Paper making generally a large amount of solid waste. Paper fibers can be recycled only a limited number of times before they become too short or weak to make high quality paper. It means that the broken, low-quality paper fibers are separated out to become waste sludge. To reduce disposal and pollution problems emanating from these industrial wastes, it is most essential to develop profitable building materials from them. Keeping this in view, investigation were undertaken to produce low cast concrete by blending various ratios of cement with hypo sludge.
This project is concerned with experimental investigation on strength of concrete and optimum percentage of the partial replacement by replacing cement via 10%,15% and 20% of Fly Ash and hypo sludge is constant 10%. We also have compared strength and cost of both the materials because Fly Ash is very vital used waste in concrete as a cementasious material. The aim of investigation is the behaviour while adding of waste with different proportions of Hypo Sludge and Fly Ash in concrete by using tests like compressive strength test and durability test.
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LIST OF TABLE
Table No. Table Description Page No.
4.1 Chemical Composition of Fly Ash as per IS: 3812-1981(%) Fly Ash 10
4.2 Specific Gravitiy of Flyash 10
4.3 Properties of Hypo Sludge 12
4.4 Binani Cement 53 grade OPC 14
4.5 Slump Test Value 20
4.6 Water Absorption Data 21
4.7 Quantity of Material 21
5.1 Sieve Analysis C.A 20 mm
23
5.2 Sieve Analysis C.A. 10 mm 24
5.3 Sieve Analysis of F.A. 25
5.4 Specific Gravity of 20mm 26
5.5 Specific Gravity of 10mm 27
5.6 Specific Gravity of Sand 27
5.7 Specific Gravitiy of Flyash 28
5.8 Impact value 28
5.9 Crushing value 29
5.10 For Course Aggregate 29
5.11 For Greet 29
5.12 For Sand 30
5.13 Hypo sludge chemical properties 30
6.1 Result of Compressive Test 31
7.1 Cost of Material of Normal Concrete/m3 33
7.2 Cost of Material Partially Replaced10% Fly Ash and 10% Hypo Sludge Concrete/m3 34
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LIST OF FIGURE
Figure No Figure Description Page No
4.1 Hypo Sludge 11
4.2 Mixing Stage-1 16
4.3 Mixing Stage-2 17
4.4 Mixing Stage-3 17
4.5 Casted concrete cube 18
4.6 Compressive Test Machine 19
LIST OF GRAPH
Graph No. Graph Description Page No.
5.1 Graphical Presentation of Sieve Analysis for Coarse Aggregate 20 mm 24
5.2 Graphical Presentation of Sieve Analysis for Coarse Aggregate 10 mm 25
5.3 Graphical Presentation of Sieve Analysis for Fine Aggregate 26
6.1 Compressive Strength With 10% Fly ash and 10% Hypo Sludge 31
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CHAPTER-1
INTRODUCTION
1.1 GENRAL INTRODUCTION
Energy plays a determinant role in growth of developing countries like India. In the reference of low availability of non-renewable energy resources with fulfilment of this resources the requirements of large quantity of energy for building materials like cement, the importance of using industrial waste cannot underestimated.
1.1.1 Concrete Composition
Concrete is a composition of construction material like cement (commonly Portland cement), sand, aggregate (generally a course aggregate made of gravel or crushed rocks such as limestone, or granite, plus a fine aggregate such as sand), water and also chemical admixtures(if required). The aim is to mix these materials in measured amounts to make concrete that is easy to: Transport, place, compact, finish, and which is set, and harden, to give a strong and durable product. The amount of each material (i.e. cement, water and aggregate) affects the properties of hardened concrete.
A concrete mix designed is to produce concrete that can be easily placed at the lowest cost. The mix design must consider the environment that the concrete is being in; i.e. sea water, load of trucks & car, foot traffic or extremes of resists hot and cold weather. The proportion of each material in the mixture affects the properties of fine hardened concrete. These proportions are measured by weight that is very accurate. But Measurement by volume is not as accurate.
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Mix design can be also defined as the process of selecting suitable ingredients of concrete and determining their relative proportions with the object of producing concrete of certain minimum strength and durability as economically as possible the purpose of designing as can be seen from the above definitions is two objects. The first object is to achieve stipulated minimum strength and durability. The second object is to make the concrete is the most economical manner. Cost wise all concrete depends primarily two factors; namely cost material and cost of labour. Labour cost, by way of formwork, batching, mixing, transporting, and curing is nearly same for good concrete. Therefore attention is mainly directed to the use of hypo sludge and fly ash to try as possible consistent with strength and durability.
1.1.2 Cement
Cement is an energical binding material. The most important uses of cement are as an ingredient in the production of mortar in masonry, and of concrete, a combination of cement and an aggregate to form a strong building material.
Cement making process use large source of non-renewable energy so we replace the fly ash and hypo sludge, because it is easily available from industrial waste. During manufacturing of 1 tonnes of ordinary Portland cement (OPC) we need about 1’1.33 tonnes of earth resources like lime stone and gypsum etc. further during manufacturing of 1 tone of ordinary Portland cement an equal amount of carbon di-oxide are replace in to the atmosphere. The Carbon Di-oxide emission act as a silent killer in the environment under various forms.
