INTERNATIONAL CONCRETE COMPETITION

CIVIL WEEK UNS 2018

“Sustainable Self Compacting Concrete”

Self Compacting Concrete With Calcium Carbide As A Partial

Replacement Of Cement

Arranged By :
STARK DREI
SYARIFAH HIDAYAH 1522201098
AHMAD DHORURI 1522201060
SILWANUS BUULOLO 1522201027

UNIVERSITAS MUHAMMADIYAH TANGERANG

2018
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 PREFACE
Concrete is one of the versatile construction materials which are used
worldwide. It is a mixture of cement, sand, gravel and water which dries hard
and strong and is used as a material for building. Concrete has to be heavily
vibrated for flow into very intricate forms or forms that have a congested
reinforcing bars. Hence to overcome these defects the self-compacting concrete
is used. Self Compacting Concrete is a type of concrete which is capable of
flowing into the form work uniformly, without segregation and bleeding, better
finishes, easier placement, thinner concrete sections, no vibration, safer working
environment without any application of vibration, which is also reducing the
pollution since vibration is one of its kind. Due to many advantages like faster
construction, reduction in site for thinner concrete sections, improved durability,
suitability for congested reinforcement; this concrete becomes popular in civil
engineering construction. And also day by day the waste materials like calcium
carbide residue from the welding industries is increasing in Tangerang. Hence,
this research is presented to make use of those waste products in the self
compacting concrete. This study mainly focuses on the self compacting concrete
which is prepared by partially replacing cement with industrial by-products. To
understand the behavior of the self compacting concrete, the fresh and
mechanical properties along with the durability characteristics have been
discussed.

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 TABLE OF CONTENTS
Cover .................................................................................................... i

Verification Sheet ............................................................................... ii

Preface ................................................................................................ iii

Table of Contents................................................................................. iv

Table of Picture .................................................................................... v

CHAPTER 1 PRELIMINARY

1.1 Background ........................................................................ 1

1.2 Formulation of the Problem............................................... 2

1.3 Aim ..................................................................................... 2

1.4 Benefits .............................................................................. 2

CHAPTER 2 LITERATURE REVIEW

2.1 Self Compacting Concrete ................................................ 3

3.2 Calcium Carbide ................................................................. 4

CHAPTER 3 METHODOLOGY

3.1 Research Methods and Data Collection ............................. 5

3.2 List of Data Material in Use .......................................... ............. 5

3.3 Mix Design Quantification .................................................. 9

3.4 Concrete Making Methods ................................................ 11

CHAPTER 4 THE STUDY CASE

4.1 Slump Flow Test ................................................................. 13

4.2 Results For Compressive Strength Tests On Concrete Cubes 13

4.3 Analysis of Occured Impact........................................... 14

CHAPTER 5 CLOSING
5.1 Conclusion .......................................................................... 15

5.2 Suggestion ................................................................................ 15

BIBLIOGRAPHY .......................................................................... 16

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 Table Of Picture

1. Picture 3.1 Coarse Aggregate .........................................................................5

2. Picture 3.2 fine Aggregate .............................................................................6
3. Picture 3.3 cement .......................................................................................7
4. Picture 3.4 calcium carbide ..........................................................................7
5. Picture 3.5 super-plasticizer.........................................................................8
6. Picture 3.6 water ..........................................................................................9
7. Picture 3.7 trial mix ....................................................................................11
8. Picture 3.8 compressive strength test .......................................................12
9. Picture 4.1 slump flow test ........................................................................13
10. Picture 4.2 Result Test Object 1 .................................................................13
11. Picture 4.3 Result Test Object 2 .................................................................13
12. Picture 4.4 Result Test Object 3 .................................................................14

