Batch 4 PDF

A Project report on
“PARTIAL REPLACEMET OF CEMENT, FINE AGGREGATES & COARSE AGGREGFATE

WITH FLY ASH, STEEL SLAG & RECYCLED AGGREGATES RESPECTIVELY IN
CONCRETE”
Submitted in the partial fulfilment of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY
In
CIVIL ENGINEERING
By
MANOHAR B 16701A0122
D. CHIDVILAS 16701A0107
V. LOKESHWAR 16701A0119
D. LOKESWARA 16701A0118
Under the guidance of
D. MADHUSUDHANA REDDY, M.tech,
Assistant Professor,
Department of CE.
Submitted to
DEPARTMENT OF CIVIL ENGINEERING
ANNAMACHARYA INSTITUTE OF TECHNOLOGY AND SCIENCES
(AN AUTONOMOUS INSTITUTION)
(Approved by AICTE, New Delhi, Affiliated To J.N.T.U.A, Anantapuramu)
(Accredited by NAAC, Bangalore)
Rajampet, Kadapa (Dist), A.P –

516126
2019-2020
CERTIFICATE
This is to certify that the project entitled “PARTIAL REPLACEMENT OF CEMENT, FINE
AGGREGATES & COARSE AGGREGATE WITH FLY ASH, STEEL SLAG &
RECYCLED AGGREGATES RESPECTIVELY IN CONCRETE”
Bonafied project work submitted by
MANOHAR B 16701A0122
D. CHIDVILAS 16701A0107
V. LOKESHWAR 16701A0119
D. LOKESWARA 16701A0118
In the department of CIVIL ENGINEERING in a partial fulfillment of requirements for the award of
degree of Bachelor of Technology in “CIVIL ENGINEERING” for the year 2019-2020. This work has been
carried out under my guidance and has not been submitted the same for any university/institution for
award of and Degree/Diploma.
PROJECT GUIDE HEAD OF DEPARTMENT
D. MADHUSUDHANA REDDY Dr. Y. SREERAMULU
Assistant Professor.
Submitted for university examination held at

ANNAMACHARYA INSTITUTE OF TECHNOLOGY AND SCIENCES::RAJAMPET
(AUTONOMOUS)
NAME OF THE EXAMINER SIGNATURE WITH DATE
1. INTERNAL EXAMINER:
2. EXTERNAL EXAMINER:
ABSTRACT
Construction industry has a wide range of work globally. In today’s world, the construction
rate is progressing very faster which results in the faster consumption of naturally occurring
construction materials. Millions of tons of waste is produced in the world each year and most of it is
not recyclable. Furthermore, recycling waste consumes energy and produces pollution. In addition,
accumulation of waste in the suburbs and the disposal of waste are very dangerous for the
environment. Using waste material in concrete production is an appropriate method for achieving
two goals: eliminating waste and adding positive properties in concrete. This project presents the
experimental result carried out to determine the compressive strength of concrete at different
replacement of cement, fine aggregates and coarse aggregates. M-20 grade of concrete (1:1.8:3.16)
at w/c of 0.5 was designed as per IS-10262-2009. Result shows that cement, fine aggregates and
coarse aggregates can be replaced at 10%, 20% and 30% by fly ash, steel slag and recycled
aggregates respectively without compromising compressive strength of concrete. We are replacing
the materials separately to know the strength how much will be increased. At some percentage it
will be increases then we are replacing all materials at a time to know the compressive strength of
concrete.
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ACKNOWLEDGEMENTS
An endeavour of a long period can be successful only with the advice of many
well-wishers. We take this opportunity to express our deep gratitude and appreciation to all those
who encouraged us for the successful completion of the project work.
We are thankful to my guide D. MADHUSUDHANA REDDY, Assistant Professor in C.E.

Department, Annamacharya Institute of Technology and Sciences, for his valuable guidance and
suggestions in analyzing and testing throughout the period, till the end of project work completion
Our special thanks to Dr Y. SREE RAMULU, Head of Civil Engineering Department, for his
timely suggestions and help during the progress of project work.
We wish to express our sincere gratitude to Dr S. M. V. NARAYANA, Principal, Annamacharya Institute

of Technology and Sciences, Rajampet for his consistent help and encouragement to complete the
project work.
We are very much thankful to Sri. C. GANGI REDDY, Honourable Secretary of Annamacharya
Educational Trust, for his help in providing good facilities in this college.
Finally, we would like to express our sincere thanks to all the faculty members of Dept. Of C.E, friends,
and lab technicians, one and all who have helped us to complete the project work successfully.
Last but not the least; we are here only because of them, their support, their patience, their
presence during tough times and of course standing beside us. In view of that we are dedicating our work
to our parents.
.......................Project Associates
LIST OF CONTENTS
S.NO TITLE NAME PAGE NO:
1. INTRODUCTION 01-05
1.1 Introduction 01-02
1.2 General 02-04
1.3 Objectives 04-05
2. LITERATURE REVIEW 06-12
3. MATERIALS USED AND ITS PROPERTIES 13-34
3.1 Materials 13-29
3.2 Properties of materials 30-34
4. MIX DESIGN 35-40
5. EXPERIMENTAL STUDY 41-48
5.1 General 41
5.2 Casting 41-42
5.3 Procedure for casting of cubes 42-43
5.4 Precautions to be taken while machine mixing concrete 43-44
5.5 Testing of cubes 44-45
5.6 Percentage of strength vs working age in days 45-46
5.7 Calculation for finding the compressive strength
of concrete 46-47
5.8 Curing 48
6. METHODOLOGY 49-51
7. TEST RESULTS 52-60
7.1 Conventional concrete cubes 52
7.2 Comparing the compressive strength with conventional
Cubes to replacement of cement by fly ash 53-54
Cubes to replacement of F.A. by steel slag 55-56
i
Cubes to replacement of C.A. by recycled aggregates 55-58
Cubes to combination replacement of all 3 materials
@20% of each 59-60
8. APPLICATIONS 61
9. CONCLUSION 62
10. REFERENCE 63
ii
LIST OF FIGURES
S.NO FIGURES NAME PAGE NO:
1. EVALUATION OF RECYCLING 04
2. CEMENT 15
3. FINE AGGREGATES 16
4. COARSE AGGREGATES 18
5. METHOD OF FLY ASH TRANSFER CAN BE
DRY, WET OR BOTH 20
6. FLY ASH 21
7. OVERVIEW OF SLAG PRODUCTION IN
MODERN INTEGRATED STEEL PLANT 24
8. STEEL SLAG 25
9. DEMOLITION WASTE AGGREGATE 27
10. WATER 29
11. INITIAL SETTING TIME 31
12. BULKING OF SAND 33
13. SLUMP CONE 34
14. CASTING OF CUBES 42
15. MIXING OF CONCRETE 43
16. CASTING OF CUBES 45
17. DIMENSIONS OF CUBES 47
18. CURING TANK 48
19. BEFORE & AFTER CRACKS FOR CONVEN-
TIONAL CUBES 52
20. BEFORE & AFTER CRACKS FOR REPLA-
CEMENT OF CEMENT BY FLY ASH 53
iii
CEMENT OF F.A. BY STEEL SLAG 55
CEMENT OF C.A. BY RECYCLED AGGREGATES 57
CEMENT OF ALL THREE INGREDIENTS @20% 59
iv
LIST OF TABLES
S.NO TABLE NAME PAGE NO:
1. CHEMICAL ANALYSIS OF CEMENT 15
2. THERMAL POWER GENERATION, COAL
CONSUMPTION & ASH GENERATION IN INDIA 20
3. CHEMICAL ANALYSIS FOR FLY ASH 21
4. CHEMICAL ANALYSIS FOR STEEL SLAG 24
5. PROPERTIES OF PORTLAND CEMENT 30
6. SIEVE ANALYSIS OF FINE AGGREGATES 31-32
7. BULKING OF SAND 33
8. PERCENTAGE OF STRENGTH VS AGE IN DAYS 46
9. WEIGHTS FOR CONVENTIONAL CUBES 49
10. WEIGHTS FOR CEMENT REPLACED BY
FLY ASH 49
11. WEIGHTS FOR F.A. REPLACED BY STEEL SLAG 50
12. WEIGHTS FOR C.A. REPLACED BY RECYCLED
AGGREGATES 50-51
13. WEIGHTS FOR COMBINATION REPLACEMENT
OF ALL THREE INGREDIENTS @20% 51
14. RESULTS FOR CONVENTIONAL CUBES 52
15. RESULTS FOR CEMENT REPLACED BY FLY ASH 53
16. RESULTS FOR F.A. REPLACED BY STEEL SLAG 55
17. RESULTS FOR C.A. REPLACED BY RECYCLED
AGGREGATES 57
18. RESULTS FOR COMBINATION REPLACEMENT
OF ALL THREE INGREDIENTS @20% 59
v
PARTIAL REPLACEMENT OF CEMENT, FINE AGGREGATES & COARSE
AGGREGATES WITH FLY ASH, STEEL SLAG & RECYCLED AGGREGATES
RESPECTIVELY IN CONCRETE
CHAPTER-1
INTRODUCTION
1.1 INTRODUCTION:
Construction industry uses approximately 20 billion tons of raw materials annually as

reported. It consumes a large amount of natural resources that cause substantial environment,
energy and economic losses as it exploits 50% raw materials, 40% of total energy, as well as
generates 50% of total waste. Concrete is the most widely used constructional material in the
world. There is a concern to more understanding and to improve its properties. Concrete is a
construction material composed of cement (commonly Portland cement) as well as other
cementitious materials such as fly ash and slag cement, aggregate (generally a coarse
aggregate such as gravel, limestone or granite, plus a fine aggregate such as sand), water and
chemical admixtures. The word concrete comes from the Latin word “concretus”, which
means “hardened” or “hard”. Concrete solidifies and hardens after mixing with water and
placement due to a chemical process known as hydration. The water reacts with the cement,
which bonds the other components together, eventually creating a stone-like material.
Concrete is used to make pavements, architectural structures, foundations, and
motorways/roads, bridges/overpasses, parking structures, brick/block walls and footings for
gates, fences and poles.
The depletion of good quality aggregates along with the increase in aggregate
requirement due to increasing infrastructure development makes the lesser availability of
natural materials, over quarrying led direct impact on environment and demand-supply chain
of construction material are getting affected. Natural aggregates are becoming increasingly
scare and their production and shipment is becoming more difficult and cement cost also
increases. Generally, millions of tons of waste are produced in the world each year and most
of it is not recyclable. Furthermore, recycling waste consumes energy and produces pollution.
In addition, accumulation of waste in the suburbs and the disposal of appropriate method for
achieving two goals: eliminating waste and adding positive properties in concrete. The
utilization of industrial waste or secondary materials has encouraged the production of
DEPT OF CIVIL ENGG, AITS RAJAMPET Page 1

