Spring 2018

CIVIL0003
PROJECT 1 Date: 22-03-2018
Sir. Sachin kuckian

PROPOSAL FORM

ID Student Name Email

16F15919 Aaqib Abdulkadir Dalvi 16F15919@MEC.EDU.OM

16F15662 Mirna Hussein Elzomor 16F15662@MEC.EDU.OM

14F12485 Yaqeen Mohaanad Salah 14F12485@MEC.EDU.OM

16f15950 Abdullah Abdulnasir Yahya 16f15950@MEC.EDU.OM

Module PROJECT1

Supervisor Sir. Sachin Kuckian

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Civil Engineering Department

TO STUDY THE USAGE OF CEMENT KILN DUST IN THE

PROJECT TITLE: MANUFACTURING OF COST EFFICIENT INTERLOCK
PAVER TILES

Abstract/Summary:

Nowadays, Interlock Concrete Block Pavement (ICBP) has gained much popularity as it
has been used in many countries. Moreover, some countries are using ICBP as an alternative to
the asphalt pavement or even concrete. But, mostly it’s used for footpaths, parking areas, and
gardens, etc. as it’s easy to lay with a good appearance and finish. ICBP is nowadays used in
many construction works scarcity of raw materials is one of the main problems encountered by
these companies.
The companies which produce interlock blocks noticed that there’s a sharp rise in its production
within the last few years. The problems faced by these companies are not being supplied with the
raw materials. But, the main issue is the rise of the material’s cost which results in the increase of
the production cost. Overall, there are four existing cement production companies in Oman, such
as Oman cement company, Al Tasnim Ent., Al Rajhi and Al Assarain.
This project aims to reduce the cost of (ICBP) by replacing the cement with cement kiln dust
(CKD) partially. All in all, CKD is simply a large quantity of solid waste produced in Oman
cement factories during the industrialization of Portland cement (OPC). Furthermore, the
replacement of OPC with CKD are beneficial from the environmental and economical aspects. In
addition, different percentages of CKD are going to be mixed with (OPC) (10%, 20%, 30% and
40%) in order to represent the compressive strength of the ICBP with cost efficiency.

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Brief background / Literature survey of the work, including sustainability

and ethical aspects?

As said, Interlock paver tiles or blocks are defined as the mixture of cement, coarse and fine
aggregate and water. They are being used for different purposes such as the road side footpath as
well as the roads in different countries and additionally for decorative purposes in construction
bases.
Cement kiln dust (CKD), is a waste or the by-product obtained from the manufacturing process
of cement. It has similar properties of cement. As per research, the Oman cement companies
release the waste CKD approximately 20,000 tons per annum. This waste is sometimes recycled
by certain processes or dumped in landfills and also in research stage for using it economically in
beneficial or sustainable manner for the environment.
By following the safety aspects and sustainable properties for the project, we have planned to
make cost efficient interlock tiles by reducing the cement percentage normally used in
preparation of this tiles by mixing CKD in a certain ratio to maintain the standards of the tile
with similar strength by performing experiments in the laboratory.

Nahla and Aseel (2010) showed the effect of the replacement of the CKD on the properties of
concrete. It was reported that by increasing the amount of CKD, the compressive and the tensile
strength slightly decreases.

Hassan (2003) shows the results of partial replacement of cement with CKD in mortar &
concrete. The partial replacement of CKD, ranged from 5%-30% by weight. He claims that
initial setting time of concrete or mortar is decreased with increasing CKD rate due to high
amount of lime & alkalis. Therefore, at the end the study concludes that 15% of CKD has better
behavior in maintaining the tensile strength of mortars at 7, 28 days.

Rahman et al (2011), claim that CKD is potentially useful in stabilization of different types of
soils. Therefore, CKD with high free lime and low alkalis in compact soil increased the

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compressive strength up to 80% was observed when 50% of CKD is mixed with normal weight
aggregate, light weight pozzollanic aggregate and cement to make a concrete block.

