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Final Year Project 2 Technical PaperFaculty of Civil And Environmental EngineeringUniversity Tun Hussein Onn Malaysia

THE EFFECTIVENESS OF THE APPLICATION OF USED CERAMIC TILES AS COARSE AGGREGATE IN NORMAL CONCRETE MIXAhmad Ubaidillah Bin Abdul Rani1, Mohamad Hairi Bin Osman21 Department of Engineering Structure and Material, Tun Hussein Onn Malaysia University, Batu Pahat, Johor2 Department of Engineering Structure and Material, Tun Hussein Onn Malaysia University, Batu Pahat, Johor*Corresponding E-mail: ahmad.ubaidillah88@gmail.comAbstractMany studies have been carried out towards residual waste as a substitute for aggregate to produce concrete. Ceramic tile is one of the industrial wastes that may be used in producing concrete. As coal ash, used rubber tires and oil palms shell, all has been researched and the effectiveness of the reuse of the industrial waste shows a satisfactory results. However, the remnants of other industries should also be emphasized because if it were to be ignored, this waste problem is to get worse. According to the Department of Environment on Environmental Quality Report 2010, a total of 3,769.56 metric tonnes of waste ceramic material recorded. Therefore, a study has been conducted to investigate the characteristics of concrete using used ceramic tiles as coarse aggregate in the replacement of 25%, 50%, 75% and 100%. The method used to determine the concretes strength such as Compression Test was carried out. Compression Test results for 25% of used ceramic tiles concrete indicates optimal strength of the concrete. However it is still low when compared with normal concrete compressive strength with a difference of 5.7% and the higher the percentage of ceramic tiles, the less compressive strength value of the concrete. This indicates that the bonding occurs is weak. Other tests such as Slump Test for the concretes workability and Compression Test (cylinder) for the modulus of elasticity were also carried out. In line with the studies that have been conducted for other industrial waste, this study aims to obtain the effectiveness of its use in the concrete mix.

Keywords: Concrete, Ceramic, Tile, Compression, Strength, Elasticity1.0IntroductionThe construction industry in Malaysia has contributed to most of the solid waste generated. However, no accurate data can describe the generation of waste, especially waste from construction wastes resources. Waste from construction industry gives the average percentage of 28% and is the second highest percentage of the total residual waste generated in the city of Malaysia [1].The disposal of consruction waste such as piling, timber and others is increasingly improved upon request and rapid development in our industry. Tile is one of the substances that are usually discarded after a modification and renovation of a building. Apart from the usage as decorator for floor, walls and furniture such as tables, it is also known for its stiff characteristic. To overcome this problem, the study applies the use of ceramic tiles, have been conducted to determine its suitability as alternative substitute materials for production of concrete in the construction. It should be able to be managed with the good or with other words with recycle our wastes this.The importance of this study is to obtain the percentage of the normal concrete mix with high workability and strength by using alternative materials for coarse aggregate. This is because, with the use of ceramic tiles used as a substitute, it can reduce the cost of materials to produce a normal concrete as it is a waste and can be used in the construction industry. With the reduction of the demand for the material, this can minimize the problem of environmental pollution arising from the activities of aggregate production. This study is based on the idea of finding new innovations in the production process of normal concrete to increase its strength, to modify the quantity of coarse aggregate percentage in addition to finding new alternatives to reduce the cost of producing normal concrete.2.0Literature ReviewIn recent years, considerable research has been conducted on the utilization of waste materials such as fly ash, silica fume and other materials in civil engineering. Each residue has a certain impact on the natural properties and hardening of cement. There are two main potential fields where recycled waste materials has successfully ben used and that is transportation and construction industries [2].Concrete is a construction material that was widely used throughout the country. It is a material made from a combination of cement, water, coarse aggregate and fine aggregate. The reaction between cement and water will produce (CSH gel) by forming a bond between aggregate and give strength and endurance on the concrete [3].According to Johnson [4], generally the metal is ductile and ceramics are brittle. Due to the different properties in ceramic materials, it is used in many applications. In general, most ceramic are stiff, fragile, non-magnetic, chemically stable, oxidation resistant and also thermal and electrical insulation.2.1Compressive StrengthCompressive strength is one of the important items in structural design requirement in order to ensure the abilities of the structure to carry the intended load. In order to ensure the high quality of the concrete, designer prefers the higher value of compressive strength. The compressive strength of the specimen also affected by the specimen size because increasing in specimen size may reduce its strength. 150 mm x 150 mm x 150mm specimen size is usually used because it has less variability and better representation of the actual strength of the concrete [5]. Concrete grade is usually C30, C35, C40, C45 and C50. However, self-compacting does not mean the concrete obtained high performance and high compressive strength when hardened [6].2.2Modulus of ElasticityThe material that consists elastic behavior should be able to response to load and able to return into its original shape when the load is removed. The elastic deformation does not change the arrangement of the atoms within the material but it just stretches the bond between the atoms. Modulus of elasticity (E) is the proportional constant between normal stress and normal strain of an axially loaded member [7]. The equation for E is:E = / (8) Where,E = modulus of elasticity, = normal strain, = normal stress3.0MethodologyThe selection of the title has been discussed with the supervisor according to the suitability of the title with the field of the study. A few titles have been proposed to the supervisor based on the availability source of data and significant to study the field.

