tuticorin. Every ton of copper will generate
approximately 2.2-3 tons of copper slag. Birla Copper
produces 3,30,000 t/year of copper slag is generated in a
year. There are different types of slag generates but they
recycle it & discard slag in one type only – Granulated
Slag. The chemical traces such as copper, sulphate and
alumina present in the slag are not harmful.
properties of slag
Absorption (%) 1%

Specific gravity 3.65

Bulk density 2297 kg/ cum

Composition of slag
Element % content

Cu 0.7

Fe 43.5

SiO2 25.6

Fe3O4 3.8

CaO 2.19

MgO 1.1

Al2O3 4.74
 Literature review of sludge

From the Imperial Journal of Interdisciplinary Research (IJIR)

Vol-2, Issue-7, 2016
ISSN: 2454-1362

Specific gravity for various samples

Sr. No Types of Sample Specific Gravity(G)

1 Sand 2.74
2 Murrum 2.35
3 Clay 2.22
4 Sludge 1
Workability Analysis

Workability
Percentage of Sand replacement
(slump value) mm
4 50
6 55

8 62
10 75
12 70

14 90
Standard 60
Compressive strength of concrete block
Sample with % of Compressive strength for respective Days of testing
sludge 7 14 28
4 18.82 22.77 28.41
6 14 24.63 34.26
8 20.5 23.65 31.29
10 21 24.13 29.37
12 12.58 14.77 20.5
14 11.71 16.5 20.7
Standard 20.18 22.56 30.18
4

10

12

14

Standard
 Literature review of slag
(International Research Journal of Engineering and Technology
(IRJET) e-ISSN: 2395 -0056
Volume: 03 Issue: 06 |
June-2016 p-ISSN: 2395-0072)

Chemical properties of Cement, Steel Slag & Marbel powder

Chemical Cement Steel Slag% Marble Waste%
compounds
Sio2 22.60 30.20 13.8
Al2o3 4.30 19.60 2.50
Fe2o3 2.40 0.60 1.9
Cao 64.40 32.40 43.2
Mgo 2.10 9.26 2.70
SO3 2.30 0.27 0.07
Na2O 0.60 - 0.90
K2O 0.60 - 0.60

properties of steel slag

Specific gravity Water Dry loose bulk Soundness% Fineness
absorption % density Kg/cum modulus
2.38 0.9 1058 1.38 3.14
Compressive strength in cubes
Marble waste (%) Steel slag (%) Compressive strength at Compressive strength at
7days (N/mm2) 28days (N/mm2)
 
 

0 0 17 23.7
5 10 18.5 24.5
  20 16.5 25.8
  30 15.2 26.5
  40 16.8 25
  50 16.5 23
10 10 20.8 28.5
  20 19.5 29.6
  30 18.6 30.2
  40 19.4 29.5
  50 19.2 27.8
15 10 18.08 20.3
  20 15.8 21.5
  30 15.01 23.8
  40 16.5 22.1
  50 16.2 21.8
20 10 15.1 19.28
  20 13.2 20.5
  30 14.5 21.9
  40 15.3 20.2
  50 15.01 19.5
 Work done
Overview of different topics
Finalized topic
Studied literature review
Decided what process will be carried out
Discussed which type of sludge and sludge water will be used in paver
blocks
Visited sewage treatment plant, Bamroli, Surat
Collected dry sludge and wastewater samples
Testing the properties of dry sludge and waste water
Sieve analysis
Bulk density test
Mix design of paver block
Prepared paver blocks for different content of dry sludge and waste water
Testing of paver block
Discussed which type of slag used in concrete block
Visited Birla copper , Dahej
Collected copper slag samples
Testing the properties of Slag
Bulk density test
Mix design of concrete block
Prepared concrete blocks for different content of slag
Testing of concrete block
Cost comparison
 Mix design of paver block
The minimum cement content for compacted concrete of pavers shall not
be less than 380 kg / cum.
The cement used in the manufacture of high quality pre-cast concrete
paving blocks shall be conforming to is 12269 (53 grade ordinary Portland
cement) or is 8112(43 grade ordinary Portland cement).
The maximum water cement ratio for paver concrete shall not be more
than 0.40
The fine and coarse aggregates shall consist of naturally occurring
crushed or uncrushed materials, which apart from the grading
requirements comply with IS 383-1970. The fine aggregates used shall
contain a minimum of 25% natural silicon sand. Lime stone aggregates
shall not be used. Aggregates shall contain no more than 3% by weight of
clay & shall be free from deleterious salt sand contaminants. Zone IV sand
shall not be acceptable. Course aggregate shall be 10 mm and below.
The pigment shall be used only on wearing and top surface and
throughout the paver block. The pigment used shall not be more than
10% of weight of cement used in the wearing course layer. However,
use of pigment shall in no way alter the required strength of the paver
block. Pigment used for colouring paver blocks shall have durable
colour. It shall not contain matters detrimental to concrete. The pigment
shall not contain zinc compound. Lead pigment shall not be used.
The compressive strength requirement of concrete paver block shall be
minimum 30.4125 MPa (N / mm2) for 28 days (testing as per IS:15658)
after applying the correction factor as per IS-15658; 2006. No lower
tolerance limit in compressive strength shall be allowed.
Compressive strength
Minimum 30.4125 MPa (N/ mm2) (for 50mm)

