A ROBUST COMPOSITION OF POLYMERS AND FLY

ASH IN CONCRETE AGAINST CORROSION

ABSTRACT:-
A new polymer concrete with the compound poly-buta-di-ene binder
(Rub Con) was investigated for its chemical resistance. Few problems which are
important for corrosion attack are discussed which are based on a set of experiments.
Mechanism of relationship between the organic & inorganic aggressive medium and
Rub Con is analysed. The elevated temperature and corrosive environment
exposition’s influence is also revealed. Application of special activating agents like
Altax, sulfur + tiuram- D, TiO2, BaSO4 has a positive effect on the chemical resistance
of the Rub Con. When the chemical resistance of Rub Con and ordinary Portland
cement concrete is compared, the chemical resistance of the Rub Con is found very
high and it even surpasses the chemical resistance of the polyester, poly-e-poxy and
vinyl ester polymer concrete.
 CHAPTER 1

INTRODUCTION
1.1. General
In today's world, a lot of steel is used to strengthen the concrete structures in
the form of inserted rods hence the life of those embedded rods bear a persistent
problem of corrosion and therefore is a cause of concern for scientists and engineers.
Corrosion of reinforcing bars embedded in concrete is the most common cause of
deterioration of concrete structures in aggressive environments (Jones A.E.K., 1997).
Corrosion of steel reinforcement results in cracking and eventual spalling of concrete.
In general, good quality concrete provides excellent protection for steel
reinforcement. Due to the high alkalinity of concrete pore fluid, steel in concrete
initially and, in most cases, for sustained long periods of time, remains in a passive
state. Initiation of corrosion occurs either due to reduction in alkalinity arising from
carbonation or the breakdown of the passive layer by the attack of chloride ions. The
time to initiation of corrosion is determined largely by the thickness and the quality of
concrete cover as well as the permeability of concrete. High quality and durable
concrete is required to reduce the rapid deterioration of concrete under severe
environmental conditions. In this context, the beneficial effects of alternative
cementing materials should be considered. When alternative cementitious materials
such as fly ash is used in concrete, not only reduced the porosity but also the pores
become finer and the change in mineralogy of the cement hydrates leads to a
reduction in the mobility of chloride ions(S. Li & Roy, 1986). If the steel which is
present in concrete corrodes an expansive force is generated due to increase in the
volume of steel which can rupture the concrete. If a crack is being formed due to this
expansive force in the structure then the rate of corrosion of steel starts even more
rapidly leading to the complete failure of the structural member involved. Therefore
worldwide, the chief concern is the early deterioration of reinforced concrete
structures which is induced due to corrosion of the embedded steel. The prevention of
the steel corrosion can be done by providing a waterproof coating which prevents the
entry of salt, water and air.
Developments in civil engineering and industrial growth have created a continual
demand for building materials with new and improved performance attributes.

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Polymer concretes (PC) appear to offer possibilities for meeting these new
requirements. By polymer concrete is meant a polymer composite with a polymer
matrix and sand and rocks, like those used in Portland cement concrete, as inclusions.
Service conditions often dictate specific material requirements that may be met by PC
when several composite properties are considered simultaneously. Advancements in
PC materials have slowed over the past 25 years as compared to the rate of
advancements in the 1970s and 1980s. The knowledge base in concrete polymer
materials has matured as many products have been made commercially available.
There are now many polymer-based construction materials that have been shown to
perform very well for their intended purposes: concrete spall repair, crack repair,
concrete overlays, and precast concrete components. The cost of polymer-based
systems is high relative to conventional Portland cement concrete materials, and it is
necessary to demonstrate the improved durability, reduced thickness/size, ability to be
placed in difficult environmental conditions, and/or the fact that other non-polymer
materials will not work. There are many situations for which concrete polymer
materials prove to be the most appropriate materials for the intended application.
Understanding of the nature of PC is necessary for the design of the most cost-
effective PC composites and to produce materials with desired properties. Polymer
concrete is usually used in severe conditions in industrial and public buildings as well
as in transportation and hydraulic structures. The main uses are repairing
strengthening, and corrosion protection of concrete structures. The main advantages
of polymer concrete over ordinary concrete are improved mechanical strength, low
permeability, and improved chemical resistance. The main limitation is their relatively
high material cost. This is why it is important to find the optimum technical/economic
compromise. To solve this problem, it is necessary to formulate a reliable predictive
mathematical model of polymer concrete material properties. One of the new kinds of
the structural polymer building materials created recently is rubber concrete based on
polybutadiene binder (is short for RubCon). The idea of using liquid rubber as the
binder for polymer concrete was the first time put forward by Prof. O. Figovsky [1].
RubCon is noted for its effective operational characteristics: the highest chemical
resistance and some physical-mechanical properties, adaptability to manufacture,
small shrinkage etc. [2]. Application of RubCon in practice of construction allows
solving a problem of corrosion, negative influence of temperature, degradation of a

