civil miniproject vamshikrishna
DESCRIPTION
Civil Miniproject VamshiKrishnaTRANSCRIPT
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ROLE OF FLY-ASH IN CONSTRUCTION
A Mini project report submitted in partial fulfilment of the
Requirement for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING
SUBMITTED BY
T.SURYA VAMSHI 08241A0150
V.VAMSHI KRISHNA 08241A0154
DEPARTMENT OF CIVIL ENGINEERING
GOKARAJU RANGARAJU INSTITUTE OF ENGINEERING
AND TECHNOLOGY
(Affiliated JNTUH, Hyderabad)
Bachupally, Nizampet Road, Kukatpally, Hyderabad-500090.
july 2011
DECLARATION
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We declare that this project entitled ROLE OF FLYASH IN CONCRETE has
been done by us and has not previously formed as the basis for the awards of any
degree or diploma or the similar title in this or any other institution.
T.SURYA VAMSHI 08241A0150
V.VAMSHI KRISHNA 08241A0154
ACKNOWLEDGEMENT
The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without the expression of appreciation of simple matter to the
people who made it possible because success is epitome of hard work, cogency for
fulfillment of the mission, indefatigable perseverance and most of all those whose
guidance and encouragement had made successful in winding up this opus.
We express our profound feeling of gratitude to prof. Dr. Venkat Ramana,
Head of the department, Civil Engineering, Gokaraju Rangaraju Institute of
Engineering And Technology for his constant words of encouragement and concrete
suggestions which helped us in completion of this project.
We would like to express our sincere thanks to M/S Surasani Constructions
pvt. Ltd, for providing us an opportunity to complete our mini project successful,
which is a part of course curriculum. This training would not have successfully
completed without the guidance and support to Mr. M. Sridhar Reddy
(Project Manager), Mr. C. Praveen Kumar(Site Engineer) and the entire project
team. We are deeply indebled to the project team members who were always ready to
help us during project time.
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ABSTRACT Fly ash is a fused residue of clay minerals present in coal. The high temperature generated when coal burns in thermal power plants, transforms the clay minerals in coal powder into a
variety of fused fine particles of mainly aluminium silicate composition.
Fly ash can be used in Portland cement concrete to enhance the performance of the concrete. Fly ash can be used for construction of road and embankment. This utilization
has many advantages over conventional methods. Fly ash is most commonly used as a
pozzolan in PCC applications.
Fly Ash Contributes to Concrete Durability and Strength
Durability is the ability to maintain integrity and strength over time. Strength is only a
measure of the ability to sustain loads at a given point in time. Two concrete mixes with equal
cylinder breaks of 4,000 psi at 28 days can vary widely in their permeability, resistance to
chemical attack, resistance to cracking and general deterioration over time all of which are
important to durability. Cement normally gains the great majority of its strength within
28 days, thus the reasoning behind specifications normally requiring determination of 28-day
strengths as a standard. As lime from cement hydration becomes available (cements tend to vary widely in their reactivity), it reacts with fly ash. Typically, concrete made with fly ash
will be slightly lower in strength than straight cement concrete up to 28 days, equal strength at
28 days, and substantially higher strength within a years time. Conversely, in straight cement concrete, this lime would remain intact and over time it would be susceptible to the effects of
weathering and loss of strength and durability.
Company details: We are hereby making our project in M/S Surasani Constructions pvt. Ltd to successfully complete our project as per standard specification.
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CONTENTS
1. INTRODUCTION
1.1 General
1.2 Use of fly ash in concrete
1.2.1 Fly ash effects in concrete
1.3 Objectives
1.4 Scope of work
2. LITERATURE REVIEW
2.1 General
2.2 Characteristics of fly ash
2.2.1 Physical Properties Of Fly Ash 2.2.2 Chemical Compositions Of Fly Ash 2.2.3 Morphology Of Fly Ash 2.2.4 Mineralogy of Fly Ash
2.3 High content of fly ash in concrete
2.4 Role of water in concrete:
2.5 Influence of Fly Ash on Water Content
2.6 High range water-reducers
2.6.1 Composition
2.6.2 Mechanism of Action
2.6.3 Effects Fresh State
2.6.3.1 Fresh concrete
2.6.3.2 Hardened State
2.6.3.3 Volume Change
3. DESIGN OF CONCRETE MIX
3.1 General
3.2 Material selection
3.2.1 Cement
3.2.2 Fly-Ash
3.2.3 Sand
3.2.4 Coarse Aggregate
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3.2.5 Water
3.2.6 Super-plasticizer
3.3 Mixture proportioning procedure
3.4 Calculation of mix proportions
4. EXPERIMENTAL WORK
4.1 GENERAL
4.2 Planning
4.3 Estimation of required material
4.4 Procurement of material
4.5 Preliminary laboratory tests
4.6 Preparation and casting of test specimen
4.7 Mixing procedure
4.8 Compaction of test specimen
4.9 Specimen conditioning and testing
5. TEST RESULTS AND DISCUSSION
5.1 General
5.2 Test results
5.2.1 Properties of fresh concrete
5.2.2 Properties of hardened concrete
6. CONCLUSION
7. BIBILOGRAPHY
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INTRODUCTION
1.1 GENERAL
Cement is the most costly and energy-intensive component of concrete. The unit cost
of concrete can be reduced by partial replacement of cement with fly ash. The
disposal of fly ash is one of the major issues for environmentalists, as dumping of fly
ash as waste material causes severe environmental problems. The utilization of fly ash
instead of dumping it as a waste material can be partly used on economic grounds as
pozzuolana for partial replacement of cement and partly because of its beneficial
effects of lower water demand for similar workability, reduced bleeding and lower
evolution of heat. It has been used particularly in mass concrete applications and large
volume placement to control expansion due to heat of hydration and also helps in
reducing cracking at early ages.
The proportion of fly ash used as a cementitious component in concrete depends on
several factors. The design strength and workability of concrete, water demand and
relative cost of fly ash compared with cement are particularly important in mixture
proportioning of concrete. One of the major developments in the area of fly ash
utilization in concrete has been the technology of high-performance, high-volume fly
ash concrete by Malhotra and Ramezanianpour [1] and Malhotra [2]. High fly ash
concretes with fly ash/cementitious ratio up to 75% (by mass) and an
aggregate/cement ratio of 6 have compressive and flexural strengths that are more
than adequate for lean concrete base or subbase application in pavement structure [3].
Concrete containing 50% replacement by mass of class F fly ash can be designed to
have 1- and 28-day cube strengths of 20 and 60 MPa, respectively [4]. High-volume
fly ash concrete has adequate early-age and later-age strength developments and
considerably lower temperature rise, and its applications should have a water content
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of not less than 115 kg/m3 and a sufficient amount of a retarded version of
superplasticizer to maintain satisfactory slump and placing characteristics [5].
1.2 USE OF FLY ASH IN CONCRETE
It has been above 70 years to research and use fly ash. With its application, the action
mechanism of fly ash had been recognized. During the initial stage, only its
pozzolanic activity is paid attention [8 and 9]. Many researchers devoted themselves
to the research of the potential activity of fly ash and the hydration process of fly ash
cement. With the deepening of the cognition for fly ash properties, some people found
that the particles of fly ash have the morphology that is different to other pozzolanic
materials. It is the unique particle morphology to make it have the ability reducing
water, which other pozzolanic materials do not have [10, 11, 12 and 13]. It influences
not only the rheological property of fresh mortar but also the initial structure of
hardened cement stone. In the end of 1970s, Jan de Zeeuw and Abersch [14] put
forward that the role of fly ash, which its particle size is less than 30 , may be similar
to that of the micro-particle of unhydrated cement in cement stone. In 1981, Danshen
and Yinji [15] and Danshen [16] summarized the previous research results and put
forward the hypothesis of "fly ash effects." They considered that fly ash has three
effects in concrete, i.e., morphological, activated and micro aggregate effects. The
three effects are relative each other. This shows that the morphological effect is the
important aspect of fly ash effects.
