OPTIMISATION MIX DESIGN AND SUPPRESS THE

ALKALI SILICA REACTION

AZIRA SALIM

SCHOOL OF ENGINEERING AND INFORMATION

TECHNOLOGY
UNIVERSITI MALAYSIA SABAH
2012

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 TABLE OF CONTENTS

Page

CONTENTS i - iii

LIST OF TABLE iii

LIST OF FIGURES iv

CHAPTER 1 INTRODUCTION

1.1 Introduction 1
1.2 Background Of Study 2
1.3 Problem Statement 3
1.4 Research Importance 4
1.5 Objectives 4
1.6 Scope Of Works 5

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 6
2.2 Alkali Silica Reaction (ASR) 7-8
2.3 Mechanism of ASR 8 - 10
2.4 Ground Granulated Blast-Furnace Slag (GGBS) 10 - 12
2.5 Factors Affecting ASR 12
2.5.1 The Effect of Admixtures in Controlling ASR 13
2.5.2 The Effect of Different Percentage Admixtures in Controlling
ASR 13 - 15
2.5.3 The Effect of Different Water Cement Ratio Admixtures in
Controlling ASR 15 - 16
2.6 Effects on Compressive Strength 16 - 19
2.7 Effects on Workability (Slump Test) 19 - 20

CHAPTER 3 METHODOLOGY

3.1 Overview 21
3.2 Flow Chart of the Methodology 22
3.3 Material Preparation 23

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 3.3.1 Slag 23
3.3.2 Water 23
3.3.3 Portland cement 24
3.3.4 Aggregate 24
3.3.5 Sand 24
3.4 Mix Design 25
3.5 Mix Description 26
3.6 Mix Proportion 26 - 27
3.7 Number of Samples 28
3.8 Lab Testing 29 - 32
3.8.1 Accelerated Mortar Bar Test (AMBT) ASTM C 1260 29 - 30
3.8.2 Compressive Strength Test ASTM C 109 30 - 32
3.8.3 Slump Test for Concrete Mix (ASTM C143, C172) 32

CHAPTER 4 EXPECTED RESULT

4.1 Overview 33
4.2 AMBT 33 - 34
4.3 Slump Test 34
4.4 Comprehensive Strength of Mortar Cube 35
4.5 Comprehensive Strength of Concrete Cube 35

CHAPTER 5 PROGRESS AND FUTURE WORK

5.1 Overview 36
5.2 The Importance of Planning Work Done 36
5.3 Milestones and Dates 37
5.4 Project Schedule 38

CHAPTER 6 CONCLUSION

6.1 Introduction 39
6.2 The Advantages Of Using Slag As Part Of Replacement By Cement 39 - 40
6.2.1 Reduced Energy 40
6.2.2 Reduced Greenhouse Gas Emissions 40
6.2.3 Reduced Virgin Raw Material 40

REFERENCES 41 – 42

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 LIST OF TABLE

TABLE PAGE

2.1 Compressive Strength Test Results in N/mm2

3.1 Chemical Composition of Slag 21

3.2 Chemical Composition of OPC 22

3.3 Mix Design for Mortar Bars and Mortar Cubes 23

3.4 Mix Design for Concrete Cubes 23

3.5 Description Of Mix Ids For Different Percentage Replacement of

Ordinary Portland Cement 24

3.6 Design Mix Proportion of Samples With Slag Replacement By

Cement for AMBT and Mortar Compressive Strength 25

3.7 Design Mix Proportion of Samples With Slag Replacement By

Cement for Concrete Compressive Strength 25

3.8 Number Of Mortar and Concrete Required 26

3.9 Interpretation of the Test AMBT Result 28

5.1 Milestones and Dates 37

LIST OF FIGURE

FIGURE PAGE

2.1 ASR Site Under a Microscope in Thin Section: Expanding Chert Sand

Particle 9

2.2 ASR Gel Deposit in a Crack Remove From The Reaction Site,

Under a Microscope in Thin Section 10

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2.3 The Three-Phase CaO-SiO2-Al2O3 Diagram 11

2.4 Reacting Cement-Silica System Graded Particle Size Distribution

Ranges Of The Silica Supplying Constituents 12

2.5 ASR Expansion Versus Dosage For Various Mineral Admixtures

Including Condensed Silicafume (CSF), Fly Ash (FA), and Slag (GBFS) 13

2.6 Influence Of Palm Oil Fuel Ash On The Expansion Of Mortar Bars 14

2.7 Various Slag Replacements On The Expansion Of Mortar Bars

2.8 Nineteen-Month Expansions For Different Water-Cement Ratio

Concrete Mixtures 15

2.9 Influence Of Slag Cement On Mortar Cube Compressive Strength 16

2.10 Compressive Strength Of Concrete Containing Various Blends Of Slag

Cement Compared With Concrete Using Only Portland Cement As A

Cementitious Material 17

2.11 Relationship Between The Slag Percent And The Slump Of Concrete

3.1 Flow Chart of Methodology 20

5.1 Gantt Chart for Progress Work 38

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 CHAPTER 1

INTRODUCTION

1.1 Introduction

Problems in existing building concrete are often identified by term such as damage or

deleterious of concrete. One of the damage is existing concrete building due to alkali silica

reaction (ASR). It also called the “cancer of concrete”. Generally, the story of Alkali-Silica

Reaction (ASR) in concrete commenced with the discovery in California in 1940 (Gunnar M.

Idorn, 1997). Damage due to ASR in concrete is become common phenomenon throughout

the world. Alkali-Silica Reaction (ASR) is a chemical reaction between the alkalis in portland

cement and certain siliceous aggregates. These aggregates, when placed in a highly alkaline

solution and in the presence of water and calcium, will expand and a gel will begin to form.

As the aggregate particle expands, it causes the concrete to crack. As the concrete

deteriorates, more water enters to fuel the reaction. This cycle continues until the concrete

deteriorates past the point of serviceability.

