Professional Documents
Culture Documents
1.1
INTRODUCTION
Today the civil engineering industries grows very rapidly the use of new material on
construction is a very important need because it saves our environment and natural resources.
Most of the construction in now days are done with cement sand aggregate and water mix
commonly called concrete. Concrete is a very versatile material it has very important
properties which makes it the best constructional material used for making any structure
which posses enough strength. The main properties of concrete are its compressive strength it
is the property of material which makes it strong to resist adequate load under certain
conditions. In now a days most of the structures are made with concrete due to its
engineering properties. In most of
because it gives them enough strength and age to resist the different loads. Today big and tall
structures like dams bridges towers nuclear power plant etc is made with concrete just
because of its strength to resist load, but every structure has a life after which it is not enough
capable to resist load it is because in its useful life it resist various natural/artificial loads
which reduces its strength then the time come to destroy the structure and make the new one
in place of it. When the structure is destroyed a huge amount of waste is produced which
include waste from bricks masonry iron bars etc and a huge amount of concrete this concrete
can be termed as demolisioned waste obtained demolishing the structure. We know that
while making the fresh concrete a huge amount of natural resources are used which we
cannot we get back once we use them so there was a problem faced by the engineer to first to
dispose the demolished material because it require a huge amount of land which we cannot
used again after dumping the waste and second to full fill the demand of raw material like
sand aggregate etc, which are used to make concrete. In both the conditions such that to full
fill the requirement of material for new construction and also the disposal of waste material
makes a huge amount of burden on our environment so as to reduce the amount of burden
from our environment there is a new concept is utilised which provides us a solution to this
problem and the solution is that to use the material obtained from waste. This is not a new
idea our ancestors knows that all the material available in the earth has a limit after that it
gets ends. So they develop the idea of utilisaing the material reusing is a process in which the
raw material which is used is obtained from the parent material. After proper studying the
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properties of material it can be used again because all the material posses adequate amount of
strength to make it workable. Concrete is the premier construction material across the world
and the most widely used in all types of civil engineering works, including infrastructure, low
and high-rise buildings, defence installations, environment protection and local/domestic
developments. Concrete is a manufactured product, essentially consisting of cement,
aggregates, water and admixture(s). Among these, aggregates, i.e. inert granular materials
such as sand, crushed stone or gravel form the major part. Traditionally aggregates have been
readily available at economic price. However, in recent years the wisdom of our continued
wholesale extraction and use of aggregates from natural resources has been questioned at an
international level. This is mainly because of the depletion of quality primary aggregates and
greater awareness of environmental protection. In light of this, the availability of natural
resources to future generations has also been realized. Given this background, the concept of
sustainable development put forward almost a decade ago, at the 1992 Earth Summit in Rio
de Janeiro, and it has now become a guiding principle for the construction industry
worldwide. In fact many governments throughout the world have now introduced various
measures aimed at reducing the use of primary aggregates and increasing reuse and
recycling, where it is technically, economically, or environmentally acceptable. For example,
the UK government has introduced a number of policies to encourage wider use of secondary
and as an alternative to naturally occurring primary aggregates. These include landfill and
future extraction taxes to improve economic viability, support to relevant research and
development work. In now a days recycling of concrete is done on a large scale because
natural resources are reduces day by day and we have to conserve them. Recycling of
concrete is not a new idea it is first it is used after the second world war. Material obtained
from Construction and Demolishing waste commonly called as (C&D) waste it is normally
constitute rubble masonry iron bars, masonry bricks and tiles sand and dust and a large
portion of concrete. This demolished concrete can be used again after proper treatments in
making different structures it can be shows that crushed rubble concrete when carefully
sieved and separated from parent demolished structure can be used as natural course
aggregate in making concrete or as a sub base and base layer in making pavements this type
of material obtained from waste is called recycle material or Granite concrete
there
utilisation of waste material is the only way to reduce it after second world war there are
many countries shows interest in recycling of material because it gives them enough material
for new construction and enough space of land for use them.
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Many countries like Japan, China Russia, London, Europe, Nietherlands Hongkong
Spain, Belgium etc were shoes interest in Recycling of Concrete due to increasing the land
prices in the recent years the cost of dumping is also increased in recent years so the persons
found that is more useful to recycled material as compared to dumping it. Various standards
are established to make good quality material from the demolished material to promote the
recycling of material proper guidelines are given to contractors to installing recycling plants
in urban places and permitted them to use recycled material in place of natural aggregate.
Recycling of material provide us higher efficiency in its useful lifecycle and its consistency
with the natural environment. When the useful life of material is completed it becomes waste
and can be transformed in to new material to make new structures which have new life and
also new strength as well. Due to large scale decrease of natural aggregates and significant
increase in demolisioned aggregate going to land fill sites.
The use of Granite Course Aggregates trend growing globally and use of granite
aggregate. These aggregates shows similar strength to concrete with similar performance to
characteristics to natural aggregate. The research project is completed with the study of
equipments which are used for making Granite Course Aggregate from granite waste in this
context it is well known how they are made. There is a significant processes followed by
different countries for making concrete. Aggregate particularly in Netherlands waste
products are used as aggregate for unbound layers in road construction because natural
aggregate in Netherlands is very scare. Similarly Dutch followed a well defined process to
produce good quality of Granite Course Aggregate s. While the recycling plants of Europe
and Britain are less well equipped when compared to Netherlands with cleaning and
shortening devices which make good quality of Granite Course Aggregates the recycled
products obtained from recycling plants are carefully examined and their physical properties
are carefully compared with natural aggregates. with the end of this century environmental
protection and sustainable development is the key role of society and we have to work hard
for this. It is very important for our environment to make it clean by different methods like
by reduction pollution emission conservation of natural resources especially for the civil
industry. In this context main problems faced by the industry are:
Natural aggregate depletion. High production and consumption of Portland cement due
to this there is a high emission of carbon dioxide Large amount of production of construction
and demolition waste and fill land space depletion. It is very big problem in European
countries. It is known that 1m3 of concrete contains about 1m3 of aggregates. here the
properties of concrete made from Granite concrete using granite waste aggregate as course
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aggregate is replaced by natural aggregate. Some proposals are made for the construction
industries to use recycles aggregate in making different structures particularly in road sub
base layer and production from masonry units. But in practice Granite Course Aggregate is
not commonly used in production of fresh concrete. The main reason is that Portland cement
is made to produce structure which meet high strength and durability requirement. Extensive
research is required to use know the properties of waste material before it can be adopted in
industry. The main aim of this research is to find the adequate strength parameters for making
high performance concrete made with granite course aggregate. By studying the various
strength properties it can be suitably used in industry.
The non availability of the sufficient quantity of ordinary natural aggregate for making
concrete is affecting the growth of the construction industry in many parts of the country.
Recently in Madhya Pradesh government has imposed the restrictions on aggregate stone
quarrying due to unsafe impact threatening on many parts of the state. On the other hand Granite
Course Aggregate generated by the industry has accumulated over the years. The main aim of
this research is to fine adequate strength parameters and the optimum percentages of the Granite
Course Aggregate used in making concrete. So by using this granite waste we can reduce the
consumption of the natural aggregate in making concrete thus for saving the environment.
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1.4
CHAPTER 1: INTRODUCTION
This chapter described the background and motivation for the study. The approach to use of
Granite Course Aggregate (GCA) into cement concrete is briefly outlined and concerns are
highlighted. The objective, aim, purpose of the dissertation is also outlined in this chapter.
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5.1 INTRODUCTION
In this chapter results obtained by Mix design of M-25 Grade of concrete from chapter
4.Cement concrete cubes prepared and casted as per chapter 4.
5.2 CONCLUSION
Remarks are made based on the results and discussion.
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CHAPTER 2
LITERATURE REVIEW
2.1 GRANITE CONCRETE AGGREGATE
2.1.1 General
In recent years certain countries have considered the reutilization of construction and
demolition waste as a new construction material as being one of the main objectives
with respect to sustainable construction activities.
The literature review presents the current state of knowledge and examples of successful uses
of alternative materials in concrete technology, and in particular the use of Granite concrete
(GCA) aggregate as a coarse aggregate fraction in non- structural and structural concrete.
Many researchers have dedicated their work to describe the properties of these kinds of
aggregate, the minimum requirements for their utilization in concrete and the properties
of concretes made with waste aggregates. It also presents a review of available literature
on physical, mechanical and durability properties of GCA aggregates, and mechanical,
durability and structural properties of GCA concrete. However, minor attention has been paid
to the structural behavior granite aggregate concrete slabs. This thesis focuses on utilization
of granite waste as an aggregate in structural concrete in flexure and punching shear.
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Fine aggregate
Fineness Modulus
Density kg/m3
Specific Gravity
2.77
1752
2.60
1805.62
2.65
Course aggregate
4.086
Granite
4.476
Course
1660.44
2.68
Aggregate
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Bulk density
The bulk density or unit weight of an aggregate gives valuable information
regarding the shape and grading of the aggregates. For a given specific gravity the
angular aggregates shows a lower bulk density. Bulk density of aggregates is of interest
when deal with light weight aggregates and heavy weight aggregates. It depends on
the strength of original concrete and size of original aggregates.
