A

PROJECT REPORT
ON:
Effect of Fly Ash,Silica Fume and PVC on Concrete
By: BUMESH SHARMA (1884-17)
PRATEEK ANAND (1888-17)
SUMANT SUDHIR (1894-17)
SHAFQAT SHAFI DAR (1910-17)

BACHELOR OF ENGINEERING
IN
CIVIL ENGINEERING
MODEL INSTITUTE OF ENGINEERING AND TECHNOLOGY , JAMMU
 DECLARATION

We hereby declare that this Project Report titled Online Student Feedback System
submitted by us and approved by our project guide , to the Model Institute of
Engineering and Technology (M.I.E.T) , Jammu University, Jammu, is a bona-fide
work undertaken by us and it is not submitted to any other University or Institution
for the award of any degree diploma / Certificate or published any time before.

Project Group : 15

Student Name : BUMESH SHARMA

PRATEEK ANAND

SUMANT SUDHIR

SHAFQAT DAR

Project Guide : Asst. Prof.

Project Co-Guide : Asst. Prof. MR ABHISHEK SHARMA

 DEPARTMENT
OF
CIVIL ENGINEERING
Model Institute of Engineering & Technology – Jammu

CERTIFICATE

Certified that minor project work entitled “Effect of Fly Ash, Silica Fume and
PVC on Concrete ” is a bona-fide work carried out in the 8th semester by
“BUMESH SHARMA, PRATEEK ANAND, SUMANT SUDHIR , SHAFQAT
DAR” in partial fulfillment for the award of Bachelor of Technology in Civil
Engineering from Model Institute of Engineering & Technology during the
academic year 2020-2021.

Project Guide
Asst. Prof.
 ACKNOWLEDGEMENT
The accomplishment of this major project report on “Effect of Fly Ash, Silica
Fume and PVC on Concrete ” was made possible by the guidance and moral
support bestowed On throughout my work period. For this I wish to express my
sincere gratitude and appreciation to all those who helped and supported me to
complete this report.

First and foremost, I would like to acknowledge the crucial role of the faculty of
Civil Department of MIET, Jammu, who gave me the permission to use all the
resources and material required to complete my report.

I would like thank Prof. , Head of the Department, Civil Engineering, M.I.E.T
Jammu for his kind cooperation and technical support.

BUMESH SHARMA
PRATEEK ANAND
SUMANT SUDHIR
SHAFQAT DAR
 ABSTRACT
The aim of this paper is to investigate the effects of silica fume and fly ash on the
fresh and Hardened properties of high performance concrete. Silica fume and fly
ash were incorporated separately And jointly in different concrete mixtures. The
individual and combined effects of silica fume and fly ash Were monitored with
respect to various fresh and hardened properties of concrete. Test results reveal that
Silica fume performed very well to improve the properties of high performance
concrete. Silica fume Contributed to provide the highest level of compressive
strength, dynamic modulus of elasticity and pulse Velocity. In addition, silica fume
produced the lowest level of initial surface absorption and drying rate, and Thus
indicated good durability. In contrast, fly ash alone could not contribute
significantly to improve the Properties of high performance concrete. However,
silica fume and fly ash jointly improved the fresh and Hardened properties of
concrete.

River sand, which is one of the Constituents used in the production of conventional
concrete, Has become very expensive and also becoming scarce due to Depletion
of river bed. Quarry dust is a waste obtained During quarrying process and PVC
powder. It has veryRecently gained good attention to be used as an effective Filler
material instead of fine aggregate. In the present study, The hardened and durable
properties of concrete using Quarry dust and PVC powder were investigated. Also,
the use Of quarry dust and PVC powder as the fine aggregate Decreases the cost of
concrete production in terms of the Partial replacement for natural river sand. This
paper Reports the experimental study which investigated the Influence of partial
replacement of sand with quarry dustAnd PVC powder.
 INDEX
S. No. Topics Page No.

