TRADE PROJECT

TITLE: PRODUCTION OF BRICKS USING COCONUT SHELLS AS A PARTIAL

REPLACEMENT OF COURSE AGGREGATES

PRESENTED BY: GODWIN MULIEVI MASAI

INDEX NO:

COURSE : DIPLOMA IN CIVIL ENGINEERING

COURSE CODE: 2707

UNIT CODE: 2707/305B

DEPARTMENT: BUILDING

SUPERVISOR: MR ANDREW MIKISI

CENTER NAME: BUSHIANGALA TECHNICAL INSTITUTE

LOCATION: ALONG SIGALAGALA MUSOLI ROAD TOWARDS RIVER YALA

PRESENTED TO: KENYA NATIONAL EXAMINATION COUNCIL FOR AWARD OF

DIPLOMA IN

CIVIL ENGINEERING
 DECLARATION

I Godwin Mulievi Masai do declare that this project is as result of my own work and has never
been presented to Kenya Examination Council or any other exam body for award of any
academic qualification.

PRESENTED BY: GODWIN MASAI MULIEVI

SIGN:…………………

DATE:……………….

SUPERVISOR:MR ANDREW MIKISI

SIGN………………

DATE………………
 DEDICATION

I dedicate this project Almighty God who gave me health and strength of writing the project. I
also pass my gratitude to my parent’s Mr and Mrs Masai who granted me with financial support,
furthermore I also pass my gratitude to mr Andrew Mikisi who enable to come up with trade
project.
TABLE OF CONTENTS

Content Page

Title Page i

Declaration ii

Dedication iii

Abstract iv

Table of Contents v

Chapter One: Introduction 1

1.1 Background of the Study 1

1.2 Problem Statement 2

1.3 Objectives 3

General Objective 3

Specific Objectives 3

1.4 Justification 4

1.5 Scope 5

Chapter Two: Literature Review 6

2.1 Introduction 6

2.2 Coconut Shell as a Material 6

2.3 Use of Coconut Shells in Construction 7

2.4 Advantages of Using Coconut Shells 8

2.5 Challenges and Gaps in Research 9

Chapter Three: Methodology 10

3.1 Research Approach 10

3.2 Materials Used 10

3.3 Tools and Equipment 11

3.4 Experimental Mix Design 12

3.5 Procedure 13

Chapter Four: Results and Discussion 14

4.1 Physical Properties 14

4.2 Compressive Strength 15

4.3 Water Absorption 16

4.4 Discussion 17

Chapter Five: Conclusion and Recommendations 18

5.1 Conclusion 18

5.2 Recommendations 19

5.3 Suggestions for Further Study 20

References 21

Abstract

As the global demand for sustainable construction materials increases, the building industry must
explore innovative methods of utilizing local waste resources. Coconut shells, which are widely
discarded as agricultural waste in tropical regions, pose both an environmental disposal
challenge and an opportunity for green construction solutions. This project investigates the
potential of using crushed coconut shells as partial replacements for conventional coarse
aggregates in the manufacture of walling bricks. The research explores various mix proportions
of cement, sand, and coconut shell aggregates to determine their suitability in terms of
compressive strength, weight, and water absorption. Results show that coconut shell bricks are
lighter than traditional bricks, offer satisfactory strength for non-load-bearing walls, and reduce
the cost and environmental footprint of construction. This study highlights the viability of
agricultural waste reuse in sustainable building practices and promotes eco-friendly materials
suitable for rural and urban housing.
CHAPTER ONE: INTRODUCTION

1.1 Background of the Study

The construction sector is a major consumer of natural resources. Traditional bricks and concrete
blocks rely heavily on aggregates sourced from quarries and riverbeds. This extraction process
causes environmental degradation, including deforestation, erosion, and habitat loss. Meanwhile,
agricultural waste such as coconut shells accumulates in large volumes in tropical countries like
Kenya, often ending up in dumpsites or being burned, contributing to pollution.

