D.A.

V INSTITUTE OF ENGINEERING & TECHNOLOGY

KABIR NAGAR, JALANDHAR

MASTER OF TECHNOLOGY
(Structural Engineering)

DIMSERTATION MID-TERM REPORT on

STRENGTH AND DURABILITY EVALUATION OF PRE-

CAST CONCRETE PAVERS USING WASTE METAL
SLAG & PET BOTTLES

Submitted by
MANOHAR SINGH

ROLL NUMBER:- 1267920

BATCH: - 2012
MASTER OF TECHNOLOGY
STRUCTURAL ENGINEERING (PART TIME)
DAVIET, JALANDHAR
Supervised by
Dr. SANJEEV NAVAL
(HEAD OF CIVIL DEPARTMENT)
DEPARTMENT OF CIVIL ENGINEERING (DAVIET)

PUNJAB TECHNICAL UNIVERSITY

KAPURTHALA, PUNJAB

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 CHAPTER-1

INTRODUCTION
1.1 GENERAL
Concrete is a strong and versatile construction material. It is estimated that the present
consumption of concrete in the world is of the order of 12 billion tons every year. In various
countries, the concrete paving blocks become an attractive engineering and economical
alternative to the both flexible and rigid pavement. Concrete paving blocks are ideal materials on
the footpaths for easy laying, better look and finish. Interlocking paving blocks are installed over
a compacted stone sub base and leveling bed of sand. Concrete paving blocks are made with
concrete basically consisting of cement, fine aggregates, coarse aggregates, water, chemical
pigments, etc. Overall performances of concrete paving blocks used are mainly governed by
properties of materials, water cement ratio, mixing process and curing process. The aggregates
typically account about 75% of the concrete volume and play a substantial role in different
concrete properties such as workability, strength, dimensional stability and durability.
Conventional concrete consists of sand as fine aggregate and gravel, limestone or granite in
various sizes and shapes as coarse aggregate. There is a growing interest in using waste materials
as alternative aggregate materials and significant research is made on the use of many different
materials as aggregate substitutes such as coal ash, blast furnace slag, and Metal slag aggregate.
Slag is a by-product generated during manufacturing of pig iron and metal. Primarily, the slag
consists of limestone (CaO) and silica (SiO2). Other components of blast furnace slag include
alumina (Alsub>2O3) and magnesium oxide (MgO), as well as a small amount of sulfur (S),
while metal making slag contains iron oxide (FeO) and magnesium oxide (MgO).
This type of use of a waste material can solve problems of lack of aggregate in various
construction sites and reduce environmental problems related to aggregate mining and waste
disposal. Concrete has basic properties like high compressive strength, less tensile strength, less
flexural strength, good workability, less resistant to cracking, abrasion, durability heavyweight,
shrinkage impermeability, etc. some of these needs to improve and it can be improved by using
some additional Industrial and domestic waste materials as replacement of basic ingredients of
concrete i.e. fine or coarse aggregates, which in turn may provides a solution of safe disposal of
these waste materials.

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On the other hand PET bottle is a major domestic waste. It can be used as plastic fibres in
Concrete to improve its properties. It is well known that plain concrete is brittle and weak in
tension. The major advantage of fibre reinforcement concrete is to transform a brittle concrete
into a pseudo ductile material. Adding fibres in concrete can arrest micro cracks which causes
gradual failure. Fibres like metal, carbon, glass, synthetic organic and natural fibres has been
incorporated in concrete and mechanical properties of such concrete are studied by many
researchers. But still it is ongoing process to improve properties of concrete. The PET waste can
also be used as a substitute of polypropylene fibres. PET is polyethylene terephthalate. It's
a plastic resin and the most common type of polyester. Two monomers modified ethylene glycol
and purified terephthalic acid, are combined to form the polymer called polyethylene
terephthalate.
The main purpose of this study is to evaluate the strength and durability properties of concrete
paving block where Metal slag will be used as a partial replacement of fine aggregate with
addition of waste PET fibres in different proportions. The performance will be evaluated in term
of effect on compressive strength, abrasion resistance and water absorption of MS and PET fibre
reinforced concrete.
1.2 INTERLOCKING PAVER BLOCK
Interlocking Pavers are the modern day solution to the outdoor flooring versatility in
applications. Paver block is solid, unreinforced pre-cast cement concrete paving units used in the
surface course of pavement. They are high strength concrete mouldings in various shapes, sizes
and colors to suit the imagination of landscape architects and nature's essence. This type of
pavement will absorb stress such as small earthquakes, freezes and thaws, and slight ground
erosion by flexing. Therefore, they do not easily crack, break or buckle like pouring asphalt or
poured concrete.

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 Fig 1.1: Various shapes of interlocking concrete paver blocks
1.2.1 HISTORY OF PAVER BLOCK

Interlocking concrete Pavers are also called Segmental Pavers. This special type of of pavers has
emerged in the United States over the last few decades. The Romans built roads with them that
are still there. But it was not until the mid-1940s that pavers began to be produced out of
concrete. It started in the Netherlands where all the roads are made to be flexible because the
country is below sea level and the ground shifts, moves and sinks. Poured concrete is not an
option because it will crack. Individual units not set in concrete and placed in sand perform far
better than concrete. Before the paver was made from concrete, either real stone or a clay product
was used. The first concrete pavers were shaped just like a brick; 4” by 8” (10 cm x 20 cm) and
they were called Holland Stones and still are today. These units turned out to be economical to
produce and were exceedingly strong.

