Utilization of foundry slag as a partial replacement of cement and sand

Transcription

1 SSRG International Journal of Civil Engineering (SSRG-IJCE) volume Issue 5 May 6 Utilization of foundry slag as a partial replacement of cement and sand Savita Devi, Shahrukh, Sanjay Meena, Sreyansh Joshi, Shubham Kumar Sharma 5 Asst. professor, Poornima Institute of Engineering and Technology, Jaipur.,,,5, B. Tech. Students, Poornima Institute of Engineering and Technology, Jaipur. Abstract the aim of this study is to evaluate the performance of Foundry Slag an industrial waste as partial replacement of cement and send in concrete. Foundry slag is high quality of silica, alumina and ferrous. It is obtained from the steel mills furnace in metal casting industry. It generates tones of slag per year and its huge quantity is dumped on empty lands which create an environmental problem. This study investigates the performance of foundry slag as partial replacement of cement and sand in concrete mixtures in terms of Compressive strength, Flexural strength and splitting tensile strength of M- grade concrete. The cement and sand is replaced by Foundry Slag from% to %( at the interval of %) by weight. Watercement ratio was kept. for all cases. Partial replacement of cement in M- concrete from Foundry Slag may increase in all strength (Compressive, Flexural & Splitting Tensile strength) and durability of vibrational mix of concrete on all age when compared to normal concrete. Strength of the different mix proportion of foundry slag has to be check. It will concludes that by utilization of foundry slag as partial replacement of cement and sand in concrete, there is a lot of positive consequences in terms of strength, durability etc. Key Words: - Foundry Slag, Workability, Compressive Strength, Flexural Strength, Splitting Tensile Strength. I. INTRODUCTION:- All the building materials such as cement, sand, aggregates are derived from the natural resources. In recent years there has been a boom in construction which has increased the demands of these resources and has also led to the chances of there depletion. The cement production with an amount of million tons per year put India to the second largest cement producing country in the world. The increase in production of cement put tremendous pressure on natural resources. Besides this its consumption is also leading to generation of large quantity of waste and environmental pollution. The increase in metal casting industries is also making the conditions worst and problems like Land filling, soil losing its fertility, environmental pollution is seen nowadays. So, the induction furnaces slag which is a byproduct generated in a metal casting industries is used as an alternative for cement and sand. To make the best use of these natural resources of these materials is best alternative. With increasing awareness about the environment and scarcity for land filling due to its increasing cost, waste byproduct utilization has become an attractive alternative to its disposal. The slag produced annually is around.7 million, it is estimated around 5 foundries are operating all over India. The Materialistic properties of foundry slag is its high quality of ferrous, Alumina and ferrous. Its physical and chemical properties will depend on the raw materials used. Foundry slag is a combination of limestone and metal impurities in casting in metal casting industry. Foundry slag is use in concrete as partially replacement of cement and sand.in this project we have to take M- concrete mix design and prepare sample of concrete at variation propositions.in this we preparedvarious sample of cement and sand replacement. II. LITERATURE REVIEW:- Alok janveja and Sanjay K. Sharma []the study of foundry slag, literature survey was carried out. For this various journals were referred. Research work concerning to the various application and methods used for testing of the concrete made by foundry slag are discussed. In paper results of experimental investigations carried out to evaluate effects of replacing of cement and sand with foundry slag on various proportional. The objective of this study was to identify alternative source of good quality aggregates. Use of foundry slag an industrial waste of metal casting industries production provides great opportunity to utilize it as an alternative to partially replace of cement and sand. In this study, concrete of M- grade was considered for a W/C ratio of. for the replacement of % to %( at the interval of %) of cement and sand by foundry slag. Whole study was done in two phases, i.e. replacement of cement with foundry slag and replacement of sand with foundry slag.the investigation revealed improvement in compressive strength, spit tensile strength and flexural strength over control mixes. The application of foundry slags as aggregate, road bed materials, soil fertility conditioner and as clinker materials depend on their chemical and mineralogical characteristics. The compressive strength find out at 7 days and 8 days. The split tensile strength was find out at 8 days this is done for cylinder. The flexural strength was find out at 8 days, this is done for beam. G. S. Patange et al. [] discussed that the ferrous foundries generate lots of amount of waste. India is the world s second largest producer of casting and also one of the top in terms of average production per plant, but our share of the global market is below percent. It is estimated around 5 Foundries are operating all over the India. Many Indian ISSN: Page 8

