Chapter 6

Cost analysis of green concrete

6.1 INTRODUCTION
This chapter gives the most important factor that determines the use of materials in
construction. Next to the engineering evaluation of the material, the practical
application in construction is the cost of the materials and the degree of work
involved. The cost analysis of the two concrete mixtures with the replacements of
cement with fly ash and fine aggregate with bottom ash for the binder content of 333
kg/m3; and fly ash for cement, bottom ash for fine aggregate and fly ash aggregate for
coarse aggregate replacements with the binder content of 389 kg/m3, were evaluated,
based on their maximum percentage of replacement and compressive strength.

6.2 COST EFFECTIVENESS IN CONCRETE

The engineering evaluation, such as strength and durability plays the primary role
next to the cost of the construction materials for the designer and for the user.

With the help of the pertinent studies, for evaluating the cost effectiveness in
concrete, a cost analysis was performed between normal and green concrete with fly
ash, bottom ash and fly ash aggregate.

6.3 COST ANALYSIS OF GREEN CONCRETE WITH FLY ASH AND

BOTTOM ASH WITH THE BINDER CONTENT OF 333 kg/m3

The cost analysis was evaluated for 1 m3 of concrete for both normal and green
concrete, with the cost of construction materials taken from the Schedule of rate,
Government of Tamil Nadu, Public Works Department (Government of Tamil Nadu,
2012-2013).

The cost analysis based on the percentage of replacement for cement and fine
aggregate was performed considering 28 to 180 days compressive strength of green
concrete. The cost of construction materials, such as cement, aggregates and HRWRA
was considered. Since green concrete exhibited strength development as the curing
increased, the compressive strength at 28 to 180 days was considered for the cost
analysis.

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The cost analysis was performed based on the replacement level and the compressive
strength of fly ash and bottom ash in concrete. The cost analysis for fly ash and
bottom ash is furnished in Table 6.1a, for 30% fly ash, 30% bottom ash and 30% fly
ash with 30% bottom ash.

 The cost analysis of the control (normal concrete) was 2597.66 INR including
the cost of HRWRA.
 The green concrete with 30% fly ash was 18% lesser than the cost of normal
concrete. The cost of 30% fly ash that showed compressive strength in the
range of 50 to 60 MPa was 2111.37 INR.
 The green concrete with 30% bottom ash showed 3.35% increase in the cost
over normal concrete due to the higher dosage of HRWRA for the strength of
40 to 55 MPa.
 Similarly, the concrete with 30% fly ash and 30% bottom ash reduced 19% of
the cost over normal concrete, that showed a strength in the range of 40 to 60
MPa.

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Table 6.1a: Cost analysis between normal and green concrete (30 FA, 30 BA and 30FA30BA) (Binder content of 333 kg/m3)

Green Concrete
Normal concrete
Rate 30FA 30BA 30FA30BA
Unit 30 MPa [50-60MPa] [40-55MPa] [40-60 MPa]
Material in
per Quantity Quantity Quantity Quantity
INR Rate Rate Rate Rate
3 3 3
per 1m per 1m per 1m per 1m3
(INR) (INR) (INR) (INR)
(kg) (kg) (kg) (kg)
Cement Bag 290 333.0 1931.40 233.1 1351.98 333.0 1931.4 233.1 1351.98
3
Fly ash m 65 0.0 0.00 99.9 2.32 0.0 0.0 99.9 2.32
20 mm m3 940 516.3 175.21 516.3 175.21 516.3 175.2 516.3 175.21
12 mm m3 871 774.4 249.84 774.4 249.84 774.4 249.8 774.4 249.84
Sand m3 110 754.0 31.42 754.0 31.42 527.8 21.9 527.8 21.99
Bottom ash m3 65 0.0 0.00 0.0 0.00 204.0 5.5 204.0 5.57
water litre 0 0.0 0.00 0.0 0.00 0.0 0.0 0.0 0.00
HRWRA litre 180 1.1 209.79 1.6 300.60 1.6 300.60 1.6 300.60
Total cost 2597.66 2111.37 2684.62 2107.52
% Savings - 18% -3.35% 19%
INR- Indian Rupee, FA- Fly ash, BA- Bottom ash, HRWRA- High range water reducing admixture

