EXPEMETNAL RESEARCH ON THE PARTIAL

REPLACEMENT OF COARSE AGGREGATE IN

CONCRETE WITH CERAMIC TILE WASTE

ABSTRACT
This experimental study explores the potential of utilizing waste ceramic tiles as a partial
replacement for coarse aggregate in concrete, with substitution levels ranging from 0% to
5%. The physical properties of tile aggregate, including flakiness index, elongation index,
fineness modulus, impact value, specific gravity, and water absorption, were found to be
within acceptable limits. Results show that concrete containing 15% to 25% waste
ceramic tile aggregate demonstrates good compressive and split tensile strength,
indicating that such reuse not only offers on effective solution for ceramic waste
management but also contributes to improving concrete quality.

INTRODUCTION
Importance of Aggregate: Aggregate is a key ingredient in concrete, contributing to
strength and volume. However, it is a non-renewable resource that is being overexploited.

Waste Tile as Alternative: Waste tiles, a byproduct of construction, can be used as a

replacement for coarse aggregates in concrete, reducing environmental impact and
managing waste effectively.

Properties of Waste Tile Aggregate: Tiles are made from natural materials and are free
from harmful chemicals. They are durable, hard, and resistant to degradation, making
them suitable for use in concrete.

Environmental Benefits: Using tile waste in concrete helps reduce depletion of natural
stone aggregate, lowers construction waste, and promotes sustainable construction
practices.

Application in Hot climates: concrete made with crushed tile aggregate (CTA) has a
lower unit weight, making it particularly beneficial for building in hot climates.
Global Construction Waste Issue: Around 75% of construction waste worldwide comes
from demolition activities, with ceramic waste being a major contributor. Recycling and
reusing this waste can reduce landfill pollution.

Waste Management in Nepal: With rapid urbanization and construction in Nepal, waste
tile disposal is becoming a challenge. Utilizing it in concrete can help manage solid waste
efficiently.

Sustainability and Cost Saving: Recycling waste tile as aggregate reduce reliance on
quarrying, lowers cost, and supports a greener environment, making it a viable alternative
for sustainable construction.

OBJECTIVE
This study aims to evaluate the feasibility of using ceramic tile waste as a partial
replacement for natural coarse aggregate in M30- grade concrete. By analyzing the
hardened properties of concrete incorporating ceramic tile waste, the research assesses its
suitability for structural application. The investigation includes compressive and flexural
strength tests after 7 and 28 days of curing. Additionally, the study compares the
mechanical properties, specific gravity, water absorption, and economic viability of
ceramic tile aggregate with natural coarse aggregate. Both destructive and non-
destructive testing methods are employed to ensure a comprehensive evalution.

SCOPE
The utilization of ceramic tile waste as a replacement for natural coarse aggregate in
concrete production not only enhances the strength and durability of concrete but also
provides an eco-friendly solution to manage industrial waste, thereby reducing
environmental pollution and promoting sustainable construction practices.

LIMITATIONS
Chemical test was not performed for any of the concrete materials (i.e. cement, sand,
aggregate and water).

There are many brand of cement available within local market but this study considers
the single brand Ordinary Portland Cement named as Shiva cement.

Tap water (i.e. potable water) was used for concrete mix as well as curing (i.e. no
consideration of pH value).
 LITERATURE REVIEW

2.1 Literature Review of Crushed Ceramic Tile Waste

R.M. Senthamarai et al. (2005) substituted conventional crushed stone aggregate with
ceramic electrical insulator. Different water cement ratio of 0.35, 0.40, 0.45, 0.50, 0.55
and 0.60 were adopted. Compressive strength, split tensile strength, flexural strength and
Modulus of elasticity were found out. It is found that the compressive, split tensile and
flexure strength of ceramic coarse aggregate are lower by 3.8%, 18.2% and 6%
respectively when compared to conventional concrete.

A.Mohd Mustafa et al. (2008) studied on various types of ceramic waste like flower
pots, tiles and clay bricks. Different water cement ratios were adopted such as 0.4, 0.5
and 0.7 with concrete of characteristics strength of 20 MPa. Flower pots gave the best
results for compressive strength of about 2.50% lesser than that of conventional concrete.

C. Medina et al. (2012) investigated on the reuse of waste as recycled coarse aggregate
in partial substitution of 15%, 20% and 25% in the manufacture of structural concrete.
Compressive strength is found out t 7, 28 and 90 days. There is an increase in strength
with increase of percentage replacement, the best results shown is at 25% with increase
of 21.12%, 11.04% and 6.70% at 7, 28 and 90 days respectively.

