GOVERNMENT POLYTECHNIC JALNA

A
PROJECT REPORT
ON

Partial Replacement
Of Cement in
Concrete with
Sugarcane Bagasse Ash

FOR THE COURSE

Construction Phase
Plan

Guided by: LaxmikantLohiya Sir

Submited By :-
1.Rohit Sanjay Kache(55)
2.Pawar RutujaRameshwar(49)
3.Patil Kundan Vijay(50)
4.Pembarti Shrishail Ajay(51)
5.Patil Sachin Anil(52)
6.Pembarti Vaishnavi Gopal(53)
7.Jafrabadkar PrabhaunshGajanan(54)
8.Taur Pranav Rajesh(56)
9.Thombal Hanuman Namdev(57)
 CONTENTS

ABSTRACT

INTRODUCTION

1. OVERVIEW

2. ORDINARY PORTLAND CEMENT

3. INTRODUCTION TO CEMENT CONCRETE

4. PROPERTIES OF CONCRETE

5. SCOPE OF WORK

6. SUGARCANE BAGASSE

7. HCLATTACK

LITERATURE REVIEW

EXPERIMENTAL INVESTIGATION

1. INTRODUCTION

2. MATERIALS USED

METHODOLOGY

1
ABSTRACT

2
 We are aware that a lot of damage is done to environment in the

manufacture of cement. It involves lot of carbon emission associated

with other chemicals. The researches has shown that every one ton of

cement manufacture releases half ton of carbon dioxide, so there is an

immediate need to control the usage of cement. On the hand materials

wastes such as Sugar Cane Bagasse Ash is difficult to dispose which

in return is environmental Hazard.

The Bagasse ash imparts high early strength to concrete and also

reduce the permeability of concrete. The Silica present in the Bagasse

ash reacts with components of cement during hydration and imparts

additional properties such as chloride resistance, corrosion resistance

etc. Therefore the use of Bagasse ash in concrete not only reduces the

environmental pollution but also enhances the properties of concrete

and also reduces the cost. It makes the concrete more durable

This project mainly deals with the replacement of cement with

Bagasse ash in fixed proportions and analysing the effect of HCl on

3
SCBA blended concrete. The concrete mix designed by varying the

proportions of Bagasse ash for 0%, 5%, 10%, 15%, 20%, 25% the

cubes are been casted and cured in normal water and 5% HCl solution

for ages of 7, 28 and 60 days. The test result indicate that the strength

of concrete increase up to 10% Sugar cane bagasse ash replacement

with cement.

4
INTRODUCTION

5
 OVERVIEW

Ordinary Portland cement is the most commonly used building

material throughout the world and it will retain its status in near

future also because of demand and expansion of construction industry

all over the world. Further the greatest challenge before the concrete

construction industry is to serve the two pressing needs of human

society, namely the protection of environment and meeting the

infrastructure requirements of our growing population Structures

which are constructed in aggressive environments are liable to be

subjected to acidic attack. One of such major problems is HCl attack

against concrete structures due to which there will be loss of weight

and reduction in strength of concrete ultimately sacrificing age of the

structure. Contaminated ground water, seawater, industrial effluents

are some of the sources of sulphate that attack concrete. The use of

blended cements have shown a sharp results in resisting the sulphate

attack on concrete, sugarcane bagasse ash which shows pozzolanic

properties is being used as a partial replacement in concrete in regular

6
intervals of 5% up to 25%. SCBA is being produced from sugar

manufacturing units as a waste material which will be grinded to the

fineness less than cement for obtaining good bonding between cement

and SCBA. This project discusses the very severe exposure of HCl on

concrete.

