Feasibility Study Of Mechanical Properties Of

Concrete Utilizing Industrial Waste- Dolochar

A report submitted in partial fulfillment of the

requirementsfor the degree of

BACHELOR OF TECHNOLGY IN CIVIL ENGINEERING

by

MURAD SEID-1801158
TEMESGEN BELETE-1801159
ABEL TEFERA-1801162

Supervisor
Prof. Ipsita Mohanty

School of Civil Engineering

Kalinga Institute of Industrial Technology
Deemed to be University
Bhubaneswar, 751024

April 2022
 CERTIFICATE

This is to certify that the project report entitled “Feasibility Study Of Mechanical Properties
Of Concrete Utilizing Industrial Waste- Dolochar” submitted by

Murad Seid 1801158

Temesgen Belete 1801159
Abel Tefera 1801162

in partial fulfilment of the requirements for the award of the Degree of Bachelor of Technology in
Civil Engineering is a bonafide record of the work carried out under my guidance and supervision
at School of Civil Engineering, KIIT (Deemed to be University).

Signature of Supervisor
School of Civil Engineering
KIIT (Deemed to be University)

The Project was evaluated by us on _____________

EXAMINER 1 EXAMINER 2

EXAMINER 3 EXAMINER 4
 DECLARATION

We, Murad Seid, Abel Tefera, Temesgen Belete, do hereby declare that
the thesis entitled, "Feasibility Study Of Mechanical Properties Of Concrete
Utilizing Industrial Waste- Dolochar" being submitted to KIIT Deemed to be
University, Bhubaneswar, Odisha; for the award of the degree of Bachelor of
Technology in Civil Engineering, is an original piece of work done by us and the
same has not submitted for any other academic degree or diploms to this
University or any other Institute Universities. Previous work in this field has been
reviewed and mentioned wherever necessary with due acknowledgement.

Signature of the Student

Name: Murad Seid Roll No. 1801158

Temesgen Belete : 1801159
Abel Tefera : 1801162

School of Civil Engineering

KIIT Deemed to be University, Bhubaneswar
 ACKNOWLEDGEMENT

We express our heartfelt gratitude and modest appreciation to Prof. (Ipsita Mohanty) for her
tremendous guidance, wholehearted cooperation, constructive criticism, and constant support
during the writing of this thesis. The current project would have remained a dream without her
help and leadership.
Prof. Ipsita Mohanty, Project Coordinator, Prof. P. C. Saha, Overall UG Project Coordinator,
Prof. S. Moulick, B.Tech Program Head, and Prof. B.G. Mohapatra, Director, School of Civil
Engineering, KIIT Deemed to be University, are also to be thanked for their innovative ideas
and provision of necessary resources.
We'd want to take this occasion to express our gratitude to all of my academic friends and
family for their unwavering support and encouragement as we worked on this project. We also
want to express our gratitude to everyone. We also want to express our gratitude to everyone
who has contributed to the accomplishment of this project, whether directly or indirectly.

April 2022,
KIIT (Deemed to be University), Bhubaneswar
 ABSRTACT

The replacement of cement with industrial by-products can reduce the usage of energy sources,
carbon dioxide emissions, and natural resources which ease the impact of pollution on the
environment. Currently, a large amount of Dolochar is generated in industries. The
advancement regarding the replacement of cement with industrial by-products indicated that
the use of substitutes cementation materials such as silica fume, blast furnace slag, fly ash, rice
husk, etc. can improve the properties of concrete while increasing the strength of concrete. The
main focus of this research work is to investigate the effect and possibility of utilizing Dolochar
as a partial replacement for cement. The setting behavior, flow-ability, and workability
characteristics of past made by partial replacement of cement with Dolochar are studied. Along
with this, the compressive strength of concrete is also studied. Based on the findings, it has
been confirmed that replacing cement in M30 concrete with Dolochar at 5%, 10%, and 15%
gives better strength than ordinary concrete. When compared to 10% and 15% replacement,
20% replacement yielded inferior results, indicating that more replacement yields lower
strength. Cement and Dolochar mortar revealed that cement and Dolochar had less chemical
interaction. Dolochar may be used as fine aggregate or coarse aggregate, and because it
contains a large quantity of silica, it improves the strength of concrete.

Keywords: Dolochar, Cement replacement, Industrial Waste, Industrial Steel Slag,

Compressive Strength, Tensile Strength
TABLE OF CONTENETS

CERTIFICATE .......................................................................................................................... 2
DECLARATION ....................................................................................................................... 3
ACKNOWLEDGEMENT ......................................................................................................... 4
ABSRTACT ................................................................................................................................... 5
TABLE OF CONTENETS................................................................................................................ 6
LIST OF TABLES ........................................................................................................................... 8
LIST OF FIGURES ......................................................................................................................... 9
ABBRIVATION ........................................................................................................................... 10
CHAPTER 1 ............................................................................................................................... 11
Introduction ............................................................................................................................. 11
1.1 General ........................................................................................................................... 11
1.2 OBJECTIVE OF PRESENT STUDY ...................................................................................... 13
CHAPTER 2 ............................................................................................................................... 14
2.1 LITERATURE REVIEW ...................................................................................................... 14
CHAPTER 3 ............................................................................................................................... 23
3. Materials .............................................................................................................................. 23
3.1 CEMENT.......................................................................................................................... 23
3.2. AGGREGATES ................................................................................................................ 24
3.2.1 Fine aggregate......................................................................................................... 24
3.2.2 Coarse Aggregate .................................................................................................... 25
3.3 DOLOCHAR ..................................................................................................................... 27
3.4 WATER............................................................................................................................ 28
3.5 FINENESS OF CEMENT AND DOLOCHAR ........................................................................ 28
3.6 Setting Time ................................................................................................................... 29
3.6.1 Initial setting Time .................................................................................................. 30
3.6.2 Final Setting Time.................................................................................................... 31
3.7 Consistency of dolochar ................................................................................................. 31
CHAPTER 4 ............................................................................................................................... 32
METHODOLOGY ....................................................................................................................... 32
4.1 MIX DESIGN OF CONCRETE ............................................................................................ 32
4.2 CASTING FOR CEMENT DOLOCHAR MORTAR ................................................................ 36
 4.3 CONCRETE CASTING ....................................................................................................... 37
4.4 CURING........................................................................................................................... 38
4.5 TESTING SPECIMENS ...................................................................................................... 39
Chapter 5 ................................................................................................................................. 40
5. Results and Discussion ......................................................................................................... 40
5.1 Compressive strength of concrete ................................................................................. 40
5.2 tensile strength of concrete ........................................................................................... 43
5.3 Economic Analysis of Concrete with Replacement of Cement with Dolochar .............. 44
5.3 Conclusion ...................................................................................................................... 44
5.4 Societal Impact ............................................................................................................... 45
Reference ................................................................................................................................. 46
LIST OF TABLES
Table 3.1 physical property of fine aggregate

