Self Compacting Concrete

To study the behavior of SCC with partial replacement of cement by Fly Ash
Chapter 1 INTRODUCTION
1.1 General
It is estimated that the present consumption of concrete in the world is of the order of 10 billion tones to 12 billion tones every year. Humans consume no material except water in such tremendous quantities. The ability of concrete to withstand the action of water without serious deterioration makes it an ideal material for building structures to control, store, and transport any material. The ease with which structural concrete elements can be formed into a variety of shapes and sizes is a positive point of use of concrete. For several years, the problem of durability of concrete structures has been a major problem posed to engineers. To make durable concrete structures, sufficient compaction is required. Compaction for conventional concrete is done by vibrating. Over vibration can easily cause segregation. In conventional concrete it is difficult to ensure uniform material quality and good density in heavily reinforced locations. If steel is not properly surrounded by concrete it leads to durability problems. The answer to the problem may be a type of concrete, which can get compacted into every corner of formwork and gap between steel, purely by means of its own weight and without the need for compaction. The self-Compacting Concrete concept was introduced to overcome these difficulties. This concept can be stated as the concrete that meets special performance and uniformly requirements that cannot always be obtained by using conventional ingredients, normal mixing procedure and curing practices. The Self Compacting Concrete is an engineered material consisting of cement, aggregates, water and admixtures with several new constituents like colloidal silica, pozzolanic materials, Portland fly ash (PFA), ground granulated blast furnace
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DEPT OF CIVIL ENGG, MCE.
slag(GGBS), micro silica, metakaolin, chemical admixtures to take care of specific requirements, such as, high-flow ability, compressive strength, high workability, enhanced resistances to chemical or mechanical stresses, lower permeability, durability, resistance against aggregation, and passing ability under dense reinforcement conditions. The properties such as, fluidity and high resistance to segregation enables the placement of concrete without vibrations and with reduced labor, noise and much less wear and tear of equipment. Use of Self Compacting Concrete overcomes the problem of concrete placement in heavily reinforced sections and it helps to shorten construction period.
1.2 Development of self-compacting concrete

In Japan, on early eighties, premature deterioration of concrete structures was detected in almost every part of the country. The main cause of the deterioration was recognized as inadequate compaction. In addition, the gradual reduction in the number of skilled workers in Japans construction industry led to a reduction in the quality of construction work .As a solution for these social and technical requirements, the concept of Self Compacting Concrete was proposed by Prof. Okamura at Tokyo University in 1988. He gave the first prototype of Self Compacting Concrete using materials already in the market. Later studies to develop Self Compacting Concrete, including a fundamental study on the workability of concrete, were carried out by Ozawa and Maekawa. Self Compacting concrete has now been taken up with enthusiasm across Europe and other parts of the world, in both site and precast concrete work. Practical application has been backed by research on its physical and mechanical characteristics of Self Compacting Concrete. Earlier Self Compacting Concrete relied on very high contents of cementations paste, the mixes required specialized and well-controlled packing methods to avoid segregation, but the high contents of cement paste made them prone to shrinkage and high heat generation. The overall costs were very high and applications therefore
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remained very limited. After series of advancements it is now an engineered material with several constituents.
1.3 General wastes used in concrete

The most commonly used materials in concrete are fly ash, blast furnace slag, silica fume, Fly ash, metakaolin, crusher dust etc. These wastes are usually generated in large amounts and disposed off. But construction industry has found its use significantly in using it in concrete. These materials are used as substitutes for any of the concrete materials like fine aggregates or cement.
1.3.1 Fly Ash

Fly ash, also known as flue-ash, is one of the residues generated in combustion, and comprises the fine particles that rise with the flue gases. Ash which does not rise is termed bottom ash. In an industrial context, fly ash usually refers to ash produced during combustion of coal. Fly ash is generally captured by electrostatic
precipitators or other particle filtration equipment before the flue gases reach the chimneys of coal-fired power plants and together with bottom ash removed from the bottom of the furnace is in this case jointly known as coal ash. Depending upon the source and makeup of the coal being burned, the components of fly ash vary considerably, but all fly ash includes substantial amounts of silicon dioxide (SiO2) (both amorphous and crystalline) and calcium oxide (CaO), both being endemic ingredients in many coal-bearing rock strata. In the past, fly ash was generally released into the atmosphere, but pollution control equipment mandated in recent decades now require that it be captured prior to release. In the US, fly ash is generally stored at coal power plants or placed in landfills. An about 43% is recycled, often used to supplement Portland cement in concrete production. Some have expressed health concerns about this.
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1.3.1.1 Classification of Fly ash

The two classes of fly ash are defined by ASTM C618: Class F fly ash and Class C fly ash. The chief difference between these classes is the amount of calcium, silica, alumina, and iron content in the ash. The chemical properties of the fly ash are largely influenced by the chemical content of the coal burned
(i.e. anthracite, bituminous, and lignite). Not all fly ashes meet ASTM C618 requirements, although depending on the application, this may not be necessary. Ash used as a cement replacement must meet strict construction standards, but no standard environmental regulations have been established in the United States. 75% of the ash must have a fineness of 45 m or less, and have carbon content, measured by the loss on ignition (LOI), of less than 4%. In the U.S., LOI needs to be under 6%. The particle size distribution of raw fly ash is very often fluctuating constantly, due to changing performance of the coal mills and the boiler performance. This makes it necessary that, if fly ash is used in an optimal way to replace cement in concrete production, it needs to be processed using beneficiation methods like mechanical air classification.
1.3.1.1.1 Class F fly ash

The burning of harder, older anthracite and bituminous coal typically produces Class F fly ash. This fly ash is pozzolanic in nature, and contains less than 5% lime (CaO). Possessing pozzolanic properties, the glassy silica and alumina of Class F fly ash requires a cementing agent, such as Portland cement, quicklime, or hydrated lime, with the presence of water in order to react and produce cementitious compounds. Alternatively, the addition of a chemical activator such as sodium silicate (water glass) to a Class F fly ash can lead to the formation of a geopolymer.
1.3.1.1.2 Class C fly ash

Fly ash produced from the burning of younger lignite or sub bituminous coal, in addition to having pozzolanic properties, also has some self-cementing properties. In the presence of water, Class C fly ash will harden and gain strength over time. Class C fly ash generally contains more than 10% lime (CaO).
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TABLE 1.1: Chemical characteristics of fly ash as per IS: 3812 - 2003 Sl.no Chemical composition percent by mass 1. 2. 3. 4. 5. 6. 7. 8. 9. Sio2 + Al2O3 + Fe2O3 Silicon dioxide (Sio2) Reactive silica Magnesium oxide (Mgo) Total sulphur as sulphur trioxide (SO3) Available alkalis as sodium oxide(Na2O) Total chlorides Loss on ignition (LOI) Lime(CaO) Class F fly ash >70% 35% 20% 5% 3% 1.5% 0.05% 5% 3-5% Class C fly ash 50-70% 25% 20% 5% 3% 1.5% 0.05% 5% 5-10%
FIGURE: 1.1 Class F fly ash
FIGURE: 1.2 Class C fly ash
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1.3.2 Present scenario of Fly ash production in India and need for Fly ash utilization
Thermal Power stations using pulverized coal or lignite as fuel generate large quantities of ash as a by-product. There are about 85 power plants in India, which form the major source of fly ash in the country. With the commissioning of super thermal power plants and with the increasing use of low grade coal of high ash content, the current production of ash is about 112 million tonnes per year. Primarily, the fly ash is disposed off using either dry or wet disposal scheme. In dry disposal, the fly ash is transported by truck, chute or conveyor at the site and disposed off by constructing a dry embankment (dyke). In wet disposal, the fly ash is transported as slurry through pipe and disposed off in impoundment called "ash pond". Most of the power plants in India use wet disposal system. This Fly ash is a great environment threat causing damage to the land and the surrounding areas in which it is disposed off. The particle size of the cement is about 35 microns. There may be formation of void in the concrete mixes, if curing is not done in properly. Thus reduces the strength and quality of the concrete. Fly ash is finer than cement having very small particle size of less than 25 microns, so much so that it fills the interstices in between the cement in the aggregate. That is where the density comes from and it can reduce the amount of cement in the concrete mix. The technical feasibility for utilization of Fly ash as a partial substitute for cement in Self Compacting Concrete is investigated in present studies.
1.4 Objective of present study

