Flyash Concrete

GOVERNMENT POLYTECHNIC, SORABA FLYASH MIX CONCRETE
CHAPTER 1
INTRODUCTION
1.1 General
Cement, fine aggregate, coarse aggregate are essential needs for any construction
industry. Fine aggregate is a major material used for preparation of mortar and concrete and
plays a most important role in mix design. In general consumption of natural fine aggregate is
high, due to the large use of concrete and mortar. Hence the demand of fine aggregate is very
high developing countries to satisfy the rapid infrastructure growth. The developing country like
India facing shortage of good quality fine aggregate and particularly in India, fine aggregate
deposits are being used up and causing serious threat to environment as well as society. Rapid
extraction of fine aggregate from river beds and causing so many problems like losing water
retaining soil strata, deepening of the river beds and causing bank slides, loss of vegetation on
the bank of river, disturbs the aquatic life as well as disturbs agriculture due to lowering the
water table in the well etc are some of the examples. The heavy exploitation of river fine
aggregate for construction purposes in Sri Lanka as laid to various harmful problems option for
various river fine aggregate alternatives, such as offshore fine aggregate. Fine aggregate also has
been made. physical as well as chemical properties of fine aggregate affect the durability,
workability and also strength of concrete, so fine aggregate is a most important constituent of
concrete and cement motor. Generally river fine aggregate or pit fine aggregate are used as fine
aggregate4 bin mortar and concrete together fine and coarse aggregate make about 75-80% of
total volume of concrete and hence it is very important to fine suitable type and good quality
aggregate nearby site. Recently natural fine aggregate is becoming a very costly material because
of its demand in the construction industry due to this condition research began for cheap and
easily available alternative material to natural fine aggregate. Some alternative materials have
already been used. Even through of shore fine aggregate is actually used in many counties such
as the UK, Sri Lanka, continental Europe, India and Singapore most of records regarding use of
this alternative found manly lesser extent of practice in the construction field.
The word is resting over a land fill oaf waste hazardous materials which may substitutes of
natural fine aggregate. Irrespective of position, location, scale, type of any structure, concrete is
the base for construction activity. In fact, concrete is the second largest consumable material
after water, with nearly free tones used annually for each person on the earth. In consumes an
DEPT. OF CIVIL ENGG 2018-19 Page 1

estimated 450 million cubic meter of concrete annually and which approximately comes to 1
tones owner Indian. We still have a long way to global consumption go by global consumption
levels but do we have enough fine aggregate to make concrete and mortar? Value of constructing
industry grew at strugaring rate of 15% annually even in the economic slowdown and as
contributed to 7-8% of the countries. GDP(at current prices) for the past eight years thus, it is
becoming increasingly discomforting for people like common people who talk about greening
the industry to have no practical answer to his very critical question. In fact we have been sitting
land fill of possible substitutes for fine aggregate. Industrial waste by products almost all
industry which have been rising hazardous problem both for the environment, agriculture and
women health and have major used in construction activity which may be use full for not only
from the economy point of view but also took reserve the environment.
1.2 Fly Ash Mix Concrete
Fly ash is very much similar to volcanic ashes used in production of the earliest known
hydraulic cements about 2,300 years ago. Those cements were made near the small Italian town
of Pozzuoli - which later gave its name to the term “pozzolan”. A pozzolan is a siliceous or
siliceous / aluminous material which when mixed with lime and water forms a cementitious
compound. Fly ash is the best known, and one of the most commonly used, pozzolans in the
world. Fly ash is the notorious waste product of coal based electricity generating thermal power
plants, known for its ill effects on agricultural land, surface and sub-surface water pollution, soil
and air pollution and diseases to mankind.
Researchers have proposed few ways of reusing fly ash for variety of application. One of
the most common reuse of fly ash is in cement concrete. Fly ash particles are almost totally
spherical in shape, allowing them to flow and blend freely in mixtures. That capability is one of
the properties making fly ash a desirable admixture for concrete. These materials greatly improve
the durability of concrete through control of high thermal gradients, pore refinement, depletion
of cement alkalis, resistance to chloride and sulphate penetration, and continued micro structural
development through a long-term hydration and pozzolanic reaction. The utilization of by-
products as the partial replacement of cement has important economical, environmental and
technical benefits such as the reduced amount of waste materials, cleaner environment, reduced
energy requirement, durable service performance during service life and cost effective structures.

