VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI - 590 018

RAJEEV INSTITUTE OF TECHNOLOGY
Department of Civil Engineering
Phase 2 presentation on

“Partial Replacement of Coarse Aggregate with Ceramic Tile in Concrete”

submitted to Visvesvaraya Technological University
during the year 2019-2020 in the partial fulfillment for the award of
the degree of
BACHELOR OF ENGINEERING
in
CIVIL ENGINEERING
By
HARSHA S [4RA15CV030]
S NAVEEN [4RA16CV081]
SAHANA S [4RA16CV087]
SANDHYA D E V [4RA16CV089]

Under the Guidance of

Mr. RAGHUNANDHAN YADAV C
1
Assistant Professor
 CONTENT
• INTRODUCTION.
• OBJECTIVES.
• LITERATURE SURVEY.
• MATERIALS & METHODOLOGY.
• SCOPE
• TEST CONDUCTED
• PROPERTIES
• REFRENCE

2
 INTRODUCTION
• The solid waste is increasing day by day from the demolitions of constructions. This waste is not
recycled in any form at present, but there is a huge usage of ceramic tiles in the present
constructions, some common manufactured ceramics include wall tiles, floor tiles.

• However the ceramic waste is durable, hard and highly resistant, so these waste tiles are selected as
a replacement material to the basic coarse aggregate and granite powder in place of fine aggregate.
to reuse them and to decrease the solid waste produced from demolitions of construction.

• As specimens of concrete are prepared according to mix design, tests will be conducted on the
workability and strength of specimen.

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 LITERATURE SURVEY
• Batriti Monhun R. Marwein (2016): The ceramic waste adopted is broken tiles. Ceramic waste
concrete (CWC) made with these tiles at 0%, 15%, 20%, 25% and 30%. M20 grade concrete. The
characteristics properties of concrete such as workability for fresh concrete, also Compressive
Strength, Split Tensile Strength are found at 3, 7 and 28 days.

• Md Daniyal and Shakeel Ahmad(2015): A large quantity of ceramic materials goes into wastage
during processing, transporting and fixing due to its brittle nature. The crushed waste ceramic tiles
were used in concrete as a replacement for natural coarse aggregates, enhances its properties and it
has been observed an increase in both compression and flexural strength.

• Parminder Singh and Dr. Rakesh Kumar Singla (2015): A research paper on utilization of ceramic
waste tiles from industries. A partial replacement to coarse aggregate has been studied. Three
different grades of concrete has been prepared and tested. The results are not appropriate with the
conventional but considering the strength properties, it is advisable to use ceramic tile aggregate in
concrete.

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OBJECTIVES
• To find the compression, flexural & compaction test of specimen.

• To check the comparison between conventional vs the ceramic tile concrete.

• To study the strength developments hardened concrete with waste ceramic aggregate.

• To observe the water absorption of ceramic material in concrete containing various content of
ceramic tile as aggregates replacement material.

• The usage of granite powder in concrete as an admixture to improve the workability of concrete and
the strength parameters.
• To replace coarse aggregate in concrete by using ceramic waste in various proportions (0%,10%, 20%,
30%,40% )

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 MATERIALS
• The following materials were used:
• Ordinary Portland Cement
• Fine aggregate and coarse aggregate
• Water
• Ceramic Tile aggregate
• Granite powder

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 METHODOLOGY
The methodology of present work is:
• Mix design for M20 grade concrete.
• Collection of materials – cement, granite powder, coarse & fine aggregate, ceramic tile wastes.
• Basic tests on materials:
• Cement: Standard consistency, setting time, specific gravity test.
• Aggregate: Sieve analysis, specific gravity & water absorption.
• Mixing of the raw materials according to mix proportions is to done.
• As the workability of concrete is checked by slump cone test.
• Casting of specimens for compression (150*150*150mm) cubes.
• Curing of specimens for 7 & 28 days.
• Compression test results.
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Based on Workability:
Slump Test
The slump test is done to assess the horizontal flow of concrete. It is most commonly used & also
indicates the resistance to segregation.

