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RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

Cost effective light weight concrete with saw dust and brick
ballast

A Garg# and P K Sharma*

School of Civil Engineering, Lovely Professional University, Phagwara, Punjab
144411, India.
#
anshulgarg2008@gmail.com, *p.sharmaji10@gmail.com

Abstract. Use of conventional material such as cement, sand and gravel for the
production of concrete has increased their demand and so created shortage of material
and escalated the cost. In this study the locally available waste materials like Saw dust
and Brick Ballast are used to partially replace the river sand and gravels respectively
to produce light weight and low cost concrete with optimum strength. The different
combinations of concrete with 4%, 8% and 12% Saw Dust (SD) and 8%, 16% and
24% Brick Ballast (BB) are being used and compared with normal concrete of M30
grade, where partial replacement of river sand and coarse aggregates are done by saw
dust and brick ballast respectively. Concrete is tested for density, workability and
compressive strength and a comparative analysis is done in terms of their physical
properties and cost savings. It has been observed from the study that on increase in
percentage of sawdust and brick ballast in concrete lead to a corresponding reduction
in workability and compressive strength. The optimum mix founded is with 4% of
sawdust and 24% of Brick ballast having compressive strength of 32.13 N/sq. mm
with the weight reduction of 10.54% and the cost reduction of 5.46%. This optimum
mix concrete can be used for lean concrete works like PCC in foundation, Flooring,
Tile making. This research will not only enrich the domain but will also be very
helpful in sustainable development of the nation.
Keyword. Sawdust, Brick Ballast, Light weight concrete, Low Cost Concrete.

1. Introduction
With the rapid growth of infrastructure and population, the need of construction materials is increasing
day by day and so various types of waste materials can be managed with the same speed of growth of
infrastructure. Normally river sand is used as fine aggregates and stones or gravels are used as coarse
aggregates in the concrete. These materials are limited on the earth and due to the increase in demand
of these materials, there is shortage of materials due to scarcity of them and so this increased the cost
of these materials. In this study waste materials like Saw dust and easily available brick ballast is
being used as a replacement to river sand and natural coarse aggregates. These materials are light in
weight, so that it is helpful to construct light weight structures. Saw dust (SD) is used as partial
replacement of river sand by taking percentages of 4%, 8% and 12% and Brick Ballast is used to
replace natural coarse aggregates by percentage of 8%, 16% and 24% and is compared with M30
grade normal concrete having conventional materials.

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
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RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

2. Literature Review
An extensive review of previous researches on using of Saw Dust and Brick Ballast is being done and
the major findings are being expressed in chronological order. In year 2009 M. Mageswari et al.,
researched on the usage of waste sawdust ash, which are generated from rice mills replaced with fine
aggregates in concrete, partially replacing fine aggregates with sawdust ash at different proportion
such as 5%, 10%, 15%, 20%, 25% and 30%. The study was focused on different properties of concrete
in its plastic and hardened stage like compressive strength, Tensile strength (cubes and cylinders) and
flexural strength with Fineness modulus, specific gravity, moisture content, water absorption, Bulk
density, % voids and % porosity (loose and compact) up to 180 days of age were compared with
normal concrete. The optimum result of concrete made with sawdust concrete was found in using 15%
saw dust in concrete [1]. Thereafter in year 2012 R. Sathish Kumar et al., had studied on the properties
of concrete varied with the use of alternate construction material in concrete, rice husk ash, sawdust,
brick bats, recycled aggregates. The maximum average compressive strength of sawdust concrete after
7 days and 28 days is 20.26 Kg/sq. Cm and 43.22 Kg/sq. cm at proportion of 1:(1+0.5):3 and water –
cement ratio of 0.75 [2]. Further a similar research done by Mahmud Abubakar et al., in year 2013
used sawdust as partial replacement for the fine aggregates from 0% to 50% in steps of 10%.
Compressive strengths were evaluated at 7, 14, 21 and 28 days and the results depicted that the
optimum sawdust content was obtained at 10% and its corresponding compressive strength at 28 days
is 7.41 N/sq. mm which falls within the characteristics strength of plain concrete (7-10 N/sq. mm)
which cannot be used in structural applications [3]. In year 2014 Tariq Ali et al., researched on the
use of Over Burnt brick ballast aggregate partially replaced with coarse aggregates in concrete at
different proportions such as 5%, 10%, 15% and 20% and compared the different properties of
concrete made with over burnt brick ballast i.e. slump value, compaction factor value, unit weight,
flexural strength and Los angles abrasion value as compared with normal concrete. From experimental
investigation it was concluded that Concrete formed with over burnt brick ballast aggregate showed
beneficial performance as compared with normal concrete. It reduced the cost of concrete by reducing
the cost of aggregates and produces economical infrastructure system [4]. Another research done in
year 2014 by O Joseph, on sawdust conclude that at the initial ages with the increase in the percentage
replacement of sawdust, the compressive strength decreases but the weight of concrete will decreases
and it can be used as Light weight concrete in non-load bearing structures [5]. Further many other
researches done in year 2014 and 2020 also depicted that on using sawdust and brick ballast strength
decreases but there is a decrease in weight and cost [6]-[17] and so it can be used for non-structural
members like tiles, PCC.