Table 3.2 Physical Properties of Coarse Aggregate

Table 3.3 Physical properties of Dolochar

Table 3.4 Chemical composition of Dolochar

Table 4.1 Volumes of Mix Components

Table 5.1 compressive strength of mortar

Table 5.2 compressive strength of concrete

Table 5.3 Tensile Strength of Concrete

Table 5.4 Economic analysis of Dolochar

LIST OF FIGURES
Fig 1.1 Mineral map of Odisha

Fig 1.1 Industrial map of India and Odisha

Fig 3.1 OPC 53 grade cement

Fig 3.2 Fine aggregate

Fig 3.3 Coarse Aggregate

Fig 3.4 Grinded dolochar

Fig 3.5 90-micron sieve

Fig 3.6 vicart apparatus

Fig 3.7 initial setting time testing sample

Fig 3.8 final setting time test sample

Fig 4.1 remoulded mortar sample

Fig 4.2 Casting and remoulding of cubes

Fig4.3 curing of concrete and mortar sample

Fig4.4 Testing of mortar Fig 4.5 testing of concrete

Fig 5.1 Compressive Testing Machine testing

Fig 5.2, 7-day compressive strength of mortar

Fig 5.2, 7-day compressive strength of concrete

ABBRIVATION
SMS Steel Melting Shop
TPY Tonnes Per Year
DRI Direct Reduction of Iron
SF Silica Fume
GGBFS Ground Granulated Blast Furnace Slag
RHA Rice Husk Ash
WTE Waste To Energy
MSW Municipal solid waste
PAC Poly Ammonium Chloride
HPC High-Performance Concrete
FA Fly Ash
MD Marble Dust
SDA Sawdust Ash
OPC Ordinary Portland Cement
 CHAPTER 1
Introduction

1.1 General

Industrial waste has become a serious problem as a result of rapid

industrialization, urbanization, and an increase in people's living standards. Industrialization
was and continues to be a necessity for emerging countries to achieve self-sufficiency and boost
their economies. On the other hand, the industry has contributed significantly to pollution
problems. As a result, it appears as though waste disposal is an unintended consequence of
development. The majority of industries are environmentally unfriendly and generate
hazardous chemical waste, endangering the planet's biodiversity. The primary generators of
industrial solid waste are thermal power plants that generate coal ash, integrated iron and steel
mills that generate blast furnace slag and steel melting slag, nonferrous industries that generate
red mud and tailings, sugar industries that generate press mud, pulp, and paper industries that
generate lime and fertilizer, and allied industries that generate gypsum. The steel industry's
most common wastes include Dolochar, coke and coal dust, BF slag, SMS (Steel Melting Shop)
slag, mill scale, scrap, oil sludge, fly ash, acid sludge, refractory wastes, and other solid wastes.

Iron ore is abundant in the predominantly tribal districts of Orissa, a mineral-rich state. Apart
from iron ore, which accounts for 32.9 percent of the country's reserves, the country also has
coal and manganese deposits, accounting for 26 percent and 67.6 percent, respectively. Around
98 percent of the country's proven chromite (chromium ore) reserves are concentrated in the
Sukinda Valley, which spans approximately 200 square kilometers in the Jaipur region and is
used to manufacture iron-chromium alloys (ferroalloys). The state has the fourth-largest
bauxite reserves in the world, with a total deposit of 1805 million tonnes, accounting for
approximately 58% of the country's total bauxite reserves. India is home to 120 manufacturers
of sponge iron, 650 micro blast furnaces, and 1,200 rollers. In Odisha, India, it is estimated that
146 rotary kilns are in operation. These kilns are capable of producing 16000 tonnes of sponge
iron per day (TPD), and the resulting Dolochar is approximately 3.8 million tonnes per year
(TPA).

For industries to support sustainable industrialization and development, sustainable solid waste
management has become vital. Diverse industries, including steel and mining, are attempting
to repurpose created wastes for development (value-added) initiatives and foster a circular
economy, which could benefit both the industrial sector and human society. Based on their
physical and chemical features, the construction industry, among others, has the potential to
employ these solid wastes as raw materials for several applications. These wastes contain
considerable amounts of alumina (Al2O3), silica (SiO2), or both, which could be utilized as a
place of cement in the manufacturing process. The most often created aluminosilicate/siliceous
wastes by companies and facilities are Dolochar, silica fume, GGBFS, fly ash, rice husk ash
(RHA), and sludge (water purification plant), ferrochrome ash and slag, LD slag, and mine
tailings & overburden.

Dolochar is a by-product of the sponge iron manufacturing method of direct reduction of iron
(DRI). To make 100 t of sponge iron, you'll need 154 t of iron ore (65% Fe) and 120 t of B
grade coal. This operation generates around 45 t of solid waste, of which 25 t is char (also
known as Dolochar). The sponge iron industries rely on low-quality (F grade) coal containing
more than 40% ash because of a paucity of excellent grade coal. As a result, the amount of raw
materials required per tonne of product is higher than necessary, resulting in waste. In Odisha,
India, there are an estimated 146 rotary kilns in use. These kilns have a combined sponge iron
production capability of 16,000 tonnes per day (TPD) and a Dolochar output of roughly 3.8
million tonnes per year (TPA). The problem of Dolochar generation is exorbitantly enormous
due to the sponge iron manufacturing industry's reliance on low-quality coal. The issue of how
to get rid of such a large sum of money is significant. Dolochar has been the subject of
numerous investigations to assess its mechanical and technical qualities, as well as its eligibility
for usage as a cementation ingredient in concrete.
To date, the Dolochar generated has been deposited in nearby dumpsites or utilized for
landfilling, with little care for both the impact on the water and soil environment. The char
created may contain harmful compounds that, if leached, might pose a significant
environmental threat. In cement, concrete, and other construction materials such as road
construction, waste materials are gaining favor as a replacement for construction materials.
They not only lower the cost of cement and concrete production, but they also have some side
effects, such as lower land-fill costs, energy savings, and environmental preservation.
 Fig 1.1 mineral map of Odisha Fig 1.2 industrial map of Odisha
Dolochar is used to predict their impact on expanding soil engineering features and strength
parameters. Waste materials are becoming more popular as a substitute for natural materials
in cement, concrete, and other construction materials such as road construction. Not only
because they lower the cost of cement and concrete production, but also because they provide
numerous indirect benefits such as lower land-fill costs, energy savings, and environmental
protection.

1.2 OBJECTIVE OF PRESENT STUDY

1. To study the nature and re usability features of Dolochar in construction industries.

2. To study the physical properties of Dolochar.
3. To prepare the mix design.
4. To study about the effect of Dolochar on mechanical properties of conventional concrete
partially replacing OPC, as compared to the standard IS code specifications for OPC concrete.
5. To achieve minimum strength between 30-40MPa, by partially replacing Dolochar with
OPC.
6. analysis and comparison of the cost between OPC concrete and Dolochar as a partial
replacement of OPC concrete.
 CHAPTER 2

2.1 LITERATURE REVIEW

Tao Luo, et. al (2022) investigated the mechanical characteristics and microstructure of
hardened concrete. The addition of SF (silica fume) or HSF (high purity silica fume)
increased the splitting tensile strength of concrete and cubic compressive strength by 26.7
percent. The cost of concrete per cubic meter was increased by only 5.3 percent.

