Project data

INTRODUCTION

CHAPTER-1

INTRODUCTION

1.0 General

Currently India has taken a major initiative in developing the infrastructures such as express

highways, Power projects, Industrial structures, Bridges and Tunnels etc., to meet the

requirements of globalization, in the construction of buildings and other structures Concrete

plays a rightful role and a large quantum of concrete is being utilized. River sand, which is one

of the constituents used in the production of conventional concrete, has become highly expensive

and also scarce. In the backdrop of such a bleak atmosphere, there is large demand for alter

native materials from industrial waste.

The consumption of cement content, workability, Compressive strength and cost of

concrete made with quarry dust were studied by researchers Babu K.K, Nagraj T.S,

Narasimahan. The Mix design proposed by Nagaraj shows the possibilities of ensuring the

workability by wise combination of rock dust and Sand, use of super plasticizer and optimum

water content using generalized lyse rule. Sahu A.K reported significant increase in compressive

strength, modulus of rupture and split tensile strength when 40 percent of sand is replaced by

quarry rock dust in concrete. Ilangovan and Nagamani reported that Natural sand with quarry

dust as full replacement in concrete as possible with proper treatment of Quarry dust before

utilization.

The utilization of quarry rock dust which can be called as manufactured sand has been

accepted as building material in the industrially advanced countries of which West for the past

there decades. As a result of sustained research and development works under-taken with respect

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to increasing application of this industrial waste. The level of utilization of Quarry rock dust in

the industrialized nations like Australia, France, Germany and UK has been reached more than

60% of its total production. The use of manufactured sand in India has not been much, when

compared to some advanced Countries.

1.1 Introduction to Ordinary Portland Cement (OPC)

Ordinary Portland cement (OPC) is the most important type of cement. Prior to 1987,

there was only one grade of OPC governed by IS269-1976. After 1987, higher grade cements

were introduced in India and OPC was classified into three grades, namely 33 grade, 43 grade

and 53 grade depending upon its strength at 28 days when tested as per IS 4031-1988. The 28

days strength shall be not less than 33 N/mm2, 43 N/mm2, 53 N/mm2 respectively for 33, 43 and

53 grades of cements. But the actual strength obtained by these cements at the factory are much

higher than the BIS specifications.

It has been possible to upgrade the qualities of cement by using high quality limestone,

modern equipments, and closer on line control of constituents, maintaining better particle size

distribution, finer grinding and better packing. Generally use of high grade cement offers many

advantages for making stronger concrete. Although they are little costlier than low grade cement,

they offer 10-20% saving in cement consumption directly besides several other hidden benefits.

One of the most important benefits is the faster rate of development of strength. In the modern

construction activities, higher grade cements have become so popular that 33 grade cement is

almost out of the market.

The manufacture of OPC is decreasing all over the world in view of the popularity of

blended cement on account of lower energy consumption, environmental population, economic

and other technical reasons. In advanced western countries, the use of OPC is as low as 40% of

the total cement production. In India for the year 1998-99 out of the total cement production i.e.,

79 million tons, the production of OPC in 57.00 million tons i.e., 70 %. The production of PPC is

16 million tons i.e., 19% and slag cement is 8 million tons i.e., 10%. In the years to come the use

of OPC still come down, but it will remain as an important type of cement for construction

purposes.3

1.2 Introduction to Quarry Stone Dust

Quarry Stone dust aggregates are a byproduct of the Coarse aggregates like 40mm, 20mm

etc. It is in the form of a poorly graded aggregate with the mixture of Stone powder and small

particles of Stones. It is considered as waste materials of the quarries and are left and dumped as

waste. The Quarry stone dust is collected from a locally available quarry near Himayath sagar

dam.

1.3 Introduction to Fly Ash

Fly ash is one of the numerous substances that cause air, water and soil pollution, disrupt

ecological cycles and set off environmental hazards. The combustion of powdered coal in

thermal power plants produces fly ash. The high temperature of burning coal turns the clay

minerals present in the coal powder into fused fine particles mainly comprising aluminium

silicate. Fly ash produced thus possesses both ceramic and pozzolanic properties. When

pulverised coal is burnt to generate heat, the residue contains 80 per cent fly ash and 20 per cent

bottom ash. The ash is carried away by flue gas collected at economiser, air pre-heater and ESP

hoppers. Clinker type ash collected in the water-impounded hopper below the boilers is called

bottom ash. The process of coal combustion results in fly ash. The problem with fly ash lies in

the fact that not only does its disposal require large quantities of land, water, and energy, its fine

particles, if not managed well, by virtue of their weightlessness, can become airborne. Currently,

90 million tonnes of fly ash is being generated annually in India, with 65 000 acres of land being

occupied by ash ponds. Such a huge quantity does pose challenging problems, in the form of

land usage, health hazards, and environmental dangers. Both in disposal, as well as in utilization,

utmost care has to be taken, to safeguard the interest of human life, wild life, and environment.

1.3.1 Fly ash use in Concrete:

Past research proved better performance characteristics, in response of fly ash concrete,

in terms of durability of concrete almost unanimously across the globe. The improvement in the

gel structure caused by pozzalanic action of fly ash leads to a very impervious concrete. This

factor improves the resistance of concrete against external aggression. Fly ash, an environmental

hazard, can be consumed constructively and thus contribute to the ecological balance by

effectively using it in concrete. As a partial replacement to cement, fly ash is very energy

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efficient and also contributes to economy resulting in large financial savings. Typically, concrete

made with fly ash will be slightly lower in strength than straight cement concrete up to 28 days,

equal strength at 28 days, and substantially higher strength within a year’s time. Thus, fly ash

concrete achieves significantly higher ultimate strength than can be achieved with conventional

concrete.

1.3.2 Physical requirements for Fly ash:

a) Fineness - Specific surface in m2/kg by Blaine’s permeability method, min 320

b) Particles retained on 45 micron IS sieve (wet sieving) in percent, Max 34

c) Lime reactivity - Average compressive in N/mm2, Min 4.5

d) Compressive strength at 28 days in N/mm2, Min Not less than 80 percent of the strength

of corresponding Plain cement mortar cubes

e) Soundness by autoclave test expansion of specimens, percent, Max 0.8

f) Specific gravity - 1.90-2.55

1.3.3 Benefits/Advantages of use of Fly ash in Concrete:

1. Enhances Concrete Workability: The “ball-bearing” effect of fly ash particles creates a

lubricating action when concrete is in its plastic state. This creates benefits in:

a) Ease of Pumping: Pumping requires less energy and longer pumping distances are

possible.

b) Improved Finishing: Sharp, clear architectural definition is easier to achieve, with less

worry about in-place integrity.

c) Reduced Bleeding: Fewer bleed channels decrease permeability and chemical attack.

