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 CHAPTER ONE.

1.0 INTRODUCTION.

Glass; is one of the oldest and the most used materials in the world and it is prepared by
melting a mixture of materials such as silica, soda ash and CaCo 3. At high temperature
followed by cooling where solidification occurs without crystallization. And the various
forms in which it I produced includes (packaging or container) bottles, flat glass
(windows)

Glass recycling; is the processing of waste glass into usable products. And glass that is
crushed or grounded glass and ready to be remelted is called cullet, which is end of
waste.

Mortar, Mortar was composing of cement, fine aggregate and water. Common mortar
that used in the construction was masonry mortar and cement mortar.

1.1 BACKGRUOND OF THE STUDY.

Glass was one of the oldest man-made materials. It was a common product that can
be found in variety of form. These products needed to be reused or recycle to minimum
the Impact of environmental issue which causes stockpiling or land filling. There were
many ways implementation of reusing the waste glass (Ismail & AL-Hashmi, 2009).

Research on using waste glass as aggregate had been attempted decades ago.
Recently research shows that it can be used as aggregate under certain condition to avoid
Alkali silica reaction damaging effect. Product that using waste glass as aggregate such
as Glass concrete, concrete masonry block unit and paving stone can be categorized as

1
Commodity product and value-added products. Glass aggregate products were also
being used in architectural and decoration application. This indicated that glass
aggregate have Commercial values in the market (Meyer,Egosi & Andela, 2001).

Recycling of waste glass into aggregate save the landfills space and it also reduces
the extract of raw material for construction activities. There fore,the waste glass cullet in
them must be as much as possible, furthermore good aesthetic effect must be archived
by selective use of glass of different sizes, (Ling and Poon)2011.

1.2 THE PROBLEM STATEMENT OF THE PROJECT.

Over the decades, the glass products had been increasing produced for commercial
Purpose. According to Traholt & Ling (2010), in Malaysia, less than 30% of new bottles
were made from recycled glass. Compared to 80% in Thailand and 60-70% in Europe.
This situation clearly described that majority of the waste glass was ending up at the
landfill. This eventually raised the environmental issue.

Continues of mining the raw materials of aggregate were eventually exhausted its
sources. This situation forced the construction field to focus on others materials as new
replacement. Glass has shown a potential of replacement aggregate in construction field
assist properties exhibited almost same as natural aggregate. By using glass as
replacement for Aggregate can solve the shortage of raw material in the near future and
reduced the solid waste issue in order to solve the environmental problem of the waste
glass and also the availability and cost of river sand has become a major concern.

1.3 OBJECTIVES OF THE PROJECT.

1.3.1 MAIN OBJECTIVE.

2
 To assess the recycled glass waste as fine aggregates for production of plastering
mortar.

1.3.2 SPECIFIC OBJECTIVES.

The objectives of this project will be;

i. Determine the effect of waste glass on the properties of mortar mixes as a partial
replacement of fine aggregate.

ii. Determine the effects of waste glass on the fresh properties of mortar mixes such
as unit weight and flow table

iii. Determine the influence of waste glass on hardened properties of mortar mixes
such as: dry bulk density, compressive strength, flexural strength, porosity, water
absorption, freeze-thaw resistance, drying shrinkage and rapid chloride
permeability.

1.4 METHODOLOGY.
i. Collecting the required documents related to usage of glass in mortar.

ii. Collecting glass bottle.

iii. Preparing the specimens according to standard specifications and testing.

iv. Discussion of test results, conclusions and recommendations for future research.

3
1.5 LITERATURE REVIEW.
i. To read different text books, journals relatives to the project content.
ii. To searching relevant materials from internet relative to the project content.

1.6 SCOPE OF THE PROJECT.

This study will base on investigation of the properties of mortar with waste glass
partially replaced as fine aggregate in term of the compressive strength, permeable
porosity and Alkali silica reaction (ASR). The fine aggregate of mortar as partial
replaced by waste glass in 15%, 25% and 35% in order to acquire the specimens for the
study. Sieve analysis will carry out to produce waste glass with the size of fine
aggregate. After casted, the Mortar cube specimens will cure under water curing and air
curing for 7, 28 and 90 days for compression test to determine its compressive strength.
The mortar cube specimens Will also tested for permeable porosity. As for the mortar
bar specimens, it will cured under water curing for 28 days for ASR test to determine its
expansion. The program of Study willcomplete in several phases starting from the
casting mortar specimens to laboratory testing.

1.7 PROJECT OUTCOME.

From the study, I expect that objectives will able to achieve. The waste
Glass will be suitable to be used as partial replacement fine aggregate in the construction
field. Purposely in production of mortar for plastering.
The uses of glass aggregate product also have an architectural value for decoration.

1.8 SIGNIFICANCE OF THE PROJECT.

The significance of the study is the waste glass replacement as fine aggregate

4
Which will applicable for construction? Not only that, the successful of using waste
glass as Aggregate able to reduce the environmental impact. Waste glass used for
replacing the fine Aggregate can be considered as alternative material for aggregate.
Besides, it was a good Opportunity for supplier to open a new market for glass
aggregate.

1.9 CONCLUSION.
This study will about partially be replacing fine aggregate with alternative material
which is waste glass. The waste glass which applicable for construction activity will able
to reduce the environmental impact by reused it as fine aggregate. Further studies have
to be conducted to ensure that glass can fully be utilized as aggregate in construction
material.

5
 CHAPTER TWO.

LITERATURE RIVIEW.

2.1 INTRODUCTION.

Glass is one of the archaic human-made materials. It is delivered in various structures,

for example, packaging, container and bulb glasses, all of which have a restricted life in
their fabricated designs but after the end of they are uses become solid waste and one of
the materials that can be reused. Because it’s a best solution to reduce the influence of
these solid glass wasted on the environment. In this study the
Waste glass will use as fine aggregate in mortar. The samples of the mortar will prepare
by using the waste glass as fine aggregate (glass sand mortar) and fine aggregate, sand
(normal mortar). The literature review is for giving a better understanding of the
materials use for mortar and the characteristic (mechanical and durability) of the
produced mortar.