1 Introduction 7-8

2 Literature Review 9-14

3 Materials Used 15-17

4 Methodology 18

5 Different Tests on Materials 19-23

6 Mix Design 24-25

7 Mixing 26-27

8 Casting and Curing 28-29

9 Results 30-32

10 Conclusion 32

11 Reference 33

12 Appendix 34-35
 1.INTRODUCTION
Silica fume and fly ash are well known supplementary cementing materials that
have been used Successfully for the production of high performance concrete
(Sarkar 1994). After high-range waterReducer, silica fume is essential, especially
for high strength and durability of high performance concrete. Fly ash also
contributes to improve the quality of concrete when used adequately (Naik et al.
1994).Therefore, the demand of silica fume and fly ash is high in the concrete
industry. Both silica fume and fly Ash are obtained as industrial by-products. Silica
fume is obtained as a by-product during the Manufacturing process of elemental
silicon and ferro-silicon alloys. It consists of very fine spheroids. The Mean
particle size of silica fume is 0.1 µm (Malhotra et al. 1992). It is about 100 times
finer than cement Particles. Silica fume possesses extremely high specific surface
in the order of 20,000 m2/kg and may Contain silicon dioxide higher than 90%
(Malhotra et al. 1992). Because of high content of silicon dioxide And extreme
fineness, silica fume is a highly reactive supplementary cementing material. On the
contrary, Fly ash is generally obtained as a finely divided residue during the
combustion of ground or powdered Coal. There are two classes of fly ash: Class C
and Class F. Class C fly ash has both cementitious and Pozzolanic properties.
However, the cemetitious property of Class C fly ash becomes very limited unless
it Is so finely divided that the average particle size is at least equal to or less than
that of cement with which It will be mixed. Conversely, Class F fly ash has higher
pozzolanic properties but little or no cementitious Properties. Owing to
considerable pozzolanic properties, class F fly ash has been mostly used in the
Production of high performance concrete (Bilodeau and Malhotra 1994). Silica
fume and fly ash are proven to improve the properties of concrete. Particularly, the
use of silica Fume results in significant increase in compressive strength and other
properties of concrete (Nawy 1996). Silica fume has lead to the production of HPC
providing a very high strength in the order of 80 MPa ormore (De Larrard 1994).
In addition, it is very effective to produce concretes with a low porosity and a very
low permeability to chloride ions and other deleterious agents, and competent to
control the expansion due to alkali-silica reaction and sulphate attack (Malhotra et
al. 1992). However, silica fume is more expensive than cement and thus the
overall material cost of concrete becomes high. The concrete industry is generally
more interested in cost-effective supplementary cementing materials. Fly ash is
more cost-effective than silica fume. It is also much cheaper than cement. In some
places, it can be obtained at no cost. Hence, the material cost decreases when fly
ash is incorporated in high performance concrete. In addition, fly ash imparts good
property improvement in concrete. It can reduce porosity, water permeability,
chloride penetration and diffusivity, and thus performs very well in resisting
freeze-thaw damage, chloride induced corrosion, sulphate attack, and expansive
reactions due to alkali-aggregate reactions (Bilodeau and Malhotra 1994).
Therefore, fly ash could be used alone or with silica fume to reduce the production
cost and to improve the properties of concrete. In this study, high performance
concretes have been produced using silica fume and fly ash as a supplementary
cementing material. This paper presents several properties of fresh and hardened
high performance concretes highlighting the individual and combined effects of
silica fume and fly ash.

Generally, using PVC powder and granule as aggregate replacement had the
positive effects of increased abrasion resistance and decreased water absorption.
Using PVC powder and granule also reduced the density of the concrete but at the
same time reduced compressive strength
Areas of Application:
1. Pavements.
2. Plain and Reinforced Concrete.
3. To make Lightweight Structures.
4. Pre-Cast Concrete Productions.
5. Structures where very high Compressive Strength is not Required.

