STUDY AND ANALYSIS OF LOW STRENGTH CONCRETE USING CERAMIC AGGREGATE AND FLY ASH

A PROJECT REPORT Submitted by

1. KASHYAP.V 2. PRASANTH GEORGE 3. TIJO.K.THOMAS

080104202023 080104202031 080104202048

In partial fulfillment for the award of the degree Of

BACHELOR OF ENGINEERING In
CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGINEERING, DHARMAPURI

ANNA UNIVERSITY OF TECHNOLOGY, COIMBATORE 641047

STUDY AND ANALYSIS OF LOW STRENGTH CONCRETE USING CERAMIC AGGREGATE AND FLY ASH
A PROJECT REPORT Submitted by

1. KASHYAP.V 2. PRASANTH GEORGE 3. TIJO.K.THOMAS

080104202023 080104202031 080104202048

In partial fulfillment for the award of the degree Of

BACHELOR OF ENGINEERING In
CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGINEERING, DHARMAPURI

ANNA UNIVERSITY OF TECHNOLOGY, COIMBATORE 641047

ANNA UNIVERSITY OF TECHNOLOGY

COIMBATORE - 641047

BONAFIDE CERTIFICATE
Certified that this project report STUDY AND ANALYSIS OF LOW STRENGTH CONCRETE USING CERAMIC AGGREGATE AND FLY ASH is the bonafide work of KASHYAP.V (080104202023) who carried out the

project work under my supervision.

SIGNATURE

SIGNATURE

SUPERVISOR

HEAD OF THE DEPARTMENT

Mr.P.JAWAHAR.M.tech

Mr.A.ARIVALAGAN.M.Tech.MBA.

DEPT OF CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGG. DHARMAPURI

DEPT OF CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGG. DHARMAPURI

Submitted to the viva voice examination ------------------------- -------------------------------

INTERNAL EXAMINER

EXTERNAL EXAMINER

ANNA UNIVERSITY OF TECHNOLOGY

COIMBATORE - 641047

BONAFIDE CERTIFICATE
Certified that this project report STUDY AND ANALYSIS OF LOW STRENGTH CONCRETE USING CERAMIC AGGREGATE AND FLY ASH is the bonafide work of PRASANTH GEORGE (080104202031) who carried

out the project work under my supervision.

SIGNATURE

SIGNATURE

SUPERVISOR

HEAD OF THE DEPARTMENT

Mr.P.JAWAHAR.M.Tech

Mr.A.ARIVALAGAN.M.Tech.MBA.

DEPT OF CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGG. DHARMAPURI

DEPT OF CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGG. DHARMAPURI

Submitted to the viva voice examination ------------------------- -------------------------------

INTERNAL EXAMINER

EXTERNAL EXAMINER

ANNA UNIVERSITY OF TECHNOLOGY

COIMBATORE - 641047

BONAFIDE CERTIFICATE
Certified that this project report STUDY AND ANALYSIS OF LOW STRENGTH CONCRETE USING CERAMIC AGGREGATE AND FLY ASH is the bonafide work of TIJO.K.THOMAS (080104202048) who carried out the project work under my supervision.

SIGNATURE

SIGNATURE

SUPERVISOR

HEAD OF THE DEPARTMENT

Mr.P.JAWAHAR.M.tech

Mr.A.ARIVALAGAN.M.Tech.MBA.

DEPT OF CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGG. DHARMAPURI

DEPT OF CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGG. DHARMAPURI

Submitted to the viva voice examination ------------------------- -------------------------------

INTERNAL EXAMINER

EXTERNAL EXAMINER

ANNA UNIVERSITY OF TECHNOLOGY

COIMBATORE - 641047

BONAFIDE CERTIFICATE
Certified that this project report STUDY AND ANALYSIS OF LOW STRENGTH CONCRETE USING CERAMIC AGGREGATE AND FLY ASH is the bonafide work of GEORGE KASHYAP.V (080104202023) , PRASANTH (080104202031) , TIJO.K.THOMAS (080104202048) who carried

out the project work under my supervision.

SIGNATURE

SIGNATURE

SUPERVISOR

HEAD OF THE DEPARTMENT

Mr.P.JAWAHAR.M.tech

Mr.A.ARIVALAGAN.M.Tech.MBA.

DEPT OF CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGG. DHARMAPURI

DEPT OF CIVIL ENGINEERING SAPTHAGIRI COLLEGE OF ENGG. DHARMAPURI

Submitted to the viva voice examination ------------------------- -------------------------------

INTERNAL EXAMINER

EXTERNAL EXAMINER

CONTENTS
S.L.NO TITLE PAGE NO

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

ACKNOWLEDGEMENT ABSTRACT INDRODUCTION GENERAL ABOUT CERAMIC AGGREGATE GENERAL ABOUT FLY ASH RAW MATERIALS AND MIXED RATIO MIXED DESIGN MANUFACTURING PROCESS OF CERAMIC AND FLY ASH MIXED CONCRETE GENERAL ABOUT CUBE TEST AND CYLINDER TEST TEST MADE ON SAMPLE CONCLUSION REFFERENCES PICTORIAL REPRESENTATION

ACKNOWLEDGEMENT

We should like to express our sincere gratitude to our grateful chairman Thiru. M.G. SEKHAR, B.A., B.L., for providing large facilities for progress.

We take great pleasure in expressing our sincere thanks to our principle Prof.K.N. Bhanuprakash, M.E, Ph.D.for his valuable ideas regarding our project.

We express our sincere thanks to Mr.A.ARIVALAGAN.M.Tech, MBA. Head of the Department, who spend his valuable time for us in guiding throughout the project work,.

We would like to express profusely our deep sense of gratitude to our Supervisor MR.P.JAWAHAR., M.E., for his kind advice, encouragement and for having granted permission to work this project.

We wish to acknowledgement our thanks to all the staff members of Department of CIVIL ENGINEERING, our friends and other well wishers who helped us to complete this project work successfully.

