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FLY ASH UTILISATION IN THE MANUFACTURE

OF GREEN PAVER BLOCKS AND TILES


M. TECH IN CIVIL ENGINEERING
SPECIALIZATION: STRUCTURAL ENGINEERING
BY

PRITAM KUMAR PATI


ROLL NO: 215CE2031
UNDER THE GUIDANCE OF

Prof. Shishir Kumar Sahu


Fly ash and its production

Fly ash is the by-product of the burning of coal for power generation. Its collection and
disposal are necessary processes in power stations.
Presently in India, the power sector depends on coal based thermal power stations
which produces a huge amount of fly ash are estimated to be around 112 million tonnes
annually.
The use of fly ash is about 30% in producing blended cement, concrete pipes, precast
prestressed product materials, paver blocks, light weight concrete blocks, autoclaved
aerated concrete and lightweight aggregate.
Depletion of Mineral Resources
Currently in India, annual consumption of cement concrete is to the tune of 400 metric
tonnes.

This causes depletion the materials like sand, aggregates and other materials required
to produce huge quantity of cement concrete.

Also the production of huge quantities of cement requires large amount of energy,
cause emission of CO2 and carry forward the allied problems.

Increasing shortage of natural fine aggregates in concrete at present has lead to search
for alternate sources for its replacement.
Paver Blocks
Concrete paver blocks were first introduced in Holland in the fifties as replacement of

paver bricks which had become scarce due to the post-war building construction boom.

The pavements in which non interlocking blocks are used are designated as Concrete

Block Pavement (CBP) or non-interlocking CBP, and those in which partially, or fully
Paver Blocks
interlocking blocks are used are designated as Interlocking Concrete Block Pavement

(ICBP).

CBP/ICBP consists of a surface layer of small-element, solid un-reinforced pre-cast

concrete paver blocks laid on a thin, compacted bedding material which is constructed

over a properly profiled base course and is bounded by edge restraints/kerb stones.

80 mm Paver mould
Summary of Literature Review
1 . Replacement of fly ash in concrete block
Siddique (2003) performed an experimental investigation which was carried out to evaluate the mechanical properties
of concrete in which fine aggregate (sand) was partially replaced with Class F fly ash.

Malhotra (2008) reported that super plasticized high-volume fly-ash concrete had inferior abrasion resistance to
concrete without fly ash. He also carried out experiments on concrete blocks containing high volumes approximately
55% of Class F fly ash.

Parvathi et al. (2013) carried out an experimental investigation to evaluate the strength performance of concrete by
replacing natural sand by fly ash in various percentages when subjected to elevated temperature. The replacement of
fine aggregate with fly ash was considered and the concrete was exposed to elevated temperature. The various
strength parameters studied are compressive strength, tensile strength, flexural strength and shear strength as per the
relevant IS standard.

Aruna Kanthi et al. (2014) studied on various percentages of sand replacement. The workability was maintained
constant range for all mixes. Strength characteristics such as compressive strength split tensile strength and modulus
of elasticity of concrete mixes were found out for 7, 14 and 28 days curing period and results are analysed.
2. Replacement of fly ash in paver block

Karasawa et al. (2003) investigated the usage of fly ash as a fine aggregate in paver blocks. Based on plastic
deformation of 1mm while demoulding and curing and flexural strength of 6 MPa they concluded that 25% of fine
aggregate can be replaced by fly ash.

Sachdeva et al. (2014) carried an experimental work on cubes and prisms to find optimum percentage replacement
of cement with fly ash for paver block. They have done mix designs for M-30, M-35, M-40 and M-50. In all mix
design cement replaced with fly ash up to 40% and compressive strength and flexural strength are reported.

Santhosh and Talluri (2015) conducted experimental study on, concrete paving blocks. The different mix proportion
prepared and cement is replaced with fly ash and waste glass powder by equal amount in all mix proportion.
CRITICAL DISCUSSION
From the above literature, it is clear that utilization of fly ash in paver block is very less
and mostly for surrounding the buildings.
No work is reported on tiles with fly ash.
Till now, proper required testing including abrasion resistance using fly ash ICBP is not
available.
Work involving sand replacement in ICBP is also very less.
So the aim of the project is to increase the utilization of fly ash in paver blocks and tiles
meeting all the strength parameters.
OBJECTIVE
The aim of the project is to find out the optimum percentage of fly ash
which can be used in paver blocks and tiles without affecting the strength
parameters.