cement and concrete in construction field. New by-products and waste materials are being
generated by various industries. Dumping or disposal of waste materials causes the
environmental and health problems. Therefore, recycling of waste materials is a great
potential in concrete industry. Fly ash, steel slag and demolition waste aggregates are the
waste materials. These are polluting the environment. So, we are replacing all three materials
in concrete such as cement with fly ash, fine aggregates with steel slag and coarse aggregates
with demolition waste aggregates (recycled aggregates) in our project to reduce the pollution.
1.2 GENERAL
Fly ash is a by-product from coal-fired electricity generating power plants. It is a residual
material of energy production using coal, which has been found to have numerous advantages
for use in concrete. Some of the advantage include improved workability, reduced
permeability, and increased ultimate strength, reduce bleeding, better surface and reduce heat
of hydration. Several types of fly ash are produced depending on the coal and coal
combustion process. Fly ash material solidifies while suspended in the exhaust gases and is
collected by electrostatic precipitators or filter bags. Since the particles solidify while
suspended in the exhaust gases, fly ash particles are generally spherical in shape and range in
size from 0.5μm to 100μm.
Fly ash is composed of the non-combustible mineral portion of coal. Fly ash is one of
the residues generated in combustion and comprises the fine particles that rise with the flue
gases. Ash which does not rise is termed bottom ash. In an industrial context, fly ash usually
refers to ash produced during combustion of coal. In some cases, such as the burning of solid
waste to create electricity, the fly ash may contain higher levels of contaminants than the
bottom ash and mixing the fly and bottom ash together brings the proportional levels of
contaminants within the range to quality as nonhazardous waste in a given state, whereas,
unmixed, the fly ash would be within the range to qualify as hazardous waste.
Steel slag is an industrial by product obtained from the steel manufacturing industry and
hundreds of tons of it are produced every year all over the world in the process of refining
metals and making alloys. The steel making industry has generated substantial solid waste.
As a construction material, concrete is the largest production of all other materials.
Aggregates are the important constituents in concrete. They give body to the concrete, reduce
shrinkage and effect economy. It appears in concrete, aggregate road materials, as ballast, and
is sometimes used as a component of phosphate fertilizer. Steel slag can be used in the
construction industry as aggregates in concrete by replacing natural aggregates.
Recycled aggregates the usage of demolition wastes as an aggregate for the manufacture of
concrete is considering in new research studies. The usage of demolition waste aggregates
helps in reducing the depletion of natural aggregates and problems related to mining the
aggregates. It is found that the quality of natural aggregates is better compared to the
demolition waste aggregates. Thus, demolition waste aggregates have limited usage.
Out of the total construction demolition waste, 40% is of concrete, 30% ceramic’s,
5% plastics, 10% wood, 5% metal & 10% other mixtures. As reported by global insight,
growth in global construction sector predicts an increase in construction spending of 4800
billion US dollars. These figures indicate a tremendous growth in the construction sector,
almost 1.5 times in 5 years.
For production of concrete, 70-75% aggregates are required. Out of this 60-
67% is of coarse aggregate and 33-40% is of fine aggregate. As per recent research by the
Fredonia group, it is forecast that the global demand for construction aggregates may exceed
26 billion tons. Recycling reduces the cost by about 34-41% and CO2 emission by about 23-
28% for dumping at public or private disposal facilities.
Concrete recycling gains importance because it protects natural resources and

eliminates the need for disposal by using the readily available concrete as an aggregate source
for new concrete is a relatively simple process. It involves breaking, removing and crushing
existing concrete into a material with a specified size and quality. The crushing
characteristics of hardened concrete are similar to those of natural rock and are not
significantly affected by the grade or quality of the original concrete.

Safety, quality Target Vector
(Quality demand)
Optimum Balance
Cost Effectiveness
(LCC)
Environmental
Impact (LCCO2)
FIG NO: 1 EVALUATION OF RECYCLING
1.3 OBJECTIVES
• To compare the compressive strength of concrete to conventional concrete.

• To reduce the pressure on naturally available aggregates by waste plastic and to
reduce the emission of CO2 during the production of cement.
• To compare the physical characteristics of recycled waste with natural aggregates.
• To study the properties of fresh and hardened concrete by replacement materials.
• To find out the percentage use of feasible for construction.
• To reduce the impact of waste materials on environment.
• To find out the ways of cost saving such as transportation, excavation etc.
• To explore possibilities of improving mechanical properties of concrete using steel
slag instead of fine aggregate partially.
• To evaluate the effect of using steel slag in concrete.

• To evaluate the effect of just replacing the cement by fly ash used in concrete and to
study the compressive strength of concrete under varying percentage of fly ash, as
well as to study, the effect of varying curing time period under different exposure
condition.
• To determine the optimum level of cement in concrete elements with highest
compressive strength.
• Study the effect of fly ash incorporating in concrete on permeability in normal
condition and aggressive condition.
In our project, mix design is done as per the bureau of Indian standards, IS 10262-2009
for M20 grade concrete with good degree of quality control. For the mix designed, specimens
are cast and investigated experimentally. The properties involve of compressive strength of
M20 conventional concrete by replacing the 0%, 10%, 20% and 30% of fly ash by cement,
steel slag by fine aggregates and recycled aggregates by coarse aggregates was added, test
was conducted on concrete cubes to study compressive strength.

CHAPTER-2
LITERATURE REVIEW
1. “Partial Replacement of Cement with Fly Ash in Concrete and Its Effect” IOSR
Journal of Engineering (IOSRJEN), ISSN (e): 2250-3021, ISSN (p): 2278-8719, Vol. 06,
Issue 10(Oct. 2016), ||V2|| PP 69-75, Authors: Vinod Goud and Niraj Soni.
In this paper, it is discussed that there is fly ash a waste generated by thermal power
plants is as such a big environmental concern. In modern decades, the industrialization and
urbanization are the two phenomena that are spreading all over the world. Apart from the
requirement of these phenomena, there should also be investigation into their negative
impacts on the worldwide environment and common life. The thermal power plants produce
considerably large quantities of solid by-product namely fly ash. They are replaced the fly
ash by cement at the percentage of 0%, 10%, 20% and 30%. Ultimate compressive strength
of concrete decreasing with increase in w/c ratio of concrete. Results were shown as the 10%
and 20% replacement of cement with fly ash shows good compressive strength for 28 days
testing, but the 30% replacements of cement with fly ash were compressive strength of
concrete decreases.
2. “Partial Replacement of Fine Aggregates Using Steel Slag” IJEDR 2018| Volume 6,
ISSN: 2321-9939, Authors: Gaurav Desai, Prem Lohakare and Akash Ugale.
The steel making industry has generated substantial solid waste. Steel slag is an
industrial by product obtained from the steel manufacturing industry. Aggregates are the
important constituents in concrete. They give body to the concrete, reduce shrinkage and
effect economy. It appears in concrete, aggregate road materials, as ballast, and is sometimes
used as a component of phosphate fertilizer. Steel slag is currently used as aggregate in hot
mix asphalt surface application, but there is a need for some additional work to determine the
feasibility of utilizing this industrial by-product more wisely as a replacement for both fine
and coarse aggregates in a conventional concrete mixture. Replacing all or some portion of
natural aggregates with steel slag would lead to considerable environment benefits. The
results are compared with the normal conventional concrete. The strength properties of

concrete are determined with the various replacement level of steel slag with fine aggregate.
The use of steel slag aggregates in concrete by replacing natural aggregates is a most
promising concept, steel slag aggregates are already being used as aggregates in asphalt
paving road mixes due to their mechanical strength, stiffness, porosity, wear resistance. They
declared by replacing the fine aggregates with steel slag is increased compressive strength of
concrete were compared to conventional concrete.
3. “Use of Demolished Concrete Waste in Partial Replacement of Coarse Aggregate in

Concrete” SSRG International Journal of Civil Engineering (SSRG-IJCE)-volume 3
In this paper, it is discussed that there is a large amount of demolished waste

generated every year in India and other developing countries. Since the very small amount of
this waste is recycled or reused. So, disposing of this waste is a very serious problem because
it requires a large amount of space. This study is a part of comprehensive program where in
the experimental investigations have been carried out to evaluate the effect of partial
replacement of coarse aggregates by demolished waste on compressive strength and
workability of demolished aggregate concrete. For the study 3, 7 and 28 days compressive
strengths were recorded. The previous study on this project shows that the compressive
strength of the demolished aggregate concrete somehow resembles with the conventional
concrete if used in a proper amount up to 30%. So in this study we have taken the demolished
concrete aggregates 10%, 20% and 30% by weight of the conventional coarse aggregate and
the concrete cubes were casted by that demolished concrete aggregate then further tests
conducted such as workability, compressive strength for that demolished aggregate concrete
and the result obtained are found to be comparable with the conventional concrete.
4. “Steel Slag as a Replacement of Fine Aggregate in terms of High Strength Concrete”

IJESRT International Journal of Engineering Sciences & Research Technology ISSN:
2277-9655, Authors: Anurag Jain, Sandeep Gupta & Mayank Gupta.
The steel slag, as a result of steel making, is delivered amid the detachment of molten
steel from polluting influences in steel making heaters. This can be utilized as sand in
concrete. Steel slag sand by and large display a penchant to extend on account of the nearness
of free lime and magnesium oxides that have not respond with the silicate structure and that

can hydrate and grow in muggy conditions. This possibly far reaching nature (volume
switches up to 10% or more owing to the hydration of calcium and magnesium oxides) could
cause troubles with items containing steel slag, and is one motivation behind why steel slag
aggregate are not utilized as a part of concrete development. The present research work deals
with a view to develop efficient concrete by addition of steel slag o evaluate the effectiveness
of the use of steel slag as a partial replacement in fine aggregates. Replacing of fine
aggregates with various percentages at 10%, 20%, 30% and 40% of steel slag waste in M25,
M30 & M35 concrete. Compressive strength of concrete shows for 7, 14 and 28 days are
having the strength more at 10%, 20% and 30% as compared to conventional, but 40%
having reduce the strength of concrete.
5. “Partial Replacement of Cement by Fly Ash in Concrete Mix Design” International

Research Journal of Engineering and Technology (IRJET) Volume-4, Issue: 11 | Nov-
2017, Author: Jagdish Virupakshi Patil.
In this paper, it is discussed the fly ash is a fine, glass-like powder recovered from
gases created by coal-fired electric power generation. Power plants produce millions of tons
of fly ash annually, which is usually dumped in landfills. Fly ash is an inexpensive
replacement for Portland cement used in concrete, while it actually improves strength, and
ease of pumping of the concrete. Fly ash is also used as an ingredient in brick, block, paving
and structural fills. With the reduction of unit water content, bleeding and drying shrinkage
will also be reduced. Since fly ash is not highly reactive, the heat of hydration can be reduced
through replacement of part of the cement with fly ash. It may be noticed that, for the fly ash
concrete the total cementitious material is greater but the OPC content is smaller, the fine
aggregate content is deliberately the same, the water is reduced and the density is reduced
because of the lower density of fly ash compared with cement.
6. “Behavior of Concrete Utilizing Recycled Aggregates-A Review” International

Journal of Engineering Research and Application (IJERA) ISSN: 2248-9622, Vol. 7,
Issue 1, (part-5) January 2017, pp.72-79, Authors: Ashish Shrimali, Digvijay S.
Chauhan and Dr. Trilok Gupta.

