A Study on the Optimization of Burning Residual as a

Concrete Additive Used as a CHB Wall Alternative

by

Alvin Kim A. Antonio

Michael Lorren E. Calitis
Arvin Jon C. Pascual
Andrea Kristel C. Silang

A Thesis Submitted to the School of Civil, Environmental and Geological

Engineering in Partial Fulfillment of the Requirements for the Degree of Bachelor
of Science in Civil Engineering

Civil Engineering

Mapúa Institute of Technology

December 2012
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 ABSTRACT

The use of coal is predominant; it is used in production of steel, concrete, and

electricity. Fly ash is one of the by products produced in burning coal which can be used as

an additive for concrete. This study aimed to provide an alternative additive for concrete mix

using burning residual. Another aim was to determine the maximum mixture of cement and

burning residual and to differentiate the strength of conventional concrete to the concrete

with burning residual. The cost of using burning residual as an additive for concrete on

structural estimates was also quantified. The result showed that the most economical range of

mix proportions of cement and burning residuals is from 22.65% to 44.37% can be replaced

by burning residuals without compromising the actual strength. This range of percentage of

cement when replaced by burning residuals costs less but has greater or equal compressive

strength with conventional concrete. The range of optimal mixtures of cement and burning

residuals is 21% to 26% of cement being replaced by burning residuals. This range of

mixtures produces compressive strength of the concrete greater than that of conventional

concrete with maximum of 16.12 MPa. Comparing the cost of materials used for load bearing

wall shows that using poured concrete with burning residuals costs less by 4.75% than using

concrete hollow blocks.

 TABLE OF CONTENTS

Chapter 1. INTRODUCTION ....................................................................................................1

1.1 Objective of the Study ......................................................................................................2

1.2 Significance of the Study ................................................................................................3

1.3 Scope and Limitations .....................................................................................................4

1.4 Major and Minor Fields of Civil Engineering .................................................................4

Chapter 2. REVIEW OF RELATED LITERATURE .............................................................16

Chapter 3. METHODOLOGY .................................................................................................24

3.1 Research Design .............................................................................................................24

3.2 Data Gathering Procedure ..............................................................................................24

3.3 Standard Specification for Concrete Aggregates ..........................................................24

3.4 Design Mix .....................................................................................................................25

3.5 Mixing ...........................................................................................................................25

3.6 Curing .............................................................................................................................26

3.7 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens 26

3.8 Data Interpretation ..........................................................................................................26

3.9 Conceptual Framework .................................................................................................27

3.10 Analytical Framework .................................................................................................28

Chapter 4. RESULT AND DISCUSSION...............................................................................29

Chapter 5. CONCLUSION .....................................................................................................36

Chapter 6. RECOMMENDATION .........................................................................................38

ACKNOWLEDGEMENTS ....................................................................................................40

REFERENCES .......................................................................................................................41

LIST OF APPENDICES ..........................................................................................................43

 Chapter 1

INTRODUCTION

In industries the use of coal is predominant. It is used in production of different

materials such as steel and concrete. Also, the electricity used to run gadgets and appliances

is produced from power plants that utilize coal as their fuel. However, aside from the benefits

that coal provides, the use of this material causes a significant increase in coal residuals

which causes problems because of its improper disposal. The ashes emit carbon dioxides and

other hazardous chemicals that pose a great risk to the environment.

One of the by products produced in the burning of coals is called fly ash. Fly ash is

the fine particles that rise to the atmosphere. One of the properties of a fly ash is the same as

that of a pozzolan that helps with the hydration of concrete.

One of the engineering solutions being offered in order to reduce the amount of these

wastes being disposed to the environment is to use burning residuals as a material for

construction purposes. Burning residuals including fly ash, bottom ash, boiler slag, and flue

gas desulfurized gypsum have an engineering application such as a raw material for concrete

production, feedstock for cement production, and mineral filler in asphalt - an aggregate in

road bases and pavement and etc.

According to Mehta (2004), the use of burning residuals to concrete has good effects

in the properties of concrete. As an example, fly ash, a principal by-product of the coal-fired

1
power plants, is well accepted as a pozzolanic material that may be used either as a

component of blended portland cements or as a mineral admixture in concrete. The property

of fly ash helps the hydration of concrete. Adding fly ash can significantly enhance its basic

properties in both the fresh and hardened states. This material also improves the durability of

concrete according to Kosior-Kazberuk & Lelusz (2007). In addition, the inclusion of fly ash

in concrete reduces the water demand, improves the workability, minimizes cracking due to

thermal and drying shrinkage, and enhances durability to reinforcement corrosion, sulfate

attack, and alkali-silica expansion (Mehta, 2004).

1.1 Objectives of the Study

The research conducted has the objective:

 The study aimed to provide an alternative additive for concrete mix using burning

residuals.

