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CHAPTER 1

INTRODUCTION

1.1. General

Nowadays, concrete made with Portland cement is probably the most widely used man

made material in the world. Despite this fact, concrete production is one of the concerns worldwide

that impact the environment with major impact being global warming due to CO2 emission during

production of cement. It is estimated that cement production is responsible for about 3% of the

global and throgenic greenhouse gas emission and for 5% of the global anthrogenic CO2 emission [12].

As about 50% of the CO2 released during cement production is related to the decomposition

of limestone during burning, mixing of clinker with supplementary materials called blending is

considered as a very effective way to reduce CO2 emission [12]

Most common blending materials used in cement production added in plant or sites are

industrial wastes. This is due to the fact that recycling of industrial wastes as blending materials

has technical, economical and environmental benefits besides the reduction of CO2 emission from

cement production.

Cement consist of grinding the raw materials, mixing them intimately in certain proportions

depending upon their purity and composition and burning them in kiln at a temperature about 1300

to 15000C,at which temperature, the material sinters and partially fuses to form nodular shaped

clinker. The clinker is cooled and ground to fine powder with additions of about 3 to 5% of

gypsum. The product formed by using this procedure is Portland cement.

There are two processes known as “wet” and “dry” processes depending upon whether the

mixing and grinding of raw materials is done in wet or dry conditions. With a little change in the

above process we have the semi-dry process also where the raw materials are ground dry and then

mixed with about 10-14 per cent of water and further burnt to clinkering temperature.

Concrete is strength and tough material but it is porous material also which interacts with

the surrounding Environment. The durability of concrete depends largely on the movement of

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water and gas enters and moves through it. The permeability of concrete depends on its pores

structure even the best of concrete is not gas tight or water tight. The permeability is an indicator

of concrete’s ability to transport water more precisely with both mechanism that is controlling the

uptake and transport of water and gaseous substances into cementitious material. Permeability is a

measure of flow of water under pressure in a saturated porous medium while Sorptivity is

materials ability to absorb and transmit water through it by capillary suction.

Marble industry produces large amounts of waste marble e what causes environmental

problems. In paving blocks based on two cement types we have partly replaced aggregate with

waste marble. Physical and mechanical tests were performed on blocks so produced. The cement

type turns out to be an important factor. Mechanical strength decreases with increasing marble

content while freeze-that durability and abrasive wear resistance increase. Waste marble is well

usable instead of the usual aggregate in the concrete paving block production.

The marble has been commonly used as a building material since ancient times. Disposal of

the waste materials of the marble industry, consisting of very fine powders, is one of the

environmental problems worldwide today. However, these waste materials can be successfully and

economically utilized to improve some properties of fresh and hardened self-compacting concrete

(SCC).

Cement consist of grinding the raw materials, mixing them intimately in certain proportions

depending upon their purity and composition and burning them in kiln at a temperature about 1300

to 15000C,at which temperature, the material sinters and partially fuses to form nodular shaped

clinker. The clinker is cooled and ground to fine powder with additions of about 3 to 5% of

gypsum. The product formed by using this procedure is Portland cement.

There are two processes known as “wet” and “dry” processes depending upon whether the

mixing and grinding of raw materials is done in wet or dry conditions. With a little change in the

above process we have the semi-dry process also where the raw materials are ground dry and then

mixed with about 10-14 per cent of water and further burnt to clinkering temperature.

Marble industry produces large amounts of waste marble e what causes environmental

problems. In paving blocks based on two cement types we have partly replaced aggregate with

waste marble. Physical and mechanical tests were performed on blocks so produced. The cement 2

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type turns out to be an important factor. Mechanical strength decreases with increasing marble

content while freeze-thaw durability and abrasive wear resistance increase. Waste marble is well

usable instead of the usualaggregate in the concrete paving block production.

Concrete is strength and tough material but it is porous material also which interacts with

the surrounding environment.The durability of concrete depends largely on the movement of water

and gas enters and moves through it. The permeability of concrete depends on its pores structure

even the best of concrete is not gas tight or water tight. The permeability is an indicator of

concrete’s ability to transport water more precisely with both mechanism that is controlling the

uptake and transport of water and gaseous substances into cementitious material. Permeability is a

measure of flow of water under pressure in a saturated porous medium while Sorptivity is

materials ability to absorb and transmit water through it by capillary suction.

The marble has been commonly used as a building material since ancient times. Disposal of

the waste materials of the marble industry, consisting of very fine powders, is one of the

environmental problems worldwide today. However, these waste materials can be successfully and

economically utilized to improve some properties of fresh and hardened self-compacting concrete

(SCC).

The aim of this study is to find some relationship between properties of the fresh SCC and

the hardened SCC containing marble powder. For this purpose, the mix design approach based on

monogram developed by Monteiro and co-workers for normal vibrated concrete was adapted to

SCC mixes. In order to obtain this monogram, a series of SCC mixes with different water/cement

ratios and water/powder ratios were prepared. Several tests such as slump-flow, T500 time, L-box,

V-funnel and sieve segregation resistance were applied for fresh concrete and tests such as

compressive strength and split-tension strength at 7 28 days were performed for hardened

concrete. In conclusion, the mix design method based on monogram can be suggested for

preliminary design in SCC





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global anthrogenic greenhouse gas emission and for 5% of the global anthrogenic CO2 emission [12].



considered as a very effective way to reduce CO2 emission [12].




cement production.

The technical importance of using wastes and by-products in concrete production is

expressed by performance improvement of concrete. The economical benefit usually attributes to

the reduction of the amount of expensive and or scarce ingredients with cheap materials.

Environmentally, when industrial wastes are recycled not only the CO2 emissions are reduced but

residual products from other industries are reused and therefore less material is dumped as landfill

and more natural resources are saved [28].

Fly ash, blast furnace slag and silica fume are most widely used industrial wastes in place

of cement for concrete production attributed to their reactivity nature called pozzolanic behavior.

In addition to pozzolanas, other inert by-products and waste materials have been used in

concrete and mortar production as inert filler for similar reasons. Among these, marble waste

powder which is a by-product of marble processing factory was studied by many researchers for its

use in concrete and mortar production as sand replacing or cement replacing material. Most of the

researches showed positive results and benefits. However as the by-product i.e. the powder differs

chemically depending on the parent marble rocks which depends on the locality, degree of

metamorphism and other factors; and also as the physical characteristics of the by-product depends

on the polishing work, it is necessary to conduct similar research in our country to incorporate it in

concrete and cement production for reduction of environmental pollution and sustainable use of

natural resources.

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The aim of this study is to find some relationship between properties of the fresh SCC and

the hardened SCC containing marble powder. For this purpose, the mix design approach based on

monogram developed by Monteiro and co-workers for normal vibrated concrete was adapted to

SCC mixes. In order to obtain this monogram, a series of SCC mixes with different water/cement

ratios and water/powder ratios were prepared. Several tests such as slump-flow, T500 time, L-box,

V-funnel and sieve segregation resistance were applied for fresh concrete and tests such as

compressive strength and split-tension strength at 7 & 28 days were performed for hardened

concrete. In conclusion, the mix design method based on monogram can be suggested for

preliminary design in SCC





global anthrogenic greenhouse gas emission and for 5% of the global anthrogenic CO2 emission [12].



considered as a very effective way to reduce CO2 emission [12].




cement production.






and more natural resources are saved [28] .

Fly ash, blast furnace slag and silica ume are most widely used industrial wastes in place

of cement for concrete production attributed to their reactivity nature called pozzolanic behavior.5

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natural resources.

The difference between fly ash and Portland cement becomes apparent under a microscope.

Fly ash particles are almost totally spherical in shape, allowing them to flow and blend freely in

mixtures. That capability is one of the properties making fly ash a desirable admixture for

concrete.






and more natural resources are saved [28].