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 ASR is a chemical reaction between the reactive silica contained in the aggregates

and the alkalis (Na2O and K2O) within the cement paste (Jan Lindgard, 2012). The result is

an alkali-silicate gel that absorbs water and increases in volume. If the gel is confined by the

cement paste, it builds up pressure as it grows causing internal stresses that eventually

could cause serious expansion and cracking in concrete that resulting in major structural

problems. There are some methods to prevent or minimize ASR deterioration with avoiding

use of reactive aggregates, limiting the alkali content of cement, and incorporation of

pozzolans and other admixtures.

The best way to minimize expansion due to ASR is the incorporation of pozzolans in

admixtures.There are two types admixtures. There are chemical admixtures and mineral

admixtures. These mineral admixtures with pozzolona characteristics are added to the

concrete mix to improve the properties of concrete or as a replacement part of cement at

certain amount.

1.2 Background Of Study

There are various problems involving concrete structures. One of them is Alkali Silica

Reaction (ASR). It is resulted from the reaction between alkalies (sodium and potassium) in

portland cement and certain siliceous rocks or minerals, such as opaline chert, strained

quartz, and acidic volcanic glass, present in some aggregates. It has been known to cause

expansion or swelling of the concrete, thus leading to cracking, followed by concrete

structural damages.

In Malaysia, ASR has been one of the problem happening on the concrete (A. S. M.

Abdul Awal, 1997) . This may lead to expansion and destruction of the concrete. ASR is a

chemical reaction between reactive silica contained in aggregate and alkalis (Na2O and K2O)

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in a mixture of cement paste (Jan Lindgard, 2012). The result is alkali-silicate gel that

absorbs water and will increase the volume of concrete. If the gel is confined by cement

paste, it builds pressure as it grows finally causing internal stress can produce cracks in

concrete. However, the most factor affecting ASR must be present are reactive silica from

the aggregates. The second most factor affecting ASR is high-alkali (pH) pore solution. The

third most affecting is the sufficient moisture. If one of these conditions is absent, ASR

cannot occur (Lane, 1995).

The one of the best way to avoid ASR is by adding or replacing part of cement at

certain amount with various pozzolans. Pozzolanic materials are widely used as

supplementary cementing material in Portland cements (V. Indrawati, 2008). Replacement

by cement is more better than adding by cement to purpose green technology. The

increasing use of concrete with strength properties and high durability cause pozzolana

materials demand is increasing day by day.

1.3 Problem Statement

Concrete is the most widely used building material in the world because of its beauty,

strength and durability, among other benefits. Concrete is used in nearly every type of

construction, including homes, buildings, roads, bridges, airports and subways, just to name

a few. And in an era of an increase the construction of concrete structures, it requires the

use a lot of cement in construction of concrete structure. Among the entire energy intensive

sector, cement industry is a major emitter of carbon dioxide (Partnerships in Environmental

Management for the Seas of East Asia, 2012). CO2 emissions from cement manufacturing are

produced as cement is calcined to produce calcium oxide. Approximately 0.5 metric tons of

carbon is released for each metric ton of cement production (Partnerships in Environmental

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Management for the Seas of East Asia, 2012). Then, the amount of CO2 produced during

manufacturing of cement gives environmental impact.

It is obvious that the increasing demand of cement in the construction industry

worldwide has contributed to the greenhouse effect and scarcity of materials and energy

sources. It show that the earth is scarce of natural fuel and the increasing cost of burning

source. in addition, it should has alternative method about the increasing demand of cement

to avoid gradual destruction to the environment.

Generally, dealing with ASR in existing concrete is a much more difficult task,

because the ingredients that keep the reaction going are already built into the structure.

Furthermore, cost repairing ASR in existing concrete takes cost a lot of money.

1.4 Research Importance

The research is to investigate the optimisation mix design and suppress the ASR. The

most importance of research is to evaluate whether concrete using slag as cement

replacement has any improvement in compressive strength. Other than that, to mitigate use

of cement in concrete structure. Due to continuous increasing of the cost of cement

throughout of the world, the alternative way to reduce use of cement will be use also as

methods to achieve these goals.

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1.5 Objectives

The aim of this study is to investigates the optimisation of concrete design mix to suppress

alkali silica reaction in concrete. To achieve this aim, the following objectives of this study

have been identifed as below:

i. To determine expansion of mortar bar using slag as cement replacement at different

percentage.

i. To determine compressive strength mortar bar and concrete that containing slag at

different percentage as replacement by cement

1.6 Scope Of Works

This study concentrated on investigation of expansion of mortar bars and compressive

strength of mortar bars and concrete cubes where ordinary portland cement (OPC) was

replaced 10%, 20%, 30%, 40%, 50% and 60% by Ground granulated blast-furnace slag

(GGBS). The plain mortar compose of cement, water, and fine aggregate were considered as

a control mix without replacing cement by slag at different percentage. For plain concrete

sample compose of cement, sand, water and coarse aggregate as a control mix without

replacing cement by slag at different percentage.

The material testing is to be done on different proportion of slag as replacement of

cement where the material testing involve of Accelerated Mortar Bar Test ASTM C 1260,

Slump Test, Compressive Strength Test ASTM C 109 and Compressive Strength BS1881-116.

Meanwhile, material testing done on compressive strength test at two types which are on

mortar and on concrete.

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 CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

This chapter will mainly review about the effect of alkali silica reaction (ASR) when slag

being replaced by cement in mortar at certain percentage. Besides, effect of admixture in

suppressing ASR expansion. Research studied and reviewed back using journals, books and

other resources that related to this research to gain the understanding about the problems,

process and result which might be useful during implementation of the study. Various aspect

of effect of alkali silica reaction when admixtures being replace by cement including the

mechanism of alkali silica reaction , effect of expansion on mortar and compressive strength

of mortar will be discussed based on the information gathered mainly through desk study.

