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CALCIUM CARBIDE WASTE (CCW) AS CEMENT REPLACEMENT IN CONCRETE
Kenneth Kho Wee Hong
Bachelor ofEngineering with HonoursTP (Civil Engineering) 770 145 2010 2010
UNIVERSITI MALA YSL SAI~A K
nORA~r Pl-l (~ FS HAN STATUS TESIS
CALCHI 1 C RBWE WASTE ( CW) AS CFIIE T _____ __---RC--PoL-A=CFl lrT I CO CRETE
SCS I ICNGAJIAL 2006 - 2010
____ K _-IFTH KHO WEf HONG_____--F ~ c
(H URUF BESAT)
mcnglku mcm bltlui-an ICS I ~ 11)1 dbil1pnn dl PUStt KJidnul l 10k umal ademlk t I Il ~ nrlli 1) l~~II
Sor(1wnk dCIl ~im synrcl l-sYilnll1 tgtg llll ilJll scpcn i btniut
I Tes ls HIIJuh 1 1~ k ll ll l jk Ui li vcr- f i Ma1~ siu S~lra a 2 Pusal Khid nml l llklLln1a AkadcllI ik Ul1i (middot ~1I1 MaLtYil u S~nLv lk tl i~lnMJ1I1 numhmu ~dtl1an IJ1l1ul
Lli lurm rCllgaliall sahaIt 3 l- k lJ dHlal re ndig ll JIl UIILtik 11111Ib 111 II I1 1-lt1n Pmgktl111 l)aLa KrmdlJllll1 re Il1Ilkn
j USl l Khi I1l l1 I~l klum jt ALILkrn lk Unic111 iVLILl y~ llt1 lt rawn k d ih~J1 rl[111 rTltrnhllill jllnLtl l c-J3
lilt -1lMgll blhdl1 JCIt UJ bullbull tJ1l IIlHHltl 1~tJt Ui i IKngl jliJillinggi S SILl t ~lfl d1kan ( ) l1i hotltlk ynng hrKel1ilUl
o SULIT (Mtn inndungi JnJk lumal yll1g hadlqah h~d amalH al1U lell1 ntingiJ Malaysia gtCpcrtl yang tC l mnl lllh di lk11Jn h rA RAIlSA RAStvll 19 72)
(MCl1golldungf 1lllkhlll1n rf R I IAD y lIl~ ldlh dltc nlul~11 nkh m gmgtiI j b ld l J J millll ]Jell ycl ld iLtn Lli l)lanJ111 J
U -llflA K TERIIAD
(TANDAI ANG IEMII IS) ITADATANGA PI N YI LL
A1lIn 1I h1ID_ I I SOCK AI IiGAM A T -J lIE
SA RA K DR DHSYf n I r___oClIlf G r ( f 1111lt1 h l1~ Ilial
l ~ 11 2H l n lllkh
CTA TAN T~I~ dl m1 ~$u kll n z~bq~11 Ie j$ hClg IjJh O~ lo r r~I IsJ[ah S~l rjlItJ liI11 SltIIJ3nJ lud J Ia kOSI$ tn i SUI I r lt1111 T E R1-IAD ~tla lampirkw sunJt darirXHI rihnk ~(rtlla~lrgmb I Io 1 bcrktWltlIl ltit njJ Il nenltllk111 sdd ji sClh dar hrnpoh le l Inl Plrlu ukcld]l l1 (hatdJ
SULlT dII r ERllAI)
T he Fo ll owing Final Year Project
Tit le Ca lc ium Carbide Waste (CCW) as Cement Replacement in Concrete
Author Kenneth Kho Wee Ho ng
Ma tri c number J6430
has been read and ce rtified by
I~gtIf~ Dr De lsye Teo Ching Lee Date
(S uperv iso r)
CALCIUM CARBIDE WASTE (CCW) AS CEMENT
REPLACEMENT IN CONCRETE
KENNETH KHO WEE HONG
This project is submitted in partial fulfillment of
the requirements for the Degree of Bachelor of Engineering with
Honours (Civil Engineering) 2010
To my be loved fami ly and friend s
11
ACKNOWLEDGEMENTS
I wo uld like to express my app reciation to my superviso r Dr Delsye Teo
Ching Lee for her constant supervision he lp and adv ice throughout th is research
Without her guidance the project repo rt would not have been co mpleted smoothly
A specia l thanks fo r my fam ily for the ir continuous morale and fin ancial
support during the peri od of the project My sincere appreciation also goes to all my
fr iends that helped me duri ng the peri od of laboratory works as it was impossible to
carry out such a hugc amount of work alone without de laying too much time
My gratitude also goes to Me Jimmy Tan from Eastern Oxygen Sun Bhd
for hi s full cooperation and help when asked for the supplies of Calcium Carbide
Waste for this pro ject No t fo rgo tten is also the concrcte lab tec hn ician for hi s help in
the co ncrete lab
Last but not least a si ncere thank s goes to all others who contribu ted direc tly
and indirectl y to help enable thi s project to be completed success ful ly
III
ABSTRACT
The most commonly used material in a construction is concrete and the most
importan t materia l in conc rete is cemen t However the product ion of cement
produces a huge amo unt of CO2 which is not benefi cia l fo r the environment and
comes with a high price lorence there are many researches conducted to search for
a lternative materials to replace cement in order to reduce th e cost and al so to keep up
wi th the dema nd s Calci um Carbide Waste (CCW) is one type of industrial waste
w hich can be used as partial replacement [or cement Thi s study focuses nn the
compress ive strength spl it tensile strength and fl ex ural strength of the concrete
containing eli tTerent percentages of CCW The cement is replaced with 5 10 15
and 20 of CC W The performance of the concrete containing CCW will be
compared to a con trol mi x that does not contain any CCW The result s show tha t
CC W can bc used as a type of cemen t replaceme nt material The early strengths of
some spec imens are comparable to the contro l specime n It was IO Li lld that the 5degmiddot
CCW replacement is simi lar and the nearest to the control spee ill1en in terms of
strength As thc amOLlnt of CCW increases the compress ive strength split tens ile
strength and tle xural strength decreases
IV
ABSTRAK
Bahan ya ng paling biasa digunakan dal am kelja pcm bangunan adalah konkrit
liltm bahan yang paling penting dal am konkrit adalah simen Tetapi pengeluaran
simen menghas il ka n banyak CO2 yang tidak berfaedah kepada persekitaran dan
datang dengan barga yang tinggi Justenl terdapat banyak kerja penyelidikan yang
dibuat untuk menca ri bahall lain bagi ll1 ellggantikan simen untuk mengurangkan
harga kos dan juga untuk dapat mengeka lkan dengan kehendak Sisa Calcium
Carb ide (CCW) adalah sejenis bahan buangan industry yang boleh digunakan untuk
mengantikan simen Kaj ian ini alean foku s terhadap kekuatan mampatall kekualan
tegangan pecah dan kekuatan lenturan rusuk bagi konkrit yang mellgandungi
pera tusan CCW yang be rJ a illan S imen diganti ka n dengan 5 l O 15 dan 20
CCW Prcstasi kOllkrit ya ng mengandungi CCW akan dibandin gka n dengan konkrit
kontrol yang tidak mengandllngi CCW Kep utusan menllnju kknn bahawa CCW
bolch digllnakan se bagai bahan gantian simen Kekuatan awa l sbahagian spesimcn
adalah sebanding clengan spesimen ko ntrol Didapati bahawa ganlian 5 CCW
ada lah serupa dan paling hampir dengan spesimen kantra l clari scgi kckuatan
