Properties of Structural Lightweight Concrete Containing Treated Oil Palm Shell as Coarse Aggregate

Swamy nadh va, Muthumani.kb

a
Faculty of civil engineering, Vellore institute of technology, Chennai, INDIA
b
research associate, department of SMBS, Vellore institute of technology, Chennai, INDIA

Abstract

One way of attaining sustainable and environment friendly structures is to use industrial waste as construction
material. Oil palm boiler clinker obtained from palm oil extraction process in palm oil industry is a promising
material which can be used for replacement of coarse aggregate in concrete. In this study development of water
absorption rate in oil palm shell is modified with water repellent admixture to maintain the mechanical properties as
same as Normal Weight Concrete (NWC). This oil palm shells (OPS) are lightweight and can be used as coarse
aggregate for structural application in construction structures. The physical and chemical properties of such
aggregate is evaluated and improved for those parameters which are deficient to produce good quality concrete.
Internal curing of concrete takes place in oil palm shell lightweight concrete which is an added advantage for
durable concrete. Properties like sorptivity, density, compressive strength were measured and discussed. Results
show that replacement of normal aggregate with industrial waste product is structurally good and environmental-
friendly, compression strength ranging from 25-30 MPa which is same in case of NWC.

Key words: water absorption; water repellent; density; oil palm shell (OPS); oil palm shell structural lightweight
concrete (OPSSLC).

1. Introduction

Construction industry is growing at a greater speed and they use natural resources extensively. The current focus of
policy planners is to increase the use of environmentally renewable concrete and makes it lighter, stronger and
durable. The new development in material is directed towards using industrial waste. Oil palm shell a by-product
form palm oil industry is widely available in the southern part of India. These shells are lightweight and have similar
mechanical properties of aggregates used in concrete. Basic physical and chemical properties of OPS are not good
enough to be used directly in making structural concrete and hence needs improvement in certain properties of
material. Structural lightweight concrete (SLC) has normal air dry density in the range of 1440 kg/m3 to 1840
kg/m3as per the ASTM 567 A Standard Test Method for determining the Density of SLC. This yields a 28 day
compressive strength of at least 17 MPa when measured in accordance with ASTM C330 / C330 - 09M "Standard
Specification for Lightweight Aggregates for Structural Concrete", and that is made from lightweight aggregates
conforming to ASTM C330 – 09M Standard Specification covering expanding, pelletizing or sintering products
such as blast-furnace slag, clay, diatomite, fly ash, shale or slate. Concrete with low density can be achieved by
natural and industrial wastes like pumice, scoria, oil palm shells etc. Generally these waste products and natural
materials are in the range of 1200 to 1750 kg/m3 [1]. SLC is lighter than normal weight concrete (NWC) of about
25% to 35% typically.

Although the LWC aggregate properties will affect the compressive strength and durability properties, the
nature of cement matrix plays a greater influence. Fine aggregates used in matrix should have fine enough particles
to maintain the cohesiveness of the concrete mixture. Mix designs for SLC have been under development for many
decades to get the optimum strength and to make the concrete durable. SLWC has been in use in Malaysia to build
sustainable environmentally structures among developing countries [2]. They use some of the agricultural wastes
and industrial by-products to make the concrete lightweight and to make the construction environmental friendly. In
tropical regions OPS is widely used and are widely available. OPS are agriculture waste from oil palm industries
throughout the world. Their by-products are oil palm shell(OPS) and palm kernel shell (PKS). Research on OPS for
SLC started in the year 1985 by Salam and Abdullah in Malaysia [3]. Malaysia, Nigeria and Indonesia and many
other countries have established oil palm industries. 57.8% of the total supply of palm oil in the world is produced
and exported to different countries by Malaysia. 28.06 billion dollar economy in export earnings from palm oil and
palm oil products is reported in 2006[4]. In Malaysia and Nigeria it was estimated that over 4 and 1.5 million tons
of OPS solid waste is produced annually. Some of the OPS were used in the production of fuel and other
applications such as palliative for un-tarred roads and for producing activated carbon.

