use of sewage sludge ash in replacement of stone dust in concrete pavement

PROJECT REPORT

Use of Sewage Sludge Ash in replacement

Of Stone dust in Concrete Pavement

Submitted by

MAHAK BASSI(110470106051)

TITIKSHA RAJPARA(110470106006)

NILAM MANSURIYA(110470106017)

In fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

In

Civil Engineering

VVP Engineering College, Rajkot

Gujarat Technological University

Ahmedabad

VVP ENGINEERING COLLEGE

VIRDA-VAJDI, KALAWAD ROAD, RAJKOT 5

CERTIFICATE

This is to certify that the project entitled Use of Sewage Sludge Ash in replacement Of Stone

dust in Concrete Pavement has been carried out by Titiksha Rajpara, Nilam Mansuriya,

Mahak Bassi under my guidance in partial fulfillment for the degree of: Bachelor of

Engineering in Civil Engineering 8th Semester of Gujarat Technological University,

Ahmadabad during the academic year 2014-15.

_____________ __________________

Internal Guide Head of Department

VVP ENGINEERING COLLEGE

VIRDA-VAJDI, KALAWAD ROAD, RAJKOT 5

DECLARATION

We hereby declare that the Project Report for the project entitled Use of Sewage Sludge

Ash in replacement Of Stone dust in Concrete Pavement submitted in partial fulfillment for the degree of Bachelor of Engineering in Civil Engineering to Gujarat Technological

University, Ahmedabad, is a bonafide record of the project work carried out at VVP

Engineering College under the supervision of Prof Jaydeep Bhanderi and that no part of

any of these reports has been directly copied from any students reports or taken from any other source, without providing due reference.

Name of the Students Sign of Students

1. Mahak Bassi

2. Titiksha Rajpara

3. Nilam Mansuriya

ACKNOWLEDGEMENT

It is our great pleasure to acknowledge the contribution & assistance of the following individuals

to this effort. We owe this moment of satisfaction with deep sense of gratitude to our project

guide Prof: Jaydeep Bhanderi whose interest, guidance & constant supervision at any stage of

work has been the greatest help for us in bringing out this work in the present form. We sincerely

acknowledge that without his support this project would not have been feasible.

Mr. Keyur Nagecha, Head of civil engineering department, has been a source of moral support

throughout the duration of this project & we articulate our special thanks to him.

We are also indebted of our lab assistant Mr. Mahindra Vyas & all other faculties for motivating

us & fostering feeling of belongingness towards our project. Their helpful solutions & comments

helped us for the betterment of the project.

Finally we would like to thank everyone who directly or indirectly helped us in the project.

ABSTRACT

Sludge is an inevitable by-product of wastewater treatment.

The disposal of sludge is a complex problem that can affect air, land & environment.

Thus the large scaled disposal of sludge is one of the major concerns of any municipality.

Currently the most common methods of sludge disposal are ocean dumping, land filling

& agricultural use.

All these disposal alternatives have varying degrees of environmental impact. Therefore

there is a need of alternative solutions to the problem of sludge disposal.

One possible solution lies in using incinerated sludge for economical uses in construction

as substitute materials.

Digested and dewatered sludge, after incineration at a high temperature, yields a hard,

cellular, porous mass with low unit weight. This hardened mass of sludge ash can be

crushed to smaller-sized aggregates, which, when graded in suitable proportions,

manifest the basic attributes required of lightweight aggregates.

This sludge can be used in replacement of stone dust in making concrete pavements.

www. plagiarism -detect .comDate: 25.4.2015Words: 5206Plagiarised sources: 7Plagiarised: 2%

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treatment facilities with sludge incinerators or from1.companies responsible for the disposal of the sludge2.Due to the relatively small quantities of sludge ash generated, provisions3.ash storage will be required to accumulate sufficient amounts for most4.be expected to decrease the density of the5.expected to result in an increase in air voids6.

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treatment facilities with sludge incinerators or from1.companies responsible for the disposal of the sludge2.Due to the relatively small quantities of sludge ash generated, provisions3.ash storage will be required to accumulate sufficient amounts for most4.

http://www.fhwa.dot.gov/publications/research/infrastructure/structures/97148/ss2.cfmplagiarised from source: >1%

be expected to decrease the density of the1.expected to result in an increase in air voids2.

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be expected to decrease the density of the1.http://www.engineering.uiowa.edu/~becker/documents.dir/density.pdfplagiarised from source: >1%

be expected to decrease the density of the1.http://www.ultratechconcrete.com/cement_composition.htmlplagiarised from source: >1%

The heat of hydration generated is generally as follows at1.http://landscaping.about.com/od/patioideas/a/stone-dust.htmplagiarised from source: >1%

it's strong enough to support the weight of stone1.

