CERAMIC WASTEAS

A PAVEMENT CONSTRUCTION MATERIAL

VIMAL GAHLOTVIMAL GAHLOT Lecturer, Govt. Polytechnic College, BIKANER,Lecturer, Govt. Polytechnic College, BIKANER,

RAJASTHANRAJASTHAN

J.P.MANDAWRAJ.P.MANDAWRALecturer, SVNIT,SURAT,Lecturer, SVNIT,SURAT,

GUJRATGUJRAT

INTRODUCTIONINTRODUCTION CERAMIC WASTECERAMIC WASTE NEED OF THE STUDYNEED OF THE STUDY EXPERIMENTAL PROGRAMMEEXPERIMENTAL PROGRAMME DISCUSSION DISCUSSION CONCLUSION CONCLUSION

INTRODUCTION In Bikaner due ot abundance of clay there are more In Bikaner due ot abundance of clay there are more

than forty ceramic industries with 240 MT/day than forty ceramic industries with 240 MT/day installed capacity, producing glazed tiles, sanitary installed capacity, producing glazed tiles, sanitary wares and mainly insulators. wares and mainly insulators.

The daily average waste generation is 10-30% of total The daily average waste generation is 10-30% of total production, which is not recycled at present. production, which is not recycled at present.

This waste is generally used for land filling or This waste is generally used for land filling or disposed off on road sides near by industries. disposed off on road sides near by industries.

As the ceramic waste is piling up everyday, there is As the ceramic waste is piling up everyday, there is pressure on the Municipal Council and ceramic pressure on the Municipal Council and ceramic industries to find a solution for its disposal. industries to find a solution for its disposal.

RAW MATERIALS USED IN THE CERAMIC INDUSTRY Sr. No. Raw Material

1 Ceramic Color, Pigments

2 Printing Bases

3 Compound, Frit, Matt. Powder, Glaze etc.

4 Borax Pentahydrate

5 Boric Acid

6 CMC

7 Ukraine Clay

8 Ceramic Pigments

9 Feldspar

10 Quartz

11 Zinc Oxide, Wollastonite

12 Cal. Carbonates

13 Alumina Baco, Corundrum

14 Probitol

15 STPP

16 Binding Material

17 Kaolin

18 Other Clays

19 Silica

Scenario of Indian ceramic industries

World ranking (in production):World ranking (in production): not in the Top 10 (India A/c for 3.30%) not in the Top 10 (India A/c for 3.30%) Global Industry Growth Rate:Global Industry Growth Rate: 5-7% 5-7% Growth Rate (India Domestic Market):Growth Rate (India Domestic Market): 10% 10% Organized sector:Organized sector:         % Share of Production: 43% % Share of Production: 43%         Production Capacity: 103300 M.T. per annum   Production Capacity: 103300 M.T. per annum   Actual Production: 95000 M.T. per annum Actual Production: 95000 M.T. per annum Unorganized sector:Unorganized sector: % Share of Production: 57%    % Share of Production: 57%     Production Capacity: 136700 M.T. per annum  Production Capacity: 136700 M.T. per annum      Actual Production: 120000 M.T. per annum Actual Production: 120000 M.T. per annum

Source: www.icctas.comSource: www.icctas.com  

PACKING OF INSULATORS AT FACTORY WASTE PILING OUT SIDE FACTORY

LABOUR CARRYING CERAMIC WASTE FOR LAND DISPOSAL

CERAMIC WASTE USED FOR LAND FILLLING

CERAMIC WASTE PILING ON URBAN ROADS

WASTE PYRAMID

PRESENT SCENARIOFOR GREENER ENVIRONMENT TURN THE WASTE PYRAMID ON ITS HEAD!

NEED OF THE STUDY In the present study an attempt has been made to find In the present study an attempt has been made to find

the suitability of the ceramic industrial wastes as a the suitability of the ceramic industrial wastes as a possible substitute for conventional crushed stone possible substitute for conventional crushed stone aggregate in Pavement construction to solve the aggregate in Pavement construction to solve the disposal problem of waste. disposal problem of waste.

Because there is no value attached to it due to lack of Because there is no value attached to it due to lack of recycling technology, such waste is often provided recycling technology, such waste is often provided free of charge by the industries.free of charge by the industries.

Experiments were carried out to determine the Experiments were carried out to determine the engineering properties of ceramic waste as a road engineering properties of ceramic waste as a road construction material and properties were compared construction material and properties were compared with the conventional aggregate. with the conventional aggregate.

EXPERIMENTAL PROGRAMME

The experimental programme comprises the The experimental programme comprises the following two stages: following two stages:

Characterization of ceramic waste aggregate Characterization of ceramic waste aggregate and comparison with crushed stone aggregate.and comparison with crushed stone aggregate.

To conduct the Marshall Stability Test with To conduct the Marshall Stability Test with ceramic waste aggregate and compare the ceramic waste aggregate and compare the respective properties with conventional respective properties with conventional aggregates.aggregates.

