Sai_ram_Project_Final_Report[1]

Department of Civil Engineering, Pydah College Page 1
CHAPTER 1
INTRODUCTION
1.1General
Sustainability was a big issue that being concern in making a development. This is
because sustainable development has become a key aspect in society, Economics and
development. Sustainable development shall meet the needs of the present without
compromising ability of future generation to meets their own needs. It also shows that
development that going to be made to sustain the planetary resources by using them
effectively without making unnecessary wastage. The usage of GGBS to replace the
cement is because the production of the cement emits carbon dioxide gas to atmosphere.
The cement industry is held responsible for some of the carbon dioxide emission, because
the production of one ton Portland cement emits approximately one ton of carbon dioxide
gas into the atmosphere. The emission of carbon dioxide will increase the effect of global
warming due to the emission of greenhouse gasses. Among the greenhouse gasses, carbon
dioxide contributes about 65% of global warming.
In the present situation as a result of rapid industrialization lots of industrial waste
like fly ash, GGBS, silica fume and copper slag were accumulating day by day.The
disposal of such industrial waste is becoming major issue. In other way concrete has
occupied significant place in construction field since few decades. It has been used in mass
concrete works as well as RCC structure like multi storied buildings, Flyovers, Bridges
deck slabs and water retaining works. The main ingredient of concrete is cement which is a
costlier material. Part of cement can be replaced with Fly ash and GGBS which are
abundantly available in industries. Thus it reduces the cost of construction and also given
very good results in terms of strength and durability particularly in coastal region.

1.2Ground Granulated Blast furnace Slag (GGBS)
Ground Granulated Blast Furnace Slag (GGBS) is a recyclable material created
when the molten slag from melted iron ore is quenched rapidly and then ground into a
powder. This material has cementatious properties and has been used as a replacement for
cement for over 100 years. Recently, Wisconsin has begun using it in some of its highway
projects. Wisconsin has experienced several problems with GGBS, which include slow
strength gain and decreased surface quality. Countering these problems, GGBS concrete
has higher late strength and lower permeability. This project investigates these GGBS
characteristics and has several objectives.
Ground Granulated Blast Furnace Slag (GGBS) is a byproduct of the steel industry. Blast
furnace slag is defined as “the non-metallic product consisting essentially of calcium
silicates and other bases that is developed in a molten condition simultaneously with iron in
a blast furnace.” In the production of iron, blast furnaces are loaded with iron ore, fluxing
agents, and coke. When the iron ore, which is made up of iron oxides, silica, and alumina,
comes together with the fluxing agents, molten slag and iron are produced. The molten slag
then goes through a particular process depending on what type of slag it will become. Air
cooled slag has a rough finish and larger surface area when compared to aggregates of that
volume which allows it to bind well with portland cements as well as asphalt mixtures.
GGBS is produced when molten slag is quenched rapidly using water jets, which produces
a granular glassy aggregate.
Fig 1.1: View of Blast furnace chamber

1.2.1 Chemical Composition
Slag is primarily made up of silica, alumina, calcium oxide, and magnesia (95%).
Other elements like manganese, iron, sulfur, and trace amounts of other elements make up
about other 5% of slag. The exact concentrations of elements vary slightly depending on
where and how the slag is produced. When cement reacts with water, it hydrates and
produces calcium silicate hydrate (CSH), the main component to the cements strength, and
calcium hydroxide (Ca (OH)2). When GGBFS is added to the mixture, it also reacts with
water and produces CSH from its available supply of calcium oxide and silica. A
pozzolanic reaction also takes place which uses the excess SiO2 from the slag source,
Ca(OH)2 produced by the hydration of the Portland cement, and water to produces more of
the desirable CSH making slag a beneficial mineral admixture to the durability of concrete.
1.3Objective
In this thesis work the primary object is to know the comparative strengths in
respect of compressive strength, spilt tensile strength and flexural strength of conventional
cement concrete of M40 grade with partial replacement of cement with GGBS ranges from
0% to 40% in two phases. Based on the comparative strength results we can assess the
optimum percentage of cement replacement with GGBS so that it can be possible to
recommend cheaper concrete as a substitute to conventional concrete
Fig 1.2: GGBS fine powder

1.4 GGBS Effects on Flexural and Compressive Strength
GGBS has a positive effect on both the flexural and compressive strength of
concrete after 28 days. In the first 7 days the compressive strength is generally slightly
lower than pure 100% Portland cement mixtures. In the 7 to 14 day range, the compressive
strength is about equal to the strength of concrete without slag. The real gain in strength is
noticed after the 28 day mark especially when 120 grade GGBS is used. . A 1992 study
which showed that the flexural strength of concrete mixes with different slag replacement
percentages was between 6.0-6.8 MPa at 14 days. The long term strength of slag cement
depends on many factors such as the amount of slag and Portland cement, and water to
cement ratio.
1.5 GGBS Production
GGBS is a nonmetallic by-product of the steel industry simultaneously produced with
iron in the blast furnace of steel mills, which consists essentially of silicates and alumina
silicates of calcium and other bases. Iron ore, limestone, and coke are crushed and blended
into a mixture constituting the raw materials for molten iron, which is produced in a ±2700
°F blast furnace. The residual molten slag is chilled rapidly by immersion in water to
vitrify the material into a glassy sand-like substance. This substance is then dried and
ground into a very fine powder with a minimum of 80 percent less than 45 microns in size.
This is the cementations material called GGBS.

CHAPTER 2
LITERATURE REVIEW
2.1 LITERATURE REVIEW
The literature review presenting the previous the previous studies relating to
characteristics effects of partial replacement of GGBS in place of cement. The topics of their
research included the basic characteristics, effect of GGBS on hardened concrete properties.
Experience of using GGBS in concrete
The hydraulic potential of blast furnace slag was first discovered in Germany in 1862.
In 1865, lime-activated blast furnace slag started to be produced economically in Germany and
in 1880 GGBS was first used in combination with Portland cement (Concrete Society,1991). In
Europe, GGBS has been used for over 100 years. In North America, the history of the use of
GGBS in quality concrete dates back about 50 years (Yazdani, 2002). In Southeast Asian
countries including Mainland ,China and Hong Kong. GGBS was used in concrete in around
1990. Between 1955 and 1995, about 1.1 billion tons of cement was produced in Germany,
about 150 million tones of which consisted of blast furnace slag (Geiseler et al, 1995)
Consumption as well as cost of construction. Industrial waste products save the environment
and conserves natural sources.
I. Prof M.V.Nagendra (2014) This research work focuses on strength characteristic
analysis of M20 grade concrete with replacement of cement by GGBS with 20%, 30%,
40% & 50% and compare with plain c.c. The test results of hardened concrete
specimens states that the maximum compressive, flexural strengths achieved at 30%
replacement of cement with GGBS. The plain cement concrete prepared by OPC
cement and natural sand of M20 grade. The maximum compressive strength achieved is
32.59 Mpa at 30% of GGBS replacement OPC cement and natural sand. This report
shows that tensile strength also give good performance for 20%, 30% and 40%
replacement which is more than normal plain concrete.

II. Sonali K.Galpalliwar (2014) conducted an experiment on hardened concrete with
10%, 20% and 30% replacement of cement by GGBS. The test results prove that the
maximum 28 days split tensile strength was obtained with 30% replaced with cement.
The maximum 28 days flexural strength was obtained at the cement was replaced with
20% of GGBS.
III. S.P.Sangeetha,P.S.Joanna (2014) studied the structural behavior of RC beams with
GGBS concrete. The results obtained from experiments states that the ultimate moment
capacity of GGBS was less than the controlled beam when tested at 28 days, but it
increases by 21% at 56 day. The measured crack width at service load ranged between
0.17 to 0.20mm and is within the limits (IS456-2000). The structural behavior of RC
beam with GGBS resulted the typical behavior of RCC beams and there increase in
load carrying capacity of GGBS beams with age. The structural behavior of Reinforced
concrete beams with GGBS resembles the typical behavior of Reinforced cement
concrete beams and there is increase in load carrying capacity of GGBS beams with
age. Hence results of this investigation suggest that concrete with 40% GGBS
replacement for cement could be used for RC beams. Having cementing properties,
which can be added in cement concrete as partial replacement of cement, without
compromising on its strength and durability, which will result in decrease of cement
production thus reduction in emission in green house gases, in addition to sustainable
management of waste? The ground granulated blast furnace slag is a waste product
from the iron manufacturing industry, which may be used as partial replacement of
cement in concrete due to its inherent cementing properties. This paper presents an
experimental study of compressive and flexural strength of concrete prepared with
Ordinary Portland Cement, partially replaced by ground granulated blast furnace slag in
different proportions varying from 0% to 40%. It is observed from the investigation that
the strength of concrete is inversely proportional to the % of replacement of cement
with ground granulated blast furnace slag. It is conducted that the 20% replacement of
cement is possible without compromising the strength with 90 days curing.
IV. Prof S.Arivalangan (2014) studied the utilization of supplementary cementation
material is well accepted, since it leads to several possible improvements in the
concrete composition as well as the overall economy. It is as effort to quantify the