In the present era of growth and development, progress is taking place in all the fields.
But, in the light of progress, man is ignoring nature and harming it. Construction area, with the
use of virgin materials like cement, is also posing the threat of global warming and
environmental degradation. The challenge in front of civil engineering community is to provide
sufficient, economical and comfortable infrastructure without causing any hardship for
environment. Taking sustainable development in view, an attempt has been made to reduce the
use of cement in concrete by replacing it with otherwise waste materials such as fly ash, slag,
silica fume and rice husk. The use of fly ash in concrete has been encouraged all over the world.
Though this has been tried at some places in India but the percentages replacements of cement by
fly ash are very small and only less than 25% of total fly ash produced is being utilized. A
confidence is required to be built up in developing countries like India to make use of fly ash
concrete in various fields of construction.
Chemical Requirements of Fly Ash (As per BIS)

SN Characrteistics Requirements
Siliceous Fly Ash Calcareous Fly Ash
1 SiO2+Al2O3+Fe2O3 (% by mass, 70 50
Min.)
2 SiO2 (% by mass, Min.) 35 25
3 Reactive silica (% by mass, Min.) 20 20
4 MgO (% by mass, Max.) 5 5
5 SO3 (% by mass, Max.) 3 3
6 Na2O (% by mass, Max.) 1.5 1.5
7 Total Chlorides (% by mass, Max.) 0.05 0.05
8 Loss on Ignition (% by mass, Max.) 5 5

CHAPTER 2
LITERATURE REVIEW
Chatterjee, (2011) reported that about 50 % of fly ash generated is utilized with present
efforts. He also reported that, one may achieve up to 70% replacement of cement with fly ash
when high strength cement and very high reactive fly ash is used along with the sulphonated
naphthalene formaldehyde super plasticizer. He reported improvement in fly ash property could
be achieved by grinding and getting particles in sub microcrystalline range.
Bhanumathidas, &Kalidas, (2002) with their research on Indian fly ashes reported that
the increase in ground fineness by 52% could increase the strength by 13%. Whereas, with the
increase in native fineness by 64% the strength was reported to increase by 77%. Looking in to
the results it was proposed that no considerable improvement of reactivity could be achieved on
grinding a coarse fly ash. Authors also uphold that the study on lime reactivity strength had more
relevance when fly ash is used in association with lime but preferred pozzolanic activity index in
case of blending with cement.
Subramaniam, Gromotka, Shah, Obla& Hill, (2005) investigated the influence of

ultrafine fly ash on the early age property development, shrinkage and shrinkage cracking
potential of concrete. In addition, the performance of ultrafine fly ash as cement replacement was
compared with that of silica fume. The mechanisms responsible for an increase of the early age
stress due to restrained shrinkage were assessed; free shrinkage and elastic modulus were
measured from an early age. In addition, the materials resistance to tensile fracture and increase
in strength were also determined as a function of age. Comparing all the test results authors
indicated the benefits of using ultrafine fly ash in reducing shrinkage strains and decreasing the
potential for restrained shrinkage cracking.
Hwang, Noguchi &Tomosawa, (2004) based on their experimental results concerning

the compressive strength development of concrete containing fly ash, the authors concluded that
the pores in concrete reduce by addition of fly ash as replacement of sand. (Siddique, 2003)
carried out experimental investigation to evaluate mechanical properties of concrete mixes in
which fine aggregate (sand) was partially replaced with class F fly ash. Fine aggregate was
replaced with five percentages (10%, 20%, 30%, 40% and 50 %) of class F fly ash by weight.

The test result showed that the compressive strength of fly ash concrete mixes with 10% to 50%
fine aggregate replacement with fly ash were higher than control mix at all ages. Also the
compressive strength of concrete mixes was increasing with increase in fly ash percentages. This
increase in strength due to replacement of fine aggregate with fly ash was attributed to
pozzolanic action of fly ash. The splitting tensile strength also increased with increase in
percentage of fly ash as replacement of fine aggregate. The tests on flexural strength and
modulus of elasticity also showed improvement in the results as compared to control concrete.
Namagg&Atadero, (2009) described early stages of a project to study the use of large
volumes of high lime fly ash in concrete. Authors used fly ash for partial replacement of cement
and fine aggregates. Replacement percent from 0% to 50% was tested in their study. They
reported that concrete with 25% to 35% fly ash provided the most optimal results for its
compressive strength. They concluded that this was due to the pozzolanic action of high lime fly
ash. (Jones & McCarthy, 2005) made an extensive laboratory based investigation in to
unprocessed low lime fly ash in foamed concrete, as a replacement for sand. For a given plastic
density, the spread obtained on fly ash concretes were up to 2.5 times greater than those noted on
sand mixes. The early age strengths were found to be similar for both sand and fly ash concrete,
the 28-day values varied significantly with density. The strength of fly ash concrete was more
than 3 times higher than sand concrete. More significantly while the strength of sand mixes
remained fairly constant beyond 28 days, those of fly ash foamed concrete at 56 and 180 days
were up to 1.7 to 2.5 times higher than 28 days values respectively.
Rebeiz, Serhal& Craft, (2004) reported investigation on the use of fly ash as
replacement of sand in polymer concrete. In the weight mix design 15% sand was replaced by fly
ash. This replacement of 15% sand with fly ash by weight increased compressive strength by
about 30%. Also there was improvement in the stress strain curve. They also reported good
surface finish due to addition of fly ash as replacement of sand which also reduce permeability
and have an attractive dark colour. Flexural strength of steel reinforced polymer concrete beams
was increased by 15%. When subjected to 80 thermal cycles polymer concrete with fly ash
exhibits slightly better thermal cycling resistance (about 7% improvement) than polymer
concrete without fly ash.