It is concluded that the Granite Course Aggregate which obtained from granite waste
is of higher strength had higher density and also the saturated surface density depends
on the kind of crushing machine employed and the energy used. The density changes
with the size of the aggregate The density of Granite Course Aggregate concrete
reduces with smaller size of aggregates. Granite Course Aggregate concrete shows
high dense than conventional concrete. Further more it is concluded that by addition of
silica fume to the Granite Course Aggregate concrete and conventional concrete,
reduces the density.
Specific gravity
It is investigated that the specific gravity decreases from 4.5 to 7.6% when
compared with specific gravity of natural aggregate. The specific gravity of
Waste Concrete Aggregates (WCA) was lower than normal crushed aggregates.
The reason for this was thought to be the fact that there was a certain proportion of
mortar over these aggregates. It is noted that the specific gravity of demolished
concrete aggregates is lower than that of natural aggregate. The average specific
gravity of aggregate usually varies from 2.6 to 2.8
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When I studied the following research papers I found that no work has been done in
the replacement of waste granite aggregate, only granite fines has been replaced and
then the various studied are done.
1. Journal
of
Civil
Engineering
Research
2014,
4(2A):
1-6
DOI:
Mr.A.Adin and Mr.T.Suresh Kannan, This granite powder waste can be utilized
for the preparation of concrete as partial replacement of sand. In order to explore the
possibility of utilizing the granite powder as partial replacement to sand, an
experimental investigation has-been carried out. The percentages of granite powder
added by weight to replace sand by weight were 0, 5, 10, 15, 20 and 25. To improve
the workability of concrete 0.5% Super plasticiser was added. This attempt has been
done due to the exorbitant hike in the price of fine aggregate and its limited
availability due to the restriction imposed by the government of Tamil Nadu. Fifty
four cubes and 36 cylinders were cast. Compressive strength and split tensile
strength were found. The test results indicate that granites replacement sand with
granite powder has beneficial effect on the mechanical properties such as
compressive strength and split tensile strength of concrete.
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3. International Journal of Advanced Engineering Research and Studies EISSN22498974, Experimental Investigation On Behaviour Of Concrete With
The Use Of Granite Fines, Divakar.Y, Manjunath.S and Dr. M.U. Aswath, In this
paper an attempt is made experimentally to investigate the Strength Behaviour of
Concrete with the use of Granite Fines as an additive. Concrete is prepared with
granite fines as a replacement of fine aggregate in 5 different proportions namely 5%,
15%, 25%,35% and 50% and various tests such as compressive strength, Split tensile
strength and Flexural strength are investigated and these values are compared with the
conventional concrete without granite fines.
4. Indian Journal of Science and Technology Vol. 3 No. 3 (Mar 2010) ISSN: 09746846,
examines the possibility of using granite powder as replacement of sand and partial
replacement of cement with fly ash, silica fume, slag and super plasticiser in concrete.
The percentage of granite powder added by weight was 0, 25, 50, 75 and 100 as a
replacement of sand used in concrete and cement was replaced with 7.5% silica fume,
10% fly ash, 10% slag and 1% super plasticiser. The effects of water pounding
o
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into cement
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No paper was focus on waste granite aggregate strength parameter which is new and
innovative in this dissertation work.
The aim of my research is to find the possibility of using low cost Granite Course
Aggregate as an alternative material to course aggregate in structural concrete and
also the optimum percentage of Granite Course Aggregate as a partial replacing of
natural aggregate in concrete, for saving the cost of construction and the natural
aggregates.
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CHAPTER 3
CEMENT CONCRETE
3.1
INTRODUCTION
After the Roman Empire collapsed, use of concrete became rare until the
technology was re pioneered in the mid-18th century. Today, concrete is the most
widely used man-made material (measured by tonnage).
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3.2
HISTORY
The word concrete comes from the Latin word "concretes" (meaning
compact or condensed), the perfect passive participle of "concrescere", from "con"
(together) and "crescere" (to grow).
Perhaps the earliest known occurrence of cement was twelve million years
ago. A deposit of cement was formed after an occurrence of oil shale located
adjacent to a bed of limestone burned due to natural causes. These ancient deposits
were investigated in the 1960s and 1970s.
On a human time-scale, small usages of concrete go back for thousands of
years. The ancient Nabataea culture was using materials roughly analogous to
concrete at least eight thousand years ago, some structures of which survive to this
day.
German archaeologists Heinrich Schliemann found concrete floors, which
were made of lime and pebbles, in the royal palace of Tiryns, Greece, which dates
roughly to 1400-1200 BC. Lime mortars were used in Greece, Crete, and Cyprus in
800 BC.
The Assyrian Jerwan Aqueduct (688 BC) made use of fully waterproof
concrete. Concrete was used for construction in many ancient structures.
The Romans used concrete extensively from 300 BC to 476 AD, a span of
more than seven hundred years. During the Roman Empire, Roman concrete (or opus
caementicium) was made from quicklime, pozzolana and an aggregate of pumice. Its
widespread use in many Roman structures, a key event in the history of architecture
termed the Roman Architectural Revolution, freed Roman construction from the
restrictions of stone and brick material and allowed for revolutionary new designs in
terms of both structural complexity and dimension.
Concrete, as the Romans knew it, was a new and revolutionary material. Laid
in the shape of arches, vaults and domes, it quickly hardened into a rigid mass, free
from many of the internal thrusts and strains that troubled the builders of similar
structures in stone or brick.
Modern tests show that opus caementicium had as much compressive
strength as modern Portland-cement concrete (ca. 200 kg/cm2). However, due to the
absence of reinforcement, its tensile strength was far lower than modern reinforced
concrete, and its mode of application was also different.
Modern structural concrete differs from Roman concrete in two important
details. First, its mix consistency is fluid and homogeneous, allowing it to be poured
into forms rather than requiring hand-layering together with the placement of
aggregate, which, in Roman practice, often consisted of rubble. Second, integral
reinforcing steel gives modern concrete assemblies great strength in tension, whereas
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Roman concrete could depend only upon the strength of the concrete bonding to
resist tension.
The widespread use of concrete in many Roman structures ensured that many
survive to the present day. The Baths of Caracalla in Rome are just one example.
Many Roman aqueducts and bridges such as the magnificent Pont du Grad have
masonry cladding on a concrete core, as does the dome of the Pantheon.
After the Roman Empire, the use of burned lime and pozzolana was greatly
reduced until the technique was all but forgotten between 500 AD and the 1300s.
Between the 1300s until the mid-1700s, the use of cement gradually returned. The
Canal du Midi was built using concrete in 1670, and there are concrete structures in
Finland that date from the 16th century.
Perhaps the greatest driver behind the modern usage of concrete was the third
Eddystone Lighthouse in Devon, England shown in figure 1. To create this
structure, between 1756 and 1793, British engineer John Smeaton pioneered the use
of hydraulic lime in concrete, using pebbles and powdered brick as aggregate.
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The most Vitruvius work was conducted by M. Vicat of France. The first
person who introduce cement was Joseph Aspedin or Yorkshire of united kingdom
he was the first who introduce Portland cement in 1824 formed by heating a mixture
of lime stone and finely divided clay in to a high temperature furnace up to a
temperature high enough to drive of the carbonic acid gas . in the year 1845, Sir
Isaac . Johnson invented the cement by increasing the temperature at which the ixture
of lime stone and clay were sufficiently burned to form clinker. This cement was the
basic model for the prototype of the modern Portland cement.
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Top View
Front View
Fig. 3 : Pantheon of Rome
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3.3
TYPES OF CONCRETE
Based on unit weight, concrete can be classified into three broad categories.
Concrete containing natural sand and gravel or crushed-rock aggregates,
generally weighing about 2400 kg/m3 (4000 lb/yd3), is called normal weight
concrete, and it is the most commonly used concrete for structural purposes. For
application where a higher strength-to-weight ratio is desired, it is possible to
reduce the unit weight of concrete by using natural or pyro-processed aggregate
with lower bulk density. The term lightweight concrete is used for concrete that
weighs less than about 1800 kg/m3 (3000 lb/yd3). Heavy weight concrete, used
for radiation shielding, is a concrete produced from high-density aggregate and
generally weighs more than 3200 kg/m3 (5300 lb/yd3).
Strength grading of cements and concrete is prevalent in Europe and many
other countries but is not practiced in the United States. However, from
standpoint of distinct differences in the microstructure-property relationship is
useful to divide concrete into three general categories based on compressive
strength:
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3.4
MICROSTRUCTURE OF CONCRETE
3.4.1 PREVIEW
Microstructure-property relationships are at the heart of modern
material science. Concrete has a highly heterogeneous and complex microstructure.
