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“Comparative evaluation of strength properties of Green Concrete and Conventional

Concrete”

CHAPTER 1

INTRODUCTION

1.1 General
Green concrete is a concrete, partially or completely substituted for cement or fine
aggregate or coarse aggregate. Alternative materials may be wastes of manufacturing
processes. Another name for Green Concrete is a resource-saving structure that reduces
environmental impact, carbon dioxide emissions, and waste water. "Green concrete" is a
revolutionary topic in the history of concrete industry. This was first invented in 1998 by
Dr.WG in Denmark.

Slag, fly ash, power plant waste, recycled concrete, mining waste, waste glass, incinerated
slag, red mud, burning soil, sawdust, burning ash and foundry sand can be properly used
in green concrete.

Green Concrete is a term given to a concrete that has had extra steps taken in the mix design
and placement to insure a sustainable structure and a long life cycle with a low maintenance
surface. e.g. Energy saving, CO2 emissions, waste water.The goal of the Centre for Green
Concrete is to reduce the environmental impact of concrete.

Advantages

• Reduce CO2 emissions in the concrete sector by 30%.

• 20% increase in the use of waste in the concrete industry.

• Use of Construction and Demolition wastes in the concrete industry.

• No environmental pollution and sustainable development.

• Green concrete requires less maintenance and repair.

• Good heat resistance and fire resistance.

• Good durability.

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Limitation

• Structures constructed with green concrete have less life than structures with conventional
concrete.

• The strength of green concrete is smaller than that of conventional concrete.

Globally, Concrete industry consumes large amount of natural resources which are
becoming insufficient to meet the demands. Also demolition waste and flyash which is a
byproduct of thermal power plant requires large area for disposal.

Green concrete is very often cheap to produce because waste materials are used as partial
substitute for cement and natural aggregates. Hence use of green concrete in concrete
industry is necessary to overcome disposal problem of wastes and cost.

Some previous studies showed that due to the use of recycled aggregates in the concrete
there is a reduction in compressive strength and split tensile strength. also water absorption,
sorptivity value and chloride ion penetration was increased compared to conventional
concrete.

Previous studies also showed that drawbacks of recycled aggregate concrete can be
improved by incorporating certain amount of flyash. It can be used as replacement for
cement or as an additional cementitious material in concrete. In the present study use of
flysh as partial cement replacement is presented. The effect of Recycled coarse aggregates
and flyash on strength and durability properties is investigated.

Three series of concrete mixtures were prepared with W/C ratio 0.4, 0.5 and 0.6In each
series recycled coarse aggregate was used as 50% replacement of natural coarse aggregates
and flyash was used as 30% replacement to cement.

1.2 Objective
The main objective of the project is comparative evaluation of strength properties of
conventional concrete and green concrete incorporating recycled coarse aggregates and fly
ash.

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1.3 Scope
➢ Selection of materials and material characterization.

➢ Concrete mix design, Casting and curing of test specimens.

➢ Study of hardened concrete properties like

 Compressive strength

 Split tensile strength test

➢ Green concrete is a revolutionary topic in the history of concrete industry. Concrete is an


environmental friendly material and the overall impact on the environment per ton of
concrete islimited. choose a material for green concrete. It presentsthe feasibility of the
usage of by product materials like fly ash and recycled concrete and masonry as aggregates
in concrete.
➢ The use of fly ash in concrete contributes the reduction of greenhouseemissions with
negative impacts on the economy.
➢ It has been observed that 0.9 tons of CO2 is produced per ton of cement production. Also,
the composition of cement is 10% by weight in a cubic yard of concrete.
➢ Thus, by the use ogreen concrete it is possible to reduce the CO2 emission in atmosphere
towards eco-friendly construction technique.
➢ To avoid the pollution and reuse the material, the present study is carried out.
➢ Thus, green concrete is an excellent substituent of cement as it is cheaper, because it uses
waste products.
➢ Saving energy consumption in the production. The concrete is made with concrete wastes
which are eco-friendly so called as Green concrete. Over and above all green concrete has
greater strength and durability than the normal concrete.

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CHAPTER 2

LITERATURE REVIEW

2.1 General
This section deals with literature review on the works carried out by earlier researchers on
strength and durability properties of green concrete. The literature review was conducted
to update the current state of knowledge on the properties of green concrete. These have
been arranged chronologically with reference to date of publication.

2.2 Literature review


Bairagi et al. (1990) studied the properties of recycled aggregates obtained by crushing
M15 grade natural aggregate concrete and concluded that the grading curve of the recycled
coarse aggregate as well as of the natural coarse aggregate do not differ appreciably except
that former type of aggregate possess lower specific gravity, higher water absorption
capacity and significantly low resistance to mechanical action such as impact and crushing

Sean Mulligan (2002) carried out Soundness test (Freeze/Thaw and Los Angeles abrasion)
on recycled concrete material and reported that with respect to the Soundness test by
Freeze/Thaw, recycled concrete material is not nearly as sound or durable as virgin
aggregates (limestone and gravel) for particle sizes greater than or equal to the #4 sieve
(4.75-mm sieve). It was also stated that with respect to the Soundness test by Los Angeles
abrasion, recycled concrete material is not as sound or durable as virgin aggregates
(limestone and gravel).

Price (2002) developed mix design specifications for low strength concretes containing
recycled and secondary aggregates to encourage the use of recycled and secondary
aggregates in low strength concrete applications in housing project. It was reported that
the.Recycled aggregate is limited to use in concrete with a maximum cube strength of 20

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N/mm2 and in only the mildest exposure conditions, whereas recycled concrete aggregate
can be used up to a characteristic cube strength of 50 N/mm2 and in a wider range of
exposure conditions.

Recycled concrete aggregate is not generally permitted in concrete exposed to sea water,
de-icing salts or severe freezing and thawing.Concrete containing recycled concrete
aggregate is also generally restricted to use in non-aggressive soils.

