its Effective Utilization in Construction Outline About CSIR-CBRI - - PowerPoint PPT Presentation

Characterization of Manufactured Sand and its Effective Utilization in Construction

Outline

• About CSIR-CBRI
• Introduction
• Why Manufactured Sand?
• Worldwide Status
• Process for M-sand
• Research Gaps
• Methodology
• Work Plan
• Financial outlay
• Outcomes
• Summary

CSIR-Central Building Research Institute, Roorkee

About CSIR-CBRI

CSIR-Central Building Research Institute, Roorkee

1947…………

Institute…..

CSIR-Central Building Research Institute, Roorkee

CSIR-CBRI, Roorkee - Established in the year 1947 -

responsibility of generating, cultivating and promoting building science and technology in the service of the country. Guiding - building construction and building material industries in finding timely, appropriate and economical solutions to the problems of materials, rural and urban housing, energy conservation, efficiency, fire hazards, structural and foundation problems and disaster mitigation.

Domain Area of Expertise

Nine R&D Groups Three Scientific Services Extension Centre : New Delhi

CSIR-Central Building Research Institute, Roorkee

R&D Groups & Scientific Services

CSIR-Central Building Research Institute, Roorkee

• Acoustics, Instrumentation & Mechanical Systems
• Architectural & Planning
• Efficiency of Buildings
• Environmental Science Technology & Clay Products
• Fire Engineering
• Geotechnical Engineering
• Organic Building Material
• Polymer, Plastics & Composites
• Structural Engineering
• Planning & Business Development
• Information & Extension
• High Computational Facility

VISION

A world class research & knowledgebase centre of National Importance for providing innovative solutions to all aspects of building science & technology.

MISSION

Dedicated to research, development & innovation (RD&I) in solving National Challenges of planning, design, materials, capacity building and construction including disaster mitigation in buildings to achieve Safety, Sustainability, resilience, smartness, Comfort, functional efficiency, speed, productivity in construction, environment preservation, energy efficiency and economy.

CSIR-CBRI, Roorkee

CSIR-Central Building Research Institute, Roorkee

Nano Materials Health Monitoring Buildings Wind Engineering Structural Fire Studies Energy Efficiency of Buildings

International Linkages

Technologies Developed : 120

Institute’s Technologies

Rural Housing Techniques

Fire Retardant Thatch Roof

Rural Drainage System

Manufactured Sand

Introduction

With the exception

• f

water and air Sand is the most used resource inthe world 16 Billion Tons of sand is used each year around the world

Source: www. world cements & Fredonia publications 2017

Natural Sand

• Natural Sand is an unconsolidated granular material
• Size varies from 75 micron to 4.75 mm
• Used as a fine aggregate in concrete and mortar

River sand Various sources of natural sand are: Marine sand Quarry Dust Sand Dune

Ban on mining

High Salt %

High fines % Poor Gradation Low strength

Questions to be Answered

What are its benefits

• ver natural sand?

How it makes concrete a sustainable material? Why Manufactured Sand? What is the outcome

• f this project?

Introduction

Up to 35%

Up to 60-70% (CA+FA) Up to 14-21% Up to 7-15%

Cement Water Air Up to 1-3%

Concrete

Coarse Aggregate Admixture (CH & ME)

Sand

Change in Change in riv river er cour course se Dis Disappearing ppearing bea beaches hes Af Affects ects flor flora a and f and fauna auna Inf Infra- st structur ucture e dama damage ge Salt w Salt water ter intr intrusion usion

Environmental Imbalance

Issues…

Why Sand Mining

Problems in India

Construction boom in India - Mining of sand Violation of environmental laws & Court’s directives Rampant illegal sand mining Loss of Rs 1,611 crores

(Source: NGT Report, 2016)

Illegal mining environmental crisis

NGT, MoEF & other bodies against excessive sand mining.

Ban on Sand Mining

Life loss Breach of laws Protests NGOs & Environmental activists PILs and Judgements

Actual consumption ..much higher Remaining ....... ?!!? Illegal Legal Quarrying MAFIAS

Legal steps for banning sand mining

2013- Supreme Court Order:

Ban on individual state laws on sand mining

2012- MoEF & Supreme Court:

Mining permitted after SEIAA

2010-NGT Act:

Sand mining ban for environmental protection

2012-Supreme Court Order :

Sand mining ban in land less than 5 Ha.

2013-NGT Order:

Mining permitted after environ. clearance

2017-NGT directive:

State government will ensure that no “illegal” sand mining

Sand mining Decimates African beaches -

Now African countries are raising the alarm because of their disappearing beaches.