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material at raised UV - exposure, radiation and other adverse natural and technogenic
factors, to increase the between-repairs period, reliability and durability of buildings
and structures, especially at the action of aggressive environments. It is necessary to
note, that RubCon is cheaper in comparison with other corrosion resistant polymer
composites. The complex of physical-mechanical, heat-physical and technological
properties of RubCon, its behavior in conditions of influence of a broad aggressive
environment spectrum, problems of durability and reliability are studied, pilot test of
RubCon as new structural building material at the enterprises of various industries is
made [2,4-9].
The development of manufacture of diene oligomers belonging to a liquid
rubber class with viscous liquids consistence allowed creating a new class of
conglomerate polymer composite materials- rubber concrete (RubCon). Rubber
concrete is the advanced constructional material created for last years. It is polymer
concrete with a unique set of physical-mechanical, chemical and technological
properties which allow to obtain highly effective building structures and products on
its basis [2]. RubCon contains no cement as a binder; its matrix is polybutadiene — a
polymer from the liquid rubber family so that RubCon has elastic properties and it is
extremely resistant to aggressive chemicals, highly repellant to water and has the
highest compression strength. RubCon does not exhibit the common failure
mechanisms of conventional concrete, such as cracking and flaking, freeze and thaw,
and it resists vibrations, making it an ideal pad material for pumps and compressors.
Furthermore, it coats reinforcing bars making the bars impenetrable to water, hence
arresting corrosion. The strength and durability of concrete depends upon the
variation of particles and the binder used with its fabrication. RubCon is applied in the
same manner as conventional concrete, formulated first from a component mixture
into a liquid and then cured for 12 - 48 hours for hardening. The initial binder
components are formulated off-site into a mixture. The component mixture consists of
a single component package for hot curing (150º to 180º C) with a shelf life of three
months (in a closed container), and a two component package for cold (20º to 25º C)
and semi-hot (70º to 100º) curing with a shelf-life of six months. For the preparation
of RubCon mix fine (quartz and stream sends, fly ash) and coarse (different kinds of
chipping and gravel) aggregate were used (Fig. 1). The components of the mix can be
easily formulated onsite in a nontoxic and completely safe manner. It will be noted

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that RubCon binder is easily applied and will adhere to metal or glass reinforcements.
After two days, RubCon binder may be walked upon and after seven days, it is ready
for work loads. With the use of special adhesives it can be applied over existing
concrete flooring.

Fig. (1). View of cross section area of a RubCon sample.

RubCon’s mechanical properties follow (Table 1). Corrosive attack of aggressive
medium on composite polymeric materials is manifested as change of its structure and
properties without disruption of integrity or with destruction of the materials. The
corrosion environment penetrates between macromolecules through micro pores and
fine capillaries and irreversibly changes a chemical structure of composite and
reinforcing bars or fibers as well. Such changes of RubCon structure are characterized
by formation of new active groups in molecular chains (carboxyl, hydroxyl, amine,
and ketone) and presence of double links resulting in a lowering of physical-
mechanical properties of the material. Water and water solutions of electrolytes
adversely affects on composite materials, causing their destruction, cracking etc. [3].
As a rule the most widespread liquid excited environments are water solutions of
acids, alkalis and salts. Chemical resistance of RubCon was specified from change of
weight and compressive strength of the samples after its exposure in liquid aggressive
environments during certain period of time. The choice of aggressive environment
compositions was based on their prevalence in industrial production.

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 CHAPTER 2

LITERATURE REVIEW

Naik et al, (1994) evaluated the effect of adding of a class C fly ash on the
permeability of concrete by replacing cement with fly ash in the range of 0-70% by
weight in the concrete composites. For the test results of air permeability, they have
concluded that at lower ages up to 28 days, the concrete having high volume of fly
ash showed higher levels of ingress of air relative to the normal Portland cement
concrete. On water permeability test results, they have reported that concrete water
permeability decreased with age. All three of the concrete mixes indicated fair
resistance to water permeability up to the ages of 14-40 days. At 91-day age, the high
volume (50%) fly ash concrete showed lower water penetrability to that of normal
Portland cement concrete. They observed that chloride penetrability reduced with age.
The 50% fly ash concrete showed the lowest permeability to chloride ions amongst all
the mixture tested. The concrete composites with 50 and 70% replacements of cement
with fly ash were better compared to the no fly ash concrete at 91 days with respect to
w.r.t chloride-ion permeability.

V. Saraswathy et al, (2002) studied numerous activation methods to improve the

resistance to corrosion and also strength of concrete by speeding up the hydration of
fly ash blended cement. The compressive strength of the concrete specimens after 7,
14, 28 and 90 days were evaluated which were prepared by replacement levels 10%,
20%, 30% and 40% of the activated fly ash and after that the results were compared
with ordinary Portland cement concrete (without fly ash). The activated fly ash
cement showed better resistance to corrosion and strength of concrete when the
replacement levels were 20–30% of activated fly ash cement. The better results were
obtained when the fly ash was chemically activated as compared to the other
activation investigated.

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Ha et al, (2005) investigated the influence of fly ash on the rusting performance of
steel in concrete and mortar by some accelerated short-term techniques in NaCl
solutions. The various techniques adopted for determination of durability
enhancements were weight loss method, OCP (Open Circuit Potential) measurements,
impressed voltage and anodic polarization technique. Apart from this macro cell
corrosion studies, pH measurements and approximation of free chloride content were
also performed. The replacement of fly ash up to 30% level helped in improving
corrosion resistance properties of the steel in concrete, improved the permeability
characteristics, delayed initiation time of corrosion and decreased the rate of
corrosion.

H.A.F. Dehwah, (2012) evaluated the corrosion resistance of SCC (Self-Compacting

Concrete) which was prepared using QDP (quarry dust powder), SF (silica fume) plus
quarry dust powder or fly ash . SCC specimens were prepared and tested for corrosion
resistance, chloride penetrability and diffusion. The permeability was moderate for
chloride in SCC specimens including QDP or fly ash and the permeability was low in
the specimens including QDP plus SF.

