EFFECT OF PARTIAL REPLACEMENT OF

CEMENT WITH ALUMINIUM DROSS IN

CONCRETE PRODUCTION

BY

CHUKWUDI EZEKIEL .O.

13H/0159/CE

A RESEARCH WORK SUBMITTED TO THE DEPARTMENT OF CIVIL

ENGINEERING, FEDERAL POLYTECHNIC NEKEDE, OWERRI IMO
STATE
IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE
AWARD OF HIGHER NATIONAL DIPLOMA (HND) IN CIVIL
ENGINEERING

OCTOBER, 2015.

APPROVAL PAGE
This is to certify that the project topic Effect Of Partial Replacement Of
Cement With Aluminium Dross In Concrete Production was undertaken by
CHUKWUDI EZEKIEL .O. with the registration number 13H/0159/CE and
was submitted to the department of Civil Engineering Technology, School of
Engineering Technology, Federal Polytechnic Nekede, Owerri, during
2014/2015 academic session.

---------------------------Engr. Anyanwu. S. C.
(Project Supervisor)

------------------------Date

----------------------------Engr. (Dr) Ezugwu C.N

(External Supervisor)

------------------------Date

----------------------------Engr. Nnamdi Chimezie

(HOD, Civil Engineering)

------------------------Date

---------------------------Engr. Charles Okonkwo

(Dean of School of Engineering Technology)

------------------------Date

ii

DEDICATION
This project work is dedicated to the Almighty God for his infinite mercies and
guidance during my course of study.

iii

ACKNOWLEDGEMENT
My profound gratitude goes to God Almighty, for his infinite grace and mercy
towards me to carry out this research.
First, I would like to express my highest appreciation to my supervisor, Engr.
Anyanwu. S. C. for his advice, guidance and encouragement during the course
of this project. His invaluable assistance and the constructive criticisms offered
have resulted in the completion of this project.
With cheerful heart I acknowledge my beloved dad Mr Okolie Chukwudi for his
supports, prayers, encouragement, advices, guidance and efforts toward my
career
To all those in one way or the other who have contributed to my success
throughout my career

iv

ABSTRACT
The construction activities in last few decades have increased many folds in
almost all the developing countries of the world. Cement is becoming a scarce
commodity globally because of its growing demand day by day. It is the need of
time to search such alternative materials that would partially replace cement
used in concretes without affecting its quality, strength and other characteristics.
This research work "Effect of the partial replacement of cement with
aluminium dross in concrete production" is aimed at investigating the effects
of a new concrete type obtained by adding aluminium dross which is an impure
aluminium mixture that results from aluminium smelting. In this study, mix
ratio of 1:2:4 and water-cement ratio of 0.5 which is constant throughout. A
total of 54 cubes is mould, cured and crushed at 7, 14, and 28 days age with
replacement

ratio 0%,10%,20%,30%,40% and 50%. The highest average

strength is obtained at 28 days age, 32.59N/mm 2. Workability of concrete

decreases with increase in percentage of replacement of aluminium dross. Based
on this aluminium dross can be used for blocks, panels but not in concrete work
that demand strength.

TABLE OF CONTENTS
Title Page

----------------------------------------------------------------------------------------- i

Approval Page
Dedication

-------------------------------------------------------------------------------- ii

----------------------------------------------------------------------------------------- iii

Acknowledgment -------------------------------------------------------------------------------- iv
Abstract

----------------------------------------------------------------------------------------- v

Table of Content

-------------------------------------------------------------------------------- vi

List of Figures

-------------------------------------------------------------------------------- ix

List of Tables

-------------------------------------------------------------------------------- x

CHAPTER ONE
INTRODUCTION
1.1

Background

1.2

1
Statement Of Problem

1.3

2
Aims and Objective Of Study ------------------------------------------------------

1.4

2
Significance Of Study

1.5

3
Scope Of Study

--------------------------------------------------------------------------------------------------------------------------------------

---------------------------------------------------------------

------------------------------------------------------------------------

3
CHAPTER TWO
LITERATURE REVIEW
2.1

Overview

---------------------------------------------------------------------------------

4
2.2

Concrete

---------------------------------------------------------------------------------

6
2.2.1 History of Concrete----------------------------------------------------------------------- 6
vi

2.2.2 Concrete at Age

------------------------------------------------------------------------

9
2.2.3 Definition of Concrete

---------------------------------------------------------------

9
2.2.4 Advantages and limitations of concrete

------------------------------------

10
2.2.4.1

Advantages

---------------------------------------------------------------

Limitations

---------------------------------------------------------------

11
2.2.4.2
13
2.2.5 Properties of concrete

---------------------------------------------------------------

13
2.2.5.1

Fresh Concrete

---------------------------------------------------------------

14
2.2.5.2

Hardened Concrete

------------------------------------------------------

17
2.2.6 Structure of concrete

---------------------------------------------------------------

19
2.2.7 Concrete mix design

---------------------------------------------------------------

20
2.2.7.1 Methods of mix design

------------------------------------------------------

22
2.2.8 Curing of concrete

---------------------------------------------------------------

22
2.2.8.1 Methods And Material Of Curing

---------------------------------------------

23
2.2.9 Components of concrete

------------------------------------------------------

24

vii

2.2.9.1

Cement

------------------------------------------------------------------------

24
2.2.9.1.1

Portland Cement ---------------------------------------------------------------

24
2.2.9.2

Aggregates ------------------------------------------------------------------------

