REPLACEMENT OF TENSILE CONCRETE

BY AAC

A PROJECT REPORT
Submitted by

ALTHASSIM H. 312814103002

DELBIN DHAYA M. K. 312814103014

SARATH R. 312814103046

VIMALNATH RAO G. 312814103056

In partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING IN

CIVIL ENGINEERING

AGNI COLLEGE OF TECHNOLOGY,

THALAMBUR

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2018

i
 BONAFIDE CERTIFICATE

Certified that this project report “REPLACEMENT OF TENSILE

CONCRETE BY AAC” is the bonafide work of ALTHASSIM H.
(312814103002), DELBIN DHAYA M. K. (312814103014), SARATH R.
(312814103046), VIMALNATH RAO G. (312814103056) who carried
out the project work under my supervision.

SIGNATURE
Mr. Ramamoorthy S. M.E (Ph.D.)
ASSO. PROFESSOR AND HEAD,
Department of Civil Engineering,
Agni College of Technology,
Chennai – 600 130.
SIGNATURE
Mr. Ramamoorthy S. M.E (Ph.D.)
ASSO. PROFESSOR AND HEAD,
Department of Civil Engineering,
Agni College of Technology,
Chennai – 600 130.

Submitted for viva – voce Examination held on.…………………….

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENT

We are very much indebted to everyone who has contributed so much for the
successful project.
We would like to express our special gratitude and thanks to our chair person
Mrs. Bhavani Jayaprakash for providing us with the required facilities and
support towards the completion of the project.
We express our Sincere thanks to our Principal Dr. R. S. Kumar,
B.E(Hons), M. Tech., Ph.D. for his kind and timely support.
We wish to express our deep sense of gratitude to our beloved Dean
Dr. Srinavasan Alavandar, M.E., Ph.D. for his constant support and for providing
constructive feedback and approval of the project.
We are most grateful to Mr. S. Ramamoorthy M.E. (Ph. D.), Associate
Professor and Head, Department of Civil Engineering for providing us all the
help needed.
We express our deep sense of gratitude to our guide Mr. S. Ramamoorthy
M.E. (Ph. D.), Associate Professor and Head, Department of Civil Engineering,
for his valuable guidance and proficient suggestion and help.
Above all, we extremely thank our parents and friends for good health,
confidence and encouragement throughout the study of the project.

ALTHASSIM H.

DELBIN DHAYA M. K.

SARATH R.

VIMALNATH RAO G.

iii
 ABSTRACT

The increasing demand in the construction industry will lead to

depletion of resources used in construction sites. Sustainable use of materials and
finding alternatives for conventional materials and construction methods are the
methods that can be adopted to tackle the depletion of resources. Concrete is the
most widely used composite construction material. But, concrete holds good for use
in compression zone only. When subjected to Tension, concrete is very poor in
taking the force. Instead of using concrete in Tension zone of flexural members, an
alternative method has been developed by replacing the Tensile concrete by AAC.
This method involves using precast AAC to replace the tensile concrete below the
neutral axis. AAC have compressive strength of 3 – 4.5 N/mm2 and have high
modulus of elasticity compared to conventional concrete. The only drawback in
replacing AAC in the tensile part of concrete in Flexural members is that the Shear
strength of the member will be affected due to low shearing capacity of AAC. AAC
blocks used in the tensile parts of flexural members were cut in trapezoidal shape to
compensate to the low shear strength of AAC. The trapezoidal shape facilitates
lower presence of AAC in the cross-section near the ends, where high shear force
acts. Experimental results show that the flexural strength of the beam is not greatly
affected due to this replacement of the tensile part of the flexural member.

iv
 TABLE OF CONTENTS
CHAPTER TITLE PAGE NO
NO.
ACKNOWLEDGMENT iii
ABSTRACT iv
TABLE OF CONTENTS v
LIST OF TABLES x
LIST OF FIGURES xi
LIST OF SYMBOLS & xiii
ABBREVATIONS

1 INTRODUCTION 1
1.1 GENERAL 1
1.2 AUTOCLAVED AERATED 1
CONCRETE
1.2.1 INTRODUCTION 1
1.2.2 HISTORY OF AAC 1
1.2.3 AAC BLOCKS – INDIAN 2
SCENARIO
1.2.4 MANUFACTUING 2
1.2.5 ADVANTAGES OF AAC 4
1.2.6 DISADVANTAGES OF AAC 5
1.2.7 COMPARISON OF NORMAL 6
CONCRETE AND AAC
1.3 BEAMS AND NEUTRAL AXIS 6
1.3.1 ASSUMPTIONS 7
1.3.2 BENDING OF BEAM AND 7
NEUTRAL AXIS

v
 1.4 REPLACING THE TENSILE PARTS 8

2 LITERATURE REVIEW 10

3 METHODOLOGY 12

4 TESTING OF MATERIALS 13
4.1 GENERAL 13
4.2 CEMENT 13
4.2.1 FINESS TEST 13
4.2.2 INITIAL AND FINAL SETTING 14
TIME
4.2.3 CONSISTENCY TEST 16
4.3 FINE AGGREGATE 16
4.3.1 SPECIFIC GRAVITY 17
4.4 COARSE AGGREGATE 17
4.4.1 SPECIFIC GRAVITY 17
4.4.2 IMPACT STRENGTH TEST 19
4.4.3 SHAPE TESTS ON COARSE 21
AGGREGATE
4.4.3.1 FLAKINESS INDEX AND 21
ELONGATION INDEX
4.4.3.2 SIEVE ANALYSIS 23
4.5 WATER 24
4.6 SUMMARY 25

5 MIX DESIGN 26
5.1 INTRODUCTION 26

vi
 5.2 STATISTICAL QUALITY CONTROL 26
OF CEMENT CONCRETE
5.3 MIX DESIGN 27
5.3.1 STIPULATIONS FOR 27
PROPORTIONING
5.3.2 TEST DATA FOR MATERIALS 27
5.3.3 TARGET STRENGTH FOR MIX 28
PROPOTIONING
5.3.4 SELECTION OF WATER CEMENT 28
RATIO
5.3.5 SELECTION OF WATER 28
CONTENT
5.3.6 CALCULATION OF CEMENT 29
CONTENT
5.3.7 PROPORTION OF VOLUME OF 29
C.A. & F.A.
5.3.8 MIX CALCULAITONS 29
5.3.9 MIX PROPORTIONS 31
5.4 TESTS ON FRESH CONCRETE 31
5.4.1 SLUMP TEST 31
5.5 TEST ON HARDENED CONCRETE 32
5.5.1 COMPRESSIVE STRENGTH TEST 32

6 DESIGN OF BEAMS 33
6.1 GENERAL 34
6.2 NEUTRAL AXIS OF BEAM 35
6.3 REPLACING THE TENSILE PART 37

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7 QUANTITY AND COST ESTIMATION 38
7.1 GENERAL 38
7.2 QUANTITY ESTIMATION 38
7.2.1 CONVENTIONAL BEAM 38
7.2.1.1 ESTIMATION FOR CONCRETE 38
7.2.1.2 ESTIMATION FOR STEEL 39
7.2.2 AAC REPLACED BEAMS 40
7.2.2.1 ESTIMATION FOR AAC 40
BLOCKS
7.2.2.2 ESTIMATION FOR STEEL 41
7.3 COST OF MATERIALS 42
7.4 COST COMPARISON 43
7.5 PERCENTAGE OF AAC REPLACED 44
FOR CONCRETE

8 CASTING AND CURING 45

8.1 PREPARING MOULD 45
8.2 PREPARING AND PLACING 45
REINFORCEMENT
8.3 BATCHING, MIXING AND 46
PLACING CONCRETE
8.4 CURING 47

9 TEST RESULTS AND DISCUSSION 49

9.1 GENERAL 49
9.2 LOADING ARRANGEMENT TO 49
DETERMINE FLEXURAL STRENGTH
9.3 TEST RESULTS 52

viii
 9.3.1 CONVENTIONAL BEAM 52
9.3.2 AAC REPLACED BEAM 53
9.4 COMPARISON OF TEST RESULTS 55

10 CONCLUSION 57
REFERENCES 58

ix
 LIST OF TABLES

TABLE NO. TOPIC PAGE NO.

01 1.2.3.1 SPECIFICATION – AAC BLOCKS 2
02 1.2.4.1 MATERIALS USED IN AAC BLOCKS 3
03 4.2.3.1 TEST RESULT ON CEMENT 16
04 4.4.2.1 SPECIFIC GRAVITY OF FINE 19
AGGREGATE
05 4.4.1.2 SPECIFIC GRAVITY OF COARSE 19
AGGREGATE
06 4.4.3.1 ELONGATION AND FLAKINESS 22
INDEX OF COARSE AGGREGATE
07 4.4.3.2 FINENESS OF FINE AGGREGATE 23
08 4.4.3.2 FINENESS OF COARSE AGGREGATE 24
09 5.4.1 SLUMP CONE TEST 31
10 5.5.1 COMPRESSIVE STRENGTH OF CUBE 33
11 6.1 DETAILS OF SPECIMEN CASTED 34
12 7.3.1 COST OF MATERIALS 42
13 7.4.1 COST OF COMPARISON OF 44
CONVENTIONAL AND AAC
REPLACED BEAMS
14 8.4.1 DIMENSION OF THE BEAM 47
15 9.3.1.1 LOAD AND DISPLACEMENT
VALUES FOR CONVENTIONAL 51
BEAM
16 9.3.1.1 LOAD AND DISPLACEMENT
VALUES FOR AAC REPLACED 53
BEAM

x
 LIST OF FIGURES

FIG. NO. TOPIC PAGE NO.

