Study On Concrete by Partial Replacement of Cement With Limestone Powder

Visvesvaraya Technological University
Jnana Sangama, Machhe, Belgaum, Karnataka – 590014
Project Report
On
Study on concrete by partial replacement of cement with
limestone powder
Submitted in partial fulfillment of the requirements for the award of degree
Bachelor of Engineering
In
Civil Engineering
Submitted By
Santosh Pattar : 1NH13CV112

Shivaprasad : 1NH13CV115
Shreekant Reddy : 1NH13CV116
Sumanth Sharma R : 1NH13CV120
Under the guidance of

Mr. Satish D
Assistant Professor
Dept. of Civil Engineering, NHCE
Outer Ring Road, Panathur post, Kadubisanahalli, Bangalore – 560103
Department of Civil Engineering – 2016-2017.
CERTIFICATE
This is to certify that the project work entitled “Study on concrete by partial replacement
of cement with limestone powder” a bonafide work carried out by Santosh Pattar
(1NH13CV112), Shivaprasad (1NH13CV115), Shreekant Reddy (1NH13CV116) and
Sumanth Sharma R (1NH13CV120) bonafide students of 8th semester in partial fulfillment
for the award of Bachelor of Engineering degree in CIVIL ENGINEERING of Visvesvaraya
Technological University, Belgaum during the year 2016 – 2017. It is certified that all
corrections/suggestions indicated for Internal Assessment have been incorporated in the
report deposited in the department library. The project report has been approved as it satisfies
the academic in respect of project work prescribed for said degree.
Signature of the guide Signature of HOD Signature of the Principal
Mr.Satish D Dr.Niranjan P.S Dr.Manjunatha
Name of the examiners Signature with date

1) ________________
2) ________________
ACKNOWLEDGEMENT
The satisfaction that accompanies the successful completion of the task would be but incomplete
without mention of the people, who made it possible, whose continuous guidance and
encouragement crown all efforts with success.
We express our sincere thanks to Dr. Mohan Manghani, Chairman of New Horizon College
of Engineering for providing necessary infrastructure and creating good environment.
We wish to express our sincere thanks to Dr. Manjunatha, Principal, NHCE, for all his
support and guidance.
We wish to express our sincere thanks to Dr. Niranjan P.S, Head of the Department of Civil
Engineering, NHCE for permitting us to pursue our project in college and encouraging us
throughout the project.
Our gratitude goes to all who has stood behind us and motivated and helped us accomplish the
goal by sharing their knowledge and views on the topic. Among them our guide Mr. Satish D,
who has guided us throughout the task with his expertise and experience.
ABSTRACT
To meet the requirements of globalization, in the construction of buildings and other
structures concrete plays the rightful role and a large quantum of concrete is being utilized.
The constituents of concrete are coarse aggregate, fine aggregate binding material and water.
Rapid increase in construction activities leads to acute shortage of conventional construction
materials and increase in cement cost. In the backdrop of such a bleak atmosphere, there is
large demand for alternative materials. Hence we are trying to use the limestone dust as an
alternative material to partially replace the cement. This experimental study presents the
variation in the strength of concrete when replacing cement by lime stone powder by 0% to
15% for preparation of M40 grade of concrete are taken into the study. The compressive
strength of concrete cubes at age of 7, 14 and 28 days is obtained at room temperature. Split
tensile strength of concrete are found at the age of 7 and 28 days. From the test results it is
found that the maximum compressive strength, tensile strength is obtained only at 10%
replacement. This result gives clear picture that lime stone powder can be utilized in concrete
mixtures as a good substitute for cement at 10% replacement.
CONTENTS
Chapter 1 Introduction 1
1.1 General introduction 1
1.2 Limestone powder 2
1.3 Objectives 4
Chapter 2 Literature Review
Chapter 3 Materials used and Methodology 8
3.1 Materials used 8
3.2 Methodology 11
3.3 Tests conducted on physical properties 12
3.4 Tests on fresh concrete 16
3.5 Tests on harden concrete 18
2.6 Concrete mix design as per IS: 10262-2009 21
Chapter 4 Results and discussions 25
4.1 Physical properties of cement 25
4.2 Physical properties of fine aggregate 27
4.3 Physical properties of coarse aggregate 29
4.4 Physical and chemical properties of limestone powder 30
4.5 Slump value 31
4.6 Density of concrete 32
4.7 Compressive strength 33
4.8 Split tensile strength 38
Chapter 5 Conclusion 42
Scope for further study 42
References 43
LIST OF FIGURES
1.1a Quarry waste lime stones dumped at Shahabad Taluk 3
1.1b Limestone at quarry site 4
3.1 Cement 8
3.2 Limestone 8
3.3 Limestone powder 8
3.4 Sieving of limestone powder in 90 micron sieve 9
3.5 Aggregate crusher 9
3.6 Flowchart of working procedure 11
3.7 Specific gravity bottle 12
3.8 Calculating standard consistency using vicat apparatus 13
3.9 Particle size distribution of different size soil 15
3.10 Measuring slump of concrete 16
3.11 Concrete slump test procedure 17
3.12 Types of concrete slump test results 17
3.13 Cube casting 18
3.14 Cubes before and after curing 19
3.15 Cubes testing in CTM 19
3.16 Split tensile strength testing 20