Therefore, it is very difficult to constitute realistic models of its microstructure from
which the behaviour of the material can be reliably predicted. However, knowledge
of the microstructure and properties of the individual components of concrete and
their relationship to each other is useful for exercising control on the properties.
3.4.2 DEFINITION
The type, amount, size, shape, and distribution of phase present in a
solid constituent its microstructure. The gross elements of the microstructure of a
material can readily be seen from a cross section of the material, whereas the finer
elements are usually resolved with the help of a microscope. The term
macrostructure is generally used for the gross microstructure visible to the human
eye; the limit of resolution of the unaided human eye is approximately one-fifth of a
millimetre (200 m). The term microstructure is used for the microscopically
magnified portion of a macrostructure. The magnification capability of modern
electron microscope is of the order of 105 times. Therefore, application of
transmission and scanning electron microscopy techniques has made it possible to
resolve the microstructure of materials to a fraction of one micrometer.
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3.4.3 SIGNIFICANCE
Progress in the field of materials has resulted primarily from recognition of the
principle that the properties originate from the internal microstructure, in other
words, properties can be modified by making suitable changes in the microstructure
of a material. Although concrete is the most widely used structural material, its
microstructure is heterogeneous and highly complex. The microstructure-property
relationships in concrete are not yet fully developed; however, some understanding
of the essential elements of the microstructure would be helpful before discussing the
factors influencing the important engineering properties of concrete, such as
strength, elasticity, shrinkage, creep, cracking, and durability.
3.4.4 COMPLEXITIES
Form examination of a cross section of concrete (Fig.: 4), the two phases that
can easily be distinguished are aggregate particles of varying size and shape, and the
binding medium composed of an incoherent mass of the hydrated cement paste.
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The aggregate phase is predominantly responsible for the unit weight, elastic
modulus, and dimensional stability of concrete. These properties of concrete depend
to a large extend on the bulk density and strength of the aggregate, which in turn are
determine by physical rather than chemical characteristics of the aggregate. In other
works, the chemical or the mineralogical composition of the solid phases in
aggregate is usually less important than the physical characteristics, such as volume,
size, and distribution of pores.
{ Internal bleed water tends to accumulate in the vicinity of elongated, flat, and large pieces of aggregate. In
these locations, the aggregate-cement paste interfacial transition zone tends to be weak and easily prone to
microcracking. This phenomenon is responsible for the shear-bond failure at the surface of the aggregate particle
marked in the photograph.}
In addition to porosity, the shape and texture of the coarse aggregate also
affect the properties of concrete. Natural gravel has a rounded shape and a smooth
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From the micro structural model of the hydrated cement paste shown in Fig. 8, it
may be noted that the various phases are neither uniformly distributed nor are they
uniform in size and morphology. In solids, micro structural in homogeneities can
lead to serious effects on strength and other related mechanical properties because
these properties are controlled by the micro structural extremes, not by the average
microstructure. Thus, in addition to the evolution of the microstructure as a result of
the chemical changes, which occur after cement comes in contact with water,
attention has to be paid to certain rheological properties of freshly mixed cement
paste that also influence the microstructure of the hardened paste. For instance, the
anhydrous particles of cement have a tendency to attach each other and form flocks,
which entrap large quantities of mixing water. Obviously, local variations in watercement ratio would be the primary sources of evolution of the heterogeneous
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microstructure. With a highly flocculated cement paste system, not only the size and
shape of pores but also the crystalline products of hydration would be different when
compared to a well-dispersed system.
3.4.6.1
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3.4.6.2
In addition to solids, the hydrated cement paste contains several types of voids which
have an important influence on its properties. The typical sizes of both the solid
phases and the voids in hydrated cement paste are illustrated in Fig 9a. the various
types of voids and their amount and significance are discussed, just for information
the size range of several objects ranging from human height to Marss diameter is
shown in Fig 9b.
Interlayer space in C-S-H.
Powes assumed the widht of the interlayer space
within the C-S-H structure to be 18 and determined that it accounts for 28
peGCAent porosity in solid C-S-H; however, Feldman and Sereda suggested the the
space may vary form 5 to 25 . This void size is too small to have an adverse effect
on the strength and permeability of the hydrated cement paste. However, as
disscussed below, water in these small voids can be held by hydrogen bonding, and
its removal under certain condition may contribute to drying shrinkage and creep.
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Capillary Voids.
Capillary void represents the space not filled by the solid
components of the hydrated cement paste. The total volume of a typical cementwater mixture remains essentially unchanged during the hydration process. The
average bulk density of the hydration products is considerably lower than the density
of anhydrous, requires about 2 cm3 of space to accommodate the products of
hydration. Thus, cement hydration may be looked upon as a process during which
the space originally occupied by cement and water is being replace more and more
by the space filled by hydration products. The space not taken up by the cement or
the hydration products consists of capillary voids, the volume and size of the
capillary voids being determined by the original distance between the anhydrous
cement particles in the freshly mixed cement paste (i.e., water-cement ratio), and the
degree of cement hydration. A method of calculating the total volume of capillary
voids, popularly known as porosity, in Portland cement pastes having either different
water-cement ratios or different degrees of hydration.
In well-hydrated, low water-cement ratio pastes, the capillary voids may range from
10 to 50 nm; in high water cement ratio pastes, at early ages of hydration, the
capillary void may be as large as 3 to 5m. typical pore size distribution plots of
several hydrated cement paste specimens tested by the mercury intrusion technique
are shown in Fig. 10. It has been suggested that the pore size distribution, not the
total capillary porosity, is a better criterion for evaluating the characteristics of a
hydrated cement paste. Capillary voids larger than 50 nm, referred to as macrospores
in modern literature, are probably more influential in determining the strength and
impermeability characteristics, whereas voids smaller than 50 nm, referred to as
microspores, play an important part in drying shrinkage and creep.
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Fig. : 9a & 9b
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Air voids. Whereas capillary voids are irregular in shape, air voids are generally
spherical. A small amount of air usually gets trapped in the cement paste during
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3.4.6.3
Under electron microscopic examination, voids in the hydrated cement paste appear
to be empty. This is because the specimen preparation technique calls for drying
the specimen under high vacuum. Actually, depending on the environmental
humidity and the porosity of the paste, the untreated cement paste is capable of
holding a large amount of water. Water can exist in the hydrated cement paste in
many forms. The classification of water into several types is based on the degree of
difficulty or ease with which it can be removed from the hydrated cement paste
when the relative humidity of the environment is reduced; the dividing line
between the different states of water is not rigid. In spite of this, the classification is
useful for understanding the properties of the hydrated cement paste. In addition to
vapour in empty or partially water-filled voids, water exists in the hydrated cement
paste in the following states:
Capillary water. This is the water present in voids larger than about 50 . It may
be pictured as the bulk water that is free from the influence of the attractive forces
exerted by the solids surface. Actually, from the standpoint of the behaviour of
capillary water is the hydrated cement paste, is desirable to divide the capillary
water into two categories: the water in large voids of the order of >50 nm (0.05
m), which may be called free water (because its removal does not cause any
volume change), and the water held by capillary tension in small capillaries (5 to
50 nm), the removal of which may cause shrinkage of the system.
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Adsorbed water. This is the water that is close to the solid surface. Under the
influence of attractive forces, water molecules are physically adsorbed onto the
surface of solids in the hydrated cement paste. It has been suggested that up to six
molecular layers of water (15 ) can be physically held by hydrogen bonding.
Because the bond energies of the individual water molecules decreases with distance
from the solid surface, a major portion of the adsorbed water can be lost when
hydrated cement paste is dried to 30 percent relative humidity. The loss of adsorbed
water is responsible for the shrinkage of the hydrated cement paste.
Interlayer water. This is the water associated with the C-S-H structure. It has been
suggested that a monomolecular water layer between the layers of C-S-H is strongly
held by hydrogen bonding. The interlayer water is lost only on strong drying (i.e.,
below 11 percent relative humidity). The C-S-H structure shrinks considerably when
the interlayer water is lost.
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Chemically combined water. This is the water that is an integral part of the
microstructure of various cement hydration products. This water is not lost on
drying; it is evolved when the hydrates decompose on heating. Based on the
Feldman-Sereda model, different types of water associated with the C-S-H are
illustrated in Fig. 11.
3.5
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Concrete is used to create hard surfaces that contribute to surface runoff, which can
cause heavy soil erosion, water pollution, and flooding, but conversely can be used
to divert, dam, and control flooding.
Concrete is a primary contributor to the urban heat island effect, though less so than
asphalt. Workers who cut, grind or polish concrete are at risk of inhaling airborne
silica, which can lead to silicosis. Concrete dust released by building demolition and
natural disasters can be a major sources of dangerous air pollution.
The presence of some substances in concrete, including useful and unwanted
additives, can cause health concerns due to toxicity and radioactivity. Wet concrete
is highly alkaline and must be handled with proper protective equipment.