01 1.3.2.1 BEAM STRUCTURE 7
02 1.3.2.2 BENDING OF BEAMS 8
03 4.2.2.1 TESTING OF CEMENT ON VICAT 15
APPARATUS
04 4.4.2.1 SPECIFIC GRAVITY TEST BY 18
PYCONOMETER
05 4.4.2.1 IMPACT STRENGTH OF COARSE 20
AGGREGATE
06 5.4.1 SLUMP CONE TEST 31
07 5.5.1 COMPRESSIVE STRENGTH TEST 32
08 5.5.2 COMPRESSIVE STRENGTH OF CUBE 33
09 6.2.1 STRESS & STRAIN DIAGRAMS OF 35
SINGLY REINFORCED BEAM
10 6.2.2 CROSS SECTION OF BEAM 36
11 6.3.1 AAC BLOCKS 37
12 a) AAC BLOCKS CUT INTO PEICES
b) AAC BLOCK FULL SIZE
13 6.3.2 L/S OF BEAM REPLACED WITH AAC 37
BLOCKS
14 8.1.1 MOULD WITH REINFORCEMENT 44
FOR CASTING
a) CONVENTIONAL BEAM
b) AAC PARTIALLY REPLACED
BEAM
15 8.3.1 BATCHING, PLACING AND 46

xi
 COMPACTING CONCRETE
16 9.2.1 LOADING ARRANGEMENT 49
17 8.1.1 FLEXURAL STRENGTH TEST ON 50
BEAM
18 9.3.1.1 LOAD VS DEFLECTION PLOT FOR 52
CONVENTIONAL BEAM
19 9.3.2.1 LOAD VS DEFLECTION PLOT FOR 53
AAC REPLACED BEAM
20 9.4.1 LOAD VS DEFLECTION 55
COMPARISON OF AAC REPLACED
AND CONVENTIONAL BEAM

xii
 LIST OF SYMBOLS AND ABBREVIATIONS

d Effective depth
D Overall depth
d’ Effective cover
fy Yield strength of steel
Ast Area of steel
fck Characteristic compressive strength of concrete
F’ck Target average compressive strength at 28 days
Xu Depth of neutral axis
∅ Diameter of steel bar
F is the force(load) at fracture point
L is the length of the support (outer) span
B is the width of the specimen
D is the depth of the specimen
Ms Mass of steel
Mc Mass of cement
Mca Mass of coarse aggregate
Mf Mass of fine aggregate
r Radius of steel bar
Es Modulus of Elasticity of Steel
Xu Depth of Neutral axis
Xu max Maximum depth of neutral axis
V Volume of beam
F. A. Fine aggregate
C. A. Coarse aggregate
PSI Per square inch

xiii
 CHAPTER 1

INTRODUCTION

1.1 GENERAL:
Concrete is the most widely used construction material in structural
industry because of its high structural strength, stability and malleability.
Nowadays the cost of construction materials is high in some parts of the world.
This situation led us to explore alternative method of casting flexural members.
AAC blocks also known as Autoclaved Aerated Concrete blocks are light
weight blocks casted without using Coarse aggregate to reduce their weight.

1.2 AUTOCLAVED AERATED CONCRETE:

1.2.1 INTRODUCTION
Autoclaved Aerated Concrete is not a "new" innovation. It has been
around for over 80 years. Invented in 1923, AAC has been used extensively in
Europe and Asia. It comprises over 40% of all construction in the United
Kingdom and 60% in Germany and 16% in India. Since Roman times,
lightweight aggregates and foaming agents have been employed to reduce the
weight of concrete. However, unlike these foamed or light aggregate mixes, true
aerated concrete relies on the alkaline binder (lime & cement) reacting with an
acid to release gases, which remain entrained in the material.

1.2.2 HISTORY OF AAC

AAC was perfected in the mid-1920s by the Swedish architect and
inventor Dr. Johan Axel Eriksson,] working with Professor Henrik Kreüger at
the Royal Institute of Technology. It went into production in Sweden in 1929 in
a factory in Hällabrottet and quickly became very popular. Siporex was
established in Sweden in 1939 and presently licenses and owns plants in 35

1
locations around the world. In the 1940s, the trademark Ytong was introduced,
and was often referred to as "blue concrete" in Sweden due to its bluish tinge.
This version of Ytong was produced from alum shale, whose combustible
carbon content made it beneficial to use in the production process.

1.2.3 AAC BLOCKS – INDIAN SCENARIO

AAC consists of basic materials that are widely available. These include
sand, cement, lime, gypsum, water and an expansion agent. Silica sand, the raw
material used in the greatest volume in AAC, is one of the world's most
abundant natural resources. At present there are 31 manufacturing plants in
India are working with heavy concentration near Surat. Gujarat: production
capacity 2000 m3/day against requirement of 3000 m3/day (Surat has 3-4
plants). In Ahmadabad, 1 m3 of AAC blocks costs Rs. 3200-3500 while 1 m3 of
clay bricks would cost Rs. 2400-2700. In spite of the price difference,
construction industry wants to use AAC blocks due to inherent advantages. It is
more used in Mumbai, Bangalore, Chennai and Hugli.

PARAMETERS in mm
Length 625
Breadth 240
Thickness 90/100/150/200
Tolerance ±1%

Table 1.2.3.1 Specification – AAC blocks

1.2.4 MANUFACTURING
Unlike most other concrete applications, AAC is produced using no
aggregate larger than sand. Quartz sand, calcined gypsum, lime (mineral) and/or
cement and water are used as a binding agent. Aluminium powder is used at a
rate of 0.05% – 0.08% by volume (depending on the pre-specified density). In

2
some countries, like India and China, fly ash generated from thermal power
plants and having 50% - 65% silica content is used as an aggregate.

Percentage of proportion
Sl. for AAC Blocks
Material with Fly ash / with
No.
Sand
1. Fly ash / Sand 65-70 / 55-65 %
2. Cement - 53 GRADE OPC 6-15 / 10-20 %
3. Lime 18-25 / 20-30 %
4. Gypsum 3–5/2–3%
3
5. Aluminium powder paste(600 kg/m ) 8%
6. Water 0.6 – 0.65 %
7. Casting system 36-40 ° C / 35-38 ° C
Table 1.2.4.1 Materials used in AAC blocks
When AAC is mixed and cast in forms, several chemical reactions take
place that give AAC its light weight (20% of the weight of concrete) and
thermal properties. Aluminium powder reacts with calcium hydroxide and water
to form hydrogen. The hydrogen gas foams and doubles the volume of the raw
mix creating gas bubbles up to 3mm (⅛ inch) in diameter.
At the end of the foaming process, the hydrogen escapes into the
atmosphere and is replaced by air. When the forms are removed from the
material, it is solid but still soft. It is then cut into either blocks or panels, and
placed in an autoclave chamber for 12 hours. During this steam pressure
hardening process, when the temperature reaches 190° Celsius (374°
Fahrenheit) and the pressure reaches 8 to 12 bar, quartz sand reacts with
calcium hydroxide to form calcium silicate hydrate, which gives AAC its high
strength and other unique properties. Because of the relatively low temperature
used AAC blocks are not considered fired brick but a lightweight concrete
masonry unit. After the autoclaving process, the material is ready for immediate
use on the construction site. Depending on its density, up to 80% of the volume
of an AAC block is air. AAC's low density also accounts for its low structural

3
compression strength. It can carry loads of up to 8 MPa (1,160 PSI),
approximately 50% of the compressive strength of regular concrete.

1.2.5 ADVANTAGES OF AAC

Lightweight saves cost and energy in transportation as well as labour
(550 kg/m3 - half of weight of light weight aggregate blocks). Larger size (6
times larger than brick) leads to faster construction and less mortar requirement
for joining.
1) Fire Resistant: It has one of the highest hourly fire resistance ratings
per inch of any building material currently used in homebuilding. This makes it
an ideal choice for fire protection around steel columns and steel beams and in
the construction of shaft walls, stairwells, corridors and firewalls.
2) AAC very Environmentally Friendly: The process of manufacturing
AAC uses only natural materials and produces no pollutants or by-products.
AAC is totally free of toxic or harmful substances. Low energy is required in
production, low raw material consumption, ease of use in construction, high
energy efficiency, better indoor air quality and recyclability add up to make
AAC a very environmentally friendly building material and system.
3) Breathable: It does not promote mold growth.
4) Good Sound Insulation Property: Its noise reduction co-efficient is
more than twice that of a standard concrete block wall and over 7 times that of
ordinary concrete.
5) Easily Workable: It can easily cut to any required shape, can be
sawed, nailed and drilled easily even than wood.
6) Durable: With good resistance to sulphate attack.
7) Attractive Finishing: Walls can be left exposed without plaster.
8) Economic: No curing is required, labour cost is saved hence.

