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TECHNICAL UNIVERSITY OF MOMBASA

PARTIAL REPLACEMENT OF AGGREGATES WITH SHREDDED


PLASTIC AND RUBBER IN CONCRETE HOLLOW BLOCKS

BETHUUEL KIPROP KURUI BTCE/111J/2017

A PROJECT PROPOSAL SUBMITTED IN PARTIAL FULFILLMENT OF THE


REQUIREMENT FOR AWARD OF THE DEGREE OF BACHELOR OF TECHNOLOGY
IN CIVIL ENGINEERING

PROJECT SUPERVISOR:

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DECLARATION

I declare that this proposal is my original work. Therefore, the materials quoted in this
proposal, which are not ours have been duly acknowledged.

Bethuel Kiprop Kurui BTCE/111J/2017

Signed……………………………………….Date …………………………

TABLE OF CONTENTS

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TABLE OF CONTENTS.............................................................................................2

1.0 INTRODUCTION TO THE STUDY....................................................................5

1.1 Background Information....................................................................................5

1.2 Problem statement..............................................................................................7

1.3 Problem Justification..........................................................................................8

1.4 Research Objectives.........................................................................................10

1.5 Research Hypothesis........................................................................................11

1.6 Scope of study..................................................................................................11

CHAPTER TWO........................................................................................................11

2.0 LITERATURE REVIEW.....................................................................................11

2.1 General.............................................................................................................11

2.2 Material.............................................................................................................11

2.2.1 Cement......................................................................................................11

2.2.4 Water........................................................................................................12

2.2.2 Plastic........................................................................................................12

2.2.3 Rubber......................................................................................................12

2.3. Use of recycled materials................................................................................13

2.3.1 Recycling Rubber waste in concrete blocks..........................................15

2.3.2 Recycling Plastic waste in concrete blocks............................................16

CHAPTER THREE....................................................................................................19

3.0 METHODOLOGY...............................................................................................19

3.1 General.............................................................................................................19

3.2 Collection and preparation of samples.............................................................20

3.2.1 Plastic........................................................................................................20
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3.2.2 Rubber......................................................................................................20

3.2.3 Cement......................................................................................................20

3.2.4 Sand..........................................................................................................20

3.3 Material Testing..........................................................................................20

3.3.1 Test on Constituent Materials................................................................20

3.3.2 Concrete Mix Design...............................................................................21

3.3.3 Tests on Fresh Concrete..........................................................................21

3.3.4 Test on Hardened Concrete....................................................................21

3.4 Tests on Hollow Blocks..............................................................................22

3.4.1 Preparation..............................................................................................22

3.4.2 Moisture absorption test.........................................................................22

3.4.3 Compressive strength test.......................................................................22

REFERENCES...........................................................................................................23

APPENDICES............................................................................................................27

Appendix A: Standard Procedures.........................................................................27

Appendix B: Budget...............................................................................................30

Appendix C: Project Work Plan.............................................................................31

LIST OF TABLES
Table 4.1 Effect of Plastic Aggregates on Compressive Strength of Concrete………………26
Table 4.2 Effect of Plastic Aggregates on Flexural Strength of Concrete……………...…….26

LIST OF FIGURES
Figure 1.1 The Dangers of Plastic to our environment ……………...………….……………..9

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Figure 2.1 Influence of coarse and fine plastic aggregates on the concrete slump……...……19

ABSTRACT
Plastic and rubber have become an incredibly important part of our daily lives. Usage of
plastic has increased by 20 times from 50 years ago. Both plastic and rubber disposal,

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however, is very difficult and they have a lower rate of recyclability compared to other types
of materials such as glass and paper. Sustainable development has become quite the slogan in
the 21st century, spear headed by the sustainable development goals (SDGs), (united nations
development programme, 2018). These are geared towards building on the success of the
millennium development goals. For there to be growth, there must be development. This
research project stems from the need to actualise some of these goals, notably, SDG 9, 11 and
13.
Crushed stone, quarry dust and sand are still the main constituents of most cement
bound building materials which are quite prevalent most especially in Kenya. This is exerting
quite a strain on our natural resources and as we speak, we are currently running out of river
sand and gravel. This has led to a soaring increase in their prices from 350 ksh in 2003 to
2500-3000 ksh in 2017, in the case of gravel (Thuita ,2017). This has made building and
development quite expensive and impractical.
Annually, 300 million tonnes of plastic are produced worldwide. This is almost
equivalent to the weight of the entire human population. Ultimately, 79% of all this plastic
ends up polluting our environment. It is projected that if this trend continues, by 2050 we
might have more plastic than fish in our oceans. The only economically viable option, as
opposed to incinerating this waste is recycling it (UN environment, 2018).
This study therefore aims to alleviate the strain on our natural environment and its
resources by using plastic waste infused with rubber as part of our building materials while
simultaneously reducing the cost of housing, furthering development, and propagating the
general wellness of our middle- and lower-class communities.