Apab ila kuantiti CCW meningkat kekll atan mampatan keku atan tcgangan pecah
cl an ke kllMan lent man rus uk menurun
v
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
UNIVERSITI MALA YSL SAI~A K
nORA~r Pl-l (~ FS HAN STATUS TESIS
CALCHI 1 C RBWE WASTE ( CW) AS CFIIE T _____ __---RC--PoL-A=CFl lrT I CO CRETE
SCS I ICNGAJIAL 2006 - 2010
____ K _-IFTH KHO WEf HONG_____--F ~ c
(H URUF BESAT)
mcnglku mcm bltlui-an ICS I ~ 11)1 dbil1pnn dl PUStt KJidnul l 10k umal ademlk t I Il ~ nrlli 1) l~~II
Sor(1wnk dCIl ~im synrcl l-sYilnll1 tgtg llll ilJll scpcn i btniut
I Tes ls HIIJuh 1 1~ k ll ll l jk Ui li vcr- f i Ma1~ siu S~lra a 2 Pusal Khid nml l llklLln1a AkadcllI ik Ul1i (middot ~1I1 MaLtYil u S~nLv lk tl i~lnMJ1I1 numhmu ~dtl1an IJ1l1ul
Lli lurm rCllgaliall sahaIt 3 l- k lJ dHlal re ndig ll JIl UIILtik 11111Ib 111 II I1 1-lt1n Pmgktl111 l)aLa KrmdlJllll1 re Il1Ilkn
j USl l Khi I1l l1 I~l klum jt ALILkrn lk Unic111 iVLILl y~ llt1 lt rawn k d ih~J1 rl[111 rTltrnhllill jllnLtl l c-J3
lilt -1lMgll blhdl1 JCIt UJ bullbull tJ1l IIlHHltl 1~tJt Ui i IKngl jliJillinggi S SILl t ~lfl d1kan ( ) l1i hotltlk ynng hrKel1ilUl
o SULIT (Mtn inndungi JnJk lumal yll1g hadlqah h~d amalH al1U lell1 ntingiJ Malaysia gtCpcrtl yang tC l mnl lllh di lk11Jn h rA RAIlSA RAStvll 19 72)
(MCl1golldungf 1lllkhlll1n rf R I IAD y lIl~ ldlh dltc nlul~11 nkh m gmgtiI j b ld l J J millll ]Jell ycl ld iLtn Lli l)lanJ111 J
U -llflA K TERIIAD
(TANDAI ANG IEMII IS) ITADATANGA PI N YI LL
A1lIn 1I h1ID_ I I SOCK AI IiGAM A T -J lIE
SA RA K DR DHSYf n I r___oClIlf G r ( f 1111lt1 h l1~ Ilial
l ~ 11 2H l n lllkh
CTA TAN T~I~ dl m1 ~$u kll n z~bq~11 Ie j$ hClg IjJh O~ lo r r~I IsJ[ah S~l rjlItJ liI11 SltIIJ3nJ lud J Ia kOSI$ tn i SUI I r lt1111 T E R1-IAD ~tla lampirkw sunJt darirXHI rihnk ~(rtlla~lrgmb I Io 1 bcrktWltlIl ltit njJ Il nenltllk111 sdd ji sClh dar hrnpoh le l Inl Plrlu ukcld]l l1 (hatdJ
SULlT dII r ERllAI)
T he Fo ll owing Final Year Project
Tit le Ca lc ium Carbide Waste (CCW) as Cement Replacement in Concrete
Author Kenneth Kho Wee Ho ng
Ma tri c number J6430
has been read and ce rtified by
I~gtIf~ Dr De lsye Teo Ching Lee Date
(S uperv iso r)
CALCIUM CARBIDE WASTE (CCW) AS CEMENT
REPLACEMENT IN CONCRETE
KENNETH KHO WEE HONG
This project is submitted in partial fulfillment of
the requirements for the Degree of Bachelor of Engineering with
Honours (Civil Engineering) 2010
To my be loved fami ly and friend s
11
ACKNOWLEDGEMENTS
I wo uld like to express my app reciation to my superviso r Dr Delsye Teo
Ching Lee for her constant supervision he lp and adv ice throughout th is research
Without her guidance the project repo rt would not have been co mpleted smoothly
A specia l thanks fo r my fam ily for the ir continuous morale and fin ancial
support during the peri od of the project My sincere appreciation also goes to all my
fr iends that helped me duri ng the peri od of laboratory works as it was impossible to
carry out such a hugc amount of work alone without de laying too much time
My gratitude also goes to Me Jimmy Tan from Eastern Oxygen Sun Bhd
for hi s full cooperation and help when asked for the supplies of Calcium Carbide
Waste for this pro ject No t fo rgo tten is also the concrcte lab tec hn ician for hi s help in
the co ncrete lab
Last but not least a si ncere thank s goes to all others who contribu ted direc tly
and indirectl y to help enable thi s project to be completed success ful ly
III
ABSTRACT
The most commonly used material in a construction is concrete and the most
importan t materia l in conc rete is cemen t However the product ion of cement
produces a huge amo unt of CO2 which is not benefi cia l fo r the environment and
comes with a high price lorence there are many researches conducted to search for
a lternative materials to replace cement in order to reduce th e cost and al so to keep up
wi th the dema nd s Calci um Carbide Waste (CCW) is one type of industrial waste
w hich can be used as partial replacement [or cement Thi s study focuses nn the
compress ive strength spl it tensile strength and fl ex ural strength of the concrete
containing eli tTerent percentages of CCW The cement is replaced with 5 10 15
and 20 of CC W The performance of the concrete containing CCW will be
compared to a con trol mi x that does not contain any CCW The result s show tha t
CC W can bc used as a type of cemen t replaceme nt material The early strengths of
some spec imens are comparable to the contro l specime n It was IO Li lld that the 5degmiddot
CCW replacement is simi lar and the nearest to the control spee ill1en in terms of
strength As thc amOLlnt of CCW increases the compress ive strength split tens ile
strength and tle xural strength decreases
IV
ABSTRAK
Bahan ya ng paling biasa digunakan dal am kelja pcm bangunan adalah konkrit
liltm bahan yang paling penting dal am konkrit adalah simen Tetapi pengeluaran
simen menghas il ka n banyak CO2 yang tidak berfaedah kepada persekitaran dan
datang dengan barga yang tinggi Justenl terdapat banyak kerja penyelidikan yang
dibuat untuk menca ri bahall lain bagi ll1 ellggantikan simen untuk mengurangkan
harga kos dan juga untuk dapat mengeka lkan dengan kehendak Sisa Calcium
Carb ide (CCW) adalah sejenis bahan buangan industry yang boleh digunakan untuk
mengantikan simen Kaj ian ini alean foku s terhadap kekuatan mampatall kekualan
tegangan pecah dan kekuatan lenturan rusuk bagi konkrit yang mellgandungi
pera tusan CCW yang be rJ a illan S imen diganti ka n dengan 5 l O 15 dan 20
CCW Prcstasi kOllkrit ya ng mengandungi CCW akan dibandin gka n dengan konkrit
kontrol yang tidak mengandllngi CCW Kep utusan menllnju kknn bahawa CCW
bolch digllnakan se bagai bahan gantian simen Kekuatan awa l sbahagian spesimcn
adalah sebanding clengan spesimen ko ntrol Didapati bahawa ganlian 5 CCW
ada lah serupa dan paling hampir dengan spesimen kantra l clari scgi kckuatan