ABSTRACT
We have taken the topic about LOW STRENGTH CONCRETE USING

CERAMIC AGGREGATE AND FLY ASH .This consists of properties of the low strength concrete,experimental investigations, test results,discussion and conclusion. The mix design is prepared with IS 10262 1982 Byreffering no. of journals we have gathered preliminary details for low strength concrete .Feauters of low strength concrete with ceramic aggregates and fly ash.

The compressive strength of low strength concreteranges from 5 to 10 N/mm2.The flexural strength of low Strength concrete ranges from 1 to 1.2 N/mm2.

The admixtures like fly ash increase the strength of the concrete along with Portland cement.In this concrete,fine aggregate is replaced by upto 50 % of fly ash and it has all the mechanical properties of cement.The ceramic aggregate is the waste product of certamic insulating factories and fly ash is the by product of thermal power plant .

INTRODUCTION

At present the majority of aggregate of the materials, Forall construction applications are obtained from primary resources Such as crushed rock and sand.Since good quality aggregate are very limited,It has become necessary to study alternative materials for construction.

Factories manufacturing ceramic insulators produce a large amount of waste.The reuse and recycling of this waste materials are still not a common practice. These waste materials are disposed in dumping grounds.Many such waste materials are generated now will remain in the environment for hundreds ,perhaps thousand of years.The creation of non decaying waste materials,coimbined with a growing consumer population,hasa resulted in waste disposal crisis.One solution for this crisis lies in recycling waste into useful product.Also fly ashwhich is an industrial by product of thrmal power plant create disposal problem in addition to affecting the environment.

So the present investigation is carried out to study the properties of low strength concrete with ceramic waste as coarse aggregate and fly ash as partial replacement for sand.

GENERAL ABOUT CERAMIC AGGREGATE

Recent decades have seen a marked upsurge in industrial and economic growth,contributing to an improved quality of life and well-being for citizens. However, we should not lose sight of the fact that every production system creates by-products and waste products which can affect the environment. These effects may occur at any point in the products life-cycle, whether during the initial phase of obtaining raw materials, during the transformation and production phase, during product distribution or when the end user must dispose of products which are no longer required. As a result, recent years have witnessed rising social concern about the problem of waste management in general, and industrial waste and waste from the construction industry in particular. This problem is becoming increasingly acute due to the growing quantity of industrial, construction and demolition waste generated despite the measures which have been taken in recent years at European Community, national and regional levels aimed at controlling and regulating waste management, in accordance with sustainable development policies and the Kyoto Protocol. The need to manage these wastes has become one of the most pressing issues of our times, requiring specific actions aimed at preventing waste generation such as promotion of resource recovery systems (reuse, recycling and waste-to energy systems) as a means of exploiting the resources contained within waste, which would otherwise be lost, thus reducing environmental impact. In addition to helping protect the environment, use of such waste offers a series of advantages such as a reduction in the use of other raw materials, contributing to an economy of natural resources. Moreover, reuse also offers benefits in terms of energy, primarily when the waste is from kiln industries (the ceramics industry) where highly endothermic decomposition reactions have already taken place, thus recovering the energy previously incorporated during production. Ceramic waste may come from two sources. The first source is the ceramics industry, and this waste is classified as non-hazardous industrial waste (NHIW). According to the Integrated National Plan on Waste 2008-2015, NHIW is all waste generated by industrial The ceramics industry is comprised of the following subsectors: wall and floor tiles, sanitary ware, bricks and roof tiles, refractory materials, technical ceramics and ceramic materials for domestic and ornamental use. In both the European Union and Spain, the scale of production within these subsectors with regard to total production follows the same trends, where the production of wall and floor tiles represents the

highest percentage with respect to the total, followed by bricks and roof tiles, and finally, the other subsectors, as can be seen in Figures 1 and 2.

Ceramicproducts are produced from natural materials containing a high proportion of clayminerals. Following a process of dehydration and controlled firing at temperatures between700C and 1000C, these minerals acquire the characteristic properties of fired clay

CERAMICS INDUSTRY WASTE

Ceramic factory waste (figure 3), known as masonry rubble, is not sorted according to the reason for rejection, which may include: - Breakage or deformation, which does not affect the intrinsic characteristics of the ceramic material. Firing defects, due to excessive heat (over-firing) or insufficient heat (under-firing), faults particularly associated with the use of old kilns and which may affect the physico-chemical characteristics of the product.

Ceramic products are made from natural materials which contain a high proportion of clay minerals. These, through a process of dehydration followed by controlled firing at temperatures of between 700C and 1000C, acquire the characteristic properties of fired clay. Thus, the manufacturing process involved in ceramic materials requires high firing temperatures which may activate the clay minerals, endowing them with pozzolanic properties and forming hydrated products similar to those obtained with other active materials. Research carried out into the influence of firing temperatures on waste product properties has found that the chemical and mineralogical composition of ceramic masonry rubble resulting from incorrect firing temperatures (over- or under-firing) varies significantly from that of products obtained from optimal firing conditions. However, the temperature applied (around 900C) is sufficient to activate the clay minerals, with the result that the different rejectsCeramic masonry rubble must be suitably fine in order to be used as a pozzolanic additive in cement, and thus must be crushed and ground until reaching the specific surface, or Blaine value, of around 3500 cm2/g. This material presents a chemical composition similar to other pozzolanic materials,

with a strongly acid nature where silica, aluminium oxide andiron oxide predominate (75.97%), and with a CaO content of 12.41% and an alkali content of4.22%. Loss through calcination is 3.44% and sulphate content, expressed as SO3, is 0.79%. Mineralogical composition, determined by X-ray diffraction, mainly comprises the crystalline compounds quartz, muscovite, calcite, microcline and anorthite. In order to assess pozzolanic activity, an accelerated method is used in which the materials reaction over time with a lime-saturated solution is studied. The percentage of lime fixed by the sample is obtained through calculating the difference between the concentration of the initial lime-saturated solution and the CaO present in the solution in contact with the material at the end of each pre-determined period. The results, which are shown in Figure 4, demonstrate that ceramic waste presents pozzolanic activity; at one day, the percentage of fixed lime is 19% of all available lime. This level of activity is lower than that corresponding to the fumed silica considered, but greater than that of the fly ash. After longer periods, fixed lime values tend to equal out, and thus after 90 days very similar results are obtained for all three materials considered. It was also established that the firing temperatures used for producing ceramic material (around 900C) are sufficient to activate the clay minerals and thus obtain pozzolanic properties. Therefore, in the light of these results, it can be stated that rejected ceramic material, or ceramic masonry rubble, presents acceptable pozzolanic properties, since the firing temperatures used in manufacture are ideal for activating the clays from which they are constituted.

