INTRODUCTION

Rapid growth in population and urbanization are pushing the growth in

construction. Especially in the developed countries, old buildings are
being demolished to be replaced with new one. But most of the
construction and demolished waste is used in land filling of low laying
area. But research in different countries has suggested the possibility of
reusing hand inert material in recycled aggregate concrete. It may be
point out that, the Asia alone produces about 760 million tons of
construction waste every year. In India, the waste from construction
industry is estimated to be about 12 to 14.7 million tones per annum. But this
demolished part such as, broken concrete and bricks mostly from building
can be used for recycled aggregate concrete.

The idea of recycling concrete waste as coarse aggregate for new

concrete construction is gaining importance on the international scale.
Recycling is a process of recovery and subsequent use of a material for the
manufacture and/or fabrication of the same similar product from which
the waste was originated.

Using the recycled aggregate concrete, we can reduce the cost of

transportation of demolition waste for disposal. Also, reduction in
material cost by utilizing recycled aggregate concrete produced from
demolished waste. Another benefit or economy achieve, from saving in
transportation cost of raw material. Also we can reduce the environmental
impact. However, an important question remains about the strength
parameters of recycled aggregate concrete. This is discussed in the
project.

1
 OBJECTIVES

• To reduce or utilize the waste generated fromstructure.

• To comparethestrengthof natural aggregate and recycled aggregate.

• To reduce the production cost of concrete in termsof natural resources, energy

and economic cost.

• Modifying the mechanical and physical properties of concrete in the

fresh and hardened state.

2
 SCOPE OF THE PROJECT
As far as concrete construction is concerned it has a history of hundred years, the
demolition has already started producing huge quantities of rubble and the
quantity

LITERATURE REVIEW
Recycling is a process of recovery and subsequent use of a material for the
manufacture of the same or similar product from which the waste was originated.
The made with used concrete aggregate is known as recycled concrete.
It is worthwhile to consider the potentiality of utilizing the waste material
from demolitions etc. instead of throwing it away which incurs a lot of
transportation expenditure. The necessity for the use of recycled aggregate
in concrete arisesdue to the following reasons:

 Diminishing supply of natural aggregate.

 Diminishing dumping area within urban limit..

So therefore it is the very need of present generation to study the
properties of recycled aggregate concrete and a comparison with natural
aggregate properties to serve the industry. Therefore it is worth mentioning
that studies on durability of recycled aggregate concrete have been the subject
of this era for civil engineers. Some studies on recycled aggregate concrete are
discussed below:
Padmini A.K. (November 2009), studied about the influence of parent
concrete on the properties of recycled aggregate concrete. Some of the
salient observation of these studies are the significant effect on recycled
aggregate concrete. As per the results the water absorption capacity of
recycled aggregate increased with increase in strength of parent concrete from
which recycled was derived. In order to achieve design compressive strength,
recycled aggregate concrete required lower w/e ratio and higher cement content
with respect to fresh granite aggregate.
3
Kiyoshi Eguchi (March 2007), developed a production method for recycled
aggregate. As per the research, charactersties of strength, durability,
structural performance and workability of recycled concrete were
investigated. According to mechanical properties tested. among the
concrete properties of recycled concrete, the compressive strength and the
drying shrinkage strain were affected by replacement ratio of recycled coarse
aggregate. When recycled concrete was produced by the present method,
the cost and the environment loads was decreased in a comparison to
construction without recycling.

Dr. S. Chakraborty and Prof. P.G.Bhattacharya (January 2006), faculty

members of dept. Of civil engineering of Bengal Engg. College presented a
paper, which deals with the statistical property of recycled aggregate
concrete

Tam C.M. (June 2005), according to the absorption rates. The

experiment showed that the compressive strength of RAC was
enhanced by two stage mixing approach. This two stage mixing
approach gave way for the cement slurry to gel up the recycled
aggregate by which stronger ITZ is provided and as a result
cracks and pores within the recycled aggregate were filled.

4
K Sahu, Sunil Kumar and A. K. Sachan (January 2003),
conduct the test and conclude that, the crushed stone waste as fine
aggregate for concrete can be use effectively to replace natural
sand in concrete. Concrete made with this replacement can attain
the same or significant increase in compressive strength and split
tensile strength. If 40% sand is replaced by the stone dust in
concrete, it will reduce the cost of concrete as well as it save large
Quantity of natural sand.

S. Mandal, A.Chakraborty and A.Gupta (June 2002),

conducted the tests at kolkata and concluded that the strength of
RAC (Recycled Aggregate Concrete) is comparatively lower than
that of similar mix of NAC (Natural Aggregate Concrete).
However with the use of fly ash, it may be possible to produce
RAC with an improvement in strength. Therefore, the Results of
this study provided a strong support for the feasibility of using
recycled aggregates Instead of natural aggregates for the
production of concrete

5
3. SYSTEM DEVELOPEMENT
3.1 Production of recycled aggregate
There are certain processes & equipment which are available for
recycling of aggregates are given below. With the help of these processes &
equipment, we can obtain the contraction material such as recycled
aggregate which are of required quality.
3.1.1 General Processes
The following are the most commonly used processes for the production of
recycled aggregates, which are,
1) Crushing
2) Grinding
3) Screening
Process for recovery of coarse aggregates which is shown in fig given
below.
Also the fig, shows component parts at site.