strength of GGBS at various replacement levels 0%, 10%, 20%, 30% and evaluated its
efficiency in concrete. Cement with GGBS replacement has emerged as major
alternative to conventional concrete and has rapidly drawn the concrete industry
attention due to its cement savings, energy savings and cost savings, environmental and
socio-economic benefits. This research evaluates the strength and strength efficiency
factors of hardened concrete, by partial replacement cement by various percentages of
GGBS for M40 graded of concrete at different ages. From this study, it can be
concluded that since the grain size of GGBS is less than that of OPC its strength at
early ages is low, but it continuous to gain strength over a period of time. The optimum
GGBS replacement as cementations material is characterized by high compressive
strength, low heat of hydration, resistance to chemical attack, better workability, good
durability and cost effective. Based on the experiment he concluded that GGBS based
concrete have achieved an increase in strength for 20% replacement of cement at the
age of 28 days. Increasing strengths due to filler effect of GGBS. The degree of
workability of concrete was normal with the addition of GGBS up to 40% replacement
level for M40 grade concrete. From the experimental results, it is proved that GGBS
can be used as an alternative material for cement reducing cement In China the
estimated total GGBS production was about 100 million tons in 2007(Chen, 2006).
GGBS has been widely used as a partial replacement of Portland cement in construction
projects. In Western Europe, the amount of GGBS used accounts for about 20% of the
total cement consumed, whereas in the Netherlands it accounts for 60% of the total
cement consumption (Tsinghua University, 2004) there are abundant examples of the
GGBS concrete in construction projects. In New York, the concrete used in the
construction of the World Trade Centre has about 40%GGBS replacement (Slag
Cement Association, 2005). At the Minneapolis Airport, the airfield pavements were
constructed using concrete with 35%GGBS replacement. Other projects using GGBS
include the world’s largest aquarium – the Atlanta’s Georgia Aquarium which used
20% to 70% GGBS replacement. The Detroit Metro Airport Terminal Expansion used
concrete with 30% GGBS replacement. The Air Train linking New York’s John
F.Kennedy International Airport with Long Island Rail ROAD trains used concrete
with 20% to 30% GGBS replacement. In China, GGBS has been widely used in major

construction projects such as the Three Gorges Dam, Beijing –Shanghai Express Rail,
and Cross-bay Bridge of Hangzhou Bay. The GGBS replacement level is generally
around 40% (China Cements, 2009; ChinaBiz,2009). In Hong Kong, GGBS was used
in the construction of the T sing Ma Bridge, which requires a design life of 120 years.
For this project, the GGBS replacement levels were from 59% to about 65% with a
maximum water/(cement +GGBS+ silica fume)ratio of about 0.39 GGBS was also used
in the construction of the Stonecutter Island Bridge with GGBS replacement of between
60% and 70%. For reinforced concrete in a marine environment, the SCCT endorsed in
year 2000 a specification, which allows the use of GGBS. The specified replacement
level for normal application is in the range of 60% to 75% by mass of the cementitous
content whilst for low heat applications it ranges from 60% to 90% (Standing
Committee on Concrete Technology, 2000). In 2004 more than 3000,000 tones of
GGBS produced in Germany. In 2008 2000,000 tones of GGBS produced in UK. In
2008 over a 4,00,000 tones available in Ireland. It is conclude by Khan & users (2003)
that workability of GGBS concrete is more and thus w/c ratio may be reduced resulting
in increase in compressive strength. Sharing (2008) found in his experiments that the
replacement of OPC in concrete with GGBS gives the optimum strength at 40% but
after curing 56days.
V. Grammer & Sippel (2005) Conducted the studies on the use of grade 100 slag
cement. Based on results studies properly cured grade 120 slag cement concrete
provides performance compatible to OPC concrete after a short latent hydration lag
period and grade 100 slag cement concrete provides less compatible performance with
greater latent hydration periods.
VI. A.Oner,S.Akyuz (2007) Conducted a laboratory investigation on optimum level of
GGBS on the compressive strength of concrete. GGBS was added according to the
partial replacement method in all mixtures. All specimens were cured for7, 14, 28,63
and 119 days before compressive strength testing. The results proved that the
compressive strength of concrete containing GGBS increases as the amount of 55% of
the total binder content the addition of GGBS does not improve the compressive
strength. This can be explained by the presence of un reacted GGBS acting as a filler
material in the paste.

VII. P.N.Rao (2010) Studied the characteristics of M30 concrete with partial replacement
of cement with GGBS. The cubes and cylinders are tested both compressive and tensile
strength. It is found that by the partial replacement of cement with GGBS helped in
improving the strength of the concrete substantially compared to normal mix concrete.
The specimens of hardened concrete with 50% of replacement of cement by GGBS
increases the compressive strength @ 11.06 and 17.60% at the age of 7 and 28 days
VIII. K. Suvarna Latha, M.V.Sheshariri rao (2012) The utilization of supplementary
cementations material is well accepted because of several improvements in the concrete
composites and due to overall economy. This paper is an effort to quantify the strength
of GGBS at various replacements levels and evaluates their efficiency in concrete in
terms of strength. In this study experiments were conducted for various levels of
cements replacement with GGBS to different mixtures M20, M40 & M60. The result of
above specimen of hardened concrete says that the partial replacement of cement with
GGBS in concrete mixes has shown enhanced performances in terms of strength and
durability in all ways. This is due to the presence of reactive silica in GGBS which
offers compatibility. It is observed that there is an increase in compressive strength for
different concrete mixes made with GGBS and HVFA replacement mixes. The increase
is due to high reactivity of GGBS and HVFA.
IX. A.H.L.Swaroop (2013) Published a new paper stating that replacement of cement with
GGBS of 20% & 40% given good strength to concrete and durable properties when
compared with conventional concrete. In sea water curing the GGBS was replaced with
2% of cement shows good response for durability criteria. The early strength is
compared to less in fly ash and GGBS concretes then conventional aggregate concrete.
The results of fly ash and GGBS concretes when replaced with 20% of cement or more
than compared to CAC at the end of 28days and 60 days for normal water curing. In sea
water curing the GGBS when replaced with 20% of cement shows good response for
durability criteria.
X. Peter.W.C.Leung & H.D.Wong (2013) As the temperature control measures were not
imposed for the mixes used, there was no significant reduction in the peak temperature
of GGBS concrete unless the replacement percentage is at least 80%. Temperature
control may need to be imposed to limit the peak temperature of the GGBS concrete. ©

The inclusion of GGBS appears to have a slight retarding effect on the early strength of
concrete. The 7-day strength of GGBS concrete between 56% and 71% of the 28-day
strength, as compared to about 80% for Portland cement concrete. The source of GGBS
does not appear to have a significant effect to the performance of GGBS concrete so
long as the GGBS complies with the relevant standards.
XI. Prof.P.Patil (2013) This study says that the production of cement results in emission of
many green house gases in atmosphere, which are responsible for global warming.
Hence, the researchers are currently focused on use of waste material
XII. STRENGTH DEVELOPMENT OF CEMENT MORTAR AND CONCRETE
INCORPORATING GGBFS. - M. Shariq, J. Prasad and A.K. Ahuja. Department
of Civil Engineering, IIT Roorkee, India. M. Shariq, J. Prasad and A.K. Ahuja
carried out an experimental study on, the effect of curing procedure on the
compressive strength development of cement mortar and concrete incorporating
ground granulated blast furnace slag is studied. The compressive strength
development of cement mortar incorporating 20, 40 and 60percent replacement of
GGBFS for different types of sand and also on two grades of concrete is
investigated. The compressive strength of cement mortar and concrete obtained at
the ages of 3, 7, 28, 56, 90 days. Tests results show that the incorporating 20% and
40% GGBFS is highly significant to increase the compressive strength of mortar
after 28 days and 150 days respectively. The magnitude of compressive strength of
mortar for standard sand is higher than the magnitude of river sand. Incorporating
60% BFS replacement is showing lower strength at all ages and water-cement ratio
for both types of sand. The compressive strength of OPC concrete shows higher
strength as compare to the GGBFS based concrete for all percent replacement and at
all ages. Incorporating 40% GGBFS is highly significant to increase the
compressive strength of concrete after 56 days than the 20 and 60% replacement.
Among GGBFS based concrete 40% replacement is found to be optimum. The
research carried out by M. Shariq, J. Prasad and A.K. Ahuja concludes that;

CHAPTER -3
METHODLOGY & GENERAL INFORMATION
3.1 Concrete
It is most widely used construction material in the world for mass concrete works
such as abutments piers of bridges retaining walls dams and as reinforced concrete for
multistoried structure bridges slabs etc. concrete is product obtained artificially by
hardening of the mixture of cement, sand, metal and water in predetermined proportion.
When these ingredients are mixed, they farm a plastic mass which can be poured in suitable
moulds, called forms and set as standing in to hard solid mass. The chemical reaction of
cement &water in the mix is relatively slow and requires time and favorable temperature
for its completion. This time is known as setting time which may be divided into three
distinct phases. The first phase designated as time of initial set i.e. 30 min. to 60min. the
second phase in final set that may vary from 5 to 6 hours. The third phase consists of
progressive hardening and increase in strength. The process is rapid in the initial stage,
until about one month after mixing at which time the concrete attains the major portion of
its potential hardness and strength.
The strength of concrete will vary based on quality & portion of the experiment
work. Pozzolanic material like GGBS is used as partial replacement for cement in the
concrete mix. In ranges of 0%,10%,20%,30% and 40% and compared the hardened
concrete strength with conventional concrete.
The following are the ingredients normally we use in different proportions as per
the strength requirements.