OPS can be used as an aggregate for making lightweight structural concrete as can be seen from various
investigations by the researchers.OPS for SLC show good mechanical and physical properties and good thermal
performance for low cost housing [5]. By using solid agricultural wastes as aggregates can reduce the cost of
construction materials and OPS is the best replacement of granite gravel which is used commonly for making
concrete. By using such industrial wastes in making concrete resolves the problem concerning the disposal of waste
products generated at different industries.

Processing of palm oil from palm oil fruit is made in four stages i.e., sterilization, separation, pressing,
depericarping, separation of kernel and shell, and clarification. In the processing stage shell are the waste product
and they are dumped as waste. Normally the colour of shell is dark gray to black. The concrete made with this oil
palm shell also looks like black after crushing of concrete. These shells are left under environment without any care
or protection. Usage of this industrial waste in the concrete had to be investigated. These shell which can be replaced
as the aggregate in concrete shows huge improvement on mechanical and physical properties. Treatment of oil palm
shell has to be done before casting. Water absorption or sorptivity value is 8 times higher than normal aggregate.
The shells after separation from the fruit and crushed the shape of the shell will be angular and polygon etc. The face
of the shells are smooth and these have thickness of about 0.5 to 8mm. Due to high porosity in OPS the density is
around 350-600 kg/m3[6], which have specific gravity in the range of 1.13 -1.38.OPS are 60% lower density than
normal weight aggregate (gravel). OPS are hard and do not deteriorate easily.

2. Materials
2.1. Binder

Cement used for making of structural lightweight aggregate concrete is Ordinary Portland cement (OPC), Specific
gravity of cement is 3.14, the Blaine specific surface area is 3510 cm2/g, silica fume used has specific gravity of
2.05 and specific surface area 15,000 m2/kg. GGBS has the specific gravity of 2.85, and specific surface area of
4000 cm2/g. The chemical composition of OPC is given in Table 1.

2.2. AGGREGATES

Normal River sand of size of 300 microns to 5 mm is used as fine aggregate while for the coarse aggregate, Oil Palm
Shells are used which has specific gravity of 1.3. These are obtained from Andhra Pradesh, and having size of 2.36
mm to 10 mm as shown in Fig 1. OPS has compacted bulk density of 510 kg/ m3 and loose bulk density of 380
kg/m3[7]. The 24hour water absorption of oil palm shell (OPS) is 22% . The partial distribution grading is given in
the granular grading analysis for the OPS aggregate. Sieve analysis is carried out and is in the range of 2-9mm in
size which is crucial in the mix design of concrete. Grading curve shows impact on mechanical properties of OPS
concrete. SLC mix design is done for a 28days compressive strength of 40 and 30 MPa and cement is partially
replaced by silica fume and GGBS to improve strength and durability properties[8].
 Figure 1. Oil palm shell

Table 1.Chemical composition of OPC.

Chemical composition (%)

SiO2 Fe2O3 CaO MgO Al2O3 SO3 LOI

21.22 3.39 64.64 2.07 5.8 2.16 0.65

Table 2. Physical properties of OPS aggregate.

Physical properties
Specific gravity Compacted bulk density Water Absorption (%) Aggregate Impact value (%)
(kg/ m3)

OPS Crushed granite OPS Crushed OPS Crushed

aggregate aggregate
1.13-1.38 350-550 1470 23-30 2-5 2.1-2.6 17.29

2.3. Water

Normal water is used to mix the concrete constituents. water/cement ratio taken is 0.35 which is about
170-220 kg/m3.

