CHAPTER-1

INTRODUCTION
1.1 GENERAL

The advancement and latest development of major construction is largely associated with
improving the efficiency of the building under seismic effect, reducing cost, economic use of
new materials etc., concrete is one such material, which is consumed in construction industry
next to water consumption in the world. This marvelous material is strong in compression but
very weak in tension. Use of dispersed reinforcement in the cement based matrix/concrete attains
promising new material and eliminates certain drawbacks and entrances certain property.

1.2 HISTORICAL BACK GROUND

Historically, fibers were used to reinforced the brittle material since ancient times,
straws were used to reinforce sun-baked bricks, horse hairs were used to reinforce plaster and
asbestos fibers were used to reinforce cement.

In 1910, porter put the idea that concrete can be strengthened by the inclusion of fibers.
Till 1963; there was only slow progress on fiber reinforced concrete (FRC). Romualdi and
Batson gave rise to FRC by conducting numerous experimental works to determine the basic
engineering properties such as compressive, tensile strength FRC.

Typical types of fibers used are steel, acrylic asbestons, glass, xylon, polyster,
polyethylene, polypropylene, rayon, rock wool and so on. Steel fibers are available in round,
flat, reimped, deformed forms. Steel fibers were used in different structural elements in various
zones and investigated its performance. Now-a-days synthetic fibers have become more
attractive and used for the reinforcement of cementitious materials.

1
 ‘Fiber Reinforced Cement’ as a material made from hydraulic cement and discrete,
discontinuous fibers (containing no aggregate). “Fiber reinforced concrete” (FRC) is made with
hydraulic cement, aggregates of various sizes, in corporating discrete, discontinuous fibers. Both
are firmly established as a new construction material.

Steel fibers and synthetic fibers find applications in civil engineering on a larger scale by
virtue of their inherent advantages; it is of interest to note that the performance of concrete can
be enhanced through the employment of these micro-reinforcements in a hybrid form. The
volume of data available on the performance studies of hybrid fiber reinforced concrete appears
to be inadequate for a better understanding the investigation, it is proposed to combine these
fibers at different proportions in the beam structural elements and engineering properties and
performance are being investigated.
The necessity for the addition of fibers in structural material is to increase the strength of
the concrete and mortar and also to reduce the crack propagation that mainly depends on the
following parameters.

➢ Strength characteristics of fiber

➢ Bond at fiber matrix interface
➢ Ductility of fibers
➢ Volume of fiber reinforcement
➢ Spacing, dispersion, orientation, shape and aspect ratio of fiber.

High strength fibers, favorable orientation large volume, fiber length and diameter of
fiber have been found independently to improve the strength of composites. The steel fiber is
known to have possessed high tensile strength and ductility.

2
 The most significant factor affecting resistance to crack propagation and strength of the
fibrous concrete and mortar are

➢ Shape and bond at fiber matrix interface

➢ Volume fraction of fibers
➢ Fiber aspect ratio and Orientation of fibers
➢ Workability and Compaction of Concrete
➢ Size of Coarse Aggregate
➢ Mixing:

A) SHAPE AND BOND AT FIBER MATRIX INTERFACE

The modulus of elasticity of matrix must be much lower than that of fiber for
efficient stress transfer. Low modulus of fibers such as nylon and polypropylene are therefore
unlikely to give strength improvement, but they help in the absorption of large energy and
therefore impart greater degree of toughness and resistance to impact. High modulus fibers such
as steel, glass and carbon impart strength and stiffness to the composite. Interfacial bond between
the matrix and the fibers also determine the effectiveness of stress transfer, from the matrix to
the fiber. A good bond is essential for improving tensile strength of the composite. The
interfacial bond could be improved by larger area of contact, improving the frictional properties
and degree of gripping and treating the steel fibers with sodium hydroxide or acetone.

B) VOLUME FRACTION OF FIBER

The strength of the composite largely on the quantity of fibers used in it. The increase in
the volume of fibers, increase approximately linearly, the tensile strength and toughness of the
composite. Use of higher percentage of fiber is likely to cause segregation and hardness of
concrete and mortar.

C) FIBER ASPECT RATIO

3
 Fiber aspect ratio is defined as the ratio of fiber length to the equivalent fiber diameter.
In order to utilize fracture strength of fibers fully, adequate bond between the matrix and the
fiber has to be developed. This depends on the shape of the fibers viz., straight, crimped, hooked
end and its aspect ratio. An aspect ratio 60 to 100 is commonly used.

D) ORIENTATION OF FIBERS

One of the differences between conventional reinforcement and fiber reinforcement is

that in conventional reinforcement bars are oriented in the direction desired while fibers are
randomly oriented. It was observed that in fiber reinforced mortar the fibers aligned parallel to
the applied load offered more tensile strength and toughness than randomly distributed or
perpendicular

E) WORKABILITY AND COMPACTION OF CONCRETE

Incorporation of steel fiber decreases the workability considerably and even prolonged
external vibration fails to compact the concrete. This situation adversely affects the
consolidation of fresh mix. The fiber volume at which this situation is reached depends on the
length and diameter of the fiber and non-uniform distribution of the fibers. Generally, the
workability and compaction standard of the mix are improved through increased water/cement
ratio or by the use of water reducing admixtures. The overall workability of fresh fibrous mixes
was found to be largely independent of the fiber type. Crimped fibers produce slightly higher
slumps, and hooked fibers were found to be more effective than straight and crimped ones.