3.2 Cement
Cement is a binder, a substance that sets and hardens independently, and can bind
other materials together. The word “Cement” traces to the Romans, who used the term opus
cementicium to describe masonry resembling modern concrete that was made from crushed
rock with burnt lime as binder. The volcanic ash and pulverized brick additives that were
added to the burnt lime to obtain a hydraulic binder in 2010, the word production of cement
was 3,300 million tones. The top three producers were china with 1,800, India with 220
and U.S.A. with 63.5 million tons respectively. The most important uses of cement are as
ingredients in the production of mortar in masonry and of concrete, a combination of
cement and an aggregate to form a strong building material.
Cements made by heating limestone 9calcium carbonate) with small quantities of
other materials(such as clay) to 14500
C in a kiln, in a process known as calcinations, where
by a molecule of carbon dioxide, or quick lime, which is then blended with the other
materials that have been included in the mix. The resulting hard substance, called ‘clinker’
is then ground with a small amount of gypsum into a powder to make ‘ordinary Portland
cement’ he most commonly used type of cement (often referred to as OPC). Portland
cement is a basic ingredient of concrete .mortar and most non-specially grout. The most
common use for Portland cement is in the production of concrete, and water. As a
construction material, concrete can be cast in almost any shape desired, and once hardened
can become a structural (load bearing) element. Portland cement may be grey or white.
Cements used in construction can be characterized as being either hydraulic or non-
hydraulic. Hydraulic cements (e.g., Portland cement) harden because of hydration, a
chemical reaction between the anhydrous cement powder and water. Thus they can harden
underwater or when constantly exposed to wet weather. The chemical reaction results in
hydrates that are not very water-soluble and so are quite durable in water non-hydraulic
cements do not harden underwater; for example, slaked limes harden by reaction with
atmospheric carbon dioxide.
Cement sets or cures when mixed with water which causes a series of hydration
chemical reactions. The constituents slowly hydrate and crystallize; the inter locking of the

crystals gives cements its strength. Maintain high moisture content in cement curing
increases both the speed of curing, and its final strength. Gypsum is often added to Portland
cement to prevent early hardening or “flash setting”, allowing a longer working time. The
time it takes for cement to cure varies depending on the mixture and environmental
conditions; initially hardening can occur in as little as twenty minutes while full cure can
take over a month cement typically cures to the extent that it can be put into service within
24hours to a week
Concrete is second only to water as the most consumed substance on earth with
nearly one ton of the material used annually for each person on the planet cement is the
critical ingredient in concrete looking together the sand gravel constituents in an inert
matrix it is the glue which holds together much of modern society infrastructure
Cement is a global commodity manufactured at thousand of local plants a cement plant is
generally located near limestone deposits and cement produced in a particular region is
mainly consumed in that region because of its weight cement supply via land transportation
is expensive and generally limited to an area within 300km of any one plant side the
industry is consolidating globally but large scale international firms account for only 30%
of the worldwide market in many developed countries marked growth is slow or nil
whereas in developing markets growth rates are more paid china is the fastest growing
marker with first place because it is both global and local the cement industry faces a
unique set of issues which attract attention from communities near the plant at a national
and an international level
There are some types of cements presently available in the market some of the important
contents are:
• Ordinary Portland cement
• Rapid hardening cement
• Sulphate resisting cement
• Portland pozzolana cement
• Quick setting cement
• Portland slag cement

About 99% percent of all cement used today is Portland cement this name was given to the
cement by Joseph Aspdin of Leeds England who obtained a patent for his product in 1824
the concrete made from the cement resembled the color of the natural limestone quarried
on the isle of Portland on the isle of Portland in the English channel the balance of cement
used today consists of masonry cement which is fifty percent Portland ground lime rock.
3.3 Aggregate
Aggregates are the important cinstituents in concrete they give body to the concrete
reduce shrinkage and effect economy one of the most important factors for producing
workable cincrete is good gradation of aggregates good grading implies that a sample
fractions of aggragates In required proporation such that the sample contains minimum
voids samples of the well graded aggregate contining minumum voids require minimum
paste to fill up the voids in the aggregates minimum paste will mean less quantity of
cement and less water which will further mean increased economy higher strength lover
shrikage and greater durablility
3.3.1 Requirements of Aggregates
1. It should be hard strong and durable
2. It should be free from inorganic materials, oils, etc
3. Porosity should be reduced
4. It should be angular in shaped
5. Low thermal conductivity
6. Should not react with cement and steel
7. Should be well graded
8. Should be free from delirious materials
3.3.2 Coarse Aggregate:
The material which is retained on BIS test sieve number 4 (4.75mm) is termed as
coarse aggregate. The broken stone is generally used as a stone aggregate. The nature of
work decides the maximum size of the coarse aggregate. Locally available coarse

aggregate having the maximum size of 20mm was used in the present work. Often referred
to as gravel it normally consists of a distribution of particles, the minimum size being
approximately 3/8 inch in diameter and the maximum being defined or restricted by the
size of the finished structure. A common maximum size for coarse aggregate in structural
concrete is 1.5inches.
The properties of concrete such as strength, durability, workability and economy are
mainly affected by the properties of aggregate. Originally aggregate was looked upon as an
inert material for economic reasons. Since characteristics of concrete are directly related to
those of its constituent aggregate, aggregates for load bearing concrete should be suitable
for the purpose required.
Stones absorbing more than 10% of their weight after 24 hours immersion in water
are considered as porous. Porous materials corrode reinforcement, elongated or laminated
particles are weak in shear. Varieties of sandstones make poor concrete and also produce
shrinkage cracks.
Aggregate must be clean and free from clay loam, vegetable and other organic
material. Clay or dirt coating on aggregates prevents adhesion of cement to aggregated,
shows down the setting and hardening of the concrete and reduce the strength of concrete.
3.3.3 Fine Aggregate:
The material which passes through BIS test sieve number 4 (4.75mm) is termed as
fine aggregate usually natural sand is used as a fine aggregate at places where natural sand
is not available crushed stone is used as fine aggregates. The sand used for the
experimental works was locally procured and confirmed to grading zone II, sieve analysis
of the fine aggregate was carried out in the laboratory as per IS 383-1970 and results are
provide. The sand was first sieved through 4.75mm sieve to remove any particle greater
than 4.75mm and then was washed to remove the dust. The results of testing carried out for
fine aggregate is provided. Fine aggregates are available form:

3.3.4 River Sand
• This is obtained from river beds and river banks.
• This is bright and clear and consists of sharp or rounded particles.
• This is best for mortar preparation and can be used for plastering works.
3.3.5 Pit Sand
• This sand is obtained from pits dug at a depth of 1.5m to 2m from the ground soil.
• The particles are sharp, angular, porous and free from the harmful salts and are
suitable for mortar.
3.3.6 Sea Sand
• This is the sand available in seashores.
• This sand is brown in color consists of rounded particles.
• These contain objectionable matter. So it is not recommended for construction
work.
3.3.7 Manufacture and (M-Sand)
• Due to the scarcity of sand from natural sources like rivers, sand is manufactured in
stone crushers, which are called m-sand.
• These are with less impurities and better control over size and quality.
3.4 WATER
Water is an important ingredient of concrete as it actively participates in the
chemical reaction with cement. Since it helps to form the strength giving cement gel, the
quality and quantity of water is required to be looked into very carefully. Portable water is
generally considered satisfactory. In the present investigation tap water was used for both
mixing and curing purposes.

