This civil engineering mini project works in civil.Replacament of cement with flyash

1. ANNAMACHARYA INSTITUTE OF TECHNOLOGY AND SCIENCES
CIVIL ENGINEERING
MINI PROJECT WORK
UNDER GUIDENCE OF
S.Hanmanthu (ASST.PROFF)
PROJECT ASSOCIATES:
B.Nithya sri 21T85A0117
D.Vandana 21T85A0139
V.Anil 21T85A0106
M.Ramesh goud 21T85A0120
G.Saikiran 20T81A0107
THE PERFORMANCE OF M30 GRADE CONCRETE BY PARTIAL
REPLACEMENT OF CEMENT WITH FLY ASH

2. The concept of partial replacement of cement which is capable for sustainable
development is characterized by application of industrial wastes to reduce consumption
of natural resources and energy and pollution of the environment. Presently large
amounts of fly ash are generated in thermal industries with an important impact on
environment and humans. This research of cement describes the feasibility of using the
thermal industry waste in concrete production as partial replacement of cement. Fly ash
can be used as filler and helps to reduce the total voids content in concrete. The cement
has been replaced the total ash accordingly in the range of 10%, 20%, 30%, 40% by
weight of cement in common for M-30 Mix. Nowadays due to rapid growth in
construction cement is very costly.
Key words: Green concrete, compressive strength, split, tensile strength, fly ash.
ABSTRACT

3. A various numbers of research have been conducted to examine the effects of use of Fly Ash as additive in
cement, admixture in concrete and as replacement of cement in concrete. The compressive strength of concrete
was checked by replacing different proportions of cement with suitable quantities of Fly Ash and the results have
been found most effective and applicable. Incidentally most of the research works have been conducted only for a
limited percentage of cement replacement that too for a lower grade of concrete. It is therefore necessary to
conduct an extensive research on compressive strength of different qualities of concrete as well as different
proportions of Fly Ash at different curing periods. Herein below the various methods of using the Fly Ash as a
cement replacement in concrete is discussed vividly.
INTRODUCTION

4. Concrete:
 Concrete plays a significant role in the construction of structure around the world. According to
construction materials (2007) concrete is a composite material obtained by mixing cement, sand, gravel
and water. A concrete mix can be considered to consist of two main parts, aggregates(sand and gravel)
and cement paste (water and cement).
 The global demand of concrete is significantly increasing due to infrastructure growth worldwide.
Therefore using alternative sources as replacement for cement and aggregates appears to be a
challenging task.
 There are many potential industrial waste products that have the potential to replace aggregates in
concrete such as: plastic, fly ash, rubber, steel slags and leather wastes. However, fly ash is the
industrial waste material that is discussed in depth in this particular research.

5. Arivazhagan (2011)
conducted a peculiar study on the environmental benefit with fly-ash stated that
there is increases in crop yields and nutrient uptake due to release of major
secondary and micro nutrients from flyash applied in the soil during crop growth.
Basically fly-ash has slightly acidic in pH and its effect is more pronounced in soils
having high pH.
Jayesh kumar Pitroda (2012)
It is shown in this paper that this research work describes the feasibility of using
the thermal industry waste in concrete production as partial replacement of cement.
The use of fly-ash in concrete formulations as a supplementary cementitious material
was tested as an alternative to traditional concrete. The cement has been replaced
by fly-ash accordingly in the range of 0% (without fly ash), 10%, 20%, 30% & 40% by
weight of cement for M-25 and M-40 mix. Concrete mixtures were produced, tested
and compared in terms of compressive and split strength with the conventional
concrete.
LITERATURE REVIEW

6. Swaroop (2013)
In his presentation the study is mainly confined to evaluation of changesin both compressive strength
and weight reduced in five different mixes of M30 Grade namely conventional aggregate concrete (CAC),
concrete made by replacing 20% of Cement by fly-ash (FAC1), concrete made by replacing 40% of
cement by fly ash(FAC2), concrete made by replacing 20% replacement of cement by GGBS (GAC1) and
concrete made by replacing 40% replacement of cement by (GAC2). The effect of 1% H2SO4 and sea
water of those concrete mixes are determined by immersing these cubes for 7 days, 28 days, 60 days in
above solutions and the respective changes in both compressive strength and weight reduction had
observed and upto a major extent we can conclude concretes made by that flyash and GGBS had good
strength and durable properties comparison to conventional aggregate in severe environment.

