LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-1

INTRODUCTION

GENERAL:

The disposal of waste plastic is becoming a major waste management problem. As plastic is
extremely durable and not naturally biodegradable, they will remain in landfill with very little
degradation over time, presenting a continuing environmental hazard. This promotes recycling
ahead of disposal and energy recovery. One of the largest potential recycling routes is in
construction of civil engineering.

In recent years, more and more attention has been given to the potential use of waste plastic as
concrete aggregate. S.Vanithaet. Al., in India used 0%, 2%, 4%, 6%, 8% and 10% waste plastics to
replace the same amount of aggregate for M20 concrete. Paver blocks and solid blocks were casted
and tested for 7, 14 and 28 days strength. T.Subramani and V.K.Pugal has concluded from their
experimental study that, 20% of plastic aggregate can be incorporated as coarse aggregate
replacement in concrete without any long term detrimental effects and with acceptable strength
development properties. Eric Ababio Ohemenget. Al., proposed that although the strengths of
plastic content pavement blocks decreased as the plastic content increased, if 10%- 50% plastic
contents are used, the compressive strengths of blocks are still satisfactory for pedestrians walk
ways or light traffic situations. K. Ramadevi, R. Manju carried out the experimental investigation
on the properties of concrete with plastic PET (bottle) fibers as fine aggregates. It is found that the
replacement of the fine aggregate with 2% of PET bottle fibers will be reasonable than other
replacement percentages like 4% and 6% as the compression and split tensile strength reduces
gradually. Fahad K. Alqahtani ET. Al., observed that, `

100% replacement of conventional lightweight aggregate with recycled plastic aggregate showed
about 13% reduction in chloride penetration. Compressive strength was reduced to 12 to 15 mpa
which can be useful for non-structural elements.

The present report focused on the objective of promoting concrete blocks by mixed with waste
plastic EVA (Ethylene Vinyl Acetate), which comes from plastic products such as sandals, sports
shoes and rubber band. The test program for mechanical properties of this new kind of moderate
concrete Blocks was explained. Lightweight concrete is a type concrete contains expanded light
weight aggregates which increase the volume of the mixture while giving additional qualities such
as lowering the dead weight. Lightweight concrete maintains its large voids and not forming
laitance layers or cement films when placed on the wall. This research was based on the
performance of lightweight concrete using expanded clay aggregate. However, sufficient water
cement ratio is vital to produce adequate cohesion between cement and water. Light weight

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concrete is usually chosen for structural purpose where its use will lead to a lower overall cost of a
structure than normal weight concrete.

This research report is prepared to show the activities and progress. Of the light weight
concrete research project. The performance of lightweight concrete such as compressive strength
test, water absorption and density and supplementary tests and comparisons has been made with
normal concrete.

Reduction of waste produced around the world is a major challenge which society is facing today.
Conventional approaches adopted include reduction of waste production and recycling as far as
possible of what is inevitably produced. Worldwide plastic production in 1950 was 1.7 Mt. By
2012, this had increased by approximately 170 times to 288 Mt [4].Polyethylene based products
form the largest percentage (about 29%) of total waste plastic [2, 5]. These include low density
polyethylene (LDPE), linear low density polyethylene (LLDPE) and high density polyethylene
(HDPE). Polyethylene terephthalate (PET) and polypropylene amount to 20% and 18%
respectively of global plastic waste [2, 5] and other polymer types represent about 33%. A large
quantity of plastic is recycled in various products [1-3], but significant quantities still end up as
waste which requires disposal.
One of the potential applications of this waste is in the construction industry, where it has been
used in concrete, either in shredded form or combined with other materials, to form a synthetic
aggregate. Since plastics have lower density than most natural materials, they can be readily used
to form lightweight aggregate which may replace naturally-existing aggregate of similar density.
Concrete produced with a conventional lightweight aggregate has been shown to exhibit
excessive shrinkage and high water absorption [7]. This is particularly the case with lightweight
aggregates (of volcanic origin) available in the Arabian Peninsula. Economic growth in this
region has led to high demand for such aggregates in concrete products as they have good
insulating properties and hence help to reduce energy costs. Good insulation is important in both
hot (as in Saudi Arabia) and cold climates. Local lightweight aggregate used in concrete produced
from volcanic rock is associated with problems such as low strength, lack of durability, high
mining and hauling costs, excessive drying shrinkage, high water absorption and limited
availability [7, 8].

© 2015. The authors - Published by Atlantis Press

Thus, if an alternative, synthetic, aggregate could be produced using waste materials which can
be used to produce lightweight concrete with similar or better insulation properties (compared to
concrete produced with local aggregate from volcanic origins) and lesser shrinkage, this will
benefit the Gulf region in reducing energy costs. In addition to this it will help to save natural
resources. Furthermore, generation of greenhouse gases such as CO emissions will be reduced as
lighter materials may result in lower self-weight of structural elements, leading to possible
reductions in consumption of cement [8]. Using waste plastic in construction would lead to
reduction in its disposal in landfills and help improve sustainability of natural resources.
A number of researchers have used waste plastic in concrete as a direct replacement for natural
aggregates [9-13]. Some researchers [7, 8, 14-18] have undertaken studies on the use of
plasticbased aggregate in concrete as a direct full or partial replacement of natural aggregate.
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Plastic aggregates such as Plasmatex© and Plasmega© have been produced from shredded
mixed plastic waste and secondary aggregates [14, 15]. These aggregates range in size from
5mm to 50 mm [14]. Similarly, synthetic lightweight aggregates (SLA) were produced from a
mix of fly ash and plastics such as polystyrene (PS), low density polyethylene (LDPE), high
density polyethylene (HDPE), and a mixture of various plastics (MP) [16]. SLA was produced at
different fly ash: plastic ratios ranging from 0:100 to 80:20 [16]. Natural aggregate was then
replaced with SLA in concrete road pavement. The results of that study showed that at 80% fly
ash, the unit weight, slump, compressive strength and split cylinder tensile strength of concretes
using SLA were reduced by about 15%, 16%, 43% and 26.4%, respectively, compared to
conventional concrete [16,17].
Waste plastic lightweight aggregate (WPLA) was also produced from polyethylene
terephthalate (PET) with granulated blast-furnace slag (GBFS) and river sand aggregate [6, 7].
The outcomes revealed that at a replacement level of 75% of WPLA aggregate, the slump of
concrete produced increased by 51%,while the density, compressive strength, split cylinder
tensile strength, modulus of elasticity and structural efficiency were reduced by 31%, 33%, 43%,
28%, and 23%, respectively, compared to normal concrete [7, 8]. On the other hand, use of
LLDPE in aggregate is less investigated compared to other types of plastics from the
polyethylene group.
The findings of a study on the effect of using recycled plastic aggregate (RPA) as a total
replacement for conventional lightweight coarse aggregates (LWA) in concrete are reported in
this paper. This includes findings on the effect of RPA on the compressive strength of concrete
and chloride ion penetrability at different w/c ratios.

