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FLY ASH
CHAPTER 1
INTRODUCTION
1.1 General
Concrete is a material synonymous with strength and longevity. It has emerged as
the dominant construction material for the infrastructure needs of the twenty-first century.
In addition to being durable, concrete is easily prepared and fabricated from readily
available constituents and is therefore widely used in all types of structural systems. The
challenge for the civil engineering community in the near future is to realize projects in
harmony with the concept of sustainable development and this involves the use of high
performance materials and products manufactured at reasonable cost with the lowest
possible environmental impact. There are various studies going on to fit materials in place
of construction materials without affecting the required strength of concrete. One such
construction material that is depleting at a very fast rate is quarry sand which is used as
fine aggregate in concrete.
1.2 Aggregate
Aggregates are the important constituents in the concrete composite that help in
reducing shrinkage and impart economy to concrete production. Most of the aggregates
used are naturally occurring aggregates, such as crush rock, gravel and sand which are
usually chemically interactive or inert when bonded together with cement. On the other
hand, the modern technological society is generating substantially high amounts of solid
wastes both in municipal and industrial sectors; posing an engineering challenging task
for this effective and efficient disposal. Hence, partial or full replacement of fine
aggregates by the other compatible materials like sintered fly ash, crushed rock dust,
quarry dust, glass powder, recycled concrete dust, and others are being researched from
past two decades, in view of conserving the ecological balance. In this project an attempt
has been made to replace sand by black cotton soil and fly ash.
LITRATURE REVIEW
2.1[1]
The experimental studies on mortar containing fly ash as a partial replacement of
sand by weight as well as by volume were carried out to quantify its utilization. Both the
types of pond and bottom fly ash in various ratios were used in preparing cement mortar
and their strengths in compression and tension were tested. Out of the various proportions
the mortar mix 1:2.5:2.5 (cement: coarse sand: pond fly ash) designed by method of
volume is found satisfactory as for as the strength is concerned. The maximum utilization
of fly ash almost 75% and cost saving about 58% were ascertained with the plain mortar
of ratio 1:5 (cement: sand). The utilization of fly ash in mortar designed by weight
provides 50% to 60% financial saving while 9% to 16% by method of volume. However,
the flyash mortar mix 1:1:5 (cement :fly ash :sand) by weight consumes about 20% less
quantity of cement and overall consumption of flyash is also less.
2.2[2]
Due to increase in the growth of industrial sectors the power requirement of the
country is rapidly increasing. India depends on Thermal Power as its main source, thus
increase in power requirement every year. Present scenario of our country shows 75 % of
countrys total installed power generation is thermal of which coal-based generation is
90%. The coal reserves of the country are predominately of lower grades (average of 35%
ash content), non cooking and as a result more than 110 million MT coal ash is being
generated every year. Ash generation may likely reach to 170 million MT by 2012. Use of
coal brings huge amount of ash every year. Lots of research has been carried out for
effective utilization of fly ash in construction industries due to its fine particles and
Pozzolonic properties. But little literature is available on pond ash utilization. Pond ash
being coarser and less Pozzolonic than fly ash can be used as fine aggregates in concrete
by partial replacement of sand.
As per M60 Mix Design in this project we will replace the alccofine and fine fly
ash partially with cement and pond fly ash as a replacement of fine aggregate. In mix G1,
J.T.M.C.O.E FAIZPUR (Department of Civil Engg)
METHODOLOGY
3.1 MATERIALS FOR CASTING
Cement
Ordinary Portland cement (OPC) 53 grade (Jypee Cement) was used for the
investigation. It was tested for its physical properties in accordance with Indian Standard
specifications.
Fine aggregate
There are two types of Fine Aggregate were used. One fine aggregate is black
cotton soil obtained from nearby field. The black cotton soil was sieved through 4.75 mm
sieve. The specific gravity was found to be 2.19. The other fine aggregate used was fly
ash.
Coarse aggregate
The coarse aggregates used were of two grades, non-reactive and available in
local quarry. One grade contained aggregates passing through 4.75 mm sieve and retained
on 10 mm size sieve. Another grade contained aggregates passing through 10 mm sieve
but retained on 20 mm sieve.
Water
Ordinary tap water used for concrete mix in all mix.
WT.OF CEMENT(W)gm
400
16
%WT OF RETAIND
4%
Page
Sr No
DESCRIPTION
SYMBOL
Wt.
1
2
3
Ww
Wc
Ww/ Wc
152 ml
400gm
33%
consistency is 38%
Page
Fig no. 3.3 Sieves used for determination of fineness of coarse agg.
