INFLUENCE OF FLY-ASH ON STRENGTH OF CONCRETE CONTAINING ISF SLAG A PROJECT REPORT Submitted in partial fulfilment of the requirement for the award of the degree of BACHELOR OF TECHNOLOGY In CIVIL ENGINEERING Submitted by

INFLUENCE OF FLY-ASH ON STRENGTH OF CONCRETE CONTAINING ISF SLAG

A PROJECT REPORT Submitted in partial fulfilment of the requirement for the award of the degree of BACHELOR OF TECHNOLOGY In CIVIL ENGINEERING

Submitted by: NEHA SRIVASTAVA GEETANSH SAWHNEY RAVI KUMAR NIKHIL CHARAN

Mentor: Dr. A. K. Vyas Head and Professor

DEPARTMENT OF CIVIL ENGINEERING MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY

JAIPUR (INDIA) MAY, 2013

DEPARTMENT OF CIVIL ENGINEERING MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY JAIPUR-302017 ______________________________________________________________________________

CANDIDATE’S DECLARATION

We hereby submit the project report entitled “Influence of fly-ash on strength of concrete containing ISF Slag” under the supervision of Dr. A.K. Vyas, Head of Department and Professor, Department of Civil Engineering, Malaviya National Institute of Technology, Jaipur. We declare that this report is a record of our original work.

NEHA SRIVASTAVA

GEETANSH SAWHNEY

(2009UCE197)

(2009UCE205)

RAVI KUMAR

NIKHIL CHARAN

(2009UCE229)

(2009UCE183)

The project report is hereby approved for submission. Date: 14/05/2013 (Prof. A. K. Vyas) Project Guide

FINAL YEAR PROJECT REPORT

Page 1

ACKNOWLEDGEMENT “It is not possible to prepare a project report without the assistance and encouragement of other people. This one is certainly no exception.” First of all, we are really thankful to our Project Guide Dr. A.K. Vyas, Head of Department and Professor, Department of Civil Engineering (DoCE), Malaviya National Institute of Technology (MNIT), Jaipur, and are ineffably indebted for his invaluable guidance, encouragement and assistance, without which the accomplishment of the project would have never been possible. We would also like to acknowledge with much appreciation the crucial role of the Dr. A. B. Gupta (Professor, DoCE, MNIT Jaipur), Dr. R. C. Gupta (Associate Professor, DoCE, MNIT Jaipur), Dr. Sandeep Choudhary (Associate Professor, DoCE, MNIT Jaipur) and the whole staff of Concrete Technology Laboratory, Road Material Testing Laboratory and Public Health Engineering (PHE) Laboratory, who gave the permission to use all required machinery and the necessary material. We are extremely grateful to all the Technicians and Staff Members of Soil Testing Laboratory, Rajasthan Agricultural Research Institute, Durgapura, Jaipur to help us in conducting Metal Leaching Tests at their facility. Any omission in this brief acknowledgement does not mean lack of gratitude.

Date: 14/05/2013 NEHA SRIVASTAVA-2009UCE197 RAVI KUMAR-2009UCE229


GEETANSH SAWHNEY-2009UCE205 NIKHIL CHARAN-2009UCE183

Page 2

ABSTRACT: This study presents the investigations of effect of fly-ash on concrete containing slag. Cement is a costly material and is used extensively for construction works all over the world. Replacing a certain fraction of cement by fly-ash contributes to the strength of concrete due to its pozzolanic reactivity. However, since pozzolanic reaction is slow, the initial strength is low. This pozzolanic reaction also makes the structure of concrete denser, resulting in decrease in water and gas permeability. Slag is generated during iron and steel production. The addition of slag reduces the rate of heat evolution and increases the resistance to chemical attack. It is made use of in hot regions due to less effect on early strength of concrete. The percentage of slag used also depends upon the aggregate. If the aggregate is highly reactive it would require more of the slag to mitigate ASR or alkali-silicate reaction. The project aims at studying the influence of these two important industrial wastes on the compressive strength of concrete. The methodology adopted for the test is the standard one taken up from Indian Standard code of concrete testing and for metal leaching a modified version of soil test is used. The test results obtained after 7 day and 28 day are then analyzed on the basis of their compressive strengths and leaching characteristics. The optimum value of slag and fly-ash is found which gives largest compressive strength. The more leaching takes place, more the porous structure is formed. Thus leaching values form an important part of the project. Slag and fly-ash available are low cost or zero cost materials and therefore can be used economizing the cost of project. Apart from economy it also saves the environmental cost of


Page 3

cement as it leads to a production of high amount of carbon dioxide that causes greenhouse effect. Concrete containing slag is effectively used in the construction of pavements as well as kerbs. This can save a lot of cost apart from being more environmentally sound. The strength is more than the normal control mix and the waste material is effectively utilized. The results of the test showed that the compressive strength increases with addition of slag whereas replacement of cement with fly-ash reduces the strength. In the metal leaching the lowest leaching is obtained for a mix of 20% fly-ash as a replacement of cement and 30% slag as replacement of fine aggregate. With addition of slag the leaching increases while flyash addition reduces the leaching. Keywords: ISF Slag, Fly-ash, Compressive Strength, Leaching, Waste Material.


Page 4

LIST OF TABLES:TABLE

TITLE

PAGE NO.

NO. 1

Physical Properties and Particle size distribution of ISF

15

slag Physical properties of ISF slag 2

Chemical composition of Sand and ISF slag

16

3

Property Determination of Materials Used

19-22

4

Mix Designs

22-29

5.1

Compressive Strength Test Results for All Mixes (7 Day 36-37 and 28 Day)

5.2

Detailed Test Results for Compressive Strength

38-39

6.1

Analysis of Mixes with 30 % Slag Replacement

50

6.2

Analysis of Mixes with 45 % Slag Replacement

51

7

Results of Metal Leaching Test

52

8

Cost Analysis of Mixes

57-59


Page 5

CONTENT TABLE: PAGE NO. Candidate’s Declaration

1

Acknowledgement

2

Abstract

3-4

List of Tables

5

CONTENTS

Chapter 1

Introduction

7

Chapter 2

Literature Survey

9

Chapter 3

Methodology a) Property of Materials

19

b)Mix Design

22 30

c)Tests Chapter 4

Results and Discussion

36

Chapter 5

Conclusions

60

Chapter 6

References and List of Websites

62

Appendix

64


Page 6

Chapter 1: INTRODUCTION ORIGIN OF THE PROBLEM: The rapid increase in the annual consumption of natural aggregates due to the expansion of the construction industry worldwide means that aggregate reserves are being depleted rapidly, particularly in desert regions. It has been reported that, if alternative aggregates are not utilized in the near future, the concrete industry will globally consume 8-12 billion tons of natural aggregates annually. Such large consumption of natural aggregates will cause destruction of the environment. Therefore, it is imperative that alternative substitutes for natural aggregates be found. One possibility is the utilization of industrial by-products and waste materials in making concrete, which will lead to a sustainable concrete design and a greener environment Concrete's potential contribution to a more sustainable world includes the possibility of using by-products from other industries that would otherwise pose awkward disposal problems. A new opportunity comes from the possible use in concrete of slags and other by-products from non-ferrous metal production. This could eventually mean an impressive double whammy, saving tax for the metal and construction industries, while helping the environment. Producers of such metals as zinc and aluminium currently pay millions to stockpile or send slag and unwanted by-products to landfill. If these were to prove viable as an aggregate, concrete manufacturers would then have a source of recycled material, exempt from the aggregates tax introduced earlier this year, while metal producers would no longer need to dump the material and pay landfill taxes and charges. Some papers have been published in this area:-