ORDINARY PORTLAND CEMENT (OPC):

Ordinary Portland cement is a controlled blend of calcium silicates,

aluminates and ferrate, which is ground to a fine powder with gypsum

and other materials. After 1987 OPC was divided into 3 types based

on the strength obtained at 28 days

1. OPC 33 grade:-strength not less than 33N/mm2 at 28 days

2. OPC 43 grade:-strength not less than 43N/mm2 at 28 days

3. OPC 53 grade:-strength not less than 53N/mm2 at 28 days

Portland cement gets its strength from chemical reactions

between the cement and water. The process is known as

hydration. This is a complex process that is best understood by

first understanding the chemical composition of cement.

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 CHEMICAL COMPOSITION OF CEMENT:
COMPOUND FORMULA MASS%
Calcium oxide CaO 61-67%
Silicon dioxide SiO2 19-23%
Aluminium oxide Al2O3 2.5-6%

Iron oxide Fe2O3 0-6%

Sulphate SO3 1.5-4.5%

Cement concrete is a mixture of aggregates and cement water

paste. The cement water paste has its role to bind the aggregates to

form a strong rock like mass after hardening has a consequence of the

chemical reaction between cement and water. Aggregates are

classified into fine aggregate and coarse aggregate. Fine aggregate

consist of sand whose particular size does not exceed 4.75mm coarse

aggregate consist of gravel, crush stone etc. of practical size more

than 4.75mm.

When the materials are mixed together so has to form a

workable concrete, it can be moulded into beams, slabs etc. A few

hours after mixing the material undergo a chemical combination and

8
have a consequence the mixture solidifies and hardness, attaining

greater strength with age. Concrete possess a high compressive

strength and has a poor tensile strength. It also develops shrinkage

stresses.

PROPERTIES OF CONCRETE:

A hardened concrete must possess the following properties:

1) Strength: Strength is defined as the resistance of the hardened

concrete to rupture under different loadings and is accordingly

designated in different - i.e., tensile strength, compressive strength,

flexural strength, etc. A good quality concrete in hardened - must

possess the desired crushing strength.

2) Durability: Durability is defined as the period of time up to

which concrete in hardened - withstands the weathering effects

satisfactorily. This property is mainly affected by water cement ratio.

A good quality concrete in hardened state must be durable.

9
3) Impermeability:The impermeability of hardened concrete may

be defined as the property to resist entry & water. This property is

achieved by using extra quantity of cement in concrete mix. A

concrete in hardened state must be impermeable.

4) Elasticity: Though hardened con- is a brittle material, it is

desired that it possess adequate elasticity.

5) Shrinkage: A hardened concrete should experience least

shrinkage. This property is guided by water cement ratio. Shrinkage is

less if w/c

ratio is less.

SUGARCANE BAGASSE ASH:-

Bagasse is a by-product from sugar industries which is burnt to

generate power required for different activities in the factory. The

burning of bagasse leaves bagasse ash as a waste, which has a

pozzolanic property that would potentially be used as a cement

10
replacement material. It has been known that the worldwide total

production of sugarcane is over 1500 million tons.

Sugarcane consists about 30% bagasse whereas the sugar recovered is

about 10%, and the bagasse leaves about 8% bagasse ash (this figure

depend on the quality and type of the boiler, modern boiler release

lower amount of bagasse ash) as a waste, this disposal of bagasse ash

will be of serious concern.

Sugarcane bagasse ash has recently been tested in some parts of the

world for its use as a cement replacement material. The bagasse ash

was found to improve some properties of the paste, mortar and

concrete including compressive strength and water tightness in certain

replacement percentages and fineness.

The higher silica content in the bagasse ash was suggested to

be the main cause for these improvements. Although the silicate

content may vary from ash to ash depending on the burning

conditions and other properties of the raw materials including the soil

on which the sugarcane is grown, it has been reported that the silicate

11
undergoes a pozzolanic reaction with the hydration products of the

cement and results in a reduction of the free lime in the concrete.