Past studies and researches are also discussed in this chapter with more attention

given to expansion due to alkali silica reaction. This chapter also will review about various

percantage replacement by cement effecting on mortar expansion all around the world from

research and study conducted by past researchers.

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2.2 Alkali Silica Reaction (ASR)

According to James A. Farny (1997), there are 3 types of alkali-aggregate reaction, namely:

- Alkali-silicon reaction: Reaction between alkali in concrete and active silicon dioxide in

aggregate

- Alkali-silica reaction: Reaction between alkali in concrete and silicate in aggregate

- Alkali-carbonate reaction: Reaction between alkali in concrete and carbonate in

aggregate

He also stated that alkali silica reaction (ASR) in concrete was identified the chemical

reaction in concrete as the cause of cracking in a concrete highway pavement that

discovered by California in 1940 investigated by Idorn (1997). It also called the cancer of

concrete. Damage due to ASR in concrete is become common phenomenon throughout the

world. ASR is a chemical reaction between the reactive silica contained in the aggregates

and the alkalis (Na2O and K2O) within the cement paste. Initially, alkali hydroxide, mainly

from the cement, react with susceptible siliceous components within aggregate particles, in

the presence of moisture, to form an alkali-silica gel. Subsequently, this gel can absorb

further moisture, swelling in the process and imposing expansive stresses on the enveloping

concrete. Water can be absorbed by the gel water is not used in the cement hydration

reaction, free water from rain, tide, river, or water condensed from the air humidity. James

A. Farny (1997) defined in general, the reaction can be concluded has two-step process,

Step 1:

Silica + alkali alkali-silica gel (sodium silicate)

SiO2 + 2NaOH + H2O Na2SiO3.2H2O (2KOH can replace 2NaOH)

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Step 2:

Gel reaction product + water expansion

Since the gel is restrained by the surrounding mortar, an osmotic pressure is

generated by the swelling. Once that pressure is larger than the tensile strength of the

concrete, cracks occur leading to additional water migration or absorption and additional gel

swelling

ASR in concrete, and especially ASR leading to damage, is rarely inevitable and

depends on the coexistance in a given circumstance of a number of conductive factors.

According to Josee (2001), the decisive parameters was identified for the course of the ASR

in concrete:

 The alkali content of the cement

 The supply of alkalis from the surrounding

 The cement content of the concrete

 The water content of the concrete

2.3 Mechanism of ASR

According to Chiara (1995), most researchers agree that the main of ASR is the

reaction between certain forms of silica present in the aggregates and the hydroxide ions

(OH-) in the pore water of concrete. In brief, their theory suggested that alkali and calcium

hydroxide in solution the pore liquid penetrated by diffusion into siliceous aggregate

particles, and there transformed the interior mineral structure into an alkali-silica gel

compound. In case of a high alkali to calcium ion ratio, the gel would become an alkali-rich

“unlimitedly swelling gel”, and thus cause expansive pressure in the reacting aggregate

particle. With a low alkali to calcium ion ratio, the gel would become calcium enriched and

non swelling.

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 The reactive silica contained in the aggregates and the alkalis (Na2O and K2O) within

the cement paste give the result of an Alkali-silicate gel. This gel can absorb further

moisture, after that swelling in the process and imposing expansive stresses on the

enveloping concrete. According to the John Newman (2003), in view of the relatively low

tensile strength of concrete matrix, these expanding sites generates radiating microcracks

like the Figure 2.1. The alkali silica gel is able to imbibe considerable quantities of water,

then the viscosity is reduced and the reaction product becomes able to migrate into the

microcracks it had previously induced (Figure 2.2).

Figure 2.1 : ASR site under a microscope in thin section: expanding chert sand

particle. View about 5 mm across (John Newman, 2003)

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 Figure 2.2: ASR gel deposit in a crack remove from the reaction site, under a

microscope in thin section. View about 5 mm across (John Newman, 2003)

2.4 Factors Causing Alkali Silica Reaction (ASR)

Alkali-Silica Reaction (ASR) is a chemical reaction between the alkalis in portland

cement and certain siliceous aggregates. Three components, reactive silica from the

aggregates, sufficient alkalis and sufficient moisture, are required in order for ASR to cause

damage to concrete structures. From the few studies found in the literature, it appears that

ASR may be affected by some of factors governing ASR are as described below.

2.4.1 Reactive silica in Aggregate

Generally, alkali aggregate reaction involves two main types of aggregates, which are

rapid and slow/late alkali reactive aggregates (John Newman, 2003). Rapid alkali reaction

aggregates will react by dissolution to form alkali silca gel at both surfaces of the reactive

particles and inside particles. For slow/late alkali reactive aggregate, the reaction initiates at

original cracks, in homogenities or grain boundaries, which act as pathway for the alkaline

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pore solution. Therefore, only certain parts of reactive particles should be considered as

alkali reactive and minimal gel formation is produced. However, the gels are capable of

separating the grain boundaries and leading to expansion of aggregate, and the resulting

cracks will appear more marked, longer and more defined.

Besides that, smaller particles will have a much higher specific surface area compared

to coarser particles. Hence, smaller particles will react quicker. However, the alkali reaction is

most damaging for certain rock typaes when the reactive rocks occur in particular size range.

Both natural aggregates, eroded to present size by natural agents, and crushed aggregates,

obtained by a deliberated fragmentation of rocks are used in concrete. The physical factors

and chemical factors might to a certain degree, differ between these types of aggregates.

This also will introduce some possible in differences the alkali reactivity of these dinstinctive

types of aggregates.

2.4.2 Moisture And Environment

The environment plays a crucial role in ASR expansion and damages of structures by

governing the availability of external moisture and ambient temperature. Without the

presence of sufficient moisture the damaging effect of ASR will not occur. This effects may

be greater in thinner elements where the interaction between external environment and

internal conditions are greater, assuming a moist condition. In larger members even in dry

environments, internal moisture will usually be retained, while the outer portions will dry.

