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To cite this article: Akkadath Abdulmatin, Weerachart Tangchirapat & Chai Jaturapitakkul (2017):
Environmentally friendly interlocking concrete paving block containing new cementing material
and recycled concrete aggregate, European Journal of Environmental and Civil Engineering, DOI:
10.1080/19648189.2017.1355265
1. Introduction
Ordinary Portland cement (OPC) is a classic construction material widely used as a cementing material
for concrete and concrete block. Current estimates of world cement manufacture are of the order of
1.7 × 109 t/year, enough to produce well over 6 km3 of concrete per year or at least 1 m3 per person
(Gartner, 2004). It is well-known that the processes of OPC manufacture release large amounts of CO2,
approximately 1 ton per ton of produced clinker, which leads to the greenhouse effect (Habert, Billard,
Rossi, Chen, & Roussel, 2010). Natural sand and limestone have been used as aggregates and their
consumption increases with increasing manufacture of concrete product. Additionally, material from
construction activities such as old building concrete, defective precast concrete, and spun concrete
piles increase the waste related to concrete construction. Therefore, the use of substitute materials to
replace OPC and natural aggregates is extremely important in reducing the environmental problems.
Bagasse ash (BA) is a waste material from burning sugar cane residue as a fuel for generating elec-
tricity in the distillation process of the sugar industry. In 2015, the total amount of sugarcane grown
in Thailand was approximately 106 million tons (Office of Cane & Sugar Board, 2014). After the sugar
production process, approximately 27.6 million tons of sugarcane bagasse (26% by weight of sugarcane)
was produced, leading to approximately 657,200 tons of BA or about 0.62% by weight of sugarcane
(Cordeiro, Toledo Filho, Fairbairn, Tavares, & Oliveira, 2004). Most BA has been disposed of in landfill
around the industry, which leads to environmental problems.
Unmodified BA has large particles and high porosity compared to OPC because the burning tem-
perature of bagasse is approximately of 600–800°C, which is lower than its melting point (Chusilp,
Jaturapitakkul, & Kiattikomol, 2009b). In general, the large particles and high porosity of unmodified BA
led to a reduction of the rate of reaction and more water absorption in the concrete mixture, resulting
in the decrease in the workability and compressive strength of concrete. Montakarntiwong, Chusilp,
Tangchirapat, and Jaturapitakkul (2013) reported that the concrete with replacement of OPC by unmod-
ified BA at 20% by weight of binder had lower compressive strength than control concrete (100% of
OPC as a binder) of 17% at 28 days. However, the use of ground BA could develop compressive strength
of concrete, especially the use of ground BA with low loss on ignition (LOI) to replace OPC at a rate
of 20% by weight of binder produced a compressive strength greater than control concrete of 9% at
28 days. In addition, Ganesan, Rajagopal, and Thangavel (2007) found that the median particle size of
5.4 micron of ground BA could be used as a pozzolan to replace OPC in concrete with 20% by weight
with no detrimental effect on the properties of the concrete.
Calcium carbide residue (CR) is obtained from a by-product of acetylene gas production. Most CR
was disposed of in landfill. CR is a highly alkaline material; thus, it impacts the soils and environment
surrounding its disposal areas. Many researchers have proposed utilising CR in mixtures for concrete pro-
duction. Jaturapitakkul and Roongreung (2003) reported that CR consists mainly of calcium hydroxide
(Ca(OH)2) and it can react with siliceous or siliceous and aluminous materials by a pozzolanic reaction,
resulting in a cementing product similar to hydration products of OPC. The utilisation of CR and BA
for use as a cementing material to substitute for OPC was investigated by Rattanashotinunt, Thairit,
Tangchirapat, and Jaturapitakkul (2013) who showed that ground CR could be mixed with ground BA
at a ratio of 50:50 by weight without OPC to produce a compressive strength of 22.9 MPa at 28 days
which was slightly lower than control concrete approximately of 8.0 MPa. In addition, adding OPC to
the binder mixture at a rate of 20% by weight can obtain a compressive strength similar to the control
concrete, even though the amount of OPC in the concrete mixture was reduced 80% by weight.
Currently, most structural members are made from concrete. Demolition activity on old and low-qual-
ity concrete results in an increase in concrete waste. The general solution is to dispose of it in landfills,
which is not a sustainable solution. In addition, the increasing usage of natural aggregates reduces
natural resources. Therefore, the utilisation of recycled concrete aggregate (RCA) to replace natural
aggregate has been widely studied to reduce environment impacts and save natural resources. In
practice, however, few concrete blocks have been made from RCA with waste materials as a binder.
