Chapter-1: 1.1. Genaral
Chapter-1: 1.1. Genaral
Chapter-1: 1.1. Genaral
INTRODUCTION
1.1. GENARAL
1
India is the world’s second largest producer of cement after china
with industry capacity of over 200 million tonnes. India is producing
different varieties of cement like Ordinary Portland Cement (OPC), Portland
Pozzolana Cement (PPC), Portland Blast Furnace Slag Cement (PBFS), Oil
Well Cement, Rapid Hardening Portland Cement, Sulphate Resisting
Portland cement, White Cement, Blended Cement, etc. Production of these
varieties of cement conform to the BIS Specifications. There are three
grades of cement used in practice.
Ordinary Portland cement 33grade is required to conform to BIS
specification IS: 269-1998 with a designed strength for 28 days being a
minimum of 33MPa. Ordinary Portland 43grade cement is required to
conform to BIS specification IS: 8112-2000 with a designed strength for 28
days being a minimum of 43MPa. Ordinary Portland 53grade cement is
required to conform to BIS specification IS: 12269-1999 with a designed
strength for 28 days being a minimum of 53MPa. OPC 53 grade gives 10 to
15% saving in cement consumption and 5 to 8% saving in steel consumption
provided higher grades of concrete say M30 and above are used. OPC 53
grade is useful for high rise buildings, flyovers, chimneys and pre-stressed
structures where high grade concrete is required. OPC 53 grade gives better
durability characteristics to concrete-high grade concrete can be made with
low water cement ratio.
At present, concrete industry is cursed with the scarcity of the
aggregates and environment pollution from cement production. The cement
industry has a significant contribution in global warming because
combustion of fuel in the cement kiln and the electricity used for grinding
the clinker, emit large amount of CO2. Cement industry is responsible for
about of 5% of global CO2 emissions. Therefore, it becomes very essential
2
and more significant to find out the substitutes for both cement as well
natural aggregates. Apart from it, the continuous growth of agro and
industrial waste is the principle cause of many environmental concerns and
burdens which can be reduced by using these wastes in concrete
construction.
Agro waste is the waste produced from various agricultural goods.
Bagasse from Sugarcane, wheat husk and wheat straw from Wheat,
groundnut shell from Groundnut, and rice husk from Paddy are the wastes of
agriculture. Nowadays, some of the wastes such as rice husk, bagasse, shell
of ground nuts etc. are partly used as a fuel for power generation. Apart from
above mentioned agro waste ashes, some researchers identified that the
sugarcane bagasse ash can also be used as pozzolan in concrete.
3
ash, silica fume, rock dust, siliceous stone powder, egg shell powder, sludge,
sugar cane bagasse ash and other such materials in concrete.
4
Sugarcane bagasse consists of approximately 50% of cellulose,
25% of hemicelluloses of ligin. Each ton sugarcane generates approximately
26% of bagasse (at a moisture content of 50%) and 0.62% of residual ash.
The residue after combustion presents a chemical composition of dominates
by silicon dioxide (sio2). In spite of being a material of hard degradation and
the present few nutrients, the ash is used on the farms as the fertilizer in the
sugarcane harvests.
SCBA has recently been tested in some parts of the world for its
use as a cement replacement material. The bagasse ash was found to
improve some properties of paste, mortar and concrete including
compressive strength and water tightness in certain replacement percentages
and fineness.
5
fume is an airborne material like fly ash, it has spherical shape. Silica fume
is extremely fine with particle size less than 1 micron and with an average
diameter of about 0.1 micron, about 100 times smaller than average cement
particles.
Silica fume has become one of the necessary ingredients for making
high strength and high performance concrete. In India, silica fume has been
used very rarely. Nuclear Power Corporation was one of the first to use
silica fume concrete in their nuclear power projects.
7
The impact energy delivered by the hammer per blow was calculated as
follows:
Impact energy U = m.n.v2/2 ……1
H = gt2/2 ……2
V = g.t
m = w/g
Where V is the velocity of the hammer, g is acceleration due to
gravity, and t is the time required for the hammer to fall from a height of 413
mm. H is the height of the fall, m is mass of the hammer, n is the number of
blows and W is the weight of the hammer.
Substituting the relevant values in equation 2
413 = 9810t2/2
t = 0.290s
V = 9810 x 0.290 = 2846.58 mm/s
The impact energy absorb per blow U, can be obtained by substituting
the values in equation 1
U = 135 x 2846.582 / 2 x 9810 = 55.75 kN-mm.
