CHAPTER 1

THE PROBLEM AND ITS SCOPE

1.1 RATIONALE

In a fast paced growing economy, many developments can be witnessed from

technology, education and construction. Various innovations and inventions came up to alter
and contribute to these changes. In construction a lot of new materials were introduced
overtime. Many were innovatively engineered and others were carefully examined and
introduced in order to speed up the construction industry.
These new materials made the possibilities to enhance performance, time
implementation and improve aesthetics. From foundation to finishes, these materials made
difference. There were also widely and typically used materials that through time were
carefully improved and enhanced specifically the partitioning materials and systems in the
construction. Materials such as 3D panels, fabricated walls and others made a big leap of
difference in the construction industry.
Segregation and disposal of waste materials is becoming a major problem in the
society right now. Having this continuously increasing amount of waste materials can lead to
pollution and can harm the environment. That is why recycling of waste materials is very
important nowadays because it can help the environment by reducing pollution and
preventing contamination of the surroundings. It is also very economical to produce a new
product from recycled waste material.

The problems of wastes contribute to the challenges in the growing economy. Among
the wastes that have a potential as recyclable material is the Acetylene Production Waste. It
is the purpose of the researchers to venture and carefully study this waste material to be
incorporated with the common construction material, the CHB. Acetylene Production Waste
or scientifically known as Calcium Hydroxide (traditionally called slake lime), is a white
powder and an inorganic compound material. Calcium Hydroxide is inexpensive and its
availability is limitless to the extent that some of it will just go to waste. This research
recognizes the potential of the Acetylene Production Waste as a fine aggregate, in
combination with natural sand, in the production of hollow concrete masonry units. The aim
of this study is to investigate the adequacy and advantages of a Concrete Hollow Block
containing Acetylene Production Waste, in combination with sand as a fine aggregate.

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 The proponents noticed that having an increasing amount of Calcium hydroxide
becoming a waste material can be a problem in the future in terms of storage and disposal.
That is why the proponents seek to find a better way to reuse this waste material as a
component in Concrete Hollow Block production. The researcher would like to determine if
the CHB will increase its strength if it has Calcium Hydroxide.
With this, the researcher intend to discover if this waste material to be integrated and
used as an additive or additional component of CHB will improve the properties of the said
material. The study is mainly to utilize the waste product of acetylene so that it would not
become trash. With this recycled material the concrete hollow block would have less sand to
be used and it may strengthen the CHB. This introduces our proposal entitled Concrete
Hollow Block integrated with Acetylene Production Waste as Substitute to Fine Aggregates.

1.2 STATEMENT OF THE PROBLEM

The purpose of the study is to determine if Acetylene Production Waste is effective in

improving the strength of CHB. Certain tests will be done to see if the CHB is load bearing
or non-load bearing. The cost effectiveness of the materials in this method of making a CHB
will be assessed. This study intends to investigate the compressive strength of a 6 x 8 x 16
Concrete Hollow Blocks containing Acetylene Production Waste. In relation to the proposed
CHB material, this study aims to answer the following questions:

Will Acetylene Production Waste enhance the properties of the CHB if to be used as
substitute for portion of sand?
Will the production of CHB mix with Acetylene Production Waste be feasible in relation to
the massive demand and will it compete with the commonly known and used CHB?
Will the CHB mix with Acetylene Production Waste be classified as load bearing material?

These are some of the statements intended to be answered as the study progresses.
The proponents seek to acquire results to support and justify the above statements.

1.3 OBJECTIVES

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 The proposed study entitled Concrete Hollow Block integrated with Acetylene
Production Waste as Substitute to Fine Aggregates will provide constructive information and
design to aid in the understanding together with the properties and conventional procedure in
the production which will then result to an enhanced property of CHB.

The proponents aim in choosing this particular topic is to help the people involved in
construction materials to learn a new approach on how to reuse Acetylene Production Waste
material. This will give some insights if Acetylene Production Waste can be an improvement
property when mixed in a Concrete Hollow Block. On one hand, this will help reduce the
increasing amount of Acetylene Production Waste. This study aims to lessen the cost of
producing a concrete hollow block.

