CHAPTER – 1

INTRODUCTION

1.1 General

Cement, in the general sense of the word, can be described as the material with adhesive
and cohesive properties which make it capable of bonding mineral fragments into a compact
whole. This definition embraces a large variety of cementing materials.

One of the common materials classified as cementious, is Pozzolana, which is a natural or

artificial material containing silica in a reactive form. A more formal definition of ASTM 618-
94a describes pozzolana as a siliceous or siliceous and aluminous material which in itself
possesses little or no cementious value but will, in finely divided form and in the presence of
moisture, chemically react with calcium hydroxide at ordinary temperatures to form
compounds possessing cementitious properties. It is essential that the pozzolana be in a finely
divided state as it is only then that the silica can combine with calcium hydroxide in the
presence of water to form compounds possessing cementitious properties. The natural
pozzolanic materials most commonly met with are: volcanic ash – the original pozzolana –
pumicite, oplaine shales, cherts, calcined diatomaceous earth and burnt clay. Pozzolanas being
a latent hydraulic material are always used in conjunction with Portland cement. The two
materials may be intergrounded or blended. Sometimes they can be combined in the concrete
mixer.

There are two classes of Pozzolanic Cement: Class II/A-V with a fly ash content of 6 to 20
percent, and Class II/B-V with a fly ash content of 21 to 35 percent. In India, the BIS 6610:1991
allows an even higher content of fly ash, namely 53 percent in so-called Pozzolanic Cement.
Additionally, pozzolanic cement has some resistance to sulfate attack and to attack by weak
acids.

Concrete is one of the most important material used for construction in the field of Civil
Engineering. Experiments and studies are done every day to find new methods to increase the
performance of Concrete. One big flaw in use of concrete is its weak tensile Strength. This was
overcome by the addition of Steel as reinforcement, giving rise to R.C.C. This was a huge
breakthrough in the use of Concrete. But, as Engineers, we are obliged to experiment in more
innovative methods to strengthen the Concrete. Many additive and replacement materials have
been tested with cement to form hybrid varieties of Concrete. For example, Fibre reinforced

1
concrete is being developed in various states so that it may provide adequate addition to the
weaker properties of Concrete.

Use of scrap and waste materials in addition or replacement with cement is widely
accepted in today’s world. Rice husk ash is used in some tertiary constructions such as
pavements and pathways. Lot of researches has been done in the use of Sugarcane Fibre as a
reinforcement material for concrete. This is done due to the availability of Sugarcane husk in
mostly all parts of India. But this combination has turned out to be not so positive as it did not
provide adequate strength as steel, not even to make up for steel’s high cost.

1.2 Need for Project

In this project, we experimentally study the difference in the strength parameters of

Concrete by the addition of Steel mill scrap (shots) to the normal mix of concrete. This addition
will favour the increase of strength properties in concrete, thus decreasing the cost of its mix
as the scrap used in this project is available in abundant quantities. Also, the use of Crusher
sand in the project plays an important role in the mix. Use of Crusher sand reduces Carbon
Footprint of the structure. This helps making the project more Eco-friendly. 20 tonnes of steel
mill scrap gets accumulated in the dump yards every day. This accumulations leads to wastage
of land. By using steel mill scrap in concrete this land fill can be avoided.

1.3 Objective

The main objective of this Project is to find out, among the mixes of 10kg addition,
20kg addition, and 30kg addition of the steel mill scrap, which of them is yielding the highest
strength and to use which mix among these three for an economic purpose. This helps in clearly
understanding the weight of the steel to be used to optimize the use of Concrete. For each
different mix, 5 Beams, 6 Cubes, 6 Cylinders and 6 moulds for RCPT were casted. The cubes
are Cured for 3, 7, 28 and 56 days, and tested for its Compressive Strength. Cylinders were
cured for 7, 28 and 56 days, to be tested for Split tensile Strength. And so were the beams cured
for 7, 28 and 56 days, for testing its Flexural Strength. As there is an addition of Steel in the
Concrete, there is a need for testing the concrete against corrosion. RCPT (Rapid Chloride
Penetration Test) moulds were casted. These moulds were cured for 28 and 56 days and were
tested.

2
 CHAPTER – 2

LITERATURE REVIEW

2.1 Experimental Investigation on Fibre Reinforced Concrete Using Waste

Materials

G.Murali, C.M.Vivek Vardhan, R.Prabu, Z.Mohammed Ali Khan, T.Aarif Mohamed,

T.Suresh
International Journal of Engineering Research and Applications (IJERA)
ISSN: 2248-9622 Vol. 2, Issue 2, Mar-Apr 2012, pp.278-283
Tto study the influence of addition of waste materials like lathe waste, soft drink bottle caps,
empty waste tins, waste steel powder from workshop at a dosage of 1% of total weight of
concrete as fibres. The lathe waste, empty tins, soft drink bottle caps were deformed into the
rectangular strips of 3mm width and 10mm length. Experimental investigation was done using
M25 mix and tests were carried out as per recommended procedures by relevant codes. The
results were compared with conventional concrete it was observed that concrete blocks
incorporated with steel powder increased its compressive strength by 41.25% and tensile
strength by 40.81%. Soft drink bottle caps reinforced blocks exhibited an increase in flexural
strength of concrete by 25.88%.

