PARTIAL REPLACEMENT OF COCONUT

SHELL ASH WITH CEMENT IN CONCRETE

A PROJECT REPORT Submitted by

ASWATHI.B 912218103003
MOHABRAMMAVEENA.J 912218103005
YUVARAJ.S 912218103302

In partial fulfilment for the award of the degree

Of BACHELOR OF ENGINEERING IN CIVIL ENGINEERING

SOLAMALAI COLLEGE OF ENGINEERINGMADURAI-625020

ANNA UNIVERSITY: CHENNAI 600 025

JUN 2022
SOLAMALAI COLLEGE OF ENGINEERING

MADURAI-625020

Certified that this project report titled “PARTIAL

 REPLACEMENT OF COCONUT SHELL ASH WITH
CEMENT IN CONCRETE ” is the bonafide work of
ASWATHI.B(912218103003), MOHABRAMMAVEENA.J(912218103005),
and
YUVARAJ.S (912218103302) who carried out the project workunder
my supervision.

SIGNATURE SIGNATURE
Mr. LETCHAM, M.E., Ph.D. Mr.SURIYA,M.E.
HEAD OF THE DEPARTMENT UNDER THE SUPERVISOR
Assistant Professor,
Department Of Civil Engineering, Department Of Civil Engineering,

Solamalai College of engineering, Solamalai College of engineering,

Madurai-625020. Madurai-625020.

Submitted for the project Viva –voce examination held on …………………...

INTERNAL EXAMINER EXTERNAL EXAMINER ACKNOWLEDGEMENT

I express my grateful thanks to our

beloved Chairman Thiru
V.S.P.SOLAMALAI PITCHAI for the wonderful facilities provide by
him.
I would also like to express our thanks to our beloved Executive directors
Mr.S.P.Anand and S.P.Aravind and Principal
Dr.G.M.BALAMURUGĄNM.E, Ph.D., for having made for guidance and
counseling throughout the work. I express my sincere thanks to
Prof.K.LETCHAM M.E, (Ph.D) Head of
Civil Department, and Solamalai College of engineering for providing all
facilities to carry out the Survey camp report efficiently.
It is privilege to work under the guidance of our guide Mr.
SURIYA M.E, Asst. prof. of the Civil Department, Solamalai College of
Engineering for his invaluable Guidance and constructive suggestions at
all stages of this Survey camp report work.
We grate fully acknowledge and bound to thank all faculty
members in Civil Engineering department for helping towards the
successful completion. In this context, we would like thank all the other
staff members, who have extendedtheir timely help and eased
TABLE OF CONTENTS
CHAPTER TITLE

ACKNOWLEDGEMENT
LIST OF
ABBREVATIONS
ABSTRACT
1 INTRODUCTION
MATERIAL USED CEMENT SAND
COARSE AGGREGATE
WATER
2 LITERATURE REVIEW
 3 METHODOLOGY
4 CEMENT PROPERIES
OF STRENGTH
SETTING TIME SOUNDNESS FINENESS STRENGTH
DURATION OF TESTING
5 COCONUT SHELL ASH
CSA PROPERITES AND
STRENGTH ANALYSIS
COCONUT SHELL ASH
CARBONIZATION OF CSA
THE PROCESSING OF
THE COCNUT SHELL PHYSICAL AND MECHANICAL OF CS
MICROSTRUCTURE OF
CS
CHEMICAL PROPERTIES OF
CS
COCONUT SHELL-
CEMENT
COMPATIBILITY
CEMENT CONTENT AND WOOD – CEMENT RATIO
WORKABILITY AND
DENSITY
6 MECHANICAL
PROPERTIES OF CSC
COMPRESSIVE
STRENGTH
EFFECT OF CURING
CONDITION ON
COMPRESSIVE
STRENGTH
UILTRASONIC PULSE
VELOCITY(UPV)
FLEXURAL AND
SPLITTING TENSILE
STRENGTH OF CSC
 IMPACT RESISTANCE OF
CSC
BOND STRENGTH OF CSC
CURING CONDITION
EFFECT ON BOND
STRENGTH OF CSC
DEVELOPMENT OF
BOND BETWEEN CS
AGGREGATE AND
CEMENT PASTE
STRUCTURAL
7 ELEMENT BEHAVIOR
OF CSC
CSC BEAMS UNDER
SHEAR
CSC BEAMS UNDER
TORSION
SHRINKAGE STUDY ON
CSC SLAB
DEFLECTION STUDY ON
CSC SLABS
STRESS-STRAIN
CHARACTERISTIC OF
CSC
DURABILITY
PROPERTIES OF CSC
PRACTICAL
IMPLEMENTATIONOF
CSC
8 PRIMILARY TEST ON
MATERIALS
SPECIFIC GRAVITY OF
CEMENT
SPEICIFIC GRAVITY OF
COCONUT SHELL ASH
CONSISTENCY OF OPC
43 AND CSA
 SETTING TIME OPC
43AND CSA
CALCULATION OF TESTING
CHEMICAL
COMPOSITION OF OPC
AND CSA
MIX DESIGH
AVERAGE
COMPRESSIVE
STRENGTH 7 DAYS
AVERAGE
COMPRESSIVE
STRENGTH 28 DAYS

AVERAGE SPILT
TENSILE STRENGTH 7
DAYS AND 28 DAYS
SLUMP CONE TEST
COMPACTION FACTOR
CAMPACTION FARTOR
RESULE
CASTING OF CUBE
MOULDS
COMPRESSION TEST
CURING OF CUBE
DURABILITY
PROPERTIES
ACID ATTACK
ADVANTAGE OF CSA
DISADVANTAGE OF CSA
CONCLUSION
REFERENCES
 LIST OF ABBRIVIATION

L Length

B Breadth D Depth m Meter

m2 Square meter mm Millimeter cm

Centimeter

N Newton

KN Kilo Newton

MPa Mega Pascal

OPC Ordinary Portland Cement

FA Fine Aggregate
ABSTRACT

The environmental impact of OPC is significant because its production emits large amount of
CO2.Utilization of industrial soil waste or secondary materials has been encouraged in
construction field for the production of cement and concrete because it contributor for reducing
the consumption of natural raw materials as resources.The volume of wastes generated in the
world has increased over the years due to increase in population, socioeconomic activities and
social development. One of the most attractive option of managing such wastes is to look in to
look into the possibility of waste minimization and re- use. The cost of cement used in concrete
works is on the increase and unaffordable, yet the need for housing and other constructions
requiring this material keep growing within increasing population, thus the need to find
alternative binding materials that can be used solely or in partial replacement of cement.
Concrete cubes were casted using replacement levels of 0%,10%15%,of OPC with CSAThe
cubes were casted and cured by immersing them in water for 14days and 28days respectively.
The Coconut Shell ash is used for the partial replacement cement. Further, use of coconut shell
ash as a value added material as in the case of binary blended cement concrete,reduces the
consumption of cement. Reduction of cement usage will reduce the production of cement
which in turn cut the CO2 emissions. The time has come for the review of progress made in the
field of development of binary blended cement concrete.