CHAPTER ONE

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1.0 INTRODUCTION TO THE STUDY
1.1 Background Information
The succession of scientific discoveries and innovations in the field of construction has
caused changes in public economic systems for several developed countries. The demand
for sustainable construction materials at low cost is growing as social, economic, and
environmental issues evolve in today’s society.
Concrete is the most widely used substance on earth after water. If the cement industry was
categorised as country it would be the third largest carbon dioxide emitter in the world with
up to 2.8 billion tonnes, the material is the foundation of modern development, putting roofs
over the heads of billions, fortifying our defences against natural disaster and providing a
structure for healthcare, education, transport, energy and industry (The Guardian, 2019). Over
the years concrete production has continually put a strain on our natural resources and our
pockets, and ways to reduce this burden saw the development of hollow blocks. The first
hollow blocks were made of clay but technology later saw the development of concrete
hollow blocks

Source; getty images (2019)


A concrete hollow block is a type of rectangular concrete masonry unit used in
building and construction. A hollow block slab is a type of composite flooring or suspended
slab system. It is a floor formed over t-beams filled with filling material. The hollow blocks
are placed between these t-beams, after which a layer of concrete (the compressive layer) is
poured over the combination of hollow blocks and the t-beam. Concrete hollow blocks are
innovative building products that are used as substitutes for traditional bricks in building.
Hollow blocks reduce the overall weight of a slab by reducing the amount of concrete below
the neutral axis. This results to a reduction in the structure’s overall weight and as a
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consequence less reinforcement is used hence the cost reduction at the end of the project is
quite significant. Hollow blocks improve the acoustic properties of the slab as well.
Initially the clay hollow bricks were made of kneaded units of clay-bearing soil,
containing sand and lime or cement, which were usually fire hardened or air dried and then
used in construction (science alert, 2014). Later came the hollow concrete blocks which are
concrete blocks having core void area larger by 25% of the gross area. They are advantageous
because they offer rapid execution of work. Increased floor areas, reduced construction cost,
better insulation properties, more durability and good bonding of mortar & plaster. (civil blog
2015).
Although conventional concrete hollow blocks have come a long way in reducing the
amount of concrete used in construction and ultimately reducing the cost of development the
housing shortage in Kenya stands almost 2 million and continues to grow, there is a
proliferation of informal settlements in urban areas with 61 percent of the urban
population living in slums in overcrowded homes typically with only one room and no
adequate ventilation, families are at high health risk of diseases such as malaria,
respiratory infections, and jigger infestation. The vulnerable, in particular women,
children, persons living with disabilities, the elderly, and orphans, are affected the most. (
habitat, organization, 2018). The search for a better future using sustainable materials
continues. More has to be done to reduce the cost of building and construction in the
country.
Bearing the concept of sustainable development in mind and the menace plastic
pollution has become, the recycling of shredded plastic waste and rubber into viable hollow
building blocks could be the solution to our housing deficit. Coupled with proper quality
control rubber infused plastic hollow blocks could house our homeless and build proper social
amenities such as schools and hospitals in our rural areas while simultaneously eradicating
plastic pollution.
1.2 Problem statement
Housing is increasingly becoming a challenge as the population continues to grow each year.
This deficit is mainly a result of the soaring cost of construction and development. The

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continual depletion of Kenya’s natural sands and gravels has led to an increase in the cost of
concrete.
About 20,000 tons of PET plastic waste is created in the country each year with less
than half of this waste is recycled and the rest is disposed in to the environment which has
detrimental effects. (Mjenzi, 2017) Like many developing nations, Kenya has no recycling
infrastructure; private companies collect unsorted household rubbish and truck it to enormous
dumps. (Rueters, 2019). Kenya requires a more lucrative economic incentive to enhance the
management of plastic waste.
When compared to other traditional building supplies, concrete blocks add a
considerable expense to a home construction. To start with, they are quite expensive and
usually cost up to two-times more than the standard quarry stones. Moreover, concrete blocks
are difficult to insulate and have longer warming and cooling cycles. (Evans, 2015) While the
price of materials varies from region to region, the blocks may not be affordable by all.
(Keith, 2018)
Figure 1.1 The Dangers of Plastic to our environment

Source; The Standard Digital; (Mambo, 2018)


1.3 Problem Justification
As the construction boom continues in the country some key challenges including
failed construction structures, financial constraints, inadequate skill among workers,
inadequate construction material and machinery and poor project management contribute to
the slow growth in the sector. Financial challenges however, are a major impediment to
Kenya’s construction industry[CITATION Con \l 2057 ].

