PERPUSTAKAAN UMP

EFFECTIVENESS OF R

111111111111111111111111111111111111111

LACEMENT ON

FOAM 0

0000092813

C)

VOON YING YONG

Report submitted in fulfilment of

requirements for the award of the degree of

B.Eng (Hons.) Civil Engineering

Faculty of Civil Engineering and Earth Resources

UNIVERSITI MALAYSIA PAHANG

JUNE 2014

ABSTRACT

The goal of this study is to assess the possibilities of incorporating red gypsum in

production of foamed concrete. Invention of lightweight composite design and construction

utilizes existing technology which has become an alternative choice in current markets to

make construction project getting easier and faster. The reuse of red gypsum waste is the

areas where great opportunity exists for cost saving in the construction industry red gypsum

as cement replacement in foam concrete in different percentage show improvement in the

development of strength. In water and air curing condition, it shows that the samples in

water curing possess higher strength compare to the air curing samples. But the strength

achieved by RGFC was still lower than the control foam concrete. By comparing to four

mixes, the strength of the lower percentage RG was higher than higher percentage of RG.

This can be concluded that 5% was not capable to be use but there maybe some condition

that needed for this type of concrete.

vi

vii

ABSTRAK

Matlamat kajian mi adalah untuk menilai kemungkinan menggabungkan gipsum

merah dalam pengeluaran konkrit berbusa. Penciptaan reka bentuk komposit yang ringan

dan pembinaan menggunakan teknologi yang sedia ada yang telah menjadi satu pilihan

alternatif dalam pasaran semasa untuk membuat projek pembinaan semakin mudah dan

lebih cepat. Penggunaan semula sisa gipsum merah adalah kawasan di mana peluang besar

wujud untuk penjimatan kos dalam industri pembinaan gipsum merah sebagai pengganti

simen dalam konkrit busa dalam berbeza peningkatan peratusan menunjukkan dalam

pembangunan kekuatan. Dalam keadaan air dan pengawetan udara, ia menunjukkan

bahawa sampel dalam pengawetan air mempunyai kekuatan yang lebih tinggi berbanding

dengan sampel pengawetan udara. Tetapi kekuatan yang dicapai oleh RGFC masih lebih

rendah daripada konkrit busa kawalan. Dengan membandingkan empat campuran, kekuatan

peratusan yang lebih rendah RG adalah lebih tinggi daripada peratusan yang lebih tinggi

RO. mi dapat disimpulkan bahawa 5% tidak mampu untuk menjadi penggunaan tetapi ada

mungkin beberapa keadaan yang diperlukan untuk jenis konkrit.