Recycled aggregate
Recycled aggregates can be defined as the result of waste treatment and managementwhere, following a process of crushing to reduce size, sieving and laboratory analysis, the waste complies with technical specifications for use in the construction sector and civil engineering. According to Ignacio (2007) it is not possible to carry out an exhaustive characterization of all kinds of recycled aggregates. Therefore, this topic will be discussed in more general terms by looking at concrete aggregates, asphalt agglomerate aggregates and other recycled aggregates which incorporate aggregates from clean ceramic material waste and aggregates from mixtures. As mentioned previously, one of the objectives of the new waste reuse and recycling policies in the construction and industrial sectors is to use recycled aggregates as a substitute for conventional natural aggregates, with the aim of reducing both use of natural resources andenvironmental impact caused by dumping.

CHARACTERISTIC PROPERTIES OF CERAMIC AGGREGATE:

CHARECTERISTICS

CERAMIC 6.17 12.5 0.16 2.39 0.55 23

Grading modulus Max size (mm) Fine content (%) Dry sample real density Water absorption coefficient Elongation index (%)

Mix

W/C RATIO

CERAMIC WASTE COARSE AGGREGATE CEMENT CONTENT (KG/m3) SLUMP TEST (mm) COMPRESSIVE SRENGTH (KG/m3) (Mpg) DENSITY

M2

0.65

285

40

15.64

2142.20

M5

0.55

345

20

23.51

2035.56

M10

0.45

422

15

30.16

2074.07

GENERAL ABOUT FLY ASH:

Fly ash is finely divided residue resulting from the combustion of the powdered coal and transported by flue gases and collected by electrostatic precipitator. In U.K it is referred as pulverized flue ash. Fly ash is the most widely used pozzolanic material all over the world. Fly ash was first used in a large scale in the construction of hungry hourse dam in America in the approximate amount of 30 per cent by weight of cement. Later on it was used inCanyon and ferry damsete. In India, fly ash was used in Rihand dam construction replacing cement up to 15 per cent. In the recent time, the importance and use of fly ash in concrete has grown so much that it was almost become a common ingredient in concrete, particularly for making high strength and high performance concrete. Extensive research has been done all over the world on the benefit that could be accrued in utilization on fly ash as a supplementary cemintitious material. High volume fly ash concrete is subject of current interest all over the world. The use of fly ash as concrete mixer not only extent technical advantages to the property of concrete but also contribute to environmental pollution control. In India alone we produce 75 million tone of fly ash per year, the disposal of which has become a serious environmental problem. The effective utilization of fly ash in concrete making, is, therefore, attracting serious consideration of concrete technologist and government department. Secondly, cement is the back bone of the global infrastructural development. It was estimated that global production of cement is about 1.3 billion tone in 1996. Production of every tone of cement emits carbon dioxide to the tune of about 0.87 ton. Expressing in another way, it can be said that 7% world carbone dioxide emission is attribute to Portland cement industry. Because of the significant contribute to environmental pollution and to the high consumption of natural resources like limestone ete.,wecan not go on producing more and more cement. One of the practical solution to economise cement is to replace with supplementary cementitious material like fly ash and slag.

In India, productin of fly ash is nearly as much as that of cement. But our utilization of fly ash is only 5%. Therefore, the use of fly ash must be popularized for more than one reason. There are two way that the fly ash can be used ; one way is to intergrid certain percentage of fly ash with cement clinker at the factory to produce Portland pozzolana cement and the second way is to use the fly ash as admixture at the time of making concrete at the site of work. The latter method gives freedom and flexibility to the user regarding the percentage adition of fly ash. There are about 75 thermal plant in India. The quality of fly ash generetted in different plant vary from one another to a large extent and hence they are not in a ready to use in condition. To make fly ash of consistent quality, make it suitable for use in concrete, the fly ash is required to be further proceed. Such processing arrangement are not available in India. The quality of fly ash is governed by IS 3812 part I 2003.The BIS specification limit for chemical requirement and physical requirement are listed in the below tables.Highfineness,low carbon content,good reactivity are the essence of good fly ash.Since fly ash is produced by rapid cooling and solidification of molten ash, a large portion of components comprising fly ash particles are in amorphous state.The amorphous characteristics greatly contribute to the pozzolanic reaction between cement and fly ash.One of the important characteristics of fly ash is the spherical form of particles.This shape of particles improves the floawability and reduces the water demand.The suitability of fly ash could be decided by finding the dry density of fully compacted sample. The fly ash is boadly classified into two classes: CLASS F: Fly ash normally produced by burning anthracite or bituminous coal, usually has less than 5 % Cao . Class F fly ash has pozzolonic properties only. CLASS C: Fly ash normally produced by burning lignite or sub bituminous coal. Some class c fly ash has Cao content in excess of 10 %. In addition to pozzolonic properties, class c fly ash also possesescementious properties.

