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STUDY ON STRENGTH AND DURABILITY OF CONCRETE BY

PARTIAL REPLACEMENT OF CEMENT WITH HYPO


SLUDGE

PROJECT REPORT

Submitted by

RAMAR KALANJIAM.P

Register No: 091038127012

in partial fulfillment for the award of the degree


of

MASTER OF ENGINEERING
in
STRUCTURAL ENGINEERING

TAMILNADU COLLEGE OF ENGINEERING


COIMBATORE – 641 659
JUNE 2011
1
TAMILNADU COLLEGE OF ENGINEERING
COIMBATORE – 641 659

Department of Civil Engineering

PROJECT WORK
PHASE II

JUNE 2011

This is to certify that the project entitled

STUDY ON STRENGTH AND DURABILITY OF CONCRETE BY


PARTIAL REPLACEMENT OF CEMENT WITH HYPO
SLUDGE

is the bonafide record of project work done by

RAMAR KALANJIAM.P

Register No: 091038127012

of M.E. (Structural Engineering) during the year 2010-2011.

----------------------------------- -----------------------------------
Project Guide Head of the Department

Submitted for the Project Viva-Voce examination held on----------------------------


----------------------------------- -----------------------------------
Internal Examiner External Examiner
2
DECLARATION

I affirm that the project work titled “STUDY ON STRENGTH AND


DURABILITY OF CONCRETE BY PARTIAL REPLACEMENT OF
CEMENT WITH HYPO SLUDGE” being submitted in partial fulfillment for the
award of MASTER OF ENGINEERING is the original work carried out by me.
It has not formed the part of any other project work submitted for award of any
degree or diploma, either in this or any other University.

RAMAR KALANJIAM.P

Register No: 091038127012

I certify that the declaration made above by the candidate is true

GUIDE,

Mr.R.SRINIVASAN, M.E.,(Ph.D.),MISTE

SENIOR LECTURER

DEPARTMENT IF CIVIL ENGINERING

TAMILNADU COLLEGE OF ENGINEERING

COIMBATORE - 641 659


3
ACKNOWLEDGEMENT

First of all I would like to acknowledge with thanks to lord almighty the fountain of all
wisdom who has been wonderfully guided me step by step. I would like to thank and express our
gratitude to few who have contributed a lot towards the completion of this project.

I express my sincere thanks to the Principal Dr.C.KALAIARASAN M.E., M.S., Ph.D.,


Tamilnadu College of Engineering, Coimbatore.

I also express my sincere thanks and sense of gratitude to our respectful Head of the
Department, Dr.A.MANI, M.Tech., Ph.D., and Faculty Advisor Prof.V.KAVIMANI, M.Sc.,
M.Phil., (Ph.D.), for the interest and encouragement shown in my project.

Immensely grateful to express my thanks to my project guide, Mr.R.SRINIVASAN,


M.E.,(Ph.D.), MISTE, Senior Lecturer, Department of Civil Engineering, Tamilnadu College of
Engineering for guiding my project to become a terrific success.

I am grateful to express my special thanks and gratitude to


Prof..M.PALANISAMY,M.E.,AMIE.,C.Engg(I).,FIV.,(Ph.D.),AssistantProfessor,
Department of Civil Engineering, Tamilnadu College of Engineering for his guidance, co-
operation and help in completing the project.

I also express my sincere thanks Mr.Manokaran, Civil Manager, TNPL, Karur, for
helping and encouragement shown in my project.

I express my thanks to faculty members of our department for helping me in solving


problems and doubts that I had faced in my project.

I also express to thank my beloved parents and friends, without whose constant support I
would have not made this career in this field. My profound thanks to them.

I also express my sincere thanks to my classmates who have encouraged and helped me
in doing this project.

4
ABSTRACT

Every year, approximately two billion tonnes of cement are produced, a figure that is
likely to rise in the future. The production of cement comes with an important release of CO2,
the cement industry accounting for 5% of anthropogenic carbon dioxide emissions alone. These
emissions come from different stages of the cement production – the calcination process of
limestone, combustion of fossil fuels in the kilns, and from power generation1. In the hope of
reducing the carbon footprint of the industry, cement has been partially replaced by other
materials with similar hydration behaviour to OPC. Hyposluge is a byproduct of the paper
industry.This sludge contained 46.20% CaO, 3.30% MgO, 9.00% SiO , 3.60% R2O3, 56.8%
2

Moisture content, 27% Loss on ignescent and 11.1% Acid insoluble. The aim of this project was to
evaluate the effects of hyposildge as a partial cement replacement. 10%, 20%, 30%, 40%, 50%, 60%
and 0% hyposludge was used in the mix to replace cement. The strength of cement/hyposludge
concrete increased with curing period but above 30% replacement, decreased with increasing
2 2
hyposludge percentage. The highest strength was 31.33 N/mm and 28 N/mm at 28 days for
30% and 0% Hyposludge respectively. The durability studies like Sulphate attack and water
absorption were studied and the results shows 30% replacement of cement was optimum. The
compressive strength and sulphate attack of cement mortar cube also done for 3, 7 and 14 days
curing period. The results indicated that increased with curing period but above 30%
replacement, decreased with increasing hyposludge percentage. The results of the conducted
experiment proved the possibility of hyposludge as replacement in ratios up to 30% without
causing significant effects on the studied properties of cement.

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TABLE OF CONTENTS

CHAPTER PAGE
TITLES
NO NO
 Acknowledgement
 Abstract
 Contents
 List of Tables
 List of Figures
 List of Symbols and Abbreviations

Introduction 1
1.1 General 1
1.2 Solid Waste from Paper Industry 1
I
1.2.1 Hypo Sludge Properties 1
1.2.2 Need for Hypo Sludge Utilization 2
1.3 Objectives 2

Literature Review 3
2.1 Concrete Deterioration Caused By Sulfuric Acid Attack 3
2.2 Sulfuric Acid Attack on Concrete 4
2.3 Resistance of Scoria-Based Blended Cement Concrete against
Deterioration and Corrosion in Mixed Sulfate Environment 5
2.4 Application and Investigate Systems for the Onsite Treatment of Organic
II
Waste 5
2.5 Wood Waste as a Construction 6
2.6 Research Concerning the Use of High Percentages of Recycled Aggregates 7
2.7 Performance of Concrete 7
2.8 Multi-Parameter Study of External Sulphate Attack in Blended Cement
Materials 8

Materials Used 9
3.1 Cement 9
3.2 Aggregate 10
III 3.2.1 Coarse Aggregate 10
3.2.2 Fine Aggregate 11
3.3 Water 11
3.4 Hypo Sludge 11

Properties of Materials 13
IV
4.1 Cement 13
6
4.2 Fine Aggregate 13
4.2.1 Sieve Analysis of Fine Aggregate 13
4.2.2 Specific Gravity of Fine Aggregate 15
4.2.3. Bulk Density of Fine Aggregate 16
4.3 Coarse Aggregate 17
4.3.1 Sieve Analysis of Coarse Aggregate 17
4.3.2 Specific Gravity of Coarse Aggregate 19
4.3.3 Bulk Density of Coarse Aggregate 20
4.4 Water 21
4.5 Hypo Sludge 22

Mix Design 25
5.1 Definition 25
5.2 Objective 25
5.3 Procedure For Mix Design as Per IS: 10262-1982 25
V
5.4 Data 27
5.5 Calculation 27
5.6 Actual Volume of Materials for Change In Condition 29
5.7 Mix Proportions 30

Experimental Work on Concrete 31


6.1 Casting and Curing of Specimens 31
6.2 Specimen and Testing Details 31
6.3 Tests on Hardened Concrete 34
6.4 Tests on Mortar Cubes 34
6.5 Compressive Strength of Concrete Cubes 34
VI
6.6 Split Tensile Strength 35
6.7 Young‟s Modulus of Concrete 36
6.8 Bulk Density 37
6.9 Sulphate Attack 37
6.10 Concrete Weight Loss 39
6.11 Compressive Test on Mortar 39

7. Results and Discussions 40


VII
7.1 Test Results of Hardened Concrete 40

VIII Conclusion 70

IX References 71

7
LIST OF TABLES

SL.NO TITLES PAGE NO

1 Table 4.1 Properties of Cement 13


2 Table 4.2 Sieve Analysis Results of Fine Aggregate 14
3 Table 4.3 Specific Gravity of Fine Aggregate 15
4 Table 4.4 Bulk Density of Fine Aggregate 16
5 Table 4.5 Properties of Fine Aggregate 17
6 Table 4.6 Sieve Analysis of Coarse Aggregate 18
7 Table 4.7 Specific Gravity of Coarse Aggregate 19
8 Table 4.8 Bulk Density of Coarse Aggregate 20
9 Table 4.9 Properties of Coarse Aggregate 21
10 Table 4.10 Properties of Raw Hypo Sludge 22
11 Table 4.11 Properties of Hypo Sludge as Cement Ingredient 23
12 Table 4.12 Comparison of Cement and Hypo Sludge 23
13 Table 4.13 Setting Time for Cement and Hypo Sludge 24
14 Table 5.1 Adjustments of Values 28
15 Table 5.2 Design Mix Proportion 29
16 Table: 7.1Compressive Strength of Cubes at 7 Days 40
17 Table: 7.2Compressive Strength of Cubes at 14 Days 41
18 Table: 7.3Compressive Strength of Cubes at 28 Days 42
19 Table: 7.4Split Tensile Strength of Cylinder at 7 Days 44
20 Table: 7.5Split Tensile Strength of Cylinder at 14 Days 45
21 Table: 7.6Split Tensile Strength of Cylinder at 28 days 46
22 Table: 7.7Comparison of Young‟s Modulus of Concrete 48
23 Table: 7.8 Bulk Density of Concrete at 7 days 49
24 Table: 7.9 Bulk density of Concrete at 14 days 50
25 Table: 7.10 Bulk density of Concrete at 28 days 51
Table: 7.11Compression Test of Concrete after Sulphate Attack at 28
26 53
days
Table: 7.12Comparison of Normal Concrete and Sulphate Attack at 28
27 54
Days
Table: 7.13Split Tensile Strength Test of Concrete after Sulphate
28 55
Attack at 28 Days
Table: 7.14Comparison of Normal Concrete and Sulphate Attack at 28
29 56
Days
30 Table: 7.15Loss of Weight Due to Sulphate Attack in Concrete Cubes 57
at 28 Days

