International Journal of Civil Engineering and Technology (IJCIET)
Volume 10, Issue 04, April 2019, pp. 1889–1900, Article ID: IJCIET_10_04_198
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJCIET&VType=10&IType=4
ISSN Print: 0976-6308 and ISSN Online: 0976-6316
© IAEME Publication
Scopus Indexed
EFFECT OF SOLID CERAMIC WASTE
POWDER IN PARTIAL REPLACEMENT OF
CEMENT ON MECHANICAL PROPERTIES AND
SORPTIVITY OF CEMENT MORTAR
Ali Hussain Ali
Assistant Professor, Building and Construction Department, Technical College of Mosul, Iraq
Dr.Aliaa Abbas Al-Attar
Assistant President of the Northern Technical University for Scientific Affairs, Iraq
Zeena Emad Kasm*
M.Sc. Students, Building and Construction Department, Technical College of Mosul, Iraq
Corresponding Author*
ABSTRACT
Some of the most serious problems of the world today concern elimination of
waste and finding a solution for reusing it. Large quantities of waste are generated
from manufacturing processes and construction destruction works. Materials waste
administration is one of the most important environmental interests in the world today
and with the reduction of space for landfilling, waste employment has become an
effective alternative to the disposal of waste. In this work, cement was replaced with
ceramic waste powder (CWP) in the range of 0%, 5%, 10%, 15%, 20%, 25%, 30%,
35%, and 40% of cement weight and the fineness of the CWP used was below 75µm.
After the moulding and curing processes, the specimen’s mortar was tested and
compared with the conventional mortar in terms of compressive, flexural and splitting
tensile strengths, and sorptivity test. The findings showed that the compressive
strength attained was up to 35% as a result of replacing cement with CWP.
Key words: Ceramic Powder, Mortar, Sorptivity, Environment, World
Cite this Article: Ali Hussain Ali, Dr. Aliaa Abbas Al-Attar, Zeena Emad Kasm,
Effect of Solid Ceramic Waste Powder in Partial Replacement of Cement on
Mechanical Properties and Sorptivity of Cement Mortar, International Journal of Civil
Engineering and Technology 10(4), 2019, pp. 1889–1900.
http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=10&IType=4
1. INTRODUCTION
Nowadays, pozzolanic materials have been used as construction materials, especially for their
effect in improving the properties and durability of concrete. At present, the concern about
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Ali Hussain Ali, Dr. Aliaa Abbas Al-Attar, Zeena Emad Kasm
environmental pollution due to the environmental protection regulations has induced further
researches on the possibility of using pozzolanic materials from industrial wastes like ceramic
wastes and fly ash. Partial replacement of cement in mortar or concrete by waste materials
such as ceramic powder would assist in solving the landfill problems and lead to improving
the properties of concrete [1]. Ceramic wastes may come from two exporters; 1) ceramic
industry (classified as non-hazardous industrial waste) and 2) construction and destruction
activities [2]. Ceramic wastes are characterised as wastes that are tough and can bear the
changes and climatic conditions (sturdy), and resist biological and chemical decomposition,
making them suitable as recycling options [3]. Every year the ceramic and construction
manufacturers dump wastes (solid or powder) on large tracts of land without recycling. This
leads to environmental pollution and conquest of a large area of land. Therefore, it is
necessary to dispose of the ceramic wastes and use in the construction industry (in concrete or
mortar) [4]. Cement is a major material in the concrete and mortar industries due to abundant
raw material and relatively low cost. However, the process of the cement industry sends a
high level of carbon dioxide emissions to the atmosphere (about one tonne of carbon dioxide
per tonne of cement). It has also been estimated that cement factories are accountable for the
emission of more than two billion tonnes of carbon dioxide (CO2) yearly. The use of ceramic
waste in the concrete industry has many environmental, economic and technological benefits,
where it works by recycling ceramic waste to save energy, reduce CO2 emissions and improve
the properties of concrete [5]. There are a few studies around the world that explore the
potential use of ceramic waste in the industrialisation of concrete as a partial replacement of
cement or aggregates. For example, one research had replaced a part of cement with ceramic
roofing waste (replacement rates ranged from 25% to 40% of cement). The results indicated
that waste possessed pozzolanic properties and had some similarities with the chemical and
physical properties of cement [6]. Many researches and studies have confirmed the prospect
of using ceramic waste in the construction industry in addition to its use as a partial
replacement for cement or aggregates in concrete or mortar; ceramic waste may be used as
fillers in ceramic bricks and solid bricks (a mixture of soil-cement and ceramic waste) [7].
