GLASS DA 30.07.2016

DESIGNING CONCRETE MIX OF M25 GRADE BY PARTIAL REPLACEMENT OF FINE AGGREGATE

WITH CRUSHED GLASS WASTE

Presented BySanjay T. Chaurasiya

Guided by : Prof. Swati Kotulkar PaiSem-14, Dissertation

M. Arch. (Construction Management)

1

CONTENT:-• Introduction• Aim & objective• Literature review• Literature review summary• Concrete mix design• Design test results analysis• Inferences• Conclusion • Recommendations • Further scope of study

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2PARTIAL REPLACEMENT OF FINE AGGREGATE WITH CRUSHED GLASS

Fig. 1: Crushed Waste Glass particle

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Introduction:

Fig. 2: Concrete construction Fig. 3: River sand as fine aggregate

Fig. 4: Glass manufacturing Fig. 5: Broken Glass

• River sand as a fine aggregate in concrete is a important ingredient.• Glass is manmade materials. Having limited life of glass products, need to

reused or recycled in order to avoid environmental hazards. [Rose & Saji, 2015]

Fig. 6: Broken Glass environmental hazard Source: Glass recycle.com

• An alternative of river sand need to be found in order to replace sand (fine aggregate).

• Use of waste materials in place of natural resources is one of the best approaches.

• In India, 0.7% of total urban waste generated comprises of glass.• Using waste crushed glass in construction sector can reduce cost of concrete.

[Sangole & Mundhada, 2015]

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Need of study:

ConcreteCost

saving

• Crushed glass exhibit characteristics similar to that of gravel or sand. Crushed glass can be used as aggregates for concrete. [Sangole & Mundhada, 2015]

Fig. 7: Glass Particle Fig. 8: Glass particle with fine aggregate

Fig. 9: Concrete

Designing concrete mix of M25 grade by partial replacement of Fine Aggregate with crushed glass waste.

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Hypothesis: Fine aggregate in concrete can be partially replaced by waste crushed glass

particle.

• To study the properties of the crushed glass waste as fine aggregate replacement.

• To study and determine the appropriate percentage of crushed glass waste in concrete grade.

• To study and find the strength and properties of concrete by using crushed glass waste as a partial replacement to fine aggregate.

Objective:

Aim:

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Methodology :• Detailed Literature review have been done with help of books, journals,

research papers, internet & case studies, etc. to study concrete, its ingredients and mix design of concrete.

• Chemical properties of glass, cement & fly ash studied.• Specific gravity, sizing and grading of fine & coarse aggregate found.• Concrete mix design M25 grade prepared, using waste glass particle replacing

20%, 25% and 30% of fine aggregate.• Workability of fresh concrete tasted using slump cone test.• Cubes (150 x 150 x 150mm) casted and Compression test done after 3 days, 7

days & 28 days.• The results was noted and analyzed.• Upon analysis of results, recommendations for effective percentage of partial

replacement of fine aggregate with waste glass particle for M25 concrete mix design suggested..

• The study conducted by 20%, 25% & 30% replacement of fine aggregate with crushed waste glass particle.

• Only M25 concrete mix design studied. • Size of the waste glass particle used in range 0.002 - 4.75mm only.

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Project Output :New mix design for M25 grade concrete, the maximum feasible percentage of partial replacement of fine aggregate with crushed glass proposed.

Scope & Limitations:

Fig. 10: Glass particle Sieve Analysis

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Literature Review:- Introduction:-

Fig. 11: Waste Glass particle

Pavement & Road

construction “glassphalt”

Silica in glass with cement - Pozzolanic

effect

Reuse in concrete avoids

environmental hazards

60%

40%

(Corinaldesi,2005).