Fly ash, blast furnace slag and silica fume are most widely used industrial wastes in place

of cement for concrete production attributed to their reactivity nature called pozzolanic behavior.








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natural resources.

1.2. Production of Marble, as Dimensional Stone, in Rajasthan

The term “dimensional stone” is defined by United States Bureau of Mines as naturally

occurring rock material cut, shaped or selected for use in blocks, slabs, sheets or other construction

units of specified shapes or sizes and used for external or interior parts of buildings, foundations,

curbing, paving, flogging, bridges, revetments or other architectural or engineering purposes. The

term is also applied to quarry blocks from which pieces of fixed dimensions may be cut [9].

Marble, granite, limestone, and sandstone provide the bulk of dimensional stone; although

slate, diorite, basalt and diabase are included. The classification of dimensional stone is not strictly

adhered to sedimentary, igneous and metamorphic grouping of geology, as the stone trade name

under “granite” refers to all true granite and gabbro, norite, and syenite. Likewise all crystalline

limestone, travertine, sandstone and serpentine that are capable of taking a polish are grouped

under marble in addition to the true marble[9].

The commercial definition of marble refers to all crystalline rocks predominantly

composed of calcite, dolomite, or serpentine. The root word for marble-mar more- was used by the

Italians in ancient Rome, referring to all hard rock’s capable of taking a polish including granite.

However, marble in the geologic usage is a metamorphosed limestone or dolostone, which

obliterated its original texture due to intensive re-crystallization [9].

1.3. Justification for the project

There are two types of by-products of marble processing. During marble processing, 30%

of the stone (in case of unprocessed stone) goes to scrap because of being smaller size and/or

irregular shape. This is then sold to chip manufacturers. In case of semi-processed slab, the scrap

level reduces to 2-5%. The other waste material is slurry. It is basically the water containing

marble powder. The water is reused till it gets thick enough (70% water and 30% marble powder)

to be reused. It can be safely estimated that 1 ton of marble stone processed in gang-saw or a

vertical/horizontal cutter produces almost 1 ton of slurry (70% water) [29].

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In addition to loss, disposal of this waste material will cause the following environmental

problems:

a) If the waste is disposed on soils, the porosity and permeability of topsoil will be reduced, the

fine marble dust reduces the fertility of the soil by increasing its alkalinity [7].

b) When the waste is dumped and dried out, the fine marble dust suspends in the air and slowly

spread out through wind to the nearby area. [7]

c) When dumped along a catchment area of natural rainwater, it results in contamination of over

ground water reservoir and also cause drainage problem [7]

Currently there are more than four marble processing plants in Rajasthan located in

different towns. The Rajasthan Marble Processing Enterprise and R.K Marble are located in

Kishangarh. The Rajasthan Marble Processing Enterprise has three branches located at Kankroli ,

Bani Sapole and Albeta sub city.

For instance Ordinary Portland cement and Portland Pozzolana cement types are the only

product produced by cement factories and found on the market for all types of work which is

expensive and uneconomical [1]. Trials to solve cement shortage only by increasing cement

factories have another negative environmental impact due to the emission of CO2 from the

factories.

1.4. Objectives of the Project

In this project our main objective is to study the influence of partial replacement of cement

with marble powder, and to compare it with the compressive and tensile strength of ordinary M 20

concrete. We are also trying to find the percentage of marble powder replaced in concrete that

makes the strength of the concrete maximum.

Nowadays marble powder has become a pollutant. So, by partially replacing cement with

marble powder, we are proposing a method that can be of great use in reducing pollution to a great

extent.

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1. To study the influence of replacement of cement by marble waste powder on compressive

& tensile strength of M25 grade concrete.

2. To find the optimum percentage of replacement of cement with marble waste powder, so

that the strength of concrete is maximum.

1.5. Procedure

Fundamental for the formation of the whole project work, a comprehensive literature

review is made to understand the previous efforts which include the review of text books,

periodicals and academic journals, and research papers.

The method In order to achieve the objectives of the project and for the development of

concepts, which are followed to achieve the objectives of the project, determines the required data,

which intern is a ground to decide on type and method of data collection and their analysis.

Different alternative data collection methods such as experiments, observations and archival

records are examined and used when proved suitable.

Both primary data (collected personally) from the source itself and secondary data from

different sources is collected and used for the analysis. The test results were presented in tabular

and graphical forms and the analysis and discussions were also made on the project findings both

qualitatively and quantitatively. Finally based on the findings, conclusions and recommendations

were forwarded.

Step 1 we check the properties of the material used in the concrete mix design.

(a) Specific gravity of the cement

(b) Initial and final setting time of the cement

(c) Standard consistency of the cement

(d) Soundness of the cement

(e) Sieve analysis of the coarse aggregate and Sand.

(f) Specific Gravity of Marble powder

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(g) Water absorption of the coarse aggregate and Sand.

(h) Apparent Specific gravity of aggregate

(i) check the consistency of cement

Step 2 Prepare a M 25 Mix design

(a) By weight

(b) Check the slump value

(c) Comp. Strength and Split Tensile Strength of the mix design in 7 days and 14 Days resp.

Step 3 Casting of Cubes and Cylinders

Total number 24 cubes and 24 cylinders will be casted in a concrete lab. Marble powder

will be added in concrete in step of 6% (0%, 4%,8%, 12%,16% and 20%). For each percent of

marble powder replacing cement, 6cubes & 6 cylinders will be casted for 7 days,14days & 28

days.

Final strength of cube & cylinder will be tested after 7, 14 & 28 days of curing.

Compression testing machine is used for testing the compressive strength of cube and split tensile

strength of cylinder.

Step 4

The Crushing loads will be noted and average compressive strength and tensile strength for

three Specimens will be determined for each.

Step 5

The test result will be presented in tabular and graphical forms.

1.6. Structure of the project

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The project has six chapters that discuss various aspects of cement and concrete related

with relevance of the project. Chapter one explains the background and the objectives of the

project. Chapter two is literature review which provides a general understanding of previous

studies and theories related to the project .

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CHAPTER-IILITERATURE REVIEW

V. M. Sounthararajan et.al(2013)have done their research on EFFECT OF THE LIME CONTENT IN MARBLE POWDER FOR PRODUCING HIGH STRENGTH CONCRETE. They found that the waste marble powder up to 10% by weight of cement was investigated for hardened concrete properties. Furthermore, the effect of different percentage replacement of marble dust on the compressive strength, splitting tensile strength and flexural strength was evaluated. It can be noted that the influence of fine to coarse aggregate ratio and cement-to-total aggregate ratio had a higher influence on the improvement in strength properties. A phenomenal increase in the compressive strength of 46.80 MPa at 7 days for 10% replacement of marble powder in cement content was noted and also showed an improved mechanical property compared to controlled concrete.

Vaidevi C (2013) have done their research on STUDY ON THE MARBLE DUST AS PARTIALLY REPLACEMENT OF CEMENT IN CONCRETE .They found that the marble dust from marble processing is a waste utilized. The use of this waste was proposed in different percentages both as an addition to and instead of cement, for the production of concrete mixtures. In this study, the use of marble dust collected during the shaping process of marble blocks has been investigated in the concrete mixtures as cementitious material. The study showed that marble wastes, which are in the dust form, could be used as cementitious material in concrete mixtures where they are available and the cost of construction is lower than ordinary concrete materials. The concrete is prepared containing 5, 10, 15 and 20% waste of marble dust with cement compared to the total quantity of normal concrete. The prepared mixtures were then studied in terms of their properties both in fresh and in hardened state. In this particular, tests they conducted and cured at different times to find compressive strength and tensile strength with and without partial replacement of marble dust in cement concrete and for mortar also determined for 14 and 28 days.

