A Project Report On

EXPERIMENTAL STUDY ON PARTIAL REPLACEMENT

OF COARSE AGGREGATE WITH COCONUT SHELL
Submitted to
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, KAKINADA

In partial fulfillment of the requirement for the award of degree of

BACHELOR OF TECHNOLOGY
In

CIVIL ENGINEERING
Submitted by
P. SAI KUMAR - 16X45A0115
O. MINNU - 16X45A0117
P. AKHIL - 15X41A0159
M. PRAVEEN KUMAR - 15X41A0156

Under the Guidance of

Mrs. G. SAHITHI M.Tech
Assistant Professor

DEPARTMENT OF CIVIL ENGIEERING

S.R.K INSTITUTE OF TECHNOLOGY
ENIKEPADU, VIJAYAWADA
(Affiliated to JNT University, Kakinada, A.P)
A.Y. 2018-2019
 S.R.K INSTITUTE OF TECHNOLOGY
(Affiliated to JNTU, KAKINADA, Approved by AICTE)
DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE

This is to certify that the major project report entitled “EXPERIMENTAL STUDY ON

PARTIAL REPLACEMENT OF COARSE AGGREGATE WITH

COCONUT SHELL” submitted by “P. SAI KUMAR (16X45A0115), O. MINNU
(16X45A0117), P. AKHIL (15X41A0159), M. PRAVEEN KUMAR (15X41A0156)” is
the bonafide work carried under the Guidence of Mrs. G. SAHITHI M.TECH in partial
fulfillment of the requirements for the award of the degree in bachelor of technology in ‘Civil
Engineering’ During the academic year 2018-2019.

Signature of the guide Signature of HOD

Signature of the External

 ACKNOWLEDGEMENT

We wish to express our sincere gratitude to our esteemed guide, Mrs. G. SAHTHI
MTECHAssistant professor in civil engineering department for her valuable guidance,
significant suggestions and help in every respect to accomplish the project work, persisting
encouragement, everlasting patience and keen interest in decision have been benefited to an
extent, she have been a continuous source of inspiration to us throughoutthe work.

We express our thanksto Dr. T SATYANARAYANA, professor and head of the

Department of Civil Engineering for the facilities provided.

Our acknowledgements remain incomplete if we do not express our gratitude to the

Staff of civil engineering for their help throughout this project.

I would like to express my heartfelt gratitude to all my Friends for their

continuous encouragement, help and support. I am very grateful to my Parents whose
blessings, continuous encouragement and support was an unremitting source of inspiration for
this work.

I thank the God Almighty, for his grace upon me throughout my life. Onceagain,
Ithank one and all who have helped me directly or indirectly in the completion of my course
and project in time

Project Associates………….

P. SAI KUMAR - 16X45A0115

O. MINNU - 16X45A0117
P. AKHIL - 15X41A0159
M. PRAVEEN KUMAR - 15X41A0156
 ABSTRACT

The high cost of conventional construction material affects economy of structure. With
increasing concern over the excessive exploitation of natural aggregates, synthetic lightweight
aggregate produced from environmental waste is a viable new source of structural aggregate
material. The uses of structural grade lightweight concrete reduce considerably the self-load
of a structure and permit larger precast units to be handled. Recently in the environmental
issues, restrictions of local and natural access or sources and disposal of waste material are
gaining great importance. Today, it becomes more difficult to find a natural resource. Use of
the waste materials not only helps in getting them utilized in cement, concrete and other
construction materials, but also has numerous indirect benefits such as reduction in land fill
cost, saving in energy, and protecting environment from possible pollution effect. It also helps
in reducing the cost of concrete manufacturing. In the present work, coconut shell as partial
replacement for coarse aggregate in concrete is studied. 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/m3 and these are within the specified
limits for lightweight aggregate. The characteristic properties of concrete such as compressive
strength, flexural strength, impact resistance, bond strength & split tensile strength using the
mix made by replacing coarse aggregate with crushed coconut shell aggregate were reviewed
in the present work.
Keywords: Coconut shell, coarse aggregate, light weight concrete.
CONTENTS

Page No
LIST OF TABLES………………………………………………………………….. V
LIST OF FIGURES…………………………………………………………………. Vi

CHAPTER-1

1. INTRODUCTION………………………………………………………………..
1.1 General
1.2 Concrete
1.3 Coconut shell
1.4 Objectives of study

CHAPTER-2

2. LITERATURE REVIEW…………………………………………………………..
2.1 . General

CHAPTER-3

3. MATERIALS AND METHODOLOGY

3.1. Materials………………………………………………………………..
3.1.1. Ordinary Portland cement
3.1.2. Coconut Shell
3.1.3. Fine aggregate
3.1.4. Coarse aggregate
3.1.6 .Water
 3.2. Methodology……………………………………………………………….
3.3. Properties
3.3.1. Test on Cement………………………………………………………..
3.3.2. Test on Fine aggregate…………………………………………………
3.3.3. Test on Coconut shell…………………………………………………..
3.3.4 .Test on Coarse aggregate……………………………………………..
3.4 Concrete Mix design…………………………………………………………...
3.4.1. Requirements of concrete mix design
3.4.2. Types of mixes
3.4.3. Slump cone test……………………………………………………..
3.5. Casting and curing……………………………………………………………

CHAPTER-4

4. RESULTS AND DISCUSSIONS

4.1.Compression test …………………………………………………………
4.2.Testing procedure………………………………………………………...
4.3.Test Results……………………………………………………………….
4.4..Discussion ……………………………………………………………….