In general, the main characteristics of fine or coarse RCA are high water absorption and low stiff-
ness; these lead to lower workability in the concrete mixture and lower compressive strength of the
concrete compared to natural aggregate concrete (Evangelista & de Brito, 2014; Seara-Paz, Corinaldesi,
González-Fonteboa, & Martínez-Abella, 2016; Silva, de Brito, & Dhir, 2015). However, RCA has been
used in this study in order to obtain data for producing recycled aggregate concrete paving blocks.
Fernández-Ledesma, Jiménez, Ayuso, Corinaldesi, and Iglesias-Godino (2016) found that the workability
of masonry mortar mixture decreased with increasing the added fine RCA, whereas the replacement of
up to 50% by weight of fine RCA did not significantly affect its compressive strength. Additionally, the
use of fine RCA in mortar had less effect on its flexural strength compared to its compressive strength.
Vegas, Azkarate, Juarrero, and Frías (2009) suggested that the fine RCA could not replace more than
25% by weight of river sand so that no effect of workability and mechanical strength of masonry mortar
would occur. However, Pereira, Evangelista, and de Brito (2012) found that the mechanical properties of
concrete with fine RCA could be improved with the use of superplasticiser in the mixture. In addition,
the choice of the aggregate-to-binder ratio in a mixture is more important factor for the properties of
concrete block. Poon and Lam (2008) reported that the compressive strength of concrete block was
increased with a decrease in aggregate-to-binder ratio. Moreover, the use of 100% fine RCA in a concrete
EUROPEAN JOURNAL OF ENVIRONMENTAL AND CIVIL ENGINEERING 3
block mixture could not meet the requirements of water absorption unless the aggregate-to-binder
ratio was reduced to 3:1 by weight.
From the available literatures, three waste materials (BA, CR and fine RCA) were proposed to use to
produce concrete paving block product that is an environmentally friendly or low-CO2 concrete block.
Some technical methods were used to produce high-quality concrete paving block such as high pres-
sure compacting and reduction of the w/b ratio in the concrete block mixture using superplasticiser.
retained on No. 325 sieve were less than 1% by weight (assigned as CB-F) for use as a small particle
binder in making concrete blocks.
2.1.2. Aggregate
In this study, fine RCA (FRCA) was used to replace 100% of sand and crushed limestone dust. The FRCA
was collected from demolished concrete spun piles (Figure 3), which were crushed by a hammer and a
concrete crusher. Before crushing, the demolished concrete spun piles were investigated for their com-
pressive strengths, which were found to vary from approximately 40 to 50 MPa. The crushed concrete
passing through No. 4 sieve was used as a FRCA for casting concrete paving block.
Table 2. Physical properties of fine recycled concrete aggregate (FRCA) and river sand.
grinding process (Chusilp et al., 2009b). CB-F, CR-L and BA-L had the material weights retained on No.
325 sieve of 0.3, 54.0 and 52.0%, respectively, and the median particle size (d50) of CB-F was 3.50 μm.
The physical properties of FRCA and river sand are shown in Table 2. FRCA had a fineness modulus
of 2.58, which was less than that of the river sand (3.07). The particles of FRCA were smaller than those
of river sand, which can be observed in Figure 5. This is because most FRCA fractions consist of mortar
dust from old concrete. The bulk relative density of FRCA was 2.36 g/cm3 and was less than that of river
sand (2.62 g/cm3). FRCA had the residues of old mortar adhered to its natural aggregate particle; thus,
the higher water absorption of 8.00% resulted, while the water absorption of river sand was 0.91%.
Similar results were found by Evangelista and de Brito (2007).
6 A. ABDULMATIN ET AL.
Figure 4. Image of particles in CR-L, BA-L and CB-F. (a) Image of large particles of calcium carbide residue (CR-L); (b) Image of large
particles of bagasse ash (BA-L); (c) Image of ground-together CR-L and BA-L (CB-F).
