EXPERIMENTAL STUDY ON CONCRETE

WITH PARTIALLY REPLACING CEMENT BY

SILICA FUME AND COARSE AGGREGATE
BY COCONUT SHELL

Project Members
Iniyamathiyazhakan.S (11116065)
Nallaiah.M (11116025)
Thirumalaikumar.S (11116073)
Velusami.P (11116075)
Guided by
Mr.M.RAMESH M.E.,Asst.Prof.,
 ABSTRACT

This project work deals with a study of characteristics

strength of concrete with partial replacement of cement by
silica fume and partial replacement of coarse aggregate by
coconut shell. In this project we are partially replacing cement
by 10% of silica fume and partially replacing coarse aggregate
by coconut shell is varies from 0 to 10% at interval of 2.5% .
For this research, M25 grade concrete was used. The
properties of cement, fine aggregate, coarse aggregate are
obtained for mix design.
 The main aim of this project work is to preventing mere
dumping of coconut shell wastes and also reduces the environmental
hazards. Also this project work aims at usage of silica fume, which is
a byproduct of silicon industry, as a supplementary cementitious
material as well as an additive in concrete.
For each level, workability test (slump test), 7 days and 28 days
compressive strength test, 28 days split tensile strength test and 28
days flexural strength test are conducted. The test results are
compared with the reference concrete without silica fume and
coconut shell. It is seen that 10% of silica fume and 2.5% of coconut
shell replacement level, the 28 days compressive strength of concrete
is 20.4% less than that of reference concrete. Compressive strength
of concrete is decreases with increasing replacement level of coconut
shell.
 INTRODUCTION
Concrete is world’s most widely used construction materials.
The utilization of concrete is increasing at a higher rate due to
development in infrastructure and construction activities all
around the world. In recent times, many researches are going
on for improving the properties of concrete with respect to
strength, durability and performance by using industrial waste
materials like Fly Ash, Silica fume, Furnace Slag etc. One
among these special concretes is the Silica fume concrete
which is new emerging as one of new generation construction
material in producing high strength and high performance
concrete for special structures.
The interest in Silica fume started in environment of air pollution
control in many countries. This implies that the industry had to
stop releasing Silica fume along with other fine gases into the
atmosphere. To find solution to this problem studies were
initiated and after some investigations, it was found that the Silica
fume could be used as a very useful material in concrete.
Silica fume is being used concrete for quite some time in
countries like Norway and U.S. very high strength concrete is
being produced using this very fine highly reactive industrial bye
product. In India, imported Silica fume is finding its use now a
days.
The large amount of agricultural waste was disposed in most
of tropical countries especially in Asia for countries like
Thailand, Philippine. If the waste cannot be disposed properly
it will lead to social and environmental problem. So coarse
aggregate is replaced by coconut shell is an agricultural waste
which are light weight aggregates. The coconut shell were
suitable as low strength-giving light aggregate when used to
replace common coarse aggregate in concrete production. It
reduce the cost of construction.
 MATERIALS USED

 Cement
 Silica fume
 Fine aggregate
 Coarse aggregate
 Coconut shell
 Water
 Literature Review
Collection of Materials
Study of properties of materials