CHAPTER-5

5. CONCLUSION………………………………………………………………..
5.1.Conclusions
5.2.Scope of future work

REFERNCES
 LIST OF TABLES

Table No. Title

3.1 Standard consistency values

3.2 Fineness values of cement

3.3 Specific gravity values of cement

3.4 Properties of cement

3.5 Properties of Coconut Shell

3.8 Sieve analysis values of fine aggregate

3.9 Properties of fine aggregates

3.10 Sieve analysis values of coarse aggregate

3.11 Properties of coarse aggregate

4.1 Mix design details

4.2 Compressive strength of concrete for 7 days

4.3 Compressive strength of concrete for14 days

4.4 Compressive strength of concrete for 28 days

vi
ii
 LIST OF FIGURES
S.NO PAGE NO

4.1. Compression testing………………………………………………….

4.2. Compressive strength for 7 days……………………………………..

4.3. Compressive strength for 14 days…………………………………….

4.4. Compression strength for 28 days…………………………………….

ix
Chapter 1

Introduction

1.1 General
Infrastructure development across the world created demands for construction material. Concrete
is the premier civil engineering material. Concrete manufacturing involve consumption of
ingredients like cement, aggregates, water & admixtures. Among all the ingredients, aggregates
form the major parts. Two billion of aggregate are produced each year in the United States.
Production is expected to increase to more than billion tons per year by the year similarly; the
consumption of the primary aggregate was 110 million tones in the UK in year 1960 and reached
nearly 275 million tones by 2006. Use of natural aggregates in such a rate leads to a question about
the preservation of natural aggregates sources. In addition, operation associated with aggregates
extraction and processing is the principal causes environmental concern. In light of this in the
contemporary civil engineering construction, using alternative materials in place of natural
aggregate in concrete production makes concrete as sustainable and environmentally friendly
construction material. Coconut shell being a hard and not easily degrade material if crushed to size
of sand can be a 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. However, the coconut shell is still under utilized in some places. The chemical composition of
the coconut shell is similar to wood. It contains 33.61% cellulose, 36.51% lignin, 29.27% and ash
at 0.61%.
1.2. CONCRETE
Concrete is the most widely used man-made construction material in the world. It is obtained by
mixing cementations materials, water, aggregate, and sometimes add mixtures in required
proportions.Fresh concrete or plain concrete is freshly mixed material which can be moulded into
any shape hardens into a rock-like mass known as concrete. The hardening is because of chemical
reaction between water and cement, which continuous for long period leading to stronger with age
1.3. Purpose OfCoconut Shell
Coconut shells: For the purpose of this project, the Coconut shells were obtained from local house.
1
They were crushed manually. The crushed materials were later being transported to the laboratory
where they are washed and allowed to 24 hours water absorption. The particle sizes of the coconut
shell range from 20 to 25 mm. Tests conducted on coconut shell includes specific gravity, water
absorption, aggregate crushing value test, and aggregate impact value test. Specific gravity of
coconut shell used was 1.25

FIG 1: COCONUT SHELL FIG 2 : COCONUT SHELL

BEFORE CUTTING AFTER CUTTING

Physical properties of Coconut Shell

1. Density of coconut shell is lesser than coarse aggregate ie550 - 650 kg/m3
2. Coconut shell in light in weight
3. Coconut shell has higher compressive strength
4. Specific gravity of coconut shell is 1.5 to 2 results in light weight weight concrete

1.5 OBJECTIVES
a. To compare the compressive strength between conventional concrete and replaced concrete
b. To reduce the aggregate content by partially replacing it with coconut shell to increase the
compressive strength and to make it light in weight
c. To increase the workability of concrete

1
 Chapter 2
Literature Review
J.P. RIES (2011) studied that Lightweight aggregate (LWA) plays important
role in today’s move towards sustainable concrete, Lightweight aggregates
contributes to sustainable development by lowering transportation
requirements, optimizing structural efficiency that results in a reduction in
the amount of overall building material being used, conserving energy,
Reducing labor demands and increasing the survive life of structural
concrete
AMARNATH YERRMALLA (2012) et al studied the strength of coconut
shells(CS) replacement and different and study the transport properties of
concrete with CS as coarse aggregate replacement. They concluded that a.
Increase in CS percentage decreased densities of the concrete. b. With CS
percentage increased the 7 days strength gain also increased with
corresponding 28 days curing strength.
VISHWAS P. KULKARNI (2013) studied that Aggregates provide volume at
low cost, comprising 66 percent to 78 percent of the concrete. Conventional
coarse aggregate namely gravel and fine aggregate is sand in concrete will
be used as control. While natural material is coconut shell as course
aggregate will be investigate to replace the aggregate in concrete.
The researcher suggested that one of the alternatives for coarse aggregate is
coconut shell. It is one of the most common agricultural solid wastes in
many tropical countries. Density of coconut shell concrete of the typical
mixes ranged from 1930 kg/cum to 1970 kg/cum
There was researched on the coconut shell use as aggregate in the study which
showed that with global economic recession coupled with the market
inflator trends. The average compressive strength for concrete cubes with
coconut shell 15.6 N/mm2 for 28 day

12
It was studied studied the compressive strength, split tensile strength, water
absorption and sorption for different coconut shell replaced concrete. By
replacement of coconut shells in place of aggregates, 10% &20%
replacement will have been decreased marginally the strength properties of
concrete compared to the normal concrete
ANAND RAMESH :The coconut shell is a material which can be a substitute
for coarse aggregate. Coconut shell concrete has better workability because
of the smooth surface on one side of the shell. The impact resistance of
coconut shell concrete is high when compared with conventional concrete
[7]. Moisture retaining and water absorbing capacity of coconut shell are
more compared to conventional aggregate. Using alternative material in
place of natural aggregate in concrete production makes concrete as
sustainable and environment friendly Construction material.
G. SANGEETHA :Since waste materials can be obtained at little or no cost,

while making significant contribution to the conservation of natural

resources and maintenance of ecological balance. Coconut shell is an
agricultural waste. It is categorized as light weight aggregate. Coconut shells
are by-products of coconut oil production. Cost reduction of 48% can be
achieved if the waste utilization can be used in the concrete mixtures. The
coconut shell when dried contains cellulose, lignin and ash in varying
percentage.
MD.ABDUL HALEEM: Concrete is one of the most versatile construction

materials. With more than 10 billion tons of concrete produced annually, it

is considered to be the most important building material (Meyer, 2009).
Consequently, the concrete industry is going to use a considerable amount of
natural resources to produce concrete.Coconut is grown in more than 93
countries and South East Asia is regarded as the origin of coconut. By using
the agricultural waste namely the coconut, replacing the stone aggregate in
concrete, a concrete has been developed which possesses the potential of
13
 being used in lightweight construction.
Kanojia and Jain (2015) also reported that coconut shell has added advantage
of high lignin content that makes the composites more weather resistant