1.2.2APPLICATIONS

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Interlocking Concrete Block Pavements have been found to have applications in several
Situations like Residential streets, Car Parks, Fuel Stations, Rural Roads through villages
Footpaths and Side-walks, Cycle Tracks, Residential streets, Car Parks, Fuel Stations, Rural
Roads through villages, Highway Rest Areas, Toll Plaza, Bus Depots Approaches to Railway
Level Crossings, Intersections, City Streets, Truck Parking Areas, Industrial floors, Urban
Sections of Highways, Road Repairs during Monsoon, Container Depots, Port Wharf and Roads,
Roads in high altitude areas.

1.2.3 Advantages of Interlocking Concrete Block Pavements.

(i) Since the blocks are prepared in the factory, they are of a very high quality, thus avoiding the
difficulties encountered in quality control in the field.
(ii) Concrete block pavements restrict the speed of vehicles to about 60 km per hour, which is an
advantage in city streets and intersections.
(iii) Because of the rough surface, these pavements are skid-resistant.
(iv) The block pavements are ideal for intersections where speeds have to be restricted and
cornering stresses are high.
(v) The digging and reinstatement of trenches for repairs to utilities is easier in the case of block
pavement.
(vi) These pavements are unaffected by the spillage of oil from vehicles, and are ideal for bus
stops, bus depots and parking areas.
(vii) They are preferred in heavily loaded areas like container depots and ports as they can be
very well designed to withstand the high stresses induced there.
(viii) In India, the laying of concrete block pavements can be achieved at a low cost because of
the availability of cheap labour.
(ix) Since the concrete blocks are grey in colour, they reflect light better then the black
bituminous pavements, thus bringing down the cost of street lighting.
(x) The cost of maintenance is much lower than a bituminous surface.
(xi) Block pavement does not need in-situ curing and so can be opened to traffic soon after
completion of construction.
(xii) Construction of block pavement is simple and labour-intensive, and can be done using
simple compaction equipment.

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(xiii) Maintenance of block pavement is simple and easy. Also, the need for frequency of
maintenance is low as compared to bituminous pavement.
(xiv) Structurally round blocks can be recycled many times over.
(xv) Unlike concrete pavements, block pavement does not exhibit very deterioratory effect due to
thermal expansion and contraction, and are free from the cracking phenomenon.
(xvi) Use of permeable block pavement in cities and towns can help replenish depleting
underground sources of water, filter pollutants before they reach open water sources, help reduce
storm water runoff and decrease the quantum of drainage structures.
1.3 SLAG DEFINED
Slag is a by-product generated during manufacturing of pig iron and steel. It is produced by
action of various fluxes upon gangue materials within the iron ore during the process of pig iron
making in blast furnace and steel manufacturing in steel melting shop. Primarily, the slag
consists of calcium, magnesium, manganese and aluminium silicates in various combinations.
The cooling process of slag is responsible mainly for generating different types of slags required
for various end-use consumers. Although, the chemical composition of slag may remain
unchanged, physical properties vary widely with the changing process of cooling.

Fig1.2: Waste Metal slag

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1.3.1 COMPARISON OF SLAG FORMATION PROCESSES
Chemical characteristics of iron and Metal slag by Nippon Slag Association conduct
investigations and research.
Table 1.1: chemical composition of various slags.

Type Electric arc furnace slag Andesite

Blast furnace Converter Ordinary
Oxidizing Reducing (for
Component slag slag cement
slag slag reference)
CaO 41.7 45.8 22.8 55.1 5.8 64.2
SiO2 33.8 11.0 12.1 18.8 59.6 22.0
T-Fe 0.4 17.4 29.5 0.3 3.1 3.0
MgO 7.4 6.5 4.8 7.3 2.8 1.5
Al2O3 13.4 1.9 6.8 16.5 17.3 5.5
S 0.8 0.06 0.2 0.4 - 2.0
P2O5 <0.1 1.7 0.3 0.1 - -
MnO 0.3 5.3 7.9 1.0 0.2 -

3.4 PET FIBRE

PET was patented in 1941 by John Rex Whinfield, James Tennant Dickson and their employer
at Calico Printers' Association of Manchester, England. The current owner of the trademark is
DuPont Teijin Films US, a partnership with a Japanese company. In the Soviet Union, PET was
first manufactured in the laboratories of the Institute of High-Molecular Compounds of
the USSR Academy of Sciences in 1949, and its name is Lavsan . The PET bottle was patented
in 1973 by Nathaniel Wyeth.

PET (polyethylene terephthalate) bottles have increasingly become an indispensable part of a

common man’s life. Polyethylene terephthalate is produced from ethylene glycol and dimethyl
terephthalate (C6H4(CO2CH3)2) or terephthalic acid.. PET is commonly recycled, and has the
number "1" as its recycling symbol. With the phenomenal increase in plastic consumption the
problems with plastic waste disposal have also aggravated. Hence the need arises to route the
waste plastic bottles to their optimum usage. That is why utilization of waste PET bottles has
become an attractive alternative for disposal.

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In this study PET bottles are used in fiber form in concrete paver blocks and study the different
experiments, case studies based on researches, experimental works and scientific reports to
determine the improvement in selected properties of PET fiber reinforced concrete. Also to
convey that the use of PET fibers as reinforcement of cement composites is a promising
technique for developing sustainable materials to be applied in the civil construction industry.
And hence concrete with waste PET bottle fiber can be used not only as an effective plastic
waste management practice but also as a strategy to produce more economic and sustainable
building materials in the future.

