BIBECHANA Vol. 21, No. 3, December 2024, 262-271 ISSN 2091-0762 (Print), 2382-5340 (Online) Journal homepage: http://nepjol.info/index.php/BIBECHANA Publisher:Dept. of Phys., Mahendra Morang A. M. Campus (Tribhuvan University)Biratnagar Enhancing high-performance concrete properties through partial replacement of fine aggregate with crusher run dust: A comprehensive experimental investigation Ishwor Thapa1, Nirmal Prasad Baral2, Krishna Raj Adhikari∗3 1Department of Civil Engineering, Sharda University, Greater Noida, India 2Department of Civil Engineering, IOE Pashchimanchal Campus, Pokhara, Nepal 3IOE Pashchimanchal Campus, Pokhara, Nepal ∗Corresponding author. Email: adhikarikrishna@wrc.com Abstract This experiment explores the potential of crusher-run dust, a waste product from crusher plants, to enhance high-performance concrete. It investigates the effects of the partial replace- ment of sand with crusher-run dust in various ratios. The replacement of fine aggregate with crusher run dust has been considered for M50 grade design mix concrete with 0%, 15%, 30%, 45%, and 60%, and the change in characteristics has been considered. A superplasticizer was utilized to keep the workability between 76mm and 85mm. In this experimental investigation, the mechanical properties of concrete, such as compressive strength, flexural strength, split tensile strength, and porosity, have been examined. The results show that the characteris- tics of concrete improved, with the best results observed when using a 30% concentration of crusher-run dust in concrete, suggesting potential benefits for the construction industry. Keywords Concrete; Crusher run dust; Fine Aggregate; Strength. Article information Manuscript received: March 30, 2024; Revised: July 14, 2024; Accepted: July 23, 2024 DOI https://doi.org/10.3126/bibechana.v21i3.65293 This work is licensed under the Creative Commons CC BY-NC License. https://creativecommons. org/licenses/by-nc/4.0/ 1 Introduction Building is its foundation, and concrete is its pri- mary component in civil engineering. The use of concrete in construction is generally acknowledged. As the fundamental component of today's techno- logically advanced construction industry, concrete plays a crucial role [1]. Every part of the world uses a significant amount of concrete. An essential com- ponent of concrete is fine aggregate. Because there is a rising need for concrete for the construction of infrastructure, there is a need for an alternative ma- terial that can meet the demand for fine aggregate 262 http://nepjol.info/index.php/BIBECHANA adhikarikrishna@wrc.com https://doi.org/10.3126/bibechana.v21i3.65293 https://creativecommons.org/licenses/by-nc/4.0/ https://creativecommons.org/licenses/by-nc/4.0/ Ishwor Thapa et al./ BIBECHANA 21 (2024) 262-271 263 in concrete [2]. Industries today produce a significant amount of garbage, posing health risks. Another critical is- sue with this garbage is disposal. This trash can be successfully used in the production of concrete [3]. Crusher-run dust, another waste product produced by crushing facilities, can be used successfully in concrete. Based on the previous study, it was dis- covered that crusher-run dust’s qualities are some- what comparable to those of fine aggregate and that it can be used in place of fine aggregate [4]. This study investigates the use of stone dust in place of natural sand in concrete. Tests on the phys- ical and mechanical characteristics of stone dust re- vealed enhanced compressive and flexural strengths with 40–60% replacement of stone dust, provid- ing a cost-effective substitute for depleting natural sand resources [5]. Due to excessive sand dredging, the building industry's reliance on concrete, which utilizes a lot of sand, has raised environmental is- sues. To replace sand in concrete, this study inves- tigates the use of crushed limestone dust, showing favorable or equivalent results in a range of me- chanical and physical qualities [6]. Cementitious composites are widely utilized yet with high CO2 emissions, looking for environmentally suitable sub- stitutes such as industrial wastes (Fly Ash, Silica Fume, GGBS). This study evaluates their durabil- ity, strength, and eco-friendliness while also substi- tuting granite quarry dust for river sand [7]. This study investigates using non-biodegradable quarry dust as a sustainable substitute for river sand in concrete. Over seven, fourteen, and twenty-eight