UTILIZATION AND EFFECT OF ADDITION OF WASTE

PLASTIC AS REPLACEMENT OF AGGREGATES IN

CONCRETE

A DISSERTATION REPORT

Submitted by
ASHFAQ MALIK (11108023)

In partial fulfillment for the award of the degree of

MASTERS OF TECHNOLOGY

IN

STRUCTURAL ENGINEERING

Under the guidance of

Mr Rohit Vasudeva

Assistant Professor

School of Civil Engineering

LOVELY PROFESSIONAL UNIVERSITY

Phagwara–144411, Punjab (India)

 DECLARATION

I hereby declare that the dissertation report titled “Utilization And Effect Of Addition Of
Waste Plastic As Replacement Of Aggregates In Concrete” is an authentic record of my
own research work carried out as a requirement for the preparation of M-Tech dissertation for
the award of Masters of Technology Degree in Structural Engineering from Lovely
Professional University, Phagwara, Punjab, under the guidance of Mr Rohit Vasudeva, during
the period between January 2015 and April 2016. All the information furnished in this report
is based upon my intensive work and is completely genuine to the best of my knowledge. And
no part of the uncited work in this report has ever been published before in any journal or
presented for the award of any degree or honour.

Place: Phagwara Ashfaq Malik

Date: 29 April 2016 11108023

CERTIFICATE

This is to certify that the declaration statement made by the below stated student is correct to
the best of my knowledge and belief. He has prepared this report under my guidance and
supervision. The present work is the result of his original investigation, effort and study. No
part of the work has ever been submitted for the award of any other degree at any University.
The report is fit for the submission for partial fulfilment of the conditions for the award of
M.Tech degree in Structural Engineering from Lovely Professional University, Phagwara.

Mrs Mandeep Kaur Mr Rohit Vasudeva

Head Of the Department Asst. Professor
School of Civil Engineering School of Civil Engineering
Lovely Professional University Lovely Professional University

i
 ACKNOWLEDGEMENTS

I would offer my sincere gratitude to Lovely Professional University, for allowing me to

pursue my research in the areas of my interest.
I have immense gratitude for my mentor, Mr Rohit Vasudeva, for helping me every step of
the way and for being profoundly patient with me all the while. Words are simply not enough
to thank him for his guidance and generosity.
I am also thankful to the Head Of the Department, Civil Engineering, Mrs Mandeep Kaur,
who guided and helped, wherever needed; the person responsible for approving this project to
go forward.
My first mentor, Ms Divya Chopra, who helped me select this topic, in the first place. Endless
gratitude.
The Research Coordinator, Mrs Geeta Mehta, who made sure we referred to indexed journals
and proper research papers.
The Head Of Labs, Civil Department, Mr Bhanu Magotra, for allowing us to conduct
experiments, with all the resources available at his disposal.
I would like to thank Mr S. Ganesh, Asst. Professor, Structural Engineering, for his valuable
feedback and advice.
Even when we have everything, the will to go forward is what it takes to accomplish tasks. And
that is why I would express endless gratitude to Mrs Dolonchapa Prabhakar, Head Of the
Department, Civil Engineering, for her unrelenting support and motivation.
And I’m indebted to all the favours shown to me by all the faculty members and laboratory
staff. This project became a lot easier with their encouragement and help.
I can not end this without mentioning my fellow scholars and friends – Ms Aayushi, Ms Ritu,
Mr Shahzoor, and Mr Jainendra. They helped me when I needed them most and all this
would not have been possible without them.

Ashfaq Malik
11108023

ii
 ABSTRACT

Concrete is the most used man-made material in the world today. Seconded only by Plastics.
While concrete is efficiently utilized in construction, plastics comprise of mostly temporary
and disposable products, resulting into a massive increase in non-biodegradable solid waste.
If we can somehow utilize the plastic wastes in a constructive manner, even in a very small
amount, it will contribute a lot to the environment and also pose as a means of cost reduction
in construction.
This report presents the results of the tests conducted on concrete for strengths in compression,
flexure and splitting tension, on the replacement of Natural Coarse Aggregates by Plastic
Coarse Aggregates at 0%, 10%, 15%, 20% and 25%.
The plastic used is High Density Polyethylene, in the form of aggregates that vary in size from
10 mm to 20 mm.
This study unveiled that Plastic Coarse Aggregates can be effectively used to partially replace
the Natural Coarse Aggregates. And the optimum value is estimated at 20% replacement.
The concrete so formed can used for the construction process, especially, when the self-weight
of the structure or structural member needs to be reduced a little.

iii
 TABLE OF CONTENTS
________________________________________________________________

CHAPTER PAGE NO.

DECLARATION i
CERTIFICATE ii
ACKNOWLEDGEMENT ii
ABSTRACT iii
TABLE OF CONTENTS iv
LIST OF FIGURES v
LIST OF TABLES
LIST OF PLATES
LIST OF SYMBOLS
CHAPTER 1 – INTRODUCTION 1-4
1.1 General 1
1.2 Historical Aspects 2
1.3 Types of Plastics 3
1.4 Challenges and possible remedies 4
CHAPTER 2 – LITERATURE REVIEW 5-11
CHAPTER 3 – RATIONALE AND SCOPE OF THE STUDY 12
CHAPTER 4 – OBJECTIVES OF THE STUDY 13
CHAPTER 5 – MATERIALS AND DESIGN METHODOLOGY 14-20
5.1 General 14
5.2 Materials 14
5.2.1 Cement 14
5.2.2 Fine Aggregates 14
5.2.3 Coarse Aggregates 15
5.2.4 Plastic Aggregates 16
5.2.5 Water 16

iv
 5.3 Mix Design 17
5.4 Casting and Curing 19
5.5 Testing Methods 19-20
5.5.1 Fresh Concrete 19
5.5.2 Hardened Concrete 20