Water absorption
Maximum 1.0% 
Parameters for mix design m-30
Grade designation = M-30
type of cement = O.P.C-43 grade
fine aggregate = zone-ii
sp. Gravity cement = 3.15
fine aggregate = 2.60
coarse aggregate- grit (10mm) = 2.65
minimum cement (taking higher value) = 380 kg /m3
maximum water cement ratio (taking higher value) = 0.45

Mix Calculation: –
1. Target mean strength = 30 + (.825 X .5) = 30.4125mpa (taking higher
value)
2. Selection of water cement ratio: assume water cement ratio = 0.42
3. Selections of water contents: for zone 2 and 10mm
w= 200 kg/m3
4. Calculation of cement content:
W/C = 0.42
C= 200/0.42= 476.19

5. Calculation for C.A. & F.A.: – As per IS:10262, cl. No. 3.5.1
V = [W + (C/sc) + (1/p). (Fa/sfa)] x (1/1000)
V = [W + (C/sc) + {1/ (1-p)}. (Ca/sca)] x (1/1000)
Where
V = absolute volume of fresh concrete, which is equal to gross volume
(m³) minus the volume of entrapped air,
W = mass of water (kg) per m³ of concrete,
C = mass of cement (kg) per m³ of concrete,
Sc = specific gravity of cement,
(P) = ratio of fine aggregate to total aggregate by absolute volume,
(Fa), (ca) = total mass of fine aggregate and coarse aggregate (kg) per m3 of
concrete respectively, and
Sfa, sca = specific gravities of saturated surface dry fine aggregate and
coarse aggregate respectively.
As per table no. 3, IS-10262, for 10mm maximum size entrapped air is 3%.
Assume fa. By % of volume of total aggregate = 40%
0.97 = [200 + (476.2 / 3.15) + (1 / 0.40) (fa / 2.60)] (1 /1000)
Fa = 644.61 kg.
0.97 = [200 + (476.2 / 3.15) + (1 / 0.60) (ca / 2.65)] (1 /1000)
Ca = 983.83 kg.

Hence mix details per m³

Cement = 476.2 kg
water = 200 kg
fine aggregate = 644.61 kg
coarse aggregate 10 mm (grit) = 983.83 kg
water: cement: F.A.: C.A. = 0.42: 1: 1.35: 2.06
 Mix design of Concrete block
• M 20 MIX DESIGN
 
