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CHAPTER: 3
EXPERIMENTAL PROGRAMME
3.1 GENERAL
The chapter describes the details of experimental programs for the measurements of
fresh properties, strength properties (compressive strength) and durability properties such as
Sorptivity and rapid chloride permeability of High performance concrete mixes made with
varying percentages of waste foundry sand as partial replacement of fine aggregates. The
basic tests carried out on concrete samples are discussed in this chapter, followed by a brief
description about mix deign and curing procedure adopted. At the end, the various tests
conducted on the specimens are discussed.
3.2 MATERIALS USED
3.2.1 CEMENT
Ordinary Portland Cement (OPC) Grade 53 Ultratech and Garde 43 Ultra tech was
used for casting cubes and cylinders for all concrete mixes.
The cement was of uniform colour i.e. grey with a light greenish shade and was free from any
hard lumps. It was tested as per Indian standard specification (BIS-8112:1989) for OPC 43
Grade. Test results are given in Table 3.1 as above.
Table 3.1: Physical Properties of Ordinary Portland Cement 43 grade
Physical Properties
BIS- 8112:1989
Test Results
Standard Consistency (%)
29.5
30 Min.
92
Final
600 Max
248
3 day
23
24.5
7 day
37.5
39.1
28 day
43
47.8
Specific gravity
3.15
Experimental Programme
Physical Properties
BIS- 12269:2013
Test Results
29.5
30 Min.
165
Final
600 Max
215
3 day
27
40.2
7 day
37
49.2
28 day
53
59.6
Specific gravity
3.15
Chemica
Ultatech
l Content OPC.
43 & 53
1.
CaO
58-60.6
2.
SiO2
21-22
3.
Al2O3
5.5-4.8
4.
Fe2O3
4.3-4.8
5.
MgO
0.9-1.1
6.
SO3
2.2-2.6
Experimental Programme
Observed values
Greyish White
Sub Angular
2.64
0.8
Experimental Programme
Chemical
Alccofine 1203
Metakolin
Content
Elkem Grade
920U
1.
CaO
32-34
04-0.8
0.2-1
2.
SiO2
28-32
54-54
85-97
3.
Al2O3
18-20
41-45
0.52
4.
Fe2O3
1.8-2
0.5-1
0.02-0.07
5.
MgO
8-10
6.
SO3
0.3-0.7
0.12-.2
Experimental Programme
2.2
200-350 kg/m3
Experimental Programme
> 2 to 3 hours
< 6 Hours
12000 cm2/gm
2.86 0.02
600 to 700 kg/m2
Experimental Programme
3.2.6 Metakolin
The Meta Prefix in the term is used to denote change .It is a borrowing from Greek meaning
after along with beyond .It is used and is recognizable, in the formation of compound words
metabolic, metamorphosis. The scientific use of the prefix is used for a combining form
denoting the least hydrated of a series. In the case of metakolin the change that is taking place
is de-hydroxylization brought on by the application of heat over a defined period of time.
At about 100-200 degrees C, clay minerals lose most of their absorbed water. The
temperature at which kaolinite loses water by de-hdroxilization is in the range of 500-800
degrees C. This thermal activation of a mineral is also referred to as calcining. Beyond the
temperature of de-hydroxylization kaolinite retains two- dimensional morder in the crystal
structure and the product is termed metakolin.
Experimental Programme
Generally, water that is suitable for drinking is satisfactory for use in concrete. Water
from lakes and streams that contain marine life also usually is suitable. When water is
obtained from sources mentioned above, no sampling is necessary. When it is suspected that
water may contain sewage, mine water, or wastes from industrial plants or canneries, it
should not be used in concrete unless tests indicate that it is satisfactory. Water from such
sources should be avoided since the quality of the water could change due to low water or by
intermittent tap water is used for casting.
