EXPERIMENTAL STUDIES ON HIGH PERFORMMANCE CONCRETE USING WASTE MATERILAS PROJECT REPORT SUBMITTED IN...

1

EXPERIMENTAL STUDIES ON HIGH PERFORMMANCE

CONCRETE USING WASTE MATERILAS

PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS FOR THE AWARD OF THE DEGREE IN

BACHELOR OF TECHNOLOGY

IN

CIVIL ENGINEERING (HABITAT DEVELOPMENT)

By

K.RENU PRIYANKA (09209025)

M.UMMU THAHIRA (09209029)

RURAL TECHNOLOGY CENTRE

GANDHIGRAM RURAL INSITUTE-DEEMED UNIVERSITY

GANDHIGRAM – 624 302

DINDIGUL DISTRICT, TAMILNADU

APRIL-2013

2

CERTIFICATE

This is to certify that the project work entitled, “EXPERIMENTAL STUDIES ON

HIGH PERFORMMANCE OF CONCRETE USING WASTE MATERIALS” is a

bonafide work done by K.RENU PRIYANKA, M.UMMU THAHIRA, under the

guidance and supervision of Dr.K.MAHENDRAN, Director i/c & Associate

professor, Rural Technology Centre, Gandhigram Rural Institute (DU),

Gandhigram.

Dr.K.MAHENDRAN Project Guide

Associate professor & Director i/c

Rural Technology Centre

Place :

Date :

Submission for viva-voce held on:

Internal examiner External examiner

3

DECLARATION CERTIFICATE

We submit this project work entitled “EXPERIMENTAL STUDIES

ON HIGH PERFORMMANCE CONCRETE USING WASTE MATERIALS” to

Rural Technology Centre, Gandhigram Rural Institute (Deemed University),

Gandhigram, Dindigul in partial fulfillment of the requirements for award of the

Bachelor of Technology in CIVIL ENGINEERING (HABITAT

DEVELOPMENT) and this is our original and independent work carried out.

RENU PRIYANKA.K

UMMU THAHIRA.M

4

TABLE OF CONTENTS

Acknowledgement 6

List of tables 7

List of figures 9

Abstract 10

CHAPTER I – INTRODUCTION

1.1 Background 11

1.2 Copper Slag 11

1.3 Rice Husk Ash 12

CHAPTER II – REVIEW OF LITERATURE

2.1 Copper slag 14

2.2 Rice husk ash 16

2.3 Objectives of study 19

CHAPTER III – RESEARCH METHODOLGY

3 Tests on Materials 21

3.1 Cement 21

3.1.1 Specific gravity 21

3.1.2 Fineness modulus of cement 21

3.1.3 Standard consistency test 22

3.1.4 Initial and Final setting time of concrete 23

3.2 Rice husk ash 24

3.2.1 Physical Properties of RHA 24


3.2.3 Fineness modulus 24

3.2.4 Standard consistency and setting time of RHA 26

3.2.5 Chemical properties of RHA 26

3.3 Fine aggregate 27


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3.3.2 Water absorption 27

3.3.3 Sieve analysis 28

3.4 Copper slag 29

3.4.1Specific gravity 29

3.4.2Water absorption 29

3.4.3Sieve analysis 30

3.5 Coarse aggregate 30

3.5.1Specific gravity 30

3.5.2 Fineness modulus 31

3.6 Water 32

3.7 Mix Design

3.7.1 Data 32

3.7.2 Target mean strength 33

3.7.3 Selection of water cement ratio 34

3.7.4 Determination of cement content 34

3.7.5 Determination of fine and coarse aggregate 34

CHAPTER – IV – TEST DATA ANALYSIS

4.1 Test on fresh concrete 37

4.1.1 Fresh concrete properties 37

4.1.2 Slump Test 38

4.1.3 Compaction factor 40

4.2 Test on hardened concrete

4.2.1 Compressive strength 42

4.2.2 Split Tensile strength 45

4.2.3 Acid resistance test 48

4.2.4 SEM analysis 50

CHAPTER V – RESULTS AND DISCUSSION 52

CHAPTER VI – CONCLUSION 54

REFERENCE 55

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ACKNOWLEDGEMENT

It gives us immense pleasure to acknowledge the assistance and contributions of

great people to this effort. First we would like to thank GOD, the almighty for

giving us chance, confidence and power and then our parent to complete this work

successfully.

We are deeply indepted to Dr.K.Mahendran, Associate professor in engineering &

Director i/c for his valuable suggestions, meticulous supervision and sincere advice

in our endeavour.

We sincerely thank Er.B.Sangeethavani and Er.R.T.Balamurali, Assistant

professors for their help and encouragement provided regarding our project work

We sincerely thank Er.A.Zahir Hussian and Er.V.Gowthami, Lecturers for their

help and advice provided regarding our project work

We also thank Mr.S.Surali muthu and Mr.S.Chandramohan Technical assistants for

their co-operation and timely help provided by them in all laboratory works to

make this work a successful treasure.

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LIST OF TABLES

Table

No

List of Tables Page No

1 Specific gravity of cement 21

2 Percentage of fineness modulus of cement 22

3 Standard consistency of cement 22

4 Initial setting time of cement 23

5 Specific gravity of Rice Husk Ash 24

6 Percentage of fineness modulus of Rice Husk Ash 25

7 Standard consistency, Initial and final setting time of Rice

Husk Ash

26

8 Chemical properties of Rice Husk Ash 26

9 Specific gravity of fine aggregate 27

10 Water absorption test on fine aggregate 27

11 Fineness modulus of fine aggregate 28

12 Specific gravity of copper slag 29

13 Water absorption test on copper slag 29

14 Fineness modulus of copper slag 30

15 Specific gravity of coarse aggregate 31

16 Fineness modulus of coarse aggregate 31

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17 Adjustment of water and sand content 34

18 Various mix proportions of concrete 36

19 Workability of concrete partially replaced with copper slag 38

20 Workability of concrete partially replaced with Rice Husk Ash 39

21 Compaction factor of concrete partially replaced with copper

slag

41

22 Compaction factor of concrete partially replaced with Rice

Husk Ash

41

23 Compression strength of concrete partially replaced with

copper slag

43

24 Compression strength of concrete partially replaced with Rice

Husk Ash

44

25 Split tensile strength of concrete partially replaced with copper

slag

45

26 Split tensile strength of concrete partially replaced with Rice

Husk Ash

47

27 Results of Acid Resistance test 48

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List of Figures

Figure

no

List of figures Page

no

1 Copper slag 12

2 Rice husk ash 13

3 Slump value of concrete partially replaced with copper slag 39

4 Slump value of concrete partially replaced with Rice Husk Ash 40

5 Compressive strength of concrete partially replaced with Copper

slag

44

6 Compressive strength of concrete partially replaced with Rice

Husk Ash

45


Husk Ash

46


Husk Ash

47

9 Loss of weight in acid resistance test 49

10 Loss of strength in acid resistance test 49

11 SEM results of control concrete 51

12 SEM results of concrete replaced with copper slag 30 % 51

13 SEM results of concrete replaced with RHA 15% 51

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ABSTRACT

Disposal of wastes is one of the issues confronting the world today. Scientists all over the world

are making efforts to minimize the production of wastes and to effectively recycle the waste.

Reducing the green house gas emission and recycling of industrial wastes are the key areas of

concern. Production of wealth will be a boon to the industries as the benefits are twofold: the

pollution problem is addressed and the raw material shortage problem is also effectively tackled.

Against this back-drop, in the present work, copper slag (CS) and Rice Husk Ash (RHA) is

utilized as viable substitutes in concrete. M20 grade concrete with different mix proportion of

sand replaced with copper slag from 0 to 70% and 0 to 25% cement replaced with Rice Husk

Ash (RHA) and a combination of both (30% CS +10% RHA) is prepared. Tests for strength

(compression and split tensile strength), acid resistance test and SEM analysis are carried out.

The results of this work undertaken have revealed that peak strength is obtained on 30%

replacement of sand with copper slag (45.3N/mm2) and 10% of cement with RHA (38.8N/mm

2)

and the combined mix gives good strength of 46.5N/mm.2

Key words- Copper slag, Rice Husk Ash, Compression test, Acid resistance test, waste disposal

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CHAPTER - I

1.1 INTRODUCTION:

Concrete is one of the prime materials for structures and it is widely used for various

applications all over the world. The usage of concrete is inevitable throughout the globe.

Aggregates and cement play a major role in concrete. In India there is a great shortage of natural

aggregates. Recently Tamil Nadu government (in India) has imposed restrictions on removal of

sand from the riverbeds due to its threatening effects. Production of cement liberates same

amount of carbon dioxide which is the great cause of ozone depletion. This effect creates a

question on the sustainability of concrete. In order to make concrete a sustainable material,

suitable engineering approaches can be done.

Apart from this waste generation has increased considerably and find no way for

disposal. In order to overcome this, industrial and agro- waste materials can be used as alternate

building materials. In our present study we made an attempt by utilizing copper slag an industrial

waste and RHA an agro waste as suitable substitutes in concrete.