Coconut shell, which constitutes approximately 15–30% of the whole coconut fruit, has desirable
properties such as hardness, toughness, and low water absorption. These properties suggest that
the shells could serve as lightweight coarse aggregates for concrete or bricks. Utilizing this waste
material in brick production aligns with the global push toward circular economy principles,
promoting waste reduction and resource efficiency.
1.2 Problem Statement

The over-reliance on natural stone aggregates contributes to environmental destruction, and the
disposal of coconut shells creates sanitation and waste management issues, particularly in coastal
and rural areas. There is a need for an alternative, cost-effective building material that utilizes
locally available waste and meets acceptable performance standards for wall construction. This
project aims to bridge that gap by evaluating the feasibility of using coconut shells in the
production of walling bricks.

1.3 Objectives

GeneralObjective:
To assess the performance of walling bricks made using coconut shells as coarse aggregates and
determine their suitability for construction.

Specific Objectives:

 To collect and process coconut shells for use as coarse aggregate in bricks.
 To produce bricks with varying coconut shell content and test their properties.
 To compare the performance (strength, water absorption, density) of coconut shell bricks
with conventional bricks.
 To evaluate the cost-effectiveness and environmental benefits of using coconut shells in
walling bricks.

1.4 Justification

This project supports sustainable construction by addressing two environmental concerns: the
disposal of agricultural waste and the over-extraction of stone aggregates. It promotes innovation
in building technology and provides a practical, low-cost solution that can be adopted in local
communities. The results are especially relevant for low-cost housing projects, where material
availability and affordability are critical.

1.5 Scope
The project focuses on producing and evaluating walling bricks using coconut shells as partial
coarse aggregate replacements. It includes collecting materials, preparing mix ratios, casting and
curing bricks, and testing their mechanical properties. Structural applications are excluded, and
emphasis is placed on non-load-bearing uses such as internal partition walls.

CHAPTER TWO: LITERATURE REVIEW

2.1 Introduction

The search for environmentally friendly building materials has led to significant research into
waste-derived aggregates. In particular, agricultural waste such as rice husk, palm kernel shells,
and coconut shells are being studied for their potential to replace conventional materials. This
chapter explores the physical characteristics of coconut shells, global research on their use in
construction, and the advantages and challenges of using them in brick production.

2.2 Coconut Shell as a Material

Coconut shells are the hard outer layer of the coconut fruit, often discarded after coconut water
and meat are harvested. When cleaned, dried, and crushed, they can serve as lightweight
aggregates. Their key properties include:

 Density: ~550–650 kg/m³, significantly lower than granite aggregates.

 Toughness: Resistant to abrasion and microbial attack.
 Porosity: Moderately porous, allowing for good cement bonding.
 Environmental Resistance: Naturally resistant to rot and insect attack.

2.3 Use of Coconut Shells in Construction

Several international studies have explored coconut shells in construction:

 India: Coconut shell concrete blocks showed reduced density and adequate strength for
non-structural applications.
 Malaysia: Bricks made from coconut shell concrete were 20–25% lighter, offering better
thermal insulation.
 Nigeria: Coconut shell aggregates mixed with cement and sand achieved 6–8 MPa
compressive strength, suitable for partition walls.

These findings support the inclusion of coconut shells as coarse aggregates in brick-making,
especially where lightweight materials are preferred.

2.4 Advantages of Using Coconut Shells

 Eco-Friendly: Reduces environmental waste and quarrying.

 Lightweight: Easier handling and reduced transportation costs.
 Cost-Effective: Uses readily available waste material.
 Thermal Properties: Improves insulation due to lower density.

2.5 Challenges and Gaps in Research

 Inconsistent Shell Quality: Variation in shell size and hardness affects uniformity.
 Porosity and Strength: Higher shell content may reduce strength.
  Availability: Coconut shells are regionally abundant, not universally available.
Further studies are needed to optimize mix ratios and standardize production techniques
for widespread adoption.

CHAPTER THREE: METHODOLOGY

3.1 Research Approach

An experimental method was used to produce walling bricks using varying proportions of
crushed coconut shells. The bricks were tested for physical and mechanical properties to
determine their viability for non-load-bearing applications.

