International Journal of Emerging Technologies and Engineering (IJETE)

Volume 1 Issue 7, August 2014, ISSN 2348 – 8050

Structural Performance of Concrete by Partial Replacement of

Cement with Hypo Sludge (paper waste)
Abdullah shahbaz khan1, Ram panth2, Gagan Krishna R.R3, Suresh G. Patil4
1
PG student, 2Assistant professor, 3Associate professor, 4Professor,
1
Srinivas School of Engineering, Suratkal Mangalore, 2Guru Nanak Dev Engineering College Bidar, 3Srinivas School of Engineering,
Suratkal Mangalore, 4PDAC Gulbarga

ABSTRACT the materials used in construction industry. Concrete is

The rapid increase in construction activities
leads to active shortage of conventional construction
materials such as cement, fine aggregate and coarse
aggregate. Researches were searching for cheaper
materials that can be used as substitute for these
materials. In the world of concrete many artificial
pozzolans are found by research such as fly ash, blast
furnace slag, silica fume, rice husk ash, etc other than
this the recent studies has show that the waste from
paper industries has pazzolanic property termed as hypo
sludge hypo sludge contains low calcium and minimum
amount of silica. Hypo sludge behaves like cement
because of silica and magnesium properties. The silica
and magnesium improve the setting of concrete. By
utilizing hypo sludge the strength will be increased and
also cost reduction in the concrete is achieved. The
present dissertation work is directed towards developing
low cost concrete from paper industry waste.
Dissertation work is carried out with M20 & M30 grade
concrete with W/c ratio of 0.55 & 0.45 respectively as a
control specimen and hypo sludge is replaced in
different percentages such as 10%, 20%, and 30% by
weight of cement. Cubes of 150mm x 150mm size,
Cylinders of 100 mm dia and 200mm height, and prisms
of 100 mm x 100mm x 500mm are casted for
conventional concrete and RPH (Replacement of hypo
sludge by weight of cement) test specimen respectively.
Test was conducted to study the mechanical properties
of concrete, such as compressive strength, split tensile
strength and flexural strength. The curing period should
be 3, 7 and 28 days.
Key words : Hypo Sludge, M20 and M30 grade concrete,
cubes, cylinders, prisms.
I. INTRODUCTION
Concrete, is most widely used man made
construction material and is the largest production of all
basically made of cementitious materials which have to
properly bind themselves together, as well as with other
materials to form a solid mass. Concrete or mortar is
made up of cement, water and aggregates (Coarse and
Fine Aggregate) and sometimes with necessary
admixtures. Concrete has attained the status of a major
building material in all the branches of modern
construction. It is difficult to point out another material
of construction which is as variable as concrete.
Concrete is the best material of choice where strength,
durability, impermeability, fire resistance and absorption
resistance are required. Compressive strength is
considered as an index to assess the overall quality of
concrete and it is generally assumed that an
improvement in the compressive strength results in
improvement of all other properties. Hence strength
investigations are generally centered on compressive
strength. Even though concrete mixes are proportioned
on the basis of achieving the desired compressive
strength at the specified age, flexural strength often play
a vital role in concrete making. Hypo sludge (paper
industry waste) has a tremendous potential in this
context and it is well documented that the use of hypo
sludge in concrete results in a significant improvement is
the rheological prosperities.
Hypo sludge is a recent arrival among
cementitions materials. It was originally introduced as
artificial pozzolana while producing paper the various
wastes are comes out from the various processes in
paper industries. From the preliminary waste named as
hypo sludge due to its low calcium is taken out for our
project to replace the cement utilization in concrete.
Paper making industries generally produces a
large amount of solid waste. Paper fibers can be
recycled only a limited number of time before they
become too short or weak to make high quality paper.
From paper manufacturing process three types of sludge
are obtained namely lime sludge (Hypo sludge), ETP