6
3.1.2 Component Parts
i) Fred stock
It is the first component part of recycling processes. It is important
part for recycling of aggregates. Feed stock is the stock, which contains
construction & demolished waste (C&D waste) excavated material,
rocks, concrete waste, ele
ii) Crushers
Crusher helps for crushing the waste to a required size for further
process.
iii) Screen
Screen is helpful for sizing the crushed material to a desired size, which
can be used for construction works. It is also helpful to separate the coarse
aggregate & fine aggregate From waste

iv) Belt Conveyor

It is used to feed the material to various processing units
v) Weight bridge
It is used for weighing purpose.
vi) Loading shovel
To load feed stock to the crushers for crushing process.

7
3.1.3 Recycling process

In the process of recycling of aggregates, the first process involved is

crushing. The waste material at site undergoes process of crashing. The
process of crushing and its different types are given below.
1) Crushing process
Crushing is another important and commonly used process involved in
the recycling of aggregates, Crushing is the process of breaking or crushing
the feedstock, by mechanical means to get the recycled material from the
waste, for its direct use or for further processing.
In the crashing process the feed stock is crushed or grinded by the
mechanical means Main get objective of crushing in recycling of aggregates
is for reducing the material to a quid size for processing or its use, and to
produce material of specified size range different types of crushing process
are given below,

I) Cone crusher
The cone crusher is comprised of a vertical conical chamber with a feed
opening at the top and a vertical conical crushing head inside. The crushing
head is lined with protective called concaves. The feedstock is crushed by
the closing of the gap between the mantle

8
II) Crushing plant:-
This is large static or semi mobile assemblies containing several pieces
of equipment. Crushing plants may contain a range of equipment. Such
as a pre screener, loading conveyor, intake hopper, magnetic separator,
crushing unit (jaw crusher, crane crusher etc) screens, undersized
conveyor and oversized conveyor (perhaps returning material for further
crushing These plants are used where considerable availability of raw
material.

III) Impact crushers:-

These are available in several forms for example, vertical shaft
impactors, hammer mills, ball mills & rod mills (these final two are less
likely to be used in recycling for aggregate production) Hammer mills
comprise a horizontal rotor with hammer attached, spinning at high
speed within a hammer lined with breaker plates. The feedstock enters
at the top of the chamber & passes through a discharge plate at the
bottom when it is of the correct size. The rotor spins at between 750 &
1800 rpm.

The feedstock is broken by the combination of direct impact by the

hammers, impact with the breaker plates lining the chamber, and impact
with other particles of the feedstock. Hammer mills are compact and
relatively low cast.
However, they are not suitable for hard material and can suffer form wear.
Vertical shaft Impactors can overcome problems associated with the
crushing of abrasive feedstock. Theycomprise of an impact chamber with
a feed point at the top within this chamber a horizontal table spins at high
speed. This throws the feedstock towards hardened alloy wheels at high
speed, where it breaks. Two main forms of impact chamber are produced,
one where the feedstock impact on hardened metal, the other where the
feedstock impacts on accumulated material. The latter has less wear, but
the former gives a better reduction ratio.

9
IV) Jaw crusher:-
These are primary crushers used for the processing of hard feedstock,
such as rock & concrete. This is done by a pair of manganese steel
plates, one jaw is fixed & the other moves back & forth. The jaws are
positioned so there is a wide opening at the top. known as the gape & a
narrow discharge aperture at the bottom, set to the desired out put Size.
The feedstock is progressively crushed, getting smaller & smaller as it
travels downward towards the discharge aperture. The motion of the
moving jaw is chosen to match the input feedstock no vertical motion for
hard abrasive feedstock, some vertical mation for softer feedstock, giving
a better throughout. Jaw crushers reduce the feedstock to approximately
1/4 to 1/6 of its original size.

V) Mobile crushing units:

These tend to be more simply a crusher mounted on vehicle. They include
a range of supporting equipment such as feed hoppers to control the input
of feedstock, screens to grade to product dust suppression sprays,
conveyors to transport the product as well as the crusher itself. Normally
mobile crushing units are track vehicles, this allows then to move around
site & onto low loader for transportation between sites. The size and in
turn the capacity of the units is highly variable, from small few hundred kg
units, where a very modest amount of crushing is required to large units
weighing up to 50 tons, that are capable of large throughputs of feedstock.

10
2) Grinding Process:
Grinding is the process in which the feedstock is grinded. Grinding isdone with
the help of mechanical means, to obtain the material of finer size. The machines
which are used for grinding purpose are suchas ball and rod mills. This is rarely
undertaken in the production of recycled aggregates.