9
Petrographic analysis of rocks pertaining to geo-technical
investigations.
Evaluation of different types of aggregates for alkali-silica reactivity
(ASR) and alkali-carbonate reactivity (ACR) studies.
Detailed microscopic investigations of fire damaged concrete,
petrographic evaluation of hydrated concrete and microstructural
analysis of hardened concrete of various ages and environment.
Petrographic analysis and Langlier equation of silt samples.
Identification and classification of heavy minerals in sand and silt
samples.
Quantitative estimation of mica in sand, silt and soil.
Setting up of optical microscopic laboratories and impart training on
operation and maintenance.
1.3. OBJECIVES:
11
CHAPTER II
LITERATURE REVIEWS
2.1. INTRODUCTION:
12
10%, 15%, 20%, and 25% and constant water cement ratio of 0.4 and 10%
of micro-silica for all concrete mixtures. The mechanical properties like
compressive strength, splitting tensile test, and durability properties like
water absorption test studied. The partial replacement of cement with 15%,
20%, and 25% Bagasse ash (BA) resulted in a reduction in compressive
strength by 8%, 24%, and 35%. Increasing the BA content in the concrete
mixtures reduces the tensile strength except for LWCBA in which strength
remained constant by 5% incorporation of SCBA. The microstructural
properties like SEM and XRD also studied for different mixes.
13
cement (Grade 43) conforming to IS 8112, Silica fume conforming to
ASTM C 1240 and IS 650 and Indian standard sand is available in three
grades (Grade1, Grade2, Grade3) was used. In this study X-ray fluorescence
analysis is used for chemical properties of cement and compressive test is
carried out by IS 4031 (part6). The degree of pozzolanic reaction decreases
with increase in the replacement level of silica fume. Of the total quantity of
silica fume added, the quantity that has fully reacted is about 3.92%–5.4%
and the reminder remains in the system taking part in pore filling process.
From the study, it is conclude that the strength of motors containing 4% and
8% replacement level of silica fume shows higher strength than the control
motors. However, Silica fume 12% shows lower strength.
P.J.P. Gleize et al., [4] studied the microstructural effects of the substitution
of 10% of Portland cement by silica fume in a masonry mortar. The
materials used in this study were cement, water, silica fume, lime and sand.
For SEM observations, and non-evaporable water content, samples were
extracting from the core of compression test samples at the age of 7 and 28
d. For SEM observations, samples were cover with a thin gold layer and C/S
ratio was measure by energy dispersive X-rays analysis (EDX) as the
average of four measurements of the same zone. From the test results, silica
fume–cement–lime mortars compressive strength is smaller and porosity is
higher than reference mortars at early age (7 days old) but becomes,
respectively, higher and smaller at a later age (28 days old).
Sidney Diamond et al., [5] studied on type of reaction products filled the
space within the original outline of the agglomerates in silica fume which is
recognizable by SEM and EDAX. The material used in this study was silica
fume. The test were performed on the silica fume was SEM and EDAX. The
14
results of this process were the formation of agglomerates of various shapes
and of sizes much larger than the original clusters. Agglomerates present in
dry densified silica fume ranges in size from 10µm to several thousand
microns. The material constitutes a dry powder that flows easily and is
readily incorporate in concrete. SEM images showed the size and shape of
agglomerates in three-dimensional. The agglomerates appeared dense. The
larger ones were roughly spherical and an onion like internal structure
commonly detected.
Medhat H. Shehata and Michael D.A. Thomas [6] investigated the effects
of cementitious systems containing Portland cement (PC), silica fume (SF)
and fly ash (FA) on the expansion due to alkali–silica reaction (ASR). The
materials used in this study were two High-alkali Portland cements (HAPC)
and one low-alkali Portland cements (LAPC) (1.00%, 1.09% and 0.60%
Na2Oe, respectively), a single source of high silica, low-alkali SF and three
FA of low, moderate and high calcium contents. Practical levels of SF and
FA introduced into HAPC systems were found to be effective in reducing
the expansion due to ASR to levels <0.04% after 3 years. Pastes samples
containing SF achieved low pore solution alkalinity at early ages. After 28
days, there was a gradual but sustained increase in the alkalinity up to 2 or 3
years. Ternary blends resulted in pore solution of low alkalinity at early ages
with no increases at later ages. The expansion of concrete prisms containing
ternary blends could explain based on the alkalinity of pore solution.