1.4 SCOPE AND LIMITATIONS

This study aims to accomplish the proposed topic with the following scope:
Materials
That this study will use the typical component of CHB (Cement, gravelly sand and water) and
the addition of Acetylene Production Waste material as part of the gravelly sand portion to
maximize the disposal of Acetylene Production Waste.
The proponents will use the Acetylene Production Waste as part of a fine aggregate, to be
combined with gravelly sand, in the production of hollow concrete masonry units.
Production
That this study will produce samples for testing and gather sufficient data.
Construction
That this study will provide information as additional source of construction material at the
same time help in waste recycling resulting in reduction in products cost.
With the above intentions, this study is limited to the availability of the materials
mentioned, and the chemical properties of the Acetylene Production Waste. The number of
samples to be produced is sufficient for testing and the cement types to be used are limited to
Portland and Pozzolan cement. In this project, the proponents do not know whether the
Concrete Hollow Block mixed with Acetylene Production Waste will have a greater strength
compared to the ordinary Concrete Hollow Block. Answers will be provided after the

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completion of this study. The proponents will also find out whether the Concrete Hollow
Block mixed with Acetylene Production Waste will be a load bearing or non-load bearing
material.

1.5 SIGNIFICANCE OF THE STUDY

The study would benefit the following:
To the Civil Engineering students who have study similar or related to this that they
may acquire additional and useful references.
To the Civil Engineering Instructors that they may use the content of this study for
their instructional purposes and references.
To the Professional Engineers that they may acquire additional information with
regards the use of Acetylene Production Waste as substitute to sand in CHB production.
To the Manufacturers of acetylene who consider the Calcium Hydroxide as waste that
they may be aware of the use of the said waste material.

1.6 DEFINITION OF TERMS

Acetylene is a colorless, flammable, explosive gas used as a fuel in welding and
cutting metals and a raw material for many organic compounds and plastics
Calcium Hydroxide Ca(OH)2 is an inorganic compound which is a colorless crystal
or a white powder.
Cement is a binder, a substance that sets and hardens independently, and can bind
other materials together.
Concrete Hollow Block (CHB) is widely used in construction industry all over the
world. It is a precast masonry unit concrete blocks with suitable size to be used for load
bearing and non-load bearing units. Concrete Hollow Blocks are usually used for external and
inter walls above or below ground, and partitions for buildings.
Engineer is a professional practitioner of engineering, concerned with
applying scientific knowledge, mathematics, and ingenuity to develop solutions for technical
problems. Engineers design materials, structures, and systems while considering the
limitations imposed by practicality, regulation, safety, and cost.
Fine Aggregates is a portion of the aggregate used in concrete that is smaller than
about 3/16 inch.

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 Hydrated Cement is a chemical combination of cement and water.
Material Transport Properties is a property of a compound or material associated
with mass or heat transport.
Oxyacetylene is a mixture of oxygen and acetylene.
Portland is the most common type of cement in general use around the world, used as
a basic ingredient of concrete, mortar, stucco, and most non-specialty grout. It usually
originates from limestone.
Pozzolan is a siliceous and aluminous material which, in itself, possesses little or no
cementitious value but which will, in finely divided form and in the presence of water, react
chemically with calcium hydroxide at ordinary temperature to form compounds
possessing cementitious properties (ASTM C618).
Super Hydrophilic is a surface which is extremely wettable by water.

CHAPTER 2
REVIEW OF RELATED LITERATURE

2.1 ACETYLENE PRODUCTION

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 The demand in production of acetylene in foreign countries continues to increase as
the economy rises. The production of acetylene in the six principal capitalist countries
increased from 1476 to 2036 thousand tons during the period 1960-1965. The world
production of acetylene was approximately 3 million tons in 1965, which 0.8 million tons
were made from hydrocarbon feedstock and 2.2 million tons from calcium carbide (Yu. Ya.
Turov and G. A. Parshina).
According to the American Chemical Society, Acetylene, when burned with oxygen
gave a flame that was 1000C hotter than any other, leading to the development of
commercial oxyacetylene welding and cutting. Friedrich Wohler discovered the production
of acetylene and calcium hydroxide. The reaction of calcium carbide with water is:
CaC2 + 2 H2O C2H2 + Ca(OH)2;
C2H2 is the acetylene gas while Ca(OH) 2 is the calcium hydroxide. Our study focuses on how
to reuse calcium hydroxide which is a waste product from the production of acetylene gas
from a calcium carbide reaction.

