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PERFORMANCE OF CEMENT GROUT INCORPORATING CERAMIC WASTE
AS FILLER
NORHARYATI SALEH
A project report submitted in partial fulfillment of the
requirements for the award of the degree of
Master of Engineering (Civil-Structure)
FACULTY OF CIVIL ENGINEERING
UNIVERSITI TEKNOLOGI MALAYSIA
JUNE 2014
iii
To my beloved late mother, father and families
NORHARYATI SALEH
2014
iv
ACKNOWLEDGEMENT
First and foremost, thanks to Lord Almighty for given me strength, wisdom
and patience to complete this research project. This report is submitted in partial
fulfillment of the requirement for the master of Civil Engineering students at
Universiti Teknologi Malaysia. In preparing this report, I was in contact in many
people, academicians and practitioners. They have contributed towards my
understanding and thought, especially for the knowledge in terms of material
properties and experimental project works.
In particular, I wish to express my sincere appreciation to my supervisor,
Prof. Ir. Dr. Mohd Warid Hussin for his enthusiastic effort and concern throughout
the project. It was not forgotten for Mr. Mustafa Samadi as a mentor for my research
project work and also my fellow friends for all their information and advice that they
give to me. Last but not least, my sincere appreciation also extends to all my family
and who ever have provided assistance at various occasions. Thank you.
v
ABSTRACTS
The large bulk of ceramic waste nowadays leads to serious environmental
problem since these materials are not reusable and recyclable. In second concern is
related to the deterioration due to crack problem facing by concrete structure. The
use of cement grout as one of repair materials for minor crack has been applied for
many years. However, the natural sand as filler used in cement grout somehow needs
another alternate material to substitute it due to depletion issue and has become
expensive. Therefore, reuse of ceramic waste as substitute in natural sand has been
proposed to minimise those problems. This research conducted focus on the
performance of cement grout incorporating ceramic tile waste as filler. The
experimental tests were performed to determine engineering properties consists of
consistency, setting time, shrinkage behavior, water absorption, compressive and
flexure strength. Different size particle of ceramic waste in range 150 µm to 850 µm
were selected as partial replacement of sand as filler in cement grout. The result
indicated the optimum of size particle that give better performance in their
engineering properties was filler with size around 150 µm, without affecting
significantly in design strength. The incorporating of ceramic waste has no negative
effects on cement grout properties and thus can be used as alternate construction
material in future. Besides, cement grout made from ceramic waste as filler may
minimise the disposal problem as was mentioned earlier.
vi
ABSTRAK
Dewasa ini, lambakan sisa seramik telah membawa masalah yang serius
kepada alam sekitar kerana bahan ini tidak digunapakai dan dikitar semula.
Manakala, perhatian juga diberikan kepada masalah berkaitan dengan kerosakan
yang dihadapi oleh struktur konkrit iaitu keretakan. Penggunaan grout simen sebagai
salah satu bahan pembaikpulihan bagi keretakan kecil sudah lama digunapakai sejak
bertahun lamanya. Namun, pasir asli perlu diganti dengan bahan alternatif kerana
faktor kekurangan dan harganya yang kian mahal. Oleh itu, mengunapakai sisa
seramik sebagai bahan ganti bagi pasir asli telah dicadangkan untuk mengatasi
masalah tersebut. Penyelidikan ini menerangkan tentang prestasi grout simen
menggunakan sisa seramik sebagai pengisi. Beberapa siri ekperimen telah dijalankan
bagi mengenalpasti sifat-sifat kejuruteraan iaitu konsistensi, masa ketetapan, sifat
pengecutan, penyerapan air, daya mampatan dan juga lenturan. Sisa seramik dari saiz
butiran yang berbeza iaitu 150 µm hingga 850 µm telah dipilih bagi mengantikan
separuh daripada pasir asli sebagai pengisi dalam grout simen. Keputusan
menunjukkan saiz butiran yang memberikan prestasi paling optimum dari segi sifat-
sifat kejuruteraan adalah pengisi bersaiz lingkungan 150 µm, tanpa memberikan
kesan ketara dalam kekuatan rekaan. Penggunaan sisa seramik tidak memberi
sebarang impak negatif kepada sifat-sifat grout simen dan seterusnya boleh
digunakan sebagai bahan pembinaan alternatif di masa hadapan. Selain itu, grout
simen yang dibuat bersama sisa seramik sebagai pengisi juga mampu mengurangkan
masalah pelupusan seperti yang dimaklumkan sebelum ini.