It is estimated 1.5 billion tons of cement is used worldwide per annum, and this figure is increasing
rapidly with the current world wide infrastructure boom. Concrete is one of the most widely used
construction materials, it is usually associated with Portland cement as the main component for
making concrete. On the other hand, the climate changes due to global warming have become major
concern. The global warming is caused by the emission of green house gases, and such as carbon
dioxide (CO2) to the atmosphere by human activities. Among green house gases carbon dioxide
contributes about 65% of global warming. The cement industry is held responsible for some of the
CO2 emission because the production of one ton of Portland cement emits approximately one ton of
carbon dioxide into atmosphere.

Several efforts are in progress to reduce the use of Portland cement in concrete in order to address
the global warming issues. These include the utilization of supplementary cementing materials such
as fly ash, silica fume, granulated blast furnace slag, rice-husk ash and metakaolin, and the
development of alternative binders to Portland cement.

In this respect, the Geopolymer technology proposed by Davidovits (1988) shows considerable
promise for application in concrete industry as an alternative binder to the Portland cement. In terms
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of global warming, the Geopolymer technology could significantly reduce the CO2 emission to the
atmosphere caused by the cement industries as shown by the detailed analyses of Gartner.

Davidovits (1988) proposed that an alkaline liquid could be used to react with the silicon (Si) and
the aluminium (Al) in a source material of geological origin or in by-product materials such as fly
ash and rice husk ash to produce binders. Because the chemical reaction that takes place in this case
is a polymerization process, he coined the term “Geopolymer‟ to represent these binders.
Geopolymer concrete is concrete which does not utilize any Portland cement in its production.
Geopolymer concrete is being studied extensively and shows promise as a substitute to Portland
cement concrete. Research is shifting from the chemistry domain to engineering applications and
commercial production of geopolymer concrete.

There are two main constituents of geopolymers, namely the source materials and the alkaline
liquids. The source materials for geopolymers based on alumina-silicate should be rich in silicon
(Si) and aluminium (Al). These could be natural minerals such as kolinite, clays, etc. Alternatively,
by-product materials such as fly ash, silica fume, slag, rice-husk ash, red mud, etccould be used as
source materials. The choice of the source materials for making geopolymers depends on factors
such as availability, cost, type of application, and specific demand of the end users. The alkaline
liquids are from soluble alkali metals that are usually sodium or potassium based. The most
common alkaline liquid used in geopolymerisation is a combination of sodium hydroxide (NaoH) or
potassium hydroxide (KoH) and sodium silicate or potassium silicate.

The exposure of aluminosilicate bodies of the type cement clinker, slag, fly ash or thermally
activated substances to very alkaline environments (hydroxides, silicates) gives rise to the formation
of new materials – geopolymers characterized by a two- to three-dimensional Si-O-Al structure.
Substantial attention has been given to these new materials. Such contributions deal not only with
the results obtained during the investigation into the synthesis of geopolymers and their
microstructure but also with their possible applications particularly in conjunction with the
valorization of inorganic rejects (first of all, fly ashes). The above contributions pay special
attention to the polymer character of the geopolymer (solid phase NMR), to its mechanical
properties and to the effect of aggressive (corrosive) environments as well as to its leaching
behavior, etc. There are only few published data dealing with the properties of concretes on the

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basis of geopolymers. Therefore, the present work deals with the investigation into the properties of
the geopolymer concrete.

TYPES OF LIGHTWEIGHT CONCRETE:

1. No-fines concrete

2. Lightweight aggregate concrete

3. Aerated/Foamed concrete

NO-FINES CONCRETE:

No-fines concrete can be defined as a lightweight concrete composed of cement and

fine aggregate. Uniformly distributed voids are formed throughout its mass. The main
characteristics of this type of lightweight concrete is it maintains its large voids and not
forming laitance layers or cement film when placed on the wall. Figure 2 shows one example
of No-fines concrete.

No-fines concrete usually used for both load bearing and non-load bearing for external
walls and partitions. The strength of no-fines concrete increases as the cement content is
increased. However, it is sensitive to the water composition. Insufficient water can cause lack
of cohesion between the particles and therefore, subsequent loss in strength of the concrete.
Likewise too much water can cause cement film to run off the aggregate to form laitance
layers, leaving the bulk of the concrete deficient in cement and thus weakens the strength.

Fig 1.1 No- Fines Concrete

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LIGHTWEIGHT AGGREGATE CONCRETE:

Porous lightweight aggregate of low specific gravity is used in this lightweight

concrete instead of ordinary concrete. The lightweight aggregate can be natural aggregate
such as pumice, scoria and all of those of volcanic origin and the artificial aggregate such as
expanded blast-furnace slag, vermiculite and clinker aggregate. The main characteristic of
this lightweight aggregate is its high porosity which results in a low specific gravity.

The lightweight aggregate concrete can be divided into two types according to its
application. One is partially compacted lightweight aggregate concrete and the other is the
structural lightweight aggregate concrete. The partially compacted lightweight aggregate
concrete is mainly used for two purposes that is for precast concrete blocks or panels and
cast in-situ roofs and walls. The main requirement for this type of concrete is that it should
have adequate strength and a low density to obtain the best thermal insulation and a low
drying shrinkage to avoid cracking.

Structurally lightweight aggregate concrete is fully compacted similar to that of the

normal reinforced concrete of dense aggregate. It can be used with steel reinforcement as
to have a good bond between the steel and the concrete. The concrete should provide
adequate protection against the corrosion of the steel. The shape and the texture of the
aggregate particles and the coarse nature of the fine aggregate tend to produce harsh
concrete mixes. Only the denser varieties of lightweight aggregate are
Suitable for use in structural concrete. Figure 3 shows the feature of lightweight
aggregate concrete.

Fig 1.2 Light weight Concrete

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AERATED CONCRETE:

Aerated concrete does not contain coarse aggregate, and can be regarded as an aerated
mortar. Typically, aerated concrete is made by introducing air or other gas into a cement slurry
and fine sand. In commercial practice, the sand is replaced by pulverized-fuel ash or other
siliceous material, and lime maybe used instead of cement.

There are two methods to prepare the aerated concrete. The first method is to inject
the gas into the mixing during its plastic condition by means of a chemical reaction. The second
method, air is introduced either by mixing-in stable foam or by whipping-in air, using an air-
entraining agent. The first method is usually used in precast concrete factories where the precast units
are subsequently autoclaved in order to produce concrete with a reasonable high strength and low
drying shrinkage. The second method is mainly used for in-situ concrete, suitable for insulation roof
screeds or pipe lagging. Figure 4 shows the aerated concrete.

Fig 1.3 Aerated Concrete

ADVANTAGES:
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1. Reduces the dead load of the building.

2. Easy to handle and hence reduces the cost of transportation and handling.

3. Improve the workability.

4. Relatively low thermal conductivity.

5. Comparatively more durable.

DISADVANTAGES:

1. Very sensitive with water content in the mixture.

2. Difficult to place and finish because of porosity and angularity of the aggregate. In some
mixes the cement mortar may separate the aggregate and float towards the surface.