EUROPEAN JOURNAL OF ENVIRONMENTAL AND CIVIL ENGINEERING 7
Figure 5. Particle size distributions of fine recycled concrete aggregate (FRCA) and river sand.
mixtures were varied between 0.40 and 0.55. The amount of superplasticiser type F was adjusted until
a suitable mixture was obtained (by observing the fresh concrete block to be fully compacted). After
casting, the specimens were removed immediately from the moulds and covered with wetted burlap
for 24 h at room temperature. All concrete blocks were cured in tap water at ambient temperature
approximately of 25–30°C until the age of testing.
fr = (3PL)∕(2bd 2 ) (4)
where, fr is the modulus of rupture (MPa), P is the maximum applied load indicated by the testing
machine (N), and L, b, and d are the span length (mm), average width of the specimen (mm) and average
depth of specimen (mm), respectively. For each mix proportion, three concrete block specimens were
tested and the average value of the flexural strength was determined.
Table 5. Oven-dry density and water absorption of concrete paving blocks at 28 days.
increased absorption more than the high fineness of CB-F binder. The higher fineness (small particles)
of CB-F binder easily fills the voids between the aggregates and aggregates-to-paste matrix; hence it
increases the density and reduces the water absorption of concrete block (Isaia, Gastaldini, & Moraes,
2003; Poon & Lam, 2008).
Furthermore, the water absorptions of all concrete blocks in this study were higher than that spec-
ified by ASTM C936 (2016), which should not be higher than 5% by weight. In addition, the CB-F and
CB-L concrete blocks had higher water absorption than the concrete block made from OPC and natural
aggregates, which was studied by Poon and Lam (2008). The water absorption of the concrete block
made from OPC and natural aggregates with the w/b ratio of 0.27 was 2.9% at 28 days, while 27CB-F
had the water absorption of 7.0% at 28 days. This was due to CB-F and CB-L concrete blocks were
produced from BA and CR, which had high porosity. Additionally, all the concrete blocks in this study
were also produced from 100% of FRCA. González-Taboada, González-Fonteboa, Martínez-Abella, and
Carro-López (2016) and Evangelista and de Brito (2014) reported that the attached mortar of FRCA
had high pores, therefore, FRCA absorbed more water than natural aggregate. de Juan and Gutiérrez
(2009) also reported that the water absorption of FRCA was directly affected by the attached mortar
content of FRCA. For these reasons, the water absorption of CB-F and CB-L concrete blocks was higher
than that specified by ASTM C936 (2016) and also higher than the concrete block made from OPC and
natural aggregates.
Figure 6. Relationship between compressive strength and oven-dry density of concrete paving blocks.
This result supports that of Chusilp et al. (2009b), who reported that the high fineness of ground BA
could accelerate the pozzolanic reaction and improve the compressive strength of concrete.
Secondly, the density of concrete block has increased through the filling effect, resulting in an
increase in its compressive strength, especially in the early ages (Isaia et al., 2003; Tangpagasit, Cheerarot,
Jaturapitakkul, & Kiattikomol, 2005). It can be observed in Figure 6 that the increase in density resulted
in increasing the compressive strength of concrete block; the relationship between the compressive
strength and the dry density of the CB-F concrete block is similar to that of CB-L concrete block. CB-F con-
crete blocks had compressive strengths of 32.5, 36.4 and 40.6 MPa with dry densities of 1950, 2020 and
2075 kg/m3, respectively. CB-L concrete blocks had compressive strengths of 12.2, 14.5 and 16.9 MPa,
corresponding to dry densities of 1770, 1790 and 1800 kg/m3, respectively. This could result because
the higher density of CB-F concrete blocks is due to the smaller porosity of CB-F binder compared to
CB-L binder; thus, it can explain the greater compressive strength of CB-F concrete blocks (Martinez,
Eliche, Cruz, & Corpas, 2012). These results also agree with those of Ling (2012), who reported that the
compressive strength of rubberised concrete paving block has increased with the increase in its density.
Poon and Chan (2007) also reported that the compressive strength of paving blocks prepared with RCA
increased with the increased density.
Thirdly, the large particles of CB-L binder required high water content in concrete block mixture, due
to its high porosities and rough surfaces. Thus, the compressive strength of CB-L concrete block was
lower than CB-F concrete block due to its higher w/b ratio and smaller surface area of binder particles.
The effects of different w/b ratios on the compressive strengths of CB-F and CB-L concrete blocks
are observed in Figures 7 and 8, respectively. The results show that the compressive strength of CB-F
Figure 7. Relationship between compressive strength and w/b ratio of CB-F concrete paving blocks.
