CHAPTER-1

INTRODUCTION
1.1 GENERAL:
Cementitious materials in the form of mortars or concretes are very useful as
construction material as they are cheap, durable and have adequate compressive
strength and stiffness for structural use. The infrastructure needs of our country is
increasing day by day and with concrete is a main constituent of construction material
in a significant portion of this infra-structural system, it is necessary to enhance its
characteristics by means of strength and durability. It is also reasonable to compensate
concrete in the form of using waste materials and saves in cost by the use of admixtures
such as fly ash, silica fume, etc. as partial replacement of cement. One of the many
ways this could be achieved by developing new concrete composites with the fibres
which are locally available that makes even non-engineered construction can work well
under severe loads like earthquakes or man-induced attacks.

Concrete is the key material used in various types of construction, from the
flooring of a hut to a multi storeyed high rise structure from pathway to an airport
runway, from an underground tunnel and deep sea platform to high-rise chimneys and
TV Towers. In the last millennium concrete has demanding requirements both in terms
of technical performance and economy while greatly varying from architectural
masterpieces to the simplest of utilities. It is the most widely used construction
materials. It is difficult to point out another material of construction which is as versatile
as concrete.

Concrete is one of the versatile heterogeneous materials, civil engineering has

ever known. With the advent of concrete civil engineering has touched highest peak of
technology. Concrete is a material with which any shape can be cast and with equal
strength or rather more strength than the conventional building stones. It is the material
of choice where strength, performance, durability, impermeability, fire resistance and
abrasion resistance are required.

Cement concrete is one of the seemingly simple but actually complex materials.
The properties of concrete mainly depend on the constituents used in concrete making.
The main important material used in making concrete are cement, sand, crushed stone

1
and water. Even though the manufacturer guarantees the quality of cement it is difficult
to produce a fault proof concrete. It is because of the fact that the building material is
concrete and not only cement. The properties of sand, crushed stone and water, if not
used as specified, cause considerable trouble in concrete.

1.2. AIM OF THE PRESENT STUDY:

The aim of our project is to study the compressive strength, split tensile
strength, flexural strength of concrete mix M30 grade, with a partial replacement of
cement with Fly ash and coarse aggregate with crushed tiles in different aspect ratio.

1.3 OBJECTIVES OF THE WORK

The main objectives of present investigation are as listed below.

1. To study the mechanical properties of the materials used in this work.
2. Optimum replacement of ceramic waste in coarse aggregate.

1.4 SCOPE OF THE WORK

The main scope of present experimental investigation is to study the

mechanical properties of concrete with fly ash and ceramic waste as partial
replacement of cement and fine aggregate. The ultimate goal is to find the optimum
mix proportion which also satisfy the strength parameters. In present investigation
cement is partially replaced with fly ash in 10%,20% and 30%. The ceramic waste
was replaced when optimum strength attained with fly ash and tiles were replaced
in 10%,20% and 30% as coarse aggregate. The results obtained are compared with
conventional concrete.

Using the techniques implemented in the study we can preserve the natural
resources for the future generations and reduce landfills due to waste.

2
 CHAPTER-2

LITERATURE REVIEW

Experimental study of partial replacement of cement with fly ash and partial
replacement of coarse aggregate with crushed tiles was carried out by several authors
earlier some of the investigations are presented below.

Aman Jatale, Karthikeya Tiwari, Sahil Khandelwal “Effects on Compressive

Strength When Cement Is Partially Replaced By Fly-Ash” India has a vast resource
of fly ash generation all across the country. This material if segregated, collected and
used properly can solve the major problems of fly ash disposal and reducing the use of
cement, which consumes lot of energy and natural resources. Especially in India many
organizations are putting their efforts to promote the awareness of fly ash concrete and
its advantages. To study the effect of partial replacement of cement by fly ash, studies
have been conducted on concrete mixes with 20%,40%,60% replacement levels. The
mixing grades are M15, M20, M25 with different percentages of fly ash can be directly
designed. In this paper the effect of fly ash on workability, setting time, density, air
content, compressive strength, modulus of elasticity are studied. The experimental
exercise has helped to study various properties of fly ash concrete and to develop the
mix design curves for concrete mix proportioning with various percentages of fly ash.

Vikas Rajora, Hitesh Bansal, Gurutej Singh Sidhu “Effect of Partial

Replacement of Fine and Coarse Aggregate (10mm) with Marble Waste on the
Properties of Concrete”. Concrete is a heterogeneous mixture of binding material
(cement or lime), coarse aggregates, fine aggregates (sand) and water. Fine and coarse
aggregates are obtained from quarrying of large rocks. This has brought up with a great
destruction to the environment. And further the disposal of the huge amount of
demolition waste was another problem. The objective of this research is to study the
utilization of marble waste as a partial replacement of fine and coarse aggregates in
concrete.

3
 P.R.Wankhede, V.A.Fulari “Effect of Fly Ash on Properties of Concrete”
The Effect of Fly Ash on Properties of Concrete. In the present study use of fly ash in
concrete imparts several environmental benefits and thus it is eco friendly. It saves the
cement required for the same strength thus saving of raw materials such as limestone,
coal etc required for manufacture of cement. Fly ash is pozzolanic material and it
improving the properties of concrete like compressive strength and durability. The
results obtained are discussed and compared with the available literature.

Amit kumar, D.Raval, Dr.Indrajit N. Patel, Prof. Jayeshkumar Pitroda has

discussed about “Ceramic waste : effective replacement of cement for establishing
sustainable concrete” Ceramic waste is one of the most active research areas that
encompass a number of disciplines including civil engineering and construction
materials. Ceramic waste powder is settled by sedimentation and then dumped away
which results in environmental pollution, in addition to forming dust in summer and
threatening both agriculture and public health. Therefore, utilization of the ceramic
waste powder in various industrial sectors especially in the construction industries
would help to protect the environment. It is most essential to develop eco friendly
concrete from ceramic waste. In this research study the (OPC) cement has been replaced
by ceramic waste powder accordingly in the range of 0%, 10%, 20%, 30% 40%, & 50%
by weight of M-20 grade concrete. Concrete mixtures were produced, tested and
compared in terms of compressive strength to the conventional concrete. These tests
were carried out to evaluate the mechanical properties for 7 and 28 days. Keeping all
this view, the aim of the investigation is to study the behaviour of concrete while
replacing the ceramic waste with different proportions in concrete.

4
 CHAPTER 3
EXPERIMENTAL PROGRAMME

3.1 DESCRIPTION OF MATERIALS

The materials used in the preparation of concrete are:
1. Cement
2. Fly ash
3. Fine aggregate
4. Crushed tiles
5. Coarse aggregate
The properties and specifications of various materials used in the preparation of
test specimens are as follows.

3.2 CEMENTITIOUS MATERIALS

3.2.1 Cement
Cement is the main ingredient in manufacturing of concrete. Cement can
be defined as a bonding material that has cohesive & adhesive properties which
makes it capable to unite with different construction materials in forming a
compacted material. The cement is fresh and of uniform colour, consistency and
free from lumps and foreign matter. The characteristics like strength and bonding
will be greatly affected by changing the cement content. The cement used for the
experimental work was Ordinary Portland Cement (OPC) confirming to IS: 12269-
2013. The cement used in this experimental work is of brand ―NAGARJUNA 53
grade. The tests on cement are conducted as per IS: 4031- 1988. The results of the
tests on cement are listed in Table 3.5. Fig. 3.1 shows the cement used in present
experimental investigation. The quantity required for this research work is
estimated and the entire quantity is purchased and stored properly in casting store
ward.

