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Experimental Investigations on Fiber Reinforced Concrete with Lathe Fibers for

Sustainable Construction

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Experimental Investigations on Fiber Reinforced Concrete with Lathe Fibers

for Sustainable Construction

Dr. S. Thenmozhi1, Dr.V. Gowri2, Shilpi Sippi Bhuinyan3, Saurav Kar4,

Swapnil Balkrishna Gorade5
1
Associate Professor, Department of Civil Engineering, St. Joseph’s College of Engineering, OMR,
Chennai – 600119, India.
2
Assistant Professor, Department of Civil Engineering, St. Joseph’s College of Engineering, OMR,
Chennai – 600119, India.
3
Assistant Professor, Department of Civil Engineering, All India Shri Shivaji memorial Society’s,College
of Engineering, Pune – 411001, Maharashtra, India.
4
Assistant Professor, Department of Civil Engineering, Heritage Institute of Technology, Kolkata-700107,
West Bengal, India
5
Assistant Professor, Department of Civil Engineering, Pimpri Chinchwad College of Engineering, Sector
No –26, Nigdi Pradhikaran, Pune – 411044, Maharashtra, India.

Abstract: Because of advancements in steel, more steel waste is being created. industries that produce
things. The increase in these wastes has a negative impact on the environment, and it also necessitates a
lot of space to store them. rather than discarding Reusing these wastes in many businesses is a significant
achievement in terms of lowering environmental pollution and supplying inexpensive goods. This led to
the motivation for this study, which looked at the impact of lathe scrap fibers produced by Computer
Numerical Control (CNC) lathe machine tools on concrete performance. An experimental investigation
was carried out on a few test specimens in order to achieve this goal while taking varying fiber contents
into account. We measured the slump and workability of concrete made with various lathe trash fibers. In
order to determine the compressive strength and splitting tensile strength of the hardened concrete, 150
mm 150 mm 150 mm cubic specimens and cylindrical specimens with a diameter of 100 mm and a
height of 200 mm were examined. Lathe waste scrap was divided into four different volume fractions
(0%, 1%, 2%, and 3%). The compressive and splitting tensile strength of fiber-reinforced concrete
increases with the addition of lathe scrap, however after a certain value of steel fiber content, there is a
loss in workability. Furthermore, microstructural analysis was performed to observe the interaction
between lathe scrap fiber and concrete. Good adhesion was observed between the steel fiber and
cementitious concrete. According to the results obtained, waste lathe scrap fiber also worked as a good
crack arrestor. Lastly, practical empirical equations were developed to calculate the compressive strength
and splitting tensile strength of fiber-reinforced concrete produced with waste lathe scrap.
Keywords:Lathe waste; recycling; mechanical properties; concrete; Scanning Electron Microscope.

1.Introduction
Concrete is a common building material used in many structural applications. It is a composite material
made of cement, aggregates, water, and various additives. Due to some of the poor characteristics of
traditional concrete, such as limited ductility and low tensile strength, it is occasionally reinforced with
fibres or polymers in addition to reinforcement bars [1–13]. Although reinforcement bars help the
concrete's mechanical characteristics, they might not be enough to prevent cracks from growing too wide.

