IJERD – International Journal of Environmental and Rural Development (2018) 9-1

Research article
erd

Effective Utilization of Ceramic Powders for ConcretePavement
EIJI MATSUO*
Faculty of Architecture and Civil Engineering, Kyushu Sangyo University, Fukuoka, Japan
Email: ematsuo@ip.kyusan-u.ac.jp

TAKENORI NAGAMATSU
Faculty of Architecture and Civil Engineering, Kyushu Sangyo University, Fukuoka, Japan

TAKAHIKO KUBODERA
Faculty of Engineering, Osaka Sangyo University, Osaka, Japan
Received 14 December 2017

Accepted 5 May 2018(*Corresponding Author)

Abstract The effective utilization of industrial wastes has been becoming the urgent
problem for the establishment of the recycling society. Especially, there are many kinds ofthe powders-formed industrial wastes, and studies on the utilization of them have been
conducted individually and widely. The powders which do not have activity are often used
as a filler of asphalt pavement, but its supply has been already saturated in Japan. Therefore,
the methods to use them as the aggregate of concrete pavement is also studied. When theapproach method is established, it will help the reduction of the environmental load in theinfrastructure development of the field of agriculture. In this study, authors focused on thepowder exhausted in the manufacturing process of the ceramic product. This ceramic
powder (CP for short) is one of the powders-formed industrial wastes which don't haveactivity. A process of the abrasion is necessary in the production of the ceramic product. On
this occasion, ceramic fines are produced as sludge-formed drainage. Under the present
condition, the drainage is dried by the sun and solidified by the addition of cement. It isdisposed as the industrial waste in the state, and effective utilization has been expected. In
this paper, CP was investigated to be used effectively as the substitute of fine aggregate. A
part of JIS standard sand was replaced to CP by volume, being based on the mix proportionin the strength test of cements. The maximum replacing ratio was establishedexperimentally from the viewpoint of fresh properties such as mortar flow test and setting
time test and strength properties. The shrinkage properties was also obtained by the test oflength change of mortar with dial gauge.
Keywords ceramic powder, concrete pavement, workability, strength, drying shrinkage

INTRODUCTION
The effective utilization of the industrial waste becomes the urgent problem in the establishment of
the recycling society (Sogo et al., 2013). Especially, the powders-formed industrial waste exist forhaving many kinds, and a study on utilization is conducted individually and widely (Malhotra et al.,2005; Matsuo et al., 2007; Hosokawa et al., 2014). The powders which do not have activity areoften used as a filler of asphalt pavement, but its supply is already saturated in Japan. Then, themethods to use them for aggregate of the concrete pavement is also studied. When the approach
method is established, it helps the reduction of the environmental load in the infrastructuredevelopment of the field of agriculture. In this paper, authors focused on the powders exhausted in
the manufacturing process of the ceramic product (CP). CP is one of the powders-formed industrial
waste which does not have activity. A process of the abrasion is necessary in the production of theceramic product. On this occasion, ceramic fines are produced as sludge-formed drainage. Under
the present condition, the drainage is dried by the sun and solidified by the addition of the cement.
It is disposed as the industrial waste in the state, and effective utilization is expected.
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Giving attention to studies on CP, Sakagami clarified the applicability as segregation control
material in the high slump concrete by replacing a part of the cement with CP (Sakagami et al.,2003). They were concerned about strength decreasing and suggested aggregate replacement notcement replacement.
In this study, CP was investigated to be used effectively as the substitute of fine aggregate. Apart of JIS standard sand was replaced to CP by volume, based on the mix proportion in thestrength test of cements. The maximum replacing ratio was acquired experimentally from theviewpoint of fresh properties such as mortar flow test and setting time test (JIS A 1147) andstrength properties. The shrinkage properties was also obtained by the test of length change ofmortar with dial gauge (JIS A 1129-3).
METHODOLOGY
1. Materials and Basic Properties
CP was dried by furnace drying to the absolute dry condition. And CP which passed 0.15mm sieve
was used to unify the particle size. Table 1 shows the ingredient analysis of CP, and the Aluminum
proportion is the most. The main materials were ordinary Portland cement (bulk density is 3.15
g/cm3) as binder, the city water as mixing water and JIS standard sand (bulk density is 2.64 g/cm3,water absorption is 0.42%) and CP (density in absolutely dry condition is 3.71 g/cm3, non-sphere)
as fine aggregate. High performance AE water reducing agent was used, and its effect wasconfirmed.