SCOPE OF THE PROJECT


The scope of this research project is finding out the compressive strength,
flexural strength, abrasion resistance and water absorption of paver blocks
and tiles.
Experimental Programme
1. Mix Design
Class F fly ash which was procured from Bhusan steel plant Sambalpur.

1.1. Mix proportioning


Grade of concrete - M40
Cement Ordinary Portland cement
Aggregate size - Angular aggregate of maximum nominal size is 10mm
Water cement ratio - 0.4 (maximum)
Slump value - zero
Condition of exposure mild
Admixture superplasticiser
Paver block details:

Sl.NO Shape Thickness (mm) Plan Area (2) Length (cm) Width(cm)

1 Zig zag 80 0.046 30 15

2 I 60 0.033 22.5 12.5

3 Dumbbell 60 0.036 26.5 11

Paver block testing:

Compressive strength
Flexural strength
Water absorption test
Abrasion resistance
Fig 1: Compressive strength setup Fig 2: Flexural strength setup
Fig 3: Abrasion resistance setup Fig 4: Paver block moulding machine
Fresh Concrete Properties for cement replacement with fly ash
Quantities for 1 cu.m for compacted concrete of grade M-40 and fresh concrete properties for
cement replacement with fly ash source of Bhusan steel plant Sambalpur is given in the following table.

Coarse Super
Cement Fly ash Fly ash
Mixture No. W/C ratio Sand (kg/ ) Aggregate Plasticizer
(kg/ ) (%) (kg/ )
(kg/ ) (%)

CR-0 370 0 0 0.4 989.67 989.67 0.5

CR-10 366.3 10 40.7 0.4 972.26 972.26 1.0

CR-20 325.6 20 81.4 0.4 967.00 967.00 1.1

CR-30 284.9 30 122.1 0.4 962.34 962.34 1.15

CR-40 244.2 40 162.8 0.4 956.736 956.736 1.2


Fresh Concrete Properties for sand replacement with fly ash
Quantities for 1 cu.m for compacted concrete of grade M-40 and fresh concrete properties for
cement replacement with fly ash source of Bhusan steel plant Sambalpur is given in the following
table.

Coarse Super
Cement Fly ash Fly ash
Mixture No. W/C ratio Sand (kg/ ) Aggregate Plasticizer
(kg/ ) (%) (kg/ )

(kg/ ) (%)

SR-0 370 0 0 0.4 989.67 989.67 0.5

SR-10 370 10 98.96 0.4 890.70 989.67 1.0

SR-20 370 20 197.93 0.4 791.74 989.67 1.1

SR-30 370 30 296.90 0.4 692.77 989.67 1.2

SR-40 370 40 395.87 0.4 593.80 989.67 1.3


RESULTS AND DISCUSSION:
Results of cement replacement with fly ash
1. Compressive Strength

7-Day Compressive Strength of ICBP with cement replacement with fly ash

Mix Fly ash Zig zag I Dumbbell


% (80 mm) (60 mm) (60 mm)
CR-0 0 54.09 53.55 52.79

CR-10 10 59.73 59.57 62.03

CR-20 20 59.57 56.86 57.28

CR-30 30 42.65 42.76 44.69

CR-40 40 40.25 41.5 42.77


Cement replacement with fly ash vs 7-day compressive strength

7 Day Compressive Strength


65 Zig zag (80mm) I Shape (60 mm) Dumbbell Shape (60 mm)

60
Compressive Strength in MPa

55

50

45

40

35

30
0 5 10 15 20 25 30 35 40 45
Cement Replacement with Fly Ash in Percentage
28-Day Compressive Strength of ICBP for cement replacement with fly ash

Mix Fly ash Zig zag I Dumbbell


% (80 mm) (60 mm) (60 mm)

