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A STUDY ON GLASS FIBRE REINFORCED SELF-COMPACTING CONCRETE FOR

THE REPLACEMENT OF NATURAL SAND WITH QUARRY ROCK DUST

Thesis · March 2014

DOI: 10.13140/RG.2.2.11534.87368

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 A STUDY ON GLASS FIBRE REINFORCED
SELF-COMPACTING CONCRETE FOR THE REPLACEMENT
OF NATURAL SAND WITH QUARRY ROCK DUST

A Project report

Submitted
in the partial fulfillment of the requirement for
the award of the degree of

Bachelor of Technology
in
Civil Engineering
By

B.T. PURANDHAR REDDY 102N1A0104

Under the guidance of

S. Ramesh Reddy garu
Assistant Professor,
BITS, Kurnool

Department of Civil Engineering

BRINDAVAN INSTITUTE OF TECHNOLOGY & SCIENCE
NH-7, KURNOOL.
March-2014
 CERTIFICATE

This is to certify that the project report entitled “A STUDY ON GLASS

FIBRE REINFORCED SELF COMPACTING CONCRETE FOR THE
REPLACMENT OF NATURAL SAND WITH QUARRY ROCK
DUST” is the bonafide record of the Project Work carried out under my
guidance and Supervision by

B.T. PURANDHAR REDDY 102N1A0104

K. SAI KUMAR 102N1A0125
S. KRANTI KUMAR 102N1A0145
B. VENKATESHWAR REDDY 112N5A0104
N. Md. IRFAN 102N1A0121
S. ALTHAF BASHA 102N1A0146

in partial fulfillment of the requirements for the award of Bachelor of

Technology in Civil Engineering and, is submitted in the Department of
Civil Engineering, Brindavan Institute of Technology & Science, NH-7,
Kurnool.

Head of the Dept Guide

(Prof. L. Ram Prasad Reddy) (S. Ramesh Reddy)
Department of CIVIL Engineering Professor, Dept of CE.
Brindavan Institute of Technology & Brindavan Institute of Technology &
Science, Kurnool. Science, Kurnool.
 ACKNOWLEDGEMENT

We express our indebtedness and deep sense of gratitude to

Prof. N. Siva Prasad Reddy, Director (Academics), for his valuable guidance,
encouragement and scholarly advice during our course of study.

We are glad to express our sincere thanks to Esteemed Principal

Dr.T.S.S.Balaji, Principal, Brindavan Institute of Technology and Science for his
mastery supervision through all the phases of our project work.

We extend our heartful thanks to our Honorable Vice Principal, P. Girish Reddy,
for providing the opportunity to carry out this work.

We are very much thankful to our beloved Professor and Head, Department of
Civil Engineering L. Ram Prasad Reddy, for granting permission for us to work on this
topic, We are very grateful to him for his encouragement and his kind advice.

We whole-heartedly thank our project guide Sri. S. Ramesh Reddy, Assistant

Professor, for his valuable guidance and needy help through out the project.

We whole-heartedly thank our project co-guide Sri. Dr.M.L.V. Prasad Raju,

(Irrigation Department) for his valuable guidance and needy help throughout the project.

We would like to extend our special thanks to all the Staff Members and
Technicians who are always here when we need technical assistance.

At the very outset, we take great pleasure in thanking Our Parents for their
assistance all along the course both financially and academically.
 ABSTRACT

Self Compacting concrete (SCC) is a high – performance concrete that can flow
under its own weight to completely fill the form work and self consolidates without any
mechanical vibration. Such concrete can accelerate the placement, reduce the labor
requirements needed for consolidation & finishing.

Concrete plays a vital role in the construction industry and on the other hand
River sand, one of the essential material used in the concrete, has become expensive and
also a scarce material. Due to increase in its usage depletion of sand deposits is
occurring. Quarry Rock Dust (QRD), a by-product from crushing process during
quarrying activities is one of the substitute materials for the natural river sand.

In general, concrete is strong in compression & weak in tensional property. In

this research, to increase the tensile property of Concrete, Glass Fibers are added with
dosage of 1kg per m3 of concrete. In this investigation, an attempt is made to introduce
the QRD in a percentage variation and to quantify the optimum usage of QRD in
replacement to Natural Sand for Fiber Reinforced Self Compacting Concrete (FRSCC).
Compressive Strength & Split Tensile Strength Tests were conducted to study the
Mechanical Properties of FRSCC for the replacement of Natural Sand with QRD. It is
observed that; at 40% replacement of Natural Sand with QRD, Target Strength is
achieved.
 CONTENTS

ABSTRACT
NOMENCLATURE

CONTENTS PAGE NO

1. INRODUCTION 1

1.1. General 1
1.2. Self Compacting Concrete 2
1.3. Quarry Rock Dust as F.A. in SCC 13
1.4. Glass Fiber Reinforcement in SCC 15
2. LITERATURE REVIEW 19

3. OBJECT AND SCOPE OF PRESENT INVESTIGATION 25

4. EXPERIMENTAL INVESTIGATION 26

5. MATERIALS & THEIR PROPERTIES 30

5.1. Cement 30
5.2. Fine Aggregate 31
5.3.Coarse Aggregate 33
5.4. Water 34
5.5. Quarry Rock Dust 34
5.6. Super Plasticizer 37
5.7. Glass Fibers 39
6. TESTS ON CONCRETE 40

6.1.Tests on Fresh SCC 41

6.2. Tests on Hardened Concrete 52

7. DISCUSSIONS ON TEST RESULTS WITH GRAPHS 56

8. CONCLUSIONS 71

REFERENCES 72

APPENDICES 74
 NOMENCLATURE

SCC Self Compacting Concrete

QRD Quarry Rock Dust

FRSCC Fiber Reinforced Self Compacting Concrete

F.A Fine Aggregate

C.A Coarse Aggregate

GF Glass Fibers

fck Characteristic Compressive Strength at 28 days

M40 M for mix; 40 denotes as 40N/mm2 strength of concrete

C.T.M Compressive Strength Machine

BIS Bureau of Indian Standards

PPC Portland Pozzalanic Cement

σc Compressive Strength

σT Tensile Strength

IS Indian Standards

MPa Mega Pascal

kN Kilo Newton

GFRC Glass Fiber Reinforced Concrete

TABLE NO. DETAILS PAGE NO.

4.1 Experimental Details of Project 26

4.2 Quantities of Materials per m3 of concrete 27

5.1 Properties of Cement 31

5.2 Physical Properties of Fine Aggregate 31

5.3 Sieve Analysis of Fine Aggregate 32

5.4 Grading Limits of Fine Aggregate- IS:383-1970 32

5.5 Properties of Coarse Aggregate 33

5.6 Properties of Quarry Rock Dust 35

5.7 Sieve Analysis of Quarry Rock Dust 36

5.8 Properties of Glass Fibers 39

6.1 Requirements of SCC Flow 42

6.2 Acceptance Criteria of SCC Flow 51

7.1 Permissible Limits for the SCC Flow Properties 56

7.2 Test Results of Fresh SCC – without Fibers 57

7.3 Test Results of Fresh SCC – with Fibers 58

7.4 Compressive Strength of Specimens – Without Fibers 59

7.5 Compressive Strength of Specimens – With Fibers 60

7.6 Split Tensile Strength of Specimens – Without Fibers 61

7.7 Split Tensile Strength of Specimens – With Fibers 62

7.8 Compressive & Split Tensile Strength of Specimens 63

7.9 %ge Increase of strength with addition of Glass Fibers 64

7.10 28 Days Strength results of M40 SCC – Without Fibers 65

7.11 28 Days Strength results of M40 SCC – With Fibers 66

 CHAPTER I

INTRODUCTION
 CHAPTER II

LITERATURE REVIEW
 CHAPTER III

OBJECT & SCOPE OF INVESTIGATION

 CHAPTER IV

EXPERIMENTAL INVESTIGATION
 CHAPTER V

MATERIALS & THEIR PROPERTIES

 CHAPTER VI

TESTS ON CONCRETE
 CHAPTER VII

DISCUSSION ON TEST RESULTS

CHAPTER VIII

CONCLUSION
REFERENCES
APPENDICES
1.1 GENERAL

Concrete occupies unique position among the modern construction materials,

Concrete is a material used in building construction, consisting of a hard, chemically
inert particulate substance, known as a aggregate (usually made for different types of
sand and gravel), that is bond by cement and water. Materials are at the heart of the
construction industry. They determine the quality of the end product and the technology
by which it is manufactured. Performance of civil engineering structures to a great extent
depends on the characteristics of the materials used for their construction. Innovation in
construction is highly linked with development of advanced construction materials and
methods.

Concrete is the most basic element of for any kind of construction work. No
matter what type of building structure it is, the concrete used should be sturdy and well
compacted. The main reasons for compacting any type of concrete are:

 To ensure attaining maximum density by removal of any entrapped air.

 To ensure that the concrete used is in full contact with both the steel
reinforcement and the form work.

Ensuring the above points not only provide additional strength to the structure but also
good finish and appearance to the final product. The compacting of any conventional
concrete is done through external force using mechanical devices.

In order to reduce or nullify the external force for compacting the concrete, Self
Compacting Concrete (SCC) is developed.

1
1.1 Self Compacting Concrete (SCC)

SCC is defined as “concrete that is able to flow and consolidate under its own
weight, completely fill the formwork even in the presence of dense reinforcement, while
maintaining homogeneity without the need of additional compaction”.

Unlike the conventional concrete, self compacting concrete doesn't require

compacting using external force from mechanical equipments such as an immersion
vibrator; instead SSC is designed in such as way that it gets compacted using its own
weight and characteristics.

Once applied, the self compacting property enables the concrete to fully reinforce
around the steel structures and completely fill the space within the framework. The self
compacting of concrete is achieved without losing any kind of strength, stability, or
change in properties.

Self-compacting concrete (SCC) was first developed in Japan as a means to create

uniformity in the quality of concrete by controlling the ever present problem of
insufficient compaction by a workforce that was losing skilled labour and by the
increased complexity of designs and reinforcement details in modern structural members.
Durability was the main concern and the purpose was to develop a concrete mix that
would reduce or eliminate the need for vibration to achieve consolidation.

Self-compacting concrete achieves this by its unique fresh state properties. In the
plastic state, it flows under its own weight and maintain homogeneity while completely
filling any formwork and passing around congested reinforcement. In the hardened state,
it equals or excels standard concrete with respect to strength and durability.

The use of SCC concrete has been increasing in the United States also during the
last 5 years. Currently the technology is being primarily applied to the precast industry.
Other segments being targeted are flatwork, columns and wall construction. The
applications of SCC are many, limited only by the industry's knowledge of it, ability to
produce it and acceptance of it.

2
1.2.1 DEVELOPMENTS OF SELF – COMPACTING CONCRETE:

For several years beginning in 1983, the problem of the durability of concrete
structures was a major topic of interest in Japan. The creation of durable concrete
structures requires adequate compaction by skilled workers. The designs of modern
reinforced concrete structures become more advanced, the designed shapes of structures
are becoming increasingly complicated and heavy reinforcing is no longer unusual.
Furthermore, the gradual reduction in the number of skilled workers in Japan’s
construction industry has led to a similar reduction in the quality of construction work.
One solution for the achievement of durable concrete structure independent of the quality
of construction work is the employment of self – compacting concrete, which can be
compacted into every corner of a form work, purely by means of its own weight and
without the need for vibrating compaction. Okamura proposed the necessity of this type
of concrete in 1986. Studies to develop Self – Compacting Concrete, including a
fundamental study on the workability of concrete, have been carried out by “Ozawa and
Maekawa” at the university of Tokyo.

The prototype of SCC was first completed in 1988 using materials already on the
market. The prototype performed satisfactorily with regard to drying and hardening
shrinkage, heat of hydration, denseness after hardening, and other properties. This
concrete was named “High Performance Concrete” and was defined as follows at the
three stages of concrete:

1. Fresh : Self – Compactable.

2. Early age : Avoidance of initial defects

3. After hardening : Protection against external factors.

“High Performance Concrete” was defined as a concrete with high durability due
to a low water-cement ratio by Professor Aitcin et al (Gangneetal 1989). Since then, the
term high performance concrete has been used around world to refer to high durability
concrete. Therefore, H.Okamura and M.Ouchi, the authors, of an invited paper on SCC
for JACT 2003 have changed the term for the proposed concrete, for their work, to “Self
– compacting High performance Concrete”.