Mark Gavin Alexander(2005) stated that this results in expansive reaction occuring internally

but not in the outer zone, giving surfaces cracking while the interior of the member may

appear uncracked.

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 ASR may also be caused or exacerbated by external sources of moisture such as

precipitation, condensation or ponding. water may be locally directed into or onto a

structure, leading to localised zones of ASR damage. Conditions promoting cyclic moisture

fluctuation also favour more rapid ASR damage.

Figure 2.3: Cracking of core due to internal ASR and external drying (Mark Gavin

Alexander, 2005)

2.4.3 Alkalis From Other Sources

The primary source of alkalis in the pore solution is cement or binder, which contains

metal alkalis -sodium and potassium hydroxide (Idorn, 1997). Other sources of alkalis in

concrete can be the environment such as marine or chemical admixtures usually containing

sodium. Idorn(1997) mention that alkali sometimes derive from the aggregate themselves,

for examples alkali containing minerals such as feldspar which react with the calcium

hydroxide released by cement hydration. The alkali contribution from aggregates, though

difficult to asses, may be important enough to take into account.

The presence alkali from Portland cement also one of components required for ASR.

When cement is mixed with water the alkali suphates go rapidly into the liquid phase

converting to alkali hydroxide which increase the concentrations of alkali in the pore water

12
solution encourage greater swelling capacities in the gel (John Newman, 2003). The

concentration of sodium and potassium compounds and hydroxyl ions is dependent on the

quantity of sodium and potassium compounds in the anhydrous Portland cement. The

hydroxyl ion concentration in the pore solution of concrete made with high alkali cement

might be ten times as that made with low alkali cement.

2.5 The Effect of Different Admixtures in Controlling ASR

Mineral admixtures are known to be effective ways to mitigate ASR expansion. The

optimum method for minimizing the potential for expansion due to ASR in concrete is to

replace a portion of the Portland cement by admixtures. These admixtures include fly ash,

silica fume, ground granulated blast-furnace slag and so on. The use of admixtures can

provide the most realistic advantages to the nature of concrete to improve durability and

resistance to the effects of ASR.

However, although there is much research done on the role of admixtures in

controlling ASR expansion, there are still some aspects of the reaction mechanism of

admixtures and their effects are not well understood. Aiqin Wang (2008) summed up the

mechanism have three basics factors from chemical effect. There are the acidity of mineral

admixture, the more the active acidic oxide of mineral admixture and the less its basic oxide,

the better the inhibiting effect. Second, the basicity of cement, about 20% Ca(OH) will yield

after Portland cement hydrated. Thus, a large quantity mineral admixtures must be added.

The mineral admixtures not only react to alkali, but also remove a large quantity of mineral

admixtures of Ca(OH)2 to make basicity of hydrated compund reduce. Only so the expansion

of ASR can be inhibited effectively. And the last one is the course of reaction. If the content

mineral admixtures is larger and Ca(OH)2 in hardened cement paste is limited, there will be

13
some unreacted microparticles. These microparticle have stronger acidity and can retain

alkali.

Figure 2.4: ASR expansion versus dosage for various mineral admixtures

including condensed silicafume (CSF), fly ash (FA), and slag (GBFS). (James A.

F,1997)

2.6 The Effect of Different Percentage Admixtures in Controlling ASR

The effect of pozzolanic materials on expansion due to ASR has been known to

depend on their alkali content, calcium content, pozzolanicity and fineness (A. S. M. Abdul

Awal, 1997). Figure 2.6 show that the graphs of expansion of mortar bars, plotted against

time, in which various amounts of POFA was being replaced OPC. It is evident from the

figure that a reduction in expansion occurred with an increase in the amount of ash content.

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 Figure 2.5: Influence of palm oil fuel ash on the expansion of mortar bars (A. S.

M. Abdul Awal, 1997)

2.6.1 Ground Granulated Blast-Furnace Slag (GGBS)

In 1950, the effectiveness of slag cemenet in controlling damaging expansion due to

ASR was first reported (John Newman, 2003). In concrete the GGBS slag will react with

calcium hydroxides from the hydrated cement and form cementitious products. The

hydration of slag, in a mixture of Portland cement and water, which was initiated by the n

alkaline solution was prepared by early hydration of Portland cement. The slag hydration

directly activated by the heat of hydration of Portland cement reaction with water (Idorn,

1997). It obviously that the efficiency of the slag cement depends on the nature of the slag

cement, the reactivity on aggregate and the alkali content of portland cement. In most

cases, 50% slag cement was sufficient for controlling damaging expansion in concrete with

highly reactive aggregates and high-alkali cement.

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 Hoogan (1981) concluded that after two years of observation, the slag cement

blends were found to be effective in reducing expansion, but the reduction was less than

that found with the low-alkali cement. When used in combination with high-alkali cement,

blends of 50% slag cement appear to be effective in reducing the potential of ASR.

Figure 2.6: Various Slag Replacements On The Expansion Of Mortar Bars (Hogan,

Et Al., 1981)

Basically the use of GGBS in concrete is beneficial for the following reasons:

- It represents a large potential energy savings. Melting in the blast furnace process

in effect until the chemical energy stored in GGBS for subsequent activation

during hydration of Portland cement in concrete

- The heat was made productive because the activation of the slag during the

Portland cement hydration consumed some of its heat hydration, and thereby

reduced peak curing temperatures (and thermal heat-damage less likely)

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 - The alkali hydroxide activation made concrete with GGBS containing resistant to

harmful ASR with reactive aggregates, and reduce the permeability of hardened

concrete, then generally increase the durability of the material.