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 International Journal of Emerging Technologies and Engineering (IJETE)
sludge and De-Inking sludge. In our project we have
utilized lime sludge as a replacement for cement. Lime
sludge (Hypo sludge is a material obtained from the
chemical recovery process of paper production. Hypo
sludge is available abundantly worldwide, but its usage
to date is very limited. Each Indian mill produces an
average 40 over-dry tones of sludge per day. The
specific gravity hypo sludge is generally 2.82 but it is
very slightly higher when the silica content is lower.
This value can be compared with the specific gravity of
Portland cement which is 3.15.
The particles of hypo sludge are extremely fine,
most of them having a diameter ranging between 0.04
and 0.3 m, the median diameter is typically below
0.1m. such a fine material as hypo sludge has a very
low bulk density 200 to 350 kg/m3 handling this light
powder is difficult.
Chemical reactions involved in partially replaced
concrete
1. Primary Hydration
Cement + Water  C-S-H (gel) + Ca (OH)2
2. Secondary Hydration
Here hypo sludge acts as a pozzolana
Ca (OH)2+ Pozzolana  C-S-H (gel)
Increase in amount of C-S-H gel increase the
compressive strength but only up to a certain extent.
Benefits of Hypo Sludge
 Hypo sludge improves the properties of fresh
and harden concrete.
 Hypo sludge reduces degradation and bleeding.
 Hypo sludge improves the durability of concrete.
 Hypo sludge improves the setting of concrete
due to presence of silica and magnesium.
 Environmental friendly.
 Light weight compare to conventional concrete.
 Hypo sludge is the cheaper substitute to OPC.
Limitations of Hypo Sludge
 Availability
 Handling problem
II. LITRETURE REVIEW
The use of paper-mill pulp in concrete
formulations was investigated as an alternative to
landfill disposal. The cement has been replaced by waste
paper sludge accordingly in the range of 10%, 20%, 30%
by weight for M20 and M30 mix. By using adequate
amount of the waste paper pulp and water, concrete
mixtures were produced and compared in terms of slump
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Volume 1 Issue 7, August 2014, ISSN 2348 – 8050
and strength with the conventional concrete(10). Over 300
million tones of industrial wastes are being produced per
annum by chemical and agricultural process in India.
These materials pose problems of disposal and health
hazards. The waste like phosphogypsum, flurogypsum
and red mud contain obnoxious impurities which
adversely affect the strength and other properties of
building material based on them. Out of several wastes
being produced at present, the use of phosphor gypsum,
flurogypsum, lime sludge, hypo sludge, red mud and
mine tailing is of paramount significance to protect the
environment(10).
Paper fibers can be recycled only a limited
number of times before they become too short or weak
to make high quality paper. It means that the broken low
quality paper fibers are separated out to become waste
sludge. All the inks, dyes, coatings, pigments, stapes
and “Stickies” (tape, plastic films etc) are also washed
off the recycled fibers to join the waste solids(02).This
paper mill sludge consumes a large percentage of local
land fill space for each and every year. Worse yet, some
of the wastes are land spread on crop land as a disposal
technique raising concerns about trace contaminants
building up in soil or running off into area lakes and
streams.
Some companies turn their sludge in incinerators
contributing to our serious air pollution problems. To
reduce disposal and pollution problems emanating from
these industrial wastes. It is most essential to develop
profitable building materials from them. Keeping this in
view investigations were under taken to produce low
cost concrete by blending various ratios of cement with
hypo sludge(03). In Trondheim, the source factory
produces 800 tons each year, with much more for the
entire(04). Waste paper sludge obtained from a paper
factory in Trondheim, Norway, It has bulk density
460kg/m3 specific gravity 2.6, ash content of 94% and a
pH value of 11.4. The material is essentially composed
of amorphous silicates and aluminates, mainly gehlenite
(2CaO.Al2O3SiO2) and melilite
(8CaO3Al2O3MgO5SiO2); which are responsible for a
pozzolanic reaction(08).
III. MATERIALS AND PROPERTIES
The materials used in research are:
1. Portland cement (53 grade)
2. Fine aggregate (4.75 mm down)
3. Coarse aggregate (20 mm down)
4. Hypo Sludge
5. Water
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 International Journal of Emerging Technologies and Engineering (IJETE)
Volume 1 Issue 7, August 2014, ISSN 2348 – 8050

