International Journal of Civil Engineering and Technology (IJCIET)
Volume 10, Issue 1, January 2019, pp.315–326, Article ID: IJCIET_10_01_030
Available online at http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=10&IType=1
ISSN Print: 0976-6308 and ISSN Online: 0976-6316
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Scopus Indexed
MECHANICAL PROPERTIES AND
DURABILITY OF CALCIUM CARBIDE KILN
DUST MORTAR
Sivakumar Naganathan
Department of Civil Engineering, SSN College of Engineering (Autonomous),
Rajiv Gandhi Salai (OMR) Kalavakkam- 603110, Tamilnadu, India
Masimawati Abdul Latif
Policy Division, Polytechnic Education Department, Ministry of Education, Level 3, Galeria
PjH, Jalan P4w, Persiaran Perdana Presint 4, 62100 W.P. Putrajaya, Malaysia
Hashim Abdul Razak
StrucHMRS Group, Department of Civil Engineering, Faculty of Engineering,
University of Malaya, 50603 Kuala Lumpur, Malaysia
Kamal Nasharuddin Mustapha
Department of Civil Engineering, Universiti Tenaga Nasional,
Jalan IKRAM-UNITEN, 43000 Kajang, Selangor, Malaysia
Salmia Beddu
Department of Civil Engineering, Universiti Tenaga Nasional,
Jalan IKRAM-UNITEN, 43000 Kajang, Selangor, Malaysia
B.Mahalingam
Department of Civil Engineering, SSN College of Engineering (Autonomous),
Rajiv Gandhi Salai (OMR) Kalavakkam- 603110, Tamilnadu, India
G.Elangovan
Department of Civil Engineering, University College of Engineering,
Thirukuvalai 610204, Tamilnadu, India
ABSTRACT
This paper reports an investigational study on the effect of calcium carbide kiln
dust (CCKD) in cement mortar and its resistance towards hydrochloric acid attack.
Mortar with various CCKD replacement levels from 5 to 40 percent by binder weight
were tested. The setting time, consistency, density, compressive strength and the
durability tests were evaluated to measure the effect of CCKD in mortar. The
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Sivakumar Naganathan, Masimawati Abdul Latif, Hashim Abdul Razak, Kamal Nasharuddin
Mustapha, Salmia Beddu, B.Mahalingam, G.Elangovan
durability was assessed in terms of loss of density and strength when the specimen
were cured in 5% hydrochloric acid (HCL) solution. The results indicate that CCKD
replacement levels from 5 to 20 percent performed on par with control mix in terms of
compressive strength, the loss in density and strength were around 30% under acid
curing. However, 30% and above CCKD replacement percentage showed low density
and compressive strength in both conditions. It is concluded that CCKD can be used
as an effective replacement for cement up to 20 percent without affecting the
performance.
Keywords: Compressive Strength; Density Loss; Calcium Carbide Kiln Dust;
Durability; Mortar.
Cite this Article: Sivakumar Naganathan, Masimawati Abdul Latif, Hashim Abdul
Razak, Kamal Nasharuddin Mustapha, Salmia Beddu, B.Mahalingam, G.Elangovan,
Mechanical Properties and Durability of Calcium Carbide Kiln Dust Mortar,
International Journal of Civil Engineering and Technology (IJCIET), 10 (1), 2019, pp.
315–326.
http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=10&IType=1
1. INTRODUCTION
The construction industry is growing rapidly with an estimated production of 5 billion tons
cement of by 2030. The cement production is extremely energy-intensive processes hence its
contributed towards 5% of global emission [1]. Turner et.al cited that for every ton of cement
produced, approximately 0.66 to 0.82 kg of carbon dioxide (CO2) is emitted [2]. This
scenario motivates more research on alternative to cement or partial cement replacement
which uses waste materials, hence reducing CO2 emission and good for the environment [3].
There are many research on the utilizations of waste in mortar such as fly ash [4-7] palm oil
fuel ash [8,9] and calcium carbide residue [10].
Generally, there are various types of by-products and wastes produced that require reliable
disposable mechanism and management. Approximately 4.2 billion tons of waste from
domestic, agricultural, industrial, and mineral sources are disposed of in landfill [11]. These
non-decaying wastes which increase over years, not only contaminate the environment but
also requires more land for disposal [12]. The cost for waste disposal also increases with the
constraint of landfill space [13]. Furthermore, waste disposal are now taxable by most
governments [14].
