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Construction
and Building

Construction and Building Materials 23 (2009) 703–712


MATERIALS
www.elsevier.com/locate/conbuildmat

Production of low cost self compacting concrete using bagasse ash


Tayyeb Akram, Shazim Ali Memon *, Humayun Obaid
National Institute of Transportation (NIT), National University of Sciences and Technology (NUST), Risalpur Cantonment, Risalpur, N.W.F.P., Pakistan

Received 10 August 2007; received in revised form 2 February 2008; accepted 19 February 2008
Available online 18 April 2008

Abstract

Self compacting concrete (SCC) is a development of conventional concrete, in which the use of vibrator for compaction is no more
required. This property of self compacting concrete has made its use more attractive all over the world. But its initial higher supply cost
over conventional concrete, has hindered its application to general construction. Therefore, for producing low cost SCC, it is prudent to
look at the alternates to help reducing the SSC cost. This research is aimed at evaluating the usage of bagasse ash as viscosity modifying
agent in SCC, and to study the relative costs of the materials used in SCC.
In this research, the main variables are the proportion of bagasse ash, dosage of superplasticizer for flowability and water/binder
ratio. The parameters kept constant are the amount of cement and water content.
Test results substantiate the feasibility to develop low cost self compacting concrete using bagasse ash. In the fresh state of con-
crete, the different mixes of concrete have slump flow in the range of 333 mm to 815 mm, L-box ratio ranging from 0 to 1 and flow
time ranging from 1.8 s to no flow (stucked). Out of twenty five different mixes, five mixes were found to satisfy the requirements
suggested by European federation of national trade associations representing producers and applicators of specialist building prod-
ucts (EFNARC) guide for making self compacting concrete. The compressive strengths developed by the self compacting concrete
mixes with bagasse ash at 28 days were comparable to the control concrete. Cost analysis showed that the cost of ingredients
of specific self compacting concrete mix is 35.63% less than that of control concrete, both having compressive strength above
34 MPa.
Ó 2008 Elsevier Ltd. All rights reserved.

Keywords: Self compacting concrete; Sugarcane; Bagasse; Bagasse ash; Compressive strength

1. Introduction to enhance stability [7–9]. The use of VMA along with ade-
quate concentration of superplasticizer (SP) can ensure
A self compacting concrete (SCC) is defined as a con- high deformability and adequate workability, leading to a
crete that has excellent deformability and high resistance good resistance to segregation. However, viscosity modify-
to segregation and can be filled in heavily reinforced or ing admixtures are very expensive and can increase the cost
restricted area without applying vibration. SCC was devel- of concrete.
oped in Japan [1] in the late 1980s, and recently, this con- One alternative approach to achieve self-consolidating
crete has gained wide use in many countries for different property is to increase significantly the amount of fine
applications and structural configurations [2–6]. materials such as bagasse ash without increasing the
Several different approaches have been used to develop cost.
SCC. One method to achieve self-consolidating property This paper presents the results of research aimed to
is to incorporate a viscosity modifying admixture (VMA) investigate the suitability of bagasse ash as a viscosity mod-
ifying agent in SCC. The utilization of bagasse ash in SCC
mix produced desired results, reduced cost, and also pro-
*
Corresponding author. Tel.: +92 923 200123; fax: +92 923 631594. vided an environment friendly disposal of agro-industry
E-mail address: shazim_memon@yahoo.com (S.A. Memon). waste product.

0950-0618/$ - see front matter Ó 2008 Elsevier Ltd. All rights reserved.
doi:10.1016/j.conbuildmat.2008.02.012
704 T. Akram et al. / Construction and Building Materials 23 (2009) 703–712

2. Potential of bagasse usage in Pakistan residual ash [12]. Therefore, Pakistan consumes approxi-
mately 42 million tons of sugarcane in the sugar manufac-
2.1. Sugarcane crop yield and sugar production turing industry, and produces approximately 11 million
tons of bagasse, with a capacity of generating over 0.26
In order to assess the potential of bagasse ash produc- million tons of bagasse ash.
tion in Pakistan, it is imperative to evaluate the sugarcane
crop yield in the country. Table 1 shows the sugarcane crop 2.2. Cogeneration of electricity using bagasse
yield and its utilization from 1999 to 2004 [10]. From sta-
tistics, it is clear that from 2002 to 2004 that the annual World Alliance for decentralized energy [13] highlighted
sugarcane produced is over 52 million tons. Approxi- abundant opportunity for the wider use of bagasse-based
mately, 81% of the sugarcane is used in sugar industry cogeneration in sugarcane producing countries. Yet this
[11]. Each ton of sugarcane produces approximately 26% potential remains largely unexploited in the world’s main
of bagasse (at a moisture content of 50%) and 0.62% of cane producing countries: Brazil, India, Thailand, Paki-