Illustrative properties of fly ash from different sources:

Property/source Specific gravity Wet analysis sieve

A 1.91

B 2.12

C 2.10

D 2.25

E 2.146 to 2.149

16.07

54.65

15.60

5.00

51.00(dry)

Specific surface 2759 Lime reactivity CHEMICAL ANALYSIS SiO2 SO3 P2O5 Fe2O3 Al2O3 Ti2 Mn2O3 CaO Mgo Na2O 50.41 1.71 0.31 3.34 30.66 0.84 0.31 3.04 0.93 50.03 --10.20 18.20 --6.43 3.20 -11.33 63.75 --30.92 ---2.35 0.95 -1.54 60.10 --6.40 18.60 --6.3 3.60 -4.90 45 59 Traces to 2.5 -0.6 4.0 23.33 0.5 1.5 -56 1.5 5 -1-2 86.8 56.0 40.3 79.3 56.25 to 70.31 1325 2175 4016 2800 to 3250

Loss on ignition 3.07 pecentage 5.02

Chemical Requirements:

SL no. (1)

Characteristic (2)

Reqirement (3)

a)

Silicon di oxide plus 70.0 aluminium oxide percent by mass

b)

Silicon di oxide per cent by 35.0 mass

c)

Reactive silica in % by mass

20.0

d)

Magnetium oxide per cent by 5.0 mass

e)

Total sulphur as sulphur tri 3.0 oxide per cent by mass

f)

Available alkalis, as sodium 1.5 oxide per cent by mass

g)

Total chloride present by mass

0.05

h)

Loss on ignition

5.0

Pysical requirements:

Sl. No

Characteristic

(1)

(2)

Requirement Grade of fly ash I II (3) (4)

a)

Fineness Specific surface in 320 m2/k.g Lime reactivity Average 4.5 compressive strength in N/mm2

250

b)

3.0

c)

Compressive strength at 28 Not less than 80 per cent of the days in N/mm2 strength of corresponding plain cement mortar cubes Soundness by autoclave test 0.8 expansion of specimens, per cent 0.8

d)

Effect of fly ash on concrete:

Good fly ash with high fineness, low carbon content highly reactive forms only a small fraction of total fly ash collected. The ESP fly ash collected in chambers I and II are generally very coarse, non spherical particles showing large ignition loss. They can be called coal ash rather than fly ash. Such fly ash is not suitable for use as pozzolan and they do not reduce the water demand. Use of right quality fly ash, results in reduction of water demand for desired slump. With the reduction of unit water content, bleeding and drying shrinkage will also be reduced. Since fly ash is not highly reactive, the heat of hydration can be reduced through replacement of part of the cement with fly ash. Fly ash when used in concrete , contributes to the strength of concrete due to it spozzolonic activity .the initial strength of fly ash concrete tends to lower than that of concrete without fly ash. Due to continued pozzolanic reactivity concrete develops greater strength at later stage

RAW MATERIALS USED AND THEIR MIXED RATIO:

RAW MATERIALS USED:

The raw materials use for construction of low strength concrete are given below. Ceramics Fly ash Portland slag cement Sand Water

MIXED RATIO

Ceramics Fly ash Portland cement Sand Water

20% 50% 10% 10% 10%

MIXED DESIGN:
INDIAN STANDARD RECOMMENDED METHOD OF CONCRETE MIX DEIGN FOR M 10 GRADE OF CONCRETE:

1. Design stipulations: i. Characteristic compressive strength required in field at 28 days = 10 Mpa

ii. iii. iv. v. vi.

Max size of aggregate Degree of workability Degree of quality control Type of exposure Compacting factor =

= = = = 0.8

10mm 0.38 good mild

2. Test data for materials: a) Specific gravity of cement [Sc] b) Specific gravity of coarse aggregate[Sca] = = = c)Specific gravity of fine aggregate [Sfa] d)absolute volume of fine aggregate[P] = = 3.15 [3.90 x 0.7] +[2.86 x 0.3] 3.89 2.75 0.40

Approximate sand and water content per cubic metere of concrete for grades uptoM35(Table no 4 of IS 10262 1982) Max size of aggregate Water content including Sand as % of total aggregate

surface water ,per cubic mt. by bsolute volume of concrete[K,g] 10 20 40 e 200 186 165 40 35 30

e) free surface moisture: 1. coarse aggregate 2.fine aggregate f) sieve analysis is shown below: 1.Coarse aggregate Seive (mm) aggregate (% of passing) size Analysis of Coarse Percentage of different fractions Remark : : nil 2.0 %

II

II

Combined (100%)

20 10

100 0

100 71.20

60 0

40 28.5

10 28.5

Conforming to IS :383-1970

4.75 2.36 --

9.40

---

3.7 --

3.7 --

2.Fine aggregate Sieve sizes 4.75mm 2.36mm 1.18mm 600micron 300micron 150micron Fine aggregate(% passing) 100 100 93 60 12 2 Remarks Conforming to grading Zone III of table no 4 of IS:385-1970

3.TARGET MEAN STRENGTH OF CONCRETE:

Grade of cement Target mean strength Fck

= = =

53 rd grade not more than 5% fck + 1.65 s

Where s is the standard deviation and it is taken as 3.3 from IS 10262 1982 . Fck = = 10 + 5.445

15.445 Mpa

4.SELECTION OF WATER CEMENT RATIO:

From the figure 2 of IS 16262 -1982 the water cement ratio required for target men strength of 15.445 Mpa is 0.70

5.SELECTION OF WATER AND SAND CONTENT:

From table no 4 of IS 10262 1982 grades upto M.35 are given and from that approximate values are taken. So, water content Sand as % of total aggregate by absolute volume} and the required water content (W) = = 40 % 200 lit. = 200 K.g

6..DETERMINATION OF CEMENT CONTENT:

Water cement ratio Water Cement content (C) = = = 200 200/0.70 285.71 Kg/m3

0.70

7. DETERMINATION OF COARSE AND FINE AGGREGATE:

V Ca

= =

{w + c/se + 1/p fa/sfa}1/1000 (1 p)/p x fa x Sca/S[fa]

(1) (2)

From equation 1 we have 0.97 0.97 0.97 0.97 x 1100 Fa Fa From equation 2 Ca = (1 p)/p x fa x Sca/S[fa] = = = = = = {200 + 285.71/3.15 + 1/0.40 fa/2.75} x (1/1000) {200 + 90.70 + fa/1.1} x (1/1000) {220 + 99.77 +fa}/1.1 x (1/1000) 220 + 99.77 + fa 1067 220 99.77 747.23

= = =

(1 -0.40) /0.40 x 747.23 x (3.89)/275 1.5 x 747.23 x 1.42 1591.5999 Kg/m3

Hence we have got all the values concerning mixed design and it is listed .