CR-0 0 59.67 59.36 58.97

CR-10 10 65.5 67.9 68.11

CR-20 20 63.77 61.69 63.89

CR-30 30 59.62 59.19 59.98

CR-40 40 57.06 56.83 58.55


Cement replacement with fly ash vs 28-day compressive strength

28 Day Compressive Strength


70 Zig zag (80mm) I Shape (60 mm) Dumbbell Shape (60 mm)

68

66
Compressive Strength in MPa

64

62

60

58

56

54

52

50
0 5 10 15 20 25 30 35 40 45

Cement Replacement with Fly Ash in Percentage


Flexural Strength of ICBP for Cement Replacement With Fly Ash
7-Day Flexural Strength
Fly ash Zig zag I Dumbbell
Mix
% (80 mm) (60 mm) (60 mm)
CR-0
0 4.61 4.93 5.12
CR-10
10 5.3 5.68 6.67
20
CR-20 4.98 4.85 6.3
4.76
CR-30 30 4.53 3.94
4.72
CR-40 40 4.5 3.82

28-Day Flexural Strength


Mix Fly ash Zig zag I Dumbbell
% (80 mm) (60 mm) (60 mm)
CR-0 0 7.17 6.94 7.63

CR-10 10 7.94 9.06 8.63

CR-20 20 6.84 6.9 7.35

CR-30 30 4.63 5.07 4.9

CR-40 40 4.6 4.97 4.90


Cement replacement with fly ash vs 7-day Flexural strength
7 Day Flexural Strength
7 Zig zag (80mm) I Shape (60 mm) Dumbbell Shape (60 mm)

6.5

6
Flexural Strength in MPa

5.5

4.5

3.5
0 5 10 15 20 25 30 35 40 45
Cement Replacement with Fly Ash in Percentage
Cement replacement with fly ash vs 28-day Flexural strength

28 Day Flexural Strength


Zig zag (80mm) I Shape (60 mm) Dumbbell Shape (60 mm)
9.5

8.5
Flexural Strength in MPa

7.5

6.5

5.5

4.5

3.5
0 5 10 15 20 25 30 35 40 45
Cement Replacement with Fly Ash in Percentage
Abrasion Resistance of Paver Blocks of control mix

Shape of Paver Block Loss in Thickness (in mm)

Zig Zag (80 mm) 0.631

I (60 mm) 0.577

Dumbbell (60 mm) 0.663


Results of Sand Replacement with Fly ash
1.Compressive strength
7-Day Compressive Strength

Mix Fly ash Zig zag I Dumbbell


% (80 mm) (60 mm) (60 mm)

SR-0 0 54.09 53.55 52.79

SR-10 10 59.72 60.56 61.46

SR-20 20 57.06 56.83 58.55

SR-30 30 52.52 54.20 54.59

SR-40 40 38.97 40.47 41.36


Sand replacement with fly ash vs 7-day Compressive strength
7 Day Compressive Strength
70 Zig zag (80mm) I Shape (60 mm) Dumbbell Shape (60 mm)

65
Compressive Strength in MPa

60

55

50

45

40

35

30
0 5 10 15 20 25 30 35 40 45
Sand Replacement with Fly Ash in Percentage
28-Day Compressive Strength of ICBP for sand replacement with fly ash

Mix Fly ash Zig zag I Dumbbell


% (80 mm) (60 mm) (60 mm)

SR-0 0 54.09 53.55 52.79

SR-10 10 66.70 65.14 67.69

SR-20 20 64.13 63.87 65.81

SR-30 30 58.37 60.02 62.39

SR-40 40 46.08 45.88 46.06


Sand replacement with fly ash vs 28-day Compressive strength

28 Day Compressive Strength


75 Zig zag (80mm) I Shape (60 mm) Dumbbell Shape (60 mm)

70
Compressive Strength in MPa

65

60

55

50

45

40
0 5 10 15 20 25 30 35 40 45
Sand Replacement with Fly Ash in Percentage
Flexural Strength of ICBP for Sand Replacement With Fly Ash
7-Day Flexural Strength
Mix Fly ash Zig zag I Dumbbell
% (80 mm) (60 mm) (60 mm)
SR-0 0 4.61 4.93 5.12

