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Sandstone cutting waste as partial replacement of fine aggregates in concrete: A

mechanical strength perspective

Sanjay Mundra, Vinay Agarwal, Ravindra Nagar

PII: S2352-7102(19)31187-8
DOI: https://doi.org/10.1016/j.jobe.2020.101534
Reference: JOBE 101534

To appear in: Journal of Building Engineering

Received Date: 9 July 2019

Revised Date: 29 April 2020
Accepted Date: 24 May 2020

Please cite this article as: S. Mundra, V. Agarwal, R. Nagar, Sandstone cutting waste as partial
replacement of fine aggregates in concrete: A mechanical strength perspective, Journal of Building
Engineering (2020), doi: https://doi.org/10.1016/j.jobe.2020.101534.

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 Sandstone Cutting Waste as partial replacement of fine aggregates in
Concrete: A Mechanical Strength perspective
Sanjay Mundra*, Vinay Agarwal, Ravindra Nagar
Malaviya National Institute of Technology, Jaipur-302017, India

Abstract: Construction activities are progressing rapidly across the globe due to the demand for
concrete and its constituent materials especially fine and coarse aggregates. The large quantity of
concrete production is causing an acute shortage of natural sand. Nowadays researchers are
finding ways by exploring better alternatives of river sand in the form of manufactured sand as
well as crushed rock sand. Sandstone cutting waste are sand-sized grains of mineral obtained from
sedimentary rocks. This research aims to find the mechanical properties of concrete containing
sandstone cutting waste collected from Bayana in Rajasthan state in India with the replacement of
natural river sand. The study was carried out by opting three different w/c ratios i.e. 0.35, 0.40 &
0.45 and concrete mixes were designed as per IS10262: 2009. The effect of sandstone cutting
waste was investigated both for fresh concrete attributes i.e. slump & density as well as hardened
Concrete attributes i.e. compressive strength of cubes, the flexural strength of beams & split
tensile strength of cylinders along with abrasion resistance in concrete cubes along with
microstructural studies of hardened concrete by scanning electron microscope(SEM), optical
microscope(OM). A comparison study was also carried out with control mix concrete having 0%
sandstone cutting waste and further river sand was replaced with sandstone cutting waste using
replacement level of 10%, 20%, 30%, 40%, 50% & 100 % along with optimum levels in between.
It was observed that sandstone cutting waste can be utilized in the production of structural
concrete as partial replacement of river sand up to 10% replacement level using w/c ratio of 0.35
& up to 30% replacement level using w/c ratio of 0.4 & 0.45.
Key Words - Sandstone Cutting Waste, Concrete, Compressive strength, Microstructure, Abrasion

1. Introduction

Concrete is utilized to a great extent worldwide as a fast consuming material in construction,

