20320130405014 2

International Journal of Civil JOURNAL OF CIVIL ENGINEERING AND
INTERNATIONAL Engineering and Technology (IJCIET), ISSN 0976 – 6308
(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME

TECHNOLOGY (IJCIET)

ISSN 0976 – 6308 (Print)
ISSN 0976 – 6316(Online)
Volume 4, Issue 5, September – October, pp. 130-142
© IAEME: www.iaeme.com/ijciet.asp
Journal Impact Factor (2013): 5.3277 (Calculated by GISI)
www.jifactor.com

IJCIET
©IAEME

HYPO SLUDGE: OPPORTUNITIES FOR SUSTAINABLE DEVELOPMENT
OF LOW COST RURAL ROADS
Prof. Jayeshkumar Pitroda1, Dr. L.B.Zala2, Dr. F.S.Umrigar3
1

Assistant Professor & Research Scholar, Civil Engg Department, B.V.M. Engineering College,
Vallabh Vidhyanagar
2
Head & professor, Civil Engineering Department, B.V.M. Engineering College, Vallabh Vidhyanagar.
3
Principal, B.V.M. Engineering College, Vallabh Vidhyanagar – Gujarat – India.

ABSTRACT
Hypo Sludge, a waste derived from paper industry is plentiful in India causing severe health,
environment and dumping problems. Utilization of Hypo Sludge in bulk quantities, ways and means
is being discovered all over the world to use it for the construction of embankments and roads. This
way the Hypo Sludge concrete are made a 'greener' building material and the discarded natural
wastes can be re-utilized, avoiding otherwise wasteful landfill and harmful open incineration.To
make value added concrete for development of sustainable infrastructure there is a great need to
study the technical details concerned with various industrial wastes in concrete and to reduce
environmental hazards. It is also needed to reduce the cost of concrete for rural development in India.
A cement concrete pavement is designed for a Rural Road in Gujarat State having a traffic volume of
up to 500 vehicles per day. The soil has a soaked CBR value of 2%, 4% and 6% and design wheel
load 30kN. So our study is concerned with eco-efficient utilization of hypo sludge as partial
replacement of cement in concrete.The aim of the present study is to investigate the low cost rural
roads made of Hypo Sludge. The Hypo Sludgewas replaced within the range of 10-40% by weight
of cement. In the present study, 5 different mixes of Hypo Sludgeconcretes are tested for parameters
like: compressive strength, flexural strength, modulus of elasticityand cost.
KEYWORDS : Hypo Sludge, Concrete, CBR, Rural Roads, Cost
INTRODUCTION
Transportation has serious impacts on the lives and welfare of the rural people. The
transportation system in a developing nation is one of its most essential assetsof its future
development. Since accessibility and mobility are involved in almost everything that developing
130

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308
countries are striving to accomplish, transport can be a key factor in the success or failure of the
entire development effort. In India, a special drive has been taken at the beginning of the new
millennium to improve the road and highway systems in the country. This will require huge
quantities of pavement construction materials. It has been observed that it would be economical to
use industrial wastes in the construction of low cost roads.Rural roads are vital for area development.
They serve as one of the key infrastructure in rural development. Agricultural productivity as well as
marketability depends to a large enormousness on road development. The agriculture based
industries are also predisposed by the provision of rural roads. Roads also have a socioeconomic
impression on the lives of rural populations. The studies in India and overseas have clearly
demonstrated the impact of accessibility on socioeconomic variables. The utilization of these waste
materials can be an economical and eco-friendly alternative in nearby areas for rural road
construction.
The problem of hypo sludge utilization is not confined to India alone but is being experienced
all over the world. However this problem is particularly acute in India. Where utilization of hypo
sludge has not received much attention. Hypo sludge properties make it very suitable for all
construction activities including roads, embankments and reclamation of low lying areas. Hypo
sludge based construction materials are becoming favourite of the construction industry, being
durable, economical, eco-friendly, easy to use and of consistent quality. Its effective use in concrete
as partial replacement of cement will lead to reduce its disposal problems and also to enhance
properties of concrete. In concrete roads, a part of cement can be replaced by hypo sludge to the
extent of 10% to 30% . This would result in lowering the cost of resultant concrete without any loss
of strength and with increased durability.
EXPERIMENTAL WORK
a) Chemical Properties of Ordinary Portland Cement (OPC) and Hypo sludge:
It is Chemical Properties of Ordinary Portland Cement (OPC) and Hypo sludgeas listed in Table 1:
TABLE 1
CHEMICAL PROPERTIES OF ORDINARY PORTLAND CEMENT (OPC) AND HYPO
SLUDGE
Chemical Properties