Apab ila kuantiti CCW meningkat kekll atan mampatan keku atan tcgangan pecah
cl an ke kllMan lent man rus uk menurun
v
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
T he Fo ll owing Final Year Project
Tit le Ca lc ium Carbide Waste (CCW) as Cement Replacement in Concrete
Author Kenneth Kho Wee Ho ng
Ma tri c number J6430
has been read and ce rtified by
I~gtIf~ Dr De lsye Teo Ching Lee Date
(S uperv iso r)
CALCIUM CARBIDE WASTE (CCW) AS CEMENT
REPLACEMENT IN CONCRETE
KENNETH KHO WEE HONG
This project is submitted in partial fulfillment of
the requirements for the Degree of Bachelor of Engineering with
Honours (Civil Engineering) 2010
To my be loved fami ly and friend s
11
ACKNOWLEDGEMENTS
I wo uld like to express my app reciation to my superviso r Dr Delsye Teo
Ching Lee for her constant supervision he lp and adv ice throughout th is research
Without her guidance the project repo rt would not have been co mpleted smoothly
A specia l thanks fo r my fam ily for the ir continuous morale and fin ancial
support during the peri od of the project My sincere appreciation also goes to all my
fr iends that helped me duri ng the peri od of laboratory works as it was impossible to
carry out such a hugc amount of work alone without de laying too much time
My gratitude also goes to Me Jimmy Tan from Eastern Oxygen Sun Bhd
for hi s full cooperation and help when asked for the supplies of Calcium Carbide
Waste for this pro ject No t fo rgo tten is also the concrcte lab tec hn ician for hi s help in
the co ncrete lab
Last but not least a si ncere thank s goes to all others who contribu ted direc tly
and indirectl y to help enable thi s project to be completed success ful ly
III
ABSTRACT
The most commonly used material in a construction is concrete and the most
importan t materia l in conc rete is cemen t However the product ion of cement
produces a huge amo unt of CO2 which is not benefi cia l fo r the environment and
comes with a high price lorence there are many researches conducted to search for
a lternative materials to replace cement in order to reduce th e cost and al so to keep up
wi th the dema nd s Calci um Carbide Waste (CCW) is one type of industrial waste
w hich can be used as partial replacement [or cement Thi s study focuses nn the
compress ive strength spl it tensile strength and fl ex ural strength of the concrete
containing eli tTerent percentages of CCW The cement is replaced with 5 10 15
and 20 of CC W The performance of the concrete containing CCW will be
compared to a con trol mi x that does not contain any CCW The result s show tha t
CC W can bc used as a type of cemen t replaceme nt material The early strengths of
some spec imens are comparable to the contro l specime n It was IO Li lld that the 5degmiddot
CCW replacement is simi lar and the nearest to the control spee ill1en in terms of
strength As thc amOLlnt of CCW increases the compress ive strength split tens ile
strength and tle xural strength decreases
IV
ABSTRAK
Bahan ya ng paling biasa digunakan dal am kelja pcm bangunan adalah konkrit
liltm bahan yang paling penting dal am konkrit adalah simen Tetapi pengeluaran
simen menghas il ka n banyak CO2 yang tidak berfaedah kepada persekitaran dan
datang dengan barga yang tinggi Justenl terdapat banyak kerja penyelidikan yang
dibuat untuk menca ri bahall lain bagi ll1 ellggantikan simen untuk mengurangkan
harga kos dan juga untuk dapat mengeka lkan dengan kehendak Sisa Calcium
Carb ide (CCW) adalah sejenis bahan buangan industry yang boleh digunakan untuk
mengantikan simen Kaj ian ini alean foku s terhadap kekuatan mampatall kekualan
tegangan pecah dan kekuatan lenturan rusuk bagi konkrit yang mellgandungi
pera tusan CCW yang be rJ a illan S imen diganti ka n dengan 5 l O 15 dan 20
CCW Prcstasi kOllkrit ya ng mengandungi CCW akan dibandin gka n dengan konkrit
kontrol yang tidak mengandllngi CCW Kep utusan menllnju kknn bahawa CCW
bolch digllnakan se bagai bahan gantian simen Kekuatan awa l sbahagian spesimcn
adalah sebanding clengan spesimen ko ntrol Didapati bahawa ganlian 5 CCW
ada lah serupa dan paling hampir dengan spesimen kantra l clari scgi kckuatan
Apab ila kuantiti CCW meningkat kekll atan mampatan keku atan tcgangan pecah
cl an ke kllMan lent man rus uk menurun
v
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
CALCIUM CARBIDE WASTE (CCW) AS CEMENT
REPLACEMENT IN CONCRETE
KENNETH KHO WEE HONG
This project is submitted in partial fulfillment of
the requirements for the Degree of Bachelor of Engineering with
Honours (Civil Engineering) 2010
To my be loved fami ly and friend s
11
ACKNOWLEDGEMENTS
I wo uld like to express my app reciation to my superviso r Dr Delsye Teo
Ching Lee for her constant supervision he lp and adv ice throughout th is research
Without her guidance the project repo rt would not have been co mpleted smoothly
A specia l thanks fo r my fam ily for the ir continuous morale and fin ancial
support during the peri od of the project My sincere appreciation also goes to all my
fr iends that helped me duri ng the peri od of laboratory works as it was impossible to
carry out such a hugc amount of work alone without de laying too much time
My gratitude also goes to Me Jimmy Tan from Eastern Oxygen Sun Bhd
for hi s full cooperation and help when asked for the supplies of Calcium Carbide
Waste for this pro ject No t fo rgo tten is also the concrcte lab tec hn ician for hi s help in
the co ncrete lab
Last but not least a si ncere thank s goes to all others who contribu ted direc tly
and indirectl y to help enable thi s project to be completed success ful ly
III
ABSTRACT
The most commonly used material in a construction is concrete and the most
importan t materia l in conc rete is cemen t However the product ion of cement
produces a huge amo unt of CO2 which is not benefi cia l fo r the environment and