Broken glass collected from household & industrial waste. Mix of bottles, broken glassware, light bulbs, window glass, etc

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Concrete ingredients:-

Fig. 12: Fresh Concrete

Fig.13: Cement

Fig.14:Fine Aggregate

Fig.15:Coarse Aggregate

Fig.16: Fly ash

Fig. 17: Water

Fig.18:crushed glass

Fig.19: Chemical Super plasticizer (TP350)

Testing of concrete -To analyse the workability & strength of concrete following tastes carried out.05/02/2023


Fig.21: Slump Cone Test

a)Workability :- Slump cone test gives workability of concrete.The diverserequirements of stability, mobility, compactability,placeability and finishability of fresh concrete mentioned above are collectively referredto as 'workability’.

Workability Slump value use

Low 25 – 75 Foundation

Medium 50 – 120 RCC

High 100 – 220 Pumping

Very High Collapse Very raise pumping /delay concreting

Table1: Workability-Slump value

Fig:20, Slump types

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Fig.23: Cube-compression test

b) Cube compression test:It gives maximum compression load taken by concrete. a) Water-cement ratio,d) The characteristics of cement, c) The characteristics and proportions of aggregates, d) The degree of compaction, e) The efficiency of curing, f) The temperature during the curing period, g) The age at the time of testing, h) The conditions of test.

Fig.24: Cube after compression test

Fig.22: Concrete cube

Case study-1: Only Compressive Strength Test, (Rose & Saji,India. 2015)

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• Grade of concrete used was M-30.• Glass waste particle (0.002-4.75mm) replaced in fine aggregate 10, 20, 30 &

40%.• Compressive strength tested after curing period of 7, 28 & 60 days• Slump cone test results not mentioned in paper.

Fig 25: Result for Compression test at 7 & 28 days.

Crushed Glass Application in Buildings:-

Learning from case study:-• Crushed glass is suitable

material for use of replacement of fine aggregate.

• The workability of concrete mix is increase with increase in waste glass content.

• Up to 30% the compressive strength increased.

Case study-2: Finding the strength of the concrete by partial replacement of fine aggregate with glass particle (Vaibhav & Mundhada, India, 2015)

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• Grade of concrete used M-25 and M-30.• Glass waste particle (0.002–4,75mm) replaced in fine aggregate 10, 20, 30 &

40%. • The concrete specimens were tested after 7, 28, & 60 days

Fig.26:Variation of slump with waste glass Fig.27: Cube compressive strength at 28 daysLearning from case study:-• The slump of concrete, decreased with increase in waste glass content.• Compressive strength increased for 20% replacement, but decreased for 30& 40

%.• The optimum replacement level of waste glass as fine aggregate is 20% effectively.

Case study-3: Characteristics of concrete with waste glass particle as fine aggregate ( Abdallah & Fan, UK, 2014,)

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Fig.28: Slump in relation to waste glass

• Controlled concrete mix ratio is 1:2.2:2.7 with water-cement ratio of 0.55.• Glass waste particle passes 4.75mm sieve replaced fine aggregate by 5, 15 &

20%.• The concrete specimens were tested after 7, 14, and 28 days.

Fig.29: Compressive strength of various mixes

Learning from case study:-• The slump of concrete, decreased with increase in waste glass content.• Compressive strength increased. best results were obtained for 20%

replacement

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Glass crusher:-Barmac - the ultimate glass crusher, ability to produce fine to very fine products.The autogenous crushing action coupled with the glass low abrasion

characteristic.

Fig.30: Glass Crusher Fig.31: Crushed glass collection

Fig.32: Crushed Glass types

Literature review summary:- 05/02/2023


a) Case study shows 20% to 30% replacement of fine aggregate with crushed glass particle for gives good result for cube compression test..

b) Use of glass particle mix concrete will be limited to specific use of concrete with percentage variation of glass particle, because the compression, split tensile & flexural tensile strengths varies in concrete.

c) Alkali-silica reaction in concrete upto some extent increase the strength of the concrete. This increase in strength is usually due to the filling of bond-area with cementitious reaction.

d) By reuse of waste glass in concrete will reduce the environmental hazards.

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Concrete mix design:-IS-10262-2009 Concrete mix design used for M25 grade concrete mix design

using waste glass particle replacing 20%, 25% and 30% of fine aggregate. Ingredients & their properties for new M25 concrete mix:-• Cement• Fly ash• Aggregate• Glass particle • Water• Admixture

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Glass particle (fine aggregate):

Waste glass collected from various source like household & glass industrial waste, mix of bottles, broken glassware, light bulbs, window glass, etc & crushed to size in glass crusher machine.

