TABLE OF CONTENTS

Certificate
Acknowledgement
Abstract
Table of Contents
List of figures
List of tables
Notations
Abbreviations
CHAPTER 1: INTRODUCTION
1.1 Background......................................................................................... 1
1.2 Aim....................................................................................................... 2
1.3 Objectives............................................................................................ 2
1.4 Significance of research work........................................................... 3
1.5 Scope................................................................................................... 3
1.6 Organization of thesis........................................................................ 4
CHAPTER 2: LITERATURE
2.1 Introduction........................................................................................ 5
2.2 Fly ash................................................................................................. 5
2.3 Visual Stability Index.......................................................................... 5
2.4 Stress-strain behavior........................................................................ 5
2.5 Previous research papers.................................................................. 8
2.5.1 Stress-strain behavior of normal concrete............................... 8
2.5.2 Effect of fly ash as a replacement on concrete....................... 8
2.5.3 Production and usage of fly ash in India.................................. 9
2.6 Need of research work...................................................................... 9
2.7 Closing remarks................................................................................ 10
CHAPTER 3: METHODOLOGY
3.1 Introduction....................................................................................... 11
3.2 Flow chart.......................................................................................... 11
3.3 Briefing.............................................................................................. 12
3.3.1 Literature survey
3.3.2 Problem formulation
3.3.3 Aim and objectives
 3.3.4 Specimen geometry
3.3.5 Testing of materials
3.3.6 Mix design
3.3.7 Casting and curing of specimens
3.3.8 Testing of specimens
3.3.9 Result and analysis of test specimens
3.3.10 Conclusion
CHAPTER 4: EXPERIMENTAL PROGRAMME
4.1 Introduction....................................................................................... 13
4.2 Test program..................................................................................... 13
4.3 Material properties............................................................................ 13
4.3.1 Cement....................................................................................... 14
4.3.2 Fine aggregate........................................................................... 14
4.3.3 Coarse aggregate...................................................................... 16
4.3.4 Fly ash........................................................................................ 18
4.3.5 Water.......................................................................................... 18
4.4 Mix Design......................................................................................... 18
4.5 Specimen geometry.......................................................................... 19
4.6 Batching............................................................................................. 19
4.7 Mixing................................................................................................. 20
4.8 Workability......................................................................................... 20
4.8.1 Slump cone test......................................................................... 21
4.8.2 VSI test........................................................................................ 21
4.9 Initial and final setting time............................................................... 22
4.10 Casting of specimens...................................................................... 22
4.11 Curing................................................................................................ 23
4.12 Testing of specimens...................................................................... 23
4.12.1 Compression test..................................................................... 23
4.12.2 Stress-strain behavior by compressometer........................... 24
CHAPTER 5: RESULT AND ANALYSIS
5.1 Introduction......................................................................................... 26
5.2 Workability.......................................................................................... 26
5.3 Visual Stability Index.......................................................................... 27
5.4 Initial and final setting time of cement paste.................................. 27
5.5 Compressive strength....................................................................... 28
5.6 Modulus of elasticity......................................................................... 29
CHAPTER 6: CONCLUSION..................................................................... 39
References............................................................................................... 40
LIST OF FIGURES
Figure 2.1: VSI=0........................................................................................... 6
Figure 2.2: VSI=1........................................................................................... 7
Figure 2.3: VSI=2........................................................................................... 7
Figure 2.4: VSI=3........................................................................................... 8
Figure 4.1: Cement....................................................................................... 14
Figure 4.2: Crushed sand............................................................................. 15
Figure 4.3: Coarse aggregate...................................................................... 17
Figure 4.4: Fly ash........................................................................................ 18
Figure 4.5: Mixing of concrete.................................................................... 20
Figure 4.6: Slump cone test........................................................................ 21
Figure 4.7: Casted cubic specimens.......................................................... 23
Figure 4.8: CTM............................................................................................ 24
Figure 4.9: Testing of cube under CTM...................................................... 24
Figure 4.10: Compressometer.................................................................... 25
Figure 5.1: Relationship between age and strength of concrete............. 28
Figure 5.2: Relationship between percentage replacement and strength of
concrete........................................................................................................ 29
Figure 5.3: Strain versus stress for conventional concrete at 25 days... 31
Figure 5.4: Strain versus stress for 10% replacement at 25 days........... 31
Figure 5.5: Strain versus stress for 20% replacement at 25 days........... 31
Figure 5.6: Strain versus stress for 25% replacement at 25 days........... 32
Figure 5.7: Strain versus stress for 30% replacement at 25 days........... 32
Figure 5.8: Strain versus stress for conventional concrete at 50 days... 32
Figure 5.9: Strain versus stress for 10% replacement at 50 days............ 33
Figure 5.10: Strain versus stress for 20% replacement at 50 days......... 33
Figure 5.11:Strain versus stress for 25% replacement at 50 days.......... 34
Figure 5.12: Strain versus stress for 30% replacement at 50 days......... 34
Figure 5.13: Strain versus stress for conventional concrete at 60 days.. 34
Figure 5.14: Strain versus stress for 10% replacement at 60 days.......... 35
Figure 5.15: Strain versus stress for 20% replacement at 60 days.......... 35
Figure 5.16: Strain versus stress for 25% replacement at 60 days.......... 36
Figure 5.17: Strain versus stress for 30% replacement at 60 days.......... 37
Figure 5.18: MOE versus various percentage replacement...................... 37
Figure 5.19: MOE versus age of concrete................................................ 38