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The choice of building materials to use in a construction is determined by factors
such as availability, cost, tenacity and durability[ CITATION Joh17 \l 2057 ]. Masonry is one
of the most popular materials for housing construction due to its useful properties such as
durability, relatively low cost, good sound and heat insulation, acceptable fire resistance,
adequate resistance to weathering and attractive appearance [CITATION SKr08 \l 2057 ].
Hollow concrete bricks are also advantageous in the sense that they offer rapid execution of
work. Increased floor areas, reduced construction cost, better insulation properties, more
durability and good bonding of mortar & plaster. (civil blog 2015). However, the global
interest about the environment and with skyrocketing prices of building materials, especially
sand, iron sheets, bricks and stones, developers are trying to look for the alternative materials
to reduce the cost of construction[ CITATION Jam13 \l 2057 ].
The pollution menace in the world in general is growing by the day, plastic waste
being the major contributor to this vice. Most countries do not have a proper system set up to
recycle their plastic waste hence the waste ends up in landfills and largely in our oceans. It is
projected that by 2050 there will be more plastic waste than fish on our oceans. (UN
environment, 2018). This waste is dumped in rivers upstream and transported by the river
currents all the way down stream and ultimately in to our oceans. The same properties that
rendered plastic useful are the same properties that make them a nuisance when it comes to
waste management. Plastic waste doesn’t decompose it only disintegrates to smaller and
smaller particles ultimately to microscopic particles which are then consumed by human
beings and animals and thereby penetrating the food chain causing adverse health effects (UN
environment, 2018).
Hollow blocks made of concrete have been instrumental in reducing the cost of
building. They have, increased floor areas, reduced construction cost, provided better
insulation properties, more durability and good bonding of mortar & plaster (civil blog 2015).
However, this is not enough as the general infrastructure deficit grows by the day as well as
the need to clean up our environment. Several researches have been done to recycle plastic
waste in to building material and most have succeeded.

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To reduce the weight of buildings the EPS panel system has also been adopted but
the material is very expensive and has rendered any costs saved in reinforcement and concrete
obsolete. Researchers have been trying investigate the viability of plastic in concrete mix
designs. Some have also created wall and paving tiles from plastic waste by infusing it with
sand, stabilised soil and recycled oil. Plastic bottles have also been used to create concrete
hollow blocks; they were used to create voids at equal distance between them in the masonry
units. Then concrete was placed around each bottle to encase it in the masonry units (Sina and
Amani, 2016). The study utilized 500-mL plastic bottles placed inside concrete masonry units
and analysed the compressive strength. Results from this study were deemed reasonable due
to the testing of concrete cylinders as a control of compressive strength for the concrete
blocks from the local market.This study shows 57% difference in the strength by using plastic
bottles compared to local concrete blocks. (Sina and Amani, 2016).
Hence proof of the necessity for further research regarding concrete mix design,
amount of cement and properties of local concrete blocks as well as other technical and non-
technical aspects to determine the appropriate mix design and feasibility in the production
industry. It also shows that there is a possibility that natural material such as crushed stone
can be eradicated from concrete mix designs, hence our project. The reuse of plastic and
rubber has the potential to limit the amount of waste being disposed of into the environment.
This research project aims at determining if plastic waste mixed with rubber can be
used as an alternative to aggregates in the concrete mix for the production of hollow blocks
for use in slabs and infill walls.

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1.4 Research Objectives
1.4.1 Main Objective
The main objective of this research is to investigate the use of shredded plastic and rubber as
partial replacement of aggregates in making concrete hollow blocks.

1.4.2 Specific Objectives


1. To investigate the material properties of shredded plastic and rubber when used as
aggregates in a concrete mix.
2. To determine the optimal concrete mix for the hollow blocks.
3. To investigate the effect of shredded plastic and rubber on the material properties
of the concrete mix for the production of concrete hollow blocks.

1.5 Research Hypothesis


How does shredded plastic and rubber perform as a replacement of natural
aggregates in concrete mix designs and also when used in production of hollow blocks? The
light weight of the resulting blocks will reduce the cost of building infrastructure in addition
to curbing the pollution nuisance in the country.

1.6 Scope of study


The project will involve the study of the material properties of concrete hollow
blocks having used shredded plastic and rubber as the constituent aggregates. These include,
the moisture absorption, density, flexural and compressive strength. The research will use
shredded plastic and rubber sourced from Diani kwale. The study will be limited to PET
plastic waste i.e. plastic bottles as it is the most readily available and prevalent plastic waste
material.

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CHAPTER TWO
2.0 LITERATURE REVIEW
2.1 General
Hollow blocks from part of building materials made primarily from a mixture of
Portland cement, sand, water and occasionally some gravel. The first concrete hollow block
was designed by Harmon S. Palmer in 1980 in the United States. Palmer’s blocks were 20 cm
x 25cm x 76cm in dimension. These hollow blocks had a substantial weight making it
difficult for construction workers to carry them. [ CITATION Cal91 \l 1033 ]
2.2 Material
2.2.1 Cement
Cement is the most common binder in concrete Blocks. Cement is manufactured
through a closely controlled chemical combination of calcium, silicon, aluminium, iron and
other ingredients. Common materials used to manufacture cement include limestone, shells,
and chalk or marl combined with shale, clay, slate, blast furnace slag, silica sand, and iron
ore. These ingredients, when heated at high temperatures form a rock-like substance that is
ground into the fine powder that we refer to as cement. Cement in the presence of water
undergoes an exothermic reaction and continually sets to forma hardened material. Hence its
prevalent use in concrete to bind various aggregates together. Ordinary Portland cement of
grade 32.5 will be used in this study.
2.2.4 Water
The quantities of cement and water to be are determined from tests.  The
water serves two purposes: it is necessary for hydration of the cement binder that hardens and
binds the plastic and rubber into a solid mass it is also used in the curing of the blocks for 7
days after casting works.
2.2.2 Plastic
Shredded plastic from a waste plastic miller will be used in this project. The main
plastic type will be from PET Bottles which is a form of high-density polyethylene (HDPE).
A sieve analysis test will ensure that the various sizes of the plastic shreds will be taken in to

