Nks Final Report.docx

USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

CHAPTER 1 INTRODUCTION Infrastructure development across the world created demand for huge amount of construction material. Concrete is premiere civil engineering material. Concrete manufacturing involves cement, aggregate, water and admixture. Among all these ingredients, aggregate forms the major parts. Resources for the aggregates are also exhausting very rapidly. So there is a need to find alternative for the aggregate. In this project coconut shell is used as a partial replacement for course aggregate. The behavior of concrete is studied by partially replacing the aggregate with coconut shell which is a waste product. The experimental work mainly concern with the study of mechanical properties like compressive strength, split tensile strength and as well as flexural strength of concrete by partial replacement of coarse aggregate by coconut shell. Tests will be carried out on cubes and beams to study the mechanical properties of concrete using coconut shell and results will be compared with normal concrete with natural aggregate. Coconut is grown in more than 93 countries. India is the third largest having cultivation on area of about 1.78 million hector. Annual production is about 7562 million nuts with an average of 5295 nuts per hectors. The coconut industry in India accounts for over a quarter of the world’s total coconut oil output and is set to grow further with the global increase in demand. However, it is also the main contributor to the nation’s pollution problem as a solid waste in the form of shells, which involves and an annual production of approximately 3.18 million tones. Coconut shell represents more than 60% of the domestic waste volume. Coconut shells which present serious disposal problems of local environment are an abundantly available agriculture waste from local coconut industries. These wastes can be used as potential material or replacement material in construction industry. This will have double advantage of reduction in the cost of construction material and also as a means of disposal of wastes. A part from its use in production of fiber-roofing material, the other possibility of using coconut shell as an aggregate in concrete production has not been given any serious attention.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

In developed countries, the construction industries have identified many artificial and natural lightweight aggregate that have replaced conventional aggregate thereby reducing the size of structural member. This has brought immerse change in the development of high rise structures using light weight concrete. However, I n Asia the construction industry is yet to utilize the advantage of light weight concrete in the construction of high rise structure. Coconut shell are not commonly used in the construction industry but are obtained dumped as agriculture waste. Following a normal growth in population, the amount and type of waste materials have increased accordingly. Many of the non-decaying waste materials will remain in the environment for hundreds, perhaps thousands of years. The non-decaying waste materials cause a waste disposal crisis, thereby contributing to the environmental problems. However, the environmental impact can be reduced by making more sustainable use of this waste. This is known as the Waste Hierarchy. Its aim is to reduce, reuse, or recycle waste, the latter being the preferred option of waste disposal. So in this project, coconut shell is being used as construction material which helps to use one of the waste products and reduce solid waste to some extent along with cost optimization of the one of the important construction element that is the concrete. Objectives of Study: 1. Use of waste material for preparing a concrete. 2. To prepare light weight concrete by using coconut shell as a replacement for coarse aggregate 3. To find the economical solution for high cost construction material.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

Chapter 2 Literature Review Following papers have been studied regarding our title of project. 1) Coconut Shell As a Partial Replacement for Coarse Aggregate. ( by Mr. Akhsay ShelkeandKalyani Ninghot) In this paper it has been studied that the use of structural grade light weight concrete reduce considerably the self-load of a structure and permit larger precast units to be handled. The concrete with ground coconut shell was found to be durable in terms of its resistance in water, acidic, alkaline and salty. Density of coconut shell is in the range of 550-650 kg/cum. And these are within the specified limits for light weight aggregate. The characteristics properties of concrete such as compressive strength, impact resistance, bond strength and split tensile strength using the mix made by replacing coarse aggregate with crushed coconut shell aggregate were reviewed in the present work. The coconut shell being a hard and not easily degrade material if crushed to size of sand can be potential material to substitute sand. At present, coconut shell has also been burnt to produce charcoal and activated carbon for food and carbonated drink and filtering mineral water use. The chemical composition of coconut shell is similar to wood. It contains 33.61% cellulose, 36.51% lignin, and ash at 0.61%. They found out the solution for reducing the high cost construction material and preparing light weight concrete by using coconut shell as coarse aggregate. Coconut shell exhibits more resistance against crushing, impact and abrasion, compared to crushed granite aggregate. Coconut shell can be grouped under lightweight aggregate. Coconut shell is compatible with the cement. The 28-day air-dry densities of coconut shell aggregate concrete are less than 2000 kg/m3 and these are within the range of structural lightweight concrete. It has been concluded that it increase the speed of construction, enhance green construction environment we can use lightweight concrete. The possibility exists for the partial replacement of coarse aggregate with coconut shell to produce lightweight concrete. There is no need to treat the coconut shell before using it as an aggregate except for water absorption. Coconut shell is compatible with the cement

