Industrial waste materials in concrete and

their influence on physical & mechanical

properties & durability of concrete

DEPARTMENT OF CIVIL ENGINEERING

Dr. B R AMBEDKAR NATIONAL INSTITUTE OF TECHNOLOGY

Mohit-Kumar
Roll no 17202114
Contents.
 Introduction .
 Pozzolan material.
 Types of Pozzolan material.
 Natural Pozzolan material
 Artificial or man made Pozzolan.
 Application of Pozzolan.
 Effects on Freshly Mixed Concrete.
 Effects on Hardened Concrete.
 Conclusion.
Introduction.
 Concrete is the matrix of water, aggregate, cement, and
any additives ( admixture mineral + chemical )
Pozzolan/Mineral admixture can be used to control
setting, increase durability, reduces cost and pollution
without significantly reducing the final compressive
strength or other performance characteristics of concrete .
 The beneficial effect of Pozzolan addition in term of
higher compressive strength, performance and greater
durability are mostly attributed to the Pozzolan reaction
in which calcium hydroxide (CH) is consumed to produce
additional calcium silicate hydrate (C-S-H) & calcium
aluminium silicate hydrate (C-A-S-H) reaction products.
Contd.
 These Pozzolan reaction products fill in pores and results
in a lowered permeability of the binder and slow down the
ingress of harmful ions such as chlorine, carbonate and
also reduces the risk of expensive alkali silica reactions
(A-S-R) b/w cement and aggregate by changing the binder
pore solution .
 The use of industrial waste materials as Portland cement
replacement, or as supplementary cementitious materials,
has the potential to be beneficial for the built
infrastructure as well as the environment.
Types of Pozzolan material.
 Pozzolans are a broad class of siliceous or siliceous
and aluminous materials which, in themselves, possess
little or no cementitious value but which will, in finely
divided form and in the presence of water, react
chemically with calcium hydroxide (CH) at ordinary
temperature to form compounds possessing cementitious
properties.
 Pozzolan
Artificial /man made/
Natural industrial by product
1.Fly ash
1.Volcanic ashes/tuffs
2.Silica fume
2.Volcanic 3.GGBFS /GGBS
glass/pumices/scoria 4.Copper slag
3.Calcined shale 5.Lime stone powder
4.Metakaolin/ calcined clay 6.Coal bottom ash
5. diatomaceous earth 7.Rice husk ash
8.Sugar cane Bagasse ash
9.Shurkhi/burnt bricks powder
10.Biomass Combustion Ash
11.Palm Oil Fuel Ash
12.Burnt Oyster Shell
13.Sewage Sludge Ash
14.Pond Ash
15.Corn cob ash
16.Bamboo leaf ash
17.Wood waste ash
18.Waste foundry sand
19.Marble /Granite dust
Natural Pozzolan material.
 Natural Pozzolan have been used as a cementitious
material for thousands of years. The earliest use shows
lime and diatomaceous earth being used together as a
cementitious binder by ancient civilizations near the
Persian Gulf. The invention of “modern” Portland cement
in the early 1800s – nearly 7,000 years after the first
recorded natural Pozzolan and did not end their use as a
binding agent in concrete.
 Natural pozzolanas are abundant in certain locations and
are extensively used as an addition to Portland cement in
countries such as Italy, Germany, Greece and China.
Contd.
 Natural pozzolans are sourced from natural mineral and
volcanic deposits. Some minerals like clay or shale require
heat treatment to transform them into pozzolans, while others
like volcanic ash exhibit pozzolanic behavior with minimal
processing.
 Metakaolin is considered a unique type of calcined clay. it is
produced by using a higher-temperature calcination process
specifically on kaolin clay before being ground finer than
traditional calcined clay. The high material fineness along with
the different calcination process results in metakaolin
exhibiting behaviors different from ordinary calcined clays.
 OPC V ASH

VG

V GLASS

CALCINED
MK SHALE
 Typical compositions
Volcanic glass/ pumice
Volcanic ashes/tuffs Metakaolin
% by mass PC /scoria Calcined shale

SiO2 21.55 46.54 46.52 65.43 51.66

Al2O3 4.25 13.46 13 14.55 35.23
Fe2O3 3.5 13.31 11.14 5.72 1.98
CaO 65 9.41 10.10 2.44 0.57
Mgo 5 7.94 9.11 2.30 0.45
SO3 3.5 0.07 0.27 0.39 0.06
Na2O 1.65 3.83 2.14 1.14 0.10
K2O 0.65 1.39 0.77 2.88 1.42
LOI 2 1 2.58 0.36 1.04