made up of cement, fine aggregates, coarse aggregates, and water. The development of any nation
depends upon construction activities which have been increased tremendously in a few decades,
resulting in an encouraging demand for concrete. Extraction and mining of natural aggregates are
rapidly increasing to cater to the demand for production of concrete, which further resulting in
depletion of resources, causing accumulation of stone wastes and slurry wastes. These wastes are
becoming dumping yard in the vicinity of the mining area and further emission of dust causing the
associated occupational exposure, deteriorates the baseline respiratory health status of workers
and nearby human-being. Continual depletion of these natural resources imposing threats
associated with the disposal of waste and health hazards, further indicating necessary utilization of
the sustainable waste materials as a substitute for conventional fine and coarse aggregates in
concrete. Raw materials like coarse aggregates and fine aggregates comprising 70%-80% of the
concrete volume are the most important constituents of concrete, the studies were carried out in
optimizing of sustainable waste materials in concrete based on various researchers’ findings.
Variety of waste materials including sludge waste, ground granulated blast furnace slag, Kota
stone slurry, fly ash, granite powder, limestone slurry, ceramic waste & rubber waste, marble
powder is being utilized in concrete production. Crushed rock dust acts as a filler and helps to
reduce the total voids in concrete (Celik T.et al, 1996).
*Corresponding Author
Email-s.mundra73@rediffmail.com(S. Mundra)
 These wastes have shown aided benefits on properties of concrete and these include
improvement in performance in terms of mechanical aspects as well as durability aspects of
concrete besides conserving earth life balance & eco-friendly approach in construction (S. Singh
et al, 2016 Aditya Rana et al, 2015).
The use of waste materials in place of virgin materials results in considerable energy
savings by reducing the various engineering process for manufacturing the end product (Ismail et
al, 2013).
Estimated reserves of sandstone in India is approximately 1000 million tones, out of that
Rajasthan state share approximately 90 percent. Sandstone is clastic sedimentary rocks formed by
sedimentation, which is not only used in construction works but also in making of decorative
articles and other artifacts. Dholpur, Karauli and Bharatpur districts share major quarries of
sandstones in Rajasthan.
Sandstone have variation in composition depending upon locations, types & their
occurrence and their effect is observed differently towards the compressive strengths. The
compressive strength of concrete comprising of sandstone approximately reduces 50% owing to
clay content while the presence of carbonates in sandstones results in better links between cement
paste and aggregate with further improvement in strength. (M. Yilmaz & A. Tugrul, 2012).
Nominal strength is significantly affected by ageing & size effect of sandstone & different
sizes of sandstone would have a variable effect on corresponding strength by taking consideration
of correct grading analysis of sandstone (Marcel R.A. Van Vliet et al, 2000).
Preliminary studies of Compressive strength indicate increasing trends while using quartz
sandstone aggregates for varied ratios of combined aggregates, however, the strength decreases
after achieving specific gradation owing to an increase in void spaces in bigger size aggregates
and segregation. (S. Kumar et al, 2016)
Variation of strength properties of crushed limestone sand concrete under high temperature
was very similar to that of natural sand concrete (Yeol Choi et al, 2013)
Interfacial transition zone (ITZ) is a narrow region between the cement & aggregate phase
is generally identified as a valuable governing phase for measuring the performance of materials
in concrete which can be verified and confirmed by viewing images of the scanning electron
microscope (SEM). This microstructure studies of concrete provide a clear picture regarding
performance in terms of mechanical attributes in Concrete. Micro Structure of ITZ especially the
volume of voids and micro-cracks present has a great influence on the stiffness or the elastic
modulus of concrete (Mehta & Monteiro, 2006)
Quantity of sustainable stone fillers & powder waste generation has increased tremendously
to a large extent (Abhishek Jain et al, 2019, Rajni Lakhani et al, 2014). The cutting wastes of
sandstone exclusively account for 30% of the mining waste reserves (as per studies carried out by
DMG in Rajasthan). Sand can be replaced by rock flour up to 40% without affecting strength and
workability (Bahoria B.V.et al, 2013)
The above literature studies suggest the influence of different sustainable waste on concrete
properties and further coarse aggregates of quartz sandstone were utilized by many researchers in
past so the author has felt to attempt the use of fine aggregates in form of sandstone cutting waste
with objectives of the economy to scale in construction, conserving river beds and sustainable
development.
Sandstones cutting wastes in this research were identified & collected from the mining area
of Bayana Tehsil in Rajasthan and these aggregates were utilized as a substitute of Banas sand in
Rajasthan, as Banas is natural river sand and mining of this is creating the loss of flora and fauna,
loss of river beds, pollution in surrounding areas and potential harm to human health, so
considering these issues, High court of Rajasthan had already imposed the ban on mining of
Banas sand, based on the report of National green tribunal(NGT) in India.
Sandstone cutting waste was procured underneath the cutting machine source at Bayana and
further investigated for chemical, physical and mechanical properties like water absorption,
specific gravity besides the slump, density, compressive, flexural and split tensile strength &
abrasion resistance of concrete samples. A little research data are available in the use of sandstone
as fine aggregates hence this study will further contribute to the economy in construction,
controlling excess mining of river sand besides balancing the ecosystem.
2. Specification of constituting materials and formulation of test samples
The constituting materials properties and methods in the analysis of test samples are reported
below.
Pozzolana Portland Cement (PPC) specified as per IS 1489:2015 (Part-1) was used (specific
gravity-2.89, normal consistency- 31%), Coarse aggregates,10 mm size (Specific gravity-2.65,
fineness modulus 6.26) and 20 mm size (specific Gravity-2.65, fineness modulus 7.18), Natural
river sand specified to Zone-II as per IS-383: 2016 (specific gravity- 2.70, free surface moisture-
1.3% and fineness modulus-2.84, water absorption-1.4%) sandstone cutting waste confirming to
Zone-III as per IS 383:2016 were used as sustainable fine aggregates (average specific gravity-
2.56, fineness modulus-2.80, open porosity value-8.7%, clay content<5%) by replacing river sand.
Glenium Sky 8233, Poly-carboxylic Ether super-plasticizer free from alkali & chloride as per IS
9103 was used. Physical properties, as well as chemical properties and gradation of sandstone
cutting waste, is shown in Table 1& 2. It was observed that sandstone cutting waste in our
research were found in sub-mature group & sub-arkose type & grains are moderate to well sorted
in nature with the shape of sub-angular to sub-rounded, according to classification suggested by
Folk, (1974). Concrete design mixes were formulated as per guidelines of IS 10262:2009 and IS
456:2000 with selected water-cement ratio of 0.35, 0.4 and 0.45. 9 Nos. of concrete cubes (10cm
x 10cm x 10cm) were prepared to test compressive strength,6 Nos. of Flexural Beams (10 cm x 10
cm x 50 cm) were prepared to test flexure strength and 6 Nos. of concrete cylinders (15 cm x
30cm) were prepared to test split tensile strength. Concrete mix (C.M.) samples were prepared at
temperatures of (27±2) Degrees Celsius (°C). For measuring the workability of concrete mixes, a
slump test was performed and with the use of new generation superplasticizers the target slump
values (100±15mm) were achieved and the same was acceptable for pump-able slump (85mm
&above) concrete on site. The temperature in the curing tank was maintained for all design mixes
and IS-specifications were used to perform compressive, flexural, tensile strength & abrasion
resistance.
Table -1 Properties of sandstone cutting waste procured from Bayana (Rajasthan)
Physical Properties Chemical Properties (%)
Specific Gravity 2.56 SiO2 94.68
Water Absorption (%) 10.5 CaO NIL
Bulk Density (kg/cum) 1650 Loss on Ignition (LOI) 0.17
Fineness Modulus 2.80 Al2O3 0.24
Color Red Fe2O3 4.90