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One of the best methods to limit crack width is to employ fibres in concrete [14]. Fibres are crucial in
preventing the concrete drawbacks listed above in addition to crack arrestment [15]. To improve qualities
including ductility, crack resistance, tensile and flexural strength, a variety of fibre types can be added to
concrete mixtures [16,17]. Widely utilisedfibre types in cement-based materials include steel, glass,
polypropylene, polyvinyl alcohol, and carbon [2,18-22]. For instance, although steel fibres are typically
used in floor slabs, bridge decks, and impact resistance constructions, glass fibres are typically favoured
for the roofs of thin concrete shell structures, precast panels, etc. Additionally, high-performance
concrete's toughness and strength are improved at various levels with fibres such steel and polyvinyl
alcohol fibre [23]. When compared to conventional steel reinforcement, fibres such waste polypropylene
(PP) and metal are more accessible and less expensive [24].
Additionally, it might be more cost-effective to use waste polypropylene and steel scrap from nearby
lathes and workshops directly as fibres rather than recycling them. The cost of waste lathe scraps gathered
from workshops and other steel businesses is quite low, according to El-Sayed [25], Sezhiyan and
Rajkumar [26], and Vijayaku-mar et al. [27]. Industrial steel fibres or waste fibres produced by diverse
businesses are two options for the regularly utilised steel fibres. Concrete benefits from industrial steel
fibres by having stronger mechanical qualities. Industrial steel fibres are pricey, too, and their use raises
the cost of fiber-reinforced concrete [27]. Because of this, using reused or recycled waste fibres in
concrete is becoming more popular [28]. In addition to being environmentally beneficial, waste fibres
function nearly as well as conventional industrial fibres [29]. Hybrid fibres, which combine waste and
industrial fibres, are utilised in some areas to outperform plain concrete in terms of performance.
Recently, the amount of waste products produced by lathe and Computer Numerical Control (CNC)
equipment has increased, including used tyres and steel swarf. These waste products can be used in the
concrete mix as fibre or to replace the natural aggregate.
Utilising recycled materials can help create ecologically friendly concrete as well as reduce land
contamination [30]. The impact of steel waste produced by lathes and CNC machines on the
characteristics of concrete has been investigated in this study. Solid trash known as steel swarf is typically
produced during the cutting, milling, and turning processes in the steel manufacturing sectors. Given how
challenging it is to recycle steel swarf, its considerable production is a significant problem [31]. It was
favoured, nonetheless, as an alternative to aggregates in concrete [28,32-34]. Additionally, steel swarf,
which has qualities similar to those of steel fibre, can be used as an alternate reinforcement in concrete.
Waste from steel lathes has been found to significantly slow the spread of cracks. The impact of various
quantities of steel lathe waste on the performance of concrete was examined by Mansi et al. [37]. Their
findings [37] showed that the use of steel lathe waste enhanced the mechanical qualities of concrete, such
as compression strength. However, when the amount of lathe steel waste increased, the concrete's
workability decreased. An experimental investigation was undertaken by Bhavana and Rangarao [38] to
look at how different steel scrap amounts affected self-compacting and conventional concrete. Eight beam
specimens were taken into consideration for comparing the deformational behaviour of these various
concrete kinds.
The flexural behaviour of concrete made by waste lathe fibre was investigated by Akshaya et al. [39].
Lathe fibre inclusion has been demonstrated to boost concrete's flexural strength and reduce fracture
breadth. An experimental investigation was conducted by Vasudev and Vishnuram [40] to determine
whether turn steel scraps may be used as a fibre in concrete of the M40 and M60 grades. The ultimate
load capacities of the M40 grade concrete and the M60 concrete both increased by 22% and 17%,
respectively, with the addition of lathe fibre. Lathe scrap's impact on the workability and compressive
strength of M30 grade concrete was researched by Gawatre et al. [41]. Lathe scrap fibres have been found
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to increase compressive strength by up to 11%. With the addition of more fibre, the workability of the
concrete decreased. Similar to this, Nazir et al. [42] looked at how straight lathe steel fibre affected the
workability and mechanical characteristics of M20 concrete. Use of lathe steel fibre results in 15%
improvements in compression strength, 30% increases in split tensile strength, and 42% increases in
bending strength. According to Joy and Rajeev [43], M25 grade concrete's flexural strength was not
significantly affected by the low quantity of steel scrap fibre, but it did perform well in compressive
strength and splitting tensile strength.
Sawdust left over from lathes is a highly valuable recycling resource that may be used in a variety of
industrial processes. The economic added value of concrete manufacturing is increased by adding waste
turning sawdust directly to the concrete without putting it through a second industrial operation. Only the
separation and sizing of additives in concrete may require further processing. Thus, since the addition of
lathe sawdust to concrete will enhance the concrete's mechanical performance, it will have benefits such
allowing for the use of less steel in steel-reinforced concrete. Previous studies have demonstrated the
usefulness of lathe scrap fibres produced by lathe and CNC machines in civil engineering applications.
For a variety of applications, recycled steel fiber-reinforced concrete still needs to perform structurally
better [44–47]. This inspiration led to the performance of an experimental research to establish the ideal
quantity of lathe scrap fibres for the concrete mixture. First, varied amounts of fibres were taken into
consideration while examining the impact of lathe waste on slump value and workability on freshly-
poured concrete. The mechanical characteristics of fiber-reinforced concrete made with various lathe
scrap fibre contents were then examined in the concrete's cured stage. Compressive strength tests on cubic
and cylinder samples were carried out for this reason. In order to determine the splitting tensile strength,
cylindrical samples were used. Additionally, beam samples with diameters of 100 100 400 mm and a span
length of 300 mm underwent experimental tests. For the bending behaviour, test specimen load-
displacement curves were developed. The most optimal fibre dosage for fiber-reinforced concrete was
then optimised using lathe scrap steel fibre. To study how lathe scrap fibre and concrete interact,
microstructural investigation was also carried out. Additionally, useful empirical formulae for the
compression strength and splitting tensile strength of fiber-reinforced concrete were derived.
2. Experimental Work
CEM I 32.5 Portland Cement was chosen as the cement in this study. Table 1 lists this cement's
chemical characteristics. For fine and coarse aggregates, maximum aggregate sizes of 4 mm and 12 mm
were used. The ratio of aggregate to cement was chosen to be 0.22, and the ratio of water to cement was
chosen to be 0.60. The ratio of coarse aggregate (4–12 mm) to fine aggregate (0–4 mm) was almost
52% to 48%, respectively. The use of lathe waste sawdust allowed researchers to examine how the fibre
ratio affects concrete's compressive strength, split tensile strength, and bending performance. Figure 1a
depicts the steel wires that were used.The recycled steel wires that were produced by the lathe machine
had a helical shape. Before use, the recycled steel wires were cut into smaller pieces. In order to conduct
a fair comparison, efforts were made to achieve the same length and proportion. The percentage of the
lengths used for the lathe waste sawdust is shown in Figure 1b. Lathe waste typically measured
between 30 and 50 mm.