Glass particle Physical property:• Crushed to size passing through 4.75 mm sieve (confirming Zone – I , by Sieve

analysis, IS:383-1970)• The glass is a mixture of a number of metallic silicates, one of which is usually

that of an alkali metal. It is an amorphous, transparent or translucent.• It has sharp edges and irregular forms compared to crushed stone.

SiO2 Al2O3 TiO2 Fe2O3 CaO MgO K2O Na2O

ZnO ZrO2

72.7 2.31 0.006 1.08 9.25 3.55 0.21 10.75 0.002 0.05

Table 2: Chemical composition of glass particle

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IS Sieve size

Weight retained

(gm)

Cumulative weight retained

(gm)

Cumulative percentage

retained


passing

4.75 mm 0 0 0.00 100.002.36 mm 20 40 0.40 99.601.18 mm 153 30.48 30.88 69.12

600 micron 199 39.64 70.52 29.48300 micron 58 11.55 82.07 17.93150 micron 58 11.55 93.63 6.97

PAN 32 6.97 100 0.00Total 500 FM 2.77

Table 3: Crushed Glass Sieve analysis (500 gm sample ) confirming Zone -IGlass particle (fine aggregate):

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Cement: Ordinary Portland Cement (OPC) 53 grade (confirming to IS:8112), Ultratech make.

Table 4: Chemical property of Cement.

Type of cement

IS code

Finenessm2/Kg(min)

Setting time in minutes

soundness Compression strength (Mpa)

initial final Le Chatelier (mm)

Auto clave (%)

3 days

7 days

28 days

OPC 53

12269 : 1987

300 30 600 10 0.8 27 37 53

pH Moisture content (%)

Acid insoluble residue (%)

Chloride (%)

Reactive silica (%)

10 1 64 0.09 38

Table 5: Chemical property of Fly ash.

Fly ash: By-product from Jindal steel plant

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Fine Aggregate: Crushed stone free from silt & clay , size between 4.75 mm to 0.002 mm (confirming to Zone – I, IS:383-1970) Silt content : 14.30 %

IS Sieve size

Weight retained

(gm)

Cumulative weight retained

(gm)


retained


passing

10.00 mm 0 0.00 0.00 100.004.75 mm 120 10.03 10.03 89.972.36 mm 293 24.48 34.50 65.501.18 mm 279 23.31 57.81 42.19

600 micron 150 12.53 70.34 29.66300 micron 124 10.36 80.70 19.30150 micron 75 6.27 86.97 13.03

PAN 156 13.03 100.00 0.00Total 1197 FM 3.4

Table 6: Crushed Stone Sieve analysis (1197 gm sample) confirming Zone -I

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Coarse Aggregate: Coarse aggregate from local quarry (confirming to Zone – I, IS:383-1970)

IS Sieve size (mm)

Weight retained (gm)

Cumulative weight retained (gm)

Cumulative % retained

Cumulative % passing

25.00 0 0.00 0.00 100.0020.00 426 14.12 14.12 85.8810.00 2566 85.05 99.17 0.834.75 25 0.83 100.00 0.00PAN 0 0.00 100.00 0.00Total 3017

Table 7: Coarse aggregate (20mm) Sieve analysis (3017 gm ) confirming Zone -II

Table 8: Coarse aggregate (10mm) Sieve analysis (3090 gm ) confirming Zone -IIS Sieve

size (mm)Weight

retained (gm)Cumulative weight

retained (gm)Cumulative % retained

Cumulative % passing

12.50 0 0.00 0.00 100.0010.00 170 5.50 5.50 94.504.75 2862 92.62 98.12 1.882.36 46 1.49 99.61 0.39PAN 12 0.39 100.00 0.00Total 3090

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Admixture :-Superplasticizer TP350 with 15-30 % water reducer. Confirming to IS : 9103-1979, Aqualoc TP make.It improves the workability of concrete and thereby reduce the water demand for a given workability

Water:-The permissible limits for solids and impurities for mixing and curing water as specified in various specifications including IS : 456-1978 are in excess of the requirements of potable water. The water is free from slags, chemical compositions.