8
Table: 7.16 Loss of Weight Due to Sulphate Attack in Concrete
31 58
Cylinder at 28 Days
32 Table: 7.17Compressive Strength of Mortar Cubes at 3 Days 60
33 Table: 7.18Compressive Strength of Mortar Cubes at 7 Days 61
34 Table: 7.19Compressive Strength of Mortar Cubes at 14 Days 62
Table: 7.20Compressive Strength of Mortar Cubes after Sulphate
35 64
Attack at 3 Days
Table: 7.21Compressive Strength of Mortar Cubes after Sulphate
36 65
Attack at 7 Days
Table: 7.22Compressive Strength of Mortar Cubes after Sulphate
37 66
Attack at 14 Days
Table: 7.23Loss of Weight Due to Sulphate Attack in Mortar Cubes at
38 67
3 Days

9
LIST OF FIGURES

SL.N PAGE
O TITLES NO

1 Fig 1.1 Raw Hypo Sludge Disposals from TNPL 2


2 Fig. 6.1 Casting and Curing of Specimen 33
3 Fig6.2 Split Tensile Strength 35
4 Fig6.3 Young‟s Modulus of Concrete 36
5 Fig. 6.4 Sulphate attack 38
6 Fig.7.1 Compressive Strength of Concrete – Bar Chart 43
7 Fig.7.2 Split Tensile Strength of Concrete – Bar Chart 47
8 Fig.7.3 Stress-Strain Curve – Graph 48
9 Fig.7.4 Bulk Density of Concrete - Bar Chart 52
Fig.7.5 Compressive Strength of Normal and Sulphate Attack on concrete –
10
Bar Chart 54
Fig.7.6 Split Tensile Strength of Normal and Sulphate Attack on Concrete –
11
Bar Chart 56
Fig. 7.7 Comparison of Loss of Weight of Cubes and Cylinder Concrete –
12
Bar Chart 59
13 Fig.7.8 Compressive Strength of Mortar Cubes – Bar Chart 63
Fig.7.9 Compressive Strength of Sulphate Attack of Mortar Cubes – Bar
14
Chart 67
15 Fig.7.10 Loss of Weight in Mortar Cubes at 3, 7 and 14Days – Bar Chart 69

10
LIST OF SYMBOLS AND ABBREVIATIONS

IS - Indian Standards (specified by Bureau of Indian Standards)

HPCs - High Performance Concretes

OPC 53 - Ordinary Portland cement of 53 Grades

OPCC - Ordinary Portland cement Concrete

PPC - Portland Pozzolana Cement

SCMs - Supplementary Cementing Materials

CTM - Compression Testing Machine

G - Specific gravity

W - Weight in grams

FA - Fine Aggregates

CA - Coarse Aggregates

Wc - Weight of cement

Wfa - Weight of fine aggregate

Wca - Weight of coarse aggregate

Ww - Weight of water

Gc - Specific gravity of cement

Gfa - Specific gravity of fine aggregates

Gca - Specific gravity of coarse aggregates

11
CHAPTER 1

INTRODUCTION

1.1 GENERAL

Energy plays a crucial role in growth of developing countries like India. In the context of
low availability of non-renewable energy resources coupled with the requirements of large
quantities of energy for Building materials like cement, the importance of using industrial waste
cannot be under estimated.

During manufacturing of one tones of Ordinary Portland Cement we need about 1-1
tonnes of earth resources like limestone, etc. Further during manufacturing of 1 tonnes of
Ordinary Portland Cement an equal amount of carbon-di-oxide are released into the atmosphere.
The carbon-di-oxide emissions act as a silent Killer in the environment as various forms. In this
Backdrop, the search for cheaper substitute to OPC is a needful one.

1.2 SOLID WASTE FROM PAPER INDUSTRY

1.2.1 HYPO SLUDGE PROPERTIES

Where, this hypo sludge contains, low calcium and maximum calcium chloride and
minimum amount of silica. Hypo sludge behaves like cement because of silica and magnesium
properties. This silica and magnesium improve the setting of the concrete.

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1.2.2 NEED FOR HYPO SLUDGE UTILIZATION

While producing paper the various wastes are comes out from the various processes in
paper industries. From the preliminary waste named as hypo sludge due to its low calcium is
taken out for our project to replace the cement utilization in concrete. Due to the cement
production green house gases are emitted in the atmosphere. For producing 4million tones of
cement, they emit one million ton green house gases are emitted. Also, to reduce the
environmental degradation, this sludge has been avoided in mass level disposal in land. To
eliminate the ozone layer depletion, production of cement becomes reduced. For this, the hypo
sludge is used as partial replacement in the concrete as high performance concrete. By utilizing
this waste the strength will be increased and also cost reduction in the concrete is achieved.

Fig 1.1 Raw Hypo Sludge Disposals from TNPL


1.3 OBJECTIVES

To investigate the utilization of Hypo Sludge as Supplementary Cementitious Materials


(SCM) and influence of these hypo sludge on the Strength and Durability of concretes made with
different Cement replacement levels.

13
CHAPTER 2

LITERATURE REVIEW

2.1 Concrete Deterioration Caused By Sulfuric Acid Attack


Kawai, K.; Yamaji, S.; Shinmi, T.
Recently, biological deterioration of concrete in sewage and wastewater treatment
plants has been reported. This deterioration is caused by sulfuric acid attack and is
dependent on the concentration of sulfuric acid, this in turn being a function of both the
specific location within the plant and also the time over which the concrete is exposed
to elevated concentrations of acid. Given that concrete may often be exposed to very
strong acid solutions, resin coatings are applied to the concrete to protect them.
However these coating are only effective if there are neither pinholes nor defects due to
coating operations. Otherwise, the deterioration of the concrete may proceed rapidly by
sulfuric acid and sulfate. The method of predicting deterioration of coated concrete
when subjected to sulfuric acid and sulfate attack has not yet been established. It is
understood that the depth of deterioration of concrete due to sulfuric acid attack is
proportional to the square root of the exposure time. This relationship is based on results
of laboratory tests where specimens are continuously immersed in acid solutions over a
specfied period of time. But in actual structures, concrete is often exposed to flowing
water that contains an acid solution such as sewage.
In other words, concrete is subjected to the shearing force of fluid that erodes the
surface of areas of deteriorated concrete. In these instances, it is predicted that concrete
deterioration caused by sulfuric acid attack will proceed at a greater rate than that
predicted from the square root relationship. Hence in this study concrete deterioration
caused by sulfuric acid attack was investigated considering the effects of the flow of
acid solution over the surface of concrete with the intent of proposing a prediction
method for the deterioration of concrete due to sulfuric acid. Cylindrical concrete
specimens and mortar prisms were immersed in various concentrations of sulfuric acid.
In certain tests the sulfuric acid solution was circulated onto concrete specimens.
In both instances, the depths of zones eroded and neutralized by acids were measured.
14
As well, the zones of deteriorated concrete were analysed with an XRD and an ion
chromatoanalyzer. It was found that the rate of concrete deterioration caused by sulfuric
acid attack depended on the pH value of acid solutions and that the depth of erosion of
concrete was nearly proportional to the exposure time of flowing acid solution to which
concrete was exposed.

2.2 Sulfuric Acid Attack on Concrete


Portland cement (PC) concrete is generally a highly durable structural material.
Nevertheless, certain chemical actions and aggressive environments in a livestock building can
cause deterioration and total collapses of structures have occurred long before they have reached
their design life.

The sulphide and sulphate resistance of three replicates of eight different reinforced
concrete mixes were investigated in a laboratory study in which one half of the 48 specimens
2t-
were half submerged in a sodium sulphate solution (20,000 ppm SO4 ) and also exposed to
hydrogen sulphide gas (1,000 ppm H2S). The other half of the 48 specimens was subjected to
hydrogen sulphide gas only. The mixes included PC concrete with W/CM ratios of 0.4 and 0.5
and six mixes with cement replacements of slag, fly ash or silica fume, all with
water/cementitious material (W/CM) ratio of 0.4.

After 23 cycles of testing over about 36 months, the electrochemical potential results and
visual inspection of the reinforcing bars indicate that the PC concrete with 0.5 W/CM ratio was
the least resistant against steel corrosion. Corrosion of the concrete was more critical than that of
the steel. All treatments containing silica fume performed much better than PC40. Treatments
that contained fly ash performed worse than plain PC concrete with the same W/CM ratio.
Sulphate resistant cement concrete was more resistant than Type 10 Portland cement concrete, in
both sets of tests. In general the samples that were exposed to hydrogen sulphide and sulphate
corroded at a higher rate then those exposed to the H2S gas only.

In subsequent tests 6 of the 8 mixes were exposed to 7% sulphuric acid for about one
year. Preliminary results indicate the greatest mass loss for the concrete with 0.5 W/CM ratio and

15
very similar amount of loss for the 5 mixes with W/CM ratio of 0.4. The least amount of mass
loss was experienced by the mix with sulphate resistant cement.

2.3 Resistance of Scoria-Based Blended Cement Concrete against Deterioration and


Corrosion in Mixed Sulfate Environment
Khandaker M. Anwar Hossain, Ph.D., P.E.
The use of blended cements incorporating supplementary cementing materials and
cements with low C3A content is becoming common to prevent the deterioration of concrete
structures subjected to aggressive environments. This paper presents the results of an
investigation on the performance of finely ground volcanic scoria (VS)-based ASTM Type I and
Type V (low C3A) blended cement concrete mixtures with varying immersion periods of up
to 48 months in environments characterized by the presence of mixed magnesium–sodium
sulfates. The concrete mixtures comprise a combination of two Portland cements (Types I and V)
and two VS-based blended cements with two water-to-binder ratio of 0.35 and 0.45. Background
experiments (in addition to strength and fresh properties) including X-ray diffraction (XRD),
differential scanning calorimetry (DSC), mercury intrusion porosimetry (MIP), and rapid
chloride permeability (RCP) were conducted on all concrete mixtures to determine phase
composition, pozzolanic activity, porosity, and chloride ion resistance. Deterioration of concrete
due to mixed sulfate attack and corrosion of reinforcing steel were evaluated by assessing
concrete weight loss and measuring corrosion potentials and polarization resistance at periodic
intervals throughout the immersion period of 48 months. Plain (Type I/V) cement concretes,
irrespective of their C3A content, performed better in terms of deterioration and corrosion
resistance compared to Type I/V VS-based blended cement concrete mixtures in mixed sulfate
environment.