In this paper shows the concrete plays a essential role in infrastructure development
having main ingredient as cement, aggregates (course & fine) & water and among these
ingredients, aggregate occu--py the largest volume of about 60-75% of total concrete volume.
Construction industry uses approximately billion tons of raw materials annually as reported.
It consumes a large amount of natural resources that cause substantial environmental, energy
and economic losses as it exploits 50% raw material, 40% of total energy, as well as
generates 50% of total waste. The depletion of good quality aggregates along with the
increase in aggregate requirement due to increasing infrastructure development makes the
lesser availability of natural materials, over quarrying led direct impact on environment and
demand-supply chain of construction material are getting affected. The alternative material is
required to reduce the depletion of natural resources with keeping great care of environmental
issues. Recycled aggregate are obtained from demolished waste concrete after recycling
process and used as a part of production of fresh concrete. In this paper, behavior of concrete
utilizing recycled aggregate is critically reviewed. Properties of recycled aggregate are
discussed at first, followed by the properties of concrete utilizing recycled aggregate. This
type of concrete has been used in many applications, so salient case studies have also been
reviewed. Recycling concrete demolition waste as aggregates are a better way of reusing
materials by keeping them from being disposing into landfills. So we are also using this type
of fresh concrete.
7. “Effect of Replacement of Fine Aggregate by Steel Slag Aggregate in Concrete” p-

ISSN: 2349-8404; e-ISSN: 2349-879X; Volume 2, Number 15; July-September, 2015 pp.
33-38, Authors: Mahadev Shreemanth and K.P. Shivananda.
In this journal says the construction industry is the largest consumer of natural
resources which led to depletion of good quality natural sand. These situations led to us
explore alternative materials and granulated slag a waste industrial byproduct is one such
material identified for utilization of it as replacement of natural sand. The experimental
investigation carried out to evaluation effects of replacing fine aggregates with that of slag,
which is an industrial waste byproduct on concrete strength properties. The aggregates (sand
and gravel) form the skeleton of the concrete, they occupy approximately 75% if its volume,
and intervene directly on the physical and mechanical properties of concrete. The main
objective of this experimental work is: substituting sand by granulated blast furnace slag for
different percentage of replacement. The use of this method of substitution permits to
improve the strength of concrete, to increase the production of building materials and to
protect environment. The experimental results obtained shows that the partial replacement of
sand by granulated slag gives better results compared with the ordinary concrete, but the full
replacement of fine aggregates by slag affect negatively on strength of concrete. This work
relates the use of waste steel slag as a fine aggregate for M20, M30 and M40 grade of concrete
and recommends the approval percentage level for use of concrete in replacement of fine
aggregates. This approval is important because the compressive strength increase up to
certain level of replacements.
8. “Effect of partial replacement of fine aggregate by steel slag and its impact on
compressive strength of concrete” Mr. Pruthviraj, L. Kadam, Anuj R. Ahir,
International Journal of Scientific & Engineering Research, Volume 7, Issue 2,
February-2016, ISSN 2229-5518.
In this paper declared as constructions are increasing at faster rate consumption of

naturally available sand is more. The fine aggregate which they use for construction is
available from natural rivers and streams. Use large amount of fine aggregates affects the
environment. Here steel slag which is waste material available from sawing and shaping of
steel and residue remains while producing steel products or working on steel in steel
manufacturing industries. This research aims to study the effect of steel slag as replacement
of fine aggregates with 0%, 10%, 20%, 30% and 40%. The specimen cubes having size
(150x150x150mm) are tested after 14 and 28days water curing. After completion of their
project they declared for 10%, 20%, 30% and 40% replacement the strength increases as
compare to 0% replacement. As the replacement goes on increasing greater than 30% the
strength decreases. And as steel slag has low cost compare to naturally available fine
aggregate. And also helps in reducing pollution of environment. So we are also replacing the
fine aggregates with steel slag.

9. “Intermittent curing of M20 Concrete” Suresh B Piplewar, Narendra M Kanthe and

Devendra Pandey, International Journal of Structural and Civil Engineering Research,
ISSN 2319-6009, Vol. 2, No. 3, August 2013.
In this present paper deals with the effect of intermittent curing methods on the
strength of M20 concrete. Concrete specimens were evaluated at temperatures <250 C. The
water curing in concrete specimens for test included 3, 7, 9, 12, 15, 18, 21, 24 and 28days.
The comprehensive and comparative study of intermittent curing and the wet curing of M20
was sought. Studies of the effect upon strength of the various curing periods of alternative dry
and wet curing at different air temperatures were done. On the basis of interpretation of the
results the following outcomes were made: (1) Full time curing, (2) If adequate intermittent
curing for 3 times a day, (3) If adequate intermittent curing for 2 times a day and (4) If
adequate intermittent curing for 1 time a day. All the concretes had the same slump (80 to
120mm). In the present study, series of tests were carried out as per IS 516-1959 with these
concretes, to determine: (1) The Crushing Load and (2) The effect of different modes of
curing on the strength. Detailed results regarding the strength development of these concretes
were analyzed. The maximum strength developed by the concrete mix-M20 on 28days curing
is 22.67MPa, whereas after 15days same concrete mix gains 20.93MPa. It seems that there is
insignificant increment in the strength. Continuous curing 28days period increased the
strength only 1.74MPa at age 15days, 1.45MPa at age 18days, 1.02MPa at age 21days and
0.14MPa at age 24days respectively. As per these results we compared our conventional
compressive strength of concrete cubes.
10. “Effect of Steel Slag as Partial replacement of Fine Aggregate on Mechanical

Properties of Concrete” (ASMMCE-2018), 03-04TH November, 2018, Authors: Shailja
Bawa, Baban Kumar and Asif Basheer.
In this paper we observe the effect of steel slag as partial replacement of fine
aggregates on mechanical properties such as compressive strength, split tensile strength and
flexural strength. The water-cement ratio was kept constant as 0.42 and high range water
reducing admixture was used at 1.55% by weight binder. Fine aggregate has been replaced
with steel slag as 20%, 30% and 40% by weight. To determine the compressive strength,
cubes each of size 150 x 150 x 150mm were tested at 7, 28, 56 and 90days. Comparisons
were made with the normal concrete to show the influence of the additions. The observational
results shows that specimen containing 30% steel slag, 20% fly ash and 10% metakaolin
performed best among all the proportionate mix. The compressive strength increases by
replacing sand by Steel slag up to 30% but it get further reduced when percent increased to
40%. The increase in compressive strength up to certain amount may be due to the fact that
steel slag has stronger strength when compared to natural sand.

CHAPTER-3
MATERIALS USED AND ITS PROPERTIES
3.1 MATERIALS:
Concrete is composite material. Fresh concrete is a mixture of cement, fine

aggregates, coarse aggregates, and water and chemical admixtures. But nowadays availability
of these materials are very less. So we are replacing the cement with fly ash, fine aggregates
with steel slag and coarse aggregates with demolition waste aggregates. The properties of
concrete, whether in the fresh state or hardened state, are affected by its ingredients and their
proportions. An understanding and knowledge of the workability are the most important for
making a well-designed concrete mix which can be easily placed and compacted with
minimum effort.
Materials are:
1. Cement
2. Fine Aggregates
3. Coarse Aggregates
4. Fly Ash
5. Steel Slag
6. Recycled Aggregates
7. Water
3.1.1 CEMENT
Cement is a binder, a substance used for construction that sets, hardens, and adheres
to other materials to bind them together. Cement is seldom used on its own, but rather to bind
sand and gravel together. Cement mixed fine aggregate produces mortar for masonry, or with
sand and gravel, produces concrete. Cement used in construction are usually inorganic, often
lime or calcium silicate based, and can be characterized as either hydraulic or non-hydraulic,
depending on the ability of the cement to set in the presence of water. Non-hydraulic cement
does not set in wet conditions or under water. Rather, it sets as it dries and reacts with carbon

dioxide in the air. It is resistant to attack by chemicals after setting. Hydraulic cements set
and become adhesive due to a chemical reaction between the dry ingredients and water. The
chemical reaction results in the mineral hydrates that are not very water-soluble and so are
quite durable in water and safe from chemical attack. This allows setting in wet conditions or
under water and further protects the chemical process for hydraulic cement was found by
ancient Romans who used volcanic ash with added lime (calcium oxide). Ordinary Portland
cement (OPC) is the most common cement used in general concrete construction when there
is no exposure to sulphates in the soil or groundwater. The cement making process can be
divided; first “clinker” is made at temperature of 1400 0C. Then the clinker is milled with
other minerals to produce the powder we know as cement.
Ordinary Portland Cement of 53 Grade of brand name Penna Cement available in the
local market was used for the investigation. Care has been taken to see that the procurement
was made from single batching in air tight containers to prevent it from being effected by
atmospheric conditions. The cement thus procured was tested for physical requirements in
accordance with IS: 10262-2009. The size of cement varies from 1 micron to 45 micron. The
colour of the cement is grey in colour. Cement is used to bind the materials of aggregates.
COMPOUNDS PERCENTAGE
SiO2 23
Al2O3 4
Fe2O3 2
CaO 64
MgO 2
SO3 2
TABLE NO: 1 CHEMICAL ANALYSIS OF PORTLAND CEMENT

FIG NO: 2 CEMENT
3.1.2 FINE AGGREGATE:
Aggregate is a granular material used to produce concrete or mortar and when the
particles of the granular material are so fine that they pass through a 4.75mm sieve. It is
widely used in the construction industry to increase the volume of concrete, thus it is a cost
saving material. Fine aggregate is the essential ingredient in concrete that consists of natural
sand or crushed stone. The quality and fine aggregate density strongly influence the hardened
properties of the concrete. Fine aggregates provide dimensional stability to the mixture. Fine
aggregates quality also influence the mixture proportions and hardening properties. The
properties of fine aggregates also have a significant impact on the shrinkage of the concrete.
Fine aggregate is on of the major constituents of concrete which can influence concrete mix
design substantially. Various factors such as fine aggregates fineness modulus, moisture
content, specific gravity and silt content affect the mix proportions of concrete. The surface
area of fine aggregates is higher. The voids between the coarse aggregate are filled up by fine
aggregates.
River sand locally available in the market was used in the investigation. The
aggregate was tested for its physical requirements such as gradation, fineness modulus,

specific gravity and bulk density in accordance with IS: 10262-1998. The sand was surface
dried before use.
FIG NO: 3 FINE AGGREGATES
3.1.3 COARSE AGGREGATE:
Coarse-grained aggregates will not pass through a sieve with 4.75mm openings.
Larger pieces offer less surface area of the particles than an equivalent volume of small
pieces. Use of the largest permissible maximum size of coarse aggregate permits a reduction
in cement and water requirements. Using aggregates larger than the maximum size of coarse
aggregates permitted can result in interlock and form arches or obstructions within a concrete
form. That allows the area below to become a void, or at best, to become filled with finer
particles of sand and cement only and results in a weakened area. Coarse aggregate is one of
the essential components of concrete and occupies the largest volume in the mix. That is why
it greatly affects the concrete mix design. Its properties are strength, maximum size, shape
and water absorption influence water demand, the quantity of cement and fine aggregate in
concrete mixture. It is reported that, high maximum coarse aggregate size leads to lower
water demand in the mixture since such aggregate has lower surface area compare with small
coarse aggregate size. As far as shape is concerned, rounded shape aggregate provides

economical mix design for normal strength concrete. However, angular coarse aggregate is
desired in the case of high strength concrete. This possibility of segregation is minimized if
coarser aggregate is properly graded. This explains how important for good grading of
concrete mix design. Locally available which have the size of 20mm.
The nominal maximum size of coarse aggregate should be as large as possible within
the limits specified but in no case greater than one-fourth of the minimum thickness of the
member, provided that the concrete can be placed without difficulty so as to surround all
reinforcement thoroughly and fill the corners of the form. For most work, 20mm aggregate is
suitable. Where there is no restriction to the flow of concrete into sections, 40mm or larger
size may be permitted. In concrete elements with thin sections, closely spaced reinforcement
or small cover, consideration should be given to the use of 10mm nominal maximum size.
Crushed aggregates of less than 20mm size produced from local crushing plants were
used. The aggregate exclusively passing through 20mm sieve size. The aggregates were
tested for their physical requirements such as gradation, fineness modulus, specific gravity
and bulk density.
----
FIG NO: 4 COARSE AGGREGATES