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is laid down as the lowest layer in a road, with fresh concrete or asphalt placed over
it.
Crushed Granite concrete can sometimes be used as the dry aggregate for brand
new concrete if it is free of contaminants, though the use of re- cycled concrete
limits strength and is not allowed in many jurisdictions. On 3 March 1983, a
government-funded research team (the VIRL research codes) estimated that almost
17% of worldwide landfill was by-products of concrete based waste. Recycled
crushed concrete is shown in figure 13.
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3.6.6 CEMENT
Portland cement is the most common type of cement in general usage. It is a
basic ingredient of concrete, mortar and plaster. English masonry worker Joseph
Aspdin patented Portland cement in 1824. It was named because of the similarity of
its colour to Portland limestone, quarried from the English Isle of Portland and used
extensively in London architecture. It consists of a mixture of oxides of calcium,
silicon and aluminium. Portland cement and similar materials are made by heating
limestone (a sources of calcium) with clay and grinding this product (called
clinker) with a source of sulphate (most commonly gypsum).
In modern cement kilns many advanced features are used to lower the fuel
consumption per ton of clinker produced. Cement kilns are extremely large,
complex, and inherently dusty industrial installations, and have emissions which
must be controlled of the various ingredients used in concrete the cement is the
most energetically expensive. Even complex and efficient kilns require 3.3 to 3.6
gigajoules of energy to produce a ton of clinker and then grind it into cement.
Many kilns can be fueled with difficult to dispose of wastes; the most common
being used tires. The extremely high temperatures and long periods of time at those
temperatures allow cement kilns too efficiently and completely burn even difficultto-use fuels.
3.6.7 WATER
Cement paste by the process of hydration. The cement paste glues the
aggregate together, fills voids within it, and makes it flow more freely.
A lower water-to-cement ratio yields a stronger, more durable concrete,
whereas more water gives a free- flowing concrete with a higher slump. Impure
water used to make concrete can cause problems when setting or in causing
premature failure of the structure.
Hydration involves many different reactions, often occurring at the same
time. As the reactions proceed, the products of the cement hydration process
gradually bond together the individual sand and gravel particles and other
components of the concrete to form a solid mass.
Page | 40
Reactions :
Cementchemistnotation:C3 S+HC-S-H +CH
Standard notation:
Ca3SiO5+ H2O (CaO)(SiO2)(H2O)(gel)+Ca(OH)2
Balanced:
2Ca3SiO5
3.6.8 AGGREGATES
Fine and coarse aggregates make up the bulk of a concrete mixture. Sand,
natural gravel and crushed stone are used mainly for this purpose. Granite Course
Aggregate s (from construction, demolition, and excavation waste) are increasingly
used as partial replacements of natural aggregates, while a number of manufactured
aggregates, including air-cooled blast furnace slag and bottom ash are also
permitted.
The presence of aggregate greatly increases the durability of concrete above
that of cement, which is a brittle material in its pure state. Thus concrete is a true
composite material.
Redistribution of aggregates after compaction often creates in homogeneity
due to the influence of vibration. This can lead to strength gradients.
Decorative stones such as quartzite, small river stones or crushed glass are
sometimes added to the surface of concrete for a decorative exposed aggregate
finish, popular among landscape designers. In addition to being decorative,
exposed aggregate adds robustness to a concrete driveway.
3.6.9 REINFORCEMENT
Concrete is strong in compression, as the aggregate efficiently carries the
compression load. However, it is weak in tension as the cement holding the
aggregate in place can crack, allowing the structure to fail. Reinforced concrete
adds steel reinforcing bars, steel fibres, glass fibbers, or plastic fibbers to carry
tensile loads.
Page | 41
Retarders slow the hydration of concrete and are used in large or difficult
pours where partial setting before the pour is complete is undesirable. Typical
retarders are sugar, sucrose, sodium glaciate, glucose, citric acid, and tartaric acid.
Page | 42
Air entrainments add and entrain tiny air bubbles in the concrete, which
reduces damage during freeze- thaw cycles, increasing durability. However,
entrained air entails a trade off with strength, as each 1% of air may decrease
compressive strength 5%. If too much air becomes trapped in the concrete as a result
of the mixing process, Deformers can be used to encourage the air bubble to
agglomerate, rise to the surface of the wet concrete and then disperse.
corrosion inhibitors are used to minimize the corrosion of steel and steel bars
in concrete.
Bonding agents are used to create a bond between old and new concrete
(typically a type of polymer) with wide temperature tolerance and corrosion
resistance.
Pumping aids improve pump ability, thicken the paste and reduce separation
and bleeding.
Page | 43
are being tested and used. This development is due to cement production being one
of the largest producers (at about 5 to 10%) of global greenhouse gas emissions, as
well as lowering costs, improving concrete properties, and recycling wastes.
3.7
CONCRETE PRODUCTION
Page | 44
measurements of the amount of water added, but must be placed closer to the work
site where the concrete will be used, since hydration begins at the plant.
Modern concrete is usually prepared as a viscous fluid, so that it may be poured into
forms, which are containers erected in the field to give the concrete its desired shape.
There are many different ways in which concrete formwork can be prepared, such as
Slip forming and Steel plate construction. Alternatively, concrete can be mixed into
dryer, non-fluid forms and used in factory settings to manufacture precast concrete
products.
There is a wide variety of equipment for processing concrete, from hand tools
to heavy industrial machinery. Whichever equipment builders use, however, the
objective is to produce the desired building material; ingredients must be properly
mixed, placed, shaped, and retained within time constraints. Once the mix is where it
should be, the curing process must be controlled to ensure that the concrete attains
the desired attributes. During concrete preparation, various technical details may
affect the quality and nature of the product.
When initially mixed, Portland cement and water rapidly form a gel of tangled
chains of interlocking crystals, and components of the gel continue to react over
time. Initially the gel is fluid, which improves workability and aids in placement of
the material, but as the concrete sets, the chains of crystals join into a rigid structure,
counteracting the fluidity of the gel and fixing the particles of aggregate in place.
During curing, the cement continues to react with the residual water in a process of
hydration. In properly formulated concrete, once this curing process has terminated
the product has the desired physical and chemical properties. Among the qualities
typically desired, are mechanical strength, low moisture permeability, and chemical
and volumetric stability.
Page | 45
Nano concrete is created by High-energy mixing (HEM) of cement, sand and water
using a specific consumed power of 30 - 600 watt/kg for a net specific energy
consumption of at least 5 kJ/kg of the mix. A plasticizer or a super plasticizer is then
added to the activated mixture which can later be mixed with aggregates in a
conventional concrete mixer. In the HEM process sand provides dissipation of energy
and increases shear stresses on the surface of cement particles.
Page | 46
Fig 16 (d) : A Concrete Slab & Concrete Cubes Ponded while Curing
3.7.7 WORKABILITY
Workability is the ability of a fresh (plastic) concrete mix to fill the form/mold
properly with the desired work (vibration) and without reducing the concretes
quality. Workability depends on water content, aggregate (shape and size
distribution), cementations content and age (level of hydration) and can be
modified by adding chemical admixtures, like super plasticizer. Raising the water
content or adding chemical admixtures increases concrete workability. Excessive
water leads to increased bleeding (surface water) and/or segregation of aggregates
(when the cement and aggregates start to separate), with the resulting concrete
having reduced quality. The use of an aggregate with an undesirable gradation can
Page | 47
result in a very harsh mix design with a very low slump, which cannot readily be
made more workable by addition of reasonable amounts of water.
Workability can be measured by the concrete slump test, a simplistic measure of
the plasticity of a fresh batch of concrete following the ASTM C 143 or EN
12350-2 test standards. Slump is normally measured by filling an "Abrams cone"
with a sample from a fresh batch of concrete. The cone is placed with the wide
end down onto a level, non-absorptive surface. It is then filled in three layers of
equal volume, with each layer being tamped with a steel rod to consolidate the
layer. When the cone is carefully lifted off, the enclosed material slumps a certain
amount, owing to gravity. A relatively dry sample slumps very little, having a
slump value of one or two inches (25 or 50 mm) out of one foot (305 mm). A
relatively wet concrete sample may slump as much as eight inches. Workability
can also be measured by the flow table test.
Slump can be increased by addition of chemical admixtures such as plasticizer
or super plasticizer without changing the water-cement ratio. Some other
admixtures, especially air-entraining admixture, can increase the slump of a mix.
High-flow concrete, like self-consolidating concrete, is tested by other flowmeasuring methods. One of these methods includes placing the cone on the
narrow end and observing how the mix flows through the cone while it is
gradually lifted. After mixing, concrete is a fluid and can be pumped to the
location where needed.
3.7.8
CURING
In all but the least critical applications, care must be taken to properly cure
concrete, to achieve best strength and hardness. This happens after the concrete
has been placed. Cement requires a moist, controlled environment to gain strength
and harden fully. The cement paste hardens over time, initially setting and
becoming rigid though very weak and gaining in strength in the weeks following.