vii
TABLE OF CONTENT
CHAPTER TITLE PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENTS iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xi
LIST OF ABBREVIATIONS xiii
LIST OF SYMBOLS xiv
LIST OF APPENDICES xv
1 INTRODUCTION 1
1.1 Background of Study 1
1.2 Problem Statement 3
1.3 Objective of Study 4
1.4 Scope of Study 5
1.5 Limitation of Study 7
1.6 Significant Contribution 8
viii
2 LITERATURE REVIEW 9
2.1 Ceramic Waste 9
2.2 Ceramic Waste as Recycled Construction Material 15
2.3 Grout 18
2.4 Properties and Design Criteria of Cementitious
Repair Grout Mix 21
2.5 Filler 24
3 RESEARCH METHODOLGY 29
3.1 Introduction 29
3.2 Overall Program of Study 30
3.3 Raw Material 31
3.3.1 Cement 31
3.3.2 Sand 31
3.3.3 Ceramic Tile Waste 33
3.4 Preparation of Test specimen 37
3.4.1 Mix Design of Cement Grout 37
3.4.2 Mixing Procedure 38
3.4.3 Cube Specimen 41
3.4.4 Prism Specimen 42
3.5 Test Procedures 44
3.5.1 Flow Table test 44
3.5.2 Vicat test 46
3.5.3 Water Absorption test 48
3.5.4 Shrinkage test 50
3.5.5 Compression test 52
3.5.6 Flexural test 53
4 RESULTS AND DISCUSSIONS 57
4.1 Introduction 57
4.2 Cement Grout Properties 58
4.3 Consistency 60
4.4 Setting Time 62
4.5 Water Absorption 63
ix
4.6 Drying Shrinkage 65
4.7 Compressive Strength 69
4.8 Flexural Strength 72
5 CONCLUSION AND RECOMMENDATION 75
5.1 Summary of Conclusion 75
5.2 Detailed Conclusion 76
5.2.1 Objective (i): Ceramic Waste as Potential
Construction Material 76
5.2.2 Objective (ii) and (iii): Compressive
Strength 77
5.2.3 Objective (ii) and (iii): Flexural Strength 78
5.2.4 Objective (ii) and (iii): Consistency 79
5.2.5 Objective (ii) and (iii): Initial Setting Time 79
5.2.6 Objective (ii) and (iii): Water Absorption 80
5.2.7 Objective (ii) and (iii): Shrinkage 81
5.3 Recommendation for Future Investigation 81
REFERENCES 84
APPENDICES 89-90
x
LIST OF TABLES
TABLE NO. TITLE PAGE
2.1 Composition of construction and demolition waste
(Mohd. Mustafa et.al, 2008) 11
2.2 Chemical properties of ceramic waste use in this study 14
2.3 Various size of standard sand (ASTM C 778) 28
3.1 Sieve analysis of sand passing through 1.18mm sieve 32
3.2 Sieve analysis of ceramic passing through 1.18mm sieve 36
3.3 Mix proportion of sample 38
4.1 Properties of cement grout mixes 59
4.2 Consistency of the grout with different
water cement ratio 61
4.3 Absorption water of cement grout 64
4.4(a) Drying shrinkage of cement grout 67
4.4(b) Drying shrinkage of cement grout 67
4.5 Compressive strength of cement grout for different periods
of time 70
4.6 Flexural strength of cement grout for different periods
of time 73
xi
LIST OF FIGURES
TABLE NO. TITLE PAGE
1.1 Ceramic floor and wall tile waste 7
2.1 Ceramic industries waste 10
2.2 Pozzolanic activity (Andrean Juan et. al.) 13
2.3 Ground ceramic tile preparation process
(D. Tavakoli et. al.,2012) 16
2.4 Ceramic waste as coarse aggregate
(A.M Mustafa Al.Bakri et. al.,2013) 17
2.5 Concrete with filler of M300
(H. Moosberg Bustnes et. al., 2004) 26
2.6 Concrete with filler of M500
(H. Moosberg Bustnes et. al., 2004) 26
2.7 Concrete with filler of M6000
(H. Moosberg Bustnes et. al., 2004) 27
3.1 Graded sand passing 1.18mm sieve 32
3.2 Particle size distribution of sand 33
3.3 Crusher machine 34
3.4 Different size of ceramic waste 34
3.5 Ceramic tile in powder form 35
3.6 Particle size distribution of ceramic 36
3.7 Mixing all the materials to gain uniformity 39
3.8 Filled the readily mixed cement grout into moulds 40
3.9 Samples placed in curing tank 40
3.10 Steel moulds for cube and prism 41