Specifically, the study aimed to meet the following objectives:

 To differentiate the compressive strength between concrete with burning residuals

and normal concrete.

 To determine the most economical mix proportion of cement and burning residuals.

 To determine the optimum mixture of cement and burning residuals.

 To quantify the costs of using burning residuals as an additive to concrete on

structural estimates.

2
1.2 Significance of the study

The study aimed to provide information about the use of burning residuals for

additive on concrete. It serves as an innovation for producing concretes that will be used on

structure with new properties. The study serves as a source of knowledge or reference for

those students who wish to pursue or improve the study about the use of burning residuals as

an additive for the concrete. The study aims to inform the society about the beneficial effects

of using burning residual in concrete. This includes the knowledge on how to minimize the

dispersal of diseases caused by the toxic chemicals present in burning residuals.

1.3 Scope and Limitations

The study focused on the use of burning residuals as an additive for concrete mix.

The main residual referred in this study is limited to fly ash only. The sample additive should

pass the specification stated in ASTM C618-05 “Standard Specification for Fly Ash and Raw

or Calcined Natural Pozzolan for use as a Mineral Admixture on Portland Cement Concrete”.

In the experiment the concrete samples went through compressive strength test using the

Universal Testing Machine (UTM). The type of cement used was Type-I Portland Cement

also known as general purpose cement and the experiment followed the standard procedures

of the American Society of Testing Materials (ASTM).

The design mix was used as a substitute on load bearing walls made of concrete

hollow blocks. Estimations for the costs of load bearing walls were made including concrete

hollow blocks, plasters, and fills. Horizontal and vertical steel reinforcements as well as labor

costs were excluded upon estimation.

3
1.4 Major and Minor Fields of Civil Engineering

This study covers three disciplines of Civil Engineering namely Construction,

Structural and Environmental Engineering.

Construction Engineering

The study revolves mainly on construction engineering since it presents a broad

comparison of a conventional concrete with another concrete with burning residuals as an

additive (in this case fly ash). In choosing this study several additives where considered that

will fit the main objective, Which is to provide an additional material that will improve the

quality of concrete to be used without compromising its cost, Considering the beneficial

effects of fly ash on the quality of concrete such as additional resistance on corrosion of

reinforcing bars, thermal stability and strength and its improvement during its preparation

(workability), It is considered as the best material for our study. The cost of the material with

the additive is also considered. The study also showed that the cost of the concrete will be

reduced to a considerable amount after the additive is induced.

Determination of Concrete mix Using ACI Method

Concrete mix design by the ACI method requires various material properties as the

input. The effect of variation of these input parameters on mix proportions has considered in

using this method.. The mix has been expressed by volume ratios of fine aggregate to coarse

aggregate and cement to fine aggregate. In this method, inter-particle voids of coarse

aggregates which is a function of gradation, plays a significant role in the prediction of mix

proportions.

Below is the actual computation for the determination of mix using ACI method.

4
Concrete Design Mix using ACI Method

Given:
Required Strength= 20 MPa
Unit wt. of coarse aggregates= 1600 Kg/m3
Max. size of aggregates= 25 mm
Slump=75-100mm

Material Cement Sand Gravel

Fineness Modulus - 2.4 -
Specific Gravity 3.15 2.6 2.7
Moisture Content - 6.5 3.5
% Absorption - 4.7 1.5
Type 1 natural angular

Abs. volume of concrete=1m3

1. w/c ratio (table 3)

w/c f’c
24.85 22.08
x 20
28.4 17.24

w/c= 26.38
2. water required= 193 li/m3

3. % entrapped air (table 4)= 1.5%

4. Wt. of coarse aggregates (table 5)= 0.7m3

5. No. of bags required/m3 of concrete

6. Abs. volume of cement

7. Abs. volume of water

5
8. Abs. volume of air

9. Abs. volume of cement paste

10. Abs. volume of solid aggregates

11. Abs. volume of gravel

12. Abs. volume of sand

13. Summary

Material Abs. Volume Specific Uncorrected Corrected

Gravity Wt. (kg) Wt.(kg)
Cement 0.0930 3.15 1000 292.95 292.95
Sand 0.2482 2.60 1000 738.40 751.69
Gravel 0.4148 2.70 1000 1120.50 1142.91
Water 0.1930 1.00 1000 193.00 157.30
Air 0.0150 - 1000 - -

14. Field Moisture = MC % abs.

F (sand) =
F (gravel) =

15. Corrected Wt.

6
 % Fly ash Cement (Kg) Fly ash (Kg) Sand (Kg) Gravel (Kg) Water(Li)
0 5.14 0 13.30 20.12 2.77
10 4.63 0.51 13.30 20.12 2.71
20 4.13 1.03 13.30 20.12 2.66
30 3.60 1.54 13.30 20.12 2.60
40 3.08 2.06 13.30 20.12 2.55
50 2.57 2.57 13.30 20.12 2.50