INDEX

Sr no Contents Page No

1. Chapter -1 Project introduction 1

1.1 Introduction

1.2 Scope

2. Chapter - 2 Literature review 4

2.1 Review of the papers

3. Chapter - 3 Materials 8

3.1 Sludge

3.2 Cement

3.3 Aggregate

3.4 Water

3.5 Stone Dust

4. Chapter - 4 Methodologies

4.1 General

4.2 Test data for material supplied

4.3 Concrete using sewage sludge

20

5. Chapter-5 Results

5.1 Result obtained by using normal concrete

5.2 Result obtained by using of sewage sludge ash in concrete

25

6. Chapter 6 Conclusion 26

7. Chapter 7 References 27

LIST OF FIGURES

Sr No Figure Page No

1. Various methods of sewage sludge ash disposal 4

2. Simplified sludge incinerator flow diagram 6

3. Microscopic properties of sewage sludge ash 9

4. Sieve analysis of aggregate 22

5. Different particle sizes of aggregate 22

6. Stone Dust 23

7. Stone Dust as paver 23

8. Mixing of the components 24

9. Tamping of material 24

10. Preparing the concrete 24

11. Removal of concrete cubes 24

12. Measuring the compressive strength of concrete 25

13. Failure of specimen 25

LIST OF TABLES

Sr No Table Page No

1. Physical properties of sludge ash 9

2. Typical range of elemental concentrations in sewage

sludge ash

10

3. Type & various tests of cement 11

4. The basic components of cement 11

5. The extent of chemical compounds in cement 12

6. Role of compounds on properties of cement 13

7. Comparative table of heat of hydration produced at

the end of 90 days

14

8. Mix design of concrete 20

9. Sieve Analysis of coarse aggregate 21

10. Sieve Analysis of fine aggregate 22

11. Concrete using sewage sludge 23

12. Result obtained after replacing sludge ash with fine

aggregate

25

CHAPTER 1

1.1 INTRODUCTION

Sludge is an inevitable by-product of wastewater treatment. The disposal of sludge is a

complex problem that can affect air, land & environment. Thus the large scaled disposal

of sludge is one of the major concerns of any municipality. Currently the most common

methods of sludge disposal are ocean dumping, land filling & agricultural use.

All these disposal alternatives have varying degrees of environmental impact. Due to

large volume of sludge, prohibition of sludge dumping in the ocean & lack of suitable

land space, municipalities are turning to incineration. These incineration processes

reduces the volume of sludge to about 10% of its original volume.

Due to limited landfill space available & stringent environmental regulations as well as

the potential for the ground water contamination generated from landfill leach ate , many

waste water treatment plants using sludge incineration processes are attempting to

develop an efficient, economic & environmentally sound alternatives for utilizing ash as

residues.

Therefore there is a need of alternative solutions to the problem of sludge disposal. One

possible solution lies in using incinerated sludge for economical uses in construction as

substitute materials. Stabilization of sludge ash into concrete blocks is a potentially viable

alternative for ash management.

1

Digested and dewatered sludge, after incineration at a high temperature, yields a hard,

cellular, porous mass with low unit weight. This hardened mass of sludge ash can be

crushed to smaller-sized aggregates, which, when graded in suitable proportions,

manifest the basic attributes required of lightweight aggregates.

When used as aggregates in the production of lightweight concrete, experimental results

show that the resulting concrete satisfies the physical requirements of a lightweight

concrete in terms of unit weight, strength, heat-insulating properties, and fire resistance,

thus indicating that sludge ash could be a potential source of suitable lightweight

aggregates.

The solution to the problem of ash seems to be directed towards utilization of ash in

Portland cement concrete roadways (i.e. for highways & airport runways), concrete

building materials, channel stabilization materials & other alternatives.

2

1.2 SCOPE OF THE STUDY

In metropolitan areas & highly populated cities the volume of sludge produced by

waste water treatment plants is enormously high. Incineration of sludge is a common

practice to reduce its volume through a burning process that converts it into ash. Still,

a considerable amount of ash is produced which creates serious disposal problems.

Attempts have been made to study the feasibility of using sludge ash as a substitute

for a portion of fine aggregates in concrete. The objectives of this papers are to:-

Determine the physical characteristics of the ash produced in Madhapar waste

water treatment plant, Rajkot.

Evaluate the utilization of the stabilized mixes (mixing ash with Portland

cement concrete) for suitability in application.

Evaluate the potential impact to the environment as a result of ash

stabilization in a concrete mix.

3

CHAPTER 2

LITERATURE REVIEW

Sewage sludge ash is the by-product produced during the combustion of dewatered sewage

sludge in an incinerator. Sewage sludge ash is primarily a salty material with some sand-size

particles. The specific size range and properties of the sludge ash depend to a great extent on the

type of incineration system and the chemical additives introduced in the wastewater treatment

process.

Sludge ash can is obtained directly from municipal wastewater treatment facilities with sludge

incinerators or from private companies responsible for the disposal of the sludge ash. Due to the

relatively small quantities of sludge ash generated, provisions for ash storage will be required to

accumulate sufficient amounts for most applications.

Figure 1 Various methods of sewage sludge ash disposal

4

The multiple hearth incinerators are a circular steel furnace that contains a number of solid

refractory hearths and a central rotating shaft. Rabble arms that are designed to slowly rake the

sludge on the hearth are attached to the rotating shaft. Dewatered sludge (approximately 20

percent solids) enters at the top and proceeds downward through the furnace from hearth to

hearth, pushed along by the rabble arms.