3.1.4 FLY ASH
Fly ash is the finely divided residue that results from the combustion of pulverized
coal and is transported from the combustion chamber by exhaust gases. Energy requirements
for the developing countries in particular are met from coal-based thermal power plants. The
disposal of the increasing amounts of solid waste from coal-fired thermal power plants is
becoming a serious concern to the environmentalists. Coal ash, 80% of which is very fine in
nature and is thus known as fly ash is collected by electrostatic precipitators in stacks. In
India, nearly 140 million tons of fly ash is generated per annum at present and is largely
responsible for environmental pollution. In developed countries like Germany, 80% of the fly
ash generated is being utilized, whereas in India only 3% is being consumed. Fly ash has
been identified as by product of coal combustion. Generally, it has been generated in thermal
power plant and boiler plant. Physical characteristics of fly ash support the workability of
concrete mix. Fly ash has heat of hydration due more stable structure. In this work fly ash is
taken from nearby bricks manufacturing industry.
Fly ash is a by-product of the combustion of pulverized coal in electric power

generation plants. When the pulverized coal is ignited in the combustion chamber, the carbon
and volatile materials are burned off. However, some of the mineral impurities of clay, shale,
feldspars, etc., are fused suspension and carried out of the combustion chamber in the exhaust
gases. As the exhaust gases cool, the fused materials solidify into spherical glassy particles
called fly ash. Due to the fusion-in-suspension these fly ash particles are mostly minute solid
spheres and hollow ecospheres with some particles even being plerospheres, which are
spheres containing smaller spheres. The size of the fly ash particles varies but tends to be
similar to slightly larger than Type-1 Portland cement. The fly ash is collected from the
exhaust gases by electrostatic precipitators or bag filters. Chemical makeup of fly ash is
primarily silicate glass containing silica, alumina, iron and calcium. Color generally ranges
from dark grey to yellowish tan for fly ash used for concrete. ASTM C 618 Standard
Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolana for use as mineral
admixture in concrete has two designations for fly ash used in concrete- Class F and Class C.

Class F Fly Ash is normally produced from burning anthracite or bituminous coal that meets
the applicable requirements. This class of fly ash has pozzolanic properties and will have a
minimum silica dioxide plus aluminum oxide plus iron oxide of 70%.
Class C Fly Ash is normally produced from sub-bituminous coal that meets the applicable
requirements. This class of Fly Ash, in addition to having pozzolanic properties, also has
some cementitious properties and will have a minimum silica dioxide plus aluminum oxide
plus iron oxide content of 50%.
FIG NO: 5 METHOD OF FLY ASH TRANSFER CAN BE DRY, WET, OR BOTH

YEAR THERMAL COAL ASH

POWER CONSUMPTION GENERATION
GENERATION (mt) (mt)
(mW)
1995 54,000 200 75
2000 70,000 250 90
2010 98,000 300 110
2020 137,000 350 140
TABLE NO: 2 THERMAL POWER GENERATION, COAL CONSUMPTION AND

ASH GENERATION IN INDIA.
FIG NO: 6 FLYASH

COMPOUNDS FLY ASH CLASS F (%) FLY ASH CLASS C (%)
SiO2 55 40
Al2O3 26 17
Fe2O3 7 6
CaO 9 24
MgO 2 5
SO3 1 3
TABLE NO: 3 CHEMICAL ANALYSIS FOR FLY ASH
ADVANTAGES OF FLY ASH IN CONCRETE:
➢ Fly ash improves concrete workability and lowers water demand.

➢ Fly ash generally exhibit less bleeding and segregation than plain concretes.
➢ Fly ash has a lower heat of hydration.
➢ Fly ash generally reduces the permeability and adsorption of concrete.
➢ Fly ash is economical.
➢ Lower water and air permeability.
➢ Superior resistance to freezing and thawing.
➢ Increases the modulus of elasticity of concrete when concretes of the same strength
with and without fly ash are compared.
➢ The increase in creep with fly ash content up to 15% is negligible.
➢ Fly ashes impart significant sulphate resistance and alkali aggregate reaction (ASR)
resistance to the concrete mixture.
➢ Fly ash is a siliceous or aluminosiliceous material. Concrete containing fly ash
pozzolan become denser, stronger and generally more durable long term as compared
to straight Portland cement concrete mixtures.
➢ Greater resistance to attack of aggressive water.
DISADVANTAGES OF FLY ASH IN CONCRETE:

➢ Use of right quality fly ash, results in reduction of water demand for desired slump.
➢ With the reduction of unit water content, bleeding and drying shrinkage will also be
reduced.
➢ Since fly ash is not highly reactive, the heat of hydration can be reduced through
replacement of part of the cement with fly ash.
➢ Fly ash, when used in concrete, contributes to making the texture of concrete due to
its pozzolanic reactivity.
➢ The pozzolanic reaction also contributes to making the texture of concrete dense,
resulting in decrease of water permeability and gas permeability.
➢ It should be noted that since pozzolanic reaction can only proceed in the presence of
water, fly ash concrete should be cured for longer time.
➢ *Dams will derive full benefits of attaining improved long term strength and water
tightness.
3.1.5 STEEL SLAG:
Steel slag, a by-product of steel making, is produced during the separation of the
molten steel from impurities in steel-making furnaces. The slag occurs as a molten liquid
melt and is a complex solution of silicates and oxides that solidifies upon cooling. The steel
slag produced during the primary stage of steel production is referred to as furnace slag or tap
slag. The steel making industry has generated substantial solid waste. Steel slag is an
industrial by product obtained from the steel manufacturing industry and hundreds of tones of
it are produced every year all over the world in the process of refining metals and making
alloys. Steel slag can be used in the construction industry as aggregates in concrete by
replacing natural aggregates. The steel slag generated from the conversion of iron to steel is
poured into beds and slowly cooled under ambient conditions. The slag of crystalline
structure is formed and hard lump slag is produced which can subsequently be crushed and
screened. The crushing and screening of materials produces the aggregate.
Steel slag has been purchased from India Mart. It is an online shopping app. It is black
in colour and has been made between natural sand and steel slag for suitability of steel slag as
fine aggregate. Steel industries are growing widely nowadays. The extract of steel means

steel slag is harmful, which increases pollution and impossible for easy disposal. The main
object of this research is waste management and use of steel slag in making low cost
concrete. Nowadays there are many steel industries which produce steel products, and we
know as there is production there will be waste generation. Steel slag is generated at very
large amount in Industrial areas. This steel slag damages and affects the environment and it is
also difficult for disposal. Aggregates are the important constituents in concrete. They give
body to the concrete, reduce shrinkage and effect economy. It appears in concrete, aggregate
road materials, as ballast, and is sometimes used as a component of phosphate fertilizer. Steel
slag can be used in the construction industry as aggregates in concrete by replacing natural
aggregates.
OXIDES PERCENTAGE
Fe2O3 97.05
MnO 1.07
TiO2 0.01
SiO2 0.8
MgO 0.4
CaO 0.4
C 0.23
S 0.21
Water Solubility 0.009
TABLE NO: 4 CHEMICAL ANALYSIS OF THE STEEL SLAG

FIG NO: 7 OVERVIEW OF SLAG PRDUCTION IN MODERN INTEGRATED

STEEL PLANT
FIG NO: 8 STEEL SLAG
ADVANTAGES OF STEEL SLAG IN CONCRETE:

➢ Steel slag contains greater hardness.

➢ Better adhesion.
➢ Greater stability and reduced wear.
➢ Blending material for Portland cement.
➢ Steel slag concrete mixes have very high stabilities and satisfactory flows and
excellent stripping resistance.
➢ Steel slag used as surface course has good wear and skid resistance.
➢ Steel slag mixes have good heat retention and compatibility.
➢ When in contact with moisture, steel slag has a potentially expansive nature up to
10% attributed to the hydration of the free Cao and magnesium hydrates.
DISADVANTAGES OF STEEL SLAG IN CONCRETE:
➢ More amount of steel slag affects environment.

➢ Difficult for disposal.
3.1.6 DEMOLITION WASTE AGGREGATES (RECYCLED AGGREGATES):
A large amount of concrete structures are demolished in India and other countries. But
only small quantities of demolished waste are reused. This will have serious problems
creating environmental pollution and also requires large amount of space for dumping the
waste. When structures made of concrete are demolished or renovated, concrete recycling is
an increasingly common method of utilizing the rubble. Concrete once routinely trucked to
landfills for disposal, but recycling has a number of benefits that have made it a more
attractive option in this age of greater environmental awareness, more environmental laws,
and the desire to keep construction costs down. Concrete aggregate collected from demolition
sites is put through a crushing machine. Crushing facilities accept only uncontaminated
concrete, which must be free of trash, wood, paper and other such materials. Metals such as
rebar are accepted, since they can be removed with magnets and other sorting devices and
melted down for recycling elsewhere. The remaining aggregate chunks are sorted by size.
Larger chunks may go through the crusher again. After crushing has taken place, other
particulars are filtered out through a variety of methods including hand-picking and water
flotation. Crushing at the actual construction site using portable crushers reduces construction

costs and the pollution generated when compared with transporting material to and from a
quarry. These systems normally consist of a rubble crusher, side discharge conveyor,
screening plant, and a return conveyor from the screen to the crusher inlet for reprocessing
oversize materials. Compact, self-contained mini-crushers are also available that can handle
up to 150 tonnes per hour and fit into tighter areas. With the advent of crusher attachments-
those connected to various construction equipment, such as excavators-the trend towards
recycling on-site with smaller volumes of material is growing rapidly. Smaller pieces of
concrete are used as gravel for new construction projects. Recycling concrete can create more
employment opportunities.
Construction materials are increasingly judged by their ecological characteristics.

Concrete recycling gains importance because it protects natural resources and eliminates the
need for disposal by using the readily available concrete as an aggregate source for new
concrete is a relatively simple process. It involves breaking, removing and crushing existing
concrete into a material with a specified size and quality. The crushing characteristics of
hardened concrete are similar to those of natural rock and are not significantly affected by the
grade or quality of the original concrete. Recycled aggregates the usage of demolition wastes
as an aggregate for the manufacture of concrete is considering in new research studies. The
usage of demolition waste aggregates helps in reducing the depletion of natural aggregates
and problems related to mining the aggregates. It is found that the quality of natural
aggregates is better compared to the demolition waste aggregates. Thus, demolition waste
aggregates have limited usage.
Out of the total construction demolition waste, 40% is of concrete, 30% ceramic’s,
5% plastics, 10% wood, 5% metal & 10% other mixtures. As reported by global insight,
growth in global construction sector predicts an increase in construction spending of 4800
billion US dollars. These figures indicate a tremendous growth in the construction sector,
almost 1.5 times in 5 years.