Keywords: compressive strength,concrete, coconut shell ash,cement.

 CHAPTER-1 INTRODUCTION

Concrete is widely used as construction material for various types of structures due to its
durability. For a long time it was considered to be very durable material requiring a little or no
maintenance. Many environmental phenomena are known significantly the durability of
reinforced concrete structures. We build concrete structures in highly polluted urban and
industrial areas, aggressive marine environments and many other hostile conditions where
other materials of construction are found to be nondurable. In the recent revision of IS: 456-
2000, one of the major points discussed is the durability aspects of concrete. So the use of
concrete is unavoidable. At the same time the scarcity of aggregates are also greatly increased
nowadays. Utilization of industrial soil waste or secondary materials has been encouraged in
construction field for the production of cement and concrete because it contributes to reducing
the consumption of natural resources. They have been successfully used in the construction
industry for partial or full replacement for fine and coarse aggregates. The composition of
World Cement Consumption in the year 2010 is 3,313 Million Metric Tons. Among that 7.0%
in India, 57.7% in China, 9.4% in Developed Countries, 25.9% in Other Emerging. The
composition of Coconut Production in India in the year 2009 is 10,894,000 tonnes. Traditional
areas of coconut cultivation are the states of Kerala (45.22%), Tamil Nadu
(26.56%), Karnataka (10.85%) and AndhraPradesh(8.93%).
MATERIAL USED
• Ordinary Portland Cement (53 Grade)
• Fine Aggregate
• Water
• Coarse Aggregate
• Coconut Shell Ash

Cement:
Cement is used right from ancient periods in construction industry. In the most
general sense of the word, cement is a binder, a substance which sets and hardens
independently, and can bind other materials together. The word “Cement“ traces to the
Romans, who used the term “opus caementicium” to describe masonry which resembled
concrete and was made from crushed rock with burned lime as binder. Te volcanic ash
pulverized brick additives which were added to the burnt lime to obtain a hydraulic binder
were later referred to as cementum, cimentum, cament and cement. Cements used in
construction are characterized as hydraulic or nonhydraulic. The most important use of cement
is the production of mortar and concrete – the bonding of natural or artificial aggregates to
form a strong building material which is durable in the face of normal environmental effects

SAND :
Sand is naturally occurring granular material composed of finely divided
rock and mineral particles.
The most common constituent of sand is silicon dioxide, usually in the
form of Quartz.
Normally fine aggregate is used as fine aggregate for preparing concrete.
An individual particle in this range is termed as sand grain.
These sand grains are between coarse aggregate (2mm to 64mm) and silt
(0.004mm to 0.0625mm).
Aggregate most of which passes 4.75mm IS sieve is used.
COARSE AGGREGAT:
Aggregates are the most mined material in the world.
Aggregates are a component of composite materials such as concrete and asphalt
concrete; the aggregate serves as reinforcement to add strength to the overall composite material.
Coarse aggregate of size 20mm is sieved and used.
Water:

Water play saconse quential role in the formation of concrete as it participates in chemical
reaction with cement. Due to the presence of water the gel is form whichavails in increase of
strength. Virtually any natural water that is drinkable and has
nopronouncedtasteorodourcanbeutilizedascommixingwater.
 CHAPTER 2

LITRERATURE REVIEW
GENERAL:

1. Sawdust Ash ( SDA ) as Partial Replacement of Cement

• C.Marthong as made a project on partial replace of cement with saw

dust ash on concrete in 2012
• To control the need of cement and make concrete economically .
• So made concrete by partial replace the cement with saw dust ash of
0 % , 10 % , 20 % , 30 % and 40 % then cured for 7,14and28 days .
• And compression strength , water absorption test shrinkage and
durable of concrete were mainly study .
• Hence the result was favourable to replace the cement with saw dust
ash on concrete which made the project success.

2. Experimental study on strength characteristics on M25concrete with

partial replacement of cement with fly ash and coarse aggregate with
coconut shell

• NAGALAKSHMI on 2014 done an experiment of replacement of

fly ash on concrete which was obtain from VTPS : Vijayawada .
• To reduce the environment pollution and use the waste material of
local resource .
• M25 grade concrete are produced by partially replacing of fly ash
in cement and coconut shell in coarse aggregate at 10 % 20 % and
30 % and cured for 7,14.28 and 56 days . Then the compressive
split tensile strength and flexural test as been conducted .
• The result as shown that the strength been degrease if the
percentage replace of fly ash replace in cement increase .
• Even though the low percentage of replace of fly ash in cement is
suitable for replace.

12
3. Effect of use of Bagasse Ash on Strength of Concrete

• Mrs.U.R. Kawade , Mr.V.R.Rathi , Miss Vaishali D. Girge done

the above mention project on 2013 .
• To make a concrete economical and reduce the environment
pollution .
• They made the concrete with replace of cement with bagasse ash
in 0 % 10 % 15 % 20 % 25 % and 30 % and cured for 7.28.50 and
90 days . Then they made compression test for hard concrete
.
• The result of this proved that the project is suitable for practical
site work.

4. PROPERTIES OF CEMENT - GROUNDNUT SHELL ASH

CONCRETE

• Dr. Ndefo okigbo dept . Of civil engineering .

