A

MAJOR PROJECT REPORT ON

“PERFORMANCE EVALUATION OF WASTE AAC BLOCK

FINE AGGREGATE PARTIALLY REPLACED IN CEMENT
MORTAR AND ADDITION OF NATURAL COIR FIBRES”

A MAJOR PROJ`ECT REPORT SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD

OF DEGREE OF

BACHELOR OF ENGINEERING
IN

CIVIL ENGINEERING
SUBMITTED BY
MOHAMMED MUZAMMIL (160521732309)
UNDER THE GUIDANCE OF
SALAHUDDIN SHAKEEB S M
(Assistant Professor, Civil Department)

DEPARTMENT OF CIVIL ENGINEERING

ISL ENGINEERING COLLEGE, BANDLAGUDA, HYDERABAD
2024-2025

1
 VISION AND MISSION OF THE INSTITUTE

VISION OF THE INSTITUTE:

Our vision is to be a top-ranking engineering college recognized for

excellence in technical education and research. To prepare all students for
successful careers imbibing core human values to meet the growing technological
and social-economics needs of our nation and the world at large.

MISSION OF THE INSTITUTE:

MD1: Our mission is to produce creative and technically strong and trained
engineers of highest quality.
MD2: To develop the potential of human resources and to meet the challenges of
the ever expanding global needs.
MD3: To enable the students to develop their own abilities and talents and create a
work culture based on strong moral and ethical values.

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 DEPARTMENT OF THE CIVIL ENGINEERING

Vision of the Department:

To emerge as a centre of excellence by imparting quality technical education through

innovation, teamwork and value creation, and to contribute to advancement of
knowledge in the field of Civil Engineering.

Mission of the Department:

 M1: Providing the students with in-depth understanding of fundamentals and

practical training related to professional skills and their applications through

effective Teaching-Learning Process and state of the art laboratories and inter
disciplinary areas.
 M2:Inculcate technical, teamwork management and communication skills to

function in multi-discipline teams across globe.

 M3: Preparing students in developing research, design, entrepreneurial skills

and employability capabilities.

 M4: Providing consultancy services and promoting Industry-Department

Interactions.

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 DEPARTMENT OF CIVIL ENGINEERING

PROGRAM EDUCATIONAL OBJECTIVES (PEOs)

 PEO1:To prepare the students with strong fundamental knowledge in Basic

Sciences & Mathematics, English as well as Engineering Sciences so as to
enable them to Analyze and Solve the Civil Engineering related problems using
latest technologies for betterment of Society.
 PEO2 :To inculcate the capability of identifying, analyzing, designing,
formulating and creating sustainable engineering solutions while using modern
design, construction tools and techniques.
 PEO3 :To motivate the students towards Research and Development for solving
complex issues of Engineering and Environment and habituate them towards
lifelong self learning.
 PEO4 :To inculcate moral values & expose them to ethical practices needed for
team work, project management and effective communication to function in
multi-discipline groups across globe.

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 DEPARTMENT OF CIVIL ENGINEERING
PROGRAM OUTCOMES (POs)

Engineering Graduates will be able to:

PO1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering problems.
PO2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.
PO3. Design/development of solutions: Design solutions for complex engineering problems
and design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
PO4. Conduct investigations of complex problems: Use research-based knowledge and
research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions.
PO5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to complex engineering
activities with an understanding of the limitations.
PO6. The engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice.
PO7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need
for sustainable development.

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 PO8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
PO9. Individual and team work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
PO10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and receive
clear instructions.
PO11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member and
leader in a team, to manage projects and in multidisciplinary environments.
PO12. Life-long learning: Recognize the need for, and have the preparation and ability to engage
in independent and life-long learning in the broadest context of technological change.

PROGRAM SPECIFIC OUTCOMES (PSOs)

PSO1: Professional Skills: An ability to understand the basic concepts in civil Engineering and to
apply them to various areas, like strength of materials, design of reinforced concrete structures,
structural analysis, design of steel structures etc.

PSO2: Problem-Solving Skills: An ability to solve complex Civil Engineering problems, using
latest hardware and software tools, along with analytical skills to arrive cost effective and
appropriate solutions.

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 DEPARTMENT OF CIVIL ENGINEERING
MAJOR PROJECT ASSESSMENT PROCESS

PROGRAMME: UG DEGREE: B.E (CIVIL ENGINEERING)

COURSE: PROJECT STAGE-II Year: IV SEM: II CREDITS: 05
COURSE CODE: PW704CE UNIVERSITY:OSMANIA UNIVERSITY
CONTACT HOURS: 14 Hours/Week.

Details:
The progress in the project work is to be presented by the middle of 4th year 1st
semester before the project review committee. By this time, the students will be in
a position to publish a paper in international/national journals/conferences. The
PRC can accept, accept with modification, and request a resubmission. The
progress of project work if found unsatisfactory by the PRC during the middle of
the semester presentation, such students has to present again to the PRC at the end
of the semester and if it is also found unsatisfactory an extension of the project
work can be given to the students.
The student's sectional marks for project will be awarded based on the presentation
of the project by the students before a doctoral committee, and external examiner.

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 DEPARTMENT OF CIVIL ENGINEERING

MAJOR PROJECT COURSE OUTCOMES

Course Objectives / Outcomes

Course Outcomes: C424-Project Stage-II

Student will able to

S.No Description Blooms

Taxonomy Level
C424.1 Understand the properties of different BTL1
construction materials
C424.2 Understand the manufacturing and properties of BTL2
bricks and blocks
C424.3 Manufacturing of blocks using alternative BTL4
materials
C424.4 Test the feasibility using recycle and fiber BTL3
materials in blocks
C424.5 Test and analyze the properties of design BTL5
alternate blocks
C424.6 Understand the properties of different BTL6
construction materials

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 DEPARTMENT OF CIVIL ENGINEERING
MAJOR PROJECT ARTICULATION MATRIX

Mapping of Course Outcomes (CO) with Program Outcomes (PO) and Program Specific
Outcomes (PSO’s):

Course Program
Outcomes Program Outcomes (PO) Specific
(CO) Outcomes
(PSO’s)
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO PO PSO PSO
11 12 1 2
C424.1 3 1 2
C424.2. 2 2 2 2
C424.3. 2 2 3 2 2 1 2
C424.4. 3 2 2 1 2 2 2
C424.5. 2 2 2 1 2 1 2 3
Average

Level:
1- Low correlation (Low), 2- Medium correlation (Medium), 3-High correlation (High)

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 DECLARATION
We hereby declare that the major project report entitled “PERFORMANCE
EVALUATION OF WASTE AAC BLOCK FINE AGGREGATE PARTIALLY
REPLACED IN CEMENT MORTAR AND ADDITION OF NATURAL COIR
FIBRES” submitted by us to ISL ENGINEERING COLLEGE, OSMANIA UNIVERSITY,
in partial fulfilment of the requirement for the award of the degree of Bachelor of Engineering in
Civil Engineering is a record of bonafide major project work carried out by us under the guidance
of Mr. SALAHUDDIN SHAKEEB S M. We further declare that the work reported in this major
project has not been copied or purchased and it would not be submitted, either in partial or in full,
for the award of any other degree in this institute or any institute or university.

DATE:
PLACE: HYDERABAD
Name, Hall Ticket Number & Signature of the Students:

MOHAMMED MUZAMMIL
HT.NO:160521732309
PH.NO:8125308745
E-Mail: [email protected]

SIGNATURE:

Place: Hyderabad
Date: June 2025

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 DEPARTMENT OF CIVIL ENGINEERING
CERTIFICATE
This is to certify that the major project stage -II work entitled “PERFORMANCE
EVALUATION OF WASTE AAC BLOCK FINE AGGREGATE PARTIALLY
REPLACED IN CEMENT MORTAR AND ADDITION OF NATURAL COIR
FIBRES” under the supervision of Dr. Mohammed Safiuddin, Associate Professor, Mr.
Salahuddin Shakeeb Assistant Professor is a bonafide work completed and submitted by; MOHD
MUZAMMIL HT. NO. 160521732309
In partial fulfillment for the award of degree of Bachelor of Engineering In “CIVIL
ENGINEERING” of Osmania University, Hyderabad during the academic year 2024-2025.
The project report has been approved as it satisfies the academic requirement prescribed for the
bachelor of engineering.

