PROPERTIES OF POLYSTYRENE CONCRETE BLOCK WITH

FLY ASH

Nurashyikin Binti Pauzi

Bachelor of Engineering with Honours

(Civil Engineering)

2009

UNIVERSITI MALAYSIA SARAWAK

BORANG PENGESAHAN STATUS TESIS

Judul: PROPERTIES OF POLYSTYRENE CONCRETE BLOCK WITH FLY

ASH

SESI PENGAJIAN: 2008/2009

Saya NURASHYIKIN BINTI PAUZI

(HURUF BESAR)

mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak

dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Malaysia Sarawak.

2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk

tujuan pengajian sahaja.

3. Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan.

4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini

sebagai bahan pertukaran antara institusi pengajian tinggi.

5. ** Sila tandakan ( ) di kotak yang berkenaan

SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan

Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/

badan di mana penyelidikan dijalankan).

TIDAK TERHAD

Disahkan oleh

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat tetap: 50, VISTA AVENUE,

JALAN SETIA RAJA, 93350 KUCHING Madam Azida Binti Rashidi

Nama Penyelia

Tarikh: Tarikh:

CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda.

** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi

berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai

SULIT dan TERHAD.

The Following Final Year Project:

Title : Properties of polystyrene concrete block with fly ash

Author : Nurashyikin Binti Pauzi

Matrix Number : 14946

Was read and certified by:

_______________________ ___________________

Madam Azida Binti Rashidi Date

Project Supervisors

PROPERTIES OF POLYSTYRENE CONCRETE

BLOCK WITH FLY ASH

NURASHYIKIN BINTI PAUZI

This project is submitted to

Faculty of Engineering,

University Malaysia Sarawak

in partial fulfilment of

the requirement for the

Degree of Bachelor of Engineering with Honours

(Civil Engineering) 2009

For my beloved mom and dad

i

ACKNOWLEDGEMENT

I would like to thank my final year project supervisor, Madam Azida binti Haji Rashidi

for her guidance and advice in conducting my research. I also would like to thank the

technicians of Civil Engineering laboratory who helps me a lot in my laboratory works,

especially to En. Nur Adha bin Abdul Wahab and Hj Affandi bin Othman.

Cooperation from Faculty of Engineering and Civil Laboratory are really appreciated.

Acknowledgement also goes to my friends and those who have helping me in my

project. Thank to my family for supporting me in my study and this project.