• The federal polytechnic bida nigeria was done the experiment of
above mention.
• This is mainly targeted for easily available resources then reduce
the need of cement and decrease the environment pollution.
• They casted the concrete cubes for 28 days only by replacing
ground nut shell ash with cement up to 10 to 30 % replacement.
• The replacement of 10 and 20 % was increase the strength when
above 30 % will decrease the strength.
• So up to 20 % replace the experiment was success . And it was
stabilize to use construction work.

5. Pravin V. Khandve, Shrikant M.Harle In this literature

partial replacement of coarse aggregate with coconut shell
in the concrete

• It can be help to reduce the waste and pollution.

• The construction industries have replaced conventional
aggregate to light weight aggregate.
• It can be used to reduce the size of the members in the
structures.

13
 • In this experimental setup percentage of increase coconut shell
the strength increase in 7days also the strength increased in 28
days curing strength.
• Replacement of coconut shell as coarse aggregate increases as
the workability Of concrete increases.
• Replacement of coarse aggregate with coconut shell increases
will reduce the specific gravity of concrete.  Density of
concrete should not be less than 2000 Kg/cum.

6. Kulkarni Parag Pramod, Prashant Ganpat Chavan, Pagar Chetan

Bhaskar

• Crushed coconut shells are replaced in concrete.

• Coconut shells are easily available at low cost price in our
country.
• In this experimental study light weight concrete can be
prepared by using aggregate with coconut shells.
• Water absorption and moisture content of the crushed coconut
shell is found to be 24% and 4.24% respectively.
• Normally coconut shell aggregates having high water
absorption capacity because of higher porosity in structure. 
The specific gravity of crushed coconut shell is 1.05.

7. Shaik.Aliimran Tippu and Vr.Prasanth Kumar

• In this literature have conducted compressive strength and

split tensile strength characteristics with complete
replacement of coarse aggregate with coconut shell to
produce light weight concrete.
• To replace cement by exploitation silica fume admixtures
with completely replacing percentages 0%, 10%, 15%,
20%, 25%, and 30%.
• The mix proportion 1: 1.47: 0.65 the concrete 63 cubes
and 63 cylinders are casted for conducting test.

8. Vignesh Kumar Nagarajan (2014)

• Carried out an experimental study on partial replacement of

cement with coconut shell ash concrete.

14
 • Agriculture waste material ,In this cases, coconut shell, which
is an environment pollutant, are collected and burnt in the
open air for three hours.
• Shell ash (CSA). Which in turn was used as pozzolana in
partial replacement of cement in concrete production author
has produced concrete mix cubes by replacing 0 and 5 percent
of OPC with CSA .

9. Utsev, J. T.,& Taku, J. K. (2012)

• Have conducted the Concrete cubes were produced using

various replacement levels of 0, 10, 15, 20, 25 and 30 percent
of OPC with CSA.
• A total of 54 cubes were produced and cured by immersing
them in water for 7, 14 and 28 days respectively.
• Properties such as compressive strength, density, setting times
and
pozzolanic activity index were determined.
• The results showed that the densities of concrete cubes for 10 -
15% replacement was above 2400Kg/m3 and the compressive
strength increased from 12.45N/mm2 at 7days to 31.78N/mm2
at 28 days curing thus meeting the requirement for use in both
heavy weight and light weight concreting.
• Thus, 10 -15% replacement of OPC with CSA is recommended
for both heavy weight and light weight concrete production.

15
16
 CHAPTER-3
METHODOLOGY
Area of project selection

Literature review

Material Investigation

Test on materials

Mix design

Experimental Investigation

Curing of specimens

Testing of specimens

Results and discussions

CHAPTER-4
Cement Properties and Strength Analysis

The physical properties of cement are Setting Time, Soundness,

Fineness, and Strength.

Setting Time
 • Cement paste setting time is affected by a number of items including: cement
fineness, water-cement ratio, chemical content (especially gypsum content) and
admixtures. Setting tests are used to characterize how a particular cement paste
sets.
• For construction purposes, the initial set must not be too soon and the final set
must not be too late.
• Initial set. Occurs when the paste begins to stiffen considerably.
• Final set. Occurs when the cement has hardened to the point at which it can
sustain some load.
• Setting is mainly caused by C3A and C3S and results in temperature rise in the
cement paste.
• False set :No heat is evolved in a false set and the concrete can be re-mixed
without adding water
• Occurs due to the conversion of unhydreous /semihydrous gypsum to hydrous
gypsum(CaSO4.2H2O)
• Flash Set: is due to absence of Gypsum. Specifically used for under water
repair.

Soundness

• When referring to Portland cement, "soundness" refers to the ability of a

hardened Cement paste to retain its volume after setting without delayed
expansion. This Expansion is caused by excessive amounts of free lime (CaO)
or magnesia (MgO). Most Portland cement specifications limit magnesia
content and expansion.
• The cement paste should not undergo large changes in volume after it has set.
However when excessive amounts of free CaO or MgO are present in the
cement, these oxides can slowly hydrate and cause expansion of the hardened
cement paste.
• Soundness is defined as the volume stability of the cement paste.
Fineness

• Fineness or particle size of Portland cement affects Hydration rate and thus the
rate of strength gain. The smaller the particle size, the greater the surface area-
tovolume ratio, and thus, the more area available for water-cement interaction
per unit volume. The effects of greater fineness on strength are generally seen
during the first seven days.
• When the cement particles are coarser, hydration starts on the surface of the
particles. So the coarser particles may not be completely hydrated. This causes
low strength and low durability.
• For a rapid development of strength a high fineness is necessary.
Strength
 Cement paste strength is typically defined in three ways: compressive, tensile
and flexural. These strengths can be affected by a number of items including:
water cement ratio, cement-fine aggregate ratio, type and grading of fine
aggregate, curing conditions, size and shape of specimen, loading conditions
and age.

Duration of Testing

Typically, Durations of testing are:

• 1 day (for high early strength cement)

• 3 days, 7 days, 28 days and 90 days (for monitoring strength progress)
• 28 days strength is recognized as a basis for control in most codes.
• When considering cement paste strength tests, there are two items to consider:
• Cement mortar strength is not directly related to concrete strength. Strength tests are
done on cement mortars (cement + water + sand) and not on cement pastes.
CHAPTER -5

COCONUT SHELL ASH

CSA Properties and Strength Analysis

• Coconut shell is one of the most important

natural fillers produced in tropical countries like
Malaysia, Indonesia, Thailand, and Sri Lanka.