xii
3.11 Cube specimens for compression and water absorption test 42
3.12 Prism section for cube flexural test 43
3.13 Prism section for shrinkage test 43
3.14 Flow table set consist of conical frustrum and
dropping table 45
3.15 Cement grout before undergo flow test 45
3.16 Cement grout after dropped 5 times in 3 seconds 46
3.17 Vicat needle apparatus for initial setting time measurement 47
3.18 Sample of cement grout 48
3.19 Specimens in water reservoir 49
3.20 Demec gauge was glued to the top surface of specimen 51
3.21 Placing stud onto marked position 51
3.22 Measuring the shrinkage using strain gauge 52
3.23 Cube specimen during compression test 53
3.24 Arrangement of support and load applied for prism
specimen 54
3.25 Prism specimen during flexural test 55
3.26 Flow chart of research methodology 56
4.1 Graph of consistency of cement grout 62
4.2 Initial setting time of cement grout 63
4.3 Water absorption of cement grout 65
4.4 Strain of cement grout 68
4.5 Compressive strength of cement grout with respect to
duration of time 71
4.6 Flexural strength of cement grout with respect to
duration of time 74
xiii
LIST OF ABBREVIATIONS
ASTM - American Society for Testing and Materials
CM - Control mix
Demec - Demountable mechanical strain
Kg/m³ - Density
MPa - Strength (Mega Pascal)
M1 - Mix 1
M2 - Mix 2
M3 - Mix 3
M4 - Mix 4
M5 - Mix 5
- Silicon dioxide
w/c - water cement ratio
xiv
LIST OF SYMBOLS
b - width
d - depth
- Compressive strength
Kg - Kilogram
L - span
m - meter
min - minute
N - Newton
P - maximum load at or prior to the moment of crack
S - stress
WA - The water absorption
- Weight of specimen before water immersion
- Weight of specimen after water immersion
µ - Micro
ºC/ ºF - Degree Celsius/ Fahrenheit
% - Percentage
xv
LIST OF APPENDICES
APPENDIX TITTLE PAGE
A Appendices for Chapter 3 87
B Appendices for Chapter 4 89
CHAPTER I
INTRODUCTION
1.1 Background of Study
Recent years have witnessed rising social concern about the problem of waste
management in general, and industrial waste and waste from the construction
industry in particular. Conserving natural resources and preserving the environment
is the essence of any development. The problem that occurs from continuous
technological, industrial and construction development is the disposal of waste
material. Besides that, in recent years the concrete structures has been facing with
durability problem such as deterioration or distress and many repair, rehabilitate and
remedial works are required. One of the major problems being concern was cracking
issue. Cracking occurred when stresses in the concrete exceed the concrete strength,
lack of site workmanship, and overall as mentioned due to general lack of durability
in concrete itself. Cracks provide a path for water, chlorides and oxygen to hack the
concrete and cause the freeze-thaw damage and attack reinforcement by corrosion
that affects the structural integrity.
Depending on the nature of crack damage, one or more repair methods may
be selected, for example, sealing of crack by using material grout. Sealing of cracks
2
repair should be used in conditions where structural repair is not necessary. Isolated
cracks whether extending through the concrete section or partially into it, should be
sealed at the concrete surfaces. Grout material commonly identifies as cement grout,
cement mortar and epoxy grout. Cement grout is formed of cement normally
Portland cement powder mixing with or without aggregate together with specific
ratio of water.
