Saint James High School of Buenavista, Agusan, Inc.

Curato Avenue, Barangay 5, Buenavista, Agusan del Norte

CULLET AS AN ALTERNATIVE ADDITIVE IN

MAKING HOLLOWBLOCKS

FRANZIE MAE ABANTAO

RUTH BASAS

JULIE GAVIOLA

KAYE MALOPA

JOHNWARREN MANALO

ALLYN MELODY MENDOZA

NEIL ANTHONY MORTERA

ARIAN PRADIA

MARINELLE KEITH QUIVES

MARCH 9,2023
 CHAPTER 1
THE PROBLEM AND ITS SETTING

1.1 Introduction and its background

The use of hollow blocks are widely known in the construction industry. It

is commonly used as a material in walls, floors, and roofs because of its strength

and durability. The most common type of hollow block is made with Portland

cement, water, and sand or other fine aggregates. However, there are other

types of hollow blocks that use other materials such as cullet. (Construction and

Building Materials, 111, 193-203)

It is now common knowledge that there is a severe shortage of natural

resources, which has driven up the price of construction commodities. In many

cases, this price increase has been so significant that it has caused widespread

housing crises. A promising strategy to alleviate this pressure is to develop more

sustainable construction practices, specifically those that make use of recycled

materials. One example of a recycled material that could potentially be used

more often in construction is cullet, which is crushed glass that is used as an

alternative additive in making hollow blocks. (Procedia Engineering, 52, 832-841)

Hollow blocks made with cullet as an alternative additive can be an

environmentally friendly option for construction because cullet is a waste material

that would otherwise end up in landfills. Cullet is a recycled glass that has been

crushed into fine particles. It is an environmentally friendly material that can help
reduce the amount of greenhouse gases emitted into the atmosphere.

(Construction and Building Materials, 268, 121099)

In addition, hollow blocks made with cullet have several advantages over

those made with conventional construction materials. Firstly, they are cheaper to

make, as cullet is a waste product that can be reused. Secondly, they have a

longer lifespan, as the blocks can resist weathering and deterioration. Finally,

they reduce the amount of energy needed to produce the blocks. (Construction

and Building Materials, 117, 28-38)

In today's modern age, hoarding glass bottles and jars is still a neglected

problem. Particularly, it is evident that a majority of the country's trash are not

segregated. This causes recycling more difficult to do and proper waste

management is disregarded. In this study, we aim to impose a way on how to

recycle unwanted glass bottles that will minimize not only workload but also

educate more people about this matter, therefore allowing more space and less

time for non-biodegradable wastes to decompose if it is implemented and also to

determine the technical and economic feasibility of using cullet as an alternative

additive in making hollow blocks.(Journal of Building Engineering, 43, 102692)

1.2 Hypothesis and Objectives

Hypothesis: There is a significant difference in using cullet as an alternative

additive in making hollow blocks.

Alternative Hypothesis: There is no significant difference in using cullet as an

alternative additive in making hollow blocks.

Objectives:

Incorporating cullet as a partial replacement for fine aggregate in making

hollow blocks can enhance the physical and mechanical properties of the blocks,

including compressive strength, water absorption, and density, while also

reducing the consumption of natural resources and the waste disposal costs for

glass manufacturers. Specifically aims to:

1. Determine the optimal percentage of cullet that can be used in making hollow

blocks without negatively affecting their physical properties or workability.

2. Identify potential challenges and limitations in using cullet as an alternative

additive in hollow block production and propose solutions to address them.

3. Assess the durability of hollow blocks made with and without cullet.

1.3 Schematic Diagram

COLLECTING OF BOTTLES

CULLET

MIXER

MOULD

HOLLOW BLOCK
1.4 Statement of the problem

1. What is the optimal percentage of cullet to be used as an additive in

hollow block production to achieve the desired compressive strength

while maintaining cost-effectiveness?

2. How does the water absorption rate of hollow blocks produced with

cullet as an additive compare to those produced using traditional

methods, and how does this affect the durability and longevity of the

blocks?

3. How many kilograms can it hold?

1.5 Significance of the study

It is expected that the outcomes or conclusions of this research will furnish

valuable insights for the following:

People/Community. To establish a method for recycling used glass

bottles that will reduce workloads and provide more space and less time for non-

biodegradable wastes to decompose.