HCL ATTACK:

The chemicals formed as the products of reaction between

hydrochloric acid and hydrated cement phases are some soluble salts

and some insoluble salts.Soluble salts, mostly with calcium, are

subsequently leached out, whereas insoluble salts along with

amorphous hydrogels, remain in the corroded layer. Besides

dissolution, the interaction between hydrogels may also result in the

formation of some Fe-Si, Al-Si, Ca-Al-Si complexes which appear to

be stable in pH range above 3.5.

Ca(OH)2 + 2HCl  CaCl2 + 2H2O

The reaction essentially causes leaching of Ca(OH) 2 from the set

cement.

12
After leaching out of Ca(OH)2, C-S-H and ettringite start to

decompose, with release of Ca2+ to counteract the loss in Ca(OH)2 and

the set cement starts to disintegrate accelerating the dissolution.

Ca6Al2(SO4)3(OH)12.26H2O  3Ca2+ +2[Al(OH)4]- +4OH- +26H2O

3Ca2+ +2[Al (OH)4]- +4OH- +12HCL  3CaCl2 + 2ALCL3 + 12H2O

There are few indications through experiments about the formation of

Friedel’s salt, C3A.CaCl2.10H2O, by the action of CaCl2, formed due

to reaction of HCL with CH and C3A

Hydrochloric acid attack is a typical acidic corrosion which can be

characterized by the formation of layer structure.

By hydroxide mixture zone a layer is formed by undissolved salts

seen as a dark brown ring.

PHYSICAL Properties of Hydrochloric acid:

Properties of Hydrochloric Acid

Molecular formula HCl in water (H2O)
Molar mass 36.46 g/mol (HCl)

13
 Appearance Clear colourless to light-yellow liquid
Density 1.18g/cm3
Melting point 27.32 °C (247 K)
Boiling point 110 °C (383 K)
Solubility in water Miscible
Acidity (pKa) −8.0
Viscosity 1.9 mPa·s at 25 °C,

14
LITERATURE REVIEW

15
M.VijayaSekhar Reddy, I.V.Ramana Reddy, December2012 studied

the behaviour of High Performance Concrete (HPC) which is being

the most used type of concrete in the construction industry. They

replaced cement with Supplementary cementing materials (SCM) like

fly ash, silica fume and metakaolin. The mix design adopted was M 60,

cubes were casted and cured for 90 days in 5% HCl(PH=2), NaOH,

MgSo4 and Na2So4

They concluded that there was a considerable increase in

service life of the concrete structures and reduction in heat of

hydration by using the supplementary cementing materials in

concrete. They observed the maximum and minimum percentage of

reduction in strength of concrete when concrete was replaced with fly

ash were 12.64% and 1.92%.

Dr. P. Srinivasa Rao et al.,studied the durability characteristics of

metakaolin blended concrete by adopting M 20 grade of concrete. An

attempt was made with H2So4and HCl. Steel fibres with 60 as aspect

ratio at 0%, 0.5%, 1.0%, and 1.5% of volume of concrete are used.

16
 They concluded that the percentage weight loss was reduced

and compressive strength was increased in the case of fibre reinforced

concrete and concrete containing 10% metakaolin replaced by weight

of cement when compared to concrete and the percentage weight loss

was less when immersed in HCl and H2So4.

P. Murthi and V. Siva Kumar 2008studied the resistance of

acid attack of ternary blended concrete by immersing the cubes for 32

weeks in sulphuric acid and hydrochloric acid solutions. Binary

blended concrete was developed using 20% class F fly ash and

ternary blended concrete was developed using 20% fly ash and 8%

silica fume by weight of cement.

Sugarcane Bagasse ash can be used as a pozzolanic material in

concrete due to its high silica content.The results of this research

indicated (10% sugarcane bagasse ash) in blended concrete had

significantly higher compressive strength, as compare to 20%

sugarcane bagasse ash. Sugarcane bagasse ash is pozzolanic material

17
which may be utilized in the production of pozzolanic cement concrete

which leads to reduction in cost.