comes with a high price lorence there are many researches conducted to search for
a lternative materials to replace cement in order to reduce th e cost and al so to keep up
wi th the dema nd s Calci um Carbide Waste (CCW) is one type of industrial waste
w hich can be used as partial replacement [or cement Thi s study focuses nn the
compress ive strength spl it tensile strength and fl ex ural strength of the concrete
containing eli tTerent percentages of CCW The cement is replaced with 5 10 15
and 20 of CC W The performance of the concrete containing CCW will be
compared to a con trol mi x that does not contain any CCW The result s show tha t
CC W can bc used as a type of cemen t replaceme nt material The early strengths of
some spec imens are comparable to the contro l specime n It was IO Li lld that the 5degmiddot
CCW replacement is simi lar and the nearest to the control spee ill1en in terms of
strength As thc amOLlnt of CCW increases the compress ive strength split tens ile
strength and tle xural strength decreases
IV
ABSTRAK
Bahan ya ng paling biasa digunakan dal am kelja pcm bangunan adalah konkrit
liltm bahan yang paling penting dal am konkrit adalah simen Tetapi pengeluaran
simen menghas il ka n banyak CO2 yang tidak berfaedah kepada persekitaran dan
datang dengan barga yang tinggi Justenl terdapat banyak kerja penyelidikan yang
dibuat untuk menca ri bahall lain bagi ll1 ellggantikan simen untuk mengurangkan
harga kos dan juga untuk dapat mengeka lkan dengan kehendak Sisa Calcium
Carb ide (CCW) adalah sejenis bahan buangan industry yang boleh digunakan untuk
mengantikan simen Kaj ian ini alean foku s terhadap kekuatan mampatall kekualan
tegangan pecah dan kekuatan lenturan rusuk bagi konkrit yang mellgandungi
pera tusan CCW yang be rJ a illan S imen diganti ka n dengan 5 l O 15 dan 20
CCW Prcstasi kOllkrit ya ng mengandungi CCW akan dibandin gka n dengan konkrit
kontrol yang tidak mengandllngi CCW Kep utusan menllnju kknn bahawa CCW
bolch digllnakan se bagai bahan gantian simen Kekuatan awa l sbahagian spesimcn
adalah sebanding clengan spesimen ko ntrol Didapati bahawa ganlian 5 CCW
ada lah serupa dan paling hampir dengan spesimen kantra l clari scgi kckuatan
Apab ila kuantiti CCW meningkat kekll atan mampatan keku atan tcgangan pecah
cl an ke kllMan lent man rus uk menurun
v
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
To my be loved fami ly and friend s
11
ACKNOWLEDGEMENTS
I wo uld like to express my app reciation to my superviso r Dr Delsye Teo
Ching Lee for her constant supervision he lp and adv ice throughout th is research
Without her guidance the project repo rt would not have been co mpleted smoothly
A specia l thanks fo r my fam ily for the ir continuous morale and fin ancial
support during the peri od of the project My sincere appreciation also goes to all my
fr iends that helped me duri ng the peri od of laboratory works as it was impossible to
carry out such a hugc amount of work alone without de laying too much time
My gratitude also goes to Me Jimmy Tan from Eastern Oxygen Sun Bhd
for hi s full cooperation and help when asked for the supplies of Calcium Carbide
Waste for this pro ject No t fo rgo tten is also the concrcte lab tec hn ician for hi s help in
the co ncrete lab
Last but not least a si ncere thank s goes to all others who contribu ted direc tly
and indirectl y to help enable thi s project to be completed success ful ly
III
ABSTRACT
The most commonly used material in a construction is concrete and the most
importan t materia l in conc rete is cemen t However the product ion of cement
produces a huge amo unt of CO2 which is not benefi cia l fo r the environment and
comes with a high price lorence there are many researches conducted to search for
a lternative materials to replace cement in order to reduce th e cost and al so to keep up
wi th the dema nd s Calci um Carbide Waste (CCW) is one type of industrial waste
w hich can be used as partial replacement [or cement Thi s study focuses nn the
compress ive strength spl it tensile strength and fl ex ural strength of the concrete
containing eli tTerent percentages of CCW The cement is replaced with 5 10 15
and 20 of CC W The performance of the concrete containing CCW will be
compared to a con trol mi x that does not contain any CCW The result s show tha t
CC W can bc used as a type of cemen t replaceme nt material The early strengths of
some spec imens are comparable to the contro l specime n It was IO Li lld that the 5degmiddot
CCW replacement is simi lar and the nearest to the control spee ill1en in terms of
strength As thc amOLlnt of CCW increases the compress ive strength split tens ile
strength and tle xural strength decreases
IV
ABSTRAK
Bahan ya ng paling biasa digunakan dal am kelja pcm bangunan adalah konkrit
liltm bahan yang paling penting dal am konkrit adalah simen Tetapi pengeluaran
simen menghas il ka n banyak CO2 yang tidak berfaedah kepada persekitaran dan
datang dengan barga yang tinggi Justenl terdapat banyak kerja penyelidikan yang
dibuat untuk menca ri bahall lain bagi ll1 ellggantikan simen untuk mengurangkan
harga kos dan juga untuk dapat mengeka lkan dengan kehendak Sisa Calcium
Carb ide (CCW) adalah sejenis bahan buangan industry yang boleh digunakan untuk
mengantikan simen Kaj ian ini alean foku s terhadap kekuatan mampatall kekualan
tegangan pecah dan kekuatan lenturan rusuk bagi konkrit yang mellgandungi
pera tusan CCW yang be rJ a illan S imen diganti ka n dengan 5 l O 15 dan 20
CCW Prcstasi kOllkrit ya ng mengandungi CCW akan dibandin gka n dengan konkrit
kontrol yang tidak mengandllngi CCW Kep utusan menllnju kknn bahawa CCW
bolch digllnakan se bagai bahan gantian simen Kekuatan awa l sbahagian spesimcn
adalah sebanding clengan spesimen ko ntrol Didapati bahawa ganlian 5 CCW
ada lah serupa dan paling hampir dengan spesimen kantra l clari scgi kckuatan
Apab ila kuantiti CCW meningkat kekll atan mampatan keku atan tcgangan pecah
