Experimental Analysis On Ultra High Performance Concerte Using Binary Packing Density Modulus-Thesis-r9

Experimental Analysis on High Performance Concrete using Binary and Ternary Packing Density Modulus
CHAPTER I
INTRODUCTION
1
Concrete
Concrete has several unusual characteristics that make it as a versatile and widely used
construction material. New developments backed by years of research have provided todays
concrete user with a unique, attractive, and practical product. Architects, engineers, and builders
have used concrete with imagination and skill to create exciting and distinctive structures.
Bouygues was the first to make the research in Reactive Powder Concrete which was first of
the kind in High Performance Concrete (HPC) to meet the demand for high strength construction
materials in the year 1990. HPC is mainly characterized with the high strength in the order of 60
MPa or above. But the ductility properties gets affected in HPC, as the concrete becomes highly
brittle with the increase in strength of the concrete. It leads to sudden blasting failure of the
concrete elements as there is no post peak load carrying capacity by the concrete element. Hence
HPC is generally reinforced with the steel fibres which have better ductile properties. HPC can
only be developed by enhancing the mechanical behavior of the concrete by choosing the right
materials, particle size of the materials and material proportioning. A concrete with high strength
can only be achieved by altering the mechanical properties of the material used in the concrete so
that any micro defects possible shall be minimized. This study mainly focuses on achieving the
maximum possible interlocking of the materials, so as to reduce the micro defects and to achieve
a higher density with a closely packed nature.
To increase the homogeneity of the concrete, smaller sized coarse aggregate is used.
Generally HPC can be produced only with lower water to binder ratio (W/B) to achieve the
higher strength. Thus high quality superplasticizer is required to increase the workability. The
ideal design of a HPC is to maintain a balance between the fluidity and the stability of the
matrix. The right fluidity is achieved using high quality superplasticizer and the stability of the
mix shall be achieved selecting the proper cement replacement materials like Silica Fume, Rice
Hush Ash, Ground Granulated Blast furnace Slag and Flyash. However Silica Fume (SF) and
Ground Granulated Blast furnace Slag (GGBS) is used in this study in various proportions to
determine the mix with best stability and higher strength. A highly dense mix shall be achieved
only by interlocking the right materials in proper gradation. Hence sub micrometer particles is
VIT University, Vellore
the key to fill the pores between the larger particles of cement. Thus the use of SF and GGBS
becomes essential to increase the interlocking of the materials.
HPC is more efficient because the concrete elements can be produced of smaller and
thinner sections due to its denser nature; the concrete elements are less susceptible to harsh
environments as the permeability is highly reduced.
1.2 Advantages of High Performance Concrete
1. The superior properties of the UPHC allows the ability to design thin, complex shapes,
curvature and highly customized textures - applications which are difficult or impossible to
achieve with traditional concrete elements.
2. The advantages of UPHC are numerous as a whole which includes reduced global costs such
as formwork, labor, maintenance and speed of construction.
3. Reduction in member size, resulting in increase in plinth area/usable area and direct savings in
the concrete volume saved.
4. Reduction in the self-weight and super imposed load with the accompanying saving due to
smaller foundations.
5. Reduction in form work area and cost with the accompanying reduction and shoring and
stripping time due to high early age gain in strength,
6. Construction of high rise buildings with accompanying savings in real estate costs in
congested areas.
7. Longer spans and fewer beams for the same magnitude of loading.
8. Reduced axial shortening of compression supporting members.
9. Reduction in number of supports and the supporting foundations due to the increase in spans.
10. Reduction in thickness of floor slabs and the supporting beam sections which are the major
component of weight and cost of the majority of the structures.
11. Superior long term service performance under static, dynamic and fatigue loading.
12. High resistance to freezing and thawing, chemical attack, and significantly improved long
term durability and crack propagation.
1.3 Applications of High Performance Concrete
Applications include bridge beams and decks, solid and perforated wall panels and
facades, urban furniture, louvers, stairs, large-format floor tiles, pipes and marine structures. The
reason for selecting HPC is that it provides a more economical aspect while considering the
entire cost incurred in the building. Generally the cost of the HPC is higher than conventional
concrete because HPC requires additional quantities of materials such as cement, flyash, silica
fume, GGBS, metakaolin, high range water reducing admixtures and retarders to meet the
specified performance. However concrete is one of the components in construction and the total
cost of the finished product is more important than the cost of an individual material. However
HPC should not be specified if there are no economical or technical advantages to be gained
from its use. The use of HPC in the columns of high rise buildings have been known for many
years. In simple terms HPC provides the most economical way to carry a vertical load to the
building foundation. The three major components contributing to the cost of the column are
concrete, steel reinforcement and form work. By using HPC, the column size is reduced.
Consequently less concrete and less formwork are required. At the same time, the amount of
vertical reinforcement can be reduced to the minimum amount allowed in code. The net result is
that the least expensive column is achieved with the smallest size column, the least amount of
reinforcement and the highest readily available concrete strength.
1.4 The Methodology of Packing Density Modulus
Generally the voids and defects in a concrete specimen or a concrete member is attributed
towards the strength reduction as the crack is initiated from the weak zone like voids and micro
defects. A concrete is classified as good concrete which has lesser voids and good homogeneity.
In order to attain a better homogeneity and a dense mix, particle size and their interaction with
each other also plays a vital role along with the other parameters such as water to binder ratio to
form a stable mix. A good mix is one which is devoid of segregation and bleeding, at the same
time should be easily workable and not harsh. This method involves in selection of particle, their
particle sizes and their interlocking properties so as to form a mix which will be highly dense.
1.1 Objective
The objective of this project is as follows:
The objective of the project is to design a high performance concrete with a

compressive strength of 60MPa.
To characterize the material properties for achieving the composite mechanical

properties
To enhance the interlocking properties of binder and filler material as a whole.
To increase the density of the concrete by using the method of Packing Density
Modulus so that the voids and micro defects are reduced to the lowest possible.
CHAPTER 2
LITERATURE REVIEW
2.1 General
Chong Wang, Changhui Yang, Fang Liu, Chaojun Wan, Xincheng Pu (2012) used smaller
coarse aggregate to enhance the property of the concrete and steel fibres was introduced to
increase the ductility of the concrete. In the study superplasticizer and large quantities of
superfine silica were added to achieve low W/B ratio to reduce porosity and to improve strength.
Also steam curing was adopted to achieve the higher strength.The test results shows that with
extremely low W/B, high binder content, multi addition of silica fume, GGBS, limestone powder
and high standard SP, HPC can be prepared with common technology. Highest compressive
strength of 175.8 Mpa at 90 days and 182.9 at 365 days were achieved. It was found that with
W/B of 0.16, binder content of 900 kg/m3 which contained 50% cement, 10% SF, 20% GGBS
and 20% limestone powder with appropriate dosage of SP were required for the successful mix.
The study made by Nguyen Van Tuan, Guang Ye, Klaas van Breugel, Oguzhan
Copuroglu (2011) focussed on the use of the rice husk ash in HPC. But the hydration and
microstructure formation of RHA was expected to vary from the commonly used admixture like
silica fume. Hence the objective of this research was to study the effect of RHA on the hydration
and microstructure development of HPC and to compare with the results obtained from the
controlled and the sample with silica fume. BSE image analysis showed that the addition of the
RHA increases the degree of cement hydration in HPC in later ages, which may be caused by the
porous structure of RHA and the uptake of water in the pore structure resulted in a kind of
internal curing RHA modified mixes. With RHA, HPC of 175 MPa at 28 days 185 MPa at 91
days were achieved.
Tina Oertel, Frank Hutter, Ricarda Tanzer, Uta Helbig, Gerhard Sextl-(2013) compared
the commonly used silica fume to the wet chemically synthesized silica. The spherical particles
had a purity of 99.97%(SiO2), and a particle size of 72 nm to 720 nm. The focus of the study
was to determine the effects of the particle characteristics on calculated particle packing
densities, the microstructure and the compressive strength of HPC. From the study it was found
that nearer the dispersion of the silica comes to the primary particle sizes, the higher is the
compressive strength. It was clear that the dispersion of the silica into primary particle sizes or
the smaller agglomerates possible is mandatory for the further improvement of compressive
strength.
The study made by R. Zaitri, M. Bederina, T. Bouziani, Z. Makhloufl, M. Hadjoudja
presents the results of an experimental program in which the mixture design modelling approach
was used in order to optimize the composition of a high performance concrete formulated from
the local materials of the area of Algeria. The valorised materials are mineral additions: siliceous
and limestone additions, obtained by fine grinding of dune sand and sieving aggregate crushing
waste respectively. Both additions are added by substitution to the cement content. In order to
model the influence of cement content and the dosages of these additions on the properties of
high performance concrete, an experimental plans method with three factors was used.
Mathematical models that explain at best test results which were identified and developed in this
work. The modelling was performed using the statistical analysis software JMP7 of Statistical
American Systems SAS-Institute. The obtained results showed that the introduction of siliceous
fillers (SF) and limestone fillers (LF) in cement leads to a significant improvement in mechanical
strength in the medium and long term which allows us to formulate a high performance concrete.
In addition, the workability has been also improved with this substitution. Moreover, it was also
shown that the use of the derived models based on the experimental design approach is very
interesting and helps us to understand the interactions between the different parameters of the
studied mixture (cement content, SF-content and LF-content).
. The experimental study made by Ehsan Ghafari, Hugo Costa, Eduardo Julio, Antonio
Portugal, Luisa Duraes aimed to evaluate the influence of nanosilica addition on properties of
ultra-high performance concrete . Thermo gravimetric analysis results indicated that nanosilica
consumes much more Ca(OH)2 as compared to silica fume, specifically at the early ages.
Mercury intrusion porosimetry measurements proved that the addition of nanosilica particles
leads to reduction of capillary pores. Scanning electron microscope observation revealed that the
inclusion of nanosilica can also efficiently improve the interfacial transition zone between the
aggregates and the binding paste. The addition of nanosilica also resulted in an enhancement in
compressive strength as well as in transport properties of the concrete. The optimum amount of
cement replacement by nanosilica in cement paste to achieve the best performance was 3 % by
weight However, the improper dispersion of nanosilica was found as a deterrent factor that
higher the percentage of the nanosilica in the cement paste there is reduction in strength.
A.M.Soliman, M.L. Nehdi studied the effect of incorporating shrinkage reducing