The morphological effect means that in concrete, mineral-powdered materials produce
the effect due to the morphology, structure and surface property of the particle and the
particle size distribution. From the influence of fly ash on the properties of cement-
based materials, the morphology effect includes three aspects: filling, lubricating and
well distributing. These roles depend on the shape, size distribution, etc., of fly ash
and influence many properties of concrete.
The pozzolanic effect is the main effect of FA, which states that the unfixed SiO2 and
Al2O3 in FA can be activated by Ca(OH)2 product of cement hydration and produce
more hydrated gel. Since the gel produced from pozzolanic action can fill in the
capillary in concrete, it effectively contributes to concrete strength, especially in
concrete with high volume fly ash (often the generation of long-term strength is
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mainly from pozzolanic effect). Taking the cement hydration as prerequisite, the
contribution of pozzolanic effect to strength can also be regarded as one part of
cement contribution. It should also be pointed out here that the above three effects of
Fly ash infect co-affect with each other, but focus on the different performance of
concrete, respectively. Since it is difficult and not necessary to distinguish the
previously mentioned three effects, often they are collectively called "fly ash effect"
or "pozzolanic effect.
Roller-compacted concrete (RCC), a kind of widely used pavement material, is a sort
of super-dry concrete with high density and high strength, resulting from its low water
demand and formation by vibration and rolling. Incorporating FA into RCC to make
RCC with fly ash (FRCC) can further reduce the cost and meanwhile specifically
improve the performance. The specific improvement lies in the following aspects: (1)
Incorporating FA by the method of super-substituting, a widely used design method,
effectively increases the total amount of binder in RCC and makes it easier to
compact. (2) Substituting Fly Ash for a part of cement in RCC can remarkably
decrease the quantity of heat produced by cement hydration. (3) Formation by
vibration and rolling, and also by its required low water-cement ratio, can somehow
make up the early age strength of FRCC, which is often cut down by the incorporation
of a large amount of FA in ordinary concrete. With the previously mentioned
advantages, FRCC is gradually extended in pavement construction. Possessing so
many favourable properties, amount of Fly Ash in FRCC can further be promoted and
the performance of pavement can still be guaranteed, while taking rational ratio
design as prerequisite.
1.2.1 Fly Ash effects in concrete
Following are the effects which was found out in roller compacted concrete with high
content of class F fly ash:
1. Since the pozzolanic reaction between FA and cement lags behind cement
hydration, High Fly ash Roller Compacted Concrete (HFRCC) strength at early
curing age is poor and decreases with increasing FA content.
2. Following the curing age, greater amounts of FA are activated and cause the
strength of HFRCC to continuously develop.
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3. Incorporating fly ash by high content and super-substituting method makes
HFRCC easier to compact, and together with the amount of crystal phase Ca(OH)2
and harmful pore reduction, HFRCC at long-term curing age becomes dense and
homogeneous. These improved properties are more beneficial to flexural strength,
which is more sensitive to inner structure characteristic than compressive strength.
Fig.1.1: SEM micrographs (8,000) of Portland cement (a) and low-calcium fly ash
(b)
1.3 OBJECTIVES
In this project work, objective is to develop engineering database on the mechanical
properties and to determine the necessary level of fluidity, generally termed as
workability (as control of workability is one of the main objectives of mixture
proportioning) of fly ash concrete incorporating VTPS fly ash and Ordinary Portland
Cement, and it is compared with controlled concrete.
Also four grades (M20, M25, M30 and M35) of concrete are targeted to select
optimum percentage of cement replacement by fly ash as cementitious material, for
obtaining maximum possible 28 days compressive strength.
To evaluate the dose of superplasticizer for the same water-cement ratio of each grade
of concrete to increase the slump value from 80-120mm.
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1.4 SCOPE OF WORK
The scope of project work is as under:
Literature review regarding requirements of fly ash, material properties and
characteristics of high performance concrete.
1. Preliminary laboratory test of fine aggregates, coarse aggregate for mix
design.
2. Mix design and proportioning for ingredients.
3. Modification and correction in mix proportioning during concrete production
to meet workability requirement.
4. Modification and correction in mix proportioning during concrete productions
for moisture content of fine aggregates.
5. Water to binder (cement plus fly ash) ratio was kept 0.50,0.46,0.42 and 0.38
for M20, M25 ,M30 and M35 grade concrete respectively.
6. 150 mm size cubes were casted, cured in water tank and weighed for unit
weight before compression testing for the determination of mechanical
properties of concretes at 7 days and 28 days .
7. Superplasticizer dose was calculated for each grade of concrete for same W/C
ratio to obtain slump value 80-120mm.
8. Test result interpretation for optimum selection of suitable part replacement of
fly ash as cementitious material.
9. Compressive strength test and analysis for the determination of mechanical
properties of concretes at 7 days and 28 days from the date of casting of the
test specimen.
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LITERATURE REVIEW
2.1 GENERAL
Fly ashes from Vijayawada thermal power plants were used in the experiments
of the present study.. A brief review of literature about the physical and chemical
properties; mineralogy and morphology behavior of fly ashes is presented. Literatures
regarding concrete applications of fly ashes have been used in construction are also
discussed.
Fly ash is produced from burning of pulverized coal in thermal power
plants. The pulverized coal is fed into the boilers and burnt with the supply of
additional air. The temperature in the boiler exceeds 1600 C and the most of the
mineral matter present in the coal are fused and altered physically and chemically.
The resulting residue is called coal combustion by-products namely bottom ash,
economizer ash, air pre-heater ash, and electrostatic precipitator ash (fly ash). These
ashes are handled and disposed off separately owing to their differing qualities by
mechanical, hydraulic and pneumatic conveying systems. The quality of ash produced
is dependent on various factors like source coal and its degree of pulverization, design
of furnace, changes in coal supply, changes in boiler load, and firing condition.
Because of this inherent variability of the material, it is necessary to study the
characteristics and engineering behavior of fly ash in detail before its use in an
application.
Fly ash is a promising and economical alternative material to construction engineering
applications. Review of literature shows that fly ash has been utilized in the
construction of pavement construction, in high strength concrete, high performance
concrete and in other applications.
A. CHARACTERISTICS OF FLY ASH
As per ASTM C 618 1993[17], there are two classes of fly ash namely class F and
class C. Class F fly ash is produced from burning anthracite or bituminous coal and is
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pozzolanic in nature and class C is obtained from lignite or sub-bituminous coal.
Class C fly ash possesses both pozzolanic and self-hardening property. Hence, it is
necessary to characterize the material scientifically to utilize it in different
applications.
i. Physical Properties Of Fly Ash
The specific gravity, loss on ignition (LOI) and specific surface area are the prominent
physical properties of fly ashes. The specific gravity of fly ash may vary from 1.3 to
4.8. The iron oxide content plays a decisive role in the specific gravity of the material.
The specific gravity is more for fly ashes containing more iron oxide and vice versa.
The presence of opaque spherical magnetite and hematite particles in sufficient
quantity will increase the value of specific gravity to about 3.6 to 4.8. On the other
hand, as the amount of quartz and mullite increases, the specific gravity decreases.
However, coal particles with some minerallic impurities will have lower specific
gravity in the range 1.3 to 1.6. The range of specific gravity of Canadian fly ashes is
reported to be in the range of 1.91 to 2.94 and that of American fly ashes in the range
of 2.14 to 2.69.
Dayal and Sinha (1999) [18] have reported the specific gravity of Indian coal ashes
to range between 1.94 and 2.34 with a mean value of 2.16 and standard deviation of
0.21. The specific gravity of fly ash decreases as the particle size increases. The
specific gravity increases when the fly ash particles were crushed. Typical values of
the specific surface of Indian fly ashes (3267 to 6842 cm2/g) were comparable with
that of the foreign ashes (2007 to 6073 cm2/g).
ii. Chemical Compositions Of Fly Ash
The main chemical compounds of class F fly ash are silica, alumina and iron oxide.
Other minor constituents include oxides of calcium, magnesium, titanium, sulphur,
sodium and potassium. Class C fly ash contains relatively higher proportion of
calcium oxide and lesser proportion of silica, alumina and iron oxide than class F fly
ash. Typical chemical compositions of various Indian fly ashes are summarized in
Table 2.2.
iii. Morphology Of Fly Ash
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Fly ash is a heterogeneous material; with the degree of heterogeneity persisting at all
levels viz macro, micro and nano structural levels (Sun Wei at al 2003)[51]. By using
scanning electron microscopy and energy dispersive X-ray analysis (EDXA)
technique the particle shape and surface characteristics of fly ash can be studied.