Mr. Salahuddin Shakeeb S M

(PROJECT GUIDE) (DEAN ACADEMICS)

Mrs. Nanchari Dr. Mohammed Masood

(H.O.D CIVIL) (PRINCIPAL)

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 ACKNOWLEDGEMENT

In the name of almighty, the most beneficent and the most merciful
We thank the Management of ISL Engineering College for providing us with an
opportunity to conduct major project work in college.
We express our deep sense of gratitude towards CHAIRMAN SIR, Principal
Sir, for tremendous support, encouragement and inspiration.
We convey our deep sense of gratitude to Mrs. Nanchari Madam Head of
the Department of Civil Engineering in ISL Engineering College for her
valuable guidance, associated to the major project work.
We are thankful to Dr. Mohammed Safiuddin, the project co-ordinator for
providing the necessary guidance to pursue and successfully the project on time
with quality.
We wish our deepest sense of gratitude to our project guide Mr. Salahuddin
Shakeeb S M, ISL Engineering College for their guidance, valuable advice,
inspiration and encouragement in executing this project work.
We whole heartedly thank all staff members of Department of Civil Engineering of
ISL Engineering College for their support and encouragement related to our
major project work.
Last but not the least, we are very much grateful to our parents, family
members for their support, encouragement, and love. We are also thankful to all
those who helped us directly and indirectly with this major project work which
turned out to be very successful, and I finally thank our beloved parents and family
for their extreme support throughout the major project.

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 ABSTRACT

Blocks of autoclaved aerated concrete (AAC) are utilized extensively in qualities

and lightweight design. Lime, Portland cement, water, aluminum powder, modern
building construction. They are renowned for their exceptional thermal insulation
calcined gypsum, and quartz sand are its constituents. Additionally, they can be
readily molded or cut to meet individual needs and come in a variety of sizes for a
range of applications. A portion of the AAC block, known as the bat, is frequently
left behind during wall building; if it is unsuitable or does not fit in that location, it
will not be used in subsequent projects.
Rather, it is waste stuff that will be thrown away. Additionally, AAC blocks are
wasted in the processing and shipment processes. They are not being used
effectively, which leads to needless waste. Because of their comparatively poor
load-bearing capability, the waste AAC blocks might not be appropriate for land
filling applications. Its high energy consumption throughout the manufacturing
process and trash generation also has a considerable detrimental influence on the
environment. Thus, it's critical to figure out how to use leftover AAC blocks.
In the current study, we go over possible approaches and tactics for encouraging
recycling or repurposing of unwanted materials and optimizing the usage of waste
AAC blocks. In particular, we examine several methods for recycling discarded
AAC blocks in building projects and look into the viability of employing them as
building materials. AAC block waste was investigated as a substitute for sand in
mortar mixes at replacement rates of 0%, 25%, 50%, and 75%. In this
investigation, the specimens underwent a compressive strength test.
Coconut fiber (coir fiber) is a plentiful, adaptable, renewable, and cost-effective
fiber that exhibits higher resistance to thermal conductivity. The purpose of this
study is to explore the potential use of coconut fiber alongside other components of
cement mortar and to examine the strength characteristics. A review of existing
literature was conducted, revealing that a comprehensive study of coconut fiber
mortar is essential, based on the experimental results of workability and
mechanical strength studies a constant length of 30mm of coir fiber and diameter
0.45mm and 0%, 0.5%, 1% & 1.5% by weight of cement were used.
Key Words: AAC Blocks, Coir Fibers, Compressive Strength, Density, Resource
Conservation.

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 TABLE OF CONTENTS

TITLE PG. NO

DECLARATION 10
CERTIFICATE 11
ACKNOWLEDGEMENT 12
ABSTRACT 13
CHAPTER 1-INTRODUCTION

1.1 GENERAL 19

1.2 SAFE DISPOSAL AND MANAGEMENT OF AAC WASTE 20

1.3 ENVIRONMENTAL IMPACT OF DISPOSING AAC WASTE 20

1.4 CARBON FOOT PRINT OF CEMENT PRODUCTION 21

1.5 EMISSION OF HEAT DURING HYDRATION OF CEMENT 22

1.6 ENVIRONMENTAL IMPACT OF RIVER SAND DEPLECTION 22

1.7 BENEFITS OF CEMENT MORTAR WITH INDUSTRIAL WASTES 23

1.8 EXPLOITATION OF INDUSTRIAL WASTES IN CEMENT MORTAR 24

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CHAPTER 2- LITERATURE REVIEW

2.1 GENERAL 25

2.2 WASTE AAC BLOCK POWDER IN MORTAR 25

2.3 SURVEY ON COIR FIBRE 27

CHAPTER 3- METHODOLOGY 30

CHAPTER 4- MATERIAL USED

4.1 GENERAL 32
4.2 BINDER 32
4.3 FINE AGGREGATE 33
4.4 COIR FIBRE 35
4.5 WATER 37

CHAPTER 5- MIXING & CASTING

5.1 MIX DESIGN 38

5.2 CONTROL MIX PROPORTIONS 38
5.3 PARTIAL REPLACEMENT MIXES 38
5.4 RATIONALISING MIX PROPORTIONS 39
5.5 CALCULATION OF MIX DESIGN 40
5.6 PREPARATION OF SPECIMENS 42
5.7 MIXING PROCEDURE 43
5.8 MOLDING AND CURING 44

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CHAPTER 6- EXPERIMENTAL INVESTIGATION

6.1 TESTS ON MATERIALS 46

6.2 CEMENT 46
6.3 FINE AGGREGATE 49
6.4 PH VALUE TEST 52
6.5 TESTS ON COIR FIBRE 53

CHAPTER 7- RESULT OF SPECIMEMEN

7.1 COMPRESSION TEST 54

7.2 DENSITY TEST 56
7.3 VISUAL TEST 57

CHAPTER 8- CONCLUSION AND RECOMMENDATIONS

8.1 SUMMARY OF KEY FINDINGS 59

8.2 PRACTICAL IMPLICATIONS 60
8.3 FUTURE RECOMMENDATIONS 60
REFERENCES 61

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 LIST OF FIGURES

S.NO FIGURES PG.NO

Figure 1 Cement 32
Fig:2 Fine aggregate 33
Fig: 3 Waste AAC Block 35
Fig: 4 Waste AAC Powder 35
Fig: 5 Coir Fibre 36
Fig: 6 Dry Mix 43
Fig: 7 wet mix 44
Fig: 8 Moulding of Cubes 44
Fig :9 Moulded Cubes 45
Fig: 10 Curing of cubes 45
Fig: 11 Cubes after Curing 45
Fig: 12 Normal consistency test 47
Fig: 13 Initial & Final test 48
Fig: 14 Bulking of Sand 50
Fig: 15 Specific gravity of Fine Aggregate 52
Fig: 16 PH value 53
Fig: 17 Pre Testing of cube 55
Fig: 18 During Test of cube 55
Fig: 19 Post Testing of cube 55
Fig: 20 CTM graph 55
Fig: 21 weighing of cube 56
Fig: 22 Visual Inspection 58

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 LIST OF TABLES

S.NO TABLES PG.NO

Table-1 Physical properties of cement 33

Table 2: Fineness of Sand 34
Table 3: Physical Properties waste AAC Fine Aggregate 35
Table 4: Mortar Mixes 39
Table 5: Normal Consistency 47
Table 6: Initial and Final Setting time tests 48
Table 7: SIEVE ANALYSIS 51
Table 8: SPECIFIC GRAVITY 52
TABLE 9: OBSERVATION OF CTM 55
TABLE 10: DENSITY VALUES 57

