ON-LINE RECOGNITION OF DEVELOPING CONTROL CHART PATTERNS

PERFORMANCE OF CONCRETE PAVEMENT CONTAINING COAL BOTTOM

ASH

ABDULLAH ADEL MOHAMED ABDEEN

A project report submitted in partial fulfilment of the

requirements for the award of the degree of

Master of Engineering (Civil)

School of Civil Engineering

Faculty of Engineering

Universiti Teknologi Malaysia

JANUARY 2019

iii

DEDICATION

This project report is dedicated to my father, who taught me that the best kind

of knowledge to have is that which is learned for its own sake. It is also dedicated to

my mother, who taught me that even the largest task can be accomplished if it is done

one step at a time.

iv

ACKNOWLEDGEMENT

In preparing this thesis, I was in contact with many people, researchers,

academicians, and practitioners. They have contributed towards my understanding and

thoughts. In particular, I wish to express my sincere appreciation to my main thesis

supervisor Dr. Muhammad Naqiuddin Mohd Warid, for encouragement, guidance,

critics and friendship. I am also very thankful to my previous supervisor Dr.

Ramadhansyah Putra Jaya for his guidance, advices and motivation. Without their

continued support and interest, this thesis would not have been the same as presented

here.

I am also indebted to Universiti Teknologi Malaysia (UTM) for funding my

master study.

My fellow postgraduate student should also be recognised for their support.

My sincere appreciation also extends to all my colleagues and others who have

provided assistance at various occasions. Their views and tips are useful indeed.

Unfortunately, it is not possible to list all of them in this limited space. I am grateful

to all my family member.

v

ABSTRACT

The purpose of this study is to investigate the performance of the concrete

pavement contains several percentages of coal bottom ash (CBA). Many power plants

produce very large quantity of the coal bottom ash as a waste. The way to get rid of

the CBA in very dangerous and could cause hazards to the environment and the

surroundings. As using of coal bottom ash can help in solving environmental problems,

thus this study is to investigate the possibility of using it as a replacement of fine

aggregate in improving the performance of concrete pavement. Concrete specimens

prepared containing 0%, 10%, 20%, 30% and 40% of coal bottom ash as a replacement

of fine aggregates. This study performed on compressive strength, Porosity,

permeability, density and skid resistance. It has been found that the compressive

strength decreases with the increase of the coal bottom ash content at early ages. Also,

the percentage of the absorption increases as the percentage of CBA content increase.

Same as the volume of permeable pore spaces (voids), it also increases with the

increase of the CBA content. On the other hand, the density decreases with the increase

of the CBA content. Results also show that the British pendulum number increases

with the increase of content of the CBA.

vi

ABSTRAK

Tujuan kajian ini adalah untuk mengkaji prestasi turapan konkrit yang

mengandungi beberapa peratus sisa arang batu. sisa arang batu yg banyak dihasilkan

sebagai sisa industri. Kaedah pelupusan sisa arang batu di tanah terbuka adalah bahaya

kepada alam sekitar dan masyarakat sekitar. Penggunaan sisa arang batu boleh

membantu dalam menyelesaikan masalah alam sekitar, maka kajian ini adalah untuk

mengkaji kemungkinan menggunakannya sebagai pengganti agregat halus dalam

meningkatkan prestasi turapan konkrit. Spesimen konkrit disediakan mengandungi

0%, 10%, 20%, 30% dan 40% sisa arang batu sebagai pengganti agregat halus. Kajian

ini dilakukan pada kekuatan mampatan, keliangan, kebolehtelapan, kepadatan dan

rintangan tergelincir. Didapati bahawa kekuatan mampatan menurun dengan

peningkatan kandungan abu bawah arang batu pada usia awal. Sama seperti jumlah

ruang liang yang dapat ditapis (lompang), ia juga meningkat dengan peningkatan

kandungan sisa arang batu. Sebaliknya, ketumpatan berkurangan dengan peningkatan

kandungan abu berasaskan arang batu. Keputusan juga menunjukkan bahawa bilangan

pendulum British meningkat dengan peningkatan kandungan sisa arang batu.

vii

TABLE OF CONTENTS

TITLE PAGE

DECLARATION Error! Bookmark not defined.