CHAPTER 6 – RESULTS AND DISCUSSIONS 21-26

6.1 General 21
6.2 Tests on Materials 21
6.2.1 Tests on cement 21
6.2.2 Tests on Natural Coarse Aggregates 21
6.2.3 Tests on Fine Aggregates 22
6.2.4 Test on Water 23
6.2.5 Tests on Recron 3S Fibre 23
6.2.6 Tests on Concrete 23-26
6.2.6.1 Slump Cone Test 23
6.2.6.2 Compressive Strength Test 24
6.2.6.3 Split Tensile Strength Test 25
6.2.6.4 Flexural Strength Test 26
CHAPTER 7 – CONCLUSION 28
7.1 General 28
7.2 Meeting Objectives 28
7.3 Future Scope 28

REFRENCES

v
 LIST OF FIGURES
________________________________________________________________
Figure No. Description Page No.

2.1 Praveen Mathew et al, Volumetric Substitution 5

6.1 Slump Test 24
6.2 Compressive Strength Test 25
6.3 Split Tensile Strength Test 26
6.4 Flexural Strength Test 27

vi
 LIST OF TABLES
________________________________________________________________
Table No. Description Page No.
1.1 Types of Plastics 3
2.1 Praveen Mathew et al, Aggregate Properties 5
2.2 Praveen Mathew et al, Concrete Slump 5
2.3 Praveen Mathew et al, Compressive Strength 6
2.4 Praveen Mathew et al, Tests on Cylinder 6
2.5 Khilesh Sarwe, Compressive Strength with plastic 6
2.6 Khilesh Sarwe, Compressive Strength with plastic & steel 7
2.7 Stamatia Gavela, reference Mix 7
2.8 Stamatia Gavela, Proportion mixes containing PP 8
2.9 Stamatia Gavela, Proportion mixes containing PET 8
2.10 Stamatia Gavela, Bulk Density 8
2.11 Stamatia Gavela, Compressive Strength 9
2.12 Stamatia Gavela, Flexural Strength 9
2.13 A.S. Balaji et al, Compressive Strength 9
2.14 A.S. Balaji et al, Split tensile Strength 10
2.15 P. Manikandan et al, Properties of plastics 10
2.16 P. Manikandan et al, Compressive Strength 11
2.17 P. Manikandan et al, Split Tensile Strength 11
5.1 Properties of Cement 14
5.2 Physical Properties of Fine Aggregates 15
5.3 Sieve Analysis of Fine Aggregates 15
5.4 Properties of Coarse Aggregates 15
5.5 Sieve Analysis of 20 mm Aggregates 16
5.6 Sieve Analysis of 20 mm Aggregates 16
5.7 Properties of Plastic Aggregates 16
5.8 Proportions of Materials 18
5.9 Specimen Quantities 19

vii
6.1 Tests on Cement 21
6.2 Tests on Natural Coarse Aggregates 21
6.3 Sieve Analysis 10mm Natural Coarse Aggregates 22
6.4 Sieve Analysis 20mm Natural Coarse Aggregates 22
6.5 Tests on Fine Aggregates 22
6.6 Sieve Analysis of Fine Aggregates 23
6.7 Properties of Recron 3S 23
6.8 Slump Cone Test 23
6.9 Compressive Strength Test 24
6.10 Split Tensile Strength Test 25
6.11 Flexural Strength Test 26

viii
Chapter 1: Introduction
___________________________________________________________________________
1.1 General
Concrete is the most utilized man-made material in the world today. And this list is closely
followed by Plastics.
However, where concrete is effectively utilized in construction, Plastic, being non-
biodegradable, does not decompose easily, and is therefore a potential hazard for the
environment and must be utilized somewhere efficiently. Plastics have a high potential to be
recycled many times. But this number of times is a finite quantity. It can effectively recycled
for only so many times. With every recycle, the plastics lose an amount of strength.
Ideally, Concrete is a mixture of a binder – which is usually Cement, Fine Aggregates – usually
natural sand, Coarse Aggregates – usually natural stones, and Fluid – Water.
The coarse aggregates provide most of the strength in concrete. They form the basis for the
strength in concrete, actually. The stronger the coarse aggregates, the better the concrete and
vice versa. The fine aggregates fill up the voids left behind by the coarse aggregates, thereby
further contributing in the strength improvement as lesser and smaller the voids or empty
spaces, more the strength. This is because the matrix would then be more compact. The binder,
having the particle size even smaller than the fine aggregates, further fills up the voids left
behind by fine aggregates and hardens in the presence of water, thereby justifying its name by
binding it all together. The fluid, water, allows it all to mix together properly and thereby
provides the workability – the ease of flow.
The coarse aggregates apart from providing the overall strength and stability are required to
possess certain qualities like Hardness – the resistance to abrasion, Toughness – the resistance
to impact loading, Soundness – the resistance to weathering, Durability – the long life, desired
shapes and sizes, as certain shapes are better at providing strength than the others because of
symmetry and line of action of forces, and there are limits to the size of stones and other
materials that can be used as coarse aggregates, and water absorption, as it can interfere with
the water-cement ratio, which is a crucial factor that influences the binding properties of the
binder, as the scarcity of water will not allow binder to set and harden up to its full potential
and the excess of water will make the concrete too fluid to be efficiently useful.
Plastic is a polymer material that consists of any of the wide range of synthetic or semi-
synthetic organic materials, which on the application of heat can be moulded into solid objects
of various forms and sizes.
A polymer is a large molecule that is made up of many smaller molecules called monomers.
These monomers undergo a chemical reaction and link together, forming a matrix. These linked
monomers are known as polymers.
Recron 3S fibres are polyster fibres that reduce the crackingin concrete to a certain degree.
Polyster is closely related to a type of plastic called Polyterephathalphate (PET).

