50

CHAPTER 3

MATERIALS FOR EXPERIMENTAL INVESTIGATION

3.1 GENERAL

This chapter profoundly discussed the materials to use in

experimental analysis to build lightweight concrete. The concrete that will be
considered is Lightweight concrete for infill in steel tubes. In the construction
of elevated structures and long-navigate structures, the use of steel-concrete
composite areas, for instance, Concrete-Filled Steel Tube (CFT) and
Concrete-Encased Steel (CES) segments have been made. An increase of
corrosion, as well as fire-resisting, is an addition advantage of the concrete
element. Experimental investigation on concrete cube and cylinder are
utilized to analyze the properties of the concrete.

3.2 MATERIALS

Before testing the concrete structure the mechanical properties of

the particular steel and concrete were tried by the corresponding standard
technique. The names of materials are utilized through this examination and
their exhibitions are recorded in this area. The assets are

• Steel material
• Ordinary Portland cement
• Lightweight Fine and Coarse Aggregate
• Water content
• Steel Material
 51

3.2.1 Steel Material

The Global Minerals Group was framed with a small group inside
Tata Steel with a clear mandate to examine the world mineral guide and
recognize resources in the steel-production crude material - Iron Ore, Coal,
Limestone, and so forth (Zheng also, Wang 2017). Other than the steel, the
concrete material additionally has an important commitment to deciding the
panel’s performance. Young’s modulus of the Tata steel material is in the scope
of 310000Mpa and density as 7850 Kg/m3. The inner concrete can upgrade the
strength and stability of the steel tube specimen appeared in Figure 3.1. Direct
strength tests of composite tubes are expected to give reliable data on
mechanical behavior and quality for those tube geometries. Inserting i-steel
inside the component can influence it to keep on playing a strong load-bearing
part after the loss of bearing capacity of the outside steel pipe.

Figure 3.1 Steel Specimen

Benefits

• Availability of different thickness and width mix test

endorsements with mechanical properties
• Customer engagement as well as information sharing
developer.
 52

• The close dimensional resistances of as-welded tubing permit

its utilization for mechanical parts with negligible downstream
processing.
• Because it experiences less processing than different kinds of
mechanical tubing, as-welded tubing can give cost preferences
to less-requesting applications.

3.2.2 Ordinary Portland Cement (OPC53 grade)

OPC is the fundamental type of concrete with 95% of it being

clinker and 5% being gypsum which is added as an added substance to
improve the setting time of the concrete. Gypsum controls the beginning of
the setting time of the cement. 53 Grade concrete (Figure 3.2) achieves higher
early strength when contrasted with some other grade of cement but since of
early pickup, does not build significantly following 28 days. In addition,
because of faster hydration process, the cement discharges heat of hydration
at a considerably faster rate at first and thusly, the chances of microcracking
of concrete are substantially more noteworthy (Sangita Bhamere 2016).

The physical as well as the chemical characteristic of OPC 53

Grade Deccan Cement easily outperforms the stringent measures determined
by Bureau of Indian Standards (BIS), including compressive strength which is
surprisingly higher than the endorsed guidelines. OPC of 53 grades was
utilized and tested for physical and chemical properties and observed to adjust
to different particulars according to 12269-1987. Specific gravity ->3.10,
Normal consistency ->30%, Initial setting time ->38min
 53

Figure 3.2 Sample for OPC53 grade

Properties of 53 grade Cement

• Fineness value is not under 225m/kg

• Expansion estimation of un aerated cement is not more than
10 mm also when tested via autoclave strategy not be over
0.8%.
• The specific gravity of the cement as 3.15
• Initial setting time is not under 30 minutes in addition to Final
setting time not is over 600 minutes.