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 Table 6.1b: Cost analysis between normal and green concrete (40FA, 100BA and 40FA30BA, 40FA60BA, 40FA100BA) (Binder content
of 333 kg/m3)

Green Concrete
Normal concrete
(40 FA) 100BA 40FA30BA 40FA60BA 40FA100BA
Rate
Unit 30 MPa [35-40MPa] [30-45MPa] [40-55MPa] [30-40MPa] [20-35MPa]
Material in
per Quantity Quantity Quantity Quantity Quantity Quantity
INR Rate Rate Rate Rate Rate Rate
per 1m3 per 1m3 per 1m3 per 1m3 per 1m3 per 1m3
(INR) (INR) (INR) (INR) (INR) (INR)
(kg) (kg) (kg) (kg) (kg) (kg)
Cement Bag 290 333.0 1931.4 199.8 1158.84 333.0 1931.40 199.8 1158.84 199.8 1158.84 199.8 1158.84
Fly ash m3 65 0.0 0.00 133.2 3.09 0.0 0.00 133.2 3.09 133.2 3.09 133.2 3.09
20 mm m3 940 516.3 175.21 516.3 175.21 516.3 175.21 516.3 175.21 516.3 175.21 516.3 175.21
12 mm m3 871 774.4 249.84 774.4 249.84 774.4 249.84 774.4 249.84 774.4 249.84 774.4 249.84
Sand m3 110 754.0 31.42 754.0 31.42 0.0 0.00 527.8 21.99 301.6 12.57 0.0 0.00
Bottom
m3 65 0.0 0.00 0.0 0.00 680.0 18.57 204.0 5.57 408.0 11.14 680.0 18.57
ash
water litre 0 0.0 0.00 0.0 0.00 0.0 0.00 0.0 0.00 0.0 0.00 0.0 0.00
HRWRA litre 180 1.1 209.79 1.8 329.67 5.5 1006.20 1.8 329.67 4.1 748.80 7.9 1438.56
Total cost 2597.66 1948.07 3381.23 1944.22 2359.50 3044.12
% Savings - 25% -7.39% 25% 9% -17%
INR- Indian rupee, FA- fly ash, BA- bottom ash, HRWRA- High range water reducing admixture

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The cost analysis based on the maximum percentage of replacement for cement and
fine aggregate such as 40% fly ash, 100% bottom ash and the combined replacements
of 40% fly ash with 30%, 60%, and 100% bottom ash was performed, considering the
28 to 180 days compressive strength and the values are furnished in Table 6.1b.

 The cost analysis of 40% fly ash was 1948 INR with the compressive strength
at 28 to 180 days in the range of 35 to 40 MPa respectively. The concrete with
40% fly ash reduced 25% of the cost compared to normal concrete.
 The cost analysis of 100% bottom ash as a fine aggregate replacement was
3381.23 INR, with the compressive strength ranging from 30 to 45 MPa. The
100% bottom ash concrete showed an increase of 7.39% in the cost over
normal concrete due to the higher dosage of HRWRA (5.59 kg/m3). On the
other hand, it completely eliminated the use of natural river sand in
construction, that is of great importance in this study.
 For the green concrete containing 40% fly ash with 30% bottom ash, the cost
(1944.22 INR) was 25% lesser than that of normal concrete. The green
concrete with 40% fly ash and 30% bottom ash for cement and fine aggregate
replacement, showed a compressive strength in the range of 40 to 55 MPa
from 28 to 180 days respectively.
 Similarly, for 40% fly ash with 60% bottom ash, the cost was 2361 INR, that
was 9% lesser than that of normal concrete, with the compressive strength in
the range of 30 to 40 MPa.
 For the concrete containing 40% fly ash and 100% bottom ash, the cost
analysis resulted in 17% increase than normal concrete, with the strength of 20
to 35 MPa. The high cost over that of the normal concrete was due to the
higher dosage of HRWRA of 7.99 kg/m3.