2.2 CALCIUM HYDROXIDE

The partial pressure of water in equilibrium with calcium hydroxide reaches 101 kPa
when heated to 512C (Halstead, P.E., Moore, A.E. (1957)). Calcium Hydroxide or also
known as slaked lime has wider use in the oil processing industry for the production of
greases and additives for mineral oils. However calcium hydroxide is produced as an
intermediate and cannot be employed in the oil processing industry because its quality does
not conform to industrial requirements (V.I. Bystrov, F.S. Nisengolts, and G.P. Sobolev).
Because of its large scale production, calcium hydroxide has also large scale applications
such as flocculant in water and sewage treatment; an ingredient in whitewash, mortar, and
plaster; also in road construction and many more.
Because of large scale production of acetylene gas which results to large amount of
waste calcium hydroxide, it is easily handled, and it is also cheap. The use of calcium
hydroxide as substitute of fine aggregates in the production of concrete hollow blocks may be
a possibility so that disposal will not be a problem and also it offers an environmentally
responsible and economically viable sustainable route.

2.3 CALCIUM HYDROXIDE IN CEMENT

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 The influence of calcium hydroxide on the fresh mortar properties varies according to
the form and structure and chemical characteristics of the raw material. There have been no
sufficient scientific results until now to describe the parameters of calcium hydroxide that
modify the plasticity in mortar systems (Deborah Klein, Sonja Haas, Sven-Olaf Schmidt, and
Bernhard Middendorf).
According to Jacques Marchand, Dale Bentz, Eric Samson, and Yannick Maltais,
calcium hydroxide is one of the main reaction products resulting from the hydration of
Portland cement with water. The three researchers investigated the influence of calcium
hydroxide dissolution and its effect on the diffusion properties of hydrated cement.
Numerical simulations clearly indicate that calcium hydroxide dissolution contributes to a
marked increase in the porosity of the hydrated cement paste. This increase in porosity has a
harmful influence on the material transport properties. Dr. Jeff Thomas and Dr. Hamlin
Jennings (both from Northwestern University, Evanston, IL) noted that Calcium Hydroxide
contributes slightly to the strength and impermeability of the cement paste, because it reduces
the total pore volume by converting some of the liquid water into solid form. Calcium
Hydroxide is a weak link in cement and concrete from a durability point of view because it is
the most soluble of the hydration products. Calcium Hydroxide will dissolve if the cement
paste is exposed to fresh water, increasing the porosity and thus making the paste more
vulnerable to further leaching and chemical attack. Calcium Hydroxide can limit the amount
of shrinkage that occurs when a cement paste is dried.
According to Mindess et al from Voigt and S.P. Shahs study, calcium hydroxide
which is also referred to as Portlandite, is a major component of the hydration products and
occupies about 20% to 25% of the solid volume of cement paste. The amount of Calcium
Hydroxide held in cement paste at a given time is widely regarded as a measure of the degree
of hydration of that material. El-Jazairi and Illston have shown that the content of calcium
hydroxide and non-evaporable water follow very similar trends during the course of
hydration. Researchers Eleonore Gueit, Evelyne Darque-Ceretti, Patrick Tintillier, and
Matthieu Horgnies proposed an innovative way to protect high-performance concrete which
exhibits very smooth surface with low porosity by surfacing based on Calcium Hydroxide.
With the adequate surface-active substance used, Calcium hydroxide closes the porosity,
reduces the water uptake, and gives the surface super-hydrophilic properties, facilitating self
cleaning mechanism. Given this background that cement already contains a certain amount

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of calcium hydroxide and it also reduces the porosity of the concrete, it will be of interest the
effects of calcium hydroxide as a substitute to fine aggregates in making a concrete hollow
block. Our study will not vary the chemical reaction of Calcium Hydroxide to cement but to
investigate the effects of a fine aggregate mixed with Calcium Hydroxide in making Concrete
Hollow Blocks and might have different results from a conventional Concrete Hollow Block.