8.THE MIX PROPOTIONS THEN BECOMES:

Water 200 0.70

Cement 285.71 1

Fine aggregate 747.23 2.7

Coarse aggregate 1591.5999 5.67

9.ACTUAL QUANTITIES REQUIRED FOR MIX PER BAG OF CEMENT: (FOR CONCRETE CUBES AND CONCRETE CYLINDERS)

Volume of the cube

= = =

l xb xh 15 x 15 x 15 3375 Cm3 r2h 3.14 x 7.5 x 7.5 x 30 5298.75 Cm3

Volume of the cylinder

= = =

Total volume

= =

3375 +5298.75 8673.75 Cm3 total volume + 20 % (8673.75 x 20)/100 1734.75 Cm3

For getting actual volume

= = =

Thus we have obtained the volume for making one cylinder and one cube = Volume of concrete needed for one Cube and one cylinder} (Vc) Where, Sc Fa S[fc] Ca Sca Hence, Vc = = = = = = = So Vc = specific gavityog cement fine aggregate specific gravity of fine aggregate coarse aggregate specific gravity of coarse aggregate 1/3.15 + 2.70/2.75 + 5.67/2.89+0.7 0.3174 +0.9818 +1.9619 + 0.7 3.96 mm = 1/sc + (%fa)/sfa + (%ca) /sfa + w/c ratio 1734.75 + 8673.75 = 10418.50 Cm3

Thus the volume of concrete needed for making one cube and one cylinder = 3.96 mm

Weight of cement for one cube and one Cylinder Wc = (1/Vc) x V

Where, Vc V Wc = = = = volume of concrete for 1 cube and I cylinder volume for making one cylinder and cube (1)/(3.96) x 10418.5 2.63 Kg

WEIGHT OF FINE AGGREGATE FOR ONE CUBE AND CYLINDER:

= =

Mix propotion of Fa x weight of cement per one cube and cylinder[Wc] 2.7 x 2.63 = 7.10 Kg

WEIGHT OF COARSE AGGREGATE FOR ONE CUBE AND CYLINDER:

= = =

Mix propotion of Ca x mix propotion of Fa 5.67 x 2.7 15.30 Kg

REQUIRED AMOUNT OF WATER FOR ONE CUBE AND ONE CYLINDER:

= =

W/C ratio x mix propotion of Fa 0.7 x 2.7 = 1.89 Lit.

VOLUME OF CONCRETE NEEDED FOR MAKING 9 CUBES AND 6 CYLINDERS:

Volume of concrete needed for making 9 cubes And 6 cylinders} = = 3.96 x 7.5 29.7 Cm3

WEIGHT OF CEMENT NEEDED FOR MAKING 9 CUBES AND 6 CYLINDERS:

Weight of cement needed for making 9 cubes And 6 cylinders = = 2.63 x 7.5 19.73 Kg

WEIGHT OF FINE AGGREGATE FOR 9 CUBES AND 6 CYLINDERS:

Weight of Fa for 9 cubes and 6 cylinders

7.10 x 7.5 = 53.25 Kg

WEIGHT OF COARSE AGGREGATE FOR9 CUBES AND 6 CYLINDERS:

Weight of Ca for 9 cubes and 6 cylinders

= =

15.30 x 7.5 114.75 Kg

REQUIRED AMOUNT OF WATER FOR 9 CUBES AND 6 CYLINDERS: Required amount of water for 9 cubes and 6 cylinders} = 1.89 x 7.5 = 14.18 lit

The above mentioned are all concerning without replacement of ceramic aggregate and fly ash .In This project we have to replace ceramic aggregate and fly ash instead of coarse aggregate and cement. Now with replacement are discussed below. The mixed ratio of the materials added are mentioned earlier and according to that the weight of cement ,coarseaggregate,fine aggregate changes WITH REPLACEMENT OF CERAMIC AGGREGATE AND FLY ASH: WEIGHT OF CEMENT FOR MAKING 9 CUBES AND 6 CYLINDERS: (with 50 % replacement of Fly ash): = = 19.75 X (50/100) 9.875 Kg

WEIGHT OF FLY ASH WHICH HAS TO BE ADDED: = = 19.75 9.875 9.875 Kg

WEIGHT OF FINE AGGREGATE NEEDED FOR MAKING 9 CUBES AND 6 CYLINDERS: (no replacement) = 53.25 Kg

WEIGHT OF COARSE AGGREGATE :(With replacement of 20 % ceraic aggregate) = = WEIGHT OF CERAMIC AGGREGATE NEEDED: = = REQUIRED AMOUNT OF WATER: = 114.75 91.8 22.95 Kg 14.18 Lit. 114.75 [114.75 x (20)/(100)] 91.8 Kg

MANUFACTURING PROCESS OF CERAMIC AND FLY ASH MIXED CONCRETE (FLOW CHART)

RAW MATERIALS

CUBE TEST & CYLINDER TEST

MIXING

CURING

SLUMP TEST

SAMPLING

ILLUSTRATION OF STEPS OF MANUFACTURING OF CERAMIC CONCRETE: Raw materials: The raw materials used for the purpose of mixing are going to be discussed here and they are a) Portland slag cement b) Fine aggregate c) Coarse aggregate d) Ceramic aggregate e) Fly ash