3
2.2 Innovative Application of Scrap-tire Steel Cords in Concrete Mixes

Ahmed N. Bdour and Yahia A. Al-Khalayleh

Assistant Professor and Assistant Dean of Engineering College, Department of Civil

Engineering, the Hashemite University
Jordan Journal of Civil Engineering, Volume 4, No. 1, 2010

This research is exploring the use of steel cords, a byproduct of the tire recycling process, in
concrete mixes. Different concrete specimens were fabricated and tested in uniaxial
compression and splitting tensile strength. The steel cords were substituted into the concrete
mix in volumetric percentages of 0% (control), 2%, 4%, 6%, 8% and 10%. Results show that
mechanical properties of concrete made with steel cords are improved compared with concrete
mix made with the traditional scrap-tires recycled material (such as crump rubber or rubber
chips). Also, the test results show that even though the compressive strength is reduced when
using steel cords, this reduction is minimal. When 2% of steel cords are used, there is an 18%
increase in ductility. Moreover, splitting tensile tests show that concrete mixtures with any steel
cords content have much greater toughness than the control mixture. This mechanical property
mix indicates an excellent potential application of modified concrete mix in Structures that
absorb large amounts of energy. On the contrary, the density, air content and workability of the
mixtures fabricated were not significantly affected.

2.3 Innovative Use of Waste Steel Scrap in Rigid Pavements

Pooja Shrivastava , Dr.Y.P Joshi - Department of Civil Engineering SATI Govt.
Engineering College, Vidisha - 464001.
Civil and Environmental Research
ISSN 2224-5790 (Paper) ISSN 2225-0514 (Online) Vol.6, No.7, 2014

This paper work assessment on the study of the workability and mechanical strength properties
of the high strength concrete reinforced with industrial waste fibres. This waste steel scrap
material which is available from the lathe is used as a steel fibre for innovative construction
industry and also in pavement construction. Lathe waste is generated by each lathe industries
and dumping of these wastes in the barren soil contaminating the soil and ground water, which
creates an unhealthy environment. In addition to get sustainable development and
environmental benefits, lathe scrap as recycled fibres with concrete are likely to be used.

4
Experimental studies are done to know about fresh and hardened concrete properties of SFRC
and their mechanical properties such as compressive strength, flexural strength and split tensile
strength are found to be increased due to the addition of steel scrap fibre in the concrete. When
compared with conventional concrete to SFRC, steel fibre increases flexural strength by 40%
and considerable increase in compressive and tensile strength. These fibres may also contribute
to improve properties such as shrinkage reduction, modulus of elasticity, toughness, resistance
to cracking and preventing crack propagation. The workability of fresh concrete containing
lathe scraps are carried out by using slump test. This paper focuses on structural strength
enhancement and improvement in fatigue life of rigid pavement by locally available scrap steel.
These rigid pavements using steel scrap promises an appreciably higher design life, offer better
serviceability and minimize crack growth and corrosion.

2.4 Impact and Energy Absorption Characteristics of Lathe Scrap Reinforced

Concrete
G Vijayakumar, P Senthilnathan, K Pandurangan and G Ramakrishna
International Journal of Structural and Civil Engineering Research 2012
ISSN 2319 – 6009 Vol. 1, No. 1, November 2012

This project work emphasis on the study of using lathe scrap as fibre reinforced concrete in the
innovative construction industry. Every day about 8 to 10 kg of lathe waste are generated by
each lathe industries in the Pondicherry region and dumped in the barren soil there by
contaminating the soil and ground water, which creates an environmental issue. Hence by
adopting proper management by recycling the lathe scrap with concrete is considered to be one
of the best solutions. The test were conducted as per the Indian standard procedure for its
mechanical properties such as flexural, split tensile, compressive, and impact strength and
compared conventional PCC. The 7 days strength of the Lathe scrap reinforced concrete shows
an increase in its compressive strength when compared with PCC, and almost become equal to
the strength when tested on 28 days under normal curing. The addition of lathe scrap in concrete
has increase the performance of beam in flexural by 40% when compared with PCC.
There is only a considerable increase in the split tensile strength of concrete with lathe scrap
when compared with PCC. The workability of fresh concrete that containing different ratios of
lathe scrap was carried out by using slump test. The result showed that addition of lathe scrap
in to PCC mixture enhanced its compressive strength while it decreased the workability of the

5
fresh concrete containing the lathe scrap. The impact strength of concrete mixed with lathe
scrap shows increased impact strength when compared with PCC.