Aegula Shravan Kumar and R. Gopi (2022) The purpose of this study is to investigate the
use of rice husk ash as a partial replacement for cement in the manufacture of paver blocks.
This work employs a water-to-cement ratio of 0.4 and a superplasticizer derived from
naphtha The mix design was created per IS 10262-2009. RHA has been used to partially
replace cement in various types of concrete mixes at concentrations of 0%, 5%, 10%, 15%,
and 20%. According to the study, a 10% RHA substitution improves both strength and
durability.

Akhil S. Raju, et. al (2021) The addition of waste LCD glass powder to concrete increases
its fresh, toughened, and durability qualities greatly. The ideal degree of substitution of waste
LCD glass powder for cement, according to the strength test findings, is a 5% substitution of
waste LCD glass powder for cement. After 7 days, 28 days, and 56 days, concrete with 5%
cement substitution has the best chloride ion penetration and sorptivity, whereas concrete
with 20% partial replacement with LCD glass powder has the best sulfate resistance and acid
attack.

Gowram Iswarya and Beulah M (2021) These studies investigated the feasibility of
incorporating a variety of different cement constituents into concrete. Further mixing reduces
certain concrete properties such as workability, water penetration, freeze-thaw resistance, and
drying shrinkage. When the correct curing and material selection are combined to create a
binder in a variety of mixing proportions and with a variety of W/C ratios, the mechanical
properties and durability are significantly improved. There are two possible paths to more
environmentally friendly concrete: green concrete production and recycling waste materials
from other industries. Both of these paths could result in the development of more
environmentally friendly concrete for buildings.
R.S. Krishna, et. al (2020) Through the use of case studies, the study intended to provide
important insight into the steel and mining industries' present industrial waste management
strategies. The purpose of this study is to examine waste management solutions used by
industries such as iron and steel and mining to promote environmentally friendly practices
and environmental sustainability in the construction sector, more specifically in geopolymer
concrete. Fly ash, Dolochar, and steel slag together account for a sizable portion of the steel
industry's waste.

Suchita Rai, et. al (2020) The purpose of this report is to highlight the efforts of researchers
worldwide to incorporate red mud into the building and construction industry. Geopolymers,
bricks, clay materials, cement, slag treatment, ceramics, fillers, and road construction are
among the building and construction sub-applications reported in this study. They concluded
that full utilisation of red mud remains a global issue, as there is a significant gap between red
mud production and consumption at the current level of technology and practice. Building
and construction are both effective ways to deal with large amounts of red mud. Numerous
applications for large quantities of red mud include road construction, brick production,
cement, and concrete production, geopolymers and ceramics production, and soil
stabilisation.

Charles Rajesh Kumar, et. al (2019) The purpose of this study is to demonstrate the
country's waste to energy (WTE) potential, including possible technologies, job, and
commercial prospects, and environmental impact. In 2018, India produced more than 62
million metric tonnes (MTs) of trash per year, with that number anticipated to rise to 165
million MTs by 2031 and 436 million MTs by 2050. Municipal solid waste (MSW) has a
WTE potential of roughly 2.554 GW, whereas urban and industrial wastes have a WTE
potential of about 1.683 GW. Waste management has several benefits, including reduced
greenhouse gas emissions, waste reduction, revenue from energy sales, and waste material
reuse.

Junaid Mansoor, et. al (2018) The goal of this study is to assess the effectiveness of
industrial byproducts such as silica fumes (SF), ground granulated blast furnace slag
(GGBFS), and marble powder (MP) in the production of SCC. It was determined that adding
SF induction to the concrete mix improved the concrete's base mechanical characteristics.
The best quantity of SF content for elevating and augmenting flexural and compressive
strengths was discovered to be between 20% and 25% in this investigation. Because of the
water/cement ratio (w/c = 0.40), the workability of fresh concrete (SF-based) was
outstanding. All mixtures, particularly those containing MP, have high penetration and flow
capabilities, according to the V-funnel and J-ring tests. The compressive, flexural split tensile
and strengths of the GGBFS-based SCC mix are higher than those of MP and SF-based SCC.
When discarded marble powder, which amounts to around 25% of the total weight of cement,
is added to sample cylinders, the split tensile strength improves. Any additional MP addition
reduces the split tensile strength of sample cylinders. Additionally, when we tested heated
concrete samples and compared them to sun-dried concrete samples, we discovered
significant differences in the strength of the concrete.

Dr Kalpataru Rout, et. al (2018) The most efficient approach to employ blast furnace
sludge in the manufacturing of iron sinter was covered in this article. Sludge from blast
furnaces (up to 5%) can be recycled without affecting the sinter characteristics required for
BF operation. Due to the presence of hematite and carbon in this waste and its low alkali
content, it can be combined with iron fines to form a sinter. Following treatment with Poly
Ammonium Chloride (PAC), the discharged sludge effluent can be used economically. When
compared to the cost of the water as an input, the price evaluation module saves 60% of the
cost. In some cases, PAC-treated sludge can be used to make sinter. Waste management has
two primary national objectives: first, converting waste into riches through the recovery of
valuables; and second, minimising the negative environmental impact of waste generation.
This research endeavours to accomplish that goal.

Pravin Kumar Kar, et. al (2018) The goal of this article was to explain how solid waste
created at the Rourkela steel industry in Odisha could be recycled and reused. This study
examines the issues surrounding solid waste generation at the Rourkela Steel Plant in Odisha,
including volume, toxicity, barriers, and initiatives to recycle and responsibly utilise garbage.
The Rourkela Steel Plant generated granulated BF Slag, BF Slag, gas cleaning systems,
sludge from sintering, flue dust, fly ash, coke breeze, mill scale, waste refractories, and
lime/dolomite dust as its principal solid wastes. They recommended the following approaches
for reducing solid waste production in the Indian steel sector: identifying the sources,
characteristics, and types of solid waste generated during the steelmaking process. The
factors that contribute to the generation of solid waste. Utilization of cutting-edge and
innovative technology in order to minimise waste while maintaining economic viability.
Developing technology that prioritises cost-effective products based on superior waste
processing and product differentiation is a difficult task.

Yasodha, T, et. al (2018) The focus of this research is to develop ecologically acceptable
building and construction materials by recycling and reusing industrial and agricultural waste
materials. He claimed that by using waste glass, he was able to boost strength while lowering
the C/B ratio. To manufacture acceptable quality bricks in an industrial setting, waste glass
can be added to the mix at a rate of 10% to 15% by mass. When water treatment sludge and
wastewater were added to clay bricks, potential advantages were revealed. The use of
agricultural wastes like husks/grounds, coffee, and sugar cane bagasse as clay brick
alternatives is being researched.

Dr. Kalpataru Rout and Jayanta Sarita Pradhan (2017) This paper is concerned with
waste reuse for long-term development and growth. Granulated blast furnace slag is a glassy
aggregate used for the production of pozzolanic cement as a raw material. Though, because
BOF granulated slag has a much more crystalline and less glassy phase than BF slag, it has a
limited scope as a pozzolanic cement. As a consequence, other techniques of reuse are being
researched or implemented. The present topic has been chosen to look at the possibility of
repurposing BOF slag as a flux in sinter. Around 10% of the BOF slag produced is used,
resulting in a noticeable increase in flux and iron ore. BOF slag, on the other hand, may be
utilised as aggregates because of its high Mohr's Scale of Hardness (6 – Orthoclase and 7 –
Quartz).