In around 4 weeks, typically over 90% of the final strength is reached, though
strengthening may continue for decades. The conversion of calcium hydroxide in
the concrete into calcium carbonate from absorption of CO2 over several decades
further strengthens the concrete and makes it more resistant to damage. However,
this reaction, called carbonation, lowers the pH of the cement pore solution and
can cause the reinforcement bars to corrode.
Hydration and hardening of concrete during the first three days is critical.
Abnormally fast drying and shrinkage due to factors such as evaporation from
wind during placement may lead to increased tensile stresses at a time when it has
not yet gained sufficient strength, resulting in greater shrinkage cracking. The
early strength of the concrete can be increased if it is kept damp during the curing
Page | 48
process. Minimizing stress prior to curing minimizes cracking. High-earlystrength concrete is designed to hydrate faster, often by increased use of cement
that increases shrinkage and cracking. The strength of concrete changes
(increases) for up to three years. It depends on cross-section dimension of
elements and conditions of structure exploitation.
During this period concrete must be kept under controlled temperature and humid
atmosphere. In practice, this is achieved by spraying or pounding the concrete
surface with water, thereby protecting the concrete mass from ill effects of
ambient conditions. The picture to the right shows one of many ways to achieve
this, ponding submerging setting concrete in water and wrapping in plastic to
contain the water in the mix. Additional common curing methods include wet
burlap and/or plastic sheeting covering the fresh concrete, or by spraying on a
water- impermeable temporary curing membrane.
Properly curing concrete leads to increased strength and lower permeability and
avoids cracking where the surface dries out prematurely. Care must also be taken
to avoid freezing or overheating due to the exothermic setting of cement.
Improper curing can cause scaling, reduced strength, poor abrasion resistance and
cracking.
3.8.6
IMPERMEABILITY
Impermeability is the resistance of concrete to the flow of water into it. The
water flows into the pore spaces in the concrete which are formed due to the
evaporation of superfluous water that does not combine with cement. In addition
to these water occupied voids, there are air voids. The impermeability of concrete
increases with the reduction such pore spaces. It increases the durability by
increasing its resistance of weathering, chemical attack and corrosion.
Impermeable concrete can be obtained by adopting low water to cement ratio
and by proper compaction so that water occupied voids and air voids are
minimum. Also, well graded aggregate and adequate curing ensures proper
hydration and improves the impermeability of concrete.
Page | 49
3.8.7
STRENGTH
The strength of concrete is the property most valued by designers and quality
control engineers. In solids, there exists a fundamental inverse relationship
between porosity (volume fraction of voids) and strength. Consequently, in
multiphase materials such as concrete, the porosity of each component of the
microstructure can become strength-limiting. Natural aggregates are generally
dense and strong; therefore, it is the porosity of the cement pate matrix as well as
the interfacial transition zone between the matrix and coarse aggregate, which
usually determines the strength characteristics of natural-weight concrete.
Although the water-cement ratio is important in determining the porosity of both
the matrix and the interfacial transition zone and hence the strength of concrete,
factors such as compaction and curing condition (degree of cement hydration),
aggregate size and mineralogy. Admixtures types, specimen geometry and
moisture condition, types of stress, and rate of loading can also have an important
effect on strength.
3.8.7.1
DEFINITION
3.8.7.2
SIGNIFICANCE
3.8.7.3
STRENGTH-POROSITY RELATIONSHIP
S = S0 e kp
. (1)
. (2)
where a is the intrinsic strength of the material at zero porosity p, and x the
solid/space ratio or the amount of solid fraction in the system, which is therefore
equal to 1 p. powers data are shown in Fig. 17c; he found the value of a to be
234 MPa (34,000 psi). The similarity of the three curves in Fig. 17 confirms the
general validity of the strength-porosity relationship in solids.
Whereas in hardened cement paste or mortar the porosity can be related to
strength, with concrete the situation is not simple. The presence of micro-cracks
in the interfacial transition zone between the coarse aggregate and the matrix
makes concrete too complex a material for prediction of strength by precise
strength-porosity relations. The general validity of strength-porosity relation,
however, must be respected because porosities of the component phases of
concrete, including the interfacial transition zone, indeed become strengthPage | 51
Page | 52
3.8.7.4
With a material such as concrete, which contains void spaces of various size
and shape in the matrix and micro cracks at the interfacial transition zone, the
failure modes under stress are very complex and vary with the type of stress. A
brief review of the failure modes, however, will be useful in understanding and
control of the factors that influence concrete strength.
Under uni-axial tension, relatively less energy is needed for the initiation and
growth of cracks in the matrix. Rapid propagation and interlink age of the crack
system, consisting of pre-existing cracks at the interfacial transition zone and
newly formed cracks in matrix, account for the brittle failure. In compression, the
failure mode is less brittle because considerably more energy is needed to form
and to extend cracks in the matrix. It is generally agreed that, in uni-axial
compression test on medium or low strength concrete, no cracks are initiated in
the matrix up to about 50 percent of the failure stress; at this stage a stable system
of cracks, called shear bond cracks, already exists in the vicinity of coarse
aggregate. At higher stress levels, cracks are initiated within the matrix; their
number and size increases progressively with increasing stress levels. The cracks
in the matrix and the interfacial transition zone (shear-bond cracks) eventually
join up, and generally a failure surface develops at about 20 to 30 from the
direction of the load.
3.8.7.5 COMPRESSIVE
AFFECTING IT
STRENGTH
&
FACTORS
The response of concrete to applied stress depends not only on the stress type
but also on how a combination of various factors affected porosity of the different
structure components of concrete. The factors include properties and proportions
of materials that make up the concrete mixture, degree of compaction, and
condition of curing. From the standpoint of strength, the relationship between
water-cement ratio and porosity is undoubtedly the most important factor
because, independent of other factor, it affects the porosity of both the cement
mortar and the interfacial transition zone between the matrix and the coarse
aggregate.
Direct determination of porosity of the individual structure component of
concretethe matrix and the interfacial transition zoneis impractical, and
therefore precise models of predicting concrete strength cannot be developed.
However, over a period of time many useful empirical relations have been found,
which, for practical use, provide enough indirect information about the influence
of numerous factors on compressive strength (compressive strength being widely
used as an index of all other types of strength). Although the actual response of
concrete to applied stress is a result of complex interactions between various
Page | 53
3.8.7.6 CHARACTERISTICS
MATERIALS
&
PROPORTIONS
OF
fc =
where w/c represents the water-cement ratio of the concrete mixture and k1 and k2
are empirical constants. From an understanding of the factors responsible for the
strength of hydrated cement paste and the effect of increasing the water cement
ratio on porosity at a given degree of cement hydration, the w/c- strength
relationship in concrete can easily be explained as the natural consequences of a
progressive weakening of the matrix caused by increased porosity with increase in
the water-cement ratio. The explanation, however, does not consider the influence
of the water-cement ratio on the strength of the interfacial transition zone. In low
and medium strength concrete made with normal aggregate, both the interfacial
transition zone
porosity and the matrix porosity determine the strength, and a direct relation
between the water-cement ratio and the concrete strength holds. This seems no
longer to be the case in high-strength (i.e., very low water-cement ratio) concrete
mixtures. For water-cement ratio under 0.3 disproportionately high increases in
the compressive strength can be achieved with very small reductions in watercement ratio. The phenomenon is attributed mainly to a significant improvement
in the strength of the interfacial transition zone at very low water-cement ratio.
Furthermore, with low water-cement ratio the crystal size of the hydration
products is much smaller and the surface area is corresponding higher.
Page | 54
Page | 55
3.8.7.6.4 AGGREGATE
In concrete technology, on overemphasis on the relationship between watercement ratio and strength has caused some problems. For instance, the influence
of aggregate on concrete strength is not generally appreciated. It is true that
aggregate strength is usually not a factor in normal strength concrete because,
with the exception of lightweight aggregates, the aggregate particle is several
times stronger than the matrix and the interfacial transition zone in concrete. In
other words, with most natural aggregates the strength of the aggregate is hardly
utilized because the failure is determined by the other two phases.
There are, however, aggregate characteristics other than strength, such as the
size, shape, surface, texture, grading (particle size distribution), and mineralogy,
which are known to affect concrete strength in varying degrees. Frequently the
effect of aggregate characteristics on concrete strength can be traced to a change
of water-cement ratio. But there is sufficient evidence in the published literature
that this is not always the case. Also, from theoretical considerations it may be
anticipated that, independent of the water-cement ratio, the size, shape, surface
texture, and mineralogy of aggregate particles would influence the characteristics
of the interfacial transition zone and therefore affect concrete strength.