2 SSRG International Journal of Civil Engineering (SSRG-IJCE) volume Issue 5 May 6 foundries have not implemented new environmental conscious technology because they are not aware the source of waste in their foundry and intensity of wastes. The objective of this paper is to be investigate foundry wastes for implementation of cleaner production in foundry particularly for MSEs (Micro and small enterprise) to sustain the environment for Indian foundries. There is a tremendous scope for these foundries to use the high quality raw material for reduce the solid waste and also use the various devices like Filters, Cyclones, Mechanical Collectors, Scrubbers to enhance the awareness in relation with cleaner production idea. There is a lack of economical information for many recent techniques. There is need of awareness with this regard towards moving for sustainable development. M.V. Deshmukh and N.R. Vidhate [] discussed that analysis of induction furnace slag of ferrous foundry slag. In India there are around 5 foundries operating, which produced slag annually is around.7 million ton. All foundries produce casting by pouring molten metal into molds, typically consisting of core and molding sands. Once the casting has cooled and hardened, it is separated from mold and core materials in the shakeout process. The casting are cleaned, inspected, and then shipped for delivery. During the cast iron production large amount of waste is generated which is hazardous to the environment. The waste is store at place near industry in which loading, unloading and transportation cost is involved. To avoid this utilization of waste is very important. III. EXPERIMENTAL PROGRAM:- Experiments were conducted on concrete prepare by partial replacement of cement and sand by foundry slag of practical size5 µm (for cement) and 6 µm (for sand).cement and sand are replaced by %,% and % of foundry slag and mix design was prepared and compressive strength,, Flexural Strength, Splitting Tensile Strength. IV. OBJECTIVE OF RESEARCH: - The main objective of this project was to know the behavior of concrete with replacement of cement and sand with replacement of foundry slag at vibration proportion. The purpose of this project is to utilize this slag waste as useful building material, save the steel mills from transport and disposal problems. In place of river sand, alternate sand may be available to builders on cheaper rates. This will prevent over exploitation of quarries and save our environment. To reduce greenhouse gases but also help in making environmentally friendly material. To Design concrete mix containing high volume foundry slag as binder and filler. To reduce the consumption of cement in concrete industry. V. MATERIAL USED:- Cement and water: - Ordinary Portland cement of grade is used to prepare the mix design of Different grade. The cement used was fresh and without any lumps Water cement ratio is. for this mix design using IS 56:7. Sr. no. properties detail Specific gravity.5 P H 9 color Gray (TABLE I)- PHYSICAL PROPERTIES OF CEMENT: - (As per International journal of civil and structural engineering volume no, ). (TABLE II)- CHEMICAL PROPERTIES OF OPC Sr. no. Chemical composition OPC SIO 8.6% Al O.75% Fe O.% CaO 6.% 5 MgO.% 6 Na O.5% 7 K O.% 8 SO.9% 9 LOI.55% (As per International journal of civil and structural engineering volume no, ). Fine aggregate: - Clean river sand of maximum Size.75 mm are used as a fine aggregate.the Experimental program was locally procured And conformed to grading zone as per IS: (TABLE III)- PROPERTIES OF FINE AGGREGATE: - Properties Observed value Specific gravity.5 Fineness modulus.6 Bulk density 587 kg/m Percentage of lumps.6 % Water absorption. % (As per ISSN 5-59, ISO 9:8 Certified Journal, Volume, Issue, October ) Coarse aggregate: The coarse aggregates are locally available was used having maximum size of mm. ISSN: Page 8