Table-2 Gradation of sandstone cutting waste (Sieve analysis)

IS Sieve Designation Cumulative Percentage(%) by Grading limits for Zone-
weight of the total sample Passing III as per IS 383-2016
each of the sieve(as per IS 2386-I) percentage(%) passing
10 mm 100 100
4.75 mm 98.10 90-100
2.36 mm 89.15 85-100
1.18 mm 75.90 75-100
 600 micron 60.40 60-79
300 micron 31.80 12-40
150 micron 9.30 0-10
75 micron 5.40 0-15

Table-3 Mix proportions for 0.35 w/c Ratio

Constituents of Sample ID
Concrete C.M. R-10% R-20% R-25% R-30% R-40% R-50% R-100%
Cement(kg/cum) 386 386 386 386 386 386 386 386
Coarse aggregates 696.8 696.8 696.8 696.8 696.8 696.8 696.8 696.8
(20mm)(kg/cum)
Coarse aggregates 458.7 458.7 458.7 458.7 458.7 458.7 458.7 458.7
(10mm)(kg/cum)
Fine aggregates 760.4 684.3 608.3 570.3 532.3 456.2 380.2 0
(Natural sand)
(kg/cum)
Sandstone Cutting 0 76.1 152.1 190.1 228.1 304.2 380.2 760.4
waste (kg/cum)
Water(kg/cum) 135.1 135.1 135.1 135.1 135.1 135.1 135.1 135.1
Admixture (%) 0.80 0.88 0.93 0.95 0.95 1.00 1.00 1.10
Table-4 Mix proportions for 0.40 w/c Ratio
Constituents of Sample ID
Concrete C.M R-10% R-20% R-25% R-30% R-40% R-50% R-100%
Cement(Kg/cum) 370 370 370 370 370 370 370 370
Coarse aggregates 700.1 700.1 700.1 700.1 700.1 700.1 700.1 700.1
(20mm)(kg/cum)
Coarse aggregates 465.6 465.6 465.6 465.6 465.6 465.6 465.6 465.6
(10mm)(kg/cum)
Fine aggregates 765.3 688.8 612.2 573.9 535.7 459.2 382.6 0
(Natural sand)
(kg/cum)
Sandstone Cutting 0 76.5 153.1 191.4 229.6 306.1 382.6 765.3
waste (kg/cum)
Water(kg/cum) 148 148 148 148 148 148 148 148
Admixture (%) 0.65 0.65 0.70 0.71 0.72 0.74 0.83 0.91

Table-5 Mix proportions for 0.45 w/c Ratio

Constituents of Sample ID
Concrete C.M. R-10% R-20% R-25% R-30% R-40% R-50% R-100%

Cement(Kg/cum) 330 330 330 330 330 330 330 330

Coarse aggregates 712.5 712.5 712.5 712.5 712.5 712.5 712.5 712.5
20mm)(kg/cum)
Coarse aggregates 475.6 475.6 475.6 475.6 475.6 475.6 475.6 475.6
(10mm)(kg/cum)
Fine aggregates 780.4 702.3 624.3 585.3 546.3 468.2 390.2 0
(Natural sand)
(kg/cum)
Sandstone waste 0 78.1 156.1 195.1 234.1 312.2 390.2 780.4
Cutting (kg/cum)
Water(kg/cum) 148.5 148.5 148.5 148.5 148.5 148.5 148.5 148.5
Admixture (%) 0.75 0.81 0.84 0.85 0.86 0.91 0.95 1.00