Problem statement, objectives, scope and significant of studyLiterature Review by journal, conference paper and text bookCubeCylinderCompression TestCompression Test (Modulus Young)Slump TestSample Preparation- Used Ceramic Tiles Concrete Mix 25%, 50%, 75%, 100% --Normal Concrete Mix-Comparison of compressive strength and modulus of elasticity between normal concrete mix and used ceramic tiles concrete mix (25%, 50%, 75%, and 100%)Conclusions & Recommendation

Figure 3.1: Flowchart of research methodology3.1Concrete Mix DesignThe volume of concrete was determined to ensure the ratio between all the constituent materials is suitable with grade 30 standards. Following are size and volume calculation for cubes and cylinders.

Cube size = 0.15 m x 0.15 m x 0.15 mCube volume= length x base x height x samples (in a mixture)= 0.15 x 0.15 x 0.15 x 3= 0.01 mCylinder size= 0.15 m x 0.3 mCylinder volume= (d/4) x cylinder x samples (in a mixture) = ( (0.15) /4) x 0.3 x 3= 0.016 m Total volume of a mixture = 0.01 m + 0.016 m = 0.026 mDetermination of the amount required in the mixture which allows the calculation of the mix design. Calculation for concrete cube is as shown in table 3.1.

Table 3.1: Normal concrete mix designs using the DOE methodQuantityCement (kg)Water (kg)Fine Aggregate (kg)Coarse Aggregate (kg)

10mm20mm30mm

Per m3 (to nearest 5kg)396180675-1149-

Per trail mix of 3.375 x 10-3 m31.30.62.3-3.90-

Table 3.2: Proportion of used ceramic tiles weight (cube)SamplePercentage of Used Ceramic Tile (%)Coarse Aggregate (kg)Used Ceramic Tile (kg)

1 (control)0%3.90

225%2.91.0

350%1.951.95

475%1.02.9

5100%03.9

Table 3.3: Proportion of used ceramic tiles weight (cylinder)SamplePercentage of Used Ceramic Tile (%)Coarse Aggregate (kg)Used Ceramic Tile (kg)

1 (control)0%6.10

225%4.571.53

3.2Sample Preparation

Materials needed in the concrete mix are water, cement, coarse aggregate, fine aggregate and used ceramic tiles. The content of each material depends on the concrete mix design. The number of required cubes and cylinders was 30 and 6 respectively. The percentage of 0%, 25%, 50%, 75% and 100% used ceramic tiles were provided to run on the desired tests. 30 concrete cubes were for compression test and 6 cylinders were to obtain elastic modulus by compression test. 3.3Slump TestThe concrete slump test is an empirical test that measures the workability of fresh concrete. Specifically, it measures the consistency of the concrete in that specific batch. This test is performed to check the consistency of freshly made concrete. Consistency is a term very closely related to workability. It is a term which describes the state of fresh concrete. It refers to the ease with which the concrete flows. It is used to indicate the degree of wetness. Workability of concrete is mainly affected by consistency i.e. wetter mixes will have more workability than drier mixes, but concrete of the same consistency may vary in workability. It is also used to determine consistency between individual batches. The test is popular due to the simplicity of the apparatus used and simple procedure. Unfortunately, the simplicity of the test often allows a wide variability in the manner that the test is performed. The slump test is used to ensure uniformity for different batches of similar concrete under field conditions, and to ascertain the effects of plasticizers on their introduction.

