1

Experimental Study of Post-Tensioned Concrete Prism by

Incorporating Polypropylene Fibers and Fly Ash
Sudhir P.Patil
1
, Keshav K.Sangle
2

___________________________________________________________________
Abstract: In this research, the experimental program was designed to verify the compressive
strength of cube samples, split tensile strength of cylinders and shear strength of prestressed
concrete prism specimens. A total of 63 cube samples and 9 cylinders were casted for
different concrete mix. The concrete mixes had 0%, 10%, 20%, and 30% of fly ash replacing
to cement by its weight, also, 0.5%, 1%, and 1.5% of polypropylene added by weight of
cement.It revealed that with 20% of fly ash and 1% polypropylene fibers were found optimum
compressive strength. The post tensioned prism specimens had length of 600mm, depth of
150mm and width of 150 mm. Each series of OPC, OPC+FA and OPC+ FA+ Polypropylene
having three concrete cylinders and three post tensioned prism specimen respectively. The
prism specimen were tested for shear strength at the age of 28 days for single point loading
and deflections were measured.

Key words: Prestressed concrete, flexural strength, fly ash, polypropylene fibers, deflection.

I. Introduction
Plain concrete has very low tensile
strength, limited ductility and little
resistance to cracking. Owing to its poor
tensile strength, crack propagation with the
application of load eventually lead to
brittle failure. One can not avoid internal
micro crack in plain concrete. Its poor
tensile strength propagates these cracks
due to eventual loadings.
__________________________________
1
Research Scholar, Structural Engineering
Department, Veermata Jijabai Technological
Institute (VJTI), Matunga, Mumbai, India.
2
Professor, Structural Engineering Department and
Planning,Veermata Jijabai Technological Institute
(VJTI), Matunga, Mumbai, INDIA.
Copyright The Authors(s)b2014.
In India about 110 million tons of fly ash
has been produced by 68 major thermal
power stations and are likely to be doubled
within next 10 years. It has been published
fact from research that waste material like
fly-ash through their use as construction
material can be converted into meaningful
wealth. Also a partial replacement of
cement with fly ash is desirable and indeed
essential due to variety of technical,
economical and ecological reasons.






2

II. Research Significance
1. The presented research was aimed at
studying the mechanical properties like
optimum percentage of fly ash and
polypropylene fibers with cement
concrete. The different trial concrete mixes
were used to determine the optimum
compressive strength.
2. The study also aims to determine the
flexural, shear strength and deflections of
the post tensioned prism specimens and
compared actual strength obtained based
on experimental results with analytical
results. The research findings will be help
engineers to understand the overall
performance of compressive, tensile
strength with FA and Polypropylene fibres
and prestressed concrete for flexural
strength.

III. Experimental Program
The experimental programme was divided
in four phases a) Concrete mix design as
per IS 10262-1982 for grade of concrete.
To determine the optimum mix design
with optimum percentages FA replacing to
cement and optimum percentage of
polypropylene fibres by weight of cement.
b) Casting of post tensioned concrete
prism specimens with length of 600mm
and depth of 150mm and width of 150mm
and concrete cylinders of size 150mm
diameter and 300mm height for different
mix design. c) Prestressing to single strand
of 4 mm diameter with a prestressing force
13578.37N (1081 MPa) at the age of 28
days of prism specimens and grouting. d)
Testing of all prestressed prism specimens
at age of 28 days with single point loading
for shear, flexural strength and deflections.
Compared the analytical and experimental
results.

IV. Specimen Design:
There were three group series of post
tensioned prism specimens-
Each series having three specimens. All
series having same dimensions with span
of 600mm and cross sectional width
150mm and depth 150mm as shown in
figure.1.

Figure-1
All specimens were designed to have same
prestressing force Pu=13578.37N and
amount of prestressed steel (12.56
mm
2
).Single strand was used having 4mm
diameter.