TABLE OF CONTENTS

CHAPTER TITLE PAGE

SUPERVISOR'S DECLARATION

STUDENT'S DECLARATION

ACKNOWLEDGEMENT v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENTS viii

LIST OF TABLES xii

LIST OF FIGURES xiii

LIST OF ABBREVIATIONS vii

LIST OF APPENDICES xviii

CHAPTER 1 INTRODUCTION

1.1 Background of Study 1

1.2 Problem Statement 2

1.3 Significance of Study 3

1.4 Objective of Study 3

1.5 Scope of Study 3

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 5

2.2 Foamed Concrete 7

2.2.1 History 7

2.2.2 Applicatioin in COIIUULIOU 7

2.3 Properties of Foamed Concrete 8

2.3.1 Density 8

2.3.2 Compressive Strength 9

viii

ix

2.3.3 Water Absorption 9

2.3.4 Porosity 10

2.4 Constituent Materials 10

2.5 Production Method 11

2.6 Effectiveness of Ordinary Portland Cement in 13

Foamed Concrete

2.6.1 Chemical Composition 13

2.6.2 Particle Size 14

2.6.3 Chemical Reaction 14

2.6.4 Hydration Process 14

2.7 Effectiveness of Pozzolan material and Behaviour 15

Foamed Concrete

2.7.1 Previous Study of RG in Mortar 15

2.7.2 Properties of RG 15

2.7.3 Chemical Composition of RG 15

2.7.4 Particle size of RG 15

2.7.5 Pozzolonic Activity RG in Mortar 16

2.7.6 Effect of RG to Compressive Strength 16

CHAPTER 3 METHODOLOGY

3.1 Introduction 18

3.2 Experimental Program 18

3.3 Preparation Material 20

3.3.1 Design Mix Composition 24

3.3.2 Production Method of RGFC 25

3.3.3 Specimens 28

3.3.4 Placing 30

3.3.5 Curing 30

3.4 Experimental Testing 31

3.4.1 Fresh properties 31

3.4.1.1 Workability test 31

3.4.1.2 Consistency and Stability 34

3.4.1.3 Procedure of stability and 35

consistency of pre formed foam

3.4.1.4 Determination of properties of pre 36

formed foam

3.4.1.5 Foamed concrete slurry 37

3.4.1.6 Procedure of stability and 37

consistency of foamed concrete

slurry

3.4.1.7 Determination of stability of foamed 38

concrete

3.4.2 Physical properties 39

3.4.2.1 Density 39

3.4.2.2 Porosity 41

3.4.2.3 Water absorption 43

3.4.3 Compression test 45

CHAPTER 4 RESULTS AND DISCUSSION

4.1 Introduction 47

47

4.2 Properties of Red Gypsum

4.2.1 Chemical composition of RG 47

47 4.2.2 Particle size of RG

4.3 Influence of RG as cement replacement on the 49

workability, consistency and stability of fresh

x

properties of RGFC

4.4 Influence of RG as cement replacement on the 50

oven dry density, water absorption and porosity of

RGFC

4.5 Influence of RG as cement replacement on the 53

compressive strength of RGFC

4.6 Relationship between oven dry density and oven 54

dry density of RGFC

4.7 Relationship between oven dry density and 55

compressive strength of RGFC

4.8 Relationship between oven dry density, water

absorption and porosity of RGFC56

CHAPTER 5 CONCLUSION

5.1 Conclusion 58

5.2 Recommendations 59

REFERENCES 60

APPENDICES

A Laboratory Test Result 62

xi

LIST OF TABLES

TABLE NO. TITLE PAGE

2.1 General Composition Limits of Portland Cement 13

3.1 Chemical composition of cement 20

3.2 Number of Samples and Test For Laboratory work 24

4.1 Chemical composition of RG 48

4.2 Classification of RG Based On Standard Raw Pozzolan 48 ASTM C-618

4.3 Influence of RGFC on Stability 50

xii

LIST OF FIGURES

FIGURES NO. TITLE PAGE

2.1 Literature Review Process 6

3.1 Study Flow Chart 19

3.2 Ordinary Portland Cement 20

3.3 Mixing Water 21

3.4 Silica Sand 21

3.5 Foaming agent and foam generator 22

3.6 Drying process 22

3.7 Grinding and sieving process 23

3.8 Pre formed foam 26

3.9 Production of RGFC 27

3.10 Equipment and apparatus of specimen 28

3.11 Preparation of specimens 29

3.12 Flow table apparatus 32

3.13 Method of flow table test 33

3.9 Curing Pond 35

3.10 Water Curing 35

3.11 Air Curing 35

3.12 Apparatus for Flow Table Test 37

xlii

3.13 Mehod for flow table test 38

3.14 Air dry mass 40

3.15 Oven dry specimen 40

3.16 Oven dry mass 40

3.17 Porosity test apparatus 42

3.18 Saturated mass after immersion 43

3.19 Position of specimen placement 46

3.20 UTM compression test machine 46

4.1 Particle size of RG and OPC 49

4.2 Influence of RGFC on workability 50

4.3 Influence of RGFC on oven dry density 51

4.4 Influence of RGFC on porosity 52

4.5 Influence of RGFC on water absorption 52

4.6 Influence of RGFC on compressive strength 53

4.7 Relationship between fresh density and oven dry density of 54

RGFC

4.8 Relationship Between Oven dry Density and Compressive 55

Strength of RGFC

4.9 Relationship between oven dry density, water absorption 56 and porosity of RGFC (water curing)

xiv

4.10 Relationship between oven dry density, water absorption 57 and porosity of RGFC (air curing)

xv

LIST OF ABBREVIATIONS

RG - Red gypsum

FC - Foam concrete

RGFC— Red gypsum foam concrete

ASTM— American Society for Testing and Materials

FKASA— Fakulti Kejuruteraan Awam dan Sumber Alam

UMP - University Malaysia Pahang

Kg/m3 - Kilogram per meter cube

N/mm2 - Newton per milimeter square

MPa - Mega Pascal

Kg - Kilogram

°C - Celcius

xvi

LIST OF APPENDICES

TITLE

PAGES

Laboratory test results 76

xvii

CHAPTER 1

INTRODUCTION

1.1 Background of Study

Nowadays, the construction industry is well developed in developing

countries especially Malaysia. The rapid infrastructure development in the country

makes the increasing in numbers of construction project. For this, concrete is widely

used in construction due to it is usually the cheapest and most readily composite

material.

