Nithin N (Bjk17ce040)

EXPERIMENTAL STUDY ON THE PARTIAL REPLACEMENT OF FINE
AGGREGATES WITH STEEL SLAG AND COARSE AGGREGATES WITH

COCONUT SHELL
PROJECT REPORT
Department of Civil Engineering

(2017-2021 Batch)
APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

2021
EXPERIMENTAL STUDY ON THE PARTIAL REPLACEMENT OF FINE
AGGREGATES WITH STEEL SLAG AND COARSE AGGREGATES WITH
COCONUT SHELL
PROJECT REPORT
Submitted in partial fulfilment of the requirements for the award of Degree of Bachelor of
Technology in Civil Engineering of APJ Abdul Kalam Technological University by,
ANJITHA (VPE17CE015)
MEGHA VIJAY (BJK17CE034)
NITHIN N (BJK17CE040)
SAJID S (BJK17CE051)
Department of Civil Engineering

(2017-2021 Batch)
APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

2021
CERTIFICATE
This is to certify that the seminar entitled

“EXPERIMENTAL STUDY ON THE PARTIAL REPLACEMENT OF FINE
AGGREGATES WITH STEEL SLAG AND COARSE AGGREGATES WITH COCONUT
SHELL"
being submitted by
NITHIN N (BJK17CE040)
is a bonafide record of the work done by them in partial fulfilment of the requirements for the
award of the Degree of Bachelor Technology in Civil Engineering of Kerala Technological
University, during the academic year 2020- 2021 under our supervision and guidance and this
work has not been submitted elsewhere for the award of any degree.
Guide Project Coordinator Head of Department
Ms. Agnes Shiji Joy Mr. Rodny Thomson Prof. Jisha B.S
Assistant Professor Assistant Professor Associate professor
Dept. of Civil Engineering Dept. of Civil Engineering Dept. of Civil Engineering
Bishop Jerome Institute Bishop Jerome Institute Bishop Jerome Institute
ACKNOWLEDGEMENT
We extend our deep sense of gratitude to our guide Ms. Agnes Shiji Joy, Assistant Professor,
Dept. of Civil Engineering, for the constant motivation, cooperation and help throughout the
seminar preparation and presentation.
We also extend our deep sense of gratitude to our project coordinator Mr. Rodny Thomson,
Assistant Professor, Dept. of Civil Engineering, for the constant motivation, cooperation and
help throughout the seminar preparation and presentation.
We are extremely thankful to Prof. Jisha B S, Assistant Professor, Head of the Department of
Civil Engineering, for providing all official formalities to start and complete this work. With
great pleasure, we acknowledge immense gratitude to Dr. D Roshan Kumar, Principal, for
providing us with all facilities to accomplish the seminar presentation and unfailing support
throughout the work.
We place on record our gratitude to all the faculty members and all other staffs for their constant
encouragement and guidance and wish to appreciate the help rendered by our friends to
complete the work.
Above all, we thank God Almighty for always showing his blessings on us and helping us face
all odds at all difficulties.
ANJITHA
MEGHA VIJAY
NITHIN N
SAJID S
i
ABSTRACT
The high demand for concrete in construction using normal-weight aggregates such as
granite drastically reduces the natural stone deposits and damages the environment, causing
ecological imbalance. There is a need to explore and find out suitable replacement material to
substitute the natural stone. Coconut shell, a waste material, and steel slag, an industrial by-
product, were found to harm the environment when disposed of. Replacing the aggregates can
lead to considerable environmental benefits and reduces their presence as waste material from
the earth.
This project presents a study on the structural behaviour of concrete by partial
replacement of fine aggregate with steel slag and coarse aggregate with coconut shell. Various
combinations of replacement of coarse aggregate by 10% and fine aggregate by 10%, 20%,
30%, and 40% were to be cast and tested to find the optimum value of slag and coconut shell
for obtaining the desired compressive, flexural, and tensile strength. The materials were
collected from their originations, and tests were conducted to find various physical properties.
Due to COVID-19 restrictions present at the time, only one combination of the materials was
conducted. Tests were carried out on the cast specimens, and the results were analysed for the
10% replacement of fine aggregate by steel slag and 10% coarse aggregate by coconut shell. It
was found that for 10% replacement of coconut shell and 10% replacement of steel slag, the
strength reduced by 4%. The cost reduction in the mix was 5%. Its utilization is cost-effective
and eco-friendly. The main objective is to encourage these seemingly waste products as
construction materials in low-cost housing.
ii
CONTENTS
TITLE PAGE NO.
1. INTRODUCTION 1
1.1 GENERAL 1
1.2 STEELSLAG 1
1.2.1 Properties 2
1.3 COCONUT SHELL 3
1.3.1 Properties 4
1.4 OBJECTIVES OF THE WORK 4
1.5 SCOPE OF THE STUDY 5
2. LITERATURE REVIEW 6
2.1 GENERAL 6
2.2 COCONUT SHELL AS REPLACEMENT OF COARSE AGGREGATE 6
2.3 STEEL SLAG AS REPLACEMENT OF FINE AGGREGATE 8
3. METHODOLOGY 10
4. EXPERIMENTAL INVESTIGATION 12
4.1 MATERIAL SELECTION 12
4.1.1 Cement 12
4.1.2 Fine Aggregate 12
4.1.3 Coarse Aggregate 15
4.1.4 Coconut Shell 17
4.1.5 Steel Slag 18
4.1.6 Water 20
5. MIX DESIGN 21
5.1 MIX PROPORTIONING 21
5.2 TRIAL MIX 1 21
5.3 TRIAL MIX 2 22
5.4 TRIAL MIX 3 22
5.5 ADOPTED MIX 23
6. CASTING AND TESTING OF SPECIMEN 24
6.1 GENERAL 24
6.2 TEST SPECIMEN DETAILS 24
6.3 CASTING AND CURING OF SPECIMEN 24
iii
6.4 TESTS CONDUCTED ON SPECIMENS 25
6.4.1 Test on Fresh Concrete 25
6.4.1.1 Slump Test 25
6.4.1.2 Compaction Factor Test 26
6.4.1.3 Vee Bee Test 27
6.4.2 Test on Mechanical Properties 28
6.4.2.1 Compressive Strength 28
6.4.2.2 Flexural Strength 29
6.4.2.3 Split Tensile Strength 29
7. EXTENDED LITERATURE SURVEY 31
7.1 COCONUT SHELL 31
7.1.1 Inference 34
7.2 STEEL SLAG 35
7.2.1 Inference 37
8. ANALYSIS OF TEST RESULTS 39
8.1 COMPARISON OF VARIATIONS IN STRENGTH FOR 10% 39
REPLACEMENT OF COCONUT SHELL AND 10%
STEEL SLAG (Ax10y10)
8.2 COMPARATIVE COST ANALYSIS OF AX10Y10 SPECIMEN 40
WITH STANDARD CONCRETE.
8.3 FUTURE SCOPE 41
9. CONCLUSON 42
REFERENCES
iv
LIST OF FIGURES
FIG NO. TITLE PAGE NO.
1.1 Steel Slag 2
1.2 Coconut Shell 4
4.1 Particle Size Distribution Graph for Fine Aggreagte 13
4.2 Sieve Shaker 13
4.3 Line Chart for Bulking Of Fine Aggregates 14
4.4 Bulking Of Fine Aggregates 14
4.5 Particle Size Distribution Graph for Coarse Aggregates 16
4.6 Bulk Density, Porosity, and Void Ratio 16
4.7 Coconut Shell Crushed To Required Size 17
4.8 Particle Size Distribution Graph for Coconut Shell 18
4.9 Steel Slag Crushed To Required Size 19
4.10 Particle Size Distribution Graph for steel slag 20
5.1 Cube Specimen 22
6.1 Cast Specimen 25
6.2 Slump Test 26
6.3 Compaction Factor Test 27
6.4 Vee-Bee Test 27
6.5 Comparison In Compressive Strength Between Ax00y00 And Ax10y10 28
6.6 Ax10y10 Cube Specimen 28
6.7 Comparison In Flexural Strength Between Ax00y00 And Ax10y10 29
6.8 Ax10y10 Beam Specimen 29
6.9 Comparison In Tensile Strength Between Ax00y00 And Ax10y10 30
6.10 Ax10y10 Cylinder Specimen 30
v
LIST OF TABLES
FIG NO. TITLE PAGE NO.
1.1 Physical Properties Of Steel Slag 3
1.2 Mechanical Properties Of Steel Slag 3
4.1 Properties Of Cement 12
4.2 Sieve Analysis Of Fine Aggregate 13
4.3 Bulking Of Fine Aggregate 14
4. 4 Properties Of Fine Aggregate 15
4.5 Sieve Analysis Of Coarse Aggregate 15
4.6 Properties Of Coarse Aggregate 16
4.7 Sieve Analysis Of Coconut Shell 17
4.8 Properties Of Coconut Shell 18
4.9 Sieve Analysis Of Steel Slag 19
4.10 Properties Of Steel Slag 20
5.1 Quantities Of Ingredients And Test Result Of Trail Mix 1 21
5.2 Quantities Of Ingredients And Test Result Of Trail Mix 2 22
5.3 Quantities Of Ingredients And Test Results Of Trial Mix 3 23
5.4 Adopted Mix Proportion 23
6.1 Specimen Details 24
6.2 Slump Value 26
6.3 Compaction Factor Result 26
6.4 Vee-Bee Test Result 27
6.5 Compressive Strength Results 28
6.6 Flexural Strength Results 29
6.7 Split Tensile Strength Results 30
7.1 Variation Of Mechanical Properties Of Coconut Shell 35
Infused Concrete
7.2 Variation Of Mechanical Properties Of Steel Slag 38
Infused Concrete
8.1 Comparison of Ax10y10 Mix With Standard Mix And Individual 39
Replacements Of Aggregates
8.2 Comparison Of Cost Between Standard Mix, Individual 40
Replacement Of Aggregates And Ax10y10 Mix
vi
Experimental Study on The Partial Replacement
Of Fine Aggregate with Steel Slag and Coarse
B. Tech Project Report, 2020 Aggregate with Coconut Shell
CHAPTER 1
INTRODUCTION
1.1 GENERAL
Concrete is one of the widely used materials after water. It plays a vital role in nation-
building as it directly affects the infrastructure and also the economy. Concrete is a composite
material composed of coarse granular materials called aggregates or filler embedded together
in the form of a matrix with the help of the cement or binding material that fills the space
between the aggregate particles and glues them together. Aggregates are usually obtained from
natural rocks, either crushed stones or natural gravel. According to some estimates, after 2010,
the global concrete industry required 8 to 12 billion metric tons of natural aggregates annually.
Over 2 billion tons of aggregates are consumed annually, with about 40% of fine aggregates.
The use of natural aggregates at such a rate leads to a question about preserving natural
aggregate sources.
Steel slag is an industrial by-product of steel manufacturing, and its increasing
production requires a higher consumption of the material. Therefore, it is a waste material, and
the amount of these wastes is increasing day by day. Usage of these as aggregates will reduce
their presence as waste material from the earth.
The coconut shell is a material that can be a substitute for coarse aggregate. Coconut
shell concrete has better workability because of the smooth surface on one side of the body.
The impact resistance of coconut shell concrete is high when compared with conventional
concrete. Moisture retaining and water-absorbing capacity of coconut shell is more compared
to traditional aggregate.
1.2 STEEL SLAG
The solid material generated by the interaction of impurities and flux during the making
and refining of steels is called steel slag. It is obtained in the following ways:
I. From the conversion of iron to steel in a Basic Oxygen Furnace (BOF)
II. By the melting of scrap to make steel in the Electric Arc Furnace (EAF).
III. Ladle slag generated during the refining process.
Dept of Civil Engineering, BJI Kollam. Page No.1

