UTILIZATION OF WASTE CRUSHED TILE MATERIALS AS

COARSEAGGREGATE IN CONCRETE
1. INTRODUCTION
Concrete is the most widely used man-made construction material. It is obtained by
mixing cement, water and aggregates (and sometimes admixtures) in required proportions. The
mixture when placed in forms and. allowed to cure becomes hard like stone. The hardening is
caused by chemical action between water and the cement and it continues for a long time, and
consequently the concrete grows stronger with age. The hardened concrete may also be
considered as an artificial stone in which the voids of larger particles (coarse aggregate) are filled
by the smaller particles (fine aggregate) and the voids of fine aggregates are filled with cement.
In a concrete mix the cement and water form a paste called cement water paste which in addition
to filling the voids of fine aggregate acts as binder on hardening, thereby cementing the particles
of the aggregates together in a compact mass. The compressive strength of concrete depends on
the water to cement ratio, degree of compaction, ratio of cement to aggregate. Concrete can be
visualized as a multiphase composite material made up of three phases namely mortar,
mortar/aggregate interface, and coarse aggregate phase
The strength, durability and other characteristics of concrete depend upon the properties
of its ingredients, on the proportions of mix, the method of compaction and other controls during
placing, compaction and curing. The popularity of the concrete is due to the fact that from the
common ingredients, it is possible to tailor the properties of concrete to meet the demands of any
particular situation. The advances in concrete technology have paved the way to make the best
use of locally available materials by judicious mix proportioning and proper workmanship, so as
to produce concrete satisfying performance requirement.
History of Concrete
The word concrete comes from the Latin word "concretus" (meaning compact or
condensed), the perfect passive participle of "concrescere", from "con-" (together) and "crescere"
(to grow).Concrete was used for construction in many ancient structures. During the Roman
Empire, Roman concrete was made from quicklime, pozzolana and an aggregate of pumice. Its
widespread use in many Roman structures, a key event in the history of architecture termed
the Roman Architectural Revolution, freed Roman construction from the restrictions of stone and
brick material and allowed for revolutionary new designs in terms of both structural complexity
and dimension. The Assyrians and Babylonians used clay as the bonding substance or cement.
The Egyptians used lime and gypsum cement. In 1756, British engineer, John Smeaton made the
first modern concrete (hydraulic cement) by adding pebbles as a coarse aggregate and mixing
powered brick into the cement.
In 1824, English inventor, Joseph Aspdin invented Portland Cement, which has remained
the dominant cement used in concrete production. Joseph Aspdin created the first true artificial
cement by burning ground limestone and clay together. The burning process changed the
chemical properties of the materials and Joseph Aspdin created a stronger cement than what
using plain crushed limestone would produce Concrete that includes imbedded metal (usually
steel) is called reinforced concrete or ferroconcrete. Reinforced concrete was invented (1849) by
Joseph Monier, who received a patent in 1867. Joseph Monier was a Parisian gardener who made
garden pots and tubs of concrete reinforced with an iron mesh. Reinforced concrete combines the
tensile or bendable strength of metal and the compressional strength of concrete to withstand
heavy loads.












Joseph Monier exhibited his invention at the Paris Exposition of 1867. Besides his pots
and tubs, Joseph Monier promoted reinforced concrete for use in railway ties, pipes, floors,
arches, and bridges.
Tiles
A tile is a manufactured piece of hard-wearing material such as ceramic, stone, metal, or
even glass. Alternatively, tile can sometimes refer to similar units made from lightweight
materials such as perlite, wood, and mineral wool, typically used for wall and ceiling
applications. Tile is produced from natural materials sintered at high temperatures. Therefore
waste tiles are stored in factory fields because of their economic value. These waste materials
can be recycled to save money. Crushed tile aggregate, CTA, is a material especially proposed
for the buildings constructed in hot climates.

Fig 1.1 Mixing and placing of concrete
Fig. 1.2 Tile texture











Tiles deposits are widespread in India: concentration in states of Rajasthan, Gujarat,
Madhya Pradesh, Haryana, and Andhra Pradesh. Next Gujarat also produces some very fine tiles
followed by Madhya Pradesh. Rajasthan is the main depository of tiles.
Depletion of natural resources is a common phenomenon in developing countries like
India due to rapid urbanization and Industrialization involving construction of Infrastructure and
other amenities. In view of this, people have started searching for suitable other viable alternative
materials for concrete so that the existing natural resources could be preserved to the possible
extent, for the future generation. In this process, different industrial waste materials such as fly
ash, blast furnace slag, quarry dust, tile waste, brick bats, broken glass waste, waste aggregate
from demolition of structures, ceramic insulator waste, etc. have been tried as a viable substitute
material to the conventional materials in concrete and has also been succeeded

Effect of waste tile on Environment
a) If the waste is disposed on soils, the porosity and permeability of topsoil will be
reduced, the fine tiles dust reduces the fertility of the soil by increasing its alkalinity.
b) When the waste is dumped and dried out, the fine tiles dust suspends in the air and
slowly spread out through wind to the nearby area.
c) When dumped along a catchment area of natural rainwater, it results in contamination
of over ground water reservoir and also cause drainage problem.

