68

CHAPTER 3

MATERIALS AND METHODS

3.1 GENERAL

The materials such as cement, SCBA, silica fume, quarry dust, river
sand, stone chips and water were used in the present work. The methodology
used for the characterisation of aforesaid materials and for the testing of
SCBA silica fume concrete, SCBA silica fume hollow concrete block and
SCBA silica fume hollow concrete block columns and prisms are also
presented in this chapter. Figure 3.1 presents a flow diagram of various
activities involved in this thesis.

Experimental Investigation

Study of Mechanical Properties on Concrete with

Sugarcane Bagasse ash, Quarry Dust and Silica fume Hollow Concrete Block with Sugarcane
Bagasse ash, Quarry Dust and Silica fume

Study of Durability properties

Load Analysis on Hollow Concrete Block Column and
Prism
SEM Analysis

ANSYS Modeling

Cost Analysis

Conclusions

Figure 3.1 Methodology for the complete investigation

 69

3.2 MATERIALS

3.2.1 Ordinary Portland Cement (OPC)

In this investigation OPC of grade 53 confirming to IS: 12269-1987

was used. The specific gravity of cement was 3.15. The cement was tested as
per the Indian Standards IS 4031-1988. The results are given in Table 3.1.

Table 3.1 Physical properties of cement

Property Results Permissible limit as

per IS 12269-1987
Normal consistency 32%
Initial setting time 65 min Not less than 30 mm
Final setting time 250 min Not more 600 mm
Specific Gravity 3.15 Not less than 10%
Fineness of cement (By 30 micron sieve ) 5% retained Not more than 10%
Soundness of cement 2 mm Not more than 10 mm
Compressive strength 7 days (N/mm2) 38.94 Not less than 37
2
Compressive strength 28 days (N/mm ) 58.72 Not less than 53

3.2.2 Sugar Cane Bagasse Ash (SCBA)

SCBA is a byproduct generated from sugar industry. SCBA used in

this study was obtained from the co-generation unit from a reputed Sugar
Industry in Tamilnadu. The calcination temperature at which SCBA produced
was very high of about 1500oC.

Specific gravity of SCBA was 1.9. The total of Silicon dioxide

(SiO2) + Aluminium Oxide (Al2O3) + Iron Oxide (Fe2O3) of SCBA used in
the present work was found to be 56.58%. Loss on ignition of SCBA was
observed as 2.43. The properties of SCBA used in this investigation are
presented in Table 3.2.
 70

Table 3.2 Properties of SCBA

Chemical Silicon Magnesium Total Total Loss Calcium Manganese

composition dioxide + Oxide Chloride Sulphur On Oxide Oxides
Aluminium (MgO) (Cl) as Ignition (CaO) (MnO)
Oxide Sulphur (LOI)
+ Iron Trioxide
Oxide (SO3)
Content in
56.58 0.33 0.002 1.01 2.43 13.47 1.14
%

3.2.3 Silica Fume (SF)

Silica fume obtained from Astra Chemicals India Ltd., Chennai was
used in the present work. The specific gravity of silica fume used was 2.2.The
properties of silica fume are given in Table 3.3.

Table 3.3 Properties of silica fume

Titanium
Chemical Particle
SiO2 MgO Al2O3 Alkalies LOI CaO Oxide
composition Size
TiO2
Content in % 99.5 0.01 0.08 0.08 0.28 0.01 0.04 800 M
Note: Where M denotes Micron

3.2.4 Fine Aggregate

Natural river sand confirming to Zone II as per IS 383-1987 was

used for control concrete. The specific gravity and the fineness modulus of
sand used were found to be 2.60 and 2.64 respectively.

Table 3.4 Properties of fine aggregate

Type of Fine Specific gravity Fineness Bulk Density Grading

Aggregate modulus kg / m3 Zone as per
IS
383(1987)
River Sand 2.60 2.64 1800 II
Quarry Dust 1.95-2.65 1.55 1850 III
Note: Specific gravity of Quarry dust based on samples taken
 71

The tests were conducted with 100% replacement of River sand

with Quarry Dust in all studies. The basic tests on quarry dust were
conducted as per IS: 383-1987. The properties of fine aggregate were studied
accordance with IS 2386-1963 and the results are given in Table 3.4.

