Major Project Report PDF

A PROJECT REPORT ON
PARTIAL REPLACEMENT OF
CEMENT WITH FLY ASH
Submitted in Partial Fulfillment of the

Academic Requirements
For the Award of the Degree of
BACHELOR OF TECHNOLOGY
In
CIVIL ENGINEERING
Submitted By
G.SUDHEER 16675A0105
G.SAGARIKA 16675A0106
A.ANANDA CHARY 16675A0101
A.RADHIKA 15671A0113
Under the essential guidance of
Mr. MARUTHI DEGALVADE, (Asst. Professor)

JBIET
DEPARTMENT OF CIVIL ENGINEERING

J.B. INSTITUTE OF ENGINEERING AND
TECHNOLOGY
(AUTONOMOUS & AFFLIATED TO JNTUH,
HYDERABAD)
Yenkapally, Moinabad Mandal, R.R. Dist.,
Hyderabad-500075
2015-2019
i
J.B.INSTITUTE OF ENGINEERING AND TECHNOLOGY
(UGC Autonomous)
Bhaskar Nagar, Moinabad, Hyderabad, Telangana
www.jbiet.edu.in
CERTIFICATE
This is to certify that the thesis titled “PARTIAL REPLACEMENT OF CEMENT WITH
FLY ASH” is a bonafide work carried out by A.ANANDA CHARY (16675A0101)
G.SAGARIKA (16675A101), G.SUDHEER(16675A0105) & A.RADHIKA (15671A0113) in
partial fulfillment for the award of the degree of Bachelor of Technology in J.B INSTITUTE OF
ENGINEERING AND TECHNOLOGY.
Project Guide Head of the Department

Mr. MARUTHI DEGALVADE Dr. J P GEORGE
(Asst. Professor) (PROFESSOR)
External Examiner
ii
J.B.INSTITUTE OF ENGINEERING AND TECHNOLOGY
(UGC Autonomous)
Bhaskar Nagar, Moinabad, Hyderabad, Telangana
www.jbiet.edu.in
DECLARATION
We G.SUDHEER, G.SAGARIKA, A.ANANDA CHARY & A.RADHIKA

are students of ‘Bachelor of Technology in CIVIL ENGINEERING, session:
2015-19, JB Institute of Engineering & Technology (UGC Autonomous),

Bhaskar Nagar, Moinabad Hyderabad, Telangana, hereby declare that the work
presented in this Project Work entitled “PARTIAL REPLACEMENT OF CEMENT
WITH FLY ASH” is the outcome of our own bonafide work and is correct to the best of
our knowledge and this work has been undertaken taking care of Engineering Ethics. It contains
no material previously published or written by another person nor material which has been
accepted for the award of any other degree or diploma of the university or other institute of
higher learning, except where due acknowledgment has been made in the text.
G.SUDHEER 16675A0105
G.SAGARIKA 16675A0106
A.ANANDA CHARY 16675A0101
A.RADHIKA 15671A0113
iii
ACKNOWLEDGEMENT
We record our profound reverence and keen gratitude to our supervisor Mr. MARUTHI
DEGALVADE Asst Professor, Department of civil Engineering, JBIET. Moinabad for his
constant Guidance, consistent supervision, resourceful criticism, valuable suggestions and
precious time given for completion of this study, which encouraged us to grow towards our goal.
we express our sincere regards to JBIET of Highway Engineering Laboratory. We thanks to our
Batch members for their constant help, support and cooperation throughout the study especially
during experimentation for successful completion of this work. We would forever remain
grateful to them.
We are also very grateful to Prof. Dr. JP GEORGE, Head of the department, for his
continuous Help and guidance during the experiments as well as for giving us any kind of help
whenever we faced problems in calculations or understanding a concept also for leading us
books for reference.
The help and encouragement received from our faculty & Batchmates regarding the concept and
experimentations.
We convey our heartfelt thanks to, Dr. TOWHEED SULTANA, Principal, JBIET. The
institute authority, and Department, Library and Laboratory staffs of JBIET for their cooperation
during our project.
We express our gratitude for our Beloved Parents who helped us a lot and provided inspirational
support for our success.
We would thank to the almighty for being with us throughout our life and rendering his
blessings.
iv
CONTENTS
1.INTRODUCTION 1-10
1.1 GENERAL 1-4
1.1.1 History of cement 1-2
1.1.2 Composition of concrete 2-3
1.1.3 Advantages & dis-advantages of concrete 3-4
1.2 FLY ASH 4-8
1.2.1 Types of fly ash 7
1.2.1 Physical properties of fly ash 7-8
1.3 ADVANTAGES & DIS-ADVANTAGES OF CONCRETE CONTAING FLY ASH 8-9
1.4 AIM & OBJECTIVES 9
1.5 SCOPE OF THIS STUDY 9
2. LITERATURE REVIEW 10-13

2.1 GENERAL 10
2.2 REVIEW OF EARLIER WOKS 10-13
3. MATERIALS AND METHODOLOGY 14-43

3.1 HYDRATION REACTIONS WHEN FLY ASH USED IN OPC 16-17
3.1.1 Reduced heat of hydration 14-15
3.1.2 Workability of concrete 15
3.1.3 Permeability and corrosion protection 15
3.2 HOW FLY ASH CAN BE USED IN CEMENT CONCRETE ? 16-17
3.3 EFFECT OF FLY ASH ON CORBONATION OF CONCRETE 17-19
3.3.1 Sulphate attack 17
3.3.2 Corrosion of steel 17-18
3.3.3 Reduced alkali aggregate reaction 18
3.3.4 Environmental benefits of fly ash used in concrete 18
3.3.5 Physical properties 19
3.4 POZZOLANIC PROPERTIES OF FLY ASH 19
3.4.1 Pozzolanic activity 19
3.5 BUREAU OF INDIAN STANDARD REQUIREMENTS 20
3.6 MATERIAL PROPERTIES 21-23
3.6.1 Cement 21
3.6.2 Fly ash 22
3.6.3 Fine aggregate 22
3.6.4 Coarse aggregate 22-23
3.7 METHODS 23-30
3.7.1 Grain size distribution of fine & coarse aggregate 23-24
3.7.2 Tests on aggregate for concrete – physical properties 24-25
3.7.3 Fineness of cement 25
3.7.4 Standard consistency of cement 25-26
3.7.5 Test on cement initial & final setting time 27-28
3.8 FRESH CONCRETE TESTS – WORKABILITY TESTS 28- 30
3.8.1 Slump cone test 28-29
3.8.2 Compacting factor test 29-30
3.9 HARD CONCRETE TESTS 31-36
3.9.1 Compressive strength of concrete 31-32
3.9.2 Split tensile test 32-34
3.10 PREPARATION OF TEST SPECIMENS 34-36
3.10.1 Details of test specimens 36
3.11 MIX PROPORTION 36-41
3.11.1 Introduction 36
3.11.2 Mix design 36-40
3.11.3 Specimen identification 40-41
4.RESULTS AND DISCUSSIONS 42-52

4.1 GRAIN SIZE DISTRIBUTION OF AGGREGATES 42-44
4.2 TEST ON AGGREGATES 44
4.3 FINENESS OF CEMENT 45
4.4 TEST ON CEMENT – INITIAL & FINAL SETTING TIME 45
4.5 NORMAL CONSISTENCY OF CEMENT 46
4.6 FRESH CONCRETE TEST – WORKABILITY TESTS 46-47
4.6.1 Slump test results 46
4.6.2 Compacting factor test results 47
4.7 HARD CONCRETE TESTS 48-50
4.7.1 Compressive strength test 48-49
4.7.2 Split tensile strength test 50
4.8 COST ANALYSIS 51-53
CONCLUSION 54-55
REFERENCES 56-60
LIST OF FIGURES
1.1 FLY ASH 5

1.2 PROCESSING DIAGRAM FOR FLY ASH 6
3.1 MECHANICAL SIEVE SHAKER 23
3.2 VICAT APPARATUS 26
3.3 TYPES OF SLUMP 29
3.4 COMPACTION FACTOR APPARATUS 30
3.5 COMPRESSIVE STRENGTH TESTING 32
3.6 SPLIT TENSILE STREGTH TESTING 33
3.7 PREPARATION OF CONCRETE 34
3.8 PREPARATION OF SPECIMENS AND MOULD 35
3.9 CURING OF SPECIMENS 35
4.1 SIEVE ANALYSIS OF COARSE AGGREGATE 43
4.2 SIEVE ANALYSIS OF FINE AGGREGATE 43
4.3 SLUMP vs MIX 46
4.4 COMPACTING FACTOR vs MIX 47
4.5 COMPRESSIVE STREGTH OF CONCRETE AT DIFFERENT STAGES 48
4.6 COMPRESSIVE STREGTH OF CONCRETE 49
4.7 SPLIT TENSILE STREGTH OF CONCRETE 50
4.8 PRICE vs MIX for cubes 51
4.9 PRICE vs MIX for cylinders 52
4.10 PRICE VS MIX for 1m³ 53
LIST OF TABLES
1.1 CHEMICAL COMPOSITION OF FLY ASH 6

3.1 PHYSICAL REQUIREMENTS OF FLY ASH as per BIS 20
3.2 CHEMICAL REQUIREMENTS OF FLY ASH as per BIS 20
3.3 PROPERTIES OF CEMENT 21
3.4 PROPERTIES OF FINE AGGREGATE 22
3.5 PROPERTIES OF COARSE AGGREGATE 23
3.6 DETAILS OF TEST SPECIMEN 36
3.7 DETAILS OF MIX PROPORTION 39
3.8 IDENTIFICATION OF CUBES 40
3.9 IDENTIFICATION OF CYLINDERS 41
3.10 MIX PROPORTION for 1m³ 41
4.1 SIEVE ANALYSIS OF FINE AGGREGATE 42
4.2 SIEVE ANALYSIS OF COARSE AGGREGATE 42
4.3 RESULTS OF SIEVE ANALYSIS 44
4.4 RESULTS ON PHYSICAL PROPERTIES OF AGGREGATES 44
4.5 RESULTS ON FINENESS OF CEMENT 45
4.6 RESULTS OF SLUMP TEST 46
4.7 RESULTS ON COMPACTION FACTOR TEST 47
4.8 RESULTS OF COMPRESSIVE STRENGTH 48
4.9 RESULTS OF SPLIT TENSILE STRENGTH 50
4.10 RATE OF MATERILS per Kg 51
4.11 COST ANALYSIS FOR CUBES 51
4.12 COST ANALYSIS FOR CYLINDERS 52
4.13 COST ANALYSIS FOR 1m³ 53

ABSTRACT
The utilization of fly-ash in concrete as partial replacement of cement is gaining huge importance
these days, principally on account of the development within the future sturdiness of concrete
combined with ecological advantages. Technological enhancements in thermal power station
operations and fly-ash assortment systems have resulted in up the consistency of fly-ash. To
review the impact of partial replacement of cement by fly ash studies are conducted on concrete
mixes with 300 to 500 kg/cum cementious materials at 15%, 20%, 25%,30% & 35% fly ash
replacement levels. during this project the result of fly-ash on workability, setting time, density,
air content, compressive strength, durability, size of aggregate, modulus of elasticity Slump test
and Compaction test are studied based on this study compressive strength of different mixes v/s
No of days curves are planned so concrete mixture of grade M30 with distinction proportion of
fly-ash are often directly designed.
PARTIAL REPLACEMENT OF CEMENT WITH FLY ASH
1.INTRODUCTION
1.1 GENERAL
Concrete is the manmade material widely used for construction purposes. The usual ingredients
in concrete are cement, fine aggregate, coarse aggregate, and water. It was recognized long time
ago that the suitable mineral admixtures are mixed in optimum proportions with cement improves
the many qualities in concrete. With increasing scarcity of river sand and natural aggregate across
the country, researches began cheaply available material as an alternative for natural sand.
Utilization of industrial waste or secondary material has increased in construction field for the
concrete production because it contributes to reducing the consumption of natural resources. In
India, there is great demand of aggregates mainly from civil engineering industry for road and
concrete constructions. But, now days it is very difficult problem for availability of fine
aggregates. So researchers developed waste management strategies to apply for replacement of
fine aggregates for specific need. Natural resources are depleting worldwide while at the same
time the generated wastes from the industry are increasing substantially. The sustainable
development for construction involves the use of nonconventional and innovative materials, and
recycling of waste materials in order to compensate the lack of natural resources and to find
alternative ways conserving the environment.
1.1.1 History of cement:

Investigations of L.J. Vicat led him to prepare an artificial hydraulic lime by calcining an intimate
mixture of limestone and clay. This process may be regarded as the leading knowledge to the
manufacture of Portland cement. James Frost also patented a cement of this kind in 1811 and
established a factory in London district. The story of the invention of Portland cement is, however,
attributed to Joseph Aspdin, a Leeds builder and bricklayer, even though similar procedures had
been adopted by other inventors. Joseph Aspdin took the patent of portland cement on 21st
October 1824. The fancy name of portland was given owing to the resemblance of this hardened
cement to the natural stone occurring at Portland in England. In his process Aspdin mixed and
ground hard limestones and finely divided clay into the form of slurry and calcined it in a furnace
similar to a lime kiln till the CO2 was expelled. The mixture so calcined was then ground to a fine
powder. Perhaps, a temperature lower than the clinkering temperature was used by Aspdin. Later
in 1845 Isaac Charles Johnson burnt a mixture of clay and chalk till the clinkering stage to make
JBIET DEPARTMENT OF CIVIL ENGINEERING Page 1

better cement and established factories in 1851. In the early period, cement was used for making
mortar only. Later the use of cement was extended for making concrete. As the use of Portland
cement was increased for making concrete, engineers called for consistently higher standard
material for use in major works. Association of Engineers, Consumers and Cement Manufacturers
have been established to specify standards for cement. The German standard specification for
Portland cement was drawn in 1877. The British standard specification was first drawn up in 1904.
The first ASTM specification was issued in 1904. In India, Portland cement was first
manufactured in 1904 near Madras, by the South India Industrial Ltd. But this venture failed.
Between 1912 and 1913, the Indian Cement Co. Ltd., was established at Portbander (Gujarat) and
by 1914 this Company was able to deliver about 1000 tons of Portland cement. By 1918 three
factories were established. Together they were able to produce about 85000 tons of cement per
year. During the First Five-Year Plan (1951-1956) cement production in India rose from 2.69
million tons to 4.60 million tons. By 1969 the total production of cement in India was 13.2 million
tons and India was then occupying the 9th place in the world, with the USSR producing 89.4
million tonnes and the USA producing 70.5 million tonnes. Prior to the manufacture of Portland
cement in India, it was imported from UK and only a few reinforced concrete structures were built
with imported cement. A three storeyed structure built at Byculla, Bombay is one of the oldest
RCC structures using Portland cement in India. A concrete masonry building on Mount Road at
Madras (1903), the har-ki-pahari bridge at Haridwar (1908) and the Cotton Depot Bombay, then
one of the largest of its kind in the world (1922) are some of the oldest concrete structures in India.
1.1.2 Composition of Concrete:

There are many types of concrete available, created by varying the proportions of the main
ingredients below. In this way or by substitution for the cementitious and aggregate phases, the
finished product can be tailored to its application with varying strength, density, or chemical and
thermal resistance properties.
"Aggregate" consists of large chunks of material in a concrete mix, generally a coarse gravel or
crushed rocks such as limestone, or granite, along with finer materials such as sand. Cement,
commonly Portland cement, and other cementitious materials such as fly ash and slag cement,
serve as a binder for the aggregate. Water is then mixed with this dry composite, which produces
a semi-liquid that workers can shape (typically by pouring it into a form). The concrete solidifies
and hardens to rock-hard strength through a chemical process called hydration. The water reacts

with the cement, which bonds the other components together, creating a robust stone-like material.
Chemicals are added to achieve varied properties. These ingredients may speed or slow down the
rate at which the concrete hardens, and impart many other useful properties including increased
tensile strength and water résistance. Reinforcements are often added to concrete. Concrete can
be formulated with high compressive strength, but always has lower tensile strength. For this
reason it is usually reinforced with materials that are strong in tension (often steel) or, with the
advent of modern technology, cross-linking styrene acrylic polymers.
1.1.3 Advantages and Disadvantages of Concrete

Concrete is an inexpensive, quick and durable way to complete many construction projects.
However, there are advantages and disadvantages associated with this material.
Advantages of Concrete
• Concrete possesses a high compressive strength and is not subjected to corrosive and
weathering effects.
• Concrete can be easily handled and moulded into any shape.
• Concrete can even be sprayed in and filled into fine cracks for repairs. The concrete can
be pumped and hence it can be laid in difficult positions also.
• In reinforced cement concrete (R.C.C), concrete and steel form a very good combination
because the coefficients of expansion of concrete and steel are nearly equal.
• Construction of all types of structures is possible by reinforcing the concrete with steel.
Even earthquake-resistant structures can be constructed.
• Form work can be used a number of times for similar jobs which results in economy.
• Concrete is economical in the long run as compared to other engineering materials. It is
economical when ingredients are readily available.
• Frequent repairs are not needed for concrete structures and the concrete gains strength with
age.
• Concrete’s long life and relatively low maintenance requirements increase its economic
benefits.
• It is not as likely to rot, corrode, or decay as other building materials.
• Building of the molds and casting can occur on the work-site which reduces cost.

• It is resistant to wind, water, rodents, and insects. Hence, concrete is often used for storm
shelters.
Disadvantages of Concrete
Besides being an ideal construction material, it does have following disadvantages.
• Concrete has low tensile strength and hence cracks easily. Therefore, concrete is to be
reinforced with mild steel bars, high tensile steel bars or mesh.
• Concrete expands and contracts with the changes in temperature. Hence expansion joints
are to be provided to avoid the formation of cracks due to thermal movements.
• Fresh concrete shrinks on drying. It also expands and contracts with wetting and drying.
Provision of contraction joints is to be made to avoid the formation of cracks due to drying
shrinkage and moisture movements.
• Concrete is not entirely impervious to moisture and contains and contains soluble salts
which may cause efflorescence. This requires special care at the joints.
• Concrete prepared by using ordinary Portland cement disintegrates by the action of
Alkalies, Sulphates, etc. Special type of cements is to be used under such circumstances.
• Concrete is heavy in weight and requires large quantity of steel in the construction as the
self load is greater.
• Creep develops in concrete under sustained loads and this factor is to taken care of while
designing dams and pre-stressed concrete structures.
• Low ductility.
• Low strength-to-weight ratio.
1.2 FLY ASH

Fly ash, also known as flue-ash, is one of the residues generated in combustion, and comprises the
fine particles that rise with the flue gases. The quantity of fly ash produced from thermal power
plants in India is approximately 80 million tons each year, and its percentage utilization is less
than 10%. Majority of fly ash produced is of Class F type. Fly ash is generally used as replacement
of cement, as an admixture in concrete, and in manufacturing of cement. Whereas concrete
containing fly ash as partial replacement of cement poses problems of delayed early strength
development.

Fly ash is a burnt and powdery derivative of inorganic mineral matter that generates during the
combustion of pulverized coal in the thermal power plant. The burnt ash of the coal contains
mostly silica, alumina, and calcium. The classification of thermal plant fly ash is considered based
on reactive calcium oxide content as class-F (less than 10 %) and class-C (more than 10 %). Indian
fly ash belongs to class-F. The calcium bearing silica and silicate minerals of ash occur either in
crystalline or non-crystalline structures and are hydraulic in nature; they easily reacts with water
or hydrated lime and develop pozzolanic property. But the crystalline mineral phases of quartz
and mullite present in the ash are stable structures of silica and silicates, and are non-hydraulic in
nature. Usually the fly ash contains these two mineral phases as the major constituents. Therefore,
the utilization of fly ash in making building materials like fibre cement sheets largely depends on
the mineral structure and pozzolanic property. Fly ash is broadly an aluminum-silicate type of
mineral rich in alumina and silica. The convecium and iron as the major chemical constituents.
Fig 1.1 Fly Ash

Table 1.1 Chemical composition of fly ash
SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI Free

lime
60.5 30.8 3.6 1.4 0.91 0.14 1.1 0.8
Fig1.2 Processing diagram for fly ash
The way of fly ash utilization includes

• Concrete production, as a substitute material for Portland cement and sand
• Embankments and other structural fills (usually for road construction)
• Grout and Flow able fill production
• Waste stabilization and solidification
• Cement clinkers production - (as a substitute material for clay)
• Mine reclamation
• Stabilization of soft soils
• Road sub base construction
• As Aggregate substitute material (e.g. for brick production)
• Mineral filler in asphaltic concrete
• Agricultural uses: soil amendment, fertilizer, cattle feeders, soil stabilization in stock feed
yards, and agricultural stakes.
• Loose application on rivers to melt ice.

1.2.1 Types of fly ash

Class F Fly ash:
The burning of harder, older anthracite and bituminous coal typically produces Class F fly ash.
This fly ash is pozzolanic in nature, And contains less than 7% lime (CaO). Possessing pozzolanic
properties, the glassy silica and alumina of Class F fly ash requires a cementing agent, such as
Portland cement, quicklime, or hydrated lime mixed with water to react and produce cementitious
compounds. Alternatively, adding a chemical activator such as sodium silicate (water glass) to a
Class F ash can form a geopolymer.
Class C Fly ash:
Fly ash produced from the burning of younger lignite or sub-bituminous coal, in addition to having
pozzolanic properties, also has some self-cementing properties. In the presence of water, Class C
fly ash hardens and gets stronger over time. Class C fly ash generally contains more than 20%
lime (CaO). Unlike Class F, self-cementing Class C fly ash does not require an activator. Alkali
and sulfate (SO4) contents are generally higher in Class C fly ashes. At least one US manufacturer
has announced a fly ash brick containing up to 50% Class C fly ash. Testing shows the bricks
meet or exceed the performance standards listed in ASTM C 216 for conventional clay brick. It is
also within the allowable shrinkage limits for concrete brick in ASTM C 55, Standard
Specification for Concrete Building Brick. It is estimated that the production method used in fly
ash bricks will reduce the embodied energy of masonry construction by up to 90%. Bricks and
pavers were expected to be available in commercial quantities before the end of 2009.
1.2.2 Physical properties of fly ash

The physical properties of fly ash affect concrete mainly in its fresh state. Workability and
bleeding of concrete containing fly ash are dependent primarily on the shape and size of the fly
ash particles.
Fly ash particles range in size from about 100 n to less than 1 n, with approximately 75% or more
passing the 45 n (No.' 325) sieve. The particle size of a fly ash depends primarily on the type of
collection system used and the efficiency of the firing unit used. For equivalent weights, fly ash
particles, being smaller than the cement particles, have a larger surface area. This has a direct
effect in reducing the bleeding rate of a fresh concrete mix. Fly ash particles act as void fillers
between the cement particles, closing pores available for water to escape through. Bleeding in

concrete containing fly ash is also reduced due to the lower mixing water content required for a
given workability as compared to a similar concrete mix containing no fly ash.
Fly ash particles are spherical in nature and can be either solid or hollow. Hollow particles are
termed cenospheres. These are lightweight particles composed of silicate spheres filled with
nitrogen and carbon dioxide. Fly ashes with large concentrations of cenospheres are not desirable
since they are lighter than water and tend to float during the finishing process, producing streaks
on the concrete surface. On the other hand the spherical nature of the solid fly ash particles imparts
improved workability on the concrete, allowing for reductions in the mixing water content as
compared to ordinary concrete mixes.
In general, fly ash has a lower bulk specific gravity than Portland cement. If cement is replaced
on an equal weight basis with fly ash, the fresh concrete will contain a larger volume of fine
particle material as compared to ordinary concrete. This results in an increased volume of paste,
improving the rheological properties of the mix.
1.3 ADVANTAGES & DISADVANTAGES OF CONCRETE CONTAING