days, tests with different replacement percentages (0%, 25%, 50%, and 75%) showed enhanced flexu- ral strength compared to conventional concrete [8]. Due to strong demand and limited availability in top nations, quarry dust is being investigated to replace river sand in M50-grade concrete. Accord- ing to research, adding quarry dust (0–100%) in place of river sand improves the compressive and tensile strength of concrete [9]. This study explores replacing river sand with Eco-Sand (a by-product of cement manufacturing) in concrete construction due to the increasing demand and cost of natural sand. Results suggest 18% as the optimal replace- ment percentage, aiming to reduce pollution and promote environmental friendliness [10]. The study investigates the use of quarry dust as a secondary by-product to improve mechanical qualities in self- compacting concrete (SCC). It looks into replac- ing different amounts of river sand (0%-100%) with quarry dust as well as the addition of alcofine and silica fume. Increased C-S-H concentration and de- creased pores are found via microstructure analysis. The strongest result is obtained when 100% of the QD is replaced. This method not only enhances the characteristics of concrete but also minimizes quarry waste [11]. Previous studies have shown that crusher-run dust, a waste product, can partially re- place sand in construction projects. In the concrete production industry, tackling the environmental and economic obstacles caused by the reduced availability of natural sand resources is essential. Recent research emphasizes the possibil- ity of utilizing industrial waste as an eco-friendly option. When stone dust is used to substitute 40-60% of natural sand in concrete, it can im- prove compressive and flexural strengths, providing a cost-effective option. Crushed limestone dust also shows favorable mechanical characteristics, making it a sustainable alternative. Additionally, studies on granite quarry dust and Eco-Sand have revealed substantial enhancements in the strength and dura- bility of concrete. Adding quarry dust into con- crete, especially in high-demand areas, enhances its compressive and tensile strengths. Moreover, us- ing crusher-run dust to partially replace sand has yielded positive outcomes, supporting the sector's efforts to promote sustainability and decrease CO2 emissions. This study aims to investigate these options further, concentrating on how they affect high-performance concrete characteristics. This study focuses on the large amounts of waste generated when extracting and treating rocks at crusher plants, specifically focusing on crusher-run dust. The study aims to examine the impact of sub- stituting some of the fine aggregates with crusher- run dust on the characteristics of high-performance concrete. This study seeks to identify the best replacement ratio that improves the mechanical characteristics of concrete, including compressive strength, flexural strength, split tensile strength, and porosity. By examining these elements, the research aims to offer an affordable and enduring substitute for natural sand, ultimately decreasing garbage and ecological footprint in the building sec- tor. 2 Research Significance The importance of this research lies in its investi- gation of utilizing crusher-run dust, a by-product of crusher plants, as a substitute for fine aggregate in high-performance concrete. This method solves the urgent problem of decreasing natural sand and the adverse environmental effects of sand extraction by presenting a sustainable and affordable alterna- tive material. The unique feature of the research is its thorough investigation of different substitu- tion rates of crusher run dust in M50 grade con- crete, offering a full comprehension of its poten- tial advantages. By using this waste material, the study not only encourages effective waste disposal but also aids in the progress of eco-friendly con- struction methods, helping to further sustainable Ishwor Thapa et al./ BIBECHANA 21 (2024) 262-271 264 solutions in civil engineering. 