14
CHAPTER-3

MATERIALS AND METHODOLOGY

3.1MATERIALS

Engineered cementitious composite is composed of:

o Cement(OPC)
o Coconut Shell

o Fine aggregate

o Coarse aggregate

o Water

3.1.1 ORDINARY PORTLAND CEMENT(OPC)

Ordinary Portland cement (OPC) manufactured in the form of different grades, the most common
in India being Grade- 33 (IS 269: 1989), Grade – 43 (IS 8112:1989) and Grade -53 (IS 1226: 1987).
OPC is manufactured by burning siliceous materials like limestone at 1400 degree Celsius and
thereafter grinding it with gypsum.

Ordinary Portland cement – Grade 53; have been certified with IS 8112:1989
standards, grade 53 is known in the market for their longer shelf life, fitness, unbeatable
consistency and high strength. Hence it is used for constructing bigger structures like building
foundations, bridges and structures designed to withstand heavy pressure.

As such, Ordinary Portland Cement is used for quite a wide range of applications.
Some of the ordinary Portland applications are in pre-stressed. Dry lean mixes, durable pre-cast
concrete and ready mixes for general purposes. The chemical components of ordinary Portland
cement are magnesium (Mg), Alumina (Al203). Silica (Sio2), Iron (Fe203) and Sulphurtrioxide
(SO3). Some of the big companies involved in OPC manufacture are Tata chemicals, Ultra-tech
cement and ACC cement. Ordinary Portland cement is in great demand in India and will continue
to be used in India infrastructural up gradation and other constructions.

15
3.1.2 COCONUT SHELL
Coconut shells used in the study are brought from local temple. The coconut shells are sundried for five
days before using it as an aggregate. The cleaning of coconut shell is carried with the help of sand paper,
the smaller extractions on the outer face of coconut is cleaned with the help of water. The outer shell is
then broken in smaller parts up to 20 mm. The broking of coconut shell is done with the help of 30 kg
hammer. Then the broken pieces are passed through IS 20 mm sieve and pieces are retained on a IS
16mm sieve are used.

3.1.4 Sand [Fine Aggregate]

Fine aggregate / natural sand is an accumulation of grains of mineral matter derived from the
disintegration of rocks. It is distinguished from grave lonely by the size of the grains or particles. But it is
distinct from clays which contain organic materials. Sands that have been sorted out and separated from
the organic material by the action of currents of water or by winds across arid lands are generally quite
uniform in size of grains. Usually commercial sand is obtained from river beds or from sand dunes
originally formed by the action of winds. The most commercially used are silica sands, often above 98%
pure. Beach sands usually have smooth, spherical too void particles from the abrasive action of waves
and tides and are free of organic matter. The white beach sands are largely silica but may also be of
zircon, monazite garnet, and other minerals .Sand is used for making mortar and concrete and for also
used for polishing and sandblasting. Sands containing a little clay are used for making molds in
foundries.
Slump from say 5 cm to about 18-20 cm without addition of water. When used to achieve
reduction in mixing water they can reduce water up to 15-20% and hence decrease W/C ratio by same
amount. This results in increase in strength and other properties like density, water tightness. Where thin
sections are to be cast super plasticizer can increase workability to pump able level and almost no
compaction is required. This helps in avoiding honeycombing. The permeability of concrete is a guide to
its durability. Gross porosity is usually due to continuous passage in the concrete due to poor
compaction or cracks which can be minimized by the use of super plasticizer, the incorporation of which
provides increased workability maintaining low w/c ratio. It isreportedthat
Coefficientofpermeabilityofcementpastereduces considerably with the reduction in w/c ratio

3.1.5 Coarse aggregate

The coarse aggregate is the aggregate which has large particle size ; coarse aggregate is defined as
the aggregate containing a high proportion of particles retained on a 5mm(0.197) in sieve in the
US and elsewhere a 4.75mm (0.187) in sieve is used as the limit . According to IS 3839(1970)
16
 machine passing through 20mm sieve and retained on 12.5mm sieve and chips passing 12.5mm
sieve and retained on 10mm sieve were used as coarse aggregate throughout the work.
(a).Physical properties
Aggregates can be classified by their mineral, physical, and chemical properties. The pavement
industry relies on the physical properties for performance characterization, an aggregates physical
properties arc a direct result of its mineral and chemical properties.
(b).Maximum Size
The smallest sieve through which 100% of aggregates sample particles passes. Super pave defines
the maximum aggregate size as “one sieve larger than the nominal maximum size”.
(c). Nominal maximum size
It is the largest sieve that retains some of the aggregates particles but generally not
more than 10% by weight.Super pave defines the nominal maximum aggregate size as
“one sieve larger than the first sieve to retained more than 10% of the material”.

3.1.7 Water

Water fit for drinking is generally considered fit for making concrete. Water should be free from acids,
oils, alkalis, vegetables or other organic Impurities. Soft waters also produce weaker concrete. Water has
two functions in a concrete mix. Firstly, it reacts chemically with the cement to form a cement paste in
which the inert aggregates are held in suspension until the cement paste has hardened. Secondly, it
serves as a vehicle or lubricant in the mixture of fine aggregates.

3.2 METHODOLOGY
The concrete mix design was carried out for the present work. The concrete mix design is
a process of selecting the suitable ingredient of concrete and determining their most
optimum proportions economically. The approximate value for the coarse aggregate
volumes are given in IS 10262-2009 for the water cement ratio. For more workable
concrete that can flow around any congested reinforcement bars, it may be desired to
reduce the coarse aggregate content.

