Utilization of Ceramic Tiles Waste as a Partial Replacement of Fine Aggregate in Cement Mortar

Abstract

The rapid growth of the construction industry has led to an increased demand for building materials, particularly aggregates. The extraction of natural aggregates has significant environmental impacts, including landscape alteration and depletion of natural resources. Therefore, finding alternative materials for sustainable construction is essential. This project aims to investigate the potential utilization of ceramic tile waste as a partial replacement for fine aggregate in cement mortar. The research methodology involves collecting ceramic tile waste from local sources and conducting laboratory experiments to evaluate the physical and mechanical properties of cement mortar incorporating different percentages of ceramic tile waste. The properties investigated include workability, compressive strength, flexural strength, and water absorption capacity. The experimental results demonstrate that the addition of ceramic tile waste as a partial replacement for fine aggregate in cement mortar exhibits promising outcomes. The workability of the mortar is within an acceptable range for construction purposes, and the compressive and flexural strengths show satisfactory performance. Moreover, the water absorption capacity of the mortar reduces with an increase in the percentage of ceramic tile waste, indicating improved durability. This research contributes to the sustainable utilization of ceramic tile waste, reducing the environmental burden associated with waste disposal and conserving natural resources. The findings provide valuable insights into the feasibility of incorporating ceramic tile waste in cement mortar, potentially leading to the development of cost-effective and environmentally friendly construction materials.

Introduction

I. INTRODUCTION

The construction industry of India is an important indicator of the development as it creates investment opportunities across various related sectors with a share of around 8.2%, the construction industry has contributed an estimated ?670,778 crores (US$ 131 billion) to the national GDP.

According to the Building Material Promotion Council (BMPTC) India generates about 150 million tons of Construction and Demolition (C&D) waste annually, out of which India manages to recover and recycle only about 1% of it. There is no uniformity among cities to quantify and characterize C&D waste to know how and what to segregate. The source for such a waste may be increase in the population due to modernization, modification in the bye-laws, capacity of old road not being sufficient to accommodate the growing traffic and natural as well as man-made disaster. Furthermore, there is an increased demand for construction materials in housing as well as road development sectors.

Majority of the developing and developed nations assume that the C&D waste as nonhazardous, less toxic and inert materials which does not cause adverse effects to the environment. They are often dumped in land without any further treatment even though it leads to ill effects such as illegal dumping and land pollution. Further, this creates an additional burden on landfill spaces and increase in the transportation cost for their disposal. From the viewpoint of sustainable development, it is essential to prevent the over-use of natural resources and also make efforts towards waste reduction. Hence recycling of aggregates from demolition waste may serve as a solution to reduce the problems of demand-supply problems, decrease the burden of dumping and also preserving the natural resources. Mortar is a widely used construction material during any construction of a building. At the same time, it is not environmentally friendly because it destroys and uses up large quantities of natural resources.

River sand being one of the natural resources which is obtained from breaking of rocks is used as fine aggregate in mortar, but overuse of the material has led to depletion of secured sand deposits. It has a greater impact on environment because after its use, it is generally deposited in landfills.

As there is change in bylaws, road have been expanded, zones have been changed, decrease in margins, expansion of building which leads to overcrowding as older building being demolished and newer building are built where it generates a huge amount of waste.

Around rough estimation of 21,000 tons of ceramic waste is been generated throughout India and around 40,860 kg of ceramic waste is generated throughout Karnataka. In recent years, recycling of construction and demolition waste has made a greater potential and also a target of interest. It mainly focuses on waste management polices encouraging minimization, reuse, recycling, and valorization of the waste as opposed to its final disposal in landfills. We have to make a right choice and refuse wasteful and polluting products. Therefore, it is desirable to obtain cheap, environmentally friendly substitutes for river sand that are preferably by products. In order to reduce the burden of landfill space, to enrich human inhabitation, ceramic tile waste is extensively used as a partial replacement of fine aggregate in mortar and also improve its strength and other durability factors. Usage of non-conventional aggregate not only turns out to be environmentally friendly but also to be economic. Ceramic materials are the mixture of clay, powder and water shaping into desired forms. Ceramic wastes are the waste generated during the process of dressing and polishing which is of 30% of its production. A portion of this waste may be utilized on-site, such as for excavation pit refill. The disposals of these waste materials acquire large land areas and remain scattered all around, spoiling the aesthetic of the entire region. It is very difficult to find a use of ceramic waste produced as they are durable, hard and highly resistant to biological, chemical and physical degradation forces, is not recycled in any form at present. The rate of growth in waste has put pressure on the ceramic industries to find a solution for its disposal.