1
1.2 Historical Aspects
The word Concrete has latin roots, as it is derived from the latin word “concretus”, that means
“condensed” or “compact” [A], which is true because this is what concrete is aimed to be, a
condensed or a compact form of all its ingredients – Cement, Coarse Aggregates, Fine
Aggregates, and Water.
The earliest human use of concrete can be traced back to a few thousand years.
Concrete-like substances were used since around 6500 BC. The advantages of hydraulic lime
was discovered by about 700 BC. Kilns were built in order to supply mortar for aiding in the
construction of houses made of rubble wall, concrete floors and water-proof cisterns that were
underground. Some of these structures survive, even today. [B]
In Egyptian and Roman times, the use of Volcanic ash was rediscovered, that its addition would
allow the concrete to work under water.
The Romans found out that the addition of horse-hair improved the crack-resistance of
concrete, and frost-resistance was improved by mixing blood into the mix. [C]
Lime mortars have also been discovered to have been used in Crete, Greece and Cyprus, in
around 800 BC.
Water-proof concrete was used in the Assyrian Jerwan Aqueduct in around 688 BC.
After the fall of Roman Empire, the use of concrete was almost discarded, until the Canal Du
Midi, that was built in 1670. [D]
Joseph Aspdin got a patent for a method of producing Portland Cement. [E]
Joseph Monier, in 1849, invented the reinforced concrete. [F]
The word Plastic, has a Greek origin. It comes from the word, “Plastikos”, that means “able to
be shaped or moulded”. [G][H]
In 1600 BC, Natural Rubber was used by Mesoamericans for making bands, balls, and
figurines. [I]
In 1800s, with the Industrial Revolution, Charles Goodyear discover the vulcanized natural-
rubber derived thermoset materials.
The title of the first man-made plastic is taken by Parkesine. For this, cellulose was treated with
Nitric Acid and dissolved in Alcohol and then hardened into an elastic substance that was also
transparent, and on heating, could be moulded. [J]
After World War – I, the chemical industry improved and around the World War – II, [K] new
polymers were discovered, such as, Polystrene (PS) and Poly Vinyl Chloride (PVC).
In 1941, Polyethylene terephthalphate (PE) was discovered, and later in 1954, PolyPopylene
(PP) was discovered. [I]

2
1.3 Types of Plastics
Table No. 1.1 Types of Plastics
S. No. Type of Plastic Denotation Example
1 Polyester PES Fibers, textiles

2 Polyethylene terephthalate PET Bottles, jars, plastic film

3 Polyethylene PE bags, plastic bottles

4 High-density polyethylene HDPE Shampoo bottles, milk jugs

5 Polyvinyl chloride PVC Plumbing pipes, shower curtains

6 Polyvinylidene chloride PVDC Food packaging

7 Low-density polyethylene LDPE Furniture, floor tiles, packaging.

8 Polypropylene PP Bottle caps, straws, car bumpers

9 Polystyrene PS Packaging foam, disposable cups,

CD
10 High impact polystyrene HIPS food packaging, vending cups

11 Polyamides (Nylons) PA Fibers, toothbrush bristles, fishing

line
12 Acrylonitrile butadiene styrene ABS Monitors, printers, keyboards,
pipes
13 Polyethylene/Acrylonitrile PE/ABS Low-duty dry bearings.
Butadiene Styrene
14 Polycarbonate PC Eyeglasses, riot shields, security
windows, traffic lights, lenses.
15 Polycarbonate/Acrylonitrile PC/ABS car interior and exterior parts,
Butadiene Styrene mobile phone bodies
16 Polyurethane PU Cushioning foams, thermal
insulation foams, printing rollers

Among these, there are main six types of plastics:

i. Polyethylene Terephthalate (PET)
ii. High density polyethylene (HDPE)
iii. Polyvinyl chloride (PVC)
iv. Low density polyethylene (LDPE)
v. Polypropylene (PP)
vi. Polystyrene (PS)

3
Out of these, High Density Polyethylene (HDPE) will be used in the replacement of Natural
Coarse Aggregates in the concrete.

1.4 Challenges and possible remedies

Plastic, being more ductile, lighter in weight and having a stable chemical structure, its use as
coarse aggregates instead of the regular natural coarse aggregates, proves to be beneficial as
it enhances most of the desirable properties of coarse aggregates. For example, the crushing
resistance of plastic coarse aggregates is higher than that of natural coarse aggregates and the
crushing of coarse aggregates causes most of the failures in concrete structures.
The only problem arises that the bond strength of plastic and concrete matrix is not as strong
as compared to the natural aggregates. This is mainly because of the smooth surface of the
plastics that prevent the mechanism of interlocking. This, however, can be taken care of to a
large extent, using rough surface of aggregates.
These enhancements, thus, make the construction and the structure more economical, which
is one of the basic aims of structural engineering.
The full and complete replacement of natural coarse aggregates with the plastic coarse
aggregates is not feasible. Therefore, only some percentage of natural coarse aggregates is to
be replaced with plastic coarse aggregates for desired and optimum results.

4
Chapter 2: Review of Literature
________________________________________________________________

Various researchers have worked on similar topics.

Praveen Mathew et al [1], replaced natural coarse aggregates (NCA) with plastic coarse
aggregates (PCA) and conducted tests as per the Indian Standard specifications.
The following are their findings:
Table No. 2.1
Property NCA PCA
Specific Gravity 2.74 0.9
Crushing Value 28 2
Density 3.14 0.81

Tests done after the aggregates were used in concrete yielded the following results:
Table No. 2.2
Particular Slump (in mm) Compaction Factor
NCA 33 0.93
20 % replacement with PCA 36 0.95

Volumetric substitution of PCA was done for various percentage substitutions. The cube size
was (15x15x15) cm, for M20 grade cement at the end of 28 days of curing. The following
graph shows the findings:

Figure No. 2.1

From the graph, the optimum substitution was taken at 22%.