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account and various size distribution tested to determine their influence on the overall
properties of the blocks produced.
A challenge that limits the recyclability of plastics to make other post-plastic waste
materials is the difference in chemical composition of the waste plastics. The plastic waste
disposed in landfills has to be sorted first before recycling processes begin. For instance,
there are industries which require Polyethylene Terephthalate (PET) waste which differs in
mechanical properties from High-Density Polyethylene (HDPE), another type of plastic. In
the use as a building material, the plastic doesn’t have to be sorted into various types. They
are simply collected, cleaned and dried and thereafter shredded into flakes.
2.2.3 Rubber
There are four types of scrap rubber particles available which are classified in
accordance to their particle size and the texture. These types consist of slit tyre particles in the
form of slits which are halved in two halves. Apart from the slit rubber particles, there are
shredded rubber particles which have been known to be utilized in concrete as a replacement
of aggregate in the concrete. The particle size varies from 300 to 400 millimetres long and
100-200 millimetres wide. There is also ground type of rubber available for the utility in
research work which is cut in the sizes of 19mm to 0.15 mm. The crumb rubber used in the
concrete has to be having a nominal size passing standard sieve dimension of 4.75 mm. In
this project I intend to use rubber as a replacement of fine aggregates in hollow blocks.
Rubber is mainly used to improve the ductile and toughness of the resulting concrete hollow
blocks. (Alan and Nouman, 2015)
2.3. Use of recycled materials
This section reviews literature on the use of waste and low energy materials in
concrete mixes hence ultimately in concrete blocks. The most influential factor in determining
whether or not a waste material or a by-product is used is the economic cost in comparison
with the alternative natural material in a particular application. These costs are primarily made
up by handling, processing and transport but the social benefits of using a waste.

2.3.1 Recycling demolished concrete as aggregates in fresh concrete.

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The early phases of many construction projects involve the demolition of concrete
foundations, sidewalks, driveways, and other concrete structures, which can leave a contractor
with a sizable volume of heavy, dense materials to deal with. Fortunately, research has led to
the recycling of this old concrete. The process involves crushing or pulverizing the concrete
rubble near the demolition or building site. Choose of methodology often depends on the size
and shape of the concrete pieces to be recycled. (Juan, 2019)
Reusing concrete can a good way to reduce construction costs while providing some
benefits to the environment by extending the life of landfill (John, 2015). Recycled concrete
also replaces other materials such as gravel that must otherwise be mined and transported for
use. This practice also saves builders disposal or tipping fees and reduces transportation costs
because concrete can often be recycled in areas near the demolition or construction site. In
some instances, new employment opportunities arise in a recycling activity that would not
otherwise exist (Ayemba, 2017).
Concrete is recycled by using industrial crushing equipment with jaws and large
impactors. After the concrete is broken up, it is usually run through a secondary impactor and
is then screened to remove dirt and particles and to separate the large and small aggregate
(Ayemba, 2017). Additional processes and equipment, such as water flotation, separators, and
magnets, may also be used to remove specific elements from the crushed concrete. An
alternative method is to pulverize the concrete, but this is not the always the best option, as it
makes it harder to complete the separation process and may leave more contamination from
smaller byproducts (Juan, 2019).
2.3.2 Recycling waste glass in concrete mixes.
Due to the excellent characteristics of glass, such as optical transparency, chemical
inertness, high intrinsic strength and low gas permeability, glass containers are the most
commonly used form for packaging beverages. Waste glasses that are not possible to be
recycled can be used in concretes as a pozzolan and coarse aggregate. (Lu and Poon, 2019)
Research has been done to investigate the possibility of using glass as a pozzolana
and as an aggregate in concrete mixes. In the first instance waste glass is considered as a fine
aggregate in a concrete mixture (Lu and Poon, 2019). The used waste glass is reduced to 5–12