F FLY ASH
Advantages:
There are definite advantages, both technical and economical, in using concrete containing fly ash
for structural applications. The use of fly ash benefits concrete in both its fresh and hardened state.
Due to the pozzolanic properties of fly ash, early uses were in mass concrete construction. Davis
et aleat the University of California were the first to conduct a thorough and comprehensive study
on fly ash, its chemical and physical properties and the effect fly ash has on the properties of fresh
and hardened concrete. For a constant water-cementitious ratio (w/cm), concrete containing fly
ash has increased workability compared to portland cement concrete. Bleeding of concrete
containing fly ash is less than that of a comparable concrete mix containing no fly ash. Due to the
pozzolanic nature of the fly ash, concrete containing. Fly ash, has a longer setting time than
portland cement, In addition hardened concrete containing fly ash has properties compared to
portland cement concrete containing fly ash has higher long term strength, sulfate resistance,
lower alkali aggregate reactivity permeability. Concrete. improved Concrete improved and lower
concrete containing fly ash develops higher strength at later ages than portland cement concrete
due to its pozzolanic properties. The increased impermeability, improved sulfate resistance and

improved durability are influenced mainly by the particle size of fly ash. Alkali aggregate
reactivity may be decreased due to the chemical composition of the fly ash.
Disadvantages:
Most of the disadvantages of using concrete containing fly ash reported by engineers result from
a lack of research and available information on the behavior of concrete containing fly ash under
actual field conditions. The high variability in the chemical and physical properties of fly ash is
the main drawback hindering the incorporation of fly ash in a larger percentage of the concrete
produced today.
Possible disadvantages resulting from the use of concrete containing fly ash include:
1. Need for increased quality control.
2. Good quality fly ash may not be readily available in a given region.
3. An additional bin for the storage of fly ash may be required at the ready mix concrete plant.
4. Formwork removal time may increase due to the slower strength gain of concrete containing
f fly ash.
1.4 AIM AND OBJECTIVES

The main objective of replacement of fine aggregate and cement is to increase the strength of
concrete by partial replacement of cement by fly ash. Specific objectives are
1. To experimentally investigate the strength of concrete with partial replacement of cement with
f Fly ash and to compare convectional concrete by conducting, Compressive test & Split tensile
s strength.
2. To study the workability of concrete containing fly ash.
1.5 SCOPE OF THIS STUDY

Total 51 concrete specimens, representing one batch of concrete is made and tested as part of this
study. While mixing procedure and slump were kept constant, the variables studied included fly
ash content, cementitious content, mixing temperature, the effect of mixing time, test age, and
curing conditions. In this study, the research approach followed was to investigate the basic
interactions among concrete components in mix proportions which are suitable for producing
concrete containing fly ash, i.e., fly ash content, and cementitious content.

2.LITERATURE REVIEW
2.1 GENERAL
The present work focuses on the effects of replacement of fine aggregate and cement in concrete.
A detailed review of literature related to the scope of this work is presented in this chapter.
2.2 REVIEW OF EARLIER WORKS

1) Aman Jatale, Kartiey Tiwari, Sahil Khandelwal (2013), “A study on Effects on Compressive
Strength When Cement is Partially Replaced by Fly Ash”. The present paper deals with the effect
on strength and mechanical properties of cement concrete by using fly ash. The utilization of fly-
ash in concrete as partial replacement of cement is gaining immense importance today, mainly on
account of the improvement in the long term durability of concrete combined with ecological
benefits. Technological improvements in thermal power plant operations and fly-ash collection
systems have resulted in improving the consistency of fly-ash. To study the effect of partial
replacement of cement by fly-ash, studies have been conducted on concrete mixes with 300 to 500
kg/cum cementitious materials at 20%, 40%, 60% replacement levels. In this paper the effect of
fly-ash on workability, setting time, density, air content, compressive strength, modulus of
elasticity are studied Based on this study compressive strength v/s W/C curves have been plotted
so that concrete mix of grades M15, M20, M25 with difference percentage of fly-ash can be
directly designed.
2) Arivalagan. S (2013), A Study on Experimental Study on the Flexural Behavior of Reinforced

Concrete Beams as Replacement of cement by fly ash". In this investigation replacement of
cement by fly ash was done to depict the compressive strength of cubes, flexural strength of beams
and split tensile strength of cylinders. The fly ash added with cement to find out the results of
concrete proportion ranging from 15%, 20%, 35%, 40%, 50%. The maximum (35.11Mpa)
compressive strength was obtained in 40% replacement. The results also revealed the effect of fly
ash on RCC concrete elements which shows increment in all compressive strength, split tensile,
flexural strength and energy absorption characters. The results also depicts the value of slump
which lies between 90 to 120 mm and the flexural strength of beam and also get increased by
(21% to 51%) due to the replacement of fly ash.

3) Prof. JayeshkumarPitrod, Dr. L.B.Zala, Dr.F.S.Umrigar, (2012) A study on Experimental

investigations on partial Replacement of cement with fly ash in design Mix concrete. In recent
years, many researchers have established that the use of supplementary cementitions materials
(SCMs) like fly ash (FA), blast furnace slag, silica fume, metakaolin, and rice husk ash (RHA),
hypo sludge etc. can, not only improve the various properties of concrete - both in its fresh and
hardened states, but also can contribute to economy in construction costs. This research work
describes the feasibility of using the thermal industry waste in concrete production as partial
replacement of Replacement of cement with fly ash. The use of fly ash in concrete formulations
as a supplementary cementitious material was tested as an alternative to traditional concrete. The
cement has been replaced by fly ash accordingly in the range of 0% (without fly ash), 10%, 20%,
30% & 40% by weight of cement for M25 and M40 mix. Concrete mixtures were produced, tested
and compared in terms of compressive and split strength with the conventional concrete. These
tests were carried out to evaluate the mechanical properties for the test results for compressive
strength up to 28 days and split strength for 56 days are taken.
4) Rafat Siddique,(2004) A study on Effect of fine aggregate replacement with class F fly ash on
the properties of concrete. This paper presents the results of an experimental investigations carried
out to evaluate the mechanical properties of concrete mixtures in which fine aggregate (sand) was
partially replaced with class F Fly ash. Fine aggregate was replaced with five percentages (10%,
20%, 30%, 40%, 50%) of class F Fly ash by weight. Tests were performed for properties of fresh
concrete. Compressive strength, split tensile strength, flexural strength and modulus of elasticity
were determined at 7, 14, 28, 56, 91, 365 days. Test results indicates significant improvements in
the strength properties of plain concrete by the inclusion of fly ash as replacement of fine
aggregates and can be effectively used in structural concrete.
5) T.G.S Kiran, and M.K.M.V Ratnam, (2014), A study on Fly Ash as a Partial Replacement of
Cement in Concrete and Durability Study of Fly Ash in Acidic (H2SO4) Environment. In this
project report the results of the tests carried out on Sulphate attack on concrete cubes in water
curing along with H2SO4 solution. Also, aiming the use of fly-ash as cement replacement. The
present experimental investigation were carried on fly ash and has been chemically and physically
characterized, and partially replaced in the ratio of 0%, 5%, 10%, 15%, 20% by weight of cement
in concrete. Fresh concrete tests like compaction factor test was hardened concrete tests like

compressive Strength at the age of 28 days, 60 days, 90days was obtained and also durability
aspect of fly ash concrete for sulphate attack was tested. The result indicates that fly ash improves
concrete durability.
6) PONNALA RAMAIAH and PUJARI SAINATH (2016), A study on partial replacement of

cement with fly ash and it’s compressive strength. Compressive strength reduces when cement
replaced fly ash. As fly ash percentage will increase compressive strength and split strength
decreases. Use of fly ash in concrete will save the coal & thermal trade disposal costs and
manufacture a ‘greener’ concrete for construction. The cost analysis indicates that % cement
reduction decreases cost of concrete, however at constant time strength also decreases. This
research concludes that ash will be innovative supplementary building material construction
material however judicious selections are to be taken by engineers.
7) Goutam Varma, Kapil Kushwah, Sharad Chaurasia & Vishwajeet Sharma (2016)a study on
partial replacement of cement with fly ash in concrete and its effects. This research concludes the
study of the effect of fly ash on the properties of concrete‖ for nominal mix of M25 grade of
concrete are as follows. Slump loss of concrete increases with increase in w/c ratio of concrete.
For w/c ratio 0.35 without any admixtures, initial slump cannot be measured by slump cone test
as it is very less. Ultimate compressive strength of concrete decreasing with increase in w/c ratio
of concrete. Slump loss of concrete goes on increasing with increase of quantity of fly ash. The
10% and 20% replacement of cement with fly ash shows good compressive strength for 28 days.
The 30% replacement of cement with fly ash ultimate compressive strength of concrete decreases.
8) Mr. Anurag Verma, Ms. Disha Srivastava, Mr. Neelesh Kumar Singh (2017) A Review on
Partial Replacement of Cement by Fly ash and Effect of Steel. Use of fly ash reduces the voids
and cracks formation and corrosion. Fly ash increases workability, durability and minimizes the
water demand. Fly ash reduces the overall cost by 10-30% of that of concrete when 50% of cement
is replaced and 46% cost reduction when 65% cement is replaced. The setting time is generally
increased by approx. 2 hours by adding fly ash to it. The development of compressive strength,
flexural strength is slow however it holds pace in later days from 7 to 28 days and from 28 to 56
days, 91,182 and 365 days. With increase in content of fly ash, air content increases whereas unit
weight decreases. With increase in content of fly ash, air content increases and unit weight

decreases. Fly ash content increases workability and drainage characteristics. There is a limitation
in addition of fly ash content in concrete so that workability is maintained.
9) Dr.S.Sundararaman & S.Azhagarsamy (2016), Partial Replacement of Cement with Fly Ash
and Silica Fume for Sustainable Construction. Compressive and split tensile strength showed an
increased value with the fly ash is replaced up to 50% at the end of 28 days. Compressive and split
tensile strength reduces when cement replaced by fly ash percentage is increased beyond 50% at
the end of 28 days. The results indicate that replacing cement with fly ash up to 50% is possible
to be used in structural concrete. From the above study, it is concluded that the fly ash and silica
fume may be used as a replacement material for cement. It can be concluded that replacement of
cement with silica fume up to 10 % and 50% of fly ash replacement would render the concrete
more strong and durable.
10) Reagan J. Case, Kai Duan,Thuraichamy & G. Suntharavadivel (2012)On Effects of Fly Ash
as a Partial Replacement of Cement on Concrete Strength. A systematic experiment study of the
effects of fly ash as a partial replacement of cement has been performed. The results demonstrate
that the strength of fly ash containing concrete improves more rapidly with aging, than their fly
ash free counterparts, and an optimum fly ash replacement ratio exists where the maximum
compressive strength of fly ash containing concrete can be achieved. In particular, the maximum
strength for the specimens aged 28 days and above is higher that of fly ash free concrete, and this
phenomenon can be explained by considering the combined effects of the fly ash-aggregate and
cement-aggregate interfaces and the different strength of cement and fly ash.
11) Rachel& J. Detwiler (2013) Research &Development Bulletin.

The original purpose of this work was to evaluate the effectiveness of fly ash as an addition to,
rather than a substitute for, cement in concrete containing alkali-reactive aggregate. The highly
reactive Spratt aggregate was used as the coarse aggregate, while a nonreactive sand was used as
the fine aggregate. Two ASTM C 618 Class F fly ashes were used at 20% and 30% of the cement
as substitution, partial substitution, and addition to the cement. The findings show that the use of
fly ash in concretes retards the strength gain at early ages, particularly when the concrete is cured
at low temperatures. Maintaining rather than reducing the cement content mitigated this effect.

