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Research Paper
waste
ABSTRACT
The fine aggregate or sand is a major component in development of all cementitious products.
Procurement of sand poses economical and environmental challenges. Various alternatives to
conventional fine aggregates were explored and reported. These alternatives are filtered sand, slag
sand, recycled construction and demolition waste, used foundry sand and many others., were used as
partial substitute to conventional fine aggregates in making mortar and concrete. Quality studies report,
considering strength requirements a maximum of 20 – 50% of alternative aggregates can be utilized as
partial replacement to conventional fine aggregates. In this study, the physical and mechanical behavior
of mortars made with brick waste as a replacement to M sand is evaluated. The fines (viz., particles
smaller than 150 μm) in fine aggregate was restricted to 15%. Basic tests such as grain size
distribution, fineness modulus, specific gravity of Msand were brick masonry waste were performed.
Two mortar proportions i.e.,1:4 and 1:5 (Cement: fine aggregate) were explored for its workability,
physical and mechanical properties. The outcome of the study indicates maximum compressive, flexure
and split tensile strength when brick masonry waste was up to 25% - 50%. Silica content in brick
masonry waste was found lesser than Msand using EDAX (Energy Dispersive Analysis of X Rays).
However, cost of mortar was found to reduce by 6.15% and 7.3% for mortar proportion 1:4 and 1:5
respectively. The embodied energy of mortar was found to reduce by 6 to 7% for every 25%
replacement of Msand replaced by brick masonry waste.
Keywords: Mortar, Msand, Brick masonry waste, Compressive strength, Cost, Embodied energy.
INTRODUCTION
Construction and demolition waste (C&D) poses significant challenges worldwide, particularly in
developing countries like India and others, where these wastes are generated in large quantities during
construction and demolition activities. The improper management of C&D waste causes pollution,
traffic congestion, and a decrease in the fertility of the soil, among other environmental problems.
Despite early efforts to recycle C&D waste, its widespread adoption has been limited. However, there
is a lack of awareness among a significant portion of the infrastructure sector regarding recycling
methods. Establishing quality standards for materials and products made from recycled aggregates is
recommended to ensure product quality and encourage adoption. Use of marble dust as a substitute to
cement, results in enhancement in water resistance, shrinkage strain reduction and reduction in cement
demand by upto 33% [1]. The porosity of mortars increased upon using waste clay brick either in
presoaked or in dry condition [2]. Mortar made with marble aggregate and porcelain aggregate with
water cement ratio of 0.485 and super plasticizer of 0.004 resulted in compressive strength of the range
of 45 MPa [3]. Replacement of Incinerator bottom ash in cement mortar causes reduction in
flowability, compressive strength and unit weight. Processed Incinerator bottom ash can improve its
cementitious properties due to pozzolanic reaction [4]. Utilization of 40% ground clay brick waste as
Alkali activated cements improved strength properties of paste and mortar after 7 and 28 day of curing
[5]. Strength properties of mortars was independent on gradation of sand, although, deformation
characteristics was significantly influenced by grading of sand [6]. Strength of mortar at initial ages
increases when nano -TiO2 is added to mortar as cement substitute by 5 – 10%. The change of
orientation index for nucleus function can be attributed as the reason of strength improvement of
mortar [7]. Use of waste plastic based aggregates results in reduced density, binding capacity and
strength of mortars [8]. In case of cement mortar, the compressive strength and split tensile strength
ratio does not vary linearly. But the ratio is inversely proportional to mortar porosity [9]. Recycled
aggregates treated with Sulfoaluminate cement and fly ash treated or impregnated with sodium silicate
resulted in increased compressive strength of mortar by 34.8% and 32.4% respectively after 28 days
curing [10]. Replacing 50% of standard sand with recycled sand, along with the addition of 1%
superplasticizer, resulted in strength characteristics comparable to mortar made with standard sand and
20% reduction in elastic modulus [11]. Using fine reused concrete particles that have been dried, led to
higher slump values and improved compressive strengths compared to mortars with saturated reused
aggregates of concrete, while the sand replacement with recycled sand reduced the mortar density [12].