Cement: impurities such as oil, alkali, acid, etc, in general, the

Cement is a fine, grey powder. It is mixed with water, which is fit for drinking should be used for
water and materials such as sand, pozzolanas to make making concrete.
mortar and concrete. The cement and water forms a
paste that binds the other materials together. In this work IV. MIX DESIGN
ordinary Portland cement of 53 grade conforming to IS: A mix M20 and M30 grade was designed as per IS
12269-1987 has been used and tested for physical and 10262:2009 and the same was used to prepare the test
chemical properties. samples. The design mix proportion is shown in blow
table.
Fine Aggregate
In the investigation fine aggregate is natural Table 4.1: Concrete Mix Design Proportion for 1 m3 of
sand from local market is used, confirming grading zone concrete
II as per IS: 383-1997. The physical properties of fine
aggregate like specific gravity, gradation and fineness Sl Typ w/c Fine Corse Hypo
Ceme
modulus are tested in accordance with IS :2386. n e of rati aggrega aggrega Sludg
nt
o mix o te te e
Coarse Aggregate
CV
Coarse aggregate crushed granite of 20 mm 0.5
1. C- 1.0 1.96 2.85 -
down size has been used as coarse aggregate. The 0
M20
physical properties of coarse aggregate like specific
S1- 0.5
gravity, gradation and fineness modulus are tested in 2. 0.9 1.96 2.85 0.10
M20 0
accordance with IS: 2386.
S2- 0.5
3. 0.8 1.96 2.85 0.20
Hypo Sludge M20 0
Hypo sludge is also known as paper industry S3- 0.5
4. 0.7 1.96 2.85 0.30
waste. It is the byproduct of the paper waste. This hypo M20 0
sludge contains low calcium and minimum amount of CV
0.4
silica. Hypo sludge behaves like cement because of silica 5. C- 1.0 1.29 2.43 -
0
and magnesium properties. M30
Hypo sludge may be used as part replacement of K1- 0.4
6. 0.9 1.29 2.43 0.10
cement. It is usually used in proportion of percent of M30 0
cement content of the mix. Hypo sludge obtained from K2- 0.4
7. 0.8 1.29 2.43 0.20
Gemini Graphics (P) Ltd., Sikenpur village district M30 0
Bidar. K3- 0.4
8. 0.7 1.29 2.43 0.30
M30 0
Table 3.1: Chemical Properties of Hypo Sludge
Percent in CVC-conventional concrete,
Sl.No. Constituent Hypo Sludge S1, S2, S3 for M20 grade concrete with different Hypo
(%) Sludge percentage 10%, 20%, 30% respectively.
1. Moisture 2.97 K1, K2, K3 for M30 grade concrete with different Hypo
Magnesium Sludge percentage 10%, 20%, 30% respectively.
2. 4.64
Oxide (MgO)
Calcium Oxide V. EXPERIMENTAL PROGRAMME
3. 15.12 The quantity of cement, fine and coarse
(CaO)
4. R2O3 9.31 aggregates, hypo sludge and water each batch of
5. Silica (SiO2) 3.09 proportion is prepared as mentioned in mix design. Then
6. Acid Insoluble 13.88 the mixing process is carried out.
Tests for Fresh Properties of concrete
Water Workability tests included the determination of
The water, which is used for making concrete slump cone test.
and for curing, should be clean and free from harmful
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 International Journal of Emerging Technologies and Engineering (IJETE)
Volume 1 Issue 7, August 2014, ISSN 2348 – 8050

Casting of Moulds Table:6.2 Results of Slump Cone Test M20 and M30
Once the workability tests are over, concrete is Mix M20 Slump M30 Slump
filled into the moulds (cubes, cylinders and beams) and designation cone (mm) cone (mm)
compaction process has to be carried out. Then casted
CVC 50 50
moulds are de-moulded and the specimens are kept
inside the water for curing till test day (3, 7 and 28 M1 48 46
days).
M2 45 42
Mechanical Properties Tests
To determine the hardened properties of M3 41 38
concrete standard tests were carried out at standard ages
(3,7days and 28 days of curing) i.e., compression test on
cubes for compressive strength (three cubes of
150x150x150mm size), split tensile test on cylinders for SLUMP VALUES
tensile strength (three cylinders of 100mm dia with 60

SLUMP VALUES IN mm
200mm height) and flexural test on beams for flexural 50
strength (three beams 500x100x100mm) of concrete for 40
each grade with different mix proportions of hypo 30
sludge. 20 M20
10
VI. RESULTS AND DISCUSSION 0 M30
Setting time for cement and hypo sludge cvc M1 M2 M3
Table:6.1 Setting Time for Cement and Hypo sludge
DIFFERENT MIX PROPORTIONS
Sl. Initial Final time
Ingredients Fig.6.1 Slump values for various mixes (M20, M30)
No. time (min) (min)
Table:6.3 Mechanical Properties of Concrete with
Cement + 0% Different mix Proportions
1 30 600
Hypo sludge Mix’s Compressive strength Split Flexural
(N/mm2) tensile strength
Cement + 10% strength (N/mm2)
2 33 596 (N/mm2)
Hypo sludge
3 days 7 28 28 days 28 days
Cement + 20% days days
3 35 598 CVC1 11.93 19.59 27.1 2.80 1.92
Hypo sludge