3.MATERIALS AND METHODOLOGY
3.1 HYDRATION REACTIONS WHEN FLY ASH IS USED IN OPC
OPC is made up of four principal mineralogical phases symbolically represented by C 3S, C2S,
C3A and C4AF. The hydration reactions of these chemical compounds as mentioned in the
respective section are as follows:
For C3S:
2C3S + 6H —> C3S2H3+3Ca(OH)2
For C2S:
2C2S + 4H —> C3S2H3+Ca(OH)2
For C3A:
C3A+ 6H —> C3AH6
One of the primary benefits of fly ash is its reaction with available lime and alkali in concrete,
producing additional cementitious compounds. The following equations illustrate the pozzolanic
reaction of fly ash with lime to produce additional calcium silicate hydrate (C-S-H) binder:
Cement Reaction : C3S/ C2S + H → C-S-H + Ca(OH)2
Pozzolanic Reaction : Ca(OH)2 + S → C-S-H
S —- Silica from Fly ash constituents
So, clearly from the above equation we can interpret that the excess lime content produced by the
hydration reactions of cement, which weakens cement by leaching and other processes, is reduced
by the use of silica. Also due to the formation of additional calcium silicate hydrate (C-S-H)
binder, the strength of the mix as whole increases.
3.1.1 Reduced heat of hydration:

In concrete mix, cement and water come in contact, a chemical reaction initiates that produces
binding material and consolidates the concrete mass. the process is exothermic and heat is released
which increases temperature of the mass when fly ash is present in the concrete mass, it plays dual
role for the strength development. Fly ash reacts with released lime and produces binder as

explained above and render additional strength to the concrete. The unreactive portion of fly ash
act as micro aggregates and fills up the matrix to render packing effect and results in increased
strength. The large temperature rise of concrete mass exerts temperature stresses and can lead
micro-cracking and improves the soundness of concrete mass. When fly ash is used as part of
cementitious material, quantum of heat liberated is low and staggers through pozzolanic reactions
and thus reduces micro concrete mass.
3.1.2 Workability of concrete:

Fly ash particles are generally spherical in shape and reduces the water requirement for a given
slump. The spherical shape helps to reduce friction between aggregates and between concrete and
pump line and thus increases workability and improve pumpability of concrete. Fly ash use in
concrete increases fines volume and decreases water content and thus reduces bleeding of
concrete.
3.1.3 Permeability and corrosion protection:

Water is essential constituent of concrete preparation. When concrete is hardened, part of the
entrapped water in the concrete mass is consumed by cement mineralogy for hydration. Some part
of entrapped water evaporates, thus leaving porous channel to the extent of volume occupied by
the water. Some part of this porous volume is filled by the hydrated products of the cement paste.
The remaining part of the voids consists capillary voids and give way for ingress of water.
Similarly,
the liberated lime by hydration of cement is water-soluble and is leached out from hardened
concrete mass, leaving capillary voids for the ingress of water. Higher the water cement ratio,
higher will be the porosity and thus higher will be the permeability. The permeability makes the
ingress of moisture and air easy and is the cause for corrosion of reinforcement. Higher
permeability facilitate ingress of chloride ions into concrete and is the main cause for initiation of
chloride induced corrosion.
Additional cementitious material results from reaction between liberated surplus lime and fly ash,
blocks these capillary voids and also reduces the risk of leaching of surplus free lime and thereby
reduces permeability of concrete.

3.2 HOW FLY ASH CAN BE USED IN CEMENT CONCRETE ?

The main objective of using fly ash in most of the cement concrete applications is to get durable
concrete at reduced cost, which can be achieved by adopting one the following two methods:
Using Fly ash based Portland Pozzolana Cement (PPC) conforming to IS:1489 Part-1 in place of
Ordinary Portland Cement II. Using fly ash as an ingredient in cement concrete.
The first method is most simple method, since PPC is factory-finished product and does not
requires any additional quality check for fly ash during production of concrete. In this method the
proportion of fly ash and cement is, however, fixed and limits the proportioning of fly ash in
concrete mixes.
The addition of fly ash as an additional ingredients at concrete mixing stage as part replacement
of OPC and fine aggregates is more flexible method. It allows for maximum utilization of the
quality fly ash as an important component (cementitious and as fine aggregates) of concrete.
There are three basic approaches for selecting the quantity of fly ash in cement concrete:
I. Partial Replacement of Ordinary Portland Cement (OPC) the simple replacement method.
II. Addition of fly ash as fine aggregates the addition method.
III. Partial replacement of OPC, fine aggregate, and water- a modified replacement method
Simple replacement method: In this method a part of the OPC is replaced by fly ash on a one to
one basis by mass of cement. In this process, the early strength of concrete is lower and higher
strength is developed after 56-90 days. At early ages fly ash exhibits very little cementing value.
At later ages when liberated lime resulting from hydration of cement, reacts with fly ash and
contributes considerable strength to the concrete. This method of fly ash use is adopted for mass
concrete works where initial strength of concrete has less importance compared to the reduction
of temperature rise.
Addition method: In this method, fly ash is added to the concrete without corresponding
reduction in the quantity of OPC. This increases the effective cementitious content of the concrete
and exhibits increased strength at all ages of the concrete mass. This method is useful when there
is a minimum cement content criteria due to some design consideration.

Modified replacement method: This method is useful to make strength of fly ash concrete
equivalent to the strength of control mix (without fly ash concrete) at early ages i.e. between 3
and 28 days. In this method fly ash is used by replacing part of OPC by mass along with adjustment
in quantity of fine aggregates and water. The concrete mixes designed by this method will have a
total weight of OPC and fly ash higher than the weight of the cement used in comparable to control
mix i.e. without fly ash mix. In this method the quantity of cementitious material (OPC + Fly ash)
is kept higher than quantity of cement in control mix (without fly ash) to offset the reduction in
early strength.
3.3 EFFECT OF FLY ASH ON CARBONATION OF CONCRETE:

Carbonation phenomenon in concrete occurs when calcium hydroxides (lime) of the hydrated
Portland Cement react with carbon dioxide from atmospheres in the presence of moisture and
form calcium carbonate. To a small extent, calcium carbonate is also formed when calcium silicate
and aluminates of the hydrated Portland cement react with carbon dioxide from atmosphere.
Carbonation process in concrete results in two deleterious effects (i) shrinkage may occur (ii)
concrete immediately adjacent to steel reinforcement may reduce its resistance to corrosion. The
rate of carbonation depends on permeability of concrete, quantity of surplus lime and
environmental conditions such as moisture and temperature. When fly ash is available in concrete;
it reduces availability of surplus lime by way of pozzolanic reaction, reduces permeability and as
a result improves resistance of concrete against carbonation phenomenon.
3.3.1 Sulphate attack:

Sulphate attacks in concrete occur due to reaction between sulphate from external origins or from
atmosphere with surplus lime leads to formation of etrringite, which causes expansion and results
in volume destabilization of the concrete. Increase in sulphate resistance of fly ash concrete is due
to continuous reaction between fly ash and leached out lime, which continue to form additional
C-S-H gel. This C-S-H gel fills in capillary pores in the cement paste, reducing permeability and
ingress of sulphate ions.
3.3.2 Corrosion of steel:

Corrosion of steel takes place mainly because of two types of attack. One is due to carbonation
attack and other is due to chloride attack. In the carbonation attack, due to carbonation of free

lime, alkaline environment in the concrete comes down which disturbs the passive iron oxide film
on the reinforcement. When the concrete is permeable, the ingress of moisture and oxygen infuse
to the surface of steel initiates the electrochemical process and as a result-rust is formed. The
transformation of steel to rust increases its volume thus resulting in the concrete expansion,
cracking and distress to the structure.
In the chloride attack, Chloride ion becomes available in the concrete either through the
dissociation of chlorides-associated mineralogical hydration or infusion of chloride ion. The
sulphate attack in the concrete decomposes the chloride mineralogy thereby releasing chloride
ion. In the presence of large amount of chloride, the concrete exhibits the tendency to hold
moisture. In the presence of moisture and oxygen, the resistivity of the concrete weakens and
becomes more permeable thereby inducing further distress. The use of fly ash reduces availability
of free limes and permeability thus result in corrosion prevention.
3.3.3 Reduced alkali- aggregate reaction:

Certain types of aggregates react with available alkalis and cause expansion and damage to
concrete. These aggregates are termed as reactive aggregates. It has been established that use of
adequate quantity of fly ash in concrete reduces the amount of alkali aggregate reaction and
reduces/ eliminates harmful expansion of concrete. The reaction between the siliceous glass in fly
ash and the alkali hydroxide of Portland cement paste consumes alkalis thereby reduces their
availability for expansive reaction with reactive silica aggregates.
3.3.4 Environmental benefits of fly ash use in concrete:

Use of fly ash in concrete imparts several environmental benefits and thus it is ecofriendly. It
saves the cement requirement for the same strength thus saving of raw materials such as limestone,
coal etc. required for manufacture of cement. Manufacture of cement is high-energy intensive
industry. In the manufacturing of one tonne of cement, about 1 tonne of CO is emitted and goes
to atmosphere. Less requirement of cement means less emission of CO2 result in reduction in
green house gas emission.
Due to low calorific value and high ash content i n Indian Coal, thermal power plants in India, are
producing huge quantity of fly ash. This huge quantity is being stored / disposed off in ash pond
areas. The ash ponds acquire large areas of agricultural land. Use of fly ash reduces area
requirement for pond, thus saving of good agricultural land.

3.3.5 Physical properties:

The fly ash particles are generally glassy, solid or hollow and spherical in shape. The hollow
spherical particles are called as cenospheres. The fineness of individual fly ash particle rage from
1 micron to 1 mm size. The fineness of fly ash particles has a significant influence on its
performance in cement concrete. The fineness of particles is measured by measuring specific
surface area of fly ash by blaine's specific area technique. Greater the surface area more will be
the fineness of fly ash. The other method used for measuring fineness of fly ash is dry and wet
Sieving. The specific gravity of fly ash varies over a wide range of 1.9 to 2.55.
3.4 POZZOLANIC PROPERTIES OF FLY ASH:

Fly Ash is a pozzolanic material which is defined as siliceous or siliceous and aluminous material
which in itself possesses little or no cementitious value, chemically react with Calcium Hydroxide
(lime) in presence of water at ordinary temperature and form soluble compound comprises
cementitious property similar to cement. The pozzolana term came from Roman. About 2,000
years ago, Roman used volcanic ash along with lime and sand to produce mortars, which possesses
superior strength characteristics & resistances to corrosive water. The best variety of this volcanic
ash was obtained from the locality of pozzolanic and thus the volcanic ash had acquired the name
of Pozzolana.
3.4.1 Pozzolanic activity:

Pozzolanic activity of fly ash is an indication of the lime fly ash reaction. It is mostly related to
the reaction between reactive silica of the fly ash and calcium hydroxide which produce calcium
silicate hydrate (C-S-H) gel which has binding properties. The alumina in the pozzolana may also
react in the fly ash lime or fly ash cement system and produce calcium aluminate hydrate,
ettringite, gehlenite and calcium mono sulpho-aluminate hydrate. Thus the sum of reactive silica
and alumina in the fly ash indicate the pozzolanic activity of the fly ash.
Salient advantage of using fly ash in cement concrete Reduction in heat of hydration and thus
reduction of thermal cracks and improves soundness of concrete mass. Improved workability /
pumpabilty of concrete converting released lime from hydration of OPC into additional binding
material – contributing additional strength to concrete mass. Pore refinement and grain refinement
due to reaction between fly ash and liberated lime improves impermeability.

3.5 BUREAU OF INDIAN STANDARD REQUIREMENTS:

To utilize fly ash as a Pozzolana in Cement concrete and Cement Mortar, Bureau of Indian
Standard (BIS) has formulated IS: 3812 Part - 1 2003. In this code quality requirement for siliceous
fly ash (class F fly ash) and calcareous fly ash (class C fly ash) with respect its chemical and
physical composition have been specified. These requirements are given in table
3.1 &3.2
Table 3.1 Physical requirements of fly ash as per BIS
SL NO CHARACTERISTICS REQUIREMENTS FOR SILICEOUS
FLY ASH & CALCAREOUS FLY ASH
1 Fineness specific surface in m²/kg by 320
blaine’s permeability method, Min
2 Particles retained on 45 micron IS 34
sieve (wet sieving) in % Max
(optional test)
3 Lime..reactivity.avg.compressive 4.5
strength in N/mm²
4 Compressive strength at 28 days in Not less than 80% of the strength of
N/mm², Min corresponding to PCC
5 Soundness by autoclave test expansion 0.8
of specimen in %, Max
Table 3.2 Chemical requirements of fly ash as per BIS

SL CHARACTERISTICS REQUIREMENTS
NO Siliceous fly ash Calcareous
fly ash
1 Silicon dioxide (SiO2) + Aluminium oxide(Al2O3) + 70 50
Iron oxide (Fe2O3) in % by mass , Min
2 Silicon dioxide in % by mass, Min. 35 25
3 Reactive silica in % by mass , Min (optional test) 20 20

4 Magnesium oxide (MgO), in % by mass, Max 5 5
5 Total Sulphur as Sulphur trioxide (SO3) in % 3 3
by mass, Max
6 Total Sulphur as Sulphur trioxide (SO3) in % 1.5 1.5
by mass, Max

3.6 MATERIAL PROPERTIES:

The properties of each material in a concrete mix were studied at this stage. Different tests were
conducted for each material as specified by relevant IS codes. Ordinary Portland cement, fine
aggregate, coarse aggregate, super plasticiser, fly ash and water were used for making the various
concrete mixes considered in this study.
3.6.1 Cement:
Ordinary Portland cement (OPC) confirming to IS 12269-1987 (53 Grade) was used for the
experimental work. Laboratory tests were conducted on cement to determine specific gravity,
fineness, standard consistency, initial setting time, final setting time and compressive strength.
The results are presented in below table.
Table 3.3 Properties of Cement

Particulars Values
Grade 53
Specific gravity 3.15
Standard consistency % 32
Fineness % 3
Initial setting time in 30

minutes
Final setting time in 600
minutes
Compressive strength 7th 37
day (N/mm²)
Compressive strength 28th 53

day (N/mm²)

3.6.2 Fly ash

Fly ash produced from the burning of younger lignite or sub-bituminous coal, in addition to having
pozzolonic properties, also has some self-cementing properties. In the presence of water, Class C
fly ash will harden and gain strength over time. Class C fly ash generally contains more than 20%
lime (CaO).
3.6.3 Fine aggregate

Manufactured sand was used as fine aggregate. Laboratory tests were conducted on fine aggregate
to determine the different physical properties as per IS 2386 (Part III)-1963. Fineness modulus is
the index of coarseness or fineness of material. It is an empirical factor obtained by adding
cumulative percentage of aggregate retained on each of the standard sieves and dividing this by
100. The properties of fine aggregate are presented in Table 3.4.
Table 3.4 Properties of fine aggregate
Particulars Values
Fineness modulus 3.06
Bulk density 1.451
Void ratio 0.644
D10 (mm) 0.37
3.6.4 Coarse aggregate

The size of aggregate between 20mm and 4.75mm is considered as coarse aggregate. Laboratory
tests were conducted on coarse aggregates to determine the different physical properties as per IS
2386 (Part III)-1963.This test was conducted for 20mm size aggregate. This method is useful for
finding the particle size distribution of aggregates. They were considered as per IS 383 -1970. The
properties of coarse aggregate are shown in Table 3.5.