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Step 1 :Stipulations for proportioning:

• Grade designation : M 25• Type of cement : OPC 53 grade conforming to IS 8112• Type of mineral admixture : Fly ash conforming to IS 38I2 (Part I)• Maximum nominal size of aggregate : 20mm• Minimum cement content : 320 kg/m• Maximum water-cement ratio : 0.45• Workability : 100 mm (slump)• Exposure condition : Severe ( for reinforced concrete)• Method of concrete placing : Pumping• Degree of supervision : Good• Type of aggregate : Crushed angular aggregate• Maximum cément (OPC) content : 450kg/m³• Chemical admixture type : Super plasticizer (TP-350)

Mix proportioning of concrete (IS:10262-2009):-

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Step 2 :Test data for materials:a) Cement used : OPC 53 grade conforming to IS 8112b) Specific gravity of cement : 3.15c) Fly ash : conforming to IS:38I2 (Part I)d) Specific gravity of fly ash : 2.20e) Chemical admixture : Super plasticizer (TP-350) f) Specific gravity of : Coarse aggregate (10mm & 20mm) : 2.85 & 2.89 Fine aggregate (Crushed stone) : 2.75 (Crushed Glass) : 1.94 (by Pycnometer test) Admixture : 1.10g) Water absorption: Coarse aggregate (10mm & 20mm) : 2.25 & 2.15 Fine aggregate (Crushed stone & Glass) : 1.93 & 0.96h) Free (surface) moisture: Coarse aggregate : NIL Fine aggregate (Crushed stone & Glass) : NILi) Sieve analysis: (IS:383-1970, Table-4) Coarse aggregate : Zone- II Fine aggregate (Crushed stone) : Zone- I

(Crushed Glass) : Zone- I


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Step 3 : Target strength for mix proportioning:f t = f ck + K. S

where f t - target mean strength.f ck =characteristic strength, K- a constant=1.65 (IS : 456-19781) S - standard deviation.

f t = f ck + 1.65 x S f t = 25 + 1.65 x 5.3 (Table 39, SP23:1982)

f t = 33.74 N/mm2

Step 4 : Selection of water – cement ratio

From Fig.46, SP:23-1982Water/Cement ratio for 33.74 N/mm2 = 0.43

Table 9: SP:23-1982, Table 39

Fig 33.: SP:23-1982, Fig.46, Water Cement ratio


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Step 5: Selection of water content :From table -2,IS:10262-2009, Maximum water content for 20 mm aggregate = 186 litre (for 25 to 50 mm slump range)Estimated water content 100 mm slump = 186 + 6/100 x 186 = 197 litreBy adding super plasticizer, the water content can be reduced up to 30%.

= 197 x 0.75 = 148 litre

Step 6: Calculation of cement and fly ash content :Water – cement ratio = 0.43Cementitious material ( cement + fly ash ) content

=148/0.43 = 344 kg/m3

Cementitious material content = 344 x 1.10 = 378 kg/m3Water content = 148 kg/m3Water – cement ratio = 148 / 378 = 0.39Fly ash @ 20% of total Cementitious material = 378 x 30% = 113 kg/m3Cement (OPC) = 378-113= 265 kg/m3

Saving of Cement using fly ash = 344 – 265 = 79 Kg/m3Fly ash used = 113 kg/m3


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Step7: Proportion of volume of coarse and fine aggregate:

(Table-3 of IS:10262-2009) Volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone I) for water-cement ratio of 0.50 =0.60

Free water-cement ratio = 0.43

(Table-44, SP:23-1982) proportion of volume of coarse aggregate is increased by 0.02 (at the rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio)

Corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.43 = 0.61.

For pumpable concrete these values should be reduced by 10 %.