1.1.3 Hypo Sludge
Paper making generally produced a large amount of solid waste. Paper fibers can be recycled only a limited number of times before they become too short or weak to make high quality paper. It means that the broken, low-quality paper fibers are separated out to become waste sludge. It is also known as hypo sludge.
Hypo sludge contains, low calcium and maximum calcium chloride and minimum amount of silica. Hypo sludge behaves like cement become of silica and magnesium properties. This silica and magnesium improve the setting of the concrete.
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This paper mill sludge consumes a large percentage of local landfill space for each and every year. Worse yet, some of the wastes are land spread on cropland as a disposal technique, Raising concerns about trace contaminants building up in soil or running off into area lakes and streams. Some companies burn their sludge in incinerators, contributing tour serious air pollution problems. To reduce disposal and pollution problems emanating from this industrial waste, it is most essential to develop profitable building materials from them. Keeping this in view, investigation were undertaken to produce low cost concrete by blending various ratios of cement with hypo sludge.
1.1.4 Fly Ash
Fly ash is a fine, glass powder recovered from the gases of burning coal during the production of electricity. These micron-sized earth elements consist primarily of silica, alumina and iron.
Fly ash closely resembles volcanic ashes used in production of the earliest known hydraulic cements about 2,300 years ago. Those cements were made near the small Italian town of Pozzuoli – which later gave its name to the term "pozzolan."
In India, the total production of fly ash is nearly as much as that of cement. But our utilization of fly ash is only about 5% of production. Therefore, the use of fly ash must be popularized for more than one reason. Availability of consistent quality fly ash in concrete are pre requisite for change of perception on fly ash from an ‘A waste material’ to ‘A recourse material’. Industrial by-products Fly ash, sludge and silica fume are used in making concrete, which helps reduced embodied energy, carbon footprint and quantity of landfill materials. So we taken fly ash for compare it with hypo sludge.
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CHAPTER-2
OBJECTIVE AND FUTURE SCOPE OF STUDY
2.1 OBJECTIVE OF STUDY
‘ To investigate the utilization of Hypo Sludge as Supplementary Cementitious Materials (SCM) and influence of these hypo sludge on the Strength on concretes made with different Cement replacement levels.
‘ To select the Hypo Sludge mix proportion for cement mortar.
‘ To investigate changes in compressive strength of cement mortar with Hypo sludge replacement.
‘ To perform the experiments on the time-dependent compressive strength of cement mortar with Hypo Sludge. The strengths were measured at the age of 7 & 28 days.
2.2 SCOPE OF STUDY
‘ In the mention experiment work different replacement ratio of hypo sludge (constant) and fly ash were replaced with respect to cement.
‘ In the concrete, we have cement replace via. 10% (constant) hypo sludge and 10%, 15%, 20% fly ash.
‘ We are carried some test(e.g. compressive test. Slump test, water absorption) on concrete for the compare normal concrete and hypo sludge and fly ash concrete.
‘ After casting of concrete cubes apply for curing in water tank.
‘ To find the optimum strength of the partial replacement of concrete.
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CHAPTER-3
LITERATURE SURVEY
3.1 EXPERIMENTAL INVESTIGATION IN DEVELOPING LOW COST CONCRETE FROM PAPER INDUSTRY WASTE (2010)
R. SRINIVASAN, K. SATHIYA AND M. PALANISAMY
Overview
Over 300 million tonnes of industrial wastes are being produced per annum by chemical and agricultural process in India. These materials pose problems of disposal and health hazards.
Paper making generally produces a large amount of solid waste. To reduce disposal and pollution problems emanating from these industrial wastes, it is most essential to develop profitable building materials from them. Keeping this in view, investigations were undertaken to produce low cast concrete by blending various ratios of cement with hypo sludge.
This project is concerned with experimental investigation on strength of concrete and optimum percentage of the partial replacement by replacing cement via 10%, 20%, 30%, 40%, 50%, 60% and 70% of Hypo Sludge.
To investigate the utilization of Hypo Sludge as Supplementary Cementations Materials (SCM) and influence of these hypo sludge on the Strength on concretes made with different Cement replacement levels.
3.2 INNOVATIVE USE OF PAPER INDUSTRY WASTE (HYPO SLUDGE) IN DESIGN MIX CONCRETE (2010)
PROF. JAYESHKUMAR PITRODA, DR. L.B.ZALA, DR.F.S.UMRIGAR.
Overview
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To produce low cost concrete by blending various ratios of cement with hypo sludge & to reduce disposal and pollution problems due to hypo sludge it is most essential to develop profitable building materials from hypo sludge. To make good quality paper limited number of times recycled Paper fibres can be used which produces a large amount of solid waste. The innovative use of hypo sludge in concrete formulations as a supplementary cementitious material was tested as an alternative to traditional concrete.