V. Materials
Prestressed strand (IS:1786-1979) having
ultimate tensile strength 175 kg/mm
2
,proof
stress at 0.2 percent extension
169.1Kg/mm
2
,modulus of elasticity(E
s
)
3

21485 Kg/mm
2
. Cement of 53
grade,Fineness of cement = 5% < 10%
(IS:269-1976),Standard Consistency
Test=29.25% <30% (IS:4031-1968),Initial
Setting Time = 115 minutes > 30 minutes
(minimum)(IS:269-1976),Final Setting
Time = 258 minutes <
600minutes(maximum)(IS:269-
1976).Batch type concrete mixing
(IS:4634:1968) was carried out. Coarse
aggregate consisted of a 20mm maximum
size with crushing value=(Weight of
fraction passing through 2.67mm I.S.
sieve/Weight of
aggregate)=(541/2888)x100=18.73%(IS:2
386-Part-4) and Aggregate impact
value=(Weight of fraction passing through
2.67mm I.S. sieve / weight of
sample)=(46/400)x100=11.50%<45%(IS
283-1970).Fine aggregate (IS 2386-(Part-
I)-1963) specific gravity=2.6 and fineness
modulus=2.9.Potable water was used for
mixing and curing of concrete (IS:456-
2000).Water/cement(W/c) ratio was
0.42<0.6 (IS 456-2000).Water reducing
admixture(IS 9103:1999) 1% by weight of
cement. Fl y Ash-class-C ( IS 3812 Part
I 2003) and Polypropylene fibres
(ASTM-C-1116).

Three concrete mixes were design as per
IS code method and the mix-2 proportion
1:1.40:2.87, W/c ratio 0.42 and Water
reducing admixture (Flowcon-PC 163 JK)
1 % by weight of cement were used for
further casting of cubes, cylinders and post
tensioned prism specimen. Refer table 1.

Table 1 Quantity of materials required per cubic meter for trial mix
Mix Cement
kg/cu.m
Fly Ash
kg/cu.m
Polypropylene
kg/cu.m
River Sand
kg/cu.m
Coarse
aggregate
kg/cu.m
Water
kg/cu.m
Admixture
kg/cu.m
Mix-1 430 -- -- 637 1306 192 4.30
Mix-2 450 -- -- 632 1293.45 192 4.50
Mix-3 504.21 -- -- 683.24 1108.13 141.61 5.04
Table 2 Quantity of materials required per cubic meter as per mix-2 with different percentage of fly ash
replacing to cement
Mix % of fly ash
replacing to
cement
Cement
kg/cu.m
Fly Ash
kg/cu.m
Polyprop
ylene
kg/cu.m
River Sand
kg/cu.m
Coarse
aggregate
kg/cu.m
Water
kg/cu.m
Admixture
kg/cu.m
Mix-4 10% 405 45 -- 632 1293.45 192 4.50
Mix-5 20% 360 90 -- 632 1293.45 192 4.50
Mix-6 30% 315 135 -- 632 1293.45 192 4.50
Table 3 Quantity of materials required per cubic meter as per mix-5 with different percentage of polypropylene
4

Mix % of
Polypropyl
ene
Cement
kg/cu.m
Fly Ash
kg/cu.m
Polypropyle
ne kg/cu.m
River Sand
kg/cu.m
Coarse
aggregate
kg/cu.m
Water
kg/cu.m
Admixture
kg/cu.m
Mix-7 0.5% 360 90 2.25 632 1293.45 192 4.50
Mix-8 1% 360 90 4.5 632 1293.45 192 4.50
Mix-9 1.5% 360 90 6.75 632 1293.45 192 4.50
Table 4 Quantity of materials required per cubic meter
Beam
Specimen

No.of
sample
Cement
kg/cu.
m
Fly Ash
kg/cu.m
Polypropyle
ne kg/cu.m
River Sand
kg/cu.m
Coarse
aggregate
kg/cu.m
Water
kg/cu.m
Admixture
kg/cu.m
Series-1 3 495 -- -- 518 1053 208 5.94
Series-2 3 420.75 74.25 -- 518 1053 208 5.94
Series-3 3 420.75 74.25 4.20 518 1053 208 5.94
Mix -2 was used for further
experimentation of concrete cylinders and
post tensioned prism specimen series-
1(refer results table-5) also same mix was
used for experimentation on different
percentages of fly ash replacing to cement,
refer table-2.Compressive strength of
above table shown in figure-3.