Cooling air is blown through the central column and hollow rabble arms to prevent overheating.

The spent cooling air with its elevated temperature is usually recalculated and used as

combustion air to save energy. Flue gases are typically routed to a wet scrubber for air pollution

control. The particulates collected in the wet scrubber are usually diverted back into the sewage

plant.

Fluidized bed incinerators consist of a vertical cylindrical vessel with a grid in the lower

sections to support a bed of sand. Dewatered sludge is injected into the lower section of the

vessel above the sand bed and combustion air flows upward and fluidizes the mixture of hot sand

and sludge. Supplemental fuel can be supplied by burning above and below the grid if the

heating value of the sludge and its moisture content are insufficient to support combustion.

Figure 1 shows a simplified flow diagram of a sludge incinerator.

The complete system includes sludge pretreatment operations such as sludge thickening

(sedimentation) and sludge dewatering (vacuum filter, centrifuge, or filter press), followed by

incineration, air pollution control, and ash handling. Sludge dewatering may involve the addition

of ferrous chloride, lime, or organic polymers to enhance the dewatering process. Auxiliary fuel

is normally needed to maintain the combustion process.

5

The quantity of auxiliary fuel required depends on the heating value of the sludge solids and,

primarily, on the moisture content of the incoming feed sludge. Operating temperatures can vary,

depending on the type of furnace, but can be expected to range from approximately 650C

(1200F) to 980C (1800F) in the incinerator combustion zone. High operating temperatures

above 900C (1650F) can result in partial fusion of ash particles and the formation of clinkers,

which end up in the ash stream. Lime may also be added to reduce the slogging of sludge during

incineration.

.

Fig 2: Simplified sludge incinerator flow diagram

(Courtesy of www. www.fhwa.dot.gov)

Sludge ash has been previously used as a raw material in Portland cement concrete production,

as aggregate in flow able fill, as mineral filler in asphalt paving mixes, and as a soil conditioner

mixed with lime and sewage sludge.

6

Sludge ash has also been proposed as a substitute lightweight aggregate product, produced by

firing sludge ash or a mixture of sludge ash and clay at elevated or sintering temperatures. Other

potential uses that have been reported include the use of ash in brick manufacturing and as a

sludge dewatering aid in wastewater treatment systems.

Applications that could potentially make use of sewage sludge ash in highway construction

include the use of ash as part of a flow able fill for backfilling trenches or as a substitute

aggregate material or mineral filler additive in hot mix asphalt. Sludge ash can is obtained

directly from municipal wastewater treatment facilities with sludge incinerators or from private

companies responsible for the disposal of the sludge ash. Due to the relatively small quantities of

sludge ash generated, provisions for ash storage will be required to accumulate sufficient

amounts for most applications.

Sludge ash properties (chemical) depend on the nature of the wastewater and the chemicals used

in the treatment and sludge handling and incineration process. Since sludge is almost always

dewatered prior to combustion, pretreatment of the sludge to enhance the dewatering process

may include the addition of ferrous salts, lime, organics, and polymers.

Ash produced at treatment plants that introduce ferrous salts or lime for sludge conditioning and

dewatering contain significantly higher quantities of ferrous and calcium, respectively, than

plants that do not. The pH of sludge ash can vary between values 6 and 12, but sludge ash is

generally alkaline.

Incineration of sewage sludge (dewatered to approximately 20 percent solids) reduces the weight

of feed sludge requiring disposal by approximately 85 percent.

7

CHAPTER 3

3.1 SLUDGE

Some of the properties of sludge ash that are of particular interest when sludge ash is used in

concrete include particle size, plasticity and organic content.

Physical properties

Particle Size: Depending on the source of ash, some sludge ash may have a significant

fraction of particles greater than 0.6 mm in size. If this is the case, then sludge ash may

have to be processed (crushed and screened) or introduced into the mix as a combination

mineral filler and fine aggregate. Sludge ash particles greater than 0.6 mm in size are

expected to comply with gradation and soundness requirements for fine aggregate

material.

Plasticity: Sludge ash is a non plastic material and meets the plasticity requirements for

mineral filler or fine aggregate.

Organic Impurities: Sludge ash can be expected to contain some small percentage

(generally less than 2 percent) of organic material, depending on the efficiency of

combustion. This small organic fraction does not appear to affect the performance of

sludge ash as a mineral filler.

The properties of a concrete containing sludge ash that are of particular interest include stability,

mix density, air voids, durability.

Stability: The addition of sludge ash in concrete mixes up to approximately 30% by

weight of aggregate reportedly increases the stability of the mix.

8

Mix Density: The addition of sludge ash can be expected to decrease the density of the

mix.

Air Voids: An increase in sludge ash concentration can be expected to result in an

increase in air voids and a corresponding increase in the cement demand of the mix.

Durability: Mix durability may be slightly improved by the addition of sludge ash.

Table 1 presents physical property characterization data for sludge ash. Sludge ash is a

silty-sandy material. A relatively large fraction of the particles (up to 90 percent in some

ashes) are less than 0.075 mm in size. Sludge ash has a relatively low organic and

moisture content. Permeability and bulk specific gravity properties are not unlike those of

natural inorganic silt. Sludge ash is a non plastic material.