F) SIZE OF COARSE AGGREGATE

4
 Several investigators recommended that the maximum size of the coarse aggregate
should be restricted to 10mm, to avoid appreciable reduction in strength of the composite. A
fiber in effect, as aggregate having a simple geometry, their influence on the properties of fresh
concrete is complex. The inter-particle friction between fibers and between fibers and aggregates
controls the orientation and distribution of the fibers and consequently the properties of the
composite. Friction reducing admixtures and admixtures that improve the cohesiveness of the
mix can significantly improve the mix.

G) MIXING

Mixing of fiber reinforced concrete needs careful conditions to avoid balling of fibers,
segregation, and difficulty of mixing the materials uniformly. Increase in the aspect ratio, volume
percentage and size and quantity of coarse aggregate intensify the difficulties and balling
tendencies. It is important that the fibers are dispersed uniformly throughout the mix. This can
be done by adding fibers before adding water. When mixing in a laboratory mixer, introducing
the fibers through a wire mesh basket will help even distribution of fibers.

1.3 SCOPE FOR THE PRESENT STUDY

5
➢ To study the physical properties of concrete using polypropylene fiber, steel fiber
➢ Evaluation of compressive strength and of splitting tensile strength of concrete with
steel fiber
➢ Evaluation of compressive strength and of splitting tensile strength of concrete with
polypropylene fiber.
➢ Evaluation of compressive strength and of splitting tensile strength of concrete without
fiber.
➢ To establish the physical properties of constituents (cement, fine aggregate, coarse
aggregate and fiber)
➢ To design the concrete mix using IS (Indian Standard)

6
1.4 EFFECT OF FIBERS IN CONCRETE

➢ Fibers are initially used in concrete to control plastic shrinkage and drying
Shrinkage cracking.

➢ They also lower the permeability of concrete and thus reduce bleeding of water.
Some types of fibers produce greater impact, abrasion and shatter resistance in
Concrete.
➢ The material ductility is increased by the addition of fibers.

➢ High-performance fiber-reinforced concrete used in bridges found to provide

Residual strength and control cracking. The residual strength is directly proportional
to the fiber content.

➢ Generally fibers do not increase the compressive strength of concrete. Fibers

cannot replace moment resisting or structural steel reinforcement. Some fibers reduce
the strength of concrete

CHAPTER-2

7
 LITERATURE REVIEW

A) Waheeb Ahmed al-khaja (1997 volume 7) studied the mechanical properties

And time dependent deformation of polypropylene fiber concrete. This investigation
conducted to study the effect of PPF used for reinforcing concrete mixes.

The compression, tension and flexural strength test were performed changing fiber 0.1
to 3 % of the cement weight content. Adding the 0.5 % of PPF the compressive strength can
obtain the maximum value.

B) K.Anbuvelan, M.M. Khadar. M.h, M.Lakshmipathy and K.S. Sathyanarayann

studies on properties of concretes containing polypropylene, steel and reengineered plastic shred
fiber work an attempt has been made to study the influence of polypropylene fibers, steel fibers
and re-engineered plastic shreds with0.1 %, 0.5 % and 0.5 % by volume of concrete mix.
1. With the addition of polypropylene fibers to plain concrete, its strength is
increased in the range of 4 %-17 %. The improvement in its wear and impact
resistance were 28 %-58 % and 72 %-134 %, respectively and reduction in
maximum crack width is to an extent of 21 %-74 %.

2. The steel fiber added to plain concrete resulted in improvement of the strength, wear
and impact resistance characteristics by 4 %-49 %, 42 %-52 % and 34 %-38 %
respectively. The reduction in maximum crack width is found to be 46 %-67 %.

3. With the addition of reengineered plastic fibers to plain concrete, strength, wear
and resistance to impact are increased to 20%-17.60%, 31%-48% and 123%-139%
respectively. The reduction in its maximum crack width is 59%-73%.

C) Maalej and Paramasivam (2002) studied the effectiveness of ductile fiber reinforced
cementitious composites (DFRCC) in retarding the corrosion of steel in reinforced concrete

8
beams. A fiber content of 1.5 % PVA & 1.0 % steel fibres was used in a DFRCC and a layer of
DFRCC was used around the main longitudinal reinforcement (FRC). The authors concluded
that the FGC concept using DFRCC material was very effective in preventing corrosion –
induced damage in RC beams and minimizing the loss in the beam load and deflection capacities.
They also reported that the functionally graded concrete (FGC) beams have higher resistance
against corrosion and cracking compared with conventional reinforced concrete.

D) Nataraja, Dhang and Gupta (1999) examined the feasibility of using UPV technique
for assessing the quality of steel fiber reinforced concrete. The study parameters included fiber
content, aspect ratio of fibres and concrete strength. The pulse velocity readings were taken
longitudinally at the centre of cylinders and prisms. The authors concluded that the quality of
SFRC could be adequately confirmed using UPV technique. They also reported that the pulse
velocity at 7 – days and 28 – days can be estimated knowing the pulse velocity at 1- day using
amplification factors of 1.11 and 1.13 for both plain and fiber reinforced concrete up to a
compressive strength of 50 MPa.

