CHAPTER 1

INTRODUCTION

1.1 GENERAL

Currently, India has taken a major initiative on developing infrastructures

such as express highways, Power projects and Industrials structures etc., to meet
the requirements of globalization. In the construction of buildings and other
structures, concrete plays the rightful role and a large quantum of concrete is being
utilized. River sand, which is one the constituents used in the production of
conventional concrete, has become highly expensive comparatively with river sand
and also scarce. So there is large demand for alternative materials from industrial
waste.
The utilisation of quarry rock dust which can be called as crusher sand has
been accepted as a building material in the industrially advanced countries of the
west for the past three decades. The level of utilization of quarry rock dust in
industrialised nations like Australia, France, Germany and UK has reached more
than 60% of its total production. The use of crusher sand in India has not been
much when compared with some advanced countries.
And also one of the fastest growing industries is a plastic industry. Around
the world almost one trillion plastic bags per year are being used and it is just one
example of a product of plastic. The plastic is one of the recent engineering
materials which have raised 1000 million kN for one year. Plastics are normally
stable and not biodegradable so their disposal is a problem. Research works are
going on in making use of plastic wastes effectively as additives in plain and
reinforced concrete mixes for variety of purposes. This study attempts to limit the
high amount of environmental degradation.

1
 This paper presents feasibility of the usage of crusher sand as 100%
substitute for conventional sand and in addition to that plastic bags wastes are used
as fibre in concrete. Tests were conducted on cubes, beams and cylinders to study
about the compressive, flexural and split tensile strengths of concrete made of
crusher sand and plastic fibres of different ratios.

1.2 ENVIRONMENTAL FACTORS

In India, domestic waste plastics are causing considerable damage to the

environment and hence an attempt has been made to understand whether they can
be successfully used in concrete to improve some of the mechanical properties as
in the case of the steel fibres. The primary objective of this investigation is to study
experimentally the properties of fibre reinforced concrete containing polythene
fibres. The properties of concrete namely compressive, flexural and split tensile
strength were studied. Plastic bags are popular with consumers and retailers as they
are a functional, light weight, strong, cheap and hygienic way to transport food and
other products. After the plastic bags are used some are recycled and most of them
are waste. Each year, plastic bags are consumed approximately 500 billion to 1
trillion around world. That is over one million bags are consumed per one minute.
Particularly in china the total number of plastic bags used is 3 billion per day.
Plastic bags create visual pollution problems and can have harmful effects on
aquatic and physical animals. Also plastic bags take long time to completely
degradation.

2
 CHAPTER 2

LITERATURE REVIEW

Dr P.Perumal and G.Bala Murugan “An Experimental study on Behaviour of

concrete on the use of quarry dust to replace sand” an international Journal
(ESTIJ), ISSN : 2250 – 3498, vol 3, no 6, December 2013.

This experimental study presents the variation in the strength of concrete

when replacing sand by quarry dust from 0% to 100% in steps of 10%. M20 grades
of concrete are taken for the study keeping a constant slump of 60mm. The
compressive strength of concrete cubes at age of 7 and 28 days is obtained at room
temperature. Split tensile strength and flexural strength of concrete are found at the
age of 28 days. This result gives clear picture that quarry dust can be utilized in
concrete mixtures as a good substitute for natural river sand with additional
strength than control concrete.

3
J. Simson Jose and Mr. M. Balasubramanian “ Experimental Investigation on
Characteristics of Polythene Waste Incorporated Concrete “ International
journal of Engineering Trends and Technlogy(IJETT) – Volume 10 number 7 –
Apr 2014.

The Disposal of large quantity of plastic cover may cause pollution of land,
water bodies and air. The proposed concrete which is made up by adding plastic in
concrete may help to reuse the plastic cover as one of the constituent’s material of
concrete, to improve the certain properties of concrete. The properties of concrete
as varying percentages of plastic will test for compressive strength and Split tensile
strength and flexural strength shows that an appreciable improvement in tensile
strength of concrete can be achieved by introducing cut pieces of plastic cover.
This paper presents the experimental investigation of feasibility of polythene cover
post consumer waste used for food packaging. The numbers of samples is prepared
in M25 concrete mix with required water/ cement ratio. Plastic waste was
converted in to fiber size form and added waste for three aspect ratios, is casted
into desire shape and size as per requirement of the tests. Each specimen was cured
for 7 days, 14 days, and 28 days. The workability of compression, tension and
flexural tests were carried out. The results are compared with normal concrete was
observed.

