Experimental investigation Of SELF COMPACTING CONCRETE USING MARBLE POWDER AND COAL ASH

By: Ranjodh Singh

Self Compacting Concrete

Self-compacting concrete (SCC) is an innovative concrete that does not require vibration for placing and compaction. It is able to flow under its own weight, completely filling formwork and achieving full compaction, even in the presence of congested reinforcement. Self compacting concrete in hardened state is dense, homogeneous and has the same engineering properties and durability as traditional vibrated concrete.

Origin of Self Compacting Concrete

In Japan, in early 80s, premature deterioration of concrete structures were detected almost everywhere in the country. The main cause of the deterioration was recognized as inadequate compaction and reduction in skilled labor. As a solution for these problems, the first ever concept of SCC was proposed by Hajime Okamura at Tokyo University in 1986. He gave the first prototype of SCC in 1988.

Basic mix-design principle for SCC

The basic mix design principle of SCC suggests that, SCC normally contains following, when compared to traditional vibrated concrete :-

lower coarse aggregate content

increased paste content low water/powder ratio increased super-plasticizer sometimes a viscosity modifying admixture

Basic mix-design principle for SCC

Use of SuperPlasticizer

High Deformability of the mortar and the concrete Self compacting Concrete

Limitation of Coarse aggregate content

High Segregation Resistance of the mortar and the concrete

Reduction in Waterpowder (w/p) ratio

Advantages of SCC

Low

noise-level in the plants and construction sites.

Eliminated problems associated with vibration. Less labor involved. Faster construction. Improved quality and durability. Higher strength.

Fresh properties of SCC

A concrete mix can only be classified as SCC if the requirements for all the following three fresh properties are fulfilled (EFNARC, 2002):

Filling ability Passing ability Segregation resistance

Methods to test fresh properties of SCC

The list of the test methods for different properties of SCC is as given below in table:S. No. 1. 2. Method Slump flow by Abrams cone T50cm slump flow Property Filling Ability Filling Ability

3.
4. 5. 6. 7. 8. 9. 10.

J-ring
V- funnel V funnel at T5minutes L-Box U-Box Fill Box GTM screen Stability Orimet

Passing Ability
Filling Ability Segregation resistance Passing Ability Passing Ability Passing Ability Segregation resistance Filling Ability

Acceptance Criteria For SCC

Typical acceptance criteria for Self-compacting Concrete given by EFNARC, with a maximum aggregate size up to 20 mm is given below.
S. No. Method Unit Typical range of values
Minimum 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Slump flow by Abrams cone T50 cm slump flow J-ring V- funnel V funnel at T5minutes L-Box U-Box Fill Box GTM screen Stability test Orimet
mm sec mm sec sec h2/h1

Maximum 800 5 10 12 +3 1.0 30 100 15 5

650 2 0 6 0 0.8 0 90 0 0

(h2-h1)mm
%

%
sec

Objectives of Study
1.

To explore the use of waste materials by replacing Fine aggregates at different percentages.

2. To carry out the self compacting properties of different SCC mixes. 3. To carry out the experimental tests to determine the fresh properties of SCC using Different percentage of Coal ash, marble powder and their combinations. 4. To carry out the experimental tests to study the hardened properties of SCC using different percentage of Coal ash, marble powder and their combinations.

Objectives of study
5. To study the relative merits and demerits of the various waste

materials used and their effect on the fresh and hardened properties of SCC. 6. To study the effect of coal ash and marble powder on Rebound

Hammer and UPV Test values and its comparison with Cube
compressive strength.

Mix Design
Mix Design is defined as the selection of constituent materials in such a way that Mix can withstand all structural properties. The mix design we used for the SCC came after doing many trial mixes. Mix Design was selected According

to EFNARC guidelines. The Target Strength for selecting

Mix Design Was 40Kn/m i.e. M40 grade.

Tests performed for Fresh properties of SCC

Slump Flow Test
A conventional slump cone is placed on a rigid, leveled, non-absorbent plate
and filled with concrete without tamping. The slump cone is lifted and the horizontal spread of the concrete is measured. Also, the time required for the

concrete to spread to a diameter of 50 cm is measured. (T50 )

Cont V Funnel Test

The funnel shown in figure is fully filled with concrete without tamping or
vibration. The door at the bottom of the funnel is opened and concrete is allowed to flow out of the funnel and into a bucket.

The flow time for all of the concrete to exit

the funnel is recoded as a measure of filling ability.