Khaled Marar et al., [7] determined the impact resistance for high-strength
fiber-reinforced concrete HSFRC composite by using drop weight impact
testing machine. The impact test was perform on 150 mm diameter x 60 mm
length concrete cylinders cut from 150 x 300 mm diameter cylinders by
15
using a masonry saw. Twelve cylinders were test to obtain the average
number of blows required to cause the first crack and the ultimate failure at
28 days of age. The weight of the drop hammer was 13.5 kg and the height
of drop was 0.30 m. During the impact, the speed of the drop hammer,
velocity V is measured, and it was calculate as 1.8088 m/s. The impact
energy is delivered to the specimen produced by the each blow was
calculated. The material used in this study is cement, aggregate, water and
steel fibers. From the test results, it was conclude that increasing the volume
of steel fibers leads to increase in impact resistance. Impact testing machine
helps the engineers in designing and construction of structures where
compression energy absorption is especially important.
G Murali et al., [8] studied the empirical relationship between the impact
energy and compressive strength was developing by using regressive
analysis. The materials used in this study were OPC, coarse aggregate, fine
aggregate, water, fibers and superplasticizer. In this study, M30 grade
concrete and steel fibers of 0%, 0.5%, 1% and 1.5% were used. Each mix of
freshly mixed concrete was then cast into cylinders 100 x 200mm, cubes
100mm and prisms 500 x 100 x 100mm, that were used in the splitting
tensile, compressive and flexural strength test respectively. Cylindrical 100 x
64mm disc, which were cut from the cylindrical specimen, used for the
impact test. From the test results, it was concluded that the impact resistance
also increase against the first visible crack and final fracture; which meant
the energy absorption capacity in concrete with fibers increased. The
empirical relationship would help to develop preliminary designs of
structures where impact resistance is especially important and further reduce
the number of experiments.
16
Trilok Gupta et al., [9] has investigated the High Impact resistance for
concrete containing waste rubber fiber and silica fume. From the study
rubber fiber is replace to cement with 0%, 5%, 10%, 15%, 20% and 25%
and Silica fume of 0%, 5% and 10% replaced to cement. Impact test and
Compressive test were conduct in this study. The compressive strength of
rubber fiber Concrete was increase of 10% replacement of replacement of
cement Silica fume. The impact resistance for first crack as well as ultimate
failure increases with the increase in rubber fiber content. From the test
results it is concluded that the Impact resistance of concrete improves on
replacement of fine aggregate by rubber fibers and on replacement of cement
by Silica fume and reduces the ductility of Rubber fiber concrete.
17
this study, ACI Impact test failed to differentiate between the rubberized
concretes with different rubber contents. From the test results, it is conclude
that, the replacement of fine aggregate by 10% with crumb rubber caused a
small decrease in concrete compressive strength and the presence of crumb
rubber of small size in concrete increased the resistance of concrete to crack
initiation under Impact load.
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materials used in the study were OPC, coarse aggregate, sand, water, silica
fume and marble dust powder. From the test results, it was find that the
strength and durability of concrete containing marble waste powder tend to
decline for replacement ratios over 10% but satisfactory results were obtain
below that level of replacement. Regarding the use of silica fume, it was
observe that it improves the strength and durability of concrete with marble
waste powder by offsetting the decline of its properties relative to
conventional concrete. In addition to obtaining approximately the same
results as the original concrete mix, using 20% marble waste powder and
10% silica fume as partial replacement of cement resulted in a 30% cement
reduction that decreases the harmful effects of cement industry on the
environment.
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levels to develop sustainable concrete and mortar. The materials used in the
study were Cement, aggregate, water and bagasse ash. Proportions for mix
design of m20, m30, m40 were studying. For m40 and m30 grade of
concrete maximum compressive strength was obtain at 15% replacement of
SCBA for cement. For m20 grade of concrete maximum compressive
strength was obtain at 10% replacement of SCBA for cement. The
compressive strength was increase up to 10% replacement of SCBA. From
the study, it is concluding that SCBA can easily replace up to 20%. The
maximum compressive strength founded at 15% replacement level, though
15% replacement gave higher strength 20% could used because the result
from 20% replacement is near about control concrete. In case of split tensile
strength 10%, replacement gave higher strength. The utilization of bagasse
ash in concrete and mortar solves the problem of its disposal thus keeping
the environment free from pollution.