FIG NO: 9 DEMOLITON WASTE AGGREGATE
ADVANTAGES OF RECYCLED AGGREGATES IN CONCRETE:
➢ Reduces the amount of virgin aggregates to be created, hence less evacuation of

natural resources.
➢ While being crushed into smaller particles a large amount of carbon dioxide is
absorbed. This reduces the amount of CO2 is the atmosphere.
➢ Provide a cost saving.
➢ Conserves landfill space, reduces the need for new landfills and hence saving more
costs.
➢ Creates more employment opportunities is recycling industry.
➢ Provide landfill tipping fees paid.
➢ Economical for poor areas unable to afford hauling costs for coarse aggregates from
other locales.
➢ Less emission of carbon due to less crushing.
➢ There are no detrimental effects on concrete and it is expected that the increase in the
cost of cement could be offset by the lower cost of Recycled Concrete Aggregate.
DISADVANTAGES OF RECYCLED AGGREGATES IN CONCRETE:

➢ Excess amount of adding of demolished concrete waste cannot attend the strength.
➢ Separation of the coarse aggregate from demolished waste takes time and labour.
➢ Less quality (e.g. compressive strength reduces by 10-30%).
➢ Duration of procurement of materials may affect life cycle of project.
➢ Land, special equipments machineries are required (more cost).
➢ Very high water absorption (up to 6%).
➢ It has higher drying shrinkage & creep.
3.1.7 WATER:
Ordinary portable water free from organic content, turbidity and salts was used for
mixing and for curing throughout the investigation. Water plays a vital role in achieving the
strength of concrete. For complete hydration it requires about 3/10th of its weight of water. It
is practically proved that minimum water-cement ratio 0.5 is required for conventional
concrete. Water participates in chemical reaction with cement and cement paste is formed and
binds with coarse aggregate and fine aggregates. If more water is used, segregation and
bleeding takes place, so that the concrete becomes weak. Hence it may avoid bleeding. If
water content exceeds permissible limits it may cause bleeding. If less water is used, the
required workability is not achieved. Portable water fit for drinking is required to be used in
the concrete and it should have pH value ranges between 6 to 9.
Water used for mixing and curing shall be clean and free from injurious amounts of
oils, acids, alkalis, salts, sugar, organic materials or other substances that may be deleterious
to concrete or steel. The sample of water taken for testing shall represent the water proposed
to be used for concreting, due account being paid to seasonal variation. The sample shall not
receive any treatment before testing other than that envisaged in the regular supply of water
proposed for use in concrete. The sample shall be stored in a clean container previously
rinsed out with similar water.
Average 28days compressive strength of at least three 150mm concrete cubes

prepared with water proposed to be used shall not be less than 90 percent of the average of
strength of two similar concrete cubes prepared with water. The cubes shall be prepared,
cured and tested.

FIG NO: 10 WATER
3.2: PROPERTIES OF MATERIALS:
3.2.1 PROPERTIES OF CEMENT:
The properties of ordinary portland cement as shown in the below table.
TEST PARTICULARS RESULTS OBTAINED REQUIREMENTS
Specific Gravity 3.10 3.10-3.15
Normal Consistency (%) 30 30-35
Initial Setting Time 35 Above 30

(Minutes)
Final Setting Time (Minutes) 570 Below 600
Compressive Strength (MPa)
For 3days 16.45 8

For 7days 19.5 13
For 28days 21.85 20
Soundness of Cement (mm) 3 10
Fineness (%) 5 10
TABLE NO: 5 PROPERTIES OF PORTLAND CEMENT
FIG NO: 11 INITIAL SEETTING TIME
3.2.2 PROPERTIES OF FINE AGGREGATES:
Naturally available sand passing through 4.75mm sieve is used.
3.2.2.1 SIEVE ANALYSIS OF FINE AGGREGATE:
S.No SIEVE WEIGHT % OF CUMULATIVE % OF

SIZE RETAINED WEIGHT % WEIGHT PASSING

(gms) RETAINED RETAINED WEIGHT

(gms) (100-
cumulative
% of weight
retained)
1. 4.75mm 16 16 1.6 98.4
2. 2.36mm 148 14.8 16.4 83.6
3. 1.18mm 176 17.6 34 66
4. 1mm 250 25.0 59 41
5. 425micron 315 31.5 90.5 9.5
6. 300micron 53 5.3 95.8 4.2
7. 150micron 27 2.7 98.5 1.5
8. 75micron 5 0.5 99.0 1.0
9. Pan 8 0.8 99.8 0.2
Total =
305.4
TABLE NO: 6 SIEVE ANALYSIS OF FINE AGGREGATE
∑ 𝐨𝐟 % 𝐩𝐚𝐬𝐬𝐢𝐧𝐠 𝐰𝐞𝐢𝐠𝐡𝐭
Fineness modulus = 𝟏𝟎𝟎
305.4
= 100
= 3.05%
Sand belongs to Zone-II sand and has a fineness modulus of 3.05%.
3.2.2.2 SPECIFIC GRAVITY OF FINE AGGREGATES- BY USING PYCNOMETER:
Weight of pycnometer (W1) = 427gms.
Weight of pycnometer + sand (W2) = 928gms.
Weight of pycnometer + sand + water (W3) = 1760gms.

Weight of pycnometer + water (W4) = 1450gms.
Weight of oven dry aggregates sample (W5) = (W2-W1)
= (928-427)
= 501gms.
𝐖𝟓
Specific Gravity of Fine Aggregate = (𝐖𝟐−𝐖𝟏)−(𝐖𝟑−𝐖𝟒)
(𝟗𝟐𝟖−𝟒𝟐𝟕)
= (𝟗𝟐𝟖−𝟒𝟐𝟕)−(𝟏𝟕𝟔𝟎−𝟏𝟒𝟓𝟎)
𝟓𝟎𝟏
= 𝟓𝟎𝟏−𝟑𝟏𝟎
= 2.62.
3.2.2.3 BULKING OF SAND:
% INITIAL FINAL {(INITIAL-

FINAL)/INITIAL}
X 100
2 600 780 30
4 600 830 38
6 600 820 36
8 600 750 25
10 600 680 13
TABLE NO: 7 BULKING OF SAND

FIG NO: 12 BULKING OF SAND
3.2.3 PROPERTIES OF CONCRETE:
3.2.3.1 WORKABILITY TEST:
Slump Cone Value = 25mm.
It’s a true slump.
FIG NO: 13 SLUMP CONE

CHAPTER-4
MIX DESIGN
Proper design of concrete mixture is intended to obtain such proportioning of
ingredients which will produce concrete of high durability performance during the designed
life of a structure.
For a particular strength, long term qualities and performance. Several factors determine
these properties.
1. Quality of cement.
2. Proportion of cement and other cement materials in relation to water in the mixture
(water-cement ratio).
3. Strength and cleanliness of aggregate.
4. Interaction or adhesion between cement paste and aggregate.
5. Adequate mixing of ingredients.
6. Proper placing, finishing and compaction of fresh concrete.
7. Curing at a temperature not below 500F while the placed concrete gains strength.
A study of these requirements shows that most of the control actions have to be taken
prior to placing the fresh concrete. Since each control is governed by the proportion and the
mechanical ease or difficulty in handling and placing, the development of criteria based on
the theory of proportioning for each mixture should be studied.
In addition, a determination has to be made as to the admixtures that need to be prescribed to

enhance the long term high performance and durability of the finished product.
CONCRETE MIX DESIGN FOR M20 CONCRETE AS PER INDIAN STANDARD

10262 -2009:
STEP-1: STIPULATIONS FOR PROPORTIONING:
A. Grade designation: M20

B. Type of cement: OPC 53 grade (penna cement)

C. Maximum nominal size of aggregate: 20mm

D. Minimum cement content: 250kg/m3
E. Maximum water-cement ratio: 0.5
F. Workability: 25mm (true slump)
G. Exposure condition: Severe (for plain concrete)
H. Degree of supervision: Good
I. Type of aggregate: Crushed angular shape aggregate
STEP-2: TEST DATA FOR MATERIALS:
A. Cement used = OPC 53 grade

B. Specific gravity of cement: 3.10
C. Specific gravity of fine aggregate: 2.62
D. Specific gravity of coarse aggregate: 2.82
E. Water absorption for fine aggregate: 1%
F. Water absorption for coarse aggregate: 0.84%
STEP-3: TARGET STRENGTH FOR MIX PROPORTIONING:
Target compressive strength, 𝒇𝟏𝒄𝒌 = 𝒇𝒄𝒌 + (𝐭 × 𝐬)
Where, 𝒇𝟏𝒄𝒌 = Target average compressive strength at 28days,
𝒇𝒄𝒌 = Characteristic compressive strength at 28days,
𝒔 = Standard deviation and
𝒕 = Tolerance factor (its take 1.65)
As per IS 10262-2009, From Table-1, Standard deviation for M20 grade of concrete is
4.0N/mm2.
Therefore, Target strength, 𝒇𝟏𝒄𝒌 = 𝟐𝟎 + 𝟏. 𝟔𝟓 × 𝟒
𝒇𝟏𝒄𝒌 = 𝟐𝟔. 𝟔 𝑵/𝒎𝒎𝟐 .
STEP-4 SELECTION OF WATER-CEMENT RATIO:

As per IS 456-2000 From Table-5, Maximum Free Water-Cement Ratio for M20 grade of
concrete is 0.5 for plain concrete.
Maximum Water-Cement Ratio = 0.5.
STEP-5 SELECTION OF WATER CONTENT:
As per IS 10262-2009 From Table-2, Maximum Water Content for 20mm aggregate is
186kgs.
Maximum Water Content = 186litres.
STEP-6 CALCULATION OF CEMENT CONTENT:
Water-Cement Ratio = 0.5
𝟏𝟖𝟔
Cement Content = = 372kgs.
𝟎.𝟓
As per IS 456-2000 Table-5, Minimum Cement Content for Severe Exposure for M20 grade
of concrete is 250kg/m3.
372kg/m3 > 250kg/m3,
Hence OK.
Cement Content = 372kg/m3.
STEP-7 PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE

AGGREGATE:
As per IS 10262-2009 Table-3, Volume of Coarse Aggregate for 20mm Aggregate and Fine
Aggregate (Zone-II sand) is 0.62
Volume of Fine Aggregate = 𝟏 − 𝐕𝐨𝐥𝐮𝐦𝐞 𝐨𝐟 𝐜𝐨𝐚𝐫𝐬𝐞 𝐚𝐠𝐠𝐫𝐞𝐠𝐚𝐭𝐞
= 𝟏 − 𝟎. 𝟔𝟐
= 𝟎. 𝟑𝟖
Volume of Fine Aggregate = 0.38.