Bleed streaking is reduced for architectural finishes.

d) Reduced Segregation

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2. Increasing Concrete Performance: In its hardened state, fly ash creates additional benefits for

concrete, including:

a) Higher Strength: Fly ash continues to combine with free lime, increasing

compressive strength over time.

b) Decreased Permeability: Increased density and long term pozzolanic action of fly ash,

which ties up free lime, results in fewer bleed channels and decreases permeability

c) Increased Durability: Dense fly ash concrete helps keep aggressive compounds on the

surface, where destructive action is lessened. Fly ash concrete is also more resistant to

attack by sulfate, mild acid, soft (lime hungry) water, and seawater.

d) Reduced Sulfate Attack: Fly ash ties up free lime that can combine with sulfates to

create destructive expansion.

e) Reduced Corrosion: By decreasing concrete permeability, fly ash can reduce the rate

of ingress of water, corrosive chemicals and oxygen — thus protecting steel

reinforcement from corrosion and its subsequent expansive result. .

f) Reduced Efflorescence: Fly ash chemically binds free lime and salts that can create

efflorescence, and dense concrete holds efflorescence producing compounds on the

inside.

g) Reduced Shrinkage: The largest contributor to drying shrinkage is water content. The

lubricating action of fly ash reduces water content and drying shrinkage. .

h) Reduced Heat of Hydration: The pozzolanic reaction between fly ash and lime

generates less heat, resulting in reduced thermal cracking when fly ash is used to

reduce Portland cement.

i) Reduced Alkali Silica Reactivity: Fly ash combines with alkalis from cement that

might otherwise combine with silica from aggregates, causing destructive expansion.

j) Increased Resistance to Freezing and Thawing

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3. Environmental Benefits:

a) Conserves natural resources: Using recovered fly ash conserves natural resources by

eliminating the need to produce new raw materials. .

b) Conserved Landfill Space: Conserving landfill space by utilizing fly ash is an obvious

environmental benefit. Just 1 ton of fly ash use avoids landfill requirement corresponding

to 455 days of solid waste produced by an average American.

c) Reduces greenhouse gas emission: Fly ash use can also significantly decrease greenhouse

gas emissions. When fly ash is used to replace cement, it reduces the need for cement

production - a highly energy-intensive process that also creates significant amounts of

greenhouse gases.

1.4 Scope for the Present Study

The present work is intended to study and compare the properties of the concrete for two

different mixes of Conventional concrete of M-20 Grade and High strength concrete of M-40

Grade with the percentage replacement of Sand with Quarry stone dust. To achieve this

objective, two concretes of M-20 Grade and M-40 Grade strengths, designed as per Indian code

(IS: 10262-1982), are considered. In the first phase of the test programme, the Compressive

strength of cubes and Split Tensile strength of cylinders are studied by varying the percentage of

Quarry Stone Dust by 0%, 25%, 50%, 100% . The strengths are obtained for different curing

periods (7, 14 & 28 days) is studied. In the second phase of the test programme, the concrete of

M-20 Grade the percentage of Quarry Stone dust is fixed at 50% and to that proportion

replacement of Cement is done in the proportion of 10%, 20%, 30%, and 40%. The compressive

and /split tensile strengths for the specimens are obtained for different curing periods (7, 14 &

28 days) is studied. Likewise the concrete of M-40 Grade the percentage of Quarry Stone dust is

fixed at 25% and to that proportion replacement of Cement is done in the proportion of 10%,

20%, 30%, 40%. The compressive and split tensile strengths for the specimens are obtained for

different curing periods (7, 14 & 28 days) are studied.

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1.7 Objective of the Present Work

The main objective of the study is

• To compare the effect of the percentage replacements of Sand with Quarry Stone Dust in

concrete of M-20 Grade strengths.

• To compare the effect of the percentage replacements of Sand with Quarry Stone Dust in

concrete of M-40 Grade strengths

• To obtain Optimized percentage of replaced materials.

1.8 SUMMARY

In this chapter, theoretical study on different concretes mix, fine aggregate, Quarry

sand and its advantages, application of stone dust, fly ash uses in concrete and its benefits has

been discussed. Also the need for present work, the scope and objective of the present study are

discussed. Based on the objective of the present study, research papers were collected and

studied. The review of research papers is discussed in the next chapter.

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LITERATURE REVIEW

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CHAPTER-II

LITERATURE REVIEW

2.1 General

A Comprehensive literature survey was carried out to review the past work in the area

of influence of replacement of Fine aggregates by Quarry dust on the mechanical properties

of concrete.

2.2 Literature review

M. Shahul Hameed and A.S.S.Sekar (2009) studied the addition of industrial waste improves

the physical and mechanical properties. The kind of innovative concrete requires large amount of

fine particles. Due to its high fineness of the marble sludge powder it provided to be very

effective in assuring very good cohesiveness of the concrete. They have concluded that the

quarry dust and the marble sludge powder may be used as a replacement material for fine

aggregate. The chemical composition of quarry rock dust and marble sludge powder such as

Fe2O3, MnO, Na2O, MgO, K2O, Al2O3, CaO and SiO2 are comparable with that of cement. The

replacement of fine aggregates with 50% marble sludge powder and 50% Quarry rock dust gives

an excellent result in strength and quality aspect. The results showed that the M40 mix induced

higher higher compressive strength, Splitting tensile strength. Increase the marble sludge powder

content by more than 50% improves the workability but effects the compressive strength and

split tensile strength of concrete. The combined effect of quarry rock dust and marble sludge

powder exhibit excellent performance due to efficient micro filling and pozzolanic activity.

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http://www.springerlink.com/content/?Author=G.+D.+Tsiskreli

Anupama P.S, Nazeer M, Nizad A, Suresh S (2010) carried out experimental Studies to find

out the feasibility of using quarry dust to partially replace sand in Concrete. These studies

revealed that, due to increased fineness, the combination require an increased water cement ratio

which results in strength reduction or the use of water reducing admixtures. Use of Super

pozzolanic supplementary material such as Silica fume, rice husk ash, metakaolin etc in concrete

and mortar improves strength even at higher water binder ratio. The effect of water binder ratio

and the metakaolin replacement level on the compressive strength of cement quarry dust mortar

was investigated. The inclusion of metakaolin results in faster early age strength development of

mortar. Mix with 15% metakaolin is superior in all water/binder ratios investigated. The drop in

compressive strength due to conversion reaction, decrease with increase in meatkaolin content

for a given water/binder ratio. Also this drop in compressive strength is almost disappeared in

mixes made of higher water binder ratios. Metakaolin admixed mortar reaches their maximum

density at 0.45 w/b ratio for a mix containing 10% matakaolin.

R. Ilangovan, Dr. K Nagamani. (2007) studied the effect of replacement of Fine aggregate by

Quarry stone dust. The experimental investigations were carried and Compressive strength, Split

tensile strength values were taken up. The workability tests were also carried out for different

mixes. A mix design is also suggested on the basis of the investigation. The experiment suggests

the full replacement of Natural Sand by Quarry stone dust.

Monasseh Joel (2010), had done an experimental investigation on the influence of replacement

of Makurdi river Natural sand by Crushed Granite Fine. Shows that replacement will require a

higher water cement ratio, when compared with the values obtained with the use of only Makurdi

river sand. Peak compressive strength and indirect tensile strength values 40.70N/mm2 and

2.30N/mm2 respectively were obtained when Mukurdi river sand was replaced with 20% CGF in

concrete production. Peak compressive strength and indirect tensile strength values 33.07N/mm2

and 2.04N/mm2 respectively were obtained when Mukurdi river sand was replaced with 20%

CGF in concrete production. Based on the findings from the study the partial replacement of

Mukurdi river sand with 20% CGF is recommended for use in concrete production for use in

rigid pavement. Where crushed granite is in abundance and river sand is scare, the complete

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replacement of river sand with CGF is recommended for use in low to moderately trafficked

roads.