Acceptance Criteria For SCC

Typical acceptance criteria for Self-compacting Concrete given by EFNARC, with a maximum aggregate size up to 20 mm is given below.
S. No. Method Unit Typical range of values
Minimum 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Slump flow by Abrams cone T50 cm slump flow J-ring V- funnel V funnel at T5minutes L-Box U-Box Fill Box GTM screen Stability test Orimet
mm sec mm sec sec h2/h1

Maximum 800 5 10 12 +3 1.0 30 100 15 5

650 2 0 6 0 0.8 0 90 0 0

(h2-h1)mm
%

%
sec

Experimental programme

An experimental programmes were planned to investigate the compressive strength, flexural strength and split tensile strength when fine aggregate is replaced by coal ash, marble powder and the combination of both materials in different percentages of 25, 50, 75 and 100. Experimental programmes were planned to compare the compressive strength at different ages i.e. 7, 28, 56 days with Ultrasonic pulse velocity test, Rebound hammer test, and direct compression test at various replacement levels.

Materials used
Cement: OPC with grade 43 was used. Properties of OPC
used are as given in table.
Characteristics Experimental Observations Value specified by IS: 12269-1987

Standard Consistency

33%

Specific gravity

3.15

Initial Setting Time

125 mins

>30 mins

Final Setting Time

215 mins

<600 mins

Fineness

330 m2/kg (Blaines Apparatus)

>225 m2/kg

Coarse aggregates
Coarse aggregates used for the study was natural coarse aggregates (angular type of 20 and 12.5mm of size).They were then washed to remove dust and were dried to surface dry condition.

Fine aggregates
Locally available sand was used for this study

Coal Ash
The fly ash produced from the burning of pulverized coal in a coal-fired boiler is a fine-grained, powdery particulate material that is carried off in the flue gas. We obtain this coal ash from Guru Gobind Singh Super Thermal Plant, ROPAR

Marble powder
Marble powder used is a waste material obtained from cutting of marble plates.

Present work Done

Replacement of fine aggregates by coal ash and marble powder in varying percentages of 25, 50, 75 and 100 with addition of VMA and SP in the mix. Mix proportions are obtained in table. The total number of specimens to be cast for various tests at the ages of 7, 28 and 56 days is shown in the tables below

Moulds for specimen

Standard cubical moulds of size 150mm x 150mm x150mm used to cast concrete specimens to test compressive strength of concrete.

Beam moulds of size 600mm x 100mm x 100mm were used to prepare concrete specimens to test flexural strength. Cylindrical samples of diameter 150mm and height 300mm were casted to test split tensile strength

Contd.

Tests performed on various samples

Direct compression Test Split tensile strength Flexural strength test Ultrasonic pulse velocity test Rebound hammer test

Direct compression test

The test was conducted on cubical moulds at the age of 7, 28, 56 days. The load was gradually applied without any shock and increased at constant rate of 14N/mm2/minute until failure of specimen takes place. It was tested on compression testing machine.

Split Tensile Test

The test was conducted on concrete cylinders at the age of 28 days. The test was performed on 100 tones capacity Compression Testing Machine. The tensile strength was calculated by ft = 2P/DL Where: ft = tensile strength P = maximum applied load L = length of cylinder D = diameter of cylinder

Flexure Test
The test was performed on concrete beam mould at the age of 28 days on 100 tones compression testing machine. In this test single point load is used and load is applied which produces constant bending moment throughout. The modulus of rupture was calculated by the relation: fr = PL/bd2 Where: fr = flexural strength P = maximum applied load L = span length b = average width of specimen d = average depth of specimen

Ultrasonic pulse velocity test

The velocity of an ultrasonic pulse is influenced by those properties of concrete which determine its elastic stiffness and mechanical strength. Hence each material has typical ultrasonic pulse velocities. These velocities can be correlated with the material properties. Comparatively higher velocity is obtained when concrete quality is good in terms of density, uniformity, homogeneity etc.

Rebound Hammer Test

Rebound number was calculated on each specimen of concrete and than the average compressive strength had been calculated.

Mix Proportions for different concrete mixes

Sr. No. Mix Cement (Kg/m3) Coarse Agg. (Kg/m3) 900 900 900 900 Fine Agg. (Kg/m3) Coal Ash (Kg/m3) Marble Powder (Kg/m3) 0 0 0 0 Total powder Water (Lt/m3) S.P. (Kg/m3) VMA (Kg/m3)