Volume of coarse aggregate = 0.61 x 0.9 =0.55

Volume of fine aggregate content = 1 - 0.55 = 0.45


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Step 8: Mix calculations :The mix calculations per unit volume of concrete shall be as follows:a) Volume of concrete = 1 m3b) Volume of cement = Mass of cement / specific gravity of cement

x 1/ 1000= 265/3.15 x 1/1000 = 0.084 m3

c) Volume of fly ash = Mass of fly ash / specific gravity of fly ash x 1/ 1000= 113/2.2 x 1/1000 = 0.051 m3

d) Volume of water = Mass of water / specific gravity of water x 1/ 1000= 148/1 x 1/1000 = 0.148 m3

e) Volume of admixture = Mass of admixture / specific gravity of (Superplasticizer) admixture x 1/ 1000

(@2% of cementitious) = 7.56/1.1 x 1/1000 = 0.007 m3

f) Volume of aggregate = a - (b + c + d - e)= 1- (0.084 + 0.051 + 0.148 – 0.007)= 0.704 m3


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g) Mass of coarse aggregate = f x volume of coarse aggregate x specific gravity of coarse aggregate x I000

= 0.704 x 0.55 x 2.87 x 1000 = 1111 kg

h) Mass of fine aggregate = f x volume of fine aggregate x specific gravity of fine aggregate x I000

= 0.704 x 0.45 x 2.75 x 1000 = 871 kg

Step 9: Mix proportions for control mix concrete:

Water Cement Fly ash Fine Aggregate Coarse aggregate Admixture

Crushed Stone

Glass particle

10 mm(40%)

20 mm(60%)

TP-350

148 265 113 871 --- 444 677 7

0.39 1 0.30 2.30 --- 2.94 --- 0.02

165 270 110 875 440 680 7

Table10: M25 new mix design

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New mix proportions for control mix concrete - M25

Water Cement Fly ash Fine Aggregate Coarse aggregate Admixture

Crushed Stone

Glass particle

10 mm 20 mm TP-350

165 270 110 875 --- 440 680 7.00

0.45 1 0.29 2.35 --- 2.65 --- 0.02

165 270 70 700 175 (20%) 440 680 5.00

165 270 70 655 220 (25%) 440 680 5.00

165 270 70 613 262 (30%) 440 680 5.00

Table 11: M25 new mix design with glass particle

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32

Design test results analysis:-

PARTIAL REPLACEMENT OF FINE AGGREGATE WITH CRUSHED GLASS

The trial mix and compression test study conducted at Ultretech ready mix Nahur plant, Mumbai

Fig. 34: Fresh Concrete

Fig. 35: Slump cone test

Fig. 36: Casting of concrete

Fig. 37: Compression Test after curing

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Workability by slump cone test:

% of Glass particle

0 20 25 30

Slump (mm) 165 160 145 140

Table 12: Slump test results

% of Glass particleFig. 38: Slump test results

• Increase in % of glass particle workability decreases.

• All slump value above 100 mm, all 20, 25 & 30 % glass particle replacement is workable.

Slu

mp

in m

m

Design test results analysis:-

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Compression test result on cube:Table 13: Compression test results

Com

pres

sion

stre

ngth

(N

/mm

2)

% of Glass particleFig. 39: Compression test result

• For 28 days result - 25 % & 30% replacement of fine aggregate gives good compression strength.

% of Glass particle

0 20 25 30 Strength in %

3days (N/mm2) 13.55 13.64 14.67 13.64 30 – 45

7days (N/mm2) 20.95 18.26 22.16 19.46 65 – 75

28days (N/mm2) 33.75 29.97 36.92 33.78 75 – 100

Target strength

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Result analysis:-• The Slump values decreases as the waste glass content increases. This is

due to sharper & irregular geometric form of glass particles compared to crushed stone, which may give rise to high friction & much less fluidity.

• Compressive strength up to 28 days at 25% (36.92N/mm2) & 30% (33.78N/mm2) replacement of fine aggregates by crushed waste glass compared to control mix target strength (33.74N/mm2) concrete.