2.4 Application and Investigate Systems for the Onsite Treatment of Organic Waste
Dr.S.P.S.Bisht, B.Praveen, Y.Rajesh* And Subhasish Sahoo
Bioconversion is the environmentally sound alternate available for the stabilization and
ultimate disposal of sludge. The main objective of the present study is to contextualize the
knowledge, application and investigate systems for the onsite treatment of organic waste through

16
bioconversion by Vermicomposting. A blend of primary and secondary sludge of 80:20 and
60:40 ratios respectively from integrated pulp and paper mill was used for composting separately
with and without food and nutrients. It was observed that blend in ratio of 80:20 with food and
nutrients proved to be very useful as value added compost. Further bioactivity of these blends
was performed through microbial assay.

2.5 Wood Waste as a Construction


Felix F.U D O E Y O, Hilary I N Y A N G, David T.Y O U N G And Edmund
The enormous amount of wastes produced during wood processing operations in
many countries provides challenging opportunities for the use of wood waste as a construction
material. In this research, wood waste (saw dust and wood shaving) ash (WWA) of pretreated
timber of 0, 5, 10, 15, 20, 25and 30% by weight of cement was added as a supplement to a
concrete of a mix proportion 1:2:4:0.56 (cement: sand: coarse aggregate: water cement ratio),
and the strengths and the water absorption of the matrix were evaluated. Also, the metal
leachability of WWA was analysed. The compressive and the flexural strengths of WWA
concrete for the ages investigated ranged from 12.83 to 28.66 N/mm2, and 3.652 to 5.57 N/mm2,
respectively, with the lowest values obtained at 30% additive level of ash. When compared with
strength of plain concrete (control), the compressive and the flexural strengths of WWA concrete
were between 62 and 91% and 65 and 95%, respectively, of the former.
The trend of the water absorption of WWA concrete was a reversal of those of the
strengths, that is, the highest water absorption values were recorded for the concrete specimens
with the highest additive level of ash. A batch leaching test also performed at an ashleachant
volumetric ratio of 20 produced leachate containing chromium, arsenic, iron, copper and zinc
with the following concentrations:410; 6,720; 150; 280 and 1,690 μg/L, respectively, when
leached at a pH = 4, and 400; 10; 670; 0; 100; 1,470 μg/L, respectively, when leached at a pH =
5. These concentration levels exceed the EPA fresh water acute criteria limits.

17
2.6 Research Concerning The Use Of High Percentages Of Recycled Aggregates

Shi C O N G K O U, Chi S U N P O O N And Dixon C H A N

Shi C o n g K o u, Chi S u n P o o n and Dixon C h a n published the results of a research


concerning the use of high percentages of recycled aggregates in concrete which would usually
worsen the concrete properties. This paper tries to address the deficiency of the use of recycled
aggregates by systematically presenting results on the influence of incorporating Class F fly ash
on concrete properties. In this study, two series of concrete mixtures were prepared with water-
to-binder (W/B) ratios of 0.45 and 0.55; the recycled aggregate was used as 0, 20, 50, and 100%
by weight replacements of natural aggregate. In addition, fly ash was used as 0, 25, and 35% by
weight replacement of the cement. The obtained results showed that the compressive strengths,
tensile strength and static modulus of elasticity values of concrete at all ages decreased as the
recycled aggregate and the fly ash contents increased. Further, an increase in the recycled
aggregate content decreased the resistance to chloride ion penetration and increased the drying
shrinkage and creep of concrete. Nevertheless, the use of fly ash as a substitute for cement
improved the resistance to chloride ion penetration and decreasing the drying shrinkage Bul. Inst.
Polit. Iaşi, t. LVI (LX), f. 1, 2010 47 and creep of the recycled aggregate concrete. The results
showed also that one of the practical ways to utilize a high percentage of recycled aggregate in
structural concrete is by incorporating 25…35% of fly ash as some of the drawbacks induced by
the recycled aggregates in concrete could be minimized.

2.7 Performance of Concrete

Tarun r. Naik, member, asce, and shiw s. Singh

This research is conducted with a view to investigate performance of concrete containing


high volumes of ASTM Class C fly ash. A ordinary cement concrete, proportioned to have 28-
day compressive strength of 6,000 psi (41 N4Pa) is used in this study. Concrete mixes are also
proportioned to have various levels of cement replacement by fly ash ranging from 40% to 70%
by weight. Concrete performance is evaluated with respect to compressive strength tensile
strength and modulus of elasticity. At a 28-day age, concrete containing fly ash consistently
shows higher compressive strength compared to the no-fly ash concrete. Analysis of results
18
shows that ASTM Class C fly ash could be substituted for cement re- placements up to 70% to
achieve design compressive strength levels greater than 6,000 psi (41 MPa).

2.8 Multi-Parameter Study of External Sulphate Attack in Blended Cement Materials


Bonakdar, Mobasher
A conventional solution in reducing the potential damage in concrete structures from
external sulphate attack is to partially replace the Portland cement with appropriate fly ash.
Presently, the compatibility of fly ash as a remedial cement substitution is based on empirically
developed ASTM classifications. With proper testing techniques and multi-parameter
approaches, one can better correlate the properties of blended cements with the expected level of
damage. In this paper, parameters affecting the sulphate resistance of concrete are reviewed and
the modifications to conventional expansion tests are discussed. The role of fly ash chemical
composition on the level of damage was studied experimentally at macro and micro-scales. The
linear expansions were determined both in paste and mortar systems using standard size and
modified size specimens. Microstructural studies using ESEM and quantitative EDS were used
to characterize the nature of reaction products and fronts. Statistical analysis of data indicated
that the sulphate resistance of cementitious materials is significantly influenced by the chemical
composition and the transport properties of the system which can be improved by appropriate fly
ash substitution. It is also demonstrated that the study of these mechanisms can be expedited
using modified size specimens.

19
CHAPTER 3

MATERIALS USED

3.1 CEMENT

Ordinary Portland cement is composed of calcium silicates and aluminate and


aluminoferrite It is obtained by blending predetermined proportions limestone clay and other
minerals in small quantities which is pulverized and heated at high temperature – around 1500
deg centigrade to produce „clinker‟. The clinker is then ground with small quantities of gypsum
to produce a fine powder called Ordinary Portland Cement (OPC). When mixed with water, sand
and stone, it combines slowly with the water to form a hard mass called concrete. Cement is a
hygroscopic material meaning that it absorbs moisture In presence of moisture it undergoes
chemical reaction termed as hydration. Therefore cement remains in good condition as long as it
does not come in contact with moisture. If cement is more than three months old then it should
be tested for its strength before being taken into use.

The Bureau of Indian Standards (BIS) has classified OPC in three different grades The
classification is mainly based on the compressive strength of cement-sand mortar cubes of face
area 50 cm2 composed of 1 part of cement to 3 parts of standard sand by weight with a water-
cement ratio arrived at by a specified procedure. The grades are

(i) 33 grade

(ii) 43 grade

(iii) 53 grade

The grade number indicates the minimum compressive strength of cement sand mortar in
N/mm2 at 28 days, as tested by above mentioned procedure.

20
3.2 AGGREGATE

Aggregates are the important constituents in concrete. They give body to the concrete,
reduce shrinkage and effect economy. One of the most important factors for producing workable
concrete is good gradation of aggregates. Good grading implies that a sample fractions of
aggregates in required proportion such that the sample contains minimum voids. Samples of the
well graded aggregate containing minimum voids require minimum paste to fill up the voids in
the aggregates. Minimum paste will mean less quantity of cement and less water, which will
further mean increased economy, higher strength, lower shrinkage and greater durability.

Aggregate comprises about 55% of the volume of mortar and about 85% volume of mass
concrete. Mortar contains of size of 4.75 mm and concrete contains aggregate upto a maximum
size of 150 mm.

3.2.1 COARSE AGGREGATE

Coarse aggregate for the works should be river gravel or crushed stone .It should be hard,
strong, dense, durable, clean, and free from clay or loamy admixtures or quarry refuse or
vegetable matter. The pieces of aggregates should be cubical, or rounded shaped and should have
granular or crystalline or smooth (but not glossy) non-powdery surfaces.Aggregates should be
properly screened and if necessary washed clean before use.

Coarse aggregates containing flat, elongated or flaky pieces or mica should be rejected.
The grading of coarse aggregates should be as per specifications of IS-383.

After 24-hrs immersion in water, a previously dried sample of the coarse aggregate
should not gain in weight more than 5%.

Aggregates should be stored in such a way as to prevent segregation of sizes and avoid
contamination with fines.

21
3.2.2 FINE AGGREGATE

Aggregate which is passed through 4.75 IS Sieve is termed as fine aggregate. Fine
aggregate is added to concrete to assist workability and to bring uniformity in mixture. Usually,
the natural river sand is used as fine aggregate. Important thing to be considered is that fine
aggregates should be free from coagulated lumps.

Grading of natural sand or crushed stone i.e. fine aggregates shall be such that not more
than 5 percent shall exceed 5 mm in size, not more than 10% shall IS sieve No. 150 not less than
45% or more than 85% shall pass IS sieve No. 1.18 mm and not less than 25% or more than 60%
shall pass IS sieve No. 600 micron.

3.3 WATER

Water is an important ingredient of concrete as it actually participates in the chemical


reaction with cement. Since it helps to from the strength giving cement gel, the quantity and
quality of water is required to be looked into very carefully.