Invention of lightweight composite design and construction utilizes existing

technology which has become an alternative choice in current markets to make

construction project getting easier and faster. (Haq.M & Liew.A).This technology is

extremely useful for the developing countries in special areas of construction such

as residential and other commercial construction. Foam concrete is a mixture of

cement, fine sand, water and special foam which results in a strong lightweight

concrete containing evenly distributed air bubbles. (Z. Fahrizal &Ramli.M, 2011).

Recycled materials like palm oil shell, rice husk and more were becoming

popular ingredients in lightweight concrete because of public awareness about

environmental issues.(M.R.Jones, et.al , 2005). The new invented concrete mix

design by using a new waste material is now applicable in building construction to

reduce the problem of wastage production in Malaysia. Red gypsum (RG) is a waste

2

product during the extraction of titanium (IV) oxide from ilmenite ores. The

production of RG which is a reddish brown mud, at least 340,000 tons per

year.(Kamarudin & Zakaria, 2007). In the cement industry, RG can used as partial

replacement of cement production in order to reduce the environmental hazard

problem.(Gazquez, Bolivar, Vaca, Garcia-Tenorio, & Caparros, 2013).

1.2 Problem Statements

The usage of construction material like Ordinary Portland Cement (OPC) has begun

since the very first building that was being built. Rapid development in our country makes

the excessive uses of OPC. OPC is a chemical compound and were used every day around

the globe and finally the cost of. So, the solution for this problem is to find a new

substitute material that is Red Gypsum (RG) to replace the OPC. The reuse of red gypsum

waste is the areas where great opportunity exists for cost saving in the construction

industry. (Haizal et.al ,2005). The production of RG which is a reddish brown mud, at least

340,000 tons per year. By using this material with concrete mixture, the problem of

disposal of RG to landfill and pollution hazards due to substantial oil content in the earth

can be reduced. (Gazquez etal., 2013)

3

1.3 Significance of Study

The significance of this study is to learn about the performance of RG lightweight

foam concrete in mechanical properties. Besides that, this study is using RG as the waste

material is becoming useful and makes benefits to the construction industry for a better

environment. Other than that, the wastage of RG will be reduced at the mining industry.

1.4 Objectives of Study

The goal of this study is to investigate the effectiveness of the Red Gypsum as

cement replacement on the foamed concrete properties. The specific objectives of this study

are:

1.4.1 To determine the workability, consistency and stability of

fresh properties of RGFC mixes

1.4.2 To determine the oven dry density, water absorption and

porosity of RGFC mixes

1.4.3 To determine the compressive strength of RGFC mixes

1.4.3 To observe the crack pattern of RGFC mixes

1.5 Scope of Study

This study has investigated to determine the performance of RG in lightweight foam concrete The Red Gypsum is taken from UMP Green Technology Sdn. Bhd. Meanwhile,

the RG is waste product which originally produce from trioxide(Malaysia) sdn. Bhd that

located at Kawasan Perindustrjan Teluk Kalung, Kemaman, Terenganu. The red gypsum is

brown in colour.

4

Laboratory test such as density test, porosity test , compressive strength test and

water absorption to study the performance of RG foam concrete mixture. The RG waste

had process to air-dry for 1 week to make sure there is no wet inside the RG particles.

After that, the RG waste was sieved and grinding to make the particles of RG become fine

and small.

During the preparation of sample, fresh properties, compressive strength and

physical properties of foam concrete were tested. For fresh properties, the fresh density test

and flow table test were conducted to determine the workability of foam concrete

according ASTM C1437. For compressive strength, the compressive strength test was

conducted to identify the mechanical strength of foam concrete. Meanwhile, the physical

properties includes oven dry density test, porosity test, and water absorption test were

conducted. The types of curing for the sample was air curing and water curing. The days of

testing were at day 3, day 7, day 14 and day 28. The size of specimen is in cube dimension,

100mm x 100mm x 100mm. There were four types of sample that prepared for this study,

foam concrete control sample, 5% RGFC,10%RGFC and 15% RGFC. 3 cubes were needed

for each testing at each different days of testing respectively. That means the total

specimens were 96 cubes. All the material and specimen preparation based on standard

code practice requirement of ASTM. The experiment testing and setup will be conducting

in FKASA Laboratory.

