Pengambilan pasir dari sungai secara berleluasa telah memberi kesan buruk terhadap alam sekitar. Kerajaan Malaysia telah mengharamkan pengambilan pasir sungai di beberapa tempat atas sebab ini.



Digging of sand from the riverbeds in access quantity is hazardous to environment.The Malaysian Government has banned the quarrying of sand from riverbed in many areas

Che Amat, Roshazita

Mohd Azizli, Khairun Azizi

Palanaiandy, Samayamutthirian

Rajeswari, M. Sri Raj

English

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1. Nama PenyelidikNama Penyelidik LainLaporan Akhir Projek Penyelidikan Jangka Pendek~V.:-\ ~BAHAGIAN PENYELIDlKAN & PEMBANGUNAN CANSELO ?/' ~... ./'<UNIVERSITI SAINS MALAYSIA "-1 () ':{k--.::J52 ! (/ & '/1.. - l~). { 1- .k /' .- \J/j.. all (,' ,'. L ..-- l' v/ l/ r )\ '/ (1' - <. " /-.. "'I ~ \Ji',. <;-:r~ I ,~()) \ ,-:.' "~1 / / 0()r. / '-. '. '(' )-) ,l vi!/' ·1., d, "'; /./, (C) ~"1' ·//v() /~ .......c9 / .......... V <'~" \....;-Prof. Madya Dr. Khairun Azizi Mohd Azizli'V i !;-TT; 9\En. Samayamutthirian all Palanaiandy ---~M. Sri Raj RajeswariRoshazita Che Amat2. Pusat Pengajian3. Tajuk Projek4. (a) Penemuan Projek / AbstrakBahasa MelayuPPK Bahan & Sumber MineralAdvanced Manufactured Sand for High StrengthConcretePengambilan pasir dari sungai secara berleluasa telah memberi kesan buruk terhadapalam sekitar. Kerajaan Malaysia telah mengharamkan pengambilan pasir sungai dibeberapa tempat atas sebab ini. Oleh itu, untuk menggantikan penggunaan aggregathalus (pasir) dalam pembuatan konkrit, satu bahan gentian lain perlu dicari. Dalam halini, batuan halus yang berbentuk kubik melepasi saiz 4.75mm digunakan untukmenggantikan pasir sungai. Walaubagaimanapun, partikel ini mempunyai sisi yang tajamdan tekstur permukaan yang kasar, dan penggunaannya dalam konkrit memerlukan bahantambah lain untuk meningkatkan keplastikan konkrit basah. Ini menunjukkan bahawamineralogi batuan juga memainkan peranan penting kepada kekuatan dan ciri-ciri laindalam konkrit.Dalam projek ini, penghasilan pasir buatan daripada sisa kuari telah dijalankan. Batuhancur adalah hasil daripada proses penghancuran batuan induk bersaiz besar. Beberapaciri seperti bentuk dan saiz partikel, dan tekstur permukaan batuan hancur tidak dapatdilihat pada batuan induk. Manakala sesetengah ciri-ciri lain boleh berubah ketika prosespenghancuran. Sesetengah mesin penghancur menghasilkan pasir hancur yangmempunyai partikel berkeping yang mana boleh menyebabkan kebolehkerjaan konkritmenurun dan memerlukan lebih nisbah air kepada simen. Kesan daripada air yangberlebihan dalam konkrit boleh mengurangkan kekuatan akhir konkrit dengan banyak.Bagi mengelakkan kekurangan ini terjadi, tekstur permukaan pasir perlu sekata dan sisiyang berbentuk bulat. Masalah ini dapat diatasi dengan menggunakan mesin penghancuryang boleh menghasilkan pasir buatan yang hamper sarna seperti pasir sungai. Pasirbuatan yang dihasilkan dalam kaj ian ini telah memberikan tekstur permukaan yang lebihbaik dan butiran yang berbentuk kubik.1Bahasa InggerisDigging of sand from the riverbeds in access quantity is hazardous to environment. TheMalaysian Government has banned the quarrying of sand from riverbed in many areas.For this reason, an alternative material must be found to replace the requirement of fineaggregate (sand) in concrete making. Fine cubical particles of stone below 4.75mm areused to replace the river sand. But as these particles have sharp edges and rough surfacetexture, its use in concrete requires some admixtures to increase the plasticity of the wetconcrete mortar. This shows that the mineralogy of the rock plays an important role in thestrength and other properties of the