Approach
1. The initial stage of experimental work involved casting of plain concrete specimens i.e.,
17
 without any replacement of materials this is called conventional concrete specimens.
2. In second stage of work involved casting 6 series of plain concrete specimens. In the first, second, third,
series of the work concrete specimens with varying amounts of replacement of cement cubes are casted
with partial replacement of coconut shell with 5%, 10%, 15%, 20%
3. Dimensions of concrete cubes are 150mmx150mmx150mm. The specimens are tested for compressive
strengths at a period of 7days, 14days, and28days from the day of casting. Results of the specimens with
partial replacements are compared with conventional concrete.

3.3 PROPERTIES
3.3.1. Tests on cement
a) Standard consistency of cement
The standard consistency of a cement paste is defined as that consistency which will permit the vacate
plunger to penetrate to a point 5to7 mm from the bottom of the vicat mould. For finding out initial setting
time, final setting time, soundness of cement and compressive strength of cement, it is necessary to fix
the quantity of water to be mixed in cement in each case. the experiment is intended to find out the
quantity of water to be mixed for a given cement to give a cement paste of normal consistency and can
be done with the help of vacate apparatus. When water is added to the cement, the paste starts stiffening
and gain strength. During the process of stiffening the following phases of action takes place
1. Setting means stiffening of cement paste are loosing of plasticity.
2. Hardening means gaining of strength.

Procedure
1. Take 400gm of cement, which passes through 90mic sieve to prepare on mould.
2. Prepare a cement paste with a measured quantity of water. The time of mixing is in between 3to5
minutes and shall be completed before any signs of setting become visible. The gauging shall be
counted from the time of adding water to the dry cement until commencing to fill the mould.
3. Fill the vicat mould resting on a non-porous plate with this paste. After completely filling the mould,
smooth off the surface and making it level. The mould may be slightly shaken to expel the air.
4. Place the test block in the mould together with non-porous resting plate under the rod attached with
the plunger.
5. Lower the plunger gently to touch the surface of the test block and quickly release, allowing it to
sink into the paste. The operation should be carried out immediately after filling the mould at room
temperature
18
6. Trail test pastes are prepared with varying percentages of water from 25% and 35% with increment
Of 2% until the amount of water necessary for making up the standard consistency is attend.
Observations:
Table 3.1: Standard consistency values

Sl.No. Quantity of % of water Volume of Reading on

Cement by weight Added Water in CC Vicat apparatus

1 300 gms 24 72 ml 35

2 300 gms 28 84 ml 20

3 300 gms 32 96 ml 5

Result:Normal consistency of the cement paste=32%

b) Fineness of Cement:
The fineness of cement has an important bearing on the rate of hydration and hence on the
rate of gain of strength and also on the rate of evolution of heat. Finer cement offers a greater
surface area for hydration and hence the faster and greater the development of strength. Increase
in fineness of cement is also found to increase the drying shrinkage of concrete. Fineness of
cement is tested either by sieving or by determination of specific surface by air-permeability
apparatus. Specific surface is the total surface area of all the particles in one gram of cement.

i. Weigh accurately 100 g of cement and place it on a standard 90 micron IS sieve.

ii. Break down any air-set lumps in the cement sample with fingers.
iii. Continuously sieve the sample giving circular and vertical motion for a period of 15 minutes.
iv. Weigh the residue left on the sieve. As per IS code the percentage residue should not exceed
10%.
Percentage of fineness % = ( W1-W2) / W1 * 100
W1 = Total weight of cement
W2 = Weight of residue

19
Observations:

Table: 3.2 fineness values of cement

Weightofsample
S.No weight of residue(g) Fineness (%)
taken(g)

1. 100 2.8 97.2

2. 100 3.3 96.7

3. 100 2.9 97

Result: Fineness of given sample of cement =97%

c) Specific Gravity of Cement:

Specific gravity is defined as the ratio between weight of a given volume of

material and weight of an equal volume of water. To determine the specific gravity of
cement, kerosene is used which does not react with cement.
i. Clean and dry the specific gravity bottle and weigh it with the stopper (W1).
ii. Fill the specific gravity bottle with cement sample at least half of the bottle and
weigh with stopper (W2).
iii. Fill the specific gravity bottle containing the cement, with kerosene (free of
water) placing the stopper and weigh it (W3).
iv. While doing the above do not allow any air bubbles to remain in the specific
gravity bottle.
v. After weighing the bottle, the bottle shall be cleaned and dried again.
vi. Then fill it with fresh kerosene and weigh it with stopper (W4).
vii. Remove the kerosene from the bottle and fill it with full of water and weigh it
with stopper (W5).

Table 3.3: Specific gravity values of cement

Description of item Values in gms
Weight of empty bottle
32.44
W1 g
20
 Weight of bottle + Cement
61.82
W2 g
Weight of bottle + Cement + Kerosene
94.2
W3 g
Weight of bottle + Full Kerosene
73.33
W4 g
Weight of bottle + Full Water
83.63
W5 g

Specific gravity of Kerosene Sk = (W4 - W1) / (W5 - W1)

= (73.33-32.44)/ (83.63-32.44) =0.8
Specific gravity of Cement Sc = (W2 - W1) / ((W4 - W1)-(W3-W2))*Sk
= (61.82-32.44)/((73.33-32.44)-(94.2-61.82))*0.8
= 2.864
d).Initial and Final Setting of Cement:

In actual construction dealing with cement, mortar or concrete, certain timeis required for
mixing, transporting and placing. During this time cement paste, mortar, or concrete should be in
plastic condition. The time interval for which the cement products remain in plastic condition is
known as the setting time. Initial setting time is regarded as the time elapsed between the
moments that the water is added to the cement to the time that the paste starts losing its plasticity.
The final setting time is the time elapsed between the moment the water is added to the cement,
and the time when the paste has completely lost its plasticity and has attained sufficient firmness
to resist certain pressure. The constituents and fineness of cement is maintained in such a way
that the concrete remains in plastic condition for certain minimum time. Once the concrete is
placed in the final position, compacted and finished it should lose its plasticity in the earliest
possible time so that it is least vulnerable to damages from external destructive agencies. This
time should not be more than 10 hours which is referred to as final setting time. Initial setting
time should not be less than 30 minutes.

i. Take 300gm. of cement, which passes through 90micron sieve to prepare one mould.
ii. Prepare a cement paste by weighing the cement with 0.85 times the water required to give a
paste of standard consistency (0.85p). Start a stopwatch at the instant when water is added to the
cement.
iii. Fill the Vicatmould with the cement paste gauged as above and smooth off the surface making it
level with the top of the mould. The cement block thus prepared in the mould is the test block.

