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WASTE MANAGEMENT OF DEBRIS TO DURABLE BLOCK USING RCA AND FLY

ASH

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 INTERNATIONAL JOURNAL OF INNOVATION IN ENGINEERING RESEARCH & MANAGEMENT ISSN: 2348-4918
Peer Reviewed and Refereed Journal, (ICMCSEH-2020)

WASTE MANAGEMENT OF DEBRIS TO DURABLE BLOCK USING RCA AND FLY ASH

1Rishav
Singh,
1B.Tech Student, Department of Civil Engineering
2Md Mainuddin,
2Assistant Professor, Dream Institute of Technology, Kolkata, India

Abstract:- Construction industry is considered as one of the prime reasons of environment

degradation globally. Waste is considered a big issue in the construction area because of its
economic and ecological impact. According to the Indian Government estimates, India
produced 12-14.7 MT of Construction and Demolition (C & D) waste per annum as reported
by CPCB in 2017. Where at present 170 MT of fly ash is produced in India annually. In this
paper it is discussed how waste concrete which is only a debris for everyone also causes
environmental pollution can be used to make a concrete block and how Fly ash which is a
waste material that gets accumulated in a large volume near the industries which causes
environmental pollution can also used to make a bricks which is 28% less weight than clay
bricks as well as shows higher strength. The strength is higher by 25% than commonly
available bricks. The key objective of the paper is to study the strength of fly ash brick and
recycled aggregate concrete block using different material proportion and also to improve
the compressive stress.
Keywords:- Recycled Concrete Aggregate; 3-R Principal; Waste Management; Fly Ash
Bricks; Economy; Environment.

1. INTRODUCTION
Man makes the mistakes and mistakes make the man. We human are born to do mistake
by virtue of being human, it’s in our DNA. Have you thought how many and big mistakes
we the humans are doing only for our benefits .currently the whole world is suffering from
Novel Corona Virus, the nature has proven how small we are and how much less advanced
technology we have more than 306,176 people died up till 15 th May 15, 2020 due to this
pandemic and still we don’t have proper treatment or any vaccine.
Definitely, we will find the proper treatment one day but we have to understand if
nature against human no one can helps us, it’s our mother nature we have to safe it. We
had everything clean and pure - Fresh air, forest life and many more but we the human
change everything for our own interest turned forest to timber, made the vast lands barren
while stirring the fresh air with poison and now we’re doomed, blues skies turned gloom,
trapped in our own space night to noon, life’s empty filled with boredom devoid of any
freedom.
To take the world back there to make Mother Nature pure and clean waste
management is the only key. In this paper, a comparative study was described on
utilization of waste concrete and fly ash in construction project. Crushing concrete to
engender coarse aggregate for the engenderment of incipient concrete is one prevalent
denotes for achieving a more environmentally cordial concrete. Recycling concrete wastes
will lead to minimization in valuable landfill space and savings in natural resources.
In fact, the utilization of recycled aggregate concrete (RAC) is acquiring particular
interest in civil construction as regards to sustainable development. Many studies
demonstrate the feasibility of the utilization of crushed concrete as coarse aggregates, its
use being already accounted for in the regulations of many countries. In Italy, the
utilization of 30% recycled concrete in lieu of natural aggregate is definitively sanctioned for
engendering structural concretes (up to C 30/37 vigor class) since July 2009.
Henry Liu et.al (2009) developed bricks made of pure fly ash which do not require
high kiln temperature similar to that in the production of clay bricks. The long term tests
conducted on the fly ash bricks resulted in higher strength due to the process of
carbonation which is caused by the absorption of carbon-di-oxide from the atmosphere. Fly
ash based bricks are prepared for different ratios of ingredients using cement as binder
material and 28 days compressive strengths are calculated.

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Though for country brick the strength obtained was only 3.5 N/mm2 which didn’t
increase even with the increase in the percentage of fly ash. Obadakayaliet.al (2005)
compared the properties of fly ash bricks to the clay bricks. The compressive strength of the
fly ash bricks is found to be 24% greater than that of any good quality brick. Again the fly
ash bricks possess 28% lesser density than the normal clay bricks.
Mei-In Chou and Shang Fu Chou (2004) reported that the paving bricks with 20 %
volume of fly ash and building bricks containing fly ash up to 40% were produced. Dayal
(1995) described that the fly ash has relatively a lesser amount of compressibility and
superior shear strength properties and also mentioned about the usage of fly ash in various
modes.
Fly-ash based bricks are categorized in two types, non-calcinite bricks (fly ash mix
with bonding agent) along with calcinite bricks (fly-ash clay brick). Percentage of fly ash
mixed varied from 10% to 80% and tested for their suitability and 40% by weight of local
silty soil found as the optimum percentage of fly ash. They tested the properties exhibited
by fly ash bricks by addition of different proportions of fly ash and baking them at different
temperature.