TABLE OF CONTENTS

Acknowledgement

Abstract

Abstrak

List of tables

List of figures

List of symbols

Page

i

ii

iii

iv

v

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CHAPTER 1 INTRODUCTION

1.1 Introduction 1

1.2 Problem statement 2

1.3 Limitations of the project 3

1.4 Objectives

1.5 Brief Outline of Chapters

1.6 Conclusion

4

5

6

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 7

2.2 Component of concrete

2.2.1 Cement

2.2.2 Fine Aggregates

2.2.3 Expanded Polystyrene

2.2.3.1 Characteristics Properties of

Expanded Polystyrene Beads

8

8

8

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9

2.2.3.2 Effect Expanded Polystyrene

Bead on Concrete Block

2.2.4 Fly Ash

2.2.4.1 Characteristics Properties of

Fly Ash

2.2.4.2 Chemical Composition and

Classification

2.2.4.3 Effect Fly Ash on Concrete

Block

2.3 Previous Studies

2.3.1 Strength of Lightweight Concrete

2.3.2 Workability of Lightweight

Aggregate Concrete

2.3.3 Water Absorption

2.3.4 Weight and Density

2.3.5 Effect of High Temperature on

Compressive Strength

2.4 Conclusion

CHAPTER 3 METHODOLOGY

3.1 Introduction

3.2 Raw Materials

3.2.1 Cement

3.2.2 Fine Aggregate

3.2.3 Expanded Polystyrene Beads

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3.2.4 Fly Ash

3.2.5 Water

3.2.6 Superplasticizer

3.3 Equipments

3.4 Production of EPS Concrete Block containing

Fly Ash

3.5 Methodology

3.5.1 Test Program

3.5.1.1 Workability Test

3.5.1.2 Dimension Test

3.5.1.3 Weight/Density Test

3.5.1.4 Water Absorption Test

3.5.1.5 Compressive Strength Test

3.5.1.6 Heat Resistance Test

3.6 Conclusion

CHAPTER 4RESULTS, ANALYSIS AND DISCUSSIONS

4.1 Introduction

4.2 Workability Test

4.2.1 Results and Analysis

4.2.2 Discussion

4.3 Dimension Test

4.3.1 Results and Analysis

4.3.2 Discussion

4.4 Weight Density Test

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4.5 Water Absorption Test

4.6 Compressive Strength Test

4.7 Heat Resistance Test

4.8 Conclusion

CHAPTER 5 CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusion

5.2 Limitation

5.3 Recommendations

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REFERENCES

APPENDIX

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v

LIST OF FIGURES

Figure Pages

2.1 Process of Suspension Polymerization 10

3.1 Water absorption test 29

3.2 Compressive Strength Machine 30

3.3 Muffle furnace 32

4.1 Slump test on the sample 35

4.2 Relationship between, weight density and EPS+fly

ash mix ratio

39

4.3

4.4

Relationship between average weight and mix

proportion

Relationship between average density and mix

proportion

40

41

4.5 Relationship between percentage of water absorption

and mix proportion

43

4.6 Relationship between compressive strength and time 46

4.7 Average compressive strength for each mix 48

4.8 Compressive strength results after exposure to high

temperature

50

4.9 Weight loss after heat to high temperature 51

4.10 Sample before heat 52

vi

4.11 Sample after heat 52

vii

LIST OF SYMBOLS

m1 - Wet brick weight

m2 - Dry brick weight

µ - Micro

°C - Degree of Celsius

% - Percentage

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LIST OF TABLES

Table Pages

2.1 Chemical composition of Fly Ash 12

2.2 Mix details of the concrete investigated 15

2.3 Strength characteristics of EPS concrete 15

3.1 Mix proportion for all samples 20

3.2 Mix proportion in kilogram 20

3.3 Grading limit for fine aggregates 22

4.1

4.2

Slump Test Result

Dimension results for each mix

34

36

4.3 Dimension according to MS76:1972 37

4.4

4.5

4.6

4.7

4.8

Average weight and density measurement

Average percentage of water absorption

Average percentage of water absorption to average

compressive strength

Data for compressive strength

Data for compressive strength due to changes in

temperature

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ABSTRACT

This project reports the results of experimental investigations into the properties of

lightweight concrete blocks containing expanded polystyrene beads with fly ash.

Lightweight concretes can be produced by replacing the normal aggregates in concrete

depending upon the requirements of density and strength. This project uses expanded

polystyrene beads as lightweight aggregate for replacement of coarse aggregate in the

mixes. The main objective of this project is to determine the properties of EPS

concretes containing fly ash. Total of 126 samples of concrete blocks were prepared for

this study. The properties studied were compressive strength, water absorption, weight

and density, and heat resistance of the polystyrene concrete block with fly ash. The

experimental results show that the compressive strength for samples with high

percentage of polystyrene gives low compressive strength but samples with high

percentage of fly ash give a higher compressive strength. The project also found that

the optimum percentage of fly ash that can be replaced in the concrete is 30%. The

properties of the block are mainly influenced by the content of polystyrene beads in the

mix and the percentage of fly ash.

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ABSTRAK

Projek ini melaporkan keputusan eksperimen penyelidikan ke atas sifat blok konkrit

ringan yang mengandungi biji-bijian polistirena padat dan abu terbang. Konkrit ringan

boleh dihasilkan dengan menggantikan sejumlah kandungan pasir di dalam konkrit

bergantung kepada isipadu dan kekuatan yang diperlukan. Kajian ini mengunakan biji-

bijian polistirena padat sebagai bahan ringan bagi pengantian pasir di dalam adunan.

Tujuan utama projek ini adalah untuk mengkaji sifat-sifat blok konkrit polistirena yang

mengandungi abu terbang. Sejumlah 126 sampel blok konkrit disediakan untuk kajian

ini. Sifat-sifat yang dikaji adalah kekuatan mampatan, penyerapan air, berat dan

kepadatan, dan sifat-sifat blok konkrit polistirena di dalam suhu yang tinggi. Kajian

menunjukkan kekuatan mampatan bagi peratusan yang tinggi abu terbang memberikan

kekuatan mampatan rendah tetapi bagi sampel yang mengandungi peratusan abu

terbang yang tinggi memberikan kekuatan mampatan yang tinggi. Kajian juga

menunjukkan peratusan optimum bagi penggantian abu terbang di dalam konkrit adalah

30%. Sifat-sifat blok konkrit polistirena dipengaruhi oleh kandungan biji-bijian

polistirena dan peratusan abu terbang di dalam adunan.

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CHAPTER 1

INTRODUCTION

1.1 Introduction

Concrete is most widely used in construction. Originally, concrete was made

using a mixture of only three materials which are cement, aggregate and water. This

mix is then placed in forms and allowed to be cured and become hard. The strength,

durability and other characteristics of concrete depend upon the properties of the

material used, the mix proportions, the method of compaction and other controls during

placing, compaction and curing.

Concrete is a solid that hardens after mixing with water due to a chemical

process known as hydration. The water reacts with the cement and enables them to

bonds together with the other components. The reactions are highly exothermic and the

build-up in heat must not affect the integrity of the structure.

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Concrete can be used for many construction works and it is the materials of

choice for commercial applications. The concrete is extensively used in the construction

of foundations, walls, roads, airfields, buildings, water retaining.