admixtures (SRA) and wollastonite microfibers on the early-age shrinkage behavior and cracking
potential of ultra-high performance concrete. Wollastonite microfibers were added at rates of 0%,
4% and 12% as partial volume replacement for cement, while SRA was added at 1% and 2% by
cement weight. Results show that the reinforcing effect induced by wollastonite microfibers
mitigated the reduction in compressive strength induced by SRA. Addition of wollastonite
microfibers to SRA mixtures did not impart a significant change in the measured free shrinkage
strain, while it enhanced the cracking resistance compared to that of mixtures incorporating SRA
alone. Moreover, adding wollastonite microfibers reduced the leaching of SRA from concrete
under submerged conditions, thus leading to higher efficiency of SRA in reducing shrinkage.
Partially replacing cement with natural wollastonite microfibers also leads to a reduction in the
cement factor, which represents economic and environmental benefits.
R. Yu, P. Spiesz, H.J.H. Brouwers arrived at the mix design and properties assessment of
Ultra-High Performance Fibre Reinforced Concrete (UHPFRC). The design of the concrete
mixtures is based on the aim to achieve a densely compacted cementitious matrix emplopying
particle packing model. The workability, air content, porosity, flexural and compressive strengths
of the designed UHPFRC are measured and analyzed. The results show that by utilizing the
improved packing model, it is possible to design UHPFRC with a relatively low binder amount.
Additionally, the cement hydration degree of UHPFRC is calculated. The results show that, after
28 day of curing, there is still a large amount of unhydrated cement in the UHPFRC matrix,
which could be further replaced by fillers to improve the workability and cost efficiency of
UHPFRC.
Tomasz Ponikiewski and Jacek Golaszewski has made a research that presents findings
on the influence of high-calcium fly ash (HCFA) on selected properties of fresh and hardened
self-compacting concrete and high performance self-compacting concrete. HCFA was used as an
additive for concrete (up to 30%) or as a main constituent in cement. Studies have confirmed the
possibility of HCFA use in self-compacting concrete, while maintaining the assumed workability
of fresh concrete and compressive strength of hardened concrete. HCFA should be processed by
grinding, and its amount in the mixture should not be higher than 30% of the cement's mass.
Cements that contain HCFA as the main component can be used in both normal and high
performance self-compacting concrete.
. Semion Zhutovsky, Konstanin Kovler and Arnon Bentur studied the effect of Internal
curing technology to counteract autogenous shrinkage of high-performance concrete. In the study
it was found that the total shrinkage of internally cured concrete is reported to be almost
unchanged after exposure to drying. On the other hand, shrinkage reducing admixtures have been
successfully used to reduce drying shrinkage. A hybrid curing technique that combines internal
curing with shrinkage reducing admixture has proved to be a promising approach for reduction
of total shrinkage and cracking potential of high-performance concrete. Ring test of concrete
made at water to cement ratio of 0.33 and internally cured by water-saturated lightweight
aggregate and super-absorbent polymer and their combination with shrinkage reducing agent was
studied. In parallel, compressive and splitting strength, drying shrinkage and mass loss of the
same concrete mixes were measured. The results demonstrate the synergy between internal
curing and shrinkage reducing admixture resulting in a marked reduction of cracking potential.
Jui-Sheng Cho and Anh-Duc Pham has found that the compressive strength of high
performance concrete (HPC) is a highly nonlinear function of the proportions of its ingredients.
The validity of relationships between concrete ingredients and supplementary cementing
materials was found questionable. The work made by them evaluates the efficacy of ensemble
models by comparing individual numerical models in terms of their performance in predicting
the compressive strength of HPC. The performance of support vector machines, artificial neural
networks, classification and regression trees, chi-squared automatic interaction detector, linear
regression, and generalized linear were applied to construct individual and ensemble models.
Analytical results show that the ensemble technique combining two or more models obtained the
highest prediction performance. For five experimental datasets, the ensemble models achieved
4.269.7% better error rates than those of prediction models in previous studies. This work
confirmed the efficiency and effectiveness of the proposed ensemble approach in improving the
accuracy of predicted compressive strength for HPC.
CHAPTER-3
EXPERIMENTAL INVESTIGATION
3.1 Materials Used
3.1.1 Cement
Ordinary Portland Cement of 53 Grade was used in casting the specimens. The results of
Specific Gravity, Fineness, Initial setting time and Consistency of the cement are given in Table
No.3.1
3.1.2 Fine Aggregate
The sand was sieved to remove all pebbles. The results of Specific Gravity, Fineness modulus,
Surface moisture and Bulk density of the Natural River Sand were given in Table No.3.2
3.1.3 Coarse Aggregate
The gradation of the coarse aggregate used was found using packing density for the different
particle sizes and the test results of the packing density will be given in Table No 3.3 . The
results of Specific Gravity, Water absorption and Bulk density of the coarse aggregate were given
in Table No.3.7
3.1.4 Water
Potable tap water available in laboratory with pH value of 7.01 and conforming to the
requirements of IS 456-2000 was used for mixing concrete and curing the specimen as well.
3.2 Properties of Materials
3.2.1 Cement
3.2.1.1 Specific Gravity
At first, the empty dry density bottle was weighed and taken as M 1. Then the bottle is
filled with cement and it was weighed as M 2. The density bottle can be dried and then it was
filled with part of cement and kerosene and it weighed as M 3. The density bottle was filled up to
the top of the bottle with kerosene and weighed it as M4.
Specific gravity of Cement (G) = (M2 - M1) / [(M2 - M1) (M3 - M4)]
M1 = Mass of empty density bottle
M2 = Mass of density bottle with cement
M3 = Mass of the density bottle with cement & kerosene
M4 = Mass of the density bottle filled with kerosene
3.2.1.2 Fineness (by sieve analysis)
The fineness of cement has an important bearing on the rate of hydration and hence on
the rate of gain of strength and also on the rate of evolution of heat. Finer cement offers a greater
surface area for hydration and hence faster development of strength.100 grams of cement was
taken on a standard IS 90 Sieve. The air-set lumps in the sample were broken with fingers. The
sample was continuously sieved giving circular and vertical motion for 15 minutes. The residue
left on the sieve was weighed.
3.2.1.3 Consistency
The objective of conducting this test is to find out the amount of water to be added to the
cement to get a paste of normal consistency. 500 grams of cement was taken and made into a
paste with a weighed quantity of water (% by weight of cement) for the first trial. The paste was
prepared in a standard manner and filled into the vicat mould plunger, 10mm diameter, 50mm
long and was attached and brought down to touch the surface of the paste in the test block and
quickly released allowing it to sink into the paste by its own weight. The depth of penetration of
the plunger was noted. Similarly trials were conducted with higher water cement ratios till such
time the plunger penetrates for a depth of 5-7 mm from the top. That particular percentage of
water which allows the plunger to penetrate only to a depth of 5-7 mm from the top is known as
the percentage of water required to produce a cement paste of standard consistency.
3.2.1.4 Initial setting time
The needle of the Vicat apparatus was lowed gently and brought in contact with the
surface of the test block and quickly released. It was allowed to penetrate into the test block. In
the beginning, the needle completely pierced through the test block. But after sometime when the
paste starts losing its plasticity, the needle penetrated only to a depth of 5-7 mm from the bottom.
The period elapsing between the time when water is added to the cement and the time at which
the needle penetrates the test block to a depth equal to 5-7 mm from the bottom was taken as the
initial setting time.
10
3.2.2 Natural River Sand