Table 2 : Consumption (in %) of plastics

(J.M. Irwan1, R.M. Asyraf2, 2013)
Sectors Plastic consumption [%]

Domestic 19
Agriculture 3
Electrical and electronics 39
Automotive 26

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 Packaging 10
Building and construction 3

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 CHAPTER -2

LITERATURE REVIEW
Brief review of the work carried out by various researchers in the field of using Metal slag and
PET fibres in simple concrete or concrete paving concrete is discussed below:-
METAL SLAG
J.Saravanan N.Suganya (2015) have replaced 100% of conventional aggregate with Metal slag
aggregate. It was observed that Compressive strength, Split tensile strength and Flexural strength
of Metal slag concrete increases in 6%, 28% and 34% respectively compared to the conventional
coarse aggregate concrete.

Mien Van Tran (2014) used 100% Metal slag as a coarse aggregate in high strength concrete
which has various compressive strengths as 60, 70 and 80MPa. Results showed that the strength
of the concrete using Metal slag has done improvement in the mechanical properties.

Chetan Khajuria (2014) observed that the early age strength gain of Metal slag concrete is higher
as compared to later ages if 30% of fine aggregate is replaced by iron slag. 10%, 20% and 30%
iron slag was replaced with the sand and noted that after adding 10% iron slag in the mix, there
was an increase in compressive strength of 26% after 7 days, 50% increase after 28 days and
43% increase after 56 days as compared to the control mix. By adding 20% and 30% iron slag ,
there was large amount of increase in percentage i.e. 68%, 91%, 78% and 125%, 113% , 87%
after 7, 28 and 56 days respectively.

Sultan A. Tarawneh (2014) used ratio 0%,20% 40% 60% 80% 100% to replace fine and coarse
aggregate with Metal slag. Thorough investigation of results have indicated that the amount of
increase in compressive strength at age of 7 days are much more than that of age 28 days for all
types of aggregate replacement. This indicates that the added slag could work as accelerator at
early age while at 28 days age, the effect is reduced. Furthermore, the fine slag replacement
showed the highest effect.

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R. C. Yeol1, Dr. M. B.Varma (2014) studied the paving blocks using waste metal aggregates (the
form of rounded bearings of size 6.35 mm) with Rubber pad used below the paving blocks.
Paving blocks cast with 30% and 40% waste rounded metal aggregates of cement content in
paving blocks give higher impact value than paving blocks cast with 0%, 10%, 20% waste
rounded metal aggregates of cement in paving blocks.

R. Padmapriya (2015) investigated the usage of Metal slag as a partial replacement of coarse
aggregate and manufactured Sand of fine aggregate respectively. Initially 20%, 40%, 60%, 80%
replacement of coarse aggregate by Metal slag. With these optimum percentage of Metal slag the
hexagonal shaped paving block specimens of side 125mm and height 80mm were casted and
tested for its compressive strength, split tensile strength, flexural Strength and water absorption
tests. It is found that replacement of river sand by 25% M sand and coarse aggregate by 40%
Metal slag gives the maximum strength.

Gozde Inan Sezer (2015) Studied on Metal slag aggregate and lime stone aggregate in concrete
and prepared 12 different mixes with different w/c ratio of 0.40, 0.55, and 0.70. Found that Used
of fine or coarse aggregates of Metal slag generally increase the unit weight of concrete mixes.
Concrete containing lime stone aggregate shows worse performance as compare concrete
containing coarse aggregate of Metal slag.

Er.K.JeganMohah,W.Mazhar (2016) Studied on saw dust ash (SDA) and Metal slag aggregate as
construction materials. Saw dust was burnt and the ash sieved using 90 micron sieve. Percentage
replacement of OPC with SDA was 0, 10, 20 and 30% and percentage replacement of coarse
aggregate with Metal slag was 0, 5, 10 and 15% respectively. Concrete acquires maximum
increase in compressive strength at 20% cement replacement for sawdust ash and10% coarse
aggregate replacement for Metal slag.

PET FIBRES
DivyeshkumarD.Paradava (2013) reviewed that glass fibre give higher strength than
polypropylene fibres. The fibre content and fibre length also important to contribute the strength
of mortar similarly as type of fibre.

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Liliana Avila Cordoba (2013) Concluded in his research that mechanical properties of the
concrete depend on the PET particle size and concentration. For lower size particles increase
compressive strength, highest compressive strength was obtain with particle size 0.5mm and
2.5% volume of fibres .

A.Sivakumar (2013) Reviewed the toughness characterization of metal fibre reinforced concrete.
Observed that the various standards have same test procedure but they give different toughness
measurements.

Ganesh Tapkir, Satish parihar (2014) used the polypropylene (PP) and polyethylene
Terepthalate (PET) as alternative replacements of a part of the conventional aggregates of
concrete. Three replacement levels 10 %, 20 %, 30 by weight of aggregates were used for the
preparation of the concrete and it is concluded that the use of 20% recycled plastic aggregate in
concrete does not affect the properties of concrete. The increase the percentage in plastic
decreases the strength of concrete. Also they found that using the plastic in concrete mix reduces
the weight of cube by 15%.

R.N.Nibudey , P.B.Nagarnaik observed the optimize benefits of using PET waste bottle
in the fibre form in concrete. Prepared several design mixes with different percentage (0%to3%)
of waste PET plastic fibres with different aspect ratios and observed that workability effected
with use of fibres and the maximum value of compressive strength, split tensile strength and
flexural strength is achieved with 1% incorporation PET fibres with aspect ratio 50 gave more
strength then aspect ratio 35.

R.N.Nibudey, P.B.Nagarnaik (2014) also studied two concrete mixes M20 and M30 grade using
PET fibres with aspect ratio 35 and 50 and %age of replacement range between 0% to 3%.
Compressive strength and sorptivity properties were observed, they concluded that workability
decrease with increase of fibre contents, failure of specimens with fibres was ductile,
compressive strength is good at1% amount of fibres and sorptivity increase with increase in fibre
contents etc.

