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CHAPTER 3
MATERIALS AND METHODS
3.1
MATERIALS
The materials such as cement, fine aggregate, coarse aggregate,
water, fly ash and fly ash aggregates were used in the present work. The
methodology adopted for the formation of fly ash aggregates is also presented
in this chapter.
3.1.1
Cement
Ordinary Portland Cement of 43 grade confirming to IS: 8112-1989
was used for the present experimental investigation. Its specific gravity is
3.15. The cement was tested as per the procedure given in Indian Standards.
The physical properties and chemical composition are given in Table 3.1 and
Table 3.2, respectively.
Table 3.1 Physical Properties of 43 Grade Cement
S.No
Test Particulars
1
2
3
4
5
6
7
8
Fineness (m2/kg)
Initial setting time (min)
Final setting time (min)
Standard consistency(%)
Soundness (mm)
Compressive strength (MPa)3-days
Compressive strength (MPa)7-days
Compressive strength (MPa)28days
Specific gravity
Results
Obtained
310
35
360
28.0
1.0
27.0
37.0
48.0
Requirements of IS
8112-1989
Minimum 225
Minimum 30
Maximum 600
Maximum 10
Minimum 23
Minimum 33
Minimum 43
3.15
34
S.No
Compound
Results %
Requirements of IS
8112-1989
CaO
63.00
SiO2
21.10
Al2O3
6.00
Fe2O3
3.50
MgO
1.50
Maximum 6
Na2O
0.20
K2 O
0.35
SO3
2.00
Loss of ignition
2.00
Maximum 5
10
Insoluble residue
0.30
Maximum 2
3.1.2
Fine Aggregate
Natural river sand with fraction passing through 4.74 mm sieve and
retained on 600 sieve was used and tested as per IS:2386. The fineness
modulus of sand is 2.68 with a specific gravity of 2.66. The physical
properties are presented in Table 3.3. River sand confirms to grading zone II
of IS: 383-1970.
Table 3.3 Physical Properties of Fine Aggregate
S.No
Test Particulars
Results Obtained
Specific gravity
2.66
1808
Size (mm)
Fineness Modulus
Below 4.75
2.68
35
3.1.3
Coarse Aggregate
Hard broken granite stone (HBG) coarse aggregates confirming to
3.1.4
Test Particulars
Results Obtained
Shape
Angular
Specific gravity
2.71
1685
Size (mm)
24.94
23.86
4.75 to 20
Water
Potable tap water available in the laboratory with pH value of 7.0
1 and confirming to the requirements of IS: 456-2000 was used for mixing
concrete and curing the specimens as well.
3.1.5
Fly Ash
Fly ash (Class F) obtained from Mettur Thermal Power Station
36
World
Std. (%)
Silica
SiO2
62.57
54.92
Alumina
Al2O3
31.45
23.04
Ferric Oxide
Fe2O3
1.87
Titanium Dioxide
TiO2
1.45
Manganese Oxide
MnO
0.005
Calcium Oxide
CaO
0.40
3.84
Magnesium Oxide
MgO
0.38
2.82
Sodium Oxide
Na2O
0.05
Potassium Oxide
K2 O
0.82
Iron
Fe2O
6.62
Phosphorus
P2 O 5
0.30
2.70
SO3
0.76
Magnesium oxide
MgO
2.82
Loss on Ignition
LOI
1.00
2.88
3.1.6
aggregates. Water is the binding material that paves the way for the function
of the aggregate with good bonding (Khaled Ramadan et al 2007).
37
3.1.6.2
concrete mixer. Water was added to the mix by adopting the water cement
ratio of 0.3. The contents were thoroughly mixed in the drum until the
complete formation of fly ash aggregates. This method of formation of fly ash
aggregates is called pelletisation. The fly ash aggregates are shown in Figure 3.1.
to dry for a day. Then the aggregates were cured in a water tank for 7 days.
3.1.6.5
based on size of pellets as shown in Figure 3.2. The aggregates having size
38
less than 4.75 mm were sieved as fine aggregates and size more than 4.75 mm
were sieved as coarse aggregate. From them 20 mm size coarse aggregates
were sieved separately to use them as coarse aggregates. The physical
properties of fly ash fine aggregate (FFA) and fly ash coarse aggregate (FCA)
are given in Tables 3.6 and 3.7, respectively. The grading curves for
conventional fine aggregate (CFA) and fly ash fine aggregate are shown in
Figure 3.3. The grading curves for conventional coarse aggregate (CCA) and
fly ash coarse aggregate are shown in Figure 3.4.
S. No
1.
2.
3.
4.
Test Particulars
Specific gravity
Bulk density (Kg/m3)
Size (mm)
Fineness Modulus
Results
Obtained
1.28
838
Below 4.75
2.70
S. No
1.
2.
3.
4.
