Studies on usage potential of broken tiles as part replacement to coarse aggregates in concretes

IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 110
STUDIES ON USAGE POTENTIAL OF BROKEN TILES AS PART
REPLACEMENT TO COARSE AGGREGATES IN CONCRETES
Aruna D1
, Rajendra Prabhu2
, Subhash C Yaragal3
, Katta Venkataramana4
1
PG Student, Department of Civil Engineering, NITK-Surathkal, India
2
Research Scholar, Department of Civil Engineering, NITK-Surathkal, India,
3
Professor, Dept of Civil Engg, NITK-Surathkal, India
4
Professor, Dept of Civil Engg, NITK-Surathkal, India
Abstract
Concrete has several appealing characteristics that have made it as a widely used construction material. It is the material of
choice where strength, performance, durability etc., are required and concrete is undoubtedly most versatile construction
material. The present study aims at utilization and to ascertain the suitability of tile aggregate as partial replacement to coarse
aggregate in normal pervious and blended concretes. The utility of partial replacement of tile waste as aggregates along with
partially replacing OPC by fly ash is also addressed in the current work. The strength performance of these concretes (Tiled
waste based, tiled waste based pervious, and tile & fly ash based blended concretes) with conventional concretes is studied and
important findings are reported.
Keywords: Clay tile aggregates, fly ash, replacement material, pervious concrete
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1. INTRODUCTION
The use of more and more concrete in construction not only
results in scarcity of materials but also turns out to be
expensive. In order to cope up with the depletion of
conventional resources it would be worth to make use of
suitable by-products to replace some of the conventional
materials. The industrial wastes like fly ash and tile
aggregates, which are produced in huge quantities that cause
environmental pollution need safe disposal. But these
materials possess potential characteristics, which can be
tapped for various uses. Thus, by using these wastes instead
of conventional materials would be preserving the natural
resources, but also solving the problem of disposal of waste,
which has become a national problem.
There are quite a number of clay tile manufacturing
industries existing in Dakshina Kannada district, located in
the coastal belt of Arabian Sea. A brief survey was made
regarding the availability of the broken tiles. There are
nearly 74 tile factories in the whole Dakshina Kannada
district producing about 6000 patented Mangalore roof tiles
per factory per day, out of which about 2% results as
wastage. Taking the weight of the single tile as about 2 kg it
comes to about 18 tonnes of waste produced per day.
Disposal of such a huge quantity is a severe problem to the
tile manufacturing industries.
Fly ash is available in large quantities in the country as a
waste product from a number of thermal power stations and
industrial plants. Its disposal and pollution effects are
posing serious problems. Almost all the fly ash produced in
the country possesses good pozzolanic activity. Fly ash can
be used as part replacement to OPC. In addition to saving
in the cement and cost, the fly ash cement mortar and
concrete possess lower permeability and better workability.
Conventional Portland cement concrete is generally used for
pavement construction. The impervious nature of the
concrete pavements contributes to the increased water runoff
into the drainage system, over-burdening the infrastructure
and causing excessive flooding in built-up areas. Pervious
concrete has become significantly popular during recent
decades, because of its potential contribution in solving
environmental issues. Typically, pervious concrete has no
fine aggregate and has just enough cementitious paste to
coat the coarse aggregate particles while preserving the
interconnectivity of the voids. However, usage of fine
aggregates to the extent of 10% in pervious concretes is
reported in literature. It has been mainly developed for
draining water from the ground surface, so that storm water
runoff is reduced and the groundwater is recharged.
Pervious concrete has been developed in USA in order to
meet US Environmental Protection Agency (EPA) storm
water regulation requirements. European countries have
developed pervious concrete, not only for water
permeability but also for sound absorption. In Japan,
pervious concrete has been researched for the usage in not
only for road surfaces but also to support vegetation along
river banks.
Strength and permeability of pervious concrete are found to
be affected by several factors including binder types,
aggregate type, aggregate grading, mix combination,
compaction and water content. The compressive strength
for highly pervious concrete is half or one-third that of
conventional concrete.
The present study aims at utilization and to ascertain the
suitability of tile aggregate as partial replacement to coarse
aggregate in normal and pervious concrete. The utility of

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partial replacement of tile waste as aggregates along with
partially replacing OPC by fly ash is also addressed in the
current work. The strength performance of these concretes
(Tiled waste based, tiled waste based pervious, and tile &
Fly ash based blended concretes) with respective
conventional concretes is studied in detail and important
findings are reported.