3) Screening Process
In the process of recycling of aggregates, another process which is
involved is screening. After the process of crushing the crushed material
undergoes process of screening. Screening is the one of the important
processes involved in the recycling of aggregates. It separatesaggregates
into different size function. After this material is retainedon the screen is
called oversize and material passing through the screen is called under size.
Screening equipment can be used to remove contamination and large
materials unsuitable for further processing.
It is also used to produce specific aggregate types. Screenscan be mounted
in decks, or placed in series, such that the undersizepassing through the
first screen in father screened to remove finer particles which are of no use.
This will help in producing single size aggregate & graded aggregate
Screens can be made of mesh, bars or from holes punched in plates. The screen
process is dependent on the size of the particles, but it alsoinfluenced by particle shape
& the duration of the screening process.Movement of the screens, as well as the
maternal increase the efficiency of the screening process. Screen can become blocked
& required cleaning & maintenance, the type of screening equipment will influence
the accessibility for such cleaning & maintenance screens will eventually wear out
due to the abrasion of aggregate material. Most equipment types allow for the
replacement of damaged or broken screens. The various types of screens which are
used for screening process according to their size and functions whichare used for
recycling process of aggregates are stated bel

11
4) Finger screens
These types of screens are used as primary screens used for separating material prior
to the other operations such as crushing. They are useful to remove such materials
from feedstock which wouldblock other types of screens, comprises a series of rows
of overlappingfingers or bars. This series of rows of fingers are sloped & vibrated,
to encourage the travel of oversize material down the rows.

a. Pre screen
These types of screens are of large, strong screens, often located at the
state of screening or crushing operation. The objectives of providing
these types of screen are,
 To protect the machinery, such as crushers or conveyors being
presented with oversized materials.
 To remove undersized material before primary crushing.

Pre screeners are as simple as a set of parallel steel ‘t’ sectionabove a

hopper. To avoid clogging and to improve the transport of theoversized
material they can be sloped vibrating sets of steel section, or groups of
rotating elliptical rollers.

b. Mobile Screens
The mobile screens, as name indicates at mobile nature. These types of screens are
mounted on the wheels or tracks and easy movement around site or between sites
.These mobile Screens are separated by man. Mobile units are not only screens, they
also have built in loadinghoppers (often with a pre screeners), feeders to transport the
feedstock from the hopper to the screens and conveyers to transport the oversize and
undersize material directly into vehicles for transport.

12
 c. Screen deck
Screen deck is units having several decks (layers) of screens, allowingseparation of
feedstock into several size ranges in one pass. The component within the screening
equipment that actually undertakes the sizing is known as the screen deck, mist,
surface, plate andsometimes screen. The screen deck can be comprised of a number
ofmaterials such that wire cloth, long slot wire cloth, perforated plates,metal fingers,
profile wire or soft cleaning rubber. Some screen unitsallow the interchanging of
different decks for different feedstock thechoice of deck is dependent on a number of
Factors, such as-feedstockabrasiveness, impact, feed stock size, moisture content
throughout, cost-effectiveness and noise level.

d. Trommel Screens
In trommel screens, the screen deck are formed into a cylinder, the cylinder is tilted
slightly to the horizontal to promote transport of thefeedstock, when it is rotated. The
screen deck sizing can be varied along the length of the trammel allowing multiple
sizing in one unit feedstock is introduced at the higher end and is transported by the
rotation along the axis of the cylinder. The undersized material falls through the
screen deck and the oversize is discharged at the lower end of the cylinder.
Advantages of using these types of screens are,

13
A) Simplicity in working
B) Low cost.
E) Vibration free etc.

However, due to relatively low capacity, more prone to blockage, it ismore difficult
to care for the screen deck. Trommel screens are usedin many mobile screening units.

VI) Vibrating Screens

This is a common type of screening process. The screens are generally

made of mesh with the aperture of the mesh controlling the size and
aggregate produced. The screens are usually inclined to improve flowand
vibrate, to improve separation efficiency. Retained oversize material is
often repeatedly presented to the screen to increase efficiency. Vibrating
screens are generally between 3 to 6m in lengthand 1 to 1.5m wide.

3.2 Process adopted in project work

For experimental work, it was not possible to purchase recycle aggregates

from concrete recycling plants. Hence, we adopted manualprocesses for
getting recycle aggregate. The processes are same as thatof any recycling
plant and are given below

14
 3.2.1 Crushing By Concrete Breaker
The concrete breaker consists of a power unit and a removable needle.The
power unit is electrically driven. The breaking stokes are causedby
needle. The frequency of strokes is made lower and increased by
frequency knob. With the use of this manually operated concrete
breaker, concrete components like columns, beams, slabs, etc. can be
easily broken.

3.2.2 Grinding/Ramming by Ramuner

Rammer consists of a steel rod connecting 20 cm diameter stoel plate weighing sh 5kg. At it's one
end. The concrete lumps obtained by cuting as he grinded or made of mer size by tamming them
using hand aer. The smaller size material.comas of mostly aggregates separated from concrete. It
also contains safer sin grit and dust particles which are further removed by screening/sieving
process,
32.3 Screening by Manual Process

In the screening process, various sizes of sieves are used, to separate the desired sine of
aggregates. The various sizes of nieves a 30mm, 20mm, 10, 4.75mm, this sieving screening is done
manually.

