1

PROJECT REPORT

on

EFFECT OF MINERAL ADMIXTURES ON CONCRETE

Submitted in Partial Fullfillment of the Requirements for the Award of Degree of Masterof
Engineering in Structural Engineering

by

[Link] - 1601-18-741-004

DEPARTMENT OF CIVIL ENGINEERING

CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY

(AUTONOMUS)

Gandipet, Hyderabad – 500075

2018
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ABSTRACT
The utilization of flyash as partial replacement in concrete is gaining the immense
importance today, mainly on account of the long term durability of combined with ecological
[Link] study the effect of partial replacement of cement by fly ash ,studies have been
conducted on concrete mixes with 300-500 kg/cum cementitious material at 10%,20%,40%
replacement levels. In this paper the effect of fly ash on workability and compressive strength
Based on this study compressive strength v /s W/cm curves have been plotted so that concrete
mix of M40 with different percentage of fly ash can be directly designed.
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CONTENTS
Abstract

[Link] TITLE PAGENO.

1. INTRODUCTION 04

2. MATERILS 06

3. MIX DESIGN AND METHODOLOGY 09

4. EXPERIMENTAL WORK 11

5. RESULTS 12

6. REFERENCES 13
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CHAPTER -1
INTRODUCTION
FLYASH:

Fly ash or flue ash, also known as pulverised fuel ash in the United Kingdom, is a coal
combustion product that is composed of the particulates (fine particles of burned fuel) that are
driven out of coal-fired boilers together with the flue gases. Ash that falls to the bottom of the
boiler is called bottom ash. In modern coal-fired power plants, fly ash is generally captured by
electrostatic precipitators or other particle filtration equipment before the flue gases reach the
chimneys. Together with bottom ash removed from the bottom of the boiler, it is known as coal
ash. Depending upon the source and composition of the coal being burned, the components of fly
ash vary considerably, but all fly ash includes substantial amounts of silicon dioxide (SiO2)
(both amorphous and crystalline), aluminium oxide (Al2O3) and calcium oxide (CaO), the main
mineral compounds in coal-bearing rock strata.

The minor constituents of fly ash depend upon the specific coal bed composition but may
include one or more of the following elements or compounds found in trace concentrations (up to
hundreds ppm): arsenic, beryllium, boron, cadmium, chromium, hexavalent chromium, cobalt,
lead, manganese, mercury, molybdenum, selenium, strontium, thallium, and vanadium, along
with very small concentrations of dioxins and PAN [Link] also has unburnt [Link] the
past, fly ash was generally released into the atmosphere, but air pollution control standards now
require that it be captured prior to release by fitting pollution control equipment. In the United
States, fly ash is generally stored at coal power plants or placed in landfills. About 43% is
recycled,often used as a pozzolan to produce hydraulic cement or hydraulic plaster and a
replacement or partial replacement for Portland cement in concrete production. Pozzolans ensure
the setting of concrete and plaster and provide concrete with more protection from wet
conditions and chemical attack.

In the case that fly (or bottom) ash is not produced from coal, for example when solid
waste is incinerated in a waste-to-energy facility to produce electricity, the ash may contain
higher levels of contaminants than coal ash. In that case the ash produced is often classified as
hazardous waste.
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CHEMICAL COMPOSITION:

Table 1.1 about chemical composition of flyash

CLASSIFICATION:

Two classes of fly ash are defined by ASTM C618: Class F fly ash and Class C fly ash. The
chief difference between these classes is the amount of calcium, silica, alumina, and iron content
in the ash. The chemical properties of the fly ash are largely influenced by the chemical content
of the coal burned.

CLASS F:

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 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.
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CHAPTER-2
MATERIALS
INGREDIENTS
CEMENT:
The ordinary portland cement of grade M53 is used conforming to IS : 8112 was [Link] 28
days compressive strength and specific surface area of 40 N/mm2 and 295 m2 /kg. The cement
which is passed through 90um sieve was used. Specific gravity of 3.15 was used.

COARSE AGGREGATE:
Coarse aggregate like gravel is used. 60% is passed through 20mm sieve and retained on 10mm
sieve. 40% of aggregate passed through 10mm sieve and retained in 4.75mm was used. Specific
gravity of 2.65 was used.

FINE AGGREGATE:
Fine aggregate of size < 2.75 mm was used. Normal sand was used. It is passed through 2.75mm
sieve and retained on 600um sieve. Specific gravity of 2.65 was used.

FLYASH:
Fly ash from thermal power station and which is sieved through 90um sieve, which is used as
partial replacement of 10%,20%,40% in cement. Specific gravity of 2.12 was used.

WATER:
Water available from underground were used.
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CHAPTER -3
MIX DESIGN AND METHODOLOGY
MIX DESIGN
Concrete of M40 grade was designed using IS :10262 .
Data required for Mix design
[Link] mean compressive strength of concrete.
[Link] of fly ash in terms of specific surface area in m2/kg.
[Link]
[Link] for 28days and tested.
DESIGN STEPS
[Link] of mass of aggregates
[Link] of fly ash.
[Link] of cement
[Link] of water content.