Salah Farhan (2011) examined the influence of Cement kiln dust partially replaced with ordinary
and white Portland cement for making mortar, for environmental and economical benefits. It
claims that increase of CKD up to 10% decreases initial and final setting time and also its
strength.

Kumar et al (2016) researched about high quality road pavement tiles, by using crushed steel as
coarse material and fly ash as cement material. Results were obtained as increase in strength by
partial replacement of cement by fly ash and coarse material.

Vennila et al (2017) prepared low cost concrete, by using waste broken tiles and acacia nilotica
ash from karuvelammaram a town, which reduces use of cement. Even the emission of
greenhouse gas is reduced. The study indicates that using waste tiles reduces environmental
pollution.

Al-Harthy (2003), investigated that the replacement of cement with (CKD) partially, wouldn’t
affect negatively on the strength properties of concrete of the mortar samples if it’s used within
low proportions.

Taffur (n.d), the importance of interlock pavement in Ghana is explained with the industrial
conditions of producing Interlocks. Also mentioned the areas where it's used most and also the
least in Ghana. The importance of interlock blocks strength to be maintained for long life span
and manufacturing of blocks is also determined. Product quality specifications are also drowned
down.

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Objectives

To analyze the physical and chemical properties of cement and CKD.

To study the normal proportion of interlock tiles.

To design cement kiln dust tiles.

To compare the compressive strength of ordinary interlock tile with the new one.

To study the aspects of interlock tiles after partial replacement of cement with CKD by
experimental procedures.

To find the cost analysis of the normal and CKD based interlock tiles.

Project Outcomes

Reduce the cost-efficient of interlock tiles by partially replacing cement with cement kiln dust
(CKD).

Stabilize the quality of interlock tile after adding the cement kiln dust (CKD) by partially
replacing cement.

Promote sustainability by using the cement kiln dust (CKD) in the manufacture of interlock tiles.

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Why are you interested in the project?

Interlock tiles are one of the most prominent modern building techniques, characterized by a
wide variety of geometrical shapes and colors, giving a greater chance of creative design. The
qualities of interlock tiles are very resistant to corrosion (less than0.5mm) and low water
absorption (less than 4%). To the above mentioned benefits, make Interlock tiles very suitable
for large projects such as; Airports, fuel stations, resorts and tourist villages. Moreover, Ordinary
people are the primary beneficiaries of this project. People always paint their dream home in
their imaginations and now it has become possible to achieve part of their ambitions by using the
Interlock tiles, people can combine different shapes and colors according to their wishes. In
addition, it is very easy to remove the Interlock tiles when it is necessary to drill down and then
re-install them without any damage or break. But because of its high cost, Interlock tiles cannot
be used by many people. So, reducing the price of Interlock tiles will benefit many people and it
is for this reason that we chose this project. In addition, cement kiln dust (CKD) is the waste
generate from the manufacture of cement. So, by using it the environment would be protected
from air pollution and the recycling process of cement waste would be improved by using this
dust in a useful way in interlocks tiles. The contribute of this study would be to reduce the
pollution and volume of landfills in Oman by demonstrating the feasibility of using CKD.

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What are the key questions the project attempts to

answer?

Why are Interlock tiles classified as one of the most important modern construction
techniques?

How it is possible to reduce the price of Interlock tiles?

What are the effects of the cement kiln dust produced as a by-product during the
manufacture of cement in the environment?

What is the ratio of cement kiln dust that can be used to maintain the strength of interlock
tiles?

Will it be suitable to use the new CKD mix interlock tiles/blocks in Oman?

What is the strength of CKD interlocks compared to normal interlock tiles?

What experimental setup/material or primary and/or secondary

data sources do you intend to use in the work?

Primary Secondary

Normal Interlock (Made from Cement kiln dust (CKD)

Materials
concrete)

Journals, articles, books,

Interview, site visit,
newspapers, pamphlets,
Data questionnaires, experimental
websites, youtube, and
tests and photographs.
encyclopedia’s.