1.1 Objectives
To compare the basic properties of blocks made with (fly ash, sand, lime, stone dust and
gypsum) and the properties of concrete made with different proportions of recycled
aggregate. To determine the sustainability, strength and other important properties of
concrete made with recycled aggregate and blocks made with fly ash, sand, lime, stone dust
and gypsum

2. ROLE OF THIS PROJECT IN ENVIRONMENT

Waste management strategies adopted in different countries. Comparative analysis was
acclimated to identify the main aspects that regime considered in ameliorating construction
waste management. The fundamental of waste management is 3R principal Reuse, Recycle
and Minimize to procure sustainability. As per report of Central Pollution Control Board
(CPCB) Delhi, India , 48 millions tones of solid wastes is engendered out of which 14.5
million tone waste is engendered from the construction sector out of which 3% waste is only
utilize for the purport of embankment.

35% Household

30%

25%
Other Economic
Waste
20%
Construction and
15%
demolition
activity
10%
Energy and water
5% supply sectors
0%

Figure 1: Total waste generated per year

From the above chart it is clear that total waste generated from construction and demolition
activity is greater than other activity so now it is becoming a major environmental problem
also causing Air Pollution, Water Pollution and Land pollution. This Construction waste is

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Peer Reviewed and Refereed Journal, (ICMCSEH-2020)

debris for everyone now in this project we are using debris as a raw material for
manufacturing of RCA blocks.

Fly Ash (MILLION TONE)

Amount of Fly Ash (MILLION TONE) 335%
150% 215% 250% 290%
180%

2008 2010 2012 2014 2016 2018

Figure 2: Total Fly ash generated per year

From the above chart the fly ash generation is increasing in such a proportion that it will
not be possible for the Cement industry along to utilize the all fly ash. In this project we are
using this Fly Ash as Raw material for Fly ash Blocks and Fly Ash bricks.

Table 1: Production rate of Brick and Concrete in different countries

SR. NO Country Brick Concrete production in
production % (million metric tons) in 2019
1 China 66.6 2200
2 India 13.33 320
3 Vietnam 1.67 95
4 United States 0.53 89
5 Egypt 0.49 76
6 Indonesia 0.34 74
7 Iran 0.24 60

From the table 1 it is clear that how large amount of brick and concrete is manufacturing
around the world and day by day their demands are increasing the debris of bricks and
concrete is now a very big challenge for the entire world in this project we discussed how to
use this debris for manufacturing of RCA blocks and by seeing the demand of clay brick if
fly ash brick is provided then same job will be done with fly ash brick in a more better way
compare to clay bricks with helping the nature also by using the fly ash which is just a
waste.

3. MATERIALS AND METHODOLOGY

1. Cement- Cement may be a material which has cohesive and cement properties
within the nearness of water. Cement was concocted by Joseph Aspdin of UK in
1824. Conventional Portland cement is utilized in this extend. Based on fabricating
Portland cement is classified as OPC 33 review (utilized agreeing to the direction IS:
269-2015), 43 review (utilized agreeing to the direction IS: 8112-1989) and 53 review
(utilized agreeing to the direction IS: 12269-1987). The stacking and storage of
cement as per IS 4082: 1996
2. Aggregate- stream total (aggregate) passing through 4.75mm and held on 7.5
micron. Two sorts of coarse total; (passing through 7.55mm and held on 4.75
micron) Total is the materials fundamentally utilized as fillers with folio fabric within
the generation of mortar and concrete. Total extending from 80 mm – 4.75 mm are
called Coarse Total whereas those are passing from 4.75 mm sifter are fine totals.
Quartz sand (0–5 mm), fine rock (6–12 mm), and rock (11–22 mm) were used.
Standard sand for testing is get As per IS 456: 2000 cl 5.3.3.

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 INTERNATIONAL JOURNAL OF INNOVATION IN ENGINEERING RESEARCH & MANAGEMENT ISSN: 2348-4918
Peer Reviewed and Refereed Journal, (ICMCSEH-2020)

3. Recycle concrete Aggregate (R.C.A.)- Recycled concrete aggregate; grain sizes

10mm,12mm and 25/20mm. Recycled aggregate fraction (11–22 mm) was used,
coming from a recycling plant in which rubble from concrete structure demolition is
suitably treated. The substance in reused concrete division of chlorides, sulfates,
and natural materials were assessed agreeing to the strategies suggested by UNI EN
1744-1 and the nearness of alkali-silica responsive materials agreeing to the
strategy prescribed by UNI EN 8520-22.
4. Fly ash- Fly ash is a waste material that gets accumulated in an immensely colossal
volume near the industries which causes environmental pollution. Thus the
utilization of fly ash as raw materials will not only grant a productive disposal of the
fly ash but withal avail to mitigate the pollution to a great extent. Henry et.al (2005)
intended to provide a solution to the fly ash disposal quandary by utilizing the fly
ash engendered from different sources. Fly ash bricks resulted in higher vigor due
to the process of carbonation which is caused by the absorption of carbon-di-oxide
from the atmosphere. This additionally results in the abbreviation of ecumenical
warming. The cement industry emits an abundance of CO2 along with high energy
consumption engender cement. To minimize these effects, the pozzolanic materials
such as fly ash may be utilized by superseding lime.