This research work is concerned with experimental investigation on strength of concrete and optimum percentage of the partial replacement by replacing cement via 10%, 20%, 30%, and 40% of Hypo Sludge for M-25 and M-40. The aim of investigation is the behaviour of concrete while adding of waste with different proportions of Hypo sludge in concrete by using tests like compression strength and split strength.
3.3 EVALUATION OF MODULUS OF ELASTICITY OF CONCRETE WITH PARTIAL REPLACEMENT OF CEMENT BY THERMAL INDUSTRY WASTE (FLY ASH) AND PAPER INDUSTRY WASTE (HYPO SLUDGE) (2013)
JAYESHKUMAR R. PITRODA, DR F.S. UMRIGAR
Overview
The use of fly ash in replacing cement to certain percentage is accepted in recent years. It saves cement, consumes industrial waste and makes durable concrete. Coal fly ash is a widely used by product material. It has been in use as a concrete additive for more than two decades. The material’s properties make fly ash a useful material in the construction industry. It is beneficial to relieve from disposal facilities.
Other waste material paper mill sludge is a major economic and environmental problem for the paper and board industry. The main recycling and disposal routes for paper sludge are land-spreading, producing paper sludge ash, or disposal to any river /stream.
In function alternative, paper sludge consists of cellulose fibres, calcium carbonate and china clay and residual chemicals bound up with water. To produce low cost concrete by replacing cement with hypo sludge. To reduce disposal and pollution problems due to hypo sludge it is most essential to develop profitable materials used for mankind from it. The cement has been replaced by hypo sludge and fly ash accordingly in the range of 0%, 10%, 20%, 30% and 40%.
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3.4 DURABILITY OF CONCRETE WITH PARTIAL REPLACEMENT OF CEMENT BY PAPER INDUSTRY WASTE (HYPO SLUDGE) (2013)
JAYESHKUMAR PITRODA, L.B.ZALA, F. S. UMRIGAR
Overview
Durable concrete is one that performs satisfactorily under the exposed environmental condition during its service life span. Concrete requires to little or zero maintenance and normal environment. Main characteristic influencing the durability of concrete is its permeability to the ingress of water. When excess water in concrete evaporates, it leaves voids inside the concrete element creating capillaries which are directly related to the concrete porosity and permeability.
By proper selection of ingredients and mix proportioning and following the good construction practices almost impervious concrete can be obtained. The flow of water through concrete is similar to flow through any porous body. The pores in cement paste consist of gel pores and capillary pores. The pores in concrete as a result of incomplete compaction are voids of larger size which give a honeycomb structure leading to concrete of low strength. There is a need for another type of test rather than the absorption test and permeability tests to measure the response of concrete to pressure. This test should measure the rate of absorption of water by capillary suction, sorptivity of unsaturated concrete. In this paper, an attempt is made to study the properties of Paper Industry Waste (Hypo Sludge) concrete to check durability. The mix design was carried out for M25 and M40 grade concrete as per IS: 10262-2009.
3.5 STUDY OF MODULUS OF ELASTICITY OF CONCRETE WITH PARTIAL REPLACEMENT OF CEMENT BY HYPO SLUDGE WASTE FROM PAPER INDUSTRY (2013)
JAYRAJ VINODSINH SOLANKI, JAYESHKUMAR PITRODA
Overview
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Paper mill sludge is a major economic and environmental problem for the paper and board industry. The material is a by-product of the de-inking and re-pulping of paper. The million tonnes quantity of paper mill sludge produced in the world. The main recycling and disposal routes for paper sludge are land-spreading as agricultural fertiliser, producing paper sludge ash, or disposal to landfill.
In functional terms, paper sludge consists of cellulose fibres, calcium carbonate and china clay and residual chemicals bound up with water. The material is viscous, sticky and hard to dry. To produce low cost concrete by blending various ratios of cement with hypo sludge and to reduce disposal and pollution problems due to hypo sludge it is most essential to develop profitable building materials from hypo sludge.
To make good quality paper limited number of times recycled Paper fibres can be used which produces a large amount of solid waste. The innovative use of hypo sludge in concrete formulations as a supplementary cementitious material was tested as an alternative to conventional concrete. The cement has been replaced by hypo sludge accordingly in the range of 0%, 10%, 20%, 30% and 40% by volume for M-25 and M-40 mix.
Concrete mixtures were produced, tested and compared in terms of modulus of elasticity with the conventional concrete. The test was carried out to evaluate the modulus of elasticity after 56 days. This study includes different concrete mixtures were produced to determine the influence of hypo sludge derived from J.K. Papers mill Pvt. Ltd, plant near Songadh, Tapi District in Gujarat State referring to the Modulus of Elasticity.
3.6 SUMMARY
From the above literature it is clear that many researchers have put their efforts to study different properties of replacement concrete. From the literature survey it is conclude that, there is not detail research papers found on the water absorption and alkalinity replacement concrete. In the present work, a small effort has been made to fill this gap.