Calcium carbide is usually used in producing acetylene gas, fruits ripening agents and
desulfurizing iron. The calcium carbide (CaC2) is a chemical compound produced from coal
(C) and calcined limestone (CaCO3). The kiln uses electric furnace to heat the coal and
limestone at 2000ºC to 2100°c. The high temperature reduces the lime and carbon (C) to
calcium carbide (CaO) and carbon monoxide (CO) as shown in these equations:
(1)
(
)
(2)
The heating process generates gases which contains particulate matter (PM) which is
filtered usually using fabric dust filter collector. The PM thus collected is calcium carbide kiln
dust (CCKD). The chemical composition of CCKD depends on the type of materials, fuel,
kiln and other operating parameters used but carbon and calcium compounds are major
chemical components (Agency 2005).
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Mechanical Properties and Durability of Calcium Carbide Kiln Dust Mortar
Calcium carbide factory in Malaysia produces 80 to 90 ton/day of calcium carbide and 3
to 4 ton/day of CCKD which is dumped in landfill [15].However, there are little research
available on the use of CCKD in construction. Therefore, this research focuses on the
possibility of replacing ordinary Portland cement with CCKD in mortar. The effects of CCKD
replacement on setting time, density and mortar compressive strength were investigated. The
resistance of CCKD mortar mixes immersed in 5% hydrochloric solution at room temperature
and compared with control mortar were also tested. The extent of resistance was evaluated by
measuring the changes in weight and compressive strength. This paper will inspire researchers
to utilize CCKD as partial cement replacement in mortar.
2. EXPERIMENTAL DETAILS
2.1. Material
This investigation used CCKD, ordinary Portland cement (OPC) confirming to Malaysian
standard MS 522: part 1: 2007 [16] manufactured silica sand, Sika Viscocrete 2199 type super
plasticizer (SP) and normal tap water. The physical and chemical properties of OPC and
CCKD are given in Table 2. The CCKD used was collected from a calcium carbide factory
located in Perak, Malaysia. The dry greyish CCKD was sieved passing sieve size 1.18mm to
remove any impurities and then kept in airtight container. The manufactured silica sand used
were in combination sizes of 8/16, 16/30, 30/60 and 50/100 in percentage derived from sieve
analysis conforming to ASTM C33-03(American Society for Testing and Materials 2001) as
shown in Error! Reference source not found.. The fineness modulus, specific gravity and
the maximum grain size of silica sand are 2.61, 2.69 and 2.36 mm respectively. It has 1.95%
water absorption determined according to ASTM C127-15(American Society for Testing and
Materials 2013a).
Figure 1 Sieve Analysis of manufactured silica sand
2.2. Mixture proportions and casting method
This experimental investigation replaced OPC with CCKD by 0% to 40% by weight of the
cement in mortar mixes. The water to binder (W/B) was 0.485 for all the mixtures and the
binder to sand (B: S) ratio was 1: 2.75. All mixtures were prepared in accordance with ASTM
C109M-13 [17]. The flow spread measured as per ASTM C230/C230M-14 [18] was fixed at
110±5mm by adding the SP as needed. The fresh mix thus prepared was then poured into 50
mm cube moulds and vibrated in a vibrating table. To minimize evaporation, damp
gunnysacks were used to cover the cubes. After 24 hours, all cubes were de-moulded and
water cured until test day. The details of mortar mixes are given in
Table 1.
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Sivakumar Naganathan, Masimawati Abdul Latif, Hashim Abdul Razak, Kamal Nasharuddin
Mustapha, Salmia Beddu, B.Mahalingam, G.Elangovan
Table 1 Mixture proportion
Mix ID
CM (control
mix)
C1
C2
C3
C4
C5
C6
C7
C8
OPC
(kg/m3)
CCKD
(kg/m3)
Water
(kg/m3)
Manufactured Silica
Sand (kg/m3)
SP
(Sika
VS2199)
(%)
550.0
0.0
266.8
1512.50
0
522.5
495.0
467.5
440.0
412.5
385.0
357.5
330.0
27.5
55.0
82.5
110.0
137.5
165.0
192.5
220.0
266.8
266.8
266.8
266.8
266.8
266.8
266.8
266.8
1512.50
1512.50
1512.50
1512.50
1512.50
1512.50
1512.50
1512.50
0.000
0.000
0.144
0.350
0.440
0.980
1.010
1.190
2.3. Testing
The specimen were separated into two groups. The first group was cured in normal tap water
until the test day for hardened density and compressive strength. The second group was cured
in normal water for 28 days and then transferred to 5% hydrochloric acid solution to assess
the effect of acid attack on the specimen.