15
3.3 MIX DESIGN

33.1 MIX DESIGN FOR NATURAL AGGREGATES:10262-2009)

A. Design Stipulation

1. Charecteristic Strength 20 Mpa

2. Maximum Size Of Aggregate 20 mm
3. Degree Of Workability 0.90
4. Degree Of Quality Control Good
5. Degree Of Exposure Mild
6. W/C Ratio 0.50
B. Test Data For Materials

1.Fine Aggregate 3.95

2. Specific Gravity Of Cement 3.15

3. Specific Gravity Of Coarse Agg. 2.67

4. Specific Gravity Of Fine Agg. 2.82

5. Water Absorption

1.Coarse Agg. 0.70%

2.Fine Aggregate 1.00%

6. Free Moisture

1. Coarse Aggregate NIL

2. Fine Aggregate 2.0%

7. Fineness Modulus

1. Coarse Aggregate. 2.90

2. Fine Aggregate 3.95

16
C. Target mean strength of cement

Fm= Fck + (t × s )
1. Ccharecteristic Strength 20 Mpa
2. Maximum Size of Aggregate 20 mm
3. Degree of Workability 0.90
4. Degree Of Quality Control Good
5. Degree Of Exposure Mild
6. Specific Gravity Of Cement 3.15
7. Specific Gravity Of Coarse Agg. 2.67
8. Specific Gravity Of Fine Agg. 2.82
9. Water Absorption
1. Coarse Aggregate 0.70%
2. Fine Aggregate 1.00
10. Free Moisture
1. Coarse Aggregate NIL
2. Fine Aggregate. 2.0%
11. Fineness modulus
1. Coarse Aggregate 2.90
Where ,

T = 1.650.

S=4
Fm = 20 + (1.65 × 4 )

= 26.60 Mpa

d) Selection of water-cement ratio

From figure the water cement ratio required for mean target strength 26.60 Mpa is 9.50. This is lower than the maximum value of
0:55 prescribed for extreme exposure (Refer table 5. IS 456-2000) adopt W/C ratio 0.50.

17
c) Selection of water and sand content

From table for 2mm maximum size of aggregate, sand conforming to grading zone Il water content per cubic meter of concrete-186
kg and sand content as percentage of total aggregate by absolute volume-35%

Determination of cement content

W/C Ratio -- 0.50

Water -- 186 Liter

Cement (1860).50)-372 Kg/m

Determination of course and fine aggregates contents

From table 6.3 for the specified maximum size of aggregates the amount of entopped ar in the wet concrete is 2%, Taking this in to
account and applying equations 1 and 2 given,

[W+(C/Sc) + (Fa/Sfa}}

1000

Where ,

V-Absolute volume of fresh concrete, which is equal to gross volume minus volume of entrapped air-100-2-98%

W -Mass of water (kg) per m' of concrete-186 Kg/m

C-Mass of cement (kg) per m'of concrete 372 Kg/m

Sc- Specific gravity of cement-3.15

P -Ratio of FA to total aggregate by absolute volume 0.35

SFa-Specific gravity of saturated, surface dry fine aggregate-2.82

SCa course aggregate respectively-2.67

Fa-631.63 Kg/m

1186 (372/3.15)+(1/0.35) X (F/2.67)]

0.98 =

1000

Fa-631.63 Kg/m

Ca(1-p)/p) x Fax [Sca/Sfa). Ca-(1-.35).35) x 631.63 x (2.67/2.82

Ca-1102.64 Kg/m3

18
Mix Proportion

Water to cement ratio=0.50

Mix proportion-1: 1.698: 2.98

Water Cement Fine Aggregate Coarse Aggregate

186 372 631.63 1110.64

050 1 1.698 2.985

19
3.3.2 MIX DESIGNFOR RECYCLED AGGREGATE (IS:10262-2009)
a) Design stipulations
1. Characteristic strength 20Mpa.
2. Maximum size of aggregates 20mm.
3. Degree of workability 0.90.
4. Degree of quality control Good.
5. Degree of Exposure Mild.
6. W/C Ratio 0.50
B) Test data for materials
1. Specific gravity of cement 3.15
2. Specific gravity of coarse aggt. 2.42
3. Specific gravity of fine aggt. 2.82
4. Water absorption
1. Coarse aggregate 4.34%
2. Fine aggregate 1.00%
5. Free moisture
1. Coarse aggregate NIL
2. Fine aggregate 2.0%
6. Fineness modulus
1. Coarse aggregate. 2.90
2. Fine aggregate. 3.95
c) Target mean strength of cement
Fm = Fck + (t x s)
Where,
t = 1.650.
s=4
Fm = 20 + (1.65 x 4)
= 26.60Mpa
d) Selection of water-cement ratio
Form figure the water cement ratio required for mean target strength 26.60 Mpa is 0.50. This is lower than
the maximum value of 0.55 prescribed for extremc exposure (Refer table 5.Is 456-2000) adopt W/C ratio 0.50.

e) Selection of water and sand content

Form table for 20mm maximum size of aggregate, sand conforming to gradling zone if water content per
cubic meter of concrete =186kg and sand content as percentage of total aggregate by absolute volume=35%.
f) Determination of cement content
W/C ratio 0.50
Water -- 186 liter
Cement = (186/0.50) =372 Kg/m3
g) Determination of coarse and fine aggregate contents
Form table for the specified maximum size of aggregates the amount of entrapped air in the wet concert is
2%. Taking this in to account and applying equations 1 and 2 given.
[ W+(C/Sc)+(Fa/SFa)]
V=
1000
Where,
V=Absolute volume of fresh concrete , which is equal to gross volume minus volume of entrapped air, =
100-2=98%
W=Mass of water (kg) per m3 of concerete = 186 Kg/m3
Ca=Mass of cement (kg) per m3 of concrete=327kg/m3
Sc=Specific gravity of cement =3.15
P= Ratio of FA to total aggregate by absolute Volume =0.35
SFa=Specific gravity of saturated,surface dry fine aggregate= 2.82
SCa course aggregate respectively=2.42
[ 186 +(372/3.15) + (1/0.35) x Fa/2.42]
0.98 =
1000

