Self Compacting Concrete Design and Performance Using Fly Ash

International Journal of Civil Engineering and Technology (IJCIET) Volume 9, Issue 4, April 2018, pp. 436–445, Article ID: IJCIET_09_04_048 Available online at http://iaeme.com/Home/issue/IJCIET?Volume=9&Issue=4 ISSN Print: 0976-6308 and ISSN Online: 0976-6316

SELF COMPACTING CONCRETE DESIGN AND PERFORMANCE USING FLY ASH

Ifrah Mushtaq M.Tech. Student, Department of Civil Engineering, Chandigarh University, India

Sandeep Nasier Assistant Professor, Department of Civil Engineering, Chandigarh University, India

ABSTRACT Concrete is the most heavily consumed man made construction material in the world. The word concrete is originated from the Latin word “concretus” which means condensed and hardened. Concrete is made from three principle ingredients cement, aggregates and water. These materials when mixed together produce a liquid that can be poured into almost any shape and with time turns into a rock like material. Preparation of concrete utilizes plenty of natural resources and hence in order to promote sustainability, use of agro industrial waste materials can possibly prevent the excessive utilization of these natural resources to the point of depletion that can have detrimental impacts. Self-compacting concrete (SCC) is a flowing concrete mixture that is able to consolidate under its own weight without undergoing any significant segregation. This paper investigates the workability and Strength characteristics of Self-Compacting Concrete (SCC) prepared by partially replacing cement (ordinary Portland cement) with fly ash at different replacement levels (10%, 15%, 20%, 25% and 30%). The Guidelines of European Federation of National Associations Representing for Concrete (EFNARC) was followed for mix designing purpose. The experiments were carried out by adopting a water-powder ratio of 0.43. Workability of the fresh concrete is determined by using tests such as: slump flow, T50cm Slump, V- funnel, and L-Box. The strength properties such as compressive strength, splitting tensile strength and flexural strength were tested at the age of 7 and 28days. Keywords: Self compacting concrete, Compaction, Fly ash, Fresh properties, Compressive strength. Cite this Article: Ifrah Mushtaq and Sandeep Nasier, Self Compacting Concrete Design and Performance Using Fly Ash, International Journal of Civil Engineering and Technology, 9(4), 2018, pp. 436–445. http://iaeme.com/Home/issue/IJCIET?Volume=9&Issue=4

1. INTRODUCTION Concrete being a versatile construction material is not only the most utilized construction material globally, but also the second largest material used world over. Concrete structures are durable, possesses thermal mass efficiency and aesthetically too pleasing. These qualities

http://iaeme.com/Home/journal/IJCIET 436 [email protected] Ifrah Mushtaq and Sandeep Nasier make concrete a versatile building material. Apart from being so advantageous over other construction materials, it has numerous limitations, out of which depletion of natural resources in the form of aggregates is very serious. In addition to this, lack of its proper compaction results in air entrapment and drastically reduces its strength which in turn affects the overall performance of the structure. Moreover in high-rise buildings, the reinforcement at joints gets congested to the level that its affects the flow of concrete, thus making concrete construction difficult. All these issues with conventional concrete lead to the development of self-compacting concrete (SCC). Self-compacting concrete is an extremely fluid mixture that can flow very easily within and around the formwork. It does not require any vibration or tamping after pouring and is thus able to consolidate under its own weight without undergoing any significant segregation. In the past, termie’s method has been widely used for placing concrete in inaccessible areas like underwater concreting. The concrete obtained with this method possessed low strength and required large amount of cement and costly admixtures. This marked the beginning to look for alternative approaches to tackle the problem under consideration. Thus in 1980s, SCC was developed in Japan. SCC is used when large areas need concreting and dense reinforcement makes normal vibration hard. SCC is a concrete that does not require any vibration. It is able to spout under its own weight and achieve the full compaction even in the occurrence of congested reinforcement. It utilizes super plasticizers & stabilizers to increase the rate of flow. It accomplishes compaction into all aspects of formwork without any segregation and bleeding. SCC mixes contain admixtures to provide stability, Super plasticizers and/or viscosity modifying agents to maintain the required fluidity. The tests carried out by Assie et al. [1] stated that cement, the most costly material used in concrete, if minimised can prove to be economical and hence can lead to sustainability. Thus utilizing mineral admixtures is a sustainable way of reducing cement content. These admixtures not only improve the particle packing of concrete but also increase the durability and decrease the permeability of concrete. They also revealed that the durability of both the concretes could be regarded as equivalent, thus at the same level of compressive strength, SCC can be considered to be as vibrated concrete. The research carried out by Deepa & Paulose [2] indicated that use of fly ash in SCC increases the passing ability of concrete mix. Better mechanical and physical properties of concrete can be obtained with the replacement of cement with fly ash. Inclusion of fly ash also reduces the bleeding and segregation in concrete mixes. The research carried out by Dhiyaneswaram et al. [3] indicated that SCC with fly ash shows higher compressive strength and acid resistance as compared to mixed without fly ash. Thus a better workable concrete can be achieved by using fly ash replacement. Moreover, saturated water absorption percentage decreases with the increase in fly ash content and thus indicates the limited porosity that can inhibit high flow of water into the concrete. Dinesh et al. [4] stated that fly ash can play a significant role in reducing the environmental hazards and thus can increase the workability of SCC. John Jino et al. [5] conducted an extensive research and stated that the increasing shortage of natural materials and the need to protect the environment against the contamination has emphasized the significance of developing the new building materials. Fly ash is an industrial waste material produced from the ignition of coal in thermal power plants. It can be used as an admixture or as a partial replacement of cement or aggregates. Fly ash improves the strength and durability properties of concrete and hence can achieve better properties of concrete. The tests carried out by Prajapati khrishnapal et al. [6] showed that the flow property and passing ability of SCC increases with the increase in percentage of fly ash content and therefore show better workability for same w/c ratio.