1.2 COPPER SLAG

Copper slag is an industrial by-product obtained during the matte smelting and refining of copper

Large quantities of slag are produced as a byproduct of metallurgical operations, resulting in

environmental concerns with disposal [1]. CS used in this work was brought from Sterlite

Industries Ltd (SIL), Tuticorin, Tamil Nadu, India. Currently, about 2600 tons of CS is produced

per day and a total accumulation of around 1.5 million tons. This slag is currently being used for

many purposes ranging from land-filling to grit blasting. These applications utilize only about

15% to 20% and the remaining dumped as a waste material and this causes environmental

pollution [2].

Copper Slag is glassy granular in nature with high specific gravity . Particle sizes are of

the order of sand and have a potential for use as fine aggregate in concrete. The presence of silica

in slag is about 26% which is desirable since it is one of the constituents of the natural fine

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aggregate used in normal concreting operations. Copper slag can be used as a replacement for

fine aggregates in order to obtain a concrete with good strength and durability requirements [3].

Fig 1: Copper Slag

1.3 RICE HUSK ASH

Rice husk is an agro-waste constitutes about one fifth of 300 million tons of rice production

annually in the world. This Rice Husk is used only as a fuel in rice boiling process. By burning

rice husk under a controlled temperature and atmosphere, a highly reactive RHA is obtained [4].

The most important property of RHA that determines pozzolanic activity is the amorphous phase

content. RHA is a highly reactive pozzolanic material suitable for use in lime-pozzolanic mixes

and for Portland cement replacement . The summary of the research findings from several

countries on the use of Rice Husk ash as a supplementary cementing materials shows that the

material itself possesses little or no cementatious value but that in finely divided form and in the

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presence of moisture will chemically react with alkali and alkaline earth hydroxides forming

compounds possessing cementitious properties . It possesses rough and abrasive surfaces that are

highly resistant to natural degradation; it can be used as a partial substitute of cement because of

its high reactivity. Properly treated ashes remain active within cement paste [5].

Fig 2: Rice husk Ash

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CHAPTER-II

REVIEW OF LITERATURE

2.1 COPPER SLAG

Brindha.D et al., (2010) The presence of silica in slag is about 26% which is desirable since it is

one of the constituents of the natural fine aggregate used in normal concreting operations.

Compressive strength and split tensile strength have shown that copper slag is superior to

corresponding control concrete. The results of compressive, split tensile strength test have

indicated that the strength of concrete increases with respect to the percentage of slag added by

weight of fine aggregate up to 40% of additions and 15% of cement. Water absorption of S40

copper slag concrete specimens is 22% lower than the controlled specimens. Water permeability

in concrete reduced up to 40% replacement of copper slag with that of sand.

Mobasher.B et al., (1996) This study points out the beneficial aspects of using copper slag as a

pozzolanic material. Copper slag is shown to significantly increase the compressive strength of

concrete mixtures. Use of lime as a hydration activator was evaluated and shown to improve the

rate of strength gain. Results obtained from this study indicate the tremendous potential of

copper slag as a mineral admixture.

Pazhani.K et al., (2010) This paper presents an experimental investigation to assess the

durability parameters of high performance concrete with the industrial wastes. The slump value

for 100% replacement of fine aggregate with copper slag increases by 60mm to 85mm. It shows

that the water consumed by the copper slag during mixing is very less as compared with river

sand.

Meenakshi Sudarvizhi.S et al., (2011) The highest compressive strength obtained was 46MPa

(for 100% replacement) and the corresponding strength for control mix was 30MPa. It has been

observed that up to 80% replacement, CS and FS can be effectively used as replacement for fine

aggregate. The results show that the compressive strength of CS&FS concrete is increased when

compared to control concrete (30.23MPa to 46.18MPa cured at 90 days), where as the increase in

strength is more or less the same different percentage of CS&FS. The results show that the split

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tensile strength of CS&FS concrete is increased when compared to control concrete (6.10 MPa

to8.65 MPa cured at 90 days), where as the increase in strength is more or less the same different

percentage of CS&FS.

Yang HS et al., (2010) “Copper slag with mgo as pozzolanic material, soundness, pozzolanic

activity and microstructure development” copper slag has little periclase material. The

consumption calcium hydroxide showed the slag exhibits high pozzolanic activity, which has

higher than that of flyash.

Brindha.D et al., (2011) The utilization of copper slag in cement and concrete provides

additional environmental as well as technical benefits for all related industries. Replacement of

copper slag in both fine aggregates and cement replacement reduces the cost of making concrete.

When copper slag replaced with cement, use of hydrated lime by 1.5% to the weight of cement

gives improvement in rate of strength gain. Replacement of copper slag increases the self weight

of concrete specimens to the maximum of 15 to 20%. For higher replacement of copper slag in

cement (greater than 20%) and sand (greater than 50%) the compressive and split tensile strength

decreases due to an increase of free water content in the mix. The results of compressive, split

tensile strength test have indicated that the strength of concrete increases with respect to the

percentage of slag added by weight of fine aggregate up to 40% of additions and 15% of cement.

Gupta R.C et al., (2012) The compressive strength, flexural strength and split tensile strength of

concrete is improved due to the addition of discarded rubber tyres and copper slag. From the

results obtained from the ultrasonic pulse velocity test, the copper slag and rubber tyre

admixtured concrete have excellent quality. The compressive strength increased up to 36% in

copper slag concrete. The test results of flexural strength test on beams show that the ultimate

load carrying capacity of the beam increases up to 38.3% for 40% replacement with copper slag.

Water absorption of copper slag admixed concrete is similar to normal concrete and that of

rubber tyre admixed concrete is greater than normal concrete.

The utilization of copper slag as a partial replacement for sand; imparts strength up to

50% replacement. It can be applied for all construction activities. Concrete mix having discarded

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rubber tyres up to 15% (for coarse aggregates) can be applied for construction of pavements,

minor works etc.

Alnuaimi.AS (2012) The use of CS as a replacement for FA is environmentally helpful due to

the reduction in the waste produced from the copper manufacturing process. It also contributes to

conservation of natural FA. The maximum difference in concrete strength between the mixes of

0% CS and 100% CS was 29%, with the difference between the measured/ control failure loads

between the columns with 0 and 100% CS was 20% the maximum difference in the measured EI

between the columns with 0 and 100% CS was 25%.

Lavanya.C et al., (2011) Comparison of values shows that the behaviour of copper slag is

similar to that of medium sands and that it can be used as a construction material in place of

sands, such as backfill of retaining walls and landfill for the construction of shallow foundations.

Copper slag has high angularity and friction angle (up to 520) of aggregates contribute to the

stability and load bearing capacity. Also copper slag aggregates tend to be free draining and are

not frost susceptible. Copper slag can be used as an alternative aggregate in bituminous mixes

2.2 RICE HUSK ASH

Jayasankar.R et al., (2010) When 20% of special mixed concrete is tested in the M20 and M25

grade concrete there is no change in the strength level. Whereas when the same mix is tested at

the M30 grade there is slight decrease in the strength level in respect of compressive strength

Ghassan Abood Habeeb et al., (2010) The RHA used in this study is efficient as a pozzolanic

material; it is rich in amorphous silica (88.32%). The loss on ignition was relatively high

(5.81%). Increasing RHA fineness increases its reactivity. Grinding RHA to finer APS has

slightly increased its specific surface area, thus, RHA APS is not the main factor controlling its

surface area. The dosage of superplasticizer had to be increased along with RHA fineness and

content to maintain the desired workability. The compressive strength of the blended concrete

with 10% RHA has been increased significantly, and for up to 20% replacement could be

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valuably replaced by cement without adversely affecting the strength. Increasing RHA fineness

enhances the strength of blended concrete.

Oyetola E.B et al., (2006) The rice husk ash produced using charcoal from firewood is

pozzolanic and therefore is suitable for use in block making. The Specific gravity, uncompacted

bulk density, and compacted bulk density of rice husk ash were found to be 2.13, 460 Kg/m3 and

530 Kg/m3. For a given mix, the water requirement increases as the rice husk ash content

increases. The setting times of OPC/RHA paste increases as the ash content increases. The

density of OPC/RHA is within the range for sandcrete blocks (500 to 2100kg/m3). The

compressive strength of the blocks for all mix increases with age at curing and decreases as the

RHA content increases. Rice husk is available in significant quantities as a waste and can be

utilized for making blocks. This will go a long way to reduce the quantity of waste in our

environment. The optimum replacement level of OPC with RHA is 20%.

Abhilash Shukla et al., (2011) There was a significant improvement in Compressive strength of

the Concrete with rice husk ash content of 10% for different grades namely M30 and M60 and at

different ages i.e.7 days and 28 days. The increase in Compressive strength was of the order of

4.23% to 10.93% for different grades and at different ages. There was also significant

improvement in Flexural strength of the Concrete with rice husk ash content of 10% for different

grades namely M30 and M60 and at the age of 28 days. There increase in Flexural strength was

of the order of 1.85% to 8.88% for different grades and at the age of 28 days. There was

reduction in Split tensile strength for 28 days at every rice husk content. There was enormous

reduction in split tensile strength as the percentage of rice husk ash increased strength decreased

enormously from 6% to 26% for both the grades and at the age of 28 days. As the concrete is a

brittle material and cannot handle tensile stress as per IS: 456-2000 proved to be right and that is

why as the percentage of rice husk ash increased strength decreased. So it can be concluded that

Split tensile strength test has a little importance for design aspects

Nagrale S.D et al., (2012) With the addition of RHA weight density of concrete reduces by 72-

75%.Thus, RHA concrete can be effectively used as light weight concrete for the construction of

structures where the weight of structure is of supreme importance. The cost of 1 m3 of OPC

concrete works out to Rs. 1157 while that of RHA concrete works out to Rs. 959. Thus, the use

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of RHA in concrete leads to around 8-12% saving in material cost. So, the addition of RHA in

concrete helps in making an economical concrete. The Compressive Strength will increase with

the addition of RHA. The use of RHA considerably reduces the water absorption of concrete.