Compaction factor Test

The compaction test conducted in laboratory, as the compaction factor is the ratio of weights of
partially compacted to fully compacted concrete. It gives more precise than slump test.

Compression Test
This test is done to determine the strength of concrete. It is calculated by dividing the failure load
with the area of application of load, usually after 28 days curing.

Flexural Strength Test

Flexural test is done to determine the tensile strength of concrete. It tests the ability of concrete
beam or slab withstand failure of bending.

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 TEST PERFORMED
➢ CEMENT – OPC 53 GRADE
REFERNCE: IS: 4031(PART-4)-1998
For finding out initial setting time, final setting time and soundness of cement, and strength a
parameter known as standard consistency has to be used. The standard consistency of a cement paste
is defined as that consistency which will permit a Vicat plunger having 10 mm diameter and 50 mm
length to penetrate to a depth of 33-35 mm from the top of the mould.

Sl.No Description Test result Maximum limit

1 Fineness test 2% Not more than 10%

2. Normal consistency 28 -

3 Initial setting time 45min Not less than 30min

4 Final setting time 500min

5 Specific gravity 3.13 3.12-3.19

Table.6.1 Properties of Cement

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➢ FINE AGGREGATES
• REFERNCE: IS: 2386 (PART-1)-1963
• This is the name given to the operation of dividing a sample of aggregate into various fractions each consisting
of particles of the same size. The sieve analysis is conducted to determine the particle size distribution in a
sample of aggregate, which we call gradation. Many a time, fine aggregates are designated as coarse sand,
medium sand and fine sand. These classifications do not give any precise meaning. What the supplier terms as
fine sand may be really medium or even coarse sand. To avoid this ambiguity fineness modulus could be used as
a yard stick to indicate the fineness of sand. Fine sand: Fineness Modulus: 2.2 - 2.6, Sand having a fineness
modulus more than 3.2 will be unsuitable for making satisfactory concrete.

Sl.No Description Test Result Maximum limit

1 Specific gravity 2.35 2.5-3

2 Fineness modulus 3.62 2-4

3 Bulk density of fine aggregate (loose compacted) 1461.33kg/m³ 1520-1680 kg/m³

Bulk density of fine aggregate (hardened compacted)

4 1636 kg/m³

Bulking of fine aggregate

5 21.05%

Grading zone
6 Zone-II Zone I-III

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Table.6.2 Properties of Fine Aggregates
➢ COARSE AGGREGATES
• REFERNCE: IS: 2386 (PART-1)-1963
• The coarse aggregates are the materials which are greater than 4.75mm in size. The size of the coarse
aggregate used, depends upon the nature and type of work. Coarse aggregates are usually obtained by
crushing granite, gneiss, crystalline lime stone and good variety of sand stone etc. Broken bricks are the
cheap aggregates can also be used as coarse aggregates only for plain concrete work, but it provides low
strength to the concrete so it should be used as per the situation. The coarse aggregate used will be as per
IS 2386:19637 specifications. The aggregate used were angular in shape. The maximum size of aggregate
was limited to 20mm and below 20mm.
Sl.No Description Test Result Maximum range

1 Nominal size used 20 mm -

2 Specific gravity 2.6 2.6-2.8

3 Impact value 20.71% <30%

4 Fineness modulus 3.75 3.5-6.5

5 Aggregate crushing value 41.67% <40%

6 Flakiness 7.49% <30%

7 Elongation index 28.55%

Table Properties of Coarse Aggregates 11

➢ CERAMIC TILE AGGREGATE
• REFERNCE: IS: 383-1970

Sl.No Description Test Result Permissible limits

1 Origin Ceramic -

2 Impact value of crushed tile 12.5% <18.2%

3 Specific gravity of crushed tile 2.6 -

4 Crushing value of crushed tile 23.2% <24.7%

5 Water absorption 0.19% -

Table.6.4 Properties of Ceramic Tile Aggregates

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 Fig.6.1 Cubical Mould

SPECIMEN PREPARTAION
• Concrete is prepared for M 20 mix, designed for plain concrete. Materials such as cement, fine aggregates,
coarse aggregates and plastic aggregates are free from impurities are weighed with an accuracy of 5%,
10% of weight of cement and weight of sand.