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Kurita & Nomura [7] observed that the utilization of fly ash material can enhance the rheological properties of concrete. It can reduce the heat of hydration of cement and thus decreases the cracking ability of concrete. The tests carried out by Rafat Siddique [8] indicated that it is possible to design SCC mixes incorporating fly ash content up to 35% .The SCC mixes containing lesser amounts of fly ash has better and improved compressive strength than those with the higher amounts of fly ash and w/c ratio. Moreover the carbonation depth increased with increase in age for all the SCC mixes. The experimental work carried out by Yahia et al. [9] to study the effects of rheological parameters on self compatibility of concrete containing various mineral admixtures revealed that the utilization of fly ash can reduce the amount of super plasticizer dosage required to obtain comparative slump flow compared to the concrete mixes containing only Portland cement.

2. CONSTITUENT MATERIALS OF SCC The constituent materials for the production of SCC are discussed as follows: 1. CEMENT: Selection of the type of cement depends on the overall requirements for concrete, such as strength and durability. Concrete produced from Portland cement is one of the most versatile construction materials available in the world. In this study Ordinary Portland cement (OPC) 43 Grade which is extensively used in India was used in all the test specimens. The specific gravity of cement used was taken as 3.15. The result of various physical properties of cement is given in table-1 below:

Table 1 Physical properties of cement S.NO PHYSICAL PROPERTIES RESULTS IS:8112-1989 OBTAINED SPECIFICATIONS 1. FINENESS OF CEMENT % 8% 10% 2. NORMAL CONSISTENCY % 28% - 3. VICAT INITIAL SETTING TIME 70 30 (min) (MINUTES) 4. VICAT FINAL SETTING TIME 235 600 (max) (MINUTES) 5. SPECIFIC GRAVITY 3.15 -

2. AGGREGATES: The maximum size and grading of the aggregates depends on the particular application. Maximum size of aggregate is usually limited to 20 mm. The coarse aggregate content in SCC is kept either equal to or less than that of the fine aggregate content. Locally available natural sand with 4.75 mm maximum size was used as fine aggregate, having specific gravity, fineness modulus and unit weight as given in table-2 and crushed stone with 12.5 mm maximum size having specific gravity, fineness modulus and unit weight as given in table-2 was used as coarse aggregate.

Table 2 Physical Properties of Coarse and Fine Aggregate PYSICAL PROPERTIES FINE AGGREGATES COARSE AGGREGATES SPECIFIC GRAVITY 2.67 2.74 FINENESS MODULUS 2.56 6.55 BULK DENSITY (kg/m3) 1410 1500 3. FLY ASH: Fly ash is a fine inorganic material with pozzalanic properties which can be added to SCC to improve its properties. Fly Ash is a by-product obtained from burning pulverized coal in electric power generating plants. Fly ash conforming to class F was used as partial replacement for cement in the present work having specific gravity of 2.89.

