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INTRODUCTION
1.1 GENERAL
Cement in general sense of the word, can be describe as the material with an
adhesive and cohesive properties which make it capable of bonding mineral
fragments into a compact mass. This definition encompasses a large variety of
cementing material. For constructional purposes the meaning of the term cement is
restricted to bonding material used with stones, brick, blocks etc. Cement is the most
important material in structural construction at it is used at different stages of
construction in form of concrete block and concrete.
In the last decade, the production of aluminum in spite of some stagnancy and set
back periods have shown a study rise of about 1℅. The ecological consequences of
aluminum production are well known; threatening of surface and underground water
and air pollution by waste gases from aluminum electrolysis plant and rolling mills.
The degree of damage inflicted to ground water and air during the single production
stages from bauxite to aluminum depends on a couple of tact of which those
connected with the alumina winning and red mud disposal.
1.2. HISTORY
In India there is a great demand of cement mainly from civil engineering
industry for road and concrete construction. But now days it is a very difficult
problem to avail of cement so researchers have developed waste management
strategies to apply in replacement of cement for specific need. Natural resources are
depleting worldwide while at the same time the generated by product from the
industry are increasing substantially. The sustainable development for construction
involves the use of non-conventional and innovative materials, and recycling of
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waste material in order to compensate the lack of natural resources and to find
alternative ways conserving the environment.
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1.3. UTILIZATION OF RED MUD
Annual
Item 2010 2015 2016 Growth
05/00 10/05
Cement 1630.0 2250.0 2830.0 6.7 4.7
Demand
North 149.6 170.0 196.0 2.6 2.9
America
Western 208.5 233.0 233.0 1.1 2.2
Asia/Pacific 954.5 1470.0 9.0 9.0 5.2
Other 328.2 401.5 506.6 4.1 4.7
region
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CHAPTER - 2
LITERATURE REVIEW
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feasible than using fly ash but it is necessary to use or recycle red mud as it has many
harmful environmental effects.
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red mud was used instead of clay and incorporated with other materials such as
limestone and sandstone, etc. to prepare cement clinker. Under the wet processing
technique, the total output of cement was 30 Mt with consumption of red mud over
8 Mt in Shandong Alumina Cement Plant. In recent years, with the implementation
of Chinese new cement standards in which the alkali content (Na 2O3 0.658K2O) in
cement is strictly limited to no more than 0.6%, the wet processing production line
of Shandong Alumina Cement Plant has been closed down. In order to push ahead
with the red mud utilization, Shandong Alumina Company built a new cement
clinker production line (dry processing) in 2003.
Currently, the capacity of cement produced from this dry processing line is 3
Mt year. However, because of the constraint of alkali content required by the cement
standard, the addition of red mud into the raw meals of clinker production has largely
decreased. High alkali content in cement is a main factor to generate alkali-aggregate
reaction and this reaction can cause expansion of the altered aggregate, leading to
spalling and loss of strength of the concrete. Considering the high content of Na2O
occurring in the red mud, solidification of Nap in red mud-containing cement to
avoid alkali-aggregate reaction of concrete could be an effective method to improve
the utilization ratio of red mud in cement production, and deep research into the
solidification mechanics of Nap in red mud-containing cement is also required.
Additionally, the red color of red mud has also to be considered as a potential
constraint during the red mud utilization in cement production, especially when red
mud is added in a large percentage. However, since the current mixed content of red
mud in cement production is relatively low (2–3 wt.%), it is thought that the issue of
dark color for the red mud utilization in cements can be negligible.
Utilization of red mud for the production of cement is an efficient method of
large-scale recycling for this bauxite residue. This review clearly points out three
directions for the use of red mud in cement production, namely the preparation of
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cement clinkers, the production of composite cements as well as alkali-activated
cements. The studies conducted on these three aspects are overviewed in detail. Due
to the super- fine particle characteristics of red mud, the produced cement containing
red mud generally exhibits slightly high normal consistency, but this does not affect
the good fluidity of red mud-containing cement. Tests demonstrate that good
physical properties and excellent mechanical properties can be obtained for those
products with proper proportion design, and they are also safe to the environment.
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Effect of Neutralized Red Mud on Standard Consistency of Cement:
The affinity of water increases by 2.50 %, 5.50 %, 8.00 %, 10.5 % & 12.75 %
with 5%, 10%, 15%, 20% and 25% of replacement of cement by neutralized red mud
respectively, compared with that of water required for standard consistency of
Portland pozzolana cement. In general it is observed that with the increase in
neutralized red mud content in the mix the water required for standard consistency
increases and this increased requirement of water shows almost a linear relationship
with standard consistency. This increase may be due to the fact that the neutralized
red mud being slightly lighter in weight has more finer particles and occupies more
volume which needs more water for the same consistency.