Quantities for 1m3 of mix unit weight of concrete is 2400kg/m3.

Maximum nominal size of aggregate = 20mm
Minimum cement content = 350kg/m3
Workability = 100 mm
Target mean strength for mix proportions
= 40+1.65S =48.25mpa
Water content = 0.45*350=160kg/m3
Volume of cement = mass /specific gravity
=350/3.15 *1/1000=0.111m3
Volume of water = 160/1000 =0.16m3
Volume of aggregate = 1- (0.111+0.16 ) =0.732m3
Mass of coarse aggregate = 0.732*0.62*2.65*1000 = 1243kg/m3
Mass of fine aggregate =0.732*0.38*2.65 *1000 = 762kg/m3
Volume of 9 cubes = 9*0.15*0.15*0.15 =0.03035m3
For 9 cubes
Weight of cement = 0.03*350 = 10.5kg
Weight of coarse aggregate = 0.03*1243 = 37.29 kg
Weight of fine aggregate =0.03*762 = 22.86 kg
Weight of water = 0.03*160 = 4.8 kg
Mix proportions = 1 : 1.58 : 2.58
Fly ash as 10% replacement
Weight of fly ash = 0.1* cement weight
Weight calculated = 0.1*10.5 =1.05 kg
Cement weight = 0.9*10.5 =9.45 kg
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.Fly ash as 20% replacement

Weight of fly ash = 0.2 *cement weight
Weight = 0.2*10.5 =2.1 kg
Cement = 0.8*10.5 =8.4 kg
Fly ash 40% replacement
Weight of fly ash =0.4*cement weight
Weight =0.4*10.5 =4.2 kg
Cement = 0.6*10.5 =7.3kg
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CHAPTER-4
EXPERIMENTAL WORK
CUBES CASTING
Total 27 cubes were casted . 9 cubes for each proportion of mix . weights recorded in the above
chapter was used to cast the cubes.

Casting is the process of filling the fresh concrete mixed with stipulated proportions into the
cubes and compacted. The mix ratio helps in knowing the mass of each and every material so
that mix can be prepared accurately. The following are the steps to be followed for the casting of
cubes:

i. First step involves procuring the materials and tools required for work.

ii. As per the mix design, the materials are collected and weighed with the help of
weighing balance.

iii. All weighed materials are placed in the pan or concrete mixer for mixing.

iv. With the help of grub hoe and trowel the materials are well mixed before adding water
in order to obtain homogenous dry mixture.

v. Water and alkali solution is slowly added and mixed well to get uniform mixture.

vi. The moulds and slump cone apparatus are then well greased.

vii. The concrete is then placed in slump cone in three layers and each layer is tamped for
25 times.

viii. After obtaining the slump, compaction factor is determined by conducting compaction
factor apparatus.

ix. The concrete is then placed in the moulds and compacted using tamping rod.

Compressive strength:

For compressive strength cubes of 150×150×150mm are cast from reference mix of SCC
and kept for different types of curing up to 28 days. The specimens are tested after 28 days,
using a calibrated compression testing machine of 2,000 KN capacity as per IS: 516-1959
(2004).
Compressive strength 𝐟𝐜 = P/A Where, P is load & A is area of cube
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Curing of cubes

Curing can be described as keeping the concrete moist and warm enough so that the hydration of
cement can continue. More elaborately, it can be described as the process of maintaining
satisfactory moisture content and a favorable temperature in concrete during the period
immediately following placement, so that hydration of cement may continue until the desired
properties are developed to a sufficient degree to meet the requirement of service.

There are various methods of curing. In the present study hot oven curing followed by ambient
curing was adopted to gain better results.

The following are the steps adopted in curing of geopolymer concrete.

i. The prepared concrete moulds are kept a side for 24 hours without causing any
disturbance.

ii. The concrete cubes are then de-moulded after 24 hours from the time of casting.

iii. They are placed in curing tank for 28 days.

iv. After 28 days the compressive strength test was performed.

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CHAPTER-5
RESULTS AND DISCUSSION
This chapter shows the results of the various tests conducted on concrete. Compressive strength
was obtained by compressive strength testing machine.

COMPRESSIVE STRENGTH FOR 28 DAYS

60

50

40

30
COMPRESSIVE STRENGTH
20 FOR 28 DAYS

10

0
10 20 30 40

The above graph shows compressive strength v/s % of replacement of fly ash . The compressive
strength after 28 days was tested.

the above results shows that at 40% the higher compressive strength was observed. But it is the
optimum percentage of replacement.
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CHAPTER-6
CONCLUSION
The use of fly ash in portland cement concrete (PCC) has many benefits and improves concrete
performance in both the fresh and hardened state. Fly ash use in concrete improves the
workability of plastic concrete, and the strength and durability of hardened concrete. Fly ash use
is also cost effective. When fly ash is added to concrete, the amount of portland cement may be
reduced.
Benefits to Fresh Concrete. Generally, fly ash benefits fresh concrete by reducing the mixing
water requirement and improving the paste flow behavior. The resulting benefits are as follows:
 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 10 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.
Benefits to Hardened Concrete. 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:
 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 .