5
 Fig-3.1 Cement

Table 3.1 Chemical composition of cement

S.No Major Components Cement

01 Silicon Dioxide SiO2 20.0%
02 Aluminium Oxide Al2O3 4.90%
03 Ferric Oxide Fe2O3 2.30%
04 Calcium Oxide CaO 65.0%
05 Magnesium Oxide MgO 3.10%
06 Sodium Oxide Na2O 0.20%
07 Potassium Oxide K2O 0.40%
08 Sulphur Oxide SO3 2.30%
09 Titanium Oxide TiO2 -
10 Loss of ignition 2.4%

3.3 FLY ASH:

Conservation of natural resource is the need of the hour throughout the world.
Steps are to be adopted in this direction which, include minimization of production of
energy consuming materials & bulk utilization of industrial by-products, thereby
making a major contribution towards solving the global warming problem and also by
bringing down the levels of environmental pollution. It is found that use of high
volumes of Fly ash, is the most effective and economical way to improve the durability
of concrete.

6
 Fig-3.2 fly ash

3.3.1 Classification of Fly ash

ASTM-C 618-93 categories natural pozzolans and Fly ash into the following categories.

Class N Fly ash: Raw or calcined natural pozzolans such as some diatomaceous
earths, stuffs volcanic ashes and pumice are come are come in this category. Calcined
kaolin clay and laterite shale also fall in this category of pozzolans.

Class F Fly ash: Fly ash normally produced from burning anthracite or
bituminous coal falls in this category. This class of Fly ash exhibits pozzolanic property
but rarely if any, self-hardening property.

Class C Fly ash: Fly ash normally produced from lignite or sub-bituminous
coal is the only material included in this category. This class of Fly ash has both
pozzolanic and varying degree of self cementitious properties. (Most class C Fly ashes
contains more than 15% CaO. But some class C Fly ash may contain as little as 10%
CaO.

7
Table No: 3.2 Requirements of Fly ash

Class Mineral admixture

Requirements A B C

Chemical requirements

Sio2 +Al2O3+Fe2O3 min % 70.0 70.0 70.0

SO3 max % 4.0 5.0 5.0

Moisture content max % 3.0 3.0 3.0

Loss on ignition max % 10.0 10.0 10.0

Physical Requirements

Amount retained when wet sieved on 45 34 34 34

µm sieve max %

Pozzolonic activity index with Portland 75 75 75

Cement at 28days min % of control

Pozzolonic activity index with lime at 5.5 5.5 -

7days min (Mpa)

Water requirement max % of control 115 105 105

Autoclave expansion or contraction 0.8 0.8 0.8

max%

Specific gravity max variation from 5 5 5

average %

Percentage retained on 45µm sieve max 5 5 5

variation

8
3.3.2 Composition of Fly Ash

Traditionally, the composition of fly ash is expressed in terms of oxide

composition, through the constituents are not strictly present in the form of oxides. The
typical composition of Indian fly ash is shown in table

The temperature in a pulverized fuel boiler would be around 1400˚C and the
fuel gas velocity is such that to remove the ash particles rapidly out of the boiler. Due
to this reaction with Ca(OH)2 and hence the pozzolonic activity of fly ash.

Table 3.3 Typical Composition of Fly Ash and Cement

Constituents Indian fly ash Cement

SiO2 49-67 17-25

Al2O3 16-33 3-8

Fe2O3 4-10 0.2-6

MgO 0.2-2.0 0.5-4

SO3 0.1-2.0 1-2

Na2O 0.1-0.2 0.5

K2 O 0.1-1.0 0.5

LOI 0.1-1.6 1-3

3.3.3. Physical Properties:

a) Fineness

Fineness is one of the primary characteristics of Fly ash that relates to its
pozzolanic activity. A large fraction of ash particles is smaller than 3µmin size. In
bituminous ashes, the particle sizes range from less than 1 to over 100µm. The average
size lies in the range of 7 to 12µm.

9
 b) Specific gravity

The specific gravity of Fly ash is related to shape as well as chemical

composition of particles. Specific gravity of Fly ash usually varies from 1.3 to 4.8. coal
particles with some mineral impurities have specific gravity between 1.3 to 1.6. opaque
spherical magnetite (ferrite spinal) and hematite particles, light brown to black in
colour, when present in sufficient quantity in Fly ash increases the specific gravity

3.3.4. Mineralogical Characteristics:

a) Anhydrite (CaSo4)

It forms from reaction of CaO, SO2 and O2 in the furnace or fuel. The amount
of anhydrite increases with the increasing SO3 and CaO contents in the ash. Anhydrite
is a characteristics phase in high calcium class C Fly ashes. For most ashes, only about
half of the SO3 is present as anhydrite.

b) Magnetite and Hematite

There is at least a small amount from 0.1 to 1% of iron present as hematite in

almost all types of Fly ashes. High calcium C Fly ashes have however less amount of
hematite as well as total Fe2O3.

c) Tri calcium Aluminate (3CaO, Al2O3)

High calcium class C Fly ashes invariably contain tri-calcium aluminate with
its relative content increasing with an increase of CaO content of ash. Sometimes
intermediate calcium ashes with CaO content of 8 to 15% have also been found to
contain this compound

3.3.5. Reaction Mechanism of Fly ash

Reaction mechanism for Fly ash can be basically explained as pozzolanic

reaction mechanism Fly ash is considered to be a Pozzolanic. Pozzolans are materials
which, though not cementitious in themselves, contain certain constituents, which at
ordinary temperatures in the presence of water, will combine with lime to form stable
insoluble compounds with cementitious properties.

10
 It is a well-known fact that the reaction of Fly ash in concrete with Portland
cement under ambient conditions is initiated only after one or more weeks. In this
“dormant” period the Fly ash behaves as a more or less inert material and serves as a
precipitation nucleus for lime for lime {Ca(OH) 2} and calcium-silicate hydrate-gel
originating from the cement hydration. The subsequent pozzolanic reaction appears to
be a slow process.

Fly ash from bituminous coal consists of a major part of glass phase with
crystallization inclusions, the glass being an alumina-silica-glass. The pozzolanic
reaction starts when the glass of the Fly ash particles dissolves. The formation of C-S-
H gel takes place when the glass of the Fly ash particles has gone into the solution. The
decomposition of the glass network appears to be strongly dependent on the alkalinity
of pore water. The glass structure of the Fly ash is only decomposed substantially
beyond a pH of about 13.2 or 13.3.

In the beginning of cement hydration, the composition of the pore water

is dominated by a saturated lime solution with gypsum. The pH of the pore solution is
lower than 13. After about one week the pH increases. The lime and sulphate

concentration decreases to very low level and concentration of hydroxyl, potassium and
sodium ions increase rapidly. This may be due to the following reasons.

The Fly ash may act as nucleus for lime precipitation so that cement reaction is
accelerated. Fly ash itself may contribute to the alkalinity. The later could be due to the
release of sodium and potassium ions from the surface Fly ash particles.

However, after some months of hardening, the pore water cement shows a
gradual decrease in the pH, which means that the reaction rate of Fly ash decreases with
time. The deceleration of Fly ash reaction is augmented by the decreasing permeability
of the concrete caused by the decreasing mobility of the ions during the densification
of the pores.

11
3.3.6 Factors Influencing the Fly Ash Reactions

a) Cement:

Rapid hardening cements develop high alkalinity faster than ordinary cements.
Consequently, Fly ash reaction starts earlier. Similarly, different cements effect
accordingly.

b) Temperature:

Development of hydroxyl concentration appears to be much slower at 2oC. At

400C the pH reaches a high value within one day of hydration so that the reaction of
Fly ash can start from the first day. Temperature also affects the reactivity of Fly ash
itself. That means at a higher temperature the reaction will be initiated at lower
alkalinity.

c) Water Cement Ratio:

There is a strong relation between Fly ash activity and water/cement ratio.
Higher the W/C ratio, lower the alkalinity and slower the reaction

3.3.7. Proportioning of Fly ash Concretes:

Using of Fly ash in concrete has to meet one or more of the following objectives.