3 Properties SSRG International Journal of Civil Engineering (SSRG-IJCE) volume Issue 5 May 6 (TABLE IV)- PROPERTIES OF COARSE AGGEREGATE Observed value Specific gravity.75 Fineness modulus 6.89 Bulk density 5 kg/m Aggregate impact value. Water absorption.69 % (As per ISSN 5-59, ISO 9:8 Certified Journal, Volume, Issue, October ) MOULDS: We here used three types of molds to check strength at various proportions of replacement. Cubical: - cubical mold of size 5*5*5 mm was used to prepare the concrete specimens for determination of compressive strength of concrete. Cylindrical: - cylindrical mold of size mm Height and 5 mm Diameter was used to prepare the Concrete specimens for determination of Splitting Tensile Strength of concrete. Beam: - Beam of size 5 mm length, mm width and mm thick was used to prepare the Concrete specimens for determination of Flexural Strength of concrete. FOUNDRY SLAG: The research was made on foundry Slag procured from metal casting industry located in Parwatsar Naguar district in Rajasthan. 7 MgO.% 8 Cr O.5% 9 (As per the Indian concrete Journal, July K O 5, Vol. 89, Issue, pp.6-7.).9% MIX DESIGN AND EXPERIMENTAL WORK: The concrete mix design was proposed according to Indian standard for control concrete. The grade was M and the ratio of cement, sand and aggregate is :.5: and water cement ratio is. which is constant for all mix design. Natural course and fine aggregate were use. The replacement level of cement and sand to foundry slag was used in the term of %, % and % in concrete. VI. RESULTS COMPRESSIVE STRENGTH TEST:- Cubes which prepared with different replacement of foundry slag is tested after 7 days and 8 days of curing for compressive strength value. For each mix three different cubes are prepare and average final value of compressive strength is calculated which is shown in table.. COMPRESSIVE STRENGTH VALUE WHEN SAND IS REPLACED BY FOUNDRY SLAG (TABLE VII)- COMPRESSIVE STRENGHT AT 7 DAYS TABLE (V) - PHYSICAL PROPERTIES OF FOUNDRY SLAG:- Sr.no. Property result Specific gravity.69 Water absorption.5 Moisture content. Fine modulus.65 (As per the Indian concrete Journal, July 5, Vol. 89, Issue, pp.6-7.) TABLE (VI) - CHEMICAL PROPERTIES OF FOUNDRY SLAG:- Sr. no. Description % S. MIX CUBES COMPRESSIVE STRENGTH AT 7 DAYS FOR M- (Mpa) C C C AVG REF S S S SiO.9% Al O.55% Fe O 8.9% CaO 7.% 5 MnO 6.6% 6 TiO.9% ISSN: Page 8

4 SSRG International Journal of Civil Engineering (SSRG-IJCE) volume Issue 5 May 6 S. Compresive at 7 days Compresi ve 9. REF S S S GRAPH : - COMPRESSIVE STRENGTH AT 7 DAYS FOR M- TABLE (VIII) COMPRESSIVE STRENGTH AT 8 DAYS MIX CUBES COMPRESSIVE STRENGTH AT 8 DAYS FOR M- (Mpa) C C C AVG REF S S.77.. S ve Compresive at 8 days REF S S S GRAPH : - COMPRESSIVE STRENGTH AT 8 DAYS FOR M-. COMPRESSIVE STRENGTH VALUE WHEN CEMENT IS REPLACED BY FOUNDRY (TABLE IX)- COMPRESSIVE STRENGHT AT 7 DAYS S. MIX CUBES COMPRESSIVE STRENGTH AT 7 DAYS FOR M- (Mpa) 5 Compresiv 5 e 5 Compresive at 7 days 9. REF C C C GRAPH : - COMPRESSIVE STRENGTH AT 7 DAYS FOR M- (TABLE X)- COMPRESSIVE STRENGHT AT 8 DAYS S. MIX CUBES COMPRESSIVE STRENGTH AT 8 DAYS FOR M- (Mpa) C C C AVG REF C C C Compresi ve Compresive at 8 days REF C C C GRAPH : - COMPRESSIVE STRENGTH AT 8 DAYS FOR M- SPLINTING TENSILE STRENGTH: Cylinders which prepared with different replacement of foundry slag is tested after 8 days of curing for splinting tensile strength value. For each mix three different cylinders are prepare and average final value of splinting tensile strength is calculated which is shown in table. C C C AVG REF C C C ISSN: Page 8