2.2 WASTE GLASS.

Hypothetically, it is a completely recyclable material; it can be reused with no damage
of value. There are a lot of numerous cases of effective reusing of waste glass: like cullet
in glass manufacture, as unrefined material of the creation of abrasives, in soil-
impacting, as a Pozzolanic added substance, in street beds, asphalt and parking areas,
like crude materials to deliver glass spherule or dabs utilized as a part of intelligent, to
manufacture fiberglass. It can also be manufactured from vacant glass pitchers and jugs.
This is normally smashed into small pieces that look like the grading sizes of rocks and

6
sands. Consequently, there is a possibility to replacement the aggregate with waste glass
due to the absence of characteristic recourses in Cyprus. Table2.1 records some of
proximate compositions and the relating employments of different regular types of glass.

Table 2.1: Approximate compositions of different regular types of glasses

Types of glasses Composition Uses

Boro - Silica 81% SiO2 , 12% B2O3, Laboratory instruments

4%Na2O and 3% Al2O3

Alumino - Silicate 65%SiO2 , 24%Al2O3 , Fiber glass isolation

10% MgO and
0.5%Na2O

Soda - Lime glass 73%SiO2 , 14%Na2O , Windows and bottles

9% CaO and 4% MgO

Crystal 57%SiO2 , 30% PbO Lead crystal

and 13%K2O

In any case of the verity that waste glass can be recycled endlessly and can be reused as,
a variety of times to create different items. In this way, continuous residual amount of
waste glass coming about due to development retrogression and should be area filled or
reused in blends as fractional substitute for coarse aggregate sand and fine aggregates.
Actually, glasses are generally made as tubes, poles, void vessels and an assortment of
exceptional shapes, as well as flat glass for use basically in science, research laboratory,
pharmaceuticals, optoelectronics, and various domestic uses. For the intention of
categorization, the large number of specialized glasses can be generally roughly
arranged in four principle bunches, as indicated by their oxide arrangement.

7
Boro - silica glasses are the primary principle class with the significant measures of SiO 2
and B2O3>8%) as glass system formers. The measure of boric oxide influences the glass
properties especially. Aside from the exceptionally safe assortments B 2O3 (≤13%) there
are others that, because of the distinctive route in which the boric oxide is fused into the
basic system have just low chemical resistance B2O3 (>15%). Besides, the alkaline-earth
aluminosilicate glasses are free of salt oxides and contain (15-25%)Al 2O3, (52-60%)
SiO2 and around (15%) soluble earths. High change temperatures and softening focuses
are normal components. Primary fields of utilization are glass globules for incandescent
lights. And for the last classification is the most seasoned glass sort and in principle,
they are antacid earth silicate glasses (pop lime glasses). It includes level glasses
(window glass) and holder glasses, which are created in vast clusters. Such glasses
contain around (15%) soluble base normally Na2O, (13-16%) basic earths CaO+MgO,
(0-2%) Al2O3 and around (71%) SiO2. Variations of the essential piece can likewise
contain noteworthy measures of BaO and basic earth content.

2.3 MORTAR.
Mortar is a mixture of cement, fine aggregate and water. Common mortar that
used in the construction was masonry mortar and cement mortar.
Masonry mortar and cement mortar have the same characteristic but the cement
mortar air content limits maximum was lower than masonry mortar by ASTM C1329.
(Portland cements Association, 2004).

2.4 MORTAR PROPERTIES.

The properties of mortar can be divided into two categories which were hardened
properties and the plastic or wet properties. "The hardened properties were the properties
involving strength, durability, dimension stability and the ability to exclude water
sufficiently and to have adequate thermal and acoustic properties" (Newman & Choo,
2003, p.7/2)

8
2.5 FACTORS INFLUENCE THE MORTAR PROPERTIES.

2.5.1 Cement content

Too much cements result in the fine cracks in the structure or surface and also in high
coats but too little cement result in a weak and porous product.

2.5.2 Water to cement ratio

The water to cement ratio of the mortar is a major factor governing mortar quality so
good quality mix of water to cement ratio must result in a mortar which hardens in the
correct time and is to demolding.

2.5.3 Fine aggregate. (Sand)

The good sand used in production of mortar is river sand, but must be clean, sharp,
suitably graded in grained size and before mixing the sand must have washed to remove
floating parts and other impurities. Beyond that can affect the quality of mortar.

2.5.4 Admixtures
The ratio of the admixture also resulting in a factor governing mortal quality, too much
workability admixture result in a low strength and high porosity and omitting them may
result in cracks during molding.

9
 2.6 CHARACTERISTICS OF GOOD MORTAR.
i. Should process is adhesion
Good mortar should provide good adhesion to building units.

ii. Should be water resistant

Good mortar should have the capacity of resisting the penetration of water

iii. Deformability of mortar should be low

iv. Should be cheap

v. Should be easily workable in the site condition

The mobility of mortar should be good in order the mortar to be paved thinly and
evenly

vi. Mortar should possess high durability

vii. Mortar must improve the speed of construction therefore should set quickly

2.7 MORTAR INGRIDIENTS

2.7.1 Cement.
It should be fresh and free from adulteration and must provides
i. Strength to plastering wall
ii. Stiffness or hardens early
iii. Possesses good plasticity
iv. Easy workable
v. Good moisture resistant

10
2.7.2 Lime.
It must be well slaked.

2.7.3 Sand.
Must be sharp, angular and porous and free from salt and other impurities.

2.7.4 Uses of sand

i. Mainly used as an inert material to increase the volume of mortar for the
economy.
ii. Using sand in the right amount can produce cheap mortar without hampering
mortar strength.
iii. Helps to prevent mortar shrinkage and cracking of mortar during setting.
iv. It offers the requisite surface area for the film of cementing materials to adhere
and spread.

