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Ganesh Project
Ganesh Project
CHAPTER - 1
INTRODUCTION
1. Introduction
1.1 General
The present day world is witnessing construction of very challenging and difficult
civil engineering structures. Researchers all over the world are attempting to develop low
density or lightweight concrete by using different admixtures in concrete up to certain
proportions
This Project deals with the development of Floating concrete by using lightweight
aggregate (Pumice stone) and Aluminum powder as an air entraining agent.
Floating concrete is made by introducing air or gas into concrete slurry, so that
when the mix sets and hardens, uniform cellular structure is formed. Thus it is a mixture
of water, cement and finely crushed sand. We mix fine powder of Aluminum to the slurry
and it reacts with the calcium hydroxide present in it thus producing hydrogen gas. This
hydrogen gas when contained in the slurry mix gives the cellular structure and thus makes
the concrete lighter than the conventional concrete.
Floating concrete can be defined as the concrete which can float on the water or
the concrete which has density less than or equal to density of water. It is one of the types
of lightweight concrete. Lightweight concrete includes expanding agents that increase the
volume of mixture.
Two-thirds of the worlds surface is covered with water. It is, therefore, not
supersizing that there has been much activity with concrete in sea in recent decades.
Numerous idea and schemes have been promoted and many have been executed.
Following the acceptance of concrete by the oil companies and the success of very large
structure in the North Sea the use of floating concrete structure, i.e. mainly temporarily
floating structure is continually growing.
The advantages of floating concrete structure lie in the economy of the materials
used (concrete is very well suited to a marine environment), in the fact that it is easy to
make concrete structure buoyant in the construction stage by using lightweight concrete.
1.2.1 Advantages:
It can be used as effective sound barrier and for acoustic solutions. Hence, highly
suitable for partition walls, floor screens / roofing and panel material in auditoriums.
Since concrete is lighter than the brick, hence the lightness of the material increases
resistance against earthquake.
iii. Insulation:
iv. Workability:
Products made from lightweight concrete are lightweight, making them easy to place
using less skilled labour. The bricks can be sawed, drilled and shaped like wood using
standard hand tools, regular screws and nails. It is simpler than brick or concrete.
v. Lifespan:
Reduces dead weight of filler walls in framed structures by more than 50% as
compared to brickwork resulting in substantial savings. Due to the bigger and uniform
shape of blocks, there is a saving in bed mortar and plaster thickness. In most cases the
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Floating Concrete By Using Light Weight Aggregate & Air Entraining Agent, 2014-15
Do not require plaster. Wallpapers and plasters can also be applied directly to the
surface
Floating Docks
Floating airports
Floating Bridges
1.2.3 Objectives
CHAPTER - 2
LITERATURE REVIEW
2 Literature Review
2.1 History
The use of lightweight concrete has been a feature in construction industry for
centuries, but like other material the expectations of the performance have raised and now
we are expecting a consistent, reliable material and predicable characteristics.
In 1984, Thomas A. Holm estimated that there were over 400 lightweight
concrete bridges throughout the world especially in USA and Canada. The research
carried out by the expanded clay and slate institute prove that most of the bridge appeared
to be in good condition.
He used aggregates having low specific gravity which is highly porous materials. In
this type of concrete, conventional aggregates are replaced by lightweight aggregates like
Pumice Stones, over burnt bricks, etc. In this he also studied different types of lightweight
aggregates as,
3) T. Parhizkar, M. Najimi and A.R. Pourkhorshidi , VOL. 13, NO. 1 (2012) pp. 43-
54. - have presented experimental investigation on the properties of volcanic pumice
lightweight aggregates concretes. To this end, two groups of lightweight concretes
(lightweight course with natural fine aggregate concrete, and lightweight coarse and
fine aggregate concrete) are built and the physical/ mechanical and durability aspects
of them are studied, the results of compressive strength, tensile strength and drying
shrinkage shows that this lightweight concrete meet the requirements of the structural
lightweight concrete.(Ref.2)
PLWC mixtures were 1997, 1696, 1638, 1477, 1368, kg/m3, respectively.