At first, the empty dry pycnometer was weighed and taken as M 1. Then the bottle is filled with
sand and it was weighed as M 2. The pycnometer can be dried and then it was filled with part of
sand and water and it weighed as M 3. The pycnometer was filled up to the top of the bottle with
water and weighed it as M4.
Specific gravity of Fine aggregate (G) = (M2 - M1) / [(M2 - M1) (M3 - M4)]
M1 = Mass of empty pycnometer
M2 = Mass of pycnometer& sand
M3 = Mass of the pycnometer, sand & water
M4 = Mass of the pycnometer filled with water
3.2.2.2 Surface Moisture
The quantity of sand was taken in the small pan and weighed as M 1. Then the pan was
kept in the oven for 24 hours. It was taken out and the dry weight is determined as M 2. The
difference between M1 and M2 gives the surface moisture of the sample.
3.2.2.3 Fineness Modulus (By Sieve Analysis)
The sample was brought to an air- dry condition by drying at room temperature. The
required quantity of the sample was taken (Kg). The sieves were placed in the order of size, with
larger sieve on the top, in a mechanical sieve shaker. Sieving was done for 10 minutes. The
material retained on each sieve after shaking, represents the fraction of the aggregate coarser
than the sieve considered and finer than the sieve above. The weight of aggregate retained in
each sieve was measured and converted to a total sample. Fineness modulus was determined as
the ratio of summation of cumulative percentage weight retained (F) to 100.
Percentage of material retained on any sieve Pn= (Mn/M) X 100.
Fineness modulus = total cumulative wt. retained/100
3.2.3 Coarse Aggregate
At first, the empty dry pycnometer was weighed and taken as M 1. Then the pycnometer is
filled with coarse aggregate and it was weighed as M2. Then the pycnometer was filled with part
of coarse aggregate and water and it weighed as M 3. The pycnometer was filled up to the top
with water and weighed it as M4.
11
Specific gravity of nominal coarse aggregate (G) = (M2 - M1) / [(M2 - M1) (M3 - M4)]
M1 = Mass of empty pycnometer
M2 = Mass of bottle & coarse aggregate
M3 = Mass of the bottle, coarse aggregate & water
M4 = Mass of the bottle filled with water
3.2.3.2. Water Absorption
400g of coarse aggregate was taken and their weight was determined, say W 1. The sample
was then immersed in water for 24 hours. It was then taken out, drained and its weight was
determined, say W2. The difference between W1 and W2 gives the water absorption of the sample.
Weight of the aggregate = W1
Weight of the aggregate after 24hrs immersion = W2
W = [(W2-W1)/W1]X100
3.2.3.3 Fineness Modulus (By Sieve Analysis)
The sample was brought to an air- dry condition by drying at room temperature. The
required quantity of the sample was taken (Kg). The sieves were placed in the order of size, with
larger sieve on the top, in a mechanical sieve shaker. Sieving was done for 10 minutes. The
material retained on each sieve after shaking, represents the fraction of the aggregate coarser
than the sieve considered and finer than the sieve above. The weight of aggregate retained in
each sieve was measured and converted to a total sample. Fineness modulus was determined as
the ratio of summation of cumulative percentage weight retained (F) to 100.
Percentage of material retained on any sieve Pn= (Mn/M) X 100
3.3 Test Results of Material Properties
Table _________Test Resuly]ts
3.1 Test results of Cement
S.NO
DESCRIPTION
RESULT
Specific gravity
3.23
Fineness by sieve
analysis
2%
12
Consistency
29.5 %
Initial setting time
45 min
INFERENCE
It is found from the Table 3.1, the properties of cement were within the allowable limits.
Table 3.2 Test results of Fine Aggregate
S.NO
DESCRIPTION
RESULT
Specific gravity
2.495
Surface moisture
0.11%
Fineness modulus
2.33
INFERENCE
It is found from the Table 3.2 that the properties of fine aggregate were as per the code IS
383-1973.
Table 3.3 Test results of Coarse Aggregate
S.NO
DESCRIPTION
RESULT
Specific gravity
2.556
Surface moisture
0.55%
13
Fineness modulus
2.87
INFERENCE
It is found from the Table 3.3, the properties of Coarse Aggregate were as per the code IS
383-1973.
CHAPTER 4
METHODOLOGY
4.1 GENERAL
The methodology used in the study is to design a high strength concrete of 60MPa and to
achieve the higher strength, conventional methods of mix design is not suitable. The method
used in this study involves binary packing density modulus. Hence mechanical properties of the
fillers and binders must be enhanced properly so as to enhance the total property of the matrix as
a whole. The concept of high packing density has been recently rediscovered, as a key for
obtaining high-performance cementitious materials. The paper presents predicting the packing
density of a particle mix, considerations on the parameter to be maximized during the mix-design
process are presented. Reference is made to the Maximum Paste Thickness concept, which leads
to choose a fine sand for optimizing the compressive strength of cementitious materials. Then, an
optimal material is sought, based on the following requirements: fluid consistency, classical
components i.e. ordinary aggregate, sand, Portland cement, silica fume, GGBS, superplasticizer,
water, and moderate thermal curing.
4.2 Packing Density of Coarse Aggregate
Packing density for the coarse aggregate is initially found for the different particle sizes
possible. This is done by collecting the samples passing and retained from different standard
sieve sizes. The various samples corresponding to different particle sizes are then taken in a
container of known volume to know its packing density. From the various journals, it is well
known that for achieving the higher strength the size of aggregates should be reduced which will
increase the density of concrete and reduce the micro defects and voids.
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Table 4.1: Packing Density of Coarse Aggregate
S.NO
PASSED
RETAINED
3
DENSITY (kg/m )
10
4.75
1355
9.5
4.75
1344
4.75
2.8
1363
4.75
2.36
1363
The packing density for the different particle sizes are given in Table 4.1. The particle
sizes considered for the study is lesser than 10 mm because smaller the aggregates, greater will
be the packing density which is a very important parameter in achieving a higher strength.
15
1365
1363
1363
1360
1355
1355
1350
PACKING DENSITY IN kg/m3
1345
1344
1340
1335
1330
0.5 1 1.5 2 2.5 3 3.5 4 4.5
PROPORTIONS
Fig4.1: Packing Density of the Coarse Aggregate