Objectives:
1. To Produce Light Weight Concrete.
2. To make Concrete Cheap and Economical by using waste products.
To Study the variation in compressive strength of concrete when cement is
replaced partially by fly ash and silica fume and partial replacement of fine
aggregate by pvc powder
 RESEARCH PAPER REVIEWED

S.NO RESEARCH YEAR RESEARCHER JOURNAL

TOPIC S
Effect Of Partial 2012 Dilip Kumar International Journal Of
1. Replacement Of Singha Roy Emerging Technology
Cement By Silica Amitava Sil And Advanced
Fume On Engineering
Hardened
Concrete

STUDY OF 2016 Lakhbir Singh, International Journal Of

2. PARTIAL Arjun Kumar Advance Research
Replacement Of Anil Singh
Cement By Silica
Fume

Experimental 2012 Dr Jayesh Kumar International Journal Of

3. Investigation On Pitodra Advanced Engineering
Partial Laxman Sinh B Technology
Replacement Of Zala
Cement With Fly
Ash In Design
Mix Concrete

Partial 2017 Jagdish International Research

4. Replacement Of Virupakshi Patil Journal Of Engineering
Cement By Fly And Technology
Ash In Concrete
Mix Design

Experimental 2018 K .N International Research

5. Study On Cement Janardhanan Journal Of Engineering
Concrete With E Mohana Priya And Technology
Pvc Powder And
Quarry Dust As
Partial
Replacement To
 Fine Aggregate

An Experimental 2019 L Pradeep International Research

6. Investigation On Kumar Journal Of Engineering
Cement Powder G Mandikandan And Technology
As Partial V Karthik
Replacement To S Hemapriya
Cement A Anusha

Experimental 2019 Marupuka Sri International Journal Of

7. Examination On Hari Innovative Technology
Blended Concrete Sai Ram Goud And Exploring
By Incorporating Durga Chaitanya Engineering
Fly Ash And Kumar
Silica Fume Arunkanthi Eluru

Effects of silica 2005 Md saifuddin Canadian society for

8. fume and fly ash civil engineering
on the properties
of high
performance
concrete

LITERATURE REVIEW
S.NO RESEARCH TOPICS OBJECTIVE METHODOLOGY FINDING AND
SCOPE

Effect Of Partial This Paper Features In This Research A Study On The concrete
Replacement Of An Experimental The Effect Partial having silica
1 Cement By Silica Study On The Replacement Of Cement By Sf fume 10% is
Fume On Hardened Nature Of Sf And Its (From 5% To 10% With A more cohesive,
Concrete Influences On The Step Of 2.5%) On M20 Grade workable and
Properties Of Fresh Concrete Designed With 53 and has more
And Hardened Grade compressive
Concrete. Then Various Tests Are Done strength than
On This Concrete And It Is normal
Compared To Conventional concrete.
Concrete

Study Of Partial This study is to Silica fume were used to The strength of
Replacement Of produce concrete replace 0% to15% of cement concrete
2 Cement By Silica that is flowable in by weight at increment of 5% increases
Fume nature and is also for both cube and cylinde r. rapidly as silica
cohesive. and then it is compared to fume increases
conventional concrete and optimum
value is at10%
concentration

Experimental The study describes The fly ash was replaced at Compressive
Investigation On feasibility of using fly 0% , 10%, 20% , 30% AND 40 strength
3 Partial Replacement ash as partial % weight of cement for m25 decreases but
Of Cement With Fly replacement of and m40 grade concrete and workability
Ash In Design Mix cement to make the compressive test and split increases.
Concrete concrete economical tensile test were done. It reduces cost
of concrete and
is green
concrete
[environment
friendly].

Partial Replacement The main objective A mix was designed for It increases
Of Cement By Fly of paper is to see characteristic strength of modulus of
4 Ash In Concrete Mix strength and 50n/mm^2 having target elasticity ,
Design workability of plain of62n/mm^2 at 28 days. 30 % superior
concrete and of fly ash is included by resistance to
concrete mix by cementious material freezing,
using fly ash. increase
sulphate
 resistance and
increase
workability.