1.2 Problem Statement

Both normal concrete and lightweight concrete have their own advantages and

disadvantages. The normal concrete consists of mixture of Portland cement, sand,

aggregate and water while the lightweight concrete is the improvement of the normal

concrete by replacing the usual mineral aggregate by cellular porous or light-weight

aggregate (M. S. Shetty, 2003).

One of the disadvantages of normal concrete is the high self-weight of the

concrete. Density of the normal concrete is in the range of 2200 kg/m3 to 2600 kg/m

3.

This heavy self-weight make it as an uneconomical structural material. Attempts have

been made in the past to reduce the self weight of concrete to increase the efficiency of

concrete as a structural material.

The advantage of light-weight concrete advantage is its low in density which can

reduce the dead load (self weight). Thus it enhances construction progress, reduce

transportation and handling costs. The weight of a building on the foundation is an

important factor in design, particularly in the case of weak soil and tall structure. In a

3

frame structure, the beams and columns have to carry loads of the floors and walls. If

floors and walls are made up of light weight concrete, it will result in considerable

economy.

Lightweight concrete is one which is comparatively lighter than normal concrete

but at the same time strong enough to be use for structural purposes. Therefore, it

combines the advantages of normal weight concrete and discards the disadvantages of

normal weight concrete. This type of concrete has advantages for future construction.

Thus, several tests and investigation are required to determine the workability of

polystyrene concrete block with fly ash so that t can be used as a material in

constructions.

1.3 Limitations of the project

This project will use EPS as aggregates replacement in the mixes and fly ash as

part of cement substitution. With various ratios between fly ash and EPS in the

experiment, the properties of this lightweight concrete are investigated experimentally.

The tests required to identify the properties are limited to workability test, dimension

test, water absorption test, weight and density test, compressive strength test, and heat

resistance test.

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1.4 Objectives

The objectives of the project are:

To find optimum mix proportion concrete block containing Expanded

Polystyrene Beads (EPS) and fly ash.

To determine the compressive strength of the concrete blocks with EPS and

fly ash

To determine the compressive strength of the concrete blocks with EPS and

fly ash due to the changes in heat/temperature.

To determine the water absorption of the concrete blocks with EPS and fly

ash.

To determine the weight density of the concrete blocks with EPS and fly ash.

To check the dimensions of the blocks according to Malaysian Standard

(MS76:1972)

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1.5 Brief Outline of Chapters

The report consists of several chapters.

Chapter (1) deals with introduction of producing lightweight concrete block

using the expanded polystyrene beads by adding various percentage of fly ash. The

problem statement, objectives and scope of study are also mentioned.

Chapter (2) studied the literature review, where works that have been done and

related works published by other researchers in this field and results of each work are

explained and concluded.

Chapter (3) discusses about the experiment that have been carried out to produce

lightweight concrete blocks by using the expanded polystyrene bead in concrete

containing fly ash as a cement replacement material.

Chapter (4) shows the results, analysis and discussion for every tests. The tests

that were carried out are compressive strength test, water absorption test, weight density

test, dimension test and heat resistance.

Chapter (5) was written as the conclusion and recommendation. The conclusion

writes about the overall findings and the summaries of the study. Some

recommendations or ideas proposed in future work section also written in this chapter.

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1.6 Conclusion

Lightweight concrete can be produced by replacing aggregate in concrete with a

certain percentage of other material like Expanded Polystyrene Bead (EPS) depending

upon the density and strength required. The replacements of cement using fly ash can

increase the workability, reduce segregation, bleeding, heat evolution and permeability,

inhibit alkali-aggregate reaction and enhance sulfate resistance of the concrete itself.

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CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

Lightweight concrete can be produced by partially replacing the normal weight

coarse aggregate particles with expanded polystyrene beads (EPS). The lightweight

concrete has practical densities between 300 and 1850 kg/m3

(D. Saradhi Babu et al

2004). With the use of lightweight concrete in construction, the formworks need to

withstand a lower pressure than that would be the case with normal weight concrete.

Therefore, the total mass of materials to be handled is reduced with a consequent

increase in productivity. Low density of lightweight concrete gives better thermal

insulation than ordinary concrete. (D. Saradhi Babu et. al 2004)

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2.2. Component of concrete

2.2.1 Cement

Cement is a material which has an adhesive and cohesive property and capable

of bonding materials. The cement is used to bind the aggregates together and fill up the

voids in between the aggregate particles to form a compact mass. The properties of

cement are affected by several factors such as chemical composition, hydration, setting

time, soundness and loss in ignition.

2.2.2 Fine Aggregates

A fine aggregates aggregate is used to describe gravels, crushed stones and other

materials which are mixed with cement and water to make concrete. The fine

aggregates in concrete served as a mass of particles which are suitable for resisting

action of applied load, abrasion, and percolation of moisture and the action of weather.

Additionally, the fine aggregates reduce the volume changes resulting from setting and

hardening of concrete.