2.4 CONCRETE USING INDUSTRIAL WASTES

The use of recycled aggregate in concrete industry has a great potential to reduce
demand for natural aggregate and the amount of solid waste dumped at landfill sites. There
are a lot of studies that focused in recycling industrial wastes for construction purposes such
as glass, plastics, fly ash and many more. These waste materials continue to grow as the
economy rises and the problem of storage and disposal are also increasing. That is why many
researchers proposed an innovative way on how to dispose or reuse these materials to help
the environment.
The study of A. Shasavandi, F. Pacheco-Torgal, Said Jalali quoted: The production of
Portland cement as the essential constituent of concrete requires a considerable energy level
and also releases a significant amount of chemical carbon dioxide emissions and other
greenhouse gases into the atmosphere. Global demand will increase almost 200% by 2050
from 2010 levels. Thus, seeking an eco-efficient and sustainable concrete may be one of the
main roles that construction industry should play in sustainable construction. The aggregates
are conserved by replacing them with recycled or waste materials among which recycled
concrete, ceramic waste, post-consumer glass, and recycled tires are the most used.
Rafat Siddique also investigated the effects of fine aggregate replacement with Class
F fly ash on the mechanical properties of concrete which resulted to significant improvement
in the strength properties of plain concrete and can be effectively used in structural concrete.
Aggregates are considered to have the largest part of the concrete volume and so it plays as
essential role in almost all concrete properties such as workability, strength, dimensional
stability, and durability. Several waste materials have been studied to be used as aggregate in
concrete. The use of waste as aggregates can consume vast amounts of waste materials as this
is the major component of cement mortar and concrete (Jorge de Brito, Nabajyoti Saikia).
Given this information of reusing industrial waste materials, Calcium Hydroxide is
also a waste material from acetylene production and is causing a problem of disposal of this

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certain waste material. This material may be a potential substitute of fine aggregates in
Concrete Hollow Block production.
In using waste materials in the construction industry, W. Gutt D. Sc., et al states that
the most influential factor in determining whether or not a waste material or by-products used
is the economic cost in comparison with the alternative natural material in a particular
application. These costs are primarily made up by handling, processing and transport but the
social benefits of using a waste, should not be forgotten. It is essential to have an adequate
knowledge of the properties of the waste materials and products containing them to allow fair
judgment on the overall desirability of using a waste material in a particular situation.

2.5 CONCRETE HOLLOW BLOCK

2.5.1 BRIEF HISTORY
According to the Concrete Masonry Association of Australia, masonry
construction is one of the oldest forms of construction used by man. During the nineteenth
century, the hydraulic cement was being developed and the concrete masonry has also
evolved. In 1900, a number of machines for making blocks began to appear in the United
States. Although the early blocks were much the same height and thickness as the largest
sizes now made, they were up to twice as long and therefore correspondingly heavier and
difficult to handle. The early machines could make only about two hundred blocks per ten-
hour day with three men. Between 1914 and 1924, power tamping replaced hand tamping,
improving density, strength and uniformity.
2.5.2 MIX DESIGNS FOR CONCRETE BLOCK
Neal Jablonski stated that an important step in producing high-quality units
was by proportioning the mix components for a concrete masonry unit. The physical
property (compressive strength, unit weight, absorption) of a masonry unit can be improved if
it has a well-proportioned mix so that it can meet or exceed ASTM C 90 Standard
Specification for Load-Bearing Concrete Masonry Units. It can also improve the durability
and appearance of the masonry unit if it has a well-proportioned mix.
According to Chris Cavette of A. Sabandal et al research, Concrete Hollow Block is
produced by mixing Portland cement, gravely sand and water. The mix should contain more
gravel content than cement for general purposes. In this mix, the block can weigh from 38-43
lb or 17.2-19.5 kg.

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 Concrete Hollow Blocks are manufactured using the following ingredients: (a.)
Cement, which gives the block its strength; (b.) Aggregates, in the form of sand and stones
are used main ingredient in block production. Sand and stone are fragments of rock and
differ only in size. Sand particles will pass through a sieve with 4.75-mm square openings. A
blend of coarse sand and fine sand, blend of fine sand and stone, or a blend of fine sand,
coarse sand and stone may be used; (c.) And finally Water that is fit for drinking is also
suitable. Most river and borehole water may be used.
The strength of well cured blocks depends on aggregate:cement ratio, degree of
compaction, and type (solid or hollow) and size of block. The degree of compaction depends
on overall grading of the aggregates, particle shape of aggregates, aggregate:cement ratio,
water content, and compactive effort.
The water content of the mixture is critical. The mixture must be wet enough to bind
together when compacted, but it should not be so wet that the blocks sag when the mould is
removed. The moisture content should be as high as possible as this allows better
compaction and thus gives the best strength. For machine mixing, the aggregate is first
mixed and then the cement. Water is added gradually while mixing until water content is
correct.
The mould of a powered machine should be filled until approximately six to eight
cycles of compaction are required to bring the compacting head to its stop. Too little or too
poor compaction should be avoided as it results in greatly reduced strengths. Removal of the
mould should be done carefully so that the fresh blocks are not damaged. Fresh blocks
should be protected from rain (with plastic sheets or any suitable covering) and from the
drying effects of the sun and wind until curing starts.
Curing is the process of maintaining satisfactory moisture content and a favorable
temperature in the blocks to ensure hydration of the cement and development of optimum
strength. Three aspects should be monitored to ensure quality masonry units. First is the
Strength, to avoid breakages, quality of blocks should be controlled so that strengths are
adequate and mixes are as economical as possible. Second is Dimension, the height can vary
the quality of blocks. It should be monitored using a simple gauge. Units of inconsistent
height lead to difficulties in the construction of masonry and possible rain penetration. Third
is Shrinkage, in order to avoid shrinkage blocks should be allowed to dry out for at least