Compressive and flexural tensile strength and unit weight of concrete were determined
at 28 days. SLWC, SPLWC-I, SPLWC-II, SPLWC-III and PLWC mixtures developed
44.1, 30.5, 27.6, 23.3, 15.8 MPa compressive strength, respectively, which satisfy the
load bearing requirements. In terms of Strength and unit weight requirements, all
concrete produced can be classified as well as used as a LWC. ( Ref .5)
CHAPTER - 3
METHODOLOGY
3. Methodology
3.2.1 Cement:
Pumice is created when super-heated, highly pressurized rock is violently ejected from
a volcano. The unusual foamy configuration of pumice happens because of simultaneous
rapid cooling and rapid depressurization. The depressurization creates bubbles by lowering
the solubility of gases that are dissolved in the lava, causing the gases to rapidly exsolve (like
the bubbles of CO2 that appears when a carbonated drink is opened). The simultaneous
cooling and depressurization freezes the bubbles in the matrix.
3.2.3 Water:
Water used in the mixing is to be fresh and free from any organic and harmful
solutions which will lead to deterioration in the properties of the mortar. Salt water is not to
be used. Potable water is feet for use mixing water as well as for curing.
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Floating Concrete By Using Light Weight Aggregate & Air Entraining Agent, 2014-15
3.2.4 Admixtures:
Special consideration shall be given to the addition of the materials to the mortar for
special purposes. Approval may be given by the consulting engineer, when the materials are
to be added directly or indirectly to reduce the water to the cement ratio or according to
approval standards, if any. In this work, the admixtures used are namely Aluminium powder
and Fly Ash.
a) Aluminium Powder
Water floating aerated concrete is made by introducing air or gas into slurry
composed of Portland cement and sand, so that when the mix sets and hardens, uniform
cellular structure is formed. Thus it is a mixture of water, cement and finely crushed sand.
We mix fine powder of Aluminum to the slurry and it reacts with the calcium hydroxide
present in it thus producing hydrogen gas. This hydrogen gas when contained in the slurry
mix gives the cellular structure and thus makes the concrete lighter than the conventional
concrete.
b) Fly Ash:
Fly Ash is finely divided residue resulting from the combustion of powdered
coal and transported by the flue gasses and collected by electrostatic precipitator. Fly
Ash is the most commonly and widely used pozzolanic material all over the world. Fly
Ash was first use in large scale in the construction of Hungry Hose dam in America in
the approximate amount of 30% by weight of cement. In India it was used in Rihand
dam construction replacing cement up to 15%.
Moulds of required size and shape were prepared for casting process the dimensions of
the moulds for the casting cubes are 150mm 150mm 150mm are used. All the moulds are
applied lubricant before concreting. After a day of casting, the moulds are demoulded and
then cubes are moved to the curing tank for the curing.
3.4.1 Cement
For finding out initial setting time, final setting time and soundness of cement and
strength parameter known as standard consistency has been used. The standard consistency of
cement paste is defined as that consistency which will permit a vicate plunger having 10 mm
diameter and 50 mm length to penetrate to a depth of 33-35 mm from the top of mould. Vicat
apparatus is used to find out the percentage of water required to produce a cement paste of
standard consistency.
2) Fineness Test
The fineness of cement has an important bearing in the rate of hydration and hence on
the rate of gain of strength and also on the rate of evolution of heat. Finer cement offers a
greater surface area for hydration and hence faster the development of strength.
Data:-
Calculation:-
= 05%
Fineness = 05%
Fineness value is less than 10%. Hence it can be used in our project work.
3) Setting Time
= 0.85 34%
= 28.9% of cement
= 86.7 gm.
= 86.7 ml
The periods elapsing between the time when water is added to the cement and the
time at which the needle penetrates the test block to the depth equal to 33-35 mm from the top
is taken as initial setting time.
When the test block has attend such hardness that the needle does not pierce through
the block more than 0.5 mm, that time is known as final setting time.
I.S. requirement = less than 600 minutes (as per I.S. 4031-1968)
3.4.2Pumice Stone
Water Absorption:-
Data:-
Calculations:-
= 29.41 %
The test is carried out for checking of how many percentage of volume of
concrete is increased by using aluminum powder. We have casted one specimen of size
15 cm15cm13.2 cm. It has been observed that after 24 hours height of specimen
increased by 2.5 cm.
= 562.50 cm3
= 18.94 %
Result:-
For this project, we got pumice stone as big as 50 mm size. So we crushed it to the size
of 20 mm & less by using the sieve analysis. The mix design for the first sample is decided
based on the studies, and then further samples were made by changing some proportions in
previous ones.
3.5.2 Procedure:
1) Batching:
2) Weigh Batching:
Weigh is the correct method of measuring the material. Use of weight system is
batching, facilitates accuracy, flexibility and simplicity.