Advantages

• Superior quality guarantees significant reserve funds in

cement utilization
• Development of high compressive strength in beginning times
helps in early de-shuttering.
• The thick and minimum permeable concrete avoids leakage
/drainage issues.
• Its high fineness offers better workability for a given water
cement proportion guaranteeing extremely dense, minimized
and durable concrete.
 54

3.2.3 Fine Aggregate

As indicated by the Indian Standards natural sand is a type of silica

(SiO2) passing particle size maximum 4.75mm was utilized as fine aggregate
(Figure 3.4 (a)). The minimum particle size of the fine aggregate is 0.075mm.
At the point, when the aggregate is sieved through 4.75mm siever, the
aggregate passed through it called as fine aggregate (Pedro, D., et al. 2017).
Natural sand is normally utilized as a fine aggregate; silt and clay are
additionally gone under this type. It is framed by deteriorations of sandstones
because of different weathering activities. Fine aggregate avoids shrinkage of
the mortar and concrete (Mishra, R. K., et al. 2016). The measures of fine
aggregate having the 300 µm (No. 50) and 150, µm (No. 100) sifters
influence workability, surface, air substance, along with bleeding of concrete.
Most details permit 5% to 30% to pass the 300 µm sieve. For simple placing
conditions or the mechanically finished concrete like pavements, the lower
limit may be sufficient. Figure 3.3 explains the particle size distribution of
fine aggregate.

Table 3.1 Fineness Modulus of Fine Aggregate

Cumulative
Weight
% of weight %
Sieve size retained on % of passing
retained of weight
sieve (grams)
retained
4.75 mm 12 1.2 1.2 98.8
2.36 mm 22 2.2 3.4 96.6
1.18 mm 141 14.1 17.5 65.0
600 µm 318 31.8 49.3 50.7
300 µm 411 41.1 90.4 9.6
150 µm 83 8.3 98.7 1.3
Pan 13 1.3 - -
 55

Dry weight of sample Aggregate: 1000 grams

Cumulative percent retained= 100  

Cum mass

 weight of sample 

Fineness Modulus of Aggregate as

 Sum of cum percent retained  260.5

  = =2.605
 100  100

Figure 3.3 Particle Size Distribution of Fine Aggregate

3.2.4 Coarse Aggregate

The LW coarse aggregate of 12mm sieve 10 mm retained rounded

obtained from the local crushing plant; is utilized as a part of the analysis. As
per the Indian Standards, a crushed angular aggregate which goes through 20
mm IS sieve and altogether hold on 10 mm IS sieve (Figure 3.4 (b)). The
specific gravity and fineness modulus of coarse aggregate was 2.67 and 6.8
respectively. Some coarse aggregate particles may glide on the water, though
 56

material passing a sieve (0.015 mm) may have a relative density moving
toward that of normal weight sand. It is the volume possessed by each part
and not the heaviness of material held on each sieve that decides the void
substance and impacts the workability of the concrete.

(a) Fine (b) Coarse

Figure 3.4 Sample Aggregates

Purpose of Aggregate

The expansive, strong coarse aggregate particles shape the

fundamental structural members from the concrete (Pedro et al. 2017). The
voids between the smaller particles are filled by still smaller particles. At last,
the voids between the littlest coarse aggregate particles are filled by the
biggest fine aggregate particles also the properties appeared in Table 3.2. In
spite of the fact, that aggregates are most ordinarily known to be inert filler in
concrete, the different properties of aggregate have a great impact on the
strength, durability, workability, and economy of concrete. These diverse
properties of aggregate allow creators and temporary workers the most
adaptability to meet their design as well as construction necessities.
 57

Table 3.2 Properties of Aggregate

Properties Fine aggregate Coarse aggregate

Size (mm) 4.75< >4.75
Specific Gravity
2.65 2.67
(kg/m3)
Density (kg/m3) 1.44 1.60
Water Absorption 1.85 0.63
Fineness Modulus 2.60 6.8

3.2.5 Water Content

In concrete mix design, the proportion of the measure of water to

the measure of cement utilized (both by weight) is known as the Water to
Cement proportion (W/C). Convenient water is considered for mixing and
curing concrete. According to IS 456:2000, water utilized for both mixing and
curing should be free from damaging measure of malicious materials.