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Figure1.Recycledsteelwires

MixProcedure,WorkabilityandSlumpTest
All aggregates, cement, and water were first combined in the mixer for the mixing process. To guarantee
a uniform distribution of the turning sawdust in the concrete mixture and to avoid agglomeration, the
sawdust was then progressively strewn into the concrete. Aggregation was seen in the mixture
containing 3% lathe waste, despite the steel wires being added to the mixture gradually. After a 2% fibre
content ratio, workability significantly decreased. Working with the combination that contained 3%
lathe (CNC) waste was exceedingly challenging. Testing for slumps was also done. Figure 2 shows the
results of the slump tests.As can be observed, the slump values obtained using steel lathe waste chips are
consistently lower than those obtained using the reference specimen. Additionally, as the fibre ratio
rises, the slump value falls. The slump value of the reference sample was 19 cm, but as the fibre content
increased, it reduced to 17, 10, and 5 cm.
TestProcedure
To ascertain the mechanical characteristics of the concrete produced by the inclusion of machine tool
wastes, four different types of experiments were performed. These tests are the splitting tensile,
bending, cubic compressive strength, and cylindrical compressive strength, respectively. Here are a few
pictures of the examined samples: Figure 3a depicts the compressive strength in cubic units, Figure 3b
in cylindrical units, Figure 3c in split tensile, and Figure 3d in flexural tests. The results were averaged
across three samples from each experimental group. Both cube specimens measuring 150 x 150 x 150
mm and cylindrical specimens measuring 100 mm in diameter and 200 mm in height were used to
assess the compressive strength capabilities.Compressive strength and stress curves were produced with
the cylindrical sample testing, however only compressive strength data were acquired with the cubic
sample tests. Cylindrical samples were fractured at a loading rate of 5 kN/s, while cubic samples were
shattered at an average loading speed of 6 kN/s. Splitting tensile tests also made use of cylindrical test
specimens. Prisms measuring 100 100 400 mm in size, with an opening of 300 mm and a loading speed
of 0.5 mm/sn, were used for the bending tests. The test produced curves that demonstrated the bending
behaviour.

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Figure2.Slump test.
The mixes were combined, then put into moulds and vibrated for 30 seconds. After casting, the samples
were left at ambient temperature for 24 hours. The samples were then examined after 28 days of curing.

Figure3.Mechanical test setups

Experimental Results and Discussions

Compressive Strength

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The test results for the compressive strength of cubic specimens measuring 150 mm, 150×mm, and × 150
mm are shown in Figure 4. The graph in Figure 4b displays the compressive strength values for the
reference samples and the concrete produced by adding lathe steel waste, going from left to right. The
samples that contained waste material outperformed the reference samples in compressive strength,
which is a good sign. The graph in Figure 4b demonstrates the relationship between the ratio of turning
waste in concrete and the increase in compressive strength.