2.4. Water Repellents

Acrylic bonding agent and penetrative waterproofing are the admixtures which form a water resistant cementitious
bonding coat and reduce porosity of the structure. It acts as an excellent bonding agent for improving adhesion of
concrete. Water absorption of OPS is about 20-25% which is 60-70% high when compared to NWC. Use of water
repellent admixture as shown in fig 2 can make the OPS aggregate to absorb less water as same as normal aggregate.
Graph shows decrease in water absorption rate with an increase of water repellent admixture (Zycocyl), which is a
reactive organ saline Nano-sealer becomes integral part of the aggregate when used before 24hours for making
OPSSLC. This gives good slump value and workability. Making of concrete directly with OPS gives low slump
value and less bonding to cement paste which is not acceptable for good bond strength of concrete. Chemical action
of penetrative waterproofing creates molecular level hydrophobic zone as in figure 3, which is high level water
resistant zone.
 Modified
WR surface
water absorption in
OPSA
30
zyco cyl 25 y = -1.14x + 23.8
(ml) 20 R² = 0.9991
15
10
5
0
0 10 20 30
Absorbance %

(a) (b)

Fig.ure 2. (a) Water repellent(WR) water bubbles on the surface of brick (b) water absorption in OPSA

Fig.ure 3. Silicon and oxygen forming series to form hydrophobic nature

3. Mix Proportion and Procedure

OPS Concrete is more pervious and absorb more water nearly 16-18% more when compared to NWC. making of
SLC with OPS need more attention, SLC is made with different percentages of silica fume which is replacement of
OPC, namely no replacement (SF0), 15% (SF15), GGBS 15, NWC. All the mixes are made with common
procedures, firstly in mixing process , OPSSLC and river sand were dry mixed and then OPC and Silica fume are
added in one batch and OPC is mixed in other batch as per the ratios. Test cylinders specimens are cast using the
above mixes. The cylinders specimens were demoulded24 hours after casting and placed in curing tank for 28days.

Table3. Mix proportion of OPSSLC

Material /mix SF0 SF 15 GGBS 15 NWC

cement (kg/ m3) 550 450 510 400

3
water (kg/ m ) 247.5 202 229.5 180

sand (kg/ m3) 820 690 848 450

aggregate (kg/ m3) 330 360 308 1350

super plasticizer(kg/ m3) 15% 15% 15% 0%

4. Tests And Results

4.1. Sieve Analysis For OPS

Sieve analysis for the sample of 50kg is carried out and represented in the percentages of each stage as shown in
table 4. Sieve analysis is carried out in accordance to collect the aggregate of size range form 8-10mm for the good
concrete. As these OPS are collected from the dumping yard of palm oil industry debris are mixed and cannot be
used directly. Sieve analysis is carried out to collect 8mm and 10mm aggregates. Table shows the sieve size
distribution of OPS and their cumulative percentages.

Table4. Results of sieve analysis show size distribution of OPS.

S.NO Sieve Retained Retained percentage Cumulative Cumulative percentage Pass percentage
weight % % weight % %
1 16 0 0 0 0 100
2 14 2.8 5.6 2.8 5.6 94.4
3 12 5.9 11.8 8.7 17.4 82.6
4 10 12.8 25.6 21.5 43 57
5 8 20.1 40.2 41.6 83.2 16.8
6 6 8.4 16.8 50 100 0

4.2. Compressive Strength

All the ingredients were blended in a pan mix for 1 or 2 min. slump test is done for the blended mix and then poured
in moulds and allow them in the room temperature for 24hours. The compressive strength test is conducted for
100mm, 150mm cubes and 300mm cylinders at the age of 7,28,56 days by UTM of 300T Capacity in accordance
with compressive strength test of concrete (IS:516-1959). Silica fumes are used to infill the LWC concrete,
replacement of silica fume in different percentages of cement can improve the durability properties of LWC. (SF 15)
silica fume of 15% by cement weight is replaced in cement shows high strength as compared to all other silica fume
replacements this is due to aspect ratio of silica fumes to cement as shown in figure 4.

Normal weight concrete has compressive strength of 34 MPa which is same in case of SF15. Remaining
mix designs shows decrease in mechanical properties than NWC which is due to aspect ratios of their respective
ingredients, GGBS 15 shows gradual decrease in compressive strength than NWC and other percentages of silica
fumes this is due to increase in silica fume to cement ratio, gel formation at this level of mix does not shows well
binding nature with the OPS and there is an decrease in compressive strength. Table 5 shows the compressive
strengths of all the mix designs which is similar to test conducted by M. Aslam et al (2016) [10].