21
 iv. Place the test block confined in the mould on the non-porous plate under the Vicat’s
initial setting needle.
v. Lower the initial setting needle gently in contact with the surface of the test block and quickly
release allowing it to penetrate into the test block.
vi. In the beginning, the needle will completely pierce the test block, repeat this procedure until the
needle, when broughtin contact with the test block and released as described above, fails to
pierce the block for about 35 mm measured from the top of the mould.

vii. The period elapsed between the time when water is added to the cement and the time at which
the needle fails to pierce the test block by about 35 ± 0.5mm shall be the initial setting time.
viii. Replace the needle of the vicat apparatus by annular attachment.
ix. The cement shall be considered as finally set when, upon applying the needle gentle to the
surface of the test block, the needle makes an impression there while the attachment fails to do
so.
x. The period elapsing between the time when water is added to the cement and the time at which
the needle makes an impression on the surface of the test block while the attachment fails to do
so shall be the final setting time.
Results:

1) Initial setting time = 34 min

2) Final setting time =420 min

Table 3.4: Properties of cement

S.no Property Value

1. Normal Consistency 32%

2. Fineness of cement 97%

3. Specific gravity 2.864

4. Initial setting time 34min

22
 5. Final setting time 420min

3.3.2 Tests on Fine Aggregate:

a) Sieve Analysisof Fine Aggregate:
Fine aggregate is sand used in mortars. The size of the fine aggregate is limited to maximum 4.75
mm (4800 microns) beyond which it is known as coarse aggregate. Fineness modulus is only a numerical
index of fineness, giving some idea about, the mean size of the particles in the entire body of concrete.
Determination of fineness modulus is considered as a method of standardization of grading of aggregates
i.e. the main object of finding fineness modulus is to grade the given aggregate for the most economical
mix and workability with minimum quantity of cement. It is obtained by sieving known weight of given
aggregate in a set of standard sieves and by adding the percent weight of material retained on all the
sieves and dividing the total percentage by 100.
i. Take 1 kg of dry Fine aggregate.
ii.Arrange the IS Sieves in the descending order with 4.75mm sieve at top and smallest size sieve at
bottom.
iii.Keep a collecting pan below to collect fine aggregate passing through smallest sizesieve.
iv.Place the aggregate on the top sieve and cover it with a lid.
v.Place the complete set of sieves on sieve shaker and sieve it for 15 minutes.
vi.Find the weight of aggregate retained on each sieve and tabulate as shown in table.
Observations
Table 3.5: Sieve analysis Values of fine aggregate
Weight
Cumulative
Sl. No Sieve size retained % retained % finer
% retained
(gm)
1 4.75mm 40 0.4 0.4 99.6
2 2.36mm 110 11 11.4 88.6
3 1.18mm 180 18 29.4 70.6
4 600µ 220 22 51.4 48.6
5 300µ 230 23 74.4 25.6
6 150µ 180 18 92.4 7.6
7 Pan 40 ---- ----- -------
Result:Fineness modulus of the given Fine aggregate is = cumulative % retained/1=256.6/100 =2.6

c).Specific Gravity of Fine Aggregate:

The specific gravity of an aggregate is generally required for calculations in connection with
cement concrete design work for determination of moisture content and for the calculations of volume
23
 yield of concrete. The specific gravity also gives information on the quality and properties of aggregate.
The specific gravity of an aggregate is considered to be a measure of strength of quality of the material.
Stones having low specific gravity are generally weaker than those with higher specific gravity values.
Specific gravity is defined as the weight of aggregate relative to the weight of equal volume of water.
i. Take the empty weight of pycnometer (jar).W1
ii. Fill the jar with sand up to 1/3 of its volume and weigh it , W2
iii. Fill the jar with sand, with water, and stir with glass rod to expel air bubbles, if any place with lid
and fill the remaining gap with water and level with top of hole. now weigh the jar , W3
iv. Empty the pycnometer .properly cleans it and then fills with water up to top of hole. Again weigh
the jar, W4.

Observations:
1) Weight of pycnometer, W1= 590 gm

2) Weight of pycnometer with sand W2= 1320 gm

3) Weight of pycnometer with sand& water W3= 1920 gm

4) Weight of pycnometer with sand W4 = 1490 gm

5) Specific gravity, G = [(W2-W1)] / [(W4-W1) – (W3 – W2)]

= [(1320-590)] / [(1490-590)-(1920-1320)]

= 2.430

Result:

Specific gravity of fine aggregate = 2.430

c).Bulk Density of Aggregates:

(i) Take the weight of empty measure (W)

(ii) Fill the measure with aggregates sample for about one third heights and tam evenly with 25
strokes of the rounded end of the tamping rod

(iii) Add a similar quantity of aggregate as second layer and tamp it evenly with 25 strokes.

(iv) Fill the measure with a third layer of aggregate up to over following and tamp it with 25
strokes

(v) Strike off the surplus aggregate using the tamping rod as a straight edge.

24
 (vi) Take the weight (W1)

(vii) Empty the measure and fill it again to over flowing by means of a shovel, the aggregate
being discharged from a height not exceeding 5 cm above the top of the measure.

(viii)Level the surface of the measure and weight it (W2).