Date 15.02.2017

THE WORLD IS RUNNING OUT OF SAND

Environmental crisis Beaches are disappearing Quarrying leads to pollution

Reso esour urce ce de deplet pletion ion En Envir vironme menta tal l issues issues Un Un - su susta staina inable le Ban Ban on

• n

San Sand mining mining High High deman demands ds for

• r Sand

and

M-Sand

Need for Technology

No No alte alterna nativ tive

Manufactured Sand

“Fine Aggregate manufactured from other than natural sources, by processing materials, using thermal or other process such as separation, washing, crushing and scrubbing”

NOTE: Manufactured fine aggregate may be Recycled Concrete Aggregate (RCA) in Annexure A

Source: IS 383-2016

Types of Manufactured Sand

Manufactured Sand

Natural Crushed Rock Sand Industrial By- product Recycled Fine Aggregate

Natural Crushed Rock Sand (CRS)

• Produced

from natural

• ccurring

rocks

• Consists of

considerable amount of stone dust

Production of CRS

Drilling Blasting Extraction Primary Crusher Screening Secondary crusher Washing and Sludge Removal Finished Product Transportation Coarse Aggregate

• Eco-friendly
• Sustainable
• Abundant
• Superior quality
• Vastu friendly

M-sand

Industrial By-products

By-products from thermal power plants, Iron & Steel mills etc.

Industrial By- products Ecological imbalance Landfill Problems

• Depletes natural resources
• Harms living organisms
• No area for landfills
• Increase in cost
• Stringent rules

Industrial By-products

GGBS

Production of Industrial By-products

Boiler Ash

• No further processing needed
• Energy saving
• Eco-friendly material
• Sustainable material
• Reduction of landfills

Recycled Fine Aggregate (RFA)

Extracted through the processing of the debris from demolition of concrete structures, broken masonry or old roads

Aggregate Service Life C&D Waste Aggregate Concrete

Constituents of Recycled Fine Aggregate

Lightweight Contaminants Organics Clay/Cement adherence High Fines content Reduces the quality and consumer perceptions of recycled fine aggregate

Production of Recycled Fine Aggregates

• Eco-friendly material
• Sustainable material
• Energy Saving

Comparison between M-sand and Natural Sand

Manufactured vs River Sand

Properties River Sand M-Sand

Cleanliness Contains impurities Very Clean

Grading

Size can not be controlled Size can be customized Shape & texture Round & Smooth Angular &Rough

Fineness Particles below 75µm is of silt, mud and clay

Fine particles are present Specific gravity 2.3 – 2.7 2.5 – 2.9 Fineness modulus 2.2 -2.8 (Zone I II and III )

2.6 – 3.0 (Zone II)

Manufactured vs River Sand

Behaviour in concrete

Properties River Sand M-Sand Workability Good Less (depends on particle size) Setting Normal Comparatively faster Compressive Strength Normal Higher Im-permeability Normal Better

Benefits

Reduces depletion of natural sources Reduces the quantity of Landfill Reduction of cost of construction

Manufactured Sand

Production of Eco- friendly material Sustainable material

Benefits

1000 2000 3000 4000 5000 6000

Cost (Rupees)

Cost Analysis Savings Water Cement Transport Admixture C.A FA Fly-Ash RS in Concrete MS in Concrete

Savings up to Rs 300/- Cost: RSC= Rs 5430/- MSC= Rs 5118/-

National & International Status

National Status

Low and medium strength (25–60 MPa) SCCs

• Nanthagopalan, et al.,

(2010) Drying shrinkage – high initially and reduces later FTIR showed Quartz M- sand is metamorphic in nature

• Shanmugavadivu et
• al. (2012)
• Gnanasarvanan

et al. (2013) Abrasion resistance of bottom ash concrete improved with age.

• Singh, et al.

(2015)

National Status

Rubber waste, rice husk ash, sludge waste etc. can be used non structural elements

• Tiwari et al. (2016)

SCC showed 14.27% and 7.21% higher compressive and splitting tensile strength

• Kristiawan et al.

(2016) Concrete with 25% granite dust had better mechanical and durability properties.

• Singh, et al. (2017)

Manufactured sand showed higher residual strength at 500°C.

• Jeyaprabha et al. (2017)

Particle Size DIstribution

Particles finer than 75 µm shall not exceed 15% for natural crushed rock sand

IS Sieve Designation Percentage Passing Grading Zone I Grading Zone II Grading Zone III Grading Zone IV

10 mm 100 100 100 100 4.75 mm 90-100 90-100 90-100 95-100 2.36 mm 60=95 75-100 85-100 95-100 1.18 mm 30-70 55-90 75-100 90-100 600 µm 15-34 35-59 60-79 80-100 300 µm 5-20 8-30 12-40 15-50 150 µm 0-10 0-10 0-10 0-15

Code recognizes M-sand as Zone II

Zone II Sand

Source : IS 383 2016 10 20 30 40 50 60 70 80 90 100 0.01 0.1 1 10

Percentage Passing Particle Size (mm)

M Sand Upper limit Lower limit

International Status

Crushed brick showed better mechanical properties than crushed concrete MS in mortar resulted in 28% lower absorptivity and 23% higher compressive strength

• Khatib, (2005)
• Gonclaves, et al.

