CHAPTER 1

INTRODUCTION

This chapter introduces the origination of concrete made with partial replacement of

admixtures such as Hypo sludge, Micro silica and Nano silica for cement at appropriate

proportions and their latest advancements and applications in the Construction Industry. The

need for the research, aims, scope and organization of the thesis are discussed in detail in this

chapter.

1.1 GENERAL

The ever-increasing demand for concrete worldwide, demands increased production of

conventional cement in huge quantities which in-turn results in emission of enormous quantity

of CO2 globally. Hence currently developing environmentally friendly concrete by blending

various wastes with cementitious properties generated from other industries as admixtures

viz. Fly Ash, Rice Husk, Hypo sludge, Silica fume GGBS, Metakoline etc. in concrete as partial

replacement to cement has become the order of the day. Substitution of these waste materials

will conserve the available natural resources and would avoid environmental and ecological

damages caused by quarrying and exploitation of raw materials for making conventional

cement.

In India, the paper consumption varies between 9 and 13 kilograms per capita as per a recent

study. As per a recent estimate 0.7 % of the total urban waste generated comprises of paper

waste. Globally there is a steady increase in the accumulation of paper making sludge with

active efforts taken by every country in the concept of paper recycling. About 300 kg of

Hypo sludge is generated from each tonne of this recycled paper. In Japan over 3,000,000 tons

of paper sludge is discharged every year as per a estimate done Ishitomo et al. (2000). These
waste if left unutilised becomes dumps at landfills as part of disposal procedure contaminating

paddy fields, lakes/water bodies and other vacant lands. If incinerated it again becomes an air

pollution problem affecting the environment. As an alternative to landfill disposal, the use of

paper-mill pulp in concrete is investigated by Baiwaik et al. (2010). They reported that use of

waste water pulp in concrete can save the pulp and paper industry disposal cost and also

produce a greener concrete . Five to Twenty % of cement by weight was replaced using paper

waste to make M20 and M-20 Grade concrete in their study. Hypo sludge consist of both

strong and weak fibres . Paper waste with strong fibres is taken for paper recycling process

whereas the weak fibres are taken to disposal dump sites (Bhanushali et al. 2019).

Hypo sludge possess good cementitious properties due to the presence of low calcium;

minimum amount of silica and maximum calcium chloride and it can be used in appropriate

quantities as a substitute to cement in concrete making. Number of experimental studies had

been already carried out by researchers to understand the effect of adding hypo sludge as a

partial replacement to cement in the properties of concrete and evaluate the right proportions

of hypo sludge to be added as a replacement to cement. Its impact in the fresh and hard

concrete properties and long-term performance of concrete were also studied.

1.2 ORIGINATION OF HYPO SLUDGE CONCRETE

Hypo sludge was originally introduced as artificial pozzolana since it consists of minimum

amount of silica, magnesium, considerable amount of lime which is the main property of

cement. This burnt paper sludge exhibits more pozzolanic activity especially at early ages

than commercially available metakaolin despite having smaller kaolinite content (Pera et al.

1998). Hence, hypo sludge can be effectively used as a proxy material for cement with the lime

content in the sludge being very high. The greatest challenge is, hypo sludge as a admixture is

a current arrival amid all other cementitious materials available in the market for partial
replacement to cement. In spite of a number of laboratory studies being carried out by

researchers on the effectiveness of adding hypo sludge in concrete in-terms of its fresh

concrete behaviour , structural behaviour of hardened concrete and long-term performance its

usage in practice is yet to grow.

This problem of practical application of hypo sludge utilization is not only confined to India

alone but is being experienced all over the world. However, this problem is particularly acute

in India, where utilization of hypo sludge has not received much attention. Hypo sludge

properties makes it very suitable for all construction activities including roads, embankments

and reclamation of low-lying areas. As concrete material since it is cost effective it can be used

for low- cost construction activities.

1.3 SALIENT FEATURES OF HYPO SLUDGE CONCRETE

• Provides economy in concrete production.