3 Materials 3.1 Cement and Aggregate Portland Pozzolana cement was utilized in this study. According to IS 1489-1:1991 [12], a bind- ing agent's specific gravity test revealed that it was 3.12. In this study, fine aggregates with a size smaller than 4.75mm were used that had been care- fully graded. The fine aggregate's specific gravity was determined to be 2.727, and its fineness mod- ulus was found to be 2.22. The coarse aggregate's maximum size was 20 mm, and its specific grav- ity was 2.71. Aggregate testing was done following IS 383:1970 [13] and IS 2386:1963. Tables 1 and 2 display Portland pozzolana cement's physical and chemical properties. Similarly, table 3 shows the properties of fine and coarse aggregate. Figure 1 illustrates the fine and coarse aggregate's particle size distribution (PSD) curve. Table 1: Physical properties of Portland Pozzolana cement Physical Requirements Units Value Specific Gravity - 3.12 Specific surface area m2/kg 295 Average particle size µm 27.6 Soundness mm 3.42 Initial Setting Time Min 146 Final Setting Time Min 281 28-Day Compression Strength 33Mpa 53 Mpa Table 2: Chemical properties of Portland Pozzolana cement Chemical Composition Test Value (%) Loss on Ignition 1.46 Insoluble Residue 7.23 MgO 4.76 SO3 3.11 Cl 0.03 CaO 53.7 SiO2 23.13 Al2O3 6.27 Fe2O3 1.89 K2O 0.95 Free Lime 1.92 Table 3: Properties of fine and coarse aggregate Properties Units Fine Aggregate Coarse Aggregate Specific Gravity - 2.59 2.72 Bulk Density (Loose) g/cm3 1.3 1.33 Bulk Density (Compacted) g/cm3 1.45 1.49 Fineness Modulus - 2.86 6.31 Crushing Strength - - 19.89% Water Absorption - 1.21% 0.44% Impact Value - - 16.70% 3.2 Crusher run dust his study used waste material called crusher-run dust from a crusher factory in Fewa Siltan Dam, Kaski, Nepal. Zone III crusher-run dust was em- ployed with a specific gravity and fineness modulus of 2.69 and 2.72. According to IS 383:1970, a sieve analysis was conducted [13]. Figure 2 below shows the PSD of crusher run dust. Ishwor Thapa et al./ BIBECHANA 21 (2024) 262-271 265 Figure 1: PSD of fine and coarse aggregate. Figure 2: PSD of crusher run dust. 3.3 Super plasticiser The concrete mix required the addition of a su- perplasticizer (MarkPlast-200F) to be usable. The amount of superplasticizer was chosen depending on how many slump trails were taken. Concrete slump was kept within a 76mm and 85mm range. A certain amount of superplasticizer was added to make it work with the weight of the cement. Table 4 presents the properties of the superplasticizer. Table 4: Properties of superplasticizer Properties Superplasticizer Name MarkPlast-200F Colour tone Dark Brown State Liquid Specific Gravity 1.06 Chemical Description Polycarboxylate ether 3.4 Concrete According to IS 10262:2019 [14], the concrete mix design for the M50 grade was created with a goal strength of 58.25 N/mm2 and a planned mix pro- portion of 1:1.36:2.59 with a constant water-to- cement ratio of 0.38. Table 5 lists alternative mix- ture proportions. Table 5: Mix Proportion for various concrete mixtures Mixture CM CD15 CD30 CD45 CD60 w/c ratio 0.38 0.38 0.38 0.38 0.38 Water (kg/m3) 170.60 170.60 170.60 170.60 170.60 Cement (kg/m3) 448.95 448.95 448.95 448.95 448.95 Fine Aggregate (kg/m3) 612 520.2 428.4 336.60 244.80 Coarse Aggregate (kg/m3) 1167.2 1167.2 1167.2 1167.2 1167.2 Crusher run Dust (CD) (kg/m3) 0 91.8 183.6 275.4 367.20 Super Plasticizer (% by weight of cement) 0.62% 0.60% 0.58% 0.52% 0.46% Ishwor Thapa et al./ BIBECHANA 21 (2024) 262-271 266 4 Experiment Work 4.1 Preparation and testing of specimens Crusher run dust, fine aggregate, coarse aggregate, and regular Portland Pozzolan cement were used to prepare the concrete. One of the six combi- nations was a control mix, while the remaining five contained various amounts of crusher run dust as a substitute for fine aggregate, including 15%, 30%, 45% and 60%. For casting, every component of the instrument was cleaned and carefully lubri- cated. Dimensional considerations were made, en- suring that no point or corner was overlooked as this could result in slurry leakage. Operations, includ- ing batching, mixing, and casting, were done metic- ulously. At first, aggregate weight was measured with a 0.5 g precision. Each component needed for each mix, including the cement, coarse aggregate (20 mm and 10 mm), fine aggregate, crusher run dust, superplasticizer, and water, was weighed sep- arately. The materials were first combined evenly in dry form, and then a mixture of superplasti- cizer and water was added. The initial mixture was made by adding between 50% and 70% water, and it was then properly mixed for 3 to 4 minutes in the mixer. The remaining water was combined with the super-plasticizer and thoroughly swirled before be- ing added to the already-made mixture in the mixer for 2 to 