3.4 HYPO SLUDGE

Paper making generally produces a large amount of solid waste. Paper fibers can
be recycled only a limited number of times before they become too short or weak to make high
quality paper. It means that the broken, low- quality paper fibers are separated out to become
waste sludge. All the inks, dyes, coatings, pigments, staples and “stickies” (tape, plastic films,
etc.) are also washed off the recycled fibers to join the waste solids.

The shiny finish on glossy magazine-type paper is produced using a fine kaolin clay
coating, which also becomes solid waste during recycling. This paper mill sludge consumes a
large percentage of local landfill space for each and every year. Worse yet, some of the wastes
are land spread on cropland as a disposal technique, raising concerns about trace contaminants
22
building up in soil or running off into area lakes and streams. Some companies burn their sludge
in incinerators, contributing to our serious air pollution problems.

To reduce disposal and pollution problems emanating from these industrial wastes, it is
most essential to develop profitable building materials from them. Keeping this in view,
investigations were undertaken to produce low cast concrete by blending various ratios of
cement with hypo sludge.

It includes chemicals such as,


 Silica
 Lime,
 Alumina,
 Magnesium,
 Calcium sulphate.

23
CHAPTER 4

PROPERTIES OF MATERIALS

4.1 CEMENT

Table 4.1 Properties of Cement

PERMISSIBLE
PARTICULARS VALUES TEST VALUES IS CODES

Fineness modulus ≤ 10% 5% IS 4031(I)-1988

Consistency 26-34% 30.5% IS 4031(IV)-1988

Initial setting time 3o min 28 min IS 269-1967

Final setting time 600min 588min IS 269-1967

4.2 FINE AGGREGATE

4.2.1 Sieve Analysis of Fine Aggregate

The natural river sand having fineness modules of 2.705 and it corresponds to grading
zone iii of IS:383-1970 grading requirements. The specific gravity of fine aggregate is 2.54.the
particle size distribution is in table 3.3.the optimum gradation of fine aggregate is determined
more by its effect on water requirement than on physical packing. It is found that sand with a
fineness modulus below 2.5 give the concrete a sticky consistency. Making it difficult to
compact sand with a fineness of about 3.0 given the best workability and compressive strength.

24
Table 4.2 Sieve Analysis Results of Fine Aggregate

WEIGHT CUMULATIVE
RETAINED % WEIGHT % WEIGHT
IS SIEVE % WEIGHT
RETAINED PASSING
(gm) RETAINED

16mm 0 0 0 100

10mm 0 0 0 100

4.75mm 0 0 0 100

2.36mm 158 7.9 7.9 92.1

1.18mm 195 9.75 17.65 82.35

600 micron 955 47.75 65.4 34.6

300 micron 335 16.75 82.15 17.85

150 micron 305 15.25 97.4 2.6

Pan 52 - - -

Total 2000 - - 270.5

Fineness modulus=cumulative percentage retained/100=270.5/100=2.705

Fine aggregate conforms to grading zone III.

25
4.2.2 Specific Gravity of Fine Aggregate

Specific gravity of aggregate is used of in the design calculation of concrete of mixes.


With the specific gravity of each constituent known, its weight can be converted in to solid
volume and hence a theoretical yield of concrete per unit volume can be calculated.

Specific gravity of sand G = (W2-W1)/ ((W4-W1)-(W3-W2))

Table 4.3 Specific Gravity of Fine Aggregate

TEST NO 1 2 3

Wt. Of pyconometer(W1)g 610 610 610

Wt. Of pycnometer + sand(W2)g 1100 1120 1080

Wt. Of pycnometer+sand+water(W3)g 1750 1760 1720

Wt. Of pycnometer +water(W4)g 1460 1460 1460

Wt. Of dry soil (W2 –W1) 490 510 440

Wt. Of equivalent volume of water 200 210 180

Specific gravity of sand 2.55 2.53 2.54

Specific gravity of sand G=2.54

26
4.2.3. Bulk Density of Fine Aggregate

The bulk density of an aggregate gives valuable information regarding the shape and
grading of aggregate. The parameter of density is also used in concrete mix design for converting
the proportions by weight into proportions by volume when weight batching equipments is not
available at the site.

Table 4.4 Bulk Density of Fine Aggregate

SL NO PARTICULARS LOOSE COMPACT

1 Weight of container(W1)kg 6.680 6.680

2 Weight of container + water(W2)kg 11.780 11.780

3 Weight of container +aggregate(W3)kg 14.660 15.340

4 Weight of container +aggregate+ water(W4)kg 16.680 17.120

5 Volume of container(V1)lit 5.1 5.1

6 Volume of water added=volume of voids(V2)lit 2.02 1.78

7 Weight of aggregate(W3-W1)kg 7.98 8.66

8 Volume of solids (V1-V2)lit 3.08 3.32

9 Bulk density=weight of aggregate/total volume of 1.560 1.698


aggregate

10 Void ratio=volume of void/volume of solids 0.656 0.536

11 Porosity=volume of voids/total volume of aggregate 0.396 0.349

27
RESULT

Loose Compact

Porosity = 0.396 0.349

Bulk density = 1.560 1.698

Table 4.5 Properties of Fine Aggregate

PARTICULARS TEST VALUES IS CODES


Optimum moisture content 6% IS 2386(I)-1963

Fineness modulus 2.8 IS 2386(I)-1963

Specific gravity 2.54 IS 2386(III)-1963

Water absorption 0.2% IS 2386(III)-1963

4.3 COARSE AGGREGATE

4.3.1 Sieve Analysis of Coarse Aggregate

The maximum size of aggregate is fixed based on sieve analysis. This influences the
requirement of sand and water in concrete and also the spacing between the reinforcement.

The sample is brought to an air dry condition before weighing and sieving condition. This
is achieved by drying at room temperature. The air dry sample is weighed and sieved on the
appropriate sieves starting with the largest at the top. Each sieve is separately over a clean tray
until not more than.

28
Table 4.6 Sieve Analysis of Coarse Aggregate

IS SIEVE WEIGHT % WEIGHT CUMULATIVE % WEIGHT


RETAINED RETAINED % WEIGHT RETAINED
(GM) RETAINED

80mm 0 0 0 100

40mm 0 0 0 100

20mm 539 17.96 17.96 82.04

10mm 1319 43.96 61.92 38.08

4.75mm 865 28.8 90.72 9.28

2.36mm 225 7.5 98.22 1.78

1.18mm 30 1 99.22 0.78

600 micron 5 0.16 99.38 0.62

300 micron 6 0.2 99.58 0.42

150 micron 4 0.13 99.71 0.29

Pan 6 - - -

Total 3000 - - 666.7

Coarse aggregate confirms to maximum size of 20mm

29
4.3.2 Specific Gravity of Coarse Aggregate

Specific gravity of aggregate is used of in the design calculation of concrete of mixes


with the specific gravity of each constituent known. Its weight can be converted in to solid
volume and hence a theoretical yield of concrete per unit volume can be calculated.

Table 4.7 Specific Gravity of Coarse Aggregate

TEST NO 1 2 3

Wt. Of pycnometer (W1)g 610 610 610

Wt. Of pycnometer +Aggregate(W2)g 1100 1070 1175

Wt. Of pycnometer +Aggregate+ water(W3)g 1770 1750 1820

Wt. Of pycnometer+ water(W4)g 1460 1460 1460

Wt. Of dry aggregate(W2-W1) 490 460 565

Wt. Of equivalent volume of water 180 170 205

Specific gravity of coarse aggregate 2.72 2.70 2.75

Specific gravity of coarse aggregate = 2.72

30
4.3.3 Bulk Density of Coarse Aggregate

Bulk density is weight of material in a given volume. It is normally expressed in kg/m3.


The parameter of bulk density is also used in concrete mix design for converting the proportions
by weight into proportions by volume when weight batching equipments is not available at the
site.

Table 4.8 Bulk Density of Coarse Aggregate

SL NO PARTICULARS LOOSE COMPACT

1 Weight of container(W1)kg 6.680 6.680

2 Weight of container + water(W2)kg 11.780 11.780

3 Weight of container+aggregate(W3)kg 14.310 15.690

4 Weight of container+aggregate+water(W4)kg 16.680 17.120

5 Volume of container(V1)lit 5.1 5.1

6 Volume of water added=volume of voids(V2)lit 2.4 1.81

7 Weight of aggregate(W3-W1)kg 7.63 9.01

8 Volume of solids (V1-V2)lit 2.7 3.29

9 Bulk density=weight of aggregate/total volume of 1.496 1.767


aggregate

10 Void ratio=volume of void/volume of solids 0.889 0.550

11 Porosity=volume of voids/total volume of aggregate 0.471 0.355

31
Result:

Loose Compact

Porosity = 0.471 0.355

Bulk density = 1.496 1.767

Table 4.9 Properties of Coarse Aggregate

PARTICULARS TEST VALUES IS CODES

Specific gravity 2.65 IS 2386(III)-1963

Water absorption 0.5% IS 2386(III)-1963

Fineness modulus 6.9 IS 2386(III)-1963

Impact value 24.63% IS 2386(III)-1963

4.4 WATER

Water is an important ingredient of concrete as it actively participates in the chemical


reactions with cement. The strength of cement concrete comes mainly from the binding action of
the hydration of cement get the requirement of water should be reduced to that required chemical
reaction of un hydrated cement as the excess water would end up in only formation undesirable
voids or capillaries in the hardened cement paste in concrete.

It is important to have the compatibly between the given cement and the chemical
material admixtures along with the water used for mixing.

32
It is generally stated in the concrete codes and also in the literature that the water fit for
drinking is fit for making concrete. This may not be true always. For example some water
containing a small amount of sugar would be suitable for drinking, but they are good for cement
concrete, as the sugar would adversely affect the hydration process.

The limits of the content of water have to be determined from the following
consideration.

1. High content of cement is susceptible to a rapid loss of workability on Account of higher


amount of heat of hydration generated. Therefore attention is required to see that the
initial hydration rate of cement should not be significally affected
2. The salt in water would not interface with the development of strength of later ages.
3. Apart from the strength consideration, the durability characteristics such as porosity,
degree of resistance to diffusion of co2, caso4 moisture, air oxygen,etc. Should also be
investigated after specified curing period.