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 CHAPTER -1
INTRODUCTION

1.1 GENERAL

In general Cement mortar is a fundamental material in construction, composed

of cement, sand, and water. It serves as a binding agent for masonry units such as
bricks, stones, and concrete blocks, ensuring structural integrity and stability. The
mixture is carefully prepared to achieve the desired consistency and strength,
making it suitable for various applications in building and repair work.
The proportion of cement to sand in mortar varies depending on the intended use.
A common ratio is 1:3 (cement: sand) for high-strength applications, while ratios
like 1:4 or 1:6 are used for general masonry and plastering. Water is added to
activate the cement and facilitate mixing, ensuring proper adhesion and
workability. In some cases, additives such as plasticizers, retarders, or pigments are
incorporated to enhance specific properties like flexibility, setting time, or
aesthetic appeal.
Cement mortar possesses several important characteristics, including high
compressive strength, durability, and resistance to environmental factors. It helps
prevent water penetration, making structures more resilient against moisture
damage. Additionally, its workability allows for easy application, ensuring smooth
finishes in plastering and effective bonding in masonry construction.
The primary uses of cement mortar include masonry work, where it binds bricks
and stones together, plastering to create smooth wall surfaces, and pointing to fill

19
gaps between masonry units. It is also employed in repair work to fix cracks and
damaged structures. Overall, cement mortar plays a crucial role in construction,
providing stability, protection, and longevity to buildings and infrastructure.
1.2 SAFE DISPOSAL AND MANAGEMENT OF AAC WASTE

Autoclaved Aerated Concrete (AAC) waste, particularly hazardous

components, must be managed carefully to prevent environmental and health risks.
Disposal methods include landfilling, recycling, and controlled incineration,
depending on the nature of the waste. Proper segregation of AAC waste ensures
that hazardous materials do not contaminate non-hazardous debris. Additionally,
chemical stabilization and biological treatment can be used to neutralize harmful
substances before disposal. Compliance with environmental regulations and
hazardous waste management guidelines is essential to minimize pollution and
ensure safe handling.

1.3 ENVIRONMENTAL IMPACT OF DISPOSING AAC WASTE

The disposal of AAC hazardous waste requires careful handling to prevent

environmental contamination and health risks. AAC waste may contain harmful
substances that need proper segregation before disposal. Common methods include
landfilling, where waste is securely contained to prevent leaching, and recycling,
which allows AAC debris to be repurposed for construction applications. In cases
where hazardous chemicals are present, chemical stabilization can neutralize
harmful components before disposal. Additionally, biological treatment methods
may be used to break down toxic substances safely.
Regulatory compliance is essential in managing AAC hazardous waste.
Governments and environmental agencies have established guidelines to ensure
20
safe handling, transportation, and disposal. The Hazardous and Other Wastes
(Management and Transboundary Movement) Rules, 2016 outline procedures for
waste management, including restrictions on improper dumping and mandates for
waste treatment facilities. Organizations must follow these regulations to minimize
pollution and protect ecosystems. Proper documentation and monitoring of waste
disposal processes help maintain accountability and ensure adherence to
environmental standards.
1.4 Carbon Footprint of Cement Production

Cement production is a major contributor to global carbon dioxide (CO₂)

emissions, accounting for approximately 7-8% of total greenhouse gas emissions
worldwide. The primary source of CO₂ emissions in cement manufacturing comes
from the chemical process of decarbonation, where limestone (CaCO₃) is heated to
high temperatures to produce clinker, releasing large amounts of CO₂.
Additionally, the energy-intensive nature of cement production, which relies
heavily on fossil fuels for heating kilns, further adds to its carbon footprint. These
emissions make cement one of the most environmentally impactful industries,
necessitating urgent measures to reduce its carbon output.
Efforts to mitigate the carbon footprint of cement production include adopting
alternative fuels, improving energy efficiency, and incorporating supplementary
cementitious materials like fly ash and slag to reduce clinker usage. Innovations
such as carbon capture and storage (CCS) and the development of low-carbon
cement are also being explored to minimize emissions. Governments and industries
are increasingly focusing on sustainable practices, including stricter regulations
and incentives for greener production methods. By implementing these strategies,
the cement industry can significantly lower its environmental impact while
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continuing to support global infrastructure development.
1.5 EMISSION OF HEAT DURING HYDRATION OF CEMENT

The heat of hydration refers to the thermal energy released when cement reacts
with water during the hydration process. This reaction is exothermic, meaning it
generates heat as the chemical bonds in cement compounds break down and reform
into stable hydration products. The primary compounds responsible for heat
generation include tricalcium silicate (C₃S), which hydrates rapidly and releases a
significant amount of heat, and dicalcium silicate (C₂S), which hydrates more
slowly, producing less heat. Additionally, tricalcium aluminate (C₃A) contributes
to substantial heat release in the early stages of hydration.
The heat of hydration plays a crucial role in concrete curing, particularly in large
mass concrete structures, where excessive heat buildup can lead to thermal
cracking. In adiabatic conditions, where heat dissipation is minimal, the
temperature rise within the concrete can be significant, affecting its structural
integrity. Engineers often implement cooling techniques, such as embedded pipes
for circulating cool water, to control temperature variations and prevent cracks.
Understanding and managing the heat of hydration is essential for ensuring the
durability and strength of concrete structures.

1.6 ENVIRONMENTAL IMPACT OF RIVER SAND DEPLECTION

River sand depletion has significant environmental consequences, affecting

ecosystems, water resources, and biodiversity. Excessive sand mining disrupts
riverbeds, leading to erosion, loss of aquatic habitats, and changes in water flow
patterns. The removal of sand reduces the river’s ability to naturally replenish

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itself, causing instability in the riverbanks and increasing the risk of flooding.
Additionally, the destruction of sand deposits impacts groundwater recharge,
leading to lower water tables and scarcity of drinking water in nearby areas.
The depletion of river sand also affects biodiversity, as many aquatic species rely
on stable riverbeds for breeding and shelter. Increased turbidity from sand mining
reduces water quality, harming fish populations and other aquatic organisms.
Furthermore, coastal areas suffer from saline water intrusion, as sand depletion
weakens natural barriers against seawater encroachment. To mitigate these
impacts, sustainable sand mining practices, stricter regulations, and alternative
materials like manufactured sand (M-sand) must be promoted to reduce
dependency on river sand.

1.7 BENEFITS OF CEMENT MORTAR WITH INDUSTRIAL WASTES

Using coir fiber and industrial wastes in cement mortar offers several benefits,
including enhanced durability, sustainability, and improved mechanical properties.
Coir fiber, derived from coconut husks, acts as a natural reinforcement material,
increasing the tensile strength and crack resistance of cement mortar. It helps
reduce shrinkage and improves flexibility, making the mortar more resilient to
environmental stresses. Additionally, coir fiber is lightweight, biodegradable, and
abundantly available, making it an eco-friendly alternative to synthetic fibers.
Studies have shown that incorporating coir pith particles in cement mortar can
provide comparable compressive strength to conventional mortar.
Incorporating other industrial wastes such as fly ash, silica fume, and ground-
granulated blast-furnace slag (GGBS) further enhances the sustainability of cement
mortar. These materials help in reducing cement consumption, lowering carbon

23
emissions, and improving thermal insulation properties. Research indicates that
coir fiber-reinforced mortars improve flexural strength and fracture toughness,
making them suitable for applications requiring enhanced durability. By utilizing
industrial and agricultural by-products, cement mortar becomes more
environmentally friendly, promoting waste reduction and resource conservation in
the construction industry.
1.8 EXPLOITATION OF INDUSTRIAL WASTES IN CEMENT MORTAR

The exploitation of industrial wastes in cement mortar offers significant

environmental and economic benefits. By incorporating materials such as fly ash,
silica fume, ground-granulated blast-furnace slag (GGBS), quarry dust, and rice
husk ash, cement mortar production can reduce reliance on natural resources while
improving mechanical properties. These industrial by-products serve as
supplementary cementitious materials (SCMs), enhancing durability, workability,
and sustainability. Additionally, using industrial waste helps in waste management,
reducing landfill disposal and minimizing environmental pollution.
From a sustainability perspective, replacing cement with 15% fly ash or other
industrial wastes can significantly lower carbon emissions and resource extraction
costs. Studies have shown that such replacements contribute to monetary savings
while maintaining structural integrity. Furthermore, life-cycle assessments indicate
that waste-based cementitious materials have lower environmental impacts across
categories such as human health, ecosystem stability, and natural resource
depletion. By adopting these practices, the construction industry can move toward
eco friendly and cost-effective solutions, - ensuring long-term sustainability.