5.
6.
Test Particulars
Shape
Specific gravity
Bulk density (Kg/m3)
Size (mm)
Crushing value (%)
IMPact Value (%)
Results
Obtained
Spherical
1.3
913
4.75 to 20
25.6
21.6
39
Figure 3.3
Figure 3.4
40
3.2
MIX PROPORTIONING
The procedure for mix proportioning is to combine different
20 MPa was developed. The mix design was carried out based on IS 10262 1982. The mix design procedure and the mix design are presented in
Appendix 1. The mix proportion and quantity of materials taken for one cubic
meter are given in Table 3.8.
3.2.2
41
The trial mixes have been made and the quantity of materials taken
for one cubic metre have been presented in Table 3.8.
Table 3.8 Materials Required Per m3 of Concrete
S.No
Mix Details
Cement
(Kg)
FA
(Kg)
FFA
(Kg)
CA
(Kg)
FCA
(Kg)
WATER
(Kg)
M1
Control
416
636.95
1112.97
208
M2
10:90
257
396
691
123
M3 12.5:87.5
257
396
691
123
M4
257
396
691
123
M5 17.5:82.5
257
396
691
123
M6
257
396
691
123
M7 22.5:77.5
257
396
691
123
3.2.3
15:85
20:80
and Vee bee Time test were conducted on fresh concrete as per IS
specification and presented in Table 3.9.
3.2.4
Slump Test
The slump test was conducted as per Indian Standards. A mould of
300 mm high frustum of a cone was placed with levelled surface. The
concrete was filled with three layers, each layer was tamped 25 times with a
16 mm diameter steel rod with a rounded nose. The top was struck off
level and the mould held firmly against the slab base. The mould was
lifted gently, the decrease in height of the concrete was measured.
(Gao Li-Xiong et al 2004).
42
3.2.5
coMPacting factor test apparatus. The top hopper was gently filled with
concrete and the bottom hopper was kept closed. The top hopper was opened
and the concrete fell from the upper hopper into the lower one. Then the
lower hopper was opened and the concrete fell from the lower hopper into the
mould (Aggarwal et al 2007).
The degree of coMPaction was calculated using the following
formula:
Compaction Factor CF
3.2.6
apparatus with standard specification. The time required for the complete
remoulding of concrete was measured.
Table 3.9 Workability of Fly Ash Aggregate Concrete Mixtures and
Control Concrete
S.No
Mix details
1
2
3
4
5
6
7
M1 Control
M2
10:90
M3 12.5:87.5
M4
15:85
M5 17.5:82.5
M6
20:80
M7 22.5:77.5
Slump (mm)
60
70
76
80
84
87
90
Workability
Compaction
Factor
0.80
0.86
0.88
0.90
0.91
0.91
0.93
Vee-Bee Time
(Sec)
25
18
16
14
13
12
11
43
3.3
compressive strength, split tensile strength and Flexural strength have been
studied in this chapter.
3.3.1
516-1959. All the specimens were tested in saturated surface dry condition,
after wiping out the surface moisture. For each mix, six identical specimens
were tested at the age of 1 day, 3 days, 7 days, 14 days, 28 days, 56 days and
90 days. The test was conducted in 120 tonne compression testing machine.
The load was applied at the rate of 140kg/cm2/min until the failure of the
specimen. The maximum load applied to the specimen until failure was
recorded. The ultimate load divided by the cross sectional area of the
specimen is equal to the ultimate cube compressive strength.
3.3.2
days, 7 days, 14 days, 28 days, 56 days and 90 days for the 150 mm diameter
and 300 mm high cylinder specimen using 120 tonne compression testing
machine according to Indian Standard specifications.
3.3.3
cylindrical specimens. Splitting 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 1200 kN compression testing machine as per
IS: 5816-1970. To avoid the direct load on the specimen, the cylindrical
44
specimens were kept in between the wooden strips. The load was applied
gradually till the specimen fails and the readings were noted. The splitting
tensile strength has been calculated using the relationship
ft =
2P
DL
Where,
ft = Splitting tensile strength of concrete in MPa
P = Load at failure in Newton
D = Diameter of the cylinder = 150 mm
L = Length of cylinder = 300 mm
3.3.4
days on the 100 mm x 100 mm x 500 mm prism specimen using 120 tonne
capacity Flexural Strength Testing Machine by subjecting the specimen to
two point loading to determine the flexural strength as per IS: 516-1959. The
flexural strength has been calculated using the formula
fr = PL/BD2
Where,
fr
= Span in mm
45
3.3.5
for the 150 mm diameter and 300 mm high cylinder specimen using 1200 kN
compression testing machine as per standards. The modulus of elasticity has
been calculated from stress strain graph of various fly ash aggregate concrete
mixtures.
3.3.6
which it has been designed over a period of years without any deterioration.