II. OBJECTIVE

1. The objective of this study to replace ceramic tile waste material with fine aggregate in mortar for its utilization.
2. To conduct basics tests on (cement, M-sand and ceramic waste sand) all the materials used in study
3. To replace the fine aggregates (M-sand) with various percentage of 25%, 50%, 75% ceramic waste in mortar
4. To assess the mechanical properties for mortar with the partial replacement of fine aggregate by ceramic waste
5. To find out water absorption and density for all the mixes.
6. To study the microstructural investigation on the material.
7. To conduct cost analysis.

III. LITERATURE REVIEW

1. G Saravana Kumar on [2016] had carried out a study on partial replacement of sand by ceramic waste in concrete. Sand being partially replaced by five percentages (10%, 20%, 30%, 40% and 50%) of ceramic waste by weight for M25 grade concrete. Compressive and tensile strength were determined for different periods of curing like 7, 14 and 28 days. The test results clearly shows that the ceramic waste can be used as a partial replacement of fine aggregate in concrete, however, higher the percentage of ceramic waste it reduces the strength of normal concrete. The tensile strength of 10%, 20%, 30% replacements at 14 days and compressive strength of 10% 20% shows the consistency in attaining the required range. Hence, replacement of river sand using 30% ceramic waste in M25 grade concrete gives the required strength and can be considered as optimum percentage.
2. Swathi DP on [7] [2020] had carried out study on concrete by partial replacement of sand with ceramic waste. Fine aggregate being partially replaced by four percentages (10%, 20%, 30% and 40%) of ceramic waste by weight in M20 grade concrete. They were tested on different periods of curing like 3, 7 and 28 days to obtain compressive and tensile strength. She observed that, increase in the percentage of ceramic as a replacement for sand results in increasing the compressive strength up to 30% from the graph. So, she clearly said that, further increase in ceramic percentage beyond 30% results in gradual decrease in strength. For 28 days, there is an increase in tensile strength of concrete with addition of 10% ceramic is about 41.4%, concrete with addition of 20% ceramic is about 61.42%, and concrete with addition of 30% ceramic is about 51.42%. Hence, ceramic waste can be used for M20 grade concrete up to 30% replacement.
3. Murlidharan T on [4] [2018] had carried out a study on partial replacement of fine aggregate in concrete using ceramic wastes. Fine aggregate being partially replaced by four percentages (15%, 20%, 25% and 30%) of ceramic waste by weight for M25 grade concrete. Compressive and tensile strength was determined for different periods of curing like 7, 14 and 28 days. The test results clearly shows that the ceramic waste can be used as a partial replacement of fine aggregate in concrete, however, higher the percentage of ceramic waste it reduces the strength of normal concrete. The tensile strength of 15%, 20%, 25%, 30% replacements at 14 days and compressive strength of 15%, 20% shows the consistency in attaining the required range. Hence, replacement of river sand using 30% ceramic waste in M25 grade concrete gives the required strength and can be considered as optimum percentage
4. Mostafa Samadi on [9] [2014] had carried out study a on effects of ceramic powder on mortar by using ceramic waste as cement replacement. Use of finer ceramic waste by four percentage (10%, 20%, 30%, 40%) by weight. Compressive strength was determined for different periods of curing like 7, 14 and 28 days. The results clearly shows that use of finer ceramic powder at 20% replacement of cement was found to produce the highest compressive strength at all ages of testing. This shows that the ceramic waste in the form of fine powder will act as pozzolanic material that can enhance the performance of mortar. The use of ceramic waste to some extend will reduce the landfill and environmental problems.

IV. MATERIALS

A. Cement

Cement may be prescribed as material with adhesive and cohesive properties which make it capable of bonding material fragments into a compact whole. The most commonly used cement in construction today is Portland cement and hence for experimental study we used Ordinary Portland Cement of 53 grade. The cement according to the Indian specification must satisfy the IS code IS:4031(part 1- 6). Material is procured from shop.