3.2.5 Coarse Aggregate (CA)

In order to explore the possibility of using sugarcane bagasse ash

and silica fume in hollow concrete block, stone chips were used in the entire
work. Stone chips were tested as per ASTM C136-06 (equivalent to IS 383-
1987) specification. The results are given in Table 3.5.

Table 3.5 Properties of coarse aggregate

Type of Coarse Maximum Moisture Unit Weight Voids Specific

Aggregate Size content % kg / m3 % Gravity
mm
Stone Chips 12.5 2.4 1138 48.8 2.84

3.2.6 Water

Water conformed to IS 456-2000 was used for both mixing and

curing of concrete specimens.

3.3 CHARACTERISTICS OF SCBA SILICA FUME CONCRETE

Concrete cube and cylinder specimens of proper sizes were made

using materials such as SCBA, silica fume, river sand, quarry dust and stone
chips in appropriate proportion and its properties were evaluated.

3.3.1 Mixture Proportion for SCBA With and Without Silica Fume
in Concrete

For the experimental investigation, M25 mix with three different

w/c ratios of 0.45, 0.55 and 1.5 were considered. A very high w/c ratio of 1.5
 72

was adopted as per the existing practice in industry for the production of
hollow concrete blocks. The mix designs were carried out based on IS: 456-
2000. In order to explore the strength of SCBA in concrete the mixture
proportions with water cement ratio of 0.45 and 1.5 were made with and
without SCBA. The cement in concrete was replaced by SCBA at various
levels such as 0%, 10%, 20%, and 30%.

Further, normal concrete and SCBA silica fume concrete were

casted and tested at all w/c ratios. The silica fume used was added as an
admixture by 10% weight of cement at all replacement level. The mix design
is presented in Appendix I. The mix proportion and quantity of materials used
in the study are given in Table 3.6.

Table 3.6 Mixture proportion for SCBA with and without silica fume
in concrete

Mixture Mixture Mixture Ingredients (kg/m3 )

Proportion Designation Cement SCBA SF River Quarry CA W/C
Sand Dust ratio
1:2.1:2.4 A(Control) 422 - - 866 - 1009 0.45
A10 380 42.2 - - 883 1009
A20 338 84.4 - - 883 1009
A30 295 126.6 - - 883 1009
1:6.5:6.5 B(Control) 150 - - 980 990 1.5
B10 135 15 - - 985 990
B20 120 30 - - 985 990
B30 105 45 - - 985 990
1:2.1:2.4 C 422 - 42.2 866 - 1009 0.45
C10 380 42.2 42.2 - 883 1009
C20 338 84.4 42.2 - 883 1009
C30 295 126.6 42.2 - 883 1009
1:3:3 D(Control) 317 - - 960 - 991 0.55
D 317 - 31.7 960 - 991
D10 285.3 31.7 31.77 - 992 978
D20 253.6 63.4 31.7 - 992 978
D30 222 95.1 31.7 - 992 978
1:6.5:6.5 E 150 - 15 980 - 990 1.5
E10 135 15 15 - 985 990
E20 120 30 15 - 985 990
E30 105 45 15 - 985 990
 73

3.3.2 Workability Tests on Concrete

In order to favour the hollow concrete block production zero slump

was maintained throughout the study. For this cubes and cylinders casted and
they were subjected to vibration using a vibration table. However, the
workability was measured using Compaction Factor tests per IS: 1199 – 1959
and presented in Table 3.7

3.3.2.1 Compaction factor test

The compaction factor was carried out as per standards with

compacting factor test apparatus. The top hopper was gently filled with concrete
while the bottom hopper kept closed. The top hopper was opened and the
concrete fell from the upper one into the lower one. Then the lower hopper was
opened and the concrete fell from the lower hopper into the mould.

