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M30 GRADE CONCRETE MIX USING SOILD WASTE AGGREGATES (COCONUT SHELL CONCRETE)

K.M.

Jayakumari1, G. Sandeep Achari2, P. Vasudeva Rao3, P. Meghana4, S. Chaitanya5

1Assistant professor SVPEC (Andhra university) Civil Engineering

2,3,4,5 B. Tech Student SVPEC (Andhra university) Civil Engineering ***

: The rising cost of construction is a growing concern, primarily driven by the increasing prices of building materials. Concrete, a key component in construction, consists mainly of coarse aggregate, fine aggregate, and cement. Construction companies heavily rely on these materials for concrete production. Recent research has focused on reducing construction costs while improving concrete strength. Various waste materials have been explored as partial replacements for aggregates based on their properties. Among them, fly ash, rice husk ash, and blast furnace slag have been identified as effective substitutes for fine aggregate in concrete. Agriculture plays a crucial role in India’s economy, with coconut production being a significant sector. However, coconut shells, a byproduct of this industry, pose disposal challenges and contribute to environmental pollution if not managed properly. Using coconut shells as a partial replacement for coarse aggregate in concrete presents a sustainable and eco-friendly solution. This study investigates the effects of replacing coarse aggregate with coconut shells

Abstract in varying proportions (0%, 10%,15%, and 20%) for M30 grade concrete. Four different concrete mixes were prepared for each grade, with three specimens cast pe

r mix. The primary goal is to assess the feasibility of utilizing agricultural waste like coconut shells, which are more cost-effective than traditional coarse aggregates, to develop affordable construction solutions. A 28-day short-term analysis was conducted to evaluate the properties of coconut shell aggregate concrete through tests such as compressive strength and workability. The results were compared with those of conventional concrete. To ensure durability, serviceability, and structural integrity, all necessary precautions were taken.

Key Words: Coconut Shell, Light Weight Concrete, Compressive Strength, Solid Waste

I. INTRODUCTION

Concreteisoneofthemost widelyusedconstruction materials due to its strength, durability, and versatility.Itiscomposedofcement,water,sand,and gravel or crushed stone. Through hydration, these materials harden over time, making concrete essential forstructures like buildings, bridges, roads,

andtunnels.Itsadaptability allowsforvarious types, such as reinforced, precast, and high-performance concrete, to meet structural and environmental needs. Concrete is also used in infrastructure projects, offshore platforms, and harbour structures. Floating concrete platforms are being explored for airportsandpowerplantstoreducelandcongestion. Despite its benefits, finding a durable and costeffective alternative remains a challenge. Durability in concrete depends on proper curing, which maintains moisture levels for strength development. However, the growing scarcity of fresh water is a concern, with nearly half the world's population expected to face shortages by 2025. Since billions of litters are used in mixing and curing, sustainable alternatives and water-efficient curing methods are crucialforthefutureofconstruction.

a) Objective of the present work

The primary objective of this study is to assess the feasibility and benefits of using coconut shells as an alternative to coarse aggregate in concrete. Before incorporating coconut shells in concrete, their properties must be thoroughly understood. While coconut shells have not been widely explored as aggregates in structural concrete, this study aims to utilizethemasstructuralcomponents.

Developing lightweight structural concrete using coconut shells an abundant agricultural waste could be a significant breakthrough for small-scale construction industries. This research seeks to determine the viability of using coconut shells as a sustainable material in lightweight structural concrete.

Thekeyobjectivesare:

 To evaluate the workability of Coconut Shell AggregateConcrete(CSAC)forM30concrete mix

 To determine the compressive strength of CSAC for M30 grade concrete by conducting compressivestrengthtests.