4.5 HYPO SLUDGE

Table 4.10 Properties of Raw Hypo Sludge

SL.NO CONSTIUTENT % PRESENT IN HYPO SLUDGE

1 Moisture 56.8

2 Magnesium oxide (mgo) 3.3

3 Calcium oxide (cao) 46.2

4 Loss on ignescent 27.00

5 Acid insoluble 11.1

6 Silica (sio2) 9.0

33
Table 4.11 Properties of Hypo Sludge As Cement Ingredient

SL.NO CONSTIUTENT % PRESENT IN HYPO SLUDGE

1 Magnesium oxide (mgo) 3.3

2 Calcium oxide (cao) 46.2

3 Loss on ignescent 27.00

4 Acid insoluble 11.1

5 Silica (sio2) 9.0

Table 4.12 Comparison of Cement and Hypo Sludge

SL. NO CONSTITUENT CEMENT (IN %) HYPO SLUDGE (IN %)

1 Lime(cao) 62 46.2

2 Silica(sio2) 22 9

3 Alumina 5 3.6

4 Magnesium 1 3.33

5 Calcium sulphate 4 4.05

34
Table 4.13 Setting Time for Cement and Hypo Sludge

SL. NO INGREDIENTS INITIAL (MIN) FINAL(MIN)

1 Cement + 0%Hypo sludge 29 600

2 Cement + 10%Hypo sludge 31 598

3 Cement + 20%Hypo sludge 33 597

4 Cement + 30%Hypo sludge 34 595

5 Cement + 40%Hypo sludge 36 593

6 Cement + 50%Hypo sludge 37 592

7 Cement + 60%Hypo sludge 38 591

8 Cement + 70%Hypo sludge 40 590

35
CHAPTER 5

MIX DESIGN

5.1 DEFINITION

Mix design is the process of selecting suitable ingredient if concrete and determines their
relative proportions with the object of certain minimum strength and durability as economically
as possible.

5.2 OBJECTIVE

The objective of concrete mix design as follows.

1. The first objective is to achieve the stipulated minimum strength.


2. The second objective is to make the concrete in the most economical Manner. Cost
wise all concrete‟s depends primarily on two factors, namely cost of material and cost
of labor. Labor cost, by way of formwork, batching, mixing, transporting and curing
is namely same for good concrete.

There are attention is mainly directed to the cost of materials. Since the cost of cement is
many times more than the cost of their ingredients, optimum usage of cement is sought for by
designing the mix.

5.3 PROCEDURE FOR MIX DESIGN AS PER IS:10262-1982

1. The following basic data are required for a concrete mix.


a. Characteristics compressive strength of concrete
b. Degree of workability desired
c. Max water cement ratio of coarse aggregate
d. Type of max size of coarse aggregate
e. Standard deviation-based on concrete control
f. Statistical constant-accepted
g. Grade of cement used

36
2. Target mean strength is determined as

3. The water/cement ratio for the target mean strength is obtained from fig 2 of IS:10262-
1982 and is limited as per table 3 of IS:456-2000

4. The air content is estimated as per table 3 of IS:10262-1982

5. Appropriate sand and water content per m3 of concrete are selected as per table 4 and 5
differs in IS:456-2000

6. Adjustment in sand percentage and water content are made as per table 6 if the condition
given for table 4 or 5 differs in IS:456-2000

7. Collected water quantity is computed and hence from W/c ratio

8. The quantity of fine aggregate and coarse aggregate per unit volume of concrete can be
calculated from the following equation

The mix proportions by weight are computed by keeping cement as one unit

37
5.4 DATA

Characteristic compressive strength required : 25 N/mm2


Maximum size of aggregate : 20mm angular
Degree of workability : 0.9 compacting factor
Degree of quality control : good
Type of exposure : mild
Specific gravity of cement : 3.15
Specific gravity of fine aggregate : 2.54
Specific gravity of coarse aggregate : 2.65
Water absorption fine aggregate : Nil
Water absorption coarse aggregate : 0.5%
Free (surface) moisture fine aggregate : 2%
Free (surface) moisture coarse aggregate : Nil
Air Content : 2% for 20mm aggregate
Water Content for zone II : 186 kg per m3 of concrete for
upto M35
Sand Content for zone II : 35% of total agg. by absolute
for upto M35

5.5 CALCULATION

Target Mean Strength,


fck*=fck + t x s
fck*=25+1.65 x 5.3
fck*=33.745N/mm2

Selection Of Water Cement Ratio : 0.425 from graph

38
Table 5.1 Adjustments of Values

ADJUSTMENT OF VALUES IN WATER CONTENT AND SAND PERCENTAGE FOR


OTHER CONDITIONS
ADJUSTMENT REQUIRED
Water %Sand in Total
CHANGE IN CONDITION STIPULATED Content aggregate
For sand conforming to grading Zone I, Zone III or Zone IV 0 -1.5
decrease in the value of compacting factor by 0.1(0.9-0.8) 3 0
Each 0.05 increase or decrease in free water-cement ratio 0 -3
For rounded aggregate 0 0
CHANGE IN CONDITION 3 -4.5

Selection of sand content = 35-4.5


= 30.5%

Selection of water content = 186+(186 x 3/100)


= 191.58 lit/m3

Calculation of cement content = 191.58/0.425


= 450.78kg/m3

Calculation of fine aggregate content,

f a = 499.93 kg/m3

39
Calculation of coarse aggregate content

ca =1188.51 kg/m3

5.6 ACTUAL VOLUME OF MATERIALS FOR CHANGE IN CONDITION

Actual qty. of water = 191.58+(1188.511 X 0.5/100)-(499.93 X 2/100)


= 187.52lit

Actual qty. of cement = 450.78kg/m3

Actual qty. of fine aggregate = 499.93+(499.93 X 2/100)


= 509.93kg/m3

Actual qty. of coarse aggregate = 1188.511-(1188.511 X 0.5/100)


= 1182.57kg/m3
Table 5.2 Design Mix Proportion

WATER CEMENT FINE COARSE


AGGREGATE AGGREGATE
By weight(kg) 187.52 450.78 509.93 1182.57

By volume 0.416 1 1.13 2.623

By bag of cement 20.8 50 56.56 131.17

40
5.7 MIX PROPORTIONS

Conventional Concrete – 1: 1.13:2.623

10% replacement – 0.90: 1.13:2.623

20% replacement – 0.80: 1.13:2.623

30% replacement – 0.70: 1.13:2.623

40%replacement – 0.60: 1.13:2.623

50% replacement – 0.50: 1.13:2.623

60% replacement – 0.40: 1.13:2.623

70% replacement – 0.30: 1.13:2.623

41
CHAPTER 6

EXPERIMENTAL WORK ON CONCRETE

6.1 CASTING AND CURING OF SPECIMENS

For ordinary concrete, fine aggregate and cement were weighted and mixed thoroughly:
the coarse aggregate was then added and mixed with the above. The required amount of water
was added and mixed thoroughly to get uniform concrete mass. And compacting the concrete in
the mould by hand compaction as per Indian Standards procedures.

For preparing the specimens for determine the compressive and tensile permanent steel modulus,
of standards size were used. The fresh concrete was filled in the mould. Care should be taken to
see that the concrete was compacted perfectly. All the moulds were remoulded after 24 hours of
casting and cured. They were tested on 14th and 28th day, as per IS 456-2000.

6.2 SPECIMEN AND TESTING DETAILS

The following specimens were casted with hypo sludge concrete.

1. 84 no‟s of cube of size 150mm X 150mm X 150mm were casted for the determination
of compressive strength of cement and partially replacement of hypo sludge concrete specimen.

2. 84 no‟s of cylinders of size 150mm Dia &300mm height were casted for the
determination of split tensile strength of cement and partially replacement of hypo sludge
concrete specimen.

3. 63 no‟s of cylinders of size 150mm Dia &300mm height were casted for the
determination of young‟s modulus of cement and partially replacement of hypo sludge concrete
specimen.

4.126 no‟s of cube size 70.6mm X 70.6mm X70.6mm were casted for the determination
of compressive strength of cement and partially replacement of hypo sludge mortar specimen.

42
43
Fig. 6.1 Casting and Curing of Specimen

44
6.3 TESTS ON HARDENED CONCRETE

1. Compressive strength.
2. Split Tensile test.
3. Young‟s modulus test.
4. Bulk density test.
5. Sulphate attack.
6. Loss of weight due to sulphate attack.

6.4 TESTS ON MORTAR CUBES

1. Compressive strength of mortar cubes.

2. Sulphate attack

3. Loss of weight due to sulphate attack.

6.5 COMPRESSIVE STRENGTH OF CONCRETE CUBES

The Compressive strength of concrete is one of the most important and useful properties
of concrete. In most structural applications concrete is used primarily to resist Compressive
stress. In those cases were strength in tension or shear is of primarily impotents, the Compressive
strength is frequently used as a measure for other properties. Compressive strength is also used
as a qualitative measure for other properties of hardened concrete. In practical the Compressive
strength increases as the specimen size decreases.

At least three cubes of 150mm X 150mm X 150mm are cast for each age, usual 7, 14, &
28 days. The specimens are cured for one day and in water for rest of the days. Specimens are
tested in saturated condition. Cubes are placed such a manner in testing machine that they line of
loading is perpendicular to direction was cast. Constant load of 140 kg/cm2/min is applied till
failure.

Compressive stress = Ultimate load / Bearing area.

45
6.6 SPLIT TENSILE STRENGTH

The test specimen shall consist of concrete cylinders of 150mmin diameter & 300mm
long. The same compressive test machine is used for finding tensile strength also.

The specimens should be kept in dry condition for 24 hours before testing. Plywood strip
of 12mm X 3mm is centered along the center of the lower axis is then shock and increased
continuously at rate to produces approximately a splitting tensile stress of 14 to 21 kg/cm2/min
until failure.