It is observed that the packing density is 1355 kg/m 3 for the particles passing through 10
mm standard sieve and retained on 4.75 mm standard sieve from the Fig 4.1. And
correspondingly the packing density is 1344 kg/m 3, 1363 kg/m3, 1363 kg/m3 for the particles
sizes trapped in between 9.5-4.75 mm, 4.75-2.8 mm, 4.75-2.36 mm standard sieve sizes
16
respectively. Thus the maximum packing density is achieved for the particles of size between
4.75 mm and 2.36 mm. The size of coarse aggregate that is selected to be used in the study from
the test results achieved by packing density test is 4.75 mm 2.36 mm.
4.3 Packing Density of Fine Aggregate
Packing density for the fine aggregate is initially found for the different particle sizes
possible. This is done by collecting the samples passing and retained from different standard
sieve sizes. The various samples corresponding to different particle sizes are then taken in a
container of known volume to know its packing density. The importance of fine aggregate is that
it fills the voids present between the coarse aggregate. The selection of materials in the concrete
should be based on the interlocking of best materials at proper proportions. Thus the size of fine
aggregates is also an important factor to achieve the maximum interlocking of the filler materials
possible.
Table 4.2 : Packing Density of Fine Aggregate
S.NO
PASSED
RETAINED
3
DENSITY (kg/m )
4.75
75
1522
2.8
75
1578
2.36
75
1578
1.7
75
1506
1.18
75
1427
4.75
150
1538
2.8
150
1506
2.36
150
1506
1.7
150
1492
10
1.18
150
1502
17
The packing density for the different particle sizes are given in Table 4.2. The packing
density for the fine aggregate is found for the possible particle sizes and are provided as given in
the table.
1600
1578
1578
1550
1538
1522
1506
1500
1506
1506 1502
1492
PACKING DENSITY IN kg/m3

1450
1427
1400
1350
0
10
12
PROPORTIONS
Fig 4.2: Packing Density of the Fine Aggregate

It is observed that the packing density is 1522 kg/m 3 for the particles passing through 4.75
mm standard sieve and retained on 75 standard sieves from the Fig 4.2. And correspondingly
the packing density is 1578 kg/m3, 1578 kg/m3, 1506 kg/m3, 1427 kg/m3, 1538 kg/m3, 1506
kg/m3, 1506 kg/m3, 1492 kg/m3, 1502 kg/m3 for the particles sizes trapped in between 2.8 mmVIT University, Vellore
18
75 , 2.36 mm- 75 , 1.7 mm-75 , 1.18 mm- 75 , 4.75 mm-150 , 2.8 mm- 150 , 2.36 mm150 , 1.7 mm- 150 , 1.18 mm- 150 standard sieve sizes respectively. Thus the maximum
packing density is achieved for the particles of size between 2.36 mm and 75 . The size of fine
aggregate that is selected to be used in the study from the test results achieved by packing
density test is 4.75 mm 2.36 mm.
4.4 Packing Density of the Binary Filler Material
This step results in obtaining the coarse aggregate to fine aggregate ratio for the mix.
After attaining the optimized particle size for the coarse and fine aggregate individually, it is
required to know the ratio at which both the material act together to give the best ;outcome i.e. in
this case the maximum density. As discussed earlier, higher strength can be achieved by
enhancing the mechanical properties as individual and as a whole. In this process the packing
density is determined for the coarse and fine aggregate together in three ratios.
Table 4.3: Packing density for Binary Filler Material
MIX
S.NO
C.A:F.A
DENSITY (Kg/m3)
60:40
1655
50:50
1665
3
40:60
1661
The packing density was found for different ratios of coarse to fine aggregate ratio are
tabulated in Table 4.3 and it could be observed that the highest packing desity is arrived for the
19
mix
with
ratio
of
50:50.
PACKING DENSITY FOR BINARY MIX

1666
1665
1664
1662
1661
1660
PACKING DENSITY IN Kg/m3 1658
1656
1655
1654
1652
1650
0.5
1.5
2.5
3.5
BINARY MIX
Fig 4.3 : Packing Density of Binary Filler Material

It is found that the maximum packing density is achieved for the coarse to fine aggregate
ratio of 50:50 from the Fig 4.3.
4.5 Influence of Binder Proportions

The next important factor for designing the high strength concrete is the selection of
binder material and their composition in different possibilities. In this study Ordinary Portland
Cement, Silica Fume and Ground Granulated Blast Furnace Slag are the materials used as binder
materials.
Mineral admixtures Silica Fume and GGBS are used because
20
GGBS and Silica Fume are micro particles finer than cement which helps in
interlocking mechanism, i.e. filling the voids between the cement particles.
The addition of Silica fume and GGBS is also required as the cement content will be
higher in HPC, and some percent of cement can be replaced with silica fume and
GGBS.
Silica Fume and GGBS are also used in the HPC generally because those materials
are highly reactive and helps in gaining higher strength compared to the conventional
concrete.
There are different binder proportions that will be used in the study. From the test results,
the best possible mix shall be selected as the mix for the HPC by the method of Binary Packing
Density Modulus.
Replacement of Cement
Silica
Fume
Mix A
Mix B
5%
GGBS
Mix C
10%
15%
Mix D
0%
Mix E
25%
Mix F
50%
For the above mixes various tests are carried out initially to know about their properties.
Consistency, Initial setting time and Final setting time are the tests required to determine the
properties for the different mixes.
4.6 Standard Consistency test
Consistency test was carried out by using the Vicat Apparatus as shown in Fig 4.4, the
percentage of water required to produce a cement paste of standard consistency has been found
21
out. This test is significant to find the initial setting time, final setting time and to find the
amount of water required for the casting of concrete. Consistency test gives the water content
required for the binder at which the mix shall be easily workable.
Fig 4.4: Standard Consistency Test

The objective of conducting this test is to find out the amount of water to be added to the
cement to get a paste of normal consistency. 500 grams of cement was taken and made into a
paste with a weighed quantity of water (% by weight of cement) for the first trial. The paste was
prepared in a standard manner and filled into the vicat mould plunger, 10mm diameter, 50mm
long and was attached and brought down to touch the surface of the paste in the test block and
22
quickly released allowing it to sink into the paste by its own weight. The depth of penetration of
the plunger was noted. Similarly trials were conducted with higher water cement ratios till such
time the plunger penetrates for a depth of 5-7 mm from the top. That particular percentage of
water which allows the plunger to penetrate only to a depth of 5-7 mm from the top is known as
the percentage of water required to produce a cement paste of standard consistency.
4.7 Consistency Test Results

The consistency test is carried out for all the six mixes and the test results are given in
Table 4.4
Table 4.4: Standard Consistency Test Result
TRIAL NO.
WT. OF THE
BINDER (g)
WATER
CONTENT (ml)
% of WATER
NEEDLE
PENETRATION
(mm)
95 % CEMENT + 5% SF
400
100
25
34
400
112
28
28
400
116
29
13
400
120
30
90 % CEMENT + 10% SF
400
112
28
31
400
116
29
28
400
120
30
18
400
122
30.5
10
400
124
31
400
112
28
33
400
116
29
31
400
120
30
28
400
124
31
15
400
126
31.5
400
128
32
D
1
100 % CEMENT + 0% GGBS

400
100
25
32
23
400
108
27
27
400
112
28
22
400
116
29
13
400
118
29.5
400
120
30
75 % CEMENT + 25 % GGBS
400
112
28
26
400
116
29
19
400
120
30
14
400
122
30.5
10
400
124
31
400
112
28
31
400
116
29
23
400
120
30
14
400
122
30.5
12
400
124
31
400
126
31.5
The consistency values for the different mix is found for the water percentage at which
the penetration of the plunger is equal to 5 to 7 mm from the top of the surface of the vicat
mould. The standard consistency values for the different mix are thus tabulated in Table 4.4.
Table 4.5 gives the consolidated result of the standard consistency test for all the mixes.
Table 4.5: Standard Consistency values for the different mixes

MIX
RATIO
CONSISTENCY (%)
95 % CEMENT + 5% SF
30
24
31
31.5
29.5
31
31.5
Standard Consistency Test Result