3. Mixing time is longer than conventional concrete to assure proper mixing.

4. Lightweight concrete are porous and poor resistance.

APPLICATION OF LIGHTWEIGHT CONCRETE:

Lightweight concrete has been used since the eighteen centuries by the Romans. The
application on the ‘The Pantheon’ where it uses pumice aggregate in the construction of cast
in-situ concrete is the proof of its usage. In USA and England in the late nineteenth century,
clinker was used in their construction for example the ‘British Museum’ and other low cost
housing. The lightweight concrete was also used in construction during the First World War.
The United States used mainly for shipbuilding and concrete blocks. The foamed blast
furnace-slag and pumice aggregate for block making were introduced in England and Sweden
around 1930.

Nowadays with the advancement of technology, lightweight concrete expands its uses.
For example, in the form of perlite with its outstanding insulating characteristics. It is widely
used as loose-fill insulation in masonry construction where it enhances fire ratings, reduces
noise transmission, does not rot and termite resistant. It is also used for vessels, roof decks
and other applications. Figure 5 shows some examples of lightweight concrete used in
different forms.

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CHAPTER-2
LITERATURE REVIEW

Generally, the properties of LWC can be indicated by doing laboratory testing, but the overall
performance of the material can only be demonstrated adequate by its performance in the field
by testing LWC structure under service.

Light weight concrete has been successfully used foe marine applications and in shipbuilding.
LWC ships were produced in the USA during the 1914-1918 war, and their success led to the
production of the USA Selma (a war ship). In both 1953 and 1980 the Selma’s durability was
assessed by taking cored samples from the water line area. On both occasion little corrosion was
noted.

In 1984, Thomas A. Holm estimated that there were over 400 LWC bridges throughout the world
especially in USA and Canada. The research carried out by the expanded clay and slate institute
proves that most of the bridges appeared to be in good condition.

THOMAS A. HOLM (1984):

Holmes was born in Wilmington, Massachusetts, where his father, john

Thomas Holmes, was chairmen of the board of selectmen. Holmes, father died when Thomas was
10 years old. Holmes graduated from Wilmington high school in 1941. In 1984, Thomas A. Holm
estimated that there were over 400LWC bridges throughout the world especially in USA and
Canada. The research carried out by the expanded clay and slate institute proves that most of the
bridges appeared to be in good condition.

According to ACI material journal by dionamarica, andrianloani, mihaifilip and lanpepenar (1994),
it was found that in japan LWC had been used since 1964 as a railway station platform. The study
on durability was carried out in 1983 has proven that LWC exhibited similar carbonation depths as
normal concrete.

Even some cracks were reported, but these posed no structure problems. A second structure
comprising both LWC and normal concrete which had been in seawater for 13 years was examined
for salt presentation.

SELMA (1914-1918):

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Lightweight concrete has been used in construction since before the days of
Roman Empire. The earliest types of lightweight concrete were made by using Grecian and latlian
pumice as the lightweight aggregate. Ordinary hydrated burned lime was used as the cementitious
material in the mix. These early lightweight concretes, by reason of the obviously weak materials.
Fell far short in structural performance of what we except and achieve today. They were however,
amazingly durable, and existing examples of these early lightweight concretes are still to be found
in various early structures of the Mediterranean area.

Light weight concrete blocks are raising materials technology with ancient roots that according to
some sources go back for 25,000 years. This technology was rediscovered in modern times just
before 30 years ago by Prof. Joseph Davidovits of France. He states that the builders of the great
pyramid used the technology to cast the stones of the pyramid in place rather than dragging heavy
stones blocks up a slippery ramp by hundreds of thousands of slaves.
Institute of Glass and Ceramics of Institute of Chemical Technology Prague and Department of
Building Technology and department of Structural Mechanics of Czech Technical University in
Prague have been involved in the research of alkali-activated materials for many years now and,
specifically, since 1973. At present, the attention has been focused on the technological and
materials research into geopolymer materials and particularly concretes. Geopolymer materials
based on rejected (mostly brown coal) fly ash have been investigated. The results obtained within
the framework of the research projects indicate that the geopolymer concrete is an economically
advantageous material exhibiting an excellent resistance. Recapitulative data obtained during the
investigation into the polymer concretes were divulged in a variety of communications and several
patents were filed too. The ulterior research activity has not neglected drawbacks exhibited by the
geopolymer concrete either, e.g. its tendency to the formation of efflorescence’s. The
investigation into the durability of geopolymer materials must also deal with their long-term
properties (of the order of several centuries). As regards the materials based on Portland cement,
fundamental long-term material data related to medieval and ancient constructions are available
(covering a period of about 2000 years). The data refer to materials with hydration products
comparable to those of Portland cement.
These are materials in which highly hydraulic lime or mixed Roman cement was used as a binder.
Davidovits formulated a hypothesis about the use of geopolymer binders during the construction
of ancient (and particularly Egyptian)monuments that are more than 4000 years old. In his
opinion, the "concrete" technology was used during the erection of Egyptian pyramids for laying
geopolymer mixes (with a limestone aggregate) into formwork; individual blocks were thus

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produced step by step. The hypothesis is corroborated by analysis of inscriptions on ancient

Egyptian steles. The above worker argues that the pictures of hieroglyphs should rather be
interpreted in technical terms than in the literary ones (as this has been done so far). These
deliberations accompanied by the interpretation of analyses (microscopy, IR and NMR
spectroscopy) of sparse specimens from ancient Egyptian constructions were published in papers.
This interpretation is also corroborated in the Demortier's work who expressed the opinion that the
"concrete-based lying" technology was known in the Cairo region in ancient times. Demortier
drew his conclusions after studying the appearance of pyramid blocks (the blocks exhibit different
porosities in the top and bottom sections) and performing X-ray and NMR analyses. A few small
pieces of pyramid blocks were used for analyses. He interpreted some ancient Egyptian scenes as
pictorial descriptions of the "concreting" during the pyramid construction. Barsoum and Gangula
analyzed specimens (5 in total) from various Egyptian pyramids including that of Cheops. For
comparison's sake, natural materials (limestone’s) from mines used as a source of raw materials
during the construction of pyramids were also analyzed. Petro graphic and point-by-point analyses
(ESEM) were carried out. Based on the data obtained the above workers argue that a much larger
number of analyses needs to be carried out before the application of the "concrete" technology
during the pyramid construction might be taken into consideration. Absolutely negative opinions
regarding the use of geopolymer binders in ancient constructions appear in other papers. The
workers base their opinions on the analyses of pyramid specimens supplied by British Museum
and those making part of the so-called "Lauer collection". Freestone and Middleton undertook a
detailed analysis of specimens from the pyramid of Cheops (British Museum) by using optical and
electron microscopy (with the point-by-point analysis), X-ray diffraction and IR spectroscopy.
Campbell paid particular attention to the petro graphic investigation of specimens from the
pyramid of Cheops and rocks (mostly limestones) from the mines exploited during the
construction of pyramids. Jana performed a detailed petro graphic and microscopic investigation
(optical and electron microscopy, X-ray diffraction) of specimens from the Khufu pyramid as
well as from the Lauer collection; furthermore, he also studied natural limestone from an ancient
Egyptian mine and samples of a man-made limestone geopolymer prepared by Davidovits. The
research workers could not identify any traces left by binding geopolymer phases in the
specimens: the specimens corresponded to natural limestone mined in Egypt. They were also able
to detect a fundamental difference between the limestone from pyramids and the man-made
limestone geopolymer prepared by Davidovits. In their opinion, the hypothesis assuming an