4
1.2.6 DISADVANTAGE OF AAC:

Some disadvantages of AAC blocks and panels are that they do contain
Portland cement, they are made in so few place which means more
transportation cost and using gas resources. Builders must learn how to use
them since the mortaring is different, some of the blocks are made to European
standards and have to be cut. They are porous so must have stucco or cladding
on the exterior to keep out water. For load-bearing, AAC may need rebar
reinforcement.
In some states, they have yet to be accepted in building codes due to lack
of test results. What is not green about Portland cement is that it is about 60
percent limestone, or calcium carbonate, and must be burned at high
temperatures in kilns using lots of energy and creating carbon dioxide (CO2), a
greenhouse gas linked to global warming.
The newer magnesia-based cement can be burned at lower temperatures
using less energy and creating less CO2. Magnesium carbonate and calcium
carbonate are both obtained by mining, but lower alkaline magnesia concrete is
able to remain strong when recycled materials are added to the mix and can
insulate better when organic materials are added. Magnesia concrete can also
absorb CO2 through a carbonation process while it is being manufactured and
used, reducing the greenhouse gas.

5
1.2.7 COMPARISON OF NORMAL AND AUTOCLAVED AERATED
CONCRETE:

S. Autoclaved Aerated Concrete Normal Aggregate Concrete

No.
1. Autoclaved aerated concrete Normal concrete has heavy
is a versatile lightweight weights compared to the AAC. 1
construction material and usually AAC Block size = 6 * brick size 1
used as blocks. AAC Block weight = 1/2 of
aggregate block weight
2. A low density and excellent High density and lower
insulation properties due to high insulation property
porosity.
3. The low density is achieved The concrete so formed has
by the formation of air voids to a high density and compact
produce a cellular structure.
4. Densities range from about Medium density concrete
3
460 to 750 kg/ m . blocks have a typical density
range of 1350-1500 kg/m3 and
dense concrete blocks a range of
2300-2500 kg/ m3
5. The finished product is up to The finished product is
five times the volume of the raw compact and non-porous.
materials used, with an air content
of 70% to 80% (depending on the
required strength and density.)
6. Easily workable – can be Cannot be sawed, nailed or
sawed, nailed and drilled easily drilled as easy as AAC blocks.
even than wood.
7. No curing required – labour Curing is must.
cost is saved of curing.
8. Compressive Strength varies Compressive Strength varies
from 3 – 4.5 N/mm . 2
from 5 to 80 N/mm2 (Range may
vary due to variation in mix
proportion).

1.3 BEAM AND NEUTRAL AXIS

A beam is defined as a rod or bar. Circular or rectangular of uniform
cross section whose length is very much greater than its other dimensions, such
as breadth and thickness. It is commonly used in the construction of bridges to

6
support roofs of the buildings etc. Since the length of the beam is much greater
than its other dimensions the shearing stresses are very small.

1.3.1 ASSUMPTIONS
While studying about the bending of beams, the following assumptions
have to be made.
1. The length of the beam should be large compared to other dimensions.
2. The load (forces) applied should be large compared to the weight of the
beam
3. The cross section of the beam remains constant and hence the
geometrical moment of inertia ig also remains constant
4. The shearing stresses are negligible
5. The curvature of the beam is very small

1.3.2 BENDING OF A BEAM AND NEUTRAL AXIS

Let us consider a beam of uniform rectangular cross section in the figure.
A beam may be assumed to consist of a number of parallel longitudinal
metallic fibers placed one over the other and are called as filaments as shown in
the figure.

Figure 1.3.2.1 Beam structure

Let the beam be subjected to deforming forces at its end as shown in the
figure. Due to the deforming force the beam bends. We know the beam consist
of many filaments. Let us consider a filament AB at the beam. It is found that
the filaments (layers) lying above AB gets compressed, while the filaments

7
lying below AB gets elongated. Therefore the filaments i.e., layer AB which
remains unaltered is taken as the reference axis called neutral axis and the plane
is called neutral plane. Further, the deformation of any filaments can be
measured with reference to the neutral axis.

1.3.2.2 Bending of Beam

1.4 REPLACING THE TENSILE PART

In case of normal simply supported reinforced concrete beam, the neutral
axis divides the tension zone and compression zone. The region below the
neutral axis is in tension and the region above neutral axis is in compression.
Since concrete is weak in taking up tension, steel reinforcements are provided at
the tension zone of the beam.
The concrete below the neutral axis act as the medium for transferring
stress from compression zone to the tension zone, i.e., steel reinforcement
provided at the bottom. So the concrete provided below the neutral axis is
known as sacrificial concrete. (The compressive force is acting in the top zone
at a distance of 0.42 is the neutral axis distance from top of section).
There are methods for increasing the effectiveness of concrete below
neutral axis such as pre-stressing and converting the beam into other shapes
such as Tee beams. But these methods cause change in the geometry of the
structure and increases the construction cost.
An alternate method of replacing the zone below the neutral axis with
inert weightless substances like Autoclaved Aerated Concrete will not greatly

8
affect the strength and stress characteristics of the beam. Also it will not affect
the geometry and shape. In this paper, study on partial replacement of concrete
below the neutral axis by replacing the concrete using AAC is discussed.
From the referred literature reviews, it is understood that in RC beams
less stressed concrete in and near the neutral axis can be replaced by some light
weight material. Different types of in-filled materials like brick, hollow pipes,
grade variation of concrete, terracotta hollow blocks and expanded polystyrene
sheets etc. gives good result in reducing the self-weight.

9
 CHAPTER 2
LITERATURE REVIEW

“Aerated Autoclaved Concrete (AAC) blocks: a revolution building

material in construction industry” (2016) by, Mallampalli. Ch. G.Subash,
V. S. V. Satyannarayana, Janga Srinivas Assistant Professor, Professor, Civil
Engineering, Department of Civil Engineering U.G, Miracle Educational
Society Group of Institutions, Bhogapuram, Vizayanagaram. He studied the
process of autoclaved aerated concrete and its advantages compared to the
normal concrete.

“Materials, Production, Properties and application of aerated

lightweight concrete: review”(2014) By Ali J. Hamad, Department of
Building and construction technology engineering/engineering technical
college, Mosul, Iraq. Ali J. Hamad focussed on the porosity, permeability,
compressive strength and splitting strength of AAC.

“Preparation and properties of porous aerated concrete”(2009) by

Ahmed Aidan, Zarook Shareefdeen, Bogdan Bogdanov, Irena Markovska,
Dimitar Rusev, Yancho Hristov, Dimitar Georgiev. In this work, they analysed
the benefits of using Aerated Autoclave Concrete, laboratory method of
preparation and some preliminary data on the properties of the materials.
Changes to raw materials, reduction in the processing time, increase in the
strength of materials and reduction in the cost of production were the main
objectives of the project.

“Experimental Investigation on Partial Replacement of Concrete

Below Neutral Axis of Beam”(2013) by Ashwathy S Kumar PG Scholar,

10
Department of Civil Engineering, Sree Buddha College of Engineering, Pattoor,
Kerala, India. In this paper, an experimental investigation on partial
replacement of concrete below the neutral axis by creating air voids using
polythene balls is discussed.

“Experimental Study on Partial Replacement of Concrete in and

Below Neutral Axis of Beam”(2016) by Er. Ima Mathew and Er. Sneha M.
Varghese, Department of Civil Engineering, Saintgits College of Engineering,
Kottayam. This paper focuses on replacing the concrete both in and near the
neutral axis and that below the neutral axis by creating air voids using waste
plastic bottles. Which helped in reduction in concrete used, thereby reducing the
self weight, cost, etc. Since waste plastic bottles were used to create air voids, it
added on to sustainability.

“Effect of Reinforced Concrete Beam with Hollow Neutral

Axis”(2014) by Jain Joy and Rajesh Rajeev, P. G. Student, Department of
Structural Engineering & Construction Management Department of Structural
Engineering. The objective of the investigation was to develop a Reinforced
Concrete Beam with hollow neutral axis which may replace the position of
reinforced concrete beam in near future.

11
 CHAPTER 3
METHODOLOGY

3.1 METHODOLOGY:

Introduction

Literature review

Collection of materials

Properties of materials

Testing of materials

Mix design

Casting and curing

Testing

Analysing the result

Report

Preparation

12
 CHAPTER 4
TESTING OF MATERIALS
4.1GENERAL:
The basic properties of the materials that are to be used in the
concrete mixture were tested and the results were compared with the Indian
standards. The objective of this work is to enable a mix design with required
strength and durability parameters.

Reinforced concrete comprises of cement, fine aggregate, coarse

aggregate, water and reinforcement. The basic properties of these materials
were determined and their results are tabulated

4.2 CEMENT

Portland cement of 53 grade conforming to IS 12269 -1987 was used.

The details of the tests carried out on various physical properties of cement are
explained below.

4.2.1 FINENESS TEST

The fineness of cement has an important bearing on the rate of

hydration and hence on the rate of gain of strength and also on the rate of
evolution of heat. Finer cement offers a greater surface area for hydration and
hence faster the development of strength. If the cement is fine then greater is its
cohesiveness, which is the property, required in the concrete because it gives
compactness to the concrete. Usually cement loses 10% of its strength within
one month of its manufacturing. Fineness of cement is tested by sieving, Weigh
correctly 100 grams of cement and take it on a standard IS sieve (90 micron).
Break down the air set lumps in the sample with fingers. Continuously sieve the
sample giving circular and vertical motion for a period of 15 minutes.