LIST OF TABLES

Table 2.1: Visual Stability values and criteria........................................... 6

Table 4.1: Number of test specimens...................................................... 13
Table 4.2: Sieve analysis of fine aggregate.............................................. 15
Table 4.3: Fine aggregate zoning.............................................................. 16
Table 4.4: Properties of fine aggregate.................................................... 16
Table 4.5: Sieve analysis of coarse aggregate........................................ 17
Table 4.6: Properties of coarse aggregate............................................... 17
Table 4.7: Mix proportion of concrete....................................................... 19
Table 4.8: Specimen geometry...................................................................19
Table 5.1: Slump values.............................................................................. 26
Table 5.2: Initial and final setting time....................................................... 27
Table 5.3: VSI values obtained for concrete mixes.................................. 27
Table 5.4: Result of compression test of cubes...................................... 28
Table 5.5: Strain, stress and MOE at 25 days with varying percentage of fly
ash.......................................................................................................... 30
Table 5.6:Strain, stress and MOE at 50 days with varying percentage of fly
ash.......................................................................................................... 30
Table 5.7:Strain, stress and MOE at 60 days with varying percentage of fly
ash........................................................................................................... 31
ABBREVATIONS

ACI American Concrete Institute

IS Indian Standard
VSI Visual Stability Index
CTM Compression Testing Machine
MOE Modulus of Elasticity
ASTM American Society for Testing of Materials
CHAPTER 1

INTRODUCTION

1.1 Background
In any country, construction accounts for about 60 percent of the plan outlay. Of
all the materials used, concrete is by far the most widely used construction material
today. Concrete is a proportionate mixture, comprising of major components viz.
cement, coarse aggregate, fine aggregate and water. Coarse aggregate is obtained by
crushing rocks into desired size. Fine aggregate i.e. sand is extracted naturally from
river beds or is obtained by crushing stones. Cement, on the other hand is
manufactured in industries. Production of cement uses conventional fuels such as coal
and petroleum. When these fuels are burned, they produce large amount of carbon
dioxide (CO2) in the environment. Carbon dioxide is an important greenhouse gas,
which in excess contributes to global warming. In India alone, the production of
cement is as much as 420 million tons. CO2 emitted from cement production industries
constitute 5-6 % of the total CO2 contributing to global warming. Furthermore, the
natural materials used for production of cement are getting depleted rapidly. Due to
these problems finding appropriate cement supplant is necessary.
To overcome these impediments research on use of sustainable materials such as
Ground Granulated Blast furnace Slag (GGBS), fly ash, recycled glass, silica fume,
etc. has been carried out. It was found that, these materials when used in various
proportions enhance the mechanical properties of concrete. IS 1489(Part I):1991
suggests replacement of cement by fly ash in the range of 15-30%.
Workability is the ease with which concrete can be placed and compacted without
losing its homogeneity. Workability is a comparative measure. A concrete mix
workable for slab may not be workable for a dam.
Visual Stability Index (VSI) test specified in ASTM C1611M involves the visual
evaluation of the self-compacting concrete patty resulting from observation of the
concrete just prior to placement and after the performance of the slump flow test. It is
used to evaluate the relative stability of batches of the same or similar chemical mixes.
It is a much easier test and requires no special equipment.
It is essential that cement set neither too rapidly nor too slowly. In the first case
there might be insufficient time to transport and place the concrete before it becomes
too rigid. In the second case too long a setting period tends to slow up the work
unduly, also it might postpone the actual use of the structure because of inadequate
strength at the desired age. The replacement of cement by fly ash may change the
setting properties due to the corresponding change in the matrix.
Stress-strain curves are an extremely important graphical measure of a material’s
mechanical properties. It is the amount of deformation at distinct condition of loading.
They are basis of generalized formulae for designing any structure. Stress-strain
relationship is affected by the type of material, homogeneity, direction of loading, rate
of loading, visco-elastic properties and fatigue. Thus, change in composition of
concrete would change its behaviour globally. When there is replacement of cement,
the matrix properties change, thus, changing the stress-strain behavior and ultimately
changing overall structural properties. Stress-strain behavior is a key parameter in
design and analysis of structure.

1.2 Aim
To experimentally investigate stress-strain behavior of concrete when cement is
replaced by fly ash with varying percentage and at various ages.

1.3 Objective
To fulfill the aim of the research work the objectives set are as follows
1. To study the effect of fly ash content on workability of concrete.
2. To study the effect of fly ash content on initial and final setting time of cement
paste.
3. To study the effect of fly ash content on Visual Stability Index (VSI) of concrete.
4. To study the stress-strain behavior of fly ash concrete with varying percentage of
fly ash
5. To study the stress-strain behavior of fly ash concrete at various ages.