Fig 1.1: Steel Slag

Slag often appears as granulated materials containing large clusters, coarse and
excellent particles. With the adverse effect of drying, concrete with slag showed a much ore
refined pore structure than ordinary Portland cement concrete. In the basic oxygen process, hot
liquid blast furnace metal, scrap, and fluxes, which consist of lime (CaO) and dolomitic lime
(CaO.MgO or “Dolime”), are charged to a converter (furnace). A lance is lowered into the
converter, and high-pressure oxygen is injected. The oxygen combines with and removes the
impurities in the charge. These impurities consist of carbon as gaseous carbon monoxide,
silicon, manganese, phosphorus, and some iron as liquid oxides, combining with lime and
Dolime to form the steel slag. At the end of the refining operation, the liquid steel is tapped
(poured) into a ladle while the steel slag is retained in the vessel and subsequently tapped into
a separate slag pot.
1.2.1 Properties
The predominant compounds in steel slag are dicalcium silicate, tricalcium silicate,
dicalcium ferrite, merwinite, calcium aluminate, calcium-magnesium iron oxides, some free
lime, and magnesia. Steel slag is mildly alkaline, with a solution pH generally in the range of
8 to 10. The physical and mechanical properties are given in the tables below:

Table 1.1: Physical Properties Of Steel Slag
Property Value
Specific Gravity 3.2-3.6
Approximate Dry rodded Unit Weight,

1600-1920 (100 -120)
kg/m3 (lb/ft3)
Water Absorption Up to 3%
Table 1.2: Mechanical Properties Of Steel Slag
Property Value
Los Angeles Abrasion (ASTM C131) % 20-25
Sodium Sulfate Soundness Loss (ASTM

<12
C88) %
The angle of internal friction 400-500
Hardness (measured by Mohr’s scale) 6-7
California Bearing Ratio Up to 300
Many steel grades can be produced, and the properties of the steel slag can change
significantly with each grade. Grades of steel can be classified as high, medium, and low,
depending on the carbon content of the steel. High-grade steels have high carbon content. To
reduce the amount of carbon in the steel, greater oxygen levels are required in the steel-making
process. It requires the addition of increased levels of lime and dolime (flux) for the removal
of impurities from the steel and increased slag formation.
1.3 COCONUT SHELL
Coconuts are naturally available in nature, and their shells are non-biodegradable.
Coconut shell is a waste product and is available in large quantities in tropical regions of the
world. They are more suitable as low strength-giving lightweight aggregate when used to

replace standard coarse aggregate in concrete production. The presence of sugar in the CS, as
long as it is not in a free sugar form, will not affect the setting and strength of concrete. It is
found that wood-based materials, being hard and organic. High lignin content makes the
composites more weather resistant.
Fig 1.2: Coconut Shell
1.3.1 Properties
The chemical composition of the coconut shell is similar to wood, and it contains
33.61% cellulose, 36.51 % lignin, and 0.61% ash. Coconut shells can be grouped under
lightweight aggregate because 28-day air-dry densities of coconut shell aggregate concrete are
less than 2000 kg/m3. The actual Density of the coconut shell is in the range of 550 - 650kg/m3.
The average specific gravity and the apparent specific gravity were 1.05–1.20 and 1.40–1.50.
1.4 OBJECTIVES OF THE WORK
• To study the mechanical properties (Compressive Strength, Flexural Strength, Split

tensile strength & Modulus of elasticity) of concrete by replacing fine aggregate with
Steel Slag and coarse aggregate with Coconut Shell
• To determine the optimum combination of Steel Slag and Coconut Shell at which
maximum increase in values of mechanical properties can be obtained for a nominal
M20 mix
• To determine the maximum replacement combination of steel slag and coconut shell
that can be incorporated in nominal M20 mix without affecting strength characteristics
adversely.

1.5 SCOPE OF THE STUDY
The construction industry and concrete manufacturers have realized that the available
source of coarse aggregates and fine aggregates are getting depleted at an alarming rate, leading
to the search for alternate sources of aggregates. The present work concerns the investigation
of partially replacing fine aggregate with steel slag and coarse aggregate with coconut shell.
In particular, the performances of concrete at different percentages of steel slag and
coconut shell were investigated. We aim to establish the combination of disposed of steel slag
and coconut shell that can be added in the mixture without too heavy penalization on
Compressive strength, Flexural strength, Split tensile strength, and Modulus of elasticity.
Concrete mixes are proportioned to replace 10%, 20%, 30%& 40% of regular concrete sand
with steel slag by weight and by fixing 10% replacement of coarse aggregate with coconut
shell.