 Reduction in cement content,

 Reduced heat of hydration,
 Improved workability and
 Gaining levels of strength in concrete beyond 90 days of testing
 Fly ash is introduced into concrete by one of the following methods.
 Cement containing Fly ash may be used in place of OPC.
 Fly ash is introduced as an additional component at the time of mixing.

The first method is simple and problems of mixing additional materials are not
there, there by uniform control is assured. The proportions of Fly ash and cement are
predetermined, and mix proportion is limited.

The second method allows for more use of Fly ash as component of concrete.
Fly ash plays many roles such as, in freshly mixed concrete, it acts as a fine aggregate

12
and also reduces water cement ratio in hardened state, because of its pozzolanic nature,
it becomes a part of the cementitious matrix and influences the strength and durability.

The assumptions made in selecting an approach to mix proportioning Fly ash

concrete are

1. It reduces the strength of concrete at early ages.

2. For same workability, concrete containing Fly ash requires less water than
concrete containing ordinary Portland cement

The basic approaches that are generally used for mix proportioning are

1. Partial Replacement of cement,

2. Addition of Fly ash as fine aggregates and
3. Partial replacement of cement, fine aggregate and water

In the first approach, there is direct replacement of cement by Fly ash. Replacement
of cement by Fly ash (either by volume or by mass basis), results in lower in
compressive and flexural strength up to 90 days of moist curing and develops greater
strengths beyond 180 days of curing. At early ages, Fly ash exhibits very little
cementing effects and acts as a fine aggregate, but at later ages cementing activity
becomes apparent and its contribution in the development of strength is observed.

In the second approach, Fly ash is added to the mix without a reduction in the
quantity of cement used. The cementitious content of the concrete is enhanced for long
periods of moist curing.

In the third approach, proportioning of Fly ash concrete requires a part of

cement to be replaced by an excess mass of Fly ash with necessary adjustments in fine
aggregate and water content.

3.3.8. Application of Fly ash:

Fly ash is highly recommended for mass concrete applications, i.e. large mat
foundations, dam etc. The Hungry Horse dam, Conyan ferry dam and the Wilson dam,
Hart well dam and sultan dam in USA, the Lednock dam in UK and sudagindam in
Japan are few examples abroad. LUI center in Vancouver successfully used 50% Fly

13
ash for all structural elements. In India, some portions of Rihand dam in UP and some
part of barrages in Bihar are some examples.

Fly ash can be used for the following

 Filling of mines,
 Replacement of low lying waste land and refuse dumps,
 Replacement of cement mortar,
 Air pollution control,
 Production of ready mix Fly ash concrete,
 Laying of roads and construction of embankments,
 Stabilizing soil for road construction using lime-Fly ash mixture.
 Construction of rigid pavements using cement-Fly ash concrete,
 Production of lime-Fly ash cellular concrete,
 Production of precast Fly ash concrete building units,
 Production of sintered Fly ash light we9ght aggregate and concrete and
 Making of lean-cement Fly ash concrete

3.3.9 Crushed Tiles:

Crushed tile is an industrial waste that causes environmental pollution. Therefore

the possible utilization of this material would reduce environmental pollution. The
utilization of crushed tile as a coarse aggregate in concrete would have a positive effect
on the economy. In concrete production, Portland cement, river sand, 4-32 mm in size
crushed stone and crushed tile as coarse aggregates in the replacement ratio of 0, 50
and 100 % were used. Mechanical and physical tests were conducted on specimens.
The strength and unit weight of crushed tile aggregate concrete were decreased
compared to the control concrete.

Absorption and capillarity coefficients were increased compared to the control

concrete. The amount of tile waste on earth is enough for use as an aggregate in
concrete. Tile is produced from natural materials sintered at high temperatures. There
are no harmful chemicals in tile. Waste tiles cause only the apparition of pollution. How
ever some parts of tiles are used in as flooring and also flooring in tennis courts,
walkways, cycling paths and gardens as a ground material. Therefore waste tiles are

14
stored in factory fields because of their economical value. Nevertheless, each year
approximately 250,000 tons of tiles are worn out, while 100 million tiles are used for
repairs. These waste materials can be recycled to save money. Crushed tile aggregate,
CTA, is a material especially proposed for the buildings constructed in hot climates.
The unit weight of concrete is decreased with use of the CTA compared to the control
concrete. In previous investigations CTA was examined and no noteworthy negative
effects on the strength of the concrete were found. The weakest bonds were between
CTA and mortar, therefore failure occurred in this surface. The strength of concrete was
increased with the addition of minerals and chemical waste. The use of CTA decreases
costs and it also supports environmental health. The other investigation examined the
utilization of rubble as an aggregate in concrete. According to this investigation an
increase in the stone ratio of rubble decreased the mechanical strength of concrete. The
use of crushed concrete as an aggregate caused drying shrinkage, decreased resistance
to abrasion and changed water absorption. The elasticity modulus of concrete produced
with CTA rubble was 70 % of the elasticity modulus of the control concrete. Both the
compressive and tensile strengths of the CTA added concrete were higher, but the
drying shrinkage was lower. The inclination of the curve in the ascending part of the
strain deformation diagrams was smaller and also deformation was higher compared to
the normal concrete due to compressive strength.

compressive strength, tensile strength and flexural strength of CTA concrete were
0.93, 1.02 and 1.15, respectively. In this study, CTA was replaced by crushed stone to
produce concrete specimens. Thereafter, the strength of the concrete was examined by
conducting mechanical and physical tests.

Fig-3.3 crushed tiles

15
3.4 TESTS ON CEMENT
3.4.1 Specific Gravity of Cement:
Specific gravity is one of the most important factors in the mix design. One can
make mix design only after knowing the specific gravities of each constituent. For
calculating the specific gravity of cement, Le-chatlier‘s flask method is used. In
this cement is tested by using kerosene. The test procedure is as follows and the
tested cement specific gravity is of 3.12.

 First empty weight of flask will be noted as W1.

 Then the flask is filled up to one third with cement and weight is noted as
W2.
 Then the remaining part of flask is filled with kerosene and weight is
noted down as W3.
 Then whole material is taken out and filled with only kerosene and weight
is noted as W4.
 Now the specific gravity of cement is calculated by using formula:

w2 −w1
Specific Gravity of cement = (w × Gk=3.12
2 −w1 )−(w3 −w4 )

Where Gk = 0.78 is specific gravity of kerosene.

3.4.2 Standard consistency test:

Normal consistency test is conducted as per IS 4031 (part 4) – 1988. The
main purpose of conducting normal consistency is to find the amount of water to
be added for producing cement paste of standard consistency. Vicat apparatus is
generally used for this test and is confirming to IS 5513 – 1976. For finding out
the initial setting time, final setting time, soundness and strength a parameter called
standard consistency has to be used. The standard consistency of a cement paste is
defined as that consistency which will permit a vicat plunger having 10 mm
diameter and 50 mm length to penetrate to a depth of 33 to 35 mm from the top of
the mould. The apparatus is called vicat plunger. This apparatus is used to find out
the percentage of water required to produce a cement paste of standard consistency.
The standard consistency of cement paste is also called as normal consistency.

16
 It is pertinent at this stage to describe the procedure of conducting standard
consistency test. The following procedure is adopted to find out the standard
consistency.

 Take about 500 grams of cement and prepare a paste with a weighed
quantity of water (say 24 percent by weight of cement).
 The paste must be prepared in a standard manner and filled into the vicat
mould within 3 to 5 minutes.
 After completely filling the mould, shake the mould to expel air.
 A standard plunger, 10 mm diameter and 50 mm long is attached and bought
down to touch the surface of the paste in the test block and quickly released
allowing it to sink into the paste by its own weight. Find the depth of
penetration.
 Similarly conduct trails with higher and higher water cement ratio till such
time the plunger penetrates for a depth of 33 to 35 mm from the top.
 That particular amount of water which allows the plunger to penetrate only
to a depth of 33 to 35 mm from the top.

