EXPERIMENTAL INVESTIGATION ON LIGHTWEIGHT CONCRETE

BY USING FLYASH, PLASTER SAND AND WASTE TILE CHIPS

1Karandeniye, D. M. W., 1Wijekoon, S. H. B

1
Faculty of Engineering & Construction, International College of Business & Technology, Sri Lanka

Abstract

In recent construction, the consumption of ceramic tiles, sanitary fittings, electrical insulation and ceramics
etc. is increasing day by day. But due to the fragile nature of these, a large amount is wasted daily during
production, transportation and installation. This is also a problem for environmental waste management.
Therefore, using this waste in concrete production can be an effective step to improve the properties of
concrete and reduce environmental problems. Similarly, flyash, a by-product of coal burning in power plants,
is also added to the environment. As these show similar properties to cement, they can be used as a substitute
for cement in the construction industry, improving the properties of concrete and minimizing
environmental impact. In this research, flyash is used as a substitute for cement at 25% percentage and
ceramic tiles are used as a substitute for naturally found coarse aggregates at 25%, 30%, 35% percentages
to investigate a mix proportion that can obtain optimum compressive strength of lightweight concrete up to
the typical M30 grade of concrete. 25% of waste ceramic proportion shows the optimum compressive strength
comparing to the control proportion.

Keywords: Lightweight concrete, Compressive strength, Workability, Fly ash, Waste ceramic tile.

1.0 INTRODUCTION tons of CO2 emissions every year for the yearly
production of 3.6 billion tons of cement. A
There are many environmental issues that underlie
significant rise in cement production is anticipated
the construction industry in the ever-developing
by 2050, making the cement industry responsible
world. For this, many people have identified the
for more than 30 % of CO2 emissions, according to
reasons and found ways to give better results
Damineli et al. (Damineli and John, 2012). (Prasad,
through various alternatives and substitutes.
2017) said, Fly ash is a fine powder that is a
Concrete is the basic element in the construction
byproduct of burning pulverized coal in electric
industry. During the production of cement used for
generation power plants. The use of fly ash in
this purpose, a large amount of carbon dioxide is
concrete enhances both the strength and durability
released into the environment as a side effect.
of hardened concrete as well as the workability of
According to the (Fayomi et al., 2019) for every
concrete.
1 kg of cement produced, 0.5–0.9 kg of CO2 is
emitted, resulting in approximately 3.24 billion

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Coarse aggregates required for concrete production 2.0 LITERATURE REVIEW
are naturally obtained from stone quarries, so it Fly ash, waste ceramic tile chips, and other
remains an environmental problem today. As an lightweight aggregates are commonly used in the
alternative to this, disposable ceramic tiles can be production of lightweight concrete. These
used. Due to its properties like durability, materials help to reduce the weight of the concrete
resistance to high heat, it can be used while maintaining its strength and durability.
for coarse aggregates. Recently, the consumption Lightweight concrete is ideal for use in
of ceramic materials is increasing day by day and applications where weight is a concern, such as
due to their fragility, there is a large scale during high-rise buildings, bridges, and precast structures.
production, transportation and installation. Additionally, the use of these waste materials in
Therefore, improving the properties of concrete by concrete production promotes sustainability by
using these wastes in concrete production can be reducing the amount of waste sent to landfills.
a fruitful step. ( Elçi, 2016)
2.1 Lightweight Concrete
AIM AND OBJECTIVES
(Meena, et al., 2020) Light weight concrete is not a
Aim latest invention done by humans. It has been used