Experimental study In this research Initially cement mortar cube The results
on cement concrete natural aggregate was studied with various show that that
5 with pvc powder was replaced percentages of replacement of addition of
and quarry dust as opartally by pvc quarry dust and pvc powder quarry dust
partial replacement powder and quarry [0% ,10% , 15%, 20%] and pvc
to fine aggregate dust Then it was compared with powder for fine
cubes of normal mortar to course
aggregate ratio
of 0.6 was to
enhance the
compressive
propertis as
well as elastic
modulus.

An Experimental The aim of the paper The cement was replaced at The
Investigation On pvc was is to show effect dosage of 12.5% and 15 %. effectiveness of
6 powder As Partial of cement modifier The physical[ density , internal curing
Replacement To behaviour of workability and water by means of
Cement concrete absorption] ,mechanical pvc applied to
properties[ split tensile test concrete is
and compressive strength] higher than
were found and studied. conventional
concrete

Experimental In this research The mix is made by replacing It has been

Examination On conventional 5% ,8% ,and10% silica fume. found that at
7 Blended Concrete concrete is compared After best resultsof silica fume 15% fly ash
By Incorporating to blended concrete it is intermingled with fly ash and 10% silica
Fly Ash And Silica having silica fume with 10 , 20 and 30% by fume
Fume and fly ash varying cement content to compressive
75 ,70 and 80% in terms of strength and
volume. Compressive strength, tensile strength
split tensile and bending is highest and
strength are studied for 7 ,28 workability is
and 56 days also good.

Effects of silica fume The aim of this The silica fume concrete was The fly ash is
8 and fly ash on the paper is to produced using 10% sf by not effective
properties of high investigate the effect weight of cement. Similarly fly alone but when
performance of silica fume on ash concrete was prepare silica fume is
concrete fresh and hardened including 10% fa as partial added to it it is
properties of replacement of cement. In used to produce
concrete addition silica fume- fly ash high
was produced using 5% sf and performance
5% fa in place of equal concrete.
amount of cement by weight.

MATERIALS USED
 THE VARIOUS INGREDIENTS USED IN THE FORMATION OF THE
CONCRETE ARE AS FOLLOWS :
1. CEMENT :

Fig: Ordinary Portland Cement

A Cement is a binder, a substance used for construction that sets,

hardens, and adheres to other materials to bind them together. Cement is
seldom used on its own, but rather to bind sand and gravel (aggregate)
together. Cement mixed with fine aggregate produces mortar for
masonry, or with sand and gravel, produces concrete. Concrete is the
most widely used material in existence and is only behind water as the
planet's most-consumed resource.
Cements used in construction are usually inorganic,
often lime or calcium silicate based, which can be characterized as non-
hydraulic or hydraulic respectively, depending on the ability of the
cement to set in the presence of water (see hydraulic and non-hydraulic
lime plaster).

Ordinary Portland cement (OPC) Of 53 grades satisfying the

requirements of IS: 8112- 1939 is used. The specific gravity of cement
was found to be 3.15.
S No. Characteristics Value
1 Normal Consistency 30%
 2 Initial Setting Time 45 Minutes
3 Final Setting Time 720 Minutes

2. FINE AGGREGATE :

Fig : Sand ( fine aggregate )

Fine aggregates are essentially any natural sand particles won from the
land through the mining process. Fine aggregates consist of natural sand
or any crushed stone particles that are ¼” or smaller. This product is
often referred to as 1/4’” minus as it refers to the size, or grading, of this
particular aggregate.
Fine aggregate (Sand) Fills voids between aggregates. It forms the bulk
and makes mortar or concrete economical. It provides resistance against
shrinking and cracking. It is naturally available.
Sand is the main component grading zone-IV of IS: 383-1978 was used
with specific gravity of 2.54 and water absorption of 1.8% at 24 hours.