Thus, concrete containing RHA can be effectively used in places where the concrete can come in

contact with water or moisture. RHA has the potential to act as an admixture, which increases the

strength, workability & pozzolanic properties of concrete.

Maurice E. Ephraim et al., (2012) The use of RHA in civil construction works will reduce

environmental pollution, improve the quality of concrete, and reduce its cost of production as

well as solving the problem of agro-waste management by putting into use this locally found

additive (RHA). Adding RHA to concrete resulted in increased water demand, increase in

workability and enhanced strength compared to the control sample. The compressive strength

values at 28days were found to be 38.4, 36.5 and 33N/mm2 compared to the control with

37N/mm2. This results show that an addition of RHA from 5-10% will increase the strength and

a further addition up to 15-25%RHA will have a slight reduction in strength of 15% and a

decreasing in strength values is pointed out when the levels of RHA are increasing.

Sathish Kumar.R (2012) The compressive strength of rice husk ash concrete was found to be in

the range of 70-80% of conventional concrete for a replacement of cement up to 20%. The study

shows that the early strength of rice husk ash concrete was found to be less and the strength

increased with age. The rice husk ash concrete occupies more volume than cement for the same

weight. So the total volume of the rice husk ash concrete increases for a particular weight as

compared to conventional concrete which results in economy. Due to the lower density of RHA

concrete the self weight of structure gets reduced which results in overall savings. From the cost

analysis it was found that the cost of RHA concrete was less compared to conventional concrete

Recycled aggregate posses relatively lower bulk density, crushing and impact values and higher

water absorption as compared to natural aggregate. The compressive strength of recycled

aggregate concrete was found to be in the range of 70 to 80 % of conventional concrete. The

compressive strength of brick bat concrete was found to be nearly 35 % of conventional

concrete... The compressive strength of saw dust concrete was found to be nearly 10 to 15% of

conventional concrete. So the concrete made with alternate construction materials like brick bats

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and saw dust can be used for partition & filling purposes & nailing purposes where the strength

is not the criteria. Wherever compressive strength is not a criteria, the concrete made with

alternate construction materials can always be preferred.

Opeyemi1 D.A et al., (2012) The substitution of Rice Husk Ash and Bone Powder can be used

up to 10% for best results in producing plain concrete for concrete structures. There is abundance

of this material in developing countries and it will help in removing thousands of tonnes of waste

from the environment annually. It is observed that the compressive strength decreases with

increase in percentage replacement. Graph of density against percentage replacement shows that

there is reduction in density of the concrete from 0 - 10% replacement of material, and an

increase in 10% - 20% which shows that the unit weight of concrete first reduced, which will

lead to reduction in total self- weight of the structure.

2.2 OBJECTIVES

In order to fulfill the research gap this study is made with following objectives:

To study the physical and chemical properties of waste materials .

To study the performance of cement concrete partially replaced with waste materials such

as CS and RHA

To access the strength and durability parameters of concrete.

To compare the test results and suggestions are made

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CHAPTER-III

RESEARCH METHODOLOGY

By considering the above studies, in order to fulfill the objectives the

following methodology has been adopted.

RESULTS AND DISCUSSIONS

TESTS ON HARDENED CONCRETE

CURING

CASTING OF SPECIMEN

TEST ON FRESH CONCRETE

ARRIVING MIX PROPORTION

BASIC TEST ON MATERIALS

PROCRUMENT OF MATERIALS

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3. MATERIALS USED

This chapter discusses the various materials such as Cement, Fine Aggregate,

Coarse Aggregate, Water, Copper slag, Rice husk ash used for the proposed study.

3.1 CEMENT

Cement is a binding material. The raw materials used for the manufacture of cement consist

mainly of lime, silica, alumina and iron oxide. Ordinary Portland Cement (OPC) of 53 grades

was used for casting all the specimens.

3.1.1 Specific gravity of Cement:

The specific gravity of cement is found out using density bottle.

Specific gravity (G) = (W2-W1)

(W4-W1) - (W3-W2)

Table. No 1: Specific gravity of cement

Sl. No

Weight of

Density bottle

(W1) g

Weight of

Density

bottle+

Cement (W2) g

Weight of

Density

bottle+

Cement+

Kerosene (W3)

g

Weight of

Density

bottle+

Kerosene (W4)

g

Specific

gravity (G)

1 5 14 34.1 28 3.10

2 5 15 34.9 28 3.20

Data derived from Laboratory

The obtained specific gravity of cement is 3.15, which is similar to the standard value of 3.15.

3.1.2 Fineness of cement:

The fineness of cement is found out with IS sieve of 90µ. The fineness modulus is

calculated by the equation,

Fineness = Weight of residue

Weight of sample

22

Table. No 2: Percentage of Fineness Modulus of cement

Sample no. Weight of sample (g) Weight of residue (g) Fineness (%)

1 100 1.3 1.3

2 100 1.3 1.3

3 100 1.4 1.3


Fineness = (weight of residue / weight of sample) x100

= (1.3/100) x100

= 1.3% < 10%

The fineness modulus is an important characteristic of cement. The fineness

modulus of cement should be within 10% for the rate of hydration. Fineness of cement reflects

great impact on the gain of strength and the evolution of heat too.

3.1.3 Standard consistency of Cement:

The standard consistency test is used to find out the setting time and strength

parameters of the cement. The Vicat apparatus is used for this test. This method is used to find

out the percentage of water required to produce a cement paste of standard consistency.

Table. No 3: Standard consistency of cement

Sl no. W/C ratio Amount of water added(ml) Depth of

penetration(mm)

1 0.24 72 0

2 0.25 75 3

3 0.26 78 6

4 0.27 81 11

5 0.28 84 13

6 0.29 87 16


Standard consistency = 0.29

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The standard consistency of the cement paste is defined as that consistency which will permit the

Vicat plunger to penetrate 5 to 7mm from the Vicat mould. The standard consistency obtained

for cement is 0.29.

3.1.4 Setting time of Cement:

Initial Setting Time

It is the elapsed between the moments that the water is added to the cement, to the

time that the paste starts losing its plasticity. This method covers the testing procedure for

determining the initial setting time of cement. The apparatus used to find the setting time is Vicat

apparatus conforming to IS: 5513-1969 with dash pot, on-absorbent mixing plate measuring

cylinder gauging trowel and stopwatch.

Final Setting Time of Cement

It is the interval between the moment that the water is added to the cement to the

time that the paste completely lost its plasticity and has attained sufficient firmness to resist

certain definite pressure. This method covers the testing procedure for determining the final

setting time of cement. The apparatus used is same as Initial setting time expect the 1mm square

needle shall be replaced by a needle with annular attachment

Table. No 4: Initial Setting time of cement

Sl no. Duration(minutes) Initial Reading(mm) Final Reading(mm)

1 5 0 0

2 10 0 0

3 15 0 0

4 20 0 0

5 25 0 1

6 30 1 4

7 35 4 8


The initial setting time is 35 minutes.

Weight of water = 0.85% of standard consistency

24

The time period elapsing between the time, water is added to the cement and the

time, the needle fails to penetrate the test block by 5.0±0.5mm measured from the bottom of the

mould, is the initial setting time. The initial setting time is 35minutes for the Ordinary Portland

Cement.

3.2 RICE HUSK ASH

Rice Husk Ash (RHA) is a by-product of the agricultural industry which contains

high amount silicon dioxide (Sio2). RHA is obtained by burning rice husk at a temperature

ranges between 600˚C and 750˚C. The obtained product is then grained in a ball mill to get fine

product.

3.2.1Specific gravity of RHA:

The specific gravity of cement is found out using density bottle.

Specific gravity (G) = (W2-W1)

(W4-W1) - (W3-W2)

Table. No 5: Specific gravity of RHA

Sl. No

Weight of

Pycnometer

(W1) g

Weight of

Pycnometer+

Cement (W2) g

Weight of

Pycnometer+

Cement (W3) g

Weight of

Pycnometer+

water (W4) g

Specific

gravity (G)

1 635 741 1569.5 1526 1.69

2 635 732.5 1567 1526 1.72


The obtained specific gravity of RHA is 1.7.

3.2.2 Fineness of RHA:

The fineness of rice husk ash is found out with IS sieve in the order of 4.75mm,

2.36mm, 1.18mm, 600µ, 300µ, 150µ, 75µand pan. The fineness modulus of RHA is found out

from the formula

Fineness modulus = Total sum of cumulative % retained

1000

25

Table. No 6: Percentage of Fineness Modulus of RHA

Sl no. I.S Sieve Weight of sand

retained(g)

Cumulative

weight of sand

retained(g)

Cumulative

% retained % Finer

1 4.75mm 0.5 0.5 0.05 49.95

2 2.36mm 0.5 1.00 0.10 49.9

3 1.18mm 2.00 3.00 0.30 49.7

4 600µ 20.5 23.5 2.35 47.65

5 300µ 440 463.5 46.35 3.65

6 150µ 33 496.5 49.65 0.35

7 75 µ 1 497.5 49.75 0.25

7 Pan 2.5 500 50 0



1000

= 1985.5/1000

= 1.985<10%

The fineness modulus of RHA lies nearer to that of cement. This fineness modulus is less than

10% which is acceptable.

