SDME Society’s
Shri Dharmasthala Manjunatheshwara
College of Engineering & Technology,
Dharwad – 580 002, Karnataka, India
(An Autonomous Institution Affiliated to VTU Belagavi & Recognized by AICTE New Delhi)
Department of Civil Engineering
MAJOR PROJECT PRESENTATION ON
“PREPARATION OF CONCRETE USING GOLD MINE WASTE”
Submitted by:
YOGESH KHANAPUR
2SD15CV091
ABHISHEK HIREMATH
2SD15CV002
CHANNABASAVA HONKAL
2SD14CV018
Under Guidance of
Prof. B M Gudaddappanavar
Asst. Professor, Civil Department.
ABSTRACT
• In recent there is a demand for making concrete in construction industry sustainable due
to depletion of natural materials. A waste product form mining plant, River sand is
becoming scare and meeting the demand of fine aggregates in the construction industry is
becoming a challenging task.
• In this investigation, an attempt is made to utilize goldmine tailings as a partial substituent
for river sand in producing concrete. River sand was replaced with 5%, 10%, 15%, 20%
and 25% gold mine tailings and the resulting fine aggregates were used in concrete mix.
Mix proportion for M20 concrete were obtained for 5 mixes as per guidelines given in IS:
10262-2009. Workability, compressive strength, tensile strength, flexural strength. The
strength was obtained at the ages of 7, 14 and 28 days. Disposal of mine tailing dumps is
one of the major problems on mining industry. Investigation are being done all over the
world do utilize tailings for useful purposes. The scope of this work is to be study the
utilization of mining tailings in manufacture of concrete.
• A lot of research and testing has happened to verify the concept of using mining dumps as
raw material for making concrete to be used in construction. Mining waste (tailing)
unscientifically causing or damage to environment, is converted into an inert component,
whose performance is most times on par with mainstream building material.
CONTENT
1.
2.
3.
4.
5.
6.
INTRODUCTION
OBJECTIVES
MATERIAL AND PROPERTIES
WORK DONE ON CONCRETE
CONCLUSION
REFERENCE
GENERAL INTRODUCTION
• Indian construction industry is one of the largest in terms on volume of raw materials/natural
resources consume. It is estimated that by the end of the year 2020, the consumption of cement will
be increased by 166%. Based on global usage, concrete is placed at 2nd position after water. Fine
aggregates are the essential components of concrete. The most commonly used fine aggregate is
natural river sand. The global consumption of natural sand is very high due to extensive use of
concrete. Concrete is widely used material in the world. Based on the global usage, it is placed at
second position after water. Fine aggregates are the essential component of concrete. The most
commonly used fine aggregate is natural sand or pit sand. The global consumption of natural sand
is very due to extensive use of concrete. Gold ore tailings are one of the primary waste products of
mining operations. They comprise of fine grained particles of the parent rock from which the ore is
extracted. The characteristics of tailings depend upon the composition of parent rock. The disposal
of this material is a major environmental problem for the mining industry. Tailings when not
utilized it will cause harm. When tailings waste is in dry state, can fly everywhere as tailings grain
is very fine. It can damage human health and disrupt agriculture. Gold ore tailings are discharged
into the tailings pond after a chemical treatment to remove free cyanide and other heavy metals.
• When tailings disposal is in the form of mud into this widely used material in the world. Based on
the global usage, it is placed at second position after water. Fine aggregates are the essential
component of concrete. The most commonly used fine aggregate is natural sand or pit sand. The
global consumption of natural sand is very high due to extensive use of concrete. Gold ore tailings
are one of the primary waste products of mining operations. They comprise of fine grained
particles of the parent rock from which the ore is extracted. The characteristics of tailings depend
upon the composition of parent rock. The disposal of this material is a major environmental
problem for the mining industry. Tailings when not utilized it will cause harm. When tailings waste
is in dry state, can fly everywhere as tailings grain is very fine. It can damage human health and
disrupt agriculture. Gold ore tailings are discharged into the tailings pond after a chemical
treatment to remove free cyanide and other heavy metals. When tailings disposal is in the form of
mud into the reservoir, treatment costs are huge. We have to build dam to accommodate the tailings
slurry, environmental pollution due to seepage and dam maintenance after the ore is closed.
Tailings disposal in the deep sea can pollute the environment due to the control that is not easy.
Disposal of gold ore is one of the major problems in mining industry. Gold ore tailings are a
common type of solid waste in KGF and have caused serious problems as landfill. The gold mining
industry at Kolar Gold Field, Kolar district of Karnataka, India has produced an abundant quantity
of tailings which are unutilized for several years. There is no vegetation on dumps, which leads to
release of fine particles into the atmosphere due to wind erosion. This causes air pollution in the
area. The tailings have affected the landscape and topography of the area as well. Hence, it is
essential to find some way to use the gold ore tailings. This study has initiated to assess the
suitability of gold ore tailings as partial substitute for fine aggregate in concrete. The evaluation
was based on parameters such as gradation results, workability, compressive strength and flexural
strength.