Amnon Katz (2003) investigated the properties of the recycled aggregates made from
crushed concrete and reported that the properties of the recycled aggregates crushed at
different ages were quite similar. It was also reported that the size distribution of the
recycled aggregates was same for the various ages of crushing, as well as other properties
such as water absorption, bulk specific gravity, bulk density, cement content and crushing
value. Microstructure of recycled aggregate prepared from the crushing of old concrete was
studied by Amnon Katz (2004) and it was found that:

• Recycled aggregate is covered with loose particles that may prevent good bonding
between the new cement matrix and the recycled aggregate.
• Old cement paste that remained on the natural aggregate was porous and cracked,
leading to weak mechanical properties of the recycled aggregate.

RafatSiddique (2003) carried out experimental investigation to evaluate the mechanical


properties of concrete mixtures in which fine aggregate (sand) was partially replaced with
Class F fly ash. Fine aggregate was replaced with five percentages (10, 20, 30, 40 and 50%)
of fly ash by weight and from the results, it was concluded that

• Compressive strength, split tensile strength, flexural strength and modulus


of elasticity of fine aggregate (sand) replaced fly ash concrete specimens were
higher than the plain concrete (control mix) specimens at all the ages. The strength
differential between the fly ash concrete specimens and plain concrete specimens
became more distinct after 28d.

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• Compressive strength, splitting tensile strength, flexural strength and modulus of


elasticity of fine aggregate (sand) replaced fly ash concrete continued to increase
with age for all fly ash percentages.32
• The maximum compressive, flexural and split tensile strength occurs with 50% fly
ash content at all ages.
• At all ages, the maximum value of modulus of elasticity occurs with 50% fly ash
content.

Bekir et al. (2004) studied the properties of waste concrete aggregates obtained by
crushing natural concrete specimens of having cylindrical compressive strength 14 MPa
and it was reported that:

• Specific gravity of waste concrete aggregates was lower than that of normal
crushed aggregates due to the fact that there was a certain proportion of mortar
over these aggregates.
• Water absorption ratio of waste concrete aggregate was found to be much higher
compared with that of normal crushed aggregates and this was due to adhered
mortar over these aggregates.

Marta et al. (2004) studied the effect of attached mortar content on the properties of
recycled concrete aggregate and it was summarized that:

• Quality of recycled concrete aggregate is lower than natural aggregate quality, due
to the mortar which remains attached to natural aggregate.
• Usual mortar content is about 23 to 44% for 8/16 mm fraction and 33 to 55% for
4/8 mm fraction. Generally, amount of mortar attached to fine fraction is higher
than to coarse fraction.
• The main properties unfavourably affected by mortar content are absorption,
density and Los Angeles abrasion.

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• Recycled concrete aggregates with mortar content less than 44%are expected to
have absorption lower than 8%. Recycled concrete aggregates with high mortar
content seem to have higher sulphate and alkalis content.
• Fine fraction of recycled concrete aggregate has poor quality due to it’s higher
mortar content and, it is not recommended to use fine recycled concrete aggregate
for the production of new concrete.
• Original concrete quality also have influence on recycled concrete aggregate
quality and generally, the lower the strength of the original concrete, the lower will
be the quality of the recycled concrete aggregate.
• A solution to control recycled concrete aggregate quality for production of
structural concrete could be to control original concrete, rejecting those concretes
with compressive strength lower than 25 N/mm2.
• Samples of coarse recycled concrete aggregate with high mortar content (more
than 44%) or samples with a low mortar quality should be rejected.

Tam C.M et al., (2005), proposed a new approach in concrete, namely, “two-stage mixing
approach (TSMA)”, intended to improve the compressive strength for recycled aggregate
concrete and hence lowered its strength variability. The study revealed that the quality of
aggregate is classified according to the absorption rates. The experiments showed that the
compressive strength of RAC was enhanced by two-stage mixing approach. When
examined under scanning electron microscopy (SEM) both the new interfacial zone and
old interfacial zone of recycled aggregate concrete were identified. This two stage mixing
approach gave way for the cement slurry to gel up the recycled aggregate by which a
stronger ITZ is provided and as a result cracks and pores within the recycled aggregates
were filled.

Evangelista et al., (2007), concerned the use of fine recycled concrete aggregates to
partially or globally replace natural fine aggregates in the production of structural concrete.
An experimental campaign was implemented in order to monitor the mechanical behavior
of such concrete. The investigation was conducted in which the recycled fine aggregates
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were obtained from laboratory grade concrete and superplasticizer were used had produced
results that contradict these initial perceptions. In some instances FRC show worse
mechanical performance than the reference concrete mixes (RC). However, in every
situation analyzed it was possible to produce FRC of good enough quality for structural
use.

Padmini A.K. et al., (2009), studied about the influence of parent concrete on the
properties of recycled aggregate concrete. Some of the salient observations of these studies
are the method of crushing of parent concrete, particle shape, water cement ratio those
which has significant effect on recycled aggregates. As per the results the water absorption
capacity of recycled aggregates increased with increase in strength of parent concrete from
which recycled aggregates was derived. The resistance against mechanical actions was
lower than fresh crushed granite aggregate. In order to achieve a design compressive
strength, recycled aggregate concrete requires lower water-cement ratio and higher cement
content with respect to fresh granite aggregate.

Marios N. Soutsos et al., (2011), undertaken a study at the University of Liverpool has
investigated the potential for using construction and demolition waste (C&DW) as
aggregate in the manufacture of a range of precast concrete products, i.e. building and
paving blocks and pavement flags. Phase II, which is reported here, investigated concrete
paving blocks. Electric hammer used previously for building blocks was not sufficient for
adequate compaction of paving blocks. Adequate compaction could only be achieved by
using the electric hammer while the specimens were on a vibrating table. The research
showed that selection of appropriate replacement levels of newly quarried with recycled
demolition aggregate can lead to paving blocks with similar mechanical properties without
the need to increase the cement content.

Dina M.Sadek et al., (2012), investigated the physical and mechanical properties of solid
cement bricks manufactured with crushed clay bricks as recycled aggregates. Furthermore,
concrete containing coarse crushed bricks had a relatively lower strength at early ages than

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normal aggregate concrete. Compressive strength, unit weight and water absorption of
solid cement bricks containing crushed brick aggregates were determined and compared
with the limits of the national and international standards for load bearing and non-load
bearing units. The results showed that crushed brick aggregates had lower specific gravity
than natural aggregates: water absorption of CBA was several times higher than that of
natural aggregates due to the porosity characteristics of the clay brick which may be 40%.
It was feasible to use crushed clay bricks in the manufacture of solid cement bricks which
satisfied the minimum requirements of the standards.