26

3.2.3 Standard consistency and setting time of RHA

Table 7: Standard consistency and initial and final setting time

Type of

cement

Consistency

(%)

Initial setting

time(min)

Final setting

time(hrs)

100%OPC 31 35 10

5% RHA 33 38 10

10% RHA 36 41 10

15% RHA 40 43 10

20% RHA 42 48 10

25%RHA 45 50 10


3.2.4 Chemical properties of RHA

Table 8: Chemical properties of RHA [13]

Sl.No Characteristic tests Results

1 Calcium oxide (CaO) 1.05%

2 Silicon Oxide (SiO2) 77.4%

3 Aluminium Trioxide (Al2O3) 0.28%

4 Iron (Fe2O3) 0.66%

5 Magnesium (MgO) 1.96%

6 Loss of Ignition 7.98%

27

3.3 FINE AGGREGATES

The aggregates which passes through a IS sieve of size 4.75mm is known as fine

aggregates. Sand is used as a filler material in concrete and it gives strength to the concrete. The

sand is naturally obtained from the gravels and rocks and it should be free from impurities. In

this investigation locally available clean and dry Cauvery river sand was used. According to the

particle size distribution the fine aggregate has divided into four grading zones. In this test zone

II grade sand has been used.

3.3.1Specific Gravity on Fine Aggregate

Table. No 9: Specific gravity of fine aggregates

Sl. No Description Trial-1 Trial-2

1 Empty weight of Pycnometer(W1)g 665 665

2 Weight of Pycnometer+ soil(W2)g 1322 1322

3 Weight of Pycnometer+ soil+ water(W3)g 1988 1983

4 Weight of Pycnometer+ water(W4)g 1578 1573

5 Specific gravity 2.65 2.66

6 Average Specific gravity 2.6


3.3.2 Water absorption test:

The water absorption of aggregate is determined by measuring the increase in

weight of an oven dry sample when immersed in water for 24 hours. The ratio of increase in

weight to the weight of dry sample expressed as a percentage is known as water absorption of

aggregate.

Table 10: Water absorption test on fine aggregate

Sl.No Dry weight of aggregate (g) Wet weight of aggregate (g) Water absorption in

percentage

1 1000 1006 0.6%

2 1000 1008 0.8%


Average water absorption = 0.7%

28

3.3.3 Sieve analysis of Fine Aggregate

Sieve analysis is the name given to the operation of dividing a sample of aggregates

into various fractions each consisting of particles of the same size. The sieve analysis is

conducted to determine the particle size distribution in a sample of aggregate, which we call

gradation. This analysis is used to find the zone conformation and also to find the fineness

modulus of fine aggregate. The zone conformation of fine aggregate is need for concrete design

mix.1000gm of fine aggregate is taken and the IS sieve are arranged in the order as

4.75mm,2.36mm,1.18mm,600µ,300µ,150µand 75µ.

Table. No 11: Fineness modulus of fine aggregates

Sl no. I.S Sieve Weight of sand

retained(g)

Cumulative

weight of sand

retained(g)

Cumulative

% retained % Finer

1 4.75mm 26 26 2.6 97.4

2 2.36mm 27 53 5.3 94.4

3 1.18mm 239 292 29.2 70.8

4 600µ 251 543 54.3 45.7

5 300µ 425 969 96.9 3.1

6 150µ 20 989 98.9 1.1

7 75 µ 7 996 99.6 0.4

7 Pan 4 1000 100 0



1000

= 4868/100

= 4.868

29

3.4 COPPER SLAG

Copper slag is an industrial byproduct. Copper slag is a glassy granular in nature.its particle size

is almost similar to sand so this can be used as a viable substitute for sand.

3.4.1 Specific Gravity of Copper slag

Table. No 12: Specific gravity of copper slag




3 Weight of Pycnometer+ soil+ water(W3)g 2245 2101





3.4.2 Water absorption test:

The water absorption of aggregate is determined by measuring the increase in

weight of an oven dry sample when immersed in water for 24 hours. The ratio of increase in

weight to the weight of dry sample expressed as a percentage is known as water absorption of

aggregate.

Table 13: Water absorption test on copper slag

Sl.No Dry weight of aggregate (g) Wet weight of aggregate (g) Water absorption in

percentage

1 1000 1004 0.4%

2 1000 1002 0.2%


Average water absorption = 0.3%

30

3.4.3 Fineness Modulus of Copper slag

1000gm of copper slag is taken and the IS sieve are arranged in the order as

4.75mm,2.36mm,1.18mm,600µ,300µ,150µ and 75µ

Table. No 14: Fineness modulus of copper slag

Sl. No I.S Sieve Weight of sand

retained(g)

Cumulative

weight of sand

retained(g)

Cumulative %

retained

% Finer

1 4.75mm 0 0 0 100

2 2.36mm 4 4 0.4 99.6

3 1.18mm 174 178 17.8 82.2

4 600µ 137 315 31.5 68.5

5 300µ 639 954 95.4 4.6

6 150µ 23 977 97.7 2.3

7 75µ 15 992 99.2 0.8

8 Pan 8 1000 100 0



1000

= 4420/1000

= 4.42

3.5 COARSE AGGREGATE

The aggregates which are retained on the 4.75mm IS sieve is known as the coarse

aggregates. Crushed aggregates with specific gravity of 2.815 and passing through 20mm sieve

and retained on 10mm will be used for casting all specimens. Several investigations concluded

that maximum size of those aggregates should be restricted in strength of the composite.

31

3.5.1 Specific Gravity of Coarse aggregate

This test can be used for finding the specific gravity of coarse aggregates using

Pycnometer. By knowing the specific gravity, its weight can be converted into solid volume and

hence theoretical yield of concrete per unit volume can be calculated.

Specific Gravity G = W2 - W1

(W2 - W1) - (W3 - W4)

Table. No 15: Specific gravity of coarse aggregates




3 Weight of Pycnometer+ soil+

water(W3)g 1978 1862





3.5.2 Fineness Modulus of Coarse Aggregate

10000 gm of coarse aggregate is taken and the IS sieves are arranged in the order

as 25mm,20mm,16mm,12.5mm,10mm and pan.

Table. No 16: Fineness modulus of coarse aggregate

Sl no. IS sieve Weight the

aggregate

retained(g)

Cumulative

weight of

aggregate

retained(g)

Cumulative %

of aggregate

retained

% Finer

1 25mm 806 806 80.6 91.94

2 20mm 5204.5 6010.5 60.10 39.9

3 16mm 2110.15 8121 81.21 18.70

32

4 12.5mm 994 9115 91.15 8.85

5 10mm 750.5 9865.5 98.65 1.35

6 Pan 134.5 10000 100 0



1000

= 439.17/100

= 4.3917

Fineness of the coarse aggregate gives the uniformity of grading size and ranges of the particles.

The fineness of coarse aggregate particles was within the limits as per Indian Standards. And it is

also required to find the cohesion properties of particles.

3.6 WATER

Casting and curing of specimens where done with the potable water that is available in

the university premises.

3.7 CONCRETE MIX DESIGN

The bureau of Indian standard, recommended a set of procedure for the design of concrete mix

mainly based on the work in national laboratories. The mix design procedures are covered in IS

10262-1982. The methods given can be applied for both medium strength and higher strength of

concrete.

The mix design for M20 grade concrete is designed as per IS 10262-1982

3.7.1 DATAS

DESIGN STIPULATIONS

i. Characteristic compressive strength…………………….. 20 Mpa

Required in the field at 28 days

ii. Maximum size of aggregate……………………………...20 mm(angular)

33

iii. Degree of workability…………………………………... 0.90

iv. Degree of quality control……………………………….. Good

v. Type of exposure………………………………………... Mild

Test data for materials

i. Cement used……………..……………Ordinary Portland cement

ii. Specific gravity of cement……………………………..3.15

iii. Specific gravity of fine aggregates…………………….2.6

iv. Specific gravity of coarse aggregates…………………2.815

v. Compressive strength ……………………………Satisfies the

requirement of cement

at 7 days

vi. Water absorption:

Fine aggregate…………………………………………..0.7%

Coarse aggregate………………………………………..0.5%

vii. Free moisture:

Coarse aggregate……………………………………………. Nil

Fine aggregate ……………………………………………….2%

viii. Sieve analysis of fine aggregate……………………conforming to

grading Zone II with reference of IS 383 - 1970

3.7.2 TARGET MEAN STRENGTH

The target mean compressive (Fck) strength at 28 days is given by

Fck = f ck + tS

where

fck = characteristic compressive strength at 28 days

34

t = risk factor (1.65) IS: 456 – 2000 and IS: 1343 – 1980

s = Standard deviation as per IS: 456 – 2000 for M20 grade concrete

Fck = 20 + (1.65+4)

= 26.6 Mpa

3.7.3 SELECTION OF WATER CEMENT RATIO

From fig 1 in IS 10262-1982,

Fck = 26.6 Mpa

The water cement ratio required for the target mean strength of 26.6 Mpa is 0.5.