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JinayM.pandya (2014) used PET fibres with 0%, 0.5%, 1.5%, and 3% by weight of cement with
addition of Alccofine (GGBS) with percentage of 0%, 3%, 6% and 9% with replacement of
cement in M30 mix. He concluded that workability decrease with fibres, Compressive strength
increase with alccofines up to 6%. Concrete with 0.5% PET and 6% alccofines gives maximum
compressive strength, and with 1.5% PET and 9% alccofines gives maximum flexural strength.

GaneshTapkire (2014) It is computed that the use of 20% Recycled plastic aggregate in concrete
which does not affect the properties of concrete paving blocks and it is possible to use the plastic
in concrete mix up to 20 % weight of coarse aggregate. It is also observed that using the plastic
in concrete mix to reduce the weight of cube up to 15%.

G.Navya,J. Venkateswara Rao (2014) Polyester fibers were added in proportions of 0.1%, 0.2%,
0.3%, 0.4% and 0.5% in volume of concrete. And investigated the compressive strength, water
absorption and flexural strength of paving blocks. The results indicated that addition of polyester
fiber by 0.4% paving block attains maximum compressive, flexural strengths and minimum
water absorption at 7 and 28 days.

Fernando Pelimsera (2012) used fibres with lengths of 10, 15 and 20 mm and volume fractions
of 0.05, 0.18 and 0.30% related to the volume of the concrete were used. Physical and
mechanical characterization of the concrete was performed, Based on the results of this
experimental investigation, it can be concluded that at a fibre volume fraction content of 0.18%
and 0.30%, though not 0.05%, 20 mm long recycled-bottle-PET fibres increased the flexural and
impact toughness of 28-day-old conventional concrete. However, at 150 days, this toughness
improvement was no longer present due to the embrittlement and degradation of the recycled-
bottle-PET fibres in the alkaline concrete environment.

H.Janfeshan Araghi [14] Studied the sulfuric acid attack with use of PET fibres; he used 0%, 5%,
10%and 15% values for replacement in concrete. He immersed the cubes with PET fibres in 5%
sulfuric acid and observation taken on 15,30,60 days with measuring dimensions, crushing load,
ultrasonic pulse velocity, weight loss of concrete samples. Concluded that sample with 15% of
PET particles have lower weight loss and also retain more load under sulfuric acid attack.

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Dr.S.M Gupta (2015) Experimental investigation conducted on strength and durability of with
addition of silica fume in concrete. Conducted different tests on fresh and hardened concrete, for
fresh concrete he conduct slump test, compaction factor test, and vee bee test. On hardened
concrete he conduct compressive strength test and for durability of concrete he conducted acid
attack test with use of sulphuric acid solution and alkaline attack with use of sodium sulphate
solution. Concluded that resistance of acid attack increase with increase of silica fume, also
compressive strength increase with silica fume.

Pramod Sambhaji Patil (2015) Investigated the possibility of using PET waste in asphalt
concrete mixes as aggregate replacement to reduce the reduce the environmental effects of PET
disposal. He used five replacement levels 10%, 20%, 30%, 40% & 50% by volume of aggregates
used for preparing concrete. He investigates effects on density, workability, compressive strength
of concrete, Split tensile strength of concrete. In his study he concluded that up to 20% replacing
fraction of plastics the concrete gives strength in permissible limit, density reduced after 20%
replacement of plastics in concrete and 10% replacements of plastics with aggregates gave
satisfy results.

Swaptik Chowdhury (2013) Studied the use of PET fibres in concrete. He used M25 grade
concrete and he replaces fine aggregate with PET fibres in concrete. Used 0.5%, 1%, 2%, 4%
and 6% of fibres with sand. Investigates Bulk density, compressive strength, split tensile
strength, Flexural strength, Deformation capacity, energy consumption and modulus of elasticity
of concrete with these replacements. Concluded that PET fibres have less compressive strength,
flexural rigidity, and tensile strength which can be attributing to the decrease bonding tendency
of PET with cement matrix. Density of PET concrete is less than ordinary concrete hence it can
be used for Light weight concretes.

Sahil Verma, Sahil Arora (2015) Studied that, the comparison of compressive strength of normal
conventional concrete with the concrete made from the partial substitution of aggregates with
Polyethylene Terephthalate bottles. In this study range of fiber 0% to 6%. Upto 2% replacement
of fine aggregates with waste PET fiber, there is increase in compressive strength of concrete.
Concrete mixed with waste PET fiber is eco-friendly, non-hazardous as it easily get dispersed in
concrete mix.

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AmaluWilson,Navaneetha (2016) Concluded that addition of silica fume in concrete,
compressive strength, split tensile strength and flexural strength of replaced concrete were higher
than the plain concrete specimens at all the stages. The replacement levels of cement by silica
fume were selected as 5%, 10%,15%, 20%, and 25% for M30 grade of concrete. polypropylene
fibers ranging from 0.1% to 0.4% along with 0.8% metal fibers on the behavior of fibrous
concrete. The maximum compressive strength, split tensile strength, flexural strength value
occurs at 10% replacement ratio of silica fume. The maximum gain in compressive strength was
achieved for 0.2% polypropylene fiber.