32
31.5
31.5
31
31.5
31
31
30.5
Consistency (%)
30 30
29.5
29.5
29
28.5
Mix ID
Fig 4.5 : Standard Consistency Test Result
25
It is understood that the water requirement is around 30 % for all the mixes from the
Table 4.5. Although the water requirement is lesser for the consistency test carried out only with
cement. Upon addition of silica fume and GGBS the consistency value is increased by less value.
4.8 Initial Setting Time (IST)
Initial Setting Time is required to know about the reactivity of the concrete upon
addition of water to the mix. IST gives the time at which the concrete stars setting and loses its
plastic nature. This is important to know about the behavior of concrete with time. During the
test the needle of the Vicat apparatus was lowed gently and brought in contact with the surface of
the test block and quickly released. It was allowed to penetrate into the test block. In the
beginning, the needle completely pierced through the test block. But after sometime when the
paste starts losing its plasticity, the needle penetrated only to a depth of 5-7 mm from the bottom.
The period elapsing between the time when water is added to the cement and the time at which
the needle penetrates the test block to a depth equal to 5-7 mm from the bottom was taken as the
initial setting time.
Table 4.6: Initial Setting Time Test Result
MIX
A
RATIO
95 % CEMENT + 5% SF
IST (MIN)
40
40
45
45
100
F
165
The initial setting time for the different mixes was found and are tabulated in Table 4.6.
Initial Setting time is important to understand the reactivity of the cementitious materials upon
addition of the water to the mix.
26
Intial Setting Time of Binder

200
165
150
IST (min) 100
100
50
0
40
45
40
45
D
Mix ID
Fig 4.6: Initial Setting Time of Binders

It is found that the Initial setting time is 40 for the test block only with cement and silica
fume combination from the Table 4.6. But addition of GGBS has increased the initial setting time
drastically.
4.9 Final Setting Time (FST)
Final Setting Time is carried out to know the time at which the binder loses its plasticity
completely and attains a hardened stage. It is found by replacing the needle in vicat apparatus
with a needle with annular ring arrangement. The test procedure is same as that of initial setting
time. The needle is made to touch the test block and released. Final setting time is the time at
which the needle can penetrate and make a mark on the test block whereas the annular ring will
not make any impression. This time indicates that the binder has attained sufficient hardness to
resist the penetration of the needle.
27
Fig 4.7: Final Setting Time Test

Table 4.7: Final Setting Time of the Binders
28
MIX
RATIO
FST (MIN)
95 % CEMENT + 5% SF
150
135
150
165
220
The final setting time is found for all the mixes and the results are tabulated in the Table
4.7.
Final Setting Time of Binder

300
275
250
220
200
FST (min) 150 150
100
165
150
135
50
0
Mix ID
Fig 4.8: Final Setting Time of Binders

It is understood that the test block made with only cement and silica fume combination
has similar results from the Fig 4.8. However with the addition of the GGBS the final setting
time has increased drastically.
29
Setting Time of Binders

300
275
250
f(x) = 25.57x + 93
R = 0.78
220
200
165
150
IST
Time (min)
100
50
150
Linear (IST)
135
f(x) = 23x - 8
R = 0.72
150
FST
40
45
Linear (FST)
100
40
165
45
Mix ID
Fig 4.9: Initial and Final Setting Time of Binders
It can be seen that the pattern is identical for both initial and final setting time as
observed from Table 4.9. Upon addition of GGBS the setting time of the binder increases
drastically.
4.10 Influence of Binder to Total Aggregate Ratio
The next important parameter in designing the HSC is to arrive at the binder to total
aggregate ratio. Having arrived at the particle size of the filler material individually and
incorporating the relation between fine and coarse aggregate by arriving at the coarse aggregate
to fine aggregate ratio which gives the maximum packing density, choosing the binder
proportion, determining the water requirement, initial and final setting time for the proposed
mixes, the final step involved in the design process is to arrive at the binder to total aggregate
30
ratio which shall be favorable and helps in establishing better mechanical properties of all the
materials in the concrete so as to improve the strength of the concrete.
The binder to total aggregate shall be assumed to desired values based on the binder
content and density of the concrete that will result based on the ratio that is assumed. Initially the
binder to total aggregate ratio is chosen arbitrarily as 0.2, 0.4, and 0.6. The density and binder
content is thus arrived as given below.
the binder to total aggregate is 0.2
Binder content
= 333 kg/m3
Density
= 1998 kg/m3
When the binder to total aggregate is 0.4
Binder content
= 666 kg/m3
Density
= 2331 kg/m3
Binder content
= 999 kg/m3
Density
= 2664 kg/m3
From the above values, the binder to total aggregate ratio of 0.4 is desirable as it gives an
appropriate density and binder content of a high strength concrete. However binder to total
aggregate ratio of 0.45 and 0.5 is also considered for casting.
Binder content
= 749.25 kg/m3
Density
= 2414.25 kg/m3
Binder content
= 832.5 kg/m3
Density
= 2497.5 kg/m3
31
Thus the different binder to total aggregate (B/TA) that will be used in the study are given as
below,
0.40
B/TA
0.45
0.50
Binder Content= 666

kg/m3
Density=2331 kg/m3
Binder Content=
749.25 kg/m3
Density=2414.25
kg/m3
Binder Content=
832.5 kg/m3
Density=2497.5 kg/m3
32
CHAPTER 5
TEST RESULTS AND DISCUSSIONS
5.1 General
After completing the initial tests of the materials used, determining their particle
interactions using packing density method, considering the mineral admixtures to be used in the
project and analyzing the water requirement for the different mixes and finally arriving at the
binder to total aggregate ratio, concrete has to casted with variables like water to binder ratio, SP
dosage and different curing regimes to arrive at the best mix.
The concrete cube of size 100mmx100mmx100mm is casted for the conventional mix
with different variables to arrive at the optimum design mix. The cubes are casted in different
sets with two constant factors and a variable factor.
33
Fig 5.1 Casted Specimens
Initially the W/B and SP dosage is fixed to 0.3 and 2% and casted for the three proposed
binder to total aggregate ratios for compressive strength of 7 days and 28 days. And the test
results are given in Table 5.1
Table 5.1: Compressive Strength for W/B=0.3 & SP=2%
MIX ID
W/B
RATIO
SP %
B/TA
STRENGT
H
(7 days)
STRENGT
H
(28 days)
TM1
0.3
0.4
15.2
38.3
TM2
0.3
0.45
16.5
42.8
TM3
0.3
0.5
14.8
41.6
34
W/B=0.3 & SP=2%

45
40
35
42.8
41.6
38.3
30
25
S TRENGTH
days )
Strength (N/mm2
) (7
20
15
S TRENGTH (28 days )
16.5
15.2
14.8
10
5
0
TM1
TM2
TM3
Mix ID
Fig 5.2: Compressive Strength for W/B=0.3 & SP=2%
The next set is cast with W/B and SP dosage fixed to 0.25 and 2% and casted for the three
proposed binder to total aggregate ratios for compressive strength of 7 days and 28 days. And the
test results are given in Table 5.2
STRENGTH
MIX ID
W/B
RATIO
SP %
B/TA
(7 days)
(28 days)
TM4
0.25
0.4
29.9
48.3
TM5
0.25
0.45
35.4
45.2
TM6
0.25
0.5
40.1
46.7
35
W/B=0.25 & SP=2%

60
50
48.3
46.7
45.2
40.1
40
35.4
Strength (N/mm2
) 30 29.9
S TRENGTH (7 days )
20
10
0
TM4
TM5
TM6
Mix ID
Fig 5.3: Compressive Strength Test for W/B=0.3 and SP=2%
The next set is cast with W/B and SP dosage fixed to 0.3 and 1% and casted for the three
proposed binder to total aggregate ratios for compressive strength of 7 days and 28 days. And the
STRENGTH
(7 days)
(28 days)
MIX ID
W/B
RATIO
SP %
B/TA
TM7
0.3
0.4
18.7
45.4
TM8
0.3
0.45
21.5
38.9
36
TM9
0.3
0.5
41.2
47.1
W/B=0.3 & SP=1%