4
M. Raghatate Atul “Use of plastic in a concrete to improve its properties
“International Journal of Advanced Engineering Research and Studies,
E-ISSN2249–8974

Plastic bags which are commonly used for packing, carrying vegetables,
meat etc creates a serious environmental problem. Plastic bag last in environment
up to 1000 years because of plastic bag last so long the number of plastic bag
accumulated increases each year. Disposal of large quantity of plastic bag may
cause pollution of land, water bodies and air. The proposed concrete which is made
up by adding plastic in concrete may help to reuse the plastic bag as one of the
constituent’s material of concrete, to improve the certain properties of concrete.
The properties of concrete containing varying percentages of plastic were tested for
compressive strength and Split tensile strength and shows that an appreciable
improvement in tensile strength of concrete can be achieved by introducing cut
pieces of plastic bags.

5
 CHAPTER 3

MATERIALS USED IN CONCRETE

3.1 MATERIALS

 Cement
 Fine aggregate (crusher sand)
 Coarse aggregate
 Plastic waste fibres

3.1.1 CRUSHER SAND

All along in India we have been using natural sand. The volume of concrete
manufactured in India has not been much when compared to some advanced
countries. The infrastructure development such as express highway projects, power
projects and industrial development have started now. Availability of natural sand
is getting depleted and also it is becoming costly. Concrete industry now will have
to go for crusher sand or manufactured sand.
An advantage of natural sand is that the particles are cubical or rounded with
smooth surface texture. The grading of natural fine aggregate is not always ideal. It
depends from place to place. Being cubical rounded and smooth texture it gives
good workability.
So far, crusher sand has not been used much in India for the reason that
ordinarily crusher sand is flaky, badly graded rough texture and hence they in
production of harsh concrete for the given design parameters. For the last 4-5 years
the old methods of manufacturing ordinary crusher sand have been replaced by
modern crushers specially designed for producing cubical, comparatively smooth
textured, well graded sand, good enough to replace natural sand.

6
 CHAPTER 4

METHODOLOGY

LITERATURE REVIEW

STUDY OF LITERATURES

COLLECTION OF MATERIALS

MATERIAL TEST

PREPARATION OF MIX DESIGN

*****

CASTING OF CUBES

REPLACEMENT OF SAND
WITH ECOSAND
COMPRESSION, FLEXURAL AND
SPLIT TENSILE TESTS

RESULT ANALYSIS

8
 CHAPTER 5

ENGINEERING PROPERTIES

5.1 PHYSICAL PROPERTIES OF CRUSHER SAND

Properties Value

Colour Grey

Particle shape More cubical than rounded

Specific gravity 2.54-2.8

Bulk density 1600- 1810 kg/m3

Absorption in % 1.2-1.5

Free moisture content in % Nil

Fine particles less than 0.0075mm in % 12-15

Sieve analysis Zone II

Manufactured as per IS,BS,ASTM

Product
standards

Table 1 - Physical Properties of Crusher sand

9
5.2 CHEMICAL COMPOSITION OF CRUSHER SAND

Constituent Value in %

SiO2 62.48

Al2O3 18.72

Fe2O3 06.54

CaO 04.83

MgO 02.56

Na2O Nil

K2O 03.18

TiO3 01.21
Table 2 - Chemical Composition

5.3 PROPERTIES OF PLASTIC BAGS

Properties Results

Thickness 40 microns

Density 1.4 gm/cc

Type Polythene film

Category Non recyclable plastic bags

Table 3 - Properties of plastic bags

10
 CHAPTER 6

CRUSHER SAND CONCRETE

6.1 INTRODUCTION

Crusher sand concrete is a recent development in concrete technology.

Crusher sand concrete is not a commodity but a range of products each specifically
designed to satisfy in the most effective way.
Recently, this concrete is referred as crusher sand concrete. ACI defines
crusher sand concrete as specially engineered concrete. Crusher sand concrete has
a low workability and which receive an adequate admixtures possessing the
following three characteristics high workability, high strength and high durability.