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

2)Light weeght Concrete Using Coconut Sells as Aggregate (By Mr. K.Gunasekaran and Mr. P. Kumar) (2008) Concrete is the widely used as number one structural material in the world today. The demand to make this material lighter has been the subject of study that has challenged scientists and engineers alike. The challenge in making a lightweight concrete is decreasing the density while maintaining strength and without adversely affecting cost. Introducing new aggregates into the mix design is a common way to lower a concrete’s density. Normal concrete contains four components, cement, crushed stone, river sand and water. The crushed stone and sand are the components that are usually replaced with lightweight aggregates. Some of the lightweight aggregates used for lightweight concrete productions are pumice, perlite, expanded clay or vermiculite, coal slag, sintered fly ash, rice husk, straw, sawdust, cork granules, wheat husk, oil palm shell, and coconut shell. Aggregates provide volume at low cost, comprising 66 percent to 78 percent of the concrete. The fresh concrete properties such as density and slump and 28-day compressive strength of a lightweight concrete made with coconut shell as coarse aggregate also presented. The findings indicated that water absorption of the coconut shell aggregate was high about 24 % but the crushing value and impact value was comparable to that of other lightweight aggregates. The average fresh concrete density and 28-day cube compressive strength of the concrete using coconut shell aggregate were 1975 kg/m3 and19.1 N/mm2 respectively. It is concluded that crushed coconut shells are suitable when it is used as substitute for conventional aggregates in lightweight concrete production. The use of alternative aggregate has become necessity for the construction industry because of the economic, environmental and technological benefits derived from their use. This will have the double advantage of reduction in the cost of construction material and also as a means of disposal of wastes.Following are the tests and conclusions they have recorded. The average moisture content and water absorption of the crushed coconut shell were found to be 4.20 % and 24.00 % respectively. The CS aggregates have higher water absorption because of higher porosity in its’ shell structure. The aggregate impact value and aggregate crushing value of CS aggregates were much lower compared to the crushed stone aggregate, which indicates that these aggregates have good Absorbance to shock.The specific gravity under SSD condition of CS and crushed granite was found to be 1.05 and 2.82 respectively.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

The fresh concrete density and 28-day hardened concrete density using coconut shell were found to be in the range between 1975 -2110 kg/m3 and 1880 - 1930 kg/m3 respectively. The 28-day compressive strength of the concrete using coconut shell aggregate was found to be 19.1 N/mm2 under full water curing and it satisfies the requirement for structural lightweight concrete. It should, however, further investigations are required before it can be used as a building material. 3)Experimental Study on Partial Replacement of Cement With Coconut Shell

In

Concrete (By Vignette Kumar Natarajan)(2014) Concrete is widely used as construction material for various types of structures due to its durability. For a long time it was considered to be very durable material requiring a little or no maintenance. Utilization of industrial soil waste or secondary materials has been encouraged in construction field for the production of cement and concrete because it contributes to reducing the consumption of natural resources. They have been successfully used in the construction industry for partial or full replacement for fine and coarse aggregates. The composition of World Cement Consumption in the year 2010 is 3,313 Million Metric Tons. Among that 7.0% in India, 57.7% in China, 9.4% in Developed Countries, 25.9% in Other Emerging. The composition of Coconut Production in India in the year 2009 is 10,894,000 tones. Traditional areas of coconut cultivation are the states of Kerala (45.22%), Tamil Nadu (26.56%), Karnataka (10.85%) and Andhra Pradesh (8.93%). These tests and properties are they checked Ordinary Portland Cement (53 Grade), Fine Aggregate,Water, Coarse Aggregate, Coconut Shell Ash these materials are used in the project work. Taking the tests on the cement like a setting time, soundness, fineness, strength, compressive strength tensile strength and flexural These strengths can be affected by a number of items including: water cement ratio, cement-fine aggregate ratio, type and grading of fine aggregate, curing conditions, size and shape of specimen, loading conditions and age. Many works have been devoted to use of other natural fillers in composites in the recent past years and coconut shell filler is a potential candidate for the development of new composites because they have high strength and modulus properties along with the added advantage of high lignin content. The high lignin content makes the composites made with these filler more weather resistant and hence more suitable for application as construction materials. Coconut shell flour is also extensively used to make products like furnishing Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