Valerie Spaeth et al., (2013), experimentally studied about the improvement of recycled
concrete aggregate properties by polymer treatments. The performance achieved was
characterized in order to show the relevance of such polymer treatment. The physical
properties of recycled aggregates were depended both on adhered mortar quality and the
amount of adhered mortar. Some investigation lead to the chemical treatment developed
which can improve the properties of RCA without removing the mortar based matrix.
Without further purification soluble sodium silicate was used as an industrial grade
product. These results showed that the positive effect was induced by polymer treatments
of water absorption capacity of RCA. The final results were very encouraging and
confirmed the interest of this kind of appropriate treatment.as a result, the polymer
treatments appeared to be an appropriate treatment .

Kazuhisa Yoda et al., (2014), applied a new technology on the use of recycled aggregate
for the upper ground structure elements. This paper presented two effective technologies
such as production of energy saving mid-quality recycled aggregate and high- quality
recycled fine aggregate. The fresh properties strength and length change behavior of the
recycled aggregate concrete were studied. The crack resistance with mock- up test was
evaluated. The surface of HMB mix looked slight white while those of the other mixes
showed no differences. Durability of the three type recycled aggregate concrete walls
constructed at the south side of the site has been continuously monitored. Strength of

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specimens subjected to various curing conditions for a long time showed equal or larger
strength than that with the standard curing of 28 days. The test wall surfaces were fair-
faced but no particular changes were observed at the ages of 3 months and one year
compared to the appearance immediately after the completion.

Neela Deshpande et al., (2014), emerged out as a promising technique for predicting
compressive strength of concrete. In the study back propagation were used to predict the
28 day compressive strength of recycled aggregate concrete (RAC) along with two other
data driven techniques namely Model Tree (MT) and Non-linear Regression (NLR).
Recycled aggregate was the current need of the hour owing to its environmental friendly
aspect of re-use of the construction waste. The study observed that, prediction of 28 day
compressive strength of RAC was done better by ANN than NLR and MT. The paper
presented the findings of a study carried out to predict the 28 day compressive strength of
concrete using the techniques Artificial Neural Network (ANN), Model Tree (MT) and
Non-linear Regression (NLR). Ten models were developed in the present study as
explained using ANN, MT and NLR technique for each model with dimensional and non-
dimensional parameters as inputs and 28 day compressive strength as output.

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2.3 Summary of literature review

➢ The Natural Resource decreases in a short period of time and therefore it is required
to reuse the waste products. Today there are number of old buildings and structures
have been demolished. The reuse of that demolished waste is a good solution to the
problem of disposal of debris.
➢ Utilization of industrial waste like flyash can be made to improve the various
properties of recycled aggregate concrete.
➢ The results from previous studies showed that mechanical properties like
compressive strength, tensile strength and modulus of elasticity of concrete at all
the ages reduced as the percentage of recycled aggregates and flyash increased.
➢ With the 40% use of recycled coarse aggregates in concrete, workable and good
strength concrete can be obtained.
➢ Durability properties of recycled aggregate concrete can be improved by
incorporation of flyash in concrete.
➢ The results from previous studies also showed that one of the helpful ways to use a
high percentage of recycled aggregate in structural concrete is by incorporating 25–
35% of fly ash as some of the disadvantages induced by the utilization of recycled
aggregates in concrete could be reduced.

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CHAPTER 3

EXPERIMENTAL STUDY

3.1 Materials

In this study materials used are cement, flyash, fine aggregates, recycled coarse aggregates,
natural coarse aggregates, potable water .

3.1.1Cement

In present studies, Ultratech cement of 53 grade confirming to grade IS 8112-1989 was


used and cement sample was tested as per IS-4031-1988 and IS 269-1976. Physical
properties like specific gravity, standard consistency, initial setting time and final setting
time of cement were determined by using the following codes

Standard consistency : (IS:4031-1988)

Initial setting time : (IS:4031-1988)

Final setting time : (IS:4031-1988)

Table 3.1 Test results of cement

specific gravity 2.9

Standard consistency (min) 29

Initial setting time (min) 90

Final setting time (min) 395

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Hydration of cement:

Cement when mixed with water forms hydrated compounds of very low solubility.
The reaction of cement with water is exothermic in nature. The reaction releases a lot of
heat which is called “Heat of hydration”

Cement storage:

Cement is hydroscopic in nature and therefore it can easily absorb moisture from
the air. Cement should therefore, be protected from dampness and high humidity as it can
rapidly lose its strength and get transformed into lumps, tendering it unsuitable for use.

Adulteration of cement:

Chances of adulterated cement being received at the site cannot be ruled out
completely. If there is any doubt, the cement manufacturer must be contacted.

It is difficult to test and determine the extent of adulteration of cement at site.


Assistance of a reputed laboratory can be sought it in doubt some simple test to determining
the adulterated.

• The suspected sample of cement should be burned for about 20 minutes on a


steel plate kept on a sore. The sample if adulterated will change in color, while
unadulterated will remains unchanged.

• Cement pat or ball can be prepared and observed after 24hrs. If the part or ball
can be easily broken by hand, then the cement is adulterated. However if
adulteration is in small quantum, it will not be indicated by these tests. Detailed
testing will be essential.

3.1.2 Flyash:

Fly ash is the byproduct of 0thermal plants and it is basically collected from of coal fired
thermal plant chimneys, using electrostatic precipitators or sometimes filters bags. They
mainly consists of (SiO2), (Al2O3) and (Fe2O3). Flyash contains 62% of silica, so it can be
used as a pozzolanic material in construction industry. It can be used as partial replacement

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to cement up to some extent. Flyash of Class F grade collected from Ahirwadi thermal power
Station(ATPS) was used in this study. From test Specific gravity of the flyash was found
to be 2.16.