Page 7

[1] Shashidhara, S.M.S. and Vyas, A.K. Properties of cement concrete with Imperial smelting furnace slag as replacement of sand, Indian Concrete Journal, Vol.84, Nov 2010 [2] R. Hooper, C. McGrath, C. Morrison, and K. Lardner, FerroSilicate Slag from ISF Zinc Production as a Sand Replacement: A Review, Special Publication, Vol.209, 811-838, Sept-2002 [3] Tripathi, B., Misra, A., and Chaudhary, S. (2012). "Strength and Abrasion Characteristics of ISF Slag Concrete", Journal of Materials in Civil Engineering, American Society of Civil Engineers (ASCE) Journal, 10.1061/ (ASCE) MT.1943-5533.0000709 (Oct, 2012). [4] C. Morrison and D. Richardson, Re-use of zinc smelting furnace slag in concrete, Proceedings of the ICE - Engineering Sustainability, Volume 157, Issue 4, 213-218, December 2004. OBJECTIVES OF THE STUDY:

1. The project aims to study and analyze the variation in the compressive strength of concrete constituting a constant percentage of fly-ash (0%, 10% and 20%) by varying the slag percentage (30% and 45%) in the mix and develop Mix-Designs for M-15. 2. The impact of ISF Slag on compressive strength of concrete. 3. To determine the leaching of Heavy Metals (Zinc) from concrete at different age. 4. To carry out the Cost Analysis of Different Mixes containing ISF Slag. 5. To find the possible applications of concrete containing ISF Slag. FINAL YEAR PROJECT REPORT

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Chapter 2: LITERATURE SURVEY Properties of Materials:1. Cement: The cement often called the magic powder is a fine ground material consisting of compound of lime, silica alumina and iron. When mixed with water it forms a paste which hardened and bind the aggregates (sand, gravel, crushed rock, etc.) together to form a durable mass called the Concrete. Cement is the binder that holds concrete and mortars together, which is why it plays the most critical role in giving strength and durability to the building. Cement uses for domestic building such as home are basically of three types:Portland Slag Cement: Portland slag cement (PSC) conforming to IS: 455 A combination of good quality blast furnace slag (from the iron steel industry) with clinker (which makes the OPC) and gypsum. Portland Pozzolana Cement: Portland pozzolana cement (PCC) conforming to IS: 1489 A, combination of Fly ash (from thermal power plant) with clinker and gypsum. Pozzolana cement is prepared by grinding Portland cement clinker with pozzolana. This type of cement is largely used in marine structures. Ordinary Portland Cement: Ordinary Portland cement (OPC) 33 grade conforming to IS: 269, 43 grade conforming to IS: 8112 and 53 grade conforming to IS: 12269 (A) combination of clinker and gypsum of good quality. Ordinary Portland cement is manufactured by first burning at a very high temperature the mixture of calcareous (mainly calcium carbonate) and argillaceous (mainly clay) and then grinding the


Page 9

calcined product (i.e. clinker) with small amount of gypsum in to a fine powder known as ordinary Portland cement. Good quality cement has the following features:  Reduced water requirement  Improve Workability  Less permissible to moisture  Improved resistance to acid and chlorides  Reduced heat of hydration  Easier to finish  Reduced shrinkage.  Reduced leaching problems because it is low as free lime.

2. Sand These are cohesion less aggregates of either, rounded, sub rounded, angular, sub angular or flat fragments of more or less unaltered rock of minerals consisting of 90% of particles of size greater than 0.06 mm and less than 2 mm. Alternatively, these are coarse grained cohesion less particles of silica derived from the disintegration of rock. These are of three types: Coarse sand: It is one which contains 90% of particles of size greater than 0.6 mm and less than 2 mm. Medium sand: It is one, which contains 90and of particles of particles size greater than 0.2 mm and less than 0.6 mm.


Page 10

Fine sand: It is one, which contains 90% of particles of size greater than 0.06 mm and less than 0.2 mm. Proper selection of sand is critical in the durability and performance of concrete mixture. It should be: · Clear, angular and hard · Free from clay, mica and soft, flaky material · Graded, which means it should be a mix of fine, medium and coarse sand · Fee from contaminates like sea salt · Consistent in moisture (water) content, this should not exceed 7%. When mixing concrete the moisture content must be taken in to consideration. The price of sand includes three or four components base cost, transportation, handling and number of intermediaries. Procuring sand in bulk directly from the source will be cheaper. 3. Aggregates Aggregates is a general term applied to those inert (that chemically inactive) material, which when bounded together by cement, form concrete. Most aggregates used in this country are naturally occurring aggregates such as sand, crushed rock and gravel. Aggregates for concrete are divided into three categories: · Fine Aggregates: Most of which passes through 4.75 mm I.S. sieve and retained on 150micron. · Coarse Aggregates: Most of which passes through 63 mm I.S. sieve and retained on 4.75micron.


Page 11

· All in Aggregate: Mixed aggregate, as it comes from the pit or riverbed. It is sometimes used for unimportant work without separating into different sizes.

Properties of Natural Aggregates: The properties should comply with the norms laid down in IS: 38-1970 Specification for C.A. and F.A. from natural sources for concrete. Aggregates should be chemically inert, strong, hard, durable, of limited porosity (water absorption when immersed in water for 24 hours should not be more than 10%.), free from adherent coating, clay lumps, coal and coal residues and should contain no organic or other admixture that may cause corrosion of the reinforcement or impair the strength or durability of the concrete. The shape (rounded, irregular, angular and flaky) and sizes of the aggregates should conform to the strength and workability requirements. Uses of the Aggregates: 1. Naturally occurring crushed stone aggregates can be used for producing any type of good concrete or R.C.C. for construction purpose. 2. Broken brick aggregates is used to produce plain concrete but not suitable for R.C.C. which is lighter than broken stone aggregate. 3. Air- cooled blast furnace slag, which is a by- product in the process of pig iron, forms a stronger and durable concrete when mixed with sand, and has a high fire resistance. 4. Lightweight aggregate produce low density concrete, which can be used for interior parts of the building where high strength are not desired. FINAL YEAR PROJECT REPORT

Page 12

4. Fly-Ash It is a Pozzolan material which itself does not have any cementitious property but in finely divided form and in the presence of moisture chemically react with lime to form compounds having cementitious properties. It is a residue resulting from the combustion of powdered coal. Properties:

They gain strength slowly and require curing over a longer period of time.