3) Measurement of water:
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Floating Concrete By Using Light Weight Aggregate & Air Entraining Agent, 2014-15
When weigh batching is adopted, the measurement of water must be done accurately.
Addition of water by graduated bucket in terms of liters will not be accurate enough for the
reason of spillage of water etc.
Metal mould , preferably steel or cast iron, strong enough to prevent distortion is
required. They are made in such a manner as to facilitate the removal of moulds. Specimen
without damage and are so maintained that, when it is assembled, the dimensions and internal
faces are required to accurate within the following limits.
5) Compacting:
The testing cube specimens are made as soon as possible after mixing and in such a
manner to produce full compaction of the concrete with neither segregation nor excessive
bleeding.
6) Curing:
The test specimens are stored in a place free from vibration in moist air of at
least 90% relative humidity and at a temperature of 27020C for 24 hours from the time
of addition of water to the dry ingredients. After this period the specimens are marked
and removed from the moulds.
7) Testing:
Compressive strength:
1) Sample1: 6 cubes
Cement: 19.15 kg
Water: 10.53 kg
2) Sample2: 6 cubes
Cement: 9 kg
Crushed sand: 3 kg
Water: 5.4 kg
3) Sample3: 6 cubes
Cement: 7.5 kg
Crushed sand: 3 kg
M2 (4.75 to 10 mm): 3 kg
Water: 6.2 kg
4) Sample4: 6 cubes
Cement: 6 kg
Pumice powder: 3 kg
M2 (4.75 to 10 mm): 4 kg
Water: 5.8 kg
5) Sample5: 6 cubes
Cement: 4.2 kg
Pumice powder: 3 kg
Water: 3.6 kg
6) Sample6: 6 cubes
Cement: 6 kg
Fly ash: 3 kg
Water: 4.5 kg
CHAPTER 4
RESULTS & DISCUSSION
4.1Sample1:
4.1.1 Result:
Table No.4.1
Broken pumice
Aggregate
4.2 Sample2:
4.2.1 Results:
Table No.4.2
This sample gives the improved results having average density 1440 kg/m3 and
average compressive strength 11.46 N/mm2, but average density of concrete is not nearly
equals to the density of water. Also the quantity of cement is high, so we discussed this
situation with our project guide. He told us that if reduce the quantity of cement it will help us
to reduce the density as well as to achieve economy. Therefore in next sample we reduced the
cement quantity and increased the pumice sand.
4.3 Sample3:
4.3.1 Results:
Table No.4.3
4.4 Sample4:
4.4.1 Results:
Table No.4.4
4.5 Sample5:
4.5.1 Results:
Table No.4.5
(a)
(b)
4.6 Sample 6:
4.6.1 Results:
Table No.4.6
Sample 6 gives lightweight concrete having surface flat & smooth and
showing a good finish. Its average density 1102 kg/m3 and average compressive
2
strength 8.62 N/mm . From the above results it seems that the compressive strength
is increased even if the density is nearly same as the previous sample. So this sample
is perfect for the mix proportion.
Compressive strength
Compressive strength
14
12
compressive 10
strength
(N/mm2) 8
0
sample 1 sample 2 sample 3 sample 4 sample 5 sample 6
Density
Density
2000
1800
1600
1400
1200
1000
Density 800
(kg/m3)
600
400
200
0
sample 1 sample 2 sample 3 sample 4 sample 5 sample 6
From the above results & discussions we selected the sample 6 as final mix proportion
of our project, because it gives better compressive strength and low density with smooth
surface.
CHAPTER 5
COMPARISON & CONCLUSION
Our first objective of this project is to reduce the dead load of the structure. For that we
have to reduce the density of our concrete and this density should be less than the density of
earth brick, i.e. 1800 kg/m3. The density of our concrete is 1250 kg/m3, which is less than the
density of the earth bricks. So we achieved our objective.
If we compare the compressive strength of our concrete with earth bricks, it gives
satisfactory results, because the compressive strength of brick is 3.5 N/mm2 and that of our
concrete is 4.52 N/mm2, which is greater than the compressive strength of brick.
For the comparison of cost of brickwork and the cost of floating concrete we did
the cost analysis of both works. Cost analysis is done as shown below:
Bricks:
Brick size with mortar layer is 20cm10cm10cm. Therefore volume of one brick
= 0.20.10.1
= 0.002 cu m.
= 5250 Nos.
Mortar:
= 2.305 cu m.