Research aim is to investigate the lightweight evidently from ancient time, it can be traced to as

concrete by using flyash, plaster sand and waste early as 3,000 BC, when Mohenjo-Daro and

ceramic tile chips, and to identify the suitable mix Harappa civilizations. (Yasar, at al 2003)

proportion of flyash and waste ceramic tile chips to investigated on the design structural LWC made

achieve optimum compressive strength of with basaltic pumice (scoria) as aggregate and FA

lightweight concrete. and hence it provides an evident advantage over the

reduction of weight. The properties of fresh
Objectives
concrete including density, and slump and due to
 To study the properties of flyash, waste ceramic these many beneficial reasons it is more
tile and identify the possibility of uses of flyash compressive and greener.
and waste ceramic tile in concrete mixture.
 To develop the lightweight concrete mixtures (H. Al-Khaiat, 2008) worked on the curing the
using flyash, plaster sand and waste ceramic physical properties and the early strength. And
tile chips with different mix proportions. moreover LWC using LWA with a slump of about
 To determine the properties of developed 100 mm, fresh unit weight of 1800 kg/m3 and 28
lightweight concrete mixtures. day cube compressive strength.
 To evaluate the properties of developed Similarly, (Bremner, 2008) to properly appreciate
lightweight concrete mixtures. lightweight concrete, it is necessary to first
comprehend the inherent nature of lightweight