The degree of compaction was calculated using the following

formula:

Density of partial compacted concrete

Compaction Factor (CF) = ------------------------------------------------
Density of fully compacted concrete

Table 3.7 Workability of SCBA silica fume concrete mixtures and

control concrete

Mixture Mixture Compaction Mixture Mixture Compaction

Proportion Designation Factor Proportion Designation Factor
1:2.1:2.4 A 0.8 1:3:3 D 0.8
A10 0.8 D10 0.81
A20 0.84 D20 0.84
A30 0.85 D30 0.86
1:6.5:6.5 B 0.8 1:6.5:6.5 E 0.8
B10 0.81 E10 0.82
B20 0.83 E20 0.83
B30 0.86 E30 0.86
1:2.1:2.4 C 0.8
C10 0.8
C20 0.83
C30 0.85
 74

3.3.3 Preparation of Sugarcane Bagasse ash Silica Fume Concrete

About 243 cubes and 162 cylinders were casted using M25 mixes
using the above proportions by replacing cement with SCBA as well as with
and without 10% addition of silica fume on all replacement level. All
specimens were vibrated in a vibration table so as to have zero slump as in
hollow concrete block production .All the materials used were batched by
weight proportions.

3.3.4 Compressive Strength of SCBA Silica Fume Concrete

3 cubes of size 150 mm x 150 mm were taken for each replacement

level and its average compressive strength were determined at 7 and 28 days.
The compressive strength test was performed according to IS: 516 (1959) in
a Universal Testing Machine (UTM) of 1000 kN capacity. The load was
applied gradually till the specimen failed and the failure loads were noted
.The ultimate load divided by the cross sectional area of the specimen is equal
to the ultimate compressive strength of concrete.

3.3.5 Split Tensile Strength of SCBA Silica Fume Concrete

This is an indirect test to determine the tensile strength of

cylindrical specimens. Split tensile strength tests were carried out at the age of
7 and 28 days for the concrete cylinder specimens of size 150 mm diameter
and 300 mm height in a Compressive Testing Machine (CTM) of 600 kN
capacity as per IS: 5816 (1999). The load was applied gradually till the
specimen failed and the failure loads were noted. The split tensile strength
was calculated using the relationship

ft = 2P/ DL
 75

where,

ft = split tensile strength of concrete in MPa

P = load at failure in Newton

D= diameter of the cylinder

L= Length of cylinder

Average of 3 cylinder specimens at each replacement level was

taken as the split tensile strength of the concrete.

3.3.6 Durability of SCBA Silica Fume Concrete

Among the mixtures studied, 1:3:3 mix and 1:6.5:6.5 mix at all
replacement level of cement by SCBA in concrete together with silica fume as
additive were subjected to durability studies. Table 3.8 provides the summary
of durability studies of SCBA silica fume concrete. About 380 specimens
were subjected to durability studies under acid, alkaline and sulphate
environments. The cubes were cast and moist cured over a period of 28 days
were considered as reference. Further the cubes were exposed for a period of
30 days, 60 days and 90 days to find out the effect of acid, alkaline and
sulphate solution on the SCBA silica fume concrete. Subsequently the cubes
were tested for loss in weight, appearance and compressive strength to
evaluate the performance of SCBA silica fume in concrete.

Table 3.8 Summary of durability studies of SCBA silica fume concrete

Exposure Test Conditions Measurement Duration of Specimen Size

Category category study (days) (mm)
Acid Resistance 5% of HCL dissolved in 1
litre of water
Alkaline 5% of NaOH dissolved in 1
30, 60, 90
Resistance litre of water Appearance, Weight,
Sulphate 5% of MgSO4 dissolved in Initial and final 100 x 100
Resistance 1 litre of water Compressive strength
5% of MgSO4 and 5% of 30, 60, 90,
Na2SO4 dissolved in 1 litre 180
of water
 76

3.3.6.1 Acid resistance

The cubes having 100 mm dimension were used in the test. The
specimens were weighed in surface dry condition after moist curing over the
period of 28 days. A 5% hydrochloric acid dissolved in 1 litre of water was
used for acid exposure. The specimens were immersed in the solution and the
solution was replaced periodically once in a week interval throughout 90 days
to maintain the concentration throughout the study. After every 30 days
interval up to a period of 90 days the samples were taken out and tested for
weight and appearance at surface dry condition. At the end of 90 days
exposure the specimens were tested for its compressive strength.