Ordinary Portland Cement
(OPC)

Hypo Sludge

Percent by mass
Silicon Dioxide (SiO2)

21.77%

5.28%

Calcium Oxide (CaO)

57.02%

47.84%

Magnesium Oxide (MgO)

2.71%

6.41%

Sulphur Trioxide (SO3)

2.41%

0.19%

Aluminium Oxide (Al2O3)

2.59%

0.09%

Ferric Oxide (Fe2O3)

0.65%

0.73%

Loss on Ignition

2.82%

38.26%

131

b) Characterization of cement
The most common cement used is an Ordinary Portland Cement (OPC). The Ordinary
Portland Cement of 53 grades is conforming to IS:8112-1989 is being used. Specific gravity,
consistency tests, setting time tests, compressive strengths, etc. are conducted on cement. The results
are tabulated in table 2.
TABLE 2
PROPERTIES OF ORDINARY PORTLAND CEMENT (OPC)
Sr.
No.

Physical properties of cement

Result

Requirements as per
IS:8112-1989

1

Specific gravity

3.15

3.10-3.15

2

Standard consistency (%)

28%

30-35

3

Initial setting time (hours, min)

35 min

30 minimum

4

Final setting time (hours, min)

178 min

600 maximum

5

Compressive strength- 7 days

38.49 N/mm2

43 N/mm2

6

Compressive strength- 28 days

52.31 N/mm2

53 N/mm2

c) Cement fly ash Mix Proportions
A mix M25 grade was designed as per IS 10262:2009 and the same was used to prepare the
test samples. The design mix proportion is shown in Table 3.
TABLE 3
CONCRETE DESIGN MIX PROPORTIONS
Concrete Design Mix Proportion
Sr.
No.

Concrete

(By Weight)

Mix
W/C
Ratio

Cement
Replacement
By

C

F. A.

C. A.

Hypo Sludge

1

A1

0.50

372.00

558.60

1251.90

-

2

C1

0.50

334.80

558.60

1251.90

37.20

3

C2

0.50

297.60

558.60

1251.90

74.40

4

C3

0.50

260.40

558.60

1251.90

111.60

5

C4

0.50

223.20

558.60

1251.90

148.80

W/C = Water/Cement , C= Cement, F. A. = Fine Aggregate, C. A. = Coarse Aggregate

132

EXPERIMENTAL RESULTS
Above 5 different concrete samples were used to find the important properties like
compressive strength, flexural strength and modulus of elasticity. To make the study from an
economic point of view cost of each mix was also worked out from the present market rates. The
results for these properties are given in Table 4, 5 & 6.
TABLE 4
AVERAGECOMPRESSIVE STRENGTH FOR CUBES OF (150X150X150) (N/mm²)AT 7, 14,
28 DAYS FOR M25

Mix

% Replacement
of Cement by
Hypo Sludge

7 Days

14 Days

28 Days

A1

0%

28.76

32.00

38.52

C1

10 %

29.24

33.63

39.70

C2

20 %

22.96

23.35

25.78

C3

30 %

20.92

22.96

23.26

C4

40 %

19.47

21.04

22.96

COMPRESSIVE STRENGHT OF
CONCRETE (N/mm2)

Concrete

Average Compressive Strength (N/mm²)