The major objective of the present study is To determine the effect of Fly ash as partial substitute of cement on the properties of self-compacting concrete in fresh state (filling ability and passing ability).
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To determine the effect of Fly ash as partial substitute of cement on the properties of self-compacting concrete in hardened state (compressive strength).
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Chapter 2 LITERATURE REVIEW

2.1 Introduction
For several years beginning in 1983, the problem of the durability of concrete structures was a major topic of interest in Japan. The creation of durable concrete structures requires adequate compaction by skilled workers. However, the gradual reduction in the number of skilled workers in Japans construction industry has led to a similar reduction in the quality of construction work. One solution for the achievement of durable concrete structures independent of quality of construction work is employment of self-compacting concrete, which can be compacted into every corner of a formwork, purely by means of its own weight and without the need for vibrating compaction. The necessity of this type of concrete was proposed by Okamura in 1986. Studies to develop self-compacting concrete, including a fundamental study on the workability of concrete, have been carried out by Ozawa and Maekawa at the University of Tokyo (Ozawa 1989, Okamura 1993 & Maekawa 1999). The prototype of self-compacting concrete was completed in 1988 using materials already on the market. The prototype performed satisfactorily with regard to drying and hardening shrinkage, heat of hydration, and denseness after hardening and the properties. This concrete was named High Performance Concrete and was defined as follows at the three stages of concrete: 1. Fresh: self-compactable. 2. Early age: avoidance of initial defects. 3. After hardening: protection against external factors. At almost the same time, High Performance Concrete was defined as a concrete with high durability due to a low water-cement ratio by Professor Aitcinetal
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(Gagne etal 1989). Since then, the term high performance concrete has been used around the world to refer to high durability concrete. In the early 1990s there was only a limited public knowledge about Self Compacting Concrete. Mainly in Japan, the fundamental and practiced know-how was kept secret by the large co-operation to maintain commercial advantage. The Self Compacting Concrete was used under trade names such as the NVC (non-vibrated concrete of Kajima co, SQC (super quality concrete) of maedaco. or the biocrete (taisei co.). Simultaneously with the Japanese development in the Self Compacting Concrete area, R&D continued in mix design and placing of underwater concrete where new admixtures were producing Self Compacting Concrete mixes with performance matching that of the Japanese Self Compacting Concrete(example: university of paisley/Scotland, university of Sherbrook/Canada etc). Modern or present day Self Compacting Concrete (SCC) can be classified as an advanced construction material. The Self Compacting Concrete, as the name suggests, does not require vibration to achieve full compaction. This offers many benefits and advantages over conventional concrete. These include an improved quality of concrete and reduction of onsite repairs, faster construction time, and lower overall cost and also facilitation of introduction of automation into concrete construction. An important improvement of health and safety is also achieved through elimination of handling of vibrators and a substantial reduction of environmental noise loading in and around a site. The composition of Self Compacting Concrete mixes includes substantial proportions of fine grained inorganic materials; this offers possibilities for utilization of dusts which are currently waste products having no practical applications and which are costly to be just disposed off. Current Indian scenario in construction shows increased construction of large and complex structures, which often leads to difficult concreting conditions. Vibrated concreting in congested locations may cause some risk to labor in addition to noise stress. There are always doubts about the strength and durability placed in such
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locations. Hence, if possible, it is worthwhile to eliminate vibration in practice. In countries like Japan, Sweden, UK, Thailand etc, the knowledge of Self Compacting Concrete has moved from domain of research to application. But in India this knowledge is yet to be wide spread.
2.2 Paper Thesis 2.2.1 Development and Properties of Self Compacting Concrete Mixed with Fly Ash ( 2012 ) by Prajapati Krishnapal, Chandak Rajeev and Dubey Sanjay Kumar:
This paper presented the study on establishment of standard mix design procedure and appropriate testing methods which are essential for widespread use of SCC. Most of Indian researchers have followed European guidelines for testing of SCC. Other countries are adopting these guidelines with slight modifications as per their local conditions. Addition of fly ash in SCC increases filling and passing ability of concrete, Increase in fly ash, super plasticizer content in SCC reduced water demand and compressive strength of concrete. In their investigation, increase in fly ash content in place of cement from 48 kg/m3 to 144 kg/m3, reduced the water requirement of mix, thereby decreasing the 28 days the strength of concrete from 52 MPa to 39MPa. Fly ash is industrial waste from thermal power station. Utilization of these waste products as cement replacement will not only help to achieve economical mix, but it is envisaged that it may improve the microstructure and consequently the durability of concrete. This provides solution to disposal problems and other environmental pollution.
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2.2.2 Development of SCC by using high volume of calcareous fly ash ( 2011 ) by I. Papayianni and E. Anastasiou :
They performed their study on following basis. Rheological and mechanical properties as well as long term volume stability seem to be the target characteristics in developing SCC for concrete applications. Calcareous fly ash as a mineral admixture in concrete mixtures often increases water demand for a required consistency. This does not favour the proportioning of SCC with this fly ash since viscous mixtures of low mobility are produced. However, calcareous fly ash exhibits noticeable self cementing capacity and could replace a high volume of Portland cement. In their experimental work, a calcareous fly ash replaced cement in different proportions up to 50% by mass and the effects on rheological properties and mechanical characteristics were measured, as well as, shrinkage deformation. All necessary modifications in proportioning and mixing are also mentioned. Based on the results, the production of SCC of adequate 28 day
strength (50 MPa) with high volume calcareous fly ash was achieved.
2.2.3 Performance of Self Compacting Concrete containing fly ash ( 2008 ) by J.M Khatib :
In this paper, the influence of including fly ash ( FA ) on the properties of selfcompacting concrete is investigated. Portland cement was partially replaced with 0 80% FA. The water to binder ratio was maintained at 0.36 for all mixes. Properties included workability, compressive strength, ultrasonic pulse velocity (V), absorption and shrinkage. The results indicate that high volume FA can be used in SCC to produce high strength and low shrinkage. Replacing 40% of PC with FA resulted in strength of more than 65 N/mm2 at 56 days. High absorption values are obtained with increasing amount of FA, however, all FA concrete exhibits absorption of less than 2%. There is a systematic reduction in shrinkage as the FA content increases and at 80% FA content, the shrinkage at 56 days reduced by two third compared with the
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control. A linear relationship exists between the 56 day shrinkage and FA content. Increasing the admixture content beyond a certain level leads to a reduction in strength and increase in absorption. The correlation between strength and absorption indicates that there is sharp decrease in strength as absorption increases from 1 to 2%. After 2% absorption, the strength reduces at a much slower rate.
2.2.4 Medium strength self-compacting concrete containing fly ash ( 2004 ) by Mohammed Sonebi :
This investigation aims to develop medium strength SCC (MS-SCC). The cost of materials will be decreased by reducing the cement content and by using pulverized fuel ash (PFA) with a minimum amount of superplasticizer (SP). A factorial design was carried out to mathematically model the influence of five key parameters on filling and passing abilities, segregation and compressive strength, which are important for the successful development of medium strength self-compacting concrete incorporating PFA. The parameters considered in the study were the contents of cement and PFA, water-to-powder (cement+PFA) ratio (W/P) and dosage of SP. The responses of the derived statistical models are slump flow, fluidity loss, Orimet time, V-funnel time, L-box, J-Ring combined to the Orimet, J-Ring combined to cone, rheological parameters, segregation and compressive strength at 7, 28 and 90 days. Twenty-one mixes were prepared to derive the statistical models, and five were used for the verification and the accuracy of the developed models. The models are valid for mixes made with 0.38 to 0.72 W/P, 60 to 216 kg/m3 of cement content, 183 to 317 kg/m3of PFA and 0% to 1% of SP, by mass of powder. The influences of W/P, cement and PFA contents, and the dosage of SP were characterised and analysed using polynomial regression, which can identify the primary factors and their interactions on the measured properties. The results show that MS-SCC can be achieved with a 28-day compressive strength of 30 to 35 MPa by using up to 210 kg/m3 of PFA.
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2.3 Scope of present investigation