M. Criado et al, (2012) examined the inhibitive consequence of two mixes of organic
composites, disodium β-glycerol phosphate or GPH with sodium 3-aminobenzoate
(3AMB) and glycerol phosphate with sodium N-phenylanthranilate (PhAMB), on the
rusting of carbon steel reinforced bars implanted in carbonated chloride-polluted OPC
and alkali-activated FA (fly ash) mortars. At room temperature and at 65% relative
humidity, the carbonation in the mortar was achieved by keeping them in the CO2
maintained chamber for 60 days. The mixture of PhAMB with GPH exhibited the
utmost protective properties.

M. Kishore Kumar et al, (2012) studied the reinforced concrete durability w.r.t
rusting of reinforcement. The initiation time and the time for cracking are determined
by change in the slope of the specimens for different grades of concrete. For 30%
replacement of cement with fly ash the initiation time of M25 grade was around 54
days as compared to other % of replacements. For 30% replacement of cement with
fly ash the initiation time of M30 grade was around 63 days as compared to other %
of replacements. For 30% replacement of cement with fly ash the initiation time was
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maximum in both grades of the concrete. For 30% replacement of cement with fly ash
the compressive strength of the concrete specimens is higher in both grades of the
concrete at 90 days of curing.

Rob B. Polder, (2012) reviewed the long lasting performance when the concrete was
made with blast furnace slag and also fly ash linked to chloride induced reinforced
steel corrosion. The penetration of chloride was deeper and faster in case of Portland
cement concrete. According to the analysis of chloride profile for slag and Portland
cement, the chloride surface fillings was similar, whereas the dispersal coefficient was
consistently lower for slag cement in comparison to Portland cement. Compound
cements with fly ash and slag at about 25% clinker replacement each behave
similarly. Critical (corrosion initiating) chloride contents appear comparable for all
cement types mentioned both fly ash and slag concrete show improved behavior
compared to the Ordinary Portland cement in aggressive environments, in particular
where penetration of chloride presents the risk of reinforcement corrosion.
Replacement of clinker with slag at high-level (50 – 70%) and fly ash at intermediary
level (20 – 30%) produces high chloride penetration resistance and high electrical
resistivity, overall decreasing the risk of rusting in chloride corrupted environments.

Ana María Aguirre-Guerrero et al., (2016) tested the performance of 2 hybrid kind
geopolymer mortars made of alkaline-activated FA and MK (Metakaolin) as
defensive coatings against the chloride-induced rusting in reinforced cement concrete.
In both cases, the coated, Portland cement (OPC)-based concretes (substrates) were
subjected to accelerated techniques such as impressed voltage and wetting/drying
cycles in the company of 3.5% NaCl solution.

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 CHAPTER 3

EXPERIMENTAL WORK
3.1. Introduction
This chapter plots the experiment program, anticipated for present examination. The
goal of the present examination has been sketched out in Chapter1. To accomplish the targets,
a trial program was wanted to examine mechanical and durability properties of concrete.

Coefficient of Chemical Resistance of RubCon

A basic guideline in a choice of corrosion environments
during the test of RubCon specimens was their wide spreading into industrial
production. Such environments where: water, 30% and 70% solutions of sulfuric acid,
5% solutions of phosphoric and acetic acids, 3% solution of nitric acid, 3% and 30%
solutions of hydrochloric acid, 10% solutions of lactic and lemon acids, caustic soda
and caustic potash, diesel fuel, acetone, 25 % water solution of ammonia, 30%
solution of copper vitriol, and saturated solution of sodium chloride. Chemical
resistance of RubCon was estimated on test specimens in the size 4x4x16 cm [4, 5].
The following values were determined in the course of experiments before and after
attack by water and corrosive media during one year of exposure at room temperature:

• 􀀂m - change of test specimen mass,

• Rc -compressive strength,
• E--modulus elasticity,
• K􀀃r- coefficient of chemical resistance,
• KE -coefficient of change of modulus elasticity,
• x -depth of penetration of corrosive liquid (was obtained by microscope-assisted
measuring of the visible front of diffusion liquid movement).
It is obvious that the durability of a structural material depends on its resistance in
corrosion environment. Indexes of this resistance are:
Coefficient of chemical resistance
K􀀂r = Rc1/Rc0, (1)
Coefficient of change of modulus elasticity
KE = E1/E 0. (2)

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Change of test specimen mass
􀀂m = (m1 –m0)*100/m0 (3)
Here Rc0, E0, m0, Rc1, E1, m1 - compressive strength, modulus elasticity and mass
of specimen correspondingly before and after corrosive media attack during one year
of exposure.

THE MECHANISM OF CORROSIVE ENVIRONMENT INFLUENCE ON

CONCRETE WITH POLYBUTADIENE MATRIX
Physical-chemical impact of a corrosive environment on a
polymer composite material is manifested in change of its structure, sometimes
resulting to destruction. Fig. (2) show that the most intensive decrease of RubCon
strength occurs during the first 6 months of the corrosion environments exposition.
Penetration of corrosive environment between macromolecules of a material through
its micro pores and fine capillaries produces reduction of a surface energy on the
"body-environment" boundaries. It leads to formation and development of cracks in a
composite, lowering of its strength, elevation of polymeric chains flexibility and
plasticization of a material. Destruction of polybutadiene occurs under the action of
nitric acid is caused by oxidation of a polymer macromolecule. In other words cross-
section links of a spatial composite network formed by vulcanization process are
broken. A well-known oxidization ability of sulfuric acid is responsible for decrease
of double links in rubber molecular structure resulting in a lowers of the RubCon
strength indexes. Corrosive attack of hydrochloric acid is linked to oxidation and
isomerization processes and therefore durability of composite depends on speed of
these processes course.
Corrosive attack of organic carboxylic acids on polybutadiene binder is
exhibited by oxidization and depolymerization processes, resulting the formation of
carboxyl groups COOH. Carboxylic acids are generally weaker than inorganic
because speed of these processes is below and therefore decrease of physical-
mechanical properties of RubCon occurs more slowly. The most intensive lowering of
RubCon strength properties (compressive strength and modulus of elasticity) at
influence of carboxylic acids attack were noted in the first 90 days. Penetration depths
of corrosive medium into body of test specimens after one year exposition are 1, 3,
1.6, and 0.9 mm for acetic, lactic an lemon acids correspondingly.

