CONCRETE BLOCK USING CRUSHED LATERITE BRICK AS ...

PERPUSTAKAAN UMP

111111111111111111111111 0000073603

CONCRETE BLOCK USING CRUSHED LATERITE BRICK AS SAND SUBTITUTION

CuE AMRI BIN CHE AZMI AA 08127

A thesis submitted in fulfillment of the requirements for the award of the degree Of

Bachelor of Civil Engineering

Faculty of Civil Engineering & Earth Resources University Malaysia Pahang

JUNE 2012

ABSTRACT

During last decades, it has been recognized with growing concern that

wastes from a construction are of large volume and that this volume is

increasing year by year The problem of waste accumulation exists

worldwide. Most of waste materials are left as a landfill materialor illegally

dumped. Environmental impact can be reduced by making more sustainable

use of this waste by recycling process. Main objectives of this research are to

determine the mechanical properties of crushed laterite brick and also to

determine the compressive strength of concrete block using crushed laterite

brick as sand substitution. Based on these two objectives, all sample will

undergoes certain process starts from finalizing mix design, then followed by

preparing samples that covered sieving, batching, mixing, compacting and

end with curing process. At age l days and 28 days all

sample will betested

on their compressive strength by compressive test method.. Data obtained

from compressive test shows that by substituting sand with crushed laterite

brick, the strength of concrete block can be enhance: As a conclusion crushed

laterite bricks meets all the requirements to be used as sand substitution in

concrete block.

V

ABSTRAK

Lebih sedekad yang lain, kebimbangan tethadap peinbuangan sisa daii

pembinaan dalam jumlah yang besar bertambah dan jumlali mi semakin

ineningkat dari tahun ke tahun. Masalah pengumpulan sisa wujud di seluruh

dunia. Kebanyakan bahan-bahan buangan yang tinggal sebagai matenialor

tapak pelupusan sampah yang dibuang secara haram. Kesan alam sekitar

dapat dikurangkan dengan penggunaan lebih mapan sisa mu melalui proses

kitar semula. Objektif utama kajian mi adalah untuk menentukan silat-sifat

mekanikal bata Latent yang dihancurkan dan juga untuk menentukan kekuatan

mainpatan blok konkrit yang menggunakan bata latent yang dihancurkan

sebagai gantian kepada pasirBerdasailcan kedua-dua objektif semua sampel

akan menjalani proses tertentu bcrmula darl memuktamadkan reka bentük

campuran, kemuclian diikuti dengan menyediakan sampel yang meliputi

pengayakan, pencampur, membancuh, memadat dan selesai dengan proses

pengawetan. Path usia 7 ban dan 28 hari semua sàmpel akan diuji tethadap

kekuatan mampatan mereka dengan kaedah ui Ian mampatan. Data yang

diperolehi dan ujian mampatan menunjukkan dengan menggantikan pasir

dengan batu-bata latent yang dihancurkan, kekuatan blok konkñt boleh

ditingkatkan. Kesimpulannya, bata latent yang dihancunkan memenubi

semua cini-cini yang diperlukan sebagai pengganti pasir dalam blok konkrit

vi

TABLE OF CONTENTS

VII

PAGE CHAPTER

I

2

TIME i TITLE

DECLARATION iv

ACKNOWLEDGEMENT v

ABSTRACT vii

TABLE OF CONTENT

LIST OF TABLES

LIST OF FIGURES

INTRODUCTION 1

11 PROBLEM STATEMENT 2 12 OBJECTIVE 3 1.3 SCOPE OF STUDY 4

LITERATURE REVIEW 4

2.1 INTRODUCTION 4

2.2 CONCRETE MIX DESIGN 6

2.3 PROPERTISE OF CONCRETE WITH 8

CRUSHED ]LATERITE BRICK AS AN

AGGREGATES

2.3.1 COMPRESSIVE STRENGTH 8

Va'

dHAIrEI( TITLE PAGE

2.4 PREVIOUS TEST OF USING FINE AND 10 COARSE CRUSHED LATERITE BRICK

AS AGGREGATES

3 METHODOLOGY 17

3.0 INTRODUCTION 17 3.1 FLOW CHART OF RESEARCH 18

METHODOLOGY

3.1 - 1 PHASE 1: LITERATURE REVIEW 19

3.1.2 PHASE 2: COLLECTING 20 MATERIAL AND PREPARING

SPECIMENS

3.1.2.1 COLLECTING MATERIAL 20 3.1.2.1.1 CEMENT 20 3.1.2.1.2 LATERITE BRICK 21 3.1.2.1.3 WATER 21 3.1.2.1.4 QUARY DUST 22