R.Ilangovana, N. Mahendrana and K Nagamanib (2008) states that the physical and chemical

properties of quarry rock dust is satisfied the requirement of code provision in properties studies

(Table 1 and 2). Natural river sand, if replaced with hundred percent Quarry Rock Dust form

quarries, may sometime give equal or better than the reference concrete made with natural sand,

in terms of Compressive and Flexural Strength studies. Studies reported shows that the strength

of Quarry Rock Dust concrete is comparatively 10-12 percent more than that of similar mix of

conventional concrete. Also the result of this investigation shows that drying shrinkage strains of

quarry dust concrete are quite large to the shrinkage strain of conventional concrete. The

durability of quarry rock dust concrete under sulphate and acid action is higher inferior to the

conventional concrete. Permeability test results clearly demonstrates that the permeability of

quarry rock dust concrete is less compared to that of conventional concrete. The water absorbtion

of the quarry rock dust concrete is slightly higher than that of conventional concrete.

Norazila Binti Kamarulzaman (2010) have investigated a Study on the effect of quarry dust

as sand replacement material on compressive and flexural strength of foam concrete was

conducted. This study was conducted to determine the compressive strength and flexural strength

of foam concrete by using quarry dust as partial sand replacement material. This presents the

feasibility of the usage of quarry dust as 10%, 20% and 30% substitutes for sand in foam

concrete. Mix design was developed for four different proportion of quarry dust in foam

concrete. Tests were conducted on cubes and beams to study the strength of concrete made of

quarry dust and results were compared with the control foam concrete. It is found that

compressive and flexural strength of foam concrete made of quarry dust are nearly 40% more

than the control foam concrete.

M R Chitlange (2010) studied the properties of concrete by replacing the Natural sand with

artificial sand. It is observed that artificial sand as fine aggregates gives consistently higher

strength than the mixes with natural sand. The sharp edges of the particles in artificial

sand provide better bond with cement than the rounded particles of natural sand resulting

in high strength. There is a marginal increase in compressive strength up to 7% and a

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noticeable increase in flexural and split tensile strength ie about 17%. It is observed that

use of admixture is necessary in all grades of concrete to restrict water cement ratio to 0.5

and below from the desired workability, specifically in artificial sand concrete. The

excessive bleeding of concrete of concrete is reduced by using artificial sand.

S N Raman, M F M Zain, H B Mahmud and K S Tan (2010) studied the stability of Quarry

dust as partial replacement material for sand in concrete. The properties of quarry dust that were

determined were aggregate crushing value, flakiness index, pH value, Soundness, specific

gravity, absorption and fineness module beside the 28 day compressive strength of concrete

specimens in which partial replacement of river sand with quarry dust were practiced, is also

reported for comparison purposes. Results obtained indicate that the incorporation of the quarry

dust in concrete mix as partial replacement material to river sand resulted in lower 28 day

compressive strength. This can partly be attributed to the properties of the quarry dust which

might contribute to the negative effects in the strength of the concrete. This also indicates that

quarry dust can be utilized as partial replacement material to sand, in the presence of silica fume

or fly ash, to produce concrete with fair range of compressive strength.

A K Sahu, Sunil Kumar and A K Sachan (2010) investigated effects of the replacement of

Sand with Crushed stone in concrete. There is a significant increase in compressive strength,

modulus of rupture and split tensile strength for both the concrete mixes when sand is partially

replaced by stone dust. The workability of the concrete mixes decrease with the increase in the

percent of stone dust as partial replacement of sand. The workability of the concrete mixes

increase with the increase in percentage of super plasticizer. If 40% sand is replaced with stone

dust in concrete, it will not only reduce the cost of concrete but also will save large quantity of

natural sand.

Chaturanga Lakshani Kapugamage (2010) studied the effect of Optimizing concrete mixes by

concurrent use of fly ash and quarry dust. The decrease in early strength by addition of fly ash is

ameliorated by addition of quarry dust. The decrease in workability by the addition of quarry

dust is reduced by the addition of fly ash. The loss in early strength due to addition of 15% fly

ash can be completely negated by the addition of 30% quarry dust. The strength at 28 day has

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not been adversely at all by the addition of up to 30% of fly ash. The addition of quarry dust

causes a loss in slump, though such loss in slump can be significantly reduced by the addition of

fly ash.

Radhikesh P Nanda, Amiya K Das, Moharana N C (2010) carried out an experimental

investigation to study Stone crusher dust as a fine aggregate in concrete for paving blocks.

Replacement of fine aggregate crusher dust up to 50% by weight has a negligible effect on the

reduction of any physical and mechanical properties like compressive strength, flexural strength,

split tensile strength etc. Water absorption is well below the limit as per Indian codes. Durability

shows no variation for different replacements of crusher dust.

2.3 APPRAISAL FOR LITERATURE REVIEW

Research on the above Literature reviews shows that Quarry dust was replaced with

Natural Sand with the clear intension of cost saving. An economy criterion is the governing

factor in choosing the replacement material for Natural sand to Quarry Stone dust. The Literature

shows that replacing Natural Sand with Quarry dust at different percentages were showing good

results or at least equal results with that of only Natural sand. So the replacement of Natural Sand

with Quarry Stone dust seems Feasible.

2.4 SUMMARY

In this chapter, the available papers on replacement of natural sand with Quarry stone

dust are discussed. The reviews of the above papers suggest that quarry sand can be used. The

experimental programme of the present study is discussed in the next chapter.

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EXPERIMENTAL PROGRAMME

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CHAPTER-III

EXPERIMENTAL PROGRAMME

3.0 GENERAL

The present investigations are aimed at studying the effect of replacement of Sand with Quarry

Stone Dust on the compressive strength and Split Tensile strength of Conventional Concretes

and High Strength Concrete. The experimental program has two phases. In the first phase, a total

of 72 cubes were cast and tested. The specimens were cast with M-20 Grade and M-40 Grade

strengths by using ordinary Portland cement (OPC-53) with varying the percentages of Sand

with Quarry Stone dust (0%, 25%, 50%, and 100%). The specimens were cast using standard

cubes (150mm X 150mm X 150mm) and cured by conventional curing. Likewise, a total of 72

cylinders were also cast and tested. The specimens were cast with M-20 Grade and M-40 Grade

strengths by using ordinary Portland cement (OPC-53) with varying the percentages of Sand

with Quarry Stone dust (0%, 25%, 50%, and 100%). In the second phase, a total of 72 cubes

were cast and tested. The specimens were cast with M-20 Grade and M-40 Grade concrete. This

time 36 cubes were cast of M-20 Grade Concrete by fixing the percentage replacement of Sand

with Quarry Stone Dust at 50% and to that proportion, percentage of fly ash (10%, 20%, 30%

and 40%) by replacing it with the ordinary Portland cement (OPC-53). And 36 cubes were cast

of M-40 Grade Concrete by fixing the percentage replacement of Sand with Quarry Stone Dust

at 25% and to that proportion, percentage of fly ash (10%, 20%, 30% and 40%) by replacing it

with the ordinary Portland cement (OPC-53). In the same way a total of 72 cylinders were cast

and tested. The specimens were cast with M-20 Grade and M-40 Grade concrete. This time 36

cylinders were cast of M-20 Grade Concrete by fixing the percentage replacement of Sand with

Quarry Stone Dust at 50% and to that proportion, percentage of fly ash (10%, 20%, 30% and

40%) by replacing it with the ordinary Portland cement (OPC-53). And 36 cylinders were cast of

M-40 Grade Concrete by fixing the percentage replacement of Sand with Quarry Stone Dust at

25% and to that proportion, percentage of fly ash (10%, 20%, 30% and 40%) by replacing it with

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the ordinary Portland cement (OPC-53). Digital compression testing machine of 3000kN

capacity was used to test all the specimens.