Table 1 Mix proportions for concrete samples

Fly Ash (%) 0 10 20 30 40 50
Water (Li) 2.77 2.71 2.66 2.60 2.55 2.50
Sand (Kg) 13.30 13.30 13.30 13.30 13.30 13.30
Gravel (Kg) 20.12 20.12 20.12 20.12 20.12 20.12
Cement (Kg) 5.14 4.63 4.13 3.60 3.08 2.57
Fly Ash (Kg) 0 0.51 1.03 1.54 2.06 2.57

Cost Reduction Determination

The study also focused on the computation of the reduction on costs using burning

residual as an admixture. For the estimation purposes, a CHB wall is considered by replacing

CHB with concrete containing burning residuals. Significant changes in costs were observed

at the end of the computation.

CHB Wall Estimated Cost

Mortar Fill

Plaster (Two Faces)

7
Reinforcement

Material Quantity Unit Unit Price Cost

6" CHB 1230 pcs. 9 11070
Cement(Fill) 96 bags 200 19200
Cement(Plaster) 57 bags 200 11400
Sand(Fill) 8 cu.m. 700 5600
Sand(Plaster) 3 cu.m. 700 2100
Reinforcement- 10mm dia. × 6m 68 pcs. 120 8160

Total Materials Cost (Php) 57530

8
Concrete Wall with Fly Ash Wall Estimated Cost

Class B (1:2:4)

Reinforcement

Formworks

Material Quantity Unit Unit Price Cost

Cement 75 bags 200 15000
Fly Ash 22 bags 2 44
Sand 7 cu.m. 700 4900
Gravel 12.5 cu.m. 750 9375
Reinforcement- 10mm dia. × 6m 68 pcs. 120 8160
Plywood- 12mm × 4 ft × 8 ft 32 pcs. 260 8320
Lumber 300 bf. 30 9000

Total Materials Cost (Php) 54799

9
Structural Engineering

For the structural component another feature supporting the construction component

since it improves the quality of concrete against compressive forces therefore increasing the

stress capacity of concrete structures. It is proven that using fly ash as an additive produces

considerable change in the compressive stress capacity based on the experiments performed.

This is very essential on making low cost houses which is one of the increasing projects

nowadays in order to withstand effects of weather and other catastrophes that hit our country.

Overall, this will improve the structural integrity of the houses to be made.

Determination of Compressive Strength

Compressive strength is a stress that results from the shortening in one dimension of

an elastic body due to oppositely directed collinear forces tending to crush it.

Compressive strength tests are usually made by using Universal Testing Machines

(UTM). This test method consists of applying a compressive axial load to molded cylinders

or cores at a rate which is within a prescribed range until failure occurs. 18 concrete cylinders

with varying burning residuals were used in this study.

10
Below is an actual data of Compression test at 30% burning residual.

11
 The figure below shows the graph of Strength vs. burning residual content. The trend

formed in the experiment was defined using the equation. The said equation was verified to

fit the said curve using correlation coefficient which showed a value of 0.988 making it “best

fit”.

Strength vs Burning Residual Content

30

25
Compressive Strength, MPa

20

15
Data Points
10 Maximum Point
y=10.80393+0.46934x-0.01036x2
5
r=0.988
0
0% 10% 20% 30% 40% 50% 60%
Burning Residual content, %

12
Environmental Engineering

Environmental engineering is considered as a minor component of the engineering

field since it deals with the integration of science and engineering principles to improve

environment such as remediating pollution in our country. Furthermore it is concerned with

finding plausible solutions in the field of health in our society.

Coal is a combustible black or brownish-black sedimentary rock usually occurring

in rock strata in layers or veins called coal beds or coal seams. It Serves as a primary source

of electricity, provides heat for the production of steel and cement and an alternative oil.

However, coal also has its own disadvantages such as: its burning contributes to

global warming. It also contains hazardous toxins and one of its by-products is fly ash.

Several studies are made in order to dispose burning residuals. These studies were

focused on providing method on how to properly handle the said materials. On the other hand

this study focused on the validation of the effectiveness of burning residuals as an additive,

therefore utilizing the material instead of disposing.

In addition, the study is aimed to be a subject for sustainable development.

Considering the abundance of the material to be used, this is also the primary residual of all

coal powered plants in the Philippines. Furthermore it is also intended to reduce the

pollution caused by the ashes which results to respiratory illnesses.

13
 The abundance of burning residual was verified by existing Coal fired power plants in

our country.

14
Source: Greenpeace.org

Philippines mainly rely on the electricity generated by these coal power plants. One

of the engineering solutions that can be applie to reduce the amount of wastes being

produced by these power plants is to recycle them.