Nutan Patel et.al(2013) have done their research on Marble Waste Opportunities For Development of Low Cost Concrete. They found that Marble waste is estimated that there are million tons of quarrying waste are produced in each year. Although a portion of this waste may be utilized on-site such as for excavation pit refill. Waste generated at quarries and fabrication plants is quite similar. Most commonly, scrap stone must be mitigated and managed, but attention must be paid to other types of wastes, as well. These include marble sludge/slurry. Marble sawing powder wastes is widespread by-product of industrial process in India. Generally these wastes pollute and damage the environment due to sawing and polishing processes. This waste is used for making a marble waste concrete. The main aim of this research is waste management is to evaluate recovery and use marble waste in making a low cost concrete.

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Baboo Rai et.al(2011) have done their research on Influence of Marble powder/granules in Concrete mix .They found that using marble powder and granules as constituents of fines in mortar or concrete by partially reducing quantities of cement as well as other conventional fines in terms of the relative workability & compressive as well as flexural strengths. Partial replacement of cement and usual fine aggregates by varying percentage of marble powder and marble granules reveals that increased waste marble powder or waste marble granule ratio result in increased workability and compressive strengths of the mortar and concrete.

Noha M. SolimanȦ (2013) have done their research on Effect of using Marble Powder in Concrete Mixes on the Behavior and Strength of R.C. Slabs.They found that the use of marble powder as partially replace of cement on the properties of concrete. The influence of using marble powder on the behavior of reinforced concrete slabs is also investigated. The main variable taken into consideration is the percentage of marble powder as partial replacement of cement content in concrete mixes. They shows that, using definite amount of marble powder replacement of cement content increases the workability, compressive strength and tensile strength and used of marble powder enhanced also the structural performance of the tested slabs as it increased the stiffness and the ultimate strength compared to the control slabs.

Er. Tanpreet Singh et.al (2013) have done their research on Influence of Marble Powder on Mechanical Properties of Mortar and Concrete Mix.They found that using waste materials from different manufacturing activities in the preparation of innovative mortar and concrete. The use of waste marble powder (dust) was proposed in partial replacement of cement, for the production of Mortar and Concrete Mix. In particular, tests they were conducted on the mortars and concrete mix cured for different times in order to determine their workability, flexural as well as compressive strength. Partial replacement of cement by varying percentage of marble powder reveals that increased waste marble powder ratio result in increased workability and compressive strengths of the mortar and concrete.

Omar M. Omar et.al (2012) have done their research on Influence of limestone waste as partial replacement material for sand and marble powder in concrete properties .They found that the replacement proportion of sand with limestone waste, 25%, 50%, and 75% were in the concrete mixes except in the concrete mix. Besides, proportions of 5%, 10% and 15% marble powder were replaced in the concrete mixes.. The investigation test of compressive strength, indirect tensile

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strength, flexural strength, modulus of elasticity, and permeability. It was found that limestone waste as fine aggregate enhanced the slump test of the fresh concretes. But the unit weight concretes were not affected. However, the good performance was observed when limestone waste as fine aggregate was used in presence of marble powder.

Prof. Veena G. Pathan (2014) have done their research on Feasibility and Need of use of Waste Marble Powder in Concrete Production. They found that the Compressive strength and Split Tensile strength of Concrete can be increased with addition of waste marble powder up to 10% replace by weight of cement and also the effects of blending marble waste on the properties of cement such as consistency, setting times, insoluble residue, and soundness remain within the acceptable ranges of different standards. The production of cheaper and more durable concrete using this waste can solve to some extent the ecological and environmental problems. Therefore it provides a scope for more research which is required to design consistent and durable concrete with this waste.

Animesh Mishra et.al (2103) have done their research on Green Cement For Sustainable Concrete Using Marble Dust . They found that Marble sludge powder can be used as filler and helps to reduce the total voids content in concrete and the feasibility of the usage of marble sludge dust hundred percent substitutes for natural sand in concrete. The compressive strength and microstructure of blended cement was investigated in this study. The hydration products of cements were identified by means of scanning electron microscopy. It was found that the blended cements developed higher strength, at 28 days compared to 7 days. The strength increase was higher, the higher the marble dust content. So, concrete prepared by marble dust which helpful to reduce consumption of natural resources and energy and pollution of the environment.

Ankit Nileshchandra Patel (2013) have done their research on Stone Waste in India for Concrete with Value Creation Opportunities. They found that the OPC cement has been replaced by stone waste accordingly in the range of 0%, 10%, 20%, 30%, 40%, & 50% by weight for M-25 grade concrete. Concrete mixtures were produced, tested and compared in terms of workability and strength to the conventional concrete. These tests were carried out to evaluate the mechanical properties for 7, 14 and 28 days. As a result, the compressive increased up to 30% replacing of stone waste. This research work is concerned with the experimental investigation on strength of concrete and optimum percentage of the partial replacement by replacing OPC cement via 0%,

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10%, 20%, 30%, 40% and 50% of stone waste. They found the behavior of concrete while replacing of waste with different proportions of stone waste in concrete by using tests like compression strength.

Dr.G.Prince Arulraj et.al (2013) have done their research on GRANITE POWDER CONCRETE .They found that the granite powder waste can be utilized for the preparation of concrete as partial replacement of sand. In order to explore the possibility of utilizing the granite powder as partial replacement to sand.The percentages of granite powder added by weight to replace sand by weight were 0, 5, 10, 15, 20 and 25. To improve the workability of concrete 0.5% Superplasticiser was added. 54 cubes and 36 cylinders were cast. Compressive strength and split tensile strength were found. The test results indicate that granite as replacement of sand with granite powder has beneficial effect on the mechanical properties such as compressive strength and split tensile strength of concrete.

Nagabhushana et.al (2011) have done their research on Use of crushed rock powder as replacement of fine aggregate in mortar and concrete . They found that The present the properties of mortar and concrete in which Crushed Rock Powder (CRP) is used as a partial and full replacement for natural sand. For mortar, CRP is replaced at 20% 40%, 60%, 80% and 100%. The basic strength properties of concrete were investigated by replacing natural sand by CRP at replacement levels of 20%, 30% and 40%.

ABRAR AWOL (2011) have done their research on USING MARBLE WASTE POWDER IN CEMENT AND CONCRETE PRODUCTION . They found that replacement of cement by marble waste powder at 5% range, in concrete production, results in comparable compressive strength as of concrete specimens without marble waste powder with slight slump reduction for both C-25 and C-50 classes. Increment of replacement ranges beyond 5%, in concrete production, results in reduction of compressive strength and slump and the replacement of sand by marble waste powder from 5-20% ranges, in concrete production, results in similar and mostly enhanced performance than the control concrete specimens; with similar compressive strength to the control specimens, with slump improvement and water permeability depth reduction than the control specimens in both C-25 and C-50 classes.

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Deborah .O.Olanrewaju (2013) have done their research on EXPERIMENTAL STUDY ON THE PARTIAL REPLACEMENT OF CEMENT BY MARBLE DUST ON CONCRETE . They found that the partial replacement of Portland Cement 0,5,10 and 20% with marble dust. The results so far have yielded some benefits for its use in construction works. The study presents an initial understanding of the current strengths and weaknesses of the concrete with tmarble dust.

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CHAPTER 3

MATERIAL AND METHODS

2.1. Topic introduction

Recycling of industrial wastes has actually environmental, economical and technical

benefits. These benefits can be seen from two different angles, one from the point of the waste

producer and the other from the user part. For the producer, the benefits of recycling industrial

wastes are economical and environmental; for the user additional technical benefits may be

attained from recycling. For the producer, the environmental benefit can be attained as far as the

waste is recycled. It is independent of where it is recycled. But the economical benefit is

determined on the demand for the waste by different users. The more users, the more demand will

be; there by more economical benefit to the producer. With respect to the user, recycling of

industrial wastes will be environmentally beneficial as far as using the waste reduces waste emitted

during production of similar product from other raw alternative materials. The economical benefit

is assured if the cost of the waste material is cheaper than other alternative raw materials. The

technical benefit is also attained if the recycled input improves the quality of the output than the

output from other alternative material. Therefore it is necessary to see recycling of marble waste

powder with respect to both the producer and the user part.