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Temperature Influence on Chemical Resistance of RubCon
In earlier investigation of RubCon, we have studied its
behavior at the elevated and negative temperatures in conditions of the no aggressive
environment operation [7]. Continuation of these researches became the examination
of RubCon resistance in liquid corrosive environments at elevated temperatures,
which visually demonstrated a destruction of the material. Joint influence of
temperature and corrosive medium was determined by the test of RubCon specimens
in the size 4x4x16 cm. Experiments were performed in 10% -solution of caustic soda
and 30% solution of sulfuric acid environments at temperatures +40ºC and +60ºC. It
can be seen that the elevated temperature reduces the chemical resistance of RubCon
samples and leads to their destruction due to the acceleration of chemical reactions
between the corrosion environment and the material.

METHODOLGY:-
For this research work, mainly fly ash was used as a pozzolanic material . In different
weight fraction (0%, 10%, 15%, 20%) to cement it was used in M25 grade of concrete
and study the 7 days and 28 days compressive strength, Durability test and flexural
strength of concrete to that of normal concrete with maintaining the water cement
ratio in the range of 0.50.
It is evident that RubCon is corrosive stable structural material because its
chemical resistance coefficient during 10 years operating in aggressive environments
exceeds 0.5. Obtained data allow to appoint the thickness of the concrete cover of a
reinforced RubCon structure.

Enhancement of Chemical Resistance of RubCon

RubCon coefficient of chemical resistance in 36%
solution of a hydrochloric acid environment is minimal. We launched the series of
experiments in order to raise the RubCon chemical resistance by introducting of
special active additives into vulcanization process. These additives make possible to
increase density of spatial crosslinks of polymeric molecules and by doing so, to
improve physical- mechanical properties and resistibility of RubCon to the corrosive
medium exposition.. Such additives were tiuram-D and altax. Optimum quantity of

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the additives in the RubCon composition was obtained by two-factor experiment. In
this case, dosage of the additives was varied parameter and with its compressive
strength of RubCon test specimens was efficiency function. In Fig. (3) is showed the
efficiency function surface for RubCon samples in 36% solution of a hydrochloric
acid depending on quantity of additives: sulfur + tiuram-D (x1) and altax (x2).
Regression formula of relationship between RubCon compressive
strength R and quantities of additives (x1- sulfur + tiuram-D and x2- altax).
Compressive strength of the RubCon samples after 90
days exposition in 36% solution of HCl peaks at x1 =__ And x2 =__. As this took
place, coefficient of chemical resistance was increased from ___ to ____; after one
year exposition in the same corrosive environment from ?. Introduction of other
additives into the RubCon mix also make possible to raise its compressive strength.
Our experiments have shown that addition of 2.3% TiO2 or 3.6% BaSO4 allows to
increase compressive strength of the RubCon samples after 90 days exposition in 36%
solution of HCl up to 11÷12% (Table 5). As illustrated in Fig. (4), growth of
compressed strength R of RubCon operated in no aggressive environments (line 1) is
connected with increase of the TiO2 doze since oxide of metals are activating agents
of vulcanization process. After 90 days exposition into 36% solution of HCl and
quantity of TiO2 more 2.3% chemical resistance coefficient Kcr and compressive
strength R are decreased (lines 2, 3). We attribute this phenomenon to intensive
formation of soluble compounds resulting in the production of micro cracks.

3.3. Materials

3.3.1. Cement
All materials that go into concrete blend are necessary, concrete is all the time
the most critical in light of the fact that it is generally the sensitive connection in the chain.
The capacity of concrete is as a matter of first importance to tie the sand and stone together
and second to top off the voids in the middle of sand and stone particles to frame a
conservative mass. In spite of the fact that it constitutes just around 20 for every penny of the
volume of concrete blend, it is the dynamic bit of restricting medium and is the main logically
controlled element of concrete. Any variety in its amount influences the compressive quality
of the concrete blend. In the present examination, Ordinary Portland Cement (OPC) of 43
Grade was utilized for all concrete blends.

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3.3.2. Aggregates
The agglomeration is the network or vital structure comprising of moderately idle and
coarse particles. The coarse agglomeration is utilized principally with the end goal of giving
mass to the concrete. The most critical capacity of fine agglomerations is to help with
delivering a workable and a uniform concrete blend. The fine agglomeration likewise helps
the concrete glue to hold the coarse agglomeration particles in suspension. This activity
advances versatility in the concrete blend and anticipates isolation of the glue and coarse
agglomerations amid its transportation. The agglomerations give around 75 for each penny of
the group of cement and consequently their impact is critical. The properties of these particles
enormously influence the execution of cement.

3.3.3. Fine Aggregate

IS: 383-1970 characterizes the fine agglomeration, as the one passing 4.75mm IS sifter. The
fine agglomeration is regularly named as a sand estimate agglomeration. Locally accessible
riverbed sand was utilized as a part of the present investigation. The per penny passing 600
micron sifter = 62.35. The sand adjusts to evaluating Zone – III according to Seems to be: 383
– 1970 separately.

