SUITABILITY OF WASTE GLASS POWDER AS A PARTIAL REPLACEMENT OF CEMENT IN FIBRE REINFORCED CONCRETE

SUITABILITY OF WASTE GLASS POWDER AS A PARTIAL REPLACEMENT OF CEMENT IN FIBRE REINFORCED CONCRETE A Project Report submitted in partial fulfillment for Diploma In CIVIL ENGINEERING BY

SHAIKH NAWAZ ALTAF KHOT MASNA ASMAT GUJAR MOHAMMAD SEEMAB KHAN MOHAMMAD AALAM KHAN FARHAN AZIM

Under the guidance of Er. Mohammad Shoeb Sayeeduddin

Civil Engineering Department A.I.A.R. KALSEKAR POLYTECHNIC New Panvel 410 206, Navi Mumbai. {MSBTE} 2012-2013

1

DECLARATION

I hereby declare that the project entitled “ SUITABILITY OF WASTE GLASS POWDER

AS

A

PARTIAL

REPLACEMENT

OF

CEMENT

IN

FIBRE

REINFORCED CONCRETE” CONCRETE” submitted for diploma in CIVIL ENGINEERING

under MSBTE, is my original work and the project has not formed the basis for the award of any degree, association ,fellowship or any other similar titles.

............................... ......... Signature of the student: ...................... Place: ...............................

Date: ...............................

2

DECLARATION

I hereby declare that the project entitled “ SUITABILITY OF WASTE GLASS POWDER

AS

A

PARTIAL

REPLACEMENT

OF

CEMENT

IN

FIBRE

REINFORCED CONCRETE” CONCRETE” submitted for diploma in CIVIL ENGINEERING

under MSBTE, is my original work and the project has not formed the basis for the award of any degree, association ,fellowship or any other similar titles.

............................... ......... Signature of the student: ...................... Place: ...............................

Date: ...............................

2

CERTIFICATE This is to certify that this dissertation report entitled “ SUITABILITY OF WASTE GLASS POWDER

AS

A

PARTIAL

REPLACEMENT

OF

CEMENT

IN

FIBRE

REINFORCED CONCRETE” CONCRETE” is a record of work carried out by by SHAIKH NAWAZ ALTAF KHOT MASNA ASMAT GUJAR MOHAMMAD SEEMAB KHAN MOHAMMAD AALAM KHAN FARHAN AZIM

Of DIPLOMA (CIVIL ENGINEERING) class and is submitted to the MUMBAI UNIVERSITY, Mumbai in partial fulfillment of the requirement for the degree of diploma in civil engineering. This project report has been approved.

...............................

..................................

Internal Guide

Head of Department

Er. Mohammad Shoeb S.

Er. Ilyas Quadri

............................... Principal

{A.I.A.R. KALSEKAR POLYTECHNIC}

3

APPROVAL OF THE PROJECT The project report entitled “SUITABILITY OF WASTE GLASS POWDER AS A PARTIAL REPLACEMENT OF CEMENT IN FIBRE REINFORCED CONCRETE”

submitted by, SHAIKH NAWAZ ALTAF KHOT MASNA ASMAT GUJAR MOHAMMAD SEEMAB KHAN MOHAMMAD AALAM KHAN FARHAN AZIM

Of DIPLOMA (CIVIL ENGINEERING) has been accepted in partial fulfillment of the requirement for the degree of diploma in civil engineering. This project report has been approved.

............................... {Internal Examiner}

............................... {External Examiner}

Date of approval: ..............................

4

TABLE OF CONTENTS Chapter no: 1 1.1 Introduction............................................................................................................13 1.2 Objectives of Work................................................................................................17 1.3 Research Methodology..........................................................................................18 1.4 Resources and Place of Work................................................................................18 Chapter no: 2 2.1 Glass.......................................................................................................................20 2.2 Classification of Glass............................................................................................21 2.3 Composition of Glass.............................................................................................22 2.4 Composition of Cement.........................................................................................23 2.5 Properties of Glass..................................................................................................24 2.6 Types of Glass........................................................................................................24 2.6.1 Soda-lime glass.......................................................................................25 2.6.2 Potash lime Glass....................................................................................25 2.6.3 Potash Lead glass....................................................................................25 2.6.4 Common Glass........................................................................................26 2.7 Manufacture of glass..............................................................................................26 2.7.1 Collecting Raw materials....................................................................... 26 2.7.2 Preparation of batch................................................................................27 2.7.3 Melting in Furnace..................................................................................27 2.7.3.1 Tank Furnace............................................................................28 2.7.4 Fabrication...............................................................................................29 2.7.5 Annealing................................................................................................30 2.8 Treatment of Glass.................................................................................................30 2.8.1Bending....................................................................................................30 2.8.2 Cutting....................................................................................................30 2.8.3 Opaque Making......................................................................................30

5

2.8.4 Silvering ..................................................................................................31 2.9 Coloured Glass.......................................................................................................31 2.10 Special Varieties of Glass.....................................................................................31 2.11 Glass Industry in India.........................................................................................32 2.12 Glass Powder.......................................................................................................34 Chapter no: 3 3.1 Fiber glass.........................................................................................................37 3.2 High Zirconia Alkali-resistant Glass Fiber............................................................38 3.3 What is ARG? ..................................................................................................38 3.4 Properties of NEG ARG Fiber.........................................................................39 3.5 Alkali resistivity of NEG ARG Fiber................................................................40 3.6 Comparison of alkali erosive attack in NEG ARG Fiber and E Glass Fiber (SEM-photographs)................................................................ 41

3.7 Product Range of NEG ARG FIBRE.................................................................... 41 3.7.1 Continuous Roving..................................................................................41 3.7.1.1 Characteristics of Continuous Roving.....................................41 3.7.1.2 Process for Continuous Roving................................................41 3.7.2 Chopped Strands...............................................................................42 3.7.2.1 High Integrity Type............................................................ 43 3.7.2.2 Water Dispersible Type........................................................ 43 3.7.2.3 Characteristics of Chopped Strands.........................................43 3.7.2.4 Process for Chopped Strands....................................................43 3.7.2.5 Standard Specifications of Chopped Strands...........................44 3.8 What is GRC? ........................................................................................................45 3.8.1 Feature of GRC.......................................................................................45 3.8.2 Features of GRC......................................................................................45

6

3.8.3 Typical properties of GRC.....................................................................45 3.8.4 Process of GRC...................................................................................47 3.8.4.1 Spray Process..........................................................................47 3.8.4.2 Premix process........................................................................47 3.9 Applications.......................................................................................................... 48 Chapter no: 4 4.1 Documented Case Study........................................................................................50 4.1.2 TECHNICAL PAPER NO: 1.................................................................49 4.1.3 TECHNICAL PAPER NO: 2.................................................................75 4.1.4 TECHNICAL PAPER NO: 3.................................................................88 Chapter no: 5 5.1 Experimental Equipments....................................................................................111 5.1.1 Concrete Mixer......................................................................................111 5.1.2 Casting Moulds.....................................................................................112 5.1.3 Tamping Rod........................................................................................113 5.1.4 Compression Testing Machine {C.T.M.}.............................................114 5.1.5 Slump Cone...........................................................................................115 Chapter no: 6 6.1 Results..................................................................................................................117 6.2 Discussions...........................................................................................................117 6.3 Photographs..........................................................................................................122 CONCLUSION......................................................................................................................136 REFERENCES.......................................................................................................................137

7

LIST OF FIGURES Chapter no: 2 Figure No.1........................................................................................................20 Figure No.2........................................................................................................22 Figure No.3........................................................................................................23 Figure No.4........................................................................................................27 Figure No.5........................................................................................................28 Figure No.6........................................................................................................29 Figure No.7........................................................................................................32 Figure No.8........................................................................................................33 Figure No.9........................................................................................................34 Chapter no: 3 Figure No.10......................................................................................................37 Figure No.11.....................................................................................................40 Figure No.12......................................................................................................41 Figure No.13......................................................................................................43 Figure No.14......................................................................................................47 Chapter no: 5 Figure No.15...................................................................................................111 Figure No.16...................................................................................................112 Figure No.17...................................................................................................113 Figure No.18...................................................................................................114 Figure No.19...................................................................................................115 Photographs Figure No. 20 to No.46..........................................................................117 -131

8

LIST OF TABLES Chapter no: 2 Table No.1.........................................................................................................31 Chapter no: 3 Table No.2.........................................................................................................39 Table No.3.........................................................................................................42 Table No.4.........................................................................................................42 Table No.5.........................................................................................................44 Table No.6.........................................................................................................44 Table No.7.........................................................................................................46 Table No.8.........................................................................................................48 Chapter no: 5 Table No.9................................................................................................111-112 Chapter no: 6 Table No.10.....................................................................................................133

9

ACKNOWLEDGEMENT

We avail this opportunity with immense pleasure to express our deep sense of sincere gratitude towards our respected guide Er. Mohammad Shoeb Sayeeduddin who has helped us throughout the period and has helped us

through times of need. He helped us in preparing this book and by his cooperation, valuable guidance and support and continuous encouragement we completed our project. Professor Ilyas Quadri {H.O.D.} was a great source of inspiration and allowed us to work in the concrete lab for extended hours. In spite of their busy schedule it was very kind of them to spare some of their precious time and give us valuable suggestions which ultimately formed the heart of the project. The departmental peons need a warm mention for helping us all along the way. We would also like to thank our friends for their direct and indirect support to us which helped us to complete the project. It is an honor and great pleasure to express our heartfelt gratitude to especially our teachers, to our friends, to the entire civil engineering department and to those who have directly or in directly contributed towards the completion of our project.

10

ABSTRACT

In this project we are going to replace the cement partially using glass powder which is rich in silica. Therefore, we have planned to prepare some numbers of cubes, using glass powder at various proportions like 4%, 8%, 12%, 16%, 20%, 24% and going to test them for its compressive strength. The casted specimens will be tested for its strength. We have also planned to prepare some numbers of cubes using conventional concrete. From the test results, we are going to compare the behavior of glass powder concrete with conventional concrete. In this work we are going to use waste glasses, so the cost will be comparatively low when compared with normal concrete.

11

12

1.1 Introduction Much of the glass produced in the World is discarded, stockpiled or land filled. This pattern has influenced environmental organizations to pressure the professional community to lower the amount of glass being discarded as well as find use to the non-recycled glass in new applications. The waste glass is one of the issues of environmental problem. Glass is used in a variety of applications right from construction, automobiles, nose-diving submarines, doors and windows, utensils, waste containers, windscreen, medicinal bottles, soft-drink bottles, tube lights, bulbs, electronic equipments, etc. Hence, the usage of glass has increased considerably, which has in essence, contributed to the increase of waste disposal. In addition, glass waste is considered as non-decaying material that pollutes the surrounding environment. Many researchers have thus come forward and have investigated usage of this waste glass into something of productive value. One such group of research scholars has highlighted the usage of glass in powdered form as a partial replacement of cement in concrete. In relation, the recycling of waste glass as a component in concrete gives waste glass a sustainable alternative to land filling and therefore makes it economically viable. A variety of public and private research was investigated to understand the limitations of glass concrete and its properties. Results found were promising as strength tests showed the glass concrete mixtures in question to have moderate to high strengths which shows that a concrete derived from recycled glass could be effectively applied to a multitude of services including structural applications. There is considerable interest in the use of recycled glass with port land cement in making a variety of different types of cement products. This interest has been motivated by the large quantity of recycled glass available through municipal recycling programs-which far exceeds the demand for such glass from conventional markets like container manufacturers. If glass could be incorporated in cement products, it

13

would greatly reduce the disposal of recycled glass and/or its use in lower valued markets such as fill and road base material. The waste glass is one of the issues of environmental problem. Glass is used in a variety of applications right from construction, automobiles, nose-diving submarines, doors and windows, utensils, waste containers, windscreen, medicinal bottles, soft-drink bottles, tube lights, bulbs, electronic equipments, etc. Hence, the usage of glass has increased considerably, which has in essence, contributed to the increase of waste disposal. In addition, glass waste is considered as non-decaying material that pollutes the surrounding environment. Many researchers have thus come forward and have investigated usage of this waste glass into something of productive value. One such group of research scholars has highlighted the usage of glass in powdered form as a partial replacement of cement in fiber reinforced concrete. Glass Fiber Reinforced Concrete (GFRC) is a type of fiber reinforced concrete. Glass fiber concretes are mainly used in exterior building façade panels and as architectural precast concrete. Somewhat similar materials are fiber cement siding and cement boards. Composition Glass fiber reinforced concrete (GFRC) consists of high strength glass fiber embedded in a cementations matrix. In this form, both fibers and matrix retain their physical and chemical identities, while offering a synergism: a combination of properties that cannot be achieved with either of the components acting alone. In general, fibers are the principal load- carrying members, while the surrounding matrix keeps them in the desired locations and orientation, acting as a load transfer medium between them, and protects them from environmental damage. In fact, the fibers provide reinforcement for the matrix and other useful functions in fiber-reinforced composite materials. Glass fibers can be incorporated into a matrix either in continuous lengths or in discontinuous (chopped) lengths. Laminates a widely used application for fiber-reinforced concrete is structural

14

laminate, obtained by adhering and consolidating thin layers of fibers and matrix into the desired thickness. The fiber orientation in each layer as well as the stacking sequence of various layers can be controlled to generate a wide range of physical and mechanical properties for the composite laminate. However, GFRC cast without steel framing is commonly used for purely decorative applications such as window trims, decorative columns, exterior friezes, or limestone like wall panels. The potential for using a glass fiber reinforced concrete system was recognized by Russians in the 1940s. The early work on glass fiber reinforced concrete went through major modifications over the next few decades. Properties the design of GFRC panels proceeds from a knowledge of its basic properties under tensile, compressive, bending and shear forces, coupled with estimates of behavior under secondary loading effects such as creep, thermal and moisture movement. There are number differences between structural metal and fiberreinforced composites. For example, metals in general exhibit yielding and plastic deformation whereas most fiber-reinforced composites are elastic in their tensile stress-strain characteristics. However, the dissimilar nature of these materials provides mechanisms for high-energy absorption on a microscopic scale comparable to the yielding process. Depending on the type and severity of external loads, a composite laminate may exhibit gradual deterioration in properties but usually would not fail in catastrophic manner. Mechanisms of damage development and growth in metal and composite structure are also quite different. Other important characteristics of many fiber-reinforced composites are their non-corroding behavior, high damping capacity and low coefficients of thermal expansion. Glass fiber reinforced concrete architectural panels have general appearance of pre-cast concrete panels, but are different in several significant ways. For example, GFRC panels will, on the average, weigh substantially less

15

than pre-cast concrete panels due to their reduced thickness. The low weight of GFRC panels decrease superimposed loads loads on the building’s structural components. The building frame becomes more economical. Sandwich panels A sandwich panel is a composite of three or more materials bonded together to form a structural panel. It takes advantage of the shear strength of a low density core material and the high compressive and tensile strengths of the GFRC facing to obtain high strength to weight ratios. The theory of sandwich panels and functions of the individual components may be described by making an analogy to an I - beam. Core in a sandwich panel is comparable to the web of an I -beam, which supports the flanges and allows them to act as a unit. The web of the I -beam and the core of the sandwich panels carry the beam shear stresses. The core in a sandwich panel differs from the web of an I -beam in that it maintains a continuous support for the facings, allowing the facings to be worked up to or above their yield strength without crimping or buckling. Obviously, the bonds between the core and facings must be capable of transmitting shear loads between these two components thus making the entire structure an integral unit. The load carrying capacity of a sandwich panel can be increased dramatically by introducing light steel framing. The light steel stud framing will be similar to conventional steel stud framing for walls, except, that the frame is encased in a concrete product. Here, sides of the steel frame are covered with two or more layers of GFRC, depending on the type and magnitude of external loads. The strong and rigid GFRC provides full lateral support on both sides of the studs, preventing studs from twisting and buckling laterally. The resulting panel is light weight in comparison with traditionally reinforced concrete, yet is strong and durable and can be easily handled.