(Rao, 2004) discussed the need to use about 650 kg/cu.m of fine material to make self
compacting concrete. This also requires fine aggregates more than 50% of total aggregate so that
coarse aggregate can float in the fine material. This requirement of fine materials can be easily
fulfilled by use of fly ash.
2.1 SUMMARY OF REVIEW OF LITERATURE

From above investigation compared to conventional concrete in fly ash mix concrete by
using optimum amount of fly ash is significantly increase in compressive strength, Split tensile
strength, modulus of elasticity and crack resistance. So fly ash were added in various percentages
like 0%,40 %, 50%, 60%, 70% and 80% by weight of coarse aggregate. The fly ash percentage
increases the compressive strength of cube and split tensile strength of the cylindrical specimen
also increases.
One of the important advantages with fly ash concrete is the resistance to alkali
aggregate reaction (AAR). Increasing AAR because of fly ash or increased fly ash content is not
registered by any authors in this literature study. Several successful field constructions with high
volume Class F fly ash concrete are mentioned. Even if the use of fly ash has a lot of advantages
there always will be events of less favourable experience, because of different cement types, fly
ashes, admixtures, aggregates, environment and temperature. However, there are few examples
of poor field constructions with fly ash concrete. Perhaps this is because of its good properties of
the fly ash concrete used in the constructions, or the reason is no one wants to report failed
projects.

CHAPTER 3
EXPERIMENTAL INVESTIGATION
3.1 Objects of testing
The main object of testing is to know the behavior of Fly ash mixed concrete in concrete in
fresh as well as in hardened state. Concrete a is prepared by adding the Fly ash in various
percentage from 0%, 40%, 50%, 60%, 70%, 80%. The main parameters studied were:
1. Workability of fresh concrete (slump and compaction factor and vee-bee test)
2. Cube compressive strength
3. Spilt tensile strength
4. Density of concrete
5. Modulus of elasticity of concrete
3.2 Materials
The materials used in this investigation are: Cement, fly ash, Fine aggregate, Coarse
aggregate, Water, Super plasticizer.
Cement
OPC 43 grade cement conforming to IS: 8112 from a single batch is used throughout the
course of the project work. The properties of cement used are shown in table 3.1
Fly Ash
In this study, The fly ash is collected from the poly fibers industry. Fly ash utilization in
concrete as partial replacement of cement. The specific gravity is obtained from the test is equal
to 1.87

Fine aggregate
Locally available river fine aggregate belonging to zone 2 of IS 383-1970 is used for the
present work. The sieve analysis data of fine aggregate are shown in table 3.2
Coarse aggregate
Crushed ballast stone of size 12mm and 20mm down confirming to IS 383 - 1970 is
used in this project the sieve analysis and properties are tested and tabulated in table 3.4 and
table 3.5 .
Water
Portable water is used in the present investigation for both casting and curing .pH of
water is between 6.5 – 8.5
Super plasticizers
Super plasticizer conforming to IS: 9103-1999
FOSROC Conplast SP 430 DIS (Sulphonated Naphthalene Formaldehyde)
Batch No. IN1MF00299416
3.3 Mix proportion of concrete
Mix design was carried out using the proportions of ingredients for M20 grade as per IS
10262- 2009; “GUIDELINES FOR CONCRETE MIX DESIGN PROPORTIONIGN” gives the
minimum cement content.
Mix design calculations has been shown in appendix- A and mix proportions for
different mixes used are shown in Table 3.9
3.4 Casting of concrete cube and cylindrical mould
Cube moulds of size 150mmX150mmX150mm and Cylindrical mould of size 150mm

dia. and 300mm length are used for casting the concrete. The moulds are cleaned and before
casting greasing to be applied on all the internal surfaces. All the cube moulds are filled in 3
layers. The heights of the mould and for each layer 1/3 rd of each layer 25 blows are given with