Figure 3.2 Slump Test3.4SamplingA fresh mixture of concrete was added into a mold in order to prepare a sample. The mould for cube test was made of Acrylonitrile Butadiene Styrene (ABS) plastic and cylinder mold is made of Galvanized Steel. The moulds should be applied with a thin layer of oil to avoid adhesion between inside surfaces and concrete.(a)3.5CuringThe samples were placed in a basin with full of water to allow the curing process (Fig. 3.3) in a duration of 7 and 28 days.

Figure 3.3 Curing3.6Compression TestCompressive strength of concrete are one of many tests applied to concrete. This is the utmost important which gives an idea about all the characteristics of concrete. By this single test one judge that whether Concreting has been done properly or not. For cube test, two types of specimens either cubes of 150mm x 150mm x 150mm depending upon the size of aggregate are used. This concrete is poured into the mould and has been tempered or compacted properly to avoid any honey comb. After 24 hours these moulds are removed and the test specimens were put in the basin of water for curing. The top surface of these specimens should be flat and smooth. This is done by putting cement paste and spreading smoothly on the whole area of the specimen. These specimens are tested by compression testing machine after 7 days of curing and 28 days. Load at the failure divided by area of specimen gives the compressive strength of concrete.

4.0Results and DiscussionsTable 4.1: Result of slump testSlump Test Result

Mixing RateUsing the DOE Method

Cones Height300mm

MixesControl25%50%75%100%

Reduction (mm)5546351522

Table 4.1 shows the workability of used ceramic tiles concrete mix according to a predetermined percent are in real decline between 30-60mm. These results demonstrate the workability of the concrete mix is in the satisfactory range.However, for concrete mixtures containing 75% and 100% used ceramic tiles were below the limit set of 15mm and 8mm respectively. Therefore it is categorized as a dry mix or rigid.This condition is caused by the content of used ceramic tiles that was used. The characteristic of ceramic are water absorbant and therefore the concrete mixture becomes dry and rigid.

Figure 4.1 Results of cube compressive strength for 7 days Figure 4.2 Results of cube compressive strength for 28 daysFrom Figure 4.1 shows the relationship between the compressive strength of concrete by the maturity at 7 days. The value of the highest compressive strength of concrete was the mixture of 25% of used ceramic tiles by 35.97 MPa, while the lowest compressive strength of concrete was the mixture of 100% of used ceramic tiles with value of 15.7 MPa. However, from the results, the concrete mix from 0%, 25%, 50% and 75% used ceramic tiles exceeds the standards of concrete grade set for grade 30. Concrete maturity on the 7th day showed only the minimum compressive strength of 75% of grade 30, which is 22.5 MPa. From the results obtained it was found that the percentage of the optimum for this test is 25% used ceramic tiles concrete by 35.97 MPa. This shows that the percentage has exceeded the limits set by maturity cubes mention it.From Figure 4.2 shows the relationship between the compressive strength of the concrete maturity on the 28th day. Through the experiments, the highest compressive strength of concrete was the control with the strength of 35.30 MPa, while the lowest compressive strength of concrete is the mixture of 100% used ceramic tiles with 21.9 MPa. For the whole, the value of compressive strength obtained was higher than the minimum strength of concrete for all samples except for 75% and 100% of used ceramic tiles concrete mix does not reach the standards. This is because ceramic tiles is naturally fragile and has no bonding agent between the materials. It was found that the concrete mixture for 25% and 50% used ceramic tiles has surpassed the standards set. In this case the percentage of used ceramic tiles used in the concrete mix is with small quantities and does not disturbing the existing concrete strength. Since the maturity of 28 days, the compressive strength of 100% of grade 30 which is 30 MPa. Percentage with the most optimal value in this research was normal concrete mix with maximum strength of 35.30 MPa.