Calculations:

Diameter of metal measure = 25cm

Height of cylinder=30.1cm

Volume of metal measure (V) =𝜋𝑟2ℎ=14.7*103 cm3

Weight of empty cylinder W= 10400 gms

Fine Aggregate:
Weight of cylinder + compacted fine aggregate W1=34763 gms
Bulk density of compacted fine aggregate = (W1-W)/V
= (34763-10400)/ (14.7*10-3)
=1657.4*103 gm/m3
=1657.4 Kg/m3
Weight of cylinder + loosely packed fine aggregate W2=33706 gms
Bulk density of loosely packed fine aggregates= (W2-W)/V
= (33706-10400)/ (14.7*10-3)
=1585.5*103 gm/m3
=1585.5 Kg/m3
Results:

Bulk density of compacted fine aggregate =1657.4 Kg/m3

Bulk density of loosely packed fine aggregates =1585.5 Kg/m3

25
Table 3.6: Properties of fine aggregates

S.no Property Value

1. Specific Gravity 2.43

2. Fineness Modulus 2.6

3. Zone IV

4. Bulk density 1657.4 Kg/m3

26
3.3.3 TESTS ON COARSE AGGREGATE

a) Sieve Analysis of Coarse Aggregate:

Coarse aggregate is broken stone used in concrete. The size of the fine aggregate is
limited to maximum 4.75 mm (4800 microns) beyond which it is known as coarse aggregate.
Fineness modulus is only a numerical index of fineness, giving some idea about, the mean size of
the particles in the entire body of concrete. Determination of fineness modulus is considered as a
method of standardization of grading of aggregates i.e. the main object of finding fineness
modulus is to grade the given aggregate for the most economical mix and workability with
minimum quantity of cement. It is obtained by sieving known weight of given aggregate in a set
of standard sieves and by adding the percent weight of material retained on all the sieves and
dividing the total percentage by 100.
i. Take 10 kg of dry coarse aggregate.
ii. Arrange the IS Sieves in the descending order with 63mm sieve at top and smallest size sieve at
bottom.
iii. Keep a collecting pan below to collect coarse aggregate passing through smallest size sieve.
iv. Place the aggregate on the top sieve and cover it with a lid.
v. Place the complete set of sieves on sieve shaker and sieve it for 15 minutes.
vi. Find the weight of aggregate retained on each sieve and tabulate as shown in table 3.9.
vii. Calculate the Percentage finer on each sieve and tabulate as shown in table 3.9.

27
Observations:
Table 3.7 Sieve analysis values of coarse aggregate

Weight Cumulative
Sl. No Sieve size % retained % finer
retained (kg) % retained
1 63 mm 0 0 0 100
2 50 mm 0 0 0 100
3 40 mm 770 7.7 7.7 92.3
4 31.5mm 260 2.6 10.8 97.4
5 25mm 3180 31.8 42.1 68.2
6 20mm 1400 14 56.1 86
7 16mm 2220 22.2 78.3 77.8
8 12.5mm 950 9.5 87.8 90.5
9 10mm 440 4.4 92.2 95.6
10 6.3mm 24.26 0.242 92.44 99.75
11 Pan 1.130 0.0113 92.45 99.9

Fineness modulus of Coarse aggregate = (sum of cumulative % wt retained)/100

= 559.89/100
=6
Result:
Fineness modulus of the given coarse aggregate is = 6

b).Specific Gravityof CoarseAggregate:

The specific gravity of an aggregate is generally required for calculations inconnection with
cement concrete design work for determination of moisture content and for the calculations of
volume yield of concrete. The specific gravity also gives information on the quality and
properties of aggregate. The specific gravity of an aggregate is considered to be a measure of
strength of quality of the material. Stones having low specific gravity are generally weaker than
those with higher specific gravity values. Specific gravity is defined as the weight of aggregate
relative to the weight of equal volume of water.
1. Take the empty weight of pycnometer (jar).W1
28
 2. Fill the jar with aggregate up to 1/3 of its volume and weigh it , W2
3. Fill the jar with aggregate, with water, and stir with glass rod to expel air bubbles, if any
place with lid and fill the remaining gap with water and level with top of hole. now weigh
the jar , W3
4. Empty the pycnometer .properly cleans it and then fills with water up to top of hole. Again
weigh the jar, W4.

Observations:

1. Weight of pycnometer, W1 = 590 gm

2. Weight of pycnometer with aggregate W2 = 1190 gm

3. Weight of pycnometer with aggregate & water W3 = 1900 gm

4. Weight of pycnometer with aggregate W4 = 1510gm

5. Specific gravity, G = [(W2-W1)] / [(W4-W1) – (W3 – W2)]

= [(1190-590)] / [(1510-590)-(1900-1190)]

= 2.857

Result:

Specific gravity of coarse aggregate = 2.857

c).Bulk Density of Aggregates:

(i) Take the weight of empty measure (W)

(ii) Fill the measure with aggregates sample for about one third heights and tam evenly with 25
strokes of the rounded end of the tamping rod

(iii) Add a similar quantity of aggregate as second layer and tamp it evenly with 25 strokes.

(iv) Fill the measure with a third layer of aggregate up to over following and tamp it with 25
strokes

(v) Strike off the surplus aggregate using the tamping rod as a straight edge.

(vi)Take the weight (W1)

29
 (vii) Empty the measure and fill it again to over flowing by means of a shovel, the aggregate
being discharged from a height not exceeding 5 cm above the top of the measure.

(viii)Level the surface of the measure and weight it (W2).