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CHAPTER-4
MATERIAL DISCRIPTION
4.1 FLY ASH
4.1.1 Fly Ash Introduction
Fly ash is finely divided residue resulting from the combustion of powered coal and transported fuel as. Fly ash is the most widely used pozzolanic material all over the world.
Fly ash was first used in large scale in the construction of hungry horse dam in America in the approximate amount of 30% by weight of cement. Latter on it was used in canyon and fery dam etc. in India, Fly ash was used in Rihand Dam Construction replacing up to 15 per cent.
In the recent time the importance and use of fly ash in concrete has grown so much that it has 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 benefits that could be accrued in the utilization of fly ash as a supplementary cementitious Material. High volume fly ash concrete is subject of current interest all over the world.
The use of fly ash as a concrete admixture not only extends technical advantages to the properties of concrete but also contributes to the environmental pollution control. In India alone, we produce about 75 million tonnes 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 considerations of concrete technologists and government departments.
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In India, the total production of fly ash is nearly as much as that of cement. But our utilization of fly ash is only about 5% of production. Therefore, the use of fly ash must be popularized for more than one reason.
There are two ways that the fly ash can be used: One way is to into grind certain percentage of fly ash with cement clinker at the factory to produce Portland.
We have used first class fly ash as receive from Megicrete Building Solution, Palsana, Navasari, Gujarat.
Table 4.1 Chemical Composition of Fly Ash as per IS: 3812-1981(%) Fly Ash
Properties Fly Ash Class
Class F Class C
Minimum percentage of silicon dioxide, aluminium oxide, iron oxide
(SiO2 +Al2O3+Fe2O3) 70.0 50.0
Maximum percentage of Sulphur trioxide (SO3) 5.0 5.0
Maximum percentage of Moisture Content 3.0 3.0
Maximum percentage of material loss on ignition (LOI) 6.0 6.0
Table 4.2 Specific Gravitiy of Flyash
Sample: Flyash(45 gms) Test
Wt. of sample in gms. 45
Reading on flask after filing kerosene in ml 0.8
Reading on flask with kerosene after introducing sample in ml 21.60
Specific gravity = Wt. of sample in gms./ Displaced volume in ml. 2.16
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4.2 SOLID WASTE FROM PAPER INDUSTRY: HYPO SLUDGE
4.2.1 Hypo Sludge Properties
Hypo sludge contains, low calcium and maximum calcium chloride and minimum amount of silica. Hypo sludge behaves like cement become of silica and magnesium properties. This silica and magnesium improve the setting of the concrete.
Figure 4.1: Hypo Sludge
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Table 4.3 Properties of Hypo Sludge (General Properties as per testing)
SR. NO. TEST PARAMETERS UNITS RESULTS TEST METHOD
1 Silicon Dioxide + Aluminium Oxide + Iron Oxide % by mass 6.014 IS : 1727
2 Magnesium oxide as MgO % by mass 2.39 IS : 1727
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3 Total Sulphur as Sulphur Trioxide SO3 % by mass 0.073 IS : 1727
4 Total Chloride % by mass 0.015 IS : 12423
5 Loss on Ignition % by mass 39.76 IS : 1727
6 Silicon oxide as SiO2 % by mass 5.08 IS : 1727
7 Available Alkalis as Na2O % by mass 0.60 IS : 4032
4.2.2 Need for Hypo Sludge Utilization
Paper making generally a large amount of solid waste. Paper fibers can be recycled only a limited number of times before they become too short or weak to make high quality paper. It means that the broken, low-quality paper fibers are separated out to become waste sludge. All the inks, days, coatings, pigments, staples and ‘stickies’ (tape, plastic films, etc.) are also washed off the recycled fibers to join the waste solid. The shiny finish on glossy magazine-type paper is produced using a fine kaolin clay coating, which also become solid waste during recycling. This paper mill sludge consumes a large percentage of local landfill space for each and every year. So that, some of the wastes are land spread on cropland as a disposal technique, Raising concerns about trace contaminants building up in soil or running off into area lakes and streams. Some companies’ burn their sludge so that produce the serious air pollution problems also increase breathing and skin diseases. To reduce disposal and pollution problems stand from these industrial wastes, it is most essential to develop profitable building materials from them.
We have used hypo sludge was receive from J.K. Papers mill Pvt. Ltd, plant near Songadh, Tapi District in Gujarat.
4.2.3 Effect of Hypo Sludge in Concrete
‘ Increases slump for same water content.
‘ Improve workability.
‘ It increase initial setting time and decrease final set times of concrete.
‘ Improved workability can influence higher achieved destiny in field concretes.
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‘ Sufficient early age compressive strengths can be achieved through proper mix.
4.3 CEMENT
Cement is energical binding material of concrete. We have used ordinary Portland cement (53 Grade). Cement is purchase by local retailer and cement brand is Binani Cement (53 grade OPC).