E) Mohammed and Kaushik (2000) investigated the influence of mixed aspect ratio of
fibres on compressive strength, splitting tensile strength, flexural strength, impact strength and
ductility of SFRC. They tried different mixed aspect ratio of fibres with a total volume fraction
of 1.0%. The authors concluded that the use of 65% long fibres and 35% short fibres gave
optimum mechanical properties.

CHAPTER-3

9
 METHODOLOGY

Collection of materials

Mix proportions
(M20 grade of concrete)

Casting of specimens

Fiber added with concrete at various %

Control concrete (without fiber)

Steel Fiber Polypropylene Fiber

Curing of Specimens

Test on Specimens

Hardened concrete
1. Comprehensive strength test
2. Split tensile strength test

Analysis and discussion of test results

Conclusion

CHAPTER-4
PROPERTIES OF MATERIALS
10
4.1 PROPERTIES OF CEMENT
The properties of ordinary Portland cement as shown in the table 4.1.

Test Particulars Result Obtained Requirements as per IS:

12269 1987
Specific gravity 3.15 3.10-3.15
Normal consistency (%) 31 30-35
Initial setting time 37 30 minimum
(minutes)
Final setting time (minutes) 570 600 maximum
Compressive strength
(MPa) 28 43
a) 3 days 38 33
b) 7 days 44 23
c) 28 days

Table 4.1: Physical properties of ordinary Portland cement

4.2 PROPERTIES OF FIBERS

4.2.1 STEEL FIBER (METALLIC FIBER)

11
 Steel fiber is one of the most commonly used fibers. Generally, round fibers are used.
The diameter may vary from 0.25 to 0.75 mm. The steel fiber is likely to get rusted and lose
some of its strength. But investigations have shown that the rusting of the fibers takes place only
at the surface. Use of steel fibers make significant improvements in flexural, impact and fatigue
strength of concrete, it has been extensively used in various types of structures, particularly for
overlays of roads, airfield pavements and bridge decks. Thin shells and plates have also been
constructed using steel fibers.

Figure 4.1: The figure shows the general view of steel fiber

4.2.2 POLYMERIC FIBER

12
 Synthetic polymeric fibers have been produced as a result of research and development
in the petrochemical and textile industries. Fiber types that have been tired with cement matrices
include arcrylic, aramid, nylon, polyester, polypropylene and polyethylene. They all have a very
high tensile strength, but most of these fibers (except for aramids) have a relatively low modulus
of elasticity. The quality of polymeric fibers that makes them useful in FRC is their very high
length to diameter ratios, their diameters are on the order of micrometers.

A.POLYPROPYLENE FIBER (PPF)

Polypropylene fibers are synthetic types of fibers. Synthetic fibers are gradually
replacing steel fibers due to the fact that are cost effective, can be used in low volume fractions
and there is no risk of corrosion by there is used in concrete. Polypropylene fibers are currently
manufactured in variety of geometries and configuration. These fibers are produced by drawing
or stretching the synthetic fiber into film sheets which are then slit longitudinally into tapes.
Polypropylene fibers are composed of crystalline and non-crystalline region.

Polypropylene fibers have a softening point in the region of 150º c and a melting point
at 160 to 170 º c. It is lowest thermal conductivity of all commercial fibers. It has excellent
chemical resistance to acid and alkalis, high abrasion resistance.

13
 Figure 4.2: The figure shows the general view of polypropylene fiber

B. NYLON FIBER

Commercial available nylon fibers are made of nylon 6. They are available in varies
lengths in single filament form. Since this fibers are very thin, a number of fibers per pound in
the range of 35 million per pound for fiber length of 0.75 inch (19 mm).

C. POLYESTER

Polyester fibers are made of ethyl acetate monomers. Their physical and chemical
properties can be changed substantially by altering manufacturing techniques. The higher
modulus of elasticity and better bonding to concrete that is important for FRB application can
be achieved by some of this modification.

14
 Figure4.3: The figure shows the general view of polyester fiber

Physical properties of polymeric fibers as shown in the given table 4.2

Fiber type Effective Dia Specific Tensile Elastic Ultimate

× 10-3 (mm) Gravity Strength Modulus Elongation
(MPa) (GPa) (%)
Nylon - 1.16 965 5.17 20

Polyester - 1.34-1.39 896-1100 17.5 -

Polyethylene 25-1020 0.96 200-300 5 3

Polypropylene - 0.9-0.91 310-760 3.5-4.9 15

Table 4.2: Physical properties of polymeric fibers

D. POLYETHYLENE

Polyethylene fibers are available both in standard length (0.52-2, 12-50 mm)and in pulp
form .the longer fiber available in the market have wart-like surface deformation, better bond to
concrete. The fibers that are available in pulp form have been promoted has a replacement for
asbestos fibers in concrete. These short fibers can also used in cement matrix to improve
ductility, impact resistance and fatigue strength

15
 Figure4. 4: The figure shows the general view of polyethylene fiber

E. GLASS FIBERS

The glass fibers are primarily used for glass fiber reinforced cement (GFRC) sheets.
Regular E-Glass fibers were found to deteriorate in concrete.