The density of mortar cubes were determined according to BS 1881-114:1983 [19] and the
average of three specimen reported. The weight loss was then calculated using equation
given below:
( )
(3)
Where:
W1 = average weight of the specimen before immersion
W2 = average weight of the cleaned specimen after immersion
The compressive strength of CM and CCKD mortar mixes cubes cured in normal tap
water were determined after 1, 3, 7, 14, 28, 56, 90, 180 and 360 days age using 100kN
capacity Universal Compression Testing Machine with loading rate at 0.5kN/sec. The ASTM
C267-01 [20] test method B was used to investigate the CCKD mortar mixes resistance
towards acid attack at 28 and 62 days. The loss incompressive strength was calculated using
the following equation:
( )
(4)
Where:
fcw = average compressive strength of specimen cured in water
fch = average compressive strength of specimen immersed in hydrochloric acid
All the test results are reported from the average of three specimen.
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3. RESULTS AND DICUSSION
3.1. Materials
The material morphology was determined using Scanning Electron Microscope (SEM). The
CCKD morphology showed that it has mostly small particles and irregular spherical shape as
shown in Error! Reference source not found.. This increases the hydration rate and the
degree of hydration. The grain size distribution of OPC and CCKD were determined using
Particle Size Analyser as shown in
Figure 2. The results showed that CCKD has smaller mean particle size (d50) of 25.89µm
compared to OPC 29.67µm.
Figure 1 SEM result of Cement and CCKD
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Sivakumar Naganathan, Masimawati Abdul Latif, Hashim Abdul Razak, Kamal Nasharuddin
Mustapha, Salmia Beddu, B.Mahalingam, G.Elangovan
Figure 2 Grading curve for OPC and CCKD
The physical and chemical properties of OPC and CCKD are presented in Table 1. The
Blaine fineness and specific gravity were determined according to ASTM C204-11[20] and
BS812: Part2: 1995 ([20] respectively.
Table 2 Chemical compositions and physical properties of OPC and CCKD
Chemical Compositions (%)
CaO
SiO2
Al2O3
SO3
Fe2O3
MgO
K2O
Na2O
TiO2
P2O5
L.O.I
SiO2 + Al2O3 + Fe2O3
Physical Properties
Specific Gravity
Mean Particle Size, d50 (micron)
Blaine fineness (cm2/g)
OPC
CCKD
64
58.69
20.29
5.37
2.61
2.94
3.13
0.17
0.24
0.12
0.07
1.4
1.60
1.66
1.07
0.13
0.18
0.01
0.20
0.01
0.01
25.87
3.39
3.16
29.67
3600
2.13
25.89
4217
The X-Ray Efflorescence (XRF) results of OPC and CCKD showed that CaO is 59% in
CCKD and 64% in OPC. Hence CCKD is equally reactive similar to OPC. The summation of
aluminium oxide (Al2O3), silicon dioxide (SiO2) and iron oxide (Fe2O3) in CCKD is very low
with only 3.39%. This categorized CCKD as non pozzolans in accordance with ASTM C61812a [21] .The SO3 compositions in OPC and CCKD is 2.61% and 1.07% which is less than
3.5% satisfying the BS12:1996 [22] requirements. The magnesium oxide (MgO) in OPC and
CCKD is only 3.13% and 0.18% which is below the limit in ASTM C150 [23]. The CCKD
has high loss on ignition (LOI) which is 25.87 whereas the LOI for cement is 1.4. Hence
CCKD exceeded the LOI limit of 3% as stated in BS12:1996. However, research by Najim
et.al showed that CCKD is still suitable for use in mortar[24].
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3.2. Consistency and setting time
The consistency and setting time tests were done according to ASTM C187 -11 and ASTM
C191-13 respectively [25,26]. Figure 3 shows relationship between consistency, setting time
and percentage replacement of CCKD. It can be observed from Fig. 4 that the addition of
CCKD increases the consistency. It is also evident from Fig.4 that increase of CCKD
accelerates the setting and hence there is decreasing trend on the setting times with the
increase of CCKD. This is due to irregular shape of CCKD particles which absorbed more
water compared to OPC. These are in agreement with S.El. Aleem et.al researched in cement
kiln dust (CKD) which also had similar accelerated setting times with the increased on CKD
in the mixes [27].
Figure 3. Consistency and setting times
The fresh density of mixtures tested are shown in Figure 4. Addition of CCKD decreases
the fresh density. The specific gravity of CCKD is 2.13 which is light in weight compared to
cement and hence decreases the fresh density. Figure 5 shows the flow spread diameter (mm)
and CCKD replacement level. As flow decreases with the increase of CCKD, SP was added to
achieve the target spread. K. Kaewmanee et.al reported that, less water required for fly ash
mixes compared to control mixes. This is because, fly ash has regular spherical particles [28].