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

This chapter discussed previous study related to the effect of red gypsum on foamed

concrete in term of engineering properties of the foamed concrete. Besides that, this chapter

also reviews the performance of the red gysum on foamed concrete in the existing

application.

I O I • Hydration

process • Pozzolanic

materials and behaviour

• Chemical Composition of RG

• Pozzolanic of RG

• Particle size of RG

• Microstructure of RG

• Density of RG • Strength of RG • Durability of

RG

• Density • Strength • Durability • Contituents of

materials • Production

Foamed Concrete

7

LGypsum

Figure 2.1: Flow chart of literature review

8

2.2 Foamed Concrete

2.2.1 History

Foamed concrete is not a peculiarly new material, it is first recorded to use in early

1920s. The application of foamed concrete for construction works was not acknowledged

until the late 1970s, when it starts to be used in Sweden in 1929s.

The first large foamed concrete project, which was in UK at Falkirk Tunnel in 1980.

This tunnel was placed about 4500m3 of 1100kg/rn3 . Substantial improvements in

production method and quality of foaming agent over the last 16 years have made to the

production of blocks and void fills. The uses of foamed concrete have been widely spread

across the worldwide (Andrew & Willian, 1978).

2.2.2 Application in construction

In Malaysia the first major application of lightweight foamed concrete in Malaysia

is at the SMART tunnel project in Kuala Lumpur. The lightweight foamed concrete

specified was density 1800 kg/m3 which achieved compressive strength of 3 N/mm2 at the

age of 28 days. Otherwise lightweight foamed concrete inert, materials such as powdered

waste plastic, rice husk and others are also being experimented. The composition is

Proposed to be injected at prescribed locations with innovative precast lightweight hollow-

core concrete pile to effect replacement of portions of the soft soil.. The system is expected

to provide cost effective geoteclmical solution as the surrounding soft ground becomes compacted while foamed concrete solidifies in situ. Foundation system with the utilization Of used tyres are being experimented in some housing project in Malaysia. Successful deployment of-the system is expected -to -provide a fast. track 11 method for affordable

Es

quality assured housing. The system is applicable for the homeless people who urgently

need a shelter. Technical specification has been prepared for an industrialized building

system complying with modular coordination (Lee, 2005).

2.3 Properties of Foamed Concrete

2.3.1 Density

Foamed concrete is manufactured by entrain relatively large volume of air into the

cement paste by use the foam agent. High volume of air contents result in lower densities,

higher porosity. Density can be either in fresh or hardened state. Fresh density is required

for mix design and casting control purposes. A theoretical equation for finding fresh density

may not be applicable as there can be scatter in the results caused by a number of factors

including continued expansion of the foam after its discharge, loss of foam during mixing.

Many physical properties of foam concrete depend upon its density in hardened state.

While specifying the density, the moisture condition needs to be indicated as the

comparison of properties of foam concrete from different sources can have little meaning

without a close definition of the degree of dryness.

According to Kearsley & Mostert (2005) have come out a mix design for foamed

concrete mix, show the casting density clearly indicated that the mix design is suitable

because the difference between the target densities aimed for and the actual measured are

within S%.cen-ient content and foamed content should be established in designer. Besides

that, Jones & McCarthy (2005), show that it is difficult to design for a specified dry density

as foamed concrete will desorbs between 50 and 200 kg/m3 of the total mix water, depending on the concrete plastic density. McCormick (2005) studied the effect of types of

fine aggregate, aggregate gradation, type of foam and sand—cement ratio on the wet density

10

of foam concrete and reported that wet densities within about 5% of the design densities

can be achieved by using solid volume calculations.