 This percentage is usually denoted as ―P.

 The consistency of cement=31mm

3.4.3 Fineness of Cement:

The fineness of cement has an important bearing on the rate of hydration
and hence on the rate of gain of strength and also on the rate of evolution of heat.
Finer cement offers a greater surface area for hydration and hence faster the
development of strength. Different cements are ground to different fineness. The
fineness of cement is tested in two ways. One is sieve test and another is air
permeability test. In present work fineness of cement is calculated by sieve method.
The test procedure is as follows:

 Weigh correctly 100 grams of cement and take it on a standard IS sieve no.
9 (90 microns).
 Break down the air set lumps in the sample with fingers.
 Continuously sieve the sample by giving horizontal and vertical motion for
a period of 15 minutes.

17
  Weigh the residue left on the sieve.
 The weight shall not exceed 10% for ordinary Portland cement.
 The fineness of cement=8%

3.4.4 Initial and Final Setting Time:

An arbitrary division has been made for the setting time of cement as Initial
and Final setting time. It is difficult to draw a rigid line between these two arbitrary
divisions. For convenience, initial setting time is regarded as the time elapsed
between the moment that the water is added to the cement, to the time that the paste
starts losing its plasticity and has attained sufficient firmness to resist certain
definite pressure. This test is confirming to IS 4031 Part 5. In this test we use Vicat
apparatus.

The procedure for performing initial setting time is as follows:

 Lower the needle gently and bring it in contact with the surface of the test
block and release quickly.
 Allow it to penetrate in to the test block.
 In the beginning the needle will completely immerse through the test block.
 But after some time when the paste starts losing its plasticity, the needle
may penetrate only to a depth of 33 – 35 mm from the top.
 The time elapsed between the time when water is added to the cement and
the time at which the needle penetrates the test block to a depth of 33 – 35
mm from the top is taken as initial setting time.
The procedure for performing final setting time is as follows:
 Replace the needle of the vicat apparatus by a circular attachment.
 The cement shall be considered as finally set when, upon, lowering the
attachment gently cover the surface of the test block, the center needle
makes an impression, while the circular cutting edge of the attachment fails
to do so.
 The time taken for final set is noted as final setting time.

 The initial setting time of cement=33 minutes

 Final setting time=10 hours

18
 PHYSICAL PROPERTIES OF PORTLAND CEMENT 53 GRADE
Table 3.4 Test Results on Cement:
S.No Particulars of tests Test Requirements as per IS
Results codes
1 Standard consistency 24% IS 4031-1988 (Part-4)
2 Fineness 8%
3 Specific gravity 3.12
4 Setting time
(a)Initial 33 minutes As per 12269-2013 30
min. Minimum
(b)Final >10 As per 12269-2013 600
min. Maximum

3.4.5 Compressive Strength of Cement:

Preparation of test specimen for each cube, take the quantities of materials (1:3)
as follows
Cement = 185gm
Standard sand = 555gm
Water = (P/4 + 3.0) percent of combined weight of cement and sand.
Mix the cement and sand with towel on non-porous plate for one minute. Then
add water to the mixture of cement, sand and mix until the mixture of uniform color is
obtained. The time of gauging shall be in any case not be less than 3 minutes and not
more than 5 minutes, gauging time is time lapped between the water added to the mix
and casting of cubes.
Apply thin layer of oil to the interior faces of mould. Place it on the table of
vibration machine, and firmly hold in position by means of clamps. Place the entire
quantity of mortar in the hopper of the cube mould and compact the same by vibrations
for period of about 2 minutes. At the end of vibration, remove the mould together with
base plate from the machine and finish the top surface of cube in the mould by
smoothing the surface with the blade of trowel. Engrave identification mark in cubes.
Keep the filled moulds in the atmosphere of at least 90% relative humility chamber,
after completion of vibration. Also maintain temperature at 27+ 20c. At end of this
period, remove cubes from moulds and immediately submerge in clean fresh water and
keep there until taken out just prior to breaking. After they are taken out and until they
are broken, the cubes shall not allow to become dry.

19
Procedure for Testing:
Place the test cube on the platform of compression testing machine without any
packing. Between cube and steel plates of the testing machine apply the load on smooth
surface on the cube steadily & uniform starting from zero at a rate of 35N/mm2 / minute
till cubes fails. Test three such cubes at the end of seven days of curing. Three cubes
at end of fourteen days of curing and if needed three cubes after 28 days of curing.
Record the crushing load. Calculate the compressive load by strength of each cube by
dividing crushing load by crushing area of cube. The compressive strength shall be
average of the strength of three cubes for each period of curing.

3.5 FINE AGGREGATE

Aggregates of size ranges between 0.075mm – 4.75mm are generally considered
as fine aggregate. The sand particles are free from any clay or inorganic materials and
found to be hard and durable. It was stored in open space free from dust and water. The
fine aggregate used in the present experimental program is river sand confirming to
zone-II as per IS 383:1970. It is clean and free from organic matter, silt and clay. The
physical properties of sand.

3.5.1 River sand

It is also called as natural sand. In this work a good quality of natural sand was used.
The sand is medium sand and is confirming to Zone-II as per standard specifications.

Fig-3.4 Fine Aggregate

3.5.2 TESTS ON FINE AGGREGATE

Tests on aggregate are confirming to IS 383 specifications. The detailed test
reports are tabulated as follows.

20
3.5.2.1 Sieve Analysis of Fine Aggregates
The procedure adopted for conducting sieve analysis is as follows:
 A gradation test is performed on a sample of aggregate in a laboratory. A
typical sieve analysis involves a nested column of sieves with wire mesh
cloth (screen).

 A representative weighed sample is poured into the top sieve which has the
largest screen openings. Each lower sieve in the column has smaller
openings than the one above. At the base is a round pan, called the receiver.

 The column is typically placed in a mechanical shaker. The shaker shakes

the column, usually for some fixed amount of time.

 After the shaking is complete the material on each sieve is weighed.

 The weight of the sample of each sieve is then divided by the total weight
to give a percentage retained on each sieve.

 The size of the average particle on each sieve is then analysed to get a cut-
off point or specific size range, which is then captured on a screen.

 The results of this test are provided in graphical form to identify the type of
gradation of the aggregate.

Natural Sand:
Sieve analysis helpful in determining the particle size distribution of the
aggregates gradation of fine aggregate. It is confirming to IS 2386 – 1963 part 1
and IS 383 – 1970

21
Table 3.5. Grading limits of fine aggregate in sieve analysis (As per IS 383 –
1970)
Percentage passing
I.S sieve size Zone I Zone II Zone III Zone IV
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 50 – 90 75 – 100 90 – 100
600 µ 15 – 34 35 – 59 60 – 79 80 – 100
300 µ 5 – 20 8 – 30 12 – 40 15 – 50
150 µ 0 – 10 0 – 10 0 – 10 0 – 15

Observations and Calculations:

Natural Sand:
Table 3.6. Sieve analysis of Fine Aggregate
S.NO Sieve weight Cumulative Cumulative % of
size passing
retained weight retained % weight
(gm) retained
(gm)
1 4.75mm 10 10 1.0 99
2 2.36mm 100 110 11.0 89
3 1.18mm 72 182 18.2 81.8
4 600 µ 362 544 54.4 45.6
5 300 µ 268 812 81.2 18.8
6 150 µ 132 944 94.4 5.6
7 Pan 56 1000 100 0
Total 260.2
Fineness modulus of sand = (Total cumulative % wt retained)/100
= 260.2/100
=2.60
Therefore conforming zone from % of weight passing from table 3.6 IS zone II