Calculations:

Diameter of metal measure = 25cm

Height of cylinder=30.1cm

Volume of metal measure (V) =𝜋𝑟2ℎ=14.7*103 cm3

Weight of empty cylinder W= 10400 gms

Coarse Aggregate:

Weight of cylinder + compacted coarse aggregate W1 =33950gms

Bulk density of compacted coarse aggregates = (W1-W)/V

= (33950-10400)/ (14.7*10-3)

=1602.6*103gm/m3

=1602.6 Kg/m3

Weight of cylinder + loosely packed aggregatesW2=33950gms

Bulk density of loosely packed aggregates= (W2-W)/V

= (32350-10400)/ (14.7*10-3)

=1493.3*103gms/m3

=1493.3 Kg/m3

Results:
Bulk density of compacted coarse aggregate =1602.6 Kg/m3

Bulk density of loosely packed coarse aggregates =1493.3 Kg/m3

30
 Table 3.8: Properties of Coarse aggregate

S. No Properties Values

1. Fineness Modulus 7.5

2. Specific Gravity 2.84

3. Bulk Density 1602.6 Kg/m3

31
3.4 CONCRETE MIX DESIGN

The process of selecting suitable ingredients of concrete and determining their relative amounts with
the objective of producing a concrete of the required, strength, durability,and workability as
economically as possible, is termed the concrete mix design.
3.4.1Requirements of concrete mix design
The requirements which form the basis of selection and proportioning of mix ingredients are:
a) The minimum compressive strength required from structural consideration
b) The adequate workability necessary for full compaction with the compacting equipment available.
c) Maximum water-cement ratio and/or maximum cement content to give adequate durability for the
particular site condition to meet the site condition and meet strength.
d) Maximum cement content to avoid shrinkage cracking due to temperature cycle in mass concrete
3.4.2TYPES OF MIXES
NOMINAL MIX
In the past the specifications for concrete prescribed the proportions of cement, fine and coarse
aggregates. These mixes of fixed cement-aggregate ratio which ensures adequate strength are termed
nominal mixes. These offer simplicity and under normal circumstances, have a margin of strength above
that specified. However, due to the variability of mix ingredients the nominal concrete for a given
workability varies widely in strength.
STANDARD MIX
The nominal mixes of fixed cement-aggregate ratio (by volume) vary widely in strength and may
result in under- or over-rich mixes. For this reason, the minimum compressive strength has been included
in many specifications. These mixes are termed standard mixes.
IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15, M20, M25, M30,
M35 and M40. In this designation the letter M refers to the mix and the number to the specified 28 day
cube strength of mix in N/mm2. The mixes of gradesM10, M15, M20 and M25 correspond
approximately to the mix proportions (1:3:6), (1:2:4), (1:1.5:3) and (1:1:2) respectively. Behaviour
ofconcrete by partial replacement of coarse aggregate with recycled plastic granules

STEP1: Design stipulations:

1. Characteristics compressive strength = 25 N/mm2
32
 2. Maximum size of coarse aggregate = 20 mm
3. Degree of workability = 10 – 30 mm
4. Degree of quality control = Good
5. Type of exposure = Moderate
6. Type of cement = OPC 53grade
7. Type of aggregate = Angular
8. Maximum W.C ratio = 0.45(Table 5 IS 456)

STEP2: Test data for materials:

Specific gravity of cement = 2.864
Specific gravity of coarse aggregate = 2.857
Specific gravity of fine aggregate = 2.43
Fine aggregate = zone 4
Specific gravity of water =1
STEP3: Target mean strength:
Target mean strength fck1 = fck+ts
= 25+1.65*4
= 31.6 N/mm2
From (table 8 of IS 456-2000 “S” =4
Risk factor = 1.65
STEP4: Water – Cement ratio:
Adopt water-Cement ratio = 0.5
From ( IS: 10262-2002)(fig1)
STEP5: Water Content:
For 20 mm nominal maximum size of aggregates, water content per cubic
meter of concrete = 186 liters

STEP6: Cement content:

Water cement ratio = 0.5
Cement content = (186)/(0.5)
= 372 Kg/m3

33
STEP7: Volume of C.A and F.A:
From table 3 (IS: 10262 – 2009)
Volume of coarse aggregate corresponding to 20mm size for W.C ratio of 0.50 = 0.62
= 0.62 m3
Volume of fine aggregate = (1 - Volume of C.A)
= (1 – 0.62)
= 0.38 m3

STEP8: Mix calculations:

(a) Volume of concrete = 1m3
(b) Volume of cement = (Mass of cement)/(S.G cement)*(1/1000)

= (372/2.86)*(1/1000)
= 0.13m3
(c) Volume of water = (Mass of water) / (S.G water)*(1/1000)

= (186 /1)*(1/1000)
= 0.186 m3
(d) Volume of all in aggregates = [a- (b + c)]

= [1-(0.13+0.186)] = 0.686m3

(e) Mass of coarse aggregate = d*Volume of C.A*S.G of C.A

= 0.6586*2.8*0.62*1000
= 1190.89 Kg/m3
(f) Mass of fine aggregate = d*Volume of F.A*S.G of F.A*1000

= 0.686*2.37*0.38*1000
= 617.8 Kg/m3

Cement content = 372 Kg/m3

Mass of coarse aggregate = 1190.89 Kg/m3
Mass of fine aggregate = 617.8 Kg/m3
Water content = 186 liters

34
STEP9:Mix proportion:
(469/469): (698/469): (1093/469)

Table no.3.9 Mix design details

COMPONENT M25
Mix ratio 1:1.6:3.2
Water cement ratio 0.5
Table no.3.10
Cement 0.13 kg/m3 mix design
Fine aggregate 1190.89 kg/m3 details
Coarse aggregate 617.8 kg/m3
Water 186 lit/m3

3.4.3: Slump cone test:

1. Mix the dry constituents thoroughly to get a uniform color and add water.
2. Place the mixed concrete in the cleaned slump cone mould is 4 layers. Each approximately1/4
of the mould. Tamp each layer 25 times with 25 times with tamping rod distributing the
strokes.
3. For the second and subsequent layers of tamping rod should penetrate into the under laying
layer.
4. Strike of the top with a trowel. So that the mould is exactly filled.
5. Remove the cone immediately. Rising it slowly and carefully in the vertical direction.
6. As soon as the concrete settlement comes to stop. Measure the subsidence of concrete in mm.
which will give the slump.