Table 1 X-ray Diffraction Analysis of CPElement
(%)
K0.4

Al89.2
Ni0.4

Si6.6
Mn0.3

Ca
1.1
Na0.2

Mg
1.0
Fe0.2

Cu
0.5
Others
0.2

Photo. 1 Ceramic powder (3000 times)
Table 2 shows the mix proportion of mortar. Unit volume water and unit volume cement wasconstant. Mixing was carried out following JIS R 5201, physical testing method for cement.
Namely, after the mixing of water and cement for 30 seconds, the fine aggregates were added andmixed for another 30 seconds. After 90 second stop, they were mixed for 60 seconds again.
Air content was measured just after mixing, and setting test and bleeding test were conducted,
each according to JIS A 1128, JIS A 1147 and JIS A 1123. In JIS A 1128, the air amount of mortar
is able to be measured by the device such as Photo.2. In JIS A 1147, the increase of penetration
resistance by time can be obtained by inserting of the bar into mortar as Photo.3. The time when
the penetration resistance was to 3.5 N/mm2 is determined as the initial setting, and that of 28.0
N/mm2 is determined as the final setting. In JIS A 1123, the water floating on the surface of themortar is absorbed in a filler directly, and the weights is measured as the bleeding (see Photo.4).
The test specimens were prisms, and the dimensions were 40*40*160 mm. Strength test wasconducted at the curing age of 3, 7, 28 and 91 days.

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Table 2 Mix Proportion of Mortar (Base)W/C *CP **SR
Fresh &Unit Weight (kg/m3)(%) (%) (%) W CS
CP SR StrengthS05000 256 512 15360 0◯
S550
50 256 512 1458 108 0◯
S1050
100 256 512 1381 216 0◯
S1550
150 256 512 1305 324 0◯
S15H150151 256 512 1305 324 10S15H250152 256 512 1305 324 20S2050
200 256 512 1228 431 0◯
S2550
250 256 512 1151 539 0◯*CP: Ceramic replacing ratio by volume**SR: Shrinkage reducing agent, 1 means the standard usage
No.

Shrinkage◯◯

Dial gauge
Air Meter
Bar for inserting

Mold of mortar

Photo. 2 Measurement of air amount

Photo. 3 Measurement of setting time

Cupped to prevent
evaporation

Bleeding water is absorbed ina filler directly.

Photo. 4 Measurement of the amount of bleeding water
2. Methods of Measurement for Length Change
Table 2 also shows the mix proportions in the length change test. "S" means the replacing ratio to
CP. Based on S0 which is the mix proportion of the cement strength test, a part of fine aggregate
was replaced by volume to CP. "H" means the amount of shrinkage reducing agent, which main
ingredient is glycol ether. "1" means the standard amount and "2" means twice as much. This agent
was used and the effect was confirmed in the mix proportion of 15% of replacing ratio of CP.

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IJERD – International Journal of Environmental and Rural Development (2018) 9-1

Plug

Measurement Length(= about 100 mm)

Dial gauge

40 mm

Plug
Plug

40 mm

160 mmFig. 1 Specimen size and position of the plugs forlength change test

Photo. 5 Length change test

The test specimens were prisms, and the dimensions
were 40*40*160 mm as same as basic tests (see Fig.1). 3
specimens were made by every mix proportion. They weredemolded on the next day of casting, and had begun to bedried after 28 days standard curing. The environmental
condition of drying in draft chamber was the room
temperature of 20 degrees Celsius and the humidity of 60%.
The length change test was conducted according to JIS B
7503 (see Photo.5).

200

Flow (mm)1800 times

15 times

1020
CP Replacing Ratio (%)

30160
140

120
100

800Fig. 2 Relationship between CP
replacing ratio and mortar
FlowRESULTS AND DISCUSSION

Bleeding Amount (cm3/cm2)

Figure 2 shows the relationship between CP replacing ratio
and mortar flow. As the replacing ratio increase, the mortar
flow decreases. Especially, when the replacing ratio
exceeded 15%, workability decreased remarkably, which isout of practical use. Because a particle size of CP isextremely smaller than JIS standard sand, and surface area
ratio is big, the adsorption water increased, which could beestimated as the factor that the workability decreased.
Figure 3 shows the result of the bleeding test. When Photo. 6 Measurement of mortar flow
the replacing ratio exceeded 10%, almost none of bleeding
0.20
0.18
occurred. Even at 5% of CP replacing ratio, bleeding
0.16
became about a one-third of basic mix proportion. This
0.14
would be because the surface of CP which particle size is0.120.10
very small absorbed water like flow test. From the above,
0.08
CP decreases the bleeding, but workability extremely
0.06
0.04
decreases when CP replacing ratio exceed 10%.
0.02
Figure 4 shows the result of the air content test. When
0.00
051015CP was mixed, the air content increased obviously. The airCP Replacing Ratio (%)
content represented the maximum value at 5% of CP
replacing ratio, and had a tendency to decrease at 10 andFig. 3 Result of bleeding test
15% of CP replacing ratio. Generally, when the amount ofpowders increases, the air content increases. In this study, there was too much quantity of particles,
and the mortar was too dry condition, that caused the difficulty of air entraining.