The long term strength is high.



Used for economising the use of cement.



Classification by ASTM: Class F (having less than 5% CaO) and Class C (CaO content in excess of 10%).



Use of good quality fly-ash reduces the water demand.



With water reduction, bleeding and shrinkage will reduce.

5. Slag WHY USE FLY-ASH and SLAG REPLACEMENT? 

Fly-Ash and Slag are artificial Pozzolanic materials that improve the properties of concrete in both fresh and hardened state.



The calcium hydroxide formed after hydration of tri-calcium and di-calcium silicate reacts with finely divided siliceous or aluminous


Page 13

compounds in fly-ash to form highly stable cementitious substances. 

Pozzolan + Ca(OH)2 + water--- C-S-H gel



In India, we produce 75 million tons of fly-ash per year, the disposal of which is a serious environmental problem.



Economise the use of cement as cement production causes production of carbon dioxide into the atmosphere which is harmful for the environment. Properties of GGBS (Ground Granulated Blast Furnace Slag):-



Surface hydration of slag is slightly slower.



Reduces heat of hydration. Therefore good for use in mass structures.



Refinement of pore structures.



Reduces permeability.



Increased resistance to chemical attack.



Possesses cementitious properties.

ISF slag from the dump yard of Hindustan Zinc Ltd., Chanderiya Lead Zinc Smelter Complex Plant, Udaipur was used to replace sand in cement concrete mixes. The ISF slag was granular in nature with some lumps formed due to long period of dumping. The slag was sieved through 4.75 mm sieve to remove lumps before the use.


Page 14

Table 1: Physical Properties and Particle size distribution of ISF slag Physical properties of ISF slag Sr. No.

Physical property

Test Value

1

Specific Gravity

3.62

2

Water Absorption

0.35%

Particle size distribution of ISF slag Sr. No.

Sieve Size

% Passing

Cumulative % Retained

1

10mm

100

0

2

4.75 mm

99.6

0.40

3

2.36 mm

90.4

9.60

4

1.18 mm

57.7

42.30

5

600 μ

18.3

81.70

6

300 μ

3.7

96.30

7

150 μ

0.8

99.20

75 μ

8

Σ Cumulative %

0.3

329.5

retained Gradation of ISF slag

Zone I

as per IS 383

Fineness modulus of

3.295

ISF slag

Source: Shashidhara, S.M.S. and Vyas, A.K. Properties of cement concrete with Imperial smelting furnace slag as replacement of sand, Indian Concrete Journal, Vol.84, Nov 2010. Chemical Composition of Sand and ISF slag: The elemental composition of sand was determined at the IIC, IIT Roorkee, by energy dispersive X-Ray analysis (EDAX). The Oxide composition of elements present in ISF slag determined by X-Ray fluorescence (XRF) was supplied. The chemical composition of sand and ISF slag are as shown in Table 2.


Page 15

Table 2: Chemical composition of Sand and

XRF of ISF slag

ISF slag (EDAX of Sand) Element

% by weight

Constituent detected

% content

C

11.91

SiO2

18.08

O

42.53

Fe2O3

34.28

Na

02.53

Al2O3

8.17

Al

06.91

CaO

17.91

Si

29.92

MgO

1.93

K

03.19

Na2O

0.68

Ca

01.16

K2O

0.71

Fe

01.85

Mn2O3

1.33

ZnO

9.21

PbO

1.22

Sulphide Sulphur

1.41

Insoluble residue

6.28

Loss on ignition (LOI)

(+)5.68

Source: Tripathi, B., Misra, A., and Chaudhary, S. (2012). "Strength and Abrasion Characteristics of ISF Slag Concrete", Journal of Materials in Civil Engineering, American Society of Civil Engineers (ASCE) Journal, 10.1061/ (ASCE) MT.1943-5533.0000709 (Oct, 2012). A variety of reports for use of ISF Slag in concrete as a replacement of slag have been written and reported in literature. A brief survey of the research work done in this area is discussed below:I. Shashidhara, S.M.S. and Vyas, A.K. [1] reported the results of replacing sand in cement concrete using imperial smelting furnace Zinc slag in Indian Concrete Journal. The fine aggregate fraction so produced conformed to the grading requirements of both fine aggregate and all in aggregate. The


Page 16

workability of concrete improved as the replacement level increased, though the packing density of the dry all-in aggregate reduced. Replacing sand with zinc slag did not affect the compressive strength, but in a leaching test, complete replacement resulted in Lead (Pb) setting leached above the permissible level. II. Hooper, R. et al. [2] focussed on setting characteristics of ISF Slag, the effect of fly-ash in minimising retardation of set as well as the European policies for reuse of secondary materials. According to them, the UK Ten Year Transport Plan, including the development of the highway infrastructure, offers opportunities to successfully demonstrate the consumption of small volume streams of secondary materials, including ISF slag, within the local area. Pavement construction offers several opportunities for consumption, the most credible of these being the replacement of the sand fractions by the slag in bound mixtures, cement and bituminous. The paper focused upon cementitious mixtures alone. The presence of zinc and lead ions in the ISF slag were proven to have an impact on the setting characteristics of concrete mixtures, although there is little difference in the compressive strengths after 28 days. The leaching, characteristics of the slag suggested that the retardation is not linearly related to the quantities of zinc or lead leached. Additionally, leaching tests in combination with pulverised fuel ash (fly ash) and ground granulated blast furnace slag indicated that it may be possible to minimise retardation of set in by including these materials in the concrete mixture. III. Tripathi, B. et al. [3] assessed the strength and abrasion characteristics of ISF Slag Concrete. In their paper they assessed the potential of ISFS (Imperial


Page 17

Smelting Furnace Slag) as sand in concrete, considering the presence of toxic elements (lead and zinc) and their detrimental effects on the early hydration of cement. Equivalent volume of sand was replaced by ISFS in different percentages. Concrete specimens were prepared at different water to cement ratios. Compressive, flexural, and pull—off strength, along with abrasion resistance, were examined. Leaching potentials of toxic lead, zinc, and cadmium from ISFS concrete mixtures were also analyzed to evaluate environmental viability. Their Results were encouraging because sign of delay in setting was not observed. Improvement in compressive and pull—off strength; comparable flexural strength and abrasion resistance; and, leaching of toxic elements within safe limits assured the potential of future use of the ISFS as sand in concrete. IV. Morrison, C. and Richardson, D.[4] in their paper ―Re-use of zinc smelting furnace slag in concrete‖ studied environmental concerns associated with the reuse of ISF Slag concrete due to the presence of heavy metals like Zinc and Lead. They concluded that the ISF slag is physically suitable for use as an aggregate, although there are several barriers that need to be overcome before it can be used in concrete. The paper also reported that the glassy nature of the slag initially raised concerns regarding the potential for alkali–silica reaction (ASR) to occur in concrete. But after a comprehensive series of accelerated ASR tests indicated that the material was not susceptible to this type of deleterious reaction.