3.2.8 ADMIXTURE
MELFLEX 2651 F is a free Flowing ,Spray dried Powder of modified
Polycaboxylic ether .Melflex 2651 F is especially optimized for plastification and water
reduction of cementitious construction material .MELFLEX 2651 F provides an excellent
development of high performance superplasticizer intended for applications where high
water reduction is required , and it has been developed for use in Self levelling underlayment
,Cementious Floor screeds Repair Mortar ,Non Shrink Grout and
, High performance
concrete. It is based on a polycarboxylic ether polymer with long lateral chains. This
mechanism considerably reduces the water demand in flowable concrete. It combines the
properties of water reduction and workability. It allows the production of high performance
concrete with highly workable and High Strength (> 100MPA). Specifications of super
plasticizer are given in Table
Table 3.8: Specifications of Superplasticizer
Basis
Appearance
Dying Loss (%)
Bulk Density(Kg/m3)
PH- Value (20OC), 20%
Solution
6.5 to 8.5
Experimental Programme
achieve high strength ,Role of w/c ratio and Agg/cement ratio are very important. But in
particularly for high strength role of aggregate / cement is more significant. As crack initiate
at the vicinity of transition Zone, it take propagate more time to join each other and capable
to more load before failure ( J.C Maso 2004)
In which with every four Cement Content with binary blending with mineral mixture like
Undensified Silica fume ,Metakolin and Alccofine 1203 with different combination of
S25(Cement +Silica fume 25%) , M25 (Cement +Metakolin 25%) , G25 (Cement + Alkofine
25%) and Ternary blending of S20M05 (Cement +Silica fume 20% +Metakolin 5%) ,
M20G05 (Cement + Metakolin 20% +Alccofine 5%) and S20G05 (Cement +Silica fume
20% +Alccofine 5%) were used
All Mix Proportions of ingredient used for the development of UHPC are shown in Table 3.8
(a d ) for four Cement content where in the OPC 53 grade and OPC 43 grade was replaced
with Silica fume ,Metakolin and Alccofine 1203 in different percentage shown in table . A
constant wokability of Mini Slump Flow of range 250-300 mm was maintained for all the
mixes by varying the superplasticiser dosage between 0.6 to 0.8 % of cementious
Table 3.9 (a) Mix proportion of trial mixes for Cementitious 900kg/m3
C1
Cement
S25
720.00
M25
720.00
G25
720.00
S20 M05
720.00
M20 G05
720.00
S20 G05
720.00
Silica
fume
Metakolin
GGBS
in kg
0.13
244.4
552
368
0.13
244.4
552
368
0.13
244.4
552
368
0.13
244.4
36.00
552
368
0.13
244.4
36.00
552
368
0.13
244.4
180.0
0
36.00
144.0
0
w/p
368
180.00
144.00
Water
552
180
144.0
0
Sand
0.5
1mm
mm
Admixtue
in %
0.60
%
0.60
%
0.60
%
0.60
%
0.60
%
0.60
%
in kg
5.4
5.4
5.4
5.4
5.4
5.4
C2
Cement
S25
840.00
M25
840.00
Silica
fume
210.0
0
Metakolin
210.00
GGBS
Sand
0.5
1mm
mm
Water
w/p
in kg
699.6
470.4
0.13
288.6
699.6
470.4
0.13
288.6
Admixtue
in %
0.70
%
0.70
%
in kg
7.35
7.35
Experimental Programme
G25
840.00
S20 M05
840.00
M20 G05
840.00
S20 G05
840.00
S60 M40
840.00
S60 M40
840.00
S40 M60
840.00
210.0
0
699.6
470.4
0.13
288.6
699.6
470.4
0.13
288.6
42.00
699.6
470.4
0.13
288.6
42.00
699.6
470.4
0.13
288.6
84.00
699.6
470.4
0.13
288.6
105.00
699.6
470.4
0.13
288.6
126.00
699.6
470.4
0.13
288.6
168.0
0
42.00
168.00
168.0
0
126.0
0
105.0
0
84.00
0.70
%
0.70
%
0.70
%
0.70
%
0.70
%
0.70
%
0.70
%
7.35
7.35
7.35
7.35
7.35
7.35
7.35
Table 3.9(c) Mix Proportion of trial Mixes for Cementitious 1475 kg/m3
C3
S25
M25
G25
S20 M05
M20 G05
S20 G05
S20 M0543+53
Cement
1180.0
0
1180.0
0
1180.0
0
1180.0
0
1180.0
0
1180.0
0
1180.0
0
Silica
fume
295.0
0
Metakolin
GGBS
0.13