3 minutes. After the necessary amount of concrete was produced, it was ensured that it was compacted and that the concrete was properly poured into the moulds. Using a trowel, the top ex- terior of the filled mould was appropriately levelled. The prepared specimens were dried in the air for a whole day. Moulds were opened and the specimen was moved to a water tank for curing after the 24- hour casting period. After seven and twenty-eight days, the specimens were taken out of the tank. 21 samples for each mixture were created, including 6 cubes (150mm X 150mm X 150mm) for 7 and 28 days of compressive strength, 6 cylinders (300mm X 150mm) for split tensile strength at 7 and 28, 6 beams (100mm X 100mm X 500mm) for flexural strength at 7 and 28, and 3 cylinders (150mm X 100mm) for a porosity test at 28 days. 4.2 Mixture description One concrete combination served as the control, and the other five were made with varying amounts of crusher-run dust. Mixtures were given the labels CM, CD15, CD30, CD45and CD60 for identifica- tion purposes. For instance, CD30 defines a con- crete mix that includes crusher-run dust in place of 30% of the fine aggregate. The results of the high-performance concrete in- vestigation are greatly influenced by the experimen- tal setup and conditions when using crusher-run dust to partially replace fine aggregate. Charac- teristics of materials, such as Portland Pozzolana cement, fine aggregates, coarse aggregates, and crusher-run dust, have a direct impact on the per- formance of concrete. Differences in mix ratios can change strength, workability, and durability. The precise amount of superplasticizer is important to keep the workability in the desired slump range; variations can result in mixes that are either too rigid or too watery, risking the structural strength. Accurate blending and measuring guarantee even the spread of substances, averting any potential flaws and fluctuations in performance. Appropri- ate curing conditions, such as temperature and hu- midity, are crucial for strengthening and decreas- ing porosity. Furthermore, it is essential to ad- here to standardized testing conditions when as- sessing mechanical properties such as compressive strength, flexural strength, split tensile strength, and porosity to ensure accurate and dependable re- sults. Changes in the conditions may lead to no- table differences in the concrete's behaviour, com- plicating the determination of the effects of replac- ing fine aggregate with crusher-run dust. 5 Results and Discussion 5.1 Property of fresh concrete Slump cone equipment was used to measure the slump values of various mixes. The concrete was treated with a superplasticizer to keep the slump value between 75mm and 85mm. Because of the larger particle size of crusher run dust compared to fine aggregate (as shown in Figure 2), slump values increased as the fine aggregate replacement increased proportionately, and the need for a su- perplasticizer to maintain slump decreased as a re- sult. Details can be observed in Table 6, which shows that while the dust content in concrete in the crusher has increased, slump value has also in- creased, and superplasticizer content has reduced. Ishwor Thapa et al./ BIBECHANA 21 (2024) 262-271 267 Figure 3: Details of superplasticizer and slump measurement. Table 6: Details of superplasticizer and slump measurement Replacement Percentage of admixture Slump (mm) CM 0.62% of cement 76 CD15 0.60% of cement 79 CD30 0.58% of cement 80 CD45 0.52% of cement 82 CD60 0.46% of cement 85 5.2 Hardened properties of concrete 5.2.1 Compressive strength The specimens' compressive strength was evaluated following IS 516-1959 (IS 516, 1959) The difference in average compressive strength for several speci- mens is depicted in Figure 4. For all combinations, the compressive strength increased from 7 days to 28 days. Additionally, it should be mentioned that compressive strength for the mixture of CD15 and CD30 was found to be higher than CM. Well-graded crusher-run dust particles, which tend to fill pores on a bigger scale and take part in chemical reactions at each stage of the strength-gaining process, are to blame for this favorable alteration. However, com- pressive strength started to decline as the percent- age of fine aggregate substituted with crusher run dust reached 45%, i.e., for mix CD30, and compres- sive strength continued declining as the percentage of crusher run dust grew in the