Figure4. 5; The figure shows the general view of glass fiber

16
4.2.3 NATURALLY OCCURING FIBERS

The oldest forms of fiber reinforced composites were made with naturally occurring
fiber such as straw and horse hair. Modern technology has made it possible to extract fibers
economically from various plants, such as jute and bamboo to use in cement composites.

The unique aspects of this fiber in the low amount of the energy required to extract
these fibers. The primary problem with used of this fibers in concrete is their tendency to
disintegrate in an alkaline environment. Effects of being made to improve durability of this fiber
in concrete by using admixture to make the concrete less alkaline and the subjecting the fibers
to special treatment.

Natural fibers used in Portland cement composite include akwara bamboo, coconut,
flax, jute, sisal, sugarcane bagases, wood, and others mechanical properties of some of these
fibers are presented in the succeeding.

A. AKWARA FIBERS

Akwara is a natural fiber derived from a plant stem grown in large quantities in Nigeria.
They are made of a cellular core covered with a smooth sheath. Akwara fibers were found to be
durable in alkaline environment of cement matrix, and they are also dimensionally stable under
wetting and drying conditions. The disadvantages are their low elastic modulus and brittleness.

B. BAMBOO FIBERS

Bamboo, which is a member of the grass family, grows in tropical and subtropical
region. Plants can grow up to a height of 15 m. their hollow stalks have intermediate joints, the
diameters of these stalks range from 0.4 to 4.0 inch (1 to 10 cm).

17
 Special techniques are needed to extract the fibers from bamboo. Bamboo fibers are
strong in tension, but have a relatively low modulus of elasticity. Their tendency absorb water
adversely affects the bonding between the fibers and the mixture during the curing process.

C. COCONUT FIBERS

A mature coconut has an outer fibrous husk. Coconut fibers, called coir, can be
extracted simply by soaking the husk in water or, alternatively, by using mechanical processes.
These short (only a few inches) stiff fibers have been used for making rope for centuries. Coir
has a low elastic modulus and is also sensitive to moisture changes.

D. FLAX AND VEGETABLE FIBERS

Flax is grown for its fiber. Flax fibers are strong under tension and also possess a high
modulus of elasticity. Fibers extracted from other plant such as elephant grass, water reed,
plantain, and musamba have also been tried as reinforcements for concrete. Most of these fibers
are removed from the stems of the plants manually.

Physical properties of naturally occurring fibers as shown in the given table 4.2

18
Fiber Coconut Sisal Sugarcane Bamboo Jute Flax Elephant Musamba Wood
Type Bagasse Grass fiber
Fiber 52 - - - 180 500 - - 2.5
Length to to to
(mm) 350 300 5
Fiber Dia 0.1 - 0.2 0.05 0.1 - - - 0.015
(mm) to to to to to
0.4 0.4 0.4 0.2 0.08
Specific 1.12 - 1.2 1.5 1.02 - - - 1.5
Gravity to to to
1.15 1.3 1.04
Modulus 19 13 15 33 26 100 4.9 .9 -
of to to to to to
Elasticity 26 16 19 40 32
(GPA)
Ultimate 120 280 170 350 250 1000 178 83 700
Tensile to to to to to
Strength 200 568 290 500 350
(MPa)
Elongatio 10 3 - - 1.5 1.8 3.6 9.7 -
n of to to to to
Break 25 5 1.9 2.2
(%)
Water 130 60 70 40 - - - - 50
Absorpti to to to to to
on (%) 180 70 75 45 75

Table4. 3: Table shows the physical properties of naturally occurring fiber

19
4.4 MAJOR ADVANTAGES OF FIBER REINFORCED CONCRETE

Various advantages of fiber reinforced concrete are

a) Resistance to micro cracking
b) Toughness and post failure ductility
c) Impact resistance
d) Resistance to fatigue
e) Improved strength in shear, tension, flexure, and compression
f) Reduced permeability

4.5 AREAS OF APPLICATION

The areas where these fibers can be used as secondary reinforcement are given as under
a) Plain and reinforced concrete
b) Plaster (stucco)
c) Pre-cast concrete productions
d) Trench-less constructions
e) Productive lining
f) Roofing product

20
 CHAPTER-5
MATERIAL SELECTION

For concrete ingredients are,

➢ Cement

➢ Aggregate

a) Fine aggregate

b) Coarse aggregate

➢ Water

5.1 CEMENT

Ordinary Portland cement is hydraulic cement that hardens by interacting with water and
forms a water resistance compound when it receives its final set. Compared with non-hydraulic
cements such as gypsum and lime, which absorb water after hardening, Portland cement is highly
durable and produces high compressive strengths in mortars and concretes.

The size of the cement particles has a strong influence on the reaction of cement with water.
For a given weight of finely ground cement, the surface area of the particles is greater than that of
the coarsely ground cement. Since there are different types of cement for various needs, it is
necessary to study the percentage variation in the chemical composition of each type n order to
interpret the reasons for variations in behavior. OPC-53 Grade con forming to IS: 12269-1987 was
used.

