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Experimental Study on Partial Replacement of Fine Aggregate by

Ceramic Waste in Concrete
Khaja Amer Uddin1, Mohammad Abdul Mujtaba2, Syed Adil Saarib3, Ms. Nanchari Kanchala4
1, 2, 3B.EStudents, Dept. of Civil Engineering, ISL Engineering College, Hyderabad
4Assistant Professor, Dept. of Civil Engineering, ISL Engineering College, Hyderabad
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Abstract - Waste and find the solution of resulting it the fine aggregate acts as an essential element in the
most serious problem of the word today. Waste utilization has construction field. In the present condition the demand of
become an attractive alternative to disposal now days. There sand is going increased, and it leads to the gradual cost
are number of researches, for use of waste in industry most of increment of river sand. Thus the M-sand have being
them related to use these waste in construction are or use of implementing in present situation. But, some of the criteria
waste in concrete to develop new type of concrete. Use of regarding the manufacturing of M-sand are limited in a
waste producing is not only makes it economical but also a particular amount. So, still the demand of sand is there, so
very good and attractive solution of disposal problem. Ceramic introducing the new fine aggregate from waste ceramic tiles,
waste from ceramic industry is used to produce a new type of by crushing it to get the required size. The 30% of ceramic
concrete by replacing the cement. According a report in India products are being waste daily, so there is a small cost for
30% of the daily production goes on waste during the this waste or sometimes it has no cost because the ceramic
manufacturing, usages and transportation. Ceramic waste products can’t be recycled and re-used. The utilization of
increases day by day because of its usages in construction, so it concrete in Indian construction industries is at the rate of
is necessary for ceramic industry for diminishing the waste about 400 million tons per year and if this continues it may
dump at ceramic industries is recycling, reusing and reach a billion tons in less than a decade. Concrete is made of
substitution of concrete ingredients. Ceramic waste produce various aggregates present in the earth's crust, in this
from industry is durable, hard, and highly resistant to manner its assets are consistently drained causing
biological, chemical and physical degradation forces. Ceramic ecological strain. Environment is also been affected by
waste powder can be used to produce lightweight concrete, various human actions which deliver solid waste in
without affecting. The compressive strength of the concrete is significant amounts i.e., more than 2500 million tons per
improved by the use of optimal dosage of ceramic tile powder. year, inclusive of all the industrial, medical, agricultural and
Utilization of Ceramic waste is one of the active research area other forms of waste from the rural and urban areas.
that encompass the effectiveness of replacement in all the Clearance of all these solid wastes causes various issues and
aspects of construction materials. It is very essential to develop complication thereby affecting the ecology. Presently large
eco-friendly concrete from ceramic waste. This paper deals amounts of ceramic wastes are generated in ceramic
with the experimental study on the mechanical strength industries which would have an important impact on
properties of M25 grade concrete with the partial replacement environment and humans. But now a days the awareness
of sand by using ceramic waste. In order to analyze the regarding the use of these ceramic waste in construction
mechanical properties such as compressive, split tensile, field has increased. Even this type of usage produce solid
flexural strength, the samples were casted with 10%, 20%, waste but the disposal of them is not much complicated
30%, 40%, replacement of sand using ceramic waste and compared to the waste and pollution by the source
tested for different periods of curing like 7 days, 14 days and industries. The non-biodegradable ceramic materials used
28 days. The optimum of percentage addition of Ceramic for Floor tiles, wall tiles, and weather course tiles, sanitary
waste is analyzed considering the requirements of mechanical ceramic products, electrical ceramic insulators and ceramic
properties of concrete. utensils etc. can be conveniently recycled into concrete
elements for various service and locations. This
Key Words: Ceramic wastes, Partial replacement, Eco- replacement has numerous ad-vantages such as the
friendly, Behavioural study. economy, using as sustainable material and reduction solid
waste disposal and minimize the environmental hazards.
1. INTRODUCTION Ceramic tiles possess a broad range of properties, and
certain tiles are better suited for some installations than
T he ceramic waste and will help to increase the high others. Few tiles are fitted for all types of installations;
compressive strength of the concrete when compared to the consequently, good knowledge of the properties is essential
other materials. Considering the environmental factors we for the consumer to achieve the desired and look forward
can recycle the Construction and debris waste used in the value of the tile. Because so many tile installations are built
concrete. Concrete is an essential construction material around or near water, and because due to porous materials it
which is usually associated with Fine aggregate henceforth can soak up the moisture and dock unwanted organisms,