Cement + 30% S1 16.49 28.74 34.79 3.8 2.43

4 37 595
Hypo sludge
S2 14.38 23.29 29.18 2.93 1.93
Cement + 40% S3 10.37 18.17 23.7 2.55 1.54
5 39 593
Hypo sludge
CVC2 17.79 24.98 39.40 4.02 2.62
Cement + 50%
6 40 590 K1 21.74 33.47 45.17 5.51 3.06
Hypo sludge
K2 18.17 27.94 40.17 3.79 2.57
Slump Cone Test results
Workability tests, slump cone tests conducted on K3 13.37 20.43 31.43 3.26 2.33
fresh concrete and the results are shown in table .
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 International Journal of Emerging Technologies and Engineering (IJETE)
Volume 1 Issue 7, August 2014, ISSN 2348 – 8050

 Here CVC1, CVC2 Conventional Concrete for M20, 4

M30 Grade concrete Respectively
3.5
 S1, S2 and S3 are 10%, 20% and 30% RPH for M20,
Grade concrete Respectively 3
 K1, K2 and K3 are 10%, 20% and 30% RPH for 2.5
M30, Grade concrete Respectively 2
1.5 28 days
40 1
35 0.5
0
30
CVC1 S1 S2 S3
25
3 days Fig.6.4 Split tensile strength results for 28 days of curing
20 for M20 Grade Concrete
7 days
15 6
28 days
10 5

5 4
0 3
CVC1 S1 S2 S3 28 days
2
Fig.6.2 Compressive strength results for different curing
period for M20 Grade Concrete 1

0
50
CVC2 K1 K2 K3
45
40 Fig.6.5 Split tensile strength results for 28 days of curing
for M30 Grade Concrete
35
30
3 days 3
25
7 days 2.5
20
15 28 days
2
10
1.5
5
28 days
0 1
CVC2 K1 K2 K3
0.5
Fig.6.3 Compressive strength results for different curing
period for M30 Grade Concrete 0
CVC1 S1 S2 S3

Fig.6.6 Flexural strength results for 28 days of curing for

M30 Grade Concrete

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 International Journal of Emerging Technologies and Engineering (IJETE)
3.5
3 The prisms which contains 30% of RPH breaks
2.5
2 higher load but CVC prisms break earlier without
1.5 28 days
1 REFERENCES
0.5
0
CVC2 K1 K2 K3
Fig.6.7 Flexural strength results for 28 days of curing for
M30 Grade Concrete
By this table and graphs results shows that there
is an increase in compressive strength, split tensile
strength and flexural strength with 10%, 20%
replacement of cement with hypo sludge and it decreases
with 30% replacement.
VII. CONCLUSION
1. COMPRESSIVE STRENGTH
Compressive strength of concrete with various
mixes with different curing periods which are 3, 7, 28
days by partial replacement of cement with hypo sludge
that is 0%, 10%, 20%, 30% which are noted as CVC1,
S1, S2, S3 and CVC2, K1,K2,K3.
The compressive strength increases as the curing
period increasing for M20, M30 grade concrete,
compressive strength of CVC and 20% are
approximately same but it increase with 10%
replacement and finally it starts decreasing in strength
with 30% replacement.
2. SPLIT TENSILE STRENGTH
It is observed that in split tensile strength of M20
and M30 grade concrete. The strength of concrete has
increased with 10% replacement of hypo sludge with
cement as compare to conventional concrete and with
20% replacement it is slightly more or we can say it as
equivalent but with 30% its start decreasing in strength.
3. FLEXURAL STRENGTH
It is observed that in flexural strength of M20 and
M30 grade concrete the strength of concrete has increased
with 10% replacement of hypo sludge with cement as
compare to conventional concrete and with 20%
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Volume 1 Issue 7, August 2014, ISSN 2348 – 8050
replacement it is slightly more or we can say it as
equivalent but with 30% its start decreasing in strength.
earlier with the influence of two point loading condition
where as 10%, 20%, shows more deflection and carries
showing mutch cracks.
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