3.0 Experimental Approach

3.1 Concrete Properties and Methodology

3.1.1. Properties of Fresh Concrete

As per specification of IS 1199:1959, the slump cone apparatus is being used to perform
the workability (Slump) measurement of fresh concrete and similar specification is being used to
ascertain the oven-dried density as well as saturated density of concrete. Workability values, as
well as saturated & oven-dry density values of concrete, were determined with an increasing
percentage of sandstone cutting waste aggregates and further comparison was established with the
control concrete comprises of natural sand aggregates only. The observation of workability
(Slump) and density values of concrete are plotted by graphs for varying water-cement ratios. As
per observation, it was identified, as the percentage replacement of sandstone cutting waste
increases, the workability of concrete is decreasing, which is due to the higher amount of water
absorption (refer table-1) by these fine particles and internal friction in sub-angular particles.
However, the target slump was achieved in our research by adding a new generation super-
plasticizer and the target slump of (100±15) was obtained for all mixes. Quartzite sand has
positively influenced the workability of concrete, as it reduces the workability at a higher
replacement level in concrete (K. Kavitha et al, 2019). Similar slump loss values (140mm
to130mm) with an increase of marble slurry were reported by A. Rana et al (2015). While
comparing to conventional fine aggregates, densities of concrete samples containing sandstone
cutting waste were found to be increased up to 25-30% replacement level at all w/c ratios and
further, it started decreasing as the sandstone cutting waste replacement level was increased in
concrete. The reason for it was mainly due to the lower specific gravity of sandstone cutting waste
and the generation of internal voids in our research study. Due to the absorption of the water by
the quarry dust, it decreases the workability of concrete with an increase in quarry dust quantity
(Akshay C. Sankh et al, 2014)
 120 1.15
Slump value (mm)
115 1.1
Admixture(%)
1.05
Slump Value (mm)

110
1

Admixture (%)
105 0.95
100 0.9

95 0.85
0.8
90
0.75
85 0.7
80 0.65
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)
Fig-1 Slump versus sandstone cutting waste at 0.35 w/c ratio

2550

2500 Saturated density

(kg/m3)

2450 Ovendry

2400
Density

2350

2300

2250
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)
Fig-2 Density versus sandstone cutting waste at 0.35 w/c Ratio
 105 0.95
Slump value (mm)
Admixture(%)
0.9
100

Admixture (%)
Slump value (mm)

0.85
95
0.8
90
0.75

85
0.7

80 0.65
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)

Fig.3 Slump versus sandstone cutting waste at 0.4 w/c ratio

 2550

2500 Saturated density

Ovendry
Density (kg/m3)

2450

2400

2350

2300

2250
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)

Fig-4 Density versus sandstone cutting waste at 0.4 w/c ratio

115 1.05
Slump value (mm)
110 Admixture(%) 1
0.95
105
Slump value (mm)

Admixture (%)
0.9
100
0.85
95
0.8
90
0.75
85 0.7
80 0.65
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)

Fig-5 Slump versus sandstone cutting waste at 0.45 w/c ratio

 2550

2500
Saturated density
Density (kg/m3)

2450 Ovendry
2400

2350

2300

2250
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)

Fig.-6 Density versus sandstone cutting waste at 0.45 w/c ratio

3.1.2 Properties of Hardened Concrete

3.1.2.1 Compressive Strength

9 samples of concrete cubes (10cm x10cm x10cm) were cast with incremental percentages
of sandstone cutting waste. It was used as a sustainable substitute for natural river sand. Samples
comprise 3 specimens of each were prepared respectively at the ages of 7, 28 & 90 days. Cubes
prepared for compressive strength tests were demoulded after attaining 24 hours and cured further
in a curing chamber as per compliance of IS 516:1959. Any foreign matter observed on the
concrete surface was removed. The test was performed by applying a uniform compressive load at
a rate of 140 kg/cm2/minute and the maximum load was noted. The results with average values of
3 specimens are shown by Fig.7 and 8 for varying w/c ratio of 0.35, 0.4 and 0.45, and the
variation in compressive strength value was observed in tested samples. The replacement of
sandstone cutting waste in concrete up to 30% showed an increase in strength(38.85MPa,
44.58MPa) at 0.4 w/c ratio and increase in strength (37.2MPa, 37.56MPa) at 0.45 w/c ratio for 28
and 90 days respectively, when compared with control mix concrete. Similarly, replacement of
sandstone cutting waste up to10% showed the increase in strength (42.33MPa, 46.66 MPa)) at
0.35 w/c ratio for 28 and 90 days respectively, when compared with the control mix concrete. The
reason for strength increase was the filler effect of sandstone cutting waste particles and the
formation of a dense matrix of concrete up to 30% replacement. Further replacement beyond the
30% sandstone cutting waste in concrete indicated the reduction in compressive strength when
compared to the control mix concrete. The maximum of 18.5 % reduction in compressive strength
was observed for 100% replacement at 0.45 w/c ratio, while the maximum of 7.6% reduction of
strength was observed up to 40% replacement when compared with control mix concrete at later
ages. The study was validated by several researchers that the maximum compressive strength was
obtained on the replacement of 30% natural fine aggregates by stone processing dust and up to
70% replacement the strength was higher than control concrete (T. Gupta et al,2019). This is
further supported by literature that aggregate type has an effect on the compressive strength of
normal concrete as the highest compressive strength was achieved from concrete containing
crushed quartzite, followed by concrete containing river gravel. (Abdullahi. M, 2012).
 45
28 day Compressive Strength
W/C 0.35
40
W/C 0.40
35 W/C 0.45
(Mpa)