Hence the production of fly ash aggregate concrete involves appropriate
selection and proportioning of the constituents to produce a composite mainly
characterised by its low porosity and pore structure.
46
W2 W1
x100
W1
Where,
W1 = Weight of specimen after drying at oven temperature of 105 C
W2 = Weight of specimen at saturated condition (saturated weight).
The test is shown in Figures 3.5 and 3.6
47
Sorptivity Test
The sorptivity test was conducted on 150 mm x 150 mm x150 mm
cubes. The sorptivity measures the rate of penetration of water into the pores
in the concrete by capillary suction. Taken that the cumulative volume of
water that has penetrated per unit surface area of exposure is plotted against
48
the square root of time t, the resulting graph that could be approximated by a
straight line is considered as a measure of rate of movement of water through
the capillary pores and is called sorptivity. The sorptivity test was conducted
on cubes by immersing them in water and measuring the gain in mass at
regular interval of 30 minutes duration over a period of 2 hours.
The test is shown in Figures 3.7 to 3.12
49
50
51
3.4.3
52
3.4.4
per ASTMC 1202. The test method consists of monitoring the amount of
electrical current passed through 51 mm thick slices of 102 mm nominal
diameter of cylindrical specimens for duration of 6 hours. The total charge
passed during this period was calculated in terms of coulombs using the
trapezoidal rule as given in ASTMC 1202. The charge passed (Q) was
calculated by the following formula.
Q = 900 (I0 + 2I30 + 2I60 + . +2I330 + I360)
Where,
Q = Charge passed (Coulombs)
I0 = Current (amperes) at t minutes after voltage is applied.
The RCPT test set up is shown in Figure 3.14 and 3.15.
53
resistance test. The cubes were cast, demoulded after 24 hours and immersed
in water for curing till the time of testing. After the end of the curing period
the cubes were weighed (W1) and immersed in 1% diluted sulphuric acid
solution and 3% sodium chloride solution for acid resistance test. The cubes
were taken outside and weighed (W2) after 45 days. The percentage loss in
weight was calculated.
Percentage of losses = W1 W2 x 100
W1
Where,
W1 = Weight of cubes before immersion in solution
W2 = Weight of cubes after immersion in solution.
The test is shown in Figures 3.16 and 3.17
54
Carbonation Test
The carbonation test was carried out on 100 mm x 100mmx100 mm
cubes. The cubes were cast, demoulded and cured. After curing the cubes
were air dried. Then they were kept in air tightened box. The CO 2 gas was
passed into the box continuously for 10 hours and 20 hours. The depth of
55
carbonation and pH values were determined after 10 hours and 20 hours. This
test was conducted to evaluate depth upto which the concrete has become
virtually acidic. The following method was adopted.
A pH indicator solution of phenolphthalein in dilute alcohol was
sprayed on a fresh concrete surface.
The pH indicator changes color according to the alkalinity of
concrete.
As pH value decreases from 10.0 to 8.2 and below, the indicator
changes from dark pink to colorless.
The test is shown in Figures 3.18 and 3.19.
56
3.4.7
considerable importance. The bond strength arises primarily from the friction
and adhesion between concrete and steel. The bond strength of concrete is a
function of compressive strength and is approximately proportional to the
compressive strength upto about 20 MPa. Debonding of concrete cover may
lead to loss of confinement and reduction of bond strength at interfacial zone
between the two materials.
Pull out measures the force required to pull out from the concrete, a
rod which has been cast into that concrete. The stronger the concrete, the
more is the force required to pull out. (Yun Bai et al 2004).
The concrete cubes of size 150 mm were cast with an 8 mm
diameter steel rod inserted for a height of 75 mm inside the concrete and
projecting above the concrete.
Pull out test was conducted in a Universal Testing Machine (UTM)
of 600 KN capacity, as per IS: 2770 (Part I -1967). Test specimens consist of
concrete cubes of size 150 mm with an 8 mm diameter steel bar embedded
vertically along a central axis in each specimen. The bar projected down for
distance of about 75mm from the bottom face the cube as cast. The concrete
specimen was mounted in Universal Testing Machine (UTM) in such a
manner that the bar was pulled axially from the cube. The load was applied to
the reinforcing bar at a rate not greater than 2250 kg/min. The slip at the
loaded end of the bar and the maximum pull was noted.
The test is shown in Figure 3.20
57
58
MICROSTRUCTURE
OF
FLY
ASH
AGGREGATE
CONCRETE
Microstructure of fly ash aggregate concrete was studied by using
scanning electron microscopy (SEM) and XRF analysis for the specimen
mixes corresponding to compressive strength, corrosion, acid resistance and
carbonation.
3.6
proportions has been worked out following the prevailing schedule of rates
and compared with control concrete. The cost details are presented in
Appendix 3.