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4. ADMIXTURE: The incorporation of a superplasticizer not only reduces the inter-particle friction but also maintain the deformation capacity and viscosity. The locally available admixture that is, CONPLAST SP 430 G8 was used as a superplasticizer with density 1.2 kg/l, specific gravity= 2.10 at 30oC, air entrainment = 1% (approximately) and blackish in colour. Conplast SP 430 G8 is based on sulphonated naphthalene polymers and is instantly dispersible in water. It has been specially formulated to give high water reduction up to 25% without loss of workability or to produce high quality concrete of reduced permeability. The volume of the conplast used in self-compacting concrete is taken as 1.2% of the volume of the cement. 5. WATER: Water used was fresh, colourless, odourless and tasteless potable water free from organic matter of any type.

3. MIX PROPORTIONS The process of mix proportioning is one of the most important tasks for achieving the required SCC properties. Many different test methods have been developed in attempts to characterize the properties of self-compacting concrete. So far, no single method has achieved the universal approval and as such no method has been found that can characterize all the relevant workability aspects. Therefore, a mix design procedure to get the proportion of the ingredients in the SCC is not standardized. No method specifies the grade of concrete in SCC, except the Nan Su et al. method [10]. In this study, mix designing was carried out for M40 grade concrete, and the procedure is based on the method proposed by Nan Su et al. This method was preferred as it has the advantage of considering the strength of the SCC mix. It gives an indication of the target strength that will be obtained after 28days of curing. A total of five SCC trial mixes including one control mix were prepared by varying the level of substitution (fly ash content) and examined to quantify the properties of SCC. The substitution levels were fixed at 10%, 15%, 20%, 25% and 30%. The water/powder ratio (w/p) was kept as constant (0.43).Table-3 presents the composition of SCC mixes.

Table 3 Mix proportions of SCC mixes. S.NO. TRIAL MIX CEMENT FLY ASH FLY F.A C.A WATER W/P SP (kg/m3) (kg/m 3) ASH (%) (kg/m3) (kg/m3) (kg/m3) 1. CONTROL 440 - 0 924 772 189 0.43 5.26 2. MFA1 396 44 10 924 772 189 0.43 5.26 3. MFA2 374 66 15 924 772 189 0.43 5.26 4. MFA3 352 88 20 924 772 189 0.43 5.26 5. MFA4 330 110 25 924 772 189 0.43 5.26 6. MFA5 308 132 30 924 772 189 0.43 5.26

4. SELF-COMPACTABILITY TESTS ON SPECIMEN Batching of trial mixes was carried out according to their respective proportions, presented in Table 3. The concrete ingredients were mixed manually to attain uniform consistency.

4.1. FRESH PROPERTIES The self-compactibility properties of the trial mixes were determined by using slump flow test, T50cm time test, V-funnel test, and L-box test. The tests were conducted in following order:

 Slump flow test and T50cm time test.  V-funnel flow test.  L-box test.

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4.2. STRENGTH PROPERTIES From each trial mix, a total of 18 concrete specimens were casted for determining the compressive strength, split tensile strength and flexural strength after 7 and 28 days of water curing for each trial mix.

5. RESULTS AND DISCUSSION 5.1. Properties of Fresh Concrete

Slump and T50 time Test The slump flow test judges the capability of concrete to deform under its own weight against friction of the surface with no restraint present. The slump flow represents the mean diameter of the mass of concrete after release of a standard slump cone (Diameter is measured in two perpendicular directions).In slump test, the cone is filled with concrete and then lifted vertically and the time measurement is started. The spread diameter T50 (the time of flow to reach a diameter of 500mm) and general visual appearance of concrete are recorded. The effectiveness of flow i.e the flowability of SCC under congested reinforcement can be studied through the slump test. A slump flow ranging from 650mm to 800mm is considered as the slump required for a concrete to be self-compacted. At more than 800mm the concrete might segregate and at less than 650mm the concrete is considered to have insufficient flow to flow through highly congested reinforcement. From the Slump and T50cm test it is seen that 30% replacement of fly ash behaves better compared with other ratios. The slump values and T50cm test values for different mixes are given in table 4

Table 4 Results of Slump flow test

S.NO TRIAL MIX SLUMP FLOW T50 SLUMP FLOW (mm) (sec) Acceptance range Acceptance range 650-800mm 2-5sec 1 CONTROL 650 4.8 2 MFA1 680 3.8 3 MFA2 710 4 4 MFA3 670 3.5 5 MFA4 675 4.5 6 MFA5 690 3.0 V-funnel Test This test was performed to assess the flow ability and stability of SCC.V-funnel test is carried on freshly mixed SCC. It consists of a V shaped steel funnel used to determine the filling ability i.e flow ability and segregation resistance. V-funnel test is used to evaluate the viscosity and filling ability of SCC through the flowing speed. The test is carried out by filling a funnel with about 12 litres of concrete and then the flowing speed is measured by the time taken for a sample to flow and drain through the funnel. The minimum time required for flowing entirely through the funnel is 6 seconds and the maximum time to fall off completely is 12seconds.As per EFNARC time ranging from 6 to 12 sec is considered adequate for SCC. The test results indicated that all the SCC mixes meet the requirements of allowable flow time and had good filling ability and segregation resistance. It was evident from the results that 30% replacement by fly ash shows better performance with respect to flow ability of concrete. Table-5 shows the results of V-funnel test of SCC mixes