2.7 Effects of Compressive Strength of Mortar

Roy et al. (1983) discovered that the concrete will have a great effect on strength at

the temperature at which concrete is cured , particularly at early ages. Concrete containing

slag is found to respond very well under elevated temperature curing conditions. The

proportion of the slag cement on mortar used affects the strength gain as show in Figure

2.9. From the Figure 2.9, obviously when highly active slag cement have been used, the

greatest 28-day strengths are found with blends as high 65% slag cement.

Figure 2.7: Influence of slag cement on mortar cube compressive

strength (Hogan and Meusel 1981)

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 Roy et al. (1983) also summarizes that the early age strength development of

mixtures con-taining GGBS is highly dependent on temperature. Under standard curing

conditions ,GGBS mortars gain strength more slowly than Portland cement mortars. The rate

of strength gain is generally inversely proportional to the fraction of slag cement used in the

blend at where early-age strengths are concerned.

2.8 Effects of Compressive Strength of Concrete

There are not many researchers discussed about on the effects compressive strength

of concrete related to ASR at different percentage replacement of cement by slag. Most of

researchers discuss the compressive strength gain characteristics of concrete containing slag

cement can vary wide range.

Through some research done by several researchers, it is found that the concrete

made with cement replacement by slag provides higher compressive strength compared with

plain Portland cement concrete.

Figure 2.8: Compressive strength of concrete containing various blends of slag

cement compared with concrete using only portland cement as a cementitious

material (Hogan, 1981)

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 The results obtained from testing compressive strength done by Hogan (1981)

conducted on concrete containing OPC replacement by various percentage of blast furnace

slag powder. In general increasing the CaO content of the slag results an increase in

compressive strength. From study it can be concluded that as the percentage of slag

replacement increase, the strength tends to increase also. However early strength

development due to may be slower than plain Portland cement due to lower the lower

hydration heat from slag cement. According to A. Dubey(2012), concrete strength at 1, 2

and even 7 days may be tend to be lower using slag–cement combinations, particularly at

low temperature or at high slag percentage.

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 CHAPTER 3

METHODOLOGY

3.1 Overview

This chapter briefly discussed about how the research being carried out in order to achieve

the objectives. The types of material needed in this research as well as their specification

and description were listed and detailed. Laboratory tests which related to the research were

conducted. Materials were firstly prepared , such as in the research, Ground Granulated Blast

Furnace Slag (GGBS) were collected. Other materials such as cement, water and coarse

aggregate also prepared as well before laboratory works were commerced. Test were

conducted once all the samples are ready. Data or results collected from tests were taken fur

further analysis.

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 3.2 Flow Chart of the Methodology

Figure 3.1 illustrated the step by steps procedures which were conducted in this

research from the initial stage until the testing was completed.

Materials Preparation:

- Cement
- Ground granulated blast furnace slag (GGBS)
- Aggregate
- Sand
- Water

Design Mix for the material:

The ratio is 1:2.25 for mortar bar (w/c = 0.47)

The ratio is 1:1.16:2.25 for concrete cubes

Casting and Curing of the samples

- Mortar bar (25 x 25 x 280 mm)

- Mortar cube (50 x 50 x 50 mm)
- Concrete cube (100 x 100 x 100 mm)

Mortar Testing Concrete Testing

- Accelerated Mortar Bar Test, ASTM C 1260 - Compressive Strength Test,

- Compressive Strength Test, ASTM C 109 on mortar BS 1881-116 on concrete cube
cube

Date Analysis

Report

Figure 3.1 : Flow Chart of Methodology

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3.3 Material Preparation

3.3.1 Ground Granulated Blast Furnace Slag (GGBS)

Slag was used as cement replacement about 10%, 20%, 30%, 40%, 50%, and 60%

from the cement. The slag was stored in dry place such as concrete lab. The chemical

composition of the slag is given in Table 3.1

Table 3.1 Chemical Compostition of Slag (A. Fernandez-Jimenez, 2002)

Oxide Percent (%)

SiO2 37.6

Al2O3 3.3

Fe2O3 0.4

CaO 17.6

MgO 11.2

SO3 1.94

Na2O 0.22

K2O 0.34

3.3.2 Water

Water taken from pipe water of School of Engineering and Information Technology

Concrete Lab. Water use in making samples shall be clean, fresh and free from impurities.

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3.3.3 Portland cement

Type I portland cement (Ordinary Portland Cement) was used as binder. The cement

was stored in dry place such as concrete lab. The chemical composition of the cement is

given in Table 3.2

Table 3.2 Chemical Compostition of OPC (A. S. M. Abdul Awal, The Effectiveness of

Palm Oil Fuel Ash in Preventing Expansion Due to Alkali Silca Reaction, 1997)

Oxide Percent (%)

SiO2 20.2

Al2O3 5.7

Fe2O3 3.0

CaO 62.5

MgO 2.6

SO3 1.8

Na2O 0.16

K2O 0.87

3.3.4 Aggregates

Type of aggregate used is reactive aggregate. Reactive aggregate used in this study was

aggregate obtained from Sabah. Coarse aggregate predominantly retained on the No. 4

(4.75 mm) sieve or that portion of an aggregate retained on the No. 4 (4.75 mm).

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3.3.5 Sand

Type of sand used in this study was river sand obtained from Sabah. For fine aggregate, fine

aggregate passing the No. 50(300 µm) sieve will be used for this study.

3.4 Mix Description

Table 3.3 Description of Mix Ids for Different Percentage Replacement of ordinary

Portland cement.