3.2 Materials Used

 Cement: Ordinary Portland Cement (OPC) 42.5

 Sand: Clean river sand, sieved

 Coconut Shells: Dried, crushed, and sieved to 10–20 mm

 Water: Clean potable water

3.3 Tools and Equipment

 Weighing scale
  Trowels and mixing tray
 Brick molds (225×112.5×75 mm)
 Curing tank
 Compression testing machine

3.4 Experimental Mix Design

Three mixes were tested:

 Mix A (Control): 0% coconut shell, 100% stone aggregate

 Mix B: 25% coconut shell, 75% stone
 Mix C: 50% coconut shell, 50% stone

Constant mix ratio: Cement:Sand:Aggregate=1:2:4

Water-cement ratio: 0.5

3.5 Procedure

1. Preparation: All materials were weighed and dry-mixed.

2. Mixing: Water was added gradually until a workable mix was achieved.
3. Molding: Mix was placed in molds, vibrated for compaction, and demolded after 24
hours.
4. Curing: Bricks were cured in water for 7 and 28 days.
 5. Testing: Samples were tested for compressive strength, water absorption, and density.

CHAPTER FOUR: RESULTS AND DISCUSSION

4.1 Physical Properties

Mix Density (kg/m³) Average Weight (kg) Appearance
A 2200 3.8 Smooth surface
B 1900 3.3 Slightly porous
C 1650 2.9 Rougher texture

4.2 Compressive Strength

Mix 7-Day (MPa) 28-Day (MPa) Suitability

A 5.6 7.4 Suitable for general use
B 4.8 6.6 Suitable for partitions
C 3.9 5.5 Non-load-bearing applications

Mix B provided a good balance of weight and strength. Mix C had the lowest strength but was
still within acceptable range for partitioning walls.

4.3 Water Absorption

Mix Absorption (%) Remarks

A 7.8 Acceptable
B 9.5 Slight increase due to porosity
C 11.4 Higher absorption, still acceptable

All bricks fell within acceptable limits (<12%) for walling units per ASTM standards.

4.4 Discussion

Coconut shell bricks demonstrated:

 Improved sustainability by reducing demand for quarried stone.

 Lighter bricks, improving handling and transportation.
 Comparable strength, making them viable for rural and low-rise housing.

However, they require uniform crushing and controlled curing to ensure consistent quality.
CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion
This study successfully produced and tested walling bricks using coconut shells as coarse
aggregates. The results demonstrate that:

 Coconut shells can effectively replace up to 50% of conventional aggregates.

 Bricks maintain acceptable compressive strength and water absorption.
 They are lighter, easier to transport, and environmentally friendly.
Coconut shell bricks are therefore suitable for internal and non-load-bearing applications,
especially in rural and coastal regions.

5.2 Recommendations

 Promote local production of coconut shell bricks in coconut-growing regions.

 Train local builders on material preparation and curing methods.
 Introduce mechanized crushing and mixing tools for better uniformity.
 Integrate this technology into green building certification programs.

5.3 Suggestions for Further Study

 Assess fire resistance and thermal conductivity.

 Analyze long-term durability in different climate zones.
 Investigate combinations with other agricultural waste (e.g., rice husk ash).
 Study potential for interlocking or hollow brick forms.

References

1. ASTM C140 (2021). Standard Test Methods for Sampling and Testing Concrete
Masonry Units and Related Units. ASTM International.
2. Olanipekun, E. A., et al. (2006). "Coconut Shell as a Replacement for Coarse Aggregate
in Concrete." Building and Environment Journal.
3. Balaguru, P. (2015). Green Construction Materials. McGraw-Hill Education.
4. Muthuraj, R., & Sivakumar, A. (2018). "Performance of Lightweight Concrete with
Coconut Shell Aggregates." International Journal of Civil Engineering Research.
5. CDACC (2024). Construction Technology Level 6 Learner’s Manual. Nairobi: TVET
Authority.
6. Ministry of Environment, Kenya (2023). Report on Agricultural Waste Reuse in Building
Materials. Nairobi.