The mixed proportions of the above are already discussed and according to that ratio they are mixed The ceramic aggregate for coarse materials are taken and they are crushed to small pieces by hammer.These small pieces are then fed to a vibrator. Vibrator is a compacting device used for the removal of entrapped air from the concrete. Vibrator are applied only for ordinary concrete there are various methods of vibrations by using various types of vibrators such as internal vibrator, external vibrator, table vibrator, platform vibrator , surface vibrator. Here we are using a table vibrator as it is best suitable here. This is the special case of form work vibrator, where the vibrator is clamped to the table or table is mounted on springs which are vibrated transferring the vibrations to the table. They are commonly used for concrete cubes.this are adopted mainly in labortaries. MIXING: Through mixing of the materials is essential for threproduction of uniform concrete. The mixing should ensure that mass becomes homogeneous, uniform in colour andconstitency . There are two methods adopted for concrete mixing they are a) Hand mixing b) machine mixing

Machine mixing is adopt for larger mixing. Mixing of concrete is almost invariably carried out by machine, for reinforced concrete work and for medium or for large scale mass concrete work. Machine mixing is not only efficient, but also economical, when the quantity of concrete to be produced is large. Since in here the quantity is not so large and hence we are adopting hand mixing Hand mixing is practiced for small scale unimportant concrete works. As the mixing cannot be through and efficient, it is desirable to add 10 % more cement to cater for the inferior concrete produced by this method Hand mixing should be done over an impervious concrete or brick floor of sufficiently large size to take one bag of cement. Spread out the measured quality of coarse

aggregate and fine aggregate in alternate layers. Pour the cement on top of it, and mix them dry by shovel, turning the mixture over and over again until uniformity of colouris achieved. This uniform mixture is spread out in thickness of about 20 cm. Water is taken in a watercan fitted with a rose-head and sprinkled over the mixture and simultaneously turned over . This operation is continued till such time a good uniform, homogeneous concrete is obtained. It is of particular importance to see that water is not poured but it is only sprinkled. Water in small quantity should be added towards the end of the mixing to get the just required consistency. At that stage, even a small quantity of water makes difference. SLUMP TEST: Slump test is the most commonly used method of measuring consistency of concrete which can be employed either in laboratory or at site of work. It is not a suitable method for very wet or very dry concrete. It does not measure all factors contributing to workability, nor is it always representative of placability of the concrete. However, it is used conveniently as a control test and gives an indication of the uniformity of concrete from batch to batch. Repeated batches of the same mix, brought to the same slump, will have the same water content and water cement ratio, provided the weight of aggregate, cement and admixtures are uniform and aggregate grading is within acceptable limits. Additional information on workability and quality of concrete can be obtained by observing the manner in which concrete slumps. Quality of concrete can also be further assessed by giving a few tappings or blows by taping rod to the base plate. The deformation shows the characteristics of concrete with respect to tendency for segregation. The apparatus for conducting the slump test essentially consist of a metallic mould in the form of a frustum of a cone having the internal dimensions as under : Bottom diameter Top diameter Height : : : 20 cm 10 cm 30 cm

It is seen that the slump test gives fairly good consistent results for a plasticmix. This test is not sensitive for a stiff-mix. In case of dry mix, no variation can be detected

between mixes of different workability. In the case of rich mixes, the value is often satisfactory, their slump being sensitive to variations in workability. IS 456 of 2000 suggests that in the very low category of workability where strict control is necessary, for example, pavement quality concrete,(PQC) measurement of workability by determination of 0.75 to 0.80

compacting factor will be more appropriate than slump and a value of compacting factor is suggested. CURING: Curing methods may be devided broadly into four categories : a) Water curing b) Membrane curing c) Application of heat d) Miscellaneous Water curing:

This is far the best method of curing as it satisfies all the requirements of curing namely, promotion of hydration, elimination of shrinkage and absorption of the heat of hydration.It is pointed out that even if the membrane method is adopted,it is desirable that a certain extent of water curing is done before the concrete is covered curing can be done in following ways. a) Immersion b) Ponding c) Spraying or Fogging d) Wet covering. In here we are adopting water curing method as it is best suitable and here we are immersing the concrete cubes in water and curing is done for 24 hours. with membranes.Water

SAMPLING: The sampling is the process of manufacturing of the testing of the samples.And in here we are making cubes and cylinders samples.The dimension of each are listed below 1) Cube 150 mm x 150 mm x 150 mm 150 mm x 300mm x 150 mm

2) Cylinders

CUBE SAMPLE: Here a cube mould of the dimensions 150 mm x 150 mm are taken and it is cleaned to avoid dust particles.Then the mixed concrete are put into it and they are well compacted inside the mould using compacting devices and all the voids are avoided .Then all the concrete will be correctly filed in it. On the next day actually after 24 hours the cube mould is removed and then we are able to get a cube, the cube is then cleaned.This is the process of cube sample manufacturing.

CYLINDER SAMPLE: Here a cylinder mould of the dimensions 150 mm x 150 mm x 150 mm are taken and it is cleaned to avoid dust particles.Then the mixed concrete are put into it and they are well compacted inside the mould using compacting meachines and all voids are avoided, then all the concrete will be correctly filled in it.On the next day actually after 24 hours the cylinder mould is removed and then we are able to get the cylinder, the cylinder is then cleaned and thus a cylinder sample is obtained.

By similar process, 9 cubes are prepared using 9 cube moulds and 6 cylinders are prepared using 6 cylinder moulds.After that tests are made on these sample

GENERAL ABOUT CUBE TEST AND CYLINDER TEST: The main function of the manufacturing of cubes and cylinders is inorder to check the strength of the concrete used in it. And for the above purpose two tests have been adopted and they are, 1) Compression Test 2) Flexural tensile test COMPRESSION TEST: Compression test is most common test conducted on hardened concrete, partially because it is easy to test perform, partially because most desirable characteristic property of concreteare qualitatively related to its compressive strength. Compression test is carried out of specimen cubical or cylindrical in shape. Prisms are also some time used, but it is not common in our country. Sometime the compression strength of concrete is determined using part of beam test in flexure. The end part of beam left intact after failure in flexure because the beam is usually in square cross section, the part of beam could be used to find out the compressive strength. The cube specimen of size 15x15x 15 cm . If the large nominal size of the aggregate does not exceed 20 mm, 10 cm size cube may also be used as an alternative. Cylindrical test specimens have 15 cm in dia and 30 cm long. Smaller test specimen may be used but a ratio of dia of the specimen to maximum size of the aggregate, not less than 3 to 1 maintained in aggregate. FLEXTURAL TENSILE TEST: Direct measurement of tensile strength of concrete is difficult. Neither specimen nor tensile apparatus have been designed which assure uniform distribution of the pull applied to the concrete. While a number of investigation involving the correct measurement of tensile strength made, beam test are found to be dependable to measure flexural strength property of concrete.