MIX ID REPLACEMENT BY DESCRIPTION

CEMENT

A0

(Control) 0 Specimen with no replacement by cement

A10 10 Specimen with GGBS 10% replacement by cement

A20 20 Specimen with GGBS 20% replacement by cement

A30 30 Specimen with GGBS 30% replacement by cement

A40 40 Specimen with GGBS 40% replacement by cement

A50 50 Specimen with GGBS 50% replacement by cement

A60 60 Specimen with GGBS 60% replacement by cement

3.4 Mix Design

Design mix was set up in order to prepare the mixtures that show the quantities of

each materials in the mortar bar samples used for the test during the research. In this study,

the mixture proportion for aggregate and cement ratio was 1:2.25 for mortar samples.. This

24
means that 1 part of the cement mix with the 2.25 part of the aggregate and the

water/cement ratio is 0.47. Meanwhile, the design mix was taken from the standard ASTM

C1260 requirements for a batch of 3 mortar bar. For concrete samples, the mixture

proportion for cement, sand and coarse aggregate is 1:1.16:2.25. This means that 1 part of

the cement mix with the 1.16 part of the sand and the coarse aggregate 2.25. The

water/cement ratio remains same is 0.47. Initially, controlled mortar sample which contains

only ordinary Portland cement, aggregate and water was casted. For controlled concrete

sample are containing ordinary Portland cement, sand , coarse aggregate and water was

casted. Then, the mortar and concrete samples with different percentage of cement

replacement were casted as well. The mixture proportions of mortar samples for slag as

replacement of ordinary Portland cement is given in table 3.6. Meanwhile, the mixture

proportions of concrete samples for slag as replacement of ordinary Portland cement is given

in table 3.7.

Table 3.4 Mix Design for Mortar Bars and Mortar Cubes

MATERIAL RATIO

Cement 1

Fine Aggregate 2.25

Water 0.47

Table 3.5 Mix Design for Concrete Cubes

MATERIAL RATIO

Cement 1

Sand 1.16

Coarse Aggregate 2.25

25
Table 3.6 : Design Mix Proportion of Samples With Slag Replacement By Cement

for Mortar Test

Design Mix Proportion of Samples With Slag Replacement By Cement for AMBT

Mix Id Weight, g
Portland Cement Slag Water Aggregate
A0 (Control) 440 0 206.8 990
A10 396 44 206.8 990
A20 352 88 206.8 990
A30 308 132 206.8 990
A40 264 176 206.8 990
A50 220 220 206.8 990
A60 176 264 206.8 990

Design Mix Proportion of Samples With Slag Replacement By Cement for Mortar
Compressive Strength
Mix Id Weight, g
Portland Cement Slag Water Aggregate
A0 (Control) 314.3 0 147.7 707.2
A10 282.9 31.4 147.7 707.2
A20 251.4 62.9 147.7 707.2
A30 220.0 94.3 147.7 707.2
A40 188.6 125.7 147.7 707.2
A50 157.15 157.15 147.7 707.2
A60 188.6 125.7 147.7 707.2

26
Table 3.7 : Design Mix Proportion of Samples With Slag Replacement By Cement

for Concrete Compressive Strength

Mix Id Weight, g
Coarse
Cement Slag Water Aggregate Sand
A0 2514.3 0 1181.7 5657.2 2916.6
A10 2262.9 251.4 1181.7 5657.2 2916.6
A20 2011.4 502.9 1181.7 5657.2 2916.6
A30 1760.0 754.3 1181.7 5657.2 2916.6
A40 1508.6 1005.7 1181.7 5657.2 2916.6
A50 1257.15 1257.15 1181.7 5657.2 2916.6
A60 1005.7 1508.6 1181.7 5657.2 2916.6

3.7 Number of Samples

Table 3.8: Number Of Mortar and Concrete Samples

MIX ID AMBT COMPRESSIVE STRENGTH TEST

Mortar cubes, Concrete cubes,

Day day

3 7 28 3 7 28

A0 3 3 3 3 3 3 3

A10 3 3 3 3 3 3 3

A20 3 3 3 3 3 3 3

A30 3 3 3 3 3 3 3

A40 3 3 3 3 3 3 3

A50 3 3 3 3 3 3 3

A60 3 3 3 3 3 3 3

27
 Total = 21 Total = 63 Total = 63

SUBTOTAL =147

Mortar bar (50mm x 50mm x 280mm) = 21 unit

Mortar cube (50mm x 50mm x 50mm) = 63 unit

Concrete cube (100mm x 100mm x 100mm) = 63 unit

3.8 Lab Testing

3.8.1 Accelerated Mortar Bar Test ASTM C 1260

Objective:

This test to determine the change length or mortar bar by AMBT . For this research, the

obejctive is to identify the minimum level percentage of replacement of cement required to

control expansion that can be determined using the 14-day expansion limit.

Procedure:

1. Each mold in the moist cabinet or room had been placimmediately after molds have

been filled. The specimen shall remain in the molds for 24 h.

28
2. The specimens have been removed from the moulds and their lengths were

measured.

3. After the first measurements of their lengths, pure water been putted at 80oC for a

period of 24 h.

4. The containers had been removed from the water bath one at a time. The time

elapsed between removal and return of the specimens to the water bath shall not

exceed 10 min.

5. The bars one time have been removed from the water and their surface had been

dried with a towel paying particular attention to the two metal gage stud.

6. The zero reading had been taken of each bar immediately after drying the bar is in

position had beed readed immediately.

7. The process of drying and reading using a length comparator have been completed.

8. After reading, the specimen on a towel is abandoned until comparatory readings have

been taken on the remainder of the bars. All specimens made had been placed with

each aggregate sample in a container with sufficient 1N NaOH, at 80oC for the

samples to be totally immersed. The 40g of the NaOH was diluted with 900mL of

water to produce the 1M NaOH solution.

9. The length readings of bars were measured every 3 days.

10. According to ASTM C 1260 (2005) expansion, 16 days after casting can be classified

as detrimental if it is more than 0.20 % and classified as potentially detrimental if it is

between 0.10 % and 0.20 %. Mortar bar consider as non-detrimental when the

percentage of expansion is less than 0.10 %. Table 3.9 showed the interpretation of

Accelerated Mortar Bar Test result.