3
How is SCC made?

Self compacting concrete is a type of concrete, which is not a product of mixing

substances having different properties but a combination of several mixes having the
same flow characteristics.

Manufacturing of a Self Compacting Concrete requires three main aspects to be fulfilled.

They are as follows:

 High amount of water reducing substance or super plasticizers is added for obtaining
high flowing characteristics.
 A type of aggregate mixture is added to gain the desired compactness. Note that the
aggregate content is of round shape and proportional in size in order to increase the
locking tendency of the concrete.
 Alteration of fluid properties is done to ensure a cohesive mix which will keep the
aggregate and paste together. These fluid properties can be achieved by adding a high
quantity of fine content such as cement fly-ash or by adding viscosity modifying
admixtures (VMA).

1.2.2 Two Main Methods of Making SCC

There are two known and main methods for making SCC. They are as followed:

Powder Method:

In this method super plasticizers are mixed with cementitious materials such as fly ash,
slag, etc. to form a paste. The paste increases the flow of the concrete and holds all the
constituents together.

Admixture Method:

In this method instead of the conventional super plasticizers, a new type of super
plasticizers known as polycarboxylate super plasticizers is used. This not only increases

4
the flow capability of the concrete but also improves the viscosity and the constituent's
retention property.

Usage of Self-Compacting Cements has increased tremendously in the past few years.
SCC not only ensures a structure with robust characteristics but also helps in timely
completion of building structures.

SCC mixes contain:

 Lower coarse aggregate contents: to reduce the friction between them and
therefore enhance the overall concrete fluidity
 Higher amounts of sand & higher amounts of cementitious materials including
Portland cement: to further increase fluidity as well as enhance its cohesiveness
and resistance to segregation and viscosity.
 Lower water/cementitious material ratio,
 Higher super plasticizer doses and
 Viscosity modifying admixtures

Control of the viscosity and cohesiveness of the paste ensures the flow of the SCC
through obstacles such as steel reinforcement without any aggregate blockages.

1.2.3 Properties:-

Compressive Strength: SCC compressive strengths are comparable to those of

conventional vibrated concrete made with similar mix proportions and water/cement
ratio. There is no difficulty in producing SCC with compressive strengths up to 60MPa.

Tensile Strength: Tensile strengths are based on the indirect splitting test on cylinders.
For SCC, the tensile strengths and the ratios of tensile and compressive strengths are in
the same order of magnitude as the conventional vibrated concrete.

5
Bond Strength: Pull-out tests have been performed to determine the strength of the bond
between concrete and reinforcement of different diameters. In general, the SCC bond
strengths expressed in terms of the compressive strengths are higher than those of
conventional concrete.

Modulus of Elasticity: SCC and conventional concrete bear a similar relationship

between modulus of elasticity and compressive strength expressed in the form E/(fc)0.5,
where E = modulus of elasticity, fc = compressive strength. This is similar to the one
recommended by ACI for conventional normal weight concrete.

Hardened Properties

The main differences between conventional vibrated concrete and SCC concrete are
related to the behaviour in the fresh state.

In terms of the hardened properties, at similar water/cementitious material ratio, properly

proportioned, produced and placed SCC is generally denser and less variable than the
equivalent conventional vibrated concrete, thereby resulting in improved strength and
durability performance.

In addition, compared to conventional vibrated concrete, SCC at similar

water/cementitious material ratio is expected to have:

 The same structural performance.

 Equal or higher compressive and tensile strength
 Equal to or lower shrinkage.
 Equal to or better bond to the steel reinforcement
 Lower surface absorption and therefore better durability.

Long-term performance of SCC mixes, such as durability and creep, are unknown at
present due to the lack of long-term performance studies. The higher sand content of
some of the mixes may lead to greater shrinkage values; however, testing to date shows
that most SCC mixes exhibit similar shrinkage values to that of normal concrete.

6
 Several test methods have been developed and together with visual inspection are
often utilised to verify the performance of fresh SCC. However, none of these methods
are standardised as yet, either nationally or internationally. Some of these test methods
include the Slump-flow test, Funnel test, U Type & Box Type tests, T50 Test, J-Ring test,
the Orimet test and the GTM Screen Stability Test.

1.2.4 Benefits of SCC:

The principal benefits of SCC are advantages derived from the properties of fresh mix
itself, namely:

 Ability to completely fill complex formwork and encapsulate areas of congested steel
reinforcement without any compaction and yet with reduced risks of voids and
honeycombing.
 Ability to develop higher early and ultimate strengths and enhanced durability
properties compared with conventional vibrated concretes.
 Potential for improved surface finishes with reduced making good costs related to
poorly compacted surfaces.

SCC offers many advantages for the precast, prestressed concrete industry and for cast-
in-place construction viz.:

 Low noise-level in the plants and construction sites

 Eliminated problems associated with vibration.

 Less labor involved

 Faster construction

 Improved quality and durability

7
Cost of SCC:- Although the SCC as a material will cost slightly more than conventional
concrete, significant costs savings can be realised through the whole concreting process
including giving consideration to SCC at the detailed design stage of a project. Such
benefits can be summarised as follows:

 Reduced construction time and labour costs.

 Reduced man power for placing and compacting.
 Lower equipment costs and less noise since vibrators are not required.
 Improved Health & Safety in the workplace environment through the elimination
of vibrating equipment and associated health and safety risks. Reduced noise
levels, reduced trip and fall hazards, less manual handling.

1.2.5 Applications

The characteristics of SCC make it invaluable particularly for such applications as:

 Concreting underwater piles and columns (Many of the VMAs used by the ready-
mixed industry contain admixtures that are used to make anti-washout concretes
and grouts.);
 Piles and columns with dense rebar cages (SCC was developed to alleviate the
need to vibrate concrete in structures containing dense rebar); and
 High-strength piles and columns (The generally higher fines content of SCC
mixes lends itself to high strength concrete. Concrete strengths in excess of 8,000
psi are regularly achieved).

The use of SCC concrete has been increasing in the United States also during the last 5
years. Currently the technology is being primarily applied to the precast industry. Other
segments being targeted are flatwork, columns and wall construction.

The applications of SCC are many, limited only by the industry's knowledge of it, ability
to produce it and acceptance of it.

8
Quality Control

Due to the lower water/cementitious material ratios used in SCC mixes and higher
dosages of dispersive super plasticizers which are key to achieving the required
rheological characteristics for flow and self-compaction, the properties of fresh SCC are
more sensitive to variations in the quality and consistency of the mix constituents,
particularly variations in water contents. As the fresh properties of SCC are fundamental
to both its short and long term performance (i.e. they cannot be compensated with further
compaction) tighter controls on materials and production consistent with the stipulated
requirements are therefore required.

1.2.6 Important Considerations

SCC Production: Production of SCC requires more experience and care than the
conventional vibrated concrete. The plant personnel would need training and experience
to successfully produce and handle SCC. In the beginning, it may be necessary to carry
out more tests than usual to learn how to handle SCC and gain the experience.

Before any SCC is produced at the plant and used at the job site, the mix must be
properly designed and tested to assure compliance with the project specifications. The
ingredients and the equipment used in developing the mix and testing should be the same
ingredients and equipment to be used in the final mix for the project.

Most common concrete mixers can be used for producing SCC. However, the mixing
time may be longer than that for the conventional vibrated concrete. SCC is more
sensitive to the total water content in the mix. It is necessary to take into account the
moisture/water content in the aggregates and the admixtures before adding the remaining
water in the mix. The mixer must be clean and moist, and contains no free water.

Admixtures for the SCC may be added at the plant or at the site. There is cost benefit in
adding the admixtures at the site. Conventional ready-mix concrete can be bought at a
lower cost than the cost of SCC bought from a ready-mix supplier.

9
Transportation: The truck drivers should be given oral and written instructions for
handling SCC. The truck drivers must check the concrete drum before filling with SCC to
make sure that the drum is clean and moist, but with no free water. Extra care must be
taken for long deliveries. In addition to the usual information, the delivery note should
show the following information:

 Slump flow - target value and acceptable range.

 Production time - time when it was produced.
 Instruction for adding admixtures at the site, if allowed.
 The truck drivers should not be allowed to add water and/or admixtures
during transit.

Casting on Site: A pre-SCC placement meeting with all personnel involved in the SCC
placement would be beneficial. The SCC placement plan, including QC/QA, and the
roles and responsibilities of the field personnel should be explained and understood.

In addition to the normal testing, the slump flow, T50 and L-box tests are useful
to check SCC at the job site before placement.

SCC can flow horizontally a distance of 15 to 20m without segregation. A well-

designed SCC may have a free fall of as much as 8m without segregation. However, it is
recommended that the distance of horizontal flow be limited to 10m and the vertical free
fall distance be limited to 5m.

For deck slab of a bridge, it would be difficult for the SCC to flow too far. This
could be handled by designing an SCC with a lower slump flow. With a lower slump
flow, a bridge deck with a slope of 2% could also be accomplished.

If an SCC placement is interrupted and the concrete has started to harden, it

would be necessary to "wake up" the placed concrete by striking a stick or board into the
concrete several times before starting the placement again. SCC takes some time before
the hardening starts, especially during cold weather conditions. When it starts to harden,
the process is very rapid, which can cause problems in leveling and treating large surface
areas.

10
Surface Finishing and Curing

Finishing and curing of SCC can follow the good practices of super plasticized
high performance concrete. Surface of SCC should be roughly leveled to the specified
dimensions, and the final finishing applied as necessary before the concrete hardens.

SCC tends to dry faster than conventional vibrated concrete, because there is little
or no bleeding water at the surface. SCC should be cured as soon as practicable after
placement to prevent surface shrinkage cracking.

Cold Joint: When placing a new layer of SCC on old SCC, the bond between the old and
new SCC is equal to or better than in the case of conventional vibrated concrete. Normal
vibration will not destroy the concrete, such as in the case of placing conventional
vibrated concrete on fresh SCC. This may be necessary when the surface slope is greater
than practicable for SCC.

Precautionary measures

The following practical considerations should be taken into account when working with
SCC:

 Due to the high fines content and viscosity, SCC concrete tends to dry faster than
conventional concrete and therefore there is a potential of increased plastic shrinkage
cracking, as there is little or no bleed water at the surface. As such it is important
that evaporative retarders are used between initial screening and finishing and curing
is implemented in a timely manner as per specification requirements. On the other
hand the reduced bleeding reduces the risk of plastic settlement
 SCC must be supplied on a continuous basis and sufficient manpower and equipment
must be on site to avoid any delays which may result in the concrete being left too
long without fresh concrete being applied thus creating the potential for a cold joint
to be formed. Where concrete has been untouched for long periods it may be
necessary to vibrate the new concrete into the old to prevent a cold joint from
occurring.
11
 In order to minimize the risk of segregation of SCC the vertical free-fall should be
limited to 3 m and the horizontal flow from point of discharge to 6 m.
 As SCC concretes are more susceptible to quality and material fluctuations than
conventional vibrated concrete, a stricter quality control regime, production control,
construction control and training regime must be put in place.
 In concreting applications other than under water and dry bores, consideration
should be given to undertaking controlled field trials where all of the critical plastic
and then hardened properties can be assessed.
 Ensure adequate and ongoing communication between the mix designer, the
contractor, supervising personnel and the personnel responsible for placing SCC
concrete.

Feasible performance specifications

Based on the current state-of-the-knowledge, the following performance

specifications for SCC are achievable through proper mix design and testing:

Workability:

Slump flow > 600 mm

Remain flowable ≥ 90 minutes

Withstand a slope of 3%

Pumpable ≥ 90 minutes through pipes ≥ 100 m long

Mechanical Properties:

28-day compressive strength = Similar to HPC (High Performance Concrete)

Creep and Shrinkage = Similar to HPC

Durability Parameter: Freeze-thaw resistance ≥ HPC

12
1.2 Quarry Rock Dust - QRD as a Natural Sand in the Production of

Self Compacting Concrete (SCC)

The global consumption of natural sand is very high, due to the extensive use of
concrete. In general, the demand of natural sand is quite high in developing countries to
satisfy the rapid infrastructural growth, in this situation developing country like India
facing shortage in good quality natural sand.