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Penetragion Resistance (N/mm2)

14Air Amount (%)

1210864200510CP Replacing Ratio (%)

1545403530252015105010864InitialFinal200510CP Replacing Ratio (%)

CP=15%

Final Setting

0Prizm Copmressive Strength (N/mm2)

Setting Time (Hour)

12

CP=5%

CP=10%
Initial Setting

Fig. 4 Relationship between CP replacing ratio
and air amount
14

CP=0%

5Time (Hour)

1015Fig. 5 Result of setting test

7060504030203 days

7 dyas1028 days

91 days00155101520
CP Replacing Ratio (%)

25Fig. 6 Relationship between CP replacing ratio Fig. 7 Relationship between CP replacing
and setting time
ratio and prizm compressive strength
Figures 5 and 6 show the results of setting test. Retardation of setting of 2 hours in S5, 5 hours
in S10 and 5.7 hours in S15, in comparison with the initial setting time of S0 (5.5 hours). And
retardation of setting of 1.8 hours in S5, 4.3 hours in S10 and 4.8 hours in S15, in comparison withthe final setting time of S0 (8.4 hours). In addition, time from initial setting time to final setting
time decreased with the increase of replacing ratio, and the difference between S0 and S15 wasapproximately 0.9 hours. From the above, it was confirmed that CP delays the setting time ofconcrete.
Figure 7 shows the results of cubic compressive strength test. At 3 day material age, although
the strength did not decrease with until 15% of CP replacing ratio, strength decreased remarkably
with after 20% of CP replacing ratio. After 7 day material age, regardless of CP replacing ratio, itwas confirmed that the strength development was approximately equal to plain mortar.
Figure 8 shows the results of bending strength test. It was able to be confirmed that thestrength development was low in the case of high replacing ratio of CP in 3 day material age, andthe strength development could be obtained in every replacing ratio after 7 days material age assame as compressive strength. Figure 9 shows the change of shrinkage strain with time. In all
specimens in which fine aggregate was replaced with CP, the shrinkage strain increased incomparison with plain specimen. And as CP replacing ratio increased, the shrinkage strain also hada tendency to increase. In S15H2 which used shrinkage reducing agent, it could be improved to thesame degree as S0, and in S15H2 it was improved to degree more than S5.
Figure 10 shows the change rate of weight with time. The change rate of weight among S10 toS25 did not have the evident difference. The performance was improved in all the specimen using
the shrinkage reducing agent in comparison with plain specimen. However, CP replacing ratio andthe change rate of weight did not have the proportion relations. It is a future problem to elucidate
the reason. Fig.11 shows the change rate of specific strain with time. Here, the specific strain is thevalue that divided the shrinkage strain by the amount of evaporated water, which could beconsidered to be a resistant index for drying shrinkage. It is confirmed that the hardness has an
influence on the length change also from this figure.

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14012-200
Shrinkage Strain (μ)

Bending Strength (N/mm2)

IJERD – International Journal of Environmental and Rural Development (2018) 9-1

10864

3 days

7 dyas228 days

91 days-400

S5S15S25-600-800-1000-1200-1400005101520CP Replacing Ratio (%)

025

Fig. 8 Relationship between CP replacing ratio
and bending strength
S0S15-0.5S5S200S10S25-1.0-1.5-2.0-2.5-3.00

50
100
Drying Time (Days)

Fig. 10 Change rate of weight with time

150

50
100
Drying Time (Days)

150

Fig. 9 Change of shrinkage strain withtime
Specific Shrinkage Strain (μ/g)

0.0Change Rate of Weight (%)

S0S10S20S0S15
S15H1-20S5S20
S15H2S10S25-40-60-80050100Drying Time (Days)

150

Fig. 11 Change rate of unit strain with time

CONCLUSION
1. When CP was mixed, the air content increased obviously and the bleeding decreased and thesetting time delayed.
2. When CP replacing ratio is high, the strength in early age is small, but the strength does notdecrease within 25% of CP replacing ratio after 7 days of curing age.
3. Without water reducing agent and so on, most adequate CP replacing ratio is 15%, considering
workability altogether.
4. Shrinkage strain have a tendency to increase with CP replacing ratio, but shrinkage reducing
agent is effective as measures, and the improvement effect is proportional to its mixing amount.
REFERENCES
Hosokawa, Y., Senga, T. and Abe. A. 2014. Properties of interlocking concrete block mixed with volcanic
ashes in southern Kyushu island. Cement Science and Concrete Technology, 67, 304-310.
Malhotra, V.M. and Mehta, P.K. 2005. High-performance, high-volume fly ash concrete. 2nd Edition.
Matsuo, E., Tamataki. K. and Yasui, W. 2007. Strength and segregation properties of super lightweightmortar made with expanded polystyrene waste as fine aggregate. Japan Society of Civil Engineers,
Journal of Materials, Concrete Structures and Pavement, E-63 (3), 368-378.
Sakagami, J., Okabe, Y. and Fujiwara, T. 2003. Applicability of the waste grime as admixture for concrete.
The Proceedings of the 58th JSCE Annual Meeting, 5 (164), 327-328.
Sogo, S., Kawano, H., Noguchi, T., Chikamatsu, R., Miyazawa, S., Naruse, H. and Mitsui. K. 2013.
Technical committee which evaluates the influence and construction on concrete performance by using
admixtures positively. Proceedings of the Japan Concrete Institute, 35 (1), 16-21.

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