concrete.In this work, a study was carried out to produce manufactured fine aggregate from thequarry waste. Crushed sand is produced by crushing a large parent rock. Some propertiessuch as shape and size of patticle and surface texture of crushed sand are not seen in theparent rock. While other properties can change due to the crushing process. Suchmachines produced sand containing flaky particles, which decrease the workability andrequires more water to cement ratio. The effect of high water to cement ratio in concretereduces its ultimate strength to a substantial amount. To avoid these deficiencies, thesurface texture of the sand particles should be smooth and the edges should be rounded.These difficulties could be overcome by using crushing machines that can producemanufactured sand that is similar to river sand. The sand manufactured from this studyexhibited good surface texture and particles that were more cubical.(b) Senarai Kata Kunci Yang Digunakan Di Dalam AbstrakSand, fine aggregate, manufactured sand, Barmac crusherBahasa InggerisSandFine AggregateManufactured sandBarmac crusherCubicle particles5. Laporan ProjekMaterialBahasa MelayuPasirAgregat HalusPasir BuatanPenghancur BarmacPartikel berkubikThis research used quarry dust obtained from a quarry in Juru. The feed size of thesample was 100% of -IO.Omm + 6.3mm particles.Sample PreparationThe sample of quarry dust was dried before crushing. The Barmac rock-on- rock velticalshaft impact crusher was used in this study. Coning and quartering method was used forsampling to obtain representative samples for the testwork.2RESULTS AND DISCUSSIONGrading is regarded as the main feature of sand (both fine aggregate and manufacturedsand). Particle size analysis covers the determination of the particle size distribution offine aggregate by sieving. Figure 1 shows the results of size distribution curve for thetestwork. The size distribution of manufactured sand gave more fines compared to theriver/natural sand, especially in the size range -O.60mm to -O.075mm. The fines couldgive advantage to reduce cement in concrete.Particle Size AnalysisPARTICLE SIZE ANALYSIS, CASCADE A1009080e:C) 70·zinIJ)<t 60· ~---0..I-ZWu 50It:w0..W 40·>i=<t-J::> 30· _._---:;;::>u201000.01: II I, II0.1LOG SIEVE SIZE (mm)__ Natural Sand Quarry Dust R1 _." 'h. R2 ---*- R3 __ R4 -t- R5 i10Fig.1: Particle Size Distribution Graph.Uncompacted Void ContentThis test method determined the loose uncompacted void content of a sample of fineaggregate and manufactured sand. Void content provides an indication of the aggregate'sangularity, sphericity, and the surface texture compared with other fine aggregates testedin the same grading. But when void content is measured on as received fine aggregategrading, it can be an indicator of the effect of the fine aggregate on the workability of amixture.3Standard Graded Sample (Test Method A) was the test method used as a standard fineaggregate grading obtained by combining individual sieve size fractions from a typicalfine aggregate sieve analysis. Meanwhile, the individual size fractions (Test Method B)was the test method used for each of three fine aggregate size fractions; -2.36-1.18mm,-1.18+0.60mm and -.60+0.30mm respectively. In this method, each size was testedseparately. Both test Method A and Test Method B provide percent void contentdetermined under standardized conditions which depend on the particle shape and textureof a fine aggregate.UNCOMPACTED VIOD CONTENT (METHOD A)51 -50.5 -----------------------------------1~ 50I-Zl1JI-is 49.5oc6> 49-u.. I"ol1JCl~ 48.5--zl1J1i1~ 4847.5·47 -Cascade A Cascade BSAMPEL FRACTIONCascade CDQuarry Dust .R1 DR2 DR3 .R4 DR5 II Natural sand