LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-1

INTRODUCTION

GENERAL:

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

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

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

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

RGMP Page 1
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

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

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

TYPES OF LIGHTWEIGHT CONCRETE:

1. No-fines concrete

2. Lightweight aggregate concrete

3. Aerated/Foamed concrete

NO-FINES CONCRETE:

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

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

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

RGMP Page 2
LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

Fig 1.1 No- Fines Concrete

LIGHTWEIGHT AGGREGATE CONCRETE:

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

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

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

Structurally lightweight aggregate concrete is fully compacted similar to that of

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

RGMP Page 3
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

Fig 1.2 Light weight Concrete

AERATED CONCRETE:

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

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

RGMP Page 4
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

Fig 1.3 Aerated Concrete

ADVANTAGES:

1. Reduces the dead load of the building.

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

3. Improve the workability.

4. Relatively low thermal conductivity.

5. Comparatively more durable.

RGMP Page 5
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

DISADVANTAGES:

1. Very sensitive with water content in the mixture.

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

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

4. Lightweight concrete are porous and poor resistance.

APPLICATION OF LIGHTWEIGHT CONCRETE:

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

Nowadays with the advancement of technology, lightweight concrete expands its

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

RGMP Page 6
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-2
LITERATURE REVIEW

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

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

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

THOMAS A. HOLM (1984):

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

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

According to ACI material journal by dionamarica, andrianloani, mihaifilip and lanpepenar

(1994), it was found that in japan LWC had been used since 1964 as a railway station platform.
The study on durability was carried out in 1983 has proven that LWC exhibited similar
carbonation depths as normal concrete.

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

RGMP Page 7
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

SELMA (1914-1918):

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

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

Fig 2.1 ‘The Pantheon’

RGMP Page 8
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-3

METHODOLOGY

INTRODUCTION:

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

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

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

2. Preparation of recycled plastic aggregate.

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

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

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

c. Mix design of M20 concrete

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

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

RGMP Page 9
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

MAKING OF PLASTIC AGGREGATE:

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

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

2. Melting point: 130C-180C

3. Specific Gravity: 0.95

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

5. Chemical resistant

6. Impact and wear resistant

7. Can withstand high temperature

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

Sorting the plastic:

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

RGMP Page 10
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

Fig 3.1 Sorting Of Plastic

Shredding the plastic:

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

Fig 3.2 Shredding and shredded HDPE Material

RGMP Page 11
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

Washing shredded plastic:

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

Fig 3.3 Washing of shredded plastic

Extruding:

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

Fig 3.4 Extruder and Extrusion of Plastic

RGMP Page 12
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

Plastic aggregate:

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

Fig 3.5 Plastic Aggregate

RGMP Page 13
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-4

MATERIALS USED

Material testing were conducted as per IS specifications.

CEMENT:

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

Table 1. Properties of Cement

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

FINE AGGREGATE:

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

Table 2. Properties of Fine Aggregate:

Fineness Modulus 4.129

Zone I

Specific Gravity 2.697

Water absorption 0.2%

RGMP Page 14
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

PLASTIC AGGREGATE:

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

Table 3. Properties of Plastic Aggregate

Fineness Modulus 5.63

Nominal Size 20mm

Specific Gravity 0.94

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

RGMP Page 15
 LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-5

CASTING OF SPECIMENS:

Specimens were casted for varying percentage replacement of 5%, 10%, 15%, 20%, 25%, 30%, 35%
and 40% of natural aggregate with plastic aggregate.

Table 4. Mix Designation

% Replacement of aggregate Mix

with plastic

5 5P

10 10P

15 15P

20 20P

25 25P

30 30P

35 35P

40 40P

Table 5. Total Number of Specimens Casted

Specimen Dimension Total No

Cube 150mm x 150mm x 150mm 05

Cylinder 150mm diameter, 300mm height 05

Beam 100mm x 100mm x 500mm 05

RGMP Page 16
LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-6

TEST RESULTS AND DISCUSSIONS

WORKABILITY BY SLUMP:

With the introduction of plastic in concrete the slump value increases i.e. the
workability of concrete increases. This is due to the influence of surface texture and water
absorption of the aggregates on workability.

Fig 6.1 Workability by Slump

RGMP Page 17
LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

COMPRESSIVE STRENGTH OF CONCRETE CUBES:

That on addition of plastic aggregate there was a gradual increase in 7 day,

14 day and 28 day compressive strength of cube. An increase in strength was observed till
30% replacement of natural aggregate with plastic aggregate and on further replacement
strength was found to be decreasing.

Fig 6.2 Showing Testing of Compressive strength

Fig 6.3 Compressive Strength of Concrete Cube

RGMP Page 18
LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

COMPRESSIVE STRENGTH OF CONCRETE CYLINDERS:

It is seen 7 day, 14 day and 28 day compressive strength of cylinder increased

gradually with the plastic replacement of natural aggregate with plastic aggregate in
concrete. Compressive strength increased till 30% replacement of natural aggregate with
plastic aggregate and on further replacement a decrease in the strength was noted.

SPLITTING TENSILE STRENGTH OF CONCRETE CYLINDERS:

An increasing trend in splitting tensile strength of concrete was observed till

30% replacement of natural aggregate with plastic aggregate. After 30P decrease in strength
was observed.

Fig 6.4 Slitting Tensile Strength of concrete cylinder.

RGMP Page 19
LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

FLEXURAL STRENGTH OF PCC CUBE:

Flexural strength increased within increase in plastic content. Replacement of natural

aggregate with plastic aggregate tends to make concrete ductile and hence increases
the ability of concrete to significantly deform before failure.

Fig 6.5 Flexural Strength of PCC cube

RGMP Page 20
LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

BREAKING LOAD OF RCC BEAMS:

Breaking load increased with the increase plastic content in concrete. Replacement
if natural aggregate with plastic aggregate tends to make concrete ductile and hence
increase the ability of concrete to significantly deform before failure.

CUBE WEIGHT:

A decreasing tend was observed in the case of cube weight. Plastic being a
light weight material tends to decrease the weight of the resultant concrete.

RGMP Page 21
LIGHT WEIGHT CONCRETE BLOCK USING PLASTIC DEPT OF CE

CHAPTER-7
REFERENCE

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

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

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

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

3. Ghassan Subhi Jameel, Study The Effect of Addition of Weste Plastic on

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

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

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

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

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

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

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

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

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

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

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

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

RGMP Page 22