18
EXPERIMENTAL

INVESTIGATION

19
EXPERIMENTAL INVESTIGAITON

In the present experimental investigation sugar cane bagasse ash has been used as

partial replacement of cement in concrete mixes. On replacing cement with

different weight percentage of SCBA the compressive strength is studied at

different ages of concrete cured in different environments like normal water and

HCL diluted solution. The details of experimental investigations are as follows.

MATERIALS

CEMENT

Ordinary Portland cement of 53 grades from a single batch was used for the entire

work and care has been taken that it has to been stored in airtight containers to

prevent it from being affected by the atmospheric and monsoon moisture and

humidity. The cement procured was tested for physical requirements in accordance

with IS: 12269-1987 and for chemical requirements in accordance with IS: 4032-

1977.

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Properties of cement:
S. No Property Value
1. Normal consistency 33mm
2. Fineness of cement 7%
Setting times

3. Initial (Minutes) 85
Final (Minutes) 240
Compressive
Strength
4.
3 Days 28.68 Mpa
7 Days 40.34 Mpa
28 Days 54.62 Mpa

SUGARCANE BAGASSE ASH

Sugarcane bagasse consists of approximately 50% of cellulose, 25% of

hemicelluloses of ligin. Each ton of sugarcane generates approximately 26% of

bagasse (at a moisture content of 50%) and 0.62% of residual ash. The residue after

combustion presents a chemical composition dominates by silicon dioxide (sio2).

In spite of being a material of hard degradation and that presents few nutrients, the

ash is used on the farms as a fertilizer in the sugarcane harvests. In this sugarcane

bagasse ash was collected during the cleaning operation of a boiler in the sugar

factory, located in the town of Anakapalli, Andhra Pradesh.

21
Physical Properties of SCBA:
S. No. Property Value
1. Density 575Kg/m3
2. Specific Gravity 2.2
3. Mean particle size 0.1-0.2 µm
Min specific surface
area 2500m2/ kg
4.
5. Particle shape Spherical

Chemical Properties of SCBA:

S No Component Symbol Percentage

1. Silica SiO2 63
2. Alumina Al2O3 31.5
3. Ferric Oxide Fe2O3 1.79
4. Manganese Oxide MnO 0.004
5. Calcium Oxide CaO 0.48
6. Magnesium Oxide MgO 0.39
7. Loss on Ignition LOI 0.71

FINE AGGREGATE

The river sand, passing through 4.75 mm sieve and retained on 600 μm sieve,

conforming to Zone II as per IS 383-1970 was used as fine aggregate in the present

study. The sand is free from clay, silt and organic impurities. The aggregate was

22
tested for its physical requirements such as gradation, fineness modulus, specific

gravity and bulk modulus in accordance with IS: 2386-1963.

Properties of fine aggregate:

S.No. Property Value

1. Specific 2.60
Gravity
2. Bulk density 1.542
gm/cc

3. Fineness Modulus 2.74

4. Zone II

COARSE AGGREGATE

Throughout the investigations, crushed coarse aggregates of 20mm procured

from the local crushing plants were used. The aggregate was tested for its physical

requirements such as gradation, fineness modulus, specific gravity and bulk density

etc.in accordance with IS: 2386-1963 and IS: 383-1970.

23
Properties of coarse aggregate:

S. No. Property Value

Bulking Density ()

1. gm/cc 1.610

Specific Gravity (G)

2. (20mm) 2.74

3. Fineness Modulus 7.17

Aggregate impact
4. Value (%) 25.21

Aggregate crushing
5. Value (%) 25.22

WATER

Fresh portable water free from organic matter and oil is used in mixing the

concrete. Water in required quantities were measured by graduated jar and added to

the concrete. The rest of the material for preparation of the concrete mix was taken

by weigh batching. The pH value should not be less than 7.

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TESTING OF SPECIMENS

A time schedule for testing of specimens is maintained to ensure their proper

testing on the due date and time. The cast specimens are tested as per standard

procedures, immediately after they are removed from curing tubs and wiped off the

surface water, as per IS 516-1959.