5
Tabulating the results:
Table No. 2.3
Compressive Strength (in MPa)
Particulars
NCA Concrete 24.2
20% PCA Concrete 30.83
100% PCA Concrete 18.74

Tests for structural behaviour were conducted to determine cylinder compressive strength, split
tensile strength and modulus of elasticity. The size of specimen was (150x300) mm. The
following are the results:
Table No. 2.4
Particulars Cylinder Splitting Tensile Modulus of Elasticity
Compressive Strength (in (in MPa)
Strength (in MPa) MPa)
NCA 11.8 2.45 16290
22% PCA 16.27 1.91 12686

It was found that 22% PCA concrete had lower split tensile strength. The reason is the
deficient bonding between PCA and the matrix. However, this concern can be minimized by
using suitable admixtures to improve bond strength.

Khilesh Sarwe [2], developed a concrete mix, with disposable cups as the waste plastic. M20
concrete, 43 grade OPC was used as the binder. Locally available sand passing through 4.75mm
IS sieve, having specific gravity of 2.65 was used was used as fine aggregates. Crushed
aggregate available from local sources, maximum size of 20mm, having specific gravity of 2.8
and the water absorption of 0.5% has been used as coarse aggregate. Steel fibers of length
50mm and width of 0.5mm were used.
The compressive strength of concrete, only with plastic, after 7 days and 28 days was tested.
The results are as follows:

Table No. 2.5

% of Plastic 7 days compressive strength 28 days Compressive Strength
(in ton) (in ton)
0 43.7 63
0.2 40.7 62.1
0.4 38.0 59.6
0.6 36.3 58.7
0.8 35.3 57.7
1.0 34.3 57

6
The compressive strength of concrete with both, plastic as well as steel fibers, was tested after
7 days and 28 days. The following are the results:

Table No. 2.6

% of Plastic / % of steel 7 days compressive strength 28 days Compressive Strength
(in ton) (in ton)
0.2 / 0.1 41 62.7
0.4 / 0.2 41.7 63.3
0.6 / 0.3 42.6 64.7
0.8 / 0.4 40.7 63.7
1.0 / 0.5 39.7 62.7

It was concluded that with 0.6% of waste plastic and 0.3% of steel fibers, the compressive
strength was comparatively, the highest.

Stamatia Gavela et al. [3], studied concrete containing thermoplastic wastes as aggregates.
They used PET and PP to replace NCA by 20% and 30% each, with water-cement ratios of 0.5
and 0.6. The concrete mix originally contained cement, sand, gravel, water, coarse aggregates.

Two reference mixes were created in the following proportions:

Table No. 2.7

Mix Component Reference Mix 1 (RM1) Reference Mix 2 (RM2)
Water (Kg/m3) 200 230
Cement (Kg/m3) 400 460
Gravel (% by Volume) 15 10
Sand (% by Volume) 85 90

7
Proportion of Mixes containing PP aggregates:

Table No. 2.8

Mix Component w/c = 0.5 w/c = 0.6
PP (Volume 20% 30% 20%
replacement)
Water (Kg/m3) 200 230 200
Cement (Kg/m3) 400 460 333.3
Sand (Kg/m3) 1138.3 970.9 1175.8
Gravel (Kg/m3) 265.5 163.6 274.4
PP aggregates 133.1 184.5 137.5
(Kg/m3)

Proportion of Mixes containing PET aggregates:

Table No. 2.9

Mix Component w/c = 0.5 w/c = 0.6
PET (Volume 20% 30%
replacement)
Water (Kg/m3) 200 200
Cement (Kg/m3) 400 333.3
Sand (Kg/m3) 1138.3 1085.4
Gravel (Kg/m3) 265.5 182.8
PET aggregates (Kg/m3) 159.6 247.4

Resultant Bulk Density:

Table No. 2.10
Concrete Mix Bulk Density (Kg/m3)
RM1 2250
RM2 2359
20% PP 2100
30% PP 1950
20% PET 2262
30% PET 2130

8
Resultant Compressive Strength:
Table No. 2.11
Concrete Mix 7 days (MPa) 28 Days (MPa)
RM1 33.4 40.2
RM2 31.5 40.6
20% PP, w/c =0.5 25.6 33.3
20% PP, w/c =0.6 20.9 25.8
30% PP, w/c =0.5 18.5 23.5
20% PET, w/c =0.5 26.7 35.1
30% PET, w/c =0.6 19.0 24.0

Resultant Flexural Strength:

Table No. 2.12
Concrete Mix 7 days (MPa) 28 Days (MPa)
RM1 4.64 5.34
RM2 4.66 6.07
20% PP, w/c =0.5 3.98 5.03
20% PP, w/c =0.6 3.06 4.14
30% PP, w/c =0.5 2.83 2.89
20% PET, w/c =0.5 4.05 4.79
30% PET, w/c =0.6 2.87 3.27

They concluded that plastic aggregates can be successfully used to replace natural aggregates
in concrete. The type of polymer does not influence the strength, only the percentage of
replacement does. Also, the drop in compressive and flexural strengths is attributed to lower
bond between cement paste and plastic aggregates.
A. S. Balaji and D. Mohan Kumar [4], conducted a study on the behaviour of concrete, by
partially replacing the coarse aggregates by plastic chips and cement by human hair. The
materials used in the concrete were Pozzolana Portland Cement 43 Grade, clean river sand with
particle size less than 2.36 mm, crushed angular coarse aggregates 20 mm in size, recycled
plastic aggregates with varying length of (0.15-12) mm and varying width of (0.15-4) mm and
human hair. M20 grade of Concrete was used with water-cement ratio of 0.45.
Compressive strength tests were conducted on concrete cubes of size (150x150x150) mm.
Following are the results after a curing period of 28 days:
Table No. 2.13
S. No. No. of days % Hair % Plastic Compressive
Strength
(N/mm2)
1 7 0% 24.67
2 14 0% 0% 28.36