% REPLACEMENT OF CEMENT BY HYPO SLUDGE V/S
COMPRESSIVE STRENGTH OF CONCRETE (N/mm2)
SPECIMEN AT 7, 14, 28, FOR M25
45.00
40.00
35.00
30.00
25.00
20.00
15.00
10.00
5.00
0.00

39.70
38.52
32.00
28.76

33.63
29.24

25.78
23.35
22.96

22.96
23.26
20.92

22.96
21.04
19.47

7 DAYS
14 DAYS
28 DAYS

A1 (0%) C1 (10%)C2 (20%)C3 (30%)C4 (40%)
% REPLACEMENT OF CEMENT BY HYPO SLUDGE

Figure 1: % Replacement of Cementby Hypo Sludge v/s Compressive Strength of Concrete
(N/mm2) Specimen at 7, 14 and 28 Days for M25

133

TABLE 5
AVERAGE FLEXURAL STRENGTH FOR BEAMS OF(100X100X500)(N/mm²) AT 28 AND
90 DAYS FOR M25
Concrete
Mix

% Replacement of
Cement by

Average Flexural Strength (N/mm²)
28 Days

90 Days

A1

0%

4.71

5.26

C1

10 %

4.49

4.94

C2

20 %

2.93

3.31

C3

30 %

2.74

3.27

C4

40 %

2.62

2.93

FLEXURAL STRENGHT OF
CONCRETE (N/mm2)

Hypo Sludge

FLEXURAL STRENGTH OF CONCRETE (N/mm2) SPECIMEN
AT 28 DAYS AND 90 DAYS FOR M25
6

5.26

5
4

4.71

4.94
4.49

3.31

3.27

2.93

3
2

2.93

28 DAYS
90 DAYS

2.74

2.62

1
0
A1 (0%) C1 (10%) C2 (20%) C3 (30%) C4 (40%)

Figure2:% Replacement of Cement by Hypo Sludge v/s Flexural Strength of Concrete (N/mm2)
Specimen at 28 Days and 90 Days for M25

134

TABLE 6
MODULUS OF ELASTICITY (150X300 DIA.) (N/mm²) AT 28 DAYS FOR M25
% Replacement of
Cement by

Modulus of Elasticity (N/mm²)

Hypo Sludge

28 Days

A1

0%

24958

C1

10 %

27500

C2

20 %

23167

C3

30 %

17875

C4

40 %

15750

MODULUS OF ELASTICITY OF
CONCRETE (N/mm2)

Concrete Mix

MODULUS OF ELASTICITY OF CONCRETE (N/mm2)
SPECIMEN AT 28 DAYS FOR M25
30000
25000
20000

24958

27500
23167
28 DAYS

17875

15000

15750

10000
5000
0
A1 (0%) C1 (10%)C2 (20%)C3 (30%)C4 (40%)

Figure3:% Replacement of Cementby Hypo Sludge v/s Modulus of Elasticity of Concrete
(N/mm2) Specimen at 28 Days for M25
DESIGN OF A CEMENT CONCRETE PAVEMENT FOR RURAL ROAD
(IRC:SP:20-2002 / IRC:SP:62-2004)
A cement concrete pavement is to be designed for a Rural Road in Gujarat State having a
traffic volume of upto 500 vehicles per day consisting vehicles, like, agricultural tractors/trailers,
light goods vehicles, heavy trucks, buses, animal drawn vehicles, motorized two-wheels and cycles.
The soil has a soaked CBR value of 2%,4%,6%. For 30kN wheel load.