21
5.2 AGGREGATES

Aggregate are those parts of the concrete that constitute the bulk of the finished product.
They comprise 60-80% of the volume of the concrete and have to be so graded that the entire mass
of concrete acts as a relatively solid, homogenous, dense combination, with the smaller sizes acting
as an inert filler of the voids that exist between the larger particles.
They are two types:

1. Coarse aggregate, such as gravel, crushed stone, or blast furnace slag

2. Fine aggregate, such as natural or manufactured slag

Since the aggregate constitutes the major portion of the mixture, the more aggregate in the
mixture, the cheaper is the concrete, provided that the mixture is of reasonable workability for the
specific job for which it is used.

The long term performance if the concrete produced, whether normal strength or high
strength is governed to a large extent by the quality of the coarse aggregate, low porosity and low
permeability, high resistance to freezing and thawing, high resistance to abrasion strength, and low
expansion that can be produce cracking, disintegration, low or no alkali-aggregate reactivity.

Aggregate should always be selected to have minimum drying shrinkage effects. Their
choice determines the long term performance of a structure, as drying shrinkage is a long term
process that takes several years for the concrete in a structural member to achieve complete drying.
The following are the factors to be taken into account in selection of the coarse aggregate.

5.2.1 COARSE AGGREGATE

22
 Crushed granite coarse aggregate conforming to IS: 383-1987 was used. Coarse aggregate
passing through 20mm, having the specific gravity and fines modulus vales 2.80-7.20 respectively
were used. Properties of the coarse aggregates affect the final strength of the hardened concrete and
its resistance to disintegration, weathering, and other destructive effects. The mineral coarse
aggregate must be clean or organic impurities and must bond well with the cement gel. The common
types are,

1. Natural crushed stone

2. Natural gravel
3. Artificial coarse aggregate

5.2.2 FINE AGGREGATE

The fine aggregate conforming to zone-II as per IS: 383-1987 was used. Fine aggregate is
smaller filler made of sand. A good fine aggregate should always be free of organic impurities, clay,
or any deleterious materials or excessive filler of size smaller than N.For radiation-shielding
concrete, fine steel shot and crushed iron ore are used as fine aggregate.

A fineness modulus (FM) in the range 2.5-3.2 is recommended for concrete, to facilitate
workability. Lower values result in decreased workability and a higher water demand. The mixing
water demand is dependent on the void ratio in the sand.

23
 CHAPTER-6
EXPERIMENTAL STUDY

6.1 GENERAL

In order to increase the performance of concrete, many types of mineral and chemical
admixtures are added. Addition of fibers may change the performance in the hardened stages.
Therefore, it is very essential to evaluate the effect of fibers on mechanical properties of concrete.
Thus chapter deals with the properties of materials used in this investigation, methodology,
preparation of test specimens, experimental test set up and testing procedure that have been
performed.

6.2 STRENGTH REQUIREMENTS

The age at is a governing criterion for selecting mixture proportions. The standard 28-day
strength for normal-strength concrete penalizes high strength concrete since the later continues
gaining strength after that age. One has also to consider that a structure is subjected to service load
at 60 to 90 days age at the earliest.

Table5.1 shows the Specific gravity test result for fine aggregate by using Pyconometer test.

24
 Description 1 2 Average
Pyconometer bottle (W1) 651.5 651.5
Wt of Pyconometer + dry soil (W2) 851.5 855.5
Wt of Pyconometer + dry soil + water 1668 1675
(W3)
Wt of Pyconometer + water (W4) 1545.5 1549.5
Specific gravity = W2-W1/[(W2-W1)- 2.6 2.6 2.6
(W3-W4)]

Table5.1: Specific gravity of fine aggregate coarse

Table5,2 shows the Specific gravity test result for coarse aggregate by using Pyconometer test.

Description 1 2 Average
Pyconometer bottle (W1) 651.5 651.5
Wt of Pyconometer + dry soil (W2) 881.5 855.5
Wt of Pyconometer + dry soil + water (W3) 1753.68 1765

Wt of Pyconometer + water (W4) 1606 1633

Specific gravity = W2-W1/[(W2-W1)-(W3- 2.8 2.8 2.8
W4)]

Table 5.2: Specific gravity of coarse aggregate

Table5.3 shows the Sieve analysis test for fine aggregate concrete.

25
 IS Sieve size Quantity Cumulative % Retained % Passing Limits for
(mm) Retained (g) Wt Retained Zone-II
(g) (IS383)
10 0 0 0 100 100
4.75 0 0 0 100 90-100
2.36 120 120 2.4 97.6 95-100
1.18 1425 1545 28.5 69.1 55-90
0.6 880 2425 17.6 51.5 35-59
0.3 1670 4095 33.4 18.1 8-30
0.15 905 5000 18.1 0 0-10

Table5.3: Sieve analysis of fine aggregate concrete

Table5.4 shows the Sieve analysis test for coarse aggregate concrete.

Sieve Size (mm) Quantity Cumulative Wt % Retained % Passing

Retained (g) Retained (g)
63 0 0 0 100
40 0 0 0 100
20 803 803 5.8 94.2
12.5 0 803 5.8 94.2
10 12562 13365 96.5 3.5
4.75 374 13739 99.2 0.8

Table 5.4: Sieve analysis of coarse aggregate concrete

CHAPTER-7

26
 MIX DESIGN

Proper design of concrete mixture is intended to obtain such proportioning of ingredients

which will produce concrete of high durability performance during the designed life of a structure,
usually 50 years.