Manpreet Singh, et. al (2017) Using ingeniously developed equipment, the impacts of
marble slurry on the hydration process, fresh and hardened concrete characteristics, and
durability features are explored. The replacement proportions for the marble slurry were kept
at ten percent, fifteen percent, twenty percent, and twenty-five percent. Experimental trials on
reinforced concrete with dried marble slurry, as well as the influence of particle size on
compressive strength, are also carried out. On the characteristics of cement pastes, there is no
visible influence. When a specified percentage replacement is employed, drying shrinkage is
minimised and mortar strength is increased. Marble slurry has been proven to have a filling
effect on concrete, causing it to become denser and more consistent in structure. It was
determined that up to 15percent of total the water in concrete might be replaced with dry
marble slurry and increase the mechanical properties. Ultrasonic pulse velocity and durability
tests show that the quality of concrete increases.

Dima M. Kannan, et. al (2017) High-performance concrete (HPC) mixes incorporating 10–
40percentage CWP (ceramic waste powder) as a mass substitute for Portland cement were
investigated. CWP is fine-particle-size-distributed silica and alumina-rich substance. When
contrast to cement without CWP, the addition of CWP had no obvious influence on cement
hydration.

B. N. Roy (2016) pollution and Waste management in steel factories were summarised in this
article. To minimize the negative effect of steel plant solid waste on Mother Earth, this waste
management paper emphasises continual waste reduction, recycling, and reuse. Enhancing
operational processes is one way to do this. Waste reduction may be considerably improved.
The following is a summary of the review's conclusion: The application of cutting-edge
technologies can drastically minimise waste. Technology will not be enough to reduce waste
output. This can be done by raising awareness among those affected and encouraging a long-
term transformation in mindset. As part of a zero-waste approach, solid wastes should be
viewed as potential raw resources that may be preserved or repurposed. Steelmakers employ
scavenging units, such as sinter plants, to create high-quality input material instead of virgin
iron ore, saving a vital natural resource.

Sushovan Sarkar and Debabrata Mazumder (2015) Management of Solid Waste in the
Steel Industry: Challenges and Opportunities is the subject of this article. The majority of
economic management solutions in the steel industry in developing countries for limiting
solid waste creation and promoting waste recycling may be classified as follows: A waste
audit should be carried out to determine the sources, amounts, and categories of solid waste
generated by different subprocesses, which include hazardous wastes. The causes of the
accumulation of these solid wastes must be identified. Cutting-edge technology with cost-
effective feasible choices for decreasing resource waste will be investigated. Efforts should
be made to minimise yield losses. Treat waste as a raw resource for related industries to
reduce secondary contamination. To provide a set of integrated utilisation programs based on
industrial system technologies and manufacturing systems.
Kirti Vardhan, et. al (2015) Waste marble powder is a non-combustible byproduct of the
sawing and processing of marble stone. The major goal of this research is to see if marble
powder may be utilised as a partial replacement for cement. flowability, the setting behavior,
and soundness of cement pastes made using marble powder as a partial replacement are
investigated. XRD (X-Ray Diffraction) analysis Marble powder up to 10% may be utilised in
place of cement without affecting the mix's technical qualities, according to the research.
High replacement content, on the other hand, leads the mixture to hydrate slower and develop
a porous microstructure. In addition, the compression strength and microstructural properties
of marble powder-modified cement are investigated. According to the findings, the chemical
composition varies between cement and marble dust and had no negative impact on the final
mix's expansion and setting qualities.

Sucharita Patel and B.K. Pal (2015) The Bayer method for converting bauxite to alumina
produces red mud, which is a solid waste product. India generates roughly 4 million tonnes of
red mud each year. This study looks at the current status and future developments in red mud
characterisation, disposal, different neutralising techniques, and use in both global and Indian
contexts. This review research determined that red mud is a very complex substance made of
a collection of components due to the range of bauxites employed and the shifting process
conditions. To reduce the alkalinity risk associated with red mud, a variety of neutralising
treatments have been tried. While developments in dry disposal technology will likely
enhance residue management, red mud neutralisation is an essential component of any long-
term solution. Residue neutralisation procedures are still in need of research, which is a
substantial obstacle to their application and control.

Mr. R. Balamurugan and Mr. R. Karthickraja (2014) In concrete compositions, hypo

sludge was tested as an additional cementing ingredient. These tests were carried out over 28
days to assess mechanical characteristics such as compressive strength. As a result, adding
hypo sludge enhanced compressive strength by approximately 10%, whereas the strength
steadily declined as the amount of hypo sludge rose. By replacing Hypo Sludge for cement at
5 percent, 10 percent, 15 percent, and 20 percent of the time, this study investigates the
compressive strength of the concrete and the appropriate amount of partial replacement. The
experiment's goal is to use compression and split strength tests to see how concrete reacts
when garbage is combined with varying percentages of hypo sludge. M25 grade concrete mix
was designed using IS 10262-2009.
Baeza, et. al (2014) Sludge ash (SSA) was replaced with rice husk ash (RHA), fly ash (FA)
and marble dust (MD) in Portland cement pastes in binary and ternary combinations.
Compressive strength is normally equivalent to or higher than the cement strength class, and
the combination of SSA, FA, and RHA (30 percent cement replacement) resulted in a
9percentage improvement in strength over the sample group.

Dr. G. Vijayakumar, et. al (2013) The results of using finely powdered used glasses as a
substitute for cement in concrete were compared to those of regular concrete. The prospect of
utilising glass powder as a partial replacement for cement in concrete is investigated in this
study. Glass powder was substituted for 10%, 20%, 30%, and 40% of the cement in
compressive, tensile, and flexural strength tests, and the results were compared to those of
standard concrete after 60 days. Glass powder with a particle size of 75 can be utilised as a
cement alternative to avoid the alkali-silica reaction, according to the findings.

Amitkumar D. Raval, et. al (2013) In this investigation, OPC cement was replaced with
ceramic waste powder in proportions of 0%, 10%, 20%, 30%, 40%, and 50% by weight for
M-25 grade concrete. The wastes were from the ceramic sector and were considered unfit for
sale due to a range of issues, such as dimension or mechanical problems, as well as fire
process flaws. The findings indicate that by actively incorporating ceramic masonry rubble
into cement, it gains desirable properties such as increased mechanical strength and cost
savings. Reusing this type of garbage has both environmental and economic benefits, such as
reducing the number of natural places used as landfills. All of the above helps to improve
people's quality of life while also integrating the concept of sustainability into the
construction sector.