3
Fa = 572.80 kg/m

20
Ca = [ (1-p)/p ] x Fa x { Sca/ Sfa }
Ca =[(1-35)/35 x 572.80 x (2.67 / 2.82 ) ]
Ca = 912.88 kg/m3
WATER CEMENT FINE AGGREGATE COARSE
AGGREGATE
186 372 572.80 912.88
0.50 1 1.53 2.45
Tabel No. 3.3.2. Mix design of recycled aggregate
MIX PROPORTION
Water to cement ratio = 0.50
MIX Proportion=1: 1.698: 2.985

21
 4. PERFORMANCE ANALYSIS

4.1 tests on aggregates

4.1.1 natural aggregates
4.1.1.1 fine aggregates sieve analysis
significance of the tests:
The F.M of test gives an idea as to whether the aggregate coarse or
fine and whether a can be used in making mortar or concrete if not ,
what corrective has to be taken is decided upon .
The particle size distribution study gives an idea that sand is well
graded or not .if the grading does not satisfy the specification
corrective action has to be taken.
Fine aggregate:
Total wt. of sample w1 =2.0 kg
I.S sieve Weight Cumulative Percent
retained gm percent passing
retained
4.75 mm 0.045 0.045 2.25%
2.36 mm 0.080 0.125 6.25%
1.18 mm 0.480 0.605 30.25%
600 micron 0.695 1.300 65.00%
300 micron 0.565 1.865 93.25%
150 micron 0.110 1.975 98.78%
95 micron 0.005 2.000 100.00%
Table 4.1.1.1 fine aggregates sieve analysis
Fineness modulus = Total of col. 3/100
Results
F.M of fine aggregate = 2.20

22
Requirements :-

The sand is classified as follows:

Sand classification F.M.
Very fine 0.50 to 2.30
Fine 2.20 to 2.60
Medium 2.60 to 2.90
Coarse 2.90 to 3.50

Conclusion
sand is medium/coarse.
4.1.1.2 Specific Gravity by pycnometer
observations
Weight of empty pycnometer W1 =
0.458 kg
Weight of pycnometer +Fine aggregates W2 = 1.383
kg
Weight of pycnometer + Fine aggregates + Water W3 = 1.86
kg
Weight of pycnometer + Water (full) W4 =
1.262 kg
Calculations
Specific gravity = (W2 -W1) / (W2 -W1) - (W3 -W4)
Specific gravity = 0.925/ (0.925 - 0.598)
Specific gravity = 2.82
4.1.1.3 Coarse aggregates sieve analysis
Maximum Size Minimum wt. of sample to be Minimum wt. of sample to be
brought for testing (kg) brought for sieving (kg)
63 100 50
50 100 35
40 50 15
25 50 5
20 25 2
16 25 2
12.5 12 1
10 6 0.5
6.3 3 0.2
4.75 3 0.2

23
observations
Total of samplers 5.0 kg
Fineness modulus = Total of col. 4/100
I.S. sieve Weight Cumulative Percent
retained got percent passing
retained
16 mm 0.345 0.545 0.50 to 2.20
12 mm 3.540 4.085 2.20 to 2.60
10 mm 0.830 4.915 2.60 to 2.90
4.75 micron 0.085 5.000 2.90 to 3.50

Conclusion
Coarse aggregate is well graded
Natural aggregate specific gravity
Calculations
specific gravity, apparent specific gravity and water absorption shall
be calculated as follows:
1) Empty weight = 1.130 kg
2) Aggregate = 2.00 kg
3) Basket + aggregates + in water = 2.250 kg

4) Empty basket in water = 1.000 kg

5) wt. of dry aggregates 990 kg
wt.
6) Oven dry wt.= 1.976 kg
Specific gravity = 1.976/ (1.990-1.250)
=2.67
Water Absorption =100(1.990-1.976)/1.976
=0.70 %
4.1.2 Recycled Aggregate
4.1.2.1 Specifie Gravity
Calculations:

24
Specific gravity, apparent specific gravity and water absorption shall
be
calculated as follows:
1) Empty weight -1.130 ke
2) Aggregates =2.00 kg
3) Basket + Ageregates + in water - 2.250 ke

4) Empty basket in water = 1.000 kg

5) wt. of dry aggregates 990 kg
wt.
6) Oven dry wt.= 1.976 kg
Specific gravity = 1.976/ (1.990-1.250)
=2.67
Water Absorption =100(1.990-1.976)/1.976
=0.70 %
4.1.2 Recycled Aggregate
4.1.2.1 Specific Gravity

25
Calculations:
Specific gravity, apparent specific gravity and water absorption shall
be
calculated as follows:
1) Empty weight -1.130 ke
2) Aggregates =2.00 kg
3) Basket + Ageregates + in water - 2.250 ke
4) Empty basket in water = 1.000 kg
5) w. of dry aggregates -2.065 kg
6) Oven dry wt.=1.979 ke
Specific gravity - 1.979 /(2.065-1.250)
2.42
Water Absorption: - 100(2.065-1.97971.979
=4.34 %

4.1.2.2 Aggregate Crushing Value

Observations
Weight of the dry sample = ₩. -2.935 kg.
Weight of the fraction passing through 2.36 mm sieve- W:= 0.436kg.
Aggregate crushing value- (W2/W1) X 100%
- 0.436/2.935X100
14.80%
Result
The aggregate rushing value of the given aggregate is. 14.80 %.