The CCKD mixtures requires more water than control mix because CCKD particles are
irregularly shaped as evident from Fig.2. It is also proved by M. Harini et.al mortar
flowability that, highly irregular particles result in lower spread [29]
Figure 4 Fresh density of mortar
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Sivakumar Naganathan, Masimawati Abdul Latif, Hashim Abdul Razak, Kamal Nasharuddin
Mustapha, Salmia Beddu, B.Mahalingam, G.Elangovan
Figure 5 Flow spread
3.3. Hardened Density
The hardened density of all the mixtures increased with age as shown in Figure 6. This is
because of the formation of hydrated products over time. However, the CCKD mixtures
showed slightly lower density compared to the control mix. The density of mixtures with
CCKD replacement from 5 to 40% were between (2130 – 2377) kg/m3 while the control mix
with 0% CCKD exhibited density from (2275 - 2394) kg/m3. The addition of CCKD reduced
the hardened density of the mixtures tested. This is because of reduced weight of CCKD.
Figure 6 Hardened density
3.4. Compressive strength
The relationship between compressive strength and age is presented in Figure 7. The
compressive strength increases with age for all the mixtures and no abnormalities were
observed in CCKD mixtures. However the compressive strength decreases with the increase
of CCKD. This is attributed to the lower contents of C2S and C3S in CCKD mortar mixes due
to reduced addition of cement. At 28 days, only 5% to 20% CCKD replacements mortar
mixes achieved 50 MPa while the mixtures with CCKD of more than 30% have lower
compressive strength. All the mixtures achieved a strength of 12.4 MPa at 3 days and
19.3MPa at 7 days which satisfies the requirements given in with ASTM C150 requirements
for Type 1 cement [24]. It is also observed that CCKD addition influences the long-term
strength much rather than the short term strength within 28 days. This because of increase
CaO in the CCKD which increases the tri calcium silicate compounds to influence the early
age strength. But after 28 days the strength is influenced by SiO2 which is less in CCKD and
hence there is more long term strength reduction in CCKD compared to the control mix.
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Figure 7 Compressive strength
3.5. Hydrochloric acid attack
Figure 8shows the relationship between weight loss and age. The maximum weight loss for
control mix is 27.79% whereas for CCKD mixtures the weight loss was ranged from 24.69%
to 27.19% at 180 days. Usually, the use of other cementitious materials will have negative
resistance towards acid attack compared to OPC. However, at 180 days the weight loss of all
CCKD mortar mixtures were only in the range of 14.03% to 15.47% compared to control mix
CM.CCKD particles are smaller that fills all CCKD mortar voids which reduced the effects of
acid attack compared with CM. The surface texture, particle shape, and gradation will
influence the density [30].
Figure 8 Weight loss
The compressive strength of mixtures after acid immersion is shown in Fig. 10. It is
observed that strength decreases with increase in immersion time. The strength of control mix
reduced from 68.1 MPa to 61.3 MPa at 28 and 56 days respectively while all CCKD mortar
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mixtures
showed
a
reduction
in
strength
of
57
MPa
to
23.8MPa.
Figure 10 shows the strength loss for all mixtures. Strength loss increases with increase of
CCKD content in the mixture at both days.
Figure 9 Compressive strength under acid immersion
Figure 10 Compressive strength loss
4. CONCLUSION
This investigation presented the mechanical properties and durability of calcium carbide kiln
dust mortar. The following conclusions are drawn from the investigation:
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
The replacement of CCKD increases the water needed for consistency. Furthermore, the
CCKD accelerates the initial and final setting times and decreases the flow.

The CCKD replacement in the range of 5 – 20% does not reduce the compressive strength
significantly. Hence, it is concluded that CCKD replacement of up to 20 % can be envisaged
in further investigation for the potential benefit of using CCKD in materials.

The loss of weight of CCKD mixtures under acid attack were less than that of control mix.
Hence, the CCKD replacement in mortar does well under aggressive acidic conditions.
ACKNOWLEDGEMENTS
The authors would like to express their sincere thanks to the Ministry of Higher Education
(MOHE), Malaysia for the support given through UM.C/625/1/HIR/MOHE/ENG/56 research
grant. Appreciation is also due to all the staff members of the Concrete Laboratory, University
of Malaya for assisting with the laboratory experiments.
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