1

STUDY OF SUSTAINABLE CONCRETE PROPERTIES GGBFS AS CONSTITUENT

MATERIAL
A REPORT

Submitted by

AMERIOCA THANGKHIEW
(19PEST0002)

In partial fulfillment for the award of the degree

of

MASTER OF
TECHNOLOGY IN
STRUCTURAL ENGINEERING
Guided by
Mr. T. NELSON PONNUDURAI
Assistant Professor in Civil Engineering

DEPARTMENT OF CIVIL ENGINEERING

SCHOOL OF MECHANICAL & CONSTRUCTION

JUNE 2021
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BONAFIDE CERTIFICATE

Certified that this Report title “STUDY OF SUSTAINABLE CONCRETE

PROPERTIES GGBFS AS CONSTITUENT MATERIAL” is the bonafide work of
AMERIOCA THANGKHIEW (19PEST0002) who carried out the work under my
supervision. Certified further that to the best of my knowledge the work reported herein
does not form part of any other thesis or dissertation on the basis of which a degree or
award was conferred on an earlier occasion on this or any other candidate.

Mr. T. Nelson Ponnu Durai M.E, Dr. A. Geetha Selvarani, M.E, Ph.D.

Assistant Professor Head of Department

Department of Civil Engineering Department of Civil Engineering
Vel Tech Rangarajan Dr. Sagunthala R & D Vel Tech Rangarajan Dr. Sagunthala R & D
Institute of Science and Technology Institute of Science and Technology

Chennai- 600 062. Chennai- 600 062.

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CERTIFICATE OF EVALUATION

PROGRAM : Master of Technology

SPECIALIZATION : Structural Engineering

SEMESTER : IV

Name of the Student AMERIOCA THANGKHIEW (19PEST0002)

Title of the Project “STUDY OF SUSTAINABLE CONCRETE PROPERTIES
GGBFS AS CONSTITUENT MATERIAL”

Name of the Guide Mr. T. Nelson Ponnu Durai M.E,

Assistant Professor
Department of Civil Engineering
Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science
and Technology, Chennai – 600 062.

The report of the project work submitted by the above scholar in partial fulfillment for

the award of Master of Technology in Structural Engineering of Vel Tech Rangarajan

Dr. Sagunthala R&D Institute of science and Technology for the Viva – Voce

examination held on..............................has been evaluated and confirmed.

INTERNALEXAMINER EXTERNALEXAMINER
Name: Name:
Designation: Designation:
Affiliation:
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ABSTRACT

Today, with the expanding pace of development, concrete is being produced on the planet

for a huge scope. It is significant for the development of framework for a long time. Yet, concrete

expends a ton of common assets because of which it isn't considered as a domain well-disposed

material. Portland cement is a significant constituent of solid which creates carbon dioxide gas

during its creation which adversely antagonistically influences the environment. Likewise, different

fixings, for example, sand and coarse aggregates are draining at a quicker rate in this way

expanding the expense of development. Because of this, there is a need to recognize exchange

materials for cement, sand and coarse aggregates. In this investigation, we can create a solid which

is using the quality of some mechanical waste or side-effects, as an incomplete substitution of its

significant fixings for example cement, sand (fine aggregates) and coarse aggregates. Such a

concrete might be characterized as a Sustainable or Green Concrete. Furthermore, this research is

done to locate the optimum percentage of the particular materials.

Key words: Sustainable Concrete, cement, sand and coarse aggregate.

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ACKNOWLEDGEMENT

I express my gratitude and sincere thanks to our respected Founder Chancellor and
President of Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and
Technology Prof. Dr. R. RANGARAJAN B.E (MECH), M.S (AUTO), D.Sc. and
Founder Chancellor & President Dr. SAGUNTHALA RANGARAJAN (M.B.B.S)
and Managing Trustee & Vice President & Vice Chancellor for providing an opportunity
to carry out this project.

I am grateful to our beloved Vice chancellor Prof. Dr. S. Salivahanan, BE, ME and
Ph.D, for providing me with an environment to complete my project report successfully.

It is a great pleasure for me to acknowledge our Head of the Department Dr. A. Geetha
Selvarani, M.E, Ph.D., for her valuable and useful suggestion which helped me in
completing the project, in time.

I would like to thank my project coordinator Dr. M. Vinod Kumar, M.E, Ph.D.,
Professor, Department of Civil Engineering for his immense guidance in this project.

I sincerely thank the domain coordinator Mr. T. Udhayakumar, M.E, (Ph.D.),

Associate Professor, and Department of Civil Engineering for his academic support
throughout the project.

My sincere thanks to my project guide Mr. T. Nelson Ponnu Durai, M.E, (Ph.D.),
Assistant Professor, and Department of Civil Engineering for his continuous support and
for providing necessary facilities to carry out the project work successfully.

I would also like to thank my parents, friends, Teaching and Non- teaching Staff of the
department of civil engineering for their whole hearted support.

AMERIOCA THANGKHIEW
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TABLE OF CONTENTS
CHAPTER
TITLE PAGE
NO.
NO.
ABSTRACT 4

ACKNOWLEDGEMENT 5

TABLE OF CONTENT 6

LIST OF TABLES 8

LIST OF FIGURES 9

LIST OF SYMBOLS AND ABBREVIATIONS 10

1 INTRODUCTION

1.1 General 11
1.2 Replacement of Cement by Supplementary Materials 11
1.3 Replacement of Fine Aggregate by Supplementary 14
Materials
17
1.4 Replacement of Coarse Aggregate by Waste Materials
21
1.5 Objectives of the Study
21
1.6 Scope of Work
2 REVIEW OF LITERATURE
2.1 General 22

2.2 Literature Review for Cement 22

2.3 Literature Review for Fine Aggregate 25

2.4 Literature Review for Coarse Aggregate 27

2.5 Summary of Literature Review 30

3 METHOLOGY
3.1 General 31

3.2 Methodology of the Project 31

3.3 Materials Collection 32

3.3.1 Partial Replacement of Cement 32

3.3.2 Alccofine 32
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3.3.3 Metakaolin 32

3.3.4 Ground Granulated Blast Furnace Slag 32

3.3.5 Partial Replacement of Fine Aggregate 32

3.3.6 Copper Slag 33

3.3.7 Waste Foundry Sand 33

3.3.8 Partial Replacement of Coarse Aggregate 33

3.3.9 Recycled Aggregate 35

3.3.10 Sintered Fly Ash Aggregate 35

3.3.11 Complete Replacement of all materials 36

3.4 Conventional Concrete 37
3.5 Replacement of Cement 38
3.6 Replacement of Fine Aggregate 39
3.7 Replacement of Coarse Aggregate 40
3.8 Preliminary Tests 40
3.8.1 Tests on Cement 40
3.8.1.1 Fineness Test 41
3.8.1.2 Specific Gravity of Cement 41
3.8.2 Tests on Fine Aggregate 41
3.8.2.1 Sieve Analysis 41
3.8.2.2 Specific Gravity Test 42
3.8.3 Tests on Coarse Aggregate 42
3.8.3.1 Impact Test on Fresh Aggregate 42

3.8.3.2 Impact Test on Recycled Aggregate 43

3.8.3.3 Impact Test on Sintered Fly Ash 43

3.8.4 Tests on Supplementary Materials 43

3.9 Mix Design 43

RESULTS AND DISCUSSIONS

4 4.1 Compressive Strength 44

4.2 Split Tensile Strength 47

SUMMARY AND CONCLUSION

5 50
5.1 Summary
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5.2 Conclusion 50

LIST OF TABLES
TABLE NO. TABLE NAME PAGE NO.

3.1 Replacement of Cement 34

3.2 Replacement of Fine Aggregate 35

3.3 Replacement of Coarse Aggregate 36

3.4 Fineness Test of Cement 40

3.5 Specific Gravity of Cement 40

3.6 Sieve Analysis of Fine Aggregate 41

3.7 Specific Gravity of Fine aggregate 41

3.8 Tests on Coarse Aggregate 41

3.9 Impact Test on Fresh Aggregate 41

3.10 Impact Test on Recycled Aggregate 42

3.11 Impact Test on Sintered Fly Ash 42

3.12 Impact Test 42

3.13 Tests on Supplementary Materials of Cement, FA 42

3.14 Tests on Supplementary Materials of CA 42

4.1 Compressive Strength Test Cement Replacement 44

4.2 Compressive Strength Test FA Replacement 44

4.3 Compressive Strength Test CA Replacement 46

4.4 Compressive Strength all Materials Replacement 46

4.5 Split Tensile Strength Cement Replacement 47

4.6 Split Tensile Strength FA Replacement 48

4.7 Split Tensile Strength CA Replacement 48

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4.8 Split Tensile Strength all Materials Replacement 49

LIST OF FIGURES
FIGURE NO. FIGURE NAME PAGE NO.
3.1 Flow chart showing the methodology 31
3.2 Supplementary Materials Cement 33
3.3 Partial Replacement of Cement 34
3.4 Supplementary Materials FA 34
3.5 Partial Replacement of FA 35
3.6 Supplementary Materials CA 36
3.7 Partial Replacement of CA 36
3.8 Replacement of all Materials 40
3.9 Preliminary Tests 44
4 Compressive Testing Machine 45
4.1 Compressive Strength Test Cement 45
4.2 Compressive Strength Test FA 46
4.3 Compressive Strength Test CA 46
4.4 47
Compressive Strength Test all Materials
4.5 48
Split Tensile Strength Cement Replacement
4.6 49
Split Tensile Strength FA Replacement
4.7 49
Split Tensile Strength CA Replacement
4.8 49
Split Tensile Strength all Materials
Replacement
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LIST OF SYMBOLS AND ABBREVIATIONS

OPC - Ordinary Portland Cement
FA - Fine Aggregate

CA - Coarse Aggregate

IST - Initial Setting Time

FST - Final Setting Time

G - Specific gravity
M - Mass
CTM - Compressive Testing Machine
UTM - Universal Testing Machine
CC - Conventional Concrete
W/C - Water - Cement
σ - Compressive strength of cubes in N/ mm2
fb - Flexural strength of prisms N/ mm2
fct - Split tensile strength of cylinders N/ mm2
fck - Characteristic Compressive Strength
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CHAPTER 1

INTRODUCTION

1.1 GENERAL:

Since time immemorial, concrete has been the main ingredient for the construction of
structures, yet the huge demand of concrete have led to extensive extraction of both sand and stone
aggregates which are the main components of concrete. Sustainable Concrete talks about whether
the material is economical, eco-friendly and feasible. In this case, we talk about the combination of
materials, thus reducing the cement cost and reducing CO 2 emission. In this project, we identify
the Fine aggregate, Coarse aggregate, and we reduce its amount by replacement with other
constituent materials. We are not talking about percentage increase; instead, we are giving a
combination of materials. Hence, the title 'Study of Sustainable Concrete properties GGBFS as
constituent material.
1.2 REPLACEMENT OF CEMENT BY SUPPLEMENTARY MATERIALS:

Cement is used as a fastener material in customary concrete; yet it includes warmth of

hydration, which prompts shrinkage of concrete along these lines, that we supplant GGBS as a
cover material in concrete. Improves workability and diminish cement usage, discount of CO 2
emission; Excessive resistance to sulphate and other chemical compounds. Thus, cost will reduce;
Fly ash is frequently used as alternative of Portland cement with the share of zero-30% by means of
the total weight of the cement. Fly ash and lime mixture ought to lessen CO 2 emission and it calls
for much less energy to produce cement; results in green concrete and additionally reduces the
price and the heat of hydration.

