UTILIZATION OF COCONUT SHELL AS FINE AGGREGATE IN ASPHALTIC CONCRETE AC14 NURFATIN AQEELA BINTI MIRON

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1 UTILIZATION OF COCONUT SHELL AS FINE AGGREGATE IN ASPHALTIC CONCRETE AC14 NURFATIN AQEELA BINTI MIRON A project report submitted in partial fulfilment of the requirements for the award of the degree of Master of Engineering(Civil-Transportation & Highway) Faculty of Civil Engineering Universiti Teknologi Malaysia JANUARY 2015

2 iii To my beloved parents for love and support Miron & Asmaliah To all the siblings for pray and motivation Radzi, Nazri, Amin, Hani, Fahmie, Nurul, Muhammad, Syafiq To all the niece & nephew, you are my strength Darwisy, Damia, Dhia, Dhaifullah, Hanis, Hilman, Harraz, Aril To all family members To my supervisor for advice and motivation Dr Ramadhansyah Putra Jaya To my other half Muhammad Raihan bin Samuri To my lab partners Amiera, Hafizah To my UTM s siblings Hayati, Hidayah, Nabiela, Naemah, Najwa To all my friends and colleagues for assists and ear toward this study

3 iv ACKNOWLEDGEMENT In the Mighty Name of Allah, The Most Beneficent, The Most Merciful First and foremost, I am grateful to Allah for giving me the strength and will in completing my research study. Thank you for giving me guidance and courage to complete this Master Project. I would like to express my sincere gratitude to my only parents, Miron bin Taarol and Asmaliah binti Mohd Sahid and also my entire family who give consistent love and support to me during my study. I would like to express my grateful and gratitude to my supervisor, Dr Ramadhansyah Putra Jaya for being the most helpful, understanding, and patient in guiding and advising me in order to finish this Master Project. Apart from that, I am very thankfull to all technicians of Highway and Transportation Laboratory of UTM, Mr Azri, Mr Sahak and Mr Azman for their assistance and helpfulness during laboratory work. Special thanks also to my lab partners, Amiera, Hafizah, Azim and Amirul for their cooperation while doing laboratory work. Besides that, big thank you to my faithful UTM s sibling who have always been there for me and give me their strength toward the completion of this study.

4 v ABSTRAC Many previous studies have been done to carry out the waste material that can use to increase the performance of road pavement. Oil palm kernel shell, scrap tyre, and building waste material are the example of waste material that have been investigate to replace aggregate in road construction. Another alternative is to use coconut shell. Coconut shell is by product from agriculture activity. This study present the laboratory evaluation of aggregate properties on coconut shell and the performance of asphaltic concrete that use coconut shell to replace the fine aggregate. Only AC14 and 80/100 PEN bitumen were consider in this study. The investigations on the aggregate properties containing coconut shell are aggregate impact value (AIV) and specific gravity & water absorption. While, tests for performance of conventional asphaltic concrete AC14 and ACCS are volumetric properties, indirect tensile strength, resilient modulus and dynamic creep test. The result of the test shows that conventional asphaltic concrete AC14 give better volumetric properties than ACCS. For mechanical properties, replacement 10% of coconut shell as fine aggregate (ACCS 10 ) shows better result than conventional asphaltic concrete AC14. Since this pavement has low strength, it will be only suitable for low traffic volume and at rural area. Keywords: Coconut Shell, Asphaltic Concrete, Fine Aggregate, Waste Material

5 vi ABSTRAK Terdapat banyak kajian lampau telah dilakukan terhadap bahan buangan yang boleh digunakan untuk meningkatkan kualiti turapan jalan raya. Tempurung kelapa sawit, tayar sekerap, dan bahan buangan binaan adalah contoh buangan yang telah dikaji untuk menggantikan batu baur dalam pembinaan jalan raya. Alternatif lain adalah dengan menggunakan tempurung kelapa. Tempurung kelapa adalah produk hasil daripada aktiviti pertanian. Kajian ini membentangkan penilaian makmal hartanah agregat pada tempurung kelapa dan prestasi konkrit asfalt yang menggunakan tempurung kelapa untuk menggantikan agregat halus. Hanya AC14 dan bitumen 80/100 PEN yang digunakan dalam kajian ini. Siasatan ke atas sifatsifat agregat yang mengandungi tempurung kelapa adalah nilai hentaman agregat (AIV) dan spesifik graviti & penyerapan air. Sementara itu, ujian untuk prestasi konvensional AC14 konkrit asfalt dan ACCS termasuk perlakuan isipadu, kekuatan tegangan tidak langsung, modulus berdaya tahan dan ujian rayapan dinamik. Keputusan ujian menunjukkan bahawa konvensional AC14 konkrit asfalt menunjukkan sifat volumetric adalah lebih baik daripada ACCS. Bagi sifat mekanik, penggantian 10% daripada tempurung kelapa sebagai agregat halus (ACCS10) menunjukkan keputusan yang lebih baik daripada konvensional AC14 konkrit asfalt. Oleh kerana turapan ini mempunyai kekuatan yang rendah, ia akan hanya sesuai untuk jumlah trafik yang rendah dan di kawasan luar bandar. Kata Kunci: Tempurung Kelapa, Konkrit Asphalt, Agregat Halus, Bahan Buangan