Advantages Of Using Fly Ash in Concrete:

● Utilization of fly ash as a part replacement of cement or as a mineral admixture in concrete

saves on cement and hence the emission of CO2.

● Use of good quality fly ash in concrete has shown remarkable improvement in durability

of concrete, especially in aggressive environment.

● Some of the technical benefits of the use of fly ash in Green Concrete are:

a) Higher ultimate strength

b) Increased durability

c) Improved workability

d) Reduced bleeding

3.1.3 Fine aggregates:

In the present work natural sand is used as fine aggregate and test were conducted as per
IS:2386-1968,Part-III.

Table 3.2 Test results of Fine aggregates

Properties Results

Specific gravity 2.6

Fineness modulus 2.6

Bulk density 1570kg/m3

Gradation Zone II

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Table 3.3 Sieve analysis of Fine aggregates

mass Cumulative Zone II


IS sieve Percent Percent
retained on Percent (as per 383-
size retained (%) passing (%)
sieve (g) retained 1970)

4.75 mm 41 4.10 4.10 95.90 90-100

2.36 mm 31 3.10 7.20 92.80 75-100

1.18 mm 156 15.60 22.80 77.20 55-90

600 µm 318 31.80 54.60 45.40 35-59

300 µm 353 35.30 89.90 10.10 5.-20

150 µm 96 9.60 99.50 0.50 0-10

Pan 5 0.50 100.00 0.00

3.1.4 Natural Coarse aggregates

In the present work, crushed stone aggregates of size 20mm down were used. And as per
IS 2386-1988 part III guidelines physical Properties of natural aggregates were determined.

Specific Gravity : (IS 2386-1968 Part III)

Bulk density : (IS 2396-1968 Part III)

Table 3.4 Test results of Natural coarse aggregates

Properties Values

Specific gravity 2.7

Bulk density 1436kg/m3

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Grading Of Aggregates for Concrete:

• Aggregate comprises about 85 % volume of mass concrete.

• Concrete contains aggregate upto a maximum size of 150 mm.

• Way particles of aggregate fit together in the mix, as influenced by the gradation,
shape, and surface texture.

• Grading effects workability and finishing characteristic of fresh concrete,


consequently the properties of hardened concrete.

• Good grading implies, sample of aggregates containing all standard fractions of


aggregate in required proportion such that the sample contains minimum voids.

• Well graded aggregate containing minimum voids will require minimum paste to
fill up the voids in the aggregate.

• Minimum paste means less quantity of cement and less quantity of water, hence
increased economy, higher strength, lower-shrinkage and greater durability.

Table 3.5 Combined gradation of Natural coarse aggregate

percent percent 60 % of 20
IS sieve Passing 20 Passing mm and 40 Lower Upper Middle
size mm and 12.5 mm % of 12.5 limit limit limit
Down and Down down

20mm 90.58 100 94.348 95 100 97

12.5mm 2.61 88.17 36.834 25 55 40

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Figure3.1.Gradation Test of Coarse Aggregates

3.1.5 Recycled coarse aggregates

In the present work, crushed recycled concrete aggregates, collected from demolished
building, of size 20mm to 12.5mm were used. And as per IS 2386-1988 part III guidelines
physical Properties of natural aggregates were determined.

Specific Gravity : (IS 2386-1968 Part III)

Bulk density : (IS 2396-1968 Part III)

Table 3.6 Test results of recycled coarse aggregates

Properties Values

Specific gravity 2.2

Bulk density 1583kg/m3

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Figure 3.2.Collection of recycled coarse aggregate

3.2 Concrete mixtures


In the laboratory total of three series of concrete mixtures were prepared. Series I,II and III
were prepared with the water to cement (W/C) ratio of 0.3, 0.4 and 0.5 respectively. Each
Series, comprises of 2 concrete types named as conventional concrete mixture with 0%
RCA and 0% flyash indicated by notation R0 and green concrete mixture with 50% RCA
and flyash was incorporated as 30% replacement to cement indicated by notation R50F30.

As per IS 10262 1982 and IS 456 the mix design of concrete for all mix proportion is done.

Table 3.7 Mix Proportion of concrete corresponding to w/c of 0.3

Constituents(kg/m3)

Notatio RCA(% total


Flyash(%) wate Flyas
n ) cementitious Cement sand NCA RCA
r h
material

1058.8
R0 0 0 197 657 657 0 525.3 0
6

R50F30 30 50 197 657 459.9 197.1 525.3 529.43 529.43

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Table 3.8 Mix Proportion of concrete corresponding to w/c of 0.4

Constituents(kg/m3)

RCA(%
Notation Flyash(%) total
) Cemen Flyas
water cementitiou Sand NCA RCA
t h
s material

R0 0 0 197 493 493 0 604.76 1116.9 0

R50F30 30 50 197 493 345 148 604.76 558.45 558.45

Table 3.9 Mix Proportion of concrete corresponding to w/c of 0.5

Constituents(kg/m3)
Flyash RCA(%
Notation total
(%) ) Cemen Flyas
water cementitiou sand NCA RCA
t h
s material

R0 0 0 197 395 395 0 682.38 1134.54 0

R50F30 30 50 197 395 276 119 682.38 567.27 567.27

3.3 Mixing
A machine operated tilting drum type mixer of capacity 200 kg was used for concrete
mixing. Initially cement and flyash were thoroughly dry mixed in pan so that uniform mix
of cement and flyash is obtained. Calculated amount of fine and coarse aggregates were
added together in the mixer and then half of the water is added to mixer and allowed for
thorough mixing, the cement and flyash mixture was then added into the mixer. The

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concrete was mixed in the mixer with all ingredients. Mixer is allowed to blend thoroughly
by rotating the mixer drum for nearly five minutes.

Figure 3.3 :Concrete Mixing

3.4 Workability of concrete


Concrete workability can be defined as the ease with which concrete can be mixed,
handled, placed and compacted. Water content, mix proportion, percentage fineness, size
and shape of aggregates, surface texture of aggregates, grading of aggregates are the factors
affecting the workability of the concrete.

The common tests used to measure the workability are;

➢ Slump Cone Test.


➢ Compaction Factor Test.
➢ Vee-Bee Consistometer Test

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In this study slump cone test was employed for finding workability of concrete.