135

TABLE 7
DESIGN OF CC PAVEMENT FOR RURAL ROADS
Design Parameters: Sample C1 (6% CBR)
Traffic Volume (A)
= UP TO 500 cvpd (Assume)
Concrete Grade (fc)
= 25 N/mm2
Characteristic Compressive Cube Strength
= 39.70 N/mm2at 28 Days Actual
Compressive Strength
Flexural Strength ( ff )
= 4.49 N/mm2[44.9kg/cm2]
90 days Flexural strength
= 4.94 N/mm2[49.4 kg/cm2]
Soaked CBR Value (%)
= 0.06 (6%)
Modulus of Subgrade Reaction (k)
= 45 (N/mm2/mm)*10-3
Effective K Value (20% more)
= 54 (N/mm2/mm)*10-3
Elastic modulus of Concrete (Ec) (As per Actual
= 27,500 N/mm2
Calculation)
Poisson’s ratio (µ)
= 0.15
Coefficient of thermal coefficient of concrete (α)
= 0.00001/˚C
Design Wheel Load (P)
= 30 kN
Tyre pressure (q)
= 0.5 N/mm2 [5 kg/cm2]
Spacing of Contraction Joints (L)
= 3.75m [3750 mm]
Width of Slab (W)
= 3.75m [3750 mm]
Radius of load contact (assumed circular), (a)
=13.82 cm
Trial Thickness for Slab, h = 150mm.
Check for Temperature Stresses:
Assuming a contraction joint spacing of 3.75 m and 3.75m width.
1. Temperature Stress (σte):
The temperature differential ( t) for Gujarat for a slab thickness of 150mm
૝

The Radius of Relative Stiffness, l = ට

ࡱ ࢎ૜
૚૛ ሺ૚ି ૛ ሻ ࢑

is 12.5˚C.

Hence, l = 618.70 mm.
L/l = 3750 / 618.70= 6.1
W/l = 3750 / 618.70 = 6.1
Both values are same, if not then adopt greater one.
Bradbury’s Coefficient, C = 0.923 (from figure 1, pg. 9)
[Value of C can be ascertained directly from Bradbury’s chart against values of L/l and W/l]
ࡱ ࢻ ∆࢚
Temperature Stress in edge region, σte = ૛ ࡯
Hence, σte = 1.59 N/mm2.
2. Edge Load Stress (σle):
From Page: 12, Edge Load Stress,
Radius of equivalent distribution of pressure (b),
b = a (if (a/h >= 1.724);
(b) =√1.6 ܽଶ ൅ ݄ଶ - 0.675 h if (a/h < 1.724),
For slab thickness of 150mm; Edge Load Stress, σte, is 3.32 N/mm2 (3.32 MPa).
Total Stress = Edge Load Stress + Temperature Stress = 3.32 + 1.59 = 4.91 N/mm2, which is less
than the allowable flexural strength of 4.94 N/mm2.
Hence, assumed thickness of slab = 150mm, is OK. [As per Temperature Stress Criteria]
Check for Corner Stresses (σlc):
136

From Fig. 5 (Page 12), Corner Load Stress for wheel load of 30kN,
for k = 54.0(N/mm2/mm)*10-3 = 0.054 N/mm2/mm = 0.054 N/mm2/mm (Approx.) and slab thickness
of 150mm is 3.08 N/mm2 (3.08 MPa).
[Temperature Stress in the corner region is negligible, as the corners are relatively free to warp,
hence it can be ignored.]
Hence, σlc = 3.08 N/mm2, which is less than the allowable flexural strength of 4.94 N/mm2.
So, the slab thickness of 150mm is Safe.
The calculations presented above are sample calculations. Similar calculations are done using
various values of flexural strengths of concrete.
ECONOMIC ANALYSIS
TABLE- 8
COST OF MATERIALS
Sr. No.

Materials

Rate (Rs/Kg)

1

Cement (OPC 53 grade)

6.40

2

Hypo Sludge

0.60

3

Fine aggregate

0.60

Coarse aggregate

0.65

Grit

0.65

4
5

TABLE-9
MATERIALS FOR DESIGNED M25 CONCRETE
%
Reducti
on in
Cement
by Hypo
Sludge

Ceme
nt
[kg/m
3
]

A1

0%

479.00

C1

10 %

431.10

C2

20 %

C3
C4

Concret
eMix

Materials
Fine
Coarse
aggrega aggrega
te
te
[kg/m3]