Moisture Content (% by

Total Weight) 0.28

Absorption (%) 1.6

Specific Gravity 2.61

Bulk Specific Gravity 1.82

Table 1: Physical properties of sludge

ash Fig 3: Microscopic properties

(a) fly ash (b) incinerated sludge

ash

9

Chemical Properties

Sludge ash consists primarily of silica, iron and calcium. The composition of the ash can vary

significantly, and depends in great part on the additives introduced in the sludge conditioning

operation. There are no specific data available relative to the pozzolanic or cementitious

properties of sludge ash, but sludge ash is not expected to exhibit any measurable pozzolanic or

cementitious activity. Table 2 lists the range of major elemental concentrations present in sludge

ash reported from two sources.

Trace metal concentrations (e.g., lead, cadmium, zinc, copper) found in sludge ash are typically

higher than concentrations found in natural fillers or aggregate. This has resulted in some

reluctance to use this material.

Plasticity Index Non plastic

Permeability (cm/sec)

4 x 10-4

Table 2: Typical range of elemental concentrations in sewage sludge ash

Element Oxide Reported as Elemental %

Concentration

Reported as %

Oxides

Silicon (Si) (SiO2) 5.6 - 25.7 14.4 - 57.7

Calcium (Ca) (CaO) 1.4 - 42.9 8.9 - 36.9

Iron (Fe) (Fe2O3) 1.0 - 16.4 2.6 - 24.4

Aluminum (Al) (Al2O3) 1.1 - 8.5 4.6 - 22.1

Magnesium

(Mg) (MgO) 0.6 - 1.9 0.8 - 2.2

Sodium (Na) (Na2O) 0.1 - 0.8 0.1 - 0.7

Potassium (K) (K2O) 0.3 - 1.6 0.07 - 0.7

Phosphorus (P2O5) 1.2 - 4.4 3.9 - 15.4

Sulphur (S) (SO3) 0.3 - 1.2 0.01 - 3.4

Carbon (C) - 0.6 - 2.2 -

10

3.2 CEMENT

The cement used in the tests is of ultratech cement of opc type of grade 43. The usual tests

carried out for cement are for chemical and physical requirements. The chemical standards

give permissible limits for insoluble residue, loss of ignition and other compounds and

impurities like Magnesium Oxide, Sulphate, etc. The physical requirements are for fineness,

soundness, setting time and compressive strength. 33, 43 and 53 grade in OPC indicates the

compressive strength of cement after 28 days when tested. Similarly for 43 grade the 28 days

compressive strength should not be less than 43 MPa.

Table 3: Type & various tests of cement

Sr

no

Type of

cement

IS Code Fineness

m2/kg

(min)

Setting Time

in minutes

Soundness Compressive Strength

in MPa

Initial

(min.)

Final

(max.)

Le

Chatelier

(mm)

Auto

Clave

(%)

3 days 7 days 28 days

1 OPC-43 8112 :

1989

225 30 600 10 0.8 23 36 47

Table 4: The basic components of cement

SiO2 17-25 %

Al2O3 4-8%

Fe2O3 0.5-0.6 %

CaO 61-63 %

MgO 0.1-4.0 %

SO3 1.3-3.0 %

Na2 + K2O 0.4-1.3 %

Cl 0.01-0.1%

IR 0.6-1.75 %

There are four major compounds in cement and these are known as C2S, C3S, C3A & C4AF,

and their composition varies from cement to cement and plant to plant.

11

There are other minor compounds such as MgO, TiO2, Mn2O3, K20 and N2O. K2O and Na2O

are found to react with some aggregates and the reaction is known as Alkali Silica Reaction

(ASR) and causes disintegration in concrete at a later date.

The silicates C3S and C2S are mainly responsible for the strength of the cement paste. C3A and

C4AF do not contribute much to the strength, but in the manufacturing process they facilitate

combination of lime and silica, and act as a flux. In a typical Portland cement, the composition

of mineralogical compounds could be as shown in the following table.

Table 5: The extent of chemical compounds in cement

Sr no Compound Composition as %

1 C3S 48-52 %

2 C2S 22-26 %

3 C3A 6-10 %

4 C4AF 13-16 %

5 Free lime 1-2 %

12

Table 6: Role of compounds on properties of cement

Characteristic C3S C2S C3A C4AF

Setting Quick Slow Rapid -

Hydration Rapid Slow Rapid -

Heat Liberation

(Cal/gm) 7 days Higher Lower Higher Higher

Early Strength High up to

14 days

Low up to

14 days

Not much

beyond 1

day

Insignificant

Later Strength Moderate High at - -

at later

stage

later stage

after 14

days

Heat of Hydration

Most of the reactions occurring during the hydration of cement are exothermic in nature (heat

is generated). This heat is called heat of hydration. It is desirable to know the heat producing

capacity of cement in order to choose the most suitable cement for a given purpose.