15
 Chapter 2

REVIEW OF RELATED LITERATURE

Aggarwal et. al. (2010) stated that the concrete construction industry is not

sustainable. It consumes a lot of virgin materials and the principal raw material of concrete

i.e. cement is responsible for green house gas emissions causing a threat to environment

through global warming. Therefore, the industry has seen various types of concrete in search

of a solution to sustainable development. Infrastructural growth has witnessed many forms of

concrete like high strength concrete, high performance concrete, self-compacting concrete

and the latest in the series is high volume fly ash concrete (HVFC). The paradigm has shifted

from one property to other of concrete with advancement in technology. The construction

techniques have been modernized with focus on high strength, dense and uniform surface

texture, more reliable quality, improved durability and faster construction. Their study

discusses the development of high volume fly ash concrete for construction with reference to

its predecessors like HSC and HPC.

As sustainability moves to the forefront of construction, the utilization of high-

volume fly ash concrete mixtures to reduce CO2 emissions and cement consumption per unit

volume of concrete placed is receiving renewed interest as studied by Bentz et. al. (2011).

Concrete mixtures in which the fly ash replaces 50% or more of the Portland Cement are

both economically and technically viable. Both the raw materials and the finished products

(mortars and concretes) are evaluated using a transient plane source method. As with most

materials, thermal conductivity is found to be a function of density, while also being

16
dependent on whether the aggregate source is siliceous or limestone. The measured values

should provide a useful database for evaluating the thermal performance of high-volume fly

ash concrete structures.

The sustainability issue for concrete construction industry is not arrived due to one or

more reasons related to the material or the technology itself. This includes it consumes large

quantities of precious natural materials; the fundamental binder in concrete is cement, a

significant contributor to greenhouse gas emissions that are implicated in global warming and

climate change. Majority of concrete structures suffer from durability issues which have an

adverse effect on the resource productivity of the industry. Use of industry waste like fly ash,

silica fume, grounded furnace slag to partly replace cementing material concrete system

addresses all three sustainability issues, its adoption will enable the concrete construction

industry to become more sustainable. The use of HVFA concrete opts in very well with

sustainable development. HVFA concrete mixtures contain lower quantities of cement and

higher volume of fly ash (up to 60%). The use of fly ash in concrete at proportions ranging

from 35 to 60% of total cementations binder has been studied extensively over the last 20

years and the properties of blended concrete are well documented. The replacement of fly ash

as a cementations component in concrete depends upon several factors. The design strength

and workability of the concrete, water demand and relative cost of fly ash compared to

cement. From the literature it is generally found that fly ash content in the cementitious

material varies from 30-80% for low strength (20MPa) to high strength (100MPa) (Patel &

Modhera, 2010).

17
 Fly ash and silica fume are the promising industrial wastes which can be easily

harnessed in construction. With the increase in the number of coal-based thermal power

plants, generation of fly ash has reached enormous proportions. In India, about 100 million

tonnes of fly ash is accumulated every year which is generated as waste from thermal plants.

This is causing enough concern as its disposal involves design and installation of ash ponds

covering large areas at each plant site. In spite of concerted efforts on a national scale, only a

very small fraction (around 6%) of the fly ash is put to use in India, compared to its

utilization to a greater extent in other countries. Thus, the potential benefit of fly ash in

Attaining the Workability of Silica Fume Concrete was observed by Singh and Nanda

(2011).

According to the study of Feng and Clark (2011), fly ash as an additive for concrete

mix has a beneficial effect on the rheological properties of cement paste and as well as the

workability of the concrete. They have proven in their study that the small particles of fly ash

can reduce the water requirement in the mixture of concrete. The main factor that affects the

workability of the mixture is the distribution of the coarse and fine material in the ash. Feng

and Clark (2011) stated that class F and class C fly ash has pozzolanic properties, as well as

some cementitious properties. The most important factors affecting the pozzolanic reactivity

of fly ashes are fineness, glass content, and acidic oxide content. Other minor factors include

Calcium oxide content and the composition of crystalline and organic substances on the

particle surfaces.

18
 Madlangbayan et. al. (2005) has investigated the corrosion behavior of steel in

mortars with fly ash. Electrochemical measurements including the half-cell potential, current

density, anodic polarization and cathodic polarization were performed. The test results

showed that corrosion current densities in chloride contaminated fly ash mortars with longer

curing are within the passivity limit. Also, from the anodic polarization curves, the passivity

grades in chloride - contaminated fly ash mortars with longer curing were the same as

Ordinary Portland Cement (OPC) mortars which indicates that mortars with this binder can

provide passivity to steel bars as effective as OPC mortars. Moreover, by cathodic

polarization test, fly ash mortars exhibited the ability to reduce oxygen availability which

leads to enhancement in corrosion performance.