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 CHAPTER I
PRELIMINARY

1.1 Background
Self Compacting Concrete is basically a concrete which is capable of
flowing into the form work, without segregation and bleeding, reduces
manpower, better finishes, easier placement, better durability, thinner
concrete sections, lesser noise levels, no vibration, safer working
environment, to fill uniformly and completely every corner of it by its own
weight without any application of vibration or other mechanism during
placing of concrete. Due to many advantages like faster construction,
reduction in site for thinner concrete sections, improved durability, suitability
for congested reinforcement; this concrete becomes popular in civil
engineering construction. The advantages of SCC make this concrete more
desirable all over the world which includes faster construction. Such concrete
should have low yield value to ensure high flow ability, a moderate viscosity
to resist segregation and bleeding, and must maintain its homogeneity during
transportation, and placing to ensure adequate structural performance and
long term durability. It has three essential fresh concrete properties filling
ability, passing ability and segregation resistance. The demand of Self
Compacting Concrete (SCC) is growing rapidly due to the shortage of skilled
labours; it is also proved to be more economical, durable and termed as high
performance concrete. The quality of concrete construction is of utmost
importance in order to have a durable concrete structure and one of the
reasons to make a durable structure is proper compaction which requires
skilled labors but due to shortage of skilled labors full compaction. The
solution to this is the use of self-compacting concrete which compacts in
every corner of formwork. The use of SCC is rising steadily over the years
because of their advantages and many scientists and organizations carried
out research on properties of SCC. SCC has economic, social and
 environmental benefits over conventionally vibrated concrete. SCC is made
from the same basic constituents as conventional concrete but with the
addition of a viscosity modifying admixture and high levels of super-
plasticizing admixtures to impart high workability. SCC can save labour,
eliminate consolidation noise and lead to innovative construction methods.
Besides, a modern life style alongside the advancement of technology has
led to an increase in the amount and type of waste being generated, leading
to a waste disposal crisis. This research try to tackle problem of the waste
that is generated from industry field such as calcium carbide waste in the
production of acetylene gas in welding. The main objective of this research
work is to determine the compressive strength and workability of concrete
when calcium carbide is used as a partial replacement of cement to reduce
its accumulation as a waste in the environment.
1.2 FORMULATION OF THE PROBLEM
Based on background above we decided the formulation of the problem as
below :
1. How the workability of self compacting concrete using calcium carbide as
a partial replacement of cement?
2. How the compressive strength result of self compacting concrete using
calcium carbide as a partial replacement of cement?
1.3 AIM
The aim of this research is :
1. To find out the workability of self compacting concrete using calcium
carbide as a partial replacement of cement.
2. To measure the compressive strength obtained.
1.4 BENEFITS
This research was expected to give information about self compacting
concrete to the readers and as a suggestion for the scientist in Indonesia to
develop the idea about utilization of waste industry in self compacting
concrete.

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 CHAPTER 2
LITERATURE REVIEW
2.1 Self-Compacting Concrete
Self-compacting concrete (SCC) is a flowing concrete mixture that
is able to consolidate under its own weight. The highly fluid nature of SCC
makes it suitable for placing in difficult conditions and in section with
congested reinforcement. Use of SCC can also help minimize hearing-
related damages on the worksite that are induced by vibration of
concrete. Another advantage of SCC is that the time required to place
large sections is considerably reduced.
Prof. Shriram H. Mahure (2014) had studied about the fresh and
hardened properties of self compacting concrete using Fly ash as partial
replacement of cement in different percentages in addition to filler. The
fresh properties have been determined by computing the Slump value, V-
funnel value and L-box value and the hardened properties are
determined by computing the Compressive strength, Flexural strength
and Split tensile strength of the specimens. It is observed that the fresh
properties of concrete shows an acceptable value upto 30% replacement
of fly ash and also the hardened properties of concrete is significantly
improved when compared to the conventional mix.
Rafat Siddique (2013) investigated about the strength and durability
properties of Self-Compacting concrete which is obtained by partially
replacing natural sand with waste foundry sand (WFS). He replaced the
Natural sand with WFS by 0%, 10%, 15% and 20% in terms of weight. He
studied the fresh properties of concrete before computing the strength
parameters. Compressive strength and split tensile strength test were
obtained at the age of 7, 28, and 56 days and to determine the durability
of the concrete, sulphate resistance was evaluated at the age of 7, 28 and
56 days and Rapid Chloride Permeability test was conducted at age of 28
days. Test results have shown that there is increase in compressive