6 vii TABLE OF CONTENTS CHAPTER TITLE PAGE DECLARATION OF THESIS STATUS SUPERVISOR S DECLARATION 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 APPENDICES xiii 1 INTRODUCTION Introduction Problem Statement Objective of Study Scope of Study Significant of Study 4

7 viii 2 LITERATURE REVIEW Introduction Flexible Pavement Bitumen Binders Aggregates Size of Aggregates Grading of Aggregates Coconut Shell Application of Coconut Shell in Civil Engineering Waste Material Used as Aggregates in Road Construction 14 3 METHODOLOGY Introduction Operational Frame Work Preparation of Coconut Shell as Aggregate Aggregate Separation Aggregate Properties Testing Aggregate Impact Value Specific Gravity and water Absorption Theoretical Maximum Density (TMD) Asphalt Concrete Properties Testing Marshall Mix Design Marshall Test Analysis of Air Void in the Compacted Mix (VTM) Voids Filled with Bitumen (VFB) Flow and Stability Test Determination of Optimum Bitumen Content (OBC) Indirect Tensile Strength Resilient Modulus Dynamic Creep Test 43

8 ix 4 RESULT AND DATA ANALYSIS Introduction Aggregates Sieving Properties of Aggregate Analysis Theoretical Maximum Density Marshall Test Analysis Determination of Optimum Bitumen Content Result of Volumetric Properties Density Analysis Voids in Total Mix Analysis Voids Filled with Bitumen Analysis Stability Analysis Flow Analysis Stiffness Analysis Indirect Tensile Strength Analysis Resilient Modulus Analysis Dynamic Creep Test Analysis 57 5 CONCLUSION AND RECOMMENDATION Introduction Conclusions Recommendation 61 REFERENCES 62 Appendices A-H 64

9 x LIST OF TABLES TABLE NO. TITLE PAGE Table 2.1 Sieve designation 11 Table 3.1 Gradation limit for AC14 (JKR, 2008) 20 Table 3.2 Mixing and compaction temperatures (ASTM D1559) 33 Table 3.3 Test and analysis parameters (JKR, 2008) 39 Table 4.1 Aggregates testing results 47 Table 4.2 Marshall test result for obtaining OBC 48 Table 4.3 Volumetric properties of AC14 and ACCS 49

10 xi LIST OF FIGURES FIGURE NO. TITLE PAGE Figure 2.1 Load transfer for flexible pavement 6 Figure 2.2 Layers of flexible pavement 7 Figure 2.3 Five grading aggregates 11 Figure 2.4 Coconut shell 13 Figure 2.5 Coconut shell as aggregates 13 Figure 3.1 Flowchart of Methodology 18 Figure 3.2 Coconut shell being crush using aggregate crushing value 17 Figure 3.3 Figure 3.4 Graphical gradation limit of asphaltic concrete AC14 (JKR,2008) Specimen was compacted by 25 strokes of the tamping rod Figure 3.5 Specimen was subjected to 15 blows 23 Figure 3.6 Fine aggregate was immersed in 6% of moisture 25 Figure 3.7 Fine aggregate retain the molded shape 25 Figure 3.8 Coconut shell immersed in water 27 Figure 3.9 Sample after dried in oven 27