Particularly in India, natural sand deposits are being depleted and causing serious
threat to environment as well as the society. Increasing extraction of natural sand from
river beds causing many problems, loosing water retaining sand strata, deepening of the
river courses and causing bank slides, loss of vegetation on the bank of rivers, exposing
the intake well of water supply schemes, disturbs the aquatic life as well as affecting
agriculture due to lowering the underground water table etc are few examples. So, there is
need for an alternative material in place of Sand. Quarry Rock Dust can be one of the best
alternative for sand.

In SCC, the influence of fine aggregates on the fresh properties is significantly

greater than that of coarse aggregate. Particles size fractions of less than 0.125 mm
should be include the fines content of the paste and should also be taken into account in
calculating the water powder ratio. The high volume of paste in SCC mixes helps to
reduce the internal friction between the sand particles but a good grain size distribution is
still very important

Partial and total replacement of fine aggregate in Self Compacting concrete with
quarry dust has been empirically conducted with the view to examining primarily the
compressive strength of the resulting composite and possible utilization of quarry sand as
fine aggregate in the production of self compacting concrete. The results of the study
revealed that its specific gravity, bulk density, porosity, water absorption, silt content, the
impact value and the aggregate crushing value showed satisfactory performance. The
percentage replacement of natural river sand with quarry sand for a designed strength of

13
40N/mm2 varied at intervals of 20% up to a maximum value of 100%. A total of 72
specimens of 36 cubes and 36 cylinders were cast and tested after 28 days of curing.

The idea of using quarry dust as an alternative aggregate was developed because
granite which is the parent material is hard and dense and therefore can serve as an
excellent aggregate material. Its use as a fine aggregate in concrete is expected to
improve certain properties, such as the compressive strength, durability, strength
development, workability and economy. With the recent trend towards utilization of
locally sourced building material so as to reduce construction cost and the availability of
quarry dust from quarry sites across the globe has brought about the research.

1.3.1 SWOT Analysis of Quarry Dust:

 Strength: The Physical and chemical properties of quarry rock dust have satisfied
the requirements of a code provision in properties studies.

 Weakness: Workability of concrete decrease made up of QRD. The presence of

flaky, badly graded and rough textured particles result in harsh concrete for given
design parameters.

 Opportunity: Quarry dust can be used as partial replacement of fine aggregate.

Past studies have shown that QD can be replaced up to 100 % as Fine Aggregate
in conventional concrete.

 Threat: Compressive & Split Tensile Strength of concrete containing Quarry dust
needs to be assessed after 28 days.

14
1.4 Glass Fiber Reinforcement in SCCV- (FRSCC):

Fiber Reinforced Concrete can be defined as composite material consisting of

mixtures of cement, mortar or concrete and discontinuous, discrete, uniformly dispersed
suitable fibers. Continuous meshes, woven fabrics and long wires or reds are not
considered to be discrete fibers. Fibers include steel fibers, glass fibers, synthetic fibers
and natural fibers.

Concrete made with cement has certain characteristics: it is relatively strong in

compression but weak in tension and tends to be brittle. The weakness in tension can be
overcome by the use of conventional rod reinforcement and to some extent by the
inclusion of a sufficient volume of certain fibers. The use of fibers also alters the
behavior of the fiber-matrix composite after it has cracked, thereby improving its
toughness. Fiber Reinforced Concrete (FRC) was invented by French gardener Joseph
Monier in 1849 and patented in 1867.

Types of different Fibers

i. Natural fibers
(a) Vegetable fibers
(b) Wood fiber
(c) Animal fibers
(d) Mineral fibers
ii. Synthetic fibers
iii. Metallic fibers
iv. Carbon fibers
v. Silicon carbide fibers
vi. Glass fibers
vii. Mineral fibers
viii. Cellulose fibers
ix. Polymer fibers
x. Acrylic polyesters
xi. Aromatic polyamids

15
 xii. Polyethylene
xiii. Coextruded fibers
xiv. Micro fibers

Factors Affecting the Properties of Fiber Reinforced Concrete

i. Relative fiber matrix stiffness

ii. Volume of Fibers
iii. Aspect ratio of the fiber
iv. Workability and compaction of concrete
v. Mixing

SELECTED FIBER – “GLASS FIBER”

Glass fiber reinforced concrete (GFRC) was first introduced to the building
industry in the early 1970’s in the United Kingdom. Today, it is one of the most popular
and innovative building materials used throughout the United States, Europe, Middle East
and Asia. In our work, Cem-FIL anti-crack high dispersion Glass Fibres(GF) were used.

Figure1.1:GLASS FIBERS

16
1.4.1 Properties of GFRC:

 GFRC does not fail immediately under load but yields gradually nevertheless in
cement and concrete tensile failure begins with micro cracks and they propagate
quickly and cause destruction. The key of this accepted behavior of GFRC is due
to randomly distribution of tiny glass fibers in it. Uniformed distributed fibers
expand the loads in a wide range and let the matrix to behave cohesive.

 The existence of glass fibers provides crack arresting system for example we can
imagine a concrete beam with numerous ties or reinforcement in different
directions. It is clear when the first crack occurs in the beam the strong fibers pick
the loads so that this characteristic allows the beam to withstand more loads. More
loading impose, only new cracks appear rather than causing first cracks to develop
which occurs in steel reinforced concrete especially in the tension area. Therefore,
failure in GFRC develops as a gradual plastic-like yielding and in the end, fracture
happens when fibers are broken.

 GFRC has a higher tensile strength than steel. [Generally, the higher the fiber
content, the higher the strength. A typical mix with 5% glass fiber has a
compressive strength of 6000 to 8000 [psi] or 4.21 to 5.62 [Kg/mm2].

 In many environments, when they exposed to salt or high moisture (marine

environment), the GFRC can be expected to perform better, as there is no steel
reinforcement to corrode. The use of glass fibers for reinforcement rather than steel
means it would not rust and can even be used under salt water and marine
environments.]. Other important characteristics of glass fiber reinforced
composites are their high damping capacity and low coefficient of thermal
expansion.

17
Advantages of Glass Fiber(GF):

 Fibers are lightweight that minimizes the load added to existing structures.

 Higher flexural strength, tensile strength and impact strength than plain concrete due
to the presence of the glass fiber.

 It does not rust or corrode.

 The materials have a good resistance for tension. This is the reason why glass fiber
is chosen as reinforcement for concrete. Right now, glass fiber is used mostly for
cladding buildings, lining, sewer pipe, shoulder of roads and etc.

 Glass fiber can control shrinkage cracks easily; shows this property particularly in
cladding purpose or rendering.

 Changing GFRC panel is very easy as compared to other cladding because of

making GFRC by panel and just installing on the site. Also if broken one panel can
be repaired or removed and a new one can be put, but if stone or tile is broken, it is
not easy to change.

18
2. LITERATURE REVIEW:

SCC is developed at Japan. Research is still going on this usage. Many researches
gave their explanations on development of SCC with suitable materials, admixtures etc.
Some of the detailed views of the Research papers are produced below:

2.1 The Future Concrete: Self-Compacting Concrete

Authors: LIANA IURE Ş and CORNELIU BOB.
Discussion:
 Fly ash can replace a significant part of the necessary filler when used into a
self compacting concrete composition.
 The elimination of vibrating equipment improves the environment protection
near construction and precast sites where concrete is being placed, reducing
the exposure of workers to noise and vibration.
 SCC is favorably suitable especially in highly reinforced concrete members
like bridge decks or abutments, tunnel linings or tubing segments, where it is
difficult to vibrate the concrete, or even for normal engineering structures.

2.2 Development of Self Compacting Concrete by use of Portland Pozzolana

Cement, Hydrated Lime and Silica Fume
Authors: Dubey Sanjay Kumar and Chandak Rajeev
Discussion: The slump flow characteristics of mix are between 600 to740 mm.
The flow improves due to addition silica fume and lime content. As far as filling
ability of mixes is concern, the results of V funnel satisfied the standard
requirement. The blocking ratio in the L box was as per the requirement of SCC
mixes as laid by EFNARC guidelines.
Self compacting concrete could be prepared without using viscosity
modifying agent as was done in the study. Portland Pozzolana cement can be used
for development of Self compacting concrete. Different types of SCC having
different compressive strength can be prepared by different combination of
cement, lime and silica fume.

19
2.3 Comparative Study of Glass & Propylene Fiber Reinforced SCC (M20):
Authors: Dr. M.L.V. Prasad & P. Rathish Kumar.
Discussion: Based on the experimental Study on FRSCC, it is studied that; SCC
could be developed for non fibrous & fibrous concretes and were satisfying the
specifications laid by EFNARC. There observed a marginal increase in
compressive strength, very good increase in the Slit Tensile Strength and good
increase in Flexural Strength of SCC with Fiber additions. The increase is slightly
on the higher side in Glass Fibers. To suit the Indian Conditions, the Nan-su’s
method of Mix proportion was slightly modified.

2.4 Study on Durability Characteristics of SCC with Fly Ash

Authors: Dhiyaneshwaran S., Ramanathan P., Baskar, I. & Venkatasubramani R.
Discussion:
 The optimum % replacement of cement with Fly Ash is 30%
 The Acid resistance of SCC with Fly Ash was higher when compared with
concrete mixes without Fly Ash at the age of 28, 56 & 90 days.
 Compressive strength loss decreases with the increase of Fly Ash.
 When the specimen is satured, is immersed in Sodium Sulphate Solution for
28, 56 & 90 days respectively, the average reduction in weight increases and
weight is decreased when flyash is increased in the concrete.

2.5 Evaluation Of Using Glass Fiber On Properties Of SCC

Authors: Mohammed Karem Abd
Discussion:The result of concrete workability test, showed that the adding of
glass fiber would reduce the value of slumpflow, T50cm, blocking ratio of L-Box
test and time flow of V-funnel test, but these results would remain within the
standards. Hardened concrete inspection results show the increasing of
compressive and splitting strength when using of glassy fibers and this increment
is proportionate directly with volume of fibers which are recommended in SCC.

20
2.6 Relation between the Workability and Strength of Self-Compacting Concrete
Authors: M Mazloom & A Ranjbar
Discussion: From the results presented in this paper, using concrete containing
different dosages of a kind of superplasticizer based on carboxylic, the main
conclusions are:
 In standard concrete mixes with constant ingredients and different dosages
of the superplasticizer, the ones incorporating silica fume, tended to have
lower workability. This finding was obvious in the self-compacting mixes.
 The relation between the compressive strength and workability of concrete
mixes was linear when the w/c ratio and other mix proportions were
constant. In other words, in this context, the compressive strength of a
concrete mixture containing a new dosage of superplasticizer could be
estimated from its workability tests.

2.7 Experimental Methods on Glass Fiber Reinforced Self Compaction Concrete

Authors: A. Deepak Raj, M. Mergin Benize, J. Esther Daisy, M. Sri Nikhil
Discussion: The addition of S-glass fibers does not affect the filling ability,
passing ability and segregation resistance of the SCC. The workability test is
conducted on 12 trial mixes of GFRSCC by varying the length of the glass and
the amount of glass fibers added to the mix. Observed from the result that the
flowability of GFRSCC is directly proportional to its length and quantity added
(i.e.) the result comes under the range of recommended values when the quantity
and length of the glass fiber added is maximum. 1% of S-glass fiber in all sizes is
more flowable than 0.25% of S-glass fiber in all sizes. We can notice that the 1%
of 2.4 mm size glass fibered SCC results are well within the ranges of the
recommended values by EFNARC.

21
2.8 Study of Properties of SCC using ‘Quarry Dust’ and ‘Fly Ash’
Authors: M.V.Rama Raju, K.V.Vivek, Dr. T. Siva Shankar Reddy & P.Srinivas
Reddy
Discussion: The results show that River sand can be completely replaced by
Quarry Dust by 100%. Though there was a decrease in compressive strength
initially the strength gained when Quarry dust was increased to 100% replacing
river sand fully. Even the strength was higher compared to the SCC with river and
the maximum compressive strength observed was 60 MPa at 28 days. This makes
the SCC more economical by utilizing the waste by product of stone crushers and
making it a green concrete. The optimum usage of Fly Ash content in place of
cement can be 30%. The increase of Fly Ash content up to 30% showed an
increase in compressive strength up to 54.81 MPa at 56 days in SCC containing
100% Quarry Dust and there was a decrease in compressive strength beyond the
usage of 30%. It may also be presumed that the strength may increase further
beyond 56 days.