materials, Rope etc. The shells also absorb less moisture due to its low cellulose content the report focuses on studying the effectiveness of coconut shell particles as a source of natural material for reinforcing epoxy resins towards their flexural properties. The name given to the operation of dividing a sample of aggregate into various fractions, each consisting of particles of the same size. The sieve analysis is conducted to determine the particle size distribution in a sample of aggregate, which we call gradation. The aggregate used for making concrete are normally of the maximum size 80mm, 40mm, 20mm, 10mm, 4.75mm,2.36mm, 600micron, 300micron, 150micron and 75micron.In the IS and AST standards, the sieve sizes are given in times of the number of openings per inch is equal to the square of the number of sieves. In the IS460-1962, the sieves are designed by size of the aperture in mm. results. Test name

0% added

30% added

Setting time, Initial

65mins

326mins

Setting time, Final

83mins

442mins

Compressive strength 7days

13.78

6.45

14days

18.82

8.67

21days

34.22

13.11

4)Comparative Study Of Concrete Properties Using Coconut Shell And Palm Kernel Shell As Coarse Aggregates . (Mr. Olanipekun and O. Ata)(2007) It was concluded that the cuss were more suitable as low strength giving lightweight aggregate when used to replace common coarse aggregate in concrete production. The main objective is to encourage the use of these seemingly waste products as construction materials in low-cost housing .it is also expect to serve the purpose of encouraging housing develops in investing in house construction incorporating these materials. Two nominal mix ratios1:1:2and1:2:4 involving crushed, granular coconut and poses as substitutes for gravel in gradation of 0%, 25%, 50%, 75%and100% were used in each case.

Test applied to the

sample The physical properties-moisture content, water absorption capacity, durability, density and specific gravity of the cost and pokes. The unit weight and the specific gravity of Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

the shells are 1738kg/co. And1.74 respectively, for cuss. The cuss can therefore be classified as lightweight aggregates, the cuss having higher density and specific gravity. The hardness of the cuss measured by the durability test using the Los Angeles abrasion method. The test results indicated high values of 98.6%.the production of concrete intended for floors and pavements expected to be subject to heavy human traffic. The results of the comparative cost analysis .the result showed that between 30% and 42% cost reduction could be achieved if concrete is produced with coconut and pokes coarse aggregate however it is cheaper to produce concrete from pokes than coconut shell And concluded that generally the compressive strength of the concrete decreased as the percentage shell substitution increased. The CSC exhibited a higher compressive strength than PKSC appears to be cheaper. It could reasonably be concluded that cuss would be more suitable than pass when used as substitute for conventional aggregates in concrete production 5)Compression of Mechanical and Bond properties of oil palmkernel shell concrete with normal weight concrete (MR. Johnson Alengaram)(2008) The compression of the ,mechanical and bond properties of grade 30 lightweight concrete, namely oil palm kernel shell concrete with normal weight concrete of similar strength is presented in this paper. Testing of specimens Workability and density tests: slump and flow table tests were used to measure the workability of concrete.Mechanical properties tests: Cube compression test. The load was applied at a constant rate of 0.25MPa/s on the specimen by a testing machine. The Oil Palm Kernel Shell Concrete produced a density reduction of about 20% and high workability compared to NWC. The reaction between silica fume and calcium hydroxide that was liberated due to hydration of cement enhanced the compressive strength, thus OPKSC produced compressive strength increase of up to 85% compared to previously reported values. The modulus of elasticity of Oil Palm Kernel Shell Concrete was found between 50-98% higher than the previously reported values. It can be concluded that the addition of 105 silica fume. 6)The Mechanical and bond properties of coconut shell concrete By (Mr. K. Gunsekaran And Mr. P. Kumar)(2011) Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