Figure 4.3 Results of cube compressive strength at 7 and 28 daysFigure 4.3 shows a graph of compressive strength of concrete at 7 and 28 days for a predetermine percentage of used ceramic tiles concrete mix. From the results, it was found that the compressive strength of the normal concrete was stronger than any percentage of used ceramic tiles as coarse aggregate. This shows that used ceramic tiles was unsuitable as coarse aggregate concrete mix. This is because the bond between the materials in normal concrete with used ceramic tiles in the concrete mix doesnt occurred and becoming weaker. Ceramics has absorbed the water and reduced water content ratio. From the results obtained according to the day of maturity of 28 days was found that the control concrete were stronger than a concrete mix used ceramic tiles.

Figure 4.4 Graph for elastic modulus of normal concrete and used ceramic tiles concrete of 25%.

Calculation to find Modulus of Elasticity for concrete palm shell (5%), E:E= (a- b) / (a - b)Where:a= fc/3 = 33.75 / 3 = 11.77N/mm2b=0.5 N/mm2a=10.00 x 10-4b=0.83 x 10-4E= (11.77-0.5) / (10.00 x 10-4 0.83 x 10-4)=12290.00 N/mm2=12.29 GPa (example calculation of the modulus elasticity)

From the graph, the elastic modulus of normal concrete and concrete mix with 25% of used ceramic tiles as coarse aggregate were tested. This shows that the elasticity difference between the two types of concrete used has significant different. The results obtained shows that the strain of the concrete mix of used ceramic tiles with 25% is higher compared to the control concrete. These results indicate that the material is very weak in terms of bonding between the materials in normal concrete and is not suitable in the construction for mega structures. From the results, the value of the modulus of elasticity of normal concrete is 12.29 GPa higher than the concrete mixture for 25% of used ceramic tiles which is only 8.95 GPa with a differences of 4.14 GPa. The elasticity characteristic of used ceramic tiles concrete of 25% is less compared with the normal concrete.

Figure 4.5: Cylinder condition after a load is applied and the reading of the "dial gauge" will be taken in accordance within a certain time of interval5.0ConclusionsFrom the compression test, it shows that the addition of used ceramic tiles by 25% achieve the highest strength at the age of 7 days with the value of 35.97 MPa and a slight decrease in percentage of 7.4% on the 28th day to the value of 33.3 MPa. This shows that 25% of the used ceramic tile concrete mix can achieve to almost equal compressive strength with normal concrete. From the tests results obtained, it can be concluded that the used ceramic tiles with 25% percentage substitute for coarse aggregate are suitable as a replacement for coarse aggregate in the concrete mix. This is because the compressive strength are higher than expected and the predetermined limit for concrete grade of 30.Based on the Compaction Test to acquire the elastic modulus, normal concrete showed high elastic modulus values than used ceramic tiles concrete mix of 12.29 GPa and elastic modulus of the used ceramic tiles concrete mix is 8.15 GPa. Thus, normal concrete is stronger in terms of elasticity than the used ceramic tile concrete.

AcknowledgementThe author wants to thanks Mr. Mohamad Hairi bin Osman and Structural and Material Laboratory.References[1] Nurul Izzati (2011). Sisa Konkrit Bagi Kerja Cerucuk, Universiti Teknologi Malaysia: Tesis Ijazah Sarjana Muda Kejuruteraan Awam.[2] Becquart, et. al. (2009). Monotonic aspects of the mechanical behaviour of Bottom Ash from Municipal Solid Waste Incineration and its potential use for road construction. Waste Manage. 29 (4), 13201329.[3] Khairul Azad (2009), Ciri-Ciri Konkrit Yang Menggunakan Tempurung Kelapa Sawit Sebagai Bahan Ganti Agregat Kasar, Universiti Teknologi Malaysia: Tesis Ijazah Sarjana Muda Kejuruteraan Awam.[4] Johnson R. L (2008) Ceramics in the Classroom. Retrieved from http://www.acers.org/membership/sc/Ceramics.doc[5] Neville A. M. (1981). Properties of Concrete. 3rd Ed. London: Pitman Publishing Limited.[6] Schutter G. D., Bartos P. J. M., Domone P., & Gibbs J. (2008). Self-Compacting Concrete. UK: Whittles Publishing.[7] Takahashi S. (1999). Technology Transfer Series 1 Concrete Technology for Engineers. Malaysia: Civil Engineering Department Politeknik Shah Alam.[8] Brouwers ( H. J. H., Radix H. J. (2005). Self-Compacting Concrete : Theoretical and Experimental Study.