26
Requirements
1. The aggregate crushing value should not be more than 45% for any
concrete
work.
2. The aggregate crushing value should not be more than 30% for
concrete for
wearing surfaces such as roads, runways, pavements etc.

27
4.2 METHODS of improving The quality OF RECYCLED
AGGREGATE CONCRETE
Waste concrete with a lower degree of contamination is a potential
source for the production of aggregate for concrete. Recycled
particles consist of substantial amount of gravely soft cement paste
component. 'These aggregates are more porous and less resistant6
etageres are more porous ando mechanical actions.
The 1n: actions. The limitations of using recycled concrete aggregate
in new concentrate detrimental influence on the concrete properties.
In comparison with natural aggregate concrete, recycled aggregate
concrete shows reduction in strength and increase in drying shrinkage
and creep. Recycled aggregate concrete may also be less durable due
to increase in porosity and permeability. Economical ways of
improving the quality of recycled aggregate econcrete is blending of
recycled aggregate with the natural aggregate. Recycling is the
process of recovery and subsequent use of material for the
manufacture and/or fabrication of the same Or similar product from
which the waste was originated. Recycling of materials used in
outdated construction is probably as old as civilization itself. In many
countries.
A considerable amount of demolition waste is generated and concrete
forms significant proportion of waste. The "waste concrete" is also
gencrated from many other sources. Inthe recast concrete industry
where wastage may arise from of precast elements during production
and transportation. In the central and site laboratories contamination
free crushed concrete are obtained from the control test breakage
testing specimens. construction At due 10 construction poor quality
sites waste workmanship concrete or is unauthorized generated from
work. Waste demolition concrete. of rejected when in size, can be
used as aggregates for concrete production. Adequately reduced

28
4.2.1 Testing
Compressive strength
Size of cube 0.15mx0.15mx0.15m

Procedure
1) After 7 days curing remove the cube from curing tank andimmediately
place the cube in the compression machine
2) Apply load gradually at a rate of 145 kg/Cm3 per minute tiltmaximum
load is
reached at which the cube fails
3) Note down the load. Test other cube. Note down the type of failure.Of
4) Find out strength of concrete for each cube. Find out average of 3results.

29
 Recycled Concrete
Introduction:
Recycled aggregate concrete (RAC) has emerged as a promising solution in
sustainable construction practices. With growing environmental concerns and the
depletion of natural resources, RAC offers a viable alternative by utilizing recycled
materials in concrete production. This report provides a comprehensive overview of
recycled aggregate concrete, including its composition, properties, advantages,
challenges, and applications in the construction industry.

1. Composition of Recycled Aggregate Concrete:

Recycled aggregate concrete is primarily composed of recycled aggregates obtained
from demolished concrete structures. These aggregates are typically derived from
construction and demolition waste (C&DW) materials such as old concrete
pavements, buildings, bridges, and other infrastructure elements. The process
involves crushing and sorting demolished concrete into suitable sizes for reuse as
aggregates in new concrete mixes. The recycled aggregates replace a portion of the
natural aggregates typically used in conventional concrete production.

2. Properties of Recycled Aggregate Concrete:

Recycled aggregate concrete exhibits comparable mechanical properties to
conventional concrete, albeit with some variations influenced by factors such as the
quality and characteristics of the recycled aggregates, the percentage of
replacement, and the concrete mix design. Key properties of recycled aggregate
concrete include compressive strength, tensile strength, durability, workability, and
shrinkage. Extensive research and testing have demonstrated that with proper
quality control measures and mix design adjustments, RAC can meet the
performance requirements of various construction applications.

30
3. Advantages of Recycled Aggregate Concrete:

Environmental Sustainability: RAC significantly reduces the demand for natural

resources, minimizes the accumulation of construction waste in landfills, and
lowers carbon emissions associated with concrete production.
Cost-effectiveness: Utilizing recycled aggregates often proves more economical
compared to sourcing natural aggregates, particularly in regions where disposal
fees for C&DW are high.
Conservation of Natural Resources: By promoting the reuse of demolished
concrete materials, RAC helps conserve natural resources and reduces the
environmental impact of aggregate mining.
LEED Certification: The use of recycled materials in construction, including
RAC, can contribute towards achieving LEED (Leadership in Energy and
Environmental Design) certification for sustainable building projects.

4. Challenges and Considerations:

Quality Control: Ensuring consistent quality of recycled aggregates poses a

challenge due to variations in the source materials and potential contamination.
Durability Concerns: Recycled aggregates may contain impurities or adhered
mortar that could affect the long-term durability of RAC. Proper quality assessment
and mix design adjustments are essential to mitigate these concerns.
Standardization and Regulations: Establishing standards and regulations for the use
of recycled aggregates in concrete construction is crucial to ensure structural
integrity and performance.
Public Perception: Overcoming perceptions regarding the quality and performance
of recycled aggregate concrete remains a hurdle in widespread adoption.