7. P. Nath and P. Sarker
The research work included replacement of cement with fly ash by 30-40%, which resulted in compressive
strength of 60 MPa after 28 days and 85 MPa after 56 days of curing. The strength for 30% replacement was more
than that of 40% replacement. The researchers also tested the chloride ion permeability and found out that it
reduced by 35 – 45% and more after 28 days. Fly ash reduced the drying shrinkage as well as the sorptivity of the
concrete.
Harison et al (2014)
Conducted a peculiar study on the utilization of materials which can fulfill the expectations of the construction
industry in different areas. In this study cement has been replaced by flyash accordingly in the range of
0%,10%,20%,30%,40%,50%,60%by weight of cement for M-25 mix with 0.46 water cement ratio. Concrete
mixtures were produced, tested and compared in terms of compressive strength. It was observed that 20% of
replacement of Portland pozzolana cement (PPC) by fly-ash strength is increased marginally (1.9% to 3.2%) at 28
days and 56 days respectively.

8. Scope
The purpose of this research is to determine the feasibility os using fly ash as a replacement of cement and fine aggregate in
concrete. Using a product such as fly ash in concrete can influence the mechanical properties of concrete. The original scope of
this study is to investigate the fresh and hardened properties of concrete with fly ash as a replacement of cement and fine
aggregate.
Aim
In order to achieve the scope of this research, the following objectives have to be met:
 Research background information on the basic materials of fly ash, cement and fine aggregate
 Research the chemical and physical properties of fly ash, cement, and fine aggregate(sand), and determine the feasibility of
replacing cement and sand with fly ash.
 Research the effects of combining fly ash into the concrete mixture.
 Concrete mixtures with different percentages of fly ash were prepared to be tested.
 A comprehensive laboratory study was performed to study the mechanical properties of concrete mixtures with different ratios
of fly ash as a replacement of either cement or fine aggregate.

9. Fly ash
Nature of fly ash and its production:
Fly ash is the finely divided residue that results from the combustion of pulverized coal and is transported from the
combustion chamber by exhaust gases. Over 61 million metric tons (68 million tons) of fly ash were produced in 2001.
Fly ash is produced by coal-fired electric and steam generating plants. Typically, coal is pulverized and blown with air
into the boiler's combustion chamber where it immediately ignites, generating heat and producing a molten mineral
residue. Boiler tubes extract heat from the boiler, cooling the flue gas and causing the molten mineral residue to
harden and form ash. Coarse ash particles, referred to as bottom ash or slag, fall to the bottom of the combustion
chamber, while the lighter fine ash particles, termed fly ash, remain suspended in the flue gas.
Production:
Fly ashes produced by FBC boilers are not considered in this document. Fly ash is captured from the flue gases
using electrostatic precipitators (ESP) or in filter fabric collectors, commonly referred to as baghouses. The physical
and chemical characteristics of fly ash vary among combustion methods, coal source, and particle shape.

10. Advantages:
Fly ash is most commonly used as a pozzolan in PCC applications. Pozzolans are siliceous or
siliceous and aluminous materials, which in a finely divided form and in the presence of water, react
with calcium hydroxide at ordinary temperatures to produce cementitious compounds.
 Used in the manufacture of Portland cement.
 Used as a soil stabilization material.
 Fly ash is also used as a component in the production of flowable fill.
 Fly ash is used as component in geo polymers.
Disadvantages:
 Pulverized fuel ash may affect the colour of concrete. According to ‘A.M. NEVILLE’ colour of fly ash
concrete to its carbon content. Usually ugly looking darker colour helps in identifying fly ash
concrete with compared to lighter colour ordinary concrete, when two are placed side by side.
 Use of fly ash leads to slower strength gain.
 Class C fly ash is sensitive to temperature, hence in the mass concreting or when temperature rises
to about 200℃ or 400℉, it does not give high strength.

