Optimizing Concrete Strength with the Partial Replacement of Aggregate with Ceramic Tiles for Sustainable Construction

The coarse aggregate replacement in part with crushed waste ceramic tiles was explored at varying percentages, ranging from 10% to 50%. Simultaneously, granite powder and ceramic tile powder were employed as substitutes for fine aggregate, each at a 10% replacement rate alongside the ceramic coarse tiles. As a result of continuous innovations and advancements in the construction industry, there has been a significant rise in the utilization of natural aggregates. The generation of solid waste from construction demolitions has also witnessed a substantial increase. Research indicates that approximately from 20% to 30% of materials produced in manufacturing plants end up as waste. To address the constraints of natural aggregate resources and mitigate construction waste, there is a pressing need to repurpose this waste material. Concrete of M25 grade was designed and subjected to testing. Mix designs for different combinations were formulated by altering the percentages of crushed tiles and granite powder in both coarse and fine aggregates. Experiments were conducted on several concrete mixes using variable volumes of discarded shattered tiles and granite powder during seven, fourteen, and 28 days of curing. These examinations included “workability assessments, compressive strength tests, split tensile strength tests, and flexural strength tests”. The results show that larger replacement percentages of granite powder and crumbled tiles boost workability. Additionally, the strength of the concrete exhibited an improvement, particularly with a 30% replacement of ceramic coarse tile aggregate. Explore the use of advanced ceramic composites with improved mechanical properties and durability for enhanced performance in concrete. Investigate the potential use of recycled ceramics or explore novel production methods that reduce energy consumption and greenhouse gas emissions, aligning with sustainable construction practices.


Concrete
Concrete is an integrated material that is mostly made up of water, aggregate, and cement.Over time, the cement forms a robust matrix that binds the other ingredients together, resulting in a durable, rigid material with diverse applications such as in buildings and pavements.The utilization of concrete on a large scale was pioneered by the ancient Romans, with the technology playing a significant role in the construction of structures like the Colosseum in Rome. 8ncrete technology experienced a revival in the modern era, and today.Its versatility and strength make it a cornerstone in construction and infrastructure projects worldwide.

Historical Background
Concrete has a rich history dating back thousands of years, with its evolution closely tied to the development of civilizations.Here is a brief overview of the history and background of concrete:

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Egyptian and Mesopotamian Use: Early forms of concrete-like materials were used by ancient civilizations such as the Egyptians and Mesopotamians.They utilized a mixture of mud and straw to create early construction materials.• Roman Advancements: The Romans made significant advancements in concrete technology around 300 BC.They used a blend of volcanic ash, lime, and seawater to create a durable concrete-like substance that played a crucial role in the construction of structures like the Colosseum and the Pantheon.Ongoing research and advancements continue to shape the future of concrete technology, with a focus on sustainability, durability, and performance.

Properties of Concrete
Concrete is a versatile construction material known for its durability, strength, and adaptability.
The properties of concrete are influenced by its constituent materials, mix proportions, and curing conditions. 12Here are some key points:

Compressive Strength
• Definition: The ability of concrete to withstand axial loads or pressure.

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Significance: Compressive strength is a critical property, indicating how well concrete can resist crushing forces.

Tensile Strength
• Definition: The ability of concrete to resist tension forces.
• Significance: While concrete is weak in tension, the addition of reinforcement (as in reinforced concrete) enhances its tensile strength.

Flexural Strength
• Definition: The ability of concrete to resist bending or deformation.

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Significance: Important for elements subjected to bending, such as beams and slabs.

Workability
• Definition: The ease with which concrete flow.Understanding and optimizing these properties allow engineers and builders to tailor concrete mixes to meet specific project requirements, ensuring the durability and performance of structures over their service life.

Lightweight Concrete
Lightweight concrete, also known as lightweight aggregate concrete, is a type of concrete that incorporates lightweight aggregates or lightweight materials to achieve a lower density compared to traditional concrete. 10This type of concrete offers various benefits, including reduced structural load, improved insulation properties, and enhanced workability.Here are key aspects of lightweight concrete: It is important to select the appropriate lightweight aggregate and mix design based on the specific requirements of each project. 17

Applications Precast Elements
Its reduced weight makes it suitable for precast concrete elements, facilitating easier transportation and installation.

Fire Resistance Enhanced Fire Resistance
Lightweight concrete can offer improved fire resistance due to the insulating properties of certain lightweight aggregates.

Reduced Structural Load Advantageous in High-Rise Buildings
In high-rise structures, where the reduction of structural load is crucial, lightweight concrete can be a preferred choice.

Cost Considerations Material Costs
While lightweight aggregates may be more expensive than traditional aggregates, the overall cost-effectiveness of lightweight concrete depends on factors such as transportation and installation savings.