cl an ke kllMan lent man rus uk menurun
v
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
ACKNOWLEDGEMENTS
I wo uld like to express my app reciation to my superviso r Dr Delsye Teo
Ching Lee for her constant supervision he lp and adv ice throughout th is research
Without her guidance the project repo rt would not have been co mpleted smoothly
A specia l thanks fo r my fam ily for the ir continuous morale and fin ancial
support during the peri od of the project My sincere appreciation also goes to all my
fr iends that helped me duri ng the peri od of laboratory works as it was impossible to
carry out such a hugc amount of work alone without de laying too much time
My gratitude also goes to Me Jimmy Tan from Eastern Oxygen Sun Bhd
for hi s full cooperation and help when asked for the supplies of Calcium Carbide
Waste for this pro ject No t fo rgo tten is also the concrcte lab tec hn ician for hi s help in
the co ncrete lab
Last but not least a si ncere thank s goes to all others who contribu ted direc tly
and indirectl y to help enable thi s project to be completed success ful ly
III
ABSTRACT
The most commonly used material in a construction is concrete and the most
importan t materia l in conc rete is cemen t However the product ion of cement
produces a huge amo unt of CO2 which is not benefi cia l fo r the environment and
comes with a high price lorence there are many researches conducted to search for
a lternative materials to replace cement in order to reduce th e cost and al so to keep up
wi th the dema nd s Calci um Carbide Waste (CCW) is one type of industrial waste
w hich can be used as partial replacement [or cement Thi s study focuses nn the
compress ive strength spl it tensile strength and fl ex ural strength of the concrete
containing eli tTerent percentages of CCW The cement is replaced with 5 10 15
and 20 of CC W The performance of the concrete containing CCW will be
compared to a con trol mi x that does not contain any CCW The result s show tha t
CC W can bc used as a type of cemen t replaceme nt material The early strengths of
some spec imens are comparable to the contro l specime n It was IO Li lld that the 5degmiddot
CCW replacement is simi lar and the nearest to the control spee ill1en in terms of
strength As thc amOLlnt of CCW increases the compress ive strength split tens ile
strength and tle xural strength decreases
IV
ABSTRAK
Bahan ya ng paling biasa digunakan dal am kelja pcm bangunan adalah konkrit
liltm bahan yang paling penting dal am konkrit adalah simen Tetapi pengeluaran
simen menghas il ka n banyak CO2 yang tidak berfaedah kepada persekitaran dan
datang dengan barga yang tinggi Justenl terdapat banyak kerja penyelidikan yang
dibuat untuk menca ri bahall lain bagi ll1 ellggantikan simen untuk mengurangkan
harga kos dan juga untuk dapat mengeka lkan dengan kehendak Sisa Calcium
Carb ide (CCW) adalah sejenis bahan buangan industry yang boleh digunakan untuk
mengantikan simen Kaj ian ini alean foku s terhadap kekuatan mampatall kekualan
tegangan pecah dan kekuatan lenturan rusuk bagi konkrit yang mellgandungi
pera tusan CCW yang be rJ a illan S imen diganti ka n dengan 5 l O 15 dan 20
CCW Prcstasi kOllkrit ya ng mengandungi CCW akan dibandin gka n dengan konkrit
kontrol yang tidak mengandllngi CCW Kep utusan menllnju kknn bahawa CCW
bolch digllnakan se bagai bahan gantian simen Kekuatan awa l sbahagian spesimcn
adalah sebanding clengan spesimen ko ntrol Didapati bahawa ganlian 5 CCW
ada lah serupa dan paling hampir dengan spesimen kantra l clari scgi kckuatan
Apab ila kuantiti CCW meningkat kekll atan mampatan keku atan tcgangan pecah
cl an ke kllMan lent man rus uk menurun
v
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
ABSTRACT
The most commonly used material in a construction is concrete and the most
importan t materia l in conc rete is cemen t However the product ion of cement
produces a huge amo unt of CO2 which is not benefi cia l fo r the environment and
comes with a high price lorence there are many researches conducted to search for
a lternative materials to replace cement in order to reduce th e cost and al so to keep up
wi th the dema nd s Calci um Carbide Waste (CCW) is one type of industrial waste
w hich can be used as partial replacement [or cement Thi s study focuses nn the
compress ive strength spl it tensile strength and fl ex ural strength of the concrete
containing eli tTerent percentages of CCW The cement is replaced with 5 10 15
and 20 of CC W The performance of the concrete containing CCW will be
compared to a con trol mi x that does not contain any CCW The result s show tha t
CC W can bc used as a type of cemen t replaceme nt material The early strengths of
some spec imens are comparable to the contro l specime n It was IO Li lld that the 5degmiddot
CCW replacement is simi lar and the nearest to the control spee ill1en in terms of
strength As thc amOLlnt of CCW increases the compress ive strength split tens ile
strength and tle xural strength decreases
IV
ABSTRAK
Bahan ya ng paling biasa digunakan dal am kelja pcm bangunan adalah konkrit
liltm bahan yang paling penting dal am konkrit adalah simen Tetapi pengeluaran
simen menghas il ka n banyak CO2 yang tidak berfaedah kepada persekitaran dan
datang dengan barga yang tinggi Justenl terdapat banyak kerja penyelidikan yang
dibuat untuk menca ri bahall lain bagi ll1 ellggantikan simen untuk mengurangkan
harga kos dan juga untuk dapat mengeka lkan dengan kehendak Sisa Calcium
Carb ide (CCW) adalah sejenis bahan buangan industry yang boleh digunakan untuk
mengantikan simen Kaj ian ini alean foku s terhadap kekuatan mampatall kekualan
tegangan pecah dan kekuatan lenturan rusuk bagi konkrit yang mellgandungi
pera tusan CCW yang be rJ a illan S imen diganti ka n dengan 5 l O 15 dan 20
CCW Prcstasi kOllkrit ya ng mengandungi CCW akan dibandin gka n dengan konkrit