Countries like Japan, Germany and Australia are doing lots of research work on Self Compacting Concrete. They have established the guidelines for production of Self Compacting Concrete based on the field experience on the application of Self Compacting Concrete in different structures such as high raised buildings, cooling towers, highly, congested and complicated sections. But in India the activity in the domain has just started. Recently organization like NTPC and BARC in India have started using Self Compacting Concrete in construction of structures, Viscosity modified agent (VMA) plays an important role in the performance of Self Compacting Concrete. On one hand a low viscosity is needed so that the concrete can deform and flow easily at a reasonable rate. However on the other hand Self Compacting Concrete requires a high viscosity to avoid segregation. How to balance these conflicting requirements becomes the art and sciences of Self Compacting Concrete mix proportioning. For proper utilization of Fly ash in Self Compacting Concrete and vibrated concrete it is necessary to know about the characteristics and possible effects on the properties of concrete produced. Following issues will be addressed in the present report: To study the effect on fresh concrete properties (filling ability and passing ability) with partial replacement of cement by Fly ash for various proportions. To study the effect on hardened concrete properties (compressive strength) with partial replacement of cement by Fly ash for various proportions. To propose a cost effective utilization of Fly ash as partial substitute for cement in self-compacting concrete.
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2.4 Scope of the study at a glance

CHART 2.1: Flow chart of scope of the study
CONCRETE
SELF-COMPACTING CONCRETE
FRESH CONCRETE
HARDENED CONCRETE
FILLING ABILITY
PASSING ABILITY
COMPRESSIVE STRENGTH
2.5 Organization of the report

The report includes the following sections: Chapter 3 discusses in detail about the characterization of the materials. Chapter 4 explains about the self-compacting concrete and its fresh and hardened state properties. Chapter 5 highlights the experimental work done in the project. Chapter 6 describes test results and discussion. Chapter 7 includes conclusions made.
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CHAPTER 3 CHARACTERISTICS OF MATERIALS

3.1 Introduction
The present section focuses on the study of characteristic properties of basic materials used in concrete. The materials are cement, coarse aggregates, fine aggregates, etc. properties of materials discussed includes chemical composition, specific gravity, water absorption, fineness, bulk density, initial setting time, final setting time, consistency, soundness, moisture content etc.
3.2 Materials used

In the present study the materials used are cement, fine aggregate (River sand), coarse aggregate (Gelly), fly ash, viscosity modified agent (Auramix 400) and water.
3.2.1 Cement
Cement is a well-known building material and has occupied an indispensible place in the construction works. Cement is finely powdered material which by itself is not a binder, develops binding properties as a result of hydration. Cement is called hydraulic when the hydraulic products are stable in aqueous environment (water resistance). There is a variety of cement available in the market and each type is used under certain conditions due its special properties. Some of them are OPC, PortlandPozzolana cement, Rapid hardening Portland cement, Portland slag cement, and High alumina cement. Super sulphate cement, High strength Portland cement, 53 grade high power cement etc. Generally OPC (43 grade) is used for the investigation and construction works. It confirmed to the requirements of Indian standard Specification IS: 81121989. The tests on cement are carried out as per IS: 4031-1996. The physical
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properties of the cement obtained from the testing are given in Table 3.1. The chemical composition of cement is given in Table 3.2. FIGURE: 3.1 Microstructure of cement
TABLE 3.1: Physical properties of OPC Sl. no 1. 2. 3. 4. Physical properties Fineness (retained on 90m sieve)% Normal consistency (%) Specific gravity of cement Vicat time of setting(minutes) a)Initial setting time b)Final setting time 5. 6. Soundness of cement(mm) Compressive strength at 28 days (MPa) 100 425 1 44.3MPa 30 minimum 600 maximum 10 maximum More than 43 MPa Result obtained 7 30 3.15 Requirement IS:8112-1989 10% maximum 30% 3.0 to 3.15
TABLE 3.2: Chemical properties of OPC

Type OPC (%) Sio2 22.48 Al2O3 7.12 Fe2O3 3.01 CaO 59.03 MgO 1.77 K2O 1.33 Na2O 0.36 TiO2 0.37 MnO 1.4 S03 4.20 LOI 1.5
3.2.2 Coarse aggregate

The coarse aggregate is defined as an aggregate most of which is retained on 4.75mm IS sieve. The aggregates are formed due to natural disintegration of rocks or
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by artificial crushing of the rock or gravels. Thus the aggregates derive many of their properties from their parent rocks. These properties are chemical and mineral composition, specific gravity, hardness, strength, pore structure. Some other properties of the aggregate, which is not possessed by the parent rocks, are particle shape and size, texture and absorption. All these properties may have a considerable effect on the quality of concrete in fresh and hardened state. The common coarse aggregates are crushed stone and gravel. The size of the aggregates generally used was 20mm down at 70% and 10mm down at 30%. Crushed granite jelly obtained from machine crusher is used as coarse aggregates. The aggregate may be classified as rounded, partly rounded, flaky, angular, elongated based on its shape and surface texture. Generally angular aggregates are used for construction work. The angular aggregate affects the workability or stability of mix, which depends on the interlocking of the particles. The physical properties of the coarse aggregate are tested as per IS 2386-part III. The results obtained are shown in the Table 3.3. The test results of sieve analysis are as shown in Table 3.4.
TABLE 3.3: Physical properties of Coarse Aggregates Sl. no Physical properties Results obtained 1. 2. 3. Specific gravity of C.A Fineness modulus of C.A Bulk density of C.A a)Dense state(Kg/m3) b)Loose state(Kg/m3) 4. 5. 6. 7. Absorption capacity of C.A (%) Surface moisture of C.A (%) Impact value (%) Crushing strength (%) 1522.78 1354.01 0.45 27.94 24.81 <0.6% Less than 45% Less than 45% 2.76 7.35 Requirement IS:2386(PT3)-1963 2.60 to 2.80 6.0 to 8.0
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TABLE 3.4: Test results of sieve analysis of Coarse Aggregates Sl. no IS sieve size in mm 25 20 16 12.50 10 6.30 4.75 Pan Percentage passing Percentage passing for single sized aggregate of nominal size 20mm as per IS: 383-1970 85-100 Remark
1. 2. 3. 4. 5. 6. 7. 8.
94.73 63.64 24.37 6.78 1.12 0.17 0 -
0-20 0-5
In the supplied sample of C.A, percentage passing are single sized aggregate of nominal size slightly larger than 20mm as per IS: 383-1970.
3.2.3 Fine aggregate

IS: 383-1970 defines the fine aggregates as particles, which will pass through 4.75mm IS sieve and retained on 150 micron IS sieve. It is also called as sand. Generally natural river sand is used for any construction work. The sand is generally considered to have a lower size limit 0.07mm. The material between 0.06mm and 0.002mm is known as silt. Still smaller particle is termed as clay.
TABLE 3.5: Physical properties of Fine Aggregates Sl. no Physical properties Results obtained 1. 2. 3. 4. Specific gravity of F.A Fineness modulus of F.A Bulking of F.A (%) Bulk density of F.A a)Dense state(Kg/m3) b)Loose state (Kg/m3) 5. 6. Absorption capacity of F.A (%) Surface moisture of F.A (%) 1564.97 1396.20 1.43 1.41 <2% <2% 2.67 2.72 36 Requirement IS:2386(PT3)-1963 2.60 t0 2.80 2.20 to 3.20 Less than 40%
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The properties of fine aggregates are determined by conducting tests as per IS: 2386-Part III. The results obtained are as shown in Table 3.5. The test results of sieve analysis are as shown in Table 3.6. TABLE 3.6: Test results of sieve analysis of fine Aggregates Sl. no IS sieve size in mm Percentage passing Percentage passing for Grading-II as per IS: 383-1970 90-100 75-100 55-90 35-59 8-30 0-10 Remark
1. 2. 3. 4. 5. 6. 7.
4.75 2.36 1.18 0.60 0.30 0.15 Pan
96.70 93.30 70.90 55.10 9.95 1.60 0
In the supplied sample of F.A, percentage passing aggregates fall under Grading-II as per IS: 383-1970.
3.2.4 Water
Water is very important ingredient in the concrete mass, as it actively participates in a chemical reaction with cement. It has been estimated that on an average of water by weight of cement is required for chemical reaction in cement compounds. Portable water free from injurious salts was used for mixing and curing of concrete.
3.2.5 Fly ash