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aggregates and how they influence the qualities of adding fly ash as a filler makes a plastic
concrete created from them. formulation stiffer but, like most fillers, reduces
impact resistance.
2.2 Flyash
(Ravina and Mehta, 1986; Matkovi´c, 1990) Use of
(Thomas, 2007) has identified the amount of fly
FA has become essential for civil engineering
ash higher replacement levels (30% to 50%) have
because of its economic and environmental
been used for large structures (such as foundations
benefits. According to the ASTM, classification of
and dams) to control the temperature rise in
fly ash, there are two classes. FA Class C has both
concrete. (Nadesan & Dinakar, 2017) it is
cementitious (high CaO content) and pozzolanic
recommended that 25% class F fly ash be used
properties, while Class F has only pozzolanic
to manage the fine lightweight aggregate. This
properties (Hou, et al., 2013). The fly ash
research is continuing fly ash with (25%).
pozzolanic properties render it beneficial for the
replacement of cement in concrete (Nonavinakere
2.3 Waste ceramic tile
and Reed, 1995; Yao et al., 2015). According to the
Ceramic tiles are made using clay. The ceramic tile
(González et al., 2009; Sarker, 2009; Yao et al.,
waste is durable, hard and highly resistant to
2015) hydration heat can be reduced by a partial
biological, chemical and physical degradation
cement replacement with Class F and hence, the
forces. The properties of these materials make them
concrete cracking risk in the early stages.
a good and suitable choice to be used in concrete.
The use of waste ceramic tiles in concrete effects
The cement content of any economical mix should
the properties of fresh and hardened concrete, and
be optimized. For this reason, supplementary
makes it economical and also solves some of the
cementitious materials such as fly ash, slag, and
disposal problems. According to the results of the
silica fume are employed. Prasad (2017) conducted
investigation done by (Topcu and Canbaz (2007)
research and discussed the additional
using crushed tile raised the water absorption ratio,
characteristics of fly ash. Low carbon fly ash
but reduced the density, compressive and tensile
(LCFA) is widely utilized in concrete as a flow able
splitting strengths of concrete.
to fill material or as a partial replacement for
Portland cement. High-carbon fly ash with carbon
The density of crushed tile concrete has reduced by
concentrations greater than about 6% is
4% according to their test results. The uses of the
significantly less practical as a secondary material
crushed tile aggregates have caused about 40% loss
because free carbon is an unwelcome impurity in
in the compressive and splitting tensile strengths.
concrete. In far smaller amounts than in the
Additionally they reported that crushed tiles
aforementioned building uses, fly ash is also used
adversely affected the abrasion and freezing
as a mineral filler in plastics. Numerous
thawing durability of the concrete. It was also
experiments employing fly ash have shown that
recommended that 100% replacement of crushed
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tile as a coarse aggregate is not suitable. But of less than 1200 kg/m3, according to Owens &
(Medina et al. 2012, 2013) carried out laboratory Newman (2010). These characteristics are mostly
investigations to evaluate the performance of caused by surface vesicles and contained pores
ceramic waste as a partial replacement of aggregate within the particle structure. The cement paste
in concrete production. They have concluded that concentration and water absorption of suitable
the resulting concrete could easily provide the aggregates for structural concrete should be low.
strength requirement for the normal concrete. Comparing the particle density of structural
concrete to that of normal natural aggregate, such
The similar results were also stated by (Guerra et as 2.6 Mg/m3, is the most accepted method for
al.2009). They investigated the mechanical doing so. The air within an aggregate's structure
characteristics of concrete produced with the permits compacted structural concrete to have a
natural aggregate and different ratio of crushed density of less than 2.6 Mg/m3, regardless of
sanitary porcelain as an alternative for the coarse whether the aggregate is lightweight or not.
aggregates. They noted that the use of crushed
sanitary porcelain as aggregate did not cause a 3.0 METHODOLOGY
remarkable reduction in the concrete strength. The This research is based on an applied experimental
crushed waste ceramic tiles were used in concrete approach, and the outcomes are presented in
as a replacement for natural coarse aggregates with quantitative terms. The methodology is under the 4
0%, 5%, 10%, 15% 20% and 25% of substitution. objectives.
After analyzing results, the optimum value of waste
ceramic tile is determined as about 20%. As per the first objective, Following materials are
(Bommisetty, et al., 2019). This research is employed in these experiments. Ordinary Portland
continuing with the percentage of 25%, 30% and cement by Sri Lanka Standard SLS 107:2015
35% Strength Class 42.5 R with specific Gravity of 3.15.
As a substitute for cement, locally available FA
2.4 Lightweight aggregates obtained from the thermal power plant and sieved
(Mehta and Monteiro, 1993) When determining the locally available plaster sand as fine aggregates
strength of normal concrete, most concrete which specific Gravity of 2.72 is used. As a coarse
aggregates are several times stronger than the other aggregates, crushed (20mm<) with specific
components in concrete and therefore not a factor Gravity of 2.85 is employed. These waste ceramic
in the strength of normal strength concrete. tile are used as replacements for coarse aggregates
Lightweight aggregate concrete may be more in concrete (20mm<).
influenced by the compressive strength of the
aggregates. BS EN 13055 defines lightweight The mix proportions were identified under the
aggregate as any aggregate with a particle density second objective. The quantities of materials used
of less than 2.0 Mg/m3 or a dry loose bulk density in normal conventional concrete is employed in the
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control mix according to the IS 10262: 2019
without using FA and wasted tile chips. The mix
proportions of materials for M30 concrete are
1:0.75:1.5 IS 10262: 2019. W/C ratio 0.45.
The materials substituting mixtures are according
to the IS 10262: 2019 using FA and wasted tile
chips. Manual mixing method is used to perform
the experiment. W/C ratio 0.45.

Table 1 Mix proportion

Mix Proportion (1:0.75:1.5) M30 Figure 1 cube casting

W/ FA Waste (20mm) Plaste
C (%) tile < CA r sand
ratio chips (Kg) (Kg)
(%)
Control 0.45 - - 20.7 10.35
1st Trial 0.45 25 25 15.525 10.35
2nd Trial 0.45 25 30 14.490 10.35
3rd Trial 0.45 25 35 13.46 10.35

Table 2 Casting Program

No of cube No of Trial No
(7days) cubes
(28days)
Control 3 3 1
1st Trial 3 3
2nd Trial 3 3 2
3rd Trial 3 3

To achieve the third objective unit density is Figure 2 concrete cubes

performed by weighing cubes and after curing it (7
days and 28 days). Slump test according to ASTM
C143 is performed using slump cone and tamping
rod BS EN 12350-2:2009. And finally, 150mm
×150mm×150mm cube molds, Lab CTM machine
BS 1881-108: 1983 is used for cube test according
to ASTM C109.