2.5 Performance of Steel Scrap in Concrete

Jais Joy, Rajesh Rajeev
Department of Civil Engineering Structural Engineering & Construction management,
M.G. University
IJSRD - International Journal for Scientific Research & Development
Vol. 2, Issue 12, 2015 | ISSN (online): 2321-0613

This project attempts to study the performance of addition of waste materials like binding wire,
steel nails, steel lathe waste fibre (turn fibre) from workshop at a dosage of 0.5%, 1% and 1.5%
of total weight of concrete. Experimental investigation was done using M25 mix and tests were
carried out as per recommended procedures by relevant codes. Total of 162 specimens of scrap
concrete and PCC were made. This paper aims to have a comparative study between turn fibre,
binding wire and steel nail in M25 concrete. The test parameters include compressive strength,
split tensile strength and flexural strength of conventional concrete and steel scrap in concrete.

2.6 Experimental Studies of the Application of Turn Steel Scraps as Fibres in

Concrete
Vasudev. R, - Associate Professor, Department of Civil Engineering, Toc H Institute
of Science & Technology, Arakkunnam, Ernakulam, Kerala
Dr. B. G. Vishnuram - Principal and Professor in Civil Engineering, P. S. R.
Engineering College, Sivakasi, Tamil Nadu.
International Journal of Engineering and Technology (IJET)
ISSN: 0975-4024 Vol - 6 No 4 Aug-Sep 2014

This paper aims to have a comparative study between ordinary reinforced concrete and steel
fibre reinforced high strength concrete under tensile and compressive loading. The fibres added
in this study are the wastes from lathe shops. The behaviour of concrete samples is investigated
by adding varying percentage of turn steel scraps as fibres, viz., 0.25%, 0.5%, 0.75% and 1%.
The behaviour of steel fibre reinforced high strength concrete is also evaluated based on
flexural capacity, load carrying capacity, cracking behaviour and deflection characteristics. The

6
basic concrete mixes adopted were M40 and M60. The results obtained were promising, which
can be adopted in the construction industry.

2.7 Reuse of Steel Scrap from Lathe Machine as Reinforcement to Enhance

Properties of Concrete
Shirule Pravin Ashok., Swami Suman and Nilesh Chincholkar
Dept. of Civil Engg., SBT’s college of Engg. & Tech., Jalgaon- 425001 (M.S)
Global Journal of Engineering & Applied Sciences,
2012: 2 ISSN 2249-2631(online): 2249-2623(Print)
Research paper: Shirule Pravin Ashok et al., 2012: Pp.164-167

The investigation reported in this paper was carried out to study the feasibility of using steel
scrap obtained from lathe machine in fibre reinforced concrete by checking the compressive
strength splitting tensile strength and flexural strength of M20 concrete and thus optimizing
the fibre proportions. In this study, a comparison has been made between plain cement concrete
and steel scrap fibre reinforced concrete (SSFRC). The results of tests done on SSFRC having
different proportion of steel scrap (i.e. 0.5%, 1.0%, 1.5%, 2.0%) by weight of cement has been
taken into account. Compressive strength, tensile strength and flexural strength of SSFRC is
found to be maximum with volume fraction of 1.5% steel scrap fibre. Conclusion: Steel scrap
fibre provide improvements in compressive strength, tensile strength and flexural strength of
concrete.

7
2.8 Study on the properties of High strength concrete using glass
Powder and lathe scrap
T.Sezhiyan, R.Rajkumar
Department of Civil Engineering, Kongu engineering College, Perundurai.
International -Journal of Innovative Research in Science, Engineering and
Technology
ISSN (Online): 2319-8753, ISSN (Print): 2347 – 6710

This research shows that there is strength loss due to fine aggregate substitution also. The aim
of the present work was to use glass powder as a replacement of cement to assess the pozzolanic
activity of fine glass powder in concrete and Study the Properties of concrete. The present study
shows that waste glass, if ground finer than 100μm shows a pozzolanic behaviour. It reacts
with lime at early stage of hydration forming extra CSH gel thereby forming denser cement
matrix. The early consumption of alkalis by glass particles mitigate alkali-silica reaction hence
increase durability of concrete. Lathe scarps are the waste materials which are collected from
workshops and other steel industries at very minimum cost. They are similar to the steel fibre
but they don’t have any regular shape and size. The dimension varies with nature of source that
is depends upon the type of industries. Scraps considered in this work are 0.5mm thickness.

8
 CHAPTER – 3

3.1 Coarse Aggregate

Coarse aggregate is obtained by crushing bed rocks. There are three kinds of rocks, namely,
igneous, sedimentary and metamorphic. These classifications are based on the mode of
formation of rocks. Aggregates are the most important constituents in concrete. They give
body to the concrete, reduce shrinkage and effect economy. The mere fact that the coarse
aggregates occupy 40-50 percent of the volume of concrete, their impact on various
characteristics and properties of concrete is undoubtedly considered. To know more about
the concrete it is very essential that one should know more about the aggregates. Irregular
Shaped aggregates were used in this project because it binds properly with the cement paste
thus giving us the good and desirable concrete. The size of the coarse aggregates used here
is 12.5mm to 20mm. The properties are as below