3.5 ADMIXTURES
Admixtures are those ingredients in concrete other than Portland cement, water, and
aggregates that are added to the mixture immediately before or during mixing. About 80%
of concrete produced in North America have one or more admixtures. About 40% of ready
–mix produces use fly ash. About 70% of concrete produced contains a water–reducer
admixture. One or more admixtures can be added to a mix to achieve the desired results.
The reasons to use admixtures are:
• Increase slump and workability;
• Reduced or prevent shrinkage;
• Modify the rate or capacity for bleeding;
• Reduce segregation;
• Improve pumpability and finishability;
• Accelerate the rate of strength development at early ages;
• Decrease permeability of concrete;
• Gas-forming;
• Foaming;
There are two main groups of admixtures.
1. Chemical admixtures
2. Mineral admixtures
3.5.1 Chemical Admixtures
They reduce the cost of construction, modify the properties of concrete and improve
the quality of concrete during mixing, transportation, placing and curing. Some of the
chemicals admixtures are:
1. Air-entrainment
2. Water-reducing
3. set-retarding

4. accelerating
5. super-plasticizers
6. corrosion-inhibitors
3.5.2 Mineral Admixtures
These are becoming more popular in recent decades. The use of recycled materials
as concrete ingredients has been gaining popularity because of increasingly strict
environmental legislation, and the discovery that such materials often have complimentary
and valuable properties.
Concrete is the world’s most consumed man-made material. With the advancement
of technology and increased field of applications of concrete and mortars, the strength,
workability, durability and other physical and chemical properties of the ordinary concrete
need modifications to make it more suitable by situations. There is a necessity to control
the increasing cost and scarcity of cement. Under these circumstances the use of
admixtures is found to be an important alternative solution. The use of pozzolana materials
in cement concrete paved a solution for modifying the properties of the concrete,
controlling the concrete production cost, to overcome the scarcity of cement, the economic
advantages disposal of industrial wastes etc.
The use of pozzolanic materials in concrete paved a solution for
• Modifying the properties of the concrete
• Controlling the concrete production cost
• To overcome the scarcity of cement
• The economic advantage of disposal of industrial wastes
These are Inorganic materials that also have pozzolanic or latent hydraulic properties.
These very fine-grained materials are added to the concrete mix to improve the properties
of concrete (mineral admixtures), or as a replacement for Portland cement (blended
cement).
• Fly Ash: A by-product of coal-fired electric generating plants which is used to
partially replace Portland cement (by up to 60% by mass). The properties of fly ash

depend on the type of coal burnt. In general, siliceous fly ash is pozzolanic, while
calcareous fly ash has latent hydraulic properties.
• Ground Granulated Blast Furnace Slag (GGBFS or GGBS): A by-product of
steel production is used to partially replacement of Portland cement ( up to 80% by
mass). It has latent hydraulic properties.
• Silica Fume: a by-product of the production of silicon and ferrosilicon alloys.
Silica fume is similar to fly ash, but has a particle size 100 times smaller. This
results in a higher surface to volume ratio and a much faster pozzolanic reaction.
Silica fume is used to increase strength and durability of concrete, but generally
requires the use of super plasticizers for workability.
• Metakaolin: Metakaolin produces concrete with strength and durability similar
to concrete made with silica fume. While silica fume is usually dark gray or black in
color, Metakaolin is usually bright white in color, making it preferred choice for
architectural concrete where appearance is important.
3.6 Applications and Uses of GGBS
Ground granulated blast furnace slag is used to make durable concrete structures in
combination with ordinary Portland cement or other pozzolanic materials. Ground
granulated blast furnace slag has been widely used in Europe and increasingly in the United
States and in Asia (particularly in Japan and Singapore) for its superiority in concrete
durability, extending the lifespan of building from fifty years to a hundred years.
Two major uses of ground granulated blast furnace slag are in the production of
quality-improved slag cement ranging typically from 30 to 70% and in the production of
ready mixed or site-batched durable concrete.
Concrete made with ground granulated blast furnace slag cement sets more slowly
than concrete made with ordinary Portland cement, depending on the amount of
ground granulated blast furnace slag in the cementitious material, but also continues to gain
strength over a longer period in production conditions. This result in lower heat of

hydration and lower temperature rises and makes avoiding cold joints easier, but also affect
construction schedules where quick setting is required.
Use of GGBS significantly reduces the risk of damages caused by alkali silica
reaction, provides higher resistance to attacks by sulphate and other chemicals,
workability-making placing and compaction easier and lower early-age temperature rise,
reducing the risk of thermal cracking in pores.
3.7 Effect of GGBS on the Properties of Finished Concrete
3.7.1 Setting Time:
GGBS concrete requires longer setting times than Portland cement concrete,
probably due to the smooth and glassy particle forms of GGBS. The setting time also
increases with increasing percentage of GGBS replacements. Duos and Eggers (1999)
reported that if the temperature was at 23C , the setting times were not significantly
affected by the GGBS replacement levels. Other research reported that if the GGBS
replacement level was less than 30% the setting times of GGBS concrete are sensitive to
low ambient temperatures. For example, in a development project in Beijing, the de
molding time was delayed by six to eight hours when the ambient temperature was lowered
from 15 C to below 5 C
3.7.2 Bleeding
A reviewing of literature reveals that there have been contradictory views on the
bleeding of GGBS concrete. It has been reported by the concrete society (1991) that when
GGBS replacement level is less than 40% bleeding is generally unaffected. At higher
replacement levels, bleeding rates may be higher (concrete society)
3.7.3 Elastic Modulus
It is widely accepted that the effect of GGBS replacement on the elastic modulus of
concrete is negligible.

3.7.4 Influences on Durability
It is generally known that the inclusion of GGBS in concrete can improve the
durability. GGBS concrete generally has a low permeability resulting in reduced chloride
penetration, enhanced resistance to sulphate attack and alkali silica reaction as compared
with ordinary Portland cement concrete. Research findings indicate that the rate of
corrosion of steel in cracked GGBS concrete at cover depths of 20mm and 40mm would be
significantly reduced by at least 40% when compared to that of port land cement concrete.
It has been reported that a higher calcium hydrate (CH) content will in general produce
concrete of poor durability due to an inhomogeneous mix with poor bonding between
calcium silicate hydrate (CSH) and CH. Higher CH contents will lead to a greater
permeability and a lower durability due to an inhomogeneous mix with poor bonding
between calcium silicate hydrate (CSH) and CH. Higher CH contents will lead to a greater
permeability and a lower durability. The GGBS particles are retained in CSH form
resulting in a hardened paste of greater density and smaller pore size as compared to
Portland cement paste. Smaller pore size gives rise to a lower permeability and hence a
higher durability in general.
3.7.5 Chloride Ingress
GGBS concrete has generally lower permeability and hence better resistance to
chloride penetration. It has been reported that the pore structure of the concrete was
changed during the reaction of GGBS particles with the calcium hydroxide and alkalis
released during hydration. The pores were filled with calcium silicate hydrates instead of
calcium hydroxide. Researchers reported that as the GGBS content increased from zero to
50%, the chloride permeability dropped significantly at 90 days. Ryou &Ann (2008) also
reported that the rate of chloride transport was reduced to the lowest level in concrete
with60% GGBS replacement.
3.7.6 Sulphate Resistance
Cement with 65% GGBS by mass is specified as high sulphate resistance cement
according to DIN 1164 (Geiseler et al, 1995). However, some studies find that GGBS of

high alumina content and high fineness level may affect the sulphate resistance of GGBS
concrete.
3.7.7 Alkali Aggregate Reaction
Many researchers confirmed that GGBS had the ability to reduce the deleterious
expansion caused by alkali aggregate reaction (AAR), especially when GGBS was used to
replace Portland cement of high alkali content. GGBS has been used in the UK, Germany,
and Japan as a means to reduce the risk of damage due to AAR. In the UK, high levels of
GGBS (50%) are generally used. Wang & Read (1995) reported that the ability of GGBS to
reduce the deleterious effect of AAR was due to its low reactive alkali content and its
ability to inhibit AAR. The overall lime-to-silica (Ca/Si) ratio of the hydration products
(CSH) was reduced by inclusion of GGBS in the concrete as partial replacement of
Portland cement as compared to pure Portland cement concrete. The hydration products of
low Ca/Si ratio can ‘immobilize’ free-alkali sand hence reduce the risk of AAR.
3.8 Strength Development
3.8.1 Early Age Strength Development
General literature review indicates that GGBS concrete has lower early strengths
because the rate of initial reaction of GGBS is slower than that of Portland cement. GGBS
is therefore generally grounded to a finer state than Portland cement. Researcher reported
that, as the fineness of GGBS increased from around 4000cm2/g to 6000cm2/g, the 28-
daystrength increased significantly. The previous studies says that the early strengths (up to
28 days) of concrete mixes (with 25%,35%,50%, and 60% GGBS replacements ) were
lower than that of Portland cement concrete mixes. By 56 days, strength of 50% and 60%
GGBS mixes exceeded that of the Portland cement mix, and by one year all GGBS mixes
were stronger than the Portland cement mixes.