For Ordinary Portland Cement, half of the total heat is liberated between 1-3 days, about th

in 7 days and nearly 90% in 28 days. It may lead to cracks if not properly dissipated. The sum

total heat produced, if spread over a longer period can be dissipated to a greater degree with

fewer problems. The hydration of C3S produces higher heat as compared to the hydration of

C2S. Fineness of cement also affects the rate of heat development. The heat of hydration

generated is generally as follows at 28 days.

13

Table 7:Comparative table of heat of hydration produced at the end of 90

days

Sr

no Compound

Heat of hydration (calories

per gram)

1 C3S 100-110

2 C2S 50-60

3 C3A 300-315

4 C4AF 95-105

It may be seen that the heat produced by C3S is twice that of C2S and that by C3A is still

higher. It follows that, reducing the proportions of C3S and C3A, the heat of hydration and its

rate can be reduced. The fully hydrated reaction can be expressed as

2C3S +6H -> C3S2H3 +3Ca(OH)2

2C2S +4H -> C3S2H3 +Ca(OH)2

C3S2H3 (Calcium Silicate Hydrate) becomes a hard mass over a period of time and normally

called as C-S-H gel. While C3S contributes to most of the strength development during the first

two weeks, C2S influences gain of strength after two weeks.

14

3.3 AGGREGATE ( FINE AGGREGATE AND COARSE AGGREGATE)

Aggregate is commonly considered inert filler, which accounts for 60 to 80 percent of the

volume and 70 to 85 percent of the weight of concrete. Although aggregate is considered

inert filler, it is a necessary component that defines the concretes thermal and elastic

properties and dimensional stability.

Aggregate is classified as two different types, coarse and fine. Coarse aggregate is usually

greater than 4.75 mm, while fine aggregate is less than 4.75 mm. The compressive aggregate

strength is an important factor in the selection of aggregate. When determining the strength

of normal concrete, most concrete aggregates are several times stronger than the other

components in concrete and therefore not a factor in the strength of normal strength concrete.

Lightweight aggregate concrete may be more influenced by the compressive strength of the

aggregates.

Other physical and mineralogical properties of include shape and texture, size gradation,

moisture content, specific gravity, reactivity, soundness and bulk unit weight.

The shape and texture of aggregate affects the properties of fresh concrete more than

hardened concrete. The surface texture of aggregate can be either smooth or rough. A smooth

surface can improve workability, yet a rougher surface generates a stronger bond between the

paste and the aggregate creating a higher strength.

The moisture content of an aggregate is an important factor when developing the proper

water/cementitious material ratio. All aggregates contain some moisture based on the

porosity of the particles and the moisture condition of the storage area. The moisture content

can range from less than 1% in gravel & up to 40% in very porous sandstone and expanded

shale.

15

Aggregate can be found in four different moisture states that include oven-dry (OD), air-dry

(AD), saturated-surface dry (SSD) and wet. Of these four states, only OD and SSD

correspond to a specific moisture state and can be used as reference states for calculating

moisture content. In order to calculate the quantity of water that aggregate will either add or

subtract to the paste, the following three quantities must be calculated:

absorption capacity

effective absorption

Surface moisture.

Most stockpiled coarse aggregate is in the air dry state with absorption of less than 1%, but most

fine aggregate is often in the wet state with surface moisture up to 5%.

The most common classification of aggregates on the basis of bulk specific gravity is lightweight,

normal-weight, and heavyweight aggregates. In normal concrete the aggregate weighs 1,520

1,680 kg/m3, but occasionally designs require either lightweight or heavyweight concrete.

Lightweight concrete contains aggregate that is natural or synthetic which weighs less than 1,100

kg/m3and heavyweight concrete contains aggregates that are natural or synthetic which weigh

more than 2080 kg/m3.

16

3.4 WATER

Water is when mixed with the dry composite (cement, sand, aggregate & fly ash), produces a

semi-liquid that can be shaped (typically by pouring it into a form). The concrete solidifies and

hardens through a chemical process called hydration.

The water reacts with the cement, which bonds the other components together, creating a robust

stone-like material. Combining water with a cementitious material forms a cement paste by the

process of hydration. The cement paste glues the aggregate together, fills voids within it, and

makes it flow more freely.

A lower water-to-cement ratio yields a stronger, more durable concrete, whereas more water

gives a free - flowing concrete with a higher slump. Impure water used to make concrete can

cause problems when setting or in causing premature failure of the structure.

Hydration involves many different reactions, often occurring at the same time. As the reactions

proceed, the products of the cement hydration process gradually bond together the individual

sand and gravel particles and other components of the concrete to form a solid mass.

Reaction:

Cement chemist notation: C3S + H C-S-H + CH

Standard notation: Ca3SiO5 + H2O (CaO)(SiO2)(H2O)(gel) + Ca(OH)2

Balanced: 2Ca3SiO5 + 7H2O 3(CaO)2(SiO2)4(H2O)(gel) + 3Ca(OH)2

Almost any natural water that is drinkable and has no pronounced taste or odor can be used as

mixing water for making concrete. However, some waters that are not fit for drinking may be

suitable for use in concrete.

17

Excessive impurities in mixing water not only may affect setting time and concrete strength, but

also may cause efflorescence, staining, corrosion of reinforcement, volume instability, and

reduced durability. Therefore, certain optional limits may be set on chlorides, sulfates, alkalies,

and solids in the mixing water. Some impurities may have little effect on strength and setting

time, yet they can adversely affect durability and other properties.