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absorption is one of the most important properties, that is concrete mix M25 has been used. The concrete with
because, in wet-area applications, it can involve health and ceramic waste as a partial replacement of fine aggregate
safety issues, and in exterior applications, it can initiate are used and the results have been evaluated. The
important freeze/thaw damage. Ceramic waste can be properties of ceramic waste fine aggregate concrete are
separated in two categories in compliance with the origin of not significantly different from those of conventional
raw materials. The first one are all fired waste generated by concrete. The compressive strength and split tensile
the ceramic factories that use only red paste to manufacture strength of concrete made using ceramic waste up to
their products, such as brick, blocks and roof tiles. The 30% replacement of fine aggregate, the strength
second one is all ignited waste manufactured in stoneware increases.
ceramic such as wall, floor tiles and sanitary ware. The
ceramic industry is comprised of the following sub-sectors  Dr. M.Swaroopa Rani, “A Study on Ceramic Waste
like wall and floor tiles, sanitary ware, bricks and roof tiles, Powder”(2016)The study shows that the addition of the
stubborn materials and ceramic materials for domestic and industrial wastes improves the physical and mechanical
ornamental. properties..The Compressive Strength of M40 grade
concrete increases when the replacement of cement with
ceramic waste is up to 10% by weight of cement, and
further replacement of cement with ceramic powder
decreases the compressive strength.

 Aruna D : For tile waste based concrete, coarse

aggregates were replaced by 20mm down size, tile
wastes by 0% , 5%, 10%, 15%, 20% and 25% and also
the cement is partially replaced by fly-ash. The average
maximum compressive strength of roof tile aggregate
concrete is obtained at a replacement of 25%. A
reduction of 10-15% of strength is observed compared to
conventional concrete at 25% of roof tile aggregate
replacement. The workability of roof tile waste concrete
is in the range of medium. Overall, the replacement of
Fig -1: Sample Ceramic aggregates tiles in concrete is satisfactory for small constructions.

2. LITERATURE REVIEW  Batriti Monhun R. Marwein : The ceramic waste adopted

is broken tiles. Ceramic waste concrete (CWC)made with
these tiles at 0%, 15%, 20%, 25% and 30%. M20 grade
 G. Sivaprakas, v. Saravana kumar and lakhi jyoti saikia,
concrete is adopted; a constant water cement ratio of
“Experimental Study on Partial Replacement of Sand by
0.48 is maintained for all the concrete mixes. The
Ceramic Waste in Concrete”(2016) says clearly that the
characteristics properties of concrete such as workability
ceramic waste can be used as replacement materials for
for fresh concrete, also Compressive Strength, Split
river sand in concrete. The concrete with 10 and 20%
replacement satisfies the compressive strength of M25 Tensile Strength are found at 3, 7 and 28 days. The paper
suggests that the replacement of waste tile aggregate
grade however higher the percentage addition of ceramic
should be in the range of 5-30% and also it is suitable to
waste reduces the strength of normal concrete. The
tensile strength of 10, 20, 30% replacements at 14 days ordinary mixes like M15 and M20.
shows the consistency in attaining the required range.
Hence the replacement of river sand using 30% ceramic  Parminder Singh and Dr. Rakesh Kumar Singla : A
waste in concrete gives the required strength and can be research paper on utilization of ceramic waste tiles from
considered as optimum percentage industries. A partial replacement to coarse aggregate has
been studied. Three different grades of concrete has been
prepared and tested. The results are not appropriate with
 C.Karthik and S.Ramesh Kumar, “Experimental
the conventional but considering the strength properties,
Investigation on Concrete with Ceramic Waste as A
it is advisable to use ceramic tile aggregate in concrete. It
Partial Replacement of Fine Aggregate”(2016) Ceramic
wastes are the main problem of tile industries and from is finally concluded that, about 20% of ceramic tile usage
in M20 grade of concrete is preferable.
demolition buildings. The aim of this investigation was
the utilization of ceramic waste collected from dressing
and polishing of metal or non-metal compounds in  Paul O. Awoyera : The usage of ceramic tiles in concrete
concrete as fine aggregate. The use of ceramic waste in was observed in this paper. In this, both the coarse and
concrete as positive effects on the environment and fine aggregates are replaced with ceramic fine and
obtaining lower costs. In this experimental investigation, ceramic coarse aggregates obtained from construction