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The effect of replacement of cement by neutralized red mud has been studied
on design mix concrete of grade M-50. The water-cement ratio 0.36 is kept constant
for different percentage replacement of cement by neutralized red mud.
It is observed that the rate of gain in strength decreases with increases in
neutralized red mud content at 7 days curing period compared to 7 days strength of
pure cement concrete.
For M-25 concrete mix the optimum replacement is 15 %. It is interesting to
note that the particular variation in average compressive strength of cement concrete
with different proportions of neutralized red mud in place of cement. It is observation
that the average compressive strength decreases with increase in neutralized red mud
content except for few percentage of replacement.
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initial dam and Bayer red mud in the sub-dams. The “mixed stocking” method
combines the advantages of both, with small investment of the initial dam and sub-
dam and uncomplicated operation management. So, the design of the yard depends
upon specific conditions. The schematic diagram of the “mixed stocking” method.
In the last decade, the production of aluminum in spite of some stagnancy and
set back periods has shown a steady rise of about 1%. The ecological consequences
of aluminum production are well known; threatening of surface and underground
water and air pollution by waste gases from aluminum electrolysis plant and rolling
mills. The degree of damage inflicted to ground water and air during the single
production stages from bauxite to aluminum depends on a couple of tact of which
those connected with the alumina winning and red mud disposal.
As to the resource utilization of red mud, alumina companies have been
carrying out many technical researches on production of construction material,
especially cement production, glass production and production of road base. And
they have made some progress, especially in the production of cement using red
mud.
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CHAPTER – 3
METHODOLOGY
MATERIAL SELECTION
DESIGN MIX
PREPARATION OF SPECIMENS
TESTING ON SPECIMENS
CONCLUSION
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CHAPTER - 4
EXPERIMENTAL INVESTIGATION
Portland pozzolana cement confirming to IS: 269-1976 was used throughout the
investigation. Different tests were performed on the cement to ensure that it confirms
to the requirements of the IS specifications. The physical properties of the cement
were determined as per IS: 4031-1968 and are presented in Table 3.
1 Standard consistency 53
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Table. 4.2 - Chemical Properties of Cement
1 Lime(CaO) 63%
2 Silica(SiO2) 22%
3 Alumina(Al2O3) 6%
4 Iron oxide(Fe2O3) 3%
7 Alkalies 0.5%
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4.1.1. Test of cement
There are following are the quality tests on cement before used,
a. Color test
b. Presence of lumps
c. Adulteration test
d. Temperature test
e. Float test
f. Strength test
g. Setting test
h. Date of packing
4.2. Red Mud
The characteristics of Red mud depend on the nature of the bauxite ore used.
Dicalcium silicate in red mud is also one of the main phases in cement clinker, and
red mud can play the role of crystallization in the production of cement clinker. Fly
ash is mainly composed of SiO2 and Al2O3, thus can be used to absorb the water
contained in the red mud and improve the reactive silica content of the cement.
Scientists conducted a series of studies into the production of cement using red mud,
fly ash, lime and gypsum as raw materials. Use of red mud cement not only reduces
the energy consumption of cement production, but also improves the early strength
of cement and resistance to sulfate attack.
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be disposed of easily. As a waste product of the Bayer process the mud is highly
basic with a pH ranging from 10 to 13.
Al2O3 14.14
SiO2 11.53
Fe2O3 48.50
TiO2 5.42
CaO 3.96
V2O5 0.116
MgO 0.049
ZnO 0.027
Na2O 7.50
P2O5 0.297
MnO 0.17
K2O 0.058
L.O.I 7.25
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Fig. 4.2 - Red mud
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California Bearing ratio test: The sample of nearly 4.5 to 5 kg was compacted in a mould
of volume 2250cc with 5 layers and 56 blows were given for each layer. For soaked CBR
value, the different sample of identical size is prepared and kept soaking for 4 days with
the surcharge. This test was conducted as per IS: 2720 (Part XXXI). The test results are
entered in the table 6.
2 pH 10-12.5
Unsoaked 7.8
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4.3. Aggregate:
Aggregate is a collective term for the mineral materials such as sand, gravel and
crushed stone that are used with a binding medium (such as water, bitumen, Portland
cement, lime, etc.) to form compound materials (such as asphalt concrete and Portland
cement concrete). Aggregate is also used for base and subbase courses for both flexible and
rigid pavements. Aggregates can either be natural or manufactured. Natural aggregates are
generally extracted from larger rock formations through an open excavation (quarry).