IFig.2: Uncompacted Void Content (Test Method A)Fig.2 shows that the quarry dust has the highest voids content (50.38%) compared to theproducts obtained from cascade A, cascade B and cascade C tests. Meanwhile, the naturalsand showed the lowest (48.63%) void content, except for the samples which was runduring cascade C with the rotor speed of R4 and R5. This shows that the Barmac crushercould produce better fine aggregate (manufactured sand) with lower voids content byincreasing the rotor speed. The changed in cascading flow also did not give muchdifference in the void content value.4UNCOMPACTED VOID CONTENT FOR CASCADE C (METHOD B)-- -- --- ------------------------~II4460 -.---58 -------.--- - ------~ 56·/--------------- ---------------1I-zWI-~ 54uc~ 52LL.oWCl;: 50zw~~ 4846(-2.36+1.18) (-1.18+0.60)SAMPLE FRACTION (mm)(-0.60+0.30)oQuarry Dust III R1 0 R2 0 R3 • R4 0 R5 Natural SandFig.3: Uncompacted void Content (Test Method B)The uncompacted void content using Test Method B showed a similar pattern for everysize fraction but not the values. From Fig.3, size fraction -2.36+1.18 mm gave the lowest,48.98% to 51.48% void content for all samples in this fraction. While the fraction of -0.60+0.30 mm gave the highest void content of 55.38% to 57.39%.An increase in void content by these procedures (test method A or test method B)indicates greater angularity, less sphrecity, or rougher surface texture. A decrease in voidcontent is associated with more rounded, spherical, or smooth-surface fine aggregate.Void content information from both test method would be useful as an indicator properysuch as: the mixing water demand of hydraulic cement concrete; flowability,pumpability, or workability factors when formulating grouts or mortars; or in bituminousconcrete, the effect of the fine aggregate; or the stability of the fine-aggregate portion of abase course aggregate.Surface Area, BETManufactured sand produced from the Barmac crusher had a higher surface area thanquarry dust. From Fig.4, it shows that the manufactured sand which was crushed at lowerrotor speed produced higher surface area than the feed (quarry dust).5SURFACE AREA (BET)(-2.36+1.18)(-1.18+0.60)(-0.60+0.30)i~ (-0.300+0.150)~1)5(-0.0150+0,075)(-0.075):\ ,. I ;I ! Ii i It'~::'.\''':~-1III I I II ,i i I'c·,0. Ii, ! I'.... ,0:""'-'1 .; II,iL c. ;, .,~ i ..,~ ,:"1 2 'i~i; "?l: 't~" ..;'!':.-i~4, , ....d', ., :"":~.""'" , ,\'«. " Io 0.1 0.2 Q3 OA Q5SAMPLE FRACTION (mm)[J Feed .20 Hz0.6 07 0.8Fig.4: Surface area analysis.Higher content of fines in the aggregate increased the fineness and total surface area ofaggregate particles, where surface area was measured in terms of specific surface, i.e. theratio of the total surface area of all the particles to their volume. Aggregates with higherspecific surface area require more water in the mixture to wet particle surfaces adequatelyand to maintain a specific workability. Obviously, increasing water content in the mixturewill adversely affect the quality of concrete.Morphological Study and Surface TextureDetermination of surface morphology of manufactured sand at various magnification wascarried out for feed and product samples. The effect of bond strength increases with thestrength of the concrete. While surface texture plays a significant role, and this will varyfrom rock type to rock type, the presence of any loose friable material on the surface willreduce bonding. This may be in the form of loose grains of the parent rock or coating ofother material such as silt or clay or adhering fines. The strong scrubbing and grindingactions that take place within the Barmac will certainly dislodge any of this loosematerial, thus ensuring a good