2.7.5 Water
Should be free from salts and other impurities, or should be of suitable for drinking
purpose.
 Should be free from chlorides.

2.8 TYPES OF MORTARS USED IN MASONRY / BRICK CONSTRUCTION

Following are the type of Mortars based on different factors:

1. Based on Application.
2. Based on binding material.

11
 Such that;

i. Cement mortar
A mixture of cement and sand is made thoroughly mixing them in dry condition.
Water is gradually added and mixed with shovels.
Uses of cement mortar
a) To plaster a slab and walls make them impervious
b) To give neat finishing to walls and concrete works
c) To fill joints and cracks in walls
d) For preparing building blocks.
e) To bind masonry units like stone, bricks, cement blocks

ii. Lime mortar

Fat lime and hydraulic limes are used for making lime mortar. If fat lime is used
sand mixed is normally 2 to 3 times the volume of lime.
Lime is prepared by pounding, if quantity required is small or by grinding, if the
required quantity is more. Pounding; for pounding pits are formed in hard grand.
The size of pit is usually 1.80m long, 0.4m wide and 0.5m deep. It is provided
with lining of bricks or stones.
Lime and sand dry mixed with required proportion is placed in the pit, small
quantity of water is added at interval the mix is pounded with wooden pounders
and the mortar is turned up and down. The process is continued till uniform color
and desired consistency is achieved.
Grinding: this is the better way of getting good mix. The grinding may be carried
out in bullock driven grinding mill or in power driven grinding mill. It consists of
a circular trench of radius 3 to 4.5m 0.3m wide and 0.4m deep. The dry mix is
placed in the trench; water is added gradually bullock driven stone wheels grind
the mix. The worker turns the mix up and down regularly. This method of
preparing mortar needs 6 hours and can produce about 1.7m3 of mortar.

12
 Lime mortar is also having good grinding property. Fat lime mortar is used for
plastering while hydraulic lime mortar is used for masonry construction.
This mortar was considered cheap in olden days and was commonly used in small
towns. However, the cumbersome process of preparation and ease in availability
of cement in market has almost replaced the use of lime mortar.

iii. Mud mortar

Clay lumps are collected and are wetted with water and allowed to mature for 1 or 2
days. It is kneeded well until it attains required consistency. Fibrous materials like
gobber are added in the mix.
It prevents cracks in the plaster. If plaster is to be used for outer walls, it is sprayed
or painted with bitumen. It is cheap mortar. Its durability is less. It is normally used for
construction of temporary sheds and cheap houses in rural areas.

3. Based on Bulky density.

4. Based on strength.
5. Based on special purpose of Mortars.

2.9 COMPRESSIVE STRENGTH

Type and quantity of cementations material used for preparing mortar play an
important role contributing its compressive strength (Portland Cement Association,
2004). Hydration process or chemical reaction of the cement with the water and
aggregate
was the process contributing to the compressive strength (Newman & Choo, 2003, p.4/3-
4/4). Neville (1981, p.269) stated that increases of water/cement ratio decreased the
compressive strength.

13
2.10 PERMEABLE POROSITY
"The permeable porosity affects the transport properties and durability of
concrete."
It was connected to many deterioration process driven by transport properties of
concrete.
One of the deterioration processes involving permeable porosity was sulfate attack and
Alkali aggregate reactivity. It also has major effect on concrete strength and other
mechanical properties (Safiuddin & Hearn, 2005).

2.11 ALKALI SILICA REACTION (ASR)

Alkali silica reaction was chemical reaction between the active silica that found in
aggregate and the alkalis in the cement. Alkali silicate gel was formed during the
reaction of siliceous minerals in the aggregate with alkaline hydroxides derived from the
alkalis.
This gel causes expansion and map cracking on mortar or concrete by absorption or
osmosis of water (Neville & Brooks, 1987, p.273).

2.12 CEMENT
Cement is an adhesive substance that acts as binder to bind particles or solid matter
(Aggregate) together into a compact whole (Hewlett, 1998, p.1).
Portland cement was produced by mixing limestone and clay or other materials that
have similarity in term of bulk composition and sufficient reactivity by heating it to the
temperature of about 1450 °C (Neville & Brooks, 1987, p.8 & Taylor, 1997, p.1).
According to Neville (1981, p.66), the most common Portland cement that used for the
General mortar or concrete construction is Ordinary Portland cement (Type I) where it is
free from sulphates attack.

14
In this study the type of the cement that will use is Ordinary Portland cement and white
cement and the testing will done in the lab.
2.13 FINE AGGRIGATE
Fine aggregate can be defined as aggregate that passed through No.4 (4.75mm)
Sieve and retained on a No. 200 (75 [Lm) sieve and the most common fine aggregate
that used was river sand (Li, Liang, Wenquan, 2011, p.24). The profile of sand (Li,
Liang, Wenquan, 2011)

Portland Cement Association (2004) stated that the masonry mortar fine aggregate
Grading should follow ASTM C144.

Table 1. Aggregate Gradation for Masonry Mortar

Gradation specified. percent passing

Sieve size no. ASTM C114"

US. (Metric) Natural sand manufactured sand
4 (4.75 mm) 100 100
8 (2.36 mm) 95 to 100 95 to 100
16 (1.18 mm) 10 to 10) 70 to 100
30 (600 µm) 40 to 75 40 to 75
50 (300µm) 10 to35 20 to 40
100 (150 µm) 2 to 15 10 to 15
200 (75µm) 0 to 5 0 to 10

Figure 2:1:13: The table of fine aggregate sieve. (Portland cements Association, 2004).