Median particle 45 75 100 23 17

size (μm)

surface area 324 350 500 730 1700

(m2/kg)

Specific 3.15 1.2 2.3 2.63 2.5

gravity(kg/m 3 )
Volcanic ashes/tuffs.
 These pyroclastic materials are rich natural alumino
silicate geo-resources and their valorization can be of
environmental and economic benefit. The current review
summarizes the main interesting research outcomes
on volcanic ashes in the fields of cements and concretes,
geopolymers, ceramics, low grade refractory materials,
lunar soil simulants and adsorbents.
 The mineralogy and chemical composition
of volcanic ashes ((Na2Ca)O⋅Al2O3⋅4SiO2⋅xH2O) depend
on the type of magma from which they originate.
Contd.
 The two common pyroclastic materials of interest for
engineering applications are scoria and pumice.
 natural Pozzolans (NP) such as volcanic ash (VA),
regionally available in the Gulf countries for the
production of blended cement and concrete. It is reported
that the volcanic scoria available in north western Saudi
Arabia could be used as fine and coarse aggregate for
producing light weight concrete satisfying the
requirements of structural concrete.
Volcanic glass/pumices.
 Pumice, called pumicite in its powdered or dust form, is a
volcanic rock that consists of highly vesicular rough
textured volcanic glass, which may or may not contain
crystals. It is typically light colored.
 Pumice has an average porosity of 90%, and initially
floats on water.
 Pumice is composed of highly micro
vesicular glass pyroclastic with very thin, translucent
bubble walls of extrusive igneous rock.
Contd.
 Pumice is considered a glass because it has no crystal
structure.
 Pumice is widely used to make
lightweight concrete or insulative low-density cinder
blocks.
 Ground pumice is added to some toothpastes and heavy-
duty hand cleaners.
Calcined shale.
 Calcined shale is heat treated in a kiln and then ground to
a finer powder and the calcination temperatures of 800
°C were used. ... Finally, the inclusion of calcined shale is
help to reduce the emissions of CO2 and revealed an
ecological advantage for concrete containing a binder
blend of cement and calcined shale.
 The effect of calcined shale on compressive strength,
resistance to alkali silica reaction and mixture workability
were evaluated. Results show that, other than early age
compressive strength, the performance of calcined shale in
cementitious mixtures is comparable to that of metakaolin.
Metakaolin.
 Metakaolin is the anhydrous calcined form of the clay
mineral kaolinite. Minerals that are rich in kaolinite are
known as china clay or kaolin, traditionally used in the
manufacture of porcelain. The particle size of metakaolin
is smaller than cement particles, but not as fine as silica
fume.
 It is a product that is manufactured for use rather than a
by-product and is formed when china clay, the mineral
kaolin, is heated to a temperature between 600 and 800ºC.
Artificial or man made Pozzolan.
 Also called ‘Supplementary Cementing Materials’
 Used when special performance is needed: Increase in
strength, reduction in water demand, impermeability, low
heat of hydration, improved durability, correcting
deficiencies in aggregate gradation (as fillers), etc.
 Result in cost and energy savings: Replacement of cement
leads to cost savings; energy required to process these
materials is also much lower than cement.
Contd.
 Environmental damage and pollution is minimized by the
use of these by-products – about 6 – 7% of total CO2
emission occurs from the production of cement.
 Usage depends on supply and demand forces, as well as
the market potential and attitudes.
OPC FLY ASH

GGBS SILICA FUME

COPER SLAG LSP

RHA SCBA
 Typical compositions
% by mass/ PC F-FA C-FA GGBFS SF CS LSP RHA SCBA

SiO2 21.55 52 37 35 92 26.91 0.04 87 78

Al2O3 4.25 24 18 12 0.8 0.21 0.06 0.5 8.5

Fe2O3 3.5 15 12.5 2 1.5 65 0.05 0.5 3.5

CaO 65 5 25 40 0.4 0.17 56 1.2 2.1

Mgo 5 2 5 8 1 - 0.10 0.4 1.7

SO3 3.5 0.4 2 1.3 - - - 0.2 -

Na2O+K2O 3 2.1 2.1 0.3 0.3 - 0.04 2.4 3.4

LOI 2 5.2 2.5 - 2.1 6.34 43.09 6.2 0.4

Median particle 45 150 150 10 0.150 500 12 300 80

size (μm)
surface area (m2 324 420 420 400 3000 350-400 538 320 650
/kg)
Specific 3.15 2.15 2.65 2.92 2.2 3.5 2.65 2.06 2.15
gravity(kg/m3 )
Chemical composition & classification.