Extracted rock is typically reduced to usable sizes by mechanical crushing. Manufactured
aggregate is often the by-product of other manufacturing industries.
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Flowchart of classification of Aggregate
Aggregate
• Rounded aggregates
• Fine aggregate
• Irregular or partly rounded
• Coarse aggregate
aggregates
• Angular aggregates
• Flaky aggregates
• Elongated Aggregates
• Flaky and elongated
aggregates
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Aggregates Based on Size
Aggregates are available in nature in different sizes. The size of aggregate used may be related
to the mix proportions, type of work etc. the size distribution of aggregates is called grading of
aggregates.
Following are the classification of aggregates based on size:
Aggregates are classified into 2 types according to size
• Fine aggregate
• Coarse aggregate
Fine Aggregate
When the aggregate is sieved through 4.75mm sieve, the aggregate passed through it called
as fine aggregate. Natural sand is generally used as fine aggregate, silt and clay are also come
under this category. The soft deposit consisting of sand, silt and clay is termed as loam. The
purpose of the fine aggregate is to fill the voids in the coarse aggregate and to act as a workability
agent.
Clay <0.002
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Fig. 4.3 - Fine aggregate
Property Value
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Coarse Aggregate:
When the aggregate is sieved through 4.75mm sieve, the aggregate retained is called coarse
aggregate. Gravel, cobble and boulders come under this category. The maximum size aggregate
used may be dependent upon some conditions. In general, 40mm size aggregate used for normal
strengths and 20mm size is used for high strength concrete. the size range of various coarse
aggregates given below
Table. 4.7 - Coarse aggregate size
Boulders >256mm
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Table. 4.8 - Properties of coarse aggregate
Property Value
2. Abrasion test
3. Impact test
4. Soundness test
5. Shape test
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4.4. Water
The water used in the mix design was potable drinking water, locally available
and it’s free from organic materials and suspended solids, which might have affected
the properties of the fresh and hardened concrete.
Fresh and clean water is used for casting and curing of specimen. The water
is relatively free from organic matters, silt, oil, sugar, chloride and acidic material as
per requirements of Indian standard. Combining water with a Cementous material
forms a cement paste by the process of hydration. A cement paste glues the aggregate
together fills voids within it and makes floor freely.
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• Through dry the pycnometer by washing thoroughly.
• Fill the cleaned pycnometer completely with water up to top with the cap
screw on.
• Weight the pycnometer after drying it on the outside thoroughly (W4).
• Repeat the procedure for three samples and obtain the average value of
specific gravity.
• And thus, the average value is fixed as the specific gravity of fine aggregate.
CALCULATION:
(W2−W1)
Specific gravity = (W2−W1)−(W3−W4)
RESULT:
Specific gravity of fine aggregate G = 2.80.
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PARTICLE SIZE DISTRIBUTION BY SIEVE ANALYSIS:
AIM:
To determine the grain size distribution of the given soil by dry analysis (sieve
analysis).
APPARATUS:
1. Set of nine Indian standard sieves (4.75 mm to 75µ)
2. Balance
3. Sieve cleaning
4. Brush
5. Sieve shaker
6. Pan
PROCEDURE:
• Arrange the set of sieves one above the other even that 4.75mm sieve is at the
top and the 75µ at the bottom.
• Take 1000g of the given sand in the top most sieve and fix the cover.
• Shake the sieve on mechanical sieve shaker or by hand holding the lid and pan
between the hands lightly for about 10 minutes.
Percentage of weight retained = (wt retained on sieve \ total wt taken) × 100
CALCULATION:
Fineness modulus = sum of cumulative % retained (without pan)/100
= 504.4/100
= 5.04%
RESULT:
The particle size distribution of fine aggregate (fineness modulus) = 5.04%
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• After tabulating and result compute the %of material retained on each of
sieve.
• Calculate the cumulative % of material retained on each sieve and the
percentage of passing.
• Compute the fineness modulus of given aggregate sample.
• Fineness modulus of coarse aggregate = (W2/W1) ×100
CALCULATION:
W1 = 5000 gm
W2= 200.92 gm
Fineness modulus of coarse aggregate = (W2/ W1) ×100
= (200.92/5000) ×100
= 4.02%
RESULT:
Fine modulus of coarse aggregate is = 4.02%
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TEST ON ABRASION VALUE:
AIM:
To determine the abrasive value of given aggregate samples by conducting
loss angles abrasion test.
