See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/303517341

Uses of bottom ash in the replacement of fine aggregate for making concrete.

Article · January 2014

CITATIONS READS

5 156

3 authors, including:

Dilip Kumar Ashish Gupta

Indian Institute of Technology (ISM) Dhanbad Bundelkhand Institute of Engineering and Technology
15 PUBLICATIONS   23 CITATIONS    19 PUBLICATIONS   34 CITATIONS   

SEE PROFILE SEE PROFILE

All content following this page was uploaded by Ashish Gupta on 15 February 2018.

The user has requested enhancement of the downloaded file.

 International Journal of Current Engineering and Technology
E-ISSN 2277 – 4106, P-ISSN 2347 - 5161
®
©2014 INPRESSCO , All Rights Reserved
Available at http://inpressco.com/category/ijcet

Research Article
Uses of Bottom ash in the Replacement of fine aggregate for Making Concrete
Dilip KumarȦ*, Ashish GuptaḂ and Sri RamȦ
Ȧ
Department of Civil Engineering, M.M.M.U.T. Gorakhpur, India
Ḃ
Department of Civil Engineering, B.I.E.T. Jhansi, India

Accepted 05 Nov 2014, Available online 01 Dec2014, Vol.4, No.6 (Dec 2014)

Abstract

Many researchers have been carried out in the area of bottom ash utilization in the past. In present study A mix design
has been done for M30 Grade of concrete by IS method. Ordinary Portland cement of 43 Grade is selected and prepared
by mixing bottom ash with cement and water for making concrete. Which is a waste material of coal firing Thermal
power plants (TPPs) and its accumulation near power plant.The bottom ash is obtained from National Thermal Power
Plants (NTPC) Anpara in Sonbhadra District in Uttar Pradesh state. In this paper author investigate the Compressive
Strength and Flexural strength test of the concrete at different ages i.e. 7 days,14 days,28 days and 56 days. Bottom Ash
is replaced 10%, 20%, 30%, 40% and 50% in the place of fine aggregate. These explain the various utilization of Bottom
ash and its ordinary Portland cement and properties in concretecauses severe pollution problems. Its utilization as a raw
material for cube (Brick) making will be a very usefully solution in our economical and environmental aspects. This
paper presents the experimental investigations carried out to study the effect of use of bottom ash as a replacement of
fine aggregate.
Keyword: Bottom ash, Cement, Coarse aggregate, concrete, sands, strengths.

1. Introduction Bottom ash is a by-product of burning coal at thermal

power plants. Bottom ash particles are much coarser than
1
India produces approximately more than 100 million the fly ash. It is a coarse, angular material of porous
tonnes of Coal ash annually. Coal-based thermal power surface texture predominantly sand-sized. This material is
plants all over the world facing serious problems of composed of silica, alumina, and iron with small amounts
handling and disposal of the ash produced.The utilization of calcium, magnesium, and sulfate Grain size typically
of fly ash is about 30% as various engineering properties ranges from fine sand to gravel in size. Chemical
requirements that is for low technical applications such as composition of bottom ash is similar to the fly ash but
in construction of fills and embankments, backfills, typically contain greater quantity of carbon.
pavement base and sub base course.bottom ash based Bottom ash exhibits high shear strength and low
artificial lightweight aggregate offer potential for large- compressibility. These engineering properties make
scale utilisation in the construction work. Apart from using bottom ash an ideal material in design construction of dam
it in concrete industry as cement replacement, fly ash and for other civil engineering applications. Bottom ash
usages by other related industries have been for cube also exhibits a relatively high permeability and grain size
(Bricks) manufacture, cellular concrete, prefabricated distribution that allows the design engineer to use it in
items and road construction. Yet about 80% of bottom ash direct contact with impervious material. Bottom ash has
remains unutilised. proved to be an economical material because it has
The management of coal fly ash produced by coal demonstrated to have not only good engineering property
thermal power station is a major problem in many parts of but also to have constructability benefits. Bottom ash can
the word. However, its generation tends to increase every be used as concrete aggregate or for several other civil
year. Although some coal fly ash is used in a range of engineering applications where sand, gravel and crushed
applications, particularly as a substitute for cement in stone are used.
concrete. Large amount remain unused and thus required Government should encourage the use of bottom ash
disposal. At present, coal fly ash is used in civil related products so that bottom ash can be used in huge
engineering for production of cement, concrete, cube and quantities in many civil engineering construction purpose.
artificial aggregate. Safe disposal of the ash without
adversely affecting the environment and the large storage 2.4 Factor Affecting the Utilization of Coal ash
area required are major concerns.
Some of the factors due to which, utilization of coal ash is
*Corresponding author Dilip Kumar, Ashish Gupta are working as
not increasing at desired rate are:
Assistant Professors and Sri Ram as Associate Professor  Lack of awareness of coal ash properties.
3891 | International Journal of Current Engineering and Technology, Vol.4, No.6 (Dec 2014)
Dilip Kumar et al Uses of Bottom ash in the Replacement of fine aggregate for Making Concrete