Some of the particles are hollow and spherical, which are termed as cenospheres
[Fig2.1 (a)].. These cenospheres are also called floaters, as they are light in weight.
Fly ashes contain small spherical particles within a large glassy sphere, called
plerospheres [Fig. 2.1 (b)]. In some particles, where regions of a spherical particle
melted or eroded away are known as clathrosphere [Fig. 2.1 (c)]. This indicates the
intense chemical activity having occurred within the particles in the furnace zone
during the short residence time. The exterior surfaces of solid and hollow spherical
particles of low calcium oxide fly ashes are generally smoother than the high calcium
oxide fly ashes, which may have surface coatings of materials rich in calcium1. In
some fly ashes small sub-micron size particles may be sticking to the large spherical
particles, due to the convexity of the surfaces. The studies conducted by Mehta
(1998)[19] on low calcium fly ashes (CaO
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Fig. 2.1 Scanning electron micrographs of inhomogeneous spherical particle
types of fly ashes (a) cenosphere (b) plerosphere And (c) clathrosphere
(Hemmings and Berry, 1987)
Diamond 1986[20] studied the particle morphologies of 13 low calcium fly ashes
collected from Indiana. The salient features of the study are as follows.
The fly ash contained spherical particles of wide size range about 1 m to more
m with smooth surface. Some of the particles were covered with surface
irregularities or deposits.
Presence of plerospheres (Thin walled hollow spheres with smaller included
spheres) and non-spherical particles were identified.
The interior structure of a particle revealed the presence of iron rich magnetic
grain on a sphere and in the adjacent sphere needle shaped particles of mullite
crystals were present.
Presence of heterogeneous structure of particles contained within a plerosphere
was also identified.
Plate like structures that constitute the surface of a sphere was also present
occasionally. These structures may represent the magnetic plate.
Garg (1995)[21] studied the morphology of Indian fly ashes. The fly ashes contained
angular as well as rounded black particles, spheroid glass, and minute silica grains.
Sharma (1993)[22] has classified Indian fly ashes based on the shape of particles as
one of the parameters. According to him group- fly ashes contained mainly spherical
particles with the size range between 2-25 m. The surfaces of glassy spheres in this
group are predominantly smooth without any deposit, only some adherence was
observed.
Group- fly ashes contained a wide range of particles (2-35 m). Most of the particles
were spherical in shape, but some sintering and surface depositions were also
observed.
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Where as group- fly ashes which were of low reactive type contained mostly
irregularly shaped and relatively coarser particles, which have undergone probably
little or no fusion in the combustion process.
2.2.4 Mineralogy of Fly Ash
Fly ash consists of both crystalline and amorphous phases. The crystalline phases
could be quartz, mullite, silimanite, crystallite, cristobalite, sulphates of iron,
magnetite etc. The amorphous phases could be of silica and silicates predominantly of
aluminium but containing calcium, magnesium, and iron in varying concentration
with and without traces of sodium and potassium.
The reactivity of fly ashes depends on the non crystalline or glass content in it. The
chemical composition of the glass in the high calcium fly ash is different from the low
calcium fly ash and hence the reactivity of both the ashes are different. The high
calcium fly ashes are more reactive than low calcium fly ashes. Diamond (1986)[20]
and Mehta (1998)[19] pointed out that the composition of glass in low calcium fly
ashes is different from high calcium fly ashes. Typically low calcium fly ashes show a
diffused halo with maxima at 2 = 21-25 and high calcium fly ashes at 30-34 .
Garg (1999)[23] conducted XRD studies of Indian fly ashes and the crystalline
constituents identified were quartz (SiO2), mullite (3 Al2O3. 2SiO2), hematite (Fe2 O3)
and magnetite (Fe3 O4).
The minerals present in fly ash obtained from Koradi thermal power plant (Nagpur)
were quartz low (syn) most predominant, mullite- predominant, brookite, sillimanite
and ferroselite (Gangadhara Rao et al. 1998)[24].
As reported by Garg (1999)[23] mentioned that quartz and mullite were the main
crystalline constituents in British fly ashes and the American fly ashes contained
magnetite and hematite in large proportions. The range of quantitative measurement
in British fly ashes was quartz (1-6.5%); mullite (935%); magnetite and hematite
(5% or less). For American fly ashes the proportions were quartz (0 - 4%); mullite (0
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16%); magnetite (030%); and hematite (18%). The glass proportions in these fly
ashes were found to range from 50 to 90%.
b. HIGH CONTENT OF FLY ASH IN CONCRETE
Poon, C.S.,et al.(2002)[25] Low calcium fly ash (ASTM Class F) has been widely
used as a replacement of cement in normal and high strength concrete. In normal
strength concrete, the replacement level can be more than 50%, while in high strength
concrete, the replacement level is usually limited to 15 25%. The main objectives of
using fly ash in high strength concrete are to reduce heat generation and to obtain
better durability properties. However, in concrete mixes prepared at a low water-to-
binder (w/b) ratio, 20% fly ash content may not be sufficient to suppress the excessive
heat of hydration.
In a laboratory investigation carried out at the Hong Kong Polytechnic University, the
temperature in-crease due to cement hydration of large concrete blocks
(1000_1000_1000 mm) was measured. It was found that for 50 MPa concrete, a 25%
fly ash replacement reduced the maximum temperature of the concrete by 6C,
whereas for 100 MPa concrete, a 20% fly ash replacement did not result in a lower
temperature rise.
This seems to indicate that in concrete at a lower w/b ratio, the effect of a normal
amount of fly ash is not significant in reducing the temperature rise due to cement
hydration.
In the past, concrete containing high volumes of low-calcium fly ash was mostly used
in mass concrete, e.g., roller compacted dams and highway base courses [3], where
high strength and high degree of workability were not required. High volume fly ash
concrete for structural use was developed by the Canada Centre for Mineral and
Energy Technology (CANMET) in 1985]. This type of concrete has typically 5060%
fly ash as the total cementitious materials' content. Superplasticizers (high-range
water reducing admixtures) are used to obtain a high degree of workability.
Successful applications of this type of concrete included concrete columns with a
compressive strength requirement of 50 MPa at 120 days, and piles with the
compressive strength requirement of 45 MPa at 28 days.
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It is known that fly ashes generally have negative effects on the concrete strength,
particularly at early ages [6]. Using large quantities of this material in concrete seem
to be in contradiction to the original aims of preparing high strength concrete.
However, as observed by many researchers [79], fly ash concrete may have better
strength performance when they are prepared at lower w/b ratios. At a w/b = 0.5, a
45% fly ash replacement resulted in about 30% reduction in 28-day compressive
strength, but at a w/b = 0.3, the strength reduction was reduced to 17%. Also, the
advances of concrete admixture technology allow concrete mixtures to be prepared
with lower w/b ratios. It is therefore believed that high strength concrete can be
obtained with large volumes of fly ash.
The generation of fly ash and its use in India along with other countries is given in
Table 2.1. In India, generally Class F type fly ash is found. The chemical [36]
requirement of chemical composition for class C and Class F type ash in various
countries is shown in Table 2.2.
c. ROLE OF WATER IN CONCRETE:
Before water is added, however close the solid particles are, there is always some
space in the system. After water is added, a part of water is filled into these spaces,
which is called as filling water. Other water forms the layer of water on the surface of
the solid particle, which is called as the layer water. Because of the adsorption of the
solid surface to water molecule, the part of water that is closer to the surface of solid
will be restrained by solid particle and is not able to move freely. The water may be
called as the adsorpted layer water. The layer water that is not restrained by solid
particle is called as the free layer water. Mixing water is the sum of filling water,
adsorpted layer water and free layer water.
In the flow process of fresh mortar, filling water does not contribute to the fluidibility
because it only fills in the space and cannot make the particles separate to decrease
the moving resistance of particle. Of course, the filling water is able to move freely,
but the fluidity of fresh paste means that cement particles move with water under the
action of water. If only the water moves but the cement particle does not, it is not the
fluidity of cement paste but the separation.