1.4 Significance of the research work

IS: 1489-1991 (Part I) suggests replacement of cement by fly ash in the range of
15-30%. Previous research showed that addition of fly-ash enhances the workability
and mechanical properties of concrete. Compressive stress–strain property of concrete
is an intrinsic component of reinforced concrete analysis and design. However, not
much work has been done on the stress-strain behavior of fly ash concrete. Also, study
of VSI is comparatively a new domain. It requires no special equipment, is easier that
other conventional plastic stage tests. The present project work aims to experimentally
investigate the stress-strain behavior of concrete at different age when fly-ash is used
as cement replacement material at varying percentage and age. The VSI index
obtained through the experimental work will be helpful to find the consistency and
stability of the concrete mix on site. The VSI is an appropriate indicator to give an
idea about segregation and bleeding of the concrete mix.

1.5 Scope of the research work

1. M30 grade of concrete was used to cast the test specimens.
2. 20 mm maximum nominal size coarse aggregate, crushed stone as fine aggregate
and potable water were used in the production of concrete.
3. Cement was replaced by fly ash with 0%, 10%, 20%, 25% and 30%.
4. Slump cone test and VSI test was performed on concrete in plastic stage.
5. Initial and final setting time of the cement paste and cement-fly ash paste with
varying percentage of fly ash.
6. Compressive strength of concrete was experimentally found at the age of 7 days, 28
days, 45 days and 90 days.
7. Modulus of elasticity of concrete was found at the age of 25 days, 50 days and 60
days.

1.6 Organization of the thesis

The present thesis is completed with six chapters. In chapter 1, background, aim,
objectives, significance and scope of the research work is covered. Chapter 2
comprises review of the previous research work and theoretical content of the topics
like workability and VSI of concrete, initial and final setting time of cement paste and
modulus of elasticity of concrete. In chapter 3, the methodology followed to achieve
the set objectives is explained. In chapter 4, the details of specimen geometry,
concrete mix design, test procedures for materials and test specimens is described. In
chapter 5, the results obtained from testing of concrete in plastic stage and the testing
of test specimens is discussed. In chapter 6, the conclusions drawn based on the
analysis of the test results are presented.
CHAPTER 2

LITERATURE REVIEW
2.1 Introduction
In this chapter, the details about fly ash, concept of VSI of concrete and stress-
strain behavior of concrete is given. The review of previous work done on use of fly
ash in concrete is presented.

2.2 Fly Ash

Fly ash is finely divided residue resulting from the combustion of powdered coal
and transported by the flue gases as in case of thermal power plants. Being a by-
product, it makes it a greener option. Further, fly ash being non-biodegradable
material its use in concrete solves its disposal issues. In India, about 176.74 million
tons of fly ash is produced out of which only 60% is utilized. Size of fly ash ranges
from 1-300 µm. Fly ash, when used in concrete, contributes to the strength of concrete
due to its pozzolanic reactivity.
Heat
Ca(OH)2 + H4SiO4 CaH2SiO4.2H2O
(Alkaline condition pH=12)

From the previous literature survey it was observed that use of fly ash in concrete
increases workability and enhances mechanical properties like tensile strength,
flexural strength and compressive strength of concrete.

2.3 Visual Stability Index

As per ASTM C1611M, stability of concrete can be observed visually by
examining the concrete mass and therefore can be used for quality control of concrete
mixes. It is easier and quicker to carry out the VSI test. Table 2.1 contains Visual
Stability Index (VSI) values with corresponding criteria to qualitatively assess the
stability of self-consolidating concrete.

Table 2.1: Visual stability values and criteria

VSI value Criteria

0 = Highly Stable No evidence of segregation or bleeding.

1 = Stable No evidence of segregation and slight bleeding observed

as a sheen on the concrete mass

2 = Unstable A slight mortar halo # 0.5 in.(# 10 mm) and/or aggregate

.
pile in the of the concrete mass

3 = Highly Unstable Clearly segregating by evidence of a large mortar halo

center of the concrete > 0.5 in. (> 10 mm) and/or a large aggregate pile in the
mass.
 Figure 2.1: VSI=0

Figure 2.2: VSI=1

Figure 2.3 VSI=2

 Figure 2.4: VSI=3

2.5 Previous research

2.5.1 Stress-Strain behavior of normal concrete
Ken Watanabe et.al. (2004) investigated stress –strain curve of concrete considering
localized failure in compression. The behavior of stress-strain curve of concrete was
studied in detail according to aspect ratio, size and shape of the specimen.
Experimental equations were proposed and their applicability was checked by
comparing experimental curves obtained.

2.5.2 Effect of fly ash as a replacement on concrete

R.D. Padheyet. al. (2016) investigated the effect of fly-ash on compressive strength
of different high grades concrete for different proportions of fly ash and different
curing periods. The properties of concrete with variable fly ash content from 0% to
60% with 10% increment was studied for M30, M40, and M50 grade of concrete.
Optimum dose of fly ash was found out to be 40% of cementations material used.
Michael D A Thomas (1994) mechanical as well as physical properties of concrete
were checked to meet Constructional requirement for sustainability, durability,
constructability. Fly ash up to 50% as a replacement can be used as far as initial
strength of concrete does not get bothered.

C FreedaChristy et. al. (2010) investigated effect of class-F fly ash as partial
replacement of cement and fine aggregate in mortar. Properties of cement mortar
studied with replacement of cement and sand by fly ash, optimum results were
obtained for 20% replacement of sand by fly ash.

