DISSERTATION REPORT

ON

PARTICLE PACKING THEORY WITH CUBICAL AGGREGATE

USING FERROCEMENT CONCRETE

Guided by:

Dr. R.M. Sawant

Associate Professor & Head, Civil Engineering Department

Submitted by:
Mohammed Safiuddin Mohammed Badiuddin
Master of Technology

(Structural Engineering)
INTRODUCTION

CONCEPT

LITERATURE REVIEW

MATERIALS

METHODOLOGY
 INTRODUCTION
 There are various methods of mix
designing such as
 Arbitrary Proportion
 Fineness modulus method
 Maximum density method
 Surface area method
 IRC – 44 method
 Entroy shckalock method
 Road note No.4
 ACI committee -211 method
 DOE method (Department of
environment)
 IS 10262 : 1982, IS 10262 : 2009
 Packing density is new kind of mix
design method used to design different
types of concrete.
 To optimize the particle packing density
of concrete, the particles should be
selected to fill up the voids between large
particles with smaller particles and so on,
in order to obtain a dense and stiff
particle structure.
 Higher degree of particle packing leads
to minimum voids, maximum density
and requirement of cement and water
will be less.
 CONCEPT OF PARTICLE PACKING THEORY

(a) (b) (c)

Fig : Concept of particle packing (after Johansen)

 Large single size particles when filled into a container will have voids as shown in Fig. (a),
 Which in turn can be filled with smaller particles, Fig (b), thereby reducing the voids or
increasing the packing density.
 This packing density in turn can be further improved by introducing a third component of
still smaller size as shown in Fig (c) and so on.
 This concept has been developed along different lines, giving rise to various theories, which
are classified next.
 Objectives of Particle Packing

I. Eco-Friendly :
• About 7% of the worlds CO2 is emitted due to Portland cement .
• Optimizing the concrete and minimizing the quantity of cement
• Thus reducing the emission of CO2, making the concrete eco-friendly.

II. To achieve economy: By adopting particle packing the concrete

can be made economical.
 WALL EFFECT & LOOSENING EFFECT

 Wall Effect:- When a coarser particle is in the

vicinity of finer particles, voids near the
contact between the particles get increased,
disturbing the packing of finer particles which
is termed as wall effect.

 Loosening Effect:- On the other hand when a finer

particle is in the matrix of coarser particles and also that
the finer particle is too large to fit in the interstices of
the coarser particles, it disturbs the packing of coarser
particles which is termed as loosening effect..
 PACKING DENSITY ?

 The packing density of a granular mix ,is the solid volume in the unit
total volume.
 The packing density of a grain mixture depends upon three parameters:-
1. The size of the grains considered
2. The shape of the grains
3. The method of processing the packing
 Mathematically the packing density(Φ) can be defined as unity minus
porosity(π).
Φ= 1-π
 Aggregate packing is one of several factors to consider in selecting
aggregates.
 The packing density, along with shape, is useful in determining amount
of paste required.
 Objectives of the study:

1. To Study the efficiency of particle packing models prepared by using cubical & round shape of coarse

aggregate in enhancing the durability parameters of concrete.

2. To check the feasibility and implementation of ferrocement with particle packed concrete and its

durability properties.
 LITERATURE REVIEW
1.Mohammed H. Mohammed, Mats Emborg, Roland Pusch, Sven
Knutsson did an investigation on, “Packing Theory for Natural and
Crushed Aggregate to Obtain the Best Mix of Aggregate”.

 The aim of their study has to  Their conclusion was

1. identify and normalize current
packing models for
comparison.
2. test the validity of selected
theoretical models for
simulating packing of
aggregate (natural and crushed)
by comparing them with results
from new experimental work.
1. from theoretical models such as Toufar and
4C-program, as well as the experimental
results, the 4C is valid in principle but that it
somewhat overrates the packing degree.
2. the natural aggregate ranged (0-27 mm)
gives packing values higher than of crushed
aggregate for the same aggregate mix
proportions for all experimental and
theoretical studies.
3. It is also found use of three types of
aggregate or more gives optimum packing
and good concrete.
2. Narasimha Raj1, Suresh G Patil 2 and B. Bhattacharjee did an investigation on,
“Concrete Mix Design By Packing Density Method ”.