For developing countries like Malaysia, the depletion of natural resource is a
common phenomenon due to rapid urbanization and industrialization involving
construction of infrastructure and other facilities. B.V. Bahoria et. al., 2013 have
mentioned in their previous study about comprehensive literature review on use of
waste product in concrete that in the last 15 years, it has become clear that
availability of natural sand with good quality is decreasing. The existing natural sand
deposits are being depleted at the same rate as increasing in construction industries
for development process. Besides, issue regarding uncontrolled extraction of natural
sand becomes one of environmental concern in this decade.
In concern on those issues, it is believe that some waste material that ends up
in the landfill can be utilized in suitable filler grouting making, whereby the amount
of waste entering the landfill will be reduced. Ceramic waste is one of those waste
materials that have recently gained attentions to be used as recycled material in
cement and concrete production. The use of ceramic waste products as filler in grout
mix not only makes it economical but also solves some of the disposal problems. As
known, producing grout mixing is quite expensive by using natural resources.
Therefore, if ceramic waste able to performed as filler in conventional cement grout
with equivalent and even higher characteristic properties, the cost of grouting for
repair works could be reduced which ultimately leads us one step closer to a
sustainable future.
3
1.2 Problem Statement
The mind set of most individuals for many years has been the disposal of
waste products directly to landfills and is seen as the most convenient way of getting
rid of the waste. The consequence being that landfills are filling up rapidly and the
amount of landfill space is decreasing accordingly whilst the earth’s natural
resources are continued to be exploited. The need to managed these wastes has
become one of the most pressing issues of our time, requiring specific action aimed
at preventing waste generation such as promotion of resource recovery system like
reuse, recycle and waste to energy systems as means of exploiting the resources
contained within waste, which would otherwise be lost, thus reducing the
environmental impact. Apart from that issue, one must recognize that many numbers
of existing concrete structures nowadays are in state of deterioration or distress. The
most serious deterioration processes leading to repair failures are caused by the
cracking.
Cracks are inevitable, and neglect will lead to a more rapid deterioration of
the concrete. Preventative maintenance can help to restore and increase strength thus
extend the life of the concrete itself. Maintenance activities can range from crack
sealing and filing, to other, more involve in surface treatments. The minor crack at
the surface ranging in depth from 6 to 25mm and minimum opening at surface of
6mm can undergo the surface sealing repair by using grout material. In Malaysia,
there are few types of grout materials used in repairing works such as cementitious
grout and epoxy grout. However, cemetitious grouts are usually used in Malaysia
due to their lower cost and availability in market.
To mentioned, other than cement material, fine aggregate normally natural
sand is one of the most common cement grout material used for the purpose of filling
cracks or voids in the concrete or other cement base materials structure member.
However, the use of natural sand has become very expensive and also becoming
scarce due to depletion of river bed. As regard in the ceramic industry the production
4
goes as waste, which is not undergoing the recycle process yet. Large bulks of
ceramic tiles change into wastage because these waste materials are not reusable and
recyclable due to lack understanding of their physical and chemical structure.
Realizing this need, this study used ceramic waste as useful filler material
instead of fully used of sand in cement grout mix design. Different size particle of
ceramic waste were selected as partial replacement of sand as filler in cement grout
and characteristic properties of cement grout incorporating ceramic waste being
observed. Using ceramic wastage in cement grout production causes no remarkable
negative effect in the properties of concrete. The properties of ceramic waste grout
were found not significantly different from those of conventional cement grout since
it contained natural pozzolanic material. In addition to helping protect the
environment, use of ceramic waste offers a series of advantages such as a reduction
in the use of other raw materials and contributing to an economy of natural
resources. Moreover, reuse also offer benefit to reduce the consumption of industrial
space or productive land for dumping such waste.
1.3 Objective of Study
In view of the problems as described in section 1.2, a research program
involving laboratory experiment were carried out to enhance the knowledge in
characteristic properties of cement grout incorporating ceramic waste as filler. The
objectives of this study include the following tasks.