kontrol yang tidak mengandllngi CCW Kep utusan menllnju kknn bahawa CCW
bolch digllnakan se bagai bahan gantian simen Kekuatan awa l sbahagian spesimcn
adalah sebanding clengan spesimen ko ntrol Didapati bahawa ganlian 5 CCW
ada lah serupa dan paling hampir dengan spesimen kantra l clari scgi kckuatan
Apab ila kuantiti CCW meningkat kekll atan mampatan keku atan tcgangan pecah
cl an ke kllMan lent man rus uk menurun
v
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
ABSTRAK
Bahan ya ng paling biasa digunakan dal am kelja pcm bangunan adalah konkrit
liltm bahan yang paling penting dal am konkrit adalah simen Tetapi pengeluaran
simen menghas il ka n banyak CO2 yang tidak berfaedah kepada persekitaran dan
datang dengan barga yang tinggi Justenl terdapat banyak kerja penyelidikan yang
dibuat untuk menca ri bahall lain bagi ll1 ellggantikan simen untuk mengurangkan
harga kos dan juga untuk dapat mengeka lkan dengan kehendak Sisa Calcium
Carb ide (CCW) adalah sejenis bahan buangan industry yang boleh digunakan untuk
mengantikan simen Kaj ian ini alean foku s terhadap kekuatan mampatall kekualan
tegangan pecah dan kekuatan lenturan rusuk bagi konkrit yang mellgandungi
pera tusan CCW yang be rJ a illan S imen diganti ka n dengan 5 l O 15 dan 20
CCW Prcstasi kOllkrit ya ng mengandungi CCW akan dibandin gka n dengan konkrit
kontrol yang tidak mengandllngi CCW Kep utusan menllnju kknn bahawa CCW
bolch digllnakan se bagai bahan gantian simen Kekuatan awa l sbahagian spesimcn
adalah sebanding clengan spesimen ko ntrol Didapati bahawa ganlian 5 CCW
ada lah serupa dan paling hampir dengan spesimen kantra l clari scgi kckuatan
Apab ila kuantiti CCW meningkat kekll atan mampatan keku atan tcgangan pecah
cl an ke kllMan lent man rus uk menurun
v
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
CONTENT
Page
DEDICA lION II
ACK NOWLEDGEMENTS III
ABSTRACT IV
ABSTRAK V
CONTENTS VI
LIST OF TABLES x
LIST OF FIGURES XI
LIST OF A I3I3REV IATIONS AND NOTATIO NS Xli
CIIAITER 1 INTRODUCT ION
Il General
12 Resea rch Objecti ves 3
13 Significance of the Research gt
14 Scope of the Research -I
15 Organ iza tion of Thes is 6
CHAPTER 2 LITERATURE REVIEW
21 General 7
22 Conc rete COllstituenL Materials 8
221 Fine aggregate 8
222 Coarse aggregate 9
V I
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
2 33 Cement 9
23 Cement Rt placement Material I 1
231 Fly as h 12
23 11 Introduction 12
23 12 Concrete properties 13
23 2 Ground granul ated blas t furnace slag 14
232 1 Introduction 14
2322 Concrete properties 15
~ j Calcium Carb ide Waste 17
2 41 Composition 17
242 P roperties 17
24 3 Manufacturing Ill e thod 18
244 Other applica tions 19
245 Stabil it y and reactivity 20
246 ToxiJogi ca l inforillation 20
25 Past Researches with CCW in Concrde 21
CUAPT F l~ 3 M InHODOLOGY amp MATERIALS liSED
3 1 General 22
32 Materials Used
32 1 Ceillent 23
322 Potable wate r 23
3 2 3 Ca lcium Carbide Was te 23
32 4 Aggrega te propert ies test
325 Coarse aggregate
VII
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
326 Fine aggregate
33 Concrete Mix Des ign
34 Specimen Preparation
35 Properties of Fresh Concrete
35 1 Slump tes t
35 2 Fresh concrete density
36 Propert ies of Hardened Concrete
36 1 Compress ive strcngth test
353 Tensil e strength test
354 Flex ural strength tes t
37 Chapter Summary
C HArTER 4 HESULTS ANALYSIS AND DISC USSIO NS
4 I Ge neral
42 Calc iu m Carb ide Waste
42 1 Spec ifi c gravity tes t
43 Mix Design
44 Properties of Fresh Concrete
44 1 Slump tes t
442 Fresh concrc te density
4 5 Properties of Hardened Concrete
4 5 1 Compress ive strength test
4 52 Tens ile strength test
453 Flexural strength test
27
29
3 1
32
32
33
34
34
36
37
38
39
39
40
41
42
42
43
-1 -1
-1-1
46
49
V I II
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
CILTER 5 CO CL SIO S AND RECOJ1IIE OATIONS 52
5 I General 52
52 Conc lusions 53
53 Recol11mendations
REFERENCES 54
APPENDIX 59
IX
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
LIST OF TABLES
Tabk Page
31 Aggrega te properties test 24
32 Coarse aggregate properties 25
33 Sieve analys is for coarse aggregate 26
34 Fine aggregate properties 27
35 Sieve analysis for fine aggregate 28
36 Mix proporti on trials 30
37 Compress ive st rength and slump ofrn ix
propo rtion tri a ls 30
41 Mix design propo rtion ratio for control mix 40
42 Propert ies or fresh conc re te for contro l mi x 41
43 Properties of hardened concrete fo r control mi x 41
44 Slump te st value 42
45 Wet density value -~ 3
46 Ratio of ten sile s trength to compress ive strength 47
47 Rat io o f fl ex ural strength to compress ive strength 50
x
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
LIST OF FIGURES
Fi glJlc Page
31 Gradi ng curve for eoarse aggregate 26
32 Grading curve fo r fine aggrega te 28
33 Slump cone 33
41 Calcium Carbide Waste 39
42 S lump test 4 ~
43 Concrete wet dens ity g raph 4
44 Compress ive strengtl1 of CCW specimens 45
45 Concrete cube specimen after compress ion test 45
46 Tens ile strength of CCW specimens 47
47 Crack patte rn 48
48 Cylinder spec imen after tensil e s trength test 48
49 Flexural s trength of CCW specimens 50
41 0 Concre te beam after fl ex ural strength tes t 51
Xl
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
LIST OF ABBREVIATIONS AND
ACI
ASTM
CaC2
CaCO)
CaO
Ca(OH)2
CCE
CCW
C02
CS H
GGBS
tvl SWI
Si0 2
SSD
NOTATIONS
American Concrete Insti tute
American Society for Tes ting and Materials
Ca lcium Carbi de
Calcium Carbonate
Calcium Oxi de
Calcium Hydrox ide
Calcium Carbonate Equi valent
Cal cium Carbide Waste
Carbon Dioxide
Calci um S ilica te Hydrates
Ground Granul ated l3last Furnace S lag
M unic ipal Solid Was te Inc inerato r
Si li con Diox ide
Sa turated Surface Dry
Xll
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
CHAPTER 1
INTRODUCTION
11 Gencral
As Ma laysia continues to develop througho ut the years the construction