The properties of concrete using coconut shell as coarse aggregate were investigated is an experimental study. Compressive, splitting tensile strength, impact resistance and bond strength were measured and compared with the theoretical values as recommended by the standard. For the selected mix, two different water –cement ratio have been considered to study the effect on the flexural were determined through pull –out test. Coconut shell concrete can be classified under structural lightweight concrete. Test applied to the sample are Flexural strength test, Splitting tensile strength test The test results has been The flexural strength is usually 10-15% of compressive strength.In concrete with conventional aggregate, the failure in tension occurs as a result of breaking of bond between the matrix and the surface of the aggregate used or by fracture of the concrete matrix itself.Compressive strength and flexural strength depend to some extent on the physical strength of conventional aggregates.The splitting tensile strength of coconut shell at 28 days is presented in the selected mixes. It has been concluded that Coconut shell concrete has better workability because of the smooth surface on one side of the shell and size of coconut shell used in this study. The 28 days in dry densities of concrete of the typical mixes ranged from 1930 kg/cub. M and these are with range of structural light weight concrete of density less than 2000 kg/cu. M. The experiment prove that coconut shell fulfill the requirements for us as light weight aggregate. 7) Experimental Study On Strength Characteristic On M25Concrete With Partial Replacement Of Cement With Coarse Aggregate With Coconut Shell. By (Miss. R. nagalakshmi.) Examine the strength characteristics such as compressive strength split tensile strength and flexural strength of concrete mix are found for 7 days, 14 days, 28 days, 56 days of curing period and result are analyzed and compared with the regular mix. Test applied on the sample are Slump cone test and Compaction factor test The results of tests are has been Slump and compaction factor test were tested when the concrete in fresh state.The cubes, cylinder and beams were tested for compressive strength, split tensile strength and flexural strength.These test carried out at the age of 7 days, 28 days and 56 days. They has been Concluded that The Slump of the concrete increased as the percentage of coconut slump increase and decrease in compression in with conventional concrete. The Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

compaction factor increased as percentage of coconut shell increases and increases in compression with conventional concrete.The specific gravity of coconut shell is as compared to the coarse aggregate and water absorption is high for coconut shell than coarse aggregate and hence the strength decreased in comparison with the conventional concrete. The specific gravity of coconut shell is low as compared to the coarse aggregate and the water absorption is high for coconut shell than coarse aggregate.

8)The Exploratory Study Of Periwinkle Shell As Coarse Aggregate In Concrete Works. (Mr. A. P. AdewuyiAnd T. Adegoke)(2010) Theses paper reports the exploratory a suitable of the periwinkle as partial or full replacement for granite in concrete works. Physical and chemical properties of periwinkle shells and crushed granite were determined and compared. Properties of aggregate are Workability, compressive strength, Density of specimens, Cost analysis. Result and conclusion the test are The chemical properties of periwinkle shell were not considered.Characteristic shape factor of the periwinkle shell used in the experiment.The strength of periwinkle shell concrete is determined based on the properties of the shell and various percentage replacement. Concrete having up to 50% periwinkle shells inclusion and still be regarded as weight concrete.Saving of about 14.8% and 17.5% can be achieved by adopting 35.4% and 42.5% periwinkle inclusion for 1:2:4 and 1:3:6 concrete mixes respectively 9)TheBarley Husk And Coconut Shell Reinforced Polypropylene Composites: The Effect Of Fiber Physical, Chemical And Surface Properties. By (Mr. Andrzej and Mr. Abdullah)(2009) The main objective of this research was to study the potential of grain by-product such as barley husk & coconut shell as reinforcement for thermoplastic as an alternative or together with wood fibers. Thermal degradation characteristics of those fibers

were studied to

investigate the feasibility of these fibers to the processing point of view .the particle morphology and particle size was investigation by scanning electron fibers as reinforcement. The chemical composition and surface chemistry of those fibers were also determined to evaluate its importance in determining the end –use properties of composites. Polypropylene Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

composites were fabricated using a high speed mixer followed by injection molding

with

40% of fiber load. Tensile and chirpy impact strength of resulting composites were investigated .There are fallowing property are below thermal property, physical properties, chemical content, elementary analysis, Fourier-transform processing,characterization of composites.This study inspected the feasibility of utilizing of grain by –products such as barley husk and coconut shell as alternative fillers for the following conclusion could be drawn as barley husk and coconut shell. The following conclusion could be drawn as shell are thermally stable at temperature as high as 235oC and195oC respectively, which compares with soft wood fiber, which is thermally stable up to a temperature of 245 _C. Structural materials(cellulose, starch) content in barley husk is 50% and in coconut shell is 34%. Both fibers (coconut shell and barley husk) showed carbon rich on their surface in compared with soft wood fiber .Coconut shell contained more inorganic compounds on the surfer ethane barley husk. Barley husk reinforced composites showed 10%better tensile strength than soft wood composites. Coconut shell and barley husk composites showed 80% and 40% better elongation. 10)The Sustainable Management OfWaste Coconut Shells As Aggregates In Concrete Mixture. By (Mr. .Tomas and Mr. Gairn) (2010) This study focuses on generating product using agricultural waste as well develop an alternative construction material that will lessen the social and environmental issues. It also paved the way to the recognition of using coconut shells and Fiber as substitute for aggregates in developing concrete hollow blocks. This paper presents the result on the Workability and compressive strength of concrete containing various percentage of coconut shell content as partial Aggregate replacement. Workability test and compressive strength test were conducted in accordance to ASTM C136 and ASTM C137 respectively. Results showed that replacement of appropriate coconut shell content able to produce workable concrete with satisfactory strength. Integration of coconut shell enhanced the strength of concrete making this early study found that addition of coconut shell as partial aggregate replacement reduces the concrete workability owing to its shape and rougher texture. However, it is interesting to note that replacement of natural coarse aggregate by coconut shell resulted in the increase of compressive strength compared to conventional concrete mixture. Nevertheless, integration of too much of coconut shell produces harsher