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alleged application of the "concrete" technology during the construction of Egyptian pyramids
ought to be corroborated by a systematic investigation carried out with a credible and reliable set
of specimens and data. For the sake of objectivity, it should be stressed, however, that the research
workers did not subject the specimens from the pyramids or samples of natural materials to the
investigation with the aid of NMR spectroscopy (Si, Al, Na) in solid state. Czech Institute of
Egyptology (Faculty of Philosophy, Charles University, Prague) has been excavating in Egypt for
many decades (since 1960); it has also been exploring ancient Egyptian constructions (pyramids,
shaft tombs, tombs of high-rank officials and members of the royal family) in the Abusir locality
(Cairo). The exploration of ancient Egyptian constructions did not reveal any signs hinting at the
use of the "concrete" technology, e.g. formwork marks on building segments. Nevertheless, the
imprints of human fingers were discovered in mortars (lime-based) or on (unfired) clay bricks. A
phenomenon suggesting a closer relationship of ancient Egyptian materials with the concrete
could only be discovered in lime plasters and lime based filler layers in sarcophagi which also
contained pebbles in addition to lime binder. The excavated shards indicate that lime mortars and
filler layers in (evidently) rather liquid conditions were transported into the tombs (to a depth of
21 m in the case of Iufa shaft tomb) in ceramic jugs up to 60 cm high. Shards of such vessels
containing residues of a thin mortar or lime filler were even found in tombs in other places too.
Therefore, in theory, there may have been a sort of a "concrete mixing plant" in the desert in the
tomb vicinity where such bodies were prepared (just to give an idea, the necessary volume of the
filler body in the case of the Iufa sarcophagus is estimated to be of the order of a few tenths of
cubic meter and it seems that the filling body was cast more or less in one single step). It may not
be excluded that even this procedure or the subsequent transportation of the mortar or any such
material wouldbe captured in Egyptian reliefs. Sorts of sledge loaded with a stone block and
drawn (obviously) by slaves were used during the construction of pyramids (for the transportation
of stone blocks). A slave stood on the sledge and poured clay slurry from a vessel into the sledge
trajectory, the slurry formed a slippery path facilitating the sledge motion. Such slurries were also
applied as bearing courses of horizontal joints; vertical joints between the blocks were also filled
with the slurry. As mentioned by Davidovits, even hairs could be found in the joints. On
concluding this communication we have to admit that "it is not quite evident how ancient
Egyptians succeeded in transporting the last block weighing a ton to the top of the pyramid …”
Hence, the ulterior research in this field is very much needed. It should be declared quite openly
that - if ancient materials (geopolymers or lime-based materials) prepared by human beings

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thousands of years ago would be discovered - then such materials would be convenient for
immobilization of high-toxicity rejects and, in particular, radioactive wastes. The stability over
thousands of years is namely required from solid materials with immobilized nuclear (radioactive)
waste. Therefore, solutions to the problems of modern times (the future of the nuclear power
technology) are being sought in the mist of passed millennia.

Many different materials have been used for lightweight concrete since Roman days, and some
have shown remarkably better structural qualities than the Roman materials. Up to the 20th century,
however, such improvements were associated with the strength of the cementing materials used
rather than with improvements to the lightweight aggregates.

Fig 2.1 ‘The Pantheon’

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CHAPTER-3

MATERIALS USED

MATERIALS FOR LIGHT WEIGHT CONCRETE BLOCK

The materials used in the experiment work are:

1. Cement
2. Fine aggregates
3. Coarse aggregates

MATERIALS FOR LIGHT WEIGHT CONCRETE WITH RECYCLED

PLASTIC

The materials used in the experiment work are:

1. Cement
2. Fine aggregates
3. Coarse aggregates
4. Plastic

MATERIALS FOR CEMENT CONCRETE

The materials used in the experiment work are:

1. Cement
2. Fine aggregates
3. Coarse aggregates
4. Water

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3.1 CEMENT:

Cement is a binder, a substance used in construction that sets and hardens and can bind other
material together. The most important types of cement are used as a component in the production
mortar in masonry, and of concrete which is combination ofcement and an aggregate to form a
strong building material.

For the project work ordinary Portland cement of grade 43 is used for conducting tests.

3.2 FINE AGGREGATE:

Grading of fine aggregate should not cause increase in water demand for concrete. It is desirable to
use a coarser variety of sand having high fineness modulus. Generally, fraction passing through
4.75 mm sieves and entirely retained on 150µ sieve are used. Locally obtained natural river sand
was used as the fine aggregate in the concrete mix.

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3.3 COARSE AGGREGATE:

Crushed Granite stone with a maximum nominal size 20mm & down was adopted as the coarse
aggregate. The tests on coarse aggregate were conducted in accordance with IS 2386-1963 to
determine specific gravity and fineness modulus.

3.4 WATER:

Potable water as obtained from Bore well of Civil Engineering. Dept., RGMP, was used for the
preparation of concrete mix.

3.5 Waste plastic

The waste plastics used for this study are thermoplastic of low density polyethylene
(LDPE) plastics, obtained from domestic, commercial and industrial wastes sites. The
waste plastics are shredded into smaller sizes of 5 mm by mechanical means. The
physical and mechanical properties of the waste granular plastic presented in Table 5. The
sample of waste plastic material obtained from dump site in Kaduna – Nigeria and the
Granulated Waste Plastic aggregates is shown in Figure 1.

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The materials used to make plastic aggregate were waste polythene bags and low density
polyethylene (LDPE) plastic. It was then sorted and separated from laminated plastics. These were
cleaned to remove other impurities and were crushed into small fractions. It is then melted at
2200C-2500C temperature and allowed to cool by spreading on ground surface. The plastic
boulders of size 100 to 120 mm were then crushed down to obtain the size of aggregates.

Table 5: Physical and Mechanical Properties of

Waste Plastic

Figure 1: Samples (a) Waste Plastic from Dump Site

(b) Granulated Waste Plastic

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Material testing were conducted as per IS specifications.

CEMENT:

Cement was tested as per IS: 456 (part-1)-2000

Table 1. Properties of Cement

Brand Portland
Pozzolona
Cement 43
grade
Standard consistency 32%
Initial Setting Time 30 min
Final Setting Time <600min
Specific Gravity 2.965
Mortar Cube Strength 43,000 N/mm²

FINE AGGREGATE:

Fine aggregate was tested as per IS: 456 (Part-1) - 2000

Table 2. Properties of Fine Aggregate:

Fineness Modulus 4.129

Zone I

Specific Gravity 2.697

Water absorption 0.2%

PLASTIC AGGREGATE:

Plastic aggregate was tested as per IS: 456 (Part-1) - 2000

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Table 3. Properties of Plastic Aggregate

Fineness Modulus 5.63

Nominal Size 20mm

Specific Gravity 0.94

WATER:
Water used for mixing and curing was clean and free form injurious amounts of oils,
acids, alkalis, salts, sugar, organic materials or other substances that are deleterious to concrete or
steel.