Page 18

Chapter 3: METHODOLOGY The properties of material used, that is, fineness modulus and specific gravity using pycnometer, of sand and slag as well as the sieve analysis of fine and coarse aggregates was determined in the laboratory. Grading curves as well as the underlying zones for the fine aggregate and slag were also determined. The compressive strength tests have been carried out using the standard procedure as prescribes in the code IS 516:1959. The Metal Leaching Test was also conducted for different mixes. TABLE 3. PROPERTY DETERMINATION OF MATERIAL USED: Based on the tests conducted in the Concrete Technology Laboratory:PROPERTY DETERMINATION 1. SLAG FINENESS MODULUS SIEVE SIZE

Retained in gm.

% Retained

Cumulative % retained

4.75mm

9.5

0.95

0.95

2.36mm

42

4.2

5.15

1.18mm

242

24.2

29.35

600 micron

326

32.6

61.95

300 micron

311

31.1

93.05

150 micron

53

5.3

98.35

75 micron

11

1.1

99.45

Residual

5.5

0.55

100

FINENESS MODULUS

3.8825

2. SPECIFIC GRAVITY WEIGHT OF PYCNOMETER(M1) WEIGHT OF


684.5 1565.5

Page 19

PYCNOMETER+WATER(M2) WEIGHT OF PYC.+ WATER+SLAG(M3)

1927.5

WEIGHT OF SLAG(M4) SPECIFIC GRAVITY

500 (M4)/(M4-(M3-M2)) 3.62

2. FINE AGGREGATES(SAND)

FINENESS MODULUS SIEVE SIZE

Retained in gm.

% Retained


4.75mm

28.5

2.85

2.85

2.36mm

12.5

1.25

4.1

1.18mm

56

5.6

9.7

600 micron

125

12.5

22.2

300 micron

621.5

62.15

84.35

150 micron

115

11.5

95.85

75 micron

21.5

2.15

98

20

2

100

RESIDUAL

FINENESS MODULUS

3.1705

2. SPECIFIC GRAVITY WEIGHT OF PYCNOMETER(M1)

684.5

WEIGHT OF PYCNOMETER+WATER(M2)

1565.5

WEIGHT OF PYC.+ WATER+SLAG(M3)

1869.5


500 (M4)/(M4-(M3-M2)) 2.55

3. COARSE AGGREGATE SPECIFIC GRAVITY(10mm) WEIGHT OF PYCNOMETER(M1)


684.5

Page 20


1565.5


1880.5


500 (M4)/(M4-(M3-M2)) 2.7

SPECIFIC GRAVITY(20mm) WEIGHT OF PYCNOMETER(M1)

684.5


1565.5


1876.5


500 (M4)/(M4-(M3-M2)) 2.645

SAND + ISF SLAG (30%) FINENESS MODULUS SIEVE SIZE

Retained in gm.

% Retained


4.75mm

11

1.1

1.1

2.36mm

18

1.8

2.9

1.18mm

113.5

11.35

14.25

600 micron

179.5

17.95

32.2

300 micron

508

50.8

83

150 micron

132.5

13.25

96.25

75 micron

28.5

2.85

99.1

9

0.9

100

Residual

328.8 FINENESS MODULUS LIMIT for Z-II 2.78-3.37

3.288

Therefore the sand corresponds to zone 2

SAND + ISF SLAG (45%) FINENESS MODULUS


Page 21

SIEVE SIZE

Retained in gm.

% Retained


4.75mm

13

1.3

1.3

2.36mm

21.5

2.15

3.45

1.18mm

151.5

15.15

18.6

600 micron

226

22.6

41.2

300 micron

441.5

44.15

85.35

150 micron

121

12.1

97.45

75 micron

22.5

2.25

99.7

3

0.3

100

Residual

347.05 FINENESS MODULUS LIMIT for Z-I 3.37-4

3.4705

Therefore the sand corresponds to zone 1

TABLE 4. MIX DESIGNS: MIX-DESIGN -1 SPECIFICATIONS 1. GRADE

M15

2. FLY-ASH

10%

3. SLAG(HIGH)

30.00%

4.SPECIFIC GRAVITY a. FINE AGGREGATE


2.55

Page 22

b. COARSE AGGREGATE

2.645

c. FLY-ASH

2.2

d. CEMENT

3.15

e. SLAG

3.62

DETERMINATION OF TARGET MEAN STRENGTH TARGET MEAN STRENGTH W/C Ratio

20.775 0.56

(OPC 43 -FIGURE 2)

CORRECTIONS PERCENT SAND IN TOTAL CHANGE IN CONDITION

W/C

AGG.

FOR SAND CONFIRMING TO ZONE 2

0

0

FOR C.F.(0.8)

0

0

FOR DECREASE IN W/C RATIO 0.56 FROM .6

0

-0.8

TOTAL

0

-0.80%

FINE AGGREGATE

35%-0.8%=34.2%

COARSE AGGREGATE

65.80%

WATER

186

MASS OF CEMENT

301.94

MASS OF FLY ASH

30.194

VOLUME OF CONCRETE

1

VOLUME OF CEMENT

0.095

VOLUME OF FLYASH

0.0137

VOLUME OF WATER

0.186

VOLUME OF ALL AGG.

0.7053

MASS OF C.A.

1227.511173

MASS OF F.A. (SAND)

430.56

MASS OF FA (ISF SLAG)

261.94

ALL IN Kg/cum

IN cum

MIX-DESIGN -2 SPECIFICATIONS 1. GRADE

M15

2. FLY-ASH

10%


Page 23

3. SLAG(HIGH)

45.00%


2.55

b. COARSE AGGREGATE

2.645

c. FLY-ASH

2.2

d. CEMENT

3.15

e. SLAG

3.62


20.775 0.56

(OPC 43 -FIGURE 2)


W/C

AGG.


0

1.5

FOR C.F.(0.8)

0

0


0

-0.8

TOTAL

0

0.70%

FINE AGGREGATE

35%+0.7%=35.7%

COARSE AGGREGATE

64.30%

WATER

186

MASS OF CEMENT

301.94

MASS OF FLY ASH

30.194

VOLUME OF CONCRETE

1

VOLUME OF CEMENT

0.095

VOLUME OF FLYASH

0.0137

VOLUME OF WATER

0.186

VOLUME OF ALL AGG.

0.7053

MASS OF C.A.

1199.528396

MASS OF F.A. (SAND)

353.138


410.16

ALL IN Kg/cum

IN cum

MIX-DESIGN -3


Page 24

SPECIFICATIONS 1. GRADE

M15

2. FLY-ASH

20%

3. SLAG(HIGH)

30.00%


2.55

b. COARSE AGGREGATE

2.645

c. FLY-ASH

2.2

d. CEMENT

3.15

e. SLAG

3.62


20.775 0.56

(OPC 43 -FIGURE 2)


W/C

AGG.