A change in the maximum size of well-graded coarse aggregate of a given
mineralogy can have two opposing effects on the strength of concrete. With the
same cement content and consistency, concrete mixtures containing larger
aggregate particles require less mixing water than those containing smaller
aggregate. On the contrary, larger aggregate tend to form weaker interfacial
transition zone containing more micro cracks. The net effect will vary with the
water-cement ratio of the concrete and the type of applied stress. The effect of
increasing maximum aggregate size on the 28-days compressive strengths of the
concrete was more pronounced with a high-strength (0.4 water-cement ratio) and
a moderate-strength (0.55 water-cement ratio) concrete than with a low-strength
concrete (0.7 water-cement ratio). This is because at lower water-cement ratios
the reduced porosity of the interfacial transition zone begins to play an important
role in the concrete strength. Furthermore, since the interfacial transition zone
characteristics have more effect on the tensile strength of concrete compared to
the compressive strength, it is to be expected that with a given concrete mixture
any changes in the coarse aggregate properties would influence the tensilecompressive strength ratio of the material. For instance a decrease in the size of
coarse aggregate, at a given water-cement ratio, will increase the tensilecompressive strength ratio.
A change in the aggregate grading without any change in the maximum size
of coarse aggregate, and with water-cement ratio held constant, can influence the
concrete strength when this change causes a corresponding change in the
consistency and bleeding characteristics of the concrete mixture. In a laboratory
experiment, with a constant water-cement ratio of 0.6, when the coarse/fine
Page | 56
3.8.7.6.6 ADMIXTURES
The water-reducing admixtures can enhance both the early and the ultimate
strength of concrete. At a given water-cement ratio, the presence of waterreducing admixtures in concrete generally has a positive influence on the rates of
cement hydration and early strength development. Admixtures capable of
accelerating or retarding cement hydrate obviously would have a great influence
on the rate of strength gain; however, the ultimate strength may not be
significantly affected. Many researchers have pointed out the tendency toward a
higher ultimate strength of concrete when the rate of strength gain at early ages
was retarded.
For ecological and economic reasons, the use of pozzolanic and
cementations by product as mineral admixtures in concrete is gradually
increasing. When used as a partial replacement for Portland cement, mineral
admixtures usually have a retarding effect on the strength at early ages. However,
the ability of a mineral admixture to react at normal temperatures with calcium
hydroxide (present in the hydrated Portland cement paste) and to form additional
calcium silicate hydrate can lead to significant reduction in porosity of both the
matrix and the interfacial transition zone. Consequently, considerable
improvements in the ultimate strength and water tightness of concrete are
achievable by incorporation of mineral admixtures. It should be noted that
mineral admixtures are especially effective in increasing the tensile strength of
concrete.
Page | 58
3.8.8
DURABILITY
3.8.8.1
DEFINITION
Page | 59
3.8.8.2
SIGNIFICANCE
3.8.8.3
GENERAL OBSERVATION
3.8.8.4
Page | 61
3.8.8.5
PERMEABILITY
Page | 62
Permeability is defined as the property that governs the rate of flow of a fluid
into a porous solid. For steady-state flow, the coefficient of permeability (K) is
determined form DaGCAys expression:
Where
H
A
L
3.8.8.6 CLASSIFICATION
OF
CONCRETE DETERIORATION
THE
CAUSES
OF
The physical causes of concrete deterioration grouped into two categories: (a)
surface wear or loss of mass due to abrasion, erosion, and cavitations; (b)
cracking due to normal temperature and humidity gradients, crystallization of
salts in pores, structural loading, and exposure to temperature extremes such as
freezing of fire. The chemical cause of deterioration into three categories: (1)
hydrolysis of the cement paste components by soft water; (2) cat ion-exchange
reactions between aggressive fluids and the cement paste; and (3) reactions
leading to formation of expansive products, such as in the case of sulphate attack,
alkali-aggregate reaction, and corrosion of reinforcing steel in concrete.
It should be emphasized again that the distinction between the physical and
chemical causes of deterioration is purely arbitrary; in practice, the two are
frequently superimposed on each other. For example, loss of mass by surface
wear and cracking increases the permeability of concrete, which then becomes the
Page | 63
Page | 64
CHAPTER 4
RESEARCH PROCEDURE
4.1
INTRODUCTION
For designing of M-25 Grade of concrete. It was necessary that to performed
various types of tests on cement concrete and their ingredient materials. To obtain
cement concrete and its ingredients actual testing values (available in our laboratory)
I was perform tests on cement concrete, fine aggregates, coarse aggregates, cement,
and on Granite Course Aggregate s. I performed lab tests of cement to get actual
values of fineness modulus of cement, consistency of cement, Initial & final setting
time of cement and compressive strength of cement. For fine aggregates, I performed
tests like specific gravity of fine aggregate, moisture content, silt content, water
absorption of fine aggregate, bulking of fine aggregate, fineness modulus of fine
aggregate similarly for coarse aggregate, I performed tests like specific gravity of
coarse aggregate, moisture content, silt content, water absorption and fineness
modulus of coarse aggregate. After lab testing of ingredients materials of concrete I
performed workability test on concrete which was done with the help of Vee-Bee
apparatus or slump cone apparatus. This test was performed to know either concrete
was workable or non-workable in laboratory conditions as well as in field
conditions.
Laboratory Tests results were help me to design M-25 grade of Mix with the
help of IS 10262:2009. After designed M-25 grade of cement concrete, I got the
value of cement, fine aggregates, coarse aggregates, Granite Course Aggregates, and
water for making of one cubic meter of cement concrete. With the help of these
values I casted cement concrete cubes of size 151515 cm3at various percentage of
granite course aggregates (GCA as total volume of course aggregates), then I was
left those cement concrete cube specimens for submerge curing of 7 days & 28 days
in soft water. After curing I was take dry weight of cubes to know the difference in
bulk and dry density of cubes due to change of percents of Granite Course Aggregate
into concrete.
In compressive strength test I tested various percentage of GCA cubes such
as 00%, 10%,20%,30%,40% of GCA(GCA as total volume of natural course
aggregates)to know its compressive strength behavior either it was increasing or
decreasing.
Page | 65
4.2
CEMENT TESTS
(d)
Compressive Strength. The average compressive strength of not less than
three mortar cubes (area of face 50 cm3) composed of one part of cement, three parts
of standard sand by mass, and p/4 + 3.0 percent (of combined mass of cement and
sand) water, and prepared, stored and tested in the manner as per IS 4031 (part 6) :
1988 shall be as follows:
a.
At 72 1 h
16 MPa, Min
b.
At 168 2 h
22 MPa, Min
c.
At 672 4 h
33 MPa, Min
NOTES
1.
P is the percentage of water required to produce a paste of standard consistency.
2.
Standard sand shall be conform to IS 650 : 1966.
(e)
Drying Shrinkage. The average drying shrinkage of mortar bars prepared
and tested in accordance with IS 4031 (part 10) : 1988 shall not be more than 0.15
percent.
Page | 66
Calculate fineness as
Fineness
Fineness
100%
= 217 grams
= 100 grams
= 2 grams
100%
4%
Hence percentage of total residue on 90 Micron IS sieve is less than 10% of total
mass of cement taken for test so this sample of cement is OK for further testing
purpose.
Page | 67
(c) Place the mould under Vicats apparatus. The plunger attached to a movable rod
is gently lowered on the paste.
(d) Settlement of plunger is noted, penetration from bottom is equal to the difference
of mould height and settlement of plunger. If penetration of the plunger is within 57mm from bottom, then water added is correct. Otherwise, water is added and
process is repeated
.
Results: Weight of total cement taken for test= 400 gms
S.N.
1.
2.
3.
4.
5.
Parentage Water
(%)
25%
30%
31%
32%
33%
Penetration from
bottom (mm)
32
25
18
12
7
Page | 68
S.N.
1.
2.
3.
4.
5.
6.
7.
8
Time
(min.)
00
10
20
30
35
40
45
50
Page | 69
(f) Take the cube out of water at the end of three days with dry cloth. Measure the
dimension of the surface (A) in which the load is to be applied. Let be L and B
dimensions respectively.
(g) Place the cube in compressive testing machine and apply the load uniformly.
Note the load at which the cubes fail, let it be P, therefore compressive strength
F = P/A (N/mm2).
Result: Amount of Cement (passing from 90 micron IS Sieve) = 185 gms
Amount of Standard sand (passing form 4.75 mm IS sieve & retaining on
micron IS Sieve) = 555 gms
Percentage of Water = [ P/4 + 3 ]
= [32/4 + 3]
90
= 11.25%
REFERANCE TESTING
AGGREGATE
S.N.
1.
2.
3.
MATERIAL
7 Days
Comp. Strength
(N/mm2)
FOR
GRANITE
COARSE
28 Days
Load (N) Comp. Strength
(N/mm2)
Load
(N)
96000
19.2
191000
95000
19.0
189000
97000
19.4
193000
2
Avg. Comp. Strength 19.2N/mm Avg. Comp. Strength
31.7
31.9
31 .6
31.64N/mm2
Page | 70
Page | 71
Result:
Percentage of Bulking =
145 mm
200 mm
100
100
S
.