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CHAPTER 4

TESTING OF MATERIALS

4.1 TESTS ON CEMENT (43 GRADE)

4.1.1 FINENESS TEST: The degree of fineness of cement is a measure of mean size of the
grains in cement. The rate of hydration and hydrolistics and consequent development of strength in
cement mortar depends upon the fineness of cement.

APPARATUS: IS standard sieve, stopwatch, and weighing balance.

PROCEDURE:

 Weigh 100gms of cement and care should be taken that there should be no lump. And transfer
that to 90µ sieve.
 Cover IS 90µ sieve with lid and place that on a rice plate then holding together, Sieve gently in
wrist motion for 15 minutes by hand.
 Weigh the retained quantity of cement on the sieve.

OBSERVATION:

By manual sieving:

W1= weight of cement =100gms

W2=weight of cement retained on 90µIS sieve = 3.5gms

Fineness of cement = W2

W1

7
= ×100
100

Fineness of cement = 7% < 10%

Fineness of cement = 7%
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4.1.1 SPECIFIC GRAVITY OF CEMENT: Specific gravity is normally defined as the

ratio between the weight of a given volume of material and weight of an equal volume of
water. One of the methods of determining the specific gravity of cement is by the use of a
liquid such as water free kerosene which does not react with cement

APPARATUS:

Specific gravity bottle, funnel, kerosene, weighing balance.

PROCEDURE:

 Weigh the dry and empty specific gravity of bottle along with lid.
 Fill the bottle full with distilled water and take the weight.
 Fill the bottle full with kerosene and take the weight.
 Fill the bottle with 1/4th of cement and add kerosene to it and care should be taken that no air
bubbles are present in the bottle

Figure showing specific gravity bottle

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OBSERVATIONS:

 W1 = empty weight of specific gravity bottle = 61.0 gm

 W2 = weight of specific gravity bottle+ water = 165 gm
 W = weight cement = 29gms
 W3 = weight of specific gravity bottle +kerosene = 145 gm
 W4 = weight of specific gravity bottle + cement + kerosene = 165.0 gm

CALCULATIONS:

Specific gravity of kerosene (S) =W3 –W1

W2 -W1

145.0−61.0
= 165−61.0

S = 0.807

Specific gravity of cement (C) = W XS

W – (W4-W3)

29
= 29−(165−145)×0.807

C = 2.60

Specific gravity of cement is 2.60

4.1.3 STANDARD CONSISTENCY OF CEMENT:

APPARATUS: Vicat apparatus, measuring jar, cement sample.

PROCEDURE:

 Take 300gms of cement which passes through 850micron IS sieve and prepare cement paste by
100ml of water. Mixing time should be 3-5min.
 Place the vicatmould on non-porous plate and oil the inside surface of the mould and then fill
the mould with cement paste. Level the top surface of the mould.

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 Place this test block on vicat apparatus such a way that the flat surface of the plunger should
touch the top surface of cement sample, and then the plunger is quickly released.
 Allowing it to penetrate point from the bottom. Repeat experiment with varying percentage of
water starting from 24% at an interval of 2% till the penetrate height has come to 5-7mm from
the bottom.
 Draw the graph between percentage of water and penetration in mm.

TABULAR COLUMMN:

Initial reading Final reading Depth of penetration

%water added
(mm) (mm) (mm)

25 40 25 15
27 40 17 23
29 40 12 28

31 40 08 32

33 40 05 35

Table showing result of standard consistency of cement

The standard consistency of cement P=38%

4.1.4 SETTING TIME OF CEMENT:

APPARATUS: Vicat apparatus, stopwatch, cement sample.

PROCEDURE:

 Prepare the cement paste by adding 0.85P water where P-standard consistency.
 Fill the mould and level the top surface ensuring these are no air bubbles.

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 Fix the initial setting time needle to the vicat apparatus.

 Place the specimen sample on position and release quickly allowing it to penetrate into the
cement paste.
 Repeat the procedure until the needle fails to pierce the block foe about 5mm measured from the
bottom.
 The time taken for this stage is recorded as the initial setting time.

Vicat apparatus

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Figure showing vicat apparatus in lab

Weight of cement = 500gm

33
Water required = 0.5P = 0.5× ×500 = 82.5ml
100

TABULAR COLUMN:

Time Initial Final reading Un penetrated

Sl. No
(min) reading(mm) (mm) depth (mm)
1 0 40 40 0
2 5 40 40 0
3 10 40 40 0
4 15 40 40 0
5 20 40 39 1
6 25 40 38 2
7 30 40 37 3
8 35 40 36 4
9 40 40 35 5

Initial setting time of43 grade cement used is 40min

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4.1.4 SOUNDNESS TEST: Soundness of cement is the property by virtue of which

the cement does not undergo any appreciable expansion after it has set, thus
eliminating any chances of disrupting the mortar of concrete.

OBSERVATION:

Weight of cement= W= 50gms

32
Volume of water to be added= 0.75P×W = 0.75×100×50

Initial length of specimen= L1 = 2

Final length of specimen = L2= 2.1

Expansion of the specimen= (L2-L1) = 0.1

Soundness of cement is 1mm

TABLE SHOWING TESTS ON CEMENT RESULTS

SL NO TESTS ON CEMENT RESULTS

01 Specific Gravity 2.6

02 Fineness of cement 3.6%

03 Standard Consistency 33%

04 Initial setting time 40min

05 Soundness test 1mm

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4.1 TESTS ON FINE AGGREGATES:

4.2.1 SPECIFIC GRAVITY:

APPARATUS: Pycnometer, weighing balance, tray.

PROCEDURE:

 Clean the pycnometer and weigh the empty weight of pycnometer [M1]
 Take around 1/3rd sand sample in empty pycnometer and weigh it [M2]
 Fill the pycnometer with water and weigh it [M3]
 Fill the pycnometer entirely with water and weigh it [M4]
 Determine the specific gravity of the sand by the formula given below

Figure showing pycnometer apparatus

OBSERVATIONS:

Mass of empty pycnometer = M1 =623gm

Mass of pycnometer + 1/3rd dry fine aggregate = M2 =1056gm

Mass of pycnometer + 1/3rd dry fine aggregate + water = M3 =1783gm

Mass of pycnometer + water = M4=1516

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FORMULA:

Specific Gravity ‘G’

G= (M2-M1)

(M2-M1) - (M3-M4)

(1056−623)
G= (1516−623)−(1783−1056)

Specific gravity of fine aggregates is 2.4

4.2.2 SIEVE ANALYSIS: Fineness modulus is only a numerical index of fineness giving some
idea of the mean size of particles in the entire body of aggregate. Determination of fineness
modulus may be considered as a method of standardization of the grading of the aggregates. It’s
obtained by sieving a unknown mass of a given aggregate on a set of standard sieves and divide
the total percentage by 100.
The object of finding the fineness modulus is to grade the given aggregate for obtaining almost
economical and workable mix with minimum gravity quantity of cement

Figure showing sieve shaker

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APPARATUS: Balance accurate, to 1gm and 0.1gm, set of IS sieves : 4.75mm, 2.36mm,1.18mm, 600µ,
425µ, 300µ, 150µ, 75µ, pan, mechanical sieve shaker, sand sample

PRINCIPLE:

Sieving is performed by arranging the various sieves one over the other in the order of their mesh
openings the largest aperture sieve being kept at the top and the smallest aperture sieve at the bottom.
A receiver is kept at the bottom and a cover is kept at the top of the whole assembly.