This research is part of an experimental work that focuses on a mixture of solid ceramic
wastes that are abundant and widespread in Iraq due to the destruction of buildings in the
recent events. In the laboratory, a mixture of ceramic wastes was ground to obtain fine
powder. Then, the CWP was sieved to produce particle size of less than 75 µm and used for
the partial replacement of cement [8]. A chemical analysis was performed and some physical
properties were studied.
2. SCOPE AND OBJECTIVE
This study aims to investigate the use of CWP as a replacement for cement in mortar
mixtures, and study the behaviour of this type of mortar after curing the specimens in plain
(normal) water. It also aims to study the effect of CWP when used as a partial replacement of
cement (0 to 40% of cement weight) on the fresh and solid properties of mortar mixtures. The
commensurable objectives are as follows:
1. Evaluate CWP for reconciliation to be used in mortar as a replacement of cement.
2. Use CWP as supplementary cementing material in mortar mixtures with different
replacement ratios.
3. Evaluate mortar properties by using mechanical tests (compressive strength, splitting
tensile strength, flexural strength and sorptivity).
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Effect of Solid Ceramic Waste Powder in Partial Replacement of Cement on Mechanical
Properties and Sorptivity of Cement Mortar
3. PRACTICAL INVESTIGATION
3.1. Materials
3.1.1. Cement
Ordinary Portland Cement (OPC) was used as it satisfied the Iraqi standard specification
No.5/1984 [9]. Table (1) and Table (2) show the chemical and physical properties of such
cement.
Table 1 Physical properties of OPC.
characteristics
Test Values
Blain Fineness, (m2/kg)
Initial setting time, (minutes)
Final setting time, (hrs)
3-day compressive strength, MPa
7-day compressive strength, MPa
270
220
5.1
23.57
31.25
Limit of Iraq specification No.5/
1984
Min. 230
Min. 45
Max. 10
Min 15
Min 23
Table 2 Chemical properties of OPC.
Oxides
CaO
SiO2
Al2O3
MgO
Fe2O3
SO3
Loss of ignition
L.S.F.
)%(Test Values
65.06
20.91
6.32
2.75
2.8
2.06
1.56
0.93
Limit of Iraq specification
........
........
........
5%≤
........
2.8%≤
4%≤
1.02-0.66
3.1.2. Ceramic waste powder (CWP)
The grinding of solid ceramic waste was carried out in the laboratory. After sieving, the CWP
had particle size of less than 75 µm with specific gravity of 2.752. The chemical compositions
of the CWP are shown in Table (3).
Figure 1 Ceramic waste material before and after grinding.
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Table 3 Chemical compositions of ceramic waste material.
Oxide composition
Lime
Silica oxide
Alumina oxide
Magnesia oxide
Ferro oxide
Sulphate
Sodium oxide
Potash oxide
Titanium Dioxide
Phosphorus Pent oxide
Manganous Oxide
Loss on ignition
Abbreviation
CaO
SiO₂
Al₂O₃
MgO
Fe2O₃
SO₃
Na₂O
K₂O
TiO2
P2o5
MnO
L.O.I
Content Percent %
11.064
55.325
18.342
0.395
6.235
0.013
0.687
1.201
0.642
0.162
0.0713
4.3%
3.1.3. Fine aggregate
Local sand was used with specific gravity of 2.63 and fineness modulus of 2.69. The sand
satisfied the limit of Iraq standard specification No. 45/1984 [10]. Table (4) shows the sieve
analysis of the sand.