Results shows the replacement of cement with silica fume at the percentage of 15 shows the higher
compressive strength than GGBS 15, SF 0 indicates LWC without any replacement of cement. The 28 days
compressive strength between these concrete mix designs are in structural range, the variation of about 10-15% of
compressive strength is noticed in LWC with 15% SF and remaining mix designs than in NWC. The decrease in
compressive strength is mainly due to the weak bond between the cement paste and the type of aggregate used in the
concrete, density of the aggregate also influences the strength of concrete [11-12].
 Table 5. Compressive strength of OPSSL Concrete (MPa)

Age (days) 7 14 28 56
SF 0 22 28 31 33
SF 15 26 33 35 37
SF 45 18 24 28 30
NWC 27 34 36 38

40

35

30
Compresive strength (MPa)

25

LWC
20
SF 15

15 GGBS
NWC
10

0
0 10 20 30 40 50 60 70
Age of Concrete in (days)

Figure 4. Compressive strength of OPSSLC

4.3. Tensile strength of SLC

Figure 5. shows the tensile strength of SLC, all the mix proportions are consider for the tensile strength to
know the differences. As expected NWC has less splitting tensile strength value when compared to SLC with SF 15,
and even GGBS 15. This is due to the fiber nature of OPS and high specific surface area of silica fume and GGBS
help to improve the tensile nature and bond strength in the concrete. Splitting tensile strength are carried out by
many researchers from long ago on reinforced concrete to carry the tensile loading coming on it. This help to
maintain the safety against seismic loading on the structures. splitting tensile strength shown in figure 6. shows
linear increase of strength in NWC and LWC with OPS, LWC with OPS as aggregate shows increase in splitting
tensile strength is due to the fiber nature of LWC aggregate, and the bonding between the matrix and the aggregate
is much more better in the LWC aggregate. The splitting tensile strength to compressive strength ratio varies from
6.8-8.1 % in LWC and in case of NWC it falls in the range of 9-13% [13].
 5

Spliting Tensile Strength

4.5
4
3.5 y = 0.204x + 2.17
3 R² = 0.9598

(MPa)
2.5
LWC
2
1.5 SF 15
1
0.5 GGBS 15
0
24 28 31 34

Compressive strength (MPa)

Figure 5. Tensile strength of OPSSLC

3.9

3.7
R² = 0.957
Splitting Tensile strength (MPa)

3.5

3.3
R² = 0.9567 NWC
LWC
3.1
Linear (NWC)
Linear (LWC)
2.9

2.7

2.5
0 10 20 30 40 50 60
Age of concrete (days)

Figure 6. Splitting tensile strength of LWC and NWC

5. Conclusions

1. OPS need pre-processing to improve the water absorption property. The strength needed for structural performance of
concrete can be obtained using OPS and other ingredients. 15% replacement of cement with silica fume shows good
compressive strength comparable to NWC, this is due to the aspect ratio of silica fume to cement. 15% of GGBS in
cement shows decrease of compressive strength, this is due to less binding property in gel formed by mix ratio of
cement and GGBS.
2. Water repellents are used to process the OPS aggregate for making of LWC, using of hydrophobic water repellent for
OPS shows decrease in water absorption rate to 2% from 24%.
3. Grading of OPS is much needed to perform the pre-processing, this is make sure of similarity in size of the aggregate as
these shells are form industrial waste there will be much more other debris present in the waste, natural gravel form
quarries are not much differ and grading of gravel is not that much needed when it is form reputed industries.
4. OPSSLC is shows similar properties as NWC and these can be used as structural concrete. Where compressive strength
of OPSSLC is 26MPa where as in NWC it is 34MPa, this shows OPSSLC falls in structural property range. This
property values can be increased by using replacements of cement and admixtures in the concrete.

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