STRENGTH OF CONCRETE MASONRY UNITS WITH PLASTIC BOTTLE CORES by SEAN M. WONDERLICH B.S., Kansas State University, 2014 A THESIS submitted in partial fulfillment of the requirements for the degree MASTER OF SCIENCE Department of Architectural Engineering and Construction Science College of Engineering KANSAS STATE UNIVERSITY Manhattan, Kansas 2014 Approved by: Co-Major Professor Kimberly Waggle Kramer, P.E., S.E. Approved by: Co-Major Professor Bill Zhang, PhD., P.E., S.E., LEED AP Copyright SEAN M. WONDERLICH 2014 Abstract Concrete masonry units are a common method of construction in the world. Since the masonry units can be constructed with ease. Fifty billion water bottles are consumed every year. Lack of waste management and recycling in third world countries has come to the attention of many organizations. The use of plastic bottles in construction materials has been around for the past twenty years, but with little focus on using full plastic bottles in the materials. The Engineers Without Borders student group on the campus at Kansas State University have found a way to utilize the full 500-mL plastic bottle in the creation of concrete walls. The bottles laid horizontally with concrete on both sides and as mortar between the bottles was used. These bottles create large voids in the wall decreasing the compressive strength of the wall. This thesis presents the results of a study conducted to determine the compressive strength of concrete masonry units with plastic bottle cores. The plastic bottles were used to create the center voids in the masonry units. Concrete was placed around the bottles to encase them in the masonry units. The study utilized 500-mL plastic bottles from five different water companies placed inside masonry units of 7.87-inch wide by 8.26-inch high by 15.75-inch long (200-mm wide by 210- mm high by 400-mm long) in size and analyzed the resultant compressive strength. The testing for compressive strength was determined according to the ASTM C140 standard. Results from this study were deemed reasonable due to the testing of concrete cylinders as a control compressive strength. Determination of the compressive strength of the concrete masonry units allows for further study to continue in concrete masonry units with plastic bottle cores to determine if they are viable in third world countries. Table of Contents List of Figures ................................................................................................................................ vi List of Tables ................................................................................................................................ vii Acknowledgements ...................................................................................................................... viii Dedication ...................................................................................................................................... ix Chapter 1 - Introduction .................................................................................................................. 1 Chapter 2 - Background .................................................................................................................. 3 Chapter 3 - Literature Review ......................................................................................................... 6 Concrete Block Masonry Mix Design ................................................................................ 6 Compressive Strength Test for Low-Strength Cement Blocks ........................................... 9 Concrete Blocks with Ecological Aggregates................................................................... 11 Chapter 4 - Test Plan and Procedure ............................................................................................. 13 Concrete Cylinders ................................................................................................................ 13 Test Specimens ................................................................................................................. 13 Fabrication Procedure ....................................................................................................... 13 Apparatus .......................................................................................................................... 14 Experimental Procedure .................................................................................................... 15 Concrete Masonry Unit ......................................................................................................... 16 Test Plan............................................................................................................................ 16 Apparatus .......................................................................................................................... 18 Fabrication Procedure ....................................................................................................... 20 Experimental Procedure .................................................................................................... 22 Chapter 5 - Test Results ................................................................................................................ 24 Test Data ........................................................................................................................... 24 Chapter 6 - Conclusion ................................................................................................................. 26 Discussion of Results ........................................................................................................ 26 Conclusion ........................................................................................................................ 29 Limitations ........................................................................................................................ 29 Recommendations for Further Research ........................................................................... 29 iv Cited Sources ................................................................................................................................ 31 References ..................................................................................................................................... 32 Appendix A - Concrete Masonry Unit Specimens ....................................................................... 33 v List of Figures Figure 2.1 Eco-Tec Plastic Bottle Wall System, reproduced from Andreas Froese ....................... 3 Figure 2.2 EWB Concrete Wall with Plastic Bottles, approval from Richard Kim ....................... 4 Figure 3.1 Loading Curve .............................................................................................................. 9 Figure 4.1 Test Cylinder Set-Up .................................................................................................. 15 Figure 4.2 Baldwin Turret Press Machine ................................................................................... 19 Figure 4.3 Loading Plate .............................................................................................................. 20 Figure 4.4 Test Specimen Set-Up ................................................................................................ 21 Figure 4.5 Loading Curve ............................................................................................................ 23 Figure 6.1 Specimen 1B Failure .................................................................................................. 27 Figure 6.2 Specimen 2C Failure .................................................................................................. 27 Figure 6.3 Load vs Time by Brand of Bottle ............................................................................... 28 Figure A.1 Specimen 1A............................................................................................................... 33 Figure A.2 Specimen 1B ............................................................................................................... 34 Figure A.3 Specimen 1C ............................................................................................................... 35 Figure A.4 Specimen 2A............................................................................................................... 36 Figure A.5 Specimen 2B ............................................................................................................... 37 Figure A.6 Specimen 2C ............................................................................................................... 38 Figure A.7 Specimen 3A............................................................................................................... 39 Figure A.8 Specimen 3B ............................................................................................................... 40 Figure A.9 Specimen 3C ............................................................................................................... 41 Figure A.10 Specimen 4A............................................................................................................. 42 Figure A.11 Specimen 4B ............................................................................................................. 43 Figure A.12 Specimen 4C ............................................................................................................. 44 Figure A.13