LIST OF TABLES
3.1. Compressive strength of concrete at various age as per IS: 456-2000 20
3.2 mix design proportion 24
4.1 standard consistency of cement 25
4.3 Physical properties of fine aggregate 28
4.4. Physical properties of coarse aggregate 29
4.5. Comparison of chemical properties of cement and limestone powder 30
4.6. Slump value for different mix 31
4.7. Density of concrete 32
4.8. Compressive strength 33
4.9. Tensile Strength 38
4.10. Cost of concrete for 1 m3 41
LIST OF CHARTS
4.1. Standard consistency of cement 26
4.2. Slump value for different proportion mix 31
4.3. Density of concrete 32
4.4. Compressive strength at 7 days 33
4.7. Compressive strength at different age 35
4.8. Compressive strength without limestone powder 35

4.9. Compressive strength at 5% replacement of cement by limestone powder 36
4.12. Compressive strength at various % replacement of cement by limestone powder 37
4.13. Split tensile strength at 7 days 38
4.14. Split tensile strength at 28 days 39
4.15. Split tensile strength vs age 39
4.16. Split tensile strength vs % of limestone powder added 40
4.17. Comparison of compressive strength and split tensile strength at 7 days 40
4.18. Comparison of compressive strength and split tensile strength at 28 days 41

Study on concrete by partial replacement of cement with limestone powder
CHAPTER 1
INTRODUCTION
1.1 GENERAL INTRODUCTION
The reduction of cement content in concrete is one of the persistent global sustainability
concerns of the 21st century. Of all the ingredients in concrete (the primary ones being
cement, supplementary cementitious materials, water, and coarse and fine aggregates),
cement has the largest footprints when it comes to both carbon dioxide release and energy
consumption. While the feasibility of achieving higher levels (greater than 50 %) of cement
replacement using fly ash, a residual product from coal combustion, has been demonstrated in
the laboratory and in practice, questions remain about the stability of the supply of quality fly
ash and local shortages have indeed been encountered in parts of the U.S. in recent years.
Similarly, high replacement mixtures using slag have demonstrated good performance, but
the worldwide slag supply is quite limited when compared to the annual demand for concrete
for new construction and repair.
Cement manufacturing produce a large amount of undesiderable products, mostly CO2,

which result in greenhouse effect that leads to the earth temperature increase. In addition,
cement production process is energy intensive as well as raw materials demanding. Technical
development to lower the environmental impact of cement production achieved by the
reduction of cement demand (blended cement). Therefore, many studies have considerable
attention on mineral additions such as slag, natural pozzolana, fly ash and limestone in order
to reduce energy consumption and CO2 emission. Nowadays limestone has been widely used
to add or replace a part of Portland cement to produce Portland limestone cement and
Portland composite cement. Consequently, all available materials options must be
investigated in earnest in the quest to reduce cement content in concrete.
One material that has been used in concrete in some parts of the world for many years, but is
receiving renewed interest globally, is limestone powder, typically available in the form of
the calcite polymorph of calcium carbonate and with varying percentages of magnesium
(carbonate). Because limestone is the major source of calcium for cement production, as well
as being one of the most commonly employed aggregates, its presence is ubiquitous within
the concrete industry.
Dept. of civil engineering, NHCE Page 1

Limestone powder can also physically improve the denseness of hardened Portland cement
paste due to its filling effect. The optimum use of limestone powder as a supplementary
material to Portland cement has therefore technical benefits, such as improved workability,
bleeding control, lower sensibility to the lack of curing, and a little bit increased early
strengths. On the other hand, loss of strength at later ages due to incorporation of limestone
has also been reported.
Limestone and cement have characteristics which make them ideal for specific applications.
However, significant problems can arise when cement is introduced to buildings originally
constructed and previously maintained using lime mortars. The aim of this study is to know
the effect of partial replacement of cement with limestone powder on compressive strength
and split tensile strength of harden concrete.
1.2 LIMESTONE POWDER
The Limestone is calcareous sedimentary rock mainly consisting of calcium carbonate

(CaCO3), commonly called calcite. Limestone is used in cement and concrete for various
purposes, namely, as a raw material for clinker production and as coarse or fine aggregate.
Limestone powder is produced by finely grinding limestone in quarrying operations and has
been suggested for use as an additive in Portland cement. Replacing of limestone into
Portland cement has been widely studied for several years. Limestone is usually considered
as an inert filler material that improves the hydration rate of cement compounds and
consequently increases the strength at early ages. The incorporation of limestone powder with
Portland cement has many advantages on early compressive strength, durability and
workability. While some authors claim that limestone acts as an active participant and that
during hydration of Portland cement some calcium carbonate is taken into system and reacts
with the alumina phases of cement to form carboaluminates and delays or impedes the
ettringite-monosulphate transformation. This leads to the stabilisation of the ettringite and
will result in an increase in the total volume of the hydration products, which might result in a
decrease in porosity and thus an increase in strength. The effect of this chemical interaction in
PC-limestone system is, however, not so pronounced due to limited aluminate content in the
clinker.

The limestone powder for our project is obtained from crushing the quarry waste limestone of
Shahabad Taluk, Gulbarga district, Karnataka the area which is very rich in limestone and the
limestone is dumped in large quantity as a waste. So our main aim to utilize that limestone as
substitute for concrete.
Fig.1.1a Quarry waste lime stones dumped at Shahabad taluk

Fig.1.1b Limestone at quarry site
1.3 OBJECTIVES
• To achieve the economy by utilising the quarry waste materials in construction works.
• The use of a quarry waste as an alternative material to partial replacement of cement
by lime stone dust.
• To minimize the cost.
• Reducing Portland cement production and CO2 emission at production level by using
limestone dust as alternative of it.