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

mix which causes difficulties to produce dense concrete thus disrupts the strength performance 11)Comparison On Pore Development Of Activated Carbon Produced From Palm Shell And Coconut Shell. By(Mr. Wan Daud and Mr .Wan Ali) The various materials are used to produce activated carbon and some of the most commonly used agriculture waste such as coconut shell. And using the methods for estimating the type of pores present in a solid is by analyzing the isotherm curve. Are the main objective of this research was to study the potential of grain by-product such as volume being represented by pores of radius of less than 1 mm. The graph of activation time versa burn off for both palm shell char and coconut shell char .Both material exhibit an linear correction between activation time and burn-off the gradient of the gradient of the curve represent the activated rate .The isotherm curves at difference burn-off for palm-shell-based activated carbon property.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

Chapter 3 METHODOLOGY 1. Concrete will be prepared using Coconut Shell as a partial replacement of coarse aggregate which will be studied and analyzed. 2. As per IS-456 2000 mix designs for M25 and M30 grade of concrete will be casted. 3. The Coconut Shell willbeused in percentage of 20%, 40% and 60% by weight of coarse aggregate. 4. The mixture will be prepared and three standard cubes of 150*150*150 mm and beam of dimensions 150*150*600 mm are casted for each mix grade. 5. After curing for 24hrs the samples will be demoulded and subjected to mechanical properties such as compressive strength test,flexural strength and tensile split test for 7, 14 and 28 days. 6. The above test results will be compared with standard concrete of M25 and M30 and also the cost comparison of the concrete replaced by Coconut Shell with standard concrete will be done. CASTING OF CONCRETE CUBES, CYLINDERS AND BEAMS The test moulds are kept ready before preparing the mix. Tighten the bolts of the moulds carefully because if bolts of themoulds are not kept tight the concrete slurry coming out of themould when vibration takes place. Then moulds are cleaned andoiled on all contact surfaces of the moulds and place the mouldson vibrating table. The concrete is filled into moulds in layers andthen vibrated. The top surface of concrete is struck off level witha trowel. The number and date of casting are put on the topsurface of the cubes, cylinders and moulds.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

3.1 Cement Cement must develop the appropriate strength. It must represent the appropriate rheological behaviour. Generally same types of cements have quite different rheological and strength characteristics, particularly when used in combination with admixtures and supplementary cementing materials. Sr.no. Parameter

Test results

1

Normal Consistency

28%

2

Fineness of cement (%)

6

3

Specific Gravity

3.148

4

Initial setting time

70mins

5

Final setting time

300mins

6

Compressive strength cement at7days – 28days -

of 17N/mm2 22.8N/mm2

3.2 Fine aggregate Fine aggregate normally consists of natural, crushed, or manufactured sand. Natural sand is the usual component for normal weight concrete. In some cases, manufactured light weight particles used for lightweight concrete and mortar. Themaximum grain size and size distribution of the fine aggregate depends on the type of product being made. Sr.no. 1 2 3

Parameter Specific gravity Fineness modulus Bulk density(Kg/M3) Loose Compacted

Test results 2.605 2.465 1488.89 1600

3.3 Coarse aggregate As coarse aggregates in concrete occupy 35 to 70% of the volume of the concrete. It may be proper to categories the properties into two groups: exterior features (maximum size, particle shape, textures) and interior quality (strength, density, porosity, hardness, elastic modulus, chemical mineral composition etc.). Smaller sized aggregates produce higher concrete strength. Particle shape and texture affect the workability of fresh concrete. The transition zone between cement paste and coarse aggregates, rather than the properties of the coarse aggregates itself. Usually an aggregate with specific gravity more than 2.55 and absorption less than 1.5% (except for light weight aggregates) can be regarded as being of good quality. Where aggregates strength is higher, concrete strength is also higher.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