20
M. Vijay sekhar reddy et al., [17] investigated utilizing Sugarcane bagasse
ash concrete, with partial replacement of cement. The replacement is at
various percentages like 0%, 5%, 10%, 15% and 20% and its effect on
properties of concrete investigated. The materials used in the study were
Cement, aggregate, water and bagasse ash. A proportion for mix design of
M20 is studied. Slump cone test and compressive strength is studied. The
experimental results showed that the maximum compressive strengths for 7
and 28 days curing period achieved are 17.93 and 30.57 N/mm2 respectively
with 10% replacement of cement by bagasse ash. From the test results, it is
concluding that the cement could advantageously replace with SCBA up to
maximum limit of 10%.
21
to increase the Durability against acid, alkaline, sulphate attack. However,
increase in SCBA replacement decreases the Durability of concrete. The
utilization of the waste ash reduces the consumption of cement thus reduces
the possible green house emission.
22
replacement level. Mix proportion of M30 and M60 Grade ternary concrete
used. The properties of concrete like compressive strength, splitting tensile
strength were tested. From the test results, it is conclude that for M60 the
optimum value occurs at 10% of SCBA. For M30 the optimum value occurs
at 10% of SCBA.
23
Three specimens tested for 7 and 28 days with each proportion of silica fume
replacement. Totally 30 cubes, 30 cylinders and 30 prisms were casted for
the strength parameters and 15 cubes for acid attack test. From the test
results, it is conclude that the optimum 7, 28 days compressive strength, and
flexural strength have obtained in the range of 10-15 % silica fume
replacement level. Increase in split tensile strength beyond 10 % silica fume
replacement is almost insignificant where as gain in flexural tensile strength
have occurred even up to 15 % replacements.
Sanjay Thakur and Harpreet Singh [23] investigated the effect of Silica
Fume and Fly Ash with Partial Replacement of Cement and Fine Aggregate.
The materials used in this study were cement, coarse aggregate, fine
aggregate, water, silica fume and fly ash. Proportions for mix design of M40
studied in this research. The M40 ordinary concrete sample were casted that
is cube, beam, cylinder. Compressive strength test, flexure strength test and
split tensile strength test conducted. For the 7days test, the result was poor
but with increase in time, there will be much better improvement in the
strength of silica fume and fly ash concrete, according to the standard 28
days result. From the test results, it concluded that the optimum of 15% of
cement is replace by silica fume and 15% of fine aggregate is replace by fly
ash.
24
out at the age of 7 and 28 days, at various percentages of marble powder and
8% of silica fume. Compressive strength of marble powder (Cube, Cylinder)
for 8%, 12% and 16% replacement with OPC cement at 7 and 28 days is
marginally decrease. Compressive strength of Silica Fume (Cube, Cylinder)
for 8% replacement with OPC cement at 7 and 28 days is increase by 3.65%,
8.58% and 7.30%, 6.05%. From the test results it is concluded that the
Compressive strength of 8% silica fume with 8% marble powder (Cube &
Cylinder) replacement with OPC cement at 7 and 28 days is increased by
1.64%, 3.92% & 2.79%, 1.78%.
K. Sai Abhinav et al., [25] Studied the impact resistance of steel fiber
reinforced concrete by using drop weight test was performed on fiber
reinforced concrete as per ACI committee 544. A fiber dosage of 0.5%, 1%,
and 1.5% by volume of concrete is use in this experimental study. In this
study, water cement raito of 0.5 was adopte for M3F grade concert and steel
of 0.5%, 1%, 1.5% volume fractions used. The results based on the number
of blows required to initial crack and number of blows that are required for
final crack. From the results, it is conclude that the steel fibers found to be
an effective in improving impact resistance of the concrete.
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CHAPTER-3
PRELIMINARY INVESTIGATION
3.0. General: Experimental investigation on material properties of
Cement, SCBA, Silica fume, Coarse aggregate and Fine aggregate.
3.1. Tests on cement:
The cement is to be test in the laboratory and further test for its quality
requirements as per Indian Standards. The cement used was ordinary
Portland cement (OPC 53) confirming to IS: 12269-1987.