The options for cement replacement are ample, without lowering the function of cement as a
construction fabric. Also, such alternatives lessen the quantity of the production of clinker, making
sure savings in gas, raw substances, and emission. Some of the major options for cement
replacement are rice husk ash (RHA), fly ash (that's obtained from the coal), ground granulated
blast furnace slag (which may be acquired from steel industry), silica fume, etc. GGBS may be
successfully utilized in area of cement which reduces the cement energy consumption, and is cost-
powerful and surroundings-pleasant. GGBS concrete develops lesser power at early ages. It
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achieves 50-60% of its power in 7 days whereas it achieves complete power at 28 days and
continues to expand power after ninety days.

Concrete enterprise has continually welcomed the use of diverse business in waste materials as a
substitute to those construction materials. Commercial waste needs to be disposed of in the form of
landfills inflicting large amount of land pollution. Use of fly ash and lime as the replacement of
cement in concrete mix is considered very eco-friendly and also affordable. It saves the cement
requirement for the identical power thus saving of raw substances together with limestone and coal.
Fly ash is pozzolanic material& it enhances the compressive strength and durability of concrete.
Lime has a better acid resistance because of its alkaline nature.

Metakaolin as a partial replacement of cement: Metakaolin is neither the derivative of an industrial

method nor is it absolutely natural. It is derived from evidently happening mineral and is synthetic
specially for cementing programs. The chemical equations describing this process
isAl2O3.2SiO2.2H2O = Al2O3.2SiO2 + 2H2O (g). For the utilization of Metakaolin as a pozzolanic
material, kaolin is a generally new material in the concrete industry, is compelling in expanding
quality, decreasing sulphate assault and improving air-void system. Pozzolanic responses change
the microstructure of concrete and science of hydration items by devouring the discharged calcium
hydroxide (CH) and creation of extra calcium silicate hydrate (C-S-H), bringing about an expanded
quality and decreased porosity and subsequently improved strength and durability.

Silica Fume has a high receptive pozzolanic property, while it is utilized in concrete in view of its
fine particles, huge surface zone and high SiO2 content. Silica fume is tremendously fined isolated
silica gotten as a side-effect in industry. Silica fume is known to improve the mechanical attributes
of concrete. The guideline physical impact of silica fume in concrete is that of filler, which as a
result of its fineness can fit into space between particles of coarse aggregates and cement grains.
The utilization of silica rage in concrete has designing potential and monetary preferred position. It
is observed that the best dose of silica fume is 5% (by weight), whilst used as component
alternative of OPC. The silica fume inclusion increases the workability and strength of concrete
substantially. Durability parameters like water absorption, permeability, and sulphate assault and
chloride infiltration opposition are higher if there should be an occurrence of concrete mixed with
silica fume when contrasted with ordinary OPC concrete.

Alccofine is a particularly processed product based on slag of excessive glass content with
excessive reactivity received via the technique of managed granulation. It is a low calcium silicate
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based totally mineral additive. It enhances the hydration manner because of apparent hydraulic
behaviour and pozzolanic reactivity. Addition of alccofine will increase packing density of
concrete and reduces the quantity of water and admixture.

It is evaluated that cement creation is answerable for about 3% of the worldwide androgenic ozone
harming substance outflow and for 5% of the worldwide androgenic CO2 emanation. As about 50%
of the CO2 discharged during concrete creation is identified with the disintegration of limestone
during burning, mixing of clinker with advantageous materials called blending is considered as a
compelling method to diminish CO2 outflow. The granite sludge dust in concrete acts as fractional
substitution of cement. Granite dust powder which is a result of Granite handling processing plant
was read by numerous analysts for its utilization in concrete and mortar creation as sand
supplanting or cement supplanting material. The majority of the investigation demonstrated
positive outcomes and advantages. Anyway, as the side-effect for example the powder varies
synthetically relying upon the parent stone rocks which relies upon the territory, level of trans-
formative nature and different elements; and furthermore, as the physical qualities of the side-effect
relies upon the cleaning work, it is important to direct comparative exploration in our nation to
consolidate it in concrete and cement creation for decrease of ecological contamination and
sustainable utilization of normal assets.

India is one of the main makers of Rice. All around rice paddy of around 600 million tons is being
created, representing a yearly creation of 120 million tons Rice Husk. In the majority of the cases,
the husk delivered during the handling of the rice is either singed or dumped as waste material.
Rice husk debris contains 90%-95% of responsive silica. It is evaluated that the world rice reap is
around 588 million tons for each year and India is the second biggest maker of rice on the planet
with a creation of 132 million tons for every year yearly. The utilization of Rice husk debris in
concrete as a trade for cement can diminish the outflow of green-house gases to a bigger degree
which consequently expands the opportunities for increasing progressively number of carbon
credits.

Quarry dust squander is produced during the devastating procedure of rock. Quarry dust squander
likewise a waste material that is created from the stone smashing industry which is accessible to the
degree of 200 million tons per annul the waste can cause land removal, wellbeing and ecological
issues. To decrease these issues elective strategy is supplanting the concrete by cement by quarry
dust reducing the issues as well as decreasing the expense of concrete in development industry.
This quarry dust is considered as solid waste material.
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With the alternative of ordinary Portland cement, GGBS is an environment pleasant construction
material. While used in concrete it replaces as tons as 80% of Portland cement of fifty-three grade.
GGBS concrete has higher water impermeability traits. And make concrete resistance from
sulphate and chloride assault. And therefore, service life is more desirable and the protection value
is decreased. This eco- pleasant alternative ground granulated blast furnace slag (GGBS) leads to
the development of concrete which utilises the industrial waste and saves big herbal assets and
strength which in flip reduces the consumption of cement. As GGBS is the item which we get in
iron hot rolling manufacturing industry, it has been seen that the creation of one ton of GGBS
would produce just about 0.07 ton of CO2 proportionate and devour just around 1300 MJ of vitality
where as one ton of Portland concrete would require roughly 1.5 ton of mineral extraction along
with 5000 MJ of vitality and would create 0.95 ton of CO2 equal.

1.3 REPLACEMENT OF FINE AGGREGATE BY SUPPLEMENTARY MATERIALS:

The alternatives that are available for the partial substitute of sand are majorly industrial
waste and by-products. These commercial waste and by-merchandise are of first-rate issue as these
materials are unsafe for both environment and human health. Such materials are used in creation
for their proper usage and incorporating such risky materials can lessen their effect on human
existence and nearby environment. Fly ash as a partial alternative for sand and is taken into
consideration to be a waste product or spinoff acquired from the technology of energy which varies
in line with the source. It carries a good quantity of silicon dioxide, which is available in nature in
both amorphous and crystalline shape i.e., Aluminium oxide and Calcium Oxide (CaO)
respectively. The utilization of fly ash has significant environmental benefits when it is used to
update one or two principal substances of the concrete.

Copper slag is a substitution for fine aggregate and is an industrial by-product material created
from the way toward assembling copper. For each ton of copper creation, about 2.2 huge amounts
of copper slag is produced. It has been evaluated that around 24.6 million tons of slag are produced
from the world copper industry. In spite of the fact that copper slag is broadly utilized in the sand
impacting industry and in the assembling of grating apparatuses, the rest is discarded with no
further reuse or recovery. The utilization of copper slag in the concrete industry as a substitution
for sand can have the advantage of decreasing the expenses of removal and help in ensuring safety
in the environment. Another alternative of reusing copper slag is by utilizing it as a fractional
substitution of concrete, it will be conceivable to reuse a squander result material usefully. A lot of
copper slag can be used by utilizing it as fine and coarse aggregates in concrete since over 75%
volume of concrete is involved by aggregates. The utilization of copper slag in concrete and
cement is ecological and has financial advantages for every single related industry, especially in
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regions where a lot of copper slag is created. It is additionally accessible with ease at places where
copper is handled.

Consequently, interest for regular sand is expanding step by step. To meet quick development of
foundation, persistent extraction of characteristic sand from waterway beds is by and by. This is
making genuine harm characteristic assets, for example, upsetting the oceanic life, extricating of
impenetrable layers, extending of waterway beds, just as agribusiness because of bringing down of
ground water table. And furthermore, as the accessibility of common sand is scare, it is turning into
an exorbitant material. In this way, to keep away from every one of these issues identified with
condition and to secure it, it is fundamental to locate some other reasonable material that will be
placed in concrete mix as a swap material for characteristic sand. Subsequently a portion of the
modern squanders are as a rule adequately utilized as a swap material for common waterway sand
in the creation of concrete mix, for example, copper slag, bottom ash, glass powder, foundry sand,
spent fire bricks, GGBS, quarry dust, construction and demolition wastes and so forth. The bottom
ash is included substitution of sand.

Foundry sand is top notch silica sand with uniform physical qualities and by result of ferrous and
non-ferrous metal throwing industry. It is demonstrated that foundry sand utilized as fine aggregate
will upgrade the quality of concrete to a more noteworthy expand.

Since the enormous interest has been put on building material industry particularly in the most
recent decade owing to the expanding population which causes an interminable lack of materials,
the structural architects have been tested to change over the losses to valuable structure and
development materials. This exploratory investigation researches the possible utilization of waste
paper and glass fiber for creating a minimal effort and light weight composite as a structure
material. Any development movement requires a few materials, for example, concrete, steel, brick,
stone, glass, earth, mud, wood, etc. Be that as it may, the cement concrete remains the fundamental
development material utilized in development businesses. For its appropriateness and flexibility as
for the evolving condition, the concrete must be with the end goal that it can ration assets, ensure
the earth, conserve also, and lead to appropriate usage of vitality. To accomplish this, significant
accentuation must be laid on the utilization of squanders and results in cement and concrete utilized
for new developments.

The idea of utilizing Quarry dust as fine aggregate is featured these days on the grounds that the
interest of river sand is exceptionally high. For substitution of sand, we required a solid material
with either same expense or less expense. Since Quarry dust gives the better outcome and cost
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effectiveness, it very well may be utilized as another option. The non-affected workability is gotten
on 20% substitution of sand yet it invigorates equivalent to standard concrete. For higher
substitution estimation of sand, workability will most likely be influenced. Because of popularity
the expense of sand is high. Sooner or later quarry dust can be utilized as completely or halfway
fine aggregate. For significant development work it is scarcely conceivable to satisfy the necessary
measure of sand. So, if we are utilizing quarry dust in substitution of sand it might prompt satisfy
the necessity and furthermore spare the enormous measure of cost.

Crump rubber has been used to replace fine aggregates in many fields. There is an increase of
about crores discarded tyre each year. Therefore, it becomes a threat to the environment. This
project aims to study the effectiveness of rubber as substitute for fine aggregate and utilize the
crumb rubber tyres in concrete, to minimize global warming. The discarded rubber obtained from
old vehicles is reduced by passing the material between rotating corrugated steel drums. By this
process an irregular shaped torn particle having large surface area are produced and these particles
are commonly known as crumb rubber. Thus, adding crumb rubber into concrete resulted in
decrease of the mechanical properties, but increased the durability. The effect caused by replacing
the mixture with crumb rubber was higher than that caused by fine aggregate replacement.
Compressive strength, splitting tensile strength, axial compressive strength and the modulus of
elasticity with reduced with the increasing percentage content of crumb rubber, while freezing
thawing resistance and sulphate resistance were improved.