16

In this research, the aim is to study the usage of glass in powdered form as a partial replacement of cement in fiber reinforced concrete and its impact on compressive strength of concrete. A considerable amount of research work is carried around the world on fiber reinforced concrete. However, most of the studies are related predominantly to the investigation of basic properties of fibrous concrete. Use of waste and byproduct as cement in fiber reinforced concrete (FRC) is of great practical significance; because of about 25% of concrete comprises cement. There are various types of waste materials that can be considered for use as cement. The experimental study for preparing nine cubes of seven different mixes using cement partially replaced by waste glass powder at varying percentage of 4%, 8%, 12%, 16%, 20%,24%, and to study the compressive strength properties.

1.2 Objective of the work 1) To assess the generation rate of glass waste in Mumbai, Thane and Navi Mumbai region 2) To study the existing methods of disposal of glass waste. 3) To economically compare conventional concrete with the concrete modified using glass waste. 4) The primary objective of this study is to investigate the practicality, versatility and 5) Feasibility of utilizing recycled glass as a partial replacement to cement. 6) This research focuses on studying the effect of waste glass on the properties of concrete mixtures as a partial replacement of cement. cement. 7) Identify the effects of adding waste glass on the fresh properties of concrete mixes such as workability by slump measures. 8) Study the influence of waste glass on hardened properties of concrete mixes such as: density and compressive strength pull out strength, flexural strength and splitting resistance. 9) Determine the optimum waste glass content to be added as a partial replacement of cement.

17

1.3 Research Methodology The following tasks are to be carried out in order to achieve the research objectives: Collecting the required information and documents related to the waste glass. 1) Visiting the Mumbai pollution control board to obtain related information and collect samples. 2) Undertaking a comprehensive Documented Case Study on relevant subjects focused on the usage of waste glass in construction field. 3) Developing an adequate experimental program to study the use of waste glass in concrete mixtures. 4) Analyzing the experimental output test results to draw conclusions. In this experimentation, an attempt would be made to find out the properties of concrete produced by replacing the cement with waste glass powder in various percentage ranging from 4% to 24% increments incr ements of o f 4% (4%, 8%, 12%, 16% and 20%, 24%.) .The experimental investigation would include casting and testing of cubes specimens to study the compressive and flexure strength of concrete cubes and beams. The Grade of concrete will be M 20.

1.4 Resources and Place of Work The proposed work shall be carried out at the laboratories of Civil Engineering Departments of Anjuman-I-Islam’s Anjuman-I-Islam’s Kalsekar Technical Campus and Kalsekar Polytechnic, New Panvel, New Mumbai. The routine testing facilities available there shall be used for testing.

18

19

2.1 Glass The glass has been used as an engineering material since ancient times. But because of the rapid progress made in glass industry in recent times the glass has come out as the most versatile engineering material of the modern times. The first glass object made by man were of natural glass such as obsidian and rock crystal. The manufactured glass dates from per historic times in the far east, India and Egypt but its exact place and date of the origin are unknown .it is however believed that the ancient Hindus knew the method of glass making long before the Christian era.

Fig. No 1 With the help of techniques developed in the glass industry the glass industry, the glass of any type and quality can be produced to suit the requirement of different industries. Just to stress the importance of glass in the engineering field of today, few of the recent development that have taken place in the glass industry are mentioned below:

20

1) A modern Boeing 707 jet plane contains more than 5000 components of glass. 2) The fiber glass reinforced with plastics can be used in the construction of furniture, lampshades, bathroom fitting, navy boats, aero planes, cars, trucks etc 3) The glass is the only material strong enough to go up to the bottom of ocean and to maintain its buoyancy. It is therefore used in the construction of noses of deep diving vehicles 4) The glass lining are applied on equipment likely to be affected by the chemical corrosion such as valves, pumps, pipes etc 5) In the field of fire arms, the glass is used to form a rifle barrel which is lighter and stronger than the conventional type 6) The body of a guided missile contains thousands of glass items 2

7) The mechanical strength of ordinary glass varies from 35 to 75 N/mm .Due to research in glass industry; it has become possible to produce glass having mechanical strength of about 420N/mm2.

2.2 Classification of glass The glass is a mixture of a number of metallic silicates, one of which is usually that of an alkali metal. It is an amorphous, transparent or translucent. It may also be considered as a solidified super cooled solution of various metallic silicates having infinite viscosity.

For the purpose of classification the glass

may be grouped into the following three categories: 1) Soda lime glass

3) Potash lead glass

2) Potash lime glass

21

One more category of glass may be formed and it may be called the common glass. The property and uses of different categories are mentioned later on this chapter.

2.3 Composition of glass The glass is not a single compound .it is therefore very difficult to give any particular chemical formula for it. Fig. No.2

22

2.4 Composition of Cement:

Fig. No. 3

23

2.5 Properties of glass The properties of glass are mainly governed by factors such as composition of the constitutions state of surface thermal treatment conditions dimensions of specimen etc. Following are the properties of glass which have made glass popular and useful: 1) It absorbs, refracts or transmits light. 2) It has no sharp melting point. 3) It is affected by alkalis. 4) It has no definite crystalline structure. 5) It is extensively brittle. 6) It is not usually affected by air and water. 7) It is available in beautiful colures. 8) It is possible to weld glass pieces by fusion. It can thus be easily appreciated that glass, though used for thousands of years, is just beginning to be understood and it is still possible to get a variety of glasses with certain chemical additives. Further investigations are yet in the process for preparing glass with extraordinary unusual characteristics and thus to increase the utility of this unique and complex material.

2.6 Types of Glass The properties and uses of the following types of glass will now be discussed: 1) Soda-lime glass 2) Potash-lime glass

3) Potash-lead glass 4) Common glass

24

2.6.1 Soda-lime glass: This is also known as the soda-glass or Soft-glass.it is mainly a mixture of sodium silicate and calcium silicate. 

Properties: Following are the properties of soda lime glass:

1) It is available in clean and clear state. 2) It is cheap. 3) It is easily fusible at comparatively low temperature. 4) It is possible to blow or to weld articles made from this glass with the help of simple sources of heat. 

Uses: It is used in manufacture of glass tubes and other laboratory apparatus, plate glass, window glass, etc.

2.6.2 Potash-lime glass: This is also known as the bohemian-glass or hard-glass. It is mainly a mixture of potassium silicate and calcium silicate. s ilicate. 

Properties: Following are the properties of potash-lime glass:

1) It fuses at high temperatures. 2) It is not easily affected by water and other solvent. 3) It does not melt so easily.

2.6.3Potash-lead glass: This is also known as the lint glass .it is mainly a mixture of potassium silicate and lead silicate. 

Properties: Following are the properties of potash-lead glass.

1) It fuses very easily. 2) It is easily attacked by aqueous solution. 3) It posses bright luster and great refractive power.

25

4) Its specifics gravity is about 3 to 3.30 5)

It turns black and opaque, if it comes into contact with reducing gases of the furnace during heating.

2.6.4 Common glass:This is known as the bottle glass. It is prepared from cheap raw materials. It is mainly a mixture of sodium silicate, calcium and iron silicate. 

Properties: - Following are the properties of common glass.

1) It fuses with difficulty. 2) It is brown, green or yellow in colour. 3) It is easily attacked by acids.

2.7 Manufacture of Glass:The procedure adopted in manufacture of glass may broadly be divided into following five stages:1) Collecting of raw materials 2) Preparation of batch 3) Melting in furnace 4) Fabrication 5) Annealing.

2.7.1 Collecting of raw materials:Depending upon the type of glass to be manufactured, suitable raw materials required. In addition to raw materials, the cullet and decolorized are also added for each type of glass.

26

Fig .no. 4 The raw materials generally contain traces of iron compound. The ferrous impart impart a green colour

to glass and ferric oxide oxide imparts imparts a very light

yellow tint.

2.7.2 Preparation of batch: The raw materials, cullet and decolorized are finely powered in grinding machines. These materials are accurate weighed in correct proportions before they are mixed together. The mixing of these materials is carried out in mixing machines until a uniform mixture is obtained .such a uniform mixture is known as the batch or frit and it is taken for further process of melting in a furnace.

2.7.3 Melting in furnace: The batch is melted either in a pot furnace or in a tank furnace. The heating is continued until the evolution of carbon dioxide, oxygen, sulphur dioxide and other gases stops.

27

Fig. no. 5 A pot is vessel made of fire-clay. this process these pots are placed in specially prepared holes in furnace .the charging and collecting doors are kept projecting outside so that raw materials may be added and molten glass may be taken out conveniently. The melting of glass by pot furnace is an intermittent process. It is used to melt small quantities of glass time at a time or to prepare specially types of glass.

2.7.3.1 Tank furnace:This furnace resembles the reverberatory furnace adopted for puddling of the wrought – iron .fig.13-2 shows the section of a tank furnace adopted for the melting of glass. It is constructed with reinforced masonry. The roof is given special shape to deflect the flames of heated gas .the ports are provided for the entry of preheated producer gas. The doors are provided of charging and for

28

taking out the molten glass. A bridge separates the tank into two unequal compartments.

Fig. no. 6 The tank is filled with raw material. The furnace is heated by following producer gas through ports. The charging of raw materials and taking out of molten mass are simultaneously. This is a continuous process and it is adopted to melt large quantities of glass at a time.

2.7.4 Fabrication: The molten glass is given suitable shape or form in this stage it can either be done by hand or by machine. The hand fabrication is adopted for small scale production and machine fabrication is adopted for a large scale production. Following are the different methods of fabrication:1) Blowing

4) Pressing

2) Casting

5) Rolling

3) Drawing

6) Spinning

29

2.7.5 Annealing:The glass articles after being manufactured are to be cooled down slowly and gradually .this process of slow and homogeneous cooling of glass articles is known as the annealing of glass. The annealing of glass is a very important process if glass articles are allowed to cool down rapidly the superficial layer of glass cools down first as glass is a bad conductor of heat. The interior portion remains comparatively hot and it is therefore in a state of strain hence such glass articles break to pieces under very slight shocks or disturbance. Following are the two methods of annealing 1) Flue treatment

&

2) Oven treatment

2.8 Treatment of glass: The glass may be given any of the following treatment: 1) Bending

3) Opaque

2) Cutting

4) Silvering

2.8.1 Bending: The glass may be bent into desired shape by placing it in ovens in which the temperature can be regulated. The glass in the form of rod sheets or tubes is placed in such ovens and heated. It is then bent when it is suitable heated.

2.8.2 Cutting: the glass is cut in required sizes with the help of diamond or rough glasses or small wheels of hardened steel.

2.8.3 Opaque Making: - The glass can also be made Opaque or impervious to light.

30

2.8.4 Silvering:- this process consist in applying a very thin coat of tin on surface of glass .the silver is deposited on this layer of tin. A suitable paint is then applied to give protection against the atmosphere effect.

2.9 Coloured glass:To make coloured glass the colouring pigment is added to the raw materials while preparing the batch for its manufacture. The whole mass is heated till becomes homogeneous.

Table no.1

2.10 Special varieties of glass:As present it is possible to alter the chemical, electrical, mechanical and optical properties of glass by suitably s uitably changing the basic composition of the glass. As a matter of fact, the glass has emerged .As a versatile engineering material which can be tailor-made to meet with the requirement of different industries most effective and economic way.

31

Fig. no. 7 The brief descriptions of some of the following important special varieties of glass are given:1) Bullet-proof glass

08) perforated glass

2) Fiber-glass

09) safety glass

3) Float glass

10) shielding glass

4) Foam glass

11) soluble glass

5) Glass blocks

12) structural glass

6) Heat-excluding glass

13) ultra-violet ray glass

7) Obscured glass

14) wired glass.

2.11 Glass Industry in India The glass industry in India has made rapid progress after independence. The central glass and ceramic research institute has been set by the government of India to guide the glass industry .the optical glass and foam glass are manufactured at the plants set up at the institute. The optical glass is a strategic

32

material and it is used for making wide variety of optical instrument .other important varieties of glass manufactured in India are ophthalmic glass fiber glass reinforced with plastic toughened glass laboratory glassware’s etc.

Fig. no. 8 In general all common types of glasses and the glass articles are produced in India and our country can certainly boast of having made the glass industry successful and profitable .however to complete in the world market and to increase the production the glass industry in India will have to consider seriously various factors such as extensive utilization of indigenous raw material system of supply of standard quality raw material to the industry improved methods of production

maintaining and improving the quality of

products co ordination between research and the industry etc.

33

2.12 Glass Powder

Fig. no. 9 Glass powder is an extremely fine powder made from ground glass. It can be used in a number of industrial and craft applications and is often available through supplier of glass and industrial supplies. High precision machining equipment is necessary to prepare it, as it needs to be very uniform, with an

34

even consistency. Costs vary, depending on the level of grind and the applications. Some companies use recycled glass to make their glass powders, while others may use specially made glass. The process can involve dry or wet grinding to achieve particles of the desired size. Pigments can be added to make colored glass powders, and companies can also work with colored glass if they want to make powders of a particular color, like blue. The finished product can be hazardous and must be handled with care.

35

36

3.1 Fiber glass: The fiber glass is composed of minute glass rods and each glass rod resembles the parent material in all respects it is soft to the touch and it is flexible in nature it does not absorb water and it is proof against fire vermin’s water and acids .It can be prepared either in the form of continuous strands just like silk or in the staple form just like wool. For making this type of glass the molten is spun at a very high speed to produce continuous fine glass fibers .This is a special type of glass and it is used for thermal insulation sheets fiber glass reinforced plastics etc.