CHAPTER 2
LITERATURE REVIEW
2.1 GENERAL
Concrete is an artificial material similar in appearance and properties to some natural

limestone rock. It is an artificial composite, the principal constituent being natural aggregates
such as gravel, crushed rock, sand, and fine cement powder particles mixed with water. As time
goes on through a process of hydration of the cement paste, the concrete produces a required
strength to withstand the load. The concrete can be strengthened only by the replacement of its
ingredients with better ones. Not only replacing some material but using a waste material makes
the environment friendly at the same time more suitable to construction. This study has been
carried out to assess the partial replacement of coarse aggregate by coconut shell and fine
aggregate by steel slag.
Several types of research were made in replacing coarse aggregates with coconut shells
in varying percentages, and its effect on the mechanical properties of concrete was determined.
In most cases, the replacement was done up to 10% and showed a considerable increment in
mechanical properties, only up to 10%. Similarly, research works have been conducted to study
the effect of replacing fine aggregates in concrete with steel slag. In most studies, increment in
mechanical properties was seen only up to 50% and decreased above that. Details of some of
the research works are given below.
2.2 COCONUT SHELL AS REPLACEMENT OF COARSE AGGREGATE.
Tharwani et al. (2017): The strength of concrete replaced with coconut shell replaced
by coconut shells were studied. The following conclusions are drawn from this experimental
work: (i) Up to 15% of aggregate replaced by coconut shell is good according to strength and
cost-wise. An increase in percentage replacements by coconut shells reduced the strength and
density of concrete. (ii) The natural coarse aggregates were replaced as 0%, 5%, 10and 15%
by coconut shells. (iii) Strength of the coconut shells concretes increased 38-84% after seven
days of curing than its corresponding 28-day strengths, respectively.
Shrikant et al. (2017): In the study “Partial Replacement Of Coarse Aggregate With
Coconut Shell In The Concrete,” an experiment on coconut shell replaced concrete. Specimens

were cast by replacing 0%, 10%, 20%, and 30% coarse aggregate with coconut shells. Tests
were conducted on the cast specimens after 7, 14, 21, and 28 days as mentioned in the IS code.
They found that the compressive strength holds well up to 10% replacement of coarse
aggregate by coconut shell. The percentage as increases above 10%, the compressive strength
decreases significantly
Rajeevan et al. (2015): They studied “Utilization Of Coconut Shell As Coarse
Aggregate In Concrete” using M20 grade concrete. Namely, compressive strength, split tensile
strength, and flexural strength of concrete, an optimum replacement of coarse aggregate with
coconut shell aggregate, corresponding to the mix ratio 1: 1.5: 3, was determined as 15%.
Cement content for 15% replacement was kept at 387 kg/m3. The observed value of 28-day
compressive strength, split tensile strength, and flexural strength were 24.6 N/mm2, 2.57
N/mm2, and 2.89 N/mm2, respectively. It indicates that concrete made with coconut shell
aggregate has strength comparable with that of conventional concrete.
Kumbhar et al. (2018): The study investigated the comparative analysis of coconut
shell concrete with traditional concrete. Concrete mixes are prepared with o 0%, 10%, 20%,
and 30% coarse aggregate replacement with coconut shell. The result they obtained is: (i)The
compressive strengths obtained by 10 %, 20%, and 30% replacement are 94 %, 80%, and 70%
of the total compressive strength of conventional (M20 grade) concrete. (ii)The flexural strength
taken on beams is reduced by 17.86%, 25%, and 30.36% for replacement of 10%, 20%, and
30%, respectively. Hence 10% replacement is allowable in construction members, and 20%
and 30 % replacement are used in some conditions. (iii)The total weight of concrete is reduced
than traditional concrete, and the quantity of material is increased by 4%, 7%, and 15% by
replacement of 10%, 20%, and 30% replacement of aggregate, respectively. (iv)The total cost
of concrete is get reduced by 2%, 3% and 4% for replacement of 10%, 20% and30%
respectively
Yogesh et al. (2013): An experimental study was conducted on waste coconut shells as
a partial replacement of coarse aggregate in the concrete mix using M20 grade concrete mix.
They cast the specimen with 25% and 50% replacement and tested the specimen for 7- and 28-
days strength. The results they obtained are: Overall cost of construction will be reduced. The
maximum compressive strength in the control mix is 21.28 N/mm2 at 28days, while the
minimum strength on the same days is 14.23 N/mm2. Thus, compressive strength decreased as
the percentage of coconut shell is increased. Therefore, coconut shells can be used where
lightweight concrete is required. Proper bonding between coconut shell and cement is not
possible because of the surface area of coconut shell aggregate.

Ramesh and Thankachan et al. (2018): An investigation was made on partial
replacement of coarse aggregate with coconut shell. For M20 grade, they choose concrete mix
proportion was1:1.66:3.33 with a water-cement ratio of 0.6. Coconut shells were replaced by
5%, 10% replacement of coarse aggregate with coconut shells. After the curing time, specimens
were tested for compressive strength, split tensile strength, and flexural strength. Results
showed a rise in compressive strength at 7days curing time for 5%, 10% replacement of coarse
aggregate with coconut shell. There was a rise in compressive strength at 28 days curing time
for 5%, but strength lowered for 15% replacement of coarse aggregate with coconut shell.
Splitting tensile strength decreased for5% replacement of coarse aggregate with coconut shell.
Compared with 5% replacement, 10% replacement has a slight increase but not much for the
conventional mix. Flexural strength has a notable decreased with an increase in replacement of
coarse aggregate with coconut shell.
2.3 STEEL SLAG AS REPLACEMENT OF FINE AGGREGATE
Bavsar et al. (2018): An experimental study was done on the topic “Partial
Replacement Of Fine Aggregate Using Steel Slag.” They had done the experiment using M20
concrete. The compressive strength, Flexural strength, Split Tensile strength is highest at 20%
replacement. Steel slag did not have any negative impact on the flexural strength of concrete.
The steel slag should be a suitable substitute for sand, as fine aggregates in concrete production.
The 28-day compressive strength of concrete containing 25 and 50% slag was 23.95N/mm2
higher than standard concrete 21.48 N/mm2.Steel slag has low water absorption than natural
sand and thus reduces the water amount required for concrete containing Steel slag.
Kadam et al. (2016): In the study “Effect Of Partial Replacement Of Fine Aggregate
By Steel Slag And Its Impact On Its Compressive Strength,” M30 grade concrete cube
specimens of size 150 mm were cast for partial replacement of steel slag with
0%,10%,20%,30%, and 40%. The results showed that 30% replacement is a desirable
percentage replacement of fine aggregate by steel slag. Compressive strength goes on
increasing up to 30% of replacement, and more than 30% it goes on decreasing.
Shreemanth et al. (2015): The topic “Effect Of Replacement Of Fine Aggregate By
Steel Slag Aggregates In Concrete” was investigated based on the percentage replacement of
fine aggregate by steel slag study the mechanical properties of concrete at different grades of
concrete. The specimen prepared after replacement of fine aggregate by steel slag for 0%, 25%,
50%, 75%, and 100% are studied for compressive strength, flexural strength, and tensile

strength for a curing period of 28 days. Optimum strength was found at the replacement level
in between 30 to 50%. The flexural strength and tensile strength were improved by 6 to 8% at
25% replacement levels, but they reduced by 8 to 10% at 100% replacements.
Sharma et al. (2015): An experimental study was done on “Beneficial Effects of Steel
Slag on Concrete.” The study presented M35 grade of concrete, each having two concrete mixes,
and the properties were determined by adopting conventional testing procedures. Hardened
concrete properties (Compressive strength, Flexural strength, and split tensile strength for the
use of steel slag as aggregate in concrete are higher than conventional concrete. Strength of the
M35 grade of concrete increases with an increase in steel slag quantity. The improvement in
strength may be due to the shape, size, and surface texture of steel slag aggregate, which
provides better adhesion between the particles and cement paste. The cost of steel slag is almost
nil to that of natural aggregate. Also, it is economical to use the steel Industrial waste product.
Also, it could be easily used as coarse and fine
Kothai et al. (2014): In the experimental investigation “Utilization of Steel Slag in
Concrete as a Partial Replacement Material for Fine Aggregates,” the study was made on the
effect of partial replacement to study the mechanical properties of M20 grade concrete. The
slump value of conventional concrete is 100mm, and it lies between 85mm to105mm. Test
results show that the compressive strength of the concrete increases, and the optimum value
was found at a slag replacement of slag decreases the compressive strength. It relates to the use
of steel slag, a cheap waste material used as fine aggregates in M20 grade of concrete, and
recommends the approval of the material for use in concrete as a replacement material for fine
aggregate. The benefits such as mass utilization of waste material are possible in construction
using steel slag as a partial replacement material for fine aggregate in concrete.