Robo sand is one of the most used materials to replace river sand, which can be used as an
alternative to fine aggregate in concrete. As the demand for Natural River sand is surpassing the
availability, has resulted in fast depletion of natural sand resources. Robo sand is the answer for
this problem, because of its consistent gradation and zero impurity.

GGBFS is a by-product of iron manufacturing industry. The molten slag has a composition of 30%
to 40% silicon dioxide and approximately 40% CaO, which is close to the chemical composition of
Portland cement. After the molten iron tapped off, the remaining molten slag, which consists of
siliceous and aluminous residues, results in formation of glassy granulate, thus forming GGBS.
Generation of waste slag according to figures of 2013-14 in India is larger than 13.5 Tg/annum.
With the partial replacement of GGBS with sand, the strength of concrete gradually increases up to
a certain limit then it gradually decreases. With the partial replacement of GGBS with sand up to
20%, the initial strength gain in concrete is high.

With the rise of metropolitan areas due to rapid urbanization, there has been an increase rate of
17

demolition of structures. Very little demolished concrete is recycled or reused. This paper studies
replacement of fine aggregate by demolished waste, on workability and compressive strength of
recycled concrete. The compressive strength thus observed has been compared with strength of
conventional concrete. Results showed compressive strength of recycled concrete with 10% fine
aggregate replacement by demolished waste at the end of 28 days has found to be comparatively
low than that of conventional concrete. Demolished waste is mostly obtained from a structure made
of concrete, which consists of lumber, dirt, steel, woods, plastics etc. The process of crushing of
rubble into aggregate particles can be done using jaw crushers, impact crushers, swing hammer etc.
Processing of demolished waste include three steps: dry, wet and thermal process. Thus, it is
concluded that recycled aggregate concrete maybe an alternative to the conventional concrete.
Optimum replacement level of Fine aggregate with recycled aggregates is 10%.

Marble powder is a by-product of marble producing industries. The main aim is to replace fine
aggregate in concrete with marble powder waste. This replacement is done in different proportions
i.e., 10%, 20%, 30% and 40% and tested for a period of 7 days, 28 days, and 90 days curing. From
the result, it is observed that the compressive strength of concrete increases when marble powder
increases to 20%. Further increase of marble powder waste decreases the compressive strength.
Therefore, waste marble powder can be successfully utilized as partial replacement of fine
aggregate in Concrete production. Thereby, reducing the problems of marble disposal and thus,
reducing environmental degradation.

Concrete is the most basic component or material used in civil construction. This research studies
the behaviour of papercrete and glass fibres in concrete. Here, 20% of papercrete and sand has been
replaced with glass fibres by 6, 8, 10, 12 and 14% to produce Concrete. The experiment continues
by carrying out several tests such as compressive strength test of cubes, split tensile strength tests
of cylinders and flexural strength of beam. Thus, it is concluded that the strength of concrete
containing papercrete of 20% and glass fibre of 12% was high, when compared with that of the
conventional mix. There was an improvement in the flexural strength, when 20% replacement of
papercrete and 12% of glass fibre in concrete. Due to less weight of these Concrete, the total dead
load of the building will be reduced.

1.4 REPLACEMENT OF COARSE AGGREGATE BY WASTE MATERIALS:

Recycled aggregates are commonly used replacement of coarse aggregate. Concrete is

considered to be the most widely used manufactured construction material in the world. It is mostly
obtained by mixing cement, coarse aggregate, fine aggregate, admixtures, water etc. It was
observed that when cement, sand and coarse aggregates are being replaced by 30% GGBS, 30%
18

Fly ash and 20% recycled aggregates respectively, the compressive strength and split tensile
strength test values show better results than conventional mix concrete. The strength of concrete
can be increased by partially changing its constituents with some other strength giving materials.
Thus, we can produce a concrete which is utilizing the strength of some industrial waste or by-
products, as a partial replacement of its major ingredients, namely, Cement, sand and coarse
aggregate. Such a concrete may be defined as a sustainable or green concrete. Thus, it can be
concluded that the compressive strength and split tensile strength of the concrete mix can be
improved when the core components of the concrete were partially replaced with recycled
products. Major improvement in both compression and tensile strength of the concrete was
observed when cement and sand were partially replaced with 30% GGBS and 30% fly ash
respectively and coarse aggregates with 20% recycled aggregates for both 7 days and 28 days.
Thus, minimizing the cost of the new structure as well as reducing the impact on the environment.

As we know, concrete plays a major role in construction. So, to reduce the cost and to enable usage
of environmentally friendly material, new materials have been introduced. Fully replacement of
concrete is not possible therefore; we develop a partial replacement of concrete material.
Replacement of coarse aggregate is done with some other materials that helps make the concrete
lighter. Hence, in this study, we test concrete which has partial replacement of coarse aggregate
by Polystyrene. For this research, M20 grade is used and the tests are done for various proportions
of Polystyrene with coarse aggregate 5%, 10%, 15%, 20%, 25%. The obtained results were
compared with those of conventional concrete. It is observed that compared to the control mix, the
polystyrene based concrete showed a decrease in the density up to 10%. The highest strength
obtained was 25.04 Mpa and the corresponding strength for control concrete was 23.56 Mpa.

Use of High-density Polyethylene: Nowadays, waste plastic materials are generated in large
amount and disposal has become a problem. Hence, usage of waste plastics as a coarse aggregate
can help recycle and reuse plastic. In this research, coarse aggregate is replaced with plastic waste
in 8%, 16%, 24% and 32%. Many experiments and investigations are conducted to use waste
plastic in an effective way as aggregate for concrete. These materials act as an alternative
construction material in concrete. In this research, cable pipe (HDPE) wastes are used as coarse
aggregate for production of concrete. Plastic aggregate and alcofine is used to produce durable
polymer concrete. It is thus concluded concrete with alcofine and HDPE has given a good strength
for 8% replacement of plastic aggregate and 15% of alcofine. Flexural strength test and split tensile
strength test results of concrete specimen has shown a higher value, which can be concluded that
plastic aggregate and alcofine utilised concrete can resist tension and rupture than the natural
coarse aggregate. Finally, density of the HDPE incorporated concrete specimens has been
19

decreased when the percentage of replacement level is increased. By introducing plastic

aggregates, the capillary rise and water absorption has been reduced.
In this research, Expanded Polystyrene Beads have been used as a replacement of coarse aggregate,
to utilize alternative materials for sustainable development. The results showed that the number of
Polystyrene beads incorporated in concrete influences the properties of hardened concrete. At 28
days, the compressive strength of 0%, 10%, 20% and 25% EPS incorporated concrete strengths
were 100%, 96.2%, 62.3% and 45% respectively when compared to concrete with EPS case.

Disposal of demolished concrete has become problematic; hence we reuse and recycle it to replace
coarse aggregate. For this study, 3, 7- and 28-days compressive strengths were recorded. We have
taken demolished concrete aggregate 10%, 20%, 40%, 60%, 80% by weight of the conventional
coarse aggregate and the concrete cubes were casted by that demolished concrete aggregate then
further tests conducted such as workability, compressive strength for that DAC (demolished
aggregate concrete). It was observed that replacement of natural coarse aggregate by 60% artificial
aggregate gives the maximum compressive strength.

As we know, disposal of demolished waste has become a major problem, as it requires more land.
Hence, it is better to recycle it and reuse it. Demolished building waste with crushed concrete
(WCC), has been used as a coarse aggregate replacement from 20%, 30%, 40% (WCC), 3% of
crushed coarse aggregate (lathe waste) to reduce the generation of demolition waste. It is thus
observed that recycled aggregates are found to possess a relatively low bulk density, higher
crushing and impact values and higher water absorption as compared to natural aggregate.

Coconut is grown in huge quantities all around the world. India is considered the third largest
cultivation area of coconut. Here, coconut shell has been used as a coarse aggregate replacement.
Coconut shell has superior workability because of the smooth surface on one side of the shells.
Moisture retaining and water absorbing capacity of coconut shell are more compared to
conventional aggregate concrete. Overall cost of construction will reduce. The maximum
compressive strength in control mix is 21.28 N/mm 2 at 28 days, when minimum strength at same
days is 14.23 N/mm2. Thus, compressive strength decreases as percentage of coconut shell is
increased. Therefore, coconut shell can be used where light weight concrete is required.

Plastic has become a very popular material due to its amazing properties, however excessive use of
plastic materials due to the rise in population has degraded the environment and also caused
problems for the human health. Plastics, because of their non-biodegradable nature, have become a
very huge problem when it comes to their disposal; therefore, this paper aims at finding a solution
20

to the disposal problem of plastics as well as safeguarding the natural aggregates by minimizing
their usage. Reducing the extraction of natural aggregates is also important as excessive extraction
can cause silting, death to aquatic life. This research has found that at 20% replacement of natural
aggregates with plastic aggregates, a comparable compressive strength is achieved, but as the
percentage of natural coarse aggregate increases, strength of concrete decreases. 84.5 kg of plastic
wastes can be used for optimum percentage replacement of 15% of unit volume of concrete.

Glass is made up of Silica, Fly ash and CaCO 3 and comes in many different shapes and sizes such
as like container glass, flat glass, such as windows, bulbs etc. About 84% of total glass
manufactured goes to the landfills even when glass is a 100% recyclable product which has wide
spread use. Some studies have shown that waste glass when crushed and graded well can be a
strong, safe and economical substitute for sand in concrete mixtures. Waste glass can be used as
replacement for aggregates in concrete mixtures but the applications are limited because of the
damaging expansion in the concrete caused by ASR between high alkali pore water in cement paste
and reactive silica in the waste glasses. Optimum replacement of waste glass as coarse aggregates
is 10%, 28-day strength is found to marginally increase up to 20% replacement level when using
waste glass as coarse aggregate replacement.

Crumb rubber is one of the strongest waste materials that can be utilized as a part of cement. In this
research, crumb rubber replaces coarse aggregate. Various tests were done for fresh concrete
(Slump test, flow test, compaction factor test). Thus, it is observed that replacement of coarse
aggregate by rubber leads to decrease of the aggregate impact value. Water absorption value of the
aggregates also increases with the increase in rubber content. Experimentally, it is seen that the
compressive strength of the concrete decreases when coarse aggregate is replaced by rubber
aggregates. The rubber aggregates can be effectively replaced up to 15%.

Cost of concrete and construction materials have undoubtedly soared higher. Thus, it is advisable
to reuse and recycle used materials. E-waste can be reused as a coarse aggregate. E-waste consists
of discarded and old computers, Tvs, refrigerators, radios etc. In this research, M20 grade concrete
is used. It is observed that the addition of E-waste attains optimum value in compressive strength in
15% replacement. It is identified that the E-waste particles can be used as the construction material.

Due to the growing population, there has been a demand for utilization of resources. Thus,
producing more waste. In this research, we study the usage of steel waste, for example steel slag.
Initially, the optimum percentage steel slag to be replaced is found out by conducting 28 days
compressive strength on cubes of size 150 mm x 150 mm x 150 mm, with 20%, 40%, 60%, 80%
21

replacement of coarse aggregate by steel slag. It is observed that the increase in strength for the
replacement of coarse aggregate by steel slag up to 40% may be due to shape, size, and surface
texture of steel slag.