As per IS 456-2000, table-5 the maximum water cement ratio for M20 and it is mild exposure

condition is 0.5. Adopt water cement ratio is 0.5

3.7.4 SELECTION OF WATER AND SAND CONTENT

From IS: 383 – 1970, for 20 mm maximum size aggregate, sand conforming to grading

zone II, water content per cubic metre of concrete = 186 kg and sand content as percentage of

total aggregate of total aggregate by absolute volume = 35%.

For change in value in water-cement ratio, compaction factor, for sand belonging to zone III,

following adjustment is required.

Table 17: Adjustments of water and sand content

Change in condition

Percent adjustment required

Water content Sand in total

aggregate

For decrease in water-cement ratio by (0.6-0.5)

that is 0.10 0 0

For increase in compacting factor (0.9-0.8)

that is 0.10 0 -3

35

For sand conforming zone II of IS: 383 – 1970 +3 0

Total +3 -3

Therefore required sand content as percentage of total aggregate by absolute volume

= 35 – 2

= 33%

Required water content = 186+[186 x 3/100]

= 186+ 5.58

= 191.6 Lit/m3

3.7.5 DETERMINATION OF CEMENT CONTENT

Water-cement ratio = 0.5

Water = 191.6 L/m3

Cement = 191.6/0.5

= 383 kg/m3

This cement content is adequate for mild exposure condition as per IS: 456 – 2000

3.7.6 DETERMINATION OF COARSE AND FINE AGGREGATE CONTENTS

From IS: 383 – 1970 for the specified maximum size of aggregate of 20mm, the amount

of entrapped air in the wet concrete is 2%

CALCULATION OF AGGREGATE CONTENT

Aggregate content can be determined from the following equations

Fine aggregate:

V = [w+ (C/Sc) + (1/p) (Fa /Sa)]

1000

P = 0.325/1 =0.325

36

V = 0.98

0.98 = [191.6 + (383.2/3.15)+1/0.325 X Fa/2.66] X (1/1000)

Fa =576.40kg/m3

Coarse aggregate:

V = [w+ (C/Sc) + (1/1-p) (Ca /Sa)]

1000

0.98 = [191.6 + (383.2/3.15) + (1/ [1-0.325]) X (Ca/2.815)] X (1/1000)

Ca =1267kg/m3

Table 18: Various mix proportions of the proposed concrete

Water Cement Sand Coarse aggregate

191.6ml 383.2kg 570kg 1267kg

0.5 1 1.48 3.30

Design mix concrete 1:1.48:3.30 and the water cement ratio is 0.5

37

CHAPTER –IV

TEST DATA ANALYSIS

PROPERTIES OF CONCRETE

The properties of concrete is two types, they are fresh and hardened concrete

properties. The performance of concrete properties are mainly depends upon the mix design,

shape and strength of aggregates. Water-cement ratio is a main factor of fresh concrete

properties. It may affect the strength and durability of concrete. The strength and life time of the

structure is mainly depending on properties of concrete only.

4.1 FRESH CONCRETE

Fresh concrete is a concentrated suspension of particulate materials of widely

differing densities, particle sizes and chemical composition in a solution of lime and other

components. While the mixing of cement and water takes place, a chemical reaction occurs due

to increase in temperature. For effective mix and place of concrete, a certain degree of fluidity or

workability is required.

4.1.1 FRESH CONCRETE PROPERTIES

The fresh concrete property is depending upon properties like cement, grading of

aggregate and water. The slump test, compaction factor test are used to find the workability of

the concrete. The required quantity of water is calculated and added to the concrete to find the

workability concrete. The test was carried out according to IS 6461 (Part 7) -1973 define the

workability as that property of freshly mixed concrete.

TESTS FOR WORKABILITY

Slump test

Compaction factor

38

4.1.2 Slump test:

This method of test specifies the procedure to be adopted either in the laboratory or

in the field during the work, for determining the workability of concrete where the nominal

maximum size of the aggregate does not exceed 38mm.

The apparatus used in the experiment are Metal slump cone of at least 1.6mm

thickness provided with suitable base plate and also handles for lifting it from the moulded

concrete test specimen vertically.

The slump measured shall be reported in terms of millimeters of subsidence of the

specimen during the test. Any slump specimen, which collapses or shears off laterally, shall be

repeated with another sample. If in the repeat test also the specimen shears, the slump shall be

measured and the fact that the specimen sheared, shall be reported. Take corrective action to

make the mix cohesive.Slump value test has been conducted for both types of concrete replaced

with copper slag and rice husk ash with water cement ratio 0.5.

Table. No 19: Workability of Concrete replaced with copper slag

Sl. No Concrete Type Slump

Value (mm)

1 Control concrete 30

2 10% Replacement of sand with CS 35


4 30 % Replacement of sand with CS 45





39

Fig 3: Slump value for copper slag

Table. No 20: Workability of Concrete replaced with RHA

Sl. No Concrete Type Slump

Value

1 Control concrete 30

2 5% Replacement of cement

with RHA 35


with RHA 40


with RHA

45


with RHA 50


with RHA 55

0

10

20

30

40

50

60

70

CC 10% ofCS

20% ofCS

30% ofCS

40% ofCS

50% ofCS

60% ofCS

70% ofCS

slu

mp

in

mm

SLUMP VALUE (mm)

40

Fig 4: Slump value for Rice husk ash

The IS code book IS 456:2000 recommended the guide line for concrete mix design

adopted slump value as a measure for workability. The w/c ratio of fresh concrete by slump test

is 0.5. For control concrete the slump value obtained is 30mm. When the percentage of

replacement increased then the subsidence increased to 35mm and 40mm for the replacement of

10% and 20% of copper slag. Finally slump value obtained for 70% replacement of copper slag

is 65mm. For the concrete rice husk ash replaced instead of cement the slump value observed for

control concrete is 30mm. As well as when the percentage of replacement increased then the

value remains 35mm and 40mm for 5% and 10% of rice husk ash. Finally slump value obtained

for 25% replacement of rice husk ash is however increased to 55mm.The slump value of

combined mix is 50mm.

4.1.3 Compaction Factor Test

The compaction factor tests were designed for very low workable concrete. The

degree of compaction called as compacting factor is measured by the density ratio. That is, ratio

of the density actually achieved in the test to the density of the same concrete fully compacted.

The apparatus used for the testing are Compaction testing machine, tamping rod and weighing

machine.

Compacting factor = Weight of partially compacted concrete

Weight of fully compacted concrete

0

10

20

30

40

50

60

CC RHA 5 RHA 10 RHA 15 RHA 20 RHA 25

Slump Value (mm)

Slump Value (mm)

41

Table 21: compaction factor for concrete replaced with copper slag

Sl. No Concrete type Water-cement ratio

Weight of

partially

compacted

concrete (w1) g

Weight of fully

compacted

concrete (w2) g

Compaction

factor

1 Control concrete 0.5 18710 21500 0.87

2 10% of sand

replaced with CS 0.5 19000 21800 0.87

3 20% of of sand

replaced with CS 0.5 18440 20950 0.88

4 30% of of sand

replaced with CS 0.5 18340 20600 0.89

5 40% of sand

replaced with CS 0.5 18720 20800 0.9

6 50% of sand

replaced with CS 0.5 18630 20700 0.9

7 60% of sand

replaced with CS 0.5 18660 20500 0.9

8 70% of sand

replaced with CS 0.45 18810 20450 0.92

Table 22: Compaction factor for concrete replaced with Rice husk ash

Sl. No Concrete type Water-

cement ratio

Weight of

partially

compacted

concrete (w1) g

Weight of fully

compacted

concrete (w2) g

Compaction

factor

1 Control

concrete 0.5 18710 21500 0.87

2

5% of cement

replaced with

RHA

0.5 17920 20600 0.87

42

3.

10% of cement

replaced with

RHA

0.5 17290 20100 0.86

4

15% of cement

replaced with

RHA

0.5 17680 20800 0.85

5

20% of cement

replaced with

RHA

0.5 17390 20450 0.85

6

25% of cement

replaced with

RHA

0.5 17260 20550 0.84

4.2 Test on hardened concrete

4.2.1 Compression Test

It is the most common test conducted on hardened concrete and an easy test to

perform. Most of the desirable characteristic properties of concrete are qualitatively related to its

compressive strength. The apparatus used for the test is Compression testing machine.

The tests were carried out on 150x150x150mm size cube, as per IS: 516-1959.

The test specimen were removed from the moulds and immediately submerged in clean fresh

water and kept there until taken out just prior to test. The specimen was placed on the

compression testing machine. The load is applied at the rate of kg/cm2 per minute, and failure

load in KN is observed from the dial gauge of compression testing machine.