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Table 2.2: Chemical requirement for fly ash in different countries
Country Germany Australia Austria Canada Spain India Japan U.K. Turky URSS USA
Standard DIN AS ONORM Canada UNE IS JIS BS TS GOST ASTM
No. 1045 1129 B 3319 3-A23 3812 A6201 3892 639 6269 C 618
Type of Fly Ash - - - C F 1 2 - - - - C F
SiO2 min% - - - - - - 35 45 - 40 -
(SAF) min% - - - - - 70 70 70 - - 70 - 70 50
MgO min% - - - - - 5 5 5 - 4 5 5 5
SO3 min% 4 2.5 3.5 5 5 4 4 3 - 2.5 5 3 5 5
CaO max% - - - - - - - - - - - - -
LOI max% 5 8 7 6 12 12 7 12 5 7 10 10 12 6
Alkalies max% - - - - - - - 1.5 - - - - 1.5 1.5
Moist. Max% 1.5 - 3 3 3 3 - 1 0.5 3 - 3 3
1. In cement LOI =Loss on ignition
2. In concrete S = SiO2
A = Al2O3
F = fe2O3
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When fresh mortar flows, adsorpted layer water moves with solid particle. It shows
the property that a solid has. Thus, it does not contribute to the fluidibility too. In fact,
this water can be exchanged with other in cement paste. This is a dynamic balance. As
a part, the adsorbed layer water does not contribute to fluidity. But for any molecule
of water, it is uncertain because it may be in the adsorbed layer or the free layer. It can
be seen from these that only free layer water contributes to the fluidibility. In the flow
process, free layer water makes the particles separate each other. The effort between
particles decreases. Thus, if the shape of solid particles is not considered, in a certain
degree, the thicker the free water layer, the better the fluidibility is. Fig. 2.1 shows the
model of water action and their contribution to the fluidibility.
Fig. 2.2: The model of water action and their contribution to fluidibility.
In fresh mortar, the amount of filling water depends on the packing density of system.
The higher the packing density, the less the filling water is. The amount of adsorpted
layer water depends on the specific surface area and surface property of solid
particles. It is the product of the specific surface area and the thickness of the
adsorpted layer. The thickness of adsorpted layer depends on the water affinity of
solid particles. The thickness of free water layer depends on the amount of free layer
water and the specific surface of solid particles. Under the condition of same amount
of free layer water, the larger the specific surface of solid particles, thinner the free
water layer is. Of course, the increase of the amount of free layer water will increase
the thickness free water layer.
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2.5.1 Influence of Fly Ash on Water Content
The particle of fly ash is different from one of cement in particle size, specific surface
and particle shape. They will influence the distribution of water in fresh mortar. This
is the essential reason of the influence of the morphological effect on the fluidibility
of fresh mortar.
2 2.6 HIGH-RANGE WATER REDUCERS (SUPERPLASTICIZERS) 3 2.6.1 Composition
The high-range water reducers presently used in the market can be classified [26]
according to their chemical nature in the following main groups:
Beta-naphthalene sulphonate formaldehyde condensates;
Melamine sulphonate formaldehyde condensates;
Modified ligno-sulphonates;
Esters of sulphonic acids;
Salts of carboxylic/hydroxy carboxylic acids.
4 2.6.2 Mechanism of Action
The mechanism of actin of high-range water reducers is mainly based on their ability
to be adsorbed on the surface of cement particles and modify the rheological
behaviour of the cement matrix. The rate of adsorption of high-range water reducers
depends on the chemical and mineralogical composition of the cement, its fineness
and in that calcium aluminate adsorbs very rapidly the high-range water reducer
molecules, while calcium silicate in the first hours of hydration adsorbs only a lower
amount of the high-range reducers. The increase of workability can be correlated with
the following properties.
1. The value of zeta potential of the electric double layer that is formed on the
surface of the cement particles by the polar groups of adsorbed superplasticizer
chains [27].
2. The molecular weight of the super plasticizer.
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The rate of workability loss is correlated to the retardation produced on the hydration
of cement.
2.6.3 Effects
The different properties of concrete indicate the specific way of using the admixture
that produces the desired modification. It is intended that if use of the admixture is not
indicated, the corresponding way of using the admixture does not exert a particular
action on the specific property cited.
2.6.3.1 Fresh State
Unit Mass
Unit mass of concrete is usually increased when high-range water reducers are used.
Workability
superplasticizers dramatically increase the ability of concrete to flow.
a. Cohesion: Cohesion is largely improved by the use of high-range water
reducer as a consequence of the reduction of water in concretes.
b. Air content:Air content may be slightly increased, especially in the case of use
of high dosages of the admixtures as superplasticizers.
c. Slump loss:At the same initial workability, slump loss may be higher in
concretes with high-range water reducers than in concrete without admixture.
At the same water/cement ratio, slump loss of concrete with superplasticizers
may be higher or lower than the control concrete without admixture as a
function of the type of superplasticizers used.
d. Pumpability: Pumpability of concrete is improved by the use of
superplasticizers, as a consequence of the increase in workability, and due to
cohesion in case of use as high-range water reducers.
e. Segregation: Segregation decreases when the admixture is either used as a
high-range water reduced or as a superplasticizers, provided that an adequate
mix design of the concrete is done.
-
17
f. Setting state: Generally the admixture used as a superplaticizer mildly retards
the setting of concrete, while use, as a high-range water reducer at normal
dosage does not give significant retardation.
g. Plastic shrinkage: Plastic shrinkage cracking can be increased by the use of
high-range water reducers if the ambient conditions are such that evaporative
demands are greater than the reduced bleeding capacity of the high-range
water reduced concrete.
h. Bleeding: Bleeding is reduced by the use of high-range water reducers. If the
aggregate size distribution is not properly designed, bleeding can be increased
when superplasticizers is used.
2.6.3.2 Hardened State
a. Strength: The strength of concretes is considerably increased by the use of
high-range water reducers as a consequence of the reduction of the
water/cement ratio, while strength is not substantially modified in case of use
as a superplasticizers.
b. Porosity: Capillary absorption of concrete is directly linked to its capillary
porosity, which is influenced by the water/cement ratio, that can be largely
reduced by the use of the admixture as a high-range water reducer.
c. Freeze-thaw attack: High-range water reducers-superplasticizers normally
induce some air entrainment in the concrete mixes, but some of the air bubbles
introduced are than those of air entraining agents and therefore are not useful
to increase the freeze-thaw durability of concretes [28].
d. Attack by aggressive solutions: The resistance of concrete to attack, by
aggressive solutions is increased by high-range water reducers because of the
reduction of concrete capillarity porosity. The use of the admixture as
superplastisizer does not change the resistance of the concrete [28,29,30].
2.6.3.3 Volume Change
a. Creep: The use of high-range water reducers reduces creep due to the
reduction of the water/cement ratio of the concrete.
-
18
b. Drying shrinkage: The shrinkage of concrete is reduced by high-range water
reducers mainly because of the reduction of the water content of the concrete.
When a concrete is manufactured with the admixture used as a
superplasticizers. Its shrinkage, for the same percentage of moisture loss, has
been found [29] to be higher then in a concrete produced with the same
quantity of water but without the use of the superplasticizers. On the other
hand it has been also shown that with the same curing condition, the shrinkage
of a superplasticized concrete is similar to that of a corresponding plain
concrete.
The concrete can be drawn that the better dispersion of cement particles in a
superplasticized concrete produces a finer capillary under normal ambient conditions,
so that the shrinkage of superplasticized concrete is practically similar to that of a
normal concrete manufactured with the same amount of water.
-
19
DESIGN OF CONCRETE MIX
3.1 GENERAL
Following the preliminary laboratory tests of materials incorporated in the concrete,
the mix proportions were selected to ensure the workability and surface finishes of
fresh concrete and shall have the required strength (not less then the target mean
strength, and durability, when hardened).
As stated earlier Mix Designing Methods according to Indian Bureau of Standard is
adopted as a general guideline along with the field experience of Project Guide for
this work programme to arrive at mix proportioning for four grade of concrete (M20,
M25,M30 and M35) with superplasticizer.