CHAPTER 3
METHODOLOGY
MATERIAL MATERIAL MIX

COLLECTION TESTING PROPORTIONING
CASTING AND
TEST ON FRESH TEST ON HARD
CURING OF
CONCRETE CONCRETE
SPECIMEN
ANALYSIS OF THE
REPORT
The literature review was studied based on particular topics on partial replacement of
fine aggregate with steel slag and coarse aggregate with coconut shell. The coconut shell was
collected from nearby residents and steel slag from the iron and steel industry. The preliminary
investigation involved the laboratory testing of constituent materials, ordinary Portland Cement
(43 grade), fine aggregate, coarse aggregate, steel slag, coconut shell. After conducting a 7-day
compressive strength test on two trail mixes, two trial mixes are cast with varying water-cement
ratios, and mix-proportion is fixed based on the mix that gave maximum strength.
Preparation of standard M20 grade concrete and casting of Cube (15 cm × 15 cm ×
15cm) for compressive strength test, Beam (10 cm depth, 10 cm width, and 50 cm span) for
Flexural Strength test and cylinder (15 cm diameter and 30 cm height) for split tensile strength
test was done. Preparation of M20 grade concrete by replacement of fine aggregate with steel
slag in varying percentages (10%, 20%, 30%, 40%) and coarse aggregate with coconut shell
by fixing 10% and casting of cubes, beams, and cylinders for Compressive strength test,
Flexural Strength test, Split Tensile Strength test in different combinations of steel slag and
coconut shell is carried out.

7th and 28th day testing on the casted specimens for compressive strength, Flexural
strength, and split tensile strength are done. A comparative study is made on the results
obtained for Standard M20 grade concrete and concrete with partially replaced fine aggregate
and coarse aggregate by steel slag and coconut shell. Results are analysed, and graphs are
plotted.

CHAPTER 4
EXPERIMENTAL INVESTIGATION
4.1 MATERIAL SELECTION

4.1.1 Cement
Portland Pozzolana cement of grade 43 confirming to IS 1489-1991, manufactured by

Ramco Cements Limited, was used for this experiment. The most important use of cement is
the production of mortar and concrete- the bonding of natural use of aggregates to a strong
building material that is the face of usual environmental effects. The tests performed were
specific gravity, fineness, consistency, initial setting time, final setting time, and compressive
strength. The properties of cement are shown in Table 4.1
Table 4.1: Properties Of Cement
Properties tested Results
Specific gravity 2.96
Fineness test 0.023%
Consistency 31.5%
Initial setting time 45 minutes
Final setting time 570 minutes
Compressive strength 21.18 Mpa
4.1.2 Fine Aggregate

Aggregates are passing through a 4.75 mm IS sieve and retaining on a 75μ IS sieve are
called fine aggregates. The purpose of fine aggregate is to fill the voids in the coarse aggregate
to act as a workability agent. It forms the bulk and makes mortar or concrete economical. In
this study, manufactured sand conforming to grading zone 1 is used as fine aggregates. Various
tests were conducted on natural sand as per IS 2386-1963.

Table 4.2: Sieve Analysis Of Fine Aggregate
Cumulative
Weight % Weight % Weight
Sieve set % weight
retained retained passing
retained
4.75mm 0.000 0 0 0
2.36mm 0.223 22.3 22.3 77.7
1.18mm 0.245 24.5 46.8 53.2
600µ 0.159 15.9 62.7 37.3
300µ 0.154 15.4 78.1 21.9
150µ 0.119 11.9 90 10
Pan 0.100 10 100 0
Fig 4.1: Particle Size Distribution Graph For Fine Aggregate
Fig 4.2: Sieve Shaker

Table 4.3: Bulking Of Fine Aggregate
Weight of
Weight of
Weight of dry sand in
Serial % of water dry
loose wet the wet % Bulking
number added compacted
sand (W2) sand of
sand(W1)
weight (W3)
1 1 5.814 5.278 5.23 11.167
2 2 5.814 4.868 4.77 21.88
3 3 5.814 4.52 4.39 32.44
4 4 5.814 4.261 4.09 42.15
5 5 5.814 4.185 3.99 45.71
6 6 5.814 4.267 4.025 44.44
7 7 5.814 4.452 4.160 39.79
50
40
% bulking
30
20
10
0
0 1 2 3 4 5 6 7
% water added
Fig 4.3: Line Chart For Bulking Of Fine Aggregates
Fig 4.4 :Bulking Of Fine Aggregate

Fig 4.6 Bulking of fine
aggregate
Table 4.4: Properties Of Fine Aggregate
Fineness modulus 9.01
Effective size 13 mm
Water absorption 1.39%
Bulk density 16.29g/cc
Void ratio 0.774
Porosity 0.436
4.1.3 Coarse Aggregate
Locally available coarse aggregate passing through a 20 mm size sieve was used. Coarse
aggregates for structural concrete consist of broken stones of hard rock like granite and
limestone (angular aggregates) or river gravels (round aggregates). The various property of
coarse aggregate obtained by using IS: 2386-1963 Part- III is given below:
Table 4.5: Sieve Analysis Of Coarse Aggregate

Cumulative
Weight % Weight
Sieve size weight Weight passing
retained retained
retained
20mm 0 .981 32.7 32.7 67.3
16mm 1.290 43 75.7 24.3
12.5mm 0.581 19.37 95.07 7.93
10mm 0.113 3.76 98.83 1.17
4.75mm 0.019 0.633 99.46 0.54
Pan 0.016 0.533 100 0

100
90
% weight passing 80
70
60
50
40
30
20
10
0
0.01 0.1 1 10
Sieve size in mm
Fig 4.5: Particle Size Distribution Graph For Coarse Aggregates
Table 4.6: Properties Of Coarse Aggregate
Effective size 13 mm
Water absorption 1.39%
Bulk density 16.29 g/cc
Void ratio 0.774
Porosity 0.436
Fig 4.6: Bulk Density, Porosity, Void Ratio

4.1.4 Coconut Shell
Coconut shells are collected from nearby houses, and fibres and husks are
removed. Further, the shells are broken into small pieces, approximately 20 mm, by
using a hammer. Broken shells are sieved through a 20 mm sieve. The coconut shell
will be having a thickness range of 3-9 mm. It was air-dried for five days approximately
at the temperature of 25 to 100C
Fig 4.7: Coconut Shell Crushed To Required Size
Table 4.7: Sieve Analysis Of Coconut Shell
Cumulative % weight
Weight % weight
Sieve size % weight passing
retained (kg) retained (kg)
retained
40mm 0 0 0 100
20mm 0.932 31.07 31.07 68.93
16mm 1.280 42.67 73.74 26.26
12.5mm 0.210 7 80.74 19.26
10mm 0.233 7.77 88.51 11.49
4.75mm 0.299 9.97 98.48 1.52
Pan 0.046 1.53 100 0

100
90
80
% weight passing
70
60
50
40
30
20
10
0
0.01 0.1 1 10
Sieve size in mm
Fig 4.8: Particle Size Distribution Graph For Coconut Shell
Table 4.8: Properties Of Coconut Shell
Properties tested Result
Effective size 20
Specific Gravity 1.12
Water absorption 19%
4.1.5 Steel Slag
200 kg of steel slag was collected from Paragon Steel Industry, Palakkad. They were
crushed into the required size using specific tools. The physical and chemical properties are as
tabulated below

Fig 4.9: Steel slag crushed to the required size
Table 4.9: Sieve Analysis Of Steel Slag
Cumulative
Weight % weight % weight
Sieve size % weight
retained (kg) retained (kg) passing
retained
4.75mm 0 0 0 100
2.36mm 0.349 34.9 34.9 65.1
1.18mm 0.378 37.8 72.7 27.3
600micron 0.154 15.4 88.1 11.9
300micron 0.069 6.9 95 5
150micron 0.024 2.4 97.4 2.6
Pan 0.026 2.6 100 0

100
90
80
% weight passing
70
60
50
40
30
20
10
0
0.01 0.1 1 10
Sieve size in mm
Fig 4.10: Particle Size Distribution Graph For Steel Slag
Table 4.10: Properties Of Steel Slag
Properties Tested Results
Effective size 0.52
Specific Gravity 3.125
4.1.6 Water
The water used for mixing and curing should be clean and free from injurious quantities
of alkalis, acids, oils, salt, sugar, organic materials, vegetable growth, and other substances that
may be deleterious to concrete or steel. Potable water is generally considered satisfactory for
mixing. The pH value of water should be not less than 6. When it contains sewage, mine water,
or wastes from industrial plants or canneries, it should not be used in the mix unless tests
indicate that it is satisfactory.