13
Mechanical sieving devices may also be used. Weigh the residue left on the
sieve. This weight shall not exceed 10% for ordinary cement.

4.2.2 INITIAL AND FINAL SETTING TIME

An arbitrary division has been made for the setting time of cement as
initial setting time and final setting time. It is difficult to draw a rigid line
between these two arbitrary divisions. For convenience, initial setting time is
regarded as the time elapsed between the moments that the water is added to the
cement, to 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. The initial and
final Setting time is calculated as per IS: 4031 (Part 5) 1988. Vicat apparatus
conforming to IS: 5513 -1976 is used to carry out the test.

 Prepare a cement paste by gauging the cement with 0.85 times the water
required to give a paste of standard consistency.

 Start a stop-watch, the moment water is added to the cement.

 Fill the Vicat mould completely with the cement paste, the mould
resting on a non-porous plate and smooth off the surface of the paste
making it level with the top of the mould. The cement block thus
prepared in the mould is the test block.

INITIAL SETTING TIME

Place the test block under the rod bearing the needle. Lower the
needle gently in order to make contact with the surface of the cement paste and
release quickly, allowing it to penetrate the test block. Repeat the procedure till

14
the needle fails to pierce the test block to a point 5 ±0.5mm measured from the
bottom of the mould. The time period elapsing between the time, water is added
to the cement and the time, the needle fails to pierce the test block by 5.0
±0.5mm measured from the bottom of the mould, is the initial setting time.

Fig 4.2.2.1 testing of cement on vicat apparatus

FINAL SETTING TIME

Replace the needle by the one with an annular attachment. The
cement should be considered as finally set when, upon applying surface if the
resting the needle gently to the test the surface of the test block the needle
makes an impression therein, while the attachment fails to do so . The period
elapsing between the time, water is added to the cement and the time, the needle
makes an impression on the surface of the test block, while the attachment fails
to do so, In other words, the paste has attained such a hardness that the centre
needle does not pierce through the paste more than 0.5mm, is the final setting
time.

15
4.2.3 CONSISTENCY TEST

Standard consistency of a cement paste is defined as that consistency

which will permit a vicat plunger having 10 mm diameter and 50 mm length to
penetrate to a depth of 33-35 mm from top of the mould.

Take 400 g of cement and place it in the enamelled tray. Mix about
25% water by weight of dry cement thoroughly to get a cement paste. Total
time taken to obtain thoroughly mixed water cement paste i.e. “Gauging time”
should not be more than 3 to 5 minutes. Fill the vicat mould, resting upon a
glass plate, with this cement paste. After filling the mould completely,
smoothen the surface of the paste, making it level with top of the mould. Place
the whole assembly under the rod bearing plunger. Lower the plunger gently so
as to touch the surface of the test block and quickly release the plunger allowing
it to sink into the paste. Measure the depth of penetration and record it. Prepare
trial pastes with varying percentages of water content and follow the steps (2 to
7) as described above, until the depth of penetration becomes 33 to 35 mm.

S.NO DESCRPTION RESULT

1 Fineness 2%
2 Initial setting time 32min
3 Final setting time 420min
4 Consistency 32%
Table 4.2.3.1 test result on cement

4.3 FINE AGGREGATE

Natural river sand was used as fine aggregate. The properties of sand
were determined by conducting tests as per IS: 23 86 (part 3). The results
obtained from the sieve analysis indicate that the sand conforms to zone I of IS:
383-1970. Tests were carried out on various physical properties of aggregates
and are ensured whether they confirm with IS codes.

16
4.3.1 SPECIFIC GRAVITY
Specific gravity of aggregates is made use of in design calculations of
concrete mixes. With the specific gravity of each constituent known, its weight
can be converted in to solid volume and hence a theoretical yield of concrete per
unit volume can be calculated. Specific gravity of aggregates is also required in
calculating the compacting factor in connection with the workability
measurements. The average specific gravity of fine aggregate varies from 2.6 to
2.8. As per IS 23 86 (Part 3): 1963, A sample of about 1 kg of fine aggregate
shall be placed in the tray and covered with water. Soon after immersion, air
entrapped in or bubbles on the surface of the aggregate shall be removed by
gentle agitation with a rod. The sample shall remain immersed for 24 hours. The
water shall then be carefully drained from the sample. The aggregate shall be
exposed to warm air until uniform drying is achieved. The aggregate shall then
be placed in the Pycnometer which shall be filled with water. The Pycnometer
shall be dried on the outside and weighed. The contents of the Pycnometer shall
be emptied into the tray. The Pycnometer shall be refilled with water to the
same level as before, dried on the outside and weighed. The sample shall be
placed in the oven in the tray at a temperature of 100 to 110°C for 24 hours,
during which period it shall be stirred occasionally to facilitate drying. It shall
be cooled in the air-tight container and weighed.
4.4 COARSE AGGREGATE
Crushed granite stones obtained from local quarries were used as
coarse aggregate. The nominal size of the aggregate is taken to be 20 mm. The
properties of coarse aggregate were determined by conducting tests as per IS: 23
86 (Part III).
4.4.1 SPECIFIC GRAVITY
As per IS 2386 (Part 3): 1963, the sample shall be thoroughly washed
to remove finer particles and dust, drained and then placed in the wire basket
and immersed in water. After immersion the entrapped air shall be removed

17
horn the sample by lifting the basket containing it, 25 mm above the base of the
tank and allowing it to drop 25 times at the rate of about one drop per second.
The basket and aggregate shall remain completely immersed during the
Operation and for a period of 24 hours afterwards. The basket and the sample
shall then be weighed in water. The basket and the aggregate shall then be
removed from the water and allowed to drain for a few minutes, after which the,
aggregate shall be gently emptied horn the basket on the dry clothes, and the
empty basket shall be returned to the water, jolted 25 times and weighed. The
aggregate shall be dried by atmospheric air for ten minutes. The aggregate shall
then be weighed. The aggregate shall then be placed in the oven in the shallow
tray, at a temperature of 100 to 110°c and maintained at the temperature for 24
Hours. It shall then remove from the oven cooled in the airtight container
weighed.

Fig 4.4.1.1 specific gravity test by Pycnometer

18
Trial no Empty mass Mass of Mass of Mass of Specific
of Pycnometer Pycnometer Pycnometer gravity
Pycnometer and dry soil and and water
sample water
(M1) (Kg) (M2) (Kg) (M3) (Kg) (M4) (Kg)
1 0.482 1.286 1.993 1.480 2.76
2 0.482 1.280 1.991 1.480 2.78
3 0.482 1.295 1.990 1.480 2.68
Table 4.4.1.1 specific gravity of fine aggregate
Specific gravity = (M2-M1)/((M2-M1)-(M3-M4))
Average specific gravity =2.74
Trial no Empty mass Mass of Mass of Mass of Specific
of Pycnometer Pycnometer Pycnometer gravity
Pycnometer and dry soil and and water
sample water
(M1) (Kg) (M2) (Kg) (M3) (Kg) (M4) (Kg)
1 0.482 1.286 1.991 1.480 2.74
2 0.482 1.280 1.991 1.480 2.78
3 0.482 1.295 2.092 1.480 2.70
Table 4.4.1.2 specific gravity of coarse aggregate

Specific gravity = (M2-M1)/((M2-M1)-(M3-M4))

Average specific gravity =2.74

4.4.2 IMPACT STRENGTH TEST

The aggregate impact value gives relative measure of the resistance of an

aggregate to sudden shock or impact. In which some aggregates differs from its
resistance to a slow compaction load. The test sample consists of aggregate

19
passing through 12.5 mm and retained on 10mm sieve. The aggregate shall be
dried in an oven for a period of four hours at a temperature of 100 ̊C to 110 ̊C
and cooled. The aggregate is filled about one-third full and tamped with 25
strokes by taping rod.

A further similar quantity of aggregate is added and tamped in the

standard manner. The measure is filled over-flowing and then struck off level.
The net weight of aggregate in the measure is determined (weight A) and this
weight of aggregate shall be used for the duplicated test on the same material.

The whole sample is filled into cylindrical steel firmly fixed on the base
of the machine. A hammer weighing about 14kg is raised to a height of 380 mm
above the upper surface of the aggregate in the cup and allowed to fall freely on
the aggregate. The test sample shall be subjected to a total 15 such blows each
being delivered at an interval of not less than one second. The crushed
aggregate is removed from the cup and whole of it is on 2.36mm I.S sieve.

Fig 4.4.2.1 impact strength test of coarse aggregate

20
 The fraction passing the sieve is weighed to an accuracy of 0.1 grams
(weight B). The fraction retained on the sieve is also weighed (weight C). If the
total weight (B+C) is less than the initial weight A by more than one gram the
result shall be discarded and a fresh test made. Two tests are made.

The ratio of the weight of fines formed to the total sample weight in each
test is expressed as percentage.

The Aggregate Impact Value = (B/A) x 100

Where,

B = weight of fraction passing 2.36mm I.S sieve.

A = weight of oven dried sample.

A = 0.643 kg

B = 0.090 kg

Impact value = (B/A) x 100 = 13.99%

The aggregate impact value should not be more than 45% by weight for
aggregate used for concrete other than wearing surfaces and 30% by weight for
concrete to be used as wearing surfaces, such as runways roads and pavements.