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seven days after curing and before being used for construction (Cement and Concrete
Institute).
According to Berg (2007) of A. Sabandal et al research, quality of the concrete hollow
blocks requires constant monitoring to produce its satisfactory properties. It would greatly
affect the strength and form of the block if there are errors during mixing. According to the
American design code (Masonry Standard Joint Committees Building Code Requirements
and Specification for Masonry Structures (TMS 402/ACI 530/ASCE 5)) that guides design
engineers in using CMU as a structural system, the compressive strength of a concrete hollow
block varies from approximately 1,000 psi (7MPa) to 5,000 psi (34 MPa) based on the type of
concrete used to manufacture the unit, and other factors. The compressive of the concrete
hollow block is affected by the type of mortar used, workmanship and curing.

2.6 HEALTH IMPLICATIONS OF CALCIUM HYDROXIDE

According to U.S, Department of Health and Human Services, exposure to Calcium
Hydroxide may occur through inhalation, skin contact, and ingestion. Calcium Hydroxide is
the most common causes of corrosive chemical eye burns. Direct contact on skin may cause
skin irritation and may also lead to corrosive chemical burns (Grant 1986; Clayton and
Clayton 1981) According to NLM 1992; the degree of damage is directly related to the
degree and duration of exposure of Calcium Hydroxide. Eye exposure may lead to tissue
destruction and blindness.

CHAPTER 3
METHODOLOGY AND PROCEDURES

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3.1 PROJECT FLOW
The study would be done according to the procedure and the guidance of our adviser.
Some of the material testing would be done are: Organic Impurities in sand; Specific
Gravity and Absorption of Aggregates; Sieve Analysis; Amount of Material Finer than no.
200 Sieves in Aggregates; Unit Weight of Aggregates; Bulking in Sand; Normal
Consistency; Time Setting of Portland Cement; Percent of Calcium Hydroxide in Acetylene
Production Waste.

3.2 REASERCH PROCEDURE

The concrete hollow block would be designed as 1 cement and 7 sand ratio. Part ratio
of the sand would be substituted with Acetylene Production Waste specifically , and of
the sand ratio shall be replaced with Acetylene Production Waste. Also, concrete hollow
block would be designed as 1 cement and 7 Acetylene Production Waste ratio.

3.3 DATA GATHERING

Data and other important information shall be provided by Calcium Hydroxide-
Acetylene Company located in Cebu. Other important information shall be gathered from
chemical testing and experiment of materials needed for the study.

3.4 MATERIAL GATHERING

The materials would be Portland and Pozzolan cement, Toledo sand, clean water and
Acetylene production waste which would be taken from Cebu Fortune Gas Inc., Sitio Tambis,
Plaridel St., Umapad, Mandaue City.

3.5 PERCENT OF CALCIUM

This procedure would be done in the USC TC Water Laboratory located at the 3 rd
floor of Bunzel Building.

3.6 ORGANIC IMPURITIES IN SAND (ASTM Designation: C40-33)

About 500 g of fine aggregates were obtained by method of quartering. A 12 oz.
graduated clear glass bottle was filled with the fine aggregates to be tested up to 4 oz.

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mark. A 3 percent solution of sodium hydroxide was added in water. The bottle was shaken
vigorously and let it stand for 24 hours. The color of the liquid on top was compared to the
reference color solution or the color chart.