3.1.2.2 PREPARING SPECIMENS 22 3.1.2.2.1 CRUSHING LATERITE 23

BRICK AND SEWING

PROCESS

3.1.2.2.2 CONCRETE MIXING 24 3.1.2.2.3 PREPARING 26

COMPRESSED

CCONCRETE BLOCK

3.1.3 PHASE 3: TESTING AND 29 COLLECTING DATA

3.1.3.1 COMPRESSION TEST 29

Ix

CHAPTER TITLE PAGE

4 DATA ANALYSIS AND DISCUSSION 32

4.0 INTRODUCTION 32 4.1 DATA MODIFICATION 33 4.2 COMPRESSIVE TEST RESULTS 35

4.2.1 COMPRESSIVE STRENGTH OF 35

LATERITE BRICK

4.2.2 CONCRETE BLOCK AGE 7-DAYS 35 4.2.3 CONCRETE BLOCK AGE 28- 39

DAYS

4.2.4 COMPARISON OF COMPRESSIVE 42

STRENGTH BETWEEN SAMPLE

AT 7-DAYS AND 28-DAYS 4.3 PROBLEMS OCCUR DURING 43

LABORATORY WORK

5 CONCLUSION AND RECOMENDATION 45

5.0 INTRODUCTION 45 5.1 CONCLUSION 45 5.2 RECOMENDATION 47

REFERENCES 48 APPENDIX 49

LIST OF TABLES

TABLE NO. TITLE PAGE

I Type of Cement And Their Compressive Strength 9

2 Type Of Brick And Their Mechanical Properties 10

3 Percentage of Sand and Crushed Clay Brick In 24 mixture

4 Weight of Every Portion For 6 Samples 25

5 Compressive Strength of Laterite Brick 35

6 100% Sand + 0% Crushed Laterite Brick at 7- 35

Days Strength

7 75% Sand + 25% Crushed Laterite Brick at 7- 36 Days Strength

8 50% Sand ± 500/0 Crushed Laterite Brick at 7- 36 Days Strength

x

XI

TABLE NO. TITLE PAGE


Days Strength


Days Strength

11 Summary of Compressive Stress For Concrete 37

Block at 7-days

12 1001/6 Sand + 0% Crushed Laterite Brick at 28- 39

Days Strength


Days Strength


Days Strength


Days Strength

16 0% Sand ± 100% Crushed Laterite Brick at 7- 40

Days Strength

17 Summary of Compressive Stress For Concrete 40

Block at 7-days

LIST OF FIGURES

FIGURE NO. TITLE PAGE

I Fine and course aggregate grading according 12 to ASTM C33

2 Compressive strength of concrete made with 13 crushed brick as aggregate

3 7-Days Compressive Strengths for Sandcrete and 14 Laterite-Cement Blocks

4 28-Days Compressive Strengths for Sandcrete 15 and Laterite-Cement Blocks

5 Concrete compressive strength with percentage 16 replacement of coarse FCB aggregate.

6 Cement 20

7 Laterite Brick 21

8 Quary Dust 22

XII

XIII


9 Laterite Brick 23

10 Jaw Crusher Machine 23

11 Water (l0%) 26

12 All Concrete Portion Before Water Added 26

13 Wet Concrete Mixture 27

14 Pouring Concrete Mixture Into Mold 27

is Compacting Process 27

16 Concrete Block After Compacting Process 28

17 Curing Process Using Wet Blanket for 7-Days 28

18 Setting Type and Sample Dimension 30

19 Placed Steel Plate On Top and Bottom of Sample 31

20 Sample Placed Into Compressive Machine 31

21 Plan View Of Concrete Block With Dimension 33

22 Maximum Load Applied On Sample At 7-Days 37

23 Compressive Strength of Concrete Block With 37

Crushed Laterite Brick Subtitution At 7-Days

xiv


24 Maximum Load Applied On Sample At 28-Days 41

25 Compressive Strength of Concrete Block With 41

Crushed Laterite Brick Subtitution At 28-Days-

26 Comparison of Compressive Strength Between 42

Sample At 7-Days And 28-Days

CHAPTER 1

1.0 INTRODUCTION

During last decades, it has been recognized with growing concern that

wastes from a construction are of large volume and that this volume is

increasing year by year. The problem of waste accumulation exists

worldwide. Most of waste materials are left as a landfill materialor illegally

dumped. Environmental impact can be reduced by making more sustainable use of this waste.