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 strength and split tensile strength of self-compacting concrete and also
the durability properties have been improved by incorporating waste
foundry sand as a replacement of Natural sand.
2.2 Calcium Carbide
Calcium Carbide Waste (CCW), a by-product from acetylene gas (C2H2)
production. It is obtained from the reaction between water and calcium
carbide (CaC2) as shown in the equation below:
CaC2 + 2H2O→ C2H2 + Ca(OH)2
Beyond its obvious values acetylene as a fuel gas is employed in
agriculture for repining of fruits and as an excellent choice for many
critical heating processes including; flame heating, flame gouging,
welding, flame hardening, flame cleaning, flame straightening, thermal
spraying and many other heating applications. However, in most of the
developing countries including Nigeria acetylene gas is used in oxy-
acetylene gas welding. The residue (CCW) is mostly disposed of carelessly
as a waste in the environment which sooner or later gets incorporated
into the soil. An investigation carried out by Abiya et al. have shown that
a concentration of CCW above 100g could drastically reduce the growth
rate of Okra plant. Regardless of its adverse effect on the environment,
CCW also has its essential advantages. A research study conducted by
Wang et al. has confirmed that the main chemical compositions of the
calcium carbide slag were basically the same as that of natural limestone.
Jaturapitakkul and Roongreung also reported that a pozzolanic reaction
could occur when calcium carbide residue is mix with rice husk ash in a
mortar and achieved a highest compressive strength of 15.6 MPa at 28
days.

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 CHAPTER 3
METHODOLOGY

3.1 Research Methods and Data Collection

The method used is an experimental method, where researchers try to
mix the calcium carbide waste in the manufacture of Self-Compacting-Concrete
mix which researcher described the process during the study, which will
eventually come to the conclusion of the researcher results.
The collection of data is the study of literature, by reading journals
associated with SCC. Then the literature used to find the most appropriate mix
design engineering in forming specimen of SCC which uses a mixture of calcium
carbide waste as a cement mixture.
3.2 List of Data Material in Use
a. Aggregate
To remind that aggregate contains of 70-75% from the
concrete volume so the quality of aggregate impact to the concrete
quality. With a good aggregate, the concrete is workable, strong,
stay longer (durable), and economic.

b. Coarse Aggregate

Picture 3.1 Coarse Aggregate

The maximum size of rough aggregate that used in SCC is 20mm.

Coarse aggregate similar to gravel as the result of natural
disintegration of rock or in the form of broken stones obtained from
breaking stones. A regulation of rough aggregate that used as a
concrete mixed as (PBI- 1971):
1. Coarse aggregates as the form of gravel that comes from natural
rocks, or a fractions as a results from stone crusher.

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 2. Coarse aggregates must be consisting of hard particles and not
porous. Grains of coarse aggregate must be eternal, meaning
that they are not broken or destroyed by the effects of weather,
such as sun and rain.
3. Coarse aggregates may not contain more than 1% sludge
(determined against dry weight).
4. Coarse aggregates may not contain substances that can damage
concrete, such as alkaline reactive substances.
To determine the characteristics of the aggregates can be done by
testing as standardized (sieving analytics, density, water absorption,
volume weight, moisture, and the cleanliness of the aggregate of
the mud). Coarse aggregate used in this study were derived from
the coarse aggregate of crushed stone.
c. Fine Aggregate

Picture 3.2 Fine Aggregate

Fine aggregates are aggregates which all the grain penetrate 4.8
mm sieve. The general requirements for fine aggregates used as
concrete mixtures are as follows (PBI-1971):
1. Fine aggregate can be either natural sand, taken from the river
or in the form of artificial sand produced from stone crusher.
2. The grain must be sharp and hard, not broken or destroyed by
the effects of weather.
3. Must not contain more than 5% sludge (determined by dry
weight).
4. Must not contain organic ingredients too much. For this color
experiments can be carried out from Abrams-Harder with NaOH
solution.