CHAPTER 5
MIX DESIGN
Mix design involves proportioning concrete ingredients such that the resulting concrete
will have the required characteristic compressive strength. For the present study, the M20 grade
concrete is to be used.
5.1 MIX PROPORTIONING
Mix proportioning was done by casting 3 trial mixes- Trial mix 1, 2 and, 3 with water-
cement ratio 0.45, 0.5, and 0.52, respectively. The objective of mix design is to choose a
desirable ratio of concrete ingredients and obtain their relative quantities with required
workability and strength. The desired ratio is to have as minimum water as possible with
workability in the range 75mm-100mm.
5.2 TRIAL MIX 1
The water-cement ratio for trial mix 1 is taken to be 0.45. The slump value obtained for
the mix utilizing slump cone was obtained as 50mm. It gives a stiff plastic mix. The details of
the mix are given in table 5.1
Table 5.1: Quantities Of Ingredients And Test Result Of Trail Mix 1
Mix proportion 1:1.5:3
Water cement ratio 0.45
Cement 392.75 Kg/m3
Fine aggregate 589.135 Kg/m3
Coarse aggregate 1178.27 Kg/m3
Water 176.70 l/m3
Slump value 50 mm
Average 3 day compressive strength 16.02 N/mm2

5.3 TRIAL MIX 2
the mix utilizing slump cone was obtained as 140mm. It gives a flowing mix. The details of
the mix are given in table 5.2
Table 5.2: Quantities Of Ingredients And Test Result Of Trail Mix 2
Cement 381.89 Kg/m3
Coarse aggregate 1144 Kg/m3
Water 197 l/m3
Slump value 140 mm
Average 7 day compressive strength 22.3 N/mm2
5.4 TRIAL MIX 3
the mix utilizing slump cone was obtained as 100mm. It gives a plastic mix. The details of the
mix are given in table 5.3
Fig 5.1 Cube Specimen

Table 5.3: Quantities Of Ingredients And Test Results Of Trial Mix 3
Cement 385.18 Kg/m3
Water 192 l/m3
Slump value 100 mm
Average 3 days compressive strength 18.08N/mm2
5.5 ADOPTED MIX
Mix design was done as per IS 456:2000. Trial mix 3 was selected from the former trial
castings. It was selected because it gave a slump of 100mm, which was desired, and gave an
average compressive strength of 18.08 N/mm2 for 3 days and 23.5 N/mm2 for 7 days strength
based on theoretical value.
Table 5.4: Adopted Mix Proportion
Cement 385.18 Kg/m3
Water 192 l/m3
Slump value 100 mm
Average 3 days compressive strength 18.08N/mm2

CHAPTER 6
CASTING AND TESTING OF SPECIMEN
6.1 GENERAL
In this experimental work, the compressive strength, flexural strength, split tensile
strength characteristics were studied. Furthermore, the different mechanical properties of
standard M20 mix are compared with concrete mixes replaced in a different coconut shell and
steel slag combinations with coarse and fine aggregates.
6.2 TEST SPECIMEN DETAILS
Each batch, 3 cubes, 2 beams, and 2 cylinders for 7tn day and 28th day each were cast.
Due to COVID-19 restrictions, only the control mix and Ax10y10 were able to be cast. Given
below is the various combinations of concrete to be cast
Table 6.1: Specimen Details
Coarse
General Cement CS Content FA Content SS Content
aggregate
denotation Content (%) (%) (%) (%)
Content (%)
Ax00y00 100 100 0 100 0
Ax10y10 100 90 10 90 10
Ax10y20 100 90 10 80 20
Ax10y30 100 90 10 70 30
Ax10y40 100 90 10 60 40
6.3 CASTING AND CURING OF SPECIMEN
Cubes of size 15 cm x 15 cm x 15 cm, PCC Beams of size 10 cm x10 cm x50 cm, and
Cylinders of 15 cm diameter and 30 cm high were cast for Ax00y00 and Ax10y10 mix. Materials
required for casting were calculated separately for cubes, beams, and cylinders. The required

materials were mixed several times until they gave a uniform colour. Within the initial setting
time of concrete, the mix was cast into the individual moulds thoroughly with a tamping rod.
After 24 hours, the specimens were demoulded and immersed in a water tank for curing. On
the 7th and 28th-day the Compressive Strength Test, Flexural Strength Test, And Split Tensile
Strength was done on the specimens.
Fig 6.1: Cast Specimens
6.4 TESTS CONDUCTED ON SPECIMENS
Testing of concrete plays a vital role in controlling and confirming the quality of cement
concrete. The cube, beam, and cylinder are tested for their strength characteristics.
6.4.1 Test on fresh concrete
The tests on fresh concrete are namely slump test, vee-bee test and, compaction factor
test. They are carried out to find the workability of the mix. Workability of concrete describes
the ease or difficulty with which the concrete is handled, transported, and placed between the
forms with minimum loss of homogeneity.
6.4.1.1 Slump Test
This test is carried out with a mould called slump cone whose top diameter is 10cm, bottom
diameter is 20 cm, and height 30 cm. It is the most common way to measure workability in
construction sites.

The values show that as coconut shell and steel slag replacement increases, the
workability decreases. It may be due to the naturally smooth side of the coconut shell, due to
which bonding between cement may decrease. According to SP 23-1982, the control mix gives
a plastic mix, and A x00y00 gives a flowing mix
Table 6.2: Slump Value
Concrete Mix Slump Value
Ax00y00 100 mm
Ax10y10 150 mm
Fig 6.2: Slump Test
6.4.1.2 Compaction Factor Test
The compaction factor test is the workability test for concrete conducted in the
laboratory. The compaction factor is the ratio of weights of partially compacted to fully
compacted concrete. The compaction factor test is used for concrete with low workability, for
which slump test is not suitable. According to SP 23-1982, the control mix gives a stiff plastic
mix, and Ax10y10 gives a plastic mix
Table 6.3: Compaction Factor Result
Concrete Mix Compaction Factor Value
Ax00y00 0.86
Ax10y10 0.91

Fig 6.3 Compaction Factor Test
6.4.1.3 Vee Bee Test
This laboratory test is used to determine the consistency of concrete using a Vee Bee
consistometer. It is based on time. According to SP 23-1982, the control mix has a stiff
consistency, and the Ax10y10 mix has a plastic consistency
Table 6.4: Vee-Bee Test Result
Concrete Mix Vee-Bee Value (Sec)
Ax00y00 8
Ax10y10 3
Fig 6.4 Vee-Bee Test

6.4.2 Test On Mechanical Properties
The following tests are conducted to find out the mechanical properties of concrete.
The overall strength of the concrete is based on their results:
6.4.2.1 Compressive Strength
The experiment aims to determine the compressive strength of M20 grade concrete with partial
replacement of coarse aggregate with coconut shell and fine aggregate with steel slag. The
apparatus for the experiment is a compression testing machine. Size of specimen is a 15cm x
15 cm x 15 cm cube. Load is applied at the rate of 14N/mm2 per minute. The Ax10y10 mix
showed a decrease in strength by 3.5% compared to the control mix.
Table 6.5: Compressive Strength Results
7th Day Compressive 28th Day Compressive

Concrete Mix Strength (N/mm2) Strength ( N/mm2)
Ax00y00 21.18 32.58
Ax10y10 20.44 31.44
40
Ax00y00 Ax10y10
Compressive Strength (N/mm2)
30
20
10
0
7 Day Compressive Strength 28 Day Compressive Strength
Cube Specimen
Fig 6.5: Comparison In Compressive Strength Fig 6.6: Ax10y10 Cube

Between Ax00y00 And Ax10y10 Specimen

6.4.2.2 Flexural Strength
The test aims to determine the Flexural Strength of concrete. The size of prism moulds
used was 10 cm x 10 cm x 50 cm. The load was applied at the rate of 1.8 kN per minute. The
bed is provided with two steel rollers, 38 mm in diameter, on which the specimen is placed at
40 cm centre to centre. The load is applied through two similar rollers spaced at 133 mm.
Ax10y10 mix showed a reduction in strength by 17.5% compared to the control mix.
Table 6.6: Flexural Strength Results
7th-day modulus of rupture 28th-day modulus of rupture
Concrete Mix
(MPa) (MPa)
Ax00y00 2.875 Not tested
3.5
3
Modulus of Rupture ( MPa)
2.5
1.5
0.5
0
Ax00y00 Ax10y10
Beam Specimen
Fig 6.7: Comparison In Flexural Strength Between Fig 6.8: Ax10y10 Beam
Ax00y00 And Ax10y10 Specimen
6.4.2.3 Split Tensile Strength
The test aims to determine the split tensile strength of concrete. The apparatus used for
the test is a compression testing machine, and the specimen used is a cylinder of 15cm diameter
and 30cm height. It is used to find the tensile strength of concrete. It was found that the strength
reduces for Ax10y010 mix by 3% than the control mix.