2. MATERIALS AND METHODS
2.1 Materials used and their Properties for Normal
Concrete
The materials used are Ordinary Portland Cement of 43
grade, class F fly ash as partial replacement to cement,
natural sand dredged from river, and of 20 mm downsize
crushed granite stone and waste clay roof tile pieces as
partial replacement to coarse aggregates. Admixtures were
used to modify the properties of concrete
Mix Proportion
The design of a concrete mix involves, determining the
relative quantities of materials such as cement, aggregate
and water for the required performance both in fresh and
hardened states, with maximum overall economy.
Mix proportion for M30 (as per IS 10262- 2009) is,
W C FA CA
168 400 689.8 1143.9
0.42 1 1.172 2.859
The partial replacement of coarse aggregate by clay roof
tiles and partial replacement of cement by fly ash is done by
volumetric method.
2.2 Materials for Porous Concretes
Ordinary Portland Cement (OPC), 4.75-10mm crushed stone
and clay roof as coarse aggregate and Fine sand at 10%
weight of the total aggregate. The water cement ratio was
determined by a trial test was 0.41. The cement content was
in the range of 150 kg/m3
to 400 kg/m3
. Coarse aggregates
were partially replaced by clay roof tiles at 10%, 20% and
30%.
Mix Proportion of Pervious Concrete
The water/cementitious materials ratio for pervious concrete
is normally around 0.30 to 0.45. It is lower than for
conventional concrete. The optimum aggregate/cement ratio
ranges from 4:1 to 4.5:1 by mass. A high amount of
aggregate led to increased permeability and dramatically
decreased compressive strength. Mix proportion for various
replacement levels are shown in Table 1.
Table 1: Details of pervious concrete mix design
Repla.
(%)
Water
content
(kg/m3
)
Cement
content
(kg/m3
)
Fine
agg.
(kg/m3
)
Coarse
agg.
(kg/m3
)
Tile
agg.
(kg/m3
)
0 78 190 172 1493 0
10 78 190 172 1343 122
20 78 190 172 1194 244
30 78 190 172 1045 366
2.3 Methodology
For tile waste based concrete, coarse aggregates were
replaced by 20mm down size, tile wastes by 0% , 5%,
10%, 15%, 20% and 25%. These mixes were designated as
T0 (reference), T5, T10, T15, T20 and T25 respectively for
the purpose of analysis. In pervious concrete, tile aggregate
waste (10mm-4.75mm) in proportion of 0%, 10%, 20% and
30%, is used to partially replace coarse aggregates. These
mixes were designated as P0, P10, P20, and P30
respectively for the purpose of analysis. A nominal 10% fine
aggregate is also adopted in design of pervious concrete. In
the third part of the study, concrete mixes were designed
using tile wastes partially replacing coarse aggregates and
also Fly ash partially replacing OPC. The designed mixes
were designated as T0F0 (reference), T5F10, T10F20,
T15F30, T20F40 and T25F50. In order to achieve the above
objectives set forth, the concrete was cast, cured and tested
for fresh and hardened state.
2.4 Tests
Workability test on fresh concrete was conducted by slump
cone and compressive test was conducted on 150 mm cubes
for hardened concrete at the age of 28 days, on a 200 ton
capacity compression testing machine.
3. RESULTS AND DISCUSSIONS
3.1 Utility of Broken Tiles as part Replacement to
Coarse Aggregate in Concrete
Table 2 and 3 present slump values and densities for various
tile based normal concrete mixes. Workability and densities
do not show significant variability.
Table 2: Slump result for tile aggregate based concrete
Sl. No. Mix designation Slump (mm)
1 T0 55
2 T5 50
3 T10 50
4 T15 50
5 T20 50
6 T25 75
Table 3: Densities of tile based concrete.
Mix T0 T5 T10 T15 T20 T25
Density
(kg/m3
)
2549 2548 2518 2499 2520 2432

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The compressive strength results are shown in Fig.1 for tile
based concretes. It is observed that the partial replacement
of clay roof tiles concrete achieve the target mean strength.
The compressive strengths of T5, T10, T15, T20 and T25
reduce by 3%, 7%, 8%, 10% and 13% with respect to T0. It
could be seen from the graph that the compressive strength
values are as low as 38.9 N/mm2
and as high as 44.30
N/mm2
.