MATERIALS

Ceramic electrical insulator industrial wastes are Ceramic electrical insulator industrial wastes are generally too big to be fed into a crushing machine. generally too big to be fed into a crushing machine. They are broken into small pieces of about 100–They are broken into small pieces of about 100–150 mm sizes by a hammer. These small pieces are 150 mm sizes by a hammer. These small pieces are then fed into a jaw crusher to get the required size .then fed into a jaw crusher to get the required size .

Bitumen of 60/07 Penetration grade were obtained Bitumen of 60/07 Penetration grade were obtained from hot mix plant and natural crushed stone from hot mix plant and natural crushed stone aggregate from local query were used.aggregate from local query were used.

DISC INSULATORS WASTE CERAMIC AGGREGATE

Test details The physical and mechanical properties of the ceramic waste coarse

aggregate and conventional crushed stone coarse aggregate were determined as per IS 2386 (Part I–VIII)-1963

To understand the Stability – Flow analysis of ceramic and conventional aggregate Marshall Test was conducted as per ASTM D 1559.As per IRC :29 -1968 the Asphalt Concrete were deigned to fulfill the following requirements .

Marshall Stability value ,Kg (Min.) =340 Marshall flow value ,0.25 mm units = 8- 16 Voids in total mix,Vv % =3-5 Voids in mineral aggregate filled with Bitumen VFB % = 75 – 85 For Mix design samples were prepared with different percentage of fine

aggregate (i.e. 0%, 7.5% ,15%,22.5 % and 30 %) and percentage of Bitumen were varied from 2.5 % to 7.5 % .

Comparison of Properties of ceramic waste aggregate

Properties Ceramic wasteConventional

Crushed stone

Specific gravity 2.45 2.68

Water absorption 24 h (%) 0.72 1.20

Crushing value (%) 27 24

Impact value (%) 21 17

Abrasion value (%) 28 20

Soundness test: weight loss after 30 cycles (%)

3.3 6.8

higher

MARSHALL STABILITY TEST

0

100

200

300

400

500

600

700

800

2.5 5 7.5

% BINDER

ST

AB

ILIT

Y V

AL

UE

(K

g)

Fine Agg.+0% CWA Fine Agg.+7.5% CWA Fine Agg.+15% CWA

Fine Agg.+22.5% CWA Fine Agg.+30% CWA

Fine agg.+15% CWA

CONCLUSION Ceramic waste can be transformed into useful road aggregate.Ceramic waste can be transformed into useful road aggregate. Waste disposal problem can be solved by using waste for Waste disposal problem can be solved by using waste for

construction work.construction work. Industries will not dispose waste on road side ,if waste has some value Industries will not dispose waste on road side ,if waste has some value

in market as a alternative construction material.in market as a alternative construction material. The properties of ceramic waste aggregate are well within the range The properties of ceramic waste aggregate are well within the range

of the values of Road making aggregates. of the values of Road making aggregates. The Marshall stability test shows that up to 15% of fine aggregate The Marshall stability test shows that up to 15% of fine aggregate

can be partially replaced with waste ceramic aggregate .can be partially replaced with waste ceramic aggregate . The cost of the construction can be reduced to some extent as the The cost of the construction can be reduced to some extent as the

waste is available free of cost . waste is available free of cost . The properties of Mix Design with waste ceramic aggregate are not The properties of Mix Design with waste ceramic aggregate are not

significantly different from those of conventional aggregates. significantly different from those of conventional aggregates. This research work is the basis for further experiments on road This research work is the basis for further experiments on road

performance with the use of ceramic waste coarse aggregate. performance with the use of ceramic waste coarse aggregate.

REFERENCES [1] A.R. Khaloo, Crushed tile coarse aggregate concrete, [1] A.R. Khaloo, Crushed tile coarse aggregate concrete, Cem Cem Concr AggregatesConcr Aggregates (1995) (2), pp. 119–125. (1995) (2), pp. 119–125.

[2] Marianne Tange Jepsen, Dorthe Mathiesen, Christian [2] Marianne Tange Jepsen, Dorthe Mathiesen, Christian Munch-Petersen, and Dirch Bager. Durability of resource Munch-Petersen, and Dirch Bager. Durability of resource saving “Green” type of concrete. In: Proceedings of FIB-saving “Green” type of concrete. In: Proceedings of FIB-symposium on Concrete and environment, Berlin, October symposium on Concrete and environment, Berlin, October 2001. 2001.

[3] Kanakasabai, V.,Rajshekharan, A.(1992)”ceramic insulator [3] Kanakasabai, V.,Rajshekharan, A.(1992)”ceramic insulator scrap as light weight aggregate in concrete”, National scrap as light weight aggregate in concrete”, National conference on cement and building materials from industrial conference on cement and building materials from industrial waste” , July, pp 8-15waste” , July, pp 8-15

[4] Sherwood, P.T.(1995) “Alternate material in road [4] Sherwood, P.T.(1995) “Alternate material in road construction”, Thomas Telford, London.construction”, Thomas Telford, London.

[5] IS 2386:1963 (PART I-VIII), Method of test for aggregate [5] IS 2386:1963 (PART I-VIII), Method of test for aggregate for concrete, Bureau of Indian Standards, New Delhi. for concrete, Bureau of Indian Standards, New Delhi.

Keep your Environment clean and green…….