718.22

485.75

718.22

383.20

485.75

718.22

30 %

335.30

485.75

718.22

40 %

287.40

485.75

718.22

Grit

% Change
in Cost

Hypo
Sludge

[m3]

0.0

4135.12

0

47.90

3857.30

(-) 6.71

95.80

3579.48

(-) 13.43

143.70

3301.66

(-) 20.15

191.60

3023.84

(-) 26.87

[kg/m
3
]
[kg/m3]

[kg/m3]

485.75

Total
Cost

137

478.8
1
478.8
1
478.8
1
478.8
1
478.8
1

TABLE 10
COST OF 1m X 1m SLAB (Rs.)
%
Reduction
in

Concret
e Mix

Cementby
Hypo
Sludge

2% CBR

4% CBR

Cost of
Slab
1m x
Thickne
1m Slab
ss (mm)
(Rs.)

Slab
Thickne
ss (mm)

6% CBR

1m x 1m
Slab (Rs.)

Slab
Thickness
(mm)

Cost of
1m x 1m
Slab
(Rs.)

Cost of

0%

190

785.67

150

620.27

150

620.27

C1

10 %

150

590.12

150

590.12

150

590.12

C2

20 %

190

680.10

190

680.10

190

680.10

C3

30 %

190

627.32

190

627.32

190

627.32

C4

40 %

200

605.17

200

605.17

200

605.17

SLAB THICKNESS (mm)

A1

% REPLACEMENT OF CEMENT BY HYPO SLUDGE V/S SLAB
THICKNESS (mm) AT 2%CBR, 4%CBR, 6% CBR [DESIGN
WHEEL LOAD= 30kN]
250
200
150

190 150
150

150
150

190
190
190

190
190
190

200
200
200
SLAB THICKNESS
(mm) AT 2% CBR

150
100

SLAB THICKNESS
(mm) AT 4% CBR

50

SLAB THICKNESS
(mm) AT 6% CBR

0
0%

10%

20%

30%

40%

Figure4:% Replacement of Cement by Hypo Sludge v/s Slab Thickness (mm) at 2%CBR,
4%CBR, 6% CBR [Design Wheel Load= 30kN]

138

COST OF 1m x 1m SLAB (Rs./Sq.mt)


% REPLACEMENT OF CEMENT BY HYPO SLUDGE V/S COST
OF 1m x 1m SLAB (Rs./Sq.mt) AT 2%CBR, 4%CBR, 6% CBR
[DESIGN WHEEL LOAD= 30kN]
900.00
785.67
800.00
680.10
627.32
590.12
700.00 620.27
680.10 627.32 605.17
590.12
605.17
600.00
680.10
620.27
627.32 605.17
500.00
590.12
400.00
300.00
200.00
100.00
0.00
0%
10%
20%
30%
40%

COST OF 1m x 1m
SLAB (Rs./Sq.mt) AT
2% CBR
COST OF 1m x 1m
SLAB (Rs./Sq.mt) AT
4% CBR
COST OF 1m x 1m
SLAB (Rs./Sq.mt) AT
6% CBR

Figure5:% Replacement of Cement by Hypo Sludge v/s Cost of 1m x 1m Slab (Rs./Sq.mt)at
2%CBR, 4%CBR, 6% CBR [Design Wheel Load= 30kN]

TABLE 11
RELATIVE COST OF SLAB

Concrete

%
Reduction
in

Mix

Cement

2% CBR

4% CBR

Cost of
1m x 1m
Slab
(Rs.)

Relative
Cost

Relative
Cost

(%)

Cost of
1m x
1m Slab
(Rs.)

6% CBR
Relative
Cost

(%)

Cost of
1m x
1m Slab
(Rs.)

