SSRG International Journal of Civil Engineering (SSRG-IJCE) – volume 3 Issue 5 – May 2016
A Review on Cement Replacement in Construction
Industry
Savita Devi1, Nitish Gandhi 2, Mahipal 3, Nimisha Marmat 4, Balveer Manda5 ,
Mahesh Vaishnav 6
1
2,3,4,5,6
Asst. prof. , Poornima Institute of Engineering and Technology, Jaipur
Students of civil engg., Poornima Institute of Engineering and Technology, Jaipur
Abstract— This review paper emphasis on various suitable
replacements of cement so as to reduce problems of global
warming and to create sustainable environment.
Cement
manufacturing industry is one of major source of CO2 emission
resulting in global warning. About 7 to 8% of greenhouse gas
emission is only due to cement production. Solution of this global
problem can be a boon for environment and ecosystem. In order
to reduce these effects on environment, there is need for
substitution of other waste material having same major
constituents.The production of cement requires high energy input
and one tonne of cement production is generating 0.55 tonnes of
chemical CO2 as well as an additional 0.39 tonnes of CO2 in fuel
emissions, hence a total of 0.94 tonnes of CO2. Concrete industry
is one of the largest consumers of natural virgin materials
Therefore, the replacement of cement in concrete by various
wastes may create tremendous saving of energy and also leads to
important environmental benefits. The study on various factors
such as strength, durability, reuse and problem solution has been
compared with previous investigations and approaches to most
suitable replacement for cement concerning all parameters.
Keywords—cement,concrete,environment ,durability
Introduction
Attempts to reduce the use of Portland cement in concrete
are receiving much attention due to environment-related.As
the industries waste is piling up every day, there is a pressure
on industries to find a solution for its disposal. The
advancement of concrete technology can reduce the
consumption of natural resources. They have forced to focus
on recovery, reuse of natural resources and find other
alternatives. The various replacement such as ceramic waste,
blast furnace slag, silica fume, fly ash, geopolymer, paper
sludge. Waste from manufacturing industries is broadly
classified into two types: industrial byproducts and recycled
wastes. Industrial byproducts are ash, sludges and slags while
later one includes different plastic and rubber waste.
Hypo sludge
About 300 kg of sludge is going to be produced for one
tone of recycled paper. Paper sludge shows similar properties
as cement because of silica and magnesium properties which
improve the setting of the concrete. Paper fibers can be
recycled only a limited number of times so as to make high
quality papers.
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CERAMIC WASTE
Ceramic waste powder is settled by sedimentation and it is
dumped away which leads to environmental pollution, in
addition to forming dust in summer and threatening both
agriculture and public health. Indian ceramic production is 100
Million ton per year. In the ceramic industry, about 15%30%
waste material generated from the total production. This
waste is not recycled in any form at present. This ceramic
waste is durable, hard and show resistant properties towards
biological, chemical, and physical degradation forces.
PAPER SLUDGE
Paper pulp produced in mill was investigated to work in
concrete as an alternative for land disposal. Paper pulp was
replaced in concrete by cement in the ratio of 5%, 10%, 15%,
and 20% by weight in M20 and M30 grade mix concrete.
Compression test, split tensile strength test and flexure test
were carried on the concrete after replacement by paper pulp.
Tests were carried out on concrete till 28 days. As a result an
increment of flexure and split tensile strength was observed till
10% replacement of paper pulp sludge, further increase in
percentage of paper pulp sludge observed a decline in the
values of flexure and split tensile strength.
Paper fibers can be recycled up to a finite limit, till they
became of low strength which produces paper of degraded
quality. Every ton of recycled paper produces 300kg of sludge
which becomes almost uneconomical to dispose by landfilling.