Advantages of Slump test:

➢ Simple test procedure.


➢ Easy to conduct in field.

The apparatus for slump cone test basically consists of a metallic mould which is in the
form of a frustum of cone having the bottom diameter as 20cm, Top diameter as 10cm
and height as 30cm.

Procedure of Slump Cone Test is as follows;

1. Initially internal surface of the mould is completely cleaned and oil is applied.
2. Then the mould is place on non absorbent smooth horizontal base plate.
3. The mould is then filled with the prepared concrete in four equal layers.
4. Each layer is tamped with 25 strokes with the help of rounded end tamping rod in
a systematic manner.
5. Then the surface is leveled with a trowel by removing excess concrete.
6. The mortar or water leaked out between mould and base plate is cleaned.
7. Mould is raised from the concrete immediately and slowly in vertical direction.
8. Slump is measured as the distance between initial surface level of concrete and final
surface level of concrete

3.5 Specimen casting :


For each concrete mixture,150 mm cubes, 150 mm X 300 mm cylinders were cast. 150 mm
cubes were used to determine the compressive strength, 150 mm X 300 mm cylinders were
used to evaluate the split tensile strength.

Casting is a manufacturing process in which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The
solidified part is also known as a casting, which is ejected or broken out of the mold to
complete the process. Casting materials are usually metals. Casting is most often used for

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making complex shapes that would be otherwise difficult or uneconomical to make by


other methods.

Figure 3.4: Specimen Casting.

3.6 Specimen Curing: Curing plays an important role on strength development


and durability of concrete. Curing takes place immediately after concrete placing and
finishing, and involve maintenance of desired moisture and temperature conditions, both
at depth and near the surface, for extended periods of time. Properly cured concrete has an
adequate amount of moisture for continued hydration and development of strength, volume
stability, resistance to freezing and thawing, and abrasion and scaling resistance.

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The length of adequate curing time is dependent on the following factors:

• Mixture proportions

• Specified strength

• Size and shape of concrete member

• Ambient weather conditions

• Future exposure conditions

There are three main functions of curing:


1) Maintaining mixing water in concrete during the early hardening process

Ponding and immersion:


Ponding is typically used to cure flat surfaces on smaller jobs. Care should be taken to
maintain curing water temperature at not more than 20 degrees Fahrenheit cooler than the
concrete to prevent cracking due to thermal stresses. Immersion is mainly used in the
laboratory for curing concrete test specimens.

Spraying and fogging


Spraying and fogging are used when the ambient temperatures are well above freezing
and the humidity is low. Fogging can minimize plastic shrinkage cracking until the
concrete attains final set..

2) Reducing the loss of mixing water from the surface of the concrete

Covering concrete with impervious paper or plastic sheets


Impervious paper and plastic sheets can be applied on thoroughly wetted concrete. The
concrete surface should be hard enough to prevent surface damage from placement
activities.

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3) Accelerating strength gain using heat and additional moisture

Live steam
Live steam at atmospheric pressure and high-pressure steam in autoclaves are the two
methods of steam curing. Steam temperature for live steam at atmospheric pressure should
be kept at about 140 degrees Fahrenheit or less until the desired concrete strength is
achieved.

Heating coil Heating coils are usually used as embedded elements near the surface of
concrete elements. Their purpose is to protect concrete from freezing during cold weather
concreting

Figure 3.5: Specimen Curing

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Table 3.10 Specimen details for conventional concrete [R0]

Geometry of W/C No. of Curing


Type of test
specimen ratio specimens time(days)

0.3 9 3,7,28
cube
1.Compression test 0.4 9 3,7,28
150x150x150 mm3
0.5 9 3,7,28

0.3 3 28
Cylinder
2.Split tensile strenght
d=150mm 0.4 3 28
test
h=300mm
0.5 3 28

Table 3.11 Specimen details for Green concrete [R50F30]

Geometry of W/C No. of Curing


Type of test
specimen ratio specimens time(days)

0.3 9 3,7,28
cube
1.Compression test 0.4 9 3,7,28
150x150x150 mm3
0.5 9 3,7,28

0.3 3 28
Cylinder
2.Split tensile strength
d=150mm 0.4 3 28
test
h=300mm
0.5 3 28

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3.7 Tests

3.7.1 Compressive strength

Compressive strength of the specimens was determined using a CTM machine with
2000kN capacity. The compression strength was measured at the ages of 3,7 and 28 days.

Procedure:

1. After completion of curing time,test specimens were taken out of curing tank and
allowed to dry.
2. Specimens were tested on CTM as shown in fig. to obtain the failure load of the
specimens. the rate loading was 1.2mm/min. The average value of 3 identical test
specimens compressive strength is noted as compressive strength of specimen.
3. The compressive strength was estimated as failure load divided by cross sectional
area of test specimen.
Compressive strength = (Failure load in N)/(Cross sectional area in mm2)

Figure 3.6: Test setup for compressive strength

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3.7.2 Split tensile strength

The split tensile strength of the test specimens was estimated using a CTM machine
with 2000kN capacity. At the age of 28 days split tensile strength of test specimens was
measured.

Split tensile strength was determined using cylinder of diameter 150mm and height
300mm.

The loading on the specimen was done as per IS 5816-1999

Split tensile strength was estimated by using the formula

F = (2P) / (πDL)

Where,

F = Split tensile strength (N/mm2)

P = Failure load in N

D = diameter of the test specimen in mm

L = length of the test specimen in mm

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Figure 3.7: Test setup for split tensile strength

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CHAPTER 4

RESULTS AND DISCUSSIONS

4.1 Workability of concrete


Workability was measured using slump cone test. Results show that conventional concrete
mixture with W/C of 0.5 had a relatively high slump of 150mm.Further concrete mix with
W/C ratio of 0.3 shows the lowest slump of 75mm. From the table 4.1 we can observe that
workability of all type of concrete mixtures increases as the w/c ratio increases from 0.3 to
0.5 Further, due to the presence of mortar on recycled aggregates water absorption of
recycled aggregates will be more. Table 4.1 shows that workability of green
concrete[R50F30] is less as compared to conventional concrete because recycled aggregate
absorb the water.