30

25

20

15
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting Waste replacement (%)
Fig.-7 Compressive Strength of cubes at 28 days with varying w/c ratio

50
45 W/C 0.35
W/C 0.40
40 W/C 0.45
90 day Compressive

35
Strength(MPa)

30
25
20
15
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)
Fig.-8 Compressive strength of cubes at 90 days with varying w/c ratio

Table-6 Compressive strength of concrete cubes with standard deviation at 28 days

W/c ratio Sandstone cutting waste (%)
0 10 20 25 30 40 50 100
0.45 37.08±1.05 38.5±1.24 38.24±1.45 37.5±1.57 37.2±1.12 30.45±1.24 29.68±1.0 28.8±0.9

0.40 38.5±1.23 40.6±1.08 39.6±1.51 39.1±1.33 38.85±1.06 37.8±1.21 32.33±1.09 31.33±1.2

0.35 41.66±1.36 42.3±1.37 41.33±1.89 39.83±1.75 39.0±1.92 37.8±1.05 34.0±1.8

32.16±0.76
 3.1.2.2 Flexural Strength

6 Nos. of Concrete beams (10cm x 10cm x 50cm) was cast with varying percentages of
sandstone cutting waste in concrete using different w/c ratios. Flexural strength tests were
performed for the ages of 28 & 90 days in compliance with IS 516: 1959. The concrete samples
were kept in water at an approximate temperature of 24 to 30 Degrees Celsius (°C). The samples
were tested in moist conditions using a two-point loading test setup. The loading rate was kept at
180 kg/min and applied gradually until the concrete specimen failed to ascertain the peak load.
Flexure strength test results indicate the higher strength values up to 25% to 30% replacement
level as compared to control mix concrete at 0.4 & 0.45 w/c ratio & higher strength value up to
10% in 0.35 w/c ratio.Though the flexural strength was found maximum with 10% replacement of
sandstone cutting waste in concrete at all the w/c ratios, the percentage increase in flexure strength
was 1.15% at 0.4 w/c ratio up to 25% replacement of sandstone cutting waste and 1.18% at 0.45
w/c ratio up to 30% replacement as compared to control mix concrete for 28 days. Flexural
strength of fines of waste glass concrete increased up to a substitution level of 20% when
compared to control concrete (K. Bisht et al, 2018). Similarly, flexural strength with limestone
slurry was found maximum at 50% replacement of river sand (Harshwardhan et al, 2018).
However, a sharp decrease in flexural strength was identified beyond the 30% replacement level
at 0.35, 0.4 & 0.45 w/c ratios.

10
28 day Flexural Strength (Mpa)

9 W/C 0.35

8 W/C 0.40
7 W/C 0.45
6
5
4
3
2
1
0 10 20 30 40 50 60 70 80 90 100

Sandstone cutting waste replacement (%)

Fig-9 Flexural strength of beams at 28 days with varying w/c ratio

Table-7 Flexural strength of beams with standard deviation at 28 days

W/c ratio Sandstone cutting waste (%)
0 10 20 25 30 40 50 100
0.35 8.96±0.41 9.32±0.45 8.44±0.49 8.14±0.34 7.88±0.25 6.24±0.39 6.12±0.33 5.48±0.13

0.40 7.86±0.29 8.65±0.24 8.44±0.51 7.95±0.20 7.48±0.12 5.82±0.25 5.80±0.19 5.07±0.18

0.45 6.78±0.23 8.03±0.13 7.88±0.20 7.14±0.19 6.86±0.14 5.19±0.23 5.32±0.15 4.45±0.16

 10
90 day lexuralStrength(MPa) W/C 0.35
9
W/C 0.40
8 W/C 0.45
7
6
5
4
3
2
1
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)

Fig-10 Flexural strength of beams at 90 days with varying w/c ratio

3.1.2.3 Split Tensile Strength

Concrete Cylinder 6 Nos. (15cm x 30cm) were cast with varying percentages of sandstone
cutting waste using different w/c ratios. This test was performed after 28 and 90 days in
compliance with IS 516: 1959. The concrete samples were kept in water at an approximate
temperature of 24 to 30 Degrees Celsius (°C). The samples were tested on a universal testing
machine while they were in a moist condition. During the testing, the load was applied until the
concrete specimen failed to ascertain the peak load. Split tensile test results shows higher strength
value (2.71MPa) up to 30% replacement level at w/c ratio of 0.4 and higher strength value
(2.7MPa) up to replacement of 25% at 0.45 w/c, when compared with control mix concrete value
(2.67MPa, 2.67MPa respectively) at 28 days, however higher strength value (3.1MPa) was
obtained up to 10% replacement level in the case of 0.35 w/c ratio when compared with control
mix concrete value (3.0MPa) at 28 days. The inclusion of fine bone china ceramic fine aggregate
resulted in a higher split tensile of the concrete. (S. Siddique et al, 2018). There was a sharp
reduction in tensile strength beyond the 30% replacement level of sandstone cutting waste in
concrete.
 28 day Split Tensil Strength (Mpa) 4