Since time immemorial, concrete has been the main ingredient for the construction of structures,
yet the huge demand of concrete has led to extensive extraction of both sand and stone aggregates
which are the main components of concrete. There have been numerous groups who have tried to
develop alternatives for the replacement of either stone aggregates or sand. One such research work
to produce the desired concrete strength is the replacement of stone aggregates with limestone
aggregates in the proportion of 25, 50, 75, and 100% with incorporation of 2% crippled steel fibre.
It was found that the incorporation of steel fibres enhances the strength by 10-20% and strength
also increases due to replacement of normal stone aggregate with the limestone aggregates. For 25
- 100% replacement there is a decrease in strength and compressive strength. Up to 75%
replacement usage of limestone is beneficial and workability also increases compared to granite
aggregates.

Ordinary Portland cement of 43 grade is selected and Sintered Fly ash aggregates is prepared by
mixing sintered fly ash with cement and water for making low-cost concrete, which is a waste
material of coal firing thermal power plant. In this paper, author investigates the compressive
strength and flexural strength test of the concrete at different ages, i.e., 3 days, 7 days, 14 days, 28
days, 56 days and 90 days. Sintered fly ash aggregate is replaced 10%, 20%, 30%, 40% and 50% in
the place of coarse aggregate. It is observed that the maximum compressive strength of 43.12
N/mm2 is found at 30% replacement of sintered Fly ash aggregate in concrete while the minimum
strength of 26.24 N/mm2 is found at 50% replacement of Sintered fly ash aggregate in concrete.

1.5 OBJECTIVES OF STUDY:

Based on this context, we compare the following aspects:

• Maximum percentage of replacement
• Optimum percentage of replacement
• Percentage Increment in strength
• Percentage Increment (in case of Splitting tensile)
1.6 SCOPE OF WORK:

The major problem in the construction field is there is scarcity of available of materials
which are mainly used for preparing the concrete. Earlier for preparing of concrete we are using
river sand, but due to scarcity of river sand we are using M sand. So, we are replacing the materials
of Fine aggregate and Coarse aggregate with the materials which are having the utmost properties
22

of Fine aggregate and Coarse aggregate. So that the replaced concrete will produce the same
strength or more strength compared to conventional concrete.

CHAPTER 2

REVIEW OF LITERATURE
2.1 GENERAL
Concrete is considered to be the most widely used manufactured construction material in the world.
It is mostly obtained by mixing cement, coarse aggregate, fine aggregate, admixtures, water etc.
The strength of concrete can be increased by partially changing its constituents with some other
strength giving materials. Thus, we can produce a concrete which is utilizing the strength of some
industrial waste or by-products, as a partial replacement of its major ingredients, i.e. Cement, sand
and coarse aggregate.
2.2 LITERATURE REVIEW FOR CEMENT:

Shanmuganathan. et.al, [2018], based on this context, it is observed that GGBS as cement in
concrete gives more compressive strength and flexural strength 0-80% replacement of GGBS in
different grade of concrete. GGBS gives more strength in 40% of replacement and attains more
than 9% strength in 7 days and increasing of 6% strength with 30% replacement attains in 28 days.
We get a high strength in M40 grade of concrete by replacing a 75% of cement compared with
normal mix design; the cost will reduce up to 40 to 75% replacement of cement by HVFA and lime
stone. The GGBS has replaced as Fine aggregate by 40%, it achieved 48.20 N/mm 2. The
replacement of fly ash 20% and 20% GGBS gives strength of 70.2 N/mm 2 in 28 days. Based on the
above study, it can be concluded that replacement of GGBS as cement by 40% in concrete attains
high compressive strength and Fly ash as 40% with high grade also produced high compressive
strength.

Aditya Kumar Tiwaryet.al, [2018], the author stated that in this experiment, cement is
replaced with fly ash and lime simultaneously in the reach of 0.5%, 10%, 15%, by weight of M-30
grade of concrete. The samples were specified as SO (control specimen), S1 (5% FA + 5% lime),
S2(10% FA +15% lime) & S3 (15% FA + 10% lime) with the replacement of cement in the
concrete mixtures. Various tests are performed such as compressive test on concrete cube for size
(150 x 150 x 150) mm, flexural strength on concrete beam (500 × 100 × 100) and split tensile
strength on concrete cylinder (150mm dia × 300mm) as per IS: 516-1959, IS: 5816-1999 & IS:
516-1959 respectively. Ultimately compressive strength of concrete goes on decreasing with
increase in w/c ratio of concrete. Concrete with 10% and 20% replacement of cement with fly ash
23

shows good compressive strength for 28 days than normal concrete for 0.35 w/c ratio but in the
case of 30% replacement of cement with fly ash ultimate compressive strength of concrete
decreases. The author observed that for mix of M25 grade of concrete loss in the slump of concrete
increases with increase in w/c ratio of concrete. Concrete with 10% and 20% replacement of
cement with fly ash shows good compressive strength for 28 days than normal concrete for 0.35
w/c ratio but in the case of 30% replacement of cement with fly ash ultimate compressive strength
of concrete decreases. The author concluded that the compressive strength increases with the
increase in the percentage of fly ash and rice husk ash up to replacement (22.5% FA & 7.5% RHA)
of cement in concrete for different mix proportions. The split tensile strength and flexural strength
of concrete was obtained after 28 days with the replacement of 22.5% fly ash and 7.5% rice husk
ash concrete.

Narmathaet.al, [2016], the author states that the substitution portion of metakaolin be used
was 5%, 10%, 20% by the weight of cement. The specimen was casted with M60 grade of concrete
with different replacement levels of metakaolin. 15% cement replacement by metakaolin is
superior to all other mixes. The increase in metakaolin content improves the compressive strength
and split tensile strength up to 15% cement replacement. The result encourages the use of
metakaolin, as pozzolanic material for partial replacement in producing high performance concrete.

GVD Sai Sandeep et.al, [2019], based on this context; cubes of size 150 mm × 150 mm ×
150 mm were casted by partial replacement of cement with fly ash. The strength variation was
monitored at the ages of 7, 28 and 90 days by conducting compressive strength test using
compression testing machine. Cement was replaced with aluminium slag at different percentages
for obtaining the optimum value of Aluminium slag and the optimum value of aluminum slag was
found to be 25%. The material used was of M40 grade concrete. Therefore, the percentage increase
in compressive strength at 7, 28 and 90 days of cement partially replaced with 25% Aluminium
slag were found to be 3%, 3.4% and 3.2%. The percentage increase in split tensile strength at 7, 28
and 90 days of cement partially replaced with 25% aluminium slag were found to be 7%, 6% and
5%. The percentage increase in flexural strength at 7, 28 and 90 days of cement partially replaced
with 25% aluminium slag were found to be 5%, 3% and 3%. The percentage increase in
compressive strength at 7, 28 and 90 days of fine aggregate partially replaced with 40% foundry
sand were found to be 2%, 1.8% and 1.2%.

ShiljaPhilominaet.al, [2017], explained that this experiment aims to produce a cost-effective

concrete and utilization of waste by partial replacement of coarse aggregate by plastic waste in 8%
16% 24% and 32% and cement by alccofine in 5%, 10%, 15% 20% and 25%. Experiments were
conducted to determine strength and durability characteristics of concrete by destructive and
24

nondestructive tests. M30 grade concrete was adopted and the mix proportion is 1:2.38:3.12 with
w/c 0.45. Therefore, compressive strength of concrete specimens with alcofine as a replacement
has been gradually increased and after 15% replacement strength has been reduced. Concrete with
alccofine and HDPE has given a good strength for 8% replacement of plastic aggregate and 15% of
alccofine. Flexural strength test and split tensile strength test results of concrete specimen has
shown higher value, which can be concluded that plastic aggregate and alccofine utilized concrete
can resist tension and rupture than the natural coarse aggregate. Thus, 8% plastic aggregate can be
used as replacement for natural coarse aggregate and 15% of alccofine for replacement of cement.

Vikas Srivastava et.al, [2015], based on this context, it is obtained that optimum
replacement level of cement by silica fu201is 5%. At 5% replacement level the strength of silica
fume concrete improved by 12.5% and 18.8% at 7 days and 28 days respectively as compared to
the referral concrete. It is reported in the Literature that inclusion of silica fume (5 to 40%)
increases the strength in the range 6.25 to 67%. Thus, the optimum replacement level of cement by
silica fume is found to be 5% by weight. Beyond optimum silica fume level, the strength decreases
but the workability increases.
G. Elangovan et.al, [2015], explained in this experimental study that granite dust powder
was used in concrete as a cementitious material, as a partial replacement of cement. Replacement
of cement was made by 5%, 10%, 15% and 20% by weight of cement. Compressive strength after
7- and 28-days curing was obtained. From the test result, it was obtained that concrete at the level
of 15% partial replacement of cement with granite dust powder has better workability and high
compressive strength of 7 days and 28 days curing. Granite powder is free of cost; hence it is
considered to be economical.

N Karthicket et.al, [2016], in this context, the author states that there are four different
replacement levels namely, 5%, 10%, 15% and 20%. From the chemical analysis conducted on
(RHA) Rice husk ash, it was found that it contains nearly 80% silica. From the experimental
Investigation, it was found that optimum replacement of rice husk ash in cement was near to 10%
in terms of workability and strength

Kankipati Dinesh Kumaret.al, [2016], explains the main purpose of this investigation is to
study the partial replacement of cement by Quarry dust of percentages 0%, 5%, 15%, 25%, 35%
for M25 grade concrete. The rice husk is added to certain proportions such as 0%, 5%, 10%, 15%
and 20%. Finally, the replacement of dust quarry has its optimum strength at 25%for the rice husk
ash. Results give better workability and increase in hardened concrete compared to normal
concrete.
25

2.3 LITERATURE REVIEW FOR FINE AGGREGATE:

Abhishek Dixitet.al, [2019], in this research, states that fine aggregate has been replaced by
recycled aggregates. GGBS, (as a partial replacement of cement), Fly ash (as a partial replacement
of sand) and recycled aggregates (as a partial replacement of coarse aggregate) were the different
recycled materials used. It was observed that when cement, sand and coarse aggregates are being
replaced by 30% GGBS, 30% Fly ash and 20% recycled aggregates respectively, the compressive
strength and split tensile strength test values show better results than conventional mix concrete. In
this project, M25 concrete mix has been used. The result of this study revealed that the minimum
compressive strength and tensile strength were observed when cement, sand and coarse aggregates
were partly replaced with 10% of GGBS, Fly ash and recycled aggregates each respectively. Also,
major improvement in both compression and tensile strength of the concrete was observed when
the cement and sand were partially replaced with 30% GGBS and 30% fly ash respectively and
coarse aggregate with 20% recycled aggregates for both 7 days and 28 days.

Ambrishet.al, [2017], in this research, replacement of fine aggregate by copper slag is

conducted in percentage of 10%, 15%, 20%. M25 grade concrete is used. The results indicated that
the water demand reduced by almost 22% at 100% copper slag replacement compared to the
control mix. The specimens were casted for 7 days, 14 days and 28 days then tested.

Meghana et.al, [2019], in this context, the bottom ash is added in replacement of sand by
0%, 20% 40% 60% 80% and 100%. The silica fume is added in partial replacement of cement by
20% by weight of cement. The experiment was conducted on M30 grade concrete. The
compressive strength of concrete to produce with replacement of natural sand by bottom ash and
partial cement replaced by silica fume is higher when 40% natural sand is replaced by bottom ash
and its value is 36.30 Mpa.