the help of tamping rod over the entire cross section of the mould uniformly. After filling and
compacting the mould, the top surface is made smooth and kept for drying for 18 hours.
Fly ash by weight of cement 0%, 40%, 50%, 60%, 70% and 80% are designated as 1FA0,
1FA40, 1FA50, 1FA60, 1FA70, 1FA80. one cylindrical and two cube moulds are casted for each
percentage of Fly ash. A total no of 18 moulds are casted with W/c 0.4 for 0%, 40%, 50%, 60%,
70% and 80% of Fly ash by weight of cement for 7 and 28 day compression and split tensile
testing. Batching, Mixing and Preparation of concrete are shown in Image 3.1 and 3.2
3.5 Curing specimens
Immersion method of curing is adopted for curing. Specimens are removed after 24
hour of casting from the moulds and are placed in tank containing water for 7 and 28 days of
curing. After the curing period, specimens are removed from the tank and the surface moisture
can be removed by wiping the surface with cloth and make sure that the specimens are in surface
dry condition. Specimens kept for curing are shown in Image 3.3

CHAPTER 4
TESTS OF CONCRETE SPECIMENS
4.1 TESTS ON FRESH CONCRETE
4.1.1 SLUMP TEST (As per IS: 1199-1959)
The internal surface of the slump cone shall be thoroughly cleaned. The mould shall be placed on
smooth, horizontal, rigid and non-absorbent surface. The mould shall be filled in four layers,
each approximately one-quarter of the height of the mould. Each layer shall be tamped with 25
stokes of the rounded end of the tamping rod. The stokes shall be distributed in a uniform
manner over the cross section of the mould and for the second and subsequent layers shall
penetrate into a underlying layer. The bottom layer shall be tamped thought its depth. After the
top layer has been rodded, the concrete shall be struck off level with a trowel or the tamping rod,
so the mould is exactly filled. The mould shall be removed from the concrete immediately by
rising its slowly and carefully in s vertical direction. This allows to concrete subside and the
slump shall be measured immediately by determining the difference between the height of the
mould and that of the highest point of the specimen being tested.
Slump in mm = (h - h1)
Where,
h = height of concrete in mm
h1 = height of subsided concrete in mm
Degree of workability for different slump value has been tabulated in table 4.1
Slump Degree of workability

0-25 Very low
25-50 Low
50-100 Medium
100-150 High
>150 Very high
Image 4.1 Slump test

4.1.2 COMPACTION FACTOR TEST (as per IS: 1199-1959)
Weigh the empty cylinder of the compaction factor apparatus as W1 placee it below the
lower hopper. For mixes are to be prepare with w\c ratio. All hoppers are cleaned, greased and
pour the concrete mix in the top hopper. Remove the tap door of the upper hopper and then
removed door of the lower hopper. The concrete gets collected in the cylinder Now, gently level
the cylinder and note down the weight the cylinder as W2. Remove all concrete then refill by 3
layers by providing 25 blows per each layer now take down the weight W3. Compaction factor is
obtained by the following formula
(W2 - W1) / (W3 - W1)
Where,
W1 = weight of empty cylinder
W2 = weight of empty cylinder + partially compacted concrete
W3 = weight of empty cylinder + fully compacted concrete
Degree of workability for different Compaction factor value has been tabulated in table 4.2
Compaction
factor
Degree of
(20mm
workability
down
aggregate)
0.66 Extremely low
0.78 Very low
0.85 Low
0.92 Medium
0.95 High
>0.95 Very high
Image 4.2 Compaction factor machine

4.1.3 VEE BEE CONSISTOMETER TEST (as per IS: 1199-1959)

1. A slump test shall be performed in the sheet metal cylindrical pot of the consistometer.
2. The glass disc attached to the swivel arm shall be moved and placed just on the top of the
slump cone in the top.
3. Before the cone is lifted up the position of the concrete cone shall be noted by adjusting the
glass disc attached to the swivel arm.
4. The cone shall then be lifted up and the slump noted on the graduated rod by lowering the
glass disc on top of the concrete cone.
5. The electrical vibrator shall then be switched on and the concrete shall be allowed to spread
out on the top.
6. The vibration shall then be continued until the whole concrete surface uniformly adverse to
the glass disc and the time taken for this to be attained shall be noted with a stop watch.
7. The time recorded in seconds.
Degree of workability for different Vee bee seconds has been tabulated in table 4.3
Vee bee degree,

Workability description
second
Extreme dry 40 to 25-20
Very stiff 20-10
Stiff 10-5
Stiff plastic 5-3
Plastic 3-1
Flowing <1
Image 4.3 Vee-bee consistometer