Sr.no. 1 2 3 4

Parameter Specific gravity Fineness modulus Water absorption (%) Bulk density(Kg/M3) Loose Compacted

Test results 2.75 8.625 0.15 1525.92 1659.20

3.4 Coconut shell The physical properties of coconut shell are shown below table. S.no. 1 2 3

Parameter Test results Specific gravity 1.33 Water absorption (%) 25 Bulk density(Kg/M3) Loose 592.59 Compacted 800

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

CHAPTER 4 TESTS AND RESULTS 4.1 Slump cone test The slump test is the most commonly used method. Consistency is a term very closely related to workability. It is aterm which describes the state of fresh concrete. It is used for the determination of the consistency of freshly mixed concrete, where the maximum size of the aggregate does not exceed 38 mm. The slump test is suitable for slumps of medium to high workability, slump in the range of 25 – 125 mm; the test fails to determine the difference in workability in stiff mixes which have zero slumps, or for wet mixes that give a collapse slump. It refers to the ease with which the concrete flows. It is used to indicate the degree of wetness. Workability of concrete is mainly affected by consistency i.e. wetter mixes will be more workable than drier mixes, but concrete of the same consistency may vary in workability. It is also used to determine consistency between individual batches. The apparatus used for conducting the slump test consists of slump cone or Abrams cone with handles and foot pieces. The size of the slump cone is 20-cm diameter base, 10 cmdiameter top and 30 cm height. Foot pieces can be fixed to the clamps on the base plate. The base plate has lifting handle for easy transportation. One graduated steel tamping rod 16 mm diameter x 600 mm long rounded at one end graduated in mm. The internal surface of the mould is thoroughly cleaned and free from moisture and adherence of any old set concrete before commencing the test. The mould should be placed on smooth surface. Oil is applying on internal surface of the mould and applies the smooth surface where the mould is placed. The types of slump are as follows. Collapse: In a collapse slumps the concrete collapses completely. Shear: In a shear slump the top portion of the concrete shears offand slips sideways. True: In a true slump the concrete simply subsides, keeping moreor less to shape S.no. Slump(mm) Conventional mix 80 1 2 Mix 1 35 3 Mix 2 42 4 Mix 3 48 Compaction factor 1 Conventional mix 0.920 2 Mix 1 0.924 3 Mix 2 0.927 4 Mix 3 0.931 4.2 Compaction factor test Compacting factor of fresh concrete is done to determine the workability of fresh concrete by compacting factor test as per IS: 1199 – 1959. This test gives behavior of concrete under the action of external forces. If measures the compatibility of concrete, by measuring the amount of compaction. This test is suitable for mixes having medium and low workability’s i.e. compaction factor in between 0.91 to 0.81, but is not suitable for concretes with very low workability’s, thecompaction factor below 0.71. The apparatus, which is commercially available, consist of a rigid frame that supports two conical hoppers vertically aligned above each other and mounted above a cylinder. The top hopper is slightly larger than the bottom hopper, while the cylinder is smaller in volume than both hoppers. To perform the test, the top hopper is filled with concrete but not compacted. The door on the bottom of the top hopper is opened and the concrete is allowed to drop into the lower hopper. Once all of the concrete Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

has fallen from the top hopper, the door on the lower hopper is opened to allow the concrete to fall to the bottom cylinder. A tamping rod can be used to force especially cohesive concretes through the hoppers. The excess concrete is carefully struck off the top of the cylinder and the mass of the concrete in the cylinder is recorded. This mass is compared to the mass of fully compacted concrete in the same cylinder achieved with hand rodding or vibration. The compaction factor is defined as the ratio of the mass of the concrete compacted in the compaction factor apparatus to the mass of the fully compacted concrete. The standard test apparatus, described above, is appropriate for maximum aggregate sizes of up to 20 mm. A larger apparatus is available for concretes with maximum aggregate sizes of up to 40 mm. The compaction factor test gives more information (that is, about compactability) than the slump test. The test is a dynamictest and thus is more appropriate than static tests for highlythixotropic concrete mixtures. 4.3 TESTS FOR CONCRETE 4.3.1 Test for Compressive strength of concrete cubes To calculate the compressive strength of concrete cubesthe universal testing machine (UTM) having capacity of 300tonnewas used. In this test the strength obtained in tonne. Themeasured compressive strength of the specimen shall becalculated by dividing the maximum load applied to the specimenduring the test by the cross sectional area calculated from meandimensions of the section and shall be expressed to the nearestN/mm2.Out of many test applied to the concrete, this is theutmost important which gives an idea about all the characteristicsof concrete. By this single test one judge that whether Concretinghas been done properly or not. For cube test two types ofspecimens either cubes of 15 cm X 15 cm X 15 cm or 10cm X 10cm x 10 cm depending upon the size of aggregate are used. Formost of the works cubical moulds of size 15 cm x 15cm x 15 cmare commonly used. These specimens are tested by compressiontesting machine after 7 days curing, 14 days curing, 28 dayscuring and 56 days curing. Load should be applied gradually atthe rate of 140 kg/cm2 per minute till the Specimens fails. Load at the failure divided by area of specimen gives the compressivestrength of concrete. Calculations: Compressive strength = Maximum load/ Area= P/A Compressive strength test results Particulars