3.8.2 Influence of Curing Temperature and Duration
Curing temperature has an important effect on the curing duration required to
achieve the designed strength or durability. The curing temperature affects the rate of
hydration of cement, which affects the strength development of concrete (Meeks &
Nicholas, 1999). Neville (1981) reported that the rate of hydration increased with a rise in
the curing temperature. This is beneficial to the early strength development of concrete up
to the age of seven days onwards may be adversely affected. Neville (op cit) explained that
a high initial temperature might cause the initial hydration rate to the too high such that
there would be insufficient time available for the hydration products to diffuse away from
the cementations grain and precipitate uniformly in the interstitial space. As a result , a
high concentration of the hydration products was built up around the hydrating grains
retarding the subsequent hydration process and adversely affected the long-term strength of
concrete (Neville, 1996). Concrete containing GGBS has slower reaction rates. A longer
curing duration is essential for proper development of the properties of GGBS (Neville,
1996). Some researchers recommended a minimum curing period of three days for high
performance or durable GGBS concrete. The reason is that durability is controlled mainly
by the quality of the concrete at surface and good curing is important for the quality of
concrete at surface. High GGBS replacement concrete is more susceptible to poor curing
conditions than Portland cement concretes probably due to the reduced formation of
hydrate at early ages. Researchers found that curing in air lowered the strength by 21% and
47% for 50% and 65% GGBS replacement concrete respectively as compared to moist-
cured samples at 180 days. The strength for a 50% GGBS replacement mix with an initial
seven days moist curing followed by air curing is not significantly affected as compared to
the moist-cured sample of the same GGBS replacement level.
3.8.3Typical level of Replacement
In the USA, the levels of GGBS replacements range from 25% to 50% for high
strength concrete (Slag cement association, 2005). In another study, it was found that slag
replacement level of 40% to 60% appeared to be the optimum level for high strength
development (Richardson, 2006). In Canada the replacement level is about 50% for control

of alkali-silica reaction. For concrete to resist sulphate attack and achieve a lower early age
heat generation, the level of replacement will need to be within 60% to 85% for mass
concrete construction (In Hong Kong, the Tsing Ma Bridge) adopted a replacement level of
about 65% in order to meet the stringent durability requirements.
3.9 Environmental Benefits
3.9.1 Co2 and other pollutants
In Ireland, cement manufacture is currently the second largest industrial source of
CO2 and NOx emissions after the generation of electrical power from fossil fuels. Almost
one tone of CO2 is generated in the manufacture of one tone of Portland cement, along with
2kg of so2 3.5 kg of NOx and 2kg of CO.
On the other hand ground granulated blast furnace slag cement is manufactured
from an industrial by-product, and has a CO2 footprint, and zero harmful pollutant
emissions such as SO2,CO and NOx ,CO2 emissions between ground granulated blast
furnace slag and Portland cement, demonstrates the savings that can be made by using
GGBS cement.
3.9.2 Energy savings
1. In addition to CO2 savings, the embodied energy of GGBS is only some
7% to 8% of that of Portland cement. The manufacture of Portland cement is
a high energy use process, involving three separate processes;
• Quarrying, crushing and blending limestone and shale
• Burning the limestone and shale in a rotating kiln to produce clinker
• Grinding the clinker to make cement
2. The energy consumption per ton. Of Portland cement produced equals 4000
MJ(1100kw.hrs)
3. In contrast, the manufacture of GGBS slag cement only involves the
transport, drying and grinding of an industrial by-product, and is a low
energy operation. In addition, it is a recycling operation and has downstream
benefits in that it eliminates the need for landfill disposal.

4. The energy consumption per ton. Of GGBS produced equals 307MJ
(85kw.hrs). thus the energy saved by replacing Portland cement with GGBS
equals 3639 MJ(1015kw.hrs) per tones
3.9.3 Natural Resources
In the production of Portland cement 1.6 tones of clay and limestone are removed
from the landscape for every tone of Portland cement produced. However, there is zero
depletion of natural resources associated with the manufacture of GGBS. The raw material
for GGBS production is an industrial by-product. This means no extraction of limestone or
clay in large-scale quarries that both deplete natural resources and disfigure the landscape,
and no associated traffic, noise and dust problems that are also generated by large-scale
quarrying operations.
3.9.4 Workability
It is generally known that GGBS particles are less water absorptive than Portland
cement particles and thus GGBS concrete is more workable than Portland cement concrete.
For equivalent workability, a reduction in water content of up to 10% is possible.
Researchers believed that this was due to the smooth and dense surface of the slag that
made GGBS less water absorptive as compared to Portland cement. Some researchers
reported that GGBS concrete mixes exhibited 20% to 50% greater slumps than ordinary
concrete with the same water/ content ratio.
3.9.5 Creep
It has been reported that under practical conditions the creep of GGBS concrete was
similar to that of Portland cement (concrete society, 1991). Other researchers reported that
GGBS concrete had similar or lower creep with replacement levels ranging from 30% to
70%.

3.9.6 Hydration Temperature
Experiments showed that the inclusion of GGBS in concrete could significantly
reduce the temperature rise during the hydration of cement. Researchers found that, with
70% GGBS replacement, it was possible to reduce the hydration temperature by about
30%. Other researchers also found that the temperature rise was reduced when GGBS
replacement level was increased up to 70%. The reduction was significant only at the 70%
replacement level.
3.9.7 Sources of GGBS
Ground granulated blast furnace slag is by-product from the blast furnaces used to
make iron. These operate at a temperature of 1500 C and fed with a carefully controlled
mixture of iron ore, coke and lime stone. The iron-ore reduced to iron and the remaining
materials from a slag that floats on top of the iron. This slag is periodically tapped off as a
molten liquid and if it is to be used for the manufacture of ground granulated blast furnace
slag is has to be rapidly quenched in large volumes of water. The quenching optimizers the
cementation properties and ground to a fine powder less than 45microns having specific
surface about 400 to 600m2/kg.

CHAPTER -4
AIM AND SCOPE OF THE PRESENT INVESTIGATION
4.1 General
The scope of present investigation is to study and evaluate the effect of partial
replacement of cement with GGBS (0%,10%,20%,30%and 40%) in concrete of target
strength 40mpa separately in two phases cubes of standard size of
100mmx100mmx100mm standard cylinders of size 150mmx300mm and prisms of
standard size of 500mmx100mmx100mm were casted and tested after a curing period for
compressive and 28days for split tensile and flexural strengths respectively.
4.2 Objective
The work described in this study relating to partial replacement of cement with
GGBS obtained from Visakhapatnam steel plant test specimens of hardened concrete
prepared with different percentages of replacement with pozzolanic materials will be tested
in terms of strengths the above results are compared with conventional concrete ultimately
based on the test results it can be possible to establish the optimum percentage of partial
replacement of cement with GGBS.
4.3 Test Program
To evaluate the strength characteristics in terms of compressive split tensile and
flexural strengths with different percentages of GGBS (0,10,20,30& 40%) as a partial
replacement of cement fine aggregate coarse aggregate and water are obtained by IS-code
method for target strength of 40Mpa .45cubes of 100mmx100mmx100mm size were casted
with replacement of 0,10,20,30and 40% in cement these cubes were tested after a curing
period of 7days,28days for compressive strength 15 cylinders 150mmx300mm size and 15

flexural prisms of 500x100x100mm size were casted of same percentages of GGBS
replacement mentioned above these specimens were tested after a curing period of 28days
for split tensile and flexural strength phase in 2nd
phase the same process will be repeated
with GGBS replacement

CHAPTER 5
EXPERIMENTAL INVESTIGATION
5.1 General
Experimental investigation helps in providing information about the physical
properties if ingredients like cement fine aggregate and coarse aggregate these parameters
helps to know the suitability to prepare hardened concrete the specimens like cubes
cylinders and flexural prisms with the designed concrete mix using GGBS as a partial
replacement in cement
5.1.1 Prosperities of Materials
The ingredients used in preparation of concrete namely cement fine aggregate
coarse aggregate was tested in laboratory as per IS codes to know the allowable values for
use in the concrete the details of tests conducted to aggregates mentioned below
5.2 Cement
Ordinary Portland Cement of 53(S) also called IRS: T-40-1985 Special grade
cement was used in the investigation.
5.2.1 OPC-53(S) Grade Cement
One of the very few cement manufacturers having the capability to manufacture this
special grade of cement which due to its enhanced quality and performance parameters has
been approved by the RDSO and is preferred by Indian Railways for manufacture of
“SLEEPERS”.
OPC-53 (S) Grade is also used in heavily loaded or pre-stressed structures, which
are subjected to high dynamic loads due to rapidly moving volumes, be it a train passing on
the railway sleepers or a great volume of water moving at high speed to generate electricity
in a Dam. The characteristics of OPC-53(S) Grade cement with the prescribed BIS
Standards IS: 12269 – 1987 can be seen in the table below.

Table 5.1: The details of test conducted on physical properties of Cement OPC-53(S)
Are described below.
S. No PHYSICAL PROPERTIES Range Required
1 Fineness (M2
/Kg) 407 370 Min.
2 Setting Time (Minutes)
Initial 145 60 Min.
Final 195 600 Max.
3 Expansion
Le. Chatelier (mm) 1.00 5.00 Max.
Auto clave (%) 0.18 0.8 Max.
4 Compressive Strength (MPa)
3 Days 36.0 Not Specified
7 Days 47.0 37.5 Min.
28 Days 60.0 Not Specified
Cement tested at temp.27± 2°C
The above cement complies with IRS: T-40-1985 (53S) of Indian Railway Standard
specification for cement used in concrete sleeper.

