Creating a "green composite binder from industrial waste stabilization" is a method to provide a greener environment for future generations. Therefore, this project mainly adds industrial waste stabilization as an admixture to replace sand for stabilization of Portland cement. The main objective of this individual final year project is to produce a green composite binder using appropriate industrial waste stabilization, create a cost-effective binder and create a lightweight and stronger binder using waste materials.
The main problem statement of this project is to review the best combination of industrial waste stabilization in order to produce a light weight and strong composite binder. The production of new green composite binders are able to increase the rating of the green building index. This invention will help make the environment greener in the future and help reduce the stabilization of industrial waste.
According to the methodology and result, it is concluded that FPM solidified industrial waste in Portland cement produces better cement complex giving 56.7 kN in air curing and meet the requirements of sound test and blaine air permeability test. Asna Mohd Zain, who has guided and supported me during these two semesters to complete this project.
INTRODUCTION
- Background of Study
- Problem Statement
- Significant of project
- Objective of the project
- Relevance of the Study
- Feasibility of the project within the scope and time frame
- Scope of Study
As this project is to develop a green composite binder, the aggregate will therefore be replaced with the selected industrial waste. As an effort to reduce the industrial waste in disposal area, this industrial waste will be analyzed and used when mixing cement to create green composite binder. By using industrial waste in the preparation of composite binder materials, the amount of cement and sand consumption can be effectively reduced.
What changes can be made to make a green composite binder using industrial waste. To answer the above problem, each selected industrial waste will be carefully analyzed for hazards and used in the experiment. To study the effect of different types of industrial waste with OPC for the production of green composite binder.
To study the effect of additive to produce a lighter weight and stronger binder using industrial waste residues. The main goal of the study which is the main pillar is to produce a green composite binder material using industrial waste stabilization.
LITERATURE REVIEW
Past research on the green composite
As referenced in Concrete Pipe Handbook page 2-2, American Concrete Pipe Association, 1988, there are 8 types of Portland cement. It is used where cement or concrete is not subject to specific exposures, such as sulfate attack from soil or water, or to an offensive temperature rise due to heat generated by hydration. Material safety and data sheet (MSDS) of this Portland cement type 1 was obtained from ASH GROVE Portland Cement Company.
The main method of health and safety treatment for Portland cement is the use of personal protective safety equipment, such as protective clothing, both, rubber gloves, dust mask, safety glasses for eyes. Some information about the binder which consists of Portland cement type 1, sand, gravel and water is taken from the lecture note from the course Concrete Technology (EVB 3022) prepared by Noor Amila Wan Abdullah Zawawi, lecturer in University Technology. The proposed green composite has a small amount of biodegradable resin is used and the matrix consists of wood chips slightly saturated with biodegradable resin.
The binder used in this mortar was developed by the reaction of inorganic minerals fly ash (FA). Anhydrous gypsum was added as a chemical activator in varying proportions of and 10% by weight of the binder. Another project that is close enough to make it the reference for my project is the creation of binder using fly ash, flurogypsum and Portland cement.
This geopolymer composition is mainly industrial waste from the by-product of the reaction taken from local heating plant furnaces. The samples are made with different mixture combinations such as wood ash (WA), town ash (BA), also ground waste glass (AGW), barley and wood ash (BTG), burnt clay wood ash (WTG) and rough ground glass (OWG) (Diana Bajare, 2010). After doing some research, it is believed that polymer type industrial waste will give a strong strength to the cement paste and mortar.
Bhd has provided their material safety and data sheet on their industrial waste which consists of health hazard, fire hazard, reactivity hazard and its physical and chemical properties. Rice husk ash (RHA) is used as an aggregate that increases the strength of the cement mortar. This invention will help the environment to become greener in the future and help reduce industrial waste stabilization (Wee, 2012).
Review on other related researches
- Research Gap
Methodology
- Research Methodology
- Preliminary Research
- Data Gathering
- Data analysis and possible solution to carry out experiment
- Experiment Work Setup
- Testing Procedure
- Key milestone
- Tools Used
- Gantt Chart
From conducting the literature review on the current research, only the characteristic polymer-like industrial wastes may be able to provide higher strength when mixed with binders. All criteria are set in order to select the best candidate of industrial waste to be mixed into the binder. After discussion with the technician and supervisor of the civil laboratory, it is finalized that a polymer like industrial waste will be perfect because it has the characteristic of natural rubber.