3.1 STUDY OF MATERIALS

The materials that are used in the study are

(1) Cement

(2) Fine Aggregate (Natural Sand)

(3) Fine Aggregate (Quarry Stone Dust)

(4) Coarse Aggregate

(5) Fly ash

(6) Water

3.1.1 Cement

In the experimental investigations ordinary Portland cement of 53 grade obtained from the Ultra

Tech Cements was used. The cement procured was tested for physical properties in accordance

with IS: 4031-1988.and is tabulated in table (3.2.1)

3.1.2 Fine Aggregate (Natural Sand)

River sand obtained from local market was used as fine aggregate in this study. The physical

properties of fine aggregate such as specific gravity, fineness modulus, porosity, void ratio etc.

were determined in accordance with IS: 2386-1963 and are shown in table (3.2.2)

3.1.3 Fine Aggregate (Quarry Stone Dust)

Quarry Stone Dust obtained from locally available quarry near Himayath sagar Dam was used

as fine aggregate in this study. The physical properties of fine aggregate such as specific gravity,

fineness modulus, porosity, void ratio etc. were determined in accordance with IS: 2386-1963

and are shown in table (3.2.3.1) and (3.2.3.2)

3.1.4 Coarse Aggregate

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20mm Coarse aggregate obtained from the local quarry has been used as coarse aggregate in the

present study. The properties of coarse aggregate like size of aggregate, shape, grading, surface

texture etc play an important role in workability and strength of concrete.

The properties of coarse aggregates are determined as follows & presented in table (3.4)

3.1.5 Fly Ash

Fly ash was obtained from NTPC Simhadri Power Plant, Vishakhapatnam, India. The Fly ash

sample is shown in plate (2).

3.1.6 Water

Potable water confirming to IS: 456-2000(7) was used for both mixing and curing. The water

was free from any objectionable materials.

3.2 Properties of materials

Table 3.1 Physical Properties of Ordinary Portland cement (OPC-53)

S.No. Property Test Method Test

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Result

1. Normal consistency Vicat apparatus (IS 4031-Part IV) 34%

2. Specific gravity Specific gravity bottle (IS 4031-Part II) 3.15

3.Initial and Final

setting timeVicat apparatus (IS 4031-Part V)

45 min

175 min

4. Fineness Sieve test on sieve no.9 (IS 4031-Part IV) 6%

Table 3.2 Properties of Fine aggregates (Natural Sand)

S.No. Property Test Result

1. Specific Gravity 2.54

2. Fineness Modulus 3.0

3. Porosity 42.8%

4. Void Ratio 0.75

5. Water Absorption 2 %

6. Moisture Content 1 %

Table 3.3 Properties of Quarry Stone Dust

S.No. Property Test Result


2. Porosity 0.33

3. Void Ratio 0.50

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Table 3.4 Properties of Coarse aggregate.

S.No. Property Coarse aggregate



3. Porosity 0.636

4. Void Ratio 1.75

5. Water Absorption 17.24 %

6. Moisture Content 3.45 %

7. Unit Weight 840 kg/m3

8. Oven Dry Loose Weight 780 kg/m3

9. Aggregate Crushing Value 53 %

10. Aggregate Impact Value 49 %

Table 3.5 Sieve Analysis Quarry Stone Dust

I S : Sieve Cumulative Percentage Specification as per I S : 383-1970 for fine Aggregate (% Passing) – Grading.

Retained Passing Zone-I Zone-II Zone-III Zone-IV

4.75 mm 0.2 99.8 90-100 90-100 90-100 95-100

2.36 mm 9.9 90.1 60-95 75-100 85-100 95-100

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1.18 mm 32.5 67.5 30-70 55-90 75-100 90-100

600micron 55.5 44.5 15-34 35-59 60-79 80-100

300micron 69.5 30.5 5-20 8-30 12-40 15-50

150micron 82.1 17.9 0-10 0-10 0-10 0-15

Remarks: The test sample satisfies the requirements of grading zone-II as per I S: 383-1970. According to I S:383-1970 for crushed stone sands the permissible limit on 150 micron IS Sieve is increased to 20%. This does not affect the 5% allowable permitted in CL.4.3 applying to other Sieve sizes.

3.3 MIXING OF CONCRETE

The proportioned volume of the concrete is maintained, and slump loss during transport is

minimized.

The performance of concrete is influenced by mixing and a proper and good practice of mixing

can lead to better performance and quality of the concrete. And M-20 Grade and M-40 Grade

concretes was designed using IS-456

Once the mix design is done, the mixing of the concrete can be carried out. In the present study

the mixing was carried out in an electrical drum mixer of 60 lts capacity.

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3.3.1 Procedure for mixing

The test procedure for the process of mixing is as follows

a) All the materials were weighed & prepared as per the proportion of mix design.

b) Before the mixing begins, the surface of the mixer is damped with a wet cloth.

c) The coarse aggregate is made damp by adding water as per its absorption value.

d) All the aggregates (fine & coarse) are added into the mixer till the aggregate is uniformly

distributed throughout the mixer.

e) Aggregates are mix with one-half to two-thirds of the mixing water for a short period

before adding cement, admixtures, and air-entraining admixture to minimize slump loss.

f) Cement is then added into the mixer containing the aggregates.

g) Remaining water is added into the mixer slowly while the mixing of aggregate and

cement is going on.

h) The concrete is mixed for about 5 minutes from the point of addition of water and then

the mixer is switched off.

i) The handle of the mixer is held down to allow the concrete fill into the pan.

3.3.2 Placing, Compaction and Casting of concrete specimens

Before the placing of concrete, the concrete mould must be oiled for the ease of concrete

specimen stripping. Once the workability test is done, the fresh concrete is placed into concrete

moulds to prepare specimens to test for hardened properties. Cubes of 150x150x150mm were

cast and were compacted on a table vibrator. After the filling of the mould is complete, care was

taken to level the surface.

3.4 EXPERIMENTAL PROGRAM

In this section tests on fresh and hardened concrete have been carried out. The workability tests

including slump and compaction factor are conducted on fresh concrete whereas the hardened

concrete cube specimen are tested for direct compression & split tension.

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The experimental programme of current investigation, involves the study in phases.

3.4.1 Phase – I. Determination of Compressive Strength and Split Tensile Strength of

Concrete:

In the first phase, M-20 Grade and M-40 Grade concretes have been designed using IS- .

For each of the concrete designed, four different concrete mixtures were prepared with the

percentage replacement of Natural Sand with Quarry Stone Dust (0%, 25%, 50%, 100%). For the

mixes, workability, wet and dry density, Compressive strength and Split Tensile strength at

different curing periods were determined.