 High transportation cost. Seals etal. (1972) presented data obtained from West
 Non-availability of dry fly ash and bottom ash. Virginia bottom ash. The standard Proctor maximum
 Lack of proper co-ordination. densities varied between 11.6 and 18.4 kN/m3; the
 Easy availability of top soil. optimum water content ranged from 12 to 34%. They also
 Variations in the quality of coal ash. performed a series of one-dimensional compression tests
on West Virginia bottom ash. They showed that, at low
2.5 Application of Bottom ash in major areas stress levels, the compressibility of bottom ash was
comparable to natural granular soils placed at the same
Ash has been investigated for its suitability for utilization
relative density.
in major areas as building material and other civil
Abernethy et al. (1969) investigated the common
engineering sectors. The areas mentioned below have
constituents of more than 600 ash samples from
tremendous scope of large scale use of Bottom ash.
commercial coals in the United States. They found that
 Building bricks and block. coal ash was composed primarily of silica (SiO2), ferric
 Road construction, Drainage media and Sound oxide (Fe2O3), and alumina (Al2O3), with smaller
insulating walls. quantities of calcium oxide (CaO), potassium oxide (K 2O),
 It is used in mining mortar in such application as rock sodium oxide (Na2O), magnesium oxide (MgO), titanium
stabilization or filling of cavities. oxide (TiO2), phosphorous pent oxide (P2O5), and sulfur
 It is used as a construction material for highway and trioxide (SO3). In bituminous coal, three major
pavement. components (SiO2, Fe2O3 and Al2O3) accounted for about
 It is used for pressure grouting in concrete highways 90% of the total components, whereas lignite and sub-
and for other purposes viz, tunnel lining. bituminous coal ashes had relatively high percentages of
 It is used as mineral filler in asphalt roads to minimize CaO, MgO, and SO3.
void content and increase the stability of bituminous Cheriafetal (1999) reported the morphological
wearing course during road construction. characteristics of bottom ash by scanning electron
 It is used as a light weight synthetic aggregate in micrograph in terms of the shape and surface
block and concrete. characteristics of the particles; bottom ash was quite
 It is used along with bottom ash as a growing media different from fly ash. Bottom ash particles were angular
for plants. and irregular in shape and had rough surface. In next page
 In concrete, bottom ash is used as replacement of fine the Fig. no. 2.1 of morphology of bottom ash is shown and
aggregate in which concrete has advantageous has been taken from Brazilian coal ash.
properties like improved workability, resistance to
chemical attack.
3. Literature Review on Bottom ash