mix. 5.2.2 Split tensile strength The specimens' split tensile strength was evaluated following IS 5816-1999 (IS 5816, 1999). The aver- age split tensile strength change for several spec- imens is shown in Figure 5. For all blends, split tensile strength values increased from 7 days to 28 days. Additionally, split tensile strength values for mix CD15 and DC30 were found to be greater than CM. Due to the well-graded crusher-run dust par- ticles' propensity to fill larger pores and take part in chemical reactions at each stage of the strength- gaining process, this noticeable variance was seen. However, as the substitution of fine aggregate with crusher run dust reached 30%, i.e., for mix CD30, split tensile strength decreased and continued to do so as the amount of crusher run dust in the mix increased. 5.2.3 Flexural strength The specimens' flexural strength was evaluated fol- lowing IS 516-1959 (IS 516, 1959) The average flex- ural strength variation for various specimens is de- picted in Figure 6. For all combinations, flexural strength values increased from 7 days to 28 days. In addition to having higher compressive and split ten- sile strengths than CM, it was determined that the CD15 and CD30 mix have higher flexural strengths. Well-graded crusher-run dust particles, which have a propensity to fill pores on a bigger scale and take part in chemical reactions at each stage of the strength-gaining process, are to blame for this nec- essary alteration. However, the flexural strength of mix CD45 began to exhibit a fall when the amount Ishwor Thapa et al./ BIBECHANA 21 (2024) 262-271 268 of crusher run dust in the mix reached 45%, and it continued to decrease as the percentage of crusher run dust in the mix increased. 5.2.4 Porosity The specimens underwent a porosity test following ASTM C64 (2006) (ASTM C64, 2006). Following a 28-day curing period, the porosity of concrete cylin- ders was assessed. As shown in Figure 6, crusher run dust has better-graded particles than fine aggre- gate, which increases strength by lowering the pro- portion of invisible pores. The final data in Figure 7 show that porosity values decrease up to 40.27% with an increase in replacement percentage at mix CD30; the lowest porosity value is attained. Even though the porosity of the mixes CD15, CD45 and CD60 improved, the final porosity was still lower than the CM. Figure 4: Compressive strength and Percentage increase in compressive strength in comparison to the control mix. Figure 5: Split tensile strength and Percentage increase in split tensile strength in comparison to the control mix. Ishwor Thapa et al./ BIBECHANA 21 (2024) 262-271 269 Figure 6: Flexural strength and Percentage increase in flexural strength in comparison to the control mix. 5.2.5 Multiple Regression Analysis Multiple Linear Regression (MLR) analysis finds the line or curve best fitting a given data point set. Due to its simplicity, a direct relationship is fre- quently used to resolve many technical challenges. When modeling and analyzing correlations between two or more variables in the fields of engineering and science, regression analysis is a statistical tech- nique that is particularly helpful [15–19]. In this research work, an attempt is made to ap- ply the multiple linear regression models to predict the compression(C), split tensile (ST), and flexural strength (FS) of crusher run dust replaced concrete from slump value (SV) and porosity(P). The gen- eral representation of a probabilistic multiple linear regression model is presented in the following equa- tion from Equations (1-6). The provided multiple regression analysis equa- tions serve as valuable tools in engineering for predicting the compressive, tensile and flexural strength of concrete at both early and long-term stages. The 7-day Compression equation estimates the concrete's compressive strength after seven days, a critical parameter for assessing early perfor- mance. It considers input factors like slump value, which measures workability and porosity. On the other hand, the 28-Day Compression equation pre- dicts the concrete's compressive strength after 28 days, signifying its long-term durability and struc- tural integrity. Similarly, equations 3 to 6 for ST and FS follow the same pattern. These equations also incorporate the same input factors. These equations are instrumental for engineers in ensuring the quality and suitability of concrete mixes for spe- cific