Fig. no. 10 High Zirconia Alkali-resistant Glass Fiber

37

3.2 High Zirconia Alkali-resistant Glass Fiber

For Glass Fiber Reinforced Concrete (GRC) and Asbestos Replacement Products

NEG ARG FIBRE NEG ARG Fiber, manufactured by Nippon Electric Glass Co., Ltd. (NEG) is used throughout the world as reinforcement for cement composites, including asbestos replacement products.

Four Advantages









NEG ARG Fiber is a high-quality alkali-resistant glass fiber containing a high percentage of zirconia (ZrO2), which enhances its resistance to alkali in cement composites. NEG ARG Fiber can be used as an asbestos replacement. NEG ARG Fiber is available in a variety of strand lengths and sizing to meet specific applications and processing requirements. NEG ARG Fiber has excellent workability characteristics.

3.3 What is ARG?

NEG ARG Fiber is a high-quality alkali-resistant glass fiber which is designed to reinforce cementitious and other alkaline matrices. NEG ARG Fiber

38

has non-combustibility characteristics, corrosion resistance, and also has high tensile strength like piano wire.

3.4 Properties of NEG ARG Fiber NEG ARG Fiber properties are highly stable because of its unique glass composition and manufacturing process using our own direct melt furnace. Tables below show general properties and chemical resistivities of NEG ARG Fiber. Property

Unit

Thermal expansion coefficient Softening point Density

X10 / C 90 o C 830 3 g/cm 2.7

Tensile strength Young's Modulus Strain to failure

GN/m 2 GN/m %

1.4 74 2

Weight loss (Saturated cement solution, 80oC X 200HR)

%

EG ARG Fiber: 0.8 E Glass Fiber : 10.5

Tensile strength retention*

%

EG ARG Fiber: 75 E Glass Fiber : 14

Weight loss o (10% HCl, 80 C X 90HR)

%


Weight loss o (10% H2SO4, 80 C X 90HR)

%


- o

2

Alkali resistivity’s

Acid resistivity’s

Table no: 2 * o Tensile strength retention rate (%) of cement paste applied strand, held at 50 C for 300 hours in 100% RH

39

3.5 Alkali resistivity of NEG ARG Fiber The alkali resistance of glass fiber is determined mainly by the zirconia (ZrO2) content in the glass. The higher the ZrO2 content, the greater the alkali resistance. As NEG ARG Fiber contains ZrO2 higher than any other marketed glass fiber, NEG ARG Fiber shows better alkali resistivity than them. The Figures below show comparison of alkali erosive attack in NEG ARG Fiber and E Glass Fiber.

3.6 Comparison of alkali erosive attack in NEG ARG Fiber and E Glass Fiber (SEM-photographs) NEG ARG Fiber

o

As manufactured

Held at 80 C for 200 hours in saturated cement solution

E Glass Fiber

o

As manufactured

Held at 80 C for 200 hours in saturated cement solution Fig. no. 11

40

3.7 Product Range of NEG ARG FIBRE 3.7.1 Continuous Roving Continuous Roving is made by gathering 100 to 200 glass filaments into a strand, then winding dozens of strands to form a cylindrical package. Continuous Roving is best suited to the spray process and is used in a wide range of products in construction, civil engineering, etc.

Fig. no. 12

3.7.1.1 Characteristics of Continuous Roving 



Roving products have excellent mortar wet-out characteristics. Roving products have excellent chopping characteristics, and stable spray process can be carried out regardless of humidity and temperature condition.

3.7.1.2 Process for Continuous Roving Spray-up, Centrifugal casting

41

Standard specifications of Continuous Roving Code

Roving tex (tex)

Strand tex (tex)

AR2500H-200

2500

80

AR2500H-103

2500

80

AR2500H-530X

2500

80

AR2500H-350Y

2500

40

Table No: 3

--Order Number Key--

(Ex.): AR2500H-200 A

Type of glass (Alkali resistant glass)

R

Type of product (Roving)

2500

Roving tex (tex*)

H-200

Sizing

*

Tex: g/1000m Table No: 4

3.7.2 Chopped Strands Chopped Strands are produced by cutting strands into required length. There are two types of Chopped Strands: 1) High Integrity Type 2) Water Dispersible Type

42

Fig. no. 13

3.7.2.1 High Integrity Type A high integrity non-filamentized strand to meet the requirements of the conventional "premix" products.

3.7.2.2 Water Dispersible Type A high filamentized dispersible strand for use in the Hatschek and Magnani process for asbestos free products.

3.7.2.3 Characteristics of Chopped Strands 



High integrity type Chopped Strands disperse as strands in a matrix of cement mortar. Water dispersible type Chopped Strands disperse into filaments in a matrix of calcium silicate or cement slurry.

3.7.2.4 Process for Chopped Strands High Integrity Type: Premix-casting, Premix- press

43

Water Dispersible Type: Hatschek, Magnani, Premix-casting

3.7.2.5 Standard Specifications of Chopped Strands Type

Code

Strand (mm)

High Integrity Type

ACS**PH-901X ACS**H-530X ACS**H-350Y ACS**H-350Z

9, 13, 19, 13, 9, 13, 13

Water Dispersible Type(Wet) ACS**S-750

6, 13, 25

Water Dispersible Type(Dry) ACS**S-707

13

Length

25 25 25

**: Strand length in mm Table No: 5

Order Number Key--

(Ex.): ACS13PH-901X A

Type of glass (Alkali resistant glass)

CS

Type of product (Chopped Strands)

13

Strand length (mm)

P

Filament diameter (P: 18 micron, Non: 13.5 micron)

H-901

Type of Sizing

X

Number of filaments per strand (High integrity type only) Table No: 6

44

3.8 What is GRC? GRC is one of applications of NEG ARG Fiber and means Glass fiber R einforced Concrete. We are glass fiber manufacturer for GRC and do not produce any GRC.

3.8.1 Feature of GRC GRC has great improved properties over those associated with conventional mortars and concretes. GRC products are widely used in construction and civil engineering.

3.8.2 Features of GRC Light weight due to thin section, Design flexibility, Non-combustibility, Anti-corrosiveness, High bending strength, High impact strength.

3.8.3 Typical properties of GRC There are mainly two kinds of GRC classified by their process, one is Spray-up GRC, and the other is Premix GRC. Typical properties of each GRC are shown in the Table below. All values shown in the Table are only for reference and not used for design. All GRC are not always satisfying the values because of various mix proportions and QC.

45

Process

Spray-up

Premix

ARG fiber content

(Wt. %)

5

3

Density (air dried state)

(g/cm )

1.8 -- 2.2

1.7 -- 2.1

MOR

(MPa)

20 -- 30

10 -- 20

LOP

(MPa)

7 -- 13

5 -- 10

(GPa)

15 -- 25

13 -- 21

UTS

(MPa)

10 -- 15

4 -- 7

BOP

(MPa)

5 -- 7

3 -- 5

Out-of-plane

(MPa)

20 -- 30

4 -- 6

In-Plane

(MPa)

7 -- 12

4 -- 6

Interlamainar

(MPa)

2 -- 4

4 -- 6

Bending

Modulus Elasticity Strength Tensile

Shear

of

.

Charpy Impact Strength

N mm/mm 15 -- 25

7 -- 12

Water Absorption

(%)

10 -- 15

10 -- 15

Drying Shrinkage

(%)

0.1 -- 0.2

0.1 -- 0.2

Thermal conductivity

(W/m K)

0.9 -- 1.5

0.9 -- 1.5

Heat

Thermal Coefficient

(X10 / C) 7 -- 12

Fire

Incombustibility

Water

Sound

.

Expansion

Transmission Loss (Thickness: 15 mm)

-6 o

7 -- 12

Incombustible material

(dB)

125 Hz

27

250 Hz

30

500 Hz

35

1000 Hz

39

2000 Hz

40

Table No: 7 MOR : Modulus Of R upture

UTS : Ultimate Tensile Strength

LOP : Limit Of Proportionality

BOP : Bend-Over Point

46

3.8.4 Process of GRC 3.8.4.1 Spray Process

Spray-up GRC is produced by using spray gun which sprays mortar fed from a "mortar" pump and "glass fibers" cut in the spray gun from Roving. And then, sprayed GRC is compacted by roller. Sprayed GRC required spray gun, Mixer, mortar pumps and air compressor. Out-line of the process is as follows. We link to UK spray equipment manufacture -- Power-Sprays Ltd.

Fig. no. 14 3.8.4.2 Premix process

Premix GRC is produced by using just a mixer where mortar (cement, sand and water) and Chopped Strands are mixed. Mixed GRC mortar is cast into mold and then vibrated or pressed.

47

3.9 Applications NEG ARG Fiber is widely used in the world. Typical applications are shown in the Table below. Product Range

Process

Applications

Spray

External wall, Interior wall, Parapet, Window cell, Ceiling, Eaves, Hand rail, Noise Barrier, Permanent Formwork, Cable Trough, Artificial Rock

Centrifugal casting

GRC pipe

Premix-cast

Planter, Artificial Rock, Cable Trough, Permanent Formwork, Exterior wall, Interior wall, Fireproofing material, Heat Insulation Material, Electricity insulating material, Roofing Tile

Premix- press

Free Access Roofing Tile

Hatschek

Interior board

Roving

Chopped Strands

Floor

Tile,

Table no. 8

48

49

4.1 Documented Case Study: TECHNICAL PAPER NO: 1

The Effect of Recycled Glass Powder and Reject Fly Ash on the Mechanical Properties of Fiber-Reinforced Ultrahigh Performance Concrete Shi Cong Kou1, 2 and Fang Xing2 1

Department of Civil and Structure Engineering, the Hong Kong Polytechnic

University, Hong Kong 2

Guangdong Durability Center for Civil Engineering, College of Civil

Engineering, Shenzhen University, Guangdong, China

Correspondence should be addressed to Shi Cong Kou, [email protected]

Received 24 December 2011; Accepted 8 February 2012

Academic Editor: Nai-Qian Fang

Copyright © 2012 S.C.Kou and F. Xing. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

This paper presents an experimental study for the purpose of reducing the cost of producing ultrahigh performance fiber reinforced Concrete (UHPFRC). Reject fly ash (r-FA) and recycled glass powder (GP) were examined as replacement materials for the silica sand and cement used to prepare UHPFRC, respectively.

50

In addition, curing UHPFRC specimens at 25◦C and 90◦C was investigated to determine differences in mechanical properties. The results showed that using rFA and GP reduces the flow ability of Fresh UHPFRC. The use of GP increased the mechanical properties of the UHPFRC. Moreover, the test results indicate a significant improvement in the mechanical properties of plain concrete by the inclusion of r-FA as partial replacement of fine aggregate (sand) and can be effectively used in UHPFRC. Furthermore, specimens cured at 25◦C give lower compressive strength, flexural strength, and fracture energy than specimens cured at 90◦C.

51

Introduction

Ultrahigh performance fiber-reinforced concrete (UHPFRC) is a very special material with superior mechanical properties and low permeability [1 – 4], and when it is reinforced with Steel fibers or steel tubes, it exhibits high ductility [5]. Indecent years, UHPFRC has been successfully applied to dam repair, bridge deck overlays, coupling beams in high-rise buildings, and other specialized structures [6, 7].However the high cost of UHPFRC is the disadvantage that restricts its wider usage. To alleviate both the environmental and economical impact of UHPFRC, industrial byproducts such as ground granulated blastfurnace slag (GGBS) and silica fume (SF), have been used as partial cement replacements without significantly affecting the mechanical properties [5, 8].The recycling of waste glass is a major issue in urban areas of developed countries [9, 10], which has resulted in significant interest of late in utilizing it in concrete. Crushed glass has been used as a coarse aggregate in concrete [11 – 14]. Attempts were made to use waste glass as a raw siliceous material in the production of Portland cement [15, 16]. The use of coarse glass powder as a hydration enhancing filler has been explored [17, 18]. However, valued addition of glass in concrete is best achieved if it is used as a cement replacement material. Glass is amorphous and has high silica content, which are the primary requirements for a pozzolanic material. A particle size of 75 μm or less is reported to be favorable for pozzolanic reaction [19]. The high alkali content of glass is a typical concern for its use in concrete, but studies [9, 10] have shown that finely ground Glass does not contribute to alkali-silica reaction. The properties which influence the pozzolanic behavior of waste glass, and most pozzolans

in general, are

fineness, composition, and the pore solution present for reaction [20 – 24]. Based on observed compressive strengths, Meyer Et al. [22] postulated that below 45 μm glass may become pozzolanic. The pozzolanic properties of glass are first notable at particle sizes below approximately 300 μm. Below100 μm, glass can 52

have a pozzolanic reactivity which is greater than that of fly ash at low percent cement replacement levels and after 90 days of curing [23, 24].The pozzolanic reactivity of fine waste glass is observed as an increase in compressive strength. In the reported data [23, 25], compressive strength is highest for specimens containing very fine glass (<100 μm), and the strength decreases as particle size increases. A number of studies [25 – 31] showed the effect of percentages of waste glass replacing OPC and fine aggregate on the compressive strength of mortar bars. The results show that a cement replacement between 10%and 20% yields the highest strength, while fine aggregate replacement of up to 40% has little effect on compressive strength. About one million tons of fly ash, as a byproduct of electricity generation, is produced annually in Hong Kong. The finer fraction (f-FA) produced by passing the rewash through a classifying process is routinely used in the production of blended cements for construction. This ash conforms to BS3892 [32], which has fineness requirement of not more than 12% by mass retained on the 45-μm test sieve and maximum loss-onignition limit of 7%. However, the remaining proportion, in the order of 200,000 tones, is rejected as a construction material, simply due to its large particle size. In Hong Kong, this rejected fly ash (r-FA) has to be disposed of in large lagoons, creating an ever increasing environmental hazard. Similar disposal problems can be expected in other coal-fired power stations. The pozzolanic properties of r-FA in cement pastes have already been reported earlier, with encouraging results [33].Poon and Ho suggested that it is technically feasible to utilize-FA as part of the powder content in the production of SCC[34].The use of low alkali cement and sand replacements in UHPFRC provides the opportunity to use finely recycled Glass powder and r-FA as an economic replacement for cement and silica sand, respectively, this not only eliminates the risk of an expansive and deleterious alkali-silica reaction (ASR), but also the cost of the concrete can be reduced. This paper presents an experimental study for the purpose of reducing the cost of producing ultra-high performance fiber-reinforced concrete 53

(UHPFRC). Reject fly ash (r-FA) and recycled glass powder (GP) were examined as replacement materials for the silica sand and cement used to Prepare UHPFR C, respectively. In addition, curing UHPFRC specimens at 25◦C and 90◦C was investigated to determine differences in mechanical properties.

2. Experimental Details

2.1. Materials 2.1.1. Cementitious Materials. Portland cement (CEM 1) and two different types of supplementary cementitious materials were used in this study, that is, recycled waste glass powder (GP) and silica fume (SF). The investigated glass powder samples were derived from recycled glass bottles and dry comminuted in a laboratory shaking mill to obtain particles smaller than 0.045 mm. A condensed silica fume (SF) named Force 10,000D micro silica with density of 2.22 g/cm3obtained from W. Grace was used. The chemical, physical, and mechanical properties of cement, GP, and SF used in this study are shown in Tables 1 and 2.