5
 Subsequently, provide recommendations for the
potential utilization of these concrete mixes in
construction projects. This multifaceted evaluation
will help determine their suitability and benefits for
real-world construction scenarios.

4.0 RESULT
This study investigates the workability and density
variations in dry mixes, as well as the influence of
fly ash and ceramic waste on compressive strength
in the development of lightweight concrete. It aims
to contribute valuable insights to the field of
sustainable construction practices

Figure 3 cube crushing

4.1 Workability
th
Under the 4 objective compare the properties of (Nagaraj & Shamanna, 2015) Says, to overcome
the developed lightweight concrete mixes to the limitations of conventional empirical tests like
conventional mixes to assess their performance the slump test, fresh concrete workability should be
using MS Excel software. Conduct economic assessed using its rheological characteristics.
analyses to evaluate their feasibility and cost-
effectiveness in practical construction applications.

Figure 4 workability results

6
As shown here, (figure 4) the slump height of the 4.2 Density variation of light weight concrete
initial control mixture is lesser than others.
However, a high slump value was shown in the When comparing concrete mixed with waste
mixtures with waste ceramic added, while a shear ceramic and fly ash to conventional concrete, the
slump was observed in the control mixture and a density exhibited variations. Initially, the density
true slump was observed in the other mixtures. was lower in the former, but it subsequently
increased in the final mixture. However, it did not
reach the same level as the conventional
concrete mixture.

Figure 5 Density variation

4.3 Compressive strength Grade concrete, the average strength of these three
The study involves the testing of concrete cube specimens is calculated. The results reveal a
specimens, each measuring 150 × 150 × 150 mm, decrease in compressive strength compared to a
at two different ages: 7 days and 28 days. These conventional mix, particularly noticeable. (Figure
tests are conducted for various concrete mixtures, 6) While there is a slight increase in strength with
including a control proportion and mixtures with 25% and 35% waste ceramic mixtures, it doesn't
different percentages of waste ceramic, all with a match the typical strength improvement seen in
constant fly ash substitution rate. For each conventional concrete mixes. This implies that
combination, three concrete cube specimens are introducing waste ceramic and fly ash does affect
tested, and their individual strengths are concrete strength but doesn't provide the same level
determined. To assess the overall strength of M30 of enhancement as in the conventional mix.
7
 waste ceramics and fly ash, offering improved
workability and reduced environmental impact

Figure 6 total compressive strength with control proportion

5.0 DISCUSSION
-through material properties and long-term
In the slump test (Figure 4) show Incorporating
durability for practical applications.
waste ceramic as a partial replacement for coarse
aggregates (25%, 30%, and 35%) while
The (Figure 5) shows after the curing, the dry
maintaining a 20% constant fly ash content in the
density results indicated a progressive decrease
cement mixture significantly influenced
compared to the control mix (2413 kg/m^3), with
workability. (K.D, 2023) Identified when increase
the 30% mix showing the lowest density at 2319
the flyash percentage the workability of the
kg/m^3. The R-square value of 0.4116 suggests a
concrete is increasing accordingly to the
modest correlation between the percentage of
percentage
waste ceramic and dry density, implying that the
The control mix showed shear slump, while relationship may not be strictly linear.
ceramic-replaced mixes exhibited true slump, with
increasing slump values as ceramic content In the study conducted by (K.D, 2023), expanded
increased, likely due to fly ash's water-absorbing clay was used as a replacement for aggregates. The
properties. True slump - The majority of the findings indicated a noticeable reduction in the
concrete's ability to retain its cone shape is a sign overall weight of the concrete system. It's worth
that the mixture is cohesive and it is not particularly noting that as the weight decreased, the density of
workable. However, the advantages of this form of the concrete also decreased.
a slump are greatest for slabs, columns, and beams.
(20 - 80mm) (Joseph & K, 2009) This suggests While the fly ash content remained constant, its
potential for eco-friendly concrete designs using influence on density appeared minimal. These
8
findings underscore the potential of using waste This research underscores the importance of
ceramic in concrete but emphasize the need for considering the trade-off between utilizing waste
careful consideration of its percentage and possible materials and maintaining desired concrete
supplementary materials for specific construction properties, particularly when early strength is
applications, prompting further research to crucial, and encourages further exploration of
optimize its integration effectively. The 35% waste additives or curing methods that could mitigate the
ceramic mixture exhibits a higher density initial strength reduction observed in higher
compared to the 30% and 25% mixtures. This ceramic content mixes.
finding suggests the potential for further
research in the future. 6.0 CONCLUSIONS