2.2. Introduction

Cement, lime and calcium sulphate based materials, most importantly concrete, are by far

the mostly produced man-made materials. The annual production in 2011 of several

materials read as follows:

Timber 4 billion ton

Plastics and rubber 250 million ton

Steel 1.2 billion ton

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Gypsum 250 million ton

Lime 130 million ton

Cement 2.6 billion ton

Concrete/mortar 14 billion ton

One can see the huge quantities in which the building materials lime, gypsum and concrete

are produced. Though these materials are produced from non-renewable mineral resources,

these are some of the world's most abundant ones. They are also relatively maintenance free.

Possibly poisonous coatings, which may leach to the environment, need not be

applied, nor their regular removal (using hazardous and dangerous materials) and reapplication.

Furthermore, their products possess a long lifetime. So they remain relatively

long in the building life cycle, which can even be lengthened by building adaptable and/or

transportable and/or easily dismantled objects. When a functional re-use of structure or

structural parts is not possible anymore, then after demolition and crushing, the broken

Material may enter another building life cycle. Cement, lime and gypsum are also useful

binders to render contaminated sludge/soil and industrial and nuclear wastes less harmful

to the environment.

A large stream of the above materials comprises by-products that substitute the

Primary raw materials/products. For instance blast furnace slag and fly ash can substitute

clinker, flue gas desulfurization gypsum. Some annual quantities of generated by-products

and their present use (as % of total) as substitute read

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Fly ash 1.2 billion ton (45%)

Blast furnace slag 120 million ton (75%)

FD Gypsum 50 million ton (100%)

Silica fume 0.3 million ton (100%)

2.3 Cement

Cement is a binder, a substance that sets and hardens independently, and can bind other

materials together. The word "cement" traces to the Romans, who used the term opus

caementicium to describe masonry resembling modern concrete that was made from crushed rock

with burnt lime as binder. The volcanic ash and pulverized brick additives that were added to the

burnt lime to obtain a hydraulic binder were later referred to as cementum, cimentum, cäment, and

cement.

Cements used in construction can be characterized as being either hydraulic or non-

hydraulic. Hydraulic cements (e.g., Portland cement) harden because of hydration, a chemical

reaction between the anhydrous cement powder and water. Thus, they can harden underwater or

when constantly exposed to wet weather. The chemical reaction results in hydrates that are not

very water-soluble and so are quite durable in water. Non-hydraulic cements do not harden

underwater; for example, slaked limes harden by reaction with atmospheric carbon dioxide. [1]

Cements used in construction can be characterized as being either hydraulic or non-hydraulic.

Hydraulic cements harden because of hydration, a chemical reaction between the cement powder

and water. Thus, they can harden underwater or when constantly exposed to wet weather. The

chemical reaction results in hydrates that are not very water-soluble and so are quite durable in

water. Non-hydraulic cements do not harden underwater; for example, slaked limes harden by

reaction with atmospheric carbon dioxide.

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The most important uses of cement are as an ingredient in the production of motor in masonry,

and of concrete, a combination of cement and an aggregate to form a strong building material.

The most important uses of cement are as an ingredient in the production of mortar in masonry,

and of concrete, a combination of cement and an aggregate to form a strong building material.

2.4 Types of cement

2.4.1. Portland Pozzolona cement

Cement is made by heating limestone (calcium carbonate) with small quantities of other materials

(such as clay) to 1450 °C in a kiln, in a process known as calcination, whereby a molecule of

carbon dioxide is liberated from the calcium carbonate to form calcium oxide, or quicklime, which

is then blended with the other materials that have been included in the mix. The resulting hard

substance, called 'clinker', is then ground with a small amount of gypsum into a powder to make

'Ordinary Portland Cement', the most commonly used type of cement (often referred to as OPC).

Portland cement is a basic ingredient of concrete, mortar and most non-specialty grout. The most

common use for Portland cement is in the production of concrete. Concrete is a composite material

consisting of aggregate (gravel and sand), cement, and water. As a construction material, concrete

can be cast in almost any shape desired, and once hardened, can become a structural (load bearing)

element. Portland cement may be grey or white.

Portland cement is by far the most common type of cement in general use around the world. This

cement is made by heating limestone (calcium carbonate) with small quantities of other materials

(such as clay) to 1450 °C in a kiln, in a process known as calcination, whereby a molecule

of carbon dioxide is liberated from the calcium carbonate to form calcium oxide, or quicklime,

which is then blended with the other materials that have been included in the mix. The resulting

hard substance, called 'clinker', is then ground with a small amount of gypsum into a powder to

make 'Ordinary Portland Cement', the most commonly used type of cement (often referred to as

OPC). Portland cement is a basic ingredient of concrete, mortar and most non-specialty grout. The

most common use for Portland cement is in the production of concrete. Concrete is a composite

material consisting of aggregate (gravel and sand), cement, and water. As a construction material,

concrete can be cast in almost any shape desired, and once hardened, can become a structural (load

bearing) element. Portland cement may be grey or white.20

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2.4.2 Class F fly ash

The burning of harder, older anthracite and bituminous coal typically produces Class F fly ash.

This fly ash is pozzolanic in nature, and contains less than 20% lime (CaO). Possessing pozzolanic

properties, the glassy silica and alumina of Class F fly ash requires a cementing agent, such as

Portland cement, quicklime, or hydrated lime, with the presence of water in order to react and

produce cementitious compounds. Alternatively, the addition of a chemical activator such as

sodium silicate (water glass) to a Class F ash can lead to the formation of a geopolymer.

2.5 Why Portland cement is preferred?

2.6 Environmental concern in Portland cement

Many of the aspects of cement making process are potentially environmentally damaging,

although these risks can be minimized [21]. Cement manufacturing is an energy intensive process [21]. The enthalpy of formation of clinker from calcium carbonate and clay minerals is about 1500

to 1700 kJ/kg. However, because of heat loss during production, actual values can be much higher.

The high energy requirements and the release of significant amounts of carbon dioxide make

cement production a concern for global warming [24]. Carbon dioxide is produced during the

calcinations phase of the manufacturing process and also as a result of burning fossil fuels. 21

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Opportunity to reduce emissions through increased energy efficiency is only possible on the latter

of the CO2 emissions [21].Approximately 1 ton CO2 is generated for making 1 ton of clinker [24].

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2.7 Properties of Portland Cement

2.7.1 Chemical properties

It is a Portland cement's chemical properties that determine most of its physical properties

and how it cures. Therefore, a basic understanding of Portland cement chemistry can help one

understand how and why it behaves as it does [6].

2.7.2 Chemical composition

The composition of Portland cement distinguishes one type of cement from another. The

phase compositions in Portland cement are denoted as tricalcium silicate (C3S), dicalcium silicate

(C2S), tricalcium acuminate (C3A), and tetracalcium aluminoferrite (C4AF). The actual components

are often complex chemical crystalline and amorphous structures, denoted by cement chemists as

"alite" (C3S), "belite" (C2S), and various forms of aluminates. The behavior of each type of cement

depends on the content of these components [21].

Table-Main Constituents in a typical Portland cement

Chemical Name Chemical Formula Shorthand Notation Percent by Weight

Tricalcium Silicate 3CaOSio2 C3S 50

Dicalcium Silicate 2CaOSio2 C2S 25

Tricalcium Aluminate 3CaOAI2O3 C3A 12

Tetracalcium

Aluminoferrite

4CaOAI2O3Fe2O3 C4AF 8

Gypsum CaSO4H2O CSH2 3.5

Tricalcium silicate (C3S) hydrates and hardens rapidly and is largely responsible for initial

set and early strength. Portland cements with higher percentages of C3S will exhibit higher early

strength [24].