Mix -5 was used with 20% replacement of
cement by fly ash for further
experimentation on concrete cylinders,
post tensioned prism specimen series-2
and different percentages of
polypropylene. Refer table-3 and figure-4.

Mix -8 was used with 20% replacement of
cement by fly ash and 1% of
polypropylene for further experimentation
on concrete cylinders, post tensioned
prism specimen of series-3.Refer table-4
and figure-5.The compressive strength of
1.5% polypropylene were slightly more
but workability was reduced and difficult
for casting also percentage polypropylene
were consume more as compared to
strength.

Mix proportions of table-4 were used for
casting of post tensioned prism specimen
series-1, 2, 3 as well as concrete cylinders.
VI. Specimen Casting
Total sixty three cube samples of size
150mmx150mmx150mm, nine concrete
cylinders of size 150mm diameter with
300mm height and nine prismatic beam
specimens of size
150mmx150mmx600mm were casted with
prestressing strand duct and grouting
holes.
i) Twenty seven cube samples were casted
for three different mix-1, 2, 3. Nine
samples for each mix respectively.
5

ii) Twenty seven cube samples for
different mix-4, 5, 6 with different
percentages of FA.i.e.10%, 20% and 30%
of FA replacing to cement to its weight
and having nine samples in every
percentage group respectively.
iii) Nine cube samples for different mix-7,
8 and 9 with different percentage of
Polypropylene i.e. 0.5%, 1%, 1.5% of
polypropylene fibres by weight of cement
having three samples in every percentage
group respectively.
iv) Three concrete cylinders and three post
tensioned prism specimens having
concrete mix-2 called as series-1.
v) Three concrete cylinders and three post
tensioned prism specimens having
concrete mix-5 called as series-2.
vi)Three concrete cylinders and three post
tensioned prism specimens having
concrete mix-8 called as series-3.
All cubes were casted in three lift and
consolidated using machine vibrator. After
final setting of cubes, the cube moulds
were removed and cubes were kept in
water tank for curing up to 7, 14, 28 days
respectively.
All concrete cylinder and post tensioned
prism specimens were casted in three lifts
and consolidated using tamping rods. After
setting the specimens were covered with
wet gunny bags. At the end of the third
day, the forms were stripped and
specimens were kept for curing up to 28
days.

VII. Stressing Procedure
The prestressing strand was tensioned by
using single strand hydraulic jack at the
age of 28 days of concrete prism
specimens. The strand force was
calculated by elongated length of
tensioned strand as well as by pressure
transducer installed on the hydraulic jack.
Tensioned strands were locked on rear end
of prism specimen by using end plate and
barrels (male and female cone).Post
tensioned ducts were grouted by injecting
cement slurry. Prism specimens were
tested for shear and flexural strength.
The step-by-step procedure used for
prestressing the strand is given as below-
1) The strand was passed through the
casted prism specimen duct and anchored
at rear end with end plate and barrels
(male and female cone), the hydraulic jack
was temporary anchor grip assembled at
other end to the strand.
2) The pump was operated after closing
and opening the necessary knobs
according to manufacturers instructions.
3) When slack of the strand was removed,
the zero indicating collars were set to the
nearest convenient graduation on the ram.
The required extension was measured from
this graduation.
6

4) After tensioning the strand up to
required extension immediately locking of
wedge was done by hammering the
wedges dolly through a slot provided in
the nose.
5) The jack was then retracted by closing
and opening the necessary knobs. The
temporary anchor grip was released from
the strand.

VIII. Test Setup
The post tensioned prism specimen was
simply supported with a concentrated load
applied at mid span, as shown in figure-2.
Load was applied by using UTM (100 tons
capacity) in 100kg increments up to failure
load. At each load increment, cracks were
inspected and marked, and the prism
specimens were photographed. Continuous
monitoring was carried out all through the
testing.