2.9 Experimental Investigation on Self Compacting Concrete Using Quarry Dust

Authors: K.S. Johnsirani, Dr. A. Jagannathan, R. Dinesh Kumar
Discussion:
 At the water/cement ratio of 0.4, slump flow test, V-funnel test and L-box
test results were found to be satisfactory, i.e. passing ability, filling ability
and segregation resistance are well within the limits only for mixes SCC_0%,
SCC_25% & SCC50% for other SCC mixes it doesn’t satisfied because
quarry dust has high fineness, its usage in the concrete is limited due to
increasing water demand.
 While fine aggregate replacement of quarry dust increases with the gradual
decreases in the strength values after replacement of 25% of quarry dust. In
the case of 100% replacement of quarry dust there will be highly decrease in
the compressive strength of cube and split tensile strength of cylinder.
 Optimum W/C ratio was chosen as 0.40 by weight, the ratio greatly beyond
or less than this may cause segregation and blocking tendency in SCC mix.

22
2.10 Advantages of using PPC or site mixing of OPC with fly ash at site.
Authors: Anil Banchhor, S. Krishnan.
Discussion: It has been found that addition of flyash to OPC in concrete improves
the properties of fresh concrete and enhance parameters of which indicate
durability. The inter-grinding of flyash with clinker and gypsum maximize the
Pozzolanic potential of the fly ash with more consistent product with good control
on variability, which results in to better performance of concrete. The site mix
flyash concrete do not have adequate gypsum, as compared to inter-ground PCC
in which gypsum is added based on the overall quantity of clinker and flyash
while grinding. The flyash should be mixed at site in the batching plant only since
mixing efficiency of the ordinary drum mixers is poor at low water content.

2.11 Comparative study on Propylene & Glass Fiber Reinforced SCC (M20):
Authors: P. Ratish Kumar & Dr. M.L.V. Prasad
Discussion: From the Experimental study on FRSCC for M20 Concrete, it is
observed that; SCC could be developed with use of Fibers within the Standards
specified by EFNARC. Glass Fibered specimens possess slightly higher strength
properties compared to Propylene Fiber. To suit the Indian Conditions, the Nan-
su’s method of Mix proportion was slightly modified.

2.12 Self Compacting Concrete Using Fly Ash and Glass Fibre
Author: Shahana Sheril P.T.
Discussion:
 The specimen with 0.05%, 0.1%, 0.15% and 0.2% of glass fibre shows an
increase of compressive strength by 8.2%, 9.2%, 7.02% and 3.5% respectively
than the SCC without fibre for the M20 grade mixes.
 The specimen with 0.05%, 0.1%, 0.15% and 0.2% of glass fibre has in
increase compressive strength of 5.1%, 7.1%, 5% and 2.3% respectively than
the SCC without fibre for M30 grade mixes.
 GFRSCC with 0.1% glass fibre showed substantial increase in the flexural
strength than the other specimens.

23
2.13 A simple mix design method for self-compacting concrete
Authors: Nan Su , Kung-Chung Hsu, His-Wen Chai
Discussion:
 The aggregate PF deter mines the aggregate content and influences the
strength, flowability and self –compacting ability.
 SCC designed and produced with the proposed mix design method contains
more sand but less coarse aggregates, thus the passing ability through gaps
of reinforcement can be enhanced.
 The amount of binders used in the proposed method can be less than that
required by other mix design methods due to the increased sand content.
 This novel mix design method is simpler, requires a smaller amount of
binders, and saves cost.
 The PF value is the control factor for filling height of U-box test. The fresh
proper ties of concrete with PF = 1.12 –1.16 can meet the requirements
specified by the Japanese mix-design method.

2.14 Quarry Rock Dust as a replacement of Fine Aggregate – State-of-Art Report

Authors: K. Sai Kumar, V. Sameer Kumar, Dr. M.L.V. Prasad.

Discussion: According to the report, Quarry Rock Dust is one of the best
alternative materials for the replacement of Sand to produce Environmental
friendly Green Concrete. In case of some quarry rock dust replacements some
workability problems were arrived but that can be overcome by using the washed
quarry dust or by using 50% marble sludge powder in addition to mineral
admixtures. The Physical and chemical properties of quarry rock dust have
satisfied the requirements of the codal provisions. Hence, Natural river sand, if
replaced by hundred percent QRD from quarries, may sometimes give equal or
better than the reference concrete made with Natural Sand, in terms of
Compressive, Split and flexural strength studies. Utilization of QRD will reduce
the use of river sand & can conserve natural resources.

24
3. OBJECT & SCOPE OF INVESTIGATION:
The reduction in the sources of natural sand and the requirement for reduction in
the cost of concrete production has resulted in the increased need to identify
substitute material to sand as fine aggregates in the production of concretes
especially in Self Compacting Concrete. Quarry dust, a by-product from the crushing
process during quarrying activities is one of such materials. Granite fines or rock dust is a
by-product obtained during crushing of granite rocks and is also called quarry dust.

SCC or Self Compacting Concrete that is not only workable at lesser water to
binder ratio but also cohesively flowable like a viscous fluid without yielding to
segregation, rendering compaction by self weight, ultimately resulting to superior
engineering properties. Due to these characteristics, SCC is ideally suited for concreting
structures, which have heavily congested reinforcement or difficult access condition. This
present work is an attempt to use Quarry Dust as partial replacement for Sand in SCC.

Attempts have been made to study the properties of such SCCs and to investigate
some properties of Quarry Dust and its suitability of those properties to enable them to be
used as partial replacement material for sand in concrete.

The specific objectives of the present investigations are as listed below.

 To study the Physical Properties of the materials used in our work.

 To introduce Quarry Rock Dust (QRD) in percentages and to quantify the
optimum usage of QRD in replacement to sand.
 To study the effect of using QRD and Glass Fibers in SCC.
 To study the Mechanical Properties of the obtained SCC & FRSCC.

To obtain the above objectives an experimental program was developed and

detailed scheme of program was explained in the next chapter.

25
4. EXPERIMENTAL INVESTIGATION:
The experimental program was designed to study the Mechanical Properties of
Self Compacting Concrete made with concrete of M40 with the Replacement of Fine
Aggregate (i.e., Sand) with QRD on Compressive & Split Tensile strength. The program
consisted of casting and testing a Total Specimens of 36 cubes (150*150*150mm), 36
cylinders(150mm & 300mm height) were casted in 6 batches for different QRD
dosages of 0%, 20%, 40%, 60%, 80% & 100% with respective to the Sand.

TABLE 4.1 : EXPERIMENTAL DETAILS OF PROJECT

28 DAYS SPLIT TENSILE

28 DAYS COMPRESSIVE
REPLACEM STRENGTH OF
STRENGTH OF CUBES
-ENT OF CYLINDERS
S.NO.
SAND WITH
QRD IN %ge WITHOUT WITH GLASS WITHOUT WITH GLASS
FIBER FIBER FIBER FIBER

1 0% 3 3 3 3

2 20% 3 3 3 3

3 40% 3 3 3 3

4 60% 3 3 3 3

5 80% 3 3 3 3

6 100% 3 3 3 3

TOTAL SPECIMENS 18 18 18 18

GRAND TOTAL OF SPECIMENS 72

26
Material Quantities:

M40 grade of concrete was selected for this study. NAN-SU MIX DESIGN
Method was used for our work. The mix proportions that adopted was

1 : 1.46 : 1.61 : 0.39

TABLE: 4.2 : TABLE OF QUANTITIES PER M3 OF CONCRETE MIX

Dosage Cement Fine Coarse Amount of Water SP Glass

of QRD Aggregate Aggregate QRD Fiber

% Kg Kg Kg Kg Lit Lit Kg

0 543.82 795.76 873.94 0.0 212.14 5.44 1.0

20 543.82 636.62 873.94 159.15 212.14 5.44 1.0

40 543.82 477.46 873.94 318.30 212.14 5.44 1.0

60 543.82 318.30 873.94 477.46 212.14 5.44 1.0

80 543.82 159.15 873.94 636.12 212.14 5.44 1.0

100 543.82 0.0 873.94 795.76 212.14 5.44 1.0

SPECIMENS FOR CASTING:

 CUBES: The moulds used for the concrete cubes are made up of cast iron with
dimensions of 150 mm X 150 mm X 150 mm for Compressive strength studies.
 CYLINDERS: Cast Iron moulds are used of size 150 mm diameter X 300 mm
height for Split Tensile Strength studies.

27
 Fig 5.1 : MIXING OF CONCRETE

Casting of Specimens:

The total casting was completed in 6 batches, for every batch ingredients
are taken according to their proportion by weight. The above ingredients are
transferred to the concrete mixer and mixed gently. Then the predetermined
amount of super plasticizer is added to the measured water in jar. The above
water was poured in to dry mix and mixed gently to get uniform color. Then the
mix is taken on to a flat surface. Then the fibers are sprinkled over the mix and
again mixed thoroughly till fibers distributed uniformly. The mix we get is called
as a FRESH CONCRETE.

Tests has to be conducted on the Fresh Concrete to confirm it as a Self

Compacting Concrete; i.e., PASSING ABILITY, FILLING ABILITY &
SEGREGATION RESISTACE TESTS which are prescribed by EUROPEAN
GUIDELINES FOR SELF COMPACTING CONCRETE – 2005 are to be
conducted for its acceptance. Then the concrete is ready to be placed in the
moulds. The moulds used for casting were oiled and all the edges of the mould
are tightened well. Then the fresh concrete was smoothly transferred in to the

28
moulds. After casting the top surface of the mould is leveled using trowel. The
specimens were demoulded after 24 hours of casting. The designation of the specimens
were marked with indelible waterproof ink and kept under water for curing.

Curing:
Specimens were cured for 28 days in the curing pond. After the completion
of curing period, the specimens were removed from water and are sent for
Testing purpose.

Figure 5.2 : Specimens in the Curing Pond.

29
5. MATERIALS & THEIR PROPERTIES:
The materials used in the preparation of Concrete are:

1. Cement
2. Fine aggregate i.e., Natural Sand
3. Coarse aggregate
4. Water
5. Quarry Rock Dust
6. Glass Fibers
7. Super Plasticiser.

To produce good quality of concrete we need good quality ingredients which

satisfy the Standards. Hence tests on different ingredients mentioned above are
conducted as per BIS standards which are presented below. Properties are represented in
the form of Tables for every material used in the production of Concrete.

5.1 Cement:

Portland Pozzolana Cement of 53+ grade of ZUARI brand confirming to B.I.S is

used in the present work. The cement is tested for its various properties as per IS: 4031 –
1988 and found to be confirming to the requirements as per IS: 1489-1999 Part-1.

In order to avoid the possible variation in the properties of cement from various
batches all the specimens are prepared from the same batch of cement.

The results of tests concluded on cement are as follows.

Cement - Portland Pozzolana Cement

Brand Name - ZUARI Brand

Specific Gravity - 2.9

Pozzolana - Fly Ash (25% of the Total Weight of Cement)

30
 TABLE 5.1: PROPERTIES OF CEMENT

S.NO PROPERTY VALUE REQUIREMENT AS PER IS:1489-1

1 Fineness 2% <10%

2 Soundness 1mm <10mm

3 Standard Consistency 32% Within the Codal Provisions

4 Initial Setting Time 63min >30min

5 Final Setting Time 360min <600min

5.2 Fine aggregate – Natural Sand:

The sand obtained from Hundri river near Kurnool is used as fine aggregate in
this project investigation. The sand is tested in accordance with IS:2386 and it is found to
be satisfied for its use in the concrete. Our sand is confirmed to Zone-II according to BIS.
Sand which is passed on 4.75mm sieve & retained on 150µ sieve are used.