3.5

W/C 0.35
3
W/C 0.40
W/C 0.45
2.5

1.5

1
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting Waste replacement (%)

Fig-11 Split tensile strength of Cylindrical samples at 28 days with varying w/c ratio

4
W/C 0.35
3.5
W/C 0.40
90 day Split Tensile Strength

W/C 0.45
3

2.5
(Mpa)

1.5

1
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)

Fig-12 Split tensile strength of cylindrical samples at 90 days with varying w/c ratio
 Flexural test of beam samples Split Tensile test of cylinders

Fig-13 Images of the flexural test of beams & split tensile strength of cylinders

3.1.2.4 Abrasion Resistance Test

This test was performed on cubes (10cmx10cmx10cm) to measure the average depth of
wear by using 3 Nos. of cubes as per IS: 1237-2012, after curing of cubes for 28 days & further
being oven-dried at (110±5) Degrees Celsius (°C) for 24 hours. Initially, Oven-dried weight (W1)
of the sample was recorded and a test for abrasion was carried out on these cubes. For this test 20
gm of abrasive powder was applied on the grinding path of the machine. A total of 600 N load
was applied to the exposed surface area of cubes. The grinding disc revolution was kept 30 per
minute. The cube was rotated at 90 degrees clockwise about the vertical axis after every 22
revolutions. Further 20 gm fresh abrasive powder was applied on grinding disc. The entire
procedure takes 9 repetitions for each specimen so that the total number of revolutions would be
220. As per codal provisions, the average depth of wear should not exceed by 3.5mm & depth of
wear of individual specimen should not exceed by 4.0mm. The analysis of results with average
abrasion value of 3 specimens are plotted by graphs, which shows a slight increase in depth of
wear for all replacement level of sandstone cutting waste in concrete except 40% replacement for
both at 0.35 and 0.4 w/c ratio as compared to control mix concrete, however, the depth of wear
was found higher for all replacement level of sandstone cutting waste in concrete at 0.45 w/c ratio
as compared to control mix concrete. The abrasion results values depend upon surface hardness
and higher depth of wear was observed due to the large proportion of sedimentary processed
cutting particles and further chipping action of sandstone cutting waste in concrete. The same was
supported in literature that chipping action of abrasion is predominant in dislodging the rough
particles of stone processing dust from the concrete matrix (T. Gupta et al, 2019). However
average values of depth of wear were observed below 2mm in all samples at all replacement
levels and not exceeded by 3.5 mm. The same study is supported by abrasion studies done on
sandstone aggregates (S. Kumar et al, 2016).
 2
W/C 0.35
1.8 W/C 0.40
Average depth of wear

W/C 0.45
1.6
(mm)

1.4

1.2

1
0 10 20 30 40 50 60 70 80 90 100
Sandstone cutting waste replacement (%)

Fig-14 The average depth of wear versus sandstone cutting waste replacement (%)

3.1.3 Microstructure assessment of concrete by scanning electron microscope (SEM)

Microstructure analysis of concrete samples indicated that the grains of sandstones cutting
waste have different sizes but normally appear together. Their constituting network is formed by
quartz, feldspar (comprises of microcline & plagioclase) &lithic fragments, and its particles are
identified in shape as subrounded to rounded. The intrinsic framework of sandstone cutting waste
comprised of a major phase of quartz, microcline & plagioclase and the minor phase of muscovite,
calcite and clay minerals at their grain surfaces. Phyllosilicate minerals composed of clay and
rocky fragments hold these sandstone cutting waste particles. High quartz percentage was
observed in these sandstone cutting waste, but a small percentage of alumina was observed in
feldspar in the sandstone cutting waste, which suggests that they were lost in the soil profile, by
abrasion during transit, by the solution during diagenesis and the hydrolytic decomposition of less
resistant alumino-silicates minerals. Dissolution of alumino-silicates is favored by an acidic
reaction within the rock, low pH being a result of weathering of sulfides and precipitating iron
oxides and feldspars are significantly altered by kaolinization and sericitization (M. Marszałek et
al, 2014). The same is reported by M. Masroor Alam et al (2000),that low percentage of alumino-
silicates (feldspar) were observed, due to their alteration and leaching along cleavage and grain
boundaries. The texture of a sandstone exerts a major influence on its geotechnical properties. The
proportion of grain contact controls both strength and deformability (Dyke & Dobereiner, 2016).
From the analysis of SEM pictures, it was identified that sandstone cutting wastes are discrete
grains or particles formed due to sedimentary rock deposition by nature reveals slightly greater
porosity while going from the control mix sample(Porosity value-6.4%) to higher replacement
interval with sandstone cutting waste, because sedimentary sandstone cutting waste absorbs
higher water and creates spaces at interlink between aggregates and cement paste and further
lower the strength of concrete with the increasing percentage of sandstone cutting waste.
Similarly, the secondary reason for high porosity is the accumulation of sedimentary layers’ over
time due to the deposition process in sandstone cutting waste resulting in micro-voids formation
within the material. Porosity &dry density had been considered as major parameters for
influencing the physical & mechanical properties of sandstone(El-Sayed Sedak Abu
Seif,2016).SEM images reported by Fig-15 establish that the concrete samples up to 30%
replacement level of sandstone cutting waste(Porosity value-6.1%) have shown better hydration
mechanism with negligible voids at interfaces and similar internal compact structure like control
mix concrete samples, however, replacement with 50% & 100% sandstone cutting waste shows
porosity values of 7.8% & 11.1% respectively which indicates the increase in porosity
percentage and voids creation, further forming the weak interfacial transition zone (ITZ) and a
noticeable reduction in concrete strength, which is supported by (M. Ludovico-Marques et
al,2012).