Compressive strength = Load N/mm2

Area

43

Table. No 23: Compression strength of Concrete replaced with Copper Slag

Sl. No Specimen Compressive strength N/mm

2

7th

day 14th

day 28th

day

1 Control Concrete 19.7 29.32 31

2 10% Replacement of sand with

copper slag 24.87 33.7 36


copper slag 34.37 42.44 43.8


copper slag 35.7 44.44 45.3


copper slag 34.9 36.3 38.7


copper slag 32.22 34.44 36


copper slag 29 30 32


copper slag 27 29 31

Fig 5: Compressive strength of concrete replaced with copper slag

7TH DAY,

14 TH DAY,

28th day,

0

20

40

60

80

100

120

140

CC CS10 CS20 CS30 CS40 CS50 CS60 CS70

COMPRESSIVE STRENGTH(N/mm2)

44

Table. No 24: Compression strength of Concrete replaced with RHA

Sl. No Specimen

Compressive strength N/mm2

7th

day 14th

day 28th

day

1 Control Concrete 19.7 29.32 31

2 5% Replacement of cement with

RHA 25.3 31 34.6


RHA 28.7 33.6 38.8


RHA 24.6 30 33.7


RHA 19 22.7 25.6


RHA 15.55 20 23.7

Fig 6: Compressive strength of concrete replaced with RHA

0

20

40

60

80

100

120


COMPRESSION STRENGTH (N/mm²)

28th day

14th day

7th day

45

The compressive strength obtained by replacement of copper slag in concrete shows maximum

strength than control concrete on 28th

day. The increase of compressive strength is due to the

replacement of copper slag instead of fine aggregate. However, compressive strength obtained by

replacement of rice husk ash in concrete shows decrease in strength than the control concrete on

28th

day. But it has obtained maximum strength compare to control concrete for 10%

replacement of RHA on 28th

day.

4.2.2 Split tensile test

It is a method of determining the tensile strength of concrete using a cylinder

which splits the specimen across the vertical diameter. It is expressed as the minimum tensile

stress (force per unit area) needed to split the material apart. The test is carried out in Universal

Testing Machine.

The specimens were taken out from the water only after 28days. The specimen

were placed or kept on the plate and the loads were applied gradually. The ultimate loads were

observed. The load is applied till the failure of the specimen occurs. After obtaining the failure

load, the split tensile strength (sp) can be determined by the following equation.

=2p/πdl N/mm2

Where,

sp

= Flexural stress (N/mm2)

P = Failure load (kg)

D = Diameter of the specimen 150mm

l = Length of the specimen 300mm

The test was carried out on 150x300mm size cylinder. The test results are tabulated in

table using the stress value

Table. No 25: Split tensile strength of concrete with Copper Slag

Sl.no Type of concrete Average failure

load(kg)x103

Split tensile

strength(N/mm2)

on 28th

day

1 Control concrete 22620 3.2

2 10% Replacement of sand 23326 3.3

46

with copper slag

3 20% Replacement of sand

with copper slag 26860 3.8




with copper slag 28280 4







Fig 7: split tensile strength of concrete replaced with copper slag

00.5

11.5

22.5

33.5

44.5

Split tensile strength(N/mm2)

Split tensilestrength(N/mm2) on 28thday

47

Table. No 26: Split tensile strength of concrete with RHA

Sl.no Type of concrete Average failure

load(kg)x103

Split tensile

strength(N/mm2)

1 Control Concrete 21210 3.2

2 5% Replacement of

cement with RHA

23750 3.36

3 10% Replacement of

cement with RHA

28980 4.1


cement with RHA

24880 3.52


cement with RHA

20220 2.86


cement with RHA

15770 2.23

Fig 8: Split tensile strength of concrete replaced with RHA

00.5

11.5

22.5

33.5

44.5




48

4.2.3Acid resistance test:

The acid resistance study were conducted for all the concrete cubes, in the present

investigation immersion techniques was adopted. After 28 days 150mm cube specimens were

immersed in 5% H2SO4 solution. The solution was kept at room temperature and the solution

was stirred regularly, at least twice a day to maintain uniformity. The solution was replaced at

regular intervals to maintain concentration of solution throughout the test period. The evalutions

were conducted after 14 days from the immersion. After removing the specimens from the

solution, the surfaces were cleaned with soft nylon wire brush under the running tap water to

remove weak products and loose material from the surface. Then the specimens were allotted to

surface dry. From the initial and final weight at particular intervals, the loss of the weight and

strength were studied. All the concrete cubes were showing percentage of mass loss less than….

The percentage of mass loss for concrete was only fraction compared to the normal concrete of

equal strength grades.

Table. No 27: Results of acid resistance test

Sl.No Mix ID Weight loss% % of Strength loss

1 CC 1.74 14.8

2 CS10 1.30 22.5

3 CS30 2.15 28.9

4 CS50 3.0 32.8

5 CS70 3.44 38.6

6 RHA 10 1.65 15.3

7 RHA 15 1.87 19.7

8 RHA 25 2.03 24.6

9 CMB 1.98 25.3

49

Fig 9 Loss of weight in Acid resistance test

Fig 10 Loss of strength in Acid resistance test

0

0.5

1

1.5

2

2.5

3

3.5

4

CC CS10 CS30 CS50 CS70 RHA 10RHA 15RHA 25 CMB

MIX ID

% OF WEIGHT LOSS

Weight loss%

0

5

10

15

20

25

30

35

40

45

CC CS10 CS30 CS50 CS70 RHA10

RHA15

RHA25

CMB

% OF STRENGTH LOSS

% of Strength loss

50

SEM analysis:

SEM (Scanning electron microscopy) is an important technique in the study of cement and

concrete. It will describe the scanning electron in the following manner:

Image analysis

Examinations of fractured and polished surface

Examination of concrete: how to do it and what information can be obtained, including:

estimation of water-cement ratios; measurement of mix proportions; cement type

determination; quantitative X-ray microanalysis and hydrate characterization;

indentification of deleterious processes and effect of admixture.

For SEM analysis three samples has selected

Sample 1- Control concrete

Sample 2- Concrete in which 30% of sand is replaced with Copper Slag.

Sample 3- Concrete in which 15% of cement is replaced with RHA.

51

Figure 11: SEM results of control concrete

Figure 12: SEM results of concrete replaced with copper slag 30 %

Figure 13: SEM results of concrete replaced with RHA 15

2 4 6 8 10 12 14 16 18 20keV

0

1

2

3

4

5

6 cps/eV

C-KO-KAl-KSi-KA Ca-KATi-KA Fe-KA

C O

Al Si

Ca

Ca Ti

Ti

Fe

Fe

2 4 6 8 10 12 14 16 18 20keV

0

2

4

6

8

10

12 cps/eV

C-KO-KAl-KSi-KA Ca-KA Fe-KA

C O

Al Si

Ca

Ca

Fe

Fe

2 4 6 8 10 12 14 16 18 20keV

0

2

4

6

8

10

12 cps/eV

C-KO-KAl-KSi-KA Ca-KA Fe-KA

C O

Al Si

Ca

Ca

Fe

Fe

52

CHAPTER – V

RESULTS AND DISSCUSSIONS

Specific gravity

The standard value of specific gravity of OPC is 3.15 which is a standard value..The

specific gravity of RHA is 1.7. This shows that concrete with less specific gravity is less dense

and thus gives light weight concrete.

The specific gravity fine aggregate is 2.66 which is within the permissible limit 2.6 to

2.8 and for coarse aggregate it is 2.815 which is within 2.6 to 2.9.The specific gravity of copper

slag is 3.52. This produce high dense concrete.

Fineness test

The test results of fineness of cement obtained is 1.4% and for RHA is 1.98%.Generally the

experiment says that the value below 2.3% is considered as very fine grade where as above 3% is

considered to be coarser grade.

Standard consistency test:

The standard value recommended for consistency is 26% to 33%.The results obtained for cement

is 29% which is within the limit. Consistency of cement replaced with RHA increases with the

increase in percentage of RHA anyhow the value is within the limit.

Setting time

The initial setting time of cement is observed as 35 minutes. Initial setting of cement

with RHA 5% is 35 minutes. Initial setting time increases with the increase in percentage of

RHA. The final setting time observed is 10 hours for all mix.

Water absorption test:

Water absorption test result for copper slag is 0.3% is lower than the river sand

(0.7%). This implies that concrete made with copper slag posses less porous

53

Slump cone test:

The slump value of all the mixes ranges between 35 and 100.this implies that all the

mixes posses good workability. The slump value increases with increase I percentage of copper

slag and RHA..

Compression test

For different mixes the compressive strength at different ages 7 , 14 and 28 days were

found out. From the above analysis it is observed that optimum strength is obtained at 30%

replacement of sand with copper slag. The increment in strength is about 46% compared to

control concrete. Anyhow upto 50% replacement compressive strength is higher than control

concrete. The results on replacement of 10% RHA on cement shows optimum strength, whereas

upto 15% the strength does not go beyond control concrete. The compressive strength of

combined mix is 46.8N/mm2

The results obtained for the different mixes are almost nearer to the values of Brindha et al [6]

Split tensile strength

The split tensile strength is observed on 28th

day. Optimum strength is obtained on 30%

replacement of sand with CS is 4.2N/mm2. In case of RHA peak value is 4.1N/mm2 on 10%

replacement of cement.the combined mix shows 4.1N/mm2. Optimum strength is obtained on the

combined mix is 4.4N/mm2

Acid resistance test

From the result of acid resistance test, mixes with high percentage of copper slag shows

less resistance to H2SO4 whereas the .mixes containing RHA gives more resistance to acid

attack.

SEM analysis

From the analysis it is found that sample 1 contains more oxygen content followed by carbon

whereas the sample 2 contain carbon 3.7% less than sample 1. calcium content is 1.65% more in

sample 2 compared to sample 1.Al content is found to be very less in RHA 10. Iron (Fe) is found

to be same in samples 1 and 2 and less in sample 3.

54

CHAPTER – VI

CONCLUSION:

The physical and chemical properties of waste materials i.e. copper slag and RHA is studied.