3.2 MATERIAL SELECTION
For the development of concrete in the laboratory, materials used were ordinary
Portland cement, fly ash, fine aggregates, coarse aggregate, water and
superplasticizers.
3.2.1 Cement
53 grade Ordinary Portland cement was used for this study program, as this cement
[31] is widely used in this country.. The physical and chemical requirement of 53
grade Ordinary Portland Cement as per IS 12269: 1987, is given in Table 3.1.
-
20
Since, different brands of cement have different strength development characteristics
and rheological behaviour in the compound compositions and fineness permitted in
IS: 12269, therefore cement from single supplier of same brand was used.
Table 3.1:Physical and chemical requirements of 53 grade OPC cement
Sl.no Test Conducted Results Requirements as per
IS:12269-1987(Ra1999)
1. Brand of cement Mahagold -
2. Type of cement 53 GradeOPC -
3. Normal Consistency 28.0% Not specified
4. Intial setting time 140 Minutes Shall not be less than
30 minutes
5. Final setting Time 225 Minutes Shall not be more than
600 minutes
6. Compressive strength:
(avg of three results)
3 days 44.6 Mpa Shall not be less than
27.0 Mpa
7 days 55.0 Mpa Shall not be less than
37.0 Mpa
28 days Awaited Shall not be less than
53.0 Mpa
7. FINENESS(by Blains
air permeability method)
326.0 m2/kg Shall not be less than
225.0 m2/kg
8. SOUNDNESS(by Le-
Chateliers method)
1.0 mm Shall not be more than
10 mm
9. Ratio of % of alumina to
that of iron oxide
1.22 Not less than 0.66
10. Insoluble Residue(%) 0.51 Not more than 3%
11. Magnesia(%) 1.11 Not more than 6%
12. Total loss on Ignition( %) 1.60 Not more than 4%
-
21
3.2.2 Fly Ash
The work done [33] on VTPS-fly ash has shown low reactivity and very less lime
content. The Vijayawada thermal Power station at Vijayawada has facilities of
collecting fly ash from hoppers in dry state with the help of electrostatic precipitator.
Fly ash collected from Vijayawada Thermal Power Plant at Vijayawada was a Class F
fly ash. It may also be noted that until very recent time, there has not been much
efforts in India to classify the dry-collected fly ash or to process the bulk collected dry
fly ash through separation of cenoshere, removal of carbon or further size reduction.
Fly ash was collected directly from hoppers in dry state with the help of electrostatic
precipitator are being used. From the previous study done on the same source of fly
ash [8,48], the following observations can be made.
Fly ash fulfil the criteria for lime reactivity specified in IS 3812-1981.
It was found that fly ash particles retained on 45 m sieve was very small (1.0-
1.5 percent) and 90 percent of particles have diameter between 17 and 20 m.
3.2.3 Sand
Natural River Sand was used which is locally available in Hyderabad region. The
specific gravity was found 2.57. Fineness Modulus is also determined using 10mm to
150 m and is found 2.972 as shown in Table 3.3. The fineness modulus gives the
idea about average size of particles in the fine aggregates. The value 2.972 indicates
medium size sand. The details of sieve analysis are presented in Table 3.2, and the
grading curve is shown in Figure 3.1. With sieve analysis data and fineness modulus
value, sand is considered as zone II grading sand of IS: 383 1970, which is
considered as good fine aggregate for concrete production. The grading limits of zone
II sand for fine aggregates as per IS: 383-1970 is also presented in Table 3.5.1, Table
3.5.2 for reference only.
-
22
GRADING OF FINE AND COURSE AGGREGATE
Table3.2: Sieve Analysis of Fine Aggregate
Weight Of sample: 2000gm
Fineness modulus = Cumulative %weight retained/100 =2972/100 =2.972
Grading Zone 11
Table: 3.3.1 Sieve Analysis of Coarse Aggregate (20mm) Weight of sample =5000gm
Fineness Modulus of Coarse Aggregate = 8.01
Sieve
Size
mm
Weight
Retained(gm)
% Weight
Retained
Cumulative %
Weight Retained
% Passing
40 0 0 0 100
20 0 0 0 100
10 0 0 0 100
4.75 36 1.80 1.80 98.20
2.36 150 7.50 9.30 90.70
1.18 560 28.0 37.30 62.70
600 476 23.80 61.10 38.90
300 554 27.70 88.80 11.20
150 202 10.10 98.90 1.10
L.P 22 1.10 100 0
Sieve
Size
mm
Weight
Retained(gm)
%
Weight
Retained
Cumulative %
Weight Retained
% Passing
40 0 0 0 100
20 310 6.20 6.20 93.80
12.5 4500 90.0 96.20 3.80
10 150 3.0 99.20 0.80
4.75 150 0.80 100 0
2.36 - - 100 0
1.18 - - 100 0
600 - - 100 0
300 - - 100 0
150 - - 100 0
-
23
Table 3.3.2: Sieve Analysis of Coarse Aggregate (12.5mm)
Weight of sample =5000gm
Sieve
Size
mm
Weight
Retained(gm)
% Weight
Retained
Cumulative %
Weight Retained
% Passing
20 0 0 0 100
12.5 50 1.0 1.0 99.0
10 1125 22.50 23.50 76.50
4.75 - - 100 0
2.36 - - 100 0
1.18 - - 100 0
600 - - 100 0
300 - - 100 0
150 - - 100 0
Fineness Modulus of Coarse Aggregate =6.245
Table 3.4: Combined Sieve Analysis Of 20mm And 12.5mmCoarse Aggregate
Table 3.5.1: Grading limits for Coarse Aggregates
IS Sieve
Designation
Percentage Passing for Single
Sized aggregate nominal size
(by weight)
Percentage Passing for graded
Aggregate of nominal size
(by weight)
20mm 12.5mm 10mm 20mm 12.5mm
20 85-
100
- - 95-100 100
12.5 - 85-100 100 - 90-100
10 0-20 0-45 85-100 25-55 40-85
4.75 0-5 0-10 0-20 0-10 0-10
2.36 - - 0-5 - -
Cumulative
Sieve size
(mm)
Cumulative
% Passing
20mm
Cumulative
% Passing
12.5mm
Cumulative %
Passing
When 20mm and
12.5mm are mixed
in 60:40 ratio
Requirements Of
Cumulative %
Passing for 20mm
graded aggregates
as per IS:383-
1970(RA2002)
40 100 100 100 100
20 93.80 100 96.30 95-100
12.5 3.80 99.0 41.90 --
10 0.80 76.50 31.30 25-55
4.75 0 0 0 0-10
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24
Table 3.5.2: Grading limits of Fine Aggregates IS: 383-1970
IS Sieve
Designation
Percentage Passing by Weight for
Grading-1 Grading-11 Grading-111 Grading-1V
10mm 100 100 100 100
4.75mm 90-100 90-100 90-100 95-100
2.36mm 60-95 75-100 85-100 95-100
1.18mm 30-70 55-90 75-100 90-100
600 micron 15-34 35-59 60-79 80-100
300 micron 5-20 8-30 12-40 15-50
150 micron 0-10 0-10 0-10 0-15
3.2.4 Coarse Aggregate
Crushed 20mm maximum size was used. The specific gravity was found 2.65
.The sieve analysis is presented in table 3.3.1,3.3.2. And the grading curve is shown in
figure 3.2 . This confirming to the grading requirement as per IS: 383-1970, Which is
suitable for good quality concrete [34] the fineness modulus is also determined and it
is found to be 6.48,Details are presented in Table 3.3
1.1
11.2
38.9
62.7
90.798.2
0
10
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5
IS Sieve Size (mm)
Perc
en
tag
e P
assin
g
Figure 3.1: Grading curve for fine aggregate
-
25
Grading curve for coarse aggregate
0
10
20
30
40
50
60
70
80
90
100
0 5 10 15 20 25
IS Sive Size (mm)
Pe
rce
nta
ge
pa
ss
ing
20
12.5
Graded
Figure 3.2: Grading curve for coarse aggregate
3.2.5 WATER
Ordinary tap water was used in the production of concrete.