3.3.4. Coarse Aggregate

The coarse agglomeration is characterized as that held on 4.75 mm IS sifter. To expand the
thickness of the subsequent concrete blend, the coarse agglomeration is every now and again
utilized as a part of at least two sizes. Two sorts of agglomerations with various sizes have
been utilized as a part of the present investigation.

The points of interest of the same are as beneath:

I. Agglomeration passing 20 mm strainer

ii. Agglomeration passing 10 mm strainer.

The coarse agglomeration utilized were washed and kept in water for 24hr's to expel clean
and earth and were dried to surface dry condition.

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3.3.5. Natural Coarse Aggregate
Crushed granite with ostensible sizes of 10 mm and 20 mm were utilized as
characteristic coarse agglomeration.

Fly Ash:
Fly ash is finely divided residue resulting from the combustion of powdered
coal and transported by the flue gases and collected by electrostatic precipitator. Fly
ash is the most widely used pozzolonic material all over the world. In the recent time,
the importance and use of fly ash in concrete has grown so much that it has almost
become a common ingredient in concrete, particularly for making high strength and
high performance concrete. To use fly ash as a supplementary cementitious material
extensive research has been done on the benefits that can be achieved by using fly
ash. All over the world high volume fly ash concrete is becoming the subject of
current interest as the use of fly ash as concrete admixture not only extends technical
advantages to the properties of concrete but also contributes to the environmental
pollution control. In India alone, we produce about 75 million tons of fly ash per year,
the disposal of which has become a serious environmental problem. The concrete
technologists and government departments are taking serious considerations on fly
ash due to its effective utilization. The tests on fly ash were carried out as per IS:
1727-1967. The specific gravity of fly ash is 2.25 and fineness is 8 % (by dry sieving
method).

3.3.8. Water
For the most part, water that is reasonable for drinking is agreeable for use in concrete. Water
from lakes and streams that contain marine life likewise typically is reasonable. At the point
when water is gotten from sources specified over, no testing is essential. When it is suspected
that water may contain sewage, mine water, or lavish from modern plants or canneries, it
ought to be utilized as a part of cement unless tests demonstrate that it is attractive. Water
from such sources ought to be maintained a strategic distance from since the nature of the
water could change because of low water or by irregular release of hurtful lavish into stream.
The water utilized was the consumable water as provided in the structures research facility of
our establishment. Water utilized for blending and curing ought to be perfect and free from
damaging measures of oils, acids, alkalis, salts and sugar, natural materials or different
substances that might be pernicious to concrete. According to May be: 456-2000 consumable
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water is by and large viewed as tasteful for blending and curing of cement. In like manner
consumable water was utilized for arrangement of every single concrete example.

3.5. Mix design

3.5.1. Quantities of materials for mix of concrete (percentage)
Different quantities of materials and the mix proportions of the materials for each mix
is shown in Table 3.2
3.6. Test Procedure
3.6.1. Tests conducted on concrete
 Slump cone test
 Compressive strength test
 Split tensile strength of test
 Initial surface absorption test
 Capillary suction test
 Ultrasonic pulse velocity (UPV) measurement
 Acid resistance test
 Alkalinity resistance test

3.7. Tests on fresh concrete

Workability is thought to be that property of concrete which demonstrates its capacity to be
blended, taken care of, transported and in particular, set with a base loss of homogeneity. All
the more definitely, it characterizes that it can be completely compacted with least vitality
input. There ought to be no indication of any isolation or seeping in workable cement. Tests,
for example, slump test and compaction factor test were carried on crisp concrete according to
IS details.

3.7.1. Slump test

Slump test is the most generally utilized technique for measuring consistency of
concrete which can be utilized either in research facility or at site work. It is not reasonable
strategy for extremely wet or exceptionally dry cement. It doesn't gauge all variables adding
to workability, nor is it generally illustrative of the place capacity of the concrete. Be that as it
may, it is utilized advantageously as a control test and gives a sign of the consistency of
cement from batch to bunch.

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3.8.1. Compressive strength test
By definition, a definitive compressive quality of a material is the estimation of uniaxial
compressive anxiety achieved when the material fails totally. The compressive quality is
normally gotten tentatively by methods for a compressive test. The mechanical assembly
utilized for this test is the same as the utilized as a part of a ductile test.

A pressure test decides conduct of materials under pulverizing loads. The example is packed
and distortion on different burdens is recorded. Compressive anxiety is ascertained and
plotted as an anxiety strain outline which is utilized to decide versatile point of confinement.

The test was led on cubes of size 100mm 100 mm. Examples were taken out from curing tank
the age of 7,28,60 and 90 days. Surface was then permitted to trickle down. Examples were
then tried on 200 tones limit pressure testing machine (CTM). The position of 3D Square
while testing was correct points to that of throwing position. Pivot of examples was
painstakingly lined up with the focal point of push of the circularly seed in addition to.

Fig 3.1 Compression strength testing machine.

The load was connected step by step with no stun and expanded consistent rate of 3.5 N/mm2
until the point when disappointment of example takes and the run of the mill setup of pressure
machine is appeared in Fig 3.1. The average of three specimens was taken as the agent
estimation of pressure quality for each bch of cement. The compressive quality was figured
by partitioning the greatest compressive load by the cross sectional range of the 3D cube
examples. In this way the compressive quality of various examples was gotten.