Volume of Coarse Aggregate = 0.62.
STEP-8 MIX CALCULATIONS:
The mix calculations per unit volume of concrete shall be as follows:
a) Volume of Concrete = 𝟏𝒎𝟑 .

b) Volume of Cement =
𝐌𝐚𝐬𝐬 𝐨𝐟 𝐂𝐞𝐦𝐞𝐧𝐭 𝟏
×
𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐆𝐫𝐚𝐯𝐢𝐭𝐲 𝐨𝐟 𝐂𝐞𝐦𝐞𝐧𝐭 𝟏𝟎𝟎𝟎
𝟑𝟕𝟐 𝟏
×
𝟑. 𝟏𝟎 𝟏𝟎𝟎𝟎
= 𝟎. 𝟏𝟐𝒎𝟑 .
c) Volume of Water =
𝐌𝐚𝐬𝐬 𝐨𝐟 𝐰𝐚𝐭𝐞𝐫 𝟏
×
𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐠𝐫𝐚𝐯𝐢𝐭𝐲 𝐨𝐟 𝐰𝐚𝐭𝐞𝐫 𝟏𝟎𝟎𝟎
𝟏𝟖𝟔 𝟏
×
𝟏 𝟏𝟎𝟎𝟎
= 𝟎. 𝟏𝟖𝟔𝒎𝟑 .
d) Volume of all in aggregate = [𝐚 − (𝐛 + 𝐜)]
= [𝟏 − (𝟎. 𝟏𝟐 + 𝟎. 𝟏𝟖𝟔)]
= 𝟎. 𝟔𝟕𝟒𝒎𝟑 .
e) Mass of Fine Aggregate
= 𝐝 × 𝐕𝐨𝐥𝐮𝐦𝐞 𝐨𝐟 𝐟𝐢𝐧𝐞 𝐚𝐠𝐠𝐫𝐞𝐠𝐚𝐭𝐞 × 𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐠𝐫𝐚𝐯𝐢𝐭𝐲 𝐨𝐟 𝐟𝐢𝐧𝐞 𝐚𝐠𝐠𝐫𝐞𝐠𝐚𝐭𝐞 × 𝟏𝟎𝟎𝟎
= 0.674 × 0.38 × 2.62 × 1000
= 671.03kgs.
f) Mass of Coarse Aggregate

= 𝐝 × 𝐕𝐨𝐥𝐮𝐦𝐞 𝐨𝐟 𝐜𝐨𝐚𝐫𝐬𝐞 𝐚𝐠𝐠𝐫𝐞𝐠𝐚𝐭𝐞 × 𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐠𝐫𝐚𝐯𝐢𝐭𝐲 𝐨𝐟 𝐜𝐨𝐚𝐫𝐬𝐞 𝐚𝐠𝐠𝐫𝐞𝐠𝐚𝐭𝐞 × 𝟏𝟎𝟎𝟎
= 0.674 × 0.62 × 2.82 × 1000
= 1178.42kgs.
STEP-9 MIX PROPORTIONS:
Mix proportions for 1m3:
A. Cement = 372kgs/m3.
B. Water = 186kgs/m3.
C. Fine Aggregate = 671.03kgs/m3.
D. Coarse Aggregate = 1178.42kgs/m3.
E. Water-Cement Ratio = 0.5.
As per these we calculate the ratio of materials 1m3.
𝟑𝟕𝟐 𝟔𝟕𝟏. 𝟎𝟑 𝟏𝟏𝟕𝟖. 𝟒𝟐

⋮ ⋮
𝟑𝟕𝟐 𝟑𝟕𝟐 𝟑𝟕𝟐
𝟏 ⋮ 𝟏. 𝟖 ⋮ 𝟑. 𝟏𝟔
STEP-10 CALCULATION FOR 1 CUBE OF CONCRETE:
Volume of Cube = 𝟎. 𝟏𝟓𝐦 × 𝟎. 𝟏𝟓𝐦 × 𝟎. 𝟏𝟓𝐦
Volume of Cube = 𝟎. 𝟎𝟎𝟑𝟑𝟕𝟓𝐦𝟑 .
𝐌𝐚𝐬𝐬 = 𝐃𝐞𝐧𝐬𝐢𝐭𝐲 × 𝐕𝐨𝐥𝐮𝐦𝐞
= 𝟐𝟒𝟎𝟎 × 𝟎. 𝟎𝟎𝟑𝟑𝟕𝟓
= 𝟖. 𝟏 𝒌𝒈𝒔.
Adding 12% extra for air loss.
𝐌𝐚𝐬𝐬 = 𝟖. 𝟏 × 𝟏. 𝟏𝟐.
= 𝟗. 𝟎𝟕 𝒌𝒈𝒔.

𝟗.𝟎𝟕
𝐂𝐞𝐦𝐞𝐧𝐭 𝐟𝐨𝐫 𝟏 𝐂𝐮𝐛𝐞 = 𝟏+𝟏.𝟖+𝟑.𝟏𝟔 = 𝟏. 𝟓𝟐 𝐤𝐠𝐬.
{For 6 cubes of cement = 6 x 1.52 = 9.12kgs}
𝐅𝐢𝐧𝐞 𝐀𝐠𝐠𝐫𝐞𝐠𝐚𝐭𝐞 𝐟𝐨𝐫 𝟏 𝐂𝐮𝐛𝐞 = 𝟏. 𝟖 × 𝟏. 𝟓𝟐 = 𝟐. 𝟕𝟒 𝐤𝐠𝐬.
{For 6 cubes of fine aggregate = 6 x 2.74 = 16.44kgs}
𝐂𝐨𝐚𝐫𝐬𝐞 𝐀𝐠𝐠𝐫𝐞𝐠𝐚𝐭𝐞 𝐟𝐨𝐫 𝟏 𝐂𝐮𝐛𝐞 = 𝟑. 𝟏𝟔 × 𝟏. 𝟓𝟐 = 𝟒. 𝟖 𝐤𝐠𝐬.
{For 6 cubes of coarse aggregate = 6 x 4.8 = 28.8kgs}.

CHAPTER -5
EXPERIMENTAL STUDY
5.1 GENERAL:
In order to increase the performance of concrete, many types of mineral and chemical
admixtures are added. Addition of materials may change the performance in the hardened
stages. Therefore, it is very essential to evaluate the effect of materials on mechanical
properties of concrete. Thus chapter deals with the properties of materials used in this
investigation, methodology, preparation of test specimens, experimental test set up and
testing procedure that have been performed.
5.2 CASTING:
Following sizes of moulds were used for casting cubes of 150mmX150mmX150mm.

Machine mixing was adopted and Machine mixing is the process of mixing the ingredients of
the concrete with a concrete mixer machine. It is highly effective for fulfilling the demands of
short mixing time, optimum consistency and homogeneous quality of concrete.
According to “A. M. Neville” (Author Properties of Concrete), machine mixing of

concrete not only imparts the uniformity of the mix but also discharges the mix without
disturbing that uniformity. Machine mixing of concrete are needed because it ensures the
consistent homogeneity of the concrete.
Nowadays various types of concrete mixers powered by petrol, diesel or electricity

are available. The process of machine mixing of concrete is, First of all, wet the inner
surfaces of the drum of concrete mixer. Coarse aggregates are placed in the mixer first
followed by sand and then cement. Mix the materials in the dry state in the mixing machine.
Normally it should be 1.5 to 3 minutes. After proper mixing of dry materials, gradually add
the correct quantity of water while the machine is in motion. Do not add more water than
required. It is not advisable as it reduces strength. After adding the water, we must mix
concrete for a minimum of two minutes in the drum. If there is any segregation of concrete
after unloading from the mixer, then remix the concrete.
FIG NO: 14 CASTING OF CUBES
5.3 PROCEDURE FOR CASTING OF CUBES:
The size of cube mould is 150mm. Take the random samples from the mix in a
ghamela, while concreting. Pour concrete in the cubes in 3 layers. Compact each layer with
35 numbers of strokes with the tamping rod. Finish the top surface by thapi/trowel after
compaction of the last layer. Each specimen should be taken from different locations of the
proposed concreting. After 24 hours, remove the specimen from the mould. While removing,
take care to avoid breaking of the edges. Code the cube with marker. Coding should be self
explanatory, building number and the date of casting. Submerge the specimen in clean, fresh
water until the time of testing.
The ingredients must not rotate for more than 2 minutes and the following pattern
must be used. First 20% water is poured in the drum and then 50% of coarse aggregate, fine
aggregate and cement is poured order-wise. Then added some water to the sample after added
water remaining coarse aggregate, fine aggregate and cement are poured. At last remaining
water is added. After mixing the concrete, it is taken in the tray. Then transfer it into the

cubes. We are tested 2 specimens for 3days, 2 specimens for 7days and 2 specimens for
28days curing.
FIG NO: 15 MIXING OF CONCRETE
5.4 PRECAUTIONS TO BE TAKEN WHILE MACHINE MIXING OF CONCRETE:
➢ Concrete mixer machine must be wet before use.

➢ Take care of mixing time, speed and numbers of revolution of mixer drum as per the
recommendation of the manufactures of the mixer machine.
➢ Concrete should be used within 30 minutes after mixing and discharging one batch of
concrete, the interior surface of the mixer drum should be cleaned thoroughly from
the mix of previous batch may form a part of the subsequent batch and deteriorate the
quality of concrete.
➢ If your mixing is of a continuous type, it is necessary to clean the concrete mixer after
fixed intervals.
➢ The inner portion of the concrete mixer should be carefully inspected at regular
intervals to check for damages, shatter or corrosion.
5.5 TESTING OF CUBES FOLLOWED BY BELOW STEPS:
➢ Check the coding and numbers of cubes received.

➢ Enter the details of cubes in the testing register.

➢ Weight the cube and note the figures in register.
➢ Cube size is 150mm cube, and then the volume of cube concrete is (150mm x 150mm
x 150mm) = 0.003375m3.
➢ Then weight of cube is not more than volume of cube X concrete density, (Concrete
density is 2400 kg per cubic meter)
➢ If cube weight is note equal to calculated weight, then we need to dry our cube again.
➢ Inform the concerned person about any damages.
➢ Check the dates of casting and testing machine, so that the load is applied to the
opposite side of the cube as cast, i.e., not on top and bottom.
➢ Record the maximum load applied to the specimen.
➢ Observe the appearance of concreted with the failure and note the same.
Calculate compressive strength = 𝐌𝐚𝐱𝐢𝐦𝐮𝐦 𝐥𝐨𝐚𝐝 𝐚𝐭 𝐟𝐚𝐢𝐥𝐮𝐫𝐞⁄𝐂𝐨𝐧𝐭𝐚𝐜𝐭 𝐚𝐫𝐞𝐚 𝐨𝐟 𝐭𝐡𝐞 𝐜𝐮𝐛𝐞.
FIG NO: 16 TESTING OF CUBES
➢ Take average strength of specimen cubes.