Mix design
Casting of elements

Testing of elements

Results and Discussion

LITRATURE REVIEW
Vishal S. Ghutke et.al.,(2014) He suggested that Portland
cement can be partially replaced by silica fume. Silica fume is
non metallic and non hazardous waste of industries. The main
objective of this research work by the author is to determine the
optimum replacement percentages which can be suitably used
under the Indian conditions. It has been seen that when cement is
replaced by silica fume compressive strength increases up to 10%
replacement. But higher replacement of cement by silica fume
gives lower strength. With the increase in w/c ratio strength of
concrete decreases. The optimum value of compressive strength
can be achieved in 10% replacement of silica fume. As strength
of 15% replacement of cement by silica fume is more than
normal concrete. The optimum silica fume replacement
percentage varies from 10% to 15% replacement level.
Workability of concrete decreases as increase with % of SF
Kathuda.H et.al.,(2009) The main of the author is to determine
the isolated effect of silica fume on tensile ,compressive and
flexure strengths on high strength light weight concrete. Many
experiments were carried out by the author replacing cement with
different percentages of silica fume at different constant water
binder ratio keeping other mix design variables constant. The
silica fume was replaced by 0%,5%,10%,15%,20%and 25% for a
water-binder ratios ranging from 0.26 to 0.42.for all mixes, split
tensile, compressive and flexure strengths were determined at 28
days.The results concluded by the author showed that the tensile
,compressive and flexure strengths increased with SF
incorporation but the optimum replacement percentage not
constant because it depends on the water cementitious material
ratio of mix.
The isolated effect of SF increase the compressive,splitting
tensile and flexure strengths. The highest increase has been
found in the flexure strength. The optimum SF replacement
percentage for obtaining maximum 28 days compressive and
flexure strength of lightweight high strength concrete ranges from
15% to 25%depending on the w/c ratio of the mix.
Amudhavalli N.K et.al.,(2012) She suggested that addition of
silica fume to concrete has many advantages like high
strength, durability and reduction in cement production. Large
scale production of cement is causing environmental problems.
Therefore the author using silica fume as a replacing material.
Consistency of cement depends upon its fineness. Silica fume
having greater fineness than cement and greater surface area so
the consistency increases greatly, when silica fume percentage
increases. The optimum 7 and 28 days compressive strength and
flexural strength have been obtained in the range of 10 to 15%
silica fume replacement level. Cement replacement upto10% with
silica fume leads to increase in compressive strength, for M30
grade of concrete.
Vikash kumar sing et.al.,(2014) He suggested natural crushed
stone is partially replaced by recycle Aggregates and coconut
shells. In concrete mix of M30 was prepared in that coarse
aggregate was replace by 5%, 10%, and 15% of recycled
aggregates and coconut shells. Performance of CS aggregate
concrete is lower than natural aggregate concrete. Performance of
RA aggregate concrete is little lower than natural aggregate
concrete .Workability decrease as we increase percentage of CS
in concrete. Little workability decrease as we increase percentage
of RA in concrete. Compressive strength is decreased with the
addition to CS in concrete. Compressive strength is good when
concrete natural aggregate is replaced by RA concrete.
Dewanshu Ahlawat et.al.,(2014) In this literature the author
explained that, M20 grade of concrete was produced by
replacing granite by coconut shell. Forty five cubes were casted
and their compressive strength and densities were evaluated at
7, 14, 28 days. The density and compressive strength of concrete
reduced as the percentage replacement increased. Concrete
produced by 2.5%, 5%, 7.5%, 10% replacement attained 28 days
compressive strength of 19.71, 19.53, 19.08, 18.91 N/mm2
respectively. Due to high water absorption of coconut shell, they
were pre soaked in water for 24 hours, prior to mixing. Increase
in percentage replacement by coconut shell reduces compressive
strength of concrete. Increase in percentage replacement by
coconut shell reduces density of concrete. Coconut shell can be
used as Partial replacement of coarse aggregate in R.C.C
concrete.
Parag S.Kambli et.al.,(2014)

The project paper of the author is to analyse compressive

strength characteristics of concrete produced using crushed, granular
coconut as substitutes for conventional coarse aggregate with partial
replacement. The coconut shell has potential as light weight aggregate
in concrete. It is concluded that the coconut shells are more suitable as
low strength-giving light weight aggregate when used to replace
common coarse aggregate in concrete production. Compressive
strength of concrete is reduced while increasing the percentage
coconut shell replacement.
PROPERTIES OF MATERIALS
Cement
a) Specific gravity = 3.07
b) Fineness modulus = 1.5%
c) Consistency = 28%
d) Initial setting time = 65 minutes
Fine aggregate
a) Water absorption = 0.7%
b) Specific gravity = 2.68
c) Grading zone = II
Coarse aggregate
a) Specific gravity = 2.72
b) Water absorption = 0.5%
Coconut shell
a) Specific gravity = 1.17
b) Water absorption = 0.7%
Silica fume
a) Specific gravity = 2.9
 Fineness of Cement

S. No Description Trial No.1 Trial No.2

1 Weight of sample (gm) 100 100

2 Weight of material retained (gm) 1.4 1.6

Percentage of residue left on the

3 1.4 1.6
90µ sieve

Fineness of cement = weight retained/weight taken

×100
Fineness of cement = 100 x (1.5/100)
Fineness of cement = 1.5%
 Consistency of Cement