3.2.6 SUPERPLASTISIZER
A High Range Water Reducing used was CONPLAST SP430 of FOSROC
CHEMICAL PVT. LTD. This super plasticiser is in dark brown colour, in an aqueous
solution. This is commercially available super plasticizer.
3.3 MIXTURE PROPORTIONING PROCEDURE
The basic steps involved in the Indian Standard method of concrete mix design can be
summarized as follows:
Step 1: Determination of Target Mean Strength or field strength
Target Mean Strength is determined as follows:
ft =fck + k s
Where ft = target mean compressive strength at 28 days,
fck = characteristics compressive strength at 28 days,
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26
k = a statical value depending upon the accepted portions of low results and
the number of tests,
s = assumed standard deviation,
Note: As per IS: 456-2000, the value of k is taken 1.65, assuming that characteristic
strength is expected to fall not more than 5 percent of test result. And value of s is
also taken from IS 456-2000 table 8, which is given for each grade of concrete. The
value of s for M20 and M25 is 4 MPa and 5 MPa for M30 and M35 grade of concrete.
Step2: Selection of water-cement ratio:
The water-cement ratio is chosen from table no. IS: 456-2000[36], which specify the
minimum cement content, maximum water cement ratio and minimum grade of
concrete for the different exposure conditions with Normal Weight Aggregates of 200
mm Nominal Maximum Size. The value selected is compared with available relations
in SP: 23-1982[35], for the determination of water-cement ratio for the target mean
compressive strength at 28 days.
It is noted here that water-cement ratio for the determined target mean compressive
strength at 28 days gives lower value than specified maximum value in table 5 of IS:
456-2000. Even curve-E, which is applicable for 53 grade of OPC, in figure 47 of SP:
23-1982[35], which consider 28 days compressive strength of cement, incorporated in
the mix proportions, also gives slightly lesser value of water-cement ratio.
Step 3: Estimation of mixing water
The approximate water content is selected from the table 35 and 38 of SP: 23-1982[],
applicable for normal concrete mix, which considers the aggregate type (whether
crushed or uncrushed), maximum size of the aggregate and required slumps as a
measure of level of workability.
Step 4: Estimation of air content
The estimated entrapped air content is taken (2%) from table No. 41 of SP: 23-1982[],
based on nominal maximum size of the aggregate.
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27
Step 5: Determination of cement content:
The cement content is calculated from the selected water-cement ratio and estimated
water content. The cement content so calculated is compared with the minimum
required cement content as per the durability consideration as stipulated in the IS:
456-2000[]. The greater of the two values is adopted. It is noted that the quantity
adopted is inclusive of the addition of part supplementary cementitious material to
OPC.
Step 6: Estimation of percentage of sand in total aggregates
The percentage of sand in total aggregates depends upon the grading of sand to be
incorporated in the mix. The general guideline is obtained from the figure 45 of SP:
23-1982[35], which is based on maximum size of coarse aggregates and the required
slump value targeted. It is to be noted that concrete with superplasticizers will have
different percentage of sand than concrete without super plasticizer for the same w/c
ratio.
Apart from the guidelines given in the figure 45 of the SP: 23-1982[35] for the
calculation of the percentage of sand in total aggregates, percentage of fine aggregates
is also seen in relation to the ratio of total fine contents (cement plus fly ash plus fine
aggregates) to total coarse aggregate content per m3
of mature. If it was not found in
the specified range then the percentage is adjusted accordingly. The ratio of total fines
to aggregates is a very important factor which influence the quality of concrete very
much, varies with the water-cement ratio of concrete for a given slump range values.
It is noted that that the water-cement ratio 0.46, 0.42 and 0.38 was kept for the
production of M20, M25,M30 and M35 concrete for slump range 80-120 mm in this
project work.
Step 7: Determination of fine and coarse aggregates
With the quantities of cement, fly ash, water and percentage of sand in total
aggregates already determined, the content of fine aggregates and coarse aggregates is
calculated from the following equations:
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28
V = [W + C/Sc + F/Sp + (1 / p) * (fa / Sfa)] x 1/1000 -(2) for FA
V = [W + C/Sc + F/Sp + {1 /(1- p)} * (Ca / Sca)] x 1/1000 -(3) for CA.
Where V = absolute volume of fresh concrete i.e. gross volume (1 m3) minus the
volume of entrapped air,
W = mass of water (kg) per m3 of the concrete,
C = mass of cement (kg) per m3 of the concrete,
Sc = specific gravity of cement,
F = mass of fly ash (kg) per m3 of the concrete,
Sp = specific gravity of fly ash,(2.16)
P = ratio of fine aggregate to total aggregates by absolute volume
fa = total mass of fine aggregates (kg) per m3 of the concrete,
Sfa = specific gravity of saturated surface dry fine aggregates,
Ca = total mass of coarse aggregates (kg) per m3 of the concrete,
Sca = specific gravity of saturated surface dry coarse aggregates.
Step 8: Adjustment of the trial mixture proportions
The trial mixture proportions were adjusted according to the following guidelines to
achieve targeted slump (as a measure of workability).
(A) Moisture content as a part of quality control during production of
concrete. It is necessary to provide moisture content correction to dry
batching. In this project work sand and coarse aggregate are dried in room
temperature after sufficient amount of water sprinkled on the aggregate to
avoid further absorption of water from the estimated mixing water
quantity. The same quality control was maintained for each batch of
concrete produced.
(B) Initial slump- If initial slump is not achieved in the desired range, then the
mixing water is adjusted so as to maintain water cement ratio same. With
a change in mixing water quantity, sand quantity is also adjusted
accordingly.
-
29
Step 9: Selection of Optimum mixture proportions
Once trial mixes have adjusted, test specimens i.e. 150 mm cubes are cast from the
concrete produced and finally from the strength tests result of the specimens, optimum
of proportioning of mixture is suggested.
3.4 CALCULATION OF MIX PROPORTIONS:
The target strength of the concrete is fixed based on the standard deviation.
Considering good degree of quality control on ingredients, batching, mixing,
placement, curing and testing of concrete, Standard deviation is assumed 4 N/mm2
for
M20 and M25 and 5 N/mm2 for M30 and M35.
Thus, Target Mean Strength is determined from the following relation, which is
already stated.
ft = fck + k s
ft = 20 + 1.65 * 4 = 26.60 N/mm2 for M20
ft =25 + 1.65 * 4 = 31.60 N/mm2 for M25
ft =30 + 1.65 * 5 = 38.25 N/mm2 for M30
ft =35 + 1.65 * 5 =43.25N/mm2 - for M35
The water-cement ratio is selected for each grade of concrete as per table no. 5 of IS:
456-2000.
Absolute volume method as discussed in previous paragraph was used to determine
the quantities of different ingredients. Preliminary trials of mix were carried out to
exactly determine unit water content, fine aggregates percentages and slump (as a
measure of workability) of the concrete for each batch corresponding to the three
grades viz, M20, M25 and M30 and M35.
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30
4 EXPERIMENT WORK
4.1 GENERAL
As discussed in previous chapters, the selection of materials, judicious mix
proportioning and proper workmanship (quality control) leads to high performance
concrete, which is required exhibit enhance strength and durability. In establishing
these requirements, careful consideration of properties of local available materials has
to be accounted for. Hence in this chapter main consideration is given to the planning,
material procurement, preparation of sample specimen, and finally testing them as per
IS code requirements.
4.2 PLANNING
In construction generally four mix (grades) are popular, which is M20, M25, M30 and
M35. So these four grades were chosen for experiments. Six variables of fly ash
replacement was taken which are control mix 0%, 15%, 20%, 25%, 30%, 35%
partially replacement of cement by fly ash. Study was carried out on both without
plasticiser and with-plasticiser Table 4.1 shows the nomenclature of different batches.
4.3 ESTIMATION OF REQUIRED MATERIAL:
Twenty four batches were to be made. Each batch would have 6 numbers of cubes.
According to above planning it was decided to cast 144 cubes. So after mix designing
quantity of material calculated taking account of 20% loses. Table 4.2 shows the
quantities of material required.