9
 3 28 0% 32.43
4 7 0.5% 26.03
5 14 0.5% 20% 30.22
6 28 0.5% 33.57
7 7 1% 28.56
8 14 1% 20% 33.78
9 28 1% 38.22
10 7 1.5% 29.34
11 14 1.5% 20% 33.89
12 28 1.5% 38.45
13 7 2% 30.34
14 14 2% 20% 34.89
15 28 2% 39.45
16 7 3% 28.26
17 14 3% 20% 32.89
18 28 3% 39.12
Split tensile strength tests were conducted on concrete cylinders of 300 mm length and 150
mm diameter. Following are the results after a curing period of 28 days:
Table No. 2.14
S. No. No. of days % Hair % Plastic Split tensile
Strength
(N/mm2)
1 28 0% 0% 3.243
2 28 0.5 % 20 % 3.357
3 28 1% 20 % 3.822
4 28 1.5 % 20 % 3.845
5 28 2% 20 % 3.945
6 28 3% 20 % 3.912

They concluded that plastics can be used to replace some of the aggregates in a concrete
mixture. It reduced the unit weight of concrete and made it more ductile. The concrete also had
better thermal insulation. Also, the addition of human hair improved the split tensile strength
of the concrete.
P. Manikandan and Dr S. Senthamil Kumar [5], studied Recycled wasted plastic concrete.
Ordinary Portland Cement and M25 grade of concrete were used for this study, along with fine
aggregates, coarse aggregates and plastic aggregates.

The properties of plastics are as follows:

Table No. 2.15

Properties Values
Specific gravity 1.04
Density (g/cc) 0.945 - 0.962
Melting point 75 – 100
Fineness < 2.36

10
Compressive strength tests were performed on cubes of sizes (150x150x150) mm, for different
percentages of plastic aggregates, for curing periods of 14 days and 28 days respectively.
Following are the results:

Table No. 2.16

% of Plastics Compressive Strength (N/mm2)
14 days 28 days
0 25.22 28.22
2 27.04 30.26
4 28.15 30.33
6 28.79 30.85
8 28.88 33.95
10 30.33 34.66
12 18.55 19.30
14 16.31 21.51
16 14.16 19.24
18 13.30 14.44
20 9.50 13.33

Split tensile strength test was tested on concrete cylinders of length 300 mm and diameter 150
mm. The following are the results:
Table No. 2.17
% of Plastics Split Tensile Strength (N/mm2)
14 days 28 days
0 3.27 3.97
2 3.28 4.08
4 3.39 4.45
6 3.61 4.53
8 3.24 3.42
10 2.72 3.31
12 2.23 3.09
14 2.39 2.91
16 2.06 2.8
18 2.39 2.69
20 2.49 2.55

They concluded that the strength of concrete increased on addition of plastics up to 10% and
then suddenly decreased. And the self-weight of the concrete decreased with the addition of
the plastics.

11
Chapter 3: Rationale and Scope of Study
________________________________________________________________

The density of concrete is 2400 Kg/m3. For tall and large structures, this leads to
implementation of various procedures of geotechnical engineering, such as soil stabilization
and soil reinforcements, and higher self-weight considerations in structural engineering.
If we can by any means decrease the weight of concrete without compromising with its
strength, the construction would be more economical as it will reduce the expenses of soil
preparation and the materials required.
And the plastic to be used for the purpose is waste plastic that has already been used and
discarded. So a percentage replacement of natural coarse aggregates with plastic coarse
aggregates, will reduce the expenses to a large extent.
The problem of plastic-pollution is widely known and recognized. Plastic is readily
manufactured, light in weight and is relatively inexpensive, that makes it an ideal choice as a
replacement of various products. Also, Plastic is a recyclable material, however its ability to
be recycled gets reduced heavily with every recycle. This results into an unusable and non-
biodegradable material that only pollutes the environment.
If we can somehow effectively utilize even a fraction of this non-biodegradable material, it will
greatly help the environment.

12
Chapter 4: Objectives of the Study
________________________________________________________________

1. To develop a concrete mix with plastic aggregates, that is light in weight yet effectively
satisfies all the structural requirements.

2. To ascertain whether Natural Coarse Aggregates can be partially replaced by Plastic

Coarse Aggregates, without adversely affecting the properties of the concrete.

3. To find out whether such concrete can be effectively utilized for construction purposes.

4. To determine whether using this concrete would be economically feasible.

5. Absorption of waste plastics from the eco-system.

13
Chapter 5: Materials and Research Methodology
________________________________________________________________

5.1 General
Experiments were carried out on cement and aggregates and then later on the resulting concrete,
in order to evaluate various parameters of the materials and the concrete, to determine whether
the materials and the concrete give the expected results or not.
5.2 Materials
The different materials used for the purpose of this study are – Cement, Fine Aggregates,
Natural Coarse Aggregates, Plastic Coarse Aggregates, Recron 3S fibres, Water.
5.2.1 Cement
Ordinary Portland Cement of grade 43 was used in this research.
The following are the different parameters that were considered in tests for cement, along with
the obtained as well as reference values from the Indian Standard Code.
Table 5.1 Properties of Cement
Values as per
S. No. Property Observed Value
IS 8112:1989
1 Fineness (%) 0.1% 0.096%
2 Specific Gravity 3.15 3.13
3 Standard Consistency (%) - 29
4 Initial Setting Time (minutes) 30 (min) 112
5 Final Setting Time (minutes) 600 (max) 169
Compressive Strength
6 7 days 33 N/mm2 (min) 39.5 N/mm2