Weight of Reading of
% of Amount of
cement pointer from
Trial No. Water water (ml)
(gm) bottom
1 400 25 100 24
2 400 26 104 20
3 400 27 108 15
4 400 28 112 6
Consistency of cement = 28%
 Initial Setting Time of Cement
S. No Time in minutes Pointer reading from bottom
1 0 0
2 5 0
3 10 0
4 15 0
5 20 0
6 25 0
7 30 0
8 35 0
9 40 1
10 45 1
11 50 3
12 55 3
13 60 4
Initial setting time of cement = 65 minutes
 Specific Gravity of Cement
S. Trial Trial Trial
Description
No No.1 No.2 No.3
1 Weight of empty bottle (W1) gm 30 30 30
2 Weight of bottle + water (W2) gm 79 79 79
3 Weight of bottle + kerosene (W3) gm 68 68 68
Weight of bottle + kerosene + cement
4 76 77 76
(W4) gm
5 Weight of cement + bottle gm 40 41 40
6 Weight of cement (W5) gm 12 13 12
7 Specific gravity of cement 3.00 3.2 3.00
Average specific gravity of cement = 3.07
FINE AGGREGATE
 Sieve Analysis of Fine Aggregate

Cumulative
IS Weight Cumulative
S. % of weight percentage
Sieve retained percentage
No retained weight
(mm) (g) passing
retained
1 4.75 24 2.4 2.4 97.6
2 2.36 4 0.4 2.8 97.2
3 1.18 228 22.8 25.6 74.4
4 0.60 265 26.5 52.1 47.9
5 0.30 369 36.9 89 11
6 0.15 53 5.3 94.3 5.7
Fineness Modulus of sand=Total percentageof cumulative/100
= 334.5100
Fineness Modulus of sand = 3.345
Sand conforming to zone II as specified in IS 383-1970.
 Specific Gravity of Fine Aggregate

S. Trial Trial Trail

Observations
No. No 1 No 2 No 3
1 Wt of empty container W1(gm) 656 656 656
2 Wt of container+sampleW2(gm) 1017 1015 1018
Wt of
3 1740 1735 1742
container+sample+waterW3(gm)
4 Wt of container+waterW4 (gm) 1512 1512 1512
5 Specific Gravity 2.71 2.64 2.712
Specific Gravity of Fine Aggregate = 2.68
COARSE AGGREGATE
 Specific Gravity Test of Coarse Aggregate
S. Trial Trail Trail
Observations
No No 1 No 2 No 3
1 Weight of empty container W1 (gm) 1272 1272 1272
Weight of container + sample
2 2230 2232 2235
W2(gm)
Weight of container + sample +
3 3512 3505 3512
water W3(gm)
Weight of container + water W4
4 2898 2898 2898
(gm)
5 Specific Gravity 2.70 2.72 2.76
Specific Gravity of Coarse Aggregate =2.72
SILICA FUME
 Specific Gravity of Silica Fume
S. Trial Trial Trial
Description
No No.1 No.2 No.3
1 Weight of empty bottle (W1) gm 30 30 30
2 Weight of bottle + water (W2) gm 79 79 79
3 Weight of bottle + kerosene (W3) gm 69 69 69
Weight of bottle + kerosene + silica
4 81 80 82
fume (W4) gm
5 Weight of silica fume + bottle gm 48 47 50
6 Weight of silica fume (W5) gm 18 17 20
7 Specific gravity of cement 3.00 2.833 2.857
Specific gravity of silica fume = 2.9
COCONUT SHELL
 Specific Gravity Test of Coconut shell