Table 6.7: Split Tensile Strength Results
7th Day Split Tensile 28th Day Split Tensile

Concrete Mix Strength (N/mm2) Strength ( N/mm2)
1.53
1.52
1.51
Split Tensile Strength
1.5
(N/mm2)
1.49
1.48
1.47
1.46
1.45
Ax00y00 Ax10y10
Cylinder Specimen
Fig 6.9: Comparison In Tensile Strength Between Fig 6.10: Ax10y10

Ax00y00 And Ax10y10 Cylinder Specimen

CHAPTER 7
EXTENDED LITERATURE SURVEY
7.1 COCONUT SHELL
Vishnu et al. (2017): The topic of study was “Improving the engineering properties of
reinforced concrete modified with coconut shell aggregates.” The study found that the addition
of coconut shell as partial aggregate replacement reduces the concrete workability due to its
shape and rougher texture and exhibits more resistance against crushing, impact, and abrasion
than crushed granite aggregate. An increase in percentage replacements by coconut shells
reduced the strength and density of concrete. According to strength and cost-wise, up to 20%
to 30% of aggregate replaced by coconut shell is good. The concrete specimens cast were of
M20 grade concrete for partial replacement of coconut up to 30% in increments of 10%. The
graph showed the reduction in slump measurement when coconut shell aggregate was added.
The concrete cubes as specimens of size 150 mm are cast. Compressive strength was highest
for 10% replacement, and deflection in flexural strength test showed least at 10%. A decrement
in the strength of about 1.1% concerning standard concrete was observed.
Sivaranjani et al. (2019): The selection topic was “Study On Mechanical Properties
Of Concrete By Partial Replacement Of Coconut Shell As Coarse Aggregate.” Percentage
replacement up to 20% with increments of 5% was used for M20 concrete. Workability
decreases as the percentage of coconut shells are increased. 5% replacement showed a 4%
increase in compressive strength than standard after that, which it reduces, and it showed higher
strength in flexural and split tensile strength than other varying percentage replacements but
reduced by 35%. Hence replacement of coconut shell can be done up to 5%. Since the flexural
strength decreases rapidly, the replacement of coconut shells in concrete can be used for
compression members only.
Amit et al. (2020): Their selection topic was “Coconut-Shell As A Fractional Substitute
To Coarse Aggregate In Mix Concrete – A Study.” M20 grade mix with a 0.5 water-cement
ratio was used. The coconut shell was replaced up to 50% within increments of 10%. It showed
a decrease in workability with the addition of coconut shells. Results show an increase in
Coconut-Shell Percentage by replacing coarse aggregate in conventional concrete, decreasing
compressive strength. Decrement in the strength of about 3.2 % concerning standard concrete.

Uday et al. (2019): The topic of study was “Concrete Mix Using Solid Waste
Aggregates (Coconut Shell Concrete)”. M20 grade concrete with replacement of coconut shell
up to 30% in increments of 10% was carried out. As the percentage replacement of coarse
aggregates increases, the workability and compaction factor value decreases. By replacing the
coconut shell with 30 %, the voids were 40 % more than in conventional concrete. If M20 grade
concrete is used, the strength is greater than 20 N/mm2 up to 30 % replacement of coarse
aggregate with CS. Decrement in the strength of about 7.7% concerning standard concrete
Vijay et al. (2017): The topic of study was “Properties Of Concrete By Using Coconut
Shell As Coarse Aggregate”. Testing was done on M20 concrete up to 30% replacement with
increments of 5%. It showed the concrete strength reducing as replacement increased but
obtained conditions acceptable up to 15% replacement. From the experimental investigation,
it is clear that coconut shell is not suitable construction material and as the percentage of
coconut shell increase in the concrete compressive strength decreased gradually. Nevertheless,
using the coconut shell density of concrete is also decreased, making lightweight concrete and
reducing the structure’s dead weight. Decrement of about 7.8% concerning standard concrete
was observed.
Sandeep et al. (2017): The topic of study was “Experimental Investigation Of Concrete
Using Coconut Shell As A Coarse Aggregate Replacement”. Testing was carried out on M20
grade concrete up to 35% replacement with increments of 5%. It was found that the
compressive strength decreased with the addition of coconut shells. Based on split tensile
strength and flexural test strength, the optimum combination was 15%, where an increase of
8% was seen.
Sravani et al. (2019): The selection topic was “Study On Behaviour Of Concrete Cubes
With Coconut Shells As A Partial Replacement Of Coarse Aggregate”. Testing was carried
out on both M20 and M30 grades. The coconut shell was replaced up to 25% with 5% increments.
The coconut shell has the potential as a lightweight aggregate in concrete from the experimental
results and discussion. It was found out that we can use the coconut shells in aggregate up to
20% replacement. It is concluded that the Coconut Shells are more suitable for lightweight
aggregate when used to replace normal coarse aggregate in concrete production. A decrement
of about 8.4% concerning standard concrete was found.
Arivalagan et al. (2020): The topic of study was “An Optimum Use Of Coconut Shell
As Partial Replacement Of Coarse Aggregate In Lightweight Concrete: An Environmental
Approach”. Combination of 5%, 10%, 20%, 30%, 40% and 50% were tested as specimens for
the study. The addition of coconut shell decreases workability. The percentage of coconut shell

as deceased compressive strength, split tensile strength, and flexural strength compared to
conventional concrete. The replacement of coconut shell up to 10% as to the good result of
compressive strength, split tensile strength, and flexural strength compared to conventional
concrete. The possibility creates for the partial replacement of coarse aggregate with coconut
shell to produce lightweight concrete. A decrement of about 8.4% concerning normal concrete
was found
Harish et al. (2017): The topic of study was “Experimental Investigation On Partial
Replacement Of Coarse Aggregate By Coconut Shell In M20 Grade Concrete”. Three
combinations of 10%, 20%, and 30% replacements were carried out for the study. By studying
the results, it was concluded that coconut shell could be replaced up to 10-12.5% as a coarse
aggregate. An increase in percentage replacement by coconut shell reduces the compressive
strength of concrete. Similarly, the split tensile strength also decreased with an increase in
coconut shell replacement. An increase in percentage replacement by coconut shell increases
the workability of concrete. A decrement of about 4.4% concerning standard concrete was
found.
Sachin et al. (2019): The topic of study was “Study of partial replacement of coarse
aggregate with coconut shell”. Testing was done on M20 concrete up to 15% replacement with
increments of 5%. It was found that an increase in percentage replacements by coconut shells
reduced the strength and density of concrete. The optimal replacement as per this study was
10%. It helps in reducing up to 15% of pollution in the environment. The slump of concrete
increases as the percentage of coconut shell increases.
Apeksha et al. (2017): The topic of study was “Performance Of Coconut Shell As
Coarse Aggregate In Concrete”. M20 grade concrete up to 40% replacement with 10%
increments were cast. Results indicate that coconut shell concrete gains less strength initially
(7 days) but shows rapid strength gain later. It can be observed that for M20 grade concrete, no
additional cement was required for 5% replacement of coarse aggregate by coconut shell. In
the case of 10% replacement, an additional quantity of cement required was only 3.6%.
However, for 25% replacement, additional cement content of 81.6 kg per m3 of concrete was
required to save 71.9 kg of conventional coarse aggregate per m3 of concrete and get added
advantage of disposing of 115.4 kg of waste coconut shell.
Mohan et al. (2017): The topic of study was “Performance of Concrete Using Coconut
Shell”. M20 grade cement with replacement up to 30% in increments of 10% was used. It was
concluded that the coconut shells were more suitable as low strength-giving lightweight
aggregate when used to replace common coarse aggregate in concrete production. However,