Low-calcium fly ash-based geopolymer concrete exhibits excellent compressive

strength, low creep, sulfate resistance, and good acid resistance. It can be used in many

infrastructure applications. The production of one ton of low-calcium fly ash that can

produce about 2.5 cubic meters of high quality geopolymer concrete is cheaper than the

production of the bulk cost of one ton of Portland cement. Given the fact that fly ash is

considered as a waste material, the low - calcium fly ash-based geopolymer concrete is,

therefore, cheaper than the Portland Cement concrete. The special properties of geopolymer

concrete can further enhance the economic benefits. Moreover, this helps to the reduction of

carbon footprint due to the production of cements. This carbon credit significantly adds to the

economy offered by the geopolymer concrete. In all, there is so much to be gained by using

geopolymer concrete (Hardjito & Rangan, 2005).

19
 Bakharev (2006) observed the thermal stability of the geopolymer materials prepared

with sodium containing activators was rather low and significant changes in the

microstructure occurred. At 800°C, the strength of the concrete was reduced due to the

increase in the average pore size where amorphous structures were replaced by the crystalline

Na-feldspars. The reverse situation was observed when potassium silicate was used as

activators because it can remain mostly amorphous up to 1200°C.After firing these materials,

it reduced average pore size and improved compressive strength of geopolymer. Fly ash

based geopolymer prepared using class F fly ash with sodium and potassium silicate show

high shrinkage as well as large changes in compressive strength with increasing fired

temperature in the range 800 to 1200°C

Setting time of geopolymer depend on many factors such as composition of alkaline

solution and ratio of alkaline liquid to fly ash by mass. However, the curing temperature is

the most important factor for geopolymer. As the curing temperature increases, the setting

time of concrete decreases (Chanh et al., 2008). During curing process, the geopolymer

concrete experience polymerization process. Due to the increasing of temperature,

polymerization become more rapid and the concrete can gain 70% of its strength within 3 to

4 h of curing (Kong and Sanjayan, 2008).

Other potential application of fly ash is for highway embankments. In the study of

Santos et al (2011), experiments showed that some type of fly ash serves as an effective

material for use in embankment construction. Fly ash and soil mixture has well defined

moisture-density relationships, which is varying with mixture ratios. The optimum water

20
content increases and dry unit weight decreases as the fly ash content increases. Fly ash

provides a better fill material due to its lesser dry unit weight while having a comparable

strength to most soils.

Another application of fly ashes is the production of mosaic tiles which involves

preparing the mix for two layers: the wearing layer and the base layer. The wearing layer

consists of a plastic mix of mosaic chips, cement, and fly ash and dolomite powder. The base

layer consists of a semi-dry mix of fly ash, cement and quarry dust. The tiles are pressed in

the tile-making machine and air-dried for 12 hours or more. Fly ash turns from a problem

ridden by-product into a component of a utility product comparable to conventional products

in strength and aesthetics. Fly ash tiles, for example, can be used for heavy-duty floors too.

The table below suggests that the properties of fly ash mosaic tiles are far superior to those of

conventional tiles (Department of Forests, Ecology & Environment, Government of

Karnataka, 2007).

Expansive clay is a major source of heave - induced structural agony. Swelling of

expansive soils causes serious problems and produces harm to many structures. Many

research organizations are doing extensive work on waste materials concerning the viability

and environmental suitability. Fly ash, a waste derivative from coal burning in thermal power

stations is plentiful in India causing severe health, environmental and dumping problems.

Attempts are made to investigate the stabilization process with model test tracks over

expansive/sand subgrade in flexible pavements. Cyclic plate load tests along with heave

measurements are carried out on the tracks with chemicals like lime and lime-cement

21
introduced in fly ash sub base laid on sand and expansive subgrades. Scanning electron

micrographs are obtained for different samples collected at a depth of 0.2m from the test

stretches. The study revealed that lime cement combination could be the potential alternative

compared to the other treatments tried in the investigation (Kumar et al., 2010).

Bagasse ash, which is comparable to fly ash, has a large potential use for concrete as

a recycled material. Angeles et al (2008) studied in their research that the addition of burnt

bagasse ash to hollow blocks gives greater compressive strength than hollow blocks with

pure Portland Cement only. Burnt bagasse ash can be added to concrete masonry for up to

10% by weight substitution and can achieve the 4.14MPa required compressive strength of a

non load-bearing concrete hollow blocks (CHB).

Macalinlag et. al. (2010) noted in their study the use of residual waste plastic as

mixed in CHB to help lessen the garbage and also to provide an alternative use of these

hollow blocks. They conducted tests on CHBs with residual waste plastic and based from the

results, the CHB with residual waste plastic has a higher compressive strength than an

ordinary CHB. Also CHB with residual waste plastic is less expensive.

Another study describes the use of burning residuals as an additive to a concrete

material. Wood waste such as sawdust burnt under 1000°C turning it into fly ash could be an

effective alternative binder in manufacturing bricks (Demafelis et.al, 2008). The study shows

a series of test in the properties of wood waste as well as testing the made bricks under

compressive stress that were carried out in order to compare the performance of the wood

22
waste ash (WWA) bricks to the ordinary concrete bricks that had been used for paving and

beautifying the sidewalks. The research proved that a portion of WWA could be used as an

alternative binder, together with cement, in making small load bearing bricks, and then it

could help reduce the amount of wood waste that seemed to be useless.