S. Trial Trail Trail

Observations
No No 1 No 2 No 3
1 Weight of empty container W1 (gm) 1272 1272 1272
2 Weight of container + sample W2(gm) 1565 1556 1528
Weight of container + sample + water
3 3029 3020 3025
W3(gm)
4 Weight of container + water W4 (gm) 2985 2985 2985
5 Specific Gravity 1.177 1.141 1.185
Specific Gravity of Coarse Aggregate =1.17
MIX DESIGN
The mix design for M25 grade concrete is as follows
Stipulations for proportioning
Grade of designation : M25
Type of cement : OPC 53 grade
Maximum nominal size of aggregate : 12.5 mm
Minimum cement content : 300 kg/m3
Maximum water cement ratio : 0.5
Workability : 100 mm(slump)
Exposure condition : Moderate
Method of concrete placing : Normal pouring
Degree of supervision : Good
Type of aggregate : Crushed angular
aggregate
Test data for materials
Cement used : OPC 53 grade conforming to IS
8112
Specific gravity of
Cement : 3.07
Fine aggregate : 2.68
Coarse aggregate : 2.72
Water absorption of
Fine aggregate : 0.7%
Coarse aggregate : 0.5%
Sieve analysis for
Fine aggregate : Confirming to zone II of table 4 of
IS 383
Coarse aggregate : Conforming to table 2 of IS 383
Fineness of cement : 1.5%
Target mean strength of mix proportioning
f*ck = fck + 1.65 s
where,
f*ck = Target average compressive strength at 28 days,
fck = Characteristic compressive strength at 28 days, and
s = Standard deviation
From table 8 IS 456:2000, Standard deviation,s = 4 N/mm2
Therefore,
Target mean strength = 25 + 1.65 x 4
= 31.6 N/mm2
Selection of water cement ratio
From table 5 of IS 456:2000, maximum water-cement ratio =
0.50
From fig 2 of IS 10262:2009, adopt water-cement ratio as 0.45
0.45 < 0.50, hence ok.
Selection of water content
From Table 2 of IS 10262:2009
Maximum water content for 12.5 mm aggregate= 202.5 kg
Estimated water content for 100 mm slump = 202.5 + (202.5 x
6/100)
Hence, water content = 214.65 kg
Calculation of cement content
Water-cement ratio = 0.45
Cement content = 214.65/0.45
= 477 kg/m3
Maximum cement content = 450 kg/m3
Hence we take cement content as 450kg/m3
Proportion of volume of coarse aggregate and fine aggregate
content
From Table 3, Volume of coarse aggregate corresponding to 12.5
mm size aggregate and fine aggregate (zone II) = 0.5
As the water-cement ratio is lower by 0.05, the proportion of
volume of coarse aggregate is increased by 0.01
Therefore, corrected proportion of volume of coarse aggregate for
the water-cement ratio of 0.45 = 0.51 m3
Volume of fine aggregate content = 1 – 0.51 = 0.49m3
Mix calculations
The mix calculations per unit volume of concrete shall be as
follows
Volume of concrete = 1 m3
Volume of cement = (Mass of cement / Specific gravity of
cement) x (1/1000)
= (450/3.07) x (1/1000)
= 0.147 m3
Volume of water = (Mass of water/Specific gravity of water)
x (1/1000)
= (214.65/1) x (1/1000)
= 0.2146 m3
Volume of aggregate = Volume of concrete – (Volume of cement +
Volume of water)
= 1- (0.147 + 0.2146)
= 0.638 m3
Mass of coarse aggregate = Volume of aggregate x Volume
of coarse aggregate x Specific
gravity of coarse aggregate x 1000
= 0.638 x 0.51 x 2.72 x 1000
= 885.03 kg
Mass of fine aggregate = Volume of aggregate x Volume
of fine aggregate x Specific gravity
of fine aggregate x 1000
= 0.638 x 0.49 x 2.68 x 1000
= 837.82 kg
Mix proportions
Cement = 450 kg/m3
Water = 0.215 m3 (215 littre/m3)
Fine aggregate = 837.820 kg
Coarse aggregate = 885.03 kg
Cement:Fine aggregate:Coarse aggregate:Water
1 : 1.862 : 1.967 : 0.45
 Various Concrete Mix Details
S.No Silica Cemen Fine Silica Coarse Coconu Coconut
Fum t Aggregat Fume Aggregat t Shell
e (kg) e (kg) e Shell (kg)
(%) (kg) (kg) (%)
1 0 31.365 58.375 - 61.687 0 -
2 10 28.23 58.375 1.568 60.087 2.5 1.6
3 10 28.23 58.375 1.568 58.487 5 3.2
4 10 28.23 58.375 1.568 56.887 7.5 4.8
5 10 28.23 58.375 1.568 55.287 10 6.4
 SLUMP FLOW TEST

Tests were carried out on each mix to evaluate the characteristics

flow. From the results the slump value has been increased with
constant replacement percentage of silica fume and increasing the
percentage replacement of coconut shell. This clearly shows that
the workability of concrete increases with increasing the
replacement percentage of coconut shell.
 Slump Flow Test