• 1. REQUIREMENTS
a) Specified minimum strength = 20 N/Sq mm
• b) Durability requirements
i) Exposure Moderate
ii) Minimum Cement Content = 300 Kgs/cum
• c) Cement
(Refer Table No. 5 of IS:456-2000)
i) Make Chetak (Birla)
ii) Type OPC
iii) Grade 43
• d) Workability
i) compacting factor = 0.7
• e) Degree of quality control Good
2. TEST DATA FOR MATERIALS SUPPLIED 
a) CEMENT
i) Specific gravity = 3.05
ii) Avg. comp. strength 7 days = 46.5 more than 33.0 OK
28 days = 55.0 more than 43.0 OK
b) COARSE AGGREGATE
i) 20mm Graded
Type Crushed stone aggregate
Specific gravity = 2.68
Water absorption = 1.46
Free (surface) moisture = 0
c) FINE AGGREGATE (Coarse sand)
i) Type Natural (Ghaggar)
Specific gravity = 2.6
Water absorption = 0.5
Free (surface) moisture = 1.4

3. TARGET MEAN STRENGTH (TMS)

a) Statistical constant K = 1.65
b) Standard deviation S = 4.6
Thus, TMS = 27.59 N/Sq mm
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• 4. SELECTION OF W/C RATIO
a) As required for TMS = 0.5
b) As required for ‘Moderate’ Exposure = 0.55
Assume W/c ratio of 0.5
• 5. DETERMINATION OF WATER & SAND CONTENT
For W/C = 0.6
C.F. = 0.8
Max. Agg. Size of 20 mm
a) Water content = 186 Kg/cum
b) Sand as percentage of total aggregate by absolute volume = 35 %
• Thus,
Net water content = 180.42 Kg/cum
Net sand percentage = 33 %
• 6. DETERMINATION OF CEMENT CONTENT
W/c ratio = 0.5
Water content = 180.42 Kg/cum
Thus, Cement content = 360.84 Kg/cum Adequate for moderate exposure
Say 360 Kg/cum

• 7. DETERMINATION OF COARSE AND FINE AGGREGATE

CONTENT
Assume entrapped air as 2 %
Thus,
0.98 cum = [180.42+360/3.05 + {1/0.33}*{fa/2.6}]/1000
& 0.98 cum = [180.42+360/3.05 + {1/0.67}*{Ca/2.68}]/1000
Hence,
fa = 584 Kg/cum
Ca = 1223.8 Kg/cum
• The final mix proportions of M-20 grade of concrete become:-
Paver block Concrete block
 Test result of sludge & waste water
7 days compressive 28 days compressive
Type of block
strength (N/mm2) strength (N/mm2)
NORMAL 20.37 25.13

SW (04%) 23.69 28.24

SW (10%) 18.66 24.21

SW (15%) 19.04 24.89

DS (04%) 19.95 25.02

DS (06%) 15.83 21.39

DS (08%) 23.21 30.45

SW – Sludge Water
DS – Dry Sludge
 Test result of slag
7 days compressive strength 28 days compressive strength
Type of block
(N/mm2) (N/mm2)

NORMAL 12.69 19.89

SL (20%) 13.11 18.09

SL (30%) 14.05 20.11

SL (40%) 14.69 24.05

Compressive strength testing machine
 Test Cost Comparison

Paver block
 

Normal 8 % Sludge replacement

30 Rs. 8 Rs.

Concrete Block
 

Normal 40 % Slag replacement

12.98 Rs. 13.32 Rs.

 Conclusion
The 28-day compressive strength of paver block increases as the
percentage of dry sludge in the mix increases. At replacement of 8% of
dry sludge, maximum strength of paver block is obtained (more than
normal paver block strength).
The 28-day compressive strength of paver block decreases as the
percentage of treated waste water in the mix increases. However, the
design strength is still attainable for up to 4% (by weight) waste water
replacement.
However the deterioration is observed in the block while testing the
compressive strength.
• The 28-day compressive strength of concrete block increases
as percentage replacement of slag increases. The maximum
strength of block is obtained at 40% replacement of slag. It is
also noted that the water requirement is slightly decreases in
the concrete containing slag.
 References
Imperial Journal of Interdisciplinary Research
Vol-2, Issue-7, 2016
ISSN: 2454-1362
Journal of Materials and Environmental Sciences
Volume 8, Issue 8, 2017
ISSN : 2028-2508
Journal of Ibracon Structures & Materials
Volume 9, Number 6, 2016
ISSN 1983-4195
International Journal of Innovative Science, Engineering & Technology
Vol. 4, Issue 6,2017
ISSN 2348 – 7968
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