• Many works have been devoted to use of other

natural fillers in composites in the recent past
years and coconut shell filler is a potential
candidate for the development of new composites
because they have high strength and modulus
properties along with the added advantage of
high lignin content.

• The high lignin content makes the composites

made with these filler more weather resistant and
 hence more suitable for application as
construction materials.

• Coconut shell flour is also extensively used to

make products like furnishing materials, rope etc.

• The shells also absorb less moisture due to its

low cellulose content the report focuses on
studying the effectiveness of coconut shell
particles as a source of natural material for
reinforcing epoxy resins towards their flexural
properties.
Coconut Shell Ash:

• Many researchers have made efforts for preparing

carbon black from agricultural by-products such
as coconut shell apricot stones, sugarcane
bagasse, nutshells, forest residues and tobacco

stems.

• Coconut shells have little or no economic value

and their disposal is not only costly but may also
cause environmental problems.

• Coconut shell is suitable for preparing carbon

black due to its excellent natural structure and
low ash content.

• Conversion of coconut shells into activated

carbons which can be used as adsorbents in water
purification or the treatment of industrial and
municipal effluents would add value to these
agricultural commodities, help reduce the cost of
 waste disposal, and provide a potentially cheap

alternative to existing commercial carbons.

Carbonization of Coconut Shell Ash

• Coconut shells are cheap and readily available in

high quantity.

• Coconut shell contains about 65 – 75% volatile

matter and moisture which are removed largely
during the carbonization process.

• The carbonization process involves converting

the
coconut shells to char (charcoal).

• The charring process (making of charcoal) is

known as the Pyrolysis, which is chemical
decomposition of the shell by heating in the
absence of oxygen.

• During the carbonization of coconut shells,

volatiles amounting to 70% of the mass of
coconut shells on dry weight basis are released to
the atmosphere, yielding 30% of coconut shell
mass of charcoal.

• The volatile released during the carbonization

process is Methane, CO2 and wide range of
organic vapors.

• The carbonization temperature range between

400 and850 sometimes reaches.
The Processing of the Coconut Shell (Carbonization)

• The coconuts were procured from a nearby local temple.

• The coconuts were broken manually to drain out the water.

• The 40 coconut half shells were sun-dried for three days.

• Sundrying was necessary to ease removal of the meat from the inner
shells of the coconut pieces.

• After scraping the meat from the inner shells, the

inner portions of the shells were cleaned using knives.

• The fibers on the outer shells were also scraped and cleaned.

• Emery paper was used to clean the outer shells.

• The cleaned coconut shells obtained from were cut into pieces of
dimensions of 1 sq.cm using hammer and were put in stainless steels
containers.

• The containers were then kept into muffle furnace for carbonization
(carbonization is the production of charred carbon from a source
material.

• The process is generally accomplished by heating the source material

usually in the absence or limited amount of air to a temperature
sufficiently high to dry and volatilize substances in the carbonaceous
material).

• The carbonization temperature selected as600 and 800 degrees.

• After a soak time of 4 hours, the sample gets carbonized.

• As the furnace cools down, containers were taken out.

• The collected char was ground to form powder using a grinding

machine.
• The powder was then sieved to a size of 2 2 μm.
Physical and Mechanical Properties of CS

• The average moisture content and water absorption of the CS was 04.20
% and 24.00 % respectively.

• The average specific gravity and the apparent specific gravity were
found as 1.05 to 1.20 and 1.40 to 1.50 respectively, which is far less
than the conventional aggregates.

• This may be the reason for that, when CS is used in concrete it fall in
the category of LWC.

• The average crushing value and impact value of the coconut shells are
2.58% and 8.15 % respectively, hence, CS can offer better resistance
against crushing and impact.
• The average percentage loss in abrasion test on the coconut shells is
1.628 %., hence, CS can also offer more resistance against abrasion,
compared to conventional aggregate.
 • The average bulk densities in loose and compacted conditions are in the
ranges of 550 kg /m3and 650 kg /m3 respectively.

• Hence, CS aggregates result in less unit weight of concrete compared to

normal weight aggregate and produces LWC [9].

Microstructure of CS

• CS specimens have very closely spaced discrete cells having sizes

between 16.36 µm and 29.33 µm and within the cells, it has micro-pores
with sizes varying from 760.6 nm to 1.64 µm.

• Similarly, CS specimens also have some long continuous chain linked

cells with different widths varying 7.35–8.88 µm.

• The thickness of continuous cells in the direction of widths varies in the

range of 852.7 nm– 1.24 µm.

• These discrete and continuous chain linked cells of CS specimens could

be the reason for resisting more impact, crushing and abrasion
resistance of CS specimens.
 

Water absorbed by the CS during soaking is stored

and the pore structures inside the CS behave like a
reservoir [7]. Microstructure of coconut shell.

Chemical Properties of CS

• Since, concrete is an alkaline material that

are readily attacked by acid, especially when
the values of pH below 6.5.

• If sugar is present in the ingredients of

concrete, virtually prevent the setting of
cement.

• The sugar present in wood is the most critical

compounds causing incompatibility between
wood and cement.

• Sugar has a strong retarding effect on the

setting and hardening of concrete.

• In severe cases of contamination with sugar,

the resulting concrete may not set or may fail
to gain appreciable strength. But, dry sugar
has no effect on hardened concrete.

• Along with the sugar, the main saccharine of

wood are cellulose, glucose, fructose,
sucrose, etc.

• Other soluble materials may have

insignificant influences on the hydration of
cement.
 • However, sugar present in CS is not going to
come out and react with other ingredients of
concrete, to alter the setting action.
• Therefore, there is no need to treat the CS
before use as an aggregate [9]

Coconut Shell – Cement Compatibility

• Coconut shell fines required more water to

obtain same consistency compared with neat
cement.

• This may be due to the high water absorption

of the coconut shell fines.

• The setting of CS fines-cement composite is

delayed, it is probably due to the presence of
botanical components and some water
soluble sugars in CS that inhibit the setting
and hardening of cement.

• If the final setting time is less than or equal

to 15 h, it is suitable for aggregate/cement
compatibility.