The split tensile strength is calculated from the following formula,

2P

Split tensile strength = ---------------

Π DL

Where,

P  maximum load, N

D  diameter of the specimen, mm

L  length of the specimen, mm

Fig6.2 Split Tensile Strength

46
6.7 YOUNG’S MODULUS OF CONCRETE

An elastic modulus, or modulus of elasticity, is the mathematical description of an object


or substance's tendency to be deformed elastically (i.e., non-permanently) when a force is applied
to it. The elastic modulus of an object is defined as the slope of its stress-strain curve in the
elastic deformation region:

where lambda (λ) is the elastic modulus; stress is the restoring force caused due to the
deformation divided by the area to which the force is applied; and strain is the ratio of the change
caused by the stress to the original state of the object. If stress is measured in Pascal‟s, since
strain is a dimensionless quantity, then the units of λ are Pascal‟s as well.

Since the denominator becomes unity if length is doubled, the elastic modulus becomes the stress
needed to cause a sample of the material to double in length. While this endpoint is not realistic
because most materials will fail before reaching it, it is practical, in that small fractions of the
defining load will operate in exactly the same ratio.

Fig6.3 Young‟s Modulus of Concrete

47
6.8 BULK DENSITY

Bulk density is a property of powders, granules and other "divided" solids, especially
used in reference to mineral components (soil, gravel), chemical substances, (pharmaceutical)
ingredients, foodstuff or any other masses of corpuscular or particulate matter.

It is defined as the mass of many particles of the material divided by the


total volume they occupy. The total volume includes particle volume, inter-particle void volume
and internal pore volume.Bulk density is not an intrinsic property of a material; it can change
depending on how the material is handled. For example, a powder poured in to a cylinder will
have a particular bulk density; if the cylinder is disturbed, the powder particles will move and
usually settle closer together, resulting in a higher bulk density.

6.9 SULPHATE ATTACK

Sulphate attack is a chemical reaction, affecting the concrete in the floor construction of
properties. Sulphates present in contaminated hardcore, together with a source of moisture it
reacts with the cement in the concrete causing it to expand and crack. The expansive force of the
chemical reaction can displace the external and sleeper walls leading to the opening of skirting
board joints, the bouncing of timber floors, cracking and displacement of brickwork as the above
photo and the disruption of concrete floors and sub-floors. It can take anything for 10 to 20 years
for the physical defects mentioned above to manifest themselves. With sulphate attack the
correct solution is to remove all defective concrete and contaminated hardcore and replace both.
This is very disruptive and costs can be substantial. Microscopic view of sulphate crystals
Sulphate attack is not normally covered by buildings insurance as it tends to be excluded by
means of a clause exempting all forms of chemical attack.

However, where it is possible to prove that an escape of water such as a cracked drain has
triggered the reaction the insurance claim may be successful. Alan Wood & Partners have the
expertise to identify the problem, to recover samples and to test the concrete to prove the
presence of sulphate attack. We also are able to advice and co-ordinate any remedial action that
may be required, advising on insurance issues where appropriate.

48
Fig. 6.4 Sulphate attack
49
6.10 CONCRETE WEIGHT LOSS

The level of attack of the concrete by the sulphate solution was determined by measuring the weight
loss of samples with time. Total weight loss over the 28 days exposure period for each mix type is presented in
Table 4. Figure 1, shows a graph of the average weight change with time (of 3 samples) for each of the trial
mixes.

6.11 COMPRESSIVE TEST ON MORTAR

It is a good practice to test the compressive strength of cement in projects which are
planned for longer durations (>12months). The shelf life of Cement is no longer than six months
and it starts losing strength even just after one month of storage. General Construction and Small
Scale Construction works does not need testing if rate of their consumption is within 6 months
.However, testing compressive strength of cement at site is very simple procedure. You just need
to have compression testing machine, a cube mould of uniform dimensions of 7.06cm, cement,
sand (confirm to IS 650:1991), water.

Mix the cement with the sand in the ratio of 1:3 and then add water in the resultant
mixture in the ratio of P/4+3% of combined weight of cement and sand. For practical purposes
one can take the ratio of water between 0.5-0.65 depending on the need of workability and sand
on the site can be used. Put the paste in the mould and prepare three such samples. Initially
moulds are kept under gunny bags for practical purpose of achieving 90% humidity, otherwise
they should be kept under 27±2OC with 90% humidity in humidifier. Then cubes are taken out
from moulds after 24 hours and immersed in water for testing the strength at 3, 7, and 28 days
respectively.

E.g. - for 33 grade 3 days and 7 days strength should not be less than 16MPa and 22MPa
respectively. One can easily get it tested at very nominal rates at certified laboratories. Many
non- destruction techniques are also made available by different companies in market these days.
You can take service from any one such good company to ease off your part of burden.

50
CHAPTER 7
RESULTS AND DISCUSSIONS

7.1 TEST RESULTS OF HARDENED CONCRETE


Table: 7.1Compressive Strength of Cubes at 7 Days
Partial Ultimate Compressive Average Ultimate
Number of Ultimate load
replacement Strength Compressive Strength
specimen in kN
in % in N/mm2 in N/mm2
295 13.11
290 12.89 13.11
0 3
300 13.33
300 13.33
310 13.78 13.33
10 3
290 12.89
295 13.11
310 13.77 13.40
20 3
300 13.33
295 13.11
335 14.88 13.99
30 3
315 13.99
140 6.22
135 6.00 6.07
40 3
135 6.00
115 5.11
105 4.66 4.89
50 3
110 4.89
85 3.77
80 3.55 3.55
60 3
75 3.33

51
Table: 7.2Compressive Strength of Cubes at 14 Days
Partial Number of Ultimate Compressive Strength Ultimate Compressive
replacement in % specimen load in kN in N/mm2 Strength in N/mm2

510 22.67
0 3 505 22.44 22.67
515 22.89
515 22.89
10 3 525 23.33 22.89
505 22.44
510 22.67
20 3 525 23.33 22.96
515 22.89
510 22.67
30 3 550 24.44 23.56
530 23.56
355 15.78
40 3 350 15.56 15.63
350 15.56
330 14.67
50 3 320 14.22 14.44
325 14.44
300 13.33
60 3 295 13.11 13.11
290 12.89

52
Table: 7.3Compressive Strength of Cubes at 28 Days

Partial Number of Ultimate load Ultimate Compressive Average Ultimate


replacement specimen in KN Strength Compressive Strength
in % in N/mm2 in N/mm2
610 27.11
0 3 650 28.89 28.00
630 28
670 29.78
10 3 640 28.44 29.04
650 28.89
670 29.78
20 3 690 30.67 30.22
680 30.22
700 31.11
30 3 710 31.56 31.33
705 31.33
585 26
40 3 590 26.22 26.07
585 26
590 26.22
50 3 550 24.44 25.41
575 25.56
510 22.67
60 3 550 24.44 23.56
530 23.56

53
Fig.7.1 Compressive Strength of Concrete – Bar Chart

Discussion

In this research the value of compressive strength for different replacement levels of hypo
sludge (0%, 10%,20%, 30%, 40%, 50%and 60%) at the end of the curing periods (7 days, 14
days and 28 days) are given in the above table. These values are plotted in graph. This shows the
variation of compressive strength with hypo sludge replacement at different curing ages
respectively.

From our research, the compressive strength increase upto 30% hypo sludge replacement
and the 40% replacement in nearly equal to conventional concrete. And the 50% and 60%
replacement of hypo sludge in compressive strength is decreases.

54
Table: 7.4Split Tensile Strength of Cylinder at 7 Days

Partial Number of Ultimate load Ultimate Split Tensile Average Ultimate Split
replacement specimen in kN Strength Tensile Strength
in % in N/mm2 in N/mm2
110 1.56
0 3 105 1.49 1.5
107 1.51
135 1.91
10 3 135 1.91 1.9
125 1.77
135 1.91
20 3 140 1.98 2.0
142 2.01
143 2.02
30 3 145 2.05 2.1
148 2.09
75 1.06
40 3 55 0.78 0.9
65 0.92
65 0.92
50 3 55 0.78 0.8
60 0.85
55 0.78
60 3 50 0.71 0.7
45 0.64

55
Table: 7.5Split Tensile Strength of Cylinder at 14 Days

Partial Number of Ultimate load Ultimate Split Tensile Average Ultimate Split
replacement specimen in kN Strength Tensile Strength
in % in N/mm2 in N/mm2
180 2.55
0 3 175 2.48 2.4
160 2.26
160 2.26
10 3 185 2.62 2.5
190 2.69
190 2.69
20 3 195 2.76 2.8
200 2.83
200 2.83
30 3 205 2.90 2.9
210 2.97
170 2.41
40 3 160 2.26 2.2
140 1.98
160 2.26
50 3 155 2.19 2.1
130 1.84
135 1.91
60 3 140 1.98 1.9
135 1.91

56
Table: 7.6Split Tensile Strength of Cylinder at 28 days

Partial Number of Ultimate load Ultimate Split Tensile Average Ultimate Split
replacement specimen in kN Strength in N/mm2 Tensile Strength in
in % N/mm2
250 3.54
0 3 270 3.82 3.7
260 3.68
260 3.68
10 3 275 3.89 3.9
290 4.10
280 3.96
20 3 290 4.10 4.0
285 4.03
310 4.39
30 3 300 4.25 4.3
305 4.32
250 3.54
40 3 240 3.40 3.5
260 3.68
210 2.97
50 3 230 3.26 3.1
220 3.11
210 2.97
60 3 200 2.83 2.9
205 2.90

57
Fig.7.2 Split Tensile Strength of Concrete – Bar Chart

Discussion

In this research the value of split tensile strength for different replacement levels of hypo
sludge (0%, 10%,20%, 30%, 40%, 50%and 60%) at the end of the curing periods (7 days, 14
days and 28 days) are given in the above table. These values are plotted in graph. This shows the
variation of split tensile strength with hypo sludge replacement at different curing ages
respectively.

From our research, the split tensile strength increase upto 30% hypo sludge replacement
and the 40% replacement in nearly equal to conventional concrete. And the 50% and 60%
replacement of hypo sludge in split tensile strength is decreases.