Sl. No PROPERTY RESULT

1 Density
1. 20 mm Aggregate 1.465 (KG/m3)
2. 12.5 mm Aggregate 1.418 (KG/m3)
2 Specific Gravity
1. 20 mm Aggregate 2.695
2. 12.5 mm Aggregate 2.677
3 Water Absorption
1. 20 mm Aggregate 0.29 %
2. 12.5 mm Aggregate 0.34 %

9
3.2 Fine Aggregate

Crushed Sand is used in this project as fine aggregate. One of the facts about this
type of sand is that, it is eco-friendly. The Crushed sand is the manufactured sand (Crushed
stone dust), as a fine aggregate, is an attractive alternative of river sand. It is purpose made
fine aggregate produced by crushing and screening or further processing i.e., washing,
grading, classifying of quarried rock, cobbles, boulders or gravels from which natural fine
aggregate had been removed. The properties of crushed sand is as follows

Sl. No PROPERTY RESULT

1.66(KG/m3)
1 Density

Specific Gravity 2.67

2

Water Absorption 2.5%

3

10
3.3 Steel Mill Scrap

Steel mill scrap is the residue of steel which was dumped by various mills, factories and
refineries such as lathe machine shots. Almost 6-8 tons of steel mill scrap is being
accumulated in and around Chennai which is not being used anywhere except as the counter
weight for heavy lifters. The steel Mill scrap is usually melted down and used again, but that’s
a longer costlier process hence they avoid it usually. This steel is grade 2 cast iron scrap. The
Steel Mill scrap in this project is of very fine quality. The specific Gravity of the steel mill scrap
is 6.88.

11
3.4 Cement

The Portland Pozzolanic cement is manufactured by the intergrinding of OPC clinker with 10
to 25 percent of pozzolanic material. A pozzolanic material is essentially a siliceous or
aluminous material which while in itself possessing no cementitious properties, which will, in
finely divided form and in the presence of water, react with calcium hydroxide, liberated in
the hydration process, at ordinary temperature, to form compounds possessing cementitious
properties. Portland pozzolana cement produces less heat of hydration and offers greater
resistance to the attack of aggressive waters than ordinary Portland cement. Moreover, it
reduces the leaching of calcium hydroxide when used in hydraulic structures. Portland
pozzolano cement can generally be used where ordinary Portland cement is usable. The
following are the properties of Portland pozzolano cement.

Sl. No PROPERTY RESULT

3.15(KG/m3)
1 Density

Initial Setting Time

2 135 min

Final Setting Time

3 165 min

12
3.5 Admixture

13
 CHAPTER-4

PROJECT SCHEDULE

14
 CHAPTER – 5

LABORATORY TEST

5.1 Specific Gravity Test

Specific gravity is the ratio of the density of a substance to the density of a reference substance;
equivalently, it is the ratio of the Mass of a substance to the mass of a reference substance for
the same given volume. In major cases, the reference substance used is water. The Specific
Gravity of water is 1, because it is compared with itself. Specific Gravity is a dimensionless
quantity. It varies with temperature and pressure.

𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑐𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑒𝑑

𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐺𝑟𝑎𝑣𝑖𝑡𝑦 =
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑊𝑎𝑡𝑒𝑟

Specific Gravity of most of the construction materials can be found out using a
Pycnometer. This gives the fairly approximate value of specific gravity of the material. A
pycnometer is usually made of glass, with a close-fitting ground glass stopper with a capillary
tube through it, so that air bubbles may escape from the apparatus. This device enables a liquid's
density to be measured accurately by reference to an appropriate working fluid, such as water
or mercury, using an analytical balance.

Coarse Aggregate

15
 Fine Aggregate

Specific Gravity- Fine Aggregate- Crushed Sand

Trail 1 (gms) Trail 2 (gms)
Empty Weight of Pycnometer (W1) 631 631
Empty Weight of Pycnometer + sample (W2) 1385 1396
Empty Weight of Pycnometer + sample + water (W3) 1973 1979
Empty Weight of Pycnometer + water (W4) 1501 1501

Specific gravity 2.674 2.666

Average value 2.67

Steel mill scrap

Specific Gravity- Steel Mill Scrap

Trail 1 (gms) Trail 2 (gms)
Empty Weight of Pycnometer (W1) 631 631
Empty Weight of Pycnometer + sample (W2) 1669 1644
Empty Weight of Pycnometer + sample + water (W3) 2388 2367
Empty Weight of Pycnometer + water (W4) 1501 1501

Specific gravity 6.87 6.89

Average value 6.88

5.2 Sieve Analysis

A sieve analysis is a practice or procedure used to assess the particle size distribution of a
granular material. The sieve analysis is mainly carried out for aggregates, both fine and coarse.
A sieve analysis can be performed on any type of non-organic or organic granular materials
including sands, crushed rock, clays, granite, feldspars, coal and soil, a wide range of
manufactured powders, grain and seeds, down to a minimum size depending on the exact
method.

The weighed sample is poured into the top sieve which has the largest screen openings.
Each lower sieve in the column has smaller openings than the one above. At the base is a round
pan, called the receiver.