3.4.2 Phase – II. Determination of Optimum Strengths with partial replacement of Cement

with fly ash:

In the second phase of test programme, fly ash concrete mixes of M-20 Grade concrete with 50%

replacement of Sand with Quarry Stone dust were designed. The fly ash concrete was varied

from 10% - 40% in steps of 10% in both strengths of concrete. Fresh concrete property of

workability was assessed for these mixes. Cube specimen of sizes 150 x 150 x 150 mm were cast

to study the strength in axial compression and split tension at 7, 14, 28 and 56 days of age. Fly

ash concrete mixes of M-40 Grade concrete with 25% replacement of Sand with Quarry Stone

dust were also designed. The fly ash concrete was varied from 10% - 40% in steps of 10% in

both strengths of concrete. Fresh concrete property of workability was assessed for these mixes.

Cube specimen of sizes 150 x 150 x 150 mm were cast to study the strength in axial compression

and split tension at 7, 14, 28 and 56 days of age. The same procedure was repeated for the

cylinders.

3.5 Tests on Fresh Concrete

The two tests, Slump and Compaction factor were employed to assess the workability of

concrete and the results are presented in tables.

3.6 Tests on Hardened Concrete specimens

In the design of concrete structures, engineers usually refer to the hardened state properties like

compressive strength, split tensile strength and flexural strength of concrete. In the present study,

experimental investigations were conducted to determine compressive strength, split tensile

23

strength of different mixes of two strength grades with different Percentage replacement of Sand

with Quarry Stone dust and fly ash percentages. For each of M-20 Grade and M-40 Grade

concretes, 4 different percentage replacements Sand with Quarry Stone Dust i.e. 0%, 25%, 50%

and 100% were employed, and 4 different percentages of fly ash i.e. 10%, 20%, 30% and 40%

were employed in Concrete to study. All the specimens are cured by Conventional wet curing.

3.6.1 Testing Procedure for Compressive Strength

The compressive strength test was performed, as per IS 516-1969, on cube specimens of size 150

x 150 x 150 mm on a digital compression testing machine of 3000 KN capacity. The specimen

after conventional water curing for 3, 7, and 28 days as of in Phase I and for 7, 14, 28 and 56

days as of in Phase II of test programme are tested under 3000 KN digital testing machine.

3.6.2 Testing Procedure for Split Tensile Strength

The split tensile strength test was performed, as per IS 5816-1970, on cube specimens of size 150

x 150 x 150 mm on a digital compression testing machine of 3000 KN capacity. The cube

specimen after conventional water curing for 7, 14, 28 and 56 days as of in Phase II of test

programme are tested under 3000 KN digital testing machine. The load at the time of failure of

specimen was recorded and split tensile strength of cube is calculated using the formula [18]:

σ sp = 0.642 P/S2

Where P is the load at failure and S is the side of the cube.

Table 3.6 Test Programme Phase I

S.NoStrength of

concreteMix

Percentage replacement of

Sand with Quarry Stone

Dust

No of cubes

1 M-20 Grade 0% 9

24

2 M-20 Grade 25% 9

3 M-20 Grade 50% 9

4 M-20 Grade 100% 9

5 M-40 Grade 0% 9

6 M-40 Grade 25% 9

7 M-40 Grade 50% 9

8 M-40 Grade 100% 9

Total 72

Table 3.7 Test Programme Phase I

S.NoStrength of

concreteMix



Dust

No of cylinders

1 M-20 Grade 0% 9

2 M-20 Grade 25% 9

3 M-20 Grade 50% 9

4 M-20 Grade 100% 9

5 M-40 Grade 0% 9

25

6 M-40 Grade 25% 9

7 M-40 Grade 50% 9

8 M-40 Grade 100% 9

Total 72

Table 3.8 Test Programme Phase II

S.No Strength of concrete

Mix



Dust

Percentage of Cement with Fly

Ash

No of cubes

1 M-20 Grade 50% 10 % 9

2 M-20 Grade 50% 20 % 9

3 M-20 Grade 50% 30 % 9

4 M-20 Grade 50% 40 % 9

5 M-40 Grade 25% 10 % 9

26

6 M-40 Grade 25% 20 % 9

7 M-40 Grade 25% 30 % 9

8 M-40 Grade 25% 40 % 9

Total 72

Table 3.9 Test Programme Phase II

S.No Strength of concrete

Mix



Dust

Percentage of Cement with Fly

Ash

No of cylinders

1 M-20 Grade 50% 10 % 9

2 M-20 Grade 50% 20 % 9

3 M-20 Grade 50% 30 % 9

4 M-20 Grade 50% 40 % 9

5 M-40 Grade 25% 10 % 9

6 M-40 Grade 25% 20 % 9

27

7 M-40 Grade 25% 30 % 9

8 M-40 Grade 25% 40 % 9

Total 72

3.4 SUMMARY

In this chapter, the study of materials used, their properties, mix design, the experimental

methodology and the procedures for testing of fresh and hardened concrete are discussed. The

results of the experimental programme discussed in this chapter are tabulated and studied in the

next chapter.

28

TEST RESULTS AND DISCUSSIONS

4

CHAPTER-IV

TEST RESULTS AND DISCUSSIONS

4.0 GENERAL

29

Results obtained from experimental investigations are the compressive strengths, split tensile

strength, of various concrete mixtures of M-20 Grade and M-40 Grade strengths containing

different percentage replacement of Natural Sand with Quarry Stone Dust.

4.1 RESULTS

The test results of the experimental investigations are presented in the Tables 4.1 to 4.11. The

test results are also shown graphically in the Figures 1 to 11.

4.2 TEST RESULTS

Table 4.1 Compressive Strength of M-20 Grade Concrete

S.No

Strength of Concrete

Mix

Percentage replacement

of Sand

Compressive Strength (MPa)

7 days 14 days 28 days

1 20 MPa 0 % 24.44 32.46 36.13

2 20 MPa 25 % 20.11 33.70 37.06

3 20 MPa 50 % 26.88 34.3 37.99

30

4 20 MPa 100 % 23.16 31.12 35.28

Table 4.2 Compressive Strength of M-40 Grade Concrete

S.No


Mix


of Sand



1 40 MPa 0 % 42.59 54.11 61.53

2 40 MPa 25 % 45.26 50.89 64.58

3 40 MPa 50 % 41.30 52.46 59.42

4 40 MPa 100 % 35.86 43.18 45.26

Table 4.3 Split Tensile Strength of M-20 Grade Concrete

S.No


Mix


of Sand

Split Tensile Strength (MPa)


1 20 MPa 0 % 2.21 2.95 3.28

2 20 MPa 25 % 2.25 3.07 3.30

3 20 MPa 50 % 2.44 3.09 3.53

31

4 20 MPa 100 % 1.91 2.79 3.20

Table 4.4 Split Tensile Strength of M-40 Grade Concrete

S.No


Mix


of Sand



1 40 MPa 0 % 3.41 4.32 4.95

2 40 MPa 25 % 3.95 4.63 5.12

3 40 MPa 50 % 3.15 4.21 4.32

4 40 MPa 100 % 2.83 3.40 4.13

Table 4.5 Compressive Strength of M-20 Grade Concrete with 50% replacement of Sand.

S.No


Mix

Percentage replacement of Cement



1 20 MPa 10 % 23.87 29.61 38.90

2 20 MPa 20 % 25.50 30.18 40.30

3 20 MPa 30 % 25.70 31.92 41.20

4 20 MPa 40 % 20.03 27.73 33.22

32

Table 4.6 Compressive Strength of M-40 Grade Concrete with 25% replacement of Sand.

