Partial Replacement of Fine Aggregate with Ceramic Waste and Brick Dust in RAC

Abstract

Society is developing concerning the development of the infrastructure and resources the word infrastructure contains the roadways, buildings, airports, runways and taxiways, and many things that make human civilization possible. Concrete is a vital element used in infrastructure projects in other words infrastructure construction is directly correlating the concrete production. Concrete is made of four basic elements water, cement, fine aggregate, and coarse aggregate where conventional coarse and fine aggregates are derived from rock and river mining from natural source that causes the natural resource depletion. Coarse aggregate and fine aggregates are chemically inert material at operational temperature. Therefore replacement of coarse or fine aggregate is possible with other inert material possess good mechanical strength and durability. In this research work we replace the conventional fine aggregate with brick dust and ceramic waste and brick dust. This experimental analysis based on two material replacement ceramic waste and brick dust up to optimum percentage to achieve maximum utilization. In this experiment, we found the optimum percentage of ceramic waste and brick dust is 20% and 15% respectively.

Introduction

• Concrete is composed of coarse aggregate, fine aggregate, cement, and water.

• Fine aggregate (typically river sand) is becoming environmentally unsustainable due to overextraction.

• Construction and demolition (C&D) waste, especially ceramic waste and broken bricks, contributes significantly to solid waste accumulation.

• Recycling of ceramic and brick waste is difficult but possible by using them as inert fine aggregate substitutes in concrete.

???? Objectives

• Replace conventional fine aggregate with ceramic waste and brick dust to:

  • Reduce environmental impact.

  • Utilize solid waste.

  • Maintain or improve concrete strength and durability.

???? Literature Review Highlights

Ceramic Waste

• India contributes ~8% of global ceramic solid waste (Meena & Jain, 2022).

• Ceramic waste classified into:

  • Red paste waste: from mud tiles.

  • White paste waste: from porcelain (tiles, basins).

• Chemical composition (El-Dieb, 2018): High in silica (68.6%) and alumina (24.5%).

Brick Dust

• Brick dust contains high silica, making it suitable as a cement replacement (Manshoor & Mehmood, 2022).

• Increases silica content, reduces lime, but can affect workability and water absorption.

Use of Recycled Aggregates

• Recycled brick aggregates (RBA) can offer better compressive strength than recycled concrete aggregates (Zheng & Lou, 2018).

???? Methodology

Materials Used

• Cement: OPC 43 grade (Ultratech).

• Fine Aggregates:

  • Conventional river sand (Zone-II).

  • Ceramic Waste: Crushed broken bathroom tiles.

  • Brick Dust: Crushed broken bricks.

• Coarse Aggregate: 20 mm stone.

• Water: For hydration.

Mix Design (M25 Grade Concrete)

• Mix Ratio (by weight): 1 (cement): 1.58 (fine agg.): 2.95 (coarse agg.)

• Designed per IS 10262:2019.

Replacement Strategy

1. Stage 1: Replace fine aggregate with ceramic waste at 0%, 5%, 10%, 15%, 20%, 25%.

2. Stage 2: Keep optimum ceramic waste (found from Stage 1), then add brick dust at 5%, 10%, 15%, 20%.

Sample Naming Convention

• C-X = X% ceramic waste (e.g., C-10 = 10% CW).

• C-X-Y = X% ceramic waste + Y% brick dust (e.g., C-20-10).

???? Testing Conducted

Fresh Concrete Tests

• Slump Test for workability.

  • Result: Workability decreases with increasing ceramic waste and brick dust.

Hardened Concrete Tests

• Performed after 14 and 28 days of curing.

• Tests Conducted:

  • Compressive strength

  • Flexural strength

  • (More details likely in full results, not included in current section)

Raw Material Tests

• Cement: Setting times, consistency.

• Aggregates: Water absorption, specific gravity, grading.

• Water: pH value.

???? Preliminary Results & Observations

• Workability decreases with increasing ceramic waste and brick dust.

• Optimum ceramic waste percentage appears to be 20%.

• Combination with brick dust further decreases slump (i.e., more dry/stiff mix).

• Compressive and flexural strength results are not fully shown but are mentioned as key tests.

Conclusion

1) Optimum replacement of conventional aggregate with the ceramic waste in first stage is 20%. 2) Combined optimum replacement of the conventional fine aggregate with the ceramic waste as well as brick dust is 20% CW and 15% of BD. 3) Conventional fine aggregate is well graded in nature but ceramic waste and brick dust is poor graded material therefore interlocking can be affected. And replacement makes concrete less workable, workability decreased by 33%. 4) Workability is decreasing with respect to increment of ceramic waste therefore this replacement cannot be possible in SCC (Self compacting concrete). 5) Workability is decreasing with respect to increment of ceramic waste therefore this replacement cannot be possible in SCC (Self compacting concrete).

References

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Copyright

Copyright © 2025 Siddharth Solanki, Rakesh Gupta, Dr. Mukesh Pandey, Farhan Rahman, Shashank Gupta. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.