Although wood chips and sawdust contain lignin which is natural glue in organic, the main problem statement of this project is to reduce the soil pollution caused by the industrial waste. Sawdust and wood chips are industrial wastes that are less harmful than chemical plant industrial wastes. Survey was carried out on small industrial waste as well as Portland cement Type 1 to understand the benefits and advantages of the material.
In addition, the Material Safety Data Sheet (MSDS) was requested to analyze the hazard code of the materials. The important raw material was identified as shown in Table 8 which is Portland cement type 1, rice husk ash (RHA) and various types of industrial waste. For data analysis, all industrial wastes were sent to the laboratory for hazard identification.
The stabilization of industrial waste is crucial, as the building that will be built with this green composite binder material should not release harmful effects after a few years. Both industrial wastes are analyzed and the result is given below in Table 9. To calculate the ratio between cement and industrial waste and RHA and water, it is important to understand and identify the moisture content of industrial waste.
In which Mn = moisture content (%) of the material, Ww = wet weight of the sample and Wd = weight of the sample after drying. The slump test is one of the methods to characterize the workability of fresh concrete. This test is carried out to know the details of the physical response of cement mortar to compressive loading as shown in Figure 18.
This test is to detect the possible risk of late expansion due to uncombined lime in the cement hydration process. Storage bins: - used to store raw materials such as rice husk ash (RHA), Portland cement type 1, and the selective industrial waste stabilization.
RESULT AND DISCUSSION
- Different ratio combination identification
- Water and cement Ratio Identification
- RHA and cement Ratio Identification
- Study the characteristic using different curing method
- Air curing method for Titan industrial waste without RHA
- Air curing method for Titan industrial waste with RHA
- Water Curing method for Titan industrial waste using RHA
- Water Curing method for FPM industrial waste using RHA
- Characterisation Study of the chosen sample
- Slump Test
- Blaine air Permeability test
- Le Chatelier (soundness) test
- Costing
Here it can be concluded that 0.15 RHA to cement ratio gives a high compressive load strength. Finally, a ratio of 0.15 is chosen to continue the experiment using industrial waste. The sample was first experimented with Titan industrial waste without using RHA and the result was shown in Figure 26 .
The strength for the sample is 37.2kN, which is higher than the normal cement sample compressive strength. Although the sample is high in strength, the load can be increased by using RHA in the mix. RHA is an admixture that can increase the strength of the specimen by 5kN to 10kN.
It can be seen that the strength of the pattern increases over the days. The use of this industrial waste clearly shows that this strength is greater than that of conventional cement and increases rapidly with a steep slope. In conclusion, industrial waste FPM gives a high strength of 56.7 kN, indicating that industrial waste can be useful in some fields.
When testing the sample, only FPM industrial waste is selected because the cost of testing the sample is expensive and time consuming. Similar to the above case, the water hardening also does not function well for FPM industrial waste. As a conclusion, the experiment herewith concludes that air curing is better in curing the industrial waste compared to water curing which is normally used in cement samples.
The sample just reaches a maximum of 47.3 kN, which is very low compared to the FPM industrial waste which reaches about 56.7 kN. Few tests have been conducted on the FPM industrial waste binder to test other criteria and safety aspects. Industrial waste cement sample cost (for 100 samples) = RM50 as the industrial waste was obtained free of charge.
CONCLUSION AND RECOMMENDATION
Conclusion
Recommendation
Water/cement ratio ranging from 0.4-0.5 is taken to identify which is the best combination ratio. The RHA/Cement ratio ranging from 0.1-0.2 is taken to identify which is the best combination ratio. Since there is no difference in peak load when you get to a ratio of 0.15, the experiment did not proceed with 0.2.
Because there is variability when using RHA, we used a cement to RHA ratio of 0.15:1 for the first part of the experiment to see the difference compared to the controlled sample. Industrial waste from polyethylene factory (resin form) This experiment was conducted with and without RHA.