S.No


Mix




1 40 MPa 10 % 38.18 48.82 65.33

2 40 MPa 20 % 38.24 49.11 66.28

3 40 MPa 30 % 41.28 53.73 70.58

4 40 MPa 40 % 37.03 41.41 61.90

Table 4.7 Split Tensile Strength of M-20 Grade Concrete with 50% replacement of Sand.

S.No


Mix




1 20 MPa 10 % 2.17 2.71 3.51

2 20 MPa 20 % 2.20 2.74 3.32

3 20 MPa 30 % 2.02 2.90 3.76

4 20 MPa 40 % 1.80 2.51 3.23

33

Table 4.8 Split Tensile Strength of M-40 Grade Concrete with 25% replacement of Sand.

S.No


Mix




1 40 MPa 10 % 3.01 3.91 5.18

2 40 MPa 20 % 3.15 3.98 5.34

3 40 MPa 30 % 3.28 4.13 4.72

4 40 MPa 40 % 2.92 3.70 5.03

Table 4.9 Slump Factor values of M-20 Grade and M-40 Grade Concrete with Percentage replacement of Sand.

Strength of

Concrete

Mix

Slump value in mm with percentage replacement of Sand

0 % 25 % 50 % 100 %

20 MPa 95 94 97 98

40 MPa 76 79 74 81

Table 4.10 Slump Factor values of M-20 Grade and M-40 Grade Concrete with Fixed percentage replacement of Sand and replacement of Cement.

34

Strength of

Concrete

Mix

Slump value in mm with percentage replacement of Sand

0 % 25 % 50 % 100 %

20 MPa 95 94 97 98

40 MPa 76 79 74 81

Table 4.11Compaction Factor values of M-20 Grade and M-40 Grade Concrete with Percentage replacement of Sand.

Strength of

Concrete

Mix

Compaction value with percentage replacement of Sand

0 % 25 % 50 % 100 %

20 MPa 0.8 0.8 0.8 0.8

40 MPa 0.9 0.9 0.9 0.9

35

Fig. 1 Variation of Compressive Strength with Percentage replacement of Sand with QD

for M-20 Grade Concrete.

36

Fig. 2 Variation of Compressive Strength with Percentage replacement of Sand with QD


Fig. 3 Variation of Split Tensile Strength with Percentage replacement of Sand with QD


37

Fig. 4 Variation of Split Tensile Strength with Percentage replacement of Sand with QD


Fig. 5 Variation of Compressive Strength for 50% replacement of Sand with Percentage

replacement of Cement for M-20 Grade Concrete.

38

Fig. 6 Variation of Compressive Strength for 25% replacement of Sand with Percentage


Fig. 7 Variation of Split Tensile Strength for 50% replacement of Sand with Percentage


39

Fig. 8 Variation of Split Tensile Strength for 25% replacement of Sand with Percentage


Fig. 9 Variation of Slump Factor Values for M-20 Grade and M-40 Grade Concrete with

percentage replacement of Sand.

40

Fig. 10 Variation of Slump Factor Values for M-20 Grade Concrete with 50% replacement

of Sand and M-40 Grade Concrete with 25% replacement of Sand and Variation

percentage replacement of Cement.

Fig. 11 Variation of Compaction Factor Values for M-20 Grade and M-40 Grade Concrete

with percentage replacement of Sand.

41

4.3 Discussion:

4.3.1 Effect of Quarry Stone Dust Percentage on Compressive strength of Conventional

Concrete (20 Mpa ):

Fig (1) depicts the variation of compressive strength for M-20 Grade concrete prepared with

different percentages of Quarry Stone Dust and cured by conventional wet curing. The

compressive strengths obtained for concrete mix with 0%, 25%, 50% and 100% Quarry Stone

Dust meets the desired characteristic strength of 20 N/mm2 beyond 28 days of age. The

compressive strength of 0%, 25% and 50% Quarry Stone Dust mix concrete were found to

increase from 36.13Mpa, 37.06Mpa and 37.99Mpa respectively. The compressive strength of

50% to 100% Quarry Stone Dust mix concrete were found to decrease from 37.99Mpa to

35.28Mpa respectively. It could be observed that optimum strength is obtained for M-20 Grade

concrete at 50% Quarry Stone Dust and the strength gets depletes with the use of higher

percentages of Quarry Stone Dust in concrete.

4.3.2 Effect of Quarry Stone Dust Percentage on Split Tensile strength of Conventional

Concrete ( 20 Mpa ):

42

Fig (3) depicts the variation of Split Tensile strength for M-20 Grade concrete prepared with

different percentages of Quarry Stone Dust and cured by conventional wet curing. The Split

Tensile strengths obtained for concrete mix with 0%, 25%, 50% and 100% Quarry Stone Dust

meets the desired characteristic strength of 20 N/mm2 beyond 28 days of age. The Split Tensile

strength of 0%, 25% and 50% Quarry Stone Dust mix concrete were found to increase from

3.28Mpa, 3.30Mpa and 3.53Mpa respectively. The Split Tensile strength of 50% to 100% Quarry

Stone Dust mix concrete were found to decrease from 3.53Mpa to 3.M-20 Grade respectively.

It could be observed that optimum strength is obtained for M-20 Grade concrete at 50% Quarry

Stone Dust and the strength gets depletes with the use of higher percentages of Quarry Stone

Dust in concrete.

4.3.3 Effect of Quarry Stone Dust Percentage on Compressive strength of High Strength


Fig (2) depicts the variation of compressive strength for M-40 Grade concrete prepared with

different percentages of Quarry Stone Dust and cured by conventional wet curing. The

compressive strengths obtained for concrete mix with 0% and 25%, 50% and 100% Quarry

Stone Dust meets the desired characteristic strength of 20 N/mm2 beyond 28 days of age. The

compressive strength of 0% and 25% Quarry Stone Dust mix concrete were found to increase

from 61.53Mpa to 64.58Mpa respectively. The compressive strength of 25%, 50% and 100%

Quarry Stone Dust mix concrete were found to decrease from 64.58Mpa, 59.42Mpa and

45.26Mpa respectively. It could be observed that optimum strength is obtained for M-40 Grade

concrete at 25% Quarry Stone Dust and the strength gets depletes with the use of higher

percentages of Quarry Stone Dust in concrete.

4.3.4 Effect of Quarry Stone Dust Percentage on Split Tensile strength of High Strength


43

Fig (4) depicts the variation of Split Tensile strength for M-40 Grade concrete prepared with

different percentages of Quarry Stone Dust and cured by conventional wet curing. The Split

Tensile strengths obtained for concrete mix with 0%, 25%, 50% and 100% Quarry Stone Dust

meets the desired characteristic strength of 40 N/mm2 beyond 28 days of age. The Split Tensile

strength of 0%, and 25% Quarry Stone Dust mix concrete were found to increase from 4.95Mpa

to 5.12Mpa respectively. The Split Tensile strength of 25%, 50% and 100% Quarry Stone Dust

mix concrete were found to decrease from 5.12Mpa, 4.32Mpa, and 4.13Mpa respectively. It

could be observed that optimum strength is obtained for M-40 Grade concrete 25% Quarry Stone

Dust and the strength gets depletes with the use of higher percentages of Quarry Stone Dust in

concrete.