24
 CHAPTER 2

LITERATURE SURVEY

2.1 GENERAL

In this chapter, The literature survey is done. The literatures related to how the
chosen replacement materials influence the Cement Mortar properties, mechanical
properties, durable properties and micro structural properties of cement mortar and
fine aggregates. The inference from the literature survey is carried out. Evaluating
the mechanical properties (compressive, flexural, and tensile strength) of modified
mortar mixes containing AAC powder and coir fibre.
2.2 WASTAGE AAC BLOCK POWDER IN MORTAR

2.2.1 Bansal, P., & Kumar, M. (2020) – Construction and Building Materials
Title: “Utilization of Autoclaved Aerated Concrete (AAC) waste in cementitious
materials”
Study: AAC waste was ground and used as a partial fine aggregate replacement in
cement mortar at 0%, 25%, 50%, and 75%.
Findings: 50% replacement gave optimal compressive strength. Beyond 50%,
strength dropped due to the porous nature of AAC.
Conclusion: AAC powder can replace sand effectively up to moderate levels
without compromising strength.

2.2.2 Patel, R., & Shah, T. (2018) – International Journal of Civil Engineering
and Technology (IJCIET)
Title: “Experimental study on cement mortar with partial replacement of sand by
AAC block waste”
25
Study: Investigated strength and durability of mortar replacing 0%, 20%, 40%,
60% sand with AAC waste.
Findings: Compressive strength increased up to 40% replacement, after which
water absorption increased drastically.
Conclusion: Replacing sand by AAC up to 40% enhances both sustainability and
performance.

2.2.3 Kumar, A., & Singh, B. (2021) – Journal of Cleaner Production

Title: “Sustainable reuse of AAC waste as fine aggregate in cement composites”
Study: Focused on microstructural analysis, mechanical strength, and durability
properties.
Findings: At 25–50% replacement, pozzolanic behavior contributed to better
matrix formation.
Conclusion: Use of AAC improves sustainability; however, water-to-cement ratio
should be adjusted for workability.

2.2.4 Thakur, D., & Jain, V. (2019) – International Research Journal of

Engineering and Technology (IRJET)
Title: “Effect of crushed AAC waste on mortar strength”
Study: Examined mortar specimens with AAC block powder up to 70%.
Findings: Highest compressive and flexural strength at 30–40%. AAC particles act
as micro-fillers, reducing porosity.
Conclusion: AAC replacement should be optimized to avoid loss of mechanical
strength due to excessive porosity.
2.2.5 Gokul, M., & Prasad, K. (2022) – Materials Today: Proceedings
Title: “Effect of AAC powder in cementitious composites”
26
Study: Compared traditional and AAC-based mortar for mechanical and thermal
performance.
Findings: Significant reduction in density and improved thermal insulation, with
slightly reduced strength at 75% AAC.
Conclusion: Lightweight and eco-friendly mortar with potential for nonstructural
applications.
2.3 SURVEY ON COIR FIBRE

2.3.1 Majid Ali, Anthony Liu, HouSou, Nawawi Chouw, "Mechanical and
Dynamic Properties of Coconut Fibre Reinforced Concrete. "Construction and
Building Materials. Reed Business Information, Inc. (US). 2012. High Beam
Research. 5 Sep. 2013. Reinforcement of concrete is necessary to enhance its
engineering properties. In this study, we are used coir fibre as they have many
advantages such as freely available and cost effective. High cost is the dominating
factor of convectional construction material which is affecting the housing system.
As an alternative method to overcome this drawback we introduced use of Coconut
Shell and Coconut Coir fibre in reinforced concrete. This is a biological issue as
coconut shell waste is difficult to biodegrade. It can be used to impart the various
engineering properties such as shear strength, tensile strength, bearing capacity and
many other properties by using various proportions and size of the Coconut shell
and Coconut coir fibre. Coconut fibre has the ability to resist cracking and spalling.

2.3.2 B. M. Ahuja et.al (2015)- Behaviour of concrete reinforced with jute, coir
and bamboo fibres”, Short discrete vegetable fibres namely jute, coir and bamboo
have been examined for their suitability for incorporation in cement concrete. The
physical properties of these fibres have shown no deterioration in a concrete
27
medium. It is shown that workable and homogeneous mixes can be obtained using
a special method of proportioning. While compressive and tensile strengths of
vegetable fibre concretes are no higher than those of control concrete, their
deformation behaviour shows improvement in ductility and reduced shrinkage.
Impact and fracture toughness of vegetable fibre concretes are also distinctly
higher. The various experiment result presented in the paper show that jute, coir
and bamboo fibres can be used with advantage in concrete in a manner similar to
other fibres. Impact strength improvement of over 25% and increased ductility
under static loading and considerably lower shrinkage characteristics of the order
of 50% to 70% associated to those of plain concrete, are noted as positive features
of vegetable fibre additions. No serious adverse effects of fibre additions have been
noted.

2.3.3 M. J. Ienamul Hasan Ali et.al (2018)- Experimental study on coir fibre
mixed concrete”, This paper presents the versatility of coconut fibre is one of the
natural fibers abundantly available in tropical regions, and is extracted from the
husk of coconut fruit the properties of composites of concrete in which coconut
fibers are used as reinforcement, are discussed. The research carried out and the
conclusions drawn by different researchers in last few decades are also briefly
presented. Coconut fibers reinforced composites have been used as cheap and
durable non-structural elements. The flexural strength of coir fibre reinforced
concrete increases for 1%, 2%, 3% of fibre used for M20 grade when compared
with conventional concrete. The coir fibre reinforced concrete is more effective
than conventional concrete. The aim of this project is to spread awareness of
coconut fibers as a construction material in Civil Engineering

28
2.3.4 Anila Kumar et.al (2018)- Comparative study of strength properties of
coconut coir fibre reinforced concrete due to partial replacement of cement by
pozzolanic materials”, The main objective of the modern-day Civil Engineering is
to achieve Sustainability and the term is also widely accepted by engineers
worldwide. The construction industry is revolutionizing in terms of both
equipment, materials. Thus, the basic cost of construction has increased
exponentially along with detrimental effectson environment. Thus, lot of research
work is been carried to reduce the usage of non-renewable resources and to achieve
economy. The primary objective of the current project is to investigate the strength
properties of coconut coir fibre reinforced concrete due to partial replacement of
cement by various pozzolanas. The coir fibre reinforced concrete along with
GGBFS, is a good material to attain both compressive and flexural strength. Both
fly ash, GGBFS has remarkably increased the strength properties.

29
 CHAPTER 3

METHODOLOGY

The methodology for this project focused on both material characterization and
experimental testing to evaluate the performance of mortar incorporating waste
AAC block powder as a partial replacement for fine aggregate and natural coir
fibers. The study aimed to assess the mechanical and properties of the modified
mortar for sustainable construction applications.

Initially, used AAC (Autoclaved Aerated Concrete) blocks were collected from
demolition waste. The blocks were crushed and ground into fine powder using a
ball mill. The powdered AAC was then sieved to pass through 4.75 mm and stored
in airtight containers for use in mortar mixes. Simultaneously, natural coir fibers
were collected from coconut waste, cleaned to remove impurities, and sun-dried.
The fibers were then cut to an average length of 30 mm and treated by soaking in
water for 24 hours to improve bonding with the cement matrix.