11 xii Figure 3.10 Sample during vacuum and agitation for 15 ± 2 min 30 Figure 3.11 Compaction hammer that being used 32 Figure 3.12 During cooling process 36 Figure 3.13 Loading strips are parallel and centered on the vertical diametral plane 41 Figure 3.14 Vertical compressive ramp load was applied 41 Figure 4.1 Effect of different percentage coconut shell to density 50 Figure 4.2 Figure 4.3 Effect of different percentage coconut shell to voids in total mix Effect of different percentage coconut shell to voids filled with bitumen Figure 4.4 Effect of different percentage coconut shell to stability 53 Figure 4.5 Effect of different percentage coconut shell to flow 54 Figure 4.6 Effect of different percentage coconut shell to stiffness 55 Figure 4.7 Figure 4.8 Figure 4.9 Effect of different percentage coconut shell to tensile strength Effect of different percentage coconut shell to resilient modulus at different test temperature Effect of different percentage coconut shell on creep modulus

12 xiii LIST OF APPENDICES APPENDIX TITLE PAGE A Distribution of Mass Aggregate of AC14 66 A1 Amount of coconut shell being replaced according to their percentage 66 B Aggregate Properties Test Result 67 C Theoretical Maximum Density for Marshall Test 70 C1 D Theoretical Maximum Density for Volumetric Properties for ACCS Marshall Test Analysis Result for Determining the Optimum Bitumen Content (OBC) D1 Graphical for Determining the Optimum Bitumen Content (OBC) 73 E Volumetric Properties for Asphaltic Concrete Containing Coconut Shell (ACCS) 74 F Indirect Tensile Strength Test Result 75 G Resilient Modulus Test Result 76 H Dynamic Creep Modulus Test Result 77

13 CHAPTER 1 INTRODUCTION 1.1 Introduction Malaysia is a country which economic growth rapidly. Therefore, Malaysia must have good roadway and transportation to cater the demand on the road. There have many factors that can give good highway such as material used to construct the road, road furniture, infrastructure and drainage. Basic materials that being used in road pavement construction for wearing course are aggregates, bitumen and filler. Aggregate is the main material that makes up about 93% of the mix. The strength is resulted from the interlocks between the aggregate and assist to distribute loads from the traffic in the pavement. While, bitumen or known as asphalt is a binder to glue the aggregate together to form an improved mix. Next, filler will fill the voids between aggregate and helps stiffening the binder to produce a stronger and stiffer mix could last longer. Nowadays, there are so many researches that has been done to improve and upgrading the materials for preparing hot mix asphalt. The utilization of waste

14 2 material as a replacement in materials for producing hot mix asphalt can give a lot of benefit to the humans. Coconut shell is a one of the alternative that can be used to replace aggregate in preparing a flexible pavement. Coconut is grown in more than 93 countries. South East Asia is regarded as the origin of coconut (Maninder and Manpreet, 2012). India is the third largest, having cultivation on an area of about 1.78 million hectares. Annual production is about 7562 million nuts with an average of 5295 nuts per hectare. The coconut industry in India accounts for over a quarter of the world's total coconut oil output and is set to grow further with the global increase in demand. However, it is also the main contributor to the nation's pollution problem as a solid waste in the form of shells, which involves an annual production of approximately 3.18 million tones. Coconut shell represents more than 60 % of the domestic waste volume. Coconut Shell, which presents serious disposal problems for local environment, is an abundantly available agricultural waste from local coconut industries. In developing countries where abundant agricultural and industrial wastes are discharged, these wastes can be used as potential material or replacement material in the construction industry. This will have the double advantage of reduction in the cost of construction material and also as a means of disposal of wastes. 1.2 Problem Statement The construction of a local two-lane highway consumes more than 15,000 tonnes of aggregates per kilometer while six-lane asphalt freeway consumes over 48,000 tonnes of aggregates for each kilometer of roadway (Khabiri, 2010). These facts show that the demand of the natural aggregate is very high. Furthermore, aggregates are not only use for new construction, but also in maintenance process like reconstruction and rehabilitation. Since of that, more hills have been

15 3 exhaustingly exploited to get natural aggregate. However, should be known that aggregates are finite natural sources in which shortage of aggregates will occur because of depletion of sources. As a result, other resources of aggregates need to be searched and more cost is needed. Therefore, others waste material can be used to replace natural aggregate and also to save the environment. Coconut milk which produces from coconut meat is needed to produce good and quality taste of food in Malaysia. After the coconut meat are taken, coconut shells being useless. Then, it will increase the generation of coconut shell. These coconut shells will be dispose at their backyard (by burning) or throw it at the landfill area and it will increase the environmental problem. Besides of dispose it, coconut shell also can be used to replace natural aggregate in the construction of wearing course. It is one way to sustain our environment and world. 1.3 Objective of Study The study on utilization of coconut shell as fine aggregate in asphaltic concrete AC14 have some objective as the guideline for the overall study which are: To investigate the performance of AC14 containing coconut shell, To determine the optimum percentage of coconut shell as fine aggregate in asphaltic concrete.