From the above study the performance of this blended concrete is found to be good. The analysis

of the study reveals that the partial replacement of fine aggregate with copper slag and cement

with RHA provides additional environmental and technical benefits for all related industries.

Further the cost of concrete reduces due to the partial replacement of wastes. This alternate

technology assures high strength and high workability concrete is possible at cheaper cost.

Additionally it is found that water absorption of blended concrete is found to be less compared to

control concrete.

This experimental study reveals that replacement of cement up to 10% gives optimum

compressive and tensile strength. However the duration and the temperature of burning and

fineness of RHA has more effect on strength .The durability of this blended concrete depends

highly on the physical and chemical properties of RHA and CS which may vary according to the

condition of regions. Further research is needed to study the durability of this blended concrete.

RECOMMENDATIONS

The behaviour of concrete can be studied for long term duration.

The increment of strength can be studied with the addition of chemical admixtures to the

concrete.

Study is needed to find the suitability of concrete in marine environment.

Corrosive nature of concrete is to examined.

55

REFERENCE

[1]ACI Committee233, “Ground Granulated Blast-Furnace Slag as a Cementitious Constituent in

Concrete” ACI Materials Journal., vol.84, no.4, pp.330, July-Aug.1987.

[2] S.Meenakshi Sudarvizhi and R.Ilangovan,”Performance of Copper slag and Ferrous slag as

partial replacement of sand in Concrete” International Journal of Civil and Structural

Engineering., vol.1. no. 4,2011

[3] Y. Akihiko and Y. Takashi, “Study of Utilization of copper slag as fine aggregate for

concrete”, Ashikaya Kogyo Daigaku Kenkyu Shuroku., 23 79-85.1996.

[4]. Zhang, M.H and Malhotra, V.M “High performance concrete Incorporating Rice Husk Ash

as a Supplementry Cementiting Material” ACI Materials Journal, Nov/Dec pp 629-636.1996

[5] M.S.Shetty, “Concrete technology”, S.Chand Publications, Ram Nagar, New Delhi pp.186

2009 Edition

[6] Brindha.D, Baskaran.T and Nagan.S, “Assessment of Corrosion and Durability

Characteristics of Copper Slag Admixed Concrete”, International journal of civil and structural

engineering, vol.1, no.2. pp. 194, 208, 2010.

[7] Mobasher.B, ASCE.M, and Devaguptapu.R, Arino.A.M, “Effect of copper slag on the

hydration of blended cementitious mixtures”, ASCE, Materials Engineering Conference,

Materials for the New Millenium, ed. K. Chong, pp. 1677-86, 1996.

[8] K. Pazhani and R. Jeyaraj, “Study on durability of high performance concrete with industrial

wastes”, ATI - Applied Technologies & Innovations., vol.2, no.4, pp.19-28, 2010.

[9] Brindha.D and Nagan.S, “Durability studies on copper slag admixed concrete”, ASIAN Journal

of civil engineering (Building and Housing) vol.12, no.5. pp.563-578, 2011.

[10] R.C Gupta, Blessen Skariah Thomas and Prachi Gupta,“ Utilization of copper slag and

discarded rubber tyres in construction” International Journal of civil and structural engineering,

vol. 3, no. 2, pp. 271-281, 2012.

[11] Alnuaimi AS,“Effects of Copper Slag as a Replacement for Fine Aggregate on the Behavior

and Ultimate Strength of Reinforced Concrete Slender Columns”TJER,vol.9,no.2,pp 90-102,

2012

56

[12] Lavanya . C, Sreerama Rao . A, Darga Kumar. N, “A Review on Utilization of copper slag

in geotechnical applications” Indian Geotechnical Conference, no.212 pp. 15-17, 2012.

[13] Jayasankar.R, Mahindran.N, Ilangovan.R,“Studies on Concrete using Fly Ash, Rice Husk

Ash and Egg Shell Powder ” International journal of civil and structural engineering, vol.1,

no.3, pp. 362-372, 2010.

[14] Ghassan Abood Habeeb, Hilmi Bin Mahmud ,“Study on Properties of Rice Husk Ash and

Its Use as Cement Replacement Material” Materials research, vol.13, no.2, pp 185-190, 2010.

[15] E. B. Oyetola and M. Abdullahi, “The Use of Rice Husk Ash in Low - Cost Sandcrete Block

Production” Leonardo Electronic Journal of Practices and Technologies, vol.8, pp. 58-70, 2006

[16] Abhilash Shukla , Singh C.K , Arbind Kumar Sharma, “Study of the Properties of Concrete

by Partial Replacement of Ordinary Portland Cement by Rice Husk Ash” International Journal of

Earth Sciences and Engineering, vol.4, no.6, pp. 965-968, 2011.

[17] Nagrale S.D, Dr. Hemant Hajare, Pankaj R. Modak, “Utilization Of Rice Husk Ash”

International Journal of Emerging Technology and Advanced Engineering, vol.2, no.9,

pp.261-26, 2012

[18] Maurice E. Ephraim, Godwin A. Akeke and Joseph O. Ukpata, “Compressive strength of

concrete with rice husk ash as partial replacement of ordinary Portland cement”Scholarly

Journal of Engineering Research, vol.1, no.2, pp 32-36, 2012.

[19] Sathish Kumar .R, “ Experimental study on the properties of concrete made with alternate

construction materials”International Journal of Modern Engineering Research (IJMER), vol.2,

no.5, pp. 3006-3012, 2012.

[20] Opeyemi1 D.A, Makinde O.O, “The suitability of partial replacement of cement with rice

husk ash and bone powder in concrete structures” International Journal of Emerging Technology

and Advanced Engineering, vol.2, no.9, pp.261-265,2012.

57

PHOTOS AT WORK

CASTING AND TESTING OF SPECIMEN

58

IMAGES OF ACIDRESISTANCE TEST

59

EXPERIMENTAL STUDY OF STRENGTH AND DURABILITY OF CONCRETE USING

WASTE MATERIALS

K.Mahendran, M.Ummu Thahira ,K.Renu Priyanka

Rural Technology Centre

Gandhigram Rural Institute-Deemed University

Gandhigram-624302.Dindigul District

TamilNadu,India

[email protected] [email protected] [email protected]

Abstract

Disposal of wastes is one of the issues

confronting the world today. Scientists all

over the world are making efforts to minimize

the production and to effectively recycle the

waste. Reducing the green house gas emission

and recycling of industrial wastes are the key

areas of concern. Production of wealth will be

a boon to the industries as the benefits are

twofold: the pollution problem is addressed

and the raw material shortage problem is also

effectively tackled. Against this back-drop, in

the present work, copper slag (CS) and Rice

Husk Ash (RHA) are utilized as viable

substitutes in concrete. M20 grade concrete

with different mix proportion of sand replaced

with copper slag from 0 to 70% and 0 to 25%

cement replaced with Rice Husk Ash (RHA)

and a combination of both (30% CS +10%

RHA) is prepared. Tests for strength

(compression and split tensile strength) and

durability (acid resistance and SEM analysis)

are carried out. The results of this work

undertaken have revealed that maximum

strength is obtained on 30% replacement of

sand with copper slag (45.3 Mpa) and 10% of

cement with RHA (38.8Mpa).

Key words- Copper slag, Rice Husk Ash,

Compression test, waste disposal

1. Introduction

Concrete is one of the prime materials for

structures and it is widely used for various

applications all over the world. Aggregates

and cement play a major role in concrete. In

India there is a great shortage of natural

aggregates Recently Tamil Nadu government

(in India) has imposed restrictions on removal

of sand from the riverbeds due to unsafe

impacts threatening many parts of the state

[1].Production of cement librates similar

amount of carbon dioxide which is the great

cause of ozone depletion. In order to

overcome these drawbacks and to make

concrete sustainable copper slag and Rice

husk Ash are used as suitable substitutes for

sand and cement respectively.

Copper slag is an industrial by-product

obtained during the matte smelting and

refining of copper. Large quantities of slag are

produced as a byproduct of metallurgical

operations, resulting in environmental

concerns with disposal [2]. The applications

utilize only about 15% to20% and the rest is

dumped as a waste material and this cause

environmental pollution [3] .Caijun Shi et al

[4] reported that copper slag is glassy and

granular in nature and has a similar particle

size range to sand, indicating that it could be

used as a replacement for the sand present in

the cementitious mixes. Khalifa S et al [5] has

investigated the performance of high strength

mailto:[email protected]

60

concrete made with copper slag as a fine

aggregate.

Rice husk is an agro-waste constitutes

about one fifth of 300 million tons of rice

production annually in the world. This Rice

Husk is used only as a fuel in rice boiling

process. By burning rice husk under a

controlled temperature and atmosphere, a

highly reactive RHA is obtained [6]. The most

important property of RHA that determines

pozzolanic activity is the amorphous phase

content Recently, Nair et al.[7] reported an

investigation on the pozzolanic activity of

RHA by using various techniques in order to

verify the effect of incineration temperature

and burning duration. He stated that the

samples burnt at 500 or 700 °C and burned for

more than 12 hours produced ashes with high

reactivity with no significant amount of

crystalline material.

Although there are many studies has been

carried out on CS and RHA not much

researches has been investigated the combined

effect of both and their durability. This paper

evaluates not only the strength but also the

durability of blended concrete.