Prof. JayeshkumarPitroda (2005) investigated gainful utilization of fly ash in

concrete. Concrete mixes were produced, tested and compared in terms of
compressive strength and flexural strength to the conventional concrete. These tests
were carried out to evaluate the mechanical properties for the test results for
compressive strength and flexural strength up to 90 days are taken.

Jayeshkumar Pitrodaet. al. (2013) investigated effects of the usage of fly ash as
partial replacement of cement on the mechanical properties of concrete were checked
to reduce the bad impact of cement used in concrete on economy, environment.
Compressive and split tensile strength found out by testing specimens at 90 days of
curing. With 20% replacement of cement by fly ash cost can be reduced up to 25.04%.

2.5.3 Production and usage of fly ash in India

Flyash for cement concrete, Ash Utilization Division, NPTC. presented information
about production methods of fly ash, amount of fly ash produced per year and the
sources of fly ash generation in India. Composition, properties and usage of fly ash
were given.

2.6 Need of research work

A review of literature shows that, although, work has been carried out in terms of
compressive strength, tensile strength and flexural strength of concrete in which
cement is replaced by fly ash, no research has been done on the study of stress-strain
relationship of the same. VSI test developed by ASTM for SCC is a relatively new
concept for normal concrete as well as concrete in which cement is replaced by fly
ash. The present research work is thus aimed at, studying the stress-strain behavior of
concrete when cement is replaced by varying percentage of fly ash and its properties
at varying age and it’s VSI.

2.7 Closing remarks

A review of recent literature on fly ash concrete, stress-strain behaviour of
concrete and production of fly ash concrete has been presented on the basis of which
the need of the present investigation has been identified.
CHAPTER 3

METHODOLOGY

3.1 Introduction
From extensive literature survey need of present investigation identified and
accordingly aims and objectives were set. To fulfill the objectives the experimental
program was prepared. The details of experimental program are given in the following
session.

3.2 Flow chart

LITERATURE SURVEY

PROBLEM FORMULATION

AIM AND OBJECTIVES

SPECIMEN GEOMETRY

TESTING OF MATERIALS

MIX DESIGN

CASTING AND CURING OF SPECIMENS

TESTING OF SPECIMENS

RESULT AND ANALYSIS

3.3 Briefing
1. Literature survey CONCLUSION
An extensive research on the related concepts and work done upon the topic was been
carried out.

2. Problem formulation
On the basis of literature survey, need of the research work was established.

3. Aim and objectives

Aim and objectives were decided upon in accordance with the need of the research
work.

4. Specimen geometry
Geometry of specimens were decided in accordance with appropriate IS code.

5. Testing of materials
The constituent materials were tested individually adhering to the methods and
requirements of the IS codes.

6. Mix design
Concrete mix was designed for all five mixes in accordance with the IS codes.

7. Casting of specimens and curing

The cubic and cylindrical specimens were cast following all the rules in the IS codes
and were kept for curing for the required age.

8. Testing of specimens
The cubes were tested for compressive strength and the cylinders were tested for
modulus of elasticity.

9. Result and analysis

The results obtained from testing of specimens were compiled and analyzed.

10. Conclusion
Base on the analysis of test results, the conclusions are drawn.
CHAPTER 4

EXPERIMENTAL PROGRAMME

4.1 Introduction
The experimental program was designed to investigate stress-strain behavior of
concrete when cement is partially replaced by fly ash in varying percentage. Details of
material properties, test specimens and test procedure are presented in the following
sections.

4.2 Test program

Using designed M30 concrete mix total 60 cube and 45 cylindrical specimens
were cast and tested to find compressive strength and modulus of elasticity of
concrete. Cement was replaced by fly ash with 10%, 20%, 25% and 30%. The cube
specimens were cured and tested for compressive strength of concrete at 7, 28, 45 and
90 days. The cylindrical specimens were tested for stress-strain behavior of concrete at
varying age. The numbers of the test specimens are given in table 4.1.

Table 4.1: Experimental program

% replacement Cube Cylinder

of cement by
fly ash 7 days 28 days 45 days 90 days 25 days 50 days 60 days

0 3 3 3 3 3 3 3

10 3 3 3 3 3 3 3

20 3 3 3 3 3 3 3

25 3 3 3 3 3 3 3
30 3 3 3 3 3 3 3

4.3 Material properties

In the preparation of designed concrete, the main constituent materials used were
cement, crushed sand as fine aggregate, coarse aggregates, water and fly ash. Testing
of all the materials was carried out to find their physical properties. The testing
procedure and their physical properties are discussed below.
4.3.1 Cement
Cement is a fine, grey powder. The ordinary cement contains two basic
ingredients namely argillaceous and calcareous. In argillaceous materials, clay
predominates and in calcareous materials calcium carbonate predominates. It is mixed
with water and materials such as sand, gravel, and crushed stone to make concrete.
The cement and water form a paste that binds the other materials together as the
concrete hardens. Ordinary Portland cement of grade – 53 (Birla super cement)
conforming to IS: 12269–1987 has been used in the present study. The specific gravity
of cement used was 3.15.