R.M.Senthamarai et al. (2011) studied the durability properties of ceramic industry

waste as coarse aggregate in concrete. Water cement ratios from 0.35- 0.60 were used
and properties such as volume of voids, water absorption, chloride penetration and
sorption were studied. Water absorption ranges from 3.74-7.21% whereas that of
conventional concrete from 3.1 – 6.52%. Concrete with Ceramic shows higher results in
all tests.
T. Sekar (2011) studied on strength characteristics of concrete utilizing waste materials
viz: ceramic tiles, ceramic insulator waste and broken glass pieces. Ceramic tiles gave the
best results when compared to the other two type of waste. The concrete produced by
ceramic tile aggregate produced similar strength in compression, split tensile and flexure
as conventional concrete.

Y. Tabak et al. (2012) studied on the mechanical and physical properties of concrete
produced form Floor Tiles Waste Aggregate (FTWA). Two samples were made, the first
one substitution by Floor Tile Waste Dust (FTDA) and the other a combination of Floor
Tile Waste Dust (FTDA) and Floor Tile Waste Aggregate (FTWA).Best result is shown b
FTWA substitution. Increase in compression strength is 13.53%, 16.70% and 2.91% for
2, 7 and 28 days. Similarly there is an increase of 23.21%, 0.1% and 19.47% respectively
for flexure strength. There is a reduction of specific density and water absorption of
0.284Kg/m3 and 0.158% respectively when compared to conventional concrete.

Umapathy et al. (2014) studied on Rice Husk Ash(RHA) as cement at 10%, 15% and
20% and waste tiles as coarse aggregate at 20%, 30% and 50%. Compression strength is
found out and the best results is with 20% tiles and 10%RHA of 80.60% to that of
conventional concrete.

Daniel RJ et al. (2021) The extent of 35% coarse aggregate were partially substituted
with ceramic waste based tile. Several studies indicate that between 20% to 30% of the
raw materials handled in tile production facilities are lost as waste.

Mainkandan KP et al. (2023) This research paper explains an experimental study on the
utilization of waste material extracted from the ceramic manufacturing.
 EXPERIMENTAL METHODOLOGY

MATERIAL PROPERTIES
Introduction
Concrete is an important element to create any structural elements. Before
concreting of the structure we find out the physical properties of concrete raw materials
(cement, fine aggregate, coarse aggregate) some of the physical properties of concrete
raw materials are given below. This chapter deals with the mix design procedure adopted
for control concrete and the studies carried out on properties of various materials used
throughout the experimental work. Also, deals of casting and testing of specimens are
explained.

Material Used

 Cement
 Fine Aggregate
 Coarse Aggregate
 Water
 Crushed Ceramic Tile Waste (Replacement of (0%, 5%, 10%, 15%, 20%, 25%,
30%& 35%)

CEMENT TEST

Table 1 Fineness Test of Cement

Total Wt. of
Sample Retained Average
Sl.No Sample Taken Fineness %
on90µ Sieve Fineness %
(Gm)
1 100 3.4 3.4
3.85
2 100 4.3 4.3
 Table 2 Physical Properties of Cement
Physical Properties OfOPC 53 Requirements As Per
Sl.No Results
Grade Cement Is:8112-1989
1 Specific Gravity 3.15 3.10-3.15
2 Standard Consistency (%) 31.5 30-35
3 Initial Setting Time(Min) 55 30 Minimum
4 Final Setting Time(Min) 325 600 Maximum

AGGREGATE TEST
Table 3 Flakiness and Elongation Index of Natural coarse aggregate
Elongated
Sieve size Flaky Remaining
Weight(gm) Aggregate
Range (mm) Aggregate(gm) Weight(gm)
weight(gm)
25-20 - - - -

20-16 1487 513 974 328

16-12.5 1008 222 786 394

12.5-10 485 112 373 166

10-6.3 265 27 238 19

Total weight 3245 874 2371 907

Table 4 Flakiness and Elongation Index of Crushed Tile aggregate

Elongated
Sieve size Flaky Remaining
Weight(gm) Aggregate
Range (mm) Aggregate(gm) Weight(gm)
weight(gm)
25-20 0 0 0 0
20-16 1338 0 1338 310
16-12.5 350 95 255 130
12.5-10 230 9.5 220.5 160
10-6.3 82 11.3 70.7 43.5
Total weight 2000 115.8 1884.20 643.5
Flakiness and elongation index of aggregates

Crushed waste ceramic Tile Separation

Table 5 Replacement Proportions for Various Concrete
Concrete Coarse Aggregate Replacement WithCrushed Waste
S.No
Type Ceramic Tileaggregate