Dr. Mukesh Kumar, et. al (2013) This study demonstrates the viability of using fly ash and
red mud in the manufacture of building materials as a means of conserving natural resources
and effectively utilising toxic industrial wastes. According to the results of the
aforementioned experiment, fly ash combined with red mud is extremely valuable at
producing cold-setting and durable building bricks that conform to the requirements of IS:
12894:2002. The use of red mud in the construction of building bricks is effective with the
use of a lime grit-based cementation binder, which has no negative effects on soda leaching.
The addition of sand, red mud, and fly ash to the bricks increases the crushing strength of the
material.
Ranjan Kumar Dwari, et. al (2012) Dolochar is made up of quartz (both free and locked),
free lime, Fe particles, Ca or Mg, and/or Ca+, Mg+, and Fe oxide phases, according to
research. Clean coal with 41 wt. percent ash can be produced at an 18 percent yield from
Dolochar with 78 wt. percent ash, according to washability data from –300 m Dolochar
samples. Additionally, the investigations revealed that obtaining Dolochar release for
unambiguous separation is difficult.

Mr. Marthong (2012) Experiments were carried out to see if sawdust ash (SDA) might be
used as a building material. The ash was sieved using a 90-micron sieve after the sawdust
was burned. SDA was substituted for OPC in percentages of 0%, 10%, 20%, 30%, and 40%,
respectively. In the experiments, concrete cubes, mortar cubes, and beam specimens are used.
After 28 days, the mix had a water-cement ratio of 0.38, resulting in a target cube strength of
30 MPa. Concrete's compressive strength, water absorption, shrinkage, and durability were
all thoroughly researched. Because of the low calcium concentration in SDA, data suggests
that it causes negligible expansion. Initial strength was found to be between 50 and 60
percent of their 28-day strength development.

Dr. Jayeshkumar Pitroda and Laxmansinh B. Zala (2012) This study looks into the
possibility of using thermal industrial waste as supplementary cementitious material in
concrete manufacturing. As a viable substitute for ordinary concrete, the use of fly ash as an
extra cement in concrete compositions was examined. In the M-25 and M-40 mixes, fly ash
has been substituted in ratios of 0 percent, 10 percent, 20 percent, 30 percent, and 40 percent
by weight of cement. Mixed concrete’s split and strengths were measured and compared to
regular concretes. Split strength of 56 days and c Compressive strength of 28days and split
strength of 56 days was recorded to evaluate mechanical features. When cement is used
instead of fly ash, the compressive strength is reduced. As the percentage of fly ash in the
mixture increases, the compressive and split strengths decrease. Fly ash has the potential to
be an innovative supplemental cementitious construction material, according to this study.
Engineers, on the other hand, must exercise caution.

Suresh Chandra Patnaik (2010) The current research focuses on the utilisation of these
solid wastes in the construction of environmentally friendly and cost-effective green
buildings in Odisha state. They propose in this paper the use of a variety of industrial wastes
in the construction sector, including Fly ash concrete made in large quantities can replace up
to 50% of the cement in concrete. Concrete can be made up to 50% stronger by substituting
cement with GGBS. Rice husks can be used to make lightweight concrete. We can use
Coconut coir in concrete as a synthetic material to increase its stiffness and ductility. Red
mud could be used in place of ordinary clay in the manufacture of bricks. Bamboo is an
excellent material for reinforcing thin and lightweight reinforced concrete structures.
Terraces and exterior walls benefit from a heat-shielding coating.

Nurhayat Degirmenci and Arin Yilma (2009) With the amounts of sand and water
remaining constant, at 0%, 5%, 10%, and 15% by weight. The cement mortar containing 5%
diatomite met the minimum compressive and flexural strength requirements specified in the
standards. As the diatomite content was increased, the expansion of mortar samples immersed
in a 5% sodium sulfate solution was reduced. Except for the 15% diatomite mortar, water
absorption decreased as the diatomite percentage increased. Since diatomite has a high level
of porosity, the cement mortar had a lower dry unit weight than the control mortar.

Asokan Pappua, et. al (2009) The article explored how India generates solid trash and how
it might be recycled into construction materials. Municipal, agricultural, mining, industrial,
and other enterprises in India today generate around 960 million tonnes of solid garbage
every year. Agricultural waste accounts for 350 million tonnes, industrial and mining waste
accounts for 290 million tonnes, and hazardous waste accounts for 4.5 million tonnes. The
current condition of hazardous and non-hazardous solid waste creation and consumption in
India is studied and discussed in depth in this report, as well as their recycling potential and
environmental implications. They claim that introducing industrial waste-derived newer
building materials into higher education curricula, emphasising their environmental value,
and showcasing real waste applications in the building and construction industry would help
the industry become more sustainable. The advancement of science in recycling and the
application of industrial and agricultural processes to waste management will eventually
enable the world to use more of its resources more efficiently.
 CHAPTER 3

3. Materials
3.1 CEMENT
Portland cement are hydraulic cement, which means that when water is added to it, it reacts
chemically and harden. Limestone, cement rock, clay, and iron ore are mixed together and
heated to 1200 to 1500 degrees Celsius to make cement. The resultant "clinker" is then
processed to a powder-like consistency. To manage the setting time, gypsum is added.

FIG 3.1 OPC 53 grade cement

The Cement that is going to use in the experimental work is OPC of Ramco company (FIG-1)
to produce 53 grades of concrete conforming to IS 10262-2009 & dolochar based concrete as
per mixed design with a partial replacement of OPC with dolochar the physical properties of
the cement obtained on conducting appropriate tests are as per IS: 10262-2009 and the
requirements are given in Table 3.2. The detailed calculation of mix design for M3 is given in
4.1.
3.2. AGGREGATES

Aggregates give concrete body, reduce structural member shrinkage, and balance the economy.
Aggregates are essential constituents in concrete. Aggregates have a bigger influence on
numerous elements, characteristics, and distinct qualities of concrete; about 70 percent to 80
percent of the volume of concrete is covered by these aggregates. Previously, aggregates were
thought to be chemically inert materials, but they have recently been recognised as chemically
active, and a portion of them shares a chemical bonding at the edge of all other aggregates and
pastes.
Aggregates keep concrete stronger and more durable, and they have a significant influence on
the many qualities and properties of concrete. Aggregates can be classified depending on the
source they were taken from, their size, or their unit weight.

Type of Aggregate based on size

1, Fine aggregate
2, Corse Aggregate
3.2.1 Fine aggregate
The aggregate is a granular substance, and fine aggregate is defined as granular material with
particles small enough to pass through a 4.75mm sieve. It is used in the building and
construction industry to maximize the volume of concrete and is a cost-effective component.
It is made up of crushed stone and sand, and its quality affects the qualities of concrete. Fine
aggregates may be chosen based on grade zone, surface texture, particle form, surface moisture,
resistance, and absorption to make concrete or mixtures more durable and stronger. It has a
rounded shape for easier workability and cost savings and fine aggregates are used to fill voids
in coarse aggregate. The qualities of aggregates, such as size, grading, form, and strength of
aggregates, as well as texture, have influenced the final concrete.