2.3.2 Compressive Srength

The strength of concrete originates from the strength of the hardening cement paste,

which is, in turn, originates from hydration products. Compressive strength of foamed

concrete influenced by many factor such as density, age, curing method, component and

mix proportion. Kearsely (2000) noted that dry density of foam concrete between 500

kg/m3 and 1000 kg/m3 , the compressive strength decreases with an increase in void

diameter. For densities higher than 1000 kg/M3, as the air-voids are far apart to have an

influence on the compressive strength, the composition of the paste determines the

compressive strength. Jones et al., (2005) reported that small changes in the water to

cement ratio does not affect the strength of foam concrete but the compression strength

increased due to higher water and cement ratio.

2.3.3 Water Absorption

Kearsley & Wainwright (2001) investigate that, the water absorption of the paste

and the foamed concrete mixtures (as expressed by the increase in mass as a percentage of

dry mass) is plotted as a function of dry density as shows in Figure 2.4, from these results it

could be concluded that because the mixtures with lower density absorb more water than

higher densities. However, water absorption maybe expressed either as increase in mass per unit of dry mass.

For the foamed concrete mixtures reported, there are significant differences in density

(1000 to 1500 kg/m3) and expressing water absorption as the increase in mass per unit

Volume as shown in Figure 2.5. It is now apparent that that foamed concrete mixtures with

low densities absorb only marginally more water than those with higher densities. It is also

I

apparent that the cement paste mixture containing no ash (w/c=0.6) absorbs more water

than any of the foamed concrete mixtures. It can also be seen that there is a trend of

increased absorption with decreasing density for all mixtures but the increase absorption is

much more significant in the paste (no foam) mixtures than in the foamed concrete

mixtures.

2.3.4 Porosity

The strength of concrete is affected by the volume of air void inside the concrete.

According to G.C.Hoff (1972), water cement ratio and density is related to the porosity of

foam concrete. The strength of foam concrete decreases as the porosity increases. The

strength of mixtures with low porosity was influenced more by small changes in porosity

than the strength of mixtures with higher porosity.

2.4 Contituents of materials

Generally the fine aggregate shall consist of natural sand, manufactured sand or

combination of them. The fine aggregate for concrete that subjected wetting, extended

exposure to humid atmosphere, or contact with moist ground shall not contain any material

that reactive in cement to cause excessive expansion of mortar concrete. Recommend that

only fine sands suitable for concrete (to ASTM C33) or mortar to ASTM C270) having

Particle sizes up to about 4 mm and with an even distribution of sizes should be used for

foamed concrete. This is mainly because coarser aggregate might settle in a lightweight mix

and lead to collapse of the foam during mixing

The water used for foamed concrete should be potable. This is crucial when using a

protein based foaming agent because organic contamination can have an adverse effect on

the quality of the foam, and hence the concrete produced. The water/cement (w/c) ratio of

the base mix required to achieve adequate workability is dependent upon the type of

12

binder(s), the required strength of the concrete, and whether or not a water reducing or a

plasticizing agent has been used. In most cases the value will be between 0.4 and 0.8. The

higher values are required with finer grained binders, and the lower values where either a

high strength is required or a super plasticizer has been employed. Where the water content

of the mix would be inadequate to ensure full hydration of the cement, water will be

extracted from the foam and might lead to its disintegration. On the other hand whilst high

w/c ratios do not significantly affect the porosity of the foamed concrete they do promote

segregation and increase drying shrinkage (Gambhir, 2004).

Synthetic or protein-based foaming agents can be used to produce foam. Because of

the possibility of degradation by bacteria and other Organisms, natural protein based agents

(i.e. fatty acid soaps) are rarely used to produce foamed concrete for civil engineering

works. However research is underway on the use of protein-based agents for developing

high strength, i.e... The chemical composition of a surfactant must be stable in the alkaline

environment of concrete. Because all surfactants are susceptible to deterioration at low

temperatures they should be stored accordingly. The properties of foamed concrete are

critically dependent upon the quality of the foam. There are two types of foaming agent:

I. Synthetic-suitable for densities of 1000 kg/m3 and above.

II. Protein-suitable for densities from 400 to 1600 kg/m3

Protein-based foaming agents come from animal proteins out of horn, blood, bones

Of cows, pigs and other remainders of animal carcasses. Its surfactants might therefore be

best suited to the production of foamed concrete of relatively high density and high strength.

Optimum performance of foam is commonly attained at a ratio of 1:25, but the optimum

value is a function of the type of surfactant and the method of production (Gambhir, 2004).