• The coconut shell-cement composites are

compatible.

• It is suggested that there is no pre-treatment

is required for coconut shell fine- cement
composites.
 

• The required compressive strength can be

achieved by adding more quantity of cement
compared with neat cement composites.

• It is probably due to the relatively low

density of the coconut shell particles.
The maximum hydration temperature of neat
cement and coconut shell fine cement composites
is observed 73°C and 63°C respectively.

• It is suggested that the maximum hydration

temperature is greater than 60°C, is
considered suitable for aggregate / cement
compatibility.

• The maximum hydration temperatures values

observed are greater than 60°C and hence, it
is compatible [6].

Cement Content and Wood –Cement Ratio

• At 28-days, minimum compressive strength

should be greater than 17 N/mm2 to satisfy
the criteria of structural LWC as per ASTM

C 330.
• Therefore, it is recommended that the cement
content to be used in the range between 480
to 510 kg/m3 for CSC to meet this minimum

requirement.

• A wood–cement ratio of 0.65 may be taken

as optimum for CS aggregate to satisfy the
 criteria of structural LWC strength as per

ASTM C 330 [10].

Workability and Density

• Because of the smooth surface on one side of

CS and the size crushed CS, CSC has better
workability and also has 28-days air-dry
densities less than 2000 kg/m3 for the typical
trial mixes of

CSC [10].
CHAPTER-6

MECHANICAL PROPERTIES OF CSC

Compressive Strength

• Strength of the cement matrix and the particle

tensile strength of the aggregate are the facts which
affect the compressive strength of concrete.

• It is usually related to the cement content, required

workability and air content, rather than water-
cement ratio.

• Since it is somewhat difficult to determine that,

how much of the total mix water is absorbed by the
aggregate and thus how much water is available for

the hydration processes.

• Therefore, while producing CSC, CS coarse

aggregates are to be used in saturated surface dry
 

(SSD) condition and the water–cement ratio is to

be optimized to obtain desired workability.

• During compression test, breakage of the CS

aggregate indicates that the individual shell
strength had a strong influence on the resultant

concrete strength [10].

Effects of Curing Conditions on Compressive Strength

• Intermittent curing (site curing) conditions

produced the highest CSC strength, followed by
full water curing, and then air-dry curing.
Since, water is continuously available in case of
full warer curing, and thus creates lubrication
between CS and the cement paste and may also

have reduced the heat of hydration.

• But, in the case of intermittent curing, water is not

available throughout its curing period.

• The absorbed water from the CS pore structure

reservoir would help for continuous hydration
process at the time of lack of water.

• Therefore, there is no chance of lubrication

development between the CS and the cement

paste.

• In the case of air-dry curing, because of no water

supply, for hydratioin process the water absorbed
by CS during the time of soaking help to some

extent.
 • Development of compressive strength takes place
in the early stages and continues to increase over
the period of age.

• Even after 365-days of age, CSC gaining the

strength and also biological decay was not evident
indicated that the CSC does not deteriorated once
CS aggregates are encapsulate into the concrete

matrix .
Ultrasonic Pulse Velocity (UPV)

• It was reported that the CSC can be graded as

good. In this parameter study also higher pulse
velocities were obtained under intermittent curing
compared with full water curing and air dry curing.
• There was an improvement on the pulse velocity
and no significant drop under all types curing like
full water curing, intermittent curing and air-dry

curing conditions at an age of 90-days.

• There is an uniformity and no defect is CSC;

because there are not much differences in pulse
velocities tests in those three curing conditions
[7].

Flexural and Splitting Tensile Strength of CSC

• Flexural strength is usually 10–15% of

compressive strength in conventional concretes.

• In CSC, flexural strength are higher than the

conventional concretes and emphasized the
 

statement that the behavior of CSC is similar to

that of conventional concrete.

• Tension failures occur by breaking the matrix bond

and surface of the aggregates or by concrete matrix

fracture in conventional concrete.

• Unlike the conventional aggregates, CS is likely to

fracture but it was not happened in CS when it is
used as aggregate in CSC.

• Therefore, the brittle nature of CS is not a

constraint to use as an aggregate in concrete

production.

Also, because of the reduction of sizes of CS, its

fracture ability may also probably decreases.

• It was stated that the behavior of CSC under

flexural tests and split tensile strength tests are

similar to that of conventional concrete [10].

Impact Resistance of CSC

• If the strength of concrete increases, impact

resistance of concrete specimen increases generally
both for initial cracks and failure cracks.

• But there is an optimum value, more than that there

is a reduction of impact resistance both at first and
final failure cracks while the strength of the

concrete increases.
 • Impact résistance of CSC is 32 blows in which
compressive strength of CSC was 26.70 N/mm2
which was nearly 50 % more compared with the 22
blows of normal aggregate concrete which had

compressive strength of around 45 N/mm2 .

• This enhancement of impact resistance of CSA is

due to the fibrous nature of CS aggregates [10].

Bond Strength of CSC

• The bond strength of CSC specimens with plain

bars ranged from 15 to 32% and deformed bars
ranged from 18 to 42% of compressive strength of

the CSC.
 

Its bond strength is comparable to the conventional

concrete and other LWC generally.

• Failure of bond took by pulling the plain bars out

of the concrete and failed by forming concrete

cover cracks on deformed bars bond tests.

• Bond strength decreases when the bar size

increases for both plain and deformed bars [10].

Curing Conditions Effect on Bond Strength of CSC

• Development of bond strength took place in early

ages for most of the specimens.

• Bond strength increases significantly up to the age

of 56-days under full water, intermittent and airdry
curing conditions.

• Thereafter, the development of bond strength was

gradual and almost constant.

• In this case also, intermittent curing condition

produces the highest bond strength followed by
full water and air-dried curing.

• The reason is the same as explained for

compressive strength in the section 5.2 above
[7].
Development of Bond between CS Aggregate and Cement Paste

• It is reported that the fissure gap between the CS

aggregate and the cement paste was approximately
 52.31–88.27 µm, 41.72–47.96 µm, and 24.94–
26.63 µm at 3 days, 7 days, and 28 days
respectively.
From this it was reported and concluded that the
fissure zone between the CS and the cement paste
was getting narrow due to age of concrete.