Jaturapitakkulet al. (2003) studied the potential of using

bottom ash from the Mae Moh power plant in Thailand as
pozzolonic material. He found bottom ash which was used
in concrete due to its pozzolonic reaction, improved its
quality by grinding until the particle size retained on sieve
325 was less than 5% by weight. Bottom ashes before and
after being ground were investigated and compared for
their physical and chemical characteristics. The bottom
ashes were used to replace Portland cement in mortar and
concrete mixtures. He found that the particle of bottom ash
was large, porous and a regular shapes. The grinding
process reduced the particle size as well as porosity of Fig 2.1 Morphology of Bottom Ash
bottom ash. Compressive strengths of mortar containing
20 to 30% of bottom ash as cement replacement were Table 3.4 Chemical characteristics of Anpara bottom ash
much less than that of cement mortar at all edges, but use
of ground bottom ash produce higher compressive strength Constituents Percentage (by weight)
than the cement mortar after 60 days. He used bottom ash SiO2 68.0
at 20% replacement of cement to make concrete, the Al2O3 25.0
concrete with higher cement content produce higher Fe2O3 + Fe3O4 2.18
percentage of compressive strength. He concluded that TiO2 1.45
ground bottom ash could be used Bottom ash as a good CaO 1.66
pozzolonic material. MgO 0.02
Huang et al. (1990) investigated the shear strength of SO4-- Nil
Indiana bottom ash and boiler slag compacted to different Loss on ignition 1.69
densities using direct shear testing. The reported friction
angles varied in a wide range from 35 to 55% depending Data as supplied by Anpara Thermal Power Project
on the density. Authority.
3892 |International Journal of Current Engineering and Technology, Vol.4, No.6 (Dec 2014)
Dilip Kumar et al Uses of Bottom ash in the Replacement of fine aggregate for Making Concrete

4. Materials Used Table 5.3 Physical Properties of Coarse Aggregates

The following materials were used for preparing the test Sr. No. Physical Property Test Result
specimens 1. Maximum Size (mm) 20
2. Fineness modulus 7.10
 Ordinary Portland cement 3. Specific Gravity 2.64
 Aggregates (Coarse Aggregate)
4. Bulk Density(gm/cc) 1.42-1.61
 Sand (Fine Aggregate)
5. Water Absorption (%) 0.15
 Bottom ash
6. Aggregate Crushing Value (%) 17.50
5. Experimental Program 7. Aggregate Impact Value (%) 14.40
8. Maximum dry density (kN/m3) 13.70
Properties of Material 9. Aggregate abrasion value (%) 28.10

The materials used in this experiment were Ordinary

Bottom Ash: Bottom ash is a hazardous by-product from
Portland Cement (OPC), bottom ash as fine aggregate and
coal based National thermal power plants.The properties
Potable water was used for mixing and curing.
of bottom ash are given in Table No. 4.
Cement: Ordinary Portland cement 43 grade in one lot Table 5.4 Physical Properties of Bottom ash
was procured and stored in air light container and it is very
fresh cement i.e., used within three month of manufacture Sr. No. Properties of Bottom ash Values
.The physical properties of cement are determined as per 1. Specific gravity 2.12
the IS 8112–1989 and result are physical property was
given below: 2. Bulk density( gm/cc) 0.642-0.747
3. Fines modules 6.28
Table 5.1 Physical Properties of Cement 4. Maximum dry density (kN/m ) 3
7.20
5. Water absorption (%) 14.10
Sr. No. Physical Properties Test results
6. Sizes produced(mm) 3.40-4.75
1. Consistency 32%
7. Aggregate impact value (%) 18.25
2. Initial setting time 90 min
8. Aggregate crushing strength (%) 19.30
3. Final Setting time 315 min
9. Aggregate abrasion value (%) 30.12
4. Specific Gravity 2.15
5. Water Absorption (%) 0.14 6. Results and Discussions
6. Fineness modulus 6.85
Compressive Strength

Fine Aggregate (Sand): The Fine aggregate use for Compressive strength of the specimen shall be calculated
casting in clean river sand from Ganga river Varanasi and by dividing the maximum compressive load taken by the
it was clean and dry. It is of size pass through 1.20 mm specimen by its cross-sectional area. Values of
sieve. Sand conforming to Zone-III was used as the fine compressive strength at different percentage of
aggregate, as per I.S 383-1970. The properties of the fine replacement at different age are given below.
aggregates are given in following Table No.2.
Compressive Strength variation with age
Table 5.2 Physical Properties of Fine Aggregates (Sand)
45
Compressive Strength (N/mm2)