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Table 5 Results of V-funnel test S.NO TRIAL MIX V-FUNNEL ACCEPTANCE (SEC) RANGE(SEC) 1 CONTROL 11 2 MFA1 10.2 3 MFA2 9.8 4 MFA3 10.47 8-12 5 MFA4 9.0 6 MFA5 8.35 L-box Test L-box test assess the flow of concrete and also the extent to which the concrete is subjected to blocking by reinforcement. Thus using L-box test, the passing ability of SCC beyond the reinforcing bars can be found. About 14 litres of concrete is required for this test. The mix having high powder content and lesser coarse aggregate passes through the reinforcing bars. The ratio of H2/H1 is used to indicate the value of the result of L-box test. As per EFNARC the minimum value of H2/H1 can be 0.8 and the max value 1.0.In the present study, the L-box ratio for all the mixes were above 0.8 which is as per EFNARC standard. Thus from the passing ability test results of SCC mixes it can be concluded that with the increase in fly ash content the passing ability also increases. The results of L-box test are given in the table-6 below:

Table 6 Results of L-B0X test S.NO TRIAL MIX L-BOX ACCEPTANCE RANGE 1 CONTROL 0.92 2 MFA1 0.95 3 MFA2 0.87 0.8-1 4 MFA3 0.91 5 MFA4 0.85 6 MFA5 0.98

5.2. Properties of Hardedned Concrete Compressive strength, flexural strength and splitting tensile strength study results at different ages are given in table-7, 8 & 9 respectively. When compared to the control mixture, increasing amount of fly ash increased the strength. 30% replacement showed better performance with respect to strength properties of concrete. Compressive Strength Compression strength testing machine is used to determine the compressive strength of a test specimen. The size of cube specimen used to perform test is 150mm × 150mm × 150mm. A test result is the average of at least three standard cured specimens made from the same concrete sample and tested at the same age. From each trial mix, a total of six concrete cube specimens of 150mm side were casted for determining the compressive strength after 7 and 28 days of water curing for each trial mix. The moulds were oiled properly for easy demoulding. The moulds were filled with concrete in three layers. Since this is a Self Compacting concrete, the concrete will flow under its own weight, therefore, the moulds were not vibrated. The specimens were demoulded after 24 hours of casting and then they were transferred to a curing tank. The specimens were cured in the water tank for 28 days. The Compressive strength was calculated by dividing the failure load by the average cross sectional area of the specimen

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Calculations

Compressive strength (fc) = P/A Where, P = Load at failure A = Surface area of bearing cube It was concluded from the compressive strength test that with the increase in fly ash content from 10% - 30% SCC mixes developed compressive strength between 33.4 & 39.16 Mpa at 7 days and 45.8 & 53.21 Mpa at 28 days. The compressive strength increased with increase in the percentage of fly ash. The compressive strength test results of SCC mixes are shown in fig 1.

Table 7 Result of compressive strength tests S.NO TRIAL MIX COMPRESSIVE STRENGTH (MPa) 7 DAYS 28 DAYS 1 CONTROL 33.4 45.8 2 MFA1 34.85 45.82 3 MFA2 36.02 47.69 4 MFA3 36.48 48.04 5 MFA4 38.72 50.11 6 MFA5 39.16 53.21

60 53.21 H 50.11 T 47.69 48.04

G 50 45.8 45.82 N

E 38.72 39.16 36.02 36.48 R 40 33.4 34.85 T S 30

VE 7 DAYS I

S 20 S 28 DAYS

RE 10

0 COMP MFA0 MFA10 MFA15 MFA20 MFA25 MFA30 FLY ASH%

Figure 1 Compressive Strength test results Flexural Strength The flexural strength is the ability of a beam or slab to resist failure in bending. A beam test is found dependable to measure flexural strength properties of concrete and same is applied for SCC. Standard beam test or modulus of rupture test was carried out on the beams of size 100mm×100mm×500mm by considering the material to be homogeneous. The specimen was placed on the machine and the load was applied on the upper most surface in such a way that the axis of the specimen was carefully aligned with the loading device. Six concrete beams were casted for each concrete mix proportions for 7 and 28 days. The flexural strength of beams was measured after 7 and 28 days. It was evident from the experimental results that the flexural strength of SCC obtained is less than that of the control mix. The graphical representation of the variation of average flexural strength at 7 days and 28th days is shown in fig 2.