Figure 3: Flow Chart of the Project for RCA Block

Figure 4: Method of Concrete Debris Waste Treatment

The major ingredients required to produce a fly ash brick are fly ash, gypsum and quarry
dust with binding material lime and/or cement. Figure 5 shows the flowchart ingredients.

Figure 5: Flowchart shows the materials used in Fly ash Bricks

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Peer Reviewed and Refereed Journal, (ICMCSEH-2020)

Figure 6: Casting of brick in steel mould and curing brick after 14 days

Table 2: Comparison between composition of Fly Ash and cement used for making
block
Chemical Composition Percentage In fly ash Percentage of cement
used in RCA Block
Silica (SiO2) 38 - 63 17-25
Alumina (Al2O3) 27 - 44 3-8
Titanium dioxide (TiO2) 0.4 - 1.8 1- 3
Iron Oxide (Fe2O3) 3.3 – 6.4 0.5- 6
Manganese oxide (MnO) 0 – 0.5 0.5- 4
Calcium Oxide (CaO) 0.2 - 8 0 60-65
Magnesium Oxide (MgO) 01 – 0.5 0.5- 4
Sodium Oxide (Na2O) 0.07 – 0.43 0.22- 0.26
Loss of Ignition (LOI) 0.2 – 3.4 11.4 at 1000 °C
Specific Gravity 2.1-3 3.15
Standard density 540-860 kg/m3 1440 kg/m3
Unit weight 9.43 KN/m3 14.4 KN/m3
Tolerance <1% ∓2%

Table 3: Comparing the Physical Properties of RCA, Natural Aggregate and Fly Ash
Physical properties RCA value Natural Aggregate Fly Ash
value value
Specific Gravity 2.54 2.78 1.46-2.66
crushing value 28.91% 23.63% 25.86%
impact value 24.17% 20.73% 17.9%
Water absorption value 2.44% 0.69% 12%
Nominal Max size (mm) 20 20 O.045
Fineness Modulus 6.79 7.68 3.66
Bulk Density (kg-m-3) 1250 1200-1750 540-860
Porosity (vol. %) 5.03 1-2 1.5-2
Absorption (wt. %) 2.03 0.71 0.30
Moisture content (wt %) 1.57 2.5-3 25

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Peer Reviewed and Refereed Journal, (ICMCSEH-2020)

35
30
25
20
15
10
5
0
Specific crushing impact Water
Gravity value value absorption
value
Natural Aggregate R.C.A. Aggregate

35
30
25
20
15
10
5
0

RCA value Fly Ash value

Figure 7: Comparing the Physical Properties of RCA, Natural aggregate and Fly Ash

Figure 8: RCA concrete block

4. EXPERIMENT RESULT
Recycled concrete aggregate was produced by crushing of old concrete cubes used for
compressive strength testing and one precast reinforce concrete column, which had in
appropriate dimensions. The primary crushing was done with a pneumatic hammer and
secondary crushing was performed in a rotating crusher. The second concrete mix had 50%
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 INTERNATIONAL JOURNAL OF INNOVATION IN ENGINEERING RESEARCH & MANAGEMENT ISSN: 2348-4918
Peer Reviewed and Refereed Journal, (ICMCSEH-2020)

of natural river coarse aggregate and 50% of recycled coarse aggregate (R50). The third
concrete had 100% of recycled coarse aggregate (R100). As all the other variables were kept
constant, this research enabled us to determine the influence of the coarse recycled
aggregate amount (0%, 50% & 100%) on tested concrete properties. Concrete mix
proportions were calculated and shown in Table 4. Dried recycled aggregate, basic water
content and additional water quantity were used to achieve the required workability of RAC.