Dry paper pulp sludge contains magnesium oxide, alumina,
calcium oxide and silica. Concrete when prepared with
replacement of paper pulp at 10%,20% show small decrease in
compressive strength. Most suitable proposition of mix is in
between 5% and 10%. As paper pulp is bulky so it consumes
water when mixed in concrete which ultimately results in
increase of water absorption of concrete. Use of paper pulp
can become economical by decreasing in costs of disposal by
landfilling.
Waste paper sludge ash
About 7% of the total greenhouse gas emission is caused
by cement industry. For reducing the above mentioned
greenhouse gas emission it is required to develop alternatives
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SSRG International Journal of Civil Engineering (SSRG-IJCE) – volume 3 Issue 5 – May 2016
to concrete industry for sustainable concrete production.
Partial replacement of paper pulp sludge ash of cement in
concrete can become an alternative. In the study sludge ash
was added in percentages of 5,10,15,20 in concrete in place of
cement for M20 mix. Tests were done to check the
compressive strength, water absorption, dry density and tensile
split strength up to 28 days of age. An increase of 10%
compressive strength at 7 days and 15% increases in
compressive strength at 28 days was observed when cement
was replaced 5% by weight in concrete by paper ash sludge.
So up to 5% replacement by weight of cement in concrete is
recommended for better results.
Waste glass powder
Like PFA and GGBS a binder known as GLP i.e. waste
glass powder can also be used as a partial replacement of
cement in concrete which will take part in hydration reaction.
For testing the effect in compressive strength replacement of
cement is done at 10%, 20% and 30%. For testing the effect of
glass powder, glass powder is divided into two grades:
1)
2)
Size of powder less than 90 micron.
Size of powder in between 90-150 micron.
Glass consists of many chemical varieties such as ternary
soda lime silicates, binary alkali silicates glass, and boro
silicate glass. Stability of cementitious material and increase
in strength of microstructure is observed after partial
replacement with glass powder.
In the research a total of four types of specimens were
prepared:
1)
Cement replacement with fine powder particle size
less than 90 micron with replacement of 10%-30%.
2)
Cement replacement with fine powder particle size
in between 90 micron to 150 micron with replacement of 10%30%.
3) Normal cement concrete.
4) Normal cement concrete with 90% to 70% of cement
that of design.
optimum GGBFS replacement as cementation material is
characterized by high compressive strength, low heat of
hydration, resistance to chemical attack, better workability,
good durability and cost-effectiveness. Blast furnace slag is a
by-product of iron manufacturing industry. Iron ore, coke and
limestone are fed into the furnace, and the resulting molten
slag floats above the molten iron at a temperature of about
1500oC to 1600oC. The molten slag has a composition of 30%
to 40% silicon dioxide (SiO2) and approximately 40% CaO,
which is close to the chemical composition of Portland cement
The production of GGBS requires little additional energy
compared with the energy required for the production of
Portland cement. The replacement of Portland cement with
GGBS will lead to a significant reduction of carbon dioxide
gas emission. GGBS is therefore an environmentally friendly
construction material. It can be used to replace as much as
80% of the Portland cement when used in concrete.
It has been reported that the manufacture of one tonne of
Portland cement would require approximately 1.5 tonnes of
mineral extractions together with 5000 MJ of energy, and
would generate 0.95 tonne of CO2 equivalent . As GGBS is a
by-product of iron manufacturing industry, it is reported that
the production of one tonne of GGBS would generate only
about 0.07 tonne of CO2 equivalent and consume only about
1300 MJ of energy.
It is observed that GGBS-based
concretes have achieved an increase in strength for 20%
replacement of cement at the age of 28 days. Increasing
strength is due to filler effect of GGBS. 2. The degree of
workability of concrete was normal with the addition of
GGBS up to 40% replacement level for M35 grade concrete.
3. From the above experimental results, it is proved that
GGBS can be used as an alternative material for cement,
reducing cement consumption and reducing the cost of
construction. Use of industrial waste products saves the
environment
and
conserves
natural
resources.
All the specimens were prepared for M30 mix design.