➢ This average strength represents the strength of concrete of particular portion of the
structure.
5.6 PERCENTAGE OF STRENGTH VS WORKING AGE IN DAYS:

Concrete gains maximum strength at 28days. Since in construction sector great

amount of capital is ay stake, so instead of checking strength at 28days we can check strength
in terms of concrete strength psi at 3 and 7 days to predict the target strength of construction
work.
From the below table it is clear that, Concrete gains 16% of its strength within 24
hours, whereas concrete gains 65% of the target strength by the time of 7 days of its casting.
We can’t judge the strength of concrete until it becomes stable. And we also won’t
wait for 28days to judge the concrete whether it suitable for construction or not to keep it
balanced, concrete is tested at various intervals.
AGE (DAYS) STRENGTH (%)

1 16
3 40
7 65
14 90
21 94
28 99
TABLE NO: 8 PERCENTAGE OF STRENGTH VS AGE IN DAYS
Above table shows the percentage of strength, as per these we are selected the
working period of compressive strength are 3, 7 and 28days. Because comparing the all
above working period strengths, percentage between 3, 7 and 28days are more different. If
we take 7, 14 and 28days, there is 14 and 28days are slightly near to know the strength
difference (i.e., 90 and 99%). But in all 3, 7 and 28days age more difference to know the
strength in percentage. So we are selected these ages of days. Totally 6 cubes we are casting
for 1 proportion, in that 2 cubes for 3days testing, and 2 cubes for 7days were testing and 2
cubes for 28days testing.
5.7 CALCULATION FOR FINDING THE COMPRESSIVE STRENGTH OF

CONCRETE:

The compressive strength of specimen can be calculated by dividing maximum load

carried by the specimen by cross-sectional area of the specimen cubes.
Mathematically, the compressive strength of concrete is
𝐌𝐚𝐱𝐢𝐦𝐮𝐦 𝐥𝐨𝐚𝐝 𝐜𝐚𝐫𝐫𝐢𝐞𝐝 𝐛𝐲 𝐬𝐩𝐞𝐜𝐢𝐦𝐞𝐧

=
𝐓𝐨𝐩 𝐬𝐮𝐫𝐟𝐚𝐜𝐞 𝐚𝐫𝐞𝐚 𝐨𝐟 𝐬𝐩𝐞𝐜𝐢𝐦𝐞𝐧
The surface area of specimen = 150 x 150 mm
= 22500 mm2.
FIG NO: 17 DIMENSIONS OF CUBE
Assume, the maximum compression load is 450 KN.
𝟒𝟓𝟎𝟎𝟎𝟎
𝐂𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐯𝐞 𝐬𝐭𝐫𝐞𝐧𝐠𝐭𝐡 𝐨𝐟 𝐜𝐨𝐧𝐜𝐫𝐞𝐭𝐞 = = 𝟐𝟎𝐍/𝐦𝐦𝟐 .
𝟐𝟐𝟓𝟎𝟎
5.8 CURING:
Test cubes should be demoulded between 24 hours after they have been made. If after
this period of time the concrete has not achieved sufficient strength to enable demoulding
without damaging the cube then the demoulding should be delayed for a further 24 hours.
When removing the concrete cube from the mould, take the mould apart completely. Take
care not to damage the cube because, if any cracking is caused, the compressive strength may
be reduced.
After demoulding, each cube should be marked with a legible identification on the top
or bottom using a waterproof crayon or ink. The mould must be thoroughly cleaned after
demoulding the cube. Ensure that grease or dirt does not collect between the faces of the
flanges, otherwise the two halves will not fit together properly and there will be leakage
through the joint and an irregularly shaped cube may result.
Curing of concrete derives its strength by the hydration of cement particles. The
hydration of cement is not momentary action but a process continuing for long time. Of
course, the rate of hydration is fast to start with, but continues over a very long time at a
decreasing rate. The quantity of the products of hydration and consequently the amount of gel
formed depends upon the extent of hydration. Curing can also be described as keeping the
concrete moist and warm enough so that the hydration of cement can continue. More
elaborately, it can described as the process of maintaining a satisfactory moisture content and
a favorable temperature in concrete during the period immediately following placement, so
that hydration of cement may continue until the desired properties are developed to sufficient
degree to meet the requirement of service. The quick surface drying of concrete results in the
movement of moisture from the interior to the surface.

FIG NO: 18 CURING TANK

CHAPTER-6
METHODOLOGY
STEP-1: COVENTIONAL CONCRETE FOR 6 CUBES
In the first step we have made 6 cubes of conventional concrete. In those 2 cubes each
of 3days, 7days and 28days are tested for compressive strength.
CEMENT (Kg) F.A. (Kg) C.A. (Kg) WATER (Lit)

9.12 16.44 28.8 4.56
TABLE NO : 9 WEIGHT OF CONVENTIONAL CUBES
STEP-2: CEMENT REPLACED BY FLY ASH FOR 6 CUBES OF EACH

PROPORTION @ 10%, 20% & 30%:
In the second step we have made 18 cubes. In those 6 cubes are made for 10%
replacement of cement by fly ash. Another 6 cubes are made for 20% replacement of cement
by fly ash. Lastly the remaining 6 cubes are made for 30% replacement of cement by fly ash.
CEMENT (Kg) FLY ASH (Kg) F.A. (Kg) C.A. (Kg) WATER (Lit)
8.208 0.912 (10% 16.44 28.8 4.56
replacement)
7.296 1.824 (20% 16.44 28.8 4.56
replacement)
6.384 2.736 (30% 16.44 28.8 4.56
replacement)
TABLE NO: 10 WEIGHTS FOR CEMENT REPLACED BY FLY ASH
STEP-3: FINE AGGREGATES REPLACED BY STEEL SLAG FOR 6

CUBES OF EACH PROPORTION @10%, 20% AND 30%:
In the third step we have made 18 cubes. In those 6 cubes are made for 10%
replacement of fine aggregates by steel slag. Another 6 cubes are made for 20% replacement
of fine aggregates by steel slag. Lastly the remaining 6 cubes are made for 30% replacement
of fine aggregates by steel slag.
CEMENT (Kg) F.A. (Kg) STEEL SLAG C.A. (Kg) WATER (Lit)
(Kg)
9.12 14.796 1.644 (10% 28.8 4.56
replacement)
9.12 13.152 3.288 (20% 28.8 4.56
replacement)
9.12 11.508 4.932 (30% 28.8 4.56
replacement)
TABLE NO: 11 WEIGHTS FOR F.A. REPLACED BY STEEL SLAG
STEP-4: COARSE AGGREGATES REPLACED BY RECYCLED

AGGREGATES FOR 6 CUBES OF EACH PROPORTION @10%, 20%
AND 30%:
In the fourth step we have made 18 cubes. In those 6 cubes are made for 10%
replacement of coarse aggregate by recycled aggregate. Another 6 cubes are made for 20%
replacement of coarse aggregate by recycled aggregate. Lastly the remaining 6 cubes are
made for 30% replacement of coarse aggregate by recycled aggregate.
CEMENT (Kg) F.A. (Kg) C.A. (Kg) RECYCLED WATER (Lit)

AGGREGATES
(Kg)
9.12 16.44 25.92 2.88 (10% 4.56

replacement)
9.12 16.44 23.04 5.76 (20% 4.56

replacement)

9.12 16.44 20.16 8.64 (30% 4.56

replacement)
TABLE NO: 12 WEIGHTS FOR C.A. REPLACED BY RECYCLED AGGREGATES
STEP-5: COMBINATION REPLACEMENT @20% OF ALL THREE

INGREDIENTS FOR 6 CUBES:
In the fifth step we have made 6 cubes. These are made for combination replacement
of all three materials at 20%.
CEMENT FLY F.A. (Kg) STEEL C.A. RECYCLED WATER

(Kg) ASH SLAG (Kg) AGGREGATES (Lit)
(Kg) (Kg) (Kg)
7.296 1.824 13.152 3.288 23.04 5.76 @20% 4.56
@20% @20%
TABLE NO: 13 WEIGHTS FOR COMBINATION REPLACEMENT OF ALL
THREE INGREDIENTS @20%
TOTAL QUANTITY OF MATERIALS REQUIRED:
1. Cement = 93.024Kgs
2. Fine Aggregates = 167.688Kgs
3. Coarse Aggregates = 293.76Kgs
4. Fly Ash = 7.296Kgs
5. Steel Slag = 13.152Kgs
6. Recycled Aggregates = 23.04Kgs
7. Water = 50.16Litres.

CHAPTER-7
TEST RESULTS
The compressive strength of concrete cubes at various percentages as shown below:
7.1 Conventional Concrete Cubes:
S NO AVERAGE COMPRESSIVE STRENGTH (N/mm2)
For 3days For 7days For 28days

1. 16.45 19.5 21.85
TABLE NO: 14 RESULTS FOR COVENTIONAL CUBES
FIG NO: 19 BEFORE & AFTER CRACK OF CONVENTIONAL CUBES

7.2 Comparing the Compressive Strength of Concrete for Conventional

Cubes with Replacement of Cement by Fly Ash:
S NO PROPORTION AVERAGE COMPRESSIVE STRENGTH

(N/mm2)
1. 0% Replacement 16.45 19.5 21.85
2. 10% Replacement 17.15 20.45 24
3. 20% Replacement 17.5 21.65 25.7
4. 30% Replacement 15.7 18.25 19.8
TABLE NO: 15 RESULTS FOR CEMENT REPLACED BY FLY ASH
FIG NO: 20 BEFORE & AFTER CRACK FOR REPLACEMENT OF CEMENT BY

FLY ASH

Bar charts show the Compressive Strength of Concrete in N/mm2 for

Comparing Conventional Cubes with Replacement of Cement by Fly Ash:
Conventional cubes
vs
Replacement of cement by fly ash
30
0% Replacement
25
Strength (in N/mm2)
20
10% Replacement
15
20% Replacement
10
5 30% Replacement
0
Working Period (in days)
Conventional cubes
vs
Replacement of cement by fly ash
0% Replacement
Strength (in N/mm2)
30
10% Replacement
20
10 20% Replacement
0
30% Replacement
For 3days
For 7days
For 28days

7.3 Comparing the compressive strength of Concrete for Conventional

Cubes with Replacement of Fine Aggregates by Steel Slag:
S NO PROPORTION AVERAGE COMPRESSIVE

STRENGTH (N/mm2)
1. 0% Replacement 16.45 19.5 21.85
2. 10% Replacement 17.4 21.75 26.85
3. 20% Replacement 18.25 23.75 32.85
4. 30% Replacement 17.45 22.45 31.2
TABLE NO: 16 RESULTS FOR F.A. REPLACED BY STEEL SLAG
FIG NO: 21 BEFORE & AFTER CRACK FOR REPLACEMENT OF F.A. BY STEEL
SLAG


Comparing Conventional Cubes with Replacement of Fine Aggregates by
Steel Slag:
Conventional cubes
vs
Replacement of Fine Aggregates by Steel Slag
35
30 0% Replacement
Strength (in N/mm2)
25
10% Replacement
20
15
20% Replacement
10
5 30% Replacement
0
Conventional cubes
vs
Replacement of Fine Aggregates by Steel Slag
0% Replacement
40
Strength (in N/mm2)
30 10% Replacement
20
20% Replacement
10
0 30% Replacemnt
For 3days
For 7days
For 28days


Cubes with Replacement of Coarse Aggregate by Recycled Aggregates:

STRENGTH (N/mm2)
1. 0% Replacement 16.45 19.5 21.85
2. 10% Replacement 16.8 21 30
3. 20% Replacement 18.95 23.5 34.5
4. 30% Replacement 19.7 24.3 33.35
TABLE NO: 17 RESULTS FOR C.A. REPLACED BY RECYCLED AGGREGATES
FIG NO: 22 BEFORE & AFTER CRACK FOR REPLACEMENT C.A. BY