II.MATERIALS AND METHODS

2.1. Cement

Ordinary Portland cement from

Ultratech Cement Company of grade

53 was used for this study. This

cement is the most widely used one in

the construction industry in India. The

specific gravity and fineness modulus

is 3.15 and 1.3 respectively

2.2 Fine aggregate

Fine aggregate of zone II is used with

specific gravity 2.66.

2.3. Coarse Aggregate

Coarse aggregates of maximum size

20mm ,specific gravity 2.815,finess modulus

4.9 is used.

2.4. Copper Slag

Copper Slag used in this work has been

brought from Sterlite Industries Ltd (SIL),

Tuticorin, Tamil Nadu, India Its Specific

gravity, water absorption and fineness are

2.66,0.7% and 4.8 respectively .copper slag

used has high iron oxide followed by silica.

2.5. Rice husk Ash

Rice Husk Ash is obtained by burning rice

husk at 700oC to 800

oC under uncontrolled

combustion. The specific gravity and fineness

of RHA used is 1.72 and 1.98 respectively. Its

chemical properties isgiven in table II

TABLE 1: Chemical composition of RHA

Sl.No Chemical composition Content

in %

1 Calcium oxide (CaO) 1.05

2 Silicon Oxide (SiO2) 77.4

3 Aluminium Trioxide

(Al2O3) 0.28

4 Iron (Fe2O3) 0.66

5 Magnesium (MgO) 1.96

6 Loss of Ignition 7.98

2.6. Water

Casting and curing of specimens were done

with the potable water that is available in the

university premises

61

MIX DESIGN

The mix design chosen for grade M20, (i.e., 1:

1.48: 3.30 with water cement ratio as 0.5.)

Concrete mixes with different proportions of

copper slag and RHA are used. 0 to 70% sand

replacement with copper slag and 0 to 25%

RHA replacement for ement. 140 cubes, 45

cylinders were prepared for these tests. The

slump tests were done on fresh concrete to

determine its workability. Compression test,

split tensile test, acid resistance test,corrosion

test and SEM analysis were done on the

specimens as per IS specifications.

TABLE 2: Concrete Mixtures With Different

Mix Proportions

MIX ID CEMEN

T

Kg/m3

F.A

Kg/m3

C.A

Kg/m3

C.S

Kg/m3

RHA

Kg/m3

CC 383.2 570 1267 0 0

CS10 383.2 513 1267 77.45 0

CS20 383.2 456 1267 154.9 0

CS30 383.2 399 1267 232.3 0

CS40 383.2 342 1267 309.8 0

CS50 383.2 285 1267 387.2 0

CS60 383.2 228 1267 464.7 0

CS70 383.2 171 1267 542.1 0

RHA 5 364 570 1267 0 19.16

RHA

10

344.88 570 1267 0 38.32

RHA

15

325.72 570 1267 0 57.5

RHA

20

306.56 570 1267 0 76.64

RHA

25

287.4 570 1267 0 95.8

CMB 344.8 399 1267 232.3 38.32

F.A-Fine Aggregate; C.A-Coarse Aggregate

CS 10-10% sand is replaced with copper slag.

RHA 5-5% of cement is replaced with RHA ,

CMB- 30%sand is replaced with copper slag

and 10% of cement is replaced with RHA.

III.TEST RESULTS AND DISCUSSIONS

3.1. Slump test

Slump test is conducted on fresh concrete of

different mix proportion. The slump value of

all mix proportion shows good workability of

concrete. The value ranges between 40 and

100.This implies that all concrete mixes shows

good workability.

3.2. Compressive Strength

Concrete cubes of size 150 mm X 150 mm X

150 mm were prepared as per IS 10086-

1982.Once the specimen is cured, it is tested

for compressive strength. The maximum load

at failure reading was taken and their average

compressive strength are given in figure1.

Figure 1 Compressive strength of various

mixes

The compressive strength results reveals that

maximum strength is obtained on 30%

replacement of sand with CS and 10% cement

with RHA. The obtained results of RHA

mixes are almost nearer to the values of

Maurice E. Ephraim et al [9] and CS mixes

are similar to Brindha.D et al [8]. The

0

50

CC

CS1

0

CS2

0

CS3

0

CS4

0

CS5

0

CS6

0

CS7

0

RH

A 5

RH

A 1

0

RH

A 1

5

RH

A 2

0

RH

A 2

5

CM

B

Compressive Strength

(KN/m3 )

28th Day

62

combined mix gives % higher strength than

control concrete.

3.3. Split Tensile Strength

Concrete cylinders of diameter 150 mm and

height 300mm were casted as per IS 10086-

1982.Once the specimen is cured, it is tested

for split tensile on 28th

day. The maximum

load at failure reading was taken and their

average compressive strength are given in

figure

Figure 2 Split tensile strength of various mix

3.4. Acid resistance test

The acid resistance tests is conducted for

selected concrete mixes. In the present

investigation immersion techniques was

adopted. After 28 days 150mm cube

specimens were immersed in 5% H2SO4

solution. The solution was kept at room

temperature and the solution was stirred

regularly, at least twice a day to maintain

uniformity. The evaluations is conducted

after14 days from the immersion.

Figure 3 Results of acid resistance test

The results shows that the concrete with

higher percentage of copper slag posses less

resistance to acid attack,whereas RHA posses

good resistance

3.5 SEM analysis:

SEM (Scanning electron microscopy) is an

important technique in the study of cement

and concrete. From the analysis it is found that

control concrete contain more oxygen content

followed by carbon .whereas the mix contain

30% of copper slag contain carbon 3.7% less

than control concrete. calcium content is

1.65% more in CS30 mix compared to control

concrete..Al content is found to be very less in

RHA 10.

012345

CC

CS1

0

CS2

0

CS3

0

CS4

0

CS5

0

CS6

0

CS7

0

RH

A 5

RH

A 1

0

RH

A 1

5

RH

A 2

0

RH

A 2

5

CM

BSplit Tensile Strength

0

10

2030

40

50

% Loss ofWeight

% Loss ofStrength

63

Figure 4.SEM analysis of Control concrete

Figure 5.SEM analysis of Coppe r slag 30%

Figure 6.SEM analysis of Rice Husk Ash 10

Conclusion

From the above study the following

conclusion is made.

The physical and chemical properties

of waste materials i.e. copper slag and

RHA is studied.

The performance of this blended

concrete is found to be good.

This alternate technology assures high

strength and high workability concrete.

it is found that water absorption of

blended concrete is found to be less

compared to control concrete

This experimental study reveals that

replacement of cement up to 10% and

sand upto 30% gives optimum

compressive and tensile strength.

1 2 3 4 5 6 7 8keV

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5 cps/eV

C O Al Si S S

K

K

Ca

Ca

Fe Fe

1 2 3 4 5 6 7 8keV

0

1

2

3

4

5

6

7

8

9 cps/eV

C O Al Si Ca Ca Fe Fe

Au Au Au

Au

1 2 3 4 5 6 7 8keV

0

2

4

6

8

10

12

14

16

cps/eV

C O Al Si K K

Ca

Ca

Sc

Sc

Fe Fe

Au Au Au

Au

64

From acid resistance test, it was

observed that the concrete containing

copper slag was found to be low

resistant to the H2So4 solution than the

control concrete.

The cost of concrete reduces due to the

partial replacement of wastes

The partial replacement of fine

aggregate with copper slag and cement

with RHA provides additional

environmental and technical benefits

for all related industries

REFRENCE

[1] C. Kanmalai Williams, P. Partheeban and

T.Felix Kala, “Mechanical Properties of High

Performance Concrete Incorporating Granite

Powder as Fine Aggregate”, International

Journal on Design and Manufacturing

Technologies, vol.2, no.1. 2008.

[2]ACI Committee233, “Ground Granulated

Blast-Furnace Slag as a Cementitious

Constituent in Concrete” ACI Materials

Journal., vol.84, no.4, pp.330, July-Aug.1987.

[3] S.Meenakshi Sudarvizhi and

R.Ilangovan,”Performance of Copper slag and

Ferrous slag as partial replacement of sand in

Concrete”,International Journal of Civil and

Structural Engineering., vol.1. no. 4,2011.

[4] Caijun Shi, Christian Meyer , Ali

Behnood, “ Utilization of copper slag in

cement

and concrete” Resources, Conservation and

Recycling 52 pp 1115–1120.2008.

[5] Khalifa S. AlJabri , Makoto Hisada,et al.

“Copper slag as sand replacement for

high performance concrete” Cement &

Concrete Composites 31 pp 483–488. 2009

[6]. Zhang, M.H and Malhotra, V.M “High

performance concrete Incorporating Rice

Husk Ash as a Supplementry Cementiting

Material” ACI Materials Journal, Nov/Dec pp

629-636.1996

[7] Nair D, Fraaij A, Klaassen A and

Kentgens A. A structural investigation relating

to the pozzolanic activity of rice husk ashes.

Cement and Concrete Research (Elmsford),

38(6): pp 861-869.2008.

[8] D.Brindha, T.Baskaran and

S.Nagan“Assessment of Corrosion and

Durability Characteristics of Copper Slag

Admixed Concrete” International Journal of

Civil and Structural Engineering., vol.1. no. 2,

2010

[9] Maurice E. Ephraim, Godwin A. Akeke

and Joseph O. Ukpata “Compressive strength

of concrete with rice husk ash as partial

replacement of ordinary Portland cement”

Scholarly Journal of Engineering Research.,

Vol. 1(2), pp. 32-36, May 2012

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