Table 3.9 Interpretation of the Test AMBT Result (ASTM C1260 3005)

29
 Percentage of Expansion Classification

Less than 0.10% Non–deleteriously reactive

Between 0.10 and 0.20% Innocuous and deleterious

More than 0.20% and above Potentially deleterios expansion

3.8.2 Compressive Strength Test ASTM C 109

Objective:

Compressive strength test used to determine the compressive strength of mortar cubes

samples. The objectives for this study was focuses on the performance of compressive

strength of mortar. Compressive strength test will be performed at the age of 3 days, 7 days

and 28 days for cube samples.

Procedure:

1. A thin layer of mineral oil was applied to the inside surface the mold. The excess oil

was removed with paper towel.

2. After mixing the mortar, the mold was filled with mortar to a depth about 1-in. The

mortar in the entire cube compartments was tamped 32 times in about 10s in four

rounds, each round to be at right angles to the other. The compartment was filled

with the remaining mortar and was tamped as specied for the first layer.

30
 3. The cubes were smoothed off by drawing the flat side of the trowel across them with

the leading edge slightly raised. The mortar was cut off to a plane surface flushed

with the top of the mold by drawing the straight edge of the trowel across.

4. Mortar cube were cured under normal condition which the specimen was stored at

room temperature for 24h and was covered with the plastic sheet. The specimen in

the mold were transferred and immersed into the water tank for curing purpose.

5. The specimen kept in the water for 7, 14 and 28 days. They were tested immediately

after removal from the curing tank. The specimen was wiped to a surface dry

condition.

6. Then, the compression load was applied to the mortar cubes surface using

compression machine at the rate of 0.3 N/mm2/s.

7. The compressive strength of all specimens and the average value had been

determined based on the formula.

FMax / A

Where :

P = Compressive Strength

FMax = Maximum Compressive Load

A = Cross-Sectional Area

3.8.3 Slump Test for Concrete Mix (ASTM C143, C172)

Objective:

To determine the slump pf the plastic concrete (workability)

31
Procedure:

1. The internal surface of the mould is cleaned and damped with water.

2. The mould is placed on a smooth, horizontal, rigid and non-absorbent surface free

from vibration and shock.

3. The mold is filled with concrete in three layers, each about 1/3 of the height of the

mold.

4. Each layer is tamped with tamping rod with 25 strokes.

5. After the top layer has tamped, cut the concrete at the top of the molds with tamping

rod rolling motion.

6. The mould is removed from the concrete by rising it vertically, slowly, and carefully

7. After the mould is removed, immediately measure the slump to the nearest 5mm.

3.8.4 Compressive Strength Test BS1881-116:1983

Objective:

Compressive strength test used to determine the compressive strength of concrete cubes

samples. The objectives for this study was focuses on the performance of compressive

strength of concrete. Compressive strength test will be performed at the age of 3 days, 7

days and 28 days for cube samples.

Procedure:

32
8. A thin layer of mineral oil was applied to the inside surface the mold. The excess oil

was removed with paper towel.

9. After mixing the concrete, the mold was filled with concrete to a depth about 1-in.

The concrete in the entire cube compartments was tamped 32 times in about 10s in

four rounds, each round to be at right angles to the other. The compartment was

filled with the remaining concrete and was tamped as specied for the first layer.

10. The cubes were smoothed off by drawing the flat side of the trowel across them with

the leading edge slightly raised. The mortar was cut off to a plane surface flushed

with the top of the mold by drawing the straight edge of the trowel across.

11. Concrete cube were cured under normal condition which the specimen was stored at

room temperature for 24h and was covered with the plastic sheet. The specimen in

the mold were transferred and immersed into the water tank for curing purpose.

12. The specimen kept in the water for 7, 14 and 28 days. They were tested immediately

after removal from the curing tank. The specimen was wiped to a surface dry

condition.

13. Then, the compression load was applied to the concrete cubes surface using

compression machine at the rate of 0.3 N/mm2/s.

14. The compressive strength of all specimens and the average value had been

determined based on the formula.

FMax / A

Where :

P = Compressive Strength

FMax = Maximum Compressive Load

A = Cross-Sectional Area

33
 CHAPTER 4

EXPECTED RESULT

4.1 Introduction

The preliminary study has been conducted through previous research.The expected result

and observation obtained from journal that have same conducted testing was discussed.

In this chapter discusses a review of expected result summarizing in the field of

expansion of mortar bar using slag as replacement of cement for reduce ASR. Meanwhile,

the expected result of compressive strength of mortar and concrete, and slump test also will

be discuss.

4.2 Expansion of Mortar Bar

It is expected that expansion of mortar bar containing GGBS reduce. Based on

previous research done by Hoogan (1981) after two years observation when 50% GGBS was

replaced appear to be effective in reducing the potential of ASR. His research stated that

that the efficiency of slag cement depends on the nature of the slag cement, the reactivity of

the aggregate, and the alkali content of the portland cement. It also expected that the slag

replacement will decrease the expansion of mortar bar.

34
 For the expected result, influence slag in expansion bars will be similar to J. S Lumley

(1992) research. The different on type of testing which are their use ASTM C227 that take

two years and ASTM C1260 taking 14 days.

4.3 Workability

It is expected that the replacement of the Portland cement by GGBS generaly

improves the workability of the concrete and allowing for a small reduction in the water

content due to higher smoothness of GGBS particles and increase in paste volume of

concrete. When GGBS is used as replacement for Portland cement in a mix , it normally acts

as water reducing-agent. According to Hisham (2009), it is clear that the use of slag reduced

the workability of concrete. Hisham (2009) stated that replacement ratios up to 50% have

only marginal effect on the workability and the concrete can still be classified as concrete of

medium workability.