A control mortar mix was designed using natural river sand, PPC 53-grade cement,
and potable water, with a constant water-to-cement ratio maintained for all mixes.
waste AAC block powder was used to replace fine aggregate at proportions of 0%,
25%, 50%, and 75% by weight. For each replacement level, coir fibers were added
at 0%, 0.5%, 1%, and 1.5% by weight of cement. A total of 4 mix combinations
were prepared, with two 70.7 mm cubes cast per mix.

The materials were mixed manually to ensure homogeneity, and the mortar was
poured into standard cube moulds in three layers, compacted properly using a
30
tamping rod. The cubes were then demoulded after 24 hours and subjected to water
curing for 3, 7, and 28 days.
After curing, the specimens were tested for compressive strength using a
compression testing machine (CTM). The results were recorded and compared
with conventional mortar to evaluate performance in terms of strength, durability,
and environmental impact.
Methodology Flow Chart:

LITERATURE SURVEY

MATERIALS COLLECTION

TESTING ON MATERIALS

MIX DESIGN & PROPORTIONING

MOTOR PREPARATION & CASTING

CURING & TESTING

DATA ANALYSIS & INTERPRETATION

31
CONCLUSION & RECOMMEDATIONS
 CHAPTER 4

MATERIALS

4.1 GENERAL
In this chapter, the sources and the properties of the materials used are given.
And method’s of project are executed

4.2 BINDER
For binding fine aggregates and waste AAC aggregates together and filling the
pores between sand and stone particles, the binder’s is added in cement mortar.

4.2.1 CEMENT
Portland Pozzolana Cement (PPC) of 53 Grade, conforming to IS 12269:2013, was
used throughout the experimental work. This grade was selected due to its high
early strength, which is ideal for studying the development of compressive strength
at early ages such as 3 and 7 days. PPC is known for its reliable setting
characteristics, compatibility with various admixtures, and durability.
The cement was stored in airtight containers to avoid exposure to moisture. Before
use, physical tests such as fineness test, standard consistency, and initial/final
setting times were conducted to ensure conformity with standard specifications
shown in Table.1

Figure 1 – CEMENT
32
 Table-1 Physical properties of cement
S.NO Property Value
1 Fineness Modulus 2
2 Specific Gravity 3.15
3 Normal Consistency 28%
4 Initial Setting Time 39 minutes
5 Final Setting Time 220 minutes

4.3 FINE AGGREGATE

Natural river sand was used as the fine aggregate. The sand was clean, well
graded, and free from clay, silt, organic matter, and other deleterious substances.
The properties of fine aggregate directly affect the workability and strength of
mortar, hence proper sieving was done through a 4.75 mm sieve.
The sand used belonged to Zone II grading as per IS: 383-2016 standards.
Important characteristics like specific gravity, bulk density, and water absorption
were tested before use. Natural sand was chosen due to its good bonding
characteristics and compatibility with cementitious systems as shown in Table 3.2

Fig:2 Fine aggregate

33
 Table 2: Fineness of Sand
S.NO. IS SIEVE %RETAINED %PASSING
DESIGNATION
(mm)
1 10 0 100
2 4.75 0.2 99.8
3 2.36 1.35 98.65
4 1.18 11.55 88.45
5 0.6 49.75 50.25
6 0.3 89 11
7 1.15 99.99 0.1
Fineness Modulus 2.52

4.3.1 WASTE AAC FINE AGGREGATE

Waste AAC Fine Aggregate refers to finely crushed particles derived from
Autoclaved Aerated Concrete (AAC) block waste, used as a partial or full
replacement for natural sand in mortar or concrete. While IS 383:2016 is the
primary Indian Standard that governs the specifications for fine aggregates for
concrete, it does not explicitly list AAC waste as a standard aggregate source.
However, it does allow for manufactured and recycled aggregates, including
materials like crushed stone sand, bottom ash, and recycled concrete aggregate,
provided they meet the required physical and chemical properties.
To use AAC waste as fine aggregate under IS 383:2016:
It must pass through a 4.75 mm IS sieve.
34
It should conform to grading limits (Zones I–IV).
It must meet criteria for silt content, specific gravity, water absorption, and
deleterious materials.
Table 3: Physical Properties waste AAC Fine Aggregate
Property Results waste AAC Fine Aggregate
Fineness Modulus 1.64
Water Absorption 28% (by wt)
Bulk Density 0.81kg/ltr

Fig: 3 Waste AAC Block Fig: 4 Waste AAC Powder

4.4 Coir Fiber

Coir fiber is a natural fiber extracted from the outer husk of coconut. It is
composed primarily of lignin and cellulose, which provide it with high durability,
resistance to saltwater, and moderate tensile strength. Due to its coarse texture,
high toughness, and eco-friendly nature, coir fiber is commonly used as a
reinforcing material in mortar and concrete composites to improve crack resistance
and ductility.

35
Extraction Process:
1. Collection: Mature coconut husks are collected from coconut farms or coir-
processing units.
2. Retting: The husks are soaked in water (usually in ponds, rivers, or tanks) for
several weeks (traditional retting) to soften the husk and loosen the fibers.
Mechanical or chemical retting methods may also be used to reduce processing
time.
3. Fiber Extraction: After retting, the husks are beaten or mechanically
decorticated to separate the long coir fibers from the pith and outer shell.
4. Washing and Drying: The extracted fibers are thoroughly washed to remove
impurities, then sun-dried or oven-dried to reduce moisture content.
5. Cutting and Sieving (if needed): Dried fibers are cut into desired lengths and
sieved to ensure uniformity for use in mortar or concrete mixes.
6. Optional Treatment: To improve compatibility with cementitious materials,
coir fibers may be treated with alkali solutions (e.g., sodium hydroxide) to remove
natural fats, waxes, and lignin, thereby enhancing bonding strength.

Fig: 5 Coir Fibre

36
4.5 WATER

Potable tap water conforming to IS: 456-2000 standards was used for mixing and
curing of mortar specimens. The water was free from impurities like chlorides,
sulfates, alkalis, and organic substances.
A constant water-to-cement (W/C) ratio of 0.5 was maintained throughout the
experimental program to ensure uniformity in hydration and workability. The
selected W/C ratio is widely accepted in mortar design as it provides a good
balance between workability and strength.
The curing of mortar specimens was also done using clean water in a curing tank
maintained at ambient laboratory temperature (~27°C ±2°C).

37
 CHAPTER 5

MIXING & CASTING

5.1 MIX DESIGN

In this experimental study, the mix design was formulated to evaluate the effect of
replacing natural fine aggregate with waste AAC block powder and the inclusion
of natural coir fibers on the properties of cement mortar. The mix design followed
standard IS code 2250 (1981) guidelines for mortar mixes, ensuring consistency in
water-to-cement ratio and cement content across all samples.
5.2 CONTROL MIX PROPORTIONS

The control mix (conventional mortar) was prepared using Ordinary Portland
Cement (OPC) 53 grade, natural river sand, and potable water without any
additives or replacements. The ratio adopted was:
Cement : Sand = 1 : 3 (by weight)
Water-Cement Ratio = 0.5
This mix was used as a benchmark for comparing the physical and mechanical
properties of modified mortar mixes.

5.3 PARTIAL REPLACEMENT MIXES

To assess the performance of mortar with sustainable materials, AAC block

powder was used to replace natural sand partially at four different levels:
0%, 25%, 50%, and 75% by weight of fine aggregate.
Additionally, natural coir fibers were added at 0%, 0.5%, 1%, and 1.5% by weight
38
of cement to improve crack resistance and post-crack behavior.