206.5
383.5
0.13
206.5
383.5
0.13
206.5
383.5
0.13
59.00
206.5
383.5
0.13
59.00
206.5
383.5
0.13
206.5
383.5
0.13
59.00
236.0
0
236.0
0
w/p
383.5
295.0
0
236.00
Water
206.5
295.00
236.0
0
Sand
0.5m
1mm
m
59.00
Admixtue
in kg
in %
268.4
5
268.4
5
268.4
5
268.4
5
268.4
5
268.4
5
268.4
5
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
in kg
11.8
11.8
11.8
11.8
75
11.8
11.8
Table 3.9(d) Mix Proportion of trial Mixes for Cementitious 1501 kg/m3
C4
S25
M25
G25
S20 M05
M20 G05
S20 G05
S20 M0543+53
Cement
1201.0
0
1201.0
0
1201.0
0
1201.0
0
1201.0
0
1201.0
8
1201.0
8
Silica
fume
300.0
0
Metakolin
GGBS
0.13
310.8
207.2
0.13
310.8
207.2
0.13
310.8
207.2
0.13
60.00
310.8
207.2
0.13
60.00
310.8
207.2
0.13
310.8
207.2
0.13
60.00
240.00
60.00
w/p
207.2
300.0
0
240.0
0
240.0
0
Water
310.8
300.00
240.0
0
Sand
0.5m
1mm
m
in kg
262.4
7
262.4
7
262.4
7
262.4
7
262.4
7
262.4
8
262.4
8
Admixtue
in %
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
in kg
12.00
8
12.00
8
12.00
8
12.00
8
12.00
8
12.00
8
12.00
8
Experimental Programme
Before casting, the entire test specimen were cleaned and oiled properly. These were securely
tightened to correct dimensions before casting. Care was taken that there is no gaps left from
where there is any possibility of leakage of slurry. Careful procedure was adopted in the
batching, mixing and casting operations. The fine aggregates were weighed first with an
accuracy of 0.5 grams. The HPC mixture was prepared in Digi Mortar Mixer. Initially, fine
aggregates were mixed thoroughly by dry mixing in pan mixer. To this mixture, the cement,
First Melflex 2651 after that Silica fume, metakolin/Alkofine was added. These were mixed
to uniform colour. Then water was added carefully so that no water was lost during mixing
and admixture was added along with it. After proper mixing concrete is checked for fresh
properties, if concrete mix fulfil the workability requirements then the specimens are casted.
For each mix 32 samples were prepared, which consists of 6 cubes (70.7x70.7x70.7) for 7 ,
28 compressive strength , 6 cylinders (200x100) for RCPT and Sorptivity Test
3.4 FRESH CONCRETE TESTS
Test for Fresh Mortar/Concrete
Mortar tests are widely used to design and evaluate SCC. In fact, assessing the properties of
SCM is an integral part of SCC design [6]. EFNARC 2002 (European Federation of National
Trade Associations) [6] is the only available standard which is dedicated to special
construction chemicals and concrete systems. It describes various tests involved in mortar
tests to determine the optimum w/cm and optimum dosage of SP and VMA in mortar. They
are mini slump cone test to measure the relative slump of the mortar and mini V-funnel test to
measure the rate of flow or viscosity of the mortar. Here in our study, mini slump cone is used
to measure the spread of the mortar as described in EFNARC 2002.
Experimental Programme
Clean the funnel and bottom gate, the dampen all the inside surface including the gate. Close
the gate and pour the sample of concrete into the funnel, without any agitation or rodding,
then strike off the top with the straight edge so that the concrete is flush with the top of the
Thapar University, Patiala
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Experimental Programme
funnel. Place the container under the funnel in order to retain the concrete to be passed. After
a delay of (10 2) s from filling the funnel, open the gate and measure the time tv, to 0,1 s,
from opening the gate to when it is possible to see vertically through the funnel into the
container below for the first time. tv is the V-funnel flow time.