4.4.3 SHAPE TESTS ON COARSE AGGREGATES

Following tests are conducted on coarse aggregates under shape tests:

 the elongation index of the given aggregates
 the flakiness index of the given aggregates

4.4.3.1 FLAKINESS INDEX AND ELONGATION INDEX TESTS

Sieve the sample through the IS sieves (as specified in the table).
Take a minimum of 200 pieces of each fraction to be tested and weigh them. To

21
separate the flaky materials, gauge each fraction for thickness on a thickness
gauge. The width of the slot used should be of the dimensions specified in
column of the table for the appropriate size of the material. Weigh the flaky
material passing the gauge to an accuracy of at least 0.1 per cent of the test
sample. To separate the elongated materials, gauge each fraction for length on a
length gauge. The width of the slot used should be of the dimensions specified
in column of the table for the appropriate size of the material. Weigh the
elongated material retained on the gauge to an accuracy of at least 0.1 per cent
of the test sample.
Size of aggregates Weight of Thickness Weight of Length Weight of
Passing Retained fraction gauge aggregates gauge aggregates
through on IS consisting size, in each size, in each
IS Sieve, Sieve, of at least fraction fraction
200 passing retained
pieces, thickness on length
gauge, gauge,
(mm) (mm) (gm) (mm) (mm) (mm) (mm)
63 50 23.90 - -
50 40 27.00 81.00 40
40 31.5 742 19.50 75 58.00 65
31.5 25 946 16.95 61 - -
25 20 390 13.50 45 40.5 35
20 16 300 10.80 27 32.4 29
16 12.5 497 8.55 85 25.5 49
12.5 10 485 6.75 86 20.2 101
10 6.3 434 4.89 138 14.7 80
Total W= 3794 517 399
Table 4.4.3.1 elongation and flakiness index of coarse aggregate

22
Flakiness Index = (X1+ X2+…..) / (W1 + W2 + ….) X 100

Flakiness index: 517/3784=13.86%

Elongation Index = (Y1 + Y2 + …) / (W1 + W2 + ….) X 100

Elongation index: 399/3277=12.81%

4.4.3.2 SIEVE ANALYSIS
The sieve analysis is conducted to determine the particle size
distribution in a sample of aggregate, which we call gradation. The sieve used
for test has square openings. Sieves are described by sizes of their openings as
80mm, 63mm, 50mm, 40mm, 25mm, 20mm, 16mm, 12.5mm, 10mm, 6.3mm,
4.75mm, 3.35mm, 2.36mm, 1.70mm, 1.18mm, 850nm, 600um, 300nm, 212nm,
150nm and 75pm. All these sieves are mounted in frames one above the other in
ascending order. The sieves used for fine and coarse aggregate are of sizes
80mm, 40mm, 20mm, 10mm, 4.75mm, 2.36mm, 1.18mm, 600nm, 300um,
150nm and 75pm. All the sieves are mounted on sieve shaker. Aggregate of
known quality is placed over the top sieve and after sieving through sieving
through the sieve test, the residue in each of sieve is weighed. The percentage of
retained to the total weight is calculated.
S.NO IS sieve Weight % retained Cumulative Cumulative
size retained(g) % retained % retained
1 4.75mm 25 2.5 2.5 97.5
2 2.36mm 102 10.2 12.7 87.3
3 1.18mm 528 52.8 65.5 34.5
4 600µm 180 18.0 83.5 16.5
5 300µm 148 14.8 98.3 1.7
6 150 µm 17 1.7 100 0
∑F=362.5
Table 4.4.3.2 fineness of fine aggregate

23
S.NO IS sieve Weight % retained Cumulative Cumulative
size retained % retained % retained
(grams)
1 25mm 0 0 0 100
2 20mm 0 0 0 100
3 16mm 150 15 15 85
4 12.5mm 370 37 52 48
5 10mm 250 25 77 23
6 6.5mm 220 22 97 3
7 4.75mm 30 3 100 0
∑F=341
Table 4.4.3.2 fineness of coarse aggregate

Finess modulus of coarse aggregate = (∑F+500)/100

= (362.5+500)/100

=8.6245

Finess modulus of coarse aggregate = (∑F+500)/100

= (341+500)/100

=8.41

4.5 WATER

Water is an important ingredient of concrete as it actively participates in

the chemical reaction with cement. Since it helps to form the strength giving
cement gel, the quantity and quality of water is required to be looked in to
carefully. Potable water free from salts was used for casting and curing of
concrete as per IS: 456 -2000 recommendations. The pH of the water shall not

24
be less than 6, it should be in the range of 6 -8 and it should be free from other
organic matters.

4.6 SUMMARY

The properties of materials like cement, fine aggregate, coarse aggregate,

water are tested as per IS codes and their conditions are satisfied. Finally the
values are tabulated. Further these values are used for the mix design
calculation

25
 CHAPTER 5

MIX DESIGN

5.1 INTRODUCTION:

Concrete Mix design is a process of attaining various proportions of raw

materials of concrete with a minimum strength requirement and to achieve
durable concrete. The Concrete mix design can be defined as the art of
obtaining a concrete of the required properties, at the lowest cost, by suitable
choice and proportions of available materials. The purpose of mix proportioning
is to obtain a product that will perform according to certain predetermined
requirements, the most essential requirements being the workability of fresh
concrete, strength and durability of hardened concrete. Needless to say, a
property designed concrete mix for the specified strength requirement should
have the minimum cement content to make mix economical. It should, however,
be stressed that the precise relationship falls between the properties of concrete
and the specific characteristics such as water cement ratio, aggregate cement
ratio and grading, apart from such elusive quantities as aggregate-particle shape
and texture. Hence, concrete mix design cannot ne mechanically done and is
likely to remain an art, rather than a science, for some time to come.

The design of concrete is science that can be described here only in its
broad outlines. The starting point of any mix design is to establish the desired
workability characteristics of wet concrete, the desired physical properties of
the cured concrete and the acceptable cost of the concrete.

5.2 STATISTICAL QUALITY CONTROL OF CEMENT CONCRETE

In concrete, it is very difficult to assess the strength of final product. It is

not possible to have a large number of destructive tests for evaluating the

26
strength of end product. The aim of quality control is to limit the variability as
much as practicable.

Limited variability means, ensuring the probability test result falling

below, the design strength is not more than specified tolerance level. Statistical
quality control method provides a scientific approach to the concrete designer to
understand the realistic variability of the materials so as to lay down design
specification with proper tolerance. Cement is a binding material, which is used
in construction work. There are varieties of cement available in the market and
each type is used under condition due to special properties.

5.3 MIX DESIGN

5.3.1 STIPULATIONS FOR PROPORTIONING

Grade designation M 25
Type of cement OPC 53 grade
Maximum nominal size of aggregate 20mm
Minimum cement content 320 Kg/m3
Maximum water-cement ratio 0.45
Workability 100mm (slump)
Exposure condition Normal
Method of concrete placing Manual
Degree of supervision Good
Type of aggregate Crushed angular aggregate
Maximum cement content 450 Kg/m3

5.3.2 TEST DATA FOR MATERIALS

5ement used OPC 53 grade

Specific gravity of cement 3.15

27
Specific gravity of Coarse aggregate 2.74
Specific gravity of Fine aggregate 2.74
Water absorption of Coarse aggregate 0.5 percent
Water absorption of Fine aggregate 1.0 percent

5.3.3 TARGET STRENGTH FOR MIX PROPORTIONING

f’ck = fck + 1.65 s

Where,

f’ck = target average compressive strength at 28 days

fck = characteristic compressive strength at 28 days, and

s = standard deviation.

From Table 1 of IS 10262:2009, Standard deviation, s = 4 N/mm2.

Therefore, target strength = 25 + 1.65 x 4 = 31.6 N/mm2.

5.3.4 SELECTION OF WATER CEMENT RATIO

From Table 5 of IS 456:2000, maximum water-cement ratio = 0.45.

Allowing fluctuation in water cement ratio up to 0.4,

Water-cement ratio of 0.4 < 0.45 is acceptable.

5.3.5 SELECTION OF WATER CONTENT:

From Table 2 of IS 10262:2009,

Maximum water content for 20 mm aggregate = 186 litres (for 25 to 50 mm

slump range)

28
 The required water content is obtained by increasing the water content by
3% for every 25 mm increase in slump value.

Estimated water content for 100 mm slump = 186 + (6*186/100)

= 197 litres.

5.3.6 CALCULATION OF CEMENT CONTENT

Water-cement ratio = 0.40

Cement content = 197/0.40
= 492.5 Kg/m3.

Cement content = 492.5 Kg/m3.

5.3.7 PROPORTION OF VOLUME OF COARSE AGGREGATE AND

FINE AGGREGATE

From Table 3, volume of coarse aggregate corresponding to 20mm size

aggregate and fine aggregate (Zone I) for water cement ratio 0.50 = 0.60

In the present case water-cement ratio is 0.40. Therefore, volume of

coarse aggregate is required to be increased to decrease the fine aggregate
content. As the water-cement ratio is lower by 0.10, the proportion of volume of
coarse aggregate is increased by 0.02 (at the rate of -/+ 0.01 for every ± 0.05
change in water-cement ratio). Therefore, corrected proportion of volume of
coarse aggregate for the water-cement ratio of 0.40 = 0.62.

5.3.8 MIX CALCULATIONS:

The mix calculations per unit volume of concrete shall be as follows:

a) Volume of concrete = 1m3.