Table 4.1 Results of slump cone test

W/C ratio Concrete type Slump(mm)

Ro 90
0.3
R50F30 75

Ro 110
0.4
R50F30 92

Ro 150
0.5
R50F30 130

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4.2 Compressive strength


In the present study, 3 cubes for each mix proportion were tested and average of 3 cubes
was taken as compressive strength of concrete.

4.2.1 Compressive Strength of the concrete for w/c of 0.3

Table 4.2Results of compressive strength for W/C of 0.3

Compressive Strength(Mpa)
No. of
Concrete type
Specimens
3 days 7 days 28 days

Conventional concrete[R0] 9 25.38 42.43 62.2

Green concrete [R50F30] 9 23.7 39.2 55.4

Figure 4.1 Variation of compressive strength with age for W/C of 0.3

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4.2.2 Compressive Strength of the concrete for w/c of 0.4

Table 4.3 Results of compressive Strength for w/c of 0.4

Compressive Strength(Mpa)
No. of
Concrete type
Specimens
3 days 7 days 28 days

Conventional concrete[R0] 9 21.4 33.83 51

Green concret [R50F30] 9 20.2 29.7 45.3

Figure 4.2 Variation of compressive strength with age for W/C of 0.4

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4.2.3 Compressive Strength of the concrete for w/c of 0.5

Table 4.4 Results of compressive Strength for w/c of 0.5

Compressive Strength(Mpa)
No. of
Concrete type
Specimens
3 days 7 days 28 days

Conventional concrete[R0] 9 18 29.5 42.5

Green concret [R50F25] 9 17.1 27.2 37.5

Figure 4.2 Variation of compressive strength with age for W/C of 0.5

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4.2.4 Analysis of compressive strength

The compressive strength of the concrete mixture in series I -III are summarized in table
4.11 to 4.13. Results shows that due to the use of recycled coarse aggregates compressive
strength decreased. Use of 30% flyash does not improve the compressive strength of
concrete. Hence green concrete compressive strength is lower compared to conventional
concrete strength. Conventional concrete [R0] with 0.4 W/C ratio gives the maximum
compressive strength of 55.98 Mpa and recycled aggregate concrete with water to cement
ratio of 0.5 gives the minimum compressive strength of 36.97 Mpa. From the tables 4.11
to 4.13 it is observed that compressive strength of all type of concretes decreases as the
W/C ratio increases from 0.4 to 0.55. Further, due to the presence of recycled aggregates
in R50F25 concretes compressive strength is reduced compared to conventional concrete.

The study shows that Green concrete compressive strength is 10 to 12% lesser than
conventional concrete. And compressive strength of recycled aggregate concrete is 11 to
15% lesser than compressive strength of conventional concrete. Hence incorporation of
25% flyash does not made much difference in compression strength gain. However, the
reduction in compressive strength can be compensated by a decreasing the W/C ratio.

Figure 4.4 Three days compressive strength of concrete

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Fig 4.5 Seven days compressive strength of concrete

Figure 4.6 Twenty eight days compressive strength of concrete

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4.3 Split tensile strength:


Split tensile strength of concrete was tested on 150mm X 300mm cylinder at the age of 28
days.The split tensile strength of the concrete mixture in series I -III are summarized in
table 4.5. Study show that split tensile strength of all type of concrete decreases as the
water cement ratio increases from 0.3 to 0.5.Conventional concrete with W/C ratio of 0.3
gives maximum split tensile strength of 4.91MPa and recycled aggregate concrete [R50]
with W/C ratio of 0.5 gives the minimum split tensile strength of 2.56MPa. The split tensile
strength results can be divided into two groups. The first group includes mixture R50 and
the results shows that split tensile strength of concrete [R50] decreased by 20 to 25%
compared to conventional concrete [R0]. This is due to the presence of recycled aggregates
in the concrete

The second group includes the green concrete mixture and the results shows that split
tensile strength of Green concrete [R50F25] decreased by 18 to 20% compared to
conventional concrete [R0]. Hence the incorporation of flyash in green concrete [R50F25]
slightly increased the tensile strength of concrete compared to recycled aggregate concrete
[R50].

Table 4.5 Results of split tensile strength for W/C of 0.3

No. of Split tensile


Concrete type
Specimens strength (Mpa)

Conventional concrete[R0] 3 4.91

Green concrete [R50F230] 3 3.85

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Table 4.6 Results of split tensile strength for W/C of 0.4

No. of Split tensile


Concrete type
Specimens strength(Mpa)

Conventional concrete[R0] 3 3.75

Green concrete [R50F30] 3 3.1

Table 4.7Results of split tensile strength for W/C of 0.5

No. of Split tensile strength


Concrete type
Specimens (Mpa)

Conventional concrete[R0] 3 3.25

Green concrete [R50F30] 3 2.72

Figure 4.7 Twenty eight days split tensile strength

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CHAPTER 5

MIX DESIGN

5.1 CONCRETE MIX DESIGN:


CONCRETE MIX DESIGN:

“It can be defined as the process of selecting suitable ingredients of concrete and
determining and their relative proportions with the object of concrete certain and minimum
strength and durability as economically as possible.”

For proportioning in connection with concrete mix four factors are important.

• Water cement ratio

• Cement content

• Gradation of aggregates

• Consistency

Methods of proportioning mix design:

Following are the methods, which are used for proportioning.

• Arbitrary proportions method

• Maximum density method

• Surface area method

• ACI committee method

• High strength concrete mix design

• Method based on flexural strength

• Indian Standard method

• Trial method

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Objects of mix design:

• To achieve a specified compressive strength foe a specified grade.

• For ensuring required workability.

• For achieving durability.

• To economics concrete production.

• For increasing yield per bag of cement without comparing strength.

• To avoid honey combing and bleeding.

• To comply with various standards.