31
5. Applications of Recycled Aggregate Concrete:
Recycled aggregate concrete finds applications in various construction projects,
including:

Road and pavement construction

Foundation and sub-base layers
Structural elements such as beams, columns, and slabs
Mass concrete applications like retaining walls and dams

32
Properties Of Recycled Aggregate Concrete
Recycled aggregate concrete (RAC) exhibits various properties that are crucial
for its performance and suitability in construction applications. These properties
are influenced by factors such as the quality of recycled aggregates, the
proportion of replacement, mix design, curing conditions, and the presence of
supplementary cementitious materials. Below are some key properties of
recycled aggregate concrete:

1. Compressive Strength: Compressive strength is one of the most important

properties of concrete, indicating its ability to withstand axial loads. The
compressive strength of recycled aggregate concrete is typically lower than that
of conventional concrete, primarily due to the weaker bond between recycled
aggregates and the cement paste. However, with proper mix design and quality
control, RAC can achieve compressive strengths comparable to conventional
concrete.

2. Tensile Strength: Tensile strength is crucial for resisting bending and tension
forces in structural elements. Similar to compressive strength, the tensile strength
of recycled aggregate concrete may be slightly lower than that of conventional
concrete. However, various methods such as fiber reinforcement or optimizing
the mix design can enhance the tensile strength of RAC.

3. Durability: Durability encompasses resistance to various deteriorative

mechanisms such as freeze-thaw cycles, chloride ion penetration, alkali-silica
reaction (ASR), and sulfate attack. The durability of recycled aggregate concrete
depends on factors like the quality of recycled aggregates, the degree of mortar
adhered to the aggregates, and the presence of contaminants. Proper quality
control measures and mix design adjustments are essential to ensure the long-
term durability of RAC.

33
4. Workability: Workability refers to the ease with which concrete can be mixed,
transported, placed, and compacted without segregation or excessive bleeding.
Recycled aggregate concrete may exhibit slightly lower workability compared to
conventional concrete, mainly due to the angular shape and higher water
absorption of recycled aggregates. Adjustments in water-to-cement ratio, use of
chemical admixtures, and optimization of aggregate gradation can enhance the
workability of RAC.

5. Shrinkage: Shrinkage refers to the reduction in concrete volume due to

moisture loss during curing and drying. Recycled aggregate concrete may
experience higher shrinkage compared to conventional concrete, primarily due to
the higher water absorption of recycled aggregates. Proper curing practices and
the use of shrinkage-reducing admixtures can help mitigate shrinkage in RAC.

6. Density: The density of recycled aggregate concrete depends on factors such as

the density of the recycled aggregates and the void content in the concrete mix.
Generally, RAC may have slightly lower density compared to conventional
concrete, but this variation is influenced by factors such as the type and
proportion of recycled aggregates used.

7. Elastic Modulus: The elastic modulus, or modulus of elasticity, represents the

stiffness of concrete and its ability to deform under stress. The elastic modulus of
recycled aggregate concrete may vary depending on factors such as the quality of
recycled aggregates, the replacement percentage, and the curing conditions.
Proper mix design and quality control are essential for achieving desired elastic
modulus values in RAC.

34
Procedure For Recycled Aggregate Concrete
The production of recycled aggregate concrete (RAC) involves several steps to
ensure the quality and performance of the final product. Below is a general
procedure outlining the key steps involved in producing recycled aggregate
concrete:

1. Collection and Sorting of Demolished Concrete:

Demolished concrete from various sources such as buildings, bridges, roads, and
other structures is collected and transported to recycling facilities.
At the recycling facility, the demolished concrete is sorted based on size, quality,
and type of aggregates. Any contaminants such as wood, metal, or plastic are
removed during the sorting process.

2. Crushing and Screening:

The sorted demolished concrete is crushed using crushers into smaller pieces of
suitable sizes for reuse as aggregates in concrete.
Screening equipment is used to separate the crushed concrete into different
aggregate sizes based on specific project requirements.

35
3. Quality Control and Testing:

Samples of the crushed recycled aggregates are collected and tested to ensure
they meet the required quality standards.
Testing may include assessments of aggregate properties such as particle size
distribution, density, water absorption, abrasion resistance, and presence of
contaminants.

4. Mix Design:

Based on the properties of the recycled aggregates and the desired performance
characteristics of the concrete, a suitable mix design is developed.
The mix design specifies the proportions of cement, water, recycled aggregates,
and other supplementary materials such as fly ash or slag to achieve the desired
strength, workability, and durability of the concrete.

36
5. Batching and Mixing:

Recycled aggregates, cement, water, and any other required additives are
accurately proportioned and batched according to the mix design.
The materials are then mixed thoroughly in a concrete mixer to ensure uniform
distribution of ingredients and achieve the desired consistency.

37
6. Placement and Compaction

The freshly mixed recycled aggregate concrete is transported to the construction

site using trucks or concrete pumps.
It is then placed into the formwork or onto the prepared sub-base and compacted
using vibratory equipment to eliminate air voids and achieve proper
consolidation.

38
7. Curing and Protection:

After placement, the recycled aggregate concrete is cured properly to promote

hydration and achieve the desired strength and durability.
Curing methods may include moist curing, curing compounds, or membrane
curing, depending on project requirements and environmental conditions.
Adequate protection measures are implemented to prevent premature drying,
excessive temperature fluctuations, or mechanical damage during the curing
period.