SR NO
IN SIEVE
WT OF AGG
CUMULATIVE
CUMULATIVE
SIZE (mm)
RETAINED
RETAINED
% RETAINED
% PASSING
40
100
20
3.375
35.83
0.55
45
16
3.05
20.33
0.46
54
12.5
1.725
11.50
0.114
85.6
10
0.790
5.2
0.9
94.06
4.75
0.090
4.1
4.32
95.68
2.36
0.064
0.042
0.44
99.56
1.18
0.105
0.007
0.7029
99.277
600micron
0.033
0.0022
0.221
99.78
10
300
0.044
0.0047
0.374
99.686
11
150
0.030
0.002
0.200
99.66
12
PAN
0.53
0.00356
0.388
99.612
Page
Page
DESCRIPTION
SYMBOL
TEST 1
3.300KG
0.715KG
NO
mm is sieve
Table no 3.4 determination of agg crushing value
The agg crushing value = (b/a)*100=21.66%
Avg agg crushing value = 21.66%
Result: the agg crushing value = 21.66%
Page
Fig no 3.5 Equipment used for test of flakiness index & elongation index
OBSERVATION & CALCULATION:
Sr No
1
2
3
4
5
6
DESCRIPTION
total wt of agg taken for flakiness test(
SYMBOL
W1
1110gm
W2
375gm
W3
1110gm
W4
285gm
flakiness index
w2/w1
0.338
elongation index
w4/w3
0.257
Wt.
Page
Where
M1=mass of empty Pycnometer,
M2= mass of the Pycnometer with dry soil
M3= mass of the Pycnometer and soil and water,
M4 = mass of Pycnometer filled with water only.
G= Specific gravity of solids.
Page
Equipment:
1. Pycnometer of about 1 litre capacity
2. Weighing balance, with an accuracy of 1g.
3. Glass rod
4. Vacuum pump
Observations and calculations:
Sl.
Observations an Calculations
1
No.
1
Pycnometer No.
Room Temperature
27 0 C
696gm
896gm
1678.5gm
1569.5gm
M2 M1
200
M3 M4
109
Table.3.6.Pycnometer Test
CALCULATION:
G=(896-696)/((896-696)-(1678.5-1569.5))
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Page
3.3Mix Design[8]
3.3.1For plain concrete
Stipulation For Proportioning according to IS: 10262:2009
Page
Table.5
of
IS:456,
minimum
cement
content
for
mild
exposure
conditions=300kg/m3
Hence OK
Proportion of volume of course aggregate and fine aggregate
From table no 3volume of course agg. corresponding to 20mm size agg. and fine agg. For
water cement ratio = 0.50 = 0.60
Page
Page
3.3.2For concrete with replacement of fine aggregate by black cotton soil and fly ash
Stipulation For Proportioning
Grade designation: M20
Type of cement: Birla type 53 grade
Maximum normal size of aggregate: 20mm
Minimum cement content: 325 kg/gm
Maximum water content: 0.50
Workability: 60mm slump
Exposure condition : moderate
J.T.M.C.O.E FAIZPUR (Department of Civil Engg)
Page
Page
= fck+1.65s
=20+1.65*4
=26.60
Page
= 0.4 x 0.7345
=0.2938m3
Use 2 type of fine agg.
1. Black cotton soil
2. Fly ash
Use 70% black cotton soil and 30% fly ash
Mass of black cotton soil
= 0.2938 x 0.7 x 2.19 x 1000
= 450.39 kg/ m3
Page
= 545.35 x 0.5
=272.67kg or 272.6L
i.
Page
Sr.No.
Material
Wt. in kg/m3
w/c ratio
0.50
Cement
383 kg/m3
Water
191.6 kg/m3
Fine agg.
727 kg/m3
Course agg.
1103 kg/m3
Table No 3.7 Quantity of Materials per cubic meter for plain concrete Grade M-20
Page
Table
3.8
Sr.No.
Material
Wt. in kg/m3
w/c ratio
0.50
Cement
325 kg/m3
Water
272.67 kg/m3
Fine agg.
450.39 kg/m3
2.fly ash
220.35
No
kg/m3
483 kg/m3
724.5 kg/m3
Quantity of Materials per cubic meter of Grade M-20 concrete with replacement of
fine aggregate by black cotton soil and fly ash (Without admixture)
Page
Sr.No.
Material
Wt. in kg/m3
w/c ratio
0.50
Cement
325 kg/m3
Water
272.67 kg/m3
Fine agg.