Table 4 Sieve analysis of sand.
Sieve No. (mm)
No.4 (4.75)
No.8 (2.36)
No.16 (1.18)
No.30 (0.6)
No.50 (0.3)
No.100 (0.15)
percentage Passing
100
94.31
76.11
44.11
10.42
0.46
Iraqi limitation No. 5/1984
95-100
80-100
50-85
25-60
5-30
0-10
3.1.4. Water
Ordinary tap water was used for all mixtures.
3.2. Strength activity index (SAI)
To estimate the activity of the CWP used, the activity index test was used (20% replacement
ratio with CWP according to ASTM C311 [11]).The SAI for 28 days was 84%.
3.3. Mixture proportion
A mixing ratio of 1:2.75 with water cement ratio of 0.5 was used in the present work. The
effects of CWP on the compressive, flexural and splitting tensile strengths were examined.
Cement was replaced with CWP by 5%, 10%, 15%, 20%25%, 30%, 35%, and 40% of cement
weight.
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Effect of Solid Ceramic Waste Powder in Partial Replacement of Cement on Mechanical
Properties and Sorptivity of Cement Mortar
Table 5 Proportions of mortar.
Mortar mix
Replacement ratio
Materials (kg/m3)
OPC
Ceramic Powder
(kg/m3)
Sand
w/c
0
(M0)
5%
(M1)
10%
(M2)
15%
(M3)
20%
(M4)
25%
(M5)
30%
(M6)
35%
(M7)
40%
(M8)
550
0
522.5
27.5
495
55
467.5
82.5
550
110
412.5
137.5
385
165
375.5
192.5
330
220
1660
0.50
1660
0.50
1660
0.50
1660
0.50
1660
0.50
1660
0.50
1660
0.50
1660
0.50
1600
0.5
4. TESTING PROGRAMMES
4.1. Flow test according to ASTM C1437-01 [12].
4.2 Fresh density test according to ASTM C 138 [13].
4.3 Compressive strength for 7, 28, and 90 days of using 50×50 mm cube specimen according
to ASTM C109 [14].
4.4 Flexural strength for 28 and 90 days of using 40×40×160 mm prism according to ASTM
C348 [15].
4.5 Splitting tensile strength for 28 and 56 days of using 200×100 mm cylinder according to
ASTM C496 [16].
4.6 Sorptivity test for 90 days of using 100×50 mm cylinder according to ASTM C1585 [17].
5. MIX PREPARATION AND CASTING
5.1. Mix preparation and casting for flexural, compressive and tensile strengths
In the beginning, cement and sand were blended manually until the dry components were
homogenous; the reference blend proportion was 1:2.75 (cement:sand). Water was
progressively added to ensure that all components were well-mixed. According to ASTM
C1437, the flowability of the mortar was measured up to the designed flow (110±5%). After
24 hr from casting, the specimens were removed and cured in water at the laboratory at a
temperature of between 21–23 °C until the time of testing.
5.2. Sorptivity
5.2.1. Sorptivity test
Sorptivity can be defined as a material’s capacity to absorb and transfer water via capillary
suction [18]. In this investigation, the sorptivity test conformed to ASTM C1585 that assesses
the sorptivity of a mortar specimen (sample used was a 100×50 mm cylinder).
5.2.2. Test procedure
After casting the cylinder sample, it was cured in water at the laboratory at a temperature of
between 21–23 °C for 90 days. Then, the specimen was dried in an oven at a temperature of
100 + 10 °C until the mass became constant. After drying, the sample was placed in an
aquarium as shown in Figure (2) with water level not more than 3–5 mm above the base of the
cylindrical sample. The flow from the peripheral surface was blocked by sealing it properly
with a non-absorbent coating. The quantity of water absorbed in time interval of 30 min was
measured by weighting the specimen. Surface water on the sample was wiped off with a
moisten fabric and each weighting operation was completed within 30 sec.
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Ali Hussain Ali, Dr. Aliaa Abbas Al-Attar, Zeena Emad Kasm
Figure 2 Sorptivity test schematic representation.