Production of tiles in India
India possesses a wide spectrum of stones ~ granite, tiles, sandstone, limestone, slate, and
quartzite. It is amongst the largest producer of raw stone material. Rajasthan is the main
depository of tiles; accounts for over 90% of total tiles production in India [1100 m tons]. Newer
varieties of tiles are being developed in Bihar, Jammu & Kashmir, Maharashtra, Sikkim, Uttar
Pradesh & Bengal. The tiles produced in India were rather bulky affairs, being more expensive
and labor intensive to produce than thatch, their introduction has been explained by their greatly
enhanced fire resistance which gave the desired protection to the costly and famous temples in
the country. Indias position in global market improved from fifth position to third position.
From the 2006-2009 India has increase 44% in the growth of production of tilessame growth rate
is retained by India in the both the urban and ruler sector. The total tile market in the world is
8115 million square meters out of which 65 percent is produced in the Asia.
2. LITREATURE REVIEW
During the past years, concrete and cement technology have attained a lot of
achievements .One of the achievements is the incorporation of industrial wastes as filler or
additive in cement and concrete production with technical, economic and environmental
advantages. Such waste materials was found to have either reactive or filler effect in cement and
concrete production. Reactive materials are named pozzolana and have been used widely
worldwide where available.
Aggregate type has effect on the compressive strength of normal concrete. Highest
compressive strength was achieved from concrete containing crushed quartzite, followed by
concrete containing river gravel. Concrete containing crushed granite shows the least strength
development at all ages.
Test result show that concrete made from river gravel has the highest workability
followed by crushed quartzite and crushed granite aggregates. Highest compressive strength at
all ages was noted with concrete made from quartzite aggregate followed by river gravel and
then granite aggregate. (Abdullahi.M, 2012)
[1]

Increasing percentage of addition of marble waste to Ordinary Portland cement concrete
results in general compressive strength increase than ordinary coarse aggregate. But other
properties of marble waste blended cements such as consistency, setting times, insoluble residue,
sulphate residue and soundness remain within the acceptable limits of different standards.
(Awol.,Awrar& March,2011).
[2]

Based on the studies conducted on strength characteristics of concrete made with utilizing
waste materials, it was found that the concrete made of waste ceramic tile aggregate produced
similar strength in compression, split tensile and conventional concrete. It was also found that the
flexural strength and splitting tensile strength results were similar to that of compression strength
test results. Hence, it can be seen that waste ceramic tiles can be used as an alternate construction
material to coarse aggregate in concrete. Besides economical and strength criteria, concrete made
from waste materials as aggregates, solves the disposal problem of these waste material. In this
process, different industrial waste materials such as fly ash, blast furnace slag, quarry dust, tile
waste, brick bats, broken glass waste, waste aggregate from demolition of structures, ceramic
insulator waste, etc. have been tried as a viable substitute material to the conventional materials
in concrete and has also been succeeded.(Sekar.,T, July 2011)
[5]


Based on the trial mixes compressive strength of partial replacement of tiles with coarse
aggregate is found to be higher than the compressive strength of conventional concrete.The tiles
are crushed to suitable size and used as coarse aggregate. In the laboratory the crushed tile
aggregate has been tried as partial replacement substitute to convectional coarse aggregate in
concrete making of cubes, cylinders, beams. These were cast and tested for compressive
strength, split tensile and flexural strength after a curing period of 7, 28, 56 days. The results
indicate effectiveness of crushed ceramic waste as partial replacement of conventional coarse
aggregate up to 40 percent, without affecting the design strength. (Kamala. R andRao.,Krishna.,
B, July 2012)
[3]


Crushed tile is an industrial waste that causes environmental pollution. Therefore the
possible utilization of this material would reduce environmental pollution. The utilization of
crushed tile as a coarse aggregate in concrete would have a positive effect on the economy. The
strength and unit weight of crushed tile aggregate concrete were decreased compared to the
control concrete. Absorption and capillarity coefficients were increased compared to the control
concrete. Waste tiles cause only the apparition of pollution. However some parts of tiles are used
in cotto as flooring and also flooring in tennis courts, walkways, cycling paths and gardens as a
ground material. The use of crushed concrete as an aggregate caused drying shrinkage, decreased
resistance to abrasion and changed water absorption. Both the compressive and tensile strengths
of the crushed tile aggregates added concrete were higher, but the drying shrinkage was lower.
These waste materials can be recycled to save money. Crushed tile aggregate, CTA, is a material
especially proposed for the buildings constructed in hot climates. The unit weight of concrete is
decreased with use of the CTA compared to the control concrete. In previous investigations CTA
was examined and no noteworthy negative effects on the strength of the concrete were found.
The weakest bonds were between CTA and mortar, therefore failure occurred in this surface. The
strength of concrete was increased with the addition of minerals and chemical waste. The use of
CTA decreases costs and it also supports environmental health. According to these results, 100
% replacement of CTA as a coarse aggregate is not appropriate. (Topcu., B. , and Canbaz .,
M.2007)
[6]