According to Hogan (1981), the greater solid volume and higher fineness of slag

allow more coarse aggregate to be used without a loss of workability. This often reduces the

stickiness of the mix. The reduction in workability is attributed to the fact that the sand has

been replaced by a finer and a more absorbing material. The higher the percentage of the

fines, the less the workability. Moreover, the slag particles have more angular shapes when

compared with normal sand particles.

4.4 Compressive Strength of Mortar Cube

It is expected that compressive strength of mortar will be increased with age and

percentage slag replacement.

35
 The expectation supported by Cahit (2012) discovered that an increase in the

replacement level of GGBS increased compressive strength of the mortars. As expected, the

compressive strength increased with age, and depending on the acceleration in the

activation reactions, the compressive strength values increased with an increase in the Na

content in the mix for a constant replacement level of GGBS. On the other hand, an increase

in the replacement level of GGBS increased compressive strength of the mortars for a

constant.

It supported by Md. Moinul Islam (2011) that the optimum use of slag in the mortar

is observed to be 40% of cement. Slag mortars with 40% cement replacement shows 19%

higher compressive strength than OPC mortar after 180 days curing.

4.5 Expecetd Result of Compressive Strength of Concrete Cube

It is expected that the result of compressive strength of concrete cube when higher

replacement of cement by slag produce decreased compressive strength at 28 days compare

to plain concrete. The strength of concrete at a given age and the rate of strength

development are depends upon the type and characteristics mix proportion of the slag in

concrete. This shows that the pozzolanic reactivity of GGBS contributes to the rate of gain of

strength at later ages.

It supported by Hogan (1981) that found that the concrete made with cement

replacement by slag provides higher compressive strength compared with plain Portland

cement concrete. This is due to increasing the CaO content of the slag results an increase in

compressive strength.

36
 CHAPTER 5

PROGRESS AND FUTURE WORK

5.1 Overview

In this chapter about summary overview the progress work already done and planning future

work. The gantt chart containing progress work done and planning future work that different

by their colour.

5.2 The Importance of Planning Work Done

Projects and tasks may appear to be endless and they very well could be without a work

plan. A work plan is an important tool for identifying tasks of a project, setting deadlines and

to help complete the tasks.

37
5.3 Milestones and Dates

The milestone shows the important activities that will be carried out in planning future work.

Focus on the important activities highlighted in the timeline.

Table 5.1 : Milestones and Dates

No Milestone Date

1 Prepare the samples for lab testing January 2013

- Accelerated Mortar Bar Test ASTM C 1260

- Slump Test for Concrete Mix (ASTM C143, C172)

- Compressive Strength Test ASTM C 109 (for mortar and

concrete cubes)

3 Analysis the result from lab testing done February 2013

- Expansion of mortar bar at different percentage of slag

replaced by cement

- Slump of concrete mix at different percentage of slag replaced

by cement

- Compressive strength of mortar and concrete cubes at

different percentage of slag replaced by cement.

4 Completed the final report April 2013

38
5.4 Project Schedule

There are prepare an implementation plan that will guide activities in future work. The project schedule described here:

Figure 5.1 : Gantt Chart for Progress Work

Details/ Sep-2012 Oct-2012 Nov-2013 Dis-2013 Jan-2013 Feb-2013 Mar-2013 Apr-2013 May-2013

Weeks 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

Collecting
Journal

Study FYP 1

1)Introduction

2)Literature

3)Methodology
Sample
preparation

Lab Testing

Analysis Data
Documentati
on

39
 CHAPTER 6

CONCLUSION

6.1 Introduction

In this chapter, discusses the advantages of using slag as part of replacement by cement in

the actual building. The effect of admixtures investigated alkali silica reaction will be judged

either meet the objectives set out at the beginning of its development or not. In addition,

contributions or results from the use of this admixtures is specified.

6.2 The Advantages Of Using Slag As Part Of Replacement By Cement

Ever since the alkali-silica reaction was discovered, researchers have reported on the

effectiveness of mineral admixtures in reducing its deleterious effects on concrete (George,

1995). Effective mineral admixtures include slag. The slag in concrete helps in mitigating the

expansions caused by alkali silica reactions. Other than that, there are also have advantages

which are;

40
6.2.1 Reduced Energy

The use of supplementary cementing materials offers additional and immediate

environmental benefits, including reduced energy consumption (such as energy required to

produce cement) and lessened pressure on natural resources (such as reduction in water

consumption).

6.2.2 Reduced Greenhouse Gas Emissions

Portland cement, the major component of concrete, is used to bind the materials that

make up concrete. The production per tonne of portland cement contributes about one ton

of CO2 into the atmosphere. Therefore, it is important that supplementary cementing

materials such as fly ash or slag GGBF will be replaced with portland cement to reduce CO2

emissions. Use of high volume slag as a replacement of cement, in any construction work,

provides lower impact on environment (reduced CO2 emission) and judicious use of

resources (energy conservation, use of by-product etc.). The use of materials in concrete not

only help reduce greenhouse gas emissions but results in environmentally friendly concrete

that has excellent long-term strength and durability characteristics, and often more

economical than ordinary portland cement concrete.

6.2.3 Reduced Virgin Raw Material

Using a mineral admixtures of concrete can avoiding ASR damage. This is also

economical because in some raw material for making concrete where use of cement content

can be reduced. Use of slag reduces the amount of cement content as well as heat of

hydration in a mortar mix. Thus, the construction work with slag concrete becomes

41
economical and also environmentally safe. Furthermore, it also reduce cementitious material

needed to achieve a specified strength.

6.3.4 Reduce disposal and increase use of a recovered industrial material

Slag is a by-product of iron produced in a blast furnace. Molten slag the non-metallic

minerals remaining after the iron is removed is tapped from the blast furnace. At this point,

slag can either become a waste, a construction aggregate or a hydraulic cement. It not only

considered a recycled material, but it can also significantly reduce energy consumption and

greenhouse gasses emitted in the production of concrete raw materials.

42
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45