7days

14days

28days

56days

Conventional

25.04

28.74

33.33

35.41

10%CS

23.11

26.78

30.78

32.11

20%CS and

21.74

24.78

28.11

30.33

30%CS and

19.74

23.03

26.59

28.78

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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4.3.2 Test for Split tensile strength of concretecylinders As we know that the concrete is weak in tension.Tensile strength is one of the basic and important properties of theconcrete. The concrete is not usually expected to resist the directtension because of its low tensile strength and brittle nature.However, the determination of tensile strength of concrete isnecessary to determine the load at which the concrete membersmay crack. The cracking is a form of tension failure. Theusefulness of the splitting cube test for assessing the tensilestrength of concrete in the laboratory is widely accepted andthe usefulness of the above test for control purposes in thefield is under investigation. The standard has been preparedwith a view to unifying the testing procedure for this type oftest for tensile strength of concrete. The load at which splittingof specimen takes place shall then be recorded. The universaltesting machine (UTM) having capacity of 150tonne was used forthe splitting tensile strength of the concrete cylinders. Calculations: The split tensile strength of the specimen calculated from thefollowing formula Tsp = (2P/ (πdL)) Where P= maximum load in tonne L= length of the specimen d= diameter of width of the specimen Final values are adopted from using standard deviation. Split Tensile Strength (N/mm2) 7days 14days 28days 56days 3.39 3.58 Conventional 2.310 2.68 2.130 2.48 3.16 3.30 10%CS 1.98 2.33 2.94 3.08 20%CS 1.80 2.17 2.76 2.89 30%CS 4.3.3 Test for Flexural strength of concrete beams For this test the beams of dimension100mmX100mmX500mm were casted. Flexural strength, alsoknown as modulus of rupture, bend strength, or fracture strength,[dubious – discuss] amechanical parameter for brittle material, isdefined as a material's ability to resist deformation under load.The transverse bending test is most frequently employed, inwhich a rod specimen having either a circular or rectangularcross-section is bent until fracture using a three point flexural testtechnique. The flexural strength represents the highest stressexperienced within the material at its moment of rupture. Thebeam tests are found to be dependable to measure flexuralstrength.The value of the modulus of rupture depends on thedimensions of the beam and manner of loading. In thisinvestigation, to find the flexural strength by using third pointloading. In symmetrical two points loading the critical crack mayappear at any section not strong enough to resist the stress with inthe middle third, where the banding moment is maximum.Flexural modulus of rupture is about 10 to 20 percent ofcompressive strength depending on the type, size and volume ofcoarse aggregate used. Calculations: Fb= PL/ bd2 Where b= width in cm of specimen d= depth in cm of specimen at point of failure L= length in cm of specimen on which specimen was supported Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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P= maximum load in kg applied to specimen Final values are adopted using standard deviations. Flexural Strength (N/mm2) 7days 14days 7.67 Conventional 7.1 6.38 6.8 10%CS 5.78 6.35 20%CS 5.33 5.78 30%CS

28days 8.67 7.9 7.17 6.78

56days 8.83 8.36 7.78 7.13

4.4RESULTS The mix proportion for M25 is 1: 1.18: 2.86 and W/Cratio of 0.44 was casted. Slump and compaction factor tests weretested when the concrete in fresh state. The cubes, cylinders andbeams were tested for compressive strength, split tensile strengthand flexural strength. These tests were carried out at the age of 7days, 14 days, 28 days and 56 days.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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USE OF COCONUT SHELL AS A PARTIAL REPLACEMENT FOR AGGREGATE