Fly ash, also known as flue-ash, is one of the residues generated in combustion, and comprises the fine particles that rise with the flue gases. Ash which does not rise is termed bottom ash. In an industrial context, fly ash usually refers to ash produced during combustion of coal. Fly ash is generally captured by electrostatic precipitators or other particle filtration equipment before the flue gases reach the chimneys of coal-fired power plants and together with bottom ash removed from the bottom of the furnace is in this case jointly known as coal ash.
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Depending upon the source and makeup of the coal being burned, the components of fly ash vary considerably, but all fly ash includes substantial amounts of silicon dioxide (SiO2) (both amorphous and crystalline) and calcium oxide (CaO), both being endemic ingredients in many coal-bearing rock strata. The figure 3.2 shows the microstructure of the fly ash. The physical properties of the fly ash obtained from the testing are given in Table 3.7. The chemical composition of fly ash is given in Table 1.3. FIGURE: 3.2 Microstructure of fly ash
TABLE 3.7: Physical properties of Fly ash Sl. no 1. 2. 3. Physical properties Fineness (retained on 45 sieve)% Specific gravity of fly ash Bulk density (kg/m3) Result obtained 43% 2.31 950 Requirement IS:3812(PT1)-2000 34% 2.2 to 2.5 -
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3.2.6 Chemical admixture

There are water-soluble components added primarily to control setting and hardening of concrete or to reduce its water requirement. Chemical admixtures are grouped according to their functions as accelerators, retarders, water reducing agents and super plasticizers. The admixture used here is Auramix 400, which is a water reducer and viscosity-modifying agent collected from FOSROC Chemicals (India) Pvt. Ltd, Bangalore. This admixture is added to increase the workability of concrete and to obtain the self compacting property in concrete.
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Chapter 4 SELF COMPACTING CONCRETE

4.1 Preview
Self-compacting concrete describes a concrete with the ability to compact itself only by means of its own weight without the requirement of vibration. Selfcompacting concrete is also known as Self-consolidating concrete or Self-leveling concrete.
4.2 Significance of self compacting concrete

Prevent blockages by allowing the concrete to remain fluid, homogeneous and resistant to segregation, even under high pumping pressures. Increased output when used in combination with a super plasticizer to give optimal pumping pressure. Reduced wear due to lubrication effect of the admixture. Assists pump restart by preventing segregation in static line.
4.3 Properties of fresh Self Compacting concrete

The main characteristics of Self Compacting Concrete are the properties in fresh state. Self - Compacting Concrete mix design is focused on the ability to flow under its own weight without vibration, the ability to flow through heavily congested reinforcement under its own weight, and the ability to obtain homogeneity without segregation of aggregates.
4.3.1 Filling ability

The ability of Self-compacting concrete to flow into and fill completely all spaces within the formwork, under its own weight is called as filling ability. It is also called as unconfined flow ability.
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4.3.2 Passing ability

The ability of Self-compacting concrete to flow through tight openings such as spaces between steel reinforcing bars without segregation and blocking is called as passing ability. It is also known as confined flow ability.
4.3.3 Segregation resistance

Segregation resistance or stability is defined as the ability of Self-compacting concrete to remain homogeneous in composition during transport and placing.
4.4 Different test methods of fresh self compacting concrete

Many different test methods have been developed in attempts to characterize the properties of Self-compacting concrete. So far, no single method or combination of methods has achieved universal approval and most of them have their adherents. Similarly, no single method has been found which characterizes all the relevant workability aspects. So, each mix design should be tested by more than one test method for the different workability parameters. The Table 4.1 shows the different tests conducted to find the fresh concrete properties of Self -Compacting Concrete. TABLE 4.1: Different tests for SCC Sl. no 1. 2. 3. 4. 5. 6. 7. Method Slump flow by Abrams cone T50 cm slump flow J-ring V-funnel V-funnel at T5 minutes L-box U-box Property Filling ability Filling ability Passing ability Filling ability Segregation resistance Passing ability Passing ability
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8. 9. 10.
Fill-box GTM screen stability test Orimet
Passing ability Segregation resistance Filling ability
For the initial mix design of Self-compacting concrete all three workability parameters are to be assessed to ensure that aspects are fulfilled. A full-scale test should be used to verify the Self-compacting characteristics of the chosen design for a particular application. For site quality to control, two test methods are generally sufficient to monitor production quality. Typical combinations are slump-flow and Vfunnel or Slump-flow and J-ring. With consistent raw material quality, a single test method operated by a trained and experienced technician may be sufficient. Some of the tests have been explained below,
4.4.1 Slump flow test and T50 cm slump flow test a) Equipment
The apparatus is shown in fig, FIGURE 4.1: Slump flow test setup
Mould is the shape of a truncated cone with the internal dimensions 200mm diameter at the base, 100mm diameter at the top and a height of 300mm, conforming to EN 12350-1(EFNARC 2002).
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Base plate of a stiff non-absorbing material, at least 700mm square, marked with a circle marking at the central location for the slump cone, and further concentric circle of 500mm diameter.
Trowel Scoop Ruler Stopwatch(optical)
b) Test procedure
About 6 liter of concrete is needed to perform the test, sampled normally. Moisten the base plate and inside of slump cone. Place the base plate on level stable ground and the slump cone centrally on the base plate and hold down firmly. Fill the cone with the scoop. Do not tamp, simply strike off the concrete level with the top of the cone with the trowel. Remove any surplus concrete from around the base of the cone. Raise the cone vertically and allow the concrete to flow out freely. Simultaneously, start the stopwatch and record the time taken for the concrete to reach the 500mm spread circle (this is the T50 time). Measure the final diameter of the concrete in two perpendicular directions. Calculate the average of the two measured diameters (this is the slump flow in mm). Note any border of the mortar or cement paste without coarse aggregate at the edge of the pool of concrete.
c) Interpretation of results
The higher slump flow value, the greater its ability to fill formwork under its weight. A value of at least 600mm is required for SCC. There is no generally accepted
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advice on what are reasonable tolerances about a specified value, though 50mm, as with the related flow table test, might be appropriate. The slump flow T50 time is a secondary indication of flow. A lower time indicates greater flow ability. The Brite EuRam research suggested that a time of 3-7 seconds is acceptable for civil engineering applications, and 2-5 seconds for housing applications. In case of severe segregation, most coarse aggregate will remain in the center of the pool of concrete and mortar and cement paste at the periphery. In case of minor segregation a border of mortar without coarse aggregate can occur at the edge of the pool of concrete. If none of these phenomena appear it is not assured that segregation will not occur, since this is a time aspect that can occur after a longer period.
4.4.2 J-Ring Test a) Equipment

The apparatus is shown in figure. FIGURE 4.2: J-Ring test setup
Mould, without foot pieces, in the shape of truncated code with the internal dimensions 200mm diameter at the base, 100mm diameter at the top and a height of 300mm.
Base plate of a stiff non absorbing material, at least 700mmsquare, marked with a circle showing the central location of the slump cone and a further concentric circle of 500mm diameter.
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Trowel. Scoop. Ruler. J-ring, a rectangular section (30mm * 25mm) open steel ring, drilled vertically with holes can be screwed threaded sections of reinforcement bar (length 100mm, diameter 10mm, and spacing 48+/-2mm).
b) Test procedure
About 6 liter of concrete is needed to perform the test, sampled normally. Moisten the base plate and inside of slump cone. Place the base plate on level stable ground. Place the J-ring centrally on the base-plate and the slump-cone centrally inside it and hold down firmly. Fill the cone with the scoop. Do not tamp, simply strike off the concrete level with the top of the cone with the trowel. Remove any surplus concrete from around the base of the cone. Raise the cone vertically and allow the concrete to flow out freely. Measure the final diameter of the concrete in two perpendicular directions. Calculate the average of the two measured diameters (in mm). Measure the difference in height between the concrete just inside the bars and that outside the bars. Calculate the average of the difference in height at four locations (in mm). Note any border of mortar or cement paste without coarse aggregate at the edge of the pool of concrete.
c) Interpretation of result
It should be appreciated that although these combinations of tests measure flow and passing ability, the results are not independent. The measured flow is certainly affected by the degree to which the concrete movement is blocked by the
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reinforcing bars. The extent of blocking is much less affected by the flow characteristics, and we can say that clearly, the greater the difference in height, the less the passing ability of the concrete. Blocking and/or segregation can also be detected visually, often more reliably than by calculation.
4.4.3 V-funnel and V-funnel at T5 minutes test a) Equipment