APPARATUS REQUIRED:
Los angles apparatus, IS sieve, weight balance.
PROCUDURE:
• Clean and dry aggregate sample conforming to the grading A to G is used for
the test.
• Aggregate weighing 5kg for grading A, B, C or D and 10kg for grading E, F
or G may be taken as test specimen and placed in the cylinder.
• The abrasion change is also charger in accordance and placed in the cylinder
of the machine and is fixed to the make dust fight.
• The machine is rotated at a speed of 30 to 33 revolution per minutes.
• The machine is rotated for 500 revolutions for grading A, B, C and D for
grading E, F and G it shall be rotated for 1000.
• Using a sieve of size large the 1.70mm IS sieve the material is first separated
into two parts and the fineness position is taken out and sieved further on a
1.7mm IS sieve.
• Let the original weight of aggregate be W1 gm, weight of aggregate retained
on 1.70mm IS sieve after the test be W2 gm.
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TABLE. 4.12 - Abrasion value
s.no Details of sample Trail
1. Weight of sample (W1) kg 7
2. Weight of sample after abrasion test coarse 6.2
than 1.7m IS sieve (W2) kg
3. Percentage wear = (W1 - W2)/W1 × 100 11.42
RESULT:
The average value of los angles abrasion test is = 11.42%
AIM:
To determine fineness of cement.
APPARATUS:
• 90µ sieve
• Tray
• Digital weighing balance
MATERIAL REQUIRED:
Cement
PROCEDURE:
• 100 grams of cement is weighed W1.
• The weighed cement is sieved in a 90µ sieve thoroughly for five minutes.
• The residue is weighed W2 and expressed as a percentage of total weight
cement and the value is reported as the fineness of cement
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OBSERVATION:
Weight of cement taken = W1 = 100 gm
Weight of residue after sieving = W2 = 95 gm
CALCULATION:
Fineness of cement = (W2 / W1) ×100
= (95/100) ×100
= 95%
RESULT:
The fineness of cement = 95%
APPARATUS:
1. Pycnometer
2. IS Sieve
3. Weight balance
4. oven
PROCEDURE:
• Dry the pycnometer and weight it with its cap (W1).
• Take about 200gm of oven dried Red Mud passing through below
4.75mm sieve into the pycnometer and weight again (W2).
• Add sufficient de aired water to cover the Red Mud and screw the cap.
• Shake the pycnometer well and removed the entrapped air.
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• After the air has been removed the pycnometer with water completely.
• Through dry the pycnometer by washing thoroughly.
• Fill the cleaned pycnometer completely with water up to top with the cap
screw on.
• Weight the pycnometer after drying it on the outside thoroughly (W4).
• Repeat the procedure for three samples and obtain the average value of
specific gravity.
• The average value is fixed as the specific gravity of the Red Mud
• The formula to calculate the specific gravity of Red Mud is mentioned below.
(W2−W1)
Specific gravity = (W2−W1)−(W3−W4)
CALCULATION:
(W2−W1)
Specific gravity = (W2−W1)−(W3−W4)
RESULT:
Specific gravity of Red Mud G = 2.65.
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4.6. Mix Design for M25 Grade
The mix design procedure adopted to obtain a M25 grade concrete is in
accordance with IS 10262- 2009.
The details are stipulated as below:
Table 4.14 - Mix design
MIX DESIGN
As per IS 10262:2009
A- 1 Stipulations for Proportioning
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4.7. TEST DATA FOR MATERIALS:
• Cement used: OPC 53 grade
• Specific gravity of cement: 3.14
• Specific gravity of coarse aggregate: 2.69
• Specific gravity of Fine aggregate: 2.80
Water absorption:
• Coarse aggregate: 0.48
• Fine aggregate: 1.0%
Free surface moisture:
• Coarse aggregate: nil
• Fine aggregate: nil
Sieve analysis:
• Coarse aggregate: conforming to table 2 of IS 383
• Fine aggregate: conforming to zonal of IS 383
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Selection of water content:
From table 2,
Maximum water content: 186 N/mm2
(for 25mm – 50mm slump range and for 12mm aggregate)
Estimated water content for 100mm slump
= 186 + 6 / 100 x 186
= 197.16
= 197 litres.
As super plasticizer is used. The water content can be reduced up 20 percent.
Based on trials with superplasticizer water. water reduction of 20 percent has been
achieved.