• Minimizes degradation to the environment due to cement production

• Improves the quality of fresh and hardened concrete

• Easily adoptable as partial replacement for cement due to its cementitious properties

• Effective usage for a waste from Paper Industry

• Reduces cost of construction and hence provide room for low-cost housing for

Economically weaker sections

• Extends the concrete lifetime - Durable

Table 1.1 and 1.2 below gives the typical physical and chemical properties of Hypo sludge

used in concretes (Ahirwar & Chandak 2018).

Table 1.1 Typical Physical Properties Of Hypo Sludge

Property Values

Gradation(75 % passing) 0.030 mm(No. 450 sieve)

Maximum Particle size 0.300 mm (no. 50 sieve)

Specific surface (cm2/g) 4600-14000

Specific gravity 2.7 -2.9

Table 1.2 Typical Chemical Composition Of Hypo Sludge

Compound % Age composition

Calcium oxide (Ca0) 47.57

Silicon Oxide (SiO2) 5.2

Aluminium Oxide (AI2O3) 0.1

Iron oxide (Fe203) 0.64

Magnesium Oxide (MgO) 6.25

Sulphur Oxide(So3) 0.17

Loss in ignition(LOI) 38.25

1.4 SOURCE MATERIALS

Microsilica (MS) is generated as a by-product from the Ferrosilicon industries in huge

quantities every day. Figuring out the best method to safely dispose this microsilica is a great

challenge which is simultaneously a socioeconomic problem. Henceforth, this could be easily

handled by adopting micro silica as a supplementary cementitious replacement.

Nanosilica (NS) is a silicon-dioxide particle at nano-scale measurements which has gained

more potential advantages in glass and concrete industries. The concrete technology has been

upgraded to the next level by implementing nanotechnology as one of its materials is utilised

at nano level.

1.5 ORGANIZATION OF THE THESIS

This thesis comprises of nine chapters with detailed investigations based on the objectives of

the research.

Chapter 1 introduces the framework of this project with a research background, the

origination of hypo sludge with a detailed discussion on the features and the current issues on

lack of application of hypo sludge in construction sector.

Chapter 2 describes the review of literature relevant to the effect of the addition of hypo

sludge, microsilica and nanosilica a partial replacement to cement in concrete . The literature

focuses on the mix design methodology, fresh concrete characteristics, hardened concrete

properties with long-term durability aspects. The research significance, objectives and scope

of the research work are presented in detail.

Chapter 3 illustrates the materials used in the research work. The material properties were

identified and characterized by some latest techniques. The methodology of the research work

is presented in this chapter. This chapter also demonstrates the characteristics of both fresh and

hardened concrete. The fresh concrete tests include the workability test such as slump flow test.

The hardened concrete properties include compressive strength, flexure and splitting tensile

strength tests. The durability terms of investigations include water absorption, sorptivity, acid

attack, sulphate attack, drying shrinkage and rapid chloride penetration test at long-term effects.
Chapter 4 presents the results of workability tests of Hypo sludge concrete and Hypo sludge

with Micros silica and Nana silica for both M25 and M40 grades. The flowability parameters

were discussed for hypo silica containing micro and nanosilica particles.

Chapter 5 presents the study conducted on strength properties and the durability

characteristics were analysed. The discussions of the obtained results are also given.

Chapter 6 summarizes the performance of Hypo sludge concrete with micro and nanosilica

by the analysis of microstructural investigation. The microstructural investigations on hypo

sludge concrete by material characterization techniques are discussed briefly. A detailed study

of Scanning Electron Microscope (SEM), Energy Dispersive Analysis of X-rays (EDAX) and

X-Ray Diffraction (XRD) conducted for concrete samples at various ages of testing are also

presented in this chapter.

Chapter 7 illustrates the numerical validation of compressive strength results for both M25

and M40 grades of Hypo sludge concrete by Multivariate statistical analysis using Statistical

Package for the Social Sciences (SPSS) software.