Waste management is one of the priorities of every community and it

has become evident that good waste management can enhance the quality of

life, the main principle of a quality waste management is in lowering the mass

Production of new, finding ways to recycle and reuse existing, and safe and

ecologically acceptable depositing of unused waste.

Laterite can be consider as one of the natural resources material that

has a lot of benefit in construction due to the low cost process and has high workability while it always been forgotten and be consider as waste in construction Laterite also comes with adequate compressive strength to be

used as load bearing wall as normal as concrete block has been used.

1

The used crushed laterite brick can be utilized as a subtitution to the

aggregates in cocncrete mixture. This research can help to reduce the

Percentage of brick in construction waste and helpfull in preserved natural

material since recycling concept is apply in this project

1.1 PROBLEM STATEMENT

Recycling and reuse of waste materials is a topic of global concern

and of great international interest The urgent need for recycling is driven

mainly by environmental considerations, due to the increase scarcity of

natural resources and the increasing cost of land till in most countries.

Construction and demolition (C&D) materials are generated by regeneration

of infrastructure such as demolition activities of buildings and construction

activities of tunnels and roads. Recycled crushed brick, crushed concrete,

crushed basaltic rock are viable substitute materials for natural construction

materials in engineering applications. However, there have only been a few

attempts to utilize recycle brick in concrete mixture.

NevertherIe, the subtituion of recycled crushed laterite brick to the

aggregate in concrete mixture will be helpfull to improve the technology of

concrete used in construction. This idea will focus on strength of concrete and their workability of the concrete.

1.2 OBJECTIVE

The purpose of this study is to minimized clay brick as wastage in

construction and utilized the used of recycled laterite brick as subttution to

the aggregates in concrete mixture. In order to archeive the result in this

study, the objective are:

1) To determine the mechanical properties of crushed laterite brick.

2) To determine the compressive of concrete using crushed laterite

brick as aggregates.

13 SCOPE OF STUDY

This study will cover most of the laboratory work that involve in

concrete work suck as curing and also compressive test for concrete.

1) Only laterite brick which interchangable to clay brick will be used

in this project, those bricks will be crushed and seived to 6mm

size.

2) Portland cement 25 will be used for all samples and mixtures.

For compressive test, this project will be using BS 1881 as

refenng standard. The size for all compressed concrete block will be

300mmx 125mmx 112mm.

3

CHAPTER 2

LITERATURE REVIEW

2.1 INTRODUCTION

What is concrete?

Concrete most widely used as construction material all over the world.

Concrete can be define as a mixture of cement, sand, aggregate and water.

In certain situation, mixture will be added to fuilfill the characteristic of

concrete to be archived. A good quality of concrete is directly related to the

high quality of material used in mixing process. In construction normally

the workability, durability and strength of concrete will be the first

characteristic that will be focus on to ensure the good result in construction..

Hardened concrete can be done by the chemical reaction between material

in mixing concrete. The strength of concrete will increase due to the age of

concrete it self.

Concrete is common material used in construction because of the

economical approach and also concrete is easy to handle compare to the

4

other material. Concrete can be molded in any shape or size depends on

needed.

The maintenance cost for concrete are also minimal and the effect of

corrosive and the weathering are also minimal. The most important

charactheristic is concrete has high compressive strength but has very low

tensile strength. The use of reinforement steel in commonly help to

overcome this problems. Concrete also sensetive due to the changes in

temperature, concrete can expand in hot temperature.

What is laterite brick?

Laterites are soil types rich in iron and aluminium, formed in hot and

wet tropical areas. Nearly all laterites are rusty-red because of iron oxides.

They develop by intensive and long-lasting weathering of the

underlying parent rock. Tropical weathering (laterization) is a prolonged

process of chemical weathering which produces a wide variety in the

thickness, grade, chemistry and ore mineralogy of the resulting soils.