The column is typically placed in a mechanical shaker. The shaker shakes the column,
usually for some fixed amount of time. After the shaking is complete the material on each sieve
is weighed. The weight of the sample of each sieve is then divided by the total weight to give
a percentage retained on each sieve.

16
Coarse Aggregate

Sieve Analysis - Coarse Aggregate-20mm

Sieve Size (mm) Weight Retained (gms) % of Weight Retained % of Cumulative Weight Retained % of Passing
40 0 0 0 100
25 0 0 0 100
20 12 0.24 0.24 99.76
12.5 4288 85.76 86 14
10 555 11.1 97.1 2.9
4.75 145 2.9 100 0
Pan 0 0 100 0

Sieve Analysis- Coarse Aggregate - 12.5mm

Sieve Size(mm) Weight Retained (gms) % of weight Retained % of Cumulative Weight Retained % of Passing
16 0 0 0.9 99.1
12.5 234 4.68 4.68 95.32
10 1539 30.78 35.46 64.54
4.75 3220 64.4 99.86 0.14
2.36 7 0.14 100 0
Pan 0 0 100 0

Fine aggregate

Sieve Analysis- Fine Aggregate- Crushed Sand

Sieve Size Weight Retained (gms) % of weight Retained % of cumulative weight retained % of Passing
4.75mm 27 2.7 2.7 97.3
2.36mm 269 26.9 29.6 70.4
1.18mm 318 31.8 61.4 38.6
600µ 65 6.5 67.9 32.1
300µ 126 12.6 80.5 19.5
150µ 88 8.8 89.3 10.7
75µ 54 5.4 94.7 5.3
Pan 53 5.3 100 0

17
Steel Mill scrap

Sieve Analysis- Steel Mill Scrap

Sieve Size Weight Retained (gms) % of Weight Retained % of Cumulative Weight Retained % of Passing
4.75 mm 9 0.9 0.9 99.1
2.36 mm 7 0.7 1.6 98.4
1.18 mm 30 3 4.6 95.4
600 µ 191 19.1 23.7 76.3
300 µ 728 72.8 96.5 3.5
150 µ 11 1.1 97.6 2.4
75 µ 8 0.8 98.4 1.6
Pan 16 1.6 100 0

5.3 Consistency test

The consistency test was conducted to determine the percentage of water required for preparing
the cement paste of standard consistency for conducting the other test such as setting time test.
The test was performed using Vicat’s apparatus. A trial paste of cement 300gm and water 30%
by weight is mixed and placed in the mould. The plunger is then brought into the contact with
the top surface of the paste and released. The plunger should penetrate to a depth of 5mm to
7mm from the bottom of the mould. The test should be repeated until the specified penetration
depth is obtained by gradually increasing the water content.

18
5.4 Setting time test

The setting time test was conducted to check the initial and final setting time of the cement.
These test was conducted using Vicat’s apparatus.

Initial setting time

Initial setting time was done by preparing the cement paste as mentioned in consistency test
and filled in the mould. The round needle of cross section area 1mm2 was attached to the
moving rod. The needle was quickly released and it was allowed to penetrate into the cement
paste. It was then taken out and released into the fresh place. The procedure was repeated at
regular intervals till the paste stiffens sufficiently for the needle to penetrate only to a point
about 5mm from the bottom; at this stage initial setting time is said to have taken place.

Final Setting Time

The final setting time test was conducted similar to as that of the initial setting time test, but
instead of round needle a needle with annular collar was used. The final setting has said to be
taken place when the needle makes no impression on the cement paste.

5.5 Impact Testing for Aggregates

Toughness of a material is the property of it to resist Impact. Aggregates should be tough so

that it would resist the loads acted upon the Concrete form, or the loads acted upon it during
transportation of the aggregate itself. This characteristic of the aggregate can be measured by
the Impact value Test. This test is conducted for aggregates of similar sizes (e.g. 12.5 mm or
20 mm aggregate). The aggregate is filled in the measuring cylinder for 1/3 rd of its depth, and
it is compacted. The same is done for another two times till the Cylinder is full. This cylinder
is fixed in the base of the machine. Now the hammer is raised till it is 380 mm above the surface
of the aggregate. It is then allowed to fall freely. 15 blows are given at successive intervals of
less than a second. The crushed aggregate is then removed and sieved through 2.36 mm IS
sieve. The aggregate impact value is measured by the Percentage of Weight of the portion
passing through 2.36mm sieve (W1), divided by the Total weight of the dry sample.

5.6 Water Absorption

This test helps to determine the water absorption of coarse aggregates as per IS: 2386 (Part III)
– 1963. For this test a sample not less than 2000g should be used.

19
 The sample should be thoroughly washed to remove finer particles and dust, drained
and then placed in the wire basket and immersed in distilled water at a temperature between 22
and 32oC.

After immersion, the entrapped air should be removed by lifting the basket and allowing
it to drop 25 times in 25 seconds. The basket and sample should remain immersed for a period
of 24 + ½ hours afterwards.