3.2.6 Structural Lightweight Concrete

A wetting prior to use to accomplish the high level of saturation

will generally need for the lightweight aggregates. The underlying utilization
of structural lightweight concrete is to diminish a dead load of a concrete
structure. Applying the huge size lightweight aggregate with lower strength
results into a lower quality of the lightweight concrete; along these lines, the
greatest size of the lightweight aggregate must be constrained to 25 mm at
most. Lightweight aggregates reasonable for structural concrete might be
natural materials, for example, pumice or scoria, or they might be prepared
aggregates, for example, extended shale's, muds, slates, and slags (Rassouli, B
et al. 2016). More permeable than normal weight particles, lightweight
 58

aggregates that are not pre-soaked will ingest the water in the concrete blend.
If the aggregate particles in lightweight concrete are legitimately pre-wetted,
then the concrete behaves like normal weight concrete.

Advantages of LWC

• Economical as far as transportation and also lessening in

manpower
• Rapid and generally simple construction.
• The utilization of LWC has some of the time made it's
conceivable to continue with the design which generally
would have been relinquished due to excessive weight. In
frame structures, significant reserve funds in cost can be
achieved by utilizing LWC for the construction floors,
segment, and an outer cladding.
• Reduction of general weight results sparing auxiliary edges,
footings or piles.
• Reduction of dead load, quicker building rates and lower haulage
and dealing with costs. The eight of the working in term of the
loads transmitted by the establishments is an essential factor in
design, particularly for the instance of tall structures.
• Has better nailing as well as sawing properties.

3.3 EXPERIMENTAL PROCEDURE

In this examination Concrete mix proportion for was acquired

based on the rules as indicated by Indian Standard particulars (IS: 456-2000
and IS: 10262-1982). The experimental examination on various concrete
blends is finished by the rate of various proportions like M20, M30 and M40 are
considered for dynamic behavior analysis. Physical, chemical properties
regarding OPC 53 grade and fine aggregate and there are no much deviations
 59

for supplanting each other. Generally, cement has surfaced as an imperative

material, in the creation of concrete which goes about as a cover to tie all the
aggregate together in construction work. Experimental examinations were
completed to examine the flexural behavior of the proposed concrete-filled
steel tube. In this investigation, the concrete cube and cylinder are utilized to
dissect their compressive strength (CS), Tensile strength (TS) of concrete
examined for 7 days and 28 days the optimum dosage of replacement of
materials. In this situation, lightweight aggregate has been supplanted with
coarse aggregate by its volume premise since the density of every material
isn't the same and it isn't conceivable to supplant by its weight basis.

3.4 MIX DESIGN FOR EXPERIMENTAL MODEL

Mix Design is a procedure of choosing reasonable fixing materials

of concrete and deciding their relative extents as financially as conceivable
that would fulfill the desired properties of fresh and hardened concrete too.
For blend configuration reason, the total information of the different
properties of the fixing materials and the conditions at the site ought to be
known already. Our analysis considers diverse blend M20, M30 and M40 (table
3.3 and 3.4) for examining the CS and TS parameters. The way toward
choosing reasonable elements of concrete and deciding their relative amounts
with the target of creating a concrete of the required, strength, durability, and
workability as economically as possible, is named the concrete mix design. In
these blends, the performance of the concrete is indicated by the designer yet
the blend extents are controlled by the maker of concrete, with the exception
of that the minimum cement substance can be set down. This is the most
reasonable way to deal with the choice of blend extents with particular
materials having pretty much extraordinary attributes. The proportioning of an
ingredient of concrete is administered by the required execution of concrete in
2 states, specifically the plastic as well as the hardened states.
 60

Mix Design for M20 Grade

Cement Content = 380 kg

Water Cement ratio = 0.50
Volume of Water = 190 litre
Fine Aggregate to Coarse Aggregate ratio = 38:62
Total Coarse Aggregate = Crushed Granite Aggregate
(CGA) and
Lightweight Aggregate (LWA)
CGA to LWA ratio = 30:70
Specific Gravity of Fine Aggregate (SFA) = 2.67
Specific Gravity of CGA = 2.60
Specific Gravity of LWA (Crushed Coconut Shell)= 1.15
Specific Gravity of Cement (Sc) = 3.15
Maximum Size of CGA = 20 mm
Maximum Size of LWA = 12 mm
Volume of total aggregate V= [{w + (C / Sc)} + (FA / SFA) + (CA / SCA)] x (1
/ 1000) Volume of total aggregate V= 689
Volume of Fine Aggregate = 262
Volume of Coarse Aggregate = 427
Volume of CGA = 128
Volume of LWA = 299
Quantity of FA Required = 262 x 2.67 = 699 kg
Quantity of CGA Required = 128 x 2.60 = 333 kg
Quantity of LWA Required = 299 x 1.15 = 344 kg
Density of Concrete = 1940 kg/m3
 61