3. Research Methodology
The materials used for experimental investigation is Pozzolanic Portland Cement of Grade 43 of
company ACC, river sand, Coarse Aggregates, Saw Dust as shown in Figure 1, Brick Ballast as shown
in Figure 2 and water. The methodology used for performing the study is testing of properties of
materials as per IS:4031-1999 [18], IS:8112-1989 [19], IS:383-1970 [20] and the results are
shown in Table 1, mix designing of M30 grade concrete as per IS:10262-2009 [21], IS:456-2000
[22] and mix proportion and its compressive strength after 7 and 28 days is shown in Table 2. Casting
of cube specimens with sawdust and Brick ballast partially replaced with fine aggregate and coarse
aggregate respectively as per the different mix proportions is shown in Table 3. The tests were
conducted to study the various physical properties such as slump test, compaction factor test and 28
days compressive strength as per IS:516-1956 [23].

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RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

Figure 1. Saw Dust Figure 2. Brick Ballast

Table 1. Test Analysis of Materials

S.No. Description Cement 20 mm 10 mm FA
agg. agg.
1 Consistency 29.42% - - -
2 Initial Setting Time 148 min - - -
3 Final Setting Time 241.5 min - - -
2
4 Comp. Strength (7 days) 41.46 N/mm - - -
5 Comp. Strength (28 52.83 N/mm2
days)
6 Specific Gravity 3.15 2.65 2.659 2.68
7 Water Absorption - 0.64% 0.68% 1.59
8 Aggregate Impact Value - 17.05 -
9 Flakiness Index (20mm - 12.30% -
& 10mm)
10 Zone of Sand - - - II
11 Fineness Modulus of - - - 2.846
Sand
Table 2. Normal Concrete Mix Design and its compressive strength after 7 and 28 days
Sample Proportion by weight 7-days Compressive 28-days Compressive
Water-Cement ratio
No. C : F.A. : C.A Strength (Mpa) Strength (Mpa)
1 1:1.23:2.53 0.42 30.73 44.00
2 1:1.23:2.53 0.42 30.03 43.53
3 1:1.23:2.53 0.42 30.16 43.20

Table 3. Detail of Test Specimens

Sr.No. Designation of
Specimen
1 M0
2 M1
3 M2
4 M3
5 M4
6 M5
7 M6
% Replacement of Sand % Replacement of Gravels
with Sawdust with Brick ballast
- -
4 8
4 16
4 24
8 8
8 16
8 24

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RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

8 M7 12 8
9 M8 12 16
10 M9 12 24

4. Results and Discussions

The tests performed for investigation of mechanical properties are done as per Indian Standards. The
test on fresh concrete performed are workability by slump cone test as shown in Figure 3 and results
are shown graphically in Graph 1, Compaction Factor Test performed is shown in Figure 4 and results
are shown graphically in Graph 2.

Figure 3. Slump Cone Test Figure 4. Compaction Factor

Test

Graph 1. Workability in millimetres using slump cone test

The value of slumps shows that slump reduces on addition of more sawdust and brick ballast as
brick ballast and sawdust has more water absorption.

4
RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

Graph 2. Workability in millimetres using slump cone test

The compaction factor reduces on increase in sawdust and brick ballast but mix designation M3
gives the highest value of compaction factor in all types of mixes having sawdust and brick ballast.
The compressive strength test is performed on hardened concrete after 28 days of curing using
Compression Strength Testing Machine of Make HEICO of capacity 1000 KN is shown in figure 5
and cube specimen casted is shown in figure 6. The results obtained are tabulated in table 4 and results
are shown in graphical representation in Graph 3.