Fig 5.1: Cement bag of OPC-53(S)
Fig 5.2: Cement powder OPC 53(S)
The details of test conducted on cement OPC-53 Grade are described below.
5.2.2 Specific Gravity Test According to IS 2720 (part III)-1980
Specific gravity is the ration of the density of a substance compares to the density
(mass of the same unit volume) of a reference substance apparent specific gravity is the
ration of the weight of a volume of the substance to the weight of an equal volume of the
reference substance the reference substance is nearly always for liquids or air for gases
specific gravity of the cement is calculated by using density bottle method.
• Cement of specific gravity is 3.13

5.2.3 Fineness Test on Cement According To IS 4.31-1986
Fineness test on cement can be calculated by sieve test or air permeability method in
commercial cement it is suggested that there should be about 25 to 30% particles less than
7 microns in size
• Fineness size of cement is 2%
5.2.4 Initial and Final Setting Time on Cement
Initial and final setting time on cement is obtained by vicat’s apparatus for the initial
setting time of the cement vicat’s needle should penetrate to a depth of 33 to 35mm form
the top for final setting time the vicat’s needle should pierce through the paste more than
0.5mm we need to calculate the initial and final setting time as per IS: 4031 (part 5)-1988
• Initial setting time of test cement: 118mins
• Final setting time of test cement: 3hrs 2mins (242mins)
5.2.5 Standard Consistency Test
The standard consistency test of a cement paste is defined as that consistency which
will permit vicat’s plunger having the 10mm diameter and 50mm length to penetrate to a
depth of 33 to 35 from the top of the mould the basic aim is to find out the water content
required to produce a cement paste of standard consistency as specified by the IS: 4301
(part 4)-1988 Standard consistency of test cement: 32%.

Table 5.2 Physical Properties of Cement (OPC 53 Grade) (Is 8112-1989)
S.NO PROPERTY VALUES
1 Specific gravity 3.13
2 Fineness of cement by sieving 2%
3 Normal consistency 32%
4 Setting time
a)Initial setting time
b)final setting time
118 min
242 min
5 Compressive strength
a) 3days
b)7days
c)28days
25.3N/mm2
36.6N/mm2
25.26N/mm2
5.3 Fine Aggregate
Aggregates smaller than 4.75mm and up to 0.075mm are considered as fine
aggregate the details of test conducted on fine aggregate are described below.
5.3.1 Specific Gravity according to IS: 2386 (Part III)
The specific gravity of an aggregate is considered to be a measure of strength or
quality of the material the specific gravity test helps in the identification of stone.
• The specific gravity of fine aggregate is 2.52
5.3.2 Fineness Modulus
The standard definition fineness modulus is as follows “An empirical factor by
adding the total percentage of sample of the aggregate retain on each of a specified series
of sieves, on dividing the sum by 100”.

5.3.3 Sieve Analysis
Helps to determine particle size distribution of coarse and fine aggregates this is done
by sieving the aggregates as per IS 2386 (Part I) -1963
• A set of IS sieves of sizes 80mm, 40mm, 20mm, 16mm, 10mm, 4.7mm, 2.36mm,
1.18mm, 600 meters, 300 m, 150 m.
• Form 80mm to 4.75mm IS sieves are used for coarse aggregate analysis and from
4.75mm to 150 m IS sieves are used for fine aggregates.
Table 5.3: sieve analysis of fine aggregates
s/no Sieves
size
Weight
retained
(g)
Cumulative
weight retains
(g)
Cumulative %
weight retains
% weight
passing
1 4.75mm 0.013 0.013 1.3 98.7
2 2.36mm 0.019 0.032 3.2 96.8
3 1.18mm 0.046 0.078 7.8 92.2
4 600 0.238 0.316 31.6 68.4
5 300 0.518 0.834 83.4 16.6
6 150 0.122 0.956 95.6 4.4
7 Pan 0.044 1 100 0
Total 322.9
The fineness modulus fine aggregate is 322.9/100 = 3.2
According to IS 383-1976 Table
The fineness aggregate belongs to zone-III.

Fig 5.3: Fine Aggregate
5.4 Coarse Aggregate (IS: 23886 PART III)
Aggregate greater than 4.75mm are considered as coarse aggregate specific gravity
according to IS: 2386 (part III)
The specific gravity of coarse aggregate is 2.73
5.4.1 Crushing Value according to is: 2386 (Part-IV)
The aggregate crushing value provides a relative measure of resistance to crushing
under a gradually applied compressive load to achieve a high quality of pavement
aggregate possessing low aggregate crushing value should be preferred.
5.4.2 Sieve Analysis according to IS: 383-1970
A sieve analysis (or graduation test) is a practice or procedure used (commonly used
in civil engineering) to assess the particle size distribution is often of critical importance to
the way the material performs in use a sieve analysis can be performed on any type of non
organic granular materials including sands crushed rock clays granite feldspars coal and
soil a wide range of manufactured powders grain and seeds down to a minimum size
depending on the exact method. Being such a simple technique of particle sizing it is
probably the most common.

Fig 5.4: Coarse aggregate
Table 5.4: Sieve analysis of coarse aggregate
s/no Sieves
size
Weight
retained
(Kg)
Cumulative
weight retains
Cumulative %
weight retains
% weight
passing
1 80mm 0 0 0 100
2 40mm 0 0 0 100
3 20mm 0.225 0.225 4.5 95.5
4 10mm 3.09 3.315 66.3 34.1
5 4.75mm 1.435 4.75 95.0 5.4
6 2.36mm 0.25 5 100 0
7 1.18mm 0 5 100 0
8 600 0 5 100 0
9 300 0 5 100 0
10 150 0 5 100 0
Fineness modulus = 6.65 Total= 665.80

Fig 5.5: IS Sieves
5.4.3 Water Adsorption of Coarse Aggregate according to IS: 236 (Part III)
Water absorption gives an idea of strength of aggregate. Aggregates having more
water absorption are more porous in nature and are generally considered unsuitable unless
they are found to be acceptable based on strength, impact and hardness tests.
5.5 GGBS and Its Properties
Ground granulated blast furnace slag GGBS is a by-product from the blast furnaces
used to make iron these operate at a temperature of about 15000
C and are fed with carefully
controlled mixture of iron-ore; remaining materials from a slag that floats on top of the iron
this slag is periodically tapped off as a molten liquid and if it is to be used form
manufacture of GGBS it has to be rapidly quenched in large volumes of water the
quenching optimizes the cementations properties and produces granules similar to coarse
sand this granulated slag is ten dried and ground to a fine powder.

Fig 5.6: GGBS fine powder
TABLE 5.5 physical Properties of GGBS
Sl.no Physical properties Slag
1 Particle shape Spherical
2 Appearance White
3 Specific gravity 2.85
4 Bulk density 1200kg/m3
5 Fineness >350m2
/kg
TABLE 5.6 Chemical Properties of GGBS
Sl.no Chemical
properties
Chemical content by
%wt
1 Sio2 35.00
2 Al2o3 13.00
3 Cao 40.00
4 Mg O 8.00
5 So3 0.85
6 Fe2o3 0.50 to 2.00

CHAPTER 6
CONCRETE MIX DESIGN
6.1Purpose of Mix Design
The mix design can be defined as the process of selecting suitable ingredients of
concrete (via, cement, sand, coarse aggregate and water) and to optimize their relative
proportions to meet the requirements of design, i.e.
• Complies with the specifications of structural strength required,
• Complies with the durability requirements in the environment in which it is use
Meets with the durability requirement. i.e. it is capable of being mixed, transported
and compacted as efficiently as possible, and Be economical without sacrificing
requirements at above two.
6.2Workability and its Requirements
Workability is the ease with which fresh concrete can be mixed, transported, placed
and compacted in the moulds or forms. Some forms can be large and some may be very
thin. Some may have high reinforcement and some have low. Concrete should have good
flow until it completely fills up the mould, surrounds the reinforcement without voids. For
this, concrete when green should have good flow without separation of constituents and
ability to get compacted. You might have observed that concrete is made workable by
adding water after its mixing. But this is unscientific and harmful to concrete. The degree
of workability required depends upon location of the concrete, the shape of element to be
concreted, thin or thick and the method of compaction, mechanical or manual. Depending
upon these factors, the workability of the concrete should be decided.

6.3. Water Content:
Cement requires about 38% of water by its weight for complete chemical reaction
and to occupy the space within gel pores. But with this quantity of water the concrete is
very stiff and cannot be poured and compacted. So more water is added to concrete to
make it workable, the upper limit is up to 60% in plain concrete and 55% in RCC.
Therefore the amount of water v/s the amount of cement i.e. water-cement ratio is very
important in mix design. Both water and cement are measured by weight. Better
workability with lower water cement ratio can be obtained by adding admixtures.
6.4 Factor required for Mix design
Two other factors viz. specific gravities of the ingredients and the moisture they
contain also require to be known:
6.4.1 Sp. Gravity of the materials:
• The mix design is based on weight of the ingredients and not on the volume. So,
specific gravities of the ingredients going into making of the concrete are required.
• The specific gravity of cement is taken as 3.15 irrespective of the grade of the
cement. Usually there is very little variation as it is made in factory conditions.
• The specific gravity of sand varies, the average value being 2.6. If the source of
sand is known and laboratory reports are available, the value may be taken from the
report. Otherwise the average value may be adopted.
• The specific gravity of coarse aggregate varies between 2.6 to 2.9 for granite. If the
sp. Gravity is known it may be used. If not it may be taken as 2.7.