Table 3.5 Properties of coarse aggregate
Particulars Values
Fineness modulus 7.17
Bulk density 1.594
Void ratio 0.878
D10 (mm) 11
3.7 METHODS:
The methods used to determine the properties of materials and concrete are given below
3.7.1 Grain Size Distribution of Fine Aggregate, Coarse Aggregate

This test is performed to determine the percentage of different grain sizes contained within a soil.
The mechanical or sieve analysis is performed to determine the distribution of the coarser, larger-
sized particles. The aggregate most of which passes IS 4.75 mm sieve is classified as fine
aggregate and retained on 4.75 mm sieve is classified as a coarse aggregate. From the sieve
analysis the particle size distribution or gradation in a sample of aggregate can be obtained. A
sample may be well graded, poorly graded or uniformly graded. The term D10 or effective size
represents sieve opening such that 10% of the particle are finer than this size. Similarly D30 and
D60 can also be obtained from the graph. The uniformity coefficient, Cu= D60/D10. Fineness
modulus is a term indicating the coarseness or fineness of the material. It is obtained by adding
the cumulative % of aggregate retained on each of the sieve and dividing them by 100.
Fig 3.1 Mechanical sieve shaker

Procedure:
i. About 2 Kg of dried sample is weighed
ii. The sieves are arranged with largest sieve on the top and pan at the bottom. this setup is then
placed in the sieve shaker.
iii. The weighed sample is placed on the top sieve and sieved continuously for 15min by operating
the sieve shaker.
iv. At the end of sieving, 150 micron and 75 micron sieves are cleaned from the bottom by light
brushing with fine hair brush.
v. On completion of sieving the material retained on each sieve together with any material cleaned
from mesh is weighed.
vi. This procedure is done for coarse, fine aggregates.
vii. A curve is drawn between percentage passing and the sieve size for coarse, fine aggregate.
3.7.2 Test on Aggregates for Concrete – Physical Properties

To determine the bulk density, void ratio, specific gravity and porosity of the given course and
fine aggregates in loose and compact states. bulk density is the weight of unit replacement of
cement by fly ash volume of aggregate. in estimating quantities of material sand in mix
computations, when batching is done on a volumetric basis, it is necessary to know the conditions
under which the aggregate volume is measured (a) loose or compact (b) dry, damp or inundated.
for general information and for comparison of different aggregates, the standard conditions are
dry and compact. for scheduling volumetric batch quantities, the unit weight in the loose, damp
state should be known. void ratio refers to the spaces between the aggregates particles. numerically
this void ratio space is the difference between the gross or overall volume of the aggregate and
the space occupied by the aggregate particles alone. void ratio is calculated as the ratio between
the volume of voids and volume of solids. porosity is the ratio between the volume of voids and
the total volume. specific gravity of aggregates is the ratio of the mass of solid in a given volume
of sample to the mass of an equal volume of water at the same temperature.
Procedure
i. Clean the cylindrical container and weighed (w1).
ii. Fill the container by coarse aggregate.
iii. Surplus aggregate is removed.

iv. The container with material is weighed (w2).

v. Water is poured into the container until the voids are completely filled. the weight is noted asw3.
vi. The container is cleaned and filled completely with water and weighed (w4).
vii. The procedure is repeated for fine aggregate.
3.7.3 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. Greater fineness increases the surface
available for hydration, causing greater early strength and more rapid generation of heat. Cement
fineness play a major role in controlling concrete properties. Fineness of cement affects the place
ability, workability, and water content of a concrete mixture much like the amount of cement used
in concrete does. Test Method: IS: 4031 (P-2)1990.
Procedure
i. Weighed accurately 100gm of cement.
ii. Placed it on a standard IS 90 micron sieve.
iii. Break down any air set lumps in the cement sample with finger.
iv. Continuously sieved the sample by holding the sieve with hands. Sieved with a gentle wrist
motion for a period of 15 minutes, rotating the sieve continuously throughout the sieving,
involving no danger of spilling the cement.
v. Weighed the residue after 15 minutes of sieving.
vi. Repeated the procedure for two more such samples.
3.7.4 Standard Consistency of Cement

Standard consistency of cement paste is defined as the consistency which will permit the vicat’s
plunger (10 mm diameter, 50 mm long) to a point 5mm to 7mm from bottom of the vicat’smould.
Cement paste of normal consistency is defined as percentage of water by weight of cement which
produces a consistency that permits a plunger of 10mm diameter to penetrate up to a depth of
5mm to 7mm above the bottom of the vicat mould. Before performing the test for initial setting
time, final setting time, compressive strength, tensile strength and soundness of cement etc. it is
necessary to fix the quantity of water to be mixed to prepare a paste of cement of standard

consistency. The quantity of water to be added in each of the above mentioned experiment beares
a definite relation with the percentage of water for standard consistency.
Fig 3.2 Vicat Apparatus
Procedure:
i. Weigh about 300g of cement accurately and place it in the enamel trough.
ii. To start with, add about 28% of clean water and mix it thoroughly with cement. Care should be
taken that the time of gauging is not less than 3minutes and not more than 5 minutes. The gauging
time shall be counted from the time of adding water to the dry cement until commencing to fill
the mould.
iii. Fill the vicat mould with this paste.
iv. Make the surface of the cement paste in level with the top of the mould with trowel. The mould
should be slightly shaken to expel the air.
v. Place this mould under the rod bearing the plunger. Adjust the indicator to show 0-0 reading
when it touches the surface of the test block.
vi. Release the plunger quickly, allowing it to sink into the paste.
vii. Prepare trial paste with varying percentage of water and the test is repeated until needle
penetrates 5mm to7mm above the bottom of the mould.
viii. Express the amount of water as a percentage by weight of the dry cement.

3.7.5 Test on Cement-Initial and Final Setting Time

The initial setting time is regarded as the time elapsed between the moment that the water is added
to the cement and the time that the paste starts losing its plasticity. The final setting time is the
time elapsed between the moment that the water is added to the cement and the time when the
paste has completely lost its plasticity and has attained sufficient firmness to resist certain definite
pressure. It is essential that cement set neither too rapidly nor too slowly. The initial setting time
should not be too long which causes insufficient time to transport and place the concrete before it
becomes too rigid. Also, the final setting time should not be too high which tends to slow down
the concrete work and also it might postpone the actual use of the structure because of inadequate
strength at the desired age.
Procedure: Initial setting time

i. Weigh about 300g of neat cement.
ii. Prepare a neat cement paste by adding 0.85 times the percentage of water required for standard
consistency.
iii. Start the stop watch at the instant when water is added to the cement.
iv. Fill the vicat mould with the cement paste prepared. Gauging time should not be less than 3
minutes and more than 5 minutes.
v. Fill the mould completely and smooth of the surface of the paste, making it level with the top
of the mould to give a test block.
vi. Place the test block under the rod bearing the needle.
vii. Lower the needle gently till it comes in contact with the surface of the test block and quickly
release, allowing it to penetrate the test block and note penetration after every two minutes. viii.
Repeat this procedure until the needle fails to pierce the block for about 5mm to7mm, measured
from the bottom of the mould and note corresponding time, which is the initial setting time.
Procedure: Final setting time

i. Replace the needle by the needle with an annular attachment.
ii. Go on releasing the needle as described earlier till the needle makes an impression there on,
while the attachment fails to do so.

iii. Time that elapse between the moment water is added to the cement and the needle with annular
attachment fails to make an impression is noted as the final setting time for the given sample of
cement.
3.8 FRESH CONCRETE TESTS - WORKABILITY TESTS

Fresh concrete or plastic concrete is freshly mixed material, which can be moulded into any shape.
The relative quantities of cement, aggregate, mineral admixtures, chemical admixtures and water
mixed together, control the concrete properties in the fresh state. Workability is defined as the
ease with which concrete can be compacted. It is the property of concrete which determines the
amount of useful internal work necessary to produce full compaction. Slump test was done to
measure the workability of concrete mix. The compacting factor test is also done because it is
more precise than the slump test and is particularly useful for concrete mixes of very low
workability as are normally used when concrete is to be compacted by vibration.
3.8.1 Slump test

Slump test is used to determine the workability of fresh concrete. The apparatus used for doing
slump test are Slump cone and Tamping rod. This is the most commonly used test of measuring
the consistency of concrete. It is not a suitable method for very wet or very dry concrete. It does
not measure all factors contributing neither workability, nor it is always representative of the place
ability of the concrete. However, it is used conveniently as a control test and gives an indication
of the uniformity of concrete from batch to batch. It is performed with the help of a vessel, shaped
in form of a frustum of a cone opened at both ends. Diameter of top end is 10 cm while that of the
bottom end is 20 cm. Height of the vessel is 30 cm. A 16 mm diameter and 60 cm long steel rod
is used for tamping purposes.
Procedure:
i. The internal surface of the mould is thoroughly cleaned and applied with a light coat of oil.
ii. The mould is placed on a smooth, horizontal, rigid and nonabsorbent surface.
iii. The mould is then filled in four layers with freshly mixed concrete, each approximately to
one-fourth of the height of the mould.
iv. Each layer is tamped 25 times by the rounded end of the tamping rod (strokes are distributed
evenly over the cross section).

v. After the top layer is rodded, the concrete is struck off the level with a trowel.
vi. The mould is removed from the concrete immediately by raising it slowly in the vertical
direction.
vii. The difference in level between the height of the mould and that of the highest point of the
subsided concrete is measured.
viii. This difference in height in mm is the slump of the concrete.
Fig 3.3 Types of slump
3.8.2 Compacting factor

Compacting factor of fresh concrete is done to determine the workability of fresh concrete. The
compacting factor test is designed primarily for use in the laboratory but can also be used in the
field. It is more precise and sensitive than the slump test. Such dry concrete are insensitive to
slump test. The equipment used for conducting this experiment consists of three containers A, B
and C. A and B are of truncated cone shaped vessels fixed to a stand and C is a detached cylinder,
which can be opened downwards. The apparatus used is Compacting factor apparatus.
Procedure
i. The sample of concrete is placed in the upper hopper up to the brim.
ii. The trap-door is opened so that the concrete falls into the lower hopper.
iii. The trap-door of the lower hopper is opened and the concrete is allowed to fall into the cylinder.

iv. The excess concrete remaining above the top level of the cylinder is then cut off with the help
of plane blades.
v. The concrete in the cylinder is weighed. This is known as weight of partially compacted
concrete.
vi. The cylinder is filled with a fresh sample of concrete and vibrated to obtain full compaction.
The concrete in the cylinder is weighed again. This weight is known as the weight of fully
compacted concrete.
weight of partially compacted concrete
Compacting factor =
weight of fully compacted concrete
Fig 3.4 Compaction factor apparatus