Construction waste in India
Construction waste in India poses significant environmental and sustainability challenges, reflecting the rapid urbanization and infrastructure development in the country.Here are key aspects related to construction waste in India 1,18 Waste Management Practices Challenges Effective construction waste management practices are often challenging to implement due to factors such as inadequate infrastructure, lack of awareness, and limited enforcement of regulations.

Recycling Initiatives
Some construction and demolition waste recycling initiatives have emerged in certain urban centers, but their scale and impact vary.

Environmental Impact Landfilling
Construction waste often ends up in landfills, contributing to land degradation and the loss of valuable space.

Air and Water Pollution
Improper disposal methods can result in air and water pollution, posing risks to ecosystems and public health.

Quantities of Waste Rapid Urbanization
India's ongoing urbanization and infrastructure development have led to an increase in construction activities, resulting in higher volumes of construction waste.

Building Demolition
The demolition of older structures, particularly in urban areas, contributes significantly to construction waste.
Tile Aggregate Concrete (Miličević, Štirmer, and Banjad Pečur 2016)"Tile aggregate concrete" typically refers to concrete that incorporates crushed tiles as a partial replacement for traditional coarse aggregates.This practice is a form of sustainable construction, as it utilizes recycled or waste materials, like discarded tiles, to reduce the environmental impact of construction activities.Here are key aspects related to tile aggregate concrete.
Tile aggregate concrete has both environmental and economic benefits.

Waste Reduction and Recycling Reuse of Waste Tiles
Incorporating crushed or recycled tiles as aggregates diverts waste materials from landfills, contributing to reduced environmental impact.

Resource Conservation
Recycling tiles conserves natural resources by decreasing the demand for traditional coarse aggregates.

Energy Savings Reduced Extraction
Using recycled tiles in concrete reduces the need for extracting new raw materials, resulting in energy savings and lower environmental disturbance associated with aggregate mining.

Lower Carbon Footprint Reduced Transportation Emissions
Utilizing locally sourced waste tiles reduces transportation distances for materials, leading to lower carbon emissions associated with material transportation.

Literature Review
To manufacture concrete from tile waste, replacement with 20 mm along the range, tile waste with "0%, 5%, 10%, 15%, 20%, and 25%," and fly ash was used to partially replace cement.Roof tile aggregate concrete achieves its average maximum compressive strength at a replacement rate of 25%. 4 When normal concrete is used to replace 25% of the roof tile aggregate replacement, the strength drops by 10% to 15%.In most cases, replacing tiles with concrete is sufficient for minor structures. 5e ceramic debris that is embraced is broken tiles.The workability and "compressive and split tensile strengths of fresh concrete are determined after three, seven, and twenty-eight days".According to the research, waste tile aggregate replacement should account for 5 to 30% of the total and can be used with typical mixes such as M 15 and M 20 . 7e research focuses on waste ceramic from the Spanish industry.

Materials and Properties Materials used
Tile aggregate concrete involves the use of crushed or recycled tiles as a substitute for traditional coarse aggregates (such as gravel or crushed stone) in the concrete mix.The choice of materials plays a crucial role in determining the properties and performance of tile aggregate concrete.Here are the key materials used in the production of tile aggregate concrete: In the process of incorporating ceramic tiles as partial replacements for traditional aggregates in concrete, various key components contribute to the formulation and performance of tile aggregate concrete.Crushed or recycled tiles serve as a sustainable alternative to conventional aggregates.Derived from damaged or unused tiles obtained during construction or demolition projects, these tiles are crushed or broken into smaller pieces for use in concrete.The versatility of this approach extends to various tile types, including ceramic tiles, porcelain tiles, and other common construction tiles. 14The binder in tile aggregate concrete is typically Portland cement.Playing a crucial role, cement binds the crushed or recycled tile aggregates together, facilitating the formation of a cohesive and hardened structure.This choice of binder is fundamental to the overall strength and durability of the resulting concrete.
Fine aggregates, such as sand, are introduced to the mix to enhance workability and fill voids between the tile aggregates.This addition not only contributes to the overall workability of the concrete but also ensures the cohesion of the mixture.
Water serves a pivotal role in the concrete-making process.It is employed to hydrate the cement, initiating the chemical reaction essential for forming the concrete matrix.Maintaining a proper watercement ratio is imperative, as it directly influences the desired strength and workability of the tile aggregate concrete.The thoughtful combination of these components showcases the adaptability and potential for innovation in the field of concrete construction using ceramic tile aggregates.

Workability
The quality of freshly mixed concrete that can be determined by measuring the material and the final product's look is workability.The following three techniques can be used to assess.

Slump-Cone Test
In order to determine the workability in a precise amount to create a homogenous mixture.