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Calculations Flexural strength of specimen expressed as modulus of rupture is calculated as: 2 Flexural strength (ff ) = PL/bd P = Maximum load at failure. L = length of beam specimen. d = depth of beam specimen.

Table 8 Result of Flexural strength tests S.NO TRIAL MIX FLEXURAL STRENGTH (MPa) 7 DAYS 28 DAYS 1 CONTROL 5.83 6.92 2 MFA1 4.68 5.84 3 MFA2 4.4 4.91 4 MFA3 4.26 5.07 5 MFA4 5.01 6.15 6 MFA5 5.34 6.78

6.92 6.78

H 7

T 6.15 5.83 5.84 G 6 5.34 N 4.91 5.07 5.01 E 4.68

R 5 4.4 4.26 T S

L 7 DAYS A 3 28 DAYS 2 XUR E

L 1 F 0 MFA0 MFA10 MFA15 MFA20 MFA25 MFA30 FLY ASH%

Figure 2 Flexural Strength test results Split Tensile Strength Split tensile strength test consists of applying diametric compressive force along the length of a cylindrical specimen. The size of the specimen is 150mmØ × 300mmL. The loading induces tensile stresses on the plane containing the applying load and tensile failure occurs rather than compressive failure. Six concrete cylinders were casted for each concrete mix proportions for 7 and 28 days. The split tensile strength of three cylinders (one set) is measured after curing period of 7 and 28days. Fig 3 shows the relation between split tensile strength of concrete and age in days i.e. 7 and 28 days of casting. SCC mixes achieved splitting tensile strength from 2.8 to 4.57mpa at 7 days and 3.98 to 5.23mpa at 28 days. Calculations

Split tensile strength (ft) = 2P/πDL Where P = compressive load at failure L = Length of cylinder. D = Diameter of cylinder

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Table 9 Result of Split tensile strength test S.NO TRIAL MIX SPLIT TENSILE STRENGTH (MPa) 7 DAYS 28 DAYS 1 CONTROL 2.83 3.98 2 MFA1 3.48 4.2 3 MFA2 4.01 4.12 4 MFA3 3.98 4.74 5 MFA4 4.04 4.4 6 MFA5 4.57 5.23

6 5.23 H

T 4.74 5 4.4 4.57

NG 4.2 3.98 4.014.12 3.98 4.04

RE 4 3.48 T S 2.83 E 3 L

I 7 DAYS S

N 2 E 28 DAYS T

I 1 L P S 0 MFA0 MFA10 MFA15 MFA20 MFA25 MFA30 FLY ASH%

Figure 3 Split Tensile Strength test results

6. CONCLUSIONS The present experimental study was carried out to describe the effects of agro industrial by product i.e fly ash on SCC using various percentage replacement levels of fly ash to determine the best performance of fly ash. The investigation shows that it is possible to design SCC mixes incorporating fly ash content up to 30%. The main conclusion drawn from the results are summarized below:  Slump flow of SCC mixes were in the range of 650-710, flow time for all the mixes was less than 4.8secs , V funnel time was in the range of 8.35 – 11secs and L box ratio was greater than 0.8 for all the mixes  The fresh properties for 30% fly ash replacement were observed to be better as compared to the other replacement levels (10%, 15%, 20%, & 25%).  The strength properties have shown significant performance differences and thus it is perceptible from the test results that the compressive strength increases with the increase in the percentage of fly ash content.  From five trial mixes, a mix with 30% replacement of cement with fly ash was found to meet the compatibility criteria and possessed maximum strength.  The SCC mixes developed compressive strength ranging from 33.4 to 39.16 Mpa at 7 days and 45.8 to 53.21 Mpa at 28 days.  The compressive strength of SCC specimens increased with the time of curing.  The split tensile strength for 7 days was found to be in the range of 2.83 to 4.57Mpa and 3.98 to 5.23 Mpa for 28 days.

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 The flexural strength developed by SCC mixes decreased with the increase in the percentage of fly ash content. Thus, it has been found out that the inclusion of fly ash in SCC has better performing properties (Strength & Workability) than the conventional concrete.

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