4.2 TESTS ON HARDENED CONCRETE

4.2.1 CUBE COMPRESSION TEST (As per IS: 516-1959)
Cube specimens are used to determine characteristic compressive strength. The cubes are
tested in compression testing machine of capacity 1000 kN. The load is applied without shock,
increased gradually at a rate of approximately 140 kg/cm2/min, the two opposite sides of the
cubes are compressed (top and bottom surface). The load is applied until the specimen fails or
breaks. The ultimate load shall be recorded and compressive strength can be calculated by using
formula.
Cube Compressive Strength (N/ mm2) =P/A
Where,
P = Ultimate load at failure in N
A = Area of concrete specimen (150 X 150 = 22500) in mm2
Image 4.4 Cube Compressive Test

4.2.2 SPLITTING TENSILE STRENGTH TEST (As per IS: 5816-1999)

Cylindrical specimens are used to determine split tensile strength. The specimens are tested in
compression testing machine of capacity 1000 kN. This test is carried out by placing a
cylindrical specimen horizontally between the loading surface of a compression testing machine
and the load is applied until failure of the cylinder, along the vertical diameter. The load is
applied without shock, increased gradually at the rate approximately 1.2 to 2.4 N/mm2/min. The
ultimate load shall be recorded and Split tensile strength can be calculated by using formula.
Split tensile strength (N/ mm2) = (2 x P) / (π X d X L)

= P X 1.414 X10-5
Where,
P = Ultimate load at failure in N
d = Diameter of cylindrical specimen in mm (150mm)
L = Length of cylindrical specimen in mm (300mm)
Image 4.5 Split Tensile Strength of Specimen

4.2.3 DETERMINATION OF DENSITY OF CONCRETE
The density of concrete is determined in hardened state. The density of concrete is

calculated by the following formula.
Density of Concrete (kN/m3) = W/ V
Where,
W = Weight of concrete in kN or kg
V = Volume of concrete in m3
For Cube Mould, Volume = 150 X 150 X 150 = 3375000 mm3 or 0.003375 m3
For Cylindrical Mould, Volume = (π X 1502 / 4) X 300 = 5301437.60 mm3
or 0.005301 m3

CHAPTER 5
RESULTS AND DISCUSSIONS

5.3 TEST RESULTS OF MATERIALS
TABLE 5.1.1: Properties of Cement
Sl. No. Properties Results
1 Specific gravity 3.13
2 Fineness of cement 6.66%
3 Normal consistency 28%
4 Initial setting time 30 min
5 Final setting time 10 hrs

6 Soundness Test 10 mm
Fine Aggregate
TABLE 5.2.1: Sieve Analysis of Fine Aggregates
Sl. No. IS sieve size (mm) Cumulative % passing

1 4.75 99.3
2 2.36 87.6
3 1.18 57.8
4 600 20.9
5 300 0.4
6 150 0.5
7 Pan 0
TABLE 5.2.2: Properties of Fine Aggregates
1 Bulking of fine aggregate 42%
3 Bulk density Kg/ltr

Coarse Aggregates
TABLE 5.3.1: Sieve Analysis 20 mm down size coarse aggregates
1 20 93.6
2 12.5 15.1
3 10 6.35
4 4.75 0.2
5 Pan 0
TABLE 5.3.2: Sieve Analysis 12 mm down size coarse aggregates
1 12.5 88.3
2 10 42.1
3 4.75 9.71
4 Pan ------
TABLE 5.3.3: Properties of coarse aggregates
2 Bulk density 1.674
3 Percentage of voids 36.06%

TABLE 5.4: For w/c ratio 0.4 mix proportion for different mixes
Coarse Aggregate (kg/m3)

Cement Fine aggregate
Fly Ash (%) (kg/m3) (% by wt. of
(kg/m3) (kg/m3)
12mm 20mm cement)
Weight (kg) 370 790 476 714
1FA0 0
Proportion
Weight (kg) 244.2 680 408 612
1FA40 162.8
Proportion
Weight (kg) 203.5 621 376 564
1FA50 203.5
Proportion
Weight (kg) 162.8 496 357.60 536.2
1FA60 244.2
Proportion
Weight (kg) 122.1 473 285.60 428.4 284.9
1FA70
Proportion
Weight (kg) 81.4 531 320.6 480.6 325.6
1FA80
Proportion
TABLE 5.5: Workability of Fresh Concrete
Slump*
Designation Compaction factor* Vee-bee seconds*
(mm)
1FA0 10 0.80 25
1FA40 10 0.78 22
1FA50 10 0.72 17
1FA60 10 0.69 13
1FA70 10 0.74 11
1FA80 10 0.76 11
* indicates average of three trials

TABLE 5.6: Cube Compressive Strength

Cube Compressive Strength* (N/mm2)
Designation
7 Days 28 Days
1FA0
1FA40
1FA50
1FA60
1FA70
1FA80
* indicates average of three specimens