For frog filling, for use of cut bricks, for bonding, for uniform joints, wastages, etc. 20% extra
mortar may be required.
= 2.766 cu m.
For wet volume increase dry volume 1/3 dry volume of mortar,
= 3.688 cu m.
=0.922 cu m
= 2.766 cu m.
Table No 5.1
As per the sample 6 the quantities required for 6 cubes are shown below:
Table No 5.2
Cement (kg) Pumice powder (kg) Fly Ash (kg) Pumice stone (kg)
6 1.5 3 10
= 0.02025 m3.
Cement = (6 0.02025) 1
= 296.30 kg.
= (296.30 50)
= 148.15 kg.
= 74.07 kg.
= 493.82 kg.
= 567.89 kg
Table No 5.3
III. Statement
From the above two cost analysis the cost of materials for both works is same, but due
to the lightweight handling of materials is easy, so number of labours require are less than that
of the brickwork. Therefore labour cost is minimum for Floating Concrete
This concrete reduces dead weight of filler walls in framed structures by more than
50% as compared to brickwork resulting in substantial savings. Due to the direct casting of
concrete in moulds of wall, there is a saving in bed mortar and plaster thickness. In most cases
the higher cost of the light-weight concrete is offset by a reduction of structural elements, less
reinforcing steel and reduced volume of concrete.
5.3 Conclusion:
In this study, the influences of aggregate types and the amount on the compressive
strength of concrete were investigated. Using different aggregate proportions (pumice) and
five different lightweight concrete mixtures were produced with a satisfied strength. The
result of the investigation showed that aggregate size and proportion influenced the unit
weight and compressive strength of concrete. Moreover, the result showed that it is possible
to produce a Floating and satisfied strength concrete by using pumice as aggregate. It was also
seen that, using light weight aggregate in the concrete mixture can reduce the dead load but
decreases the concrete strength. However for the sample 6 it is Reverse, because this
proportion gives compressive strength 8.62 N/mm2, which is good for the light weight
concrete having density 1102 kg/m3. From cost analysis it is proved that the cost of our
project is less than that of brick masonry.
The study showed that using pumice aggregate as a commixture enable to produce
different strength grade lightweight concrete with different unit weight. These concrete does
not satisfies the strength requirements for load bearing structural elements.
In this study only strength and unit weight were considered, other properties including
carbonation and drying shrinkage, thermal conductivity and sound insulation properties can
be investigated as a further study.
Now days many high rise buildings are constructed all over the world, for that it is
required that the dead load of the buildings should be less. So light weight concrete
has great demand in the construction field.
In the world construction work becomes so faster. So it is necessary that the speed of
construction should be increased. To achieve the speedy construction light weight
concrete is used.
This concrete provides good quality building material that can be satisfy the condition
of hot coastal environment.
CHAPTER - 6
REFERENCES
6. References
6) Banthia, N. and Trottier, J., Concrete reinforced deformed steel fibbers, part 1: Bond-
slip mechanisms, ACI MaterialJournal 91 (5) (1994) 435-446.
9) Al-Jabri KS, Hago AW, Al -Nuaimi AS, Al -Saidy AH (2008). Concrete blocks for
thermal insulation in hot climate. Cem. Concr. Res. 35: 1472-1479.
10) Al-Khaiat H, Haque MN (1998). Effect of initial curing on early strength and physical
properties of lightweight concrete. Cem. Concr. Res. 28: 859-866.Kilic et al. 965
11) Bamforth PB (1980). In situ measurement of the effect of partial Portland cement
replacement using either fly ash or ground granulated blast furnace slag on the
performance of mass concrete. Proc. Inst. Civ. Eng. 69: 777-800.
12) Kili A, Ati_ CD, Ya_ar E, zcan F (2003). High strength lightweight concrete made
with scoria aggregate containing mineral admixtures. Cem. Concr. Res. 33: 1595-1599.
13) Yasar E, Atis CD, Kilic A, Gulsen H (2003). Strength properties of lightweight concrete
made with basaltic pumice and fly ash. Mater. Lett. 57: 2267-2270.
15) Gunduz L (2008). The effects of pumice aggregate/cement ratios on the low-strength
concrete properties. Constr. Build. Mater. 22: 721-728.IMO (1997). Code of Earthquake
for Buildings. Turkish Chamber of Civil Engineering Turkish, Ankara, Turkey.
7. Achievement
1. Participated and won first prize in National level Technical fest SHODH 2K15
Project Presentation.
Project Team