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Dicalcium silicate (C2S) hydrates and hardens slowly and is largely responsible for

strength increases beyond one week [24].

Tricalcium Aluminate (C3A) hydrates and hardens the quickest. It liberates a large amount

of heat almost immediately and contributes somewhat to early strength. Gypsum is added to

Portland cement to retard C3A hydration. Without gypsum, C3A hydration would cause Portland

cement to set almost immediately after adding water [24].

Tetracalcium aluminoferrite (C4AF) hydrates rapidly but contributes very little to

strength. Its presence allows lower kiln temperatures in Portland cement manufacturing. Most

Portland cement color effects are due to C4AF [24].

2.8 Concrete

Concrete is a composite material composed of coarse granular material (the aggregate or

filler) embedded in a hard matrix of material (the cement or binder) that fills the space among the

aggregate particles and glues them together.[2]

Concrete is widely used for making architectural structures, foundations, brick/block walls,

pavements, bridges/overpasses, highways, runways, parking structures, dams, pools/reservoirs,

pipes, footings for gates, fences and poles and even boats.

Famous concrete structures include the Burj Khalifa (world's tallest building), Hoover

Dam, the Panama Canal and the Roman Pantheon.

There are many types of concrete available, created by varying the proportions of the main

ingredients below. In this way or by substitution for the cementitious and aggregate phases, the

finished product can be tailored to its application with varying strength, density, or chemical and

thermal resistance properties.

"Aggregate" consists of large chunks of material in a concrete mix, generally a coarse

gravel or crushed rocks such as limestone, or granite, along with finer materials such as sand.

"Cement", commonly Portland cement, and other cementitious materials such as fly ash and slag

cement, serve as a binder or a Ligare for the aggregate.

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Water is then mixed with this dry composite, which produces a semi-liquid that workers

can shape (typically by pouring it into a form). The concrete solidifies and hardens to rock-hard

strength through a chemical process called hydration. The water reacts with the cement, which

bonds the other components together, creating a robust stone-like material.

"Chemical admixtures" are added to achieve varied properties. These ingredients may

speed or slow down the rate at which the concrete hardens, and impart many other useful

properties.

"Reinforcements" are often added to concrete. Concrete can be formulated with

high compressive strength, but always has lower tensile strength. For this reason it is usually

reinforced with materials that are strong in tension (often steel).

"Mineral admixtures" are becoming more popular in recent decades. The use of recycled

materials as concrete ingredients has been gaining popularity because of increasingly stringent

environmental legislation, and the discovery that such materials often have complimentary and

valuable properties. The most conspicuous of these are fly ash, a by-product of coal-fired power

plants, and silica fumes, a byproduct of industrial electric arc furnaces. The use of these materials

in concrete reduces the amount of resources required as the ash and fume acts as a cement

replacement. This displaces some cement production, an energetically expensive and

environmentally problematic process, while reducing the amount of industrial waste that must be

disposed of.

The mix design depends on the type of structure being built, how the concrete is mixed and

delivered, and how it is placed to form the structure.

2.8.1 Workability of Concrete

To defines workability as the property determining the effort required to manipulate a

freshly mixed quantity of concrete with minimum loss of homogeneity. The term “manipulate”

includes the early age operations of placing, compacting and finishing [23] .

Three factors in concrete are involved in determining the consistency of concrete: water

cement ratio, aggregate cement ratio and water content. Only two of the three factors are

independent. If the aggregate cement ratio is reduced, the water content must increase for the w/c

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ratio to remain constant. The water required to maintain a constant consistency will increase as the

w/c ratio is increased or decreased. The increase in fine aggregate to coarse aggregate ratio

generally increases the water content required to produce a given workability. If finer aggregate is

substituted in a mixture, the water content typically must be increased to maintain the same

workability [22] .Lowering the cement content of concrete with given water content typically will

lower workability.

Cement replacing materials also affect workability. For example freshly mixed concrete are

generally more workable when a portion of the cementious material is fly ash, in part because of

the spherical shape of fly ash particles; but highly reactive or pozzolanas can cause loss of

workability through early hydration.[22]

2.8.2 Strength of Concrete

Generally a concrete is required to provide a specified strength. The most common measure

of concrete strength is the compressive strength, determined in either a cube test or a cylinder test.

The strength of concrete is very much dependent upon the hydration reaction . Water plays a

critical role, particularly the amount used. The hydration reaction itself consumes a specific

amount of water. Concrete is actually mixed with more water than is needed for the hydration

reactions. This extra water is added to give concrete sufficient workability. The water not

consumed in the hydration reaction will remain in the microstructure pore space. These pores make

the concrete weaker due to the lack of strength-forming calcium silicate hydrate bonds. Some

pores will remain no matter how well the concrete has been compacted[4] . Cement replacing

materials can play roles in improving concrete strength by improving microstructure space of

concrete.

2.8.3 Durability of Concrete

Durability is the property of concrete by virtue of which it is capable of resisting its

disintegration and decay which may be caused due to: use of unsound cement, use of less durable

aggregate, entry of harmful gases and salts through the pores and voids present in the concrete,

freezing and thawing of water sucked through the cracks or crevices by capillary action, expansion

and contraction resulting from temperature changes and alternate drying and wetting [26].

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The durability of concrete depends mostly upon conditions of exposure, grade of concrete

used, quality of its materials and the extent of voids and pores present in the concrete mass. The

amount permeability [26].Cement replacing materials can play role in reducing the extent of voids in

concrete which in turn improves permeability of concrete.

2.9 Marble Powder

Marble powder is a non-foliated metamorphic rock minerals composed of recrystallized carbonate

minerals. Geologists use the term "marble powder" to refer to metamorphosed limestone; however,

stonemasons use the term more broadly to encompass unmetamorphosed limestone.

2.9.1 Geological Formation of Marble

Marble is a metamorphic rock produced from limestone by pressure and heat in the earth

crust due to geological process [17].Metamorphism involves the alteration of existing rocks by either

excessive heat or pressure or through chemical action of fluids. This alteration can cause chemical

change or structural modification to the minerals making up the rock.

Structural modification may involve the simple re-crystallization of minerals into layers or

the aggregation of minerals in to specific areas within the rock [17]. The pressure and heat in the

earth’s crust cause limestone to change in texture and makeup. This process is called re-

crystallization. Fossilized materials in the limestone, along with its original carbonate minerals, re-

crystallize and form large, coarse grains of calcite [30].

Impurities present in limestone during the re-crystallization period affect the mineral

composition of marble which is formed [16]. Impurities incorporated during the original carbonate

precipitation especially from the cold marine water solution form characteristics of colors.

Accordingly a pure calcite marble is white but tiny amounts of impurities such as iron and

magnesium color marble significantly green. Graphite (algae) colors marble dark, pyrite

commonly colors marble greenish grey, finely disseminated hematite will color marble pink [18].

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2.9.2 Chemical and Physical Properties of Marble

2.9.2.1 Chemical Properties of Marble

Chemically, marbles are crystalline rocks composed predominantly of calcite, dolomite or

serpentine minerals. The other mineral constituents vary from origin to origin. Quartz, muscovite,

tremolite, actinolite, micro line, chert, talc, garnet, osterite and biotite are the major mineral

impurities whereas SiO2, limonite, Fe2O3, manganese, 3H2O and FeS2 (pyrite) are the major

chemical impurities associated with marble [16].