The compressive strength performance (Figure 6) 6.1 Conclusions

comparing with the control mix displayed the In the first control test, 6 samples were made and
highest strength at both time intervals, with 29.88 tested for 7 and 28 days by mixing cement, plaster
MPa after 28 days. The R-square values for the 7- sand, and coarse aggregates appropriately for M30.
day and 28-day results, 0.7182 and 0.6204 Similarly, the above process was followed for fly
respectively, suggest a moderate to strong ash and waste ceramic mixed lightweight concrete,
correlation between ceramic content and and by replacing waste ceramic 25%, 30%, and
compressive strength. These results indicate that 35% % with coarse aggregates, flyash was added
waste ceramic, when used as a partial aggregate as a partial replacement for cement, and 18 samples
replacement, may impact early strength were made and workability, dry density and the
significantly, but the strength gap between the compressive strength was tested.
mixes tends to narrow as curing time progresses,
Flyash is replaced with the OPC cement (20%),
possibly due to pozzolanic reactions.
hence the heat of hydration is reduced but the
mixture acted like a paste as a result true slump is
In the context of these findings, the decreasing
occurred and showed higher workability than the
trend in strength with higher ceramic content aligns
control mix. The density of the concrete was
with expectations, as ceramic aggregates tend to be
reduced by replacing WC with coarse aggregates as
less dense and may not provide the same
a result of which the self – weight of the concrete
mechanical properties as conventional coarse
reduced. Balancing the advantages of waste
aggregates. However, the relatively high R-square
ceramic with the required properties of concrete is
values indicate a relatively strong relationship
a critical consideration for engineers and builders,
between the ceramic content and strength,
and this study contributes to a deeper
especially in the early stages of curing, suggesting
understanding of how waste materials can be
that the impact of ceramic replacement on
effectively integrated into concrete mix designs.
concrete's strength can be predictably quantified.
9
The relatively high R-square values (0.7182 for 7 6.3 Recommendations
days and 0.6204 for 28 days) indicate a robust When considering material cost, lightweight
correlation between ceramic content and strength, concrete save 8% of the cost compared to normal-
particularly in the early stages of curing. This weight concrete. As a result, lightweight concrete
research emphasizes the trade-off between is a more economical option than normal concrete.
incorporating waste materials and achieving
specific concrete properties, especially when In this experiment, a variable compressive strength
considering the importance of early strength, and was observed with a decrease at 30% waste
encourages further investigation into additives and ceramic content, followed by an increase at 35%.
curing methods that may mitigate initial strength These findings suggest the potential for future
reductions in mixes with higher ceramic content. research involving tensile strength testing.
Furthermore, the test results highlight the promise
One side of the recycled ceramic waste exhibited a
of lightweight concrete mixes containing 25% and
smooth surface, while the other side was notably
35% waste ceramic, as they exhibited both high
rough. The concrete mix showed poor adhesion to
compressive strength and excellent workability,
the smoother surfaces. Additionally, it was
making them strong candidates for further
observed that strong sunlight and prevailing windy
improvement and development
conditions in the laboratory area led to rapid water
evaporation from the mix.
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