 All fly ash includes (both amorphous and crystalline)SiO2,

Al2O3 & CaO.
 Ash that falls to the bottom of the boiler is coal bottom
ash.
Components Bituminous Sub bituminous Lignite

Sio2 20-60 40-60 15-15

Al2o3 5-35 20-30 20-25

Fe2o3 10-40 4-10 4-15

Cao 1-12 5-30 15-40

LOI 0-15 0-3 0-5

Fly ash class –F.
 The burning of harder, older anthracite and bituminous
coal typically produces Class F fly ash. This fly ash
is pozzolanic in nature, and contains less than
7% lime (CaO).
 Possessing pozzolanic properties, the glassy silica and
alumina of Class F fly ash requires a cementing agent,
such as Portland cement, quicklime, or hydrated lime—
mixed with water to react and produce cementitious
compounds.
Fly ash class –c.
 Fly ash produced from the burning of younger lignite or
sub-bituminous coal, in addition to having pozzolanic
properties, also has some self-cementing properties.
 In the presence of water, Class C fly ash hardens and gets
stronger over time.
 Class C fly ash generally contains more than 20% lime
(CaO).
GGBFS.
 Ground-granulated blast-furnace slag (GGBS or GGBFS) is
obtained by quenching molten iron slag (a Industrial by-
product of iron and steel-making) from a blast furnace in water
or steam, to produce a glassy, granular product that is then
dried and ground into a fine powder.
 Common crystalline constituents of blast-furnace slags
are merwinite and melilite. Other minor components which
can form during progressive crystallization
are belite, monticellite, rankinite, wollastonite and forsterite.
Minor amounts of reduced sulphur are commonly encountered
as oldhamite.
Contd.
 GGBS significantly reduces the risk of damages caused
by alkali–silica reaction (ASR), provides higher resistance
to chloride ingress — reducing the risk of reinforcement
corrosion — and provides higher resistance to attacks
by sulfate and other chemicals.
 The main components of blast furnace slag are CaO (30-
50%), SiO2 (28-38%), Al2O3 (8-24%), and MgO (1-18%).
Silica Fume.
 Silica fume is a byproduct of producing silicon metal or
ferrosilicon alloys. One of the most beneficial uses
for silica fume is in concrete. Because of its chemical and
physical properties, it is a very reactive pozzolan.
Concrete containing silica fume can have very high
strength and can be very durable.
 Silica fume, also known as microsilica, is an amorphous
polymorph of silicon dioxide, silica. It is an ultrafine
powder consists of spherical particles with an average
particle diameter of 150 nm.
Contd.
 The reduction of high-purity quartz to silicon at
temperatures up to 2,000°C produces SiO2 vapours,
which oxidizes and condense in the low- temperature zone
to tiny particles consisting of non-crystalline silica.
 The main components of silica fume are CaO (0-0.4%),
SiO2 (84-92%), Al2O3 (0.3-0.8%), and MgO (0.5-1%).
Copper Slag.
 Copper slag is a by-product of copper
extraction by smelting. During smelting, impurities
become slag which floats on the molten metal. Slag that
is quenched in water produces angular granules which
are disposed of as waste or utilized.
 Physico-mechanical and chemical characteristics of
copper slag lead to its utilisation to prepare various value
added products such as cement, filler, ballast, aggregates,
abrasive and granular material.
Lime Stone Powder.
 Limestone was most popular in the late 19th and early
20th centuries. Train stations, banks and other structures
from that era are normally made of limestone.
 About 10% of all sedimentary rocks are limestones
 Limestone is very common in architecture, especially in
Europe and North America.
 Many landmarks across the world, including the Great
Pyramid and its associated complex in Giza, Egypt, The
oldest temples in India were made of limestone.
Rice Husks Ash.
 Rice husk are the hard protecting coverings of grains
of rice. In addition to protecting rice during the growing
season, rice husks can be put to use as building
material, fertilizer, insulation material, or fuel.
 Combustion of rice husks affords rice husk
ash (acronym RHA). This ash is a potential source of
amorphous reactive silica.
 The husks contain approximately 50% cellulose, 25-30%
lignin, and 15-20% silica
Sugar Cane Bagasse Ash.