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3.8.3. Initial surface absorption test
The Initial Surface Absorption Tests (ISAT) was directed as per BS 1881: Part 208:
1996 (20) on all examples following 2 months from the date of throwing. The Initial Surface
Absorption test was executed as a pointer for the durability of the blends. The concrete cubes
were at first broiler dried. A top was connected to the concrete surface. This top was
associated with a store with a water weight head of 200 mm. The top was likewise associated
with an even slim tube. Water was permitted to infiltrate the concrete surface from the
repository into the top. Toward the finish of 0, 30, 60 and 120 minutes, the store stream was
shut and the water was permitted to enter the concrete surface from the narrow tube and the
setup is appeared in Fig 3.3. The test gives the water stream (M1/M2.sec) into the surface of
the dry 3D cube example utilizing the adjustment of the hair like tube.

Fig 3.3. Initial surface absorption test

3.8.4. Acid resistance test

Concrete blocks of size 150mm x 150mm were thrown and put away in a place at a
temperature of 32°C for 24 hours and after that the examples were water cured for 56 days.
Following 56 days curing, the examples are taken out and permitted to dry for one day.
Starting weights of the concrete cubes were taken. For acid resistance test, 1% weaken
Sulphuric acid (H2SO4) by volume of the water with pH estimation of around 2 was kept up.
After that 3D cubes were inundated in the above said acid water for a time of 30 days and the
setup is appeared in Fig 3.7. The examples were taken out from the Acid arrangement at 30
days, and last weights of the dry blocks were taken.

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 Fig 3.4. Cubes under acid testing and the PH meter.

3.8.5. Alkalinity resistance test

Concrete 3D cubes of size 150mm x 150mm was thrown and put away in a place at a
temperature of 32°C for 24 hours and afterward the examples were water cured for 56 days.
Following 56 days curing, the examples are taken out and permitted to dry for one day.
Introductory weights of the concrete cubes were taken. For basic assault, 5% sodium
hydroxide (NaOH) by volume of the water with pH estimation of around 10-12 was kept up.
After that 3D cubes were submerged in the above said basic water for a time of 30 days. The
examples were taken out from the Acid arrangement at 30 days, and last weights of the dry
3D cubes were taken.

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 CHAPTER 4
RESULTS AND DISCUSSIONS

4.2. Quantities of materials for mix of concrete (percentage)

Here S.F alludes to Silica Fume, Cag is coarse agglomerations and RCA is reused
concrete agglomerations. M1 is the primary blend with 0% substitution of reused
agglomerations; M2 is the second blend with 10% trade of reused agglomerations and for M3
with 20% substitution, M4 with 30% substitution, M5 with 40% supplanting lastly M5 with
half substitution of reused agglomerations in the concrete blends.

4.3.1. Slump test

Slump test is the most regularly utilized technique for measuring consistency of
concrete Slump test was completed on all the concrete blends in the concrete research
center. This test was exceptionally valuable in distinguishing variety in the
consistency of a blend of given proportions. It likewise gives a thought of Water
cement proportion to be utilized for various blends. Crisp unsupported concrete
streams to and soaking in the stature happens. This vertical settlement is known as
Slump. Concrete is said to be workable if it can be effortlessly blended, compacted
and effectively wrapped up.
The inner surface of cube was cleaned altogether and free from
dampness and any concrete before starting the test. The cube was set on rigid, flat and
non-retentive surface. The cube filled in 4 layers, each roughly one fourth of stature of
the form. Each layer should be messed with 25 strokes. In the wake of leveling the
best, the form was expelled from concrete quickly by bringing it gradually up in a
vertical bearing. This enables the concrete to die down and slump might be measured
by measuring distinction between the statures of cube and most astounding purpose of
example being tried.

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 Table 4.2. Slump values for different concrete mixes
Mix Slump (mm)
description

From Table 4.2, it can be seen that the slump esteem is reducing with
increment in the reused concrete rate in the blend. This is on the grounds that the
reused agglomerations assimilates more water than the ordinary agglomerations as a
result of the nearness of tidy and the mortar on the surface of reused agglomerations.
All slump esteems were kept up in the middle of 90-110mm by differing the dose of
super plasticizer.

4.3.2. Compressive strength results

Cubes of sizes 100 x 100 x 100 mm were thrown for strength testing. These
concrete cubes were cured for 7, 14, 28, 56 and 90 days and tried in Compression
testing machine having a limit of 200 T. The examples were permitted to dry in
daylight for 1 day and are put midway in testing machine and load was connected
ceaselessly, consistently and with no stun.
The load was expanded until the point that the
example comes up short. The greatest load taken by the example was noted. Trial was
rehashed for two examples of a similar blend. The results of the quality tests led on
concrete examples of various blends cured at various ages are introduced and talked
about in this area. The compressive quality test results of all the blends at various
curing ages are appeared in

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 Table 4.3. Compressive strength (M Pa) values of all mixes at different curing ages
Mix Mix Description Compressive Strength (M Pa)
Name

7 days 14 Days 28 Days 56 Days 90 days

M1
M2
M3
M4
M5
M6

From the above test outcomes and the graphical variety as appeared in Fig 4.1,
it was watched that the compressive strength results of the M2, M3 and M4 are
similar with the blend M1. This demonstrates the compressive strength of reused
agglomeration cement with up to 30% supplanting of natural agglomerations with
reused agglomerations gives similar esteems when contrasted with the typical
agglomerations concrete or customary cement. The rate misfortune in quality from
0%RA blend to 30%RA blend was 5.30% following 90 days, and at 28 days the loss
of quality from M1 to M4 is 1.15%. After 30% substitution i.e., 40% and half
supplanting of NA with RA demonstrates the sporadic conduct in compressive quality
esteems at both 28 days and 90 days. At early time of curing i.e. 28 days, the
distinction in compressive quality of M1, M2, M3 and M4 is less, though at 90 days
the distinction in compressive quality of M1, M2, M3 and M4 is extensive. So it was
watched that the ideal level of supplanting of NA with RA is 30%. Past 30%
substitution the outcomes indicating Reducing pattern as far as compressive quality at
all curing ages.