• Mould Dimensions (under REFERENCE IS: 10086-1982)

• 1. Cubical mould
• Cubical mould is having the dimensions of 150mm × 150mm × 150mm. Typical cubical mould used in this project
is as shown in the below figure.

Fig.6.1 Cubical Mould

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 2. Cylindrical mould
• Cylindrical mould used in this project is having the dimensions of 150mm diameter and 300mm height.

Fig. Cylindrical Mould

3. Flexural mould
• The beam moulds shall conform to IS: 10086-1982. The standard size shall be 15 × 15 × 70 cm. Alternatively, if
the largest nominal size of the aggregate does not exceed 19 mm, specimens 10 × 10 × 50 cm may be used

Fig. Flexural Mould

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➢ MOULD PREPARTION
• Mould is cleaned properly and greased with mould oil. The prepared concrete is placed in the greased mould of
dimension 150mm × 150mm × 150mm in 3 layers each of height approximately 50mm. After the placement of
first layer of concrete it is compacted by a tamping rod of 16mm diameter, 0.6m long and bullet pointed at the
lower end. The stroke of the rod is uniformly distributed over the cross section of the mould. Each layer is
compacted with 35 strokes and next scoop of concrete is placed followed by same manner of compaction and
finally after 3 layer of compaction the top layer should be finished. Each layer is compacted with 30 strokes and
the next scoop of concrete is placed followed the same manner of compaction and finally the top layer should
be finished.

➢ CURING
• The test specimens shall be stored in a place, free from vibration, in moist air of at least 90 percent relative
humidity and at a temperature of 27° ± 2°C for 24 hours ± ½ hour from the time of addition of water to the
dry ingredients. After this period, the specimens shall be marked and removed from the moulds and,
unless required for test within 24 hours, immediately submerged in clean, fresh water or saturated lime
solution and kept there until taken out just prior to test.

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➢ MIX DESIGN
• 5.1 MIX DESIGN FOR CONVENTIONAL CONCRETE
Illustrating the mix proportions for a concrete of M-20 grade.
Stipulations for proportioning
a) Grade of concrete : M20
b) Type of cement : OPC 53 grade conforming to IS 8112
c)Maximum nominal size of aggregate : 20mm
d) Minimum cement content : 250 kg/m³
e) Workability : 100mm (slump value)
f) Exposure condition : Severe
g) Method of concrete placing : Non pumping/Manual
h) Degree of supervision : Good
i) Type of aggregate : Crushed angular aggregate
j) Maximum cement content : 360 kg/m³
Test data for materials
a) Specific gravity of cement : 3.29
b) Specific gravity of
• Coarse aggregate : 2.6
• Fine aggregate : 2.35

c) Free moisture
• Coarse aggregate : Nil
• Fine aggregate : Nil

d) sieve analysis
• Coarse aggregate : 3.75
• Fine aggregate : 3.62 16
1. Target strength for mix proportion
f’ ck= f ck + 1.65*S
Where,
f’ ck=target average compressive strength at 28 days
f ck =characteristic compressive strength at 28 days
S = standard deviation
From table 1 of IS 10262-2009, S=4 N/mm²
Therefore, target strength = 20+1.65*4= 26.6 N/mm²

2. Selection of water-cement ratio

From figure-1 of IS 10262-2009, maximum water -cement ratio is 0.5. Therefore, adopt water-cement ratio= 0.45

3. Selection of water content

From table 2 of IS 10262-2009, maximum water content for 20mm aggregate = 186 liters (for 25 to 50mm slump range)
Estimated water content for 100mm slump = 186 + (3/100) × 186= 191.58 liters
Hence the calculated water content = 191.58 liters

4.Calculation of cement content

Water cement ratio = 0.45
Water = 191.58 liters
Cement content = 191.58/0.45 = 425.73 kg/m³
From durability point of view the maximum cement content from IS 456:2000= 360 kg/m³
Minimum Cement content = 250 kg/m³
Hence, adopt 360 kg/m³