(a) (b)
Figure4.Results of compressive strength.
According to the findings of the cubic samples' compressive strength tests, the reference sample's
compressive strength was 29.5 MPa, but after adding 1%, 2%, or 3% of lathe waste chips, it was
closer to 32.8 MPa, 35.9 MPa, or 39.1 MPa (Figure 4a). Using an analytical solution, the results of
the compressive strength experimental strength test are also estimated. The results show that there is
a about 1% variation between the experimental results and the estimated results. This demonstrates
that by using the analytical approach instead of experimenting, future studies will be able to forecast
outcomes. In their investigation, Yazc et al. [48] discovered that by adding three different fibre
quantities of carbon, the strength of concrete rose by 4% to 19% 0.5, 1, and 1.5 percent, depending
on the volume of concrete. According to this study, adding lathe waste chips to concrete boosts its
compressive strength by 9% to 32%. As a result, waste turning sawdust offers superior compressive
strength, as demonstrated by the research done by Yazc et al. [48]. Table 2 displays the experimental
and analytically projected compressive strength values.

Table1.Experimental and predicted compressive strength.

Vf LatheWasteChi
ps
% Experime Predictio
nt n
0 29.5 29.5
1 32.8 32.5

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2 35.9 35.4
3 39.1 38.4

Compressivestrengthwithrecycledsteelwirescanbecomputedutilizedthefollowingproposedequations:
fLATHE,c=fc′1+0.10Vf(1)
where fLATHE,c is the compressive strength of concrete with lathe waste chips and fc′ is the
compressive strength of plain concrete.
The results of the cylindrical samples' compressive strength are shown in Figure 5. The specimens'
ability for elastic behaviour and maximum strength have increased, according to the data. Strength
and ductility increased proportionally to the waste volume ratio. According to Neves and Almeida's
[49] research, fibre additions can boost concrete's compressive strength by up to 1.5% while
slightly lowering its Young's modulus. However, it is clear from the graph that the addition of lathe
waste chips results in a very significant rise in Young's modulus.
The findings of Shah and Rangan's investigation showed that lathe waste greatly raised final pressure
while also improving the hardness and ductility of concrete [50]. To corroborate this, Tscheg et al.'s
study [51] found that, in comparison to synthetic macrofiber-reinforced concrete samples, steel fiber-
reinforced concrete samples generally showed a substantially larger rise in load-displacement curves. In
his research with fibre volume ratios of 0.25%, 0.375%, and 0.50%, Lee [52] concluded that as the fibre
volume ratio in concrete rises, so does the capacity to absorb energy. The graphs in Figure 5 also show
that as the fibre volume ratio rises, the energy absorption capacity increases at a faster pace.
SplittingTensileStrength
The split tensile strength test is used to determine the tensile strength of concrete. Figure 6 displays the
concrete's splitting tensile strength results after the addition of lathe waste chips. An analytical solution
verified the results that were obtained. The experimental method findings and analytical solution
estimations are compared in Figure 6a. The graph lines' overlap is evidence of the accuracy of the
experimental work. Figure 6b demonstrates that the split tensile strength test is improved by the use of
lathe waste.
The actual and anticipated split tensile strength values are presented in Table 3. The analytical
solution result was 2.82 MPa, while the experimental result for the reference sample was 2.83
MPa. The experimental result was 3.08 MPa with 1% addition of lathe waste chips, whereas the
analytical solution was 3.04 MPa. The experimental result was 3.29 MPa with a 2% contribution,
while the analytical solution result was 3.26 MPa. The findings were 3.53 MPa and 3.48 MPa in
the analytical solution with a 3% contribution. As the additive ratio of the lathe material increases,
the results in the table demonstrate a proportional increase in strength of 1.09%.

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(a) (b)

Figure5.Results of splitting tensile strength.

Flexural Performance
Figure 6 depicts the effects of adding lathe waste chips on the flexural strength of concrete. The
findings demonstrate that the addition of high lathe waste chips causes the flexural strength to rise
proportionately. When lathe waste chips are added, it can be seen that the flexural strength
improves when compared to the reference sample; a 1% addition results in a flexural strength of
3.8 kN. The value for a 2% increment was 4.5 kN. At a 3% increase, it offered a 5 kN bending
strength. While the displacement of the reference sample was roughly 2 mm, the addition of lathe
waste chip caused an impressive increase in the fibre ratio.Zhenng and Feldmen [53] studied
synthetic fiber-reinforced concrete and found that it had higher post-crack energy absorption
capacity and ductility, as well as significantly higher flexural fatigue strength and toughness limit
than plain concrete. Fiber-reinforced concretes may, however, also suffer from drawbacks such
clumping. With the lathe waste chips addition, no such issue was experienced. According to Xu et
al. [54], the best hook-end fibre increased the ultimate flexural strength of concrete produced by
adding straight, corrugated, and hook-end steel fibres by a maximum of 165.07%. Furthermore, it
is encouraging that this outcome was achieved using a lathe waste chips additive, which is not an
industrial good and does not.