28 days 43 N/mm2 (min) 51.4 N/mm2

5.2.2 Fine Aggregates

River Sand of Zone II was used for the purpose of this research.
Sieve Analysis and tests for water absorption, specific gravity and fineness modulus tests were
performed.
Below are the findings:

14
 Table 5.2 Physical Properties of Fine Aggregates
Property Observed Value
Specific Gravity 2.68
Moisture Content 4.4%
Fineness Modulus 2.87

Table 5.3 Sieve Analysis of Fine Aggregates

IS-Sieve Weight Retained Percentage Cumulative % Percentage
S. No.
(mm) (g) Retained Retained Passing
1 4.75 10 1 1 99
2 2.36 150 15 16 84
3 1.18 240 24 40 60
4 600 µ 180 18 58 42
5 300 µ 280 28 86 14
6 150 µ 110 11 97 3
7 Pan 30 3 - -

5.2.3 Coarse Aggregates

Two types of coarse aggregates were used for this study – Natural coarse aggregates and Plastic
Coarse Aggregates.
Natural Coarse Aggregates:
Natural Aggregates of sizes between 10 mm and 20 mm were used in this study.
Below are the findings:
Table 5.4 Properties of Coarse Aggregates
Property Observed Value Observed Value
Maximum Size 20 mm 10 mm
Shape Angular Angular
Specific Gravity 2.65 2.66
Fineness modulus 6.97 7.05
Moisture Content 0.4 % 1.03 %
Bulk Density 1618.679 Kg/m3 1618.679 Kg/m3

15
 Table 5.5 Sieve Analysis of 20 mm Coarse Aggregates
Sr. IS-Sieve Wt. Retained %age %age Cumulative %
No. (mm) (kg) retained passing retained
1 80 0.000 0.00 100 0.00
2 40 0.000 0.00 100 0.00
3 20 0.023 1.15 98.85 1.15
4 10 1.930 96.5 2.35 97.65
5 4.75 0.034 1.70 0.65 99.35
6 Pan 0.013 0.65 - -
Total 2.000 198.15 + 500

Table 5.6 Sieve Analysis of 10 mm Coarse Aggregates

Sr. IS-Sieve Wt. Retained %age %age Cumulative %
No. (mm) (Kg) retained passing retained
1 20 0.000 0.00 100 0.00
2 12.5 0.030 1.5 98.5 1.5
3 10 0.370 18.5 80 20
4 4.75 1.350 67.5 12.5 87.5
5 2.36 0.180 9 3.5 96.5
6 Pan 0.070 3.5 - -
Total 2.000 205.5+500

5.2.4 Plastic Coarse Aggregates

Plastic Aggregates of sizes 20mm – 10mm were used for this study.
Below are the tests that were conducted:
Table 5.7 Properties of Plastic Aggregates
Property Value
Bulk Density (Rodded) 356.199 Kg/m3

5.2.5 Water
Potable tap water is considered to be good enough for mixing concrete.
The pH of the water was found to be 8.

16
5.3 Mix Design
An M25 grade concrete was designed as the provisions if IS 10262:2009
1. Target Mean Strength (F’ck):

F’ck = Fck + 1.65*S [IS 10262:2009, Clause 3.2]

Fck = characteristic compressive strength = 25 N/mm2;

S = standard deviation = 4 [IS 10262:2009, Table 1]

F’ck = 25 + 1.65*4

F’ck = 31.6 N/mm2

2. Water – Cement Ratio: [IS 456:2000, Table 5]

Min cement content = 300 Kg/m3

Max cement content = 450 Kg/m3

Max w/c ratio = 0.50

3. Water Content: [IS 10262:2009, Table 2]

Nominal maximum size of aggregates = 20 mm

Max water content = 186 Kg

4. Cement Content:

𝑊 186
= 0.5  =𝐶  C = 372 Kg
𝐶 0.5

5. Mix Calculations:

i. Volume of Concrete = 1 m3
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑒𝑚𝑒𝑛𝑡 1
ii. Volume of Cement = x 1000
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐺𝑟𝑎𝑣𝑖𝑡𝑦 𝑜𝑓 𝐶𝑒𝑚𝑒𝑛𝑡

350 1
= x = 0.12 m3
2.9 1000
iii. Volume of Water:

17
 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 1 186 1
𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑔𝑟𝑎𝑣𝑖𝑡𝑦 𝑜𝑓 x = x = 0.186 m3
1000 1 1000
𝑤𝑎𝑡𝑒𝑟

iv. Volume of Aggregates:

1 – (0.12 + 0.186) = 0.694 m3

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐶𝑜𝑎𝑟𝑠𝑒 𝐴𝑔𝑔𝑟𝑒𝑔𝑎𝑡𝑒𝑠

v. = 0.66 [IS 10262:2009, Table 3]
𝑇𝑜𝑡𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐴𝑔𝑔𝑟𝑒𝑔𝑎𝑡𝑒𝑠

 Volume of Coarse Aggregates = 0.66 x 0.694 = 0.458 m3

vi. Volume of Fine Aggregates = (1 – 0.66) x 0.694 = 0.235 m3

vii. Mass of Coarse Aggregates = 0.694 x 0.458 x 2.64 x 1000 = 839.12 Kg

viii. Mass of Fine Aggregates = 0.694 x 0.235 x 2.63 x 1000 = 428.92Kg

6. Ratio:
Cement : Fine Aggregates : Coarse Aggregates : Water Content
 350 : 428.92 : 839.12 : 186

 1 : 1.225 : 2.397 : 0.5

Below are the proportions of the various materials used, for each batch:

Table 5.8 Proportions of Materials

Replacement Cement FA CA Water PA Fibre
(%) (Kg) (Kg) (Kg) (kg) (kg) (kg)
0 56.72 119.69 150.89 28.368 0 1.416
5 56.72 119.69 143.35 28.368 1.66 1.416
10 56.72 119.69 135.801 28.368 3.32 1.416
15 56.72 119.69 128.2565 28.368 4.98 1.416
20 56.72 119.69 120.712 28.368 6.64 1.416
25 56.72 119.69 113.1675 28.368 8.3 1.416
Total 340.32 718.14 792.18 170.21 24.9 8.5

18
Where, CA = Natural Coarse Aggregates
PA = Plastic Coarse Aggregates
FA = Fine Aggregates

5.4 Casting and Curing

Specimens were casted for testing the Compressive, Split tensile, and Flexural Strengths.
Six batches of specimens were casted in total, for 0%, 5%, 10%, 15%, 20% and 25%
replacements of Natural Coarse Aggregates with Plastic Coarse Aggregates.
The batch for 0% replacement was the Control Mix.
Each batch contained 3 cubes each for 7 days, 14 days and 28 days, for checking the
compressive strength, 3 cylinders each for 7 days, 14 days and 28 days, for checking the split
tensile strength and 3 beams each for 7 days, 14 days and 28 days, for checking the flexural
strength.
The table below explains it.

Table 5.9 Specimen Quantities

7 days 14 Days 28 Days
% Cube Beam Cylinder Cube Beam Cylinder Cube Beam Cylinder
0 3 3 3 3 3 3 3 3 3
5 3 3 3 3 3 3 3 3 3
10 3 3 3 3 3 3 3 3 3
15 3 3 3 3 3 3 3 3 3
20 3 3 3 3 3 3 3 3 3
25 3 3 3 3 3 3 3 3 3
18 18 18 18 18 18 18 18 18

The specimens were cured in submergence, for 7 days, 14 days and 28 days, respectively,
depending upon the age at which they were to be trusted for strength.

5.5 Test method

Four tests were conducted on concrete, in total. One on fresh concrete and three on hardened
concrete.
5.5.1 Fresh Concrete
On fresh concrete, the test that was conducted was:
i. Slump Cone Test

19
 On each batch of concrete, the Slump Cone Test was conducted to determine the
workability, in accordance with IS 7320 : 1974

5.5.2 Hardened Concrete

The three tests conducted on the hardened concrete were:
i. Compressive Strength Test
As per IS 516 : 1959, cubes of size 150 mm x 150 mm x 150 mm, were casted and tested
under Universal testing Machine, after 7 days, 14 days or 28 days, depending upon the age
at which the strength was to be tested. The rate of loading was 5 KN/sec.
ii. Split-tensile Strength Test
As per IS 516 : 1959, Cylinders of size 150 mm – diameter, 300 mm – height, were casted
and tested under Universal testing Machine, after 7 days, 14 days or 28 days, depending
upon the age at which the strength was to be tested. The rate of loading was 2.1 KN/sec.
iii. Flexural Strength Test
As per IS 516 : 1959, Beams of size 100 mm x 100 mm x 500 mm, were casted and tested
under Universal testing Machine, after 7 days, 14 days or 28 days, depending upon the age
at which the strength was to be tested. The distance between rollers loads should be 200
mm to 135 mm and the loading should be applied without any shocks. The rate of loading
was 0.1 KN/sec.

20
Chapter 6: Results and Discussions
________________________________________________________________

6.1 General
This chapter gives the results of the various tests conducted on the ingredient materials of the
concrete as well as on the final concrete in both fresh and hardened states.
6.2 Tests on Material
Various tests were performed on the constituent materials of the concrete.
6.2.1 Tests on Cement
Test on Cement were Conduced as the provisions given in IS 8112 : 1989
Table 6.1 Tests on Cement
Values as per
S. No. Property Observed Value
IS 8112:1989
1 Fineness (%) 0.1% 0.096%
2 Specific Gravity 3.15 3.13
3 Standard Consistency (%) - 29
4 Initial Setting Time (minutes) 30 (min) 112
5 Final Setting Time (minutes) 600 (max) 169
Compressive Strength

6 7 days 33 N/mm2 (min) 39.5 N/mm2

28 days 43 N/mm2 (min) 51.4 N/mm2

6.2.2 Tests on Natural Coarse Aggregates

Table 6.2 Tests on Natural Coarse Aggregates
Property Observed Value
Maximum Size 20 mm 10 mm
Specific Gravity 2.65 2.66
Fineness modulus 6.97 7.05
Moisture Content 0.4 % 1.03 %
Shape Angular
Bulk Density 1618.679 Kg/m3
Aggregate Crushing Value 25.29 %
Aggregate Impact Value 18.2 %
Los Angeles Abrasion Value 24.8 %

21
 Table 6.3 Sieve Analysis 10mm Natural Coarse Aggregates
Sr. IS-Sieve Wt. Retained %age %age Cumulative %
No. (mm) (kg) retained passing retained
1 80 0.000 0.00 100 0.00
2 40 0.000 0.00 100 0.00
3 20 0.023 1.15 98.85 1.15
4 10 1.930 96.5 2.35 97.65
5 4.75 0.034 1.70 0.65 99.35
6 Pan 0.013 0.65 - -
Total 2.000 198.15 + 500

Table 6.4 Sieve Analysis 20mm Natural Coarse Aggregates

Sr. IS-Sieve Wt. Retained %age %age Cumulative %
No. (mm) (Kg) retained passing retained
1 20 0.000 0.00 100 0.00
2 12.5 0.030 1.5 98.5 1.5
3 10 0.370 18.5 80 20
4 4.75 1.350 67.5 12.5 87.5
5 2.36 0.180 9 3.5 96.5
6 Pan 0.070 3.5 - -
Total 2.000 205.5+500