11. CEMENT
 Cement is a binding material .which holds the coarse aggregate,fine aggregate together.
 cement is considered to be the best binding material and at present, no construcyion work can be taken up without
cement.
 The product obtained by burning and crushing to powder,an intimate mixture of well proportioned calcareous and
argillaceous materials Is called cement.
uses of cement:
 Preparing mortars for masonry work, plastering, pointing, flooring etc.
 For constructing water tanks,retaining walls,swimming pools etc.
 Used for manufacturing pre cst pipes,piles, piles electric posts, railway sleepers etc.,

12. TEST ON CEMENT
 It is necessary to finf the physical nd chemical properties of a cement before casting or construction.
• Fineness of cement
• Consistency test
• Initial nd final setting time of cement
• Soundness test

13. Fineness of cement
Aim: Determination of fineness of cement.
Apparatus required:
IS-90 micron sieve conforming to IS: 460 (Part 1-3)-1985; Weighing balance; Gauging trowel; Brush
Procedure:
1. Weigh accurately 100 g of cement to the nearest 0.01 g and place it on a standard 90 micron IS sieve.
2. Break down any air-set lumps in the cement sample with fingers.
3. Agitate the sieve by giving swirling, planetary and linear movements for a period of 10 minutes or until no more fine
material passes through it.
4. Collect the residue left on the sieve, using brush if necessary, and weigh the residue.
5. Express the residue as a percentage of the quantity first placed on the sieve to the nearest 0.1 percent. 6. Repeat the
whole procedures two more times each using fresh 100 g sample
Result: Percentage residue of cement sample by dry sieving is ___________ percentage.

14. CONSISTENCY TEST ON CEMENT
Aim: Determination of percentage of water by weight of cement required to prepare a standard acceptable (consistent)
cement paste.
Apparatus: Vicat apparatus conforming to IS: 5513-1998; Weighing balance; Gauging trowel; measuring cylinder.
Material: Ordinary Portland cement; Water.
Procedure:
1. Take 400 g of cement sieved through 90 micron IS sieve and keep it on a nonporous, non-absorbent plate.
2. Add 120 ml of water (i.e. 30% by weight of cement) to the cement and mix thoroughly with two trowels for 3 to 5 minutes
till a uniform cement paste is achieved.
3. Fill the past in mould and level with trowel. Shake or tap to remove air bubbles.
4. Place the nonporous plate and the mould under the plunger.
5. Release the plunger gently to touch the surface of paste. Record the initial reading.
6. Release the plunger quickly and allow penetrating into the paste. When the plunger comes to rest, note the final reading.
7. Repeat the procedure with fresh paste varying the water percentage until the plunger penetrates to a depth 5 to 7 mm
from the bottom of the Vicat mould.
Result:

15. DETERMINATION OF SETTING TIMES OF CEMENT
Aim: Determination of initial and final setting time of cement and determine whether the values
satisfy IS standards.
Apparatus: vicat apparatus conforming to IS: 5513-1998; Weighing balance; Gauging trowel;
measuring cylinder; stop watch.
Material: Ordinary Portland cement; Water.
Procedure:
1. Prepare a uniform cement paste by gauging 400 g of cement with 0.85 times the water required to
give a paste of standard consistency. The procedure of mixing and filling the mould is same as
standard consistency.
2. Start the stopwatch or note down the time when water is added to the cement.
Determination of initial setting time:
Place the test block confined in the mould and resting on the non-porous plate, under the rod
bearing the initial setting needle (with cross section 1 mm2 ); lower the needle gently until it comes in
contact with the surface of the test block and quickly release, allowing it to penetrate into the test
block
4. Repeat this procedure until the needle, when brought in contact with the test block and released as
described above, fails to pierce the block beyond 5.0 ± 0.5 mm measured from the bottom of the
mould. Note the time.
5. The difference of time between operations (2) and (4) provides the initial setting time of cement.
Determination of final setting time:
6. Replace the initial setting needle of the Vicat apparatus by the needle with an annular attachment.
7. The cement shall be considered as finally set when, upon applying the needle gently to the surface
of the test block, the needle makes an impression thereon, while the attachment fails to do so.
8. The interval of time between operation (2) and (7) provides the final setting time of cement.