4.3.5 Effect of Fly Ash Percentage on Compressive strength of Conventional Concrete

( M-20 Grade ):

Fig (5) depicts the variation of compressive strength for M-20 Grade concrete with 50%

replacement with Quarry Stone Dust prepared with different percentages of fly ash and cured by

conventional wet curing. The compressive strengths obtained for concrete mix with 10%, 20%,

30% and 40% fly ash meets the desired characteristic strength of 20 N/mm2 beyond 28 days of

age. The compressive strength of 10%, 20% and 30% fly ash mix concrete were found to be

increase from 38.90Mpa, 40.30Mpa and 41.M-20 Grade respectively. The compressive strength

of 30% and 40% fly ash mix is found to decrease from 41.M-20 Grade to 33.22Mpa

respectively. It could be observed that optimum strength is obtained for concrete with 30% fly

ash and the strength gets depletes with the use of higher percentages of fly ash in concrete.

4.3.6 Effect of Fly Ash Percentage on Split Tensile strength of Conventional Concrete

(M-20 Grade):

Fig (7) depicts the variation of Split Tensile strength for M-20 Grade concrete with 50%

replacement with Quarry Stone Dust prepared with different percentages of fly ash and cured by 44

conventional wet curing. The Split Tensile strengths obtained for concrete mix with 10%, 20%,


age. The Split Tensile strength of 10%, 20% and 30% fly ash mix concrete were found to be

increase from 3.51Mpa, 3.32Mpa and 3.76Mpa respectively. The Split Tensile strength of 30%

and 40% fly ash mix is found to decrease from 3.76Mpa to 3.23Mpa respectively. It could be

observed that optimum strength is obtained for concrete with 30% fly ash and the strength gets

depletes with the use of higher percentages of fly ash in concrete.

4.3.7 Effect of Fly Ash Percentage on Compressive strength of High Strength Concrete

(M-40 Grade):

Fig (6) depicts the variation of compressive strength for M-40 Grade concrete with 25%


conventional wet curing. The compressive strengths obtained for concrete mix with 10%, 20%,


age. The compressive strength of 10%, 20% and 30% fly ash mix concrete were found to be

increase from 65.33Mpa, 66.28Mpa and 70.58Mpa respectively. The compressive strength of

30% and 40% fly ash mix is found to decrease from 70.58Mpa to 61.90Mpa respectively. It

could be observed that optimum strength is obtained for concrete with 30% fly ash and the

strength gets depletes with the use of higher percentages of fly ash in concrete.

4.3.8 Effect of Fly Ash Percentage on Split Tensile strength of High Strength Concrete

(M-40 Grade):

Fig (8) depicts the variation of Split Tensile strength for M-40 Grade concrete with 25%


conventional wet curing. The Split Tensile strengths obtained for concrete mix with 10%, 20%,


age. The Split Tensile strength of 10%, 20% and 30% fly ash mix concrete were found to be 45

increase respectively. The Split Tensile strength of 30% and 40% fly ash mix is found to

decrease from respectively. It could be observed that optimum strength is obtained for concrete

with 30% fly ash and the strength gets depletes with the use of higher percentages of fly ash in

concrete.

4.3 SUMMARY

In this chapter, the results obtained from the experimental programme are tabulated and

are represented in the form of graphs. The results were studied and based on the study, the

conclusions were drawn. The conclusions of the present work are given in the next chapter.

Plate 1. Sample of Quarry Stone Dust Aggregate

46

Plate 2. Sample of Fly Ash

Plate 3. Electrical Drum Mixer of 60 lts capacity

47

Plate 4. Moulds kept on Vibrator

Plate 5. Curing Tank

48

Plate 6. Compression Testing Machine

49

CONCLUSIONS

50

CHAPTER-V

CONCLUSIONS

5.1 GENERAL

Studies have been carried out on natural aggregate, percentage replacement of Natural

sand by Quarry stone dust. Fly Ash as partial replacement of cement with various percentages of

Quarry stone dust. The parameters studied include Quarry Stone dust, Fly ash content. Based on

the study conducted, the conclusions are drawn.

5.2 CONCLUSIONS

Based on the study conducted on M-20 Grade and M-40 Grade concretes with Quarry Stone

Dust aggregate of different percentage replacements, the following conclusions are drawn:

• Compressive Strength values increase with the percentage replacement of Natural Sand

with Quarry Stone Dust upto 50% and decrease upon further replacement for Conventional

Concrete M-20 Grade.And the values increase with the percentage replacement of Natural

Sand with Quarry Stone Dust upto 25% and decrease upon further replacement for High

Strength Concrete M-40 Grade.

• Split Tensile Strength values increase with the percentage replacement of Natural Sand

with Quarry Stone Dust upto 50% and decrease upon further replacement for Conventional

Concrete M-20 Grade.And the values increase with the percentage replacement of Natural

Sand with Quarry Stone Dust upto 25% and decrease upon further replacement for High

Strength Concrete M-40 Grade.

51

• M-20 Grade concrete with fly ash replacement, attained the optimum compressive and split

tensile strengths at 28 days of age with 30% replacement of cement with fly ash.

• M-40 Grade concrete with fly ash replacement, attained the optimum compressive and split

tensile strengths at 28 days of age with 30% replacement of cement with fly ash.

• For M-20 Grade concretes, compressive and split tensile strengths decreased with increase

in percentage replacement of cement by fly ash after 30% replacement.

• For M-40 Grade concretes, compressive and split tensile strengths decreased with increase

in percentage replacement of cement by fly ash after 30% replacement.

5.3 SCOPE FOR FUTHER INVESTIGATION

• It is advisable to continue the procedure by replacing the percentages of Fly ash in the

percentages (10%, 20%, 30%, 40%) for all the percentages of replacement of Natural Sand

with Quarry Stone dust of (0%, 25%, 50%, 100%) for Conventional Concrete M-20 Grade.

• It is advisable to continue the procedure by replacing the percentages of Fly ash in the

percentages (10%, 20%, 30%, 40%) for all the percentages of replacement of Natural Sand

with Quarry Stone dust of (0%, 25%, 50%, 100%) for High Strength Concrete M-40 Grade.

Studies have been carried out on conventional concrete and high strength concrete with

Natural Fine aggregate, percentage replacement of Natural fine aggregate by Quarry stone dust

aggregate and Fly Ash with cement. The parameters studied include Fly ash and quantity of

Quarry stone dust aggregate. The results show the variation of the strengths in concrete.

52

BIBLIOGRAPHY

53

BIBLIOGRAPHY

1. M Shahul Hameed, A.S.S.Sekar, (2009) “Properties of Green Concrete Containing

Quarry Rock Dust and Marble Sludge Powder as Fine Aggregates”, ARPN Journal of

Engineering and Applied Sciences, Vol. 4, No 4.

2. R.Ilangovana, N. Mahendrana and K Nagamanib, “Strength and Durability

Properties of Concrete containing Quarry Rock Dust as Fine Aggregate”, ARPN

Journal of Engineering and Applied Sciences, Vol. 3, No 5, 2008.

3. Norazila Binti Kamarulzaman, “An Investigation on Effect of Quarry Dust as Sand

replacement on Compressive and Flexural Strength of Foam Concrete”, Universiti

Malaysia Pahang, 2010.

4. Radhikesh P. Nanda, Amiya K. Das, Moharana.N.C, “Stone Crusher Dust as a

Fine Aggregate in Concrete for Paving Blocks”, International Journal of Civil and

Structural Engineering, Vol 1, No 3,2010.