Construction Industry. Provide critical information that will help

construction industry professionals make informed decisions about the use of

cullet in hollow block production, leading to more sustainable and efficient

building practices.
 Future Researchers. To create a resource manual that can be utilized for

future studies on the use of cullet as a substitute additive in producing hollow

blocks, as well as other related research that is relevant to this research.

1.6 Scope and Delimitation

This study will focus on evaluating the feasibility and effectiveness of

using cullet as a partial replacement for sand in making hollow blocks in

Barangay 5 Buenavista, Agusan del Norte. The study aims to reduce non-

biodegradable waste and preserve natural resources by using recycled glass as

an alternative additive. The research will be conducted over a period of one

month, and will involve crushing bottled glass to create cullet, mixing the cullet

with cement and water in specified proportions, casting the mixture into molds,

and curing the blocks. The materials and equipment required for the study

include bottled glass, cement, and water, a hammer for crushing the glass,

gloves, and goggles for personal protective equipment. The study will evaluate

the compressive strength, water absorption, and durability of the resulting blocks,

and compare them with traditional blocks made of sand and cement. The study

will also assess the environmental benefits of using cullet, such as reducing the

amount of waste going to landfills and conserving natural resources. The results

of the study can potentially provide a more sustainable and cost-effective solution

for the construction industry.

1.7 Definition of terms

Cullet - a recycled glass that has been crushed into fine particles
 Hollow block - a type of concrete block used to build interior and exterior

walls

CHAPTER 2

REVIEW OF RELATED LITERATURE

Hollow blocks, also known as concrete masonry units (CMUs) are

commonly used building materials in construction. They are made of cement,

water, and aggregates, such as sand, gravel, or crushed stone. The blocks are

molded into various shapes and sizes, including rectangular, square, and round,

with hollow cores that reduce their weight and increase their insulation properties

(Jawed et al., 2019).

The use of hollow blocks dates back to ancient civilizations, such as the

Romans, who used hollow clay bricks in their construction projects (Laefer,

2013). However, the modern hollow block as we know it today was first

developed in the 19th century in Europe and North America. In 1832, Joseph

Aspdin invented Portland cements, which became the primary binding agent for

hollow blocks (Ramezanianpour et al., 2011).

The first recorded use of hollow blocks in construction was in the United

States in 1850, when a builder named Harmon S. Palmer patented a machine for

making hollow blocks from concrete (Cusatis et al., 2016). The machine made it

possible to mass-produce hollow blocks, which soon become popular in the

construction industry due to their affordability, durability, and fine resistance

(Pacheco-Torgal et al., 2013).

One of the most significant advantages of using hollow blocks in

construction is their lightweight nature, which makes them easy to handle and

transport. Additionally, their hollow cores provide thermal insulation, which can

help reduce heating and cooling costs in buildings. Hollow blocks are also

versatile and can be used for a variety of construction purposes, including in

landscaping from creating retaining walls or decorative features

(Kothandaraman, S. et al (2014). Construction and Building Materials, 65, 288-

294).

Moreover, hollow blocks offer structural stability, which makes them an

ideal choice for buildings in areas with high seismic activity. Their hollow cores

help to reduce the weight of the building, which reduces the risk of structural

damage during earthquakes. Hollow blocks can also withstand high levels of

moisture, making them a good choice for areas with high humidity or where

flooding is a common occurrence (Zheng, J et al. (2019). Advances in Structural

Engineering, 22(11), 2418-2432).

However, there are also some challenges associated with using hollow

blocks in construction. One of the major concerns is the durability of the blocks

over time. Hollow blocks can be prone to cracking and chipping, especially in

areas with extreme weather conditions (J. M. W. Brownjohn et al. 2019).

Additionally, their hollow cores can also provide a breeding ground for pests and
rodents, which can damage the blocks from the inside (A. B. Adeyemo et al.

2020).

To overcome these challenges, manufactures have developed new types

of hollow blocks that are more durable and resistant to damage. For example,

some manufacturers use high-strength concrete in their hollow blocks, which

makes them more resistant to cracking and chipping (E. O. Adewumi et al. 2021).