FIGURE 4.3: V Funnel Test Setup
V-funnel Bucket (+/-12 liter) Trowel Scoop Stopwatch
b) Test procedure
About 12 liter of concrete is needed to perform the test, sampled normally. Moisten the inside surfaces of the funnel. Keep the trap door open to allow any surplus water to drain. Close the trap door and place a bucket underneath. Fill the apparatus completely with concrete without compacting or tamping; simply strike off the concrete level with the top with the trowel.
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Open 10 seconds after filling the trap door and allow the concrete to flow out under gravity. Start the stopwatch when the trap door is opened, and record the time for the discharge to complete (the flow time). This is taken to be when light is seen from above through the funnel.
The whole test has to be performed within 5 minutes.
This test measures the ease of flow of the concrete; a shorter flow time indicates the greater flow ability. For self-compacted concrete a flow time 10 seconds is considered appropriate. The inverted cone shape restricts flow, and prolonged flow times may give some indication of the susceptibility of the mix to blocking. After 5 minutes of settling, segregation of concrete will show a less continuous flow with an increase in flow time.
4.4.4 L-box test a) Equipment

The apparatus is shown in figure. FIGURE 4.4: L-box test apparatus
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L box of a stiff non absorbing material trowel scoop stopwatch
b) Procedure
About 14 liter of concrete is needed to perform the test, sampled normally. Set the apparatus level on firm ground, ensure that the sliding gate can open freely and then close it. Moisten the inside surfaces of the apparatus, remove any surplus water. Fill the vertical section of the apparatus with the concrete sample. Leave it to stand for 1 minute. Lift the sliding gate and allow the concrete to flow out into the horizontal section. Simultaneously, start the stopwatch and record the times taken for the concrete to reach the 200 and 400 mm marks. When the concrete stops flowing, the distances H1 and H2 are measured. Calculate H2/H1, the blocking ratio. The whole test has to be performed within 5 minutes.
If the concrete flows as freely as water, at rest it will be horizontal, so H2/H1 = 1. Therefore the nearer this test value, the blocking ratio, is to unity, the better the flow of the concrete. The EU research team suggested a minimum acceptable value of 0.8. T20 and T40 times can give some indication of ease of flow, but no suitable values have been generally agreed. Obvious blocking of coarse aggregate behind the reinforcing bars can be detected visually.
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4.4.5 U-box test a) Equipment

The apparatus is shown in figure. FIGURE 4.5: U-box test apparatus
U box of a stiff non-absorbing material Trowel Scoop Stopwatch
b) Procedure
About 20litre of concrete is needed to perform the test, sampled normally. Set the apparatus level on firm ground, ensure that the sliding gate can open freely and then close it. Moisten the inside surfaces of the apparatus, remove any surplus water. Fill the one compartment of the apparatus with the concrete to sample. Leave it to stand for 1 minute. Lift the sliding gate and allow the concrete to flow out into the other compartment.
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After the concrete has come to rest, measure the height of the concrete in the compartment that has been filled, in two places and calculate the mean (H1). Measure also the height in the other compartment (H2).
Calculate H1-H2, the filling height. The whole test has to be performed within 5 minutes.
If the concrete flows as water, at rest it will be horizontal, so H1-H2=0. Therefore the nearer this test value, the filling height, is to zero, the better the flow and passing ability of concrete.
4.4.6 Fill box test a) Equipment

The apparatus is shown in figure. FIGURE 4.6: Fill box test setup
Front view
Side view
Fill box of a stiff, transparent, non-absorbing material. Scoop. Ruler. Stopwatch.

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b) Test procedure
About 45 liter of concrete is needed of perform the test, sampled normally. Set the apparatus level on firm ground. Moisten the inside surfaces of the apparatus, remove any surplus water. Fill the apparatus with the concrete. Fill the container by adding each 5 seconds one scoop with 1.5 liter of fresh concrete into the funnel until just covered the first top obstacle. Measure after the concrete has come to rest, the height at the side at which the container is filled on two places and calculate the average (h1). Do this also on the opposite side (h2). Calculate the average filling percentage. Average filling %: F= {(h1+h2)/2*h1}*100%. The whole test has to be performed within 8 minutes.
If the concrete flows as freely as water, at rest if will be horizontal, so average filling percentage =100%. Therefore the nearer this test value, better the self compacting characteristics of the concrete.
4.4.7 GTM screen stability test a) Equipment

10 liter bucket with lid 5 mm sieve 350 mm diameter sieve pan balance, accuracy 20g minimum capacity 20 kg stopwatch
b) Test procedure About 10 liter of concrete is needed to perform the test, sampled normally. Allow the concrete in the bucket to stand for 15 minutes covered with a lid to prevent evaporation.
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Determine the mass of the empty sieve pan. Inspect the surface of the concrete if there is any bleeding water and note it. Pour the top 2 liter or approximately 4,8kg 0,2kg only of the concrete sample within the bucket into a pouring container. Determine the mass of the filled pouring container. Determine the mass of the empty sieve pan. Pour all the concrete from the pouring container onto the sieve from a height of 500mm in one smooth continuous movement. Weigh the empty pouring container. Calculate mass of concrete poured onto sieve, Ma. (i.e. the difference between the weights full and empty). Allow the mortar fraction of the sample to flow through the sieve into the sieve pan for a period of 2 minutes. Remove sieve and determine mass of 'filled' sieve pan. Calculate mass of sample passing sieve, Mb, by subtracting the empty sieve pan mass from the filled sieve pan mass.
Calculate the percentage of the sample passing sieve, the segregation ratio: (Mb/Ma) x 100.
Empirical observations suggest that if the percentage of mortar which has passed through the sieve, the segregation ratio, is between 5 and 15% of the weight of the sample, the segregation resistance is considered satisfactory. Below 5% the resistance is excessive, and likely to affect the surface finish (Blow holes likely). Above 15%, and particularly above 30%, there is strong likelihood of segregation.
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4.4.8 Orimet test a) Equipment

The apparatus is shown in figure. FIGURE 4.7: Orimet test setup
Orimet device of a stiff non absorbing material bucket ( 10 liter ) trowel scoop stopwatch
b) Test procedure About 8 liter of concrete is needed to perform the test, sampled normally. Set the Orimet on firm ground. Moisten the inside surfaces of the casting pipe and the orifice. Keep the trap door open to allow any surplus water to drain. Close the trap door and place a bucket underneath. Fill the apparatus completely with concrete without compacting or tapping, simply strike off the concrete level with the top with the trowel. Open the trap door within 10 seconds after filling and allow the concrete to flow out under gravity.
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Start the stopwatch when the trap door is opened, and record the time for the discharge to complete (the flow time). This is taken to be when light is seen from above through the orifice section. The whole test has to be performed within 5 minutes.
This test measures the ease of flow of the concrete; shorter flow times indicate greater flow ability. For SCC a flow time of 5 seconds or less is considered appropriate. The inverted cone shape at the orifice restricts flow, and prolonged flow times may give some indication of the susceptibility of the mix to blocking and segregation.
4.5 Properties of hardened Self Compacting Concrete

The basic ingredients used in Self Compacting Concrete mixes are practically the same as those used in the conventional HPC, vibrated concrete, except they are mixed in different proportions and the addition of special admixtures to meet the project specifications for Self Compacting Concrete. Laboratory and field tests have demonstrated that the Self-Compacting Concrete hardened Properties are indeed similar to those of HPC. Table 4.2 shows some of the structural properties of Self Compacting Concrete. TABLE 4.2: Structural properties of SCC Item Water-binder ratio (%) Air content (%) Compressive strength(age:28 days)(M Pa) Compressive strength(age:91 days)(M Pa) Splitting tensile strength(age:28 days)(M Pa) Elastic modulus(G Pa) Shrinkage strain(*10-6) Range 25 to 40 4.5 to 6.0 40 to 80 55 to 100 2.4 to 4.8 30 to 36 600 to 800
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4.5.1 Compressive strength

Self-Compacting concrete compressive strength are comparable to those of conventional vibrated concrete made with similar mix proportions and water/cement ratio. There is no difficulty in producing Self Compacting Concrete with compressive strength up to 60M Pa.
4.5.2 Tensile strength

Tensile strength is based on the indirect splitting test on cylinders. For Self Compacting concrete, the tensile strengths are the ratios of tensile and compressive strengths are in the same order of magnitude as the conventional concrete.
4.5.3 Bond strength

Pullout tests to determine the strength of the bond between concrete and reinforcement of different diameters. In general, the Self Compacting concrete bond strengths expressed in terms of the compressive strengths are higher than those of conventional concrete.
4.5.4 Modulus of elasticity

Self -Compacting concrete and conventional concrete bear a similar relationship between modulus of elasticity and compressive strength. This is similar to the one recommended by ACI for conventional normal weight concrete.
4.6 Requirements for constituent materials