CHAPTER 5 CONCLUSIONS The following conclusions can be drawn from the experimentalinvestigation carried out 1. The slump of the concrete increased as the percentage ofcoconut shell increases and decrease in comparison withthe conventional concrete. 2. The compaction factor increased as the percentage ofcoconut shell increases and increased in comparisonwith the conventional concrete. 3. The specific gravity of coconut shell is low as comparedto the coarse aggregate and the water absorption is highfor coconut shell than coarse aggregate and hence thestrength decreased in comparison with the conventionalconcrete. 4. The slump of the concrete increased as the percentage ofcoconut shell increases and decrease in comparison withthe conventional concrete. 5. The compaction factor increased as the percentage ofcoconut shell increases and increased in comparisonwith the conventional concrete. 6. The specific gravity of coconut shell is low as comparedto the coarse aggregate and the water absorption is highfor coconut shell than coarse aggregate and hence thestrength decreased in comparison with the conventionalconcrete. 7. 20% of cement replaced with fly ash and 10%, 20%,30% of coarse aggregate replaced with coconut shellresulted that the compressive strength is reduced when compared with the conventional concrete. 8. The compressive strength of the concrete reduced withincreasing percentage of the coconut shell replacement. 9. The cube compressive strength of concrete at the age of 7 days resulted in marginal reduction with 10% and20% replacement of coarse aggregate with coconutshell. 10. The Split Tensile strength at 7days was reduced by 8%with 20% replacement of fly ash and the 10%replacement of coarse aggregate with coconut shellwhen compared with conventional concrete. 11. The strength of concrete decreased as the percentage ofreplacement of the conventional material increased 12. The reduction in compression strength is less incomparison with the split tensile strength with thereplacement of conventional material. 13. The split tensile strength at the 7 and 14 days for allpercentage replacements of conventional material ismarginal. 14. The reduction in Flexural Strength of all percentagereplacements at the age of 56days is less whencompared with early strength of the concrete. 15. The decrease in strength percentage of compressive splittensile and flexural strengths varies from each coconutshell replacement. 16. The decrease in strength percentage of flexural strengthfor 10% replacement at the age of 56 days is marginal(5%) and it is less when compared to other ages andother replacements. 17. The compressive strength, split tensile strength andflexural strength decreased with the percentagereplacement of coconut shell increases at the ages 7days, 14 days, 28 days and 56 days. 18. The compressive split tensile and flexural Strength withpercentage replacement of cement and coarse aggregatesdecreased is very less and hence can be used for lessimportant work utilizing the waste material which isproduced in large quantities.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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5.1 FURTHER SCOPE OF WORK 1. The study can be carried out with varying percentagereplacement of the material for specific low costhousing applications. 2. The engineering properties like water absorption,reduction in weight of concrete and study on economicaspects can be carried out. 3. The effect of temperature on the concrete developed canbe studied. 4. The study can be extended to assess the durabilityaspects of the concrete with varying replacementproportions.

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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CHAPTER 6 REFERENCES 1. E. A. Olanipekun, K. O. Olusola ,and O. Atia, “Comparative study between palm kernel shell and coconut shell as coarse aggregate”, Journal of Engineering and Applied Science, Asian Research Publishing Network. Japan, 2005. 2. U. O. Kabiru, and A. Saleh, “Exploratory study of coconut shell as

coarse aggregate

in concrete”, Journal of engineering and applied sciences, Vol. 2, December 2010. 3. K. Gunasekaran, and P. S. Kumar, “Lightweight Concrete using Coconut Shells as Aggregate”, Proceedings, International Conference on "Innovations in Building Materials, Structural Designs and Construction Practices (IBMSDCP-2008), 15-17 May 2008, pp.375-382. 4. K. Gunasekaran, “Utilization of Coconut Shell as Coarse Aggregate in the Development of Lightweight Concrete”, PhD Thesis, Department of Civil Engineering, SRM University, Kattankulathur, 2011. 5. C. B. Gopal, and K. B. Ranjan, “Effect of Coconut Shell Aggregate on Normal Strength Concrete”, International Journal of Engineering Research & Technology, Vol. 2 Issue 6, June – 2013, pp: 2405 -2415. 6. Y. Amarnath, and C. Ramachandrudu, “Properties of Concrete with Coconut Shells as Aggregate Replacement”, International Journal of Engineering Inventions, Volume 1, Issue 6 (October 2012), pp: 21-31. U. Johnson Alengaram, Baig Abdullah Al Muhit, and Mohd Zamin bin Jumaat, “Utilization of oil palm kernel shell as lightweight aggregate in concrete”, Construction and Building Materials, Volume 38, January 2013, Pages 161-172

Dept. of CivilEngg., Sanjay Ghodawat Group of Institutions, Atigre, Kolhapur.

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