Oil palm shell a new innovative idea in building materials

1. Project proposal for G+1 to G+4 buildings using
oil palm shell lightweight concrete
Proposed by
Dr.V.Swamy Nadh
(Structural Engineer)
Guided by
Dr.K.Muthumani
Senior scientist (CSIR-SERC)
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2. Contents
 Introduction
 Methodology
 Properties of oil palm shells
XRD analysis
Mechanical properties
Microstructural properties
Durability properties-Alkali-silicate reaction
 Conclusions
 Publications and Patent
2

3. Introduction
• Utilization of industrial wastes to produce environmental friendly
concrete as sustainable alternative.
• Oil palm shell (OPS) is an industrial waste obtained after the extraction
of palm oil from palm oil fruit.
• Palm oil waste produced during the extraction process is 115 million tons
globally per year.
• OPS has a density of 33% that of conventional aggregate (CA).
• OPS is a renewable material, a potential alternative to the non-renewable
conventional aggregate like gravel.
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4. Consumption of gravel in India
According to Indian ministry of environment, forest and climate
change 2018
• Gravel used in India is 1,180 million tons
• OPS waste produced in India is 35 million tons per year.
• Replacement of gravel with OPS can reduce usage of gravel by
4-5%.
• This sustainable alternate reduces the use of non-renewable
source in concrete.
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5. POTENTIAL OIL PALM PRODUCTION
STATES
State Potential Area (ha)
Andhra Pradesh 469500
Karnataka 260000
Tamil Nadu 205000
Gujarat 260250
Maharastra 180000
Chattishgarh 48000
Kerala 6500
Odisha 56000
Bihar 200000
West Bengal 25000
Total 17,10,250
Andhra
Pradesh
27%
Karnataka
15%
Tamil Nadu
12%
Gujarat
15%
Maharashtra
11%
Chhattisgarh
3%
Kerala
0%
Odisha
3% Bihar
12%
West Bengal
2%
Potential area (in ha)
Details courtesy- National mission on oil seeds and oil palm -2014-2017

6. STATE WISE AREA AND PRODUCTION OF FFBs AND CPO (2015-16)
State Area coverage
(ha)
FFBs Production
(in MT)
CPO Production
(in MT)
Andhra Pradesh 1,50,530 11,44,092 1,93,562
Telangana 16,239 63,508 11,289
Karnataka 41,431 14,740 2,538
Tamil Nadu 29,510 7,810 1,222
Gujarat 5,054 523 0
Goa 953 3,217 581
Odisha 18,484 4,569 618
Tripura 530 0 0
Assam 570 0 0
Kerala 5,769 40,611 7,016
Maharashtra 1,474 0 0
Mizoram 25,741 3,753 432
Chhattisgarh 2162 0 0
Arunachal Pradesh 330 0 0
Andaman & Nicobar 1,593 0 0
Nagaland 140 0 0
Total 3,00,510 12,82,823 2,17,258

7. OPS formation as aggregate
Fig 2: Palm fruit Fig 3: OPS 10-12mm
Fig 1: Palm oil tree 7

8. Objectives
• To produce lightweight concrete for low cost housings.
• To reduce density of concrete by 25%.
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9. Methodology
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Collection of materials
Collection of oil palm shells from palm oil industry
Pre process of oil palm shells
Design of lightweight concrete mix
Production of oil palm shell lightweight concrete

10. 10
Preparation of OPS aggregate
Fig 5: oil palm shells
Fig 6: soaking of OPS
Fig 7: drying of OPS

11. Aggregate properties
Bulk density:
Conventional aggregate (CA) – 1440 kg/m3
Oil Palm Shell – 380-400 kg/m3 which is only 27% of CA
• According ACI 318-R Oil Palm Shell falls under lightweight
aggregate
• Density of Oil Palm Shell concrete ranging from 1790-1890
kg/m3
• Specific gravity of Oil Palm Shell is 1.24 where as CA is 2.61
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12. Table 1:Comparison of Malaysian OPS and Indian OPS
properties
Properties Oil Palm Shell
(Malaysia)
Oil Palm Shell
(India)
Conventional
aggregate
Maximum shell size (mm) 12.5 11 40
Thickness (mm) 0.6-8 0.1-3 -
Bulk density (kg/m3) 425-460 380 1470-1580
Specific gravity (SSD) 1.41 1.24 2.67
24-h Water absorption (%) 20-24 25 2-4
Aggregate impact value (%) 22.5 29.5 17.8
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13. OPS concrete properties
• Compressive strength is 28.5 MPa for 28
days
7 days 14 28 56
15.8 MPa 23.4 28.5 28.9
Fig10: OPS concrete cube 150*150*150 mm
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14. Comparison of compressive strengths
0
5
10
15
20
25
30
35
7 14 28 56
Compressive
strength
(MPa)
Age of curing (days)
Variation in Compressive strength LWC NWC
14
LWC- Light weight concrete, NWC- Normal weight concrete

15. Microstructural study
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16. Bond strength of OPS concrete
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Fig 14: Pull out testing machine
Fig 15: OPS concrete specimen

17. 17
 Stress between the reinforcing bar and the surrounding concrete along
the embedded length of the bar.
S = Pmax*1000 / (π×L×d)
Pmax= maximum pull out load (26.7 kN)
d=diameter of the bar (12mm)
L =Embedded bar length (100mm)
 Bond strength of OPS concrete is 7.16 kN/mm2. Similar bond strength of
8.12 kN/mm2 is noticed in conventional concrete.

18. Conclusions
1: Use of this industrial waste (OPS) as a replacement of coarse
aggregate in concrete can reduce the density of concrete by 25%.
2: OPS is Alternative material for non-renewable material
(Gravel).
3: OPS reduces the cost of the construction by 20%. And reduce
the percentage of steel usage of 10%.
4:Similar strength and durability properties as conventional
concrete.
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19. Publications
Title Journal name Year Volume and Page no Indexing
Critical review on lightweight
concrete
International Journal of Civil
Engineering & Technology
2017 Volume 8, Issue 2, pp
252-263
Scopus
Seismic performance of
lightweight concrete structures
Advances in civil engineering 2018 Volume 2018, pp 1-6 Thomson Reuters- SCI
indexed/ Scopus
Impact factor-0.827
Properties of structural
lightweight concrete containing
treated oil palm shell as coarse
aggregate
Asian journal of civil engineering 2018 Volume 19, Issue 6, pp
673-678
Springer-Scopus
indexed
Microstructural properties of oil
palm shell lightweight concrete
International journal of
microstructural and material
properties
2019
Volume 14, Issue 5, pp
448-461
Elsevier- Scopus
indexed
Heat of hydration and Alkali-
silicate reaction in oil palm shell
structural lightweight concrete
Silicon 2019 Accepted, In press Thomson Reuters- SCI
indexed/ Scopus
Impact factor: 1.267
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20. Patent filed in India
Application number – 201841019569
Title- Method of producing water repellent oil palm shells
lightweight aggregate for the high impact value
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21. 21
Thank you
Palm oil fruit
Oil palm shell concrete