12 A. ABDULMATIN ET AL.
Figure 8. Relationship between compressive strength and w/b ratio of CB-L concrete paving blocks.
concrete block has increased with the decrease in w/b ratio. These results indicated that the fineness of
CB-F binder could reduce the w/b ratio in a concrete block mixture, leading to the higher compressive
strength and this behaviour could also be observed in normal concrete (Behnood & Ziari, 2008; Nguyen,
Chang, Chen, Yang, & Nguyen, 2015; Poon, Lam, & Wong, 2000). On the other hand, the compressive
strength of CB-L concrete block has increased with increasing w/b ratio. Moreover, some amount of
superplasticiser was absorbed together with the mixing water into the CB-L binder, resulting in less
water content of CB-L concrete blocks at the lower w/b ratio; thus, the mixing water is not sufficient to
complete the pozzolanic reaction as well as the compaction. This finding suggests that sufficient water
content is an important parameter in the pozzolanic reaction process and compaction, especially in
the case of pozzolanic material with high porosity.
ASTM C936 (2016) defines the compressive strength of interlocking concrete paving block at least of
55 MPa at the time to work site, however, the compressive strength results of the concrete blocks in this
study do not meet the specification of this standard. In addition, when compared the concrete blocks in
this study to the concrete blocks made from OPC and natural aggregates with the binder to aggregate
ratio of 1:3 by weight and w/b ratio of 0.27 (Poon & Lam, 2008), it was found that the concrete blocks
made from OPC and natural aggregates had the compressive strength of 85.8 MPa at 28 days, which
was higher than the compressive strength of 27CB-F concrete block. It should be noted that all the
concrete blocks in this study had no OPC in the mixture, moreover, FRCA was also used to replace the
fine natural aggregate. The lower compressive strength of CB concrete block could be explained by
the study of Rattanashotinunt et al. (2013), who reported that the concrete made from calcium carbide
residue mixed with BA as a binder decreased the compressive strength of concrete by approximately
18 to 26% as compared to concrete made from OPC as a binder. In addition, Khatib (2005) found that
the compressive strength of concrete with 100% replacement of fine natural aggregate by fine RCA was
reduced between 26 and 36% as compared to the reference concrete (100% of fine natural aggregate).
However, comparing the obtained results with the TIS 827 standard (1988), 27CB-F concrete block had
the compressive strengths of 36.4 and 41.9 MPa at 28 and 60 days, respectively, and 25CB-F concrete
block had the compressive strengths of 40.6 and 47.3 MPa at 28 and 60 days, respectively, which have
exceeded the minimum requirement of 40.0 MPa at the testing age of not less than 7 days for inter-
locking concrete paving block as specified by TIS 827 standard (1988).
Table 7. Flexural strength and percentage of flexural strength as compared to the compressive strength of 25CB-F and 55CB-L
concrete paving blocks.
The flexural strengths of 25CB-F concrete blocks at 7, 28 and 60 days were 2.4, 3.5 and 4.4 MPa,
while those of 55CB-L concrete blocks were 1.7, 2.2 and 2.5 MPa, respectively. The flexural strength
of 25CB-F concrete block was higher than 55CB-L concrete block because the 25CB-F concrete block
had higher compressive strength. A similar result was also found by Wongkeo, Thongsanitgarn,
Pimraksa, and Chaipanich (2012) who reported that flexural strength had direct relationship with
its compressive strength, i.e. the flexural strength increased with the increase in compressive
strength. In addition, it was attributed that Ca(OH)2 within FRCA could react with pozzolanic mate-
rial, resulting in the new paste at interface of FRCA (Kou & Poon, 2009). This characteristic might
occur with 25CB-F concrete block, which had high fineness of BA in the mixture. The flexural
strengths of CB-F and CB-L concrete blocks ranged from 8.5 to 9.5% and from 12.5 to 15.5% of their
compressive strengths, respectively. It should be noted that the flexural strength was less than
10% of the compressive strength for the high compressive strength of the concrete block (25CB-F
concrete block). On the other hand, for the low compressive strength 55CB-L concrete block, the
flexural strength was higher than 10% of its compressive strength. This result suggested that the
ratio of flexural strength to compressive strength (as a percentage) decreases with increasing of
compressive strength, which is similar to that of normal concrete (Arιoglu, Girgin, & Arιoglu, 2006).
This finding indicates that CB-F and CB-L concrete blocks have the same characteristics as normal
concrete, even though the materials used to make the blocks are industrial waste materials and
no OPC was included in mixture.