29
b) Volume of cement Mass of cement
= x (1/1000)
Specific gravity of cement
492.5
=
3.15 x 1000

= 0.1563m3.

c) Volume of water Mass of water

= x (1/1000)
Specific gravity of water
197
=
1 x 1000

= 0.197m3.

d) Volume of all in aggregate = [ a – (b + c)]

= 1- ( 0.1563 + 0.197)
= 0.6467m3.

e) Mass of coarse aggregate = Volume of all in aggregate x

Volume of coarse aggregate x Specific
gravity of coarse aggregate x 1000
= 0.6467 x 0.62 x 2.74 x 1000
= 1098.61 Kg/m3.

f) Mass of fine aggregate = Volume of all in aggregate x

Volume of fine aggregate x Specific
gravity of fine aggregate x 1000
= 0.6467 x 0.38 x 2.74 x 1000
= 673.34 Kg/m3.

30
5.3.9 MIX PROPORTIONS

Cement 492.5 Kg/m3

Water 197 Kg/m3
Fine Aggregate 673.34 Kg/m3
Coarse Aggregate 1098.61 Kg/m3
Water-cement ratio 0.40

5.4 TESTS ON FRESH CONCRETE

Fresh concrete or plastic concrete is a freely mixed material which can be
moulded into any shape. The relative quantities of cement, aggregates and water
mixed together, to control the properties of cement in wet and hardened state.
5.4.1 SLUMP TEST
Slump test is the most commonly used method of measuring workability
of concrete. Slump is a measure of consistency or relative ability of the concrete
flow. It is used to indicate the degree of wetness. Workability of concrete is
mainly affected by consistency i.e. wetter mixes will be more workable than
drier mixes, but concrete of the same consistency may vary in workability. The
test is carried out using a mould known as a slump cone or Abram’s cone.
The apparatus for conduction the slump test consists of a metallic mould
in the form of a frustum cone having the internal dimension as follow,
Bottom Diameter : 20 cm
Top Diameter : 10 cm
Height : 30 cm
The mould is filled with concrete in four layers. Each layer is tamped 25
times by the tamping rod taking care to distribute the strokes evenly over the
cross section. The mould is removed from the concrete by raising it slowly and
carefully in a vertical direction.. The slump tests conducted shows slump value
of 50mm.

31
 Fig 5.4.1 slump cone test

Grade of concrete Water cement ratio Slump value

M25 0.40 50mm
Table 5.4.1 slump cone test

5.5 TESTS ON HARDENED CONCRETE

Concrete has hardened, it can be subjected to a wide range of test to
prove its ability to perform or discover its characteristics. Testing on hardened
concrete can investigate the fundamental physical behaviour of concrete such as
elastic properties and strength characteristics. There are various tests to be
carried out on hardened concrete. Compressive strength test and split tensile
strength is performed.

Fig 5.5.1 compressive strength test

32
5.5.1 COMPRESSIVE STRENGTH TEST
Compressive test are made at recognized ages of the test specimens. Least
three specimens, preferably from different batches shall be made for testing at
each selected age. Compressive strength was measured using a compression
testing machine with a maximum capacity 200KN. The cube of size
150x150x150 mm is used. The cubes are placed in the compression testing
machines in such manner that the load is applied to the opposite sides of the
cube as cast. The load is applied at the rate of 2.5 KN per second
(approximately) until the failure of the specimen.
load applied on the cube specimen
Compressive strength of concrete =
gross area of cube
Average Strength of Cubes
Cubes tested on
(N/mm2)
7th day 17.56
14th day 22.38
28th day 26.31

Table 5.5.1 compressive strength of cube

30

25

20

15 Compressive Strength
of Cube
10

0
7th day 14th day 28th day

Fig 5.5.2 compressive strength of cube

33
 CHAPTER 6

DESIGN OF BEAM

6.1 GENERAL
The Conventional beam and AAC replaced beam are designed for
1.1mx0.23mx0.13m. The size of AAC block used in the replaced beam was
calculated based on the depth of neutral axis and the space available within the
reinforcement cage. Generally, a loss in shear strength of the beam is expected
because of the low shear strength of the AAC blocks. In order to minimize the
loss of shear strength compared to conventional beam, the volume of AAC
blocks used near the ends in the cross section of the beam are reduced. This is
done by placing AAC blocks with ends sloping towards the ends of the beam.

Grade of concrete (fck) M25

Grade of Steel (fy) Fe500
Stirrup diameter (Øds) 6mm
Main bar diameter(Ød) 10mm
Spacing of Stirrups 200mm
Clear Cover 20mm
Length of Beam(L) 1100mm
Breadth of Beam(B) 130mm
Depth of Beam(D) 230mm
Grade of Cement OPC 53 Grade
Water Cement Ratio 0.40

Table 6.1 Details of Specimen Casted

34
6.2 NEUTRAL AXIS OF BEAM

6.2.1 Stress and Strain Diagrams of Singly reinforced beam

Triangles representing the Strain in Steel and Concrete are similar.

By Similar triangle concept,

𝟎. 𝟎𝟎𝟑𝟓 𝒙𝒖 𝒎𝒂𝒙
=
𝟎. 𝟖𝟕𝒇𝒚 𝒅 − 𝒙𝒖 𝒎𝒂𝒙
+ 𝟎. 𝟎𝟎𝟐
𝑬𝒔

𝑥𝑢 𝑚𝑎𝑥 0.0035
=
𝑑 0.87𝑓𝑦
+ 0.002 + 0.0035
𝐸𝑠

𝑥𝑢 𝑚𝑎𝑥 0.0035
=
𝑑 2.175 𝑥 10−3 + 0.002 + 0.0035

𝑥𝑢 𝑚𝑎𝑥 0.0035
=
𝑑 0.007675
𝑥𝑢 𝑚𝑎𝑥
= 0.456
𝑑

Effective depth, d = 205 mm

35
 Xu max = 205 x 0.456

Maximum depth of Neutral Axis, Xu max = 93.48 mm

Area of Steel used in the specimen,

Ast = 2 x 𝝅𝒓𝟐 = 2 x 𝝅(𝟓)𝟐 = 157.07 mm2

For Singly Reinforced Beams, the Compression force acting in the

compression zone in concrete will be equal to the tensile force acting in the
Tension zone in Steel.

Compression acting in concrete = Tension acting in steel

0.36 fck Xu b = 0.87 fy Ast

0.36 (25) Xu (130) = 0.87 (500) (157.07)

Xu = 68325.45 / [(130) (25) (0.36)]

Depth of Neutral Axis, Xu = 58.397 mm.

Figure 6.2.2 Cross Section of Beam

36
6.3 REPLACING THE TENSILE PART

The depth of Neutral axis (Xu) and the maximum depth of Neutral axis
(Xumax) are found to be 58.5mm and 93.5mm respectively. The AAC blocks
replaced in the tensile part of the beam are cut into trapezoidal shape with depth
100mm and breadth 60mm. The total length of the AAC block is 930mm, with a
slope of 2:3 at both the ends for the last 150mm.

(a)AAC block cut into pieces (b)AAC block full size piece
Figure 6.3.1 AAC blocks
The Blocks were cut to required dimensions and shape using saw. Since
the Maximum length of the AAC blocks are 600 mm, blocks are cut into pieces
and placed in the reinforcement cage.

Figure6.3.2 Longitudinal section of Beam replaced with AAC block

37
 CHAPTER 7

QUANTITY AND COST ESTIMATION

7.1 GENERAL

The quantity of material required for casting conventional beam and

Beam whose tensile part is replaced by AAC block are determined. Estimation
is done for various materials used in the beam and cost comparison between
these two beams is done.

7.2 QUANTITY ESTIMATION

In order to determine the quantity of various materials used in the beam,

the quantity of concrete required to cast the beam and the reinforcements used
in the beams are calculated. From the quantity of concrete required, various
components that make up the concrete are determined.

7.2.1 CONVENTIONAL BEAM

7.2.1.1 ESTIMATION FOR CONCRETE

Length of the beam(L) = 1.1m

Breadth of the beam(B) = 0.13m
Depth of the beam(D) = 0.23m
Volume of the beam =LxBxD
= 1.1 x 0.13 x 0.23
Volume of the beam(V) = 0.03289m3.
Mix ratio for M25 grade concrete is 1:1:2, as obtained earlier in the design
mix. Mix ratio shows the presence of one part of Cement, One part of Coarse
aggregate and two parts of Fine aggregate in the concrete.
Volume of Cement in the beam = 0.03289/4
= 0.008225m3.

38
Volume of Fine Aggregate = 0.03289/4
= 0.008225m3.

Volume of Coarse Aggregate = 0.03289/2

= 0.01645m3.

Mass of Cement = Volume of Cement x Specific gravity x 103

= 0.008225 x 3.15 x 103
Mass of Cement(Mc) = 25.9Kg.

Mass of F. A. = Volume of F. A. x Specific gravity x 103

= 0.008225 x 2.74 x 103
Mass of F. A.(M f) = 22.53Kg.

Mass of C. A. = Volume of C. A. x Specific gravity x 103

= 0.01645 x 2.74 x 103
Mass of C. A,(Mca) = 45.059Kg.