S No. Characteristics Value

 1 Size of Particles Finer than 4.75mm
2 Specific Gravity 2.65

3. COARSE AGGREGATE:

Fig : COARSE AGGREGATE

Coarse aggregates are particulates that are greater than 4.75mm. The
usual range employed is between 9.5mm and 37.5mm in diameter.
Mechanically crushed stone of 20 mm maximum size, satisfying
to IS: 383-1978 was used. The specific gravity was found to be 2.74
and water absorption is 3% at 24 hours of 20 mm aggregates
respectively.

5. FLY ASH: Fly ash or flue ash, coal ash, and also known as pulverised fuel
ash in the United Kingdom, or coal combustion residuals (CCRs), is a coal
combustion product that is composed of the particulates (fine particles of burned
fuel) that are driven out of coal-fired boilers together with the flue gases. Ash that
falls to the bottom of the boiler's combustion chamber (commonly called a firebox)
is called bottom ash. In modern coal-fired power plants, fly ash is generally
captured by electrostatic precipitators or other particle filtration equipment before
the flue gases reach the chimneys. Together with bottom ash removed from the
bottom of the boiler, it is known as coal ash. Depending upon the source and
composition of the coal being burned, the components of fly ash vary considerably,
but all fly ash includes substantial amounts of silicon dioxide (SiO2)
(both amorphous and crystalline), aluminium oxide (Al2O3) and calcium
oxide (CaO), the main mineral compounds in coal-bearing rock strata.
6. SILICA FUME: Silica fume, also known as microsilica, is
an amorphous (non-crystalline) polymorph of silicon dioxide, silica. It is an
ultrafine powder collected as a by-product of the silicon and ferrosilicon alloy
production and consists of spherical particles with an average particle diameter of
150 nm. The main field of application is as pozzolanic material for high
performance concrete.

7. POLYVINYL CHLORIDE:
Polyvinyl chloride (colloquial: polyvinyl, vinyl;[6] abbreviated: PVC) is the
world's third-most widely produced
synthetic plastic polymer (after polyethylene and polypropylene[7]). About 40
million tons of PVC are produced each Ayear.

8. Water : The water used was clean tap water free from any deleterious
substances and impurities and was collected fromthe tap in the workshop
technology lab of our campus. Water is an important ingredient of
concrete as it actively participates in the chemical reaction with cement.
Since it helps to form the strength giving cement gel, the quantity and
quality of water is required to be looked into very carefully. Mixing
water should not contain undesirable organic substances or inorganic
constituents in excessive proportions. In this project clean potable water
is used.

METHODOLOGY :
 5. DIFFERENT TESTS ON THE
MATERIALS
1. CEMENT:
1.1 FIELD TEST

A: Color Test of Cement:

The typical colour of the cement should be grey with a light greenish side. This colour
should be uniform.
B: Presence of Lumps :

Due to the moisture from the atmosphere,cement develops lumps.But it’s not good
to use that for construction. Any bag which is delivered to the site with lumps
should be rejected.
C: Adulteration Test :

This test is performed by feeling the cement with fingers.It should feel
smooth when rubbed in between fingers. If it feels rough, it implies that the
cement is adulterated with sand.

1.2 STANDARD CONSISTENCY TEST :

A:Vicat Apparatus test:

Single mould
The Vicat mould is in the foam of a frustum of a cone having an internal
diameter of 60+/-0.5mm, at the top, 70 +/- 0.5mm at the bottom and height
40 +/_ 0.5mm
.
Test Procedure :