0

0

FOR C.F.(0.8)

0

0


0

-0.8

TOTAL

0

-0.80%

FINE AGGREGATE

35%-0.8%=34.2%

COARSE AGGREGATE

65.80%

WATER

186

MASS OF CEMENT

276.7857143

MASS OF FLY ASH

55.35

VOLUME OF CONCRETE

1

VOLUME OF CEMENT

0.0879

VOLUME OF FLYASH

0.0252

VOLUME OF WATER

0.186

VOLUME OF ALL AGG.

0.7010

MASS OF C.A.

1219.979424

MASS OF F.A. (SAND)

427.9226383


260.3495716


ALL IN Kg/cum

IN cum

Page 25


M15

2. FLY-ASH

20%

3. SLAG(HIGH)

45.00%


2.55

b. COARSE AGGREGATE

2.645

c. FLY-ASH

2.2

d. CEMENT

3.15

e. SLAG

3.62


20.775 0.56

(OPC 43 -FIGURE 2)


W/C

AGG.


0

1.5

FOR C.F.(0.8)

0

0


0

-0.8

TOTAL

0

0.70%

FINE AGGREGATE

35%+0.7%=35.7%

COARSE AGGREGATE

64.30%

WATER

186

MASS OF CEMENT

276.7857143

MASS OF FLY ASH

55.35

VOLUME OF CONCRETE

1

VOLUME OF CEMENT

0.0879

VOLUME OF FLYASH

0.0252

VOLUME OF WATER

0.186

VOLUME OF ALL AGG.

0.7010


ALL IN Kg/cum

IN cum

Page 26

MASS OF C.A.

1192.168343

MASS OF F.A. (SAND)

350.9716376


407.6526186

MIX-DESIGN -M15 CONTROL MIX SPECIFICATIONS (AS FLYASH 1. GRADE

M15

and SLAG-0%)


2.55

b. COARSE AGGREGATE

2.645

d. CEMENT

3.15


20.775 0.56

(OPC 43 -FIGURE 2)


W/C

AGG.


0

0

FOR C.F.(0.8)

0

0


0

-0.8

TOTAL

0

-0.80%

FINE AGGREGATE

35%-0.8%=34.2%

COARSE AGGREGATE

65.20%

WATER

186

MASS OF CEMENT

332.1428571

VOLUME OF CONCRETE

1

VOLUME OF CEMENT

0.1054

VOLUME OF WATER

0.186

VOLUME OF ALL AGG.

0.7086

MASS OF C.A.

1233.181121


ALL IN Kg/cum

IN cum

Page 27

MASS OF F.A.

617.9332776


M15

2. FLY-ASH

0%

3. SLAG(HIGH)

30.00%


2.55

b. COARSE AGGREGATE

2.645

c. FLY-ASH

2.2

d. CEMENT

3.15

e. SLAG

3.62


20.775 0.56

(OPC 43 -FIGURE 2)


W/C

AGG.


0

0

FOR C.F.(0.8)

0

0


0

-0.8

TOTAL

0

-0.80%

FINE AGGREGATE

35%-0.8%=34.2%

COARSE AGGREGATE

65.80%

WATER

186

MASS OF CEMENT

332.1428571

VOLUME OF CONCRETE

1

VOLUME OF CEMENT

0.1054

VOLUME OF WATER

0.186

VOLUME OF ALL AGG.

0.7086

MASS OF C.A.

1233.181121


ALL IN Kg/cum

IN cum

Page 28

MASS OF F.A. (SAND)

432.5532943


263.1668782


M15

2. FLY-ASH

0%

3. SLAG(HIGH)

45.00%


2.55

b. COARSE AGGREGATE

2.645

c. FLY-ASH

2.2

d. CEMENT

3.15

e. SLAG

3.62


20.775 0.56

(OPC 43 -FIGURE 2)


W/C

AGG.


0

1.5

FOR C.F.(0.8)

0

0


0

-0.8

TOTAL

0

0.70%

FINE AGGREGATE

35%+0.7%=35.7%

COARSE AGGREGATE

64.30%

WATER

186

MASS OF CEMENT

332.1428571

VOLUME OF CONCRETE

1

VOLUME OF CEMENT

0.1054

VOLUME OF WATER

0.186

VOLUME OF ALL AGG.

0.7086


ALL IN Kg/cum

IN cum

Page 29

MASS OF C.A.

1205.069089

MASS OF F.A. (SAND)

354.7695879


412.0639277

TESTS 1. Compressive Strength Test The project aims at determination of concrete compressive strength after adding a certain percentage of fly-ash and slag in the concrete. The compressive strength test as specified in the code IS 516:1959 was used. 

At the onset, Mix designs were done on paper using code IS 10262:1982.



By the mix design we obtain the total amount of cement, sand, aggregate required along with a specified % of slag and Fly-ash per cubic metre.



We then calculate the total quantity of material required for 9 cubes per mix design. (3 cubes for 7 day testing, 3 for 28 days testing and 1 for Metal Leaching Test and 2 for long term tests).



Each cube is of 15*15*15 cm in size. Thus total volume of material is calculated.



Casting is done using the standard procedure (see Appendix).



Compressive strength Testing is done after 7 and 28 days and Metal Leaching Test is done after 28 Days.


Page 30



Results obtained are noted and graphs are plotted showing the strength variation.

FIG 1. CASTED CONCRETE CUBES

FIG 2. DEVELOPMENT OF CRACKS IN CONCRETE CUBES AFTER COMPRESSIVE STRENGTH TEST


Page 31

2. METAL LEACHING TEST Source: Method Developed by Dr. Ajay S. Kalamadhad, Assistant Professor, IIT Guwahati for Metal Leaching Test in Soil Compost (As told by a student of II Year M.Tech (Environmental Engineering), MNIT Jaipur). The metal leaching test was carried out to find the leaching of metals especially zinc after 28 days of curing the cube. The test aims at understanding the durability aspect of the cube and its strength as a heavy amount of leaching reduces the durability of the cube in adverse environmental situation. The steps for testing are as follows: 1. Concrete cube is first crushed in the compression testing machine. 2. To further crush the concrete, aggregate impact testing machine is used. 3. The residue from the impact testing machine is then passed through a sieve of 250 micron. 4. The material passing through 250 micron sieve is weighed to 0.6 grams in a sensitive balance. 5. The material is then put into the flask of the extracting unit and is heated to 60-70 degree Celsius.


Page 32

6. 7.5 ml of HCl and 7.5 ml of H2SO4 is then added to the flask resulting in white fumes and then are allowed to react for 15-20 min until black fumes emerge out. 7. Add H2O2 drop by drop till brown fumes emerge out of the mix. Keep adding peroxide for 3-4 times. 8. The mixture is allowed to digest and then allowed to cool after which a yellow colour is obtained which shows the completion of digestion. 9. Dilute the mix to 100 ml and filter it with What Mann paper no. 42. 10. Obtain the filtrate for further test of metal leaching on AAS (Atomic Absorption Spectrophotometer). The test was carried out at Soil Testing Laboratory, Rajasthan Agriculture Research Institute, Durgapura, Jaipur, Rajasthan.