50
45
47.1
45.4
40
41.2
38.9
35
30
S TRENGTH
(7 days )
Strength (N/mm2
) 25
20 18.7
21.5
15
10
5
0
TM7
TM8
TM9
Mix ID
Fig 5.4: Compressive Strength Test for W/B=0.3 & SP=1%
The next set is cast with B/TA and SP dosage fixed to 0.5 and 1.5% and casted for the
three W/B ratio= 0.21, 0.22 and 0.23 for compressive strength of 7 days and 28 days. And the
Table 5.4: Compressive Strength for B/TA=0.45 & SP=1.5%
STRENGTH
MIX ID
W/B
RATIO
SP %
B/TA
(7 days)
(28 days)
TM10
0.21
1.5
0.5
31.3
48
TM11
0.22
1.5
0.5
21.9
44.2
37
TM12
0.23
1.5
0.5
30.3
44
B/TA=0.5 & SP=1.5%

60
50
48
44.2
44
40
31.3
S TRENGTH
(7 days )
Strength (N/mm2
) 30
30.3
21.9
20
10
0
TM10
TM11
TM12
Mix ID
Fig 5.5: Compressive Strength for B/TA=0.45 & SP=1.5%
The next set is cast with B/TA and SP dosage fixed to 0.45 and 1.5% and casted for the
three W/B ratio= 0.21, 0.22 and 0.23 for compressive strength of 7 days and 28 days. And the
Table 5.5: Compressive Strength for B/TA=0.45 & SP=1.5%
STRENGTH
MIX ID
W/B
RATIO
SP %
B/TA
(7 days)
(28 days)
TM13
0.21
1.5
0.45
38.2
45.7
38
TM14
0.22
1.5
0.45
31.4
49.1
TM15
0.23
1.5
0.45
30
45.6
B/TA=0.45 & SP=1.5%

60
50
49.1
45.7
40
45.6
38.2
31.4
S TRENGTH
days )
Strength (N/mm2
) (730
30
20
10
0
TM13
TM14
TM15
Mix ID
Fig 5.6: Compressive Strength for B/TA=0.45 & SP=1.5%

The next set is cast with B/TA and SP dosage fixed to 0.5 and 1% and casted for the three
W/B ratio= 0.21, 0.22 and 0.23 for compressive strength of 7 days and 28 days. And the test
results are given in Table 5.6
Table 5.6: Compressive Strength for B/TA=0.5& SP=1%
STRENGTH
MIX ID
W/B
RATIO
SP %
B/TA
(7 days)
(28 days)
TM16
0.21
0.5
34
43
39
TM17
0.22
0.5
34.6
42.8
TM18
0.23
0.5
34.9
41.5
B/TA=0.5 & SP=1%

50
45
40
35
43
42.8
41.5
34
34.6
34.9
30
25days )
S TRENGTH
Strength (N/mm2
) (7
20
15
10
5
0
TM16
TM17
TM18
Mix ID
Fig 5.7: Compressive Strength for B/TA=0.5& SP=1%
40
Fig 5.8: Failure Pattern of the specimens
Fig 5.9: Failure Pattern of the Specimens
41
From the initial trial mixes casted and tested, four best mixes are chosen and casted by
replacing cement with GGBS by 25% and the compressive test results are given in Table 5.7
Table 5.7: Compressive Strength Results of Trial Mix with GGBS
MIX ID
W/B RATIO
SP %
B/TA
Strength in
N/mm2
(28 days)
TM19
0.25
0.4
51.7
TM20
0.25
0.5
49.3
TM21
0.21
1.5
0.5
54.8
TM22
0.22
1.5
0.45
59.4
42
Compressive strength
70
60
59.4
54.8
50
51.7
49.3
40
Strength (N/mm2 )
30
20
10
0
TM19
TM20
TM21
TM22
Mix ID
Fig 5.10:
43
Compressive Strength of Trial Mix with 25% of GGBS
5.2 Final Mix

The best mix is chosen from the 22 mixes that were casted before with different
parameters such as
i.
ii.
iii.
Water to Binder ratio (W/B)

Binder to Total Aggregate ratio (B/TA)
SP dosage
The first 18 mix were casted with 100% cement as binder material and the optimization
of the parameters used in the study as per packing density modulus is decided based on the
compressive strength achieved for a particular mix. From the consistency test results it was
found that the water requirement for the binder is around 30 % for all the mixes. And the size of
coarse aggregate to be used in the mix were finalized to particle size passing from 4.75 mm and
retaining on 2.36 mm sieve size. To optimize the interlocking properties between binder and total
aggregate three binder to total aggregate ratios were considered- 0.40, 0.45 and 0.50. The first
three trial mixes were casted with W/B= 0.3 and SP dosage= 2% with varying B/TA and it was
observed that the mix was highly flowable and instable. Thus for the next three mixes i.e. for
TM4-6, the W/B is reduced to 0.25 with SP dosage of 2%. The further mix were casted with
casted with changing the SP dosage. The stable and mix with good form were observed for mixes
with low W/B in the order of 0.21, 0.22 and 0.23. From the eighteen mixes, four mixes were
selected which produced better compressive results and were casted with 25% replacement of
cement with GGBS and were tested. The best trial mix produced a compressive strength of
59.4Mpa and the mix produced a consistent better result with conventional mix also. Thus the
further castings were proceeded with the following parameters which were consistent in
producing better compressive strength results and also had better workability.
Thus the final mix used in the study had following parameters
I.
II.
III.
Water to binder ratio,(W/B)

SP dosage, (SP)
Binder to total aggregate ratio,(B/TA)
= 0.22
= 2%
= 0.45
44
45
Fig 5.11: Specimens cured under different Curing Regimes

5.3 Curing Regimes
Three different curing regimes were considered for the study for the final mix and were
casted for all the 6 different mixes. The curing regimes used in the study were,
i.
ii.
iii.
Normal Water Curing

