Chapter 1

PROJECT OVERVIEW

BACKGROUND OF THE STUDY

Rice Production in the country of Philippines is important to the food supply

in the country and economy. The Philippines is the 8th largest rice producer in the

world accounting for 2.8% of global rice production (Ganate, 2015). Rice is the first

main crop in the Philippines and the most important food crop. This new

generation, some researchers finding some step on how waste reduce its capacity

due to the high volume of population. Some waste are considered hazardous and

some of this are not. Here In the country of Philippines, some waste is found in

agriculture category and one of this is Rice husk. Previous studies found out that

the ash of rice husk can use as partial replacement of cement because the

properties of it can strengthen the concrete.

Some research had shown that small amounts of inert filler have always

been acceptable as cement replacements, what more if the fillers have the

pozzolanic properties, in which it will not only impart technical advantages to the

resulting concrete but also enable larger quantities of cement replacement to be

achieved.

Due to the effect of climate change, some heritage structures can be easily

damaged and need to be restore. There are steps to restore it but heritage

structures requires the use of compatible materials similar to or prepared by the

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reproduction of the historic materials and construction technology. The complete

characterization of the originally employed historic materials that also provides

information of their manufacturing processes can lead to the success of the

restoration process (Gulzar, Chaudhry, Burg and Saeed, 2013).

In the proposed study, RHA used a K-Type cement that can very useful in

Heritage Structures. It will prioritized the strength, breathability and durability of

the structure, environmental impact and the cost efficiency of the said cement.

STATEMENT OF THE OBJECTIVES

The main objective of the study is to Design a K-Type Cement use for

Heritage Structures. Specifically, it looked into the following:

1. K – Type cements properties and standards.

2. Design a K – Type cement using RHA in the following mixtures:

a.) 100% RHA;

b.) 75% RHA and 25% Lime Powder; and

c.) 50% RHA and 50% Lime Powder;

d.) 25% RHA and 75% Lime Powder.

3. Show a comparison of RHA and K – Type cement in terms of:

a.) Compressive Strength;

b.) Breathability;

c.) Economic.

4. Characteristics of RHA used.

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SIGNIFICANCE OF THE PROJECT

The proposed study shall benefit the following persons and entities:

School administration can use the RHA Cement as an adhesive material for

bricks in pathways and any other light weight construction project of the school.

Civil engineering department can use the RHA Cement as a contribution in the

enhancement of the civil engineering program.

Instructors can use the RHA Cement as a teaching aid in teaching the needed

knowledge to keep and develop the quality of learning through laboratory activities.

Students can use the RHA Cement as an actual standard on the theories learned

in the subject Construction Material Testing.

Future researchers can use the RHA Cement as a foundation in undertaking

similar studies and succeeding fabrication of other related laboratory

experimentation for use by the civil engineering department and other colleges of

the university.

SCOPE AND DELIMITATION OF THE STUDY

The study will mainly focus on the study of the compressive strength and

the breathability factor of rice husk ash when it applied in heritage structures. This

will ensure that this breathable capability will not be blocked which could

cause the structure to decay or could adversely affect the interior air

quality.

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The study will concentrate on the utilization of locally available

materials such as rice husk ash which is considered as an agricultural

waste.

RESEARCH METHODOLOGY

This part of the chapter presents a discussion on the methods of

research and in the making of this study. This includes the research design, testing

and evaluation of the RHA K-Type Cement.

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Materials

Materials used during this experimental study are listed below.

 Lime Powder

Lime powder was used in this research work which is made by oyster

shell by lime slaking process.

 Rice Husk Ash (RHA)

The rice husk was collected from local rice mills was burned in Furnace

for a temperature of 800 ° C.

 Fine aggregate

The fine aggregate that used for concrete mixing was river sand.

 Coarse aggregate

Granite was used in concrete mixing in this experimental study. Granite

is formed naturally from stone that was quarried and crushed to produce

various sizes of aggregate. It is commonly used in construction industry as

coarse aggregate. The aggregate used was cleaned and dried under the

ambient temperature before concrete mixing.

 Water

Tap water was chosen for the concrete mixing and curing process.

Water is considered as an important ingredient that required for concrete

mixing. Impurities in the water and the pH value may affect the setting time,

compressive strength of the concrete and also may causes staining on the

concrete surface (Sumadi & Lee, 2008). The quality of tap water satisfied

the requirements of concrete mixing.

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 Brick

A common brick made by clay was chosen for the breathability test.

Preparation of rice husk ash (RHA)

Rice husk ash collected from the furnace must past trough in No. 200

sieve.

Mixing proportions Concrete

75 psi concrete was chosen to be the mixing grade of concrete. 75 psi

concrete refers to the tested concrete will achieve compressive strength of 75 psi

at 28 days. The mix designations are the same for both concrete using 800 °C

RHA respectively. The mixing designation of 75 psi concrete was listed below.

Table 3.1 Mix designation of material composition for 1 m3 of 75 psi concrete

Mix Designation Sample 1 Sample 2 Sample 3 Sample 4

(S1) (S2) (S3) (S4)

RHA (kg) 0 0.75 0.50 0.25

Lime Powder (kg) 1 0.25 0.50 0.75

Fine aggregate 2 2 2 2

(kg)

Coarse aggregate 4 4 4 4

(kg)

Water (kg) 1 1 1 1

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Table 3.2 Mix designation of RHA and Lime Powder

Sample Temperature of RHA (%) Lime Powder (%)
RHA (°C)
S1 800 100.0 0.0
S2 800 75.0 25.0
S3 800 50.0 50.0
S4 800 25.0 75.0

Casting process

Mixing of concrete was carried out in the construction workshop. Hand

mixing of concrete was used in this study and all the mixing was done in a piece

of plywood. All the materials were weighted accurately before mixing. The surface

of plywood was wetted before putting the materials to reduce the water loss. River

sand, granite, RHA and Lime powder were put on the plywood accordingly and

mixed well with shovel. The fresh concrete was then poured into the mould to form

dimension of 15 cm × 15 cm × 15 cm concrete cube. The concrete was De-

moulded after 24 hours and cured in a tank of water. The concrete samples were

tested at the concrete age of 7, 14, 21 and 28 days after curing.