2.1.2. Aggregate (a) Silica Sand. The Silica sand used in this study is a commercial product, provided by Hong Kong Win long Minerals LTD., has a narrow grading distribution between 150 and300 μm for approximately 90% of par ticles. (b) Reject Fly Ash (r-FA). The r-FA with particle sizes larger than 45 μm was used in this study and was generated as byproducts from a local coal-fired power plant. The particle size distribution of r-FA is also shown in Table 2.2.1.3. Steel Fiber. The special steel fibers were obtained from local company which are made using high carbon steel withal tensile strength of 2000MPa and conform to the British Standard [35]. Each fiber is coated with brass and is 0.2mmin

54

diameter and 13mm in length. Obtained from W. Grace was used. The chemical, physical, and mechanical properties of cement, GP, and SF used in this Study is shown in Tables 1 and 2.

55

56

2.1.4. Superplasticiser. The super plasticizer used in this study was ADVA 109 which is poly carboxyl ate based and commercially available in Hong Kong. 2.2. Mix Proportions. Three series of UHPFRC mixtures with different recycled glass powder and r-FA content were prepared. In all concrete mixtures, the silica fume content was kept constant at levels of 128 kg/m3, and the steel fiber content of UHPFRC was 2% by volume of the total mixture. This is commonly considered the optimum proportion to achieve a balance between mechanical properties and financial cost [36]. Use of the super plasticiser

(ADVA 109)

enabled a water-binder ratio of 0.15 to be achieved, which met the low water requirement of UHPFRC [2, 5]. In Series, two UHPFRC mixtures were prepared with recycled glass powder (GP). The GP was used as 15 and 30% by weight replacement of the cement. In Series II, three concrete mixtures were prepared with r-FA which was used as 15, 30 and 50% by weight replacement of the silica sand. In Series III, two UHPFRC mixtures were prepared with cement

2.1.4. Superplasticiser. The super plasticizer used in this study was ADVA 109 which is poly carboxyl ate based and commercially available in Hong Kong. 2.2. Mix Proportions. Three series of UHPFRC mixtures with different recycled glass powder and r-FA content were prepared. In all concrete mixtures, the silica fume content was kept constant at levels of 128 kg/m3, and the steel fiber content of UHPFRC was 2% by volume of the total mixture. This is commonly considered the optimum proportion to achieve a balance between mechanical properties and financial cost [36]. Use of the super plasticiser

(ADVA 109)

enabled a water-binder ratio of 0.15 to be achieved, which met the low water requirement of UHPFRC [2, 5]. In Series, two UHPFRC mixtures were prepared with recycled glass powder (GP). The GP was used as 15 and 30% by weight replacement of the cement. In Series II, three concrete mixtures were prepared with r-FA which was used as 15, 30 and 50% by weight replacement of the silica sand. In Series III, two UHPFRC mixtures were prepared with cement replacement level of 15% by GP and sand replacement level Of 15 and 30% by r-FA, respectively. The control mixture was prepared with only cement, silica fume, steel fiber, and silica sand to compare the mechanical properties of the concrete. The detailed mix proportions of the UHPFRC are shown instable 3. 2.3. Specimen Preparation. Each series of specimens was cast comprising 50mm cubes for compressive strength [37] and40 × 40 × 160mm prisms for flexural strength [38]. The solid UHPFRC mix constituents, in the order of cement, SF, GP, and sand or r-FA, were weighed according to the mix proportions and dry mixed in a horizontal pan mixer withal 15 – l capability for approximately 1 min. The mixture of water and superplasticiser was gradually added to the rotating mixer. The steel fibers were added after mixing for approximately 10min. This time enabled the superplasticiser become fully effective and a consistent mixture was reached. Usually, a further mix duration of approximately5min helped to achieve good flow ability and an even Distribution of steel fibers in the cement matrix. The fresh UHPFRC was then transferred into steel moulds and 57

compacted for 1 min using a vibrating table. The specimens were after one day, they were remolded and cured in water either at 20◦C or at 90◦C. The heat cured specimens were stored in a hot water bath from the age of 1 day. These specimens were then stored in air at room temperature until testing. The 20◦Ccured specimens were kept in a standard curing Tank until testing. 2.4. Testing. The workability of the fresh concrete was measured with a flow table [39]. All cube specimens were tested using a loading rate of 0.8 ken/s [37]. The prism specimens were tested under four-point loading using displacement control and using a testing machine controlled by an external displacement transducer, such that the mid-span deflection rate of the prism specimen was held constant throughout the test. The specimen mid-span deflection rate was 0.15 mm/min, with a span of 120 mm. The fracture energy [40] of specimens tested was calculated by integrating the area under the flexural stress versus deflection up to1.25 mm. The mechanical test schedule of UHPFRC specimens is shown in Table 4 and each reading was taken as the Average of three test results.

58

3. Results and Discussion 3.1. Fresh Concrete. Figure 1 shows measurements from the Flow table test. It can be seen that the flow diameter of Concrete varied between 256 and 195mm in the sequence of Control, GP-15, GP-30, r-FA-15, r-FA-30, r-FA-50, G15+rFA30, and G15+rFA30.Moreover, the flow diameter of concrete decreased with an increase in recycled glass powder and r-FA content. Concrete mixture G15+rFA30 with 15% of glass powder and 30% of r-FA had the lowest slump flow value of 195 mm. It was observed during mixing and testing that the flow ability of the fresh concrete had a close relationship with the fineness of the cementitious material sand the aggregate. The same sequence of Control, GP-15, GP-30, r-FA-15, r-FA-30, r-FA-50, G15+rFA30, and G15+rFA30was followed as the fineness of the materials. No bleeding segregation was observed when mixing.

59

3.2. Hardened Concrete 3.2.1. Effect of GP, r-FA, and Steam Curing on the Compressive Strength of UHPFRC. The development of the compressive strength of UHPFRC prepared with GP, r-FA and GP+rFA illustrated in Figures 2 – 4, respectively. Each presented value is the average of three measurements. It is seen from Figure 2that at early ages (before 7 days), the use of GPAs a partial replacement of cement caused a reduction in the compressive strength. At day 1, the UHPFRC mixturesGP-15 and GP-30 prepared with 15% and 30% GP had an average of 4.4% and 11.8% reduction in compressive strength compared to the control mixture. However, after 28Days, the replacement of cement with glass powder increased the compressive strength of the concrete mixtures, while the rate of increase in strength decreased with increase in GP content. The concrete mixtures prepared with 15%GP had an average 7.0% increase in compressive strength compared to the control mixture, whereas the corresponding Concrete mixture with 30% GP had only a 2.82% increase in strength. This is consistent with the results of Shi et al. [20] who indicated that glass powders with particle smaller than60 μm have very high pozzolanic reactivity; replacement of20% cement with ground glass powder can develop higher strength than 100%Portland cement at 28 days. Figure 2 also indicates that after steam cured at 90◦C, the compressive strengths of the concrete mixtures control, GP-15, and GP-30 were 20.5%, 28.6% and 30.6% higher than the corresponding concrete with standard curing at25◦C. Moreover, at all test ages, the steam cured UHPFRC at 90◦C had higher compressive strength than corresponding Concrete with standard curing at 25◦C.After 365 days the 25◦C cured specimens had a very high Compressive strength but did not match that of the 90◦Ccured specimens. From observations of the rate of increase in strength it seems unlikely that the strength of the 25◦C cured specimens would reach that of th e 90◦C cured specimens at later ages. However, the compressive strengths of 25◦Ccured UHPFRC at 28 days, that is, 140– 150MPa, are still considered very 60

high strength and this can be applied very effectively for building structures. Figure 3 shows the variation in compressive strength of UHPFRC with r-FA percentages at different ages. From the test results, it can be seen that the compressive strength of UHPFRC mixtures with 15%, 30%, and 50% silica sand replacement with r-FA, were higher than the control mixture at all ages. Moreover, there is increase in strength with increase in r-FA percentages; however, the rate of increase of strength decreases with the increase in r-FA content. This trend is more obvious between 30% and 50% replacement levels. Maximum strength at all ages occurs with 50% fine aggregate replacement. At 1 day, the compressive strength of the concrete mixtures r-FA-15, r-FA-30, and rFA-50 with15%, 30%, and 50% r-FA was about 3%, 8%, and 10% higher than the control mixture, whereas at 365 days, the corresponding concrete mixture had an average 10.9%, 21.8%,and 27.6% increase in compressive strength compared to the control mixture. This increase in strength due to the replacement of fine aggregate with r-FA is attributed to (1) the improvement of packing density with r-FA and (2) the pozzolanic action of r-FA. In the beginning (early age), r-FA reacts very slowly with calcium hydroxide liberated during hydration of cement and does not contribute significantly to the densification of the concrete matrix at early ages. Concrete with r-FA shows higher strength at early ages because inclusion of r-FA as partial replacement of sand starts pozzolanic action and densification of the concrete matrix and due to this strength of r-FA concrete is higher than the strength of the control mixture even at early ages.

61

It is clear from Figure 3 that the steam curing at 90◦Cincreased the compressive strength of r-FA UHPFRC at all tests ages. The rate of increase in strength at an early age (before 28 days) was higher than that at a late stage (365days). At 1 62

day, for the concrete mixtures with 15%, 30%, and 50% r-FA, the steam curing increased the compressive strength by 22.4%, 26.2%, and 28.6% respectively, when compared with the corresponding concrete mixtures with standard curing at 25◦C, whereas, at 365 days, these increased values were reduced to 17.9%, 13.7%, and 13.6%, respectively. Figure 4 shows the effect of combined GP and r-FA on the compressive strength of UHPFRC. It is seen that at 1 day, the compressive strength of concrete mixtures G15+rFA15andG15+rFA30 with standard curing at 25◦C was similar to that of the control mixture. However, at 365 days, the compressive strength of the corresponding concrete mixtures was 16.0%and 26.9% higher than that of the control mixture, respectively. The concrete mixture G15+rFA30 had the highest compressive strength. This might be attributed to the pozzolanic reaction between both GP and r-FA ands (OH) 2. Figure 4 also indicates that at all test ages, the steam curing at 90◦Csignificantly increased the compressive strength of the concrete prepared with both GP and rFA. After 1 day steam curing at 90◦C, the compressive strength of concrete mixtures G15+rFA15and G15+rFA30was 33.1% and 38.5% higher than corresponding concrete with standard curing at 25◦C. 3.2.2. Effect of GP, r-FA and Steam Curing on the Flexural Strength of UHPFRC. Figures 5 – 7 show the development of the flexural strength of UHPFRC made with GP, r-FA, and GP+rFA, respectively. Each presented value is the average of three measurements. From Figure 5, it can be seen that at 1day, the replacement of cement with produced the flexural strength of the concrete. The concrete mixture GP-30 had the lowest flexural strength, whereas after 28 days, the replacement of cement by 15% GP increased the flexural strength of the concrete. Moreover, the flexural strength of concrete mixtures GP-15 and GP-30 was increased with steam curing.

63

64

At 90◦C. After 1-day steam curing, the flexural strength of concrete mixtures GP-15 and GP-30 was14.6% and 16.0%higher than corresponding concrete with standard curing. Furthermore, the rate of increase in strength of the concrete mixtures with GP was higher than that of control mixture. It is clear from Figure 6 that the replacement of silica sand by r-FA increased the flexural strength of the concrete mixture with both standard curing at25◦C and steam curing at 90◦C at all ages. At 28 days, the flexural strength of standard cured concrete mixtures r-FA-15, r-FA-30 and r-FA-50 was 6.8%, 11.8%, and 16.7%higher, respectively 65

than that of control mixture. Moreover, flexural strength continued to increase with increase in r-FA percentages at all ages, and there was significant increase in strength compared to that of the control mixture. This is believed to be due to the large pozzolanic reaction and improved interfacial bonding between the paste and aggregates. After 1-day steam curing, the flexural strength of concrete mixtures r-FA-15, r-FA-30, and r-FA-50 was 12.1%, 14.0%, and15.1% higher than corresponding concrete with standard curing. Figure 7 shows the effect of combined GP and r-FA on the flexural strength of UHPFRC. It is seen that both the replacement of cement and sand by GP and r-FA, respectively, increased the flexural strength of the concrete. At 1day, the flexural strength of concrete mixtures G15+rFA15and G15+rFA30 with standard curing at 25◦C was increased by 3.2% and 7.0%, respectively, when compared with the control mixture. However, at 365 days, the flexural strength Of the corresponding concrete mixtures was 5.5% and 9.8%higher than that of the control mixture, respectively. The concrete mixture G15+rFA30 had the highest flexural strength. Figure 7 also indicates that at all ages; the steam curing at 90◦C significantly increased the flexural strength of the concrete prepared with both GP and r-FA.3.2.3. Effect of GP, r-FA and Steam Curing on the Fraction Energy of UHPFRC. The fracture energy versus age of UHPFRC specimens prepared with GP, r-FA and steam curing are shown in Figures 8 – 10. Each presented value is the average of three measurements. It is seen from Figure 8 that at all ages; the replacement of cement by GP increased the fracture energy of the concrete with both standard curing at25◦C and steam c uring at 90◦C. At 28 days, the replacement of cement by 15% and 30% GP increased the fracture energy by 3.6% and 2.2%, respectively. This may be attributed to the pozzolanic reaction between GP and Ca (OH) 2 in the concrete which further increases the bond strength between fiber Moreover, at 28 days, comparison of the properties from UHPFRC mixtures control, GP-15 and GP-30 cured at 90◦C and 20◦C shows that 20◦C cured UHPFRC 66

Is 15%, 16.6%, and 17.2% lower, respectively, in compressive Strength. Figure 9 indicates that at all ages, the replacement of standby r-FA increased the fracture energy of the concrete with both standard curing at 25◦C and steam curing at 90◦C.Moreover, the fracture energy was increased with increase in r -FA content. As the fracture energy is closely related to efficiency of the fiber bond, the variation in fracture Energy can be attributed to a different bond action foxfires embedded in the concrete matrix. For r-FA specimens, the fibers appeared to keep their original direction in the concrete matrix before being pulled out. The greater fineness of r-FA aggregate can also facilitate the propagation of cracks, initially due to a stronger bond between the r-FA particles and the cement paste. Subsequently the r-FA aggregate can initiate matrix strengthening which further increases the Fiber bonding strength. 67

Figure 10 shows the effect of combined GP and r-FA on the fracture energy of UHPFRC. It can be obtained that atoll ages, the replacement of cement and sand by GP and r-FA, respectively, increased the fracture energy of the concrete with both standard curing at25◦Cand steam curing at90◦C. At 28 days, the fracture energy of concrete mixtureG15+rFA15 andG15+rFA30 with steam curing at 90◦C was22.5% and 24% higher than that corresponding concrete with standard curing at 25◦C, respectively. Moreover, the fracture energy of the concrete was increased with increase in r-FA content. The concrete mixture G15+rFA30 had the highest fracture energy.4. Conclusion The following conclusions can be drawn from the present investigation.(1) The replacement of cement by glass powder decreased the early (before 7 days),but increased theater (after 28 days) 68

compressive

strength,

flexural

strength,

and

fracture

energy

of

UHPFRC.(2)Compressive strength, flexural strength, and fracture energy of silica-sand-replaced r-FAUHPFRC specimens were higher than for the control specimens atoll ages.(3) At all ages, the replacement of cement and sand big and r-FA, respectively, increased the compressive strength, flexural strength, and fracture energy.(4) Steam curing at 90◦C increased the compressive strength between 20% and 30% for GP concrete, 20%and 28% for r-FA concrete, and 20% and 38% for GP+rFA concrete; the flexural strength between 11%and 16% for GP concrete, 11% and 15% for r-FA concrete, and 11% and 20%for GP+rFA concrete; and fracture energy between 15% and 17% for GP concrete, 15% and 19% for-FA concrete, and 15%and 24% for GP+rFA concrete.(5) Glass powder and r-FA can be used to replace cement And sand for producing lower cost UHPFRC.