The value of the modulus of the repture depend on on the dimension on the beam and manner of loading. In the central point loading, maximum fiber strength will below the point of loading where bending moment is maximum. In the case of cylindrical two point loading , the critical crake may appear at any section , not strong enough to resist the stresswithin the middle third, where the bending moment is maximum. It can be expressed in two point loading will yield a lower value of modulus of repture than the central pointing of loading. The modulus should be of metal preferable steel or cast iron and the metal should be sufficient thickness to prevent spreading. The modulus should be constructed with the longer dimensionhorizontally and in a such a manner as to facilitatethe removal of the modulus specimen without damage. The tempering bar should be a steel bar weighing 2 kg, 40 cm long and should have a ramming face 25 mm square. The testing machine may be any reliable type of sufficient capacity for the test and capable of applying the load at the rate specified. The bed of test specimen should be provided with two steel roller, 38mm in diameter on which the specimen is to be supported , and these roller should be mounted that the distance from center to centeris 60 mm for 15 cm specimen or 40 cm for 10 cm specimen. The load is divided equally between to loading roller and all loaded are mounded in a such a manner that load is applied axially and without subjecting specimen to any torsional stresses or restrains. USAGE OF UNIVERSAL TESTING MEACHINE: The bearing surfaces of the supporting and loading rollers are wiped clean, and any loose sand or other material removed from the surfaces of the specimen where they are to make contact with the rollers. The specimen is then placed in the machine in such a manner that the loads is applied to the uppermost surface as cast in the mould, along two lines spaced 20.0 or 13.3 cm apart. The axis of the specimen is carefully aligned with the axis of the loading device. No packing is used between the bearing surfaces of the specimen and the rollers. The load is applied without shock and increasing continuously at a rate such that the extreme fibre stress increases at approximately 0.7 kg/sq cm/ min that is, at a rate of loading

of 400 kg/min for the 15.0 cm specimens and at a rate of 180 kg/min for the 10.0 cm specimen. The load is increased until the specimen fails, and the maximum load applied to the specimen during the test is recorded. The appearance of the fractured faces of concrete and any unusual features in the type of failure is noted. The flexural strength of the specimen is expressed as the modulus of rupture fb Which if a equals the distance between the line of fracture and the nearest support, measured on the center line of the tensile side of the specimen, in cm, is calculated to the nearest 0.05 Mpa as follows :

fb

(p x l ) / (b x d2)

When a is greater than 20.0 c.m for 15.0 c.m specimen or greater than 13.3 c.m for a 10.0 c.m specimen, or

fb

(3p x a) / ( b x d2)

When a is less than 20.0 cm but greater than 17.0 cm for 15.0 specimen, or less than 13.3cm but greater than 11.0 cm for a 10.0 cm specimen where
b

= = = =

measured width in cm of the specimen, measured depth in cm of the specimen at the point of failure, length in cm of the span on which the specimen was supported maximum load in kg applied to the specimen.

If a is less than 17.0 cm for a 15.0 cm specimen, or less than 11.0 cm for a 10.0 cm specimen, the result of the test be discarded. As mentioned earlier, it is difficult to measure the tensile strength of concrete directly. Of late some methods have been used with the help of epoxy bonded end pieces to facilitate direct pulling. Attempts have also be made to find out direct tensile strength of

concrete by making briquette of figure 8 shape for direct pullig but this method was presenting some difficulty with grip and introduction of secondary stresses while being pulled. Whatever may be the methods adopted for finding out the ultimate direct tensile strength, it is almost impossible to apply truly axial load. There is always some eccentricity present. The stress are changed due to eccentricity of loading. These may introduce major error on the stresses developed regardless of specimen size and shape. The third problem is the stresses induced due to the grips. There is a tendency for the specimen to break near the ends. This problem is always overcome by reducing the section of the central portion of the test specimen . The method in which steel plates are glued with the epoxies to the ends of the specimen, eliminates stresses due to gripping , but offers no solution for the eccentricity problem. All direct tension test methods require expensive universal testing machine. This explains why these tests are not used on a routine basis and are not yet standardized. A COMPARISON BETWEEN CUBE AND CYLINDER STRENGTH: It is difficult to say wheather cube test give more realistic strength properties of concrete or cylinders give a better picture about the strength of concrete.However it can be said that the cylinder is less affected by the end strains caused by platents and hence it seems to give more uniform results than cube.Therefore the use of cylinder becomes more popular particularly in research laboratories. Cylinders are cast and tested in same position, whereas cubes are cast in one direction and tested in the other direction. In actual structures in the field, the casting and loading is similar to that of the cylinder and not like the cube. As such, cylinder simulates the condition of the actual structural member in the field in respect of direction of load. The points in favor of the cube specimen are that the shape of the cube resembles the shape of the structural members often met with on ground. The cube does not require capping, whereas cylinder requires capping.The capping material used in case cylinder may influence to some extent the strength of the cylinder.