3.7 SPECIFIC GRAVITY AND ABSORPTION OF AGGREGATES (ASTM Designation:

C128)
As specified in the Materials Testing Laboratory Manual, the procedures in
determining the specific gravity of fine aggregates were done accordingly:
A kilo of fine aggregates taken from method of quartering was obtained. The
sample was placed in a pan and covered with water and allowed to stand for
24 hours.
After the sample was brought to a saturated surface dry condition,
approximately 500 g of the SSD fine aggregate was taken and the exact weight
was recorded.
The specific gravity bottle was filled with water up to 800 ml mark and the
weight of the bottle plus water was then recorded.
About 200 ml of water was retained from the specific gravity bottle and the
SSD fine aggregate was added into the bottle. Enough water was added to
establish the level to about 450 ml mark.
A flask was rolled on a flat surface to eliminate entrapped air before finally
adding more water up to 800 ml mark as before. The weight of saturated
aggregate plus water plus specific gravity bottle was recorded.
The contents of the bottle was poured in a pan and placed inside the oven. The
oven dry weight was obtained after 24 hours and recorded as (A).
The specific gravity and absorption was obtained by the following formulas:

a.) Apparent Specific Gravity

b.) Bulk Specific Gravity (Dry)

c.) Bulk Specific Gravity (SSD)

d.) Absorption

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3.8 SIEVE ANALYSIS (ASTM Designation: C136)
A kilo of sand would be oven dried. The sieve that would be use would be weight.
The sieves that would be use are 3/8, no.4, no.8, no.10, no.16, no.30, no 40, no.50, no.60,
no.70, no.100 and the pan. It would be piled from largest to smallest and the base would be
the pan. The aggregates are place at the very top which compose of the largest hole. The
sieves would be place in the sieve shaker for 10 minutes. The sieves are carefully weighted
and the retained would be compute.

3.9 AMOUNT OF MATERIAL FINER THAN NO. 200 SIEVES IN AGGREGATES

(ASTM Designation: C117-13)
The sample was placed in the oven and dried to constant weight at a temperature not
exceeding 110C, the weight was then recorded. After the oven dry, the sample was placed in
a pan and sufficient amount of water was added to cover it. The wash waster was poured
over the nested sieves with the sieve No. 200 at the bottom and the contents of the pan were
agitated vigorously and until the wash water was clear. The washed aggregates were then
dried to constant weight temperature not exceeding 110C, and the weight was then recorded.

3.10 UNIT WEIGHT OF AGGREGATE (ASTM Designation: C29)

About 2 kilos of sand is air dried, the cylindrical metal measure would be 1/3 filled
and tamp with 25 strokes then 2/3 filled tamp with 25 stokes and lastly overflow tamp with
25 strokes. The weight of the compacted sand in the metal measure would be determined.
The unit weight would be solved.

3.11 BULKING IN SAND

The beaker was filled with dry sand without shaking or tamping and the weight of the
beaker plus sand was then recorded. The sand was then poured out to the mixing pan and 2
percent of water was added by weight, it was mixed thoroughly and poured back into the
beaker. Adding increment of water was continued until sand will not retain more.
3.12 NORMAL CONSISTENCY (ASTM Designation: C187-98)
A 500-gm sample of cement was placed on a smooth non-absorbent surface and a
crater was formed at the center. A measured quantity of clean water was poured into the

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crater, and the cement on the outer edge shall be turned into the crater within 30 seconds.
After additional interval of 30 seconds for the absorption of water, during which interval the
dry cement around the outside of the cone was lightly troweled over the remaining mixture to
reduce the evaporation losses and to promote absorption, the operation was completed by
continuous, vigorous mixing, squeezing, and kneading with the hands for 1 minutes.
The cement paste was quickly formed into a ball and tossed six times from one hand
to another. The ball resting in the palm of one hand was pressed into the larger end of the
conical ring. The ring was placed on a glass plate and the excess paste was sliced off by a
single oblique stroke of a sharp edge trowel.
The paste in the ring was centered under the rod, the plunger end was brought to
contact with the surface of the paste, with the set screw tightened. The movable indicator
was set to upper zero mark of the scale. The rod was released 30 seconds after the
completion of mixing. The paste was in normal consistency when the rod settled to a point
10mm 1mm below the original surface in 30 seconds after being released.

3.13 TIME SETTING OF PORTLAND CEMENT (ASTM Designation: C191-08)

The preparation of the cement paste was the same as the preparation of the cement
paste for the normal consistency test. The moulding of the test specimen was also the same
as the normal consistency procedure.
With the use of Vicat Apparatus, the needle of the rod was lowered until it rests on top
of a portion of the glass plate which projects beyond the ring. The adjustable indicator was
then set to zero mark of the scale. The needle was carefully brought in contact with the
surface of the paste and the rod was quickly released. The initial set was secured when the
needle ceases to pass a point 5 mm above the glass plate in 30 seconds after being released.
The final set was when the needle does not sink visible into the paste.