TABLE 5.7: Hardened concrete properties of Cube Specimens
7-day 28-day
Elastic Flexural Elastic Flexural
Designation Density* Density*
modulus* Strength modulus* Strength
(KN/m3) (KN/m3)
(N/mm2) (N/mm2) (N/mm2) (N/mm2)
1FA0
1FA40
1FA50
1FA60
1FA70
1FA80

TABLE 5.8: Split Tensile Strength
Split Tensile Strength * (N/mm2)

Designation
7 Days 28 Days
1FA0
1FA40
1FA50
1FA60
1FA70
1FA80
TABLE 5.9: Hardened concrete properties of Cylindrical Specimens

7 day 28 days
Designation Density* Density*
(KN/m3) (KN/m3)
1FA0
1FA40
1FA50
1FA60
1FA70
1FA80

Figure F5A: Slump v/s Percentage of Flyash
Figure F5B: Compaction factor v/s Percentage of Flyash

Figure F5C: Vee-bee seconds v/s percentage of flyash
Figure F5D: 7 day density of cubes v/s

Figure F5E: 28 day density of cubes v/s
Figure F5F: 7 day density of cylindrical specimen v/s

Figure F5G: 28 day density of cylindrical specimen v/s P
Figure F5H: 7 day cube compressive strength v/s

Figure F5I: 28 day cube compressive strength v/s
Figure F5J: 7 day specimen split tensile strength v/s

Figure F5K: 28 day specimen split tensile strength v/s
Figure F5L: Cube Compressive strength of 7 and 28 day test results

Figure F5M: Split tensile strength of 7 and 28 day test results
Figure F5N: Modulus of elasticity v/s percentage of for 7 day compressive test
Figure F5O: Modulus of elasticity v/s percentage of for 28 day compressive test
Figure F5P: 7 day flexural strength of cube v/s percentage of

Figure F5Q: 7 day flexural strength of cube v/s percentage of

CHAPTER 6
CONCLUSIONS

APPENDIX- A
MIX DESIGN (IS CODE OF PRACTICE-10262: 2009)
Stipulations for proportioning
1. Grade designation : M20
2. Type of cement : OPC 43 grade
3. Maximum nominal size of aggregate : : 20mm
4. Minimum cement content : 320 kg/m3
5. Maximum water-content ratio : 0.45
6. Exposure condition : Mild
7. Method of concrete placing : Conventional
8. Degree of supervision : Crushed angular aggregates
9. Maximum cement content : 450 kg/m3
10. Maximum water content : 186 kg/m3
11. Chemical admixture : Super plasticizer
 Target strength for mix proportioning:

f1ck = fck+1.65s
f1ck =target average compressive strength at 7 days and 28 days,
f ck = characteristics compressive strength at 28 days = 20 N/mm2 (for M20 concrete)
S = standard deviation
Refer table 1 of IS: 10262:2009, Standard deviation for M20 grade of concrete, S = 4 N/mm2
f1ck =20 + 1.65 X 4
fck = 26.6 N/mm2
 Selection of water cement ratio :
Maximum water cement ratio =0.45
Based on experience, adopt Water - Cement Ratio = 0.40
(As per IS 456:2000, For RCC work maximum water cement ratio for exposure,
a) Mild = 0.55, b) Moderate = 0.50, c) Sever = 0.45, d) Very severe = 0.45, e) Extreme =0.40)
0.4 < 0.45 hence o. k

 Selection of water content :

Refer table 2 of IS: 10262:2009, Note down the value of the quantity of water content for
20mm aggregate = 186 liter (25to 50mm slump range)
The required water content may be established by an increase of about 3% for every
additional 25mm slump, i.e., 6% for additional 50mm slump, since slump given 100m
Estimated water content for 100mm slump = 186 + 6 / 100 X 186 = 197.16 liters
Since super plasticizer is used, the water content can be reduced up 25%.
Based on trials with super plasticizer water content reduction of 25% has been achieved.
(Percentage of water content =100-25 =75 )
Hence, the arrived water content =197.16 X 0.75 =148 liters
 Calculation of cement content :
Cement content = Water content / Water Cement ratio = 148/0.4 =370 kg /m3
(As per IS 456 :2000, For RCC work Minimum cement content in kg /m3 for exposure
1) Mild =300, 2) Moderate =300, 3) Severe = 320, 4) Very severe = 340,

5) Extreme = 360)
In this case Exposure condition given in the problem as Mild ( for reinforced concrete),
Therefore Minimum cement content should be 300kg /m3

370kg /m3 > 300kg /m3 hence o.k.
 Proportion of volume of coarse aggregate and fine aggregate content
Refer Table 2 of IS 10262 : 2009, note down volume of coarse aggregate corresponding to 20mm
size aggregate and fine aggregate (Zone 1) for water cement ratio of 0.5 =0.6
In the present case water cement ratio is =0.40.
For 0.1 change water cement ratio, volume of coarse aggregate is increased by = 0.02.
Therefore, corrected proportion of volume of coarse aggregate for the water cement ratio of
0.40 = 0.60+0.02 = 0.62.
Therefore, volume of coarse aggregate = 0.62
Volume of fine aggregate content = 1-0.62 =0.38.