23
 Chapter 3

METHODOLOGY

3.1 Research Design

The study was conducted in order to come up with an alternative additive that can be

mixed with concrete. The researchers made use of burning residuals as the specimen to be

tested during the study. The study was identified as an experimental and descriptive research

which includes testing of concrete cylinder according to the standard procedure of ASTM

C39 “Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens”

and cost-benefit analysis of different mix proportion of cement and burning residuals.

3.2 Data Gathering Procedure

The experiment consist of six sets of three concrete cylinders in order to determine

the compressive strength of concrete with different amount of burnt residue, total of 18

concrete cylinders. The six sets of concrete contain varied amount of fly ash, from 0%, 10%,

20%, 30%, 40%, to 50%. The samples were tested after 28 days of curing. The controlled

variables for the experiment are cement, sand, gravel, water, and fly ash.

3.3 Standard Specification for Concrete Aggregates

This specification defines the requirements for grading and quality of fine and coarse

aggregate (other than lightweight or heavyweight aggregate) for use in concrete. The

aggregates were tested in accordance to ASTM C33, “Standard Specification for Concrete

Aggregates”.

24
3.4 Design Mix

Prior to the process of mixing concrete cylinders, the researchers gathered necessary

information for the design of concrete mix using ACI method. Mechanical properties such as

moisture content and percent absorption were identified. Table 1 shows the summarized

output of the design of concrete mix with varying amount of burning fly ash. The complete

computation of the design mix is found in the appendix.

Table 1 Mix Proportions for Concrete Samples

Fly Ash (%) 0 10 20 30 40 50

Water (Li) 2.77 2.71 2.66 2.60 2.55 2.50

Sand (Kg) 13.30 13.30 13.30 13.30 13.30 13.30

Gravel (Kg) 20.12 20.12 20.12 20.12 20.12 20.12

Cement (Kg) 5.14 4.63 4.13 3.60 3.08 2.57

Fly Ash (Kg) 0 0.51 1.03 1.54 2.06 2.57

3.5 Mixing

Concrete cylinders were made by following the procedures based from ASTM C

192/C 192M – 02 “Standard Practice for Making and Curing Concrete Test Specimens in the

Laboratory”. The necessary apparatus for the experiment were: concrete cylinder molds

(150mm x 300mm), slump cone apparatus, tamping rods, mixing pans, and other mixing

materials.

Amounts of fly ash were manually added to concrete aggregates and cement. Sand,

cement, gravel, and fly ash were thoroughly mixed before water is introduced. Water is

constantly added to the mixture to obtain the desired slump height.

25
 Oil was first applied to the moulds before using. Concrete mix were filled for about

one thirds of the mould and tamped to avoid formation of voids. This was made until filling

the mould completely.

3.6 Curing

The curing shall be made by soaking the cylinders under water for 28 days. Water

curing is needed to avoid the required water for hydration to evaporate. After which the

cylinders are to be tested for compressive strengths.

3.7 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

This test method consists of applying a compressive axial load to molded cylinders or

cores at a rate which is within a prescribed range until failure occurs. The compressive

strength of the specimen is calculated by dividing the maximum load attained during the test

by the cross-sectional area of the specimen.

3.8 Data Interpretation

After undergoing compressive strength tests, the results were collected and compared

using a graph that shows the relationship between the compressive strength and percentage of

burning residuals. A curve is produced that defines the points established from the obtained

data using polynomial regression. The optimum point or the point which has the maximum

strength and most burning residual content is located. The economical range which

encompasses high percentages of burning residuals that competes with the strength of the

conventional concrete was identified.

26
 Cost analysis and estimate were also made to compare the monetary values of load

bearing walls made of CHB and concrete with burning residuals.

3.9 Conceptual Framework

Sand, gravel, water,

Burning residuals
and cement

Different mix
proportion of cement Concrete cylinder
and burning residuals

Cost analysis and

estimates

A conceptual framework was created in order to set up an outline of the research

which can help on the analysis of the problem. The diagram will help the researchers

establish the scope of the study.

27
3.10 Analytical Framework

Statement of the
Problem

Review of Related
Literature

ASTM C618-05
ATSM C39
ASTM C33
Experimentation
Materials and
Apparatus

Cost analysis and

Data Analysis
estimates

Discussion of Results

Conclusion Recommendation

An analytical framework was established in order for the researchers to have an idea

on the flow of the study. The study consists of statement of the problem, review of related

literature, experimentation procedure, analysis of the data, results and discussion, and

conclusion and recommendation.