Concrete Mix Design Procedure as per is 10262 – 2009

Procedure for concrete mix design requires following step by step process:

1. Calculation of target strength of concrete

2. Selection of water-cement ratio

3. Determination of aggregate air content

4. Selection of water content for concrete

5. Selection of cement content for concrete

6. Calculation of aggregate ratio

7. Calculation of aggregate content for concrete

8. Trial mixes for testing concrete mix design strength

Step 1: Calculation of Target Strength of Concrete

Target strength is denoted by ft which is obtained by characteristic compressive strength of


concrete at 28 days (fck) and value of standard deviation (s)

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ft = fck + 1.65 s

Standard deviation can be taken from below table

Grade of concrete Standard deviation (N/mm2)

M10 3.5

M15 3.5

M20 4.0

M25 4.0

M30 5.0

M35 5.0

M40 5.0

M45 5.0

M50 5.0

Step 2: Selection of Water-Cement Ratio

Ratio of the weight of water to weight of cement in the concrete mix is water-cement ratio.
It is the important consideration in concrete mix design to make the concrete workable.
Water cement ratio is selected from the below curve for 28 days characteristic compressive
strength of concrete.

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Fig: Selection of Water-Cement Ratio for Concrete Mix Design

Similarly, we can determine the water-cement ration from the 7-day concrete strength, the curves
are divided on the basis of strength from water cement ratio is decided. Which is observed from the
below graph.

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Concrete”

Fig: Concrete Compressive Strength vs. Water Cement Ratio

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Step 3: Determination of Aggregate Air content

Air content in the concrete mix is determined by the nominal maximum size of aggregate
used. Below table will give the entrapped air content in percentage of volume of concrete.

Nominal maximum size of aggregate Air content (% of volume of concrete)

10mm 5%

20mm 2%

40mm 1%

Step 4: Selection of Water Content for Concrete

Select the water content which is useful to get required workability with the help of nominal
maximum size of aggregate as given in below table. The table given below is used when
only angular shaped aggregates are used in concrete as well as the slump should be 25 to
50mm.

Nominal maximum size of aggregate Maximum water content

10mm 208

20mm 186

40mm 165

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If the shape of aggregate or slump value is differing from above, then some adjustments
are required as follows.

Condition Adjustment

Sub angular aggregate Reduce the selected value by 10%

Gravel with crushed stone Reduce the selected value by 20kg

Rounded gravel Reduce the selected value by 25kg

Using plasticizer Decrease the selected value by 5-10%

Using superplasticizer Decrease the selected value by 20-30%

For every increment of 25mm slump Increase the selected value by 3%

Step 5: Selection of Cement Content for Concrete

Water – cement ratio is determined in step2 and quantity of water is determined in step -4.
So, we can easily calculate the quantity of cement from these two conditions. But, the value
obtained should satisfy the minimum conditions as given in the below table. The greater of
the two values is decided as quantity of cement content.

Cement Content for Plain Cement Concrete

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Cement Content for Reinforced Concrete

Step 6: Calculation of Aggregate Ratio

For the given nominal maximum size of aggregate, we can calculate the ratio of volumes
of coarse aggregate and volume of total aggregates for different zones of fine aggregates
from the below table.

Step 7: Calculation of Aggregate Content for Concrete

We already determine the coarse aggregate volume ratio in the total aggregate volume. So,
it is very easy that, 1 – volume of coarse aggregate will give the volume of fine aggregate.
Alternatively, there are some formulae to find the volume of fine and coarse aggregates as
follows.

Mass of fine aggregate is calculated from below formula

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Similarly, mass of coarse aggregate is calculated from below formula.

Where, V = volume of concrete

W = water content

C = cement content

Gc = sp. Gravity of cement

P = aggregate ration obtained in step6

F.A & C.A = masses of fine and coarse aggregates

Gf & Gca = sp. Gravities of fine and coarse aggregates.

Step 8: Trial Mixes for Testing Concrete Mix Design Strength

Based on the values obtained above, conduct a trail test by making at least 3 cubes of
150mm size as per above standards. Test that cubes and verify whether the required
strength is gained or not. If not, redesign the mix with proper adjustments until required
strength of cube occurs.

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APPENDIX –I

Mix design for 0.3w/c ratio:

Fromfigure-2 of IS 10262-1982,

For w/c ratio 0.4 referring the curve E [51.5-56.4N/mm2]

Target mean strength = 53 N/mm2

From IS 10262-2009

1. Selection of water content

From table 2, maximum water content for 20mm down size =186 liters

[For 25-50mm slump]

For 100 mm slump = 186+0.6x186

197.16 liters

2. Calculation of cement content

Cement content = 197.16/0.3

=657.2 Kg/m3

According to IS 456:2000 for 0.3 w/c ratio minimum cement =450 kg/m3 [Hence ok]

3. Proportions of Volume of Coarse Aggregate and Fine Aggregate

From table 3 for zone II

For 20mm aggregate =0.62 for w/c ratio 0.5

0.5=0.62

For the present case w/c ratio =0.3

Therefore increasing the coarse aggregate volume by 0.02

Volume of coarse aggregate for 0.3 w/c ratio= 0.66

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Volume of fine aggregate = 1-0.66 = 0.34

Mix Calculations:

a) volume of concrete = 1m3

b) Volume of cement = (mass of cement/ Specific gravity) x (1/1000)

= (657.2/3.15) x (1/1000)

0.2086 m3

c) Volume of water = 197.16/1000

= 0.19716 m3

d) Volume of all in aggregate = [a- (b+ c)]

= [1-(0.2086 + 0.19716)]

= 0.5942 m3

e) Mass of coarse aggregate = 0.5942 x0.66 x2.7 x 1000

= 1058.86 m3

f) Mass of fine aggregate = 0.5942 x 0.34 x 2.6 x 1000

= 525.27 m3

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APPENDIX –II

Mix design for 0.4w/c ratio:

Fromfigure-2 of IS 10262-1982 ,

For w/c ratio 0.4 referring the curve E [51.5-56.4N/mm2]

Target mean strength = 44 N/mm2

From IS 10262-2009

1. Selection of water content

From table 2, maximum water content for 20mm down size =186 liters

[for 25-50mm slump]

For 100 mm slump = 186+0.6x186=197.16 liters

2. Calculation of cement content

Cement content = 197.16/0.4=492.9 Kg/m3

According to IS 456:2000 for 0.4 w/c ratio minimum cement =360 kg/m3 [Hence ok]