For a particular strength and long term qualities and performance. Several factors determine
these properties.

1. Quality of cement

2. Proportion of cement and other cementations materials in relation to water in the

mixture (water/cementation ratio)

3. Strength and cleanliness of aggregate

4. Interaction or adhesion between cement paste and aggregate

5. Adequate mixing of ingredients

6. Proper placing, finishing, and compaction of fresh concrete

7. Curing at a temperature not below 50° F while the placed concrete gains strength

8. Chloride content not exceeds 0.15% in reinforced concrete exposed to chlorides in

service and 1% for dry protected concrete.

A study of these requirements shows that most of the control actions have to be taken prior
to placing the fresh concrete. Since each control is governed by the proportion and the mechanical

27
ease or difficulty in handling and placing, the development of criteria based on the theory of
proportioning for each mixture should be studied.

In addition, a determination has to be made as to the admixtures that need to be prescribed

to enhance the long-term high performance and durability of the finished product.

There are several types of strength-modifying admixtures: high range water reducers (super
plasticizer), polymers, granulated blast furnace slag, fly ash, or slica fume. However, in mixture
proportioning for very high strength concrete, isolating the water/cementation materials ratio
W/(C+P) (often called simply w/cm) from the paste/aggregate ratio due to the very low water content
can be more effective in arriving at the optimum mixture with fewer trial mixtures and field trial
batches. The very low w/cm material ratio required for strength in the range 138 Mpa or higher
requires major modification to the present standard approach used in mixture proportioning that
seems to work well for strength up to 83 Mpa. The optimum mixture that can be chosen with
minimum trials has to produce satisfactory concrete product in both its plastic and hardened states.

7.1 VARIOUS METHODS OF DESIGN MIX PROPORTIONING

28
 ➢ Arbitrary proportion

➢ Maximum density method

➢ Fineness modulus method

➢ Surface area method

➢ ACI Committee method

➢ Grading curve method

➢ IRC-44 method

➢ High strength concrete mix design

➢ Design based on flexural strength

➢ Indian standard method

7.2 CONCRETE MIX DESIGN FOR INDIAN STANDARD METHOD

STEP 1: Design stipulation

A) Characteristic compressive strength = 20 N /mm2

B) Max size of aggregate = 20 mm (angular)

C) Degree of workability = 0.9 compacting factor

D) Degree of quality control = good

E) Type of exposure = severe

STEP 2: Test data for materials

29
 Cement used opc = 53 grade

Specific gravity of cement = 3.15

Specific gravity of fine aggregate = 2.6

Specific gravity of coarse aggregate = 2.8

Water absorption

1. Coarse aggregate = 0.5%

2. Fine aggregate = 1%

STEP 3: Target mean strength of concrete

Target compressive strength F ck = f ck + t.s

fck = Characteristic compressive strength at 28 days

s = Standard deviation

t = tolerance factor (its take 1.65)

For using table(1) the target mean strength for the specified characteristic strength

20 + (1.65 × 4.6) = 27.6 N/ mm2

STEP 4: Selection of water-cement ratio

The w/c ratio required for target mean strength of 27.6 N/ mm2 is 0.5 from table
5 of IS 456-2000.

STEP 5: Selection of water and sand content.

30
 Table 4 of IS 10262-1282 (for 20 mm nominal max size aggregate)
And confirming to grading zone-II

Water content per m3 concrete = 186 kg sand content as percentage of total

aggregate by absolute volume = 35% for changes in values in water-cement ratio
for following adjustment is required.

Changing Condition Adjustment Required

In water content % %sand in total

aggregate
For decrease in water cement ratio 0 -2.0
(0.6-0.5)=0.1
For increase in compacting factor +3 0
(0.9-0.8)=0.1
For sand conforming zone-II of table 4 0 -1.5
IS 383-1970
3% -3.5%

Therefore required sand content as % of total aggregate by absolute volume = 35-

3.5 = 31.5%
Required water content = 186 + (186×3)/100
=191.6 l/m3

STEP 6: Determination of cement content

31
 Water cement ratio = 0.5
Water = 191.6 l
Cement = 191.6/0.5
=383 kg/m3
This cement content is adequate for extreme exposure condition. According to IS:
456-2000

STEP 7: Determine aggregate content

By using equation 3.15 form 10262-1982

V = [w + (C/Sc) + (1/p) + (fa/Sfa)] × (1/1000)

Where

V = absolute volume of fresh concrete, which is equal to gross volume (m 3)

minus the volume of entrapped air,
W = mass of water (kg) per m3 of concrete,
C = mass of cement (kg) per m3 of concrete,
Sc = specific gravity of cement,
p = ratio of fine aggregate to total aggregate by absolute volume,
fa = total masses of fine aggregate and coarse aggregate (kg) per m3 of concrete
respectively, and
Sfa = specific gravities of saturated surface dry fine aggregate and coarse
aggregate respectively.

32
 From IS: 383 : 1970 specified maximum size of aggregate 20 mm, the amount of
entrapped air in the wet concrete is 2%, taking this into account and apply into the
above equation.