2.14 WATER
Water that used for the batching mortar should be cleaned and freed from any

15
Concentrated minerals (Portland Cement Association, 2004). Neville & Brook (1987,
p.74) Indicated that drinking water with low concentration of sodium and potassium and
washing Water can be. used for mixing accordance to ASTM C 94 (1992a).

2.14.1 Water Proofing Compound.

They are not required especially it correct type and quality of other materials of mortar
are available. Where it is used, it should disperse uniformly and mixed properly in
mortar.

2.14.2 Workability Admixtures

Plasticizers can be used in warm or cold weather condition as desired with field
requirements. In addition of water should be carefully monitored and should be added in
such a quantity that it gives the required workability.

2.15 WASTE GLASS.

Glass was a significant solid waste produce by the daily activities in the society.
Mostly glass was used as bottle, container for storing consumables or window. Glass
was one of the unique wastes if compared to the others wastes because it can be fully
recycled (Traeholt & Ling, 2010). So the direction for recycling the waste glass will be
as a replacement of natural aggregate in the manufacture of mortar in building
construction and helps to improve the sustainability of developed materials and also will
be eliminated, reducing the long impact to the environment and human health due to
excessive waste glass exploitation to the environment.

16
2.16 CHEMICAL COMPOSITION OF GLASS
Properties of glass that have large quantities of silicon and calcium making it act
as Pozzolanic or even cementitious in nature when it was finely ground. It was suitable
for replacing cement and aggregate. "Glass can be categories as vitreous silica, alkali
silicates, Soda-lime glasses, borosilicate glasses, lead glasses, barium glasses and
aluminosilicate Glasses. Among all the categories the most of the glasses that found in
waste glass was soda-lime glasses" (Shi & Zheng, 2007).

Table 2.1. Chemical composition of selected commercial glasses (McLellan and Shand,
1984).

Glasses and uses Si02 Al203 B203 Na2O K20 MgO CaO O

Soda-lime glasses 66-75 66- 75 0.7-7 12-16 0.1-3 0.1-5 6 4

Containers 72 78 75 77 7 5 5 7
Float 73-74 73- 74 15 0.2 3.8 5 3
5
Sheet 71 - 73 71-73 1.5 12-15 3.5 45 - -
Light bulbs 73 73 5 1 4 7 5
45
Tempered 75 75 4 4 1.5 1 14
ovenware 4
Borosilicate 44 52 11 12 15 12 13 4
Chemical 81 45 81 2 4 1
apparatus 3
Pharmaceutical 72 72 6 11 7 1
Tungsten sealing 74 74 1 15 4
Lead glasses 12 78 8 7 7 15 11 22
Color TV funnel 54 49 54 2 4 4 5 8
Neon tubing 63 63 1 8 6 2 2 3
Electronic parts 56 56 2 4 9 1 2 3

17
Optical dense 32 32 1 2 7 8 4
flint
Aluminosilicate 42 5 45 6 7 0.3 7
glasses
Combustion 62 5 17 62 11
tubes
Fiberglass 64 564. 5 0.5 10.5 0.6 -
24.5
Resistor 57 57 16 47 10 42 11 1
substrates
Tan & Du (2013) stated a more simplified waste glass chemical composition
analysis according to its color and compared it with the natural sand composition.

2.17 PLASTERING.
Is a process of applying one or more coats of mortar to a concrete surface, brick work,
stone masonry or lathing? It must be durable such that it resists the penetration of
moisture and should be able to weather uniformly. It should also be pleasing in
appearance. These properties depend upon material used, composition of mix, and
degree of mechanical bond between the plaster and the backing surface and
workmanship.

2.17.1 Surface Preparation.

The joint shall be raked to a depth of 15mm for brickwork and 20mm for stonework.
And the surface must be thoroughly cleaned washed with water and brushing if not
scrapping in order to remove efflorescence. And kept wet for the days previous and up
to time when will start the work and shall be kept very damp during the process of the
plastering.

18
2.17.2 Concrete Surface
All monolithic concrete walls should be roughed by hacking at close intervals with bush
hammers or with a chisel and hammers and then washed with water to remove all dirt
and loose particles. Monolithic concrete can be roughened with a heavy wire brush or a
special scouring tool if forms are removed early. Forms of concrete that is to receive
plaster should not be given excessive mould oil coating. As it likely to remain on the
concrete, interfering with the bond. Sothe special care must be taken to remove the
mould oil coating before plaster is applied. Curing compound if used should also be
removed completely before connecting the plaster work.

2.17.3 Brick And Stone Masonry Surface

These are excellent bases for direct application of cement plaster. The surface should be
hard, rough and clean. The joints should be racked. It may be desirable to roughen with a
pick or a similar sharp tool if the surface of stone or brick is too smooth.

2.18 OBJECIVE OF PLASTERING:

Plastering is done to achieve the following objects.
i. To protect the external surfaces against penetration of rain water and other
atmospheric agencies.
ii. To give smooth surface in which dust and dirt cannot lodge.
iii. To give decorative effect.
iv. Covers up the use of inferior quality material and joints.
v. Provides satisfactory base for white washing, and color washing
vi. Conceals the defective of workmanship.

2.19 REQUIREMENTS OF GOOD PLASTER:

i. It should adhere to the background and should remain adhered during all
variations of the climatic changes
ii. It should be cheap and economical

19
 iii. It should be hard and durable.
iv. It should be possible to apply it during all weather conditions.
v. It should be effectively check the entry or penetration of moisture from
the surface.
vi. It should possess good workability.

2.20 INGRIDIENTS OF PLASTERING:

i. Cement
ii. Lime or clay
iii. Aggregates
iv. Water
v. Accelerator
vi. Admixture
vii. Waste colored glass
The waste glass to be used for the experimental program is variously colored waste
glass. In order to obtain optimal result 3 types of recipes with different waste glass
proportions, 25%, 50%, and 100% respectively to develop.