CHAPTER 2
LITERATURE REVIEW
In past studies different researches had been done with limestone powder for the
improvement in concrete mix. Mainly limestone powder is replaced with constituents of
concrete to test the mechanical properties and also its economical value.
Dr. Abdul Hakeem Hamed Ahmed (2009) described the feasibility of the use of limestone
powder as cement partial replacement in concrete mixes and studies the effect of elevated
temperature on the compressive, and tensile strengths. The following conclusions could be
extracted from this study:
• Limestone powder offers a number of advantage for its use as cement compensating
by enhance flow properties and increase compressive strength.
• The slump of concrete relatively increases with higher values of the percentage of
compensating of cement with limestone powder.
• Based on the results, it was observed that the compressive strength of concrete
increase with the increase in limestone powder compensating, concrete made with
15% limestone powder compensating showed higher compressive strength.
• In general, the compressive strength of limestone powder concrete, like that of normal
concrete, decrease with increasing temperature. At 400°C a higher value in the
compressive strength is observed to that at 200 °C is observed.
Wendimu Gudissa @ all (2010) The investigation has revealed that,

• Replacement of ordinary Portland cement by fine limestone powder from 5% to 10%
2
with Blain fineness value of 4000 to 4500 cm /gm satisfies the standard compressive
strength requirement of high early strength cement as per the standard requirements.
• The grinding results indicated that, as the replacement of limestone increases by
weight, increases in cement fineness and decrease in grinding time were observed
compared to pure ordinary Portland cement. Since limestone is softer to grind than
pure clinkers the energy required is also relatively less than required to grind pure
clinker for Portland cement production.
th
• The test results indicated that, 28 days compressive and flexural strengths of
hardened cement mortar decrease with the increase in the percentage addition of

limestone content for same blain fineness and also increase with the increase of
fineness
Didier Lootens @ all (2017) the study revealed that the ability of both limestone and silica
powders to accelerate early-age hydration and reduce/maintain initial setting times has been
demonstrated. When used as partial replacements for cement, these fillers provide ample
surfaces to serve as templates for the growth of cement hydration products and their relatively
inert cores become incorporated as part of the three-dimensional percolated backbone that
provides setting, rigidity, and strength to these materials. The precipitation-friendly surfaces
of the fillers reduce the amount of hydration product precipitation occurring initially on the
cement particles, so that the renewed reactivity of (unexposed) aluminates, etc., typically
observed as a second heat flow peak or a shoulder on the primary hydration peak, is
enhanced, particularly for cement replacement levels of 80 % and higher. While the
limestone powder is slightly more efficient at accelerating hydration than the silica on a per
unit surface area basis, it provides further benefits in rheological properties by reducing the
yield stress and lowering the consistency factor, when used to replace cement on a one-to-one
volume basis. Due to their acceleration of cement hydration, replacement levels of up to 40 %
of these fillers for cement have minimal impact on initial setting times, suggesting that these
sustainable binary blends may be particularly attractive in applications where controlled
setting is more important than development of high strengths, such as mortar tile adhesives,
other grouts, and renderings for building facades.
P. Thongsanitgarn @ all (2011) In this study limestone powders with different particle sizes
of 5, 10 and 20 µm were used to replace a part of Portland cement in different replacement
levels to produce Portland-limestone cement pastes. The percentages of limestone
replacement are 0, 5, 7.5, 10, 12.5, 15 and 20% by weight. The effect of fineness and the
amount of limestone powders on compressive strength and setting time are investigated. It
has been established that limestone replacement causes reduce the compressive strength due
to the dilution effect, but it can reduce energy consumption and CO2 emission in cement
manufacturing. The fineness of limestone powder used has influence on the observed
compressive strength values. From the standard consistency results, it seems that limestone
has no effect on water requirement compared to Portland cement. Moreover, the increase in
level of fine particles would require much water. Both initial and final setting times were
decreased with an increase in the amount of limestone. Furthermore, at the same level
replacement, the cement pastes using 5 µm of limestone show lower setting time than those
using 10 and 20 µm, respectively.
Tarun R. Naik @ all (2003) In general limestone powder filler in cement and concrete
effects acceleration of hydration, dilution of cement paste, increase of effective w/c, ratio and
increases the strength at early ages. The addition of limestone powder filler to fine cement
pastes and mortars reduces the diffusion coefficient of chloride ions. The use of limestone
powder in cement and concrete provides economic and environmental advantages by
reducing Portland cement production and CO2 emission, as well as improving the early and
the later age compressive strength. Limestone powder to cement changes the phase
composition of pastes in comparison with pastes without addition. They also demonstrated
limestone powder prevents the transformation of ettringite to sulphoaluminates
(monosulphate, hemisulphate and solid solutions), instead of which carboaluminate phases
more resistant to sulphate attack (monocarbonate, hemicarbonate) are formed.
D, Gowrisanker @ all (2016) This experimental study presents the variation in the strength
of concrete when replacing sand by quarry dust and cement by lime powder also replacement
by from 0% to 30% in steps of 10%. M20 grades of concrete are taken for the study keeping a
constant slump of 60mm. The compressive strength of concrete cubes at age of 7 and 28 days
is obtained at room temperature. Split tensile strength of concrete are found at the age of 28
days. From the test results it is found that the maximum compressive strength, tensile strength
are obtained only at 30% replacement. This result gives clear picture that quarry dust can be
utilized in concrete mixtures as a good substitute for natural river sand at 30% replacement
with additional strength than control concrete.