Table 4.4 Binani Cement 53 grade OPC
BIS BS ASTM GERMANY JAPAN BINANI CEMENT
Specifications 43 Grade 53 Grade BS-12 C-150 T-1 OPC-I OPC-II 43 Grade 53 Grade
LOI (%) max 5.00 4.00 3.00 3.00 5.00 5.00 3.00 2.30 2.10
IR (%) max 3.00 3.00 1.50 0.75 3.00 3.00 – 2.10 2.00
SO3 (%) max 3.00 3.00 3.50 3.00 3.50 3.50 3.00 2.10 2.00
MgO (%) max 6.00 6.00 4.00 6.00 5.00 5.00 5.00 1.98 1.98
Blaine (M2 / kg) max 225 225 275 280 220 220 250 300 320
Setting Time (Mins)
– Initial (Minimum) 30 30 45 45 60 60 60 125 120
– Final (Minimum) 600 600 600 375 720 720 600 175 170
Soundness
– Le-Chatelier (mm)
Maximum 10 10 10 – – – – 1.00 1.00
– Auto Clave (%)
Maximum 0.80 0.80 – 0.80 – – – 0.10 0.10
Compressive
Strength (MPa)
– 3 days min 23.0 27.0 25.0 12.7 – – 7.0 42.0 41.0
– 7 days min 33.0 37.0 – 19.70 18.4 – 15.0 52.0 53.0
– 28 days min 43.0 53.0 42.5 –
62.5 28.2 35.7 –
56.1 35.7 –
56.1 30.0 62.0 65.0
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4.4 AGGREGATE
Aggregates are the important constituents in concrete. We used 20 mm and 10 mm irregular shape aggregate. Source of aggregate in south Gujarat at Chikhali. We are purchase the aggregate local retailer at Surat. We are used aggregate in wet condition.
4.5 SAND
We are use the black sand and it source from Tapi river. we have purchase the sand from local retailer These are cohesion less aggregate of either, rounded, sub rounded, angular, sub angular or flat fragments of more or less unaltered rock of minerals consisting of 90% of particles of size greater than 0.06 mm and less than 2mm.Alternatively, these are coarse grained cohesion less particles of silica derived from the disintegration of rock.
4.6 WATER
Generally any natural water which can be drinkable and has no pronounced taste or odor is used for concrete mix as per IS:10500-1991.Due to impurities in water, dampness of concrete, efflorescence, risk of corrosion damage etc will occur in concrete mix.
4.7 CASTING OF THE SPECIMEN
4.7.1 Batching
The measurement of materials for making is known as batching. There are two method of batching.
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(1) Volume batching
(2) Weight batching
‘ Weight Batching
Strictly speaking, weight batching is the correct method of measuring the materials .For important concrete, invariably, weight batching system should be adopted of weight system in batching, facilitates accuracy, flexibility and simplicity. Different types of weight batchers are available. The particular type to be used depends upon the nature of the job.
4.7.2 Mixing
Hand mix concrete ‘on the deck’, either using a slab of existing concrete (which can be hosed off and cleaned down afterwards) or on a large mixing board. In other countries they seem to prefer to mix in a barrow or tub.
When measuring out the cement and ballast (or sharp sand/gravel), it is best to actually use a bucket rather than measuring by ‘shovel loads’, get more ballast on a shovel than cement. You may not want to use a large bucket; when you add up all the ingredients, you could end up with an enormous pile. It is far easier to mix two small piles than one large one.
‘ Clean off the working surface, use a brush and hose it down.
‘ Carefully measure out onto the mixing surface about half the ballast (or sand and gravel – do one of each in turn so that they start to mix) needed into a rough cone shape.
‘ With a shovel, make a crater in the centre of the heap then measure and add all the cement required.
‘ Measure out the rest of the ballast (or sand and gravel) and add to the heap forming a cone shape.
‘ Mix all the ingredients together using a shovel, work around the heap turning the mixture over three or four times to achieve an evenly coloured (grey) mixture.
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Figure 4.2: Mixing Stage-1
With a shovel, form another crater in the top of the heap and add some water.
Figure 4.3: Mixing Stage-2
‘ Shovel the ballast from the sides of the heap into the central crater and turn part of the heap to distribute the water throughout the mixture.
‘ Repeat forming the heap, making the crater, adding water, turning the heap until the whole mixture is wetted.
Figure 4.4: Mixing Stage-3
‘ As the dry material becomes absorbed with water, flatten out the heap and start ‘chopping’ across the top with the shovel, move around the heap to evenly mix in the water.
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‘ A good mix should be smooth and plastic, not wet and runny or dry and crumbly. As a guide, keep an eye on the ridges as the top of the heap is ‘chopped’ – if between the ridges fills with cement slurry, the mixture is OK; if they fill with a water mix or the ridges disappear, the mix is too wet; if between the ridges stays dry, the mix is too dry.
4.7.3 Placing of concrete in mould
Place the mould on a firm, level surface. Form the test sample by placing concrete in the mould in three layers of approximately equal volume. Move the scoop around the top edge of the mould to ensure a symmetrical distribution of the concrete within the mould. Rod each layer with 25 strokes of the tamping rod. For layers 2 and 3, the rod shall penetrate about 25 mm into the underlying layer. Distribute the strokes uniformly over the cross-section of the mould. Close the voids left by the tamping rod by lightly tapping the sides of the mould. After the top layer has been rodded, the surface will be struck off with a trowel and covered with saran wrap to prevent evaporation. Store the specimen undisturbed for 24 hours in such a way as to prevent moisture loss and to maintain the specimen within a temperature range of 15oC to 27oC.