22
Table 3.7 Limits of Fineness modulus of Fine aggregate
Range Sand belongs to
2.2 – 2.6 Fine sand
Fineness modulus
2.6 – 2.9 Medium sand
2.9 – 3.2 Coarse sand
Sand having fineness modulus more than 3.2 will be unsuitable for making of
concrete

3.5.2.2 Specific Gravity of Fine aggregate

Specific gravity is the major property of the aggregate. Specific gravity is
calculated by the cylindrical (Pycnometer Bottle) method. This test is conducted as
per IS: 383- 1970. The procedure for finding out the specific gravity of fine
aggregate is as follows:

Now the specific gravity of cement is calculated by using formula:

Table 3.8. Specific gravity of Natural Sand

S.no Observation Weight

1 Weight of empty bottle (W1) 0.420
2 Weight of bottle with aggregate (W2) 1.20
3 Weight of bottle + aggregate + water 1.67
(W3)
4 Weight of bottle only with water (W4) 1.21
Specific gravity of sand 2.43

Summary of test results of Fine Aggregate:

The following test are carried out on a sand as per IS 2386- 1986 (part 3) and IS
383 – 1970.

23
Table 3.9. Test Results on fine aggregate
Test Natural sand Requirements as per
S.no IS codes
1 Sieve analysis Zone II
2 Fineness modulus 2.60 IS 2386- 1986 (part 3)
3 Specific gravity 2.43 IS 383 – 1970

3.6TESTS ON FLY ASH:

3.6.1 Specific gravity test

The specific gravity of fly ash is calculated by using formula:

Table 3.10. Specific gravity of Natural Sand:

S.no Observation Weight

1 Weight of empty bottle (W1) 0.025
2 Weight of bottle with fly ash (W2) 0.045
3 Weight of bottle +fly ash+ kerosene 0.075
(W3)
4 Weight of bottle only with kerosene 0.065
(W4)
Specific gravity of sand 1.56

3.7 COARSE AGGREGATE:

For this study natural coarse aggregate (NCA) are used. Aggregates of size more
than 4.75mm are generally considered as coarse aggregate. The maximum size of
coarse aggregate used in this experimental work is 20 mm. A good quality of coarse
aggregate is obtained from nearest crusher unit and various tests are carried out on
coarse aggregate as per IS 2386- 1963 (part 3) and IS 383-1970.

24
 Fig-3.5 Coarse Aggregate

3.8 TESTS ON COARSE AGGREGATE: (AS PER IS 383 – 1970

AND IS 2386 PART-3)
The maximum size of Coarse aggregate used in this process is 20 mm. The
test reports are tabulated as follows

3.8.1 Sieve Analysis of Coarse Aggregate (Is 2386 Part-3) Sieve analysis
helpful in determining the particle size distribution of the aggregate gradation of
fine aggregate. It is confirming to IS 2386 – 1963 part 3 Grading limits of
Coarse Aggregate (as per IS 383 – 1970, Clause 4.1 and 4.2)

Table 3.11. Grading limits of Singe sized aggregate:

IS Sieve Percentage passing for Coarse aggregate (%)

20mm 16mm 12.5mm 10mm
40mm 100 - - -

20mm 85-100 100 - -

16mm - 85-100 100 -
12.5mm - - 85-100 100
10mm 0-20 0-30 0-45 85-100
4.75mm 0-5 0-5 0-10 0-20
2.36mm - - - 0-5

25
 Table 3.12. Sieve Analysis of Coarse aggregate:

Sieve size weight retained % of weight Cumulative % of % of passing

S.NO retained weight retained
(gm)
1 80mm 0 0 0 0
2 40mm 0 0 0 0
3 20mm 2620 52.4 52.4 47.6
4 10mm 2350 47 99.4 53
5 4.75mm 30 0.6 100 99.4
6 2.36mm 0 0 100 0
7 1.18 mm 0 0 100 0
8 600 µ 0 0 100 0
9 300 µ 0 0 100 0
10 150 µ 0 0 100 0
11 Pan 0 0 0 0
Total 751.8
Fineness modulus of sand = (Total cumulative % wt retained)/100
= 751.8/100
= 7.518
3.8.2 Specific Gravity of Coarse Aggregate (IS 2386 Part-3)
Specific gravity is the major property of the Coarse aggregate. Specific gravity is
calculated by the Cylindrical (Pycnometer Bottle) method.
w2 −w1
Specific gravity (G) = (w
2 −w1 )−(w3 −w4 )

Table 3.13. Specific gravity of Coarse aggregate:

S.NO Observation Weight (Kg)
1 Weight of empty bottle (W1) 0.61
2 Weight of bottle with aggregate (W2) 1.44
3 Weight of bottle + aggregate + water (W3) 2.06
4 Weight of bottle with water (W4) 1.52
Specific gravity of Coarse Aggregates 2.86

Summary of Test Results:

The following test are carried out on a coarse aggregate as per IS 2386- 1986 (part
3) and IS 383 – 1970.

26
Table 3.14. Test results on coarse aggregate
Property Result Requirements as per IS
codes
Specific gravity 2.86 IS 383 – 1970

Fineness Modulus 7.518 IS 2386- 1986 (part 3)

3.9 TESTS ON CRUSHED TILES:

3.9.1 Specific Gravity of Tiles:

The pycnometer is used for tiles less than 20mm size. Dry the pycnometer
thoroughly & weigh it with cap (W1). Pycnometer is filled with crushed tiles to about
1/3rd and weigh again. Add sufficient water till top & allow the entrapped air into
escape. Fill the pycnometer with water slowly to top of cap without spilling (W3)
through pipe. Clean the pycnometer by washing with water thoroughly. Fill the
pycnometer with only water as alone & weigh it (W4). Repeat the test twice as more
and take the average for better results.
w2 −w1
Specific gravity (G) = (w
2 −w1 )−(w3 −w4 )

Table 3.15 Specific gravity of tiles

S.no Observation Weight (kg)
1 Weight of empty bottle (W1) 0.61
2 Weight of bottle with tiles (W2) 1.05
3 Weight of bottle + tiles + water (W3) 1.71
4 Weight of bottle only with water (W4) 1.47
Specific gravity of ceramic waste 2.09

3.10 WATER
In this study portable water is used confirming to IS: 456-2007. The water
used for the study was free of acids, organic matter, suspended solids, alkalis and
impurities which when present may have adverse effect on the strength of concrete.

27
 CHAPTER-4
MIX DESIGN

The steps involved in the design of concrete mix as per IS: 10262-2009, IS: 456-2000.
4.1 Stipulations for proportioning:
Grade designation : M30
Type of Cement : OPC 53 grade confirming to IS 12269:1987
Maximum nominal size of aggregate : 20 mm
Exposure condition : Severe
Degree of supervision : Good
Maximum cement content :450 Kg/m3
Minimum Cement content : 320 Kg/m3
Type of aggregate : Crushed angular aggregate
Workability : 25-50mm
4.2 Test data for Materials:
Cement used: OPC 53 grade confirming to IS 12269:1987
Specific gravity of Cement: 3.12
Specific gravity of aggregates:
 Coarse aggregate :2.86
 Fine aggregate :2.43
Sand conforming zone – II of 383-1970.
4.3 Mix Design
STEP-1:
Target mean strength for mix proportioning:
fck′=fck+1.65 S
fck′ =30+1.65(5) =38.25N/mm2
fck′= Target average Compressive strength at 28 days
fck= Character Compressive strength at 28 days
S = Standard deviation (taken from Table1 of IS: 10262-2009); S=5
STEP-2:
Selection of Water-Cement ratio
From IS: 456-2000, Table 5 by taking severe exposure condition for M30
grade, the maximum water Cement ratio is 0.45.