Table 4: Design Quantity of Component Material for RCA blocks

Material Cement Effective Agg. Additional Effective Total Bulk
Concert (Kg/M3) Water Kg/m3 Water W/C W/C Density
Mixture Kg/m3 Kg/m3 Kg/m3
RO 350 180 1857 1857 0.514 0.514 2.387
R50 350 180 1816 1816 0.514 0.569 2.365
R100 350 180 1776 1776 0.514 0.620 2.343

Table 5: Result of Compressive Test for RCA blocks

Tri Material Cemen Fine Natural RCA Compressive Strength
al Concret t% Aggregat Aggregate % (N/mm2)
No e e % 3 7 14 28
Mixture % day days days days
s
1. RO 20 0 80 0 10 12.5 16.5 18.56
2. RO 20 20 60 0 12 14 16 19
3. R50 15 15 35 35 9.8 12 16.2 19.2
4. R50 20 30 25 25 12 14.9 17.2 19.7
5. R100 20 20 0 60 11,1 14.5 16.5 18.9
6. R100 20 0 0 80 9.8 11.4 13.6 17.9

Fly ash bricks are prepared using seven different proportions. Among these seven
proportions, four different proportions were prepared without cement content but adding
hydride lime and gypsum as shown in table 6. Three bricks of each proportion were made
and tested to check their compressive strength. Table 7 shows the peak load and stresses
as achieved by testing these bricks made without cement.

Table 6: Design Quantity of Component Material for brick test without cement
content
Material Ratio of Material (%)
Name Experiment Experiment Experiment Experiment
1 2 3 4
Fly Ash 45 62.5 60 50
Sand/Stone 40 22.5 20 25
Dust
Hydride lime 10 10 15 20
Gypsum 5 5 5 5
Cement 0 0 0 0

Table 7: Result of Compressive Test of Fly ash brick (without Cement)

Experiment 1 Experiment 2 Experiment 3 Experiment 4
1 2 3 1 2 3 1 2 3 1 2 3
Peak Load 120 112 105 135 142 137 175 199 189 205 212 207
(KN)
Stress 6 5.6 5.25 6.75 7.1 6.85 8.75 9.95 9.45 10.25 10.60 10.35
(N/mm2 )
Average
Stress 5.61 6.90 9.38 10.40
(N/mm2 )

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Peer Reviewed and Refereed Journal, (ICMCSEH-2020)

From Table 7 it can be observed that the maximum stress and minimum stress generated
are 6 MPa and 5.25 MPa respectively by combination of fly-ash, quarry dust, hydride lime
and gypsum in experiment 1. The average stress being 5.61 MPa. Similarly from other
experiment it can conclude that the average stresses are varying according to changing
value of fly ash and hydride lime. If the percentage of fly ash is increased to 60% in
experiment 7 reducing the percentage of sand/stone dust to 20 % and a small percentage of
cement is reduced, the stress carrying capacity of the brick is increased to 11.04 Mpa.

Table 8: Design Quantity of Component Material for brick test with cement content
Ratio of Material (%)
Material Name Experiment Experiment Experiment
5 6 7
Fly Ash 47.5 50 60
Sand/Stone Dust 42.5 40 32
Hydride lime 0 0 0
Gypsum 0 0 0
Cement 10 10 8

Table 9: Result of Compressive Test Fly ash brick (with Cement)

Experiment 5 Experiment 6 Experiment 7
1 2 3 1 2 3 1 2 3
Peak Load (KN) 186 185.9 162.8 169.2 190.4 189.7 200 213.9 248.6
Stress (N/mm2 ) 9.3 9.29 8.1 8.46 9.52 9.49 10 10.69 12.43
Average Stress
8.9 9.15 11.04
(N/mm2 )

Stresses for different ratio of material

10.4 11.04
9.38 8.9 9.15
6.9
5.61

1 2 3 4 5 6 7

Figure 9: Comparison of mean stresses obtained from load test data

5. CONCLUSION
Here an attempt has been done to study the behavior of fly ash based bricks and RAC
blocks using different material proportion. In experiment result strength characteristics of
all type of block is shown above graphs and tables. Based on the results obtained from the
experimental study it can be concluded that, Fly ash based brick develop sufficient strength
using both the hydride lime and the cement as a binder material. By different trial ratios it
is observed that RCA block achieve less compressive strength compare to natural aggregate
block.
But RCA block (R50) shows better strength which is near to natural aggregate block.
Where using slug lime (cement) fly ash based bricks achieve more compressive strength
than hydride lime even if using fifty percent of fly ash. Also it can be concluded that with a
lesser percent of cement with 60% of fly ash a good strength of fly ash based brick can be
prepared.

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Peer Reviewed and Refereed Journal, (ICMCSEH-2020)

From financial point of view reused concrete and fly ash could be a construction
materials that the community does not go to pay for those who created the concrete
squander pay for charge to have it recycled. This RCA blocks can be used to build low
public toilets the construction cost will be very much less in compare to other concrete
blocks. With this RCA mix design we can build pavement tiles. The whole project is based
on 3-R Principal that is Reduced- Reuse- Recycles without harming our nature anymore.

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