Amrutha et.al, [2017], this Research proves that foundry sand used as fine aggregate will
enhance the strength of concrete to a greater extend. The only variable considered in this study is
volumetric replacement (10%, 20%, 30%, 40%, and 50%) of sand. Out of these 5 replacement
levels, best 3 were chosen by trial works. The concrete was tested for Slump test, Compression test,
flexural test, split tensile test for 7 & 28 days and acid attack test for 7 days. M20 grade concrete
mix was used. Result obtained was compressive strength increase of 46.63% and 19.28% in 7 and
28 day curing respectively for F3 specimen than conventional concrete. There is a cost reduction of
26

2.56% at the level of 30% replacement as compared to conventional concrete.

Selvarasanet.al, [2017], in this investigation, 20% of papercrete and sand has been replaced
with Glass fibers by 6, 8, 10, 12 and 14% to produce concrete. The strength of concrete containing
papercrete of 20% and glass fibre of 12% was high, when compared with that of the conventional
mix. Fine aggregate replacement level of 12% glass fibre with coarse aggregate replacement level
of 20% papercrete in concrete mixes was found to be optimum level to obtain higher value of the
strength and durability at the age of 7 days. An improvement in flexural strength was seen at 20%
replacement of papercrete and 12% of glass fibre used in concrete.

Shalinee Kishore et.al, [2017], this experimental study focuses specially on the compressive
strength of M20 and M25 grades concrete on partial replacement of sand by Quarry dust by 20%,
30%, 40% and 50%. The compressive strength of concrete cubes is obtained after 7 and 28 days of
curing. The result shows that when sand is replaced by 40% it gives strength up to 22.25Mpa in 7
days and 27.34 Mpa in 28 days for M20 and 24.60 Mpa in 7 days and 32.98 Mpain28 days for
M25. Thus, result says that Quarry dust can be used as fine aggregate in replacement of sand.

Priyadharshiniet.al, [2018], in this study, Ordinary Portland cement of Ultra tech brand of
53 grade confirming to IS 12269-1987 was used. M30 grade concrete was used. Adding crumb
rubber into concrete resulted in a significant decrease of mechanical properties, but increased the
durability. Compressive strength, splitting tensile strength, axial compressive strength and the
modulus of elasticity were reduced with the increasing percentage content of crumb rubber, while
freezing thawing resistance and sulfate resistance were improved. A 20% replacement of fine
aggregate and a 5% replacement of the total mixture with crumb rubber met the safety strength
requirements of concrete and had excellent durability.

Rukmangadhara Raoet.al, [2015], In the present investigation, workability and strength of

concrete was evaluated by replacement of natural sand by Robo sand in proportions of 0%, 50%,
75%, and 100% is studied for M25 and M35 grade concrete cubes, cylinders and prisms. Slump
cone test is done for finding workability. By replacement of natural sand with robo sand, the cost of
the construction can be reduced to 10% per cum. The strength the strength of the quarry rock dust
concrete is comparatively 8-12% more than that of similar mix of conventional concrete.

Jyoti Mali et.al, [2017], in this study, M20 grade with nominal mix as per IS 456-2000 was
used. The concrete mix proportion (Cement: Sand: Coarse aggregate) is 1:1.5:3 by weight and a
27

water cement ratio of 0.45. GGBS partially replaced in concrete in step of 20% (0%, 20%, 40% and
60%). Total number 12 cubes and 8 cylinders were casted. For each percent of marble powder
replacing cement, three cubes & two cylinders were casted for 28 days. The compressive strength
of cubes is increased with the partial replacement of GGBS up to 40% replace by weight of sand
and further any partial replacement of GGBS with sand lead to a decrease in compressive strength.
Thus, we found out the optimum percentage for partial replacement of GGBS with sand is almost
40% for cubes and cylinders.

MohdMonishet.al, [2012], in this research, compressive strength test is done at a period of 7

and 28 days. Test result showed the compressive strength of recycled concrete with 10% fine
aggregate replacement by demolished waste at the end of 28 days has been found to be marginally
lower than that of conventional concrete. The recycled concrete achieved up to 77% compressive
strength and above 90% for splitting tensile and flexural strength and a cost saving of 15%.

Janakiramet.al, [2018], in this research, workability and strength of concrete was evaluated
by replacement of natural sand by Quarry dust and marble powder in equal proportions of 0%,
10%, 20%, 30%, 40%, 50% and 60%. M25 grade concrete is used. Cubes were tested at the age of
7 and 28 days. Workability is tested using Slump cone test. Therefore, it is obtained that
Workability of concrete decreases with increase in quarry dust and marble powder content. It is
obtained that the compressive strength of concrete increases up to 50% of replacement (25% quarry
dust + 25% marble powder).

2.4 LITERATURE REVIEW FOR COARSE AGGREGATE:

Abhishek Dixxitet.al, [2019], in this research, fine aggregate has been replaced by recycled
aggregates. GGBS, (as a partial replacement of cement), Fly ash (as a partial replacement of sand)
and recycled aggregates (as a partial replacement of coarse aggregate) were the different recycled
materials used. It was observed that when cement, sand and coarse aggregates are being replaced
by 30% GGBS, 30% Fly ash and 20% recycled aggregates respectively, the compressive strength
and split tensile strength test values show better results than conventional mix concrete. In this
project, M25 concrete mix has been used. The result of this study revealed that the minimum
compressive strength and tensile strength were observed when cement, sand and coarse aggregates
were partly replaced with 10% of GGBS, Fly ash and recycled aggregates each respectively. Also,
major improvement in both compression and tensile strength of the concrete was observed when
the cement and sand were partially replaced with 30% GGBS and 30% fly ash respectively and
coarse aggregate with 20% recycled aggregates for both 7 days and 28 days.

Murugesanet.al, [2015], for this research, M250 grade concrete is used. The tests are conducted for
28

various propositions of Polystyrene with coarse aggregate 5%, 10%, 15%, 20%, 25%. Compared to
the control mix, the Polystyrene based concrete showed a decrease in the density up to 10%. The
highest strength obtained was 25.04 Mpa (Mix A 5% replacement) and the corresponding strength
for control concrete was 23.56 Mpa. Thus, mix B (with 10% replacement) is considered to be good
for compressive, tensile and flexural strengths with density 5.43% less than the actual concrete.

ShiljaPhilominaet.al, [2017], this experiment aims to produce a cost-effective concrete and

utilization of waste by partial replacement of coarse aggregate by plastic waste in 8% 16% 24%
and 32% and cement by alccofine in 5%, 10%, 15% 20% and 25%. Experiments were conducted to
determine strength and durability characteristics of concrete by destructive and nondestructive
tests. M30 grade concrete was adopted and the mix proportion is 1:2.38:3.12 with w/c 0.45.
Therefore, compressive strength of concrete specimens with alccofine as a replacement has been
gradually increased and after 15% replacement strength has been reduced. Concrete with alccofine
and HDPE has given a good strength for 8% replacement of plastic aggregate and 15% of
alccofine. Flexural strength test and split tensile strength test results of concrete specimen has
shown higher value, which can be concluded that plastic aggregate and alccofine utilized concrete
can resist tension and rupture than the natural coarse aggregate. Thus, 8% plastic aggregate can be
used as replacement for natural coarse aggregate and 15% of alccofine for replacement of cement.

Punitha P et.al, [2019], in this research, the results showed that the number of Polystyrene
beads incorporated in concrete influences the properties of hardened concrete. At 28 days, it was
found that the compressive strength of 0%, 10%, 20% and 25% EPS incorporated concrete
strengths were 100%, 96.2%, 62.3% and 45% respectively when compared to concrete with EPS
case. Thus, it is obtained increase in EPS beads content in concrete mixes reduces the compressive
and tensile strength of concrete. Workability increases with increase in EPS beads content.

V.Sai Kiran Kumar et.al, [2017], for this study, 3, 7- and 28-days compressive strengths
were recorded. Author has taken the demolished concrete aggregate 10%, 20%, 40%, 60%, 80% by
weight of the conventional coarse aggregate and the concrete cubes were casted. Thus, replacement
of natural coarse aggregate by 60% artificial aggregate gives the maximum compressive strength.
Finally, the concrete mix with 60% of aggregate replaced by demolished concrete gives the best
mix with high compressive strength with high workability.
VijayvenkateshChandrasekaranet.al, [2015], In this research, author refused waste crushed
concrete maters (WCC) from the lath wastage of crushed concrete replacing from coarse aggregate
20%, 30%, 40% (WCC) 3% of crushed coarse aggregate (lathe waste) to reduce the generation
ofdemolished wastes. The mold cast is to be ready in (7, 14, and 28) days under hydration. M20
grade concrete is used. Thus, recycled aggregates are found to possess a relatively lower bulk
29

density higher crushing and impact values and higher water absorption as compared to natural
aggregate. The compressive strength of recycled aggregate concrete is relatively lower than natural
aggregate concrete.
Yogesh Narayan Sonawaneet.al, [2016], in this context, M20 grade concrete is used. The
author observed that the cost of construction has reduced. The maximum compressive strength in
control mix is 21.28 N/mm2 at 28 days, while the minimum strength at same days is 14.23 N/mm 2.
Thus, compressive strength decreased as percentage of coconut shell is increased. Therefore,
coconut shell can be used where light weight concrete is required. Proper bonding between coconut
shell and cement is not possible because of surface area of coconut shell aggregate.

JagdishKesariyaet.al, [2018], in this project, M25, M30, M35, M40 grade concrete is used.
It is observed that plastic can be disposed of by using it as construction material. The workability
property of concrete was affected in waste plastic aggregates to the movement of concrete. The dry
density was also reduced and made concrete light weight. Increase of compressive strength was
10% of waste plastic aggregates compared to normal concrete. Increase of Split tensile strength
was 10% compared to normal concrete.

Vikas Srivastava et.al, [2014], While use of waste glass as coarse aggregate replacement, 28
days strength is found to marginally increase up to 20% replacement level. Marginal decrease in
strength is observed at 30 to 40% replacement level of waste glass with coarse aggregate. The
optimum replacement level of waste glass as coarse aggregate is 10%.

Suma et.al, [2019], in this context, it is observed that replacement of coarse aggregate by
tire leads to decrease of the aggregate impact value. After replacing the rubber by 15%, the impact
hammer starts bumping and becomes difficult to conduct the test by increasing the percentage of
waste rubber. Water absorption values of the aggregate also increases with the increase of the
rubber. Therefore, it is observed that compressive strength of concrete decreases with increase of
rubber content. The rubber content can be effectively replaced up to 15%.

Karuna Devi et.al, [2017], This experimental study is made on study of electronic waste as
coarse aggregate in concrete with a percentage replacement ranging from 0 to 20% on the strength
criteria of M20 concrete. The addition of E-waste attains optimum value in compressive strength in
15% replacement. The optimum strength is obtained in 15% replacement of E-waste. The
compressive strength of the concrete will gradually decrease when the coarse aggregate is partially
replaced beyond 15% with Electronic waste.

Padmapriyaet.al, [2015], in this context, initially the optimum percentage steel slag to be
replaced is found out by conducting 28 days compressive strength on cube of size 150 mm x 150
30

mm x 150 mm with replacement of 20%, 40%, 60%, 80% replacement of coarse aggregate by steel
slag. Thus, optimum level replacement for steel slag is found to be 40%. The combination of 25%
replacement of M sand and 40% of steel slag gave compressive strength of about 48.7 Mpa.