Figure 2: Test set up


Figure 3: Compressive strength results of concrete
mix 1,2,3
Concrete cubes for mix-1,2,3 were tested
on compressive testing machine (CTM).
From above test results it was revealed that
concrete mix-2 cube specimen were
having optimum compressive strength and
it was used for further experimentation.

Figure 4: Compressive strength results for mix-4,
5, and 6
From above test results it was revealed that
mix -5 was having 20% Fly-ash replacing
to cement (about its weight) was most
favorable combination with cement, then
increasing percentage of FA reducing
compressive strength. Refer figure-4.

Figure 5: Compressive Strength of mix-7, 8, and
9
From above test results it was revealed
that Fly-ash with 20% replacement to
cement (about its weight) and 1% of
Polypropylene Fibre (PF) was most
favorable combination for further
experimentation of post tensioned (prism)
flexural member. Refer table -5 and
figure-6.
24.65
31.85
35.35
31.65
44.08 44.07
35.51
48.98
53.33
0
10
20
30
40
50
60
Mix-1 Mix-2 Mix-3
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
n
g
t
h

i
n

M
P
a

Concrete mixes
7 days
14 days
28 days
24.93
23.25
19.93
26.3
27.28
25.55
39.7
42.35 42.08
0
5
10
15
20
25
30
35
40
45
Mix-4 Mix-5 Mix-6
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
n
g
t
h

i
n

M
P
a

Concrete mixes with different % of Fly ash
7 days
14 days
28 days
45.87
50.43
50.75
42
44
46
48
50
52
Mix-7 Mix-8 Mix-9
C
o
m
p
r
e
s
s
i
v
e

S
t
r
e
n
g
t
h

i
n

M
P
a

Concrete mixes with different % of Polypropelene
28 days Compressive
Strength
7


Figure 6: Shear Strength of series-1, 2 and 3 of
prism specimen
Figure-6 shows experimental and
analytical results of shear and flexural
strengths of post tensioned prism
specimen. From above test results it was
revealed that polypropylene improved the
flexural strength of post tensioned prism
specimens but plain concrete and Fly-ash
specimen reduced it as well. Experimental
and analytical values of shear and flexural
strength were approximaly same for all
specimen. For sample calculations refer
Annexure B-I/II.

Figure 7: Central deflections of beam specimens
of Series-1
Mix-2 was used for casting of plain
concrete post tensioned prism specimen
designated as PC-OPC-1-B1, 2, 3
respectively. At the age of 28 days central
single point load was applied with the help
of UTM. Refer figure-2 for test set up.
Central vertical deflection was measured
with the help of dial gauge. Load vs
Deflection shown in figure-7. Deflection
were linearly varying and there were
abrupt failure of beam specimen with
central cracks. Specimen PC-OPC-1-B-3
was having less deflection compared to
first two specimen PC-OPC-1-B-1 and 2.

Figure 8: Central deflections of beam specimens
of Series-2
Mix-5 was used for casting of post
tensioned prism specimen with 20% FA
replacing to cement, designated as PC-FA-
2-B-4,5 and 6 respectively. At the age of
28 days central single point load had
applied with the help of UTM.
Experimental test set up and deflection
measurement were same as series-1. Refer
figure-8 for load vs deflection. Deflections
were linearly varying with certain
fluctuations. There were also abrupt failure
of post tensioned prism specimen with
central cracks. But less toughness were
observed in series -2 than series-1.

Figure 9: Central deflections of beam specimens of
Series-3
0
5000
10000
15000
20000
25000
0 1 2 3 4
Experimental
Shear
Strength
Analytical
Shear Strength
0
5
10
15
20
0 0.2 0.4
L
o
a
d

i
n

K
N

Deflections in mm
PC-OPC-1-B1
PC-OPC-1.B-2
PC-OPC-1-B-3
0
5
10
15
20
0 0.1 0.2 0.3 0.4
L
o
a
d

i
n

K
N

Deflection- in mm
PC-FA-2-B-4
PC-FA-2-B-5
PC-FA-2-B-6
0
5
10
15
20
25
0 0.1 0.2 0.3 0.4
L
o
a
d

i
n

K
N

Deflection in mm
PC-PP-1-B-7
PC-PP-1-B-8
PC-PP-1-B-9
8

Table 5: Results summary
Series
Prism
Specimen

Size
(WidthxDe
pthxLengt
h) in mm
Point
load
Fck in
MPa
Experimental Analytical
Splitting
tensile
strength
in MPa
Avg.
Splitting
tensile
strength
in MPa
Shear
Stren
gth in
(N)
Avg.
shear
strength
in (N)
Flexural
strength
in MPa
Deflec
tion
in mm
Avg.
defle
ction
in
mm
Shear
strengt
h in (N)
Flexural
strength
in MPa
Deflec
tion
in mm