SL.NO PROPERTIES SPECIFICATION

1 Specific gravity 2.63
2 Fineness modulus 2.47
3 Water absorption 1.0%
4 gradation Zone Ⅲ
Table 3.1 physical property of fine aggregate
 Fig 3.2 Fine aggregate

3.2.2 Coarse Aggregate

Concrete attributes like as abrasion resistance, hardness, elastic modulus, and

other characteristics such as durability, strength, and cost are all influenced by coarse
aggregate. As coarse aggregates, 10mm and 20mm stone chips are used. Crushed granite with
particular sizes of 10 mm and 20 mm is commonly referred to as coarse aggregate. The particle
size should be in accordance with the IS: 383-1970 requirements. In technical terms, coarse
aggregates are particles that are retained on the number 4 sieve (Le 4.75 mm sieve) and pass
through a sieve of 3-inch size. It has been determined that the more the aggregate quantity in
the concrete mix, the less expensive the concrete mix will be. According to 10 15 2386 (Part
111), the bulk specific gravity and water absorption rate of stones of 20 and 10 (mm) size are
2.6 and 0.50 percent, respectively, under SSD circumstances.
 Fig 3.2 Coarse Aggregate

According to [IS 383 (1970)], the sieve analysis is determined by the size of
20mm and 10mm coarse material. Although larger CA have less surface area than smaller
CA, using aggregates that are larger than the code's specified sizes can cause arching or cause
concrete to get interlocked and distorted. As a result, the underlying region becomes a void,
resulting in a weakened area. The coarse aggregate used is crushed with a maximum size of
20 mm, as per IS 383, and the laboratory test results for coarse aggregate are listed below.
The table below lists the physical qualities of coarse aggregate.

SI. NO Properties Test Results

1 Water Absorption (%) 0.60

2 specific gravity (SSD) 2.74
3 Gradation well Graded
4 Fineness Modulus 6.2
5 Unit weight (kg/m3) 1572
Specific gravity of oven dry
6 2.71
(OD)
7 Percentage void in aggregate (%) 43.65
Table 3.2 Physical Properties of Coarse Aggregate
3.3 DOLOCHAR

Dolochar is a char that is created as a by-product of the direct reduction of iron (DRI) process
used to make sponge iron. Dolochar is named from the devolatilized dolomite and coal that are
used to create sponge iron from iron ore. Dolochar represents the non-magnetic component of
the DRI process. A sample of Dolochar was taken from one of Odisha's sponge iron facilities.
The cost of the raw ingredient was nothing. Fine aggregate is the form of this Dolochar (Sponge
Iron Scrap) substance. In this case, we're grinding the material to make it suitable for use as a
cement substitute in cement concrete.
Physical, chemical, and mineralogical features of dolochar were investigated in order to
maximise its efficiency. Detailed research on physio-chemical characteristics and petrography
were conducted using X-ray diffraction (XRD), optical microscopy, and scanning electron
microscopy (SEM). The dolochar is composed of quartz (both locked and free), Fe oxide
phase, Fe particles, Ca or Ca+, Mg or Mg+, free lime, according to characterization
investigations.

Fig 3.4 grinded dolochar

 S No Property Test result
1 Fineness modulus 50 %
2 Specific gravity 2.421
3 Initial setting time 130 min
4 Final setting time 220 min
5 Consistency 54% water by weight of cement
Table 3.3 Physical properties of Dolochar

Constituents % by weight
SiO2 61.2
Al2 O3 16.1
Fe2O3 14.0
Fe 9.8
MgO 4.2
CaO 4.1
Table 3.4 Chemical composition of Dolochar

3.4 WATER
Concrete samples were mixed and cured with clean drinkable water acquired from KIIT
University's School of Civil Engineering's laboratory. For building purposes, the water quality
is comparable to that of drinking water. It is done to ensure that the water is free of
contaminants including organic matter, dissolved salts, and suspended particles, all of which
can have a detrimental impact on concrete properties like hardening, durability, setting time,
strength, and pit value.

3.5 FINENESS OF CEMENT AND DOLOCHAR

Cement fineness is a crucial physical parameter that determines the particle size and surface
area of cement particles. When calculated as a modulus with sieving, it is given as percentage.
Another quality control criterion that professionals monitor in the laboratory is cement
fineness. The surface area and heat of hydration are affected by the size of OPC particles. The
fineness of cement the we have used is less than 10%.
 Fig 3.5 90-micron sieve
Dolochar fineness is a crucial physical parameter that determines the particle size and surface
area of dolochar particles and its compatibility with ordinary Portland cement. When calculated
as a modulus with sieving, it is given as percentage. Another quality control criterion that
professionals monitor in the laboratory is cement fineness. The surface area and heat of
hydration are affected by the size of OPC particles. In the same manner the fineness of dolochar
was found to be 52 % after grinding. The normal procedure to find the fineness of cement has
been followed to find out the fineness of dolochar.

3.6 Setting Time

It depends on a number of elements, including fineness, water cement ratio, admixtures, and
so on. When the time it takes to set early is not too short and the ultimate set is not too high,
cement can be utilised in conventional buildings. Hence The following are the two types of
time setting:
 Fig 3.6 vicart apparatus

3.6.1 Initial setting Time

It's the time when the cement begins to harden. It usually happens within 30-45 minutes. The
combination of OPC and Dolochar collected for this study took 100 minute. It was discovered
in Vicar's equipment. Tie initial setting time took longer than cement allon.

Fig 3.7 intial setting time testing sample

3.6.2 Final Setting Time
It's the time when cement is already set or hardened Mostly within 10 hrs. It has taken 3 hours
and 40 minute for the final setting time for partial replacement of cement with dolochar.

Fig 3.8 final setting time test sample

3.7 Consistency of dolochar

It's known as the ability to flow It's measured in Vical's apparatus. The Dolochar paste will be
kept in the Vicat's mould then the plunger will be taking down to touch the top surface of the
cement paste. Then it'll be let plunger to lower down & it'll go up to a certain depth & reading
will be measured. For this study, the consistency value was found as 54%. it is much more
than that of cement.
 CHAPTER 4

METHODOLOGY

4.1 MIX DESIGN OF CONCRETE

Concrete Mix Design is the process of determining the right amount of cement, sand, and
coarse particles to achieve a desired structural strength. To find the right mix proportions, many
processes, calculations, and laboratory testing are used in the concrete mix design. Typically,
the process is used in the construction of structures with higher concrete grades, such as M30
and above, as well as large construction projects that use a lot of concrete. The advantages of
concrete blend design are that it represents the proper resource proportions, making concrete
construction cost effective in obtaining the desired structural strength. Because large buildings
require large amounts of concrete, the expense of material quantities such as cement results in
a cost-effective project.

Procedure for designing concrete mix of M30 grade concrete

Step 1- Determination of target strength

The Hemsworth constant for the 5% risk factor is 1.65. In this case, the standard deviation
obtained from IS: 456 and M30 is 5.0. is

Target strength= fck+1.65 x S

= 30 + 1.65 x 5.0 = 38.25N/mm²

Here, S = standard deviation (N/mm² = 5) (according to Table 1 of IS 10262-2009)

Step 2 - Selection of water / cement ratio:

From Table 2 of IS 10262:1970(Table 20)

Maximum water-cement ratio under mild exposure conditions = severe
From curve 2 for severe condition the cement OPC 53 grade ratio of water is set to 0.48.