-
31
Table 4.1: Nomenclature of Different types of mix compositions
Cube
ID Cementetious Material
Grade of
concrete
W/(C +
F)
CM200 100 Percentage Cement M20 0.5
CF201 85 Percentage Cement + 15 Percentage Flyash M20 0.5
CF202 80 Percentage Cement + 20 Percentage Flyash M20 0.5
CF203 75 Percentage Cement + 25 Percentage Flyash M20 0.5
CF204 70 Percentage Cement + 30 Percentage Flyash M20 0.5
CF205 65 Percentage Cement + 35 Percentage Flyash M20 0.5
CM250 100 Percentage Cement M25 0.46
CF251 85 Percentage Cement + 15 Percentage Flyash M25 0.46
CF252 80 Percentage Cement + 20 Percentage Flyash M25 0.46
CF253 75 Percentage Cement + 25 Percentage Flyash M25 0.46
CF254 70 Percentage Cement + 30 Percentage Flyash M25 0.46
CF255 65 Percentage Cement + 35 Percentage Flyash M25 0.46
CM300 100 Percentage Cement M30 0.42
CF301 85 Percentage Cement + 15 Percentage Flyash M30 0.42
CF302 80 Percentage Cement + 20 Percentage Flyash M30 0.42
CF303 75 Percentage Cement + 25 Percentage Flyash M30 0.42
CF304 70 Percentage Cement + 30 Percentage Flyash M30 0.42
CF305 65 Percentage Cement + 35 Percentage Flyash M30 0.42
CM350 100 Percentage Cement M35 0.38
CF351 85 Percentage Cement + 15 Percentage Flyash M35 0.38
CF352 80 Percentage Cement + 20 Percentage Flyash M35 0.38
CF353 75 Percentage Cement + 25 Percentage Flyash M35 0.38
CF354 70 Percentage Cement + 30 Percentage Flyash M35 0.38
CF355 65 Percentage Cement + 35 Percentage Flyash M35 0.38
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40
Table No:4.2 Mixture Proportions for M20, M25 Grades of concrete
Note : FA- Fine aggregates, CA Coarse aggregates, Spl. Super plasticizer (in Kg/m3)
Cementitious Material
Mix No:
W/(C + F)
Quantities in Kg/m3 Water
S.Pl
Cement Flyash FA CA
100 % Cement CM200 0.5 315.00 0.00 759 1152 157.5 2.20
85 % Cement + 15 % Flyash CF201 0.5 267.75 47.25 752 1141 157.5 2.00
80 % Cement + 20 % Flyash CF202 0.5 252.00 63.00 750 1139 157.5 1.63
75 % Cement + 25 % Flyash CF203 0.5 236.25 78.75 747 1135 157.5 1.63
70 % Cement + 30 % Flyash CF204 0.5 220.50 94.50 745 1131 157.5 1.63
65 % Cement + 35 % Flyash CF205 0.5 204.75 110.25 742 1127 157.5 1.63
100 % Cement CM250 0.46 340.00 0.00 750 1139 156.4 2.30
85 % Cement + 15 % Flyash CF251 0.46 289.00 51.00 742 1127 156.4 2.20
80 % Cement + 20 % Flyash CF252 0.46 272.00 68.00 739 1123 156.4 2.20
75 % Cement + 25 % Flyash CF253 0.46 255.00 85.00 736 1118 156.4 2.20
70 % Cement + 30 % Flyash CF254 0.46 238.00 102.00 734 1114 156.4 2.20
65 % Cement + 35 % Flyash CF255 0.46 221.00 119.00 732 1111 156.4 2.10
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41
Table No: 4.3 Mixture Proportions for M20, M25 Grades of concrete
Cementitious Material Mix No: W/(C + F) Quantities in Kg/m
3
Water S.Pl
Cement Flyash FA CA
100 % Cement CM300 0.42 370.00 0.00 740 1124 155.4 2.88
85 % Cement + 15 % Flyash CF301 0.42 314.50 55.50 731 1110 155.4 2.64
80 % Cement + 20 % Flyash CF302 0.42 296.00 74.00 729 1106 155.4 2.64
75 % Cement + 25 % Flyash CF303 0.42 277.50 92.50 726 1102 155.4 2.64
70 % Cement + 30 % Flyash CF304 0.42 259.00 111.00 723 1098 155.4 2.40
65 % Cement + 35 % Flyash CF305 0.42 240.50 129.50 720 1094 155.4 2.40
100 % Cement CM350 0.38 400.00 0.00 730 1109 152 3.24
85 % Cement + 15 % Flyash CF351 0.38 340.00 60.00 721 1095 152 3.24
80 % Cement + 20 % Flyash CF352 0.38 320.00 80.00 718 1090 152 2.88
75 % Cement + 25 % Flyash CF353 0.38 300.00 100.00 715 1086 152 2.88
70 % Cement + 30 % Flyash CF354 0.38 280.00 120.00 712 1081 152 2.64
65 % Cement + 35 % Flyash CF355 0.38 260.00 140.00 709 1076 152 2.64
Note: FA- Fine aggregates, CA Coarse aggregates, Spl. Super plasticizer (in Liter/m3)
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42
4.4 PROCUREMENT OF MATERIAL
Fly ash was procured from VTPS. Ordinary Portland cement of grade 53 was used.
Locally available materials for fine and coarse aggregate ware used.
4.5 PRELIMINARY LABORATORY TESTS
The testing of physical properties such as sieve analysis, unit weight and fineness
modulus of fine and coarse aggregates were carried out in a standard manner. The
results are shown in Tables 3.3 as already mentioned, which were required in
designing mix of concrete.
4.6 PREPARATIONS AND CASTING OF TEST SPECIMEN
Water to binder (cement and fly ash) ratio was kept 0.50, 0.46, 0.42 & 0.38 for M20,
M25, M30 & M35 grade of concrete respectively.
Each grade of concrete having 0, 15, 20, 25, 30, 35 percentage part replacement of
Ordinary Portland cement to VTPS fly ash, with super plasticizers with same water
content for a given mix proportion.
4.7 MIXING PROCEDURE
The 20 mm coarse and fine aggregates were initially fed into the concrete mixer.
Cement, fly ash fed and then 10 mm size coarse aggregate fed. Superplasticizer is
well mixed in half water. Start the mixer for one minute to dry mix the aggregates and
binder, and then gradually half quantity of water is pored. While the mixer was in
operated condition, remaining water and superplasticizer mix added into the mixer.
The mixing time was 2.2 to 3.5 minutes (approximately) from the time when all the
mix ingredients had been charged into the mixer.
4.8 COMPACTION OF TEST SPECIMENS
Cubes were casted in three layers. For all specimens steel moulds were used.
-
43
4.9 SPECIMEN CONDITIONING AND TESTING
After casting, the specimens were stored for 24 h in the laboratory environment
(27 5 ) and then demoulded and stored in curing tank at room temperature till the
time of testing.
The compressive strength of the cubes was determined after 7 and 28 days of casting.