(2007)

Resistance to chloride penetration increased with increase in the fine recycled aggregate

• Kou, et al.

(2009)

Stone powder admixture delayed initial plastic cracking and increases durability

• Wang et al. (2014)

International Status

MS with low particle angularity and low fines reduced the water demand in the mix

• Dilek et al. (2015)

High SP dosages inhibited negative influence of CGA on plastic viscosity.

• Cordeiro et al.

(2016) Microstructure of MS-UHSC is very dense and the hydration products are finer

• Shen, et al., (2017)

SCC with RFA had better mechanical properties & dense micro structure

• Carro-Lopez, et al. (2017)

International Standards

BS EN 12620-2013, “Aggregates for Concrete”

Specifies the grading requirements

• f

crushed rock fine aggregate;

• Considers as “crushed rock dust” or simply “dust”, i.e. particles

passing 75 µm BS test sieve.

• Allows a dust content of up to 15% by mass for crushed rock fine

aggregates and 10% by mass for crushed rock all-in aggregates.

Other Standard:

• ASTM C33-2016, “Standard Specifications for Concrete Aggregate
• Cement Concrete & Aggregate (Australia)- “Guide to use

manufactured sand concrete”

• CS3-2013 (Hong Kong)-” Aggregates for Concrete”

White Space Mapping

252 96 50 15 14 9 7

50 100 150 200 250 300 Number of Scientific Publications

World China India South Korea UK Russia USA

Case Study

Production of M-sand

Crushing CRS Screening Washing Washed M sand Hydrocyclone Process Sludge & Water Recycling Manufactured Sand

Source: CDE Asia

Manufactured Sand Concrete

Cement: PPC Slump retention: 2 hrs.

Production of Manufactured Sand

Source: CDE Asia

Research Gaps

Research Gaps

Limited study on characterization and optimization No standard/ guidelines for mix proportioning No microstructural study and modelling No life cycle cost analysis including CO2 emission for sustainable structural design

Objective

‘To develop a sustainable concrete by replacing natural sand with manufactured sand’

Scope of the Work

• Manufacturing process
• Characterization and optimization
• Guidelines for mix proportionating
• Rheological behaviour of M-sand concrete
• Fresh and hardened properties
• Durability studies
• Comparison with river sand
• Life cycle cost analysis
• CO2 emission analysis
• Sustainable structural design

Methodology

Collection/ Manufacture Characterisation & optimization Experimental investigations Durability Studies IMACC modelling for life cycle cost & CO2

MS from various sources shall be collected Particle size analysis sieve analysis, methylene blue test void content bulk density water absorption, soundness test XRD, SEM, Chemical analysis Fresh Properties: Slump Vee-Bee Flow ability test rheological properties Hardened Properties: Compressive strength tensile strength flexural strength porosity permeability elastic modulus impact test Durability test:- Fire, Drying and plastic shrinkage Creep acid and alkaline attack sulphate attack, alkali-silica reaction RCPT abrasion Integrated modelling for Cost and CO2

Filtration of Ultra-fines Particles

Hydrocyclone Process

Work Plan

Financial Outlay

S.N Heads Cost (Lakhs)

A

Capital Equipment

 Planetary Mixer (10 lakhs)  Mini crushing plant (40 Lakhs)  Permeability testing equipment as per DIN 1048 (5 Lakhs)  Water bath/ accelerated curing chamber (5 lakhs)  Automated sieve shaker, densimeter (5 lakhs)  Automated Blaine’s apparatus (5 lakhs)  Other small equipments (5 lakhs) 75.00 B

Pilot plant/ Prototypes

Nil C

Cost of testing and trials of prototype or pilot plant

Nil D

External payments envisaged (for hiring infrastructural facilities/experts / labours, Project Assistant etc.)

10.50 E

Manpower Cost (Principal contributors & S&T staff etc.)

10.00 F

Travel Cost including international travel

7.50 G

Consumable/raw materials/ components chemicals, glass wares, etc. OPC Clinker, Cement, aggregates, sensors, etc.

12.00 H

Contingencies

05.00

Total cost of Project 115.00

Outcomes

• Publications
• SCI Journals - 2
• Conferences - 4
• Patent - 1
• Technology - 1
• Guidelines M-sand
• BIS standards

Value Added Products

NBCC will be partner in technology & Patent

Summary

 Mitigation to environmental issues  Effective implementation of NGT directives  Abiding Supreme & High Court orders  Better gradation of M-sand  Better concrete properties  Utilization of industrial by-products  Sustainable design and construction  Reduction in crime

Manufactured Sand