construction applications, aiding in structural design and performance assessment. The experiment results showed a notable en- hancement in the concrete's mechanical character- istics by substituting part of the fine aggregate with crusher-run dust. Higher percentages of crusher run dust resulted in increased compressive strength, split tensile strength, and flexural strength, with peak values attained at a 30% substitution level. In particular, the compressive strength experienced a 4.93% increase, split tensile strength saw a 12.70% increase and flexural strength showed a 6.11% in- crease in comparison to the control mix, which is confirmed by [20–24] The improvements result from the well-graded crusher-run dust particles that bet- ter fill the gaps and aid in the chemical reactions for hydration. After surpassing a 30% replacement level, the mechanical properties started to decrease, suggesting there was an ideal replacement thresh- old. Porosity examinations also confirmed these re- sults, revealing a reduction in porosity of up to 30% when using replacements, which was closely linked to strength enhancement [25]. The research find- ings strongly support the advantages of incorporat- ing crusher-run dust into concrete mixtures. This presents a sustainable and efficient substitute for natural sand that improves the strength and effec- tiveness of concrete buildings. Ishwor Thapa et al./ BIBECHANA 21 (2024) 262-271 270 Figure 7: Average porosity (%) after 28 days. 6 Conclusion The study presented a comprehensive analysis of the effects of curing time and fine aggregate sub- stitution with crusher-run dust on the mechanical properties of concrete. Firstly, the research demon- strated that the mechanical qualities of concrete exhibit significant enhancement as curing time in- creases from 7 to 28 days. This finding aligns with established concrete curing principles, highlighting the importance of allowing sufficient time for con- crete to attain its maximum strength. Moreover, the study identified a critical threshold at which a 30% substitution of fine aggregate with crusher run dust yielded maximum compressive strength, split tensile strength, and flexural strength, beyond which strength declined. This observation is vi- tal for optimizing concrete mix designs, as it em- phasizes the importance of balancing the use of crusher run dust to achieve the desired strength characteristics. Additionally, the slump cone test results indicated that increased crusher run dust led to improved workability, substantiating the po- tential benefits of the fine aggregate replacement. The noteworthy increase of 4.93% in compres- sive strength, 12.70% in split tensile strength, and 6.11% in flexural strength when 30% fine aggregate was substituted with crusher run dust further un- derscores the practical advantages of this substitu- tion in enhancing concrete's mechanical properties. In conclusion, this study provides valuable insights and engineering justifications for optimizing con- crete mix designs by considering both curing time and the percentage of crusher-run dust substitu- tion, ultimately leading to developing more durable and high-performance concrete structures. The results of this study have important con- sequences for both practical application and future research. Essentially, adding crusher-run dust as a substitute for fine aggregate in concrete mixes is a practical and efficient way to enhance concrete's mechanical characteristics like compressive, tensile, and flexural strengths. This replacement improves concrete performance and encourages the use of in- dustrial by-products, aiding in waste reduction and environmental sustainability within the construc- tion sector. These findings reveal new opportu- nities for investigating the ideal ratios of crusher- run dust in different concrete mixes and use in fu- ture studies. Additional research could examine the long-term durability of these modified concrete mixes and how they perform in various environmen- tal conditions. 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Introduction Research Significance Materials Cement and Aggregate Crusher run dust Super plasticiser Concrete Experiment Work Preparation and testing of specimens Mixture description Results and Discussion Property of fresh concrete Hardened properties of concrete Compressive strength Split tensile strength Flexural strength Porosity Multiple Regression Analysis Conclusion