Table 4.4: Properties of hardened concrete (M20, M25 grades):-
Cementitious Material Mix No: W/(C + F) Compressive Strength
7- days 28- days
100 % Cement CM200 0.5 28.83 37.34
85 % Cement + 15 % Flyash CF201 0.5 25.84 36.90
80 % Cement + 20 % Flyash CF202 0.5 23.31 35.07
75 % Cement + 25 % Flyash CF203 0.5 20.27 33.25
70 % Cement + 30 % Flyash CF204 0.5 19.53 32.18
65 % Cement + 35 % Flyash CF205 0.5 17.83 29.05
100 % Cement CM250 0.46 28.12 51.58
85 % Cement + 15 % Flyash CF251 0.46 26.34 50.27
80 % Cement + 20 % Flyash CF252 0.46 25.38 47.01
75 % Cement + 25 % Flyash CF253 0.46 23.81 46.42
70 % Cement + 30 % Flyash CF254 0.46 21.74 43.59
65 % Cement + 35 % Flyash CF255 0.46 21.38 38.44
Note: 1. Test for compressive strength was carried out on 150x150x150mm cubes
2. Each value is average of three test results
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44
Table 4.5: Properties of hardened concrete (M30, M35 grades):-
Cementitious Material Mix No: W/(C + F) Compressive Strength
7- days 28- days
100 % Cement CM300 0.42 30.22 54.67
85 % Cement + 15 % Flyash CF301 0.42 27.7 52.61
80 % Cement + 20 % Flyash CF302 0.42 26.36 51.62
75 % Cement + 25 % Flyash CF303 0.42 25.69 47.31
70 % Cement + 30 % Flyash CF304 0.42 24.99 45.00
65 % Cement + 35 % Flyash CF305 0.42 24.32 42.86
100 % Cement CM350 0.38 36.93 57.83
85 % Cement + 15 % Flyash CF351 0.38 35.77 54.82
80 % Cement + 20 % Flyash CF352 0.38 34.06 53.40
75 % Cement + 25 % Flyash CF353 0.38 33.4 50.41
70 % Cement + 30 % Flyash CF354 0.38 29.92 48.76
65 % Cement + 35 % Flyash CF355 0.38 27.61 46.42
Note: 1. Test for compressive strength was carried out on 150x150x150mm cubes
2. Each value is average of three test results
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45
TEST RESULTS AND DISCUSSION
5.1 GENERAL
The results of all the tests carried out on VTPS fly ash mix concrete and control
concrete are presented and discussed in this chapter.
5.2 TEST RESULTS
First of all some basic tests like sieve analysis of fine and coarse aggregate were
conducted then fineness modulus is find out and compared with the table given in IS
code. For the graded mix coarse aggregate requirement 40%, 10 mm size aggregate
and 60%, 20 mm aggregate used. After this control concrete mix of M20, M25, M30 and
M35 were designed as per IS code provisions. The details of the mix designs are listed
in Table 4.2.
Twenty four samples of 6 cubes 150x150x150 size each (total 144 cubes) casted for
0%, 15%, 20%, 25%, 30%, 35% partially replacement of cement by fly ash with super
plasticizer and tested at 7th
and 28 days. The detail results of compression tests are
summarized in Table 4.4 and 4.5
5.2.1 PROPERTIES OF FRESH CONCRETE
Specific Gravity:
The specific gravity of VTPS fly ash was determined to be 2.16, which is much lower
than the specific gravity of cement (3.15). So partially replacement of cement by fly
ash reduces the density of concrete. Results are shown in Fig. 5.1
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46
Density variation with increase of Flyash
2330
2340
2350
2360
2370
2380
2390
2400
0 10 20 30 40
Percentage Flyash
De
ns
ity
Kg
/cu
m
M20
M25
Fig: 5.1.1 Density Vs Flyash Graph
Fig: 5.1.2 Density Vs Flyash Graph
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47
Slump and Vee Bee Time
The replacement of cement (by mass) with five percentage of fly ash (0%, 15%, 20%,
25%, 30%, 35%) increased the workability. For the economical consideration the SPL
dosage will be reduced due to increment of Flyash Percentage to maintain the slump
between 80 120 mm. This is due to the ball Bearing action of the spherical
particles of fly ash. Results are shown in Fig. 5.2. (a), 5.2 (b), 5.2 (c), 5.2 (d)
Fig. 5.2(a): Fly ash Vs Slump Graph
S l ump Gr a ph f or M 2 5 Gr a de c onc r e t e
80
90
100
110
120
130
0 5 10 15 20 25 30 35 40
Percentage Flyash
Slu
mp
(m
m)
with SP
Fig.5.2 (b): Fly ash Vs Slump Graph
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48
Slump Graph for M30 Grade concrete
70
80
90
100
110
120
130
0 5 10 15 20 25 30 35 40
Persentage Flyash
Slu
mp
(m
m)
w ith SP
Fig.5.2(c): Fly ash Vs Slump Graph
Slump Graph for M35 Grade concrete
70
80
90
100
110
120
130
0 5 10 15 20 25 30 35 40
Percentage Flyash
Slu
mp
(m
m)
w ith SP
Fig.5.2(c): Fly ash Vs Slump Graph
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49
5.2.2 PROPERTIES OF HARDENED CONCRETE:
7 Days compressive strength
The replacement of cement (by mass) with five percentage of fly ash (15%, 20%,
25%, 30%, 35%) content reduced the compressive strength of concrete (for M35
Grade) 3.14%,7.77%,9.55%,18.98%,25.23%respectively. This is probably due to
non-contribution in compressive strength of fly ash at early age. Results are shown in
Fig. 5.3.
28 days compressive strength
The replacement of cement (by mass) with five percentage of fly ash
(15%,20%,25%,30%,35%) content improves the strength gain but still reduced(for
M35 Grade) by 5.2%,7.66%,12.83%,15.68%, and 19.73% respectively with super
plasticizer. Fly ash starts reaction with Ca(OH)2 after 14 days. Results are listed in
Fig. 5.3 (a).
Compressive Strength of M20 Grade Concrete
0
5
10
15
20
25
30
35
40
0 5 10 15 20 25 30 35 40
Percentage of Flyash
Str
ength
in M
Pa
7 Days Strength
28 Days Strength
Fig. 5.3 (a): Variation in Compressive Strength with Fly ash Increase
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50
Compressive Strength of M25 Grade Concrete
15
20
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40
Percentage of Flyash
Str
ength
in M
Pa
7 Days Strength
28 Days Strength
Fig. 5.3 (b): Variation in Compressive Strength with Fly ash Increase
Compressive Strength of M30 Grade Concrete
20
25
30
35
40
45
50
55
60
0 5 10 15 20 25 30 35 40
Percentage of Flyash
Str
en
gth
in
Mp
a
7 Days Strength
28 Days Strength
Fig. 5.3(c): Variation in Compressive Strength with Fly ash Increase
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51
Compressive Strength of M35 Grade Concrete
20
25
30
35
40
45
50
55
60
0 5 10 15 20 25 30 35 40
Percentage of flyash
Str
ength
in M
Pa
7 Days Strength
28 Days Strength
Fig. 5.3(d): Variation in Compressive Strength with Fly ash Increase
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52
56 days compressive strength (Imaginary graphical representation)
The replacement of cement (by mass) with five percentage of fly ash
(15%,20%,25%,30%,35%) content of (ex:for M35 grade) concrete given strength
almost equal to control mix. This shows that fly ash reaction continues for longer time
up to 90 days or more. Results are listed in Fig. 5.3 (e).
Compressive Strength of M35 Grade Concrete
20
30
40
50
60
70
0 5 10 15 20 25 30 35 40
Percentage of Flyash
Str
ength
MP
a:
7 Days Strength
28 Days Strength
56 Days Strength
Fig. 5.3(e): Variation in Compressive Strength with Fly ash Increase
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53
4.2.6.1.1.1 CONCLUSIONS
In this chapter conclusions of the so far done study/Experimental work of this project
are given. Following conclusions are given from the present study:
VTPS Fly ash (class F) incorporation in the mix ingredient enhances
performance of concrete by improving workability, flow-ability, finishibility
and compactibility in fresh state of concrete in both plasticizerised as well as
unplasticizeried concrete.
Increasing fly ash content decreases the strength. Although the strength of
High Fly ash Concrete (HFC) is very poor at early curing age, it develops
rapidly with longer curing age, resulting in long-term strength almost equal to
that of control mix (with no fly ash).
By the analysis fly ash effect in HFC becomes positive after 7 days of curing
age, and it develops rapidly. The contribution of fly ash in HFC with 56-day
curing age to strength is equal or approaches 80%, and is more remarkable
compressive strength.
Finally, cement contribution to strength of HFC can be divided into two
aspects. The first is through the hydrated products produced in the hydration
of itself, and the second is the fly ash effect activated by it. At early curing
age, the former is the dominant factor, while the latter is more significant
afterward. After 56 days, the contribution of fly ash effect to strength of HFC
approaches 80%.
Incorporating fly ash by high content and super-substituting method makes
HFC easier to compact, and together with the amount of crystal phase
Ca(OH)2 and harmful pore reduction, HFC at long-term curing age becomes
dense and homogeneous.
With the current data and results, it is very possible to design a mix with
VTPS fly ash as supplementary material in concrete that will be more durable
and economical.
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54
5
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