5. Manasseh JOEL, “Use of Crushed Granite fine as replacement to River Sand in

Concrete Production”, Leonardo Electronic Journal of Practices and Technologies,

2010.

6. Raman S.N, Safiuddin M, Zain M.F.M, “Non-Destructive evaluation of Flowing

concretes incorporating quarry waste”, Asian Journal of Civil Engineering (Building

and Housing), 2007,8(6), p.597-614.

7. Uchikawa H.S, Hanehara Hirao H, “Influence of microstructure on the physical

properties of concrete prepared by substituting material powder for part of fine

aggregate, Cement and Concrete Research, 1996,26(1), p.101-111.

8. Siddique R, “Effect of Fine Aggregate replacement with Class F fly ash on the

Mechanical properties of Concrete”. Cement and Concrete Research, 2003, 33(4).

9. Nagaraj T.S, Banu Z, “Effective Utilization of rock dust and Pebbles as Aggregate

in Portland Cement Concrete”. The Indian Concrete Journal, 1996, 70(1).

10. Safiuddin M.D, Raman S.N, Zain M.F.M, “Utilization of Quarry Waste Fine

Aggregate in Concrete Mixtures”, Journal of Applied Sciences Research, Instinet

Publications, 2007, vol 5(13), pp no.1952-1963.

54

11. Murdock L.J, Brook K.M, Dewar J.D, Concrete Material and Practice. Edward

Arnold London, 1991.

12. Neville. A.M., “Properties of Concrete”, 4th Edition, Pitman Publishing Limited,

London 1997.

13. Gambhir M.L. “Concrete Technology”, 3rd Edition, The McGraw Hill Companies,

New Delhi, 2004.

14. Mindess S, Young JF, Concrete. Englewood Cliffs, NJ: Prentice Hall; 1981.

55

APPENDIX

56

APPENDIX

Mix design for Structural Concrete: (As per I S Code : SP 23-1982)

Before having any concrete mixing, the selection of mix materials and their required materials

proportion must be done through a process called mix design. In the present study I S Code

method for Concrete has been adopted and altogether sixteen batches of mixtures were

determined. The grade of concrete is of M-20 Grade and M-40 Grade Strengths.

In the first phase, concrete mix design using eight different concrete mix (M-1) of M-20 Grade

and M-40 Grade strengths with the exclusive use of 20mm down aggregates. And in the second

phase, fly ash concrete mixes of M-20 Grade and M-40 Grade concrete with aggregate of size

resulting in optimum strength were designed.

Mix Design for M-20 Grade Strength:

Mix M-1:

a) Design Stipulations:

I. Characteristic Strength required at 28 days = M-20 Grade.

II. Maximum size of Aggregates = 20 mm (Angular).

III. Degree of Quality control = Good.

IV. Type of Exposure = Mild.

b) Test data for Materials:

I. Specific Gravity of Cement = 3.15.

II. Specific Gravity of Coarse Aggregates = 2.55.

III. Specific Gravity of Fine Aggregates = 2.65.

IV. Water Absorbtion.

57

1) Coarse Aggregates = 0.5 %

2) Fine Aggregates = 1.0 %

V. Free Surface Moisture.

1) Coarse Aggregates = Nil.


VI. Sieve Analysis of a Sand Confirming to Zone-III.

VII. Target mean strength of Concrete.

20+ (1.65x4) = 26.6 Mpa.

VIII. Selection of water cement ratio

W/C = 0.50.

IX. Selection of water and sand content

Standard for zone II

Water Content per cubic meter = 186 Lts.

Sand content as percentage of total Aggregates = 35 %.

For Change in Values of w/c ratio, Compacting factor for Zone-III

58

Change Conditions Adjustments

Water Content Percentage Sand in Total

Aggregates.

For Sand Confirming to

Zone III

0 -2

For Increase in

Compacting factor

+3 0

For Decrease in Water –

Cement ratio by (0.6-0.5)

that is 0.1

0 -1.5

Total +3 -3.5

Therefore required sand content as percentage of total aggregate by absolute volume : 35-3.5 =

31.5%.

Required Water content : 186 + 5.58 = 191.6 L/m3.

X. Determination of Cement content

W/C = 0.5

Water = 191.6 Lts

Therefore Cement = 191.6/0.5 = 383 kg/m3

This Cement content is adequate for mild exposure.

XI. Determination of Fine Aggregates.

0.98 = (191.6 + (383/3.15) + ((1/0.315)x(fa/2.6)) x (1/1000)

59

Fa = 546 kg/m3

XII. Determination of Coarse Aggregates.

0.98 = (191.6 + (383/3.15) + ((1/0.685)x(Ca/2.6)) x (1/1000)

Ca = 1188 kg/m3

The Mix proportion than becomes

Water : 191.6 : 0.50

Cement : 383 kg : 1

Fine Aggregates 546 kg : 1.425

Coarse Aggregates 1188 kg : 3.10

Mix Design for M-40 Grade Strength:

Mix M-2:

c) Design Stipulations:

I. Characteristic Strength required at 28 days = M-40 Grade.

60

II. Maximum size of Aggregates = 20 mm (Angular).

III. Degree of Quality control = Good.

IV. Type of Exposure = Mild.

d) Test data for Materials:

V. Specific Gravity of Cement = 3.15.

VI. Specific Gravity of Coarse Aggregates = 2.55.

VII. Specific Gravity of Fine Aggregates = 2.65.

VIII. Water Absorption.

3) Coarse Aggregates = 0.5 %


IX. Free Surface Moisture.

3) Coarse Aggregates = Nil.


X. Sieve Analysis of a Sand Confirming to Zone-III.

XI. Target mean strength of Concrete.

40+ (1.65x5) = 48.25 Mpa.

XII. Selection of water cement ratio

W/C = 0.31.

XIII. Selection of water and sand content

Standard for zone II

61

Water Content per cubic meter = 186 Lts.

Sand content as percentage of total Aggregates = 35 %.

For Change in Values of w/c ratio, Compacting factor for Zone-III

Change Conditions Adjustments

Water Content Percentage Sand in Total

Aggregates.

For Sand Confirming to

Zone III

0 -1.5

For Increase in

Compacting factor

+3 0

For Decrease in Water –

Cement ratio by (0.6-0.5)

that is 0.1

0 -5.8

Total +3 -7.3

Therefore required sand content as percentage of total aggregate by absolute volume : 35-7.3 =

27.7%.

Required Water content : 186 + 5.58 = 191.6 L/m3.

XIV. Determination of Cement content

W/C = 0.31

Water = 191.6 Lts

Therefore Cement = 191.6/0.31 = 618.064 kg/m3

Cement as per IS Code content should not exceed 450 kg/m3.

Therefore Correcting Cement

62

Cement = 450 kg/m3

W/C = 0.31

Water = 0.31 x 450

= 139.5 L/m3

XV. Determination of Fine Aggregates.

0.98 = (139.5 + (450/3.15) + ((1/0.277)x(fa/2.65)) x (1/1000)

Fa = 512.42 kg/m3

XVI. Determination of Coarse Aggregates.

0.98 = (139.5 + (450/3.15) + ((1/0.723)x(Ca/2.55)) x (1/1000)

Ca = 1286.22 kg/m3

The Mix proportion than becomes

Water: 139.5 : 0.31

Cement: 450 kg : 1

Fine Aggregates 512.42 kg : 1.138

Coarse Aggregates 1286.22 kg : 2.858.

63

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