28
 0.4 <0.45, Hence ok (Adopt W/C = 0.4)

STEP-3:
Selection of water content
From IS: 10262-2009, Table 2 depending upon the nominal size of aggregate
(20mm), the maximum water content is 186 litres.
There fore Consider water content per cubic meter of concrete for 20mm aggregate
is 170liters.
STEP-4:
Calculation of Cement content
The minimum Cement content required for M30 as per IS: 456-2000 of table is
320Kg/m3 (Severe exposure condition)
W/C =0.4
170/C = 0.4
C = 425 Kg/m3
Hence we obtained Cement content as 425 Kg/m3
320Kg/m3 <425 Kg/m3<450 Kg/m3 (hence, OK)
STEP-5:
Proportion of volume of coarse aggregate and fine aggregate content
0.50=0.62
0.5-0.4=0.1
Therefore, Correspond corrected proportion of volume of Coarse aggregate
=0.62+0.02=0.64
Final volume of coarse aggregate=0.64
Volume of fine aggregate = 1-0.64=0.36
STEP-6:
Mix Calculations
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
= (425/3.12) ×1/1000
=0.136 m3

(c)Volume of water = (Mass of water /specific gravity of water) ×1/1000

29
 = (170/1) ×1/1000
=0.17 m3
(d) Volume of all in aggregate =1-(0.136+0.17)
=0.694 m3
(e) Mass of Coarse aggregate = Volume of all in aggregate× Volume of Coarse
Aggregate× Specific gravity of coarse aggregate ×1000
=0.694×0.64×2.86×1000
=1270.29 kg/ m3
(f) Mass of fine aggregate = Volume of all in aggregate× Volume of fine aggregate
×Specific gravity of fine aggregate ×1000
=0.694×0.36×2.43×1000
=607.11 kg/ m3
Cement: F.A: C.A
425: 607.11: 1270.29
1: 1.42: 2.9

Table 4.1: Mix proportion ratio

Cement Kg/m3 Fine aggregate Coarse aggregate Water l/m3
Kg/m3 Kg/m3
425 607.11 1270.29 170

1 1.42 2.9 0.4

30
4.4 Quantities required for one m3 of concrete
Table 4.2: Quantities for cement with fly ash

Percentage of
coarse fine
replacement cement Water
S.no aggregate Fly ash kgs aggregate
of cement in kgs in Ltrs
in kgs in kgs
with fly ash

1 0 425 1270.29 0 607.11 170

2 10 382.5 1270.29 42.5 607.11 170

3 20 340 1270.29 85 607.11 170

4 30 297.5 1270.29 127.5 607.11 170

Table 4.3 Types of material and description

Material Description
Cement Type-OPC 53 grade
Fly Ash in% 20%
Fine Aggregate Natural sand
Coarse Aggregate 20mm nominal size aggregate
Crushed tiles 20mm nominal size
Mix Ratio 1:1.42:2.9
w/c Ratio 0.4

31
 Table 4.4: Quantities required for fly ash and crushed tiles

S.no % replacement Cement Fly Coarse Fine Crushed Water

of cement with in kgs ash in aggregate aggregate tiles kgs in Lts
fly ash & C.A kgs in kgs in kgs
with CTA

1 20%Fly 382.5 42.5 1143.261 607.11 127.029 170

ash+10% CTA

2 20%Fly 340 85 1016.232 607.11 254.058 170

ash+20% CTA

3 20%Fly 297.5 127.5 889.203 607.11 381.087 170

ash+30% CTA

32
 4.5 DETAILING OF MIXES:
Table. 4.5: The following combinations of cement, fly ash, and crushed tiles are
used in the project.

S.NO. TYPE OF CONCRETE MIX NO OF NO OF NO OF NO OF

CUBES CUBES CYLINDERS BEAMS
7 DAYS 28 DAYS 28 DAYS 28
DAYS

1 M30 Grade Conventional Concrete 3 3 3 3

2 Conventional Concrete+10% Fly Ash 3 3 3 3

3 Conventional Concrete+ 20% Fly Ash 3 3 3 3

4 Conventional Concrete+ 30% Fly Ash 3 3 3 3

5 Conventional Concrete+20% Fly Ash+10% 3 3 3 3

crushed tiles

6 Conventional Concrete+20% Fly Ash+20% 3 3 3 3

crushed tiles

7 Conventional Concrete+20% Fly Ash+30% 3 3 3 3

crushed tiles

TOTAL 21 21 21 21

33
 CHAPTER 5
TESTING OF SPECIMENS
5.1 GENERAL

Calculation of fresh and hardened properties is the main criteria in concrete

testing. The well cured specimens in curing tank are tested for compressive, split tensile
and flexural strengths. By taking out the specimens from the curing tank, the specimens
were exposed to sun light for surface drying. After the drying process, the specimens
are processed for testing. The specimens are tested for 7 days and 28 days strengths. In
this chapter the testing procedures and formulations are discussed and presented as
follows.
5.2 TESTING OF FRESH CONCRETE

Fresh properties of concrete are observed at the time of concreting. To measure

the fresh properties of concrete workability test is very important. Concrete good in
workability will shows better properties in its life time. Before pouring concrete into
the moulds we need to check the workability by slump cone method.
The workability test for concrete is confirms to IS 1199 – 1959.

5.2.1 WORKABILITY

Compaction factor measures the workability in an indirect by determining the

degree of compaction achieved by a standard amount of work done by allowing the
concrete to fall through a standard height.
The sample of concrete to be tested is placed in the upper hopper up to the brim.
The trap door is opened so that the concrete falls in the lower hopper. The trap door of
the lower hopper is opened and concrete is allowed to fall into the cylinder. In the case
of a dry mix, it is likely that the concrete may not fall on opening trap door. In such
case a slight pocking by the rod may be required to set the concrete in motion. The
excess concrete remaining top level of cylinder is then cut off with the help of plain
blades supplied with apparatus. The surface of cylinder is wiped clean and weighed to
the nearest 10gms. This weight is known as “weight of partially compacted concrete”.
The cylinder is emptied and then refilled with the concrete from the sample in layers of
each about 5cm depth. The layers are heavily rammed or preferably vibrated so as to

34
obtain full compaction. The top surface of fully compacted concrete is then carefully
struck off and the cylinder is weighed to the nearest 10gms. The weight is known of
fully compacted concrete.

5.3 FACTORS EFFECTING WORKABILITY

Workable concrete is the one which exhibits very little internal friction between
particle and particle or which overcomes the frictional resistance offered by the
formwork surface. The factors helping concrete to have more lubricating effect to
reduce internal friction for helping easy compaction are given below.

 Water Content
 Mix Proportion
 Size of Aggregates
 Shape of Aggregates
 Surface texture of Aggregate
 Grading of Aggregate
 Use of Admixtures

5.4 MEASUREMENT OF WORKABILITY

 Slump Test
 Compacting Factor Test
 Flow Test
 Kelly Ball Test
 Vee Bee Consistometer Test

DEFINITION

 Slump is a measurement of concrete's workability, or fluidity.

 It's an indirect measurement of concrete consistency or stiffness.

A slump test is a method used to determine the consistency of concrete. The

consistency, or stiffness, indicates how much water has been used in the mix. The
stiffness of the concrete mix should be matched to the requirements for the finished
product quality

35
SLUMP TEST

The concrete slump test is used for the measurement of a property of fresh concrete.
The test is an empirical test that measures the workability of fresh concrete. More
specifically, it measures consistency between batches. The test is popular due to the
simplicity of apparatus used and simple procedure.

PRINCIPLE OF SLUMP TEST

The slump test result is a measure of the behavior of a compacted inverted cone of
concrete under the action of gravity. It measures the consistency or the wetness of
concrete.