Mechanical Test

Compressive strength test were done to determine the mechanical

properties of the concrete samples.

Breathability Test

The sample is place into a pan of water. Then after a period of time (24

hours) check the sample if there was a moist in each sides and if there was a moist,

the sample is breathable.

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Mortar Test

For cube test the types of specimens chosen was 5cm x 5cm x 5cm.

This concrete is poured in the mould and tempered properly so as not to have any

voids. After 24 hours these moulds are removed and test specimens are put in

water for curing. The top surface of these specimen should be made even and

smooth. This is done by putting cement paste and spreading smoothly on whole

area of specimen. These specimens are tested by compression testing machine

after 7, 14, 21 and 28 days curing.

Compression Testing Machine

For most of the works cubical moulds of size 15 cm x 15cm x 15 cm are

commonly used. This concrete is poured in the mould and tempered properly so

as not to have any voids. After 24 hours these moulds are removed and test

specimens are put in water for curing. The top surface of these specimen should

be made even and smooth. This is done by putting cement paste and spreading

smoothly on whole area of specimen. These specimens are tested by compression

testing machine after 7, 14, 21 and 28 days curing. Load should be applied

gradually at the rate of 140 kg/cm2 per minute till the Specimens fails. Load at the

failure divided by area of specimen gives the compressive strength of concrete.

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THEORETICAL FRAMEWORKS

Rice Husk Ash (RHA)

Rice husk is the outermost part of rice paddy, it covers about 20 to 25 % of

the rice weight. RHA is a SCM and being studied in a past few decades in order to

replace cement through its pozzolanic properties. RHA is obtained from raw rice

husk changed into ash by combustion method to remove volatile organic carbon

such as cellulose and lignin. It has a very high surface area of 50000 to 100000

m2 per kg (Gambhir, 2004). RHA is a very fine material and its average particle

size of RHA is ranged from 5 to 10 micron (Evi et al, 2014). RHA is composed

mostly of silica in amorphous form (85-90%) and it has a highly micro-porous

structure which is able to create a new type of cement through its pozzolanic

reaction. The amorphous silica of RHA can react with the calcium hydroxide crystal

that formed during the hydration of concrete. Secondary C-S-H gel is formed to fill

up the pore structure in concrete. Besides, RHA also can improve the interlocking

between the concrete mixture and fill up the space between cement particles

(Hesami, Ahmadi & Nematzadeh, 2013).

Fineness of RHA is another important factor that could influence the

reactivity of RHA. RHA is basically finer and less reactive compared to Portland

cement but it could disperse in the mixture and create a numerous quantity of

nucleation sites for the precipitation of CH which can refer as pozzolanic reaction.

This reaction creates a denser and more homogenous concrete (Isaia, Gastaldini

& Moraes, 2003). RHA exist in concrete can reduce permeability, w/c-ratio, make

denser packing and increase the hydration of cement (Sumadi & Lee, 2008). RHA

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is influencing the mechanical properties of concrete through its chemical and

physical properties.

Factors influencing the mechanical properties of concrete

The strength and durability of concrete is normally to be governed by such

factors as water binder ratio (cementitious content), the efficiency of curing,

compactness, admixture and also content of cement in the mix (Lun, 2015).

Curing Process

Curing is a very important process that could affect the concrete strength.

Curing is defined as the process of creation of an environment for the concrete to

setting and hardening right after the concrete is placed and compacted (Gambhir,

2013). Curing which mean by putting the concrete immediately after set and

compacted to the suitable condition of water and temperature. Concrete needed

curing is because of the hydration of cement which can only happen in water-filled

capillaries. Upon the concrete contacts with water, the hydration of cement will

occur internally and externally. The hydration products will get deposit outside of

the cement particles while the nucleus of Un-hydrated cement will reduce gradually

inside of the concrete. In order to obtain a concrete of complete strength

development, evaporation should be prevented and have enough of water for

hydration process (Lun, 2015).

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DEFINITION OF TERMS

Rice husk. The outermost layer of the paddy grain that is separated from

the rice grains.

Rice husk ash (RHA). A by-product from the burnt rice husk.

K-Type Cement. Is a pre-blended cement consisting of inter ground

component. TYPE K CEMENT is used to produce concrete and other low

shrinkage concrete and non-shrink grout materials that offer lower permeability,

improved sulfate resistance, and maximum durability.

Compression strength. Is the capacity of a material or structure to

withstand loads tending to reduce size, as opposed to tensile strength, which

withstands loads tending to elongate.

Pozzolans. Are a broad class of siliceous or siliceous and aluminous

materials which, in themselves, possess little or no cementitious value but which

will, in finely divided form and in the presence of water, react chemically with

calcium hydroxide at ordinary temperature to form compounds possessing

cementitious properties.

Furnace. A device used for high-temperature heating.

Breathable. Permitting air to pass through.

Breathability. The ability of a fabric to allow moisture vapour to be

transmitted through the material.

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