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sites of Ota, Lagos and Nigeria in various percentages. 3. PROPERTIES OF MATERIALS AND METHODOLOGY
The ceramic fine and coarse aggregates are replaced in
conventional concrete individually and the strength Ceramic Waste:
parameters are studied. Finally, it states that usage of Tiles Ceramic waste is accessible from vast ceramic
ceramic waste in concrete gives considerable increase in industrial facilities, ceramic item producing units and from
strength compared to conventional concrete. regular development exercises. Customary ceramics, for
example, blocks, rooftop and floor tiles, other development
 P. Rajalakshmi: Use of ceramic waste will ensure an materials, and specialized ceramics, for example, porcelain
effective measure in maintaining environment and are normally very heterogeneous because of the wide
improving properties of concrete. The replacement of compositional scope of the common mud utilized as crude
aggregates in concrete by ceramic wastes will have major materials. Around 300 kg of wastes from an Indian ceramic
environmental benefits. In ceramic industry about 30% organization (RAK Ceramics Pvt. Ltd., Chennai) was smashed
production goes as waste. The ceramic waste aggregate is with an altering pole physically to make the ceramic
hard and durable material than the conventional coarse aggregate. In this manner, by utilizing this framework to
aggregate. It has good thermal resistance. The durability pound a ceramic waste is conceivable to acquire coarse
properties of ceramic waste aggregate are also good. This aggregates, fine aggregates. And ceramic powder that
research studied the fine aggregate replacement by subsequent to sieving (IS 4.75 mm strainer) can be utilized
ceramic tiles fine aggregate accordingly in the range of without extra work and with insignificant cost suggestions.
10% and coarse aggregate accordingly in the range of
30%, 60%, and 100% by weight of M-30 grade concrete. Cement
This paper recommends that waste ceramic tiles can be Ordinary Portland cement of 53 grade conforming to IS
used as an alternate construction material to coarse and 8112-1989 was used. The initial setting time of cement is 30
fine aggregate in concrete irrespective of the minutes and the specific gravity of cement is 3.15.
conventional concrete; it has good strength properties
i.e., 10% CFA and 60% CCA being the maximum strength.

 Prof. Shruthi H. G.: Ceramic tiles were obtained from

manufacturing industries, from construction and
demolition sites, this cause’s environmental pollution.
The utilization of crushed tile as a coarse aggregate in
concrete would also have a positive effect on the Table-1 Properties of cement
economy. study, Ceramic tile waste were used in concrete Fine aggregate
as a replacement for natural coarse aggregate with 0%, Natural river sand which is locally available obtained from
10%, 20% and 30% of the substitution and M20 grade the Godavari river is used as fine aggregates. Manufactured
concrete were used. The concrete moulds were casted sand with fraction passing the 4.75mm sieve and retained on
and tested for Compressive Strength and Split Tensile the 600micron sieve was used and fineness modulus of 4.04
Strength after a curing period of 3, 7 & 28 days. The with the specific gravity of 2.64 was used. The grading zone
results indicate that, the maximum compressive strength of aggregate was zone 2.
is obtained for the 30% replacement of ceramic tile
aggregate with natural coarse aggregate. Coarse aggregate
Aggregates greater than 4.75mm are considered as aCoarse
 Wadhah M.Tawfeeq : This study investigated the effects aggregate. Crusted granite coarse aggregate of 20mm
of using crushed tiles (CT) as coarse aggregates in the downsize were used and the fineness modulus of 4.32 with a
concrete mix. The technology of concrete recycling is well specific gravity of 2.63 was used.
established in the U.S. Recycling of Portland cement
concrete, as well as asphaltic concrete, has been shown to Water
be a cost-effective alternative for road, street and Water to be used for the Mixing and Curing purpose of
highway construction. It includes not only the water cement concrete should be free of dirt and pollution. As per
content and tiles but also the gravel/sand ratio. They the IS: 456-2000 specifications.
concluded that as the water cement ratio decrease, the
compressive strength increases. The paper consists of Methodology
replacement of crushed tiles to 50% and 100% only. The Collection of material: for ceramic waste for concrete and
results show that replacement of crushed tiles as coarse materials are collected like normal grade of cement,
aggregate below 50% will have considerable properties. aggregates, water.