Sunil Kumar Reddy et.al, [2017], in this context, coarse aggregate is replaced in percentage
of 25%, 50%, 75% and 100% with incorporation of 2% crimpled steel fiber for concrete works.
Thus, the workability for limestone aggregate was increased when compared with granite aggregate
concrete. The compressive strength was decreased with increase of limestone aggregate in
concrete. The incorporation of steel aggregate enhances strength up to 10 to 20%. For 25 to 100%
replacement of limestone aggregate concrete, there is decrease in strength. The usage of limestone
up to 75% is beneficial for the concrete works.

Dilip Kumar et.al, [2014], in this context, M25 grade concrete is used. Compressive
strength and flexural strength test are done at different stages:3 days, 7 days 14, 28, 56 and 90 days
respectively. Sintered fly ash is replaced at percentage of 10%, 20%, 30%, 40%, and 50%. Thus,
the maximum compressive strength was obtained as 43.12 N/mm2 at 30% replacement of sintered
fly ash while minimum strength was 26.24 N/mm 2 at 50% replacement of sintered fly ash.
Maximum flexural strength was 11.16 N/mm2 at 30% replacement of sintered fly ash in concrete
while minimum flexural strength was 2.10 N/mm 2 at 50% replacement of sintered fly ash in
concrete.

2.5 SUMMARY OF LITERATURE REVIEW:

The Literature Survey gave an overall idea about the utilization of waste materials, as a
supplementary replacement of cement, fine aggregate and coarse aggregate. Therefore, based
on the Literature Reviews, the problem identification is obtained. The huge demand of concrete
has led to extensive extraction of both sand and stone aggregates, which are the main
components of concrete, thereby leading to emission of harmful CO 2 emission. A solution for
such problem is by reusing the waste construction materials, selecting new materials and
creating new concrete combinations. We can use optimum percentage replacement of new
materials like Alccofine, Metakaolin, Ground Granulated Blast Furnace Slag, Copper Slag,
Foundry Sand, Recycled Aggregate and Sintered Fly Ash.

CHAPTER 3
 31

METHODOLOGY
3.1 GENERAL
In this chapter, the brief description of the methodology and the sequence of the works to be
carried out in this complete duration of project are presented. The sequence of activity to be carried
out throughout the project is shown as follows.

3.2 METHODOLOGY OF THE PROJECT

LITERATURE SURVEY

MATERIALS COLLECTED

CONVENTIONAL CONCRETE PARTIALLY REPLACED CONCRETE

SPECIFIC GRAVITY TEST SPECIFIC GRAVITY TEST

SEIVE ANALYSIS SEIVE ANALYSIS

INITIAL & FINAL SETTING TIME CEMENT INITIAL & FINAL SETTING TIME CEMENT

FRESH CONCRETE PROPERTIES FRESH CONCRETE PROPERTIES

HARDENED CONCRETE HARDENED CONCRETE

COMPRESSION TEST

SPLIT TENSILE TEST

RESULTS AND DISCUSSION

CONCLUSION

Fig.3.1 Flow Chart of Methodology

In the above figure 3.1, it shows the step-by-step flow chart of Methodology, starting from
Literature Review, Material Collection, several tests for Conventional Concrete and Partially
Replaced Concrete; followed by Results and Discussion and finally, Conclusion.

3.3 MATERIALS COLLECTION:

The Materials which are all used and their properties are explained as follows. The partial
32

replacement of cement, fine aggregate and coarse aggregate is done according to the grade of
concrete M20.

3.3.1 PARTIAL REPLACEMENT OF CEMENT:

Replacement of Cement will be done by three materials, namely Alccofine at 15%
replacement, Metakaolin at a 10% replacement, GGBFS at a 30% replacement, which sums up to a
total of 55% Cement replacement, specimens casting as shown in Figure 3.3. The Supplementary
materials for cement are shown below in Figure 3.2.

Fig.3.2 Supplementary Materials for Replacement of Cement

3.3.2 ALCCOFINE:
Alccofine is an ultra-fine material, available as a Cementous material for the replacement
of cement. Since it’s a new material, a study is tried out with the combination of GGBS. Totally,
24 numbers of cubes, 24 numbers of cylinders and 2 numbers of beams have been casted with the
replaced supplementary materials.

3.3.3 METAKAOLIN:
Metakaolin is a pozzolan, probably the most effective pozzolanic material for use in
concrete. The particle size of metakaolin is smaller than cement particles, but not as fine as silica
fume. Metakaolin is a generally new material in the concrete industry, is compelling in expanding
quality, decreasing sulphate assault and improving air-void system.

3.3.4 GROUND-GRANULATED BLAST-FURNACE SLAG:

Ground-granulated blast-furnace slag (GGBS or GGBFS) is obtained by quenching molten
iron slag (a by-product of iron and steel-making) from a blast furnace in water or steam, to
produce a glassy, granular product that is then dried and ground into a fine powder. Ground-
granulated blast furnace slag is highly cementitious and high in CSH (calcium silicate hydrates)
which is a strength enhancing compound which improves the strength, durability and appearance
33

of the concrete.

Fig.3.3 Partial Replacement of Cement

3.3.5 PARTIAL REPLACEMENT OF FINE AGGREGATE:
Replacement of Fine Aggregate will be done by two materials, namely Copper Slag at a
50% replacement, Foundry Sand at a 30% replacement, which sums up to a total of 80% Fine
Aggregate replacement, specimens casting as shown in Figure 3.5. The Supplementary materials
for Fine aggregate are shown below in Figure 3.4.

Fig.3.4 Supplementary Materials for Replacement of Fine Aggregate

34

3.3.6 COPPER SLAG:

Copper slag is an industrial by-product material produced from the process of
manufacturing copper. For every ton of copper production, about 2.2 tons of copper slag is
generated. It has been estimated that approximately 24.6 million ton of slag are generated from
the world copper industry. The use of copper slag in the concrete industry as a replacement for
cement, Fine aggregate can have the benefit of reducing the costs of disposal and help in
protecting the environment. The effect of copper slag replacement has good properties of
concrete.
3.3.7 WASTE FOUNDRY SAND 
Waste foundry sand (WFS) is a byproduct from the production of both ferrous and nonferrous
metal castings. It is high quality silica sand. Foundries use high quality size-specific
silica sands for use in their molding and casting operations. In the casting process,
molding sands are recycled and reused many times.

Fig.3.5 Partial Replacement of Fine Aggregate

35

3.3.8 PARTIAL REPLACEMENT OF COARSE AGGREGATE

Replacement of Coarse Aggregate will be done by two materials, namely Recycled
Aggregate at a 20% replacement, Sintered Fly Ash Aggregate at a 30% replacement, which sums
up to a total of 50% Coarse Aggregate replacement, specimens casting as shown in Figure 3.7. The
Supplementary materials for Coarse aggregate are shown below in Figure 3.6.

Fig.3.6 Supplementary Materials for Replacement of Coarse Aggregate

3.3.9 RECYCLED AGGREGATE

Recycled aggregates: Recycled aggregates have two origins: washed aggregates from fresh
concrete (Gathered in concrete plants and delivery trucks) and especially aggregates from old
demolished concrete. The recycled coarse aggregate contains original aggregates attached with
mortar. The attached mortar is light and porous in nature. Therefore, it is obvious that the specific
gravity and density of recycled aggregates are relatively less when compared to natural aggregates.

3.3.10 SINTERED FLY ASH AGGREGATE

Sintered Fly Ash Aggregate: The sintered fly ash aggregate is produced by mixing
materials, Then the mix is made into spherical shape and over dried at a temperature of 1100 ºC in
muffle furnace.

Fig.3.7 Partial Replacement of Coarse Aggregate

36

3.3.11 COMPLETE REPLACEMENT OF ALL MATERIALS

Cubes and Cylinders have been casted for complete replacement of all materials, with a
combination of 15% Alccofine, 10% Metakaolin, 30% GGBFS and balance 45% cement,
including 50% Copper Slag, 30% Foundry Sand and balance 20% Fine aggregate and finally
20% Recycled Aggregate, 30% Sintered Fly Ash and balance 50% Coarse aggregate,
specimens casting as shown below in Figure 3.8.

Fig.3.8 Replacement of all Materials

3.4 CONVENTIONAL CONCRETE

The conventional concrete is prepared by using M-sand according to the grade of concrete
M25 the concrete is mixed and casted in cubes. The compressive strength of the cubes is tested.
37

3.5 REPLACEMENT OF CEMENT:

Table 3.1 shows the replacement of Cement by supplementary materials namely; Fly Ash, GGBFS,
Lime, Metakaolin, Aluminium Slag, Alccofine, Silica Fume, Granite Dust powder, Rice Husk Ash
and Quarry Dust.
Table 3.1: Replacement of Cement

Maximum Percentage Percentage

percentage Optimum Percentag Increment Increment
S.No. of percentage Percentage e (In case of (In case of
Supplementary replacemen of Increment decrement Splitting Flexural
Materials t replacement in Strength in Cost tensile) Strength)
1 Fly Ash 60 40 14  - 8  -
2 GGBFS 80 40 9 -  -  -
58.456014
3 GGBFS 30 30  -  -  -
4
14.581458 -
4 10 10  - 3.806228374
Fly Ash 1 15.63421829
14.581458 -
5 15 15  - 3.806228374
Lime 1 15.63421829
19.148936
6 20 10  - 5.882352941 8.333333333
Metakaolin 2
7 Metakaolin 20 15 17.45  - 20.56 7.2
3.4782608
8 30 25  - 6 2.978723404
Aluminium Slag 7
9 Alccofine 25 15 18.201234  - 28.71794872 12.71929825
10 Silica fume 35 5 18.18  -  -  -

11 20 10  -  -  -  -
Silica fume
Granite dust 44.181034
12 20 15 8.3
Powder 5  -  -
8.5185185
13 20 10  - 10.52631579 19.90521327
Rice Husk Ash 2
39.948167
14 35 25  - 141.6666667  -
Quarry dust 3
20.293637
15 10 10  -  -  -
Rice Husk Ash 8
4.6040515
16 GGBFS 80 40  -  - 27.63157895
7
38

3.6 REPLACEMENT OF FINE AGGREGATE:

Table 3.2 shows the replacement of Fine Aggregate by supplementary materials namely,
Fly Ash, Copper Slag, Bottom Ash, Foundry Sand, Glass fibre with Papercrete, Quarry Dust,
Crumb rubber, Robo sand, GGBFS, Demolished waste, Marble Powder and Papercrete.