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mm in size corresponding the proportions of 0%–50% in the production of CEM I type
cement. The other instance waste glass powder (WGP) are ground and incorporated into
concrete with the levels of 5%, 15% and 30% by the weight of binder. The experimental
results indicate for the group I; using WGA as aggregate doesn’t have marked effects on the
workability of concrete ( Lu and Poon, 2019). For group II; the experimental results indicate
that the mixtures which are ground with 5% waste glass as a pozzolan and 10% waste glass as
fine aggregate gave compressive strength performance similar to the reference mixture.
Higher percentage of waste glass (15%) replacement yielded lower strength values.
(Kılıçoğlu and Çoruh, 2017)
Ultimately the compressive strength values of all waste glass powder concrete
mixtures tend to decrease below the values for the reference concrete mixtures with increasing
the waste glass powder ratio all curing ages. Compressive strength has been observed to
decrease the proportion of W/C ratio in concrete which produced increased. As a result, w/c
ratio was a significant important value of concrete mixture design. Expansions of less than
0.10% are indicative of non-deleterious expansion. It is seen that the use of waste glass
powder supplemented with 5% can be used to reduce the expansion. It can be concluded that
the waste glass powder can be used as a pozzolan and fine aggregate for the production of
concrete. Though waste and recycling management plans should be developed for any
construction project prior to the start of work in order to sustain environmental, economic,
and social developed principles. In addition, using industry waste product in the manufacture
of concrete converts it into an eco-efficient material, as it reduces the accumulation of
residues and exploits incorporated energy. (Kılıçoğlu and Çoruh, 2017)
2.3.1 Recycling Rubber waste in concrete blocks
Rubber is produced excessively worldwide every year. It cannot be discharge off
easily in the environment as its decomposition takes much time and also produces
environmental pollution. In such a case the reuse of rubber would be a better choice. In order
to reuse rubber wastes, it has added to concrete as fine aggregate and its different properties
like compressive strength, Tensile strength and ductility among other properties were
investigated and compared with ordinary concrete.

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As a result, research has found that rubberized concrete is durable, less ductile, has
greater crack resistance but has a low compressive strength when compared with ordinary
concrete. The compressive strength of rubberized concrete can be increased by adding some
amount of silica to it. Furthermore, research on using rubber as aggregate in concrete has led
to the conclusion that when rubber is used instead of aggregates in concrete it shows less
compressive strength when compared with ordinary concrete. But it also shows some ductile
behaviour before failure. Rubberized concrete also shows reduction in density of concrete
when compared with control concrete specimen. (Nouman, 2015).
On another research done to substitute fine aggregates in concrete at 0% to 100% to
crushed sand in concrete mix with recycle crumb rubber results showed that up to 25%
replacement to the crushed sand gives a good compressive strength and also results in 8%
decrease in density of concrete whereas the ductility of concrete increases therefore suitable in
shock resisting elements. (Cammille A Issa, et, 2013)
It has also been determined that concrete made of crumb rubber as fine aggregate
shows much strength when compared with concrete made of chipped rubber as coarse
aggregate. No appreciable increment in the compressive strength of concrete density by using
different percentage of rubber as fine aggregates in concrete. It is recommended to use silica
fume in rubberized concrete to increase its compressive strength. They also find it
recommendable to use rubberized concrete in small structures like road curbs and non-bearing
walls. (Alam, 2015)
2.3.2 Recycling Plastic waste in concrete blocks
Researchers in the construction sector have sort to tame the menace that is plastic
waste. Studies have presented methods of reducing the amount of plastic waste by recycling
plastic containers in construction work. Non-load-bearing concrete blocks for safe and
efficient use can be manufactured using plastic flakes as an alternative material aggregate.
Studies have developed such blocks and tested them for compressive strength integrating four
major factors: (1) the cement to aggregate ratio, (2) the water to cement ratio, (3) the size of
plastic flakes used and (4) the proportion of plastic flake that replaced sand. The findings
revealed that using a ratio of 1:3 cement to aggregate, where the aggregate mix comprised of

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20% small and medium sized (combined at 1:1) plastic flakes plus 80% sand and a water to
cement ratio of 0.5, provided the optimal compressive strength to form a concrete block that
can be used to construct a non-load bearing wall. (Marzouk et al, 2005)
The use of plastic bottle waste as a substitution for sand aggregate in composite
materials for building applications has been studied before. It was seen that PET waste affected
the compressive strength and density of concrete. The density and compressive strength
significantly decreased when the PET aggregates exceeded 50% by volume of sand. (Marzouk et
al, 2005).
An investigation on the effects of waste PET bottles aggregate on the properties of
concrete. The waste plastic could reduce the weight by 2 to 6% of normal weight concrete.
However, the compressive strength reduced by up to 33% compared to the normal concrete mix
design. (Choi et al. 2005)
Likewise, from the results of another study a decrease of compressive strength with
increase in plastic content proportions was evident. For a mix with 20% sand, the compressive
strength was reduced by about 70% in comparison to that of normal concrete. (Batayeneh, 2007)
A study on the development of Concrete Blocks containing PET plastic bottle flakes
indicated that the concrete blocks, with plastic flakes replacing sand in the mortar mix at a
ratio of 20% by weight, can be used in the construction of non-load-bearing walls.
[ CITATION War17 \l 1033 ].
Another study was done to determine possibility of using plastic aggregate as coarse
aggregate in concrete. The researcher found that the modified concrete mix, with addition of
plastic aggregate replacing conventional aggregate up to certain 10% gives strength with in
permissible limit. (Arivalagan 2016)
Various researchers have investigated and reported the influence of waste plastics as
fine and coarse aggregates on the workability of concrete. The slump test is used to determine
the workability of the fresh mix. Factors such as particle size grading, the shape of particles,
the water-cement ratio, and the amount of plasticizer in the mix are directly related to the
concrete workability.
The water-cement ratio (w/c) and the amount of cement paste also influenced the
slump of concrete since the mobility of particles depends on these factors. Research findings
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have shown varying performances and results of concrete workability due to the use of waste
plastic aggregates, as illustrated in Figure 2.1.