0.48 <0.55 Hence, it is OK.

Step 3-Selection of water content:

From table 4 IS 456-200: water content for nominal maximum size of aggregate 20 is 186kg.
Estimated water content for 75mm slump 3% of water for every 25mm increased slump

Water Content = 191.58 ≈ 190 kg

Maximum moisture content = 190 kg (in the case of nominal maximum size of aggregate-20
mm)

Step 4 - Select the contents of the cement:

Water-cement ratio= 0.48

Content of cement

=395 kg/m3

From Table 5 of IS 456,

Minimum cement content for mild exposure conditions = 300 kg/m³

So 395kg/m³ is OK

This value checks durability requirements from IS: 456.

In this example, the minimum cement content is 300 kg/m³ for mild exposure and in the case
of reinforced concrete; it is less than 395 kg/m³. Therefore, a cement content of 395 kg/m³ was
adopted. Section 8.2.4.2 of IS: 456

Maximum amount of cement=450 kg/m³.

Step 5: Estimation of coarse aggregate ratio: -

From Table 3 of IS 10262-2009.

in the case of aggregate = 20 mm, which is the nominal maximum size,

Zone of fine aggregate = zone II

When w/c=0.5

A volume of coarse aggregate per unit volume of total aggregate

= 0.62

Note 1: Change the coarse aggregate ratio by 0.01 for each change in w/c 0.05. If the w/c ratio
is less than 0.5 (the standard value), it is important to increase the coarse aggregate content in
order to reduce the fine aggregate content. The coarse aggregate volume declines and the fine
aggregate content increases as w/ c exceeds 0.5. If the coarse aggregate is not angular, it may
be required, based on experience, to increase the amount of coarse aggregate. Note 2: In the
case of pumpable concrete or dense reinforcement, the coarse aggregate fraction can be reduced
to 10%.

For water cement ratio 0.5 = 0.62

For water cement ratio 0.48= X
0.05=0.01
0.02=X
X= 0.004
Fraction of Coarse aggregate = 0.62+ 0.004 = 0.624
Volume of Fine aggregate = 1- 0.624 = 0.376

Step 6: Estimation of the mix ingredients

a) Volume of concrete = 1 m3

b) Total Volume of water

0.190 m3

c) Total Volume of cement

0.12 m3

d) Volume of total aggregates = Total volume of concrete – (Total Volume of cement + Total
volume of water)

= 1 - (0.125 + 0.190)

= 0.685 m3

e) Mass of coarse aggregates = Volume of total aggregate × Volume of coarse aggregate ×

Specific gravity of coarse aggregate × 1000

= 0.685 x 0.625× 2.74 × 1000 = 1171 kg/m3

f) Mass of fine aggregates = Volume of total aggregate x volume of fine aggregate × Specific
gravity of fine aggregate × 1000

= 0.685 × 0.376 × 2.74 × 1000 = 705.71 kg/m3

Step 7. Partial Replacement of cement with Dolochar are given below:
Total Content of cement = 395 kg/m3

Table 4.1 Volume of Mix Components

Volume
Replacement Volume of Volume Volume of
Mix of
of cement Dolochar of FA Volume of CA (Kg/m3) water
No (Kg/m3)
with dolochar (Kg/m3) (Kg/m3) (Kg/m3)
cement

M1 5% 19.75 375.25 705.71 1171 190

M2 10% 39.5 355.5 705.71 1171 190
M3 15% 59.5 335.75 705.71 1171 190
M4 20% 79 316 705.71 1171 190

4.2 CASTING FOR CEMENT DOLOCHAR MORTAR

For one mould its dimension is 70mm*70mm*70mm and requires 200 grams of cement + 600
grams of fine aggregate + 85*water percentage consistency.
100
its consistency 5% is 32%
its consistency 10% is 31%
its consistency 15% is 31.5%
its consistency 20% is 32%
Casting procedure for cement dolochar mortar:
I. Six moulds have been properly cleaned and grease were applied to all the cubes as
lubrication
II. The mortar has been filled in each mould in three layers
III. After each layer, proper compaction has been done by applying 25 strocks using a tamping
rod.
IV. The specimen has been kept for 24 hours, undisturbed.
V. After the end of 24 hours the mould has been removed.
VI. All the specimens have been marked by writing the date of casting and give the specimen
number
VII. All the specimens have been kept in water tank till 7 days, 14 days, 21 days, 28 days.

Fig 4.1 Remoulded mortar sample

4.3 CONCRETE CASTING
After the proper design of concrete mix, the following procedures has been followed to cast
the cubes specimen
I. 12 moulds have been properly cleaned and grease were applied to all the cubes as
lubrication
II. The concrete has been filled in each mould in three layers
III. After each layer, proper compaction has been done by applying 25 strocks using a tamping
rod.
IV. After the end of 3rd layer of compaction, the top surface has been finished using a flat
trowel.
V. The specimen has been kept for 24 hours, undisturbed.
VI. After the end of 24 hours the mould has been removed.
VII. All the specimens have been marked by writing the date of casting and give the specimen
number
 Fig 4.2 Casting and remoulding of cubes

4.4 CURING
After casting of all the specimens, they were kept for 24hrs at room temperature, after 24hrs of
casting specimens were de-moulded and then immersed them into the curing chamber for
curing purpose until the specimens were being tested it has been cured for 7days, 14, 21 and
28days to check the increase of strength in all the specimens. The pozzolanic reaction between
amorphous silica (in mineral admixture) and calcium hydroxide (liberated during cement
hydration) requires water to proceed, hence curing is more required for concrete containing
mineral admixtures than for standard concrete. Furthermore, water curing has a greater impact
on the sorptivity of concrete than on its strength.

fig 4.3 curing of concrete and mortar sample

4.5 TESTING SPECIMENS
Cubes of size 150mm were being casted for the determination of compressive strength. All the
specimens were being measured first then has been casted in concrete mixer and then putted
into the moulds in three to four layers and have been compacted by tamping rod with a diameter
of 16mm and length of 610mm and then all the specimens were vibrated through a table
vibrator.