8. Quality Assurance and Inspection:

Throughout the production process, quality assurance measures are implemented

to monitor the performance of recycled aggregate concrete.
Periodic inspections and testing are conducted to verify compliance with project
specifications, industry standards, and regulatory requirements.

39
How To Determine Strength Of Recycled Concrete
1. Sample Preparation:

Obtain representative samples of recycled concrete from the construction

site or production facility. These samples should be collected following
proper procedures to ensure they accurately represent the material being
tested.

2. Specimen Preparation:

Prepare cylindrical or cube-shaped specimens from the recycled concrete

samples.
The dimensions and number of specimens depend on the testing standards
being followed (e.g., ASTM, BS, EN).
Ensure that the specimens are prepared in accordance with the relevant
standards, including proper curing procedures and moisture conditioning if
required.

40
3. Compressive Strength Testing:

Perform compressive strength testing on the prepared specimens using a

compression testing machine.

The testing machine applies a gradually increasing compressive load to the

specimen until failure occurs. The maximum load at failure is recorded.

Calculate the compressive strength of the recycled concrete specimen using

the following formula:

Compressive Strength (f_c) = Maximum Load / Cross-sectional Area

Cross-sectional area should be calculated based on the dimensions of the

specimen (diameter for cylinders, side length for cubes).

41
4. Testing Standards:

Ensure that the testing procedures and equipment used comply with
relevant standards such as ASTM C39/C39M (for cylindrical specimens) or
ASTM C109/C109M (for cube specimens) in the United States, or
equivalent standards in other regions (e.g., BS EN 12390 series in Europe).
5. Number of Specimens and Testing Frequency:

Determine the number of specimens required for testing based on statistical

analysis and project requirements. Typically, a minimum of three
specimens are tested for each sample batch.
Testing frequency may vary depending on project specifications and quality
control protocols.

6. Interpretation of Results:

Evaluate the compressive strength results obtained from testing and

compare them against specified requirements or acceptance criteria.
Interpret the results in terms of the structural adequacy and performance of
the recycled concrete for the intended application.

42
 7. Quality Control and Assurance:

Implement quality control measures throughout the testing process to

ensure accuracy, reliability, and repeatability of results.
Maintain proper documentation of testing procedures, equipment
calibration, and test results for quality assurance purposes.

Compare Concrete
Parameter New Concrete Recycled Concrete
Naturally occurring aggregates (e.g., Recycled aggregates from demolished
Source of Aggregates gravel, sand) concrete
High carbon footprint due to extraction Lower carbon footprint by reducing demandfor
and processing of naturalaggregates virgin materials and minimizing waste disposal
Environmental Impact
Consumes natural resources (sand, Utilizes recycled materials, conserving natural
Resource Consumption gravel, limestone) resources
Involves quarrying, crushing, and Involves crushing and sorting demolished
Production Process processing of raw materials concrete, requiring less energy and water
Cost can be higher due to expenses Cost-effectiveness due to reduced need for virgin
associated with quarrying and materials and potential savings in wastedisposal
Cost transportation of raw materials fees

Quality can be more predictable and Quality control may be more challenging dueto
consistent due to controlled production variability in recycled aggregates and potential
Quality Control processes contaminants

Can meet specified performance May exhibit slightly different properties

requirements with proper mix designand depending on the quality of recycled
Performance quality control aggregates and mix design adjustments

Durability influenced by quality of recycled

Generally durable with proper mix aggregates, presence of contaminants, and
Durability design and curing practices adherence to proper quality control measures

Offers significant environmental benefits by

Limited environmental benefits reducing landfill waste, conserving natural
Environmental Benefits compared to recycled concrete resources, and lowering carbon emissions

Suitable for a wide range of applications including

Widely used in various construction road construction, foundations, andstructural
Applications projects elements

43
GROUP IMAGE

44
Conclusion
Recycled aggregate concrete (RAC) stands as a beacon of sustainable
innovation inthe construction industry, offering a viable solution to
mitigate environmental impact while meeting the demands of modern
infrastructure projects. Through a comprehensive analysis of its
properties, advantages, challenges, and applications, it becomes evident
that RAC holds immense promise for shaping a more sustainable
future.RAC embodies the ethos of circular economy principles by
repurposing waste materials from demolished structures into valuable
resources fornew construction. By diverting construction and
demolition waste from landfills and reducing the reliance on virgin
aggregates, RAC significantly lowers carbon emissions, conserves
natural resources, and minimizes environmental degradation associated
with traditional concrete production methods. While challenges such as
quality control, durability concerns, and public perception remain,
ongoing research, technological advancements, and regulatory support
are driving continuous improvement in the quality and performance of
RAC. With proper mix design, quality control measures, and adherence
to standards, RAC can meet or exceed the performance requirements of
various construction applications, offeringcomparable strength,
durability, and versatility to conventional concrete.

Reference
Title: "Recycled Aggregate in Concrete: Use of Industrial,
Construction andDemolition Waste"
Author: Jorge de Brito and
Nabajyoti SaikiaPublisher:
Woodhead Publishing
Publication Date: May 28, 2019
ISBN-13: 978-0081024805
45