industry remains stab lc However as the wo rld economy weakens the construct ion
industry is a lso affected as demands for new construction projec ts decreased due to
the drop in sales Hence it is undeniable that the pri cing is one of the main factors
that have to be taken into consideration
For a building production cost a round two-thirds of the cost comes fro m th e
materi als used for the constructio n As the price of the material s continuc to ri se the
total cos t for the construction is affccted as we ll and it makes the local houses
becom e less affordable fo r the citi zens especiall y those fro m the third wor ld
coun tries Therefore one of the best ways to red uce cost wo uld be to find a way to
reduce the price of the materi als used wi th l ittle e ffect on the quality of he end
prod uct (Ayangade e t a i 2004)
The 1110st commonly used materi al fo r construct ion is concrete Concrete is
made up of coa rse aggrega tes fine aggrega tes water and cement Depend ing on the
mix proportions of the materials diffe rent strength of the concrete CC1 11 be achieved
For the aggregates they can be obtained from loca l resources The strength and
properties of the aggrega te s do no t differ much therefo re in o rd er 10 achieve highe r
streng th th e mi x des ign proport ion is im po rtant
1
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
One of the mos t important elements in orde r to achieve higher slrngth is the
amount of cement However it is not economical if the pe rcentage of cement in a
mi x design is too high He nce there are many researches done to search for
altclllative cement replacing material s in order to redu ce the cos t and also to keep up
with the demands Hence researches are being done to find suitabl e cemcntiti ous
materials to enabl e larger quant ity of cement rep lacement in the fu ture
Th is research focuses on the replacement of a percentage of the cemcnt with
Calc ium Carbidc Waste (CCW) The cement used is th e Port land Cement Type [
which is commonly used in construction Cement is a very expensive materi al and
the dema nds for the cemcnt is expected to continue ri s ing th rou ghout the years
l-lence resea rches are being done in order to determine suitable mater ials that can be
used to re placc a portion o r th e cement so that the demand ror the cement can be met
and a lso reducing the price of the raw materia l at the same time
The usage of CCW as a cement replacement materi al is c urrentl y being
studied in the recent years However there are still a lo t tests a nd researches to be
done in order to determine if the usage of CCW as partial cement rep lace ment will
have any significant effec ts One of the main concerns of lI si ng CCW as the cemcnt
replacement materia ls is that whether the quality and durab ilit y of the concrete will
be adequate to be Ll sed in the constructi on industry Shoul d the test prove thJt the
concrete made from the partial replacement is strong and du rable enough without
a ny side effec ts then it is poss ible for the CCW to be used as the partial cement
rep lacement in the future
2
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
12 O hjective of the csearch
The obj ectives of the research are
1 To identify the optimum amount of CCW to be used as the partia l cement
repl aceme nt matcrial
2 To determine the engineering properties of the concrete containing CCW as
the partial re placement material fo r cemen t
3 To compare be tween the e ngineering properties o f the concrete with CCW as
the partial cement replacement wi th conve ntio nal concrete
13 Significance of thc rescarch
Co ncrcte is a very important materi al in constructi on and it con tains a lot of
raw materials The main element affec ting the concrete is the cement hence it is
important to research more in o rder to find newer and more su itable methods to
replace cement and reducing the cost
CC W is a waste product produced from the l11 Jn ufacturing of Calcium
Carbide (CaC2) The chemical name for CCW is Calcium Hydrox ide (Ca(OH)2) It
is al so known as hyd ra ted lime CCW is di sposed after the prod uction of CaC l
Hence the disposed product may cause some environmental problems if not taken
care o f properly
3
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
The ad van tages of using CCW are that the re are more chances 10 exp lore and
research regarding the possibilities of using it as a parti al cement replacement
material From there more information rega rding CCW can be obtained for research
purposes I f success ful it will prove to be benefi c ia l to the local peo ple and also to
the economics o f the country as well This is because the de ma nd s [or the cement
matcrial can be met and also the cost to r construction can be reduced as well without
affecting the quality of works At the same time it is also beneficial to the
elw lronment s ince CC V iII be reused instead o f being disposed There fore it will
so lve the enviro nmenta l problems that the di sposal ofCCW poses
14 Scope of the rescarch
This research is done in order to determine the pro perties o Clhe concrete with
the introduction of CCW as the partial replace ment material for cement The most
important propel1y o f concre te is the strength since the most important fea ture of a
concrete is to be ab le to withstand the loads From there o ther properties of the
concrete are also determined through tensile strength test and fle xural strength test
The research project is d ivided into se veral different stages r 11st of all the
ph ys ical properties and o ther details of the aggregates used ar determined through
laboratory tests The laboratory tests are ca rried out to determine the spec illc gravity
unit weight total mo istme content surface moisture content vo id ratio and
absorption rate
Next the mi x des ign proportion for the conc rete is determined The concrete