Construction and demolition waste are normally composed of concrete rubble , bricks,
blocks, and tiles, sand, dust, timber, plastics, cardboard, and paper, and metals. Crushed tiles
waste can be used as a suitable for natural coarse aggregate in concrete or as a base layer in
pavement or in production of bricks and blocks. Amount of coarse aggregate in also plays an
important role in controlling the compressive strength of concrete. Recycled aggregates from
coal combustion by products are being used in construction sectors.(Nataraja. C. M and Lelin
Das, may 2011)
[4]


3. NECESSITY OF THE PROJECT
In this industrial world, recycling construction materials plays an important role to preserve the
natural resources. The use of recycle aggregates and solid waste from construction and
demolition waste shows a prospective application in construction and alternative to primary and
natural aggregates. The aim of this investigation was the utilization of tiles collected from
demolition buildings in concrete as coarse aggregate.

Due to urbanization and industrialization involving in construction and infrastructure
there is depletion of natural resources available for construction. So there is need of search of
material which can be replaced with the other natural aggregate in the construction to save the
natural aggregate for future generation.
The use of tiles in concrete has positive effects on the environment and obtaining lower
costs. Waste crushed tiles causes environment pollution so there is need of possible utilization of
the crushed tiles to reduce the environment pollution.

4. OBJECTIVE OF THE STUDY
The primary objective of this study
1. To investigate the Compressive Strength of Cement Concrete Mix cubes containing
coarse aggregate replaced with different ratios of waste crushed tiles i.e., 25%,
50%, 75% and 100%.
2. To investigate the Split Tensile Strength of Cement Concrete Mix Cylinders
containing coarse aggregate replaced with different ratios of waste crushed tiles i.e.,
25%, 50%, 75% and 100%.
3. To investigate the Flexural Strength of Cement Concrete Beams containing coarse
aggregate replaced with different ratios of waste crushed tiles i.e., 25%, 50%, 75%
and 100%.
4. To study the effect of Waste Crushed Tiles as Coarse Aggregates on unit weight of
concrete.

5. PROBLEM FORMULATION
An experimental programme is planned in which different proportions of waster
crushed tiles will be replaced with coarse aggregates and the final mixes will be prepared
and beam, cube and cylindrical specimens will be cast to obtain the different mechanical
properties. The specimens incorporated as 25%, 50%, 75% and 100% replacement of coarse
aggregates with waste crushed tiles. The beam specimens will be tested under four point
static flexural loading to obtain the static flexural strength of different concrete mixes
containing waste crushed tiles . In addition, cube specimens and cylindrical specimens will
also be tested to obtain its static compressive strength and split tensile strength, respectively.

6. EXPERIMENTAL PROGRAMME
Materials: Ordinary Portland Cement (OPC) 43 grade, crushed stone coarse aggregates with
maximum size of 12.5 mm and locally available river sand will be used. The waste tile from
the nearby local site will be taken and crushed to the maximum size of 12.5 mm will be used
to replace coarse aggregates in concrete mix. The replacement level of cement will depend
upon the initial tests. The replacement level coarse of aggregates with waste crushed tiles is
from 0 to 100% with 25% increment. The materials conformed to the relevant Indian.
Suitable dosages of admixtures will be used as per the requirement of workability and
stability of mixes.
Methodology/Procedure: A suitable control mix will be prepared and subsequently mixes
containing replaced coarse aggregates with waste crushed tile aggregates will be obtained.
The mixes will be filled into the moulds without the use of any mechanical vibrator. The
specimen used for compressive strength tests will be of 150 x 150 x 150 mm size cubes, for
split tensile strength test will be 100mm x 200mm, whereas standard beams of size 100 x
100 x 500 mm will be used for flexural strength tests. The specimens will be casted in
different batches, each batch consisting of three standard flexural test beam specimens, three
cubes for determining the 28-day compressive strength and three cylinders for split tensile
strength of each mix. All the specimens will be cured for 28 days in potable water. The cube
specimens will be tested after 7 days and 28 days of curing, whereas the cylindrical and
beam specimens will be tested after 28 days of curing. The compressive strength tests and
split tensile strength tests were conducted in a 2000 kN Compressive Strength Testing
Machine. The static flexural strength concrete mix will be obtained by testing beam
specimens under four point bend test on a 100 kN servo-controlled actuator





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