Water containing less than 2000 parts per million (ppm) of total dissolved solids can generally be

used satisfactorily for making concrete. Water containing more than 2000 ppm of dissolved

solids should be tested for its effect on strength and time of set. It is important to remember that

cement is the powder that reacts with water to form cement paste, a hard, solid material that

forms the matrix for the concrete composite.

18

3.5 STONE DUST

Stone dust is a darker, coarser version of sand. It is a byproduct of running stones through a

crushing machine to make crushed stone. Stone dust makes a great setting bed for stone

pavers. It can be smoothed to create a very flat surface and its strong enough to support the

weight of stone pavers.

Stone dust is more prone than sand to settling and drainage problems. It absorbs moisture,

holds onto it and drains very slowly. Stone dust does not compact well due to its powdery

nature. Not all stone dust are poor choices for pavers, crusher run also called processed

gravel is a rock or stone dust made of particles about size of grain of sand. It is coarse thus

superior to regular stone dust.

Using one particular material over the other for a paver project does not guarantee how long

it will last before problems occur. Various factors affecting it are- appropriate depths of bas

materials, proper compaction, loads that these materials are subjected to etc.

19

CHAPTER 4

METHODOLOGIES

4.1 GENERAL

Different batches of concrete were prepared using incinerated sludge and without using it.

Three cubes each of sludge ash content 10%, 20% and 30% were made. Three cubes of

normal concrete were made and the compressive strengths of the cubes were tested. Nominal

Mix Design for making the concrete cubes was used.

Grade of Concrete: M 20

Total Aggregate (CA + FA) per 50 kg cement 250 kg,

FA of Zone II (say)

Water content: 30 lit per 50 kg cement

W/c ratio= 30/50= 0.60

Considering FA: CA= 1: 2

Sand= (250 X 1)/ 3= 83 kg

Coarse Aggregate= (250 X 2)/ 3= 167 kg

Table 8 Mix Design for concrete

CEMENT FINE

AGGREGATE

COARSE

AGGREGATE

WATER

5Okg 83kg 167kg 30litres

(By weight) 1.66 3.32 0.6

1.43kg/l 1.52kg/l 1.6kg/l

35l 54.6l 104.4l 30l

(by volume) 1 1.56 2.98

20

4.2 TEST DATA FOR MATERIALS SUPPLIED

CEMENT

Specific Gravity 3.05

Average compressive strength more than 43

Exposure moderate

COARSE AGGREGATE

20 mm graded

Crushed stone aggregate

Specific gravity 2.68

Water absorption 1.46

Free moisture 0

Table 9 Sieve Analysis of coarse aggregate

IS SIEVE (mm)SIZE % Retained Cumulative retained %passing

40 0 0 100

20 .6 .6 99.4

10 73.5 74.1 25.9

4.75 22.9 97 3

21

Figure 4 Sieve analysis of aggregate Figure 5 Different particle sizes

Of aggregates

FINE AGGREGATE

Type- natural

Specific Gravity- 2.6

Water Absorption 0.5

Free moisture 0.4

Table 10 Sieve analysis of fine aggregate

IS SIEVE %retained Cumulative retained %passing

10 mm 0 0 100

4.75 mm 5.2 5.2 94.8

2.36 mm 3 8.2 91.8

1.18 mm 8.6 16.8 83.2

600mic 25.8 42.6 57.4

300mic 32.8 75.4 24.6

150mic 20.7 96.1 3.9

22

TARGET MEAN STRENGTH

ft = fck + k. s

Where, ft = target mean compressive strength at 28 days

fck = Characteristic compressive strength of concrete at 28 days

k = usually 1.65 (as per IS 456-2000)

s = standard deviation.( Here it is 4.6)

Target mean strength ft= 27.59 N/mm2

SELECTION OF WATER CEMENT RATIO

Assume water cement ratio 0.5

Table 11 Concrete using sewage sludge

% sludge

ash

CEMENT

(kg)

FINE

AGGREGATE (kg)

COARSE

AGGREGATE(kg)

WATER(litre)

0 50 83 167 30

10 50 74.7 167 30

20 50 66.4 167 30

30 50 58.1 167 30

Figure 6 Stone Dust Figure 7 Stone Dust used in paver

23

Figure 8 Mixing of the components Figure 9 Tamping of material

Figure 10 Preparing the concrete Figure 11 Removal of concrete cubes

24

CHAPTER 5

TEST RESULTS

Table 12 Result obtained after replacing sludge ash with fine aggregate

% of sewage sludge ash 7 days compressive strength 28days compressive strength

0 21.96 31.8

10 20.65 29.35

20 19.86 28.03

30 17.03 26.36

Figure 12 Measuring the compressive Figure 13 failure of specimen

Strength of concrete

25

CHAPTER 6

CONCLUSION

The 28-day compressive strength of concrete decreases as the percentage of sludge ash in the

mix increases. However, the design strength is still attainable for up to 30% (by weight) ash

replacement.