69

References

[1] H.H. Bache, “Introduction to compact reinforced composite, “Nordic Concrete Research, no. 6, pp. 19 – 33, 1987. [2] P. Richard and. Cheyrezy, “Composition of reactive powder concretes,” Cement and Concrete Research, vol. 25, no. 7, pp.1501 – 1511, 1995. [3] P. Rossi, A. Arca, E. Parant, and P. Fakhri, “Bending and compressive behaviors of a new cement composite,” Cement and Concrete Research, vol. 35, no. 1, pp. 27 – 33, 2005. [4] J. P. Charron, E. Denarié, and E. Brühwiler, “Permeability of UHPFRC under high stresses,” in Proceedings of the RILE Symposium on Advances in Concrete Through Science and Engineering, p. 12, Evanston, Ill, USA, March 2004. [5] T. T. Le, M. N. Soutsos, S. G. Millard, and S. J. Barnett, “Ultrahigh performance fiber reinforced concrete —optimization of mix proportions,” in Proceedings of the International Conference Entitled Concrete Platform, pp. 339 – 349, Belfast, UK,2007. [6] M. Schmidt and E. Fehling, “Ultra -high-performance concrete research development and application in Europe,” in Proceedings of the 7th international Symposium on the Utilization of High-Strength/High-Performance Concrete, American Concrete Institute, Washington, DC, USA, 2005. [7] V. C. Li, “Strategies for high performance fiber reinforced cementitious composites development. Fiber reinforced concrete: from theory to practice,” in Proceedings of the North American/European Workshop on Advances in Fiber Reinforced Concrete, pp. 93 – 98, Bergamo, Italy, 2004.

70

[8] A. Oner and S. Akyuz, “An experimental study on optimum usage of GGBS for the compressive strength of concrete,” Cement and Concrete Composites, vol. 29, no. 6, pp. 505 – 514, 2007. [9] W. Jin, C. Meyer, and S. Baxter, “Glascrete— Concrete with glass aggregate,” ACI Structural Journal, vol. 97, no. 2, pp. 208– 213, 2000. [10] A. Shayan and A. Xu, “Value-added utilization of waste glassing concrete,” Cement and Concrete Research, vol. 34, no. 1, pp.81 – 89, 2004. [11] C. Meyer, N. Egosi, and C. Adela, “Concrete with waste glasses aggregate,” in Recycling and Reuse of Glass Cullet. Proceedings of the International Symposium, Concrete technology unit office and University of Dundee, March 2001. [12] I. B. Topçu and. Canbaz, “Properties of concrete containing waste glass,” Cement and Concrete Research, vol. 34, no. 2, pp.267 – 274, 2004. [13] C. M. Sangha, A.M. Alani, and P. J.Walden, “Relative strength of green glass cullet concrete,” Magazine of Concrete Research, vol. 56, no. 5, pp. 293– 297, 2004. [14] S. B. Park, B. C. Lee, and J. H. Kim, “Studies on mechanical properties of concrete containing waste glass aggregate,” Cement and Concrete Research, vol. 34, no. 12, pp. 2181 – 2189,2004. [15] G. Chen, H. Lee, K. L. Young et al., “Glass recycling in cement productionan innovative approach,” Waste Management, vol.22, no. 7, pp. 747 – 753, 2002. [16] Z. Xie and Y. Xi, “Use of recycled glass as a raw material in the manufacture of Portland cement,” Materials and Structures/Materiaux ET Constructions, vol. 35, no. 252, pp. 510 – 515, 2002.

71

[17] N. Neithalath and N. Schwarz, “Cement pastes incorporating coarse glass powder hydration, strength, and heat development, “Materials and Structures. In press. [18] N. Schwarz, M. DuBois, and N. Neithalath, “Electrical conductivity based characterization of plain and coarse glass powder modified cement pastes,” Cement and Concrete Composites, vol. 29, no. 9, pp. 656 – 666, 2007. [19] Y. Shao, T. Lefort, S. Moras, and D. Rodriguez, “Studies on concrete containing ground waste glass,” Cement and Concrete Research, vol. 30, no. 1, pp. 91 – 100, 2000. [20] C. Shi, Y. Wu, C. Riefler, and H. Wang, “Characteristics and pozzolanic reactivity of glass powders,” Cement and Concrete Research, vol. 35, no. 5, pp. 987 – 993, 2005. [21] A. Shayan and A. Xu, “Performance of glass powder as pozzolanic material in concrete: a field trial on concrete slabs, “Cement and Concrete Research, vol. 36, no. 3, pp. 457 – 468, 2006. [22] C. Meyer, S. Baxter, and W. Jin, “Potential of waste glass for concrete masonry blocks,” in Proceedings of the 4th Materials Engineering Conference, pp. 666 – 673, Washington, DC, USA, November 1996. [23] C. Shi, Y. Wu, C. Riefler, and H. Wang, “Characteristics and pozzolanic reactivity of glass powders,” Cement and Concrete Research, vol. 35, no. 5, pp. 987 – 993, 2005. [24] N. Schwarz, H. Cam, and N. Neithalath, “Influence of a fine glass powder on the durability characteristics of concrete and its comparison to fly ash,” Cement and Concrete Composites, vol. 30, no. 6, pp. 486 – 496, 2008.

72

[25] Y. Shao, T. Lefort, S. Moras, and D. Rodriguez, “Studies on concrete containing ground waste glass,” Cement and Concrete Research, vol. 30, no. 1, pp. 91 – 100, 2000. [26] A. Shayan and A. Xu, “Value-added utilization of waste glassing concrete,” Cement and Concrete Research, vol. 34, no. 1, pp.81 – 89, 2004. [27] C. Meyer, N. Egosi, and C. Andela, “Concrete with waste glasses aggregate,” in Proceedings of the 4th Materials Engineering Conference, vol. 2, pp. 1388 – 1397,Washington, DC, USA,November1996. [28] S. Laldji and A. Tagnit-Hamou, “Glass frit for concrete structures: a new, alternative cementitious material,” Canadian Journal of Civil Engineering, vol. 34, no. 7, pp. 793 – 802, 2007. [29] V. S. Panchakarla and M. W. Hall, “Glascrete?— disposing of nonrecyclable glass,” in Proceedings of the 4th ASCE Materials Engineering Conference, pp. 509 – 518, Washington, DC, USA, November 1996. [30] C. H. Chen, R.Huang, J. K.Wu, and C. C. Yang, “Waste E -glass particles used in cementitious mixtures,” Cement and Concrete Research, vol. 36, no. 3, pp. 449 – 456, 2006. [31] M. J. Terro, “Properties of concrete made with recycled crushed glass at elevated temperatures,” Building and Environment, vol. 41, no. 5, pp. 633– 639, 2006. [32] BS 3892, Pulverized-fuel ash: part 1. Specification for pulverized-fuel ash for use with Portland cement. British Standard, 1997. [33] C. S. Poon, X. C. Qiao, and Z. S. Lin, “Pozzolanic properties of reject fly ash in blended cement pastes,” Cement and Concrete Research, vol. 33, no. 11, pp. 1857 – 1865, 2003.

73

[34] C. S. Poon and D. W. S. Ho, “A feasibility study on the utilization of r -FA in SCC,” Cement and Concrete Research, vol.34, no. 12, pp. 2337– 2339, 2004. [35] BS EN 10016 Part 3: non-alloy steel rods for drawing and/or cold rolling. Specific requirements for rimmed and rimmed substitute low carbon steel rod, 1995. [36] S. J. Barnett, S. G. Millard, M. N. Soutsos, G. Schleyer, A.Tyas, and T. T. Le, “Ultra high performance fiber reinforced concrete for explosion resistant structures,” in Pr oceedings of the International Conference Entitled Concrete Platform, pp.565 – 575, Belfast, UK, 2007. [37] BS EN 1881 Part 116: testing concrete. Method for determination of compressive strength of concrete cubes, 1983. [38] BS EN 12390 Part5: testing hardened concrete. Flexural strength of test specimens, 2000. [39] BS EN 4551 Part1: methods of testing mortars, screeds and plasters, 1998. [40] P. Richard and M. Cheyrezy, “Reactive powder concretes with high ductility and 200 –800 MPa compressive strength, “Concrete Technology, vol. 144, pp. 507 – 525, 19

74

TECHNICAL PAPER NO: 2

A.L.Ardeshana, Dr Atul K Desai / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 4, July-August 2012, pp.215

DURABILITY OF FIBER REINFORCED CONCRETE OF MARINE STRUCTURES A.L.Ardeshana*, Dr Atul K Desai** *(Research Scholar, Applied Mechanics Department, S V National Institute of Technology, Surat – 395 007 Gujarat, India) ** (Associate Proff., Applied Mechanics Department, S V National Institute of Technology, Surat – 395 007 Gujarat, India) Abstract

The usefulness of fiber reinforced concrete (FRC) in various civil engineering applications is indisputable. Fiber reinforced concrete has so far been successfully used in slabs on grade, shotcrete, architectural panels, precast products, offshore structures, structures in seismic regions, thin and thick repairs, crash barriers, footings, hydraulic structures and many other applications. This paper presents a brief state-of-the-art report on mechanical properties and durability of fiber reinforced concrete. Civil infrastructure around the world the problem is at the apparent lack of durability in our construction materials, inability on part of the owners to provide timely maintenance, absence of advanced condition assessment tools and lack of long-lasting, cost effective repair materials and technologies. This paper will present data to support the argument that fiber reinforced concrete (FRC) is an ideal material for achieving these goals. The paper also discusses fiber reinforced concrete materials carrying Polypropylene Triangular Fibers. This material can help us to develop intelligent infrastructure with elegantly integrated sensing.

Keywords Fiber reinforced concrete, toughness, polypropylene triangular, Durability

75

I. Introduction

Compared to other building materials such as metals and polymers, concrete is significantly bleeding, plastic settlement, thermal and shrinkage strains and stress concentrations imposed by external restraints. Under an applied load, distributed micro-cracks propagate, coalesce and align themselves to produce macro-cracks. When loads are further increased, conditions of critical crack growth are attained at the tips of the macro-cracks and unstable and catastrophic failure is precipitated. Under fatigue loads, concrete cracks easily, and cracks create easy access routes for deleterious agents leading to early saturation, freeze-thaw damage, scaling, discoloration and steel corrosion. The micro and macro-fracturing processes described above can be favorably modified by adding short, randomly distributed fibers of various suitable materials. Fibers suppress the formation of cracks. The concerns with the inferior fracture toughness of concrete are alleviated to a large extent by reinforcing it with fibers of various materials. The resulting material with a random distribution of short, discontinuous fibers is termed fiber reinforced concrete (FRC) and is slowly becoming a well accepted mainstream construction material. Significant progress has been made in the last thirty years towards understanding the short and long-term performances of fiber reinforced cementitious materials, and this has resulted in a number of novel and innovative applications. II. Literature Review

S.C.Yaragal [7] have studied the effects of fibers in concrete for momentcurvature relationship, cracking characteristics and ductility and also confirmed the veracity of the assumptions of elastic and plastic theories of flexure. A.P.Singh [1] found the addition of steel in form of short and discrete fibers to plain concrete to enhance its engineering properties like compressive, tensile, and flexural and shear strength and also its toughness and ductility. S.P.Singh [8] has studied Flexural fatigue strength of concrete reinforced with steel polypropylene hybrid fibers. Manote Sappakittipakorn [6] conducted a test on loaded RC beams and studied the corrosion effects after adding fibers. Dr.J.Premalatha-madurai [3] has studied the Effect of steel fibers and longitudinal reinforcement inn effective moment of inertia of reinforced high strength fibrous concrete beams. Dr.G.Mohankumar [2] has studied the increase in split tensile strength in HFRC. Dr.Lalu mangal.Arun [4] Edwin conducted tests on the effect of fiber in concrete in terms of compressive strength , Poisson's ratio , split tensile strength and flexural strength and modulus of 76

elasticity. Dr. P. Srinivasa Roa found the effects of glass fibers to improve the durability of self compacting. III. Mix Design and Testing Consideration The concentration of fibers can affect the mix’s workability because of the relatively high surface area of fibers that must be coated with mortar (cement, fine aggregates, and water). An increase in the amount of fine aggregate to coarse aggregate ratio cement, and/or a high-range, water-reducing admixture (super plasticizer) will typically improve workability. Batch operators should resist the temptation to just add water to improve workability, because this causes many additional problems unrelated to fiber reinforcement. Fiber manufacturers have developed coarse-filament fibers in order to reduce the surface area of the fibers and, consequently, the demand for water. In addition to the normal battery of fresh concrete tests, the inverted slump-cone test can be performed (ASTM C995). This test measures the time it takes for the uncompacted concrete to flow through a slump cone with a vibrator inserted into the cone. Also, quality-control personnel should be aware that fibers will reduce slump (ASTM C143) from 25 to 100 mm. It may be necessary to perform flexural toughness testing (ASTM C1018) and/or residual strength testing (ASTM C1399) when using a FRC mix. IV. Structural Consideration Currently, the concrete industry is under pressure to improve productivity and efficiency. The use of fiber reinforcement has been suggested as a means of reducing the amount of primary standard reinforcing steel required in a particular product. Engineer should not replace reinforcing steel with fiber reinforcement and expect the concrete to behave in the same manner. Standard steel reinforcement and fiber reinforcement are two completely different materials. Reinforcing steel, including rebar and WWR, are continuous reinforcing elements that are placed discreetly in the concrete to provide tensile resistance in specific areas. This makes the placement of reinforcing steel critical. Because fiber reinforcement is discontinuous and is dispersed randomly throughout the concrete mix, placement of fibers is not as critical. This discontinuity and random orientation typically does not allow enough bond strength to develop in the concrete to fully utilize the fibers’ tensile strength. For optimal performance, however, both fiber and standard reinforcement should be used together, making use of the beneficial properties of both. Currently, performance testing of final products is the best indicator of the structural capabilities of Fiber-reinforced concrete. According to Mel Galinat of Synthetic Industries, no standard design methodology currently exists for FRC in the United States. An appropriate structural design approach would be completely different than that currently used for design of reinforced-concrete structures (e.g., ACI 318-99). Mixing of FRC can be accomplished by several 77

methods, with the choice of method depending on the job requirements and the facilities available. It is important to have a uniform dispersion of the fibers and to prevent the segregation or balling of the fibers during mixing .Balling of the fibers during mixing is related to a number of factors. The most important factors appear to be the Aspect Ratio of the fibers, the volume percentage of fibers, the maximum size and gradation of the aggregates, and the method of adding the fibers to the mixture. As the first three of these factors increase, the tendency for balling increases. The fiber strength, stiffness, and the ability of the fibers to bond with the concrete are important fiber reinforcement properties. Bond is dependent on the aspect ratio of the fiber. Typical aspect ratios range from about 20 to100, while length dimensions range from 6.4 to 76 mm. There are currently 200,000 metric tons of fibers used for concrete reinforcement. Following Table shows the existing commercial fibers and their properties. V. Properties of Fibers Used As Reinforcement in Concrete