Others use special additives that make the blocks more resistant to pests and

rodents (A. S. Abdulrahman et al. 2018).

In conclusion, hollow blocks are an excellent choice for construction

projects because of their lightweight nature, thermal insulation properties, and

structural stability. They can be used for a variety of construction purposes and

can withstand high levels of moisture and seismic activity. However, there are

also some challenges associated with using hollow blocks, such as their

durability and susceptibility to pests and rodents. With the development of new

types of hollow blocks that are more durable and resistant to damage, these

challenges can be overcome (Deja. J. et al. (2018). Construction and Building

Materials, 178, 345-354).

Cullet, also known as recycled glass, has become an increasingly

important resource in the glass industry due to its economic and environmental

benefits. Cullet is produced by recycling post-consumer or post-industrial glass,

which can then be used as a raw material in the production of new glass

products (Nayar, P. 2015).

One of the primary benefits of cullet is its environmental impact. The

production of new glass products using cullet as a raw material requires less

energy and emits fewer greenhouse gases than the production of glass from

virgin raw materials (Petersen, 2017). This is because cullet melts at a lower

temperature than virgin raw materials, which reduces the energy required to melt

it. Additionally, cullet usage reduces the need for virgin raw materials, which can

help to conserve natural resources and reduce the carbon footprint of the glass

industry (Nayar, 2015).

In addition to its environment benefits, cullet also provides economic

benefits to the glass industry. The use of cullet as a raw material reduces the

cost of production for glass manufacturers, as cullet is typically less expensive

than virgin raw materials (Petersen, 2017). This cost saving can be passed on to

consumers in the form of lower prices for glass products, which can increase

demand for glass products and boost the profitability of glass manufacturers

(Nayar, 2015).

While cullet provides significant benefits to the glass industry, its usage

also presents certain challenges. One of the main challenges is the quality of the

cullet, as it must be properly sorted and cleaned to ensure that it is free of

contaminants that can affect the quality of the final product (Petersen, 2017).

Additionally, the availability of high-quality cullet can be limited, particularly in

regions where glass recycling infrastructure is not well developed (Nayar, 2015).
 Despite these challenges, the use of cullet in the glass industry has been

steadily increasing in recent years. According to the Glass Packaging Institute,

the use of cullet in the production of new glass containers has increased from

32% in 2000 to 39% in 2018 in the United States (Glass Packaging Institute,

2019). However, there is still room for growth, particularly in developing countries

where glass recycling infrastructure is not as well developed (Nayar, 2015). In

these regions, increased investment in glass recycling infrastructure and

education about the benefits of cullet usage could help to increase cullet

recycling rates and promote sustainable development in the glass industry.

Looking to the future, the prospects for cullet recycling appear to be bright.

The increased awareness of the environmental and economic benefits of cullet

usage, combined with advances in glass recycling technology, is expected to

drive further growth in cullet recycling and usage in the glass industry (Petersen,

2017).

Additionally, initiatives such as extended producer responsibility programs, which

require manufacturers to take responsibility for the end-of-life disposal of their

products, could help to incentivize greater cullet recycling rates (Nayar, 2015).

In conclusion, cullet is an important resource for the glass industry due to

its environmental and economic benefits. While there are challenges associated

with cullet usage, the increasing awareness of its benefits and advances in

recycling technology are expected to drive further growth in cullet recycling and

usage in the future. By investing in glass recycling infrastructure and promoting

education about the benefits of the cullet usage, the glass industry can promote
sustainable development and reduce its environmental impact, while also

increasing its profitability through cost and savings and lower prices for

consumers. Therefore, it is important for glass manufacturers and policy makers

to continue to prioritize cullet recycling and usage in the production of new glass

products (Petersen, E. 2017).

Hollow blocks are widely used in the construction industry for its high

strength and durability. The conventional method of producing hollow blocks

uses cement, sand, and gravel. However, the production process requires a high

energy consumption and generates a considerable amount of greenhouse gases.

Moreover, the extraction of sand and gravel can cause environmental

degradation. In recent years, researchers have been exploring the use of cullet

as an alternative additive in the production of hollow blocks. Cullet is a waste

glass material that can be used as a partial replacement of sand in the

production process (Journal of Cleaner Production, vol. 201, pp. 304-316, 2018).