Fig 4.1: Cement

4.3.2 Fine Aggregates

The material which passes through 4.75 mm sieve is termed as fine aggregate.
Usually natural sand is used as a fine aggregate. Locally available crushed sand
confirming to IS: 383–1970 was used in the experimental work. Sieve analysis of the
sand was carried out in accordance with IS: 2386–1963 Part 1 and the results are
shown in table 4.2. The testing of sand for the physical properties was done in
accordance with IS: 2386–1963 Part 3. The sieve analysis and grading curve for the
fine aggregate are given In Table 4.2 & Graph 4.1 respectively.
Fig 4.2 Crushed Sand

Table 4.2: Sieve analysis of fine aggregate

Weight cum.%
Sr. No. IS Sieve,mm % retained cum.% Passing
retained ,g retained
1 10 0 0.00 0.00 100
2 4.75 6 0.60 0.60 99.40
3 2.36 274 27.40 28.00 72.00
4 1.18 262 26.20 54.20 45.80
5 600µ 114 11.40 65.60 34.40
6 300µ 134 13.40 79.00 21.00
7 150 108 10.80 89.80 10.20
8 75 50 5.00 94.80 5.20
9 Pan 52 5.20 100.00 0.00
∑ F =388

Fineness Modulus of fine aggregate= ∑F/100=3.88

Table 4.3: Fine aggregate zoning

IS Sieve Grading Grading Grading Grading Experimental
Size (mm) zone-I zone-II zone-III zone-IV Value
10 100 100 100 100 100

4.75 90-100 90-100 90-100 95-100 98.49

2.36 60-95 75-100 85-100 95-100 60

1.18 30-70 55-90 75-100 90-100 32.33

600 15-34 35-59 60-79 80-100 36.02

300 5-20 8-30 12-40 15-50 16.11

150 0-10 0-10 0-10 0-15 10.19

From the test results of fineness modulus and using the specifications given in IS: the
used sand was found to be in Zone I

Properties Test results IS code Limits

Specific gravity 2.69 IS-2386 (part 3) 2.5-3
Fineness modulus 3.17 IS-2386 (part 1) 2.9-3.2
Water absorption 0.15% IS-2386 (part 3) 0.1%-0.2%
Silt content 5.2% IS-383-1970 10%
Table 4.4: Properties of fine aggregates

4.3.3 Coarse aggregates

The material which passes through 4.75 mm sieve is termed as fine aggregate.
Usually natural sand is used as a fine aggregate. Locally available natural sand
confirming to IS: 383–1970 is used in the experimental work. Sieve analysis of the
sand is carried out in accordance with IS: 2386–1963 Part 1 and the results are shown
in Table 4.1. The testing of sand for the physical properties is done in accordance with
IS: 2386–1963 Part 3. The sieve analysis and grading curve for the coarse aggregate
are given in Table 4.5 & Graph 4.2 respectively.
 4.3: Coarse aggregate

Table 4.5: Sieve analysis of coarse aggregate

Sr.No. IS Sieve Weight % cum.% cum.% Limits (As Per

mm retained retained retained Passing I.S.383-1970)
1 40 0 0.00 0.00 100 100

2 25 0 0.00 0.00 100

3 20 194 3.88 3.88 96.12 85 - 100

4 16 2276 45.52 49.40 50.60

5 12.5 1794 35.88 85.28 14.72

6 10 678 13.56 98.84 1.16 0 - 20

7 4.75 38 0.76 99.60 0.40 0-5

8 Pan 20 0.40 100.00 0.00

Table 4.6: Properties of coarse aggregate

Properties Test results IS code Limits
Specific gravity 2.93 IS:383-1970 2.67
Fineness modulus 7.9 IS:2386-1963(part 1 ) 6-8.5
Water absorption 0.91% IS :2386-1963(part 3) 0.5%-1%

4.3.4 Fly ash

The quality of fly ash is governed by IS 3812-Part I: 2003. The type of fly ash
used in the experimentation is class F type (Ashtech )
Figure 4.4: Fly ash

4.3.5 Water
Water is an important ingredient of concrete as it actively participates in the
chemical reaction with cement. Since it helps to form the strength giving cement gel,
the quantity and quality of water is required to be looked into very carefully. Potable
water is generally considered satisfactory. In the experimental investigation, tap water
was used for both mixing and curing purposes.

4.4 Mix design

Concrete mix was designed for M30 grade in accordance with IS 10262–2009.
The water cement ratio was kept as 0.45. The desired workability of the mix was kept
at 100mm slump. The mix proportion obtained was 1:1.87:3.38. The quantities of the
materials for designed proportions are given in table 4.5

Table 4.7: Mix proportion of concrete

Mix % W/C Water Cement Fly ash Fine Coarse
Fly Content (kg/m3) (kg/m3) aggregate aggregate
ash (kg/m3) (kg/m3) (kg/m3)

M-1 0 0.45 157.5 350 00 654 1183

M-2 10 0.45 157.5 315 35 654 1183
M-3 20 0.45 157.5 280 70 654 1183
M-4 25 0.45 157.5 262.5 87.5 654 1183
M-5 30 0.45 157.5 245 105 654 1183

4.5 Specimen geometry

For determining compressive strength of concrete cube specimens were used. For
determining modulus of elasticity of concrete cylindrical specimen were used.
Standard size of cube and cylinders specimen were used which complies with IS
10086:1982.The dimensions of various specimens are given in Table 4.5.

