A PROJECT REPORT ON “APPLICATION OF INDUSTRIAL WASTE- IN THE MANUFACTURING OF SELF COMPACTING CONCRETE” SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR AWARD OF B. E. CIVIL, DEGREE OF SHIVAJI UNIVERSITY, KOLHAPUR BY MMMMrrrr.... SSSSuuuurrrraaaajjjj NNNN.... SSSShhhhaaaahhhh.... MMMMiiiissssssss.... SSSShhhhwwwweeeettttaaaa SSSS.... SSSSuuuuttttaaaarrrr.... MMMMiiiissssssss.... AAAArrrrcccchhhhaaaannnnaaaa SSSS.... SSSShhhheeeellllaaaakkkkeeee.... MMMMrrrr .... YYYYooooggggeeeesssshhhh BBBBhhhhaaaaggggwwwwaaaatttt.... MMMM rrrr.... AAAA mmmmaaaarrrr SSSShhhh iiiinnnnddddeeee.... MMMM iiiissssssss.... PPPP rrrriiiiyyyyaaaannnn kkkkaaaa SSSS.... KK KKhhhhuuuurrrrdddd.... MMMMrrrr.... DDDDaaaasssshhhhaaaarrrraaaatttthhhh BBBBaaaaggggaaaaddddeeee.... MMMMiiiissssssss.... SSSSuuuupppprrrriiiiyyyyaaaa HHHH.... DDDDhhhheeeekkkkaaaalllleeee.... MMMMrrrr.... VVVViiiisssshhhhnnnnuuuu JJJJaaaaddddhhhhaaaavvvvaaaarrrr .... MMMMrrrr.... NNNNaaaarrrreeeesssshhhh MMMMaaaaddddaaaassss.... UNDER THE GUIDANCE OF Prof. M. B. KUMTHEKAR DEPARTMENT OF CIVIL ENGINEERING, GOVT. COLLEGE OF ENGINEERING, KARAD. 2008-09 GOVRNMENT COLLEGE OF ENGINEERING, KARAD Vidyanagar, Tal. Karad, Dist. Satara, Maharashtra, India Phone No : 91-2164-2764-271711, 271712 Fax No. : 91-2164 – 271713 Web Site : www.gecek.org CCCCEEEERRRRTTTTIIIIFFFFIIIICCCCAAAATTTTEEEE This is to certify that, following batch of students MMMMrrrr.... SSSSuuuurrrraaaajjjj NNNN.... SSSShhhhaaaahhhh.... MMMMiiiissssssss.... SSSShhhhwwwweeeettttaaaa SSSS.... SSSSuuuuttttaaaarrrr.... MMMMiiiissssssss.... AAAArrrrcccchhhhaaaannnnaaaa SSSS.... SSSShhhheeeellllaaaakkkkeeee.... MMMMrrrr .... YYYYooooggggeeeesssshhhh BBBBhhhhaaaaggggwwwwaaaatttt.... MMMMrrrr.... AAAAmmmmaaaarrrr SSSShhhhiiiinnnnddddeeee.... MMMMiiiissssssss.... PPPPrrrriiiiyyyyaaaannnnkkkkaaaa SSSS.... KKKKhhhhuuuurrrrdddd.... MMMMrrrr.... DDDDaaaasssshhhhaaaarrrraaaatttthhhh BBBBaaaaggggaaaaddddeeee.... MMMMiiiissssssss.... SSSSuuuupppprrrriiiiyyyyaaaa HHHH.... DDDDhhhheeeekkkkaaaalllleeee.... MMMMrrrr.... VVVViiiisssshhhhnnnnuuuu JJJJaaaaddddhhhhaaaavvvvaaaarrrr .... MMMMrrrr.... NNNNaaaarrrreeeesssshhhh MMMMaaaaddddaaaassss.... has completed the project work entitled. “Application of Industrial Waste in Self Compacting Concrete” This work is being submitted for the award of degree of BACHELOR OF ENGINEERING in CIVIL ENGINEERING as a partial fulfillment of the requirement of the prescribed syllabus of Shivaji University, Kolhapur. PROF. M. B. KUMTHEKAR Guide & H.O.D. Civil Engineering Dept. Govt. College of Engineering, Karad- 415124. ACKNOWLEDGEMENT It is indeed pleasure and a moment of satisfaction for us to express our gratitude and sincere thanks to our project guide Prof. M. B. Kumthekar Head of Civil Engineering Dept. Government College of Engineering, Karad, who have been constant source of inspiration, guidance and encouragement. We also express our sincere thanks to Prof. Dr. Pranesh Mrunal, Head of Applied Mechanics Dept., for providing all the facilities for carrying out this project work. Also we can not overlook the fact that, without the support of our Lion Personality Principal Dr. A. S. Pant, our work would not have been accomplished in its perfectance. We express our special thanks to Mrs. Sucheta Kalwar and Mr. Sachin Bhawasar of ACC Cement, Pune for sponsorship. We express our special thanks to Mr. Kale, Perma Chemicals, Karad. We are specially thanks to Hindalco, Belgaum and Kolhapur Steel Ltd., Kolhapur. And finally we thank all the associates and colleagues who helped us directly or indirectly in bringing up this system. Mr. Suraj N. Shah. Miss. Shweta S. Sutar. Miss. Archana S. Shelake. Mr . Yogesh Bhagwat. Mr. Amar Shinde. Miss. Priyanka S. Khurd. Mr. Dasharath Bagade. Miss. Supriya H. Dhekale. Mr. Vishnu Jadhavar . Mr. Naresh Mada “APPLICATION OF INDUSTRIAL WASTE IN MANUFACTURING OF SELF COMPACTING CONCRETE” INDEX SR.NO. CONTENT PAGE 1. INTRODUCTION TO SELF COMPACTING CONCRETE 1 2. NEED FOR SCC 4 2.1. Advantages 2.2. Dis advantages 3. INGRADIENTS OF SCC 10 4 PROPERTIES OF SCC 14 3.1 Fresh SCC Properties 5. SCC AND MESUREMENT OF IT’S FLOW PROPERTIES 16 5.1 General 5.2 Test Methods 6. RED MUD AND FOUNDRY WASTE SAND 32 7. AIM OF EXPERIMENTATION 44 8. EXPERIMENTAL PROCEDURE AND TEST RESULTS 46 8.1 General 8.2 Materials Used 8.3 Experimental Procedure 8.4 Test Results 9. COST COMPARISION 80 10. CONCLUSION 83 11. SCOPE FOR FURTHER STUDY 84 GOVT. COLLEGE OF ENGG. KARAD 4 “APPLICATION OF INDUSTRIAL WASTE IN MANUFACTURING OF SELF COMPACTING CONCRETE” SYNOPSIS Self-compacting concrete (SCC) is an innovative concrete that does not require vibration for placing and compaction. It is able to flow under its own weight, completely filling formwork and achieving full compaction, even in the presence of congested reinforcement. The hardened concrete is dense, homogeneous and has the same engineering properties and durability as traditional vibrated concrete. Due to industrialization there is huge amount of red mud and foundry waste sand created. Aluminum is now consume during manufacture red mud which is used Red Mud and Foundry waste Sand are industrial waste and causing threat to environment so the reduce the cost of the construction also to make structure more durable, reduce problem of this material the project has been undertaken so that it can be used for construction fashion following points attempted. 