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Figure6.Results offlexural strength.

The toughness of concrete is one of the most significant findings from this investigation. The
toughness values are shown in Figure 8. Generally speaking, brittle materials are less tough than
ductile materials. According to the data, it can be seen that adding sawdust to lathe waste chips
increases their toughness significantly. While the toughness of the reference sample is almost zero,
it can be seen that adding 1.2 kN, 2% 10 kN, and 3% lathe waste chips increases the toughness to
about 22 kN. In their experimental work using steel fibres with various geometries, Soluioti et al.
[55] found that hook-end fibres offer more resilience in concrete than fibres with wavy
geometry.Although the geometry of lathe waste chips was wavy and irregular, it still provided high
toughness. According to Yoo et al. [56], spun fibres have the maximum flexural strength, but at a
Vf of at least 1.5%, they are comparable to straight fibres in terms of strength and toughness. They
reported that poorer flexural strength and toughness were seen in hook fibre samples compared to
straight ones at a Vf greater than or equal to 1.0%. As a result, waste lathe chips are longer, and
their high addition to concrete greatly increases both strength and hardness, as shown by the graph
in Figure 7.
Figure7.Effects of fiber volume fraction on toughness.

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On sample pieces collected from concrete samples made from lathe waste chips, scanning electron
microscope (SEM) analysis was done. Figure 10 displays the primary observed findings of the SEM
investigation. Note that the concrete samples created using lathe waste chips are magnified 500 times in
the SEM examination photos. Figure 10a,b illustrates how adding lathe waste chips to the concrete's
microscopic porosity structure results in a strong connection. Additionally, the connection between the
fibres and the concrete results in an improvement in the ductility, toughness, and elastic resistance
capacity of the concrete. The lathe waste chips' waved texture is another crucial characteristic that
contributes to effective adherence.Lathe chips bond well with cement and aggregate, as seen in Figures
10c, d. The interface and gap states of the lathe waste chips are depicted in Figure 10e,f.

6.Conclusions and Summary

From an economic and environmental standpoint, waste materials are a major concern. The importance
of finding long-lasting answers to these issues is growing daily. One of the most prevalent waste types—
waste chips produced by lathe and CNC machines—was considered in this study, and its impact on the
performance of concrete was examined. In order to achieve this goal, the performance of waste chip-
produced concrete was evaluated in both the fresh and hardened phases. The workability and slump
characteristics of concrete made with various amounts of lathe scrap fibre were identified for fresh
concrete.Mechanical characteristics such as compressive strength, splitting tensile strength, and bending
strength were examined in the case of hardened concrete. Then, these characteristics were contrasted
with those of regular concrete. Additionally, microstructural study was done to see how lathe scrap fibre
and concrete interacted. The following are the main conclusions reached by this study:
In the slump test, it was shown that the slump and workability reduced as the amount of waste chips
rose. The slump value reduced by 11% with the addition of 1% waste chip, 47% with the addition of 2%
waste chip, and 74% with the addition of 3% waste chip. The results of the compressive tests revealed
that ordinary concrete had a compression strength of 29.5 MPa. The compression strength was improved
by 11%, 22%, and 33%, respectively, by the addition of 1%, 2%, and 3% lathe waste chips.
Additionally, it was discovered that the compressive strength increases proportionally as the quantity of
lathe waste chips increases.The splitting tensile strength of plain concrete was calculated to be 2.83
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MPa based on the findings of the split tensile strength test. With an increase in chip content,
concrete's split tensile strength rose. In comparison to plain concrete, the splitting tensile strength
of the concrete created with additives of 1%, 2%, and 3% chips rose by 9%, 16%, and 25%,
respectively.
Analytical equations for the compressive strength and split tensile strength were derived by using
curve fitting to the data collected from the test results. About 1% separate experimental values from
estimated values.Generalised strength equations were created by taking into account these proposed
expressions and earlier studies carried out by other academics. These suggested equations can be
used to determine the compressive strength and splitting tensile strength of fiber-reinforced
concrete made from leftover lathe scrap.

Given the increased workability and capacity, it is advised to use 2% lathe waste. Workability
issues can arise when more than 2% of the steel from the lathe is used. According to the findings of
the microstructural investigation, the waste steel lathe and cement-based concrete exhibit strong
adhesion, and the waste lathe scrap fibre is crucial in reducing the crack width.

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