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The production of cement is a significant contributor to global warming. In addition to optimising the energy efficiency of Portland cement production plants, the amount of cement used in concrete mixes can be reduced by using cement substitutes.
Cement substitutes
All cement substitutes have the dual benefit of replacing energy-intensive Portland cement, and of using material that would otherwise be landfilled. To varying degrees, cement substitutes work in two ways: First, they hydrate and cure like portland cement. Second they are "pozzolans," providing silica that reacts with hydrated lime, an unwanted byproduct of concrete curing.
Strength
Blast-furnace slag is most like Portland cement and least like a pozzolan. Class F PFA is most like a pozzolan, with Class C PFA between . While stronger and more durable in the end, it takes more time for pozzolans to gain strength than it does portland cement. For most construction purposes, high early strength is very desirable because it allows quicker finishing of slabs and earlier removal of forms. Reducing the amount of water, in part, can compensate for slow strength gain.
Durability
There are two durability conditions that cement substitutes help alleviate: Alkali-Silica Reaction (ASR): High-silica aggregates and high-alkali cement (which is becoming more common) can create ASR, which causes internal expansion and crazing of concrete. Cement substitutes, especially slag, remove the alkalinity through pozzolanic action. Class C PFA varies in this ability, while Class F PFA is very effective. Sulfate Attack: Concrete made with 60% or more slag is very effective in mitigating attack by sulfates, found in some arid soils, seawater and wastewater. The pozzolanic action of fly ash also contributes to sulfate resistance.
Assume F.A. by % of volume of total aggregate = 36.5 % 0.98 = [ 160 + ( 400 / 3.15 ) + ( 1 / 0.365 ) ( Fa / 2.61 )] ( 1 /1000 ) => Fa = 660.2 kg Say Fa = 660 kg. 0.98 = [ 160 + ( 400 / 3.15 ) + ( 1 / 0.635 ) ( Ca / 2.655 )] ( 1 /1000 ) => Ca = 1168.37 kg. Say Ca = 1168 kg. Considering 20 mm : 10mm = 0.6 : 0.4 20mm = 701 kg . 10mm = 467 kg . Hence Mix details per m3 Cement = 400 kg Water = 160 kg Fine aggregate = 660 kg Coarse aggregate 20 mm = 701 kg Coarse aggregate 10 mm = 467 kg Admixture = 0.6 % by weight of cement = 2.4 kg. Recron 3S = 900 gm Water: cement: F.A.: C.A. = 0.4: 1: 1.65: 2.92 Observation: -A. Mix was cohesive and homogeneous. B. Slump = 110mm C. No. of cube casted = 12 Nos. 7 days average compressive strength = 51.26 MPa. 28 days average compressive strength = 62.96 MPa which is greater than 48.25MPa Hence the mix is accepted.
MIX DESIGN Take Sand content as percentage of total aggregates = 36% Select Water Cement Ratio = 0.43 for concrete grade M35 (From Fig 2. of I.S. 10262- 1982) Select Water Content = 172 Kg (From IS: 10262 for 20 mm nominal size of aggregates Maximum Water Content = 186 Kg/ M3 ) Hence, Cement Content= 172 / 0.43 = 400 Kg / M3 Formula for Mix Proportion of Fine and Coarse Aggregate: 1000(1-a0) = {(Cement Content / Sp. Gr. Of Cement) + Water Content +(F a / Sp. Gr.* Pf )} 1000(1-a0) = {(Cement Content / Sp. Gr. Of Cement) + Water Content +C a / Sp. Gr.* Pc )} Where Ca = Coarse Aggregate Content Fa = Fine Aggregate Content Pf = Sand Content as percentage of total Aggregates = 0.36 Pc = Coarse Aggregate Content as percentage of total Aggregates. = 0.64 a0 = Percentage air content in concrete (As per IS :10262 for 20 mm nominal size of aggregates air content is 2 %) = 0.02 Hence, 1000(1-0.02) = {(400 /3.15) + 172 +(Fa / 2.62 x 0.36)} Fa = 642 Kg/ Cum As the sand is of Zone II no adjustment is required for sand. Sand Content = 642 Kg/ Cum 1000(1-0.02) = {(400 /3.15) + 172 +(Ca / 2.67 x 0.64)} Hence, Ca = 1165 Kg/ Cum From combined gradation of Coarse aggregates it has been found out that the proportion of 53:47 of 20 mm & 10 mm aggregates produces the best gradation as per IS: 383. Hence, 20 mm Aggregates = 619 Kg And 10 mm Aggregates = 546 Kg To obtain slump in the range of 150-190 mm water reducing admixture brand SP430 from Fosroc with a dose of 0.3 % by weight of Cement shall be used. Hence the Mix Proportion becomes:
Cem W/C Water Sand 20mm 10mm Admix 400 0.43 172 635 619 564 1.2 1 0.43 1.6 1.547 1.36 0.003
Units Kg/ M3