(%)

A1

0%

785.67

100

620.27

100

620.27

100

C1

10 %

590.12

75.11

590.12

99.95

590.12

99.95

C2

20 %

680.10

86.57

680.10

109.64

680.10

109.64

C3

30 %

627.32

79.84

627.32

101.13

627.32

101.13

C4

40 %

605.17

77.02

605.17

97.56

605.17

97.56

139

RELATIVE COST SLAB (%)


RELATIVE COST SLAB (%) AT 2%CBR, 4%CBR, 6% CBR
[DESIGN WHEEL LOAD= 30kN]
120.00

100.00
100.00
100.00
100.00
80.00

99.95

109.64
109.64

99.95
86.57
75.11

60.00

101.13 97.56
101.13 97.56
79.84

77.02

40.00

RELATIVE COST SLAB
(%) AT 2% CBR
RELATIVE COST SLAB
(%) AT 4% CBR

20.00
0.00
0%

10%

20%

30%

40%

RELATIVE COST SLAB
(%) AT 6% CBR

Figure6:% Replacement of Cement by Hypo Sludge v/s Relative Cost Slab (%) at 2%CBR,
4%CBR, 6% CBR [Design Wheel Load= 30kN]

CONCLUSIONS
Based on limited experimental investigations concerning the compressive strength, flexural
strength and modulus of elasticity test of concrete (M25 Grade) for rigid pavement, the following
observations are made in the ray of the objectives of the study:
(a) For a CBR value of 2% and Wheel Load (P) of 30KN; Cost of rigid pavement decreases from Rs.
785.67 per sq.mt. to Rs. 605.17 per sq.mt. shown in figure-5.
(b) For a CBR value of 4%, 6% and Wheel Load (P) of 30KN; Cost of rigid pavement decreases
from Rs. 620.27 per sq.mt. to Rs. 605.17 per sq.mt. shown in figure-5.
(c) 10% replacement of cement by hypo sludge in concrete for rural road construction gives Slab
Thickness 150mm and low cost of rigid pavement i.e Rs. 590.12 per sq.mt. for a CBR value of
2%, 4%, 6% and Design Wheel Load (P) of 30kN.
(d) For a CBR value of 2% and Wheel Load (P) of 30KN; Relative Cost of Slab decreases from
100%. to Rs. 75.11%. at 10% Replacement Cement by Hypo Sludge shown in figure-6.
(e) For a CBR value of 4%, 6% and Wheel Load (P) of 30KN; Relative Cost of Slab decreases from
100%. to Rs. 99.95%. at 10% Replacement Cement by Hypo Sludge and Rs. 97.56%. at 40%
Replacement Cement by Hypo Sludge shown in figure-6.
(f) Use of hypo sludge in concrete can save the paper industry disposal costs and produce a ‘greener’
concrete for low cost rural roads.
(g) This research concludes that hypo sludgecan be an innovative Supplementary Cementitious
Material useful for development oflow cost rural roads.
(h) India should aggressively identify projects that can use large amounts of hypo sludge in road
construction so that harmonizing environment and ecological sustainability can be developed.
140

(i) Use of hypo sludge in road construction works will result in the less depletion of naturally
available stone metal, gravel, sand and soil; and will save cement, which is the costliest
ingredient will lead to reduction in construction cost. With adequate knowledge on the
performance of hypo sludge based road pavements, a huge demand can be expected from the
road sector to use hypo sludge for construction purposes, but judicious decisions are to be taken
by engineers, for development of low cost rural roads.
(j) This research study concludes that there is a great scope for eco-efficient utilization of hypo
sludge for sustainable development of Indian Road Network.
ACKNOWLEDGMENT
The Authors thankfully acknowledge to Dr. C. L. Patel, Chairman, Charutar Vidya Mandal,
Er.V.M.Patel, Hon.Jt. Secretary, Charutar Vidya Mandal, Prof. J. J. Bhavsar, Associate Professor and
PG Coordinator of Construction Engineering and Management, B.V.M. Engineering College, Mr.
Yatinbhai Desai, Jay Maharaj construction, Vallabh Vidyanagar, Gujarat, India for their motivations
and infrastructural support to carry out this research.
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[6] Gambhir, M. L. (2004), “Concrete Technology”, Tata Mc-Graw Hills.
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