In this work
 the co-relation curves are developed for packing density method between
compression strength and water cement ratio.
 Large number of trial casting were carried out for each grade of concrete
(i.e., M20, M25, M30, M35 and M40) with different water cement ratio and
three paste contents in excess of void content.
 To finalize mix proportions using packing density method flow table tests were
carried out to decide water cement ratio and paste content in excess of void
content for each grade of concrete.
 The co-relation curves were plotted between compressive strength vs water
cement ratio at 7 and 28 days curing age and compressive strength vs paste
content at 7 and 28 days curing age.
 These curves can be used to decide the water cement ratio and paste content
for the specified grade of concrete incase of packing density method thus
reducing the material and time involved in trial testing
3. Mangulkar M. N., Dr. Jamkar S.S. did an investigation on ,
“Review of Particle Packing Theories Used For Concrete Mix
Proportioning”

In this investigations
 They had compare different theories regarding particle packing
theory.
 The review of the research work shows that all the popular packing
models are based on the assumption that the particles are spherical.
 Actually review studies have shown that shape factor and convexity
ratio are the most important shape parameters and mean size,
 specific gravity and voids ratio are the most important size
parameters influencing the packing of aggregate.
 Packing of aggregate seems to be sound concept to predict the
behavior of fresh concrete and hardened concrete. A concrete mix is
constituted largely of aggregate and its quality is hence dependent
on the grading, size, and shape of the aggregate used.
4. Sonja A.A.M. Fennis, Joost C. Walraven did study on,
“Using particle packing technology for sustainable concrete
mixture design”.

Their work concluded to -

 The packing density of a particle mixture by itself is a powerful
parameter in the design of concrete mixtures.
 It helps to determine the suitability of aggregates and fillers for the use
in concrete mixtures.
 Higher packing densities leave less space for voids to be filled with
water, which reduces the water demand and increases the strength of
concrete mixtures
 Based on experiments on ecological concrete it was demonstrated how
particle packing technology can be effective to lower cement contents,
without changing concrete properties in a negative way.
PHASE 1 :- PROPERTIES OF MATERIAL

 Materials used are

1. Coarse aggregate
A. Cubical
2. Fine aggregate
3. Cement
4. Ferro-Cement
Properties to be determined are

1. Specific gravity and water absorption

I. Coarse aggregate
A. Cubical
II. Fine aggregate
III. Fly ash
IV. Cement
2. Fineness modulus of all the aggregates
3. Water absorption of all the aggregates
4. Packing density of all the aggregate
SPECIFIC GRAVITY AND WATER ABSORPTION
(as per IS 2386(part 3)-1963)
 The procedure is different for coarse aggregate, fine
aggregate, fly ash and cement.
1.COARSE AGGREGATE:

STEP 1 STEP 2 STEP 3 STEP 4

Wt of Wt of empty Wt of Wt of oven
saturated basket in saturated dried
water surface dry aggregate
aggregate in aggregate in
water air
2. FINE AGGREGATE((as per IS 2386(part 3)-1963)

1. FA is kept immersed in water for 24 hrs

2. Then the wt of saturated surface dried aggregate is taken
3. Then the wt of saturated aggregate in pycnometer with
water is taken
4. Then the wt of pycnometer with water is taken

3. Fly ash : procedure is same as that of the fine aggregate

4. Cement : procedure is same as that of

the fine aggregate but instead of water
kerosene is used
SR NO MATERIAL SPECIFIC WATER
GRAVITY ABSORPTION

1 CUBICAL 2.64 1.53%

AGGREGATE

2 FINE 2.62 0.93%

AGGREGATE

3 FLY ASH 1.25 ---

4 CEMENT 3.13 ---

 FINENESS MODULUS

A. CUBICAL AGGREGATE

GRADING OF CUBICAL
120 AGGREGATE
PERCENTAGE PASSING

100
100 90.2
80
60
40 27.5 Cubical aggregate
20
0 0
0
m m m m m
7 5m .3m 1 0m .5m 1 6m
4. 6 1 2

IS SIEVES
B. FINE AGGREGATE REF-IS 383-1970 TABLE NO 4

Chart Title
PERCENTAGE PASSING
350

300 100

250 95

200 100
70
83.8
150

100 58.2 90
34
60
50 20 28.4
30
10 8
5 15
1.8
0
0
150μ 300μ 600μ 1.18mm 2.36mm 4.75mm

IS SIEVES

Lower limit for zone 1 Used FA Upper limit for zone 2

MOISTURE CONTENT
MATERIALS MOISTURE CONTENT

CUBICAL AGGREGATE 0.84%

FINE AGGREGATE 1.62%

Determination of packing
density of aggregates
Packing densities
TYPE OF SIZE OF IS SIEVE PACKING DENSITY =
AGGREGATE W/(VC*SP.GRAVITY)

CUBICAL 16mm 0.7136

12.5mm 0.7136
10mm 0.7177
6.3mm 0.5010
FINE 4.75mm 0.6780
2.36mm 0.7422
1.18mm 0.7119
600μ 0.6903
300μ 0.5695
150μ 0.5495
Method of Mix Design
` By Francois de larrard
Casting
Compaction procedure used

 Each mold is filled into 5 layers.