Compressive Strength for the Cube Strength
After preparing the concrete according to the specifications, create the specimen by placing it into the appropriate mould shape-a 15 cm by 15 cm by 15 cm cube-and properly compacting it.After 24 hours, place the specimen in water to cure.

Procedure of Split-Tensile
After preparing the concrete according to the specifications, create the specimen by placing it into the appropriate mould shape-a 15 cm by 15 cm by 15 cm cube-and properly compacting it.After 24 hours, place the specimen in water to cure.

Flexural Strength Test
After preparing the concrete according to the specifications, create the specimen by filling the mould in the appropriate shape-a 10x10x50 cm prism-and properly compacting it.After a day, place the specimen in water to cure.The perfect concrete is one that can be prepared, put, compacted, and moulded with ease and under all circumstances.The two approaches used to evaluate the workability in this chapter are as follows:

Test of Slump Cones
The test was run on recently mixed concrete that had not yet been moulded.At various times, a total of fourteen concrete mixes are created.

Compaction Factor Test
The same mix that underwent a slump cone test for workability was used for the compaction factor.

Split Tensile Strength
The split tensile strength achieved by testing the cylindrical specimen for M25 grade concrete to all the mixes specified for various replacements is as follows:

Flexural Test
The beam's strength increases in a linear fashion.
For the three grades, the strength variation is growing.The strength gain after seven days is nearly the same for all three grades, however after fourteen days, M25's strength grows more quickly.Although we are not comparing this concrete to regular concrete, the strength achieved is still acceptable.

Discussion
The partial replacement of traditional aggregates with ceramic tiles in concrete is an innovative approach gaining attention in the construction industry.Similar studies and research have explored the impact of incorporating alternative materials into concrete mixes to enhance properties such as strength, durability, and sustainability.
The study investigated the use of recycled ceramic aggregates in concrete production.The findings indicated that the incorporation of ceramic aggregates led to improved compressive strength compared to traditional concrete mixes.This aligns with our study's results, where the 28-day compressive strength of 56.6 MPa exceeded the minimum requirement of 53 MPa.9 The study delved into the environmental aspects of using recycled materials in concrete.Their life cycle assessment revealed a reduction in carbon footprint when recycled materials were employed.
Our study aligns with this sustainability focus, as the use of crushed or recycled ceramic tiles reflects a commitment to reducing waste and promoting ecofriendly construction practices. 3e study explored the influence of different binders on the performance of ceramic-based concrete.Their research highlighted the importance of the binder material in achieving optimal strength and durability.In our study, Portland cement was the chosen binder, showcasing its effectiveness in binding ceramic tile aggregates and contributing to the overall structural integrity. 13's essential to note that variations in ceramic tile properties, such as size, type, and source, can impact concrete performance.Smith's work emphasized the need for careful material selection, supporting our consideration of various tile types, including ceramic and porcelain, to ensure versatility and performance. 6

Summary and Conclusion
The study's main goal is to replace both coarse and fine particles in concrete to create a material that is significantly more stable and long-lasting than ordinary concrete.A total of 90 specimens are manufactured and evaluated in terms of strength.Mix designs have been completed for all material replacements.

Conclusions
As tile aggregate replenishment increases, so does concrete's workability.The inclusion of granite powder, which functions as an admixture because of its chemical makeup, increases the workability even further.
• When ceramic aggregate was added to concrete, its characteristics increased linearly up to a 30% replacement, after which they dropped linearly.

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In comparison to the other mixes, the concrete generated by the M3 mix exhibited superior "compressive strength, split tensile strength, and flexural strength".However, mixtures containing up to 50% ceramic coarse aggregate may be applied.

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When comparing the strengths of all mixtures, M3, M8, and M12 have the greatest, with 30% coarse aggregate replacement.The inclusion of granite powder improves both strength and workability.

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This achievement indicates a meticulous formulation that accelerates early strength for rapid construction phases while ensuring robust long-term performance, a critical innovation for efficient project timelines.

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This demonstrates an innovative commitment to performance-driven standards, where the mix is designed not just to meet specifications but to excel in strength characteristics, ensuring reliability in structural applications.

Fig. 19 :
Fig. 19: Flexural strength comparison M 25 grades for M 3 mix with conventional • Significance: Workability affects construction processes and the quality of the final product. 15

Table 1 : Cement -Properties
16a Minimum of 53Mpa BASIM et al., Mat.Sci.Res.India, Vol.20(3), pg.195-212 (2023)It's important to note that the specific types and proportions of these materials can vary based on the desired properties of the concrete, the application, and the availability of materials.The mix design is a critical aspect that needs to be carefully optimized to ensure the desired performance of tile aggregate concrete.Additionally, quality control measures are essential to maintain consistency in material properties and overall concrete performance.16