Specimen Replacement Replacement Slump value

% of Silica % of Coconut
fume shell
CM - - 98
M1 10 2.5 110
M2 10 5 116
M3 10 7.5 125
M4 10 10 132
 Compressive strength
Tests were carried out on each mix to evaluate the characteristics
compressive strength of concrete. From the result the compressive
strength of nominal concrete at 7 days was 18.487 N/mm2. After the
replacement of cement by 10% of silica fume and 5% of coarse
aggregate by coconut shell the compressive strength was increased to
23.309 N/mm2. But the compressive strength of nominal concrete at
28 days was 39.072 N/mm2. After the replacement of cement by 10%
of silica fume and 2.5% of coarse aggregate by coconut shell the
compressive strength was decreased to 31.086 N/mm2. The
compressive strength of replacement concrete is decreased with
increasing the percentage replacement of coconut shell.
 7-Days Compressive Strength of Cubes

Compressive
% of Coconut
Specimen % of Silica fume Strength on 7
shell
day(N/mm2)
CM - - 18.487
M1 10 2.5 19.763
M2 10 5 23.309
M3 10 7.5 23.05
M4 10 10 15.5
 7 Days

25

20
COMPRESSIVE STRENGTH

15

23.309 23.05

19.763
10 18.487

15.5

0
CM SF 10% & CS 2.5% SF 10% & CS 5% SF 10% & CS 7.5% SF 10% & CS 10%
REPLACEMENT %
 28-Days Compressive Strength of Cubes

Compressive
% of Coconut
Specimen % of Silica Strength on 28
shell
fume day(N/mm2)

CM - - 39.072
M1 2.5 10 31.086
M2 5 10 30.518
M3 7.5 10 29.31
M4 10 10 27.88
 28 Days

40

35

30
COMPRESSIVE STRENGTH

25

39.072
20

31.086 30.518
29.31
15 27.88

10

0
CM SF 10% & CS 2.5% SF 10% & CS 5% SF 10% & CS 7.5% SF 10% & CS 10%
REPLACEMENT %
 Average Compressive Strength at 7 & 28 days

Compressiv Compressive
Specim % of Silica % of Coconut e Strength Strength on 28
en fume shell on 7 day(N/mm2)
day(N/mm2)
CM - - 18.487 39.072
M1 10 2.5 19.763 31.086
M2 10 5 23.309 30.518
M3 10 7.5 23.05 29.31
M4 10 10 15.5 27.88
 45

7 Days 28 Days
40 39.072

35

31.086
30.518
29.31
COMPRESSIVE STRENGTH IN N/mm2

30
27.88

25
23.309 23.05

19.763
20 18.487

15.5
15

10

0
CM SF 10% & CS 2.5% SF 10% & CS 5% SF 10% & CS 7.5% SF 10% & CS 10%
REPLACEMENT %
 Split tensile strength

Tests were carried out on each mix to evaluate the

characteristics split tensile strength of concrete. From the
result the split tensile strength of nominal concrete at 28 days
was 1.463 N/mm2. After the replacement of cement by 10% of
silica fume and 5% of coarse aggregate by coconut shell the
split tensile strength was increased to 1.806 N/mm2. Then
further increment in percentage of coconut shell the split
tensile strength of concrete was decreased. This clearly shows
that 10% of silica fume and 5% of coconut shell was found to
be optimum value.
 Split Tensile Strength of Cylinder

% of Silica
% of Coconut Split tensile strength
S. No fume
shell (N/mm2)

CM - - 1.463

M1 10 2.5 0.995

M2 10 5 1.806

M3 10 7.5 1.34

M4 10 10% 1.31
 28 Days

1.8

1.6

1.4
SPLIT TENSILE STRENGTH

1.2

1
1.806

0.8 1.463
1.34 1.31

0.6
0.995

0.4

0.2

0
CM SF 10% & CS 2.5% SF 10% & CS 5% SF 10% & CS 7.5% SF 10% & CS 10%
REPLACEMENT %
 Flexural strength

Tests were carried out on each mix to evaluate the

characteristics flexural strength of concrete. From the result
the flexural strength of nominal concrete at 28 days was 5.488
N/mm2. After the replacement of cement by 10% of silica
fume and 2.5% of coarse aggregate by coconut shell the
flexural strength was increased to 5.933 N/mm2. Then further
increment in percentage of coconut shell the flexural strength
of concrete was decreased. This clearly shows that 10% of
silica fume and 2.5% of coconut shell was found to be
optimum value.
 Flexural Strength of Beam