TABLE 5.2: PHYSICAL PROPERTIES OF NATURAL SAND

S.NO PROPERTY VALUE REQUIREMENTS AS PER IS 383

1 Fine Aggregate Sand As per Indian Standards

2 Specific Gravity 2.65 2.6-2.8

3 Water Absorption 0.25% Should not be > 1% for construction

4 Density 1450 gm/cc Within the Codal Provisions

5 Fineness Modulus 2.74 2.6-2.9

31
 TABLE 5.3: SIEVE ANALYSIS OF NATURAL SAND

S.NO. I.S sieve Weight retained Cumulative Wt. Cumulative Cumulative

(grams) retained Percentage Percentage
(grams) Weight Retained Weight Passing

1. 4.75 90 90 4.5 95.5

2. 2.36 234 324 16.2 83.8

3. 1.18 639 963 48.15 51.85

4. 600 µ 448 1411 70.55 29.45

5. 300 µ 430 1841 92.05 7.95

6. 150 µ 149 1990 99.5 0.5

7. 75 µ 8 1998 99.90 0.1

TABLE 5.4 : GRADING LIMITS OF FINE AGGREGATE AS PER IS 383:1970

I.S.Sieve Percentage passing by weight

Designation Grading Zone-I Grading Zone-II Grading Zone-III Grading Zone-IV

10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 95-100

2.36 mm 60-95 75-100 85-100 95-100

1.18 mm 30-70 55-90 75-100 90-100

600 µ 15-34 35-54 60-79 80-100

300 µ 5-20 8-30 12-40 15-50

150 µ 0-10 0-10 0-10 0-15

32
5.3 Coarse aggregate:

The Coarse aggregate is free from clayey matter, silt and organic impurities etc.,
the coarse aggregate is also tested for specific gravity and it is 2.82, fineness modulus of
coarse aggregate is 4.07. Aggregate of normal size 20 mm downgraded 60% passed on
20.0 mm sieve and remaining 40% is taken from the sieve 10.0 mm (passing) and 4.75
mm (retained) is used in the experimental work, which is acceptable according to IS: 383
– 1970.

TABLE 5.5 : PROPERTIES OF COARSE AGGREGATE

S.no Property Value Requirements as Per IS 383

1. Coarse Aggregate Machine crushed Granite Within the Codal Provisions

2. Specific Gravity 2.75 2.6 to2.8

3. Water Absorption 0.33% Should not be >1%

4. Fineness Modulus 7.78 6.5-8.5

5. Shape Tests as per IS 2386part 1, the

flakiness index &
a)Elongation index 16.2%
elongation index should not

b)Flakiness index 18.65% be more than 30%

6. Density 1530 kg/m3 Within the Codal Provisions

33
5.4 Water:

Water is an important constituent of concrete, it should receive due attention in

preparation and for quality control of concrete. Strength and other properties of concrete
are developed as a result of reaction of cement and water (hydration) and thus water plays
a critical role. Quality of mixing and curing water sometimes leads to distress and
disintegration of concrete reducing the useful life of the concrete structure. Water used
or concrete mixture should not contain substances which can have harmful effect on
strength (i.e., on hydration process of cement) or durability of the concrete in service.
Certain substances if present, in sufficient quantities in water may have an injurious
effect upon concrete. Water used for mixing and curing shall be clean and free from
injurious amounts of oils, acid, alkalis, salts, organic matter, sewage, and other
substances which are deleterious to concrete or steel reinforcement. Portable water is
generally considered satisfactory for mixing and curing of concrete.

In our Project work, for preparation of Concrete and Curing purpose; we used
Potable Water.

5.5 Quarry Rock Dust:

Quarry Rock Dust can be defined as residue, tailed waste material after the
extraction and processing of rocks to form fine particles less than 4.75mm. Quarry dust is
fine rock particles. When boulders are broken into small pieces quarry dust is formed. It
is gray in color and it is like fine aggregate. Quarry dusts are produced during the
extraction and processing of aggregates.

Availability of quarry rock dust:

Quarry Rock Dust can be defined as residue, tailing or other non-voluble waste
material after the extraction and processing of rocks to form fine particles less than
4.75mm. it is abundantly available to an extent of 200 million tonnes per annum which
has landfill disposal problems, health hazard and Environmental problems. Usually,
Quarry Rock Dust is used in large scale in the highways as a surface finishing material

34
and also used for manufacturing of hollow blocks and lightweight concrete prefabricated
Elements. The utilization of Quarry rock dust which can be called as manufactured sand
has been accepted as a building material in the industrially advanced countries of the west
for the past three decades. As a result of this, a sustained research and developmental
works under-taken with respect to increasing application of this industrial waste. The
level of utilization of Quarry Rock Dust in the industrialized nations like Australia,
France, Germany and UK has been reached more than 60% of its total production.

Regarding Self Compacting Concrete – SCC; the amount of the fines in the
concrete should be more to satisfy the SCC Properties. So, we made an effort to introduce
Quarry Rock Dust(QRD) in percentages at an interval of 20%(starting from 0% to 100%)
and to quantify the optimum usage of QRD in replacement to sand.

QRD which is used in our Project work is brought from the premises of
Vulindakonda mandal of Kurnool City. QRD is tested in accordance with IS:2386 and it
is found to be satisfied for its use in the concrete. It is confirmed to Zone-II according to
BIS. Dust which is passed on 4.75mm sieve & retained on 150µ sieve are used. The
physical properties are shown below:

TABLE: 5.6 : PROPERTIES OF QUARRY ROCK DUST

S.NO PROPERTY VALUE REQUIREMENTS AS PER IS 383

1 Fine Aggregate QRD -

2 Specific Gravity 2.62 2.6-2.8

3 Water Absorption 0.58% Should not be > 1% for construction

4 Density 1650 kg/cum Within Codal Provisions

5 Fineness Modulus 2.91 2.6-2.9

35
 TABLE 5.7 : SIEVE ANALYSIS OF QUARRY ROCK DUST:

S.NO. I.S sieve Weight retained Cumulative Wt. Cumulative Cumulative

(grams) retained Percentage Percentage
(grams) Weight Retained Weight Passing

1. 4.75 0 0 0 100

2. 2.36 102 102 10.2 89.8

3. 1.18 94 196 19.6 80.4

4. 600 µ 198 394 39.4 60.6

5. 300 µ 430 824 82.4 17.6

6. 150 µ 108 932 93.2 6.8

7. 75 µ 51 983 98.3 1.7

TABLE 5.8 : GRADING LIMITS OF FINE AGGREGATE AS PER IS 383:1970

I.S.Sieve Percentage passing by weight

Designation Grading Zone-I Grading Zone-II Grading Zone-III Grading Zone-IV

10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 95-100

2.36 mm 60-95 75-100 85-100 95-100

1.18 mm 30-70 55-90 75-100 90-100

600 µ 15-34 35-54 60-79 80-100

300 µ 5-20 8-30 12-40 15-50

150 µ 0-10 0-10 0-10 0-15

36
5.6 Super Plasticizer:

Super plasticizers are high range water reducing admixtures conforming to an

essential component of SCC. Other admixtures including air entraining, accelerating and
retarding may be used in the same way as in traditional vibrated concrete but advice
should be sought from the admixture manufacturer on use and the optimum time for
addition.
Choice of admixture for optimum performance may be influenced by the physical
and chemical properties of the binder/addition. Factors such as fineness, carbon content,
alkalis and C3A may have an effect. It is therefore recommended that compatibility is
carefully checked if a change in supply of any of these constituents is to be made.

The admixture should bring about the required water reduction and fluidity but
should also maintain its dispersing effect during the time required for transport and
application. The required consistence retention will depend on the application. Precast
concrete is likely to require a shorter retention time than for concrete that has to be
transported to and placed on site.

In our Project work, CONPLAST SP 430 is used. It produces a high degree of

workability.

Advantages
 Improved workability - Easier, quicker placing and compaction.
 Increased strength - Provides high early strength for precast concrete if water
reduction is taken advantage of.
 Improved quality - Denser, close textured concrete with reduced porosity and
hence more durable.
 Higher cohesion - Risk of segregation and bleeding minimized; thus aids
pumping of concrete
 Chloride free - Safe in Prestressed concrete and with sulphate resisting cements
and marine aggregates.
Standards
Conplast SP43 complies with IS:9103:1999 and BS:5075 Part 3 and ASTM-C-494 Type
'F' as a high range water reducing admixture and Type G at high dosage.

37
Description of Conplast SP430
 It is a brown liquid instantly dispersible in water.
 It has been specially formulated to give high water reductions upto 25% without
loss of workability or to produce high quality concrete of reduced permeability.
Properties
 Specific gravity: 1.18 at 300 C
 Chloride content: Nil. As per IS: 9103-1999 and BS: 5075
 Air entrainment: Approx. 1% additional air over control
 Compatibility: Can be used with all types of cements except high alumina
cement. Site trials should be carried out to optimize dosages.

Dosage: 0.7 – 2 lit for 100Kg of Cement.

An over dose of double the recommended amount of ConplastSP430 (G), will
result in very high workability and some retardation of setting time will occur. However,
the ultimate compressive strength will not be impaired.

5.6.1 Role of S.P in Cement:

The main action of S.P is to make fluidic the mix and improve the workability of
concrete. Portland Pozzolana cement, being in fine state of division will have a tendency
to flocculate in wet concrete. This flocculation’s entraps certain amount of water used in
the mix and there by all the water is not freely available to fluidity the mix. When
plasticizers are used, they get absorbed on cement particles. The absorption of charged
polymer on cement particle creates particle to particle repulsive forces, which overcome
the attractive forces. This repulsive force is called zeta potential, which depends on the
base, solid contents and quality of super plasticizer used. The overall result is that the
cement particles are deflocculated and the water trapped inside the flocks gets released
and now available to fluidity the mix.

Precaution while using SP: Conplast SP43 is non-toxic. Any splashes on the skin
should be washed immediately with water. Splashes to the eyes should be washed
immediately with water and medical advice should be sought.

38
5.7 Glass Fibers:
The Glass fiber use shall be high-quality Alkaline–Resistant glass fiber which is
designed to reinforce cementitious and other alkaline matrix
Glass Fibers used in our Project work are Cem-FIL anti-crack high dispersion glass fibers
which are manufactured SAINT GOBAIN GLASSWARES PVT LTD.

TABLE 5.8 : THE PROPERTIES POSSESSED BY THE GLASS FIBERS.

S.No. CHARACTER GLASS FIBERS

1 Number of fibres 212 million/kg

2 Aspect ratio 857:1

3 Typical addition rate 0.6 to 1.0 kg/m3 of concrete

4 Tensile strength 1700 Mpa

5 Modulus of elasticity 73 Gpa

6 Corrosion resistance Excellent

7 Specific gravity 2.6

8 Density 26 KN/m3

9 Filament diameter 14 µ

10 Filament length 12 mm

In our Project work, Dosage of Glass Fibers is kept constant for all the batches.
The Dosage of GF is of 1Kg per m3 of concrete. Dosage is analysed by the Literature.

39
6. TESTS ON CONCRETE:

Introduction:

Testing of concrete plays an important role in controlling and conforming the

quality of cement works. Systematic testing of raw materials, fresh concrete and
hardened concrete are inseparable part of any quality control program for concrete, which
to achieve higher efficiency of the material used greater assurance of the performance of
the concrete with regard to both strength and durability .The tests methods should be
simple, direct and convenient to apply. One of the purposes of testing hardened
concrete is to conform that the concrete used at site has developed the required strength.

The basic tests to be conducted in the field as well as in the lab based on its state
of Concrete are given below.

1. Tests on Fresh SCC.

2. Tests on hardened concrete.

Fresh concrete or plastic concrete is a freshly mixed material which can be casted
into any shape. Strength of concrete primarily depends upon the strength of cement paste.
In other words, the strength of paste increases with cement content and decreases air and
water content.

The grading and shape of aggregates even from same source vary widely.
Considerable variations occur partly due to quality of plant available and partly due to
efficiency of operation. There are no unique attributes to define the quality of concrete in
its entirety. Under such a situation the concrete is generally referred to as being of good,
fair or poor quality.

40
6.1 TESTS ON FRESH SCC:

6.1.1 GENERAL:

In general, we follow the “European Guidelines for Self Compacting Concrete”.

However, these Tests are not exact. Appropriate Test methods for SCC are provided by
the guidelines. It is important to appreciate that none of the test methods for SCC has yet
been standardized and the test described are not yet perfected or definitive. The methods
presented here test procedures are descriptions rather than fully detailed procedures.
They are mainly ad-hoc methods, which have been devised specifically for SCC.

 One principal difficulty in devising such tests is that they have to assess
three distinct, though related, properties of fresh SCC-its filling ability(flow
ability),its passing ability(free from blocking at reinforcement),and its
resistance to segregation(stability).No single test so far devised can measure
all three properties.
 There is no clear relation between test results and performance on site.
 There is little precise data, therefore no clear guidance on compliance a limits.
 Duplicate tests are advised.
 The test methods and values are started for maximum aggregate size of up
to 20 mm; different test values and for different equipment dimensions may be
appropriate for other aggregate sizes.
 Different test values may be appropriate for concrete being placed in
vertical and horizontal elements.
 Similarly different test values may be appropriate for different reinforcement
densities.
 In performing the tests, concrete should be sampled in accordance with EN
12350-1.It is wise to mix the concrete first with a scoop, unless the
procedure indicates otherwise.