CHAPTER 3
MATERIALS USED AND METHODOLOGY

3.1. METERIALS USED
3.1.1 Ordinary Portland cement (OPC) of 53 grade was used throughout the course of the
investigation. The physical properties of the cement as determined from various tests
conforming to Indian Standard IS: 1489:1991.
Fig.3.1 Cement
3.1.2 LIMESTONE POWDER: waste limestone powder was collected by crushing the
limestone which is collected from limestone quarry. It was sieved by IS-90 micron sieve
before mixing in concrete. The sample was collected from Shahabad Taluk, Gulbarga district,
Karnataka. The area is rich in limestone content.
Fig.3.2 Limestone fig.3.3 Limestone powder

Fig.3.4 sieving of limestone powder in 90 micron sieve
Fig.3.5 Aggregate Crusher

3.1.3 AGGREGATES: are those chemically inert materials which when bonded by cement
paste form concrete. Aggregates constitute the bulk of the total volume of concrete and hence
they influence the strength of concrete to great extent. The properties of concrete are directly
related to those of its constituents and as such aggregate used in a concrete mix should be
hard, strong, dense, durable, and free from lumps of clays, loam, vegetable and other such
foreign matter. The presence of all such debris prevents adhesion of cement on the surface of
aggregates and hence reduces the strength of concrete.
FINE AGGREGATES: the material which passed through I.S. Sieve No. 480
(4.75mm) is termed as fine aggregates. Function of fine aggregates is to make
concrete dense, by filling voids of coarse aggregates, reduces the shrinkage of cement
and makes an economical mix. Natural sand or crushed stone dust is used as a fine
aggregate in concrete mix. Sand may be obtained from sea, river, lake or pit, but
when used in a concrete mix, it should be properly washed and tested to ascertain that
total percentage of clay, silt, salts and other organic matter does not exceed specified
limit. Sand as obtained from the above sources may be round or angular in grains.
Angular grained sand has good interlocking property which results in a strong mix
while rounded grained sand does not afford sufficient interlock in the matrix. But for
our project m-sand is used.
COARSE AGGREGATES: The material whose particles size such that they are
retained on I.S. Sieve No. 480 (4.75mm) is termed as coarse aggregates. Coarse
aggregates, like fine aggregates, must consist of sound durable inert particles to make
the concrete strong and weather resistant. It should be free chemicals or coating or
clay or other fine material that may affect bonding of cement paste. The size of the
coarse aggregates used depends upon the nature of work. Crushed hard stone and
gravel are the common materials used as coarse aggregates for structural concrete.
Coarse aggregates are usually obtained by crushing granite, gneiss, crystalline lime
stone and good variety of sand stone etc. As far as possible flaky and elongated
pieces of stone should be avoided.

3.2. METHODOLOGY
Fig.3.6 Flowchart of working procedure

3.3 TESTS CONDUCTED ON PHYSICAL PROPERTIES

3.3.1 SPECIFIC GRAVITY OF CEMENT.
Specific gravity is calculated by density bottle method (Le-chatelier’s flask). It is made use of
in design calculations of concrete mixes. It is required in calculating the compacting factor in
connection with the workability measurements. It is also considered when dealing with light
weight and heavy weight concrete. Fig shows Specific gravity bottle (Le-chatelier’s flask).
Fig.3.7 shows Specific gravity bottle (Le-chatelier’s flask).

3.3.2 STANDARD CONSISTENCY OF CEMENT (IS 4031:1991 – Part 4)
Standard consistency of a cement paste is defined as that consistency (The amount of water
expressed as percentage by mass of the dry cement) which will permit the vicat plunger to
penetrate to a point 5 to 7mm from the bottom of the vicat mould when the cement paste is
tested. Standard consistency is calculated by vicat apparatus.
The purpose of the test is to determine the percentage of weight of water to be added to
cement to produce a cement paste of standard consistency, i.e. the paste of certain solidity,
which is used to fix the quantity of water to be mixed in cement before performing tests for
Initial setting time, final setting time, soundness and compressive strength of cement.

Fig.3.8 Calculating standard consistency using vicat apparatus
3.3.3 SETTING TIME OF CEMENT (IS 4031:1988 – Part 5)

Setting refers to the stiffening process which the cement paste undergoes as time elapses.
The time interval for which the cement products remain in plastic condition is known as
setting time. Initial setting time is regarded as the time elapsed between the moment the water
is added to the cement and the time when the paste has completely lost its plasticity and has
attained sufficient firmness to resist certain definite pressure. The setting time during which
the cement products remain in plastic condition is required for mixing, transporting and
placing cement products.
As per IS specifications the initial setting time should be less than 30 minutes and final
setting time should not be more than 10 hours for ordinary Portland cement.
Mass of cement taken = 400gms
Mass of water taken = 0.85 x P x 400 = --------------------ml.
Where “P” is the standard consistency.

3.3.4 DETERMINATION OF SPECIFIC GRAVITY OF FINE AGGREGATE

BY PYCNOMETER METHOD.
Theory:
Specific gravity of sand is the ratio of the mass/weight in air of a given volume of sand solids
to the mass/weight of equal volume of distilled water at 4°C. It is represented as G.
G=
.
G=
Coarse grained sand: 2.6-2.7

Fine grained sand: 2.7-2.8
Organic sand: 2.3-2.5
3.3.5 DETERMINATION OF SPECIFIC GRAVITY AND WATER ABSORPTION OF

COARSE AGGREGATES.
To determine the specific gravity and water absorption of coarse aggregate. Apparatus: Wire
basket, weighing balance, spring balance, bucket containing water and oven. The water
absorption value gives us the amount of water that can be absorbed by the coarse aggregate.