The use of reused fine aggregates improved compressive strength, bond strength, and flexural qualities,
although these characteristics were inferior when compared to mortars made aggregates acquired from
natural sources [13]. Due to the enhancement of the interfacial transition zone and microhardness of the
paste matrix, recycled fine aggregates (RFA) replacement was found to be favorable in boosting the
compressive strength of cement mortars [14]. Incorporating 10% fine ceramics in mortars improves
compressive and bending strengths. Considering shrinkage and permeability, 10% replacement
exhibited optimal properties despite potential limitations [15]. Use of ultra fines derived from recycled
or natural aggregates resulted in brittle abrupt failure [16]. The influence of sand grading viz., decrease
in fineness modulus led to increased water cement ratio and water retentivity, while decreasing density
and compressive strength [17]. Use of marble and brick waste are used in place of aggregate in mortars
resulted in enhanced compressive and bending strength by 7% and 56%, respectively [18]. The
consistency of mortar was greatly dependent on the utilization percentage and type of recycled
aggregate used [19, 23]. Microstructure studies indicate good adhesion of cement and brick waste after
28th day of curing and mortar production [20]. Physical and pozzolanic pore-filling effects due to
addition clay brick waste (CBW) lead to enhanced strength and density in the cured mortars [21, 25].
Similar to other recycled aggregates, use of waste brick powder resulted in linear decrement in
workability and density of mortar when water/binder ratio was maintained constant. Although, for low
percentage of brick waste utilization viz., 20%, the cement content can be decreased by 33% [26].
Findings from both, the literature survey as well as that of real time concerns of the construction sector,
two major concerns are highlighted. One, the continuous consumption of river sand and M – sand.
Second, the continuous production of construction and demolition waste. Addressing these issues will
impart multifold benefits such as conservation of natural resource and effect utilization and
management of industrial waste. Thus the current research was focused to analyse the properties and
characteristics of mortar with the sand replacement with fine aggregate sourced from construction
waste by limiting fines content.
120
100
Percentage passing (%)
80 C&DW
25% C&DW
60
50% C&DW
75% C&DW
40
M-sand
20 ZII UL
ZII LL
0
0.1 1 10
Particle size (mm)
The fines in all the mixes were restricted to 15 %. The specific gravity linearly decreased as percentage
replacement of M sand by BMW was increased. M-sand and Modified M-sand was found to confirm
Grade II category as per of IS:383-2016 [27]. All variants of sand with different proportions of
construction waste are classified as well graded.
• The study is associated with the evaluation of physical properties of mortars of proportion 1:4 and
1:5 (cement: fine aggregate).
• The fine aggregates used in mortars will be replaced by brick waste at intervals of 25 to 100 % at
increament level of 25%.
• Fines (fine aggregates <150 microns) present in the aggregate will be limited to 15% by weight of
the mortar samples.
• Properties such as compressive strength, bending strength, water absorption were studied at 7, 14
and 28 day intervals.
The mortar compression strength were evaluated by testing cube of size 50*50*50 mm conforming to
IS 10086-1999 [28]. The compression strength is determined by loading the cube with the compression
loads. The mould is placed in a compression testing machine. A constant loading of 4 MPa /min was
adopted as per IS 2250 -1980.
Mortar bending strength was evaluated by testing a beam sample of size 40mmx40mmx160mm
beams, as per ASTM 348, 349 - 14. The beam is marked such that single point loading is facilitated. A
proving ring of 100KN capacity was used to measure to failure load of cubes and beams.
The split tensile strength of mortar were evaluated using cubes of dimension 150mm *150mm *150mm
according to IS 5816-1999 [29]. An uniform loading at 1.8MPa was fixed corresponding ultimate load
was noted.
18 7 day
15 14 day
28 day
12
9
6
3
0
0% 25% 50% 75% 100% 0% 25% 50% 75% 100%
1:4 proportion 1:5 proportion
Compressive strength Compressive strength
Mortar respectively when M sand was replaced by 50%.It was also observed from the experimental
results that the flexural strength was around 7 to 8% of compressive strength of mortar across both the
proportions. Whereas, split tensile strength had a higher variation ranging between 15% to 26% for
both mortar proportions.