When moist, laterites can be easily cut with a spade into regular-sized

blocks. Laterite is mined while it is below the water table, so it is wet and

soft.Upon exposure to air it gradually hardens as the moisture between the

flat clay particles evaporates and the larger iron salts lock into a rigid lattice

structure and become resistant to atmospheric conditions. The art of

quarrying laterite material into masonry is suspected to have been

introduced from the Indian subcontinent

Normally in construction, the intention to maximized the use of

aggregates in concrete mixture always a priority in order to reduce cost as

the price of aggregates is cheaper compared to the cement binder. Aggregate

occupies between 70 % and 80 % of the total concrete volume, and because

of that the strength of aggregate is very important the final strength of the concrete. [Ivana & etal I-

2.2 CONCRETE Mix DESIGN

In simplest form, concrete in a mixture of cement, aggregates and water. In this study Portland cement will be used while recycled crushed Clay brick will be used as aggegates subtitution in concrete mixture. By

using recycle crushed brick as an aggregates in concrete mixture, it is

possible to design concrete mixtures in the same way as the design mixtures

for commonly used aggregates.

The bond between brick and mortar is largely influenced by the tug-of- war between the capacity of the brick to absorb water and the ability of

the mortar to retain the water. This water is needed for the proper hydration

of cement where the mortar contacts the brick If the brick wins this tug-of-

war (and sucks the water too quickly from the mortar), the mortar strung out

for the bed joint stiffens so rapidly that the bricks in the next course cannot

be Properly bedded.. If the mortar retains too much water the bricks tend to

float on the mortar bed, which makes it difficult to lay plumb walls at a

reasonable rate. In either case there will be poor bond High suction bricks

require a mortar with very high water retention, making it necessary to

shorten the length of the bed joint or wet the bricks to reduce their suction.

It should be noted however that wetting the bricks can lead to efflorescence

in the brickwork, Bricks - Influence of Initial Rate of Water Absorption on

Mortar Bonding <pJ/wwwazoucom/jcleaspx?c1eff)l> (28/11/2011)

6

7

The water absorption of recycled crushed brick is estimated to a value

between 22 % and 25 % by weight in relation to the material in its dry state.

From the studies of absorption recycled bricks aggregates, it was concluded

that recycled crushed brick will be almost saturated with water after water

submission in 30 minutes. Submersion for a further 24 hour produces only

an increase of about 2 % water absorption.. [Heusen 1992 ]

By using recycled aggregates, the dust content must be taken into

consideration because it can cause a reduction in workability. In that case,

if extra water has to be added to the concrete mix to increase the

workability, the loss of strength will be evident. If the reduction in strength

is limited to around 5%, the maximum amount of dust should be limited

also. That limitation could be in ranges from 5%of the total aggregate

content for low workability with a coarse grading, 10 % for low workability

with fine grading and 20 % for a high workability with fine grading-

[ Xhalaf & Dc Venny 20041

As using crushed recycled brick as aggregates, concrete will has a lower density due to the density of recycled brick that 8-17% than

commonly used concrete that situation will increase the percentage of

entrained air. [Debieb & Kenai 2008]

2.3 PROPERTISE OF CONCRETE WITH CRUSHED LATERITE

BRICK AS AN AGGREGATES

23.1 COMPRESSIVE STRENGTH

Compressive strength is the capasity of material to withstand direct

axial load given. Generally, using crushed recycled brick as aggregates will

couse low compressive strength due to higher water absorbtion compared to

normal concrete.

By using Ordinary Portland Cement or Sulphate Resisting Portland

Cement the compressive strength of concrete can be estimated based on

ordinary concrete test mixes made with free-water, cement ratio of 0.5 and

the value of compressive strength should be increasing due days and

normally this test will be conducted when concrete's age 3 days, 7 days, 28

days and 91 days.

8

9

TABLE I: Type of Cement And Their Compressive Strength.

