Review on “Application of Hypo Sludge in RCC

Structure”
S.P.Chavan , Patil Varsha , Jagtap Shubhangi ,Khapare Arati, Khan
Hajrakhatun, Nangre Kajal , Sayali Jadhav

Department of Civil Engineering, AGTI’S, DACOE Karad.

ABSTRACT

An existing system, high quantity of waste is contributed by paper industry. To reduce disposal and pollution
problems emanating from these industrial wastes, it is most essential to develop profitable building materials
from them .Based on this project, to avoid those problems, Hypo sludge is a recent arrival among cementations
materials. It was originally introduced as artificial pozzolana while producing paper the various wastes are
comes out from the various processes in paper industries. Concrete has attained the status of a major building
material in all the branches of modern construction.700mm x 150mm x 150mm RCC beams were casting using
M20 grade concrete. Specimens with OPC replaced with hypo sludge at 5%, 10 % and 15% . During casting the
RCC beams where mechanically vibrated by using a table vibrator after 24 hours, the specimen where removed
from the mould and subjected to water curing for 28 days. After curing the, specimens where tested for flexural
strength using universal testing machine. Flexural strength known as modulus of rupture, bend strength, or
fracture strength, it defined as material ability to resist deformation under load. The transvers load applied on
rectangular cross section is bend until fracture using two point flexural test technique. The flexural strength
represent the highest stress experienced within the material at its moment of rupture. It is measured in term of
stress.

KEYWORDS: Hypo sludge , Cement, RCC, Fine aggregate, Coarse aggregate, Flexural strength.

1. INTRODUCTION

To save energy and to earn carbon credit is very much essential for the betterment of mankind. To produce 1
tons of Ordinary Portland Cement we use earth resources like limestone, etc. & during manufacturing of 1 tons
of Ordinary Portland Cement an equal amount of carbon-dioxide are released into the atmosphere which is
harmful to the environment.

Cement manufacturing industry is one of the carbon dioxide emitting sources besides deforestation and burning
of fossil fuels and concrete industry is one of the largest consumers of natural virgin materials. The global
cement industry contributes about 7% of greenhouse gas emission to the earth’s atmosphere.

In order to address environmental effects associated with cement manufacturing and constantly depleting natural
resources, there is a need to develop alternative binders to make concrete industry sustainable. This work
examines the possibility of using waste paper sludge ash as partial replacement of cement for new concrete. An
enormous quantity of waste paper sludge is generated all around the world. In India, 0.7% of total urban waste
generated comprises of paper sludge. Paper mill sludge is a major economic and environmental problem for the
paper and board industry. The material is a by-product of the de-inking and re-pulping of paper .In order to
make concrete industry sustainable, the use of waste materials in place of natural resources is one of the best
approaches.
2.1. MATERIAL USES

For the casting of RCC beam , such type of material are used.

1. Hypo sludge
2. Cement
3. Aggregate
4. Water

2.1.1 HYPO SLUDGE

Hypo sludge is a solid waste from the paper industry. Hypo sludge is a recent arrival among cementations
materials. It was originally introduced as artificial pozzolana while producing paper the various wastes are
comes out from the various processes in paper industries. From the preliminary waste named as hypo sludge due
to its low calcium is taken out for our project to replace the cement utilization in concrete.

Paper making industries generally produces a large amount of solid waste. Paper fibers can be recycled only a
limited number of time before they become too short or weak to make high quality paper. From paper
manufacturing process three types of sludge are obtained namely lime sludge , Hypo sludge and De-Inking
sludge. In our project we have utilized Hypo sludge as a replacement for cement. Hypo sludge is a material
obtained from the chemical recovery process of paper production.

Hypo sludge is available abundantly worldwide, but its usage to date is very limited. Each Indian mill produces
an average 40 over-dry tones of sludge per day. Where, this hypo sludge contains, low calcium and maximum
calcium chloride and minimum amount of silica. Hypo sludge behaves like cement because of silica and
magnesium properties. This silica and magnesium improve the setting of the concrete. The Hypo sludge can
minimize the demand for cement and reduce the cost of construction.

2.1.1.1 NEED FOR HYPO SLUDGE UTILIZATION

While producing paper the various wastes are comes out from the various processes in paper industries. From
the preliminary waste named as hypo sludge, due to its low calcium is taken out for our project to replace the
cement utilization in concrete. Due to the cement production green house gases are emitted in the atmosphere.
For producing 4 million t of cement, 1 million green house gases are emitted. Also, to reduce the environmental
degradation, this sludge has been avoided in mass level disposal in land. To eliminate the ozone layer depletion,
production of cement becomes reduced. For this, the hypo sludge is used as partial replacement in the concrete
as high performance concrete. By utilizing this waste the strength will be increased and also cost reduction in
the concrete is achieved.
2.1.2 CEMENT

The most common cement used is an ordinary Portland . the ordinary porland cement of 53 grade ( Altratech
OPC ) conforming to IS:8112 is be use.