Apparatus

 Slump cone,
 Scale for measurement,
 Temping rod (steel)

The apparatus for conducting the slump test essentially consists of a metallic
mould in the form of a cone having the internal dimensions as under:

Bottom diameter :20cm

Top diameter :10cm
Height :30cm

All dimensions are in cm

Fig-5.1 Dimensions of Slump Cone

36
Procedure of Concrete Slump test:
1. The mold for the slump test is a frustum of a cone, 300 mm (12 in) of height.
The base is 200 mm (8in) in diameter and it has a smaller opening at the top of
100 mm (4 in).
2. The base is placed on a smooth surface and the container is filled with concrete
in three layers, whose workability is to be tested.
3. Each layer is temped 25 times with a standard 16 mm (5/8 in) diameter steel
rod, rounded at the end.
4. When the mold is completely filled with concrete, the top surface is struck off
(leveled with mould top opening) by means of screening and rolling motion of
the temping rod.
5. The mould must be firmly held against its base during the entire operation so
that it could not move due to the pouring of concrete and this can be done by
means of handles or foot - rests brazed to the mould.
6. Immediately after filling is completed and the concrete is leveled, the cone is
slowly and carefully lifted vertically, an unsupported concrete will now slump.
7. The decrease in the height of the center of the slumped concrete is called slump.
8. The slump is measured by placing the cone just besides the slump concrete and
the temping rod is placed over the cone so that it should also come over the area
of slumped concrete.
9. The decrease in height of concrete to that of mold is noted with scale. (usually
measured to the nearest 5 mm (1/4 in).

37
 Fig-5.2 Slump cone test

Precautions in Slump Test

In order to reduce the influence on slump of the variation in the surface friction,
the inside of the mould and its base should be moistened at the beginning of every test,
and prior to lifting of the mould the area immediately around the base of the cone should
be cleaned from concrete which may have dropped accidentally.

Types of Concrete Slump:

The slumped concrete takes various shapes, and according to the profile of
slumped concrete, the slump is termed as;

1. Collapse Slump
2. Shear Slump
3. True Slump

38
 fig-5.3 Types of slumps

Collapse Slump:

In a collapse slump the concrete collapses completely. A collapse slump will

generally mean that the mix is too wet or that it is a high workability mix, for which
slump test is not appropriate.

Shear Slump:

In a shear slump the top portion of the concrete shears off and slips sideways

If one-half of the cone slides down an inclined plane, the slump is said to be a shear
slump.

1. If a shear or collapse slump is achieved, a fresh sample should be taken and the
test is repeated.
2. If the shear slump persists, as may the case with harsh mixes, this is an
indication of lack of cohesion of the mix.
True Slump:
In a true slump the concrete simply subsides, keeping more or less to shape
1. This is the only slump which is used in various tests.
2. Mixes of stiff consistence have a Zero slump, so that in the rather dry range no
variation can be detected between mixes of different workability.

However, in a lean mix with a tendency to harshness, a true slump can easily change to
the shear slump type or even to collapse, and widely different values of slump can be
obtained in different samples from the same mix; thus, the slump test is unreliable for
lean mixes.

39
 Applications of Slump Test:

1. The slump test is used to ensure uniformity for different batches of similar
concrete under field conditions and to ascertain the effects of plasticizers on
their introduction.
2. This test is very useful on site as a check on the day-to-day or hour- to-hour
variation in the materials being fed into the mixer. An increase in slump may
mean, for instance, that the moisture content of aggregate has unexpectedly
increases.
3. Other cause would be a change in the grading of the aggregate, such as a
deficiency of sand.
4. Too high or too low a slump gives immediate warning and enables the mixer
operator to remedy the situation.
5. This application of slump test as well as its simplicity, is responsible for its
widespread use.

Table 5.1: Workability, Slump and Compacting Factor of concrete with 19 or 38

mm (3/4 or 11/2 in) maximum size of aggregate.

Slump Compacting
Degree of
Use for which concrete is suitable
workability
Mm In Factor
Very dry mixes; used in road
Very low 0-25 0-1 0.78 making. Roads vibrated by power
operated machines.
Low workability mixes; used for
foundations with light
Low 25-50 1-2 0.85
reinforcement. Roads vibrated by
hand operated Machines.
Medium workability mixes;
manually compacted flat slabs using
crushed aggregates. Normal
Medium 50-100 2-4 0.92
reinforced concrete manually
compacted and heavily reinforced
sections with vibrations.
High workability concrete; for
sections with congested
High 100-175 4-7 0.95
reinforcement. Not normally
suitable for vibration

40
TESTING OF HARDENED CONCRETE
Testing of hardened concrete plays an important role in controlling and
confirming the quality of cement concrete works. Systematic testing of raw materials,
fresh concrete and hardened concrete are inseparable part of any quality control
programme for concrete, which helps to achieve higher efficiency of the material used
and greater assurance of the performance of the concrete with regard to both strength
and durability. The test methods should be simple, direct and convenient to apply.

One of the purposes of testing hardened concrete is to confirm that the concrete
used at site has developed the required strength. As the hardened of the concrete takes
time, one will not come to know, the actual strength of concrete for some time. This is
an inherent disadvantage inconventional test. But, if strength of concrete is to be known
at an early period, accelerated strength test can be carried out to predict 28 days
strength.

5.5 CASTING PROCEDURE

5.5.1 Preparation of moulds

The moulds for concreting are need prepare carefully before casting.
All the moulds should be fitted properly. Oiling is done on the surface of
the moulds for an easy removal of specimens.

5.5.2 Calculation of materials

The required materials are calculated for casting. The materials

should be dry and well graded.
5.5.3 Mixing of materials
The prepared materials are poured in rotating miller and careful
supervision is required here.

5.5.4 Measuring the fresh properties

Before pouring concrete into the moulds we need to observe the
fresh properties of concrete by slump cone method.

41
5.5.5 Concreting the moulds
Place the concrete into the moulds with a trowel. The concreting
should be done in layers of 5cm each. For each layer proper compaction is
required by tamping bar. After compacting top layer, the moulds are
vibrated on the vibrating table for better mixing and bonding.
5.5.6 Naming of the trials
The casted moulds are named and set for undisturbed for 24 hrs for setting.

5.5.7 Remoulding
The specimens should be removed after proper setting concrete. The
specimens are removed and processed for curing.

5.6 CASTING OF CUBES

For each trail 6 cube specimens were casted for calculating 7 days and 28days
strengths. The dimensions of specimen for cube are of 150mm x 150mm x 150mm

5.7 CASTING OF CYLINDERS

For each trail 3 cylinder specimens were casted for calculating 28days
strengths. The dimensions of the cylindrical specimen are of height = 300mm,
diameter = 150mm.

Fig-5.4 casting of cylinders

42
5.8 CASTING OF BEAMS

For each trail 3 beam specimens were casted for calculating 28days
strengths. The dimensions of the beam specimen are of 500mm x 100mm x 100mm.

Table 5.2: Details of specimens

Properties Tested Size in mm

Compressive strength 150x150x150
Split Tensile Strength 150 x300
Flexural Strength 100x100x500

Fig-5.5 Casting of specimens

5.9 CURING OF SPECIMENS

The specimens are left in the moulds undisturbed at room temperature for
about 24 hours after casting. The specimens are then removed from the moulds and
immediately transferred to the curing tank i.e. cubes are cured in fresh water.
Curing is most important process in concreting. Concrete strength increases with
age of curing. The specimens should keep in curing tank for better improvement in
strength. Generally curing is done by ponding curing tanks. The water used for
concrete curing should be free from salinity, scrap, vegetation and chemicals. We
need to change the water for every 7 days of curing. The specimens are tested for
7 days and 28 days of curing.