5. Proportion of volume of coarse aggregate and fine aggregate content

From table 3 of IS:10262-2009, volume of coarse aggregate corresponding to 20mm size aggregate and fine aggregate (zone Ⅱ) for water-cement ratio of 0.5 is 0.60.
In the present case water-cement ratio is 0.45. For every 0.05 change in w/c ratio, the coarse aggregate proportion is to be changed by 0.01
Therefore, corrected proportion of volume of coarse aggregate for the water cement ratio of 0.45= 0.61
Volume of coarse aggregate=0.61 m³ 17
Volume of fine aggregate =1-0.61=0.39 m³
6. Mix calculations
The mix calculations per unit volume of concrete shall be as follows
a) Volume of concrete = 1m³
b) Volume of cement = (mass of cement)/ (specific gravity of cement)*1/1000
= (360)/3.29 * 1/1000= 0.109 m³
c) Volume of water = (mass of water)/ (specific gravity of water)*1/1000
= (191.58)/1 * 1/1000= 0.191m³
d) Volume of all in aggregates =[a-(b+c)]
= [1-(0.109+0.191)] = 0.763 m³
e) Mass of coarse aggregate= e* volume of coarse aggregate* specific gravity of coarse
aggregate* 1000
=0.7*0.61*2.6*1000=1110.2 kg
f) Mass of fine aggregate = e*volume of fine aggregate * specific gravity of fine
aggregate * 1000
= 0.7*0.39*2.35*1000=641.55 kg

7. Mix proportion
a) Cement= 360 kg/m³
b) Fine aggregate= 641.55 kg/m³
c) Coarse aggregate= 1110.2 kg/m³
d) water= 191.58 liters
e) Water-cement ratio= 0.45
Therefore, mix proportion for M20 Grade concrete is 1:1.83:3.17:0.54

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➢ EXPERIMENTAL INVESTIGATION
➢ Test to be conducted on Fresh concrete
SLUMP TEST
• Slump test is the most commonly used method of measuring consistency of concrete which can be employed
either in laboratory or at site of work. It is not a suitable method for very wet or very dry concrete. It indicates
the characteristic of concrete in addition to the slump value. If the concrete slumps evenly it is called true
slump. If one half of the cone slides down, it is called shear slump. In case of a shear slump, the slump value is
measured as the difference in height between the height of the mould and the average value of the subsidence.
After tamping the top layer was leveled. The mould was removed from concrete immediately by rising it slowly
and carefully in vertical direction. Slump was measured (in mm) immediately by determining the difference
between the height of the mould and that of the highest point of the specimen being tested.

Fig. Slump Test

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 Compaction factor test
• To find the workability of concrete thoroughly mix cement, sand And coarse aggregate according to designed mix proportions
to form a homogenous mix of concrete. Find the Weight of empty cylinder (W1). Fill the upper hopper with the freshly
prepared concrete and after 2 minutes, release the trap door of the hopper. Immediately after the concrete has come to rest,
open the trap door of the lower hopper and allow the concrete to fall into the cylinder which brings the concrete to a partially
compacted state. Remove the excess concrete over the top of the cylinder by a trowel. Clean the cylinder properly and weigh
it with the partially compacted concrete (W2). Empty the cylinder and refill it with the same sample of concrete in four layers,
compaction of each layer by giving 25 blows with the tamping rod. Level up the mi and weigh the cylinder with the fully
compacted concrete (W3).

Fig. Compaction Factor Test

COMPACTION FACTOR= (W2 - W1)/( W3 - W1)

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➢ Test to be conducted on Hardened concrete
• COMPRESSIVE STRENGTH TEST

Sl.No Age of Weight of Cross Load(N) Compressive Average

cube cement sectional Strength compressive
cube(gms) area(mm²) (N/mm²) strength(Mpa)
1 3 days
2
3
1 7 days
2
3
1 28
days