Physical Properties of Cement Different blends of cement used in construction are characterized by their physical properties. Some key parameters control the quality of cement. The physical properties of good cement are based on:

1. Fineness of cement
2. Soundness
3. Consistency
4. Strength
5. Setting time
6. Heat of hydration
7. Loss of ignition
8. Bulk density
9. Specific gravity (Relative density)

These physical properties are discussed in details in the following segment. Also, you will find the test names associated with these physical properties

Properties of Fine Aggregates

While making the selection for appropriate aggregates to be used in particular concrete mix, few properties need to be considered, such as:

1. Void content.
2. Shape and texture.
3. Absorption and surface moisture
4. Abrasion and skid resistance.
5. Grading Zone of Fine Aggregate

Fine aggregate passes through sieve of 4.75 mm is used for the experimental use. The purpose of the fine aggregate is to fill the voids in the coarse aggregate and to act as a workability agent. The M sand, according to the Indian specification must satisfy the IS code IS:2386 -part 2. For the studies the M sand of Zone-II is used in all the references. M sand is procured from local site.

A good concrete mix must include aggregates that are clean, hard, strong and free of absorbed chemicals or coatings of clay and other fine materials. Ignorance of these characteristics can cause the deterioration of concrete, thus regulatory authorities have decided grading zone of fine aggregate, where each zone defines the percentage of fine aggregate passed from the 600 microns sieve size:

Zone I: 15% to 34%

Zone II: 34% to 59%     

Zone III: 60% to 79%

Zone IV: 80% to 100%

You can assess the quality of fine aggregate with help of the grading zones. However, for precise assessment, you can seek help from experts who are well versed in performing tests for bulk density, bulkage, and specific gravity to find the best in class      material.

C. Ceramic

Ceramic material is an inorganic, non-metallic oxide, nitride, or carbide material. Some elements, such as carbon or silicon, may be considered ceramics. Ceramic materials are brittle, hard, strong in compression, and weak in shearing and tension. They withstand chemical erosion that occurs in other materials subjected to acidic or caustic environments. Ceramics generally can withstand very high temperatures, ranging from 1,000 °C to 1,600 °C (1,800 °F to 3,000 °F).

The crystallinity of ceramic materials varies widely. Most often, fired ceramics are either vitrified or semi-vitrified as is the case with earthenware, stoneware, and porcelain. Varying crystallinity and electron composition in the ionic and covalent bonds cause most ceramic materials to be good thermal and electrical insulators (researched in ceramic engineering). With such a large range of possible options for the composition/structure of a ceramic (nearly all of the elements, nearly all types of bonding, and all levels of crystallinity), the breadth of the subject is vast, and identifiable attributes (hardness, toughness, electrical conductivity) are difficult to specify for the group as a whole. General properties such as high melting temperature, high hardness, poor conductivity, high moduli of elasticity, chemical resistance and low ductility are the norm, [8] with known exceptions to each of these rules (piezoelectric ceramics, glass transition temperature, superconductive ceramics). Many composites, such as fiberglass and carbon fiber, while containing ceramic materials are not considered to be part of the ceramic family. [9]

Highly oriented crystalline ceramic materials are not amenable to a great range of processing. Methods for dealing with them tend to fall into one of two categories – either make the ceramic in the desired shape, by reaction in situ, or by "forming" powders into the desired shape, and then sintering to form a solid body. Ceramic forming techniques include shaping by hand (sometimes including a rotation process called "throwing"), slip casting, tape casting (used for making very thin ceramic capacitors), injection moulding, dry pressing, and other variations.

The principle waste coming into the ceramic industry is the ceramic powder, specifically in the powder forms. Ceramic wastes are generated as a waste during the process of dressing and polishing. It is estimated that 15 to 30% waste are produced of total raw material used, and although a portion of this waste may be utilized on-site, such as for excavation pit refill, The disposals of these waste materials acquire large land areas and remain scattered all around, spoiling the aesthetic of the entire region. It is very difficult to find a use of ceramic waste produced. Ceramic waste can be used in concrete to improve its strength and other durability factors. Ceramic waste can be used as a partial replacement of cement or as a partial replacement of fine aggregate sand as a supplementary addition to achieve different properties of concrete. Ceramic tile waste is procured from local site. Obtained ceramic tile waste is crushed by UTM and sieved through sieve 4.75mm and used as replacement of sand.