78

VI. Durability of Fiber Reinforced Concrete

In the last decade, there has been a considerable increase in the interest of FRC; for concrete secondary reinforcement in the construction industry. The fibers are an interesting material for concrete reinforcement. A great deal of research has been addressing durability of fibers in concrete in recent years. The required service life of concrete reinforcement is usually in the order of 50 to 100years, and as results is desirable within only one or a few years. Accelerated ageing is generally used to speed up the degradation. Typically, changes in mechanical properties after exposure in alkaline solutions at an elevated temperature are determined, and considered a measure of the Durability. So far most of the durability research conducted in this field has been qualitative, comparing different FRP types to determine which perform better. For this new material to be generally accepted by the building industry, a good durability must be proven also in quantitative terms. Therefore a big challenge for researchers within this field is to determine the deterioration rate, and thereby the service life of fibers in concrete. This knowledge is needed to be able to choose proper safety factors, taking account for the deterioration due to environmental influence, for fiber design guidelines. 

     

The approach for service life prediction used in this project will discussed and some experimental results obtained so far will research work of durability of FRC. Collect and prepare all materials for concrete as per mix design. testing of all materials as per IS standards Prepare mix design of M30 concrete Mix different % of fibers with concrete as per mix design. Casting of cube The experimental program is designed to study the loss of weight and loss of compressive strength and permeability behavior of conventional concrete and polymer triangular fibers reinforced concrete 28 days curing in pure water specimens after immersing them in different solutions of NaCl, MgSO4 and Na2SO4 for 90 days

VII. Research work of fiber reinforced concrete  The main objective of the present studies the properties of fiber reinforced concrete and to compare with those of conventional concrete and environmental effect in durability of concrete...  The properties to be studied will be studied will be compressive strength.

79

VIII. Chemical admixture

As per manufacturer’s certificate and technical guideline and as per IS 9103: 1999 Concrete Admixtures – Specification 

Water:- potable /distilled/mineral water



Fiber: - polypropylene triangular shape 12 mm manufacturer’s s pecifications and technical guideline.



Solutions: - NaCl, MgSO4 and Na2SO4 as per manufacturer’s specifications

long as per

80

IX. OPC 53 Grade Cement testing research work Consistency Test The standard consistency of cement was tested and found 27 %. The fixed quantity of cement, course aggregate, fine aggregate (sand), admixture and water with variable percentage of polypropylene fiber of triangular shape and 12 mm length. The first 15 cubes were casted without fibers. The second batch was with fiber of 0.15 % of cement and after that 0.20%, 0.25%, 0.30%, 0.35%, 0.40% of polypropylene fiber were casted. (Each of 15 Nos.)

Mix proportions of conventional concrete:- As per IS 10262-2009 mix design for M30 prepared by trial and error and minimum water cement ratio decided for maximum compressive strength. After deciding quantity of each ingredients the casting of concrete as conventional and with different percentage of polypropylene fibers in moulds for compressive strength tests.

X. DURABILITY TEST PROCEDURE

Sodium sulphate resistance of conventional concrete and polypropylene fiber reinforced concrete Sodium sulphate resistance of conventional concrete determined by immersing C.C. Cubes of size 150x150x150 mm in 8% sodium sulphate (Na2SO4) solution. The effect on conventional concrete and polypropylene fiber reinforced concrete (PFRC) specimens measured as percentage reduction in weight and compressive strength at 90 days. Magnesium sulphate resistance of conventional concrete and polypropylene fiber reinforced concrete: Magnesium Sulphate resistance of conventional concrete will be determined by immersing 150x150x150 mm test cubes in 10% 81

magnesium sulphate (MgSO4) solution. The effect on conventional concrete and polypropylene fiber reinforced concrete (PFRC) specimens measured as percentage reduction in weight and compressive strength at 90 days. Acid Attack on conventional concrete and polypropylene fiber reinforced (PFRC): Marine environment attack determined by immersing C.C. Cubes of size 150x150x150 mm individually in7% sodium chloride (NaCl) solutions. The deterioration of conventional concrete and polypropylene fiber reinforced concrete (PFRC) specimens measured as percentage reduction in weight and compressive strength at 90 days. The three cubes were tested on 7 days period, other three cubes were tested on 28 days and remaining nine cubes were immersed in chemical solution of NaCl, Na2SO4, and MgSO4 to research the marine environment effect on fiber reinforced concrete after 28 days curing in pure water. These cubes were kept for 90 days. Than compressive strength were checked and compared with other results of specimens.

82

83

84

XI. Conclusion





Addition of polypropylene triangular fibers improved durability of concrete. The loss in weight and loss/gain in compressive strength of the cube specimens improved with age. Compressive strength of concrete increases with increase in fiber dosage up to 0.3%, then it starts decreasing. So the optimum percentage fiber found from experiment is 0.3%. Higher the durability, higher will be the resistance to marine structures Attacks. The polypropylene fibers bridge the cracks and minimize interconnecting voids. This resulted in dense concrete. Therefore this can be used for water retaining structures like water tanks, swimming pools, which ought to be designed as impermeable.

85

XII. References Research Papers

[1] A.P.Singh, S.P.Singh, C.D.Modhera S.Bhalla, B.Bhattacharjee, D.Shah, ,S.Bhalla, B.Bhattacharjee, “Enhancing structural performance utilizing fibers”, Proceedings of the international UKIERI concrete congress new Delhi India 810 march 2011 page no.153-176 [2] Dr.G.Mohankumar , L.BangaruChandran, “Structural behavior of hybrid fiber reinforced concrete beams”, The Indian concrete journal published cynic Limited vol.83 October 2009 no.10.page no.14-20 [3] Dr.J.Premalatha, Dr.R.Sundara raja, “Effect of steel fibers and longitudinal reinforcement inn effective moment of inertia of reinforced high strength fibrous concrete beams”, The Indian concrete journal published bynACC limited vol.83 October 2009 no.10.page no.7-13 [4] Dr.Lalu mangal.Arun Edwin, Dr. S.Suresh, “Studies on fiber reinforced pre packed concrete”, The Indian concrete journal published bynACC Limited vol.83 October 2009 no.10.page no.37-43[5] Dr.P.Srinivasa Rao, Dr.Seshadri Sekhar.T, Dr.P.Sravana, “Durabilty studies on glass fiber SCC”, The Indian concrete journal published bynACC Limited vol.83 October 2009 no.10.page no.44-52 [6] Manote Sappakittipakorn and Dr.Nemkumar Banthia, “Corrosion control in RC structures using fiber reinforced concrete”, The Indian concrete journal published bynACC Limited vol.84 October 2010 no.10.page no.7-20 [7] S.C.Yaragal,K.S.Babu narayan, NIT Karnataka, “Performance enhancement of concrete using fibers”, Proceedings of the international UKIERI concrete congress new Delhi India 8-10 march 2011 page no.31-42 [8] S.P.Singh,A.P.Singh,V.Bajaj, “Flexural fatigue strength of concrete reinforced with steel-polypropylene hybrid fibers”, Proceedings of the international UKIERI concrete congress new Delhi India 8-10 march 2011 page no.205-218 [9] IS 383: 1970 Specification for coarse and fine aggregates from natural sources for concrete. [10] IS 650: 1991 Specification for standard sand for testing of cement. 86

[11] IS 1199: 1959 Methods of sampling and analysis of concrete. [12] IS 456: 2000 Plain and Reinforced Concrete - Code of Practice [13] IS 516: 1959 Method of test for strength of concrete [14] IS 3085: 1965 Method of Test for Permeability of Cement Mortar and Concrete [15] IS 4031:1988 Methods of physical tests for hydraulic cement [16] IS 12269: 1987 Specification for 53 grade ordinary Portland cement [17] IS 10262: 2009 Recommended guidelines for concrete mix design? [18] IS 5816: 1999 Splitting Tensile Strength of Concrete Method of Test [19]IS 9103: 1999 Concrete Admixtures – Specification.

87

TECHNICAL PAPER NO: 3

Value-added Utilization of Waste Glass in Concrete .

Ahmad Shayan is a Chief Scientist at ARRB Transport Research. He has over 22 years of experience in the assessment of concrete deterioration and its prevention, and also utilization waste materials in concrete and recycling. He has published around 110 papers and written 185 technical reports on these issues.

Summary

A large proportion of the post consumer glass is recycled into the packaging stream again, and some smaller proportion is used for a variety of purposes including concrete aggregate. However, significant proportion which does not meet the strict criteria for packaging glass is sent to landfill, taking the space that could be allocated to more urgent uses. Glass is unstable in the alkaline environment of concrete and could cause deleterious alkali-silica reaction problems. This property has been used to advantage by grinding it into a fine glass powder (GLP) for incorporation into concrete as a pozzolanic material. In laboratory experiments it can suppress the alkali-reactivity of coarser glass particles, as well as that of natural reactive aggregates. It under goes beneficial pozzolanic reactions in the concrete and could replace up to 30% of cement in some concrete mixes with satisfactory strength development. The drying shrinkage of the concrete containing GLP was acceptable.

Keywords: glass aggregate; glass powder; ASR; pozzolanic reaction; strength development.

88

1. Introduction Glass is produced in many forms, including packaging of container glass (bottles, jars), flat glass (windows, windscreens), bulb glass (light globes), cathode ray tube glass (TV screens, monitors, etc), all of which have a limited life in the form they are produced and need to be reused/recycled in order to avoid environmental problems that would be created if they were to be stockpiled or sent to landfill. This paper deals with the recycling aspects of container glass, and the term “glass “hereafter refers to this type only. 1.1 Recycling of glass Post-consumer glass containers have traditionally been disposed of either in domestic refuse, which ends up in landfill, collected in designated collection spots for reuse/recycling, or collected from kerb side and then transported to collection sites. The major aim of environmental authorities is traduce, as far as possible, the disposal of post-consumer glass in landfill and diversion to economically viable glass product streams. Glass is a unique inert material that could be recycled many times without changing its chemical properties. In other words, bottles can be crushed into cullet, then melted and made into new bottles without significant changes to the glass properties. Most of the glass produced is in the form of containers, and the bulk of what is collected post-consumer is again used for making containers. The efficiency of this process depends on the method of collecting and sorting glass of different colours. If different color glass (clear, green, amber) could be separated, then they could be used for manufacturing similar color glass containers. However, when the glass colors get mixed, they become unsuitable for use as containers, and are then used for other purposes, or sent to landfill. Rind (1998) reported the many non-container uses of glass cullet, which included road construction aggregate, asphalt paving, concrete aggregate, building applications (glass tiles and bricks, wall panels, etc), fiber glass insulation, glass fiber, abrasive, art glass, agricultural fertilizer, landscaping, reflective beads, tableware, hydraulic cement, among other applications. The utilization of glass in concrete is of particular interest for the work reported here. A major concern regarding the use of glass in concrete is the chemical reaction that takes place between the silica-rich glass particles and the alkali in the pore solution of concrete, i.e., alkali-silica reaction (ASR). This reaction can be very detrimental to the stability of concrete, unless appropriate precautions are taken to minimize its effects. Such preventative actions could be achieved by incorporating a suitable pozzolanic material such as fly ash, silica fume, or ground blast furnace slag in the concrete mix at appropriate proportions. The susceptibility of glass to alkali implies that coarse glass or glass fibers could undergo ASR in concrete, possibly with deleterious effects. However, it would be expected that fine ground glass (i.e. glass powder), would exhibit pozzolanic properties such as those of the materials named above, and 89

would be an effective ASR-suppressant, preventing ASR damage to concrete in the presence of reactive aggregates. Rind (1998) presented a summary of work conducted bother researcher’s reorganizations. For example, he quotes from Boral company, Linesville , North Carolina that ground soda-lime glass of < 100 mesh was effective against ASR, and from Clean Washington Centre that glass as fine aggregate (rather than powder) can weaken the concrete matrix due to ASR. He quoted work by Saturn (1974) on this issue, which indicated that fine glass powder (< 200 mesh, or< 75 μm particle size), could act like a pozzolanic material to reduce the tendency of reactive aggregate to undergo ASR. Patting (1973) had apparently also found similar effects. The work of Phillips and Cahn (1973) has been quoted to have shown that up to 35% glass cullet could be used in concrete in combination with low alkali cement, without detrimental effects. Recently, New York State Energy Research and Development Authority (NYSERDA), sponsored research on the utilization of recycled glass for concrete masonry blocks, and it was shown that waste glass can be used as both coarse aggregate and as additive, provided that certain conditions are met (NYSERDA, 1997). Another project dealt with the use of recycled glass and fly ash in precast concrete and encouraging results were obtained (NYSERDA, 1998).Bezant et al. (1998) found that glass particle size of around 1.5 mm caused excessive expansion, whereas particles < 0.25 mm caused no expansion in laboratory tests on concrete. Jin, Meyer and Baxter (2000) found that glass particles of around 1.2 mm caused the largest mortar bar expansion in the particle size range of 0.15 – 4.75 mm. They found that the largest expansion resulted when glass particles formed 100% of the aggregate, and that green glass containing more than 1.0%chromium oxide had a beneficial suppressive effect on ASR. Carpenter and Cramer (1999) also reported that powdered glass was effective in reducing ASR expansion in accelerated mortar bar tests, similar to the effects of fly ash, silica fume and slag. This is in agreement with the present authors’ unpublished results Shayan and CSU, (1998), where it was shown that glass powder could suppress the ASR expansion caused by natural reactive aggregates and coarse glass particles. From the above it appears that glass could be used in concrete in three forms; as coarse and fine aggregate, and in powder form. The coarse and fine glass aggregates could cause ASR in concrete, but the glass powder could suppress their ASR tendency, an effect similar to supplementary cementitious materials (SCMs). On a market price basis, it would be much more profitable to use the glass in powder form as a cement replacement material (i.e., as an SCM), than as aggregate. This would be a value-added material, produced from contaminated, mixed color glass chips which are not useable for packaging purposes. Although such material could also be used as abrasive grit, although the volume used for this application is not very high compared to that of SCMs. In the following sections data are presented in relation to the utilization glass in concrete in the three forms mentioned above. 90

2. Experimental work

Three aspects of glass utilization in concrete were addressed in the research program undertaken attars. These included coarse glass aggregate, fine glass aggregate and glass powder. The particle size range for each of these products is given below:

The chemical composition of these products is similar for a given type of glass, and typical chemical compositions of the various color glass have been presented in Table 1.