3.3.6 SIEVE ANALYSIS OF AGGREGATES.

The particle size distribution or grain size distribution of the soil fraction retained on
0.075mm sieve is carried out by sieve analysis, and that passing 0.075mm sieve is carried out
by the principle of sedimentation.
Sieve analysis is used for classification of soil. Name of the soil is given depending upon the
maximum percentage of the above components. Soils having less than 5% particles of size
smaller than 0.075 mm.
Fig.3.9 Particle size distribution of different types of soils.
3.3.7 DETERMINATION OF MOISTURE CONTENT OF FINE AGGREGATE BY

OVEN DRYING METHOD.
Soil is an aggregate of soil particles having a porous structure. The pores (voids) may have
water or air. If voids are fully filled with water, the soil is called saturated soil and if voids
have only air, it is called dry soil.
Moisture content is defined as the ratio of the mass or weight of water to the mass or weight
of soil solids expressed as percentage. That means it gives the clear idea that how much water
that can be absorbed by the fine aggregates.

3.3.8 DETERMINATION OF AGGREGATE IMPACT VALUE IS: 2386 (Part IV) –

1963)
The property of a material to resist the impact is known as toughness. Due to the
movement of vehicles on road the aggregates are subjected to impact resulting in their
breaking down into smaller pieces. The aggregates should therefore have sufficient toughness
to resist their disintegration due to impact. This characteristic is measured by impact value
test. The aggregate impact value is a measure of resistance to sudden impact or shock, which
may differ from its resistance to gradually applied compressive load.
3.4 TESTS ON FRESH CONCRETE
3.4.1 SLUMP CONE TEST
Concrete slump test is to determine the workability or consistency of concrete mix prepared
at the laboratory or the construction site during the progress of the work. Concrete slump test
is carried out from batch to batch to check the uniform quality of concrete during
Fig.3.10 Measuring Slump of Concrete

Fig.3.11 Concrete Slump Test Procedure
Fig.3.12 Types of Concrete Slump Test Results

True Slump – True slump is the only slump that can be measured in the test. The
measurement is taken between the top of the cone and the top of the concrete after the cone
has been removed as shown in figure-1.
Zero Slump – Zero slump is the indication of very low water-cement ratio, which
results in dry mixes. This type of concrete is generally used for road construction.
Collapsed Slump – This is an indication that the water-cement ratio is too high, i.e.
concrete mix is too wet or it is a high workability mix, for which a slump test is not
appropriate.
Shear Slump – The shear slump indicates that the result is incomplete, and concrete
to be retested.
3.5. TESTS ON HARDEN CONCRETE

3.5.1. COMPRESSIVE STRENGTH OF CONCRETE
Out of many test applied to the concrete, this is the utmost important which gives an idea
about all the characteristics of concrete. by this single test one judge that whether concreting
has been done properly or not.
Compressive strength of concrete depends on many factors such as water-cement ratio,
cement strength, quality of concrete material, and quality control during production of
concrete etc.
Fig.3.13 Cube casting

Fig.3.14 Cubes before curing Cubes after curing
Fig.3.15 Cube testing using CTM

Table 3.1. Compressive strength of concrete at various age as per IS:456-2000
.
Age strength per cent
1 day 16%
3 days 40%
7 days 65%
14 days 90%
28 days 99%
3.5.2. Split tensile test

The tensile strength of concrete is one of the basic and important properties. Splitting tensile
strength test on concrete cylinder is a method to determine the tensile strength of concrete.
The concrete is very weak in tension due to its brittle nature and is not expected to resist the
direct tension. The concrete develops cracks when subjected to tensile forces. Thus, it is
necessary to determine the tensile strength of concrete to determine the load at which the
concrete members may crack.
Fig.3.16 Split tensile strength testing

3.6. CONCRETE MIX DESIGN AS PER IS: 10262: 2009

Grade : M40
Type of cement : OPC 53
Maximum size of aggregate : 20mm
Maximum water cement ratio : 0.4
Workability : 100mm slump
Exposure condition : very severe
Method of concrete placing : normal
Degree of supervision : good
Specific gravity of cement : 3.15
Specific gravity of coarse aggregate : 2.72
Specific gravity of water : 1.00
Specific gravity of limestone powder : 2.48
Grading of coarse aggregate confining to TABLE 2 of IS: 383
Grading of fine aggregate confining to ZONE 1
1. TARGET MEAN STRENGTH
f’ck=fck+1.65s
Where, f’ck= target average compressive strength at 28days,
fck= characteristic compressive strength at 28 days, and
s= standard deviation.
From table 1, standard deviation, s= 5 N/mm2.
Therefore, target mean strength = 40+ (1.65*5) = 48.25 N/mm2.