N
.
Wt
. of
em
pty
Py
cn.
(W
1)
(g)
Wt.
of
Pycn.
+ dry
aggre
gate
(W2)
(g)
Wt.
of
Pyc
n.
+w
ater
(W
4)
(g)
= 303 gms
1.
303
503
Wt.
of
Pycn.
+ dry
aggre
gate
+
water
(W3)
(g)
1324
Specific
Gravity of fine
Aggregate
2.
303
503
1321
1202
2.622
3.
303
503
1326
1202
2.632
1202
2.645
Page | 73
IS
Sieve
Size
(mm
& )
(1)
Weight
retained
(gms)
(2)
Cumulativ
e weight
retained
(gms)
(4)= 100col(3)
Percentage
finer
00
(3)
Cumulativ
e
percentage
weight
retained
0.0 %
1.
4.75
mm
00
2.
2.36
mm
22
22
4.4 %
95.6 %
3.
1.18
mm
70
92
18.4 %
81.6 %
4.
600
74
166
33.2 %
66.8 %
5.
300
90
256
51.2 %
48.8 %
6.
150
100
356
71.2 %
28.8 %
7.
75
104
460
92.0 %
8%
8.
PAN
40
500
100.00 %
0%
100 %
Page | 74
100%
= 500 gms
After washed oven dried fine aggregate sample weight (W2 = 496.5 gms
Moisture Content
Moisture Content
Moisture Content
100%
100%
0.6 %
Hence Moisture content is in permissible limit as per IS 2386 (part 3) : 2002 so this
fine aggregate is suitable for further tests.
Page | 75
= 500 gms
Oven dried, air cooled fine aggregate sample weight (W2) = 498 gms
Water Absorption
Water Absorption
Water Absorption
100%
100%
1.25 %
Page | 76
(c) Immediately after immersion the entrapped air shall be removed from the sample
by lifting the basket containing it 25 mm above the base of the tank and allowing it
to drop 25 times at the rate of about one drop per second. The basket and aggregate
shall remain completely immersed during the operation and for a period of 24
hours afterwards.
(d) The basket and the sample shall then be jolted and weighted in water at a
temperature of 22C to 32C, if it is necessary for them to times as described above
in the new tank before weighting (weight A1).
(e) The basket and the aggregate shall then be removed from the water and allowed
to drain for a few minutes, after which the aggregate shall be gently emptied from
the basket on to one of the dry clothes, and the empty basket shall be returned to the
water, jolted 25 times and weighted in water (A2).
(f)The aggregate placed on the dry cloth shall be gently surface dried with the cloth,
transferring it to the second dry cloth when the first will remove no further moisture.
It shall them be spread out not more than one stone deep on the second cloth, and lest
exposed to the atmosphere away from direct sunlight or any other source of heat for
not less than 10 minutes, or until it appears to be completely surface dry (which with
some aggregate may take on hour or more). The aggregate shall be turned over at
least once during this period and a gentle current of unheated air may be used after
the first ten minutes to accelerate the drying of difficult aggregates. The aggregate
shall then be weighed (Weight B).
(g)The aggregate shall then be placed in the oven in the shallow tray, at a
temperature of 100C to 110C and maintained at this temperature for 24 hours.
It shall then be removed from the oven, cooled in the airtight container and weighed
(weight C).
Result: Weight of saturated aggregate in water ({A1 A2} = A)
Weight of saturated surface dried Aggregate in air (B)
Weight of oven-dried aggregate in air (C)
Specific Gravity
Specific Gravity
Specific Gravity
= 1314 gms.
= 2010 gms.
= 2000 gms.
2.65
NOTE: Testing of Specific Gravity of Coarse Aggregate was done as per IS 2386
(part 3):2002. Tests of Specific Gravity of coarse aggregate were repeated for three
samples, in these samples values were same as above value of S.G. (0.009).
Page | 77
S.N.
1.
2.
3.
4.
5.
6.
7.
IS
Sieve
Size
(mm
)
40
mm
20
mm
16
mm
12.5
mm
10
mm
4.75
mm
PAN
(1)
Weight
retained
(gms)
(3)
Cumulative
percentage
weight
retained
80%
(4)=
100col(3)
Percentage
finer
6400
(2)
Cumulativ
e weight
retained
(gms)
6400
240
6640
83%
44.5 %
160
6800
85%
33.37 %
160
6960
87%
26.94 %
480
7440
93%
13.5 %
480
7920
99%
0.125 %
80
8000
100 %
00 %
100 %
Fineness Modulus =
Fineness Modulus =
Page | 79
Results: Washed coarse aggregate oven dried sample weight (W1) = 1000 gms
Oven dried, air cooled coarse aggregate sample weight (W2) = 995 gms
Water Absorption
Water Absorption
Water Absorption
100%
100%
0.52%
100%
= 1000 gms
After washed oven dried coarse aggregate sample weight (W2) = 994 gms
Moisture Content
Moisture Content
Moisture Content
100%
100%
0.6 %
Hence Moisture content is in permissible limit as per IS 2386 (part 3) : 2002 so this
coarse aggregate is suitable for further tests.
Page | 80
Water
Cement
202.4
446.00
0.454
Fine aggregate
Coarse
aggregate
632
1151
1.417
2.581
= 84 mm
= 78 mm
= 75 mm
= 79.00 mm
Hence this Mix design is OK for casting of cement concrete cubes with Granite Course
Aggregate ..
Page | 81
Fig. 18 (a)
Fig. 18 (b)
Fig. 18 (c)
Page | 82
Fig. 18 (d)
Fig. 18 (e)
Fig. 18 (f)
Page | 83
Fig. 19 (c)
Fig. 19 (d)
Results: Compressive strength testing results with Graphs and tables are shown in
Chapter 5 in detail.
Page | 84
Amount of raw material require for concrete cubes casting are as follows in
Table Number: - 6 (a) to 6 (e).
S.N.
1.
Name of Material
Cement
Fine Aggregate
Coarse Aggregate
Water
GCA
0.00% G.C.A
Material require for
casting one cube
(gms)
2,286
3,360
5371.44
982ml
00
Total
12000
S.N.
2.
Name of Material
Cement
Fine Aggregate
Coarse Aggregate
Water
GCA
10% G.C.A.
Material require for
casting one cube
(gms)
2286
3360
4834
982.8ml
537
Total
12,000
Name of Material
Cement
Fine Aggregate
Coarse Aggregate
Water
GCA
20% G.C.A
Material require for
casting one cube
(gms)
2286
3360
4297
982.8ml
1074
Total
12000
S.N.
4.
Name of Material
Cement
Fine Aggregate
Coarse Aggregate
Water
GCA.
30% G.C.A
Material require for
casting one cube
(gms)
2286
3360
3760
982.8
1611
Total
12000
S.N.
5.
Name of Material
Cement
Fine Aggregate
Coarse Aggregate
Water
GCA
40% G.C.A.
Material require for
casting one cube
(gms)
2286
3360
3224
982.8ml
2148
Total
12000
Page | 86
4.5.3.2
fck'
fck
= Standard Deviation
fck'
= 25 + (1.65 x 4)
fck'
= 31.6 N/mm2
4.5.3.3
Page | 87
Serial
No.
1.
2.
3.
Change in condition
Adjustment
Water
content
Percentage of
sand in total
aggregate
+3%
-
-3.4%
-1.5%
+3%
-4.9%
..
. Require
..
. Require
Where :-
= 0.43
= 191.6 L/m3
Page | 88
From IS 456:2000 for M-25 (table 5) minimum cement content for R.C.C. in severe
exposure was 320 Kg/m3.
445.58 > 320 Kg/m3
Hence O.K
4.5.3.5
Page | 89
Sfa , Sca = specific gravity of saturated surface dry fine aggregate & coarse
aggregate respectively.
or
fa = 499.44 Kg/m3
Ca = 1299.07 Kg/m3
Water
Cement
191.6
0.43
4.5.3.6
Fine aggregate
Coarse
aggregate
446.00
500
1300
1.211
2.920
CORRECTION OF WATER
In this mix Design I used Granite Course Aggregate and natural course aggregate
which
give approx. water absorption of 0.6% of its total weight in both cases.
Actual water quantity require for M-30 Mix = 191.6+10.8 = 202.4 Kg/m3
= 30.1%
= 30.1%+08% = 38.1%
fa = 655
Kg/m3
Ca = 1048 Kg/m
Page | 91
MIX PROPORTION
The designed proportion by mass on the basis of proportion of the available ingredient of
concrete is as follows:-
GRADE M 25
INGRADIENT
WATER
PROPORTION 0.40
BY MASS
PROPORTION 419
BY WEIGHT
CEMENT
1.00
FINE
AGGREGATE
1.45
COARSE
AGGREGATE
2.95
167
607.55
1240
Following quantities of different material are required for one cum of concrete.