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d. Binder
Binder is a binding material in a concrete mixture consisting of
cement and filler, if it’s used as a filler. In this study researchers used
calcium carbide waste as a mixture of Self-Compacting-Concrete
making.
e. Cement

Picture 3.3 Cement

Portland cement has several chemical compounds that each

have their own properties. The four main chemical compounds from
portland cement include Tricalcium Silicate (C3S), Dicalcium Silicate
(C2S), Tricalcium Aluminate (C3A), and TetracalsiumAluminoferrit
(C4AF). Cement that the researcher uses in this research is Semen
Gresik.
f. Calcium Carbide

picture 3.4 calcium carbide

Calcium carbide is a chemical compound with the chemical

formula of CaC2, the pure material is colourless, but most of

sample have a colour ranging from black to grayish- white,

depending on the grade. Its main use industrially is in the
production of acetylene and calcium cyanamide. In order to

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 dispose of or at least reduce the accumulation of certain kind
of waste, it has been suggested to reuse some of these waste
materials to substitute a percentage of theprimary material
used in concrete (cement). The recycling of these materials
not only helps conserve natural resources but also help to
solve growing waste disposal crisis. The calcium carbide has a
chemical formula of CaC2 , when it react with water it produce

ethylene (ethylene gas) and the by product is calcium oxide

(Ca0), which is the one used for this research.

From this reaction it was observe that calcium carbide waste

contains some cement chemical composition.
g. Super-Plasticizer

Picture 3.5 Super-plasticizer

Super-plasticizer (high range water reducer admixture) is a

chemical that serves to reduce water up to 12% or even more
(ASTM C494-82). To produce concrete with high quality (concrete
compressive strength), it takes super-plasticizer (high range water
reducer). Super-plasticizer or high range water reducer in this case
is absolutely necessary because of the condition of the water
cement factor (FAS) which is generally very low in high quality
concrete or very high, to be able to control and produce the optimal
slump value in fresh (workable) concrete, so that it can be produced
good concrete casting performance. But in all cases, the use of the
super-plasticizer needs to be in accordance with the ASTM-C 494-82
standard.

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 h. Water

Picture 3.6 water

Cement cannot be a paste without water. Water must always

be in liquid concrete, not only for the hydration of cement, but also
to turn it into a paste so that the concrete is workable.For concrete
mixes, the water used must meet certain requirements, especially
the limitations (Subakti, 1994):

1. The water used for making concrete must be clean, must not contain
oil, alkaline acids, salts, organic substances or other materials that
can damage concrete or reinforcing steel.
2. It should not contain chloride (Cl)> 500 mg per liter of water.
3. Fresh water that cannot be drunk shouldn't be used for making
concrete.

3.3 Mix Design Quantification

Mix Design using MPa Quality

a. Calculation of Water-Cement Ratio (W/C Ratio)

W/C = 0,37 →Target Necessity
165 𝑘𝑔
Water = 𝐶𝑒𝑚𝑒𝑛𝑡 = 0,37
165
Cement 𝑥 0,37 = 446 kg/m3
b. Estimation of Coarse and Fine Aggregate Amounts
Size of solid-dry coarse aggregate per unit
Maximum
volume of concrete for various modulus of
Aggregate Size
sand fineness
(mm)
2.4 2.6 2.8 3
10 0.5 0.48 0.46 0.44
12.5 0.59 0.57 0.55 0.53
20 0.66 0.64 0.62 0.6
25 0.71 0.69 0.67 0.65
40 0.76 0.74 0.72 0.7

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 50 0.78 0.76 0.74 0.72
75 0.82 0.8 0.78 0.76
150 0.87 0.85 0.83 0.81

From the table above, we obtained:

 Sg = 2,59
 Absorption = 2,66→Absorption Capacity 1%
 Humidity = 2,5%
 Dry-Weight = 1948,2 kg/m3
 Aggregate Vol. = 0,597 kg/m3
= 0,597 x 1948,2
= 1163,075 kg/m3
 SSD Weight = 1163,075 x 1,01
= 1174,706 kg/m3→Coarse Aggregate
≈ 1175 kg/m3
165
 Water = 1000 = 0,165 m3
446
 Cement = = 0,142 m3
1000 𝑥 3.15
1174,706
 Coarse Aggregate = 1000 𝑥 2.6 = 0,452 m3

 Air = 0,006 m3
 Total = 0,765
From the calculation above, we obtained:
 Fine Aggregate = 1 – 0,765= 0,235
 SSD Weight = 0,235x 2,59 x 1000
= 609,142 kg
__________________________________
 Coarse Aggregate = 1175 kg
 Fine Aggregate = 609,142 kg
 Water = 165 kg
 Cement = 446 kg

c. Material Requirements in 0.0318 m3

 Cement = 14,272 kg
 Coarse Aggregate = 37,6 kg
 Fine Aggregate = 19,52 kg
 Water = 5,248 kg