Sr. No. Physical Property Test Result 40

3 Days
35
1. Fineness modulus 2.40 30 7 Days
2. Specific Gravity 2.65 25
20 14 Days
3. Bulk Density(gm/cc) 1.53-1.58
15
28 Days
4. Water Absorption (%) 0.72 10
5 56 Days
Coarse Aggregates: The coarse aggregate used was 0
90 Days
broken granite-crushed stone and it was free from clay,
weeds, and any other organic matters, they are non-
porous. The water absorption capacity is less than 1%. The Percentage of replacement of sintered fly ash aggregate
size of which pass through 26 mm sieve and retained on
19 mm sieve. The properties of the coarse aggregate are
given in following Table No.3. Figure 6.1Compressive strength at various ages
3893 |International Journal of Current Engineering and Technology, Vol.4, No.6 (Dec 2014)
Dilip Kumar et al Uses of Bottom ash in the Replacement of fine aggregate for Making Concrete

Table5.5 Compressive Strength of Concrete with Bottom ash

Days 0%BA(N/mm2) 10% BA 20%BA 30%BA 40%BA 50%BA

(N/mm2) (N/mm2) (N/mm2) (N/mm2) (N/mm2)
7 23.56 26.67 28.12 31.67 32.14 28.34
14 28.18 30.98 32.14 33.52 34.85 30.42
28 30.40 32.40 33.40 35.17 36.20 32.25
56 32.87 35.28 36.70 38.23 39.16 33.42

Table 5.6 Flexural strength at different ages (N/mm2)

Days 0%BA 10%BA(N/ 20%BA 30%BA 40%BA 50%BA

(N/mm2) mm2) (N/mm2) (N/mm2) (N/mm2) (N/mm2)
7 2.20 3.35 5.10 6.80 7.94 4.51
14 3.10 5.11 6.95 8.10 8.80 6.89
28 3.40 6.25 7.66 8.70 9.04 7.40
56 4.27 7.00 8.18 8.98 9.24 7.85

6.2 Flexural Strength days, 14 days, 28 days and 56 days respectively at 40%
replacement of bottom ash in concrete while minimum
For flexural test beams of 150×150×700 cubic mm size flexural strength of concrete is found 2.20 N/mm2, 3.10
were adopted. The load was applied without shock and N/mm2, 3.40 N/mm2 and 4.27 N/mm2 is at 7 days, 14 days,
was increased until the specimen failed, and the maximum 28 days and 56 days respectively when there is no
load applied which is on the meter to the prism during the replacement of bottom ash in concrete. After 40%
test was recorded. The appearances of the fractured faces replacement of bottom ash in the concrete it is found that
of concrete failure were noted. Three-point load method the flexural strength is decreasing.
was used to measure the flexural strength of bottom ash To increase the speed of construction, enhance green
aggregate concrete. construction environment we can uselightweight concrete.
The possibility exists for the partial replacement of coarse
Flexural strength variation with ages aggregatewith bottom ash aggregate to produce in thermal
12 power plants waste materials. Bottomash is compatible
Flexural strength (N/mm2)