Hot Air Oven Curing
Steam Curing
5.4 Normal Water Curing

The strength gain in concrete with age is due to the hydration process of cement which
forms a matrix to bond together the aggregates. The process of hydration is a long process and is
initiated with the addition of the water to the cement. And even after addition of water during
casting, water is required for the hydration process to continue. So water curing is required to
provide moisture to the concrete to make the concrete attain its strength. Normal water curing
provides moisture content and favorable temperature for the hydration process to take place.
Lack of water also causes the concrete to shrink, which leads to tensile stresses within the
concrete.
5.5 Hot Air Oven Curing
Hot air oven curing is the process of curing the concrete at elevated temperatures by
application of heat. In this method hot air is used for the curing of the specimens. Generally such
type of curing is suitable for geopolymer materials, since polymerization is the process that takes
place in geopolymer concrete and by application of heat, the process of polymerization is much
enhanced. There are two different temperature conditions adopted in this curing- 100C and
200C. But various literatures have shown that the curing process is much positive when hot air
oven curing is carried out at 100 C. At elevated temperature beyond 100C, breaking of
polymerization bonds occurs thereby reducing the strength of concrete. Hence in this study hot
air oven curing is carried out at a temperature of 100 C.
5.6 Steam Curing
Steam curing is the process of curing the concrete by application of steam in a closed
chamber. There are two methods in steam curing- warm water curing and accelerated curing.
Warm water curing is carried out at 75C for 6-8 hours. The process of warm water curing
46
produces good results in concrete with mineral admixtures because the process of polymerization
is enhanced at this optimum elevated temperature. However by increasing the temperature
beyond this curing regime, the process is accelerated, however better results are produced with
warm water curing. Hence warm water curing is used in this study.
5.7 Casting of specimens for the final mix
The final mix is casted for all the 6 binder conditions- conventional, cement replacement
by silica fume for 5%, 10% and 15%, cement replacement by GGBS for 25% and 50%. The test
specimens were casted for 28 days compressive strength.
5.8 Strength Results for Normal Water Curing
The strength results for the all the six mixes under normal water curing are tabulated in
Table 5.8
Table 5.8 Compressive Strength Results for Normal Water Curing
Strength in N/mm
Mix
Ratio
95 % CEMENT + 5% SF
51.3
53.2
47.7
48.4
52.3
54.4
47
56
54.4
54
53.2
52.3
52
51.3
Strength (N/mm2) 50
48
48.4
47.7
46
44
Mix ID
Fig 5.12: Compressive Strength Test Result for Normal Water Curing
It is understood from the Fig 5.11 that the maximum compressive strength is achieved for
the mix with 50 % GGBS by attaining a compressive strength of 54.4 MPa followed by the mix
with 10% Silica Fume attaining a compressive strength of 53.2 MPa. The result attained was
poor for the mix with 15% silica fume and conventional concrete. The addition of silica fume
beyond 10% has negative impact on the compressive strength of the concrete. Also it is
understood from the study that the mix with mineral admixtures- GGBS and Silica Fume has
shown better results comparative to the conventional concrete for the normal water curing
condition. However it should be understood from the above test result that the addition of
mineral admixtures should be limited to the optimum percentage beyond which the strength gain
is reduced.
5.9 Strength Results for Hot Air Oven Curing
The strength results for the all the six mixes under hot air oven curing are tabulated in
Table 5.9
48
Table 5.9: Compressive Strength Results for Hot Air Oven Curing
Strength in N/mm
Mix
Ratio
95 % CEMENT + 5% SF
49.2
50.5
48.7
43.6
49.8
51.4
54
52
51.4
50.5
50
49.8
49.2
48.7
48
Strength (N/mm2) 46
44
43.6
42
40
38
Mix ID
Fig 5.13: Compressive Strength Test Result for Hot Air Oven Curing
49
the mix with 50 % GGBS by attaining a compressive strength of 51.4 Mpa followed by the mix
with 10% Silica Fume attaining a compressive strength of 50.5 Mpa. The result attained was
poor for the mix with 15% silica fume and conventional concrete. The addition of silica fume
beyond 10% has negative impact on the compressive strength of the concrete. Also it is
understood from the study that the mix with mineral admixtures- GGBS and Silica Fume has
shown better results comparative to the conventional concrete for the hot air oven curing
condition. However it should be understood from the above test result that the addition of
mineral admixtures should be limited to the optimum percentage beyond which the strength gain
is reduced. While comparing the curing regimes it is found that the normal water curing has
given better results than hot air oven curing. Generally hot air oven curing is suitable for
geopolymer concrete where polymerization process is the main chemical reaction causing the
strength gain of the concrete mix. However the main governing factor in this study is the process
of hydration since cement content is higher in conventional and mix with silica fume
replacement. The mix with 50% GGBS where both process are predominant has produced higher
strength in hot air oven curing condition. But strength gain is not predominant over the normal
water curing because of the low water to binder ratio where the water required for the hydration
process is not available under hot air oven curing condition.
5.10 Strength Results for Steam Curing
The strength results for the all the six mixes under steam curing are tabulated in Table
5.10
Table 5.10: Compressive Strength Results for Steam Curing
Strength in N/mm
Mix
Ratio
95 % CEMENT + 5% SF
54.9
53.2
49.5
50
43.7
44.8
56.8
60
54.9
56.8
53.2
50
49.5
44.8
43.7
40
Strength (N/mm2) 30
20
10
0
Mix ID
Fig 5.14: Compressive Strength Test Result for Steam Curing

the mix with 50 % GGBS by attaining a compressive strength of 56.8 Mpa followed by the mix
with 5% Silica Fume attaining a compressive strength of 54.9 Mpa. The result attained was poor
for the mix with 25% GGBS and conventional concrete. The addition of silica fume beyond 10%
has negative impact on the compressive strength of the concrete. Also it is understood from the
study that the mix with mineral admixtures- GGBS and Silica Fume has shown better results
comparative to the conventional concrete for the steam curing condition. However it should be
understood from the above test result that the addition of mineral admixtures should be limited to
the optimum percentage beyond which the strength gain is reduced. The strength of concrete
with 5% and 10% of Silica Fume are almost consistent in this type of curing. The strength
51
attained for conventional mix and mix with 25% of GGBS also have got similar strength of
43.7Mpa and 44.8Mpa.
5.11 Strength Comparison for different curing regimes
The compressive strength achieved for all the six mixes under three different curing
regimes- Normal water curing, hot air oven curing and steam curing are given in Table 5.11
Table 5.11: Compressive Strength Results for different curing regimes
Strength in N/mm2
Mix
Ratio
Normal Water
Curing
Hot Air Oven

Curing
Steam Curing
95 % CEMENT + 5% SF
51.3
49.2
54.9
53.2
50.5
53.2
47.7
48.7
49.5
48.4
43.6
43.7
52.3
49.8
44.8
54.4
51.4
56.8
52
58
56.8
56
54.9
54
54.4
53.2
52
52.3
51.4
51.3
50.5
50
49.8
49.5
48.7
49.2
Stre ngth (N/mm2) 48

Normal water Curing
46
48.4
47.7
Hot Air Oven Curing
Steam Curing
44.8
44
43.7
43.6
42
40
Mix ID
Fig
5.15: Compressive strength result comparison for different curing regimes
It could be found from the Fig 5.14 that the compressive strength achieved under normal
water curing is consistent for all the mixes producing higher strength of 54.4Mpa for the Mix F
with 50% GGBS followed by strength attainment of 53.2 Mpa for the Mix B with 10% silica
fume. For specimens cured under hot air oven curing, the maximum strength was achieved for
Mix F by attaining a compressive strength of 51.4Mpa followed by Mix B with 50.5Mpa. For the
steam curing regime, the maximum strength of 56.8Mpa is achieved for the Mix F followed by
Mix A with compressive strength of 54.9Mpa and Mix B with compressive strength of 53.2Mpa.
The test results were consistent for all the mixes when cured under normal water curing
condition. For the other two curing regimes there is a remarkable decrease in compressive
strength for Mix D and Mix E.
5.11 Ternary Mix
The main objective of the study is to increase the density of the concrete by enhancing
the properties of filler and binder materials and enhancing the interlocking of the materials in the
concrete as the whole. From the packing densities of the coarse and fine aggregate for different
particle sizes, the size of coarse and fine aggregate particles that was used in the project was
found. The optimization of packing density was proceeded by determining the water requirement
for the mix using consistency test and arbitrarily assuming the binder to total aggregate ratio to
53
0.40, 0.45 and 0.50. From the compressive strength achieved for the different mixes the final mix
was achieved with W/B=0.22, SP dosage= 1.5% and B/TA=0.45. The final mix was casted and
cured under different curing regimes. From the compressive strength test results, it was found
that the mix with 50% GGBS and the mix with 10% silica fume as binders produced consistently
better result in all the curing conditions. Thus the final ternary mix was casted with 10% silica
fume and 50% GGBS by using the method of re-vibration. And the strength results are given in
Table 5.12
Table 5.12: Compressive Strength Results for the Ternary Mix
Mix Ratio
Normal Water Curing
Hot Air Oven Curing
Steam Curing
40% Cement + 10%