20
 FIGURE: Ingredient of Plastering.

2:21 MIXING OF INGREDIENTS OF PLASTER:

It is preferable to mix the ingredients in a mixer. Dry mortar Is mixed initially
and there after water is added to the dry mix to get the required consistency. It is
observed that excess mortar is often prepared and not utilized in time. The workers even
break for lunch leaving the wet mixed mortar dry out. Water is again added resulting in
lower strength and more shrinkage problem. The quantity of the mortar made at a time
should be such that it can be consumed within 30minutes. Any mortar that falls to the
ground in the process of application, it is thrown away and on no account reused. If
excess mortar is prepared it dries up either due to evaporation of water or due to water
absorption by sand or due to water consumed by cement hydration.
Addition of water should be carefully monitored and should be added in such a
quantity that it gives the required workability.

21
2.22 TYPES OF PLASTERING:
Depending upon the binding material
i. Cement Plastering
When cement is used as the binding materials, it is called the Cement plaster. It is
especially suited for damp condition.
Cement plaster is usually applied in one coat, the thickness of coat can be 12mm,
15mm or 20mm depending upon the site conditions and the type of building. When the
thickness of cement plaster is more than 15mm. 6mm thickness of cement plasters and
cements mortar 1:3 or 1:4. It is recommended for cement plastering on RCC surfaces

22
 ii. Mud Plastering
The surface to be plastered is prepared exactly in the same manner as that for cement
plaster or lime plaster.
Mud plaster is generally applied in two coats, the first coat being 18mm thick while
the thickness of the second coat is kept 6mm.

iii. Lime Plastering

When Lime is used as the binding materials, it is called Lime plaster.
Lime plaster is a type of a plaster composed of hydrated lime, sand and water.
Lime plaster is similar to lime mortar, the main difference is the based on use rather than
composition.
Hydrated lime is harder and stronger. Mortar for lime plaster is usually prepered by
mixing sand and lime in equal properties. Cemnt is small quantity added to the mixer to
improve its strength. Lime mortar or lime-cement mortar used shall have fat lime to sand
ratio of 1:3 or 1:4. If hydrated limeis used mix proportion (lime:sand) is 1:2. Richer mix

23
being used for outer walls to combine the cost effectivenes of lime mortar and good
quality of cement mortar will be use lime – cement mortar of proportion ( cement: lime:
sand ) of 1:1:6 or 1 : 1 : 8 or 1 : 2 : 8

iv. Stucco plaster

Stucco is the name given to a decorative type of plaster which gives an excellent finish.
Stucco plaster can be used for interior as well as exterior surfaces. It is usually laid
in three coats and making the total thickness of the plaster to about 25mm. the first coat
is called the scratch coat; the second a finer coat, also known as the brown coat, and the
third is called white coat or finishing coat.

24
2:23 TOOLS FOR PLASTERING:
The following tools are used for plastering
i. Gauging trowel
ii. Floats
iii. Floating rule
iv. Plumb bob
v. Straight edge
vi. Bushes
vii. Set square
viii. Sprit level
ix. Scratcher
x. Plumb rules

25
2:24 PLASTERING METHOD
i. Preparation of tools
ii. Preparation of plaster
iii. Applying plaster
iv. Finish(treatment)

2:25 APPLICATION OF PLASTER

Applying mortar coats on the surfaces of walls, columns, ceiling etc. to get smooth
finish is term as plastering; the surface shall be prepared as above and rendered with a
mortar of cement, lime or maybe mud and fine sand in specified proportions. At suitable
intervals 15cm × 15 cm mortar squares to full thickness of base coat shall be first laid to
serve as a guide to ensure a plane, smooth layer of plaster over the entire surface
example wall. The mortar shall be dashed against the surface to be plastered with
considerable forced and shall be thoroughly worked into all joints and other surface
depressions to ensure a permanent bond. The plaster surface will be roughened and not
beaten. Ceiling plaster shall be completed before commencement of the wall plastering.

26
 Plastering shall be started from the top and worked down, filling all put log holes
in advance of the plastering as the scaffolding is being taken down. All corners arise,
angles and junctions shall be truly vertical or horizontal as the case may be, and shall be
carefully finished.
Rounding or chamfering corners, arises, junctions etc. where required shall be
carried out with proper templates to the required sizes. At the end of the day suspending
plastering work shall be left and clean to line both horizontally and vertically. Horizontal
joints in plaster work shall not occur on parapet tops and copings.
NB: Scaffolding, it is always advisable to provide double scaffolding for
plastering work. It is easier to fix and remove at various heights without damaging the
masonry or plaster.

2:26 COATS FOR PLASTERING:

2.26.1 Scratch coat:

The thickness of this coat should approximately 10mm to 12.5mm and must be laid over
the full length of the wall or the natural breaking points like doors and window.

2.26.2 Base coat (in case of thick plaster):

The surface of the scratch coat should be dampened evenly before base coat applied.
This coat is about 10mm thick depending upon the overall thickness and then roughened
with a wooden float to provide bond for the finishing coat. The second coat must be
dump cured for at least seven days and then allowed to become dry.

2.26.3 Finishing Coat:

Before this coat is applied, the base coat is dampened evenly, joints should be avoided
and the finishing coat should be applied in one operation with thickness not exceeding
6mm.

27
2.26.4 External plaster:
The external plaster is made in richer cement mortar proportional than the internal
plaster. It is usually done in two layers. First layer is of 10mm to 12.5mm and final layer
is of 6mm thickness. Waterproofing compound may be added in case the plaster is
exposed to severe wet conditions. The finish can be of the type specified.

2.26.5 Internal Plaster:

The internal plaster is usually done in single layers of 12.5mm

2:27 FINISH
The plaster shall be finished to a true and plumb surface to the required degree of
smoothness. The work shall be tested frequently as it precedes with a true straightedge
not less than 2.5m long and with plumb bob as the work proceeds.

2:28 PLASTER FINISHES:

There are four different types of finishes that can be obtained with cement plaster.