Series-1
PC-OPC-1-B-1 150x150x600 Single 48.98 3.24
3.49
18000
18000

4.84

0.29
0.28

18320

4.92 0.056 PC-OPC-1-B-2 150x150x600 Single 48.98 3.70 17000 0.25
PC-OPC-1-B-3 150x150x600 Single 48.98 3.54 19000 0.32

Series-2
PC-FA-2-B-4 150x150x600 Single 42.35 3.10
2.96
18000

17000


4.57

0.29
0.25

16330

4.48 0.054 PC-FA-2-B-5 150x150x600 Single 42.35 2.82 16000 0.23
PC-FA-2-B-6 150x150x600 Single 42.35 2.96 17000 0.25

Series-3
PC-PP-3-B-7 150x150x600 Single 50.43 4.06
4.16
20000
20333.3
3

5.44
0.35
0.32

20830


5.59

0.063 PC-PP-3-B-8 150x150x600 Single 50.43 4.28 19000 0.33
PC-PP-3-B-9 150x150x600 Single 50.43 4.16 20000 0.30
Mix-8 were used for casting of post
tensioned prism specimen with 20% FA
replacing to cement and 1% of
polypropylene fibers by weight of cement,
designated as PC-PP-3-B-7,8 and 9
respectively. Experimental load, deflection
measurement were same as series-1 and 2.
Initially deflections were very small but
after certain loading, they were linearly
varying with certain fluctuations.
There were ductile failure of prism
specimen and minor hair cracks were seen
at center before failure. Deflection of
specimen PC-PP-3-B-8 was less compared
to another two specimen. Refer figure-9.

IX. Result Analysis and Discussion

After reviewing and comparing the result,
the following points were
mentioned/discussed as given below.
1) As observed from the experimental
compressive testing results of three trial
mixes of concrete, mix-2 was selected for
further experimentations and it was found
to be satisfactory result as compare to
other mixes. Refer figure-3.
2) It was also observed from the
experimental compressive testing results
by adding Fly ash as 10%, 20% and 30%
replacement to cement by using mix-2.
The 20% replacement of cement by FA
was
found to be satisfactory result. Refer
figure-4.
3) It was also observed from the
experimental compressive testing results
by adding Fly ash 20% replacement to
cement and 0.5%,1%,1.5% polypropylene
by weight of cement(refer figure 4 & 5).
The 20% replacement of cement by FA
and 1% of polypropylene by weight of
cement was found to be satisfactory result.
9

4) As indicating in graph series-1 and
series-2 prism specimens were initially
deflect gradually and exceeds its limiting
deflection value (Refer figure 7 & 8),
where as in series-3 of fly ash +
polypropylene prism specimens initially
deflects slowly and does not exceed its
limiting deflection value (Refer figure 9),
hence from aspect of structural design it
would be advantageous to use Fly ash in
partial replacement to cement and
polypropylene.
The polypropylene fibers in concrete was
increasing ductility of prism specimens.
5) While mixing of concrete with
polypropylene fibers, it was observed that
it formed lumps with the other ingredients
of concrete. Thus, super plasticizer was
used to maintain the workability.
6) Polypropylene fibres increased flexural
strength of post tensioned prism specimens
as well as deflections were reduced.
Series-1 and 2 were have less deflection
and having abrupt failure, but series-3
were have moderate deflection and ductile
failure i.e. in case series-1 and series-2 of
prism specimens, the cracks were
developed at early stage and load carrying
capacity were less than series-3 and prism
ended after development of cracks.(Refer
Fig.7,8 &9)