The constituent materials, used for the production of Self-compacting concrete (SCC) shall generally comply with the requirements of EN 206. The materials shall be suitable for the intended use in concrete and not contain harmful ingredients in such quantities that may be detrimental to the quality or the durability of the concrete, or cause corrosion of the reinforcement.
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4.5.1 Cement
General suitability is established for cement conforming to IS: 8112-1989.
4.5.2 Aggregates
Aggregates shall conform to IS: 383-1970. The maximum size of the aggregates depends on the particular application and is usually limited to 20mm. Particles smaller than 0.125mm contributes to the powder content. The moisture content should be closely monitored and must be taken into account in order to produce Self-compacting concrete of constant quality.
4.5.3 Mixing water

Suitability is established for mixing water and for recycled water from concrete production conforming to Bureau of Indian standards.
4.5.4 Admixtures
Admixtures used shall comply with IS: 9103-1999, specifications and physical requirements where appropriate. Super plasticizers are an essential component of Self-compacting concrete to provide the necessary workability. Other types may be incorporated as necessary, such as viscosity modifying agent for stability, airentraining admixtures to improve freeze-thaw resistance, retarders for control of setting etc. Due to the special archeological requirements of Self-compacting concrete, both inert and reactive additions are commonly used to improve and maintain the workability, as well as to regulate the cement content and so reduce the heat of hydration. Other types of admixture additions can also significantly improve the long-term performance of the concrete.
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CHAPTER 5 EXPERIMENTAL WORK

The experimental program is carried out in the following four different phases. The first phase is the material testing in which all the material properties for all ingredients of concrete are investigated. Second phase is mixing and casting of the samples, in which the optimum mix proportion of concrete is find out and then the casting and curing of samples is done. Third phase is testing of samples, in which the cured samples are tested for determining compressive strength. Fourth phase of experiment is results and discussions, which includes comparison of results obtained for concrete cubes with and without Fly ash.
5.1 Material testing

The material properties for all ingredients of concrete are already mentioned in section 3.2
5.2 Mixing and casting of samples 5.2.1 Mix proportion

One grade of concrete mixes M25 having characteristics strength of 25MPa is examined. In the absence of any codal recommendation available for designing selfcompacting concrete, the mixture proportioning was carried out by using the guidelines given by EFNARC 2002. Self-compacting concrete is largely affected by the characteristics of materials and the mix-proportion. The mix design selection and adjustments can be made according to the procedure as shown in figure. The coarse aggregate and fine aggregate contents are fixed so that self-compatibility can be achieved easily adjusting the water powder ratio and viscosity-modifying agent only.
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The following indicative typical ranges of proportion and quantities are given by the EFNARC. Water/powder content by volume 0.8 to 1.10. Total powder content 400-600 kg/m3. Coarse aggregate content 28 to 35% by volume. Water content <200 kg/m3. Sand content balances the volume of the other constituents. Adjusting the viscosity modified agent. One control mixture (MF0%) without Fly ash was designed approximately keeping in mind some of the basic concepts. Then we decided the mix proportion based on slump flow test, T50cm slump flow test and J-ring test. Over target strength is 50 N/mm2, to arrive the target strength we arrive at a mix proportion of 1:1.75:1.25 with w/c ratio=0.46, we have used an admixture named Auramix 400 to get better flow ability. From all trials finally we arrived at an admixture dosage of 0.6% by weight of binding material. The other three concrete mixtures were made by replacing cement with 30%, 40% and 50% of Fly ash by mass. Table 5.1 shows the quantities of materials required per cubic meter of concrete for various mix proportions. TABLE 5.1: Quantities of materials Sl. no. 1. 2. 3. 4. 5. 6. 7. 8. Mix identification Raw materials Cement (kg/m3) Fly ash (kg/m3) Fine aggregate(kg/m3) Coarse aggregate(kg/m3) Water/cement ratio Water content (kg/m3) Water/powder content % of C.A content by volume 423.91 0 1140.09 736.0 0.46 195 0.80 32 289.13 123.91 1181.96 705.0 0.46 190 0.85 30 242.55 161.70 1190.75 705.0 0.47 190 0.85 30 193.88 193.88 1207.24 705.0 0.49 190 0.85 30 MF0% MF30% MF40% MF50%
Admixture used was 0.60% of weight of binder.

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CHART 5.1: Mix design selection
Set required performance
Select materials Evaluate alternative materials
Adjust and design mix
Verify or adjust performance in laboratory Not ok Verify performance in concrete plant or at a site
5.2.2 Mixing
The required amount of all dry materials such as coarse aggregate (Gelly), fine aggregate (sand), cement and fly ash is weighed and placed in the concrete mixer or in a tray. It is mixed dry for one minute to get a uniform dry mix. Admixture is added in to the water and then stirred with stirrer and allow some time, to have reaction between water and admixture. The mixture of water and admixture is then added to the dry mix and then the materials are mixed properly to obtain a homogeneous concrete mix. The mixing time should not exceed 5 minutes. After proper mixing, the fresh concrete is tested for its workability, which is measured using flow ability test.
5.2.3 Casting
All ingredients were weighing and batched as per mix proportion adopted. Standard steel cube moulds of 150mm*150mm*150mm were used for casting
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purpose. The specimens are not compacted since it is self-compacting concrete, without vibration the concrete is allowed to settle by itself. Here 12 cubes are casted for each mix proportion and hence a total of 48 cubes. The details of test samples are as given in Table 5.2. TABLE 5.2: Details of test samples Sl. Types Sample size No. of sample for compressive strength test 7days 14days 28days 56days Total no.
No of mix 1. 2. 3. 4. MF 0%
of samples
150mm*
3 3 3 3
3 3 3 3
3 3 3 3
3 3 3 3
12 12 12 12
MF 30% 150mm* MF 40% 150mm MF 50%
5.2.4 Curing
In case of SCC it is always true that it extends the setting time to unavoidable circumstances of 2 days due to addition of admixture during mixing. Curing helps in protection of concrete for last specified period of time after placement to provide moisture for hydration of the cement, to provide proper temperature and to protect the concrete from damage by loading or mechanical disturbance. The necessity for curing arises from the fact that hydration of cement takes place only in water filled capillaries. For this reason, a loss of water by evaporation from the capillaries must be prevented. The concrete starts attaining its strength, immediately after setting completed and the strength continues to increase along with the time. Addition of Fly ash makes the concrete to gain later stages of strength. Generally curing period for concrete is 28 days. We have tested for 7days, 14days, 28days, and 56days strength. In the first 7days of the 65% of the actual strength is achieved.90-95% of the actual strength is attained in 28days. The strength
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achieved in 28days of curing is called as design strength. The specimens were immersed in water till the date of testing and proper schedule was prepared for their testing at 7, 14, 28 and 56 days.
5.3 Testing of concrete 5.3.1 Testing of fresh concrete

Fresh concrete is a freshly mixed material, which can be moulded into any shape. The relative quantities of cement, aggregate and water containing appropriate quantity of admixture mixed together. Control the properties of concrete in the wet state as well as in hardened state. Workability of concrete is nothing but its consistency. The factors affecting the workability are water content, size and shape of aggregate, mix proportion, grading of aggregate and use of admixture. List of test methods for workability properties of SCC is mentioned in section 4.4. The acceptance criteria for self compacting concrete are as given in table 5.3. TABLE 5.3: Acceptance criteria for SCC Sl. No Method Unit Typical range of values Minimum 1. 2. 3. 4. 5. 6. 7. 8. 9. Slump flow by Abrams cone T50cm slump flow J-ring V-funnel V-funnel at T5minutes L-box U-box Fill box GTM screen stability test mm Sec mm Sec Sec mm mm % % 650 2 0 6 0 0.8 0 90 0 Maximum 800 5 10 12 3 1.0 30 100 15
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10.
Orimet
Sec
Here each batch of concrete is tested for filling ability test by slump flow test and T50 time test and passing ability by J-ring test. The results are discussed in section 6.1 and 6.2.
5.3.2 Testing of hardened concrete