Figure 9. Relationship between weight loss due to abrasion and compressive strength of paving concrete blocks.
14 A. ABDULMATIN ET AL.
strengths of 27.2, 40.6 and 47.3 MPa, respectively. The 55CB-L blocks had abrasion losses of 14.7, 13.7 and
12.1 g corresponding to the compressive strengths of 11.2, 16.9 and 19.7 MPa, respectively. The 25CB-F
concrete block had lower abrasion losses than the 55CB-L concrete block at all testing ages because
the compressive strength of the block was the important factor controlling the abrasion resistance
(Naik, Singh, & Hossain, 1995; Siddique, 2004). This result agrees with other researches showing that
the abrasion resistance of concrete follows its compressive strength (Atiş, 2002, 2003; Gjorv, Baerland, &
Ronning, 1990; Naik et al., 1995). In addition, the hardened paste in the 55CB-L concrete block mixture
may have some incomplete residues from the pozzolanic reaction due to the large particles of the
binder. The binder residues are softer materials than that of paste from pozzolanic product, resulting
in a decrease in abrasion resistance.
Considering the weight loss due to abrasion of CB concrete block compared to normal concrete
(Langan et al., 1990) (Figure 9), the abrasion losses of CB blocks tend to be higher than those of normal
concrete. In general, the abrasion resistance of concrete is related to the strengths of the mortar phase
and coarse aggregate phase (Shamsai, Rahmani, Peroti, & Rahemi, 2012). In this case, the abrasion
resistance of CB concrete block was controlled by the mortar phase while that of normal concrete was
controlled by both the mortar and coarse aggregate phases. CB concrete block was produced from
FRCA which was weaker than normal aggregate. Moreover, RA consists of old mortar attached on the
aggregate surface, resulting in its low hardness. Therefore, CB concrete blocks had higher weight losses
than those of normal concrete. Pereira et al. (2012) found that the mixture of concrete with 100% FRCA
had increased depth of wear due to abrasion by approximately 20% compared to the normal concrete.
A similar result was confirmed by Bravo, de Brito, Pontes, and Evangelista (2015), who reported that fully
replacement of the fine natural aggregate by FRCA resulted in increasing abrasion losses between 18
and 53% depending on sources of FRCA.
Summarising, the use of CR and BA as a binder in concrete block did not significantly affect abrasion
resistance, because the abrasion resistance depends on compressive strength more than the type of
binder. The abrasion resistance of concrete block made with CR and BA as a binder can be improved
by increasing its fineness, reducing the unreacted residue in the concrete block and increasing its
compressive strength. However, the use of FRCA to produce concrete block results in the decrease in
abrasion resistance as compared to normal concrete.
Figure 10. Output from the utilisation of three waste materials; CR, BA and FRCA.
4. Conclusions
This study used three types of wastes to produce interlocking concrete paving block: calcium carbide
residue (CR), bagasse ash (BA) and recycle concrete aggregate (FRCA). The conclusions are as follow:
(1) The compressive strength of interlocking concrete paving block made from a binder of CR and
BA with FRCA as an aggregate could increase by increasing the fineness of binder and reducing
the w/b ratio of the mixture.
(2) The use of unmodified CR, BA and FRCA caused interlocking concrete paving block to have
higher water absorption and lower dry density due to the physical characteristics of materials.
However, the water absorption of the interlocking concrete paving block could be decreased
by increased fineness of the binder.
(3) The types of materials had no effect on the flexural strength of interlocking paving block;
flexural strength closely correlated with its compressive strength. However, the use of FRCA
resulted in decreased abrasion resistance of the interlocking concrete paving block.
16 A. ABDULMATIN ET AL.
(4) Interlocking concrete paving block made from three types of waste materials, CR, BA and FRCA,
could have compressive strength of at least 40 MPa, meeting the requirement of the TIS 827
standard (1988).
Disclosure statement
No potential conflict of interest was reported by the authors.
Funding
The authors gratefully acknowledge financial support from the Office of the Higher Education Commission, Thailand,
for supporting this work under the Strategic Scholarships Fellowships Frontier Research Networks (specific for Thailand’s
southern region) for the Thai Doctoral degree Ph.D. program. Thanks also extent to King Mongkut’s University of Technology
Thonburi under the National Research University (NRU) project and the Thailand Research Fund (TRF) under TRF [grant
number TGR 5780073] for New Researcher Scholar.
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