The coarse and fine glass particles are used as replacement for the corresponding size ranges of natural aggregate materials, whereas the glass powder has been studied as pozzolanic materialize. 91

The same application as for silica fume or fly ash. A comparison between the compositions of mixed crushed glass and glass powder with that of silica fume is presented instable 2, showing the more silica-rich nature of the latter:

The natural materials used in this work were non-reactive, natural, Victorian concrete sand, and crushed basalt coarse aggregate. A reactive greywacke coarse aggregate frowns was used to assess the effectiveness of glass powder in suppressing AAR expansion. 3. Coarse and fine glass aggregates in concrete

The influence of physical properties of glass aggregate such as grading on the properties of the concrete mix is well known. Glass, due to its silica-rich nature and amorphous structure is susceptible to chemical attack under the high alkali conditions provided by the hydrated cement phase in the concrete. This chemical attack on glass could produce extensive formation of AAR gel (Figures 1), which is expansive and could cause premature cracking in the concrete, if appropriate precautions are not put in place in the formulation of the concrete mix.

92

The nature of the glass reactivity has important implications in its utilization in concrete. For instance, some natural aggregates cause excessive expansion in concrete when used as a small proportion of total aggregate content, and some other ones when used at 100% of the total aggregate. The reactivity of aggregate is assessed by accelerated mortar bar testing (AMBT),conducted in 1M Noah at 80oC, according to ASTM C1260 or an Australian method RTA T363(RTA, NSW specification B80, Test Method T363).

93

The AMBT results obtained at ARRB have shown that the larger the content of glass in mortar bars, the higher the expansion. Figure 2illustrates this effect. The criteria for this test, according to the RTA Test Method T363, are that expansion values smaller than 0.10% at the age of 21 days are associated with non-reactive aggregate (smaller than 0.15% for sand), and expansions greater than 0.10% at10 days associated with reactive aggregates. Expansions smaller than 0.10% at 10 days but exceeding 0.10% at21 days indicate slowly reactive aggregate. Based on these criteria, Figure 2 indicates that use of up to 30% glass in the concrete may not cause deleterious effects, particularly if the alkali content of the concrete is low (below 3 kg Na2Oequivalent per cubic meter). At higher alkali contents of concrete further expansion may result. In addition to the glass content of mortar bars, the particle size also has an effect on the expansion. This is illustrated in Figure 3 for four particle size ranges, including powder (<10 μm), very fine sand (0.30– 0.15 mm) and two coarser sand fractions. The results shown in Figure 3 indicate that glass particle sizes below 0.30 mm would not cause deleterious expansions, whereas fractions above0.60 mm would cause significant deleterious expansions

94

Therefore, the magnitude of expansion would depend on the interaction of glass content, particle size and alkali content of the concrete. These results have shown that glass can react and produce AAR gel and that once the particle size is sufficiently reduced, it can act as pozzolanic material. It is well known that the reactivity of aggregate and its consequent expansion can be suppressed by incorporating appropriate amounts of supplementary cementitious materials such as silica fume and fly ash. Fine glass powder can also act in a similar manner (see later).So far as utilization as fine and coarse aggregate is concerned, trial mixes were undertaken with the view of establishing how much fine and coarse glass could be used in concrete mixtures that would-be suitable for some structural applications and for concrete pavements. The trials aimed at producing concrete appropriate as Vic Roads 32 MPa strength grade. This mix contained a binder of255 kg/m3 cement and 85 kg/m3 fly ash. The coarse aggregate and sand contents were 1080 and780 kg/m3, respectively. After a number of trials, adjusting the properties of fresh and hardened concrete, the following concrete mix formulations were found to be satisfactory, as detailed instable 3.

It is evident from the strength results that these mixes easily meet and exceed the requirements of the 32 MPa concrete, while incorporating large quantities of waste glass. For non-structural applications, where lower strength (e.g. 25 MPa) is required, the same mix without the water reducer or superplasticiser could be used to achieve the required strength. Two mixes containing 50% coarse glass without and with50% fine glass are detailed in Table 4. Due tithe presence of 25% fly ash these mixes would remain free of ASR. 95

The drying shrinkage of the concrete mixes was well below the limit of 0.075% specified by the Australian Standard AS 3600. Figure 4 shows typical drying shrinkage curves for the concrete Specimens with various glass contents. From the above, it is concluded that up to 50% of each of fine and coarse glass could be used income structural and non-structural concrete applications. However, other engineering properties of such concrete mixes also need to be investigated.

96

3.1 Glass powder

The initial work undertaken by ARRB on the utilization of glass as a pozzolanic material was partially supported by Eco Recycle Victoria in 1998, and subsequently by VISY Recycling – Glass Division. The following section summarizes the results obtained during this research program. 4. Effects of glass powder (GLP) on mortar strength

The particle size distribution of the glass powder (GLP) used is as follows:

The specific surface area of the GLP was 800 m2/kg, which is around double that of most Australian cements (~ 400 m2/kg).The effects of cement or sand replacement by GLP on the strength of mortar cubes (aggregate to cement ratio of 2.25 and water/cement ratio of 0.47) are shown in Figures 5 and 6. In the case of cement replacement, the reduction in the 28 days strength, may, to some extent, be a short-term effect because in such short periods the pozzolanic effects would not become evident. Fly ash also exhibits a similar effect when it replaces an equal mass of cement.

97

Longer-term strength development was studied in comparison with silica fume. This series consisted of control specimens in whom the fine aggregate was a reactive greywacke and other specimens that contained either of 10% silica fume (SF), 20% GLP or 30%GLP, each replacing corresponding amounts of the cement. In one case 30% GLP replaced the aggregate. Figure 7shows the strength development of each combination over 270 days.

98

These results indicate that 10% SF replacement produces higher strength than the GLP replacements, but they also show that mortar specimens containing GLP continue to develop further strength with time, indicating pozzolanic reactivity. It should be noted that when 30% sand was replaced by GLP, the 90day strength was the same as that of the SF-bearing specimens. To verify the positive effect on strength of aggregate replacement by glass powder two additional tests were conducted on mortar cubes cured for up to 270 days. In one set of specimens 20%cement was replaced by glass powder and in the other set, in addition, 10% of aggregate was also replaced by glass powder. Figure 8 confirms that this replacement is beneficial, probably due to improvement in the particle packing, as well as the pozzolanic reaction. It should be noted that the strength achieved with 30% glass powder replacing 20% cement and 10%aggregate exceeds that of the silica fume-containing mix. The apparently larger effect of SF on strength gain compared to glass powder is exaggerated in these tests, because those with SF have 90% cement, whereas those with glass powder have 80 and 70% cement. For a comparison based on similar cement contents, mortar strength tests were conducted on two further sets of specimens that contained crushed, graded glass as the fine aggregate (80% glass + 20% natural sand), and in which 30% of the cement was replaced by other materials. In one set 30% of cement was replaced by glass powder, and in the other set by admixture of 10% silica fume plus 20% pulverized basalt powder (non pozzolanic). This made the cement content of the two sets the same. Figure 9 shows the strength results forth two sets to beery similar. It should be noted that the strength results presented in Figures7and 9 are not comparable due to completely different aggregates in the mortar mixes. Therefore, it is confirmed that the reduced strength observed in Figure 7 forth mix containing glass powder, is due to the lower cement content rather than the nature of the glass powder. In thecae where glass powder replaces aggregate, without reduction in the cement content, the resulting strength is greater than those of specimens containing SF. The above indicates the favorable effects of glass powder on strength development of mortar specimens containing it.

99

5. Effect of glass powder on mortar expansion

As shown in Figures 2 and 3 coarse sand size particles of glass can cause deleterious AAR expansion, particularly at high glass contents in the accelerated mortar bar test .Therefore , six sets of mortar bars were made to contain 80% 100

glass particles in the aggregate phases the reactive component. The control set contained the aggregate and plain cement, and in the other five sets the cement was replaced by 5% SF, 10% SF, 10%, 20% and 30% GLP. Figures 10and 11 show the expansion results for these combinations and indicate that both SF and GLP are effective in suppressing AAR expansion when used in sufficient amounts (10% SF and>20% GLP). Better than 10% SF.

Due to the large soda content of the glass (around 13%), it is important to find out whether or not the GLP itself could cause long-term mortar bar expansion, or trigger the expansion of reactive aggregates if present in the specimen. Longterm mortar bar expansion testing, conducted at 38oC,100% RH, were undertaken in combination with nonreactive and reactive aggregates, and with the same levels of cement replacement as mentioned above. Expansion values less than 0.1% at 1 year indicate innocuous combinations.

101

Figure 12 show that the GLP itself does not cause any expansion when the aggregate is nonreactive. Moreover, Figure 13 shows that when the aggregate is reactive, the presence of even 30%GLP does not trigger the reactivity of the very susceptible aggregate used. Even when the cement is not replaced, and GLP has replaced the aggregate, still the 30% GLP does not cause deleterious mortar bar expansion. The data indicate that GLP could be used without fear of harmful effects. 102

103

6. Glass powder in concrete

The efficiency of glass powder was also assessed in concrete expansion tests. A very reactive aggregate was employed in the concrete prism test conducted according to theta T364 test method (similar to ASTM C1293). Deleterious expansions are considered to be above 0.03% or0.04% in one year. Figure 14 shows that even 40% GLP, which has the potential to release more alkali than 30% GLP, has effectively suppressed the enormous expansion of thievery reactive aggregate in the concrete (80% reduction).

For less reactive aggregates, the expansion would have been completely suppressed. This confirms the beneficial effects of GLP in improving the durability properties of concrete when various proportions of GLP were used with non-reactive aggregate in concrete of raised alkali level (5.8 kg Na2O equivalent/m3), the material itself did not cause deleterious expansion as shown 104

in Figure 15. The latter results also confirm that GLP would not cause harmful expansion in concrete.

6.1 Effects of glass powder on concrete shrinkage and strength

Concrete specimens corresponding to those represented in Figure 15 but of lower alkali content were employed for determining the drying shrinkage of concrete containing various amounts ogle and SF. Long-term data presented in Figure 16 show that the drying shrinkage of the various mixtures are not excessive and they easily meet the requirements of AS 3600, being values less than0.075% at 56 days. 105

106

The strength properties of the concrete mixes represented in Figure 16 are given in Figure 17. It is seen that although the mixes containing GLP have lower initial strength values, due to significantly lower cement content, they keep developing strength with time under moist curing conditions, and approach the strength of the control mixes; particularly when GLP replaces sand, the strength insignificantly greater than that of the control mixture. The continued strength development clearly indicates the beneficial pozzolanic reaction of the GLP in concrete. 7. Microstructure of mortar phase containing GLP The mortar specimens containing GLP, which had 270 days of moist curing, were examined by scanning electron microscopy (SEM). These mortar specimens would also represent similar concrete of the same history. Figure 18 shows the dense microstructure that has developed in mortar incorporating 30% GLP, and illustrates the consumption of fine glass particles by their pozzolanic reaction with cement. In both cases fracture surfaces of the mortar specimens were indicative of a compact micro structure.

107

8. Conclusions The data presented in this paper show that there is great potential for the utilization of waste glass in concrete in several forms, including fine aggregate, coarse aggregate and glass powder. It is considered that the latter form would provide much greater opportunities for value adding and cost recovery, as it could be used as a replacement for expensive materials such as silica fume, fly as hand cement. The use of glass powder in concrete would prevent expansive ASR in the presence of susceptible aggregate. Strength gain of GLP-bearing mortar and concrete is satisfactory. Micro structural examination has also shown that GLP would produce a dense matrix and improve the durability properties of concrete incorporating it. It has been concluded that30% GLP could be incorporated as cement or aggregate replacement in concrete without any long-term detrimental effects. Up to 50% of both fine and coarse aggregate could also be replaced in concrete of 32 MPa strength grade with acceptable strength development properties.

9. Acknowledgements The author wishes to thank Dr A CSU and Mr. S Cardona for the experimental results reported here.

108

10. References

[1] RINDL, J. Report by Recycling Manager, Dane County, Dept of Public Works, Madison, USA, August 1998. [2] SAMTUR, H.R. Glass Recycling and Reuse, University of Wisconsin, Madison Institute for Environmental Studies, Report No. 17, March 1974. [3] PATTENGIL, M. Glass as a Pozzolanic, Albuquerque Symposium on Utilization of Waste Glass, Second Prod. 1973. [4] PHILLIPS, J.C. and CAHN, D.S. Refuse Glass Aggregate in Portland cement. Proc. 3rd Mineral Waste Utilization Symposium, 1973, pp. 385-390. [5] NYSERDA. Use of Recycled Glass for Concrete Masonry blocks. Report 97-15, Nov. 1997. [6] NYSERDA. Use of Recycled Glass and Fly Ash for Precast Concrete. Report 98-18, Oct. 1998. [7] BAZANT, Z.P., JIN, W. and MEYER, C. Fracture Mechanics of Concrete Structures, Proc. FRA MCOS – Vol. 3, 1998, pp. 1687-1693. [8] JIN, W., MEYER, C. and BAXTER, S. ACI Materials Journal , Vol. 97, March-April 2000, pp. 208-213. [9] CARPENTER, A.J. and CRAMER, S.M. Mitigation of ASR in Pavement Patch Concrete that Incorporates Highly Reactive Fine Aggregate. Transportation Research Record 1668, Paper No. 99-1087, 1999, pp. 60-67. [10] SHAYAN, A. and XU, A. Utilization of Glass as a Pozzolanic Material in Concrete. ARRB TR Internal Report RC91132, November 1999, 11 pp

109

110

5.1 Experimental Equipments

5.1.1 Concrete Mixer

A concrete mixer is a device that homogeneously combines cement, aggregate such as sand or gravel, and water to form concrete. A typical concrete mixer uses a revolving drum to mix the components. For smaller volume works portable concrete mixers are often used so that the concrete can be made at the construction site, giving the workers ample time to use the concrete before it hardens. An alternative to a machine is mixing concrete or cement by hand. This is usually done in a wheelbarrow; however, several companies have recently begun to sell modified tarps for this purpose. The concrete mixer was invented by Columbus industrialist Gebhardt Jaeger.