Figure 2.1 Influence of coarse and fine plastic aggregates on the concrete slump

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Source; Engineering Properties of Concrete with Waste Recycled Plastic: A
Review (Adewumi, 2019)
2.4 Advantages and Disadvantages of Plastic-Rubber Hollow Blocks Slabs
2.4.1 Advantages
1. These materials can be easily recycled and reused at the end of their life cycle.
2. Modification and refurbishing of waste rubber and plastic ensures low embodied
energy.
3. Environmental conservation as stone aggregates mined from quarries are not used.
4. The wasteful use of materials in construction is avoided.
5. Tyre granules and the voids present in the hollow blocks both serve as acoustic
insulating and absorbing materials.
6. Heat insulation is also improved.
7. Easy to construct compared to solid slabs.
8. It is economical especially for spans greater than 5m that have medium live loads.
(1.5-3 kN/m2)
9. A long life is assured since durable and low maintenance materials are used.
2.4.2 Disadvantages

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1. It is uneconomical when constructing small spans.
2. This type of slab is not suitable for dynamic loads and heavy loads.
3. It is difficult to strengthen or repair in case of damages
2.5 Summary and Research Gap
Due to its versatility, light weight and cost-effective nature, global production of
plastics has surged from 15 million tonnes in 1964 to 311 million metric tonnes in 2014. As of
2012, about 2 million waste tyres are generated in Kenya. This is according to a presentation
by Kenya Motor Industry (KMI) on Waste Tyre Management in Kenya. The rapid growth of
the consumer society poses a further danger to the environment. Beyond the consequences to
the environment, most of the plastics and rubber on landfills could be reused and repurposed,
which means that this huge amount of waste has a negative economic impact. The building
material made from rubber infused plastic should be lower in weight and density compared to
the blocks currently on the market. A study revealed that a cement to aggregate ratio of 1:3
where the aggregate mix comprised of 20% small and medium sized plastic flakes 1:1 plus
80% sand, and a water to cement ratio of 0.5 provided the optimal compressive strength to
form a concrete block that can be used as a non-load bearing wall. (Waroonkoon, 2017)
Research has also shown that rubberized concrete is durable, less ductile, has low
compressive strength compared to ordinary concrete. (Nouman, 2015) This research will
therefore focus on the effects on the material properties of the standard concrete hollow
blocks when both aggregates are replaced with rubber and plastic flakes.

CHAPTER THREE
3.0 METHODOLOGY
3.1 General
The research methods will cover the various ways through which the objectives of
the study will be accomplished. There are standard procedures that will also be used to check
the engineering properties of the materials that make up the hollow blocks which will be
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derived from the British Standards. The Kenyan Building Code also contains specifications
and guidelines for the material properties of concrete hollow blocks.
3.2 Collection and preparation of samples.
3.2.1 Plastic
The plastic used in this research will be shredded plastic obtained from the Kwale
plastic plus collectors in Diani. A sieve analysis test will be conducted to know the individual
particle size distribution of the collected plastics.
3.2.2 Rubber
Shredded rubber will be obtained from bridgestone Mombasa. The shredded rubber
will help increase the volume of mortar hence makes mortar more economical.
3.2.3 Cement
The type of cement used will be pozzolanic cement of class 32.5 in accordance to the
BS12 (1996). The Portland cement to be used will be purchased from a local hardware in
mombasa town. Consistency and soundness tests will be conducted to check the quality of the
cement.
3.2.4 Sand
The sand in the concrete mix will offer a requisite surface area for the film of
binding material (cement paste) to adhere and spread. The sand also plays the role of adding
to the density of the mortar and concrete thus preventing excessive shrinkage of the mortar or
concrete.
3.3 Material Testing
3.3.1 Test on Constituent Materials
Sieve analysis
Sieve analysis is important for analyzing materials because particle size distribution
can affect a wide range of properties, such as the strength of concrete. The sieve analysis
determines the gradation or the distribution of the shredded rubber and plastic particles, by
size, within a given sample in order to determine compliance with design, and verification
specifications. This also helps to meet control requirements for individual mix designs. The
particles are sieved in accordance to BS 812-103 Part 1.