Table 4.8: Specimen Geometry

Specimen Size Test performed

Cube 150mm x 150mm x 150mm Compressive strength

Cylinder 150mm x 150mm x 300mm Modulus of Elasticity

4.6 Batching
Batching of concrete means measuring different ingredients of concrete (i.e.
Cement, sand, coarse aggregate and water) before mixing it. There are two types of
batching:
A. Weigh batching: When this measurement is done on the basis of weight, we call it
weigh batching.
B. Volume batching: When this measurement is done on the basis of volume, we call
it volume batching.
Volume batching has disadvantages like no application in case of reinforced
concrete structure, can be only used for small concrete works and is uneconomical,
hence weigh batching is preferred. As weigh batching is more accurate than volume
batching we have adopted weigh batching mixing.

4.7 Mixing
Thorough mixing of the materials is essential for the production of uniform
concrete. There are two methods for mixing of concrete:
A. Hand mixing
B. Mechanical/Machine mixing
As mechanical/machine mixing is efficient, it is adopted in the experimental
work. Rotating and tilting type mechanical mixer was used for mixing the ingredients
for the preparation of the concrete. Fine aggregates, coarse aggregates& cement were
thoroughly mixed for two minutes. Fly ash in the designed quantity was added and the
dry mix was mixed for next one minute. Then wet mixing was carried out in which
initially 50% of the designed water was added and mixed for one and half minute.
Then remaining quantity of water was added and mixed for another one and half
minute.

Figure 4.5: Mixing of concrete ingredients

4.8 Workability
Workability test on the fresh mix concrete is performed to determine theease and
homogeneity with which it can be mixed, placed, compacted and finished. IS:516-
1959recommends following tests to measure workability of fresh concrete.
1) Slump cone test
2) Compaction factor test
3) Vee-Bee Consistency test
4) Flow test

4.8.1 Slump cone test

 In this test the distance that a cone full of concrete slumps down is measured
when the cone is carefully lifted from around it. The concrete slumps can vary from
zero for dry (stiff) mixes to complete collapse for very wet and lean mixes.
Due to simplicity of apparatus used and simple procedure slump cone test was
used in the experimental work to measure the consistency of fresh concrete. The test
was performed in accordance with IS: 516-1959.
.

Figure 4.6: Slump cone test

4.8.2 VSI test

As per ASTM C1611M, stability of concrete can be observed visually by
examining the concrete mass and therefore can be used for quality control of concrete
mixes. It is easier and quicker to carry out the VSI test .The concrete mix is placed on
a base with 500 mm diameter circular marking. After spreading of the concrete has
stopped the concrete mixture is visually inspected by observing the distribution of the
coarse aggregate within the concrete mass the distribution of the mortar fraction
particularly along the perimeter, and the bleeding characteristics. Thus, a Visual
Stability Index (VSI) value to the concrete spread using the criteria shown.

4.9 Initial and Final setting time of cement

Initial setting time is that time period between the time water is added to cement
and time at which 1 mm square section needle fails to penetrate the cement paste,
placed in the Vicat’smould 5 mm to 7 mm from the bottom of the mould. Final setting
time is that time period between the time water is added to cement and the time at
which 1 mm needle makes an impression on the paste in the mould but 5 mm
attachment does not make any impression. The test is carried out with reference to IS:
4031-Part-5-1988. Vicat's apparatus was used as per IS: 5513-1976.

4.10 Casting of specimens

1. Cube and cylindrical specimens were used in the experimental work.
2. The oil was applied to the inside surface of the moulds.
3. To cast cube and cylindrical specimens, the concrete was poured in the moulds.
4. The concrete waspoured in the moulds in three layerswith each layer being
compacted with a tamping rod giving 25 numbers of blows.

Figure 4.7: Casting of Specimen

4.11 Curing of specimens

The process of creation of an environment during a relatively short period
immediately after the placing and compaction of the concrete, favorable to the setting
and hardening of concrete is termed as ‘Curing’. After 6 hours of casting the test
specimens were covered with wet gunny bags and stored in place free from vibration, in
moist air of at least 90% relative humidity and at a temperature of 28°C for 24 hours .
After 24 hours of casting, the test specimens were removed from the moulds and cured
in water at room temperature for 28 days.

4.12 Testing of specimens

In this section test setup for both the tests (compressive strength test and test for
modulus of elasticity) are discussed.

4.12.1 Compression test

Compression test is the most common test conducted on hardened concrete. The
compression test was carried out on cubical specimens. After 7, 28, 45and 90 days of
curing, the cubes were tested using digital Compression Testing Machine (CTM) at a
uniform loading rate of 4.5kN/min as per I.S:516-1959. The failure load was recorded.
Three cubes were tested and their average value was reported. The compressive
strength was calculated using following expression:

Figure 4.8: CTM

 Figure 4.9: Testing of cube under CTM

4.12.2 Stress-strain behaviour by compressometer

The modulus of elasticity was performed in accordance with IS 516:1959. After
28 days of curing the specimens were taken out from curing tank and kept outside for
1 hour. The compressometer was attached to the cylindrical specimen as shown in the
fig 4.10. The stains developed on the lateral surface were observed, under gradually
increasing load applied at the rate of 4KN/minute. The load was continued till one
third of compressive strength.