Fig 3.1Cement
26
Table 3.1 Physical properties of cement
27
Fig 3.2 Specific gravity bottle
Table 3.2 Observations of Specific Gravity of cement
1 Weight of empty specific gravity bottle 35gms
W1=
2 Weight of bottle with cement W2= 70gms
3 Weight of bottle with cement and 113gms
kerosene W3=
4 Weight of bottle with fresh kerosene 83gms
W4=
28
Procedure:
S.No. Sample
Description
I
1 Weight of cement (W) gms 10
2 IS sieve size microns 90
3 Sieving time minutes 15
4 Weight retained on sieve (W1) gms 0.78
Procedure:
The mould along with non-porous plate is place under the rod-bearing
plunger. The plunger is gently lower to the surface of the cement paste and
then quickly released. As the plunger penetrates in to the paste and its depth
of penetration is measure and recorded. This process is repeated again by
30
adding 2% (by dry weight of cement) water to the paste. The process is
repeat until the needle penetrates to a depth of about 5mm to 7mm above the
bottom of the mould.
32
Procedure:
The needle with an annular attachment replaces the needle of the Vicat
apparatus. The needle is lower and quickly released. The process repeated
until the annular ring made an impression on the cement paste. The time
elapsed between the times of adding water to the cement to the time when
the annular ring failed to make the impression on the cement plate is record.
33
Table 3.6 Test on Fine aggregate
34
carefully drained from the sample by decantation through a filter paper and
the material retained on filter paper is return to the sample.
35
Fine aggregate means the aggregate that passes through 4.75mm sieve.
To find the fineness modulus of fine aggregate we need sieve sizes of
4.75mm, 2.36mm, 1.18mm, 0.6mm, 0.3mm and 0.15mm. Fineness modulus
of finer aggregate is lower than fineness modulus of coarse aggregate.
Procedure:
The air-dry sample of 1 kg fine aggregate is placed on the set of IS
sieves, where sieves are arranged in decreasing order from top to bottom.
Sieving was complete by shake sieves for about 15min with lid above and
with a pan below. The shaking is complete with a varied motion, backward
and anti-clockwise. After completion of sieving, the material retained on
each sieve is weigh and following results are obtain.
Cumulative Cumulative
Weight
IS Sieve No. Weight % of total wt.
Retained
Retained Retained
10mm 0 0 0
4.75mm 111 111 11.1
2.36mm 53 164 16.4
1.18mm 215 379 37.9
600µ 78 457 45.7
300µ 492 949 94.9
150µ 28 977 97.7
Pan 23 1000 100
36
3.3. Tests on Coarse Aggregate:
Aggregate that retained on the 4.75mm IS Sieve called coarse aggregate.
The function of Coarse Aggregate is to act as the main load – bearing
component of the concrete. According to IS 383 – 1970, Coarse Aggregate
used in this present study confirms to single-sized aggregate. Locally
available coarse aggregate having the maximum size of 20mm used in this
present study. It is important to test the quality of aggregates used in the
concrete for the further experimental testing procedures because the
aggregates occupy the major volume in the concrete mix. They will be
around 75-80% of the total volume.
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3.3.1 Specific Gravity and Water Absorption of Coarse Aggregates: [IS
2386 (Part-3) - 1986]:
Specific gravity is a measure of a material’s density (mass per unit volume)
as compared to the density of water at 23°C. Therefore, by definition, water
at a temperature of 23°C has a specific gravity of 1.
Procedure:
38
3.3.2 Fineness modulus of coarse aggregates: [IS 2386 (Part-1) - 1963]:
Fineness modulus of coarse aggregates represents the average size of the
particles in the coarse aggregate by an index number. It is calculate by
performing sieve analysis with standard sieves.
Procedure:
The air-dried sample is taken and weighed and is placed on the IS sieve and
sieved, sieves are arranged in decreasing order from top to bottom. At the
end of the sieving, 150 micron and 75 micron sieves are clean from the
bottom by light brushing with fine camel hairbrush. After completion of
sieving, the material retained on each sieve is weigh.
39
3.4. Workability of concrete: [IS 1199-1959]:
Workability is that property of freshly mixed concrete or mortar which
determined homogeneity with which it can mixed, placed, consolidated and
finished. The strength and durability of hardened concrete, depends concrete
have appropriate workability. Workability test methods has classified in
terms of the type of flow produced during the test. Commonly used test
methods are
Slump test
Compaction factor test
Vee Bee consistometer test
Flow table test
In present study, workability is founded by compaction factor test. The
test is empirical test that measures the workability of fresh concrete. The test
is popular due to simplicity of apparatus used in the simple procedure. The
apparatus consists of trowels, hand scoop, a rod of steel or other suitable
material and a balance.