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Hydraulic Compressive Testing Machine

DESCRIPTION OF COMPRESSION TESTING MACHINE

The compression testing machine used for testing the cube specimens is of

standard make. The capacity of the testing machine is 2000 KN. The machine has

a facility to control the rate of loading with a control valve .The plates are cleaned

and oil level is checked, and kept ready in all respects for testing.

26
After the required period of curing, the cube specimens are removed from the

curing tubs and cleaned to wipe off the surface water. It is placed on the machine

such that the load is applied centrally. The smooth surfaces of the specimen are

placed on the bearing surfaces. The top plate is bought in contact with the specimen

by rotating the handle. The oil pressure valve is closed and the machine is switched

on. A uniform rate of loading 140 kg/sq.cm/min is maintained.

TESTS CONDUCTED

WORKABILITY

The workability was measured using slump cone and compaction factor apparatus

for different percentage replacement of cement with sugarcane bagasse ash in

concrete.

COMPRESSIVE STRENGTH OF CONCRETE SPECIMENS

Concrete specimens are casted to determine the compressive strength of different

weight percentages of sugarcane bagasse ash concrete as per IS 5161969.

DURABILITY

The durability of sugarcane bagasse ash concrete was tested for resistance 10ml

HCL diluted solution. The response of chemical attack on different percentage

replacement of cement with sugarcane bagasse ash in concrete was studied by

reduction in compressive strength. For conducting these tests, concrete cubes of

27
100mm x 100mm x 100mm size with ordinary and different percentage

replacement of cement with sugarcane bagasse ash were cast. These cubes were

immersed in a HCL solution by maintaining 4 to 4.5 ph values for different periods

of 7, 28 and 60days.

Durability studies on Cement Conventional Concrete & Sugar Cane Bagasse

Ash Concrete

Concrete is the most versatile material of construction the world over. It is achieved

that the distinction of being the “largest man-made material” with the average per

capita consumption exceeding 2 kg. Concrete is the material of choice for a variety

of applications such as housing, bridges, highway pavements, industrial structures,

water carrying and retaining structures etc. The credit for this achievement goes to

well-known advantages of concrete such as easy availability of ingredients,

adequate engineering properties for a variety of structural applications, adaptability,

versatility, relative low-cost etc. Moreover, concrete has an excellent ecological

profile compared with other materials of construction. With the continuing

expansion of infrastructure and housing construction, especially in the developing

countries of Asia, Africa, and South America, the rate of consumption of cement

and concrete is rising and is bound to go further. In India, concrete construction

scenario has been witnessing considerable growth in recent years.

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METHODOLOGY

29
Standard sieves

A) Sieve Analysis

Table I : Sieve analysis of Coarse Aggregate

S .No. I.S. Sieve Weight Percentage weight Cumulative Percentage
No. retained
Retained (gms) Percentage Passing
Retained

1. 40mm 0 0 0 100
2. 20mm 877 17.54 17.54 82.46
3. 10mm 4085 81.70 99.24 0.76
4. 4.75mm 38 0.76 100.00 0
5. 2.36mm 0 0 100.00 0
6. 1.18mm 0 0 100.00 0
7. 600µ 0 0 100.00 0
8. 300µ 0 0 100.00 0
9. 150µ 0 0 100.00 0
Total : 716.78

Fineness modulus = 716.78 / 100 = 7.17

Table II : Sieve Analysis of Fine Aggregate

30
S. No. I.S. Sieve No. Weight retained Percentage Cumulative Percentage
weight percentage passing
(gm) retained retained

1. 40mm 0 0 0 100
2. 20mm 0 0 0 100
3. 10mm 0 0 0 100
4. 4.75mm 21 2.10 2.10 97.90
5. 2.36mm 65 6.50 8.60 91.40
6. 1.18mm 180 18.00 26.06 73.94
7. 600µ 278 27.80 54.04 45.96
8. 300µ 280 28.00 82.04 17.96
9. 150µ 176 17.06 100.00 0
Total : 274.00