TYPE OF TYPE OF COARSE COMPRESSIVE

CEMENT AGGREGATE STRENGTH (N/mm2)

AGE (DAYS)

3 7 28 91

Ordinary Portland Unchrushed 22 30 42 49

Cement @ Sulphate Crushed 27 36 49 56

Resisting Portland

Cement

Rapid Hardening Unchnished 29 37 48 54

Portland Cement Crushed 34 43 55 61

1 N/mm' = 1 MN/rn' =1 Mpa

Increasing of the rate of substitution natural aggregate with brick

decreases the compressive strength. After 28 days o , the decreasing in

compressive strength was in the order of 10-350/ofor the recycled coarse

aggregates concrete in comparison with an ordinary concrete. [Debieb &

Kenai 2008]. Strength of concrete with crushed recycle clay brick as

aggregates can be estimated based on strength of original brick-

In this situation, type of recycled brick must be first determined for

better result estimation. For example, engineering brick is one of the best

type for this study because it was designed to withstand load.

10

2.4 PREVIOUS TEST OF USING FINE AND COARSE CRUSHED LATERITE BRICK AS AGGREGATES

Clay brick is common material used in construction. In Malaysia, the used of clay brick in construction has refer to BS 3291: 1985 (Specification for Clay Brick). Further, clay brick can be classified into three categories; common brick, facing brick and engineering brick based on their properties and strength.

TABLE 2: Type Of Brick And Their Mechanical Properties.

Class Con ressis-esijeuth.. Water absoiplion..

xvawi^ I; toy mass nñwethiA 70 43

EijneeijnB >50 Damppmofcmwse I 45 Dawp.pnofajujse2 S

AUothess 2!5 - No limit NOTE I Theis no diiecne ionsiñp beeu cessi-e SMUgM and warr abscnpitn, as iveu in this sable and dwabiluiy. NOTE 2 Danip-pioofconxse I tricks are xecommejjded for use in buildãt whilst danrp-pxuof course 2 kicks are recurnmeudj for use in ecrernaj wcts (see Table 13 of BS 5625-3:19551

Some work has been carried out into the possibility of using crushed brick as an aggregate in concrete but most of the research dates back to just after WorldWar 11 Only a small amount of work has been carried out using the types of brick that are commonly used in construction today and there is little knowledge on the subject in the United Kingdom and other countries.

11

Recently, Akhtaruzzaman and Hasnat (1983) carried out some research

using well burnt brick as coarse aggregate in concrete. They found that it

was possible to achieve concrete of high strength using crushed brick as the

coarse aggregate. [Khalaf and De Venny 2004] Their research was mainly

concentrated on determining the mechanical properties of brick aggregate

concrete rather than the properties of the brick aggregate itself Khaloo

(1994) used crushed clinker bricks as the coarse aggregate in concrete. He

reported only a 71/o loss in concrete compressive strength compared with

concrete made with natural aggregates. In contrast to this decrease in

strength, there is a decrease in the unit weight of crushed brick concrete of

9.5%.

In Ferdowsi University in Iran, one research on using crushed clay

brick as aggregate in concrete has been made. Brick was taken from

demolition building. Discharged brick aggregate was sieved according to

ASTM C33 designation. Coarse aggregate were sized-screened to a

maximum 19 mm. The fine grading must be within the fine aggregate zone

specified by ASTM. The lower bound of this zone was selected since the

grading of crushed aggregate in the laboratory jaw crusher was very close to

this boundary

- Rem. nvdV,. Sddgjngiora Fine aggrepw Coraz1f El:

12

50

40

(mm) 03 0A15 0.6 uS 2.36 435 93 123 19.0 2 1 = =

z z z z z z -

FIGURE 1: Fine and course aggregate grading according to ASTM C33.

Figure 2 illustrates the selected grading of fine and coarse aggregate

based on ASTM C 33. Before adding water, coarse and fine aggregates and

cement were placed in the mixer and mixed for about 1 mm. Then water

was added gradually for a period of about of 2 mm, and then the concrete

was mixed for 3 minutes to produce a uniform mix.

150

>too

IMI

190 -

' 180

15010 -'U 44) 50 60 '70 80 100

Day

200

13

50, 100 200 300 400

Ccmcnt (kg/rn3)

FIGURE 2. Compressive strength of concrete made with crushed brick

as aggregate.

A water cement ratio of w/6=0.5 was selected for different cement

content (150-350 kg1m3). The prescribed constant water ratio led to

workability with slump varying from 40 mm to 90 mm respectively. The

CONCRETE BLOCK USING CRUSHED LATERITE BRICK AS ...

Documents

Transcript of CONCRETE BLOCK USING CRUSHED LATERITE BRICK AS ...