0.98 = [191.6 + (383/31.5) + (1/0.315) + (fa/2.6)] × (1/1000)

fa = 545 kg/m3
Therefore
Ca = (1-0.315/0.315) × (1/1000)
Ca = 1188 kg/m3
fa = amount of fine aggregate
Ca = amount coarse aggregate

MIX PROPORTION

Water Cement Fine Aggregate Coarse Aggregate

191.6 kg 383kg 545 kg 1188 kg
0.5 1 1.4 3.1

CHAPTER-8

33
 TESTING OF SPECIMEN

8.1 SPECIMEN PREPARATION

➢ The steel fiber and polypropylene fiber added in the range of 0.25%, 0.50%, 0.75, 2%, and
2.5% by volume of concrete specimen.
➢ The concrete was mixed in hand then the decided quantity of fiber was added evenly and
mixed to get the uniform distribution and homogeneous mixer without forming fiber balls.
➢ The compressive strength and tensile strength performance were evaluated using 150 mm
cube, 100 mm diameter and 200 mm height cylinder.
➢ The specimens were cast in steel mould. The test specimens were normal cured under water.

8.2 COMPRESSIVE STRENGTH TEST

The compressive strength of concrete is one of the most important and useful properties
of concrete. I most structure applications concrete is employed primarily to resist compressive
stresses. In those case where strength in tension or in shear is of primary importance, stresses. In
those cases where strength in tension or in shear is of primary importance, the compressive strength
is frequently used as a measure of these properties. Therefore, the concrete making properties of
varies ingredients of mix are usually measured in terms of the compressive strength. Compressive
strength is also used as a qualitative measure for other properties of hardened concrete.
The modulus of elasticity in this case does not follow the compressive strength. The other
case where the compressive strength does not indicate the useful property of concrete is when the
concrete is subjected to freezing and thawing.
Concrete containing about 6 percent of entrained air which is relatively weaker is strength
is found to be more durable than dense and strong concrete.

The compressive strength of concrete is generally determined by testing cubes or

cylinders made in laboratory or field or cores drilled from handed concrete at site or from the non-

34
destructive testing of the specimen or actual structures. The testing of hardened concrete is discussed
in the subsequent chapter.

Strength of concrete is its resistance to rupture. It may be measured in a number of ways,

such as, strength in compression, in tension, in shear or in flexure.

In order to determine the compressive strength, a total number of 144 cubes were cast.
After 24 hours of casting, the specimens were de-molded and cured under water.

At the end of curing period, the above specimens were tested in a compressive testing
machine as per: IS516-1989.

8.3 SPLIT TENSILE STRENGTH TEST

This is also sometimes referred as, “Brazilian Test”. This test was developed in Brazil in
1943.At about the some time this was also independently developed in Japan. The test is carried out
by placing a cylindrical specimen horizontally between the loading surfaces of a compression testing
machine and the load is applied until failure of the cylinder, along the vertical diameter.

When the load is applied along the generatrix, an element on the vertical diameter of the
cylinder is subjected to a vertical compressive stress. In order to determine the split tensile strength
of various concretes test was conducted as per IS: 5816-1999.

A total number of 96 cylindrical specimens were cast and after 28 days of curing, they
were tested in a compression testing machine by loading it on the longitudinal direction.

CHAPTER-9

TEST RESULTS

35
The compressive strength of various percentage steel fibers added are given by the table9.1.

Sl. no Mix Steel fiber (%) Compressive Strength (Mpa)

At 3days At 7 days At 28 days
1. CC 0 12.5 15.5 18
2. SF1 0.25 13.5 19 20
3. SF2 0.5 14.6 20 23.5
4. SF3 0.75 14.8 21.4 24.5
5. SF4 1 16 24.2 26
6. SF5 1.5 18.5 25.3 29
7. SF6 2 18 23 26.3
8 SF7 2.5 17.3 22 26

Table 9.1: Compressive strength of M20 grade concrete with and without steel fiber
Where
CC – Control Concrete
SF1– 0.25 % steel fiber added concrete
SF2 – 0.5 % steel fiber added concrete
SF3 – 0.75 % steel fiber added concrete
SF4- 1 % steel fiber added concrete
SF5 – 1.5 % steel fiber added concrete
SF6 – 2 % steel fiber added concrete
SF7 – 2.5 % steel fiber added concrete

36
 35
Compressive Strength (MPa)

30
25
20 3 Days
7 Days
15
28 Days
10
5
0
0 0.5 1 2
Percentage of Fiber Added

Figure 9.1: Graph showing the compressive strength of M20 grade concrete with and without
steel fiber

37
The compressive strength of various percentage added Polypropylene fiber added concrete as given
by the table9.2.

Mix Polypropylene Compressive Strength (Mpa)

Sl. No fiber (%) At 3days At 7 days At 28 days
1. CC 0 12.5 15.5 18
2. PPF1 0.25 13.5 18.5 21
3. PPF2 0.5 18 21.3 25.5
4. PPF3 0.75 17.3 20 24.3
5. PPF4 1 17 19.2 23
6. PPF5 1.5 16.6 18.6 22
7. PPF6 2 15.3 17.9 21.1
8 PPF7 2.5 14 17 20.8