Hence the arrived water content = 197 x 0.80
= 157.6
= 157 litres.
Calculation of cement content:
Water cement ratio = 0.40
Cement content = 157/0.40
= 392 kg/m3 > 320 kg/m3
From table 5 of IS 456, minimum cement,
Moderate exposure condition =300 kg/mm3, hence OK
Proportion of volume of aggregate and fine aggregate content:
From table 3, volume of coarse aggregate corresponding to 20mm size
aggregate and the fine aggregate (zone I) for water cement ratio of 0.50 = 0.60
Adopted water cement ratio is 0.40
Volume of coarse aggregate = 0.62
Volume of fine aggregate = 1-0.62
= 0.38
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4.9. MIX CALCULATION:
The mix calculation per unit volume of concrete shall be as follow,
40
Table. 4.15 - Quantity details
MATERIAL QUANTITY
42
CHAPTER – 5
RESULTS AND DISCUSSION
Calculation:
Where,
P = Load at failure (N)
As = Area of the specimen (𝑚𝑚2 )
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Table.5.1 - Compressive Strength of Red Mud Concrete
%
7th day 14th day 28th day
27.12
26.09
25.12
24.05 23.65
COMPRESSIVE STRENGTH N/MM2
22.03 22.14
21.45 21.05
20.12 20.13
18.25
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In 28 day curing Compressive Strength value for the control mix was 25.12
N/mm2, for adding 0.50% Red Mud the Compressive Strength value is 27.12 N/mm2,
the strength was gradually increased and reduced to 26.09 N/mm2 for 0.75% addition
of Red Mud. Strength increment is 15% more than the nominal mix when Red
Mud is added up to 25%and this percentage the strength decreases.
Where,
P = load at failure (N).
D = Diameter of specimen (mm).
L = Length of specimen (mm).
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Table. 5.2 - Split Tensile Strength of Concrete with Red Mud
3.37
3.18
2.82 2.92 3.01
2.56
46
In 28 day curing Split Tensile Strength value for the control mix was 2.56
N/mm2, for adding 0.50% Red Mud the Compressive Strength value is 3.37
N/mm2, the strength was gradually increased and reduced to 3.01N/mm2 for 0.75%
addition of Red Mud. Strength increment is 15% more than the nominal mix
when Red Mud is added up to 25%and this percentage the strength decreases.
σ = Pl/𝑏𝑑 2 (N/mm2 )
47
7 days 14 days 28 days
6.6
FLEXURAL STRENGTH N/MM2
5.7 5.6
5.2
• In 14th day curing, the flexural strength value for the control concrete was 3.2 MPa
and Red Mud - 5% was 4.0 and beyond this percentage of adding of Red Mud,
strength was gradually increased 4.3 MPa for 15% addition of Red Mud and the
Flexural strength was gradually decreased 4.2 MPa for 25 % addition of Red Mud.
• In 28th day curing the flexural strength value for the control concrete was 5.2 MPa
and Red Mud - 5% was 5.7 MPa and beyond this percentage of adding of Red Mud,
strength was gradually increased and reaching 6.6 MPa for 15% addition of Red
Mud and the Flexural strength was gradually decreased 5.6 MPa for 25% addition
of Red Mud.
48
CHAPTER - 6
CONCLUSION
49
REFERENCES
[1] Kedar S. Shinge and Sandeep S. Pendhari. “Use of Red Mud for Partial Cement
Replacement”. International Journal of Modern Trends in
Engineering.and Research.
[2] P. Ashok and M.P. Suresh Kumar. “Experimental Studies On Concrete Utilising
Red Mud As A Partial Replacement Of Cement With Hydrated Lime”. IOSR Journal
of Mechanical and Civil Engineering (IOSR-JMCE).
[5] Mr. A. B. Sawant, Mr. Dilip B. Kamble, Ms. Triveni B. Shinde. “Utilization of
industrial waste (Red Mud) in concrete construction”.UG Student, Department of
Civil Engineering, KIT College of Engineering, Kolhapur, MS (India).
[6] Er.Vedpal Nain, Er. Mohd. Usman, Er. Ayay Kumar, Er. Sanjay Sangwan.
“Properties of Red Mud Admixed Concrete” International Journal for Research in
Applied Science & Engineering, Technology (IJRASET)”.
50
[7] BIS – IS 10262: 2009, “Indian Standard, recommended guidelines for concrete
mix designs”, Bureau of Indian Standard, New Delhi.
[9] Concrete Technology by Gambhir M.L., Second edition 1988, Tata McGraw
Hill, New Delhi.
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