The basket and aggregates should then be removed from the water, allowed to drain for
a few minutes, after which the aggregates should be gently emptied from the basket on to one
of the dry clothes and gently surface-dried with the cloth, ,transferring it to a second dry cloth
when the first would remove no further moisture. The aggregates should be spread on the
second cloth and exposed to the atmosphere away from direct sunlight till it appears to be
completely surface-dry. The aggregates should be weighed (Weight ‘A’).

The aggregates should then be placed in an oven at a temperature of 100 to 110oC for
24hrs. It should then be removed from the oven, cooled and weighed (Weight ‘B’).

(𝐴 − 𝐵)
𝑊𝑎𝑡𝑒𝑟 𝑎𝑏𝑠𝑜𝑟𝑝𝑡𝑖𝑜𝑛 = 𝑋 100
𝐵

20
5.7 Density

Density of a material is the ratio of its mass to its volume. It is denoted by the symbol ρ (rho).
The density of a material varies with temperature and pressure. This variation is typically small
for solids and liquids but much greater for gases. Increasing the pressure on an object decreases
the volume of the object and thus increases its density. Increasing the temperature of a
substance decreases its density by increasing its volume.

The density of a construction material can be easily found out by a simple procedure.
The material is first filled in a container of known volume. It is just filled without compacting
it. Also, the material must be surface dry.

Now the whole setup is weighed and the weight is noted (w1). Now the container is
emptied and is weighed (w2). Now the weights are subtracted and is divided by the volume to
get the Surface dry Density of the material.

Density = (w1-w2)/V

Where, V – Volume of the container.

21
 CHAPTER – 6

MIX DESIGN

Concrete is made up of four major components: Water, Cement, Fine aggregate and Coarse
aggregate. These are mixed in a certain ratio, for optimum use of Concrete, called as mix ratio.
The determination of this ratio is called the Mix design. The procedure of Mix design is as
follows:

1. First the Individual weights of Cement, water, and Admixture are taken for 1m3 volume
of the mix.
2. The remaining ratio is the ratio comprising the Aggregates, both fine and Coarse
(12.5mm and 20mm sized). So, the Specific gravity of these materials are considered
for computing the weight of each component. Also, the percentage of aggregate used is
needed for the determination of its weight.
3. The total weight of aggregates are known. With this value the individual weight of
aggregates (20 mm, 12.5 mm, and fine aggregate) can be found out. Also, the
aggregates absorb some of the water, so the rate of absorption should be also
considered, to add to the total water required.
4. After this step, the quantity of each components are to be calculated for 0.030m3 of the
volume, as this is the capacity of the mixer used.
5. This mix design is for a Controlled mix. For computing the weight of the steel mill
scrap to be added, it is just converted to the weight required for 0.030m3. This is because
the steel mill scrap is an addition material, not a replacement material, therefore its
addition would not disrupt the mix design.

22
 GRADE OF CONCRETE M 25 TYPE OF CONCRETE PCC/RCC

MAXIMUM SIZE OF AGGREGATE 20mm CONCRETE CONFIRMS TO IS 456 & IS 10262

SLUMP OF CONCRETE, mm 200±25 CONCRETE MIX FOR

(MIX DESIGN TO HAVE 120 MIN SLUMP RETENTION)

Data on Ingredients:
INGREDIENTS TYPE OF SOURCE OF AVG. WATER MATERIAL
MATERIAL MATERIALS SPECIFIC ABSORPTION PERCENTAGE
GRAVITY % USED
Cement PPC 53G 3.15 100

Coarse 1 20 MM 2.695 0.29 33

Aggregate
2 12.5 MM 2.6775 0.34 22

Fine Aggregate Crushed Sand 2.67 2.5 45

Chemical SUPAFLO PC DON - 0.6

Admixture 711 CHEMICALS

TARGET STRENGTH (30 + (1.65 X 5)) = 38.25 N/mm2

Materials required per m3 of Concrete

Free water content 180 Litres

Air Content 15 %

Cement Content 360 Kg

Dry Coarse Aggregate 20 MM 624 Kg

Dry Coarse Aggregate 12.5 MM 416 Kg

Dry Fine Aggregate Crushed Sand 851 Kg

Chemical Admixture SUPAFLO PC 711 2.16 Litres

Water for absorption PPC 53 24 Litres

Total Water 204 Litres

MIX PROPORTION BY WEIGHT

CEMENT FINE AGGREGATE COARSE AGGREGATE

1.00 2.36 2.89

AGGREGATE CEMENT RATIO 5.25

Note: Moisture correction on aggregates to be done at before start of Concrete daily.

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 CHAPTER – 7

Methodology

7.1 Slump Cone Test

The slump cone test is carried out as per Indian Standards. The workability for all the concrete
mix made for carrying out various tests measured. The workability of concrete mixes prepared
for different volume of addition of steel mill scrap namely, 10kg addition, 20 kg addition and
30 kg addition. The slump cone test values were recorded.