The calculated capillary suction depth versus the square root of time was used to estimate
the sorptivity index as follows:
Sorptivity (mm)=I/ time0.5
Where,
I= change in weight/area exposed × water density [19].
6. RESULTS AND DISCUSSIONS
6.1. Flowability
The results for flowability (workability) of mortar cement are shown in Figure (3). The figure
shows the flowability of all mortar mixtures with different substitution ratios. The flow test
results showed that the operating capacity increased slightly with the increase of cement
substitution ratio of ceramic powder. There were no significant differences between the
reference mortar and the mortar containing CWP as a partial replacement. The increase in the
flow measurement may be due to two factors: 1) ceramic powder had lower fineness than
cement, therefore, it had a lower surface area, causing the reduction in water absorption; 2)
ceramic powder is initially an inert powder because the process of the pozzolanic reaction
usually takes time [20].
6.1. Strength activity index (SAI)
The results showed that the SAI for 28 days of CWP was equal to 84% (greater than 75%
according to ASTM C618 [21]), which proved that the CWP had the pozzolanic property.
Therefore, the CWP is suitable for use as a replacement for cement in concrete mortar mixes.
6.2. Compressive strength
Table (6) and Figure (4) show the compressive strength of mortar mixes for 28 and 90 days.
The use of CWP as a partial replacement for cement via the compressive strength test showed
that with the increase in the percentage of replacement, the compressive strength gradually
decreased (decreased slightly) to a replacement ratio of 25%. This may be due to the
pozzolanic reaction that happened between silicon oxide (SiO2) and calcium hydroxide
Ca(OH)2 from the hydration process [22]. Then, the value of compressive strength started to
decrease as compared to the reference mortar. Table (‎7) explains the percentage change in the
mortar mixture strength when compared with the control mix (when the replacement ratio was
0%) at different ages, i.e. 7, 28 and 90 days and CWP percentages from 5% to 40%.
6.3. Flexural strength
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Effect of Solid Ceramic Waste Powder in Partial Replacement of Cement on Mechanical
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The results of the flexural strength test are shown in Figure (5). The value obtained for 28
days showed that the percentages of replacement (5%, 10% and 15% down to 20%) showed
no considerable differences in flexural strength compared to the normal mortar. The result can
be assigned to the activity index of CWP.
6.4. Tensile strength
Figure (6) explains the tensile strength values of mortar mixes. The results showed that even
with the replacement of CWP with cement up to 30%, the acceptable results and the resulting
mortar retained their properties compared to the control mix. The pozzolanic effects of the
CWP were the main reasons for the results.
6.5. Sorptivity test
Figure (7) explains the tensile strength values of mortar mixes. The sorptivity at 15%, 20%
and 25% of replacement with CWP showed a decrease in value compared to the reading of
the reference mortar. Then, the absorption rate started to rise with the increase of the
replacement ratio.
6.6. Fresh density
Figure (8) shows the fresh density of the cement mortar for all cement percentages with CWP.
The fresh density of mortar mixes varied depending on the replacement ratios. From the
figure, it can be noted that with the increase in replacement ratio, the reference density of the
cement mortar at zero replacement ratio was 2.25 gm/cm3. The fresh density decreased
gradually; the higher the percentage of the cement substrate, the less the density of the CWP.
The decrease in fresh density was due to the increase in the amount of CWP in the mortar
mixture to the specific weight of the CWP, which was 0.4 times the value of the specific
weight of the cement [23].
140
120
Flow (%)
100
80
60
40
20
0
Figure 3 Flowability results of mortar.
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Ali Hussain Ali, Dr. Aliaa Abbas Al-Attar, Zeena Emad Kasm
Table 6 Results of compressive strength.