Cullet is a waste glass material that is generated from various sources,

such as bottles, jars, and window panes. Cullet can be used as a partial

replacement of sand in the production process of hollow blocks. The use of cullet

as an additive in the production process has several benefits. Cullet has a high

silica content, which makes it a suitable replacement for sand (Jagadish et al.,

2019). Moreover, cullet has a lower melting point compared to raw materials,
used in the production process, which reduces the energy required for the

melting process (Garcia et al. 2016).

Several studies have investigated the effect of cullet on the properties of

hollow blocks. In a study conducted by Sathawane et al. (2021), cullet was used

as a partial replacement of sand in the production process of hollow blocks. The

study found that the compressive strength of hollow blocks increased with the

increased in the percentage of cullet used in the production process. The study

also found that the use of cullet reduced the water absorption capacity of hollow

blocks, which indicates that the durability of hollow blocks can be improved by

using cullet as an additive.

Research has demonstrated that the addition of cullet to concrete can

have a positive impact on the mechanical properties of hollow blocks. In a study

by Rahal et al. (2015), the compressive strength of hollow blocks containing 20%

cullet was found to be 21% higher than that of control samples made with only

sand and cement. Similarly, Ardame & Menadi (2013) found that the use of cullet

in hollow blocks resulted in a significant increase in compressive strength

compared to samples without cullet. Additionally, the use of cullet can enhance

the durability of hollow blocks, as cullet has a lower porosity than sand, reducing

the permeability of the final product (Ardame & Menadi, 2013).

In addition to improving the mechanical properties of hollow blocks, the

use of cullet as an additive can also have a positive impact on the thermal

insulation properties of the hollow blocks. A study by Kockar and Demir (2015)

found that the thermal conductivity of concrete samples containing cullet was
lower than that of control samples made without cullet. This suggests that the

use of cullet in hollow blocks can reduce heat transfer through the blocks, making

them more energy-efficient.

In addition to these benefits, using cullet as an additive in hollow block

production can also have economic advantages. A study found that using cullet

as a partial replacement for sand in the production of hollow blocks resulted in a

lower overall cost per block, despite the added cost of the cullet itself (Memon et

al., 2018). The study also found that the finished blocks had a higher market

value due to their increased strength and durability.

The use of as an additive in the production of hollow blocks can have a

positive impact on the environment by reducing the amount of waste glass that

ends up in landfills. Additionally, the use of cullet in place of natural resources

like sand can help to conserve these resources, which becoming increasingly

scarce (Ardame & Menadi, 2013). It can also reduce the demand for sand and

gravel, which can reduce the environmental degradation caused by the extraction

of these material (Ganesan et al., 2019). Moreover, the use of cullet reduces the

energy required for the production process, which can reduce the greenhouse

gas emissions associated with the production process (Garcia et al., 2016).

The use of cullet as an additive in the production of hollow blocks has the

potential to improve the mechanical properties, thermal insulation properties,

reduced water absorption, and environmental impact of the final product. By

using cullet as a partial replacement for sand, the amount of natural resources

required for the production of hollow blocks can be reduced, while the durability
and energy efficiency of the blocks can be improved (Journal of Building

Engineering, Volume 19, June 2018, Pages 258-266).

However, further research is needed to explore the long-term performance

of hollow blocks containing cullet, particularly with regard to their resistance to

weathering and degradation over time. Also the optimal percentage of cullet that

can be used in the production process of hollow blocks.

CHAPTER 3

RESEARCH METHODOLOGY

3.1 Research Design

The researchers will use a quasi-experimental design to compare the

durability and water absorption of hollow blocks made with and without cullet.

The study will involve two groups of hollow blocks- one group made with cullet as

an additive, and the other group is the commercial one. Both groups will be

subjected to the same tests and conditions to determine their durability and water

absorption.

The durability of the blocks will be tested by subjecting them to various

weights on the top of the block, ranging from 25kg to 40kg. The presence or

absence of a break in the block will be noted and recorded on a binary graph or

chart, which rows representing the weights and columns representing the
presence or absence of a break in the block. So it will be needing 8 hollow blocks

on this test, since there will be two groups of hollow blocks.