The apparatus for conducting the slump test consists of a metallic mould in the form of a cone
having the internal dimensions as below

Bottom diameter: 20 cm

Top Diameter: 10 cm

Height: 30cm

7.2 Casting and Curing of samples

The concrete of different mix ratios namely control mix, 10kg addition of steel mill scrap, 20
kg addition of steel mill scrap and 30 kg addition of steel mill scrap were casted into cubes,
cylinders beams and into the RCPT moulds. 3 samples of each mix was casted for testing on
3rd day, 7th day, 28th day and 56th day from the day of casting. The casted cubes, beams and
cylinders were cured in a tank until the testing day. The compressive strength, split tensile
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strength and the flexural strength of the cube, cylinder and beam were tested respectively. The
testing of strengths were done in a compressive testing machine. The following procedure was
followed for the testing of samples.

7.3 Testing Details

7.3.1 Compressive Strength test

Compression test was carried out on cube specimens. The cubes were of the dimension
150mmX150mmX150mm. Three samples for each age of concrete was tested and the strength
was obtained as an average. The specimens stored in water were tested immediately on the
removal from tank. The specimens were wiped off and the dimensions of the specimens and
their weight were recorded before testing.

The bearing surfaces of the testing machine were wiped and cleaned. While placing the cubes
in the machine, care was taken such that the load was applies to opposite sides of the cubes as
casted and not to the top and bottom. The axis of the specimen was carefully aligned with the
center of thrust of the spherically seated plates. As the spherical seated block is to bear the
specimen, the movable portion is rotated gently by hand so that uniform seating was obtained.
The maximum load applied to the specimen was recorded and any usual appearance in the type
of failure was noted. The measured compressive strength of the specimen was calculated by
dividing the maximum load applied to the cross section of the specimen.

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 𝑃
𝐹= N mm-2
𝐴

Where

F= Compressive Stress (N/mm2)

P= Load at which specimen fails (N)

A= Area over which the load is applied in mm2.

The compressive strength test was done on 3rd day, 7th day, 28th day and the 56th day from the
day of casting. The compressive testing machine was used to determine the compressive
strength of the cube.

Compression testing machine with sample

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The Loading of the Cube is done as shown below

7.3.2 Split Tensile Test

The cylindrical specimens were tested for split tensile strength at an age of 28
days. The specimen was tested immediately after taking out from the water. The weight
of the specimen was noted down before testing.

The specimen was placed in such a way that the central horizontal axis of the specimen
is exactly perpendicular to the load applying axis. The load was applied without shock
and increased continuously until the resistances of the specimen to the increasing load
broke down and no greater load can be sustained. The maximum load applied was then
recorded. Any unusual type of failure was noted.

The size of specimen is 150mm dia and height of 300mm

2𝑃
Tensile Strength =
𝜋𝐿𝐷
Where,

P = Load on the cylinder in KN

L= Length of the cylinder in mm

D= Diameter of the cylinder in mm

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The Split Tensile strength test was done on 7th day and the 28th day from the day of casting.
The Split Tensile testing machine was used to determine the Split tensile strength of the cube.

Split Tensile Strength testing machine with sample

The cylinder is loaded as shown in the fig. below

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 7.3.3 Flexural Strength Test

The beam specimens were tested for flexural strength at the end of 28 days. The
specimens were tested immediately on removal from water and wiped and tested. The
dimension of each specimen were noted before testing.

The bearing surface of the supporting and loading rollers was wiped clean. The specimen was
then places on the rollers in such a way that the load will be applied to the upper most surface
as cast in the mould along two lines spaced 200mm apart. The axis of the specimen was
carefully aligned with the axis of the loading device. The load was applied without shock and
increasing continuously. The load was increased until the specimen failed and the maximum
load applied to the specimen was recorded. Unusual fractures were recorded.

The specimen are of sizes 150mm X 150mm X 700mm

𝑃𝐿
𝐹𝑙𝑒𝑥𝑢𝑟𝑎𝑙 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ =
𝑏𝑑𝑑
Where,

P = Maximum load in KN

B= Breadth of the specimen in mm

D= Depth of the specimen in mm

L= Effective span

The Flexural strength test was done on 7th day and the 28th day from the day of casting. The
Flexural strength testing machine was used to determine the Flexural strength of the cube.

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 Flexural Strength testing machine with sample

The beam is loaded as shown below for testing its flexural strength.

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 CHAPTER – 8

RESULTS AND DISCUSSIONS

8.1 Compressive Strength Testing

The Compressive strength of the Concrete in the Cube mould was tested for 3 days, 7 days, 28
days, and 56 days. This strength will be the criteria to check whether the concrete has gained
its characteristic strength. The characteristic Strength for M30 Concrete is 38.25 N/mm 2.
Compressive strength of the Concrete is found by the Compressive strength testing machine.
The results were obtained as below.