28
 Chapter 4

RESULTS AND DISCUSSION

After mixing and curing six sets of samples with varying content of burning residuals

for 28 days, the samples went through compressive strength test using the Universal Testing

Machine. Table 4.1 shows the results for the compressive strength test giving the maximum

stress that the cylinder can carry.

Table 4.1 Summary of Strengths of Samples

Strength Mpa 0% 10% 20% 30% 40% 50%

Sample 1 11.80 13.61 14.53 15.66 13.63 7.57

Sample 2 11.04 12.88 16.90 15.32 13.34 7.55

Sample 3 10.89 14.70 16.28 17.01 12.96 9.14

Average 11.24 13.73 15.90 16.00 13.31 8.09

29
 Strength of Samples
Compressive Trength, MPa 20

15

10 Sample 1
Sample 2
Sample 3
5

0
0% 10% 20% 30% 40% 50%
Experimental Series

Figure 4.1: Compressive Strength of Specimens with Varying Burning Residual Content

Figure 4.1 shows the difference in strength of using burning residuals as an additive

for concrete. The graph shows that as the amount of burning residual increases, the maximum

compressive strength also increases until it reaches its maximum point. Conventional

concrete mix yielded an average maximum stress of 11.24 MPa while concrete with burning

residuals yielded strength up to 16MPa. Three cylinders are tested for each burning residual

percentages in order to improve the integrity of the data to be obtained, and for this particular

matter, reliability of the data is attained through the precision of compressive strengths of

each sample.

30
 Strength vs Burning Residual content
30

25
Compressive Strength, MPa

20

15
Data Points
10 Maximum Point
y=10.80393+0.46934x-0.01036x2
5
r=0.988
0
0% 10% 20% 30% 40% 50% 60%
Burning Residual content, %

Figure 4.2: Maximum Strength that Concrete with Burning Residuals Can Attain

Figure 4.2 shows that varying the amount of burning residuals with respect to the

strength of concrete generates a curve that increases the strength up to 16.12 MPa having a

content of burning residuals at 22.65%

The graph shows that there is a significant increase in strength on concrete with

burning residuals. The optimal range of burning residual is within 21% to 26% replacement

of cement. However, continuous accumulation of the additive roughly beginning at 27% and

more causes considerable reduction on its strength until it reaches for about 47% burning

residuals induced. The concrete with this burning residual content has strength equal to a

concrete with no additive at 11.24 Mpa which happens to be the basis of the strength

required. Any further addition of burning residual is considered insignificant for application.

31
 Comparison on Strength
Compressive Strength, Mpa 25

20
16.12
15
11.24
10 Comparison on Strength

0
Conventional concrete Concrete with burning
residuals

Figure 4.3: Difference on Strength between Conventional Concrete and Concrete with

Burning Residuals

The bar chart shows that conventional concrete yields strength of 11.24 MPa while

concrete with burning residuals yields strength up to 16.12 MPa. This proves that there is an

increase on compressive strength for up to 30.27% when utilizing the optimum amount of

burning residuals specifically at 22.65% added to concrete.

32
 Strength vs Burning Residual content
30

25

20
Strength, MPa

15
11.24 Data Points
10

y=10.80393+0.46934x-0.01036x2
5
r=0.988
0
0% 10% 20% 30% 40% 50% 60%
Burning Residual Content, %

Figure 4.4: Economical Benefits of Using Burning Residuals as an Additive for Concrete

Figure 4.4 shows that the strength of the conventional concrete, which is 11.24 MPa,

will have an equivalent value as the amount of burning residuals reaches 44.37%. This means

that burning residuals can replace cement up to 44.37% of the total cementitious material

without compromising the actual strength.

Since burning residuals costs extremely cheaper than cement using it as a replacement

for a portion of cement will result to a low-cost concrete. And based on the graph, utilization

of additives starting from 22.65% is permissible for up to 44.37% considering the amount of

burning residual to be used significant reduction on costs for concrete can be observed. The

said range of burning residual content can be referred as economical threshold, this offers a

low-cost good performance concrete to be produced in the industry.

33
 For a detailed rationalization of the economical benefits of using burning residuals as

an additive for concrete, a comparison on costs between a load bearing wall using a CHB and

concrete with burning residuals is made.

Considering the strength achieved by the specimens for the study, a practical

application for the mixture is on a load bearing wall for a residential structure. With the

dimensions of the structure tabulated below, a normal CHB load bearing wall costs for about

57530 Php while a load bearing wall made with concrete with burning residuals costs for

only 54799 Php. The reduction on costs considered for the said structure was made on the

assumption that the formworks will be reused for the succeeding floor. Therefore the benefits

of using concrete with burning residuals will be more evident as the level of the structure

increases, resulting to a greater reduction on material costs. Tentatively, this will also reduce

the working time for building the structure since the methods used for building is monolithic.