FIG 3. CRUSHING OF CONCRETE USING AGGREGATE IMPACT TESTING MACHINE


Page 33

FIG 4. FINELY CRUSHED CONCRETE PASSING THROUGH 250 MICRON

FIG 5. SENSITIVE WEIGHING BALANCE


Page 34

FIG 6. EXTRACTION UNIT

FIG 7. HCL, H2SO4 andH2O2

BOTTLES

FIG 8. (42) NO.WHATMANN PAPER


Page 35

Chapter 4: RESULTS and DISCUSSION The compressive strength was determined for the cubes at the end of 7 and 28 days. The graphs were developed between the compressive strength and the percentage of fly-ash keeping slag as constant and percentage of slag keeping fly-ash as constant for both 7 and 28 days separately. The metal leaching test was carried on at the end of 28 days in the PHE laboratory. The procedure of the test is stated under the heads below. The leaching test showed the influence of fly-ash in controlling the leaching which increases with increase in slag content.

TABLE 5.1 Compressive Strength Test Results for All Mixes (7 Day and 28 Day): S. NO.

MIX DESIGN

7-Day Strength (in

28 Day Strength (in

N/mm2)

N/mm2)

1

M-15 Control Mix

12.33

18.67

2

0% F.A.-30% Slag

17.11

23.26 ( 22 Day strength)*

3

0% F.A.-45% Slag

20.41

29.93 ( 20 day strength )*

4

10% F.A.-30% Slag


15.4

17.32

Page 36

5

10% F.A.-45% Slag

16.07

20.60

6

20% F.A.-30% Slag

16.47

20.67

7

20% F.A.-45% Slag

15.32

21.25

*- Due to paucity of time we were not able to measure the value of Compressive Strength at 28 days for the two mixes.


Page 37

TABLE 5.2 DETAILED TEST RESULTS FOR COMPRESSIVE STRENGTH:

S. No.

CASTING

CURING

7 DAY ( in N/ sq.

28 DAY ( in N/ sq.

DATE

DATE

mm)

mm)

13-Mar

14-Mar

16

18.67

17.77

15.78

12.44

17.5

15.40

17.31

12.44

19.33

17.11

18.67

18.67

23.78

16.07

20.59

16.55

20

16.33

22

16.55

20

16.47

20.67

18

21.55

11.5

19.33

16.44

22.88

15.31

21.25

13.7

17.11

MIX DESIGN 10% FLY-ASH, 30%

1

SLAG

Average Strength

10% FLY-ASH, 45% 2

SLAG

14-Mar

15-Mar

Average Strength

20% FLY-ASH, 30% 3

SLAG

15-Mar

16-Mar

Average Strength

20% FLY-ASH, 45% 4

SLAG

03-Apr

04-Apr

Average Strength

5

CONTROL MIX


12-Mar

13-Mar

Page 38

M15 11.9

19.11

11.4

19.77

12.33

18.66

17.77

23.56

16

24.89

17.55

21.33

17.10

23.26*

20.777

29.78

19.8889

31.56

20.555

28.44

20.40

29.93*

Average Strength

0% FLY-ASH,30% 6

SLAG

17-Apr

18-Apr

Average Strength

0% FLY-ASH, 45% 7

SLAG

19-Apr

20-Apr

Average Strength *-THE VALUES AS NOTED ON 10/05/2013


Page 39

GRAPHICAL RESULTS and ANALYSIS OF COMPRESSIVE STRENGTH TESTS: The graphs were developed between the compressive strength and the percentage of fly-ash keeping slag as constant and percentage of slag keeping fly-ash as constant for both 7 and 28 days separately. GRAPH 1 : Keeping Fly Ash Content Constant-10% Y-Axis: Compressive strength ( N/mm2)

7 DAY STRENGTH 20 15 10 5 0

CONTROL MIX

30% SLAG, 10% F.A.

45% Slag, 1 F.A.

COMMENTS:

As % of slag increases, strength increases. Slag makes the structure of concrete denser.


Page 40

GRAPH 2: Keeping Fly Ash Content Constant-20% Y-Axis: Compressive strength ( N/mm2)

COMMENTS:

There is a marginal decrease when slag is changed from 30 to 45 %. The presence of excess slag leads to formation of gelatinous precipitates that retards the process of hydration and strength decreases only gradually.


Page 41

GRAPH 3: Keeping Slag Content Constant-30% Y-Axis: Compressive strength ( N/mm2)

7 Day Strength 20 15

10 5 0

Control Mix 0% F.A.- 10 % F.A Addition of fly-ash increases the strength due to pozzolanic action in the 30% Slag 30 % Sla

COMMENTS:

presence of moisture.


Page 42


7 Day Strength 25 20 15 10 5 0 Control Mix

0 % F.A.- 45 10 % F.A.-45 20% F.A % Slag % Slag % Sla

COMMENTS:

There is a marginal decrease in the strength due to increase in fly ash as the cement content reduces.



This behaviour is opposite to the case when the strength increase was seen with 20% fly-ash and 30% slag. However it is only within 15 % error range and since concrete behaves in a non-linear fashion the error is not significant.


Page 43


COMMENTS:

With addition of slag the strength of mix increases rapidly but the strength increase from 30% addition to 45% addition is slow due to presence of excess of metal ions forming gel substances affecting retardation.


Page 44


COMMENTS:On the addition of fly-ash to the control mix the quantity of cement decreases thereby decreasing the strength of mix. But once the fly-ash is constant replaced, the addition of more slag increases the packing of materials and increases the strength.


Page 45


COMMENTS:The rate of increase of strength with 20% FA and 30% slag is more as compared to the rate when slag is 45%. This is due to the presence of large amount of zn ions that form gelatinous precipitate and prevent the hydration of cement at the desired rate. The anomaly obtained in between the graphs is due to the nonlinear behaviour of concrete. However it is well within the 15% range.


Page 46


COMMENTS:Addition of slag increases the strength of the mix, but when cement is replaced by fly-ash strength reduces. But with further addition of fly-ash and reduction of cement content the strength increases due to the pozzolanic action of fly-ash which helps in formation of cementitious products.


Page 47

GRAPH 9: Keeping Fly Ash Content Constant-0% Y-Axis: Compressive strength (N/mm2)

COMMENTS:As the slag content increases the strength of the mix increases due to better packing of material in the mix that becomes dense by slag addition.


Page 48


COMMENTS:Addition of slag increases the strength of the mix, but when cement is replaced by fly-ash strength reduces. But with further addition of fly-ash and reduction of cement content the strength increases due to the pozzolanic action of fly-ash which helps in formation of cementitious products.


Page 49

ANALYSIS OF RESULTS: TABLE 6.1 ANALYSIS OF MIXES WITH 30 % SLAG REPLACEMENT: S.NO.