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF ABBREVIATIONS xiii

LIST OF SYMBOLS xiv

CHAPTER 1 INTRODUCTION 1

1.1 Problem Background 1

1.2 Problem Statement 1

1.3 Research Goal 2

1.3.1 SCOPE OF THE RESEARCH 3

1.3.2 Significant of The Research 3

CHAPTER 2 LITERATURE REVIEW 4

2.1 Introduction 4

CHAPTER 3 Research Methodology 15

3.1 Introduction 15

3.2 Proposed Method 15

3.3 Material Preparation 16

3.3.1 Aggregates 16

3.3.2 Cement 16

3.3.3 Coal Bottom Ash 17

viii

3.3.3.1 Chemical Properties 17

3.3.3.2 Physical properties 18

3.3.4 Sieve Analysis 19

3.4 Concrete Mix Design 22

3.4.1 Mix design procedure are described by the

following steps: 23

3.4.1.1 Stage 1: Determining the Water/

Cement Ratio 23

3.4.1.2 Stage-2: Calculation of the target

mean strength, fm 23

3.4.1.3 Stage-3: Determination of the Free-

Water Content 26

3.4.1.4 Stage-4: Determination of Cement

Content 27

3.4.1.5 Stage 5: Determining the Total

Aggregate Content 27

3.4.1.6 Stage 6: Determining of The Fine

and Coarse Aggregate Contents 29

3.4.2 Procedures of Design Mixing 31

3.4.2.1 Production of Trial Mix Design 31

3.4.2.2 Tests on Trial Mix Design 32

3.5 Performed Tests 35

3.5.1 Compressive Strength Test 35

3.5.2 Density, Absorption and Volume of Voids 37

3.5.3 Skid Resistance 40

3.5.3.1 Levelling the Apparatus 42

3.5.3.2 Testing Procedure 43

3.6 Chapter Summary 44

CHAPTER 4 Results and Discussion 45

4.1 Results in General 45

4.2 Results and discussion 46

4.2.1 Compressive Strength Test 46

4.2.2 Density, Porosity and Permeability 47

ix

4.2.3 Skid Resistance 51

CHAPTER 5 CONCLUSION AND RECOMMENDATIONS 54

5.1 Research Outcomes 54

5.2 Contributions to Knowledge 55

5.3 Future Works 55

REFERENCES 56

x

LIST OF TABLES

TABLE NO. TITLE PAGE

Table 2.1 Physical properties of bottom ash according to different Thermal

Power Plants in India 11

Table 3.1 Number of specimens used in compressive strength test 15

Table 3.2 Sieve analysis for sand and CBA and the finesse modulus 21

Tabe 3.3 Approximate compressive strength (N/mm2) of concrete mixes made

with a water/cement ratio of 0.5 24

Table 3.4 Quantity Calculation for three (100mm) Concrete cubes 35

Table 4.1 results of the compressive strength test in MPa 46

Table 4.2 results and calculations of density, absorption and voids 47

Table 4.3 British Pendulum Number (BPN) for each percentage of CBA 51

xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE

Figure 2.1 Screening of Coal Bottom Ash 7

Figure 2.2 Finesse modulus of sand and CBA in A S Cadersa study 7

Figure 2.3 Coal Bottom Ash effect on workability 8

Figure 2.4 Effect of bottom ash replacement on plastic density 9

Figure 2.5 Compressive strength with Bottom Ash Content 10

Figure 3.1 The shaker used to perform sieve analysis 20

Figure 3.2 Coal bottom ash is found to be a dark grey material by having

angular particles shapes 21

Figure 3.3 Sieve Analysis of Sand and CBA 22

Figure 3.4 Relationship between standard deviation and characteristic strength.

23

Figure 3.5 Relationship between compressive strength and water/ cement ratio.

25

Figure 3.6 Approximate free-water contents (kg/m3) required to give various

levels of workability. 26

Figure 3.7 Estimated wet density of fully compacted concrete. 28

Figure 3.8 Recommended proportions of fine aggregate according to percentage

passing a 600 μm sieve. 30

Figure 3.9 Some of the prepared specimens 33

Figure 3.10 Concrete mix design form used in the study 34

Figure 3.11 Compressive strength machine used in this study 36

Figure 3.12 Ballance to record the weight of the specimens 38

Figure 3.13 Oven with 110 ± 5 oC 38

Figure 3.14 Placing the specimens in the oven for 24 hours 38

Figure 3.15 Emersion the specimens in water for 48 hours 38

Figure 3.16 British Pendulum Tester 41

Figure 3.17 British Pendulum tester 44

Figure 3.18 Specimens to test the skid resistance 44

xii

Figure 4.1 results of the compressive strength test with different CBA content 47

Figure 4.2 Absorption and Volume of voids 49

Figure 4.3 Density results for every CBA percentages 50

Figure 4.4 relationship between the percentages of CBA and the British

pendulum number 51

Figure 4.5 relationship between the BPN and the car moving speed 52

*

xiii

LIST OF ABBREVIATIONS

RHA - rice husk ash

FA - Fly Ash

MK - metakaolin

SF

LOI

-

-

silica fume

Loss on Ignition

CBA - Coal Bottom Ash

ACAA - American Coal Ash Association

ASTM - American Society for Testing and Materials

BPN - British Pendulum Number

UTM - Universiti Teknologi Malaysia

xiv

LIST OF SYMBOLS

A - Mass of oven dried sample in air

B - Mass of surface-dry sample in air after immersion

C - Mass of surface-dry sample in air after immersion and

boiling

D - Apparent mass of sample in water after immersion and

boiling

g1 - Bulk density, dry

g2 - Apparent density

ρ - Density of water

Mg - Mega grams

m - meters

kN - Kilo Newton

MPa

D

C

W

-

-

-

-

Mega Pascals

The wet density of concrete

The cement content

The free-water content

1

CHAPTER 1

INTRODUCTION

1.1 Problem Background

The waste of construction and industry is very dangerous to the environment.