RESEARCH GAP AND PROBLEM FORMULATION

In general it is observed in literature that Metal slag has improved the mechanical properties like
compressive, tensile strength, abrasion resistance and impact toughness of concrete and increase
in the weight of concrete was noticed also. Very little or no information is available on the use of
Metal slag and PET fibres as a combination in concrete paving block. on the other hand used of
PET fibre in concrete mixes reduces the weight of concrete, improve the tensile strength,
compressive strength, flexural strength with little friction replacement in concrete mass with
respect to use of Polypropylene fibres (PP) etc. The literature shows that the properties of
concrete using Metal slag or PET fibres individually has been studied by the researchers and
both the materials has been found to be effective in enhancing these properties. However use of
PET fibres in concrete paving blocks is still an area of interest. The Investigations can be carried
out to study the beneficial effect of using PET fibres and Metal slag in concrete paving blocks.
Thus the present experimental investigation is
designed to explore the improvement in the properties of concrete paving blocks using MS- PET
fibres. Concrete mixes will be prepared by using different proportions of MS and PET fibres and
paving block samples will be cast. The mechanical strength performance will be evaluated by the
Compressive strength tests and durability properties will be evaluated through abrasion
resistance and water absorption of MS and PET fibres reinforced concrete paving blocks.
Now in this present study the properties of concrete paving blocks using combination of Metal
slag and PET fibres to investigate their combined beneficial effects to improve the quality of the
paving blocks.

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OBJECTIVES
The present study has been designed to achieve the following major objectives
1. To evaluate the Compressive strength of MS and PET fibre reinforced concrete paving
blocks.
2. To evaluate the Abrasion resistance of MS and PET fibre reinforced concrete paving
blocks.
3. To evaluate the water absorption of MS and PET fibre reinforced concrete paving blocks.

MATERIAL USED
Cement: - In this study ordinary portland cement (OPC) will be used.
Fine aggregates: - Crushed stone coarse sand confirming to IS 383-1970.
Coarse aggregates: - Locally available Crushed stones size between ≤ 12 mm will be used.
Metal slag;-Metal slag will be used, as available from the nearby Iron and metal making
industry.
Fibres: - Fibres obtained from shredding of waste PET bottles.
Water: - Portable drinking water is used for mixing of concrete.

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 CHAPTER- 3

EXPERIMENTAL PROGRAMME
3.1 General
The present chapter deals with the presentation of results obtained from various tests
conducted on material used for the concrete. In order to achieve the objectives of present study,
an experimental program was planned to investigate the effect of Metal slag and PET fibre
reinforced on compressive strength of concrete paver blocks. Nine concrete mix samples
containing different percentage of Metal slag and PET fibre reinforced are used in this study and
designated as MIX1, MIX2, MIX3, MIX4, MIX5, MIX6, MIX7, MIX8 and MIX9.

Material characterization:-The material testing was done in laboratory as per

recommendation of IS 15658:2006, IS Code -383-1970, IS 1237: 2012, IS Code 2386(part 1-8)
etc. For cement compressive test, consistency test, initial & final setting time, soundness test,
specific gravity tests was done and for slag, coarse and fine aggregates specific gravity, water
absorption, bulk density, and fineness modulus tests was done in laboratory with the help of
standard apparatus.

3.2 Physical Properties Materials

Different materials used in present study were cement, coarse aggregates, fine aggregates,
in addition to Metal slag and PET fibres. The aim of studying of various properties of material is
used to check the appearance with IS codal requirements and to enable an engineer to design a
concrete mix for a particular strength. The description of various materials which were used in
this study is given below:

3.3.1 Cement
In This study ordinary portland cement (OPC) is used.

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 Table 3.1: Physical properties of Cement
Values Specified
Sr. No. Properties Observations
By IS 1489-1991

1 Fineness (90 micron IS Sieve) 0.28percent -

30 (minimum)
2 Initial setting time 133 min
600 (maximum)
3 Final setting time 205 min

4 Standard consistency 34.5 -

5 Specific Gravity 3.05 -

47.6 N/mm2
6 28-days compressive strength 33 N/mm2 , Min

3.3.2 Aggregates
Aggregates constitute the bulk of a concrete mixture and give dimensional stability to
concrete. To increase the density of resulting mix, the aggregates are frequently used in two or
more sizes. The most important function of the fine aggregate is to assist in producing
workability and uniformity in mixture. The fine aggregate assist the cement paste to hold the
coarse aggregate particles in suspension. This action promotes plasticity in the mixture and
prevents the possible segregation of paste and coarse aggregate, particularly when it is necessary
to transport the concrete some distance from the mixing plant to placement. The aggregates
provide about 75% of the body of the concrete and hence its influence is extremely important.
They should therefore meet certain requirements if the concrete is to be workable, strong,
durable and economical. The aggregates must be proper shape, clean, hard, strong and well
graded.

(a) Fine Aggregates:

Crushed stone coarse sand confirming to IS 383-1970 was used as fine aggregate. The
aggregates most of which pass through 4.75 mm IS sieve are termed as fine aggregates. The fine
aggregate may be of following types:
i) Natural sand, i.e. fine aggregate resulting from natural disintegration of rocks.
ii) Crushed stone sand, i.e. fine aggregate produced by crushing hard stone.

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 iii) Crushed gravel sand, i.e. fine aggregate produced by crushing natural gravel.

According to size, the fine aggregate may be described as coarse, medium and fine
sands.Depending upon the particle size distribution. IS: 383-1970 has divided the fine aggregate
into four grading zones (Grade I to IV). The grading zones become progressively finer from
grading zone I to IV. The sand was sieved through 4.75 mm sieve to remove any particles greater
than 4.75 mm and conforming to grading zone II. It was coarse sand grey in colour. Sieve
analysis and physical properties of fine aggregate are tested as per IS: 383-1970 and The particle
size distribution and other physical properties of the fine aggregates are listed in Table 3.2 & 3.3
respectively.