58
Stress-strain curve

Fig.7.3 Stress-Strain Curve - Graph

Table: 7.7Comparison of Young‟s Modulus of Concrete

Partial replacement in % Stress 1 X 105 in N/mm 2 Strain


0 5.37 0.0074
10 4.53 0.0085
20 5.37 0.0089
30 5.37 0.0093
40 5.37 0.0072
50 5.37 0.0067
60 5.37 0.0057
Discussion

In this research the value of young‟s modulus of concrete for different replacement levels
of hypo sludge (0%, 10%,20%, 30%, 40%, 50%and 60%) at the end of the curing periods (7
days, 14 days and 28 days) are given in the above table. These values are plotted in graph. This
shows the variation of young‟s modulus with hypo sludge replacement at different curing ages
respectively.

From our research, the strain is increase upto 30% hypo sludge replacement and the 40%
replacement in nearly equal to conventional concrete. And the 50% and 60% replacement of
hypo sludge in strain is decreases.
59
Table: 7.8 Bulk Density of Concrete at 7 days

Partial Number of Bulk density in Average Bulk density


Sl.No
replacement in % specimen kg/ m3 in kg/m 3
2475.78
1 0 3 2493.488 2518.7
2586.831
2501.556
2 10 3 2488.892 2489.606
2478.371
2465
3 20 3 2537.517 2509.168
2524.986
2539.272
4 30 3 2555.569 2523.545
2475.795
2392.69
5 40 3 2385 2390.174
2392.832
2431.237
6 50 3 2419.772 2431.677
2444.023
2399.013
7 60 3 2406.42 2405.933
2412.365

60
Table: 7.9Bulk density of Concrete at 14 days

Partial Number of Bulk density in Average Bulk density


Sl.No
replacement in % specimen kg/ m3 in kg/m 3
2490.78
1 0 3 2508.49 2533.7
2601.83
2516.56
2 10 3 2503.89 2504.606
2493.37
2480
3 20 3 2552.52 2524.168
2539.99
2554.27
4 30 3 2570.57 2538.545
2490.8
2407.69
5 40 3 2400 2405.174
2407.83
2446.24
6 50 3 2434.77 2446.677
2459.02
2414.01
7 60 3 2421.42 2420.933
2427.37

61
Table: 7.10 Bulk density of Concrete at 28 days

Partial Number of Bulk density in Average Bulk density


Sl.No
replacement in % specimen kg/ m3 in kg/m 3
2462.62
1 0 3 2563.05 2540.708
2596.46
2522.34
2 10 3 2503.43 2532.611
2572.07
2515.21
3 20 3 2598.9 2538.704
2502.01
2599.17
4 30 3 2510.48 2544.089
2522.62
2471.82
5 40 3 2429.67 2454.714
2462.66
2460.09
6 50 3 2452.55 2450.93
2440.15
2437.46
7 60 3 2435.04 2432.612
2425.34

62
Fig.7.4 Bulk Density of Concrete - Bar Chart

Discussion

In this research the value of bulk density of concrete for different replacement levels of
hypo sludge (0%, 10%,20%, 30%, 40%, 50%and 60%) at the end of the curing periods (7 days,
14 days and 28 days) are given in the above table. These values are plotted in graph. This shows
the variation of bulk density with hypo sludge replacement at different curing ages respectively.

From our research, the bulk density increase upto 30% hypo sludge replacement and the
other 40%, 50% and 60% replacement of hypo sludge in bulk density are decreases.

63
Table: 7.11Compression Test of Concrete after Sulphate Attack at 28 days

Partial Number of Ultimate load Ultimate Compressive Average Ultimate


replacement specimen in kN Strength Compressive Strength
in % in N/mm2 in N/mm2
460 20.44
0 3 455 20.22 20.67
480 21.33
475 21.11
10 3 465 20.67 20.74
460 20.44
465 20.67
20 3 470 20.89 20.89
475 21.11
490 21.78
30 3 480 21.33 21.48
480 21.33
420 18.67
40 3 400 17.78 17.93
390 17.33
300 13.33
50 3 280 12.44 13.33
320 14.22
240 10.67
60 3 260 11.56 11.48
275 12.22

64
Table: 7.12Comparison of Normal Concrete and Sulphate Attack at 28 Days

Compressive strength at 28 days in N/mm2


Partial replacement in %
Normal concrete Sulphate attack concrete
0
28.00 20.67
10 29.04 20.74
20 30.22 20.89
30 31.33 21.48
40 26.07 17.93
50 25.41 13.33
60 23.56 11.48

Fig.7.5 Compressive Strength of Normal and Sulphate Attack on concrete – Bar Chart

Discussion

In this research the value of compressive strength of concrete for different replacement
levels of hypo sludge (0%, 10%,20%, 30%, 40%, 50%and 60%)are curing into water and
sulphuric acid at the curing periods of 28 days and given in the above table. These values are
plotted in graph. This shows the variation of compressive strength with hypo sludge replacement
at different curing ages respectively. The results are increase upto 30% and decrease above 40%.
65
Table: 7.13Split Tensile Strength Test of Concrete after Sulphate Attack at 28 Days

Partial Number of Ultimate load Split Tensile Average Split Tensile


replacement in % specimen in kN Strength in N/mm2 Strength in N/mm2
200 2.83
0 3 220 3.11
3.0
210 2.97
210 2.97
10 3 225 3.18
3.2
240 3.40
230 3.26
20 3 240 3.40
3.3
235 3.33
260 3.68
30 3 250 3.54
3.6
255 3.61
200 2.83
40 3 190 2.69
2.8
210 2.97
160 2.26
50 3 180 2.55
2.4
170 2.41
160 2.26
60 3 150 2.12 2.2
155 2.19

66
Table: 7.14Comparison of Normal Concrete and Sulphate Attack at 28 Days

Split Tensile Strength at 28 days in kN/mm2


Partial replacement in %
Normal concrete Sulphate attack concrete
0 3.7 3.0
10 3.9 3.2
20 4.0 3.3
30 4.3 3.6
40 3.5 2.8
50 3.1 2.4
60 2.9 2.2

Fig.7.6 Split Tensile Strength of Normal and Sulphate Attack on Concrete – Bar Chart

Discussion

In this research the value of split tensile strength of concrete for different replacement
levels of hypo sludge (0%, 10%,20%, 30%, 40%, 50%and 60%)are curing into water and
sulphuric acid at the curing periods of 28 days and given in the above table. These values are
plotted in graph. This shows the variation of split tensile strength with hypo sludge replacement
at different curing ages respectively. The results are increase upto 30% and decrease above 40%.
67
Table: 7.15Loss of Weight Due to Sulphate Attack in Concrete Cubes at 28 Days

Partial Weight of concrete Weight of concrete Loss of Percentage Average


replacement cubes at 28 days cubes after sulphate weight of losses Percentage of
in % curing in kg attack in kg in kg in % losses in %
8.96 8.69 0.27 3.01
0 8.67 8.38 0.29 3.34 3.14
8.8 8.53 0.27 3.07
8.65 8.41 0.24 2.77
10 8.87 8.63 0.24 2.71 2.70
8.75 8.52 0.23 2.63
8.57 8.34 0.23 2.68
20 8.53 8.33 0.2 2.34 2.54
8.5 8.28 0.22 2.59
8.57 8.37 0.2 2.33
30 8.64 8.45 0.19 2.20 2.21
8.55 8.37 0.18 2.11
8.15 8.01 0.14 1.72
40 8.2 8.02 0.18 2.20 1.96
8.1 7.94 0.16 1.98
8.44 8.32 0.12 1.42
50 8.37 8.23 0.14 1.67 1.55
8.35 8.22 0.13 1.56
8.3 8.17 0.13 1.57
60 8.29 8.15 0.14 1.69 1.49
8.25 8.15 0.1 1.21

68
Table: 7.16 Loss of Weight Due to Sulphate Attack in Concrete Cylinder at 28 Days

Partial Weight of concrete Weight of concrete Loss of Percentage Average


replaceme cylinder at 28 days cylinder after sulphate weight of losses Percentage of
nt in % curing in kg attack in kg in kg in % losses in %
13.62 13.34 0.28 2.06
0 13.55 13.24 0.31 2.29 2.18
13.70 13.40 0.30 2.19
13.15 12.89 0.26 1.98
10 13.24 12.98 0.26 1.96 1.86
13.52 13.30 0.22 1.63
13.20 12.94 0.26 1.97
20 13.09 12.85 0.24 1.83 1.82
13.17 12.95 0.22 1.67
13.03 12.82 0.21 1.61
30 13.04 12.84 0.20 1.53 1.55
13.31 13.11 0.20 1.50
12.72 12.53 0.19 1.49
40 12.56 12.38 0.18 1.43 1.44
12.80 12.62 0.18 1.41
12.82 12.65 0.17 1.33
50 12.85 12.68 0.17 1.32 1.30
12.75 12.59 0.16 1.25
12.80 12.65 0.15 1.17
60 12.79 12.67 0.12 0.94 0.99
12.75 12.64 0.11 0.86

69
Fig. 7.7 Comparison of Loss of Weight of Cubes and Cylinder Concrete – Bar Chart

Discussion

In this research the value of loss of weight of concrete cubes and cylinder for different
replacement levels of hypo sludge (0%, 10%,20%, 30%, 40%, 50%and 60%) at the end of the
curing periods (28 days) are given in the above table. These values are plotted in graph. This
shows the variation of loss of weight of concrete cubes and cylinders with hypo sludge
replacement at different curing ages respectively.

From our research, the loss of weight is decrease in all replacement of hypo sludge
compare to conventional concrete.