Fig. No. 15 111

5.1.2 Casting Moulds

The cube moulds of required size (150 mm for nominal size of aggregate not exceeding 38 mm) shall be made in such a manner as to facilitate their separation into two parts. Cube moulds shall be provided with a base plate and they shall be as per IS: 10086-1982. The dimensions, tolerance and materials of cube moulds shall be as given in table-1

Fig. No. 16

Dimension, tolerance and materials of 150 mm cube mould. Sr.No.

Description

1

Requirements

150 ± 0.2 Distance between opposite faces, mm

2

150 ± 0.2 Height of mould, mm

3

8 Thickness of wall plate, mm

4

90 ± 0.5

0

Angle between adjacent interior faces and between interior faces and top and bottom plates of mould. 5

280 Length of base plate, mm

112

6

215 Width of base plate, mm

7

8 Thickness of base plate, mm

8 Permissible variation in the plainness of interior faces: for new moulds, mm

0.03

for moulds in use, mm

0.05

9

0.03 Permissible variation in the plainness of base plate, mm

10

Cast iron Materials a) Side plate b) Base plate

Cast iron

Table no. 9

5.1.3 Tamping Rod

As per IS: 10086-1982, the tamping rod shall be 16±0.5 mm die and 600±2 mm long with a rounded working end and shall be made of mild steel.

Fig. No. 17 113

5.1.4 Compression Testing Machine {C.T.M.}

The compression testing machine shall be as per IS: 14858-2000. The machine shall be capable of applying the load at the specified rate, uniformly without shock using manual or automatic control. The percentage of error shall not exceed ±1.0 percent of the indicated load. On regular basis the machine should be calibrated with in a period not exceeding 12 months from previous verification. The machine is required to be calibrated on original installation or relocation, subject to major repairs or adjustment and whenever there is reason to doubt the accuracy of the results, without regard to the time interval since the last verification.

Fig.no.18 114

5.1.5 Slump Cone

Metal mould, in the shape of the frustum of a cone, open at both ends, and provided with the handle, top internal diameter 102 mm, and bottom internal diameter 203 mm with a height of 305 mm. A 610 mm long bullet nosed metal rod, 16 mm in diameter.

Fig. No. 19

115

116

Fig. No. 20

Fig. No. 21 117

Fig. No. 22

Fig. No. 23 118

Fig. No. 24

Fig. No. 25 119

Fig. No. 26

Fig. No. 27 120

Fig. No. 28

Fig. No. 29 121

Fig. No. 30

Fig. No. 31 122

Fig. No. 32

Fig. No. 33 123

Fig. No. 34

Fig. No. 35 124

Fig. No.36 125

Fig. No. 37

Fig. No. 39 126

Fig. No. 40

Fig. No. 41 127

Fig. No.42 128

Fig. No. 43 129

Fig. No. 44 130

Fig. No. 45

Fig. No. 46 131

132

6.1 Results The result in variation of compressive strength of concrete produced by replacing cement with glass powder with glass fiber for 7, 21, 28 days. The results also show the variation of compressive strength of concrete replacement of glass powder for 7, 21, 28 days.

6.2 Discussions An increasing trend in strength was observed with increasing replacement of cement with glass powder up to 20%.Beyond 20%, the compressive strength started to fall steadily. The increase in the strength up to 20% replacement of cement with glass powder may be due to the pozzolanic reaction of glass powder. However, beyond 20 %, the dilution effect takes place over and the strength starts to drop. Thus it can be concluded that 20 % replacement of cement with glass powder is the optimum percentage with which cement can replaced. Unit weight of concrete without waste glass is higher than with waste glass. Such a difference was attributive to the fact that the specific gravity of waste glass is 2.58 which is much lower than the specific gravity of cement which is 3.15

Grade of concrete

% of Glass powder added

Quantity of Glass fiber {gm}

Compressive strength @ 28 days {N/mm2}

M20

4%

60

22.68

M20

8%

60

23.82

M20

12%

60

25.69

M20

16%

60

29.34

M20

20%

60

29.36

M20

24%

60

19.68

Table no.10 Showing Compressive Strength of Concrete at 28 days

133

COMPRESSIVE STRENGTH AT 7 , 21 , AND 28 DAYS 40

} a

34.27

35

p 30 M { S S 25 E R T S 20

29.34

31.64

29.36

25.69 23.82

22.68 22.86

E T 15 A M I T L 10 U

22.96

22.55

23.59

23.1

22.98

19.68 18.48

16.28

15.95

15.76

15.03

16.85

12.38

5

0

Conventional + Fibre

4% Glass Powder + Fibre






7 days

22.86

15.03

15.76

15.95

16.28

16.85

12.38

21 days

31.64

22.55

22.96

22.98

23 .1

23.59

18.48

28 days

34.27

22.68

23.82

25.69

29.34

29.36

19.68

BAR CHART NO: 1 134

Compressive Strength at 7 days 24% Glass Powder, 12.38

Conventional + Fibre, 22.86

20% Glass Powder, 16.85 4% Glass Powder, 15.03


8% Glass Powder, 15.76


4% Glass Powder

8% Glass Powder

16% Glass Powder

20% Glass Powder

24% Glass Powder

PIE CHART NO: 1

12% Glass Powder







4% Glass Powder

8% Glass Powder

16% Glass Powder

20% Glass Powder

24% Glass Powder

12% Glass Powder

PIE CHART NO: 1



20% Glass Powder, 23.59 4% Glass Powder, 22.55 16% Glass Powder, 23.1 12% Glass Powder, 22.98



4% Glass Powder

8% Glass Powder

16% Glass Powder

20% Glass Powder

24% Glass Powder

12% Glass Powder

PIE CHART NO: 2 135

Compressive Strength at 28 days








4% Glass Powder

4% Glass Powder

4% Glass Powder

4% Glass Powder

4% Glass Powder

4% Glass Powder

PIE CHART NO: 3

136

CONCLUSION 

The data presented in this paper show that there is great potential for the utilization of waste glass in the form of glass powder.



It is considered that the glass powder form would provide much greater opportunities for value adding and cost recovery, as it could be used as a replacement for expensive materials such as silica fume, fly as hand cement.



Addition of Glass powder improved compressive strength of concrete. Compressive strength of concrete increases with increase in glass powder dosage up to 20% replacement to cement, then it starts decreasing. So the optimum percentage Glass powder found from experiment is 20%.



Higher the durability, higher will be the resistance to marine structures attacks. NEG ARG Fiber imparts into concrete non-combustibility characteristics, corrosion resistance and high-quality alkali-resistant. Thus addition of glass fiber increases the durability if concrete.

137

REFERENCES

1. www.honors.ufl.edu/apps/Thesis.aspx/Download/2005 2. www.trivitro.com/pdfs/iabse_glass_in_concrete.pdf 3. www.columbia.edu/cu/seas/earth/wtert/.../meyer_egosi_paper.pdf 4. www.icevirtuallibrary.com/content/article/10.../coma.2007.160.4.165 5. zdb.ru.lv/conferences/3/VTR8_II_125.pdf 6. www.astm.org/DIGITAL_LIBRARY/JOURNALS/.../JTE10117J.htm 7. www.degruyter.com/view/j/cons.2012.../v10311-012-0004-z.xml 8. www.bespartangreen.msu.edu/.../soroushian brief field investigation 9. www.care-uk.org/care07/content/pdf/liang%20hong.pdf 10.ubithesis.ubi.pt/bitstream/10400.6/588/1/oliveiraetal11dbmcpd.pdf 11.www.columbia.edu/cu/.../74_ByarsMeyerZhuDundee20032.pdf 12. josbrouwers.bwk.tue.nl/publications/Conference84.pdf 13. books.google.co.in/books?isbn=0727732846 14.ethesis.nitrkl.ac.in/3339/1/Randheer_%26_Ankur__final_Thesis.pdf 15.H.H. Bache, “Introduction to compact reinforced composite, “Nordic Concrete Research, no. 6, pp. 19 – 33, 1987. 16.P. Richard and. Cheyrezy, “Composition of reactive powder concretes,” Cement and Concrete Research, vol. 25, no. 7, pp.1501 – 1511, 1995. 17.P. Rossi, A. Arca, E. Parant, and P. Fakhri, “Bending and compressive behaviors of a new cement composite,” Cement and Concrete Research, vol. 35, no. 1, pp. 27 – 33, 2005. 18.T. T. Le, M. N. Soutsos, S. G. Millard, and S. J. Barnett, “Ultrahigh performance

fiber

reinforced

concrete — optimization

of

mix

proportions,” in Proceedings of the International Conference Entitled Concrete Platform, pp. 339 – 349, Belfast, UK,2007. 19.M. Schmidt and E. Fehling, “Ultra-high-performance concrete research development and application in Europe,” in Proceedings of the 7th

138

international Symposium on the Utilization of High-Strength/HighPerformance Concrete, American Concrete Institute, Washington, DC, USA, 2005. 20.V. C. Li, “Strategies for high performance fiber reinforced cementitious composites development. Fiber reinforced concrete: from theory to practice,” in Proceedings of the North American/European Workshop on Advances in Fiber Reinforced Concrete, pp. 93 – 98, Bergamo, Italy, 2004. 21.A. Oner and S. Akyuz, “An experimental study on optimum usage of GGBS for the compressive strength of concrete,” Cement and Concrete Composites, vol. 29, no. 6, pp. 505 – 514, 2007. 22.W. Jin, C. Meyer, and S. Baxter, “Glascrete— Concrete with glass aggregate,” ACI Structural Journal, vol. 97, no. 2, pp. 208– 213, 2000. 23.A. Shayan and A. Xu, “Value-added utilization of waste glassing concrete,” Cement and Concrete Research, vol. 34, no. 1, pp.81– 89, 2004. 24.C. Meyer, N. Egosi, and C. Adela, “Concrete with waste glasses aggregate,” in Recycling and Reuse of Glass Cullet. Proceedings of the International Symposium, Concrete technology unit office and University of Dundee, March 2001. 25.I. B. Topçu and. Canbaz, “Properties of concrete containing waste glass,” Cement and Concrete Research, vol. 34, no. 2, pp.267– 274, 2004. 26.C. M. Sangha, A.M. Alani, and P. J.Walden, “Relative strength of green glass cullet concrete,” Magazine of Concrete Research, vol. 56, no. 5, pp. 293 – 297, 2004. 27.S. B. Park, B. C. Lee, and J. H. Kim, “Studies on mechanical properties of concrete containing waste glass aggregate,” Cement and Concrete Research, vol. 34, no. 12, pp. 2181 – 2189, 2004.

139

28.G. Chen, H. Lee, K. L. Young et al., “Glass recycling in cement production-an innovative approach,” Waste Management, vol.22, no. 7, pp. 747 – 753, 2002. 29.Z. Xie and Y. Xi, “Use of rec ycled glass as a raw material in the manufacture of Portland cement,” Materials and Structures/Materiaux 30.ET Constructions, vol. 35, no. 252, pp. 510 – 515, 2002. 31. N. Neithalath and N. Schwarz, “Cement pastes incorporating coarse glass powder hydration, strength, and heat development, “Materials and Structures. In press. 32. N. Schwarz, M. DuBois, and N. Neithalath, “Electrical conductivity based characterization of plain and coarse glass powder modified cement pastes,” Cement and Concrete Composites, vol. 29, no. 9, pp. 656 – 666, 2007. 33.Y. Shao, T. Lefort, S. Moras, and D. Rodriguez, “Studies on concrete containing ground waste glass,” Cement and Concrete Research, vol. 30, no. 1, pp. 91 – 100, 2000. 34.C. Shi, Y. Wu, C. Riefler, and H. Wang, “Characteristics and pozzola nic reactivity of glass powders,” Cement and Concrete Research, vol. 35, no. 5, pp. 987 – 993, 2005. 35.A. Shayan and A. Xu, “Performance of glass powder as pozzolanic material in concrete: a field trial on concrete slabs, “Cement and Concr ete Research, vol. 36, no. 3, pp. 457 – 468, 2006. 36.C. Meyer, S. Baxter, and W. Jin, “Potential of waste glass for concrete masonry blocks,” in Proceedings of the 4th Materials Engineering Conference, pp. 666 – 673, Washington, DC, USA, November 1996. 37.C. Shi, Y. Wu, C. Riefler, and H. Wang, “Characteristics and pozzolanic reactivity of glass powders,” Cement and Concrete Research, vol. 35, no. 5, pp. 987 – 993, 2005.

140

38. N. Schwarz, H. Cam, and N. Neithalath, “Influence of a fine glass powder on the durability characteristics of concrete and its comparison to fly ash,” Cement and Concrete Composites, vol. 30, no. 6, pp. 486– 496, 2008. 39.Y. Shao, T. Lefort, S. Moras, and D. Rodriguez, “Studies on concrete containing ground waste glass,” Cement and Concrete Research, vol. 30, no. 1, pp. 91 – 100, 2000. 40.A. Shayan and A. Xu, “Value-added utilization of waste glassing concrete,” Cement and Concrete Research, vol. 34, no. 1, pp.81– 89, 2004. 41.C. Meyer, N. Egosi, and C. Andela, “Concrete with waste glasses aggregate,” in Proceedings of the 4th Materials Engineering Conference, vol. 2, pp. 1388 – 1397,Washington, DC, USA,November1996. 42.S. Laldji and A. Tagnit-Hamou, “Glass frit for concrete structures: a new, alternative

cementitious

material,”

Canadian

Journal

of

Civil

Engineering, vol. 34, no. 7, pp. 793 – 802, 2007. 43.V. S. Panchakarla and M. W. Hall, “Glascrete?— disposing of nonrecyclable glass,” in Proceedings of the 4th ASCE Materials Engineering Conference, pp. 509 – 518, Washington, DC, USA, November 1996. 44.C. H. Chen, R.Huang, J. K.Wu, and C. C. Yang , “Waste E-glass particles used in cementitious mixtures,” Cement and Concrete Research, vol. 36, no. 3, pp. 449 – 456, 2006. 45. M. J. Terro, “Properties of concrete made with recycled crushed glass at elevated temperatures,” Building and Environment, vol. 41, no. 5, pp. 633 – 639, 2006. 46. BS 3892, Pulverized-fuel ash: part 1. Specification for pulverized-fuel ash for use with Portland cement. British Standard, 1997.

141

SUITABILITY OF WASTE GLASS POWDER AS A PARTIAL REPLACEMENT OF CEMENT IN FIBRE REINFORCED CONCRETE

Recommend Documents