with the cement. Uses and applications of bottom ash as

10 3 Days
fine aggregate can reduce the cost of construction
8 7 Days Materials and it is useful in environmental protection also.
6 14 Days References
4 28 Days
Ghafoori, N., and Bucholc, J. (1997).Properties of high-calcium
2 56 Days dry bottom ashconcrete. ACI Mater.J., 94(2), pp.90–101.
M.P. Kadam, and Y.D. Patil, Effect of Coal Bottom Ash as Sand
0 90 Days Replacement on theProperties of Concrete with different W/C
ratio, International Journal of AdvancedTechnology in Civil
Engineering, vol. 2, Issue 1, 2013, pp.45-50.
Sivasundram and Malhotra, V.M., High performance high
Percentage replacement of sintered fly ash aggregates
volume fly ash concrete,Indian Concrete Journal, Nov (2004)
13-21.
Figure 6.2Flexural strength at various ages Hiroshi K., Jinhwan J., Hiroki W., Eiichi F., Kiminori T & Akio
S. (2008),Development of Artificial High Strength Light
Conclusion Weight Aggregate made from Coal Ashexpanding Shale
Powder.,Journal of structural and construction engineering. pp
1425 1432.
From above investigation we found that the maximum
P. Aggarwal, Y. Aggarwal, and S.M. Gupta, Effect of Bottom
compressive strength of mix proportion is 32.14 N/mm2, Ash as replacement ofFine Aggregates in Concrete, Asian
34.85 N/mm2, 36.20 N/mm2and 39.16 N/mm2at 7 days, 14 Journal of Civil Engineering (Building andHousing), vol. 8,
days, 28 days and 56 days respectively at 40% No.1, 2007, pp.49-62
replacement of bottom ash in concrete while the minimum RafatSiddique Effect of fine aggregate replacement with Class F
compressive strength is found 23.56 N/mm2, 28.18N/mm2, fly ash on themechanical properties of concrete, Cement and
30.40 N/mm2 and 32.87 N/mm2 is at 7 days, 14 days, 28 Concrete Research, vol. 33, 2003,pp.539–547.
days and 56 days respectively when no replacement of YogeshAggarwal, RafatSiddique, Microstructure and properties
bottom ash in concrete. After 40% replacement of bottom of concrete usingbottom ash and waste foundry sand as partial
replacement of fine aggregateConstruction and Building
ash in the concrete it is found that the compressive Materials Volume 54, 15 March 2014, 210-223.
strength is decreasing. S.Lokesh,M.G.Ranjith Kumar, S.Loganathan Effective
The maximum flexural strength of concrete is found Utilization of High Volume Flyash with Light Weight
7.94 N/mm2,8.80 N/mm2, 9.04 N/mm2and 9.24 N/mm2at 7 Aggregate in Concrete for Construction industry; 2013.
3894 |International Journal of Current Engineering and Technology, Vol.4, No.6 (Dec 2014)
 Dilip Kumar et al Uses of Bottom ash in the Replacement of fine aggregate for Making Concrete