4.7.4 Curing of the Specimen
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Figure 4.5: Casted concrete cube
Remove the test specimen from the mould between 20 and 48 hours and transfer carefully to the place of curing and testing. If moulds are being shipped it is permissible to leave Specimen in cardboard mould during transit. Place the specimen in the water bath and store for the curing period designated in the contract. After the specimen has been cured for the proper length of time in the water bath remove and cap. Specimens will be kept moist until time of test.
4.8 COMPRESSIVE STRENGTH TEST
Figure 4.6: Compressive Test Machine (IS: 516:1959)
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150 mm ?? 150 mm ?? 150 mm concrete cubes is cast by using M20 grade concrete. Specimens with ordinary Portland cement (OPC) and OPC replaced with hypo sludge and fly ash at 10%, 20%, 30% and 40% levels is cast. During casting the cubes is mechanically vibrated vibrator. After 24 h the specimens is remove from the mould and subjected to water curing for 14 and 28 days. After curing, the specimens are tested for compressive strength using a calibrated compression testing machine of 2,000 KN capacity.
4.9 SLUMP TEST (As per IS: 1199:1959)
Table 4.5 Slump Test Value
Replacement concrete Slump value
Mm
Normal
concrete 48
10% hypo sludge +
10% fly ash 43
10% hypo sludge +
15% fly ash 45
10% hypo sludge +
20% fly ash 39
4.10 WATER ABSORPTION (As per ASTM C42)
Three full size blocks shall be completely immersed in clean water at room temperature for 28 days.
The blocks shall then be removed from the water and visible surface water being removed with a cloth. After surface dried put into oven at 105o C for 24 hours. After 24 hours take a dry weight of concrete cube (A).
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After taking dry weight cube immersed in water for 72 hours period.
After 72 hours removed from the water and visible surface water being removed with a cloth, the saturated and surface dry blocks immediately weighed. This weigh is known wet weight of concrete cube (B).
The water absorption calculates as given below:
Absorption, percent =(B-A)/A * 100
Where,
A = dry mass of unit in kg.
B = wet mass of unit in kg.
Table 4.6 Water Absorption Data
Sample of cubes Dry weight of cube(A) Wet weight of cubes(B) Wet weight- Dry weight
(B-A) Absorption Percentage
=(B-A)/A * 100
1 8342 8526 184 2.205
2 8272 8445 173 2.091
3 8263 8442 179 2.166
Average 8292.33 8471 178.67 2.156
4.11 METHODOLOGY
4.11.1 Mix Design:
Table 4.7 Quantity of Material
Description Quantity kg/m3
(Normal Concrete) Quantity kg/m3
(Replacement Concrete)
Cement 344 275.2
Fly ash – 34.4
Hypo sludge – 34.4
Coarse aggregate I 814 814
Coarse aggregate II 427 427
Fine aggregate 629 629
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After calculating mix design for each trial materials were weighted as per calculation. Laboratory mixer machine was used for concrete mixing. First of all machine was cleaned by the water and washed water was put out from the machine. Coarse aggregate 20 mm and 10 mm were mixed in machine with 25 percent part of the water was added in the running machine and after three to four rotation of machine Mineral admixture was mixed in machine. Then fine aggregate 1, fine aggregate 2, cement and remaining 75 percent water was added in the mixer machine. Machine was allowed to rotate till 2 minutes.
Concrete Mix was bringing out from the machine for the testing of workability. Slump cone test were performed for workability test. Slump cone is filled by the concrete mix in four layers with 25 strokes in each layer in the cone with 16 mm diameter rod.
After performing workability test of concrete mix concrete mould size of 15 cm X 15 cm X 15 cm were casted on the vibrating table. Each mould was casted in three layers of concrete with 35 strokes of 16 mm diameter rod. Required surface finishing was done and numbering and trial numbers were noted on cube with wetted paper tag. Next day after casting of concrete mould were opened and concrete cube was putted in curing tank and allowing them till for 7 and 28 days for the compression testing.