Table -Typical Chemical Properties of Marble[16]

Chemical Marble (%)

Lime (CaO) 28-32

Silica 3-30

MgO 20-25

FeO+Fe2O3 1-3

LOI 20-45

2.9.2.2 Physical Properties of Marble

Physically, marble is re-crystallized hard, compact, fine to very fine grained

metamorphosed rocks capable of taking shining polish [16].

Table-Typical physical

properties of marble[16]

28

Properties Marble

Hardness 3 to 4 moh‟s scale

Density 2.55-2.7kg/cm

Compressive strength 70-140N/mm2 Water absorption <0.5 %

Porosity very low

Weather impacts resistance

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2.9.3 Uses of Marble

Colorless or light colored marble are a very pure sources of calcium carbonate, which is

used in a wide variety of industries. Finely ground marble or calcium carbonate powder is a

component in paper, and consumer products such as toothpaste, plastics, and paints. Ground

calcium carbonate can be made from limestone, chalk and marble; about three-quarters of the

ground calcium carbonate worldwide is made from marble.

Ground carbonate is used as a coating pigment for paper because of its high brightness and

as paper filler. Ground calcium carbonate is used in consumer products such as food additives, in

toothpaste, and as inert filler in pills. It is used in plastics because it imparts stiffness, impact

strength, dimensional stability, and thermal conductivity. It is used in paints because it is a good

filler and extender, has high brightness and is weather resistance [15].The constructional use of

marble in most cases is for dimensional stone production although in some places it is also used as

raw material in cement production

2.9.4 Marble Processing and Production

The Rajasthan Enterprise Produces Marble Block from three region namely from

Kishangarh, Makrana and Udaipur it extracts marble. The Enterprise produces different types of

marble block from these three quarry sites.

The colour of the marble from these three quarries varies, example Kishangarh marble is

white gray, and white, while “Makrana” marble is multi-colour, and rose, “Udaipur” marble

mainly has a white colour [25] .Annually the three regions are estimated to process marble blocks of

160000 m3.

CHAPTER 3

MATERIALS USED IN THE PROJECT

3.1. Introduction

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In this chapter, the materials used for the investigation are described with respect to their

sources and relevant physical properties. All laboratory investigations on the materials used in

studying the properties of cement , coarse sand &aggregate and marble waste powder; whereas the

properties of concrete made by incorporation of marble waste powder ingredient is studied in

A.C.E.T Civil Engineering Department, concrete lab.

3.2 Aggregates

Throughout the experiment, river sand and basaltic crushed stone from local market, with

the following physical characters, were used as fine and coarse aggregate respectively

3.2.1. Silt Content of Fine Aggregate

The presence of dust, loam and clay materials with sand decreases the bond between the

materials to be bound together thereby decreases the strength of concrete besides decreasing the

quality of concrete. Accordingly, the sand for the experiment was tested for silt content and was

found to have 13% silt content .This is above the maximum value recommended by Indian

standard. Therefore, the sand, before used in all tests, was washed until clear water came out.

3.2.2. Gradation of Fine and Coarse Aggregate

Aggregate grain size distribution or gradation is one of the properties of aggregates which

influence the quality of concrete. Therefore, fine aggregate and coarse aggregate with gradation

satisfying the grading requirement of Indian standard test sieve (IS: 383-1970 respectively) were

used throughout the experiment.

3.2.3Sieve analysis

(a) Sand

Quantity of sand = 1000 gm

Time of sieving = 15 minutes

Table 3.1: Gradation of fine aggregate used for the test

SL.NO. SIEVE

SIZE

WEIGHT

RETAINED

% OFWEIGHT

RETAINED

CUM. %

RETAINED

% PASSING

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1 4.75 mm 9 .9 .9 99.1

2 2.36 mm 46.5 4.65 5.55 94.45

3 1.18 mm 163 16.3 21.85 78.15

4 600 micron 148 14.8 36.65 63.35

5 300 micron 333.5 33.35 70 30

6 150 micron 247.5 24.75 94.75 5.25

7 pan 52 0.52 Ʃ= 229.7

Fineness modulus Ʃ=229.7/100 = 2.297

(b) Coarse Aggregate

Quantity of Coarse Aggregate = 3000 gm

Time of sieving = 25 minutes

Table 3.2 Gradation of coarse aggregate used for test

SL. NO

Sieve size Weight Retained

% of weight Retained

Cum. % of Weight Retained

% Passing

1 80 mm 0 0 0 100

2 40mm 0 0 0 100

3 20mm 0 0 0 100

4 10mm 1492gm 49.8 49.8 50.2

5 4.75mm 1212gm 40.4 90.2 59.6

pan 293.5gm Ʃ =140

Fineness modulus = 140+500/100 =6.4

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3.3 Cement:

Portland Pozzolona cement of Acc conforming to IS 269-1976 and IS 4031-1968 was adopted in

this work.

The test conducted on cement is shown in table no 3.4

Table No. 3.4

Sr.no. Test Result Is requirement

1. Fineness of cement 5% As per IS 269-1976

max. 10 %

2. Consistency of cement 32%

3. Initial setting time 42 min As per IS 4031-1968

Min 30 min

4. Final setting time 540 min As per IS 4031-1968

Max. 600 min

5. Compressive strength of

cement

18.59 N/mm2

in 3 days &

25.54 N/mm2

in 7 days

As per IS 1489-1991

16N/mm2 in 3 days

&22N/mm2 in 7 days

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The Test Conducted on Cement is shown in Table No. 3.5

0

5

10

15

20

25

30

35

40

consistency of cement

consistency of cement

Sr. no. Test Data For Material Result

1 Cement used Portland Pozzolona Cement

2 Specific Gravity of Cement 3.15

3.4 Marble Waste Powder

In this test, commercially called marble waste powder processing factory by-product, from

The Rajasthan Marble Processing Factory, with Blaine fineness value of 4843cm2/g was used as

partial replacement in cement. The specific gravity of marble waste powder is 2.55

3.5Water

Clean tap water was used for washing aggregates, and mixing and curing of concretes.

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4.3.2. Mix Designing and Trial Mix Preparation

Mix design can be defined as the process of selecting suitable ingredients of concrete and

determining their relative proportions with the object of producing concrete of certain minimum

strength and durability as economically as possible as per IS 456-2000 used

CONCRETE MIX DESIGN (M25)

Design Stipulations

(1)Characteristic comp. strength required

In the field at 28 days 32 Mpa

Level of quality control Good

Standard Deviation 4.6

Mean Target strength 25+1.65x4.6 =32.59 Mpa

(2)Maximum Size of the Aggregate 20 mm

(a) Test Data for Materials

(1) Specific Gravity Of Cement 3.15

(2) Comp. Strength Of Cement at 7 days Satisfies the requirement

Of IS: 269-1989

(3) Specific Gravity of Coarse Aggregate 2.80

Specific Gravity of Fine Aggregate 2.88

(4) Water Absorption

Coarse Aggregate 1.69%

Fine Aggregate 1.01%

(5) Water Cement Ratio 0.46

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(c) Selection of Water and Sand Content

For 20 mm Maximum Size aggregate , sand conforming to grading zone2, water content

per cubic meter of concrete =151 kg and sand content as percentage of total aggregate by absolute

volume = 34%

(b) Determination of cement content

Water-cement ratio = 0.46

Water = 186 litre

Cement = 186/ 0.46

= 405 kg/m3

(b) Determination of coarse and fine contents

1000 = 186+405/3.15+1/.34xfa/2.88

Fa= 607 kg/ m3

1000 = 186+405/3.15+1/1-0.34xca/2.80

Ca= 1211 kg/ m3

So the mix proportion becomes,

4.3.3 Volume of cube

Size of cube = .15x.15x.15 =.003375 m3

Total volume = 6x.003375 =0.02025 m3

Weight of cement = 8.20 kg

Weight of coarse aggregate =24.522 kg

Weight of coarse sand=12.29kg

Required amt. of water = 3.77 lt

36

Water Cement Fine aggregate Coarse aggregate

186lt 405kg 907kg/ m3 1211 kg/ m3

0.46 1 1.65 2.99

2013

4.3.4 Volume of cylinders

Volume Of cylinder =3.14x50x50x200 =.00157 mm3

Total volume = 6x.00157 =.00942mm3

Weight of cement = 3.315kg

Weight of fine aggregate = 3.315x1.912 = 6.33kg

Weight of coarse aggregate = 3.315x3.93 =13.027kg

Required amt. of water = 3.315x0.47 =1.55lt

4.3.5 Preparation and Curing Of Specimen

Standard cubic specimens of 150 mm size were cast. Concrete cube were cast for

compressive strength. Comp. strength of concrete was undertaken on 15 cm cubic specimens at

7,14 days &28 days of age. All specimens were removed 24 hrs. After casting, and then transferred

to regular condition till testing.