2.28.1 Smooth finish:

When a smooth is desired, the minimum amount of working should be applied to the
wetted surface and wooden float, rather than a steel trowel is to be used.

2.28.2 Roughcast finish.

This finish suitable for rural or coastal areas and the sever conditions of the exposure.
This is a finish which is splashed on to the surface as a wet mix and left rough. The
maximum size of sand, crushed stone or gravel vary from 12.5mm to 6.3mm

28
2.28.3 Pebbledash finish:
This is most durable of all finishes and is generally free from defects. This gives a rough
texture and is obtained by means of small pebbles or crushed stone, graded from
12.5mm to 6.3mm being splashed on to a fresh coat of mortar and left exposed. This
pebbles or stones are sometimes lightly pressed or tapped in to the mortar.

2.28.4 Textured finishes:

Textured finishes are now becoming very popular and may be obtained in a variety of
ways in many different designs. Special effects can be obtained by scraping the surface
of the rendering with a straight edge, hacksaw blade or with the edge of a steel trowel.

2.29 CURING:
Curing shall be started 6 hours or 24 hours after finish the plaster. The plaster shall be
kept wet for 7 days during which period it shall be suitably protected from all damages
at the contractor’s expenses by such means as the engineer may approve, the dates of
plaster shall be legibly marked o the various sections of the wall so that curing for the
specified period thereafter can be watched.

2.30 DEFECTS IN PLASTERING:

2.30.1 Cracks:
Appear on the plastered surface in of hair cracks or wider cracks. Its due to old surface is
not properly dressed, bad workmanship and due to expansion and shrinkage in plaster
coat during drying. Prevented by proper curing 10 days and keeping thickness of plaster
uniform (<15mm)

29
2.30.2 Efflorescence:
Sometime soluble salts are present in plaster making materials or bricks. They are
appearing on the plastered surface in whitish patches and produced ugly appearance. It
may remove by brushing and washing the surface several times. And avoided by
washing the surface with zinc sulphate solution and water

2.30.3 Blistering Of Plastered Surface:

30
Small patches swell out beyond the plastered surface like boils, arising out of late
slaking of lime particles in the plaster.

2.30.4 Falling Out Of Plaster:

Due to in adequate water bondage, water absorption by dry wall, avoided by proper
cleaning of joints and proper washing of surface of wall.

31
2.30.5 Discoloration:
The usual causes of discoloration in plaster are to variation in the cement and water
content of mortar from place to place, uneven suction of the backing and un- uniform
curing and in adequate mixing of the material resulting in lack of uniformity.

2.30.6 Crazing:
Crazing is the network of lines or cracks in the fired grazed surface. It happens when a
glaze is under tension. A craze pattern can develop immediately after removal from the
kiln or years later.

32
2.30.7 Grinning:
Grinning is the term given to the appearance of a plastered wall when the position of the
mortar joints is clearly visible through the plaster. It is caused by the difference in
suction between the masonry units and the mortar. Ranking out mortar joints also causes
grinning and the practice should thus be limited to soft clay brickwork.

2:31 WAYS TO MINIMIZE THE DEFECTS IN PLASTERING WORK:

Defects in plastering work can spoil all your creativity; can be minimized by following
techniques.
33
 i. The brick and plastering work should be carried out by skilled masons in the best
workmanship manner.
ii. Bond of rick work should be properly maintained.
iii. Efflorescence is removed by rubbing brushes on the damaged surface. A solution
of one part of hydrochloric acid or sulphuric acid and five parts of clean water is
prepared and is applied with the help of brushes on the affected area. The surface
is then washed with clean water. It should however be remembered that it is
desirable to prevent efflorescence than to cure it. Building material should select
of superior quality and suitable methods of construction should be employed.
iv. Water should not be used to wash the surface so as to remove efflorescence. In
that case, soluble salts will be partly carried inside the surface and efflorescence
will appear again. For this purpose, the deposit is brushed off from the surface as
it appears and the surface is kept under observation for a further period of few
days. After curing, if efflorescence appears again it is removed with a dry brush
and the process is repeated till all the soluble salts are removed under the
conditions of normal drying. It is advisable to postpone painting till efflorescence
ceases.
v. Water free from salts should be used for brick work and plastering work.
vi. The surface to be plastered should be well watered so that it may not absorb
water from the plaster.
vii. Excessive troweling should be avoided.
viii. Damp – proof courses should be provided at convenient places in the building.
ix. The overall construction should be such that penetration of moisture is
prevented.

x. Fresh plastered surface should be protected from the superfluous quantity of

water such as rain and excessive heat such as sun.

34
2:32 ADVANTAGES OF PLASTERING:
i. Easy in application.
ii. No surgery is required
iii. Plaster is the most common form of interior wall finishing.
iv. If properly mixed and applied, a plaster coating creates a stronger and more
durable.
v. Protect the basic work of the climate action.

2:33 DISADVANTAGES OF PLASTERING:

i. When plaster cracks then difficult to repair.
ii. Repairing is very expensive.
iii. Despite the extra labor of hanging and finishing drywall, it tends to be less
expensive than plastering.

CHAPTER: THREE
METHODOLOGY:
3:0 INTRODUCTIONS:
This chapter discusses the methodology used in order to archive the specific objective,
collecting and analyzing. Test will be LAA Test and particle size distribution for
grounded waste colored glass as fine aggregate.

The process of mixing design by combining the fine aggregates of grounded waste
colored glass, cement, and water for obtaining normal mortar were performed by citing
standard guideline and literature review. Testing of fresh mortar and testing of hardening
mortar were conducted so as to determine the workability of mortar, compressive
strength test of hardened mortar was determined. Final conclusion and

35
Recommendations provided to the end of this project. Also this chapter demonstrates the
properties of materials used to make the mortar samples. And mixture properties are
given together with test methods.