7.2.1.2 ESTIMATION FOR STEEL

Length of Reinforcing steel bar = 1m

Diameter of steel bar (Ød) = 0.01m
Radius of Reinforcing steel bar = 0.005m
Number of bars used =4
Volume of one bar = 𝜋𝑟 2l
= 𝜋(0.005)2 x 1
=7.854 x 10-5m3.

Volume of steel for four bars = 4 x 7.854 x 10-5

= 3.1416 x 10-4m3

39
Mass of Steel used(Ms) = Volume of Steel x Density
= 3.1416 x 10-4 x 7700
Mass of Steel used(Ms) = 2.42Kg.
Stirrup diameter = 6mm
Number of Stirrups =4

7.2.2 AAC REPLACED BEAM

7.2.2.1 ESTIMATION FOR AAC BLOCK

Length of AAC block = 0.93m

Breadth of AAC block = 0.06m
Depth of AAC block = 0.1m
Base of Triangular portion = 0.15m
Volume of AAC in Beam = Volume of two triangular portions +
Volume of rectangular portion
Volume of Triangular portion = (1/2) x (0.15) x (0.1) x 0.06 x 2
= 9 x 10-4m3
Volume of Rectangular portion = 0.63 x 0.06x 0.1
= 3.78 x 10-3m3
Volume of AAC in Beam = 4.68 x 10-3m3
Volume of Beam(V) = 0.03289m3
Volume of Concrete in the beam = Volume of Beam – Volume of AAC in
beam
= 0.02821m3.
Mix ratio for M25 grade concrete is 1:1:2, as obtained earlier in the design
mix. Mix ratio shows the presence of one part of Cement, One part of Coarse
aggregate and two parts of Fine aggregate in the concrete.
Volume of Cement in the beam = 0.02821/4
= 7.0525x10-3m3.

40
Volume of Fine Aggregate = 0.02821/4
= 7.0525x10-3m3.

Volume of Coarse Aggregate = 0.02821/2

= 0.014105m3.

Mass of Cement = Volume of Cement x Specific gravity x 103

= 7.0525x10-3 x 3.15 x 103
Mass of Cement(Mc) = 22.22Kg.

Mass of F. A. = Volume of F. A. x Specific gravity x 103

= 7.0525x10-3 x 2.74 x 103
Mass of F. A.(Mf) = 19.33Kg.

Mass of C. A. = Volume of C. A. x Specific gravity x 103

= 0.014105 x 2.74 x 103
Mass of C. A,(Mca) = 38.66Kg.

7.2.2.2 ESTIMATION FOR STEEL

Length of Reinforcing steel bar = 1m

Diameter of steel bar (Ød) = 0.01m
Radius of Reinforcing steel bar = 0.005m
Number of bars used =4
Volume of one bar = 𝜋𝑟 2l
= 𝜋(0.005)2 x 1
=7.854 x 10-5m3.

Volume of steel for four bars = 4 x 7.854 x 10-5

= 3.1416 x 10-4m3

41
Mass of Steel used(Ms) = Volume of Steel x Density
= 3.1416 x 10-4 x 7700
Mass of Steel used(Ms) = 2.42Kg.
Stirrup diameter = 6mm
Number of Stirrups =4

7.3 COST OF MATERIALS

The Cost of Various materials used in Casting of the beam are listed
below. Transportation cost, labour charge and centring charges are not taken
into account for calculation as they do not affect the actual rate of the beam. The
cost specified in the table may vary from place to place, depending upon the
retailers, availability of stock, etc.

Basic
Material Mass/Quantity Cost(INR)
cost(INR)

Cement 50Kg/bag 360 7.2/Kg

Fine Aggregate 1Kg 4.5 4.5/Kg

Coarse Aggregate 1Kg 2 2/Kg

Steel 1Kg 44 44/Kg

Stirrup 1nos. 6.75 6.75/piece

AAC Block 1Block(100x200x600)* 50 4100/m3

Table 7.3.1 Cost of Materials

*Note:

1. Dimensions are in mm

2. Cost Specified in the columns are in Indian Rupees.

42
7.4 COST COMPARISON

From the cost mentioned earlier and the quantity estimation done on both
conventional and AAC replaced beams, a cost comparison is done to check the
economical property of the beam. Comparison is done between one specimen of
conventional beam and one specimen of AAC replaced beam.

Conventional Beam AAC Replaced Beam

Material
Mass/ Mass/
Cost(INR) Cost(INR)
Quantity Quantity

Cement 25.9Kg 186.5 22.22Kg 160

Fine Aggregate 22.53Kg 101.5 19.33Kg 87

Coarse Aggregate 45.059Kg 112 38.66Kg 77.5

Steel 2.42Kg 106.5 2.42Kg 106.5

Stirrups 4nos. 27 4nos. 27

AAC block - - 4.68x10-3m3 19

Total cost 533.5 Total cost 477

Table7.4.1 Cost comparison of Conventional and AAC replaced beam

From the above cost comparison, it is clearly understandable that the

AAC replaced beam is far economical than conventional beam. This is due to
the lower cost of AAC blocks when compared to conventional concrete.
Percentage saving of cost = (1- (cost of AAC replaced beam/Cost of
conventional beam) )x100%
= (1 - (477/533.5))x100%
Percentage saving of cost = 10.59%

43
7.5 PERCENTAGE OF AAC REPLACED FOR CONCRETE

Total volume of Beam = 0.03289m3

Total volume of AAC in beam = 4.68x10-3m3

Percentage of concrete replaced = (Total volume of AAC in beam/Total

volume of beam)x100%

= (4.68x10-3/0.03289)x100%

= 14.23%

Percentage of concrete replaced = 14.23%

44
 CHAPTER 8
CASTING AND CURING

8.1 PREPARING MOULD

For both conventional beam and beam casted with the tensile part
partially replaced by AAC, plywood is used as mould. The Plywood is first cut
to the outer dimensions of the beam to be casted and then the plywood to make
the mould is fitted together using nails.

(a) Conventional Beam (b) AAC partially replaced beam

8.1.1 Mould with reinforcement for casting

8.2 PREPARING AND PLACING REINFORCEMENT

The Reinforcement used in the beams is of Fe500 HYSD bards. The

diameter of the bars used as reinforcement is 10mm. The Reinforcements were
cut into 1m length each. Two bars were placed in the tensile zone and two bars
were used as hanging bars for supporting the reinforcements.

Shear reinforcements of diameter 6mm is used at centre to centre spacing

of 200mm. Binding wires were used to keep in place the shear reinforcements.

To ensure proper placing of the reinforcement cage, Cover blocks are

used. 20mm Clear cover is provided at the bottom of the reinforcement. This

45
cover prevents exposing the steel reinforcement to the external environment and
also prevents corrosion of the member.

8.3 BATCHING, MIXING AND PLACING CONCRETE

The Successful placement of concrete is dependent upon careful batching,

mixing and transportation of the concrete. Mixing concrete is simply defined as
the “complete blending of the materials which are required for the production of
homogeneous concrete”. This can vary from hand to machine mixing, with
machine mixing being the most common. In this project, Hand mixing has been
used.

However, no successful mixture can be achieved without the proper

batching of all materials. Batching is the “Process of weighing or
volumetrically measuring and introducing into the mixer the ingredients for a
batch of concrete”. Quality assurance, suitable arrangement of materials,
equipment, and correct weighing of the materials are the essential steps that
must be completed before any mixing takes place. In order to ensure proper
batching, weigh batching has been used in this project.

Placing of the concrete is done manually and was done in four layers.
Each layer was very well compacted about 25 times to ensure minimum void
presence in the beam.

Mixing of the dry ingredients was done initially and slowly water was
added to until the required amount of water was achieved as calculated. Care
was taken to ensure that the mix did not result to be too stiff or too sloppy. It is
difficult to form good test specimens if it is too stiff. If it is too sloppy, water
may separate (bleed) from the mixture. Too sloppy mixture also has the
disadvantage of void formation in the beam after the initial setting of concrete.

46
 Casting the beams with AAC blocks is done by placing the blocks inside
the reinforcement cage. The AAC blocks were placed in the cage such that the
blocks are sloping towards the ends. Since, Concrete is has good shear strength
compared to AAC blocks, complete replacement of the tensile part i.e. to the
ends will result in the lowering of shear strength of the beam resulting in earlier
failure by shearing.

8.3.1 Batching, Placing and compacting concrete

The tops of the beams were floated off smoothly with a straight edge.
Along with each series of beams auxiliary specimens were also cast to
determine the material properties of concrete.

8.4 CURING

The specimens were cured by providing wet gunny bags for 28 days and
air dried for 1 day before testing.

47
 Dimension Stirrups
Sl. No. of Beam
Description (mm) spacing
No. Beams ID
Length Breadth Depth (mm)

Partially
1 AAC
2 C1T1 1100 130 230 200
replaced
beams
subjected to
pure bending

Conventional
2 Beams
2 C2T2 1100 130 230 200
subjected to
pure bending

Table 8.4.1 Dimensions of the beam

48
 CHAPTER 9

TEST RESULTS AND DISCUSSIONS

9.1 GENERAL

This chapter presents the details of the experimental setup used to test the
specimen, results of the tests and discussion on the results. Tests done on the
specimens include Flexural strength test of beams done on loading frame using
two point loading method i.e. Loading setup for pure bending.

