Project Information

Cement Production

Cement Production Process

During the cement production process, raw material is crushed and heated in a rotary kiln.
Two by-products are produced during this heating process: carbon dioxide and Cement Kiln Dust (CKD). When Carbon dioxide is sequestered from the kiln process and reacted with CKD the result is Carbonated Cement Kiln Dust (CCKD). The production and use of CCKD could potentially reduce the cement industry's carbon footprint.

Project Purpose

The purpose of this project is to investigate the plausibility of CCKD as a partial cement substitute by analyzing its effect on the strength and durability of concrete. This will be accomplished by executing and analyzing compressive strength and durability testing conducted on different concrete mixes.

Experimental Plan

The team will be following the experimental plan below to conduct all testing.

 
 

% of Cement Reduction

Water to Cement Ratio

# of Samples

Control (4000 psi)

None

0.44

3

CKD
Substitution

5

0.46

3

10

0.49

3

15

0.52

3

CCKD
Substitution

5

0.46

3

10

0.49

3

15

0.52

3

Cement reduction

5

0.46

3

10

0.49

3

15

0.52

3
Total
30

 

In addition to testing proportions of CKD and CCKD cement substitution, a control will be tested as a baseline. Cement reduction will also be tested to verify that any changes in strength and durability between the control and the CKD and/or CCKD substitution can be attributed to the use of CKD and CCKD and not to the reduction of the amount of cement in the concrete.

The following list outlines the project tasks that must be completed in order to successfully execute the experiment.

Tasks

  1. Design of concrete mixes
    1. Concrete mixing
    2. Sample preparation
  2. Testing
    1. Strength Testing (ASTM C39-16)
    2. Durability Testing
      1. Alkali-Silica Reactivity (ASTM C1567-13)
      2. Water Absorbtion (ASTM C1585-13)
  3. Data Compilation
      1. Quality data control
      2. Data analyis
  4. Project Management
    1. Communication
      1. Team Meetings
      2. Client/Technical Advisor Meetings
    2. Deliverables
      1. 50% Design Report
      2. Final Design Report
      3. Presentation
      4. Website

Project Information

Scheduling

The team's Gantt chart can be seen below.

Gantt Chart

The following table shows the scheduled end dates for all tasks and the actual completion dates.

Project Schedule

 
 

Scheduled End Date

Actual End Date

1.0 Design of Concrete Mixes

    

1.1 Concrete Mixing

02/24/17

03/25/17

1.2 Sample Preparation

02/24/17

03/25/17

2.0 Testing

    

2.1 Strength Testing

03/24/17

03/24/17

2.2 Durability Testing

03/24/17

04/14/17

3.0 Data Analysis

03/31/17

04/23/17

4.0 Project Management

    

4.1 Communication

05/02/17

05/02/17

4.2 Deliverables

    

4.2.1 50% Design Report

03/02/17

03/02/17

4.2.2 Reflection Document

04/06/17

04/06/17

4.2.3 Final Report

05/02/17

05/02/17

4.2.4 Final Presentation

04/26/17

04/26/17

4.2.5 Website

05/02/17

05/09/17

 

The dates highlighted in yellow indicate an actual end date that was behind schedule. The team completed the mixing and sample preparation about a month later than anticipated due to the need to remix a couple batched of concrete. The duribility testing lasted longer than expected because the team decided to push back the Alkali-Silica Reactivity test, which in turn delayed the data analysis completion date. Finally, this website was completed a week later than scheduled because the due date was extended.

Staffing

The following table was used to keep track of the hours spent on each task by each team member.

Staff Hours

Senior Engineer
Engineer
Lab Technician
Intern
Tasks
MJ
AA
FC
AR
MJ
AA
FC
AR
MJ
AA
FC
AR
MJ
AA
FC
AR
1.0 Concrete Mix Design
3
2
2
2
10
10.5
13.5
11
4
4.5
3.5
2
1.1 Concrete Mixing
10.5
7
7
4
1
2
2.5
2
1.2 Sample Preparation
3.5
3.5
6.5
1.5
2
3
2.5
1.5
2.0 Testing
1
1
1
1
1
2.5
1
1
1
1
1
1
2.1 Strength Testing
7.5
8
6
7
4
1
3.5
1
2.2 Durability Testing
3.5
2
3.5
2
1.5
1.5
3.5
3.5
3.5
3.5
6
1
4
1.5
5.5
3.0 Data Compilation
1
2
2
1
2
1
3.1 Data Quality Control
1
1
1
1.5
2
3
1
2
1
1.5
3.2 Data Analysis
1
1.5
1
2
4
9
6.5
1
2
4.0 Project Management
1.5
0.5
0.5
4.1 Communication
3.5
3
3.5
4
9.5
9
8.5
10
1.5
2.5
2
2.5
4.2 Deliverables
3
5
5
3
16
17
17
15.5
0.5
1.5
2
1.5
2
4.2.1 50% Design Report
5
4.2.2 Final Design Report
1
1
1
1
9
9
9
9
4.2.3 Final Presentation
7
8
11
8.5
4.2.4 Website
2
2
2
2
SUM
16
14
14
21.5
73.5
74
87
75
15
16.5
11.5
17.5
16
21.5
20.5
22.5

 

Total hours
Ali Altameemi 126
Aide Robles 136.5
Felicia Curry 133
Mohamed Jatit 120.5