3. SELECTION OF WATER-CEMENT RATIO
From table 5 of IS: 456, maximum water-cement ratio is 0.45.

Based on experience, adopt water-cement ratio as 0.4.
0.4< 0.45, hence ok.
4. SELECTION OF WATER CONTENT
From table 2, maximum water content for 20mm aggregate

= 186 litres (for 25 to 50mm slump range)
Estimated water content for 75mm slump = 186+ (6/100*186) = 197litres
5. CALCULATION OF CEMENT CONTENT
Water cement ratio = 0.4

Cement content = 197/.4= 495 kgs/m3
From table 5 of IS: 456, minimum cement content for “very severe” exposure condition =
minimum 340kg/m3 and maximum 450 kg/m3
Hence consider 450 kg/m3
6. CALCULATION PROPORTION OF COARSE AGGREGATE AND FINE

AGGREGATE CONTENT.
From table 3, volume of coarse aggregate corresponding to 20mm size aggregate and fine
aggregate (zone 2) for water cement ratio of 0.5= 0.6.
In present case water cement ratio is 0.4. Therefore, volume of coarse aggregate is required to
be increased to decrease the fine aggregate content. As the water cement ratio is lower by 0.1,
the proportion of volume of coarse aggregate is increased by 0.02(at the rate of +/- 0.01 for
every +/- 0.05 change in water-cement ratio).
Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of
0.4 =0.62.
Volume of fine aggregate content = 1-0.62 = 0.38
1. MIX CALCULATIONS
2. The mix calculations per unit volume of concrete shall be as follows:
a. Volume of concrete= 1m3.
b.
Volume of cement = (mass of cement/specific gravity of cement)*(1/1000)
= (450/3.15)*(1/1000)
= 0.142m3
c. Volume of water = (mass of water/specific gravity of water)*(1/1000)
= (197/1)*(1/1000)
= 0.197m3
d. Volume of all in aggregates= [a-(b+c)]= [1-(0.142+0.197)]
= 0.661m3
e. Mass of coarse aggregate= e*volume of coarse aggregate*specific gravity of
coarse aggregate*1000 = 0.661*0.62*2.72*1000
= 1114.7kgs
Taking 20 mm: 12.5 mm aggregate = 60 : 40
Therefore mass of 20 mm aggregate = 668.8 kg
Mass of 12.5 mm aggregate = 445.9 kg
f. Mass of fine aggregate= e*volume of fine aggregate*specific gravity of fine
Aggregate*1000 = 0.661*0.38*2.53*1000
= 635.48kgs
8. SIGHT CORRECTIONS
Initial moisture content in fine aggregate = 1.9%

Initial water content in coarse aggregate = 0.5%
Mass of fine aggregate = 635.48-(635.48*1.9/100) = 623.4kgs
Mass of coarse aggregate = 1114.7-(1114.7*0.5/100) = 1109.13kgs
Total water content = 197+18 = 215 litres.

9. MIX PROPORTIONS
Cement = 450kg/m3
Water = 215kg/m3
Fine aggregates = 623.4kg/m3
Coarse aggregate = 1109.13kg/m3
Water-cement ratio= 0.4
Table 3.2 mix design proportion
Mix design proportion

Cement Fine aggregate Coarse aggregate Water-cement ratio
1 1.4 2.5 0.4

CHAPTER 4
RESULT AND DISCUSSIONS
4.1. PHYSICAL PROPERTIES OF CEMENT
Ordinary Portland cement (OPC) of 53 grade was used throughout the course of the
investigation. The physical properties of the cement as determined from various tests
conforming to Indian Standard IS: 1489:1991.
4.1.1. Specific Gravity of Cement by density bottle
Specific Gravity =
Specific Gravity Trial 1 = 2.97
Trail 2 = 3.60
Trial 3 = 2.88
Specific Gravity of the cement sample = 3.15

From the obtained result the specific gravity of cement is 3.15, it is within the limit 3.10-3.15
as specified in IS: 8112-1989.
4.1.2. Standard consistency of cement by vicat apparatus

From the test conducted, it is obtained that the consistency of cement is 27. It is found that
the nearly the same value when cement partially replaced with limestone powder. And it is
within the limit 25-35 as specified in IS: 8112-1989.
Table 4.1 standard consistency of cement
Si No. % of limestone added Standard consistency
1. 0 27
2. 5 27
3. 10 28
4. 15 28

Chart 4.1 standard consistency of cement
Table 4.2 Physical Properties of cement

Physical properties of cement
SI no. Physical Properties Of OPC 53 Results Requirement as per

Grade Cement IS: 8112-1989
1. Specific Gravity 3.15 3.10-3.15
2. Standard Consistency (%) 27 25-35
including different % of limestone
powder
3. Initial Setting Time(Min) 32 30 minutes Minimum
4. Final Setting Time(Min) 300 600 minutes Maximum
5. Compressive strength(N/mm2) 54 53 N/mm2

4.2. PHYSICAL PROPERTIES OF FINE AGGREGATE

4.2.1. Specific Gravity of fine aggregate by pycnometer
Tabular column for Specific Gravity of fine aggregate
Empty Weight of Pycnometer (W1) 0.62kg
Weight of Pycnometer + 1/3rd F.A (W2) 1.22kg
Weight of Pycnometer + 1/3rd F.A + Water (W3) 1.87kg
Weight of Pycnometer + Water(W4) 1.51kg
Specific Gravity = = 2.53
4.2.2. Bulk density of fine aggregate
Initial Weight of Vessel (W1) = 152gm

Final Weight of Vessel (W2) = 966gm
Volume of Vessel = 0.5 litres = 0.5/1000m3
Bulk Density = Mass/Volume
= (W2-W1)/v = 1628kg/m3

4.2.3. Sieve analysis of fine aggregates
Tabular column of sieve analysis

I.S Sieve Size Particle Size Weight of soil Percentage Cumulative Percentage
(mm) Retained (kg) Weight Percentage Fineness (100-
Retained Weight a)
Retained (a)
4.75mm 4.750 0.000 0.000 0.000 100.000
2.36mm 2.360 0.068 6.800 6.800 93.200
1.18mm 1.180 0.224 22.400 29.200 70.800
600micron 0.500 0.130 13.000 42.200 57.800
300micron 0.300 0.204 20.400 62.600 37.400
150micron 0.150 0.154 15.400 78.000 22.000
75micron 0.075 0.126 12.600 90.600 9.400
Pan 0.094 9.400 100 0.000
Total Percentage Fineness 309.4
Finess modulus = (cumulative % retained) / 100 = 309.4/100 = 3.09
Table 4.3 Physical properties of fine aggregate