Table 9.2: Compressive strength of M20 grade concrete with and without polypropylene fiber
Where
CC – Control concrete
PPF1 – 0.25 % polypropylene fiber added concrete
PPF2 – 0.5 % polypropylene fiber added concrete
PPF3 – 0.75 % polypropylene fiber added concrete
PPF4 – 1% polypropylene fiber added concrete
PPF5 – 1.5 % polypropylene fiber added concrete
PPF6– 2 % polypropylene fiber added concrete
PPF7– 2.5 % polypropylene fiber added concrete

38
 30
Compressive Strength (MPa)

25

20
3 Days
15 7 Days
28 Days
10

0
0 0.5 1 2
Percentage of Fiber Added

Figure 9.2: Graph shows the compressive strength of M20 grade concrete with and
without polypropylene fiber

39
The Split tensile strength of various percentage steel fiber added concrete as given by the table9.3.

Sl. no Mix Steel fiber (%) Tensile Strength (Mpa)

At 3days At 7 days At 28 days
1. CC 0 1.5 1.8 3
2. SF1 0.25 1.6 2.2 3.1
3. SF2 0.5 1.72 2.6 3.3
4. SF3 0.75 1.81 2.8 3.5
5. SF4 1 2 3.31 3.9
6. SF5 1.5 2.2 3.8 4.5
7. SF6 2 2.15 3.6 4.2
8. SF7 2.5 2.1 3.52 4.1

Table9.3: Split tensile strength of M20 grade concrete with and without steel fiber

Where
CC – Control Concrete
SF1– 0.25 % steel fiber added concrete
SF2 – 0.5 % steel fiber added concrete
SF3 – 0.75 % steel fiber added concrete
SF4- 1 % steel fiber added concrete
SF5 – 1.5 % steel fiber added concrete
SF6– 2 % steel fiber added concrete
SF7– 2.5 % steel fiber added concrete

40
 5
4.5
Split Tensile Strength (MPa)

4
3.5
3 3 Days
2.5 7 Days
2 28 Days
1.5
1
0.5
0
0 0.5 1 2
Percentage of Fiber Added

Figure9.3: Graph showing the split tensile strength of M20 grade concrete with and without
steel fiber

The Split tensile strength of various percentage Polypropylene fiber added concrete as given by the
table9.4.

41
 Sl. no Mix Polypropylene Tensile Strength (Mpa)
fiber (%) At 3days At 7 days At 28 days
1. CC 0 1.5 1.8 3
2. PPF1 0.25 2 3.8 4.2
3. PPF2 0.5 2.2 4 4.23
4. PPF3 0.75 2.3 4.1 4.5
5. PPF4 1 3 4.5 5.2
6. PPF5 1.5 2.8 4.4 5.1
7. PPF6 2 2.72 4.32 5.02
8. PPF7 2.5 2.61 4.2 4.8

Table9.4: Split tensile strength of M20 grade concrete with and without polypropylene fiber

Where
CC – Control concrete
PPF1 – 0.25 % polypropylene fiber added concrete
PPF2 – 0.5 % polypropylene fiber added concrete
PPF3 – 0.75 % polypropylene fiber added concrete
PPF4 – 1% polypropylene fiber added concrete
PPF5 – 1.5 % polypropylene fiber added concrete
PPF6– 2 % polypropylene fiber added concrete
PPF7– 2.5 % polypropylene fiber added concrete

42
 6
Split Tensile Strength (MPa)

4
3 Days
3 7 Days
28 Days
2

0
0 0.5 1 2
Percentage of Fiber Added
Figure 9.4: Graphs shows the split tensile strength of M20 grade concrete with and without
polypropylene fiber

43
Figure 9.5: Photo views on compressive strength testing of specimens

44
Figure 9.6: Photo views on split tensile strength testing of specimens

45
Figure 9.7: Different photos views on compressive strength test

46
Figure 9.8: Different photos views on split tensile strength test

47
 CHAPTER-10

CONCLUSION

The following conclusions have been drawn based on the experimental investigation
carried out on concrete mixture.

1. Higher compressive strength is obtained for 1.5 % steel fiber and 0.5% for
Polypropylene Fiber added concrete.

2. Higher split tensile strength is obtained for 1.5 % steel fiber and 1% for
Polypropylene Fiber added concrete.

3. Concrete attained maximum compressive and split tensile strength when mixing
Minimum amount of polypropylene fiber compared to steel fiber.

48
 CHAPTER-11

REFERENCE

1. IS 10262:1982 ‘Hand Book of Concrete Mix Design’, Bureau of Indian

Standards, New Delhi
2. IS 383:2000, ‘Code of Practice for Plain and Reinforced Concrete’, (4th
Revision), Bureau of Indian Standards, New Delhi.
3. IS 383:1970, Specification for coarse and fine aggregates from natural
sources for concrete
4. IS 5816:1999 Splitting Tensile Strength of Concrete Test.
5. M.S. SHETTY (2000).,Concrete Technology, S.CHAND and Company Ltd.
M.L. GAMBHIR (1998) “Concrete Technology “, Tata McGraw-Hill
7. ACI Committee 2111, (1994) mechanical properties
and time dependent deformation of polypropylene fiber concrete. ACI
Manual of Concrete Practice.

8. ACI Committee 544, (1982) properties of concretes containing

polypropylene, steel and reengineered plastic shred fiber.

49