Table 1
Sugarcane yield in Pakistan during last five years
Year Province Mills No. Cane production Cane crushed Sugar production Recovery percentage
Million tons Million tons Million tons
1999–2000 Punjab 37 25.00 16.83 1.316 7.8
Sind 25 12.10 10.86 0.996 9.2
NWFP 5 4.90 1.30 0.103 7.9
Balochistan 0 0.04 0.00 0
Total 67 42.04 28.99 2.415 8.3
2000–2001 Punjab 35 26.74 18.07 1.437 8
Sind 25 12.05 10.49 0.968 9.2
NWFP 5 4.80 0.85 0.061 7.2
Balochistan 0 0.03 0.00 0
Total 65 43.62 29.41 2.466 8.1
2001–2002 Punjab 37 31.80 25.25 2.152 8.5
Sind 27 11.42 10.16 0.941 9.3
NWFP 5 4.79 1.29 0.105 8.1
Balochistan 0 0.04 0.00 0 0
Total 69 48.05 36.07 3.198 8.6
2002–2003 Punjab 38 33.17 27.58 2.351 8.5
Sind 28 13.80 12.42 1.159 9.3
NWFP 5 5.05 1.79 0.145 8.1
Balochistan 0 0.03 0.00 0 0
Total 71 52.05 41.79 3.655 8.7
2003–2004 Punjab 38 34.42 28.60 2.599 9.1
Sind 28 14.61 12.99 1.221 9.4
NWFP 5 4.75 2.07 0.176 8.5
Balochistan 0 0.04 0.00 0 0
Total 71 53.82 43.66 3.996 9.5

Table 2
Global bagasse cogeneration – market potential
Countries Sugarcane production Share of global cane Potential for Present national Bagasse cogeneration
(Million tons/year) production (%) electricity (GWh) electricity demand potential as percentage
(TWh) of electricity demand
Brazil 366.32 28.60 38.62 335.90 11.50
India 290.00 21.48 29.00 497.20 5.83
Thailand 74.07 5.49 7.47 90.91 8.15
Pakistan 52.05 3.88 5.20 62.27 8.36
Mexico 45.12 3.34 4.51 186.70 2.42
Colombia 38.80 2.71 3.88 39.81 9.91
Cuba 34.70 2.57 3.47 13.38 25.93
Philippines 25.83 1.91 2.58 42.04 6.15
Total 944.62 69.96 94.48 1268.21 7.45
T. Akram et al. / Construction and Building Materials 23 (2009) 703–712 705

Table 3
Mix design of concrete mixes
a b
Mix Water/binder Water Cement Bagasse Fine Coarse Sikament NN Sika Viscocrete-1
design ratio (kg/m3) (kg/m3) ash aggregate aggregate (% by weight (% by weight
(kg/m3) (kg/m3) (kg/m3) of binder) of binder)
c
CC2SP 0.45 225 500 – 875 750 2 2
CC2.5SP 0.45 225 500 – 875 750 2.5 2
CC3SP 0.45 225 500 – 875 750 3 2
CC3.5SP 0.45 225 500 – 875 750‘ 3.5 2
CC4SP 0.45 225 500 – 875 750 4 2
d
5B2SP 0.43 225 500 25 875 750 2 –
5B2.5SP 0.43 225 500 25 875 750 2.5 –
5B3SP 0.43 225 500 25 875 750 3 –
5B3.5SP 0.43 225 500 25 875 750 3.5 –
5B4SP 0.43 225 500 25 875 750 4 –
10B2SP 0.41 225 500 50 875 750 2 –
10B2.5SP 0.41 225 500 50 875 750 2.5 –
10B3SP 0.41 225 500 50 875 750 3 –
10B3.5SP 0.41 225 500 50 875 750 3.5 –
10B4SP 0.41 225 500 50 875 750 4 –
15B2SP 0.39 225 500 75 875 750 2 –
15B2.5SP 0.39 225 500 75 875 750 2.5 –
15B3SP 0.39 225 500 75 875 750 3 –
15B3.5SP 0.39 225 500 75 875 750 3.5 –
15B4SP 0.39 225 500 75 875 750 4 –
20B2SP 0.37 225 500 100 875 750 2 –
20B2.5SP 0.37 225 500 100 875 750 2.5 –
20B3SP 0.37 225 500 100 875 750 3 –
20B3.5SP 0.37 225 500 100 875 750 3.5 –
20B4SP 0.37 225 500 100 875 750 4 –
a
Second generation of superplasticizer, used as high range water reducing admixture, from sika construction chemicals, Switzerland.
b
Third generation of superplasticizer, used as viscosity modifying agent, from sika construction chemicals, Switzerland.
c
This particular designation represents control concrete mix made by incorporating viscosity modifying admixture and having 2% of superplasticizer by
weight of binder content.
d
In 5B2SP, 5B refers to the percentage of the bagasse ash by weight of binder content and 2SP refers to the amount of superplasticizer in percent by
weight of binder content. This particular designation represents mix having 5% of bagasse ash with 2% of superplasticizer by weight of binder content.