PROCEDURE:

 Take about 1000gm of sand sample stack the sieve in such a way that the smaller size sieve
comes at the bottom and the larger size sieve at the top.
 Pour the taken sand sample on the top most sieve and cover it with a lid, keep it in a mechanical
sieve shaker for 10 min.
 Measure the contents retained in each sieve and pan calculate cumulative sand retained and
percentage finer, make sure that empty weight of sieve is taken.

TABULAR COLUMN:

Weight of sand taken W = 500gms

Particulars Empty Weight of Mass Percentage Cumulative Percentage

size weight of sieve + retained of sand percentage of finer
(mm) sieve+ mass mass X1(gms) retained retained 100-C
retained retained X=X1*100 C
(gms) (gms) W
4.75 424 444 20 4 4 96
2.36 418 457 39 7.8 11.8 88.2
1.18 399 522 123 24.6 36.4 63.6
0.60 329 441 112 22.4 58.8 41.2
0.30 319 468 149 29.8 88.6 11.4
0.15 321 376 55 11.0 99.6 0.4
Pan 397 399 2 0.4 100 0.0
Total 500 299.2

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RESULT:

Fineness modulus of fine aggregates = 299.2 /100

= 2.99

4.2.3 BULKING OF SAND: The volume increase of fine aggregates due to presence of
moisture content is known as bulking. Fine sand bulks more as compared to coarse sand.
Extremely fine sand particularly the manufacture fine aggregates bulks as much as about 40%
TABULAR COLUMN

Sl. no Volume of Percentage Initial Change in Percentage

sand taken of water volume of volume of of bulking
added sand in cc sand in cc (X-Y)/X
X Y *100

1 3 1% 300 335 11.66

2 6 2% 300 350 16.66

3 9 3% 300 360 20.00

4 12 4% 300 385 28.33

5 15 5% 300 380 26.66

6 18 6% 300 375 25.00

7 21 7% 300 365 22.66

The maximum percentage of bulking of sand is 28.33 at 4%

TABLE SHOWING TESTS ON CEMENT RESULTS

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Sl. No Name of Tests Results

01 Fineness modulus 2.99

02 Specific gravity 2.6

03 Bulking of Sand 28.33%

4.3 TESTS ON COARSE AGGREGATES

4.3.1 SPECIFIC GRAVITY AND MOISTURE CONTENT TEST:

APPARATUS: Basket, weighing balance, cloth.

0BSERVATION:

Weight of dry aggregate = W =2000g

Weight of basket in water = W1 =750g

Weight of basket in water + aggregate = W2 =2000g

Weight of saturated surface dry aggregate = W3 =2005g

Weight of saturated aggregate= Ws =(W2-W1)=(2100-1000)

=1250g

FORMULA:

SPECIFIC GARAVITY = (W)

(W3-Ws)

2000
=(2005−1250)= 2.64

WATER ABSORPTION = (W3-W)*100

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(2005−2000)∗100
= =0.25%
2000

RESULTS:

Specific gravity =2.8

Water absorption=0.25%

4.3.2 AGGREGATE IMAPCT VALUE TEST: The property of a material to

resist impact is known as toughness. The aggregates should therefore have sufficient
toughness to resist their disintegration due to impact. This characteristic is measured by
impact value test. The aggregate impact value is a measure of resistance to sudden
impact or shock, which may differ from its resistance to gradually applied compressive
load.

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OBSERVATIONS:

Empty weight of measuring cylinder=W1=714g

Weight of measuring cylinder + aggregates=W2=1051g

Weight of portion passing 2.36 mm sieve= W3=103g

FORMULA:

Aggregate Impact Value (percent) = W3/ (W2 –W1) X 100

Aggregate Impact Value (percent) = 103/ (1051–714) X 100

=30.56%

RESULTS:

The aggregate impact value of the given sample=30.56%

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4.3.2 SIEVE ANALYSIS OF COARSE AGGREGATES:

Weight of coarse aggregates taken w =2000gms

Particle Empty Weight of Mass Percentage Cumulative Percentage

size weight of sieve + retained of sand percentage finer
(mm) sieve mass X retained retained 100 -C
(gms) retained X1=x*100 C
(gms) W

25 375 0 0 0 0 100
20 321 451 13 6.5 6.50 93.50
16 381 1188 627 31.35 37.85 62.15
12.5 335 1507 972 48.6 86.45 13.55
10 319 558 239 11.95 98.40 1.60
6.3 380 402 22 1.1 99.50 0.50
4.75 399 400 1 0.05 99.55 0.48
PAN 361 370 9 0.45 100 0
TOTAL 428.25

RESULT:

Sieve analysis of coarse aggregate is= 428.25 / 100= 4.28

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TABLE SHOWING RESULTS OF COARSE AGGREGATES

SL NO NAME OF TEST RESULTS

01 Fineness Modulus 4.28

02 Specific gravity 2.64

03 Impact value 30.56%

04 Water absorption 0.25%

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CHAPTER 6

TESTS ON FRESH CONCRETE

Before casting the cubes, cylinders and prisms, the tests on fresh concrete are to be conducted
to check more importantly the flow of the concrete that is prepared and to confirm whether it is within
the limits as mentioned in the guidelines or not. Also, the other tests are conducted to check the filling
and passing ability of PC.

Therefore, the tests that are being conducted in this research work on fresh concrete are:

1. Slump test
2. Vee-Bee consistometer test
3. Compaction factor test

7.1 SLUMP TEST

Figure showing Slump

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PRINCIPLE:

The concrete slump test is an empirical test that measures workability of fresh concrete. The
slump test measures the resulting behaviour of a compacted inverted cone of concrete under the action
of gravity. It indicates consistency or wetness of concrete.

EQUIPMENT:

 Base plate of size at least 900 × 900 mm, made of impermeable and rigid material (steel or
plywood) with smooth and plane test surface (deviation of the flatness not exceed 3 mm), and
clearly marked with circles of Ø200mm and Ø500mm at the centre.
 Cone with the internal upper/lower diameter equal to 100/200 mm and the height of 300 mm.
 Tamping rod
 Ruler (graduated in mm).
 Moist sponge or towel for wetting the inner surface of the cone and the test surface of the base
plate.
 Rag for cleaning spilled concrete if any.

TEST PROCEDURE:

 Mix the dry constituents thoroughly to get a uniform colour and the add water.
 Place the mixed concrete in the cleaned slump cone in the 4 layers, each approximately ¼ of the
height of the mould.
 Tamp each layer 25 times with the tamping rod.
 Strike off the top with a trowel or tamping rod so that the mould is exactly filled.
 Remove the cone immediately raising it slowly and carefully in the vertical direction.
 As soon as the concrete settlement comes to a stop measure the subsidence of concrete in cms
which will give the slump
 Clean the base plate and the cone after testing.

