Use of Stone Dust in the Design of High Performance Concrete

Abstract

This research evaluated the suitability of stone dust in the design and production of High Performance Concrete (HPC). HPC mix was designed, tested, costed and a comparison of concrete classes used in the market (Class 25, 30 and 35) done using Cost Benefit Analysis (CBA). The cost benefit was analyzed using Internal Rate of Return (IRR) and Net Present Value (NPV). Laboratory tests established the properties concrete obtained from the design mix. Compressive strength, slump, and modulus of elasticity were tested and analyzed. Structural analysis using BS 8110 was done for a 10 storey office building to establish the structural member sizes. Members obtained from concrete Classes 25, 30, 35 and the new compressive strengths from HPC (Class 80) were obtained and compared. Analysis was done for structural members’ sizes and area freed as a result of designing with HPC as well as the steel reinforcement used. To justify the initial cost of HPC if adopted, the Cost Benefit Analysis (CBA) was used to estimate increased costs versus income resulting from increased let table space created. The minimum class of concrete used in design was limited to Class 25 N/mm2. The research shows that it is possible to manufacture high strength concrete using locally available stone dust. The stone dust sampled from Mlolongo quarries achieved a characteristic strength of 86.7 N/mm2 at a water cement ratio of 0.32. With the results structural analysis of a 10 storey office structures with columns spaced at 8 meters center to center was designed using the four classes and results compared. There was a reduction of columns from 1.2 m wide to 0.65 m wide (over 45%) when concrete class changes from Class 25 to Class 80 creating over 3% of the total space area per floor. Cost benefit analysis using Net Present Value (NPV) and Internal Rate of Return (IRR) presented business case for the use of HPC. With Class 80, the IRR was at 3% and NPV being 8% of the total initial investment. The steel reinforcement increased by 8.64% using Class 30, 11.68% using Class 35 and reduced by 8.37% at Class 80. Further analysis needs to be done to understand the trend of steel reinforcement keeping all the member sizes the same. In this study the member sizes were optimized based on the steel reinforcement and serviceability. This paper provides useful information to design Engineers and Architects and inform future design of multi storey structures.