stan, Mexico, Cuba, Colombia and Philippines. The major approved 700 MW electricity generation using bagasse as
sugarcane producing countries and their bagasse cogenera- fuel [14]. The decision would result in production of large
tion potentials are enumerated in Table 2. Bagasse cogene- amount of ash and associated problem of its disposal. It
ration could account for almost 26% of Cuba’s national further highlights the importance of evaluation, regarding
electricity demand. Similarly, bagasse cogeneration could environment friendly utilization of bagasse ash by the con-
account for over 8% of Pakistan’s national electricity crete industry in Pakistan.
demand. In first phase, Government of Pakistan has

3. Experimental investigation
Table 4
Chemical and physical properties of cementitious materials For the entire experiment work, twenty five different
Chemical composition (%) OPC Bagasse ash mixes were prepared. These include five control concrete
Silicon dioxide (SiO2) 19.00 62.44 mixes and twenty mixes with different proportions of
Aluminum oxide (Al2O3) 09.87 6.74 bagasse ash. The experimental matrix for the mix design
Ferric oxide (Fe2O3) 03.46 5.77 is summarized in Table 3.
Calcium oxide (CaO) 60.00 6.16
Magnesium oxide (MgO) 01.63 2.97
Sulfur trioxide (SO3) 02.63 0.72 3.1. Materials
Sodium oxide (Na2O) 00.84 3.15
Potassium oxide (K2O) 01.19 6.87
Moisture content – 2.6 Through out the experimental work ordinary Portland
Loss on ignition 01.03 2.58 cement confirming to ASTM C150 [15] was used. The
Physical property OPC Bagasse ash chemical and physical properties of cement are tabulated
Specific gravity 3.10 2.22 in Table 4.
706 T. Akram et al. / Construction and Building Materials 23 (2009) 703–712

The sieve analysis of fine and coarse aggregate was per- Table 6
formed in accordance with ASTM C136-04 [16]. The Technical data of Sikament NN and Sika Viscocrete 1
results of sieve analysis of fine and coarse aggregate as Sikament NN Sika Viscocrete-1
compared with the requirement of ASTM C33-03 [17] are Type Naphthalene formaldehyde Modified polycarboxylate
shown in Figs. 1 and 2. The physical properties of fine sulphonate
and coarse aggregate are summarized in Table 5. Appearance Dark brown Green liquid
Density (kg/l) 1.2 1.1
To achieve superior workability and placeability, high
range water reducing concrete admixture, Sikament NN
was used. The dosage of superplasticizer was varied from
2% to 4% by weight of binder content. The technical data
of Sikament NN is illustrated in Table 6.
For control concretes, Sika Viscocrete-1 was used as vis-
cosity modifying agent. It is a third generation of superp-
lasticizer and meets the requirements for superplasticizer
according to SIA 162 (1989) and prEN 934-2. The dosage
of superplasticizer was kept as 2% by weight of binder con-
tent. The technical data of Sika Viscocrete-1 is illustrated in
Table 6.

Fig. 3. L-box apparatus.

Fig. 1. Grading of fine aggregate.

Fig. 2. Grading of coarse aggregate.