43
 Fig-5.6 Curing of specimens in curing tank

5.10 TESTING OF SPECIMENS:

The cube specimens cured as explained above are tested as per standard
procedure after removal from curing tank and allowed to dry under shade. The cube
specimens are tested.

5.10.1 Compressive Strength Test:

In compressive strength test the cube specimen was placed with the cast faces
of the cube at right angles to that as cast in the compression testing machine.
According to standard specifications the load on the cube was applied at standard
constant rate up to the failure of the specimen and the ultimate load was noted. Cube
compressive strength was tested.

Compressive strength =

Where, P = Compressive load (kN)

A = Area of the cube (150 X 150 mm)

44
 Fig-5.7 Compression testing machine

5.10.2 Split tensile Strength Test:

The test is carried out by using the cube specimens. The cube specimens were
placed with the cast faces at right angles to that as cast in the compression testing
machines. In order to apply the magnitude of high compressive stress near the point
of application of load,2 narrow packing wooden sticks of 200 mm long was used. So
exactly at center of the cube the splitting takes place. According to standard
specifications the load on the specimens was applied at constant rate up to the failure
of the specimen and the ultimate loads are noted. Split tensile strength for all the
specimens tested and results were noted.

Split tensile strength Fcr =

Where, P = Split tensile load

D = Diameter of the specimen (150 mm)

L = Length of the specimen

A is cross sectional area of the specimen in mm2.

5.10.3 Flexural strength test:

This test was conducted on flexural testing machine. The load was applied at
the middle third points of the effective span of flexural beam. Special precautionary
measures were taken to keep axis of the specimen aligned with the axis of the loading
device. The load was applied with shock and increased continuously at a uniform rate

45
 of loading. The load was increased until the specimen failed and maximum load
applied to the specimen during the test was recorded.

The appearance of the fractured faces of concrete and any usual features in the
type of failure were noted. The flexural stresses corresponding to maximum flexural
load are furnished.

Flexural strength = PL/bd2 N/mm2

Fig-5.8 Universal testing machine

46
 CHAPTER 6

TEST RESULTS AND GRAPHS

6.1 COMPRESSION TEST

Table 6.1: The average compressive strength of concrete with partial

replacement of cement with fly ash at 7 and 28 days

Average Compressive
%of replacement cement
S.no strength of the concrete at
with fly ash
different ages(N/mm2)
7days 28days
1 0 24.9 38.82
2 10 25.01 39.09
3 20 27.36 40.31
4 30 22.45 32.44
Compressive strength (MPa)

7 days
28 days

0% 10% 20% 30%

Fly ash mix

Fig-6.1 Graph between fly ash mix and compressive strength

47
6.2 SPLIT TENSILE TEST
Table 6.2: The average split tensile strength of concrete with partial
replacement of cement with fly ash at 28 days

Percentage of Average Split tensile

S.no Replacement Cement With strength of the concrete at
Fly Ash different ages(N/mm2)
28days
1 0 6.38
2 10 7.21
3 20 7.80
4 30 6.81

7
Split tensile strength (Mpa)

4
28 days
3

0
0% 10% 20% 30%
Fly ash in %

Fig-6.2 graph between fly ash mix and split tensile strength

48
6.3 FLEXURAL STRENGTH TEST
Table 6.3: The average flexural strength of concrete with partial
replacement of cement with fly ash at 28 days

Percentage of Average Flexural strength

S.no
replacement cement with of the concrete at different
fly ash ages(N/mm2)

28days
1 0 7.45
2 10 7.57
3 20 7.67
4 30 6.75

7.8

7.6

7.4
Flexural strength (Mpa)

7.2

7
28 days
6.8

6.6

6.4

6.2
0% 10% 20% 30%
Fly ash in %

Fig-6.3 Graph between fly ash mix and flexural strength

20% of cement is replaced by Fly Ash in different proportions of crushed tiles.

The Compressive strength of cube specimens at 7days and 28 days, split tensile
strength at 28 days & flexural strength at 28 days are noted down below.

49
Table 6.4: Average compressive strength, split tensile strength and flexural
strength of concrete with partial replacement of fly ash and crushed tiles

Type of Mix Compressive strength Split tensile Flexural

strength in strength in
(N/mm2) (N/mm2)

7 days 28 days 28 days 28 days

20% of flyash+10% of 27.52 40.62 7.3 7.71

crushed tiles

20% of flyash+20% of 28.21 41.02 7.8 7.87

crushed tiles

20% of flyash+30% of 27.31 40.95 6.91 6.77

crushed tiles

Fly ash = f.a & Crushed tile aggregates = CTA

45

40

35
Compressive strength (MPa)

30

25

20 7 days
28 days
15

10

0
0% 10% 20% 30%
20% of f.a + CTA

Fig-6.4 Graph between fly ash mix and crushed tiles and compressive strength

50
 9

7
Split tensile strength (Mpa)
6

4
28 days
3

0
0% 10% 20% 30%
20% of f.a + CTA

Fig-6.5 Graph between fly ash mix and crushed tiles and split tensile strength

7.8

7.6
Flexural strength (Mpa)

7.4

7.2

7
28 days
6.8

6.6

6.4

6.2
0% 10% 20% 30%
20% of f.a + CTA

Fig-6.6 Graph between fly ash mix and crushed tiles and flexural strength

51
 CHAPTER 7

CONCLUSIONS

Based on the study conducted within the scope of the research, the following
specific and general conclusions can be drawn.

1. Using the techniques implemented in the study we can preserve the natural
resources for the future generations and reduce landfills due to waste.

2.By using the fly ash we can reduce the water content so that there will be increase
in the strength of concrete.

3. Fly ash use in concrete increases fines volume and decreases water content and
thus reduces bleeding of concrete.

4.The compressive strength of concrete increases up to 20% replacement of cement

with fly ash and later on the strength decreases.

5.Slump loss of concrete goes on increasing with increase of quality of fly ash.

6.when 30% of fly ash was replaced, the flexural strength reduces as compared to
10% and 20% of replacement.

7.By using fly ash there will be reduce in cost and construction waste

8.For 20% of crushed tiles are replaced in place of coarse aggregate there is an
increment in compressive strength, spilt tension strength, flexural strength and
bond strength when compare to conventional concrete strength results after 7 and
28 days curing period.

9. At the age of 28 days curing, the compressive strength of 10% replacement

27.52 N/𝑚𝑚2 higher; at 20% replacement is 28.21 N/𝑚𝑚2 higher than the
conventional concrete.

10. At the age of 28 days curing, the spilt tensile strength of 10% replacement 7.3
N/𝑚𝑚2 higher; at 20% replacement is 7.87 N/𝑚𝑚2 higher than the conventional
concrete.

52
 CHAPTER 8

REFERNCES
1.Fly ash – cast in concrete, NAEB JOURNAL
2.M.S.Shetty,- concrete technology theory and practice ,S. Chand & Company LTD,
pp.124-147,174-183,349-361,2011.
3.Amit Mittal, M.B. Kaisare and Rajendra kumar Shetty,-EXPERMENTAL STUDY
ON USE OF FLY ASH IN CONCRETE.
4.Vikas Rajora and Gurtej Singh Sidhu,” Effect of Partial Replacement of Fine and
coarse aggregate (10mm) with ceramic waste on the properties of Concrete”
International Journal of science and Research(IJSR) ISSN(online): 2319-7064 Index
Copernicus Value (2013):6.14 Impact Factor (2015):6.391.
5. P.Rajalakshmi , Dr.D.suji ” studies on Strength Characteristics on Utilization of
Waste Ceramic Tiles a Aggregate in concrete” in IJCSER, 2015.
IS codes:
6. IS 10262-2009: Indian Standard “Guidelines for concrete mix proportioning”-code
of practice.
7. IS 456-2000: Indian Standard “ Plain and reinforced concrete “- code of practice.

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