bonding surface.The surface texture of the manufactured sand became smoother with increasing rotorspeed. Fig.6 shows that the surface texture of the quarry dust was rougher compared toFig.8, Fig.lO and Fig.12 which were samples of manufactured sand.6Fig5: Quarry Dust Particles(0.60mm)Fig7: Surface Texture of particles at 20 Hz(0.60mm particles)Fig6: Surface Texture of Quarry Dust(0.60mm)Fig8: Surface Texture of particles at 20Hz(0.60mm)Fig9: Surface Texture of particles at 40Hz Fig10: Surface Texture of particles at 40Hz(0.60mm) (0.60mm)7FigII: 60Hz (O.60mm particles) FigI2: Surface Texture of particles at 60Hz(O.60mm)The Barmac crusher was also capable to reshape the quarry dust particles upon producingmanufactured sand. There were less elongated and flaky particles in manufactured sandcompared to the feed material. From Fig.7, Fig.9 and Fig.II, the shape of themanufactured sand was more cubical compared to the quarry dust.CONCLUSIONSand can successfully be manufactured from rock, and can be used to alleviate theshortage of natural sand. Furthermore, the waste fines from crushing operations, ifprocessed correctly, can be converted into a premium product. The results from the testworkshowed that manufactured sand can possibly be used as a substitute for natural sand in concretethus protecting the exploitation of natural sand to safeguard the environment.REFERENCESAnon, (1997): "Enhancing-Manufactured sand ", Quarry Journal, 28-49Hammer.M.D (1990) "The vertical shaft rock on rock impacted crusher as a producer of qualityconstruction materials", Tidco International, New ZealandHudson.B (1997): "Shape Aids Product Performance, vol.5, No.3, p.56Tahie celik and Khaled Marar (1996): "Effects of Crushed Stone Dust on Some Properties ofConcrete", Cement and Concrete Research, vo1.26, No.7, p.1121-113086. Output dan Faedah Projek(a) PenerbitanKhairun Azizi, M. A., Sri Raj Rajeswari, M., Roshazita, C. A., Samayamutthirian, P.,Syed Fuad, S. H., Hashim, H., Megat Azmi, M. J. & Metso Minerals (2004). HighQuality Shape Aggregates (HIQSA) For Superior Performance In Concrete.CIRAS'04: Construction Industry Research & Development Achievement SeminarProceeding. Construction Industry Development Board, Kuala Lumpur: Malaysia.Sri Raj Rajeswari, M., Khairun Azizi, M. A., Roshazita, C. A., Samayamutthirian, P.,Syed Fuad, S. H., Hashim, H., Megat Azmi, M. 1. & Metso Minerals (2004). FromCrusher To Higher Quality Or Superior Concrete: An Innovative R&D Approach.Malaysia Quarry Conference & Exhibition (MQc) 2004. Kuala Lumpur: Malaysia.Roshazita Che Amat and Khairun Azizi M. Azizli (2002). Manufactured Sand As ASubstitute For Natural Sand In High Technology Concrete. MAMIP Post GraduateResearch Papers 2001/2002. Universiti Sains Malaysia. p.69-70.(b) Faedah-faedah Lain Seperti Perkembangan, Produk, Prospek Komersialisasidan Pendaftaran PatenManufactured sand produced from waste material such as quarry dust has beenproduced from this work.Manufactured sand can be used as a replacement for natural/river sand Inconcrete making.Initial testwork has shown that manufactured sand can produce compatiblestrength in concrete or in certain cases, higher strength in concrete.(c) Latihan Gunatenaga Manusia1. Pelajar MSc2. Pelajar-Prasiswazah7. Peralatan Yang Telah Dibeli: 1 orang: 3 orang telah menyiapkan tesis tahun akhirTiada. Menggunakan peralatan yang sedia ada di Pusat Pengajian dan yangdipinjamkan oleh Metso Minerals (New Zealand dan Australia).9

Advanced manufactured sand for high strength concrete.

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Advanced manufactured sand for high strength concrete.

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