% Slag and

STRENGTH

Flay-ash

( 7 Day)

1

Control Mix

12.33

2

30% Slag+0%

17.11

Fly-Ash

REMARKS

REASONS

Replacing fine

As compared to Fine Agg.

aggregate with slag

Slag makes the concrete

increases the strength

structure more dense reducing

by 38.76%.

permeability and excess voids.

3

30% Slag+ 10%

15.40

Fly-Ash

Replacing 10% cement

Fly ash addition reduces the

with fly ash reduces

cement content therefore

strength of slag cement

reducing strength.

concrete. 4

30% Slag+ 20%

16.47

Fly-Ash

Replacing 20% cement

Thought fly ash addition leads

reduces strength of

to increase in pozzolanic

concrete.

activity but initial strength is lower than that of slag cement as pozzolanic activity is a slow process.

SUMMARY: For 7-day strength concrete containing only 30% slag+ 0% Fly ash gives best results. REASON: Addition of fly-ash does not lead to increase in strength because: 

There is a reduction in the cement content.



Fly-Ash does not contribute in initial strength as pozzolanic activity proceeds slowly.


Page 50

TABLE 6.2 ANALYSIS OF MIXES WITH 45 % SLAG REPLACEMENT:

S. No.

% Slag and Flay-

STRENGTH

ash

( 7 Day)

1

Control Mix

12.33

2.

45% Slag+0%

20.4

Fly-Ash

REMARKS

REASONS

As the fine

Slag addition

aggregate is

makes the

replaced by slag,

concrete more

the strength

dense and reduces

increases by

permeability.

65.45 %. 3.

45% Slag+10%

16.07

Fly-Ash

With 10% cement

Cement content

replacement with

reduces and

fly-ash strength

strength reduces.

reduces. 4.

45% Slag+20%

15.32

Fly-Ash

With 20%

With more

addition of fly-

reduction in

ash, strength gets

cement content

reduced by

and with addition

24.24% as

of fly-ash the

compared to

strength further

control mix.

goes down.

SUMMARY: 

For 7 day strength a higher % of slag, i.e., 45% gives more strength as compared to 30% slag.



Addition of fly-ash reduces early strength as pozzolanic action proceeds slowly. Therefore this is not used at places where high early strength is required.


Page 51

TABLE 7. RESULTS OF METAL LEACHING TEST: S.NO

MIX

Zn

Absorptivity

Transmittance

4.97

0.908

12.3

5.17

0.944

11.3

4.92

0.859

12.6

5.10

0.907

11.7

4.89

0.893

12.8

5.01

0.915

12.1

(ppm)

1

0% F.A.30% slag

2

0%F.A.-45% Slag

3

10% F.A.30%Slag

4

10%F.A.45%Slag

5

20%F.A.30% Slag

6

20%F.A.45% Slag

SOURCE: Tests Conducted at STL, RARI Durgapura, Jaipur


Page 52

GRAPHICAL ANALYSIS OF METAL LEACHING TESTS:GRAPH 11: Y-Axis: Zinc Leaching ( p.p.m.)

COMMENTS:- Zinc Metal Leaching is decreasing with increase in Fly ash Content in the Concrete which shows that the presence of Fly Ash in the concrete containing ISF Slag, retards the process of leaching of metals. GRAPH 12: Y-Axis: Zinc Leaching ( p.p.m.)

COMMENTS:- Here also, the same behaviour is observed as was observed in 30 % Slag Replacement case. Zinc Metal Leaching is decreasing with increase in Fly ash


Page 53

Content in the Concrete which shows that the presence of Fly Ash in the concrete containing ISF Slag, retards the process of leaching of metals. GRAPH 13:

COMMENTS:- For Absorptivity, a Non-Linear Behaviour is observed for different Fly Ash contents for a constant perecentage (30 %) of ISF Slag as a replacement of Fine Aggregate. GRAPH 14:


Page 54

COMMENTS:- For Absorptivity, a Non-Linear Behaviour is observed for different Fly Ash contents for a constant perecentage (45 %) of ISF Slag as a replacement of Fine Aggregate. GRAPH 15:

COMMENTS:- An almost Linear Relationship is obtained between Tramittance and varying Percentages of Fly Ash for a constant replacement (30 %) of ISF Slag as a Fine Aggregate. GRAPH 16:


Page 55

COMMENTS:- A Linear Relationship is obtained between Tramittance and varying Percentages of Fly Ash for a constant replacement (45 %) of ISF Slag as a Fine Aggregate.


Page 56

TABLE 8. COST ANALYSIS OF MIXES: COST ANALYSIS FOR DIFFERENT MIXES TOTAL VOLUME OF CONCRETE

1 cum

(NOT INVOLVING TRANSPORTATION COST, COST OF WATER and SLAG)

CURRENT MARKET RATES OF BUILDING MATERIALS (IN RUPEES)

CEMENT

275

per bag

1520

per cum

10 mm

1140

per cum

20 mm

1000

per cum

RIVER SAND COARSE AGGREGATE

SLAG

0

FLY ASH (F.A.)

1.8

WATER

(WASTE PRODUCT) per kg

0

QUANTITY FOR MATERIALS IN FOLLOWING UNITS:

CEMENT

BAGS

RIVER SAND

cum

COARSE AGGREGATE 10 mm

cum

20 mm

cum

SLAG

cum

FLY ASH (F.A.)