RECYCLED AGGREGATE


Comparing Conventional Cubes with Replacement of Coarse Aggregate by
Recycled Aggregate:
Conventional cubes
vs
Replacement of Coarse Aggregate by Recycled Aggregate
40
35
0% Repalcement
Strength (in N/mm2)
30
25
10% Replacement
20
15
20% Replacement
10
5
30% Replacement
0
Working Period (in days))
Conventional cubes
vs
Replacement of Coarse Aggregate by Recycled Aggregate
0% Replacement
Strength (in N/mm2)
40
30 10% Replacement
20
20% Replacement
10
0
30% Replacement
For 3days
For 7days
For 28days


Cubes with Combination Replacement of all 3 Ingredients @20% of each
material:

STRENGTH (N/mm2)
1. 0% Replacement 16.45 19.5 21.85
2. 20% Replacement 17 22.2 25.95

of all 3 materials
TABLE NO: 18 RESULTS FOR COMBINATION REPLACEMENT OF ALL THREE

INGREDIENTS
FIG NO: 23 BEFORE & AFTER CRACK OF REPLACEMENT OF ALL 3

MATERIALS @20%


Comparing Conventional Cubes with Combination Replacement of all 3
Ingredients @20% of each material:
Conventional cubes
vs
Combination Replacement of all 3 Ingredients @20% of each material
30
Strength (in N/mm2)
25
20
0% Replacement
15
10 20% Replacement of all 3
materials
5
0
Conventioal cubes
vs
Combination Replacement of all 3 ingredients @20% of each material
Strength (in N/mm2)
30
20
0% Replacement
10
20% Replacement of
0 all 3 materials
For 3days
For 7days
For 28days

CHAPTER-8
APPLICATIONS
❖ It is used in base application, construction of unpaved parking lots, as a shoulder
material, and also in the construction of beams and embankment.
❖ It is also used in agriculture because it has minerals like iron, manganese, magnesium,
zinc and molybdenum which are valuable plant nutrients.
❖ It is environment friendly. During the production of cement, the CO2 emissions are
reduced as slag has previously undergone the calcinations process.
❖ Steel slag aggregates are used for soil stabilization or soil improvement material and
for remediation of industrial waste water run-off.
❖ Many old buildings, concrete pavements, bridges and other structures have overcome
their age and limit of use due to structural deterioration beyond repairs and need to be
demolished.
❖ The structures, even adequate to use are under demolition because they are not
serving the needs in present scenario; New construction for better economic growth.
❖ Structures are turned into debris resulting from natural disasters like earthquake,
cyclone and floods etc.
❖ Creation of building waste resulting from manmade disaster/war.
❖ Sustainable development of structures can be achieved by using waste demolished
concrete aggregate.
❖ We can use the plastic waste also as coarse aggregate in concrete.
❖ Fine aggregate in the demolished concrete can also be utilized in future.
❖ Demolished bricks and stones posses the same properties as coarse aggregates.
❖ Does not contain materials such as chlorides organic impurities, clay and shells.
❖ Increased strength as materials age.
❖ Does not generate alkali-aggregate reactions.
❖ Blast furnace slag fine aggregate does not contain materials that may affect the
strength and durability of concrete, such as chlorides, organic impurities clay and
shells.

CHAPTER-9
CONCLUSION
This research concludes the study of the effect of replaced materials on the properties of
concrete for nominal mix of M20 grade of concrete are as follows:
❖ The compressive strength of as fine aggregate in M20 grade of

concrete for replaced concrete was concrete and recommends the
similar to conventional concrete. approval of the material for use in
❖ Fly ash can be added in OPC concrete as a replacement material
concrete as partial replacement of for fine aggregates. The partial
OPC up to 20% without substitution of natural aggregates
compromising compressive with steel slag aggregates permits a
strength of concrete. Workability is gain of compressive strength and
decreased with increase in modulus of elasticity of concrete
replacement level of fly ash. up to an optimum value of
❖ The 10% and 20% replacement of replacement.
cement with fly ash shows good ❖ The 10%, 20% and 30%
compressive strength for 28days replacement of coarse aggregates
and but the 30% replacement of with recycled aggregates shows the
cement with fly ash, the better compressive strength for
compressive strength of concrete is 28days as compared to
slightly near as compare to conventional concrete cubes.
conventional concrete cubes. ❖ When demolished waste aggregates
❖ The 10% and 20% replacement of are used in concrete, the cost of
fine aggregates with steel slag production will be economical.
shows better compressive strength ❖ At last we are prepared the
for 28days and the 30% combination replacement of all
replacement of fine aggregates with three materials at a time @20% of
steel slag also good compressive each material such as cement by fly
strength as compare to ash, fine aggregates by steel slag
conventional concrete cubes. But and coarse aggregate by recycled
the 30% replacement is decreased aggregate, the compressive strength
as compared to 10% and 20% of concrete is increased as
replacement. compared to conventional concrete
❖ This work relates the use of steel cubes.
slag; a waste cheap material used

CHAPTER-10
REFERENCES
A. Oner, S. Akyuzb, R. Yildiza, (2004) “An experimental study on strength development of
concrete containing fly ash and optimum usage of fly ash in concrete” cement and concrete
research, Vol. 35, Issue 6, pp 11651171.
A.H.L. Swaroop, K. Venkateswara Rao, P. Kodandaramarao (2013) – “Durability studies on

concrete with Fly ash & GGBS” International Journal of Engineering Research and
Applications Vol. 3, pp. 258-289 ISSN: 2248-9622.
Mr. Tushar R Sonawane, Prof. Dr. Sunil S. Pimplikar “Use of Recycled Aggregate Concrete”
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), ISSN: 2278-1684, pp:52-
59.
Mr. I. Michael raj, Mr. J. Venkatesh (2018) “Experimental study on Partial Replacement of
Steel Slag with Fine Aggregate in RCC Elements” IRJET, Vol. 05, Issue: 12, Dec 2018 e-
ISSN: 2395-0056, P-: 2395-0072.
Mr. Pruthviraj L. Kadam, Anuj P. Shete, jit R. Ahir (2016) “Effect of partial replacement of
fine aggregate by steel slag and its impact on compressive strength of concrete” IJSER, Vol.
7, Issue 2, February-2016.
K.G. Hiraskar and Chetan Patil (2013) “Use of Blast Furnace Slag Aggregate in Concrete”
IJSER, Vol 4, Issue 5, May 2013, ISSN 2229-5518.
Krishna Prasanna p, Venkata Kiranmayi K (2014) “Steel slag as a substitute for fine
aggregate in high strength concrete” IJERT, ISSN: 2278-0181, Vol. 3, Issue 10, October-
2014.
Gozde Inan Sezer & Mert Gulderen (2015) “Usage of steel slag in concrete as fine and coarse
aggregate” IJEMS, Vol. 22, June 2015, pp. 339-334.

Sultan A. Tarawneh, Emhaidy S. Gharaibeh and Falah M. Saraireh (2014) “Effect of using
steel slag aggregate on mechanical properties of concrete” American Journal of Applied
Sciences 11 (5): 700-706, 2014, ISSN:1546-9239.
K.V. Sabarish, “Experimental studies on partial replacement of cement with fly ash in
concrete elements” IJCIET, Vol 8, Issue 9, September 2017, pp. 293-298.
Dr. Ramakrishna Hegde, Prof. Shrinath Rao K, Shashank h, “A study on strength

characteristics of concrete by replacing coarse aggregate by demolished column waste”
IJERT, ISSN: 2278-0181 Vol. 7, Issue 06, June-2018.
N V V S S L Shilpa Devi Gadde, P. Mani Kumar and K. Abhiram “A study on demolished

concrete by partial replacement of coarse aggregate” IJEIT, Vol 6, Issue 9, March 2017,
ISSN: 2277-3754.
Vinod Goud and Niraj Soni (2016) “Partial replacement of cement with fly ash in concrete
and its effect” IOSRJEN, ISSN (e): 2250-3021, ISSN (p0: 2278-8719, Vol. 06, Issue 10 (Oct.
2016), ||V2|| PP 69-75.
Vikas Srivastava and Alvin Harison, “Effect of fly ash as partial replacement of cement in
ppc concrete” ResearchGate, Article: July 2015, DOI: 10.15680/IJIRSET.2015.0407193.
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IRJET, Vol. 04, Issue: 11, Nov-2017, e-ISSN: 2395-0056, p-ISSN: 2395-0072.

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A Project report on

“PARTIAL REPLACEMET OF CEMENT, FINE AGGREGATES & COARSE AGGREGFATE

Under the guidance of

D. MADHUSUDHANA REDDY, M.tech,

(Accredited by NAAC, Bangalore)

Rajampet, Kadapa (Dist), A.P –

Bonafied project work submitted by

PROJECT GUIDE HEAD OF DEPARTMENT

D. MADHUSUDHANA REDDY Dr. Y. SREERAMULU

Submitted for university examination held at

Sources included in the report

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URL: FINAL DESSERTATION REPORT.docx

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URL: sai thesis.docx

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URL: PRINT THESIS PANKAJ FINAL.pdf

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URL: THESIS (Final).pdf

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URL: Ajay Yadav 0206CE15MT03.docx

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We are thankful to my guide D. MADHUSUDHANA REDDY, Assistant Professor in C.E.

We wish to express our sincere gratitude to Dr S. M. V. NARAYANA, Principal, Annamacharya Institute

S.NO TABLE NAME PAGE NO:

1. CHEMICAL ANALYSIS OF CEMENT 15

2. THERMAL POWER GENERATION, COAL

CONSUMPTION & ASH GENERATION IN INDIA 20

3. CHEMICAL ANALYSIS FOR FLY ASH 21

4. CHEMICAL ANALYSIS FOR STEEL SLAG 24

5. PROPERTIES OF PORTLAND CEMENT 30

6. SIEVE ANALYSIS OF FINE AGGREGATES 31-32

8. PERCENTAGE OF STRENGTH VS AGE IN DAYS 46

9. WEIGHTS FOR CONVENTIONAL CUBES 49

10. WEIGHTS FOR CEMENT REPLACED BY

11. WEIGHTS FOR F.A. REPLACED BY STEEL SLAG 50

12. WEIGHTS FOR C.A. REPLACED BY RECYCLED

13. WEIGHTS FOR COMBINATION REPLACEMENT

OF ALL THREE INGREDIENTS @20% 51

14. RESULTS FOR CONVENTIONAL CUBES 52

15. RESULTS FOR CEMENT REPLACED BY FLY ASH 53

16. RESULTS FOR F.A. REPLACED BY STEEL SLAG 55

17. RESULTS FOR C.A. REPLACED BY RECYCLED

18. RESULTS FOR COMBINATION REPLACEMENT

OF ALL THREE INGREDIENTS @20% 59

Construction industry uses approximately 20 billion tons of raw materials annually as

DEPT OF CIVIL ENGG, AITS RAJAMPET Page 1

Concrete recycling gains importance because it protects natural resources and

DEPT OF CIVIL ENGG, AITS RAJAMPET Page 3

Safety, quality Target Vector

FIG NO: 1 EVALUATION OF RECYCLING

• To compare the compressive strength of concrete to conventional concrete.

DEPT OF CIVIL ENGG, AITS RAJAMPET Page 4