the overall strength decreased with coconut shell replacement when compared to control
concrete. An increase in coconut shell replacement showed an increase in permeable voids.
Ajeeb et al. (2020): The topic of study was “Flexural Behaviour Of Reinforced
Concrete Beam With Partial Replacement Of Coarse Aggregate With Coconut Shell”. M20
grade concrete with replacement up to 25% with increments of 5% is cast for this experiment.
The observations show a gradual decrease of flexural strength in all the combinations of
concrete mix. The slight variations in the result of flexural strength in 5% to 20%. This project
suggested 20% of coconut shell in concrete mixing time.
Mardiha et al. (2021): The topic of study was “Concrete Block With Partial
Replacement Of Coarse Aggregate By Coconut Shell: A Review”. It was concluded that the
overall strength of concrete decreases when the coarse aggregate is partially replaced by
coconut shells compared to control concrete. The results demonstrate that as coconut shell
aggregate increases, concrete slump value and workability will decrease. Utilizing coconut
shells to replace aggregates partially makes the concrete structure more economical and good
strength criteria. It can help construct a low-cost housing society and leads to sustainable
development in the construction field. A decrement of about 4.5% concerning standard
concrete was found.
Ravi et al. (2019): The topic of study was “Coconut Shell as Coarse aggregate in
Conventional Concrete”. M20 grade of concrete up to 30% replacement with 10% increments
were used. From the experimental results and discussion, it can be concluded that coconut shell
can be replaced up to 10- 12.5% as a coarse aggregate. It is observed that an increase in
percentage replacement by coconut shell reduces the compressive strength of concrete. Similar
to compressive strength, the split tensile strength also decreased with an increase in coconut
shell replacement. An increase in percentage replacement by coconut shell increases the
workability of concrete. A decrement of about 4.8% concerning standard concrete was found.
7.1.1 Inference
Replacement of conventional aggregate by waste coconut shell showed a decrease in

compressive strength. For M20 grade concrete, average compressive strength at 28 days is quite
similar in strength with the conventional concrete, for up to 10% replacement of coarse
aggregate with coconut shell. The split tensile strength and flexural strength also decreased
with an increase in coconut shell replacement but gave around 90%-95% strength compared to
standard concrete. Thus, making the replacement both technically and economically feasible

and viable. Coconut shell concrete can be used in rural areas and places where coconut is
abundant and may also be used where the conventional aggregates are costly. It also proves a
powerful way of utilizing coconut shells in construction rather than ending up in a landfill.
Calculating an average of the values based on the various literature reviews, the percentage
decrease in compressive strength, flexural strength, and split tensile strength is given in Table
7.1.
Table 7.1: Variation of Mechanical Properties of Coconut Shell Infused Concrete
Decrease in % compared to standard
Strength
concrete
Compressive 3-8
Split tensile 4-8
Flexural 2-6.5
7.2 STEEL SLAG
Subathra et al. (2014): The topic of study was “Properties Of Concrete Manufactured
Using Steel Slag”. Test samples were produced with fine and coarse aggregate, progressively
replaced by steel slag at 10% intervals, by weight, up to 50%. The water/cement ratio is kept
constant at 0.55 throughout the investigation. The compressive strength of concrete increases
gradually, as the percentage of replacement increases, up to 40% for fine aggregate and 30%
for coarse aggregate, and then it gradually decreases. The slump decreases as the percentage
replacement level increases. From the test results, the compressive strength of concrete
increased 4.6% when the coarse aggregate is replaced by 30% steel slag and 27.04% when the
fine aggregate was replaced by 40% steel slag. While replacing a single factor, the flexural
strength increased by 48.1% for 30% coarse aggregate replacement and 74.2% for 40% fine
aggregate replacement than the conventional concrete of 0% replacement. The optimum
combination is found to be 30%-40%.
Soundar et al. (2014): The selection topic was “Study On Strength Properties Of
Concrete By Partial Replacement Of Sand By Steel Slag”. Partial replacement of sand with
steel slag will be made for varying percentages such as 10%, 20%, 30%, 40%, 50% by weight
of sand. The compressive strength increase with an increase in the percentage of steel slag up
to 30% by weight of fine aggregate. The split tensile strength increases with an increase in the

percentage of steel slag up to 30% by weight of fine aggregate. The flexural strength increases
with an increase in the rate of steel slag up to 30% by weight of fine aggregate. From the results
of compressive strength, split tensile strength, and flexural strength of 7 days and 28 days
curing, 30% replacement of fine aggregate by steel slag is the optimum percentage of
replacement of M20 grade concrete. It decreases considerably in further replacement of slag in
concrete. From the stress-strain curve graph, 30% steel slag replaced M20 concrete is similar to
M20 conventional concrete.
Vidhya et al. (2016): The selection topic was “Study On Strength Properties Of
Concrete By Partially Replacing Fine Aggregate As Steel Slag”. Steel slag of varying
percentages such as 10%, 20%, 30%, 40%, 50% was replaced to fine aggregate. It was evident
that compressive strength, split tensile strength, and flexural strength increases with an increase
in the percentage of steel slag up to 30% by weight of fine aggregate. The enhancement in
compressive strength is about 25% for 7-day strength and 18.85% for 28-day strength. The
enhancement in split tensile strength is approximately 15.97% for 7days curing and 12.53%
for 28 days curing. The enhancement in flexural strength is about 27.2% for 7 days curing and
9.21% for 28 days. The optimum combination is found to be 30%.
Atthikumaran et al. (2018): The topic of study was “Design And Investigation Of
Steel Slag As A Partial Replacement For Fine And Coarse Aggregate In Concrete”. Concrete
of M20 grade was considered with a W/C ratio of 0.55. Replacement of 0%, 10%, 20%, 30%,
40%, and 50% of both fine and coarse aggregates by steel slag were carried out. The study
concluded that the compressive strength of concrete improved by 4% to 7 % at the percentage
replacements of normal crushed coarse aggregate with crystallized slag. In replacements of fine
aggregate, the strength improvement was notably observed at 30 & to 50 % replacement. It
could be said that complete substitution of slag aggregate with crushed coarse aggregate
improved the flexural and split tensile strength at 40% of replacement by 6% to 8%, and in
case of replacing fine aggregate with slag, the strength improvement was at 30% to 50 %
replacement levels by 5% to 6%. Hence, it could be recommended that slag aggregate be
effectively utilized as coarse and fine aggregate in all concrete applications as a partial
replacement of ordinary crushed coarse up to 30% and fine aggregate up to 40%.
Kothai et al. (2014): The topic of study was “Utilization Of Steel Slag In Concrete As
A Partial Replacement Material For Fine Aggregates”. Test results show that the compressive
strength of the concrete increases, and the optimum value was found at a slag replacement
proportion of 30% for fine aggregate. After that, any further replacement of slag decreases the

compressive strength. The workability was found to decrease with an increase in the
replacement of steel slag. The optimal combination was found to be 30%.
Tamboli et al. (2015): The topic of study was “Compressive Strength Of Steel Slag
Aggregate And Artificial Sand In Concrete”. In this study, the coarse aggregate was partially
replaced with steel slag aggregate with different replacement percentages in concrete, i.e., 0%,
10%, 20%, and 30%. The enhancement in compressive strength was observed to be 1.1 times
that of our conventional concrete at 28 days of curing. An increase in compressive strength at
20% of replacement ratio with 100% replacement of natural sand with artificial sand in
concrete was optimal.
Pintu et al. (2020): The topic of study was “Effect Of Partial Replacement Of Fine
Aggregate With Steel Slag And Complete Replacement Of Natural Coarse Aggregate In
Cement Concrete”. It can be reported that as the percentage of steel slag increases, the strength
increases. After a specific limit, the strength decreases. From the investigation, the optimum
ratio of steel slag is reported to be 20%. The use of recycled coarse aggregate provides concrete
with the ability to absorb more water, and consequently, the structure would have less creep
and shrinkage. The addition of steel slag in concrete also provides some ductility. The study
investigates that improvement in strength depends on the shape, size, and surface texture of
steel slag aggregates, which provide better adhesion between the particles and cement matrix.
This investigation recommends using steel slag, a cheap waste material used as fine aggregates,
and recycled coarse aggregate in M20 grade of concrete.
7.2.1 Inference
The partial replacement of fine aggregate with steel slag permits compressive, tensile,
and flexural strength up to 10% of replacement. Thus, it helps in cost reduction and mass
utilization of waste material in construction. In addition, natural coarse aggregates are moving
towards scarcity because of a lack of resources; therefore, their production and shipment have
become more difficult. It is recommended that steel slag, a cheap waste material, be used as
fine aggregates and recycled coarse aggregate in M20 grade of concrete. This method eliminates
the disposal problem of demolished concrete structure which is need of the hour for the
environment