SR-10 10 5.85 6.45 6.06

SR-20 20 4.71 5.51 4.85

SR-30 30 4.65 5.25 4.59

SR-40 40 3.76 3.79 3.09

28-Day Flexural Strength


Mix Fly ash Zig zag I Dumbbell
% (80 mm) (60 mm) (60 mm)
SR-0 0 7.17 6.94 7.63

SR-10 10 7.90 8.87 9.02

SR-20 20 7.29 7.00 7.87

SR-30 30 5.87 6.07 6.70

SR-40 40 5.21 4.90 5.65


Sand replacement with fly ash vs 7-day Flexural strength

7 Day Flexural Strength


7 Zig zag (80mm) I Shape (60 mm) Dumbbell Shape (60 mm)

6.5

6
Flexural Strength in MPa

5.5

4.5

3.5

2.5

2
0 5 10 15 20 25 30 35 40 45
Sand Replacement with Fly Ash in Percentage
Sand replacement with fly ash vs 28-day Flexural strength

28 Day Flexural Strength


10 Zig zag (80mm) I Shape (60 mm) Dumbbell Shape (60 mm)

9
Flexural Strength in MPa

4
0 5 10 15 20 25 30 35 40 45
Sand Replacement with Fly Ash in Percentage
CONCLUSIONS
The 7-day compressive strength paver block for all the shapes increases with increasing fly ash as a cement replacement
material up to 10%, after that it decreases, however for 20% replacement, strength is more than control mix. But for 30%
and 40% replacement 7-day compressive strength is less than the control mix.
The 28-day compressive strength paver block for all the shapes increases with increasing fly ash as a cement replacement
material up to 10% after that it decreases however for 20% and 30% replacement strength is more than control mix.
The 7-day flexural strength paver block for all the shapes increases with increasing fly ash as a cement replacement
material up to 10%, after that it decreases, however for 20% replacement, strength is more than control mix. But for 30%
and 40% replacement, strength is less than control mix.
The 28-day flexural strength paver block for all the shapes increases with increasing fly ash as a cement replacement
material up to 10%, after that it decreases and is less than control mix.
The 7-day and 28-day compressive strength paver block for all the shapes increases with increasing fly ash as a sand
replacement material up to 10% after that it decreases however for 20% and 30% replacement strength is more than
control mix.
The 7-day flexural strength paver block for all the shapes increases with increasing fly ash as a sand replacement material
up to 10%, after that it decreases, however for 20% and 30% replacement, strength is more than control mix. But for 40%
replacement, strength is less than control mix.
The 28-day flexural strength paver block for all the shapes increases with increasing fly ash as a sand replacement
material up to 10%, after that it decreases, however for 20% replacement, strength is more than control mix. But for 30%
and 40% replacement, strength is less than control mix.
References
Aruna Kanthi.E., Kavitha.M. (2014). Studies on Partial Replacement of Sand with Fly ash in Concrete. European
Journal of Advances in Engineering and Technology, 1(2), 89-92.
Karasawa. A., Suda. S., Naito. H., and Fujiwara. H., (2003). Application of fly ash to concrete paving block.
Proceedings of the 7th International Conference on Concrete Block Paving. , (PAVE AFRICA 2003)12th-15th .ISBN
Number: 0-958-46091-4,SunCity,SouthAfrica.
Malhotra VM, Mehta PK. (2008) High performance, high-volume fly ash concrete. 3rd ed., Supplementary
Cementing Materials for, Sustainable Development, p. 3945..
Sachdeva S. N., Aggarwal.V., Gupta. S. M., (2014). High Volume Fly Ash Concrete for Paver Blocks. World
Academy of Science &Engineering and Technology. International Journal of Civil, Structural, Construction and
Architectural Engineering.8(3).
Santhosh J., Talluri.R., (2015). Manufacture of interlocking concrete Paving blocks with fly ash and glass powder.
International Journal of Civil Engineering and Technology (IJCIET)., ISSN 09766308 (Print), ISSN 0976
6316(Online), 6(4), 55-64.
Siddique R., (2003). Effect of fine aggregate replacement with Class F fly ash on the mechanical properties
concrete. Cement and concrete Research. , 33(4), 539-547.

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