Specime % of Coconut Flexural strength

n % of Silica fume shell (N/mm2)

CM - - 5.488

M1 10 2.5 5.933

M2 10 5 5.65

M3 10 7.5 4.75

M4 10 10 3.2
 6
28 Days

4
FLUXURAL STRENGTH

5.933
3 5.65
5.488

4.75

2
3.2

0
CM SF 10% & CS 2.5% SF 10% & CS 5% SF 10% & CS 7.5% SF 10% & CS 10%
REPLACEMENT %
 Weight of cubes

SPECIMEN % of SILICA % of COCONUT WEIGHT of

FUME SHELL CUBES

CM - - 8.582

M1 10 2.5 8.285

M2 10 5 8.222

M3 10 7.5 7.711

M4 10 10 7.608
 When partially replacing coarse aggregate by coconut shell,
the weight of concreteshould be decreased.When adding 10% of
silica fume by the weight of cement and 10% of coconut shell by
the weight of coarse aggregate it gives 10% weight lesser than the
nominal concrete.
 WEIGHT OF CUBES

8.6

8.4

8.2
WEIGHT OF CUBES IN Kg

8.582
7.8

8.285
8.222
7.6

7.4 7.711
7.608

7.2

7
0% SF 10% & CS 2.5% SF 10% & CS 5% SF 10% & CS 7.5% SF 10% & CS 10%

REPLACEMENT IN %
 CONCLUSION

From this project we have studied that the split tensile strength was
increased when the cement is partially replaced by 10% of silica fume
and coconut shell is partially replaced by 5% of coconut shell.
Also the flexural strength of concrete was increased when the
cement is partially replaced by 10% of silica fume and coconut shell
is partially replaced by 2.5% of coconut shell.
The compressive strength of concrete was decreased with
increasing the percentage replacement of coconut shell.
When adding 10% of silica fume by the weight of cement and 10%
of coconut shell by the weight of coarse aggregate it gives 10%
weight lesser than the nominal concrete.
Our suggestion those who made an alternative study on the silica
fume and coconut shell is that they can be used along with addition of
other admixtures may yield good strength.
 REFERENCES

1. Amudhavali.N.K and Jeena Mathew (2012) “Effect of Silica Fume

On Strength and Durability Parameters of Concrete”, International
Journal of Engineering Science & Emerging Technologies, Vol.7.
2. Dewanshu Ahlawat, L.G.Kalurkar (2014) “Coconut Shell As Partial
Replacement of Coarse Aggregate”, International Journal of Civil
Engineering and Technology(IJCIET),Vol.4.
3. IS 10262:2009 “Code of Practice for Concrete Mix Proportioning”,
Bureau of Indian Standards publication-New Delhi.
4. IS 456:2000 “Code of Practice forPlain and Reinforced Concrete”,
Bureau of Indian Standards publication-New Delhi.
5. IS 383:1970 “Indian Standard Specifications for Coarse and Fine
Aggregates from Natural Sources for Concrete.
6. Katkhuda.H, Hanayneh.B, Shatarat.N (2009), “Influence of Silica
Fume on High Strength Light Weight Concrete”, World Academy of
Science, Engineering and Technology,Vol-3.
7. Parag S.Kambli, Sandhya R.Mathapati (2014), “Compressive
Strength of Concrete by Using Coconut Shell”, IOSR Journal
of Engineering (IOSRJEN),Vol.04
8. Vikash Kumar Singh, Pradeep Tiwari, Devansh Jain (2014),
“Comparative Study of The Compressive Strength of
Concrete When Natural Crushed Stone Coarse Aggregate is
Replaced by Recycled Aggregates and Coconut Shells”,
International Journal of Engineering Research And
Management(IJERM),Vol.01.
9. Vishal S.Ghutke, Pranita S.Bhandari (2014), “Influence of
Silica Fume on Concrete”, IOSR Journals of Mechanical and
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THANK YOU