3. Proportions of Volume of Coarse Aggregate and Fine Aggregate


From table 3 for zone II

For 20mm aggregate =0.62 for w/c ratio 0.5

0.5=0.62

For the present case w/c ratio =0.4

Therefore increasing the coarse aggregate volume by 0.02

Volume of coarse aggregate for 0.4 w/c ratio= 0.64

Volume of fine aggregate = 1-0.64= 0.36

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Mix Calculations:

a) Volume of concrete = 1m3

b) Volume of cement = (mass of cement/ Specific gravity) x (1/1000)

= (492.9/3.15) x (1/1000)

0.1564 m3

c) Volume of water = 197.16/1000

= 0.19716 m3

d) Volume of all in aggregate = [a- (b+ c)]

= [1-(0.1564+0.19716)]

= 0.6464 m3

e) Mass of coarse aggregate = 0.6464 x0.64x2.7x1000

= 1116.99 kg/m3

f) Mass of fine aggregate = 0.6464 x 0.36 x2.6x1000

= 604.76 kg/m3

APPENDIX –III

Mix design for 0.5 w/c ratio:


From figure-2 of IS 10262-1982,

For w/c ratio 0.4 referring the curve E [51.5-56.4N/mm2]

Target mean strength = 32 N/mm2

From IS 10262-2009

1. Selection of water content

From table 2, maximum water content for 20mm down size =186 liters

[For 25-50mm slump]

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For 100 mm slump = 186+0.6x186

197.16 liters

2. Calculation of cement content

Cement content = 197.16/0.5

=394.32 Kg/m3

According to IS 456:2000 minimum cement content=330 kg/m3 [Hence ok].

3. Proportions of Volume of Coarse Aggregate and Fine Aggregate

From table 3 for zone II

For 20mm aggregate =0.62 for w/c ratio 0.5

0.5=0.62

For the present case w/c ratio =0.5

Volume of coarse aggregate for 0.5 w/c ratio= 0.62

Volume of fine aggregate = 1-0.62

= 0.38

Mix Calculations:

a) volume of concrete = 1m3

b) Volume of cement = (mass of cement/ Specific gravity) x (1/1000)

= (394.32/3.15) x (1/1000) =0.1251 m3

c) Volume of water = 197.16/1000

= 0.19716 m3

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d) Volume of all in aggregate = [a- (b+ c)]

= [1-(0.1251 + 0.19716)]

= 0.6778 m3

e) Mass of coarse aggregate = 0.6778 x0.62 x2.7 x 1000

= 1134.54 m3

f) Mass of fine aggregate = 0.6778 x 0.38 x 2.6x 1000

= 682.375 m3

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CHAPTER 6

CONCLUSIONS

From the results of the experimental study, following conclusions can be made:

1. Results show that conventional concrete mixture with W/C of 0.5 had a relatively high
slump of 150mm. Further concrete mix R50F30 with W/C ratio of 0.3 shows the lowest
slump of 75mm. workability of the green concrete is less compared to the conventional
concrete.

2. The compressive strength and split tensile strength decreased for recycled aggregate
concrete. The study shows that Green concrete compressive strength is 10 to 12% lesser
than conventional concrete. And compressive strength of recycled aggregate concrete is 11
to 15% lesser than compressive strength of conventional concrete. On the other hand, the
decrease in compressive strength can be compensated by a decreasing the W/C ratio.

3. Results shows that Split tensile strength of Green concrete [R50F30] decreased by 18 to
20% compared to conventional concrete [R0].

4. Green concrete having reduced environmental impact with reduction of the concrete
industries co2 commissions by 30%. Green concrete is having good thermal and fire
resistant.

5. In this concrete recycling use of waste material such as aggregates, so increased concrete
industry use of waste products by 20%. Hence green concrete consumes less energy and
becomes economical.

6. So definitely use of concrete product like green concrete in future will not only reduce
the emission of co2 in environment and environmental impact but also economical to
produce. Green concrete having reduced environmental impact with reduction of the
concrete industries co2 commissions by 30%. Green concrete is having good thermal and
fire resistant.

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REFERENCES

[1] C. S. Poon, Z. H. Shui, L. Lam, H. Fok, S. C. Kou, “Influenceofmoisture states of natural

and recycled aggregates on the slump and compressive strength of concrete,” Cement and

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[2] M. Barra de Oliveira, E. Vazquez, “Theinfluence of retained moisture in aggregates from


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[3] L. Evangelista, J. de Brito, “Mechanical behavior of concrete made with fine recycled
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[5] Roumiana Zaharieva,François Buyle-Bodin, Frédéric Skoczylas, Eric Wirquin,


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[6]Shi Cong Kou, Chi Sun Poon, Dixon Chan[2007] “Influence of fly ash as a cement
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Concrete”

[7] M.L. Berndt[2009] “Properties of sustainable concrete containing fly ash, slag and
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[8] Mark Reiner, Stephan A.Durham and Kevin L.Rens[2010] “Development and analysis
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[9] Torben CH. “The second RILEM state of the art report on recycled aggregate and recycled
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[10] S.F.U.Ahmed[2013] “Properties of Concrete Containing Construction and Demolition


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[11] Prof. Chetna M Vyas, Prof.Darshana R Bhatt(2013) “Concept of Green Concrete


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[12] P.Saravanakuma and G.Dhinakaran[2014] “Strength Characteristics of High-Volume


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[13] A.Domingo-Cabo, C.Lázaro, F.López-Gayarre, M.A.Serrano-López, P.Serna, J.O. Castaño-


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[14] M. Etxeberria, E. Vázquez, A. Marí, M. Barra, “Influence of amount of recycled coarse


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[15] Jianzhuang Xiao, Jiabin Li, Ch.Zhang, “Mechanical properties of recycled aggregate
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[16]Roumiana Zaharieva, François Buyle-Bodin, Frédéric Skoczylas, Eric Wirquin,


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[17]Valeria Corinaldesi, “Mechanical and elastic behaviour of concretes made of recycled-


concrete coarse aggregates,” Construction and Building Materials, v24, 1616-1620, 2010.

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