Under the presence of clay lumps in ash may have contributed to the reduction in

compressive strength. Ash is a water-absorbent material but, unlike plastic soils, it does not

undergo undesirable volume change.

Excess water in the ash will obviously result in considerable reduction of strength. This

excess water should be either accounted for in the mix proportionalities or, preferably, the

ash should be dried before being added into the concrete mix.

More than 20% sewage sludge ash content is not acceptable. Use of 20% sludge ash gives

exact 28.03 N/mm2 at 28 days. So it is better not to replace more than 15% sludge ash in

concrete.

26

CHAPTER 7

REFERENCES

Research Papers-

Disposal method and use of sewage sludge Inventors: William C. Webster; Robert G.

Hilton; Ronald F. Cott

Manufacturing method of lightweight construction materials using sludge waste

Inventor: se-Lin lee

Lightweight aggregate from fly ash and sewage sludge. Inventor Timothy m. nechvatal,

waukesha; glenn a. heian, franklin.

Fixation and utilization of ash residue from the incineration of municipal solid waste

Inventors: Frederick H. Gustin; Hugh P. Shannonhouse; Robert W. Styron, all of

Marietta, Ga.

Process for forming light weight aggregate. Inventor: Robert w. Styron, Marietta, Ga.

Websites-

www.fhwa.dot.gov

www.sciencedirect.com

www.rmrc.wisc.edu

www.engineeringcivil.com

Books-

Concrete Technology by MS Shetty

Concrete Technology ML Gambhir

Advanced Concrete Technology Zongjin Li 27

GIC Patent Drafting Exercise 4764Project Team:

(FOR OFFICE USE ONLY)Application No:Filing Date:Amount of Fee paid:CBR No:

FORM 1THE PATENTS ACT 1970

(39 OF 1970)&

THE PATENTS RULES, 2003APPLICATION FOR GRANT OF PATENT

5818

1. APPLICANT(S)AddressID Email AddressMobile No.NationalityName

MAHAK BASSI Indian 8511103205 [email protected] 90-E,sector 6,Reliance Greens,Moti Khavdi,Jamnagar

TITIKSHA RAJPARA Indian 9558669694 [email protected] rajkot

NILAM MANSURIYA Indian 9427452554 [email protected]

3 rajkot

2. INVENTOR(S)Email AddressMobile No.AddressNationalityNameID

1 MAHAK BASSI Indian 90-E sector 6 reliance greens moti khavdi jamnagar

8511103205 [email protected]

2 TITIKSHA RAJPARA Indian rajkot 9558669694 [email protected]

3 NILAM MANSURIYA Indian rajkot 9427452554 [email protected]

3. TITLE OF INVENTION / PROJECTUSE OF SEWAGE SLUDGE ASH AS REPLACEMENT OF STONE DUST IN CONCRETE PAVEMENT

4. ADDRESS FOR CORRESPONDENCE OF APPLICANT/AUTHORIZED PATENT AGENT IN INDIAMAHAK BASSI90-E sector 6 raliance greens moti khavdi jamnagar

Name:Address:Mobile: 8511103205

[email protected] ID:

NOTE: This is just a mock Patent Drafting Exercise (PDE) for semester 8, BE students of GTU. These documents are not to be submitted with any patent office.

Page 1 of 4


5. PRIORITY PARTICULARS OF THE APPLICATION(S) FIELD IN CONVENTION COUNTRY

6. PARTICULARS FOR FILING PATENT COOPERATION TREATY (PCT) NATIONAL PHASE APPLICATION

7. PARTICULARS FOR FILING DIVISIONAL APPLICATION

8. PARTICULARS FOR FILING PATENT OF ADDITION

Country Application No. Filing Date Name of the Applicant Title of the Invention

N/A N/A N/A N/A N/A

International application number International filing date as alloted by the receiving office

N/A N/A

Main Application / Patent Number

Original(First) Application Number Date of filing of Original (first) application

Date of filing of main application

N/A N/A

N/A N/A

9. DECLARATIONS:(i) Declaration by the inventor(s)

I/We, the above named inventor(s) is/are true & first inventor(s) for this invention and declare that the applicant(s) herein is/are my/our assignee or legal representative.

Date: 19-April-2015

Name Sign & Date

MAHAK BASSI1

TITIKSHA RAJPARA2

NILAM MANSURIYA3(ii) Declaration by the applicant(s) in the convention country

I/We, the applicant (s) in the convention country declare that the applicant(s) herein is/are my/our assignee or legal representative.

Not Applicable


Page 2 of 4


The said invention is an improvement in or modification of the invention particulars of which are given in para 8.

The application is divided out of my/our application(s) particulars of which are given in para 7 and pray that this application may be treated as deemed to have been filed on ___________under section 16 of the Act.

My/Our application in India is based on international application under Patent Cooperation Treaty (PCT) as mentioned in para 6.

I/we claim the priority from the above mentioned applications(s) filed in the convention country/countries & state that no application for protection in respect of invention had been made in a convention country before that date by me/us or by any person from which I/we derived the title.

The application or each of the application,particulars of each are given in the para 5 was the first application in the convention country/countries in respect of my/our invention.