9.2 LOADING ARRANGEMENT TO DETERMINE FLEXURAL

STRENGTH
The loading frame is of the self-straining type, made from rolled steel
joist sections, channel sections and flats. The capacity of the loading frame is
50T. The supports for the test specimen are at a level, which is comfortable for
taking deflection readings. The saddle support for bending is made of mild steel.
The cylindrical surface rests on a cylindrical groove in the bottom block. When
the test slab rotates the reaction offered to the beam will be always normal
because of the property of cylindrical surface. After erecting the supports in
position as per the specified span length, the beam specimen is lifted manually
and brought over the supports.

The diameter of steel rollers used in the testing is 38mm in diameter. The
specimen is mounted on the steel rollers and care should be taken to ensure that
the centre to centre distance between two rollers is 0.9m. The load is applied
through two similar rollers mounted at the one-third points of the supporting
span i.e. Spaced at 300mm centre to centre. The load is to be dived equally
between the two loading rollers and all rollers are mounted in such a manner
that the load is applied axially and without subjecting the specimen to any

49
torsional stresses or restraints. One suitable arrangement which complies with
these requirements is indicated in the figure 9.1 below.

Fig 9.2.1 loading arrangement

Test specimens are stored in water at a temperature of 24°C to 30°C for

48 hours before testing. The specimen is tested immediately on removal from
the water whilst they are still in a wet condition. The dimensions of each
specimen are noted before testing. No preparation of the surfaces is required.

The specimen shall then be placed in the machine in such a manner that
the load is applied to the uppermost surface as cast in the mould, along two lines
spaced 300mm apart.

The load is applied without shock and increasing continuously. The load
is increased until the specimen fails; the maximum load applied to the specimen
during the test is recorded. The appearance of fractured faces of concrete and
any unusual features in the type of failure is noted.

The testing for flexural strength is done on four-point bending setup

where the loading span is one third of the support span.

50
 9.2.2 Flexural strength test on beam

The flexural strength of rectangular beam (𝜎) on four-point bending setup

where the loading span is one-third of the support span is given by,

𝐹𝐿
𝜎=
𝑏𝑑 2

Where,

F is the force(load) at fracture point

L is the length of the support (outer) span
B is the width of the specimen
D is the depth of the specimen

The deflection is measured at the centre using dial gauge. The loads are
applied in small increments and at every increment of loading, the deflection
was recorded. The load and deflection values obtained for conventional beams
and reinforced concrete beams are tabulated.

51
9.3 TEST RESULTS

9.3.1 CONVENTIONAL BEAM

The deflection of the specimen increased with load. The maximum

deflection obtained for conventional beam is 6.71mm. Graph drawn for Load vs
Deflection of conventional beam is shown below and the values of deflection
obtained to the corresponding loads are tabulated.

Comparing to the beam whose tensile part is replaced by AAC, the

Conventional beam showed greater load carrying capacity and flexural strength.
Up to the maximum load carrying capacity, the Load Vs Displacement
relationship is linear. After that the load and displacement reduces gradually and
leads to shear failure of the beam.
Load in Displacement in mm
S. No.
KN (at centre)

1. 8.24 0.43

2. 16.45 0.78

3. 24.67 1.26

4. 32.94 1.93

5. 41.00 3.05

6. 49.30 3.95

7. 48.2 4.75

8. 47.0 6.00

9. 45.5 6.71

Table 9.3.1.1 Load and displacement values for conventional beam

52
 Flexural Strength test
60

50
Load (KN)

40 Conventional
beam
30

20

10

0
0 2 4 6 8
Deflection (mm)

Figure 9.3.1.1 Load Vs Deflection Plot for conventional beam

From the graph, the load at fracture point (F) is 50KN.

F = 50x103N
L = 900mm
B = 130mm
D = 230mm

Flexural Strength of beam, 𝜎 = FL/bd2

= (50x103x900)/(130x2302)

Flexural Strength of beam, 𝝈= 6.54 N/mm2.

9.3.2 AAC REPLACED BEAM

The deflection of the specimen increased with load. The maximum

deflection obtained for conventional beam is 6.71mm. Graph drawn for Load
Vs Deflection of conventional beam is shown below and the values of
deflection obtained to the corresponding loads are tabulated.

53
 Load in Displacement in mm
S. No.
KN (at centre)

1. 8.34 0.54

2. 16.75 0.86

3. 24.07 1.31

4. 32.73 2.01

5. 41.00 3.27

6. 47.92 4.03

7. 46.13 4.89

8. 45.21 6.17

9. 43.57 6.91

Table 9.3.2.1 Load and displacement values for AAC replaced beam

Flexural Strength test

60

50
Load (KN)

40

30
AAC Replaced
20 beam
10

0
0 2 4 6 8
Deflection (mm)

Figure 9.3.2.1 Load Vs Deflection Plot for AAC replaced beam

54
From the graph, the load at fracture point (F) is 50KN.
F = 47.92x103N
L = 900mm
B = 130mm
D = 230mm

Flexural Strength of beam, 𝜎A = FL/bd2

= (47.92x103x900)/(130x2302)

Flexural Strength of beam, 𝝈A= 6.27 N/mm2.

9.4 COMPARISON OF TEST RESULTS

It is visible from the results that the AAC replaced beams have a slight
reduction in flexural strength when compared to conventional concrete beam.
But the there is nothing much to separate the strength of the beams. The load at
fracture for conventional beam is 50KN and that of AAC replaced beam is
47.92KN.

Load Vs Deflection Comparison

60

50

40
Load (KN)

30 AAC Replaced
beam
20 CONVENTIONA
L BEAM
10

0
0 2 4 6 8
Deflection (mm)

Figure 9.4.1 Load Vs Deflection comparison of AAC replaced and

conventional beam

55
Reduction in Flexural strength = (1-( 𝜎A/𝜎 ))x 100 %
= (1-(6.27/6.54))x 100%
Reduction in Flexural strength = 4.13%

Reduction in Flexural Strength (or) Load carrying capacity of AAC beam

when compared to conventional beam is 4.13%.

56
 CHAPTER 10

CONCLUSION

From the results obtained in the flexural strength test, cost and quantity
estimation and comparison of the results, the following conclusions are arrived.

 The beam whose tensile part is replaced by AAC is much more

economical than conventional beams. The percentage of cost saved is
found to be 10.59% for replacing the concrete by 14.23%.
 Reduction in the flexural strength and load carrying capacity of the beam
is 4.13%.
 It has been observed that replacing the tensile part of concrete in beam
has decreased the flexural strength of concrete and the decrease in the
flexural strength of the beam is negligible.
With this slight reduction of strength and higher saving of cost, these
beams can be implemented practically. The only difficulty in using this type of
beams in construction is the placing of AAC blocks in the reinforcement cage.
This could cause an increase in the construction time.
As AAC blocks have higher thermal resistance when compared to
conventional concrete, the beams will also have higher thermal resistance.

57
 REFERENCE

 IS 10262:2009 (First Revision), Concrete mix proportioning – Indian

Standard code of practice, Bureau of Indian Standards, New Delhi, 2009.
 IS: 456 (Fourth Revision), Plain and Reinforced Concrete – Indian
Standard code of practice, Bureau of Indian Standards, New Delhi, 2000.
 “ESTIMATION AND COSTING IN CIVIL ENGINEERING”,
Twenty seventh revised edition by Prof. Dutta B. N. B.E.C.E., B.Sc.
(Hons.), A.M.I.E(Ind.), Formerly Head of the Civil Engineering
Department, Hewett Polytechnic, Lucknow and Engineer P.W.D (U.P).
 “REINFORCED CONCRETE DESIGN”, Second Edition by
Unnikrishna Pillai S. Fellow, American Society of Civil Engineers.
Director, Cooperative Academy of Professional Education, Trivandrum
and Devdas Menon Professor, Department of civil Engineering, Indian
Institute of Technology, Madras, Chennai.
 “Aerated Autoclaved Concrete (AAC) blocks: a revolution building
material in construction industry” (2016) by, Mallampalli. Ch.
G.Subash, V. S. V. Satyannarayana, Janga Srinivas Assistant
Professor, Professor, Civil Engineering, Department of Civil Engineering
U.G, Miracle Educational Society Group of Institutions, Bhogapuram,
Vizayanagaram
 “Materials, Production, Properties and application of aerated
lightweight concrete: review”(2014) By Ali J. Hamad, Department of
Building and construction technology engineering/engineering technical
college, Mosul, Iraq. Ali J. Hamad.
 “Preparation and properties of porous aerated concrete”(2009)
by Ahmed Aidan, Zarook Shareefdeen, Bogdan Bogdanov, Irena
Markovska, Dimitar Rusev, Yancho Hristov, Dimitar Georgiev.

58
 “Experimental Investigation on Partial Replacement of
Concrete Below Neutral Axis of Beam”(2013) by Ashwathy S Kumar
PG Scholar, Department of Civil Engineering, Sree Buddha College of
Engineering, Pattoor, Kerala, India
 “Experimental Study on Partial Replacement of Concrete in and
Below Neutral Axis of Beam”(2016) by Er. Ima Mathew and Er.
Sneha M. Varghese, Department of Civil Engineering, Saintgits College
of Engineering, Kottayam.
 “Effect of Reinforced Concrete Beam with Hollow Neutral
Axis”(2014) by Jain Joy and Rajesh Rajeev, P. G. Student, Department
of Structural Engineering & Construction Management Department of
Structural Engineering.

59