Table 4.1 Composition of ceramic

D. Water

Water is one of the most important elements in construction and is required for the preparation of mortar, mixing of cement concrete and for curing work etc. The quality of water used has a direct impact on the strength of the motor and cement concrete in the construction work. The water used for curing and mixing must be free from high quantities of alkalis, acid, oils, salt, sugar, organic materials, vegetable growth, etc. that might be deleterious to bricks, concrete or iron.

Impurities in water can cause metal corrosion, introduce unwanted silt and clay into the concrete, adversely affect the hardening process of concrete and also reduce the strength by even 25%. Thus, the need to ensure the quality of water used during construction is vital.

IS 456:2000 standards lays certain parameters for which quality of water must be tested. In     the same lines, we have in

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Conclusion

1) The test results show clearly that the ceramic waste can be used as replacement materials for m-sand in mortar. 2) The mortar with 25% replacement of ceramic tiles has the compressive strength compared to the control mix. However, higher the percentage addition of ceramic waste reduces the strength of normal mortar. 3) The mortar with 25% replacement of ceramic tiles has optimum water absorption compared to 50% and 75% replacement of ceramic tiles. 4) The mortar with 25% of replacement of ceramic tiles has high density. Density decreases with increase in ceramic content. A. Further Study 1) So according to this research work, sand is replaced by ceramic waste also further investigation is required for that this replacement to find exact percentage replacement limit in future utilization. 2) In future it can be increase in the percentage of replacement of ceramic material as ceramic also possess pozzolanic properties. 3) In the concrete ceramic replace by performing of mechanical properties and durability test that is water absorption and penetration test, but for the confirmation of that replacement other durability test i.e., acid attack test, chloride attack test, carbonation test and micro-structure study are required. 4) Ceramic can be added in other percentage for concrete for different water cement ratio. Ceramic waste can be used in mortar cubes and check the properties. Investigation on behavior of concrete in structural applications. Fatigue resistance of concrete can be studied. Applications of these concrete in road works may be explored. Flexural strength and other workability and durability studies can be undertaken.

References

[1] Hemanth kumaret al- Effect of Waste Ceramic Tiles in Partial Replacement of Coarse and Fine Aggregate of Concrete, International Advanced Research Journal in Science, Engineering and Technology Vol. 2, Issue 6, June 2015 ISSN (Online) 2393-8021 ISSN (Print) 2394-1588 [2] IS 4031 - 1(1996) : Methods of physical tests for hydraulic cement , part 1-6 (CED 2: cement and concrete) [3] IS 2386 -1 (1963) : Methods of test for aggregates for concrete, part1 : particles size and shape (CED 2:cement and concrete) [4] M. Veera Reddy, Investigations on Stone Dust and Ceramic Scrap as Aggregate Replacement In Concrete, Int. J. Civil Struct. Engin., 1(3), 661-666 (2010). [5] G. Shivaprakash, Experimental study on partial replacement of sand by ceramic waste in concrete, Int. J. Chem. Sci.: 14(S1), 2016, 266-274 ISSN 0972-768X. [6] Rashmi rawat, investigation of ceramic waste as supplementary cementitious material in concrete, International Journal of Applied Engineering Research ISSN 0973-4562 Volume 14, Number 9, 2019 (Special Issue) © Research India Publications. [7] Ahmed, A. E. and EI. Kourd A. A. ( 1989), ‘Properties of concrete incorporating natural sand and crushed stone very fine sand’, American Concrete Journal, 86(4), 417-424 [8] Parminder Singh and Dr. Rakesh Kumar Singla- Utilization Of Waste Ceramic Tiles As Coarse Aggregate In Concrete, Journal of Multidisciplinary Engineering Science and Technology (JMEST) ISSN: 3159-0040 Vol. 2 Issue 11, November – 2015. [9] C. Karthik and S. Ramesh Kumar, “Experimental Investigation on Concrete with Ceramic Waste as A Partial Replacement of Fine Aggregate” (2016)

Copyright

Copyright © 2023 Sumanth C, Mahendra K R, Yashwanth H B, Nikil H, Arun Kumar B R, Uma A. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.