I am/we are the assignee or the legal representative of true & first inventors.

There is no lawful ground of objection to the grant of the patent to me/us.

The invention as disclosed in the specification uses the biological material from India and the necessary permission from the competent authority shall be submitted by me/us before the grant of patent to me/us.

The provisional specification relating to the invention is filed with this application.

I am/We are in possession of the above mentioned invention.

I/We, the applicant(s) hereby declare(s) that:-

(iii) Declaration by the applicant(s)


Page 3 of 4


10. FOLLOWING ARE THE ATTACHMENTS WITH THE APPLICATION:

(j) ........................................ Fees Rs.XXX in Cash/Cheque/Bank Draft bearing No.XXX Date: XXX on XXX Bank.

I/We hereby declare that to the best of my /our knowledge, information and belief the fact and mtters stated herein are correct and I/We request that a patent may be granted to me/us for the said invention.

Dated this ........ day of .......... 20.......

(a) Provisional specification/Complete specification

(b) Complete specification(In confirmation with the international application) / as amended before the international.Preliminary Examination Authority(IPEA),as applicable(2 copies),No.of pages.....No.of claims.....

(c) Drawings(In confirmation with the international application)/as amended before the international Preliminary Examination Authority(IPEA),as applicable(2 copies),No.of sheets.....

(d) Priority documents

(e) Translations of priority documents/specification/international search reports

(f) Statement and undertaking on Form 3

(g) Power of Authority

(h) Declaration of inventorship on Form 5

(i) Sequence listing in electronic Form

Sign & DateName

MAHAK BASSI1

TITIKSHA RAJPARA2

NILAM MANSURIYA3ToThe Controller of PatentThe Patent Office, at Mumbai.


Page 4 of 4


FORM 2THE PATENTS ACT, 1970

(39 OF 1970)&

THE PATENTS RULES, 2003PROVISIONAL SPECIFICATION

1. TITLE OF INVENTION / PROJECTUSE OF SEWAGE SLUDGE ASH AS REPLACEMENT OF STONE DUST IN CONCRETE PAVEMENT

2. APPLICANT(S)

MAHAK BASSI (Indian )90-E,sector 6,Reliance Greens,Moti Khavdi,Jamnagar

TITIKSHA RAJPARA (Indian )rajkot

NILAM MANSURIYA (Indian )rajkot

3. PREAMBLE TO THE DESCRIPTIONThe following specification describes the invention.


Page 1 of 3


4. DESCRIPTIONa. Field of Application / Project / Invention

Concrete technology

b. Prior Art / Background of the Invention / ReferencesIn the project we use sewage sludge by 10%,20%,30% of the stone dust content in concrete cubes. The cubes are then tested for compressive strength.

c. Summary of the Invention/ProjectIn the project we use sewage sludge by 10%,20%,30% of the stone dust content in concrete cubes. The cubes are then tested for compressive strength.

d. Objects of the Invention/Projectthe project involves use of sewage sludge ash in replacement of stone dust.

e. Drawing(s)

f. Description of the Invention we use sewage sludge by 10%,20%,30% of the stone dust content in concrete cubes. The cubes are then tested for compressive strength.We can use sewage sludge upto 10 percent in concrete pavement.

g. Examples

h. Unique Features of the Projectthe project involves use of sewage sludge ash in replacement of stone dust.

5. DATE & SIGNATURE19-April-2015Date:

Sign & DateName

MAHAK BASSI1

TITIKSHA RAJPARA2

NILAM MANSURIYA3


Page 2 of 3


6. ABSTRACT OF THE INVENTIONIn the project we use sewage sludge by 10%,20%,30% of the stone dust content in concrete cubes. The cubes are then tested for compressive strength.


Page 3 of 3


FORM 3

THE PATENTS ACT, 1970(39 OF 1970)

&THE PATENTS RULES, 2003

STATEMENT AND UNDERTAKING UNDER SECTION 8

1. Declaration I/We, MAHAK BASSI

TITIKSHA RAJPARANILAM MANSURIYA

2. Name, Address and Nationality of the joint Applicant

MAHAK BASSI (Indian )90-E,sector 6,Reliance Greens,Moti Khavdi,Jamnagar

TITIKSHA RAJPARA (Indian )rajkot

NILAM MANSURIYA (Indian )rajkot

(i) that I/We have not made any application for the same/substantially the same invention outside India.

(ii) that the right in the application(s) has/have been assigned to,

hereby declare:

Name of the Country

Date of Application

Application Number

Status of the Application

Date of Publication

Date of Grant

N/A N/A N/A N/A N/A N/A

(iii) that I/We undertake that up to the date of grant of patent by the Controller , I/We would keep him inform in writing the details regarding corresponding application(s) for patents filed outside India within 3 months from the date of filing of such application.Dated this _____________day of ___________ ,20____

3. Signature of Applicants

(Sign and Date)

MAHAK BASSI(Sign and Date)

TITIKSHA RAJPARA(Sign and Date)

NILAM MANSURIYA

ToThe Controller of PatentThe Patent Office, at Mumbai.


Page 1 of 1

use of sewage sludge ash in replacement of stone dust in concrete pavement

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