Fineness modulus of sand = 274.1 /100 = 2.74

Confirming to zone II (I.S.: 383-1970)

Table III : Physical Properties of Fine and Coarse Aggregate

31
 S. No. Properties Test results

Fine Aggregate Coarse Aggregate

1. Specific gravity 2.60 2.74

2. Bulk Density (Kg/m3)

a) loose 1600 kg/m3 1400 Kg/m3

b) compacted
1750 kg/m3 1580 Kg/m3
3. Fineness Modulus 2.74 7.17

0% 5% 10% 15% 20%

Slump 10mm 13mm 16mm 20mm 25mm
Table IV- Workability of concrete

From the test conducted are Sieve analysis on coarse aggregate and fine aggregate,

the fineness modulus is 7.17 (from Table-10) for coarse aggregate. This should be

between 6.5 to 8, and as Zone-II sand is used, the fineness modulus of fine

aggregate is 2.54(Table-11), this should be in a range of 2.2 to 2.6 as per IS383.

And we observed a varying slump value as the Persentageof Sugarcane bagasse ash

increases. There is increase in slump value as percentage of Sugarcane bagasse ash

increases, Table-13 shows you the increase in slump value as sugarcane bagasse

ash increases (i.e 0%-10mm, 5%- 13mm etc.).

DESIGN OF MIX CONCRETE(M35)

Aggregate size : 20mm

Minimum cement content: 320 kg/m3(from table 5 IS 456)

32
w/c ratio: 0.4

workability: 75mm (slump)

Exposure: Severe

1) Target Mean Strength of concrete

From IS: 10262-2009, the target mean strength for the specified

characteristic cube strength is

= ƒck + 1.65 s

Then = 35 + (5 1.65) = 43.25 N/mm2

('s' is standard deviation N/mm2 s =5, from table 1 IS 10262:2009)

2) Selection of Water-Cement Ratio

The free Water Cement ratio required for the target mean strength of 43.25 N/mm 2

is W/C =0.40.

5) Selection of water content:

for 20mm aggregate = 186 litres (25 to 50mm slump) for 75mm slump = 186 +

3/100 * 186(for every 25mm increase in slump 3% water should be increased)

33
191.58ltrs (from table 2 IS 10262:2009) 4)

GRAPHS:
45

40

35
Comp.Strength, N/mm2

30

25

20 M35(WATER)
M35(HCL)
15

10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 1: Compression test results for 7 days in normal water & HCL Solution

34
 60

Comp.Strength, N/mm2
50

40

30
M35(WATER)
20 M35(HCL)

10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 2: Compression test results for 28 days in normal water &Hcl Solution

60

50
Comp.Strength, N/mm2

40

30
M35(WATER)
20 M35(HCL)

10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 3: Compression test results for 60 days in normal water &Hcl Solution

35
 60

50

Comp.Strength N/mm2
40

30 7 days
28 days
20
60 days
10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 4: Compression test results for 7, 28 & 60 days in normal water

60

50
Comp.Strength N/mm2

40

30 7 days
28 days
20
60 days
10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 5: Compression test results for 7, 28 & 60 days in HCl Solution

36
As the percentage of sugarcane bagasse ash increases the compressive strength of

concrete tends to increase up to certain percentage and then start’s decreasing with

the increase of ash content.

The strength of 10% sugarcane bagasse ash concrete is more than 5% sugar cane

bagasse ash concrete and strength of 5% sugar cane bagasse ash concrete is more

than normal concrete. This shows that till 10% sugarcane bagasse ash concrete the

strength increases while percentage of sugarcane bagasse ash increases.

The strength of cubes having 10% sugar cane bagasse ash is almost equal to 15%

sugar cane bagasse ash concrete.

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