o Sugar cane bagasse is an industrial waste which is used

worldwide as fuel in the same sugar-cane industry
o The combustion yields ashes containing high amounts of
unburned matter, silicon and aluminium oxides as main
components.
 It has been reported that replacements of up to 30% of PC
with SCBA increased compressive strength at ages beyond
28 days Concrete.
Contd.
 incrporating 30% replacement of PC with SCBA
experienced reductions in water permeability of
approximately 50% and 70% at ages of 28 and 90 days
respectively.
 The main components of sugar cane bagsse ash (SCBA)
are CaO (2.1-3%), SiO2 (60-78%), Al2O3 (5-8.5%), and
MgO (1.7-2%).
Application of Pozzolan.
 Economic gain obtained by replacing a substantial part of the
Portland cement by cheaper natural pozzolans or industrial by-
products.
 Lowering of the blended cement environmental cost associated
with the greenhouse gases emitted during Portland cement
production.
 Increased durability of the end product.
 Lowered permeability of the binder.
 The beneficial effects of pozzolan addition in terms of higher
compressive strength, performance and greater durability are
mostly attributed to the pozzolanic reaction in which calcium
hydroxide is consumed to produce additional C-S-H.
Effects on Freshly Mixed Concrete.

 Concrete mixtures containing fly ash generally require

less water (1% to 10% less) for a given slump than
concrete containing only Portland cement. Similarly
ground slag decreases water demand by 1% to 10%
depending on dosage.
 The water demand of concrete containing silica fume
increases with increasing amounts of silica fume, unless
water reducer or superplasticizer is used.
 Natural Pozzolans have little effect on water demand at
normal dosages.
Contd.
 Fly ash, ground slag, and some natural pozzolans
generally improve the workability of concretes of equal
slump. While silica fume may reduce the workability and
contribute to the stickiness of a concrete mixture.
 Due to the reduced water demand, concretes with fly ash
generally exhibit less bleeding and segregation than plain
concretes.
 Ground slag (with similar fineness as cement) may
increase the rate and amount of bleeding with no adverse
effect on segregation. Ground slag finer than cement
reduce bleeding.
Contd.
 Fly ash, ground slag, and natural pozzolans will generally
increase the setting time of concrete. Silica fume may
reduce the setting time of concrete.
 Silica fume concrete may exhibit an increase in plastic
shrinkage cracking due to the effect of low bleeding
characteristics. Proper protection against drying is
required during and after finishing. Other supplementary
cementing materials that significantly increase setting
time can increase the risk of plastic shrinkage.
Contd.
Effects on Hardened Concrete.
 All supplementary materials contribute to the strength
gain of concrete. However, the strength of concrete
containing these materials can be higher or lower than
concrete with only cementing materials.
 The strength gain can be increased by one or combination
of the following:
 Increasing the amount of cementitious materials in concrete.
 Adding high-early strength cementitious materials.
 Decreasing the w/c ratio.
 Increasing the curing temperature.
 Using an accelerating admixture.
Conclusion.
 When used in low to moderate contents, the effect of
supplementary materials on the drying shrinkage and creep is
small and of little practical significance.
 With adequate curing the concrete with supplementary
materials will reduce the permeability and water absorption.
 Silica fume and other pozzolanic materials can improve the
chloride resistance under 1000 Coulombs using ASTM C
1202.
 The sulphate and seawater damaging effect on concrete can
be reduced significantly by using silica fume, fly ash, and
ground slag. The improvement can be reached by reducing the
permeability and reducing the reactive materials such as
calcium needed for expansive sulphate reactions.
Contd.
 The improvement in corrosion resistance of concrete can be
achieved by reducing the permeability and increasing the electrical
resistivity of concrete.
 Silica fume greatly reduce the permeability and increase the
electrical resistivity.
 Fly ash can reduce the permeability of concrete to water, air, and
chloride ions.
 Ground Granulated blast-furnace slag –(GGBS)
 Reduce temperature rise due to hydration heat.
 Suppress alkali-silica reaction.
 Improve resistance to sulfates.
 Improve chemical resistance to sea water (incl. salt damage).
 Give high strength.
 Give high fluidity.
.

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