Experimental Programme
Tests shall be made at recognized ages of the test specimens, the most usual being 7
and 28 days. The ages shall be calculated from the time of the addition of water to the dry
ingredients.
Number of Specimens
At least three specimens, preferably from different batches, shall be made for testing at each
selected age.
Procedure
Cube specimens of size 70.06mm were cast for compressive strength as per Indian
standard specifications BIS: 516-1959. After casting, all tests specimens were finished with
steel trowel. Immediately after finishing, the specimens were covered with sheets to minimize
the moisture loss from them. Specimens were demoulded after 24-hours and then cured in
water at approximately room temperature till testing. Compressive strength tests for cubes
were carried out at 7 and 28. All the specimens were tested in an automated CTM shown in
Fig.3.7
The compressive strength was then calculated according to the formula:
=P/A
Where
Experimental Programme
Experimental Programme
I = w/Ad
w = Change in weight = W2 W1
W1 = Oven dry weight of cylinder in grams.
W2 = Weight of Cylinder after 30 min capillary suction of water in grams
A = Surface area of the specimen through which water penetrated
D = Density of water
Acceptance criteria
Laboratory Concrete
As-built Structures
Full acceptance
Conditional acceptance
Remeadial measures
Rejection
Sorptivity
<6
<9
9 to 12
12 to 15
>15
.
3.6.2 RAPID CHLORIDE PERMEABILITY TEST (ASTM C 1202)
The rapid chloride permeability test was originally developed for the Federal
Highway Administration (FHWA) by the Portland Cement Association (Whiting,1981) to
provide a rapid test method that correlated well with ponding tests, such as AASHTO T 259.
Ponding tests are considered to be the best method of determining the chloride permeability
of concrete, but they take 90 days or more to complete, making them impractical for project
quality assurance testing.Two very similar standards (AASHTO T 277 and ASTM C 1202)
describe the rapid chloride permeability test. The tests are performed using 2 in. (51 mm)
long, 3.75 in. (95 mm) diameter cylindrical specimens cut from cores obtained with a
diamond-dressed coring bit (alternatively, tests are performed using 4 in. (100 mm) diameter
cast cylinders, and the test values are normalized using the ratio of the standard to the actual
cross-sectional areas).After the curved surface of a test specimen is coated with epoxy, the
specimen is vacuum saturated with water Rapid Chloride Permeability Tests and then soaked
for 18 hours. As shown in Fig. 3.9. and Fig. 3.10. The specimen is then placed in the testing
apparatus where one end of the specimen is exposed to a solution containing sodium chloride
(NaCl) and the other end is exposed to a solution containing sodium hydroxide (NaOH). To
increase the rate of chloride penetration into the specimen, thus speeding up the test, a
constant 60 V potential is applied across the specimen. The current across the specimen is
measured at least every 30 minutes during the 6-hour test. In theory, as the chlorides
penetrate deeper into the concrete, the pore solution becomes more conductive and the
current readings
Thapar University, Patiala
Page 16
Experimental Programme
increase. In concretes with high conductivity values, however, these effects are small relative
to changes in conductivity due to temperature rise. To reduce the effects of heating and
resultant changes in conductivity over the 6-hour period of the test, its been suggested that
earlier values be adjusted to obtain an equivalent 6-hour coulomb value. For example, data
taken at 30 minutes would be multiplied by 12 to obtain an equivalent 6-hour value. Because
the test results are highly variable (as with most, if not all, penetration resistance tests), two
or three specimens are usually tested for each concrete sample. The total charge passing
through the specimen (in coulombs) is found by calculating the total area under the plot of
time versus current. Therefore, higher coulomb values at the completion of the test indicate
higher permeability. The original researchers found good correlation between the coulomb
values and the results of ponding tests performed on specimens from the same mixture for a
wide variety of concretes.
Experimental Programme
> 4000
High
2000 4000
Moderate
1000- 2000
Low
100 1000
Very Low
< 100
Negligible