Figure 4.10: Compressometer

A typical calculation of modulus of elasticity of concrete is as shown below:

1. Load calculation for cube = (Compressive stress/Area of cube)
2. Load of cylinder = (Crushing load of cube *0.8*Area of cylinder)/1000
3. Dial Gauge Reading = Measured on the dial gauge of instrument
4. Deflection =(Dial gauge reading)/100
5. Actual Deflection – (Deflection)/2
6. Gauge length = 150mm
7. Area of cylinder = (π/4)*d2
8. Strain = (Actual Deflection)/(Gauge length)
9. Stress = (Load) /(Area of cylinder)

Results can be calculated as follows

1. Average stress = Last reading of stress – First reading of stress.
2. Average strain = Last reading of stress – First reading of stress
3. Experimental M.E = (Average stress)/ (Average strain)

CHAPTER 5

RESULT AND DISCUSSION

5.1 Introduction
The aim of the research work was to study the stress-strain behaviour of concrete
when cement is replaced by fly ash in varying percentage at various ages. The effect
of fly ash content was also studied on workability of the concrete mix, initial and final
setting time of cement paste and VSI of concrete. Compression test was performed to
study the compressive strength of concrete and modulus of elasticity of concrete was
found out at varying percentage of fly ash. The results obtained are presented and
analysed in the subsequent modules.

5.2 Workability
Slump cone test was carried out in accordance with IS: 516-1959. The results
obtained are as shown in Table 5.1.
Table 5.1: Slump Cone Test Results
Sr.No % Replacement of Slump value (mm)
cement by
fly ash
1. 0 90
2. 10 100
3. 20 100
 4. 25 110
5. 30 120

The slump values found to be increased with the increase in fly ash content due to
the spherical shape of fly ash particles causing ball bearing effect, hence, increased
workability of the concrete.

5.3 Initial and final setting time

Initial and final setting time test of the cement paste with fly ash in varying
replacement percentage was carried out in accordance with IS: 5513-1976. The test
results are as shown in Table 5.2.

Table 5.2: Initial and final setting time

Sr.No % replacement of Initial setting time Final setting time
cement by fly ash (minute) (minute)
1. 0 230 255
2. 10 225 242
3. 20 215 200
4. 25 200 190
5. 30 180 150

The initial and final setting time of the cement with fly ash paste was decreased
with increase in fly ash content. This is because at the initial stages of concrete, fly ash
behaves like a fine aggregate material. As percentage of cement decreased by increase
in fly ash content the cementitious material decreased and hence, the initial and final
setting time of the paste was decreased.

5.4 VSI of concrete

VSI test was carried out as per ASTM C1611M and the results are as shown in
table 5.3.
Table 5.3 VSI values obtained for concrete mixes
Sr.No % Replacement of VSI value
cement by fly ash
1. 0 0
 2. 10 0
3. 20 0
4. 25 0
5. 30 0

The VSI for all concrete mixes was found to be 0 indicating uniform distribution of
aggregates and no evidence of segregation or bleeding.

5.5 Compressive strength

The compression test was performed on the cube specimens of size 150mm x
150mm x 150mm. The test was performed as per IS: 516-1959. The cubes were tested
at 7 days, 28 days, 45 days and 90 days for various percentage replacements. Average
compressive strength of three identical cube specimens is given in Table 5.4

Table 5.4: Compression test results

% replacement
of cement by fly
ash Compressive strength (MPa)
7 days 28 days 45 days 90 days
0 25.83 39.86 40.56 41.28
10 21.13 29.27 35.64 38.62
20 18 25.44 32.63 36.33
25 17.23 21.47 27.25 33.77
30 18.93 20.3 26.32 32.94
 Strength (Mpa)
0%
10%
20%
25%
30%

Age(Days)

Figure 5.1: Relationship between age and strength of concrete

Strength(Mpa)

7
Days
28
Days
45
Days

% Replacement

Figure 5.2: Relationship between % replacement and strength of concrete

Figure 5.1 represents effect of age on the compressive strength of concrete. It is

found that the compressive strength of concrete increased with the age of concrete.
The strength of conventional concrete was almost constant after 28 days. In case of
concrete with fly ash the strength in kept on increasing. From figure 5.2 it is found
that the compressive strength decreased with the increase in fly ash content.

5.6 Stress-strain behaviour

 The stress-strain behaviour of concrete was studied on cylindrical specimens. The
specimens were cast using different mixes. The specimens were tested at various
ages. The test results are as shown in table 5.5, 5.6 and 5.7.