Table 3.2: Fineness Modulus of Fine Aggregates

S.No. Sieve size Mass Cumulative Cumulative Passing (gm) Zone 2

retained (gm) Mass Percentage
retained(gm) mass
retained (%)

1. 4.75mm 6 6 0.6 99.4 90-100

2. 2.36mm 104 110 11 89 75-100

3. 1.18mm 203 313 33.3 66.7 55-90

4. 600µ 171 484 48.4 51.6 35-59

5. 300µ 269 753 75.3 24.7 8-30

6. 150µ 176 929 92.9 7.1 0-10

7. Pan 71 1000 100

Fineness modulus of fine aggregates = 2.61

Table 3.3: Physical properties of Fine aggregate.

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 Sr. No. Properties Observations

1. Fineness modulus of fine aggregate 2.61

2. Specific gravity of fine aggregate 2.66

3. Bulk density of fine aggregate 1797kg/m3

4. Water absorption of fine aggregate 0.8

Coarse Aggregates:
The aggregate which is retained over IS Sieve 4.75 mm is termed as coarse aggregate. The
coarse aggregates may be of following types:-
1. Crushed graves or stone obtained by crushing of gravel or hard stone.
2. Uncrushed gravel or stone resulting from the natural disintegration of rocks.
3. Partially crushed gravel obtained as product of blending of above two types.
The normal maximum size is gradually 10-20 mm; however particle sizes up to 40 mm or more
have been used in Self Compacting Concrete. Gap graded aggregates are frequently better than
those continuously graded, which might expensive grader internal friction and give reduced flow.

Regarding the characteristics of different types of aggregate, crushed aggregates tend to

improve the strength because of interlocking of angular particles, while rounded aggregates
improved the flow because of lower internal friction.

Locally available Crushed stones size between ≤ 12 mm was used in this work. The
aggregates were washed to remove dust and dirt and were dried to surface dry condition. The
aggregates were tested as per IS: 383-1970. Specific gravity and other properties of coarse
aggregates are given in Table 3.5. The sieve analysis of coarse aggregate was done. Table 3.4
show the result of sieve analysis.

Table 3.4: Fineness Modulus of Coarse aggregates.

S.No. Sieve size Mass Percentage Cumulative %age

retained (gm) retained (%) retained, C

20
 1. 16mm 0 0 0

2. 12.5mm 322 6.44 6.44

3. 10mm 1021 20.42 26.86

4. 4.75mm 3218 64.36 91.22

5. 2.36mm 420 8.4 99.62

6. 1.18mm - - 100

7. 600 micron - - 100

8. 300 micron - - 100

9. 150 micron - - 100

Fineness modulus of coarse aggregates is 6.24.

Table 3.5: Physical properties of Coarse aggregate.

Sr. No. Properties Observations

1. Fineness modulus of coarse aggregate 6.24

2. Specific gravity of coarse aggregate 2.88

3. Bulk density of coarse aggregate 1621 kg/m3

4. Water absorption of coarse aggregate .5%

3.2.3 Water
As per IS: 456-2000 potable water is generally considered satisfactory for mixing and
curing of concrete. Generally, water that is suitable for drinking is satisfactory for use in
concrete. Water from lakes and streams that contain marine life also usually is suitable. When
water is obtained from sources mentioned above, no sampling is necessary. When it is suspected
that water may contain sewage, mine water, or wastes from industrial plants or canneries, it
should not be used in concrete unless tests indicate that it is satisfactory. Water from such
sources should be avoided since the quality of the water could change due to low water or by
intermittent tap water is used for casting. The potable water is generally considered satisfactory

21
 for mixing and curing of concrete. Accordingly potable water was used for making concrete
available in Material Testing laboratory. This was free from any detrimental contaminants and
was good potable quality.

3.3.4 Metal slag

In this work, Metal slag is taken from the nearby Iron and steel making industry located
at Batala Punjab. The sieve analysis and physical properties of Metal slag is shown in Table 3.6 and
3.7.

Table 3.6: Fineness Modulus of Metal slag

S.No. Sieve size Mass Cumulative Cumulative Passing (gm) Zone- 1

retained (gm) Mass Percentage
retained(gm) mass
retained (%)

1. 4.75mm 3 3 .3 99.7 90-100

2. 2.36mm 147 150 15 85 60-95

3. 1.18mm 329 479 47.9 52.1 30-70

4. 600µ 197 676 67.6 32.4 15-34

5. 300µ 145 821 82.1 17.1 5-20

6. 150µ 134 955 95.5 4.5 0-10

7. Pan 45 1000 100

Fineness modulus of fine aggregates = 3.0

Table 3.7: Physical properties of Metal slag

Sr. No. Properties Observations

1. Fineness modulus 3.08

2. Specific gravity 2.66

3. Bulk density 1528 kg/m3

4. Water absorption 0.45%

22
3 Plastic fibers
The post consumed PET mineral water bottles were collected and the fibers were cut after
removing the neck and bottom of the bottle. The length of fibers was kept 18-20 mm and the
breadth was 1 mm and 1.5mm. The aspect ratio (AR) of waste plastic fibers were 35 (AR-35)
and 50 (AR-50).

Table 5: Physical properties of PET fibers

Characteristics Results obtained

Material Waste plastic bottles

Density(loose) Kg/m3 1038
Specific gravity 1.29
Absorption .6%
Color Opaque White gray
Length 18-20mm

3. Concrete Mix Design of M35 Grade:

The detail of Concrete Mix Design for M35 Grade of Concrete done as per IS 10262:2009 and IS
15658:2006 is given as follows:-

Note: From table 1 of IS15658:2006. For light-traffic the grade Designation of paver blocks is
M35 and recommended minimum paver block thikness for M35 is 60mm.