Specimens of size 150*150*150 were casted and
compressive strength was tested for 7 days and 28 days. On
addition of glass powder sludge initial strength is not very
high but when tested for 28 days it meets the desired design
strength.
Ground Granulated Blast Furnace Slag
Cement with GGBS replacement has emerged as a major
alternative to conventional concrete and has rapidly drawn the
concrete industry attention due to its cement savings, energy
savings, cost savings, environmental and socio-economic
benefits. This research evaluates the strength and strength
efficiency factors of hardened concrete.From this study, it can
be concluded that, since the grain size of GGBS is less than
that of ordinary Portland cement, its strength at early ages is
low, but it continues to gain strength over a long period. The
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SSRG International Journal of Civil Engineering (SSRG-IJCE) – volume 3 Issue 5 – May 2016
Sr.
No
Author,country
&
year
Amitkumar D. Raval1,
Dr.Indrajit N. Patel2, Prof.
Jayeshkumar Pitroda3
Ref.
No
Mix proportion
replacement
Advantages
Problem
solution
1
w/c ratio-.52
replacement10%,20%,30%,
40%,
50%
Ceramic waste
powder
To reduce the
problem of pollution
produced by ceramic
waste
Reduce
the consumption
of natural
resources
2
Mr.R.Balamurugan1,
Mr.R.Karthickraja2
2
Hypo
sludge
3
Professor and HoD,
Department of Civil
Engineering, Educational
and Research Institute,
Dr.M.G.R. University,
Chennai
C Freeda Christy
And D Tensing
3
Replacement50%,60%,70%,
80%,90%,100%
Replacement20%,30%,40%
To resolve the
dumping problem of
hypo sludge
High strength of
concrete is achieved.
A low cost
concrete can be
formed.
Better
workability and
good durability of
concrete is
achieved.
4
Cement mortar:
1:3,1:4.5,1:6
Glass fly ash
Increase of masonry
bond strength
Solve problem of
of disposal of fly
ash.
5
Sumit A Balwaik; S P Raut
5
Replacement5%,10%,15%,20%
M20 w/c =.50
M30 w/c =.45
Waste paper pulp
Alternative to
landfill
disposal.
6
DHANARAJ MOHAN
PATIL1, DR. KESHAV K.
SANGLE2
6
Replacement10%,20%,30%
M30
Waste glass
powder
Compressive
strength,
split tensile strength,
flexure strength
increase by 10%
Overall performance
of 20% replacement
is better than 10%
and 30%
7
Sajad Ahmad, M. Iqbal
Malik, Muzaffar Bashir
Wani, Rafiq Ahmad
7
Replacement5%,10%,15%,20%
Waste paper
sludge ash
Replacement up to
5% by weight can be
used for positive
outcomes
Sustainable
concrete industry
8
Chandana Sukesh1, Bala
Krishna Katakam1, P
Saha2+ and K. Shyam
Chamberlin2
8
Replacement10%,20%,30%,
40%
Industrial waste
Solution to the
problem of land
disposal.
9
Ivan Razl, Ph.D., P.Eng
9
M30
Flexible polymer
5% plastic partial
replacement with
cement achieves
doubles the strength
when compared to
normal concrete
Increases toughness,
tensile and bending
strength.
10
Prof. P.A. Shirulea*, Ataur
Rahmanb , Rakesh D.
Guptac
10
Replacement5%,10%,15%,20%
Marble dust
powder
Compressive strength
increases up to 10%
replacement
Sustainable
developement
11
Prof. Jayeshkumar Pitroda1,
Dr.
L.B.Zala2,
Dr.F.S.Umrigar3
11
Replacement10%,20%,30%
,40%
Fly ash
Fly ash use saves the
disposal costs of coal
industry
Cost saving and
saving of natural
resources
12
Noor Faisal Abas
12
Replacement5%,10%,15%
Waste paper
sludge
Best results came
with 20%
replacement after 40
days
A step towards
Green
environment
13
G. Moriconi
13
Replacement25% to 30%
Recyclable
material
Compressive strength
can be improved to
equal or even exceed
the natural concrete.