M.S.Shetty(2013).Concrete Technology,S.Chand& co Publising Geetha, S., Ramamurthy, K., (2011), Properties of sintered low
Company. calcium bottom ashaggregate with clay binders Construction
IS 10262-1982 recommended guide lines for concrete mix and Building Materials, 25, pp2002-2013.
design. Saikia, N., Cornelis, G., Mertens, G., Elsen, J., Van Balen, K.,
IS 8112:189, Specification for 43 grades OPC, reaffirmed 1997. Van Gerven, T.,Vandecasteele, C. (2008).Assessment of Pb-
Properties of High-calcium Dry Bottom Ash Concrete, ACI slag, MSWI bottom ash and boiler and flyash for using as a
Materials Journal, (1997)pp.90-101. fine aggregate in cement mortar.Journal of Hazardous
Bai Y, Basheer PAM. Influence of furnace bottom ash on Materials.Volume 154, Issue 1-3, pp.766- 777.
properties of concrete Iceproceedings, structures and Berg, E. and Neal, J.A. (1998) Concrete masonry unit mix
buildings, special issue new materials and new uses of forold designs using municipalsolid waste Bottom ash, ACI Mater. J.
materials 2003; 156(1): pp 85–92. 95 (4) pp.470–479.
Ghafoori, N., Cai, Y., and Ahmadi, B. (1997), Use of dry bottom ChandanaSukesh, KatakamBala Krishna, P. Sri Lakshmi SaiTeja
ash as a fine aggregatein roller compacted concrete, ACI Spec. and S. KanakambaraRao,(2013) Partial Replacement of Sand
Publ. (SP-171) pp. 487– 507. with Quarry Dust in Concrete, InternationalJournal of
Ghafoori, N., Cai, Y. (1998), Laboratory-Made Roller Innovative Technology and Exploring Engineering, vol. 2,
Compacted ConcretesCointaining Dry Bottom Ash: Part II- Issue 6, pp.254-258.
Long-term Durability, ACI Materials Journal,Vol. 95, No. 3, A.U Abubaker, KhairulSallehBaharudhen,(2012) Properties of
pp.244-251. concrete using Tanjhunbin powder plant bottom
Bai Y and Basheer P.A.M. (2003) Influence of furnace bottom ash,international journal of construction engineering
ash as fine aggregate onproperties of concrete. Structures and andtechnology, vol. 3, Issue
Buildings Vol. 156, No. 1,pp 85-92. K. SomanDivyaSasi K.A Abubaker,(2014) Strength properties of
Kazuhiro Hasezaki, AkifumiNakashita, Gen-yo Kaneko1and concrete withpartial replacement of sand by bottom
Hideaki Kakuda,(2007),Unburned Carbon Behavior in ash(IJIRAE) ISSN: 2349-2163 Vol.1Issue7,pp 223-227
Sintered Coal Fly-Ash Bulk Material by Spark PlasmSintering, http://ijirae.co
Materials Transactions, Vol. 48, No. 12 pp. 3062 to 3065 Jaturapitakkul C and Cheerarot R (2003),Development of Bottom
,SpecialIssue on Growth of Ecomaterials as a Key to Eco Ash AsPozzolanic Material, Journal of Materials In Civil
Society III #2007 The Japan Instituteof Metals. Engineering, Jan-Feb.pp.48-53.
DjwantoroHardjito.C and Shaw ShenFung(2009) Parametric P. Bhuvaneshwari* and R. Murali,(2013), Strength
Study on the Propertiesof Geopolymer Mortar Incorporating characteristics ofglass fibre on bottom ash based concrete
Bottom Ash Selected paper from the Asia PacificStructural International Journal ofScience, Environmentand Technology,
Engineering Conference, APSEC. Vol. 2, No 1,pp 90 – 10
Arvind Kumar and Dilip Kumar, (2014) Strength Characteristics Kim, H.K. and H.K. Lee, (2011) Use of power plant bottom ash
of Concrete with Sintered flyash Aggregate Journal of IJSRD as fine and coarseaggregates in high strength concrete. Constr.
Volume 2, Issue 7, Sept-2014. Build. Mater., 25: 1115-1122.
Yu-shun Guo et al. (2000)Comparison of properties of high Mangaraj, B.K. et al., (1994). Use of ponded fly ash as part of
performance lightweightaggregate and normal lightweight replacement of fineaggregate in mortar and concrete. ICJ, pp:
aggregate. Journal of Concrete (China),(6), pp.22-26. 279-282.
Majidzadeh, K., EI-Mitiny, R. N., and Bokowski, G. Cheriaf M, Cavalcante J and Pera J (1999) Pozzolanic properties
(1977).Power Plant Bottom Ashin black base and bituminous of pulverized coalcombustion bottom ash Cement and
surfacing. Vol.2, Users Mannual, Federal Concrete Research Vol. 29, No.9, pp387-391
HighwayAdministration, Report No. FHWA/RD-78-148, Targan S, Olgun A, Erdogan Y and Sevinc V (2004)Mineralogy
Washinton, D.C. and Organic MatterContent of Bottom Ash Samples from
S. Shanmugasundaram at al (2010) Study on Utilization of Fly AgiosDemitrios Power Plant, Greece Bulletinof the Geological
Ash Aggregates inConcrete Modern Applied Science, Society of Greece Vol. 36, Proceeding of the 10th
www.ccsenet.org/mas, Vol. 4, No. 5;pp. 44-56. internationalCongress, Thessaloniki, 321-6.
Neetesh Kumar, Dilip Kumar,(2014) Strength Properties of Dilip Kumar, Arvind Kumar, Ashish Gupta
Coconut Shell as CoarseAggregate In Concrete International (2014)Replacement of Coarse Aggregate with Sintered Fly
Journal of Computer & Mathematical SciencesIJCMS ISSN Ash Aggregates for Making Low Cost Concrete IJSRD -
2347 – 8527 Vol. 3, Issue 5.pp43-52. International Journal for Scientific Research & Development|
Vol. 2, Issue 08, ISSN (online): 2321-0613,pp307-310.

3895 |International Journal of Current Engineering and Technology, Vol.4, No.6 (Dec 2014)

View publication stats