41
Some of Test methods are:

 Passing Ability: The ability of fresh concrete to flow through tight openings such
as spaces between steel reinforcing bars without blocking.
 Filling Ability: The ability of fresh concrete to flow into and fill all spaces within
the formwork, under its own weight.
 Segregation Resistance: The ability of SCC to remain homogeneous in
composition during transport and placing.

TABLE 6.1 : REQUIREMENTS OF SCC FLOW

S.NO. PROPERTY TEST

1. PASSING ABILITY L-BOX

SLUMP FLOW (H-FLOW)

2. FILLING ABILITY T-50 SLUMP FLOW

V-FUNNEL

3. SEGREGATION RESISTANCE V-FUNNEL AT T5 MINUTES

The above tests were performed on the Fresh Concrete. The acceptance criteria
for the SCC flow is achieved from the tests for our concrete mix proportion.

The detailed procedure of the Tests is explained as follows.

42
6.1.2 PASSING ABILITY – L-BOX TEST:

Introduction
The L-box test is used to assess the passing ability of self-compacting concrete to
flow through tight openings including spaces between reinforcing bars and other
obstructions without segregation or blocking. There are two variations; the two bar test
and the three bar test. The three bar test simulates more congested reinforcement.

Scope: This study specifies the procedure for determining the passing ratio, using the L-
box test, for self-compacting concrete.

Principle
A measured volume of fresh concrete is allowed to flow horizontally through the gaps
between vertical, smooth reinforcing bars and the height of the concrete beyond the
reinforcement is measured.

Apparatus:

Figure 6.1 : L-BOX APPARATUS

43
 The typical dimensions shown in the above figure are in mm. The procedure for
the test is explained below.
Test Sample: About 17 litres of Concrete is necessary for the test.
Procedure:
a) Support the L-box on a level horizontal base and close the gate between the vertical
and horizontal sections.
b) Pour the concrete from the container into the filling hopper of the L-box and allow
to stand for (60 ± 10) s. Record any segregation and then raise the gate so that the
concrete flows into the horizontal section of the box.
c) When movement has ceased, measure the vertical distance, at the end of the
horizontal section of the L-box, between the top of the concrete and the top of the
horizontal section of the box at three positions equally spaced across the width of
the box.
d) By difference with the height of the horizontal section of the box, these three
measurements are used to calculate the mean depth of concrete as H2 mm.
e) The same procedure is used to calculate the depth of concrete immediately behind
the gate as H1 mm.
Test Result:
Passing Ability shall be calculated from the following equation:
PA = H2 ÷ H1

Figure 6.2 : L-BOX WITH FLOWING CONCRETE

44
Interpretation of Results:
If the concrete flows as freely as water, at the rest it will be horizontal, so
H2/H1=1. Therefore the nearer this test value, the “blocking ratio” is to unity, the better
the flow of concrete. Obvious blocking of course aggregate behind the reinforcing bars
can be detected visually.

6.1.3 FILLING ABILITY:

There are three tests regarding FILLING ABILITY. They are:

 SLUMP FLOW (H-FLOW)

 T-50 SLUMP FLOW
 V-FUNNEL

SLUMP FLOW & T500 - SLUMP FLOW:

Introduction
The slump-flow and T500 time is a test to assess the flowability and the flow rate

of self compacting concrete in the absence of obstructions. The result is an indication of

the filling ability of self-compacting concrete. The T500 time is also a measure of the

speed of flow and hence the viscosity of the self-compacting concrete.

Principle

The fresh concrete is poured into a cone as used for slump test. When the cone is
withdrawn upwards the time from commencing upward movement of the cone to when
the concrete has flowed to a diameter of 500 mm is measured; this is the T500 time. The

largest diameter of the flow spread of the concrete and the diameter of the spread at right
angles to it are then measured and the mean is the slump-flow.

Apparatus: Slump Flow Cone & Base plate.

45
Procedure:

 Prepare the cone and base plate.

 Fit the collar to the cone if being used.
 Place the cone on the base plate and hold in position by standing on the foot
pieces (or use the weighted collar), ensuring that no concrete can leak from under
the cone.
 Fill the cone without any agitation or rodding, and strike off surplus from the top
of the cone. Allow the filled cone to stand for not more than 30s; during this time
remove any spilled concrete from the base plate and ensure the base plate is damp
all over but without any surplus water.
 Lift the cone vertically in one movement without interfering with the flow of
concrete. If the T500 time has been requested, start the stop watch immediately the

cone ceases to be in contact with the base plate and record the time taken to the
nearest 0.1 s for the concrete to reach the 500 mm circle at any point. Without
disturbing the base plate or concrete, measure the largest diameter of the flow
spread and record as dm to the nearest 10 mm.

 Then measure the diameter of the flow spread at right angles to dm to the nearest

10 mm and record as dr to the nearest 10 mm.

Check the concrete spread for segregation. The cement paste/mortar may
segregate from the coarse aggregate to give a ring of paste/mortar extending several
millimetres beyond the coarse aggregate. Segregated coarse aggregate may also be
observed in the central area. Report that segregation has occurred and that the test was
therefore unsatisfactory.

Test result

 The slump-flow or H-flow is the mean of dm is expressed to the nearest 10 mm.

 The T500 time is reported to the nearest 0.1 s.

46
Figure 6.3 : SLUMP FLOW APPARATUS & BASE PLATE

Fig 6.4: SLUMP FLOW(H-FLOW) MEASUREMENT

47
Interpretation of Results:

The higher the slump flow (SF) value, the greater its ability to fill formwork
under its own weight. A value of at least 650 mm is required for SCC. There is no
generally accepted advice on what are reasonable tolerances about a specified value,
through ±50mm, as with the relative flow able test might be appropriate.

The T50 time is a secondary indication of flow. A lower time indicates

greaterflow ability. The Brite Euram research suggested that a time of 3-7 seconds is
acceptable for civil engineering applications and 2-5 seconds for housing applications.
In case of severe segregation most coarse aggregate will remain in the centre of
the pool of concrete and mortar and cement paste at the concrete periphery. In
case of minor segregation border segregation a border of mortar without coarse aggregate
can occur at the edge of the pool of concrete. If none of these phenomena appear it is no
assurance that segregation will not occur since this is a time related aspect that can occur
after a longer period.

V-FUNNEL TEST:

Introduction

The V-funnel test is used to assess the viscosity and filling ability of SCC.

Principle

A ‘V’ shaped funnel is filled with fresh concrete and the time taken for the concrete to
flow out of the funnel is measured and recorded as the V-funnel flow time.

Test sample: A sample of at least 12 lit. shall be used to fill the funnel.

48
Procedure
 Clean the funnel and bottom gate, the dampen all the inside surface including the
gate.
 Close the gate and pour the sample of concrete into the funnel, without any
agitation or rodding, then strike off the top with the straight edge so that the
concrete is flush with the top of the funnel.
 Place the container under the funnel in order to retain the concrete to be passed.
 After a delay of (10 ± 2) s from filling the funnel, open the gate and measure the
time tv, to 0.1s, from opening the gate to when it is possible to see vertically through

the funnel into the container below for the first time. tv is the V-funnel flow time.

V-Funnel Apparatus with dimensioned(mm) figure is shown below.

Figure 6.5 : V-FUNNEL APPARATUS

49
6.1.4 SEGREGATION RESISTANCE: V-FUNNEL AT T5 MINUTES

Introduction

The V-funnel test is used to assess the viscosity and filling ability of SCC.

Principle: A ‘V’ shaped funnel is filled with fresh concrete and the time taken for the
concrete to flow out of the funnel after 5 minutes of settlement is measured and recorded
as the V-funnel flow time at T5 MINUTES.

Test sample: A sample of at least 12 lit. shall be used to fill the funnel.

Figure 6.6 : V-FUNNEL TESTS

50
Procedure:
 After the completion of V-Funnel Test(normal), this test is to be performed.
 Close the trap door & refill the V-funnel immediately after the first measure.
 Fill the apparatus completely with concrete without compacting or tapping,
simply strike off the concrete.
 Level the top with the trowel.
 Open the trap door 5 minutes after the second fill of the funnel and allow the
concrete to flow out under gravity.
 Simultaneously start the stopwatch when the trap door is opened and
record the time for the discharge to complete (the flow time at T5 minutes).

Interpretation of Result:

This test measures the ease of flow of the concrete; shorter flow time
indicates greater flow ability. For SCC a flow time of 10 seconds is considered
appropriate. The inverted cone shape restricts flow, and prolonged flow times may
give some indication of the susceptibility of the mix to blocking.

After 5 minutes of settling, segregation of concrete will show a less

continuous flow with an increase in flow time.

TABLE 6.2: ACCEPTANCE CRITERIA OF THE SCC FLOW TESTS:

TYPICAL RANGE OF VALUES

METHOD UNIT
MINIMUM MAXIMUM

SLUMP FLOW BY ABRAMS CONE mm 650 800

T50 CM SLUMP FLOW Sec 2 5

V-FUNNEL Sec 6 12

Time increase, V-funnel @ T5 minutes Sec 0 +3

L-BOX H2/H1 0.8 1.0

51
6.2 TESTS ON HARDENED CONCRETE:

For testing of concrete in hardened state, it is required to cast the various moulds like cubes, and
cylinders. It is cured for the required period after 24 hrs of casting.

The specimens are casted as follows.

Initially the mould is applied with oil for lubrication. Concrete is laid in the mould.
Concrete is to be filled in both the Cube Specimens & Cylinder Specimens. The testing procedure
is as follows.

6.2.1 Compressive strength:

Compressive strength of concrete is the most important parameter and representative of
almost overall quality of concrete. It mainly depends upon the water/cement ratio of the mix and
curing and age after it is cast. Compressive strength of concrete is determined by testing the
cylindrical or cubical specimens of concrete using a compression testing machine, at various age
such as: 7 days and 28 days.

Procedure for finding Compressive Strength of Concrete :.

 Compression test is done as per IS: 516-1959.

 All the concrete specimens were tested in a 2000KN capacity compression-testing machine.

 Concrete cube of size 150mm X 150mm X150mm is placed on the Compressive Testing
Machine and grip it firmly between top and botttom plates.

 Apply the load at the rate of 140 kg/sq.cm/minute till the specimens failed.

 Note down the ultimate load at the failure of specimen,when the load is applied.

 Divide the ultimate load by the area of specimen,

 Then the compressive strength has been calculated.

Compressive strength has been calculated by using formula

σc = load/area in N/mm2

52
Figure.6.7 : COMPRESSION TESTING MACHINE WITH A CUBE SPECIMEN

Figure 6.8 : CUBE SPECIMEN AT COMPRESSION TEST

53
6.2.2 Split Tensile Strength
The tensile strength is one of the basic and important properties of the concrete. The concrete is
not usually expected to resist the direct tension because of its brittle nature. However, the
determination of tensile strength of concrete is necessary to determine the load at which the
concrete member may crack. The cracking is a form of tension failure.

Apart from the flexure test the other methods to determine the tensile strength of concrete can be
broadly classified as

 Direct methods and

 Indirect methods

The direct methods suffers from a number of difficulties related to holding the
specimen properly in the testing machine without introducing stress concentration, and to the
application of uniaxial tensile load which is free from eccentricity to the specimen.

Because the concrete is weak in tension even a small eccentricity of load will induce combined
bending and axial force condition and concrete fails at the apparent tensile stress other than the
tensile strength.

Because of the difficulties associated with direct tension test. A number of indirect
methods have been developed to determine the tensile strength. In these tests in general a
compressive force is applied to a concrete specimen in such a way that the specimen fails due to
tensile stresses developed in the specimen. The tensile stress at which the failure occurs is termed
the tensile strength of concrete.

The splitting tests are well known indirect tests used for determining the tensile
strength of concrete sometimes referred to as split tensile strength of concrete

Testing of cylinders for split tensile strength:

This test is Compression–testing machine by placing the cylindrical specimen

horizontally, so that its axis is horizontal between the plate’s of the testing machine. The load is
applied uniformly at a constant rate until failure by splitting along the vertical diameter takes
place. Load at which the specimen failed is recorded. Test is performed as per IS: 5816-1970.