Fig 4.4 Testing of mortar Fig 4.5 testing of concrete

 Chapter 5

5. Results and Discussion

5.1 Compressive strength of concrete

The compressive strength test of concrete is used to determine the hardness of concrete and
several other cubical and cylindrical structures that are made of concrete. concrete cubes have
been crushed once a particular limit of compressive strength is reached. Compressive tests have
been utilised in most construction sectors to achieve the ultimate needed strength or strength
of concrete as per the design specifications. The most popular performance among all other
tests is the compressive test, which is used by most engineer to assess the ultimate compression
of concrete.
The Concrete specimens' compressive strength is calculated by dividing the greatest load
achieved during testing by the area of the specimen that actually resists the axial load.
Compressive strength in higher commercial constructions can range from 17 to 28 MPa.
Compressive strength refers to a material's or structure's ability to withstand axially directed
pressing stresses. For casting and determining the compressive strength of concrete, cube
specimens measuring 1501*50*150mm were utilised, as well as a compression testing
equipment.
The test will continue at the set rate until it fails. By making concrete mixes as per different
mix-proportions and with the needed w/c ratio, the mixes were placed first into the concrete
mixer, and then the mixture was poured into the moulds once the mixing was completed. Prior
to pouring, the moulds should be thoroughly greased or oiled. After mixing, a table vibrator
was employed to ensure adequate compaction and the elimination of excess pores, and the
surface of the moulds should be level. vibrating and compacting.
The moulds should then be demoulded after 24 hours and stored within the curing chamber at
a temperature of 27+2°C until the day of testing. After 7 days, or the required curing time, the
specimens were removed from the curing chamber and thoroughly dried, allowing any extra
water to be easily wiped away. The specimens were then placed in the compression testing
equipment, where readings were obtained and compressive strength was determined.
 Fig 5.1 Compressive Testing Machine testing

Average
% of Peak Peak
Sample Mass Area compressive
Dolochar Load Stress
No. (g) (mm2) strength
replacement (KN) (N/mm2)
(Mpa)
M1 817 46 4.98 9.2
5% M2 811 72.8 4.98 14.46 14.057
M3 821 92.2 4.98 18.51
M1 799.59 73.6 4.98 14.779
10% M2 799.59 63.8 4.98 12.811 15.227
M3 812 90.1 4.98 18.092
M1 812 70 4.98 14.056
15% M2 824 65 4.98 13.05 12.181
M3 821 47 4.98 9.437
M1 785 74.6 4.98 14.979
20% M2 774 52.1 4.98 10.461 13.152
M3 775 69.8 4.98 14.016

Table 5.1 compressive strength of mortar

 COMPRESSIVE STRENGTH OF MORTAR
COMPRESSIVE STRENGTH(MPA)

18.5 18.1
14.4 14.8 14.1 14.9 14.0
12.8 13.1
9.4 10.4
9.2

1 2 3 4 5 6 7 8 9 10 11 12

sample M1 M2 M3 M1 M2 M3 M1 M2 M3 M1 M2 M3
7day strength 9.2 14.4 18.5 14.8 12.8 18.1 14.1 13.1 9.4 14.98 10.4 14.01
Fig 5.2, 7-day compressive strength of mortar

Average
Peak Peak
% of Dolochar Mass Area compressive
Sample No. Load Stress Remarks
replacement (kg) (mm2) strength
(KN) (N/mm2)
(Mpa)
M1 8.45 584.7 22.5 25.99
> 64% of
5% M2 8.46 588 22.5 26.13 25.683
38.25 MPa
M3 8.5 560.9 22.5 24.93
M1 8.56 715.5 22.5 31.80
> 64% of
10% M2 8.4 633.9 22.5 28.17 30.231
38.25 MPa
M3 8.46 691.2 22.5 30.72
M1 8.44 553 22.5 24.58
> 64% of
15% M2 8.53 604.6 22.5 26.87 26.646
38.25 MPa
M3 8.58 641 22.5 28.49
M1 8.46 587.5 22.5 26.11
> 64% of
20% M2 8.42 588.6 22.5 26.16 25.676
38.25 MPa
M3 8.49 557 22.5 24.76
Table 5.2 Compressive strength of concret
 Compressive Strength(MPa)
COMPRESSIVE STRENGTH OF CONCRETE

31.8
28.2 30.7 28.5 26.1 26.1
26.0 26.1 24.9 24.6 26.8 24.7

1 2 3 4 5 6 7 8 9 10 11 12

sample M1 M3 M2 M3 M1 M2 M3 M1 M2 M3
M2 M1
7day strength 26.0 26.1 24.9 31.8 28.2 30.7 24.6 26.8 28.5 26.1 26.1 24.7

Fig 5.3 7-day compressive strength of concrete

5.2 tensile strength of concrete

The flexural and splitting tensile strengths can be obtained from IS 456- 2000.
fcr= 0.7 √fck where fcr ,flexural strength , fck characteristic cube compressive strength

Mix designation Compressive strength Tensile strength Mean

(MPa) (MPa) slump(mm)
fcr= 0.7 √fck
7-day strength 7-day strength
OPC 19.78 3.11 25-75 mm
5% Dolochar 25.683 3.54 30 mm
10% Dolochar 30.231 3.85 10 mm
15% Dolochar 26,643 3.61 7.5 mm
20% Dolochar 25.673 3.55 0 mm
Table 5.3 Tensile Strength of Concrete
5.3 Economic Analysis of Concrete with Replacement of Cement with Dolochar

Mix with Replacement of Cement with Dolochar Without

Constituent
M1(in INR) M2 (in INR) M3 (in INR) M4 (in INR) Dolochar

Cement 141.12 134.148 125.57 119.28 155.064

Dolochar 2.4 2.64 3.96 5.4 -

Fine Aggregate 34.54 34.54 34.54 34.54 34.54

Coarse Aggregate 50.046 50.046 50.046 50.046 50.046

Water 0.05 0.05 0.05 0.05 0.05

Total 228.156 221.424 214.166 209.316 239.7

Table 5.4 Economic analysis of Dolochar

5.3 Conclusion

• Based on the findings, it has been confirmed that replacing cement in M30 concrete
with Dolochar at 5%, 10%, and 15% gives better strength than ordinary concrete. When
compared to 10% and 15% replacement, 20% replacement yielded inferior results,
indicating that more replacement yields lower strength. Cement and Dolochar mortar
revealed that cement and Dolochar had less chemical interaction.
• The Economic analysis of concrete with Dolochar Replacement showed that the cost
reduces as the replacement amount increases.
• Dolochar may be used as fine aggregate or coarse aggregate, and because it contains a
large quantity of silica, it greatly boosts the strength of concrete.
This research suggests that industrial by-products that have a negative impact on the
environment can be utilized in the building industry. The compressive strength tests on several
specimens all yielded the same result.
5.4 Societal Impact
⚫ It helps the reductions in carbon dioxide emission since the chemical process emits zero
carbon dioxide, and the fuel much less, resulting in a reduction of carbon dioxide
emissions.
⚫ Replacement of cement will help to conserve the natural resource since we are using
limestone as the main raw material for the production of Ordinary Portland cement (OPC)
in huge amounts, we will face a shortage of raw material after 20 to 30 years.
⚫ In Odisha, there are 146 rotary kilns and These kilns are capable of producing 16000 tonnes
of sponge iron per day, which will result in 58.4 lakh tones of Dolochar. Utilizing this
Industrial by-product Enables us to reduce its Negative Impact.
⚫ As an observed form, the economic analysis of replacing cement with dolochar using
industrial by-products as a replacement for Cement reduces the overall cost of concrete.
⚫ Using Dolochar as Fine Aggregate and coarse aggregate help in conserving the natural
resource and at the same time provides better strength To the Concrete.
⚫ A huge amount of energy is required for the production of cement. By Replacing cement
concrete, we can save a huge amount of energy required for the production of cement.
⚫ Utilizing industrial byproducts in the contraction industry enables us to Conserve a large
area of land that would have been used for industrial waste disposal.
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