Table 1. Compressive Strength

TYPE OF

HOLLOWBLOCKS WEIGHTS

25 kg 30 kg 35 kg 40 kg

COMMERCIAL

MADE WITH

CULLET

The water absorption of the blocks will be tested by submerging them in

water for 5 minutes, and the amount of water absorbed will be determine by

weighing the block before and after the test. The percentage of water absorbed

will be calculated and converted to grams, which will be plotted on a bar graph,

with the x-axis representing the weight of the blocks and the y-axis representing

the amount of water absorbed in grams.

3.2 Research Locale

The study will be conducted in Barangay 5 Buenavista, Agusan del Norte, the

Philippines whenever in 2023. Since the location has a wide area, it may be an

ideal place to conduct research that requires outdoor space, such as testing the

strength and durability of hollow blocks made with cullet.

Map of Sampling Site

Barangay 5 Buenavista, Agusan del Norte
3.3 Data Gathering Procedure

The research process of using cullet as an alternative additive in making

hollow blocks requires a step-by-step and systematic approach, as well as the

proper materials and equipment.

The first step of the research process entails the preparation of necessary

materials and equipment. The materials needed to conduct the research are

cement, cullet, and water. Which is the cement is bought at Bautistalla Interprice

located at Barangay 3 Buenavista, Agusan del Norte and the glass bottles to

make the cullet will be collected at Barangay 9. The appropriate equipment

needed for the research are shovel, hammer, gloves, and eye goggles, molds,

and a scale.

The second step of the research involves designing the experiment. This

includes determining the variables to be tested and the parameters of the

experiments. The variables to be tested are cement-to-cullet ratio, cement-to-

sand ratio, and water-to-cement ratio. In the study by Rahal et al. (2014), the

cement-to-cullet ratio used was 1:2, the cement-to-sand ratio was 1:3, and the

water-to-cement ratio was 0.5:1. The parameters of the experiment are the

strength of the hollow blocks, the weight of the hollow blocks, and the

compressive strength of the hollow blocks.

The third step of the research process is to conduct the experiment. The

experiment will involve mixing the necessary materials in the proper ratios using

a shovel. The mixture will then be poured into the molds and left to dry in 3 days.

After the mixture has dried, the hollow blocks will be tested for compressive

strength and weight.

The fourth step of the research process involves the analysis of the data

collected from the experiment. This includes the comparison of the results to the

predetermined parameters. The results of the experiment will then be compared

to the predetermined parameters and analyzed to determine if using cullet as an

additive in making hollow blocks is a viable option.

The fifth and final step of the research process is to report the results. This

entails summarizing the results of the experiment and providing a conclusion.

The conclusion of the research should include using cullet as an additive in

making hollow blocks is a viable option and should also provide

recommendations for further research and experimentation.

3.4 Statistical Tools

 The statistical tool to use in our research of using cullet as an alternative

additive in making hollow blocks is the t-test.

A t-test is a statistical method used to determine whether there is a

significant difference between the means of two groups. It is often used in

experimental research to compare the means of a control group to a treatment

group.

In the context of researching the use of cullet as an additive in making

hollow blocks, a t-test can be used to compare the strength of hollow blocks

made with cullet to those made without it. This can help to determine if there is a

significant difference in the strength of the two types of blocks and if cullet can be

considered a viable alternative additive.

The formula for a t-test is: t = (x1 - x2) / (s1^2/n1 + s2^2/n2)^0.5 where x1

and x2 are the means of the two groups, s1 and s2 are the standard deviations of

the two groups, and n1 and n2 are the sample sizes of the two groups.

T-test allows for a quick and accurate assessment of the strength

difference between blocks made with cullet and those made without it, providing

valuable insights into the viability of cullet as an additive.

 TABLE OF CONTENTS

CHAPTER I

1.1 Introduction and its background

1.2 Hypothesis and Objectives

1.3 Schematic Diagram

1.4 Statement of the Problem

1.5 Significance of the Study

1.6 Scope and Delimitation

1.7 Definition of Terms

CHAPTER II
 2.1 Review of Related Literature

CHAPTER III

3.1 Research Design

3.2 Research Locale

3.3 Data Gathering Procedure

3.4 Statistical Tools