GOLD MINE WASTE
• It is emphasized that industrial and mine wastes can be used to develop sustainable alternate
building tech. Amit Rai and Rao have discussed about the potential of utilizing industrial/mining
rejects and tailings as building materials. They have classified them into 3 groups. Gold mine
tailings come under the Group-III, which has the potential of being used as fine aggregates in
concrete. Among the 960 million tonnes of solid waste generated annually in India, nearly
290million tonnes are inorganic waste of industrial a n d mining sectors. Investigation on grain size
distribution of gold mine tailings obtained from different sources revealed that the gold mine
tailings comprise mainly of fine sand. Disposal of gold ore is one of the major problems in the
mining industry. Gold ore tailings are a common type of solid waste in KGF and caused serious
problem as landfill. About 70% of gold mine tailings are coarse than 75micron size and 63% of this
material Belongs to fine sand category. Chemical composition of gold mine tailings shows that the
major component is silica. Due to the presence of silica content, the gold waste in different
industrial applications ensure environmental sustainability and economic benefits. The presence of
cyanides contained in gold mine waste is very less. Thus, gold mine tailings are safe as
construction materials. The workability of concrete in terms of both slump and compaction factor
for concrete containing gold mine tailings alone is very low, which can be attributed by the
presence very fine. Concrete containing gold mine waste was observed good workability. The
acceptability of utilizing gold mine tailings as a substituent to sand in concrete production was
found to be satisfactory on the basis of compressive strength and durability.
• The gold mining industry at Kolar Gold Field, Kolar district of Karnataka, India has produced an
abundant quantity of tailings which are utilized from about 100B.C to 2003A.D. It has recorded a
history of 2000 years since Tippu sultan’s era. It is one the deepest goldmine in the world i.e. about
3.2km. About 32million tonnes of tailing waste is present in the site, consuming about 12,500acres
of land. There is no vegetation on dumps, which leads to the release of fine particles into the
atmosphere due to wind erosion. This causes air pollution in the area. The tailings have affected the
landscape and topography of the area as well. Hence, it is essential to find some want to use the
gold ore tailings.
• This study is initiated to assess the sustainability of gold mine tailings as a partial substituent for
fine aggregate in concrete. The evolution was based on parameters such as gradation results,
workability, compressive strength and flexural strength. A detailed research on durability studies on
concrete prepared with gold mine tailings as a partial substituent for fine aggregates will be
required before the commercial production.
OBJECTIVES
• To study the influence on workability of concrete by partial replacement of
fine aggregate with gold mine tailings/waste dumps.
• To study the influence on density of concrete by partial replacement of fine
aggregate with gold mine tailing/waste dumps.
• To study the influence on strength of concrete by partial replacement of fine
aggregate with gold mine tailing/waste dumps.
• To study the influence on durability of concrete by partial replacement of
fine aggregate with gold mine tailing/waste dumps.
• Analysis of cost.
• To reduce the adverse effect of gold mine tailings/waste on environment
(Air, water, land and vegetation).
SCOPE OF PROJECT
• This study is initiated to assess the suitability of gold mine tailing dumps, as they
are one of the primary wastes. Product of mining operation. Tailing dumps which
is extracted from the mining industry, the disposal of waste is the major problem
for mining industry.
• Fine aggregates are becoming scare and meeting the demand of aggregates in the
construction industry which is becoming a challenging task.in this investigation,
an attempt is utilize gold mine tailing dumps as a substituent for fine in production
of concrete.
• Concrete of M25 grade was using and mixture were modified by partial replacing
gold mine tailings with natural available sand. The properties of concrete in the
fresh and hardened state examined are workability and strength respectively. The
workability of concrete mixture was evaluated in terms of slump and compaction
factor tests the strength of concrete was evaluated in terms of compression,
flexural and split tensile stress.
MATERIALS
• Gold mine tailings the chemical composition and particle size
distribution were evaluated as per IS: 20001985 (11) and IS: 2386
(part-II)-1963 (12) respectively. The fraction of material passing
through 75 microns sieve was analyzed through hydrometer analysis.
The specific gravities of gold mine tailings and natural sand are 2.82
and 2.66 respectively. The chemical composition of gold mine tailings
is shown in Table 1.
SL.
TEST
AS PER IS
VALUES
CODE
OBTAINED
MOISTURE
IS 2386-
2.2
--
CONTENT
3(1963)
1417.47kg/m3
--
45%
--
2.4
BELOW
NO.