22
Specific Gravity
The Specific gravity of the material is a key property that aids in making other
computations for mix design and proportioning, bulk density, absorption and voids analysis.
Gilson’s Specific Gravity equipment will be used since it yields accurate results. The
procedures followed will meet the specifications of BS 812-2: 1995.
3.3.2 Concrete Mix Design
The purpose of concrete mix design is to determine the most optimum proportions of
the constituent materials that are necessary to fulfill the desired minimum strength in the
hardened state. The design process will also aid in obtaining the desired workability of the
concrete in the plastic stage and to help produce a concrete mix as economically as possible.
3.3.3 Tests on Fresh Concrete
Slump Test
The concrete slump test measures the consistency of fresh concrete before it sets. It
is performed to check the workability of freshly made concrete, and therefore the ease with
which concrete flows.
3.3.4 Test on Hardened Concrete
Compressive Strength Test
Compressive strength of concrete is one of the most important and useful properties.
As a construction material, concrete is employed to resist compressive stresses. The ultimate
compressive strength of a material the maximum stress or imposed load that can be applied on
the surface of the material without undergoing failure through cracking or deflection. Various
concrete mix designs will be prepared and tested for strength; this test will be done in
accordance to BS EN 12390-3:2019. This test will help determine the quality of the hollow
block infused with rubber and plastic.
Flexural test
Flexural test evaluates the tensile strength of concrete indirectly. It tests the ability of
an unreinforced concrete beam or slab to withstand failure in bending. The results of flexural
test on concrete is expressed as a modulus of rupture which is denoted as (MR) and the unit
are in MPa.

23
3.4 Tests on Hollow Blocks
3.4.1 Preparation
Dry materials shredded plastic,( plastic held at 20% replacement by the volume of
the coarse aggregates) sand, quarry dust, rubber and cement will first be mixed until a uniform
mixture is produced. Water is then added gradually as mixing continues. This is done until a
homogeneous mix is obtained. The mixed sample is then placed into prepared moulds and
manually compacted in order to remove air voids and produce the blocks. The dimensions of
the hollow blocks will be 380mm x 200mm x 150mm.
A total number of 10 to 20 blocks will be made. The blocks will be cured with clean
water and other sample blocks will be submerged in water for 7, 14 and 28 days before other
tests are conducted on the blocks. This will facilitate the gaining of strength of the hollow
blocks.
3.4.2 Moisture absorption test
The water absorption test determines the water holding capacity of the rubber and
plastic particles. The main objective of this test is to, determine the hollow blocks ability to
hold water and how the water affects the long-term strength and quality of the blocks,
3.4.3 Compressive strength test
Before conducting this test, the blocks are left to dry either by air or in an oven at
40ºC and also inspected for cracks. The blocks should not have cracks visible to the naked
eye. Dry compressive strength test will be carried on dry blocks. The blocks will be wiped to
remove any dust and then crushed.

3.4.4 Determination of the Unit Weight


The aim of obtaining the unit weight of the hollow block is to facilitate the design of
a ribbed hollow pot slab and evaluate the amount of material usage reduced as an advantage
over normal solid slabs.

3.5 Design of Ribbed Slabs containing Rubber Infused Plastic Hollow Blocks

24
The plastic/rubber hollow blocks Design of slabs for low rise industrial or residential
structures in concrete steel. A one-way solid slab or two-way solid slab may be selected for
design.
The design of a solid slab will be compared with that of a ribbed plastic/rubber
hollow block slab. It is anticipated that the cost of construction of the hollow pot slab will be
cheaper than that of the solid slab since less reinforcement will be required. There is also an
increase in the effective depth of the slab. The higher effective depth ratio of a ribbed slab
reduces the amount reinforcement needed.

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Camille A. Issa, G. S. (2013). Utilization of recycled crumb as fine in concrete mix design,
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Choi, Y. W. (2005). Effects of waste PET bottles aggregate on the properties of concrete. pp.
10,38,39.

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M. Batayneh Marie I., A. I. (2007). Use of selected waste materials in concrete mixes.

Nduire, J. (2017, February Saturday). Building Materials. The most commonly used
construction materials in Kenya.

Nduire, J. (2018, october). Commonly used construction materials in Kenya. Construction


Kenya, II(4), pp. 67-80.

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for Computer Methods and Advances in Geomechanics. Goa: pp. 4362-4368.

Wanzala, J. (2013, September Thursday). Reduce construction cost by 30 per cent.