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7.3 COMPACTION FACTOR TEST:

Figure showing conduction of compaction test in lab

PRINCIPLE:

Compaction factor test works on the principle of determining the degree of compaction achieved
by a standard amount of work done by allowing concrete to fall through a standard height. A degree of
compaction called the compaction factor is measured by the density ratio i.e., the ratio of the density
actually achieved in the test density of some concrete fully compacted.

EQUIPMENT:

Compaction factor apparatus

Tamping rod

Trowel

Graduated cylinder of 500 ml capacity

Balance weight

Iron bucket

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PROCEDURE:

 Keep the compaction factor apparatus on a level ground and grease the inner surface of the
hopper and the cylinder.
 Fasten the hopper doors.
 Weight the empty cylinder accurately and note down the weight as W 1.
 Fix the cylinder on the base with the nut and bolt in such a way that central point of hopper and
cylinder lie on one line.
 Add required percentage of the water to the mixture and mix it thoroughly until the concrete
appears to be homogeneous.
 Fill the freshly mixed concrete in the upper hopper gently and carefully with hand sloop without
compacting.
 After two minute release the top door so that the concrete mix fall into the lower hopper.
 Remove the excess concrete above the top of the cylinder by a pair of trowel.
 Clean the cylinder from all sided properly find the weight of partially compacted thus filled in
the cylinder say W 2.
 Refill the cylinder with the same sample of concrete in approximately 3 layers by tamping 25
times each layer so as to obtain full compaction of concrete expelling all the air, level it up and
weight it say W3.
 Now tabulate the readings and apply suitable formula and find compaction factor for both
conventional concrete and pervious concrete.

OBSERVATIONS: (For 0.4 w/c)

 Weight of empty cylinder W1 = 9100 gm

 Weight of cylinder + partially filled concrete W2 = 17750 gm
 Weight of cylinder + fully compacted concrete W3 = 20200 gm

Compaction factor = W2-W1

W3-W1

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𝟏𝟕𝟕𝟓𝟎−𝟗𝟏𝟎𝟎
= 𝟐𝟎𝟐𝟎𝟎−𝟗𝟏𝟎𝟎

= 0.78

OBSERVATIONS: (for 0.45 w/c )

 Weight of empty cylinder W1 = 9100 gm

 Weight of cylinder + partially filled concrete W2 = 17200 gm
 Weight of cylinder + fully compacted concrete W3 = 18900 gm

Compaction factor =W2-W1

W3-W1

𝟏𝟕𝟐𝟎𝟎−𝟗𝟏𝟎𝟎
= 𝟏𝟖𝟗𝟎𝟎−𝟗𝟏𝟎𝟎

= 0.83

TEST RESULTS OF FRESH CONCRETE:

Sl
Test Water cement ratio Result
no
0.4 True slump (0 mm)
1 Slump test
0.45 75mm
0.4 0.78
2 Compaction factor test
0.45 0.83

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DESIGN OF LIGHT WEIGHT CONCRETE MIXTURES

6.1 MATERIAL REQUIREMENT CALCULATIONS:

Concrete mixture design process is vast and generally based on performance criteria. The performance
criteria of a Geopolymer concrete mixture depend on the application. For simplicity, the compressive
strength of hardened concrete and the workability of fresh concrete are selected as the performance
criteria. In order to meet these performance criteria, the alkaline liquid-to-fly ash ratio by mass, water-
to-Geopolymer solids ratio by mass, the wet-mixing time, the ambient-curing temperature.With regard
to alkaline liquid-to-fly ash ratio by mass, values in the range of 0.30 and 0.45 are recommended.

Assume the cube size of 150mm×150mm×150mm, for M20 grade, using the same method as in
Portland cement concrete calculate amount of fly ash, aggregates coconut fibres water required as
follows.

6.2FOR CONVENTIONAL CONCRETE CUBES:

Grade of concrete: M20 (1:1.5:3)

Volume of mould: 15x15x15=3375cc

Dry volume: 1.1x3375= 3712.5cc ≈ 3700cc

Weight of concrete= 3700x 2.4 =8880cc

Weight of cement= 8880x (1 /5.5) =1.6kg/cube

Weight of Fine aggregates: 8880 x (1.5/ 5.5) =2.42kg/cube

Weight of Coarse aggregates: 8880 x (3/5.5) =4.8kgs/cube

Water Required: 0.45×1.6= 0.72ltr

Total number of cubes conventional concrete cubes required are 9numbers for 3days, 7days and
28days compression test.

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FOR LIGHT WEIGHT CONCRETE BLOCK WITH PLASTIC

Grade of concrete: M20 (1:1.5:3)

Volume of mould: 15x15x15= 3375cc

Dry volume: 1.1x 3375= 3712.5cc ≈ 3700cc

Weight of concrete= 3700x 2.4 =8880cc

Weight of Fine aggregates: 8880 x (1.5/ 5.5) =2.42kg/cube

Weight of Coarse aggregates: 8880 x (3/5.5) =4.8kgs/cube

Quantity of solution per cube: 0.45x1.6= 0.72lt

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CHAPTER-6

CASTING OF CUBES

INTRODUCTION:

Lightweight concrete has been used since the eighteen by the Romans. The application on the ‘The
Pantheon’ where it uses pumice aggregate in the construction of cast in-situ concrete is the proof of its
usage. In USA and England in the late nineteenth century. Clinker was used in their construction for
example ‘British Museum’ and other low cost housing. The lightweight concrete was also used in
construction during the First World War. The united states used mainly for shipbuilding and concrete
blocks. The foamed blast furnace-slag and pumice aggregate for block making were introduced in
England and Sweden around 1930s. Nowadays with the advancement of technology, lightweight
concrete expands its uses. For example, in the form of perlite with its outstanding insulating
characteristics. It is widely used as loose-fill insulation in masonry construction where it enhance fire
ratings, reduce noise transmission, does not rot and termite resistant. It is also used for vessels, roof
decks and other applications.

The successive steps that were followed to complete the study were as follows:

1. Collection of high density polyethylene (HDPE) materials.

2. Preparation of recycled plastic aggregate.

3. Various tests were conducted on cement, fine aggregate and coarse aggregate to determine its
physical properties.

a. Test on cement: Specific gravity, standard consistency, initial and final setting time,
compressive strength of mortar cube.

b. Test on aggregates: Specific gravity, sieve analysis.

c. Mix design of M20 concrete

d. Cubes, cylinders and beams were casted for varying percentage replacement (5, 10, 15, 20,
25, 30, 35, and 40) of natural aggregate by plastic aggregate.

e. Workability, Compressive strength, splitting tensile strength and flexural test.