1] To study the properties of foundry waste sand. 2) To blend to mix or to replace cement by different % by foundry waste sand. 3) To study properties of Red mud 4) To prepare the concrete by blending or by replacing the cement by Red mud 5) To study the comparativeness. Facing lot more problem of foundry waste. Very close to the kolhapur there is project of steel industry, sand used for the formation of mould when the molds are opened GOVT. COLLEGE OF ENGG. KARAD 5 “APPLICATION OF INDUSTRIAL WASTE IN MANUFACTURING OF SELF COMPACTING CONCRETE” the waste sand is dumped for the filling the low lying areas while doing this the agriculture areas is converted into barren area Because there is no. space for the waste other than the land filling similar case is in case of Aluminum industry where red mud is concluded to be waste. Which contains lot amount of bauxite and that is why red mud is also dump in the nearby areas here it is causing big threat for the society and it is disturbing the eco system of the environment. So it is the dire need to use this particular otherwise waste material for the constructive in such fashion in the case of concrete so that concrete which became cost effective as well as ecofriendly. And hence this project is attempted. CHAPTER 1 INTRODUCTION TO SELF COMPACTING CONCRETE The development of new technology in the material science is progressing rapidly. In last three decades, a lot of research was carried out throughout globe to improve the performance of concrete in terms of strength and durability qualities. Consequently concrete has no longer remained a construction material consisting of cement, aggregate, and water only, but has becomes an engineered custom tailored material with several new constituents to meet the specific needs of construction industry. The growing use of concrete in special architectural configurations and closely spaced reinforcing bars have made it very important to produce concrete that ensures proper filling ability, good structural performance and adequate durability. In recent years, a lot of research was carried out throughout the world to improve the performance of concrete in terms of its most important properties, i.e. GOVT. COLLEGE OF ENGG. KARAD 6 “APPLICATION OF INDUSTRIAL WASTE IN MANUFACTURING OF SELF COMPACTING CONCRETE” strength and durability. Concrete technology has under gone from macro to micro level study in the enhancement of strength and durability properties from 1980’s onwards. Till 1980 the research study was focused only to flow ability of concrete, so as to enhance the strength however durability did not draw lot of attention of the concrete technologists. This type of study has resulted in the development of self compacting concrete (SCC), a much needed revolution in concrete industry. Self compacting concrete is highly engineered concrete with much higher fluidity without segregation and is capable of filling every corner of form work under its self weight only (Okamura 1997). Thus SCC eliminates the needs of vibration either external or internal for the compaction of the concrete without compromising its engineering properties. This concrete was first developed in Japan in late 80’s to combat the deterioration of concrete quality due to lack of skilled labours, along with problems at the corners regarding the homogeneity and compaction of cast in place concrete mainly with intricate structures so as to improve the durability of concrete and structures. After the development of SCC in Japan 1988, whole Europe started working on this unique noise free revolution in the field of construction industry. The last half of decade 1991-2000 has remained very active in the field of research in SCC in Europe. That is why, Europe has gone ahead of USA in publishing specifications and guidelines for self compacting concrete (EFNARC 2002). Now, all over the world, a lot of research is going on, so as to optimize the fluidity of concrete with its strength and durability properties without a drastical increase in the cost. The first North American conference on design and use of self-consolidation concrete was organized in November 2002. At present many researchers are working in numerous universities and government R&D organizations GOVT. COLLEGE OF ENGG. KARAD 7 “APPLICATION OF INDUSTRIAL WASTE IN MANUFACTURING OF SELF COMPACTING CONCRETE” due to benefits of the use of this concrete. A very limited work is reported from India, where the future for concrete is very bright due to scarcity of skilled man power, non-mechanization of construction industry, abundant availability of construction materials available at very low cost. Therefore, it