6.2 PROPORTIONING OF CONCRETE MIXES USING CRUSHER SAND

Crusher sand concrete mix proportions chosen should be such that the
concrete is of adequate workability for the placing condition of the concrete and
can be properly compacted with the means available. Hardened state concrete
should have required strength, durability and surface finish. Fine aggregate is one
of the important constituents of concrete. The use of crusher sand as a replacement
of fine aggregate in concrete receiving increased attention.

6.3 MECHANISM OF CRUSHER SAND CONCRETE

Concrete is a three phase composite material the first two phases are
aggregates and bulk hydrated cement paste, the third phase being transition zone is
the interfacial region between the aggregate particles in concrete. The proper
shape, surface texture, desirable grading to minimize void content, a highly
workable mix with given parameter of mix design was achieved in crusher sand
concrete.

11
6.4 PROPERTIES OF CRUSHER SAND CONCRETE

The mix must be sufficiently workable for the solids to disperse in such a
manner that dense packing is achieved which requires de-flocculation of cement
particles. The variation of workability of fresh concrete is measured in terms of
slump value. For the given water - cement ratio, the highest slump and compaction
factors were recorded for the mixes designed by IS method. The overall
workability value of crusher sand concrete is less when compared to conventional
concrete. If we want more workability in crusher sand concrete use the
recommended admixtures. The workability influenced greatly by particle size
distribution, particle packing affect the voids present in the solid system. Typical
concrete mixtures don’t have an optimum particle size distribution and this
accounts undesirably high water requirement to achieve certain workability.

12
 CHAPTER 7

PLASTIC FIBERS CONCRETE

7.1 PLASTIC WASTE CONSUMPTION (P/C/YEAR)

The comparison of per capita plastic consumption per year in India with rest
of the world is given below.

Country/Continent Per Year Consumption(tonnes)

India 6.0

East Europe 10.0

South East Asia 10.0

China 24

West Europe 65.0

North America 90.0

World Average 25.0

Table 4 - Plastic Waste Consumption (P/C/YEAR)

7.2 PLASTIC FIBRE CONCRETE

In order to increase the strength of the concrete, fibres can be added in the
concrete. In his project we have used polythene bags as fibre in concrete. The
ordinary polythene plastic film having thickness of 40 microns is collected and
investigation for the plastic waste classification, category and density is checked
before the use. The film should be made as four folding and required temperature
of heat should be given and melted. Hand cut is made for length 3cm.

13
 CHAPTER 8

EXPERIMENTAL INVESTIGATION

8.1 GENERAL

In this chapter, crusher sand is used for concrete and the plastic fibres are
added to check the strength. The compressive, flexural and split tensile strength of
crusher sand concrete and plastic fibre concrete is compared.

8.2 SELECTION OF MATERIALS

8.2.1 CEMENT

PPC (Portland Pozzolana Cement) was used for the entire

investigation. The required quantity was stored in airtight bags and used for the
experimental program. The High Strength concrete incorporates Chemical
admixture. Therefore, the cement should not be affected by these chemicals. It is
finely ground material which on addition of requisite quality of water is capable of
hardening both under water and air by the chemical interaction of its constituents
with water.
The Cement is classified into three grades namely 33 Grade, 43 Grade, 53
Grade depending upon the strength of 28 days. It is possible to upgrade the
qualities of cement by using high quality limestone, modern equipments,
maintaining better particle size distribution, finer grinding and better packing.
Generally use of high grade cement offers many advantages for making stronger
concrete. Although they are little costlier than low grade cement, they offer 10-
20% saving in cement consumption and also they offer many hidden benefits. One
of the most important benefits is the faster rate of development of strength. The
various tests conducted on cement are initial and final setting time, specific

14
 Weight of the sample taken = 1000gm

IS Weight Cumulative %
Percentage Percentage of
S.No sieve Retained of weight
Retained (gm) Fineness
(mm) (gm) retained