Table 3.3 LWC Mix proportion for different grades

Density of
Cement FA LWA CGA Water
Grade Concrete
(kg/m3) (kg/m3) (kg/m3) (kg/m3) (kg/m3)
(kg/m3)

M20 380 699 344 333 190 1940

M30 430 684 336 325 190 1960

M40 500 660 325 315 190 1980

Table 3.4 Mix proportion based on materials

Grade/ Materials M20 M30 M40

Cement 1 1 1

Fine Aggregate 1.84 1.59 1.32

Coarse Aggregate 1.78 1.54 1.28

w/c ratio 0.50 0.44 0.38

The quantity of fine in addition to coarse aggregate the specified

maximum size of aggregate of 20 mm, the amount of entrapped air as a
percentage of the volume of concrete is 2%.

3.5 COMPRESSIVE STRENGTH OF THE CONCRETE

The compressive strength of concrete relies upon many factors, for

example, water-cement proportion, cement strength, nature of the concrete
material, in addition to quality control at the time of production of concrete
and so forth (Wang also, Park 2017). Test for compressive quality is done
either on cube appeared in Figure 3.5. Different standard codes prescribe
 62

concrete cylinder or concrete cube as the standard example for the test.
Concrete is poured in the shape and tempered legitimately so as not to have
any voids. 24 hours later, these molds are expelled and test examples are
placed in water for curing.

Figure 3.5 Experimental setup for cube

The top surface of this specimen ought to be made even as well as

smooth. These specimens are tested by compression testing machine
following 7 days curing, 28 days curing and 56 days curing. Load ought to be
connected at the rate of 140 kg/cm2 per minute till the Specimens comes up
short. Load at the failure stage, separated by a region of specimen gives the
compressive strength of concrete.

3.6 TENSILE STRENGTH OF THE CONCRETE

Test data attained from the split tensile test. The split tensile
strength of various cylinders was tested following 7 and 28 days of curing.
The chambers were tested (Figure 3.6) on compression testing machine when
loaded in split tensile testing get together under consistently increasing the
load (Zhao et al. 2016). The cylinder mold is of metal, 3mm thick. Each mold
is fit for being opened longitudinally to encourage the expulsion of the
 63

specimen and is furnished with methods for keeping it shut while being used.
While compacting by hand, the standard packing bar is utilized and the stroke
of the bar ought to be dispersed in a uniform way.

Figure 3.6 Experimental setup for Cylinder

Purpose and Advantages of Compression and Tensile Tests

• The objective of a compression test is to decide the behavior

or reaction of a material while it encounters a compressive
load by estimating key factors, for example, strain, stress, and
distortion.

• By testing material in compression the compressive strength,

yield strength, extreme strength, flexible farthest point, and
the elastic modulus among different parameters may all be
resolved.

• The setting of the material in tension distinguishes the

Young's Modulus of the material: the measure of extends in
the material for a particular measure of applied pressure.

• Ultimate Tensile Strength (UTS), this will disclose to you the

most extreme pressure apply to the material before the failure
happens. At the point, when the concrete sets and hardens
 64

around the bars, the reinforced concrete confronts pressure

along with compression.

• The concrete gives the compressive strength, and the steel

gives the tensile strength. Steel is utilized for the
reinforcement since it grows and contracts in heat and cold
nearly an indistinguishable route from concrete, which implies
it won't spoil the concrete by extending at an alternate rate.

3.7 SUMMARY

This chapter described the properties of materials which have been

used to prepare concrete as lightweight with mixing design materials. And
also clearly about the testing arrangements of the specimens (cube and
cylinder) and required materials used for making high strength concrete.