Table 7.2: Variation of Mechanical Properties of Steel Slag Infused Concrete
Strength Increase in % compared to standard concrete
Compressive 1.1-3.2
Split tensile 3-6
Flexural 2-8

CHAPTER 8
ANALYSIS OF TEST RESULTS
8.1 COMPARISON OF VARIATIONS IN STRENGTH FOR 10% REPLACEMENT OF

COCONUT SHELL AND 10% STEEL SLAG (Ax10y10)
The mechanical testing done shows that 10% replacement for coarse and fine
aggregates causes a decrease in strength. The combination gives comparable strength in the
case of compressive and splits tensile strength. However, flexural strength shows an 18 %
decrease compared to standard concrete.
The optimum combinations based on individual replacements were 30% for steel slag
and 10% for coconut shell. Due to the prevailing condition of COVID-19, the rest of the
combinations were unable to be cast, and hence, the proper comparison was not able to be
carried out. However, for the variety with 10% replacement of fine aggregate with steel slag
and 10% replacement of coarse aggregate with coconut shell, variation in strength compared
to standard mix and individual replacement are given in table 8.1.
Table 8.1: Comparison Of Ax10y10 Mix With Standard Mix And Individual
Replacements Of Aggregates
Mechanical property Variation of strength in % compared to standard concrete
Literature (Coconut Literature (Steel

Experiment
Shell) Slag)
Compressive
3.4 -(3-8) + (1.1-3.2)
Strength
Split tensile Strength 2.4 -(4-8) +(3-6)
Flexural Strength 17.4 -(2-6.5) +(2-8)

8.2 COMPARATIVE COST ANALYSIS OF AX10Y10 SPECIMEN WITH STANDARD

CONCRETE.
Due to the unavailability to conduct the remaining combinations, only the cost
comparison of Ax10y10 is done. From table 8.2, it is shown that replacing with both steel slag
and coconut shell becomes more economical than replacing individual items. The cost
comparison showed a saving of about 5% when the replacement was done for 10% fine
aggregate and 10% coarse aggregate. On further combinations, it will become more
economical, as evident by the replacement of steel slag and coconut shell, both waste products
Table 8.2: Comparison Of Cost Between Standard Mix, Individual Replacement Of

Aggregates, And Ax10y10 Mix
Fine Coarse
Cement (bag)
Concrete aggregate (m3). aggregate (m3) Total cost
(Rate-Rs.
denotation (Rate-Rs. (Rate-Rs. (Rs)
350/bag)
820/m3) 1200/m3)
Ax00y00 7.5 0.425 0.825 3963.5
Ax10y00 7.5 0.425 0.743 3865
Ax00y10 7.5 0.383 0.825 3929.1
Ax10y10 7.5 0.383 0.743 3830.66*
Axy where A indicates the type of concrete mix:

x stands for coarse aggregate replaced with coconut shell
y stands for fine aggregate replaced with steel slag.

8.3 FUTURE SCOPE
Furthermore, combinations of varying percentages of coconut shell and steel slag

replacements may be carried out. Durability tests, thermal conductivity, and acid resistance
tests may be carried out, which will help predict the above products' lives. Studies may be
carried out to find how the impact resistance property of coconut will affect applications. The
porosity and voids created by replacing aggregates in reinforced beams may be carried out to
study the effects on applications in reinforced pavements and slabs. An investigation may be
done for higher grades of concrete and with different water-cement ratios with the same
materials.
.

CHAPTER 9
CONCLUSION
The concrete mix’s strength decreases by replacing fine aggregate with 10% steel slag
and coarse aggregate with 10% coconut shell. Due to the smooth surface finish on one side of
the coconut shell, the bond between cement and coconut shell was weak evident from the
broken surface of test specimens. The addition of steel slag was found to reduce workability
due to its porous nature. Replacement of fine and coarse aggregates by 10% will reduce the
cost by 3.4%. Coconut shell and steel slag combination could be utilized for low-cost
construction where the products are in abundance. It is a suitable waste re-utilization method
for the products which would instead end up in landfills.
Due to the difficulty caused by COVID-19 restrictions, the optimal combination was
not found as the laboratory was unavailable. Future scope exists where better strength may be
achieved by replacing 40% fine aggregate by steel slag, and 10% coarse aggregate by coconut
shell based on previous literature surveys studied.

REFERENCES
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EXPERIMENTAL STUDY ON THE PARTIAL REPLACEMENT OF FINE

AGGREGATES WITH STEEL SLAG AND COARSE AGGREGATES WITH

Department of Civil Engineering

APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

Department of Civil Engineering

APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

This is to certify that the seminar entitled

Guide Project Coordinator Head of Department

1.2 STEEL SLAG

Dept of Civil Engineering, BJI Kollam. Page No.1

Fig 1.1: Steel Slag

Dept of Civil Engineering, BJI Kollam. Page No.2

Specific Gravity 3.2-3.6

Approximate Dry rodded Unit Weight,

Table 1.2: Mechanical Properties Of Steel Slag

Los Angeles Abrasion (ASTM C131) % 20-25

Sodium Sulfate Soundness Loss (ASTM

The angle of internal friction 400-500

Hardness (measured by Mohr’s scale) 6-7

California Bearing Ratio Up to 300

1.3 COCONUT SHELL

Dept of Civil Engineering, BJI Kollam. Page No.3

Fig 1.2: Coconut Shell

1.4 OBJECTIVES OF THE WORK

• To study the mechanical properties (Compressive Strength, Flexural Strength, Split

Dept of Civil Engineering, BJI Kollam. Page No.4

1.5 SCOPE OF THE STUDY

Dept of Civil Engineering, BJI Kollam. Page No.5

Concrete is an artificial material similar in appearance and properties to some natural

2.2 COCONUT SHELL AS REPLACEMENT OF COARSE AGGREGATE.

Dept of Civil Engineering, BJI Kollam. Page No.6

Dept of Civil Engineering, BJI Kollam. Page No.7

2.3 STEEL SLAG AS REPLACEMENT OF FINE AGGREGATE

Dept of Civil Engineering, BJI Kollam. Page No.8

Dept of Civil Engineering, BJI Kollam. Page No.9

MATERIAL MATERIAL MIX

Dept of Civil Engineering, BJI Kollam. Page No.10

Dept of Civil Engineering, BJI Kollam. Page No.11

4.1 MATERIAL SELECTION

Portland Pozzolana cement of grade 43 confirming to IS 1489-1991, manufactured by

Properties tested Results

Specific gravity 2.96

Fineness test 0.023%

Initial setting time 45 minutes

Final setting time 570 minutes

Compressive strength 21.18 Mpa

4.1.2 Fine Aggregate

Dept of Civil Engineering, BJI Kollam. Page No.12

2.36mm 0.223 22.3 22.3 77.7

1.18mm 0.245 24.5 46.8 53.2

600µ 0.159 15.9 62.7 37.3

300µ 0.154 15.4 78.1 21.9

150µ 0.119 11.9 90 10

Pan 0.100 10 100 0

Fig 4.1: Particle Size Distribution Graph For Fine Aggregate

Fig 4.2: Sieve Shaker

Dept of Civil Engineering, BJI Kollam. Page No.13

1 1 5.814 5.278 5.23 11.167

2 2 5.814 4.868 4.77 21.88

3 3 5.814 4.52 4.39 32.44

4 4 5.814 4.261 4.09 42.15

5 5 5.814 4.185 3.99 45.71

6 6 5.814 4.267 4.025 44.44