Procedure:
Place the concrete sample gently in the upper hopper to its brim using
the hand scoop and level it. Cover the cylinder. Open the trapdoor at
the bottom of the upper hopper so that concrete falls into the lower
hopper. Push the concrete sticking on its sides gently with the road.
Open the trapdoor of the lower hopper and allow the concrete to fall
into the cylinder below. Cut of the excess of concrete above the top
level of cylinder using trowels and level it. Clean the outside of the
cylinder. Weight the cylinder with concrete to the nearest 10g. This
weight is known as the weight of partially compacted concrete. Empty
40
the cylinder and then refill it with the same concrete mix in layers
approximately 5cm deep, each layer being heavily rammed to obtain
full compaction. Level the top surface. Weigh the cylinder with fully
compacted. This weight is known as the weight of fully compacted
concrete. Find the weight of empty cylinder.
41
3.5. SUGARCANE BAGASSE ASH:
Bagasse ash collected from NCS sugar limited, Bobbili, Vizianagaram
district, AP, India, was used as one of the mineral admixture. The plant was
designed to operate with boiler of travelling gate type with outlet steam
parameters of 87kg/cm2 at 600˚c using bagasse as a main fuel. The ash was
grinded in ball mill in order to make it as fine as the cement fineness. The
physical and chemical properties of SCBA are presented in table
respectively.
42
Table 3.14 Physical properties of SCBA
S.NO. Physical properties of SCBA Value
1 Density 575 Kg/m3
2 Specific gravity 2.2
3 Mean size particle 0.1-0.2µm
4 Mean specific area 2500 m2/Kg
5 Colour Dark black
43
Slurry is produce by mixing undensified micro silica powder and
water in equal proportions by weight. Slurry is the easiest and most
practical way to introduce micro silica into the concrete mix
Surface area 15–20 m2/g
45
STEP 3: TARGET STRENGTH FOR MIX PROPORTIONS f ck
́ = fck
+1.65s
Where, f ck
́ = target average compressive strength at 28 days,
fck = characteristic compressive strength at 28 days,
s = standard deviation.
From table 1 of IS 10262 – 2009, Standard deviation, s = 5 N/mm2
2
Target strength, f ck
́ = 30 + 1.65 x 5 = 38.25N/mm
STEP 4: SELECTION OF WATER TO CEMENT RATIO
From table 5 of IS 456 – 2000, Maximum water to cement ratio is 0.45.
STEP 5: SELECTION OF WATER CONTENT
From table 2 of IS 10262 – 2009, Maximum water content is 186 litres.
STEP 6: CALCULATION OF CEMENT CONTENT
Water to cement ratio = 0.45
3
Cement content = 186/0.45=413.33 Kg/m
From table 5 of IS 456 – 2000, Minimum cement content for mild exposure
3
of reinforced concrete is 300Kg/m . Hence, it is okay.
STEP 7: PROPORTIONING OF VOLUME OF COARSE
AGGREGATE AND FINE AGGREGGTES CONTENT FROM
TABLE 3 OF IS 10262 – 2009
a) Volumes of coarse aggregates corresponding to 20mm size of
aggregate and fine aggregate of zone II were consider.
b) From water cement ratio, 0.50 = 0.62 (Aggregate Volume)
c) Volume of coarse aggregates content = 0.62 x 0.9 = 0.583
d) Volume of fine aggregates content = 1 – 0.583 = 0.417
46
STEP 8: MIX CALCULATIONS
Mix calculations per unit volume of concrete as follows
Table 3.17 Observation of mix design
Volume of
= 1 m3
concrete
(Mass of cement)/(specific gravity of cement x 1000)=
Volume of
413.33/(3.15 x 1000) = 0.131
cement
(Mass of water)/(specific gravity of water x 1000)=
Volume of water 186/(3.15 x 1000) = 0.059
Volume of all 1 - (sum of volume of aggregates and volume of
aggregates cement)= 1 - (0.131 + 0.059) = 0.81
Mix Proportions:
Mix Design is done for M30 grade of concrete as per code
specifications IS 10262-2009.
10262 Several
ral trail mixes are carry out and cubes
casted for the above grades of concrete to attain the required target strength
before the final design mixes are fixed by considering the optimum cement
content and water-cement
cement ratio as per BIS Standards.