Table 4.1 partial replacement of cement by marble waste powder (cubical moulds)

% Replacement 0% 4% 8% 12% 16% 20%

Cement 8.2kg 7.87kg 7.544kg 7.216kg 6.88kg 6.560kg

Sand 13.58kg 13.58kg 13.58kg 13.58kg 13.58kg 13.58kg

Coarse aggregate 24.54kg 24.54kg 24.54kg 24.54kg 24.54kg 24.54kg

Marble powder -- 328gm 656gm 984gm 1312gm 1640gm

w/c Ratio .47 .47 .47 .47 .47 .47

The Standard Cylindrical Specimen of 100 mm diameter and 200 mm height of Cylindrical

Specimen Were Caste for Tensile strength .Split Tensile Strength of concrete was undertaken on

cylindrical specimen at 7 days & 28 days of age all specimens were removed 24 hrs. After casting,

and then transferred to regular condition till testing.

Table 4.2 partial replacement of cement by marble waste powder(cylindrical moulds)

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% replacement 0% 4% 8% 12% 16% 20%

Cement(gm) 3315 3116 3005 2917 2718 2510

Sand(in gm) 6338 6338 6338 6338 6338 6338

Coarse

aggregate(in gm)

13027 13027 13027 13027 13027 13027

Marble powder

(in gm)

00 199 265 398 597 663

w/c Ratio .47 .47 .47 .47 .47 .47

4.3.6 Concrete

Workability

It is observed here that degree of workability is medium as per IS 456-2000. The slump

value of the concrete obtained from the waste marble powder mix give negligible effect as

compared to the normal mix concrete .as shown in Table 4.3

% Replacement Slump Value (mm)

0% 28mm

4% 27mm

8% 27mm

10% 27mm

12% 26mm

16% 25mm

20% 25mm

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Fig.4.3 Graphical Representation of Slump Value for Concrete Mix (M25)

0% 4% 8% 12% 16% 20%23.5

2424.5

2525.5

2626.5

2727.5

2828.5

slump value (in mm)

slump value (in mm)

4.4 TESTING OF HARENED CONCRETE

Table 4.4 Compressive Strength – 7 Days

Replacem

ent (%)

Failure Load

(KN)

Failure Load

(KN)

Average Load

(KN)

Compressive

Strength

(Mpa)

0% 430 450 440 19.55

4% 456 460 458 20.55

8% 525 520 523 23.22

12% 570 580 575 25.55

16% 350 400 375 16.67

20% 225 350 287.5 12.77

Table 4.5 Compressive Strength -14 Days

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Replacement

(%)

Failure Load

(KN)

Failure Load

(KN)

Average Load

(KN)

Compressive

Strength

(Mpa)

0% 550 600 575 25.66

4% 600 635 617 27

8% 640 650 645 28.66

12% 660 665 662 29.44

16% 580 600 590 26.22

20% 525 520 523 23.22

Table 4.6 Compressive Strength -28 Days

Replacement

(%)

Failure Load

(KN)

Failure Load

(KN)

Average Load

(KN)

Compressive

Strength

(Mpa)

0% 750 775 763 33

4% 780 820 800 35.6

8% 830 850 840 37

12% 860 840 850 37.8

16% 710 730 720 32

20% 520 610 565 25

Table 4.6 Split Tensile Strength -7Days

Replacem

ent (%)

Tensile Load

(KN)

Tensile Load

(KN)

Average Load

(KN)

Tensile

Strength

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(Mpa)

0% 115 125 120 2.26

4% 121 135 128 2.40

8% 120 150 135 2.55

12% 135 161 148 2.79

16% 121 134 127.5 2.4

20% 111 121 116 2.19

Table 4.7 Split Tensile Strength -14Days

Replacem

ent (%)

Tensile Load

(KN)

Tensile Load

(KN)

Tensile Load

(KN)

Average Load

(KN)

Tensile

Strength

(Mpa)

0% 121 139 100 120 2.73

4% 140 146 113 133 2.88

8% 132 149 114 131.66 2.48

12% 135 161 118 138 2.93

16% 110 138 94 114 2.66

20% 95 125 80 100 1.89

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Table 4.8 Split Tensile Strength -28 Days

Replacem

ent (%)

Tensile Load

(KN)

Tensile Load

(KN)

Tensile Load

(KN)

Average Load

(KN)

Tensile

Strength

(Mpa)

0% 180 188 154 174 3.29

4% 192 195 164 184 3.38

8% 196 205 173 191 3.16

12% 207 211 179 199 3.52

16% 175 180 148 168 3.20

20% 152 159 129 146 2.77

Graphical representation of above readings

y-axis:compressive strength

x-axis:%age of replacement of cement

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Fig. 4.5 Graphical Representation of Split Conpresive Strength

Fig. 4.6Graphical Representation of tensile Strength

y-axis:Tensile strength

x-axis:%age of replacement of cement

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CHAPTER 5

RESULT AND DISCUSSION

5 .1Compressive Strength

Compressive strength of concrete is tested on cube at different percentage of marble

powder content in concrete. The strength of concrete has been tested on cube at 7 days,14 days

curing and 28 days.7 days test has been conducted to check the gain in initial strength of concrete,

14 days test has been conducted to check the gain in median strength of concrete and 28 days test

gives the data of final strength of concrete at 28 days curing. Compression testing machine is used

for testing the compressive strength test on concrete. At the time of testing the cube is taken out of

water and dried and then tested keeping the smooth faces in upper and lower part.

The strength of concrete is very much dependant up on the hydration reaction [4].The type

and amount of cement used in concrete determines the hydration reaction. In this experiment, in all

cases, i.e. for 6 to 20 % replacement of cement by marble waste powder the test results, as shown

in Table 4.4,4.5,4.6 and4.7 show that the seventh ,fourthenth and twenty eighth days compressive

and split tensile strengths of specimens with marble waste powder are less than that of the

corresponding control specimens. The reduction of the strength increased with increasing

percentage of marble waste powder. These decreases in strength mainly occur due to replacement

of Portland cement with powder addition causing dilution of C3S and C2S which is responsible for

strength

Table 5.1 Percentage Increase of Compressive Strength in 7 Days

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Replacement (%) Compressive

Strength (Mpa)

Percentage Increase

(%)

Percentage Decrease

(%)

0% 19.55

4% 20.55 5%

8% 23.22 18.72%

12% 25.55 30.6%

16% 16.67 14%

20% 12.77 34%



Strength (Mpa)

Percentage Increase

(%)

Percentage Decrease

(%)

0% 25.66

4% 27 5 %

8% 28.66 11%

12% 29.44 14%

16% 26.22 2%

20% 23.22 9%


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Strength (Mpa)

Percentage Increase

(%)

Percentage Decrease

(%)

0% 33

4% 35.6 7%

8% 37 12%

12% 37.8 14%

16% 32 3%

20% 25 24%

Table 5.3 Percentage Increase of Split Tensile Strength in 7 Days

Replacement (%) Split Tensile Strength

(Mpa)