International Research Journal of Engineering and Technology (IRJET) e-ISSN:2395-0056

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II. LITERATURE REVIEW

Utsev,J.T.,Taku, J. K.- The coconut shells which are considered as an environmental pollutant are collected and burnt in order to produce ash of coconut shell. This ash is used as a pozzolana and is replaced partially with cement in the production of concrete. By replacing thecement with coconut shell ash in various percentages of 0, 10, 20 and 30 percentage concrete cubes were prepared. These concretecubes werecuredfor7,14and28daysand the various properties like density, compressive strength and setting time of the concrete are determined. The density of the concrete cube was greater than 2400 Kg/m3 for 15-20 % replacement. The compressive strength of the concrete for 7 days and 28 days is 13.52 N/mm2 and 32.81 N/mm2 respectively and thus meeting the requirements for using it as both heavy weight and light weight concrete. Finally, it is concluded that OPC can be replacedwithcoconutshellashupto10-15%andat this percentage it can be recommended to use it as lightweightandheavyweightconcrete.

R. Naga Lakshmi - An attempt has been made to determinethepropertiesoftheconcretebyreplacing 20% of the fly ash obtained from the Vijayawada thermal power station with cement and also replacing the coarse aggregate with coconut shell in various percentages like 10 %, 20 % & 30 % for the M25gradeconcretemix.Thestrengthcharacteristics of M25 grade concrete are examined by conducting the various tests such as compressive strength test, flexure strength test, split tensile strength test for 14,28,56 days curing period and the obtained test resultsArtecomparedwiththenominalconcretemix by following IS code provisions. Various workability tests are conducted in order to maintain water cementratio.Itisconcludedthattheresultsobtained are closer to the results obtained from the conventionalmix.

Olanipekun- Olanipekun has made an attempt on comparing the strength properties and analysing the cost of concrete which is obtained by replacing coarse aggregate with the crushed coconut granules and palm kernels inthe ratio of 0 %, 25 % and 50 % with conventional concrete of grades M20 and M25. A total of about 320 concrete cubes were casted and tested them in order to know their mechanical and physical properties. It is concluded that compressive strength of coconut shell is more than the compressivestrengthofpalmkernelshell.Butasthe percentage of coconut shell is increasing the compressive strength of concrete is decreasing in both the grades of concrete. When coarse aggregate isreplacedbycoconutshellandpalmkernelshellthe

cost of the concrete is reduced by 32 % and 44 % respectively

SaravananR–Thecoconutfibrewasusedinorderto verify the mechanical, physical and fracture behaviour of reinforced cement concrete with coconut fibre and also gave a report on how the properties are enhancing for fly ash concrete mixed with natural coconut fibre. M20 grade concrete was prepared with the mix design of 1:1.5:2.8 with the water cement ratio of 0.46 by replacing cement. Finally,itisconcludedthatthereisanincreaseinthe mechanical properties of the concrete by using coconutfibreintheconcrete.

SabarudinBinMohdandSitiAminahBt Tukiman- In their study they have utilized the naturally available materials like coconut shell and palm kernels. Six different concrete mixes are prepared by partially replacing coarse aggregate with coconut shell and partially replacing fine aggregate with grained palm kernelsinvariouspercentagesof0%,20%,40%,60 %, 80 % and 100 %. For each concrete mix three different samples are prepared and various parameters like flexural strength, tensile strength, compressive strength, young’s modulus, durability and crack deflection behaviour are determined. The final conclusion given by them is when coconut shell and grained palm kernel shell combined together givesgoodresultsandcanbeeffectivelyusedaslight weightconcrete.

III. METHODOLOGY

a) Materials

 Cement(opc)

 Fineaggregate

 Coconutshell

 Coarseaggregate

 Water

Cement: Portland cement is the most common type of cement which is generally used in construction activities. This cement is made by heating limestone with other materials such as clay to 1450 °C in a kiln by a process knownascalcination.ThisliberatesCO2fromthecalcium carbonatetoformcalciumoxide,orquicklimewhichthen chemically combines with the other materials in the mix to form calcium silicates and other cementitious compounds. This result in the formation of harder substancescalledclinkerwhichisfurthergroundedwitha small amount of gypsum into a powder form to make OrdinaryPortlandcement.