Com

pres

sion

stre

ngth

(N/m

m2)

% of Glass particleFig. 40: Compression test result

Target strength33.74 N/mm2

• Even though decrease in compression strength of concrete, the maximum replacement of 30% glass particle is effective replacement.

• The corrected new mix design shows savings of Fly ash @ 35%, Super plasticizer admixture @ 25 % and fine aggregate 30%.

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• Addition of crushed glass particles in concrete reduces cementitious material.• The amount of coarse aggregates is less and finer materials are more in the

mix, the passing ability of concrete through congested reinforcement can be enhanced.

• Cost analysis of new mix design:-

Ingredients Quantity (kg) Rate/Kg (Rs) Cost (Rs)

Cement 270 6.2 1674.00

Fly ash 110 5 550.00Fine Aggregate (Crushed stone)

875 3 2625.00

Course Aggregate 1120 2.2 2464.00

Water 165 2 330.00

Admixture 7 270 1890.00

Total 9533.00

Table 14: Cost of 1m3 of control in M25 mix design:

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Table 15: Cost of 1m3 of with fine aggregate replacement with 30% Glass particle in M25 mix design:

Ingredients Quantity (kg) Rate/Kg (Rs) Cost (Rs)

Cement 270 6.2 1674.00

Fly ash (65%) 70 5 350.00Fine Aggregate (70%)(Crushed stone)

613 3 1839.00

Fine Aggregate (30%)(Glass particle)

262 2.5 655.00

Course Aggregate 1120 2.2 2464.00

Water 165 2 330.00

Admixture (75%) 5 270 1350.00

Total 8662.00

Cost analysis of new mix design with partial replacement of fine aggregate:-Saving of for 1 m3 Concrete with 30% glass particle replacement with crushed

stone: = 9533.00 – 8662.00 = 871.00 Rs. = -9.14 % of control mix concrete cost.

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Inferences:-

a) Compressive strength of the concrete with partial replacement of fine

aggregates by crushed waste glass increased.

b) The optimum replacement level of waste glass as fine aggregate is 30%.

c) By addition of crushed glass particles, cementitious materials reduced.

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Conclusion:-

a) The crushed glass particle replaces fine aggregate in concrete.

b) The maximum percentage of partial replacement of fine aggregate with

waste glass particle for M25 concrete mix design is 30%.

c) Addition of crushed glass particles in concrete reduces cementitious

material.

d) Use of waste glass in concrete will reduce the disposal problem of waste

glass.

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Recommendations:-

a) The crushed glass particle replaces fine aggregate in concrete.

b) The effective percentage of partial replacement of fine aggregate with waste

glass particle for M25 concrete mix design is 30%.

c) Awareness need to be done with technical experts for the use of such

materials in construction industry

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Future scope of work:-

a) Further split tensile, bending flexural, rebound hammer & ultrasound taste to

be done on M25 concrete mix design to analyse the strength of concrete.

b) Further the same taste need to be carryout for M30, M35, M40 concrete mix to

analyse the strength of concrete with percentage replacement of fine

aggregate with crushed glass particle.

Reference : 05/02/2023


1. Sangole Vaibhav S. & Mundhada Ashok R., Addition Of Crush Waste Glass Particles As Partial Replacement Of Fine Aggregates In Concrete, International Journal of Advance Engineering and Research Development Volume 2,Issue 5, May -2015.

2. Dr Rose A.Leema & Saji Megha.S., Using Glass Waste As A Partial Replacement For Fine Aggregate On The Strength Of The Concrete, International Journal of Engineering Research-Online, Vol.3., Issue.1, 2015.

3. IS:456-19834. IS:383-19705. IS:10262-20096. Abdallah Sadoon & Fan Mizi, Characteristics Of Concrete With Waste Glass As Fine

Aggregate Replacement, International Journal of Engineering and Technical Research (IJETR), Volume 2,Issue 6, June-2014.

7. Shetty M.S., Concrete technology Theory and Practical Book, 1982.

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43- : THANK YOU : -

GLASS DA 30.07.2016

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