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 1.2 1
 Super-Plasticizer = 100 𝑥 19,52 𝑥 1.08
𝑥 1000

= 158,6 ml
15 1
 Calcium Carbide = 100 𝑥 19,52 𝑥 2.22
𝑥 1000

= 0,964 kg

The use of calcium carbide and water in dissolving calcium carbide

is 1:4,

 1 (calcium carbide) ; 2 (water) → 0,964 kg : 3,856 kg

From the comparison above, we obtained the use of residual water
for Self-Compacting-Concrete (SCC):

=5,248 – 3,856

= 1,392 kg

3.4 Concrete Making Method

a. Material Checking
1. Fine Aggregate Inspection
2. Water Inspection
3. calcium carbide waste Inspection
b. Job Mix Design Concrete
The purpose of the concrete mix planning process is to get the
composition or proportion of concrete mixture that conforms to the concrete
quality standards so that the concrete used in construction is concrete quality
according to the plan

c. Trial Mix

Picture 3.7 trial mix

After the composition or proportion of the concrete mixture is known,

then a mixed trial (Trial Mix) is carried out on the mixing machine so that the
test samples are printed as needed, namely the cube or cylinder.

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d. Slump Flow Test
For this research we use slump cone (Abram Cone), testing with slump
cone is done to find out how much the ability of the concrete mixture to fill the
room (Filling ability).

e. Concrete Compressive Strength Test

Picture 3.8 Compressive Strength Test

Test specimens either in the form of cylinders then can be compressed

on a press machine according to the planned concrete life. After the
compressive strength test object is done, it is obtained or produced the
compressive strength of concrete (α destroyed).

f. Report
From the evaluation of the compressive strength test will be
obtained the value of "Compressive Strength of Concrete" which is one day
old, so that it can be known whether or not the target compressive strength
(f’cr) is reached. The results of the overall examination are summarized in
the form of reports.

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 CHAPTER IV

THE STUDY CASE

4.1 Slump Flow Test

The results of workability test carried out using slump test on scc mix ccw
was shown in picture below, the results show that the values are 64 cm, within
the assumed slump range from mix design.

Picture 4.1 Slump Flow Test

4.2 Results For Compressive Strength Tests On Concrete Cubes

The result of compressive strength test for 1 days with 3 object test is shown on
picture below.

Picture 4.1 Result Test Object 1

Picture 4.2 Result Test Object 2

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 Picture 4.3 Result Test Object 3

4.3 Analysis of Occured Impact

There are several impact occurs based on this research, from the environment
aspects we did decrease the amount of calcium carbide waste but we also make
air pollution because the calcium carbide still smelly. From the economical
aspects, using admixtures can reduce the amount of cement used. With the
lower amount of cement means lower cost because the cement price has rapidly
increased due to the sharp increase in the cost of energy since the 1970s.

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 CHAPTER V
CLOSING

5.1 Conclusion
From the results of the current study, the following conclusions can be
drawn:
1. CCW possess certain potential characteristics for use as admixture in
mortar.
2. The use of CCW in cement have increased the consistency, but
decreased both the initial and final setting times, hence CCW could be
classified as an accelerating admixture in cement mortar.
3. The compressive strength decreases with an increase in the percentage
of calcium carbide waste.
5.2 Suggestion
Based on our research we suggest not to use calcium carbide waste more
than 20% cement.

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 BIBLIOGRAPY
Dinesh A., “Experimental Study On Self Compacting Concrete”. Sri Ramakrishna
Engineering College, 2017.
BS 1887, ”Method of determination of compressive strength of concrete cubes,”
part116 code of practice for design and construction, British standard institution.
1983.
th
Shetty M.S,”Concrete technology, theory and practice”. 5 edition. S. chand and
company limited, New Delhi-India. 2002.
Nagataki S, “Mineral admixture in concrete,” state of the Art and trends, special
publication, materials journal vol.144. pg. 447-482. 1994.

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