Do not show any
deleterious
effects.
1
4
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GGBS
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Environment
friendly, energy
sustainability and
cost saving
Water proofing
and protection of
concrete
structures
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SSRG International Journal of Civil Engineering (SSRG-IJCE) – volume 3 Issue 5 – May 2016
RESEARCH NEEDS:
Research and current researches shows the following:
1. Further efforts are required to understand the properties of
concrete primarily high strength comprising of silica fumes and
fly ash.
2.
Research work should be done on durability and workability of
glass fly ash concrete.
3. Study should be done on adding of GGBS as partial replacement
of concrete over 40% to know about strength characteristics.
4.
Research should be done on compressive strength of flexible
polymer concrete.
SUMMARY AND CONCLUSION:
In the paper, a study of many types of replacement materials has been
done by comparing their 7, 14 and 28 day compressive strength,
flexure strength and split ensile strength. Materials such as fly ash
and silica fumes are used in the concrete industry from almost an
decade as partial replacement of cement in concrete. Silica fume and
fly ash potentials was well understood and they were utilized in huge
quantities materials such as paper pulp, paper pulp sludge are
produced in such huge quantities that it becomes almost impossible to
dispose them economically , so to solve this problem we neeed to use
paper pulp inn concrete industry. Waste such as glass powder and
ceramic waste show good strength results when compared to natural
concrete. GGBS i.e. Glass Granulated Blast Furnace Slag also
produces significant results when added as partial replacement of
cement in concrete. By comparison of compressive strength, flexure
strength and split tensile strength we can conclude that GGBS ha s a
lot of potencial as an supplement to cement and can give high
strength, durability and workability when added in desired
proportions to concrete.
[10] Prof. P.A. Shirulea*, Ataur Rahmanb , Rakesh D. Guptac,” Partial
Replacement of Cement with Marble Dust Powder”, International
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[11] Prof. Jayeshkumar Pitroda1, Dr. L.B.Zala2, Dr.F.S.Umrigar3,”
Experimental Investigations On Partial Replacement Of Cement
With Fly Ash In Design Mix Concrete”, Pitroda et al., International
Journal of Advanced Engineering Technology,E-ISSN 0976-3945
[12] Noor Faisal Abas,” Waste Paper Sludge as a Cement Replacement
Material in Green Concrete: Engineering Properties “, Australian
Journal of Basic and Applied Sciences, 9(7) April 2015, Pages: 294-298
[13] G. Moriconi,” Recyclable materials in concrete technology:
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[14]Bahoria B.V.*1, Parbat D.K.2 and Naganaik P.B.3,” Replacement of
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[16]Chandana Sukesh1, Bala Krishna Katakam1, P Saha2+ and K. Shyam
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Partial Replacement of Cement,” 2012 IACSIT Coimbatore
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References
[1]Amitkumar D. Raval1, Dr.Indrajit N. Patel2, Prof. Jayeshkumar Pitroda3,”
Ceramic Waste : Effective Replacement Of Cement For Establishing
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Technology (IJETT) - Volume4 Issue6- June 2013
[2]
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Mr.R.Karthickraja2,”
An
Experimental
Investigation of Partial Replacement of Cement by Industrial Waste
(Hypo Sludge),” Mr. R. Balamurugan et al Int. Journal of Engineering
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[3] 1) Professor and HoD, Department of Civil Engineering, Educational and
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[6] Dhanaraj Mohan Patil1, Dr. Keshav K. Sangle2,” Experimental
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Cement in Concrete
[7] Sajad Ahmad, M. Iqbal Malik, Muzaffar Bashir Wani, Rafiq Ahmad,”
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Partial Replacement of Cement ,” IOSR Journal of Engineering
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Their Applications
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