54
The following relation is used to find out the split tensile strength of the concrete

σt =
2P
in N/mm2
 DL

Where, P = Load at the failure of cylinder

Figure .6.9 : SPLIT TENSILE STRENGTH TESTING OF SPECIMEN

6.2.3 Relation between Compressive and Flexure strength of concrete.

The Indian standard IS 456-2000 gives the following relationship between the
compressive strength and flexural strength

Flexural strength = 0.7

The results have been tabulated and graphical variations have been studied.

55
7. DISCUSSIONS ON TEST RESULTS:
INTERPRETATION AND DISCUSSION OF TEST RESULTS:

The results obtained from the detailed experimental program conducted on M40
grade Fiber Reinforced SCC with the replacement of Quarry Rock Dust are presented
below. Table shows the details about compressive strength, split strength and flexural
strength for M40 grade concretes. The optimum replacement dosage of Fine
Aggregate(sand) with Quarry Rock Dust is found to be 40% from the experimental study.

SCC FLOW TESTS:

1. SLUMP FLOW - SF
2. T500 SLUMP FLOW - TSF
3. V-FUNNEL - VF
4. V-FUNNEL AT T5 MINUTES. - TVF
5. L-BOX - LB

7.1 PERMISSIBLE LIMITS FOR THE SCC FLOW PROPERTIES:

TYPICAL RANGE OF VALUES

METHOD UNIT
MINIMUM MAXIMUM

SLUMP FLOW BY ABRAMS CONE mm 650 800

T500 mm SLUMP FLOW Sec 2 5

V-FUNNEL Sec 6 12

Time increase, V-funnel @ T5 minutes Sec 0 +3

L-BOX H2/H1 0.8 1.0

56
 Table: 7.2 TEST RESULTS OF FRESH CONCRETE: WITHOUT FIBER

DESIGNATION SF TSF VF TVF LB

Units
mm Sec Sec Sec H2/H1
QRD %

0 780 2.1 4.2 6.3 1.0

20 754 3.3 6.2 7.1 0.98

40 726 3.7 6.8 7.7 0.92

60 688 4.1 7.4 8.8 0.90

80 662 4.6 9.8 12.1 0.88

100 630 5.8 12.8 15.4 0.82

Discussion:

For the SCC mix without Glass Fibers, with the increase of Dosage of QRD, the
SCC Flow properties are decreasing to some extent. For the 100% replacement of Sand
with QRD; SCC Flow properties are not achieved successfully.

57
 Table 7.3: TEST RESULTS OF FRESH CONCRETE: WITH FIBER

DESIGNATION SF TSF VF TVF LB

Units
mm Sec Sec Sec H2/H1
QRD %

0 768 2.4 4.2 6.4 0.98

20 740 3.5 6.8 7.6 0.94

40 702 4.2 7.2 8.6 0.90

60 664 4.9 8.1 10 0.82

80 640 5.9 10.1 12.6 0.81

100 602 6.3 12.2 16.2 0.76

Discussion:

For the SCC mix with Glass Fibers i.e., FRSCC, with the increase of Dosage of
QRD, the SCC Flow properties are decreasing. For 100% QRD Dosage, Slump Flow is
not achieved. For the dose of upto 60% QRD; SCC Flow Properties holds good.

58
 TABLE 7.4: COMPRESSIVE STRENGTH OF SPECIMENS

LOAD AT COMPRESSION FAILURE

AVERAGE
DOSAGE OF
COMPRESSIVE
LOAD FOR 3 COMPRESSIVE
QRD IN %ge
STRENGTH (MPa)
SPECIMENS (kN) STRENGTH (MPa)

1150 51.11

0 1060 47.11 49.04

1100 48.89

1080 48.00

20 1085 48.22 48.37

1100 48.89

1065 47.33

40 1070 47.56 47.93

1100 48.89

1080 48.00

60 940 41.78 45.04

1020 45.33

970 43.11

80 1020 45.33 42.81

900 40.00

900 40.00

100 950 42.22 41.04

920 40.89

59
Table 7.5: COMPRESSIVE STRENGTH OF SPECIMENS (with GF)

LOAD AT COMPRESSION FAILURE

AVERAGE
DOSAGE OF
COMPRESSIVE
LOAD FOR 3 COMPRESSIVE
QRD IN %ge
STRENGTH (MPa)
SPECIMENS (kN) STRENGTH (MPa)

1150 51.11

1050 46.67 49.63(1.2%)

0
1150 51.11

1120 49.78

20 1080 48.00 49.48

1120 49.78

1140 50.67

40 1090 48.44 49.4

1110 49.33

1020 45.33

60 1080 48.00 46.07

1010 44.89

970 43.11

80 1000 44.44 44.30

970 43.11

910 40.44

100 950 42.22 41.63

910 40.44

60
 Table 7.6: SPLIT TENSILE STRENGTH (without GF):

LOAD AT FAILURE
DOSAGE OF SPLIT TENSILE
QRD IN %ge LOAD FOR 3 AVERAGE LOAD STRENGTH (MPa)
SPECIMENS (kN) (kN)

220

0 240 230.00 3.25

230

220

20 225 225.00 3.18

230

210

40 220 216.67 3.06

210

210

60 220 213.33 3.02

210

210

80 190 193.33 2.73

200

160

100 190 170.00 2.40

160

61
 Table 7.7: SPLIT TENSILE STRENGTH (with GF):

LOAD AT FAILURE
DOSAGE OF SPLIT TENSILE
LOAD FOR 3 AVERAGE LOAD
QRD IN %ge STRENGTH (MPa)
SPECIMENS (kN) (kN)

250

260 253.33 3.58

0
250

260

20 250 256.67 3.63

260

260

40 250 256.67 3.68

260

230

60 270 250.00 3.54

250

210

80 220 216.67 3.06

220

190

100 180 186.67 2.64

190

62
TABLE 7.8:
COMPRESSIVE & SPLIT TENSILE STRENGTH RESULTS (Without GF)

COMPRESSIVE SPLIT TENSILE

STRENGTH (MPa) STRENGTH (MPa)
DOSAGE OF
S.NO.
QRD IN %
WITHOUT WITH WITHOUT WITH
FIBER FIBER FIBER FIBER

1 0 49.04 49.63 3.25 3.58

2 20 48.37 49.48 3.18 3.63

3 40 47.93 49.40 3.06 3.68

4 60 45.04 46.07 3.02 3.54

5 80 42.81 44.30 2.73 3.06

6 100 41.04 41.63 2.40 2.64

Discussion:

The above table presents the strength criteria for the CUBE & CYLINDER
Specimens with respective to Compressive Strength & Split Tensile Strength. It can be
observed that; with the increase of QRD dose, Strength properties are not to the Specified
one, i.e., Target Strength. The maximum replacement of Natural Sand with QRD is upto
40%; at this dose, SCC Flow properties & Strength criterion holds good.

63
TABLE 7.9:

PERCENTAGE INCREASE OF STRENGTH WITH THE ADDITION OF GF

%ge Increase in %ge Increase in

Dosage of
S.NO Compressive Strength Split Tensile Strength
QRD in %ge
with Fibers with Fibers

1 0 1.20 10.15

2 20 2.29 14.15

3 40 3.07 20.26

4 60 2.29 17.21

5 80 1.72 12.10

6 100 1.44 10.00

Discussion:

For every increase in the QRD dose, Percentage increase in the Strength, both in
Compression as well as Split Tensile Strength were calculated. From the table, it can be
observed that the Compressive Strength is increased to a maximum of about 3% & Split
Tensile Strength is increased to a maximum of about 20% at 40% replacement of Natural
Sand with QRD. Therefore, it can be stated that; at 40% QRD dose, Strength criteria hold
good.

64
TABLE 7.10: 28 DAYS STRENGTH RESULTS OF M40 SCC (Without GF):

Compressive Split Tensile Flexural

Dosage of SPLIT Strength
Strength Strength COMPRESSION
QRD in %ge
(Mpa) = 0.7 f ck
(Mpa)

0 49.04 3.25 0.46 4.9

20 48.37 3.18 0.46 4.87

40 47.93 3.06 0.44 4.85

60 45.04 3.02 0.45 4.70

80 42.81 2.73 0.42 4.58

100 41.04 2.40 0.37 4.48

65
TABLE 7.11: 28 DAYS STRENGTH RESULTS OF M40 SCC (With GF):

Compressive Split Tensile Flexural

Dosage of SPLIT Strength
Strength Strength COMPRESSION
QRD in %ge
= 0.7 f ck
(Mpa) (Mpa)

0 49.63 3.58 0.51 4.93

20 49.48 3.63 0.52 4.92

40 49.40 3.68 0.52 4.92

60 46.07 3.54 0.52 4.75

80 44.30 3.06 0.46 4.66

100 41.63 2.64 0.41 4.52

Discussion:

In our work, we made an effort to make a relationship between Compressive

Strength & Split Tensile Strength, by the literature study, the relationship is established.
From IS: 456-2000, Flexural Strength relation with Compressive Strength is used.

66
 COMPRESSIVE STRENGTH vs QRD%

55

WITH OUT FIBER WITH GLASS FIBER

COMPRESSIVE STRENGTH MPa

49.63
50 49.04 48.89
48.37
47.93 48.07

45.48
45.04
45
42.81 43.11

41.04 41.48

40

35
0% 20% 40% 60% 80% 100%

QRD %ge

GRAPH 1(A):

VARIATION OF COMPRESSIVE STRENGTH WITH QRD DOSE.

67
 %ge Increase in Compressive Strength in with Glass Fibers'

%ge Increase in Compressive Strength

5
%ge of Compressive Strength

3.07
3
2.29 2.29

2 1.72
1.44
1.2

0
0% 20% 40% 60% 80% 100%

QRD in %ge

GRAPH 1(B) :

VARIATION OF % INCREASE IN COMPRESSIVE STRENGTH WITH QRD

DOSE.

68
 SPLIT TENSILE STRENGTH vs QRD%

With out Fiber With Glass Fiber

5
SPLIT TENSILE STRENGTH MPa

4 3.68
3.58 3.63 3.54
3.25 3.18
3.06 3.02 3.06
3 2.73
2.64
2.4

1
0% 20% 40% 60% 80% 100%

QRD %ge

GRAPH 2(A):

VARIATION OF SPLIT TENSILE STRENGTH WITH QRD DOSE.

69
 %ge Increase in Split Tensile Strength with Glass Fibers'

%ge increase of Split Tensile Strength

30
%ge of Split Tensile Strength

25
20.26
20
17.21
14.15
15
12.1
10.15 10
10

0
0% 20% 40% 60% 80% 100%

QRD %ge

GRAPH 2(B):

VARIATION OF % INCREASE IN SPLIT TENSILE STRENGTH WITH QRD

DOSE.

70
8. CONCLUSION:

Based on the experimental study on the Fiber Reinforced SCC for M40 grade concrete,
the following conclusions are drawn:

 The Mix Design for Fiber Reinforced SCC using NAN-SU method &
“EUROPEAN GUIDELINES FOR SCC” is arrived.
 Conventional Fine Aggregate i.e., Sand is replaced with Quarry Rock Dust
and based on the test results, the optimum dose is found.
 The Replacement dosage is made at a variation of 20% interval.
 The optimum replacement of Sand is found to be 40% from the study.
 SCC flow properties are satisfied with the EUROPEAN GUIDELINES at the
Optimum Dose of QRD.
 The Target Mean Strength is achieved mostly at 40% replacement of Sand
with QRD in FRSCC. At this dose, by the use of Glass Fibers, there is a
significant increase in the Split Tensile Streng of about 20%; and increase in
Compressive Strength is about 3% is observed.
 Due to presence of Glass Fibers in SCC, Strength results are more
predominant compared to normal SCC mix.
 Relation between Split Tensile Strength & Compressive Strength is
established.
 The relationship between compressive strength and flexural strength which
has been given by IS: 456-2000 is tabulated.
 The fibrous specimens failed only by splitting the fiber and there was no
debonding of fibers noticed in any of the specimens.

71
9. REFERENCES:

 M.S.SHETTY., - “CONCRETE TECHNOLOGY”.