Waroonkun, T. (2017). The Development of a Concrete Block Containing PET Plastic Bottle .
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John, G. (2015). Tips for Reusing Old Concrete. Retrieved from:
[ CITATION bam18 \l 1033 ]ttps://www.proest.com/tips-for-reusing-old-concrete/
UN Environment (2018) UN Environment Annual Report 2017. Retrieved from;
https://www.unenvironment.org/resources/un-environment-annual-report-2017
Watts, J (2019) Concrete: the most destructive material on Earth retrieved from;
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material-on-earth
Mjenzi. (2017) Investigation of Construction Failures In Kenya for Enhancement of
Development Control. Retrieved from: https://nca.go.ke/investigation-of-
construction-failures-in-kenya-for-enhancement-of-development-control/
Reuters, (2019) plastic everywhere but not for African recyclers. Retrieved from:
https://www.theeastafrican.co.ke/scienceandhealth/Plastic-plastic-everywhere-but-
not-for-african-recyclers/3073694-5229536-view-asamp-hrl7h9/index.html
Evans, K (2015) Advantages and disadvantages of concrete block homes
https://www.hunker.com/13401639/disadvantages-of-concrete-blocks-in-building-houses
Suryakanta Civil blog (2015) What are the advantages of hollow concrete block masonry?
Retrieved from: https://civilblog.org/2015/09/23/what-are-the-advantages-of-hollow-concrete-
block-masonry/ Trends in applied sciences research
Maharaj R, (2014) Optimization of ingredients for clay block manufacture: unfired
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Habitat for Humanity. (2018) The housing need in Kenya. Retrieved from:
https://www.habitat.org/where-we-build/kenya
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country is fast depleting its quarries. Retrieved from:
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Amani Al-Kalbani and Sina Safinia. (2016). Use of recycled plastic water bottles in
concrete blocks
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https://www.thebalancesmb.com/recycling-concrete-how-and-where-to-reuse-old-concrete-
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Ayemba, D. (2017). Tips on how and where to reuse concrete. Retrieved from:
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%3famp
Chi Sun, P (2019) Recycling of waste glass in construction materials
New Trends in Eco-Efficient and Recycled Concrete, Pp.153-167
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Amalu, G. (2016) Use of Waste Plastic as Fine Aggregate Substitute in
Concrete. International Journal of Scientific & Engineering Research, Volume 7, Issue 4,172
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Plastic: A Review Department of Building, Faculty of Environmental Design and
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Bambo, J(2018) Published on June 5 th 08:32:55 GMT +0300 The dangers
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APPENDICES
Appendix A: Standard Procedures
Sieve Analysis
The purpose of this test is to determine the relative proportions in the various plastic
sizes as they are distributed. A sample of 2000g will be used for the test. The test will be done
in accordance to the BS 812-103.1 (1985)
Procedure
Test Procedure:
1. A 2000g representative sample is weighed and then oven dried.
2. The mass of each sample is determined accurately and recorded as Wt (g).
3. A stack of sieves is prepared with sieves having larger opening sizes (lower numbers)
placed above the ones having smaller opening sizes (higher numbers). The sieves used for the
sieve analysis will be the 30, 25, 20, 15.9 and 9.52mm sieves.
4. Ensure the sieves are clean, and in the case of stuck particles in the openings, they are
poked out using wire brushes.
5. All individual sieves are then weighed and the pan weighed separately and the values
recorded.
6. The sample is then poured into the stack of sieves and covered. The stack is shaken for
about 10-15 minutes.
7. After shaking, the mass of each sieve together with the retained aggregates is measured and
recorded.
8. The measured values are then recorded in a sample table.

Compressive Strength Test

29
Before conducting this test, the blocks are left to dry either by air or in an oven at
40ºC and also inspected for cracks. The blocks should not have cracks visible to the naked
eye. Dry compressive strength test will be carried on dry blocks. The blocks will be wiped to
remove any dust and then crushed.
Procedure
1. The specimen is centered between the plates of the press, so that the geometric center
of the loaded surface is located on the axis of the plate to the nearest ± 1mm:
2. Ensure that the specimen is centered by checking on all the four sides, the distances
between the edges of the specimen and the sides of the plates. This can be done using
a ruler.
3. The load is then applied at a constant rate of 0.02mm/s, or a rate corresponding to an
increase in pressure of between 0.15 and 0.25MPa/s until the specimen fails
completely.
4. The maximum load at which the specimen fails is then recorded.
Determination of the Unit Weight
Procedure
1. 5 hollow blocks are weighed with an electronic balance. The hollow blocks selected
for weighing should be dry and free of dust. The average weight of the five hollow
blocks is then calculated.
2. The volume of the hollow block is computed according to the geometric size of the
hollow block.
3. The unit weight is then calculated using the formula
average mass
Unit weight=
volume
Moisture absorption test
The main objective of this test is to, determine the hollow blocks ability to hold
water and how the water affects the long-term strength and quality of the blocks,
Procedure

30
1. The specimen is dried to a constant mass in the oven at a temperature of 115oC. It is
then cooled. Each specimen is then weighed accurately.
2. Immediately after weighing, the 5 samples are placed in one layer inside a tank of
water for 24 hours. A gap of about 10mm between the blocks is maintained. This
ensures that water circulates freely through all the sides of the blocks.
3. The blocks are then removed from the tanks and weighed

Calculation
The water absorbed by each specimen will be calculated. A, is expressed as a
percentage of the dry mass, using the following expression.
( wet mass – dry mass ) x 100
A= ………………………………………… (Equation
dry mass
3.3)

31
Appendix B: Budget
No Description Rate Quantity Total

1 Shredded Rubber - 30kg 5000

2 Shredded Plastic - 40kg 5000

3 Cement (32.5N) - 50kg 700

4 Sand @2/-per kg 100kg 200

5 Transport - 3000

6 Mould - 3000

Printing and
7 binding of reports - 600

8 Labour - 1800

TOTAL 19,300/-

32
Appendix C: Project Work Plan

ACTIVITY APR MAY JUNE JUL AUG SEP OCT NOV


2021 2021 2021 2021 2021 2021 2021 2021

1 CONCEPT
FORMULSTION
2 PROPOSAL
WRITTING
3 PROPOSAL
PRESENTATI0
N
4 MATERIAL
ACQUISITION
5 LABORATORY
EXPERIMENTS
6 DATA
COLLECTION
AND ANALYSIS
7 FINAL REPORT
8 PROJECT
PRESENTATI0
N

33

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