Percentage Increase

(%)

Percentage Decrease

(%)

0% 2.26

4% 2.40 6.19%

8% 2.55 12%

12% 2.79 23%

18% 2.4 2.63%

2.19 3%

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Table 5.4 Percentage Increase of Split Tensile Strength in 14 Days


(Mpa)

Percentage Increase

(%)

Percentage Decrease

(%)

0% 2.73

4% 2.88 2.66%

8% 2.48 9%

12% 2.93 6.53%

18% 2.66 2.81%

20% 1.89 30%

Table 5.4 Percentage Increase of Split Tensile Strength in28 Days


(Mpa)

Percentage Increase

(%)

Percentage Decrease

(%)

0% 33

4% 35.6 7.87%

8% 37 12.12%

12% 37.8 14.54%

16% 32 3%

20% 25 24.24%

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5.2 DISCUSSION:

1. with the inclusion of Marble powder the strength of concrete gradually increases up to a

Certain limit but the gradually decreases. At 4% the initial compressive strength gain 5% in 7 days

see in table 5.1

With the inclusion of marble powder up to 4% the initial compressive strength increases

7% in 28 days see in table 5.2

2. With the inclusion of Marble powder up to 12%the initial strength gain in concrete is high.

At 12% there is 30.6% increase in initial compressive strength for 7 days see in table 5.1, At 12%

there is 14% increase in initial compressive strength for 14 days see in table 5.1

At 12% there is 14% increase in initial compressive strength for 28 days. See in table 5.2

compressive strength increases with increase in cement content. During the hydration of cement,

C3S and C2S present in cement reacts with water forming complex calcium silicate hydrates (C-S-

H). The C-S-H gel thus formed, fills the void space and binds the particles together imparting

strength to the mass. With the increase in cement content in the mixture, the quantity of gel

formation increases, which binds the particles more effectivel

3. The initial strength gradually decreases from16%.with the inclusion of marble powder up to

18% the initial compressive strength decrease 14% in 7days,at 16% the initial compressive

strength decrease 2% in 14days at 16% the initial compressive strength decrease 3% in 28 days see

in table 5.2 . These decreases in strength mainly occur due to replacement of Portland cement with

powder addition causing dilution of C3S and C2S which is responsible for strength

5.3 Split Tensile Strength

Split Tensile strength of concrete is tested on cylinders at different percentage of marble

powder Content in concrete. The strength of concrete has been tested on cylinder at 7 days

curing,14 days and 28 days. 7days test has been conducted to check the gain in initial strength of

concrete. 28 days test gives the data of final strength of concrete at 28 days curing .Compression

testing machine is used for testing the Split Tensile strength test on concrete along with two

wooden boards. At the time of testing the cylinder taken out of water and dried and then tested.

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5.4 DISCUSSION:

1. With the inclusion of Marble powder the strength of concrete gradually increases up to a

certain limit but the gradually decreases. with the inclusion of marble powder up to 4% the

initial tensile strength gain 6.19% in 7 days, with the inclusion of marble powder up to 6% the

initial tensile strength gain 2.66% in 14 days and at the 4% the initial tensile strength gain up to

7.87% in 28 days

2. With the inclusion of Marble powder upto12% the initial strength gain in concrete is high.At

12% there is 23% increase in initial Split Tensile strength for 7 days see in table 5.3, the

inclusion of Marble powder upto12% the initial strength gain in concrete is high.At 12% there

is 6.53% increase in initial Split Tensile strength for 14 days see in table 5.4 At 12% there is

14.54% increase in initial Split Tensile strength for 28 days see in table 5.5 compressive

strength increases with increase in cement content. During the hydration of cement, C3S and

C2S present in cement reacts with water forming complex calcium silicate hydrates (C-S-H).

The C-S-H gel thus formed, fills the void space and binds the particles together imparting

strength to the mass. With the increase in cement content in the mixture, the quantity of gel

formation increases, which binds the particles more effectively.

3. The initial strength gradually decreases from 20%.the initial Split Tensile strength decrease 3%

in 7 days, The initial strength gradually decreases from 20%.the initial Split Tensile strength

decrease 30% in 14 days with the inclusion of marble powder up to 18% the initial Split

Tensile strength decrease 24.24% in 28 days. These decreases in strength mainly occur due to

replacement of Portland cement with powder addition causing dilution of C3S and C2S which is

responsible for strength

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CHAPTER 6

ECONOMICAL AND ENVIRONMENTAL

6.1. Introduction

Recycling of industrial wastes has actually environmental, economical and technical

benefits. These benefits can be seen from two different angles, one from the point of the waste

producer and the other from the user part. For the producer, the benefits of recycling industrial

wastes are economical and environmental; for the user additional technical benefits may be

attained from recycling. For the producer, the environmental benefit can be attained as far as the

waste is recycled. It is independent of where it is recycled. But the economical benefit is

determined on the demand for the waste by different users. The more users, the more demand will

be; there by more economical benefit to the producer. With respect to the user, recycling of

industrial wastes will be environmentally beneficial as far as using the waste reduces waste emitted

during production of similar product from other raw alternative materials. The economical benefit

is assured if the cost of the waste material is cheaper than other alternative raw materials. The

technical benefit is also attained if the recycled input improves the quality of the output than the

output from other alternative material. Therefore it is necessary to see recycling of marble waste

powder with respect to both the producer and the user part.

6.2. For the Marble Waste Powder Producer

As it is mentioned in part 6.1, the producer of a waste will ensure environmental benefits as

far as the waste is recycled. It is also expected that it can get more economical benefits when there

is more demand for the waste. Therefore, the use of marble waste in the construction industry

undoubtedly will increase the demand for the waste thereby benefits the producer both

environmentally and economically

6.3. For the Construction Industry

6.3.1. Environmental Benefits

One of the greatest environmental concerns in construction industry is the production of

cement which emits large amount of CO2 gas to the atmosphere. It is estimated that 1 tone clinker

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production releases 1 tone CO2 [21] .Mixing of clinker to supplementary materials called blending is

considered as a very effective way to reduce CO2 emission [18] It is estimated that The Rajasthan

Marble Processing Enterprise produces 1800m3 (4500 tons) marble waste annually, which implies

that using marble waste of The Rajasthan Marble Processing Enterprise as cement replacing

material can indirectly reduce CO2 emission to the atmosphere by 4500 tons annually. Recycling

marble waste powder in substitution of sand also indirectly can reduce environmental problem

related with sand production.

6.3.2 Economical Benefits

In this Project work, detail cost break down and economical analysis was not worked out

as the cost of cement and sand depends on its user point location and also due to lack of necessary

data and required information; but to give insight for cost benefits, the average cost of cement,

sand and selling price of marble waste is presented below in Table 6.1.

Table 6.1: Average price of cement, sand and marble waste

Sr.no Type of Material Average Price

1. Cement 640 per Quintal

2. Sand 220 Per m3

3. Marble Powder 50 Per Quintal

The above figures clearly show that using of marble waste in replacement of cement can

play cost reduction in concrete production

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CONCLUSIONS

1. The Compressive strength of Cubes are increased with addition of waste marble powder up to

12% replace by weight of cement and further any addition of waste marble powder the

compressive strength decreases.

2. The Split Tensile strength of Cylinders are increased with addition of waste marble powder up

to 12% replace by weight of cement and further any addition of waste marble powder the Split

Tensile strength decreases.

3. Thus we found out the optimum percentage for replacement of marble powder with cement and

it is almost 12%cement for both cubes and cylinders.

4. We have put forth a simple step to minimize the costs for construction with usage of marble

powder which is freely or cheaply available; more importantly.

5. We have also stepped into a realm of saving the environmental pollution by cement production;

being our main objective as Civil Engineers.

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