Physical properties of fine aggregate
Si. No. Description Value
1. Specific gravity 2.53
2. Water absorption 4.8%
3. Finess Modulus 3.09
4. Bulk density 1628kg/m3

4.3. PHYSICAL PROPERTIES OF COARSE AGGREGATE

4.3.1. Specific Gravity of Coarse Aggregates
Tabular column for Specific Gravity of Coarse Aggregates
Empty Weight of wire bucket(W1) 0.74kg
Weight of aggregate in Water(W2) 2.05kg
Weight of surface dry aggregates(W3) 2.02kg
Weight of oven dry aggregates(W4) 1.93kg
Specific Gravity = = 2.72
4.3.2. Bulk Density of Coarse Aggregate

Tabular column for bulk density of coarse aggregate
Empty Weight of Container (W1) 3.62kg 3.62kg
Container + Aggregates(W2) 8.30kg 8.54kg
Volume of
3
Vessel = 3 litres = 3/1000m
Bulk Density = Mass/Volume = (W2-W1)/(3/1000) = 1550kg/m3
Table 4.4. Physical properties of coarse aggregate
Physical properties of coarse aggregate

Sl. No. Description Value
1. Specific Gravity 2.72
2. Finess Modulus 6.3
3 Density 1550kg/m3
4. Flakiness index 35.8%
5. Elongation index 45.6%
5. Water absorption 0.5%

4.4. PHYSICAL AND CHEMICAL PROPERTIES OF LIMESTONE

POWDER
4.4.1. Specific gravity of limestone powder

Specific gravity = 2.48
Table 4.5. Comparison of chemical properties of cement and limestone powder
Component Cement (%) Lime stone powder (%) Requirement as per

IS: 3812-1981 (%)
Sio2 21.8 11.25 17-25
Al2O3 4.8 2.76 3.0-8.0
Fe2O3 3.8 1.15 0.5-6.0
CaO 63.3 43.77 60-67
SO3 2.04 0.27 1.3-3.0
MgO 0.91 2.15 0.1-4.0
Na2O 0.21 0.35 0.4-1.3

4.5. SLUMP VALUE
Table 4.6. Slump value for different mix

Si No. % of limestone w/c ratio Slump(mm)
powder added
1. 0 0.4 110
2. 5 0.4 60
3. 10 0.4 50
4. 15 0.4 45
Chart 4.2. Slump value for different proportion mix
From the chart we can observe that the slump value is decreasing with increase in the
limestone powder.

4.6. DENSITY OF CONCRETE
Table 4.7. Density of concrete

% of limestone powder added Mass of cube(kg) Volume of cube(m3) Density ( kg/m3)
0 8.46 0.003375 2506.6

5 8.4 0.003375 2488.8
10 8.34 0.003.75 2471.1
15 8.25 0.003375 2444.4
Chart 4.3. Density of concrete
From the graph we can conclude that the density is decreasing with increase of limestone
powder.

4.7. COMPRESSIVE STRENGTH
Table 4.8. Compressive strength

SL No. % of limestone Average compressive strength (Mpa)
powder
7 days 14 days 28 days
1. 0 45.23 53.01 62.96

2. 5 46.6 50.7 60.8
3. 10 42.77 48.63 55.31
4. 15 31.2 35.4 39.5
Chart 4.4. Compressive strength at 7 days
From the chart we can observe that the compressive strength is maximum for 5% replacement
of cement by limestone powder, which means the hydration process is maximum at early age.
And it is reduced for higher percent replacement.


Chart 4.7. Compressive strength at different age
From the charts we can conclude that the hydration process is maximum at early age.
Chart 4.8. Compressive strength without limestone powder

Chart 4.9. Compressive strength at 5% replacement of cement by limestone powder

Chart 4.12. Compressive strength at various % replacement of cement by limestone

powder

4.8. SPLIT TENSILE STRENGTH
Table 4.9. Tensile Strength

SL No. % of limestone Tensile Strength(Mpa)
powder added 7days 28 days
1. 0 3.182 5.14
2. 10 2.9 5.04
3. 15 2.74 4.14
Chart 4.13. Split tensile strength at 7 days

Chart 4.14. Split tensile strength at 28 days
Chart 4.15. Split tensile strength vs age
From the chart above we can conclude that nearly required split tensile strength can be
achieved at 10% replacement of cement by limestone powder.

Chart 4.16. Split tensile strength vs % of limestone powder added
Chart 4.17. Comparison of compressive strength and split tensile strength at 7 days

Chart 4.18. Comparison of compressive strength and split tensile strength at 28 days
From the above charts we can observe that required target mean strength and tensile strength
is obtained at 10% replacement of cement by limestone powder.
Table 4.10. Cost of concrete for 1 m3

materials Rate/ kg (Rs.) Required quantity( kg) Total cost (1m3)
cement 7.8 450 3510
Fine aggregate 0.6 623 373.8
Coarse aggregate 0.5 1109 554.6
Total cost for concrete without blending limestone powder = 4440 Rs./m3
For concrete with 10% replacement of cement by limestone powder, 45 kg of cement can be
saved for 1m3 of concrete that means 390 Rs. /m3 can be saved.