A1 Design Stipulations
a) Characteristic Compressive Strength of Concrete at 28 days 35 N/mm2
b) Maximum Size of aggregate 12 mm
c) Slump 25 mm
d) Degree of Quality Control Good
e) Type of Exposure Severe
A2 Test Data for Materials
a) Cement Used opc

23
 b) Specific Gravity of Cement 3.05
c) Specific Gravity
i) Coarse Aggregates 2.88
ii) Fine Aggregates 2.66
d) Water Absorption
i) Coarse Aggregates 0.5
ii) Fine Aggregates 0.8
e) Zone of Fine Aggregates 2
f) Chemical Admixture Type -
Specific Gravity -

A3 Target Mean Strength of Concrete, ft = fck +1.65 S 43.25 N/mm2

S = Standard Deviation (Table 8 in IS 456:2000) 5

A4
a) Maximum W/C Ratio for precast concrete paver blocks 0.40
It is less than 0.45 IS 456-2000

A5 Selection Water Content

a) From Table 2 of IS 10262:2009, Maximum Water Content for 208
10mm aggregates. (slump of 25-50 mm)

b) Estimated Water Content for 12 mm aggregate 203.6

c) Reduction of water content 3% percent for every 25mm slump 197.5
decrese

A6 Calculation of Cement Content

a) Water - Cement Ratio 0.40
b) Cement – Content 493.75 kg/m3
Minimum cement content for severe exposure condition foe precast paver block is
380>493.75, Hence O.K.

24
A7 Proportion of Volume of Coarse Aggregates and Fine Aggregates Content
From Table 3 of IS 10262:2009, volume of coarse aggregate corresponding 10 mm to
20 mm size of aggregate .
a) Volume of Coarse aggregate corresponding to 10 mm size 0.46
aggregate and fine aggregate(Zone II) for w/c ratio of 0.50 is
For 12mm size of aggregate .492
b) In present case, w/c ratio is 0.4
c) Correction at the rate of -/+ 0.01 for every -/+ 0.05 change in
water cement ratio
d) Corrected Volume of Coarse Aggregate for the water cement 0.51
ratio of 0.4
e) Volume of Fine Aggregates Content = 1-Volume of C.A. 0.49

A8 Mix Calculations
The mix calculations per unit volume of concrete shall be as follows:
a) Volume of Concrete 1m3
b) Volume of Cement = Mass of Cement / Specific Gravity of 0.160
Cement
c) Volume of Water = Mass of Water / Specific Gravity of Water 0.197
d) Volume of all in aggregate = [a-(b+c)] 0.643

e) Mass of Coarse Aggregates = e x Volume of C.A. x S. Gravity of 944.43

C.A. x 1000
f) Mass of Fine Aggregates = e x Volume of F.A. x S. Gravity of 838.08
F.A. x 1000
A7 Mix Proportion
Quantity units
a) Cement Content 493 Kg/m3
b) Fine Aggregates Content 838.08 Kg/m3
c) Coarse Aggregates Content 944.43 Kg/m3
d) Water 197.5 Kg/m3

25
1) Designing of concrete mix: - Controlled concrete mix was design as per BIS 10262-
2009. Additional number of mixes prepared by replacing fine aggregates with the
different proportions of Metal slag (SS) and addition of different volume fractions of
PET fibres.
2) Mixing of materials:-Mixing of materials was done in 100 liters capacity electrically
operated mixer. First coarse aggregates, fine aggregated and Metal slag charged in
mixture and mixed for 3 minutes to make it homogeneous mix. After mixing of coarse
and fine aggregates cement were charged in mixer and it was mixed with aggregates for
two minutes. After mixing, fibres added in mix and again mixing was done until proper
mixing of fibres is achieved. At last water is added to mix and it was mixed for two
minutes. The mixed concrete collect in trays. Metal slag was added to replaced the
equal weight of fine aggregates & PET fibres was added by volume fraction of concrete
to prepare mixes of concrete containing different proportions of Metal slag and PET
fibres.

3) Casting of concrete paver block samples: - Standard moulds for paver blocks were
fabricated. All mould were cleaned and oiled from inner surfaces. Then the moulds were
filled and compacted as per standard procedures. The moulds were open manually with
the help of spanner after 24 hours of casting.

4) The numbers of samples used for each concrete mix are shown in table below:-
Type of test Thickness of Total No. of No. of No. of Remarks
paver block block blocks for 7 blocks for
days testing 28 days
testing
Compressive 60mm
strength 6 3 3
Abrasion 60mm
Resistance 3 - 3

26
 Water
Absorption 60mm 3 - 3

TOTAL 12

5) Curing of samples: - After removal of samples from moulds, these samples will be
cured in curing tank available in laboratory. All samples will be marked with date and
identification on the surface with permanent marker.
7) Strength of samples: - The strength samples will be tested after 7days and 28 days of
casting. The sample will be tested surface dry condition. For testing, strength of samples
recommendation of Indian Standards will be considered. Water absorption and abrasion
test will be conduct as per IS procedures after 28 days of curing.

8) Analysis of Test results: - The results of the various tests of all concrete mixes will be
analyzed to evaluate the performance of SS and PET fibres reinforced. Concrete paver
blocks in terms of compression strength, abrasion resistance and water absorption in
comparison with control concrete mix paver block.