6.5 Methods of Mix Design
There are more than 10 methods to work out the mix design. But we shall confine
ourselves to method recommended by Indian standards (IS: 10262 – 1982, reaffirmed
1999).
As most professionals who will be reading this booklet will be engaged in
construction in
India, this method will be acceptable to most clients.
6.5.1 IS Method of Mix Design:
The IS method is based on the two important assumptions, viz.
• The compressive strength of concrete is governed by free water-cement ratio.
• The workability of concrete is dependent on the amount of water added for a given
size, shape and grade of aggregate.
6.6 Basic parameters required:
• Characteristic strength of concrete (Grade of concrete).
• Degree of quality control expected to be exercised at construction site.
• Type and max. Size of aggregate.
• Degree of workability desired (slump or compaction factor).
• Type of exposure – mild, moderate, etc.
• Standard deviation of compressive strength of concrete.
6.7 Test data on materials required:
1. Sp. Gravity of cement.
2. Test data on cement – testing (28 days comp. strength if available).
3. Sp. Gravity and water absorption of coarse and fine aggregate.
4. Grading of coarse and fine aggregates.

MIX DESIGN BASED ON IS: 10262 – 2009
6.8 MIX DESIGN OF M40 GRADE CONCRETE (using Ordinary Portland cement)
A-1 STIPULATIONS FOR PROPORTIONING
a) Grade designation: M40
b) Type of cement: OPC 53 grade conforming to IS 12269
c) Max. Nominal Size of aggregate: 20 mm
d) Minimum cement content: 360 Kg/m3 (Table-5, IS 456:2007)
e) Maximum W/C ratio: 0.45
f) Workability: 100 mm (slump)
g) Exposure condition: Severe
h) Degree of supervision: Good
i) Type of aggregate: Crushed angular aggregate
j) Maximum cement content: 450 Kg/m3 (as per IS 456:2000)
k) Chemical Admixture: No
A-2 TEST DATA FOR MATERIALS
a) Cement used: OPC 53 grade
b) Specific Gravity of cement: 3.15
c) Specific Gravity of
Coarse aggregate: 2.73
Fine aggregate: 2.52
d) Water Absorption of
Coarse aggregate: 0.5%
Fine aggregate: 1%
e) Free (surface) moisture of
Coarse aggregate: Nil
Fine aggregate: Nil
f) Sieve Analysis of
Coarse aggregate: Graded
Fine aggregate: confirming to grading zone III (of table-4, IS 383)

A-3 TARGET STRENGTH FOR MIX PROPORTIONING
f'ck = fck + 1.65 S
Where, f’ck = Target average compressive strength @ 28 days
fck = Characteristic compressive strength @ 28 days
S = Standard deviation.
From table -1,
Standard deviation S = 5 N/mm2
Target strength = 40 + 1.65 x 5 = 48.25 N/mm2
A-4 SELECTION OF WATER – CEMENT RATIO
From table -5 of IS 456:2000 Maximum W/C ratio = 0.45
A-5 SELECTION OF WATER CONTENT
From table -2,
Maximum Water content for 20 mm aggregate = 186 liters (for 25mm to 50mm
slump). Estimated water content for 100 mm slump = 186+ = 197lt
186lt ( Hence OK)
A-6 CALCULATION OF CEMENT CONTENT
W/C ratio = 0.45
Cement content = 197/0.45 = 437.7Kg/m3
From table -5 of IS 456:2000 Minimum cement content for moderate exposure
Condition = 320 Kg/m3
Therefore, 430 Kg/m3 > 320 Kg/m3, hence OK.
A-7 PROPORTION OF VOLUME OF COARSE AND FINE AGGREGATE
CONTENT
From table -3,
IS 10262:2009 Volume of coarse aggregate corresponding to 20 mm size of coarse
aggregate & fine aggregate (Zone III) for W/C ratio of 0.50 = 0.64
In the present case W/C ratio is = 0.45 Therefore, volume of coarse aggregate is required to
be increased to decrease the fine Aggregate content. As the W/C ratio is lower by 0.05, the
proportion of volume of coarse Aggregate is increased by 0.01 (at the rate of + 0.01 for
every + 0.05 change in W/C ratio).

Volume of coarse aggregate for the w/c ratio of 0.45 = 0.65
Therefore, Volume of coarse aggregate = 0.65
Volume of fine aggregate = 1.0 – 0.65= 0.35
A-8 MIX CALCULATIONS
The mix calculations per unit volume of concrete shall be as follows.
a) Volume of concrete = 1 m3
b) Volume of cement = mass of cement /specific gravity of cement x (1/1000)
= 437.7/ 3.15 x (1/1000)
= 0.138 m3
c) Volume of water = mass of water /specific gravity of water x (1/1000)
= 197/ 1.0 x (1/1000)
= 0.197m3
d) Volume of All in Aggregate = [ a – ( b + c ) ]
= [1 – (0.138+ 0.197]
= 0.66 m3
e) Mass of Coarse Aggregate = e x volume of CA x sp.gr.of CA x 1000
= 0.692 x 0.65 x 2.73 x 1000
= 1136 kg = 1171 kg
f) Mass of Fine Aggregate = e x volume of FA x sp.gr.of FA x 1000
= 0.66 x 0.35x 2.53 x 1000
= 584kg
A-9 MIX PROPORTIONS
a) Cement = 437 Kg/m3
b) Fine Aggregate = 584 Kg/m3
c) Coarse Aggregate = 1171 Kg/m3
d) Water = 197 lts
e) W / C Ratio = 0.45 ….( Mix proportion: 1 : 1.3 : 2.7)

Fig 6.1: Weigh Balance Used For Weighing Of Materials
Fig 6.2: Mixing of Materials Using Laboratory Mixer
Fig 6.3: Checking For Slump Value

6.9 Casting
The cubes were cast in steel moulds of inner dimensions of 100 x 100 x 100 mm for
testing the compressive strength of the specimens the cylinders were cast in steel moulds f
inner dimensions as 15mm diameter and 300 mm height for testing the split tensile strength
and finally the flexural beams were cast in steel moulds with inner dimensions of 500 x 100
x 100 mm for flexural strength of the specimens are made with OPC-53.
The cement sand coarse aggregate and GGBS mixed thoroughly approximately 25%
of water required is added and mixed thoroughly with a view to obtain uniform mix after
that the balance of 75% of water was added and mixed thoroughly with a view to obtain
uniform mix care has to be taken in mixing to avoid balling effect
For all test specimens moulds were kept on table vibrator and the concrete was
poured into the moulds in three layers by tampering with a tamping rod and the vibration
was effected by table vibrator after filling up moulds the concrete filled moulds are shown
in plate the specimens were taken after twenty four hours and were kept immersed in clean
water tank up to the specified period of time curing before testing the specimens were
taken out dried under shade and weight of the specimens was noted Eighteen cubes , six
cylinders and six flexural beams were casted for each percentage of replacement in this test
45 cubes,15 cylinders and 15 prisms were casted and test for cement replacement with
GGBS of M40mix design .
Fig 6.4: Specimen Kept For Vibration

Fig 6.5: Table Vibrator

6.10 Curing: Curing is done for 28days and tests on specimens conducted on 3days,
7 days, 28 days.
Fig 6.6: specimens kept for curing
Fig 6.7: showing specimen after 7days curing

CHAPTER 7
STRENGTH STUDIES ON CONCRETE & RESULTS
7.1 COMPRESSIVE STRENGTH TEST according to IS: 516-1959
This test meant for conducting to know the compressive strength of hardened
concrete the cubes were taken out from curing tank dried and placed in compressive testing
machine of 300T capacity the cube will be placed in testing machine in such way that the
load exerted on specimen should be perpendicular the load on the cube applied at a
constant rate up to the failure of specimen and the ultimate load at failure is noted the cube
compressive strength of the concrete mix is then computed a sample calculation for
determination of cube compressive strength is presented in APPENDIX-I this test has been
carried out on cube specimens at 3,7,and 28days of age the values are presented in table .
Compressive strength =P/4
Where,
P=maximum load in Kg applied to the specimen
A=cross sectional area of the cube on which load is applied (150 x 150mm)
Fig 7.1: Cube Moulds of size (10x10x10)mm

Fig 7.2: Specimen after Compression Test
Fig 7.3: Compression Testing Machine

7.2 SPLIT TENSILE TEST According to IS: 5816-1999
This test is conducted on 300T compression testing machine as shown in plate no.
The cylinders prepared for testing are 150mm on diameter and 300mm height .After noting
the weight of the cylinder, diametrical lines are drawn on the two ends ,such that they are
in axial plane .Then the cylinder is placed on the bottom compression plate of the testing
machine and it is aligned such that the lines marked on the ends of the specimen are
vertical. Then the top compression plate is brought into contact at the top of the cylinder.
The loads applied at uniform rate, until the cylinder fails and the load is recorded. From
this load, the split tensile strength is calculated for each specimen. A sample calculation for
computation of split tensile strength is presented in Appendix-I. In the present work, this
test has been conducted on cylinder specimens after 28days of curing. The values are
presented in the table.
Fct=
Where, P=Maximum load in Newton’s applied to the specimen
d=cross sectional dimensions of the specimen in mm (150mm)
l=Length of the specimen in mm
Fct=Split tensile strength
Fig 7.4: Cylindrical mould specimen under load

7.3 FLEXURAL STRENGTH TEST According to IS: 516-1959
This test is conducted on 10T Universal Testing Machine .The loading arrangement
to test the concrete beam specimens for flexure is shown in the plate no. The beam element
is simply supported on two steel rollers of 38mmin diameter d these rollers should be so
mounted that the distance from the center to centre is 400mm for 10.0cm specimens the
load is applied through two similar rollers mounted at the third points of the supporting
span, which is spaced 13.3cm center to center. The load is divided equally between the two
loading rollers, and all the rollers are mounted in such a manner that the load is applied
axially and without subjecting specimen to any tensional stresses. The specimen is placed
in the machine in such a manner that the load is applied to the uppermost surface as cast in
the mould, along two lines spaced 13.3cm apart. The axis of the specimen is carefully
aligned with the axis of the loading device. No packing is used between the bearing
surfaces of the specimen and the rollers. The load is applied without shock and increasing
continuously at a rate such that the extreme fiber stresses increases at a rate of 180kg/min
for the 10.0cm specimens. The load is increased until the specimen fails, and the maximum
load is applied to the specimen during the test is recorded. Also the distance between the
line of fracture and the nearer support is measured. The sample calculation for computing
flexural strength is presented in appendix-I . In the present investigation, this test has been
conducted on beam specimens after 28 days of curing. The values are presented in the
table.
Fb=
Where, Fb = flexural strength
P= maximum load in kg applied to the specimen
l=length in cm if the span on which the specimen was supported
b=Measured width in cm of the specimen
d=Measured depth in cm of the specimen at the point of failure.