450.39 kg/m3
2.fly ash
220.35
SP. 500
kg/m3
483 kg/m3
724.5 kg/m3
2.72 kg/m3(0.5%)
Table No 3.9 Quantity of Materials per cubic meter of Grade M-20 concrete
with replacement of fine aggregate by black cotton soil and fly ash (With
admixture)
Page
CHAPTER 4
RESULT
4.1.STANDARD RESULTS OF A M20 PLAIN CONCRETE
Sr.no
AGG AT
CRUSHING
COMPRESSIV
AVERAGE
TESTING
LOAD
E STRENGTH
COMPRESSIVE
OBSERVED ON
(N/MM )
STRENGTH(N/MM2)
MACHINE
7 DAYS
390
17.33
17.32N/mm2
14DAYS
500
22.22
22.22N/mm2
28 DAYS
600
26.67
26.67N/mm2
Page
25
20
15
10
7 Days
14Days
28Days
Graph no 4.1. Avg compressive strength for 7 ,14 and 28 Days for M20 plain
concrete
4.2.RESULT OF COMPRESSIVE STRENGTH OF M20 CONCRETE BY
REPLACING FINE AGGREGATE WITH BLACK COTTON SOIL AND FLY
ASH (without admixture)
Date of Casting :18/02/2015
Sr.n
WT.OF
AGG AT
CRUSHIN
COMPRESSIV
AVERAGE
SPECIME
TESTIN
G LOAD
E STRENGTH
COMPRESSIVE
OBSERVE
(N/MM2)
STRENGTH(N/MM
D ON
MACHINE
Date of testing : 25/02/2015
Page
8295
7 DAYS
390
17.33
8280
7DAYS
380
16.88
8315
7 DAYS
400
17.77
17.32N/mm2
8310
14 DAYS
515
22.8
8350
14 DAYS
520
23.11
8285
14 DAYS
490
21.77
22.56N/mm2
8795
28 DAYS
590
26.22
8450
28 DAYS
580
25.77
8560
28
580
25.92N/mm2
25.77
DAYS
Page
25
20
15
10
7 Days
14Days
28Days
Graph no 4.2 Avg compressive strength for 7 ,14 and 28 Days for concrete with replacement
of fine aggregate by black cotton soil and fly ash (without admixture)
Page
WT.OF
AGG AT
CRUSHING
COMPRESSIV
AVERAGE
SPECIMEN
TESTING
LOAD
E STRENGTH
COMPRESSIVE
OBSERVED
(N/MM )
STRENGTH(N/MM2)
ON
MACHINE
Date of testing : 19/03/2015
1
2
3
8675
8600
8700
7 DAYS
395
17.55
7DAYS
400
17.77
7 DAYS
390
17.33
17.53N/mm2
8680
14
520
23.11
8540
DAYS
14 DAYS
525
23.33
8675
14 DAYS
530
23.55
23.33N/mm2
8700
28DAYS
600
26.67
8655
28 DAYS
590
26.22
8680
28 DAYS
600
26.67
26.51N/mm2
Page
30
25
20
15
10
7 Days
14Days
28Days
Graph no 4.3 Avg compressive strength for 7 and 28 Days for concrete by replacing
fine aggregate by black cotton soil and fly ash (with admixture)
Page
Id mark
PLAIN CONCRETE
T1
7DAYS
17.32
14DAYS
22.22
28DAYS
26.67
17.32
22.56
25.92
17.53
23.33
26.51
CONCRETE BY
REPLACING FINE
AGGREGATE
WITHOUT
3
ADMIXTURE
T2
CONCRETE BY
REPLACING FINE
AGGREGATE WITH
ADMIXTURE
Graph no 4.4 Compressive strength Vs No. of days (With and without Admixture)
CHAPTER 5
CONCLUSION
It is observed from results that concrete with Replacement of fine aggregate by black
cotton soil and fly ash gives similar strength to that of a plain concrete.
Page
Compressive strength of 7 days and 14 days increased to about 1.2% when fine
aggregates are replaced by black cotton soil and fly ash as compared to plain concrete
Compressive strength of 28 days was almost same of that of plain concrete and of
concrete of replaced fine aggregates with very little variation.
CHAPTER 6
REFERENCES
1.
Page
Jay Patel, Kunal Patel, Gaurav Patel, UTILIZATION OF POND FLY ASH AS A
PARTIAL REPLACEMENT IN FINE AGGREGATE WITH USING FINE FLY ASH
AND ALCCOFINE IN HSC , Volume: 02 Issue: 12 | Dec-2013.
3.
Rafat Siddique, Effect of fine aggregate replacement with Class F fly ash on the
mechanical properties of concrete, Received 28 February 2002; accepted 16 September
2002
4.
5.
M. Mageswari, and Dr. B.Vidivelli, The Use of Sheet Glass Powder as Fine
Aggregate Replacement in Concrete,The Open Civil Engineering Journal, 2010, Volume
4
6.
7.
8.
9.
10.
IS 383-1970: Specification for coarse and fine aggregates from natural sources for
concrete, Bureau of Indian Standards, New Delhi
11.
IS 456-2000: Code of practice for plain and reinforced concrete Bureau of Indian
Standards, New Delhi.
Page
13.
Web references
http://en.wikipedia.org/wiki/black-cotton_soil
http://www.sciencedaily.com/releases/2012/01/120123101829.htm
http://en.wikipedia.org/wiki/Flyash#cite_note-ecfibre-3
http://en.wikipedia.org/wiki/blackcottonsoilandflyash#Properties
www.sciencedirect.com
www.elsevier.com
www.springerlink.com
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