Table 5.5: Strain, stress and MOE at 25 days with varying percentage of fly ash
% replacement of Strain Stress Modulus of
cement by fly ash (MPa) elasticity
(MPa)

0 9.9E-05 5.37 54348.31

10 0.000205 8.97 44508.89
20 9.93E-05 4.80 48440.53
25 9.64E-05 4.38 45737.20
30 7.7E-05 3.67 48139.36

Table 5.6: Strain, stress and MOE at 50 days with varying percentage of fly ash
% replacement of Strain Stress Modulus of
cement by fly ash (MPa) elasticity
(MPa)

0 0.000105 5.51 52752.79

10 0.000201 5.09 25368.19
20 0.000126 4.80 38073.29
25 9.31E-05 4.38 47122.20
30 7.55E-05 3.67 49051.84

Table 5.7: Strain, stress and MOE at 60 days with varying percentage of fly ash
% replacement of Strain Stress Modulus of
cement by fly ash (MPa) elasticity
(MPa)

0 1.389E-04 5.65 40778.05

10 1.389E-04 4.80 22115.87
20 1.30E-04 4.80 36905.95
25 8.86E-05 3.67 41458.92
30 7.17E-05 3.23 45337.52
STRAIN

STRESS

Figure 5.3: Stress-strain behaviour of conventional concrete at 25 days

STRAIN

STRESS

Figure 5.4: Stress-strain behaviour of fly ash concrete by 10% replacement at 25

days
 STRAIN

STRESS

Figure 5.5: Stress-strain behaviour of fly ash concrete by 20% replacement at 25

days
STRAIN

STRESS

Figure 5.6: Stress-strain behaviour of fly ash concrete by 25% replacement at 25

days
STRAIN

STRESS

Figure 5.7: Stress-strain behaviour of fly ash concrete by 30% replacement at 25

days
 STRAIN

STRESS

Figure 5.8: Stress-strain behaviour for conventional concrete at 60 days

STRAIN

STRESS

Figure 5.9: Stress-stain behaviour of fly ash concrete by 10% replacement at 60

days
STRAIN

STRESS
Figure 5.10: Stress-strain behaviour of fly ash concrete by 20% replacement at 60
days

STRAIN

STRESS

Figure 5.11: Stress-strain behaviour of fly ash concrete by 25% replacement at 60

days
STRAIN

STRESS

Figure 5.12: Stress-strain behaviour fly ash concrete by 30% replacement at 60

days
 STRAIN

STRESS

Figure 5.13: Stress-strain behaviour of conventional concrete at 90 days

STRAIN

STRESS

Figure 5.14: Stress-strain behaviour of fly ash concrete by 10% replacement at 90

days
STRAIN

STRESS

Figure 5.15: Stress-strain behaviour of fly ash concrete by 20% replacement at 90

days
 STRAIN

STRESS

Figure 5.16: Stress-strain behaviour of fly ash concrete by 25% replacement at 90

days
STRAIN

STRESS

Figure 5.17: Stress-strain behaviour of fly ash concrete by 30% replacement at 90

days
MOE(MPa)

25
Days
50
Days

% Replacement of cement by fly ash

Figure 5.18: MOE versus various % replacement

MOE(MPa)

0%
10%
20%
25%
30%

Age(Days)

Figure 5.19: MOE versus age of concrete

CHAPTER 6

CONCLUSION

 Workability was found to be increasing with the increase in percentage of fly

ash content.
 Visual Stability Index of all mixes was found out to be 0 indicating no
evidence of bleeding or segregation. This test can be used as a quick
preliminary test on site to check the stability and consistency of fresh concrete.
 Initial and final setting time was found to be increasing with increase in fly ash
content.
 Compressive strength was found to have steady increase in the compressive
strength of the flyash concrete after 28 days whereas in conventional concrete
the increase in compressive strength after 28 days was minute. Compressive
strength decreases with increase in percentage of flyash. The early age strength
of the flyash concrete is hampered and with the increase in age the percentage
difference between conventional concrete and fly ash concrete decreases.
 No promising results have been obtained for modulus of elasticity, hence,
thorough work is required in future.

REFERENCES
1. M.S. Shetty, “Concrete Technology” Theory and Practice, Seventh revised
edition 2013.
2. IS 10262:2009 “Code of concrete mix proportioning–guidelines (first
revision).”
3. IS 1489(Part 1):1991 “Specification for Portland pozzolana cement Fly ash
based.”
4. IS 1727:1967 “Methods of test for pozzolanic materials.”
5. IS 516:1959 “Method of test for strength of concrete.”
6. IS 455:1989 “Specification for Portland slag cement.”
7. IS: 3812( Part – 1):2003 “Quality requirement for siliceous fly ash (class F fly
ash) and calcareous fly ash (class C fly ash) with respect its chemical and
physical composition.”
8. IS 383:1970 “Specification for coarse and fine aggregates from natural sources
for concrete (second revision).”
9. IS 1199:1959 “ Methods of sampling and analysis of concrete.”
10. Michael D A Thomas (2010) “Optimizing Fly Ash Content For Sustainability,
Durability and Constructibility.”
11. R.D. Padhey, et.al (2016) “Cement Replacement By Fly Ash In Concrete”
International Journel of Engineering Research, Volume No.5, pp: 60-62.
12. Anis Mohhamad Ali,B.J. Farid “Stress Strain Relationship Of Concrete
Compression Made Of Local Material”, JKAU: Eng. Sci., Vol. 2, pp. 183-194
(1410 A.H. 11990 A.D.)
13. Prof. Jayaskumar Pitroda (2015) ”Gainful Use of Fly Ash In Concrete ”,
Journal Of International Academic Research For Multidisciplinary, ISSN
2320-5083.S