27
2.2.9.3

Water

------------------------------------------------------------------------

30
2.3

Aluminium --------------------------------------------------------------------------------31

2.3.1 Properties of Aluminium

------------------------------------------------------

32
2.3.2 Uses of Aluminium

---------------------------------------------------------------

32
2.3.3 Production of Aluminium-----------------------------------------------------2.3.3.1

Primary Aluminium

------------------------------------------------------

Secondary Aluminium

------------------------------------------------------

33
2.2.3.2
35
2.4

Aluminium dross

---------------------------------------------------------------

35
2.4.1. Formation of Aluminium dross -----------------------------------------------------36
2.4.2 Physical and Chemical Properties
Aluminium dross -----------------------------------------------------------------------37
2.4.3 Environmental issues of Aluminium
Dross

---------------------------------------------------------------------------------

38
viii

33

CHAPTER THREE
MATERIALS AND METHODOLOGY
3.1

Design of the Research --------------------------------------------------------------39

3.2

Material Preparation

---------------------------------------------------------------

39
3.3

Apparatus and Instrument Used -----------------------------------------------------40

3.4

Sample and Sampling Techniques

---------------------------------------------

41
3.4.1 Calculation of quantity of materials

---------------------------------------------

42
3.5

Specimen Preparation (Procedure)

---------------------------------------------

43
3.6

Experiment carried out

---------------------------------------------------------------

44
3.6.1 Slump Test --------------------------------------------------------------------------------44
3.6.2 Compressive Test -----------------------------------------------------------------------46
3.7

Curing of Concrete-----------------------------------------------------------------------48

CHAPTER FOUR
DATA ANALYSIS AND RESULT PRESENTATION
4.1

Introduction --------------------------------------------------------------------------------50
ix

4.2

Calculation of quantity of materials

---------------------------------------------

50
4.2

Slump Test Values -----------------------------------------------------------------------52

4.3

Compressive strength result

------------------------------------------------------

52
4.4

Average Compressive strength result of Concrete(7 days Age) ----------56

4.5

Average Compressive strength result of Concrete(14 days Age) ----------57

4.6

Average Compressive strength result of Concrete(28 days Age) ----------58

4.7

Graphical Representation of Data

---------------------------------------------

59
4.8

Discussion --------------------------------------------------------------------------------64

4.8.1 Compressive Strength of Concrete

---------------------------------------------

64
4.8.2 Workability of Concrete

------------------------------------------------------

66
CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
5.1

Conclusion --------------------------------------------------------------------------------67

5.2

Recommendation -----------------------------------------------------------------------68

5.3

References --------------------------------------------------------------------------------69

LIST OF FIGURES

Figure 3.1 Universal Testing Machine

---------------------------------------------

41
Figure3.1

Weighing balance ---------------------------------------------------------------

41
Figure3.3

Concrete Mould

---------------------------------------------------------------

Aggregate Mix

---------------------------------------------------------------

Concrete Slump

---------------------------------------------------------------

41
Figure3.4
44
Figure3.5
46
Figure 3.6

Curing Bay ------------------------------------------------------------------------

49
Figure 3.7

Concrete before curing

------------------------------------------------------

Concrete after curing

------------------------------------------------------

49
Figure 3.8
49
Figure 4.1

Bar chart of Slump value against % replacement ratio

60

xi

---------

Figure 4.2

Bar chart of Average compressive strength

------------------

60
Figure 4.3

Bar chart of Average compressive strength against

% replacement ratio at 14 days ---------------------------------------------

61
Figure 4.4

Bar chart of Average compressive strength against

% replacement ratio at 28 days

------------------------------------

61 Figure 4.5

Graph of Slump Value against Replacement ratio

------------------

62

Figure 4.6

Graph of Average compressive strength against

Replacement ratio at 7 days

---------------------------------------------

62
Figure 4.7

Graph of Average compressive strength against

Replacement ratio at 14 days

---------------------------------------------

63
Figure 4.8

Graph of Average compressive strength against

Replacement ratio at 28 days

---------------------------------------------

63
Figure 4.9

Graph of Average compressive strength against

xii

Replacement ratio for all samples

------------------------------------

64
Figure 4.9

Graph of Average compressive strength against

Age for the various replacement ratios

---------------------------

64
LIST OF TABLES
Table 2.1

Types of Cement and their constituent

---------------------------

26
Table 2.2

Physical and Chemical Properties

------------------------------------

37
Table 4.1

Quantity of materials used

---------------------------------------------

51
Table 4.2

Slump Values

---------------------------------------------------------------

52
Table 4.3

Compressive Strength test results 7days

---------------------------

Compressive Strength test results 14 days

---------------------------

52
Table 4.4
53

xiii

Table 4.5

Compressive Strength test results 28 days

54 Table 4.6 Average

Compressive

---------------------------

56

Table 4.7

Compressive

---------------------------

57

Table 4.9

Strength

Average Compressive Strength at 14 days

57 Table 4.8 Average

---------------------------

at

days

---------------------------

Strength

at

28

days

Average Compressive Strength for all Ages ---------------------------

59

xiv