The cost analysis for the green concrete with the binder content of 333 kg/m3 clearly
revealed, that fly ash and bottom ash can be used as cost effective construction
materials as cement and fine aggregate replacements respectively, that can be
designed for 25 to 55 MPa. The high cost involved for 100% bottom ash was due to
its water absorption property in the concrete that increased the dosage of HRWRA,
but it eliminated the use of natural river sand in construction.

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6.4 COST ANALYSIS OF GREEN CONCRETE WITH FLY ASH,
BOTTOM ASH AND FLY ASH AGGREGATE WITH THE BINDER
CONTENT OF 389 kg/m3

The cost analysis of the green concrete involving fly ash aggregate, includes the cost
of calcium hydroxide, cement, fly ash and electric power consumed by the pelletizer
for manufacturing fly ash pellets. The cost involved for the manufacturing of 100 kg
of fly ash pellets was 50 INR. The cost analysis of green concrete with 30% fly ash ,
30% bottom ash and 20% fly ash aggregate resulted in 2633.93 INR, that was 14%
lesser than that of the normal concrete with 3066.66 INR as given in the Table 6.2.
The green concrete with 30% fly ash, 30% bottom ash and 20% fly ash aggregate that
attained a compressive strength of 45 to 50 MPa (28 to 180 days) reduced 14% of the
cost involved in the construction.

Table 6.2: Cost analysis of the green concrete with fly ash, bottom ash and fly ash
aggregate (Binder content of 389 kg/m3)

Eco-friendly Green
Concrete
Normal Concrete
Rate 30FA30BA20FAA
Unit
Material in [45-50 MPa]
per
INR Quantity Quantity
Rate Rate
per 1m3 per 1m3
(INR) (INR)
(kg) (kg)
Cement Bag 290 389.0 2256.20 272.3 1579.34
Fly ash m3 65 0.0 0.00 116.7 2.71
20 mm m3 940 511.4 173.54 409.1 138.83
12 mm m3 871 767.0 247.43 613.6 197.94
FAA 12 mm kg 50 0.0 0.00 117.4 58.71
FAA 20 mm kg 50 0.0 0.00 78.2 39.14
Sand m3 110 715.6 29.82 302.0 12.58
Bottom ash m3 65 0.0 0.00 193.5 5.29
Water litre 0 0.0 0.00 0.0 0.00
HRWRA litre 180 1.9 359.64 3.3 599.4
Total cost 3066.63 2633.93
% Savings - 14%
INR- Indian Rupee, FA- fly ash, BA- bottom ash, FAA- fly ash aggregate,
HRWRA- High range water reducing admixture

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The cost analysis of green concrete, clearly showed that fly ash, bottom ash and fly
ash aggregate enhanced the engineering, environmental and cost effectiveness in
construction, without compromising the strength and durability of the structure. This
practice of construction with the replacements of cement with fly ash, fine aggregate
with bottom ash and coarse aggregate with fly ash aggregate respectively, serves to be
cost effective and eco-friendly green concrete.

By considering the indirect beneficial effect of Green House Gas emission from the
cement industry, reducing the usage of natural river sand, reduction in quarrying of
natural rocks, and saving the natural land for the disposal of fly ash and bottom ash,
this experimental study will be the foundation for future research. The use of fly ash,
bottom ash and fly ash aggregate in construction promotes the concept of green
technology in construction, that will lead sustainable development for the future
generation.

6.5 SUMMARY OF THE COST ANALYSIS

The cost analysis of the green concrete with the replacements of cement with fly ash
and fine aggregate with bottom ash in Phase I; fly ash for cement, bottom ash for fine
aggregate and fly ash aggregate for coarse aggregate replacements in Phase II is
summarised below;

The green concrete in Phase I with the binder content of 333 kg/m3 reduced up to 25%
of the cost over that of normal concrete, where as in Phase II with the binder content
of 389 kg/m3 it reduced to 14%. The green concrete with fly ash, bottom ash and fly
ash aggregate with the incorporation of HRWRA, and by increasing the curing period,
can be designed as a cost effective and eco-friendly one without compromising the
strength and durability of the normal concrete.

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