X. Conclusions
After reviewing and analyzing the intact
methodology which involves analytical
study, design of member, mix design
procedure, prestressing procedure to aim
of experimental work it can be included
that.
Compressive strength of concrete were
reduced, when FA replacing to cement.
When different percentage of
polypropylene fibers were added with
different percentage of FA replacing to
cement, the compressive strength of
concrete were slightly increased.
1% polypropylene fibers by weight of
cement and 20 % of FA replacing to
cement were optimum replacement to
improve the strength of concrete.
The shear and flexural strength of
polypropylene fibers prestressed
concrete prism specimens of series-3
were more than series-1 and series-2.
The shear and flexural strength of
series-2 prestressed prism specimens
were less than series-1.
Deflection of series-3 were less and
having ductile failure due to
polypropylene fibres. Fibres were
interlocking in concrete particles and
improves ductility, flexural strength.
Series-1 and Series-2 prism specimens
were having brittle failure.


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Appendix A
List of Symbols and Word Meaning
Symbol Description
PC-OPC-
1-B-1,2,3
Prestressed concrete
Ordinary Portland Cement
Concrete (plain
concrete)prism specimens
14

1,2 and 3 respectively.
PC-FA-2-
B-4,5,6
Prestressed
concrete OPC+FA
prism specimens 4
5 and 6 respectively.
PC-PP-3-
B-7,8,9
Prestressed concrete
OPC+FA+ Polypropylene
prism specimens 7,8 and 9
respectively.
E
s
Modulus of elasticity of
steel in MPa=200x10
3
MPa
E
c
Modulus of Elasticity
of Concrete in MPa
=5000F
ck
as per
IS 456-2000
F
ck
Characteristic compressive
strength of concrete in
MPa
F
pu
Ultimate tensile strength
of steel in MPa= 1800Mpa
F
cr
Flexural and splitting
tensile strengths of
concrete=0.7F
ck

OPC Ordinary Portland cement
FA

Fly Ash
e Eccentricity
M
L
Bending moment due to
Live load
W
L
Live load on Prism
specimen (Single point
load)
f
t
Tensile strength of
concrete
Y and Total Deflection
W
D
Dead load of Prism
specimen
M
D
Bending moment due to
Dead load
Bending stress at top/
bottom fibre

Appendix B:
I) Beam Analysis:
Data:
Cross section of beam = 150 mm x 150
mm
Length of beam = 0.6 m
Stress in wire = 1081 N/mm
2

Diameter of wire = 4 mm
Area of wire = = 12.56 mm
2

I = = 42.18 x10
6
mm
2

Y = d/2 = 75 mm
Z = I / Y = 562.4 x 10
3
mm
3

Pu = Prestressing Force = 13578.37 N
Eccentricity = e = 50 mm
Self-weight of
beam(W
D
)=0.15x0.15x1x24=0.54KN/m
Assume 20% prestressed losses

To find out safe superimposed load for
bottom stress -3.49MPa:
F
b
=


M
T
= 2772.632x10
3
N.mm
Where,
M
T
= M
L
+ M
D

15

2772.6.2x10
3
= W
L
x L/4 + W
D
xL
2
/8 =
W
L
x 600/4 +(0.54x600
2
)/8= W
L
x600/4
+24.30x10
3


W
L
= 18320 N
Deflection at center of Simply Supported
Beam () = +W
L
xL
3
/48EI
= 0.056mm

Max. Permissible deflection=1.09mm to
1.38mm as per IS 456-2000 and R.
Prabhakara et al.2007.

II) Bending stress analysis:-
Experimental sample calculation of Series-
1:-
M
Total
= M
L
+ M
D
= W
L
x L/4 + W
D
xL
2
/8
= 18x 0.6/4 +(0.54x0.6
2
)/8=2.7243KN-m
We have,

= =4.8MPa

and
As per Clause 6.2.2 page-16 (I S456:2000
and I S5816)
Tensile strength or flexural strength of
concrete= f
ct
=0.7fck
f
ct
=0.7x48.98=4.89 MPa


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