Figure 5. Compressive Strength Testing of Cube Figure 6. Cube Specimen

Specimen

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RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

Table 4. Compressive strength of various Mix proportion at 28 days

Compressive Strength of Specimen
(After 28 days)
Designation Specimen
S.NO. Mean
of Mix Name Compressive
Load (KN) Compressive
Strength (N/mm2)
Strength (N/mm2)
1 990 44.00
1. M0 2 998 44.53 43.91
3 972 43.20
1 868 38.57
2. M1 2 858 38.13 38.17
3 851 37.82
1 790.2 35.12
3. M2 2 777.6 34.56 34.52
3 762.75 33.90
1 765 34.00
4. M3 2 718 31.91 32.13
3 686 30.48
1 798 35.46
5. M4 2 781 34.71 34.76
3 768 34.13
1 745 33.11
6. M5 2 706 31.37 31. 47
3 682 30.31
1 598 26.57
7. M6 2 565 25.11 27.74
3 552 24.53
1. 736 32.71
8. M7 2 718 31.91 31.96
3 704 31.28
1 640 28.44
9. M8 2 628 27.91 27.74
3 605 26.88
1 470 20.88
10 M9 2 456 20.26 20.21
3 430 19.11

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RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

Graph 3. Compressive strength of different mix designations

The strength alone cannot interpretate the optimum mix and so percentage reduction in weight and
cost analysis is being performed and results are being shown in Table 5. A combined graph is being
plotted to find the optimum mix and is shown in Graph 4.

Table 5. Weight reduction of Concrete of Various mix designations

Weight of specimen Cost of 1
(After 28 days in Kg) Percentage Cubic Percentage
Mean
Sr. Mix Reduction Meter reduction
Value
No. designation in weight Concrete in in Cost
I II III (Kg)
(%) Indian (%)
Rupees
1. M0 8.380 8.490 8.435 8.435 0.000 6832.00 0.00
2. M1 7.856 7.930 7.880 7.888 6.485 6694.96 2.01
3. M2 7.760 7.910 7.700 7.81 7.410 6577.01 3.73
4. M3 7.410 7.680 7.550 7.546 10.539 6459.05 5.46
5. M4 7.550 7.710 7.730 7.663 9.152 6675.88 2.29
6. M5 7.340 7.580 7.485 7.468 11.464 6557.93 4.01
7. M6 7.220 7.315 7.300 7.278 13.717 6439.97 5.74
8. M7 7.650 7.450 7.580 7.560 10.373 6656.80 2.56
9. M8 7.315 7.425 7.480 7.406 12.199 6538.85 4.29
10. M9 7.050 7.250 7.168 7.156 15.163 6420.89 6.02

7
RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

Graph 4. Combined data and Combined Factor for Optimization

The combined factor is being calculated taking all factors in consideration where higher strength,
weight reduction, cost reduction, slump and compaction factor more is better for mix and hence taken
positive and combined factor is being founded and mix designation M3 is founded to be optimum for
use in non-structural use like PCC in foundation, Flooring, Tile making.

5. Conclusion
It is concluded from the extensive research that using sawdust and brick ballast in 4% and 24%
respectively is giving the best optimized mix that can be used for non-structural applications. The
workability reduces on addition of sawdust and brick ballast to concrete and so there is a need of using
admixtures to improve workability.

References
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Concrete J. of Envir. Res. and Devel. 3.
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construction materials Int. J. of Mod. Engi. Res. 2 3006-12.
[3] Abubakar M, Abdullahi A Nand Afolayan A 2013 Partial replacement of sand with sawdust in
concrete production Proc. Int. Conf. 3rd Biennial Engi. Conf. vol 1 (Federal University of
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[4] Ali T, Iqbal N, Khan M A and Ali M 2014 Evaluation of flexure strength behaviour of over
burnt brick ballast aggregate concrete Int. J. of Eng. Res. and App. 4 15-21.

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RAFAS-2021 IOP Publishing
Journal of Physics: Conference Series 2267 (2022) 012110 doi:10.1088/1742-6596/2267/1/012110

[5] Joseph O O 2014 Investigation of properties of concrete using sawdust as partial replacement of
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