MIX MATRIX

A total of 4 different combinations of mortar mixes were prepared using factorial

combinations of AAC powder and bagasse fiber percentages, as shown in the table
below:

Table 4: Mortar Mixes

AAC POWDER COIR
MIX REPLACEMENT FIBER
ID (%) ADDITION
(%)
M1 0 0
M2 25 0.5
M3 50 1
M4 75 1.5

The cement content and water-cement ratio were kept constant across all mixes.
Sand and AAC powder were adjusted based on the target replacement percentage.

5.4 RATIONALISING MIX PROPORTIONS

The mix proportions were chosen based on the following considerations:

5.4.1 AAC Block Powder Replacement Levels

25%, 50%, and 75% levels were selected to analyze the gradual effect of increased
replacement of sand with AAC powder.
These levels help identify the optimum replacement percentage that can improve
39
sustainability without severely compromising strength.

5.4.2 COIR FIBRE DOSAGE

Natural fibers affect workability and bonding characteristics.

A dosage range of 0% to 1.5% was chosen based on previous literature and trial
mixes.
0.5%, 1.0%, and 1.5% allowed us to observe the fiber’s effect on crack control,
flexural strength, and ductility.

5.4.3 CONSISTENT WATER CEMENT RATIO (0.5)

Maintaining the same W/C ratio helped isolate the effects of AAC powder and
fiber content on the mortar's performance.

5.4.4 PRATICAL AND RESEARCH ORIENTED REPORT

The selected mix combinations provide a balanced experimental setup to study

interactions between two sustainable components (AAC waste and bagasse fiber).
The factorial design helps in comparative analysis and identification of the
bestperforming mix for potential field applications.

5.5 CALCULATION OF MIX DESIGN

Proportion = 1:3
Volume = 7.05x7.05x7.05
= 350.402cm3
40
 = 0.000350m3
Density = Density of cement mortar
= 2070 kg/m3
Weight = Volume x Density
= 0.0705 x 2070
= 0.725kg = 725gm
Adding 5% Extra for wastages
= 725+5%
= 762gm
Summation of proportion
= 1+3 = 4
0% CUBE
1. Cement = 762/4 = 190.5gm’s
2. Sand = 571.5gm’s
3. Water Cement Ratio = 0.5
= 0.5 x 190.5
= 95.25 = 96ml
0.5% Fiber + 25% AAC
1. Cement = 190.5gm’s
2. Sand (Total 571.5gm’s)
a. Natural sand = 428.5gm’s
b. AAC Sand (25%) = 143gm’s
3. Fibers (0.5% by weight of cement)
= 190.5 x 0.5%
= 0.95gm’s
Water Ratio = 96ml
41
1% Fiber + 50% AAC

1. Cement = 190.5gm’s
2. Sand = 571.5hm’s
a. Natural Sand = 285.75gm’s
b. AAC Sand = 285.75gm’s
3. Fibers (1% by weight of cement)
= 1.90g
1.5% Fiber + 75% AAC
1. Cement = 190.5gm’s
2. Sand = 571.5gm’s
a. Natural Sand (25%) = 142.87 = 143gm’s
b. AAC Sand (75%) = 428.6gm’s
3. Fibers (1.5%)
= 190.5 x 1.5%
= 2.85gm’s
Water = 96ml
5.6 PREPARATION OF SPECIMENS

To evaluate the influence of recycled AAC block powder and natural bagasse
fibers on the properties of cement mortar, a systematic procedure was followed for
the preparation of mortar specimens. The process included careful proportioning,
proper mixing, molding, and curing to ensure consistency and reliability of results.

42
5.7 MIXING PROCEDURE

The mixing procedure was carried out in accordance with IS 2250:1981 and IS
4031. The steps followed were:
Material Collection and Measurement:
The required quantities of cement, natural sand, recycled AAC block powder, and
bagasse fibers were weighed accurately based on the selected mix proportions.
The water-cement ratio was kept constant for all mixes to maintain uniformity
(typically 0.5 unless otherwise specified).

Dry Mixing:
Cement, natural sand, and AAC block powder (in their respective replacement
percentages: 0%, 25%, 50%, 75%) were first mixed thoroughly in dry condition for
about 2–3 minutes to ensure uniform distribution.
In mixes containing coir fibers (0%, 0.5%, 1%, 1.5%), the fibers were uniformly
spread and mixed with the dry mix to prevent balling or clumping.

Fig: 6 Dry Mix

Addition of Water:
The pre-calculated quantity of water was gradually added to the dry mix while
continuously mixing to achieve a homogeneous mortar mix.
43
Mechanical or hand mixing was done for 5–7 minutes until a uniform consistency
was obtained.

Fig: 7 wet mix

Final Mixing Check:

The mix was checked visually to ensure there were no dry pockets and the fibers
were evenly distributed throughout the mortar mass.

5.8 MOULDING AND CURING

Molding of Specimens:
The fresh mortar was poured into standard cube molds of size 70.7 mm × 70.7 mm
× 70.7 mm, in two layers.
Each layer was compacted manually using a tamping rod to remove entrapped air
and ensure proper compaction.
The top surface was leveled and finished smoothly using a trowel.

Fig : 8 Moulding of Cubes

44
Demoulding:
After 24 hours of casting, the specimens were carefully removed from the molds to
avoid damage.

Fig :9 Moulded Cubes

Curing:
The demolded specimens were placed in a curing tank filled with clean potable
water.
The curing was done for 3, 7, and 28 days, respectively, based on the testing
schedule.
Specimens were taken out of the tank just before testing and wiped to remove
surface water.

Fig: 10 Curing of cubes Fig: 11 Cubes after Curing

45
 CHAPTER 6

EXPERIMENTAL INVESTIGATION

6.1 TESTS ON MATERIALS

6.2 CEMENT
6.2.1 NORMAL CONSISTENCY TEST
To determine the normal consistency of cement, the Vicat apparatus is used along
with a plunger of 10 mm diameter, a non-porous glass plate, a measuring cylinder,
weighing balance, a trowel or spatula, and a clean Vicat mould. First, 300 grams of
cement is weighed and placed on the glass plate. A calculated amount of water,
starting with about 25% of the cement's weight, is added and mixed thoroughly for
3 to 5 minutes to form a uniform paste. This paste is then quickly filled into the
Vicat mould, which is placed on the glass plate, and leveled at the top. The
standard plunger is brought into contact with the surface of the paste and then
released freely to allow it to penetrate vertically. The depth of penetration is
observed. If the plunger penetrates to a point 5 to 7 mm from the bottom of the
mould, the water content used is considered the normal consistency. If the
penetration is more or less, the water content is adjusted, and the test is repeated
with a fresh sample until the desired penetration depth is achieved.

46
 Fig: 12 NORMAL CONSISTENCY TEST

Table 5: Normal Consistency observation

Trial No. % Water Added Penetration Depth (mm)

1 25% 12 mm

2 28% 7 mm

3 30% 4 mm
Result: The normal consistency of cement =28%

6.2.2 INITIAL AND FINAL SETTING TIME TEST:

The test for determining the initial and final setting time of cement is conducted
using a Vicat apparatus, which includes a mold, a set of needles (initial setting
needle of 1 mm² and final setting needle with an annular attachment), a stop watch,
weighing balance, measuring cylinder, non-porous glass plate, trowel, and clean
water. About 300 grams of cement is taken and mixed with water whose
percentage is based on the normal consistency test. The time of adding water is
recorded as the starting point of the test. The cement paste is then placed into the

47
Vicat mold, which rests on the glass plate. For determining the initial setting time,
the square needle is gently lowered to touch the surface and released. This process
is repeated at regular intervals until the needle penetrates the paste to a depth of
about 33–35 mm from the top (i.e., 5–7 mm from the bottom of the mold). This
point marks the initial setting time. To determine the final setting time, the needle
is replaced with the circular attachment. The final setting time is the moment when
the needle fails to penetrate the paste and leaves only a slight impression on the
surface, indicating that the cement paste has hardened sufficiently.
Table 6: Initial and Final Setting time tests
Observation type Time(min)
Initial Setting Time 39 minutes
Final Setting Time 220 minutes