Mix no
M0
M1
M2
M3
M4
M5
M6
M7
M8
7 days (MPa)
33.45
33.87
32.42
30.21
28.76
26.57
23.92
21.25
19.42
28 days (MPa)
42.32
43.62
41.21
38.68
35.45
33.26
30.75
29.61
25.35
90 days (MPa)
45.35
45.75
43.52
40.68
37.92
35.36
32.32
30.52
27.34
50
Compresive strenght MPa
45
40
35
30
7 days
25
28 days
20
90 days
15
10
5
0
M0% M5% M10% M15% M20% M25% M30% M35% M40%
Figure 4 Compressive strength of different mixes.
Modulus of Rupture
8
Flextural Strengh Mpa
7.5
7
6.5
6
5.5
5
4.5
4
3.5
M%0
M%5
M%10 M%15 M%20 M%25 M30% M%35 M%40
Ceramic Waste Powder Content%
Figure 5 Flexural strength of different mixes.
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Properties and Sorptivity of Cement Mortar
Table 7 Percentage change in strength of mortar mixtures relative to reference mix.
Mixture Age
7-Days
28-Days
90-Days
M5%
M10%
1.25%
3%
0.8%
-3%
-2.6%
-4%
M15
%
-9.6%
-8.6%
-10%
M20%
M25%
M30% M35%
-14%
-16.2
-16.3%
20.5%-21%
-22
-28.4%
-27.3
-28%
36.4%
-30%
-32%
M40%
-41.9
-40%
-39.7
Splitting Tensile Strenght
Splitting tensile strenght
3.5
3
2.5
2
1.5
28 days (Mpa)
1
58 days (Mpa)
0.5
0
Ceramic waste powder content %
Figure 6 Splitting tensile strength of different mixes.
Sorptivity Test (Rate Of Absorption Of Water)
sorptivity(mm/min0.5)
6
5
4
3
2
1
0
0
10
20
30
40
50
Ceramic waste powder content %
Figure ‎7 Sorptivity test values for 90 days.
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Density(g/cm3)
Ali Hussain Ali, Dr. Aliaa Abbas Al-Attar, Zeena Emad Kasm
2.5
2.4
2.3
2.2
2.1
2
1.9
1.8
1.7
1.6
1.5
0
5
10
15
20
25
30
35
40
Percentage of ceramic powder(%)
Figure 8 Fresh density for mortar mixtures in (g/cm3).
6. CONCLUSIONS
The feasibility of using CWP as a replacement for cement in the production of mortar at eight
different cement replacement levels of 0%, 5%, 10%, 15%, 20%, 25%, 30%, 35% and 40%
CWP by cement mass and its contribution to sustainable mortar mixtures were investigated in
this research. This research also examined the viability of using recycled CWP that partially
replaced cement in concrete mixtures. Based on the results of this laboratory work, the
following conclusions can be drawn:
1. Increase in ceramic powder lead to the increase in the workability of cement mortar, where
the workability at the replacement ratios of 15%, 20%, 25%, 30%, 35% and 40% increased by
about 9.5%, 11%, 14%, 19%, 23%, and 28% respectively, for the reference mixture, M0%.
2. Mortar that contained ceramic powder as the partial replacement of cement had less
compressive strength than the normal mortar. The results showed that replacement of less
than 20% had no considerable effect on the compression strength, and at M20%, the decreases
in the compressive resistance were 14%, 16.2%, and 16.3% for 7, 28, and 90 days,
respectively. After replacement ratio of 40% of cement weight, the compression strength
started to decrease significantly and affected the properties of the mortar.
3. With the addition of CWP, the splitting tensile and flexural strengths of cement mortar will
reduce gradually without any significant impact on their values so that they remain within the
safe limit.
4. The sorptivity values decreased by 9%, 27%, and 54% at 20%, 25%, and 30% replacement
ratios, respectively, as compared to the control mixture. The reduction of water absorption
rate indicated the reduction in the capillary porosity and connectivity of capillary pores. The
pozzolanic effects of the CWP were the main reasons for the reduction.
5. The use of CWP as a partial replacement of cement is an effective waste disposal solution
and it reduces cost without compromising the strength of concretes.
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Effect of Solid Ceramic Waste Powder in Partial Replacement of Cement on Mechanical
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