CHAPTER 5
CONCLUSION
This study reports the effect of the amount of limestone powder on concrete properties. The
following conclusions can be drawn from the obtained experimental data:
• Maximum 10% of cement can be replaced by limestone powder without change in the
strength of the concrete.
• Required split tensile strength can be achieved by 10% replacement of cement by
limestone powder.
• The addition of limestone filler in to Portland cement results in increase in cement
fineness and this fineness of the cement provide higher rate of hydration and hence
faster development of the early strength.
• The use of limestone powder in cement and concrete provides economic and
environmental advantages by reducing Portland cement production and CO2
emission.
• From the standard consistency results, it seems that limestone has no effect on water
requirement compared to Portland cement. Moreover, the increase in level of fine
particles caused requires much water.
Scope for further study

In the present study on mechanical properties concrete by partial replacement of cement with
0,5,10 and 15 % limestone powder has been done. Due to the limitation of time the study was
restricted to few parameters, the exhaustive list of future scope of study as follows
1. The effect of partial replacement of cement with limestone powder in cement-
limestone paste can be studied.
2. The mechanical properties of concrete by using admixtures with partial replacement
of cement with limestone powder can be studied.
3. The properties of concrete can be studied by using limestone as aggregate.
4. Compressive strength of self compacting concrete blended with limestone powder can
be studied.

REFERENCES
1. M. Heikal, H. El-Didamony and M.S. Morsy, Limestone-filled pozzolanic cement,

Cement and Concrete Research 30 (2000) 1827-1834
2. Livesy, P., 1991, “Performance of limestone-filled cements,” Blended Cements, Ed.:
Swamy, R. N., Elseiver Science, Essex, UK, pp. 1-15.
3. Bonavetti, V., Donza, H., Rahhall, V., and Irrassar, E., 2000, “Influence of initial curing
on properties of concrete containing limestone blended cement,” Cement and Concrete
Research. Vol. 30, No. 5, pp. 703-708.
4. G. Menendez, V. Bonavetti and E.F. Irassar, Strength development of ternary blended
cement with limestone filler and blast-furnace slag, Cement & Concrete Composites 25
(2003) 61-67.
5. S. Tsivilis, G. Batis, E. Chaniotakis, Gr. Grigoriadis and D. Theodossis, Properties and
behavior of limestone cement concrete and mortar, Cement and Concrete Research 30
(2000) 1679-1683.
6. Howard, I.L., Shannon, J., Cost, V.T., and Stovall, M., “Davis Wade Stadium Expansion
and Renovation: Performance of Concrete with Portland-Limestone Cement, Fly Ash, and
Slag Cement,” Journal of Materials in Civil Engineering, 27 (12), 2015
7. Lothenbach, B., Saout, G., Gallucci, E., Scrivener, K.,” Influence of limestone on the
hydration of Portland cements”, Cement and Concrete Research, vol. 38, 2008, pp: 848-
860.

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Visvesvaraya Technological University

Jnana Sangama, Machhe, Belgaum, Karnataka – 590014

Santosh Pattar : 1NH13CV112

Under the guidance of

Signature of the guide Signature of HOD Signature of the Principal

Mr.Satish D Dr.Niranjan P.S Dr.Manjunatha

Name of the examiners Signature with date

Chapter 3 Materials used and Methodology 8

3.1 Materials used 8

3.3 Tests conducted on physical properties 12

3.4 Tests on fresh concrete 16

3.5 Tests on harden concrete 18

2.6 Concrete mix design as per IS: 10262-2009 21

Chapter 4 Results and discussions 25

4.1 Physical properties of cement 25

4.2 Physical properties of fine aggregate 27

4.3 Physical properties of coarse aggregate 29

4.4 Physical and chemical properties of limestone powder 30

4.5 Slump value 31

4.6 Density of concrete 32

4.7 Compressive strength 33

4.8 Split tensile strength 38

1.1a Quarry waste lime stones dumped at Shahabad Taluk 3

1.1b Limestone at quarry site 4

3.3 Limestone powder 8

3.4 Sieving of limestone powder in 90 micron sieve 9

3.5 Aggregate crusher 9

3.6 Flowchart of working procedure 11

3.7 Specific gravity bottle 12

3.8 Calculating standard consistency using vicat apparatus 13

3.9 Particle size distribution of different size soil 15

3.10 Measuring slump of concrete 16

3.11 Concrete slump test procedure 17

3.12 Types of concrete slump test results 17

3.13 Cube casting 18

3.14 Cubes before and after curing 19

3.15 Cubes testing in CTM 19

3.16 Split tensile strength testing 20

3.1. Compressive strength of concrete at various age as per IS: 456-2000 20

3.2 mix design proportion 24

4.1 standard consistency of cement 25

4.3 Physical properties of fine aggregate 28

4.4. Physical properties of coarse aggregate 29

4.5. Comparison of chemical properties of cement and limestone powder 30

4.6. Slump value for different mix 31

4.7. Density of concrete 32

4.8. Compressive strength 33

4.9. Tensile Strength 38

4.10. Cost of concrete for 1 m3 41

4.1. Standard consistency of cement 26

4.2. Slump value for different proportion mix 31

4.3. Density of concrete 32

4.4. Compressive strength at 7 days 33

4.5. Compressive strength at 14 days 34

4.6. Compressive strength at 28 days 34

4.7. Compressive strength at different age 35

4.8. Compressive strength without limestone powder 35

4.10. Compressive strength at 10% replacement of cement by limestone powder 36

4.11. Compressive strength at 15% replacement of cement by limestone powder 37