3.14 CHB PRODUCTION

Certain amount of cement and gravelly sand was mixed. Water was added gradually
while mixing until water content is correct. The mixture was poured into the mould of the
CHB machine and was compacted up to 8 blows while the CHB machine was still vibrating.
The CHB was unmolded, piled accordingly. For the CHB design mix, refer to
Appendix A (Proposed CementSandAcetylene Production Waste CHB Mix)

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 3.15 CURING OF CHB
The concrete hollow block would be covered with plastic in a specified area so that
the temperature would be monitored. The pouring of water would be scheduled in the
morning and afternoon.

3.16 SATURATED SURFACE DRY

A day before the testing of the CHB, 1 sample of each design mix was soaked in
water. After 24 hours of soaking, the CHB was surface dried and was weighed in air using
digital scale, and was weighed in water using the heavy duty solution balance. It was then
oven dried for another 24-hour. After oven drying, it was weighed in the digital scale.

3.17 COMPRESSIVE STRENGTH OF CHB (ASTM Designation: C140)

The samples were brought to the laboratory by the proponents. The data; width (in.),
length (in.), height (in.), was gathered and recorded. The Maximum Compressive Load (P),
Saturated Weight of CHB (Ws), Immersed Weight of CHB (Wi), Oven-dry Weight of CHB
(Wd), Received Weight of Specimen (Wr) were obtained and recorded.

The Compressive strength of the CHB was obtained by the following formulas:

a) Density, lb/cu ft (D) = [Wd (Ws - Wi)] x 62.4

b) Net Volume, cu ft (Vn) = Wd D

c) Average Net Area, sq in (An) = (Vn x 1728) H

d) Gross Area, sq in (Ag) = L x H

e) Absorption, % = [(Ws - Wd) (Wd)] x 100

f) Water Content, % = [(Wr - Wd) (Ws - Wd)] x 100

g) Gross Area Strength, psi = P Ag

h) Net Area Compressive Strength, psi = P An

3.18 TREATMENT OF DATA

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 The data would be a tabulated table which would indicate the design mix, of the
weight of sand, cement, calcium hydroxide and water.

CHAPTER 4
SCHEDULE OF ACTIVIIES AND BUDGET

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4.1 COST ESTIMATE

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APPENDIX

APPENDIX A

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Table A.1 PROPOSED CEMENT-SAND-Acetylene Production Waste CHB MIX

DESIGN MIX
TOTAL
VOLUME
CHB MIXERS VOLUME (m3) PERCENTAGE
ADMIX
RATIO
SAND KALBURO KALBUR
CEMENT SAND KALBURO CEMENT SAND
CEMENT (m3) (m3) O
(m3)
COMMO
N 1 7 0 0.02832 0.198 0 0.2265 12.50% 87.50% 0%
QUARTE
R 1 5.25 1.75 0.02832 0.149 0.049555 0.2265 12.50% 65.62% 21.87%

HALF 1 3.5 3.5 0.02832 0.099 0.09911 0.2265 12.50% 43.75% 43.75%

THIRDS 1 1.75 5.25 0.02832 0.05 0.148664 0.2265 12.50% 21.87% 65.62%

FULL 1 0 7 0.02832 0 0.198219 0.2265 12.50% 0% 87.50%

MEASUREMENT (pongkee)
BASE say TOTAL BATCH
AREA HEIGHT
MAT L W HEIGHT
(m2) (cm) FULL REMAIN
(m) (m) (cm)

CEMENT 0.3 0.3 0.09 179.457 180 0 180

SAND 0.3 0.3 0.09 1256.2 1257 4 57
KALBURO 0.3 0.3 0.09 0 0 0 0

Table A.2 COMMON CHB MIX

Table A.3 CHB QUARTER MIX

Page | 25
 MEASUREMENT (pongkee)
BASE say TOTAL BATCH
AREA HEIGHT
MAT L W HEIGHT
(m2) (cm) FULL REMAIN
(m) (m) (cm)

CEMENT 0.3 0.3 0.09 179.457 180 0 180

SAND 0.3 0.3 0.09 942.147 943 3 43
KALBURO 0.3 0.3 0.09 314.049 315 1 15

Table A.4 CHB HALF MIX

MEASUREMENT (pongkee)
BASE say TOTAL BATCH
AREA HEIGHT
MAT L W HEIGHT
(m2) (cm) FULL REMAIN
(m) (m) (cm)
CEMENT 0.3 0.3 0.09 179.457 180 0 180
SAND 0.3 0.3 0.09 628.098 629 2 29
KALBURO 0.3 0.3 0.09 628.098 629 2 29