Weighing and mixing process: material are weighed in

proper ratio as per design and after then mixed in proper
way. Moulding process: concrete mixer is molded in cube
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sized 150*150*150 mm3 and beam size of 500*100*100

mm3. Removing of mould After 24 hours the moulds are
removed. Curing process: concrete cubes and beams are 80
cured in fresh water for 7 days to 28 days. Testing process: 70
after removing the moulds, concrete cubes and beams are
60
tested in campus concrete laboratory. Analysis and test
result: after various test on cube and beams, result are 50
calculated. 40
30
In this research paper, M25, mix proportion is designed as
per guidelines of Indian Standard recommended method IS 20
10262:2009. We used 53-grade cement; also zone 2 is taken 10
into consideration from IS 383(1970) for fine aggregate. The
coarse aggregate is selected passing through 20mm and 0
M-0 M-10 M-20 M-30 M-40
retained on 10mm Sieve.
Slump Value 75 62 54 47 38

Table -4 Slump values

Compressive Strength
Compressive strength tests were conducted on cured cube
specimen at 7 days and 28 days age using a compression
testing machine of 200 kN capacity. The cubes were fitted at
Table-2 Material Quantity center in compression testing machine and fixed to keep the
cube in position. The load was then slowly applied to the
Ceramic tested cube until failure.
Mix
Cement FA CA waste as
Designation Concrete cubes of size 150mm x150mm x 150mm were
FA
M-0 100% 100% 100% 0% casted for 0%, 10%, 20%, 30%, 40%, ceramic aggregate
replacement. The compressive strength for M25 grade of
M-10 100% 90% 100% 10%
concrete is tested for 7, 28 days of curing and the results are
M-20 100% 80% 100% 20% tabulated and plotted.
M-30 100% 70% 100% 30%
M-40 100% 60% 100% 40% Ceramic Cube
waste as
Table-3 Details of Replacement by sand Sl.no Mix (days) FA Compressive
replace strength (N/mm2)
ment%
4. RESULTS AND DISCUSSIONS
0% 17.14
All the tests have been performed in standard procedures 10%
and the results and load values obtained were tabulated and 18.6
calculated in following sections. 20%
1 7 18.86
Workability 30% 25.23
Slump of Concrete Mixes
The use of fine ceramic aggregate as replacement of sand in 40% 22.9
concrete mixes resulted in a decrease in the slump as the
percentage of the replacement ratio increases as shown in 0% 26.37
Fig... When replacement of coarse aggregates reached 40%,
the loss in slump was 61.1%, while loss in slump reached 10% 28.60
100% when replacement level of fine aggregate was 60%.
20% 29.03
This expected reduction of slump is due to the high water 2 28
absorption of ceramic aggregates.
30% 38.83
40% 35.30

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Table-5 Compressive Strength values

5
40
4
35
3
30
28 days
2
25 M-0
M-10 1
20
M-20
0
15 M-30
M-0 M-10 M-20 M-30 M-40
M-40
10

5 Chart -2 Split Tensile Strength

0
7 days 28 days 5. SUMMARY AND CONCLUSIONS

The present research focused on investigating the mechanical

Chart -1 Compressive Strength and physical properties of the recycled ceramic tile aggregate
Split Tensile Strength and the different characteristics of concrete incorporating
this type of aggregate compared with concrete made of
The split tensile test were conducted as per IS 5816:1999. natural aggregate.
Concrete cylinders of size 150mmx300mm were casted for
0%, 10%, 20%, 30%, 40% replacement of ceramic aggregate. Based on the results of the experimental work carried out in
The split tensile strength for M25 grade of concrete is tested this research, the following conclusions could be drawn.
for 28 days of curing and the results are tabulated and plotted The test results show clearly that the ceramic waste can be
below used as replacement materials for river sand in concrete.
Ceramic Cylinder The use of ceramic aggregates enhances some of the concrete
waste as properties such as compressive strength due to decrease in
Sl.no Mix (days) FA Split Tensile free-water. On the other hand, a decrease in workability was
replace strength (N/mm2) detected as the percentage of replacement increases since
ment% ceramic has high water absorption. Therefore, slump
0% 3.09 decreases as percentage of ceramic waste replacement
increases for all cases. The decrease was remarkable in case
10% 3.23 of fine ceramic aggregate
20% 3.96 The concrete with 10%, 20%, 30% & 40% replacement
1 28 satisfies the compressive strength of M25.
30% 4.41 The tensile strength of 10, 20, 30% replacements at 28 days
shows the consistency in attaining the required range.
40% 4.34
Hence the replacement of river sand using 30% ceramic
waste in concrete gives the required strength and can be
considered as optimum percentage.
Table -6 Split Tensile Strength values
ACKNOWLEDGEMENT

We are thankful to Dr. Mohammed Masood, Principal,

ISLEC, for his encouragement throughout the project. We
would also like to express our heartfelt thanks to Ms. K.
Nanchari, Head of Civil Engineering Department, ISLEC for
her help and unending cooperation with us during
completion of this work.

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