Table 5
Physical properties of fine and coarse aggregate
Unit weight Bulk specific gravity Absorption Fineness
(Kg/m3) (SSD) modulus
1953.54 2.671 1.65 2.62
1529.28 2.678 1.07 –
Fig. 4. V-funnel apparatus.
T. Akram et al. / Construction and Building Materials 23 (2009) 703–712 707

For mixes other than control concrete, bagasse ash from by using compaction factor apparatus as described by Nev-
Premier sugar mills, Pakistan, was used as viscosity modi- ille [18]. Compressive strength of cylinders at 7 and 28 days
fying agent. The chemical and physical properties of was carried out according to ASTM C39 [19]. Brief expla-
bagasse ash are tabulated in Table 4. nation and illustration of L-box and V-funnel test is given
below.
3.2. Specimens designation
3.3.1. L-box test
The various mixes used in this experimental program are It assesses filling and passing ability of SCC. The appa-
abbreviated in two different forms, namely CC2SP and ratus is shown in Fig. 3. The vertical section is filled with
5B2SP. In case of CC2SP, CC refers to the control concrete concrete, and then gate lifted to let the concrete flow into
mix made by incorporating viscosity modifying admixture the horizontal section. When the flow has stopped, the
and 2SP refers to the amount of superplasticizer in percent heights ‘H1’ and ‘H2’ are measured as shown in Fig. 3. Clo-
by weight of binder content. This particular designation ser to unity value of ratio ‘H2/H1’ indicates better flow of
represents control concrete mix made by incorporating vis- concrete [20].
cosity modifying admixture and having 2% of superplasti-
cizer by weight of binder content. 3.3.2. V-funnel test
Similarly, in 5B2SP, 5B refers to the percentage of the The test measures flowability and segregation resistance
bagasse ash by weight of binder content and 2SP refers of concrete. The apparatus is shown in Fig. 4. At first, the
to the amount of superplasticizer in percent by weight of test assembly is set firmly on the ground and the inside sur-
binder content. This particular designation represents mix faces are moistened. The trap door is closed and a bucket is
having 5% of bagasse ash with 2% of superplasticizer by placed underneath. Then the apparatus is completely filled
weight of binder content. with concrete without compacting. After filling the con-
crete, the trap door is opened and the time for the discharge
3.3. Testing of specimens is recorded. This is taken to be when light is seen from
above through the funnel. To measure the flow time at
For each mix, slump flow, L-box and V-funnel test were T5 min, the trap door is closed and V-funnel is refilled imme-
carried out. The density of fresh concrete was determined diately. The trap door is opened after 5 min and the time

Fig. 5. Bagasse ash vs. slump with different percentage of superplastizer.


708 T. Akram et al. / Construction and Building Materials 23 (2009) 703–712

Fig. 6. Bagasse ash vs. L-box ratio with different percentage of superplastizer.

Fig. 7. Bagasse ash vs. V-funnel flow with different percentage of superplastizer *Mix 20B2SP was stucked.
T. Akram et al. / Construction and Building Materials 23 (2009) 703–712 709

for the discharge is recorded. This is the flow time at T5 min. and without any blockage. The results of L-box test show
Shorter flow time indicate greater flowability [20]. that the ratio of L-box increased with the increase in the
quantity of superplasticizer used for flowability. Propor-
4. Test results and discussions tionally, the ratio decreased with the increased quantity
of bagasse ash. The experimental readings achieved in the
4.1. Properties of fresh SCC L-box test were from 0 to 1. L-box test results are shown
in Fig. 6.
Properties of freshly mixed concrete were tested for qual-
ifying within the specified EFNARC range of SCC [20]. 4.1.3. V-funnel test
As far as filling ability of the mixes was concerned, most
4.1.1. Slump flow test of the results of V-funnel tests remained more towards the
The slump flow for all control concrete mixes were minimum range or even lesser. This showed more filling
within the EFNARC range of SCC, whereas, for SCC ability but less viscous mix. But as the quantity of bagasse
mixes with bagasse ash, the slump flow was between 333 ash was increased, the viscosity of the mix started increas-
mm to 815 mm, which have exceeded both the minimum ing. V-funnel test results are shown in Fig. 7.
and maximum range. The results of slump flow show that
the flow increased with the increase in the quantity of 4.1.4. V-funnel at T5 min test
superplasticizer used for flowability. Proportionally, the V-funnel at T5 min test shows the potential to segregation
flow decreased with the increased quantity of bagasse resistance. The results of this test remained very encourag-
ash. Slump flow results are shown in Fig. 5. ing and within the EFNARC range. V-funnel at T5 min test
results are shown in Fig. 8.
4.1.2. L-box test Properties of freshly mixed concrete, which qualified all
While testing the concrete for passing ability, few of the the four tests range limits, were five in numbers. Among
mixes were so viscous that they could not even reach the them were 10B2.5SP, 15B2.5SP, 15B3SP, 20B3.5SP and
other end of the horizontal section of the L-box, whereas, 20B4SP. The concrete mixes which remained very close
majority of the mixes passed through the bars very easily to the EFNARC range were also five. They were CC2SP,