70
Table: 7.17Compressive Strength of Mortar Cubes at 3 Days

Partial Compressive Average Compressive


Ultimate load
replacement strength in strength
in % In div In N N/mm2 in N/mm2
5 5000 10.03
0 6 6000 12.04 11.03
5.5 5500 11.04
5.5 5500 11.04
10 6 6000 12.04 11.70
6 6000 12.04
6.5 6500 13.04
20 6 6000 12.04 13.38
7.5 7500 15.05
7 7000 14.04
30 7.5 7500 15.05 15.05
8 8000 16.05
7.5 7500 15.05
6.5 6500 13.04 14.04
40
7 7000 14.04
5 5000 10.03
50 5.5 5500 11.04 10.03
4.5 4500 9.03
3 3000 6.02
60 4.5 4500 9.03 7.36
3.5 3500 7.02

71
Table: 7.18Compressive Strength of Mortar Cubes at 7 Days

Partial Ultimate load Compressive Average Compressive


replacement strength in strength
In div In N
in % N/mm2 in N/mm2
9 9000 18.06
17.05
0 8.5 8500 17.05
8 8000 16.05
8.5 8500 17.05
18.39
10 9 9000 18.06
10 10000 20.06
9.5 9500 19.06
19.39
20 10 10000 20.06
9.5 9500 19.06
10 10000 20.06
20.06
30 9.5 9500 19.07
10.5 10500 21.07
8.5 8500 17.05
18.06
40 9 9000 18.06
9.5 9500 19.06
8 8000 16.05
16.05
50 8.5 8500 17.05
7.5 7500 15.05
8 8000 16.05
60 7.5 7500 15.04 15.05
7 7000 14.04

72
Table: 7.19Compressive Strength of Mortar Cubes at 14 Days

Partial Ultimate load Compressive Average Compressive


replacement strength in strength
In div In N
in % N/mm2 in N/mm2
23 230000 46.14
0 22.5 225000 45.14 23.41
22 220000 44.14
19.5 195000 39.12
10 20 200000 40.13 23.74
21 210000 42.13
21.5 215000 43.14
20 20 200000 40.13 24.74
22 220000 44.14
23.5 235000 47.15
30 24 240000 48.15 26.08
22 220000 44.14
19.5 195000 39.12
40 17.5 175000 35.11 20.06
18 180000 36.11
16 160000 32.10
50 15.5 155000 31.10 13.38
17 170000 34.11
14 140000 28.09
60 13.5 135000 27.09 10.03
15 150000 30.09

73
Fig.7.8 Compressive Strength of Mortar Cubes – Bar Chart

Discussion

In this research the value of compressive strength of mortar cubes for different
replacement levels of hypo sludge (0%, 10%,20%, 30%, 40%, 50%and 60%) at the end of the
curing periods (7 days, 14 days and 28 days) are given in the above table. These values are
plotted in graph. This shows the variation of compressive strength of mortar cubes with hypo
sludge replacement at different curing ages respectively.

From our research, the compressive strength increase upto 30% hypo sludge replacement
and the other 40%, 50% and 60% replacement of hypo sludge in compressive strength are
decreases.

74
Table: 7.20Compressive Strength of Mortar Cubes after Sulphate Attack at 3 Days

Partial Ultimate load Compressive Average Compressive


replacement In div In N strength in strength
in % N/mm2 in N/mm2
4 4000 8.03
0 4.5 4500 9.03 9.03
5 5000 10.03
5 5000 10.03
10 4.5 4500 9.03 9.70
5 5000 10.03
5 5000 10.03
20 5.5 5500 11.04 11.37
6.5 6500 13.04
7 7000 14.04
30 6 6000 12.04 13.04
6.5 6500 13.04
5.5 5500 11.04
40 6 6000 12.04 12.04
6.5 6500 13.04
4 4000 8.03
50 4.5 4500 9.03 9.03
5 5000 10.03
3 3000 6.02
60 3.5 3500 7.02 5.68
2 2000 4.01

75
Table: 7.21Compressive Strength of Mortar Cubes after Sulphate Attack at 7 Days

Partial Ultimate load Compressive Average Compressive


replacement In div In N strength in strength
in % N/mm2 in N/mm2
8 8000 16.05
0 7.5 7500 15.05 15.05
7 7000 14.04
7 7000 14.04
10 8 8000 16.05 15.72
8.5 8500 17.05
8.5 8500 17.05
20 8.5 8500 17.05 17.39
9 9000 18.06
9 9000 18.06
30 9.5 9500 19.06 18.39
9 9000 18.06
7 7000 14.04
40 7.5 7500 15.05 14.04
6.5 6500 13.04
6 6000 12.04
50 6.5 6500 13.04 12.37
6 6000 12.04
4.5 4500 9.03
60 5.5 5500 11.04 9.36
4 4000 8.03

76
Table: 7.22Compressive Strength of Mortar Cubes after Sulphate Attack at 14 Days

Partial Ultimate load Compressive Average Compressive


replacement In div In N strength in strength
in % N/mm2 in N/mm2
8.5 8500 17.05
0 9.5 9500 19.06 18.06
9 9000 18.06
9.5 9500 19.06
10 9 9000 18.06 18.73
9.5 9500 19.06
10 10000 20.06
20 9.5 9500 19.06 19.73
10 10000 20.06
10.5 10500 21.07
30 11 11000 22.07 21.07
10 10000 20.06
8.5 8500 17.05
40 9 9000 18.06 16.72
7.5 7500 15.05
6.5 6500 13.05
50 6 6000 12.04 12.04
5.5 5500 11.04
3.5 3500 7.03
60 3 3000 6.02 6.69
3.5 3500 7.02

77
Fig.7.9 Compressive Strength of Sulphate Attack of Mortar Cubes – Bar Chart

Discussion

In this research the value of compressive strength of mortar cubes for different
replacement levels of hypo sludge (0%, 10%,20%, 30%, 40%, 50%and 60%) are curing in to
water and sulphuric acid at the end of the curing periods (7 days, 14 days and 28 days) are given
in the above table. These values are plotted in graph. This shows the variation of compressive
strength of mortar cubes with hypo sludge replacement at different curing ages respectively.

From our research, the compressive strength increase upto 30% hypo sludge replacement
and the other 40%, 50% and 60% replacement of hypo sludge in compressive strength are
decreases.

78
Table: 7.23Loss of Weight Due to Sulphate Attack in Mortar Cubes at 3 Days

Partial Weight of mortar Weight of mortar Loss of Percentage Average


replacement cubes at 3 days cubes after sulphate weight of losses in Percentage of
in % curing in kg attack in kg in kg % losses in %
940 910 30 3.19
0 930 900 30 3.23 3.23
920 890 30 3.26
910 880 30 3.30
10 920 890 30 3.26 3.10
915 890 25 2.73
900 875 25 2.78
20 910 875 35 3.85 2.94
905 885 20 2.21
900 880 20 2.22
30 890 875 15 1.69 2.25
880 855 25 2.84
870 855 15 1.72
40 880 865 15 1.70 2.08
885 860 25 2.82
885 875 10 1.13
50 880 860 20 2.27 1.71
865 850 15 1.73
865 850 15 1.73
60 875 865 10 1.14 1.34
880 870 10 1.14

79
Fig.7.10 Loss of Weight in Mortar Cubes at 3, 7 and 14Days – Bar Chart

Discussion

In this research the value of loss of weight of mortar cubes for different replacement
levels of hypo sludge (0%, 10%,20%, 30%, 40%, 50%and 60%) at the end of the curing periods
(7 days, 14 days and 28 days) are given in the above table. These values are plotted in graph.
This shows the variation of loss of weight of mortar cubes with hypo sludge replacement at
different curing ages respectively.

From our research, the loss of weight is decrease in all replacement of hypo sludge
compare to conventional concrete.

80
CHAPTER 8

CONCLUSION

The following conclusions could be drawn from the study:


1. Hyposludge as waste product from paper industry available in India could be used as
mineral admixtures in concrete. Its use in concrete could save as much as 40 percent of cement
as binding material, while providing the same strength.
2. Hyposludge concrete could be produced with satisfactory slump and setting times with
nearly the same water cementing material ratio as in normal concrete without mineral.
3. Under certain conditions, replacement of cement by hyposludge appears to increase the
strength of concrete.
4. Under sulphate attack, performance of cement concrete cube specimen prepared with 40
percent cement replaced by hyposludge has been found to be comparable to that of the control
specimen prepared without hyposludge.
5. The compressive strength and sulphate attack of cement mortar cubes results indicated
that increased with curing period but above 30% replacement, decreased with increasing
hyposludge percentage.
6. In mass concrete, use of hyposludge as mineral admixture would reduce the heat
of hydration, which could help to control the development of secondary stresses.
7. Partial replacement of Ordinary Portland Cement with about 30% Hyposludge in
concrete is gives more strength compared to conventional concrete. The 40% replacement
slightly equal to the conventional concrete.

81
REFERENCES
1. K.Ganesan K.Rajagopal an K.Thangavelu “Effects of the Partial replacement of cement
with agro waste ashes on strength and durability of concrete
2. IS 383 -1970 “Specifications for Coarse and Fine Aggregates from Natural Sources for
Concrete”, Bureau of Indian Standards, New Delhi.
3. IS 10262 -1981 “IS Method of Mix Design”, Bureau of Indian Standards, New Delhi
4. IS 516 -1959 “Methods of Tests for strength of concrete”, Bureau of Indian Standards,
New Delhi
5. IS 456 -2000 “Code of Practice for Plain and Reinforced Concrete”, Bureau of Indian
Standards, New Delhi.
6. Paper mill sludge: waste disposal problem or opportunity for new product development.
Forest research institute Malaysia (FRIM), 236-239
7. Pulp Mill Sludge Draft - November 1997, Reach for unbleached foundation.
8. Bioconversion of solid paper-pulp mill sludge by earthworms, vol. 57, no2, (28 ref.),
CAT .INIST, 173-177, (1996)
9. Nath Gopabandhu and Deb U.K.Vermicomposting- an effective technique for paper mill
solid waste utilization and value addition, IPPTA, vol.20, No.2, Apr-Jun,127-132, (2008)
10. ASTM C 1012. Standard test method for length change of hydraulic-cement mortars
exposed to a sulfate solution. Am Soc Test Mater 2004.
11. Tixier R, Mobasher B. Modeling of damage in cement-based materials subjected to
external sulfate attack – part 1: formulation. ASCE J Mater Eng 2003;15(4):305–13.
12. Clifton JR, Ponnersheim JM. Sulfate attack of cementitious materials:volumetric
relations and expansions. NIST IR 5390, Gaithersburg, Maryland;1994.
13. Attiogbe, E.K. and S.H. RizkallaI (1988). “Response of Concrete to Sulfuric Acid
Attack.” ACI Materials Journal 85(6): 481–488
14. Chang, Z.T., X.J. Song, et al. (2005). “Using limestone aggregates and different cements
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