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CHAPTER-5
EXPERIMENTAL WORK AND RESULT ANALYSIS
Table 5.1 Sieve Analysis C.A 20 mm
Is Sieve Weight Retain on Sieve in gm % Retain on Sieve=
(X/W1)*100 Cumulative % Retain Cumulative % Passing =
100 ‘ Y
X Y
31.5 0 0 0 100
25 268 5.36 5.36 94.64
20 2010 40.20 45.56 54.44
16 1315 26.30 71.86 28.14
12.5 913 18.36 90.12 9.88
10 409 8.18 98.30 1.70
6.3 140 0.80 99.1 -1.10
TOTAL(W1) 5055
5.1 SIEVE ANALYSIS OF COARSE AGGREGATE 20 MM
For data of mixed design followings test were conducted at the laboratory
Graph 5.1:-Graphical Presentation of Sieve Analysis for Coarse Aggregate 20 mm
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5.2 SIEVE ANALYSIS OF COARSE AGGREGATE 10 MM
Table 5.2 Sieve Analysis C.A. 10 mm
IS Sieve Weight Retain on Sieve in gm % Retain on Sieve =
(X/W1) x 100 Cumulative % Retained Cumulative % Passing =
100 ‘ Y
X Y
12.5 mm – 0.00 0.00 100
10 mm 2 0.07 0.07 99.93
6.3 mm 29 0.97 1.03 98.97
4.75 mm 379 12.63 13.67 86.33
2.36 mm 1158 38.60 52.07 47.73
1.18 mm 1374 45.80 98.07 1.93
600 micron 21 0.70 98.77 1.23
300 micron 6 0.20 98.97 1.03
150 micron 4 0.13 99.10 0.90
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Pan 21 0.90 100.0 0.00
Total (W1) 2994
Graph 5.2:- Graphical Presentation of Sieve Analysis for Coarse Aggregate 10 mm
5.3 SIEVE ANALYSIS OF FINE AGGREGATE
Table 5.3 Sieve Analysis of F.A.
`IS sieve Weight retain on sieve in gram % Retain on sieve = (X/W1) X 100 Cumulative % retained Cumulative % passing =
100 ‘ Y
X Y
4.75 mm 73 4.87 4.87 95.13
2.36 mm 37 2.47 7.33 92.67
1.18 mm 202 13.47 20.80 79.2
600 micron 150 10.0 30.80 69.2
300 micron 901 60.07 90.87 9.13
150 micron 115 7.67 98.53 1.47
75 micron 13 0.87 99.40 0.60
PAN 5 0.60 100 0
Total (W1) 1496
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Graph 5.3 Graphical Presentation of Sieve Analysis for Fine Aggregate
5.4 SPECIFIC GRAVITIY AND WATER ABSOBTION OF COARSE AGGREGATE 20 MM:
Table 5.4 Specific Gravity of 20mm
Trial Weight Basket + water (A2) in gm Weight of Basket + Aggregate in water-(A1) in gm Weight of
Surface dry Aggregate (B) in gm Weight of oven dry Aggregate (C) in gm Specific Gravity =
[C/(B -(A1-A2 ))] Water Absorption in % =
100 *(B-C)/C
1 830 2172 2040 2002 2.87 1.90
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5.5 SPECIFIC GRAVITIY AND WATER ABSOBTION OF COARSE AGGREGATE 10 MM
Table 5.5 Specific Gravity of 10mm
Trial Weight Basket + water (A2) in gm Weight of Basket + Aggregate in water-(A1) in gm Weight of
Surface dry Aggregate (B) in gm Weight of oven dry Aggregate (C) in gm Specific Gravity =
[C/(B -(A1-A2 ))] Water Absorption in % =
100 *(B-C)/C
1 1548 1880 505 491 2.84 2.851
5.6 SPECIFIC GRAVITIY AND WATER ABSOBTION OF FINE AGGREGATE
Table 5.6 Specific Gravity of Sand
Trial Weight Pycnometer + water (A2) in gm Weight of Pycnometer + Sand in water-(A1) in gm Weight of
Surface dry Sand (B) in gm Weight of oven dry Sand (C) in gm Specific Gravity =
[C/(B -(A1-A2 ))] Water Absorption in % =
100 *(B-C)/C
1 1570 1882 502 486 2.56 3.29
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5.7 SPECIFIC GRAVITIY OF FLYASH
Table 5.7 Specific Gravitiy of Flyash
Sample: Flyash TEST
Wt. of sample in gms. 45
Reading on flask after filing kerosene in ml 0.8
Reading on flask with kerosene after introducing sample in ml 21.60
Specific gravity = Wt. of sample in gms./ Displaced volume in ml. 2.16
5.8 IMPACT TEST OF COARSE AGGREGATE:
Table 5.8 Impact value
Trial Weight of sample in measure Weight of fraction passing 2.36mm sieve Weight of fraction retained on 2.36mm sieve Aggregate Impact value
A B C
1 356 42 314 11.79
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5.9 CRUSHING TEST OF COARSE AGGREGATE:
Page 29
Table 5.9 Crushing value
size of Aggregate for test Weight of sample in gm
(a) Weight of sample passing through sieve aftercrushing
(b)
Crushing value in %=
(ba) *100
passing on sieve size retained on sieve size TEST 1 TEST 1 TEST 1
2.36mm 1.18 2514 287 11.42
5.10 BULK DENSITY
Table 5.10 for Course Aggregate
Trial Weight of mould in kg Weight of mould + sample in kg Volume in cc Bulk density
Kg/m3
1 3673 8250 3000 1526
Table 5.11 for Greet
Trial Weight of mould in kg Weight of mould + sample in kg Volume in cc Bulk density
Kg/m3
1 3673 7853 3000 1393
Table 5.12 for Sand
Trial Wt of mould in kg Wt of mould + sample in kg Volume in cc Bulk density
Kg/m3
1 3673 8447 3000 1591
5.11 HYPO SLUDGE PROPERTIES
Table 5.13 Hypo sludge chemical properties
Sr. no. Test Parameters Units Results Test Method
1 Silicon Dioxide + Aluminium Oxide + Iron Oxide % by mass 6.014 IS : 1727
2 Magnesium oxide as MgO % by mass 2.39 IS : 1727
3 Total Sulphur as Sulphur Trioxide SO3 % by mass 0.073 IS : 1727
4 Total Chloride % by mass 0.015 IS : 12423
5 Loss on Ignition % by mass 39.76 IS : 1727
6 Silicon oxide as SiO2 % by mass 5.08 IS : 1727
7 Available Alkalis as Na2O % by mass 0.60 IS : 4032
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CHAPTER 6
DISCUSSION AND CONCLUSION
As per mixed design performed for Fly ash, Hypo sludge compression test of casted cubes were tested at3 days, 7 days and 28 days. Test results of these practical are given below.