Fig 7.5: Prism mould specimen
Fig 7.6: prism after demoulding

Fig 7.7: Universal Testing Machine
Table 7.1 Quantities required for 1m3 of concrete with partial replacements GGBS in
cement for target strength of 40mpa
% of
replacement
water Cement in
Kg’s
Sand in
Kg’s
Coarse aggregate in kg’s GGBS
10mm 20mm
0 190 380 663 464 696 0
10 190 342 663 464 696 38
20 190 304 663 464 696 76
30 190 266 663 464 696 114
40 190 228 663 464 696 152

7.4 Analysis of Test Results of Cement Replaced With GGBS
7.4.1 Compressive strength results and graphs
Table 7.2 Compressive Strength of Concrete of Target Strength 40mpa with Different
Replacement Percentages Of GGBS
Compressive strength of specimens in (N/mm2
)
% of cement replacement 7days 28days
G0 36.25 41.5
G10 37.75 47.5
G20 38.5 50.5
G30 35 52.25
G40 32.5 48.5
Fig 7.8: Compression Strength of concrete by replacing cement with GGBS
Compressivestrengthofspecimensin
(N/mm2)
% of cement replacement of GGBS By weight
Compression strength with repect to the variation of % GGBS

7.5 Spilt Tensile Strength Results and Graphs
TABLE 7.3 Split tensile strength of concrete of target strength 40mpa with different
replacement percentages of GGBS.
Split tensile strength of specimens in (N/mm2
)
% of cement replacement 28days
G0 2.26
G10 2.96
G20 3.45
G30 2.63
G40 2.17
Fig 7.9: ! " " #$ %" " & '
Splittensilestrengthofin(N/mm2)
Split tensile strength with repect to the variation of %
GGBS

7.6 Flexural strength results and graphs
TABLE 7.4 Flexural strength of concrete of target strength 40mpa with different
replacement percentages of GGBS
Flexural strength of specimens (N/mm2
)
% of cement replacement 28days
G0 5.84
G10 6.16
G20 6.68
G30 6.06
G40 4.64
Fig 7.10: () % ! " " #$ %" " & '
Flexuralstrengthofspecimens(N/mm2)
() % ' " *% % ! +

CHAPTER 8
CONCLUSIONS
SUMMARY
Results found from laboratory tests were analyzed to derive the useful
conclusions relating to the suitability of partial replacement of GGBS in cement and
finding out the optimum % of replacement in terms of compressive strength, split tensile
strength & flexural strength.
8.1 Cement replacement with GGBS
a) The Compressive Strength of concrete cubes is increased by 26.5% at a replacement of
30% of cement with GGBS when compared with controlled concrete at 28days.
b) It is concluded that the optimum strength obtained at a replacement of 30% of cement
with GGBS for curing period of 28days, and later on it decreases.
c) The Split Tensile strength of concrete cylinders is increased by 50% at a replacement of
20% of cement with GGBS when compared with controlled concrete at 28 days.
d) The Flexure Strength of Concrete Prisms when tested at 28days, increases the strength
by 14% at a replacement of 20% of cement with GGBS when compared with controlled
concrete.

CHAPTER 9
SCOPE OF FURTHER WORK
SCOPE OF FURTHER WORK
1. The above research work can be carried out to Reinforced concrete beams for its
suitability.
2. A study can be carried out to determine the effects of partial replacement of GGBS
with cement would have on the durability of concrete.
3. Studies can be carried out considering different adverse environment like attacks
against sodium chloride and sodium sulphate.
4. Studies can be carried out sustainability against sea water.

APPENDIX-I
STRENGTH CALCULATIONS
A. Compressive Strength of cube:
Average compressive load (P) = 510 kN
Area of the cube, (A) in mm2
= 100 100 mm2
Compressive strength of the cube = P/A
=
= 51 N/mm2
B. Split Tensile strength of cylinder:
Average tensile load (P) = 160 kN
Area of cylinder , (A) in mm2
=
Split tensile strength of cylinder =
=
= 2.26 N/mm2

C. Flexural Strength of Prism:
Average flexural load (P) = 1170 Kg
Volume of Prism (l,b,d) mm3
= 500
Flexural Strength of Beam =
=
= 5.84 N/mm2

REFERENCES
REFERENCES:
1. S.Arivalangan (2014) “Sustainable studies on concrete with GGBS” as a
replacement material in cement vol.8 no.3 of Jordan journal of Civil Engineering.
2. P.N.Rao (2010) “High performance of concrete with GGBS” published in
International journal of engineering, science & technology.
3. A.H.L.Swaroop “Durability studies on concrete with GGBS, vol.3, Issue 4, of
International journal of engineering research and application.
4. S.P.Sangeetha, P.S.Joanna “flexural behavior of RC beam with partial replacement
of GGBS, American journal of engineering research.
5. K.Swarna latha , M.V.Seshagiri Rao., “Estimation of GGBS and HVFA strength
efficiency in concrete with age of IJEAT vol.2
6. Atul Dubey, Chandak R, Yadav R.K., “Effect of blast furnace slag powder on
compressive strength of concrete” International journal of Science & Engineering
Research ISSN: 2229-5518 Vol.3, Issue. 8, August 2012.

IS CODES
IS CODES
1. IS 383:1970 Indian standard institution ,Specifications of coarse and fine aggregates
from natural sources of concrete, New Delhi
2. IS 456:2007 Plain and Reinforced Concrete Code of Practice, Bureau of Indian
Standards, New Delhi.
3. IS 455:1989 Specification for Portland Slag Cement. Bureau of Indian Standards,
New Delhi, Reaffirmed 1995
4. IS 516:1959 Specification for Method of Tests of Strength of Concrete, Reaffirmed
1999, Edition 1.2, Bureau of Indian Standards, New Delhi.
5. IS 1199:1959 Specification for methods of sampling and analysis of concrete,
Bureau of Indian Standards, New Delhi.
6. IS: 2386 (Part I)-1963 Specification for methods test for aggregates for concrete.
Part I particle size and shape. Reaffirmed 1997. Bureau of Indian Standards, New
Delhi.
7. IS:2386 (Part II)-1963 Specification for methods test for aggregates for concrete.
Part II estimation of deleterious materials and organic impurities. Reaffirmed 1990.
8. IS: 2386 (Part III)-1963 Specification for methods test for aggregates for concrete.
Part III specific gravity, density, voids, absorption and bulking. Reaffirmed 1997.
9. IS: 2386 (Part IV)-1963 Specification for methods test for aggregates for concrete.
Part IV Mechanical properties. Reaffirmed 1997. Bureau of Indian Standards, New
Delhi.
10. IS: 2386 (Part V)-1963 Specification for methods test for aggregates for concrete.
Part V Soundness test. Reaffirmed 1997. Bureau of Indian Standards, New Delhi.
11. IS 4031:1968 Specification for fineness test of cement, Bureau of Indian Standards,
New Delhi.

12. IS 4031 (Part I ):1996 Specification for Methods of physical tests for hydraulic
cement : Part I Determination of fineness by dry sieving. Bureau of Indian
Standards, New Delhi.
13. IS 4031 (Part V) – 1988 Specification for Initial and Final Setting time of cement.
14. IS 5816:1999 Specification for Split Tensile Strength of Concrete – Method of Test,
first revision. Bureau of Indian Standards, New Delhi.
15. IS 8112 – 1989 Specification for 43 grade ordinary Portland cement, Bureau of
Indian Standards, New Delhi.
16. IS 10262-2009 and SP 23:1982. Recommended Guidelines for concrete Mix
Design. Bureau of Indian Standards, New Delhi.

BIBILOGRAPHY
BIBILOGRAPHY
1. Shetty,M.S., “Concrete Technology” Chand.S and Co.Ltd,India (2009).
2. Nevelli, “ Properties of Concrete” Longman Publications, New Delhi, Reprint 2013

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