Fig.15 SEM images of sandstone cutting waste in concrete samples

Fig.-16-Optical microscope images of concrete slices containing sandstone cutting waste

 3.1.4 Optical Microscope studies for the microstructure of Concrete

In the present investigation, concrete slices were taken from the in-situ concrete core
samples extracted from concrete cubes and were studied by using a stereoscope zoom microscope
(SMZ-1500) comprising the Nikon imaging system. This helps to evaluate the scanned images of
concrete with the magnification of 168.75x and micrometer scale as shown in Fig.-16.
Observation of the concrete surface in ultraviolet light using an optical microscope at the
magnification of 10 times is sufficient to detect Meso-level fine cracks and to provide an
automatic evaluation of the crack system (M.A. Glinicki et al, 2006). The major components
observed in the concrete cores are coarse aggregates, cement, and fine aggregates. The coarse
aggregates used in concrete are heterogeneous. The surface texture of coarse aggregate is
crystalline in all observed concrete slices & based on thin and polished sections of concrete slices
for control mix samples & samples of concrete containing 50% & 100 % sandstone cutting waste.
A thin-section image under UV light provides information about the features that may indicate the
quality of paste and aggregate, the air void system, structural defects such as cracks, their size and
distribution, thereby helping to determine the cause of concrete distress (J. Wawrzenczyk et al,
2019). It was observed that fine aggregates are uniformly distributed in the core and air voids in
control mix samples indicate corroded margins with the size of (8µm to 0.85mm), air voids at
30% replacement level of sandstone cutting waste indicates smooth margins with the size of (6
µm to 0.54mm), while at 50% replacement level it shows smooth margins but increase in the size
of air voids (15µm to 2.89mm) and at 100% replacement level it shows corroded margins but
further increases in the size of air voids (22µm to 4.33mm). In the control mix and up to 30%
replacement, the percentage of the closed void is more than open voids, while in 50% & 100%
replacement level, the percentage of the open void is more than closed voids. In control mix and at
30% replacement voids that are developed on the boundaries of aggregates are less in number,
while in 50% &100% replacement micro-cracks are developed at the margins of few voids.
Despite the limitation of pore size analysis by stereoscope zoom, it was observed that pore size
distribution was found in-homogenous and random in nature and percentage porosity values were
found increased beyond 50% as mentioned in 3.1.3, however, the stereoscope zoom microscopic
images represented by Fig-16 indicates air voids formation increases in size at higher
replacement level i.e. beyond 50% sandstone cutting waste in concrete and its reason is high
porosity, change of the microcrack opening with the formation of weak Interfacial Transition
Zone (ITZ) and this study is also supported by SEM Images as shown in Fig.-15 where better
rheology and compact microstructure was observed only up to 30% replacement level with
sandstone cutting waste.