34
CHB Wall Estimated Cost

Unit
Material Quantity Unit Price Cost
6" CHB 1230 pcs. 9 11070
Cement(Fill) 96 bags 200 19200
Cement(Plaster) 57 bags 200 11400
Sand(Fill) 8 cu.m. 700 5600
Sand(Plaster) 3 cu.m. 700 2100
Reinforcement- 10mm dia. ×
6m 68 pcs. 120 8160

Total Materials Cost (Php) 57530

Concrete Wall with Fly Ash Wall Estimated Cost

Unit
Material Quantity Unit Price Cost
Cement 75 bags 200 15000
Fly Ash 22 bags 2 44
Sand 7 cu.m. 700 4900
Gravel 12.5 cu.m. 750 9375
Reinforcement- 10mm dia. × 6m 68 Pcs. 120 8160
Plywood- 12mm × 4 ft × 8 ft 32 Pcs. 260 8320
Lumber 300 Bf. 30 9000

Total Materials Cost (Php) 54799

35
 Chapter 5

CONCLUSION

This study provides an alternative additive for concrete mix using burning residual or

fly ash. The utilization of burning residuals as an alternative additive for concrete mix

produced positive result with regards to its compressive strength. The use of concrete mix

with this additive will not only help reduce the by-products of coal and minimize the usage of

cement, but also decreases the cost for concreting works.

This study’s results showed that the compressive strength of concrete with burning

residuals is much greater than that of conventional concrete. The compressive strength of

concrete with burning residuals is 16.12 MPa from the results of the experiment, stronger by

30.27% compared to 11.24 MPa strength of the conventional concrete.

The most economical range of mix proportions of cement and burning residuals is

from 22.65% to 44.37% of cement replaced by burning residuals without compromising the

actual strength. The said range of percentage of cement when replaced by burning residuals

cost less but has greater or equal compressive strength with conventional concrete.

The range of optimal mixtures of cement and burning residuals is from 21% to 26%

of cement being replaced by burning residuals. This range of mixtures produces compressive

strength of the concrete greater than that of conventional concrete with maximum of 16.12

MPa.

36
 The cost of materials used for load bearing wall shows that using poured concrete

with burning residuals costs less by 4.75% than using CHB. Using 6 inch CHB with plaster

for a 94.45 square meter of load bearing wall, the estimated cost of materials is Php 57530

while the cost of using poured concrete with burning residual is only Php 54799. This is very

substantial especially for bigger structures.

37
 Chapter 6

RECOMMENDATION

After a thorough analysis and understanding of the study, recommendations for this

study can be accounted to the following: studies regarding the workability and other physical

properties of concrete can also be particularly determined for each burning residual

percentages to fully understand the behaviour of the additive. With this being identified,

activities during construction can be made with ease. In addition, modifications of burning

residual percentages on concrete can be made without compromising the strength of the

structure.

It is also advisable to do a study concerning the behavior of the burning residuals

under different climate conditions when added to concrete. The said study may minimize the

variables to be considered in the performance of the structure to be made.

Aside from buildings and other vertical structures, studies on the use of burning

residual regarding application on horizontal structures can also be done to increase the

application of concrete with burning residual in the construction industry, considering that

horizontal structures costs on par with vertical structures the said study is very substantial. In

addition, with the ability of burning residual to fill up voids offers the idea of improving the

quality of roads against axle loads which is one of the leading causes of high maintenance

costs on roads.

38
 Other types of cement such as Type II: Moderate sulphate resistant cement, Type III:

High early strength cement and Type V: High sulphate resistant cement can be used aside

from Type I: Portland cement in order to find out on what specific type of cement will cause

maximum utilization of the additive. Moreover, tests on the chemical reactions of the

additive to the type of cement that will be used should be made in utmost consideration

before proceeding to other tests to identify capability of such mixture when used in

construction. These will ensure the compatibility of the additive to the type of cement.

Upon considering the suggested studies this may serve as a basis for new types of

concrete which will be suitable to any kind of construction projects that provides ease and a

new level on cost reduction and strength.

39
 ACKNOWLEDGEMENT

We would like to thank first and foremost our Almighty God, who provided us the

wisdom and guidance throughout our whole study. Without him, this will not be possible.

We would like to also thank our school Mapua Institute of Technology for providing us the

best education possible which led us to the completion of our study. Gratitude is extended to

our thesis coordinator Engr. Geoffrey L. Cueto, for his guidance and never ending assistance

on our group and to our thesis adviser Engr. Ivan D.L. Marquez for his suggestions and

unwavering efforts which helped us a lot especially on boosting our confidence and trust to

our study. Thanks were also extended to Pozzolanic Philippines for providing us our main

ingredient fly ash used for our experiments and for providing us important data required for

our study.

Finally, heartfelt gratitude is extended to our dearly loved parents for their financial

assistance, love and guidance.

THE AUTHOR

40
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