1
LIMITS
TEST
2
BULK
DENSITY
3
BULKING
IS 23863(1963)
4
5
SPECIFIC
IS 2386-
GRAVITY
3(1963)
FINENESS
IS 2386-
MODULUS
3(1963)
2.65
5.392
Table 1: The test results for gold mine waste/tailing dumps.
2.0-4.0
• GOLD MINE TAILING/WASTE DUMPS
• Tailing dump was used throughout the course of the experiment in different proportions with
respect to fine aggregates. The physical properties of tailing dumps are determined from various
tests.
• CEMENT
• Ordinary Portland cement confirming IS: 1489-1991 was used throughout the course of
investigation. Conduction of experiments like setting time, standard consistency, compressive
strength, fineness, specific gravity and soundness tests.
• RIVER SAND
• The materials which is passed through IS Sieve No 480(4.75mm) is termed as fine aggregate. Its
function is to make concrete dense, by filling voids of coarse aggregates, reduces shrinkage of
cement and makes an economical mix. Natural sand or crushed stone dust may be used as fine
aggregates of concrete.
• COARSE AGGREGATES
• Aggregates are those chemically inert materials which when bonded by cement paste form
concrete. Aggregates constitute the bulk of total volume of concrete and hence they influence the
strength of concrete to great extent. The properties of concrete are directly related to those of its
constituents and such are aggregate used in a concrete mix should be hard, strong, dense, durable,
free from lumps of clays, loam, vegetables and other such foreign matter. The presence of all such
materials prevents adhesion of cement on the surface of aggregates and reduces the strength of
concrete.
SL.
TEST
AS PER IS CODE
NO.
VALUES
LIMITS
OBTAINE
D
1
STANDARD
IS4031-PART-1988
28.5%
24%-34%
3.17
3-4
CONSISTENCY
2
SPECIFIC GRAVITY
3
SETTING TIME
IS 4031-PART5-
1. INITIAL SETTING
1988
NOT
115 MIN
LESSTHAN 30
MIN
TIME
NOT
2. FINAL SETTING
295 MIN
TIME
LESSTHAN
600 MIN
4
FINESS OF
7.6
CEMENT
Table 2: The test results for cement
SL.
TEST
AS PER IS
VALUES
CODE
OBTAINED
SPECIFIC
IS 2389-PART-
2.547
2.65-2.67
GRAVITY
III
FINENESS
IS 2386-PART I
3.7
2-4
IS 2386-PART-
1601.198Kg/m3
1520-
NO.
1
2
LIMITS
MODULUS ZONE
3
BULK DENSITY
1680Kg/m3
III
4
WATER
IS 2386 PART V
3.7
ABSORPTION
Table 3: The test results of fine aggregates.
--
SL.
TEST
AS PER IS CODE
NO.
1
VALUES
LIMITS
OBTAINED
Specific
IS 2386-Part-III
2.6
2.4-3
Gravity
2
Bulk Density
IS 2386-Part-III
1650.16Kg/m3
1520-1680Kg/m3
3
Water
IS 2386-Part-III
0.305%
0.1-2%
IS 2386-Part-IV
22.69%
Not More Than
Absorption
4
Aggregate
Crushing
5
Aggregates
30%
IS 2386-Part-IV
19.85%
Impact
10-20% Strong
Aggregate
6
Abrasion Test
IS 2386-Part-IV
20.6%
7
Sieve
IS 2386-Part-I
8.61
Analysis
Table 4: Test results for Coarse Aggregates.
WORK DONE ON CONCRETE
TESTS ON CONCRETE
• FRESH CONCRETE
Slump cone test
Compaction factor test
• HARDENED CONCRETE
Compressive strength
Flexural strength
TRAIL CASTING
• MIX DESIGN BY IS METHOD
Indian standard institution has brought out mix design (M20). Procedure mainly work done in national
laboratories i.e., covered in IS 10262-2009 to obtain the medium strength concrete.
• MIXING
Mixing is done on hard surface manually. First the sand and cement taken in correct proportion and
mixed in dry state. Then the coarse aggregates are added and mixed till the color is homogeneous and the mix is
workable.
• CASTING
Cubes specimens of 150x150x150mm and beam specimens of size 100x100x500mm were cast using
the finalized mix proportion from table No.1 for M20 grade concrete (control mix and gold mine tailings
concrete). The specimen was prepared as IS: 516-1989 and test for compressive strength at 7, 14 and 28 days.
• CURING
The specimens were kept in water tank and cured as per IS standard, water being changed at regular
interval. After the period of curing the specimens were taken from water tank and allows to dried the specimen
and then the specimen were tested.