1 4.75 3.5 0.35 0.35 99.65

2 2.36 4 0.4 0.75 99.25

3 1.18 184.5 18.45 19.2 80.80

4 600 µ 233.5 23.35 42.55 57.45

5 300 µ 217.5 21.75 64.30 35.70

6 150 µ 250 25 89.30 10.70

7 75 µ 75.5 7.55 96.85 3.15

8 PAN 31.5 3.15 100 0

Table 7 - Sieve Analysis Report(Fine Aggregate)

Figure 4 - Particle Size Distribution

17
S.No Properties Value

1 Specific Gravity 2.72

2 Crushing value 17%

3 Void Ratio 0.7

4 Fineness Modulus 4.14

5 Impact value 24.61%

6 Bulk Density 1656.25 kg/m3

Table 8 - Properties of Coarse Aggregate

8.2.4 PLASTIC BAGS

We have used shopping bags of 40 microns in this project. It has been

selected according to the Plastic Identification Codes.

8.2.5 WATER

Water is an important ingredient of concrete as it actively participating in the

chemical reaction of the cement. The strength of cement comes mainly from the
binding action of the hydration of cement get the requirement of water should be
reduced to that required chemical un hydrated cement as the access water would
end up in only formation undesirable voids or capillaries in the hardened cement
paste in the concrete.
 It is important to have compatibility between the cement and the chemical
materials along with the water used from mixing.

19
 High content of cement is susceptible to a rapid loss of workability on
account of higher amount of head of hydration generated. Therefore,
attention is required to see that the initial hydration rate of cement
significantly affected.
 The salt in water would not interface with the development of strength of
later ages.
 Apart from the strength considerations, the durability characteristics such as
porosity, degree of resistance to diffusion of CO2, CaSO4 moisture, air
oxygen, etc. should also be investigated after specified curing period.

20
 CHAPTER 9

CONCRETE MIX DESIGN

9.1 GENERAL

Mix design is the process of selecting suitable ingredient of concrete and

determines their relative proportions with the object of certain minimum strength
and durability as economically a possible.

9.2 OBJECTIVES OF MIX DESIGN

The objective of concrete mix design is as follows.

 The first objective is to achieve the stipulated minimum strength.
 The second objective is to make the concrete in the most economical
manner. All concrete’s depend primarily on two factors, namely cost of
materials and cost of labour.
 Since the cost of cement is many times more than the cost of their
ingredients, optimum usage of cement is sought for by designing the mix.

9.3 MIX DESIGN AS PER IS: 10262-1982

The following basic data are required for design of a concrete mix.
 Characteristics compressive strength of concrete
 Degree of workability desired
 Max water cement ratio of coarse aggregate
 Type and max size of coarse aggregate
 Standard deviation - based on concrete control
 Statistical constant - accepted
 Grade of cement used

21
9.4 MIX DESIGN CALCULATION

Target strength for mix proportioning

f’ck = fck + 1.65s

= 20 + (1.65 x 4)
= 26.6 N/mm2
Where,
f’ck is target average compressive strength at 28 days
fck is characteristic compressive strength at 28 days
S is Standard Deviation
S value is referred from IS 10262:2009 ; table – 1
S = 4 N/mm2
Target strength is 26.6 N/mm2
Selection of water-cement ratio

From table 5 of IS456,

Maximum water-cement ratio is 0.55.
Let’s adopt, water-cement ratio as 0.50.
0.50 < 0.55 , hence ok.
Selection of water content

From table 2 of IS10262,

Maximum water content for 20mm aggregate = 186 litre (for 25 to 50 mm
slump range)
Estimated water content for 75mm slump = 186 +

Water content = 192 litre

22
Calculation of cement content

Water-cement ratio is 0.50

Cement content = = 384 Kg/m3

Proportion of volume of coarse aggregate and fine aggregate

From table 3 of IS10262,

Volume of coarse aggregate corresponding to 20mm size aggregate and fine
aggregate (zone II) for water-cement ratio of 0.50 is 0.62.
Volume of coarse aggregate = 0.62
Volume of fine aggregate = 1 – 0.62 = 0.38
Mix calculations

a) Volume of concrete = 1m3

b) Volume of cement =

= 0.123 m3

c) Volume of water =

= 0.192 m3
d) Volume of all in aggregate = [a - (b + c)]
= [1 – (0.123 + 0.192)]
= 0.685 m3
e) Mass of coarse aggregate = e x volume of CA x sp. gr. CA x 1000
= 0.685 x 0.62 x 2.72 x 1000
= 1146.69 Kg/m3