3.3.6.2 Alkaline resistance

The cubes having 100 mm dimension were used in the test. The
specimens were weighed in surface dry condition after moist curing over the
period of 28 days. A 5% NaOH dissolved in 1 litre of water was used for
alkaline exposure. The specimens were immersed in the solution and the
solution was replaced periodically once in a week interval throughout 90 days
to maintain the concentration throughout the study. After every 30 days
interval up to a period of 90 days the samples were taken out and tested for
weight and appearance at surface dry condition. At the end of 90 days
exposure the specimens were tested for its compressive strength.

3.3.6.3 Sulphate resistance

The cubes having 100 mm dimension were used in the test. The
specimens were weighed in surface dry condition after moist curing over the
period of 28 days. For sulphate resistance the exposure conditions were
performed in two phases. In Phase I, 5% MgSO4 dissolved in 1 litre of water
 77

was used for sulphate exposure. The specimens were immersed in the solution
and the solution was replaced periodically once in a week interval throughout
90 days to maintain the concentration throughout the study. After every 30
days interval up to a period of 90 days the samples were taken out and tested
for weight and appearance at surface dry condition. At the end of 90 days
exposure the specimens were tested for its compressive strength.

In Phase II, 5% MgSO4 + 5%Na2SO4 dissolved in 1 litre of water

was used for sulphate exposure. The specimens were immersed in the solution
and the studies were continued up to 180 days as per ASTM C 1012-04
(2004). At every 30 days interval up to a period of 180 days the samples were
taken out and tested for weight and appearance at surface dry condition. At
the end of 180 days exposure the specimens were tested for its compressive
strength.

3.4 MINERALOGICAL AND MORPHOLOGICAL STUDIES

The morphological and mineralogical studies on normal concrete,

silica fume concrete and SCBA silica fume concrete at 28 days was done
using Scanning Electron Microscope (SEM) and EDAX analysis for mixture
proportion of 1:3:3 and 1:6.5:6.5.

3.5 CHARACTERISTICS OF SCBA SILICA FUME HOLLOW

CONCRETE BLOCK

Preliminary studies on SCBA silica fume hollow concrete block

were carried out to evaluate its characteristics and to find its suitability in
hollow concrete block masonry structures.
 78

3.5.1 Mixture Proportion for SCBA Silica Fume Hollow Concrete

Block

For the experimental investigation, M25 mix with three different

w/c ratios of 0.45, 0.55 and 1.5 were considered. The cement in hollow
concrete block was replaced by SCBA at various replacement levels such as
0%, 10%, 20%, and 30% in all mixes. The silica fume was added as
admixture by 10% weight of cement at all replacement level. The trial mixes
have been made and the quantity of materials taken for ten hollow concrete
blocks has been presented in Table 3.9. Estimation of quantity of materials is
presented in Appendix II.

Table 3.9 Mixture proportion for SCBA silica fume hollow concrete block

Mixture Mixture Mixture Ingredients in kg/ ten block

Proportion Designation Cement SCBA SF River Quarry CA W/C
Sand Dust ratio
1:2.1:2.4 C 29 - - 61 70 0.45
C10 26.1 2.9 2.9 61 70
C20 23.2 5.8 2.9 61 70
C30 20.3 8.7 2.9 61 70
1:3:3 D 37 - - 110 110 0.55
D10 33.3 3.7 3.7 110 110
D20 29.6 7.4 3.7 110 110
D30 25.9 11.1 3.7 110 110
1:6.5:6.5 E 10 - - 65 65 1.5
E10 9 1 1 65 65
E20 8 2 1 65 65
E30 7 3 1 65 65
 79

3.5.2 Preparation of Hollow Concrete Block

After exploring the strength properties of concrete, the same mix

proportion was adopted to cast a total of 950 hollow concrete block specimens
of different sizes 400 x 150 x 150 mm and 400 x 100 x 200 mm using SCBA
silica fume concrete. All ingredients were weigh batched. Mixing, casting,
and accelerated curing of all hollow masonry units were performed by the
manufacturing plant following their standard commercial production
procedure. The specimens were cured in water tank up to the testing age.
Figure 3.2 and 3.3 shows the hollow concrete block casting machine and
casted hollow concrete blocks under investigation.