Coarse Aggregate: The particles which retain on the 4.75 mm sieve and can undergo 3 inches screen area are known as coarse aggregate. The course the aggregate the

International Research Journal of Engineering and Technology (IRJET) e-ISSN:2395-0056

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more economical will be the mix. Larger items can offer less area of the particles than constant volume of tiny items. Use of the utmost permissible size of the coarse aggregatespermitsadiscountincementandwaterneeds.

Fine Aggregate: The particles which are passing through 4.75mmsieveandretainingon75µsievethoseparticles are called as fine aggregates. Rounded shape fine aggregates are used in order to increase the workability. The main intention of using fine aggregates is to fill the voids in the concrete that are created by the coarse aggregate and can be effectively used as a workability agent.

Coconut Shell: In order to analyse the properties of coconut shells which are used in this study are collected fromlocallyavailableoilmillsandcoconutindustriesasa half-rounded shell. The coconut shell will be having a thickness range of 3-9 mm. The collected coconut shells werecrushedintosmallerpieceshavingarangeofabout 3-10mminlength.These brokenpiecesofcoconutshells are washed with water several times and soak them in water for 1 day. After 1 day remove the coconut shell pieces from water and dry them in the sun in order to saturate the coconut shell pieces. Then the required amountofcrushedCSpiecesisutilisedforcasting.

Water: Water in concrete always gets least importance and often ignored by the people at the time of construction. We should not forget that water is an integralpartofconstructionandanykindofcompromises in quality of water during construction may ruin all our effortsmadeatthetimeofconstruction.

b) MixDesign

MixDesigniscarriedoutinB.I.SMethod(BureauofIndian Standards)AsperIS10262:2009

MIXDESIGNPROCEDUREFORTHECONCRETEOFGRADE M30:

1.Targetstrength:

f’ck=(fck+ks)or(fck+x)

fck=Targetmeancompressivestrengthat28days

K=1.65

S = 5 N/mm2 standard deviation (IS-10262-2019, table-2 P.No:3)

X=factorbasedongradeofconcreteaspertable-1

X=6.5(IS-10262-209,Table-2P.No:3)

f’ck1=30+(1.65×5)

f’ck1=38.25N/mm^2

f’ck2=30+6.5

f’ck=36.5N/mm^2

f’ck1>f’ck2

38.25>36.5N/mm2

f’ck=38.25N/mm2

2.Watercementratio:

UsingIS-456-2000,table–3&5,P.No:20

Watercementratio=0.45(severrange)

3.Watercontent:

UsingIS-10262,Table-4,P.No:5

20mmcoarseaggregate=186kg(for50mmslump)

100mmslump:

Forevery25mm–add3%(IS-10262-2019,cl:5.30)

186+6%=197kg

4. Calculationofcementcontent:

Watercementratio=watercontent/cementcontent

Cement=watercontent/watercementratio

Cement=197kg/0.45=437.78kg

minimum cement content = 320 kg (IS: 456:2000, P. No:20)

437.78>320kg

5. Aggregate proportion (coarse aggregate &fine aggregate):

IS-10262-2019,Table–5,P.No:6,cl:5.51

Zone-2-0.62(W/C-0.5)

Every0.05decreaseincrease0.01

(W/C-0.45)=(0.45-0.45)=0

0.62+0=0.62kg

Coarseaggregate=0.620kg

Volumeoffineaggregate=1-0.620=0.380kg

Fineaggregate=0.380kg

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6.Mixcalculation:

Volumeofconcrete–1m^3

b) Volumeofcement

(mass/sp.gravity)×(1/1000)

=437.78/(3.16*1000)=0.139m^3

c) VolumeofWater=197/(1×1000)=

d) Volumeofallinaggregate:

1-(b+c)=1-(0.139+0.197)=0.664kg

e) Massofcoarseaggregate:

Volume of all in aggregate × volume of coarse aggregate × sp. gravity of coarse aggregate ×1000 = 0.664×0.630×2.73×1000=1142kg

f) Massoffineaggregate:

Volumeofallinaggregate×volumeoffineaggregate ×sp.gravityoffineaggregate×1000=

0.664×0.370×2.46×1000=604kg

7 Summary:

Cement=437.78kg/m^3

Water=194kg/m^3

Fineaggregate=604kg/m^3

Coarseaggregate=1142kg/m^3

The ratio of the mix is 1:1.38:2.60 (Cement: fine aggregate:coarseaggregate)

IV. RESULTS AND ANALYSIS

TestsonConcrete(beforecasting)

•SlumpTest:

The most commonly used method for determining the workability of the concrete is slump cone test which can be done either in the field or in the laboratory. This method is not suitable if the concreteisverywetorverydry.

Table: Slump value for different percentage replacementsinM30gradeconcrete

• CompactingFactorTest:

The most commonly used workability test in the laboratory is compaction factor test. The results of the compaction factor test are more accurate than the results obtained from the slump cone test. The mainadvantageofthecompactionfactortestisitcan beeffectivelyusedfortheconcretemixesofverylow workability.

Table: Compaction factor values for different percentagereplacementsinM30gradeconcrete

TestsonHardenedConcrete

•COMPRESSIONTEST

In order to determine the compressive strength of the hardened concrete one of the most commonly used test is compression test. This test is conducted on the hardened concrete blocks by applying the loadsgradually.

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Table:CompressivestrengthofM30gradeconcrete cubesafter7days

Coconut shell grade Load crushing in (KN)

Table:CompressivestrengthofM30gradeconcrete cubesafter14days

Coconut shell grade Load crushing in (KN)

Table:CompressivestrengthofM30gradeconcrete cubesafter21days

shell grade Load crushing

Table:CompressivestrengthofM30gradeconcrete cubesafter28days

Coconut shell grade Load crushing in (KN)

V. CONCLUSION

Thisstudyconcludesthatreplacingcoarseaggregatewith coconut shell results in lightweight concrete with lower strength compared to conventional concrete, while still meetingstructuralrequirements.

Keyfindingsinclude:

Experimental results on compressive strength and workability for different mix proportions, where coarse aggregate was replaced with coconut shell at varying percentages, were analysed and compared with conventional concrete. The findings indicate that while coconut shell can serve as an alternative aggregate, its performance is slightly lower than that of normal concrete.

An increase in coconut shell content leads to higher void content in concrete. For a 20% replacement, the voids increasedby40%comparedtoconventionalconcrete.

The 28-day compressive strength of M30 grade concrete withcoconutshellreplacementwas:

 35.56N/mm²(0%replacement)

 31.56N/mm²(10%replacement)

 32.14N/mm²(15%replacement)

 22.72N/mm²(20%replacement)

These values satisfy the requirements for structural lightweightconcrete.

In conclusion, coconut shell concrete is a sustainable and economical alternative for lightweight construction, contributing to environmental conservation by utilizing solid waste materials effectively. Further studies should focus on the effects of coconut shell replacement on split tensilestrengthandflexuralstrength.

REFERENCES

1.IS456:2000-Plainandreinforcedconcrete-Codeof practice

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2. IS 383:1970 - Specification for coarse and fine aggregatefromnaturalsourcesforconcrete

3. IS 516: 1959 - Methods of tests for strength of concrete.

4.IS3025-Waterqualityparametersforconcrete.

5.IS299-Propertiesofcement.

6.IS2387-Testsofaggregate.

7. IS 10262: 2009 - Guidelines for concrete mix design proportioning.

8.Propertiesofconcrete-A.MNeville(1997).

9. Concrete Technology by M.L. Gambhir 5th edition, 2013andbyM.S.Shetty.

10. Light Weight Aggregate Concrete – Science, Technology