TEST FOR COMPRESSIVE STRENGTH
• Standard moulds of 150mmx150mmx150mm size are used for casting
concrete cubes. The cubes were compacted in three layers. Nine concrete
cubes were casted for each mix. A total of forty-five concrete cubes were
casted. Cubes were immersed in water for curing till the date of testing. The
specimens were prepared as per IS: 516-1989 and tested for uniaxial
compressive strength at 3, 7 and 28 days. The results obtained are the
average of three specimens tested and the results. To determine the
compressive strength of HIGH STRENGTH CONCRETE, cubes of size
150mm x 150mm x 150mm we re-casted for all the molarities mentioned.
All cubes will be tested for 7, 14 and 28 days. The compressive strength
was calculated based on the following expression tabulate.
Compressive strength=Load (P) / Cross sectional area [l*b] N/mm2
%
of
Replacement
Slump
in
Avg. Compressive Strength(N/mm2)
mm
GMW
7 Days
14 Days
28 Days
0
50
19.7
23.58
29.18
5
45
20.00
25.32
32.09
10
45
20.14
28.71
34.66
15
40
22.51
30.66
35.66
20
35
19.55
22.58
30.65
25
35
15.7
19.7
24.58
Table 5: Compression strength test on concrete.
Strength variation along the replacement.
40
35
30
25
20
15
10
5
0
0%
5%
10%
7 Days
15%
14 Days
28 Days
Graph 1: Strength variation along the replacement
20%
25%
TEST FOR FLEXURAL STRENGTH
• Standard moulds of section 150mm x 150mm and length 700mm were used
for casting beams. Nine beams were casted for each mix. The specimens
were prepared as per IS: 5161989 and tested for flexural strength at 28 days.
Two-point loading test was conducted using Universal Testing Machine
(UTM) of 400KN capacity. The results obtained are the average of three
specimens tested and the results are presented in Table 6.
• To determine the Flexural strength of concrete, beams of size 100mm x
100mm and 500 mm height were casted for all the molarities mentioned. All
beams were tested for 14 and 28 days. The tensile strength was calculated
based on the following expression.
Tensile Strength = PL/bd² N/mm2
d= depth of beam in mm. L= length of beam in mm.
% of Replacemnt
Workability(Slump in
Avg. Flexural Strength
GMW
mm)
(N/mm2)
0
50
5.45
5
45
5.92
10
45
6.527
15
30
6.43
20
35
5.29
25
35
5.6
Table 6: Flexure strength value at 28 days
Avg. Flexural Strength (N/mm2)
Flexural Strength Results
7
6
5
4
3
2
1
0
0%
5%
10%
15%
% of replacement of GMW
28 Days
Graph 2: Test results of flexural strength
20%
25%
CONCLUSION
• In this experimental investigation, an attempt has been made use Gold Ore Tailings to replace the fine
aggregates in concrete.
• Following are some of the conclusions drawn from the results of this investigation:
• Gold ore tailings are the finer materials which can reduce the voids in concrete.
• Up to 20% replacement of fine aggregates by gold ore tailings, the results obtained are satisfactory.
• From the above results 15 % replacement of GOT gives high Compressive and flexural Strength.
• Kolar Gold Fields of Karnataka have 33 million tons of gold waste which can be utilized in construction
resulting in conservation of around 19.8 million tons of sand and reduction in pollution.
• By using these wastes instead of conventional materials, which would not only be preserving the natural
precious resources, but also solving the problems of disposal of waste, which has become a problem.
• Construction of buildings from ore waste is eco-friendly as it utilizes waste and reduces air, land and
water pollution. It is energy efficient and also cost effective.
• There is large scope for utilizing ore wastes for the manufacture of building materials and products. This ore
wastes are used as fine aggregates in concrete can meet the demand for next few decades.
REFERENCES
• B M Ramalinga Reddy, K S Satayanarayanan H N Jaganath Reddy and N Parthasarathi “use of gold mine tailings in production of concrete’’
a feasibility study international journal of earth sciences and environmental, vol.9, no.03, pp;197-202,2016
• Daud and David “Engineering properties of gold mine tailings”, International journals of surface mining, reclamation and environment.13,
pp:91-96,1999
• International journals of latest technology in engineering, management and applied science (IJLTEMAS)volume VI, issues IV, April
2017/ISSN 2278-2540
• Preethi A V, Dr. S Rajendra, Navneeth, Pawan Kumar L
• Sudhakar Rao and B.V Venkataramana Reddy
• IS-2386-PART I (1963)
• IS-2386-PART II (1963)
• IS-2386-PART III (1963)
• IS-2386-PART IV (1963)
• IS-2389-PART-III (1963)
• IS4031-PART-1988
• IS4031:1988-PART5
• IS: 2000 “IS code for methods of chemical analysis for ore” Bureau of Indian standard. New Delhi, India,1985
• IS-2386 “IS code for method of test for aggregates for concrete”, Bureau of Indian standard. New Delhi, India,1963
• IS: 10262-2009, recommended guidelines for concrete mix design, Bureau of Indian standard. New Delhi, India.