 Nan Su., et al., “A simple mix design method for Self Compacting Concrete”;
Journal of Cement and Concrete Research 31 (2001) pp1799 – 1807.
 M.L.V.Prasad and P.Rathish Kumar, “Comparative Study of Glass and
Polypropylene Fiber Reinforced Self Compacting Concrete(FRSCC)”, National
Conference on Emerging Trends in Civil Engineering for Infrastructure
Development(ETC-ID 2008), Raipur, February - 2008.
 Dubey Sanjay Kumar et al., “Development of Self Compacting Concrete by use
of Portland Pozzolana Cement, Hydrated Lime and Silica Fume” ISCA Journal of
Engineering Sciences, Vol. 1(1), 35-39, July (2012)
 D.L.N.B. Jayawardane et al., “Physical and Chemical Properties of Fly Ash based
Portland Pozzolana Cement”, Civil Engineering Research Exchange Symposium.
 Alvin Harison et al., “Effect of Fly Ash on Compressive Strength of Portland
Pozzolona Cement Concrete”, Journal of Academia and Industrial Research
(JAIR) Volume 2, Issue 8 January 2014
 Liana iure et al., “The Future Concrete: Self-Compacting Concrete”, Universitatea
Tehnică „Gheorghe Asachi” 2010
 Dhiyaneshwaran, S. et al., “Study on Durability Characteristics of Self-
Compacting Concrete with Fly Ash”, Jordan Journal of Civil Engineering ,
Volume 7, No. 3, 2013
 Mohammed Karem et al., “Evaluation Of Using Glass Fiber On Properties Of
Self-Compacting Concrete”, Journal of Kerbala University, Vol. 11, 2013.
 A. Deepak Raj et al., “Experimental Methods on Glass Fiber Reinforced Self
Compaction Concrete”, IOSR Journal of Mechanical and Civil Engineering
Volume 11, Issue 2 Ver. IV (Mar- Apr. 2014).
 P.A. Ganeshwaran et al., “Evaluation Of Mechanical Properties Of Self
Compacting Concrete With Manufactured Sand And Fly Ash”, International
Journal Of Civil Engineering And Technology (IJCIET), Volume 3, Issue 2, July-
December (2012).

72
 M.V.Rama Raju et al., “Study of Properties of SCC using ‘Quarry Dust’ and ‘Fly
Ash”, International Journal of Engineering Sciences Research-IJESR, Vol 02,
Issue 04; August-September 2011
 K.S. Johnsirani et al, “Experimental Investigation on Self Compacting Concrete
Using Quarry Dust”, International Journal of Scientific and Research
Publications, Volume 3, Issue 6, June 2013.
 Anil Banchhor et al., “Advantages of using Fly Ash in Concrete PPC or site
mixing of OPC and fly ash site”, The Associated Cement Companies Li mited,
Cement House, 121, M. K. Road, Mumbai.
 C. I. Goodier, “Development of self-compacting concrete”, Proceedings of the
Institution of Civil Engineers, Structures & Buildings, November 2003.
 Shahana Sheril P.T. “Self Compacting Concrete Using Fly Ash and Glass Fibre”,
International Journal of Engineering Research & Technology (IJERT)Vol. 2 Issue
9, September – 2013 ISSN: 2278-0181.
 M Mazloom et al., “Relation Between The Workability And Strength Of Self-
Compacting Concrete”, 35th Conference on “Our World In Concrete &
Structures”: 25 - 27 August 2010, Singapore.
 T. Noguchi et al., “Rheological Approach to Passing Ability between Reinforcing
Bars of Self-Compacting Concrete”.
 “EUROPEAN GUIDELINES FOR SELF COMPACTING CONCRETE” – May
2005.
 IS:383-1970 “Specification for Coarse & Fine aggregates from natural resources”
 IS: 516-1959 “Methods of tests for strength of concrete”.
 IS: 5816 “Method of test for splitting tensile strength”.
 IS: 1489 (Part 1) “PORTLAND POZZOLANA CEMENT – Its Specifiations”.
 Sai Kumar K. et al., “Quarry Rock Dust as a replacement of Fine Aggregate –
State-of-Art Report”, A National Level Conference on ‘Innovations in Green
Building Technology – IGBT- 2014’, Institution of Engineers (India) at Nagpur.

73
 APPENDIX – A

MIX DESIGN FOR M40 GRADE SCC BY NAN-SU METHOD

DESIGN STIPULATIONS:
Characteristics compressive strength required in the field at 28 days = 40 MPa
Maximum size of aggregate = 20 mm

TEST DATA FOR MATERIALS:

Specific Gravity of Cement - Gc = 2.90
Specific Gravity of Fine Aggregate (sand) – Gfa = 2.65
Bulk Density of Fine Aggregate (sand) - fa = 1.45 gm/cc
Specific Gravity of Coarse Aggregate - Gca = 2.75
Bulk Density of Coarse Aggregate - ca = 1.53 gm/cc

1: ASSSUMPTIONS ACCORDING TO ‘NAN-SU’ & ‘EUROPEAN

GUIDELINES FOR SCC’ :
Assuming,
Target Mean Strenth - fc = 48 MPa
Volume of Coarse Aggregate content = 51%
Volume of Fine Aggregate content = 49%
Packing Factor – PF = 1.10
Water/Cement ratio - W/C = 0.40
Volume of Air Content - Vac = 1%

NOTE:
In general, Quantites are calculated as requirement for a Cubic Meter of a Concrete.
So, the Quantities which will be mentioned over here are of a Kg per a m3 of Concrete.

74
STEP – 2: DETERMINING OF COARSER & FINER AGGREGATES:
Weight of Sand (Ws) = fa x 1000 x PF x 49%
= 1.45 x 1000 x 1.12 x 49 x 0.01
= 795.76 Kg.
Weight of Coarse Aggregate (Ws) = ca x 1000 x PF x 51%
= 1.53 x 1000 x 1.12 x 51 x 0.01
= 873.94 Kg.

STEP – 3: DETERMINING OF CEMENT CONTENT:

Generally, HPC or SCC used will provides a Compressive Strength of 0.115 Mpa/Kg of
Cement.
Hence, Cement content - Wc = fc / 0.115
= 48 / 0.115
= 417.39 Kg

STEP – 4: DETERMINING OF WATER CONTENT:

Amount of Water required, Wwc = Wc x (W/C)
= 417.39 x 0.40
= 166.96 Lit.

STEP – 5: DETERMINING ADDITIONAL POWDER CONTENT FOR THE

SCC FLOW PURPOSE:

Volume of Additional powder required = Vp =

= 0.061 m3.

75
Weight of Additional Powder required, Wp =

= 126.43 Kg.

STEP – 6: DETERMINIG WATER CONTENT FOR ADDITIONAL POWDER:

Water content to be added, Wwp = Wp *

= 126.43 * 0.40
= 50.57 Lit.

STEP – 7: DETERMINIG DOSAGE OF SUPERPLASTICIZER(SP):

Amount of Super Plasticizer, Wsp = 1% of Binder Content

= 0.01 * (417.39 + 126.43)
= 5.44 Kg

STEP – 8: ADJUSTMENT OF MIXING WATER NEEDED FOR SCC:

Amount of Solids in SP = 1% of Total Weight

Amount of Water in SP, Wwsp = (1 – 0.01) * Wsp
= (1 – 0.01) * 5.44
= 5.38 Lit.

Adjusted amount of Water = (Wwc + Wwp) – Wwsp

= (166.96 + 50.57) – 5.38
= 212.14 Lit

76
TOTAL CONTENTS FOR A CUBIC METER OF CONCRETE:

Total Amount of Binder content = Wc + Wp

= 417.39 + 126.43
= 543.82 Kg.

Total Amount of Fine Aggregate = 795.76 Kg

Total Amount of Coarse Aggregate = 873.94 Kg

Total Amount of Water = 212.14 Lit

Total Amount of SP = 5.44 Kg

MIX PROPORTIONS:

Water Binder Fine aggregate Coarse aggregate SP

212.14 543.82 795.76 873.94 5.44

0.39 1 1.46 1.61 0.01

77
 APPENDIX - B
QUANTITIES REQUIRED FOR 3 CUBES AND 3 CYLINDERS:

Volume of concrete required for 3 cubes = 3 × 0.15 × 0.15 × 0.15 = 0.010125m3

Volume of concrete required for 3 cylinder = x 0.152 x 0.30 x 3 = 0.0159 m3

Total volume of concrete = 0.026025 m3

Quantity of Cement required for 0.026025 m3

= 0.026025 x 543.82 = 12.65 Kg.
3
Quantity of Water required for 0.026025 m of concrete
= 0.026025 × 212.14 = 5.52 Lit
Quantity of Coarse aggregate required for 0.026025 m3 of concrete
= 0.026025 × 873.94 = 22.74 Kg
Quantity of Fine aggregate required for 0.026025 m3 of concrete
= 0.026025 × 795.76 = 20.71 Kg
3
Quantity of Glass Fibers required for 0.026025 m of concrete
= 0.026025 × 1 = 26 grams
Quantity of Super Plasticizer for 0.026025 m3 of concrete
= 0.026025 × 5.44 = 142 ml

SAMPLE CALCULATIONS FOR FINDING THE COMPRESSIVE STRENGTH:

COMPRESSIVE STRENGTH OF CUBES WITHOUT FIBERS:

1. 0% QRD WITHOUT FIBERS:

LOAD 1 = P = 1150 kN.
Compressive Stress = P/A = (1150x1000)/(150x150) = 51.11 N/mm2.
LOAD 2 = P = 1060 kN.
Compressive Stress = P/A = (1060x1000)/(150x150) = 47.11 N/mm2.
LOAD 3 = P = 1100 kN.
Compressive Stress = P/A = (1100x1000)/(150x150) = 48.89 N/mm2.
Average Strength = (51.11+47.11+48.89)/3 = 49.04 N/mm2.

78
 2. 40% QRD WITHOUT FIBERS:
LOAD 1 = P = 1070 kN.
Compressive Stress = P/A = (1070x1000)/(150x150) = 47.33 N/mm2.
LOAD 2 = P = 1065 kN.
Compressive Stress = P/A = (1065x1000)/(150x150) = 47.56 N/mm2.
LOAD 3 = P = 1100 kN
Compressive Stress = P/A = (1100x1000)/(150x150) = 48.89 N/mm2.
Average Strength = 47.93 N/mm2.

COMPRESSIVE STRENGTH OF CUBES WITH GLAS FIBERS:

1. 0% QRD WITH FIBERS:

LOAD 1 = P = 1150 kN.
Compressive Stress = P/A = (1150x1000)/(150x150) = 51.11 N/mm2.
LOAD 2 = P = 1050 kN.
Compressive Stress = P/A = (1050x1000)/(150x150) = 56.67 N/mm2.
LOAD 3 = P = 1150 kN
Compressive Stress = P/A = (1150x1000)/(150x150) = 51.11 N/mm2.
Average Strength = (51.11+56.67+41.11)/3 = 49.63 N/mm2.

2. 40% QRD WITHOUT FIBERS:

LOAD 1 = P = 1140 kN.
Compressive Stress = P/A = (1140x1000)/(150x150) = 50.67 N/mm2.
LOAD 2 = P = 1090 kN.
Compressive Stress = P/A = (1090x1000)/(150x150) = 48.44 N/mm2.
LOAD 3 = P = 1110 kN
Compressive Stress = P/A = (1110x1000)/(150x150) = 49.33 N/mm2.
Average Strength = 49.40 N/mm2.

79
 SAMPLE CALCULATIONS FOR FINDING THE SPLIT TENSILE STRENGTH:

SPLIT TENSILE STRENGTH OF CYLINDERS WITHOUT FIBERS:

1. 0% QRD WITHOUT GLASS FIBERS:

Average Load of 3 Cylinders = P = 230 kN.
Split Tensile Strength = 2P / (πDL) = (2x230x103)/(πx300x150) = 3.25 N/mm2.

2. 40% QRD WITHOUT GLASS FIBERS:

Average Load of 3 Cylinders = P = 216.67 kN.
Split Tensile Strength = 2P / (πDL) = (2x216.67x103)/(πx300x150) = 3.06 N/mm2

SPLIT TENSILE STRENGTH OF CYLINDERS WITH GLASS FIBERS:

1. 0% QRD WITH GLASS FIBERS:

Average Load of 3 Cylinders = P = 253.33 kN.
Split Tensile Strength = 2P / (πDL) = (2x253.33x103)/(πx300x150) = 3.58 N/mm2

2. 40% QRD WITH GLASS FIBERS:

Average Load of 3 Cylinders = P = 256.67 kN.
Split Tensile Strength = 2P / (πDL) = (2x216.67x103)/(πx300x150) = 3.68 N/mm2

80

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