16 4 1.4 Scope of Study All the samples are prepared in accordance with the JKR specifications (JKR/SPJ/2008) using Marshall design procedures. This study was focus on the performance of coconut shell as aggregate in asphaltic concrete with 14mm nominal aggregate size. The size of coconut shells that being used was retained on 3.35mm. Coconut shells that replace aggregate are 10%, 20%, 30% and 40%. This study used standard penetration grading which is PEN and only use one optimum bitumen content (OBC) for all the samples include the sample which have coconut shell as fine aggregates replacement (ACCS). Value OBC is following the result of conventional sample OBC. Coconut shell was added in the mixes by using dry process method where the coconut shell was added as part of the aggregate component before it was mixed with asphalt cement. Marshall test was done to give the volumetric properties of each mix design. Besides, resilient modulus test, dynamic creep test and indirect tensile strength test was conducted to identify the best percentage of coconut shell that can be replace in asphaltic concrete Significant of Study From this study, the feasibility and performance of AC14 using coconut shell as fine aggregate replacement can be obtained. Marshall samples will determine with JKR specification either the mixes meet the specification or not. Coconut shell samples will be compare with natural aggregate based on their performance and then determine the best application for that performance. The coconut shell production can generate money by producing it for highway material construction. It also can reduce the cost for dumping area to dispose the agriculture waste like coconut shell.

17 REFERENCES American Society for Testing and Materials (2012). Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate. Philadelphia, ASTM C American Society for Testing and Materials (2012). Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Fine Aggregate. Philadelphia, ASTM C American Society for Testing and Materials (2012). Standard Test Method for Indirect Tensile (IDT) Strength of Bituminous Mixtures. Philadelphia, ASTM D American Society for Testing and Materials (1995). Standard Test Method for Indirect Tension Test for Resilient Modulus of Bituminous Mixtures. Philadelphia, ASTM D (Reapproved 1995). American Society for Testing and Materials (2006). Standard Test Method for Marshall Stability and Flow of Bituminous. Philadelphia, ASTM D American Society for Testing and Materials (1992). Standard Test Method for Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus. Philadelphia, ASTM D American Society for Testing and Materials (2011). Standard Test Method for Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures. Philadelphia, ASTM D2041/ D2041M-11. B.Damodhara Reddy, S.Aruna Jyothy, Fawaz Shaik (2014). Experimental Analysis of the Use of Coconut Shell a Coarse Aggregate. British Standard (2010). Bituminous Mixtures Test Methods for Hot Mix Asphalt Part 25: Cyclic Compression Test. BS EN rev 2013.

18 63 British Standard (2010). Testing Aggregate Part 2: Method for Determination of Aggregate Impact Value (AIV). BS EN :2010. Coconut Research Centre (2014). Coconut (Cocos Nucifera). Retrieved from E.A. Olanipekun, K.O Olusola, O. Ata (2005). A Comparative Study of Concrete Properties Using Coconut Shell and Palm Kernel Shell as Coarse Aggregates. Building and Environment 41 (2005) JKR (2008), Standard Specification for Road Works Section 4: Flexible Pavement. Khabiri, M. M (2010). The Influence of Waste Construction Materials Usage on Highway Subbase Layer. Electronic Journal of Geotechnical Engineering. 15: Maninder Kaur, Manpreet Kaur (2012). A Review on Utilization of Coconut Shell as Coarse Aggregates in Mass Concrete. Research India Publications. Mohd Rosli Hainin, Che Ros Ismail, Haryati Yaacob (2013). Highway Engineering. Desktop Publisher. Ramesh Gavva, Kasarla Shanthan (2013). Behavior of Reinforced Concrete Beams with Coconut Shell as Coarse Aggregates. Retrieved from Teoh Cherh Yi (2008). Performance Evaluation of Steel Slag as Natural Aggregates Replacement in Asphaltic Concrete. Vietnam National Administration of Tourism (2013). Restored Historic Houses to be Journey Back in Time for Tourist. Retrieved from