16. DETERMINATION OF SOUNDNESS OF CEMENT
Aim: Determination of soundness of cement by Le-Chatelier method.
Apparatus: Le- Chatelier apparatus conforming to IS: 5514-1969; Measuring cylinder; Gauging trowel; Balance; Water
bath Material: Ordinary Portland cement; Water; Greas
Procedure:
1. Weigh accurately 100 g of cement to the nearest 0.15 g and add to it 0.78 times the water required to give a paste of
standard consistency (i.e. 0.78×P).
2. Place the lightly grease mould on a lightly grease glass sheet and fill it with cement paste, taking care to keep the edges of
the mould gently together. 9
3. Cover the mould with another piece of lightly grease glass sheet, place a small weight on this covering glass sheet and
immediately submerge the whole assembly in water at a temperature of 27 ± 20 𝐶𝐶.
4. Keep this assembly under water for 24 hrs. After this, take the mould out of water and measure the distance between two
indicators. Submerge the mould again in the water.
5. Bring the water to boiling with the mould kept submerged, and keep it boiling for 25 to 30 minutes.
6. Remove the mould from the water allow it to cool and measure the distance between the indicator points.
7. The difference between these two measurements represents the expansion of the cement. 8. Repeat the whole
procedures two more times each using fresh 100 g sample.
Result: Average expansion of the cement is obtained is ___________ mm.

17. DETERMINATION OF SPECIFIC GRAVITY OF CEMENT
Aim: Determination of specific gravity of cement using Le-Chatelier flash.
Apparatus: Le Chaterliers flask, weighing balance, kerosene (free from water).
Material: Ordinary Portland cement; Water; Grease
Procedure:
1. Dry the flask carefully and fill with kerosene or naphtha to a point on the stem between zero and 1 ml. 11
2. Record the level of the liquid in the flask as initial reading.
3. Put a weighted quantity of cement (about 60 g) into the flask so that level of kerosene rise to about 22 ml mark, care
being taken to avoid splashing and to see that cement does not adhere to the sides of the above the liquid.
4. After putting all the cement to the flask, roll the flask gently in an inclined position to expel air until no further air bubble
rise3s to the surface of the liquid. .
5. Note down the new liquid level as final reading.
Observations:
• Weight of cement used in g. (W1) : _______
• Initial reading of flask in ml (V1) : _______
• Final reading of flask in ml (V2) : _______
• Volume of cement particle (V2 - V1) : _______
• Weight of equal volume of water in g. (W2) : _______
• Specific gravity of cement (W1/ W2) : _______
Result : Specific gravity of the given cement obtained as ___________.

18. SIEVE ANALYSIS OF COARSE AND FINE AGGREGATES
Aim: To determine fineness modulus and grade of fine and coarse aggregate.
Apparatus:Set of sieves* ; Balance; Gauging Trowel; Watch. a) * For fine aggregates: 4.75 mm, 2.36 mm, 1.18 mm, 600
micron, 300 micron & 150 micron, pan b) * For coarse aggregates: 80mm, 40mm, 20mm, 10mm, 4.75mm, pan
Material: a) Fine aggregates (1 K)g) b) Coarse aggregates (5 Kg).
Procedure:
1. Take the aggregate from the sample by quartering.
2. Sieve the aggregate using the appropriate sieves.
3. Record the weight of aggregate retained on each sieve.
4. Calculate the cumulative weight of aggregate retained on each sieve.
5. Calculate the cumulative percentage of aggregate retained.
6. Add the cumulative weight of aggregate and calculate the fineness modulus using formula.

19. SPECIFIC GRAVITYAND WATER ABSORPTION OF FINE AGGREGATES
Aim: To determine specific gravity and water absorption of fine aggregate.
Apparatus: Pycnometer, 1000-ml measuring cylinder, thermostatically controlled oven, taping rod, filter papers
and funnel.
Material: Fine aggregates (500 g).