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MAKING OF PLASTIC AGGREGATE:

After a review of various research studies, high density polyethylene (HDPE) was selected as a
substitute for natural aggregate. HDPE is the largest of the three polyethylene by volume of
consumption. HDPE is prepared from ethylene by a catalytic process. If it also harder, more opaque and
can withstand higher temperature. They are impact and wear resistant and can have very high elongation
before breaking when compared to others materials. They are chemical resistant ad cheap too. It has
very linear structure with only a few short side branches and hence leading to higher density rang as
well as more crystalline structure. These properties give HDPE its higher strength compared to the other
PEs, allowing a wider range of use. The properties of HDPE are:

1. Excellent resistant (no attack) to dilute and concentrated acids, alcohols and bases.

2. Melting point: 130C-180C

3. Specific Gravity: 0.95

4. Water absorption: 0,001%-0.010%

5. Chemical resistant

6. Impact and wear resistant

7. Can withstand high temperature

The plastic aggregates were prepared from recycled HDPE sheets. Generally the plastic recycling can
be completed through 5 steps: sorting, shredding, washing and extruding. The various steps involved
in recycling and making of plastic are described below.

Sorting the plastic:

Once the recyclable plastic materials were collected. The first stage of recycling began by
sorting out the plastic recycling is a complex process compared to other recycling process because of
the different types of plastic that exists. Mixed plastic cannot be used as it is poor in quality. Therefore
its essential to sort out plastic materials. HDPE is thus sorted out.

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Fig 3.1 Sorting Of Plastic

Shredding the plastic:

The plastic materials were then prepared for melting by cutting them into small pieces. The
plastic items are fed into a machine which as set of blades that slides through the materials and break
the plastic into tiny bits.

Fig 3.2 Shredding and shredded HDPE Material

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Washing shredded plastic:

All residues of products contained in the plastic. Items and various other contaminants are
removed. A particular wash solution consisting of an alkaline, cationic detergent and water are used to
effectively get rid of all the contaminants on the plastic.

Fig 3.3 Washing of shredded plastic

Extruding:

This is the final stage in the recycling process. The cleaned and chipped pieces of plastic are
melted down and put through a machine called extruder. After the plastic is melted and compressed,
it is channeled into the metering section. Here, the plastic undergoes pressurized pumping, while the
root diameter of the screw and the flight size remain constant.

Fig 3.4 Extruder and Extrusion of Plastic

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Plastic aggregate:

These melted plastics were allowed to fall on a rough surface through the die. Plastic
sheets of 20mm thick were made out of these recycled materials. Undulations were made on the
surface of the sheets. These sheets were then cut into aggregate of 20mm.

Fig 3.5 Plastic Aggregate

2. BATCHING:
The measurement of materials for making concrete is known as batching. There are two
methods of batching: Volume batching and Weigh batching, We have adopted weigh batching.
Weigh batching is the correct method of measuring the materials. For important concrete, invariably,
weigh batching system should be adopted. Use of weigh system in batching facilitates accuracy,
flexibility and simplicity. The materials are taken and correctly measured as per calculation using
weighing machine.

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3. MIXING :
Thorough mixing of the materials is essential for the production of uniform concrete. The
mixing should ensure that the mass becomes homogeneous. Uniform in colour and consistency. First
dry mixing of all the materials has to be made, then the alkaline solution is poured and the uniform
mixing has to be made.

Dry mixing of materials

4. PLACING AND COMPACTION:

150 mm moulds should be filled in three approximately equal layers (50 mm deep). A
compacting bar is provided for compacting the concrete. It is a 380 mm long steel bar, weighs 1.8 kg
and has a 25 mm square end for ramming. During the compaction of each layer with the compacting
bar, the strokes should be distributed in a uniform manner over the surface of the concrete and each
layer should be compacted to its full depth. During the compaction of the first layer, the compacting
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bar should not forcibly strike the bottom of the mould. For subsequent layers, the compacting bar
should pass into the layer immediately below. The minimum number of strokes per layer required to
produce full compaction will depend upon the workability of the concrete, but at least 35 strokes will
be necessary except in the case of very high workability concrete. After the top layer has been
compacted, a trowel should be used to finish off the surface level with the top of the mould, and the
outside of the mould should be wiped clean.

Casting of cubes

5. DEMOULDING OF CUBES:
After the 24hours the cubes are to be demoulded and kept for curing.
6. CURING:
All specimens are cured for 3 days, 7 days, & 28 days as per standard procedure. After 24hrs
concrete specimens are removed from the mouldsthe Geopolymer concrete cubes and Geopolymer
concrete cubes with coconut fibers are kept in atmospheric temperature for ambient curing. And the
conventional concrete cubes are kept for curing in water bath for the required days of curing.

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LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

TESTING OF CUBES:

PROCEDURE FOR COMPRESSION TESTING OF CUBES

1. After specified curing time of cubes

2. Take the dimension of the specimen to the nearest 0.2m and weigh the specimen
3. Clean the bearing surface of the testing machine
4. Place the specimen in the machine in such a manner that the load shall be applied to
the opposite sides of the cube cast.
5. Align the specimen centrally on the base plate of the machine.
6. Rotate the movable portion gently by hand so that it touches the top surface of the
specimen.
7. Apply the load gradually without shock and continuously
8. Record the maximum load and note any unusual features in the type of failure.

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LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-7

REFERENCE

1. Daniel yaw osei, experimental investigation on recycled plastics as aggregate in

concrete, International journal of structural and civil engineering Research, ISSN: 2319
– 6009, Vol. 3, No. 2, May 2014, pp. 168-174.

2. Dr. M. Vijayasekhar Reddy, D. Mrudula, M. Seshalalitha, Strength and Density

Characteristics of light Weight Concrete by Using HDPE Plastic Waste, International
Journal For Research in Applied Science and Engineering Technology (IJRASET),
issn: 2321 – 9653, Vol. 3, Special Issue-1, May 2015, pp. 149-152

3. Ghassan Subhi Jameel, Study The Effect of Addition of Weste Plastic on Compressive
and Tensile Strength of Structural Lightweight Concrete Containing Broken Brick as a
Coarse Aggregate, International Journal of Civil Engineering and Technology
(IJCIET), ISSN: 0976 – 6308 (Prient), ISSN: 0976 – 6316 (Online), Vol. 4, Issue 2,
March – April (2013), pp. 451-432.

4. J. N. S. Suryanarayana Raju, M. Senthil Pandian, Mechanical Study on Concrete with

Waste Plastic, International Journal of Research in Civil engineering Architecture and
design, Vol. 1, Issue 1, July – September, 2013, pp. 62-67.

5. Kasib R. Malak, Use of Waste plastic in Concrete Mixture as Aggregate Replacement,

International Journal of Engineering, Education and Technology (ARDIJEET), April
2015.

6. Vishal Yadav, Arvinder Singh, “Study on Properties of Concrete Containing Recycled

Plastic aggregate”, International Journal of recent research Aspects, ISSN: 2349 – 7688,
Vol. 1, Issue 3, December 2014, pp. 24 – 27.

7. IS: 456 – 2000, Plain and Reinforced Concrete – Code of Practice.

8. IS: 1489 (Part 1) – 1991, Portland pozzolona Cement – Specification.

9. IS: 2386 (Part 1,3) – 1963, Method of Test for Aggregate For Concrete.

10. IS: 383 – 1970, Specification for Coarse and Fine Aggregate from Natural Sources for
concrete.

11. IS: 10262 – 1982, Recommended Guideline For Concrete Mix Design.

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