3:1 EXPERIMENTAL MATERIALS

3:1:1 Cement
There are more than eight types of cement according to American standards (ASTM
C150) and cement is significant for mortar and it’s the most important part for mortar
mixture. For experimental part of this study White cement and Portland composite
cement [CEM II/ B-M (S-L)] PO32.5R was used. Table 3:1: shows the chemical
properties of cement and Table 3.5 shows the physical properties of cement used for this
work.

Table 3.1: Chemical properties of Portland composite cement:

OXIDE AMOUNT%
CaO 63.2
SiO2 19.8
Al2O3 6.3
Fe2O3 3.2
MgO 1.5
K2O 1.0
SO3 2.5

Table 3.2: Physical properties of Portland composite cement

PHYSICAL PROPERTIES VALUE
Initial setting time(min) 80
Final setting time(min) 520
Loss on ignition (%) 1.8
2
Fineness- Blaine(m / kg) 225
Compressive strength (Mpa)

36
 2 days 13
7 days -
28 days 46

3:2 White cement:

A white cement (WC) CEM II/B-LL 32.5 R (AQUILA BIANCA Italcementi S.p.A.),
with an average clinker: limestone ratio of 2.6 by weight, was chosen for aesthetic and
architectural mortar applications. White cement can guarantee the most versatile range
of colors by possible additions of pigments. Moreover, white cement is particularly
suitable for exposed decorative glass aggregate finishes because it contains
comparatively low alkali content, and thus it can reduce a potential deterioration due to
ASR expansion. The chemical composition of WC is presented in Table 1.
Table 3:4 Chemical composition of WC cement in oxides (wt%).
SiO2 Al2O3 Fe2O CaO MgO Na2O K2O SO3 Loss on ignition
% 21.4 5.3 0.2 67.5 1.2 0.05 0.08 2.6 1.6

Table 3:5 Chemical composition of recycled glass in oxides (wt%).

SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O SO3
% 73.3 1.5 0.06 9.8 0.35 14.2 0.6 0.2

3:2:1 Water
Generally, cement needs water for hydration, because adding water will give flexibility
for the mixture which gives the mortar workability. During the experiment, W/C ratio is
(0.6). The drinking water is used for the mortar mix must satisfying. The quantity and
quality of water are required to be looked into very carefully.
3:2:2 Aggregate
Aggregate is an inert, inexpensive material dispersed throughout the cement paste so as
to produce a large volume of mortar and also give stability and durability to mortar. The
physical properties of the aggregates (crushed sand and crushed waste glass) as given in

37
Table 3.8. The sieve analysis of the crushed sand given in Table 3.6. Grain size
distribution of aggregates is given in Figure 3.9

Table 3.6: crushed sand sieve analysis results.

BS Sieve Weight Total Percentage Cum. Cum.
size(mm) retained (gr) weight retained Percentage Percentage
retained (gr) retained passing
4.75 15.0 15.0 3.0 3.0 97.0
2.36 142.5 157.5 28.5 31.5 68.5
1.18 91.5 249.0 18.3 49.8 50.2
0.6 78.0 327.0 15.6 65.4 34.6
0.425 28.0 355.0 5.6 71.0 29.0
0.3 19.5 374.5 3.9 74.5 25.1
0.15 23.0 397.5 4.6 79.5 20.5
0.075 17.5 415.0 3.5 83.0 17.0
Pan 85.0 500.0 17.0 100 0

3:2:3 Waste glass

All of the glasses used for this study were obtained by crushing glass bottles consisting
primarily of beer, medicine bottles from Medical Store Department (Msd) and soft drink
bottles (green, blue and purple) collected from various places of Famagusta city. The
initial treatment of the bottles consisted of a hot bath where labels and all other foreign
materials were removed, after allowing the bottles to dry, crushed by LOS ANGELES
ABRASION TEST (LAA) Machine to get the required size and also to get a powder
glass for replacing with aggregate by weight at percentages of 0, 5, 15, 25, 35 and 45 see
Table 3.8.The physical properties of the waste glass used in this research are given in
Table 3.6. Table 3.7 shows the sieve analysis of the waste glass and the grain size
distribution of crushed sand is given in table 3.6

Table 3.7 Sieve analysis results of crushed waste glass

Sieve size Weight Total weight Percentage Cum Cum

38
(mm) retained(gr) retained(gr) retained percentage percentage
retained passing
4.75 0 0 0 0 100
2.36 0 0 0 0 100
1.18 0 0 0 0 100
0.6 2.5 2.5 0.5 0.5 99.5
0.425 28.5 31.0 5.7 6.2 93.8
0.3 28.0 59.0 5.6 11.8 88.2
0.15 241.0 300.0 48.2 60.0 40.0
0.075 65.0 365.0 13.0 73.0 27.0
Pan 135.0 500 27 100 0

Table 3.8: physical properties of crushed sand and crushed waste grass.
Properties of aggregate Crushed sand Crushed glass
Relative density SG (OD) 2.67 2.38
Relative density SG (SSD) 2.73 2.39
Apparent relative density 2.85 2.39
SG
Absorption 2.46 0

Figure 3.9 grading curve of crushed sand and crushed glass

39
 Waste crushed or grounded colored glass

3:2:4 Admixtures.
An acrylic-based super plasticizer with 30% of active ingredient by emulsion weight
was used to give satisfactory fluidity to the different mixes. As hydrophobic admixture,
a 45% water solution of butyl-ethoxy-silane was used. Analogous mixtures of with the
addition of a 1% by cement weight of hydrophobic admixture were considered (labeled
with H in table) the proportions of the mixes are given in table 3.10

3:3 MIX PROPORTION.