Fig. 8. Bagasse ash vs. V-funnel at T5 min with different percentage of superplastizer *Mix 15B2SP and 20B2SP were stucked.
710 T. Akram et al. / Construction and Building Materials 23 (2009) 703–712

Fig. 9. Superplastizer vs. compressive strength with different percentage of bagasse ash.

Fig. 10. Bagasse ash vs. compressive strength with different percentage of superplastizer.
T. Akram et al. / Construction and Building Materials 23 (2009) 703–712 711

5B2.5SP, 5B3SP, 10B3SP and 10B3.5SP. Four mixes were irrespective of the fact that the mix was within the EFN-
totally out of the range for all four tests. They were ARC range or not.
10B2SP, 15B2SP, 20B2SP and 20B2.5SP.
4.3. Density of hardened SCC
4.2. Compressive strength of SCC
Densities of all the mixes are shown graphically in
The compressive strengths of 25 mixes for 7 and 28 days Fig. 11. The density increased with the increase in the con-
are graphically in Figs. 9 and 10. From Fig. 9, it is clear tent of bagasse ash and reached the maximum value when
that among the five control concrete mixes, the control 15% of bagasse ash was used. This is due to micro filler
concrete CC2SP developed highest compressive strength effect caused by bagasse ash. The decrease in density of
of 37.71 MPa at 28 days. As compared with the mixes the mix, containing 20% of bagasse ash, may be because
which contained bagasse ash, two mixes showed higher of the reason that pores present in the concrete were com-
strengths than that of control concrete at 28 days pletely filled by bagasse ash when 15% bagasse ash was
(Fig. 10). They were 15B2SP and 20B2SP having 39.59 used. Since, density is a function of specific gravity and spe-
and 37.93 MPa respectively. Increase in strength is due to cific gravity of bagasse ash is less than that of cement there-
reduced water/binder ratio, dense particle packing, pore fore density of the mix decreased when bagasse ash took
size refinement and grain-size refinement. 20B4SP mix the place of cement after filling all the pores in the concrete.
had shown the lowest strength of 19.03 MPa at 28 days,
although it had a reduced water/binder ratio. The only dif- 4.4. Comparison of cost analysis
ference was of the dosage of superplasticizer. More the dos- Cost analysis of the materials used, has been analyzed as
age of superplasticizer than the required quantity, lesser the per the purchased price from the market (as of February
strength would be. Mixes with lesser dosage of superplast- 2006). The mixes selected for calculation and analysis were
icizer showed more compressive strength at 7 and 28 days those which could pass maximum properties of freshly

Fig. 11. Bagasse ash vs. density of hardsmed concrete with different percentage of superplastizer.
712 T. Akram et al. / Construction and Building Materials 23 (2009) 703–712

Table 7
Comparison of the cost analysis
Material Unit costa(PKR) Control concrete (CC2.5SP) SCC with bagasse ash (15B2.5SP)
3
Quantity (kg/m ) Amount (PKR) Quantity (kg/m3) Amount (PKR)
Cement (kg) 6 500 3000 500 3000
Coarse aggregate (kg) 0.198 750 148.5 750 148.5
Sand (kg) 0.105 875 91.87 875 91.87
Superplasticizer (Sikament NN) (L) 69 12.5 862.5 14.375 991.875
Superplasticizer (Sika viscocrete 1) (L) 247.25 10 2472.5 – –
Bagasse ash (kg) Free of cost – – 75 –
Total – – 6575.37 – 4232.245
Percent reduction in cost = 35.63
a
PKR stands for Pakistani rupee.

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