used in this research would be of Gracie 30 Hence the optimum mi x proportion for a
4
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
f u- i a ~ llh uuJ bull 1 n4aU(Ullk lfNJVEIltSITI MAl IISIA SAil ~w
Grade 30 concrete wi ll be determined and used as the reference for normal concrete
It is used to com pare wit h the concrete containing CCW
The o the r spec imens contain certain percentages of CCW as the pa rti a l
cement replacement material T he percentages of the CCW 3re 5 10 150 and
20 The propcrties of the conc re te are tested and compared w ith the reference
spec imen Then the most economical a moun t of CCW is determined from the resu lts
For a ll the spec imens they are casted in the Civil Engi neeri ng Lab of
VNIMAS Then the spec imens are put in to a curing process and the tests for the
hardened conc re te propcL1ies are conducted at the specific age of 3 days 7 da ys 28
days and 56 days The tests include the compress ive strength test th~ sp lit tensi le
st rength tes t and th e nexural st re ngth test Al l the in fo rmation and results ob taincd
fro m the tes ts are used in order to ful fill the objecti ves o f the researc h
5
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
----
15 Organiza tio n of t hesis
For thi s thes is there will be 5 main chapters
Chapter one gives an introduct ion to the re sea rch It includes the general
iniormation rega rd i ng the purpose obj ec ti ve and scope of wo rk of the research The
main purpose of thi s chapter is to give a general idea regarding the contents o f the
thes is
Chapter two concentrates on the literature revIew and e labo rates further
regarding the mater ial s in vo lved in the resea rch and a lso rega rding similar type of
researches done by othe r people
Chapter th ree descri bes about th e methodology used to carry out the
ex periments and tes ts in orde r to obtain the required resul ts
Chapter four is the compilat ion of the data ob ta ined from th~ laboratory tes ts
The da ta will be ana lyzed and illustrated according to suita ble format This chapter
a lso discusses the re sults and the Endings of the research
Chapter 5 contain s the summary conc lusions and a lso the rCC(l I11I1l ndati ons
iiom this research
6
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
CHAPTER 2
LITERATURE REVIEW
21 General
In this chapter in fo rm ation related to the research is provided The fOC ll S of
the research is on the concrete Hence the in fo rma tion regard ing the constituent
material s of the concrete is given regarding their properties and sources The
methods and tes ts done to obtain the inIi)rmat ion are di scussed in Chapter three
f or thi s resea rch the main point is regarding the usage of CCW as a p3rtia l
replacement materi al to r the cement Thereto re the litera ture rev iew includes
information regarding similar technologies involving the replaceme nt of cement with
other suitable materia ls The information also includes rev iew on the re~ldts of past
resea rches done
The li terature review also includes more detailed information regarding the
CC W The properties sources manufacturing methods and other applications of the
CC W wi ll be included
The information rev iewed in this chapter is used to form the b is of the
hypothesis and serves as a reference for ex tra in formation regarding the research
7
_shy ~
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
22 Con ucte constituent materials
According to DVOlkin amp Dvorkin (2U06) concrete can be classified as
composite material and that is a combination of diffe rent components which improve
their perFo rm ance propert ies The components include cement aggregates and wa tcr
According to Nev ille (1995) the watercement rati o is the largest sin gle fac tor in the
strength of Full y compacted concrete The water used should be normal water that is
Free of materials thM will aFfec t the hyd rat ion reac tions of Portland cement (S teinour
1960) For some cases ad mi xtu res are added in for specific reasons such as
enhancing the concrete strength red ucing amount of wa ter req uired reducing the
se lling time dec reas ing permeability and others
22 1 Fine aggregates
According to AC I (A merican Concrete Institute) Commi ttee 207 (1997) fine
aggregate is that rrac ti on almost cntirely passing the NO4 (476 mm) sieve It may
be composed of natura l gra ins manufac tured grains obtained by cruhi ng larger sizc
rock panic les 01 a mi xture o f the two Fine aggregate should consist of hard densc
durab le and ullcoa ted panicles
8
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9
222 Coarse aggrega te
Accordi ng to ACT Committee 207 (1997) coa rse aggregate is defined as
gravel crushed gravel or crushed rock or a mi xture of these nominally larger than
the No4 sieve and sma ller than 150 mm sizes for large structures However the
maximum size of the coarse aggrega te shou ld not exceed one-fo urth of the least
dimension of the structure nor two-thirds of the least clear di stance between
re inforci ng bars in horizontal mats Coarse aggregate should consist of hard dense
durable and uncoated particles
223 Cement
Nevi lle (1995) described ce ment as a material with ad hesive and cohesive
properties which make it capable of bonding mineral fragment s into a compact
whole Raw materials for manufacturing cement consist of basicall y calcareous and
si liceous material The mi xture is hea ted to a high temperature wit hin a rotating kiln
to produce a comp lex group ofci1emica ls co llec tivel y cu ll ed cltmcnt clinker (Neville
amp Brooks 1987) The American Society for Testing and Mate ri als (ASTM ) Standard
C 150 Speci fi cation for Portland ce ment provides for the fo ll owing types of
Portland cement
Type I General Portland cement
Type l Moderate-sulfate-resistant ccment
Type III High-early-strength cement
Type JV Low- hcat-of-hydration cement
Type V High-sulfate-resistant cement
9