Control
Mix

10 Kg
Addition
Of Steel
Mill Scrap

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 20 kg
Addition
of Steel
Mill Scrap

30 kg
Addition
of Steel
Mill Scrap

These values suggest that there is an increase in the Compressive strength with respect to the
increase in addition of Steel. The Characteristic Strength has been obtained in the tests after
28th day curing, of the 30 kg addition of Steel mill scrap mix. Also, due to the use of PPC, the
Strength of the Concrete will still rise till its 56 day Curing. This data suggests that the
Characteristic Strength will be gained, by all of the mixes, by 56 days.

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8.2 Split Tensile Strength Testing

Split Tensile Strength is computed to test the Tensile Strength of Concrete. Concrete is very
weak in Tension due to its brittle nature. It would not resist the direct tension. So, to find its
Tensile strength, the cylindrical cast of Concrete is loaded along its Failure Plane. The
cylindrical cast was cured for 7, 28 and 56 days. The following results were obtained.

CONTROL
MIX

10 KG
ADDITION
OF STEEL
SCRAP

20 KG
ADDITION
OF STEEL
SCRAP

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 30 KG
ADDITION
OF STEEL
SCRAP

The Split tensile strength of the Concrete was observed to be the same for all types of mixes.
But its strength has increased for the 28 day cured sample. This lack of difference in the Tensile
strength of concrete can be explained by the small particle size of the steel mill scrap. Although,
the material is dense, it would not account for the tensile strength of the Concrete.

8.3 Flexural Strength Testing

Flexural strength of a material would be the same as its tensile strength, if the material was
homogenous. But, in the case of Concrete, it comprises of three materials – Cement, Sand, and
Aggregate. These materials will have defects which creates a tension in the mix. This gives rise
to a need to test its flexural strength. This test is conducted on a concrete casted in the form of
a Beam of dimensions 700 mm x 150 mm x 150 mm. The beam is loaded at two points making
the loading pattern a four point loading.

CONTROL
MIX

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 10KG
ADDITION
OF STEEL
SCRAP

20KG
ADDITION
OF STEEL
SCRAP

30KG
ADDITION
OF STEEL
SCRAP

From the results obtained, it can be observed that there is a slight increase in the Flexural
Strength of Concrete at the addition of 30kg of steel scrap mix. This is due to the binding
property of the steel mill scrap added. Also there is an increase in the strength between the 7
day cured sample and the 28 day cured sample.

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8.4 Rapid Chloride Penetration Test

The test which is simple to conduct and can also be performed in a short time is the most
preferred one. All kinds of structure has different rates of permeability which is in connection
with its rate of corrosion. So, the permeability of Concrete must be found out, to determine its
corrosion rate. The Rapid chloride permeability test (RCPT) meets the goals mentioned above.

The test is denoted as ASTM C 1202. The RCPT is performed by monitoring the
amount of electrical current that passes through a sample 50 mm thick X 100 mm in dia, for 6
hours. The sample used for this test is shaped in the form of a cylinder. A voltage of 60V DC
is maintained across the ends of the Sample. There are two leads attached to the sample. One
side is immersed in a 3.0% of Salt solution (NaCl), and the other in a 0.3 M sodium hydroxide
solution (NaOH).

The current that passes through the sample, in the testing duration, indicates the
movement of all ions in the pore solution (the sample’s Electrical conductivity). The
penetration of the electric charge through the sample gives us the permeability value of
Chloride. The following formula is used to find the average current flow through one cell.

Q = 900 ((I0 + I360) + 2(I30 + I60 + I90 + I120 + I150 + …….. + I360)

Where,

Q = Current flow (coulombs)

I0 = Current Reading in amperes immediately after application of Voltage

It = Current reading in amperes at t minutes after voltage is applied.

Charge passing Chloride Permeability

> 4000 High
2001 – 4000 Moderate
1001 – 2000 Low
100 – 1000 Very low
< 100 Negligible

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Material Test Report on Rapid Chloride Penetration test

Chloride
Average
Date of Dater of RCPT Value Permeability
ID RCPT
Casting Testing (in Coulombs) as per ASTM
Value
CT202
702
1875 30-01-2016 17-03-2016 660 Very Low
618
780
1876 02-02-2016 17-03-2016 670 708 Very Low
677
482
1877 03-02-2016 16-03-2016 658 652 Very Low
815
626
1878 04-02-2016 16-03-2016 564 578 Very Low
543

Reinforced concrete has a major disadvantage, Corrosion. The reinforcement could get easily
corroded, due to the penetration of water into it, or due to the attack of chemicals. This can be
tested by the method of Rapid Chloride Penetration Test.

This test is conducted on a sample casted in a Rubber mould specially designed for the
test, and cured for 28 days. The size of the sample is 50mm long and 100 mm diameter. After
the curing period of 28 days, the sample is tested for Chloride penetration, by placing the
sample in between solutions of 0.3 M NaOH solution on one side and 3.0% NaCl Solution, and
an electric current is passed through it. The coulombs of charge passing through the sample
determines the rate of corrosion of the sample.

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 The test details showed that the rate of coulombs passing through the sample is
considerably low. In addition to this, the chloride penetration in the samples with the addition
of the steel mill scrap, is less than the control mix. This proves that the sample can easily resist
corrosion.

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