4.3.3. Split Tensile Strength results

Concrete cubes of size 100×100×100mm were threw and cured for 7, 14, 28,
56 and 90 days. Subsequent to curing age the concrete cubes were permitted to dry in
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the daylight for 1 day and were tried under strength testing machine by putting the
cubes corner to corner in the middle. The load was expanded until the point when the
example comes up short. The most extreme load taken by the example was noted.
Investigation was rehashed for two examples of a similar blend and the normal esteem
was taken as last. The consequences of the quality tests directed on concrete examples
of various blends cured at various ages are displayed and talked about in this segment.
The split elasticity test consequences of all the blends at various curing ages are
appeared in Table - 4.4. Variety of compressive quality of all the blends with curing
age is appeared in Fig. - 4.2.

Table 4.4.Split tensile strength test (M Pa) values of all mixes at different curing ages.

Mix Name Mix Description Split Tensile Strength (M Pa)

7 days 14 Days 28 Days 56 Days 90 days

M1
M2
M3
M4
M5
M6

From the above test outcomes and the graphical variety as appeared in Table 4.4 and Fig 4.2,
it was watched that the split rigidity consequences of the M2, M3 and M4 are practically
identical with the blend M1. This demonstrates the split elasticity comes about of reused
agglomeration cement with 30% supplanting of natural aggregates with reused
agglomerations gives similar esteems when contrasted with the typical agglomerations
concrete or traditional cement. After 30% substitution i.e., 40% and half supplanting of NA
with RA demonstrates the sporadic conduct in split rigidity esteems. The rate misfortune in
quality from 0%RA blend to 30%RA blend was 5.01% following 90 days, and at 28 days the
loss of quality from M1 to M4 is 0.7%. So the ideal level of supplanting of NA with RA is
30%.

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 Past 30% substitution the outcomes demonstrating Reducing pattern as far as split
rigidity. The most elevated estimation of split rigidity was watched for blend with 0% reused
agglomerations at both introductory stage and later phases of curing. The most minimal
estimation of split elasticity was watched for blend with half reused agglomerations at both
introductory stage and later phase of curing. The lessening in the split pliable estimation of
reused agglomeration cement from one blend to other is high in the underlying stages i.e. 7,
14, 28 days, while the reduction in split ductile incentive at 56, 90 days is uniform this can be
unmistakably appeared in the graph. Along these lines, reused agglomeration cement
performed preferred with less over 30% substitution in the underlying stages.

4.3.4. Initial surface absorption test results (ISAT)

The ISAT was performed to have a thought regarding the water saturation of cement
especially at the concrete surface. Concrete cover is the weakest, most penetrable and
absorptive piece of the concrete network when contrasted with the inside microstructure. The
close surface cement is very heterogeneous in nature, because of the relative construction of
cement glue and agglomerations amid the compaction of crisp cement and seeping of blend
water in the beginning times of concrete hydration. Therefore, there is a porosity angle in the
close surface concrete, where the porosity of close surface is higher than that of interior piece
of cement. Subsequently, the concreteness of the entire cement can be portrayed by just
deciding the penetration attributes of the concrete surface, which is considered as the most
basic and defenseless part towards outside liquid entrance. The results of the ISAT led on
concrete examples of various blends cured at various ages are displayed and examined in this
segment. For a specific curing age, the retention was measured at 3 diverse eras i.e. 10, 30
and an hour.

The assimilation of water or stream of water reduced with time. This was on the grounds that
the rate of ingestion of water turns out to be less as time increments when the external zone of
the surface is soaked and it is more troublesome for water to be consumed by the internal
pores. It was discovered that the stream information at interim of 10 minutes give a more
agent pattern of the surface ingestion attributes. Stream rate at less than 10 minutes won't not
speak to a steady and consistent stream of water into the concrete, and the stream rates at 30
and 60 min. interims would not be reasonable since the concrete surface would as of now be
in an immersed state and the information acquired won't be appropriate for relative purposes.

Table: 4.5. Initial Surface Absorption values in [ml/ (m2.Sec)] at 10 min.

Mix no. Description Initial Surface Absorption

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 [ml/(m2.Sec)]
at 10 min.
56 days 90 days

1
2
3
4
5
6

Table: 4.6. Initial Surface Absorption values in [ml/ (m2.Sec)] at 30 min.

Mix no. Description Initial Surface Absorption
[ml/(m2.Sec)]
at 30 min.
56 days 90 days

1
2
3
4
5
6

The underlying surface ingestion esteems (ISAT) for 10 min, 30 min and 60 min of different
blends at various curing ages is appeared from Table 4.5 to Table 4.7. From the qualities it
can be seen that the assimilation Reduces with increment in curing time.

Table: 4.7. Initial Surface Absorption values in [ml/(m2.Sec)] at 60 min.