23
 f) Mass of fine aggregate = e x volume of FA x sp. gr. FA x 1000
= 0.685 x 0.38 x 2.6 x 1000
= 676.78 Kg/m3
Mix proportions for 1 m3
Cement = 384 Kg/m3
Water = 192 Kg/m3
Fine aggregate = 676.78 Kg/m3
Coarse aggregate = 1146.69 Kg/m3
Water-cement ratio = 0.50

Mix ratio
Cement: Fine aggregate: Coarse aggregate
384: 676.78: 1146.69
1: 1.76: 2.98

Quantities for 1 cube (150mm x 150mm)

Cement = 1.27 Kg
Water = 0.648 Kg
Fine aggregate = 2.28 Kg
Coarse aggregate = 3.87 Kg

Quantities for 1 beam (500mm x 100mm x 100mm)

Cement = 1.92 Kg
Water = 0.6 Kg
Fine aggregate = 3.38 Kg
Coarse aggregate = 5.73 Kg

24
Quantities for 1 cylinder (Diameter = 150mm, Height = 300mm)
Cement = 2.035 Kg
Water = 1.018 Kg
Fine aggregate = 3.58 Kg
Coarse aggregate = 6.079 Kg

PERCENTAGES OF PLASTIC FIBERS ADDED IN CONCRETE

Percentages of
Plastic Fibres Cube Beam Cylinder

0.2% 16.2 gm 23.9 gm 25.4 gm

0.6% 48.5 gm 72 gm 76.3 gm

1% 80 gm 120 gm 127.1gm

Table 9 - Percentages of plastic fibres added in concrete

25
 CHAPTER 10

EXPERIMENTAL STUDY

10.1 CASTING OF SPECIMEN

1. The standards moulds are used to cast cubes, beams and cylinders.
2. The required proportions of the available materials are weighed in proper
manner.
3. After weighing, the raw materials are put into the mechanical mixer device
and given a dry mix for five minutes.
4. The water is added to the mix as specified in the mix design.
5. Before placing the concrete, the surface of the mould is cleaned and waste
oil is applied.
6. The workable concrete is placed in the mould and is it hand compacted or
compaction by vibration is given.
7. After compacting, the scoop is required to be moved around the top edge of
the mould and the concrete is brought to the finished level using a trowel.
8. After casting of cubes, beams, cylinders, the next day it should be placed for
curing till 7th, 14 th and 28 th days.

10.2 COMPRESSIVE STRENGTH

Compressive strength test was carried out on 150mm x 150mm x 150mm

specimen for three cubes on adding various percentages of plastic fibres. Strength
of each cube was evaluated after 7, 14, 28 days respectively.

26
 The compressive strength of crusher sand concrete and percentage of fibre
used concrete as conducted for 3cm length is shown in the following table.

Cross Compressive
Days of Ultimate
Description Sectional Strength
Testing Load (kN)
Area (mm2) (N/mm2)

Crusher Sand
7 650 22500 28.88
Cube

14 760 22500 33.77

28 870 22500 38.66

Plastic Fiber
0.2% 7 790 22500 35.11

14 900 22500 40.00

28 1010 22500 44.89

0.6% 7 760 22500 33.77

14 800 22500 35.56

28 840 22500 37.33

1% 7 580 22500 25.77

14 640 22500 28.44

28 700 22500 31.11

Table 10 - Compressive strength on concrete cubes for 7, 14 and 28 days

testing

28
 The flexural strength of crusher sand concrete and percentage of fibre used
concrete is conducted for 3cm length is given below.