3.9 HARD CONCRETE TESTS

3.9.1 Compressive strength of concrete
For cube test two types of specimens either cubes of 15 cm X 15 cm X 15 cm upon the size of
aggregate are used. For most of the works cubical moulds of size 15 cm x 15cm x 15 cm are
commonly used. This concrete is poured in the mould and tempered properly so as not to have
any voids. After 24 hours these moulds are removed and test specimens are put in water for curing.
The top surface of these specimens should be made even and smooth. This is done by putting
cement paste and spreading smoothly on whole area of specimen. These specimens are tested by
compression testing machine after 7 days curing or 28 days curing. Load at the failure divided by
area of specimen gives the compressive strength of concrete.
Procedure:
i. Mix the cement and fine aggregate on a water tight none-absorbent platform until the mixture is
thoroughly blended and is of uniform color.
ii. Add the coarse aggregate and mix with cement and fine aggregate until the coarse aggregate
is uniformly distributed throughout the batch.
iii. Add water and mix it until the concrete appears to be homogeneous and of the desired
consistency.
iv. Clean the moulds and apply oil.
v. Fill the concrete in the moulds in layers.
vi. Compact each layer with 25 strokes per layer using a tamping rod.
vii. Level the top surface and smoothen it with a trowel. The test specimens are stored in moist
air for 24 hours and after this period the specimens are marked and removed from the moulds
and kept submerged in clear fresh water until taken out prior to test.
viii. Remove the specimen from water after specified curing time of 7 and 28 days and wipe out
excess water from the surface.
ix. Clean the bearing surface of the testing machine.
x. Place the specimen in the machine in such a manner that the load shall be applied to the
opposite sides of the cube cast.
xi. Align the specimen centrally on the base plate of the machine. Rotate the movable portion
gently by hand so that it touches the top surface of the specimen.
xii. Apply the load gradually without shock and continuously till the specimen fails.

xiii. Record the maximum load of failure and note the values at 7th and 28th days.
Fig 3.5 Compressive strength testing
3.9.2 Split tensile tests

The concrete is not usually expected to resist the direct tension because of its low tensile stress
and brittle nature. However, the determination of tensile strength of concrete is necessary to
determine the load at which the concrete members may crack. The cracking is a form of tension
failure. The split tensile strength was determined by testing cylinders of size 150mm diameter and
300mm height in compressive testing machine. The split tensile strength of concrete was then
calculated using the equation.
T = 2P/ (πDL)

Fig 3.6 Split tensile strength testing
Procedure:
i. Mix the cement and fine aggregate on a water tight none-absorbent platform until the mixture is
thoroughly blended and is of uniform color.
ii. Add the coarse aggregate and mix with cement and fine aggregate until the coarse aggregate is
uniformly distributed throughout the batch.
iii. Add water and mix it until the concrete appears to be homogeneous and of the desired
consistency.
iv. Clean the moulds and apply oil.
v. Fill the concrete in the moulds in layers.
vi. Compact each layer with 25 strokes per layer using a tamping rod.
vii. Level the top surface and smoothen it with a trowel. The test specimens are stored in moist air
for 24 hours and after this period the specimens are marked and removed from the moulds and
kept submerged in clear fresh water until taken out prior to test.
viii. Remove the specimen from water after specified curing time of 7 and 28 days and wipe out
excess water from the surface.
ix. Set the compression testing machine for the required range.
x. Bring down the upper plate to touch the specimen.

xi. Apply the load without shock and increase it continuously at the rate to produce a split tensile
stress of approximately 1.4 to 2.1N/mm²/min, until no greater load can be sustained. Record the
maximum load applied to specimen.
3.10 PREPARATION OF TEST SPECIMENS
Fig 3.7 Preparation of concrete
Mixing was done in a laboratory by hand mixing. While preparation of concrete specimens,
aggregates, cement and mineral admixtures were mixed with the showel and trowels. After
proper mixing, mixture of water and plasticizer were added. The mixing was continued until a
uniform mix was obtained. The concrete was then placed into the moulds which were properly
oiled. After placing of concrete in moulds proper compaction was given using the tamping
roads. Specimens were demoulded after 24 hours of casting and were kept in a curing tank for
curing till the age of test.

Fig 3.8 Preparation of specimen and mould
Fig 3.9 Curing of specimens

3.10.1 Details of Test Specimens

Standard moulds were used for casting 150mm cube specimen, 150mm diameter and 300mm
height cylinders. A total of 51 specimens were cast and the details are given in Table 3.6.
Table 3.6 Details of test specimen
Serial No Specimen Size (mm) Numbers

1. Cube 150x150x150 36
2. Cylinder 150x300 15
3.11 MIX PROPORTION

3.11.1 Introduction
The mix proportion for the M30 grade of concrete was arrived through trial mixes. Mix design is
done as per IS: 10262-2009.The mix proportion for M30 grade of concrete is shown in Table 3.7.
3.11.2 Mix design
Design stipulations for proportion
• Grade designation : M30
• Type of cement : OPC 53 grade
• Maximum nominal size of aggregate : 20mm
• Minimum cement content : 300kg/m³
• Maximum water cement ratio : 0.55
• Workability : 25 mm Slump
• Exposure condition : Mild
• Degree of supervision : Good
• Type of aggregate : Crushed granular
• Maximum cement content : 450kg/m³
Test data for materials
• Cement used : OPC 53 grade
• Specific gravity of cement : 3.15
• Specific gravity of
1. Coarse aggregate : 2.65

2. Fine aggregate : 2.38

• Water absorption
1. Coarse aggregate : 0.5
2. Fine aggregate : 1.0
• Free[ surface] moisture
1. Coarse aggregate : Nil
2. Fine aggregate : Nil
• Sieve analysis
1. Coarse aggregate : Confirming to Table 8(IV) of IS 383-2016
2. Fine aggregate : Confirming to Zone-I of IS 383-2016
A. Target strength for mix proportioning:

f 'ck = fck + ks
From IS 10262-2009of table-1, standard deviation,(S) = 5 N/mm²
Therefore target strength = 30 + [5x1.65]
= 38.25 N/mm²
B. Selection of w/c ratio:

From table 5 of IS 456:2000,
Maximum water cement ratio = 0.55
Adopt water cement ratio as 0.5 which is less than 0.55, hence O.K.
C. Selection of water content:

From table, maximum water content = 186 liters [for 25 -50slump]
[For workability other than 25 mm - 50 mm range the required water content may be increased by
about 3 percent for every additional 25 mm slump].
Final water content = 186 liters
D. Calculation of cement content:

w/c ratio = 0.5
Cement content = 186/0.5 = 372 kg/m³

(From the table-5 of IS 456-2000 the minimum content for mild exposure in RCC is 300
kg/m³)∴∴ 372 > 300 kg/m³ OK
E. Determination of coarse aggregate and fine aggregate content:

(From the table-3 of IS 10262-2009 volume of coarse aggregate corresponding to 20mm
size aggregate of zone-II is 0.6)
Volume of fine aggregate = 1-0.6 = 0.4
Mix Calculation:-
a) Volume of concrete = 1 m³
b) Volume of cement = (mass of cement / specific gravity of cement× 1000)
= (372/3.15 x 1000) = 0.1180 m³
c) Volume of water = mass of water/1000
= 186/1000 = 0.186 m³
d) Volume of CA & FA = a-(b+c)
= 1-[0.118+0.186] = 0.696
e) Mass of coarse aggregate = (d)×Vol of CA×S.G of CA×1000
= 0.696×0.6×2.65×1000
= 1107 kg
f) Mass of fine aggregate = (d)×Vol of FA×S.G of FA×1000
= 0.696×0.4×2.38×1000
= 662.6 kg
Mix Proportion
For 1m³ concrete
Cement = 372 kg/m³
Water = 186 liters/m³
Fine aggregate = 662 kg/m³
Coarse aggregate = 1107 kg/m³
w/c ratio = 0.5

Table 3.7 Details of Mix
Mix No Water (liters) Cement Fine aggregate Coarse aggregate w/c ratio
(kg/m³) (kg/m³) (kg/m³)
1 186 372 662 1107 0.5
Design Mix Proportion = 1 :1.78 :2.97
Quantity of materials required:

For one cube of size 150mm×150mm×150mm
The formula for calculation of materials for required volume of concrete is given by:
Where,
Vc = Absolute volume of fully compacted fresh concrete
W = Mass of water
C = Mass of cement
Fa = Mass of fine aggregates
Ca = Mass of coarse aggregates
Sc, Sfa and Sca are the specific gravities of cement, fine aggregates and coarse aggregates
respectively
The air content has been ignored in this calculation.
This method of calculation for quantities of materials for concrete takes into account the mix
proportions from design mix or nominal mixes for structural strength and durability requirement.

Calculating Quantity of Materials required for one cube of 150 mm size:
0.5y y 1.78y 2.97y

0.15³ = + + +
1000 1000X3.15 1000X2.38 1000X2.65
Where,
y = quantity of cement required for one cube of size 150mm
By solving the above equation we got y = 1.256 kg
∴ Quantity of materials required for one cube of 150 mm size

Cement = 1.25 kg
Water = 0.62 kg
Fine aggregate = 2.23 kg
Coarse aggregate = 3.37 kg
Similarly For one cylinder of size 15 cm diameter and 30 cm height is

Cement = 1.97 kg
Water = 0.98 kg
Fine aggregate = 3.51 kg
Coarse aggregate = 5.86 kg
3.11.3 Specimen Identification:

a) identification for cubes
Table 3.8 Identification of cubes
Designation Cement % Fly ash % Fine aggregate % Coarse aggregate % No of cubes
N 100 0 100 100 6
S1 85 15 100 100 6
S2 80 20 100 100 6
S3 75 25 100 100 6
S4 70 30 100 100 6
S5 65 35 100 100 6

b) identification for cylinders

Table 3.9 identification of cylinders
Designation Cement % Fly ash % Fine aggregate % Coarse aggregate % No of cubes
N 100 0 100 100 3
S1 85 15 100 100 3
S2 80 20 100 100 3
S3 75 25 100 100 3
S4 70 30 100 100 3
Table 3.10 Mix Proportion for 1m³

Mix Water Cement Fly ash Fine Coarse Test specimen
designation (liters) (kg/m³) (kg/m³) aggregate aggregate
cubes cylinders
(kg/m³) (kg/m³)
N 186 372 0 662 1107 6 3
S1 186 316.2 55.8 662 1107 6 3
S2 186 297.6 74.4 662 1107 6 3
S3 186 279 93 662 1107 6 3
S4 186 260.4 111.6 662 1107 6 3
S5 186 241.8 130.2 662 1107 6 ---

4. RESULTS AND DISCUSSIONS

4.1 GRAIN SIZE DISTRIBUTION OFAGGREGATES
Results
Table 4.1 Sieve analysis of fine aggregate
IS Sieve size Weight retained % Weight retained Cumulative% Cumulative
weight retained weight of passing
4.75mm 0.105 5.25 5.25 94.75
2.36mm 0.137 6.85 12.1 87.9
1.18mm 0.366 18.3 30.4 69.6
600µ 0.686 34.3 64.7 35.3
300µ 0.589 29.45 94.15 5.85
150µ 0.107 5.35 99.5 0.5
Σ cumulative % retained
Fineness modulus = = 3.06 %
100
Table 4.2 Sieve analysis of coarse aggregate
IS Sieve size Weight % Weight Cumulative% Cumulative

retained retained weight retained weight of passing
80mm 0 0 0 100
40mm 0 0 0 100
20mm 0.5 25 25 75
10mm 1.41 70.5 95.5 4.5
4.75mm 0.071 3.55 99.05 0.95
2.36mm 0.010 0.5 99.55 0.45
1.18mm 0 0 99.55 0.45
600µ 0 0 99.55 0.45
300µ 0 0 99.55 0.45
150µ 0 0 99.55 0.45
Σ cumulative % retained
Fineness modulus = = 7.713%
100

Fig 4.1 Sieve analysis of Coarse aggregate
Fig 4.2 Sieve analysis of Fine aggregate

Table 4.3 Results of sieve analysis

Particulars Coarse aggregate Fine aggregate
Effective size D10 11 0.37
Uniformity coefficient 1.54 2.54
Coefficient of curvature 1.048 0.807
Fineness % 7.173 3.06
Zone Zone 1 Zone1
4.2 TESTS ON AGGREGATES

Properties
Table 4.4 Results on physical properties of aggregate
Particulars Fine aggregates Coarse aggregates
Bulk density(kg/m³) 1.451 1.594
Void ratio 0.644 0.878
Specific gravity 2.386 2.994
Porosity 39.18 46.75
Discussions:
The bulk density depends on the particle size distribution and shape of the particle. The higher the
bulk density, lower the void content to be filled by the aggregate. Here, the bulk density is higher
in compact condition than in loose condition i.e, the voids are less in compact condition. And it
can be understood from void ratio and porosity that voids are less in compact condition.