Mix calculation
A. Volume of concrete = 1 m3
B. Volume of cement = (mass of concrete/specific
Gravity) X (1/1000)
= (370/3.15) X (1/1000)
= 0.117 m3
C. Volume of all in aggregate = (mass of water/specific
Gravity) X (1/1000)
= (148/1) X (1/1000)
= 0.148 m3
D.
Super plasticizer (2% by mass of
Cementatious material) = (mass of chemical admixture/
Specific gravity) X (1/1000)
= (7.4/1.21) X (1/1000)
= 0.006115 m3
E.
Volume of all aggregate = A-(B+C+D)
= 1-(0.117+0.148+0.006115)
= 0.7289 m3
F.
Mass of coarse aggregate = E X volume of coarse aggregate
X specific gravity X 1000
= 0.7289 X 0.62 X2.7 X 1000
= 1220.17 kg
G.
Mass of fine aggregate = E X volume of fine aggregate X
Specific gravity X 1000
= 0.7289 X 0.38 X 2.6 X 1000
= 720.153 kg
Mix proportion
Cement = 370 kg/ m3
Fine aggregate = 720.153 ~ 721kg
Coarse aggregate = 1190 ~ 1220 kg
Chemical admixture = 0.6% by weight of cement
Water cement ratio = 0.4

Mix proportion for 1 mould of 150 X 150 X 150 mm

Cement = 1.25 kg
Fine aggregate = 2.43 kg
Coarse aggregate = 4.12 kg
Chemical admixture = 7.48 ml
Mix proportion for 1 cylindrical mould 150mm dia 30 cm

Cement = 2 kg
Fine aggregate = 3.82 kg
Coarse aggregate = 6.5 kg
Chemical admixture = 12 ml

COST ANALYSIS
Conventional concrete Fly Ash Mix Concrete

Description Rate per Amount Rate per Amount
Quantity Quantity
unit (Rs) (RS) unit (Rs) (RS)
Cement
Fine aggregate
Coarse aggregate
Fly ash
Super plasticizer
Total = Total =

IMAGES
Image P1: Mixing of concrete
Image P2: Compaction factor test

Image P3: Casting of moulds
Images P4: Curing of concrete

Images P5: Cylindrical specimen before Applying Loa
Image P6: Failure of Cylindrical Specimen

ImagesP7: Failure Load of concrete cube

 REFERENCES
 Bhanumathidas N and Kalidas, N, (2002) Fly Ash for Sustainable Development, Institute
for Solid Waste Research and Ecological Balance . Chatterjee, A. K. (2011), Indian Fly
Ashes: Their Characteristics and Potential for MechanochemicalAcivation for Enhanced
Usability, Journal of Materials in Civil Engineering, June 2011, pp-783-788.
 Hwang, K., Noguchi, T., and Tomosawa, F. (2004) Prediction model of compressive
strength development of fly ash concrete, Cement and Concrete research, vol-34, pp-
2269-2276.
 Malhotra, V. M. and Ramezanianpour, A. A. (1994) Fly Ash in Concrete, Second
Edition, Natural Resources, Canada.
 Siddique, R. (2004), Performance Charectristics of High Volume Class F Fly Ash
Concrete, Cement and Concrete Research, Vol. 34, pp 487- 493
 Subramaniam, K. V., Gromotka, R., Shah, S. P., Obla, K. and Hill, R. (2005) Influence of
Ultrafine Fly Ash on the Early Age Response and the Shrinkage Cracking Potential of
Concrete, Journal of Materials in Civil Engineering, Jan-Feb 2005, pp-45-53.
 IS.383, “Specifications for Coarse and Fine Aggregates from Natural Sources for
Concrete,” Bureau of Indian Standards, New Delhi, 1970.
 I.S.1489-1991, “Specification for Portland Pozzolona cement Part 1 Fly ash based (Third
Revision)”, Bureau of Indian Standard, New Delhi, 1991.
 I.S.10262-1982, “Indian Standard Recommended Guidelines for Concrete Mix Design”,
Bureau of Indian Standard, New Delhi, 1983.
 IS:1199-1959 methods of sampling and analysis of concrete.
 IS 456-2000- plain and reinforced concrete- code of practice.
 IS 23866(Part 1): 1963 Methods of test for aggregates for concrete: Part 1 Particle size
and shape.
 IS 2386 (Part 3):1963 Methods of test for aggregates for concrete: Part 3 Specific gravity,
density, voids, absorption, and bulking.
 IS 2430:1986 Methods for sampling of aggregates for concrete.
 IS 5816:1999 Method of test for splitting tensile strength of concrete.
 IS 7325:1974 Specification for apparatus for determining constituents of fresh concrete.
 IS 7320:1974 Specification for concrete slump test apparatus.
 IS 8112:1989vSpecification for 43 grade ordinary Portland.