Physical properties of cement

Physical properties of cement Value of cement

Specific gravity 3.15
Standard consistency (%) 28%
Initial setting time (hrs, min ) 35 min
Final setting time ( hsr, min) 178 min

2.1.3. AGGREGATE

Aggregates are the important constituents in concrete. They give the body to the concrete , reduce shrinkage and
effect economy. One of the most important factors for producing workable concrete is a good gradation of
aggregates.

2.1.3.1 FINE AGGREGATE

The fractions from 4.75mm to 150 micron are termed as fine aggregates. The river sand and crushed sand is
used in combination as fine aggregate.

2.1.3.2 COARSE AGGREGATE

These are igneous rocks are fine grained, strong and dense formed by the cooling of parts of the bodies molten
material which is called I general Basalt are more common igneous rocks. Aggregate developed by crushing of
these rocks are black in colour and very common used for concrete work also known as black trap. Sedimentary
rocks also called derivative rocks were deposited in some geological age mechanically through the agency of
water, wind or ice action chemically or organically.

These rocks cover about three quarters of the earth’s land surface, sandstone is one of its types used in concrete
production being hard and durable. Sandstone in the forms of strips is also used in slab construction.
Metamorphic rocks are formed from igneous or sedimentary rocks. The igneous crust where they are upon by
great heat and pressure because of these agencies rock are also partly or wholly changed and new is formed.

3. CONCRETE BEAM

Concrete beam of standard size 700mm x 150mm x 150mm is used for the study. A total number of 24
specimens were cast for different proportion of hypo sludge was constituted with replacement of 0%, 5%, 10%
and 15%. Three specimens were prepared for every replacement percentage and these beams were tested for
flexural strength on UTM.
4. FLEXURAL TEST ON BEAM

Flexure test are generally used to determine the flexural modulus or flexural strength of material. A flexural test
is more affordable than a tensile test and test results are slightly different. The beam laid horizontally over two
points of contact and then a force is applied to the top of the material through either one or two points of contact
until sample fails. The maximum recorded force is the flexural strength of the beam.. Flexural strength of beam
is calculated as per IS 516-1959

5. ASSUMPTIONS

Before conducting the experiments some assumptions are made as follows :

 The planes of cross section of the beam consider will be remains plain before bending and after bending.
 The bonding between the concrete and steel will be perfect and homogeneous .
 The stress strain behaviour of concrete and steel are mostly similar.
 The tensile strength of concrete is ignored .All the tensile stress is taken only by the reinforcement.
 The stress and strain relationship for the compressive zone in concrete is assumed to be parabolic that
result in obtaining the strength .

6. EXPERIMENTAL SETUP

Simply supported RCC beams where subjected to pure flexural failure by subjecting them to two point loading
test. The beam is used in study were 150mm x 150mm in cross section and 700mm in length. Two 12mm
diameter bars were used for flexural reinforcement at a bottom and two 10mm rod were provided for top
reinforcement. For each beam 6mm diameter mild steel bars used as stirrups, spaced 400mm c/c for shear
reinforcement. For this investigation total number of 24 specimen were cast and tested for cement replacement.
All beams were cast by using M20 grade concrete with 20mm size of coarse aggregate, local available sand,
crush sand and OPC of 53 grade.

All beams(150mm x 150mm in cross section and 700mm in length ) where tested as simply supported beams
under two point loading over an effective span of 600mm the load applied at distance of 100mm on either side
of mid span of beam. To study the performance of hypo sludge replaced specimen these beams where tested in
UTM.
 Fig. Two point load test

7. PROCEDURE:

1. Prepare the test specimen by filling the concrete into the mould in three layers of approximately equal
thickness. Tamp each layer 35 times using the tamping bars as specified above . Tamping should be
distributed uniformly over the entire cross section of the beam mould and through out the depth of each
layer.
2. Clean the bearing surface of the supporting and loading rollers , and remove any losses sand and other
material from the surface of the specimen where they are to make contact with rollers.
3. Circular rollers manufactured out of steel having cross section with diameter 20mm will be used for
providing support and loading points to the specimen .
4. The specimen is removed from the water. The test specimen shall be placed in a machine correctly centred
with the longitudinal axis of the specimen at right angle to the rollers .

Result:

Sr. No. Partial Replacement Ultimate flexural strength

In % (kg/cm^2) (28 Days)
1 0 297.735
2 5 287.12
3 10 302.675
4 15 250.69
CONCLUSION:

It is observed that the flexural strength of M20 grade concrete has increased by 10% replacement of cement
with hypo sludge as compared to the conventional concrete. The result goes on decreasing by 5 % and 15%
replacement of cement with hypo sludge.

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