Fig: 13 Initial & Final test

6.2.3 FINENESS TEST:

The primary apparatus used includes a 90-micron IS sieve, a weighing balance

(accurate to 0.01g), a standard brush, and a tray. First, 100 grams of cement is
taken and dried if necessary. This sample is placed on the 90-micron sieve, which
48
is fixed over a pan. The sieving is done manually by holding the sieve in one hand
and rubbing it gently with a circular and vertical motion using the other hand for
about 15 minutes. During sieving, care is taken to avoid overloading or aggressive
rubbing, which might break the particles. After sieving, the residue left on the
sieve is weighed. The percentage of retained cement is calculated using the
formula:
Fineness (%retained) = (weight of residue/original weight of cement) x100
Weight of cement sample taken = 100 g
Residue left on the 90-micron sieve = 2 g
Fineness = (2/100) × 100 = 2%

6.3 FINE AGGREGATE

6.3.1 BULKING OF SAND:
To perform the bulking of sand test, a 250 ml graduated measuring cylinder is used
along with a steel or glass rod for stirring, a sample of fine dry sand, and clean
water. Initially, the dry sand is filled into the graduated cylinder up to the 100 ml
mark without compacting it. This represents the dry volume of the sand. Water is
then added slowly in small quantities to the sand, and the mixture is stirred gently
using the rod to ensure uniform moisture distribution throughout the sand. As
water is added, the sand particles repel each other due to the formation of a thin
water film around them, which causes an increase in volume — a phenomenon
known as bulking. After thorough mixing, the new volume of moist sand is noted;
in this case, it rises to 125 ml. The percentage of bulking can be calculated using
the formula:
Percentage bulking = (125-100/100) x 100 =25%

49
 Fig: 14 Bulking of Sand

6.3.2 SIEVE ANALYSIS

To conduct the sieve analysis of fine aggregate, the apparatus required includes a
set of standard IS sieves (typically 4.75 mm, 2.36 mm, 1.18 mm, 600 µm, 300 µm,
and 150 µm), a mechanical or manual sieve shaker, a weighing balance accurate to
0.1 g, a dry cloth or tray, and a clean, dry sample of fine aggregate weighing about
1000 grams. The procedure starts by oven-drying the fine aggregate sample at
110°C for 24 hours to remove all moisture. Once cooled, the sample is weighed
accurately and placed in the top sieve of a sieve stack arranged in descending order
of size with a pan at the bottom. The sieve stack is then shaken either manually or
using a mechanical shaker for 10–15 minutes to allow proper separation of
particles. After shaking, the material retained on each sieve is carefully collected
and weighed. The weights retained on each sieve are used to compute the
cumulative percentage retained and the percentage passing through, which helps in
determining the grading of the fine aggregate and its fineness modulus.

50
 S.NO. IS SIEVE %RETAINED %PASSING
DESIGNATION
1 10 0 100
2 4.75 0.2 99.8
3 2.36 1.35 98.65
4 1.18 11.55 88.45
5 0.6 49.75 50.25
6 0.3 89 11
7 1.15 99.99 0.1
Fineness Modulus 2.52

Table 7: SIEVE ANALYSIS

6.3.3 SPECIFIC GRAVITY.

As per IS 2386 Part 3 -1963 About 500 grams of fine aggregate is taken and placed
in a tray. It is then soaked in water for 24 hours to ensure full saturation. After
soaking, the surface moisture is removed using a cloth, and the saturated surface-
dry (SSD) sample is weighed (Weight = W1). The SSD aggregate is then placed in
a pycnometer and filled with distilled water up to the mark. The weight of the
pycnometer with aggregate and water is recorded (Weight = W2). The pycnometer
is then emptied, and the aggregate is dried in an oven at 100°C–110°C for 24
hours. After cooling, the oven-dry weight of the aggregate is recorded (Weight =
W3). The empty weight of the pycnometer is also noted (Weight = W4).

51
 Observation Symbol Sample Value (g)

Weight of saturated surface-dry aggregate W1 500

Weight of pycnometer + SSD agg. + water W2 1620

Weight of pycnometer + water only W4 1450

Weight of oven-dry aggregate W3 480

Table 8: SPECIFIC GRAVITY

Fig: 15 Specific gravity of Fine Aggregate

6.4 PH VALUE TEST

To determine the pH value of a water sample, the pH meter is first calibrated using
standard buffer solutions of known pH values (typically pH 7, 4, and 9.2) by
immersing the electrode in each buffer solution and adjusting the reading
accordingly. After calibration, the electrode is thoroughly rinsed with distilled
water and gently dried. A clean beaker is then filled with the water sample to be
tested, and the electrode of the pH meter is immersed in it. The reading is allowed
to stabilize before recording the pH value displayed on the meter. It is important to
ensure that the electrode is fully immersed and not touching the beaker walls to
avoid error.

52
 Fig: 16 PH value

6.5 TESTS ON COIR FIBRE

To determine the diameter of a fiber, a screw gauge (micrometer) is used due to its
high precision in measuring small thicknesses. The apparatus consists of a
calibrated screw, thimble, ratchet, and anvil with a least count typically of 0.01
mm. Before measurement, the zero error is checked and noted if any. The fiber is
placed gently between the spindle and anvil, and the thimble is rotated until the
fiber is just held without compressing it. The main scale reading and the circular
scale reading are noted. The diameter of the fiber is calculated using the formula:
Diameter = Main scale reading + (Circular scale reading × Least count) ± Zero
error.
The process is repeated at least three different points along the fiber to account for
irregularities, and the average diameter is taken as the final value. This method is
widely used in material testing labs for precise and consistent fiber thickness
measurement.

53
 CHAPTER 7

RESULT OF SPECIMEMEN

7.1 COMPRESSION TEST

The apparatus required for conducting the compressive strength test on cement
mortar cubes includes standard cube moulds of size 70.7 mm × 70.7 mm × 70.7
mm, a Compression Testing Machine (CTM), a steel trowel, a weighing balance, a
curing tank, measuring instruments like a vernier caliper or steel scale, and clean
water. Additionally, a mixing tray and tools for hand mixing may be used for
preparing the mortar. The CTM used should be calibrated and capable of applying
a uniform load at a controlled rate.

To perform the test, cement and standard sand are mixed in the ratio of 1:3 by
weight, and water is added to achieve the desired consistency, usually specified in
the IS code. The mortar is thoroughly mixed to obtain a uniform paste and then
filled into lubricated cube moulds in three equal layers. Each layer is compacted
either by hand tamping or by a vibration table to eliminate air voids and ensure
uniform compaction. The moulds are then kept at room temperature (27 ± 2°C) for
24 hours. After this initial setting period, the cubes are demoulded and immersed in
clean water in a curing tank for a curing period of either 7 or 28 days. On
completion of curing, the cubes are removed from water, surface moisture is wiped
off, and the dimensions are verified. Each cube is placed in the CTM such that the
load is applied vertically and uniformly on its faces. The load is gradually applied
at a rate of 35 N/mm² per minute until the cube fails. The maximum load at failure
is noted, and the compressive strength is calculated by dividing this load by the
cross-sectional area of the cube.
54
Fig: 17 Pre Testing of cube Fig: 18 During Test of cube Fig: 19 Post Testing of cube

TABLE 9: OBSERVATION OF CTM

Mix ID AAC(%) Fibre(%) Compressive

Strength (N/MM2)
M1 0% 0% 10.36
M2 25% 0.5% 6.76
M3 50% 1.0% 5.86
M4 75% 1.5% 4.5

RESULT: The compressive strength decreased with age in all mixes.The highest
compressive strength was obtained for the mix with 0% AACand 0%
fibre(10.36N/MM2)