6.2.3 Tests on Fine Aggregates:

Table 6.5 Tests on Fine Aggregates

Property Observed Value
Specific Gravity 2.68
Moisture Content 4.4%
Fineness Modulus 2.87

22
 Table 6.6 Sieve Analysis of Fine Aggregates
IS-Sieve Weight Retained Percentage Cumulative % Percentage
S. No.
(mm) (g) Retained Retained Passing
1 4.75 10 1 1 99
2 2.36 150 15 16 84
3 1.18 240 24 40 60
4 600 µ 180 18 58 42
5 300 µ 280 28 86 14
6 150 µ 110 11 97 3
7 Pan 30 3 - -

6.2.4 Test on Plastic Coarse Aggregates

Test Result
Bulk Density (Rodded) 356.199 Kg/m3
Aggregate Crushing Value 21.32 N/mm2
Los Angeles Abrasion Value 7.45 %
Aggregate Impact Value 5.26 %
Fineness Modulus 6.21
Specific Gravity 0.2857
Water Absorption Negligible

6.2.5 Test on Water

pH of water = 8
6.2.6 Tests on Recron 3s Fibre
Table 6.7 Properties of Recron 3S
Property Result
Denier 1.5 d
Cut Length 12 mm
Melting Point 250o C
Dispersion Excellent
Acid Resistance Excellent
Alkali Resistance Good

6.2.7 Tests on Concrete

6.2.7.1 Slump Test
Table 6.8 Slump Cone Test
23
 % Replacement Slump Value (mm)
0 90
5 93
10 95
15 97
20 101
25 105

Figure 6.1 Slump Tests

Slump Tests
120

105
101
100 95 97
93
90

80
mm

60

40

20

0
0% 5% 10% 15% 20% 25%
% Replacement

Slump Value - . Linear (Slump Value)

24
6.2.7.2 Test for Compressive Strength

Table 6.9 Compressive Strength Test

% Replacement 7 Days 14 Days 28 Days
0 21.9 30.396 36.36
5 22.3 31.7 37.41
10 23.1 33.2 38
15 23.8 33.91 40.1
20 24.5 34.23 40.27
25 23.1 32.62 39.33

Figure 6.2 Compressive Strength Test

Compressive Strength
45
40.1 40.27
39.33
40 38
37.41
36.36
33.91 34.23
35 33.2 32.62
31.7
30.396
30

23.8 24.5
25 23.1 23.1
21.9 22.3

20

15

10

0
0% 5% 10% 15% 20% 25%

7 days 14 Days 28 Days

25
6.2.7.3 Test for Split Tensile Strength

Table 6.10 Split Tensile Strength

% Replacement 7 Days 14 Days 28 Days
0 2.32 2.89 3.43
5 2.22 2.54 2.74
10 2.13 2.33 2.652
15 1.93 2.1 2.48
20 1.71 1.93 2.39
25 1.55 1.79 2.28

Figure 6.3 Split Tensile Strength

Split - tensile Strength

4

3.43
3.5

3 2.89
2.74
2.652
2.54 2.48
2.5 2.32 2.33 2.39
2.22 2.28
2.13 2.1
1.93 1.93
2 1.79
1.71
1.55
1.5

0.5

0
0% 5% 10% 15% 20% 25%

7 days 14 Days 28 Days

26
6.2.7.4 Test for Flexural Strength

Table 6.11 Flexural Strength

% Replacement 7 Days 14 Days 28 Days
0 7.5 8.981 11.33
5 7.2 8.34 11.1
10 6.91 7.52 10.42
15 5.44 6.84 9.22
20 4.89 6.12 8.56
25 4.11 5.67 7.30

Figure 6.4 Flexural Strength Test

Flexural Strength
14

12 11.33 11.1
10.42
10 9.22
8.981
8.34 8.56

8 7.5 7.52 7.3

7.2
6.91 6.84
6.12
6 5.44 5.67
4.89
4.11
4

0
0% 5% 10% 15% 20% 25%

7 days 14 Days 28 Days

27
Chapter 7: Conclusion
________________________________________________________________

7.1 General
The basic aim of this research was to ascertain whether Plastic Coarse Aggregates can
effectively replace Natural Coarse Aggregates, effectively or not.
After evaluating and analyzing the results, is found that it is possible to partially replace Natural
Coarse Aggregates with Plastic Coarse Aggregates.
The optimum replacement percentage at which all the strengths – Compressive, Split-tensile
and Flexural, show optimum results collectively, is taken to be at 20%
The value of slump showed a liner increase that can be attributed to the fact that plastic
Aggregates don’t absorb water.

7.2 Meeting the Objectives

A concrete mix was developed that incorporated plastic aggregates that was lighter in weight
and yet provided the appropriate strength.
Therefore, Plastic Aggregates can be effectively used in concrete.
The developed concrete can be used for construction purposes as well.
Plastics being less expensive comparatively, prove to be economical.
The utilization of plastics in concrete can help decrease the pollution caused by it.

7.3 Future Scope

Plastics are relatively profoundly inexpensive. So using plastics in concrete, can lead to huge
amount of money being saved and also help the environment and eco-system.
It can be further studied for many attributes and aspects:
i. Fire Resistance
ii. Micro-structure Analysis using Scanning Electron Microscopy
iii. The use of Plastic Aggregates of a different type than HDPE
iv. The use of Plastic Aggregates in Self Compacting Concrete
v. Torsion Resistance
vi. Shear Resistance
vii. Impact Resistance
viii. Rapid Chloride Permeability Test
ix. Porosity Test
x. X-Ray Diffraction

28
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aggregates; National Technical University of Athens, School of Engineering, Greece,
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4. A.S.Balaji and D.Mohan Kumar, laboratory investigation of partial replacement of

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