Testing of hardened concrete plays an important role in controlling and confirming the quality of cement concrete works. The test methods should be simple, direct and convenient to apply. Tests are made by casting cubes or cylinder from the representative concrete or cores cut from the actual concrete, partly because it is an easy test to perform and partly because most of the desirable characteristic properties of concrete are qualitatively related to its compressive strength. Generally the compression test is carried out on specimens cubical or cylindrical or also sometimes prisms. The cube specimen is of the size 150mm*150mm*150mm. Sometimes if the largest nominal size of the aggregate does not exceed 20mm, 100mm size cubes may also be used as an alternative. The cubes were tested properly in the Universal Compressive Testing Machine at the age of 7 days, 14 days, 28 days and 56 days. Here 3 cubes of each proportion is tested for 7 days, 14 days, 28 days and 56 days. The compressive strength was computed by using the expression given below. Compressive strength, fc = Load / Area of the cube i.e. fc = P/(b*b) Where, fc = compressive strength in MPa P = the maximum applied load in N b = width of the cube specimen in mm
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FIGURE 5.1: Placement of concrete cube for testing
FIGURE 5.2: Failure plane in the concrete cubes.
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CHAPTER 6 TEST RESULTS AND DISCUSSIONS

6.1 Effect of fly ash on fresh properties of self-compacting concrete
The main characteristics of Self Compacting Concrete are the properties in fresh state. Self - Compacting Concrete mix design is focused on the ability to flow under its own weight without vibration, the ability to flow through heavily congested reinforcement under its own weight, and the ability to obtain homogeneity without segregation of aggregates etc, and also all these properties are discussed in section 4.3.
6.1.1 Effect of fly ash on filling ability of SCC

The filling ability and was tested by slump flow test and T50cm slump flow test. The Table 6.1 gives the results of slump flow test and Table 6.2 gives the results of T50cm slump flow test. TABLE 6.1: Results of slump flow test W/C ratio 0.46 0.46 0.47 0.49 Fly ash in percentage 0 30 40 50 Mix proportion Flow value in mm 645 635 630 620 Remark For SCC minimum slump flow of 650+/-50 mm is required as per EN.
1:1.75:1.25
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TABLE 6.2: Results of T50 slump flow test W/C ratio 0.46 0.46 0.47 0.49 Fly ash in percentage 0 30 40 50 1:1.75:1.25 Mix proportion Time taken to reach 50cm diameter in sec 3 4 4 5 Remarks For SCC flow time is between 3-5 seconds as per EN requirement.
The Graph 6.1 and 6.2 shows the variation of results of slump flow and T50cm slump flow tests with the percentage replacement of cement by fly ash respectively. GRAPH 6.1: Slump flow v/s percentage of replacement
Slump flow v/s Percentage of replacement

Flow difference in mm
650 645 640 635 630 625 620 615 0 10 20 30 40 50 60
Percentage of replacement
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Graph 6.2: T50cm slump flow time v/s percentage of replacement
T50 cm flow time in seconds
T50cm flow time v/s Percentage of replacement

6 5 4 3 2 1 0 0 10 20 30 40 50 60
6.1.2 Effect of fly ash on passing ability of SCC

The passing ability was tested by J- ring test. Table 6.3 gives the results of Jring test. TABLE 6.3: Results of J-ring test Fly ash in percentage Depth measured inside the Jring in mm 33 35 38 40 Depth measured outside the Jring in mm 25 25 28 29 Difference in depth in mm 8 10 10 11 Remarks
0 10 20 30
For SCC minimum difference in depth is 10 mm as per EN requirement.
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The Graph 6.3 shows the variation of results of J-ring test with the percentage replacement of cement by fly ash. GRAPH 6.3: Depth v/s percentage replacement
Depth difference in mm
Depth v/s Percentage replacement

12 10 8 6 4 2 0 0 10 20 30 40 50 60
Discussion: It is observed from both Slump flow v/s percentage of replacement and T50cm slump flow time v/s percentage of replacement graphs that the filling ability of the SCC decreases with the increase in the percentage of replacement of cement by fly ash. In the same way, from the graph of J-ring test, also it is observed that the passing ability of SCC decreases with the increase in the percentage of replacement of cement by fly ash. This may be due to the fly ash used in our project is less finer than cement, the fineness values are given in Table 3.1 and 3.7. But the values obtained are within the limits specified by EFNARC. Hence cement can be successfully replaced by fly ash in SCC up to 50%.
6.1.3 Effect of fly ash on density of SCC

The variations of density with respect to the percentage of replacement of cement by fly ash are as given in Table 6.4.
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TABLE 6.4: Density variation of SCC W/C ratio 0.46 0.46 0.47 0.49 Fly ash in percentage 0 30 40 50 1:1.75:1.25 Mix proportion Density in kg/m3 2425 2326 2277 2207 % variation of density 4.08 6.10 8.98
The Graph 6.4 shows the variation of density of SCC with the percentage replacement of cement by fly ash. GRAPH 6.4: Density v/s percentage replacement
Density v/s Percentage replacement

2450 2400 2350 2300 2250 2200 2150 0 10 20 30 40 50 60
Density in kg/m3
Discussion: It is observed from the graph the density of concrete decreases with the increase in the percentage replacement of cement by fly ash. This is because of the lower specific gravity of fly ash i.e., lesser than the specific gravity of cement. The test results for the specific gravity of cement and fly ash are given in Table 3.1 and Table 3.7 respectively.
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6.2 Effect of fly ash on compressive strength of self-compacting concrete (Hardened properties).
The compressive strength was tested for hardened concrete after 7 days, 14 days, 28 days and 56 days of curing in water. And also all these properties are discussed in section 4.5. The variation of compressive strength with respect replacement of Fly ash and the age is shown in table and represented in the graph. TABLE 6.5: Compressive strength test results Sl. no 1. 2. 3. 4. Cement in Kg/m3 423.91 289.13 242.55 193.88 Fly ash In % 0 30 40 50 In Kg/m3 0 123.91 161.70 193.88 W/C ratio 0.46 0.46 0.47 0.49 Compressive strength in N/mm2 7 days 14 days 28 days 56 days 37.06 27.47 16.57 13.95 40.55 30.52 19.79 17.44 49.05 38.41 25.64 23.54 53.69 43.60 30.46 28.74
GRAPH 6.5: Comparison of compressive strength of different percentage of replacement with age
60 50 Compressive strength 40 30 20 10 0 0% 30% 40% Percentage of replacement 50% 7 days 14 days 28 days 56 days
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GRAPH 6.6: Variation of compressive strength with number of days for 0% replacement
60
Compressive strength
50 40 30 20 10 0 0 10 20 30 40 50 60
Number of days of curing
50 45 40 35 30 25 20 15 10 5 0 0 10 20 30 40 50 60
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35
30 25 20 15 10 5 0 0 10 20 30 40 50 60
35
30 25 20 15 10 5 0 0 10 20 30 40 50 60
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Discussion: Here it is observed that as the percentage of Fly ash increases, compressive strength of the concrete decreases to a certain extent. From the table it has been seen that the strength at 7 days decreases as the percentage of Fly ash is increased. It is further observed that the 7 day strength obtained is almost 65%-75% of 28 days strength of the concrete mix. From the compressive strength test results it is also observed that, there is a marginal increase in strength of 28 days when percentage of Fly ash added is between 30%-50%. From the above graph it can be seen that the compressive strength for individual replacement is increasing from 7 days to 28 days but the compressive strength is decreasing from 0% replacement to 50% replacement of fly ash.
6.3 Application 6.3.1 Current condition on application of self-compacting concrete

After the development of the prototype of self-compacting concrete at the University of Tokyo, intensive research was begun in many places, especially in the research institutes of large construction companies. As a result, self-compacting concrete has been used in many practical structures. The first application of selfcompacting concrete was in a building in June 1990. Self-compacting concrete was then used in the towers of a pre stressed concrete cable-stayed Shin-KibaOhashi bridge in 1991. Lightweight self-compacting concrete was used in the main girder of a cable-stayed bridge in 1992. Since then, the use of self -compacting concrete in actual structures has gradually increased. Self-compacting concrete has been successfully used in France, Denmark, Netherlands, Germany, USA and UK, apart from Japan. A typical application example of self-compacting concrete is the two anchorages of Akashikaikyo (straits) Bridge opened in April 1998, a suspension bridge with the longest span in the world (1,991 meters). The volume of the cast concrete in the two anchorages amounted to 290,000 m3. A new construction system, which makes full use of the performance of self-compacting concrete, was introduced for this. The
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concrete was mixed at the batcher plant beside the site, and was then pumped out of the plant. It was transported 200 meters through pipes to the casting site, where the pipes were arranged in rows 3 to 5 meters apart. The concrete was cast from gate valves located at 5 meters interval along the pipes. These valves were automatically controlled so that a surface level of the cast concrete would be maintained. In the final analysis, the use of self-compacting concrete shortened the anchorage construction period by 20%, from 2.5 to 2 years. Self-compacting concrete was used for all the walls of a large LNG tank belonging to the Osaka Gas Company, whose concrete casting was completed in June 1998. The volume of the self-compacting concrete used in the tank amounted to 12,000 m3. The adoption of self-compacting concrete means that (1) The number of lots decreases from 14 to 10, as the height of one lot of concrete casting was increased. (2) The number of concrete workers was reduced from 150 to 50 in the scenario. (3) The construction period of the structure decreased from 22 months to 18 months. Self- compacting concrete is often employed in concrete products to eliminate the noise of vibration. This improves the working environment at plants and makes it possible for concrete product plants to be located in the urban area. The annual production of concrete products using self-compacting concrete exceeded 2, 00,000 tons in 1996. Application in under water construction. 40000 m3 of concrete placed under water by using the Tremie method for the construction of a dry dock. Massive structures such as reinforced foundations for skyscrapers. Vertical walls & columns congested for skyscrapers. SCC pumped into column. SCC used in block fill. RMC application. Precast concrete element plants.
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CHAPTER 7 CONCLUSIONS