Figure 3.2 View of hollow concrete block casting machine

Figure 3.3 View of hollow concrete blocks casted

 80

3.5.3 Properties of Hollow Concrete Block

The compressive strength test was carried out after various curing
ages as per the test procedure detailed in IS: 2185(2005) in Universal Testing
Machine of 1000 kN capacity .The tests were conducted for eight specimens
and the average was taken for each mix proportion at all replacement level .
Further, water absorption and density property for hollow concrete blocks
were investigated as prescribed in IS: 12440 (1998) at all replacement levels
and the average results of 3 blocks at each replacement level were determined.

3.5.3.1 Compressive strength of hollow concrete block

Hollow concrete block specimens of were casted and tested at 7,

14, 28, 56 and 90 days to determine the compressive strength. The specimens
were cured in water tank up to the testing age. The compressive strength test
was carried out as per the test procedure detailed in IS: 2185 Part-I (2005).
Universal testing machine of 1000 kN loading capacity was used to conduct
the compressive strength test. Figure 3.4 depicts the testing of a hollow
concrete block specimen. A steel plate of 25 mm was provided at top and
bottom of specimen at the time of compressive test to distribute the load
evenly. The specimens were wiped upon removal from the curing tank just
before the test.

The specimens were loaded gradually without shock and the

ultimate failure load was recorded .Then the compressive strength was
calculated as per Indian standard IS: 2185 for concrete masonry units. The
tests were conducted for eight specimens and the average was taken for each
mix proportion at all replacement levels.
 81

Figure 3.4 View of hollow concrete block testing in UTM

3.5.3.2 Water absorption of hollow concrete block

The test specimens were completely immersed in water at room

temperature for 24 hours. Then the specimens were removed from curing
tank, wiped and they were weighed for its wet mass. Subsequently after
saturation, all the specimens were dried in an oven at 110°C for 24 hours,
cooled and weighed to determine the dry mass of the specimen. The average
of 3 specimens was taken for each mix ratio at all replacement level for water
absorption.

Absorption (%) = W – D x 100

D

where W = Wet mass of unit in kg,

D= Dry mass of unit in kg

3.5.3.3 Density of hollow concrete block

Three hollow concrete block specimens were taken at each

replacement level and dried in oven at 100°C. Then the blocks were cooled,
 82

weighed and their dimensions were measured. Then the overall volume of the
block was computed in cubic centimeters .The density of each hollow
concrete block was calculated as follows:

Density = Mass of block

Volume of specimen

The average of the three blocks at each replacement level was taken
as the density of hollow concrete block.

3.5.3.4 Modulus of elasticity of hollow concrete block

The modulus of elasticity test was carried out at the age of 28 days
for the hollow concrete block specimen using universal testing machine of
1000 kN loading capacity. The modulus of elasticity has been calculated from
stress- strain graph of control hollow concrete block and SCBA silica fume
hollow concrete block.

3.5.4 Load Analysis on SCBA Silica Fume Hollow Concrete Block

Masonry Structures

Hollow concrete block prisms and columns using 1:3:3 mixtures for
normal and 10% SCBA, 10% silica fume were casted as shown in Figure 3.5
and 3.6 .The prism with the size of 400 x 100 x 600 mm and columns with the
size of 420 x 420 x 600 mm were casted. The 1:4 mortars was used for joint
with 10 mm thickness and tested for its load carrying capacity experimentally
in a loading frame of 400 kN capacity. Figure 3.7 shows the loading frame
used under investigation. A steel plate of 25 mm was provided at top and
bottom of specimen at the time of compressive test to distribute the load
evenly. Then the experimental results were validated analytically using
ANSYS software.
 83

Figure 3.5 SCBA silica fume Figure 3.6 SCBA silica fume
hollow concrete hollow concrete block
block prisms casted columns casted

Figure 3.7 Loading frame used for testing

3.5.5 Cost analysis of SCBA Silica fume Hollow concrete block

The cost of SCBA silica fume hollow concrete block has been
worked out following the prevailing schedule of rates and compared with the
control concrete.