• Therefore, there was the development of bonding

between CS aggregate and cement paste [7].

• The bond development between cement paste and

CS in CSC at 3, 7, and 28 days respectively [7].
 

CHAPTER-7 STRUCTURAL ELEMENT BEHAVIOR OF

CSC

CSC Beams under Flexure

• Under flexural tests, CSC beams behavior was also

in traditionally structural in parallel to conventional
concrete.

• It was reported that, bond failure was not occurred

between the reinforcement and CSC.

• Experimental ultimate moments were 09–45%

higher than the theoretical moments for CSA
beams when reinforcements ratio of 3.14% or

less.

• For reinforcement ratios higher than 3.89%, it was

about only 5% higher. For the estimation of
ultimate moment of CSA beams, both BS 8110 and

IS 456 can also be used.

• Under service loads, defelctions of CSC beams

were within the limits allowable as per the
standards. Because of the nature of good shock
absorbance potentials of CS aggregates, CSC
beams under flexure shows relatively good

ductility.

• Crcak widths developed in CSC beams under

flexural tests in service loads were within the limits
specified by the standards.
 CSC beams able to attain strain capacity fully
under flexure.

• Just prior to failure of CSC beams under flexure,

the developed end rotations were comparable to
other LWC [11].

CSC Beams under Shear

• Under shear tests also, CSC beams behavior were

also in traditionally structural in parallel to
conventional concrete.

• When CSC beams not provided with shear

reinforcement and tested, diagonal tension failure
were occurred.

• Flexural mode of failure was noticed in CSC

beams when provided with shear reinforcement.

• CSC beams tested under shear suggested that there

is strong bonding exist between the reinforcement
and CSC as it is happening traditionally in

conventional concrete.

• There is proper justification for the occurrence of

good interlocking of CS aggregates in CSC from
the pattern of initiation of cracks and its

propagations to the final positions.

• Large anchorage stresses was developed in the

support zone, however no horizontal splitting of


concrete was found both in shear and flexural

zones.

• Deflections developed in CSC beams were greater

than the conventional beams both with and without
shear reinforcement cases due to low modulus of
elasticity of CSC compared to conventional

concrete.

• However, at service loads the defalcations were

within the allowed limits.

• Because of due to good CS aggregate interlocking,

experimental results higher than the predicted
value as per the standard.

• Compared to conventional concrete beams, shear

and flexural cracks appeared twice in CSC
beams.

• Until the formation of cracks in concrete, there was

a linear relationship in tensile and compressive
strains in CSC beams of with and without shear

links.

• Once the cracks formed, strains in steel increase in

a steady manner until yielding.

• Before the main reinforcement fails, higher strains

happened in shear links.

• Both in the cases of with and without shear links in

CSC beams, higher concrete compressive strains
 measured prior to failure compared to conventional

concrete beams.

• This shows that there was strong bonding

between
 the CS aggregates and the reinforcements [12].

CSC Beams under Torsion

• Initially cracks developed on the wider face of the

CSC beam, propagated suddenly to the entire depth
then formed in shorter face of the beam before the

beam fails.

• Spiral cracks were developed approximately at 45°

and extended over the test area of the CSC beam.

• It was reported that the applied torsion was resisted

by the concrete up to the formation of cracks and
CSC beams behaves elastically, since the torque
versus twists obtained was linear and hence it was

confirmed.

• CS aggregates have less stiffness comparatively with

conventional aggregates and because of this, cracking
occurs in CSC beams earlier than the conventional

concrete beams.

• To calculate the theoretical crack strength under

torsion, equation suggested by Macgregor is more

conservative compared to ACI prediction [13].

• After the formation of cracks, torque versus twists

reported as non-linear.

• Due to the fibrous nature of CS, ultimate torque

strength resistance of CSC beams were high

compared to conventional concrete beams and it

was quite interesting.
 • To calculate the ultimate strength under torsion, ACI
prediction is more conservative compared to equation

suggested by Macgregor [13].

• Compared to ACI and Macgregor equations,

Indian Standard is also conservative, however it was
under estimated. In ductility parameter study, CSC
beams have similarity behviour compared to

conventional concrete beams.

• Again from this also, it was stressed that, due to the

fiberous nature of CS aggregates, ductility was more
in CSC beams.

• Because of less stiffness of CS aggregates, crack

widths were slightly on higher side compared to

conventional concrete beams crack widths.

• To calculate the theoretical stiffness, equation

suggested by Park and Paulay is conservative [13]

Shrinkage Study on CSC Slabs

• Both density and compressive strength of CSC are

inversely proportional to percentage of CS
aggregates used in the production of CSC.

• Similarly, plastic shrinkage characteristics of CSC

also inverse with the addition of percentage of CS
aggregates and plays an important role on the

property of shrinkage of concrete [14].

Deflection Study on CSC Slabs

• Central deflection of CSC slabs is directly

proportional to percentage of CS aggregates used.

• CS aggregates exhibits and plays an important role

for the enhancement of ductility property of concrete,
because CSC slabs under test gave warning time
more before it fails compared to conventional

concrete [14].

Stress-Strain Characteristic of CSC

• For conventional concrete as per IS 456: 2000 the

ratio of cylinder to cube strength is approximately

0.8, but it was slightly less in CSC.

• Similarly, stress-strain curve obtained for CSC was

not conservative in parallel with IS 456:200 which
is applicable for conventional concrete.

• Static modulus of elasticity of CSC is concurrent

with oil palm shell concrete.

• This value was varied from 6.9 to 7.5 GPa. CSC

beams attained the similar pattern of parabolic
stress-strain curve of conventional concrete, but the

strain value of CSC was higher.

• At failure of CSC beams, ultimate strain of CSC

was found as 0.006 and this value is

approximately twice as that of conventional

concrete.
 • Compared to over reinforced CSC beams, under
reinforced CSC beams had less moment capacity
and vice versa in the study of deflection due to the

yield of tension steel.

• CSC beams final failure strains results in ductile

failure and the ductility ratio of CSC beams ranged
from 2.68 to 4.9 and these values conservative with

oil palm shell concrete beams.

• In CSC beams, at serviceable loading conditions,

crack width developed is within the allowable limits
specified by codes and standards [15]. Fig. 5 shows

the cross sectional view CSC cylinder specimen.