SCC is made from the ingredients, which are same as that used in producing in conventional concrete. It is seen from the compressive strength test conducted that there is a clear increase in the compressive strength of SCC when 50% replacement is considered with time. Hence it could be adopted as effective replacement percentage.
Self-compacting concrete, as well as conventional slump concrete requires proper mix proportion to become a durable concrete. The use of pozzolanic materials, such as Fly ash, will help self-compacting concrete more durable and prove to be a good replacement material for cement in concrete, otherwise these are waste products with no practical applications and which are costly to dispose off.
There is a considerable improvement in exposed surface (Fair Faced Concrete) and is pollution free with respect to sound pollution. Self-compacting concrete is ideal for concrete parts with complicated shapes and elements with high quality visible concrete. Use of right quality fly ash also results in reduction of water demand for desired slump flow. With the reduction of unit water content bleeding and drying shrinkage will also be reduced.
Fly ash is not highly reactive, the heat of hydration can be reduced through replacement of part of the cement by fly ash. Vibrated concrete in congested locations may cause some risk to labor in addition to noise stress. There are always doubts about the strength and durability placed in such locations. So it is worthwhile to eliminate vibration in practice, if possible.
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Chapter 8 SCOPE FOR STUDY RELATED TO THE PROJECT

1. To study the behavior of fresh concrete properties by using other methods when replacement of cement is done by Fly ash, such as 1. L-box test --- passing ability 2. V-funnel test --- filling ability 3. U-tube test --- passing ability 4. Orimet test --- filling ability 2. To study the behavior of hardened properties of concrete when cement is replaced in certain percentage by Fly ash, such as 1. Tensile strength 2. Flexural strength 3. Durability 3. To study the behavior of self-compacting concrete by using crushed stones or quarry dust. 4. To study the behavior of self-compacting concrete when partial replacement of fine aggregate with coarsely grinded Fly ash is carried out.
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REFERENCES
1. Text book on "Concrete technology" by M.S.Shetty, fifth revised edition 2002, published by S. Chand & company ltd. 2. EFNARC, specification and guidelines for self-compacting concrete, Feb 2002. 3. IS 4031:1996, Methods of physical tests for hydraulic cement. 4. IS 8112:1989, 43 grade ordinary Portland cement specification. 5. IS: 3812:1981, Specification for Fly ash for use as pozzolana and Admixture. 6. IS 383:1970, Specification for coarse and fine aggregates from natural sources for concrete. 7. IS 2386(Part 2):1963, Methods of test for aggregates for concrete: Part 1 Particle size and shape. 8. IS 2386(Part 3):1963, Methods of test for aggregates for concrete: Part 3 Specific gravity, density, voids, absorption and bulking. 9. IS 2386(Part 4):1963, Methods of test for aggregates for concrete: Part 4 Mechanical properties. 10. IS 516:1959, Indian code for method of tests for concrete. 11. Invited papers on "Self-compacting concrete" by Hajime Okamura & Masahiro Ouchi, published in journal on advance concrete technology, volume 1, no 1,5-15, April 2003. 12. Paper on "Development of properties of Self compacting concrete mixed with fly ash" by Prajapati krishnapal, Chandak Rajeev and Dubey Sanjay Kumar, published in Research journal of Engineering sciences, vol.1(3),11-14, Sept 2012. 13. Paper on "Development of Self compacting concrete by using high volume of calcareous fly ash" by I.Papayianni, E.Anastasiou, presented at World od Coal Ash conference, May 9-12, 2011 in Denver, CO, USA. 14. Paper on "Self compacting concrete containing fly ash" by J.M Khatib, published in Construction and Building materials journal, vol. 22, issue 9, September 2009, Pages 1963-1971.
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15. Paper on "Medium strength self compacting concrete containing fly ash" by Mohammed Sonebi, published in journal of Cement and Concrete research, vol. 34, issue 7, July 2004, Pages 1199-1208. 16. Paper on "Guidelines for testing fresh Self compacting concrete" by G.DE Schutter published in European Research Project, September 2005. 17. Research paper on "Incorporating European Standards for Testing SelfCompacting Concrete in India Conditions" published in International Journal of Recent Trends in Engineering, Vol. 1, No. 6, May 2009.
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Self Compacting Concrete

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To study the behavior of SCC with partial replacement of cement by Fly Ash

DEPT OF CIVIL ENGG, MCE.

1.2 Development of self-compacting concrete

1.3 General wastes used in concrete

1.3.1 Fly Ash

DEPT OF CIVIL ENGG, MCE.

1.3.1.1 Classification of Fly ash

1.3.1.1.1 Class F fly ash

1.3.1.1.2 Class C fly ash

FIGURE: 1.1 Class F fly ash

FIGURE: 1.2 Class C fly ash

DEPT OF CIVIL ENGG, MCE.

1.4 Objective of present study

DEPT OF CIVIL ENGG, MCE.

Chapter 2 LITERATURE REVIEW

DEPT OF CIVIL ENGG, MCE.

DEPT OF CIVIL ENGG, MCE.

DEPT OF CIVIL ENGG, MCE.

2.3 Scope of present investigation

DEPT OF CIVIL ENGG, MCE.

2.4 Scope of the study at a glance

2.5 Organization of the report

DEPT OF CIVIL ENGG, MCE.

CHAPTER 3 CHARACTERISTICS OF MATERIALS

3.2 Materials used

TABLE 3.2: Chemical properties of OPC

3.2.2 Coarse aggregate

DEPT OF CIVIL ENGG, MCE.

94.73 63.64 24.37 6.78 1.12 0.17 0 -

3.2.3 Fine aggregate

DEPT OF CIVIL ENGG, MCE.

4.75 2.36 1.18 0.60 0.30 0.15 Pan

96.70 93.30 70.90 55.10 9.95 1.60 0

3.2.5 Fly ash

DEPT OF CIVIL ENGG, MCE.

3.2.6 Chemical admixture

DEPT OF CIVIL ENGG, MCE.

Chapter 4 SELF COMPACTING CONCRETE

4.2 Significance of self compacting concrete

4.3 Properties of fresh Self Compacting concrete

4.3.1 Filling ability

DEPT OF CIVIL ENGG, MCE.

4.3.2 Passing ability

4.3.3 Segregation resistance

4.4 Different test methods of fresh self compacting concrete

DEPT OF CIVIL ENGG, MCE.

Fill-box GTM screen stability test Orimet

Passing ability Segregation resistance Filling ability

DEPT OF CIVIL ENGG, MCE.

Trowel Scoop Ruler Stopwatch(optical)

DEPT OF CIVIL ENGG, MCE.

4.4.2 J-Ring Test a) Equipment

DEPT OF CIVIL ENGG, MCE.

4.4.3 V-funnel and V-funnel at T5 minutes test a) Equipment

V-funnel Bucket (+/-12 liter) Trowel Scoop Stopwatch

DEPT OF CIVIL ENGG, MCE.

The whole test has to be performed within 5 minutes.

4.4.4 L-box test a) Equipment

DEPT OF CIVIL ENGG, MCE.

L box of a stiff non absorbing material trowel scoop stopwatch

DEPT OF CIVIL ENGG, MCE.

4.4.5 U-box test a) Equipment

U box of a stiff non-absorbing material Trowel Scoop Stopwatch

4.4.6 Fill box test a) Equipment