1 2 3 4

MR MCA1 MCA2 MCA3

450 450 450 450

800 600 400 200

0 200 400 600

450 650 850 1050

158.6 206.9 212.5 219.4

450 450 450 450

112.5 112.5 112.5 112.5

5
6 7 8 9 10 11 12 13

MCA4
MMP1 MMP2 MMP3 MMP4 MMC1 MMC2 MMC3 MMC4

450
450 450 450 450 450 450 450 450

900
900 900 900 900 900 900 900 900

0
600 400 200 0 600 400 200 0

800
0 0 0 0 100 200 300 400

0
200 400 600 800 100 200 300 400

1250
650 850 1050 1250 650 850 1050 1250

221.2
175.5 185.9 257.7 263.4 191.3 194.3 201.5 208.6

450
450 450 450 450 450 450 450 450

112.5
112.5 112.5 112.5 112.5 112.5 112.5 112.5 112.5

Contd.
Where MR is reference mix MCA1 is 25 % F.A. replaced with coal ash. MCA2 is 50 % F.A. replaced with coal ash. MCA3 is 75 % F.A. replaced with coal ash. MCA4 is 100 % F.A. replaced with coal ash. MMP1 is 25 % F.A. replaced with marble powder. MMP2 is 50 % F.A. replaced with marble powder. MMP3 is 75 % F.A. replaced with marble powder. MMP4 is 100 % F.A. replaced with marble powder. MMC1 is 25 % F.A. replaced with coal ash (12.5%) and marble powder (12.5%). MMC2 is 50 % F.A. replaced with coal ash (25%) and marble powder (25%). MMC3 is 75 % F.A. replaced with coal ash (37.5%) and marble powder (37.5%). MMC4 is 100 % F.A. replaced with coal ash (50%) and marble powder (50%).

Mix designation MR MCA1 MCA2 MCA3 MCA4 MMP1 MMP2 MMP3 MMP4 MMC1 MMC2 MMC3 MMC4

Variations of slump flow for different mixes

Percentage replacement 0 25 50 75 100 25 50 75 100 12.50+12.50 25+25 37.50+37.50 50+50 Slump flow (mm) 700 690 685 675 665 685 675 670 665 680 675 670 660

Compressive strength of mix with Coal Ash replacement

%age Replacement with Coal Ash Cube Compressive Strength(Mpa) Compressive Strength by Rebound Hammer(Mpa) Compressive Strength by UPV(Mpa)

7 day

28 day

7 day

28 day

7 day

28 day

39.2

45.4

40

42

38.8

46.6

25

31.7

38.4

33

37

31.75

38.2

50

29.7

34.2

29

34

30.20

35.2

75

28.2

33.8

26

31

25.5

29

100

26.5

31.3

21

29

22.6

27.5

Compressive strength of mix with Marble powder replacement

%age Replacement with Marble powder Cube Compressive Strength(Mpa) Compressive Strength by Rebound hammer(Mpa) Compressive Strength by UPV(Mpa)

7 day

28 day

7 day

28 day

7 day

28 day

39.2

45.4

40

42

38.8

46.6

25

20.9

25.7

18

28

24.4

26.6

50

20.3

24.3

16

26

19.2

25.7

75

14.2

17.04

12

20

16.8

21.3

100

6.49

8.2

10

13

8.4

12.2

Compressive strength of mix with Coal Ash and Marble powder replacement
%age Replacement with Marble powder & Coal Ash Cube Compressive Strength(Mpa) Compressive Strength by Rebound Hammer(Mpa) Compressive Strength by UPV(Mpa) 7 day 28 day 7 day 28 day 7 day 28 day

39.2

45.4

40

42

38.8

46.6

12.5MP+12.5CA

25.3

31.4

20

34

28.75

34.25

25.0MP+25.0CA

22.2

25.6

18

25

24

25.6

37.5MP+37.5CA

19.6

22.8

16

21

19.5

21.2

50.0MP+50.0CA

17.4

21.3

15

18

12.5

18.4

Compressive strength with Coal Ash replacement

50 45 40 35 30 25 20 15 10 5 0 0 25 50 %age replacement 75 100 28 Days compression test value 28 days Rebound Values

compressive strength(Mpa)

28 Days UPV values

Compressive strength with Marble powder replacement

50 45 40 35 30 25 20 15 10 5 0 0 25 50 %age replacement 75 100 28 Days compression test value 28 days Rebound Values

compressive strength(Mpa)

28 Days UPV values

Compressive strength variation with Coal Ash and Marble Powder

50 45 40 35 30 25 20 15 10 5 0 0 25 50 %age replacement 75 100 28 Days compression test value 28 days Rebound Values

compressive strength(Mpa)

28 Days UPV values

Conclusions
Good hardened properties were achieved for the concretes with 25% replacement with coal Ash which can be considered as the optimum content for high compressive strength Marble powder being an inert fine material helps to fill the micro pores and makes concrete more dense Marble powder gives good hardened properties at 25% replacement and this goes on decreasing at higher replacement levels

 Combined replacement of coal ash and marble powder gives better hardened properties as compared to replacement with marble powder only Comparison of compressive strength calculated from compression test, UPV and RH test indicates that these non destructive tests can give fairly good idea about the quality of concrete

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