4.3 FINENESS OF CEMENT

Result
Table 4.5 Results on fineness of cement
SL NO Weight of cement tested Weight..of % Weight of Fineness of cement
(g) cement retained retained (%)
on sieve (g)
1 100 3 3
3
2 100 3 3
Average fineness of cement = 3%
Discussions
Fineness of cement will give large surface area of chemical reaction and thereby increasing the
rate of heat evolution and rate of hydration. As per IS 4031-1988, the fineness of cement should
not be exceed 10%. The obtained value is 3%, which is less than specified value. Therefore it can
be used for building construction.
4.4 TEST ON CEMENT-INITIAL AND FINAL SETTING TIME

Results
Initial setting time is 30 minutes and Final setting time is 600 minutes which is approximately 10
hrs.
Discussion
As per IS 4031 (part 5) the initial setting time of Portland cement should not be less than 30
minutes and final setting time is about 10 hours. The setting time is influenced by temperature,
humidity and quantity of gypsum in cement. For the given sample the initial setting time was
obtained as 30 minute and final setting time as 600 minute. Hence it can be used for transportation,
placing, compaction and delaying the process of hydration or hardening of cement. The final
setting time facilitates safe removal of scaffolding or form.

4.5 NORMAL CONSISTENCY OF CEMENT

Results: Normal consistency of cement is 32%.
Discussion
As per IS 4031 (part 4) 1988, the standard consistency is percentage of water by weight of cement
that permits the plunger of 10mm diameter to penetrate upto a depth of 5mm7mm about the bottom
of mould. Its relative mobility of a freshly mixed cement paste or mortar or its ability to flow.
Generally, thenormal consistency of standard cement ranges from 26%-33%. In the experiment,
the normal consistency of cement was obtained as 32%, which is within the specified limit. Hence
this consistency can be used to determine water content for other tests like initial and final setting
time, soundness and compressive strength.
4.6 FRESH CONCRETE TESTS-WORKABILITY TESTS

4.6.1 Slump tests results
Table 4.6 Results of slump test
Mix Slump (mm)
N 25
S1 27
S2 30
S3 33
S4 32
S5 36
Slump vs Mix
40 36
35 33 32
30
30 27
25
25
Slump
20
15
10
5
0
N S1 S2 S3 S4 S5
Mix
Fig 4.3 Slump vs Mix

4.6.2 Compacting factor tests

Results
Table 4.7 Results on compaction factor test
Mix Compacting factor
N 0.9
S1 0.85
S2 0.88
S3 0.91
S4 0.92
S5 0.94
Compaction factor vs Mix

0.96
0.94
0.94
0.92
0.92 0.91
Compaction factor
0.9
0.9
0.88
0.88
0.86 0.85
0.84
0.82
0.8
N S1 S2 S3 S4 S5
Mix
Fig 4.4 Compacting factor vs Mix

Discussions of Workability tests:
It is clear that the workability of concrete increases significantly with the increase of fly ash
content in concrete mixes. This considerable increase in the workability with the increase of fly
ash quantity is attributed to the low water absorption characteristics of fly ash.The highest
compaction factor is obtained at 35% replacement. The spherical shaped particles of fly ash act as
miniature ball bearing with in the concrete mix and this leads to the improvement of workability
of concrete or reduction of unit water content.

4.7 HARD CONCRETE TESTS

4.7.1 Compressive strength tests
Results
Table 4.8 Results of compressive strength
Mix 7thday (N/mm²) 28th day(N/mm²)
N 24.4 37.3
S1 21.5 34.9
S2 22.7 36.7
S3 29.4 44.6
S4 25.1 39.2
S5 18.2 31.6
Compressive strength (N/mm²)

50
44.6
45
39.2
40 37.3 36.7
34.9
35 31.6
29.4
30
24.4 25.1
25 21.5 22.7
20 18.2
15
10
5
0
N S1 S2 S3 S4 S5
Mix
7th day 28th day
Fig 4.5 Compressive strength of concrete at different stages

50 Compressive strength of cubes (N/mm²)

44.6
45
39.2
40 37.3
36.7
34.9
35
31.6
29.4
30
24.4 25.1
25 22.7
21.5
20 18.2
15
10
0
7th day 28th day
Mix
N S1 S2 S3 S4 S5
Fig 4.6 Compressive strength of concrete
Discussions:
It can be seen that there is increase in strength with the increase in fly ash percentages. The highest
compressive strength was achieved by 25% replacement of fly ash, which was found about
44.60Mpa compared with 37.3Mpa for the control mixture at 28th day. The compressive strength
of concrete is increased as fly ash content increases up to 30%, beyond that compressive strength
was significant decreases due to increases free water content in the mixes. This means that there
is an increase in the strength of 20% compared to the control mix. However, mixtures with 35%
replacement of fly ash gave the lowest compressive strength 31.6Mpa. It is recommended that up
to 35% of fly ash can be use as replacement of cement.

4.7.2 Split tensile strength
Result
Table 4.9 Results of split tensile strength
Mix 28th day
N 2.73
S1 2.85
S2 2.98
S3 3.66
S4 2.61
Split tesile stregth at 28th day (N/mm²)

4 3.66
Split tensile strength (N/mm²)
3.5
2.98
3 2.85
2.73
2.61
2.5
1.5
0.5
0
N S1 S2 S3 S4
Mix
28th day
Fig 4.7 Split tensile strength of concrete (N/mm²)

Discussions:
The highest split tensile strength was achieved by 25% replacement of fly ash, which was found
about 3.66N/mm² compared with 2.73 N/mm² for the control mix. This means that there is an
increase in the strength of almost 35% compared to the control mix at 28 days.

4.8 COST ANALYSIS
Cost analysis was performed for the standard and current rates of material. Table shows the rate
of each material per kilogram.
Table 4.10 Rate of materials per kg
Material Current rate/kg
Cement 8
Fly ash 1
Fine aggregate 2.5
Coarse aggregate 2
Table 4.11 Cost analysis for cubes

Material Rate/kg N (kg) S1 (kg) S2(kg) S3(kg) S4(kg) S5(kg)
Cement 8 1.25 1.062 1.00 0.937 0.875 0.812
Fly ash 1 0 0.187 0.25 0.312 0.375 0.437
F.A 2.5 2.23 2.23 2.23 2.23 2.23 2.23
C.A 2 2.97 2.97 2.97 2.97 2.97 2.97
No of cubes ---- 6 6 6 6 6 6
Cost per cube ---- 21.51 20.2 19.76 19.31 18.88 18.45
Total cost ---- 129.1 121.2 118.6 115.9 113.3 110.7
Price vs Mix
22 21.51
21.5
21
Price per one cube
20.5 20.2
20 19.76
19.31
19.5
18.88
19 18.45
18.5
18
17.5
17
16.5
N S1 S2 S3 S4 S5
1 F 5.1 P Mix
Fig 4.8 Price vs Mix for cubes

Table 4.12 Cost analysis for cylinders
Material Rate/kg N (kg) S1 (kg) S2(kg) S3(kg) S4(kg)

Cement 8 1.97 1.674 1.576 1.477 1.379
Fly ash 1 0 0.295 0.394 0.492 0.591
F.A 2.5 3.51 3.51 3.51 3.51 3.51
C.A 2 5.86 5.86 5.86 5.86 5.86
No of cylinders ---- 3 3 3 3 3
Cost per cube ---- 36.23 34.16 33.5 32.8 32.13
Total cost(INR) ---- 108.7 102.5 100.5 98.4 96.4
Price vs Mix
37
36.23
36
35
Price per one cube
34.16
34 33.5
32.8
33
32.13
32
31
30
N S1 S2 S3 S4
Mix
Fig 4.9 Price vs Mix for cylinders
The cost analysis indicates that percent of cement decrease the cost of concrete, but at the same
time strength also increases. The most economical mix is S3 which is 25 % replacement, this gives
highest strength with least amount.

Table 4.13 Cost analysis for 1m³

Material Rate/kg N (kg) S1(kg) S2(kg) S3(kg) S4(kg) S5(kg)
Cement 8 372 316.2 297.6 279 260.4 241.8
Fly ash 1 0 55.8 74.4 93 111.6 130.2
F.A 2.5 662 662 662 662 662 662
C.A 2 1107 1107 1107 1107 1107 1107
Total cost per 1m³ ---- 6845 6454 6324 6194 6063 5933
Price vs Mix
7000
6845
6800
6600
6454
6400 6324
6194
Price
6200
6063
6000 5933
5800
5600
5400
N S1 S2 S3 S4 S5
Mix
Fig 4.10 Price vs Mix for 1m³

CONCLUSION
By our project, we conclude that the strength of concrete increased by the replacement of cement
by fly ash. Fly ash replaces Portland cement, save concrete materials costs. Here we using OPC
of 53 grade, class F fly ash, well graded coarse and fine aggregate.
• 35% fly ash replacement showed maximum workability. The workability of concrete had
been found to decrease after 40% in concrete.
• Among different mixes of concrete 25% showed maximum compressive strength at later
ages.
• Maximum split tensile strength is obtained for S3 mix which is 25% replacement of
cement.
• The cost analysis indicates that percent of cement reduction decrease the cost of concrete,
but at the same time strength increases.
• It has been shown that concrete containing fly ash is more economical than ordinary
concrete. Concrete containing fly ash, delivered to the construction site, can be from 10 to
35% more economical than ordinary concrete. The main factor affecting the reduction in
cost is the fly ash content of the mix. The user should be aware of concrete containing fly
ash requiring a high dosage of air-entraining admixture for the development of a proper
air-void system. In many cases, the increase in cost due to the admixture requirements may
eliminate any savings in cost obtained by the use of fly ash.
• Concrete containing fly ash having a slump in the range of 7.5 to 10.5cm. can be produced
even when mixing temperatures are of the order of 1000 F and the total period of mixing
does not exceed 60 minutes.
• Improved workability. The spherical shaped particles of fly ash act as miniature ball
bearings within the concrete mix, thus providing a lubricant effect. This same effect also
improves concrete pumpability by reducing frictional losses during the pumping process
and flat work finishability.
• Decreased water demand. The replacement of cement by fly ash reduces the water demand
for a given slump. When fly ash is used at about 20 percent of the total cementitious, water
demand is reduced by approximately 1 percent. Higher fly ash contents will yield higher
water reductions. The decreased water demand has little or no effect on drying
shrinkage/cracking. Some fly ash is known to reduce drying shrinkage in certain situations.

• Reduced heat of hydration. Replacing cement with the same amount of fly ash can reduce
the heat of hydration of concrete. This reduction in the heat of hydration does not sacrifice
long-term strength gain or durability. The reduced heat of hydration lessens heat rise
problems in mass concrete placements.
• Increased ultimate strength. The additional binder produced by the fly ash reaction with
available lime allows fly ash concrete to continue to gain strength over time. Mixtures
designed to produce equivalent strength at early ages (less than 90 days) will ultimately
exceed the strength of straight cement concrete mixes.
• Reduced permeability. The decrease in water content combined with the production of
additional cementitious compounds reduces the pore interconnectivity of concrete, thus
decreasing permeability. The reduced permeability results in improved long-term
durability and resistance to various forms of deterioration.
• Improved durability. The decrease in free lime and the resulting increase in cementitious
compounds, combined with the reduction in permeability enhance concrete durability.
This affords several benefits:
• The observed slow set and low early strength obtained with fly ash has caused a reduction
in the amount of this mineral admixture used in concrete. Although some fly ash materials
will reduce early strength and slow the setting time it does not have to be the case today.
Some fly ash actually accelerates set. The addition of accelerators, plasticizers and/or a
small amount of additional CSF, as well as the proper beneficiated fly ash, can mitigate
this problem.
The S3 mix is the most economical and gives high strength compared to control mix. Other uses:
❖ Greater strength
❖ Decreased permeability
❖ Increased durability
❖ Reduced alkali silica reactivity
❖ Reduced heat of hydration
❖ Reduced efflorescence.