Cement
50 kg
Water
20 kg
Fine aggregate
Course aggregate
INGRADIENT
WATER
PROPORTION 0.40
BY MASS
PROPORTION 419
BY WEIGHT
CEMENT
1.00
FINE
AGGREGATE
1.45
COARSE
AGGREGATE
2.95
167
607.55
1240
Page | 92
Page | 93
CHAPTER 5
RESULT AND DISCUSSION
5.1
INTRODUCTION
In this chapter results obtained by Mix design of M-25 Grade of concrete from
chapter 4.Cement concrete cubes prepared and casted as per chapter 4 (process of
cube casting was mention in chapter 4).Results and values of chapter 4 presented and
discussed in the following section:
Workability
Workability for all the mixes are same however. The water requirement for
all the mixes is different and specially for the mix with Granite Course
Aggregate coarse the water once mix start absorbing water by Granite
Course Aggregate and slump goes reducing with time however super
plasticizer can be used .
Compressive strength
The important aspect the designing and its getting accepted is the
compressive strength. In the given set of mixes and attempt was made to
check the acceptability of Granite Course Aggregate for M25 grade of
concrete. The table show the value of compressive strength of various mix.
The compressive strength rate of natural aggregate is higher than that of
Granite Course Aggregate. However Reason of decrease of the strength is
due to surface of Granite Course Aggregate .When the water absorbed by the
aggregate more space left by the water being absorbed can be occupied by
aggregate in a unit volume hence the density of Granite concrete is lower.
Page | 94
Page | 95
S.N
1.
2.
3.
4.
5.
% of Cube
GCA
name
in
conc.
Date
of Date
of Crushing
Manufacturing Testing of load
of
concrete
(KN)
concrete
cubes
cubes
Stress
C1
0.00 % C2
C3
C1
10%
C2
C3
20%
C1
C2
C3
30%
C1
C2
C3
40%
C1
C2
C3
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
20.00
19.956
19.86
20.53
20.58
20.52
21.82
21.73
21.69
22.36
22.40
22.31
21.56
21.54
21.51
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
22/Apr/2015
450
447
449
462
463
461
491
488
489
503
502
504
485
484
485
(N/mm2)
Average Percentage
Stress
of increase
2
(N/mm ) in strength
19.95
20.5
21.75
22.36
21.54
Increase of
00
%
Strength
Increase of
1.92
%
Strength
Increase of
2.92
%
Strength
Increase of
3.80
%
Strength
Decrease
of 1.66 %
Strength
Page | 96
7 days Values of
Stress
7 days Values of
Stress
19.95
Stress (N/mm2)
Stress (N/mm2)
20
19.9
19.85
19.8
19.75
0.00 %G.C.A
Cu
be
1
20
Cu
Cu
be
be
2
3
19.86 19.95
Cub
e1
10 % G.C.A 20.53
21.65
21.6
Cu
Cu
Cu
be
be
be
1
2
3
20 % G.C.A 21.82 21.69 21.73
Axis Title
Stress in
21.7
Cub
e3
20.49
7 days value of
stress
21.85
21.75
Cub
e2
20.58
7 days Values of
Stress
21.8
20.58
20.56
20.54
20.52
20.5
20.48
20.46
20.44
22.4
22.38
22.36
22.34
22.32
22.3
22.28
22.26
Cu
Cu
Cu
be
be
be
1
2
3
30 % G.C.A 22.36 22.314 22.4
Page | 97
Axis Title
Cube 1
21.56
Cube 2
21.51
Cube 3
21.56
Stress (N/mm2)
0.0%
G.C.A
19.95
10%
G.C.A
20.53
20%
G.C.A
21.75
30%
G.C.A
22.36
40%
G.C.A
21.54
Page | 98
S.N
1.
2.
3.
4.
5.
% of Cube
RCA
name
in
conc.
Date
of Date
of Crushing
Manufacturing Testing of load
of
concrete
(KN)
concrete
cubes
cubes
Stress
C1
0.00 % C2
C3
C1
10%
C2
C3
20%
C1
C2
C3
30%
C1
C2
C3
40%
C1
C2
C3
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
15/Apr/2015
28.40
28.44
28.49
29.96
29.96
29.91
31.73
31.64
31.51
32.76
32.80
32.71
32.20
31.24
31.82
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
14/May/2015
639
640
641
674
674
673
714
712
710
737
738
736
702
703
716
(N/mm2)
Average Percentage
Stress
of increase
2
(N/mm ) in strength
28.44
29.94
31.62
32.75
31.42
Increase of
00%
Strength
Increase of
1.27%
Strength
Increase of
2.63%
Strength
Increase of
03.57%
Strength
Decrease
of 1.76%
Strength
Page | 99
28.44
28.43
28.42
28.41
28.4
28.39
28.38
0 % G.C.A
28 days Values of
Stress
29.96
Stress (N/mm2)
Axis Title
28 days value of
stress
Cu
be
1
28.4
28 days Values of
Stress
Stress (N/mm2)
Stress (N/mm2)
Cu
Cu
Cu
be
be
be
1
2
3
20 % G.C.A 31.73 31.64 31.51
29.9
Cu
Cu
Cu
be
be
be
1
2
3
10 % G.C.A 29.96 29.94 29.91
28 days Values of
Stress
31.75
31.7
31.65
31.6
31.55
31.5
31.45
31.4
29.92
29.88
Cu
Cu
be
be
2
3
28.44 28.42
29.94
32.8
32.78
32.76
32.74
32.72
32.7
32.68
32.66
Cu
be
1
30 % G.C.A 32.76
Cu
be
2
32.8
Cu
be
3
32.71
Graph 3(c): M-25 Concrete Cubes Graph 3 (d): M-25 Concrete Cubes
at 20% G.C.A
at 30% G.C.A
Page | 100
31.8
31.6
31.4
31.2
31
30.8
40 % G.C.A
Cube
1
31.2
Cube
2
31.24
Cube
3
31.82
Stress (N/mm2)
00 %
G.C.A
28.44
10 %
G.C.A
29.94
20%
G.C.A
31.62
30%
G.C.A
32.75
40%
G.C.A
31.42
Page | 101
From 28 days test result the strength is increased up to 30% replacement of G.C.A and then
after it was slightly decreased when the replacement is done up to 40 %. So I found that the
optimum replacement is done up to 30% the strength of the concrete is safe at the
replacement up to 30%. We can use the granite aggregate as a partial replacement of coarse
aggregate. The result of the compressive strength test for the testing of the concrete samples
is shown above. The above result shows the result of the testing of the 7 days and 28 days
respectively of the three specimens. It is observed that from the waste granite material good
quantity of material can be obtained which can be used for making aggregates.
These aggregates posses good engineering properties and adequate
strength. I found that at 7 days strength is increased when that granite course aggregate is
replaced by 10% the increase in strength is increased to 2.92% as compared to 0%
replacement, when the replacement is increased to 20% the strength is increased to 3.42%
when compared to 0% replacement, when the replacement is done to 30% the strength is
increased to 4.40%, further when the replacement is increased to 40% the strength is
decreased by 1.66%. the loss of the strength is due to higher workability of the concrete and
the high value of slump. The target compressive strength (31.6N/mm2) is achieved for 30%
replacement.
Both the test result of 7 days and 28 days shows that the optimum amount of
granite waste which can be used for making concrete is up to 30% replacement of natural
aggregate after it the strength decreased by a certain percent this may be due to lower water
absorption of granite aggregate. Further if the good treatment processes are applied such as
use of superplasticisers and curing processes may be lead to increase in strength. I found
that 30% is the safer limit to which it can be used this will help in reduction of the
consumption of the natural aggregate. The compressive strength is particularly higher in all
the ages is higher when compared to reference mix(G.A 0%), there was increase in strength
when the days of curing is increased. The compressive strength of GCA30% yielded higher
values than any other.
Page | 102
5.2 Conclusion
Research on the usage of the waste constructional material is very important,
because, constructional waste material is gradually increased with the increasing
population and also increasing urban development. The reason is that many
investigation and analysis are done on granite fines as partial replacement of fine
aggregate, because a high amount of granite fines are available in factories where
the cutting of granite is done these fines also posses good properties so that they
can be used my focussed is that a larger amount of granite stones is available
which can be used for making aggregate after proper grading. Granite aggregate is
easy to obtain and their cost is also lower than the natural aggregate.
The main aim of this research is to determine strength
and durability characteristics of granite waste for the potential application in high
concrete structural concrete. The study shows that:1.When the percentage of the granite waste aggregate is increased upto 30% the
strength is increased. After 40% it was slightly decreased. However it can be
minimised by adjusting water cement ratio.
2.The target compressive strength is achieved at 30% to 40% of granite course
aggregate. This is classified as concrete strength and can be used in making
structural component.
3. The compression test result indicate that an increasing trend of compressive
strength up to 40% replacement of Granite course aggregate then it was slightly
decreased.
4. Hence granite course aggregate can be used up to 30% replacement of natural
aggregate.
Page | 103
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