3.5
3.0
2.5
Stress (MPa)
2.0 0%
1.5 25%
50%
1.0 75%
0.5 100%
0.0
0.00000 0.00020 0.00040 0.00060 0.00080 0.00100
Strain
3.5
3.0
2.5
Stress (MPa)
2.0 0%
1.5 25%
50%
1.0 75%
0.5 100%
0.0
0.00000 0.00020 0.00040 0.00060 0.00080 0.00100
Strain
Table 5: Elemental Composition of M – Sand and BMW Passing IS for 4.75mm sieve.
Elemen M - Sand BMW
t Weigh Weight Atom Weight Weight Atom
Line t % % % % Error %
% Error
CK 2.26 ± 0.59 3.5 3.65 ± 0.53 5.57
8
OK 58.80 ± 0.51 70.1 64.46 ± 0.48 73.85
0
Na K 0.51 ± 0.10 0.4 --- --- ---
2
Al K 1.00 ± 0.07 0.7 1.90 ± 0.11 1.29
1
Si K 36.25 ± 0.25 24.6 28.93 ± 0.20 18.88
2
KK 0.59 ± 0.06 0.2 --- --- ---
9
Ca K 0.59 ± 0.07 0.2 0.51 ± 0.10 0.23
8
Fe K --- --- --- 0.56 ± 0.12 0.18
Note:
Table 7(b): Cost analysis for 1:5 mortar mix for 1m3
Cost analysis ( in INR)
BMW replacements (%) 0 25 50 75 100
Cement 2594 2594 2594 2594 2594
DBW 0 68.75 137.5 206.25 275
M - Sand 1441.8 1081.35 720.9 360.45 0
Labour 496 496 496 496 496
Intermediate Total 4532 4241 3949 3657 3335
Water Charges 67.98 63.15 59.23 54.86 50.03
Tools and Plants 67.98 63.15 59.23 54.86 50.03
Total material costs 4668 4368 4068 3767 3436
Contractor's profit 467 437 407 377 344
Overall costs 5135 4805 4475 4144 3780
FINE AGGREGATE COST VARIATION
Total Fine Aggregate Cost 1441.8 1150.1 858.4 566.7 275
% Variation FA Cost ----- 20.23 25.36 33.98 51.47
Cost analysis was performed to understand the variation of cost mortar and modified fine aggregates
used. The cost saving of 1:4 mortar was found to vary from 5.6 for 25% to 22.43% for 100%. The
average cost reduction for every 25% of M-sand replaced by BMW was 6.15%. Similar cost saving
observed for 1:5 mortar proportion, reduction in cost observed to vary from 15.08% to 33.19%.
Average cost reduction was 7.37%.
4. CONCLUSIONS
1. Specific gravity of M sand and modified M sand reduced steadily from 2.81 to 2.14 as the
replacement percentage of M sand was increased from 0 to 100% of C&D waste. No considerable
variation in fineness modulus was observed as the fines percentage of fine aggregate was limited
to 10%. Fineness modulus of aggregates was found to range from 2.82 to 2.97.
2. Water cement ratio and water absorption of hardened mortar increased with increased percentage
of C&D waste. With maximum values of water cement ratio and water absorption was 1.3 – 1.5%
and 22 – 23% respectively.
3. Mortar compressive and flexural strength increased for 25% M sand replaced Mortar for both
grades. However, maximum split tensile strength was found when M sand was replaced by 50%
of C&D waste. Maximum compressive strength values were 18MPa and 16.8MPa for 1:4 and 1:5
mortar grade respectively. Maximum flexural strength values were 1.31MPa and 1.19MPa for 1:4
and 1:5 mortar grade respectively. Flexural strength was found to be around 7 – 8% of
compressive strength across all mortar grades and replacements. The maximum split tensile
strength values were 3.21MPa and 2.65MPa for 1:4 and 1:5 mortar grade respectively.
4. For every 25% M sand replacement with brick waste, 6.15 to 7.37% reduction in total cost of
mortar was observed for 1:4 and 1:5 mortar mix respectively. Maximum cost saving of the order
22.43% (1:4 mortar) to 33.19 (1:5 mortar) was observed when 100% BMW was used.
5. Average energy reduction for both the mortar proportion was found to be in the range of 6-7%.
However, mortars with 50% M-sand and 50% BMW exhibited compressive strength more than
10MPa (H1 grade as per IS 1905-1987 [31]), this results in reduction in energy for every 1m 3
mortar.
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