Fig: 20 CTM graph

55
7.2 DENSITY TEST

To determine the density of a cement mortar cube, the following apparatus are
required: a weighing balance with an accuracy of at least 1 gram, a standard cube
mould of size 70.7 mm × 70.7 mm × 70.7 mm, a tamping rod, a trowel, a tray for
mixing, and water. The procedure begins by preparing the cement mortar mix in
the specified ratio (commonly 1:3 cement to sand by weight) with a water-cement
ratio as per standards, typically around 0.5. The dry cement and fine aggregate are
thoroughly mixed in a tray until a uniform color is achieved, then the required
amount of water is added, and mixing is continued to obtain a homogenous paste.
The fresh mortar is then filled into a clean and oiled cube mould in three layers,
each layer being compacted with 25 strokes of the tamping rod. After filling and
leveling the surface, the mould is kept undisturbed for 24 hours at room
temperature. Once set, the cube is removed from the mould and cured under water
for 7 or 28 days, depending on test requirements. After curing, the cube is surface-
dried and weighed in air using the weighing balance. Its volume is calculated based
on the known mould dimensions. Finally, the density is calculated using the
formula:

Fig: 21 weighing of cube

56
 TABLE 10: DENSITY VALUES

MIX WT OF CUBE (gms) Density

(g/cm3)
M1 240 2.31
M2 190 1.83
M3 150 1.44
M4 127 1.22

7.3 VISUAL TEST

The visual inspection test on cement mortar cubes is a preliminary assessment

carried out to check the physical appearance and integrity of the hardened cubes
before performing strength tests. The apparatus required includes hardened cement
mortar cubes, a clean flat surface or tray for placement, and adequate lighting for
clear observation. Optional tools like a measuring scale or crack gauge may also be
used to measure any visible surface defects.
For the procedure, after the specified curing period (usually 7 or 28 days), the
mortar cubes are taken out of water and gently wiped to remove excess moisture.
Each cube is placed on a flat surface under proper lighting conditions. The entire
surface is carefully examined for visible cracks, surface voids, honeycombing,
segregation, discoloration, and edge damage such as chipping or spalling. The
presence of efflorescence, which appears as white salt deposits, is also checked as
it may indicate water ingress or material incompatibility. Any surface irregularities
or deformation are noted. If cracks are observed, their width and pattern may be
measured using a fine scale. This visual test ensures that the mortar cubes are free
from physical defects and are suitable for further mechanical testing such as
compressive strength.

57
Fig: 22 Visual Inspection

58
 CHAPTER 8

CONCLUSION AND RECOMMENDATIONS

8.1 Summary of Key Findings:

This research focused on assessing the behavior of cement mortar where natural
sand was partly substituted with recycled AAC (Autoclaved Aerated Concrete)
block powder, and coir fibers—sourced from sugarcane waste—were incorporated
as a natural additive. The evaluation was carried out through compressive and
flexural strength testing, density measurements, and visual inspection analysis. The
key findings are outlined below.

The density of the mortar mixtures tended to decrease slightly as the proportion of
AAC powder increased. This reduction is attributed to the inherently lower unit
weight of AAC material compared to natural sand. Despite this, the mixes retained
sufficient compactness and cohesion within acceptable engineering limits.

From the visual assessment, mortar specimens with higher AAC and fiber content
showed a rougher texture and more porous surface appearance. Minor surface
irregularities and visible micro-cracks were more prominent at 75% AAC
replacement, indicating slightly compromised finish quality at higher substitution
levels.

The compressive strength of the mortar experienced a moderate reduction as the

AAC replacement level rose, with a noticeable drop when 75% of the natural sand
was replaced. However, the inclusion of coir fibers significantly enhanced the
flexural strength, promoting better crack resistance and increased flexibility under
bending loads.
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Overall, optimal results were achieved when AAC replacement was kept between
25% and 50%, and the coir fiber content ranged from 0.5% to 1.0%, offering a
balanced combination of strength, density, and appearance

8.2 Practical Implications:

The findings of this study suggest that recycled AAC block powder and natural coir
fibers can be effectively utilized in cement mortar production as partial replacements
for conventional materials. From a practical standpoint, adopting AAC powder up to
50% and incorporating coir fibers within 1.0% can offer a sustainable and eco-
friendly alternative without significantly compromising strength and performance.
This approach contributes to waste reduction, resource conservation, and lower
environmental impact in the construction sector. Additionally, the improved flexural
performance due to fiber inclusion makes the mortar more suitable for applications
requiring enhanced crack resistance, such as floor toppings, wall plaster, and repair
works.

8.3 Future Recommendations:

For future research, it is recommended to explore the long-term durability
characteristics of such mortars under varying environmental conditions, including
freeze-thaw cycles, chemical exposure, and high humidity. Further investigations
could also focus on optimizing the fiber treatment methods to improve bonding with
the cement matrix. Scaling up the study to assess behavior in full-scale structural
elements and exploring compatibility with different grades of cement or admixtures
would provide deeper insights for real-world implementation.

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 REFERENCES

Bansal, P., & Kumar, M. (2020) – Construction and Building Materials

“Utilization of Autoclaved Aerated Concrete (AAC) waste in cementitious
materials”

Patel, R., & Shah, T. (2018) – International Journal of Civil Engineering and
Technology (IJCIET)
“Experimental study on cement mortar with partial replacement of sand by
AAC block waste”

Kumar, A., & Singh, B. (2021) – Journal of Cleaner Production

“Sustainable reuse of AAC waste as fine aggregate in cement composites”

Thakur, D., & Jain, V. (2019) – International Research Journal of

Engineering and Technology (IRJET)
“Effect of crushed AAC waste on mortar strength”

Gokul, M., & Prasad, K. (2022) – Materials Today: Proceedings

Effect of AAC powder in cementitious composites”

Majid Ali, Anthony Liu, HouSou, Nawawi Chouw, "Mechanical and Dynamic
Properties of Coconut Fibre Reinforced Concrete

B. M. Ahuja et.al (2015)- Behaviour of concrete reinforced with jute, coir and
bamboo fibres”,

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M. J. Ienamul Hasan Ali et.al (2018)- Experimental study on coir fibre mixed
concrete

Anila Kumar et.al (2018)- Comparative study of strength properties of

coconut coir fibre reinforced concrete due to partial replacement of cement by
pozzolanic materials

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 Major Project Checklist (A.Y. 2024 - 25)
All the guides, HOD’s to make sure that every major project report is formatted as per the standard
guidelines framed by the college. Below is the checklist of items which should be checked for
every report.
Dept: Batch: Guide: Short Title:
S.No ITEM Yes/No Remarks
1 Project report must have a structure and properly formatted (Fonts,
Spacing) .
2 Title Page (Cover Page-Hard Bound)
Inner Title Page (Starting of inner pages)
3 College Vision, Mission
4 Department Vision, Mission
5 POs, PSOs, COs,
6 CO - PO Mapping (Project Specific)
7 Declaration (Signed by all student in batch)
8 Certificate (Signed by guide, coordinator, HOD, Dean, Principal)
9 Acknowledgments
10 Abstract (Executive summary of project in small paragraphs)
11 Table of Contents with numbered chapters, headings and sub headings
with page numbers.
12 List of Figures (with chapter wise numbering and page numbers)
13 List of Tables
14 Introduction (Clearly outlines the objectives, scope, limitations of the
project).
15 Literature Review (Reasonable good number literature review of previous
works in related field / topics)
16 Research Methodology (Follows a rational and scientific way of
describing the process of project execution including data collection and
data analysis, (Programming, Execution, Tests etc.. which ever is
applicable).
17 Data Collection / Programming / Coding / Materials, (Check
genuineness of data collected, coding, programming, etc..supported with
real pictures)

63
18 Data Analysis / Execution / Tests to be performed with relevant IS Code
numbers, (Supported with pictures, figures, tables and charts).
19 The report is evidence-based and is supported by data.
20 Results and Conclusions (drawn from the data analysis, aligning with the
objectives of the project).
21 Recommendations / future scope – a pathway for future researchers,
students who intend to do project in the same area(s).
22 References (Properly formatted and numbered)
23 Appendices (Print out of program execution, analysis etc..)
24 Paper Publication / Patent (Write Status in remarks)

64