 IS 9013:1978 Method of making, curing, and determining compressive strength

accelerated cured concrete test specimens.
 IS 9103:1999 Specification for admixture for concrete.
 IS 10086:1982 Specification for moulds for use in tests of cement and concrete.
 IS 10262:2009 Guidelines for concrete mix proportioning.
 IS 10510:1983 Specification for Vee-Bee consistometer.
 IS 13311 (Part 2):1992 Methods of non- destructive testing of concrete : Part-2 Rebound
hammer.
 IS 14959 (part 1): 2001 Method of test for determination of water soluble and acid
soluble chlorides in mortar and concrete: part 1 Fresh mortar and concrete.
 Shetty M S(2003) Concrete Technology, S.Chand and Company Ltd, New Delhi.


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GOVERNMENT POLYTECHNIC, SORABA FLYASH MIX CONCRETE

DEPT. OF CIVIL ENGG 2018-19 Page 1

1.2 Fly Ash Mix Concrete

DEPT. OF CIVIL ENGG 2018-19 Page 2

Chemical Requirements of Fly Ash (As per BIS)

DEPT. OF CIVIL ENGG 2018-19 Page 3

Subramaniam, Gromotka, Shah, Obla& Hill, (2005) investigated the influence of

Hwang, Noguchi &Tomosawa, (2004) based on their experimental results concerning

DEPT. OF CIVIL ENGG 2018-19 Page 4

DEPT. OF CIVIL ENGG 2018-19 Page 5

2.1 SUMMARY OF REVIEW OF LITERATURE

DEPT. OF CIVIL ENGG 2018-19 Page 6

3.1 Objects of testing

DEPT. OF CIVIL ENGG 2018-19 Page 7

Super plasticizer conforming to IS: 9103-1999

FOSROC Conplast SP 430 DIS (Sulphonated Naphthalene Formaldehyde)

Batch No. IN1MF00299416

3.3 Mix proportion of concrete

3.4 Casting of concrete cube and cylindrical mould

Cube moulds of size 150mmX150mmX150mm and Cylindrical mould of size 150mm

DEPT. OF CIVIL ENGG 2018-19 Page 8

3.5 Curing specimens

DEPT. OF CIVIL ENGG 2018-19 Page 9

h1 = height of subsided concrete in mm

Slump Degree of workability

Image 4.1 Slump test

DEPT. OF CIVIL ENGG 2018-19 Page 10

4.1.2 COMPACTION FACTOR TEST (as per IS: 1199-1959)

W1 = weight of empty cylinder

W2 = weight of empty cylinder + partially compacted concrete

W3 = weight of empty cylinder + fully compacted concrete

Image 4.2 Compaction factor machine

DEPT. OF CIVIL ENGG 2018-19 Page 11

4.1.3 VEE BEE CONSISTOMETER TEST (as per IS: 1199-1959)

Vee bee degree,

Image 4.3 Vee-bee consistometer

DEPT. OF CIVIL ENGG 2018-19 Page 12

4.2 TESTS ON HARDENED CONCRETE

Image 4.4 Cube Compressive Test

DEPT. OF CIVIL ENGG 2018-19 Page 13

4.2.2 SPLITTING TENSILE STRENGTH TEST (As per IS: 5816-1999)

Split tensile strength (N/ mm2) = (2 x P) / (π X d X L)

Image 4.5 Split Tensile Strength of Specimen

4.2.3 DETERMINATION OF DENSITY OF CONCRETE

The density of concrete is determined in hardened state. The density of concrete is

DEPT. OF CIVIL ENGG 2018-19 Page 15

DEPT. OF CIVIL ENGG 2018-19 Page 16

5.3 TEST RESULTS OF MATERIALS

TABLE 5.1.1: Properties of Cement

Sl. No. Properties Results

1 Specific gravity 3.13

2 Fineness of cement 6.66%

3 Normal consistency 28%

4 Initial setting time 30 min

5 Final setting time 10 hrs

TABLE 5.2.1: Sieve Analysis of Fine Aggregates

Sl. No. IS sieve size (mm) Cumulative % passing

TABLE 5.2.2: Properties of Fine Aggregates

Sl. No. Properties Results

1 Bulking of fine aggregate 42%

2 Specific gravity 2.83

3 Bulk density Kg/ltr

DEPT. OF CIVIL ENGG 2018-19 Page 17