Table 3.2: Replacement of Fine Aggregate

Percentage Percentage
Maximum Optimum Percentag Increment Increment (In
Supplementary
S.No percentage percentage Percentage e (In case of case of
Materials
of of Increment decrement Splitting Flexural
replacement replacement in Strength in Cost tensile) Strength)
58.456014
1 Fly Ash 30 30  -  -  -
4
2 Copper slag 20 20 14.267347  - 33.34642577 -3.03030303
20.718323
3
Bottom Ash 100 40 9  - 10.86 25.84
8.1130355
100   7.580928741
4 Copper slag 40 5  -
19.354838
5 12.36749117 0.636942675
Foundry sand 50 30 7 2.56%
1.8260869
3.5 2.857142857
6 Foundry sand 60 40 6  -
Glass Fiber with 5.3473684
7 40 12.78409091
Paper crete 14 12 2  -
6.2842410
 -  -
8 Quarry dust 50 40 6  -
-
-
9 0.6904487  -
2.553191489
Crumb rubber 20 20 9  -
14.434947
Robo sand 7.466666667 32.78195489
10 100 50 8 10
10.531032
11 Robo sand 5.04587156 22.02998847
100 50 9 10
12 GGBFS 60 40 20.13267  - 116.9354839  -
-
13 Demolished 5.2631578 13.18  -  -
waste 30 10 9
1.3498520
 -  -
14 Marble Powder 40 20 7  -
11.682980
15 17.35015773  -
Quarry dust 30 25 7  -
11.682980
17.35015773  -
16 Marble Powder 30 25 7  -
44.638574
17 100  -  -
Copper slag 50 9  -
4.1935483 - -
Papercrete
18 15 5 9  - 9.747292419 27.77777778
39

3.7 REPLACEMENT OF COARSE AGGREGATE:

Table 3.3 shows the replacement of Coarse Aggregate by supplementary materials namely,
Recycled Aggregate, Polystyrene, High density Polyethylene, Expanded Polystyrene Beads,
Demolished concrete aggregate, Demolished Building Waste with Crushed Concrete, Coconut
shell, Plastic, Glass, Crumb Rubber, E-Waste, Steel Slag, Lime Stone and Sintered Fly Ash
Aggregates.
Table 3.3: Replacement of Coarse Aggregate

Maximum Percentage Percentage

Supplementar percentage Optimum Percentag Increment Increment
S.No of percentage Percentage e (In case of (In case of
y Materials
replacemen of Increment decrement Splitting Flexural
t replacement in Strength in Cost tensile) Strength)
Recycled 58.456014
1 30 20  -    
Aggregate 4
6.2818336 1.12359550
2 25 5  - 1.050420168
Polystyrene 2 6
3 High Density 32 8  -  -  -  -
Polyethylene
Expanded -
4 Polystyrene 25 10 -2.7118644  - 51.1111111  -
Beads 1
Demolished 8.4130019
5 concrete 80 60  -  -  -
1
aggregate
Demolished
Building
38.0200860
6 Waste with 40 20 41.5  - 10.625
8
Crushed
Concrete
7 Coconut shell 100 25 -5.075188  -  -  -
-
8 20 20 -2.1813516  - -38.125
Plastic 8.208955224
3.8956958 1.77304964
9 20 10  - 5.010438413
Plastic 8 5
10 Glass 50 10 4.4826424  -  -  -

11 Crumb 20 5 -7.7917981  -  -  -
Rubber
18.472109 22.6277372
12  -
E-Waste 20 15 9  - 3
13 Steel Slag 80 40 27.021276  -  -  -
40

6
14 Lime Stone 100 25 -12.68  -  -  -
Sintered Fly
27.445830
15 Ash 183.045977
6
Aggregates 50 30  -  -

3.8 PRELIMINARY TESTS:

The Preliminary tests on the Supplementary Materials have been performed as shown in Figure 3.9.

Fig.3.9 Preliminary Tests of Materials

3.8.1 TESTS ON CEMENT
3.8.1.1 Fineness Test
Fineness = (W2/W1) * 100
Where, W1 =Weight of the Cement Sample,
W2 =Weight of Cement retained on sieve,
Table 3.4 shows the Fineness Test of the Cement sample.
Table 3.4: Fineness Test of Cement
S.No. Weight of Cement Sample Weight of Cement Sample Fineness of
retained on 90µ m Sieve Cement
1. 100 gm 4.65 4.65%
2. 100 gm 8.25 8.25%
3. 100 gm 7.95 7.95%
Average 6.95%
Therefore, Fineness Modulus of the Cement Sample= 6.95%

3.8.1.2 Specific Gravity of Cement

Specific Gravity of solids is determined using the relation:
M 2−M 1
G=
( M 2−M 1 )−(M 3−M 4 )
Where, M1 =Mass of empty Pycnometer,
M2 = Mass of the Pycnometer with cement,
M3 = Mass of the Pycnometer with cement and water
M4 = Mass of the Pycnometer with water only
41

G = Specific gravity of cement

Table 3.5 shows the Specific Gravity Test of the Cement sample.
Table 3.5: Specific Gravity Test of Cement
S.No. Weight of empty Weight of empty Weight of ‘M2’ Weight of
Pycnometer ‘M1’ gms Pycnometer + + kerosene ‘M3’ Pycnometer +
Cement ‘M2’ gms kerosene ‘M4’
gms gms
640 960 1470 1275
Therefore, Specific Gravity of the Cement Sample = 2.56

3.8.2 TESTS ON FINE AGGREGATE:

3.8.2.1 Sieve Analysis for Fine Aggregate
∑
Fineness Modulus for Fine Aggregate = iC
100
Table 3.6 shows the Sieve Analysis of Fine Aggregate.
Table 3.6: Sieve Analysis of Fine Aggregate
S.No. Sieve size Weight Retained % retained Cumulative %
(in Kg) C3 Percentage passed
∗100 retained (W1-W2)
WF
C1 C2 C3 C4 C5 C6
1. 4.75 0.035 Kg 3.5% 3.5 96.5
2. 2.80 0.030 Kg 3% 6.5 93.5
3. 1.18 0.270 Kg 27% 33.5 66.5
4. 500µ m 0.375 Kg 37.5% 71 29
5. 150 µ m 0.265 Kg 26.5% 97.5 2.5
6. pan 0.025 Kg 2.5% 100 0
Total: 1 Kg 100% 312
Therefore, Fineness Modulus for Fine Aggregate = 3.12

3.8.2.2 Specific Gravity of Fine Aggregate

Table 3.7 shows the Specific Gravity Test of Fine Aggregate.
Table 3.7: Specific Gravity Test of Fine Aggregate
S.No. Weight of empty Weight of empty Weight of ‘M2’ + Weight of
Pycnometer ‘M1’ Pycnometer + Sand water ‘M3’ gms Pycnometer +
gms ‘M2’ gms water ‘M4’ gms
635 1263 1741 1445
Therefore, Specific Gravity of Fine Aggregate= 1.89

3.8.3 TESTS ON COARSE AGGREGATE:

Table 3.8 shows the Tests performed on Coarse Aggregates.
Table 3.8: Tests on Coarse Aggregates
S.No. Test Values
1. Sieve Analysis Test Fineness Modulus=8.775
2. Impact Test Aggregate Impact = 6.25
3. Specific Gravity Test G = 2.89
4. Water Absorption Test Water Absorption=0.23%

Impact Test on Aggregates

Empty Weight of Cylinder = 1.290 kg
3.8.3 .1 Impact Test on Fresh Aggregates
Table 3.9 shows the Impact Test on Fresh Aggregates.
42

Table 3.9: Impact Test on Fresh Aggregates

Total Weight of Aggregate filled in cylinder = 1.930 kg
measure (W1)  (1.930- 1.290) = 0.64 kg (W1)
Weight of Aggregate passing through 2.36 = 0.040 (W2)
mm sieve
(W2)
Aggregate Impact Value = (W2/W1) * 100 = (0.040/0.64) *100
 Aggregate Impact Value =6.25%

3.8.3.2 Impact Test on Recycled Aggregates

Table 3.10 shows the Impact Test on Recycled Aggregates.
Table 3.10: Impact Test on Recycled Aggregates
Total Weight of Aggregate filled in cylinder = 1.890 kg
measure (W1)  (1.890- 1.290) = 0.6 kg (W1)
Weight of Aggregate passing through 2.36 = 0.090 (W2)
mm sieve
(W2)
Aggregate Impact Value = (W2/W1) * 100 = (0.090/0.6) * 100
 Aggregate Impact Value =15%

3.8.3.3 Impact Test on Sintered Fly Ash

Table 3.11 shows the Impact Test on Sintered Fly Ash.
Table 3.11: Impact Test on Sintered Fly Ash
Total Weight of Aggregate filled in cylinder = 1.670 kg
measure (W1)  (1.670- 1.290) = 0.38 kg (W1)
Weight of Aggregate passing through 2.36 = 0.100 (W2)
mm sieve
(W2)
Aggregate Impact Value = (W2/W1) * 100 = (0.100/0.38) *100
 Aggregate Impact Value =26.32%
Table 3.12 shows the Impact Tests on Fresh Aggregate, Recycled Aggregate and Sintered Fly Ash.
Table 3.12: Impact Test
S No Particulars Impact Value
1 Fresh Aggregate 6.25%
2 Recycled Aggregate 15%
3 Sintered Fly Ash 26.32%

3.8.4 TESTS ON SUPPLEMENTARY MATERIALS:

Table 3.13 shows the Tests on Supplementary Materials of Cement and Fine Aggregate.
Table 3.13: Tests on Supplementary Materials of Cement and Fine Aggregate
S.No. Materials Tests Values
1. Alccofine Specific Gravity Test G=1.66
2. Metakaolin Specific Gravity Test G=4.5
3. GGBS Specific Gravity Test G=2.3
4. Foundry Sand Sieve Analysis FM=1.96
5. Copper Slag Sieve Analysis FM=3.04
Table 3.14 shows the Tests on Supplementary Materials of Coarse Aggregate.
Table 3.14: Tests on Supplementary Materials of Coarse Aggregate
S.No. Tests Materials
Recycled Coarse Aggregate Sintered Fly Ash
1. Specific Gravity Test G=3.174 G=2.17
43

2. Sieve Analysis FM=8.31 FM=4.48

3. Impact Test I=15% I=26.32%
4. Density Test Y=1.16 Kg/liter Y=650 kg/m3
5. Elongation Index 20.90% Nil
6. Flakiness Index 6.08% Nil

3.9 MIX DESIGN

Mix Design Calculation:
Step 1: Determination of Target Mean Strength:
Fm = fck + 1.65S
= 20 + 1.65 x 1
Target Mean Strength= 26.6 N/mm2
Step 2: Determination of Water Cement ratio:
W/C ratio = 0.50
Step 3: Determination of Water Content:
Max size of aggregate = 20mm
Water content = 186 Liters
Estimated water content for 100 mm Slump = 186 + 6% x 186
Water content = 197 Liters
Step 4: Determination of Cement Content:
W/C ratio = 0.50
Cement content = water content/ w/c ratio
= 197/0.50
Cement content = 394 kg/m3
Min cement content for ‘mild’ exposure condition = 300 kg/m3
394 kg/m3 > 300 kg/m3 Hence, safe.
Step 5: Determinate Volume of C.A & F.A:
Assume Zone no. as Zone I
W/c ratio= 0.50
Thus, Volume of C.A = 0.60
Also, Volume of F.A = 1-0.60 = 0.4
Step 6: Mix Calculation:
a. Volume of Concrete = 1 m3
b. Volume of Cement = Mass of cement/ Sp. Gravity of cement x 1/1000
= 394/3.15 x 1/1000
= 0.125 m3
c. Volume of water = Mass of water/ Sp. Gravity of water x 1/1000
= 197/1 x 1/1000
= .197 m3
d. Volume of all in aggregate = [a - (b+c)]
= [1 - (0.125 + 0.197)]
= 0.678 m3
e. Mass of Coarse Aggregate = d x Vol. of C.A x Sp. gravity of C.A x 1000
= 0.678 x 0.60 x 2.74 x 1000
= 1114.632 kg
f. Mass of Fine Aggregate = d x Vol. of F.A x Sp. gravity of F.A x 1000
= 0.678 x 0.4 x 2.74 x 1000
= 743 Kg
To find the mix ratio - Cement: Sand: Aggregate: water
a. Mass of cement: 394 kg/m3
b. Cement = 394/394
=1
c. Sand (F.A) = Mass of F.A/ Mass of cement
44

= 743/394
= 1.8
d. Aggregate (C.A) = Mass of C.A/ Mass of cement
= 1114.63/394 = 3.0
The Mix Design Ratio is 1:1.5:3

CHAPTER 4

RESULTS AND DISCUSSIONS

4.1 COMPRESSIVE STRENGTH:

For the determination of cube compressive strength of concrete, Specimens of size 150X150X150
mm size were cast and cured for 7, 14 and 28 days. After specimens were dried in open air and
subjected to cube compression testing under Compressive Testing Machine as shown in Figure 4.1,
the cube compressive strength (f) was computed from the fundamental principle:
F=P/A.
Where, F= Load at failure/cross sectional area (N/mm2)
A= Area of the specimen (mm2).