Cross Flexural
Days of Ultimate
Description Sectional Strength
Testing Load (kN)
Area (mm2) (N/mm2)

Crusher Sand
7 18.00 50000 09.00
Concrete

14 20.40 50000 10.20

28 23.00 50000 11.50

Plastic Fiber
0.2% 7 14.50 50000 09.99

14 19.98 50000 12.00

28 24.00 50000 12.75

0.6% 7 11.60 50000 05.80

14 16.00 50000 08.00

28 25.00 50000 12.50

1% 7 10.00 50000 05.00

14 17.00 50000 08.50

28 25.50 50000 12.85

Table 11 - Flexural strength on concrete beams for 7, 14 and 28 days

testing

30
 The Split tensile strength of crusher sand concrete and percentage of fibre
used concrete as conducted for 3cm length is shown in the following table.

Cross Split Tensile

Days of Ultimate
Description Sectional Strength
Testing Load (kN)
Area (mm2) (N/mm2)

Crusher Sand
Cylinder 7 200 176.64 x 103 02.83

14 280 176.64 x 103 03.96

28 360 176.64 x 103 05.09

Plastic Fiber
0.2% 7 200 176.64 x 103 02.83

14 240 176.64 x 103 03.39

28 280 176.64 x 103 03.96

0.6% 7 140 176.64 x 103 01.98

14 190 176.64 x 103 02.68

28 240 176.64 x 103 03.39

1% 7 360 176.64 x 103 05.09

14 490 176.64 x 103 06.93

28 620 176.64 x 103 08.77

Table 12 - Split Tensile strength on concrete cylinders for 7, 14 and 28
days testing

32
 CHAPTER 11

CONCLUSION

Based on the results of the experimental investigation following conclusions

are drawn:

 The compressive strength has increased by 16% with the use of 0.2%
addition of plastic fibers. With increase of plastic fibers up to 1% decreasing
compressive strength to 19%.
 The Flexural strength has increased by 12% with the use of 1% addition of
plastic fibers.
 The Split Tensile strength has increased by 72% with the use of 1% addition
of plastic fibers.
 The quarry dust is cheaper and available so we can replace quarry dust
according to the needs.
 The concrete mix with plastic fiber in crusher sand concrete have more
flexural and split tensile strength when compared to crusher sand concrete.
 The increase in the various mechanical properties of the concrete mixes with
polythene fibers is not in same league as that of the steel fibers.
 Crusher sand concrete with addition of plastic fibres is more environ-
friendly and has the potential to reduce the plastic wastes.

34
 CHAPTER 12

BIBLIOGRAPHY

1. M.S. Shetty(2004).” Concrete Technology”, Theory and practices, 5th

edition, S.Chand & company Ltd.
2. A.K.Sahu, Sunil kumar and A.K.Sachan, “Crusher stone waste as fine
aggregate for concrete”, The Indian Concrete Journal, January 2003.
3. Raghatate Atul. M , “Use of plastic in a concrete to improve its
properties” vol 1, Issue 3, April – June 2012.
4. J. Simson Jose, Mr. M. Balasubramanian, “Experimental Investigation on
Characteristics of Polythene Waste Incorporated Concrete”,
International Journal of Engineering Trends and Technology (IJETT) –
Volume 10 Number 7 - Apr 2014.
5. Amit Gawandea, ”An overview on waste plastic utilization in asphalting
of roads” Journal of engineering research and studies, vol 3,April- june
2012.
6. Bhogayata1, “Performance of concrete by using Non recyclable plastic
wastes as concrete constituent”, International Journal of Engineering
Research & Technology(IJERT), vol 1, June 2012.
7. N. K. Arora, ”Feasibility of Waste Metallised Polythene Used As
Concrete Constituent” International Journal of Engineering and Advanced
Technology(IJEAT), vol 1, June 2012.
8. P.Muthupriya, K. Subramanian, B.G. Vishuram, “Experimental
investigation on high performance reinforced concrete column with
silica fume and fly ash as admixtures” Journal of Structural engineering,
vol 38, April – May 2011.

35
CODE BOOKS
1. IS 456:2000 - Indian standard “Plain and reinforced concrete”- code of
practice Bureau of Indian Standards.
2. IS 383 – 1970, IS 10262 – 1982, “ Recommended guidelines for concrete
mix design”.
3. IS 516:1959 - Indian standard “Methods of testing the strength of concrete”
4. IS 2386(PART 3) – “Method of test for Aggregates for Concrete”
5. Plastic Identification Codes for SELECTION OF PLASTIC BAGS.

36