SF + 50 % GGBS
58.4
53.7
62.7
40% Cement + 10% SF + 50 % GGBS

62.7
64
62
58.4
60
58
56
53.7
54
52
50
48
Normal Water Curing
Hot Air Oven Curing
Steam Curing
Fig 5.16: Compressive Strength for the Ternary Mix under different curing regimes
It is found from the Fig 5.15, it is found that the higher strength is achieved for the
ternary mix under steam curing condition using the method of re-vibration by attaining a
compressive strength of 62.7 Mpa followed by normal water curing attaining a compressive
54
strength of 58.4Mpa. It should be noted that the specimens cured in hot air oven has attained
remarkably less strength of 53.7 Mpa.
Chapter 6
CONCLUSION
From the study, it is concluded that maximum compressive strength of 62.7Mpa can be
achieved by using a ternary mix with 40% cement, 10% silica fume and 50% GGBS by
using Packing Density Modulus Method.
The method of re-vibration is required to attain the highest possible strength in the study.
From the study it is found that the optimum Water to Binder ratio is 0.22 which produces
a stable mix with better compressive strength.
The dosage of SP should be maintained at 1.5% beyond which the mix become highly
flowable and when reduced the mix becomes harsh.
Binder to Total Aggregate ratio was arbitrarily fixed to 0.4, 0.45 and 0.50 at initial stage
and from the study it is found that the B/TA of 0.45 has consistently produced better
results achieving a density of 2414 kg/m3 and the binder content required for this binder
to total aggregate ratio is 750 kg/m3.
From the packing density test the maximum packing density was arrived for particle size
between 4.75mm and 2.36mm for coarse aggregate.
The particle size of fine aggregate that is selected for the study as obtained from the
packing density test was 2.36mm to 75.
55
From the packing density test for the binary filler material, maximum density was arrived
for coarse to fine aggregate ratio of 50:50.
From the test results of the binary mix, it is found that the specimens cured under normal
water produced consistent results for all the mixes achieving a higher strength of 54.4
Mpa for the Mix F with 50% GGBS. However the highest compressive strength was
achieved for the Mix F cured in steam attaining a strength of 56.8Mpa.
Specimens that were cured in Hot Air Oven has attained comparatively lesser strength
than Normal water curing and Steam curing. This is due to the reason that hydration was
the governing chemical reaction occurring in the mix due to the higher quantity of cement
in the mix compared to the mineral admixtures. Mineral admixtures like GGBS, Silica
fume, Metakaolin and Bentonite clay when used in concrete produces a strong matrix by
the process of polymerization which is enhanced at accelerated temperatures and hot air
oven curing enhances polymerization. Since hydration was the predominant reaction in
the mix, the strength achieved was comparatively reduced.
It is also observed that there is reduction of compressive strength beyond an optimum
point of replacement of cement with mineral admixtures. In this study beyond 10%,
addition of Silica fume had negative impact on the compressive strength of the concrete.
It is found that the optimum percentage of silica fume is 10% and the mix with 50%
GGBS has produced better results than the mix with 25% GGBS.
From the binary mix, maximum compressive strength of 59.4 Mpa with Mix E having
25% of GGBS with re-vibration technique.
However the highest strength is achieved for the ternary mix with 50 % GGBS and revibration is also carried out.
Thus by the method of packing density modulus, high performance concrete can be
produced with ternary binder materials, careful selection of the material size for coarse
and fine aggregate, the ratio of coarse to fine aggregate and the ratio of binder to total
aggregate.
56
PAPERS PUBLISHED BASED ON THIS WORK

Presented a paper on the title Experimental Analysis on High Performance Concrete
using Binary Packing Density Modulus an International Conference organized by
S.R.I. College of Engineering and Technology.
57
REFERENCES
[1] Chong Wang, Changhui Yang, Fang Liu, Chaujun Wan, Xincheng Pu, Preparation of Ultra
High Performance Concrete with common technology and materials , Cement and Concrete
Composites, 2012, Vol 34, pp. 538-544.
[2] R. Deeb, A. Ghanbari, B.L. Karihaloo, Development of self-compacting high and ultra high
performance concretes with and without steel fibres , Cement and Concrete Composites, 2012,
Vol 34, pp. 185-190
[3] Seung Hun Park, Dong Joo Kim, Gum Sung Ryu, Kyung Taek Koh, Tensile Behavior of
Ultra High Performance Hybrid Fiber Reinforced Concrete, Cement and Concrete Composites,
2012, Vol 34, pp. 172-184
[4] Nguyen Van Tuan, Guang Ye, Klaas Van Breugel, Oguzhan Copuruglu, Hydration and
microstructure of ultra high performance concrete incorporating rice husk ash , Cement and
Concrete Research, 2011, Vol 41, pp. 1104-1111
[5] Tina Oertel, Frank Hutter, Ricarda Tanzer, Uta Helbig, Gerhard Sextl, Primary particle size
and agglomerate size effects of amorphous silica in ultra high performance concrete , Cement
and Concrete Composites, 2013, Vol 37, pp. 61-67
[6] M.A.A. Aldahdooh, N. Muhamad Bunnori, M.A. Megat Johari, Evaluation of ultra high
performance fiber reinforced concrete binder content using the response surface method ,
Materials and Design, 2013, Vol 52, pp. 957-964
[7] R. Zaitri, M. Bederina, T. Bouziani, Z. Makhloufl, M. Hadjoudja, "Development of high
performnace concrete based on the addition of grinded dune sand and limestone rock using the
mixture design modelling approach", Construction and Building Materials, 2014, Vol-60, pp. 816.
58
[8] Ehsan Ghafari, Hugo Costa, Eduardo Julio, Antonio Portugal, Luisa Duraes, "The effect of
nanosilica addition of flowability, strength and transport properties of ultra high performance
concrete", Materials and Design, 2014, Vol-59, pp. 1-9.
[9] A.M.Soliman, M.L. Nehdi, "Effects of Shrinkage Reducing Admixture and Wollastonite
microfiber on early-age behavior of ultra high performance concrete" , Cement and Concrete
Composites, 2014, Vol- 46, pp. 81-89.
[10] R. Yu, P. Spiesz, H.J.H. Brouwers, "Mix Design and properties assessment of Ultra High
Performance Fiber Reinforced Concrete", Cement and Concrete Research, 2014, Vol-56, pp. 2939.
[11] Tomasz Ponikiewski and Jacek Golaszewski, "The influence of high calcium fly ash on the
properties of fresh and hardened self-compacting concrete and high performance self-compacting
concrete" , Journal of Cleaner Production, 2014.
[12] Semion Zhutovsky, Konstanin Kovler and Arnon Bentur, "Effect of hybrid curing on
cracking potential on high performance concrete", Cement and Concrete Research, 2013, Vol-54,
pp. 36-42.
[13] Jui-Sheng Cho and Anh-Duc Pham, "Enhanced artificial intelligence for ensemble approach
to predicting high performance concrete compressive strength", Construction and Building
Materials, 2013, Vol-49, pp. 554-563.
[14] A.A. Aldahdooh, N. Mohammad Bunnori and M.A. Megat Johari, "Evaluation of ultra-high
performance-fiber reinforced concrete binder content using response surface method", Materials
and Design, 2013, Vol- 52, pp. 957-965.
[15] Lei Mao, Stephanie Barnett, David Begg, Graham Schleyer and Gavin Wight, "Numerical
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International Journal of Impact Engineering, 2014, Vol-64, pp. 91-100.
59

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Experimental Analysis on High Performance Concrete using Binary and Ternary Packing Density Modulus

VIT University, Vellore

VIT University, Vellore

VIT University, Vellore

The objective of the project is to design a high performance concrete with a

To characterize the material properties for achieving the composite mechanical

To enhance the interlocking properties of binder and filler material as a whole.

VIT University, Vellore

VIT University, Vellore

A.M.Soliman, M.L. Nehdi studied the effect of incorporating shrinkage reducing

VIT University, Vellore

VIT University, Vellore

3.2.2 Natural River Sand

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Initial setting time

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Table 4.1: Packing Density of Coarse Aggregate

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Fig4.1: Packing Density of the Coarse Aggregate

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PACKING DENSITY IN kg/m3

Fig 4.2: Packing Density of the Fine Aggregate

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PACKING DENSITY FOR BINARY MIX

Fig 4.3 : Packing Density of Binary Filler Material

4.5 Influence of Binder Proportions

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Fig 4.4: Standard Consistency Test

4.7 Consistency Test Results

100 % CEMENT + 0% GGBS

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Table 4.5: Standard Consistency values for the different mixes

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100 % CEMENT + 0% GGBS

Standard Consistency Test Result

Fig 4.5 : Standard Consistency Test Result

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100 % CEMENT + 0% GGBS

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Intial Setting Time of Binder

Fig 4.6: Initial Setting Time of Binders

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Fig 4.7: Final Setting Time Test

100 % CEMENT + 0% GGBS

Final Setting Time of Binder

Fig 4.8: Final Setting Time of Binders

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Setting Time of Binders

Fig 4.9: Initial and Final Setting Time of Binders

When the binder to total aggregate is 0.4

When the binder to total aggregate is 0.6

When the binder to total aggregate is 0.5

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Binder Content= 666

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Fig 5.1 Casted Specimens

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W/B=0.3 & SP=2%

S TRENGTH (28 days )

Fig 5.2: Compressive Strength for W/B=0.3 & SP=2%