Table 3.18 Mix Proportions for Natural Aggregate Concrete
Grade cement Coarse Water W/C
3
designation ( kg/m ) Fine aggregates aggregates (kg/m3)
3
( kg/m ) ( kg/m3)
M 30 330 725 1242 148.5 0.45
47
CHAPTER IV
EXPERIMENTAL INVESTIGATION
4.0. Introduction:
In this chapter, detailed investigation of ternary concrete made with partial
replacement of cement by SCBA and silica fume. The experimental
procedure carried out in various stages such as batching, mixing, placing
and compacting, demoulding, curing, and testing of specimens.
4.1. Casting of cubes, cylinders and prisms:
Cement is replaced with 10% silica fume and SCBA in various proportions
i.e. 0%, 5%, 10%, 15%, 20% and 25%. Cubes of 100mm x 100mm x
100mm, cylinders of 150mm x 300mm and prisms of 100mm x 100mm x
500mm sizes specimens were casted by use of silica fume, SCBA, cement,
fine aggregate and coarse aggregate. Three specimens for each mix were
casted and all details are in table 4.1
Table 4.1 Percentage of Silica and SCBA
TBASF0 0% 0%
TBASF5 10% 5%
TBASF10 10% 10%
TBASF15 10% 15%
TBASF20 10% 20%
TBASF25 10% 25%
48
4.2. Mixing Procedure:
The mixing procedure employed in this research work is pan mixing
followed by hand mixing. As the setting time of this concrete is much less
concrete was hand mixed as quickly as possible after pan mixing. Mixing
was continued until the entire mix becomes homogeneous and uniform in
appearance. The entire period of mixing is not more than 3 minutes.
49
Fig 4.2 smooth finishing of moulds
4.5. Curing
The casted specimens were generally demould after 24hrs from the time of
adding the water to the ingredients. The specimens then marked for
identification. These demoulded specimens were then stored in curing tank
for 56 days.
1. Ensuree that concrete specimen must well dried before placing it on the
UTM.
2. Weight of samples is noted in order to proceed with testing and it must
not be less than 8.1Kg.
3. Testing specimens are place in the space between bearing surfaces.
50
4. Care must taken to prevent the existence of any loose material or grit
on the metal plates of machine or specimen block.
5. The concrete cubes placed on bearing plate and aligned properly with
the centre of thrust in the testing machine plates.
6. The loading must applied axially on specimen without any shock and
increased at the rate of 140kg/sq cm/min until the specimen collapse.
7. Due to the constant application of load, the specimen starts cracking at
a point & final breakdown of the specimen must noted.
1. Prepare the test specimen by filling the concrete into the mould in 3
layers of approximately equal thickness. Tamp each layer 35 times
using the tamping bar as specified above. Tamping should distribute
uniformly over the entire cross section of the beam mould and
throughout the depth of each layer.
51
2. Clean the bearing surfaces of the supporting and loading rollers, and
remove any loose sand or other material from the surfaces of the
specimen where they are to make contact with the rollers.
3. The specimen stored in water shall test immediately on removal from
water. The test specimen shall place in the machine correctly centred
with the longitudinal axis of the specimen at right angles to the rollers.
For moulded specimens, the mould filling direction shall be normal to
the direction of loading.
4. The load shall apply at a rate of 180 kg/min for the 10.0 cm specimens
until the specimen collapse.
5. Due to the constant application of load, the specimen starts cracking at
a point & final breakdown of the specimen must noted.
52
4.8. Split tensile strength of concrete: [IS 516-1959]:
53
4.8. IMPACT TESTING:
TESTING
4.8.1 DROP WEIGHT IMPACT TEST ON 96 MM
CYLINDRICAL SPECIMEN:
54
4.9. PREPARATION OF THE THIN SECTION SAMPLE
FOR OPTICAL MICROSCOPIC ANALYSIS:
After casting the specimen (i.e. of fine aggregate replaced with copper
slag) it is tested at the end of 28 days in Universal Testing Machine and then
the sample is prepared by the following steps:
• Extraction
• Cutting
• Grinding
• Polishing
55
Fig 4.8 Extraction of sample and Sample placed on the glass plate after
cutting
56
by weight of a fluorescent dye. It may vary from epoxy to epoxy and
dye to dye.
• The epoxy/dye mixture is completely homogenized and then it is
stirred before use.
• The epoxy is then poured into the small vessel, containing the
specimen.
• The penetration depth of the epoxy depends largely on the viscosity
and it is observed that the concrete is impregnated with dye to a depth
of approximately 1-2 mm.