1. Keep the vicat apparatus on a level base (when using vicat apparatus with dashpot,
keep the bearing movable rod to its highest position and pin it.) Unscrew the top of
the dashpot.Half fill the dash pot with any suitable oil of viscosity and screw the
top. Work the plunger a number of times.
2. Attach the plunger for determining standard consistency to the movable rod.
Work the plunger a number of times.
3. Take 400 gm of cement in a pan and a weighed quantity of water in a beaker.
4. Prepare a paste with the water added to cement.Start as top watch at the time of
adding water to cement.
5. Keep the vicatmould on a non porous plate and fill the cement paste in it.
6. After completely filling the mould ,shake its lightly to expel the air. Smooth off
the surface
Of the paste making it level with the top of the moulder .The cement paste thus
prepared is the test block.
7. Place the test block resting on the non porous plate under the movable
rod,bearing the needle.
8. Lower the plunger gently to touch the surface of the cement paste and quickly
release( when vicat apparatus with dashpot is used, place the mould filled with
cement paste and the non absorbent plate on the base plate of the vicat apparatus.
Raise the plunger of the dash pot, bring it in contact with the top cap of the movable
bearing rod.
9. Remove the pin holding the movable bearing rod to the surface of the cement
paste and quickly release by pushing down the plunger to sink in to the paste). This
operation shall be done immediately after filling the mould.
10. Prepare trial test specimens with varying percentages of water until plunger
penetrates to a point 5 to 7mm from the bottom of the vicatmould, which is read on
the scale. Express the water required as percentage by weight of the dry cement.
Observations and Calculations :

1. Weight of cement taken (g) = 400 gm

2. Initial percentage of water added to cement = 30%

3. Quantity of water added to cement = 120gm

TABLE

S.No. Quantity of water added (in gm) Penetration Value ( in mm )

1 112 4
2 116 6
3 120 7

Standard Consistency of Cement =

( Quantity of water for 5 - 7mm penetration / Weight of Cement) x 100 = 30%

(1) Initial and Final Setting Time Test: Vicat Apparatus was used.
Procedure:

1. Take 400g of cement and place it in a bowl or tray.

2. Now add water of Start the stopwatch at the moment water is added to
the cement. Water of quantity 0. 85P.times (Where P is the Standard
consistency of cement) is considered.
 3. Now fill the mix in Vicat mould. If any excessive paste remained on
Vicat mould is taken off by using a trowel.
4. Then, place the VICAT mould on non-porous plate (Glass plate) and
see that the plunger should touch the surface of VICAT mould gently.
5. Release the Plunger and allow it to sink into the test mould.
6. Note down the penetration of the plunger from the bottom of mould
indicated on the scale.
7. Repeat the same experiment at different positions on the mould until
the plunger should stop penetrating 5 from the bottom of the mould.

The time period elapsed between the moment water is added to the cement and the
time, the needle fails to penetrate the mould of 5mm when measured from the
bottom of the mould, is the initial setting time of cement.
Initial setting time was found to be 45 minutes.

(a) (b)

Fig (a), (b) : Consistency Test of Cement

The time period between the moment water is added to the cement and the time at
which needle makes an impression on the surface of the mould, while the
attachment fails to do so, is the final setting time of cement.
Final setting time was found to be 720 minutes.
 2. Fine Aggregates:

(1) Pycnometer Test:

Fig : Weighing of Empty Pycnometer.

1. Measure the weight of empty pycnometer (W1).

2. Take sample of sand and place it in pycnometer. Measure the weight (W2).
3. Pour Distilled water in pycnometer to just immerse the sample.
4. Remove the entrapped air by shaking or rotating the pycnometer.
5. Pycnometer is now completely filled with water up to the top and weighed
(W3).
6. Now empty the pycnometer and clean it.
7. Refill the pycnometer with only water up to the top. It should be completely dry
from the outside. Now weigh it (W4).

Description 1 2 Average
Pycnometer Bottle (W1) 545 545 545
Pycnometer + Sand (W2) 1045 1050 1047
Pycnometer + Sand + Water 1826 1830 1828
(W3)
Pycnometer + Water (W4) 1514 1514 1514
Specific Gravity = ( W2 - W1 ) = 2.65

(W4-W1) –(W3-W2)

(2.) Sieve Analysis: The sample was sieved using 4.75 mm sieve and the
sample which passed through the sieve was used in the project. The sand
used was finer than 4.75mm.