1 C0 Standard Concrete

2 C1 5% Replacement

3 C2 10% Replacement

4 C3 15% Replacement

5 C4 20% Replacement

6 C5 25% Replacement

7 C6 30% Replacement

8 C7 35% Replacement

Table 6 Design Mix Proportions

Types
Cement Fine Aggregate Coarse Aggregate W/C
of
(Kg/m3) (Kg/m 3) (Kg/m3) Ratio
Mix

0% CTA 1 1.50 2.71 0.479

5% CTA 1 1.50 2.67 0.482

10% CTA 1 1.31 2.31 0.463

15% CTA 1 1.31 2.28 0.464

20% CTA 1 1.31 2.15 0.484

25% CTA 1 1.31 2.09 0.484

30% CTA 1 1.31 2.07 0.492

35% CTA 1 1.23 2.00 0.478

 Table 7 Details of M30 Grade Concrete Mix

Fine
OPC Aggregate Coarse Aggregate No of Specimens
Mix Cement NFA NCA CTA Cube Cylinder
0% 100% 0% 3 3
5% 95% 5% 3 3
10% 90% 10% 3 3
15% 85% 15% 3 3
100% 100%
20% 80% 20% 3 3

25% 75% 25% 3 3

30% 70% 30% 3 3
35% 65% 35% 3 3
CONGRETE TEST
Table 8: Split Tensile Strength of Cylinders at 7 Days & 28 Days
Sl. No. Mix Average Split Tensile StrengthIn N/mm2
7 Days 28 Days
1 0% 1.06 2.65
2 5% 1.27 2.86
3 10% 1.27 2.97
4 15% 1.70 2.97
5 20% 1.80 2.76
6 25% 1.59 3.08
7 30% 1.06 3.29
8 35% 1.49 3.18
Table 9: Compressive Strength of Cubes at 7, 14, and 28 Days

Average Compressive Strength

Sl. No. Mix In N/mm2
7 Days 14 Days 28 Days

1 0% 20.78 23.89 29.67

2 5% 22.44 25.81 30.22

3 10% 24.67 28.37 30.33

4 15% 23.89 27.47 30.56

5 20% 22.44 24.68 30.89

6 25% 23.22 25.54 32.00

7 30% 22.26 24.43 31.78

8 35% 19.04 20.98 30.11

RESULT
Flexural Strength of Values at 7 Days
Mix %
bd2 Flexural
of Load
Sl. Days 1 x 10 6
Strength
No. Ceramic 3
KN
( mm )) ( N/mm2)
tiles

1 0% 21.25 3.78
15cm x 15cm x
2 10 % 23.75 4.22
7 Days 70cm
3 20 % 26.25 4.67
(3.375)
4 30 % 25.00 4.44
 Flexural Strength of Values at 14 Days
Mix %
bd2 Flexural
of Load
Sl. Days 1 x 10 6
Strength
No. Ceramic KN
( mm3 ) ( N/mm2)
tiles

1 0% 33.00 5.87
15cm x 15cm x
2 10 % 14 35.00 6.22
70cm
3 20 % Days 36.875 6.55
(3.375)
4 30 % 39.375 7.00
Flexural Strength of Values at 28 Days
Mix %
bd2 Flexural
of Load
Sl. Days 1 x 10 6
Strength
No. Ceramic 3
KN
( mm ) ( N/mm2)
tiles

1 0% 3.375 6.44
15cm x 15cm x
2 10 % 28 3.375 6.90
70cm
3 20 % Days 3.375 7.33
(3.375)
4 30 % 3.375 7.67

CONCLUSIONS AND RECOMMENDATIONS

Conclusions

The following conclusions were reached from the present investigations

concerning the behavior of crushed tile as coarse aggregate in concrete mixes:
 Gradation (sieve analysis) of 20 mm down waste Ceramic tile aggregate can be
obtained within a permissible value as per IS 383, when tiles are crushed with
manual hammering method.
 20 mm down tile crushed aggregate have better flakiness and elongation index
than natural crushed aggregate.
 Ceramic tile aggregate have lower specific gravity, higher water absorption ratio
than that of natural aggregate.
 There is no significantly difference was obtained on impact value of tile and
natural aggregate.
 Up to 30% replacement of natural aggregate by tile aggregate shows better 7 and
28 days compressive strength than that of 0% tile aggregate.
 With addition of tile aggregate, split tensile strength was increased.
Recommendation

 Waste ceramics tile aggregate can be used in construction industry. For this 15 to
25 percentage replacement of natural aggregate by CTA was preferable.
 To increase tensile strength of concrete structure 20 to 30 percent replacement of
NA by CTA was preferable.
 As we found that CTA have good physical properties, so, waste ceramics tile
should be recycled and reuse.

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