REFERENCES
1. T.G.S Kiran, and M.K.M.V Ratnam, (2014), “A study on Fly Ash as a Partial Replacement of
Cement in Concrete and Durability Study of Fly Ash in Acidic (H2SO4) Environment”,
International Journal of Engineering Research and Development e-ISSN: 2278-067X, p-ISSN:
2278-800X, Volume 10, Issue 12.
2. Aman Jatale, Kartiey Tiwari, Sahil Khandelwal (2013) “A study on Effects on Compressive
Strength When Cement is Partially Replaced by Fly Ash”, IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE) e-ISSN: 2278-1684 Volume 5, Issue 4.
3.Prof. JayeshkumarPitrod, Dr. L.B.Zala, Dr.F.S.Umrigar, (2012) “A study on Experimental

investigations on partial Replacement of cement with fly ash” indesign Mix concrete, International
Journal of Advanced Engineering Technology, Vol.III E-ISSN 0976-3945.
4. A.H.L.Swaroop, K. Venkateswara Rao, P. Kodandaramarao (2013) - “Durability stuties on

concrete with Fly-ash&GGBS” International Journal of Engineering Research and Applications
Vol.3, pp. 258289 ISSN: 2248 – 9622.
5. Berry. E.E., and Malhotra, V.M., "Fly Ash for Use in Concrete--A Critical Review,"· Journal of
the American Concrete Institute, Proceedings, Vol. 77, N~ 2~arch-April 1980.
6.Cook, James E., "Research and Application of High Strength Concrete Using Class C Fly Ash,"
Concrete International, Vol. 4, No.7, July 1982.
7.Cook, James E., "Fly Ash in Concrete--Technical Considerations," Concrete International, Vol.
5, No.9, September 1983.
8. Davis, R.E., Carlson, R.W., Kelley, J.W., and Davis, H.E., "Properties of Cements and
Concretes Containing Fly Ash," Journal of the American Concrete Institute, Proceedings, Vol. 33,
No.5,May-June 1937.

9.Gebler, Steven, and Klieger, Paul, "Effect of Fly Ash on the Air-Void Stability of Concrete," SP
79-5, The Use of Fly Ash, Silica Fume, Slag and Other Mineral Products in Concrete, American
Concrete Institute, Detroit1983.
10. Lane, R.O., "Effects of Fly Ash on Freshly Mixed Concrete," Concrete International, Vol. 5,
No. 10, October 1983
11. Lovewell, C.E., and Washa, George W., "Proportioning Concrete Mixtures Using Fly Ash,"
Journal of the American Concrete Institute, Vol. 54, No. 12, June 1958
12. Manz, Oscar E., "Review of International Specifications for Use of Fly Ash in Portland Cement
Concrete," SP79-8, The Use of Fly Ash, Silica Fume, Slag and Other Mineral By-Products in
Concrete, American Concrete Institute, Detroit, 1983
13. Mehta, P. Kumar, "Pozzolanic and Cementitious By-Products as Mineral Admixtures for
Concrete--A Critical Review." SP79-1. The Use of Fly Ash, Silica Fume, Slag and Other Mineral
ByProducts inConcrete, American Concrete-Institute, Detroit, 1983
14.A. Oner , S. Akyuzb, R. Yildiza,(2004)“An experimental study on strength development of

concrete containing fly ash and optimum usage of fly ash inconcrete” Cement and Concrete
Research , Vol.35, Issue 6, pp 11651171
15. Bhatty, JI., J Gajda, PE., Botha, F. and MM Bryant, PG. 2006. Utilization of Discarded Fly
Ash as a Raw Material in the Production of Portland cement. Journal of ASTM International, Vol.
3, No. 10.
16. A.H.L.Swaroop, K. Venkateswara Rao, P. Kodandaramarao (2013) - “Durability studies on

concrete with Fly-ash& GGBS” International Journal of Engineering Research and Applications
Vol.3, pp. 258289 ISSN: 2248 – 9622.

17. Aman Jatale, Kartiey Tiwari, Sahil Khandelwal (2013) - “Effects on Compressive Strength
When Cement is Partially Replaced by Fly Ash” IOSR Journal of Mechanical and Civil
Engineering, e-ISSN 2278-1684, Vol. 5, pp 34-43.
18.Fareed Ahmed Menon, Nafees Ahmed Menon and Rizwan ali Memom(2010) -“Study of
compressive strength of concrete with coal power plant Fly-ash as partial replacement of cement
and Fine aggregate” Mehran University Research Journal of Engineering & Technology, Vol.
29. .no.4, ISSN 0254-7821
19. Srila Dey, “Study of Compressive Strength of Fly Ash Concrete with Varying Proportion of
Fly Ash and Silica Fume”, SSRG International Journal of Civil Engineering (SSRG-IJCE) –
Volume 3 Issue 3– March 2016.
20. Gopala Krishna, S., Rajamane, N.P.Neelamegam, M., Peter, J.A. and Dattatreya, J.K. 2001.
“Effect of partial replacement of cement with fly ash on the strength and durability of HPC”. The
Indian Concrete Journal, pp. 335- 341.
21. A. Oner ,S.Akyuzb, R.Yildiza,(2004e” Cement and Concrete Research , Vol.35, Issue 6, pp
11651171. )“An experimental study on strength development of concrete containing fly ash and
optimum usage of fly ash in concrete”
22. Peterman, M.B., and Carrasquillo, R.L., "Production of High Strength Concrete," Research
Report 315-1F, Center for Transportation Research, The University of Texas at Austin, October
1983, 286pp.
23. Popovi cs, Sandor, "Strength Relationships for Fly Ash Concrete," Journal of the American
Concrete Institute, Vol. 79, No.1, January-February 1982, pp. 43-49.
24. "Properties and Use of Fly Ash in Portland Cement Concrete," Technical Report CR-81-1,
Singleton Materials Engineering Laboratory, Tennessee Valley Authority, April 1981, 60pp.

25. Swamy, R.N., Ali, A.R., and The odorakopoulos, D.O., "Early Strength Fly Ash Concrete for
Structural Applications”, Journal of the American Concrete Institute, Vol. 80, No.5, September-
October 1983, pp. 414-423.
26.Yamato, Takeshi, and Sugita, Hideaki, "Shrinkage and Creep of Mass Concrete Containing
Fly Ash," SP79-4, The Use of Fly Ash, Silica Fume, Slag and Other Mineral Byproducts in
Concrete, Ameri can Concrete Institute, Detroit, 1983, pp. 103-142.
27.Pasko, T.J., and Larson, T.D., "Some Statistical Analyses of the Strength and Durability of Fly
Ash Concrete," Proceedings, ASTM, Vol. 62, 1967, pp. 1054-1067.
28. JayeshkumarPitroda, L.B. Zala and F.S. Umrigar, “Experimental Investigations on Partial
Replacement of Cement with Fly Ash in Design Mix Concrete,” International Journal of Advanced
Engineering Technology, vol. 3, Issue 4, Oct.-Dec. 2012, pp. 126-129.
29. “Concrete Technology (Theory and Practice)” M.S. Shetty. Publisher S. Chand & company
LTD, 16th edition.
30. “Contribution of Fly Ash to the Properties of Mortar and Concrete”, International Journal on
Earth Science & Engineering, ISSN 0974-5904, Volume 04, No 06 SPL, pp.1017-1023, October
2011.
31. AlvinHarison, VikasSrivastava and Arpan Herbent (2014) - “Effect of Fly-ash on Compressive
Strength of Portland Pozzolona Cement Concrete” Journal of Academia and Industrial Research,
Vol. 2, ISSN:2278-5213.
32. IS: 383–1970 – “Specification for coarse and fine aggregate from natural sources for
concrete”, Bureau of Indian Standards, New Delhi.
33. IS: 456-2000, “Plain and Reinforced Concrete- Code of Practice”, Bureau of Indian
Standards, New Delhi, 2000.

34. IS: 10262-1982- “Recommended guidelines for Concrete Mix Design”, Bureau of Indian
35. IS: 12269-1987- “Specification for 53 Grade Ordinary Portland cement”, Bureau of Indian
36. BS 1881-116: 1993, “Method for determination of compressive strength of concrete cubes”.
37. IS 2386 (Part 4): 1963 “Methods of test for aggregates for concrete”: mechanical properties.
38.IS 383: 1970 “Specification for coarse and fine aggregates from Natural sources for concrete”.
39. I.S: 516-1959, “Indian Standard Methods of Test for Strength of concrete”. Bureau of Indian
Standards, New Delhi.
40. I.S: 2386-1963, “Methods of Test for aggregates for concrete” -: Specific gravity, Density,
Voids, Absorption and Bulking, Bureau of Indian Standard, New Delhi.
41. I.S: 5816: 1999, “Methods of tests for splitting tensile strength of concrete”.
42. IS: 1489 part-1 1991 – “Portland Pozzolana Cement fly ash based (Reaffirmed2005)”.
43. ASTM International C: 618-03 “Standard specification for coal Fly ash and Raw or Calcined
Natural Pozzolana for use in Concrete”.
44. High Lime Fly Ash as a Cementing Agent “SP19-16, The Use of Fly Ash, Silica Fume, Slag
and Other Mineral by-products in Concrete”, American Concrete Institute, Detroit.
45. “Some Statistical Analyses of the Strength and Durability of Fly Ash Concrete” Proceedings,
ASTM.





Major Project Report PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Major Project Report PDF

Uploaded by

Copyright:

Available Formats

A PROJECT REPORT ON

Submitted in Partial Fulfillment of the

Mr. MARUTHI DEGALVADE, (Asst. Professor)

DEPARTMENT OF CIVIL ENGINEERING

DEPARTMENT OF CIVIL ENGINEERING

Project Guide Head of the Department

DEPARTMENT OF CIVIL ENGINEERING

We G.SUDHEER, G.SAGARIKA, A.ANANDA CHARY & A.RADHIKA

2015-19, JB Institute of Engineering & Technology (UGC Autonomous),

2. LITERATURE REVIEW 10-13

3. MATERIALS AND METHODOLOGY 14-43

4.RESULTS AND DISCUSSIONS 42-52

1.1 FLY ASH 5

1.1 CHEMICAL COMPOSITION OF FLY ASH 6

4.13 COST ANALYSIS FOR 1m³ 53

1.1.1 History of cement:

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 1

1.1.2 Composition of Concrete:

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 2

1.1.3 Advantages and Disadvantages of Concrete

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 3

1.2 FLY ASH

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 4

Fig 1.1 Fly Ash

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 5

Table 1.1 Chemical composition of fly ash

SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI Free

Fig1.2 Processing diagram for fly ash

The way of fly ash utilization includes

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 6

1.2.1 Types of fly ash

1.2.2 Physical properties of fly ash

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 7

1.3 ADVANTAGES & DISADVANTAGES OF CONCRETE CONTAING

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 8

1.4 AIM AND OBJECTIVES

1.5 SCOPE OF THIS STUDY

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 9

2.2 REVIEW OF EARLIER WORKS

2) Arivalagan. S (2013), A Study on Experimental Study on the Flexural Behavior of Reinforced

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 10

3) Prof. JayeshkumarPitrod, Dr. L.B.Zala, Dr.F.S.Umrigar, (2012) A study on Experimental

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 11

6) PONNALA RAMAIAH and PUJARI SAINATH (2016), A study on partial replacement of

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 12

11) Rachel& J. Detwiler (2013) Research &Development Bulletin.

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 13

3.MATERIALS AND METHODOLOGY

3.1 HYDRATION REACTIONS WHEN FLY ASH IS USED IN OPC

2C3S + 6H —> C3S2H3+3Ca(OH)2

2C2S + 4H —> C3S2H3+Ca(OH)2

C3A+ 6H —> C3AH6

Cement Reaction : C3S/ C2S + H → C-S-H + Ca(OH)2

Pozzolanic Reaction : Ca(OH)2 + S → C-S-H

S —- Silica from Fly ash constituents

3.1.1 Reduced heat of hydration:

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 14

3.1.2 Workability of concrete:

3.1.3 Permeability and corrosion protection:

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 15

3.2 HOW FLY ASH CAN BE USED IN CEMENT CONCRETE ?

II. Addition of fly ash as fine aggregates the addition method.

JBIET DEPARTMENT OF CIVIL ENGINEERING Page 16