I. To reuse the ceramic waste as potential construction material in
cement grout production in order to reduce use of natural resource and
environmental impact causes by dumping and depletion of natural
sand.
5
II. To investigate the effect of various size particle of ceramic waste (150
µm to 850 µm) at different replacement level as filler for fine
aggregate (sand) for providing better understanding and guidelines in
the application of such cement grout as concrete repair material.
III. Study of the properties of conventional cement grout and cement
grout using ceramic waste as filler for representative determination of
the important engineering grout parameter including consistency,
setting time, water absorption, compressive and flexural strengths
behavior and shrinkages effect.
1.4 Scope of Study
This research conducted focus on characteristic properties of cement grout
made with utilizing of ceramic waste from floor and wall tile (Figure 1.1). The
scopes of this study are:
I. Mix samples of cement grout made using different size of graded sand
that passing 1.18 mm without incorporating ceramic waste are
prepared as control sample. Meanwhile, different mix design also
made using various size particles of ceramic wastes (850 µm, 600 µm,
300 µm and 150 µm) were used to replaced part of sand as filler. The
proportion of ceramic waste used to replace proportion of sand was
fixed to be half of the total proportion of filler. The water cement ratio
was selected by trial mix design.
6
II. The major properties of grout which is consistency and strength
characteristic were study. In order to understand the engineering
influence on the properties of the cement grout with the addition of
the ceramic waste powder, a series of experimental tests were
performed. The tests were conducted under fresh state and hardened
state condition.
III. The flow table testing for the fresh grout and the setting time were
both examined in fresh state of cement grout. For the hardened state,
the 50 x 50 x 50 mm cement grout cube was casted to determine the
compressive strength characteristic. Different size particle of ceramic
waste from 150 to 850 µm were added in mix design together with
plain cement grout mix design. For every mix proportion, three
samples are made and test were carried out at 7 days, 28 days and 40
days by using universal testing machine (UTM) in order to determine
the development of strength for each cube. In addition, test on flexural
strength, shrinkage and water absorption were performed for grout in
hardened state in order to studies the influence of engineering
properties when using various size ceramic wastes as filler
The comparisons of performance between cement grout with ceramic waste
replacement and conventional cement grout were observed throughout the
experiment. Base on finding, the suitable size particle of ceramic waste that gives
optimum result was discussed.
7
Figure 1.1 Ceramic floor and wall tile waste
1.5 Limitation of Study
The limitation in the study is necessary to avoid any waste and undesirable
material or work that may encountered during research progress. In this research,
mainly three materials were used namely ceramic waste, sand and cement. Ceramic
wastes were used come from ceramic industry source which is wall and floor tiles
only. The experimental work focused on physical properties and strength
development of cement grout with ceramic powder for their performance study. The
strength development only focuses on their compressive and flexural behavior. The
cube sample provided for compression test used the 50 mm x 50 mm x 50 mm in
their size rather than 100 mm x 100 mm x 100 mm of sizing. This common size
comply the standard requirement as defined in ASTM C 942 (Compressive Strength
of Grouts). Indeed, cubes of size 50 mm give comparable compressive strength when
compared to the larger cube and wastage of concrete can be avoided. Meanwhile,
8
due to time constraint, the strength development tests of grout were performed up to
40 days. Other unnecessary tests are not carried out in this study.
1.6 Significant Contribution
The results, obtained in the frame of this study, are expected to provide the
information and highlight the contribution of ceramic waste as a substitute for
natural sand to structural concrete field area. Previous study has showed that reuse of
ceramic wastes in construction has improved or provide similar performance as
natural sand without associating with negative effect. Otherwise, the reuse of
ceramic wastes in concrete and grout technology will reduce the consumption of
natural resources and reduce the burden pollutants on the environment. This study
also expected to form basis data for selection of size particle of ceramic waste that
will give optimum performance in engineering properties for cement grout. With
high content of pozzolanic material and non negative effect in grout performance, the
ceramic wastes are hoping to become one of eco-efficient material in grout and
concrete construction for the future.
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85
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