However, many researches have been studying the suitable alternatives for these

wastes. The major problem that is facing the environment and the human being is the

disposal of these kinds of wastes. Disposing these kinds of wastes is the main concerns

and the most focused subjects to insure a safe environment. Coal bottom ash is

considered to be the biggest industrial waste the power plants produce. A study

recently shows that the burning around 3 million to of the coal could produce around

1 million on of the bottom ash. The production of many sorts of energy and many sorts

of materials such as steel and concrete in mainly uses coal. Coal is considered as a

significant source of fuel in Malaysia. Nowadays, fossil fuels become the foremost

basis for energy generation. The demand for fossil fuels has increased due to a high

demand for electricity generation, as well as the consumption of fossil fuels by several

countries such as USA, EU, India, and China.

1.2 Problem Statement

Concrete is a composite material composed of fine and coarse aggregate

bonded together with a cement paste that hardens over time. When aggregate is mixed

together with dry Portland cement and water, the mixture forms a fluid slurry that is

easily poured and molded into shape. The cement reacts chemically with the water and

other ingredients to form a hard matrix that binds the materials together into a durable

stone-like material that has many uses. Often, additives (such as pozzolans or

superplasticizers) are included in the mixture to improve the physical properties of the

2

wet mix or the finished material. Concrete has been widely used as paving material for

highways, airports, streets, local loads, parking lots, industrial facilities, residential

areas, and among other types of infrastructures. Concrete pavement is one of the oldest

forms of road construction and is still widely used until today. Concrete is the main

component of concrete pavements. Concrete pavement is slightly deflected under

loading because of the high elasticity modulus of the surface course. By varying the

proportions of Portland cement, aggregate, and water, newly mixed concrete

pavements exhibit plastic and malleable properties, whereas hardened pavements

show strong and durable properties. Concrete has been widely used as paving material

for highways, airports, and residential areas, among others. Pozzolanic materials, such

as silica fume (SF), fly ash (FA), metakaolin (MK), blast-furnace lag, and rice husk

ash (RHA) are used to improve the performance and durability of Portland cement

concrete.

Concrete pavement completely depends on flexural strength not as same as

concrete asphalt, so it is critically important to find the replacement optimum

percentage of the coal bottom ash which gives the highest compressive strength and

the other durability factors. Malaysia produces million tons of CBA (coal bottom ash)

as an industrial waste. Reusing this waste instead of disposal as a replacement with the

fine aggregate in concrete in an environmentally friendly option. Through a number of

percentages of coal bottom ash replacements in order to improve the performance and

the durability factors of the concrete pavement is the key issue.

1.3 Research Goal

Research Objectives

This study carried out the investigation of replacing the sand (fine aggregates)

by CBA (coal bottom ash) with the percentages (0% (control mix), 10%, 20%, 30% and

40%) on concrete pavement and determine the optimum replacement. Compressive

3

strength test performed on specimens containing mixes with percentages replacement

mentioned above in the ages of 7, 14, 28 and 56 days, and some other durability aspects

the significantly affects concrete pavement like density, porosity, permeability and

skid resistance.

There are a several numbers of objectives that can be achieved by replacing a

percentage of fine aggregates with CBA (coal bottom ash), this work is focused at the

following objectives:

1) To investigate the properties of the concrete pavement containing coal bottom

ash.

2) To determine the optimum percentage of replacing coal bottom ash in the

concrete pavement.

1.3.1 SCOPE OF THE RESEARCH

The central question to be examined in this study is to seek the optimum

percentage of replacing the fine aggregates with CBA (coal bottom ash) in the concrete

pavement. Furthermore, to study the performance of the concrete pavement, more

specifically the effects on the compressive strength, density and other durability

aspects that influences the concrete pavement.

1.3.2 Significant of the Research

The environmental issue is a major problem in many countries. They are

seriously taken this problem with technology and enforcement by law to reduce this

pollution. In Malaysia, the way in handling the pollution on coal ash is by using

conventional method which is the waste were stored in manmade ponds. This study

might contribute to solve some of the coal waste problems and reduce the pollution.

56

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