can be said that SCC is still quite unknown to many researchers, builders, ready mix concrete producers, academia etc. Self compacting concrete is basically a concrete which is capable of flowing in to the formwork, without segregation, to fill uniformly and completely every corner of it by its own weight without any application of vibration or other energy during placing. There is no standard self- compacting concrete. There fore each self-compacting concrete has to be designed for the particular structure to be constructed. However working on the parameters which affect the basic properties of self-compacting concrete such as plastic viscosity, deformability, flowability and resistance to segregation, self-compacting concrete may be proportioned for almost any type of concrete structure. To establish an appropriate mixture proportion for a self- compacting concrete the performance requirements must be defined taking into account the structural conditions such as shape, dimensions, reinforcement density and construction conditions. The construction conditions include methods of transporting, placing, finishing and curing. The specific requirement of self-compacting concrete is its capacity for self-compaction, without vibration, in the fresh state. Other performances such as strength and durability should be established as for normal concrete. To meet the concrete performance requirements the following three types of self-compacting concretes are available. a) Powder type of self-compacting concrete: This is proportioned to give the required self-compactability by reducing the water-powder GOVT. COLLEGE OF ENGG. KARAD 8 “APPLICATION OF INDUSTRIAL WASTE IN MANUFACTURING OF SELF COMPACTING CONCRETE” (material<0.1mm) ratio and provide adequate segregation resistance. Super plasticizer and air entraining admixtures give the required deformability. b) Viscosity agent type self-compacting concrete: This type is proportioned to provide self-compaction by the use of viscosity modifying admixture to provide segregation resistance. Super plasticizers and air entraining admixtures are used for obtaining the desired deformability. c) Combination type self-compacting concrete: This type is proportioned so as to obtain self-compactability mainly by reducing the water powder ratio, as in the powder type, and a viscosity modifying admixture is added to reduce the quality fluctuations of the fresh concrete due to the variation of the surface moisture content of the aggregates and their gradations during the production. This facilitates the production control of the concrete. CHAPTER 2 NEED FOR SCC Now having a look over history of SCC, question arises that what is needed to go for SCC? So, here are some of the important aspects to go with SCC: Foundry sand and red mud has pozzolanic properties hence increasing the binding properties and gives the better strength at the same time it reduces the cost problems. And also reduces the following problems. 1. Foundry waste dumping 2. Red mud dumping. In dumping land become useless. It starts polluting the groundwater. GOVT. COLLEGE OF ENGG. KARAD 9 “APPLICATION OF INDUSTRIAL WASTE IN MANUFACTURING OF SELF COMPACTING CONCRETE” So it should be used in some constructive fashion. Which is going to cater in two ways Help in getting better quality of concrete. For several years, the problem of the durability of concrete structures has been a major problem posed to engineers. To make durable concrete structures, sufficient compaction is required. Compaction for conventional concrete is done by vibrating. Over vibration can easily cause segregation. In conventional concrete, it is difficult to ensure uniform material quality and good density in heavily reinforced locations. If steel is not properly surrounded by concrete it leads to durability problems. This is the problem mainly with heavily reinforced sections where a very high congestion of reinforcement is seen. In this case, it becomes extremely difficult to compact the concrete. Then what can be done to avoid honeycombing? The answer to the problem may be a type of concrete which can get compacted into every corner of form work and gap between steel, purely by means of its own weight and without the need for compaction. The SCC concept was required to overcome these difficulties. The SCC concept can be stated as the concrete that meets special performance and uniformity requirements that cannot always be obtained by using conventional ingredients, normal mixing procedure and curing practices.The SCC is an engineered material consisting of cement, aggregates, water and admixtures with several new constituents like colloidal silica, pozzolanic materials, chemical admixtures to take care of specific requirements, such as, high-flowability, compressive strength, high workability, enhanced resistances to chemical or mechanical stresses, lower permeability, durability, resistance against segregation, and possibility under dense reinforcement conditions. GOVT. COLLEGE OF ENGG. KARAD 10