Mix no. Description Initial Surface Absorption
[ml/(m2.Sec)]
at 60 min.
56 days 90 days

1
 1
2
3
4
5
6

Table 4.5 to Table 4.7 demonstrates the outcomes got from the ISAT test performed on 6
blends at 56 days and 90 days of curing age. The most minimal esteem was recorded as 0.124,
0.107 ml/(m2.Sec) for blend 100%NA+0%RCA for 56 and 90 days at 60 min individually.
While the most elevated esteem was recorded as 0.475, 0.445 ml/(m2.Sec) for blend
50%NA+50%RCA for 56 and 90 days at 10 min separately. From the Fig 4.3 and 4.4 it can
be seen that the expansion in reused agglomeration rate in the blend is the purpose behind
more ingestion. This is a result of the nearness of mortar and clean on the reused
agglomerations and is additionally permeable, so reused agglomeration cement assimilates
more water. Additionally the underlying esteems i.e. 10 min esteem is more than the rest of
the 30 min and 60 min, after 10 min of persistent supply of water the concrete 3D cube gets
soaked so it won't retains more water after 10min. From the above outcomes slant it can be
watched that the ISAT esteem is expanding with the expansion in the level of reused
agglomeration substance in the blend. It can likewise be watched that the ingestion is more in
the 56 days test time than contrasted with the assimilation in 90 days test time. Along these
lines, with increment in curing time we can reduce the assimilation limit of cement.

4.3.5. Acid Resistance Test

For acid resistance, 1% weaken sulphuric Acid (H2SO4) by volume of the water with pH
estimation of 2 was kept up. Cubes were inundated in acid for a time of 28 days. The activity
of acids on hardened cement is the transformation of ferrous mixes into the ferrous salts of the
assaulting acid. Because of these responses, the structure of cement gets wrecked. The
measurement of cube examples was decreased 3mm at all sides at 28 days of curing. From the
test outcomes, the concrete containing reused agglomerations was observed to be lesser in
imperviousness to the H2SO4 arrangement than the control concrete. The impact of acid on
compressive quality and the outcomes were appeared in the Table 4.8 and the examples were
appeared in Fig 4.5.

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 Fig 4.5 Acid tested specimen and normally cured specimen.

From the test outcomes, unmistakably the concrete arranged with reused aggregates
demonstrated moderately higher mass change. Albeit both control blend and reused aggregate
concrete blend endured slight mass, the general misfortune in mass of reused aggregate
cement was significantly higher. The greatest decrease of mass is gotten at half substitution of
reused aggregates i.e. 5.35%, and decrease of mass in the control blend is 1.5%. Every
concrete example get influenced by basic analysis. The rate contrast in compressive quality
for 0% RA is less contrasted with half RA blend and the pattern is appeared in table beneath.
Along these lines, it can be presumed that the impact of Acid expanded with the expansion in
the reused agglomeration rate in the blend.

4.3.6. Alkalinity resistance test

For alkalinity test 5% sodium hydroxide (NaOH) by volume of the water with pH
estimation of 12 was kept up. Cubes were drenched in the above answer for a time of 28 days.
It was watched that the heaviness of examples expanded when kept in arrangement following
28 days curing.

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The impact of alkaline solution on compressive quality and the outcomes are appeared in
Table 4.9 and the tried examples were appeared in Fig 4.6

Fig 4.6 Base tested specimen and normally cured specimen.

From the Table 4.9, it can be watched that every one of the examples demonstrated increment
in the weight after expulsion from the alkaline solution tank. This is a direct result of the
nearness of salts in the arrangement. These salts collect in the pores of the concrete examples,
so the weight is expanded by a maximum estimation of 0.58% by weight of 3D square. So it
can be watched that every one of the examples demonstrated higher resistance towards
alkaline solution contrasted with Acid arrangement. The weight contrast after the test on
concrete with alkaline solution is less contrasted with Acid arrangement test. The compressive
quality misfortune additionally watched less in alkaline solution contrasted with the quality
misfortune in acid arrangement. It can likewise be watched that the quality misfortune and
weight reduction increments with increment in the reused material in the concrete blends. The
quality misfortune and weight reduction in basic arrangement is less and all blends performs
well in alkaline solution.

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 CHAPTER 5
CONCLUSIONS
5.1. Introduction
In this examination, the mechanical and durability properties of cement arranged with reused
agglomerations were explored. In light of the results of this trial study, the accompanying
conclusions can be drawn.

5.2. Conclusions
RubCon offers the universal chemical resistance many times higher than ordinary Portland
cement concrete and surpasses of chemical resistance of polyester, polyepoxy and vinyl este
polymer concrete.
• The most intensive decrease of RubCon strength occurs during the first 6 months of the
corrosion environments exposition.
• Destruction of polybutadiene under the action of inorganic acids is caused by oxidation of a
macromolecule of polymer and depends on the speed of this process course. In other word
cross-section links of a spatial composite network formed by vulcanization process ar
broken.
• Elevated temperature (up to 60°C) insignificantly reduces the chemical resistance of
RubCon samples and leads to their destruction due to acceleration of chemical reaction
between the corrosion environment and a material.
• Chemical resistance coefficient of RubCon operating in aggressive environments during 10
years exceeds 0.5. Obtained data allow appointing the thickness of the concrete cover of a
reinforced RubCon structure.
• Additives make possible to improve physical mechanical properties of RubCon and its
resistibility to the corrosive medium Optimum quantity of the sulfur + tiuram-D and altax
additives in the RubCon composition is 4.45% and 0.28%, correspondingly. Optimum
quantity of the TiO2 or BaSO4 additives in the RubCon composition is 2.3% and 3.6%,
correspondingly.
• Fiber reinforced RubCon is chemical resistance material.
• RubCon, displays universal chemical stability and keeps it after 􀀁-radiation exposure

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