Table . Observation
Fig. Compression Testing Machine

Compressive strength: load/ area

Result
i) The average 3 Days Compressive Strength of given cement sample is found to be______
ii) The average 7 Days Compressive Strength of given cement sample is found to be______
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iii) The average 28 Days Compressive Strength of given cement sample is found to be_____
➢ SPILT TENSILE TEST
The bearing strips are placed between the specimen and both upper and lower bearing blocks of the testing machine or
between the specimen and the supplemental bars or plates. Place the specimen on the plywood strip and align so that the
lines marked on the ends of the specimen are vertical and centered over the plywood strip. Place a second plywood strip
lengthwise on the cylinder, centered on the lines marked on the ends of the cylinder. Apply the load continuously and without
shock, at a constant rate within, the range of 689 to 1380 kPa/min splitting tensile stress until failure of the specimen. Record
the maximum applied load indicated by the testing machine at failure. Note the type of failure
Sl.No Age Identificati Dia of Depth Load Tensile Average tensile
of on specimen (mm) (N)) Strength strength(Mpa)
cub (N/mm²)
e
1 3

2 days

3
1 7

2 days

3
Fig. Split Tensile Machine 1 28
days

σsp = (2P)/ (πDL) N/mm²

Where, Table. Observation
P= Applied load in KN
D= Diameter of the cylinder in mm
L= Span of the cylinder in mm

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➢ Flexural test
• The specimen shall then be placed in the machine in such a manner that the load shall be applied to the uppermost surface as
cast in the mould, along two lines spaced 20.0 or 13.3 cm apart. The axis of the specimen shall be carefully aligned with the axis of the
loading device. No packing shall be used between the bearing surfaces of the specimen and the rollers. The load shall be increased
until the specimen fails, and the maximum load applied to the specimen during the test shall be recorded. The appearance of the
fractured faces of concrete and any unusual features in the type of failure shall be noted.
Sl.No Age Identification Size of Span Load Position of Modulus of
of specimen length (N)) fracture rupture (Mpa)
cube (mm) (mm) ‘a’(mm)

1 3
2 days

3
1 7
2 days

3
1 28
days

Table. Observation

23
FUTURE SCOPE OF PROJECT:
• The usage of left over tile waste can be used in making waste slabs for parking purposes & portico

• THE tiles wastes can be used for aesthetic purposes in tile.

•With combination of recycled aggregate and tile aggregate in different proportions can be investigated
to enhance the concrete properties and also to reduce the pollution or waste from industry.

•The mechanical properties of concrete with marble aggregate (waste) either

from manufacturing units can be investigated to improve the properties like permeability.

•Ceramic tile aggregate in high strength concrete can be studied further to check
the possibility of its use in high rise buildings

24
 PROPERTIES
• High melting points (so they're heat resistant).
• Great hardness and strength.
• Considerable durability (they're long-lasting and hard-
wearing).
• Low electrical and thermal conductivity

25
 REFERENCE

• N.Naveen Prasad, P.Hanitha, N.C.Anil IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 13, Issue 6 Ver. V (Nov. - Dec. 2016), PP 168-176.

• [2] R. Marwein, Bharathidasan International Journal of Scientific & Engineering Research, Volume 7,
Issue 4, April-2016 ISSN 2229-5518. 3. Iranian Journal of Science & Technology, Transaction B,
Engineering, Vol. 31, No. B5, pp 561-565 Printed in The Islamic Republic of Iran, 2007.

• [3] P.Rajalakshmi, Dr.D.Suji, M. Perarasan, E.Niranjani International Journal of Civil and Structural
Engineering Research ISSN 2348-7607 (Online) Vol. 4, Issue 1, pp: (114-125), Month: April 2016 -
September 2016.

• [4] T.Sekar, “Study on Strength Characteristics on Utilisation of Waste Materials As Coarse Aggregate
in Concrete”, International Journal of Engineering Science and Technology, Vol. 3, No.7, Pp. 5436-
5440, 2011.

26
CODE RECOMMENDATIONS

IS 10262-2009 for mix design

IS 383-1970 for zoning of aggregates.
IS 4031-1988 determination of consistency of standard cement
paste.
IS 516-1959 for compressive strength of concrete.
IS 516-1956 for flexural strength of concrete.
IS 2386- 1968: physical properties of fine and coarse aggregate.
Is 2386- 1963: specific gravity and fineness modulus of
aggregate.
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