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Provide draft chapter headings for your proposal

TITLE PAGE:

INTRODUCTION:

BACKGROUND OF PROJECT:

STATEMENT OF PROBLEMS:

AIM & OBJECTIVES:

LITERATURE REVIEW:

METHODOLOGY & EXPERIMENTAL PROCEDURE:

CONCLUSION

REFERENCES

Gantt chart

ACTIVITIES WEEKS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Searching for information     
sources such as: (Journals,
Interviews, case studies)
Finding materials that is   
required (CKD, lab)
Writing &submitting proposal 
Writing the abstract  

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Writing the introduction  

Preparing a literature review   
Preparing the methodology   

Preparing interlocks    
Testing interlocks    
Writing results &discussion  
Preparing conclusion  
Checking grammar and format  
Submitting first draft 
Submitting final report project 

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References

Al Harthy, Ramzi T., Faisal A. M. (2003), ‘Effect of cement kiln dust (CKD) on mortar
and concrete mixtures’. Construction and building materials [online] 17(5), 353-360
available from < https://www.sciencedirect.com/science/article/pii/S0950061802001204>
[23 March 2018]

Nahla N. H and Aseel M. M (2010), ‘Re-using the by-product of cement industry(CKD)

to produce the concrete’. Anbar journal for engineering sciences [online] 3(2), 1-14
available from
<https://www.researchgate.net/profile/Nahla_Hilal2/publication/311615469_Re-
using_The_By-
product_of_Cement_Industry_Cement_Kiln_Dust_To_Produce_The_Concrete/links/588
2374892851c21ff42d65f/Re-using-The-By-product-of-Cement-Industry-Cement-Kiln-
Dust-To-Produce-The-Concrete.pdf> [23 March 2018]

M. K. Rahman, S. Rehman and O. S. B. Al- Amoudi (2011) ‘Literature review on cement

kiln dust usage in soil and waste stabilization and experimental investigation’. Literature
review on cement kiln dust usage in soil [online] 7(1), 77-87 available from
<https://pdfs.semanticscholar.org/3495/bdb9a3e4f8a62dd346da18f99ef627feca10.pdf>
[1 April 2018]

Salah F. A. S. (2011) ‘Influence of cement kiln dust as partial replacement on some

properties of ordinary and white Portland cement’. Tikrit Journal of Engineering sciences
[online] 18(3), 23-32 available from
<https://www.iasj.net/iasj?func=fulltext&ald=69249> [23 March 2018]

O. M. Abdulkareem, I. H. Hassan and Ahmed Y. S. (2013) ‘Utilization of cement kiln

dust (CKD) as a partial replacement of cement in mortar and concrete’. Utilization of
cement kiln dust (CKD) as a partial replacement [online] 21(6), 72-87 available from
<https://www.iasj.net/iasj?func=fulltext&ald=82390> [23 March 2018]

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Kumar A. M., Varun K., Swabhav S. T., Yogesh K., Tapesh J. (2016) ‘A research paper
on use of waste material in interlock tiles to improve its quality’. SSRG International
journal of Civil Engineering (SSRG-IJCE) [online] 3(5), 60-63 available from
<http://www.sphinxsai.com/2017/ch_vol10_no8/2/(355-358)V10N8CT.pdf> [24 March
2018]

R. Anuradha, R. Vennila and S. Kavitha (2017) ‘Compressive strength on interlocking

concrete blocks with acacia nilotica ash and broken tiles’. International journal of
ChemTech research [online] 10(8), 355-358 available from
<http://www.internationaljournalssrg.org/IJCE/2016/Volume3-issue5/IJCE-
V3I5P112.pdf > [1 April 2018]

Y. A. Tuffour (n. d) ‘The manufacture and use of interlocking concrete paving blocks in
Ghana’, 65-72 available from <http://www.sept.org/techpapers/685.pdf> [23 March
2018]

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