5 S. MIX SSRG International Journal of Civil Engineering (SSRG-IJCE) volume Issue 5 May 6. SPILLTING TENSILE STRENGTH VALUE WHEN SAND IS REPACED BY FOUNDRY SLAG TABLE (XI) SPLIT TENSILE STRENGTH AT 8 DAYS CYLINDERS SPLIT TENSILE STRENGTH AT 8 DAYS FOR M- (Mpa) C C C AVG REF S S S.6... Split Tensile Split Tensile Strenght at 8 days REF S S S Splite Tensile Strenght Split Tensile Strenght at 8 days.9.6. REF S S S GRAPH 6: - SPLIT TENSILE STRENGTH AT 8 DAYS FOR M- FLEXURAL STRENGTH TEST: Beams which prepared with different replacement of foundry slag is tested after 8 days of curing for flexural strength value. For each mix three different cylinders are prepare and average final value of flexural strength is calculated which is shown in table:graph 5: - SPILLTING TENSILE STRENGTH AT 8 DAYS FOR M- GRAPH 5: - SPLIT TENSILE STRENGTH AT 8 DAYS FOR M-. SPITTING TENSILE STRENGHT VALUE WHEN CEMENT IS REPLACED BY FOUNDRY SLAG TABLE (XII):- SPLIT TENSILE STRENGTH AT 8 DAYS S. MIX CYLINDERS SPLIT TENSILE STRENGTH AT 8 DAYS FOR M- (Mpa). FLEXURAL STRENGHT VALUE WHEN SAND IS REPLACED BY FOUNDRY SLAG. TABLE (XIII):- FLEXURAL STRENGTH AT 8 DAYS S. No MIX BEAMS FLEXURAL STRENGTH AT 8 DAYS FOR M- C C C AVG REF C C....6 C.... C C C AVG REF S S S ISSN: Page 8

6 Flexural 6 5 SSRG International Journal of Civil Engineering (SSRG-IJCE) volume Issue 5 May 6 Flexural Strenght at 8 days REF S S S GRAPH 7: - FLEXURAL STRENGTH AT 8 DAYS FOR M-. FLEXURAL STRENGHT VALUE WHEN CEMENT IS REPLACED BY FOUNDRY SLAG S. TABLE (XIV):- FLEXURAL STRENGTH AT 8 DAYS MIX BEAMS FLEXURAL STRENGTH AT 8 DAYS FOR M- C C C AVG REF C C C Flexural Strenght Flexural Strenght at 8 days REF C C C GRAPH 8: - FLEXURAL STRENGTH AT 8 DAYS FOR M- VII. CONCLUSION. The project provide quantified data on strength of M- concrete containing Foundry slag and firm basis for its utilization in structural concrete N/mm was the maximum compressive strength which was obtained at replacement level of % by weight of sand and 5.7 N/mm was the maximum compressive strength which was obtained at replacement level of % by weight of cement... N/mm was the maximum split tensile strength which was obtained at replacement level of % by weight of Sand and.6 N/mm was the maximum split tensile strength which was obtained at replacement level of % by weight of cement N/mm was the maximum flexural strength which was obtained at replacement level of % by weight of sand and 5. N/mm was the maximum flexural strength which was obtained at replacement level of % by weight of cement. 5. Use of Foundry slag in concrete causes saving of cement and address the problem of disposal of Foundry slag and resolve environmental problems. 6. Use of Foundry slag minimize the greenhouse gases and lead to sustainable construction. 7. It reduces the metal industrial waste and disposal problem related to it. 8. Economical concrete. 9. Procuring higher grade of concrete by mixing Foundry slag in M- concrete.. The increased strength of concrete can be used in heavy structures. REFFERENCE. The Indian Concrete Journal, July 5, Vol. 89, Issue7, pp G.S. Patange, M.P. Khond and N.V. Chaudhari, Some Studies And Investigation Of Foundry wastes For Sustainable Development, International journal of industrial engineering, vol., pp. 5-5,.. M.V. Deshmukh, Analysis of induction furnace slag of ferrous foundry, IJSRD, Vol., Issue /5/.. Naik T.R. et al. (996). Application of foundry by-product materials in manufacturing of concrete and masonry products., ACI materials Journal, V T. Yuvaraj et al., Environmental Feasibility in Utilization of Foundry Slag (IOSR-JESTFT) Volume 9, Issue, Ver. (Jan. 5) ISSN 5-59, ISO 9:8 Certified Journal, Volume, Issue, October ) 8. International journal of civil and structural engineering volume no, ). 9. IS 6:9 for Mix Design. IS 56: (Plain Concrete and RCC Concrete). ISSN: Page 85