Table 6.1: Result of Compressive Test
Mix Design Compressive Strength
N/mm2
Replacement %
Fly ash 3-Day 7-Day 28day
10% 7.37 14.52 22.33
15% 7.01 13.82 21.25
20% 6.34 12.49 19.21
*Note: 10% hypo sludge constant in replacement of fly ash instead of cement
Graph 6.1 Compressive Strength With 10% Fly ash and 10% Hypo Sludge
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Note: From above data we are considered only 10% replacement data.
Conclusion
We have concluded on concrete strength after various replacement tests. We have achieved the best strength of replacement concrete than normal concrete. So we have considered replacement is 10% hypo sludge and 10% fly ash replaced at place of cement in normal concrete from trial mix and error method.
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CHAPTER-7
ECONOMIC FEASABILITY
Cost analysis is carried out for the optimum proportion of percentage of hypo sludge in concrete. This project was carried out in Bhumi Laboratory, Surat .The cost is compared to the conventional concrete.
7.1 Cost of Materials
Cost of Cement per bag = Rs.300.00
Cost of Coarse Aggregate per tonne = Rs.750
Cost of grit per tonne = Rs.800
Cost of Sand per tonne= Rs.500
Cost of hypo sludge per tonne = Rs.500
Cost of Fly Ash per kg =Rs.700
Table 7.1: Cost of Material of Normal Concrete/m3
Description Quantity kg Cost(Rs.) Cost of Material(Rs.)
Cement 344 6/kg 2064
Coarse aggregate I 814 0.75/kg 610
Coarse aggregate II 427 0.80/kg 341
Fine aggregate 629 0.50/kg 314
Total Cost 3329
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Table 7.2 Cost of Material Partially Replaced10% Fly Ash and 10% Hypo Sludge Concrete/m3
Description Quantity kg/m3 Cost(Rs.) Cost of material(Rs.)
Cement 275.2 6/kg 1651
Fly ash 34.4 0.7/kg 24
Hypo sludge 34.4 0.50/kg 17
Coarse aggregate I 814 0.75/kg 610
Coarse aggregate II 427 0.80/kg 341
Fine aggregate 629 0.50/kg 314
Total cost 2957
The compared values of cost show gradual decrement in total cost of per cubic meter concrete. The above table shows cost values up to 10% replacement and the difference in cost from normal concrete to partially replaced concrete was Rs.372
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‘
Page 35
CHAPTER 8
REFRENCE
‘ Book and Paper
M.S. Shetty ‘CONCRETE TECHNOLOGY THEORY AND PRACTICE’ S.Chand & Company Ltd. 6th Edition.
D.L. Narsimha Rao, Editor ‘Cement and Building Materials Form Industrials Wastes Proceedings of the national conference’ July 24-25′ 1992 (India)
Workshop on Utilization of Fly Ash, May 19-20, 1988 (Roorkee)
Jayesh Pitroda (2010); paper on ‘A study of utilization aspect of fly ash in Indian Context’
‘ IS CODE
IS 383:1970 Specification for Coarse and Fine aggregate from Natural Sources for Concrete
Indian Standards 2386-1963 (Part I, II, III, IV, V, VI, VII): Methods of Test for Aggregates for Concrete.
Indian Standards 12269-1987: Specification for 53 Grade Ordinary Portland cement.
Indian Standards 1199 ‘ 1959: Indian Standard Methods of Sampling and Analysis of Concrete.
Indian Standards 10262 ‘ 2009: Recommended Guidelines for Concrete Mix Design.
Indian Standards 456 ‘ 2000: Plain and Reinforced Concrete Code of Practices Specifications 23 ‘ Specification for the concrete Mix designs.
‘ Website
1. www.engineeringcivil.com
2. www.wikipedia.org
3. www.flyash.co.in
4. www.ijaet.org
5. www.indianconcreteinstitute.org
6. www.icjonline.com
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