Fig.1: 28th day Compressive strength in normal concrete
with broken tiles as aggregates
3.2 Scope for Waste Tiles Utilization in Porous
Concretes
The porosity of pervious concretes is shown in Table 4 the
porosity of each specimen mean value is reported. Pervious
concrete shows considerably higher porosity than
conventional concrete. With increase in percentage of partial
replacement of tile to coarse aggregate the porosity of the
samples gradually increased. The porosity of pervious
concrete lies between 15% to 40%. The different types of
pore structure are responsible for this phenomenon.
However, the porosity in pervious concrete is mainly large
size air voids which are bigger than the pores in cement
paste. The porosity of pervious concrete is influenced by
aggregate grading and compaction. Hence, the porosity of
the pervious does not noticeably changed with an increase in
the age of concrete. The results showed that clay roof tiles
replacement does not show significant change in porosity.
The density obtained is as shown in Table 5. The density
decreases with increase in percentage of tiles.
Table 4: Porosity of tile based pervious concrete.
Tiles
(%)
Subm-
erged
wt. (kg)
Dry
wt.
(kg)
Vol.
of
solids
(litre
s)
Vol. of
voids
(litres)
Poros-
ity
(%)
Avg.
poro
sity
(%)
0
3.882 6.360 2.647 1.235 26.6
27.43.713 6.104 2.191 1.522 29.2
3.913 6.397 2.689 1.224 26.4
10
3.708 6.145 2.438 1.270 27.8
27.43.707 6.142 2.391 1.316 27.9
3.751 6.230 2.570 1.181 26.5
20
3.660 6.020 2.509 1.151 30.1
27.73.511 5.990 2.490 1.021 26.5
3.500 5.978 2.808 0.692 26.6
30
3.170 5.650 2.247 0.923 26.5
27.93.403 5.786 2.432 0.971 29.4
3.354 5.787 2.433 0.921 27.9
Table 5: Average densities of tile based pervious concrete.
Tiles
(%)
Dry
wt. (
kg)
Density of the
material
(kg/m3
)
Avg.
density
(kg/m3
)
0
6.360 1884.44
1862.86.104 1808.59
6.397 1895.41
10
6.145 1820.74
1828.86.142 1819.85
6.23 1845.93
20
6.02 1783.70
1776.65.99 1774.81
5.978 1771.26
30
5.65 1674.07
1701.05.786 1714.37
5.787 1714.67
Fig.2: Compressive strength

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3.3 Suitability of Broken Tiles in Blended Concrete
The slump, densities and compressive strengths obtained are
as shown in Tables 6, 7 and 8 respectively. It could be seen
from the tabulated results, that the compressive strength
varies from 24.96 N/mm2
to 44.30 N/mm2
. Partial
replacement by fly ash- clay roof tiles concrete, it is
observed that up to T20F40, target mean strength is
achieved.
Table 6: Slump result for fly ash-tile aggregate based
concrete
Sl. No.
Mix
designation
Slump
(mm)
1 T0F0 50
2 T5F10 75
3 T10F20 75
4 T15F30 75
5 T20F40 75
6 T25F50 75
Table 7: Densities of tile-fly ash based concrete.
Mix
T0F
0
T5F1
0
T10F2
0
T15F3
0
T20F4
0
T25F5
0
Avg.
densit
y
(kg/m
3
)
254
9
2505 2480 2434 2418 2389
Table 8: 28 day Compression test results of fly ash-tile
based concrete
Mix
designation
Specimen
wt. (kg)
Failure
load
(kN)
Comp.
strength
(MPa)
Avg.
comp.
strength
(MPa)
T0F0
8.692 920 40.89
44.38.655 1050 46.67
8.460 1020 45.33
T5F10
8.506 740 32.89
34.88.402 800 35.56
8.422 810 36
T10F20
8.390 770 34.22
35.68.340 910 40.44
8.377 720 32
T15F30
8.231 850 37.78
36.08.122 780 34.67
8.286 800 35.56
T20F40
8.149 735 32.67
31.9
8.155 735 32.67
8.170 685 30.44
T25F50
8.122 590 26.22
25.08.015 545 24.22
8.048 550 24.44
Fig. 3: Compressive strength variation with increase in tile
and fly ash replacement
Figure 3 has been drawn to indicate the 28 days average
compressive strength. It is observed that in Table 8, the
partial replacement by clay roof tiles in concrete satisfies the
target mean strength. It is observed that partial replacement
by fly ash and clay roof tiles concrete designated by T5F10,
T10F20 and T15F30, the compressive strength gradually
increased and T20F40 and T25F50 gradually decreased. The
conventional concrete strength is higher than that with the
inclusion of clay tile aggregate as partial replacement to
crushed stone aggregate.