kg

WATER

cum

S.NO

TYPE OF MIX

ITEMS

CONTROL MIX

CEMENT

1

QUANTITY

RATE

COST

6.6428

275

1826.77

SAND

0.342

1520

519.84

C.A. 10

0.329

1140

375.06


Page 57

C.A. 20

0.329

1000

329

SLAG

0

0

0

FLYASH

0

1.8

0

0.186

0

0

WATER

TOTAL COST

2

0 % F.A. 30 % SLAG

3050.67

CEMENT

6.6428

275

1826.77

SAND

0.2394

1520

363.888

C.A. 10

0.329

1140

375.06

C.A. 20

0.329

1000

329

SLAG

0.1026

0

0

0

1.8

0

0.186

0

0

FLYASH WATER

TOTAL COST

3

0 % F.A. 45 % SLAG

CEMENT

2894.718

6.6428

275

1826.77

SAND

0.19635

1520

298.452

C.A. 10

0.3215

1140

366.51

C.A. 20

0.3215

1000

321.5

SLAG

0.16065

0

0

0

1.8

0

0.186

0

0

FLYASH WATER

TOTAL COST

4

10 % F.A. 30 % SLAG

2813.232

CEMENT

6.0388

275

1660.67

SAND

0.2394

1520

363.888

C.A. 10

0.329

1140

375.06

C.A. 20

0.329

1000

329

SLAG

0.1026

0

0

FLYASH

30.194

1.8

54.3492

WATER

0.186

0

0

TOTAL COST

5

10 % F.A. 45 % SLAG

CEMENT


6.0388

2782.967

275

1660.67

Page 58

SAND

0.19635

1520

298.452

C.A. 10

0.3215

1140

366.51

C.A. 20

0.3215

1000

321.5

SLAG

0.16065

0

0

FLYASH

30.194

1.8

54.3492

WATER

0.186

0

0

TOTAL COST

6

20 % F.A. 30 % SLAG

CEMENT

2701.481

5.535

275

1522.125

SAND

0.2394

1520

363.888

C.A. 10

0.329

1140

375.06

C.A. 20

0.329

1000

329

SLAG

0.1026

0

0

FLYASH

55.35

1.8

99.63

WATER

0.186

0

0

TOTAL COST

7

20 % F.A. 45 % SLAG

CEMENT

2689.703

5.535

275

1522.125

SAND

0.19635

1520

298.452

C.A. 10

0.3215

1140

366.51

C.A. 20

0.3215

1000

321.5

SLAG

0.16065

0

0

FLYASH

55.35

1.8

99.63

WATER

0.186

0

0

TOTAL COST


2608.217

Page 59

Chapter 5: CONCLUSIONS After conducting the tests of compressive strengths on concrete with varying percentages of Fly Ash and Slag, the following conclusions were obtained: 1. With the addition of slag in the control Mix, the strength increases. 2. The addition of fly-ash reduces the early stage strength due to slower pozzolanic action. 3. The most optimum strength is obtained at a mix of: 7 day: 0% Fly Ash and 45% slag. 28 day: 0% Fly Ash and 45% slag. 4. According to the leaching test the lowest amount of leaching was obtained for a mix of 20% fly-ash as a replacement of cement and 30% slag as a replacement of fine aggregate. The increase in slag content increases the leaching as more amount of zinc is present. The addition of fly-ash reduces the leaching due to pozzolanic reaction that helps in formation of C-S-H gel making the structure denser and compact thus helping in the improvement of durability and strength. 5. According to cost analysis: the Lowest Cost is for mix: 20% Fly Ash and 45 % Slag (Rs. 2608.217 for Materials required for preparing 1 cum of Same Mix). and the Highest Cost is for Control Mix (Rs. 3050.67 for Materials required for preparing 1 cum of Same Mix). 6. The best possible applications of using slag is : a.) Concrete pavements b.) Structures and foundations ( dense structure and reduced permeability)


Page 60

c.) Mass concrete applications such as dams and retaining walls ( due to low heat of hydration and thermal stress mitigation) d.) Precast and pre-stressed concrete. e.) Concrete blocks and pipes. f.) Concrete exposed to harsh environment such as waste water treatment and marine applications. g.) High performance or high strength concrete such as a high rise building or 100 year service life bridges.


Page 61

Chapter 6: REFERENCES and LIST OF WEBSITES JOURNAL REFERENCES:[1] Shashidhara, S.M.S. and Vyas, A.K. Properties of cement concrete with Imperial smelting furnace slag as replacement of sand, Indian Concrete Journal, Vol.84, Nov 2010 [2] R. Hooper, C. McGrath, C. Morrison, and K. Lardner, FerroSilicate Slag from ISF Zinc Production as a Sand Replacement: A Review, Special Publication, Vol.209, 811-838, Sept-2002 [3] Tripathi, B., Misra, A., and Chaudhary, S. (2012). "Strength and Abrasion Characteristics of ISF Slag Concrete", Journal of Materials in Civil Engineering, American Society of Civil Engineers (ASCE) Journal, 10.1061/ (ASCE) MT.1943-5533.0000709 (Oct, 2012). [4] C. Morrison and D. Richardson, Re-use of zinc smelting furnace slag in concrete, Proceedings of the ICE - Engineering Sustainability, Volume 157, Issue 4, 213-218, December 2004.


Page 62

LIST OF WEB MATERIAL REFERRED:-

1. http://www.scribd.com/doc/127009062/Strength-and-AbrasionCharacteristics-of-ISF-Slag-Concrete 2. http://www.concrete.org/PUBS/JOURNALS/AbstractDetails.asp?ID=125 34 3. http://dspace.cusat.ac.in 4. http://www.icevirtuallibrary.com/content/article/10.1680/ensu.2004.157.4. 213 5. http://www.wrap.org.uk/sites/files/wrap/Ferrosilicate_zinc_slag_in_bitum inous_bound_mixes.pdf 6. http://link.springer.com/content/pdf/10.1007%2Fs12205-012-1240-2.pdf 7. http://theconstructor.org/concrete/compressive-strength-of-concretecubes/1561/ 8. http://solid-waste.org/journal/abstracts-of-published-papers/volume-362010/ 9. http://pyro.co.za/Mintek/Files/2004JonesSlag.pdf


Page 63

APPENDIX I. STANDARD PROCEDURE FOR TESTING OF COMPRESSIVE STRENGTH: PREPARATION OF CUBE SPECIMENS: The proportion and material for making these test specimens are from the same concrete used in the field.

SPECIMEN: 6 cubes of 15 cm size.

MIXING: Mix the concrete either by hand or in a laboratory batch mixer

HAND MIXING: (i)Mix the cement and fine aggregate on a water tight none-absorbent platform until the mixture is thoroughly blended and is of uniform colour

(ii)Add the coarse aggregate and mix with cement and fine aggregate until the coarse aggregate is uniformly distributed throughout the batch

(iii)Add water and mix it until the concrete appears to be homogeneous and of the desired consistency

SAMPLING: (i) Clean the mounds and apply oil.

(ii) Fill the concrete in the moulds in layers approximately 5cm thick. FINAL YEAR PROJECT REPORT

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(iii) Compact each layer with not less than 35strokes per layer using a tamping rod (steel bar 16mm diameter and 60cm long, bullet pointed at lower end).

(iv) Level the top surface and smoothen it with a trowel.

CURING: The test specimens are stored in moist air for 24hours and after this period the specimens are marked and removed from the moulds and kept submerged in clear fresh water until taken out prior to test.

PRECAUTIONS: The water for curing should be tested every 7days and the temperature of water must be at 27+-2oC.

PROCEDURE: (I) Remove the specimen from water after specified curing time and wipe out excess water from the surface.

(II) Take the dimension of the specimen to the nearest 0.2m

(III) Clean the bearing surface of the testing machine

(IV) Place the specimen in the machine in such a manner that the load shall be applied to the opposite sides of the cube cast.

(V) Align the specimen centrally on the base plate of the machine.

(VI) Rotate the movable portion gently by hand so that it touches the top surface of the specimen.


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(VII) Apply the load gradually without shock and continuously at the rate of 140kg/cm2/minute till the specimen fails

(VIII) Record the maximum load and note any unusual features in the type of failure.

NOTE: Minimum three specimens should be tested at each selected age. If strength of any specimen varies by more than 15 per cent of average strength, results of such specimen should be rejected. Average of three specimens gives the crushing strength of concrete.


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INFLUENCE OF FLY-ASH ON STRENGTH OF CONCRETE CONTAINING ISF SLAG A PROJECT REPORT Submitted in partial fulfilment of the requirement for the award of the degree of BACHELOR OF TECHNOLOGY In CIVIL ENGINEERING Submitted by

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