Fig.4. Compressive Testing Machine

Table 4.1 shows the Compressive Strength for Conventional specimens and specimens with
Replacement of Cement at age 7, 14 and 28 days respectively. Comparison of the two is shown in
Figure 4.1.
Table 4.1: Compressive Strength Test for Replacement of Cement

S.No Compressive 7th Day 14th Day 28th Day

. Strength Test
for Cubes : Strength(N/mm2) Strength(N/mm2) Strength(N/mm2)
1. Conventional 13.48148148 18.88888889 21.11111111
45

Specimens
2. Replacement 15.62962963 20.08888889 23.55555556
of Cement

Compressive Strength (N/mm2)

Conventional Replacement of Cement
25
20
15
10
5
0
7th 14th 28th
No. of Days

Fig.4.1 Comparison of Compressive Strength for Replacement of Cement

Table 4.2 shows the Compressive Strength for Conventional specimens and specimens with
Replacement of Fine Aggregate at age 7, 14 and 28 days respectively. Comparison of the two is
shown in Figure 4.2.

Table 4.2: Compressive Strength Test for Replacement of Fine Aggregate

S.No. Compressive 7th Day 14th Day 28th Day

Strength Test
for Cubes : Strength(N/mm2) Strength(N/mm2) Strength(N/mm2)
1. Conventional 13.48148148 18.88888889 21.11111111
Specimens
2. Replacement 15.91111111 21.24444444 23.22962963
of Fine
Aggregate
Compressive Strength (N/mm2)

Conventional Replacement of Fine Aggregate

25
20
15
10
5
0
7th 14th 28th
No. of Days

Fig.4.2 Comparison of Compressive Strength for Replacement of Fine Aggregate

Table 4.3 shows the Compressive Strength for Conventional specimens and specimens with
Replacement of Coarse Aggregate at age 7, 14 and 28 days respectively. Comparison of the two is
shown in Figure 4.3.
46

Table 4.3: Compressive Strength Test for Replacement of Coarse Aggregate

S.No Compressive 7th Day 14th Day 28th Day
. Strength Test
for Cubes : Strength(N/mm2) Strength(N/mm2) Strength(N/mm2)
1. Conventional 13.48148148 18.88888889 21.11111111
Specimens
2. Replacement 16.82962963 21.25925926 24.41481481
of Coarse
Aggregate
Compressive Strength (N/mm2)

Conventional Replacement of Coarse Aggregate

30
25
20
15
10
5
0
7th 14th 28th
No. of Days

Fig.4.3 Comparison of Compressive Strength for Replacement of Coarse Aggregate

Table 4.4 shows the Compressive Strength for Conventional specimens and specimens with all
materials Replacement at age 7, 14 and 28 days respectively. Comparison of the two is shown in
Figure 4.4.
Table 4.4: Compressive Strength Test for Replacement of all Materials

S.No Compressive 7th Day 14th Day 28th Day

. Strength Test
for Cubes : Strength(N/mm2) Strength(N/mm2) Strength(N/mm2)
1. Conventional 13.48148148 18.88888889 21.11111111
Specimens
2. All Materials 17.31851852 22.19259259 26.1037037
Replacement
Compressive Strength (N/mm2)

Conventional Replacement of All Materials

30
25
20
15
10
5
0
7th 14th 28th
No. of Days
47

Fig.4.4 Comparison of Compressive Strength for Replacement of all Materials

4.2 SPLIT TENSILE STRENGTH:

For the determination of splitting tensile strength of concrete, cylinder specimens of diameter
to length ratio 1:2 was selected, with diameter as 150 mm and length as 300 mm specimens were
dried in open air after 7, 14 and 28 days of curing and subjected to splitting tensile test under
compressive testing machine. The splitting tensile strength (f) was obtained using the formula:
F=2P/3.14dl (N/mm2)
Where, P= Load at failure (N)
d= diameter of specimen (mm)
l= length of specimen (mm)
Table 4.5 shows the Split Tensile Strength for conventional specimens and specimens with
Replacement of Cement at age 7, 14 and 28 days respectively. Comparison of the two is shown in
Figure 4.5.

Table 4.5: Split Tensile Strength Test for Replacement of Cement

S.No Split Tensile 7th Day 14th Day 28th Day

. Strength Test for
Cylinders : Strength(N/mm2) Strength(N/mm2) Strength(N/mm2)
1. Conventional 2.675159236 3.085633404 3.807501769
Specimens
2. Replacement of 2.854446803 3.208303845 3.958480774
Cement
Split Tensile Strength (N/mm2)

Conventional Replacement of Cement

5
4
3
2
1
0
7th 14th 28th
No. of Days

Fig.4.5 Comparison of Split Tensile Strength for Replacement of Cement

Table 4.6 shows the Split Tensile Strength for conventional specimens and specimens with
Replacement of Fine Aggregate at age 7, 14 and 28 days respectively. Comparison of the two is
shown in Figure 4.6.
48

Table 4.6: Split Tensile Strength Test for Replacement of Fine Aggregate

S.No Split Tensile 7th Day 14th Day 28th Day

. Strength Test for
Cylinders : Strength(N/mm2) Strength(N/mm2) Strength(N/mm2)
1. Conventional 2.675159236 3.085633404 3.807501769
Specimens
2. Replacement of 3.161122906 3.453644728 4.019815994
Fine Aggregate

Conventional Replacement of Fine Aggregate

Split Tensile Strength (N/mm2)

4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
7th 14th 28th
No. of Days

Fig.4.6 Comparison of Split Tensile Strength for Replacement of Fine Aggregate

Table 4.7 shows the Split Tensile Strength for conventional specimens and specimens with
Replacement of Coarse Aggregate at age 7, 14 and 28 days respectively. Comparison of the two is
shown in Figure 4.7.

Table 4.7: Split Tensile Strength Test for Replacement of Coarse Aggregate

S.No Split Tensile 7th Day 14th Day 28th Day

. Strength Test for
Cylinders : Strength(N/mm2) Strength(N/mm2) Strength(N/mm2)
1. Conventional 2.675159236 3.085633404 3.807501769
Specimens
2. Replacement of 2.731776362 3.095069592 3.939608398
Coarse
Aggregate
49

Conventional Replacement of Coarse Aggregate

Split Tensile Strength (N/mm2)

4
3
2
1
0
7th 14th 28th
No. of Days

Fig.4.7 Comparison of Split Tensile Strength for Replacement of Coarse Aggregate

Table 4.8 shows the Split Tensile Strength for conventional specimens and specimens with all
materials Replacement at age 7, 14 and 28 days respectively. Comparison of the two is shown in
Figure 4.8.

Table 4.8: Split Tensile Strength Test for Replacement of all Materials

S.No Split Tensile 7th Day 14th Day 28th Day

. Strength Test for
Cylinders : Strength(N/mm2) Strength(N/mm2) Strength(N/mm2)
1. Conventional 2.675159236 3.085633404 3.807501769
Specimens
2. All Materials 3.378155225 3.44420854 4.458598726
Replacement

Conventional Replacement of All Materials

Split Tensile Strength (N/mm2)

5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
7th 14th 28th
No. of Days

Fig.4.8 Comparison of Split Tensile Strength for Replacement of all Materials

50

CHAPTER 5

SUMMARY AND CONCLUSION

5.1 SUMMARY:

The major problem in the construction field is that there is scarcity of available materials
which are mainly used for preparing the concrete. Earlier, for preparing concrete, we use river sand
but due to scarcity of river sand, we are use M sand. So, we are replacing the materials of Fine
aggregate and Coarse aggregate with the materials which are having the utmost properties of Fine
aggregate and Coarse aggregate. So that the replaced concrete will produce the same strength or
more strength compared to conventional concrete.
Replacement of Cement has been done by three materials, namely Alccofine at a 15%
replacement, Metakaolin at a 10% replacement, GGBFS at a 30% replacement, which sums up to a
total of 55% Cement replacement. Replacement of Fine Aggregate has been done by two
materials, namely Copper Slag at a 50% replacement, Foundry Sand at a 30% replacement, which
sums up to a total of 80% Fine Aggregate replacement. Replacement of Coarse Aggregate has
been done by two materials, namely Recycled Aggregates at a 20% replacement, Sintered Fly Ash
Aggregate at a 30% replacement, which sums up to a total of 50% Coarse Aggregate replacement.

5.2 CONCLUSION:

Therefore, based upon this project, we collected different supplementary materials for replacement
of Cement, Fine Aggregate and Coarse Aggregate.
1) The Compressive and Tensile strength of the newly combined concrete has been compared.
2) The Percentage Increase of the specimens has been checked.
3) Compressive strength of concrete is increased by replacement of cement with 15% Alccofine,
10% Metakaolin and 30% GGBFS; replacement of Fine Aggregate with 50% Copper Slag and
30% Foundry Sand; replacement of Coarse Aggregate with 20% Recycled Aggregates and 30%
Sintered Fly Ash Aggregate, after 28 days of testing as compared to conventional specimens.
4) In comparison between conventional specimens and Cement replaced specimens, the Percentage
Increase in Compressive Strength is 2.14% and 2.44% at age 7 and 28 days, respectively. Whereas,
the Percentage Increase in Split Tensile Strength is 0.18% and 0.15% at age 7 and 28 days,
respectively.
5) In comparison between conventional specimens and Fine Aggregate replaced specimens, the
Percentage Increase in Compressive Strength is 2.43% and 2.12% at age 7 and 28 days,
respectively. Whereas, the Percentage Increase in Split Tensile Strength is 0.49% and 0.21% at age
51

7 and 28 days, respectively.

6) In comparison between conventional specimens and Coarse Aggregate replaced specimens, the
Percentage Increase in Compressive Strength is 3.35% and 3.30% at age 7 and 28 days,
respectively. Whereas, the Percentage Increase in Split Tensile Strength is 0.06% and 0.13% at age
7 and 28 days, respectively.
7) Finally, in comparison between conventional specimens and all materials replaced specimens,
the Percentage Increase in Compressive Strength is 3.84% and 4.99% at age 7 and 28 days,
respectively. Whereas, the Percentage Increase in Split Tensile Strength is 0.7% and 0.65% at age 7
and 28 days, respectively.
8) The concrete is thus, eco-friendly.

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52

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