4. CONCLUSION
The test results obtained were analysed and discussed in the
previous section. Based upon the detailed analysis
following conclusions have been drawn.
1) T25 design mix could be recommended for tile based
concrete, as about 10-15% decrease in strength is
observed, however waste tiles are used as fillers and
there is a substantial benefit in waste handling and
management also.
2) Compressive strength of the porous concrete
containing partial replacement by clay roof tile to
coarse aggregates decreases with increase in
percentage of clay roof tile as aggregate. The
reduction in strength is of the order of 10%, 17% and
46% corresponding to P10, P20 and P30 mixes. One
can recommend using 20% tile wastes in place of
stone aggregates in porous concretes.

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3) T20F40 concrete mix is recommended for use which
is economical in using tile wastes in place of coarse
aggregates as well as fly ash in place of OPC.
REFERENCES
[1] ACI, Pervious concrete ACI 522R-06, 2006: 25.
[2] Ghafoori, N. and S. Dutta (1995), Laboratory
investigation of compacted no-fines concrete for
paving materials. Journal of Materials in Civil
Engineering,: 7(3): p. 183-191.
[3] cement pervious concrete pavement systems. Journal
of Environmental Management, 81(1): p. 42-49.
[4] IS:383-1970, “Specification for coarse and fine
aggregate from natural sources for concrete”, Indian
Standard Institution, New Delhi.
[5] IS:456-2000, “Plain and reinforced concrete-code
practice concrete”, Indian Standard Institution, New
Delhi.
[6] IS:516-1959, “Methods of test for strength of
concrete cylinders”, Indian Standard Institution, New
Delhi.
[7] IS:2386-1963,(Part I, Part III and Part IV), “Methods
of test for aggregate for concrete”, Indian Standard
Institution, New Delhi.
[8] IS:4031-1968, “Methods of physical tests for
Hydraulic cement", Indian Standard Institution, New
Delhi.
[9] IS:8112-1989, “Specification of 43 grade ordinary
Portland Cement”, Indian Standard Institution, New
Delhi.
[10] IS:10262-2009, “Recommended guidelines for
concrete mix design”, Indian Standard Institution,
New Delhi.
[11] Mallikharjuna Rao Repudi, (2003), “ Experimental
investigation on strength characteristics of concrete
with tile aggregate and iron ore tailings as fine
aggregate”. A thesis submitted for the degree of
master technology in Industrial structures, NITK,
Surathkal.
[12] Tennis, P.D., M.L. Leming, and D.J. Akers, (2004)
Pervious concrete pavements. Portland Cement
Association, Skokie, Illinois, & National Ready
Mixed Concrete Association, Silver Spring,
Maryland.
[13] Zhuge, Y., (2008), Comparing the performance of
recycled and quarry aggregate and their effect on the
strength of permeable concrete. In Future in
Mechanics of Structures and Materials. Toowoomba,
Australia, p. 343-349.
BIOGRAPHIES
Aruna D, P.G Student, graduated in Civil
Engineering from Malnad College of
Engineering, Hassan, Karnataka, in the
year 2011.
K. Rajendra Prabhu obtained his B.E
(Civil) and M. Tech (Structural Engg.)
from MIT, Manipal. He worked in the
areas of consultancy, teaching and ready
mix concrete industry. Currently he is
pursuing his doctoral degree in the area
of concrete technology in NITK, Surathkal.
Dr. Subhash C. Yaragal graduated
from NITK Surathkal and obtained his
post-graduation and doctoral degree
from the Indian Institute of Science,
Bangalore. He completed his post-
doctoral studies in Japan, Tokyo, in the
area of Wind Hazard Mitigation”. Currently he is working
as Professor in the department of Civil Engineering at
NITK, Surathkal, India. His areas of research include
Concrete Technology, Pervious Concrete and Performance
of Concrete at Elevated Temperature. He has 18 years of
Teaching, Research and Industrial consultancy experience.
Prof. Katta Venkataramana graduated
from NIE Mysore, did his Master’s
degree from Kagoshima University,
Japan. He obtained his doctoral degree
from University of Kyoto, Japan. He is
serving as Professor in the Dept. of Civil
Engineering, NITK, Surathkal from 2002. Currently he is
also discharging his duties as Head of the Department. His
areas of research interests include Earthquake engg. and
Earthquake resistant design, concrete technology, etc

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