Slump = 10mm (very low)

35
TYPES OF SLUMPS

3.5 PROCEDURE
Compression testing has been performed for 0%, 10%, 25% and 50% replacement of stone chips with CS. It
has been observed that the compressive strength of the concrete decreases as the percentage of the coconut
shells increase in the concrete mixer as presented in Table 2. It is also observed that the concrete compressive
strength of the cylinder specimens increases with the increasing curing days. According to ACI, a concrete is
considered structural lightweight aggregate concrete when made with lightweight aggregates conforming to
ASTM C 330 and has a compressive strength in excess of 2,500 psi (17.25 MPa) at 28 days of age. From
Figure 7 it can be observed that the compressive strength (at 28 days and 90 days) of concrete produced with
10% and 25% replacement of stone chips with coconut shells is approximately 90% and 65% of the concrete
produced with 100% stone chips coarse aggregate and therefore, satisfies the strength requirements for
lightweight concrete. An examination of the failure surfaces showed breakage of the CS aggregate, indicating
that the individual shell strength had a strong influence on the resultant concrete strength.
The batches were prepared and cured accordingly:
1. Concrete cubes were prepared with replacements of 0,5,10,15,20% of Coarse aggregate with
coconut shells
2. The slump test was carried out following IS: 1199-1959. Place the mixed concrete in a clean
slump cone 4 layer each approximately one fourth of the weight of mould after applying a thin
coat of oil to the inner surface of cone. Tamping each layer 25 times with tamping rod
uniformly throughout the surface of the mould. Smooth the surface by using straight edge after

36
 the cone is completely filled by the concrete. Lift the cone vertically by holding the lifting
handles and measure the slump (i.e.) the average height of falling concrete.
3. Repeat the same procedure for different aggregate replacements.
4. The moulds used were 150mmx150mmx150mm rigid steel forms. The moulds were filled with 3
lifts of freshly mixed concrete, tamping each lift 25 times with tamping rod and tamping each lift
lightly with mallet 10-15 times. The excess concrete was struck off and finished to a smooth
surface with steel or wooden trowel. The moulded cubes were left covered with room
temperature for about 24 hours after which the moulds were removed under then the cubes were
transferred to curing tank at a temperature of 26oc and relative humidity of approximately 95-
100%.
5. The cubes were used to test for compressive strength. Once set of 3 cubes were tested after 7
days and another set of 3 cubes were tested after 28 days.
During the test of compressive strength, the load p was collected and the strength was
calculated based on the equation below.
𝑙𝑜𝑎𝑑
𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ =
𝑠𝑢𝑟𝑓𝑎𝑐𝑒𝑎𝑟𝑒𝑎𝑜𝑓𝑐𝑜𝑛𝑐𝑟𝑒𝑡𝑒
Where;
Load= noted from compressive testing machine (KN)
Surface area of concrete= 150mmx150mmx150mm.
The compressive strength is taken in N/mm2

37
 CHAPTER 4

RESULTS AND DISCUSSION

4.1 COMPRESSION TEST

Testing hardened concrete plays an important role in controlling and conforming the quality of cement
concrete work. The main factor in favour of the use of concrete instructures is its compressive strength.
One of the important properties of the hardenedconcrete is its strength which represents its ability to
resist forces. The compressivestrength of the concrete is considered to be the most important and is often
taken as anindex of the overall quality of concrete. The compressive strength of concrete is definedas the
load which causes the failure of specimen per unit cross section on compressionunder given rate of
loading.

Apparatus: Cube moulds 150mm size, weighing machine, tampming rodsand compressiontesting
machine

Procedure:

1. Take three cube moulds for each mix. Assemble the mould with base plate so that it is rigidly
held together
2. Clean the inside of the mould and see that joints (at the edges) are perfectly tight.
3. Pour properly mixed concrete for the given mix to the cube moulds
4. Compaction by needle vibrator or will be preferred. If vibrator is not available, handcompaction
is to be done by placing concrete in three layers; each layer be compacted with the help of
standard temping rod by means of 25 blows.
5. Level the concrete at the top of the mould by means of trowel and give properidentification mark
of the specimen.
6. Keep the cubes in laboratory for 24 hours.
7. After 24 hours, dismantle the plates of cube mould and take out the hardenedconcrete cubes
carefully so that edges specimens are not damaged.
8. Immerse the cubes in curing tank filled with water. Keep it for curing up to 28 days.
9. Test the cubes after 7, 14 and 28 days of curing to find the compressive strength.
10. Tabulate Compressive strength for each cube and calculate average value for each
38
 4.2TESTING PROCEDURE:
The molded cubes are removed from curing tank after the specified curing. Excess water
is wiped out on the specimen is dried. Dimensions of the specimens are measured to the nearest
0.2 meter. The specimens are taken for the testing at compressive testing machine is cleaned and
the specimens are placed in such a manner that the load is applied to the opposite sides of the
cube cast uniformly. The specimen is aligned centrally on the base plate of the machine and the
movable portion is rotated by hand so that it touches the top surface of the specimen. The load is
applied gradually without shock and continuously at the rate of 140 kg/cm3/min till it fails. The
maximum load is recorded and any usual features in type of failure are noted. A min of 3
specimens are tested at selected age. If any strength is varied by more than 15% of average
strength results of such specimen should be rejected. Average of three specimens gives the
crushing strength of concrete.

During the compressive strength, the load P is collected and the strength was calculated

TEST RESULTS

Table no.4.1 Compressive strength details for 7 days

S.NO Percentage of coconut Compressive strength for

shell 7 days (N/mm2)

1 0

2 5

3 10

4 15

5 20

39
Table no.4.2. compressive strength for 14 days

S.NO Percentage of Coconut Compressive strength

shell for 14 days (N/mm2)

1 0

2 5

3 10

4 15

5 20

Table no.4.3. compressive strength for 28 days

S.NO Percentage of Coconut Compressive strength for

Shell 28 days (N/mm2)

1 0

2 5

3 10

4 15

5 20

40
41