4.0 Result & Discussions

• Slump values were found to be reduced in all concrete samples containing sandstone cutting
waste as compared to control mix concrete samples (comprises natural sand only), the reason of
it was the higher water absorption phenomenon and internal friction developed in sub-angular
particles of sandstone cutting waste, however, the target slump along with the pump-able slump
in concrete was achieved by using Poly-carboxylic Ether (PCE) super-plasticizer at all selected
w/c ratio.
• The results of saturated and oven-dried densities of concrete comprising sandstone cutting waste
were found to be increased up to 10% replacement level at 0.35 w/c ratio and up to 25 % at 0.40
& 0.45 w/c ratios, the reason of it was better particle packing of sandstone cutting waste particles
in concrete, however with further replacement beyond these limits as mentioned above indicated
the declining trends in the density values of concrete.
• From the analysis of results of compressive strength at w/c ratio of 0.35, 0.40 & 0.45, it was
identified that concrete samples comprise sandstone cutting waste, the strength was increased up
to 10% replacement level at 0.35 w/c ratio and up to 30 % replacement level at 0.40 & 0.45 w/c
ratios when compared with control mix concrete, however, at higher replacement beyond this, a
sharp decrease in compressive strength was observed.
• Flexural strength, as well as Split tensile strength test results, indicate that samples containing
sandstone cutting waste were found to be improved in comparison to control mix concrete, it was
observed that up to replacement of 25%-30 % sandstone cutting waste in concrete, the flexural
and tensile strength values were increased both at 0.4 & 0.45 w/c ratios, and the improvement in
strength for w/c ratio at 0.35 was observed up to 10 % replacement level only. However, beyond
this, a sharp decrease in strength was observed.
• Microstructure studies carried out with scanning electron microscope and stereoscope zoom
microscope shows that homogenous and dense matrix of concrete was formed up to 30%
sandstone waste in concrete, which was due to better hydration mechanism between aggregates
and cement paste, however interconnecting pore voids with an increase in pore size and micro
cracks at interfacial transition zone (ITZ) indicated the improvement in porosity between
aggregates and cement paste especially beyond 50 % replacement levels with sandstone cutting
waste and it was identified that internal cracks were formed at 50% and higher replacement of
sandstone cutting waste in concrete in all investigated series.
• Abrasion resistance test of sandstone cutting waste samples indicate that depth of wear was
increased slightly for all replacement level except at 40% replacement both at 0.35 & 0.4 w/c
ratios and the depth of wear was found increased for all replacement level at 0.45 w/c ratio when
compared to control concrete and depth of wear was found under 2.0 mm value at all w/c ratio
i.e. (0.3, 0.4 &0.45).

5.0 Conclusions

• The assessment of properties of sandstone cutting waste from the literature survey and testing
carried out in the laboratory, suggest that 25-30% sandstone cutting waste can be suitably
utilized in concrete by replacing river sand.
• The mix comprises of higher sandstone cutting waste requires a higher dosage of super-
plasticizer when the water-cement (w/c) ratio is low. This research shows that slump values are
decreasing with increasing levels of sandstone cutting waste in concrete when compared with
control mix concrete.
• The analysis of results of compressive strength of concrete comprising sandstone cutting waste
indicates higher strength values at 10% replacement level at 0.35 w/c ratio & higher strength
values up to 30% replacement level at 0.40 & 0.45 w/c ratio for both 28 & 90 days when
compared with control mix concrete. Filler effect of sandstone cutting waste is responsible for
gaining strength.
• Flexural strength & split tensile results also furnish the higher strength values up to 25-30%
replacement level both at 0.4 & 0.45 w/c ratios, when compared with control mix concrete.
• Abrasion Testing of all concrete samples for selected w/c ratio indicates a slight increase in
depth of wear as compared to control mix concrete because sandstone cutting waste is not
considered as hard aggregates & chipping action might be responsible for higher abrasion.
Overall values were found within 3.5mm limit at all replacement levels as per the provision of
code.
• Concrete microstructure studies carried out with SEM & Stereoscope zoom microscope indicate
that stable composition, densification, and better morphology was observed up to replacement
level of 30 % at all w/c (0.35, 0.4 & 0.45) of our research program. Due to the increase in
 porosity in finer grain texture of sandstone cutting waste particles, internal cracks were formed
especially beyond 50% replacement of sandstone cutting waste in concrete.
• Sandstone cutting waste can be considered as a genuine alternative of natural river sand based on
the performance of its mechanical perspectives and where strength is primarily important and
validate a worthwhile material in the production of structural concrete and lightweight concrete
applications.

Acknowledgments

Research data collected & summarised in this research paper is the outcome of the studies
done from many research projects & literature survey. The author appreciates the help &
valuable support provided by the Centre for Development of Stones, Jaipur and Material
Research Centre Lab at MNIT Jaipur, Rajasthan.

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 Highlights

• Sandstone concrete waste is used as partial replacement of natural fine river sand in cement concrete.
• Compressive, flexure and tensile strength were improved up to 30% replacement of sandstone cutting waste in
concrete.
• Sand stone cutting waste improves the particle packing and filler effect in concrete which is responsible for strength
improvement.
• Microstructure studies also indicated better hydration mechanism and compact internal structure up to 30 % use of
sandstone cutting waste in concrete.
 AUTHOR DECLARATION
We wish to show our full co-operation with this publication (title“Sandstone Cutting Waste
as partial replacement of fine aggregates in Concrete: A Mechanical Strength
perspective”) and there has been no significant financial support for this work that could
have influenced its outcome. We confirm that the manuscript has been read and approved by
all named authors and that there are no other persons who satisfied the criteria for authorship
but are not listed. We further confirm that the procedures and concepts listed in the
manuscript has been approved by all of us.
We confirm that we have given due consideration to the protection of intellectual property
associated with this work and that there are no impediments to publication, including the
timing of publication, with respect to intellectual property. We confirm that we have followed
the regulations of our institutions concerning intellectual property.
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Sanjay Mundra (Corresponding Author),

Doctoral candidate,
Dept. of Civil Engineering,
Malaviya National Institute of Technology,Jaipur, India.