DURABILITY PROPERTIES OF CSC

• It was reported that the CSC specimen water

absorption and permeable pore voids were
decreases as the age of curing increases under full
water, intermittent and air-dry curing conditions

employed.

• At early age of curing, water absorption of CSC

specimen does not show any significant effect due
to different state of curing conditions.

• Since CS has the capacity to absorb water and

retain in its as a reservoir which helps for internal

curing was the possible reason for the above.
 • However, there were significant differences
happened at later ages.

• Therefore to overcome this, there is a need of

proper curing whenever CS is used as aggregate in
concrete production.

• Sorptivity values of CSC were comparatively well

with those of other LWC prepared from expanded
shale and sintered pulverized fuel ash, and oil palm

shell.

• Rapid chloride penetration test indicated that the

CSC specimen shown moderate chloride-ion

penetrability.

• Due to the porous nature of CS, surface chloride

concentration on CSC specimen were quite high.

• However, chloride content decereases towards

depth inside the CSC specimen from the surface.

• CSC specimen tested under elevated temperature

results showed that the resistance, change of
colours and the residual strength of CSC specimen
were comparatively well with other LWCs

reasonably [16].
PRACTICAL IMPLEMENTATION OF CSC

• To show the use of CSC in practice and to made the

awareness about this established CSC, some of the
non-structural elements like hollow blocks, joinery
items were produced with CSC and also a precast
 reinforced CSC slab was cast using layman
methodology without any technical force during the

year 2007 in the University premise.

• This precast CSC slab was constructed with the

supports of CSC hollow blocks and the slab being

allowed to bear some practical loading till today.

• Till today, that CSC slab performing well without

any difficult experience technically.

• Therefore, from the review of literatures on CS and

CSC and also this example of using CSC in practice
gives confident that the CSC is one of the
potentially developed special concrete and CS
become one of the fine alternate for convenetional

aggregate in the near future.

• some of the elements made use of CSC for practical

implementation.

CHAPTER -8

PRIMILARY TEST ON MATERIALS

1.SILT CONTENT

Determination of slit content

SR NO DESCRIPTION SAMPLE
1 Volume of sample 96
2 Volume of slit 04
 3 Percentage of slit 4.16

The permissible silt content in sand percentage is only 6%

1. SPECIFIC GRAVITY

Specific gravity of cement

W1=weight of empty flask

W2=weight of flask +cement

W3=weight of flask+cement+kerosene

W4=weight of flask+kerosene

0.79=specific gravity of kerosene

W1=94g,w2=112g,w3=141g,w4=130g

Sp.gravity=(w2-w1)/(w2-w1)-(w3-w4)×0.79

Sp.gravity=18/(18)-(11)×0.79 = 3.25
Specific gravity of coconut shell ash W1=

weight of empty flask

W2=weight of flask + cement

W3=weight of flash + cement + kerosene

W4=weight of flask + kerosene

0.79=specific gravity of kerosene

W1=94g , w2=104g ,w3=132g ,w4=126g ,

Sp.gravity=(w2-w1)/(w2-w1)-(w3-w4)×0.79
Sp.gravity = (104-94)/(104-94)-(132-126)×0.97
Sp.gravity = 10/3.16=3.16 CONSISTENCY OF OPC
43 AND CSA
Normal Consistency 10mm Needle Use

% REPLACEMENT OPC43 CSA(gm) CONSISTENCY

CSA (gm)
 00 400 00 30
10 360 40 32
15 340 60 33

SETTING TIME OPC 43 AND CSA

%REPLACEMENT INITIAL SETTING

FINAL SETTING
CSA TIME (MINUTE) TIME (MINUTE)

00 49 326

10 112 486

15 145 520
CALCULATION OF TESTING
CALCULATION
Initial Setting Time = T2-T1 Final
Setting Time = T3- T1
Where,
T1= Time At Which Water Is First Added To The Cement .
T2= Time At Which Needle Fail To Penetrate The 5mm To 7mm Mark From
Bottom Of The Mould .
T3= Time At Which Needle Make Impression ,But Fail To Do. So,
The Gauging Time Period Should Not Be Less Than 3 Minutes And Not
Exceeds To 5 Minutes.
CEHMICAL COMPOSITION OF OPC AND CSA
Particulars OPC 43 Garde C.S.A
Silicon dioxide (sio2) 20.7 37.97

Aluminium oxide (al2o3) 5.75 24.12

Iron oxide (fe2o3) 2.5 15.48

Calcium oxide (cao) 6.4 4.98

Sodium oxide (na2o) 0.6 0.95

Potassium oxide (k2o) 0.15 0.83

SILT CONTENT
Determination of Silt Content
 S.NO DESCRIPTION SAMPLE

1 Volume of Sample (v1) 96

2 Volume Of Slit (v2) 04

3 Percentage Of Silt (v1/v2)*100 4.16

MIX DESIGH

M25 GRADE (1:1:2)

%REPLACEMENT OPC 43 CSA COURSE
FINE WATER IN
AGGREGATE(kg) LITRE
(Kg) (kg) AGGREGATE(kg)

00 12.150 00 12.150 24.300 5.83

10 10.935 1.215 12.150 24.300 5.83

15 10.328 1.822 12.150 24.300 5.83

AVERAGE COMPRESSIVE STRENGTH 7 DAYS
% Replacement Of CSA Compressive Strength (N/mm2)

00 17.55

10 17.85

15 15.85
 compressive strength
25

20

15

compressive strength
10

0
0% 5% 10% 15%

AVERAGE COMPRESSIVE STRENGTH 28 DAYS

% Replacement Of CSA Compressive Strength (N/mm2)

00 31.56

10 33.22

15 32.59
 28 days Compressive strength
34

33.5

33

32.5
28 days Compressive
32 strength

31.5

31

30.5
0% 5% 10% 15%

AVERAGE COMPRESSIVE STRENGTH 7 DAYS AND 28 DAYS

% Replacement Of 7 days Compressive 28 days

CSA strength N/mm2 Compressive
strength N/mm2

00 17.55 31.26

10 17.85 33.46

15 15.85 32.59
Flow chart average compressive strength 7 days and 28 days .
60

50

40

28 days compressive
30 strength
7days compressive strength
20

10

0
0% 5% 10% 15%

AVERAGE SPILT TENSILE STRENGTH 7 DAYS AND 28 DAYS

% Replacement Of 7 days split tensile 28 days spilt tensile
CSA strength N/mm2 strength N/mm2