27
 CHAPTER: 4
RESULTS AND DICUSSIONS

4.1 GENERAL
This segment of report enumerates the results concluded from different tests done on
interlocking concrete paver block samples cast without and with Metal slag and pet fibre
reinforcement. The prime aim of the research proposal was to known the durability and strength
aspects of interlocking paver blocks by using Metal slag as a fractional substitution for fine
aggregate with the addition of pet fibres. For fulfilment of the current study proposal, the
experiments were planned to determine the effect of Metal slag on compressive strength of
interlocking paver blocks.
The following parameters are included in the present research design.
1. Compressive strength

4.2 COMPRESSIVE STRENGTH TEST & RESULTS

4.2.1 Results
The following parameters Zigzag shape test specimens of size 245× 120× 60 mm were prepared
for testing the compressive strength of concrete. The test was done at 7 days and 28 days of
curing ages. The compressive strength test was conducted at curing ages of 7-days and 28 days.
The concrete mixes with varying percentage of Metal slag and pet fibres were cast into paver
blocks mould for subsequent testing. The test was executed as per IS: 15658-2006 and IS: 516-
1959 on Compression Testing. The results of tests at various curing ages are presented in Table-
4.1. The Variations and comparison of the compressive strength of all the mixes cured at 7-days
and 28-days are also shown in Figure. 4.2 to Figure. 4.6 respectively.
The two steel bearing blocks were fitted in the compressive testing machine to hold the concrete
paver blocks. Wiped and cleaned bearing plates were used for testing the pavers blocks. The
paver block specimen was lined with those bearing plates for testing. The minimum thickness
and hardness of bearing plates are 25mm and 60 HCR respectively. In the alternatively, plywood
sheets having 4 mm thick were used for support the specimen. The overall size of the plywood
sheets was 5mm exceeded from all sides of the specimen. The strength of single concrete paver
block found out with the help of ultimate load in N by dividing the top surface area of the
specimen in mm2.

28
 Fig 4.1: Compression testing machine

Table 4.1: Values of compressive strength for the different mix

IDs of % of % of % of % of Pet fibres Results of Compressive strength

mix Cement Metal sand Coarse in N/mm2
(by wt of
slag agg. cement)
7 days 28 days
45.80
MIX1 100 0 100 100 0 36.66

MIX2 100 0 100 100 0.5 44.59 51.54

29
 0
MIX3 100 100 100 1 40.85 47.32

25
MIX4 100 75 100 0 42.27 49.20

MIX5 100 50 50 100 0 37.68 46.24

MIX6 100 25 75 100 0.5 47.04 54.52

MIX7 100 25 75 100 1 43.57 49.41

MIX8 100 50 50 100 0.5 44.48 50.04

MIX9 100 50 50 100 1 39.59 47.02

 Graphically representation of Compressive strength results

60

50

40
Axis Title

30 7 days

20 28 days

10

0
MS 0%-PET 0% MS 25% MS 50%

Fig 4.2: Comparison of ordinary concrete vs Metal slag concrete

60
50
40
30 7 days
20 28 days
10
0
SS 0%-PET 0% PET 0.5% PET 1%

Fig 4.3: Comparison of ordinary concrete vs pet fibre reinforced concrete

30
 60
50
40
30
20 7 days
10
28 days
0
MS 0%- MS 25%- MS 25%- MS 50%- MS 50%-
PET 0% pet 0.5% pet 1% pet 0.5% pet 1%

Fig 4.4: Comparison of ordinary concrete vs Metal slag and pet fibre reinforced concrete

60

50

40

30

20

10

0
MS 0%- MS 25%- MS 25%- MS 50%- MS 50%-
PET 0% pet 0.5% pet 1% pet 0.5% pet 1%

Fig4.5: Comparison of Metal slag concrete vs Metal slag and pet fibre reinforced concrete

60
50
40
30 7 days
20 28 days
10
0
PET 0.5% PET 1% MS 25%- MS 25%- MS 50%- MS 50%-
pet 0.5% pet 1% pet 0.5% pet 1%

31
Fig4.6: Comparison of Pet fibre reinforced concrete vs Metal slag and pet fibre reinforced
concrete

4.2.2 Discussion
In compressive strength test, there was a maximum increase of 28.31% and 19.03% strength of
concrete paver blocks by using 25% Metal slag and 0.5% pet fibre reinforcement after 7 and 28
days of curing shown in fig 4.4 to 4.6. The compressive strength was also increased up to
12.53%, 3.31%, and 7.42% 0.96% by using 0.5%, 1% pet fibre and 25%, 50% Metal slag after
28 days respectively, shown in figure 4.2 and 4.3. While combining the use of Metal slag and pet
fibre reinforcement, there was an increase of compressive strength up to 7.88%, 9.25%, and
2.66% with using 1% pet fibre-25% Metal slag, 0.5%-50% and 1%-50% after 28 days
respectively. The 25% replacement of Metal slag with sand and 0.5% pet fibre reinforcement
addition in concrete shown a better result in both combine and separate cases. The strength gain
of concrete at initial age i.e.7 days, was higher than as compared to 28 days of concrete.
The combination i.e. 0.5% pet fibre and 25% Metal slag gave optimum results for both,
Compressive strength and flexural strength. This may be attributed to the better interlocking
effect of PET fibers reinforcement, to arresting micro cracks at the initial stage. In Both cases, it
was found that after a certain limit, the compressive strength and flexural strength were
decreases due to use of more percentage of Metal slag and pet fibre reinforcement, whether it
was used in combine or separate form. The reason behind that, the Metal slag aggregates were
replaced with the sand. The reduction of strength after 25% replacement of Metal slag with sand
due to the sub-angular shape of the Metal slag aggregate and the bonding region or interfacial
transition zone (ITZ) in concrete is going to weak. At the macroscopic level, there is two reaction
of hydration, one is cement-sand-water and second is between slag and water. In lower
replacement level here is not any serious effect in the reaction of hydration, after increasing the
dose of Metal slag, the requirement of water for hydration is also less due to less water
absorption of Metal slag aggregate as compared to sand.

32
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35