Table A.5 CHB MIX

MEASUREMENT (pongkee)
BASE say TOTAL BATCH
AREA HEIGHT
MAT L W HEIGHT
(m2) (cm) FULL REMAIN
(m) (m) (cm)
CEMENT 0.3 0.3 0.09 179.457 180 0 180
SAND 0.3 0.3 0.09 314.049 315 1 15
KALBURO 0.3 0.3 0.09 942.147 943 3 43

Table A.6 CHB FULL ACETYLENE PRODUCTION WASTE MIX

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 MEASUREMENT (pongkee)
BASE say TOTAL BATCH
AREA HEIGHT
MAT L W HEIGHT
(m2) (cm) FULL REMAIN
(m) (m) (cm)
CEMENT 0.3 0.3 0.09 179.457 180 0 180
SAND 0.3 0.3 0.09 0 0 0 0
KALBURO 0.3 0.3 0.09 1256.2 1257 4 57

APPENDIX B

Page | 27
 (DATA GATHERING)

Table B.1 ORGANIC IMPURITIES IN SAND

GOVERNING SPECIFICATIONS (ASTM Designation: C40-33)

Color #1-#2 Sands suitable for use in high grade concrete
Color #2-#3 Sands which may be used in unimportant concrete work
Color #3-#4 Sands which should never be used in concrete
Color #4-#5 An unusually bad sand, soil, or loam

Table B.2 SPECIFIC GRAVITY AND ABSORPTION OF AGGREGATES

Maximum Size
Weight of SSD Aggregate in Air, g
Weight of Saturated Aggregate in Water, g
Weight of Oven Dry Aggregate, g

Apparent Specific Gravity

Bulk Specific Gravity (Dry)
Bulk Specific Gravity (SSD)
Absorption, %

Table B.3 SIEVE ANALYSIS

Page | 28
Sieve Sieve Sieve Opening Weight Cumulative Percent Percent Governin
No. Weight (mm/in) Retained Weight Retained Passing g
(g) (g) Retained (g) % % Specs

Initial Weight of CA =
3" 443.9 75
2 453.4 63
1/2"
2" 457.1 50
1 478.9 37.5
1/2"
1" 471.8 25
3/4" 483.8 19
1/2" 485.4 12.5
3/8" 465.7 9.5
#4 450.1 4.75
#8 424.2 2.36
PAN 275.4
Total 4889.7
Initial Weight of FA =
3/8" 465.1 9.5
#4 450.6 4.75
#8 424.1 2.36
#10 425 3
#16 382.6 1.18
#20 373.3
#30 346 600micrometer

#40 322.2 425

#50 318.2 300
#70 300.6 212
#80 301.5 150
#100 293
PAN 274.6
Total 4676.8

Table B.3 AMOUNT OF MATERIAL FINER THAN NO. 200 SIEVES IN AGGREGATES

Sample Identification

Page | 29
Original Oven Dry Weight of Aggregate + Pan, kg
Weight of Pan, kg
Original Oven Dry Weight of Aggregate, kg (A)
Washed Oven Dry Weight of Aggregate, kg (B)

Percent Finer than No. 200 Sieve, %

Table B.4 UNIT WEIGHT OF AGGREGATES

FINE AGGREGATE
Total Weight of Aggregate + Measure, g
Weight of Measure, g
Weight of Aggregates, g
Volume of Measure, cu cm
Unit Weight, g/cu cm
Average Unit Weight, g/cu cm
Unit Weight, pcf
Average Unit Weight, pcf
% Difference from Average

Table B.5 BULKING OF SAND

Wt. Of Sand + Wt. Of Beaker, Wt. Of Sand + Percent

Water + Beaker, gm Water, gm Dry
gm Weight, %
Dry
With 2% water
With 4% water
With 6% water

Table B.6 NORMAL CONSISTENCY

TRIAL NO. VOLUME OF Weight of POINT OF % water by

WATER Dry Cement SETTLING weight
(ml) (g) (mm)
1
2

Table B.7 TIME SETTING OF PORTLAND CEMENT

TIME SETTING VICAT METHOD GILLMORE NEEDLE

Page | 30
Time start
Initial setting time
Final setting time
Total time setting

BIBLIOGRAPHY

Page | 31
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 W. Gutt D. Sc., Ph.D., P.J. Nixon Ph.D. 1979. Materiaux et Construction. Volume 12,
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