00 2.12 4.10

10 2.73 5.02

15 2.36 4.16

Flow chart Average Split tensile strength 7days and 28 days

 9

5
28 days split tensile strength
4 7days split tensile strength
3

0
0% 5% 10% 15%

FRESH CONCRETE TEST SLUMP

CONE TEST

The apparatus used for conducting the slump test consist of slump cone. The internal surface
of mould is thoroughly cleaned free from moisture and adherence of any old set concrete
before commencing the test . concrete is placed in the mould and is remove for slump value .
TYPES OF SLUMP
Collapse slump
Shear slump
True slump

% Of Replacement Slump cone value

(mm)

0% 99.5

10% 98.5

15% 97
COMPACTION FACTOR
Compacting factor of fresh concrete is done to determine the workability of fresh
concrete by compacting factor test as per IS: 1199 – 1959.
Compaction Factor Results

% OF COMPACTION FACTOR
REPLACEMENT

0% 0.92

10% 0.91

15% 0.89
CASTING OF CUBEMOULDS
Cube Mould is internal surface of mould is thoroughly cleaned .concrete cube of size
of 150mm×150mm. the concrete in the cube must be fully compacted with
compacting bar or vibrating table .after 24 hours this mould are removed.
 HARDENED CONCRETE TEST
COMPRESSION TEST :

compressive strength of concrete is one of the most important and useful properties of
concrete. It is generally by testing cubes of size 150x150x150mm that was done by in
the lab. In this test cubes are subjected to compressive force in a compressive force in
a compressive testing machine and the ultimate load at which the failure occurs is
noted. Then the compressive stress is ultimate load by exposed to load and stress
value is obtained in N/mm2.
URING OF CUBE

For curing the specimen sample in kept submerged in fresh water until take out for
testing after 7 days and 28 days. The temperature of water must be 27˚c±2˚c

S.NO %OF 7 DAYS CURING ACID CURING

REPLACEMENT

1 0% 53.24 47.5

2 10% 53.5 45.1

3 15% 54.6 44.7

DURABILITY PROPERTIES
Acid Attack
The acid attack test was conducted for the concrete cube of size 150x150x150mm size.
Concrete specimen is immersed in water and it should be cured for 30 days. After 28 days of
curing , the specimens were weighed (W1) and the specimen immersed with 5% hydrochloric
acid by weight of water for acid test for 30 days. The pH was maintained throughout the
period of 30 days. After 30 days, the specimen is taken out and it should be weighed as (W2).
Then the compressive strength of cube specimen should be noted at W1 and W2 and it is
considered as C1 and C2. After analyzing , the percentage of weight loss and percentage of
strength loss is determined.
% of weight loss after 30 days = (W1-W2/W1) x100
% of strength loss after 30 days = (C1-C2/C1) x100
Advantage of CSA Concrete
• Decrease the cost of concrete . ●
Decrease the need of cement .

● It can used as light weight concrete .

● The was very feasibility in agriculture area .
• It increase the initial setting time which is useful for it site work .
 ● The coconut shell ash is easily available and cheap .

 It make the coconut plastic limit increase .

● It increase the durability of concrete .

Disadvantage of CSA Concrete

● At after above 15 % of replace of coconut shell ash the compressive strength
decrease
. • It also increase the final setting time .
• The burning processing is should be made proper otherwise it will defect the
concrete .
CONCLUSION
Due to the depletion of natural resources of conventional aggregates, researchers are searching

for sustainable development of the alternative aggregates is one of the prime of importance in

concrete production and construction industries as well. One of the research area taken by

many researchers is an attempt to replace the conventional aggregate by coconut shell and all

of them have succeeded in their research and found encouraged and positive results to use CS

as one of the promised material as an aggregate in concrete production.

From the review of literatures surveyed on coconut shell concrete, it can be concluded that the

coconut shell is one of the agricultural wastes, produced in abundance and has the potential to

be used as coarse aggregate in concrete. Indonesia, Philippines, India, Brazil and SriLanka are

the major contributors to coconut production. Coconut shells are widely used to manufacture

insect / mosquito repellent coil, mouldings, bakelite powder, abrasives, plywood, mica,

foundry chemicals, and agarbathis, incense sticks and also find its use in plastic industries. Use

of coconut shell in concrete has the dual advantage of diminution in the cost of construction

material and also as a way of clearance of wastes. Also, shell charcoal, shell based activated
carbon, shell powder, shell handicrafts, shell ice cream cups and beer glasses, ladles, forks,

show pieces, shell buttons, etc. are the coconut shell based products available.

CS aggregates result in less unit weight of concrete compared to normal weight aggregate and

produces LWC. No need to treat the CS before use as an aggregate in concrete production

except for its water absorption characteristics. The coconut shell-cement composites are

compatible. It is recommended that the cement content to be used in the range between 480 to

510 kg/m3 for CSC to meet this minimum requirement. A wood–cement ratio of 0.65 may be

taken as optimum for CS aggregate to satisfy the criteria of structural LWC strength as per

ASTM C 330. Even after 365-days of age, CSC gaining the strength and also biological decay

was not evident indicated that the CSC does not deteriorated once CS aggregates are

encapsulate into the concrete matrix. There is an uniformity and no defect is CSC. Behavior of

CSC under flexural tests and split tensile strength tests are similar to that of conventional

concrete. There was enhancement of impact resistance of CSC due to the fibrous nature of CS

aggregates. Bond strength of CSC were comparable to that of conventional concrete and other

LWC. Structural element behavior of CSC beams under flexure, shear and torsion were

comparable with conventional concrete and also with other LWCs. CS aggregates plays an

important role on the property of shrinkage of CSC. CSC slabs under test gave warning time

more before it fails compared to conventional concrete. Durability tests on CSC specimen

were given encouraged results to use CS as an alternate aggregate in the concrete production.

Practically applied CSC elements under service for the past ten years of service proved that the

coconut shell become one of the best alternatives for normal coarse aggregate.

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