 Each layer is vibrated for 3 min on vibrating table
 Curing techniques
1. Normal curing for 28 days
2. Accelerated curing.

Accelerated curing (as per IS-9013-1978)

 After the specimens have been made,

 they shall be stored in a place free from vibration, in moist air of at least 90
percent relative humidity
 at a temperature of 27 ± 2"C for 23 hours 15 minutes from the time of addition
of water to the ingredients.
 The specimens shall then be gently lowered into the curing tank and
shall remain totally immersed. for a period of 3 1/2 hour ± 5 minutes.
 temperature of the water in the curing tank shall be at boiling ( 100°C).
Nomenclature and no. of
specimens
1. RA - concrete with round aggregate and accelerated curing (6
cubes).
2. RN - concrete with round aggregate and normal curing (6
cubes).
3. AA - concrete with angular aggregate and accelerated curing (6
cubes).
4. AN - concrete with angular aggregate and normal curing (6
cubes).
5. CA - concrete with cubical aggregate and accelerated curing (6
cubes).
6. CN - concrete with cubical aggregate and normal curing (6
cubes).
Testing
 Using compression testing machine.
RESULTS
1. Compressive Strength of Concrete

Compressive
Aggregate Percentage
Age of Cubes Strength
Variation
(N/mm2)

28 days 40 % 38.35 N/mm2

28 days 50 % 44.87 N/mm2

28 days 60 % 52.33 N/mm2

 Compressive Strength of Concrete (N/mm2)

60 52.33

44.87
50
38.35

40

30

20

10

Compressive Strength of Concrete

2. Flexural Strength of Concrete

Age of Aggregate Percentage Flexural strength

Cubes Variation (MPa)

28 days 40 % 2.85 MPa

28 days 50 % 3.05 MPa

28 days 60 % 3.13 MPa

 Flexural Strength of Concrete (N/mm2)
3.2

3.15 3.13

3.1
3.05
3.05

2.95

2.9
2.85
2.85

2.8

2.75

2.7

Flexural Strength of Concrete

CONCLUSIONS
The quilting viscosity value will remain same irrespective of grade of concrete.

2. In packing viscosity system, paste content in excess of void content will increase with
the increase in grade of concrete.

3. In case of packing viscosity system water cement rate decreases with increase in grade
of concrete.

4. The plasticity of concrete achieved is more in packing viscosity system, as the water
cement rate is slightly advanced in packing viscosity system. The fine total patches
needed are more in case of packing viscosity system thus, water and cement needed in
case of packing viscosity is more.

5. Use of 3rd generation PCE based HRWR is recommended for producing stable and
workable SCM.
6. Optimum dosage of admixture is 1% which gives relative viscosity.

7. Fly ash replacement provided significant improvement in slump flow, stability and
strength of SCM.

8. Fly ash produced thixotropic effect that can reduce formwork pressure of SCM.

9. The study proposed a new VSI rating for SCM that rationally evaluates the static stability
of SCM.

10. The optimal water cement ratio is 0.37 with 1:2.5 Proportion which gives satisfactory
result of all the test i.e. Slump flow, V funnel, Mesh ring, Free fall etc.

11. Though, relevant experience, strict quality control and trials are essential to produce
satisfactory SCM, its potential use to efficiently produce good quality Ferrocement product.
Refrences
1. Packing Theory for Natural and Crushed Aggregate to Obtain the Best
Mix of Aggregate by Mohammed H. Mohammed, Mats Emborg, Roland
Pusch, Sven Knutsson ,world academy of science engineering and
technology, 2012,pp 819-825.
2. Concrete Mix Design By Packing Density Method by Narasimha Raj1,
Suresh G Patil 2 and B. Bhattacharjee ,IOSR-JMCE Volume 11, Issue 2,
Ver. 1(Mar-Apr.2014),pp34-46.
3. Review of Particle Packing Theories Used For Concrete Mix
Proportioning by Mangulkar M. N., Dr. Jamkar S.S,IJSER Vol 4, Issue
5,May 2013,pp143-148.
4. Using particle packing technology for sustainable concrete mixture design
by Sonja A.A.M. Fennis, Joost C. Walraven HERON Vol 57,2012,pp 73-
101.
5. Concrete mixture proportioning by Francois de Larrard.
6. IS 9013-1978
THANK YOU