57
specimen grinding the opposite face carefully in order to obtain a
completely level surface.
• It should also be ensured that the final operations of the grinding
procedure be performed as fast as possible as carbonation of the
freshly ground surface might otherwise occur.
4.9.4 POLISHING PROCESS:
• Polishing the sample should be done later on using FORCIPOL and
FORCIMAT polishing machine at a constant pressure of 20 N/mm2.
• Since the vacuum is not available the same has to be polished
manually by running it for a certain stipulated time till the polished
surface is attained with the help of Silicon Carbide powder (1000 and
320 grit)
• The excess epoxy on the ground face is to be carefully removed after
it is hardened by polishing on the disc.
• The polished surface is to be covered with a cover glass by applying
one drop of epoxy to the center of the sample and carefully pressing
the cover glass down vertically on the drop.
• No air bubbles must be trapped beneath the glass as it would reduce
the quality of the thin section.
58
4.9.5 OPTICAL MICROSCOPIC ANALYSIS:
59
CHAPTER-V
RESULTS AND DISCUSSION
5.1 Results
5.1.1compressive strength results:
COMPRESSIVE STRENGTH OF
TERNARY BLENDED CONCRETE
50
COMPRESSIVE STRENGTH
45
40
35
30
MPa
25
20
15
10
5
0
TBASF0 TBASF5 TBASF10 TBASF15 TBASF20 TBASF25
7DAYS 26.66 27.55 28.88 30.22 25.77 24.88
28DAYS 38.6 39.11 40.44 42.22 37.33 36
56DAYS 40 41.3 42.22 44 39.11 38.22
60
5.1.2Flexural strength results:
5
FLEXURAL STRENGTH
4
MPa
0
TBASF0 TBASF5 TBASF10 TBASF15 TBASF20 TBASF25
7DAYS 3.72 3.8 3.92 4.2 3.6 3.2
28DAYS 4.12 4.4 4.6 4.92 4 3.8
56DAYS 4.2 4.6 4.72 5 4 3.92
61
5.1.3Split tensile strength results:
2.5
2
MPa
1.5
0.5
0
TBASF0 TBASF5 TBASF10 TBASF15 TBASF20 TBASF25
7DAYS 1.69 1.84 1.98 2.19 1.62 1.55
28DAYS 2.68 2.83 2.9 3.04 2.76 2.61
56DAYS 2.83 2.97 3.04 3.18 2.83 2.76
62
5.1.4 Impact strength results:
63
Table 5.6 Impact strength of ternary blended concrete for 56 days
300
IMPACT STRENGTH
250
200
kN-mm
150
100
50
0
TBASF0 TBASF5 TBASF10 TBASF15 TBASF20 TBASF25
7DAYS 55.755 111.51 111.51 223.02 111.51 111.51
28DAYS 111.51 111.51 111.51 278.775 167.265 111.51
56DAYS 111.51 167.265 167.265 334.53 167.265 111.51
64
5.1.5 Optical microscope:
Bonding
g between coarse aggregate air void in cement matrix
ma
and cement
ement matrix
65
5.2 Discussions:
From fig 5.1, it is observed that the compressive strength of TBASF15
is greater than that of control mix TBASF0 by 11.83%.
From fig 5.2, it is observed that the flexural strength of TBASF15 is
greater than that of control mix TBASF0 by 14.4%.
From fig 5.3, it is observed that the Split tensile strength of TBASF15
is greater than that of control mix TBASF0 by 18.8%.
From fig 5.4, it is observed that the impact strength of TBASF15 is
greater than that of control mix TBASF0 by 13.08%.
From fig 5.5, it is observed through optical microscope there is good
bonding between aggregates and cement matrix for TBASF15.
66
CHAPTER-VI
CONCLUSION
67
REFERENCES
68
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71
LIST OF CODES
IS 383-1970, Specification for coarse and fine aggregate from natural
sources for concrete.
IS 12269-1987, Specifications for OPC 53 grade cement.
IS 4031-1988, Tests on cement.
IS 2386-1963, Indian standard methods of test for aggregates for
concrete.
IS 2386-1963, Indian standard methods of test for aggregates for
concrete.
IS 10262-2009, Guidelines for concrete mix design proportioning.
IS 456-2000, Indian Standard code of practice for general structural
use of plain and reinforced concrete.
72
ANNEXURE
73