TEST MADE ON SAMPLE: (TABULATION)

VALUES OBSERVED DURING COMPRESSION TEST:

Sl .no

Mix

W/C ratio

Compression strength 3 days 7 days 28 days

1 2 3

M 10 M 10 M10

0.65 0.55 0.45

VALUES OBSERVED DURING TENSILE TEST:

Sl .no

Mix

W/C ratio

Tensile strength 3 days 7 days 28 days

1 2 3

M 10 M 10 M10

0.65 0.55 0.45

CONCLUSION: In our project we studied and analyzed about LOW STRENGTH CONCRETE USING CERAMIC AGGREGATE AND FLY ASH and their various characteristics in the field. We collected the information by browsing various website in internet, visiting number of chambers general library, construction shop and other colleges libraries to collect various reference books. Specimens are made and test like compressive strength, flexure strength and split tensile test are conducted and their results are tabulated respectively. A detailed analysis of the results obtained in the various assays has lead to the following initial conclusions. Recycled aggregates obtained from industrial waste produced by the sanitary ceramics industry are suitable for manufacture of concrete. Recycled concrete obtained through partial substitution of natural coarse is suitable for structural purposes.

Fly ash the next material used are also a waste material which obtained in thermal power plant. These fly ash causes great disposal problems as it may contain radioactive materials. By taking this , a great amount of radioactive waste material can also be replaced. Now coming to the total mixed concrete, a large amount of coarse aggregate and sand are needed. By this project these two can be very much reduced.Thus the unwanted wastage of sand ,coarse aggregate can be made possible.

 The main advantage is that all the usual mixing materials in concrete are very much expensive and by the usage of the mentioned low strength concrete the expense of whole construction process can be reduced and thus profitable.

From the test result and discussion, the following conclusions are drawn from the study on ceramics waste as coarse aggregate and fly ash as fine aggregate , they are applicable for the range of parameters and materials in this study. Ceramics waste can be transformed into useful coarse aggregate and fly ash as fine aggregate. The properties of ceramics waste coarse aggregate are within the range of the values of concrete-making aggregate and they are not significantly different from those of conventional concrete. This research work is the basic for further experiment on normal concrete with the use of ceramics waste. The use of Low Strength Concrete in the field results in providing more advantage. Hence it is a trend setting material in this developing modern technology and their growth in the scientific method of construction. Thus we have analyzed various characteristics of the LOW STRENGTH CONCRETE in the best and more attracting way which appears to our knowledge and most economical.

REFFERENCE: [1]M.S.Shetty . Concrete Technology Theory and practice. S.Chand & Company Ltd.

[2] Binici, H. Effect of crushed ceramic and basaltic pumice as fine aggregates on concrete mortars properties. Construction and Building Materials, vol. 21 (2007), 1191 1197

[3] Correia, J.R.; de Brito,J.; Pereira, A.S. Effects on concrete durabi[lity of using recycled ceramic aggregates. Materials and Structures, vol. 39 (2006), 169-177

[4] De Brito,J.; Pereira, A.S.; Correia, J. R. Mechanical behaviour of non-structural concrete made with recycled ceramic aggregates. Cement and Concrete Composites, vol. 27 (2005), 429-433

[5] RM. Senthamarai, P.Devadas Manoharan, Concrete with ceramic waste aggregate, Cem Concr compos 27 (2005) 910-913

[6] How-Ji chen, Tsong Yen, Kuan-Hung Chen, Use of building rubbles as recycled aggregates, Cem Concr Res 33 (2003) 125-132

[7] Gemma Rodriquez de Sensale, Strength development of concrete with rice-husk ash, Cem Concr Compos 28 (2006) 158-160

[8] Khaloo AR. Crushed tile coarse aggregate concrete. Cem. Concrete Aggregate 1995; 17(2): 119-125

[9] Binici, H. (2007). Effect of crushed ceramic and basaltic pumice as fine aggregates on concrete mortars properties. Construction and Building Materials, vol. 21, Issue 6, (June 2007), 1191 1197, 0950-0618.

[10] ASTM International Standard ,ASTM C 618 -05 ,Standard Test Method for Coal fly ash and raw or calcinated natural pozzolan for use in concrete.

[11] Owens , P.L. Fly ash and its usage in concrete. Concrete: The journal of the concrete society, 1979.13: 21 26

[12] Helmuth R, Fly ash in cement and concrete, Portland cement association ,1987.

[13] Malahothra, V.M., Ramezanianpour,A.A., Fly ash in concrete, CANMET ,1984.

[14] Minnick, L.J., Webster , WC., and Purdy, E.J., Predictions of the effect of fly ash in Portland cement mortar and concrete ,Journal of materials,1971,6:163 187 [15] Philleo, R.E., Recent developments in pozzolan specifications.Proceedings , 2nd International Conference on the use of fly ash silica fume slag and natural pozzolans in concrete ,Madrid,Spain,Apr.21 - 25,1986, supplementary paper 27. [16] Brizzi ,A., Puccio , M., and Valenti, G.L., Corelations between physic chemical characteristics of fly ash and its technical properties for use in concrete,Proceedings, 3rd CANMET/ACI International Conference on the usuage of fly ash ,Silica fume, Slag, and Natural pozzolans in concrete,Trondheium,Norway,June 18 -23 ,1989, Supplementary paper 139

[17] ASTM International Standard ,ASTM C 311 -05 ,Standard Test Method for sampling and testing fly ash or natural pozzolans for use in Portland cement concrete. [18] IS 10262 1982 ., BUREAU OF INDIAN STANDARD

[19] Senthamarai, RM.; Devadas Manhoharan, P. Concrete with ceramic waste aggregate. Cement & Concrete Composites, vol. 27 (2005), 910-913. [20] Pereira Goncalves, J. Use of ceramic industry residuals in concrete. REM: R. Esc. Minas, Ouro Preto, octubre diciembre 2007, n 64, 639 644

[21] Cachim, P.B. (2009) Mechanical properties of brick aggregate concrete.

PICTORIAL REPRESENTATION:

FLY ASH SAMPLE

PORTLAND POZZOLANO CEMENT

CERAMIC AGGREGATE

COARSE AGGREGATE

FINE AGGREGATE

MIXING

HAND MIXING

COMPACTING

CUBES DAY 1

CUBES DAY 2

CUBES DAY 3

CYLINDERS DAY 1

CYLINDERS DAY 2

CYLINDERS DAY 3

CURING

TOTAL CUBES AND CYLINDERS

STRENGTH TESTING USING UNIVERSAL TESTING MEACHINE