All the mixtures were proportioned with a fixed water/ cement (w/c) ratio of 0.47 and
aggregate/cement (a/c) ratio equal to 2.25 by weight. These ratios were chosen following
literature data (Ling and Poon 2011).
To enhance the aesthetic value of glass based mortars, glass of larger sizes proportions
should be included in the mortar mix. Since fine aggregate (sand) grain size distribution
is comparable with that of glass, to investigate the influence of large glass particles on
the properties of mortars, the sand was replaced by recycled glass at the dosage rate of

40
0–33–66–100% in volume. In this way the widest possible replacement range was
considered in order to exploit all the potentials of valorizing waste glass in mortars.
Table 3:10 mixing design of mortars (kg/m3)
specimen Water(kg/m3) Cement Sand Glass Super Silane
(kg/m3) (kg/m3) (kg/m3) plasticizer (kg/m3)
(kg/m3)
0% 286 609 548 0 0.5 -
33% 286 609 548 256 0.4 -
66% 286 609 548 512 0.3 -
100% 286 609 548 776 0.2 -
0%+H 282 609 548 0 0.5 6.77
33%+H 282 609 548 256 0.4 6.77
66%+H 282 609 548 512 0.3 6.77
100%+H 282 609 548 776 0.2 6.77
H – hydrophobic addition.

3:4 TESTING PROGRAM.

3:4:1 Testing of Fresh Mortar.
3:4:1:1 Unit Weight.
A sample of freshly mixed mortar was obtained according to ASTM C 138 in the
following order. The mass and volume of an empty vessel was recorded and three equal
layers of mortar were added to the vessel. The first layer was filled and compacted. The
second layer was added on top of the first layer and the same action was performed.
Following this, the third layer was added to fill the entire vessel.

3:4:1:2 Flow Table

Consistency was measured according to ASTM C 1437. A sample of fresh mortar was
obtained and placed in the flow table. Sequentially, the table was dropped 25 times on
the sample in 15 sec time interval. Four measurements were taken and the average of
them was recorded.

41
3:4:2 Testing of Hardened Mortar.
3:4:2:1 Dry Bulk Density.
Following the BS EN 1015-10 standard a dry sample of mortar was obtained and placed
in the oven for 24 hours. After removing the sample from the oven it was placed to cool
down to room temperature. Subsequently, the sample was immersed in water (20 ± 2)
for a period of 24 hours in order to be fully saturated. Two measurements were taken of
the sample. Once while the sample was immersed in the water and the second when it
was removed from the water.

3:4:2:2 Compressive Strength.

According to ASTM C349 compressive strength tested by three different ages of
3, 7 and 28 days. The testing machine was adjusted to have a rate of loading 0.5
MPa/sec.

3:4:2:3 Flexural Strength.

According to ASTM C348 the sample size is 40 × 40 × 160 mm and tested by three
different ages of 3, 7 and 28 days. The rate of loading was adjusted to be 0.5
MPa/sec.

3:4:2:4 Porosity.
According to standard test method TS 699 and ASTM C20 the test specimens were put
in oven for 24 hours and the weight recorded and then immersed in water (20 ± 2) for 24
hours to be fully saturated and the weight was also recorded.

3:4:2:5 Absorption.
Two ways of calculation of absorption were performed. The first calculation used the
weight of water absorption per unit area. According to BS EN 1015-18 a sample of

42
mortar was dried in the oven at 105 for 24 hours then placed to cool down to room
temperature. Subsequently, the sample was placed in a pan containing 5mm of deionized
water. Furthermore, the weight of the sample was recorded at different time intervals.
The second way to calculate the percentage of absorption by mass is according to TS
699.

3:4:2:6 Freeze – Thaw Resistance.

A solution of sodium sulfate was prepared 48 hours prior to use according to ASTM
D5240 A sample was dried at constant mass at (110) in the oven and the mass was
immediately recorded. Subsequently the sample was immersed in the prepared solution
of sodium sulfate that had a depth of 12.5 mm, for 17 hours and then removed. The
process was repeated for a total of five cycles.

3:4:2:7 Drying Shrinkage.

According to ASTM C596 and ASTM C157 the sample was removed after three days of
being immersed in water and reading were recorded after 4, 11, 18, and
25 days in air storage.

3:4:2:8 Rapid Chloride Permeability

Specimens of 51 mm thick slices and 102 mm diameter according to ASTM C1202)
were obtained. Two separate solutions of sodium chloride and sodium hydroxide were
prepared at temperature less than 90. The sample was placed in a vacuum desiccators for
three hours at (6650 Pa) and then the water stopcock was opened to cover the specimen
and not allow air to enter desiccators. Subsequently the desiccators were opened with the
specimen immersed in water for 20 hours. The last step involved putting the
permeability chamber for 6 hours and then the results were recorded.
REFERENCES.

43
[1] Meyer, C., Egosi, N., & Andela, C., (March, 2001). Concrete with Waste Glass
as Aggregate International. Symposium Concrete Technology Unit of ASCE and
University of Dundee

[2] Shayan, A., & Xu, A., (2004). Value-added utilization of waste glass in concrete.
Cement and concrete research.

[3] Ismail, Z. Z., & Al-Hashmi, E. A. (2009). Recycling of waste glass as a partial
replacement for fine aggregate in concrete. Waste Management, 29(2), 655-659.

[4] Turget, p., & Yahlizade, E. S. (2009). Research into concrete blocks with waste
glass. International journal of Civil and Environment Engineering.

[5] Abdul-Jalil, M. A. (2010). Sustainable development in Malaysia: a case study on

household waste management. Journal of Sustainable Development, 3(3), 91.

[6] Blengini, G. A., Busto, M., Fantoni, M., & Fino, D. (2012). Eco-efficient waste
glass recycling: Integrated waste management and green product development through
LCA. Waste Management, 32(5), 1000-1008.

[7] (2014, February 20) Waste and Landfill Waste Collection and Transportation.
Mena Report.

[8] Al-Najar, H. (2005). Solid waste management in the Gaza Strip Case Study
Ministry of Health, Gaza.

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